Deutz D2008 (2009) Workshop Manual Engine

Workshop Manual D 2008/2009

0312 3422

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

2

en

Workshop Manual D 2008/2009

Workshop Manual

D 2008/2009

0312 3422 en

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.

The engine company.

DEUTZ AG Service Information Systems

Ottostraße 1 51149 Köln

Deutschland Tel.: +49 (0) 221-822-0

Fax: +49 (0) 221-822-5850

Web: http://www.deutz.com

D 2008/2009

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

4 Technical data

4.1 Testing and setting data

4.2 Tightening specifications

Table of contents

5 Job card overview

5.1 Sorted numerically

6Job cards

7Commercial tools

8 Special tools

1/2

Table of contents

D 2008/2009

2/2

DEUTZ engines

1 Foreword

Foreword

1

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Foreword

DEUTZ engines

1

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DEUTZ engines

Foreword

z Read and observe the information in this docu-

mentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine.

z This engine is built exclusively for purpose ac-

cording 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 bears the sole risk.

z Use for the intended purpose also includes ob-

servance 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 this and are aware of the risks involved.

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 may lead

to malfunctions and engine damage as well as injury to persons for which the manufacturer will not accept any liability.

z Prerequisite for proper maintenance and repair is

the availability of all the necessary equipment, conventional and special tools and their perfect condition.

z Engine parts such as springs, clamps, elastic re-

taining rings etc. pose an increased risk of injury when handled incorrectly.

z The pertinent rules for the prevention of acci-

dents and other generally recognised health and safety regulations must be observed.

z Maximum economy, reliability and long life is only

guaranteed when using DEUTZ original parts.

z Repair of the engine must correspond to its use

for the intended purpose. Only parts released by the manufacturer for the respective purpose may be used for conversion work. Unauthorised modifications to the engine exclude manufacturer liability for resulting damages. Failure to observe this will void 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 installa-

tion case, i.e. not all the parts and components described in this documentation are installed in your engine necessarily.

z We have done our best to highlight the differenc-

es 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

1

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Foreword

DEUTZ engines

1

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DEUTZ engines

2 General

General

2

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General

DEUTZ engines

2

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DEUTZ engines

DEUTZ engines are the product of years of re-

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

Maintenance and care are the only way the engine can satisfy the demands you make on it. Compliance 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 particularly 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.

General

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General

DEUTZ engines

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3 User notes

User notes

3

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User notes

3

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User notes

3.1 General

The documentation of the workshop manual has been created based on the engine available at the time of going to press. There may be deviations in the descriptions, illustrations and parts due to further developments.

The maintenance work described in the operation manual and in the workshop manual must be carried out on schedule and completely. The maintenance personnel must have the necessary technical knowledge to perform the work. Safety and protection devices which are removed during maintenance work must be replaced again afterwards.

Caution!

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

Reference is made in the workshop manual job cards to the regulations in chapter 3.2. These must be read before working on the engine and must be strictly followed.

The maintenance intervals and the work to be performed are specified in the maintenance schedule of the operation manual. The job cards contain technical documentation on the execution of maintenance work.

3.2 Specifications

3.2.1 Accident prevention and safety regulations

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

Special protection measures are specified depending on the work being carried out, and are identified in the job description.

Among other things it generally applies that:

z for the personnel:

– Only briefed personnel may operate or main-

tain the engine. Unauthorised persons are prohibited access to the machine room.

– Wear close-fitting clothing and ear protectors

in the machine room when the engine is in operation.

– Only deploy trained personnel to do repairs

and maintenance work.

– Do not work on the fuel system when the en-

gine is running. The fuel system is under high pressure - danger of death.

– Go to the workshop immediately in case of

leaks in the fuel system.

z for the engine room:

– Ensure adequate ventilation (do not cover air

shafts).

– Provide first aid kit and suitable fire extinguish-

ers. Check the filling and readiness for operation regularly.

– Only store inflammable materials in the ma-

chine room if they are essential for operation of the system.

– Smoking and naked flames are prohibited in

the machine room.

z for operation, maintenance and repairs on the

engine:

– After all work on the fuel system, it must be

bleeded - see the operation manual, chapter "6.2 Fuel system“.

– Only start the engine when all the protective

devices have been fitted. Make sure no-one is standing in the danger area.

– Cleaning, maintenance and repair work may

only be performed with the engine at a standstill and secured against starting.

– Injection lines and high pressure pipes must

not be deformed.

– Damaged injection lines and high-pressure

pipes must be renewed.

3

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User notes

– Injection lines and high pressure fuel lines

must never be connected when the engine is running.

– Do not place hands near to a leak in the high

pressure fuel system.

– Also carefully check all high pressure compo-

3

nents visually before performing tests on the running engine. Wear suitable protective clothing (for example protective glasses). Leaks are a potential source of danger for workshop personnel.

– Even if no leaks are discernible on the high

pressure fuel system, the workshop personnel should avoid the immediate danger zone or wear suitable protective clothing (such as protective glasses) when performing tests on the running engine and during the first trial run.

– Always stay out of range of a fuel jet, as it

could cause severe injury.

– Smoking is strictly prohibited when working on

the fuel system.

– Do not work near to sparks and flames.

3.2.2 Disposal regulations

The work described in the operation manual and workshop manual necessitates renewal of parts and operating materials among other things. The renewed parts / operating materials must be stored, transported and disposed of according to regulations. The owner himself is responsible for this.

Disposal includes recycling and the scrapping of parts / operating materials, although 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 Operation manual and workshop

manual

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

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

It contains the following chapters:

1. Contents, General

2. Engine description

3. Operation

4. Operating media

5. Maintenance

6. Care and maintenance work

7. Faults, causes and remedies

8. Engine conservation

9. Technical data

10.Service

The workshop manual assumes knowledge of the contents of the operation manual. This applies especially for the safety regulations. The workshop manual describes repairs to the engine and components for which more effort and appropriately qualified technicians are required.

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User notes

3.4 Job cards

The job cards are divided in the workshop manual into "W" and "I" job cards. The "W" job card documents standard repairs on the engine and/or its components. The necessary tools and special tools are also specified in the "W" job card. The "I" job card additionally documents the appropriate work procedures for repairing the engine and/ or its components. The workshop must satisfy special conditions to perform these work procedures. Special tools and machine tools must be available, for example.

3.4.1 Numbering of job cards

The job card numbers follow the pattern W 02-04-

01. The individual parts of this pattern are explained

below:

z W 02-04-01: Documentation type

– WWorkshop manual

– I...... Repair instructions

z W 02-04-01: Maintenance group

– 00... General / interdisciplinary activities

– 01... Cylinder head

– 02... Drive system

– 03... Crankcase

– 04... Engine control system

– 05... Speed governing

– 06... Exhaust system / Charging

– 07... Fuel system

– 08 ... Lube oil system

– 09... Cooling system

– 10... Compressed air system

– 11... Monitoring system

– 12... Other components

– 13... Electrical system

z W 02-04-01: Component grouping

z W 02-04-01: Consecutive number

3.4.2 Structure of a job card

1 2 3

16

15

14

13

12

11

1. DEUTZ AG,

publisher of service documentation

2. Engine type (e.g. TCD 2013 4V)

3. Maintenance group

4. Job card number or topic

5. Title of job card

6. Reference to other job cards

7. Chapter

8. Graphic or photo

9. DEUTZ internal creation number

10.Page number

11.Date of issue of job card

12.Note

13.Danger / Important

14.Work sequence

15.Special tools; auxiliary materials

16.Conventional tools

10

Triebwerk

W 02-04-01

9

4

3

575

6

8

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User notes

3.5 Explanation of symbols

Danger!

of death or to health. Must be observed! For example: The incorrect use or conversion of the turbocharger can lead to serious injury.

3

Caution!

Danger to the component/engine. Noncompliance 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 or job cards for the work process. For example: Job card W 04-05-05

Reference

to a document or a job card within the work process.

Test and setting data

The necessary values are specified here. If several values are necessary, a cross reference is given to the Test and Setting Values table. For example: ID no. P01 61 = valve clearance, inlet

Tightening specification

The necessary values are specified here. If several values are necessary, a cross reference is given to the Tightening Specifications table. For example: ID no. A01 001 = cylinder head screws

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D 2008/2009

4 Technical data

4.1 Testing and setting data

Technical data

4

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Technical data Testing and setting data

D 2008/2009

4

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D 2008/2009

Technical data

Testing and setting data

3

-

L3 538 mm

L4 627 mm

 1

 0

naturally aspirated

engine with indirect

injection

L3 155 kg

L4 189 kg

L3 1170 cm

L4 1560 cm

L3 1-2-3 -

L4 1-3-4-2 -

4

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P00 30 Total volume D 2008

P00 31 Bore D 2008 76 mm

P00 32 Stroke D 2008 86 mm

P00 40 Compression ratio D 2008 23,5 : 1 -

P00 50 Direction of rotation looking onto the flywheel D 2008 left -

P00 60 Max. declared speed D 2008 3000 [rpm]

P00 61 Min. idling speed D 2008 900 [rpm]

P00 71 Ignition sequence D 2008

Power train

P02 34 Permissible axial backlash of crankshaft D 2008 0,13 - 0,56 mm

P02 71 Piston, diameter, standard D 2008 74 mm

ID no. Name Information Series Value Unit

General engine data

P00 01 Length of engine D 2008

P00 02 Width of engine D 2008 480 mm

P00 03 Height of engine D 2008 620 mm

P00 04 Engine weight according to DIN 70020-A approx. D 2008

P00 10 Working procedure D 2008 four-stroke diesel -

P00 20 Combustion system D 2008

Technical data Testing and setting data

°

D 2008/2009

4

 0,008

 0,003

120

(offset to each other)

D 2008 L3 110 °

D 2008 L3 not available °

D 2008 L4 110 °

D 2008 L4 110,5 °

D 2008 L4 not available °

Part number: 0411 4267,

at 1,500 rpm (fixed speed)

Part number: 0411 4267,

at 1,800 rpm (fixed speed)

Part number: 0411 4267,

at 3,000 rpm (variable speed)

Part number: 0411 4276,

at 1500 rpm (fixed speed)

Part number: 0411 4276,

at 1,800 rpm (fixed speed)

Part number: 0411 4276,

at 300 rpm (variable speed)

P02 75 Piston projection D 2008 0,65 - 0,9 mm

P02 78 Piston pin bore D 2008 25 mm

P02 79 Piston height D 2008 66,15 mm

P02 95 Position of the piston ring joints D 2008

Control system

P04 35 Camshaft, axial backlash Nominal D 2008 0,07 - 0,29 mm

Fuel system

ID no. Name Information Series Value Unit

P07 31 Start of pumping (static)

Cooling system

P07 52 Nozzle opening pressure fuel injector D 2008 150 - 158 bar

P09 11 Coolant thermostat start of opening D 2008 86 - 90 °C

P09 13 Coolant thermostat, stroke distance D 2008 at least 8 mm

Other components

P12 11 Tension of the V-belt First assembly D 2008 450 N

4/14

Technical data

D 2008/2009

20

20

Testing and setting data

4

D 2008 300 N

Check after 15 minutes running under

load

P12 21 Tension of the V-belt

ID no. Name Information Series Value Unit

5/14

Technical data Testing and setting data

3

D 2008/2009

3

4

L3 180 kg

L3 597 mm

L4 680 mm

L4 205 kg

D 2009 L3 490 mm

TD 2009 L4 518 mm

D 2009 L3 612 mm

D 2009 L4 612 mm

TD 2009 L4 633 mm

D 2009 L3 1718 cm

D/TD 2009 L4 2289 cm

D 2009 19,6 : 1 -

TD 2009 18 : 1 -

D 2009 L3 1-2-3 -

D/TD 2009 L4 1-3-4-2 -

P00 10 Working procedure D/TD 2009 four-stroke diesel -

P00 20 Combustion system D/TD 2009 Direct injection -

P00 01 Length of engine TD 2009 L4 696 mm

ID no. Name Information Series Value Unit

General engine data

P00 01 Length of engine D 2009

P00 02 Width of engine

P00 03 Height of engine

P00 04 Engine weight according to DIN 70020-A approx. D 2009

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P00 30 Total volume

P00 31 Bore D/TD 2009 90 mm

P00 32 Stroke D/TD 2009 90 mm

P00 40 Compression ratio

P00 50 Direction of rotation looking onto the flywheel D/TD 2009 left -

P00 71 Ignition sequence

P00 60 Max. declared speed D/TD 2009 3000 [rpm]

D 2008/2009

Technical data

Testing and setting data

°

0,5

0,5

0,008

0,030

120 (offset to each

other)

4

D 2009 L3 90 °

D 2009 L3 89 °

D 2009 L4 105 °

D 2009 L4 100 °

D 2009 L4 102,5 °

ID no. Name Information Series Value Unit

P00 61 Min. idling speed D/TD 2009 900 [rpm]

Power train

P02 34 Permissible axial backlash of crankshaft D/TD 2009 0,13 - 0,56 mm

P02 71 Piston, diameter, standard D/TD 2009 88 mm

P02 75 Piston projection D/TD 2009 0,70 - 1,0 mm

P02 78 Piston pin bore D/TD 2009 28 mm

P02 79 Piston height D/TD 2009 71,65 mm

P02 95 Position of the piston ring joints D/TD 2009

Control system

P04 35 Camshaft, axial backlash Nominal D/TD 2009 0,07 - 0,29 mm

Fuel system

Part number: 0411 2478,

at 1500 rpm (fixed speed)

Part number: 0411 2476,

at 1,800 rpm (fixed speed)

Part number: 0411 4099,

at 3,000 rpm (variable speed)

P07 31 Start of pumping (static)

Part number: 0411 4088,

at 1,500 rpm (fixed speed)

Part number: 0411 4085,

at 1,800 rpm (fixed speed)

Part number: 0411 4421,

at 3000 rpm (fixed speed)

P07 31 Start of pumping (static)

Part number: 0411 2192,

at 3,000 rpm (variable speed)

P07 31 Start of pumping (static)

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Technical data Testing and setting data

20

4

20

D 2008/2009

TD 2009 L4 103,5 °

Part number: 0411 4102,

TD 2009 L4 not available °

at 1500 rpm (fixed speed)

Part number: 0411 4104,

TD 2009 L4 102,5 °

at 1,800 rpm (fixed speed)

Part number: 0411 4074,

at 3,000 rpm (variable speed)

D/TD 2009 300 N

Check after 15 minutes running under

load

P07 31 Start of pumping (static)

ID no. Name Information Series Value Unit

P07 31 Start of pumping (static)

Cooling system

P07 52 Nozzle opening pressure fuel injector D/TD 2009 250 - 258 bar

P09 11 Coolant thermostat start of opening D/TD 2009 86 - 90 °C

P09 13 Coolant thermostat stroke distance D/TD 2009 at least 8 mm

Other components

P12 11 Tension of the V-belt First assembly D/TD 2009 450 N

P12 21 Tension of the V-belt

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D 2008/2009

4.2 Tightening specifications

Technical data

Tightening specifications

4

9/14

Technical data Tightening specifications

D 2008/2009

4

10/14

Post-clam-

ping value

Pre-clam-

ping value

41 Nm

D/TD 2008/

2009

D 2008/2009

35 Nm

60°

35 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

41 Nm

D/TD 2008/

2009

D/TD 2008/

15 Nm 27 Nm

2009

41 Nm

D/TD 2008/

2009

21 Nm

D/TD 2008/

2009

Technical data

Tightening specifications

35 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

32 Nm

D/TD 2008/

2009

39 Nm

D/TD 2008/

2009

81 Nm

D/TD 2008/

2009

4

ID no. Name Screw type Notes / Remarks Series

A00 003 Engine mounting on crankcase M10 x 1.5

A01 001 Cylinder head on crankcase M12 x 1.75 Use new screws

A01 002 Rocker arm bracket on cylinder head M8 x 1.25

A01 004 Cylinder head cover on cylinder head M8 x 1.25

A01 092 Lifting log on cylinder head M8 x 1.25

A02 010 Main bearing housing on crankcase M8 x 1.25

11/14

A02 012 Main bearing housing on crankcase M10 x 1.5 Locking screw

A02 013 Main bearing housing (assembly) M8 x 1.25 Hexagon socket

A02 020 Big end bearing cap on connecting rod M8 x 1.0

A03 020 Gear case cover on crankcase M8 x 1.25

A03 030 Lubricating oil pan on crankcase M8 x 1.25

A03 031 Drain plug on lubricating oil pan M14 x 1.5

A03 080 Connection housing to crankcase M14 x 1.5

Technical data Tightening specifications

Post-clam-

ping value

D 2008/2009

4

Pre-clam-

81 Nm

ping value

D/TD 2008/

2009

D/TD 2008/

10 Nm 81 Nm

2009

21 Nm

D/TD 2008/

2009

81 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

28 Nm

D/TD 2008/

2009

9 Nm

D/TD 2008/

2009

10 Nm

D/TD 2008/

2009

15 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

21 Nm

D/TD 2008/

2009

21 Nm

D/TD 2008/

2009

ID no. Name Screw type Notes / Remarks Series

A04 001 Cam shaft toothed gear on camshaft M12 x 1.75

A04 004 Fuel injector toothed gear on fuel injector pump M14 x 1.5

A04 005 Thrust washer camshaft on crankcase M8 x 1.25 Torx screw

A04 011 Idler gear on crankcase M12 x 1.75

A06 001 Exhaust manifold on cylinder head M8 x 1.25

A06 030 Intake manifold on cylinder head

A07 001 Clamping shoe fuel injector on cylinder head M8 x 1.25

12/14

A07 003 Union nuts for high pressure pipes M12 x 1.5

A07 006 Pipe clamp for high pressure pipes M6 x 1.0

A07 013 Blocking screw on fuel injector pump

A07 019 Fule line on fuel supply pump

A07 024 Fuel supply pump on crankcase M8 x 1.25

A07 031 Fuel injector pump on crankcase M8 x 1.25

A07 084 Fuel lines on fuel filter console M10 x 1.5

Post-clam-

ping value

D 2008/2009

Technical data

Tightening specifications

Pre-clam-

41 Nm

ping value

D/TD 2008/

2009

41 Nm

D/TD 2008/

2009

4 Nm 9 Nm

D/TD 2008/

2009

41 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

27 Nm

D/TD 2008/

2009

96 Nm

D/TD 2008/

2009

300 Nm

D/TD 2008/

2009

9 Nm

D/TD 2008/

2009

41 Nm

D/TD 2008/

2009

22 Nm

D/TD 2008/

2009

21 Nm

D/TD 2008/

2009

21 Nm

D/TD 2008/

2009

4

ID no. Name Screw type Notes / Remarks Series

A07 087 Fuel filter console on crankcase M10 x 1.5

A08 003 Oil filter console on crankcase 3/4" Hollow screw

A08 010 Lubricating oil pump on crankcase M6 x 1.0

A08 016 Oil suction pipe holder on crankcase M10 x 1.5

A08 098 Oil pressure regulating valve on crankcase 3/8"

A09 005 Outlet nozzle on cylinder head M8 x 1.25

M8 x 1.25

Bracket (generator) on gearcase cover and brak-

ket

A09 010 Coolant pump on gearcase cover M8 x 1.25

A12 001 Flywheel on crankcase M12 x 1.5

A12 031 V-belt pulley on crankcase M20 x 1.5

A12 046 V-belt pulley and fan impeller on coolant pump M6 x 1.0

A13 001 Starter on connection housing M10 x 1.5

A13 012 Generator on gearcase cover M8 x 1.25

A13 013 Generator on bracket M8 x 1.25

A13 018

13/14

Technical data Tightening specifications

Post-clam-

ping value

D 2008/2009

4

Pre-clam-

15 Nm

ping value

D/TD 2008/

2009

2.5 Nm

D/TD 2008/

2009

9 Nm

D/TD 2008/

2009

ID no. Name Screw type Notes / Remarks Series

A13 032 Heating plug on cylinder head M10 x 1.0

A13 033 Connecting rail on heating plug M4 x 0.7

A13 071 Cable (cl. 30) on starter

14/14

D 2008/2009

5 Job card overview

5.1 Sorted numerically

Job card overview

5

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Job card overview Sorted numerically

D 2008/2009

5

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Job card overview

D 2008/2009

Job card Activity Maintenance group

W 01-02-02 Removing and installing the rocker arm Cylinder head

W 01-04-04 Removing and installing the cylinder head Cylinder head

W 01-04-09 Measuring the piston projection Cylinder head

W 01-05-01 Removing and installing the valves Cylinder head

W 02-01-04 Checking the axial clearance of the crankshaft Drive system

W 02.02.02 Renewing the crankshaft sealing ring (flywheel side) Drive system

Sorted numerically

W 02-02-04

W 02-04-01 Removing and installing the crankshaft Drive system

W 02-09-03 Removing and installing the piston and con rod Drive system

W 02-09-07 Checking the piston Drive system

W 03-09-04 Removing and installing the connection housing Crankcase

W 04-04-09 Removing and installing the gearcase cover Crankcase

W 04-05-05 Removing and installing the camshaft Engine control

W 06-01-05 Removing and installing the exhaust manifold Exhaust system / Charging

W 06-07-03 Removing and installing the air intake manifold Exhaust system / Charging

W 07-04-01 Removing and installing the fuel injector pump Fuel system

W 07-07-01 Removing and installing the fuel injectors Fuel system

W 07-10-08 Removing and and installing the fuel filter console Fuel system

W 07-11-01 Removing and installing the fuel supply pump Fuel system

W 08-04-05 Removing and installing the lubricating oil pump Lube oil system

W 08-04-06 Removing and installing the oil suction pipe Lube oil system

Renewing the crankshaft sealing ring (opposite side to flywheel)

Drive system

5

W 08-04-07 Removing and installing the lubricating oil pan Lube oil system

W 08-11-10

W 09-07-08 Removing and installing the coolant pump Cooling system

W 09-08-01 Checking the coolant thermostat when uninstalled Cooling system

W 09-08-02 Removing and installing the coolant thermostat Cooling system

W 12-02-02 Removing and installing the V-belt, V-belt pulley Other components

W 12-06-01 Removing and installing the flywheel Other components

W 13-02-03 Removing and installing the generator Electrical system

W 13-03-02 Removing and installing the starter Electrical system

W 13-06-01 Removing and installing the heating plugs Electrical system

Removing and installing the oil pressure regulating valve

3/4

Lube oil system

Job card overview

D 2008/2009

5

4/4

DEUTZ engines

6Job cards

Job cards

6

1/2

Job cards

DEUTZ engines

6

2/2

D 2008/2009

Removing and installing the rocker arm

Commercial available tools

Cylinder head

W 01-02-02

6

Removing the rocker arm

z Loosen hose clip (1).

z Unscrew screws (2).

z Remove cylinder head cover (3).

z Remove gasket (4).

z Unscrew screw (1).

z Remove rocker arm bearing (2).

z Remove rocker arm (3).

Lay out components in the order in which they should be installed.

2

3

4

1

2

1

z Visually inspect the components.

02/2006 5991-001

1/2

3

Cylinder head W 01-02-02

Installing the rocker arm

D 2008/2009

z Grease the rocker arm (arrow) lightly.

z Mount rocker arm (3) and rocker arm bearing (2).

Align rocker arm centred to the valve spring!

z Fasten screw (1).

1

2

3

6

z Press down rocker arm (1) and pushrod.

z Tighten screw (2).

 27 Nm

Oil rocker arm lightly!

2

1

z Clean sealing surfaces.

The sealing surfaces must be dry and free from grease and dirt.

z Mount new gasket (4).

z Mount cylinder head cover (3).

z Fit on the venting hose (1).

z Tighten screws (2).

 27 Nm

Tightening sequence: From the centre outwards.

z Tighten hose clip (1).

02/2006 5991-001

2/2

2

3

4

1

D 2008/2009

Removing and installing cylinder head

Commercial available tools – W 01-02-02

Cylinder head

W 01-04-04

– W 01-04-09 – W 06-01-05 – W 06-07-03

6

Removing the cylinder head

1. Valve

2. Rocker arm

3. Cylinder head bolts

4. Pushrods

5. Thermostat housing

6. Fuel injector

7. Coolant duct

z Remove rocker arm.

 W 01-02-02

z Remove exhaust manifold.

3

2

5

7

1

6

4

 W 06-01-05

z Remove intake manifold.

 W 06-07-03

1/6

Cylinder head W 01-04-04

z Remove push rods (1).

Lay out components in the order in which they should be installed.

z Visually inspect the components.

1

D 2008/2009

6

Representation: 3-cylinder engine

Loosen the screws in the specified order.

z Remove screws.

Representation: 4-cylinder engine

Loosen the screws in the specified order.

z Remove screws.

7 3 2 6

8 4 1 5

7 3 2 6 10

8 4 1 5 9

2/6

D 2008/2009

z Lift the cylinder head carefully from the crankcase.

z Remove gasket.

z Clean sealing surfaces.

Do not place cylinder head on sealing surface.

Cylinder head

W 01-04-04

6

Installing the cylinder head

z Measure piston projection.

 W 01-04-09

Note installation position of the hydro tappets.

Make sure the clamping bushings (1) are in place.

z Fit a new cylinder head gasket.

The sealing surfaces for the cylinder head gasket must be clean and free of oil.

Label OBEN / TOP facing the cylinder head.

1

3/6

Cylinder head W 01-04-04

z Fit cylinder head.

Pay attention to clamping bushings (1).

D 2008/2009

!

1

6

Representation: 3-cylinder engine

Attention!

Use new screws.

z Oil the cylinder head screws slightly.

z Tighten the screws according to the tightening se-

quence.

– Step 1:

 35 Nm

– Step 2:

 60°

– Step 3:

 60°

Representation: 4-cylinder engine

Attention!

Use new screws.

7 3 2 6

8 4 1 5

7 3 2 6 10

z Oil the cylinder head screws slightly.

z Tighten the screws according to the tightening se-

quence.

– Step 1:

 35 Nm

– Step 2:

 60°

– Step 3:

 60°

4/6

8 4 1 5 9

D 2008/2009

z Lightly oil pushrods.

z Insert pushrods in hydro-tappets (1).

Note installation position!

Cylinder head

W 01-04-04

1

6

z Mount intake manifold.

 W 06-07-03

z Install exhaust manifold.

 W 06-01-05

z Install rocker arm.

 W 01-02-02

5/6

Cylinder head W 01-04-04

D 2008/2009

6

6/6

D 2008/2009

Measuring the piston projection

Cylinder head

W 01-04-09

Commercial available tools: – Micrometer gauge

Special tools:

– Dial gauge. . . . . . . . . . . . . . . . . . 100400

– Measuring device . . . . . . . . . . . . 100750

z Remove cylinder head.

 W 01-04-04

z Clean sealing surfaces.

– W 01-04-04

6

z Turn the crankshaft until the respective piston is just

in front of the top dead centre (arrow).

1/4

Cylinder head W 01-04-09

z Insert dial gauge into measuring beam.

z Place shims (1) and measuring beam (2) on the seal-

ing surface of the crankcase.

z Apply the stylus to the piston base (arrow) under pre-

tension.

z Continue turning the crankshaft evenly until the re-

versal point of the pointer on the dial gauge is reached.

The piston is now at top dead centre (TDC).

D 2008/2009

1

2

6

z Move the measuring beam.

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

ing surface with pre-tension (arrow).

z Adjust dial gauge to "0".

Measuring points see diagram.

Measuring points (1) and (2).

1

2

2/4

D 2008/2009

z Align the measuring apparatus on the spacing wash-

ers in such a way that the stylus lies on the specified measuring points.

Measuring points see diagram.

Do not position the stylus on the piston marking.

z Note the largest measured value.

z Compare actual value with setpoint value.

 P02 75

Cylinder head

W 01-04-09

6

3/4

Cylinder head W 01-04-09

D 2008/2009

6

4/4

D 2008/2009

Removing and installing the valves

Cylinder head

W 01-05-01

Commercial available tools:

– Assembly pliers. . . . . . . . . . . . . . . . 8024

– Assembly lever . . . . . . . . . . . . . . . . 9017

Special tools:

– Assembly sleeves . . . . . . . . . . . . 121420

– Assembly tool . . . . . . . . . . . . . . . 121430

Removing the valves

1. Exhaust valve

2. Inlet valve

3. Valve spring

4. Rocker arm

5. Pushrod

– W 01-04-04 – W 07-07-01 – W 13-06-01

6

4

3

z Remove cylinder head (1).

 W 01-04-04

z Remove heating plugs (2).

 W 13-06-01

z Remove fuel injectors (3).

 W 07-07-01

2

1

5

2

3

1

1/4

Cylinder head W 01-05-01

z Attach assembly lever with screw (1) to cylinder

head.

z Press down valve spring with assembly lever.

z Remove both tapper collets (2).

z Remove valve spring plates, valve springs and

valves.

z Remove assembly lever.

D 2008/2009

2

6

z Pull off valve stem seal (1) with assembly pliers (2).

2

1

z Clean cylinder head, check and visually inspect for

damage.

z Visually inspect the components.

2/4

D 2008/2009

Installing the valves

z Oil the valve stem lightly.

z Insert and hold valve.

z Mount assembly sleeve.

z Push new valve stem seal onto valve guide over the

assembly sleeve with assembly tool (1).

Cylinder head

W 01-05-01

1

6

z Mount assembly lever.

z Insert valve spring.

z Insert valve spring plate (2).

z Press down the valve spring with the assembly lever

and insert both tapper collets (1).

z Remove assembly lever.

Make sure the tapper collets fit correctly in the valve keyway.

1

2

3/4

Cylinder head W 01-05-01

z Install cylinder head (1)

D 2008/2009

 W 01-04-04

2

z Install fuel injectors (3)

 W 07-07-01

z Install heating plugs (2)

 W 13-06-01

3

1

6

4/4

D 2008/2009

Checking the axial clearance of the crankshaft

Drive system

W 02-01-04

8190

Commercial available tools: – Magnetic measuring stand – Micrometer gauge

Special tools:

– Dial gauge. . . . . . . . . . . . . . . . . . 100400

Checking the axial backlash

z Mount magnetic measuring stand.

z Insert dial gauge.

z Apply stylus to the crankshaft end with pre-tension.

z Press crankshaft in direction of arrow.

z Adjust dial gauge to "0".

6

z Push crankshaft in the direction of the arrow and read

off the value on the meter.

 P02 34

z Compare actual value with setpoint value.

z Remove magnetic measuring stand.

z Remove dial gauge.

1

1/2

Drive system W 02-01-04

D 2008/2009

6

2/2

D 2008/2009

Renewing the crankshaft sealing ring (flywheel side)

Drive system

W 02-02-02

Commercial available tools:

– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198

– Assembly lever . . . . . . . . . . . . . . . . 9017

Special tools:

– Assembly tool . . . . . . . . . . . . . . . 142780

– Self-tapping screw – Washer

Removing the crankshaft sealing ring

z Remove flywheel.

 W 12-06-01

– W 12-06-01

6

z Make a hole of approximately 3 mm in the crankshaft

sealing ring with a pricker.

Attention!

Do not damage the main bearing housing and crankshaft.

1/2

Drive system W 02-02-02

z Turn in a self-tapping screw with washer.

z Pull out the crankshaft sealing ring with assembly le-

ver.

z Visually inspect all running surfaces.

D 2008/2009

6

Installing the crankshaft sealing ring

Use new crankshaft sealing ring.

The sealing lip faces the crankcase.

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

ly.

z Place the crankshaft sealing ring on the assembly

tool.

z Mount the assembly tool on the crankcase pin.

z Drive in crankshaft sealing ring to the stop with the

assembly tool.

1 mm installation depth between connection housing and crankshaft sealing ring.

z Remove assembly tool.

z Install flywheel.

 W 12-06-01

2/2

D 2008/2009

Renewing the crankshaft sealing ring (opposite side to flywheel)

Drive system

W 02-02-04

Commercial available tools:

– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198

– Assembly lever . . . . . . . . . . . . . . . . 9017

Special tools:

– Assembly tool . . . . . . . . . . . . . . . 142790

– Self-tapping screw – Washer

Removing the crankshaft sealing ring

z Remove V-belt pulley.

 W 12-02-02

z Make a hole of approximately 3 mm in the crankshaft

sealing ring with a pricker.

Attention!

Do not damage the gearcase cover and crankshaft.

– W 12-02-02

6

z Turn in a self-tapping screw with washer.

z Pull out the crankshaft sealing ring with assembly le-

ver.

z Visually inspect all running surfaces.

1/2

Drive system W 02-02-04

Installing the crankshaft sealing ring

Use new crankshaft sealing ring.

The sealing lip faces the crankcase.

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

ly.

z Place the crankshaft sealing ring on the assembly

tool.

z Mount the assembly tool on the crankcase pin.

z Drive in crankshaft sealing ring to the stop with the

assembly tool.

The installation depth is determined by the assembly tool.

D 2008/2009

6

z Remove assembly tool.

z Install V-belt pulley.

 W 12-02-02

2/2

D 2008/2009

Removing and installing the crankshaft

Drive system

W 02-04-01

Commercial available tools: – Assembly lever – 3-arm puller

Special tools:

– Dial gauge. . . . . . . . . . . . . . . . . . 100400

– Assembly tool . . . . . . . . . . . . . . . 143860

– Assembly tool . . . . . . . . . . . . . . . 143870

– Threaded rod . . . . . . . . . . . . . . . 143880

Removing crankshaft

1. Crankshaft

2. Connecting rod

3. Piston

4. Bearing housing

5. Main bearing housing

– W 02-01-04 – W 02.02.02 – W 02-09-03 – W 04-04-09 – W 08-11-10 – W08-04-06 – W 12-06-01

6

3

2

z Remove gear case cover.

 W 04-04-09

z Remove flywheel.

 W 12-06-01

z Remove piston and connection rod.

 W 02-09-03

1

4

5

1/10

Drive system W 02-04-01

z Unscrew screw (1).

z Pull out journal (2).

z Remove idler gear (3).

1

D 2008/2009

3

2

6

z Unscrew screw (1).

z Remove camshaft toothed wheel (2).

z Pull off camshaft toothed wheel with 3-arm puller.

2

1

2/10

D 2008/2009

z Unscrew screws (1).

z Lever out main bearing housing (2) with a suitable

tool in the recess clearances.

Make sure that the thrust washer halves do not fall into the crankcase.

z Visually inspect the components.

Drive system

W 02-04-01

z Unscrew screw (1).

z Remove oil suction pipe (2).

z Unscrew fixing screws (3).

z Remove oil pressure regulating valve (4).

 W 08-11-10

2

3

1

2

4

6

z Remove crankshaft.

z Visually inspect the components.

3/10

Drive system W 02-04-01

Removing the main bearing

z Insert thrust pad (1) in bearing bush.

z Insert threaded rod (2).

z Insert counter support (3).

z Mount washers and screw on nuts.

D 2008/2009

1

6

z Turn the nut (1) clockwise.

The bearing bush is pressed onto the crankcase by the thrust pad.

z Dismantle assembly tool.

z Remove bearing bush.

32

1

z Clamp main bearing housing in the vice.

Use cushioned jaws.

2

z Insert thrust pad (1) in bearing bush.

z Insert threaded rod (2).

z Insert counter support (3).

z Mount washers and screw on nuts.

z Turn nut (4) clockwise.

The bearing bush is pressed onto the main bearing housing by the thrust pad.

4/10

1

3

4

D 2008/2009

Installing the main bearing

z Oil bearing bush with engine oil.

z Press in bearing bush with assembly tool 143870.

Make sure the bearing bush is not twisted.

The installation depth is determined by the assembly tool.

Mark the position of the lubricating oil bore on the main bearing housing.

Drive system

W 02-04-01

6

z Oil bearing bush with engine oil.

z Mount bearing bush.

z Mount guide plate (1).

z Insert threaded rod (2).

z Insert counter support.

z Mount washers and screw on nuts.

Mark position of the lubricating oil bore.

Position bearing bush.

z Turn the nut (1) clockwise.

The bearing bush is pressed into the crankcase by the thrust pad.

The installation depth is determined by the assembly tool.

Make sure the bearing bush is not twisted.

1

2

1

5/10

Drive system W 02-04-01

z Dismantle assembly tool.

z Remove assembly tool.

z Check that the lubricating oil bore is in line.

If the lubricating oil bore is not in line, the bearing bush must be removed and reinstalled.

z Check installation depth of the bearing bush with

depth measuring appliance.

 ca. 3 mm

D 2008/2009

6

Installing the crankshaft

z Lightly oil bearing bush (1) with engine oil.

z Push crankshaft into crankcase.

Align screw thread (2) and through hole (3).

z Insert thrust washers (4) at the rear with grease.

Lubricating oil grooves face the crankshaft.

z Push in the crankshaft in the direction of the arrow to

the stop.

z Tighten locating screws (1).

z Install oil suction pipe.

1

4

3

2

 W 08-04-06

6/10

1

D 2008/2009

z Install main bearing housing (1).

z Tighten screws (2).

– Step 1:

 15 Nm

– Step 2:

 27 Nm

z Renewing the crankshaft sealing ring.

 W 02-02-02

Drive system

W 02-04-01

2

z Check axial backlash of crankshaft.

 W 02-01-04

z Heat up crankshaft toothed wheel to approx. 100 °C.

Danger!

Danger of burning!

z Mount crankshaft toothed wheel (1).

Note installation position of Woodruff key (2) and groove.

z Install oil pressure regulating valve.

 W 08-11-10

1

2

1

6

z Mount camshaft toothed wheel.

Mount camshaft toothed wheel with the bore on the clamping pin (1).

z Fasten screw (2).

1

2

7/10

Drive system W 02-04-01

The marks (1) of the crankshaft toothed wheel and the camshaft toothed wheel must be in line!

z Tighten screw (2).

D 2008/2009

 81 Nm

1

2

6

z Insert idler gear.

The marks (1) of the crankshaft toothed wheel, intermediate gear and fuel injector toothed wheel must be in line!

1

z Oil the journal lightly.

z Insert the journal carefully into the needle bearing.

z Tighten screw.

 81 Nm

8/10

D 2008/2009

z Install piston and connection rods.

 W 02-09-03

z Mount gearcase cover.

 W 04-04-09

z Install flywheel.

 W 12-06-01

Drive system

W 02-04-01

6

9/10

Drive system W 02-04-01

D 2008/2009

6

10/10

D 2008/2009

Removing and installing the piston and con rod

Drive system

W 02-09-03

Commercial available tools

Special tools:

– Universal piston ring pliers . . . . . 130300

– Piston ring compressor . . . . . . . . 130510

Removing the piston and con rod

1. Piston rings

2. Piston

3. Piston pin

4. Connection rod

5. Big end bearing cap

6. Coolant duct in the crankcase

– W 01-04-04 – W 02-09-07 – W 08-04-07 – W 08-04-06

6

1

2

3

6

4

z Remove cylinder head.

 W 01-04-04

z Remove lubricating oil pan.

 W 08-04-07

z Remove oil suction pipe.

 W 08-04-06

z Pull out oil dipstick.

5

1/6

Drive system W 02-09-03

Removing the big end bearing cap

z Position lifting bearing journal in LDC position.

z Unscrew screws (1).

z Remove big end bearing cap (2).

z Remove bearing shell (3).

Lay out components in the order in which they should be installed.

Note order of cylinders.

D 2008/2009

3

2

1

6

z Press out the piston and connection rod.

Lay out components in the order in which they should be installed.

Note order of cylinders.

z Remove con rod bearing shells (1).

z Visually inspect the components.

1

Removing the piston

z Remove locking ring with locking ring pliers.

z Press piston bolts out of piston and con rod.

z Remove connection rod.

z Visually inspect the components.

2/6

D 2008/2009

z Remove piston rings with universal piston ring pliers.

z Check piston.

 W 02-09-07

Drive system

W 02-09-03

6

Completing con rod and piston

z Insert new locking ring.

Ensure that the installation location is free from faults.

z Insert con rod.

The labelling on the piston base and the numbered label of the connection rod face the camshaft side.

z Oil the piston bolt lightly.

z Press the piston bolt through.

z Insert new locking ring.

Ensure that the installation location is free from faults.

Installing the piston and con rod

z Insert bearing shell in the con rod.

Note the assignment of the bearing shells. The anti-rotation lock (1) must lock in groove (2).

z Insert bearing shell in the respective big end bearing

cap.

Note the assignment of the bearing shells. The anti-rotation lock must lock in groove.

1

3/6

2

?

Drive system W 02-09-03

z Install piston rings with universal piston ring pliers.

z Arrange the piston ring joints with an offset of

about 120° to each other.

Do not turn the piston rings any further.

D 2008/2009

120°

6

0°

z Lightly oil cylinder running surface, piston, piston

rings and lifting bearing journal lightly.

z Clamp piston rings with piston ring compressor.

z Set lifting journal at bottom dead centre (BDC).

z Push piston and con rod completely into cylinder.

The piston ring compressor must lie flat on the crankcase.

z Press the con rod carefully against the lifting journal.

UT

Note installation position!

The numbered label faces the camshaft side.

xxx

1

Attention!

xxx

Do not jam the con rod with the crankshaft.

z Mount big end bearing cap.

Note the assignment of the big end bearing cap.

- The identification numbers (1) on the con

UT

rod and the big end bearing cap must be identical and opposite to each other when assembled.

z Tighten new screws.

 35 Nm

4/6

D 2008/2009

z Insert oil dipstick.

z Install oil suction pipe.

 W 08-04-06

z Install lubricating oil pan.

 W 08-04-07

z Install cylinder head.

 W 01-04-04

Drive system

W 02-09-03

6

5/6

Drive system W 02-09-03

D 2008/2009

6

6/6

D 2008/2009

Checking the piston

Drive system

W 02-09-07

Commercial available tools: – Micrometer gauge – Internal measuring device

Special tools:

– Dial gauge. . . . . . . . . . . . . . . . . . 100400

Checking the piston bolt bore

z Remove piston.

 W 02-09-03

– W 02-09-03

When the piston wear limit is reached the piston must be replaced.

6

z Prepare internal measuring device:

– Mount probe bolt for the appropriate measuring

range in the internal measuring device.

– Mount dial gauge with approx. 1 mm pre-tension in

the internal measuring device.

– Set micrometer gauge to 28 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".

1/4

Drive system W 02-09-07

Diagram for measuring the piston bolt bore at the points "a" and "b" in the levels "1" and "2".

D 2008/2009

6

z Insert internal measuring device in the piston bolt

bore.

z Balance the internal measuring device at the given

measuring points and read off the measured value at the reversal point of the pointer.

See schematic diagram for measuring points.

 P02 78

Checking the piston diameter

Diagram for measuring the piston diameter at the measuring points "1, 2 and 3", transverse to the piston bolt bore.

3

2

1

2/4

D 2008/2009

z Measure piston diameter with micrometer gauge.

See schematic diagram for measuring points.

 P02 71

z Complete con rod and piston.

 W 02-09-03

Drive system

W 02-09-07

6

3/4

Drive system W 02-09-07

D 2008/2009

6

4/4

D 2008/2009

Removing and installing the connection housing

Commercial available tools – W 13-03-02

– W 12-06-01

Crankcase

W 03-09-04

6

Removing the connection housing

z Remove starter (1).

 W 13-03-02

z Remove flywheel (2).

 W 12-06-01

z Remove screws.

z Remove connection housing.

z Visually inspect the component.

2

1

1/2

Crankcase W 03-09-04

Installing the connection housing

z Mount connection housing.

z Tighten screws.

 81 Nm

D 2008/2009

6

z Install flywheel (1).

 W 12-06-01

z Install starter (2).

 W 13-03-02

1

2

2/2

D 2008/2009

Removing and installing the gearcase cover

Engine control

W 04-04-09

Commercial available tools

Special tools:

– Assembly tool . . . . . . . . . . . . . . . 142790

Removing the gearcase

z Remove V-belt pulley.

 W 12-02-02

z Remove fan impeller.

z Remove generator.

– W 12-02-02 – W 09-07-08 – W 13-02-03 – W 08-11-10 – W 08-10-07

Collect leaking operating substances in suitable vessels and dispose of according to regulations. The engine oil and coolant should be added according to the operating manual.

6

 W 13-02-03

z Remove coolant pump.

 W 09-07-08

z Remove oil filter.

z Remove oil filter console.

1/4

Engine control W 04-04-09

z Remove screws.

z Remove gearcase cover.

Attention!

Do not damage the sealing surfaces.

z Clean sealing surfaces.

z Visually inspect sealing surfaces (arrows).

D 2008/2009

6

Installing the gearcase cover

z Knock out crankshaft sealing ring (1).

Attention!

Do not damage sealing surface when knocking out.

z Clean sealing surfaces.

z Fix the new gasket to the crankcase with a little

grease.

Note installation position!

Make sure the clamping bushings (1) are in place.

1

2/4

D 2008/2009

Engine control

W 04-04-09

z Mount gearcase cover.

Ensure that the installation location is free from faults.

z Tighten the screws according to the tightening se-

quence.

 27 Nm

z Mount oil filter console.

z Tighten screws.

 41 Nm

10 17 1 9 16 2 8 15

18

11

19

12

20

13 3 6 4

7

14

5

21

6

z Install oil filter.

z Install coolant pump.

 W 09-07-08

z Install generator.

 W 13-02-03

z Install crankshaft sealing ring (flywheel side).

 W 02-02-04

z Install fan impeller.

z Install V-belt pulley.

 W 12-02-02

3/4

Engine control W 04-04-09

D 2008/2009

6

4/4

D 2008/2009

Removing and installing the camshaft

Engine control

W 04-05-05

Commercial available tools

Special tools:

– Fixing pin . . . . . . . . . . . . . . . . . . 144180

– Dial gauge. . . . . . . . . . . . . . . . . . 100400

Removing the camshaft

z Remove cylinder head (1).

 W 01-04-04

z Remove gearcase cover (2).

 W 04-04-09

– W 01-04-04 – W 04-04-09 – W 07-11-01

6

1

z Remove fuel supply pump (3).

 W 07-11-01

z Set piston (1) at top dead centre.

z Fix flywheel with fixing pin (2).

2

3

1

2

1/6

Engine control W 04-05-05

z Pull out hydro-tappet (1).

Use magnetic rod.

D 2008/2009

1

6

z Unscrew screw (1).

z Remove camshaft toothed wheel (2).

z Remove screws.

z Remove thrust washer.

2

1

2/6

D 2008/2009

z Fasten screw (1).

z Pull out the camshaft carefully in the direction of the

arrow.

z Visually inspect the components.

Engine control

W 04-05-05

1

6

Installing the camshaft

z Oil camshaft bearing lightly.

z Insert camshaft carefully.

z Mount thrust washer.

z Tighten screws.

 21 Nm

3/6

Engine control W 04-05-05

Checking the axial backlash

z Mount magnetic measuring stand.

z Insert dial gauge.

z Apply stylus to the camshaft end with pre-tension.

z Press crankshaft in direction of arrow.

D 2008/2009

6

z Adjust dial gauge to "0".

z Press crankshaft in direction of arrow.

z Read actual value from dial gauge.

z Setpoint :

 0,07 - 0,29 mm

The axial backlash is not adjustable.

If the axial backlash is greater than the setpoint, the camshaft must be renewed.

z Remove magnetic measuring stand.

z Remove dial gauge.

z Mount camshaft toothed wheel.

Mount camshaft toothed wheel with the bore on the clamping pin (1).

z Fasten screw (2).

1

2

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D 2008/2009

The marks (1) of the crankshaft toothed wheel and the camshaft toothed wheel must be in line!

z Tighten screw (2).

Engine control

W 04-05-05

 81 Nm

z Oil the hydro-tappet lightly.

z Insert hydro-tappet.

Note installation position of the hydro tappets.

2

1

6

z Install the fuel supply pump (1).

 W 07-11-01

z Mount gearcase cover (2).

 W 04-04-09

z Install cylinder head (3).

 W 01-04-04

2

5/6

3

1

Engine control W 04-05-05

D 2008/2009

6

6/6

D 2008/2009

Removing and installing the exhaust manifold

Commercial available tools

– Fitting compound

DEUTZ S1

Exhaust system / Charging

W 06-01-05

6

Removing the exhaust manifold

z Unscrew screws (1).

z Remove exhaust manifold (2).

z Remove gasket (3).

z Visually inspect the components.

Installing the exhaust manifold

z Clean sealing surfaces.

3

2

1

1/2

Exhaust system / Charging W 06-01-05

z Coat the screws with fitting compound .

z Insert new seal (1).

z Mount exhaust manifold (2).

z Tighten screws (3).

 27 Nm

D 2008/2009

1

Tightening sequence: From the centre outwards.

2

3

6

2/2

D 2008/2009

Removing and installing the intake manifold

Exhaust system / Charging

W 06-07-03

Commercial available tools

– Fitting compound

DEUTZ S1

Removing the intake manifold

z Loosen pipe clip.

z Unscrew union nuts of the high pressure pipes.

z Remove all injection pipes.

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 national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating fluids in suitable vessels and dispose of according to regulations.

6

z Loosen hose clip (1).

z Unscrew screws (2).

z Remove intake manifold (3).

z Remove gasket (4).

z Unscrew fuel line (5).

1/2

1

4

5

3

2

Exhaust system / Charging W 06-07-03

z Clean sealing surfaces.

D 2008/2009

6

Install intake manifold

z Screw on fuel line (5).

z Coat the screws (2) with fitting compound.

z Mount gasket (4).

z Mount intake manifold (3).

z Tighten screws (2).

 27 Nm

Tightening sequence: From the centre outwards.

z Tighten pipe clip (1).

z Mount high pressure pipes.

z Screw on union nuts.

Attention!

Install injection pipes without tension.

1

5

4

3

2

z Tighten union nuts.

 28 Nm

z Position pipe clip.

z Tighten screw.

 9 Nm

2/2

D 2008/2009

Removing and installing the fuel injector pump

Fuel system

W 07-04-01

Commercial available tools

Special tools:

– Measuring pin . . . . . . . . . . . . . . . 110180

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 national specifications for handling fuels. Close all connections immediately after opening with new, clean plugs/caps. Do not remove plugs/caps until immediately before assembling. Collect leaking operating fluids in suitable vessels and dispose of according to regulations.

– W 04-04-09

6

Removing the fuel injector pump

z Remove gearcase cover.

 W 04-04-09

z Loosen pipe clip.

z Unscrew union nuts of the high pressure pipes.

z Remove all injection pipes.

1/4

Fuel system W 07-04-01

z Turn crankshaft.

The marks (1) of the crankshaft toothed wheel, intermediate gear and fuel injector toothed wheel must be in line!

D 2008/2009

1

6

z Push the measuring pin (1) through the marking

hole (arrow) into the crankcase.

The bore in the fuel injector toothed wheel must be in line with the bore in the crankcase.

z Loosen blocking screw (1).

z Push locking ring (2) towards larger opening.

The blocking screw can now be screwed in further.

1

2

z Tighten blocking screw (1).

The fuel injector shaft is blocked.

1

Attention!

Pay attention to perfect fit of the blocking screw and locking plate.

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D 2008/2009

z Unscrew nut (1).

z Remove washer (2).

z Remove measuring pin (3).

z Pull off fuel injector toothed wheel (4).

Use suitable puller if necessary.

Fuel system

W 07-04-01

3

z Disconnect cables.

z Unscrew screws (1).

z Remove fuel injector pump(2).

4

1

2

6

2

1

Installing the fuel injector pump

z Mount fuel injector pump (2).

z Tighten screws (1).

 21 Nm

Attention!

The blocking screw may not be loosened.

3/4

2

1

Deutz D2008 (2009) Workshop Manual Engine

Specifications and Main Features

Frequently Asked Questions

User Manual