WHB DEUTZ TTCD 7.8 L6 Agri Kompetenzklasse 3 FENDT900VarioS4 en 112014 Locked 91629

Workshop Service Manual
TTCD 7.8 L6
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This document is subject to changes which may become necessary in the course of further development
of the engines. Reprinting and reproductions of any kind, even in part, require our written permission. .
Only available digitally!

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

and development. The profound expertise gained
through this, in combination with high demands on
quality, attests to the fact that our engines possess
all the qualities of long life, high reliability and low 2
fuel consumption. It goes without saying that the
high environmental protection requirements are
also met.
Maintenance and care are the only way the engine

can satisfy the demands you make on it. Compli-
ance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particular-
ly heeded.
Please consult one of our service representatives

responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.
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General DEUTZ engines
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DEUTZ engines Safety information / User information
OBJ_DOKU-46318-001.fm
3 Safety information / User information
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Safety information / User information DEUTZ engines
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3.1 General 3.2 Specifications

The documentation of the workshop manual has 3.2.1 Accident prevention and safety regula-
been created based on the engine available at the tions
time of going to press.
The legally prescribed rules for the prevention of ac-
There may be deviations in the descriptions, illustra-
cidents must be observed. These are available from
tions and parts due to further developments.
professional associations or from dealers. These
The valid documents published by DEUTZ AG (such are dependent on the application site, operating 3
as Service Info Technology, Technical Bulletin, mode and the operating and auxiliary materials be-
Service Bulletins, Installation guidelines etc.) must ing used.
be observed.
Special protection measures are specified depend-
The prescribed tightening specifications as well as ing on the work being carried out, and are identified
the test and setting data must be taken into consid- in the job description.
eration and adhered to.
Among other things it generally applies that:
The high safety and quality level of our engines is
● for the personnel:
constantly guaranteed due to technical improve-
ments and further developments. As a result, there – Only briefed personnel may operate or main-
may be deviations between the documentation and tain the engine. Unauthorised persons are
the current state of technological knowledge. prohibited access to the machine room.
As a result of further developments, changes may – Wear close-fitting clothing and ear protectors
be announced at short notice by means of bulletins in the machine room when the engine is in op-
(Service Info Technology, Technical Bulletin, Serv- eration.
ice Bulletin). – Only deploy trained personnel to do repairs
The maintenance work prescribed in the operating and maintenance work.
instructions and workshop manual must be carried – Do not work on the fuel system when the en-
out properly and completely. The maintenance staff gine is running. The fuel system is under high
must have the necessary expertise for carrying out pressure - danger of death.
the work. Any safety and protection devices which – Go to the workshop immediately in case of
had to be dismantled during maintenance work leaks in the fuel system.
must be reinstalled.
● for the engine room:
Caution!
– Ensure adequate ventilation (do not cover air
The rules for the prevention of accidents and the shafts).
safety regulations must be observed during mainte-
– Provide first aid kit and suitable fire extinguish-
nance work.
ers. Check the filling and readiness for opera-
Reference is made in the workshop manual job tion regularly.
cards to the regulations in chapter 3.2. These must
– Only store inflammable materials in the ma-
be read before working on the engine and must be
chine room if they are essential for operation
strictly followed.
of the system.
The maintenance intervals and the work to be per-
– Smoking and naked flames are prohibited in
formed are specified in the maintenance schedule
the machine room.
of the operation manual. The job cards contain tech-
nical documentation on the execution of mainte- ● for operation, maintenance and repairs on the
nance work. engine:
– The common rail systems used work with op-
erating pressures up to
approximately 2000 bar. In the case of poten-
tial faults, the pressure can even rise to signif-
icantly higher values before the pressure
reducing valve opens.
– Ignition must be switched off.
– Do not start engine.
– Depending on version of the common rail sys-
tem, the electrical fuel supply pump is activat-
ed when the ignition is switched or during
starting and supplies the fuel directly.
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– After shutting down the engine, wait at least 3.2.2 Cleanliness instructions and measures
30 seconds before performing work on the fuel for working with common rail systems
system.
The common rail systems used in DEUTZ engines
Depending on the version of common rail sys-
comprise high-precision components subjected to
tem, the fuel pressure in the common rail sys-
extreme loads. In view of the high-precision technol-
tem will still not have dissipated after 30
ogy, ensure utmost cleanliness when working on
seconds. The fuel pressure can permanently
the fuel system.
3 be several 100 bar.
The fuel pressure here does not drop until the Notes and measures to be observed before starting
fuel system is opened and the fuel can es- work on the fuel system
cape. ● The fuel system must be closed. Make a visual
– Only start the engine when all the protective inspection for leaks / damage to the fuel system.
devices have been fitted. Make sure no-one is ● Clean the whole engine and engine room with the
standing in the danger area. system closed before starting work on the fuel
– Cleaning, maintenance and repair work may system.
only be performed with the engine at a stand- ● The engine must be dry when you start working
still and secured against starting. on the fuel system.
– Fuel lines, injection lines or fuel high-pressure ● Blowing (dry) with compressed air is only permis-
lines must never be disconnected when the sible with the fuel system closed.
engine is running.
● When using a steam blaster, the components
– Danger of injury ! (e.g. cable plugs, all other electrical plug connec-
The fuel jet can deeply penetrate the skin. tions, control unit, generator, starter, solenoid
– Do not come close to the leakage area in the valves, transmitters, sensors etc.) must first be
fuel high-pressure system with any body parts covered and must not be directly impacted with
(e.g. hand, head). the steam blaster.
– Always carry out an exact visual inspection of ● Electrical plug connections must be plugged
all high-pressure carrying components before when spraying.
tests on the running engine. Wear suitable ● Remove loose parts (for example paint chips
protective clothing (for example goggles, from assembly work) with an industrial vacuum
gloves) for this. Leakages entail potential haz- cleaner or other suction device. Only suction may
ard sources for the workshop personnel. be used in assembly work on the open fuel sys-
– Even if no leakages can be discerned in the tem.
fuel high-pressure system, the workshop per- ● Only work on the fuel system in a clean environ-
sonnel should avoid the direct hazard zone or ment (no dust, no grinding or welding). Avoid
wear protective clothing (for example goggles, draughts (dust). Clean the workshop floor regu-
gloves) during tests when the engine is run- larly. No brake or performance test benches may
ning and during the first test run. be kept or operated in the same room.
– Always stay out of range of a fuel jet, as it ● Air currents which kick up dust, such as those
could cause severe injury. caused by brake repairs or the starting of en-
– Fuel lines, injection lines and high-pressure gines, should be avoided.
lines must not be deformed. ● For work such as removal and installation on de-
– Damaged fuel lines, injection lines and high- fective hydraulic components on the Common
pressure lines must be replaced. Rail System it is recommended to partition off a
– Smoking is strictly prohibited when working on separate workshop area in the factory. This must
the fuel system. be separate from other areas in which general
vehicle repairs such as brake repairs are carried
– Do not work near to sparks and flames.
out.
– Never disconnect an injector when the engine
● No general machine tools may be operated in
is running.
this room.
– Loosen screw connections slowly and not
● Regular cleaning of the workshop area is manda-
abruptly
tory. Draughts, ventilation systems and heating
– Open screw connections on the fuel system fans should be minimised.
with extreme caution.
● Areas of the engine room from which particles of
– After all work on the fuel system, it must be dirt could be loosened (for example the bottom
bleeded - see the operation manual, chapter
"6 Fuel system“.
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part of the tipped driver cab) must be covered vehicle repairs such as brake repairs are carried
with fresh clean film. out.
● Working materials and tools must be cleaned be- ● The workshop floor is sealed or tiled.
fore work. Only use tools without damage to the ● No welding gear, grinders, general machine
chrome plating or tools which are not chrome- tools, brakes or performance test benches may
plated. be operated in this room.
Notes and measures to be observed during work on ● Regular cleaning of the workshop area is manda- 3
the fuel system or with the fuel system open. tory. Draughts, ventilation systems and heating
● Only work in clean overalls. fans should be minimised.
● Only lint-free cleaning cloths may be used for Notes and measures for workbench and tools in the
work on the fuel system. vehicle hall
● Remove loose parts (for example paint chips ● A special workbench must be set up for work on
from assembly work) with an industrial vacuum removed components.
cleaner or other suction device. Only suction may ● Clean the removal and installation tools regularly
be used in assembly work on the open fuel sys- and keep them in a closed tool cabinet.
tem.
● Remove loose parts (for example paint chips
● Working materials and tools must be cleaned be- from assembly work) with an industrial vacuum
fore work. Only use tools without damage to the cleaner or other suction device.
chrome plating or tools which are not chrome-
● Working materials and tools must be cleaned be-
plated.
fore work. Only use tools without damage to the
● Do not use used cleaning fluid or test fluid for chrome plating or tools which are not chrome-
cleaning. plated.
● Compressed air must not be used for cleaning on 3.2.3 Additional information and measures for
the open fuel system.
the handling of exhaust aftertreatment
● Work on removed components may only be per- systems
formed at a suitably equipped workbench.
● Basically all the same regulations and instruc-
● When removing and installing components, no tions up to and including chapter 3.2.2 must also
materials which can leave behind particles or fi- be observed for work on exhaust aftertreatment
bres (cardboard, wood, cloths) may be used. systems!
● Removed parts may only be rubbed down with ● Utmost cleanliness must be observed for all
clean, lint-free cloths. No dirt particles may be
work.
rubbed into the components.
DPF (Diesel Particle Filter)
● Openings on the components and on the engine
must be closed immediately with suitable stop- ● The filter regeneration must be deactivated or, in
pers/caps. systems with a filter regeneration prompt, not ac-
tivated before performing service work.
● The stoppers/caps may only be removed imme-
diately before installing. ● The duration of a full filter regeneration is 30 min-
utes on average. High exhaust temperatures oc-
● Store stoppers/caps free from dust and dirt in the cur in the exhaust system/on the end exhaust
original packaging and dispose of after using pipe independently of the actual load state of the
once. engine (i.e. also during engine idling).
● Only remove new parts from the original packag- ● No foreign bodies may get into the exhaust line or
ing just before installation. the combustion chamber. If this happens, the en-
● Removed components must be kept in new, seal- gine must be "run free" without
able bags or - if available - in the packaging of the diesel particle filter.
new parts.
● Tensions and deformations of the shape of the V-
● Always use the original packaging of the new part belt clip must be avoided. The DPF module may
to send back the removed components. only be transported using the transport sleeves.
Notes and measures for the vehicle workshop area ● V-belt clips and seals may not be reused (this
● For work such as removal and installation on de- also applies as soon as the screw connection has
fective hydraulic components on the Common been loosened once).
Rail System it is recommended to partition off a Ignition system (engines with ignition system)
separate workshop area in the factory. This must
be separate from other areas in which general
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● Caution! Dangerous high voltage. ● When carrying out electrical welding work, the
The ignition system operates with ignition voltag- earth terminal of the welding device must be con-
es up to 10000 Volts. nected directly to the part that is to be welded.
● The ignition system must not be operated without ● For electrical welding parts, all plug connectors
a secondary load. must be disconnected from the control unit to
● Dirt and moisture on the primary and high voltage protect the electronics.
connections can cause malfunctions (leakage ● Opening sensors, transmitters, actuators and
3 current, misfiring, high voltage sparks). control units is not permissible. Otherwise, any
● Check the protective caps of the ignition lines for warranties will be invalidated.
discolouration, deformation and cracks before ● When the engine is running, do not interrupt the
each usage. connection between the battery, generator and
SCR (Selective Catalytic Reduction) regulator.
● AdBlue® is a caustic medium which causes ● When using a steam blaster, the components
heavy corrosion damage when it comes into con- (e.g. cable plugs, all other electrical plug connec-
tact with electronic components or similar. tions, control unit, generator, starter, solenoid
valves, transmitters, sensors etc.) must first be
● Leaks on the AdBlue® pipes, the tank, the supply
covered and must not be directly impacted with
module and the feeding unit must be fixed imme-
the steam blaster.
diately to avoid leakage of AdBlue®.
● Electrical plug connections must be plugged
● Make sure the room is well ventilated.
when spraying.
● Contact with the skin should be avoided. Wear la-
● Store the components in a dry and clean area.
tex gloves if possible.
● It is not permitted to: store the components tem-
● Wash hands thoroughly before taking breaks and
porarily or stack them without their transport
at the end of shifts.
packaging.
● If the substance comes into contact with eyes,
● Components may only be stored and transported
rinse thoroughly with water.
in the specified packaging.
● If swallowed, rinse out mouth with a lot of water,
● Only remove new parts from the original packag-
drink plenty of water and seek medical advice.
ing just before installation.
● If discomfort or illness continues, seek medical
● Incorrectly operated or damaged components or
advice.
parts that have been dropped must not be in-
● Product can pose danger of slipping if spilled. It stalled.
is essential to remove spilled liquid. In so doing,
● Do not subject the components to any hard im-
ensure that the liquid does not enter the sewage
pacts or any other use of force.
system or ground/surface water. This means that
the contamination should be physically removed ● Faulty earthing, cable and plug connections can
and disposed of in suitable containers. Minimal lead to malfunctions. Electronic components can
amounts of remaining liquid may be rinsed away be destroyed.
with a lot of water. ● A pressure balance element and the sealing area
● The so-called lag time is application-dependent of the components (e.g. control units) must not
and may be up to 2 minutes because the SCR be immersed in water. It is not permitted to soak
pipes have to be pumped empty in this time. the components with water, especially when
cleaning using a high-pressure cleaner or similar.
3.2.4 General information on the electrical
● Use the fastening points provided for fastening.
system, electrical/electronic compo-
Tensions must be avoided during assembly.
nents/systems
● Drills or additional fastenings on the control unit
● Do not touch live parts. housing are impermissible.
● Ensure correct polarity of the connections. ● The prescribed tightening specifications for all
● When disconnecting the battery, electronically components (e.g. transmitters, sensors etc.)
stored data may be lost. must be complied with.
● When disconnecting the battery, always discon- ● Cable plugs must only be removed or connected
nect the minus pole first. Otherwise there is a when the supply voltage is switched off, where
danger of short circuiting! possible at the end of the lag time.
● When connecting, connect the plus pole first and ● Cable plugs must be inserted and removed care-
then the minus pole. Otherwise there is a danger fully so that metal lugs and plastic retainers are
of short circuiting! not damaged.
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● Rubber seals in the cable plug must always be 3.3 Operation manual and workshop man-
pressed down flat onto the housing edges. ual
3.2.5 Disposal regulations In order to structure the information layout in a user-
The work described in the operation manual and friendly way, the service documentation is divided
workshop manual necessitates renewal of parts and into operating instructions and job cards (workshop
operating materials among other things. The re- manual).
newed parts / operating materials must be stored, The operation manual contains a general descrip- 3
transported and disposed of according to regula- tion and instructions for all other maintenance work.
tions. The owner himself is responsible for this.
It contains the following chapters:
Disposal includes recycling and the scrapping of
1. Contents, General
parts / operating materials, although recycling has
priority. 2. Engine description
Details of disposal and their monitoring are gov- 3. Operation
erned by regional, national and international laws 4. Operating media
and directives which the system operator must ob- 5. Maintenance
serve on his own responsibility.
6. Care and maintenance work
7. Faults, causes and remedies
8. Transport and storage, protecting the engine
against corrosion
9. Technical data
The use of job cards (workshop manual) presuppos-
es knowledge of the operating instructions content,
this applying in particular for the service specifica-
tions. Repairs to the engine and components are
described in the job cards (workshop manual), for
the implementation of which more effort and corre-
spondingly qualified experts are required.
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3.4 Job cards 3.4.2 Structure of a job card

The job cards are differentiated into "W" and "I" job
cards. 1 2 3
The "W" job card documents the standard repairs to
the engine and/or its components. The necessary 4
tools and special tools are also indicated in the "W" 5
3 job card.
The "I" job card also documents corresponding 6
17
workflows for repairing the engine and/or its compo- 7
nents. Special prerequisites must be fulfilled by the
workshops for implementation of these workflows. 16
6 8
For example, special tools and machine tools must
be available. 15
3.4.1 Numbering of job cards 9

14
The job card numbering uses the format W 08-03-
01. The individual parts of this format are explained
below:
● W 08-03-01: Documentation type 13
9
– W.... Workshop manual
– I ...... Repair manual
● W 08-03-01: Module
according to module list
12 11 10
● W 08-03-01: Component group
● W 08-03-01: Consecutive number 1. DEUTZ AG,
publisher of service documentation
2. Not occupied
3. Assembly - Designation
4. Numbering of the job cards
5. DEUTZ internal creation number
6. Title of job card
7. References / Notes
8. Chapter
9. Graphic or photo
10.DEUTZ internal designation
11.Page number
12.Date of issue of job card
13.Note
14.Danger / Important
15.Parts list / Workflow
16.Auxiliary materials
17.Standard tools, special tools
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3.5 Explanation of symbols

Danger!
of death or to health. Must be observed!
For example: The incorrect use or conver-
sion of the turbocharger can lead to serious
injury.
Caution! 3
Danger to the component/engine. Non-
compliance can lead to destruction of the
component/engine.
Must be observed!
Note
General notes on assembly, environmental
protection etc. No potential danger for man
or machine.
Tool
Conventional and special tools required for
the work.
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
References
to important documents
Reference
within the workflow or to assemblies in
which further documents or job cards are
provided.
Test and setting data
The necessary values are indicated here
with link to a table within the job card.
Tightening specifications
The necessary values are indicated here
with link to a table within the job card.
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DEUTZ engines Job cards
6 Job cards
6
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Job cards DEUTZ engines
© 07/2014
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Crankcase
W 01-01-01
Removing and installing the crankcase bleeding

Standard tools – Safety information / User
information
Special tools:
– Hose clip pliers 01899399
– Disassembly tool 02992127
Removing the crankcase bleeding

1 Oil return line
2 Pipe clip
3 Sealing ring
5 Crankcase breather
6 Hexagon head screw
7 Hose clip
8 Rubber sleeve
9 Moulded seal
10 Hollow screw
12 Return shut-off valve
13 Sealing ring
14 Adapter
© 49894-0
● Loosen hose clips (1) with hose clip pliers.

● Pull off hose pipe (2).
● Unscrew screws (3).
● Remove crankcase breather (4).
© 49542-0
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Crankcase
W 01-01-01
● Remove moulded seal (1) with disassembly tool.
6
© 48553-0
● Unscrew screw (1).

● Unscrew hollow screw (3).
● Remove sealing rings (4).
● Remove bleed line.
© 49865-0
● Unscrew shut-off valve (1).

● Remove sealing ring (2).
© 49866-0
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Crankcase
W 01-01-01
Install crankcase bleeding

● Clean sealing surfaces.
● Insert new moulded seal (1).
6
© 48553-1
● Mount crankcase bleeding (1).

● Tighten screws (2).
 30 Nm
© 49546-0
● Mount sealing ring (1).

● Tighten shut-off valve (2).
 29 Nm
© 49547-0
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Crankcase
W 01-01-01
● Mount sealing rings (1).

● Screw on hollow screw (2).
● Position pipe clips (3).
 13 Nm
● Tighten hollow screw (2).
 29 Nm
6
© 49868-0
● Mount the hose pipe (1).

● Position hose clips (2).
● Fasten hose clips with hose clip pliers.
© 49550-0
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Crankcase
W 01-01-01
Technical Data
ID no. Name Screw type Notes / Remark Value
Crankcase breather on cylinder head
A01 060 30 Nm
cover
A01 063 Return shut-off valve on gearcase M12x1.5 29 Nm
Hollow screw
A12 092 Pipe union, ring piece 29 Nm
M12x1.5
A12 095 Pipe clip, fastening 13 Nm
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
6
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Crankcase
W 01-01-01
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Front cover
W 01-02-01
Renewing the crankshaft sealing ring

information
Special tools:
– Pricker 01899103
– Assembly lever 01899110
– Assembly tool 02992239
– Self-tapping screw
– Washer
Removing the crankshaft sealing ring

1 Front cover
2 Shaft sealing ring
© 49563-0
● Removing torsional vibration damper.

 Module 05
● Remove clamping bushing (1).
© 43373-0
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Front cover
W 01-02-01
● Make a hole of approximately 3 mm in the crankshaft

sealing ring with a pricker.
Attention!
Do not damage the front cover or cranks-
haft.
6
© 43643-0
● Turn in a self-tapping screw with washer.

● Pull out the crankshaft sealing ring with assembly le-
ver.
Ensure that the crankshaft does not get
damaged.
● Visually inspect the crankshaft sealing ring running

surface.
© 43644-0
Installing the crankshaft sealing ring

● Mount guide sleeve (1).
© 49772-0
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Front cover
W 01-02-01
6
© 49773-0
● Oil the sealing lip of the crankshaft sealing ring light-

ly.
● Push the crankshaft sealing ring carefully onto the
guide sleeve.
The sealing lip faces the crankcase.
© 49774-0
● Pay attention to installation depth of crankshaft seal-

ing ring and select shim accordingly.
– First assembly = 2 shims
– 1. Repair installation depth = 1 shim
– Maximum installation depth = without washers
© 49775-0
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Front cover
W 01-02-01
● Mount assembly sleeve (1).

● Press on the crankshaft sealing ring to the stop.
6
© 49776-0
● Plug in the bearing (1).

● Screw on nut (2).
● Tighten nut to the stop of the assembly sleeve (3).
The crankshaft sealing ring is now at the
pre-selected installation depth.
© 49777-0
● Tighten nut to the stop of the assembly sleeve (1).

The crankshaft sealing ring is now at the
pre-selected installation depth.
● Remove assembly tool. 1
© 42629-0
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Front cover
W 01-02-01
● Insert clamping bushing (1).

● Install torsional vibration damper.
 Module 05
6
© 43373-0
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Front cover
W 01-02-01
© 11/2014
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Front cover
W 01-02-02
Assembling/disassembling shaft sleeve on the crankshaft

Standard tools
– Packing compound
DEUTZ DW 74
Installing the shaft sleeve

● Remove the crankshaft sealing ring.
 Module 01
● Remove clamping bushing (1).
● Visually inspect the crankshaft journal.
1
● Clean the crankshaft journal carefully.
Unevenness such as running marks,
notches or very rough surfaces can cause
lubricating oil leaks between the crankshaft
and the shaft sleeve.
● Repair unevenness with packing compound.
© 43373-0
Attention!
Do not damage the peripheral surfaces
and the sealing surfaces.
● Join the impact sleeve (1) and the shaft sleeve (2).
● Place the shaft sleeve with impact sleeve centrally on
the crankshaft with the collar (3) facing the crank-
shaft.
© 39872-0
© 11/2014
1/4
Front cover
W 01-02-02
● Knock the shaft sleeve onto the crankshaft up to the

stop by hitting the impact sleeve (1) lightly in the cen-
tre.
● Knock on the shaft sleeve evenly all round.
The installation depth of the shaft sleeve is
determined by the impact sleeve.
The shaft sleeve must cover the running
marks.
6
© 39891-0
After installing the shaft sleeve, check that

there is no burr on the surface of the
crankshaft.
● Oil the crankshaft journal lightly.
To avoid dust and dirt deposits, do not wet
the crankshaft sealing ring and fleece ring
with lubricating oil.
The manufaturer has already coated the
sealing lip with a lubricating wax.
● Install a new crankshaft sealing ring.
 Module 01
© 39875-0
Removing the shaft sleeve

● Remove the crankshaft sealing ring.
 Module 01
● Remove oil suction pipe
 Module 16
● Place two mounting levers on the gate of the front
cover (arrows).
Attention!
Do not damage the sealing surfaces.
© 39873-0
© 11/2014
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Front cover
W 01-02-02
● Pull off the shaft sleeve.

● Remove front cover.
6
© 39874-0
● Install front cover.

 Module 01
● Install new shaft sleeve.
 Installing the shaft sleeve
● Install oil suction pipe.
1
 Module 16
 Module 01
© 44875-0
© 11/2014
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Front cover
W 01-02-02
© 11/2014
4/4
Front cover
W 01-03-01
Removing and installing the front cover

(Fastening parts)
Standard tools
Remove the front cover

3 Clamping bush
4 Seal
264 Packing compound
© 49553-0
● Removing torsional vibration damper.

 Module 05
● Remove oil suction pipe
 Module 16
● Mount two mounting levers on sprue (arrows) and le-
ver out.
● Remove front cover (2).
● Remove gasket.
● Visually inspect the components.
© 49554-0
© 11/2014
1/6
Front cover
W 01-03-01
● Knock out crankshaft sealing ring (1).

Attention!
Do not damage sealing surface when
knocking out.
● Clean the sealing surfaces on the front cover and
crankcase.
6
© 49555-0
Install front cover

Attention!
Only use sheet beading seal (2).
See spare parts documentation.
© 49556-0
● Fill lubricating oil into the oil pump housing.
© 49557-0
© 11/2014
2/6
Front cover
W 01-03-01
● Position the inner rotor on the crankshaft.

The countersinks on the crankshaft and
the guides on the inner rotor must
match (arrows).
The inner rotor and crankshaft only match
up in one position.
6
© 49558-0
● Attach front cover (1).

M8x35
● Fasten screws (3).
M8x70
Do not tighten screws.
© 49559-0
● Press the front cover up and align flush with the oil
pan sealing surface (arrows).
© 49560-0
© 11/2014
3/6
Front cover
W 01-03-01
● Tighten the screws according to the tightening se-

quence.
 30 Nm
6
© 49561-0
Attention!
Projecting rubber (arrows) must not be
removed.
● Install oil suction pipe.
 Module 16
● Install crankshaft sealing ring (opposite side to fly-
wheel)
 Module 01
● Install torsional vibration damper.
 Module 05
© 49562-0
© 11/2014
4/6
Front cover
W 01-03-01
Technical Data
M8x35-10.9 Observe tightening
A01 020 Front cover on crankcase 30 Nm
M8x70-10.9 sequence
© 11/2014
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Front cover
W 01-03-01
© 11/2014
6/6
Crankcase
W 01-05-01
Checking the overhang of the cylinder liner

8190
information
Special tools:
– Dial gauge 01899126
– Measuring device 02992041 Attention!
Do not turn the crankshaft without the liner
holder.
The sealing surfaces must be dry and free

from grease and dirt.
Checking the overhang of the cylinder liner

● Remove cylinder head.
 Module 08
The cylinder liner must be pressed in the
crankcase to the stop.
● Insert dial gauge into measuring beam.

● Fix dial gauge with knurled nut.
● Place shims (1) and measuring beam (2) on the seal-
ing surface of the crankcase.
1 2 1
© 43613-0
● Apply stylus of the dial gauge to the crankcase seal-

ing surface with pre-tension (arrow).
● Adjust dial gauge to "0".
© 43614-0
© 08/2014
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Crankcase
W 01-05-01
Measuring points see diagram.

3 1
6 2 4
© 34151-4
● Move the measuring beam and spacing washers un-

til the stylus (arrow) is touching the sealing surface of
the cylinder liner.
+ 0.05
 0.10 −0 mm
Make measurements at at least 3 other
points on the cylinder liner.
When the wear limit is reached, the
cylinder liner must be renewed.
● Install cylinder head.
 Module 08
© 43615-0
© 08/2014
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Crankcase
W 01-05-01
Technical Data
Testing and setting data
ID no. Name Additional information Value
+ 0.05
P01 39 Cylinder liner, overhang 0.10 −0 mm
© 08/2014
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Crankcase
W 01-05-01
© 08/2014
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Crankcase
W 01-05-03
Removing and installing the cylinder liner

8190
information
Special tools:
– Extraction tool 01899140
– Plate 02992287
– Assembly lever 02992289
– Washer 02992290
– Fitting compound
DEUTZ AP1908
Removing the cylinder liner

● Remove con rod.
 Module 06
● Pre-mount the disassembly device
– Mount the plate (1) on the disassembly device
2 2
– Adapt the counter support (2) according to the di-
ameter of the cylinder liner.
1
© 43564-0
● Fold the plate (1) to the side and insert the disassem-
bly device in the cylinder liner.
Make sure that the running surface and the 1
sealing surface are not damaged.
Pay attention to the piston cooling nozzle.
© 43565-0
© 08/2014
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Crankcase
W 01-05-03
● Place the plate (1) with the lay-on surfaces against

the cylinder liner (2) and hold them together.
6
© 43609-0
● Turn the nut (1) clockwise.

1
© 43566-0
● Pull the cylinder liner up and out.

● Remove disassembly device.
● Remove the O-rings from the cylinder liner.
© 43567-0
© 08/2014
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Crankcase
W 01-05-03
Install cylinder liner

● Check the overhang of the cylinder liner.
 Module 01
● Clean cylinder liner.
● Insert new O-rings.
6
© 43568-0
● Coat the cylinder liner in the "X" area with fitting com-
pound.
Make sure that the liner surface and the
crankcase are absolutely clean before
installing the cylinder liner.
© 43612-0
● Insert the cylinder liner in the crankcase.
© 43569-0
© 08/2014
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Crankcase
W 01-05-03
● Select the pressing disc (1) according to the diame-

ter of the cylinder liner and screw to the assembly le-
ver.
6
© 43610-0
● Screw in a cylinder head screw.

● Hook assembly lever (1) to cylinder head screw.
● Mount disc (2) on cylinder liner.
● Press in the cylinder liner to the stop with the assem-
bly lever.
● Remove assembly lever.
● Remove con rod.
 Module 06
1 2
© 43611-1
© 08/2014
4/4
Crankcase
W 01-06-01
Removing and installing crankshaft bearings

Standard tools
Removing the crankshaft bearing

1 Shim Standard
2 Crankshaft bearings Standard
950 Crankshaft bearings Undermeasure stage 1
953 Shim Undermeasure stage 1
© 48699-1
● Remove crankshaft bearing cover.

 Module 01
● Remove crankshaft.
 Module 05
● Remove both shim halves (1).
● Remove all main bearing shells (2).
Lay out components in the order in which
they should be installed.
Note order of cylinders.
© 48866-1
© 10/2011
1/4
Crankcase
W 01-06-01
● Remove all main bearing shells (1).

6
© 48867-0
Installing the crankshaft bearing

● Insert upper main bearing shells.
Attention!
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).
● Insert crankshaft.
 Module 05
© 48868-0
● Install upper thrust ring halves according to meas-

ured axial clearance.
Oil grooves of the thrust ring halves face
the crankshaft web face.
Insert thrust ring halves between
crankcase and crankshaft web (arrow).
© 43505-0
© 10/2011
2/4
Crankcase
W 01-06-01
● Insert lower main bearing shells in the respective

main bearing cover.
● Insert bearing shell with twist protection (1) in
groove (2).
Attention!
6
© 48869-0
© 10/2011
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Crankcase
W 01-06-01
© 10/2011
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Crankcase
W 01-06-02
Checking the crankshaft bearing

Standard tools:
– Micrometer gauge
– Internal measuring device
Checking the crankshaft bearing

1 Shim Standard
2 Crankshaft bearings Standard
953 Shim Undermeasure stage 1
© 48699-1
● Measure wall thickness of the shim with micrometer

gauge.
– Standard
+ 0.05
 2,9 +0 mm
– oversize level
+ 0.05
 3,1 +0 mm
© 43504-0
© 10/2011
1/4
Crankcase
W 01-06-02
● Measure main bearing diameter with internal meas-

uring instrument.
Nominal value:
 85.05 - 85.07 mm
6
© 48909-0
© 10/2011
2/4
Crankcase
W 01-06-02
Technical Data
P01 31 Main bearing shells, diameter, internal Standard 85.05 - 85.07 mm
P01 32 Main bearing shells, diameter, internal two undermeasure stages, each 0.25 mm
Theoretical radial clearance between
P01 33 0.030 - 0.090 mm
main bearing and main journal
Standard + 0.05
P01 35 Thrust washer, wall thickness 2,9 +0 mm
(upper and lower half)
+ 0.05
P01 36 Thrust washer, wall thickness Overmeasure stage 3,1 +0 mm
© 10/2011
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Crankcase
W 01-06-02
© 10/2011
4/4
Crankcase
W 01-08-01
Removing and installing the piston cooling nozzles

Standard tools
Removing the piston cooling nozzles

1 Piston cooling nozzle
© 49653-0
 Module 05
● Remove piston cooling nozzle (2).
© 49654-0
© 10/2011
1/4
Crankcase
W 01-08-01
Installing the piston cooling nozzles

● Clean the bores for the piston cooling nozzles in the
crankcase.
● Mount piston cooling nozzle (1).
● Tighten screw (2).
 21 Nm
● Install crankshaft.
 Module 05
6
© 49655-0
© 10/2011
2/4
Crankcase
W 01-08-01
Technical Data
A01 071 Piston cooling nozzle on crankcase M8x35-10.9 21 Nm
© 10/2011
3/4
Crankcase
W 01-08-01
© 10/2011
4/4
Crankcase
W 01-11-01
Removing and installing the camshaft bearing

information
Special tools:
– Disassembly/assembly
The work process is described for a
tool 02992254
bearing liner. The procedure is the same to
install and remove further bearing liners.
Removing camshaft bearing

● Insert pressure piece (1).
● Insert guide piece (2).
2 1
© 46615-0
● Insert counter holder (1).

● Insert spindle (2).
© 46616-0
© 08/2014
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Crankcase
W 01-11-01
6
© 46617-1
● Hold spindle (1).

● Tighten nut (2).
2
Tighten the nut further until the bearing
liner falls out.
© 46618-0
● Unscrew nut (1).

● Remove pressure piece (2).
● Remove bearing liner (3). 3 2
© 46619-1
© 08/2014
2/4
Crankcase
W 01-11-01
Installing camshaft bearing

Note the different bearing liners.
The wide bearing liner is installed on the
flywheel side.
● Mark the position of the lubricating oil bore on the
crankcase (1).
● Check camshaft bearing bore in the crankcase.
1
6
© 46620-1
● Position new bearing liner on the pressure piece.

The fixing ball (1) must snap into the 1
hole (2). 2
© 43687-0
● Position the bearing liner and pressure piece (1).

● Bring the marking (2) in line with the help
marking (3).
Attention!
Do not turn the bearing liner.
2
● Insert spindle.
© 46621-0
© 08/2014
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Crankcase
W 01-11-01
● Insert counter bearing (1).

● Insert guide piece (2).
Attention!
Make sure that the lubricating oil bores are
in line.
6
© 43350-0
● Press in bearing liner with assembly fixture until it is

in line with the lubricating oil bore.
The bearing bush is pressed into the
crankcase by the thrust pad.
© 46618-1
● Check that the lubricating oil bores (1) are in line.

If the lubricating oil bore is not in line, the
bearing bush must be removed and re-
installed.
© 46623-0
© 08/2014
4/4
Crankcase
W 01-11-02
Checking the camshaft bearing

Standard tools: – Safety information / User
– Micrometer gauge information
Special tools:
Testing camshaft bearing

● Prepare internal measuring device:
– Mount probe bolt for the appropriate measuring
range in the internal measuring device.
– Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
– Set micrometer gauge to 73 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the dial gauge at the reversal point of the pointer to
"0".
© 34768-2
Diagram for measuring the camshaft

bearing at the points "a and b" in the
levels "1 and 2".
© 37239-1
© 08/2014
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Crankcase
W 01-11-02
● Insert internal measuring device.

● Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
 73.000 - 73.064 mm
– Wear limit
 73.080 mm
When the wear limit is reached, the cams-
haft bearing must be replaced.
6
© 43347-0
© 08/2014
2/4
Crankcase
W 01-11-02
Technical Data
Camshaft bearings, locating hole, diame- + 0.019
P01 11 77 0 mm
ter
Camshaft, bearing bushing, diameter,
P01 13 when installed 73.000 - 73.064 mm
internal
Camshaft, bearing bush, diameter, inter-
P01 14 Wear limit 73.080 mm
nal
© 08/2014
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Crankcase
W 01-11-02
© 08/2014
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Crankcase
W 01-12-01
Removing and installing crankshaft bearing covers

information
Special tools:
– Socket wrench insert 01899054
– Rotation angle disc 01899093
Removing the crankshaft bearing cover

● Unscrew all screws (1).
1
© 43547-0
● Remove bearing cap (1).

● Remove crankshaft bearing. 1
 Module 01
● Remove lower thrust ring halves (2).
● Remove all crankshaft bearing covers.
they should be installed. 2
 Module 05
© 43548-0
© 09/2014
1/4
Crankcase
W 01-12-01
Installing the crankshaft bearing cover

● Pay attention to clamping bushing (1).
● Install crankshaft bearing.
 Module 01
 Module 05
6
© 48887-0

● Insert shims. 1
 Module 01
● Insert bearing cap (1).
● Hold lower thrust ring halves on fit bearing cover and
insert together with fit bearing cover.
● Insert main bearing cover (2) according to the num- 2
bering.
Note assignment and installation position:
Insert main bearing cover with the
number 1 on the flywheel side.
© 43548-0
● Tighten all screws (1) with the socket wrench insert

alternately working from the centre to the outside.
– Stage 1:
 50 Nm
● Screw all screws (1) with the socket wrench
insert 8035 and tighten with rotation angle disc.
– Stage 2:
 60°
– Stage 3:
 60°
Attention! 1
Screws can be reused a maximum 3 times
with written documentation.
Otherwise renew every time they are loo- © 43554-1
sened.
© 09/2014
2/4
Crankcase
W 01-12-01
Technical Data
Stage 1:
Can be used 3 times if
documented in writing.
A01 010 Main bearing cover on crankcase 50 Nm
Otherwise:
Use new screwsOb-
serve tightening order
A01 010 Main bearing cover on crankcase Stage 2: 60°
A01 010 Main bearing cover on crankcase Stage 3: 60°
For the tightening procedure according to torque using a torque wrench, a maximum variation of the 6
© 09/2014
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Crankcase
W 01-12-01
© 09/2014
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Lubricating oil sump
W 02-01-01
Removing and installing the lubricating oil pan

(Heavy version)
– 4 pin bolts M8x70 information
Special tools:
– Disassembly tool 02992127 Danger!
– Separating tool 02992301 When using hoists (workshop crane) the
safety regulations for handling hoists must
be observed.
DEUTZ DW 74
It is not permitted to stay under moving
– Locking agent
loads.
DEUTZ DW 72
– Adhesive KL 5A 01321601 The following work process is described for
a removed engine as an example. 6
Work on the installed engine is to be car-
ried out in the same way.
The documentation of the vehicle manu-
facturer / equipment manufacturer must be
observed.
Collect draining lubricating oil and dispose
of properly.
The engine oil shall be filled according to
the operating manual.
Removing the lubricating oil pan

1 Lubricating oil pan
2 Lubricating oil screen
3 Cap
4 Screw plug
5 Sealing ring
6 Screw plug 110 Nm
7 Sealing ring
9 Cap
10 O-ring
11 Seal
185 Locking agent © 56569-0
© 11/2014
1/10
W 02-01-01
● Drain lubricating oil, collect and dispose of according

to regulations.
● Unscrew locking screw (1).
6
© 56570-0
● Drive in all sealing covers (1) laterally.
© 56571-0
● Pull out all sealing covers (1).
© 56572-0
© 11/2014
2/10
W 02-01-01
6
© 56573-0
Note different screw lengths.

© 56574-0
Attention!
Do not damage the components.
Drive in separating tool carefully.
Area X:
It is not permissible to drive in the separa-
ting tool in this area.
● Drive in separating tool (1) to the stop (2).
● Drive in second separating tool (1) to the stop (2).
© 56632-0
© 11/2014
3/10
W 02-01-01
● Lever out lubricating oil pan at the recesses (arrows).

Lubricating oil pan becomes detached from
the sealing surface.
● Lift the lubricating oil pan with the workshop crane.
6
© 56575-0
● Scrape off sealing compound with separating tool.

● Remove the O-ring (1) with the disassembly tool.
● Remove seal (2) with disassembly tool.
© 56576-0
Installing the lubricating oil pan

The round sealing ring and seal are fixed
using adhesive.
● Apply adhesive (arrows) to the inside of the sealing
ring groove (1) in drops.
● Apply adhesive (arrows) to the inside of the sealing
ring groove (2) in drops.
Attention!
Observe drying time of the adhesive.
© 56633-0
© 11/2014
4/10
W 02-01-01
● Insert new O-ring (1).

● Insert new seal (2).
Ensure that the installation location is free
from faults.
6
© 56576-1
● Apply the sealing compound evenly.

● Apply sealing compound (1) evenly on the sealing
surface.
Thickness 3.5 mm
Attention!
Observe the drying time for the packing
compound.
Packing compound must not enter the
lubricating oil pan or the oil channels!
© 56577-0
● Apply the sealing compound evenly.

● Apply sealing compound (1) evenly on the sealing
surface.
Thickness 3.5 mm
Attention!
compound.
Packing compound must not enter the
lubricating oil pan or the oil channels!
© 56577-1
© 11/2014
5/10
W 02-01-01
● To align the lubricating oil pan, screw four pin bolts

(1) diagonally opposed into the crankcase.
● Lower the lubricating oil pan down carefully onto the
crankcase.
● Align the lubricating oil pan in the appropriate instal-
lation position with the pin bolts.
● Mount lubricating oil pan.
Attention!
Do not move the lubricating oil pan any
more.
compound.
● Unscrew the pin bolts.
6
© 56578-0
● Insert screws (1) with locking agent.

● Fasten all screws (1).
© 56579-0
© 56573-0
© 11/2014
6/10
W 02-01-01

 300 Nm
6
© 56580-0

quence.
 35 Nm
© 56581-0
Use new sealing covers.
● Insert all sealing covers (1) using locking agent.

● Drive in all sealing covers (1) flush with the oil pan
surface.
© 56582-0
© 11/2014
7/10
W 02-01-01
● Insert new sealing ring (1).

● Tighten screw plug (2).
 55 Nm
● Fill in lubricating oil according to operating manual.
6
© 56570-1
© 11/2014
8/10
W 02-01-01
Technical Data
Observe tightening
A02 030 Lubricating oil pan on crankcase 35 Nm
sequence!
A02 030 Lubricating oil pan on crankcase M16x390 300 Nm
A02 031 Locking screw on lubricating oil pan M18x1.5 Replace sealing ring 55 Nm
© 11/2014
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W 02-01-01
© 11/2014
10/10
W 02-01-03
Removing and installing the lubricating oil screen

information
– Locking agent Collect draining lubricating oil and dispose

DEUTZ DW 72 of properly.
The engine oil shall be filled according to
the operating manual.
Removing the lubricating oil screen

1 Lubricating oil pan
2 Lubricating oil screen
3 Cap
4 Screw plug
5 Sealing ring
6 Screw plug 110 Nm
7 Sealing ring
9 Cap
10 O-ring
11 Seal
185 Locking agent © 56569-0
© 11/2014
1/4
W 02-01-03
● Remove lubricating oil pan.

 Module 02
Use a suitable tool.
● Drive in sealing cover (1) laterally.
6
© 56583-0
● Pull out sealing cover (1).
© 56584-0
● Roll in the lubricating oil screen (1) slightly.

● Pull out the lubricating oil screen (1).
© 56585-0
© 11/2014
2/4
W 02-01-03
Installing the lubricating oil screen

● Roll up the lubricating oil screen (1).
● Insert lubricating oil screen (1).
Overlap:
Dimension X
approximately 10 mm
6
© 56586-0
● Insert sealing cover (1) with locking agent.

Use a suitable tool.
● Drive in sealing cover (1) until it is fixed in place.

● Install lubricating oil pan.
 Module 02
© 56587-0
© 11/2014
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W 02-01-03
© 11/2014
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W 02-90-01
Closing parts
information

of properly.
1 Blind oval flange

2 Seal
3 Hexagon head screw 20 Nm
Use a new gasket.
© 56263-0
© 11/2014
1/2
W 02-90-01
© 11/2014
2/2
V-rib belt pulley add-on
W 05-01-01
Removing and installing the V-rib belt pulley

information
– Operation manual
Removing the V-rib belt pulley

1 Torsional vibration damper
2 Torx screw
3 Clamping bush
4 V-rib belt pulley
5 Cylinder head screw
© 56399-0
● Relieve the V-rib belt tension with the belt tightener.

 Operation manual
● Remove V-rib belt.
● Remove V-rib belt pulley (2)
© 56400-0
© 11/2014
1/4
W 05-01-01
Installing the V-rib belt pulley

● Mount V-rib belt pulley (1).
 110 Nm
● Fit the V-rib belt according to the running direction.
6
© 56400-1
© 11/2014
2/4
W 05-01-01
Technical Data
V-rib belt pulley on torsional vibration
A05 030 110 Nm
damper
© 11/2014
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W 05-01-01
© 11/2014
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Torsional vibration damper
W 05-02-01
Removing and installing torsional vibration damper

information
Special tools: – Operation manual
– Socket wrench insert Torx
E20 01899061
– Turning gear / locking
device 02992465
Removing the torsional vibration damper

1 Torsional vibration damper
2 Torx screw
3 Clamping bush
4 V-rib belt pulley
© 56399-0
● Relieve the V-rib belt tension with the belt tightener.

● Remove V-rib belt pulley.
 Module 05
● Install turning gear / locking device.
 Module 49
● Remove the torsional vibration damper (2).
© 56401-0
© 11/2014
1/4
W 05-02-01
Installing the torsional vibration damper

● Mount torsional vibration damper (1).
Clamping pin (2) must engage in the
hole (3).
6
© 56402-0
Attention!
Renew screws every time they are loo-
sened.
● Oil new screws lightly.
Use a Torx E20 socket wrench insert.
● Turn in new screws (1).

● Tighten new screws (1) with socket wrench insert
and rotation angle disc.
● Tighten all screws (1).
– Stage 1:
 30 Nm
© 56403-0

– Stage 2:
 60°
– Stage 3:
 60°
● Mount V-rib belt pulley.
 Module 05
● Remove turning gear / locking device.
 Module 49
© 56403-0
© 11/2014
2/4
W 05-02-01
Technical Data
Stage 1:
Torsional vibration damper on cranks-
A05 030 Use new screws. 30 Nm
haft
Oiled screws.
A05 030 Stage 2: 60°
haft
A05 030 Stage 3: 60°
haft
tightening torque of +/- 10% is permissible. 6
© 11/2014
3/4
W 05-02-01
© 11/2014
4/4
Flywheel
W 05-03-01
Removing and installing the flywheel

(Fastening parts)
– Guide pin (self-const- information
ructed)
– Auxiliary screws M10x120
Special tools:
– Turn-over gear 02992033
Removing the flywheel

3 Double-hex bolt
4 Spiral clamping pin
© 56380-0
● Insert turn-over gear (1).

 Module 49
© 56381-0
© 11/2014
1/6
Flywheel
W 05-03-01
● Screw in auxiliary screws (1).

● Hold crankshaft with turning gear.
● Remove flywheel using auxiliary screws.
6
© 56382-0
● Remove clamping pin (1).
© 56383-0
Installing the flywheel

● Drive in the new clamping pin (1) as far as it will go.
© 56383-0
© 11/2014
2/6
Flywheel
W 05-03-01
● Insert self-made guide pin (arrow).

The bores in the flywheel must match the
threaded bores in the crankshaft flange.
● Mount flywheel using auxiliary screws.
6
© 56384-0
● Insert turn-over gear (1).

● Hold crankshaft with turning gear.
© 56381-0
Attention!
sened.
● Tighten screws (1) alternately.
– Stage 1:
 30 Nm
● Tighten screws with rotation angle disc.
– Stage 2:
 60°
– Stage 3:
 60°
● Remove guide pin.
● Unscrew auxiliary screws. © 56385-0
© 11/2014
3/6
Flywheel
W 05-03-01
● Remove turning gear (1).
6
© 56381-0
See spare parts documentation.
● Drive plugs into the threaded bores (arrows) to the

stop.
© 56386-0
© 11/2014
4/6
Flywheel
W 05-03-01
Technical Data
Stage 1:
Use screws
a maximum 5 timeswith
A05 001 Flywheel on crankshaft proof. 30 Nm
Otherwise use new
screws.
Screws oiled.
A05 001 Flywheel on crankshaft Stage 2: 60°
A05 001 Flywheel on crankshaft Stage 3: 60°
6
© 11/2014
5/6
Flywheel
W 05-03-01
© 11/2014
6/6
Flywheel
W 05-03-03
Renewing toothed starter ring on the flywheel

information
Danger!
Danger of injury, do not touch hot parts!
The following procedure is described,

using a flywheel as an example.
Proceed in the same way for other fly-
wheels.
Removing toothed starter ring

1 Flywheel
2 Ring gear
© 49810-0
● Drill toothed wheel.

Block flywheel with suitable tool.
© 45698-0
© 08/2014
1/2
Flywheel
W 05-03-03
● Remove toothed starter ring with suitable tool.

● Clean flywheel.
6
© 45699-0
Install toothed starter ring

● Heat up toothed starter ring to 220 °C.
● Place toothed starter ring on flywheel.
The toothed starter ring must lie evenly on
the joint of the flywheel.
© 45701-0
© 08/2014
2/2
Crankshaft
W 05-05-01
Removing and installing the crankshaft

Standard tools
Removing crankshaft
1 Crankshaft
5 Threaded insert
© 48779-0
● Remove front cover.

 Module 01 2
● Remove the gear case cover.
 Module 09
● Remove con rod.
 Module 06 1
The markings (arrows) must be in line

when the crankshaft is installed.
A help mark (colour) can be made. 3
● Make a mark (1) on the camshaft gear wheel for as-

sistance.
Your mark must be on a line between the
marking (2) and the middle (3) of the
camshaft. © 42651-0
© 10/2011
1/2
Crankshaft
W 05-05-01
● Turn the crankshaft evenly until the marking (1) on

the crankshaft flange is in line with your mark (2) on
the camshaft gear wheel.
The marking on the camshaft gear wheel is
covered by the crankshaft flange when it is 1
in line.
● Remove crankshaft bearing cover.
 Module 01
● Remove crankshaft bearing.
2
 Module 05
6
© 42652-0
Installing the crankshaft

● Check axial backlash of crankshaft.
 Module 05
● Position camshaft. 1
 Module 05
● Lightly oil bearing surfaces.
● Insert the crankshaft carefully in the crankcase.
2
The marking (1) on the crankshaft flange
must be in line with your mark (2).
© 42652-0
● Install crankshaft bearing cover.

 Module 01
● Install con rod.
 Module 06
● Install the gear case cover.
 Module 09
● Install front cover.
 Module 01
© 10/2011
2/2
Crankshaft
W 05-05-02
Checking the crankshaft

– Magnetic measuring stand information
– Prisms
– Hardness tester
Special tools:
Checking the bearing pin hardness

● Put hardness tester on journal.
© 30560-1
● Raise stylus (1) and press release (2).

Stylus (1) falls down, briefly strikes the sur-
face and jumps up to the measured value. 1
© 43499-0
© 08/2014
1/6
Crankshaft
W 05-05-02
● Read off displayed value (arrow) from hardness test-

er.
– Nominal value, at least
 58 HRc
The measured value is to be converted
according to the table of the measuring
device.
6
© 43515-0
Checking the diameter of the main bearing

pins
Diagram for measuring the journals at the
points 1 and 2 in the levels a and b.
© 36424-2
● Measure main bearing pin with micrometer gauge.

Nominal value:
– Standard
 85 − 0.02 mm
– Undermeasure stage
 0.25 mm
See schematic diagram for measuring
points.
© 42603-0
© 08/2014
2/6
Crankshaft
W 05-05-02
Checking the diameter of the lifting journals

● Measure lifting journal with micrometer gauge.
Nominal value:
 79 − 0.02 mm
– Undermeasure stage
 0.25 mm
points.
6
© 42604-0
Checking the rotation

● Place crankshaft on prism.
● Mount magnetic measuring stand.
● Insert dial gauge.
● Apply stylus to the main bearing pin with pre-tension
(arrow) and adjust dial gauge to "0".
● Turn crankshaft evenly and check rotation.
Nominal value:
 0.1 mm
● Remove magnetic measuring stand.
● Remove dial gauge.
© 42605-0
Measuring the fit bearing width

● Set micrometer gauge to 32 mm.
● Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".
© 35825-2
© 08/2014
3/6
Crankshaft
W 05-05-02
● Measure bearing width with internal measuring de-

vice between thelay-on surfaces of the thrust rings.
Nominal value:
+ 0.06
 33.9 mm
– 1. Undermeasure stage
 0.4 mm
6
© 42606-0
© 08/2014
4/6
Crankshaft
W 05-05-02
Technical Data
P05 03 Main journal, diameter Standard 85 − 0.02 mm
P05 04 Main journal, diameter two undermeasure stages per 0.25 mm
Main journal, lifting journal,
P05 07 58 HRc
surface hardness
+ 0.06
P05 11 Fit bearing pin, width Standard 33.9 mm
P05 12 Fit bearing pin, width one overmeasure stage 0.4 mm
+ 0.3
P05 21 Lifting journal, width 34.1 mm
P05 22 Lifting journal, diameter Standard 79 − 0.02 mm
P05 23 Lifting journal, diameter two undermeasure stages 0.25 mm
P05 26 Radial run-out deviation, crankshaft maximum permissible deviation 0.1 mm 6
© 08/2014
5/6
Crankshaft
W 05-05-02
© 08/2014
6/6
Crankshaft
W 05-05-03
Checking the axial clearance of the crankshaft

8190
– Magnetic measuring stand information

Special tools:
Checking the axial backlash

● Mount magnetic measuring stand.
● Insert dial gauge.
● Apply stylus to the crankshaft end with pre-tension.
● Press crankshaft in direction of arrow.
● Adjust dial gauge to "0".
© 43507-0
● Press crankshaft in direction of arrow.

● Read off measured value.
– Nominal value:
 0.1 - 0.32 mm
If there is any differing axial clearance, the
permitted amount of axial clearance must
be ensured by replacing the thrust washer
halves.
© 43529-0
© 08/2014
1/4
Crankshaft
W 05-05-03
● Measure wall thickness of the shim with micrometer

gauge.
– Standard
+ 0.05
 2.9 0 mm
– 1. Overmeasure
+ 0.05
 3.1 0 mm
● Select the thrust washers in accordance with the
measured value.
6
© 43504-0
● Set micrometer gauge to 32 mm.

● Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".
© 35825-2
● Measure locating bearing width

● Note measured value, dimension (a).
© 42606-0
© 08/2014
2/4
Crankshaft
W 05-05-03
● Install the thrust washer halves onto the fit bearing

cover (arrows)
● Measure width with micrometer gauge.
● Note measured value, dimension (b).
● Determine axial backlash.
– Nominal value:
 0.1 - 0.32 mm
Calculation example
Desired: Axial backlash
Given: -
Measured: (a) = 32.8 mm
Calculation: (b) = 32.7 mm
Dimension (a) - Dimension (b)
Result: = 0.1 mm
6
© 35827-2
● Check axial backlash of crankshaft.

– Nominal value:
 0.1 - 0.32 mm
● Remove magnetic measuring stand.
● Remove dial gauge.
© 43507-0
© 08/2014
3/4
Crankshaft
W 05-05-03
Technical Data
P01 34 Crankshaft, permissible axial clearance when installed 0.1 - 0.32 mm
Standard + 0.05
P01 35 Thrust washer, wall thickness 2.9 0 mm
(upper and lower half)
+ 0.05
P01 36 Thrust washer, wall thickness Overmeasure stage 3.1 0 mm
© 08/2014
4/4
Connecting rod
W 06-01-01
Removing and installing the con rod

Standard tools Attention!
The assignment of con rod and big end
Special tools:
bearing cover must stay as it is. If con rod
and big end bearing cover are assembled
– Assembly device 02992168
the wrong way around, the con rod will be
– Piston ring compressor 02992172
unusable!
– Liner holder 02992288
Do not damage the fracture surfaces of the
con rod and big end bearing cover!
Remove con rod

1 Con rod
2 Con rod liner
3 Screw
© 49219-0

 Module 08 1
● Mount liner holder (1).
● Tighten screws .
© 43522-0
© 08/2014
1/8
Connecting rod
W 06-01-01
● Set lifting journal at bottom dead centre (BDC).

● Remove big end bearing cap (2).
● Remove bearing shell.
Attention!
Do not place the big end bearing cover on
the broken surface.

6
© 49220-0
● Remove piston and connecting rod.

Attention!
unusable!

● Remove piston.
 Module 07
© 49221-0
For a better overview, the mounting of the

assembly device (1) and the protection
plug (2) on a removed con rod are shown.
© 43524-1
© 08/2014
2/8
Connecting rod
W 06-01-01
Attention!
Do not damage the fractured surfaces of 1
the con rod!
● Screw on assembly tool (1).
● Insert protection plug (2).
2
6
© 49329-0
● Press out piston with assembly device.

● Remove assembly device and protective plug.
● Position con rod and piston according to the installa-
tion location and alignment.
Attention!
The alignment of the con rod and big end
bearing cover must be maintained. If the
con rod and the big end bearing cover are 1
installed the wrong way around, the con
rod will be useless!
Do not damage the break areas of the con
rod and the big end bearing cover!
© 49328-0
Install con rod

● Install piston.
 Module 07
● Insert bearing shell in the con rod.
Attention!
groove (2).
© 49222-0
© 08/2014
3/8
Connecting rod
W 06-01-01
● Insert bearing shell in the respective big end bearing

cap.
Attention!
groove (2).
6
© 49223-0
Attention!
The arrow (1) on the big end bearing cover
faces the flywheel.
The symbol flywheel/crankshaft (2) faces
the flywheel.
© 49224-0
● Insert protective plug (1) in con rod.

● Mount assembly device on con rod.
© 43524-0
© 08/2014
4/8
Connecting rod
W 06-01-01
● Locate piston ring joints offset to one another.

 120°
● Position of the spring ring joint:
120°
 180°
120°
Do not turn the piston rings any further.
0° 6
© 41046-0
● Lightly oil cylinder running surface, piston, piston

rings and lifting bearing journal lightly.
● Clamp piston rings with piston ring compressor (1).
© 49226-0
● Position lifting bearing journal in LDC position.

● Push piston and con rod into cylinder liner together
with assembly device.
© 43574-0
© 08/2014
5/8
Connecting rod
W 06-01-01
● Set lifting journal at bottom dead centre (BDC).

Note the cylinder assignment of the piston.
Note the label indicating the installation
position on the piston base.
The symbol flywheel/crankshaft (1) must
face the flywheel.
The piston ring clamping band must lie flat
on the crankcase.
● Push piston with con rod into the cylinder.
6
© 49877-0
● Pull the con rod with assembly device (1) until it rests
on the lifting journal.
● Remove assembly device and protective plug. 1
Attention!
Do not damage the fractured surfaces of
the con rod!
© 43527-0
● Press the con rod carefully against the lifting journal.

Attention!
Do not jam the con rod with the crankshaft.
© 49227-0
© 08/2014
6/8
Connecting rod
W 06-01-01
Installing the big end bearing cap

Attention!
Note the assignment of the big end bearing
cap.
The identification numbers (1) on the con
rod and the big end bearing cap must be
identical and opposite to each other when
assembled.
Attention!
1
unusable!
Do not damage the fracture surfaces of the 6
con rod and big end bearing cover! © 43459-0
● Mount the big end bearing cover (1) and the big end
bearing shell.
Attention!
sened.
© 49228-0
● Tighten new screws (1).

– Stage 1:
 30 Nm
● Tighten new screws with rotation angle disc.
– Stage 2:
 60°
– Stage 3:
 60°
 Module 08
© 49230-0
© 08/2014
7/8
Connecting rod
W 06-01-01
Technical Data
P07 95 Piston ring joint, installation position Offset 120°
Offset the spring ring joint to the
P07 96 Oil control ring 180°
ring joint,
Stage 1:
A06 020 Con rod bearing cover on con rod Use new screws. 30 Nm
Oiled screws
A06 020 Con rod bearing cover on con rod Stage 2: 60°
6 A06 020 Con rod bearing cover on con rod Stage 3: 60°
© 08/2014
8/8
Connecting rod
W 06-01-02
Checking the con rod

Standard tools: Attention!
– Micrometer gauge The assignment of con rod and big end
– Internal measuring device bearing cover must stay as it is. If con rod
Special tools: and big end bearing cover are assembled
– Rotation angle disc 01899093 the wrong way around, the con rod will be
– Dial gauge 01899126 unusable!
Checking the con rod liner

"0".
© 34768-2
Schematic representation for measuring

the con rod liner at points "a" and "b" in
levels "1" and "2".
© 37239-1
© 08/2014
1/8
Connecting rod
W 06-01-02

● Swing out internal measuring instrument at the spec-
ified
measuring points and read off measured value at the
turning point.
– Nominal value:
+ 0.05
 46 + 0.04 mm
Con rod liner pressed in.
● Note the measured value, dimension (A).

The dimension A is required to determine
the piston bolt clearance.
6
© 34770-2
Determine piston bolt clearance

The piston bolt clearance is derived from
the difference between the internal diame-
ter of the con rod liner (dimension A) and
the diameter of the piston bolt (dimension
B).
 Module 07
– Nominal value:
 0.040 - 0.056 mm
Calculation example
Desired: Piston pin clearance
Given:
Measured: (A) = 40.045 mm
Calculation: (B) = 40.006 mm
Dimension (A) - dimension (B)
Result: = 0.039 mm
Checking the con rod bearing bore

● Mount big end bearing cap.
Attention!
Note the assignment of the big end bearing 1
cap.
The identification numbers (1) on the con
rod and the big end bearing cap must be
identical and opposite to each other when
assembled.
© 42630-0
© 08/2014
2/8
Connecting rod
W 06-01-02
● Tighten screws alternately with rotation angle disc

and socket wrench insert.
– Stage 1:
 30 Nm
– Stage 2:
 60°
– Stage 3:
 60°
6
© 42632-0

"0".
© 36094-2
Diagram for measuring the con rod bearing

bore at the points "a" and "b" in the
levels "1" and "2".
© 37239-1
© 08/2014
3/8
Connecting rod
W 06-01-02

ified
turning point.
– Nominal value:
+ 0.02
 82.60 mm
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.
6
© 42633-0
Checking internal diameter of the con rod

bearing shells
2
● Insert bearing shell in the con rod.
Attention!
groove (2).
1
unusable!
© 42635-0
● Insert bearing shell in the respective big end bearing

cap.
Attention! 2
groove (2).
© 42636-0
© 08/2014
4/8
Connecting rod
W 06-01-02
● Mount big end bearing cap.

Attention!
The identification numbers (1) on the con-
necting rod and the big end bearing cover
must be identical and opposite to each
other when assembled. 1
6
© 42631-0
● Tighten screws alternately with rotation angle disc

and socket wrench insert.
– Stage 1:
 30 Nm
– Stage 2:
 60°
– Stage 3:
 60°
© 43012-0

"0".
© 36094-2
© 08/2014
5/8
Connecting rod
W 06-01-02
Diagram for measuring the inside diameter

of the con rod bearing shells at the
points "a" and "b" in the levels "1" and "2".
6
© 37239-1

ified
turning point.
– Nominal value:
 79.036 - 79.076 mm
If the values up to maximum 0.015 mm are
above the bearing tolerances, the connec-
ting rod can still be used.
When the limit value is reached, the con-
necting rod must be replaced.
● Note the measured value, dimension (C).
The dimension (C) is required to determine
the big end bearing clearance. © 42634-0
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 (C) and the
lifting journal diameter (D).
– Nominal value:
 0.036 - 0.096 mm
Calculation example
Desired: Big end bearing clearance
Given:
Measured: (C) = 70.030 mm
Calculation: (D) = 69.994 mm
Dimension (A) - dimension (B)
Result: = 0.036 mm
© 08/2014
6/8
Connecting rod
W 06-01-02
Technical Data
+ 0.05
P06 43 Con rod liner, diameter, internal when installed 46 + 0.04 mm
Theoretical clearance between piston
P06 45 0.040 - 0.056 mm
bolt and con rod liner
Con rod, hole for con rod, diameter, inte- + 0.02
P06 49 49 mm
rior
Big end bearing shell top and bottom,
P06 51 29.2 − 0.5mm
width
P06 52 Con rod bearing shells, diameter, internal when installed 79.036 - 79.076 mm
P06 54 Con rod bearing shells, diameter, internal two undermeasure stages, each 0.25 mm
+ 0.02
P06 55 Con rod, bearing bore, diameter, internal 82.60 mm
6
Theoretical clearance between the con
P06 56 0.036 - 0.096 mm
rod bearing and lifting journal
Stage 1:
A06 020 Con rod bearing cover on con rod Use new screws. 30 Nm
Oiled screws
© 08/2014
7/8
Connecting rod
W 06-01-02
© 08/2014
8/8
Cylinder head cover
W 08-01-01
Removing and installing the cylinder head cover

Standard tools
Removing cylinder head

1 Cylinder head cowling
2 Seal
4 Screw
© 49765-0
● Removing the crankcase breather.

 Module 01
Gasket and screws are captively locked on
the cylinder head hood.
© 49766-0
© 11/2014
1/4
Cylinder head cover
W 08-01-01
Installing cylinder head cover.

Make sure the gasket fits perfectly.
The gasket can be reused several times if
it is not damaged.
6
© 49767-0
● Mount cylinder head cover (1).
© 49768-0
● Tighten all screws according to the tightening se-

quence.
 9 Nm
● Install crankcase breather.
 Module 01
© 49769-0
© 11/2014
2/4
Cylinder head cover
W 08-01-01
Technical Data
Observe tightening
A08 004 Cylinder head cover on cylinder head 9 Nm
sequence
© 11/2014
3/4
Cylinder head cover
W 08-01-01
© 11/2014
4/4
Cylinder head
W 08-90-14
Engine suspension
information
Danger!
Check suspension plate before reinstalling.
If there is any damage or cracks present,
the suspension plate must be replaced.
Attention!
Remove suspension plate after installing
the engine.
1 Hanging plate
© 56378-0
© 11/2014
1/2
Cylinder head
W 08-90-14
© 11/2014
2/2
Gearcase
W 09-01-01
Renewing the crankshaft sealing ring

(flywheel side)
information
Special tools:
– Pricker 01899103
– Assembly lever 01899110 Attention!
– Assembly tool 02992238 The crankshaft sealing ring is coated in
wax at the factory.
– Self-tapping screw Do not lubricate the crankshaft sealing
– Washer ring.
Installation tool:
the spacer discs are not used.
6
Removing the crankshaft sealing ring

● Remove flywheel.
 Module 05
● Make a hole of approximately 3 mm in the crankshaft
sealing ring with a pricker.
Attention!
Do not damage the gearcase cover and
crankshaft.
© 56428-0
● Screw in a self-tapping screw (1) with washer.
© 56429-0
© 11/2014
1/4
Gearcase
W 09-01-01
● Pull out the crankshaft sealing ring with assembly le-

ver.
● Visually inspect the crankshaft sealing ring running
surface.
6
© 56430-0
Install crankshaft sealing ring

The bores in the guide sleeve must match
the threaded holes in the crankshaft
flange.
● Position guiding piece (1).
© 56431-0
● Place the crankshaft sealing ring carefully on the pe-

ripheral surface.
The sealing lip faces the crankcase.
© 56432-0
© 11/2014
2/4
Gearcase
W 09-01-01
● Mount assembly sleeve (1).
6
© 56433-0
● Insert ball bearing (1).

Attention!
Crankshaft sealing ring must not be
pushed in too deep.
Crankshaft sealing ring must not be distor-
ted.
● Tighten nut (2).
Crankshaft sealing ring must sit flush with
the gear case.

● Withdraw ball bearing (1).
© 56434-0
● Withdraw installation sleeve.

● Check that the crankshaft sealing ring (1) and gear
case (2) are flush.
● Remove guiding piece (4).
● Install flywheel.
 Module 05
© 56435-0
© 11/2014
3/4
Gearcase
W 09-01-01
© 11/2014
4/4
Gearcase
W 09-02-01
Removing and installing the gearcase

information
Special tools:
DEUTZ DW 67
– Mounting compound
Removing the gearcase

2 O-ring
4 Bolt
5 O-ring
242 Mounting compound
© 56444-0
● Remove starter.
 Module 44
 Module 05
● Remove connection housing.
 Module 52
● Remove lubricating oil pan.
 Module 02
● Remove gear case (2).

© 56445-0
© 11/2014
1/6
Gearcase
W 09-02-01
6
© 56446-0
● Remove bolt (1) in direction of arrow.
© 56447-0
● Remove the O-rings (1) with the disassembly tool.
© 56448-0
© 11/2014
2/6
Gearcase
W 09-02-01
● Knock out crankshaft sealing ring (1).

Attention!
Do not damage sealing surface when
knocking out.
6
© 56449-0
Installing the gearcase

● Clean the sealing surfaces on the gear case and
crankcase.
Sealing bead thickness approx. 1.4 mm.
● Apply packing compound (arrow).
Attention!
The assembly must be completed
within 1 hour at most.
© 56450-0
● Lightly coat new round sealing rings with DEUTZ

AP1908 mounting compound.
● Insert new O rings (1).
© 56451-0
© 11/2014
3/6
Gearcase
W 09-02-01
● Preassemble bolt (1).

Attention!
Chamfer (2) is facing the connection hou-
sing.
6
© 56452-0

Assemble round sealing ring when dry and
free from grease.
© 56453-0
● Attach gear case (1) to crankshaft journal.

● Align bolt (2) with holder (3).
Attention!
Do not move the gear case once it has
been attached.
The sealing thread must not be obliterated.
The sealing thread must not come into
contact with grease.
● Fix the gear case (1) in position.
● Push bolt (2) into the crankcase to the limit stop.
© 56454-0
© 11/2014
4/6
Gearcase
W 09-02-01

M8x65
M8x30
6
© 56455-0

quence.
 35 Nm
● Install new crankshaft sealing ring (flywheel side).
 Module 09
● Install connection housing.
 Module 52
 Module 05
● Install starter.
 Module 44
© 56456-0
© 11/2014
5/6
Gearcase
W 09-02-01
Technical Data
Observe tightening
A09 092 Gear case on crankcase 35 Nm
sequence
© 11/2014
6/6
Camshaft
W 10-02-01
Removing and installing the camshaft

information
Removing the camshaft

1 Camshaft
© 49770-0
● Remove high-pressure pumps and roller tappets.

 Module 17
● Remove the valve control.
 Module 11
 Module 05
● Turn camshaft.
● Carefully pull out camshaft (1).
© 49771-0
© 08/2014
1/2
Camshaft
W 10-02-01
Installing the camshaft

● Oil camshaft bearing lightly.
● Oil cam shaft pin lightly.
● Insert camshaft carefully.
 Module 05
● Install valve control.
 Module 11
● Install high-pressure pumps and roller tappets.
 Module 17
6
© 49771-0
© 08/2014
2/2
Camshaft
W 10-02-02
Checking the camshaft

Standard tools:
– Prisms
Checking the camshaft

● Visually inspect cams and bearing pins for wear.
● Check camshaft gear wheel for visible signs of wear.
Diagram for measuring the journals at the
points 1 and 2 in the levels a and b.
© 36424-2
Checking the diameter of the journal

● Measure the bearing pin.
− 0.05
 73 − 0.07 mm
points.
When the limit value is reached the cams-
haft must be replaced.
© 42714-0
© 10/2011
1/2
Camshaft
W 10-02-02
Technical Data
− 0.05
P10 31 Camshaft, bearing pin, diameter 73 − 0.07 mm
© 10/2011
2/2
Control parts
W 11-01-01
Checking and setting the valve clearance

8190
information
– Screwdriver insert for Attention!
hexagon socket head Observe engine rotation direction - see
screws (4 mm) 01899097 operating manual
– Open end wrench adapter 01899099
Allow the engine to cool down for at least
30 minutes before setting the valve
clearance. Engine oil temperature < 80 °C
Setting valve clearance

● Remove the cylinder head hood.
 Module 08
● Attach turning gear.
 Module 49
© 00000-0
● Depending on the installation situation mount the ap-

propriate tool on the turning gear (1) for extension.
● Turn crankshaft with turning gear until reaching the
valve overlap of cylinder 1, in direction of engine ro-
tation.
1
Valve overlap: Outlet valve is not yet
closed, inlet valve begins to open.
Ignition
1-5-3-6-2-4
sequence:
Valves Cylinders
set to 1 5 3 6 2 4
overlap 6 2 4 1 5 3
© 49638-0
© 11/2014
1/6
Control parts
W 11-01-01
● Fix magnet of rotation angle disc on cylinder head.

● Set the rotation angle disc with a screwdriver insert 1
at the adjusting screw.
● Plug on the tee handle (1).
● Loosen lock nut (2).
Hold with tee handle.
Do not rotate adjusting screw.
6 2
© 45312-0
Check
● Hold adjusting screw.
● Set rotation angle disc to "0".
● Hold setting screw with screwdriver insert (1).
© 45311-0
● Turn the setting screw with screwdriver insert (1) in

the direction of the arrow until the setting screw is
touching without clearance.
If the setting screw is already touching wit-
hout clearance, there is no valve
clearance.
Causes must be eliminated.
● Read the rotation angle degrees from the rotation an-
gle disc.
© 45310-0
© 11/2014
2/6
Control parts
W 11-01-01
Settings
● Turn the setting screw with screwdriver insert (1) in
the direction of the arrow until the setting screw is
touching without clearance.
6
© 45310-0
● Set rotation angle disc to "0".

● Hold setting screw with screwdriver insert (1).
© 45311-0
● Turn setting screw back with screwdriver insert (1)

until the specified rotation angle is reached.
Industry
– Inlet valve
+ 10°
 75° − 10°
– Exhaust valve
+ 10°
 105° − 10°
Agricultural engineering
– Inlet valve
 130°
+ 10° 1
− 10°
– Exhaust valve
+ 10°
 165° − 10°
© 45310-1
© 11/2014
3/6
Control parts
W 11-01-01
● Plug on the tee handle (1).

Hold with tee handle. 1
Do not rotate adjusting screw.
● Tighten lock nut (2) with open wrench.

 20 Nm
Set all other valves according to the valve
setting diagram.
● Remove turning gear.

 Module 49
● Mount cylinder head cover.
 Module 08
6 2
© 45312-0
© 11/2014
4/6
Control parts
W 11-01-01
Technical Data
Industry
+ 10°
P11 61 Valve clearance (inlet) with rotation angle disc 75° − 10°
+ 10°
P11 62 Valve clearance (outlet) with rotation angle disc 105° − 10°
Agricultural engineering
+ 10°
P11 61 Valve clearance (inlet) with rotary angle disc 130° − 10°
+ 10°
P11 62 Valve clearance (outlet) with rotary angle disc 165° − 10°
Lock nut, 6
A11 003 20 Nm
valve clearance setting screw
© 11/2014
5/6
Control parts
W 11-01-01
© 11/2014
6/6
Control parts
W 11-03-01
Removing and installing control units

information
Special tools:
– Special pliers 02992349
Removing control units

1 Roller tappet
2 Stop rod
3 Valve bridge
© 49822-0
● Remove rocker arm and rocker arm brackets.

 Module 11
● Remove valve bridges (1).
● Remove stop rods (2).
© 48740-0
© 08/2014
1/4
Control parts
W 11-03-01

 Module 08
● Pull out roller tappet (1) with special pliers.
6
© 50525-0
Installing control units

● Oil the roller tappet lightly.
● Insert roller tappet (1) with special pliers.
Note the assignment of the tappets.

 Module 08
© 50525-0
● Insert stop rods (1).

● Mount valve bridges (2).
● Install rocker arms and rocker arm brackets.
 Module 11
© 48740-1
© 08/2014
2/4
Control parts
W 11-03-01
Bore (1) points towards exhaust side.
6
© 43477-0
© 08/2014
3/4
Control parts
W 11-03-01
© 08/2014
4/4
Lubricating oil cooler
W 15-02-01
Removing and installing the lubricating oil cooler

information
Collect leaking operating substances in
– Fitting compound suitable vessels and dispose of according
DEUTZ AP1908 to regulations.
The appropriate operating manual should
be observed for emptying and filling the
engine.
Removing the lubricating oil cooler

1 Lubricating oil cooler
Use new moulded seals.
© 56489-0

● Remove lubricating oil cooler (2).
of properly.
© 56490-0
© 11/2014
1/4
W 15-02-01
● Remove moulded seals (1) with disassembly tool.

of properly.
6
© 56491-0
Installing the lubricating oil cooler

● Coat new moulded seals with mounting compound.
● Insert new moulded seals (1).
Note installation position.
© 56492-0
● Install the lubricating oil cooler (1).

Make sure the moulded seals fit correctly.
© 56493-0
© 11/2014
2/4
W 15-02-01
● Tighten all screws (1) in order.

 30 Nm
6
© 56495-0
● Install the lubricating oil cooler (2).

Make sure the moulded seals fit correctly.
© 56494-0
● Tighten all screws (1) in order.

 30 Nm
© 56496-0
© 11/2014
3/4
W 15-02-01
Technical Data
Lubricating oil cooler on oil cooler Observe tightening
A15 052 30 Nm
housing sequence
© 11/2014
4/4
W 15-02-02
Removing and installing the lubricating oil cooler housing

(Fastening parts)
information

suitable vessels and dispose of according
to regulations.
Observe the appropriate operating instruc-
tions for emptying and filling the engine.
Removing the lubricating oil cooler housing

1 Seal
2 Seal
© 56499-0
● Remove coolant line.

● Remove the lubricating oil cooler.
 Module 15
● Remove lubricating oil filter.
● Unlock cable plug and disconnect.
● Remove lubricating oil cooler housing (4).
© 56500-0
© 11/2014
1/4
W 15-02-02
● Remove gasket (1).

6
© 56501-0
Installing the lubricating oil cooler housing

● Insert screws (1).
M8x100-10.9
● Fasten new seal (2) with screws on lubricating oil
cooler housing.
M10x50-10.9
● Fasten new seal (4) with screws on lubricating oil
cooler housing.
Attention!
Do not bend or deform metal beading gas-
ket.
from faults. © 56502-0

● Mount the lubricating oil cooler housing (1).
Attention!
from faults.
Pay attention to different screw lengths.

M8x100-10.9
M8x50-10.9
● Turn in all screws (4).
M10x50-10.9
© 56503-0
© 11/2014
2/4
W 15-02-02
See graphic for tightening sequence.

quence.
– Stage 1:
 3 Nm
6
© 56504-0

quence.
M10x50-10.9
– Stage 2:
 60 Nm
© 56505-0

quence.
M8x50-10.9
M8x100-10.9
– Stage 2:
 30 Nm
● Plug in and lock cable plug.
● Install the lubricating oil cooler.
● Install coolant pipe.
 Module 15
● Install lubricating oil filter.
© 56506-0
© 11/2014
3/4
W 15-02-02
Technical Data
Stage 1:
A15 051 Oil cooler housing on crankcase Observe tightening 3 Nm
sequence
Stage 2:
sequence
Stage 2:
M8x50-10.9
M8x100-10.9
sequence
6
© 11/2014
4/4
W 15-90-27
Pipes
information
DEUTZ AP1908 Collect leaking operating substances in
to regulations.
1 Lubricating oil cooler housing

2 Housing seal
3 Seal
4 Nozzle
5 Screw-in nozzle
6 Sealing ring
7 Cylinder head screw 22 Nm
8 Screw plug 42 Nm
10 Flange
11 O-ring
13 Screw plug 80 Nm
14 Bypass valve
15 Sealing ring
18 Screw plug © 56557-0
19 Sealing ring
20 Pipe
22 Clamp
23 Pipe
24 Screw plug 11 Nm
25 Sealing ring
27 Sealing ring
29 Screw 9Nm
32 O-ring
34 Pressure sensor 25 Nm
35 Coupling plug
37 O-ring
38 Sealing cover
42 O-ring
Attention!
Use new sealing rings.
Use a new O-ring
© 11/2014
1/2
W 15-90-27

Position
32
Use mounting compound.
Attention!
Use a new O-ring
6
© 56558-0

Position
37
Attention!
Use a new O-ring
© 56559-0
© 11/2014
2/2
High-pressure pump
W 17-01-01
Removing and installing the control block

(Fastening parts)
information
Special tools:
– Plugs/caps 01899368
Danger!
Do not carry out work on the fuel system
when the engine is running.
The fuel system is under high pressure -
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 6
the fuel system is opened and the fuel can
escape outside.
Attention!
Pay attention to utmost cleanliness for all
work.
Remove any paint residue and dirt par-
ticles before disassembly.
Clean the area around the components
concerned carefully. Blow damp parts dry
with compressed air.
Observe safety regulations and national
specifications when handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove the stoppers/caps until
immediately before assembly.
Collect escaping operating media in
suitable containers and dispose of
according to regulations.
Vent the fuel system after doing any work
on it - see chapter 6 "Fuel System" of the
operating manual.
© 11/2014
1/4
High-pressure pump
W 17-01-01
Removing the control block

6
© 54651-0
● Unlock cable plug.

● Pull out cable plug.
● Remove fuel pipes.
 Module 21
● Remove control block (3).
© 48573-0
Installing the control block

● Insert screw (1).
● Insert screw (2).
● Insert control block.
● Pre-assemble screws loosely.
© 48573-1
© 11/2014
2/4
High-pressure pump
W 17-01-01
Attention!
Observe the following order of tightening.

 20 Nm
 20 Nm
● Install fuel pipes.
 Module 21
● Plug on cable plug.
from faults.
6
Bleed the fuel system via the manual fuel © 48573-2
pump on the fuel pre-filter according to the
operation manual.
© 11/2014
3/4
High-pressure pump
W 17-01-01
Technical Data
Observe tightening
A17 032 Control block on crankcase 20 Nm
sequence.
© 11/2014
4/4
High-pressure pump
W 17-01-03
Dismantling and assembling the control block

(2000 bar Injection system)
information
Special tools: – Service Info Technology
– Diagnostic tool – SerDia manual 2010
SerDia 2010
– Plugs/caps 01899368 Danger!
– Fitting compound when the engine is running.
DEUTZ AP1908 The fuel system is under high pressure -
Danger of death.
up to several 100 bar even after stopping 6
the engine.
Here the fuel pressure is only reduced if
escape outside.
Attention!
Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the
affected parts. Blow damp areas dry with
compressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
After all work on the fuel system, it must be
bleeded - see the operation manual, chap-
ter "6 Fuel system“.
© 10/2014
1/8
High-pressure pump
W 17-01-03
Dismantling the control block

1 Control block
2 Overflow valve
3 O-ring
4 O-ring
5 Torx screw
6 Solenoid valve
7 O-ring
8 Sealing ring
9 Threaded bush
10 Sealing ring
950 Throttle
6
© 49637-2
● Remove control block.

 Module 17
An error diagnosis must be made before
carrying out any work on the control block.
 Diagnostic tool SerDia 2010

SerDia manual
 Service Info Technology

0199-17-04049

● Remove solenoid valve (2).
© 48567-0

© 48568-0
© 10/2014
2/8
High-pressure pump
W 17-01-03
● Unscrew throttle (1).

6
© 48569-0
● Unscrew overflow valve (1).

● Remove O-ring (3).
© 48570-0
● Unscrew threaded bush (1).

© 56479-0
© 10/2014
3/8
High-pressure pump
W 17-01-03
● Clean non-return valve (1).

● Visually inspect the component.
Attention!
The control block must be renewed if the
non-return valve is damaged.
6
© 56480-0
Assembling the control block

● Clean components.
● Flush all bores well.
© 48571-0

● Screw in threaded bush (2).
● Tighten threaded bush (2).
 40 Nm
© 56479-1
© 10/2014
4/8
High-pressure pump
W 17-01-03

● Coat new round sealing ring slightly with mounting
compound.
● Coat overflow valve slightly with mounting compound
(arrow).
● Screw in overflow valve (3).
 33 Nm
6
© 48570-1
● Screw in throttle (1).

 12 Nm
© 48569-0
● Coat new round sealing rings slightly with mounting

compound.
© 48568-0
© 10/2014
5/8
High-pressure pump
W 17-01-03
● Mount solenoid valve (1).

 4.5 Nm
● Install control block.
 Module 17
6
© 48567-1
© 10/2014
6/8
High-pressure pump
W 17-01-03
Technical Data
A17 033 Solenoid valve on control block 4.5 Nm
A17 034 Throttle on control block housing 12 Nm
Overflow valve on control block hou-
A17 035 33 Nm
sing
Threaded bush on control block hou-
A17 036 40 Nm
sing
6
© 10/2014
7/8
High-pressure pump
W 17-01-03
© 10/2014
8/8
High-pressure pump
W 17-01-04
Removing and installing the high-pressure pump

(Fastening parts)
– Socket wrench insert, information
10 mm, 12-edge
Special tools: Danger!
– Plugs/caps 01899368 Do not carry out work on the fuel system
– Assembly case with when the engine is running.
assembly sleeves, guides The fuel system is under high pressure -
and disassembly tool 02992126 Danger of death.
– Special pliers 02992349
– Special wrench 02992477
– Mounting compound 01008420 the engine.
escape outside.
Attention!
Pay attention to utmost cleanliness for all
work.
concerned carefully. Blow damp parts dry
specifications when handling fuels.
opening with new, clean stoppers/caps.
Do not remove the stoppers/caps until
immediately before assembly.
suitable containers and dispose of
Vent the fuel system after doing any work
on it - see chapter 6 "Fuel System" of the
operating manual.
© 11/2014
1/6
High-pressure pump
W 17-01-04
Removing the high-pressure pump

1 Collar screw
6
© 48744-1
The following work procedure describes

the removal and installation of a high-pres-
sure pump.
All figures and graphics are only examples.
The procedure is the same for removing/
installing a further high-pressure pump.
● Remove control block.
 Module 17
● Remove injection line.
● Remove high-pressure line.
 Module 21
● Attach turning gear.
 Module 49
● Loosen screws (1) evenly

Loosen screws evenly to avoid jamming
the high-pressure pump.
If necessary, turn the crankshaft with turn-
over gear in the direction of rotation of the
engine until the high-pressure pump is felt
to release.
● Unscrew screws (1) evenly.
● Remove high-pressure pump (2).
© 48751-0
© 11/2014
2/6
High-pressure pump
W 17-01-04
● Carefully remove the O-ring (1) from the high-pres-

sure pump with the disassembly tool.
Attention!
Do not damage the high-pressure pump.
6
© 48747-0
Do not use magnetic tools for removing the

roller tappet.
● Pull out roller tappet (1) with special pliers.

Attention!
Do not damage the roller tappet!
© 48746-0
Installing the high-pressure pump

● Turn the crankshaft with the turn-over gear until the
cam for the high-pressure pump is on the cam base
circle (arrow).
Roller tappet stroke is less than 0.5 mm.
© 42816-0
© 11/2014
3/6
High-pressure pump
W 17-01-04
● Oil roller tappet lightly and insert carefully with spe-

cial pliers.
The guide pin (1) on the roller tappet must 1
grip in the groove (2).
2
6
© 42817-0
● Push assembly guide (1) onto high-pressure pump.

● Push the new O-ring (2) onto the assembly guide.
© 43329-0
● Push the O-ring (1) with assembly sleeve (2) up to

the groove (3).
● Coat the O-ring, mounting bore and chamfers in the
crankcase with fitting compound.
1
2
3
© 43330-0
© 11/2014
4/6
High-pressure pump
W 17-01-04
● Insert the high-pressure pump carefully in the crank-

case.
● Lightly oil screws (1).
– Stage 1:
 10 Nm
– Stage 2:
 50 Nm
6
© 48751-0
● Install control block.

 Module 17
● Install new high-pressure line.
● Install new high pressure pipe.
 Module 21
● Remove turning gear.
 Module 49
© 11/2014
5/6
High-pressure pump
W 17-01-04
Technical Data
A17 031 High pressure pump to crankcase Stage 1: 10 Nm
A17 031 High pressure pump to crankcase Stage 2: 50 Nm
© 11/2014
6/6
Injector
W 19-01-01
Removing and installing the injector (with bronze sealing disc)

(2000 bar Injection system)
information
– Diagnostic tool – Service Bulletin
SerDia 2010 – SerDia manual 2010
– Assembly pliers 01899050
– Torx tool set 01899092 Danger!
– Lever tool 02992117
– Disassembly device 02992118
Danger of death.
– Assembly case with
assembly sleeves, guides The fuel pressure can continuously remain 6
and disassembly tool 02992126 up to several 100 bar even after stopping
– Extraction tool 02992137 the engine.
– Slide hammer 02992294 Here the fuel pressure is only reduced if
– Special wrench 02992477 the fuel system is opened and the fuel can
escape outside.
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts
carefully. Blow damp areas dry with com-
pressed air.
to regulations.
© 11/2014
1/12
Injector
W 19-01-01
Remove injector
1 Clamping claw support
2 Clamping claw
3 Torx screw
4 Injector
5 O-ring
6 Sealing disc
7 Pressure piece
8 O-ring
9 O-ring
10 Pressure pipe nozzle
11 O-ring
12 Union screw
6
© 56377-0
2000 bar Injection system
Attention!
Note assignment of the injector to the
cylinder.
The injector is assigned by the relevant
IMA code (1) to the corresponding
cylinder.
The assignment is saved in the control
unit.
Each time an injector is replaced/renewed,
the correct assignment to the relevant
cylinder must be made by transferring the
new IMA code in the control unit.
Observe installed injection system!
The IMA codes of the different injection
systems are basically different. © 49117-0
The injector calibration depends on the
installed injection system.
Reset injector correction values (ZFL).
The exact procedure can be taken from the

listed documentation and must be obser-
ved.
SerDia manual
Report back changed data record to

DEUTZ AG.
e-mail address:
service-kompaktmotoren.de@deutz.com
 Service Bulletin
0199-99-11045
© 11/2014
2/12
Injector
W 19-01-01

the removal and installation of an injector.
Proceed in the same way to remove further
injectors.
● Remove the cylinder head hood.
 Module 08
● Remove injection lines.
● Remove high-pressure lines.
 Module 21
● Unscrew union screw (1).
6
© 49642-0
● Remove pressure pipe nozzles (1) with disassembly

device (2).
© 49643-0
● Unscrew pressure piece (1).
© 49644-0
© 11/2014
3/12
Injector
W 19-01-01

6
© 49645-0
© 49646-0
● Insert lever tool (1) in the clamping claw.

● Loosen the injector by moving the lever tool (1) in the
direction of the arrow.
● Remove injector and clamping claw.
Attention!
cylinder.
© 49647-0
© 11/2014
4/12
Injector
W 19-01-01
Attention!
Do not brush off the nozzle tip of the injec-
tor.
Do not damage nozzle head on the injector
during disassembly of the sealing disc (1).
● Grip fixed sealing disc (1) using the assembly
pliers (2) and pull off with slight turning movements.
6
© 48730-0
Removing fixed sealing disc at cylinder head

● Insert extraction device (1).
The supports (arrow) must rest in the bore
of the sealing disc.
© 45354-1
● Screw in spindle (1) until the sealing disc is fastened

on the pull-out device.
Hold puller on hexagon.
● Install adapter (2) on disassembly device.
© 45355-1
© 11/2014
5/12
Injector
W 19-01-01
● Install slide hammer (1) on disassembly device.

● Pull out fixed sealing disc.
6
© 45356-1
● Remove the round sealing ring (1) carefully from the

injector with the disassembly tool.
Attention!
Do not damage the injector.
© 48731-0
Installing the injector

● Push assembly guide (1) onto injector.
● Push the new O-ring (2) onto the assembly guide.
© 43333-1
© 11/2014
6/12
Injector
W 19-01-01
● Push the O-ring (1) with assembly sleeve (2) up to

the groove (3).
6
© 43334-1
● Mount new sealing disc (1) on injector.
© 48732-1
Attention!
Before installing the injector, combustion
residue must be cleaned carefully from the
bore on the cylinder head.
Suck off dirt particles.
● Position the injector so that the mounting bore (1) is
facing the operating side.
© 48734-0
© 11/2014
7/12
Injector
W 19-01-01
Attention!
cylinder.
● Insert the injector (1) with clamping claw (2) carefully
in the cylinder head.
6
© 45246-1

– Stage 1:
 4 Nm
● Relieve the load on the injector by loosing the screw
(1).
Attention!
No axial force may be exerted on the injec-
tor.
from faults.
© 49646-0
Use a suitable assembly aid.

Provide protection for sharp edges.
● Mount new O-rings (1).
© 49649-0
© 11/2014
8/12
Injector
W 19-01-01
● Screw in pressure piece (1).

● Tighten pressure piece.
 80 Nm
6
© 49644-0
Attention!
The pressure pipe nozzle must always be
renewed.
Position pressure pipe nozzle and press

into pressure piece so that the balls (1) of
the twist protection rest perfectly in the
grooves (2) of the pressure piece.
● Insert the pressure pipe nozzle in the cylinder head
with a new round sealing ring.
© 49650-0
● Pre-fit union screw (1).

– Stage 1:
 15 Nm
© 49642-0
© 11/2014
9/12
Injector
W 19-01-01

– Stage 2:
+1
 10 −1 Nm
Use rotaqtion angle disc.
– Stage 3:
+ 15°
 130°
6
© 49646-0
● Tighten pressure pipe nozzle with union screw (1).

● Stage 2:
 42 Nm
● Mount high-pressure lines.
● Install injection lines.
 Module 21
● Mount cylinder head cover.
 Module 08
© 49642-0
© 11/2014
10/12
Injector
W 19-01-01
Technical Data
Stage 1:
Observe assembly
Injector on cylinder head, clamping
A19 001 M8x1.25x42 sequence. 4 Nm
claw
Install injector without
tensioning.
Injector on cylinder head (bronze +1
A19 001 Stage 2: 10 −1 Nm
sealing disc), clamping claw
Injector on cylinder head, clamping + 15°
A19 001 Stage 3: 130°
claw
Stage 1:
A19 036 Union screw for pressure piece nozzle M22x1,5 Observe the tightening 15 Nm 6
specification
A19 036 Union screw for pressure piece nozzle M22x1,5 Stage 2: 42 Nm
A19 037 Pressure piece on cylinder head M26x1,5 80 Nm
© 11/2014
11/12
Injector
W 19-01-01
© 11/2014
12/12
Fuel pump
W 20-02-01
Removing and installing the fuel supply pump

(Fastening parts)
information
Special tools:
– Disassembly tool 02992127 Danger!
Danger of death.
the engine.
escape outside.
Attention!
before removing.
pressed air.
to regulations.
© 11/2014
1/4
Fuel pump
W 20-02-01
Removing the fuel supply pump

6
© 49662-0

● Remove fuel supply pump.
© 49666-0

© 49664-0
© 11/2014
2/4
Fuel pump
W 20-02-01
Installing the fuel supply pump

● Clean contact surfaces.
● Mount new O-ring (1).
6
© 49665-0
● Mount fuel supply pump.


 21 Nm
Vent fuel system according to operating
instructions.
© 49666-0
© 11/2014
3/4
Fuel pump
W 20-02-01
Technical Data
M8x25-10.9
A20 024 Fuel supply pump on gearcase 21 Nm
M8x55-10.9
© 11/2014
4/4
Fuel pipes
W 21-01-02
Removing and installing the fuel line

(control block - high-pressure pumps)
information
Special tools:
– Special wrench 02992477 Danger!
Danger of death.
the engine.
escape outside.
Attention!
before removing.
pressed air.
to regulations.
© 11/2014
1/4
Fuel pipes
W 21-01-02
Removing the fuel line

1 Fuel line
2 Hollow screw
3 Sealing ring
4 Screw-in nozzle 18 Nm
5 Sealing ring
Attention!
6
© 56375-0
Collect draining fuel and dispose of

● Hold screw-in nozzle (1).

● Unscrew lock nuts (2).
● Remove sealing rings.
● Remove fuel pipe.
© 56376-0
Mounting the fuel line

● Position fuel pipe.
Attention!
Install fuel pipe tension free.
from faults.
● Mount union nuts (3) tension-free.
● Attach hollow screw (1) with new sealing rings with-
out tensioning.
 39 Nm
● Hold screw-in nozzle (2).
● Tighten union nuts (3). © 56376-1
 20 Nm
© 11/2014
2/4
Fuel pipes
W 21-01-02
Technical Data
A12 084 Pipe union Union nut 20 Nm
Pipe union, pipe diameter 10 mm, Hollow screw
A12 093 39 Nm
ring piece M14x1.5
© 11/2014
3/4
Fuel pipes
W 21-01-02
© 11/2014
4/4
Fuel pipes
W 21-04-01
Removing and installing the rail

information
– Long socket wrench insert 01899132
– Plugs/caps 01899368 Danger!
– Marker pen, waterproof, The fuel system is under high pressure -
permanent Danger of death.
– Assembly grease 01016496 The fuel pressure can continuously remain
the engine.
Here the fuel pressure is only reduced if
6
escape outside.
Attention!
on the fuel system.
compressed air.
No foreign bodies may get into the rail.
Ensure utmost cleanliness. Especially on
the thread and the sealing surface of the
rail.
1 Rail
3 Injection line
4 Injection line
5 Injection line
6 Injection line
7 High-pressure line
8 Spacer
9 Repair kit
Pressure sensor
Pressure limiting valve
11 Vibration damper
14 Vibration damper © 56481-0
© 11/2014
1/12
Fuel pipes
W 21-04-01
17 O-ring
19 Vibration damper
259 Mounting grease
Positions
11
14
19
– Installation position of vibration damper.
 Module 21
Attention!
6 Ensure that the installation location is free
from faults.
Removing high-pressure lines

● Unscrew lock nuts (1) with special wrench.
Support the pipe connection of the high
pressure pump.

● Remove high pressure lines.
© 56536-0
Removing injection pipes

● Remove injection lines.
● Remove fuel return line.
 Module 21
© 56537-0
© 11/2014
2/12
Fuel pipes
W 21-04-01
● Unlock cable plug.

● Pull out cable plug.
● Remove the rail (2).
● Remove spacer (3).
6
© 56538-0
Removing the pressure sensor

● Unscrew the rail pressure sensor (1) with the socket
wrench.
© 56539-0
Attention!
Do not touch the pin contacts of the rail
pressure sensor with your hands to avoid
electrostatic discharging.
Ensure absolute cleanliness of the connec-
tor.
● Visually check the thread and the sealing
edge (arrows)of the rail pressure sensor.
© 43017-0
© 11/2014
3/12
Fuel pipes
W 21-04-01
Installing the pressure sensor

Attention!
rail.
See the spare parts documentation.
Rail pressure sensor and pressure limiting
valve must be replaced as a pair.
● Clean thread and sealing area of the rail.
● Coat the thread and sealing edge of the rail pressure
sensor lightly with assembly grease.
6
© 43017-0
Attention!
Only tighten the rail pressure sensor with
the hexagon.
● Screw in rail pressure sensor (1).
● Tighten rail pressure sensor (1) with the socket
wrench insert.
 70 Nm
© 56539-0
Removing the pressure limiting valve

● Unscrew pressure limiting valve (1).
© 56540-0
© 11/2014
4/12
Fuel pipes
W 21-04-01
● Visually check the thread and the sealing edge of the

pressure limiting valve.
6
© 49175-0
● Remove the O-ring with the disassembly tool.
© 49176-0
Installing the pressure limiting valve

Attention!
1
rail.
Rail pressure sensor and pressure limiting
valve must be replaced as a pair.
© 49177-0
© 11/2014
5/12
Fuel pipes
W 21-04-01
● Lightly coat the thread and sealing edge of the pres-

sure limiting valve with assembly grease.
6
© 49178-0
● Clean thread and sealing area of the rail.

● Screw in pressure limiting valve (1).
● Tighten pressure limiting valve.
 110 Nm
© 56540-0
Mounting rail
● Mount rail (1) with spacer (2).
● Loosely preassemble rail (1) with screws (3).
© 56538-1
© 11/2014
6/12
Fuel pipes
W 21-04-01
Installing injection pipes

Attention!
The injection lines must always be
renewed after disassembly.
Note assignment and installation position

of the injection lines.
● Mount new injection lines (1).
6
© 56537-1
Attention!
Pay attention to alignment of the injection
pipes.
Lines must not be in the bores (1) of the
union nuts.
Install injection lines without tension and
without touching.
They must be a safe distance away from
adjacent parts.
● Align injection lines.
● Tighten union nuts hand-tight.
© 56541-0

 30 Nm
© 56542-0
© 11/2014
7/12
Fuel pipes
W 21-04-01
● Tighten union nuts with special spanner in the tight-

ening sequence.
– Beginning with cylinder 1
● Stage 1:
 10 Nm
6
© 56543-0
● Draw help markings (1).

● Tighten union nut.
● Stage 2 (2):
1
+ 15°
 60°
● Check the injection pipes for perfect installation posi-
tion. 1
°
60 2
© 51250-0
Mounting high-pressure lines

Attention!
The high-pressure lines must always be
renewed after disassembly.
Note assignment and installation position

of the high-pressure lines.
● Mount new high-pressure lines (1).
© 56544-0
© 11/2014
8/12
Fuel pipes
W 21-04-01
Attention!
Pay attention to alignment of the high pres-
sure pipes.
Lines must not be in the bores (1) of the
union nuts.
Install high-pressure lines without tension
and without touching.
They must be a safe distance away from
adjacent parts.
● Align high-pressure lines.
● Tighten union nuts hand-tight.
6
© 56545-0
● Tighten union nuts with special spanner in the tight-

ening sequence.
– Beginning at high-pressure pump (1), (flywheel
side)
● Stage 1:
 10 Nm
© 56546-0
● Draw help markings (1).

● Tighten union nut.
● Stage 2 (2):
1
+ 15°
 60°
● Check the high pressure pipes for perfect installation
position. 1
2
Positions
11 60
°
2
14
19
 Module 21
Attention!
Note installation position. © 51250-0
© 11/2014
9/12
Fuel pipes
W 21-04-01
● Mount fuel return line.

 Module 21
Vent fuel system according to operating
instructions.

Ensure that the connection is perfect.
© 11/2014
10/12
Fuel pipes
W 21-04-01
Technical Data
Injection line on rail and pressure pipe Stage 1:
nozzle, Observe assembly
A21 003 Union nut 10 Nm
High pressure pipe on high pressure instructions.
pump and on rail Use new line.
Injection line on rail and pressure pipe
nozzle, + 15°
A21 003 Stage 2: 60°
High pressure pipe on high pressure
pump and on rail
Observe assembly
A21 038 Rail on cylinder head 30 Nm
instructions.
Lightly coat the thread 6
A21 039 Pressure limiting valve on rail M20x1.5 and sealing edge with 110 Nm
assembly grease.
Lightly coat the thread
A21 040 Pressure sensor on rail M18x1.5 and sealing edge with 70 Nm
assembly grease.
© 11/2014
11/12
Fuel pipes
W 21-04-01
© 11/2014
12/12
Fuel pipes
W 21-90-30
Fuel line
Connection parts
information
Special tools:
Danger!
Danger of death.
the engine.
escape outside.
Attention!
before removing.
pressed air.
to regulations.
© 11/2014
1/2
Fuel pipes
W 21-90-30
Fuel line
1
Return line
2 Hollow screw
3 Sealing ring
6
© 56367-0
2 Hollow screw 39 Nm
Attention!
Hold the fuel line (1) to loosen and tighten.
from faults.
© 56368-0
© 11/2014
2/2
Fuel pipes
W 21-90-30
Fuel pipes
(Fuel supply pump, fuel filter, control block, rail, cylinder head)
information
Special tools:
– Special wrench 02992477 Danger!
Danger of death.
the engine.
escape outside.
Attention!
before removing.
pressed air.
to regulations.
© 11/2014
1/4
Fuel pipes
W 21-90-30
1 Fuel line
2 Hollow screw
3 Hollow screw
4 Sealing ring
5 Hollow screw
6 Sealing ring
7 Fuel line
8 Hollow screw
9 Sealing ring
10 Pipe clip
11 Fuel line
12 Hollow screw
13 Sealing ring
6 14 Pipe clip
15 Sealing ring © 56547-0
16 Stopper
18 Hexagon head screw M8x16 30 Nm
19 Double hollow screw
20 Coupling plug
21 Sealing ring
22 Cap
23 Connection nozzle
24 Fuel line
25 Hollow screw
26 Sealing ring
27 Pipe clip
28 Holder
29 Holding plate
Attention!
from faults.
© 11/2014
2/4
Fuel pipes
W 21-90-30
Fuel line
1
Return line
Attention!
from faults.
6
© 56548-0
7 Fuel line
19 Double hollow screw 49 Nm
23 Connection nozzle
24 Fuel line
Attention!
Install fuel pipes tension free!
from faults.
© 56549-0
7 Fuel line
24 Fuel line
28 Holder
Attention!
Install fuel pipes tension free!
from faults.
© 56550-0
© 11/2014
3/4
Fuel pipes
W 21-90-30
11 Fuel line
14 Pipe clip
Attention!
from faults.
6
© 56551-0
Fuel line with coupling plug
Unlock coupling plug:

● Press together holding springs on both sides (1).
Attention!
from faults.
Lay the hose pipe free from chafing and ten-
sion.
© 56552-0
© 11/2014
4/4
Fuel pipes
W 21-90-71
Vibration damper
(installation position)
information
Danger!
Danger of death.
the engine.
escape outside.
Attention!
on the fuel system.
compressed air.
rail.
© 11/2014
1/4
Fuel pipes
W 21-90-71
1 Rail
3 Injection line
4 Injection line
5 Injection line
6 Injection line
8 Spacer
9 Repair kit
Pressure sensor
Pressure limiting valve
11 Vibration damper
6 12 Hexagon head screw 6 – 8 Nm
14 Vibration damper © 56481-0
15 Hexagon head screw 6 – 8 Nm

17 O-ring
19 Vibration damper
20 Hexagon head screw 6 – 8 Nm
259 Mounting grease
Positions
7
10
18
– High-pressure lines
 Module 21
© 11/2014
2/4
Fuel pipes
W 21-90-71

Attention!
from faults.
Vibration damper may not come into
contact with adjacent components.
Ensure sufficient access for special tool to
install and remove the high-pressure line.
I Connection rail
3 Injection line
14 Vibration damper
6
– Dimension X © 56482-0
from the inward pipe bend to the vibration damper

8.5 mm
● Align the vibration damper (14) parallel to the injec-
tion line (3).
© 11/2014
3/4
Fuel pipes
W 21-90-71

Attention!
from faults.
The vibration damper is situated exactly in
the radius (arrow).
I Connection rail
11 Vibration damper
6
● Align vibration damper vertically.
© 56483-0
– Alignment parallel to the cylinder axis

Attention!
from faults.
I Connection rail
19 Vibration damper
– Dimension X
from the inward pipe bend to the vibration damper © 56484-0
5.8 mm
5 Injection line
19 Vibration damper
Position
19
Observe inclination.
– Dimension I
5°
– Dimension II
approximately 7.7 mm
© 56498-0
© 11/2014
4/4
Charge air line
W 22-01-01
Removing and install the charge air line

information
DEUTZ AP1908
DEUTZ S1
Remove charge air line

1 Mixing pipe
2 Seal
3 Heating flange
4 Seal
5 Stud 10 Nm
7 Hexagonal nut 20 Nm
8 Charge air line
9 Seal
10 Throttle valve
12 Stud 10 Nm
13 Insulator
14 Plus pole 25 Nm © 56412-0
15 Minus pole 11 Nm
16 O-ring
17 Insulator
18 Hexagon head screw 8.5 Nm
19 Console
20 Stud 10 Nm
21 Pressure/Temperature sensor
22 O-ring
26 Washer
29 Pressure/Temperature sensor 25 Nm
30 O-ring
31 Screw-in nozzle 18 Nm
32 Sealing ring
33 Holder
37 Heat shield
© 11/2014
1/6
Charge air line
W 22-01-01

39 Sealing ring
40 Screw plug 26 Nm
41 Protective cap
● Remove turbocharger.
 Module 43
● Remove the exhaust gas nozzle.
 Module 41
● Remove the heating flange.
 Module 22
● Remove console (2).
© 56415-0

● Remove the heat shield (3).
© 56416-0
© 11/2014
2/6
Charge air line
W 22-01-01

● Remove the heat shield (3).
6
© 56417-0

● Remove charge air pipe (2).
● Remove gaskets (3).
© 56418-0
Install charge air line

● Mount new gaskets (1).
● Turn in the screws a few turns into the gaskets.
The gaskets are stopped by the screw
thread.
Ensure that the installation location of the
gaskets is free from faults.
© 56419-0
© 11/2014
3/6
Charge air line
W 22-01-01
● Mount charge air line (1).

Do not move gaskets.
6
© 56420-0

quence.
 60 Nm
© 56421-0
● Attach the heat shield (1).

● Fasten screw (2).
M8x20-10.9
M8x16-10.9
● Tighten all screws.
 30 Nm
© 56417-1
© 11/2014
4/6
Charge air line
W 22-01-01
● Attach the heat shield (1).

 13 Nm
 20 Nm
6
© 56416-1
● Mount console (1).

● Tighten all screws alternately.
 60 Nm
● Install the heating flange.
 Module 22
● Attach the exhaust gas nozzle.
 Module 41
● Install the turbocharger.
 Module 43
© 56415-1
© 11/2014
5/6
Charge air line
W 22-01-01
Technical Data
A22 027 Heat shield (sensor) on charge air line M6x12-10.9 13 Nm
A22 027 Heat shield (sensor) on charge air line 20 Nm
A22 028 Heat shield on charge air line 30 Nm
A22 029 Console on charge air line 60 Nm
Observe tightening
A22 030 Charge air line on cylinder head 60 Nm
sequence.
6
© 11/2014
6/6
Charge air line
W 22-05-01
Removing and install the heating flange

information
Special tools:
Attention!
– Fitting compound Ensure utmost cleanliness for all work.
DEUTZ AP1908 Remove any paint residue and dirt par-
– Fitting compound ticles before disassembly.
DEUTZ S1 Clean the area around the components
concerned carefully. Blow wet parts dry
tely before assembling. 6
Removing the heating flange

1 Mixing pipe
2 Seal
3 Heating flange
4 Seal
5 Stud 10 Nm
7 Hexagonal nut 20 Nm
8 Charge air line
9 Seal
10 Throttle valve
12 Stud 10 Nm
13 Insulator
14 Plus pole 25 Nm © 56412-0
15 Minus pole 11 Nm
16 O-ring
17 Insulator
18 Hexagon head screw 8.5 Nm
19 Console
20 Stud
22 O-ring
26 Washer
30 O-ring
31 Screw-in nozzle
32 Sealing ring
33 Holder
37 Heat shield
© 11/2014
1/4
Charge air line
W 22-05-01

39 Sealing ring
40 Screw plug
41 Protective cap
● Remove the cable from the connection (1).

Attention!
Hold on the hexagon of the plus pole
screw.
● Remove mixing pipe.
 Module 22
Attention!
● Pull off heating flange (2).

© 56414-0
Installing the heating flange

Attention!

● Mount gasket (1).
● Mount heating flange (2).
● Mount mixing pipe.
 Module 22
Attention!
screw.
Ensure that the cables are connected pro-
perly.
© 56414-1
© 11/2014
2/4
Charge air line
W 22-05-01
Position
16
Use new round sealing ring.
● Install the cable to the connection (3).
 12 Nm
● Fit the protective cap over the connection.
 Module 22
© 11/2014
3/4
Charge air line
W 22-05-01
Technical Data
Without fastened cables.
A22 081 Hexagonal nut on positive pole screw 2 – 5 Nm
Use new self-locking
nuts.
With fastened cables.
A22 082 Hexagonal nut on positive pole screw 12 Nm
nuts.
6 For the tightening procedure according to torque using a torque wrench, a maximum variation of the
© 11/2014
4/4
Charge air line
W 22-06-01
Removing and installing the mixing pipe

information
Special tools:
Attention!
Ensure utmost cleanliness for all work.
Remove mixing pipe

1 Mixing pipe
2 Seal
3 Heating flange
4 Seal
5 Stud 10 ‚Nm
7 Hexagonal nut
8 Charge air line
9 Seal
10 Throttle valve
12 Stud 10 Nm
13 Insulator
14 Plus pole © 56412-0
15 Minus pole
16 O-ring
17 Insulator
19 Console
20 Stud
22 O-ring
26 Washer
30 O-ring
31 Screw-in nozzle
32 Sealing ring
33 Holder
37 Heat shield
© 11/2014
1/4
Charge air line
W 22-06-01

39 Sealing ring
40 Screw plug
41 Protective cap

● Remove the exhaust gas nozzle.
 Module 41
● Unscrew nuts (1).
● Remove mixer pipe (2).
© 56413-0
Mount mixing pipe

● Attach mixing pipe (2).
● Screw on nuts (3).
● Tighten nuts alternately.
 20 Nm
● Attach the exhaust gas nozzle.

 Module 41
© 54835-0
© 11/2014
2/4
Charge air line
W 22-06-01
Technical Data
A87 042 Mixing pipe on charge air line Use new nuts 20 Nm
© 11/2014
3/4
Charge air line
W 22-06-01
© 11/2014
4/4
Charge air line
W 22-07-01
Removing and installing the throttle valve

information
Special tools:
Attention!
Remove throttle valve

1 Mixing pipe
2 Seal
3 Heating flange
4 Seal
5 Stud
7 Hexagonal nut
8 Charge air line
9 Seal
10 Throttle valve
12 Stud
13 Insulator
14 Plus pole © 56412-0
15 Minus pole
16 O-ring
17 Insulator
19 Console
20 Stud
22 O-ring
26 Washer
30 O-ring
31 Screw-in nozzle
32 Sealing ring
33 Holder
37 Heat shield
© 11/2014
1/4
Charge air line
W 22-07-01

39 Sealing ring
40 Screw plug
41 Protective cap
● Unlock cable plug (1) and disconnect.

● Remove washers (3).
© 54830-1
● Take off throttle valve (1).

© 54831-1
© 11/2014
2/4
Charge air line
W 22-07-01

Pay attention to smooth action of the
moving parts.
6
© 54367-0
Mount throttle valve

● Mount new gasket (1).
Do not move gasket.
● Attach throttle valve (2).
© 54832-1
● Mount washers (1).

 13 Nm
● Insert cable plug (3) and lock into place.
© 54833-1
© 11/2014
3/4
Charge air line
W 22-07-01
Technical Data
A22 031 Throttle valve on mixing pipe 13 Nm
© 11/2014
4/4
Charge air line
W 22-90-08
Heat protection plate

8190
information
1 Heat protection plate

© 56359-0
© 11/2014
1/2
Charge air line
W 22-90-08
© 11/2014
2/2
Charge air line
W 22-90-20
Pressure sensor / temperature sensor

(charge air)
information
Special tools:
Attention!
opening with new, clean plugs/caps. 6
1 Mixing pipe
2 Seal
3 Heating flange
4 Seal
5 Stud
7 Hexagonal nut
8 Charge air line
9 Seal
10 Throttle valve
12 Stud
13 Insulator
14 Plus pole
15 Minus pole © 56412-0
16 O-ring
© 11/2014
1/2
Charge air line
W 22-90-20
17 Insulator
19 Console
20 Stud
22 O-ring
26 Washer
30 O-ring
31 Screw-in nozzle
32 Sealing ring
33 Holder
6 34 Hexagon head screw
37 Heat shield
38 Hexagon head screw M8x12 20 Nm
39 Sealing ring
40 Screw plug
41 Protective cap
Position
37
● Remove heat protection shield.

Position
22
Attention!
To assemble the sensor, press in - do not
knock in!
from faults.
● Mount heat protection shield.
© 56422-0
© 11/2014
2/2
Charge air line
W 22-90-32
Line
(Pressure sensor)
information
DEUTZ S1
1 Line 37 Nm
Attention!
Hold screw-in nozzle when loosening/tigh-
tening the union nut.
Coat thread and contact surfaces with

mounting compound.
© 56645-0
© 11/2014
1/2
Charge air line
W 22-90-32
© 11/2014
2/2
Coolant pump
W 37-03-01
Removing and installing the coolant pump

information
DEUTZ AP1908 Danger!
Observe specifications for working on the
cooling system - see operating manual.
Attention!
concerned carefully. Blow wet parts dry 6
to regulations.
Removing coolant pump

1 Carrier plate
2 Belt tensioner
6 Seal
7 Holding plate
9 Coolant pump
10 Deflection pulley
© 56292-0
© 11/2014
1/6
Coolant pump
W 37-03-01
● Drain, collect and dispose of coolant according to

regulations.
● If present: Remove coolant hose from outlet nozzle.
● Remove belt tensioner (level 1).
● Remove deflection pulley.
 Module 39
● Remove generator (level 1).
 Module 44
6 ● Remove holding plate (3).
© 56333-0

● Remove coolant pump (3) in direction of arrow.
© 56334-0
● Pull out plug element (1).

© 56335-0
© 11/2014
2/6
Coolant pump
W 37-03-01
Installing coolant pump

● Coat plug piece (1) with mounting compound.
● Insert plug element (1).
6
© 56335-1

● Insert screws (arrows).
M8x55-10.9
● Fasten new seal (1) with screws on coolant pump.
© 56336-0

● Mount coolant pump (1) in direction of arrow.
M8x55-10.9
M8x95-10.9
© 56334-1
© 11/2014
3/6
Coolant pump
W 37-03-01
● Fit holding plate (1).

M6x16-10.9
 8.5 Nm
M8x100-10.9
6
© 56333-1
● Tighten all screws (1) alternately.

 30 Nm
● If present: Push coolant hose onto outlet nozzle and
fasten.
● Mount deflection pulley.
● Mount belt tensioner (level 1).
 Module 39
● Mount generator (level 1).
 Module 44
● Fill cooling system according to the operating manu-
al.
© 56337-0
© 11/2014
4/6
Coolant pump
W 37-03-01
Technical Data
A37 010 Coolant pump on carrier plate 30 Nm
A37 014 Holding plate on coolant pump 8.5 Nm
© 11/2014
5/6
Coolant pump
W 37-03-01
© 11/2014
6/6
Thermostat housing
W 38-01-01
Removing and installing the thermostat

8190
information
to regulations.
Removing the thermostat

1 Thermostat housing
2 Sealing ring
3 Thermostat
4 Outlet nozzle
5 Hose connection 26 Nm
6 Screw plug 110 Nm
7 Sealing ring
8 Sealing ring
9 Sealing ring
11 Temperature sensor 22 Nm
14 Plug piece
15 Screw plug 42 Nm
16 Seal © 56322-0

© 11/2014
1/4
Thermostat housing
W 38-01-01

regulations.
● Remove outlet nozzle (2).
6
© 56327-0
● Remove thermostats (1).

Attention!
© 56328-0

© 49990-0
© 11/2014
2/4
Thermostat housing
W 38-01-01
Installing the thermostat

● Fit new sealing rings (1).
Note installation position of the sealing
ring.
6
© 49990-1

● Insert thermostate (1).
© 56328-0
● Fit outlet nozzle (1).

 30 Nm
fasten.
al.
© 56327-1
© 11/2014
3/4
Thermostat housing
W 38-01-01
Technical Data
A38 002 Outlet nozzle on thermostat housing 30 Nm
© 11/2014
4/4
Thermostat housing
W 38-01-02
Checking the thermostat (in the removed state)

– Thermometer information
Danger!
Risk of injury!
Hot water and hot thermostat.
Checking thermostat
● Measure beginning of stroke, dimension (a).
● Note measured value, dimension (a).
© 56371-0
● Heat up the thermostat in the water bath.

● Determine beginning of opening.
In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the ther-
mostat.
Do not touch the thermostat.
The water should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place fas-
ter than 1°C/min. Otherwise the beginning
of opening will be delayed accordingly.
– Nominal value:
 83 °C
© 56372-0
© 11/2014
1/4
Thermostat housing
W 38-01-02
● Measure water temperature.

– Nominal value:
 95 °C
● Measure end of stroke, dimension (b).
● Note measured value, dimension (b).
6
© 56371-1
● Determine stroke.
Calculation example
Desired: Stroke
Given: -
Measured: Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Calculation: Dimension (b) - dimension (a)
Result: = stroke
● Compare result with setpoint value.
– Nominal value:
 8 mm
© 56371-2
© 11/2014
2/4
Thermostat housing
W 38-01-02
Technical Data
P38 11 Thermostat, beginning of opening 83 °C
P38 13 Thermostat, stroke at 95 ℃ , minimum 8 mm
P38 14 Thermostat, stroke, test temperature 95 °C
© 11/2014
3/4
Thermostat housing
W 38-01-02
© 11/2014
4/4
Thermostat housing
W 38-02-01
Removing and installing the thermostat housing

8190
information
to regulations.
Removing thermostat housing

1 Thermostat housing
2 Sealing ring
3 Thermostat
4 Outlet nozzle
5 Hose connection 26 Nm
6 Screw plug 110 Nm
7 Sealing ring
8 Sealing ring
9 Sealing ring
11 Temperature sensor
14 Plug piece
15 Screw plug 42 Nm
16 Seal © 56322-0

© 11/2014
1/6
Thermostat housing
W 38-02-01

regulations.
● Remove the fan drive.
 Module 39
● Unlock cable plug (1) and disconnect.
6
© 56323-0

● Remove thermostat housing (3) in direction of arrow.
© 56324-0
● Remove plug element (1) in direction of arrow.

© 56325-0
© 11/2014
2/6
Thermostat housing
W 38-02-01
Installing thermostat housing

● Coat chamfers and locating hole with mounting com-
pound.
● Coat plug piece (1) with mounting compound.
● Insert plug element (1) in direction of arrow.
6
© 56325-1

● Insert screws (arrows).
M8x30-10.9
● Fasten new seal (1) with screws on thermostat hous-
ing.
© 56326-0

● Mount thermostat housing (1) in direction of arrow.
● Tighten screws alternately.
M8x30-10.9
● Turn in screw (3).
M8x65-10.9
● Tighten screws alternately.
 30 Nm
© 56324-1
© 11/2014
3/6
Thermostat housing
W 38-02-01
● Install fan drive.

 Module 39
● Mount cable plug (1) and lock.
fasten.
al.
6
© 56323-0
© 11/2014
4/6
Thermostat housing
W 38-02-01
Technical Data
M8x60-10.9
A38 001 Thermostat housing on cylinder head M8x30-10.9 30 Nm
M8x65-10.9
© 11/2014
5/6
Thermostat housing
W 38-02-01
© 11/2014
6/6
Coolant pipes
W 38-05-01
Removing and installing the connection line

(Coolant pump - exhaust gas recirculation)
8190
information
– Fitting compound Collect leaking operating substances in

DEUTZ AP1908 suitable vessels and dispose of according
to regulations.
Remove connection line

7 Connection line
8 Seal
9 Plug piece
10 Sealing ring
11 Screw plug 34 Nm
Use a new sealing ring.
© 56265-0

● Remove connection line (3) in direction of arrow.
© 56266-0
© 11/2014
1/4
Coolant pipes
W 38-05-01

6
© 56267-0
Mount connection line

● Thinly coat the connector (1) with assembly paste
(arrows).
© 49603-0

● Insert plug element (1) in direction of arrow.
© 56267-1
© 11/2014
2/4
Coolant pipes
W 38-05-01

● Locating holes and chamfers coated with mounting
compound.
● Insert connection line (1) in direction of arrow.
 30 Nm
Attention!
Mount lines without tension!
6
© 56266-1
© 11/2014
3/4
Coolant pipes
W 38-05-01
Technical Data
Connection line on coolant pump
A38 061 30 Nm
(exhaust gas recirculation)
© 11/2014
4/4
Coolant pipes
W 38-05-01
Removing and installing the connection line

(Thermostat housing, exhaust gas circulation, coolant line)
information
Special tools:
– Fitting compound suitable vessels and dispose of according
DEUTZ AP1908 to regulations.
Remove connection line

16 Connection line
18 Seal
20 Sealing ring
21 Screw plug 34 Nm
22 O-ring
© 56250-0

● Remove connection line (4) in direction of arrow.
© 56251-0
© 11/2014
1/4
Coolant pipes
W 38-05-01

6
© 56252-0
Mount connection line

● Coat new round sealing ring (1) with mounting com-
pound.
© 56253-0

compound.
● Insert connection line (1) in direction of arrow.
 30 Nm
 13 Nm
Attention!
Mount lines without tension!
© 56251-1
© 11/2014
2/4
Coolant pipes
W 38-05-01
Technical Data
Connection line on coolant line
A38 062 30 Nm
Connection line to cooler (exhaust
A38 063 13 Nm
gas recirculation)
© 11/2014
3/4
Coolant pipes
W 38-05-01
© 11/2014
4/4
Add-on parts
W 39-01-01
Removing and installing the belt tensioner

(V-rib belt, level 1)
– Retaining pin, diameter 6 mm information
Removing the belt tensioner

1 Carrier plate
2 Belt tensioner
6 Seal
7 Holding plate
9 Coolant pump
© 56292-0
● Tighten the belt tensioner (1) in the direction of the

arrow until the bores (2) are in line.
© 56330-0
© 11/2014
1/4
Add-on parts
W 39-01-01
● Lock belt tensioner with retaining pin (1).
6
© 56331-0

● Remove belt tightener (2).
© 56332-0
Installing the belt tensioner

● Mount belt tensioner (1).
 45 Nm
© 56332-1
© 11/2014
2/4
Add-on parts
W 39-01-01
● Hold the belt tensioner.

● Remove holding pin (1).
● Relieve the belt tightener.
6
© 56331-0
© 11/2014
3/4
Add-on parts
W 39-01-01
Technical Data
A39 043 Belt tensioner on coolant pump 45 Nm
© 11/2014
4/4
Add-on parts
W 39-01-01
Removing and installing the belt tensioner

– Retaining pin, diameter 6 mm information
Removing the belt tensioner

1 Support console
2 Belt tensioner
4 Holding plate
5 Deflection pulley
6 Clamping pin
© 56274-0

● Remove belt tightener (2).
© 56275-0
© 11/2014
1/4
Add-on parts
W 39-01-01
Installing the belt tensioner

● Mount belt tensioner (1).
 45 Nm
● Remove the retaining pin.
6
© 56275-1
© 11/2014
2/4
Add-on parts
W 39-01-01
Technical Data
A39 041 Belt tightener on carrying console 45 Nm
© 11/2014
3/4
Add-on parts
W 39-01-01
© 11/2014
4/4
Add-on parts
W 39-02-06
Removing and installing the support console

information
Removing the support console

1 Support console
2 Belt tensioner
4 Holding plate
5 Deflection pulley
6 Clamping pin
© 56274-0
● Remove the air-conditioning compressor.

 Module 82
– Remove belt tensioner (level 2).
– Remove generator (level 2).
– Remove deflection pulley.
 Module 44
● Remove holding plate (2).
© 56288-0
© 11/2014
1/4
Add-on parts
W 39-02-06

● Remove the carrying console (2) in the direction of
the arrow.
● Remove clamping pins (3).
6
© 56289-0
Mounting the support console

● Drive in the clamping pins (1) to the stop.
© 56290-0
● Centre the carrying console (1) over the clamping

pins (arrow).
● Tighten screws (2) alternately working from the cen-
tre to the outside.
 60 Nm
© 56291-0
© 11/2014
2/4
Add-on parts
W 39-02-06
● Fit holding plate (1).

 30 Nm
– Mount deflection pulley.
– Mount generator (level 2).
– Mount belt tensioner (level 2).
 Module 44
– Install the air-conditioning compressor.
 Module 82
 Operation manual 6
© 56288-1
© 11/2014
3/4
Add-on parts
W 39-02-06
Technical Data
A39 051 Retaining plate on carrying console 30 Nm
Carrying console (generator, at
A39 052 60 Nm
exhaust side) on carrier plate
© 11/2014
4/4
Fan bearing
W 39-03-01
Removing and installing the fan bearing

(Fastening parts)
information
Removing the fan bearing

© 56283-0

Note post-assembly position of the fan
bearing.

● Remove fan bearing (2).
© 56284-0
© 11/2014
1/4
Fan bearing
W 39-03-01
Installing the fan bearing

Note post-assembly position of the fan
bearing.
● Mount fan bearing (1).

 60 Nm
6
© 56284-1
© 11/2014
2/4
Fan bearing
W 39-03-01
Technical Data
M10x45-10.9
A09 040 Fan bearing on thermostat housing 60 Nm
M10x50-10.9
© 11/2014
3/4
Fan bearing
W 39-03-01
© 11/2014
4/4
Fan bearing
W 39-03-03
Dismantling and assembling the fan bearing

– Locking ring pliers information
– Press
Special tools: Attention!
– Rotation angle disc 01899093 The ball bearings should only be pressed
in over the outer and inner ring. No force
may be exerted on the balls.
Dismantling the fan bearing

1 Fan bearing
2 V-rib belt pulley
4 Ball bearing
5 Locking ring
6 Hollow shaft
7 Washer
8 Ball bearing
9 Deflection pulley
© 56277-0
● Turn in screws (arrows).

– M10x45-10.9
© 56278-0
© 11/2014
1/8
Fan bearing
W 39-03-03
● Clamp the screws in the vice.

● Loose screw (1) a few turns.
Attention!
Screw has left-hand thread.
6
© 56279-0
● Clamp the fan bearing in the vice.

● Loose the V-rib belt pulley by lightly tapping against
the screw (1) with a plastic hammer.
© 49202-0

● Remove washer (2).
● Remove V-rib belt pulley (3).
© 56280-0
© 11/2014
2/8
Fan bearing
W 39-03-03
● Tension out fan bearing.

● Press out shaft and inside ball bearing.
6
© 48382-0
● Press out outside ball bearing.
© 48383-0
● Remove locking ring (1).
© 56281-0
© 11/2014
3/8
Fan bearing
W 39-03-03
● Press pulley out of the inside ball bearing.
6
© 42881-0
● Press shaft out of the inside ball bearing.

© 42882-0
Assembling fan bearing

● Press shaft into the inside ball bearing to the stop.
© 42883-0
© 11/2014
4/8
Fan bearing
W 39-03-03
● Press pulley into the inside ball bearing to the stop.
6
© 42884-0
● Press the outside ball bearing into the housing to the

stop.
The press-in tool (1) must touch the outer
ring of the ball bearing (arrow).
© 48386-1
● Insert locking ring (1).

Make sure the locking ring fits correctly in
the groove.
© 56282-0
© 11/2014
5/8
Fan bearing
W 39-03-03
● Press in shaft and inside ball bearing to the stop.

Support inside ring of the outside ball
bearing with a suitable tool (arrow).
6
© 48387-0
● Clamp the fan bearing in the vice.

● Mount washer (2).
● Screw in new screw (3).
Attention!
© 56279-1
● Clamp the screws in the vice.

● Tighten new screw (1).
Attention!
– Stage 1:
 30 Nm
● Tighten screw with rotation angle disc.
– Stage 2:
 90°
© 56279-2
© 11/2014
6/8
Fan bearing
W 39-03-03
6
© 56278-1
© 11/2014
7/8
Fan bearing
W 39-03-03
Technical Data
Stage 1:
A39 049 V-ribbed pulley on fan bearing Use new screws. 30 Nm
oiled.
A39 049 V-ribbed pulley on fan bearing Stage 2: 90°
© 11/2014
8/8
Add-on parts
W 39-04-01
Removing and installing the deflection pulley

information
Removing the deflection pulley

1 Carrier plate
2 Belt tensioner
6 Seal
7 Holding plate
9 Coolant pump
© 56292-0

● Remove deflection pulley (2).
© 56293-0
© 11/2014
1/4
Add-on parts
W 39-04-01
Mounting the deflection pulley

● Position deflection pulley (1).
 60 Nm
6
© 56293-1
© 11/2014
2/4
Add-on parts
W 39-04-01
Technical Data
A39 019 Guide roller on coolant pump 60 Nm
© 11/2014
3/4
Add-on parts
W 39-04-01
© 11/2014
4/4
Add-on parts
W 39-04-01
Removing and installing the deflection pulley

information
Removing the deflection pulley

1 Support console
2 Belt tensioner
4 Holding plate
5 Deflection pulley
6 Clamping pin
© 56274-0

● Remove deflection pulley (2).
© 56276-0
© 11/2014
1/4
Add-on parts
W 39-04-01
Mounting the deflection pulley

● Position deflection pulley (1).
 60 Nm
6
© 56276-1
© 11/2014
2/4
Add-on parts
W 39-04-01
Technical Data
M10x45-10.9
A09 049 Deflection pulley on console M10x52-10.9 60 Nm
M10x65-10.9
© 11/2014
3/4
Add-on parts
W 39-04-01
© 11/2014
4/4
Fan console
W 39-90-05
Fastening parts
8190
information

© 56249-0
© 11/2014
1/2
Fan console
W 39-90-05
© 11/2014
2/2
Exhaust pipe
W 41-01-01
Removing and installing the exhaust line

information
Special tools:
DEUTZ S1
Removing exhaust line

Danger!
Hot parts!
● Remove turbocharger.
 Module 43
● Remove cooler.
 Module 41
● Remove the plug-in pieces (2).

© 56236-0
● If present:
© 56237-0
© 11/2014
1/6
Exhaust pipe
W 41-01-01

● Remove the rings (2).
● Remove the wave spring seals (3).

● Remove shielding plate.
 Module 41
6
© 56238-0

● Remove spacing sleeves (2).
● Remove exhaust line (3).
© 56239-0
● Remove the exhaust pipe (1) in direction of the ar-

row.
● Remove the steel ring (3).
● Remove the wave spring seal (4).
© 56240-0
© 11/2014
2/6
Exhaust pipe
W 41-01-01
Installing exhaust line

● Mount the new wave spring seal (1).
● Mount the steel ring (2).
● Coat new round sealing ring slightly with mounting
compound.
● Mount the new seals (4).
● Mount the exhaust pipe (5) in the direction of the ar-
row.
Attention!
from faults.
6
© 56241-0

● Coat new screws with mounting compound.
● Mount spacer sleeves (1).
● Mount screws (2).
● Mount new gaskets (3).
© 56242-0

● Mount exhaust line (1).
Attention!
from faults.
© 56239-1
© 11/2014
3/6
Exhaust pipe
W 41-01-01

quence.
– Stage 1:
 15 Nm
– Stage 2:
 45 Nm
● Mount shielding plate.
 Module 41
6
© 56243-0
● Mount the new wave spring seals (1).
● Mount the rings (2).
● Mount the new seals (3).
Attention!
from faults.
© 56238-1

compound.
● Insert new O-rings (1).
© 56244-0
© 11/2014
4/6
Exhaust pipe
W 41-01-01

● Insert plug elements (1).
● Fit new seals (2).
Attention!
from faults.
● Install cooler.
 Module 41
● Install the turbocharger.
 Module 43
6
© 56236-1
© 11/2014
5/6
Exhaust pipe
W 41-01-01
Technical Data
Stage 1:
A41 001 Exhaust pipe on cylinder head Observe tightening 15 Nm
sequence
Stage 2:
A41 001 Exhaust pipe on cylinder head Observe tightening 45 Nm
sequence
6
© 11/2014
6/6
Exhaust gas recirculation
W 41-01-06
Removing and installing the exhaust gas nozzle

(cooler - mixing pipe)
information
Danger!
Hot components!
Danger of burns / explosion!
Let the engine / components cool down
sufficiently (to at least ambient tem-
perature).
The filter regeneration must be deactivated
or, in systems with a filter regeneration
prompt, not activated before performing 6
service work.
Attention!
Removing the exhaust gas nozzle

1 Exhaust gas nozzle
2 Bush
3 Hose clip
4 Seal
© 56347-0
© 11/2014
1/6
W 41-01-06
● Loosen hose clip (1).

● Pull off exhaust gas pipe (4) in direction of arrow.
6
© 56348-0
● Loosen hose clip (1).

● Pull off bush (2) in direction of arrow.
© 56349-0
● Pull off hose clips (1) in direction of arrow.

© 56350-0
© 11/2014
2/6
W 41-01-06
Installing the exhaust gas nozzle

Attention!
Bush must be free from cracks.
● Push on hose clips (1) in direction of arrow.
6
© 56350-1

● Push on bush (1) in direction of arrow.
© 56349-1

● Push on exhaust gas nozzle (1) in direction of arrow.
 60 Nm
© 56348-1
© 11/2014
3/6
W 41-01-06
● Position hose clips (1).

– Dimension X
+1
4.5 −1 mm
● Tighten hose clips (1).
 4 Nm
Position the hose clips facing upwards in
an easy to reach position.
6
© 56351-0
© 11/2014
4/6
W 41-01-06
Technical Data
Exhaust gas nozzle on cooler
A41 049 60 Nm
A99 051 Hose clip, fastening 4 Nm
© 11/2014
5/6
W 41-01-06
© 11/2014
6/6
W 41-01-06
Removing and installing the exhaust gas nozzle

(cooler - Venturi tube)
8190
information
Special tools:
Danger!
– Fitting compound Hot components!
DEUTZ S1 Danger of burns / explosion!
perature).
prompt, not activated before performing 6
service work.
Attention!
Removing the exhaust gas nozzle

1 Exhaust gas nozzle
2 Connection piece
3 O-ring
4 Seal
© 56352-0
© 11/2014
1/4
W 41-01-06

● Pull off exhaust gas nozzle (3) in direction of arrow.
6
© 56353-0
● Remove connection piece (1) in direction of arrow.

© 56354-0

© 56355-0
© 11/2014
2/4
W 41-01-06
Installing the exhaust gas nozzle

compound.
6
© 56356-0

● Mount connection piece (1) in direction of arrow.
© 56354-1

● Push on exhaust gas nozzle (1) in direction of arrow.
Attention!
from faults.
 20 Nm
© 56353-1
© 11/2014
3/4
W 41-01-06
Technical Data
Exhaust gas nozzle on Venturi tube
A41 048 20 Nm
© 11/2014
4/4
W 41-90-08
Heat protection plate

8190
information
1 Heat protection plate

Danger!
Hot parts!
© 56247-0
© 11/2014
1/2
W 41-90-08
© 11/2014
2/2
W 41-90-09
Holder
(cooler - exhaust gas recirculation)
information
Special tools:
Attention!
1 Holder
● Clean sealing surface.
© 56423-0
© 11/2014
1/4
W 41-90-09
5 Coolant line
6 O-ring
9 Pipe clip
11 Holder
6
© 56423-1
4 Coolant line
7 Rubber sleeve
8 Hose clip 4 Nm
9 Pipe clip
12 Holder
© 56423-2

Position
6
© 56424-0
© 11/2014
2/4
W 41-90-09
Position
7
Align rubber bushing (arrow) centrally.
6
© 56425-0
Position
8
Position hose clips so that they are easy to
reach (arrow).
© 56426-0
© 11/2014
3/4
W 41-90-09
© 11/2014
4/4
Exhaust gas turbocharger
W 43-01-01
Removing and installing the turbocharger

information
Special tools:
– Assembly tool 01899150 Attention!
– Fitting compound Remove any paint residue and dirt par-
DEUTZ S1 ticles before disassembly.
to regulations.
Removing turbocharger
1 Seal
6 Stud
7 Hexagonal nut
© 56305-0
© 11/2014
1/6
W 43-01-01
● Remove intake nozzle.

 Module 22
● Remove connecting pipe.
 Module 58
● Remove the lubricating oil line.
 Module 43
● Remove lubricating oil return line.
 Module 43
● Loosen nuts (1) alternately.
6
© 56306-0
● Unscrew nuts (1).

● Remove turbocharger (2).
© 56307-0
● Unscrew pin screws (1) with disassembly tool.

© 56308-0
© 11/2014
2/6
W 43-01-01
● Mount disassembly tool (1) on pin screw.

● Unscrew pin screw in direction of the arrow.
6
© 49300-0
Installing the turbocharger

● Coat new pin screws with mounting compound.
● Screw on new pin screws (1).
Attention!
Screw pin screws with the short thread end
into the exhaust line.
● Mount assembly tool.
© 56308-0
● Screw assembly tool (1) onto pin screws in direction

of the arrow.
● Tighten pin screws with assembly tool (1).
 10 Nm
© 49301-0
© 11/2014
3/6
W 43-01-01

Beading (elevation) faces the Exhaust gas
turbocharger.
● Mount turbocharger (2).

● Screw on new nuts (3).
6
© 56309-0
● Tighten nuts according to the tightening sequence.

 63 Nm
● Install lubricating oil line.
 Module 43
● Install lubricating oil return line.
 Module 43
● Install connecting pipe.
 Module 58
● Fit intake nozzle.
 Module 22
© 56310-0
© 11/2014
4/6
W 43-01-01
Technical Data
Use new nuts and pin
A06 020 Turbocharger on exhaust line M12 63 Nm
screws
Use new pin screws.
A41 004 Pin screws on exhaust line Insert using DEUTZ S1 10 Nm
mounting compound.
© 11/2014
5/6
W 43-01-01
© 11/2014
6/6
Lubricating oil pipe
W 43-04-01
Removing and installing the lubricating oil line

(exhaust turbocharger with/without actuator)
information
Special tools:
Attention!

to regulations.
Removing the lubricating oil line

1 Lubricating oil line
2 Hollow screw
3 O-ring
4 Lubricating oil line
5 Hollow screw
6 O-ring
7 Pipe clip
© 56212-0
© 11/2014
1/8
W 43-04-01
● Exhaust turbocharger (1) with actuator.

● Exhaust turbocharger (2) without actuator.
6
© 56369-0

● Loosen lubricating oil line (3).
© 56213-0

● Loosen pipe clips (2).
© 56214-0
© 11/2014
2/8
W 43-04-01

6
© 56215-0
– Exhaust turbocharger with actuator

● Loosen lubricating oil line (3).
© 56216-0
– Exhaust turbocharger without actuator

● Remove lubricating oil pipe (3).
© 56217-0
© 11/2014
3/8
W 43-04-01
● Hold connection nozzle (1).

● Unscrew lock nuts (2).
6
© 56224-0
Installing the lubricating oil line

● Mount union nuts (2) tension-free.
© 56224-0

● Mount lubrication oil line (1).
© 56217-1
© 11/2014
4/8
W 43-04-01

Attention!
Install line without tension!
from faults.
Do not twist the hose line.
6
© 56216-1

 39 Nm
Attention!
from faults.
© 56213-1

 20 Nm
Attention!
from faults.
© 56214-1
© 11/2014
5/8
W 43-04-01

 20 Nm
Attention!
from faults.
6
© 56215-1

 39 Nm
Attention!
from faults.
© 56218-0

 39 Nm
Attention!
from faults.
© 56219-0
© 11/2014
6/8
W 43-04-01

Attention!
from faults.
● Tighten union nuts (2).
 42 Nm
6
© 56224-0
© 11/2014
7/8
W 43-04-01
Technical Data
Hollow screw
A12 093 Pipe union, ring piece 39 Nm
M14x1.5
A12 070 Union nut on screw connection 42 Nm
Pipe clip, connection of oil return and
A43 045 20 Nm
lubricating oil line
© 11/2014
8/8
W 43-05-01
Removing and installing the lubricating oil return line (at the bottom)
(exhaust turbocharger with/without actuator)
information
Special tools:
– Disassembly tool 02992127 Attention!
– Fitting compound Remove any paint residue and dirt par-
DEUTZ AP1908 ticles before disassembly.

to regulations.
Removing the oil return line

1 Return line
2 O-ring
3 Return line
4 O-ring
5 Adapter
6 Seal
8 Pipe clip
9 Plug piece
10 O-ring
11 Holding bracket
14 Holder © 56294-0
© 11/2014
1/10
W 43-05-01

18 Pipe clip
19 Bushing
● Exhaust turbocharger (1) with actuator.

● Exhaust turbocharger (2) without actuator.
© 56369-0

● Loosen pipe clip (2).
© 56295-0
© 11/2014
2/10
W 43-05-01

6
© 56296-0

● Remove sleeve (3).
© 56297-0

© 56298-0
© 11/2014
3/10
W 43-05-01

● Remove holding braket (2).
● Pull out oil return line (3) in direction of arrow.
● Pull out oil return line (4) in direction of arrow.
6
© 56299-0

© 56300-0

● Pull out adapter (3) in direction of arrow.
© 56301-0
© 11/2014
4/10
W 43-05-01
6
© 56302-0

© 56303-0
Mounting the oil return line

● Coat the O-rings with fitting compound.
© 56303-1
© 11/2014
5/10
W 43-05-01

compound.
● Push in the plug piece (1) in the direction of the arrow
as far as the limit stop.
6
© 56302-1

compound.
● Push in the adapter (1) in the direction of the arrow
as far as the limit stop.
– M8x60
– M8x20
● Tighten all screws.
 20 Nm
© 56301-1

● Coat the O-rings with fitting compound.
© 56300-1
© 11/2014
6/10
W 43-05-01

Attention!
from faults.
compound.
● Mount oil return pipe (1).
● Insert oil return line (1) in direction of arrow.
● Insert oil return line (2) in the direction of the arrow.
● Attach holding bracket (3).
● Tighten screws (4). 6
● Tighten screws (4). © 56299-1
 20 Nm

Attention!
from faults.
 20 Nm
© 56298-1
© 11/2014
7/10
W 43-05-01
Attention!
from faults.
● Attach bushing (1).
 8.5 Nm
6
© 56297-1

Attention!
from faults.
 20 Nm
© 56296-1
Attention!
from faults.
 20 Nm
© 56295-1
© 11/2014
8/10
W 43-05-01
Technical Data
A12 095 Pipe clip, fastening 8.5 Nm
A12 096 Pipe clip, fastening 20 Nm
A43 034 Oil return line on oil return line M8x20-10.9 20 Nm
Holding bracket (oil return line) on
A43 049 20 Nm
adapter
A43 050 Adapter (oil return line) on crankcase 20 Nm
6
© 11/2014
9/10
W 43-05-01
© 11/2014
10/10
Generator
W 44-02-03
Removing and installing the V-rib belt pulley

(with clamping cone)
– Hexagon socket wrench information
width across flats 8 mm
– Socket wrench insert
27 mm
external diameter
37 mm
Special tools:
– Multi-tooth socket wrench 01899069
– optional
– Star drive socket insert 01899098
– Pipe wrench with exten- 6
sion 01899136
– Protective gloves
Removing the V-rib belt pulley

1 V-rib belt pulley
2 Clamping cone
3 Washer
4 Hexagonal nut
All figures and graphics are only examples.
© 49856-0
© 11/2014
1/4
Generator
W 44-02-03
● Remove generator.
 Module 44
● Clamp the generator in the vice.
● Loosen nut (1) with special spanner (2) in direction of
arrow.
● Hold generator shaft with torque wrench (3). 1 3
● Remove washer.
6
© 48246-1
Place the generator on a soft base.
● Use suitable socket wrench insert (1). 1
© 48800-0
The socket must rest on the flange (1) of

the V-belt pulley, not on the clamping cone
(2)!
© 48801-0
© 11/2014
2/4
Generator
W 44-02-03
Danger!
Risk of injury!
Attention!
1
● Lift generator slightly at V-rib belt pulley.
● Use a plastic hammer to hit the socket (1) until the
clamping cone is released. 2
● Remove the clamping cone.
● Remove V-rib belt pulley (2)
6
© 48802-2
Installing the V-rib belt pulley

● Attach the clamping cone (2).
● Install the washer (3).
© 49856-0
● Clamp the generator in the vice.

● Insert special wrench (1).
● Hold generator shaft with torque wrench (2).
● Loosen nut (3) with special wrench (1) in direction of 3 1
arrow.
 75 Nm
● Install generator.
 Module 44
© 48247-1
© 11/2014
3/4
Generator
W 44-02-03
Technical Data
A44 021 V-belt pulley on the generator 75 Nm
© 11/2014
4/4
Starter
W 44-90-05
Fastening parts
(Starter)
information
© 48674-1
© 11/2014
1/2
Starter
W 44-90-05
© 11/2014
2/2
Starter
W 44-90-04
Connection
(Starter)
information
1 Starter
3 Covering cap
4 Locking nut 15 Nm
● Disconnect the battery's negative terminal.

Attention!
Lay the cables free from chafing and ten-
sion.
© 56358-0
© 11/2014
1/2
Starter
W 44-90-04
© 11/2014
2/2
Add-on parts
W 44-90-05
Fastening parts
(Generator)
information
© 56321-0
© 11/2014
1/2
Add-on parts
W 44-90-05
© 11/2014
2/2
Electrical equipment
W 48-10-01
Removing and installing the cable rails

8190
information
Special tools:
– Grooved nut wrench 01899030
DEUTZ AP1908
Remove cable rails

1 Cable rails
3 Grooved nut
4 Locking plate
© 50017-0
● Bend back the lock latch (1).

● Unscrew the grooved nut (2) with the grooved nut
wrench.
● Remove locking plate (1).
© 50075-0
© 11/2014
1/6
W 48-10-01
● Press the cable plug (1) inwards in the direction of ar-

row.
Ensure that the cables do not buckle or get
damaged.
6
© 50076-0
● Unscrew all nuts (1).
© 50077-0

● Remove cable rail (2).
© 50078-0
© 11/2014
2/6
W 48-10-01
Install cable rails

● Coat sealing surface (1) with mounting compound.
6
© 50079-0
● Position cable rail.

● Press the cable plug (1) outwards in the direction of
arrow.
Ensure that the cables do not buckle or get
damaged.
© 50080-0
● Fit locking plate (1).

● Tighten the grooved nut 2) with the grooved nut
wrench.
– Plastic nut:
 10 Nm
The conical side of the grooved nut should
face the cylinder head.
One groove of the grooved nut must be in
line with a fastening lug.
● Bend back lock latch (1) to secure the slotted nut.
© 50075-0
© 11/2014
3/6
W 48-10-01
● Position cable rail (1).

 8.5 Nm
6
© 50081-0
● Screw on all nuts (1).

● Tighten all nuts (1).
 1.5 Nm
© 50077-0
© 11/2014
4/6
W 48-10-01
Technical Data
A48 041 Cable rail on rocker arm brackets M6x10-8.8 8.5 Nm
A48 051 Cable connection on injector 1.5 Nm
A48 064 Cable plug on the cylinder head Grooved nut 10 Nm
© 11/2014
5/6
W 48-10-01
© 11/2014
6/6
Cable harness
W 48-90-05
Fastening parts
information
1 Holder
2 Holder
3 Holder
4 Holder
5 Holder
6 Holder
7 Holder
8 Holder
9 Holder
10 Holder
11 Holder
12 Holder
13 Holder
14 Holder
15 Holder © 56647-0
16 Holder
17 Holding plate
18 Pipe clip
19 Washer
28 Holding tape
29 Holding tape
30 Covering cap
32 Holder
39 Holding tape
42 Attachment angle
© 11/2014
1/8
Cable harness
W 48-90-05
43 Relay
Heating flange
43 Relay
Starter
Attention!
Ensure that the cables are laid perfectly.
perly.
from faults.
Positions
14 Holder
© 56648-0
Positions
23, 24
14 Holder
2 Holder
12 Holder
© 56649-0
© 11/2014
2/8
Cable harness
W 48-90-05
Positions
4 Holder
8 Holder
6
© 56650-0
Positions
13 Holder
15 Holder
© 56651-0
Positions
1 Holder
10 Holder
11 Holder
© 56652-0
© 11/2014
3/8
Cable harness
W 48-90-05
Positions
3 Holder
6
© 56653-0
Positions
25, 27
6 Holder
19 Washer
43 Relay
Starter
© 56654-0
Attention!
perly.
Danger of short circuit!

After fastening the lines, secure connec-
tions against short circuiting using corres-
ponding protective caps.

1 Nut M6 3 – 4.5 Nm
© 56661-0
© 11/2014
4/8
Cable harness
W 48-90-05
Positions
17 Holder
6
© 56655-0
Positions
5 Holder
© 56656-0
Positions
7 Holder
16 Holder
32 Holder
© 56657-0
© 11/2014
5/8
Cable harness
W 48-90-05
Positions
9 Holder
19 Washer
43 Relay
Heating flange
6
© 56658-0
Attention!
perly.

After fastening the lines, secure connec-
tions against short circuiting using corres-
ponding protective caps.

1 Nut M6 3 – 4.5 Nm
© 56661-0
Positions
18 Pipe clip
© 56659-0
© 11/2014
6/8
Cable harness
W 48-90-05
Position
6
© 56660-0
© 11/2014
7/8
Cable harness
W 48-90-05
© 11/2014
8/8
W 48-90-77
Connection line
(relay - heating flange)
information
1 Connection line
Attention!
from faults.
screw.
Connection line
Heating flange
– Hexagonal nut
self-locking
© 56646-0
 12 Nm
● Fit the protective cap over the connection.
© 11/2014
1/2
W 48-90-77
Technical Data
Without fastened cables.
A22 081 Hexagonal nut on positive pole screw 2 – 5 Nm
nuts.
With fastened cables.
A22 082 Hexagonal nut on positive pole screw 12 Nm
nuts.
© 11/2014
2/2
Measuring instruments
W 51-90-20
Impulse transmitter
(camshaft)
information
1 Impulse transmitter
© 56373-0
© 11/2014
1/2
Measuring instruments
W 51-90-20
© 11/2014
2/2
Connection housing
W 52-01-01
Removing and installing the connection housing

information
Special tools:
Danger!
When using hoists (workshop crane) the
safety regulations for handling hoists must
be observed.
It is not permitted to stay under moving
loads.
Removing the connection housing

1 Connection housing
7 Washer
8 O-ring
12 Cover
© 56457-0
● Install impulse transmitter (crankshaft).

 Module 51
● Remove starter.
 Module 44
 Module 05
● Hook connection housing to workshop crane.
© 56458-0
© 11/2014
1/6
Connection housing
W 52-01-01

● Remove washer (2).
● Remove round sealing ring (3) with disassembly tool.
6
© 56459-0

● Remove connection housing.
● Lay the connection housing aside.
● Unhook workshop crane.
© 56460-0
● Remove bolt (1) in direction of arrow.
© 56461-0
© 11/2014
2/6
Connection housing
W 52-01-01
6
© 56448-0
Installing the connection housing

● Lightly coat new round sealing rings with DEUTZ
AP1908 mounting compound.
● Insert new O rings (1).
© 56451-0
● Push bolt (1) into place.

Attention!
Chamfer (2) is facing the connection hou-
sing.
© 56461-1
© 11/2014
3/6
Connection housing
W 52-01-01

● Hook connection housing to workshop crane.
● Attach the connection housing (1).
● Align the connection housing using the bolt and the
crankshaft.
● Fix the connection housing (1) in position.
6
© 56462-0

● Mount washer (2).
M16x180-10.9
© 56459-1

M16x200-10.9
M16x120-10.9
M12x190-10.9
M12x130-10.9
M8x70-10.9
© 56463-0
© 11/2014
4/6
Connection housing
W 52-01-01
– Tightening order
 280 Nm
 110 Nm
● Tighten all bolts (3).
 35 Nm
 35 Nm
6
© 56464-0

 40 Nm
● Unhook workshop crane.
 Module 09
 Module 05
● Install starter.
 Module 44
● Install impulse transmitter (crankshaft).
 Module 51
© 56460-0
© 11/2014
5/6
Connection housing
W 52-01-01
Technical Data
Observe tightening
A52 080 Connection housing on crankcase 35 Nm
sequence
Observe tightening
sequence
Observe tightening
sequence
Observe tightening
sequence
© 11/2014
6/6
Charge air line
W 58-90-31
Connection line
(exhaust turbocharger with actuator - charge air cooler)
8190
information
Special tools:
Attention!
DEUTZ S1 Remove any paint residue and dirt par-
1 Connecting pipe
2 Connecting pipe
3 Connection hose
4 Clip 7 Nm
5 Hose clip 4 Nm
6 O-ring
Use new round sealing rings.

Position the clamps to be freely accessible.
Attention!
from faults.
© 56357-0
© 11/2014
1/2
Charge air line
W 58-90-31
© 11/2014
2/2
Exhaust gas treatment
W 71-05-04
Removing and installing the sensor

(NOx)
information
– Plugs/caps 01899368 – Service Bulletin
– Dog wrench 02992345
Danger!
DEUTZ S1 Hot components!
perature).
The duration of the so-called lag time is 6
application-dependent and can be up to 2
minutes in engines with SCR system, for
example, because the SCR pipes have to
be pumped empty in this time.
prompt, not activated before performing
service work.
Attention!
Replacing the NOx sensors influences the
emissions and therefore has an effect on
the certification of the vehicle. As such, the
information in the Service Bulletin
0199-51-11041 must be observed.
© 11/2014
1/4
W 71-05-04
Removing the sensor

the removal and installation of one sensor.
The procedure is the same to install and
remove further sensors.
Mark assignment of cables/connections
before removing.
● Unlock cable plug and remove.
● Unscrew union screw (1) with claw wrench.
● Remove sensor (2).
6
© 51302-0
Installing the sensor

Attention!
Replacing the NOx sensors influences the
emissions and therefore has an effect on
the certification of the vehicle. As such, the
information in the Service Bulletin
0199-51-11041 must be observed.
SerDia manual
● Coat the thread (1) with fitting compound.
● Mount sensor (2).
© 51303-0
Attention!
Do not turn the cable.
● Hold the sensor with your hand.
● Screw in union screw (1) with claw wrench (2).
 50 Nm
© 51336-0
© 11/2014
2/4
W 71-05-04
Attention!
Note assignment and installation position.
– NOx sensor assignment:

1
Colour of plug
Installation site
connection (1)
Diesel particle filter black
SCR (Selective Catalytic Reduction)

before catalytic converter grey
after catalytic converter black
6
© 52098-1
● Lay cable between NOx sensor and NOx control unit

with a a safety loop.
Attention!
Ensure that the cables are laid perfectly. X
Lay the cables free from chafing and ten-
sion. 180°
The length of the safety loop must be
1
based on the appropriate documentation of
the vehicle/equipment manufacturer. 2
4
Position Remark/name Value
3
1 Last fastening point
2 Safety loop 180°
3 Exhaust system
4 NOx sensor
at least 100 © 52047-0
X Length
mm
© 11/2014
3/4
W 71-05-04
Technical Data
Insert with DEUTZ S1
A71 068 NOx sensor, fastening 50 Nm
mounting compound.
© 11/2014
4/4
W 71-06-02
Removing and installing the dosing device

information
Danger!
DEUTZ S1 Hot components!
– Protective gloves Danger of burns / explosion!
– Protective glasses Let the engine / components cool down
perature).
The duration of the so-called lag time is
application-dependent and can be up to 2 6
service work.
Attention!
Ensure the utmost cleanliness when per-
forming all work.
Before dismounting, remove any paint
residues and dirt particles.
regulations when working with fuels.
Seal all connections immediately with new
and clean stoppers/caps after opening.
Only remove stoppers/caps immediately
before assembly.
suitable vessels and dispose of them
The following must be observed for
installation:
Installation guidelines of DEUTZ AG.
Installation guideline / documentation of
the vehicle manufacturer / equipment
manufacturer.
complied with for dismantling and
installing.
Installation variant shown as an example.
© 11/2014
1/4
W 71-06-02
Removing the dosing device

● Unlock cable plug and remove.
● Unlock coupling plug and pull off.
● Remove lines.
● Carefully remove the dosing device (2).
Attention!
Do not damage the component.
6
© 51262-0

© 51263-0
Installing the dosing device

Attention!
Do not use any sharp tools.
Do not damage the sealing surfaces.
Pay attention to utmost cleanliness.
All sealing surfaces / sealing points must
be completely clean.
The nozzle hole disc must not be touched.
from faults.
© 51263-0
© 11/2014
2/4
W 71-06-02
● Carefully insert the dosing device.

● Insert screws.
● Tighten the screws in sequence until the sealing
plate is pressed down.
 hand tight
6
© 51264-1

quence.
 8 Nm
Attention!
Install line without tension and contact.
from faults.
● Align the lines.
● Insert lines.
● Mount coupling plug and latch into place.
© 51264-0
© 11/2014
3/4
W 71-06-02
Technical Data
Stage 1:
A71 091 Dosing device, fastening Observe tightening hand tight
sequence.
Stage 2:
A71 091 Dosing device, fastening Observe tightening 8 Nm
sequence.
6
© 11/2014
4/4
W 71-07-01
Removing and installing temperature transmitter

(before diesel oxidation catalyst)
information
– Plugs/caps 01899368 – Installation guideline
Danger!
Hot components!
perature).
The filter regeneration must be deactivated 6
service work.
Attention!
Observe installation guideline /
documentation of the vehicle manufacturer
/ equipment manufacturer.
Removing temperaure transmitter

the removal and installation of a tem-
perature transmitter.
The procedure is the same for removing/
installing a further temperature transmitter.
● Unscrew union nut (1) with special wrench.
© 49883-0
© 11/2014
1/4
W 71-07-01
Attention!
The temperature transmitter may only be
handled in the area shown (1).
The following are not permitted:

- Soaking or oscillating,
- Swinging or similar movements or exer-
tion of force
of the entire temperature transmitter on the
plug.
6
© 49884-0
Attention!
Note axial removal position.
Sensor tip must not be damaged.
● Remove temperature transmitter (1) in direction of
arrow.
Attention!
Storage time without plugged-in mating
plug:
maximum 24 hours
© 49885-0
Installing temperature transmitter

Attention!
The following must be observed during
installation:
DEUTZ AG installation guidelines.
Installation guideline/documentation of the
vehicle manufacturer/equipment manu-
facturer.
Note axial installation position.
Sensor tip must not be damaged.
from faults.
● Insert temperature transmitter (1) in direction of ar-
row.
● Tighten temperature transmitter (1).
© 49886-0
 45 Nm
© 11/2014
2/4
W 71-07-01
● Lay cable strand free from tension and chafing.

● Fit together cable plug.
Attention!
© 11/2014
3/4
W 71-07-01
Technical Data
A71 067 Temperature transmitter, fastening 45 Nm
© 11/2014
4/4
W 71-90-20
Exhaust back pressure sensor (mixing pipe)

information
– Plugs/caps 01899368 – Installation guideline
Danger!
Hot components!
perature).
service work.
Attention!
© 11/2014
1/2
W 71-90-20
1 Pressure sensor
Exhaust back pressure
Attention!
To avoid electrostatic discharges, do not
touch the plug contacts with your bare
hands.
Observe DEUTZ AG installation
guidelines.
Note assignment and installation position.
6 from faults.
© 56602-0
Attention!
Do not seal pressure balance opening (1)
when pulling out the protective cap (2).
© 56603-0
Mating plug for exhaust back pres-

sure sensor 1
Chamber 4
Attention! 2
Seal (1) must close flush with the housing.
The seal opening (2) must not be closed.
The seal opening balances the pressure.
2
© 48276-0
© 11/2014
2/2
W 71-90-47
Supply pump
information
Danger!
– Protective gloves
– Protective glasses Hot components!
– glycerine Danger of burns / explosion!
perature).
Wear protective gloves and glasses!
service work.
Attention!
Ensure the utmost cleanliness when per-
forming all work.
Before dismounting, remove any paint
residues and dirt particles.
regulations when working with fuels.
Seal all connections immediately with new
and clean stoppers/caps after opening.
Only remove stoppers/caps immediately
before assembly.
suitable vessels and dispose of them
The following must be observed for
installation:
Installation guidelines of DEUTZ AG.
Installation guideline / documentation of
the vehicle manufacturer / equipment
manufacturer.
complied with for dismantling and
installing.
© 11/2014
1/2
W 71-90-47
1 Supply pump
2 Main filter
Filter cartridge
3 Filter cover
4 Nozzle 4 – 4.5 Nm
5 O-ring
7 O-ring
9 O-ring
6
© 56722-0
Attention!
All sealing surfaces / sealing points must
be completely clean.
To avoid electrostatic discharges, do not
touch the plug contacts with your bare
hands.
Use new round sealing rings.

Coat new round sealing rings slightly with
glycerine.
Supply pump
– Filter cartridge
 Operation manual © 56723-0
© 11/2014
2/2
Coolant compressor
W 82-90-05
Fastening parts
8190
information
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 Coolant compressor
Attention!
Emptying and filling the air-conditioning
system must be carried out according to
the operating manual and the appropriate
documentation/specifications of the
vehicle/equipment manufacturer.
© 56387-0
© 10/2014
1/2
Coolant compressor
W 82-90-05
© 10/2014
2/2
Hydraulic pump drive
W 83-90-01
Closing parts
8190
information
– Locking agent
DEUTZ DW 72
● Locking parts up to construction month 04.2003:

2 Screw plug 34 Nm
3 Sealing ring
4 Cap
5 O-ring
7 Sealing ring
8 Screw plug 30 Nm
185 Locking agent

● Insert screws with locking agent.

© 56393-0
● Locking parts from construction month 05.2003:

2 Screw plug 34 Nm
3 Sealing ring
4 Cap
5 O-ring
185 Locking agent

● Insert screws with locking agent.
© 56393-1
© 11/2014
1/2
Hydraulic pump drive
W 83-90-01
© 11/2014
2/2
Wiring diagram
S 91-10-00
Wiring diagram
Title Engine harness
Part number 0421 1426
Number of sheets 7
Language English / German
© 03/2014 OBJ_DOKU-41380-001.fm
Permitted for application
checks and service!
Schaltplan/Wiring diagram
Motor Kabelbaum /
Engine harness
R
Rail Druck Drehzahl Drehzahl
Steller MPROP Kraftstoff Nockenwelle Kurbelwelle
Injektor Injektor Injektor Injektor Injektor Injektor ACTUATOR RAIL PRESSURE ENGINE SPEED ENGINE SPEED
INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR MPROP FUEL CAMSHAFT CRANKSHAFT
B49
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 1 2 3 1 2 3
KB
sheet3:X23:7
sheet3:X23:6
KA
X32.1:2
X32.1:4
X32.1:5
X32.1:7
X32.2:4
X32.2:5
X32.2:2
X32.2:7
X17.1:9
X17.1:1
X17.1:34
X17.1:35
X17.1:36
X17.1:37
X17.1:38
X17.1:32
X17.1:39
X17.1:33
X17.1:20
X17.1:19
X17.1:30
X17.1:25
X17.1:31
X17.1:14
X17.1:13
X17.1:15
X17.1:21
VA VB
VC
85 64 86 65 87 66 43 22 44 23 45 24 90 91 25 46 36 78 17 100 99 75 102 101 96 97

D2.1
ECU Motor
ECU ENGINE
13 74 11 21 73 72 35 54 53 48 31 49 95 94 42 63 88 58
VE
X17.1:6
X17.1:7
X17.1:8
X17.1:24
X17.1:28
X17.1:29
X17.1:22
X17.1:23
X17.1:26
X17.1:27
X17.1:17
X17.2:46
KD
KC
checks and service!
1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2
sheet5:K2.1
sheet5:K2.2
sheet5:K2.3
sheet4:B78.1
sheet5:X17.1:2
sheet5:X17.1:3
B6 B51 B60
Temperatur Druck / Temperatur Druck Motoröl Niederdruck Abgasgegendruck Rlais EPV /
Kühlmittel Ladeluft OIL PRESSURE Kraftstoff vor Turbolader Abgasklappe
COOLING BOOST PRESSURE / FUEL LOW EXHAUST EXHAUST FLAP / Motor Kabelbaum /
TEMPERATURE TEMPERATURE PRESSURE GAS BACK EPV RELAY
BEFOR TURBINE
Engine harness
R
Temperatur
EGR nach
Venturi
Drosselklappe EGR
Ansaugluft Delta p Venturi TEMPERATURE
AIR INTAKE DELTA p BEHIND
THROTTLE VENTURI VENTURI
B61
sheet4:VH
sheet4:B58.3
sheet3:X23:1
1 4 3 5 2 1 2 3 1 2
Vss
GND
VSS
Signal
GND
MV
UB
UB85
MV86
PWM1
PWM2
Signal
KG
KF
sheet7:X17.2:23
sheet7:X17.2:22
X23:1
X23:2
X23:3
X23:4
X23:5
X23:6
X23:7
X23:8
X17.2:18
X17.2:19
X17.2:37
X17.2:13
X17.2:24
X17.2:30
X17.2:41
VF
sheet7:VR
VG
sheet7:VS
56 52 27 12 20 30 28 67 02 76 55 18 51 08 34 98 77
sheet2:D2.1.90
sheet2:D2.1.91
19 33 71 81 07 84 104 68 69 103 50 83 01 38 105
sheet6:M2.PWM
Motor Kabelbaum /
Engine harness
R
checks and service!
Temperatur Abgas
Abgas vor Temperatur
Differenzdruck Oxy Kat vor SCR Urea Druck
DPF EXHAUST GAS EXHAUST nach Pumpe Niveau / Temperatur Druck DS
DPF TEMPERATURE GAS UREA Urea DPF
DIFFERENTIAL BEFOR TEMPERATURE PRESSURE UREA LEVEL AND PRESSURE
PRESSURE OXY CAT BEFOR SCR AFTER PUMP TEMPERATURE DS DPF
B58 B63 B88
3 2 1 1 2 1 2 1 2 3 1 2 3 4 1 2 3
VH
VI
29 09 32 15 19 57 10 14 70 79
sheet2:D2.1.48
26 47 82 05 92 62 80 04 37 61 89 59 03 41
VM
sheet6:VQ
sheet6:F83.B1
VL
VK
checks and service!
VJ
1 2 1 2 1 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 3 4 5 1 2 3 4
M10
Urea Absaugventil Heizventil Relais Relais Relais Relais Urea Pumpe Relais
Dosierventil Urea Urea Tank Heizelement Heizelement 1 Heizelement 2 Heizelement 3 UREA PUMP SCR
UREA DOSING UREA PURGE UREA TANK Einspeisungs- Saugleitung Drosselleitung Druckleitung Ansteuerung Motor Kabelbaum /
VALVE VALVE HEATING modul RELAY RELAY RELAY RELAY
VALVE RELAY HEATER 1 HEATER 2 HEATER 3 SCR
SUPPLY SUCTION THROTTLE PRESSURE CONTROL Engine harness
MODULE LINE LINE LINE
HEATER
R
A1
B1
Vorheizrelais Starter Relais

PRE-HEAT STARTER
RELAY RELAY
1 2 3 4 1 2 3 4
M M1
2 Starter
Heizflansch
HEAT FLANGE STARTER
X17.1:2
X17.1:3
sheet2:X17.1:6
sheet2:X17.1:7
sheet2:X17.1:8
sheet2:D2.1.95
sheet2:D2.1.94
Motor Kabelbaum /
Engine harness
R
checks and service!
VP
Sicherung
SCR-System
FUSE
SCR-SYSTEM
A1 A1 A1 A1 A1
F83
B1 B1 B1 B1 B1
Urea
Qualität, Niveau
NOx Sensor NOx Sensor Urea und Temperatur
Kühlwasserpumpe nach SCR Kat vor SCR Kat Abgasrückführung Qualität UREA
COOLING WATER NOx SENSOR NOx SENSOR EXHAUST GAS Waste Gate UREA QUALITY, LEVEL
PUMP AFTER SCR CAT FOR SCR CAT RECIRCULATION WASTE GATE QUALITY AND TEMP.
B87 B90
sheet4:K31.3
K15 K31 PWM 4 3 2 1 4 3 2 1 1 2 4 5 3 6 1 2 4 5 3 6 1 2 3 4 1 4 2 3
VN KH
VO KI
X17.2:57
X17.2:59
sheet4:VK
VQ
Motor Kabelbaum /
Engine harness
R
checks and service!
Urea
Qualität, Niveau
NOx Sensor NOx Sensor Urea und Temperatur
Abgasrückführung nach SCR Kat vor SCR Kat Qualität UREA
EXHAUST GAS Waste Gate NOx SENSOR NOx SENSOR UREA QUALITY, LEVEL
RECIRCULATION WASTE GATE AFTER SCR CAT FOR SCR CAT QUALITY AND TEMP.
B87 B90
1 2 4 5 3 6 1 2 4 5 3 6 4 3 2 1 4 3 2 1 1 2 3 4 1 4 2 3
VR VT
VV
VS VU
VW
X17.2:23
X17.2:22
X17.2:29
X17.2:28
sheet3:VF
sheet3:VF
sheet3:VG
sheet3:VG
Motor Kabelbaum /
Engine harness
R
checks and service!
Impulse transmitter
Technical data
– Multimeter information
– Measuring tips
Measuring
Speed
variable
passive without voltage supply
© 52053-0
Switching diagram
Signal (UDC) 1,65 V
(S1) 1
(S2) 2
© 52055-0
© 01/2012
1/2
Pin assignment
Pin / socket
1 Signal
2 Signal
3 Shielding
(S1) 1
● Measurement
– Impulse transmitter (S2) 2
Pin / Pin /
Condition Nominal
socket socket
°C Ω 3
+ 10%
20 1 2 880 − 10%
Danger!
6
Rotating parts!
© 52054-0
Risk of injury!
● Measurement
– Impulse transmitter
Pin / Pin / Nomin
Condition Polarity
socket socket al
V
Crankshaft
turns at start- 1 2 1,65 +
up speed
© 01/2012
2/2
Impulse transmitter
Technical data
– Multimeter information
– Measuring tips
Measuring
Speed
variable
passive without voltage supply
© 52139-0
Switching diagram
(S1) 1
(S2) 2
© 52055-0
© 01/2012
1/2
Pin assignment
Pin / socket
1 Signal
2 Signal
3 Shielding
(S1) 1
● Measurement
– Impulse transmitter (S2) 2
Pin / Pin /
Condition Nominal
socket socket
°C kΩ 3
+ 20% + 10 %
23 − 20% 1 2 3,8 - 10 %
Danger!
6
Rotating parts!
© 52054-0
Risk of injury!
● Measurement
at load resistance 5.6 kohm
Pin / Pin / Nomin

Condition Polarity
socket socket al
V
Crankshaft
turns at start- 1 2 > 0,2 +
up speed
● Measurement
at load resistance 10 kohm
Pin / Pin / Nomin

Condition Polarity
socket socket al
V
Crankshaft
turns at start- 1 2 > 0,8 +
up speed
© 01/2012
2/2
Standard tools
W 49-00-01
7 Standard tools
© 06/2012
1/10
Standard tools
W 49-00-01
Orders
Conventional tools /
special tools:
These must be ordered like normal DEUTZ
spare parts with specification of the order
number.
© 06/2012
2/10
Standard tools
W 49-00-01
8002
Pressure pump
Checking cooling system for leak-tightness
© 35409-2
7
8003
Assembly sleeve
Mounting valve shaft seal
© 49283-0
8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
© 49376-0
© 06/2012
3/10
Standard tools
W 49-00-01
8011
Hose clip pliers
Loosen hose clips and fasten
© 39426-1
7
8024
Assembly pliers
Removing valve shaft seals
© 49353-0
8035
Socket wrench insert
reinforced, size 22
removing and installing main bearing
© 49354-0
© 06/2012
4/10
Standard tools
W 49-00-01
8113
Torx - E 14
© 49355-0
7
8114
Torx - E 20
© 49340-0
8189
Torx tool set
Contents of case:
- Double-ended ring spanner E6/E8
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
© 39432-1
© 06/2012
5/10
Standard tools
W 49-00-01
8190
Rotation angle disc
with magnet
© 49342-0
7
8192
Bowl wrench
Fuel pre-filter (type: Racor)
© 43193-1
8193
Screwdriver insert
with pressed in hexagonal pin (5 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)
© 49346-1
© 06/2012
6/10
Standard tools
W 49-00-01
8195
Multi-toothed screwdriver set
260 mm long
Remove and install air compressor
© 43195-0
7
8196
Open end wrench adapter
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.
© 49344-0
8202
Pricker
Removing rotary shaft lip seal
© 49345-0
© 06/2012
7/10
Standard tools
W 49-00-01
8510
Disassembly tool
Disassemble pin screw
(M10)
© 49303-0
7
8512
Disassembly tool
(M12)
© 49303-0
8538
Disassembly tool
(M8)
© 49303-0
© 06/2012
8/10
Standard tools
W 49-00-01
9017
Assembly lever
e. g. removing and installing valves
© 37511-2
7
9090
Spring band pliers
320 mm
Tighten spring clamp
© 35420-3
9092
Spark plug socket insert
Wrench size 16 mm,
Removing and installing spark plug.
© 49911-0
© 06/2012
9/10
Standard tools
W 49-00-01
9208
Assembly tool
Mount pin screw
(M8)
© 49302-0
7
9210
Assembly tool
Mount pin screw
(M10)
© 49302-0
9212
Assembly tool
Mount pin screw
(M12)
© 49302-0
© 06/2012
10/10
Special tools
W 49-01-01
8 Special tools
© 11/2014
1/18
Special tools
W 49-01-01
Orders
Special tools::
These must be ordered like normal DEUTZ
spare parts with specification of the order
number.
© 11/2014
2/18
Special tools
W 49-01-01
01899028
Engine lifting device
Load (2000 kg), 3-point suspension, spindle clamp,
cross member, chains and hooks
© 43184-0
01899030
Slotted nut wrench 8
Grooved nut, cable plug fastening on the cylinder head
© 43199-0
01899031
Pressure pump
Checking cooling system for leak-tightness
© 35409-2
© 11/2014
3/18
Special tools
W 49-01-01
01899034
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
© 49376-0
01899037
8 Hose clip pliers
© 56004-0
01899050
Assembly pliers
Pull out fixed injector sealing disc
© 49353-0
© 11/2014
4/18
Special tools
W 49-01-01
01899060
Torx - E 14
© 49355-0
01899061
Socket wrench insert 8
Torx - E 20
© 49340-0
01899092
Torx tool set
Contents of case:
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
© 53310-0
© 11/2014
5/18
Special tools
W 49-01-01
01899093
Rotation angle disc
with magnet
© 49342-0
01899097
8 Screwdriver insert
using a pressed-in hexagonal pin (4 mm),
3/8 Inch, long version
(in conjunction with 01899093 rotary angle disc and
adapter 1/2 inches on the inside to 3/8 Inch on the out-
side)
© 49346-1
01899098
Multi-toothed screwdriver set
260 mm long
Remove and install air compressor
© 56005-0
© 11/2014
6/18
Special tools
W 49-01-01
01899099
Open end wrench adapter
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.
© 49344-0
01899103
Pricker 8
Removing rotary shaft lip seal
© 49345-0
01899105
Disassembly tool
(M10)
© 56006-0
© 11/2014
7/18
Special tools
W 49-01-01
01899106
Disassembly tool
(M12)
© 56006-0
01899108
8 Disassembly tool
(M8)
© 56006-0
01899110
Assembly lever
Removing crankshaft sealing rings
© 37511-3
© 11/2014
8/18
Special tools
W 49-01-01
01899112
Spring band pliers
320 mm
Tighten spring clamp
© 56007-0
01899132
Socket wrench insert 8
Wrench size 27,
Version: long
Removing and installing the pressure sensors
(rail pressure, oil pressure, fuel pressure)
© 49357-0
01899136
Pipe wrench
with extension,
Wrench size 24,
Loosening and tightening the nut for the V-belt pulley /
V-rib belt pulley
© 48248-0
© 11/2014
9/18
Special tools
W 49-01-01
01899142
Special wrench
Unscrewing the filter cartridges
© 37629-3
01899368
8 Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
© 43663-0
01899148
Assembly tool
Mount pin screw
(M8)
© 56009-0
© 11/2014
10/18
Special tools
W 49-01-01
01899149
Assembly tool
Mount pin screw
(M10)
© 56009-0
01899150
Assembly tool 8
Mount pin screw
(M12)
© 56009-0
01899184
Torque handle
0.6 - 1.5 Nm
© 51488-0
© 11/2014
11/18
Special tools
W 49-01-01
01899185
Insert holder
Drive square 1/4“
Drive hexagon 1/4“
© 51489-0
01899399
8 Hose clip pliers
SPECIAL TOOL UNDER PREPARATION
© 00000-0
02992018
Connector
(in conjunction with compression pressure tester
01899034)
© 49347-0
© 11/2014
12/18
Special tools
W 49-01-01
02992077
U-tube pressure gauge
Check crankcase pressure
© 56707-0
02992033
Turning gear 8
on hub torsional vibration damper/V-belt pulley
© 49699-0
02992117
Lever tool
Removing the injector
© 49375-0
© 11/2014
13/18
Special tools
W 49-01-01
02992118
Disassembly device
Removing the pressure pipe nozzle
© 49359-0
02992126
8 Assembly case
Case for O-rings, complete with:
Disassembly tool 02992127 and three
assembly sleeves with guide
Assembly guides:
- high-pressure pump (Ø 36), 02992617
- injector, 4V engine (Ø 23), 02992619
Assembly sleeves:
- high-pressure pump (Ø 36), 02992618
Remove and install O-ring
© 49358-0
02992127
Disassembly tool
Removing O-ring
© 49360-0
© 11/2014
14/18
Special tools
W 49-01-01
02992137
Puller
(in conjunction with slide hammer 02992294)
Removing fixed injector sealing disc
© 56010-0
02992238
Assembly tool 8
Installing crankshaft sealing ring
(flywheel side)
© 49366-0
02992239
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)
© 49365-0
© 11/2014
15/18
Special tools
W 49-01-01
02992275
Counter support
for torsional vibration dampers
© 49367-0
02992294
8 Slide hammer
(in conjunction with extraction tool 02992137)
Removing fixed injector sealing disc
© 49372-0
02992301
Separating tool
Removing metal sheet lubricating oil pan from crank-
case
© 49373-0
© 11/2014
16/18
Special tools
W 49-01-01
02992345
Claw wrench
NOx sensor, removal and installation
© 49899-0
02992349
Special pliers 8
for removing the roller tappet
© 54518-0
02992465
Turning gear / locking device
Turn or block crankshaft at the flywheel
© 54986-0
© 11/2014
17/18
Special tools
W 49-01-01
02992477
Special wrench
Wrench size 17
Removing and installing high-pressure lines
© 56012-0
Diagnostic tool
8 SerDia 2010
© 00000-0
© 11/2014
18/18

WHB DEUTZ TTCD 7.8 L6 Agri Kompetenzklasse 3 FENDT900VarioS4 en 112014 Locked 91629

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WHB DEUTZ TTCD 7.8 L6 Agri Kompetenzklasse 3 FENDT900VarioS4 en 112014 Locked 91629

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Workshop Service Manual

Only available digitally!

DEUTZ engines are the product of years of research

Maintenance and care are the only way the engine

Please consult one of our service representatives

3 Safety information / User information

3.1 General 3.2 Specifications

3.4 Job cards 3.4.2 Structure of a job card

3.4.1 Numbering of job cards 9

3.5 Explanation of symbols

Removing and installing the crankcase bleeding

Removing the crankcase bleeding

● Loosen hose clips (1) with hose clip pliers.

● Remove moulded seal (1) with disassembly tool.

● Unscrew screw (1).

● Unscrew shut-off valve (1).

Install crankcase bleeding

● Mount crankcase bleeding (1).

● Mount sealing ring (1).

● Mount sealing rings (1).

● Mount the hose pipe (1).

Renewing the crankshaft sealing ring

Removing the crankshaft sealing ring

● Removing torsional vibration damper.

● Make a hole of approximately 3 mm in the crankshaft

● Turn in a self-tapping screw with washer.

● Visually inspect the crankshaft sealing ring running

Installing the crankshaft sealing ring

● Tighten screws (1).

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

● Pay attention to installation depth of crankshaft seal-

● Mount assembly sleeve (1).

● Plug in the bearing (1).

● Tighten nut to the stop of the assembly sleeve (1).

● Remove assembly tool. 1

● Insert clamping bushing (1).

Assembling/disassembling shaft sleeve on the crankshaft

Installing the shaft sleeve

● Knock the shaft sleeve onto the crankshaft up to the

After installing the shaft sleeve, check that

Removing the shaft sleeve

● Pull off the shaft sleeve.

● Install front cover.

Removing and installing the front cover

Remove the front cover

● Removing torsional vibration damper.

● Knock out crankshaft sealing ring (1).

Install front cover

● Fill lubricating oil into the oil pump housing.

● Position the inner rotor on the crankshaft.

● Attach front cover (1).

● Tighten the screws according to the tightening se-

Checking the overhang of the cylinder liner

The sealing surfaces must be dry and free

Checking the overhang of the cylinder liner

● Insert dial gauge into measuring beam.

● Apply stylus of the dial gauge to the crankcase seal-

Measuring points see diagram.

● Move the measuring beam and spacing washers un-

Removing and installing the cylinder liner

Removing the cylinder liner

● Place the plate (1) with the lay-on surfaces against

● Turn the nut (1) clockwise.

● Pull the cylinder liner up and out.