Workshop Manual: Is No T

Workshop Manual
competence level 3
D 2009
TD 2009
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This document is subject to changes which may become necessary in the course of further de-
velopment of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.
Regarding copyright questions and licensing agreements
please contact :
TE-FI, Mr. Sonntag
Tel.: + 49 (0) 221 822-3053
EMail: sonntag.j@deutz.com
DEUTZ AG
Service Information Systems
Ottostraße 1
D-51149 Köln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
Internet: www.deutz.com
E-Mail: info@deutz.com
Printed in Germany
All rights reserved
1st Edition, 01/2008
The engine company. Order No. 0312 3488 en
D 2009
TD 2009 Table of contents
1 Foreword
2 General
3 User notes
3.1 General
3.2 Specifications
3.3 Operating manual and workshop manual
3.4 Job cards
3.5 Explanation of symbols
4 Technical data
4.1 Testing and setting data
4.2 Tightening specifications
5 Job card overview

5.1 Sorted alphabetically
5.2 Sorted numerically
6 Job cards
7 Commercial tools
8 Special tools
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D 2009
Table of contents TD 2009
© 01/2008 2/2 16338-001

DEUTZ engines Foreword
1 Foreword
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Foreword DEUTZ engines
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DEUTZ engines Foreword
z Read and observe the information in this docu- z Repair of the engine must correspond to its use
mentation. You will avoid accidents, retain the for the intended purpose. Only parts released by 1
manufacturer's warranty and possess a fully the manufacturer for the respective purpose may
functional and ready to operate engine. be used for conversion work. Unauthorised mod-
z This engine is built exclusively for purpose ac- ifications to the engine exclude manufacturer lia-
cording to the scope of delivery - defined by the bility for resulting damages. Failure to observe
equipment manufacturer (use for the intended this will void the warranty!
purpose). Any use above and beyond this is con- z The engines made by DEUTZ are developed for
sidered improper use. The manufacturer will not a wide range of applications. A wide range of var-
be liable for damages resulting from this. The iants ensures that the respective special require-
user bears the sole risk. ments are met.
z Use for the intended purpose also includes ob- z The engine is equipped according to the installa-
servance of the operating, maintenance and re- tion case, i.e. not all the parts and components
pair instructions specified by the manufacturer. described in this documentation are installed in
The engine may only be used, maintained and your engine necessarily.
repaired by persons who are familiar with this z We have done our best to highlight the differenc-
and are aware of the risks involved. es so that you can easily find the operating, main-
z Make sure that this documentation is available to tenance and repair instructions relevant to your
everyone involved in the operation, maintenance engine.
and repair and that they have understood the
contents.
z Failure to observe this documentation may lead
to malfunctions and engine damage as well as in-
jury to persons for which the manufacturer will
not accept any liability.
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
We are at your service for any questions you may
safety regulations must be observed.
have in this matter.
z Maximum economy, reliability and long life is only
guaranteed when using DEUTZ original parts.
Your DEUTZ AG
© 01/2008 3/4 16339-001

Foreword DEUTZ engines
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DEUTZ engines General
2 General
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General DEUTZ engines
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DEUTZ engines General
DEUTZ engines are the product of years of re-

search and development. The profound expertise
gained through this, in combination with high de-
mands on quality, attests to the fact that our engines
possess all the qualities of long life, high reliability 2
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. Compli-
ance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particular-
ly heeded.
Please consult one of our service representatives

responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.
© 01/2008 3/4 16340-001

General DEUTZ engines
© 01/2008 4/4 16340-001

DEUTZ engines User notes
3 User notes
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User notes DEUTZ engines
© 01/2008 2/6 16341-001

3.1 General 3.2 Specifications

The documentation of the workshop manual has 3.2.1 Accident prevention and safety regu-
been created based on the engine available at the lations
time of going to press.
The legally prescribed rules for the prevention of ac-
There may be deviations in the descriptions, illustra-
cidents must be observed. These are available from
tions and parts due to further developments.
professional associations or from dealers. These
The maintenance work described in the operation are dependent on the application site, operating 3
manual and in the workshop manual must be carried mode and the operating and auxiliary materials be-
out on schedule and completely. The maintenance ing used.
personnel must have the necessary technical
Special protection measures are specified depend-
knowledge to perform the work. Safety and protec-
ing on the work being carried out, and are identified
tion devices which are removed during maintenance
in the job description.
work must be replaced again afterwards.
Among other things it generally applies that:
Caution!
z for the personnel:
The rules for the prevention of accidents and the
safety regulations must be observed during mainte- – Only briefed personnel may operate or main-
nance work. tain the engine. Unauthorised persons are
prohibited access to the machine room.
Reference is made in the workshop manual job
cards to the regulations in chapter 3.2. These must – Wear close-fitting clothing and ear protectors
be read before working on the engine and must be in the machine room when the engine is in op-
strictly followed. eration.
The maintenance intervals and the work to be per- – Only deploy trained personnel to do repairs
formed are specified in the maintenance schedule and maintenance work.
of the operation manual. The job cards contain tech- – Do not work on the fuel system when the en-
nical documentation on the execution of mainte- gine is running. The fuel system is under high
nance work. 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 opera-
tion 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 stand-
still and secured against starting.
– Injection lines and high pressure pipes must
not be deformed.
– Damaged injection lines and high-pressure
pipes must be renewed.
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– Injection lines and high pressure fuel lines 3.3 Operation manual and workshop
must never be connected when the engine is manual
running.
To structure the information to suit the user, the
– Do not place hands near to a leak in the high
service documentation is divided into operation
pressure fuel system.
manual and workshop manual.
– Also carefully check all high pressure compo-
The operation manual contains a general descrip-
3 nents visually before performing tests on the
tion and instructions for all other maintenance work.
running engine. Wear suitable protective
clothing (for example protective glasses). It contains the following chapters:
Leaks are a potential source of danger for 1. Contents, General
workshop personnel. 2. Engine description
– Even if no leaks are discernible on the high 3. Operation
pressure fuel system, the workshop personnel
4. Operating media
should avoid the immediate danger zone or
wear suitable protective clothing (such as pro- 5. Maintenance
tective glasses) when performing tests on the 6. Care and maintenance work
running engine and during the first trial run. 7. Faults, causes and remedies
– Always stay out of range of a fuel jet, as it 8. Engine conservation
could cause severe injury.
9. Technical data
– Smoking is strictly prohibited when working on
10.Service
the fuel system.
The workshop manual assumes knowledge of the
– Do not work near to sparks and flames.
contents of the operation manual. This applies es-
3.2.2 Disposal regulations pecially for the safety regulations. The workshop
The work described in the operation manual and manual describes repairs to the engine and compo-
workshop manual necessitates renewal of parts and nents for which more effort and appropriately quali-
operating materials among other things. The re- fied technicians are required.
newed parts / operating materials must be stored,
transported and disposed of according to regula-
tions. 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 gov-
erned by regional, national and international laws
and directives which the system operator must ob-
serve on his own responsibility.
© 01/2008 4/6 16341-001

3.4 Job cards 3.4.2 Structure of a job card

The job cards are divided in the workshop manual
into "W" and "I" job cards. 1 2 3
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 Triebwerk
W 02-04-01 4
card.
5
3
The "I" job card additionally documents the appro-
16
priate work procedures for repairing the engine and/ 6
or its components. The workshop must satisfy spe-
cial conditions to perform these work procedures. 15
6 7
Special tools and machine tools must be available,
for example. 14
3.4.1 Numbering of job cards 8

13
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 12
8
– WWorkshop manual
– I ...... Repair instructions
z W 02-04-01: Maintenance group
– 00 ... General / interdisciplinary activities
11 10 9
– 01 ... Cylinder head
– 02Drive system 1. DEUTZ AG,
– 03 ... Crankcase publisher of service documentation
– 04 ... Engine control system 2. Engine type (e.g. TCD 2013 4V)
– 05 ... Speed governing 3. Maintenance group
– 06 ... Exhaust system / Charging 4. Job card number or topic
– 07 ... Fuel system 5. Title of job card
– 08 ... Lube oil system 6. Reference to other job cards
– 09 ... Cooling system 7. Chapter
– 10 ... Compressed air system 8. Graphic or photo
– 11 ... Monitoring system 9. DEUTZ internal creation number
– 12 ... Other components 10.Page number
– 13 ... Electrical system 11.Date of issue of job card
z W 02-04-01: Component grouping 12.Note
z W 02-04-01: Consecutive number 13.Danger / Important
14.Work sequence
15.Special tools; auxiliary materials
16.Conventional tools
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3.5 Explanation of symbols

Danger!
of death or to health. Must be observed!
For example: The incorrect use or conver-
sion of the turbocharger can lead to serious
injury.
3 Caution!
Danger to the component/engine. Non-
compliance can lead to destruction of the
component/engine.
Must be observed!
Note
General notes on assembly, environmental
protection etc. No potential danger for man
or machine.
Tool
Conventional and special tools required for
the work.
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
References
to important documents 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 re-
ference is given to the Test and Setting Va-
lues 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 re-
ference is given to the Tightening Specifi-
cations table.
For example:
ID no. A01 001 = cylinder head screws
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D 2009 Technical data
TD 2009 Testing and setting data
4 Technical data
4.1 Testing and setting data
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Technical data D 2009
Testing and setting data TD 2009
ID no. Name Additional information Value

D / TD 2009
P00 31 Bore, diameter Nominal value 90 mm
P00 32 Stroke 90 mm
P00 50 Direction of rotation looking onto the flywheel left
25 - 30 bar
P00 51 Compression pressure
(2500 - 3000 kPa)
P01 31 Valve stem, diameter, inlet 7.155 - 7.170 mm
4 P01 32 Valve stem, diameter, outlet 7.155 - 7.170 mm
P01 35 Valve edge thickness, inlet 0.1 - 0.4 mm
P01 36 Valve edge thickness, outlet 0.1 - 0.4 mm
P01 37 Valve plate, diameter, inlet 36.90 - 37.10 mm
P01 38 Valve plate, diameter, outlet 33.90 - 34.10 mm
P02 03 Main journal, diameter 55.005 - 55.020 mm
P02 07 Bearing pin, surface hardness 53 - 58 HRc
P02 22 Lifting journal, diameter Standard 49.990 - 50.005 mm
P02 34 Crankshaft, permissible axial clearance in the installed state 0.13 - 0.56 mm
maximum permissible deviation
Parallelism of the con rod with respect to
P02 41 at a distance of 100 mm, 0.03 mm
the piston bolt
vertical
the piston bolt
horizontal
P02 43 Piston bolt bush, diameter, inside 28.010 - 28.025 mm
P02 52 Con rod bearing shells, diameter, inside 50.045 - 50.057 mm
P02 55 Con rod, bearing bore, diameter, inside 53.525 - 53.545 mm
Theoretical clearance between the big
P02 56 0.040 - 0.067 mm
end bearing and lifting journal
P02 61 Piston pin, diameter, outside 28 −0.005
−0.01 mm
Theoretical clearance between piston pin
P02 62 0.015 - 0.035 mm
bush and piston pin
P02 75 Piston protrusion 0.70 - 1.0 mm
P02 78 Piston pin bore 28 +0.008
+0.003 mm
+0.20
P02 84 Piston ring 1, joint clearance 0,15 +0 mm
+0.25
+0.25
P02 87 Piston ring 1, axial clearance 0.11 - 0.15 mm
Camshaft bearing, locating hole, diame-
P03 11 50.060 - 50.095 mm
ter
P03 13 Camshaft bearing, diameter, inside in the installed state 45.960 - 45.980 mm
Crankshaft, bearing bush, installation
P03 29 approx. 3 mm
depth
+0.025
P03 31 Cylinder, diameter, inside Standard 90 +0 mm
P04 31 Camshaft, bearing pin, diameter 41.925 - 41.955 mm
Camshaft, bearing pin, diameter (drive
P04 31 45.950 - 45.970 mm
side)
P04 35 Camshaft, axial clearance (not adjustable) 0.07 - 0.29 mm
P09 11 Thermostat, start of opening 86 - 90 °C
P09 13 Thermostat, stroke distance at least 9 mm
P12 11 V-belt tension First assembly 450 N
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TD 2009 Testing and setting data

Check after 15 minutes running
P12 21 V-belt tension
under load. 300 +20
−20 N
D / TD 2009 L03
P00 04 Engine weight according to DIN 70020-A approx. 180 kg
P00 71 Ignition sequence 1-2-3
D / TD 2009 L04
P00 71 Ignition sequence 1-3-4-2
4
D 2009
Indirect injection -
P00 20 Combustion process eddy chamber
method
P00 40 Compression ratio 22 : 1
P02 71 Piston, diameter, standard Measuring point 1 = height 10 mm 89,400 +0.167
+0.153 mm

−0.008 mm
P02 73 Piston, diameter, standard Measuring point 3 = height 65 mm 89,400 −0.175

−0.145 mm
TD 2009
P00 20 Combustion process Direct injection
P00 40 Compression ratio 17 : 1
+0.138 mm
−0.009 mm

−0.190 mm
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Testing and setting data TD 2009
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TD 2009 Tightening specifications
4.2 Tightening specifications
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Tightening specifications TD 2009
ID no. Name Screw type Notes / Remark Value

A00 001 Clamping bracket on crankcase M10x20-10.9 41 Nm
Clamping bracket on adapter for
A00 002 90 Nm
assembly block
Mounting foot/engine mounting on
A00 003 M10x20-10.9 41 Nm
crankcase
Use new screws.
M12x130-
A01 001 Cylinder head on crankcase Observe tightening 35 Nm + 60° + 60°
10.9
order.
4
A01 002 Rocker arm on cylinder head M8x30-8.8 27 Nm
A01 004 Cylinder head cover on cylinder head M8x50-10.9 27 Nm
A01 092 Transport bracket on cylinder head M8x16 21 Nm
A02 010 Main bearing housing on crankcase M8x20-8.8 Stage 1: 15 Nm
A02 012 Bearing housing in crankcase M10x80-8.8 41 Nm
Big end bearing cover on connecting
A02 020 M8x52-10.9 Use new screws. 20 Nm + 45°
rod
M8x35-12.9
A03 020 Gearcase cover on crankcase M8x50-10.9 27 Nm
M8x70-8.8
Observe tightening
A03 030 Lubricating oil pan on crankcase M8x20-8.8 32 Nm
sequence.
Use new Cu sealing
A03 031 Locking screw on lubricating oil pan M14x14 39 Nm
ring.
A03 060 Oil trap on crankcase M8x40-8.8 27 Nm
A03 080 Connection housing to crankcase M12x25-12.9 Locking screw 81 Nm
A04 001 Camshaft gear wheel on camshaft M12x35-8.8 81 Nm
A04 002 Camshaft, shim on crankshaft M8x16-8.8 Torx screw 21 Nm
Injection pump gear wheel on injec-
A04 004 Stage 1: 10 Nm
tion pump
A04 004 Stage 2: 81 Nm
tion pump
A04 011 Intermediate gear on crankcase M12x75-10.9 81 Nm
M8x70-8.8
A04 022 Cap on gearcase cover Torx screw 27 Nm
M8x20-8.8
A06 001 Exhaust pipe at cylinder head M8x55-10.9 27 Nm
Insert with Deutz S1
A06 010 Exhaust manifold to turbocharger M8x25-10.9 41 Nm
mounting compound.
M10x20-10.9 Insert with Deutz S1
A06 020 Turbocharger on exhaust pipe 41 Nm
M8x16-8.8 mounting compound.
Observe tightening
A06 030 Charge air pipe on cylinder head M8x45-10.9 27 Nm
sequence.
Air suction intake pipe on cylinder Observe tightening
A06 030 M8x70 27 Nm
head sequence.
A06 059 Exhaust return pipe to cooler M8x12-10.9 25 Nm
A06 062 Exhaust return pipe to charge air pipe M8x70-8.8 20 Nm
A06 063 Compensator pipe on exhaust pipe M8x20-10.9 20 Nm
A06 064 Compensator pipe to cooler M8x12-8.8 25 Nm
Exhaust retgurn pipe to exhaust
A06 070 M8x20-8.8 20 Nm
return valve
A06 083 Charge air manifold to charge air pipe M8x20-8.8 21 Nm
A07 001 Fuel injector on cylinder head M8x35-10.9 Torx screw 35 Nm
A07 001 Fuel injector on cylinder head M22 68 Nm
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TD 2009 Tightening specifications

Injection line on fuel injector/injection
A07 003 M12x1.5 28 Nm
pump
A07 006 Injection lines, fastening, pipe clip M6x10-8.8 9 Nm
A07 012 Injection pump on crankcase M8x30-10.9 27 Nm
A07 013 Blocking screw on injection pump 10 Nm
A07 015 Fuel line on injection pump 1/2’’ 9 Nm
Fuel lines on fuel supply pump and
A07 019 1/2’’ 9 Nm
fuel filter console
4
A07 024 Fuel supply pump on crankcase M8x55-10.9 27 Nm
A07 044 Fuel lines on crankcase, pipe clip M8x12-10.9 27 Nm
A07 084 Fuel line to fuel filter console M10x1.5 Hollow screw 21 Nm
A07 087 Fuel filter console to crankcase M10x25-10.9 41 Nm
Lubricating oil filter on lubricating oil Oil gasket lightly.
A08 001 M14x1.5 Hand tighten
cooler See operating manual
A08 003 Adapter on gearcase cover 3/4“ 41 Nm
A08 010 Lubricating oil pump on crankcase M6x25-8.8 4 Nm + 9 Nm
A08 016 Oil suction pipe, holder on crankcase M10x80-8.8 41 Nm
Lubricating oil pipe on exhaust turbo-
A08 040 M14x1.5 15 Nm
charger
A08 044 Oil return line to turbocharger M6x16-8.8 9 Nm
A08 051 Lubricating oil cooler on adapter M22x1.5 41 Nm
A08 091 Oil pressure switch in crankcase M10x1 20 Nm
M12x1
A08 091 Oil pressure switch in crankcase 50 Nm
M14x1.5
Oil pressure control valve on crank-
A08 098 3/8“ 21 Nm
case
A09 002 Outlet nozzles on cylinder head M8x30-10.9 27 Nm
M8x70-8.8 Observe tightening
A09 010 Coolant pump on gearcase cover 27 Nm
M8x30-10.9 sequence.
A09 021 Pipe, holder to holder M8x16-8.8 21 Nm
Temperature transmitter on cylinder Insert gasket with
A09 031 4 Nm
head packing compound.
A12 001 Flywheel on crankshaft M12x50-10.9 Use new screws. 96 Nm
A12 031 V-belt pulley on crankshaft M20x55-10.9 300 Nm
A12 046 V-belt pulley on coolant pump M6x10-8.8 9 Nm
A13 001 Starter on connection housing M10x45-8.8 41 Nm
A13 012 Generator on gearcase cover M8x120-8.8 21 Nm
A13 015 Generator on clamping bracket M8x20-8.8 21 Nm
A13 016 Clamping bracket on gearcase cover M8x16-8.8 21 Nm
A13 032 Glow plug on cylinder head M10 15 Nm
A13 033 Connecting rail to glow plug M4 Locking nut 2.5 Nm
Charge air pressure switch in charge
A13 046 M10 20 Nm
air line
A13 071 Cable (terminal 30) to starter M8 9 Nm
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Tightening specifications TD 2009
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D 2009 Job card overview
TD 2009 Sorted alphabetically
5
5 Job card overview
5.1 Sorted alphabetically
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Job card overview D 2009
Sorted alphabetically TD 2009
© 01/2008 2/8 16343-001

TD 2009 Sorted alphabetically
Activity Job card Maintenance group

Checking piston overhang W 01-04-09 Cylinder head
Checking the axial clearance of the crankshaft W 02-01-04 Drive system
Checking the camshaft W 04-05-06 Engine control
Checking the compression pressure
W 00-02-06 General
D 2009
W 00-02-06 General
TD 2009
Checking the con rod W 02-03-01 Drive system 5
Checking the crankshaft W 02-01-07 Drive system
Checking the cylinder W 03-03-01 Crankcase
Checking the piston W 02-09-07 Drive system
Checking the piston rings and piston ring grooves W 02-10-03 Drive system
Checking the thermostat (in the removed state) W 09-08-01 Cooling system
Checking the valves W 01-05-04 Cylinder head
Mounting engine on assembly block and demoun-
W 00-05-01 General
ting
Removing and install the charge air line W 06-07-03 Exhaust system / Charging
Removing and installing cylinder head W 01-04-04 Cylinder head
Removing and installing temperature transmitter W 09-12-01 Cooling system
Removing and installing the camshaft W 04-05-05 Engine control
Removing and installing the connection housing W 03-09-04 Crankcase
Removing and installing the coolant pump W 09-07-08 Cooling system
Removing and installing the cooler
W 06-09-04 Exhaust system / Charging
(Exhaust gas recirculation)
Removing and installing the crankshaft W 02-04-01 Drive system
Removing and installing the exhaust gas return val-
ve
Removing and installing the exhaust line W 06-01-05 Exhaust system / Charging
Removing and installing the flywheel W 12-06-01 Other components
Removing and installing the fuel filter console W 07-10-08 Fuel system
Removing and installing the fuel injector pump W 07-04-01 Fuel system
Removing and installing the fuel injectors
W 07-07-01 Fuel system
D 2009
TD 2009
Removing and installing the fuel supply pump W 07-11-01 Fuel system
Removing and installing the gearcase cover W 04-04-09 Engine control
© 01/2008 3/8 16343-001

Sorted alphabetically TD 2009
Activity Job card Maintenance group

Removing and installing the generator W 13-02-03 Electrical system
Removing and installing the glow plugs W 13-06-01 Electrical system
Removing and installing the intake manifold W 06-07-03 Exhaust system / Charging
Removing and installing the lubricating oil cooler W 08-08-02 Lube oil system
Removing and installing the lubricating oil pan W 08-04-07 Lube oil system
Removing and installing the lubricating oil pump W 08-04-05 Lube oil system
Removing and installing the oil pressure regulating
W 08-11-10 Lube oil system
5 valve
Removing and installing the oil pressure switch W 08-11-08 Lube oil system
Removing and installing the oil suction pipe W 08-04-06 Lube oil system
Removing and installing the piston and con rod W 02-09-03 Drive system
Removing and installing the rocker arm W 01-02-02 Cylinder head
Removing and installing the starter W 13-03-02 Electrical system
Removing and installing the thermostat W 09-08-02 Cooling system
Removing and installing the turbocharger W 06-06-04 Exhaust system / Charging
Removing and installing the valves W 01-05-01 Cylinder head
Removing and installing the V-belt pulley W 12-02-02 Other components
Removing and installing, testing camshaft bearing W 03-11-01 Crankcase
Renewing the crankshaft sealing ring
W 02-02-02 Drive system
(flywheel side)
(opposite side to flywheel)
Setting the injection pump W 07-04-14 Fuel system
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TD 2009 Sorted numerically
5
5 Job card overview
5.2 Sorted numerically
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Sorted numerically TD 2009
© 01/2008 6/8 16343-001

TD 2009 Sorted numerically
Job card Activity Maintenance group

W 00-02-06 General
D 2009
W 00-02-06 General
TD 2009
Mounting engine on assembly block and demoun-
W 00-05-01 General
ting
W 01-02-02 Removing and installing the rocker arm Cylinder head
W 01-04-04 Removing and installing cylinder head Cylinder head 5
W 01-04-09 Checking piston overhang Cylinder head
W 01-05-01 Removing and installing the valves Cylinder head
W 01-05-04 Checking the valves Cylinder head
W 02-01-04 Checking the axial clearance of the crankshaft Drive system
W 02-01-07 Checking the crankshaft Drive system
(flywheel side)
W 02-03-01 Checking the con rod Drive system
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 02-10-03 Checking the piston rings and piston ring grooves Drive system
W 03-03-01 Checking the cylinder Crankcase
W 03-09-04 Removing and installing the connection housing Crankcase
W 03-11-01 Removing and installing, testing camshaft bearing Crankcase
W 04-04-09 Removing and installing the gearcase cover Engine control
W 04-05-05 Removing and installing the camshaft Engine control
W 04-05-06 Checking the camshaft Engine control
W 06-01-05 Removing and installing the exhaust line Exhaust system / Charging
W 06-06-04 Removing and installing the turbocharger Exhaust system / Charging
W 06-07-03 Removing and installing the intake manifold Exhaust system / Charging
W 06-07-03 Removing and install the charge air line Exhaust system / Charging
Removing and installing the exhaust gas return val-
ve
W 07-04-01 Removing and installing the fuel injector pump Fuel system
© 01/2008 7/8 16343-001

Sorted numerically TD 2009
Job card Activity Maintenance group

W 07-04-14 Setting the injection pump Fuel system
D 2009
TD 2009
W 07-10-08 Removing and installing the fuel filter console Fuel system
W 07-11-01 Removing and installing the fuel supply pump Fuel system
5 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
W 08-04-07 Removing and installing the lubricating oil pan Lube oil system
W 08-08-02 Removing and installing the lubricating oil cooler Lube oil system
W 08-11-08 Removing and installing the oil pressure switch Lube oil system
Removing and installing the oil pressure regulating
W 08-11-10 Lube oil system
valve
W 09-07-08 Removing and installing the coolant pump Cooling system
W 09-08-01 Checking the thermostat (in the removed state) Cooling system
W 09-08-02 Removing and installing the thermostat Cooling system
W 09-12-01 Removing and installing temperature transmitter Cooling system
W 12-02-02 Removing and installing the 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 glow plugs Electrical system
© 01/2008 8/8 16343-001

DEUTZ engines Job cards
6 Job cards
6
© 01/2008 1/2 16344-001

Job cards DEUTZ engines
© 01/2008 2/2 16344-001

General
D 2009 W 00-02-06

Commercial available tools: – W 13-06-01
– Compression pressure
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005
Special tools:
– Connector . . . . . . . . . . . . . . . . . . 100220

z Disconnect the shutoff solenoid.
z Remove the glow plugs.
W 13-06-01
2
z Insert connector (1).
z Tighten the connection piece.
15 Nm
z Connect adapter (2) to connector.
© 41413-0
z Mount the compression tester on the adapter.

z Turn over engine with starter.
25 - 30 bar (2500 - 3000 kPa)
© 41415-0
© 01/2008 1/4 16345-001

General
W 00-02-06 D 2009
The measured compression pressure

depends on the starting speed during the
measuring process and the altitude of the No.
engine installation site. Therefore, limit Kompression in bar
Compression value in bar
values cannot be determined exactly. The Pression en bar
Dat. _________
compression pressure measurement is
10 15 20 25 30 35 40
only recommended as a reference measu-
Zyl.
rement of all cylinders of an engine to each
other. If more than 15% deviation has been 1
determined, the cause should be determi- 2
ned by disassembling the cylinder unit con- 3
4
cerned. 5
6
7
8 Best. Nr. 5 1341 250 00
DBGM Made in Germany
6 MOTOMETER 7250 Leonberg
© 43669-0
z Remove the compression pressure tester and

adapter (1).
© 41415-1
z Remove connector (1).

z Install the glow plugs.
W 13-06-01
z Connect the shutoff solenoid.
© 41414-0
© 01/2008 2/4 16345-001

General
D 2009 W 00-02-06
Technical Data
Testing and setting data
25 - 30 bar
(2500 - 3000 kPa)
Tightening specifications
© 01/2008 3/4 16345-001

General
W 00-02-06 D 2009
© 01/2008 4/4 16345-001

General
TD 2009 W 00-02-06

– Compression pressure
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005
– Torx tool set . . . . . . . . . . . . . . . . . . 8189
Special tools:
– Connector . . . . . . . . . . . . . . . . . . 100170
– Clamping claw . . . . . . . . . . . . . . 100210

z Disconnect the shutoff solenoid.
z Removing fuel injectors.
W 07-07-01
z Mount sealing ring (1).
z Insert connector (2).
© 41350-0
z Mount clamping shoe (1).

z Tighten screw (2).
35 Nm
1 2
© 41348-0
© 01/2008 1/4 16346-001

General
W 00-02-06 TD 2009
z Connect adapter (1) to connector.
6
© 41349-0
z Mount the compression tester on the adapter.

z Turn over engine with starter.
25 - 30 bar (2500 - 3000 kPa)
© 46308-0
The measured compression pressure

depends on the starting speed during the
measuring process and the altitude of the No.
engine installation site. Therefore, limit Kompression in bar
Compression value in bar
values cannot be determined exactly. The Pression en bar
Dat. _________
compression pressure measurement is
10 15 20 25 30 35 40
only recommended as a reference measu-
Zyl.
rement of all cylinders of an engine to each

other. If more than 15% deviation has been 1
determined, the cause should be determi- 2
ned by disassembling the cylinder unit con- 3
4
cerned. 5
6
7
8 Best. Nr. 5 1341 250 00
DBGM Made in Germany
MOTOMETER 7250 Leonberg
© 43669-0
© 01/2008 2/4 16346-001

General
TD 2009 W 00-02-06
z Remove the compression pressure tester and

adapter (1).
6
© 46308-1
z Unscrew screw (2).

z Remove clamping shoe (1).
z Remove connector.
z Remove sealing ring.
z Install fuel injectors.
W 07-07-01
z Connect the shutoff solenoid.
1 2
© 41348-0
© 01/2008 3/4 16346-001

General
W 00-02-06 TD 2009
Technical Data
25 - 30 bar
(2500 - 3000 kPa)
© 01/2008 4/4 16346-001

D 2009 General
TD 2009 W 00-05-01
Mounting engine on assembly block and demounting

Commercial available tools: Different customer scopes are not taken
– Lifting gear into account in the repair sequence shown
– Suspension ropes here, accessories which deviate from the
Special tools: standard equipment are not shown.
– Assembly block. . . . . . . . . . . . . . . . 6067
– Clamping bracket . . . . . . . . . . .6067 200
– Engine lifting device . . . . . . . . . . . . 6068
Mounting engine on assembly block

z Hang the engine director onto the transport lashes
(arrows) with support chain.
– D / TD 2009 L03
approx. 180 kg
– D / TD 2009 L04
approx. 220 kg
z Hang engine on workshop crane.
z Remove all mounting feet.
z Insert engine in engine block.
© 41351-0
z Mount clamping holder (1).

z Tighten screws (2).
41 Nm
2 4
z Mount clamping holder (3).
2 4
41 Nm
1 3
© 41251-1
© 01/2008 1/4 16347-001

General D 2009
W 00-05-01 TD 2009
z Align engine on engine block.

z Tighten screws (1) and nuts (2). 2
90 Nm
z Unhook the engine from the workshop crane.
1
2
6
© 41387-0
Demounting engine from assembly block

z Hang the engine director onto the transport lashes
(arrows) with support chain.
– D / TD 2009 L03
approx. 180 kg
– D / TD 2009 L04
approx. 220 kg
z Hang engine on workshop crane.
© 41351-0
z Unscrew the nuts (2).

z Remove screws (1). 2
1
2
© 41387-0
© 01/2008 2/4 16347-001

D 2009 General
TD 2009 W 00-05-01
z Unscrew screws (2).

z Remove clamping bracket (1).
z Remove clamping bracket (3). 2 4
z Install all mounting feet.
41 Nm 2 4
z Set down engine.
z Unhook the engine from the workshop crane.
1 3
6
© 41251-1
© 01/2008 3/4 16347-001

General D 2009
W 00-05-01 TD 2009
Technical Data
D / TD 2009 L03
D / TD 2009 L04
A00 001 Clamping bracket on crankcase M10x20-10.9 41 Nm
Clamping bracket on adapter for
A00 002 90 Nm
assembly block
6 Mounting foot/engine mounting on
A00 003 M10x20-10.9 41 Nm
crankcase
© 01/2008 4/4 16347-001

D 2009 Cylinder head
TD 2009 W 01-02-02
Removing and installing the rocker arm

Commercial available tools:
– Open-ended spanner
(24 mm spanner size)
– Hose clip pliers . . . . . . . . . . . . . . . . 8011
Special tools:
– Disassembly tool. . . . . . . . . . . . . 110901
Removing the rocker arm

– TD 2009 2
z Place charge air pipe (2) to one side.
© 41252-1
– TD 2009
z Remove the O-ring (1) with the disassembly tool.
© 41254-0
© 01/2008 1/6 16348-001

Cylinder head D 2009
W 01-02-02 TD 2009
z Loosen hose clip (1).

z Place pipe (2) to one side.
1
2
6
© 41253-1
z Unscrew all screws (1).

z Remove cylinder head cowling (2).
z Remove gasket (3).
© 41001-3

z Remove rocker arm bearing (2).
z Remove rocker arm (3). 1
Lay out components in the order in which

they should be installed. 2
z Visually inspect the components. 3
© 41183-0
© 01/2008 2/6 16348-001

TD 2009 W 01-02-02
Installing the rocker arm

z Grease the rocker arm (arrow) lightly.
1
z Mount rocker arm (3) and rocker arm bearing (2).
Align rocker arm centred to the valve
2
spring!
z Fasten screw (1). 3
6
© 41002-1
z Press down rocker arm (1) and pushrod.

z Hold rocker arm with open-ended wrench (2).
27 Nm
1
© 41255-1
z Clean sealing surfaces.

The sealing surfaces must be dry and free
from grease and dirt.
z Mount new gasket (3). 1

z Mount cylinder head cover (2).
2
27 Nm
Tightening sequence: From the centre out- 3
wards.
© 41001-3
© 01/2008 3/6 16348-001

W 01-02-02 TD 2009
z Push in pipe (1).

z Fix the hose clip (2) with the hose clip pliers.
1
2
6
© 41253-1
– TD 2009
z Insert new sealing ring (1).
1
© 41254-1
– TD 2009
z Clean sealing surfaces. 1
z Mount charge air pipe (1).
21 Nm
© 41252-2
© 01/2008 4/6 16348-001

TD 2009 W 01-02-02
Technical Data
A01 002 Rocker arm on cylinder head M8x30-8.8 27 Nm
A01 004 Cylinder head cover on cylinder head M8x50-10.9 27 Nm
© 01/2008 5/6 16348-001

W 01-02-02 TD 2009
© 01/2008 6/6 16348-001

TD 2009 W 01-04-04
Removing and installing cylinder head

– Rotation angle disc . . . . . . . . . . . . . 8190 – W 01-04-09
– W 06-06-04
– W 06-07-03 . . . . . . . . . . . . . . . . . D 2009
– W 06-07-03 . . . . . . . . . . . . . . . . TD 2009
Removing the cylinder head

3
1. Valve
2
2. Rocker arm 5
3. Cylinder head bolts
4. Pushrods
5. Thermostat housing
6. Fuel injector
7 1
4
6
© 41014-0
z Remove turbocharger.
W 06-06-04
3
z Loosen hose clips (1).
z Unscrew screws (2). 2
z Remove the oil trap (3).
1
2
© 41256-1
© 01/2008 1/8 16349-001

W 01-04-04 TD 2009
z Remove the rocker lever.

W 01-02-02
z Remove the charge air pipe.
– D 2009
W 06-07-03
– TD 2009
W 06-07-03
6
© 41006-1
z Remove push rods (1).

z Put aside components in the order in which they were
removed.
z Visually inspect the components.
© 41007-1
– D / TD 2009 L03
z Loosen screws in specified order.
z Remove screws.
7 3 2 6
8 4 1 5
© 41178-0
© 01/2008 2/8 16349-001

TD 2009 W 01-04-04
– D / TD 2009 L04
z Loosen screws in specified order.
z Remove screws.
7 3 2 6 10
8 4 1 5 9
6
© 41177-0
z Lift the cylinder head carefully from the crankcase.

z Remove gasket.
Do not place cylinder head on sealing sur-
face.
© 41009-1
Installing the cylinder head

1
z Check piston overhang.
W 01-04-09
Note installation position of the hydro tap-
pets.
z Pay attention to clamping bushing (1).

1
© 41010-0
© 01/2008 3/8 16349-001

W 01-04-04 TD 2009
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.
6
© 41011-1
z Fit cylinder head.

z Pay attention to clamping bushing (1).
!
© 41012-1
– D / TD 2009 L03
Attention!
Use new screws.
7 3 2 6
z Oil the cylinder head screws slightly.
z Tighten new screws with rotation angle disc accord-
ing to the tightening order.
35 Nm + 60° + 60°
8 4 1 5
© 41178-0
© 01/2008 4/8 16349-001

TD 2009 W 01-04-04
– D / TD 2009 L04
Attention!
Use new screws.
7 3 2 6 10
z Oil the cylinder head screws slightly.
z Tighten new screws with rotation angle disc accord-
ing to the tightening order.
35 Nm + 60° + 60°
8 4 1 5 9
6
© 41177-0
z Grease the ball heads of the pushrods lightly.

z Insert pushrods in hydro-tappets (1).
Note installation position.
© 41013-1
z Install the charge air pipe.

– D 2009
W 06-07-03
– TD 2009
W 06-07-03
z Install the rocker arm.
W 01-02-02
© 41006-1
© 01/2008 5/8 16349-001

W 01-04-04 TD 2009
z Mount oil trap (1).

27 Nm 1
z Fasten hose clips (3) with hose clip pliers. 2

z Install the turbocharger.
W 06-06-04 3
3
2
6
© 41256-2
© 01/2008 6/8 16349-001

TD 2009 W 01-04-04
Technical Data
Use new screws.
M12x130-
A01 001 Cylinder head on crankcase Observe tightening 35 Nm + 60° + 60°
10.9
order.
A03 060 Oil trap on crankcase M8x40-8.8 27 Nm
© 01/2008 7/8 16349-001

W 01-04-04 TD 2009
© 01/2008 8/8 16349-001

TD 2009 W 01-04-09
Checking piston overhang

– Micrometer gauge
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Measuring device . . . . . . . . . . . . 100750
z Remove cylinder head.

W 01-04-04
© 41155-0
z Turn the crankshaft until the respective piston is just

in front of the top dead centre (arrow).
© 41156-0
© 01/2008 1/4 16350-001

W 01-04-09 TD 2009
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. 2
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). 1
1
6
© 41149-2
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".
© 41157-1
Measuring points see diagram.

Measuring points (1) and (2).
© 41148-0
© 01/2008 2/4 16350-001

TD 2009 W 01-04-09
z Align the measuring apparatus on the spacing wash-

ers in such a way that the stylus lies on the specified
measuring points.
Do not position the stylus on the piston
marking.
z Note the largest measured value.
z Compare actual value with setpoint value.
0.70 - 1.0 mm
z Install cylinder head.
W 01-04-04
6
© 41149-1
© 01/2008 3/4 16350-001

W 01-04-09 TD 2009
Technical Data
P02 75 Piston protrusion 0.70 - 1.0 mm
© 01/2008 4/4 16350-001

TD 2009 W 01-05-01
Removing and installing the valves

Commercial available tools: –W 01-04-04
– Assembly pliers. . . . . . . . . . . . . . . . 8024 –W 07-07-01 . . . . . . . . . . . . . . . . D 2009
– Assembly lever . . . . . . . . . . . . . . . . 9017 –W 07-07-01 . . . . . . . . . . . . . . . TD 2009
Special tools: –W 13-06-01
– Assembly sleeves . . . . . . . . . . . . 121420
– Assembly tool . . . . . . . . . . . . . . . 121430
Removing the valves

1. Exhaust valve
4
2. Inlet valve
3. Valve spring
4. Rocker arm 3
5. Pushrod
5
© 41018-1

W 01-04-04
z Remove the glow plugs.
W 13-06-01
z Removing fuel injectors.
– D 2009
W 07-07-01
– TD 2009
W 07-07-01
© 41019-1
© 01/2008 1/4 16351-001

W 01-05-01 TD 2009
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. 2
6 1
© 41020_2
z Pull off valve stem seal (1) with assembly pliers (2).
© 41021-1
z Clean cylinder head, check and visually inspect for

damage.
© 41022-1
© 01/2008 2/4 16351-001

TD 2009 W 01-05-01
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).
6
© 41023-1
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).
© 41179_0
z Remove assembly lever.

Make sure the tapper collets fit correctly in
the valve keyway.
© 41024-1
© 01/2008 3/4 16351-001

W 01-05-01 TD 2009
z Install fuel injectors.

– D 2009
W 07-07-01
– TD 2009
W 07-07-01
z Install the glow plugs.
W 13-06-01
W 01-04-04
6
© 41019-1
© 01/2008 4/4 16351-001

TD 2009 W 01-05-04
Checking the valves

– Slide gauge
Clean all valves.
When the wear limit is reached, the valve
must be renewed.
Checking valve stem diameter

z Remove valves.
W 01-05-01
z Measure valve stem diameter with micrometer
gauge.
– Inlet valve
7.155 - 7.170 mm
– Exhaust valve
7.155 - 7.170 mm
© 42182-1
Checking valve edge thickness

z Measure valve edge thickness with slide gauge.
– Inlet valve
0.1 - 0.4 mm
– Exhaust valve
0.1 - 0.4 mm
© 42183-1
© 01/2008 1/4 16352-001

W 01-05-04 TD 2009
Checking valve head diameter

z Measure valve head diameter with slide gauge.
– Inlet valve
36.90 - 37.10 mm
– Exhaust valve
33.90 - 34.10 mm
z Install valves.
W 01-05-01
6
© 42184-1
© 01/2008 2/4 16352-001

TD 2009 W 01-05-04
Technical Data
P01 31 Valve stem, diameter, inlet 7.155 - 7.170 mm
P01 32 Valve stem, diameter, outlet 7.155 - 7.170 mm
P01 35 Valve edge thickness, inlet 0.1 - 0.4 mm
P01 36 Valve edge thickness, outlet 0.1 - 0.4 mm
P01 37 Valve plate, diameter, inlet 36.90 - 37.10 mm
P01 38 Valve plate, diameter, outlet 33.90 - 34.10 mm
© 01/2008 3/4 16352-001

W 01-05-04 TD 2009
© 01/2008 4/4 16352-001

D 2009 Drive system
TD 2009 W 02-01-04
Checking the axial clearance of the crankshaft

– Magnetic measuring stand
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Checking the axial backlash

z Remove the gear case cover.
W 04-04-09
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.
© 41158-1

z Read off measured value.
0.13 - 0.56 mm
z Remove magnetic measuring stand.
z Remove dial gauge.
z Install the gear case cover.
W 04-04-09
© 41159-1
© 01/2008 1/2 16353-001

Drive system D 2009
W 02-01-04 TD 2009
Technical Data
P02 34 Crankshaft, permissible axial clearance in the installed state 0.13 - 0.56 mm
© 01/2008 2/2 16353-001

D 2009 Drive system
TD 2009 W 02-01-07
Checking the crankshaft

– Magnetic measuring stand
– Internal measuring device
– Stylus extension
– Prisms
– Hardness tester
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Checking the bearing pin hardness

z Remove crankshaft.
W 02-04-01
z Place crankshaft on prism.
© 41390-0
z Put hardness tester on journal.

z Raise stylus (1) and press release (2).
Stylus (1) falls down, briefly strikes the sur- 1
face and jumps up to the measured value.
© 43499-0
© 01/2008 1/4 16354-001

Drive system D 2009
W 02-01-07 TD 2009
z Read off displayed value (arrow) from hardness test-

er.
– Nominal value, at least
53 - 58 HRc
The measured value is to be converted
according to the table of the measuring
device.
6
© 43515-0
Checking the diameter of the main bearing

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

– Standard
55.005 - 55.020 mm
See schematic diagram for measuring
points.
© 41389-0
© 01/2008 2/4 16354-001

D 2009 Drive system
TD 2009 W 02-01-07
Checking the diameter of the lifting jour-

nals
z Measure lifting journal with micrometer gauge.
49.990 - 50.005 mm
points.
6
© 41389-1
Visual inspection
z Visually inspect the component.
z Check the running surfaces (1) of the crankshaft
sealing rings visually.
z Visually inspect gear wheel (2).
z Install crankshaft.
W 02-04-01
© 41390-0
© 01/2008 3/4 16354-001

Drive system D 2009
W 02-01-07 TD 2009
Technical Data
P02 03 Main journal, diameter 55.005 - 55.020 mm
P02 07 Bearing pin, surface hardness 53 - 58 HRc
P02 22 Lifting journal, diameter Standard 49.990 - 50.005 mm
© 01/2008 4/4 16354-001

D 2009 Drive system
TD 2009 W 02-02-02

(flywheel side)
– 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
© 41025-0
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.
© 41026-0
© 01/2008 1/2 16355-001

Drive system D 2009
W 02-02-02 TD 2009
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.
6
© 41027-0
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 connec-
tion housing and crankshaft sealing ring.
© 41028-1
z Remove assembly tool.

z Install flywheel.
W 12-06-01
© 41025-0
© 01/2008 2/2 16355-001

D 2009 Drive system
TD 2009 W 02-02-04

– 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.
© 41174-0
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.
© 41173-0
© 01/2008 1/2 16356-001

Drive system D 2009
W 02-02-04 TD 2009
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.
6 z Remove assembly tool.
z Install V-belt pulley. © 41055-0
W 12-02-02
© 01/2008 2/2 16356-001

D 2009 Drive system
TD 2009 W 02-03-01
Checking the con rod

– Rotation angle disc . . . . . . . . . . . . . 8190
– Con rod test device
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
z Remove piston and connecting rod.

W 02-09-03
z Remove piston from con rod.
© 41044-1
Checking small end bush

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".
© 34768-2
© 01/2008 1/10 16357-001

Drive system D 2009
W 02-03-01 TD 2009
Diagram for measuring the small end bush

at the points "a" and "b" in the
levels "1" and "2".
6
© 37239-1
z Insert internal measuring device.

z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
28.010 - 28.025 mm
z Note the measured value, dimension (A).

The dimension A is required to determine
the piston bolt clearance.
© 41391-0
Checking diameter of the piston bolt

z Measure piston pin with micrometer gauge.
−0.005
28 −0.01 mm
z Note the measured value, dimension B.
The dimension B is required to determine
the piston bolt clearance.
© 35908-3
© 01/2008 2/10 16357-001

D 2009 Drive system
TD 2009 W 02-03-01
Determining piston pin clearance

The piston pin clearance is given by the
difference between the internal diameter of
the small end bush (a) and the piston pin
diameter (b).
0.015 - 0.035 mm
Calculation example
Desired: Piston pin clearance
Given: -
Measured: Internal diameter small end bush (a)
(a) = 28.015 mm
Diameter piston pin (b)
(b) = 27.990 mm
Calculation: Dimension (a) - Dimension (b)
28.015 mm - 27.990 mm
Result: = 0.025 mm
6
Checking the con rod bearing bore

z Mount big end bearing cap.
Attention!
Note the assignment of the big end bearing
2
651
cap.
The identification numbers (1) on the con 9
1
rod and the big end bearing cap must be
identical and opposite to each other when
265
assembled.
19
© 41395-1
z Tighten screws alternately with rotation angle disc

and socket wrench insert.
20 Nm + 45°
© 41396-1
© 01/2008 3/10 16357-001

Drive system D 2009
W 02-03-01 TD 2009

"0".
6
© 36094-1
Diagram for measuring the con rod bearing

bore at the points "a" and "b" in the
levels "1" and "2".
© 37239-1

53.525 - 53.545 mm
When the wear limit is reached the con rod
must be replaced.
© 41392-0
© 01/2008 4/10 16357-001

D 2009 Drive system
TD 2009 W 02-03-01
Checking internal diameter of the con rod

bearing shells
z Remove the con rod bearing cover.
6
© 41393-0
z Insert bearing shell in the con rod.

Attention!
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).
2
1
© 41048-2
z Insert bearing shell in the respective big end bearing

cap.
Attention!
groove (2).
1
© 41394-0
© 01/2008 5/10 16357-001

Drive system D 2009
W 02-03-01 TD 2009

Attention!
The identification numbers (1) on the con-
necting rod and the big end bearing cover
must be identical and opposite to each
265
other when assembled.
19
1
265
19
6
© 41395-0
z Tighten screws alternately with rotation angle disc

and socket wrench insert.
20 Nm + 45°
© 41396-0

"0".
© 36094-1
© 01/2008 6/10 16357-001

D 2009 Drive system
TD 2009 W 02-03-01
Diagram for measuring the inside diameter

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

points.
50.045 - 50.057 mm
z Note measured value, dimension (a).
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.
© 41397-0
Determine big end bearing clearance

The big end bearing clearance is given by
the difference between the internal diame-
ter of the big end bearing shell (a) and the
lifting journal diameter (b).
0.040 - 0.067 mm
Calculation example
Desired: Big end bearing clearance
Given: -
Measured: Internal diameter big end bearing shell (a)
(a) = 50.040 mm
Diameter lifting journal (b)
(b) = 50.000 mm
Calculation: Dimension (a) - Dimension (b)
50.040 mm - 50.000 mm
Result: = 0.040 mm
© 01/2008 7/10 16357-001

Drive system D 2009
W 02-03-01 TD 2009
z Remove screws.
z Remove the con rod bearing cover.
6
© 41396-0
Checking the con rod

z Mount connecting rod on test instrument without
bearing shells. A
Attention!
Aligning the con rod is not permissible. B
z Move test fork in direction of arrow.
z Check that the con rod is parallel.
z Permissible deviation from (A) to (B).
0.03 mm
Distance between “A“ and “B“ = 100 mm.
© 30579-1
z Move test fork in direction of arrow.

z Check the angle of the con rod.
z Permissible deviation from (C) to (D).
0.03 mm
Distance between “C“ and “D“ = 100 mm
C
D
z Assembly pistons and con rod.
z Install piston and connecting rod.
W 02-09-03
© 30580-1
© 01/2008 8/10 16357-001

D 2009 Drive system
TD 2009 W 02-03-01
Technical Data
the piston bolt
vertical
the piston bolt
horizontal
P02 43 Piston bolt bush, diameter, inside 28.010 - 28.025 mm
P02 52 Con rod bearing shells, diameter, inside 50.045 - 50.057 mm
P02 55 Con rod, bearing bore, diameter, inside 53.525 - 53.545 mm
Theoretical clearance between the big
P02 56 0.040 - 0.067 mm
end bearing and lifting journal 6
P02 61 Piston pin, diameter, outside 28 −0.005
−0.01 mm
Theoretical clearance between piston pin
P02 62 0.015 - 0.035 mm
bush and piston pin
rod
© 01/2008 9/10 16357-001

Drive system D 2009
W 02-03-01 TD 2009
© 01/2008 10/10 16357-001

D 2009 Drive system
TD 2009 W 02-04-01
Removing and installing the crankshaft

– Depth-measuring – W 02-02-02
appliance – W 02-09-03
– 3-arm puller – W 04-04-09
Special tools: – W 08-04-06
– Disassembly/assembly – W 12-06-01
tool . . . . . . . . . . . . . . . . . . . . . . . 143860
– Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . . . . . . 143870
– Blocking tool . . . . . . . . . . . . . . . . 144200
– Fitting compound
DEUTZ AP1908
6
Removing crankshaft
1. Crankshaft
2. Connecting rod
3. Piston 3
4. Bearing housing
2
5. Main bearing housing
1 4 5
© 41033-2

W 04-04-09
© 41029-2
© 01/2008 1/12 16358-001

Drive system D 2009
W 02-04-01 TD 2009
z Mount blocking tool (1).

z Loosen screw (2).
z Loosen screw (3).
z Remove blocking tool (1).
3
6
© 41258-2

z Pull out journal (2).
z Remove idler gear (3).
© 41030-0

z Remove camshaft toothed wheel (2).
© 41031-0
© 01/2008 2/12 16358-001

D 2009 Drive system
TD 2009 W 02-04-01
z Remove cylindrical pin (1).
6
© 41261-0
z Turn in screw (1) a few turns.

z Pull off camshaft toothed wheel with 3-arm puller.
© 41260-0
z Remove flywheel.
W 12-06-01
W 02-09-03
© 41029-2
© 01/2008 3/12 16358-001

Drive system D 2009
W 02-04-01 TD 2009

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.
6 2 1
© 41034-1
z Unscrew fixing screws (1).

z Remove oil suction pipe (2). 1
1
z Unscrew oil pressure control valve (3).
© 41059-1
z Remove crankshaft.
© 41035-0
© 01/2008 4/12 16358-001

D 2009 Drive system
TD 2009 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.
1
3 2
6
© 41060-1
z Turn the nut (1) clockwise.

The bearing bush is pressed onto the
crankcase by the thrust pad. 1
z Dismantle disassembly/assembly tool.

z Remove bearing bush.
© 41061-1
z Clamp main bearing housing in the vice.

Use cushioned jaws.
2
z Insert thrust pad (1) in bearing bush.

z Insert assembly bell (3).
z Mount washers and screw on nuts. 1
z Turn nut (4) clockwise. 3
The bearing bush is pressed onto the main

bearing housing by the thrust pad.
4
© 41384-0
© 01/2008 5/12 16358-001

Drive system D 2009
W 02-04-01 TD 2009
Installing the main bearing

z Oil bearing liner with lubricating oil.
z Press in bearing liner with disassembly/assembly
tool 143870.
Make sure the bearing bush is not twisted.
assembly tool.
Mark the position of the lubricating oil bore
on the main bearing housing.
6
© 41058-2
z Oil bearing liner with lubricating oil.

z Mount bearing bush.
1 2
z Mount guide plate (1).
z Insert counter support.
z Mount washers and screw on nuts.
Mark position of the lubricating oil bore.
Position bearing bush.
© 41062-1
z Turn the nut (1) clockwise.

The bearing bush is pressed into the
crankcase by the thrust pad.
assembly tool.
Make sure the bearing bush is not twisted.
© 41063-1
© 01/2008 6/12 16358-001

D 2009 Drive system
TD 2009 W 02-04-01
z Dismantle disassembly/assembly tool.

z Remove disassembly/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 re-
installed.
z Check installation depth (1) with depth measuring
appliance.
approx. 3 mm
6
© 41064-1
Installing the crankshaft

z Oil bearing liner (1) lightly with lubricating oil. 1
z Push crankshaft into crankcase.
Align screw thread (2) and through
hole (3).
4
z Insert thrust washers (4) at the rear with grease.
Lubricating oil grooves face the crankshaft.
3
2
© 41036-1
z Push in the crankshaft in the direction of the arrow to

the stop.
z Tighten locating screws (1).
41 Nm
z Install oil suction pipe. 1
W 08-04-06
© 41037-1
© 01/2008 7/12 16358-001

Drive system D 2009
W 02-04-01 TD 2009
z Insert new O-ring (1).

z Coat O-ring with DEUTZ AP1908 mounting com-
pound.
1
6
© 41398-0
z Coat the back of the shims with a little grease.

2
The lubricating oil grooves (2) face
upwards. 1
z Install shims (1).
© 41399-0
z Install main bearing housing (1).

– Stage 1:
15 Nm
– Stage 2:
27 Nm
z Renew crankshaft sealing ring (flywheel side).
W 02-02-02
1
© 41038-1
© 01/2008 8/12 16358-001

D 2009 Drive system
TD 2009 W 02-04-01
z Install flywheel.
W 12-06-01
W 04-04-09
6
© 41029-2
z Check axial backlash of crankshaft.

W 02-01-04
z Heat up crankshaft toothed wheel to approx. 100 °C.
2
Danger!
Danger of burning!
z Mount crankshaft toothed wheel (1).
Note installation position of Woodruff
key (2) and groove. 1 3
z Tighten oil pressure control valve (3).

21 Nm
© 41039-1
z Insert cylindrical pin (1).

z Insert camshaft toothed gear with cylindrical pin (1)
in bore (2).
© 41262-1
© 01/2008 9/12 16358-001

Drive system D 2009
W 02-04-01 TD 2009
The marks (1) of the crankshaft toothed

wheel and the camshaft toothed wheel
must be in line!
z Fasten screw (2).
2
1
6
© 41081-1
z Insert idler gear.

wheel, intermediate gear and fuel injector
toothed wheel must be in line!
1
© 41066-0
z Oil the journal lightly.

z Insert the journal carefully into the needle bearing.
z Fasten screws.
© 41067-0
© 01/2008 10/12 16358-001

D 2009 Drive system
TD 2009 W 02-04-01

81 Nm
z Tighten screw (2). 3
81 Nm
z Remove blocking tool (1). 1
6
© 41258-2

W 02-09-03
© 41029-2
© 01/2008 11/12 16358-001

Drive system D 2009
W 02-04-01 TD 2009
Technical Data
Crankshaft, bearing bush, installation
P03 29 approx. 3 mm
depth
A02 012 Bearing housing in crankcase M10x80-8.8 41 Nm
6 A04 011 Intermediate gear on crankcase M12x75-10.9 81 Nm
A08 098 3/8“ 21 Nm
case
© 01/2008 12/12 16358-001

D 2009 Drive system
TD 2009 W 02-09-03
Removing and installing the piston and con rod

– Rotation angle disc . . . . . . . . . . . . . 8190 – W 08-04-06
Special tools:
– Universal piston ring pliers . . . . . 130300
– Piston ring compressor . . . . . . . . 130510
Removing the piston and con rod

1
1. Piston rings
2. Piston
3. Piston pin 2
4. Connection rod
3
5. Big end bearing cap
4
© 41042-1

W 01-04-04
z Remove oil suction pipe
W 08-04-06
z Pull out oil dipstick.
© 41040-0
© 01/2008 1/6 16359-001

Drive system D 2009
W 02-09-03 TD 2009
Removing the big end bearing cap

z Position lifting bearing journal in LDC position.
z Remove big end bearing cap (2).
z Remove bearing shell (3).
they should be installed.
Note order of cylinders.
3
2 1
6
© 41041-0
z Press out the piston and connection rod.

they should be installed.
Note order of cylinders.
z Remove con rod bearing shells (1).
1
© 41043-1
Removing the piston

z Remove locking ring with locking ring pliers.
z Press out piston pin.
z Remove connection rod.
© 41044-1
© 01/2008 2/6 16359-001

D 2009 Drive system
TD 2009 W 02-09-03
z Remove piston rings with universal piston ring pliers.
6
© 41045-0
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.
from faults.
© 41047-1
Installing the piston and con rod

z Insert bearing shell in the con rod.
groove (2).
z Insert bearing shell in the respective big end bearing
cap.
Note the assignment of the bearing shells. 2
The anti-rotation lock must lock in groove.
?
1
© 41048-1
© 01/2008 3/6 16359-001

Drive system D 2009
W 02-09-03 TD 2009
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. 120°
120°
z Lightly oil cylinder running surface, piston, piston
rings and lifting bearing journal lightly.
z Clamp piston rings with piston ring compressor.
6 0°
© 41046-0
z Set lifting journal at bottom dead centre (BDC).

z Push piston and con rod completely into cylinder.
Attention!
Numeric identification faces the camshaft
side.
z Place piston ring clamping band flat on the crank-
case.
z Push piston and con rod completely into cylinder.
Attention!
Do not jam the con rod with the crankshaft.
UT
© 41049-0

Attention!
xxx
Renew screws every time they are loo-

1
sened.
xxx
Note assignment and installation position:

The identification numbers (1) on the con-
necting rod and the big end bearing cover
must be identical and opposite to each
other when assembled.
z Tighten new screws with rotation angle disc. UT
20 Nm + 45°
© 41068-1
© 01/2008 4/6 16359-001

D 2009 Drive system
TD 2009 W 02-09-03
z Insert oil dipstick.

z Install oil suction pipe.
W 08-04-06
W 01-04-04
6
© 41040-0
© 01/2008 5/6 16359-001

Drive system D 2009
W 02-09-03 TD 2009
Technical Data
rod
© 01/2008 6/6 16359-001

D 2009 Drive system
TD 2009 W 02-09-07
Checking the piston

Special tools: When the piston wear limit is reached, the
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 piston must be renewed.
Checking the piston bolt bore

W 02-09-03
© 41044-1

"0".
© 34768-2
© 01/2008 1/4 16360-001

Drive system D 2009
W 02-09-07 TD 2009
Diagram for measuring the piston bolt bore

at the points "a" and "b" in the
levels "1" and "2".
6
© 37239-1
z Insert internal measuring device in the piston bolt

bore.
points.
+0.008
28 +0.003 mm
© 43483-0
Checking the piston diameter

z Measure piston diameter with micrometer gauge.
© 43427-0
© 01/2008 2/4 16360-001

D 2009 Drive system
TD 2009 W 02-09-07
– D 2009
– Measuring point 1
+0.167
89,400 +0.153 mm
+0.008 3
89,400 −0.008 mm
−0.175
2
89,400 −0.145 mm
Measuring point height - see Technical
Data.
1
6
© 41154-0
– TD 2009
89,825 +0.152
+0.138 mm
89,825 +0.009
−0.009 mm
3
2
89,825 −0.220
−0.190 mm
Measuring point height - see Technical

Data.
1
z Assemble con rod and piston.
W 02-09-03
© 41154-0
© 01/2008 3/4 16360-001

Drive system D 2009
W 02-09-07 TD 2009
Technical Data
D 2009
+0.153 mm

−0.008 mm

−0.145 mm
TD 2009
+0.138 mm
−0.009 mm

−0.190 mm
6 D / TD 2009
+0.008
P02 78 Piston pin bore 28 +0.003 mm
© 01/2008 4/4 16360-001

D 2009 Drive system
TD 2009 W 02-10-03
Checking the piston rings and piston ring grooves

– Feeler gauges
Special tools:
– Universal piston ring pliers . . . . . 130300
Checking the piston rings and piston ring

grooves
W 02-09-03
Attention!
Do not overstretch the piston ring!
z Only set the universal piston ring pliers to the maxi-

mum necessary diameter.
z Remove piston rings with universal piston ring pliers.
© 44263-1
z Clean piston.
z Visually inspect piston.
z Visually inspect piston ring grooves.
© 44264-1
© 01/2008 1/4 16361-001

Drive system D 2009
W 02-10-03 TD 2009
Checking the piston ring joint clearance

z Insert the piston ring (1) in the cylinder.
z Align the piston ring in the cylinder by pushing the
piston.
1
6
© 41388-0
z Measure the piston ring joint clearance with a feeler

gauge.
– 1. piston ring
0,15 +0.20
+0 mm
– 2. piston ring = taper-faced ring
0,15 +0.25
+0 mm
– 3. piston ring = bevelland-edge oil control ring
0,30 +0.25
+0 mm
When the wear limit is reached, the piston
ring must be renewed.
© 41386-1
z Mount the piston rings with the marking "TOP" facing

the combustion chamber.
Order and position of the piston rings as
seen from the piston base: 1
z (1):
2
– 1. piston ring
z (2):
3
– 2. piston ring = taper-faced ring
z (3):
– 3. piston ring = bevelland-edge oil control ring
© 41154-1
© 01/2008 2/4 16361-001

D 2009 Drive system
TD 2009 W 02-10-03
z Install piston rings with universal piston ring pliers.

Set spring joint of the bevelland-edge oil
control ring 180° to the ring joint.
6
© 44268-0
Checking the piston ring axial clearance

Check with new piston rings.
z Check axial backlash with feeler gauge between pis-

ton ring and piston ring groove.
– 1. piston ring
0.11 - 0.15 mm
– 2. piston ring
0.045 - 0.090 mm
– 3. piston ring
0.045 - 0.090 mm
When the piston wear limit is reached, the
piston must be renewed. © 44269-0
z Assemble con rod and piston.

W 02-09-03
© 41047-0
© 01/2008 3/4 16361-001

Drive system D 2009
W 02-10-03 TD 2009
Technical Data
+0.20
+0.25
+0.25
© 01/2008 4/4 16361-001

D 2009 Crankcase
TD 2009 W 03-03-01
Checking the cylinder

– Depth-measuring The crankshaft bearing covers must be
appliance mounted properly for measuring the cylin-
Special tools: ders.
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Checking the cylinders

W 02-09-03
z Check cylinder for visible signs of wear.
© 41029-3

"0".
© 36094-1
© 01/2008 1/4 16362-001

Crankcase D 2009
W 03-03-01 TD 2009
Diagram for measuring the cylinder run-

ning surface at the points "a" and "b" in the
levels "1" - "3".
a b
1
a b
2
a b
3
6
© 39100-1
z Insert internal measuring device in cylinder.

+0.025
90 +0 mm
points.

W 02-09-03
© 41416-0
© 01/2008 2/4 16362-001

D 2009 Crankcase
TD 2009 W 03-03-01
Technical Data
+0.025
P03 31 Cylinder, diameter, inside Standard 90 +0 mm
© 01/2008 3/4 16362-001

Crankcase D 2009
W 03-03-01 TD 2009
© 01/2008 4/4 16362-001

D 2009 Crankcase
TD 2009 W 03-09-04
Removing and installing the connection housing

Commercial available tools – W 12-06-01
– W 13-03-02
Removing the connection housing

z Remove starter.
W 13-03-02
z Remove flywheel.
W 12-06-01
1
2
© 41070-0

z Remove connection housing.
© 41071-0
© 01/2008 1/4 16363-001

Crankcase D 2009
W 03-09-04 TD 2009
Installing the connection housing

z Mount connection housing.
81 Nm
6
© 41072-0
z Install flywheel.
W 12-06-01
z Install starter.
W 13-03-02
2
1
© 41073-0
© 01/2008 2/4 16363-001

D 2009 Crankcase
TD 2009 W 03-09-04
Technical Data
A03 080 Connection housing to crankcase M12x25-12.9 Locking screw 81 Nm
© 01/2008 3/4 16363-001

Crankcase D 2009
W 03-09-04 TD 2009
© 01/2008 4/4 16363-001

D 2009 Crankcase
TD 2009 W 03-11-01
Removing and installing, testing camshaft bearing

– Counter support . . . . . . . . . . . . . . . 8200
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Internal extractor. . . . . . . . . . . . . 143500
– Assembly tool . . . . . . . . . . . . . . . 143890
– Cable tie
Testing camshaft bearing

z Remove camshaft.
W 04-05-05
"0".
© 34768-2
Diagram for measuring the camshaft bea-

ring at the points "a and b" in the
levels "1 and 2".
© 37239-1
© 01/2008 1/8 16364-001

Crankcase D 2009
W 03-11-01 TD 2009

45.960 - 45.980 mm
When the wear limit is reached, the cams-
haft bearing must be replaced.
6
© 41373-0
Removing camshaft bearing

z Insert internal extractor (1).
z Splay and centre the internal extractor.
z Splay the internal extractor to the stop.
z Screw spindle (2) to internal extractor.
z Mount counter holder (3). 2
z Position holder.
1
3
© 41382-0
z Hold spindle (1).

z Tighten nut (2).
z Remove bearing halves (3).
1
2
© 41383-0
© 01/2008 2/8 16364-001

D 2009 Crankcase
TD 2009 W 03-11-01

"0".
6
© 34768-2
Diagram for measuring the camshaft bea-

ring at the points "a and b" in the
levels "1 and 2".
© 37239-1

50.060 - 50.095 mm
When the wear limit is reached, the crank-
case must be exchanged.
© 41374-0
© 01/2008 3/8 16364-001

Crankcase D 2009
W 03-11-01 TD 2009
Installing camshaft bearing

z Tighten pin bolts (1).
6 1
© 41376-0
z Place bearing halves (1) on pressure piece (2).

z Fix bearing halves (1) with cable tie (3).
1 2
© 41377-0
z Mount pressure piece (1).

z Position bearing halves (2).
© 41378-0
© 01/2008 4/8 16364-001

D 2009 Crankcase
TD 2009 W 03-11-01
z Tighten knurled nuts (1).
1 6
© 41379-0
© 41380-0
Attention!
Do not damage the bearing shells.
z Remove cable tie (1).
© 41381-0
© 01/2008 5/8 16364-001

Crankcase D 2009
W 03-11-01 TD 2009
z Unscrew studs (1).

z Install the camshaft.
W 04-05-05
6 1
© 41376-0
© 01/2008 6/8 16364-001

D 2009 Crankcase
TD 2009 W 03-11-01
Technical Data
Camshaft bearing, locating hole, diame-
P03 11 50.060 - 50.095 mm
ter
P03 13 Camshaft bearing, diameter, inside in the installed state 45.960 - 45.980 mm
© 01/2008 7/8 16364-001

Crankcase D 2009
W 03-11-01 TD 2009
© 01/2008 8/8 16364-001

D 2009 Engine control
TD 2009 W 04-04-09
Removing and installing the gearcase cover

– W 08-08-02
– Assembly tool . . . . . . . . . . . . . . . 142790 – W 12-02-02
– Special wrench . . . . . . . . . . . . . . 170050 – W 13-02-03
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.
Removing the gearcase

z Remove coolant pump.
W 09-07-08
z Remove V-belt pulley.
W 12-02-02
z Remove the oil cooler.
W 08-08-02
z Remove generator.
W 13-02-03
© 41051-1
© 41265-0
© 01/2008 1/4 16365-001

Engine control D 2009
W 04-04-09 TD 2009

z Remove spacer (3).
z Remove gearcase cover.
2 3
Attention!
Do not damage the sealing surfaces.
1
6
© 41266-0
Installing the gearcase cover

z Knock out crankshaft sealing ring (1).
Attention!
Do not damage sealing surface when
knocking out. 1
© 41054-1
z Fix the new gasket to the crankcase with a little

grease.
Make sure the clamping bushings (1) are
in place. 1
© 41056-0
© 01/2008 2/4 16365-001

TD 2009 W 04-04-09
z Mount gearcase cover.

from faults.
z Mount spacer (1). 1

z Fasten all screws.
6
© 41266-1
z Tighten the screws according to the tightening se-

quence. 10 17 1 9 16 2 8 15
27 Nm
Note different screw lengths.
18
7
11
14
19
5
12
21
20
13 3 6 4
© 41069-1
z Install crankshaft sealing ring (opposite side to fly-

wheel)
W 02-02-04
z Install generator.
W 13-02-03
z Install oil cooler.
W 08-08-02
z Install V-belt pulley.
W 12-02-02
z Install coolant pump.
W 09-07-08
© 41051-1
© 01/2008 3/4 16365-001

W 04-04-09 TD 2009
Technical Data
M8x35-12.9
A03 020 Gearcase cover on crankcase M8x50-10.9 27 Nm
M8x70-8.8
© 01/2008 4/4 16365-001

TD 2009 W 04-05-05
Removing and installing the camshaft

– W 04-04-09
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 – W 07-11-01
– Special pliers. . . . . . . . . . . . . . . . 103220
– Fixing pin . . . . . . . . . . . . . . . . . . 144180
Removing the camshaft

W 01-04-04
W 04-04-09
z Remove fuel supply pump.
W 07-11-01
z Remove fuel filter console.
W 07-10-08
© 41082-1
z Set piston (1) at top dead centre.

z Fix flywheel with fixing pin (2). 1
© 41075-0
© 01/2008 1/8 16366-001

W 04-05-05 TD 2009
z Pull out hydraulic tappet (1) with special pliers.

6
© 41076-1

z Loosen screw (2).
© 41258-3

z Remove camshaft toothed wheel (2).
© 41031-1
© 01/2008 2/8 16366-001

TD 2009 W 04-05-05
z Remove cylindrical pin (1).
6
© 41261-0

z Remove thrust washer (2). 1
© 41264-0
z Fasten screw (1).

z Pull out the camshaft carefully in the direction of the
arrow.
© 41078-1
© 01/2008 3/8 16366-001

W 04-05-05 TD 2009
Installing the camshaft

z Oil camshaft bearing lightly.
z Oil cam shaft pin lightly.
z Insert the camshaft (1) carefully in the direction of the
arrow.
6
© 41079-0
z Bore (1) faces the lubricating oil pan.

z Mount thrust washer (2).
z Tighten screws (3). 3
21 Nm
3
1
© 41264-2
Checking the axial backlash

z Mount magnetic measuring stand.
z Insert dial gauge.
z Apply stylus to the camshaft end with pre-tension.
© 41160-1
© 01/2008 4/8 16366-001

TD 2009 W 04-05-05

z Read actual value from dial gauge.
– Nominal value:
0.07 - 0.29 mm
The axial backlash is not adjustable.
If the axial backlash is greater than the set-
point, the camshaft must be renewed.
z Remove magnetic measuring stand.
z Remove dial gauge.
6
© 41161-1
z Insert cylindrical pin (1).

z Insert camshaft toothed gear with cylindrical pin (1)
in bore (2).
© 41262-0

wheel and the camshaft toothed wheel
must be in line!
z Fasten screw (2).
2
1
© 41081-1
© 01/2008 5/8 16366-001

W 04-05-05 TD 2009

81 Nm
z Remove blocking tool (1). 2
6
© 41258-3
z Oil the hydro-tappet lightly.

z Insert hydraulic tappet (1) with special pliers.
Note installation position of the hydro tap-
pets.
© 41084-0
z Install the fuel filter console.

W 07-10-08
z Install fuel pump.
W 07-11-01
W 04-04-09
W 01-04-04
© 41082-1
© 01/2008 6/8 16366-001

TD 2009 W 04-05-05
Technical Data
P04 35 Camshaft, axial clearance (not adjustable) 0.07 - 0.29 mm
A04 002 Camshaft, shim on crankshaft M8x16-8.8 Torx screw 21 Nm
© 01/2008 7/8 16366-001

W 04-05-05 TD 2009
© 01/2008 8/8 16366-001

TD 2009 W 04-05-06
Checking the camshaft

– Prisms
Checking the camshaft

z Remove camshaft.
W 04-05-05
z Visually inspect cams and bearing pins for wear.
© 41358-0
Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.
© 36424-2
© 01/2008 1/4 16367-001

W 04-05-06 TD 2009
z Measure bearing pin (1).

45.950 - 45.970 mm
points.
When the limit value is reached the cams-
1
haft must be replaced.
6
© 41358-1
z Measure bearing pin (1).

41.925 - 41.955 mm
points.
When the limit value is reached the cams- 1 1
haft must be replaced.
© 41358-2
z Install the camshaft.

W 04-05-05
© 41358-0
© 01/2008 2/4 16367-001

TD 2009 W 04-05-06
Technical Data
P04 31 Camshaft, bearing pin, diameter 41.925 - 41.955 mm
Camshaft, bearing pin, diameter (drive
P04 31 45.950 - 45.970 mm
side)
© 01/2008 3/4 16367-001

W 04-05-06 TD 2009
© 01/2008 4/4 16367-001

Exhaust system/Charging
TD 2009 W 06-01-05
Removing and installing the exhaust line

Special tools:
– Fitting compound
DEUTZ S1
Removing exhaust line

z Remove gasket.
© 41299-0

z Remove charge air pipe (2).
© 41300-0
© 01/2008 1/8 16368-001

W 06-01-05 TD 2009
z Unscrew lock nut (1).
6
© 41301-0

z Remove gasket.
© 41302-0
© 41303-1
© 01/2008 2/8 16368-001

TD 2009 W 06-01-05

z Remove the compensator pipe (2).
z Remove seals.
6
© 41307-0

z Remove exhaust line (2).
z Remove gasket.
z Remove turbocharger. 1 1
2
W 06-06-04
1 1
© 41305-0
© 41308-0
© 01/2008 3/8 16368-001

W 06-01-05 TD 2009
Installing exhaust line

z Install the turbocharger.
W 06-06-04
6
© 41306-0

z Mount new gasket.
z Mount exhaust line (2).
z Tighten screws (1). 1 1
2
Coat screws with DEUTZ S1 mounting
compound.

27 Nm
Tightening sequence: From the centre out-
wards.
1 1
© 41305-0
z Mount new gaskets.

z Mount compensator pipe (2).
1
1
© 41307-0
© 01/2008 4/8 16368-001

TD 2009 W 06-01-05
z Fasten screw (1).
6
© 41303-1

20 Nm
25 Nm 1
© 41303-3

21 Nm
© 41303-1
© 01/2008 5/8 16368-001

W 06-01-05 TD 2009
z Mount new gasket.

9 Nm
6
© 41302-0
z Tighten lock nut (1).

15 Nm
Attention!
Lay the hose pipe free from chafing and
tension.
© 41301-0
© 41254-0
© 01/2008 6/8 16368-001

TD 2009 W 06-01-05

z Position hose clip (2).
6
© 41300-1

21 Nm
© 41299-0
© 01/2008 7/8 16368-001

W 06-01-05 TD 2009
Technical Data
A06 001 Exhaust pipe at cylinder head M8x55-10.9 27 Nm
Lubricating oil pipe on exhaust turbo-
A08 040 M14x1.5 15 Nm
charger
A08 044 Oil return line to turbocharger M6x16-8.8 9 Nm
A09 021 Pipe, holder to holder M8x16-8.8 21 Nm
© 01/2008 8/8 16368-001

TD 2009 W 06-06-04
Removing and installing the turbocharger

– Fitting compound Collect leaking operating substances in

DEUTZ S1 suitable vessels and dispose of according
to regulations.
Emptying and filling the engine with opera-
ting media must be carried out according to
the operating manual and the appropriate
documentation of the vehicle/equipment
manufacturer.
Removing exhaust manifold

z Remove the exhaust pipe.
W 06-01-05 1
z Remove exhaust manifold (2).
2
3
1
© 41309-0
Removing turbocharger
z Remove turbocharger (2).
z Remove gasket.
2
© 41310-0
© 01/2008 1/4 16369-001

W 06-06-04 TD 2009

z Pull off hose pieces (2). 2
1
6
© 41311-0
© 41312-0
Installing the turbocharger

2
z Push on hose pieces (2).
Ensure that the installation location is free 1
from faults.
z Position hose clips (1). 2

z Fasten hose clips with hose clip pliers.
© 41311-0
© 01/2008 2/4 16369-001

TD 2009 W 06-06-04

z Mount gasket (1).
6
© 41314-0
z Mount turbocharger (2).

z Tighten all screws (1).
41 Nm
compound.
2
© 41310-0
Installing exhaust manifold

z Mount gasket (3). 1
z Mount exhaust manifold (2).
41 Nm
compound.
z Install the exhaust pipe.

W 06-01-05 2
3
1
© 41309-0
© 01/2008 3/4 16369-001

W 06-06-04 TD 2009
Technical Data
Insert with Deutz S1
A06 010 Exhaust manifold to turbocharger M8x25-10.9 41 Nm
mounting compound.
M10x20-10.9 Insert with Deutz S1
A06 020 Turbocharger on exhaust pipe 41 Nm
M8x16-8.8 mounting compound.
© 01/2008 4/4 16369-001

D 2009 W 06-07-03
Removing and installing the intake manifold

Commercial available tools Danger!
Special tools: Wait 30 seconds after switching off the
– Special wrench . . . . . . . . . . . . . . 110520 engine before working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
– Fitting compound Ensure utmost cleanliness when working
DEUTZ S1 on the fuel system.
Carefully clean the area around the affec-
ted parts. Blow damp areas dry with com-
pressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps. 6
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
Removing the intake manifold

z Unscrew lock nuts (1) with special wrench. 1 1 1
© 41404-0
© 01/2008 1/6 16370-001

W 06-07-03 D 2009

z Remove pipe clamp (2).
z Remove all injection pipes.
1 2
6
© 41405-0

z Remove intake manifold (3).
z Remove gasket (4). 5
1
z Unscrew fuel line (5).
3
2
© 41088-0
© 41089-0
© 01/2008 2/6 16370-001

D 2009 W 06-07-03
Install intake manifold

z Screw on fuel pipe (5).
z Coat the screws (2) with fitting compound.
z Mount gasket (4). 5
1
z Mount intake manifold (3).
27 Nm
wards.
z Tighten pipe clip (1). 4
3 6
2
© 41090-1
z Mount high pressure pipes.

z Screw on union nuts.
Attention!
Install injection pipes without tension!
z Mount pipe clamp (2). 1 2

z Fasten screw (1).
© 41405-0
z Tighten union nuts (1) with special wrench.

28 Nm 1 1 1
© 41404-0
© 01/2008 3/6 16370-001

W 06-07-03 D 2009

9 Nm
from faults.
6
© 41405-1
© 01/2008 4/6 16370-001

D 2009 W 06-07-03
Technical Data
Air suction intake pipe on cylinder Observe tightening
A06 030 M8x70 27 Nm
head sequence.
A07 003 M12x1.5 28 Nm
pump
© 01/2008 5/6 16370-001

W 06-07-03 D 2009
© 01/2008 6/6 16370-001

TD 2009 W 06-07-03
Removing and install the charge air line

– W 07-04-01
Special tools:
Attention!
– Fitting compound Ensure utmost cleanliness when working
DEUTZ S1 on the fuel system.
pressed air.
opening with new, clean plugs/caps.
6
lations.
Remove charge air line

z Remove fuel injector.
W 07-04-01
z Remove the exhaust gas return valve.
W 06-09-06
z Remove gasket.
© 41315-0
© 01/2008 1/6 16371-001

W 06-07-03 TD 2009

6
© 41300-0
© 41316-0

1 1
2
1 1 1
© 41317-0
© 01/2008 2/6 16371-001

TD 2009 W 06-07-03

1
6
© 41318-0
Install charge air line

z Mount gasket (1).
© 41318-0
z Mount charge air line (1).

27 Nm
2 1 2
wards.
2 2 2
© 41317-1
© 01/2008 3/6 16371-001

W 06-07-03 TD 2009

27 Nm
Attention!
Install fuel pipe tension free.
6
© 41316-0
© 41254-0

© 41300-1
© 01/2008 4/6 16371-001

TD 2009 W 06-07-03

21 Nm
z Install the exhaust gas return valve
W 06-09-06
z Install the fuel injector.
W 07-04-01
6
© 41315-0
© 01/2008 5/6 16371-001

W 06-07-03 TD 2009
Technical Data
Observe tightening
A06 030 Charge air pipe on cylinder head M8x45-10.9 27 Nm
sequence.
A07 044 Fuel lines on crankcase, pipe clip M8x12-10.9 27 Nm
© 01/2008 6/6 16371-001

TD 2009 W 06-09-04

Commercial available tools Collect leaking operating substances in
8190

to regulations.
manufacturer.
Removing the cooler

z Pull off hose pipes (2).
2
2
1
1
© 41417-0

z Unscrew screw (2). 1
z Remove cooler (3).
1
2
© 41418-0
© 01/2008 1/6 16372-001

W 06-09-04 TD 2009

z Remove gaskets (2).
1 1
2 2
6
© 41419-0

© 41420-0
Installing the cooler

z Mount gasket (1).
z Mount the exhaust gas return pipe (2).
z Fasten screws (3).
2
© 41421-0
© 01/2008 2/6 16372-001

TD 2009 W 06-09-04
z Mount gasket (1).

6
© 41422-0
z Mount new gaskets (1).
© 41423-0

3
Mount pipe without tension and touching
flat.
z Fasten screws (3). 3

1
4 4
© 41424-1
© 01/2008 3/6 16372-001

W 06-09-04 TD 2009

20 Nm
1
20 Nm 2
25 Nm
25 Nm
4 3
6
© 41425-0

21 Nm
1
27 Nm 2
2
1
4 3
© 41425-1
z Push on hose pipes (1).

z Position hose clips (2).
z Tighten hose clips (2).
1
1
2
2
© 41417-1
© 01/2008 4/6 16372-001

TD 2009 W 06-09-04
Technical Data
A01 092 Transport bracket on cylinder head M8x16 21 Nm
A06 070 M8x20-8.8 20 Nm
return valve
© 01/2008 5/6 16372-001

W 06-09-04 TD 2009
© 01/2008 6/6 16372-001

TD 2009 W 06-09-06
Removing and installing the exhaust gas return valve

Commercial available tools
Removing the exhaust gas return valve

z Disconnect cable connections.
z Loosen screw (1).
z Remove gasket.
1
© 41267-0

z Remove exhaust gas return pipe (2).
z Remove gasket.
2
1
© 41268-0
© 01/2008 1/6 16373-001

W 06-09-06 TD 2009

z Remove exhaust gas return valve (2).
z Remove gasket.
1
6
© 41269-0
Installing the exhaust gas return valve

z Mount gasket (1).
z Mount exhaust gas return valve (2). 3 1
© 41269-2
z Mount gasket (1).

2
3
© 41268-3
© 01/2008 2/6 16373-001

TD 2009 W 06-09-06
z Mount new gasket.

6
© 41267-1

20 Nm
© 41268-1

25 Nm
© 41267-1
© 01/2008 3/6 16373-001

W 06-09-06 TD 2009

20 Nm
1
6
© 41268-2

27 Nm
z Connect cable.
© 41267-2
© 01/2008 4/6 16373-001

TD 2009 W 06-09-06
Technical Data
A06 070 M8x20-8.8 20 Nm
return valve
© 01/2008 5/6 16373-001

W 06-09-06 TD 2009
© 01/2008 6/6 16373-001

D 2009 Fuel system
TD 2009 W 07-04-01
Removing and installing the fuel injector pump

Commercial available tools: Attention!
– Extraction tool . . . . . . . . . . . . . . . . . 8310 Ensure utmost cleanliness when working
– Special bit . . . . . . . . . . . . . . . . . . . . 9123 on the fuel system.
Special tools: Carefully clean the area around the affec-
– Special pliers. . . . . . . . . . . . . . . . 110120 ted parts. Blow damp areas dry with com-
– Measuring pin . . . . . . . . . . . . . . . 110180 pressed air.
– Special wrench . . . . . . . . . . . . . . 110520 Observe the safety regulations and natio-
– Disassembly tool. . . . . . . . . . . . . 110901 nal specifications for handling fuels.
– Fixing pin . . . . . . . . . . . . . . . . . . 144180 Close all connections immediately after
– Counter support . . . . . . . . . . . . . 144190 opening with new, clean plugs/caps.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Do not remove plugs/caps until immedia-
vessels and dispose of according to regu- 6
lations.
Removing the fuel injector pump

z Unscrew lock nuts (1) with special wrench.
1 1
© 41271-0

Note assignment and installation position
of the injection lines.
2
1 1
© 41272-0
© 01/2008 1/12 16374-001

Fuel system D 2009
W 07-04-01 TD 2009
z Disconnect cables.
z Unscrew union nuts (1).
1
1
6
© 41273-0
z Pull off hose pipe (1).

© 41274-0
z Unscrew screw (1) with special bit.

2
2
1
© 41275-0
© 01/2008 2/12 16374-001

D 2009 Fuel system
TD 2009 W 07-04-01
z Remove cap (1).

z Remove O-ring.
1
6
© 41276-0
z Turn crankshaft.
Attention!
The marks (1) of the fuel injector toothed
wheels and the idler gear must be in line.
The marks of the crankshaft toothed wheel,
intermediate gear and fuel injector toothed
wheel must be in line!
© 41277-0
The bore in the fuel injector toothed wheel

must be in line with the bore in the crank-
case.
z Push the measuring pin (1) through the marking hole 1
into the crankcase.
© 41279-0
© 01/2008 3/12 16374-001

Fuel system D 2009
W 07-04-01 TD 2009
z Loosen blocking screw (1).

z Push locking ring (2) towards larger opening. 2
The blocking screw can now be screwed in
further.
z Tighten blocking screw (1). 1

The fuel injector shaft is blocked.
Attention!
Pay attention to perfect fit of the blocking
screw and the locking ring.
z Remove measuring pin.
6
© 41095-0
z Mount holder (1) on V-belt pulley.

Attention! 1
Do not turn crankshaft.
© 41278-0
z Unscrew nut (1).

z Remove washer (2).
© 41280-0
© 01/2008 4/12 16374-001

D 2009 Fuel system
TD 2009 W 07-04-01
z Mount the extraction tool (1).

z Pull off the fuel injector pump toothed gear with the
extraction tool (1).
6
© 41281-0

z Remove fuel injector pump(2).
© 41145-0

© 41284-0
© 01/2008 5/12 16374-001

Fuel system D 2009
W 07-04-01 TD 2009
Installing the fuel injector pump

6
© 41364-0
z Mount fuel injector pump (2).

27 Nm
Attention!
The blocking screw may not be loosened.
2
© 41146-0
z Push fuel injector toothed wheel (4) onto fuel injector

shaft.
4 3
Attention!
The marks of the fuel injector toothed
wheels and the idler gear must be in line.
z Push the measuring pin (3) through the marking hole
into the crankcase.
z Mount washer (2).
z Tighten nut (1). 2 1
10 Nm
© 41147-0
© 01/2008 6/12 16374-001

D 2009 Fuel system
TD 2009 W 07-04-01
z Loosen blocking screw (1).

z Push locking ring (2) towards smaller opening.
Attention! 1
Loosening the blocking screw releases the
blocking of the fuel injector shaft.
Never start the engine with the fuel injector 2
shaft blocked!
z Tighten blocking screw (1).
10 Nm
6
© 41143-0
z Remove measuring pin.

z Tighten nut (1).
81 Nm
© 41280-1
z Remove holder (1).

1
© 41278-0
© 01/2008 7/12 16374-001

Fuel system D 2009
W 07-04-01 TD 2009
z Pull new round sealing ring onto cap.

z Mount cover (2).
z Tighten all screws (1). 1
1
27 Nm
1
6
© 41275-1

27 Nm
1
© 41275-2
z Mount the hose pipe (2).

© 41274-0
© 01/2008 8/12 16374-001

D 2009 Fuel system
TD 2009 W 07-04-01
Attention!
Install fuel pipes tension free!
z Screw on union nuts (1).

z Tighten lock nuts (1).
9 Nm
1
1
6
© 41273-0
Attention!

of the injection lines. 2

z Mount pipe clamp (2).
1 1
© 41272-0

28 Nm
1 1
© 41271-0
© 01/2008 9/12 16374-001

Fuel system D 2009
W 07-04-01 TD 2009

9 Nm
from faults.
1 1
6
© 41272-1
© 01/2008 10/12 16374-001

D 2009 Fuel system
TD 2009 W 07-04-01
Technical Data
A04 004 Stage 1: 10 Nm
tion pump
A04 004 Stage 2: 81 Nm
tion pump
M8x70-8.8
A04 022 Cap on gearcase cover Torx screw 27 Nm
M8x20-8.8
A07 003 M12x1.5 28 Nm
pump
A07 012 Injection pump on crankcase M8x30-10.9 27 Nm
A07 013 Blocking screw on injection pump 10 Nm
6
A07 015 Fuel line on injection pump 1/2’’ 9 Nm
© 01/2008 11/12 16374-001

Fuel system D 2009
W 07-04-01 TD 2009
© 01/2008 12/12 16374-001

D 2009 Fuel system
TD 2009 W 07-04-14
Setting the injection pump

Commercial available tools: – Service Bulletin
– 0168-17-9476
Attention!
The service for the injection pumps made
by DELPHI may only be performed by part-
ners authorised by DEUTZ AG and/or
DELPHI partners.
© 01/2008 1/2 16375-001

Fuel system D 2009
W 07-04-14 TD 2009
© 01/2008 2/2 16375-001

Fuel system
D 2009 W 07-07-01

Commercial available tools: Danger!
– Assembly pliers. . . . . . . . . . . . . . . . 8024 Wait 30 seconds after switching off the
Special tools: engine before working on the fuel system.
– Puller. . . . . . . . . . . . . . . . . . . . . . 110090
– Special pliers. . . . . . . . . . . . . . . . 110120 Attention!
– Special wrench . . . . . . . . . . . . . . 110520 Ensure utmost cleanliness when working
– Extraction tool . . . . . . . . . . . . . . . 120680 on the fuel system.
– Slide hammer . . . . . . . . . . . . . . . 150800 Carefully clean the area around the affec-
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 ted parts. Blow damp areas dry with com-
pressed air.
– Fitting compound Observe the safety regulations and natio-
DEUTZ AP1908 nal specifications for handling fuels.
lations.
The following work procedure describes

the removal and installation of a fuel injec-
tor.
Proceed the same to remove another fuel
injector.
Removing the fuel injectors

z Unscrew lock nuts (1) with special wrench. 1 1 1
© 41404-0
© 01/2008 1/8 16376-001

Fuel system
W 07-07-01 D 2009

1 2
6
© 41405-0
z Pull leak fuel lines (1) off the fuel injectors with spe-
cial pliers.
1 1
© 41406-0
z Unscrew fuel injector (1).

Attention! 1
Do not damage the sealing surfaces.
z Remove sealing ring (2). 2
© 41407-0
© 01/2008 2/8 16376-001

Fuel system
D 2009 W 07-07-01
Attention!
Do not damage the nozzle tip of the injec-
tor valve when removing the sealing
ring (1).
z Grip a tight sealing ring (1) with the assembly
pliers (2) and pull off, turning slightly.
z Visually inspect sealing surface.
6
© 41408-0
Removing a tightly fixed sealing ring from

the cylinder head
z Insert extraction device (1).
The holders (arrow) must sit in the bore of
the sealing ring.
© 41409-0
z Turn in the spindle (1) until the sealing ring is fixed to

the extraction device.
Hold extraction device against the flats.
© 41410-0
© 01/2008 3/8 16376-001

Fuel system
W 07-07-01 D 2009
z Mount adapter (1) and slide hammer (2) on extrac-

tion device.
2
z Remove tight sealing ring.
6
© 41411-0
Installing the fuel injector

z Mount new sealing ring (1) on fuel injector.
© 41412-0
z Screw on fuel injector (1).

z Tighten fuel injector.
1
68 Nm
© 41407-1
© 01/2008 4/8 16376-001

Fuel system
D 2009 W 07-07-01
z Plug leak fuel lines (1) to the fuel injectors.
1 1
6
© 41406-0

Attention!
z Mount pipe clamp (2). 1 2

z Fasten screw (1).
© 41405-0

28 Nm 1 1 1
© 41404-0
© 01/2008 5/8 16376-001

Fuel system
W 07-07-01 D 2009

9 Nm
from faults.
6
© 41405-1
© 01/2008 6/8 16376-001

Fuel system
D 2009 W 07-07-01
Technical Data
A07 001 Fuel injector on cylinder head M22 68 Nm
A07 003 M12x1.5 28 Nm
pump
© 01/2008 7/8 16376-001

Fuel system
W 07-07-01 D 2009
© 01/2008 8/8 16376-001

Fuel system
TD 2009 W 07-07-01

Commercial available tools: Danger!
– Assembly pliers. . . . . . . . . . . . . . . . 8024 Wait 30 seconds after switching off the
Special tools: engine before working on the fuel system.
– Puller. . . . . . . . . . . . . . . . . . . . . . 110090
– Special pliers. . . . . . . . . . . . . . . . 110120 Attention!
– Special wrench . . . . . . . . . . . . . . 110520 Ensure utmost cleanliness when working
– Disassembly tool. . . . . . . . . . . . . 110901 on the fuel system.
– Extraction tool . . . . . . . . . . . . . . . 120690 Carefully clean the area around the affec-
– Slide hammer . . . . . . . . . . . . . . . 150800 ted parts. Blow damp areas dry with com-
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 pressed air.
– Fitting compound nal specifications for handling fuels.
DEUTZ AP1908 Close all connections immediately after
lations.
The following work procedure describes

the removal and installation of a fuel injec-
tor.
Proceed the same to remove another fuel
injector.
Removing the fuel injectors

z Unscrew lock nuts (1) with special wrench.
1 1
© 41271-0
© 01/2008 1/8 16377-001

Fuel system
W 07-07-01 TD 2009

2
1 1
6
© 41272-0
z Pull leak fuel lines off the fuel injectors with special
pliers.
© 41285-0

z Remove clamping shoe (2). 1
2
z Pull out fuel injector (3).
Attention!
Do not damage the sealing surfaces. 3
Up to two sealing rings per fuel injector
may be installed depending on the version.
z Remove sealing ring (4). 4
z Visually inspect sealing surface.
© 41097-0
© 01/2008 2/8 16377-001

Fuel system
TD 2009 W 07-07-01
Removing stuck fuel injectors

z Assembly sliding hammer (1) and puller (2).
z Tighten lock nut (3).
3
6
© 41360-0
z Mount sliding hammer on fuel injector.

z Screw on lock nut (1).
z Pull out stuck fuel injector.
© 41286-0
Attention!
Do not damage the nozzle tip of the injec-
tor valve when removing the sealing
ring (1).
z Grip a tight sealing ring (1) with the assembly
pliers (2) and pull off, turning slightly.
© 46846-0
© 01/2008 3/8 16377-001

Fuel system
W 07-07-01 TD 2009
6
© 00000-0
Removing a tightly fixed sealing ring from

the cylinder head
z Insert extraction device (1).
The holders (arrow) must sit in the bore of
the sealing ring.
© 41354-0
z Turn in the spindle (1) until the sealing ring is fixed to

the extraction device.
Hold extraction device against the flats.
© 41366-0
© 01/2008 4/8 16377-001

Fuel system
TD 2009 W 07-07-01
z Mount adapter (1) and slide hammer (2) on extrac-

tion device.
z Remove tight sealing ring.
6
© 41367-0
Installing the fuel injector

z Mount new O-ring (1).
z Coat the O-ring with fitting compound.
© 41368-0
z Mount new sealing ring (1) on fuel injector.

Attention!
Up to two sealing rings per fuel injector 1
may be installed depending on the version.
See spare parts documentation.
© 41098-1
© 01/2008 5/8 16377-001

Fuel system
W 07-07-01 TD 2009
z Insert fuel injector (3).

1
The leak fuel connection faces the exhaust
2
pipe.
z Mount clamping shoe (2).

3
Note installation position of the clamping
shoe.

35 Nm
6
© 41097-1
z Plug hose pipes (1) to the fuel injectors.
1 1
© 41289-0

Attention!
2
z Mount pipe clamp (2).
1 1
© 41272-0
© 01/2008 6/8 16377-001

Fuel system
TD 2009 W 07-07-01

28 Nm
1 1
1 6
© 41271-0

9 Nm
from faults.
1 1
© 41272-1
© 01/2008 7/8 16377-001

Fuel system
W 07-07-01 TD 2009
Technical Data
A07 003 M12x1.5 28 Nm
pump
© 01/2008 8/8 16377-001

D 2009 Fuel system
TD 2009 W 07-10-08
Removing and installing the fuel filter console

Commercial available tools – User notes
– Operation manual
Special tools:
– Special wrench . . . . . . . . . . . . . . 170050
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
Attention!
Ensure utmost cleanliness when working
on the fuel system.
pressed air.
6
lations.
Removing the fuel filter console

z Loosen water drainage screw (1).
Collect draining water and dispose of pro-
perly.
z Unscrew fuel filter (2) with special wrench.

Collect draining fuel and dispose of accor-
ding to regulations.
2
© 41346-0
© 01/2008 1/4 16378-001

Fuel system D 2009
W 07-10-08 TD 2009
z Unscrew hollow screw (1).

z Remove sealing rings.
z Unscrew fuel pipes (2).
1
z Pull off fuel return line.
6
© 41361-0

z Remove fuel filter console (2).
2
© 41347-0
Installing the fuel filter console

z Install the fuel filter console (2).
41 Nm 1
2
© 41347-0
© 01/2008 2/4 16378-001

D 2009 Fuel system
TD 2009 W 07-10-08
z Mount fuel pipes.

z Tighten hollow screw (1) with new sealing rings.
21 Nm
1
z Tighten union nuts (2).
9 Nm
z Mount fuel return line.
Check fuel lines and renew if necessary.
2
of the fuel lines.
2
6
© 41361-0
z Lightly oil gasket on new fuel filter.

z Screw on fuel filter by hand.
The seal must fit evenly.
z Tighten the fuel filter by another half turn (tightening

torque see fuel filter print).
© 41346-1
© 01/2008 3/4 16378-001

Fuel system D 2009
W 07-10-08 TD 2009
Technical Data
A07 019 1/2’’ 9 Nm
fuel filter console
A07 084 Fuel line to fuel filter console M10x1.5 Hollow screw 21 Nm
A07 087 Fuel filter console to crankcase M10x25-10.9 41 Nm
© 01/2008 4/4 16378-001

D 2009 Fuel system
TD 2009 W 07-11-01
Removing and installing the fuel supply pump

Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Danger!
Attention!
Ensure utmost cleanliness when working
on the fuel system.
pressed air.
6
lations.
Removing the fuel supply pump

Danger!
z Unscrew union nuts (1).
1
z Remove fuel pipe.
© 41342-0
© 01/2008 1/4 16379-001

Fuel system D 2009
W 07-11-01 TD 2009

z Remove fuel supply pump (2).
z Remove adapter (3).
z Remove pump tappet.
2
1 1
3
6
© 41343-0
© 41344-0
Installing the fuel supply pump

© 41344-1
© 01/2008 2/4 16379-001

D 2009 Fuel system
TD 2009 W 07-11-01
6
© 41345-0
z Turn crankshaft.
z Install pump tappet.
The pump plunger must touch the base
circle of the camshaft.
z Mount adapter (3). 2

1 1
z Mount fuel supply pump (2).
z Tighten all screws (1).
27 Nm
3
© 41343-0
z Mount fuel pipe.

z Tighten lock nuts (1).
9 Nm
Bleed the fuel system via the manual fuel
pump on the fuel pre-filter according to the
operation manual. 1
© 41342-0
© 01/2008 3/4 16379-001

Fuel system D 2009
W 07-11-01 TD 2009
Technical Data
A07 019 1/2’’ 9 Nm
fuel filter console
A07 024 Fuel supply pump on crankcase M8x55-10.9 27 Nm
© 01/2008 4/4 16379-001

D 2009 Lube oil system
TD 2009 W 08-04-05
Removing and installing the lubricating oil pump

– W 04-04-09
– W 08-04-06

to regulations.
Removing the lubricating oil pump

W 04-04-09
z Remove intermediate gear wheel.
W 02-04-01
z Remove oil suction pipe
W 08-04-06
© 41106-2

z Remove lubricating oil pump (2).
© 41107-0
© 01/2008 1/4 16380-001

Lube oil system D 2009
W 08-04-05 TD 2009
Installing the lubricating oil pump

z Insert lubricating oil pump (2).

4 Nm + 9 Nm
2
6
© 41107-0
z Install oil suction pipe.

W 08-04-06
z Install intermediate gear wheel.
W 02-04-01
W 04-04-09
© 41106-2
© 01/2008 2/4 16380-001

TD 2009 W 08-04-05
Technical Data
A08 010 Lubricating oil pump on crankcase M6x25-8.8 4 Nm + 9 Nm
© 01/2008 3/4 16380-001

W 08-04-05 TD 2009
© 01/2008 4/4 16380-001

TD 2009 W 08-04-06
Removing and installing the oil suction pipe

Removing the oil suction pipe

z Remove lubricating oil pan.
W 08-04-07
© 41108-0

z Remove oil suction pipe (2).
z Remove O-ring (3).
3
1
2
© 41109-0
© 01/2008 1/4 16381-001

W 08-04-06 TD 2009
Installing the oil suction pipe

z Lightly oil O-ring (3).
z Mount oil suction pipe (2).
41 Nm
3
1
6 2
© 41109-0
z Install lubricating oil pan.

W 08-04-07
© 41108-0
© 01/2008 2/4 16381-001

TD 2009 W 08-04-06
Technical Data
A08 016 Oil suction pipe, holder on crankcase M10x80-8.8 41 Nm
© 01/2008 3/4 16381-001

W 08-04-06 TD 2009
© 01/2008 4/4 16381-001

TD 2009 W 08-04-07
Removing and installing the lubricating oil pan

Commercial available tools – Operation manual

to regulations.
Observe the appropriate operating instruc-
tions for emptying and filling the engine.
Removing the lubricating oil pan

z Unscrew locking screws (1).
Collect lubricating oil and dispose of accor-
z Insert new sealing ring.

z Tighten locking screws (1).
39 Nm
1 1
© 41110-1

z Remove strips (2). 2
z Remove strips (3).
z Remove lubricating oil pan. 3
z Remove gasket.
© 41111-1
© 01/2008 1/4 16382-001

W 08-04-07 TD 2009
Installing the lubricating oil pan

z Grease lubricating oil pan (arrows). 1
z Mount new gasket.
z Mount lubricating oil pan.
Attention!
Do not move the gasket when mounting
the lubricating oil pan.
z Mount strips (1).
z Tighten screws (arrows).
z Fasten all screws.
6
© 41112-1

quence.
8 7 6 5 4 17 18 19
32 Nm
Representation: 4-cylinder engine
9 20
26 21
25 22
24 23
12 16
11 10 1 2 3 13 14 15
© 41259-0
z Fill in lubricating oil according to operating manual.
max.
min.
© 41142-0
© 01/2008 2/4 16382-001

TD 2009 W 08-04-07
Technical Data
Observe tightening
A03 030 Lubricating oil pan on crankcase M8x20-8.8 32 Nm
sequence.
Use new Cu sealing
A03 031 Locking screw on lubricating oil pan M14x14 39 Nm
ring.
© 01/2008 3/4 16382-001

W 08-04-07 TD 2009
© 01/2008 4/4 16382-001

TD 2009 W 08-08-02
Removing and installing the lubricating oil cooler

Commercial available tools – Operation manual
Special tools:
– Special wrench . . . . . . . . . . . . . . 170050
to regulations.
manufacturer.
Removing the lubricating oil cooler

z Remove lubricating oil filter (1) with special
wrench 170050.
z Drain lubricating oil, collect and dispose of according
to regulations.
© 41291-0

z Drain, collect and dispose of coolant according to
regulations.
1 2
© 41290-0
© 01/2008 1/6 16383-001

W 08-08-02 TD 2009

z Remove lubricating oil cooler (2).
2
6
© 41292-0
© 41293-0
Removing the adapter

z Remove adapter (1).
© 41295-0
© 01/2008 2/6 16383-001

TD 2009 W 08-08-02
6
© 41296-0
Installing the adapter

© 41297-0
z Mount sealing ring (2).

z Fit new sealing rings (1).
1 1
© 41298-0
© 01/2008 3/6 16383-001

W 08-08-02 TD 2009
z Mount adapter (1).

z Tighten hollow screw (2).
41 Nm
6 1
© 41295-0
Installing the lubricating oil cooler

© 41294-0
z Mount lubricating oil cooler (2).

z Tighten hollow screw (1).
41 Nm
© 41292-0
© 01/2008 4/6 16383-001

TD 2009 W 08-08-02

1 2
6
© 41290-0
z Position hose clips (1).

z Fasten hose clips with hose clip pliers.
© 41291-1
z Lightly oil sealing ring on new oil filter cartridge.

z Screw on lubricating oil filter (1) by hand.
Hand tighten
© 41291-2
© 01/2008 5/6 16383-001

W 08-08-02 TD 2009
Technical Data
Lubricating oil filter on lubricating oil Oil gasket lightly.
A08 001 M14x1.5 Hand tighten
cooler See operating manual
A08 003 Adapter on gearcase cover 3/4“ 41 Nm
A08 051 Lubricating oil cooler on adapter M22x1.5 41 Nm
© 01/2008 6/6 16383-001

TD 2009 W 08-11-08
Removing and installing the oil pressure switch

Special tools:
– Long socket wrench insert . . . . . 110700
Pay attention to utmost cleanliness when
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
working on the lube oil system.
pressed air.
nal specifications for handling lube oils.
Do not remove plugs/caps until immedia- 6
Removing the oil pressure switch

z Unscrew oil pressure switch (1).
Collect lubricating oil and dispose of accor-
© 41340-0
© 41341-0
© 01/2008 1/4 16384-001

W 08-11-08 TD 2009
Installing the oil pressure switch

z Clean components.
6
© 41341-0
z Tighten the oil pressure switch (1) with the socket

wrench insert.
– M10x1
20 Nm
– M12x1.5 / M14x1.5
50 Nm
z Connect cable.
Ensure that the connection is perfect.
z Fill in lubricating oil according to operating manual. 1
© 41340-0
© 01/2008 2/4 16384-001

TD 2009 W 08-11-08
Technical Data
A08 091 Oil pressure switch in crankcase M10x1 20 Nm
M12x1
A08 091 Oil pressure switch in crankcase 50 Nm
M14x1.5
© 01/2008 3/4 16384-001

W 08-11-08 TD 2009
© 01/2008 4/4 16384-001

TD 2009 W 08-11-10
Removing and installing the oil pressure regulating valve


to regulations.
Removing the oil pressure regulating

valve
W 04-04-09
© 41115-0
z Unscrew oil pressure regulating valve.

© 41116-0
© 01/2008 1/4 16385-001

W 08-11-10 TD 2009
Installing the oil pressure regulating valve

z Insert oil pressure regulating valve.
z Tighten oil pressure control valve.
21 Nm
6
© 41116-0

W 04-04-09
© 41115-0
© 01/2008 2/4 16385-001

TD 2009 W 08-11-10
Technical Data
A08 098 3/8“ 21 Nm
case
© 01/2008 3/4 16385-001

W 08-11-10 TD 2009
© 01/2008 4/4 16385-001

D 2009 Cooling system
TD 2009 W 09-07-08
Removing and installing the coolant pump

– W 13-02-03

to regulations.
The appropriate documentation of the
vehicle/equipment manufacturer should be
observed for emptying and filling the coo-
ling system.
Removing coolant pump

z Drain, collect and dispose of coolant according to
regulations.
z Loosen screws (1).
1
© 41332-0

z Hold nut (2). 1
z Press generator in direction of arrow.
z Remove V-belt. 1
1
© 41323-0
© 01/2008 1/6 16386-001

Cooling system D 2009
W 09-07-08 TD 2009

z Remove V-belt pulley (2).
1
6
© 41333-0

Collect and dispose of coolant according to
regulations.
© 41334-0

Collect and dispose of coolant according to
regulations.
z Remove coolant pump (1).

z Remove gasket.
© 41335-0
© 01/2008 2/6 16386-001

TD 2009 W 09-07-08
6
© 41336-0
Installing coolant pump

z Mount gasket (1).
© 41337-0
z Mount coolant pump (1).

z Fasten all screws (2).
Note different screw lengths.
© 41335-0
© 01/2008 3/6 16386-001

W 09-07-08 TD 2009

quence. 2
27 Nm
Tightening order:
screw (1), then screw (2), then the other
screws in any order.
6 1
© 41335-3

z Fix the hose clip with the hose clip pliers.
© 41334-0
z Mount V-belt pulley (2).

z Mount V-belt.
© 41333-0
© 01/2008 4/6 16386-001

TD 2009 W 09-07-08

V-belt is clamped. 1
4
21 Nm
z Hold nut (2).
21 Nm
21 Nm
2
6
3
© 41323-1

9 Nm
z Check V-belt tension.
W 13-02-03 1
z Fill cooling system according to the operating manu-
al.
© 41332-0
© 01/2008 5/6 16386-001

W 09-07-08 TD 2009
Technical Data
M8x70-8.8 Observe tightening
A09 010 Coolant pump on gearcase cover 27 Nm
M8x30-10.9 sequence.
A12 046 V-belt pulley on coolant pump M6x10-8.8 9 Nm
© 01/2008 6/6 16386-001

TD 2009 W 09-08-01
Checking the thermostat (in the removed state)

– Thermometer
Danger!
Risk of injury!
Hot water and hot thermostat.
Checking thermostat
z Remove thermostat.
W 09-08-02
© 41120-0
z Measure beginning of stroke, dimension (a).

z Note measured value, dimension (a).
a
© 41121-0
© 01/2008 1/4 16387-001

W 09-08-01 TD 2009
z Heat up the thermostat in the water bath.

In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the ther-
mostat.
The water should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place
faster than 1°C/min. Otherwise the begin-
ning of opening will be delayed accordin-
gly.
z Determine beginning of opening.
86 - 90 °C
6
© 41123-0
z Measure end of stroke, dimension (b).

z Note measured value, dimension (b).
© 41122-0
z Determine stroke.
Calculation example
Desired: Stroke
Given: -
Measured: Beginning of stroke, dimension (a)
(a) = 31.2 mm
End of stroke, dimension (b)
(b) = 40.2 mm
Calculation: Dimension (b) - dimension (a)
40.2 mm - 31.2 mm
Result: = stroke
b
= 9 mm
z Compare result with setpoint value.
– Nominal value stroke travel:
at least 9 mm
© 41122-0
© 01/2008 2/4 16387-001

TD 2009 W 09-08-01
z Install thermostat.
W 09-08-02
6
© 41120-0
© 01/2008 3/4 16387-001

W 09-08-01 TD 2009
Technical Data
P09 11 Thermostat, start of opening 86 - 90 °C
P09 13 Thermostat, stroke distance at least 9 mm
© 01/2008 4/4 16387-001

TD 2009 W 09-08-02
Removing and installing the thermostat


to regulations.
The appropriate documentation of the
vehicle/equipment manufacturer should be
observed for emptying and filling the coo-
ling system.
Removing the thermostat

z Remove gasket.
© 41267-0

z Remove exhaust gas return pipe (2).
z Remove gasket.
2
1
© 41268-0
© 01/2008 1/6 16388-001

W 09-08-02 TD 2009

6
© 41326-1

z Remove outlet nozzle (2).
© 41327-0
z Remove sealing ring (1).

z Remove thermostat (2).
z Check thermostat.
W 09-08-01
© 41328-0
© 01/2008 2/6 16388-001

TD 2009 W 09-08-02
Installing the thermostat

1
6
© 41329-0
z Insert thermostat (1).
© 41330-0
z Mount outlet nozzle (2).

z Fasten screw (1).
© 41327-0
© 01/2008 3/6 16388-001

W 09-08-02 TD 2009

z Tighten hose clip (2).
1
6
© 41326-1
z Mount new gasket.

2
1
© 41268-0
z Mount new gasket.

z Fasten screw (1).
© 41267-0
© 01/2008 4/6 16388-001

TD 2009 W 09-08-02

20 Nm
6
© 41268-1

25 Nm
27 Nm
© 41267-0

27 Nm
© 41331-0
© 01/2008 5/6 16388-001

W 09-08-02 TD 2009
Technical Data
A06 070 M8x20-8.8 20 Nm
return valve
© 01/2008 6/6 16388-001

TD 2009 W 09-12-01
Removing and installing temperature transmitter

Commercial available tools Collect leaking operating substances in
to regulations.
manufacturer.
Removing temperaure transmitter

z Unscrew temperature transmitter (1).
© 41338-0
© 41339-0
© 01/2008 1/4 16389-001

W 09-12-01 TD 2009
Installing temperature transmitter

z Clean components.
z Insert gasket (1) with packing compound.
6
© 41339-1
z Tighten temperature transmitter (1).

4 Nm
z Connect cable.
Ensure that the connection is perfect.
© 41338-0
© 01/2008 2/4 16389-001

TD 2009 W 09-12-01
Technical Data
Temperature transmitter on cylinder Insert gasket with
A09 031 4 Nm
head packing compound.
© 01/2008 3/4 16389-001

W 09-12-01 TD 2009
© 01/2008 4/4 16389-001

D 2009 Other components
TD 2009 W 12-02-02
Removing and installing the V-belt pulley

– V-belt tension measuring
device . . . . . . . . . . . . . . . . . . . . . . . 8115
Special tools: Attention!
– Blocking tool . . . . . . . . . . . . . . . . 144210 Only test / tighten / renew V-belts when the
engine is not running.
The V-belt tension of new V-belts must be

checked after they have been running for
15 minutes.
Removing the V-belt, V-belt pulley

z Loosen screws (1). 1
z Hold nut (2).
1
z Remove V-belt.
1
© 41323-0
z Insert blocking tool (1).

© 41352-0
© 01/2008 1/4 16390-001

Other components D 2009
W 12-02-02 TD 2009

z Remove V-belt pulley (2).
1
6
© 41325-0
Installing the V-belt, V-belt pulley

z Mount V-belt pulley (2).
300 Nm
© 41325-0

z Mount V-belt.
z Check V-belt tension.
W 12-02-02
© 41352-0
© 01/2008 2/4 16390-001

TD 2009 W 12-02-02
Technical Data
A12 031 V-belt pulley on crankshaft M20x55-10.9 300 Nm
© 01/2008 3/4 16390-001

W 12-02-02 TD 2009
© 01/2008 4/4 16390-001

TD 2009 W 12-06-01
Removing and installing the flywheel

Special tools:
– Blocking tool . . . . . . . . . . . . . . . . 144210
Removing the flywheel

© 41352-0
© 41362-0
© 01/2008 1/4 16391-001

W 12-06-01 TD 2009

z Remove flywheel.
6
© 41352-0
Installing the flywheel

z Mount flywheel.
z Turn in new screws (1).
© 41362-0

© 41352-0
© 01/2008 2/4 16391-001

TD 2009 W 12-06-01
See graphic for tightening sequence.

3 1 6
z Tighten all screws.
96 Nm
5 2 4
6
© 41181-1

© 41352-0
© 01/2008 3/4 16391-001

W 12-06-01 TD 2009
Technical Data
A12 001 Flywheel on crankshaft M12x50-10.9 Use new screws. 96 Nm
© 01/2008 4/4 16391-001

D 2009 Electrical system
TD 2009 W 13-02-03
Removing and installing the generator

(V-belt drive)
Commercial available tools: – Operation manual
– V-belt tension measuring
device . . . . . . . . . . . . . . . . . . . . . . . 8115
Attention!
Only test / tighten / renew V-belts when the
engine is not running.
The V-belt tension of new V-belts must be

checked after they have been running for
15 minutes.
Removing the generator

z Disconnect the battery.
z Remove cable from generator.
© 41135-1

z Hold nut (2). 1
z Remove V-belt. 1
1
© 41323-0
© 01/2008 1/6 16392-001

Electrical system D 2009
W 13-02-03 TD 2009

z Hold nut (2).
z Remove generator.
1
2
6
1
© 41535-0
© 41324-0
Installing the generator

z Mount generator.
1
z Hold nut (2).
z Mount V-belt.
1
© 41535-0
© 01/2008 2/6 16392-001

TD 2009 W 13-02-03

V-belt is clamped. 1
4
21 Nm
z Hold nut (2).
21 Nm
21 Nm
2
6
3
© 41323-1
z Remove cable from generator.

z Connect the battery.
© 41135-1
Check V-belt tension with V-belt tension

measuring device
z Lower indicator arm (1) into V-belt tension measuring
device.
1
z Mount V-belt tension measuring device on V-belt.
© 41129-0
© 01/2008 3/6 16392-001

W 13-02-03 TD 2009
z Press the V-belt measuring device against the V-belt

with the button (1) until you hear it click.
z Read measured value at the intersection (arrow) of
the indicator arm and scale.
– First assembly:
450 N
– Check after running for 15 minutes under load:
+20
300 −20 N
Note different units on the scale.
z If the nominal value is not reached, the tensioning

process must be repeated. 1
6
© 41130-0
© 01/2008 4/6 16392-001

TD 2009 W 13-02-03
Technical Data
P12 11 V-belt tension First assembly 450 N
Check after 15 minutes running
P12 21 V-belt tension
under load. 300 +20
−20 N
6
© 01/2008 5/6 16392-001

W 13-02-03 TD 2009
© 01/2008 6/6 16392-001

TD 2009 W 13-03-02
Removing and installing the starter

Removing the starter

z Disconnect the battery's negative terminal.
z Disconnect cables.
z Remove starter.
z Visually inspect the component. 1
© 41138-1
Installing the starter

z Insert starter.
41 Nm
z Connect cables.
9 Nm 1
Note the assignment of the terminal desi-
gnations.
z Connect the battery's negative terminal.
© 41139-2
© 01/2008 1/2 16393-001

W 13-03-02 TD 2009
Technical Data
A13 001 Starter on connection housing M10x45-8.8 41 Nm
A13 071 Cable (terminal 30) to starter M8 9 Nm
© 01/2008 2/2 16393-001

TD 2009 W 13-06-01
Removing and installing the glow plugs

Removing the glow plugs

z Disconnect the battery.
z Unscrew nuts (1).
z Remove connecting rail (2).
1 1
© 41319-0
z Unscrew charge air pressure switch (1).
© 41320-0
© 01/2008 1/4 16394-001

W 13-06-01 TD 2009
z Unscrew glow plugs (1).
6
© 41321-0
© 41322-0
Installing the glow plugs

z Tighten glow plugs (1).
15 Nm
1
© 41321-0
© 01/2008 2/4 16394-001

TD 2009 W 13-06-01
z Tighten charge air pressure switch (1).

20 Nm
6
© 41320-0
z Mount the connecting rail (2).

z Tighten nuts (1).
2.5 Nm
z Connect the battery.
1 1
© 41319-0
© 01/2008 3/4 16394-001

W 13-06-01 TD 2009
Technical Data
A13 033 Connecting rail to glow plug M4 Locking nut 2.5 Nm
Charge air pressure switch in charge
A13 046 M10 20 Nm
air line
© 01/2008 4/4 16394-001

D 2009
TD 2009 Standard tools
7 Standard tools
© 01/2008 1/6 16395-001

D 2009
Standard tools TD 2009
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bäcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Tel.: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com
© 01/2008 2/6 16395-001

D 2009
8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
© 35410-3
7
8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe
© 39426-1
8024
Assembly pliers
Removing valve shaft seals
© 37509-2
© 01/2008 3/6 16395-001

D 2009
8115
V-belt tension measuring device
150 to 600 N
Check V-belt tension
© 35416-3
7
8189
Torx tool set
Contents of case:
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
© 39432-1
8190
Rotation angle disc
with solenoid
© 42528-1
© 01/2008 4/6 16395-001

D 2009
8198
Pricker
Removing rotary shaft lip seal
© 43206-1
7
8200
Counter support
Removing the camshaft bearing
© 41162-1
9017
Assembly lever
e. g. removing and installing valves
© 37511-2
© 01/2008 5/6 16395-001

D 2009
9123
Special bit
25 mm long
for safety screw on injection pump toothed gear cap
© 39435-1
© 01/2008 6/6 16395-001

D 2009
TD 2009 Special tools
8 Special tools
© 01/2008 1/14 16396-001

D 2009
Special tools TD 2009
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bäcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Tel.: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com
© 01/2008 2/14 16396-001

D 2009
100170
Connector
(in conjunction with compression pressure tester 8005)
(in conjunction with clamping claw 100210)
© 39400-1
100210
Clamping claw 8
(in conjunction with adapter 100170)
© 41363-0
100220
Connector
(in conjunction with compression pressure tester 8005)
© 40400-0
© 01/2008 3/14 16396-001

D 2009
100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
© 35424-1
100750
8 Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection
© 39402-2
103220
Special pliers
for removing the roller tappet
© 43175-0
© 01/2008 4/14 16396-001

D 2009
110090
Puller
(in connection with sliding hammer 150800)
Removing fuel injector
© 35433-2
110120
Special pliers 8
Disassembly/assembly for leak fuel pipes
© 41369-0
110180
Measuring pin
Positioning the fuel injector pump toothed wheel
© 41171-0
© 01/2008 5/14 16396-001

D 2009
110520
Special wrench
Wrench size 16 mm,
Removing and installing injection pipes
© 35436-0
110540
8 Extraction tool
Pull off injection pump toothed gear
© 41190-0
110700
Socket wrench insert
long version
© 43198-2
© 01/2008 6/14 16396-001

D 2009
110901
Disassembly tool
Removing and installing the O-rings
© 45950-1
120690
Puller 8
(in connection with sliding hammer 150800)
© 45111-0
120900
Support bracket
pivoting
Clamping cylinder head
© 35438-3
© 01/2008 7/14 16396-001

D 2009
120910
Base plate
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)
© 35439-3
121420
8 Assembly sleeves
Set of assembly sleeves for valve shaft seal
© 43210-0
121430
Assembly tool
Mounting valve shaft seal
© 37614-2
© 01/2008 8/14 16396-001

D 2009
130300
Universal piston ring pliers
Removing and installing the piston rings
© 43021-0
130510
Piston ring compressor 8
Piston diameter 90 mm
© 39408-1
142780
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
© 41168-0
© 01/2008 9/14 16396-001

D 2009
142790
Assembly tool
Installing crankshaft sealing ring
© 41169-0
143500
8 Internal extractor
Removing the camshaft bearing
(in conjunction with holder 8200)
© 41169-0
143860
Disassembly/assembly tool.
Removing and installing main bearing
Crankcase
© 41164-1
© 01/2008 10/14 16396-001

D 2009
143870
Disassembly/assembly tool.
Removing and installing main bearing
Main bearing housing
© 41165-1
143890
Assembly tool 8
Installing the camshaft bearing
© 41166-2
144180
Fixing pin
Fixing the flywheel
© 41163-0
© 01/2008 11/14 16396-001

D 2009
144190
Counter support
Hold crankshaft on the V-belt pulley.
© 41370-0
144200
8 Blocking tool
Blocking gear drive
© 41188-0
144240
Blocking tool
Blocking flywheel
© 41371-0
© 01/2008 12/14 16396-001

D 2009
150800
Slide hammer
© 35449-2
170050
Special wrench 8
Unscrewing the filter cartridges
© 37629-2
170160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
© 43663-0
© 01/2008 13/14 16396-001

D 2009
6067
Assembly block
Engine clamping, one-sided
© 35451-2
6067 200
8 Clamping bracket
consisting of:
1 clamping holder 6067 201 left,
1 clamping holder 6067 202 right
(in conjunction with assembly block 6067)
Engine clamping, one-sided
© 41187-0
6068
Engine lifting device
Load (2000 kg), 3-point suspension, spindle clamp,
cross member, chains and hooks
© 43184-0
© 01/2008 14/14 16396-001

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5 Job card overview

© 01/2008 1/2 16338-001

© 01/2008 2/2 16338-001

© 01/2008 1/4 16339-001

© 01/2008 2/4 16339-001

© 01/2008 3/4 16339-001

© 01/2008 4/4 16339-001

© 01/2008 1/4 16340-001

© 01/2008 2/4 16340-001

DEUTZ engines are the product of years of re-

Maintenance and care are the only way the engine

Please consult one of our service representatives

© 01/2008 3/4 16340-001

© 01/2008 4/4 16340-001

© 01/2008 1/6 16341-001

© 01/2008 2/6 16341-001

3.1 General 3.2 Specifications

© 01/2008 3/6 16341-001

© 01/2008 4/6 16341-001

3.4 Job cards 3.4.2 Structure of a job card

3.4.1 Numbering of job cards 8

© 01/2008 5/6 16341-001

3.5 Explanation of symbols

© 01/2008 6/6 16341-001

© 01/2008 1/8 16342-001

ID no. Name Additional information Value

© 01/2008 2/8 16342-001

ID no. Name Additional information Value

P02 72 Piston, diameter, standard Measuring point 2 = height 44 mm 89,400 +0.008

P02 73 Piston, diameter, standard Measuring point 3 = height 65 mm 89,400 −0.175

P02 73 Piston, diameter, standard Measuring point 3 = height 66 mm 89,825 −0.220

© 01/2008 3/8 16342-001

© 01/2008 4/8 16342-001

4.2 Tightening specifications

© 01/2008 5/8 16342-001

ID no. Name Screw type Notes / Remark Value

© 01/2008 6/8 16342-001

ID no. Name Screw type Notes / Remark Value

© 01/2008 7/8 16342-001

© 01/2008 8/8 16342-001

© 01/2008 1/8 16343-001

© 01/2008 2/8 16343-001

Activity Job card Maintenance group

© 01/2008 3/8 16343-001

Activity Job card Maintenance group

© 01/2008 4/8 16343-001

© 01/2008 5/8 16343-001

© 01/2008 6/8 16343-001

Job card Activity Maintenance group

© 01/2008 7/8 16343-001

Job card Activity Maintenance group

© 01/2008 8/8 16343-001

© 01/2008 1/2 16344-001

© 01/2008 2/2 16344-001

Checking the compression pressure

Checking the compression pressure