Deutz 2011 Workshop manual

Workshop Manual
2011

0312 1936

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

en

Workshop Manual
2011

Workshop Manual

2011

0312 1936 en

Illustrations and data in this workshop manual are subject to technical change in
the course of improvements to the engines. Reprinting and reproductions of any
kind, even in part, require our written permission.

© 11/2004

Deutz AG

Service Information Systems

Deutz-Mülheimer Strasse 147-149

D - 51063 Köln

Tel.: + 49 (0) 221-8 22-0

Fax: + 49 (0) 221-8 22-53 58

http://www.deutz.de

Printed in Germany

All rights reserved

1st edition, 11/2004

Order No. 0312 1936

2011

1 Foreword

2 General

3 User notes

3.1 General

3.2 Specifications

3.2.1 Safety regulations and rules for the prevention of accidents

3.2.2 Disposal regulations

3.3 Operating manual and workshop manual

3.4 Job cards

3.5 Explanation of symbols

Contents

1

4 Technical data

4.1 Test and adjustment data

4.2 Tightening specifications

5 Job card overview

5.1 Alphabetical sorting

5.2 Numeric sorting

5.3 Job card references

6 Job cards

7 Commercial tools

8 Special tools

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1

Contents

2011

Notes

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1 Foreword

1

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1

1 Foreword

2011

Notes

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1 Foreword

2011

z Read and observe the information in this documentation. You will avoid accidents, retain the manufacturer’s

warranty and have a fully functional, ready to use engine at your disposal.

z This engine is built exclusively for the purpose according to the scope of delivery - defined by the equipment

manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use.
The manufacturer will not be liable for damages resulting from this. The user will bear the sole risk in this
case.

z Use for the intended purpose also includes observance of the operating, maintenance and repair

instructions specified by the manufacturer. The engine may only be used, maintained and repaired by
persons who are familiar with it and instructed in the dangers.

z Make sure that this documentation is available to everyone involved in the operation, maintenance and

repair and that they have understood the contents.

z Failure to observe this documentation can lead to malfunctions and engine damage as well as

injury to persons for which the manufacturer will accept no liability.

1

z Prerequisite for the proper maintenance and repair is the availability of all necessary equipment,

commercial tools and special tools as well as their perfect working order.

z Engine parts such as springs, clamps, elastic retaining rings etc. constitute an increased risk of injury when

not used properly.

z The pertinent rules for the prevention of accidents and other generally recognized safety and industrial

medicine rules must be observed.

z Maximum cost effectiveness, reliability and long life is only guaranteed when DEUTZ original parts are

used.

z Repair of the engine must comply with use for the intended purpose. Only parts released by the

manufacturer for the respective purpose may be used for conversion work. Unauthorized modification to the
engine exclude manufacturer liability for resulting damages. Failure to observe this will lead to voiding of the
warranty!

z The engines made by DEUTZ are developed for a wide range of applications. A wide range of variants

ensures that the respective special requirements are met.

z The engine is equipped according to the installation, i.e. not all the parts and components described in this

documentation are installed in your engine.

z We have done our best to clearly identify the differences so that you can easily find the operating,

maintenance and repair instructions relevant to your engine.

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

Your DEUTZ AG

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1 Foreword

2011

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2 General

2

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2

2 General

2011

Notes

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2 General

2011

DEUTZ engines

are the product of years of research and development. The profound know-how gained in connection with high
quality requirements is the guarantee for manufacturing of engines with a long life, high reliability and low fuel
consumption. Naturally the high requirements for protection of the environment are also met.

Maintenance and care

are decisive for whether the engine satisfactorily meets the set demands. Compliance with the prescribed
maintenance times and the careful execution of maintenance and care are therefore essential. Difficult
operating conditions deviation from normal operation must be observed especially.

DEUTZ AG

Please consult one of our service representatives responsible for operating faults and spare parts questions.
Our trained specialist personnel ensures fast, professional repairs using original parts in the event of damage.
Original parts of the DEUTZ AG are always produced according to the latest state of the art.
Information about our service can be found at the end of this documentation.

2

Take care when the engine is running

Only perform maintenance work or repairs when the engine is at a standstill. Replace any removed protective
devices upon completion of the work. When working on the running engine, work clothing must be close fitting.

Safety

!

This symbol accompanies all safety notes. Observe these carefully.
Also pass on the safety instructions to your operating personnel. The ”General safety regulations and
rules for the prevention of accidents” of the legislator must be observed additionally.

Note

This symbol accompanies information of a general kind.
Observe these carefully.

Asbestos

Gaskets used in this engine are asbestos-free. Please use the appropriate spare parts for
maintenance and repair work.

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2 General

2011

Notes

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3User notes

3

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3

3 User notes

2011

Notes

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3 User notes

2011

3.1 General

The maintenance work prescribed in the operating manual and in the workshop manual must be performed on
schedule and completely.

The maintenance personnel must possess the necessary technical knowledge to perform the work. Safety and
protection devices which are removed during maintenance work must be replaced again afterwards.

!

Also observe the special safety regulations for the different maintenance groups which are listed in detail as
job cards in the Job cards chapter (cf. also section 1.2).

See the maintenance schedules for the maintenance intervals. These also inform you of the work to be
performed.

The job cards provide technical instructions for performing the work.

3.2 Specifications

3.2.1 Safety regulations and rules for the prevention of accidents

For various maintenance groups, detailed safety notes in the form of job cards have been compiled, these
precede the job cards of the respective maintenance groups.

The legally prescribed rules for the prevention of accidents (available from professional associations or from
dealers) must be observed. These are dependent on the installation site, operating mode and the operating
and auxiliary materials being used.

Special protection measures depending on the respective work are specified and identified in the job
description.

Caution!

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

3

It generally applies among other things:

z for the personnel

- Only instructed personnel may operate or maintain the engine. Unauthorized persons may not enter the
engine room.

- Wear close fitting clothing and ear protectors in the engine room when the engine is running.

- Only appoint qualified personnel to do repairs and maintenance.

z for the engine room:

- Ensure adequate ventilation (do not cover air shafts)

- Install first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly.

- Only store inflammable materials in the engine room if these are necessary for operating the system.

- Smoking and naked lights are prohibited in the engine room.

z For operation and maintenance of the engine:

- Only start the engine when all protection devices are installed. Make sure that no-one is standing in the
danger area.

- Only perform cleaning, maintenance and repair work when the engine has been shut down and secured
against starting.

!

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3 User notes

2011

3.2.2 Disposal regulations

The work described in the operating manual and workshop manual necessitates renewal of parts and operating
materials. The renewed parts / operating materials must be stored, transported and disposed of properly. The
owner himself is responsible for this.

Disposal includes recycling and the scrapping of parts / operating materials whereby recycling has priority.

Details of disposal and their monitoring are governed by regional, national and international laws and directives
which the system operator must observe on his own responsibility.

3.3 Operating manual and workshop manual

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

The operating manual contains a general description and instructions for all other maintenance work.

It contains the following chapters:

1. General, Contents

2. Engine description

3. Operation

4. Operating materials

5. Maintenance

6. Care and maintenance work

7. Faults, causes and remedies

8. Engine corrosion protection

9. Technical data

10. Service

The workshop manual assumes knowledge of the contents of the operating manual, this applies especially
for the safety regulations. Minor repairs and emergency measures on components are described
the execution of which requires more effort and appropriately qualified personnel.

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3 User notes

2011

3.4 Job cards

The job cards are divided into job cards of the workshop manual e. g. W 04-05-01 and the maintenance
manual I 04-05-01.

Numbering of job cards

Dokumentationsart

• Der führende Buchstabe steht für die Art der Dokumentation.
W = Werkstatthandbuch
I = Instandsetzungsanleitung

Instandhaltungsgruppe (für alle Motoren gleich)

00 Allgemein / übergreifende Tätigkeiten
01 Zylinderkopf
02 Triebwerk
03 Kurbelgehäuse
04 Motorsteuerung
05 Drehzahlregelung
06 Abgasanlage / Aufladung

07 Kraftstoffsystem
08 Schmierölsystem
09 Kühlflüssigkeitssystem
10 Druckluftsystem
11 Überwachungssystem
12 Sonstige Bauteile
13 Elektrische Anlage

3

Teilsystem (Bauteil)

• Die Teilsysteme unterscheiden sich je Instandhaltungsgruppe.

• Allgemein gültig:
00 Teilsysteme-übergreifend bzw. Sicherheitsvorschriften (SV)
01 Systemparameter bzw. generelle Kontrollen

Fortlaufende Nummer

• Zählend je Teilsystem (Bauteil)

• Verschiedene Tätigkeiten je Teilsystem (Bauteil)

• Versions-Unterschiede

W 03-03-03

©

80301 3

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3 User notes

Structure of a job card

13

12

1 2 3

Kurbelgehäuse

W 00-00-00

2011

4

3

11

10

5

6

6

9

7

8

39744 1

©

1. DEUTZ, publisher of the

service documentation

2. Engine type (e. g. 914)

3. Maintenance group

4. Job card number

5. Reference to other job cards,

Specifications and similar

6. Explanatory graphics

7. Page number

Note

For inquiries about the job card please always state the engine type (2), the job card number (4), the
page number (7), the date of issue (9) or alternatively the DEUTZ-internal part number (8).

© 11/2004

8. DEUTZ-internal part number of job card and
technical order number

9. Date of issue of the job card

10. Work sequence

11. Safety and general notes

12. Necessary tools, auxiliary materials and
spare parts

13. Title of the job card

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2011

3.5 Explanation of symbols

3 User notes

!

Auxiliary material

Caution!

For example: Lifting gear, adhesive

Tools

for example:100 400 - meter

3

Note

For example: Cylinder head is dismantled.

Always renew when assembling

For example: Gaskets

01 61

01001

References

For example: Job card no. W xx-yy-zz

See technical data (test and setting data)

Line note, for example: ”01 61 – Valve clearance (inlet)”

See technical data (tightening specifications)

Line note, for example: ”01001 – Cylinder head on crankcase”

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3 User notes

2011

Notes

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4 Technical data

4.1 Test and adjustment data

4

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4 Technical data

4

4.1 Test and adjustment data

Notes

2011

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4 Technical data

2011

00 00 Engine general

ID

No.

00 04 Engine weight according to

DIN 70020-A

Name Remark Value Unit

4.1 Test and adjustment data

F2L engine 175

F3L engine 217

F4L engine 256

F2M engine 169

F3M engine 210

kg

F4M engine 248

4

BF3L engine 222

BF4L engine 257

BF3M engine 215

BF4M engine 250

00 10 Working principle four-stroke diesel

00 20 Combustion process Direct injection

00 31 Bore Diameter 94 mm

00 32 Stroke 112 mm

00 40 Compression ratio FL/M engines 19:1

BFL/M engines 17.5:1

00 50 Direction of rotation looking onto the

flywheel

left

00 51 Compression pressure FL/M engines 25 to 30 bar

BFL/M engines 22 to 27 bar

00 70 Ignition distance 2 and 4 cylinder 180 °

3-cylinder 120 °

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4 Technical data

4

4.1 Test and adjustment data

ID

No.

00 71 Ignition sequence 2-cylinder 1 - 2

00 81 Cylinder arrangement

2-cylinder
A = Manifold side
B = Operating side

Name Remark Value Unit

3-cylinder 1 - 2 - 3

4-cylinder 1 - 3 - 4 - 2

A

12

B

Cylinder arrangement
3-cylinder
A = Manifold side
B = Operating side

A

123

2011

© 39617 0

Cylinder arrangement
4-cylinder
A = Manifold side
B = Operating side

B

A

1234

B

© 39618 0

© 39619 0

01 00 Cylinder head

ID

No.

01 01 Bore diameter for valve seat ring (inlet) Standard 42.590 - 42.615 mm

01 02 Bore diameter for valve seat ring (outlet) Standard 36.010 - 36.015 mm

Name Additional information Value Unit

01 03 Bore diameter for valve seat ring (inlet) 1. Overmeasure step 42.800 - 42.825 mm

01 04 Bore diameter for valve seat ring (outlet) 1. Overmeasure step 37.200 - 37.225 mm

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4 Technical data

2011

ID

No.

01 05 Bore diameter for valve guide Standard 8.000 - 8.025 mm

01 06 Bore diameter for valve guide • 1. Overmeasure step

01 08 Height of cylinder head Standard 118.00

01 09 Height of cylinder head Undermeasure 117.96

01 10 Valve guide

01 12 External diameter of the valve guide • 1. Overmeasure step

01 16 Internal diameter of valve guide (inlet) • Repair

Name Additional information Value Unit

• Repair

• Fit H7

• Repair

•FitE7

4.1 Test and adjustment data

12.000 - 12.018 mm

±0.1

±0.1

12.025 - 12.035 mm

8.025 - 8.040 mm

mm

mm

4

01 17 Internal diameter of valve guide (outlet) • Repair

•FitE7

01 20 Valve seat ring

01 21 External diameter of the valve seat ring

(inlet)

01 22 External diameter of the valve seat ring

(outlet)

01 23 External diameter of the valve seat ring

(inlet)

01 24 External diameter of the valve seat ring

(outlet)

01 27 External diameter of the valve seat ring

(inlet)

01 28 External diameter of the valve seat ring

(outlet)

Standard 42.680

Standard 37.075

Repair standard 42.67

Repair standard 37.07

1. Overmeasure step 42.87

1. Overmeasure step 37.27

8.025 - 8.040

±0.006

±0.006

±0.005

±0.005

±0.005

±0.005

mm

mm

mm

mm

mm

mm

mm

01 30 Valve

01 31 Valve shaft diameter (inlet)

© 11/2004

Standard 7.98

5/22

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4 Technical data

4

4.1 Test and adjustment data

ID

No.

01 32 Valve shaft diameter (outlet)

01 33 Valve shaft clearance (inlet) Wear limit 0.5 mm

01 34 Valve shaft clearance (outlet) Wear limit 1.3 mm

01 35 Valve edge strength on valve head

(inlet)

01 36 Valve edge strength on valve head

(outlet)

Name Additional information Value Unit

Standard 7.96

• Wear limit

• FL/M engines

• Wear limit

• BFL/M engines

• Wear limit

• FL/M engines

2011

-0.015

0.8 mm

1.4 mm

1.2 mm

mm

• Wear limit

• BFL/M engines

01 37 Valve head diameter (inlet) 41.5

01 38 Valve head diameter (outlet) 35.4

01 40 Valve seat

01 41 Valve seat width on valve seat ring

(inlet)

01 42 Valve seat width on valve seat ring

(outlet)

01 45 Valve lag dimension (inlet) • Wear limit

FL/M engines 1.7

B/FL/M engines 1.58

FL/M engines 1.7

B/FL/M engines 1.7

• FL/M engines

• Wear limit

• B/FL/M engines

1.2 mm

1.53 mm

1.3 mm

±0.1

±0.1

±0.4

±0.4

±0.4

±0.4

mm

mm

mm

mm

mm

mm

01 46 Valve lag dimension (outlet) • Wear limit

• FL/M engines

• Wear limit

• B/FL/M engines

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1.53 mm

1.3 mm

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4 Technical data

2011

ID

No.

01 47 Valve seat angle (inlet) FL/M engines 45 °

01 48 Valve seat angle (outlet) FL/M engines 45 °

01 50 Valve spring

01 51 Valve spring length (unclamped normal) Wire diameter 3.35 mm 38.9 mm

01 60 Valve clearance

Name Additional information Value Unit

B/FL/M engines 30 °

BFL/M engines 45 °

Wire diameter 3.40 mm 39.3 mm

4.1 Test and adjustment data

4

01 61 Valve clearance (inlet) • after a cooling time of at

least 0.5 h (oil
temperature < 80 °C)

• Test and setting values
in inspections from a
running time of
50 operating hours of
the engine or life of the
cylinder head gasket
(see maintenance
schedule)

• Setting values when
changing the cylinder
head gasket

01 62 Valve clearance (outlet) • after a cooling time of at

least 0.5 h (oil
temperature < 80 °C)

• Test and setting values
in inspections from a
running time of
50 operating hours of
the engine or life of the
cylinder head gasket
(see maintenance
schedule)

• Setting values when
changing the cylinder
head gasket

0.3

(0.4

0.5

(0.6

±0.05

mm

±0.05)

±0.05

mm

±0.05)

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4 Technical data

4

4.1 Test and adjustment data

ID

No.

01 63 Valve clearance setting scheme

• Turn over engine up until reaching the valve overlap cyl. no. 1.

Note

According to the order below (see table) the valve clearance setting is possible with
2 crankshaft revolutions á 360°.

Crankshaft setting 1 Cyl. no. 1 = overlap

Name Additional information Value Unit

2011

white = not adjustable
black = adjustable

Crankshaft setting 2

• Turn the crankshaft one rev on (360°).

white = not adjustable
black = adjustable

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4 Technical data

2011

ID

No.

01 70 toggle lever / toggle lever block

01 72 toggle lever bore for toggle lever axle

(outlet)

01 73 toggle lever bore for toggle lever axle

(inlet)

01 74 diameter of the toggle lever axle 17.97

01 93 Roughness of the sealing surface 15 - 18 Rz

01 98 Length of the cylinder head screw

Name Additional information Value Unit

Standard 150.000

4.1 Test and adjustment data

±0.27

18

18

±0.27

±0.01

+0.8

-0.8

mm

mm

mm

mm

4

02 00 Drive system

ID

No.

02 02 Main bearing pin

02 03 Diameter of the main bearing pin Standard 69.970 - 69.990 mm

02 04 Undermeasure graduation for main

bearing pin

02 05 Limit value for undermeasure

graduation of the main bearing pin

02 06 Unroundness of the main bearing pin Wear limit 0.008 mm

02 07 Surface hardness of the main bearing

pin

Name Additional information Value Unit

1. Stage 0.25 mm

2. Stage 0.50 mm

69.47 mm

Standard 58

+4

HRC

02 10 Fit bearing pin

02 11 Width of fit bearing pin 35

02 12 Undermeasure graduation for fit bearing

pin

02 13 Limit value for undermeasure

graduation of the fit bearing pin (width)

© 11/2004

1. Stage 0.4 mm

9/22

+0.04

35.44 mm

0312 1642 - 0138

mm

4 Technical data

4

4.1 Test and adjustment data

ID

No.

02 20 Lifting journal

02 21 Width of lifting bearing journal 31

02 22 Diameter of the lifting bearing journal Stroke 112 mm 54.970 - 54.990 mm

02 23 Undermeasure step for lifting bearing

journal

02 24 Limit for undermeasure step

of the lifting bearing journal

02 25 Unroundness of the lifting bearing

journal

Name Additional information Value Unit

1. Stage 0.25

2. Stage 0.50

Wear limit 0.01 mm

2011

+0.2

54.47 mm

mm

mm

02 26 Concentricity of the crankshaft max. deviation 0.05 mm

02 27 Hollow throat radius lifting and main

bearing journal

02 30 Crankshaft main bearing

02 31 Internal diameter of the main bearing

shells

02 32 Undermeasure graduation for main

bearing shells

02 34 Axial clearance of crankshaft Standard 0.100 - 0.273 mm

02 35 Strength of the starting rings

• Do not damage hollow
throat when reworking!

•Stroke112mm

Standard 70.020 - 70.055 mm

1. Stage 0.25

2. Stage 0.50

Wear limit 0.4 mm

Standard 2.4

1.9

+0.5

+0.05

mm

mm

mm

02 36 Strength of the starting rings

02 40 Con-rod

02 41 Parallelism of the con rod to the piston

bolt

© 11/2004

1. Overmeasure step 2.6

at a distance of 100 mm 0.03 mm

10/22

+0.05

0312 1642 - 0138

mm

4 Technical data

2011

ID

No.

02 42 Parallelism of the con rod to the piston

bolt

02 43 Internal diameter of the piston bolt bush • Standard

02 45 Theoretical clearance between

Piston bolt bush (con rod) and piston
bolt

02 48 Clearance between piston and piston

bolt

Name Additional information Value Unit

at a distance of 100 mm
max. perm. deviation

• FL/M engines

• Standard

• BFL/M engines

Wear limit 0.08 mm

Wear limit 0.004 - 0.015 mm

4.1 Test and adjustment data

0.03 mm

26.025 - 26.035

mm

30.025 - 30.035

4

02 50 Con rod bearing

02 52 Internal diameter of the con rod bearing

shells (in installed state)

02 53 Limit value for undermeasure

graduation of the con rod bearing shells

02 54 Undermeasure graduation of the con

rod bearing

02 55 Con rod bearing bore in con rod 58.500 - 58.520 mm

02 56 Theoretical clearance between the con

rod bearing and the lifting journal

02 57 Con rod bearing clearance Wear limit 0.12 mm

02 60 Piston bolt

02 61 Diameter of the piston bolt FL/M engines 25.995 - 26.000

BFL/M engines 29.995 - 30.000

55.024 - 55.055 mm

54.524 - 54.555 mm

0.25 mm

0.014 - 0.07 mm

mm

02 62 Piston bolt clearance between con rod

and piston bolt

02 70 Piston

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0.025 - 0.04 mm

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4 Technical data

4

4.1 Test and adjustment data

ID

No.

02 71 Diameter of the piston • Measuring point 1 at

02 72 Diameter of the piston • Measuring point 2 at

Name Additional information Value Unit

height 22 mm

• FL/M engines

• Measuring point 1 at
height 25 mm

• BFL/M engines

• Measuring point 1 at
height 25 mm

• BFL engines without
cooling duct

height 44.5 mm

• FL/M engines

2011

93.920

93.900

93.880

93.856

mm

• Measuring point 2 at
height 47 mm

• BFL/M engines

• Measuring point 2 bat
height 47 mm

• BFL engines without
cooling duct

02 73 Diameter of the piston • Measuring point 3 at

height 69.7 mm

• FL/M engines

• Measuring point 3 at
height 66.5 mm

• BFL/M engines

• Measuring point 3 at
height 66.5 mm

• BFL engines without
cooling duct

02 74 Overmeasure graduation 0.5 mm

93.840

93.820

93.670

93.720

93.700

mm

mm

02 75 Piston overlap for cylinder head gasket 1 Notch 0.514 - 0.69 mm

02 76 Piston overlap for cylinder head gasket 2 Notches 0.691 - 0.76 mm

02 77 Piston overlap for cylinder head gasket 3 Notches 0.761 - 0.83 mm

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4 Technical data

2011

ID

No.

02 78 Piston bolt bore FM engines 26.004 - 26.010 mm

20 79 Determine piston class • Piston class A

02 80 Piston rings

02 81 Piston ring 1st ring

• Rectangular ring

Piston ring 1st ring

• Double-sided trapezoidal ring

Name Additional information Value Unit

BFL/M engines 30.004 - 30.010 mm

• Stroke 112 mm

• only in FL/M engines

• Piston class B

• Stroke 112 mm

• only in FL/M engines

• External diameter/
internal diameter x
height

• FL/M engines

• External diameter/
internal diameter x
height

• BF3/4L/M engines

4.1 Test and adjustment data

196.380 - 196.490 mm

196.491 - 196.690 mm

94.0 x 2.0 x 3.9

mm

94.0 x 3.0 x 3.9

4

02 82 Piston ring 2 ring

• minute ring

02 83 Piston ring 3 ring

• Roof chamfer ring

Piston ring 3 ring

• Oil slit ring

02 84 Piston ring joint clearance of the 1st

piston ring

• BFL/M engines

Piston ring joint clearance of the 1st

piston ring

• FL/M engines

External diameter/
internal diameter x
height

External diameter/
internal diameter x
height

External diameter/
internal diameter x
height

External diameter/
internal diameter x
height

• Double-sided
trapezoidal ring

• Wear limit

Rectangular ring 0.3 - 0.5

Wear limit 0.8

94.0 x 1.99 x 4.05

91.0 x 2.5 x 3.8

94.0 x 3.0 x 3.73

94.0 x 2.99 x 2.9

0.3 - 0.5

mm

mm

mm

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4 Technical data

4

4.1 Test and adjustment data

ID

No.

02 85 Piston ring joint clearance of the 2nd

piston ring
B/FL/M engines

02 86 Piston ring joint clearance of the 3rd

piston ring

02 87 • Axial clearance of the 1st piston ring

• Rectangular ring

Axial clearance of the 1st piston ring • Wear limit

Name Additional information Value Unit

2011

minute ring 1.5 - 2.0

Wear limit 2.5

Roof chamfer ring 0.4 - 0.7

• Wear limit

• FL/M engines

• Oil slit ring

• B/FL/M engine

• Wear limit

• FL/M engines

• BFL/M engines

gauge contact with

1.2

0.3 - 0.6

0.2

Trapezoidal

groove wear

piston

mm

mm

mm

02 88 Axial clearance of the 2nd piston ring Wear limit 0.2 mm

02 89 Axial clearance of the 3rd piston ring Wear limit 0.15 mm

02 91 Piston ring height 1st. piston ring Rectangular ring 1.975 - 1.990

Double-sided
trapezoidal ring

02 92 Piston ring height 2nd piston ring minute ring 1.975 - 1.990 mm

02 93 Piston ring height 3rd piston ring • Roof chamfer ring

• Wear limit

• Oil slit ring

• Wear limit

02 95 Position of the piston ring joints Angle of twist to each

other

02 96 Position of the piston ring joints roof

chamfer ring

Angle of twist of spring
joint to piston ring joint

3.0

2.975 - 2.990

2.975 - 2.990

90 - 120 °

180 °

mm

mm

20 97 Compression height Piston class A 51.67 mm

Piston class B 51.77 mm

© 11/2004

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0312 1642 - 0138

4 Technical data

2011

ID

No.

02 99 Piston ring height 3rd piston ring Roof chamfer ring 2.975 - 2.990 mm

Name Additional information Value Unit

4.1 Test and adjustment data

03 00 Crankcase

ID

No.

03 10 Camshaft bearings

03 11 Bore diameter for camshaft bearing liner

in crankcase

03 12 External diameter of the camshaft

bearing liner

Name Additional information Value Unit

Fit H7 58

Standard 58.075

+0.030

+0.045

mm

4

mm

03 13 Internal diameter of the camshaft

bearing liner

03 14 Camshaft bearing liner Wear limit 54.08 mm

03 20 Bore for camshaft main bearing

03 21 Diameter of the main bearing bore • Standard

03 27 Fit bearing width on crankcase

03 30 Cylinder

03 31 Bore diameter of the cylinder

03 32 Bore diameter of the cylinder Wear limit 94.1 mm

03 41 Bore diameter of the cylinder

in the installed state 54.000 - 54.054 mm

30

+0.019

- 0.033

+ 0.020

+ 0.020

• Fit H6

Standard 94.000

Overmeasure step 94.500

75.000

mm

mm

mm

mm

03 42 Bore diameter of the cylinder Wear limit of the

overmeasure step

© 11/2004

15/22

94.6 mm

0312 1642 - 0138

4 Technical data

4

4.1 Test and adjustment data

2011

04 00 Engine control

ID

No.

04 10 Control times for 1 mm valve

clearance

04 11 Inlet opens after UT 3°12’ °

04 12 Inlet closes after LT 16°48’ °

04 13 Outlet opens before LT 27°48’ °

04 14 Outlet closes before UT 4°12’ °

04 20 Camshaft

04 21 Cam stroke (inlet) 6.6

Name Additional information Value Unit

±0.08

mm

04 22 Cam stroke (outlet) 6.8

04 31 Diameter of the camshaft bearing pin Standard 53.045 - 53.060 mm

±0.08

05 00 Speed governing

ID

No.

05 00 Speed governing

05 04 Setting screw for full load stop 12

05 05 Setting screw for minimum speed 23

05 06 Screw in depth of the adapter capsule 6.4

05 41 Full load stop (charge pressure-

dependent) in fuel filter console

Name Additional information Value Unit

±0.5

±0.1

±0.5

Stop screw 18

±1

mm

mm

mm

mm

mm

© 11/2004

16/22

0312 1642 - 0138

4 Technical data

2011

4.1 Test and adjustment data

07 00 Fuel system

ID

No.

07 01 Pump

07 02 Make/Type no specification

07 10 injection pump

Name Additional information Value Unit

Note

Only injection pumps with the same classification may be
installed per engine.

07 11 Make/Type (Motorpal) PCIM9F2071

PCIM9F2073

4

Make/Type (Bosch) PF 30 V, see rating plate

PF 30 V, see rating plate

© 11/2004

17/22

0312 1642 - 0138

4 Technical data

4

4.1 Test and adjustment data

ID

No.

07 16 • Injection pump length "X"

• Standard roller tappet

• Motorpal

• TN 0428 1810

• Injection pump length "X"

• Standard roller tappet

• Motorpal

• TN 0428 1814

• Injection pump length "X"

• Hydro-roller tappet

• Motorpal

• TN 0428 6791

• Injection pump length "X"

• Hydro-roller tappet

• Motorpal

• TN 0428 6450

Name Additional information Value Unit

• Color marking: black

• Camshaft stroke

11.0 mm

• FL/M engine

• Color marking: green

• Camshaft stroke

11.0 mm

• BFL/M engine

• Color marking: blue

• Camshaft stroke

11.0 mm

• FL/M engine

• Color marking: red

• Camshaft stroke

11.0 mm

• BFL/M engine

2011

60.9 mm

60.9 mm

52.1 mm

52.1 mm

• Injection pump length "X"

• Standard roller tappet

• Motorpal

• TN 0428 6681

• Injection pump length "X"

• Hydro-roller tappet

• Motorpal

• TN 0428 6792

07 17 Classification of the injection pump A

07 19 Camshaft stroke for injection pump 11.0 mm

• Color marking: green

• Camshaft stroke

11.7 mm

• BFL/M engine

• Color marking: red

• Camshaft stroke

11.7 mm

• BFL/M engine

61.6 mm

52.8 mm

B
C
D

11.7 mm

© 11/2004

18/22

0312 1642 - 0138

4 Technical data

2011

ID

No.

07 21 Selection of the shim gasket

0417 8522 up to 0.37 9 mm

0428 6587 0.38 – 0.42 14

0417 8523 0.43 – 0.47 12

0428 6588 0.48 – 0.52 17

0417 8524 0.53 – 0.57 15

0428 6589 0.58 – 0.62 20

Name Additional information Value Unit

Part number

4.1 Test and adjustment data

Determined difference

(S

)

s

Dimension "a" of
the identification

4

0417 8525 0.63 – 0.67 18

0428 6590 0.68 – 0.72 23

0417 8526 0.73 – 0.77 21

0428 6591 0.78 – 0.82 26

0417 8527 0.83 – 0.87 24

0428 1633 0.88 – 0.92 8

0417 8528 0.93 – 0.97 27

0428 1634 0.98 – 1.02 11

0427 2923 1.03 – 1.07 30

0428 6592 1.08 – 1.12 29

0427 2924 1.13 – 1.17 33

© 11/2004

0428 6593 1.18 – 1.22 7

0428 1635 1.23 – 1.27 10

0428 6696 1.28 – 1.32 13

19/22

0312 1642 - 0138

4 Technical data

4

4.1 Test and adjustment data

ID

No.

07 31 Beginning of pumping see company plate °

07 50 Injection valve

07 51 Nozzle type • Bosch

07 52 Nozzle opening pressure of the injection

valve (leak oil-less)

Name Additional information Value Unit

• FL engines

• Bosch

• BFL engines

• Motorpal (leak oil-less)

• B/FL engines

Motorpal

2011

DSLA 144 P547

5-hole

DLLA 144 P521

5-hole

DOP152P522

3898

+10

170

+1

17

bar

MPa

07 53 Pressure for leak test

of the injection valve

08 00 Lube oil system

ID

No.

08 10 Lube oil pump

08 41 • Pressure limiting valve

• Standard

• without cabin heater connection

• Pressure limiting valve

• with cabin heater connection

08 42 • Pressure limiting valve

• Cabin heater connection

Name Additional information Value Unit

below the previously
read opening pressure

Opening pressure 3.0 bar

Color marking green

Opening pressure 1.0 bar

Color marking yellow

Opening pressure 1.7 bar

Color marking red

20 bar

08 43 • Pressure limiting valve

• Cabin heater connection

• Engine input

© 11/2004

Opening pressure 0.3 bar

Color marking blue

20/22

0312 1642 - 0138

4 Technical data

2011

ID

No.

08 44 Length of the compression spring

(green) for the oil pressure regulating
valve

Length of the compression spring
(yellow) for the oil pressure regulating
valve

08 45 Length of the compression spring (red)

for the oil pressure regulating valve

08 46 Length of the compression spring (blue)

for the oil pressure regulating valve

08 50 Lube oil pressure

Name Additional information Value Unit

4.1 Test and adjustment data

without heater
connection

with heater connection 80.5 mm

with heater connection 78.4 mm

with heater connection 61.8 mm

56.5 mm

4

08 51 Lube oil pressure in low idle Oil temperature

approx. 110 °C

08 73 Lube oil thermostat Starts opening 93

Fully open 110

08 74 Length of the compression spring for the

lube oil thermostat

09 00 Cooling system

ID

No.

09 91 Gap dimension between running wheel

and blower jacket inlet

Name Additional information Value Unit

min. = 0.2

max. = 0.8

12 00 Other components

1.4 bar

°C

116.7 mm

mm

ID

No.

12 11 Tension of the single V-belt First assembly 450

12 21 Tension of the single V-belt Check after 15 min

© 11/2004

Name Additional information Value Unit

running under load

21/22

300

±50

±20

0312 1642 - 0138

N

N

4 Technical data

4

4.1 Test and adjustment data

Notes

2011

© 11/2004

22/22

0312 1642 - 0138

2011

4 Technical data

4.2 Tightening specifications

4

© 11/2004 0312 1643 - 0138

1/14

4 Technical data

4

4.2 Tightening specifications

Notes

2011

© 11/2004

2/14

0312 1643 - 0138

4 Technical data

2011

00000 Engine general

ID no. Name

00001 Clamp holder on crankcase 90 Nm

00002 Clamp holder on adapter for

assembly block

00003 Engine mount on crankcase elast.

mounting

tightening

value

90 Nm

180 Nm + 30°

Pre-

4.2 Tightening specifications

Re-tightening

value

Remark

4

© 11/2004

3/14

0312 1643 - 0138

4 Technical data

4

4.2 Tightening specifications

01000 Cylinder head

ID no. Name

01001 Cylinder head on crankcase

Tightening order 2-cylinder

Pre-

tightening

value

30 Nm

4 2

5 1 3

Re-tightening

value

+ 80 Nm
+ 160 Nm
+ 90°

6

2011

Remark

• In case of provability use
max. 5 times.

• oil lubricated

• See tightening order

© 39152 1

Tightening order 3-cylinder

Tightening order 4-cylinder

01002 Toggle lever block on cylinder

head

7 3 4

5 1 2

8

10

21 Nm

6 4

3 1

6

8

© 39153 1

5

9

2

7

© 39154 1

01003 Lock nut on valve setting screw 20 ± 2 Nm

01004 Cylinder head cover on cylinder

head

© 11/2004

8.5 Nm

4/14

0312 1643 - 0138

4 Technical data

2011

02000 Drive system

ID no. Name

02010 Main and fit bearing covers on

crankcase 50 Nm

02015 Crankshaft gear wheel/flange hub

on crankshaft

02020 Con rod bearing cover on con rod

(crack con rod) 30 Nm

Con rod bearing cover on con rod

4.2 Tightening specifications

Pre-

tightening

value

130 Nm + 210° Central screw

30 Nm

Re-tightening

value

+ 60°
+ 45°

+ 60°
+ 60°

+ 60°
+ 60°

• in case of provability use
max. 3 times

• with lube oil

• tighten alternately

• in case of provability use
max. 5 times

in case of provability use
max. 5 times

Remark

4

03000 Crankcase

ID no. Name

03003 Locking screw on crankcase

03004 Locking screw on crankcase

Pre-

tightening

value

18 ± 2 Nm

18 Nm

Re-tightening

value

Remark

• Setting bolt for crankshaft
lock

• Holder for setting bolt for
crankshaft lock

• Renew CU sealing ring

• Setting bolt for control linkage
lock

• Holder for setting bolt for
control linkage lock

• Renew CU sealing ring

© 11/2004

5/14

0312 1643 - 0138

4 Technical data

4

4.2 Tightening specifications

ID no. Name

03007 Locking screws

• M18 x 1.5mm - item 5

• Note installation position of the
sealing ring!

• Always renew after
disassembly.

• M12 x 1.5mm - item 6 26 Nm

• M30 x 1.5mm - item 7

• Always renew after
disassembly.

• M20 x 1.5mm - item 10

• Always renew after
disassembly.

• M18 x 1.5mm - item 15

• Always renew after
disassembly.

Pre-

tightening

value

50 Nm

95 Nm

56 Nm

50 Nm

Re-tightening

value

2011

Remark

© 33822 1

03010 Rear cover on crankcase 21 Nm Note tightening order!

03020 Front cover on crankcase 21 Nm Note tightening order!

03030 Oil tray (plate), 2, 3 and 4-cylinder,

Oil tray (cast), 4-cylinder

Oil tray (cast), 4-cylinder

Oil tray (cast), 4-cylinder

03031 Oil drain screw on lube oil tray

03060 Crankcase bleeding on:

• Front cover

• Cylinder head cover

• Cylinder head

0.5 Nm 21 Nm

0.5 Nm 31 Nm

0.5 Nm 21 Nm

0.5 Nm 180 Nm

55 ± 5 Nm

8.5 Nm

• Screws M8 x 16 mm

• Note tightening order!

• Screws M8 x 30 mm

• Note tightening order!

• Screws M8 x 5 mm

• Note tightening order!

• Cylinder head bolts

• Note tightening order!

• oiled

• Renew CU sealing ring

© 11/2004

6/14

0312 1643 - 0138

4 Technical data

2011

Pre-

ID no. Name

03081 Connection housing on crankcase

03082 Connection housing on crankcase 180 Nm • M14 x 55mm

Connection housing on crankcase

Connection housing on crankcase

tightening

value

106 Nm

45 Nm

60 Nm

4.2 Tightening specifications

Re-tightening

value

• M12 x 20mm

• M12 x 30mm

• M12 x 35mm

• M12 x 55mm

• M12 x 70mm

• M12 x 75mm

• M12 x 95mm

• M10 x 40mm

• M10 x 30mm

• M10 x 25mm

•hex

• M10 x 40mm

• Cylinder head bolts

Remark

4

Connection housing on crankcase

22 Nm

03085 Cap on connection housing 9 Nm

Cover plate on connection
housing

9 Nm

04000 Engine control

ID no. Name

04001 Camshaft toothed belt wheel on

camshaft

04002 Start-up disc on camshaft 21 Nm

04052 Clamping roller on front cover

tightening

value

30 Nm + 210° Central screw

21 Nm

Pre-

Re-tightening

value

• M8 x 10mm

• M8 x 30mm

• M8 x 50mm

Remark

• Note tightening order!

• Note assembly specification!

04053 Protective hood (toothed belt) on

front cover

© 11/2004

7 Nm

7/14

0312 1643 - 0138

4 Technical data

4

4.2 Tightening specifications

2011

05000 Speed governing

Pre-

ID no. Name

05004 Lock nut on setting screw 9.2 Nm Full load stop

05005 Lock nut on setting screw 6 ± 0.6 Nm Minimum speed

05006 Lock nut on setting screw 16 ± 1.6 Nm Screw spring pre-tension

05007 Lock nut on setting screw

05008 Lock nut on setting screw

05011 Speed governor on connection

housing

05021 Regulator lever shaft on front

cover

tightening

value

4.5 Nm Shutoff stop

6 ± 0.6 Nm Adapter capsule

8.5 Nm

9.2 Nm

Re-tightening

value

Remark

05022 No load capsule on front cover 4.6 ± 0.4 Nm

05023 Adapter capsule on front cover 10 ± 1 Nm Lock nut

05024 Eccenter shaft on front cover 10 ± 1 Nm

05025 Cap (speed adjustment lever) on

front cover

4.5 Nm
Valve crankshaft housing bleeding
on front cover

05041 Lifting magnet (shutoff magnet) on

front cover

05065 Lifting magnet (start volume

release) on front cover

8.5 Nm

10 Nm

06000 Exhaust system / Charging

ID no. Name

Pre-

tightening

value

Re-tightening

value

Remark

06001 Exhaust manifold on cylinder head 55 Nm with DEUTZ S1

06020 Turbocharger on exhaust manifold 21 Nm with DEUTZ S1

06024 Reducer on turbocharger 4 ± 1 Nm Hose clip

© 11/2004

8/14

0312 1643 - 0138

4 Technical data

2011

ID no. Name

06030 Air intake pipe on cylinder head 21 Nm

Charge air on cylinder head 21 Nm

06094 Solenoid valve on LDA 10 Nm

07000 Fuel system

ID no. Name

07001 Injection valve on cylinder head 21 Nm

07002 Injection nozzles lock nut on

nozzle holder (leak oil-less)

tightening

value

tightening

value

35 ± 5 Nm Motorpal

Pre-

Pre-

4.2 Tightening specifications

Re-tightening

value

Re-tightening

value

Remark

Remark

4

Injection nozzles lock nut on
nozzle holder

07003 Injection line on:

• Injection valve

• injection pump

07012 Injection pump on (Bosch/

Motorpal) crankcase

07015 Fuel supply line to injection pump

07024 Fuel pump on crankcase

07061 Overcurrent line to injection pump

07062 Overcurrent line to cylinder head

bolt

07071 Locking screw on injection pump

(Motorpal)

45 ± 5 Nm Bosch

25 ± 2.5 Nm Union nut

21 Nm

29 Nm

21 Nm

29 Nm

8.5 Nm

45 ± 5 Nm Renew CU sealing rings

• Hollow screw

• DIN 7643-8

• Piston pump

• Diaphragm pump

• Renew CU sealing rings

• Hollow screw

07082 Fuel filter console on crankcase 21 Nm

07087 Fuel filter console on holder

27 Nm

© 11/2004

9/14

• Hexagon bolt M8 x 50mm
and hexagon nut M8

0312 1643 - 0138

4 Technical data

4

4.2 Tightening specifications

Pre-

ID no. Name

07095 Charge pressure-dependent full

load stop (LDA) on crankcase

07096 Cap on charge pressure-

dependent full load stop (LDA)

07099 Fuel filter on fuel filter console 9 ± 1 Nm hand tight

tightening

value

22 Nm

8 Nm

08000 Lube oil system

Pre-

ID no. Name

08001 Oil filter

tightening

value

10 -12 Nm

Re-tightening

value

Re-tightening

value

• Oil gasket lightly

• Screw on by hand and screw
tight

2011

Remark

Remark

08003 Oil filter console on crankcase 21 Nm Torx screw

08010 Lube oil pump on crankcase 22 Nm

08015 Oil suction intake pipe on

crankcase

08035 Pipe support oil dipstick guide

pipe on oil pump

08042 Oil pressure line on:

• Turbocharger

• Crankcase

08044 Oil return pipe on turbocharger 40 Nm Screwed socket

Oil return pipe on turbocharger 8.5 Nm Flange socket

08046 Holder for stopper on crankcase 8.5 Nm FL/M engine

Oil return pipe (ATL) holding plate
on crankcase

21 Nm

30 Nm

29 Nm

8.5 Nm BFL/M engines

• Note gasket coating

• Sealant DEUTZ DW 73

• Renew CU sealing rings

• Hollow screw

• Before assembling the line
ATL via pressure oil
connection bore, pre-oil with
approx. 1 cm³ engine oil!

08047 Oil return pipe (ATL) on crankcase 29 Nm Hollow screw

08048 Oil line to (control line):

• oil filter console

• Crankcase

© 11/2004

18 Nm

10/14

• Injection adjustment

• Renew CU sealing rings

• Hollow screw

0312 1643 - 0138

4 Technical data

2011

Pre-

ID no. Name

08051 Oil cooler fastening screws 21 Nm Torx screw M8

08053 Locking screw thermostat for

injection adjuster on oil filter
console

08054 Oil cooler connection on

crankcase

08061 Transfer nipple on crankcase

(heater connection)

08062 Locking screws M18 x 1.5 mm at

transfer nipple (heater connection)

08072 Locking screw oil cooler

thermostat on crankcase

tightening

value

90 Nm Injection adjustment

13 Nm

111 ± 11 Nm

50 Nm Renew CU sealing rings

50 Nm Hexagon socket

4.2 Tightening specifications

Re-tightening

value

• M6 x 60mm

• Hexagon head screw

• Renew sealing rings

• Note installation position

Remark

4

08091 Oil pressure switch (locking

screw) on crankcase

08093 Oil pressure sensor on crankcase 20 +2 Nm

08094 Locking screw (oil pressure

sensor) on crankcase 50 Nm

08095 Oil temperature sensor on

crankcase

08096 Locking screw (oil temperature

sensor) on crankcase

08098 Locking screw (oil pressure

regulating valve) on crankcase

08099 Locking screw on crankcase

(without air press lubrication)

13 ± 1.5 Nm

25 ± 2.5 Nm

28 Nm

111 Nm

18 ± 2 Nm
60 ± 6 Nm
80 ± 8 Nm

Oil pressure switch M10 x
1mm

• Oil pressure switch / oil
pressure sensor

• M18 x 1.5mm

• Renew CU sealing rings

• Oil temperature sensor

• Renew CU sealing rings

• Oil pressure regulating valve

• M10 x 1mm

• M18 x 1.5mm

• M22 x 1.5mm

© 11/2004

11/14

0312 1643 - 0138

4 Technical data

4

4.2 Tightening specifications

2011

09000 Cooling system

Pre-

ID no. Name

09041 Fan on fan drive 22 Nm M8 x 22mm / bolts 8.8

09042 Fan on flange hub, crankshaft 30 Nm M8 x 40mm

09065 Cooling blower jacket on

generator

09066 Blower jacket on cylinder head 22 Nm

Cooling blower on:

• air duct

• Cylinder head

tightening

value

30 Nm M8 x 20mm / bolts 10.9

4 Nm

21 Nm

Re-tightening

value

Remark

09067 Blower jacket inlet on generator 22 Nm

09070 Stand plate on:

• crankcase

• Oil cooler

09087 Air duct cowling on:

• Cylinder head

• Stand plate

09089 Air duct on cooling blower 3 Nm 21 Nm

09098 Air duct on cylinder head

21 Nm Torx screw 8 x 20mm

21 Nm

3 Nm

+21 Nm

12000 Other components

ID no. Name

12001 Flywheel on crankcase

Pre-

tightening

value

30 Nm

Re-tightening

+ 60°
+ 30°

value

Remark

Renew screws after every
disassembly

12030 Flange hub on toothed belt wheel,

crankshaft

12031 V-belt pulley on toothed belt

wheel, crankshaft

12041 V-belt tensioning roller (holder) on

front cover

© 11/2004

43 Nm M10 x 40mm

42 ± 4 Nm

45 Nm

12/14

0312 1643 - 0138

4 Technical data

2011

Pre-

ID no. Name

12043 V-belt tensioning roller on holder

12046 V-belt pulley on fan mounting 22 Nm Torx M8 x 16mm

12047 V-belt guard on front cover 21 Nm

12051 Hydraulic pump on hydraulic

pump console

12052 Toothed belt tensioning roller on

hydraulic pump console

12056 Protective hood on hydraulic

pump console

12057 Hydraulic pump console on

crankcase

tightening

value

21 Nm

57 Nm Hexagon bolts

8 +2 Nm + 21 ±2 Nm Hydraulic pump drive

8.5 Nm

57 Nm

4.2 Tightening specifications

Re-tightening

value

• M8 x 20mm

• M8 x 30mm

Remark

4

13000 Electrical components

Pre-

ID no. Name

13001 Starter on crankcase 43,5 Nm

13006 Starter console on crankcase 75 ± 7 Nm without connection housing

13009 Heat shield for starter 8.5 Nm Bolts M6

13010 Generator console on:

crankcase
Cylinder head

Generator console on crankcase

13012 Generator on console

tightening

value

34 Nm

30 Nm 49°

34 Nm

34 Nm

Re-tightening

value

Remark

• with built up fan drive

• Unit design

• with built up fan drive

• Unit design

• with built up fan drive

• Unit design

• with built up fan drive

• Building machine design

13015 Generator on clamping bracket

© 11/2004

22 Nm

21 Nm

13/14

• with built up fan drive

• Unit design

• with built up fan drive

• Building machine design

0312 1643 - 0138

4 Technical data

4

4.2 Tightening specifications

ID no. Name

13016 Clamping bracket on console

Generator

13017 V-belt clamping bracket on front

cover

13018 Generator console on cylinder

head

13021 Pulley on generator 50 Nm

Running wheel on generator 50 Nm

13022 Fan drive on generator console

tightening

value

22 Nm

21 Nm

45 Nm

34 Nm with in-built fan drive

30 Nm 120°

Pre-

Re-tightening

value

2011

Remark

• with built up fan drive

• Unit design

• with built up fan drive

• Building machine design

• M10 x 110mm

• with built up fan drive

• Unit design

13031 Helical heater plug in:

charge air line
Suction pipe

13071 Charging current cable on starter max. 15 Nm

13081 Charging current cable on

generator B+

13082 Cable G1.D+ on generator 4.5 ± 0.8 Nm

13083 Cable G1.W on generator 4 Nm

13092 Cable harness holder on

crankcase

Cable harness holder on:
Starter
crankcase

60 Nm

5.5 -7 Nm

14 Nm Torx screw M8 x 16mm

8.5 Nm M6

© 11/2004

14/14

0312 1643 - 0138

2011

5 Job card overview

5.1 Sorted alphabetically

5

© 11/2004 0312 1644 - 0138

1/6

5 Job card overview

5

5.1 Sorted alphabetically

Notes

2011

© 11/2004

2/6

0312 1644 - 0138

5 Job card overview

2011

Activity Job card Maintenance group

Assemble and disassemble engine on assembly stand W 00-05-01 Engine general

Check and repair injection valve W 07-07-02 Fuel system

Check and set valve clearance W 01-01-01 Cylinder head

Check camshaft W 04-05-06 Engine control

Check compression W 00-02-06 Engine general

Check con rod W 02-03-01 Drive system

Check con rod (crack con rod) W 02-03-01 Drive system

Check crankcase W 02-01-07 Drive system

Check cylinder W 03-03-01 Crankcase

5.1 Sorted alphabetically

5

Check engine control times W 04-04-11 Engine control

Check piston W 02-09-07 Drive system

Check piston rings and piston ring grooves W 02-10-03 Drive system

Check start of pumping W 07-06-04 Fuel system

Check valve guide W 01-06-03 Cylinder head

Check valve lag W 01-07-08 Cylinder head

Check valves W 01-05-04 Cylinder head

Check V-belt, renew (in FL and BFL engines) W 12-02-01 Other components

Check V-belt, renew (in FM and BFM engines) W 12-02-01 Other components

Checking and setting injection valves (leak fuel-less) W 07-07-05 Fuel system

Determine the thickness of the shim gasket W 07-06-03 Fuel system

Disassemble and complete, check toggle lever and toggle
lever block

W 01-02-06 Cylinder head

Dismantle and complete cooling blower, check W 09-11-02 Cooling system

Dismantle and complete fan drive W 09-13-01 Cooling system

Dismantle and complete front cover (speed governor with
torque adaption)

© 11/2004

3/6

W 03-08-03 Crankcase

0312 1644 - 0138

5 Job card overview

5

5.1 Sorted alphabetically

Activity Job card Maintenance group

Dismantle and complete front cover (speed governor
without torque adaption)

Machine valve seat ring I 01-07-07 Cylinder head

Remove and install air intake pipe W 06-07-03

Remove and install cable harness W 13-01-02

Remove and install camshaft W 04-05-05 Engine control

Remove and install camshaft bearing, check W 03-11-01 crankcase

Remove and install charge pressure-depedent full load stop
(LDA)

Remove and install connection housing W 03-09-04 crankcase

W 03-08-03 Crankcase

W 07-08-02 Fuel system

2011

Exhaust system / Charging

Electrical system

Remove and install cooling blower W 09-11-01 Cooling system

Remove and install crankcase W 02-04-01 Drive system

Remove and install crankcase bleeding W 03-01-11 crankcase

Remove and install cylinder head W 01-04-04 Cylinder head

Remove and install exhaust manifold W 06-01-05 Exhaust system / Charging

Remove and install flywheel W 12-06-01 Other components

Remove and install front cover (opposite side to flywheel) W 03-08-01 Crankcase

Remove and install fuel filter console W 07-10-08 Fuel system

Remove and install fuel lines (with Bosch injection pumps) W 07-10-06 Fuel system

Remove and install fuel lines (with leak fuel line) W 07-10-06 Fuel system

Remove and install fuel pump W 07-11-01 Fuel system

Remove and install generator (in FL and BFL engines) W 13-02-03

Electrical system

Remove and install generator and holder
(in FM and BFM engines)

Remove and install control linkage and guide bushes W 07-02-06 Fuel system

Remove and install helical heater plugs W 13-06-01

Remove and install hydraulic pump W 12-08-02 Other components

© 11/2004

4/6

W 13-02-03

Electrical system

Electrical system

0312 1644 - 0138

5 Job card overview

2011

Activity Job card Maintenance group

Remove and install injection pumps (Bosch) W 07-04-01 Fuel system

Remove and install injection pumps (Motorpal) W 07-04-01 Fuel system

Remove and install injection valves W 07-07-01 Fuel system

Remove and install lifting magnet (shutoff magnet) W 11-00-03 Monitoring system

Remove and install lifting magnet for start volume release W 07-02-07 Fuel system

Remove and install lube oil pump W 08-04-05 Lube oil system

Remove and install lube oil tray W 08-04-07 Lube oil system

Remove and install oil cooler W 08-08-02 Lube oil system

Remove and install oil filter cartridge W 08-10-06 Lube oil system

5.1 Sorted alphabetically

5

Remove and install oil filter console W 08-11-07 Lube oil system

Remove and install oil intake pipe W 08-04-06 Lube oil system

Remove and install oil pressure sensor W 08-11-09 Lube oil system

Remove and install oil pressure line (turbocharger) W 08-15-01 Lube oil system

Remove and install oil pressure regulating valve, check W 08-11-02 Lube oil system

Remove and install oil pressure switch W 08-11-08 Lube oil system

Remove and install oil line for injection adjuster supply W 08-16-01 Lube oil system

Remove and install oil return line (turbocharger) W 08-15-02 Lube oil system

Remove and install oil temperature sensor W 08-11-11 Lube oil system

Remove and install oil temperature sensor (in engines with
injection adjustment)

Remove and install oil thermostat (oil cooler) W 08-11-12 Lube oil system

W 08-16-02 Lube oil system

Remove and install piston bolt bush W 02-03-03 Drive system

Remove and install piston cooling nozzles W 02-15-01 Drive system

Remove and install pistons and con rod W 02-09-03 Drive system

Remove and install pistons and con rod (crack con rod) W 02-09-03 Drive system

Remove and install rear cover (flywheel side) W 03-09-01 Crankcase

© 11/2004

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0312 1644 - 0138

5 Job card overview

5

5.1 Sorted alphabetically

Activity Job card Maintenance group

Remove and install solenoid valve (LDA) W 07-08-01 Fuel system

Remove and install speed governor W 05-07-01 Speed governing

Remove and install starter W 13-03-02

Remove and install toggle lever and toggle lever block W 01-02-02 Cylinder head

Remove and install toothed belt and clamping roller of the
hydraulic pump

Remove and install turbocharger W 06-06-04 Exhaust system / Charging

Remove and install V-belt clamping roller W 12-02-06 Other components

Remove and install valves W 01-05-01 Cylinder head

Renew camshaft sealing ring (opposite side to flywheel) W 04-03-01 Engine control

W 12-08-03 Other components

2011

Electrical system

Renew crankshaft sealing ring (opposite side to flywheel) W 02-02-04 Drive system

Renew crankshaft sealing ring (flywheel side) W 02-02-02 Drive system

Renew injection lines W 07-03-01 Fuel system

Renew toothed belt and clamping roller (new version of
clamping roller)

Renew toothed belt and clamping roller (old version of
clamping roller)

Renew toothed starter flywheel ring W 12-06-03 Other components

W 04-04-12 Engine control

W 04-04-12 Engine control

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2011

5 Job card overview

5.2 Sorted numerically

5

© 11/2004 0312 1645 - 0138

1/6

5 Job card overview

5

5.2 Sorted numerically

Notes

2011

© 11/2004

2/6

0312 1645 - 0138

5 Job card overview

2011

Job card Activity Maintenance group

W 00-02-06 Check compression Engine general

W 00-05-01 Assemble and disassemble engine on engine block Engine general

W 01-01-01 Check and set valve clearance Cylinder head

W 01-02-02 Remove and install toggle lever and toggle lever block Cylinder head

W 01-02-06

W 01-04-04 Remove and install cylinder head Cylinder head

W 01-05-01 Remove and install valves Cylinder head

W 01-05-04 Check valves Cylinder head

W 01-06-03 Check valve guide Cylinder head

Disassemble and complete, check toggle lever and toggle
lever block

5.2 Sorted numerically

Cylinder head

5

I 01-07-07 Machine valve seat ring Cylinder head

W 01-07-08 Check valve lag Cylinder head

W 02-01-07 Check crankcase Drive system

W 02-02-02 Renew crankshaft sealing ring (flywheel side) Drive system

W 02-02-04 Renew crankshaft sealing ring (opposite side to flywheel) Drive system

W 02-03-01 Check con rod Drive system

W 02-03-01 Check con rod (crack con rod) Drive system

W 02-03-03 Remove and install piston bolt bush Drive system

W 02-04-01 Remove and install crankcase Drive system

W 02-09-03 Remove and install pistons and con rod Drive system

W 02-09-03 Remove and install pistons and con rod (crack con rod) Drive system

W 02-09-07 Check piston Drive system

W 02-10-03 Check piston rings and piston ring grooves Drive system

W 02-15-01 Remove and install piston cooling nozzles Drive system

W 03-01-11 Remove and install crankcase bleeding Crankcase

W 03-03-01 Check cylinder Crankcase

© 11/2004

3/6

0312 1645 - 0138

5 Job card overview

5

5.2 Sorted numerically

Job card Activity Maintenance group

W 03-08-01 Remove and install front cover (opposite side to flywheel) Crankcase

W 03-08-03

W 03-08-03

W 03-09-01 Remove and install rear cover (flywheel side) Crankcase

W 03-09-04 Remove and install connection housing Crankcase

W 03-11-01 Remove and install camshaft bearing, check Crankcase

W 04-03-01 Renew camshaft sealing ring (opposite side to flywheel) Engine control

W 04-04-11 Check engine control times Engine control

Dismantle and complete front cover (speed governor with
torque adaption)

Dismantle and complete front cover (speed governor
without torque adaption)

2011

Crankcase

Crankcase

W 04-04-12

W 04-04-12

W 04-05-05 Remove and install camshaft Engine control

W 04-05-06 Check camshaft Engine control

W 05-07-01 Remove and install speed governor Speed governing

W 06-01-05 Remove and install exhaust manifold Exhaust system / Charging

W 06-06-04 Remove and install turbocharger Exhaust system / Charging

W 06-07-03 Remove and install air intake pipe Exhaust system / Charging

W 07-02-06 Remove and install control linkage and guide bushes Fuel system

W 07-02-07 Remove and install lifting magnet for start volume release Fuel system

W 07-03-01 Renew injection lines Fuel system

Renew toothed belt and clamping roller (old version of
clamping roller)

Renew toothed belt and clamping roller (new version of
clamping roller)

Engine control

Engine control

W 07-04-01 Remove and install injection pumps (Bosch) Fuel system

W 07-04-01 Remove and install injection pumps (Motorpal) Fuel system

W 07-06-03 Determine the thickness of the shim gasket Fuel system

W 07-06-04 Check start of pumping Fuel system

© 11/2004

4/6

0312 1645 - 0138

5 Job card overview

2011

Job card Activity Maintenance group

W 07-07-01 Remove and install injection valves Fuel system

W 07-07-02 Check and repair injection valve Fuel system

W 07-07-05 Checking and setting injection valves (leak fuel-less) Fuel system

W 07-08-01 Remove and install solenoid valve (LDA) Fuel system

W 07-08-02

W 07-10-06 Remove and install fuel lines (with Bosch injection pumps) Fuel system

W 07-10-06 Remove and install fuel lines (with leak fuel line) Fuel system

W 07-10-08 Remove and install fuel filter console Fuel system

W 07-11-01 Remove and install fuel pump Fuel system

Remove and install charge pressure-depedent full load stop
(LDA)

5.2 Sorted numerically

Fuel system

5

W 08-04-05 Remove and install lube oil pump Lube oil system

W 08-04-06 Remove and install oil intake pipe Lube oil system

W 08-04-07 Remove and install lube oil tray Lube oil system

W 08-08-02 Remove and install oil cooler Lube oil system

W 08-10-06 Remove and install oil filter cartridge Lube oil system

W 08-11-02 Remove and install oil pressure regulating valve, check Lube oil system

W 08-11-07 Remove and install oil filter console Lube oil system

W 08-11-08 Remove and install oil pressure switch Lube oil system

W 08-11-09 Remove and install oil pressure sensor Lube oil system

W 08-11-11 Remove and install oil temperature sensor Lube oil system

W 08-11-12 Remove and install oil thermostat (oil cooler) Lube oil system

W 08-15-01 Remove and install oil pressure line (turbocharger) Lube oil system

W 08-15-02 Remove and install oil return line (turbocharger) Lube oil system

W 08-16-01 Remove and install oil line for injection adjuster supply Lube oil system

W 08-16-02

© 11/2004

Remove and install oil temperature sensor (in engines with
injection adjustment)

5/6

Lube oil system

0312 1645 - 0138

5 Job card overview

5

5.2 Sorted numerically

Job card Activity Maintenance group

W 09-11-01 Remove and install cooling blower Cooling system

W 09-11-02 Dismantle and complete cooling blower, check Cooling system

W 09-13-01 Dismantle and complete fan drive Cooling system

W 11-00-03 Remove and install lifting magnet (shutoff magnet) Monitoring system

W 12-02-01 Check V-belt, renew (in FL and BFL engines) Other components

W 12-02-01 Check V-belt, renew (in FM and BFM engines) Other components

W 12-02-06 Remove and install V-belt clamping roller Other components

W 12-06-01 Remove and install flywheel Other components

W 12-06-03 Renew toothed starter flywheel ring Other components

2011

W 12-08-02 Remove and install hydraulic pump Other components

W 12-08-03

W 13-01-02 Remove and install cable harness

W 13-02-03 Remove and install generator (in FL and BFL engines)

W 13-02-03

W 13-03-02 Remove and install starter

W 13-06-01 Remove and install helical heater plugs

Remove and install toothed belt and clamping roller of the
hydraulic pump

Remove and install generator and holder (in FM and BFM
engines)

Other components

Electrical system

Electrical system

Electrical system

Electrical system

Electrical system

© 11/2004

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2011

5 Job card overview

5.3 Job card references

5

© 11/2004 0312 1646 - 0138

1/10

5 Job card overview

5

5.3 Job card references

Explanation of job card reference:

Owing to the job card structure, individual parts of the work processes may overlap or repeat.
Illustrations of the same working environment may also deviate slightly.

2011

© 11/2004

2/10

0312 1646 - 0138

5 Job card overview

2011

5.3 Job card references

00 Engine general

Job card Activity Other job cards necessary for performing the activity

W 00-02-06 Check compression W 01-01-01 W 07-07-01 W 08-08-02

Assemble and

W 00-05-01

disassemble engine on
engine block

W 13-03-02

01 Cylinder head

Job card Activity Other job cards necessary for performing the activity

W 01-01-01

W 01-02-02

Check and set valve
clearance

Remove and install toggle
lever and toggle lever
block

W 01-01-01

5

Disassemble and

W 01-02-06

W 01-04-04

W 01-05-01 Remove and install valves W 01-04-04

W 01-05-04 Check valves W 01-05-01

W 01-06-03 Check valve guide W 01-05-01

I 01-07-07 Machine valve seat ring W 01-05-01 W 01-07-08

W 01-07-08 Check valve lag W 01-04-04

complete, check toggle
lever and toggle lever
block

Remove and install
cylinder head

W 01-02-02

W 01-02-02 W 06-07-03 W 07-07-01 W 09-11-01 W 13-02-03

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3/10

0312 1646 - 0138

5 Job card overview

5

5.3 Job card references

2011

02 Drive system

Job card Activity Other job cards necessary for performing the activity

W 02-01-07 Check crankcase W 02-04-01

W 02-02-02

W 02-02-04

W 02-03-01 Check con rod W 02-03-03

W 02-03-01

W 02-03-03

Renew crankshaft sealing
ring (flywheel side)

Renew crankshaft sealing
ring (opposite side to
flywheel)

Check con rod (crack con
rod)

Remove and install piston
bolt bush

W 12-06-01

W 03-08-01

W 02-03-03

W 02-09-03

W 04-04-12 W 04-04-12

(old version) (new version)

W 02-04-01

W 02-09-03

W 02-09-03

W 02-09-07 Check piston W 02-09-03

W 02-10-03

W 02-15-01

Remove and install
crankcase

Remove and install pistons
and con rod

Remove and install pistons
and con rod (crack con
rod)

Check piston rings and
piston ring grooves

Remove and install piston
cooling nozzles

W 02-01-07 W 02-09-03 W 03-08-01 W 03-09-01

W 01-04-04 W 02-10-03 W 08-04-06

W 01-04-04 W 02-10-03 W 08-04-06

W 02-09-03

W 02-04-01

© 11/2004

4/10

0312 1646 - 0138

5 Job card overview

2011

5.3 Job card references

03 Crankcase

Job card Activity Other job cards necessary for performing the activity

W 03-01-11

W 03-03-01 Check cylinder W 01-04-04

W 03-08-01

W 03-08-03

W 03-08-03

Remove and install
crankcase bleeding

Remove and install front
cover (opposite side to
flywheel)

Dismantle and complete
front cover (speed
governor with torque
adaption)

Dismantle and complete
front cover (speed
governor without torque
adaption)

W 04-03-01

W 03-08-01

W 03-08-01

W 04-04-12

(new

version)

W 04-04-12

(old version)

W 08-04-05 W 08-08-02

5

W 03-09-01

W 03-09-04

W 03-11-01

Remove and install rear
cover (flywheel side)

Remove and install
connection housing

Remove and install
camshaft bearing, check

W 03-09-04 W 08-04-07

W 00-05-01 W 12-06-01

W 01-02-02 W 02-04-01

W 07-04-01

(Motorpal)

W 07-04-01

(Bosch)

W 07-11-01

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5/10

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5 Job card overview

5

5.3 Job card references

2011

04 Engine control

Job card Activity Other job cards necessary for performing the activity

W 04-03-01

W 04-04-11

W 04-04-12

W 04-04-12

W 04-05-05

Renew camshaft sealing
ring (opposite side to
flywheel)

Check engine control
times

Renew toothed belt and
clamping roller (old version
of clamping roller)

Renew toothed belt and
clamping roller (new
version of clamping roller)

Remove and install
camshaft

W 04-04-12

(old version)

W 04-04-12

(old version)

W 12-02-01

(FL, BFL
engines)

W 12-02-01

(FL, BFL
engines)

W 01-02-02 W 03-09-01

W 07-04-01

(Bosch)

W 04-04-12

(new

version)

W 04-04-12

(new

version)

W 12-02-01

(FM, BFM

engines)

W 12-02-01

(FM, BFM

engines)

W 07-11-01

W 12-08-03

W 12-08-03

W 04-04-12

(old version)

W 04-04-12

(new

version)

W 07-04-01

(Motorpal)

W 04-05-06 Check camshaft W 04-05-05

05 Speed governing

W 05-07-01

Remove and install speed
governor

06 Exhaust system / Charging

W 06-01-05

W 06-06-04

Remove and install
exhaust manifold

Remove and install
turbocharger

W 06-06-04

W 06-07-03

© 11/2004

Remove and install air
intake pipe

W 06-01-05

6/10

0312 1646 - 0138

5 Job card overview

2011

5.3 Job card references

07 Fuel system

Job card Activity Other job cards necessary for performing the activity

W 07-02-06

W 07-02-07

W 07-03-01 Renew injection lines W 08-08-02

W 07-04-01

W 07-04-01

Remove and install control
linkage and guide bushes

Remove and install lifting
magnet for start volume
release

Remove and install
injection pumps (Bosch)

Remove and install
injection pumps (Motorpal)

W 03-08-01 W 03-09-04

W 08-11-12 W 09-11-01 W 13-02-03

W 07-03-01 W 07-06-04 W 07-10-06

W 07-03-01 W 07-06-03 W 07-06-04 W 07-10-06

W 07-04-01

(Motorpal)

W 07-04-01

(Bosch)

W 07-08-02

5

W 07-06-03

W 07-06-04 Check start of pumping W 07-03-01

W 07-07-01

W 07-07-02

W 07-07-05

W 07-08-01

W 07-08-02

Determine the thickness of
the shim gasket

Remove and install
injection valves

Check and repair injection
valve

Checking and setting
injection valves (leak fuel­less)

Remove and install
solenoid valve (LDA)

Remove and install charge
pressure-depedent full
load stop (LDA)

W 07-04-01

W 07-03-01

W 07-07-05 W 07-07-01

W 07-07-01

W 07-10-06

(Bosch)

W 07-10-06

(Motorpal)

W 11-00-03

W 07-10-06

W 07-10-06

W 07-10-08

0312 1646 - 0138

Remove and install fuel
lines (with Bosch injection
pumps)

Remove and install fuel
lines (with leak fuel line)

Remove and install fuel
filter console

W 08-08-02

7/10

0312 1646 - 0138

5 Job card overview

5

5.3 Job card references

Job card Activity Other job cards necessary for performing the activity

W 07-11-01

Remove and install fuel
pump

2011

08 Lube oil system

Job card Activity Other job cards necessary for performing the activity

W 04-04-12

(new

version)

W 08-04-05

W 08-04-06

W 08-04-07

Remove and install lube oil
pump

Remove and install oil
intake pipe

Remove and install lube oil
tray

W 04-04-12

(old version)

W 08-04-07

W 08-08-02

W 08-10-06

W 08-11-02

W 08-11-07

W 08-11-08

W 08-11-09

W 08-11-11

W 08-11-12

Remove and install oil
cooler

Remove and install oil filter
cartridge

Remove and install oil
pressure regulating valve,
check

Remove and install oil filter
console

Remove and install oil
pressure switch

Remove and install oil
pressure sensor

Remove and install oil
temperature sensor

Remove and install oil
thermostat (oil cooler)

W 08-10-06

W 08-08-02

W 08-15-01

W 08-15-02

© 11/2004

Remove and install oil
pressure line
(turbocharger)

Remove and install oil
return line (turbocharger)

8/10

0312 1646 - 0138

5 Job card overview

2011

Job card Activity Other job cards necessary for performing the activity

Remove and install oil line

W 08-16-01

W 08-16-02

for injection adjuster
supply

Remove and install oil
temperature sensor (in
engines with injection
adjustment)

5.3 Job card references

09 Cooling system

Job card Activity Other job cards necessary for performing the activity

W 12-02-01

(FL, BFL
engines)

W 09-11-01

Remove and install cooling
blower

5

W 09-11-02

W 09-13-01

Dismantle and complete
cooling blower, check

Dismantle and complete
fan drive

W 09-11-01

11 Monitoring system

Job card Activity Other job cards necessary for performing the activity

W 13-02-03

(FM, BFM

engines)

W 11-00-03

Remove and install lifting
magnet (shutoff magnet)

W 12-02-06

12 Other components

Job card Activity Other job cards necessary for performing the activity

W 12-02-01

W 12-02-01

W 12-02-06

0312 1646 - 0138

Check V-belt, renew (in FL
and BFL engines)

Check V-belt, renew (in
FM and BFM engines)

Remove and install V-belt
clamping roller

W 12-02-01

(FL, BFL
engines)

9/10

W 12-02-01

(FM, BFM

engines)

0312 1646 - 0138

5 Job card overview

5

5.3 Job card references

Job card Activity Other job cards necessary for performing the activity

W 12-06-01

W 12-06-03

W 12-08-02

W 12-08-03

Remove and install
flywheel

Renew toothed starter
flywheel ring

Remove and install
hydraulic pump

Remove and install
toothed belt and clamping
roller of the hydraulic
pump

W 12-06-01

W 12-02-01

(FL, BFL
engines)

W 12-02-01

(FM, BFM

engines)

2011

13 Electrical components

Job card Activity Other job cards necessary for performing the activity

W 13-01-02

W 13-02-03

W 13-02-03

W 13-03-02 Remove and install starter

W 13-06-01

Remove and install cable
harness

Remove and install
generator (in FL and BFL
engines)

Remove and install
generator and holder (in
FM and BFM engines)

Remove and install helical
heater plugs

W 12-02-01

W 12-02-01

© 11/2004

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2011

6 Job cards

6

© 11/2004 0312 1647 - 0138

1/2

6

6 Job cards

2011

Notes

© 11/2004

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0312 1647 - 0138

Engine general

2011

W 00-02-06 Check compression

Tools

- Commercial tools

8005 - Compression tester
8189 - Torx tool kit

- Special tools

100 120 - Connecting piece

Check compression

z Check and set valve clearance

Î Job card W 01-01-01.

W 00-02-06

References

- W 01-01-01

- W 07-07-01

- W 08-08-02

6

z Remove injection valves

Î Job card W 07-07-01.

In FL, BFL engines

z Install oil cooler

Î Job card W 08-08-02.

z Insert adapter (1) with sealing ring.

Note

Use sealing ring from injection valve.

© 39104 0

1

© 39105 0

© 11/2004 0312 1553 - 0138

1/4

Engine general

6

W 00-02-06

z Fit clamping claw (1) and tighten screws (2)

.

Note

Note installation position.

07001

z If necessary, mount adapter (1) on connection piece.

2011

1

2

© 39106 0

z Connect compression tester to connection piece or

adapter.

z Turn over engine with starter.

00 51

1

© 39107 0

© 39102 0

© 11/2004

2/4

0312 1553 - 0138

Engine general

2011

z The measured compression pressure depends on

the starting speed during the measuring process and
the altitude of the engine installation site.
Limit values can therefore not be determined exactly.
The compression measurement is only
recommended as a reference measurement of all
cylinders of an engine to each other. If more than
15% deviation has been determined, the cause
should be determined by disassembling the cylinder
unit concerned.

z Remove the compression tester and adapter.

No.

Kompression in bar
Compression value in bar
Pression en bar

10

15 20 25 30 35 40

Dat. _________

Zyl.

1
2
3
4
5
6
7
8

Best. Nr. 5 1341 250 00

DBGM Made in Germany

OTOMETER

M

7250 Leonberg

W 00-02-06

© 33771 1

6

z Unscrew screw (1).

z Remove connection piece with sealing ring.

In FL, BFL engines

z Remove oil cooler

Î Job card W 08-08-02.

z Install injection valves

Î Job card W 07-07-01.

© 11/2004

3/4

© 39102 0

1

© 39103 0

0312 1553 - 0138

Engine general

6

W 00-02-06

Notes

2011

© 11/2004

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Engine general

2011

W 00-05-01 Mount engine on assembly stand and disassemble

Tools

- Commercial tools

- Special tools

6067 - Engine assembly block
6067/115 - Clamping holder
6067/114 - Support arm

Auxiliary material

- Lifting gear

- Support ropes

- Eyebolts

Assemble engine on engine block

z Remove starter

Î Job card W 13-03-02.

z Screw in eyebolt (1).

References

- W 13-03-02

Note

In the repair procedure shown here
different customer scopes are not taken
into consideration, i.e. add-on parts
deviating from standard are not shown.

1

W 00-05-01

6

1

z Hang engine on suitable workshop crane.

z Unscrew screws (1) and remove engine bearing (2)

of the Manifold side.

00 81

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Engine general

6

W 00-05-01

In FL, FM engines

z Unscrew screw (1) and remove holder.

z Pull out stopper (2).

In BFL, BFM engines

z Unscrew screw (1) and remove holder.

2011

2

1

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z Remove oil return pipe (arrow).

z Mount clamping holder (1) on the Manifold side and

tighten screws (2).

00001

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Engine general

2011

z Mount clamping holder on engine assembly block.

z Fit counter plate (1).

z Insert screws and nuts (2).

00002

z Unhook engine from workshop crane and unscrew

eyebolt.

Remove engine from assembly block.

z Screw in eyebolt.

W 00-05-01

1

2

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6

z Hang engine on suitable workshop crane.

z Unscrew nuts (2), remove counter plate (1) and

bolts.

z Unscrew screws (2) and remove clamping

holder (1).

1

2

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Engine general

6

W 00-05-01

In FL, FM engines

z Pull new round sealing ring (arrow) onto stopper.

z Insert stopper (2).

2011

© 39505 0

Note

Oil round sealing ring lightly

z Mount holder and tighten screw (1).

08046

In BFL, BFM engines

z Pull new round sealing rings onto screwed

socket (arrow) and oil return pipe.

2

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Engine general

2011

z Insert oil return pipe (arrow).

z Mount holder and tighten screw (1).

08044

z Mount engine bearing (2) and tighten screws (1).

W 00-05-01

1

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6

00003

z Unhook engine from workshop crane and unscrew

eyebolt.

z Install starter

Î Job card W 13-03-02

1

2

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Notes

2011

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Cylinder head

2011

W 01-01-01 Check and set valve clearance

Tools

- Commercial tools

Feeler gauges

Note

The standard valve clearance setting is
possible:

- On cold or warm engine after a cooling
time of at least 0.5 h.

- Oil temperature < 80 °C.

Removal

z Unscrew screws (arrows), remove starter cylinder

head cover (1) and gasket.

W 01-01-01

6

Set engine to valve overlap

z Turn crankshaft until reaching valve overlap on

cylinder no. 1.

01 63

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Cylinder head

6

W 01-01-01

Note

Valve overlap means:

- Outlet valve not yet closed.

- The inlet valve starts opening.

Check valve clearance

z Arrangement of inlet and outlet valves.

- IN = inlet valve

- EX = outlet valve

2011

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z Check valve clearance setting with feeler gauge

blade on the appropriate cylinder.

01 63 01 61

01 62

Note

The feeler gauge blade must go between the
toggle lever sliding surface and the valve with
little resistance.

EX EX EX EX

IN IN IN IN

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Cylinder head

2011

Setting valve clearance

z Loosen lock nut (1).

z Correct valve clearance by turning the setting

screw (2).

Note

- If valve clearance is too small, unscrew the
setting screw.

- If valve clearance is too great, screw in the
setting screw.

01 61 01 62

z Tighten lock nut (1).

W 01-01-01

2

1

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6

Note

Do not turn the setting screw (2) when
tightening the lock nut.

01003

z Check the valve clearance again with a feeler gauge

blade.

Assembly

z Clean the sealing surface on the cylinder head cover

and cylinder head.

z Fit gasket.

2

1

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Note

Note installation position, the gate (arrow)
must face the front cover.

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Cylinder head

6

W 01-01-01

z Mount cylinder head cover and tighten screws

alternately.

01004

2011

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Cylinder head

2011

W 01-02-02 Remove and install toggle lever and toggle lever block

Tools

- Commercial tools

Remove toggle lever and toggle lever block

z Unscrew screws (arrows).

Remove cylinder head cover (1) and gasket.

References

- W 01-01-01

W 01-02-02

6

z Unscrew screws (1) and remove toggle lever with

toggle lever block (2).

Note

- Loosen screws evenly to avoid jamming the
toggle lever blocks.

- Set down the components in the order of
installation.

1

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2

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Cylinder head

6

W 01-02-02

z Remove stop rods (1).

Note

Set down the components in the order of
installation.

z Check stop rods for visible signs of damage.

z Insert stop rods (1).

2011

1

1

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Note

- Note the assignment of the stop rods.

- The stop rod must be seated in the socket of
the ram with the ball head.

Install toggle lever and toggle lever block

z Loosen the lock nuts of the setting screws and turn

back the setting screws.

z Mount toggle lever block (1).

1

1

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Note

The ball heads must be seated in the sockets
of the stop rods (arrows).

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Cylinder head

2011

z Tighten (1) screws alternately.

Note

- Make sure that the stop rods are not under
stress due to valve overlap when tightening
the bolts.

- Align toggle lever to the stop rods/valves.

01002

z Check and set valve clearance

Î Job card W 01-01-01.

z Clean the sealing surface on the cylinder head cover

and cylinder head.

W 01-02-02

1

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6

z Fit gasket.

Note

Note installation position, the gate (arrow)
must face the front cover.

z Mount cylinder head cover and tighten screws

alternately.

01004

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Cylinder head

6

W 01-02-02

Notes

2011

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Cylinder head

2011

W 01-02-06 Disassemble and complete, check toggle lever and toggle lever

W 01-02-06

block

Tools

- Commercial tools

Internal measuring device
Micrometer gauge

Dismantle toggle lever block

z Remove toggle lever and toggle lever block

Î Job card W 01-02-02.

References

- W 01-02-02

1

6

z Remove locking rings (1).

z Remove toggle lever.

1

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