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Workshop Manual

competence level 2

D 2011 w

TD 2011 w, TCD 2011 w

0312 4176 en

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.

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Summary of Contents for Deutz TD 2011 w

Page 1
Workshop Manual competence level 2 D 2011 w TD 2011 w, TCD 2011 w 0312 4176 en 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…
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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 Sales & Service Information Systems Ottostraße 1 D-51149 Köln (Cologne) Phone.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 Internet: www.deutz.com…
Page 3: Table Of Contents

DEUTZ engines Table of contents Foreword General User notes General Specifications Operating manual and workshop manual Job cards Explanation of symbols Technical data Testing and setting data Tightening specifications Job card overview Sorted alphabetically Sorted numerically Job cards Commercial tools Special tools ©…
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Table of contents DEUTZ engines © 06/2008 17761-001…
Page 5: Foreword

DEUTZ engines Foreword Foreword © 05/2005 17762-001…
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Foreword DEUTZ engines © 05/2005 17762-001…
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(use for the intended purpose). Any use above and beyond this is con- The engines made by DEUTZ are developed for sidered improper use. The manufacturer will not a wide range of applications. A wide range of var- be liable for damages resulting from this.
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Foreword DEUTZ engines © 05/2005 17762-001…
Page 9: General

DEUTZ engines General General © 11/2005 17763-001…
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General DEUTZ engines © 11/2005 17763-001…
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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 and low fuel consumption.
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General DEUTZ engines © 11/2005 17763-001…
Page 13: User Notes

DEUTZ engines User notes User notes © 06/2008 17764-001…
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User notes DEUTZ engines © 06/2008 17764-001…
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DEUTZ engines User notes 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.
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Rail System Working materials and tools must be cleaned be- fore work. Only use tools without damage to the The DEUTZ Common Rail system used in the chrome plating or tools which are not chrome- DEUTZ engines consists of high-precision compo- plated.
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DEUTZ engines User notes When removing and installing components, no operating materials among other things. The re- materials which can leave behind particles or fi- newed parts / operating materials must be stored, bres (cardboard, wood, cloths) may be used.
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User notes DEUTZ engines 3.3 Operation manual and workshop 3.4 Job cards manual The job cards are divided in the workshop manual into «W» and «I» job cards. To structure the information to suit the user, the The «W» job card documents standard repairs on the service documentation is divided into operation engine and/or its components.
Page 19: Explanation Of Symbols

Test and Setting Va- 8. Graphic or photo lues table. For example: 9. DEUTZ internal creation number ID no. P01 61 = valve clearance, inlet 10.Page number Tightening specification 11.Date of issue of job card The necessary values are specified here.
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User notes DEUTZ engines © 06/2008 17764-001…
Page 21: Technical Data

D 2011 w Technical data TD 2011 w, TCD 2011 w Testing and setting data Technical data Testing and setting data © 12/2008 19484-001…
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Check after 15 minutes running P12 21 V-belt tension, individual V-belts AVX 10 −20 under load D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head Identification, cylinder head gas- P02 75 Piston overhang 9.820 — 10.140 mm…
Page 23: Tightening Specifications

D 2011 w Technical data TD 2011 w, TCD 2011 w Tightening specifications Tightening specifications © 12/2008 19484-001…
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TD 2011 w, TCD 2011 w ID no. Name Screw type Notes / Remark Value D 2011 w / TD 2011 w / TCD 2011 w A00 001 Clamping bracket on crankcase 90 Nm Clamping bracket on adapter for A00 002 90 Nm…
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D 2011 w Technical data TD 2011 w, TCD 2011 w Tightening specifications ID no. Name Screw type Notes / Remark Value M8x35-10.9 A09 010 Coolant pump on thermostat housing 20 Nm M8x100-10.9 A09 020 Pipe clip on holder M6x16…
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8 Nm (exhaust gas return) 30IPR A07 087 Fuel filter console to crankcase 21 Nm TD 2011 w / TCD 2011 w A06 004 Pin bolts on exhaust pipe coated Use new pin bolts 12 Nm A06 020 Turbocharger on exhaust pipe…
Page 27: Job Card Overview

D 2011 w TD 2011 w, TCD 2011 w Job card overview Job card overview Sorted alphabetically 1/12 © 12/2008 19488-001…
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Job card overview D 2011 w Sorted alphabetically TD 2011w, TCD 2011 w 2/12 © 12/2008 19488-001…
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D 2011 w Job card overview TD 2011w, TCD 2011 w Sorted alphabetically Activity Job card Maintenance group Checking piston overhang W 01-04-09 Cylinder head Checking the compression pressure W 00-02-06 General Checking the thermostat (in the removed state) W 09-08-01 Cooling system Disassembling, assembling and checking the rocker arm and rocker arm…
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Job card overview D 2011 w Sorted alphabetically TD 2011w, TCD 2011 w Activity Job card Maintenance group Removing and installing the oil filter console W 08-11-07 Lube oil system Removing and installing the oil pressure switch W 08-11-08 Lube oil system Removing and installing the rocker arm and rocker W 01-02-02 Cylinder head…
Page 31: Sorted Numerically

D 2011 w Job card overview TD 2011 w, TCD 2011 w Sorted numerically Sorted numerically 5/12 © 12/2008 19488-001…
Page 32: Job Cards

Job card overview D 2011 w Sorted numerically TD 2011 w, TCD 2011 w 6/12 © 12/2008 19488-001…
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D 2011 w Job card overview TD 2011 w, TCD 2011 w Sorted numerically Job card Activity Maintenance group W 00-02-06 Checking the compression pressure General Mounting engine on assembly block and demoun- W 00-05-01 General ting W 01-01-01 Setting valve clearance…
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Job card overview D 2011 w Sorted numerically TD 2011 w, TCD 2011 w Job card Activity Maintenance group 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 09-08-04…
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DEUTZ engines Job cards Job cards © 11/2005 17767-001…
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Job cards DEUTZ engines © 11/2005 17767-001…
Page 37: Special Tools

D 2011 w General TD 2011 w, TCD 2011 w W 00-02-06 Checking the compression pressure Commercial available tools: – W 01-01-01 – Compression pressure – W 07-07-01 tester……8005…
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General D 2011 w W 00-02-06 TD 2011 w, TCD 2011 w Mount clamping shoe (1). Tighten screw (2). 21 Nm © 47535-0 Connect adapter (1) to connector. © 47536-0 Mount the compression tester on the adapter. Turn over engine with starter.
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D 2011 w General TD 2011 w, TCD 2011 w W 00-02-06 The measured compression pressure depends on the starting speed during the measuring process and the altitude of the Kompression in bar engine installation site. Therefore, limit Compression value in bar values cannot be determined exactly.
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General D 2011 w W 00-02-06 TD 2011 w, TCD 2011 w Unscrew screw (1). © 47535-1 Remove connector (1). Remove sealing ring. Install fuel injectors. W 07-07-01 © 47534-1 © 12/2008 17768-001…
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D 2011 w General TD 2011 w, TCD 2011 w W 00-02-06 Technical Data Testing and setting data ID no. Name Additional information Value 25 — 30 bar P00 51 Compression pressure (2500 — 3000 kPa) Tightening specifications ID no.
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General D 2011 w W 00-02-06 TD 2011 w, TCD 2011 w © 12/2008 17768-001…
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D 2011 w General TD 2011w, TCD 2011 w W 00-05-01 Mounting engine on assembly block and demounting Commercial available tools: – W 13-03-02 – Lifting gear – Suspension ropes – Eyelet bolts Danger! Special tools: When using hoists (workshop crane) the –…
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D 2011 w W 00-05-01 TD 2011w, TCD 2011 w Unscrew screws (1). Remove all mounting feet. – TD 2011 w, TCD 2011 w Unscrew screw (2). Remove holder (3). Remove oil return pipe (4). © 47532-3 Mount clamping holder (1).
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D 2011 w General TD 2011w, TCD 2011 w W 00-05-01 Unhook the engine from the workshop crane. Unscrew eyelet bolts (1). © 47538-0 Demounting engine from assembly block Screw in eyelet bolts (1). Hang engine on workshop crane. approx. 268 kg ©…
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Mount oil return pipe (1). Attention! Install tension-free. Mount holder (2). Tighten screw (3). 8.5 Nm – D 2011 w, TD 2011 w, TCD 2011 w Install all mounting feet. Tighten screws (4). 200 Nm © 47532-4 © 12/2008 17769-001…
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D 2011 w General TD 2011w, TCD 2011 w W 00-05-01 Danger! Put the engine down on a secure surface. Unhook the engine from the workshop crane. Unscrew eyelet bolts (1). Install starter. W 13-03-02 © 47538-0 © 12/2008 17769-001…
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M14x55-12.9 A00 003 200 Nm crankcase M14x100-12.9 TD 2011 w, TCD 2011 w Torx, A08 049 Holder oil return line on crankcase 8.5 Nm M6x14-8.8 For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 49: Setting Valve Clearance

D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-01-01 Setting valve clearance Commercial available tools: Attention! – Feeler gauges In case of internal exhaust gas recircula- tion, the inlet valve is opened briefly by an additional cam on the camshaft.
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Cylinder head D 2011 w W 01-01-01 TD 2011 w, TCD 2011 w Arrangement of the inlet and exhaust val- ves. IN = inlet valve EX = exhaust valve Valve overlap means: The inlet valve starts opening,exhaust valve closes. Attention!
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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-01-01 Check the valve clearance with feeler gauge (1). © 47543-1 Hold adjusting screw (2). Tighten lock nut (1). 20 Nm Do not turn the setting screw when tighte- ning the locking nut.
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Cylinder head D 2011 w W 01-01-01 TD 2011 w, TCD 2011 w Valve clearance setting schematic According to the order given below, the setting of the valve clearance is possible in two turns of the crankshaft (each 360°). Crankshaft position 1 Turn over crankshaft until the valve overlap is achieved on cylinder 1.
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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-01-01 Mount cylinder head cover. Oil the screws lightly. Tighten all screws (1) alternately. 8.5 Nm © 47540-1 © 12/2008 17770-001…
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Cylinder head D 2011 w W 01-01-01 TD 2011 w, TCD 2011 w Technical Data Testing and setting data ID no. Name Additional information Value P00 71 Ignition sequence 1-3-4-2 P01 61 Valve clearance (inlet) 0.3 mm P01 62 Valve clearance (outlet) 0.5 mm…
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D 2011 w Cylinder head TD 2011w, TCD 2011 w W 01-02-02 Removing and installing the rocker arm and rocker arm bracket Commercial available tools: – W 01-01-01 – Torx tool set ….8189 Removing the rocker arm and rocker arm bracket Unscrew all screws (1).
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Cylinder head D 2011 w W 01-02-02 TD 2011w, TCD 2011 w Remove push rods (1). Lay out components in the order in which they should be installed. Visually inspect the components. © 47565-0 Installing the rocker arm and rocker arm bracket Insert stop rods (1).
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D 2011 w Cylinder head TD 2011w, TCD 2011 w W 01-02-02 Lightly oil screws (1). Tighten screws . 21 Nm Attention! Makes sure that the stop rods are not under stress due to valve overlap when fastening the screws. Set valve clearance.
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Cylinder head D 2011 w W 01-02-02 TD 2011w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A01 002 Rocker arm bracket on cylinder head 21 Nm A01 004 Cylinder head cover on cylinder head 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-02-06 Disassembling, assembling and checking the rocker arm and rocker arm bracket Commercial available tools: – W 01-02-02 – Internal measuring device – Micrometer gauge – Locking ring pliers Special tools: –…
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Cylinder head D 2011 w W 01-02-06 TD 2011 w, TCD 2011 w Hold adjusting screw (2). Loosen lock nut (1). Unscrew adjusting screw (2). Lay out components in the order in which they should be installed. © 47031-0 Visually inspect the components.
Page 61
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-02-06 Checking the rocker arm 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.
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Cylinder head D 2011 w W 01-02-06 TD 2011 w, TCD 2011 w Assembling the rocker arm bracket Lightly oil the rocker arm pin. Push rocker arm (1) onto rocker arm pin. © 39149-2 Insert new locking rings (1). Ensure that the installation location is free from faults.
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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-02-06 Technical Data Testing and setting data ID no. Name Additional information Value +0.27 P01 72 Rocker arm, bore, diameter (outlet) +0.27 P01 73 Rocker arm, bore, diameter (inlet) +0.01…
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Cylinder head D 2011 w W 01-02-06 TD 2011 w, TCD 2011 w © 12/2008 17772-001…
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– W 06-02-03 … . TD 2011 w, – Dog wrench….8018 TCD 2011 w –…
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Unscrew lock nuts (1) with dog wrench. Remove thermostat housing. W 09-08-04 – D 2011 w Remove the air intake pipe. W 06-07-03 – TD 2011 w, TCD 2011 w Remove the charge air pipe. W 06-02-03 Remove exhaust gas collection pipe. W 06-09-08 © 47550-0 Remove rocker arm and rocker arm bracket.
Page 67
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-04 Installing the cylinder head Measure the piston overhang on all pistons. Select cylinder head gasket according to the largest piston projection measured. Check piston overhang. W 01-04-09 ©…
Page 68
Cylinder head D 2011 w W 01-04-04 TD 2011 w, TCD 2011 w Clean sealing surfaces. The sealing surfaces for the cylinder head gasket must be clean and free of oil. Make sure the clamping bushings (1) are in place.
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Install rocker arm and rocker arm bracket. W 01-02-02 – D 2011 w Install the air intake pipe. W 06-07-03 – TD 2011 w, TCD 2011 w Install the charge air pipe. W 06-02-03 © 47547-0 Install exhaust gas collection pipe.
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Cylinder head D 2011 w W 01-04-04 TD 2011 w, TCD 2011 w Position clamping claws (1). Attention! Install tension-free. Tighten screws (2). 21 Nm © 47551-0 © 12/2008 17773-001…
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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-04 Technical Data Testing and setting data ID no. Name Additional information Value Identification, cylinder head gasket P02 75 Piston overhang 0.325 — 0.604 mm = 1 recess…
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Cylinder head D 2011 w W 01-04-04 TD 2011 w, TCD 2011 w © 12/2008 17773-001…
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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-09 Checking piston overhang Commercial available tools – W 01-04-04 8190 Special tools: – Dial gauge….100400 –…
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Cylinder head D 2011 w W 01-04-09 TD 2011 w, TCD 2011 w – Recess cylinder head Insert dial gauge 100410 in measuring beam. Place holders (1) on the sealing surface of the crank- case. Place measuring beam (2) on the holders.
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D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-09 – Recess cylinder head Move the measuring beam. Apply the stylus to the piston base (arrow) under pre- tension. Continue turning the crankshaft evenly until the re- versal point of the pointer on the dial gauge is reached.
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Cylinder head D 2011 w W 01-04-09 TD 2011 w, TCD 2011 w – Recess cylinder head Select cylinder head gasket according to the largest piston projection measured. – 1 recess 9.820 — 10.140 mm – 2 recesses 10.141 — 10.239 mm –…
Page 77
Identification, cylinder head gasket P02 77 Piston overhang 0.705 — 0.804 mm = 3 recesses D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head Identification, cylinder head gasket P02 75 Piston overhang 9.820 — 10.140 mm…
Page 78
Cylinder head D 2011 w W 01-04-09 TD 2011 w, TCD 2011 w © 12/2008 17774-001…
Page 79
D 2011 w Crankcase TD 2011 w, TCD 2011 w W 03-01-11 Removing and installing the crankcase bleeding Commercial available tools Special tools: – Disassembly tool… . . 110901 Removing the crankcase bleeding Unscrew screw (1).
Page 80
Crankcase D 2011 w W 03-01-11 TD 2011 w, TCD 2011 w Install crankcase bleeding Clean sealing surfaces. Insert new O-ring (1). © 47160-0 Mount crankcase vent (2). Ensure that the installation location is free from faults. The crankcase bleeding must fit evenly.
Page 81
D 2011 w Crankcase TD 2011 w, TCD 2011 w W 03-01-11 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Crankcase bleeding on front cover / A03 060 on cylinder head cover / on cylinder 8.5 Nm…
Page 82
Crankcase D 2011 w W 03-01-11 TD 2011 w, TCD 2011 w © 12/2008 17790-001…
Page 83
W 06-06-04 – Torx tool set ….8189 Removing exhaust line – TD 2011 w, TCD 2011 w Remove turbocharger. W 06-06-04 Unscrew all screws (1).
Page 84
Clean sealing surfaces. Mount exhaust line (1). Mount new gaskets. Note installation position. Turn in new screws (2). Tighten new screws (2). 55 Nm – TD 2011 w, TCD 2011 w Install the turbocharger. W 06-06-04 © 47523-2 © 12/2008 17805-001…
Page 85
D 2011 w Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-01-05 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Torx screw, A06 001 Exhaust pipe at cylinder head Use new screws. 55 Nm…
Page 86
Exhaust system/Charging D 2011 w W 06-01-05 TD 2011 w, TCD 2011 w © 12/2008 17805-001…
Page 87
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-02-03 Removing and install the charge air line Commercial available tools: – W 06-06-04 – Torx tool set ….8189 –…
Page 88
Exhaust system/Charging W 06-02-03 TD 2011 w, TCD 2011 w Install charge air line Mount charge air line (1). Mount new gaskets. Tighten screws (2) alternately working from the cen- tre to the outside. 21 Nm Install the exhaust pipe.
Page 89
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-02-03 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Torx screw, A06 030 Charge air pipe on cylinder head Use new screws. 21 Nm coated For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 90
Exhaust system/Charging W 06-02-03 TD 2011 w, TCD 2011 w © 12/2008 17806-001…
Page 91
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-06-04 Removing and installing the turbocharger Commercial available tools: Attention! – Clamping tongs….9088 Do not remove the stoppers/caps until –…
Page 92
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Loosen spring band clip (1) with spring band pliers. Remove reducer (2). © 47554-0 Unscrew hollow screw (1). Remove lubricating oil pipe (2). Remove sealing rings. Press in stoppers. © 47526-0 Loosen spring band clip (1) with spring band pliers.
Page 93
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-06-04 Unscrew nuts (1). © 47528-0 Remove turbocharger in the direction of the arrow. Remove gasket (1). © 47555-0 Remove the O-ring (1) with the disassembly tool. Unscrew screw-in nipple (2).
Page 94
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Unscrew studs (1). Check components for visible signs of wear. © 47523-0 Installing the turbocharger Mount sealing ring (1). Tighten screw-in nipple (2). 40 Nm Insert new O-ring (3). © 47529-1 Clean sealing surfaces.
Page 95
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-06-04 Mount gasket (1). Plug in the tubing connection (2). Insert turbocharger in the direction of the arrow. © 47555-1 Mount turbocharger (1). Turn on new nuts (2). Tighten nuts (2).
Page 96
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Mount lubrication oil line (1). Mount sealing rings (2). Screw on hollow screw (3). © 47526-1 Insert new O-ring (1). Lightly oil new O-ring (1). © 39378-2 Mount oil return pipe (1).
Page 97
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-06-04 Attention! Install tension-free. Tighten hollow screw (1). 29 Nm © 47526-2 Mount the reducer (1). Attention! Install tension-free. Position spring band clip (2) with spring band pliers. © 47554-1 Position hose clip (1) with clamping tongs.
Page 98
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A06 004 Pin bolts on exhaust pipe coated Use new pin bolts 12 Nm A06 020 Turbocharger on exhaust pipe…
Page 99
Exhaust system/Charging D 2011 w W 06-07-03 Removing and installing the intake manifold Commercial available tools: – W 06-01-05 – Torx tool set ….8189 Removing the intake manifold Remove the exhaust pipe.
Page 100
Exhaust system/Charging W 06-07-03 D 2011 w Installing the intake manifold Mount new gaskets. Mount intake manifold (1). Tighten new screws (2) alternately working from the centre to the outside. 21 Nm Install the exhaust pipe. W 06-01-05 © 47645-1 ©…
Page 101
Exhaust system/Charging D 2011 w W 06-07-03 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Air suction intake pipe on cylinder Torx screw, A06 030 Use new screws. 21 Nm head coated For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 102
Exhaust system/Charging W 06-07-03 D 2011 w © 12/2008 17808-001…
Page 103
Exhaust system/Charging D 2011 w W 06-09-06 Removing and installing the exhaust gas return valve Commercial available tools: – Special bit, 70 mm long..9120 Removing the exhaust gas return valve Unscrew screw (1) with special bit.
Page 104
Exhaust system/Charging W 06-09-06 D 2011 w Unscrew hollow screws (1). Remove pipe (2). Remove sealing rings (3). © 46935-0 Unscrew hollow screw (1). Remove sealing rings (2). Unscrew hollow screw (3). Remove sealing rings (4). Remove pipe (5). © 46938-0 Unscrew screws (1).
Page 105
Exhaust system/Charging D 2011 w W 06-09-06 Remove gasket (1). © 46940-0 Unscrew screws (1). Remove the exhaust gas return valve. © 46941-0 Remove gasket (1). © 46942-0 © 12/2008 17809-001…
Page 106
Exhaust system/Charging W 06-09-06 D 2011 w Visually inspect the components. © 46965-0 Installing the exhaust gas return valve Clean sealing surfaces. Mount gasket (1). Mount exhaust gas return valve (2). © 46943-0 Tighten screws (1). Tighten screws (1). 20 Nm ©…
Page 107
Exhaust system/Charging D 2011 w W 06-09-06 Clean sealing surfaces. Mount gasket (1). Mount exhaust gas collection pipe (2). Fasten screws (3). Tighten screws (3). 20 Nm © 46939-1 Insert pipe (5). Mount new sealing rings (4). Screw on hollow screw (3). Mount sealing rings (2).
Page 108
Exhaust system/Charging W 06-09-06 D 2011 w Press in pipe holder (1). © 46937-0 Plug in the cable plug (3). Mount the safety cover (2). Fasten screw (1). Tighten screw (1) with special bit. 8 Nm © 46964-0 © 12/2008 17809-001…
Page 109
Exhaust system/Charging D 2011 w W 06-09-06 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Pipe to exhaust gas return valve/cylin- Hollow screw A06 057 29 Nm der head (cooling — intake) M12x1.5 Exhaust return pipe to exhaust return A06 062 M8x65-10.9 20 Nm…
Page 110
Exhaust system/Charging W 06-09-06 D 2011 w © 12/2008 17809-001…
Page 111
Exhaust system/Charging D 2011 w W 06-09-07 Removing and installing the exhaust gas return pipe Commercial available tools: – Special bit, 70 mm long..9120 Removing the exhaust gas return pipe Unscrew screw (1).
Page 112
Exhaust system/Charging W 06-09-07 D 2011 w Unscrew hollow screws (1). Remove pipe (2). Remove sealing rings (3). © 46935-0 Unscrew hollow screw (1). Remove sealing rings (2). Unscrew hollow screw (3). Remove sealing rings (4). Remove pipe (5). © 46938-0 Unscrew screws (1).
Page 113
Exhaust system/Charging D 2011 w W 06-09-07 Remove gasket (1). © 46940-0 Unscrew screws (1). Remove the exhaust return pipe. © 46961-0 Remove gasket (1). © 46962-0 © 12/2008 17810-001…
Page 114
Exhaust system/Charging W 06-09-07 D 2011 w Unscrew screws (3). Remove exhaust gas return valve (2). Remove gasket (1). © 46960-0 Visually inspect the components. © 46963-0 Installing the exhaust gas return pipe Clean all sealing surfaces. Mount gasket (1). Mount exhaust gas return valve (2).
Page 115
Exhaust system/Charging D 2011 w W 06-09-07 Clean all sealing surfaces. Mount gasket (1). © 46962-0 Install the exhaust gas return pipe. Tighten screws (1). Tighten screws (1). 8.5 Nm © 46961-0 Clean sealing surfaces. Mount gasket (1). Mount exhaust gas collection pipe (2). Fasten screws (3).
Page 116
Exhaust system/Charging W 06-09-07 D 2011 w Insert pipe (5). Mount new sealing rings (4). Screw on hollow screw (3). Mount sealing rings (2). Tighten hollow screw (1). 29 Nm Tighten hollow screw (3). 12 Nm © 46938-0 Insert pipe (1). Mount sealing rings (2).
Page 117
Exhaust system/Charging D 2011 w W 06-09-07 Plug in the cable plug (3). Mount the safety cover (2). Fasten screw (1). Tighten screw (1). 8 Nm © 46964-0 © 12/2008 17810-001…
Page 118
Exhaust system/Charging W 06-09-07 D 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Pipe to exhaust gas return valve/cylin- Hollow screw A06 057 29 Nm der head (cooling — intake) M12x1.5 Exhaust return pipe to exhaust return A06 062 M8x65-10.9 20 Nm…
Page 119: Exhaust Gas Recirculation

Exhaust system/Charging D 2011 w W 06-09-08 Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation) Commercial available tools: – W 06-01-05 – Cleaning brush ….8167 –…
Page 120
Exhaust system/Charging W 06-09-08 D 2011 w Remove gaskets (1). © 46948-0 Clean exhaust channels (1) with cleaning brush (2). Clean all sealing surfaces. © 46949-0 Install exhaust gas collection pipe Check that mounting lugs (1) are sufficiently pre-ten- sioned. ©…
Page 121
Exhaust system/Charging D 2011 w W 06-09-08 Mount gasket (1). Make sure that the installation site of the mounting lugs (2) is in perfect condition. © 46951-0 Mount new gaskets (3). Mount new throttle (2). Note installation position. The marking (arrow) on the throttle is dependent on the engine version.
Page 122
Exhaust system/Charging W 06-09-08 D 2011 w Tighten new screws (1). 55 Nm Install the exhaust gas return pipe. W 06-09-07 Install the exhaust pipe. W 06-01-05 © 46947-0 © 12/2008 17811-001…
Page 123
Exhaust system/Charging D 2011 w W 06-09-08 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Torx M10x25-10.9 Exhaust gas collection pipe (exhaust Torx A06 073 Use new screws. 55 Nm gas return) on cylinder head M10x30-10.9 Torx M10x45-10.9…
Page 124
Exhaust system/Charging W 06-09-08 D 2011 w © 12/2008 17811-001…
Page 125
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-02-07 Removing and installing the lifting magnet (Start amount release) Commercial available tools: Collect leaking operating substances in – Plier insert….8027 suitable vessels and dispose of according to regulations.
Page 126
Fuel system D 2011 w W 07-02-07 TD 2011 w, TCD 2011 w Remove the O-ring (1) with the disassembly tool. Visually inspect the components. © 47392-0 Install lifting magnet Insert new O-ring (1). © 47392-0 Clean all sealing surfaces.
Page 127
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-02-07 Tighten lifting magnet (1) with plier insert. 10 Nm Note direction of terminal. © 39664-1 Plug in the cable plug (1). © 47128-0 © 12/2008 17814-001…
Page 128
Fuel system D 2011 w W 07-02-07 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Lifting magnet (start amount release) A05 065 10 Nm on front cover For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 129
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-03-01 Renewing the injection lines Commercial available tools: Danger! – Dog wrench….8018…
Page 130
Fuel system D 2011 w W 07-03-01 TD 2011 w, TCD 2011 w Remove injection pipes (1). Lay out components in the order in which they should be installed. Note assignment! © 47652-0 Mount the caps (1). © 47654-0 Visually inspect the components.
Page 131
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-03-01 Installing injection pipes Pull off the caps (1). Mount new injection pipe. © 47654-0 Screw on union nuts (1). Attention! Install injection line without tension. Note installation position.
Page 132
Fuel system D 2011 w W 07-03-01 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Injection line on fuel injector / injection A07 003 M12x1.5 25 Nm pump For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 133
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-07-01 Removing and installing the fuel injectors Commercial available tools: – W 07-03-01 – Assembly pliers….8024 –…
Page 134
Fuel system D 2011 w W 07-07-01 TD 2011 w, TCD 2011 w Unscrew screw (1). Remove clamping shoe (2). © 47562-0 Pull out fuel injector (1) and sealing ring (arrow). Lay out components in the order in which they should be installed.
Page 135
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-07-01 Mount sliding hammer on fuel injector. Screw on lock nut (1). Pull out stuck fuel injector. © 47564-0 Grip a tight sealing ring (1) with the assembly pliers (2) and pull off, turning slightly.
Page 136
Fuel system D 2011 w W 07-07-01 TD 2011 w, TCD 2011 w Installing the fuel injector Mount new sealing ring (1) on fuel injector. © 47351-0 Insert fuel injector. Mount clamping shoe. Note installation position of the clamping shoe.
Page 137
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-07-01 Install injection lines. W 07-03-01 © 47557-0 © 12/2008 19502-001…
Page 138
Fuel system D 2011 w W 07-07-01 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A07 001 Fuel injector on cylinder head 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 139
Fuel system TD 2011 w, TCD 2011 w W 07-08-01 Removing and installing the lifting magnet (charge air pressure-dependent full load stop) Commercial available tools: – Plier insert….8027 Special tools: –…
Page 140
Fuel system W 07-08-01 TD 2011 w, TCD 2011 w Install lifting magnet Mount new O-ring. Insert lifting magnet (1). © 47648-0 Tighten lifting magnet (1) with plier insert. 10 Nm © 47646-0 © 12/2008 17821-001…
Page 141
Fuel system TD 2011 w, TCD 2011 w W 07-08-01 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A06 094 Lifting magnet on fuel filter console Renew O-ring 10 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 142
Fuel system W 07-08-01 TD 2011 w, TCD 2011 w © 12/2008 17821-001…
Page 143
Fuel system TD 2011 w, TCD 2011 w W 07-08-02 Installing and removing charge air pressure-dependent full load stop Commercial available tools: – W 07-10-08 – Plier insert….8027 Special tools: –…
Page 144
Fuel system W 07-08-02 TD 2011 w, TCD 2011 w Unscrew lifting magnet (1) with plier insert. © 39387-1 Remove the O-ring with the disassembly tool. Visually inspect the components. © 47647-0 Installing the charge air-pressure depend- ent full load stop Clean sealing surfaces.
Page 145
Fuel system TD 2011 w, TCD 2011 w W 07-08-02 Insert spring (1). Insert diaphragm (2) and cap (3). Attention! Note installation position. © 39389-1 Tighten screws (1). 8 Nm Install the fuel filter console. W 07-10-08 © 39385-2 © 12/2008…
Page 146
Fuel system W 07-08-02 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A06 094 Lifting magnet on fuel filter console Renew O-ring 10 Nm Cap on charge air-dependent full load…
Page 147
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-10-06 Removing and installing fuel pipes Commercial available tools: Danger! – Hose clip pliers ….8011 Wait 30 seconds after switching off the –…
Page 148
Fuel system D 2011 w W 07-10-06 TD 2011 w, TCD 2011 w Loosen spring band clips (1) with spring band pliers. © 47572-0 Pull off hose pieces (1) in the direction of the arrow. © 47573-0 Loosen hose clip (1).
Page 149
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-10-06 Loosen hose clip (1). Pull off fuel pipe (2). Collect draining fuel and dispose of accor- ding to regulations. © 47614-0 Unscrew hollow screws (1). Remove fuel pipe (2).
Page 150
Fuel system D 2011 w W 07-10-06 TD 2011 w, TCD 2011 w Visually inspect the components. © 47618-0 Installing fuel pipes Mount fuel return pipe (1). Mount sealing rings (2). Tighten hollow screw (3). 29 Nm © 47617-1 Mount fuel pipe (1).
Page 151
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-10-06 Mount fuel hose (2). Lay hose without contact. Ensure that the installation location is free from faults. Mount new hose clip (1). Fix the hose clip (1) with the hose clip pliers.
Page 152
Fuel system D 2011 w W 07-10-06 TD 2011 w, TCD 2011 w Push on hose pieces (1) in the direction of the arrow. © 47573-1 Position spring band clips (1) with spring band pliers. © 47572-0 Position clamping claws (1).
Page 153
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-10-06 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A07 015 Fuel supply line to injection pump Hollow screw Replace sealing rings 29 Nm…
Page 154
Fuel system D 2011 w W 07-10-06 TD 2011 w, TCD 2011 w © 12/2008 17823-001…
Page 155
Fuel system TD 2011 w, TCD 2011 w W 07-10-08 Removing and installing the fuel filter console Commercial available tools: Danger! – Hose clip pliers ….8011 Wait 30 seconds after switching off the –…
Page 156
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w Pull off hose pipe (1). © 47593-0 Unscrew screws (1). Remove fuel filter console (2). © 47594-0 Remove the O-ring (1) with the disassembly tool. © 47595-0 © 12/2008 17824-001…
Page 157
Fuel system TD 2011 w, TCD 2011 w W 07-10-08 Visually inspect the components. © 47596-0 Installing the fuel filter console Clean sealing surfaces. © 47597-0 Insert new sealing ring (1). © 47598-0 © 12/2008 17824-001…
Page 158
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w Install the fuel filter console (2). Tighten screws (1). 22 Nm © 47594-0 Mount the hose pipe (1). © 47593-0 Note assignment! Lay hoses without contact. Install fuel hoses. Mount new hose clips (1).
Page 159
Fuel system TD 2011 w, TCD 2011 w W 07-10-08 Position protective hoses, dimension X. 20 mm © 47599-0 © 12/2008 17824-001…
Page 160
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Fuel filter console/full load stop to Torx, A07 087 22 Nm crankcase M8x50-8.8 For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 161
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-11-01 Removing and installing the fuel supply pump Commercial available tools: Danger! – Hose clip pliers ….8011…
Page 162
Fuel system D 2011 w W 07-11-01 TD 2011 w, TCD 2011 w Loosen hose clip (1). Pull off fuel pipe (2). Pull off protective hose (3). Collect draining fuel and dispose of accor- ding to regulations. © 47610-0 Unscrew screws (1).
Page 163
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-11-01 Installing the fuel supply pump Turn the crankshaft until the eccentric of the cam- shafts is in the top dead centre (arrow). © 47398-0 Insert new O-ring (1).
Page 164
Fuel system D 2011 w W 07-11-01 TD 2011 w, TCD 2011 w Slip protective hose (3) over with mounting com- pound. Lay hose without contact. Mount fuel hose (2). Mount new hose clip (1). © 47610-0 Position protective hose, dimension X.
Page 165
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-11-01 Insert oil dipstick (1). © 47608-0 © 12/2008 17825-001…
Page 166
Fuel system D 2011 w W 07-11-01 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A07 024 Fuel supply pump on crankcase 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 167
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-08-02 Removing and installing the lubricating oil cooler Commercial available tools – W 08-11-07 Collect leaking operating substances in suitable vessels and dispose of according to regulations.
Page 168
Lube oil system D 2011 w W 08-08-02 TD 2011 w, TCD 2011 w Installing the lubricating oil cooler Visually inspect the components. © 47519-0 Clean sealing surfaces. Insert new sealing ring (1). © 47518-0 Mount lubricating oil cooler (1).
Page 169
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-08-02 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Lubricating oil cooler on oil filter con- A08 051 M6x16-10.9 13 Nm sole For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 170
Lube oil system D 2011 w W 08-08-02 TD 2011 w, TCD 2011 w © 12/2008 17829-001…
Page 171
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-07 Removing and installing the oil filter console Commercial available tools: – Operation manual – Torx tool set ….8189 –…
Page 172
Lube oil system D 2011 w W 08-11-07 TD 2011 w, TCD 2011 w Unscrew hollow screw (1). Remove sealing rings (2). © 47514-0 Unscrew lubricating oil filter (1) with special wrench. Collect draining lubricating oil and dispose of properly.
Page 173
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-07 Remove gasket (1). Clean sealing surfaces. © 47520-0 Installing oil filter console Visually inspect the components. © 47521-0 Fix new gasket (1) to the crankcase with a little grease.
Page 174
Lube oil system D 2011 w W 08-11-07 TD 2011 w, TCD 2011 w Mount oil filter console (1). Do not move gasket. Tighten screws (2). Turn in screw (3). Tighten screws (2). 21 Nm Tighten screw (3). 21 Nm ©…
Page 175
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-07 Push on hose pieces (1) in the direction of the arrow. © 47573-1 Position the spring band clip (1) with the spring band pliers. © 47572-0 ©…
Page 176
Lube oil system D 2011 w W 08-11-07 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Torx M8x50-8.8 A08 003 Oil filter console on crankcase 21 Nm Torx M8x90-8.8…
Page 177
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-08 Removing and installing the oil pressure switch Commercial available tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. Removing the oil pressure switch Pull out cable plug (1).
Page 178
Lube oil system D 2011 w W 08-11-08 TD 2011 w, TCD 2011 w Visually inspect the components. © 47433-0 Installing the oil pressure switch Screw on oil pressure switch (1). © 47434-0 Tighten oil pressure switch (1). 13 Nm ©…
Page 179
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-08 Plug in the cable plug (1). Ensure that the connection is perfect. © 47344-0 © 12/2008 17832-001…
Page 180
Lube oil system D 2011 w W 08-11-08 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A08 091 Oil pressure switch on crankcase M10x1 13 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 181
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-12 Removing and installing the thermostat (Lubricating oil cooler) Commercial available tools: Collect leaking operating substances in – Slide gauge suitable vessels and dispose of according – Torx tool set ….8189 to regulations.
Page 182
Lube oil system D 2011 w W 08-11-12 TD 2011 w, TCD 2011 w Remove the O-ring (1) with the disassembly tool. © 47439-0 Visually inspect the components. © 47568-0 Installing the thermostat Measure length of the compressor spring with calli- per gauge.
Page 183
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-12 Clean sealing surfaces. Oil the thermostat lightly. Insert compression spring. Insert thermostat (1). Note installation position. © 47575-0 Lightly oil new O-ring (1). Insert new O-ring (1).
Page 184
Lube oil system D 2011 w W 08-11-12 TD 2011 w, TCD 2011 w Technical Data Testing and setting data ID no. Name Additional information Value P08 74 Thermostat, compression spring, length 45.7 mm Tightening specifications ID no. Name Screw type Notes / Remark…
Page 185
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-16-01 Removing and installing the control line Commercial available tools – W 07-10-08 – W 08-11-07 Collect leaking operating substances in suitable vessels and dispose of according to regulations.
Page 186
Lube oil system D 2011 w W 08-16-01 TD 2011 w, TCD 2011 w Visually inspect sealing surfaces (arrows). © 47651-0 Visually inspect the components. © 47649-0 Installing control line Insert control line (1). Mount sealing rings (2). Screw in all hollow screws.
Page 187
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-16-01 Install the fuel filter console. W 07-10-08 Mount oil filter console. W 08-11-07 Insert control line (1). Mount sealing rings (2). Tighten hollow screw (3). 18 Nm ©…
Page 188
Lube oil system D 2011 w W 08-16-01 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Control line to oil filter console / crank- Hollow screw A08 048 18 Nm…
Page 189
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-07-08 Removing and installing the coolant pump Commercial available tools – Operation manual 8190 – W 13-02-03 Special tools: – Disassembly tool… . . 110901…
Page 190
Cooling system D 2011 w W 09-07-08 TD 2011 w, TCD 2011 w Clean sealing surfaces. © 47511-0 Installing coolant pump Clean sealing surfaces. Insert new O-ring (1). © 47512-0 Mount coolant pump (1). Pay attention to different screw lengths.
Page 191
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-07-08 Install V-belt. W 13-02-03 Fill cooling system according to the operating manu- © 46986-2 © 12/2008 17835-001…
Page 192
Cooling system D 2011 w W 09-07-08 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value M8x35-10.9 A09 010 Coolant pump on thermostat housing 20 Nm M8x100-10.9 For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 193
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-01 Checking the thermostat (in the removed state) Commercial available tools: – W 09-08-02 – Thermometer Danger! Risk of injury! Hot water and hot thermostat. Checking thermostat Remove thermostat.
Page 194
Cooling system D 2011 w W 09-08-01 TD 2011 w, TCD 2011 w Measure end of stroke, dimension (b). Note measured value, dimension (b). © 34679-2 Determine stroke. Calculation example Desired: Stroke Given: Measured: Beginning of stroke, dimension (a) End of stroke, dimension (b)
Page 195
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-01 Technical Data Testing and setting data ID no. Name Additional information Value P09 11 Thermostat, start of opening 86 — 90 °C P09 13 Thermostat, stroke distance at least 9 mm ©…
Page 196
Cooling system D 2011 w W 09-08-01 TD 2011 w, TCD 2011 w © 12/2008 17836-001…
Page 197
D 2011 w D 2011 w Cooling system Cooling system TD 2011 w, TCD 2011 w TD 2011 w, TCD 2011 w W 09-08-02 W 09-08-02 Removing and installing the thermostat Commercial available tools – W 09-08-01 Collect leaking operating substances in suitable vessels and dispose of according to regulations.
Page 198
Cooling system Cooling system D 2011 w D 2011 w W 09-08-02 W 09-08-02 TD 2011 w, TCD 2011 w TD 2011 w, TCD 2011 w Check thermostat. W 09-08-01 Visually inspect the components. © 46984-0 Installing the thermostat Clean sealing surfaces.
Page 199
D 2011 w D 2011 w Cooling system Cooling system TD 2011 w, TCD 2011 w TD 2011 w, TCD 2011 w W 09-08-02 W 09-08-02 Mount outlet nozzle (2). Tighten screws (1). 22 Nm © 46982-0 © 12/2008 17837-001…
Page 200
Cooling system Cooling system D 2011 w D 2011 w W 09-08-02 W 09-08-02 TD 2011 w, TCD 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A09 002 Outlet nozzles on thermostat housing M8x30-10.9…
Page 201
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-04 Removing and installing the thermostat housing Commercial available tools: – Operation manual 8190 – Spring band pliers ….9090 –…
Page 202
Cooling system D 2011 w W 09-08-04 TD 2011 w, TCD 2011 w Unscrew screw (1). Unscrew screws (2). Remove the thermostat housing (3). © 46990-0 Pull out plug element (1). Pull out plug element (2). © 46991-0 Remove the O-ring (1) with the disassembly tool.
Page 203
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-04 Installing thermostat housing Clean all sealing surfaces. Visually inspect the components. © 46993-0 Insert new O-ring (1). © 46992-0 Insert plug element (1). Insert plug element (2).
Page 204
Cooling system D 2011 w W 09-08-04 TD 2011 w, TCD 2011 w Mount thermostat housing (1). Ensure that the installation location is free from faults. Tighten screws (2). 34 Nm Turn in screw (3). © 46990-1 Coat hose pieces with mounting compound.
Page 205
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-04 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A09 001 Thermostat housing to crankcase M8x100-10.9 34 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 206
Cooling system D 2011 w W 09-08-04 TD 2011 w, TCD 2011 w © 12/2008 17838-001…
Page 207
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-12-01 Removing and installing temperature transmitter Commercial available tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with opera-…
Page 208
Cooling system D 2011 w W 09-12-01 TD 2011 w, TCD 2011 w Installing temperature transmitter Tighten temperature transmitter (1). 25 Nm Make sure the sealing ring is in place. Connect cable. Ensure that the connection is perfect. © 46994-0 ©…
Page 209
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-12-01 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Temperature transmitter on thermo- A09 031 25 Nm stat housing For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 210
Cooling system D 2011 w W 09-12-01 TD 2011 w, TCD 2011 w © 12/2008 17839-001…
Page 211: Engine Shutdown

D 2011 w Monitoring system TD 2011 w, TCD 2011 w W 11-00-03 Removing and installing the lifting magnet (Engine shutdown) Commercial available tools – W 12-02-01 Special tools: – Disassembly tool… . . 110901 Remove lifting magnet –…
Page 212
Monitoring system D 2011 w W 11-00-03 TD 2011 w, TCD 2011 w Remove cable tie (1). Unscrew screws (2). Remove lifting magnet (3). © 47606-0 Remove the O-ring (1) with the disassembly tool. Visually inspect the components. © 47355-0 Install lifting magnet Insert new O-ring (1).
Page 213: Monitoring System

D 2011 w Monitoring system TD 2011 w, TCD 2011 w W 11-00-03 Insert lifting magnet (1). Tighten screws (2). 8.5 Nm Fasten cable plug with cable tie (3). © 47606-1 Mount V-belt tensioning pulley (1). Fasten screw (2). Turn in screw (3).
Page 214
Monitoring system D 2011 w W 11-00-03 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Lifting magnet (engine shutdown) on A05 041 8.5 Nm front cover For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 215
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-01-04 Removing and installing the V-belt pulley Commercial available tools – W 12-02-01 Removing the V-belt pulley Remove V-belt. W 12-02-01 Unscrew screws (1). Remove fan (2). © 47574-0 Unscrew screws (1).
Page 216
Other components D 2011 w W 12-01-04 TD 2011 w, TCD 2011 w Remove V-belt pulley (1). © 47014-0 Remove centrifugal disc (1). Note installation position. Visually inspect the components. © 47015-0 Installing the V-belt pulley Mount centrifugal disc (1).
Page 217
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-01-04 Mount V-belt pulley (1). © 47014-0 Mount flange hub (2). Tighten screws (1). 43 Nm © 47013-0 Attention! Note installation position: «Engine side» label faces engine! Mount fan (2).
Page 218
Other components D 2011 w W 12-01-04 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A09 042 Ventilator on flange hub M8x40-10.9 30 Nm V belt pulley/flange hub on output A12 031 M10x30-8.8…
Page 219
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-02-01 Renew V-belts, check V-belt tension Commercial available tools: Attention! – V-belt tension measuring Only test / tighten / renew V-belts when the device ….. . . 8115 engine is not running.
Page 220
Other components D 2011 w W 12-02-01 TD 2011 w, TCD 2011 w Loosen screws (1). Loosen screw (2). Swing generator (3) in the direction of the arrow. © 46987-0 Unscrew screw (1). Remove air bearing (2). Remove V-belt pulley (3).
Page 221
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-02-01 Swing generator (1) in the direction of the arrow. Tighten screws (2). Fasten screws (3). © 46987-1 Tighten new screw (1). – Stage 1: 30 Nm Tighten screw (1) with socket wrench insert and rota- tion angle disc.
Page 222
Other components D 2011 w W 12-02-01 TD 2011 w, TCD 2011 w Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow). © 46997-1 Press the V-belt measuring device against the V-belt with the button (1) until you hear it click.
Page 223
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-02-01 – Version with V-belt tensioning pulley Mount V-belt (1). Swing V-belt tensioning pulley (2) in the direction of the arrow. Fasten screws (3). © 46986-1 Press clamping strap (1) in direction of arrow with a suitable tool.
Page 224
Other components D 2011 w W 12-02-01 TD 2011 w, TCD 2011 w Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. Read measured value at the intersection (arrow) of the indicator arm and scale.
Page 225
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-02-01 Technical Data Testing and setting data ID no. Name Additional information Value P12 11 V-belt tension, individual V-belts AVX 10 First assembly −50 Check after 15 minutes running…
Page 226
Other components D 2011 w W 12-02-01 TD 2011 w, TCD 2011 w © 12/2008 17842-001…
Page 227
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-06-01 Removing and installing the flywheel Commercial available tools: – Self-made mandrin guide – Rotation angle disc … . . 8190 Removing the flywheel Block flywheel with suitable tool.
Page 228
Other components D 2011 w W 12-06-01 TD 2011 w, TCD 2011 w Installing the flywheel Screw two long screws into the threaded bores. To improve the removal and installation of the flywheel. Insert self-made mandrin guide (1). For example a pin bolt.
Page 229
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-06-01 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Stage 1: A12 001 Flywheel on crankshaft 30 Nm Use new screws A12 001 Flywheel on crankshaft Stage 2: 60°…
Page 230
Other components D 2011 w W 12-06-01 TD 2011 w, TCD 2011 w © 12/2008 17843-001…
Page 231
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-08-02 Removing and installing the hydraulic pump Commercial available tools – Graphite grease G 500 Removing the hydraulic pump Remove the hydraulic pipes. Press in stoppers. Unscrew screws (1).
Page 232
Other components D 2011 w W 12-08-02 TD 2011 w, TCD 2011 w Installing hydraulic pump Pull collar (1) onto coupling sleeve (3). Align cutting on the toothing of the coupling sleeve. Pull collar (2) onto coupling sleeve (3). Align cutting on the toothing of the coupling sleeve.
Page 233
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-08-02 Insert hydraulic pump (1) and coupling sleeve. Toothing of the coupling sleeve must engage with the gear shaft. Tighten screws (2). 57 Nm Pull out stoppers. Insert hydraulic pipes.
Page 234
Other components D 2011 w W 12-08-02 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Hydraulic pump on hydraulic pump A12 051 57 Nm console For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 235
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-02-03 Removing and installing the generator Commercial available tools – W 12-02-01 Removing the generator Disconnect the battery’s negative terminal. Remove cable from generator. Note assignment! — (1) = terminal W…
Page 236
Electrical system D 2011 w W 13-02-03 TD 2011 w, TCD 2011 w Unscrew screw (1). Remove generator. © 47602-0 Installing the generator Mount generator. Fasten screw (1). © 47602-0 Mount generator. Insert screw (1). Mount protective plate (2). Mount protective plate (3).
Page 237
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-02-03 Remove cable from generator. Note assignment! — (1) = terminal W — (2) = terminal D+ — (3) = terminal B+ – (Position 2) 3.5 Nm – (Position 3) 6.5 Nm…
Page 238
Electrical system D 2011 w W 13-02-03 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Charging current cable to generator A13 081 6.5 Nm A13 082 Cable G1.D+ to generator 3.5 Nm…
Page 239
TD 2011 w, TCD 2011 w W 13-03-02 Removing and installing the starter Commercial available tools Removing the starter – TD 2011 w, TCD 2011 w Disconnect the battery’s negative terminal. Disconnect cables. Unscrew screws (1). Remove shielding plate (2).
Page 240
Electrical system D 2011 w W 13-03-02 TD 2011 w, TCD 2011 w Visually inspect the components. © 47476-0 Installing the starter Insert starter. Tighten screws (1). 43.5 Nm © 47579-0 Mount shielding plate (1). Tighten screws (2). Make sure that the installation site of the rubber pad (3) is in perfect condition.
Page 241
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-03-02 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A13 001 Starter on crankcase 43.5 Nm A13 009 Shield on crankcase M6x14-8.8 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 242
Electrical system D 2011 w W 13-03-02 TD 2011 w, TCD 2011 w © 12/2008 17848-001…
Page 243
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-06-01 Removing and installing the heating plugs Commercial available tools Special tools: – Assembly tool ….120440 Removing the glow plugs Disconnect the battery.
Page 244
Electrical system D 2011 w W 13-06-01 TD 2011 w, TCD 2011 w Installing the glow plugs Screw in heating plug (1). Tighten heating plug (1) with assembly tool. 21 Nm Connect cables to heating plugs. Connect the battery. © 46969-0 ©…
Page 245
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-06-01 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A13 032 Heating plug on cylinder head 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 246
Electrical system D 2011 w W 13-06-01 TD 2011 w, TCD 2011 w © 12/2008 17849-001…
Page 247
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-06-02 Removing and installing the glow plug Commercial available tools Removing the glow plug Disconnect cable connections. Unscrew glow plug (1). Remove sealing ring. © 47477-0 Visually inspect the components.
Page 248
Electrical system D 2011 w W 13-06-02 TD 2011 w, TCD 2011 w Installing the glow plug Insert new sealing ring. Insert glow plug (1). © 47479-0 Tighten glow plug (1). 60 Nm Connect cable. 4 Nm © 47477-0 © 12/2008…
Page 249
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-06-02 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Glow plug in charge air line / intake A13 031 60 Nm pipe A13 034 Cable connection to glow plug…
Page 250
Electrical system D 2011 w W 13-06-02 TD 2011 w, TCD 2011 w © 12/2008 17850-001…
Page 251
D 2011 w TD 2011 w, TCD 2011 w Standard tools Standard tools © 12/2008 19492-001…
Page 252
D 2011 w Standard tools TD 2011 w, TCD 2011 w 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…
Page 253
D 2011 w TD 2011 w, TCD 2011 w Standard tools 8005 Compression pressure tester for diesel engines 10 — 40 bar Checking compression pressure © 35410-3 8011 Hose clip pliers Loosen and fasten hose clips e. g. fuel return pipe ©…
Page 254
D 2011 w Standard tools TD 2011 w, TCD 2011 w 8024 Assembly pliers Removing valve shaft seals © 37509-2 8027 Plier insert Removing and installing the lifting magnet © 39531-1 8115 V-belt tension measuring device 150 to 600 N Check V-belt tension ©…
Page 255
D 2011 w TD 2011 w, TCD 2011 w Standard tools 8116 Socket wrench insert Torx — E18 © 35415-1 8167 Cleaning brush Cleaning exhaust channels © 46283-0 8189 Torx tool set Contents of case: — Double-ended ring spanner E6/E8…
Page 256
D 2011 w Standard tools TD 2011 w, TCD 2011 w 8190 Rotation angle disc with magnet (e. g. setting valve clearance) © 42528-1 9088 Clamping tongs Loosening and tightening hose clips © 39433-1 9090 Spring band pliers 320 mm Tighten spring clamp ©…
Page 257
D 2011 w TD 2011 w, TCD 2011 w Standard tools 9120 Special bit 70 mm long © 39434-1 © 12/2008 19492-001…
Page 258
D 2011 w Standard tools TD 2011 w, TCD 2011 w © 12/2008 19492-001…
Page 259
D 2011 w TD 2011 w, TCD 2011 w Special tools Special tools © 12/2008 19496-001…
Page 260
D 2011 w Special tools TD 2011 w, TCD 2011 w 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…
Page 261
D 2011 w TD 2011 w, TCD 2011 w Special tools 100120 Connector (in conjunction with compression pressure tester 8005) © 39400-1 100400 Dial gauge with fixing wheel Measuring range 0 — 10 mm / 0.01 mm © 35424-1 100410 Digital gauge Measuring range 0 — 30 mm / 0.01 mm…
Page 262
D 2011 w Special tools TD 2011 w, TCD 2011 w 100750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection © 39402-2 110090 Puller (in connection with sliding hammer 150800) Removing fuel injector ©…
Page 263
D 2011 w TD 2011 w, TCD 2011 w Special tools 120440 Assembly tool Removing and installing the glow plugs © 40333-1 150180 Holder (in conjunction with measuring device 100750) Measure piston overhand on recess cylinder head © 43181-0 150800…
Page 264
D 2011 w Special tools TD 2011 w, TCD 2011 w 170050 Special wrench 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 6067 Assembly block Engine clamping, one-sided ©…
Page 265
D 2011 w TD 2011 w, TCD 2011 w Special tools 6067/114 Supporting bracket (in conjunction with assembly block 6067) Engine clamping, one-sided © 39369-1 6067/115 Clamping bracket (in conjunction with assembly block 6067) Engine clamping, one-sided © 39425-1 © 12/2008…
Page 266
D 2011 w Special tools TD 2011 w, TCD 2011 w © 12/2008 19496-001…

Источник

Workshop Manual

competence level 2

D 2011 w

TD 2011 w, TCD 2011 w

men

This doc

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orm

0312 4176 en

This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.

The engine company.

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
Sales & Service Information Systems
Ottostraße 1
D-51149 Köln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
Internet: www.deutz.com
E-Mail: info@deutz.com

Printed in Germany
All rights reserved
1st Edition, 12/2008
Order No. 0312 4176 en

DEUTZ engines 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

6Job cards
7Commercial tools
8 Special tools

1/2

DEUTZ enginesTable of contents

2/2

DEUTZ engines Foreword

1 Foreword

1/4

DEUTZ enginesForeword

2/4

DEUTZ engines Foreword

z Read and observe the information in this docu-

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

z This engine is built exclusively for purpose ac-

cording to the scope of delivery — defined by the
equipment manufacturer (use for the intended
purpose). Any use above and beyond this is considered improper use. The manufacturer will not
be liable for damages resulting from this. The
user bears the sole risk.

z Use for the intended purpose also includes ob-

servance of the operating, maintena nce and repair instructions specified by the manufacturer.
The engine may only be used, maintained and
repaired by persons who are familiar with this
and are aware of the risks involved.

z Make sure that this documentation is available to

everyone involved in the operation, maintenance
and repair and that they have understood the
contents.

z Failure to observe this documentation may lead

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

z Prerequisite for proper maintenance and repair is

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

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

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

z The pertinent rules for the prevention of acci-

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

z Maximum economy, reliability and long life is only

guaranteed when using DEUTZ original parts.

z Repair of the engine must correspond to its use

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

z The engines made by DEUTZ are developed for

a wide range of applications. A wide range of variants ensures that the respective special requirements are met.

z The engine is equipped according to the installa-

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

z We have done our best to highlight the differenc-

es so that you can easily find the operating, maintenance and repair instructions relevant to your
engine.

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

Your DEUTZ AG

3/4

DEUTZ enginesForeword

4/4

DEUTZ engines General

2 General

1/4

DEUTZ enginesGeneral

2/4

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 demands on quality, attests to the fact that our engines
possess all the qualities of long life, high reliability
and low fuel consumption. It goes without saying
that the high environmental protection requirements
are also met.

Maintenance and care are the only way the engine
can satisfy the demands you make on it. Compliance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating co nditio ns,
deviating from normal operation, must be particularly heeded.

Please consult one of our service representatives
responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.

3/4

DEUTZ enginesGeneral

4/4

DEUTZ engines User notes

3 User notes

1/8

DEUTZ enginesUser notes

2/8

DEUTZ engines User notes

3.1 General

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

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

Caution!
The rules for the prevention of accidents and the

safety regulations must be observed during maintenance work.

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

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

3.2 Specifications

3.2.1 Accident prevention and safety regulations

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

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

Among other things it generally applies that:
z for the personnel:

– Only briefed personnel may operate or main-

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

– Wear close-fitting clothing and ear protectors

in the machine room when the engine is in operation.

– Only deploy trained personnel to do repairs

and maintenance work.

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

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

– Go to the workshop immediately in case of

leaks in the fuel system.

z for the engine room:

– Ensure adequate ventilation (do not cover air

shafts).

– Provide first aid kit and suitable fire extinguish-

ers. Check the filling and readiness for operation regularly.

– Only store inflammable materials in the ma-

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

– Smoking and naked flames are prohibited in

the machine room.

z for operation, maintenance and repairs on the

engine:
– Wait 30 seconds after switching off the engine

before working on the fuel sytem.

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

bleeded — see the operation manual, chapter
«6 Fuel system“.

– Only start the engine when all the protective

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

– Cleaning, maintenance and repair work may

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

– Injection lines and high pressure pipes must

not be deformed.

3/8

DEUTZ enginesUser notes

– Damaged injection lines and high-pressure

pipes must be renewed.

– Injection lines and high pressure fuel lines

must never be connected when the engine is
running.

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

pressure fuel system.

– Also carefully check all high pressure compo-

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

– Even if no leaks are discernible on the high

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

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

could cause severe injury.

– Smoking is strictly prohibited when working on

the fuel system.
– Do not work near to sparks and flames.
– Never disconnect an injector when the engine

is running.

3.2.2 Cleanliness instructions and measures for handling the DEUTZ Common Rail System

The DEUTZ Common Rail system used in the
DEUTZ engines consists of high-precision components which are exposed to extreme stress . Grea t
attention must be paid to cleanliness when working
on the fuel system due to the high precision technology.

Notes and measures to be observed before
starting work on the fuel system

z The fuel system must be closed. Make a visual

inspection for leaks / damage to the fuel system.

z Clean the whole engine and engine room with the

system closed before starting work on the fuel
system.

z The engine must be dry when you start working

on the fuel system.

z Blowing (dry) with compressed air is only permis-

sible with the fuel system closed.

z When using a steam jet, first cover up the control

unit, the cable plugs, all other electrical plug connections and the generator. Also, the steam jet
may not be pointed directly at them.

z Electrical plug connections must be plugged

when spraying.

z Remove loose parts (for example paint chips

from assembly work) with an industrial vacuum
cleaner or other suction device. Only suction may
be used in assembly work on the open fuel system.

z Only work on the fuel system in a clean environ-

ment (no dust, no grinding or welding). Avoid
draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may
be kept or operated in the same room.

z Air currents which kick up dust, such as those

caused by brake repairs or the starting of engines, should be avoided.

z For work such as removal and installation on de-

fective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.

z No general machine tools may be operated in

this room.

z Regular cleaning of the workshop area is manda-

tory. Draughts, ventilation systems and heating
fans should be minimised.

z Areas of the engine room from which particles of

dirt could be loosened (for example the bottom
part of the tipped driver cab) must be covered
with fresh clean film.

z Working materials and tools must be cleaned be-

fore work. Only use tools without damage to the
chrome plating or tools which are not chromeplated.

Notes and measures to be observed during work
on the fuel system or with the fuel s ystem ope n.

z Only work in clean overalls.
z Only lint-free cleaning cloths may be used for

work on the fuel system.

z Remove loose parts (for example paint chips

from assembly work) with an industrial vacuum
cleaner or other suction device. Only suction may
be used in assembly work on the open fuel system.

z Working materials and tools must be cleaned be-

fore work. Only use tools without damage to the
chrome plating or tools which are not chromeplated.

z Do not use used cleaning fluid or test fluid for

cleaning.

z Compressed air must not be used for cleaning on

the open fuel system.

z Work on removed components may only be per-

formed at a suitably equipped workbench.

4/8

DEUTZ engines User notes

z When removing and installing components, no

materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.

z Removed parts may only be rubbed down with

clean, lint-free cloths. No dirt particles may be
rubbed into the components.

z Openings on the components and on the engine

must be closed immediately with suitable stoppers/caps.

z The stoppers/caps may only be removed imme-

diately before installing.

z Store stoppers/caps free from dust and dirt in the

original packaging and dispose of after using
once.

z Only remove new parts from the original packag-

ing just before installation.

z Removed components must be kept in new, seal-

able bags or — if available — in the packaging of the
new parts.

z Always use the original packaging of the new part

to send back the removed components.

Notes and measures for the vehicle workshop
area

z For work such as removal and instal la tion on de-

fective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which gener al
vehicle repairs such as brake repairs are carried
out.

z The workshop floor is sealed or tiled.
z No welding gear, grinders, general machine

tools, brakes or performance test benc he s ma y
be operated in this room.

z Regular cleaning of the workshop area is manda-

tory. Draughts, ventilation systems and heating
fans should be minimised.

Notes and measures for workbench and tools in
the vehicle hall

operating materials among other things. The renewed parts / operating materials must be stored,
transported and disposed of according to regulations. The owner himself is responsible for this.

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

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

z A special workbench must be set up for work on

removed components.

z Clean the removal and installation tools regularly

and keep them in a closed tool cabinet.

z Remove loose parts (for example paint chips

from assembly work) with an industrial vacuum
cleaner or other suction device.

z Working materials and tools must be cleaned be-

fore work. Only use tools without damage to the
chrome plating or tools which are not chr o me plated.

3.2.3 Disposal regulations

The work described in the operation manual and
workshop manual necessitates renewal of parts and

5/8

DEUTZ enginesUser notes

3.3 Operation manual and workshop

manual

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

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

It contains the following chapters:

1. Contents, General

2. Engine description

3. Operation

4. Operating media

5. Maintenance

6. Care and maintenance work

7. Faults, causes and remed ies

8. Engine conservation

9. Technical data

10.Service

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

3.4 Job cards

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

3.4.1 Numbering of job cards

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

01. The individual parts of this pattern are explained

below:
z W 02-04-01: Documentation type

– WWorkshop manual

– I……Repair instructions

z W 02-04-01: Maintenance group

– 00…General / interdisciplinary activities
– 01…Cylinder head
– 02Drive system
– 03…Crankcase
– 04…Engine control system
– 05…Speed governing
– 06…Exhaust system / Charging
– 07…Fuel system
– 08…Lube oil system
– 09…Cooling system
– 10…Compressed air system
– 11…Monitoring system
– 12…Other components
– 13…Electrical system

z W 02-04-01: Component grouping
z W 02-04-01: Consecutive number

6/8

DEUTZ engines User notes

Triebwerk

W 02-04-01

1 2 3

575

3.4.2 Structure of a job card

1. DEUTZ AG,

publisher of service documentation

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

3. Maintenance group

4. Job card number or topic

5. Title of job card

6. Reference to other job cards

7. Chapter

8. Graphic or photo

9. DEUTZ internal creation number

10.Page number

11.Date of issue of job card

12.Note

13.Danger / Important

14.Work sequence

15.Special tools; auxiliary materials

16.Conventional tools

3.5 Explanation of symbols

Danger!

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

Caution!

Danger to the component/engine. Noncompliance can lead to destruction of the
component/engine.
Must be observed!

Note

General notes on assembly, environmental
protection etc. No potential danger for man
or machine.

Tool

Conventional and special tools required for
the work.

Auxiliary materials

Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)

References

to important documents or job cards for the
work process.
For example: Job card W 04-05-05

Reference

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

Test and setting data

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

Tightening specification

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

7/8

DEUTZ enginesUser notes

8/8

D 2011 w Technical data
TD 2011 w, TCD 2011 w Testing and setting data

4 Technical data

4.1 Testing and setting data

1/6

D 2011 wTechnical data

TD 2011 w, TCD 2011 wTesting and setting data

ID no. Name Additional information Value
D 2011 w / TD 2011 w / TCD 2011 w

P00 04 Engine weight according to DIN 70020-A approx. 268 kg
P00 51 Compression pressure
P00 71 Ignition sequence 1-3-4-2

P01 61 Valve clearance (inlet) 0.3 mm
P01 62 Valve clearance (outlet) 0.5 mm

P01 72 Rocker arm, bore, diameter (outlet)
P01 73 Rocker arm, bore, diameter (inlet)
P01 74 Rocker arm pin, diameter

P02 75 Piston overhang

P02 76 Piston overhang

P02 77 Piston overhang

Identification, cylinder head gasket = 1 recess

Identification, cylinder head gasket = 2 recesses

Identification, cylinder head gas-

ket = 3 recesses
P08 74 Thermostat, compression spring, length 45.7 mm
P09 11 Thermostat, start of opening 86 — 90 °C
P09 13 Thermostat, stroke distance at least 9 mm

P12 11 V-bel t tension, individual V-belts AVX 10 First assembly
P12 21 V-belt tension, individual V-belts AVX 10

Check after 15 minutes running

under load

D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head

P02 75 Piston overhang

P02 76 Piston overhang

P02 77 Piston overhang

Identification, cylinder head gas-

ket = 1 recess

Identification, cylinder head gas-

ket = 2 recesses

Identification, cylinder head gas-

ket = 3 recesses

25 — 30 bar
(2500 — 3000 kPa)

18 mm
18 mm
17,97 mm

0.325 — 0.604 mm

0.605 — 0.704 mm

0.705 — 0.804 mm

450 N
300 N

9.820 — 10.140 mm

10.141 — 10.239 mm

10.240 — 10.310 mm

2/6

D 2011 w Technical data
TD 2011 w, TCD 2011 w Tightening specifications

4.2 Tightening specifications

3/6

D 2011 wTechnical data

TD 2011 w, TCD 2011 wTightening specifications

ID no. Name Screw type Notes / Remark Value
D 2011 w / TD 2011 w / TCD 2011 w

A00 001 Clam pin g bracke t on cran kc as e 90 Nm
A00 002

A00 003

A01 001 Cylinder head on crankcase

A01 001 Cylinder head on crankcase Stage 2 80 Nm
A01 001 Cylinder head on crankcase Stage 3 160 Nm
A01 001 Cylinder head on crankcase Stage 4 90°
A01 002 Rocker arm bracket on cylinder head 21 Nm
A01 003 Lockin g nut, va lve adju ste r 20 Nm

A01 004

A03 060

A05 041

A05 065

A06 001 Exhaust pipe at cylinder head
A07 001 Fuel injector on cylinder head 21 Nm
A07 003
A07 015 Fuel supply line to injection pump Hollow screw Replace sealing rings 29 Nm

A07 024 Fuel supply pump on crankcase 21 Nm
A07 061 Fuel return line on injection pump Hollow screw Replace sealing rings 29 Nm

A08 003 Oil filter console on crankcase

A08 048

A08 051

A08 072
A08 091 Oil pressure switch on crankcase M10x1 13 Nm

A09 001 Thermostat housing to crankcase M8x100-10.9 34 Nm
A09 002

Clamping bracket on adapter for
assembly block

Mounting foot/engine mounting on
crankcase

Cylinder head cover on cylinder
head

Crankcase bleeding on front cover /
on cylinder head cover / on cylinder
head

Lifting magnet (engine shutdown) on
front cover

Lifting magnet (start amoun t release)
on front cover

Injection line on fuel injector / injection pump

Control line to oil filter console /
crankcase

Lubricating oil cooler on oil filter console

Thermostat on crankcase, locking
screw,

Outlet nozzles on thermostat housing

90 Nm

M14x55-12.9
M14x100-12.9

Stage 1:
Cylinder head screws
can be used a maximum of 3x with written
documentation.
Otherwise use new
cylinder head screws.
Observe tightening
sequence.

Torx screw,
coated

M12x1.5 25 Nm

Torx
M8x50-8.8
Torx
M8x90-8.8

Hollow screw
M10x1

M6x16-10.9 13 Nm

M8x30-10.9 22 Nm

Use new screws. 55 Nm

200 Nm

30 Nm

8.5 Nm

10 Nm

21 Nm

18 Nm

90 Nm

4/6

D 2011 w Technical data
TD 2011 w, TCD 2011 w Tightening specifications

ID no. Name Screw type Notes / Remark Value

A09 010 Coolant pump on thermostat housing
A09 020 Pipe clip on holder M6x16 21 Nm
A09 031
A09 042 Ventilator on flange hub M8x40-10.9 30 Nm
A09 045 Air bearing on console M10x110-12.9
A09 045 Air bearing on console M10x110-12.9 Stage 2: 120°
A12 001 Flywheel on cra nk sha ft
A12 001 Flywheel on crankshaft Stage 2: 60°

A12 001 Flywheel on crankshaft Stage 3: 30°
A12 031

A12 041

A12 051

A12 052

A12 056
A13 001 Starter on crankcase 43.5 Nm

A13 009 Shield on crankcase M6x14-8.8 8.5 Nm
A13 012 Generator on console
A13 015 Clamping bracket on generator M8x30-8.8 22 Nm

A13 016 Clamping bracket on console M8x35-8.8 22 Nm
A13 031
A13 032 Heating plug on cylinder head 21 Nm

A13 034 Cable co nn ec tio n to glo w plu g 4 Nm
A13 081
A13 082 Cable G1.D+ to generator M5 3.5 Nm

D2011w

A06 030

A06 057

A06 062

A06 063

A06 071

A06 072

Temperature transmitter on thermostat housing

V belt pulley/flange hub on output
flange

V-belt tensioning pulley (holder) on
front cover

Hydraulic pump on hydraulic pump
console

Tensioning pulley on hydr au lic pump
console

Protective hood on hydraulic pump
console

Glow plug in charge air line / intake
pipe

Charging current cable to generator
B+

Air suction intake pipe on cylinder
head

Pipe to exhaust gas return valve/
cylinder head (cooling — intake)

Exhaust return pipe to exhaust return
valve

Exhaust gas collection pipe to
exhaust gas return valve

Pipe to crankcase (exhaust gas
return — cooling — return)

Pipe to exhaust gas return valve
(exhaust gas return — cooling —

return)

M8x35-10.9
M8x100-10.9

Stage 1:
Use new screw.

Stage 1:
Use new screws

M10x30-8.8 43 Nm

M8x70-10.9
M8x75-10.9

Torx screw,
coated

Hollow screw
M12x1.5

M8x65-10.9 20 Nm

Hollow screw
M8x1

Hollow screw
M12x1.5

Use new screws. 21 Nm

20 Nm

25 Nm

30 Nm

45 Nm

57 Nm

21 Nm

8.5 Nm

34 Nm

60 Nm

6.5 Nm

29 Nm

20 Nm

12 Nm

29 Nm

5/6

D 2011 wTechnical data

TD 2011 w, TCD 2011 wTightening specifications

ID no. Name Screw type Notes / Remark Value

Torx
M10x25-10.9

A06 073

A06 074

Exhaust gas collection pipe (exhaust
gas return) on cylinder head

Exhaust gas return pipe to cylinder
head (exhaust gas return)

A06 075

A07 087 Fuel filter console to crankcase 21 Nm

TD2011w / TCD2011w

A06 004 Pin bolts on exhaust pipe coated Use new pin bolts 12 Nm
A06 020 Turbocharger on exhaust pipe M8 21 Nm

A06 030 Charge air pipe on cylinder head
A06 094 Lifting magnet on fuel filter console Renew O-ring 10 Nm
A07 096

A08 042

A08 044

A08 049 Holder oil return line on crankcase

Safety cover on sensor housing
(exhaust gas return)

Cap on charge air-dependent full
load stop

Lubricating oil pipe on turbocharger /

crankcase

Oil return line, hex spuds to turbocharger

Torx
M10x30-10.9
Torx
M10x45-10.9

Locking screw
Torx-Plus
30IPR

Torx screw,
coated

Hollow screw Replace sealing rings 29 Nm

M16x1.5 Use new sealing ring 40 Nm
Torx,

M6x14-8.8

Use new screws. 55 Nm

8.5 Nm

8Nm

Use new screws. 21 Nm

8Nm

8.5 Nm

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

6/6

D 2011 w
TD 2011 w, TCD 2011 w Job card overview

5 Job card overview

5.1 Sorted alphabetically

1/12

D 2011 wJob card overview

TD 2011w, TCD 2011 wSorted alphabetically

2/12

D 2011 w Job card overview
TD 2011w, TCD 2011 w Sorted alphabetically

Activity Job card Maintenance group

Checking piston overhang W 01-04-09 Cylinder head
Checking the compression pressure W 00-02-06 General
Checking the thermostat (in the removed state) W 09-08-01 Cooling system
Disassembling, assembling and checking the rocker

arm and rocker arm
bracket

W 01-02-06 Cylinder head

Installing and removing charge air pressure-dependent full load stop

Mounting engine on assembly block and demounting

Removing and install the charge air line W 06-02-03 Exhaust system/Charging
Removing and installing cylinder head W 01-04-04 Cylinder head
Removing and installing fuel pipes W 07-10-06 Fuel system
Removing and installing temperature transmitter W 09-12-01 Cooling system
Removing and installing the control line W 08-16-01 Lube oil system
Removing and installing the coolant pump W 09-07-08 Cooling system
Removing and installing the crankcase bleeding W 03-01-11 Crankcase
Removing and installing the exhaust gas collection

pipe (Exhaust gas recirculation)
Removing and installing the exhaust gas return pipe W 06-09-07 Exhaust system/Charging
Removing and installing the exhaust gas return val-

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

W 07-10-08 Fuel system

W 00-05-01 General

W 06-09-08 Exhaust system/Charging

W 06-09-06 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 injectors W 07-07-01 Fuel system
Removing and installing the fuel supply pump W 07-11-01 Fuel system
Removing and installing the generator W 13-02-03 Electrical system
Removing and installing the glow plug W 13-06-02 Electrical system
Removing and installing the heating plugs W 13-06-01 Electrical system
Removing and installing the hydraulic pump W 12-08-02 Other components
Removing and installing the intake manifold W 06-07-03
Removing

air pressure-dependent full load stop)
Removing and installing the lifting magnet (Engine

shutdown)
Removing and installing the lifting magnet (Start

amount release)
Removing and installing the lubricating oil cooler W 08-08-02 Lube oil system

and installing the lifting magnet (charge

W 07-10-08 Fuel system

W 11-00-03 Monitoring system

W 07-02-07 Fuel system

Exhaust system/Charging

3/12

D 2011 wJob card overview

TD 2011w, TCD 2011 wSorted alphabetically

Activity Job card Maintenance group

Removing and installing the oil filter console W 08-11-07 Lube oil system
Removing and installing the oil pressure switch W 08 -11-08 Lube oil system
Removing and installing the rocker arm and rocker

arm bracket
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 thermostat (Lubricating

oil cooler)
Removing and installing the thermostat housing W 09-08-04 Cooling system
Removing and installing the turbocharger W 06-06-04 Exhaust system/Charging
Removing and installing the V-belt pulley W 12-01-04 Other components
Renew V-belts, check V-belt tension W 12-02-01 Other components
Renewing the injection lines W 07-03-01 Fuel system
Setting valve clearance W 01-01-01 Cylinder head

W 01-02-02 Cylinder head

W 08-11-12 Lube oil system

4/12

D 2011 w Job card overview
TD 2011 w, TCD 2011 w Sorted numerically

5.2 Sorted numerically

5/12

D 2011 wJob card overview

TD 2011 w, TCD 2011 wSorted numerically

6/12

D 2011 w Job card overview
TD 2011 w, TCD 2011 w Sorted numerically

Job card Activity Maintenance group

W 00-02-06 Checking the compression pressure General

W 00-05-01

W 01-01-01 Setting valve clearance Cylinder head

W 01-02-02

W 01-02-06

W 01-04-04 Removing and installing cylinder head Cylinder head
W 01-04-09 Checking piston overhang Cylinder head
W 03-01-11 Removing and installing the crankcase bleeding Crankcase
W 06-01-05 Removing and installing the exhaust line Exhaust system/Charging
W 06-02-03 Removing and install the charge air 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 06-09-06

W 06-09-07 Removing and installing the exhaust gas return pipe Exhaust system/Charging

Mounting engine on assembly block and demounting

Removing and installing the rocker arm and rocker
arm bracket

Disassembling, assembling and checking the rocker
arm and rocker arm
bracket

Removing and installing the exhaust gas return valve

General

Cylinder head

Exhaust system/Charging

W 06-09-08

W 07-02-07

W 07-03-01 Renewing the injection lines Fuel system
W 07-07-01 Removing and installing the fuel injectors Fuel system
W 07-10-06 Removing and installing fuel pipes Fuel system

W 07-10-08

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
W 08-08-02 Removing and installing the lubricating oil cooler Lube oil system
W 08-11-07 Removing and installing the oil filter console Lube oil system
W 08-11-08 Removing and installing the oil pressure switch Lube oil system

W 08-11-12

Removing and installing the exhaust gas collection
pipe (Exhaust gas recirculation)

Removing and installing the lifting magnet (Start
amount release)

Removing and installing the lifting magnet (charge
air pressure-dependent full load stop)

Installing and removing charge air pressure-dependent full load stop

Removing and installing the thermostat (Lubricating
oil cooler)

Exhaust system/Charging

Fuel system

be oil system

W 08-16-01 Removing and installing the control line Lube oil system
W 09-07-08 Removing and installing the coolant pump Cooling system

7/12

D 2011 wJob card overview

TD 2011 w, TCD 2011 wSorted numerically

Job card Activity Maintenance group

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 09-08-04 Removing and installing the thermostat housing Cooling system
W 09-12-01 Removing and installing temperature transmitter Cooling system

W 11-00-03

W 12-01-04 Removing and installing the V-belt pulley Other components

W 12-02-01 Renew V-belts, check V-belt tension Other components
W 12-06-01 Removing and installing the flywheel Other components
W 12-08-02 Removing and installing the hydraulic pump Other components
W 13-02-03 Removing and installing the generator Electrical system
W 13-03-02 Removing and installing the starter Electrical system
W 13-06-01 Removing and installing the heating plugs Electrical system
W 13-06-02 Removing and installing the glow plug Electrical system

Removing and installing the lifting magnet (Engine
shutdown)

Monitoring system

8/12

DEUTZ engines Job cards

6Job cards

1/2

DEUTZ enginesJob cards

2/2

D 2011 w General

TD 2011 w, TCD 2011 w W 00-02-06

Checking the compression pressure

Commercial available tools:
– Compression pressure

tester. . . . . . . . . . . . . . . . . . . . . . . . 8005

Special tools:
– Connector. . . . . . . . . . . . . . . . . . 100120

– W 01-01-01
– W 07-07-01

Attention!

Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and natio nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
After all work on the fuel system, it must be
bleeded — see the operation manual, chapter «6 Fuel system“.

Checking the compression pressure

z Set valve clearance.

 W 01-01-01

z Removing fuel injectors.

 W 07-07-01

z Mount sealing ring (1).

Use sealing ring (1) for fuel injector.

z Insert connector (2).

1/6

D 2011 wGeneral

TD 2011 w, TCD 2011 wW 00-02-06

z Mount clamping shoe (1).
z Tighten screw (2).

 21 Nm

z Connect adapter (1) to connector.

z Mount the compression tester on the adapter.
z Turn over engine with starter.

 25-30bar (2500-3000kPa)

2/6

D 2011 w General

TD 2011 w, TCD 2011 w W 00-02-06

The measured compression pressure
depends on the starting speed during the
measuring process and the altitude of the
engine installation site. Therefore, limit
values cannot be determined exactly. The
compression pressure measurement is
only recommended as a reference measurement of all cylinders of an engine to each
other. If mor e than 15% deviation has been
determined, the cause should be determined by disassembling the cylinder unit concerned.

No.

Kompression in bar
Compression value in bar
Pression en bar

Zyl.

1
2
3
4
5
6
7
8

DBGM

OTOMETER

Made in Germany

Dat. _________

z Remove the compression pressure tester.

z Remove the compression pressure tester and

adapter (1).

3/6

D 2011 wGeneral

TD 2011 w, TCD 2011 wW 00-02-06

z Unscrew screw (1).

z Remove connector (1).
z Remove sealing ring.
z Install fuel injectors.

 W 07-07-01

4/6

D 2011 w General
TD 2011 w, TCD 2011 w W 00-02-06

Technical Data

Testing and setting data

ID no. Name Additional information Value

P00 51 Compression pressure

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A07 001 Fuel injector on cylinder head 21 Nm

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

25 — 30 bar
(2500 — 3000 kPa)

5/6

D 2011 wGeneral

TD 2011 w, TCD 2011 wW 00-02-06

6/6

D 2011 w General

TD 2011w, TCD 2011 w W 00-05-01

Mounting engine on assembly block and demounting

Commercial available tools:
– Lifting gear
– Suspension ropes
– Eyelet bolts

Special tools:
– Assembly block. . . . . . . . . . . . . . . . 6067
– Supporting bracket . . . . . . . . . .6067/114
– Clamping bracket . . . . . . . . . . .6067/115

Mounting engine on assembly block

z Remove starter.

 W 13-03-02

z Screw in eyelet bolts (1).

– W 13-03-02

Danger!

When using hoists (workshop crane) the
safety regulations for handling hoists must
be observed.
It is not permitted to stay under moving
loads.

Different customer scopes are not taken
into account in the repair sequence shown
here, accessories which deviate from the
standard equipment are not shown.

z Hang engine on workshop crane.

 approx. 268 kg

1/6

z Unscrew screws (1).

z Remove all mounting feet.

– TD 2011 w, TCD 2011 w

z Unscrew screw (2).
z Remove holder (3).
z Remove oil return pipe (4).

D 2011 wGeneral

TD 2011w, TCD 2011 wW 00-05-01

z Mount clamping holder (1).
z Tighten screws (2).

 90 Nm

z Align engine on engine block.
z Mount retainer plate (1).
z Tighten screws (2) and lock nuts.

 90 Nm

2/6

D 2011 w General

TD 2011w, TCD 2011 w W 00-05-01

z Unhook the engine from the workshop crane.
z Unscrew eyelet bolts (1).

Demounting engine from assembly block

z Screw in eyelet bolts (1).
z Hang engine on workshop crane.

 approx. 268 kg

z Loosen lock nuts.
z Unscrew screws (2).
z Remove retainer plate (1).

3/6

D 2011 wGeneral

TD 2011w, TCD 2011 wW 00-05-01

Danger!

Lower engine with workshop crane.

z Unscrew screws (2).
z Remove clamping bracket (1).

– TD 2011 w, TCD 2011 w

z Insert new O-ring (1).
z Lightly oil new O-ring (1).

– TD 2011 w, TCD 2011 w

z Mount oil return pipe (1).

Attention!

Install tension-free.

z Mount holder (2).
z Tighten screw (3).

 8.5 Nm

– D 2011 w, TD 2011 w, TCD 2011 w

z Install all mounting feet.
z Tighten screws (4).

 200 Nm

4/6

D 2011 w General

TD 2011w, TCD 2011 w W 00-05-01

Danger!

Put the engine down on a secure surface.

z Unhook the engine from the workshop crane.
z Unscrew eyelet bolts (1).
z Install starter.

 W 13-03-02

5/6

D 2011 wGeneral

TD 2011w, TCD 2011 wW 00-05-01

Technical Data

Testing and setting data

ID no. Name Additional information Value

P00 04 Engine weight according to DIN 70020-A approx. 268 kg

Tightening specifications

ID no. Name Screw type Notes / Remark Value

A00 001 Clam pin g bracke t on cran kc as e 90 Nm
A00 002

A00 003

TD 2011 w, TCD 2011 w

A08 049 Holder oil return line on crankcase

Clamping bracket on adapter for
assembly block

Mounting foot/engine mounting on
crankcase

M14x55-12.9
M14x100-12.9

Torx,
M6x14-8.8

90 Nm

200 Nm

8.5 Nm

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

6/6

D 2011 w Cylinder head

TD 2011 w, TCD 2011 w W 01-01-01

Setting valve clearance

Commercial available tools:
– Feeler gauges

z Unscrew all screws (1).
z Remove cylinder head cowling (2).
z Remove gasket.

Attention!

In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an
additional cam on the camshaft.
This is not to be confused with the valve
overlap.

Allow the engine to cool down for at least
30 minutes before setting the valve clearance. Engine oil temperature < 80 °C

The following work procedure describes
the setting of the valve clearance on an
inlet valve. The procedure is the same for
the setting on an outlet valve, taking into
consideration the setting dimension.

Setting engine to valve overlap

z Turn crankshaft in th e direction of the engine (arrow).
z Turn over crankshaft until the valve overlap is

achieved on cylinder 1.

1/6

D 2011 wCylinder head

TD 2011 w, TCD 2011 wW 01-01-01

Arrangement of the inlet and exhaust valves.
IN = inlet valve
EX = exhaust valve

Valve overlap means:
The inlet valve starts opening,exhaust
valve closes.

Attention!

In case of internal exhaust gas recirculation, the inlet valve is opened briefly by an
additional cam on the camshaft.
This is not to be confused with the valve
overlap.

z Select feeler gauge.
z Check the setting on the appropriate valve.

The feeler gauge must pass between the
rocker arm’s sliding surface and the valve
without too much resistance.

Setting valve clearance

z Loosen lock nut (1).
z Hold adjusting screw (2).
z Set valve clearance.

If there is not enough valve clearance, unscrew setting screw (2).

If there is too much valve clearance, turn in
setting screw (2).

–Inlet

 0.3 mm

–Outlet

 0.5 mm

2/6

Loading…

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Deutz Engines 912, BF4M2012, F4M2011, BF4M2011, 1011F operators, service and maintenance manuals, error codes list, DTC, spare parts manuals & catalogues, wiring diagrams, schematics free download PDF

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Deutz Engines

Modern technologies and materials, top quality, dependability, durability, and longevity are all features of Deutz diesel engines manufactured in Germany. German brand engines have high specific power and torque at the lightest possible weight for power plants with such specs. As a result, Deutz engines, which use the company’s unique innovations, can function well even in the most adverse circumstances and at a high maximum load for extended periods without diminishing motor resources or increasing overhaul time, therefore saving operational expenses.

After years of research at the company’s scientific and design bureaus, Deutz engineers developed motors that balance low operating costs and little impact on the environment. Because of their low fuel consumption, power plants from the German company Deutz are among the most cost effective in the world per kilowatt-hour produced, and they conform to the strictest standards for environmental protection. This means you may save money on gasoline and put Deutz generator installations close to where people live and work.

The Deutz 413 Series consists of V-shaped (V-Twin) diesel engines with 6, 8, 10, or 12 cylinders, a horizontal selection shaft, and valves in the upper location (OHV) for use in industrial and domestic applications. Focused on usage in sub-zero temperatures (down to -30 degrees Celsius), the 137 hp. (100 kW) to 322 hp. (236 kW) range of power and forced air conditioning;

Four-stroke, overhead-valve (OHV), horizontal power-shaft (HPS), and forced-air-cooled (FAC.) Deutz 912 Series diesel engines are designed for typical circumstances and may produce anywhere from 47 horsepower (34 kilowatts) to 111 horsepower (70 kW) (82 kW). The W models have a two-stage fuel combustion mechanism;

The Deutz 913 Series consists of 4-stroke, 3, 4, and 6-cylinder diesel engines with OHV, a horizontal power shaft, and forced air cooling, designed for use in typical circumstances and ranging in output from 59 horsepower (44 kilowatts) to 191 horsepower (141 kilowatts);

The Deutz 914 Series consists of four-stroke, three-, four-, five-, and six-cylinder diesel engines designed for professional and household appliances, featuring overhead valves, a horizontal power shaft, and forced air cooling, and optimized for normal conditions of operation between 59 horsepower (44 kilowatts) and 189 horsepower (141 kilowatts);

The Deutz 912/914 Genset Series includes 19 hp (14 kW) to 97.9 hp (4-stroke, 2, 3, 4, 6, 6-cylinder, OHV, horizontal air-cooled shaft, air-cooled) diesel engines for electro generators designed for usage in normal and harsh climatic situations (73 kW) manufactured with a mechanical or electronic (optional) fuel supply regulator;

The Deutz 1008 Series is a line of four-stroke, 2, 3, and 4-cylinder diesel engines designed for use in construction machinery, featuring overhead valves (OHV), a horizontal power shaft, liquid cooling, and an emphasis on operating in harsh environments, with outputs ranging from 17.7 horsepower (13 kilowatts) to 42 horsepower (31 kilowatts).

The Deutz 1011 Series is a line of 30-liter, 4-stroke, 2-, 3-, and 4-cylinder diesel engines used in construction machinery. These engines have overhead valves (OHV), a horizontal power shaft, and liquid cooling and are optimized for usage in harsh climates. (22 kW) up to (89.5 hp) (61 kW). Gas emission regulations that are in line with those of the European Union’s STEP II and the United States CFR 40, part 89, Tier II;

The Deutz 1013 Series consists of 4-stroke, 4- and 6-cylinder diesel engines with OHV, the horizontal power shaft, liquid cooling, and an output range of 154 hp (115 kW) to 313 hp (233 kW) for use in industrial and construction equipment in both mild and severe climates.

The Deutz 1015 Series consists of 6- and 8-cylinder V-shaped diesel engines with OHV, a horizontal power shaft, liquid cooling, and an output range of 407 hp (300 kW) to 598 hp (440 kW) that are designed for usage in typical climates.

The Deutz 1013/1015 Genset Series consists of four-stroke, six- and eight-cylinder diesel engines for electric generators, with overhead valves (OHV), a horizontal power shaft, liquid cooling, and an output ranging from 103 horsepower (77 kilowatts) to 571 horsepower (362 kilowatts) (426 kW) produced using both a mechanical regulator and electronic control (as an extra);

With power ranging from 31 horsepower (23 kilowatts) to 88 horsepower (65 kilowatts), the Deutz 2011 Series consists of 2, 3, 4, and 4-cylinder diesel engines for mobile medium-power mobile equipment with OHV, horizontal power shaft, air or liquid cooling, and an emphasis on operation in normal climatic conditions; the L models feature a heat exchanger.

The Deutz TCD 2011 Series is a line of air-cooled, OHV, horizontally-mounted, 2- and 3-cylinder diesel engines for medium-power mobile equipment ranging in output from 31 to 100 horsepower (23 to 74 kilowatts) (74.9 kW). Meet the gas emission requirements of European Union (EU) STEP III and United States (US) Tier 3;

Deutz f4m2011

The Deutz 2012 Series is a line of four- and six-cylinder diesel engines designed for medium-power mobile equipment. They feature overhead valves (OHV), a horizontal power shaft, and liquid cooling and are optimized for use in typical climates. Their output ranges from 101.8 horsepower (74.9 kilowatts) to 210 horsepower (155 kilowatts).

The Deutz TCD 2012 Series is a four-stroke and six-cylinder diesel engine line designed for medium-power mobile equipment. They feature overhead valves (OHV), a horizontal power shaft, and liquid cooling and are optimized for use in temperate climates.

The Deutz 2011/2012 Genset Series consists of four-stroke 2, 3, and 4-cylinder diesel engines for electric generators with overhead valves, horizontal power shafts, liquid or air cooling, and a primary focus on operation in both normal and difficult climatic conditions, with outputs ranging from 15.5 horsepower (11.4 kilowatts) to 101 horsepower (75 kilowatts);

The Deutz TCD2013 Series is a line of four- and six-cylinder diesel engines designed for use in mobile medium-power equipment. These engines feature overhead valves (OHV), a horizontal power shaft, liquid cooling, and are optimized for use in temperate climates. Their output ranges from 173 horsepower (129 kilowatts) to 325.9 horsepower (243 kW). Meet the requirements for gas emissions set out by the European Union’s STEP III A and the United States’ Tier 3;

The Deutz TCD2013 Genset Series consists of four- and six-cylinder diesel engines with an output ranging from 121 horsepower (90 kilowatts) to 314 horsepower (234 kilowatts) with an emphasis on normal climate operating.

The Deutz TCD 2015 Series consists of 6 and 8-cylinder, OHV, the horizontal power shaft, liquid-cooled, industrial diesel engines designed for usage in typical climates and capable of producing between 489 horsepower (360 kilowatts) and 670 horsepower (500 kilowatts);

The Deutz TCD 2.9-16 liter Series consists of 4, 6, and 8-cylinder diesel engines for mobile equipment; their engine volumes range from 2.9 to 16 liters; they feature overhead valves (OHV), a horizontal power shaft, water cooling, and are optimized for use in extreme climates; their outputs range from 50 horsepower (36.9 kW) to 697 horsepower (600 lb-ft) (520 kW).

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please contact :

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DEUTZ AG

Sales & Service Information Systems

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D-51149 Köln (Cologne)

Phone.: +49 (0) 221-822-0

Fax: +49 (0) 221-822-3525

Internet: www.deutz.com

E-Mail: info@deutz.com

Printed in Germany

1st Edition, 12/2008

Order No. 0312 4176 en

+ 49 (0) 221 822-3053

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This document is subject to changes which may become necessary in the course of further de-

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Page 1
Workshop Manual competence level 2 D 2011 w TD 2011 w, TCD 2011 w 0312 4176 en 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…
Page 2
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 Sales & Service Information Systems Ottostraße 1 D-51149 Köln (Cologne) Phone.: +49 (0) 221-822-0 Fax: +49 (0) 221-822-3525 Internet: www.deutz.com…
Page 3: Table Of Contents

DEUTZ engines Table of contents Foreword General User notes General Specifications Operating manual and workshop manual Job cards Explanation of symbols Technical data Testing and setting data Tightening specifications Job card overview Sorted alphabetically Sorted numerically Job cards Commercial tools Special tools ©…
Page 7
(use for the intended purpose). Any use above and beyond this is con- The engines made by DEUTZ are developed for sidered improper use. The manufacturer will not a wide range of applications. A wide range of var- be liable for damages resulting from this.
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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 and low fuel consumption.
Page 15
DEUTZ engines User notes 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.
Page 16
Rail System Working materials and tools must be cleaned be- fore work. Only use tools without damage to the The DEUTZ Common Rail system used in the chrome plating or tools which are not chrome- DEUTZ engines consists of high-precision compo- plated.
Page 17
DEUTZ engines User notes When removing and installing components, no operating materials among other things. The re- materials which can leave behind particles or fi- newed parts / operating materials must be stored, bres (cardboard, wood, cloths) may be used.
Page 18
User notes DEUTZ engines 3.3 Operation manual and workshop 3.4 Job cards manual The job cards are divided in the workshop manual into «W» and «I» job cards. To structure the information to suit the user, the The «W» job card documents standard repairs on the service documentation is divided into operation engine and/or its components.
Page 19: Explanation Of Symbols

Test and Setting Va- 8. Graphic or photo lues table. For example: 9. DEUTZ internal creation number ID no. P01 61 = valve clearance, inlet 10.Page number Tightening specification 11.Date of issue of job card The necessary values are specified here.
Page 21: Technical Data

D 2011 w Technical data TD 2011 w, TCD 2011 w Testing and setting data Technical data Testing and setting data © 12/2008 19484-001…
Page 22
Check after 15 minutes running P12 21 V-belt tension, individual V-belts AVX 10 −20 under load D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head Identification, cylinder head gas- P02 75 Piston overhang 9.820 — 10.140 mm…
Page 23: Tightening Specifications

D 2011 w Technical data TD 2011 w, TCD 2011 w Tightening specifications Tightening specifications © 12/2008 19484-001…
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TD 2011 w, TCD 2011 w ID no. Name Screw type Notes / Remark Value D 2011 w / TD 2011 w / TCD 2011 w A00 001 Clamping bracket on crankcase 90 Nm Clamping bracket on adapter for A00 002 90 Nm…
Page 25
D 2011 w Technical data TD 2011 w, TCD 2011 w Tightening specifications ID no. Name Screw type Notes / Remark Value M8x35-10.9 A09 010 Coolant pump on thermostat housing 20 Nm M8x100-10.9 A09 020 Pipe clip on holder M6x16…
Page 26
8 Nm (exhaust gas return) 30IPR A07 087 Fuel filter console to crankcase 21 Nm TD 2011 w / TCD 2011 w A06 004 Pin bolts on exhaust pipe coated Use new pin bolts 12 Nm A06 020 Turbocharger on exhaust pipe…
Page 27: Job Card Overview

D 2011 w TD 2011 w, TCD 2011 w Job card overview Job card overview Sorted alphabetically 1/12 © 12/2008 19488-001…
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D 2011 w Job card overview TD 2011w, TCD 2011 w Sorted alphabetically Activity Job card Maintenance group Checking piston overhang W 01-04-09 Cylinder head Checking the compression pressure W 00-02-06 General Checking the thermostat (in the removed state) W 09-08-01 Cooling system Disassembling, assembling and checking the rocker arm and rocker arm…
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Job card overview D 2011 w Sorted alphabetically TD 2011w, TCD 2011 w Activity Job card Maintenance group Removing and installing the oil filter console W 08-11-07 Lube oil system Removing and installing the oil pressure switch W 08-11-08 Lube oil system Removing and installing the rocker arm and rocker W 01-02-02 Cylinder head…
Page 31: Sorted Numerically

D 2011 w Job card overview TD 2011 w, TCD 2011 w Sorted numerically Sorted numerically 5/12 © 12/2008 19488-001…
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D 2011 w Job card overview TD 2011 w, TCD 2011 w Sorted numerically Job card Activity Maintenance group W 00-02-06 Checking the compression pressure General Mounting engine on assembly block and demoun- W 00-05-01 General ting W 01-01-01 Setting valve clearance…
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Job card overview D 2011 w Sorted numerically TD 2011 w, TCD 2011 w Job card Activity Maintenance group 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 09-08-04…
Page 37: Special Tools

D 2011 w General TD 2011 w, TCD 2011 w W 00-02-06 Checking the compression pressure Commercial available tools: – W 01-01-01 – Compression pressure – W 07-07-01 tester……8005…
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General D 2011 w W 00-02-06 TD 2011 w, TCD 2011 w Mount clamping shoe (1). Tighten screw (2). 21 Nm © 47535-0 Connect adapter (1) to connector. © 47536-0 Mount the compression tester on the adapter. Turn over engine with starter.
Page 39
D 2011 w General TD 2011 w, TCD 2011 w W 00-02-06 The measured compression pressure depends on the starting speed during the measuring process and the altitude of the Kompression in bar engine installation site. Therefore, limit Compression value in bar values cannot be determined exactly.
Page 40
General D 2011 w W 00-02-06 TD 2011 w, TCD 2011 w Unscrew screw (1). © 47535-1 Remove connector (1). Remove sealing ring. Install fuel injectors. W 07-07-01 © 47534-1 © 12/2008 17768-001…
Page 41
D 2011 w General TD 2011 w, TCD 2011 w W 00-02-06 Technical Data Testing and setting data ID no. Name Additional information Value 25 — 30 bar P00 51 Compression pressure (2500 — 3000 kPa) Tightening specifications ID no.
Page 43
D 2011 w General TD 2011w, TCD 2011 w W 00-05-01 Mounting engine on assembly block and demounting Commercial available tools: – W 13-03-02 – Lifting gear – Suspension ropes – Eyelet bolts Danger! Special tools: When using hoists (workshop crane) the –…
Page 44
D 2011 w W 00-05-01 TD 2011w, TCD 2011 w Unscrew screws (1). Remove all mounting feet. – TD 2011 w, TCD 2011 w Unscrew screw (2). Remove holder (3). Remove oil return pipe (4). © 47532-3 Mount clamping holder (1).
Page 45
D 2011 w General TD 2011w, TCD 2011 w W 00-05-01 Unhook the engine from the workshop crane. Unscrew eyelet bolts (1). © 47538-0 Demounting engine from assembly block Screw in eyelet bolts (1). Hang engine on workshop crane. approx. 268 kg ©…
Page 46
Mount oil return pipe (1). Attention! Install tension-free. Mount holder (2). Tighten screw (3). 8.5 Nm – D 2011 w, TD 2011 w, TCD 2011 w Install all mounting feet. Tighten screws (4). 200 Nm © 47532-4 © 12/2008 17769-001…
Page 47
D 2011 w General TD 2011w, TCD 2011 w W 00-05-01 Danger! Put the engine down on a secure surface. Unhook the engine from the workshop crane. Unscrew eyelet bolts (1). Install starter. W 13-03-02 © 47538-0 © 12/2008 17769-001…
Page 48
M14x55-12.9 A00 003 200 Nm crankcase M14x100-12.9 TD 2011 w, TCD 2011 w Torx, A08 049 Holder oil return line on crankcase 8.5 Nm M6x14-8.8 For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 49: Setting Valve Clearance

D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-01-01 Setting valve clearance Commercial available tools: Attention! – Feeler gauges In case of internal exhaust gas recircula- tion, the inlet valve is opened briefly by an additional cam on the camshaft.
Page 50
Cylinder head D 2011 w W 01-01-01 TD 2011 w, TCD 2011 w Arrangement of the inlet and exhaust val- ves. IN = inlet valve EX = exhaust valve Valve overlap means: The inlet valve starts opening,exhaust valve closes. Attention!
Page 51
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-01-01 Check the valve clearance with feeler gauge (1). © 47543-1 Hold adjusting screw (2). Tighten lock nut (1). 20 Nm Do not turn the setting screw when tighte- ning the locking nut.
Page 52
Cylinder head D 2011 w W 01-01-01 TD 2011 w, TCD 2011 w Valve clearance setting schematic According to the order given below, the setting of the valve clearance is possible in two turns of the crankshaft (each 360°). Crankshaft position 1 Turn over crankshaft until the valve overlap is achieved on cylinder 1.
Page 53
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-01-01 Mount cylinder head cover. Oil the screws lightly. Tighten all screws (1) alternately. 8.5 Nm © 47540-1 © 12/2008 17770-001…
Page 54
Cylinder head D 2011 w W 01-01-01 TD 2011 w, TCD 2011 w Technical Data Testing and setting data ID no. Name Additional information Value P00 71 Ignition sequence 1-3-4-2 P01 61 Valve clearance (inlet) 0.3 mm P01 62 Valve clearance (outlet) 0.5 mm…
Page 55
D 2011 w Cylinder head TD 2011w, TCD 2011 w W 01-02-02 Removing and installing the rocker arm and rocker arm bracket Commercial available tools: – W 01-01-01 – Torx tool set ….8189 Removing the rocker arm and rocker arm bracket Unscrew all screws (1).
Page 56
Cylinder head D 2011 w W 01-02-02 TD 2011w, TCD 2011 w Remove push rods (1). Lay out components in the order in which they should be installed. Visually inspect the components. © 47565-0 Installing the rocker arm and rocker arm bracket Insert stop rods (1).
Page 57
D 2011 w Cylinder head TD 2011w, TCD 2011 w W 01-02-02 Lightly oil screws (1). Tighten screws . 21 Nm Attention! Makes sure that the stop rods are not under stress due to valve overlap when fastening the screws. Set valve clearance.
Page 58
Cylinder head D 2011 w W 01-02-02 TD 2011w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A01 002 Rocker arm bracket on cylinder head 21 Nm A01 004 Cylinder head cover on cylinder head 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 59
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-02-06 Disassembling, assembling and checking the rocker arm and rocker arm bracket Commercial available tools: – W 01-02-02 – Internal measuring device – Micrometer gauge – Locking ring pliers Special tools: –…
Page 60
Cylinder head D 2011 w W 01-02-06 TD 2011 w, TCD 2011 w Hold adjusting screw (2). Loosen lock nut (1). Unscrew adjusting screw (2). Lay out components in the order in which they should be installed. © 47031-0 Visually inspect the components.
Page 61
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-02-06 Checking the rocker arm 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.
Page 62
Cylinder head D 2011 w W 01-02-06 TD 2011 w, TCD 2011 w Assembling the rocker arm bracket Lightly oil the rocker arm pin. Push rocker arm (1) onto rocker arm pin. © 39149-2 Insert new locking rings (1). Ensure that the installation location is free from faults.
Page 63
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-02-06 Technical Data Testing and setting data ID no. Name Additional information Value +0.27 P01 72 Rocker arm, bore, diameter (outlet) +0.27 P01 73 Rocker arm, bore, diameter (inlet) +0.01…
Page 65
– W 06-02-03 … . TD 2011 w, – Dog wrench….8018 TCD 2011 w –…
Page 66
Unscrew lock nuts (1) with dog wrench. Remove thermostat housing. W 09-08-04 – D 2011 w Remove the air intake pipe. W 06-07-03 – TD 2011 w, TCD 2011 w Remove the charge air pipe. W 06-02-03 Remove exhaust gas collection pipe. W 06-09-08 © 47550-0 Remove rocker arm and rocker arm bracket.
Page 67
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-04 Installing the cylinder head Measure the piston overhang on all pistons. Select cylinder head gasket according to the largest piston projection measured. Check piston overhang. W 01-04-09 ©…
Page 68
Cylinder head D 2011 w W 01-04-04 TD 2011 w, TCD 2011 w Clean sealing surfaces. The sealing surfaces for the cylinder head gasket must be clean and free of oil. Make sure the clamping bushings (1) are in place.
Page 69
Install rocker arm and rocker arm bracket. W 01-02-02 – D 2011 w Install the air intake pipe. W 06-07-03 – TD 2011 w, TCD 2011 w Install the charge air pipe. W 06-02-03 © 47547-0 Install exhaust gas collection pipe.
Page 70
Cylinder head D 2011 w W 01-04-04 TD 2011 w, TCD 2011 w Position clamping claws (1). Attention! Install tension-free. Tighten screws (2). 21 Nm © 47551-0 © 12/2008 17773-001…
Page 71
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-04 Technical Data Testing and setting data ID no. Name Additional information Value Identification, cylinder head gasket P02 75 Piston overhang 0.325 — 0.604 mm = 1 recess…
Page 73
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-09 Checking piston overhang Commercial available tools – W 01-04-04 8190 Special tools: – Dial gauge….100400 –…
Page 74
Cylinder head D 2011 w W 01-04-09 TD 2011 w, TCD 2011 w – Recess cylinder head Insert dial gauge 100410 in measuring beam. Place holders (1) on the sealing surface of the crank- case. Place measuring beam (2) on the holders.
Page 75
D 2011 w Cylinder head TD 2011 w, TCD 2011 w W 01-04-09 – Recess cylinder head Move the measuring beam. Apply the stylus to the piston base (arrow) under pre- tension. Continue turning the crankshaft evenly until the re- versal point of the pointer on the dial gauge is reached.
Page 76
Cylinder head D 2011 w W 01-04-09 TD 2011 w, TCD 2011 w – Recess cylinder head Select cylinder head gasket according to the largest piston projection measured. – 1 recess 9.820 — 10.140 mm – 2 recesses 10.141 — 10.239 mm –…
Page 77
Identification, cylinder head gasket P02 77 Piston overhang 0.705 — 0.804 mm = 3 recesses D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head Identification, cylinder head gasket P02 75 Piston overhang 9.820 — 10.140 mm…
Page 79
D 2011 w Crankcase TD 2011 w, TCD 2011 w W 03-01-11 Removing and installing the crankcase bleeding Commercial available tools Special tools: – Disassembly tool… . . 110901 Removing the crankcase bleeding Unscrew screw (1).
Page 80
Crankcase D 2011 w W 03-01-11 TD 2011 w, TCD 2011 w Install crankcase bleeding Clean sealing surfaces. Insert new O-ring (1). © 47160-0 Mount crankcase vent (2). Ensure that the installation location is free from faults. The crankcase bleeding must fit evenly.
Page 81
D 2011 w Crankcase TD 2011 w, TCD 2011 w W 03-01-11 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Crankcase bleeding on front cover / A03 060 on cylinder head cover / on cylinder 8.5 Nm…
Page 83
W 06-06-04 – Torx tool set ….8189 Removing exhaust line – TD 2011 w, TCD 2011 w Remove turbocharger. W 06-06-04 Unscrew all screws (1).
Page 84
Clean sealing surfaces. Mount exhaust line (1). Mount new gaskets. Note installation position. Turn in new screws (2). Tighten new screws (2). 55 Nm – TD 2011 w, TCD 2011 w Install the turbocharger. W 06-06-04 © 47523-2 © 12/2008 17805-001…
Page 85
D 2011 w Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-01-05 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Torx screw, A06 001 Exhaust pipe at cylinder head Use new screws. 55 Nm…
Page 87
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-02-03 Removing and install the charge air line Commercial available tools: – W 06-06-04 – Torx tool set ….8189 –…
Page 88
Exhaust system/Charging W 06-02-03 TD 2011 w, TCD 2011 w Install charge air line Mount charge air line (1). Mount new gaskets. Tighten screws (2) alternately working from the cen- tre to the outside. 21 Nm Install the exhaust pipe.
Page 89
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-02-03 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Torx screw, A06 030 Charge air pipe on cylinder head Use new screws. 21 Nm coated For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 91
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-06-04 Removing and installing the turbocharger Commercial available tools: Attention! – Clamping tongs….9088 Do not remove the stoppers/caps until –…
Page 92
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Loosen spring band clip (1) with spring band pliers. Remove reducer (2). © 47554-0 Unscrew hollow screw (1). Remove lubricating oil pipe (2). Remove sealing rings. Press in stoppers. © 47526-0 Loosen spring band clip (1) with spring band pliers.
Page 93
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-06-04 Unscrew nuts (1). © 47528-0 Remove turbocharger in the direction of the arrow. Remove gasket (1). © 47555-0 Remove the O-ring (1) with the disassembly tool. Unscrew screw-in nipple (2).
Page 94
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Unscrew studs (1). Check components for visible signs of wear. © 47523-0 Installing the turbocharger Mount sealing ring (1). Tighten screw-in nipple (2). 40 Nm Insert new O-ring (3). © 47529-1 Clean sealing surfaces.
Page 95
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-06-04 Mount gasket (1). Plug in the tubing connection (2). Insert turbocharger in the direction of the arrow. © 47555-1 Mount turbocharger (1). Turn on new nuts (2). Tighten nuts (2).
Page 96
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Mount lubrication oil line (1). Mount sealing rings (2). Screw on hollow screw (3). © 47526-1 Insert new O-ring (1). Lightly oil new O-ring (1). © 39378-2 Mount oil return pipe (1).
Page 97
Exhaust system/Charging TD 2011 w, TCD 2011 w W 06-06-04 Attention! Install tension-free. Tighten hollow screw (1). 29 Nm © 47526-2 Mount the reducer (1). Attention! Install tension-free. Position spring band clip (2) with spring band pliers. © 47554-1 Position hose clip (1) with clamping tongs.
Page 98
Exhaust system/Charging W 06-06-04 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A06 004 Pin bolts on exhaust pipe coated Use new pin bolts 12 Nm A06 020 Turbocharger on exhaust pipe…
Page 99
Exhaust system/Charging D 2011 w W 06-07-03 Removing and installing the intake manifold Commercial available tools: – W 06-01-05 – Torx tool set ….8189 Removing the intake manifold Remove the exhaust pipe.
Page 100
Exhaust system/Charging W 06-07-03 D 2011 w Installing the intake manifold Mount new gaskets. Mount intake manifold (1). Tighten new screws (2) alternately working from the centre to the outside. 21 Nm Install the exhaust pipe. W 06-01-05 © 47645-1 ©…
Page 101
Exhaust system/Charging D 2011 w W 06-07-03 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Air suction intake pipe on cylinder Torx screw, A06 030 Use new screws. 21 Nm head coated For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 103
Exhaust system/Charging D 2011 w W 06-09-06 Removing and installing the exhaust gas return valve Commercial available tools: – Special bit, 70 mm long..9120 Removing the exhaust gas return valve Unscrew screw (1) with special bit.
Page 104
Exhaust system/Charging W 06-09-06 D 2011 w Unscrew hollow screws (1). Remove pipe (2). Remove sealing rings (3). © 46935-0 Unscrew hollow screw (1). Remove sealing rings (2). Unscrew hollow screw (3). Remove sealing rings (4). Remove pipe (5). © 46938-0 Unscrew screws (1).
Page 105
Exhaust system/Charging D 2011 w W 06-09-06 Remove gasket (1). © 46940-0 Unscrew screws (1). Remove the exhaust gas return valve. © 46941-0 Remove gasket (1). © 46942-0 © 12/2008 17809-001…
Page 106
Exhaust system/Charging W 06-09-06 D 2011 w Visually inspect the components. © 46965-0 Installing the exhaust gas return valve Clean sealing surfaces. Mount gasket (1). Mount exhaust gas return valve (2). © 46943-0 Tighten screws (1). Tighten screws (1). 20 Nm ©…
Page 107
Exhaust system/Charging D 2011 w W 06-09-06 Clean sealing surfaces. Mount gasket (1). Mount exhaust gas collection pipe (2). Fasten screws (3). Tighten screws (3). 20 Nm © 46939-1 Insert pipe (5). Mount new sealing rings (4). Screw on hollow screw (3). Mount sealing rings (2).
Page 108
Exhaust system/Charging W 06-09-06 D 2011 w Press in pipe holder (1). © 46937-0 Plug in the cable plug (3). Mount the safety cover (2). Fasten screw (1). Tighten screw (1) with special bit. 8 Nm © 46964-0 © 12/2008 17809-001…
Page 109
Exhaust system/Charging D 2011 w W 06-09-06 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Pipe to exhaust gas return valve/cylin- Hollow screw A06 057 29 Nm der head (cooling — intake) M12x1.5 Exhaust return pipe to exhaust return A06 062 M8x65-10.9 20 Nm…
Page 111
Exhaust system/Charging D 2011 w W 06-09-07 Removing and installing the exhaust gas return pipe Commercial available tools: – Special bit, 70 mm long..9120 Removing the exhaust gas return pipe Unscrew screw (1).
Page 112
Exhaust system/Charging W 06-09-07 D 2011 w Unscrew hollow screws (1). Remove pipe (2). Remove sealing rings (3). © 46935-0 Unscrew hollow screw (1). Remove sealing rings (2). Unscrew hollow screw (3). Remove sealing rings (4). Remove pipe (5). © 46938-0 Unscrew screws (1).
Page 113
Exhaust system/Charging D 2011 w W 06-09-07 Remove gasket (1). © 46940-0 Unscrew screws (1). Remove the exhaust return pipe. © 46961-0 Remove gasket (1). © 46962-0 © 12/2008 17810-001…
Page 114
Exhaust system/Charging W 06-09-07 D 2011 w Unscrew screws (3). Remove exhaust gas return valve (2). Remove gasket (1). © 46960-0 Visually inspect the components. © 46963-0 Installing the exhaust gas return pipe Clean all sealing surfaces. Mount gasket (1). Mount exhaust gas return valve (2).
Page 115
Exhaust system/Charging D 2011 w W 06-09-07 Clean all sealing surfaces. Mount gasket (1). © 46962-0 Install the exhaust gas return pipe. Tighten screws (1). Tighten screws (1). 8.5 Nm © 46961-0 Clean sealing surfaces. Mount gasket (1). Mount exhaust gas collection pipe (2). Fasten screws (3).
Page 116
Exhaust system/Charging W 06-09-07 D 2011 w Insert pipe (5). Mount new sealing rings (4). Screw on hollow screw (3). Mount sealing rings (2). Tighten hollow screw (1). 29 Nm Tighten hollow screw (3). 12 Nm © 46938-0 Insert pipe (1). Mount sealing rings (2).
Page 117
Exhaust system/Charging D 2011 w W 06-09-07 Plug in the cable plug (3). Mount the safety cover (2). Fasten screw (1). Tighten screw (1). 8 Nm © 46964-0 © 12/2008 17810-001…
Page 118
Exhaust system/Charging W 06-09-07 D 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Pipe to exhaust gas return valve/cylin- Hollow screw A06 057 29 Nm der head (cooling — intake) M12x1.5 Exhaust return pipe to exhaust return A06 062 M8x65-10.9 20 Nm…
Page 119: Exhaust Gas Recirculation

Exhaust system/Charging D 2011 w W 06-09-08 Removing and installing the exhaust gas collection pipe (Exhaust gas recirculation) Commercial available tools: – W 06-01-05 – Cleaning brush ….8167 –…
Page 120
Exhaust system/Charging W 06-09-08 D 2011 w Remove gaskets (1). © 46948-0 Clean exhaust channels (1) with cleaning brush (2). Clean all sealing surfaces. © 46949-0 Install exhaust gas collection pipe Check that mounting lugs (1) are sufficiently pre-ten- sioned. ©…
Page 121
Exhaust system/Charging D 2011 w W 06-09-08 Mount gasket (1). Make sure that the installation site of the mounting lugs (2) is in perfect condition. © 46951-0 Mount new gaskets (3). Mount new throttle (2). Note installation position. The marking (arrow) on the throttle is dependent on the engine version.
Page 122
Exhaust system/Charging W 06-09-08 D 2011 w Tighten new screws (1). 55 Nm Install the exhaust gas return pipe. W 06-09-07 Install the exhaust pipe. W 06-01-05 © 46947-0 © 12/2008 17811-001…
Page 123
Exhaust system/Charging D 2011 w W 06-09-08 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Torx M10x25-10.9 Exhaust gas collection pipe (exhaust Torx A06 073 Use new screws. 55 Nm gas return) on cylinder head M10x30-10.9 Torx M10x45-10.9…
Page 125
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-02-07 Removing and installing the lifting magnet (Start amount release) Commercial available tools: Collect leaking operating substances in – Plier insert….8027 suitable vessels and dispose of according to regulations.
Page 126
Fuel system D 2011 w W 07-02-07 TD 2011 w, TCD 2011 w Remove the O-ring (1) with the disassembly tool. Visually inspect the components. © 47392-0 Install lifting magnet Insert new O-ring (1). © 47392-0 Clean all sealing surfaces.
Page 127
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-02-07 Tighten lifting magnet (1) with plier insert. 10 Nm Note direction of terminal. © 39664-1 Plug in the cable plug (1). © 47128-0 © 12/2008 17814-001…
Page 128
Fuel system D 2011 w W 07-02-07 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Lifting magnet (start amount release) A05 065 10 Nm on front cover For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 129
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-03-01 Renewing the injection lines Commercial available tools: Danger! – Dog wrench….8018…
Page 130
Fuel system D 2011 w W 07-03-01 TD 2011 w, TCD 2011 w Remove injection pipes (1). Lay out components in the order in which they should be installed. Note assignment! © 47652-0 Mount the caps (1). © 47654-0 Visually inspect the components.
Page 131
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-03-01 Installing injection pipes Pull off the caps (1). Mount new injection pipe. © 47654-0 Screw on union nuts (1). Attention! Install injection line without tension. Note installation position.
Page 132
Fuel system D 2011 w W 07-03-01 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Injection line on fuel injector / injection A07 003 M12x1.5 25 Nm pump For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 133
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-07-01 Removing and installing the fuel injectors Commercial available tools: – W 07-03-01 – Assembly pliers….8024 –…
Page 134
Fuel system D 2011 w W 07-07-01 TD 2011 w, TCD 2011 w Unscrew screw (1). Remove clamping shoe (2). © 47562-0 Pull out fuel injector (1) and sealing ring (arrow). Lay out components in the order in which they should be installed.
Page 135
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-07-01 Mount sliding hammer on fuel injector. Screw on lock nut (1). Pull out stuck fuel injector. © 47564-0 Grip a tight sealing ring (1) with the assembly pliers (2) and pull off, turning slightly.
Page 136
Fuel system D 2011 w W 07-07-01 TD 2011 w, TCD 2011 w Installing the fuel injector Mount new sealing ring (1) on fuel injector. © 47351-0 Insert fuel injector. Mount clamping shoe. Note installation position of the clamping shoe.
Page 137
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-07-01 Install injection lines. W 07-03-01 © 47557-0 © 12/2008 19502-001…
Page 138
Fuel system D 2011 w W 07-07-01 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A07 001 Fuel injector on cylinder head 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 139
Fuel system TD 2011 w, TCD 2011 w W 07-08-01 Removing and installing the lifting magnet (charge air pressure-dependent full load stop) Commercial available tools: – Plier insert….8027 Special tools: –…
Page 140
Fuel system W 07-08-01 TD 2011 w, TCD 2011 w Install lifting magnet Mount new O-ring. Insert lifting magnet (1). © 47648-0 Tighten lifting magnet (1) with plier insert. 10 Nm © 47646-0 © 12/2008 17821-001…
Page 141
Fuel system TD 2011 w, TCD 2011 w W 07-08-01 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A06 094 Lifting magnet on fuel filter console Renew O-ring 10 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 143
Fuel system TD 2011 w, TCD 2011 w W 07-08-02 Installing and removing charge air pressure-dependent full load stop Commercial available tools: – W 07-10-08 – Plier insert….8027 Special tools: –…
Page 144
Fuel system W 07-08-02 TD 2011 w, TCD 2011 w Unscrew lifting magnet (1) with plier insert. © 39387-1 Remove the O-ring with the disassembly tool. Visually inspect the components. © 47647-0 Installing the charge air-pressure depend- ent full load stop Clean sealing surfaces.
Page 145
Fuel system TD 2011 w, TCD 2011 w W 07-08-02 Insert spring (1). Insert diaphragm (2) and cap (3). Attention! Note installation position. © 39389-1 Tighten screws (1). 8 Nm Install the fuel filter console. W 07-10-08 © 39385-2 © 12/2008…
Page 146
Fuel system W 07-08-02 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A06 094 Lifting magnet on fuel filter console Renew O-ring 10 Nm Cap on charge air-dependent full load…
Page 147
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-10-06 Removing and installing fuel pipes Commercial available tools: Danger! – Hose clip pliers ….8011 Wait 30 seconds after switching off the –…
Page 148
Fuel system D 2011 w W 07-10-06 TD 2011 w, TCD 2011 w Loosen spring band clips (1) with spring band pliers. © 47572-0 Pull off hose pieces (1) in the direction of the arrow. © 47573-0 Loosen hose clip (1).
Page 149
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-10-06 Loosen hose clip (1). Pull off fuel pipe (2). Collect draining fuel and dispose of accor- ding to regulations. © 47614-0 Unscrew hollow screws (1). Remove fuel pipe (2).
Page 150
Fuel system D 2011 w W 07-10-06 TD 2011 w, TCD 2011 w Visually inspect the components. © 47618-0 Installing fuel pipes Mount fuel return pipe (1). Mount sealing rings (2). Tighten hollow screw (3). 29 Nm © 47617-1 Mount fuel pipe (1).
Page 151
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-10-06 Mount fuel hose (2). Lay hose without contact. Ensure that the installation location is free from faults. Mount new hose clip (1). Fix the hose clip (1) with the hose clip pliers.
Page 152
Fuel system D 2011 w W 07-10-06 TD 2011 w, TCD 2011 w Push on hose pieces (1) in the direction of the arrow. © 47573-1 Position spring band clips (1) with spring band pliers. © 47572-0 Position clamping claws (1).
Page 153
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-10-06 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A07 015 Fuel supply line to injection pump Hollow screw Replace sealing rings 29 Nm…
Page 155
Fuel system TD 2011 w, TCD 2011 w W 07-10-08 Removing and installing the fuel filter console Commercial available tools: Danger! – Hose clip pliers ….8011 Wait 30 seconds after switching off the –…
Page 156
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w Pull off hose pipe (1). © 47593-0 Unscrew screws (1). Remove fuel filter console (2). © 47594-0 Remove the O-ring (1) with the disassembly tool. © 47595-0 © 12/2008 17824-001…
Page 157
Fuel system TD 2011 w, TCD 2011 w W 07-10-08 Visually inspect the components. © 47596-0 Installing the fuel filter console Clean sealing surfaces. © 47597-0 Insert new sealing ring (1). © 47598-0 © 12/2008 17824-001…
Page 158
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w Install the fuel filter console (2). Tighten screws (1). 22 Nm © 47594-0 Mount the hose pipe (1). © 47593-0 Note assignment! Lay hoses without contact. Install fuel hoses. Mount new hose clips (1).
Page 159
Fuel system TD 2011 w, TCD 2011 w W 07-10-08 Position protective hoses, dimension X. 20 mm © 47599-0 © 12/2008 17824-001…
Page 160
Fuel system W 07-10-08 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Fuel filter console/full load stop to Torx, A07 087 22 Nm crankcase M8x50-8.8 For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 161
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-11-01 Removing and installing the fuel supply pump Commercial available tools: Danger! – Hose clip pliers ….8011…
Page 162
Fuel system D 2011 w W 07-11-01 TD 2011 w, TCD 2011 w Loosen hose clip (1). Pull off fuel pipe (2). Pull off protective hose (3). Collect draining fuel and dispose of accor- ding to regulations. © 47610-0 Unscrew screws (1).
Page 163
D 2011 w Fuel system TD 2011 w, TCD 2011 w W 07-11-01 Installing the fuel supply pump Turn the crankshaft until the eccentric of the cam- shafts is in the top dead centre (arrow). © 47398-0 Insert new O-ring (1).
Page 164
Fuel system D 2011 w W 07-11-01 TD 2011 w, TCD 2011 w Slip protective hose (3) over with mounting com- pound. Lay hose without contact. Mount fuel hose (2). Mount new hose clip (1). © 47610-0 Position protective hose, dimension X.
Page 166
Fuel system D 2011 w W 07-11-01 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A07 024 Fuel supply pump on crankcase 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 167
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-08-02 Removing and installing the lubricating oil cooler Commercial available tools – W 08-11-07 Collect leaking operating substances in suitable vessels and dispose of according to regulations.
Page 168
Lube oil system D 2011 w W 08-08-02 TD 2011 w, TCD 2011 w Installing the lubricating oil cooler Visually inspect the components. © 47519-0 Clean sealing surfaces. Insert new sealing ring (1). © 47518-0 Mount lubricating oil cooler (1).
Page 169
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-08-02 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Lubricating oil cooler on oil filter con- A08 051 M6x16-10.9 13 Nm sole For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 171
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-07 Removing and installing the oil filter console Commercial available tools: – Operation manual – Torx tool set ….8189 –…
Page 172
Lube oil system D 2011 w W 08-11-07 TD 2011 w, TCD 2011 w Unscrew hollow screw (1). Remove sealing rings (2). © 47514-0 Unscrew lubricating oil filter (1) with special wrench. Collect draining lubricating oil and dispose of properly.
Page 173
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-07 Remove gasket (1). Clean sealing surfaces. © 47520-0 Installing oil filter console Visually inspect the components. © 47521-0 Fix new gasket (1) to the crankcase with a little grease.
Page 174
Lube oil system D 2011 w W 08-11-07 TD 2011 w, TCD 2011 w Mount oil filter console (1). Do not move gasket. Tighten screws (2). Turn in screw (3). Tighten screws (2). 21 Nm Tighten screw (3). 21 Nm ©…
Page 175
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-07 Push on hose pieces (1) in the direction of the arrow. © 47573-1 Position the spring band clip (1) with the spring band pliers. © 47572-0 ©…
Page 176
Lube oil system D 2011 w W 08-11-07 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Torx M8x50-8.8 A08 003 Oil filter console on crankcase 21 Nm Torx M8x90-8.8…
Page 177
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-08 Removing and installing the oil pressure switch Commercial available tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. Removing the oil pressure switch Pull out cable plug (1).
Page 178
Lube oil system D 2011 w W 08-11-08 TD 2011 w, TCD 2011 w Visually inspect the components. © 47433-0 Installing the oil pressure switch Screw on oil pressure switch (1). © 47434-0 Tighten oil pressure switch (1). 13 Nm ©…
Page 179
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-08 Plug in the cable plug (1). Ensure that the connection is perfect. © 47344-0 © 12/2008 17832-001…
Page 180
Lube oil system D 2011 w W 08-11-08 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A08 091 Oil pressure switch on crankcase M10x1 13 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 181
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-12 Removing and installing the thermostat (Lubricating oil cooler) Commercial available tools: Collect leaking operating substances in – Slide gauge suitable vessels and dispose of according – Torx tool set ….8189 to regulations.
Page 182
Lube oil system D 2011 w W 08-11-12 TD 2011 w, TCD 2011 w Remove the O-ring (1) with the disassembly tool. © 47439-0 Visually inspect the components. © 47568-0 Installing the thermostat Measure length of the compressor spring with calli- per gauge.
Page 183
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-11-12 Clean sealing surfaces. Oil the thermostat lightly. Insert compression spring. Insert thermostat (1). Note installation position. © 47575-0 Lightly oil new O-ring (1). Insert new O-ring (1).
Page 184
Lube oil system D 2011 w W 08-11-12 TD 2011 w, TCD 2011 w Technical Data Testing and setting data ID no. Name Additional information Value P08 74 Thermostat, compression spring, length 45.7 mm Tightening specifications ID no. Name Screw type Notes / Remark…
Page 185
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-16-01 Removing and installing the control line Commercial available tools – W 07-10-08 – W 08-11-07 Collect leaking operating substances in suitable vessels and dispose of according to regulations.
Page 186
Lube oil system D 2011 w W 08-16-01 TD 2011 w, TCD 2011 w Visually inspect sealing surfaces (arrows). © 47651-0 Visually inspect the components. © 47649-0 Installing control line Insert control line (1). Mount sealing rings (2). Screw in all hollow screws.
Page 187
D 2011 w Lube oil system TD 2011 w, TCD 2011 w W 08-16-01 Install the fuel filter console. W 07-10-08 Mount oil filter console. W 08-11-07 Insert control line (1). Mount sealing rings (2). Tighten hollow screw (3). 18 Nm ©…
Page 188
Lube oil system D 2011 w W 08-16-01 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Control line to oil filter console / crank- Hollow screw A08 048 18 Nm…
Page 189
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-07-08 Removing and installing the coolant pump Commercial available tools – Operation manual 8190 – W 13-02-03 Special tools: – Disassembly tool… . . 110901…
Page 190
Cooling system D 2011 w W 09-07-08 TD 2011 w, TCD 2011 w Clean sealing surfaces. © 47511-0 Installing coolant pump Clean sealing surfaces. Insert new O-ring (1). © 47512-0 Mount coolant pump (1). Pay attention to different screw lengths.
Page 191
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-07-08 Install V-belt. W 13-02-03 Fill cooling system according to the operating manu- © 46986-2 © 12/2008 17835-001…
Page 192
Cooling system D 2011 w W 09-07-08 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value M8x35-10.9 A09 010 Coolant pump on thermostat housing 20 Nm M8x100-10.9 For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 193
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-01 Checking the thermostat (in the removed state) Commercial available tools: – W 09-08-02 – Thermometer Danger! Risk of injury! Hot water and hot thermostat. Checking thermostat Remove thermostat.
Page 194
Cooling system D 2011 w W 09-08-01 TD 2011 w, TCD 2011 w Measure end of stroke, dimension (b). Note measured value, dimension (b). © 34679-2 Determine stroke. Calculation example Desired: Stroke Given: Measured: Beginning of stroke, dimension (a) End of stroke, dimension (b)
Page 195
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-01 Technical Data Testing and setting data ID no. Name Additional information Value P09 11 Thermostat, start of opening 86 — 90 °C P09 13 Thermostat, stroke distance at least 9 mm ©…
Page 197
D 2011 w D 2011 w Cooling system Cooling system TD 2011 w, TCD 2011 w TD 2011 w, TCD 2011 w W 09-08-02 W 09-08-02 Removing and installing the thermostat Commercial available tools – W 09-08-01 Collect leaking operating substances in suitable vessels and dispose of according to regulations.
Page 198
Cooling system Cooling system D 2011 w D 2011 w W 09-08-02 W 09-08-02 TD 2011 w, TCD 2011 w TD 2011 w, TCD 2011 w Check thermostat. W 09-08-01 Visually inspect the components. © 46984-0 Installing the thermostat Clean sealing surfaces.
Page 199
D 2011 w D 2011 w Cooling system Cooling system TD 2011 w, TCD 2011 w TD 2011 w, TCD 2011 w W 09-08-02 W 09-08-02 Mount outlet nozzle (2). Tighten screws (1). 22 Nm © 46982-0 © 12/2008 17837-001…
Page 200
Cooling system Cooling system D 2011 w D 2011 w W 09-08-02 W 09-08-02 TD 2011 w, TCD 2011 w TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A09 002 Outlet nozzles on thermostat housing M8x30-10.9…
Page 201
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-04 Removing and installing the thermostat housing Commercial available tools: – Operation manual 8190 – Spring band pliers ….9090 –…
Page 202
Cooling system D 2011 w W 09-08-04 TD 2011 w, TCD 2011 w Unscrew screw (1). Unscrew screws (2). Remove the thermostat housing (3). © 46990-0 Pull out plug element (1). Pull out plug element (2). © 46991-0 Remove the O-ring (1) with the disassembly tool.
Page 203
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-04 Installing thermostat housing Clean all sealing surfaces. Visually inspect the components. © 46993-0 Insert new O-ring (1). © 46992-0 Insert plug element (1). Insert plug element (2).
Page 204
Cooling system D 2011 w W 09-08-04 TD 2011 w, TCD 2011 w Mount thermostat housing (1). Ensure that the installation location is free from faults. Tighten screws (2). 34 Nm Turn in screw (3). © 46990-1 Coat hose pieces with mounting compound.
Page 205
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-08-04 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A09 001 Thermostat housing to crankcase M8x100-10.9 34 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 207
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-12-01 Removing and installing temperature transmitter Commercial available tools Collect leaking operating substances in suitable vessels and dispose of according to regulations. Emptying and filling the engine with opera-…
Page 208
Cooling system D 2011 w W 09-12-01 TD 2011 w, TCD 2011 w Installing temperature transmitter Tighten temperature transmitter (1). 25 Nm Make sure the sealing ring is in place. Connect cable. Ensure that the connection is perfect. © 46994-0 ©…
Page 209
D 2011 w Cooling system TD 2011 w, TCD 2011 w W 09-12-01 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Temperature transmitter on thermo- A09 031 25 Nm stat housing For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 211: Engine Shutdown

D 2011 w Monitoring system TD 2011 w, TCD 2011 w W 11-00-03 Removing and installing the lifting magnet (Engine shutdown) Commercial available tools – W 12-02-01 Special tools: – Disassembly tool… . . 110901 Remove lifting magnet –…
Page 212
Monitoring system D 2011 w W 11-00-03 TD 2011 w, TCD 2011 w Remove cable tie (1). Unscrew screws (2). Remove lifting magnet (3). © 47606-0 Remove the O-ring (1) with the disassembly tool. Visually inspect the components. © 47355-0 Install lifting magnet Insert new O-ring (1).
Page 213: Monitoring System

D 2011 w Monitoring system TD 2011 w, TCD 2011 w W 11-00-03 Insert lifting magnet (1). Tighten screws (2). 8.5 Nm Fasten cable plug with cable tie (3). © 47606-1 Mount V-belt tensioning pulley (1). Fasten screw (2). Turn in screw (3).
Page 214
Monitoring system D 2011 w W 11-00-03 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Lifting magnet (engine shutdown) on A05 041 8.5 Nm front cover For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 215
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-01-04 Removing and installing the V-belt pulley Commercial available tools – W 12-02-01 Removing the V-belt pulley Remove V-belt. W 12-02-01 Unscrew screws (1). Remove fan (2). © 47574-0 Unscrew screws (1).
Page 216
Other components D 2011 w W 12-01-04 TD 2011 w, TCD 2011 w Remove V-belt pulley (1). © 47014-0 Remove centrifugal disc (1). Note installation position. Visually inspect the components. © 47015-0 Installing the V-belt pulley Mount centrifugal disc (1).
Page 217
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-01-04 Mount V-belt pulley (1). © 47014-0 Mount flange hub (2). Tighten screws (1). 43 Nm © 47013-0 Attention! Note installation position: «Engine side» label faces engine! Mount fan (2).
Page 218
Other components D 2011 w W 12-01-04 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A09 042 Ventilator on flange hub M8x40-10.9 30 Nm V belt pulley/flange hub on output A12 031 M10x30-8.8…
Page 219
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-02-01 Renew V-belts, check V-belt tension Commercial available tools: Attention! – V-belt tension measuring Only test / tighten / renew V-belts when the device ….. . . 8115 engine is not running.
Page 220
Other components D 2011 w W 12-02-01 TD 2011 w, TCD 2011 w Loosen screws (1). Loosen screw (2). Swing generator (3) in the direction of the arrow. © 46987-0 Unscrew screw (1). Remove air bearing (2). Remove V-belt pulley (3).
Page 221
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-02-01 Swing generator (1) in the direction of the arrow. Tighten screws (2). Fasten screws (3). © 46987-1 Tighten new screw (1). – Stage 1: 30 Nm Tighten screw (1) with socket wrench insert and rota- tion angle disc.
Page 222
Other components D 2011 w W 12-02-01 TD 2011 w, TCD 2011 w Mount V-belt tension measuring device on V-belt. The V-belt must be between the guides (arrow). © 46997-1 Press the V-belt measuring device against the V-belt with the button (1) until you hear it click.
Page 223
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-02-01 – Version with V-belt tensioning pulley Mount V-belt (1). Swing V-belt tensioning pulley (2) in the direction of the arrow. Fasten screws (3). © 46986-1 Press clamping strap (1) in direction of arrow with a suitable tool.
Page 224
Other components D 2011 w W 12-02-01 TD 2011 w, TCD 2011 w Press the V-belt measuring device against the V-belt with the button (1) until you hear it click. Read measured value at the intersection (arrow) of the indicator arm and scale.
Page 225
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-02-01 Technical Data Testing and setting data ID no. Name Additional information Value P12 11 V-belt tension, individual V-belts AVX 10 First assembly −50 Check after 15 minutes running…
Page 227
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-06-01 Removing and installing the flywheel Commercial available tools: – Self-made mandrin guide – Rotation angle disc … . . 8190 Removing the flywheel Block flywheel with suitable tool.
Page 228
Other components D 2011 w W 12-06-01 TD 2011 w, TCD 2011 w Installing the flywheel Screw two long screws into the threaded bores. To improve the removal and installation of the flywheel. Insert self-made mandrin guide (1). For example a pin bolt.
Page 229
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-06-01 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Stage 1: A12 001 Flywheel on crankshaft 30 Nm Use new screws A12 001 Flywheel on crankshaft Stage 2: 60°…
Page 231
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-08-02 Removing and installing the hydraulic pump Commercial available tools – Graphite grease G 500 Removing the hydraulic pump Remove the hydraulic pipes. Press in stoppers. Unscrew screws (1).
Page 232
Other components D 2011 w W 12-08-02 TD 2011 w, TCD 2011 w Installing hydraulic pump Pull collar (1) onto coupling sleeve (3). Align cutting on the toothing of the coupling sleeve. Pull collar (2) onto coupling sleeve (3). Align cutting on the toothing of the coupling sleeve.
Page 233
D 2011 w Other components TD 2011 w, TCD 2011 w W 12-08-02 Insert hydraulic pump (1) and coupling sleeve. Toothing of the coupling sleeve must engage with the gear shaft. Tighten screws (2). 57 Nm Pull out stoppers. Insert hydraulic pipes.
Page 234
Other components D 2011 w W 12-08-02 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Hydraulic pump on hydraulic pump A12 051 57 Nm console For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 235
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-02-03 Removing and installing the generator Commercial available tools – W 12-02-01 Removing the generator Disconnect the battery’s negative terminal. Remove cable from generator. Note assignment! — (1) = terminal W…
Page 236
Electrical system D 2011 w W 13-02-03 TD 2011 w, TCD 2011 w Unscrew screw (1). Remove generator. © 47602-0 Installing the generator Mount generator. Fasten screw (1). © 47602-0 Mount generator. Insert screw (1). Mount protective plate (2). Mount protective plate (3).
Page 237
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-02-03 Remove cable from generator. Note assignment! — (1) = terminal W — (2) = terminal D+ — (3) = terminal B+ – (Position 2) 3.5 Nm – (Position 3) 6.5 Nm…
Page 238
Electrical system D 2011 w W 13-02-03 TD 2011 w, TCD 2011 w Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Charging current cable to generator A13 081 6.5 Nm A13 082 Cable G1.D+ to generator 3.5 Nm…
Page 239
TD 2011 w, TCD 2011 w W 13-03-02 Removing and installing the starter Commercial available tools Removing the starter – TD 2011 w, TCD 2011 w Disconnect the battery’s negative terminal. Disconnect cables. Unscrew screws (1). Remove shielding plate (2).
Page 240
Electrical system D 2011 w W 13-03-02 TD 2011 w, TCD 2011 w Visually inspect the components. © 47476-0 Installing the starter Insert starter. Tighten screws (1). 43.5 Nm © 47579-0 Mount shielding plate (1). Tighten screws (2). Make sure that the installation site of the rubber pad (3) is in perfect condition.
Page 241
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-03-02 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A13 001 Starter on crankcase 43.5 Nm A13 009 Shield on crankcase M6x14-8.8 8.5 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 243
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-06-01 Removing and installing the heating plugs Commercial available tools Special tools: – Assembly tool ….120440 Removing the glow plugs Disconnect the battery.
Page 244
Electrical system D 2011 w W 13-06-01 TD 2011 w, TCD 2011 w Installing the glow plugs Screw in heating plug (1). Tighten heating plug (1) with assembly tool. 21 Nm Connect cables to heating plugs. Connect the battery. © 46969-0 ©…
Page 245
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-06-01 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value A13 032 Heating plug on cylinder head 21 Nm For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.
Page 247
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-06-02 Removing and installing the glow plug Commercial available tools Removing the glow plug Disconnect cable connections. Unscrew glow plug (1). Remove sealing ring. © 47477-0 Visually inspect the components.
Page 248
Electrical system D 2011 w W 13-06-02 TD 2011 w, TCD 2011 w Installing the glow plug Insert new sealing ring. Insert glow plug (1). © 47479-0 Tighten glow plug (1). 60 Nm Connect cable. 4 Nm © 47477-0 © 12/2008…
Page 249
D 2011 w Electrical system TD 2011 w, TCD 2011 w W 13-06-02 Technical Data Tightening specifications ID no. Name Screw type Notes / Remark Value Glow plug in charge air line / intake A13 031 60 Nm pipe A13 034 Cable connection to glow plug…
Page 252
D 2011 w Standard tools TD 2011 w, TCD 2011 w 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…
Page 253
D 2011 w TD 2011 w, TCD 2011 w Standard tools 8005 Compression pressure tester for diesel engines 10 — 40 bar Checking compression pressure © 35410-3 8011 Hose clip pliers Loosen and fasten hose clips e. g. fuel return pipe ©…
Page 254
D 2011 w Standard tools TD 2011 w, TCD 2011 w 8024 Assembly pliers Removing valve shaft seals © 37509-2 8027 Plier insert Removing and installing the lifting magnet © 39531-1 8115 V-belt tension measuring device 150 to 600 N Check V-belt tension ©…
Page 255
D 2011 w TD 2011 w, TCD 2011 w Standard tools 8116 Socket wrench insert Torx — E18 © 35415-1 8167 Cleaning brush Cleaning exhaust channels © 46283-0 8189 Torx tool set Contents of case: — Double-ended ring spanner E6/E8…
Page 256
D 2011 w Standard tools TD 2011 w, TCD 2011 w 8190 Rotation angle disc with magnet (e. g. setting valve clearance) © 42528-1 9088 Clamping tongs Loosening and tightening hose clips © 39433-1 9090 Spring band pliers 320 mm Tighten spring clamp ©…
Page 260
D 2011 w Special tools TD 2011 w, TCD 2011 w 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…
Page 261
D 2011 w TD 2011 w, TCD 2011 w Special tools 100120 Connector (in conjunction with compression pressure tester 8005) © 39400-1 100400 Dial gauge with fixing wheel Measuring range 0 — 10 mm / 0.01 mm © 35424-1 100410 Digital gauge Measuring range 0 — 30 mm / 0.01 mm…
Page 262
D 2011 w Special tools TD 2011 w, TCD 2011 w 100750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection © 39402-2 110090 Puller (in connection with sliding hammer 150800) Removing fuel injector ©…
Page 263
D 2011 w TD 2011 w, TCD 2011 w Special tools 120440 Assembly tool Removing and installing the glow plugs © 40333-1 150180 Holder (in conjunction with measuring device 100750) Measure piston overhand on recess cylinder head © 43181-0 150800…
Page 264
D 2011 w Special tools TD 2011 w, TCD 2011 w 170050 Special wrench 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 6067 Assembly block Engine clamping, one-sided ©…
Page 265
D 2011 w TD 2011 w, TCD 2011 w Special tools 6067/114 Supporting bracket (in conjunction with assembly block 6067) Engine clamping, one-sided © 39369-1 6067/115 Clamping bracket (in conjunction with assembly block 6067) Engine clamping, one-sided © 39425-1 © 12/2008…

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Сборник руководств по ремонту дизельных двигателей Deutz, в котором мы собрали различные справочники, workshop manual, руководства по ремонту и обслуживанию, схемы и коды самодиагностики и прочее. В архиве вы найдете руководства по ремонту и обслуживанию дизельных двигателей Deutz B/FM 1008/F, 1011F, 1012, 1013, WH 912, 913, FL511, TCD 2015, 226, TD / TCD 2012 L04 / 06 2V, TD / TCD 2013 L04/06 2V, D 2008 / 2009. Все руководства Deutz в формате pdf некоторые из них отсканированные руководства, а другие изначально в компьютерном варианте. Языки, в которых представлена документация Deutz где-то английский текст изложения технических работ, где-то русский, где-то немецкий. Все руководства выпущены с 1986 года по 2011 год выпуска. Все технические работы, узлы и агрегаты очень хорошо проиллюстрированы. В каждом руководстве представлены пошаговые инструкции по ремонту всех представленных двигателей. Для того чтобы легче было искать неисправность даны коды самодиагностики неисправностей для некоторых моделей двигателей. Представленные руководства по ремонту моторов Deutz B/FM 1008/F, 1011F, 1012, 1013, WH 912, 913, FL511, TCD 2015, 226, TD / TCD 2012 L04 / 06 2V, TD / TCD 2013 L04 / 06 2V, D 2008 / 2009, разбиты на отдельные файлы.

Год выпуска: 1986-2011 г.
Автор: Deutz
Издательство: Deutz
Формат: PDF
Качество: Изначально компьютерное (eBook) и отсканированные книги
Язык авто-книги : Английский, Русский, Немецкий

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Summary of Contents for Deutz TD 2011 w

Page 3: Table Of Contents

Page 5: Foreword

Page 9: General

Page 13: User Notes

Page 19: Explanation Of Symbols

Page 21: Technical Data

Page 23: Tightening Specifications

Page 27: Job Card Overview

Page 31: Sorted Numerically

Page 32: Job Cards

Page 37: Special Tools

Page 49: Setting Valve Clearance

Page 119: Exhaust Gas Recirculation

Page 211: Engine Shutdown

Page 213: Monitoring System

DEUTZ engines Table of contents

1 Foreword

2 General

3 User notes

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

6Job cards

Checking the compression pressure

Mounting engine on assembly block and demounting

Setting valve clearance

Deutz 912

Deutz 914

Deutz 1008

Deutz 1011

Deutz 1012 1013

Deutz 1015

Deutz 2011

Deutz 2012

Deutz TCD 2012

Deutz TCD 2013

Deutz Engine TCD 2015 Service Manual

Deutz Engines

Related Manuals for Deutz TD 2011 w

Quick Links

Related Manuals for Deutz TD 2011 w

Summary of Contents for Deutz TD 2011 w

Page 3: Table Of Contents

Page 5: Foreword

Page 9: General

Page 13: User Notes

Page 19: Explanation Of Symbols

Page 21: Technical Data

Page 23: Tightening Specifications

Page 27: Job Card Overview

Page 31: Sorted Numerically

Page 32: Job Cards

Page 37: Special Tools

Page 49: Setting Valve Clearance

Page 119: Exhaust Gas Recirculation

Page 211: Engine Shutdown

Page 213: Monitoring System

Комментарии к Deutz Workshop Manual