Deutz Workshop Manual D, TD, TCD 2011w 03123336 PDF

Workshop Manual
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This document is subject to changes which may become necessary in the course of further de-
velopment of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.
Regarding copyright questions and licensing agreements
please contact :
TE-FI, Mr. Sonntag
Tel.: + 49 (0) 221 822-3053
EMail: sonntag.j@deutz.com
DEUTZ AG
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
The engine company. Order No. 0312 3336 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
6 Job cards
7 Commercial tools
8 Special tools
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Table of contents DEUTZ engines
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DEUTZ engines Foreword
1 Foreword
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Foreword DEUTZ engines
© 05/2005 2/4 17762-001

DEUTZ engines Foreword
z Read and observe the information in this docu- z Repair of the engine must correspond to its use
mentation. You will avoid accidents, retain the for the intended purpose. Only parts released by 1
manufacturer's warranty and possess a fully the manufacturer for the respective purpose may
functional and ready to operate engine. be used for conversion work. Unauthorised mod-
z This engine is built exclusively for purpose ac- ifications to the engine exclude manufacturer lia-
cording to the scope of delivery - defined by the bility for resulting damages. Failure to observe
equipment manufacturer (use for the intended this will void the warranty!
purpose). Any use above and beyond this is con- z The engines made by DEUTZ are developed for
sidered improper use. The manufacturer will not a wide range of applications. A wide range of var-
be liable for damages resulting from this. The iants ensures that the respective special require-
user bears the sole risk. ments are met.
z Use for the intended purpose also includes ob- z The engine is equipped according to the installa-
servance of the operating, maintenance and re- tion case, i.e. not all the parts and components
pair instructions specified by the manufacturer. described in this documentation are installed in
The engine may only be used, maintained and your engine necessarily.
repaired by persons who are familiar with this z We have done our best to highlight the differenc-
and are aware of the risks involved. es so that you can easily find the operating, main-
z Make sure that this documentation is available to tenance and repair instructions relevant to your
everyone involved in the operation, maintenance engine.
and repair and that they have understood the
contents.
z Failure to observe this documentation may lead
to malfunctions and engine damage as well as in-
jury to persons for which the manufacturer will
not accept any liability.
z Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and special tools and their perfect
condition.
z Engine parts such as springs, clamps, elastic re-
taining rings etc. pose an increased risk of injury
when handled incorrectly.
z The pertinent rules for the prevention of acci-
dents and other generally recognised health and
We are at your service for any questions you may
safety regulations must be observed.
have in this matter.
z Maximum economy, reliability and long life is only
guaranteed when using DEUTZ original parts.
Your DEUTZ AG
© 05/2005 3/4 17762-001

Foreword DEUTZ engines
© 05/2005 4/4 17762-001

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

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

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

responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.
© 11/2005 3/4 17763-001

General DEUTZ engines
© 11/2005 4/4 17763-001

DEUTZ engines User notes
3 User notes
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User notes DEUTZ engines
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3.1 General 3.2 Specifications

The documentation of the workshop manual has 3.2.1 Accident prevention and safety regu-
been created based on the engine available at the lations
time of going to press.
The legally prescribed rules for the prevention of ac-
There may be deviations in the descriptions, illustra-
cidents must be observed. These are available from
tions and parts due to further developments.
professional associations or from dealers. These
The maintenance work described in the operation are dependent on the application site, operating
3
manual and in the workshop manual must be carried mode and the operating and auxiliary materials be-
out on schedule and completely. The maintenance ing used.
personnel must have the necessary technical
Special protection measures are specified depend-
knowledge to perform the work. Safety and protec-
ing on the work being carried out, and are identified
tion devices which are removed during maintenance
in the job description.
work must be replaced again afterwards.
Among other things it generally applies that:
Caution!
z for the personnel:
The rules for the prevention of accidents and the
safety regulations must be observed during mainte- – Only briefed personnel may operate or main-
nance work. tain the engine. Unauthorised persons are
prohibited access to the machine room.
Reference is made in the workshop manual job
cards to the regulations in chapter 3.2. These must – Wear close-fitting clothing and ear protectors
be read before working on the engine and must be in the machine room when the engine is in op-
strictly followed. eration.
The maintenance intervals and the work to be per- – Only deploy trained personnel to do repairs
formed are specified in the maintenance schedule and maintenance work.
of the operation manual. The job cards contain tech- – Do not work on the fuel system when the en-
nical documentation on the execution of mainte- gine is running. The fuel system is under high
nance work. pressure - danger of death.
– Go to the workshop immediately in case of
leaks in the fuel system.
z for the engine room:
– Ensure adequate ventilation (do not cover air
shafts).
– Provide first aid kit and suitable fire extinguish-
ers. Check the filling and readiness for opera-
tion regularly.
– Only store inflammable materials in the ma-
chine room if they are essential for operation
of the system.
– Smoking and naked flames are prohibited in
the machine room.
z for operation, maintenance and repairs on the
engine:
– 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 stand-
still and secured against starting.
– Injection lines and high pressure pipes must
not be deformed.
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– Damaged injection lines and high-pressure z Remove loose parts (for example paint chips
pipes must be renewed. from assembly work) with an industrial vacuum
– Injection lines and high pressure fuel lines cleaner or other suction device. Only suction may
must never be connected when the engine is be used in assembly work on the open fuel sys-
running. tem.
– Do not place hands near to a leak in the high z Only work on the fuel system in a clean environ-
3 pressure fuel system. ment (no dust, no grinding or welding). Avoid
draughts (dust). Clean the workshop floor regu-
– Also carefully check all high pressure compo-
larly. No brake or performance test benches may
nents visually before performing tests on the
be kept or operated in the same room.
running engine. Wear suitable protective
clothing (for example protective glasses). z Air currents which kick up dust, such as those
Leaks are a potential source of danger for caused by brake repairs or the starting of en-
workshop personnel. gines, should be avoided.
– Even if no leaks are discernible on the high z For work such as removal and installation on de-
pressure fuel system, the workshop personnel fective hydraulic components on the Common
should avoid the immediate danger zone or Rail System it is recommended to partition off a
wear suitable protective clothing (such as pro- separate workshop area in the factory. This must
tective glasses) when performing tests on the be separate from other areas in which general
running engine and during the first trial run. vehicle repairs such as brake repairs are carried
out.
– Always stay out of range of a fuel jet, as it
could cause severe injury. z No general machine tools may be operated in
this room.
– Smoking is strictly prohibited when working on
the fuel system. z Regular cleaning of the workshop area is manda-
tory. Draughts, ventilation systems and heating
– Do not work near to sparks and flames.
fans should be minimised.
– Never disconnect an injector when the engine
z Areas of the engine room from which particles of
is running.
dirt could be loosened (for example the bottom
3.2.2 Cleanliness instructions and meas- part of the tipped driver cab) must be covered
ures for handling the DEUTZ Com- with fresh clean film.
mon Rail System z Working materials and tools must be cleaned be-
The DEUTZ Common Rail system used in the fore work. Only use tools without damage to the
DEUTZ engines consists of high-precision compo- chrome plating or tools which are not chrome-
nents which are exposed to extreme stress. Great plated.
attention must be paid to cleanliness when working Notes and measures to be observed during work
on the fuel system due to the high precision technol- on the fuel system or with the fuel system open.
ogy.
z Only work in clean overalls.
Notes and measures to be observed before
z Only lint-free cleaning cloths may be used for
starting work on the fuel system
work on the fuel system.
z The fuel system must be closed. Make a visual z Remove loose parts (for example paint chips
inspection for leaks / damage to the fuel system. from assembly work) with an industrial vacuum
z Clean the whole engine and engine room with the cleaner or other suction device. Only suction may
system closed before starting work on the fuel be used in assembly work on the open fuel sys-
system. tem.
z The engine must be dry when you start working z Working materials and tools must be cleaned be-
on the fuel system. fore work. Only use tools without damage to the
z Blowing (dry) with compressed air is only permis- chrome plating or tools which are not chrome-
sible with the fuel system closed. plated.
z When using a steam jet, first cover up the control z Do not use used cleaning fluid or test fluid for
unit, the cable plugs, all other electrical plug con- cleaning.
nections and the generator. Also, the steam jet z Compressed air must not be used for cleaning on
may not be pointed directly at them. the open fuel system.
z Electrical plug connections must be plugged z Work on removed components may only be per-
when spraying. formed at a suitably equipped workbench.
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z 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. transported and disposed of according to regula-
z Removed parts may only be rubbed down with tions. The owner himself is responsible for this.
clean, lint-free cloths. No dirt particles may be Disposal includes recycling and the scrapping of
rubbed into the components. parts / operating materials, although recycling has
z Openings on the components and on the engine priority. 3
must be closed immediately with suitable stop- Details of disposal and their monitoring are gov-
pers/caps. erned by regional, national and international laws
z The stoppers/caps may only be removed imme- and directives which the system operator must ob-
diately before installing. serve on his own responsibility.
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 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 The workshop floor is sealed or tiled.
z No welding gear, grinders, general machine
tools, brakes or performance test benches 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.
Notes and measures for workbench and tools in
the vehicle hall
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 chrome-
plated.
3.2.3 Disposal regulations
The work described in the operation manual and
workshop manual necessitates renewal of parts and
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3.3 Operation manual and workshop 3.4 Job cards

manual The job cards are divided in the workshop manual
To structure the information to suit the user, the into "W" and "I" job cards.
service documentation is divided into operation The "W" job card documents standard repairs on the
manual and workshop manual. engine and/or its components. The necessary tools
and special tools are also specified in the "W" job
The operation manual contains a general descrip-
3 tion and instructions for all other maintenance work.
card.
The "I" job card additionally documents the appro-
It contains the following chapters: priate work procedures for repairing the engine and/
1. Contents, General or its components. The workshop must satisfy spe-
2. Engine description cial conditions to perform these work procedures.
3. Operation Special tools and machine tools must be available,
for example.
4. Operating media
3.4.1 Numbering of job cards
5. Maintenance
The job card numbers follow the pattern W 02-04-
6. Care and maintenance work
01. The individual parts of this pattern are explained
7. Faults, causes and remedies below:
8. Engine conservation z W 02-04-01: Documentation type
9. Technical data – WWorkshop manual
10.Service – I ...... Repair instructions
The workshop manual assumes knowledge of the z W 02-04-01: Maintenance group
contents of the operation manual. This applies es-
– 00 ... General / interdisciplinary activities
pecially for the safety regulations. The workshop
manual describes repairs to the engine and compo- – 01 ... Cylinder head
nents for which more effort and appropriately quali- – 02Drive system
fied technicians are required. – 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
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3.4.2 Structure of a job card 3.5 Explanation of symbols

Danger!
1 2 3
of death or to health. Must be observed!
For example: The incorrect use or conver-
sion of the turbocharger can lead to serious
Triebwerk
W 02-04-01 4 injury.
Caution! 3
5
16 Danger to the component/engine. Non-
6 compliance can lead to destruction of the
component/engine.
15
6 7 Must be observed!
14 Note
General notes on assembly, environmental
8
protection etc. No potential danger for man
13
or machine.
Tool
Conventional and special tools required for
12 the work.
8
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
11 10 9 References
to important documents or job cards for the
1. DEUTZ AG, work process.
publisher of service documentation For example: Job card W 04-05-05
2. Engine type (e.g. TCD 2013 4V) Reference
3. Maintenance group to a document or a job card within the work
4. Job card number or topic process.
5. Title of job card Test and setting data
The necessary values are specified here.
6. Reference to other job cards
If several values are necessary, a cross re-
7. Chapter ference is given to the Test and Setting Va-
8. Graphic or photo lues table.
9. DEUTZ internal creation number For example:
ID no. P01 61 = valve clearance, inlet
10.Page number
11.Date of issue of job card Tightening specification
The necessary values are specified here.
12.Note If several values are necessary, a cross re-
13.Danger / Important ference is given to the Tightening Specifi-
14.Work sequence cations table.
15.Special tools; auxiliary materials For example:
ID no. A01 001 = cylinder head screws
16.Conventional tools
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D 2011 w Technical data
TD 2011 w, TCD 2011 w Testing and setting data
4 Technical data
4.1 Testing and setting data
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Technical data D 2011 w
Testing and setting data TD 2011 w, TCD 2011 w
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
25 - 30 bar
P00 51 Compression pressure
(2500 - 3000 kPa)
P00 71 Ignition sequence 1-3-4-2
P01 31 Valve stem, diameter (inlet) 7.98 −0.015 mm
P01 32 Valve stem, diameter (outlet) 7.96 −0.015 mm
4
P01 33 Valve stem clearance (inlet) 0.045 - 0.075 mm
P01 34 Valve stem clearance (outlet) 0.065 - 0.095 mm
+0.05
P01 35 Valve edge thickness (inlet) 2.6 −0.1 mm
+0.05
P01 36 Valve edge thickness (outlet) 2.8 −0.1 mm
+0.1
P01 37 Valve plate, diameter (inlet) 41.5 −0.1 mm
+0.1
P01 38 Valve plate, diameter (outlet) 35.4 −0.1 mm
P01 45 Valve lag dimension (inlet) Wear limit 1.53 mm
P01 46 Valve lag dimension (outlet) Wear limit 1.53 mm
P01 51 Valve spring, length (untensioned) Standard 39.3 mm
P01 61 Valve clearance (inlet) 0.3 mm
P01 62 Valve clearance (outlet) 0.5 mm
+0.27
P01 72 Rocker arm, bore, diameter (outlet) 18 mm
+0.27
P01 73 Rocker arm, bore, diameter (inlet) 18 mm
+0.01
P01 74 Rocker arm pin, diameter 17,97 −0.01 mm
−0.01
P02 03 Main journal, diameter Standard 70 −0.03
mm
P02 04 Main journal, underdimension stage two underdimension stages per 0.25 mm
+0.4
P02 07 Main journal, surface hardness 58 HRc
P02 08 Main journal, radial run-out maximum 0.05 mm
+0.04
P02 11 Fit bearing pin, width Standard 35 +0 mm
Fit bearing pin, width, underdimension
P02 12 one underdimension stage 0.4 mm
stage
Oversize,
P02 13 Fit bearing pin, width 35.44 mm
wear limit
−0.01
P02 22 Lifting journal, diameter Standard 58 −0.03 mm
P02 23 Lifting journal, underdimension stage two underdimension stages per 0.25 mm
P02 34 Crankshaft, permissible axial clearance in the installed state 0.100 - 0.273 mm
+0.05
P02 35 Stop ring, wall thickness Standard 2,4 +0 mm
+0.05
P02 36 Stop ring, wall thickness Oversize level 2,6 +0 mm
maximum permissible deviation
Parallelism of the con rod with respect to
P02 41 at a distance of 100 mm, 0.03 mm
the piston bolt
vertical
the piston bolt
horizontal
+0.035
P02 43 Small end bush, diameter, inside Standard, when installed 30 +0.025 mm
P02 52 Con rod bearing shells, diameter, inside 57.944 - 58.036 mm
P02 55 Con rod, bearing bore, diameter, inside 61,6 +0.02
−0 mm
Theoretical clearance between the big
P02 56 0.014 - 0.07 mm
end bearing and lifting journal
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TD 2011 w, TCD 2011 w Testing and setting data

P02 61 Piston pin, diameter, outside 30 −0.005
−0 mm
Theoretical clearance between piston pin
P02 62 0.025 - 0.040 mm
bush and piston pin
P02 74 Piston, diameter, overmeasure one overmeasure stage 0.5 mm
Identification, cylinder head gas-
P02 75 Piston overhang 0.325 - 0.604 mm
ket = 1 recess
ket = 2 recesses 4
ket = 3 recesses
+0.014
P02 78 Piston pin bore 30 +0.008 mm
+0.2
P02 84 Piston ring 1, joint clearance 0.30 +0 mm
P02 84 Piston ring 1, joint clearance Wear limit 0.8 mm
+0.5
+0.3
P02 86 Piston ring 3, joint clearance Wear limit 1,2 mm
P02 87 Piston ring 1, axial clearance Trapezoidal groove wear gauge -
P02 88 Piston ring 2, axial clearance 0.080 - 0.115 mm
P03 13 Camshaft, bearing liner, diameter, inside in the installed state 54.000 - 54.054 mm
P03 14 Camshaft, bearing liner, diameter, inside Wear limit 54.08 mm
+0.020
P03 31 Cylinder, diameter, inside Standard 96.000 mm
P03 32 Cylinder, diameter, inside Wear limit 96.1 mm
P04 31 Camshaft, bearing pin, diameter 53.945 - 53.960 mm
Minimum speed, setting screw, basic set- +1
P05 05 23 mm
ting
Screw-in depth of the adjusting capsule, +0.5
P05 06 6,4 −0.5 mm
basic setting
+10
Fuel injector (without leak oil), nozzle 170 bar
P07 52
opening pressure (17
+1
MPa)
Oil pressure regulating valve, opening
P08 41 pressure Coloured marking, yellow 1 bar
(with cabin heating connection)
P08 41 pressure Coloured marking, green 3 bar
(without cabin heating connection)
P08 42 pressure Coloured marking, red 1.7 bar
P08 43 pressure Coloured marking, blue 0.3 bar
Oil pressure regulating valve, compres-
P08 44 with heating connection, yellow 80.5 mm
sion spring, length
P08 44 without heating connection, green 56.5 mm
sion spring, length
P08 45 with heating connection, red 78.4 mm
sion spring, length
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Testing and setting data TD 2011 w, TCD 2011 w

P08 46 with heating connection, blue 61.8 mm
sion spring, length
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-belt tension, individual V-belts AVX 10 First assembly +50
450 −50 N
Check after 15 minutes running +20
P12 21 V-belt tension, individual V-belts AVX 10 300 −20 N
4 under load
D 2011 w
P02 71 Piston, diameter, standard Measuring point 1 = height 22 mm 95.900 +0.009
−0.009 mm
P02 72 Piston, diameter, standard Measuring point 2 = height 47 mm 95.830 mm
Measuring point 3 = height 62.2 +0.015
P02 73 Piston, diameter, standard 95.700 −0.015 mm
mm
Distance between crankcase sealing sur- Piston class A 188.380 -
P02 79
face and lifting journal Stroke 125 mm 188.548 mm
Distance between crankcase sealing sur- Piston class B 188.549 -
P02 79
TD 2011 w / TCD 2011 w
−0.009 mm
P02 72 Piston, diameter, standard Measuring point 2 = height 47 mm 95,778 mm
−0.015 mm
TD 2011 w / TCD 2011 w High crankcase
P02 79
TD 2011 w / TCD 2011 w Recess cylinder head
P02 79
D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head
ket = 1 recess
ket = 2 recesses
ket = 3 recesses
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TD 2011 w, TCD 2011 w Tightening specifications
4.2 Tightening specifications
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Tightening specifications 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
assembly block
Mounting foot/engine mounting on M14x55-12.9
A00 003 200 Nm
crankcase M14x100-12.9
Stage 1:
4 Cylinder head screws
can be used a maxi-
mum of 3x with written
A01 001 Cylinder head on crankcase documentation. 30 Nm
Otherwise use new
cylinder head screws.
Observe tightening
sequence.
A01 001 Cylinder head on crankcase Stage 2 80 Nm
A01 001 Cylinder head on crankcase Stage 4 90°
A01 002 Rocker arm bracket on cylinder head 21 Nm
A01 003 Locking nut, valve adjuster 20 Nm
Cylinder head cover on cylinder
A01 004 8.5 Nm
head
Stage 1:
Screws can be used a
maximum of 3x with
A02 010 Main bearing cover on crankcase 50 Nm
written documentation.
Otherwise use new
A02 010 Main bearing cover on crankcase Stage 2: 60°
Stage 1:
A02 015 Toothed belt wheel on crankshaft 130 Nm
Use new screw.
A02 015 Toothed belt wheel on crankshaft Stage 2: 210°
Big end bearing cover on connecting Stage 1:
A02 020 30 Nm
rod Use new screws.
Big end bearing cover on connecting
A02 020 Stage 2: 60°
rod
A02 020 Stage 3: 60°
rod
Adapter for adjustable
bolt on camshaft lock/
A03 003 Locking screw on crankcase M10x1 18 Nm
crankshaft lock.
Replace sealing ring.
bolt on control linkage
A03 004 Locking screw on crankcase 18 Nm
lock.
A03 007 Locking screw on crankcase M18x1.5 Use new locking screw. 50 Nm
Locking screw on crankcase (oil rise
A03 008 M20x1.5 Use new locking screw. 56 Nm
tube)
Observe tightening
A03 010 Rear cover on crankcase 21 Nm
sequence
A03 020 Front cover on crankcase 21 Nm
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A03 024 Assembly tool on crankcase 21 Nm
Lubricating oil pan (plate) on crank- Observe tightening
A03 030 M8x16 21 Nm
case sequence!
A03 031 Locking screw on lubricating oil pan Replace sealing ring 55 Nm
Crankcase bleeding on front cover /
A03 060 on cylinder head cover / on cylinder 8.5 Nm
head
M12x20 4
M12x30
M12x35
Connection housing/connection ring
A03 081 M12x55 106 Nm
to crankcase
M12x70
M12x75
M12x95
Cylinder head
A03 082 Connection housing to crankcase screws 60 Nm
M10x40
M8x10
A03 082 Connection housing to crankcase M8x30 22 Nm
M8x50
M10x40
A03 082 M10x30 45 Nm
to crankcase
M10x25
A03 082 M14x55 180 Nm
to crankcase
A03 085 Cover plate to connection housing 9 Nm
Stage 1:
A04 001 Toothed belt wheel on camshaft 30 Nm
Use new screw.
A04 001 Toothed belt wheel on camshaft Stage 2: 210°
A04 002 Shim on camshaft 21 Nm
A04 052 Tensioning pulley on front cover 21 Nm
Protective hood (toothed wheel) on
A04 053 7 Nm
front cover
Locking nut on setting screw, shut-off
A05 005 6 Nm
stop
Speed transmitter on connection
A05 011 8.5 Nm
housing
A05 021 Regulator lever shaft on front cover 9.2 Nm
A05 022 Idling capsule on front cover 4.6 Nm
Adjusting capsule on front cover,
A05 023 10 Nm
clamping nut
A05 024 Eccentric shaft on front cover Locking nut 7 Nm
Cap (speed adjusting lever) on front
A05 025 4.5 Nm
cover
Lifting magnet (engine shutdown) on
A05 041 8.5 Nm
front cover
Lifting magnet (start amount release)
A05 065 10 Nm
on front cover
Torx screw,
A06 001 Exhaust pipe at cylinder head Use new screws. 55 Nm
coated
A07 001 Fuel injector on cylinder head 21 Nm
Injection valve, clamping nut on
A07 002 45 - 50 Nm
nozzle holder (without leak oil)
© 12/2008 7/10 17765-001


Injection line on fuel injector / injec-
A07 003 M12x1.5 25 Nm
tion pump
A07 012 Injection pump on crankcase 21 Nm
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
A07 071 Locking screw on injection pump Replace sealing ring 45 Nm
4 Torx
M8x50-8.8
A08 003 Oil filter console on crankcase 21 Nm
Torx
M8x90-8.8
A08 010 Lubricating oil pump on crankcase 21 Nm
Packing compound
A08 015 Oil suction pipe on crankcase 21 Nm
DW73
Control line to oil filter console / Hollow screw
A08 048 18 Nm
crankcase M10x1
Lubricating oil cooler on oil filter con-
A08 051 M6x16-10.9 13 Nm
sole
Lubricating oil cooler connection on
A08 054 M6x60 13 Nm
crankcase
Locking screw on transfer fitting
A08 062 M18x1.5 Use new sealing ring 50 Nm
(heating connection)
Locking screw on transfer fitting
(heating connection)
Transfer fitting on crankcase (hea-
ting connection)
Thermostat on crankcase, locking
A08 072 90 Nm
screw,
A08 091 Oil pressure switch on crankcase M10x1 13 Nm
A09 001 Thermostat housing to crankcase M8x100-10.9 34 Nm
Outlet nozzles on thermostat hou-
A09 002 M8x30-10.9 22 Nm
sing
M8x35-10.9
A09 010 Coolant pump on thermostat housing 20 Nm
M8x100-10.9
A09 020 Pipe clip on holder M6x16 21 Nm
Temperature transmitter on thermo-
A09 031 25 Nm
stat housing
A09 042 Ventilator on flange hub M8x40-10.9 30 Nm
Stage 1:
A09 045 Air bearing on console M10x110-12.9 30 Nm
Use new screw.
A09 045 Air bearing on console M10x110-12.9 Stage 2: 120°
Stage 1:
A12 001 Flywheel on crankshaft 30 Nm
Use new screws
A12 001 Flywheel on crankshaft Stage 2: 60°
V belt pulley/flange hub on output
A12 031 M10x30-8.8 43 Nm
flange
V-belt tensioning pulley (holder) on
A12 041 45 Nm
front cover
Hydraulic pump on hydraulic pump
A12 051 57 Nm
console
© 12/2008 8/10 17765-001


Tensioning pulley on hydraulic pump
A12 052 21 Nm
console
Protective hood on hydraulic pump
A12 056 8.5 Nm
console
A13 001 Starter on crankcase 43.5 Nm
A13 009 Shield on crankcase M6x14-8.8 8.5 Nm
M8x75-10.9
A13 010 Console on cylinder head 34 Nm
M8x100-10.9 4
M8x70-10.9
A13 012 Generator on console 34 Nm
M8x75-10.9
A13 015 Clamping bracket on generator M8x30-8.8 22 Nm
A13 016 Clamping bracket on console M8x35-8.8 22 Nm
Glow plug in charge air line / intake
A13 031 60 Nm
pipe
A13 032 Heating plug on cylinder head 21 Nm
A13 034 Cable connection to glow plug 4 Nm
Charging current cable to generator
A13 081 6.5 Nm
B+
A13 082 Cable G1.D+ to generator M5 3.5 Nm
D 2011 w
Air suction intake pipe on cylinder Torx screw,
A06 030 Use new screws. 21 Nm
head coated
Pipe to exhaust gas return valve/ Hollow screw
A06 057 29 Nm
cylinder head (cooling - intake) M12x1.5
Exhaust return pipe to exhaust return
A06 062 M8x65-10.9 20 Nm
valve
Exhaust gas collection pipe to
A06 063 20 Nm
exhaust gas return valve
Pipe to crankcase (exhaust gas Hollow screw
A06 071 12 Nm
return - cooling - return) M8x1
Pipe to exhaust gas return valve
Hollow screw
A06 072 (exhaust gas return - cooling - 29 Nm
M12x1.5
return)
Torx
M10x25-10.9
Exhaust gas collection pipe (exhaust Torx
gas return) on cylinder head M10x30-10.9
Torx
M10x45-10.9
Exhaust gas return pipe to cylinder
A06 074 8.5 Nm
head (exhaust gas return)
Locking screw
Safety cover on sensor housing
A06 075 Torx-Plus 8 Nm
(exhaust gas return)
30IPR
Sensor exhaust gas return on crank-
A06 076 21 Nm
case
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 M8 21 Nm
Torx screw,
A06 030 Charge air pipe on cylinder head Use new screws. 21 Nm
coated
© 12/2008 9/10 17765-001


A06 094 Lifting magnet on fuel filter console Renew O-ring 10 Nm
Fuel filter console/full load stop to Torx,
A07 087 22 Nm
crankcase M8x50-8.8
Cap on charge air-dependent full
A07 096 8 Nm
load stop
Lubricating oil pipe on turbocharger /
A08 042 Hollow screw Replace sealing rings 29 Nm
crankcase
4 Oil return line, hex spuds to turboch-
arger
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.
© 12/2008 10/10 17765-001

D 2011 w
TD 2011 w, TCD 2011 w Job card overview
5
5 Job card overview
5.1 Sorted alphabetically
© 12/2008 1/12 17766-001

Job card overview D 2011 w
Sorted alphabetically TD 2011w, TCD 2011 w
© 12/2008 2/12 17766-001

D 2011 w Job card overview
TD 2011w, TCD 2011 w Sorted alphabetically
Activity Job card Maintenance group

Check start of injection W 07-06-01 Fuel system
Checking fuel injectors W 07-07-02 Fuel system
Checking piston overhang W 01-04-09 Cylinder head
Checking the axial clearance of the crankshaft W 02-01-04 Drive system
Checking the camshaft W 04-05-06 Engine control
Checking the compression pressure W 00-02-06 General
Checking the con rod W 02-03-01 Drive system 5
Checking the crankshaft W 02-01-07 Drive system
Checking the cylinder W 03-03-01 Crankcase
Checking the piston W 02-09-07 Drive system
Checking the piston rings and piston ring grooves W 02-10-03 Drive system
Checking the thermostat (in the removed state) W 09-08-01 Cooling system
Checking the valve guide W 01-06-03 Cylinder head
Checking the valve lag W 01-07-08 Cylinder head
Checking the valves W 01-05-04 Cylinder head
Determining the thickness of the shim W 07-06-03 Fuel system
Disassembling, assembling and checking the rocker
arm and rocker arm W 01-02-06 Cylinder head
bracket
Dismantling and assembling the front cover W 03-08-01 Crankcase
Installing and removing charge air pressure-depen-
W 07-10-08 Fuel system
dent full load stop
Mounting engine on assembly block and demoun-
W 00-05-01 General
ting
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 rear cover W 03-09-01 Crankcase
Removing and installing small end bush I 02-03-03 Drive system
Removing and installing temperature transmitter W 09-12-01 Cooling system
Removing and installing the camshaft W 04-05-05 Engine control
Removing and installing the connection housing W 03-09-04 Crankcase
Removing and installing the control line W 08-16-01 Lube oil system
Removing and installing the control linkage W 05-04-15 Speed control
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 crankshaft W 02-04-01 Drive system
© 12/2008 3/12 17766-001


Removing and installing the exhaust gas collection
W 06-09-08 Exhaust system/Charging
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
Removing and installing the flywheel W 12-06-01 Other components
Removing and installing the front cover W 03-08-01 Crankcase
5
Removing and installing the fuel filter console W 07-10-08 Fuel system
Removing and installing the fuel injector pump W 07-04-01 Fuel system
Removing and installing the fuel injectors W 07-07-01 Fuel system
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 guide bushes (Control
W 07-02-06 Speed control
linkage)
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 impulse transmitter W 05-07-01 Speed control
Removing and installing the intake manifold W 06-07-03 Exhaust system/Charging
Removing and installing the lifting magnet (charge
air pressure-dependent full load stop)
Removing and installing the lifting magnet (Engine
W 11-00-03 Monitoring system
shutdown)
Removing and installing the lifting magnet (Start
amount release)
Removing and installing the lubricating oil cooler W 08-08-02 Lube oil system
Removing and installing the lubricating oil pan (me-
W 08-04-07 Lube oil system
tal sheet lubricating oil pan)
Removing and installing the lubricating oil pump W 08-04-05 Lube oil system
Removing and installing the magnet clip (Exhaust
gas recirculation)
Removing and installing the oil filter console W 08-11-07 Lube oil system
Removing and installing the oil pressure regulating
valve
Removing and installing the oil pressure switch W 08-11-08 Lube oil system
Removing and installing the oil suction pipe W 08-04-06 Lube oil system
Removing and installing the piston and con rod W 02-09-03 Drive system
Removing and installing the piston cooling nozzles W 02-15-01 Drive system
© 12/2008 4/12 17766-001

TD 2011w, TCD 2011 w Sorted alphabetically

Removing and installing the rocker arm and rocker
W 01-02-02 Cylinder head
arm bracket
Removing and installing the sensor (Exhaust gas re-
circulation)
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 5
Removing and installing the toothed belt wheel W 04-04-15 Engine control
Removing and installing the turbocharger W 06-06-04 Exhaust system/Charging
Removing and installing the valves W 01-05-01 Cylinder head
Removing and installing the V-belt pulley W 12-01-04 Other components
Removing and installing, testing camshaft bearing W 03-11-01 Crankcase
Renew camshaft sealing ring (opposite side to flyw-
W 04-03-01 Engine control
heel)
Renew toothed belt and tensioning pulley W 04-04-12 Engine control
Renew toothed belt and tensioning pulley (Hydraulic
W 12-08-03 Other components
pump)
Renew V-belts, check V-belt tension W 12-02-01 Other components
Renewing the crankshaft sealing ring (flywheel side) W 02-02-02 Drive system
Renewing the crankshaft sealing ring (opposite side
W 02-02-04 Drive system
to flywheel)
Renewing the injection lines W 07-03-01 Fuel system
Renewing toothed starter ring on the flywheel W 12-06-03 Other components
Setting valve clearance W 01-01-01 Cylinder head
© 12/2008 5/12 17766-001

© 12/2008 6/12 17766-001

TD 2011 w, TCD 2011 w Sorted numerically
5
5.2 Sorted numerically
© 12/2008 7/12 17766-001

Sorted numerically TD 2011 w, TCD 2011 w
© 12/2008 8/12 17766-001

Job card Activity Maintenance group

I 02-03-03 Removing and installing small end bush Drive system
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 Cylinder head
Removing and installing the rocker arm and rocker
W 01-02-02 Cylinder head
arm bracket
Disassembling, assembling and checking the rocker 5
W 01-02-06 arm and rocker arm Cylinder head
bracket
W 01-04-04 Removing and installing cylinder head Cylinder head
W 01-04-09 Checking piston overhang Cylinder head
W 01-05-01 Removing and installing the valves Cylinder head
W 01-05-04 Checking the valves Cylinder head
W 01-06-03 Checking the valve guide Cylinder head
W 01-07-08 Checking the valve lag Cylinder head
W 02-01-04 Checking the axial clearance of the crankshaft Drive system
W 02-01-07 Checking the crankshaft Drive system
W 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Drive system
Renewing the crankshaft sealing ring (opposite side
W 02-02-04 Drive system
to flywheel)
W 02-03-01 Checking the con rod Drive system
W 02-04-01 Removing and installing the crankshaft Drive system
W 02-09-03 Removing and installing the piston and con rod Drive system
W 02-09-07 Checking the piston Drive system
W 02-10-03 Checking the piston rings and piston ring grooves Drive system
W 02-15-01 Removing and installing the piston cooling nozzles Drive system
W 03-01-11 Removing and installing the crankcase bleeding Crankcase
W 03-03-01 Checking the cylinder Crankcase
W 03-08-01 Removing and installing the front cover Crankcase
W 03-08-01 Dismantling and assembling the front cover Crankcase
W 03-09-01 Removing and installing rear cover Crankcase
W 03-09-04 Removing and installing the connection housing Crankcase
W 03-11-01 Removing and installing, testing camshaft bearing Crankcase
Renew camshaft sealing ring (opposite side to flyw-
W 04-03-01 Engine control
heel)
W 04-04-12 Renew toothed belt and tensioning pulley Engine control
W 04-04-15 Removing and installing the toothed belt wheel Engine control
© 12/2008 9/12 17766-001


W 04-05-05 Removing and installing the camshaft Engine control
W 04-05-06 Checking the camshaft Engine control
W 05-04-15 Removing and installing the control linkage Speed control
W 05-07-01 Removing and installing the impulse transmitter Speed control
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
5 W 06-07-03 Removing and installing the intake manifold Exhaust system/Charging
Removing and installing the exhaust gas return val-
ve
W 06-09-07 Removing and installing the exhaust gas return pipe Exhaust system/Charging
Removing and installing the exhaust gas collection
pipe (Exhaust gas recirculation)
Removing and installing the sensor (Exhaust gas re-
circulation)
Removing and installing the magnet clip (Exhaust
gas recirculation)
Removing and installing the guide bushes (Control
W 07-02-06 Speed control
linkage)
Removing and installing the lifting magnet (Start
amount release)
W 07-03-01 Renewing the injection lines Fuel system
W 07-04-01 Removing and installing the fuel injector pump Fuel system
W 07-06-01 Check start of injection Fuel system
W 07-06-03 Determining the thickness of the shim Fuel system
W 07-07-01 Removing and installing the fuel injectors Fuel system
W 07-07-02 Checking fuel injectors Fuel system
W 07-10-06 Removing and installing fuel pipes Fuel system
Removing and installing the lifting magnet (charge
air pressure-dependent full load stop)
Installing and removing charge air pressure-depen-
dent full load stop
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 08-04-05 Removing and installing the lubricating oil pump Lube oil system
W 08-04-06 Removing and installing the oil suction pipe Lube oil system
Removing and installing the lubricating oil pan (me-
tal sheet lubricating oil pan)
W 08-08-02 Removing and installing the lubricating oil cooler Lube oil system
© 12/2008 10/12 17766-001


Removing and installing the oil pressure regulating
valve
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
Removing and installing the thermostat (Lubricating
oil cooler)
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
5
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
Removing and installing the lifting magnet (Engine
W 11-00-03 Monitoring system
shutdown)
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 12-06-03 Renewing toothed starter ring on the flywheel Other components
W 12-08-02 Removing and installing the hydraulic pump Other components
Renew toothed belt and tensioning pulley (Hydraulic
W 12-08-03 Other components
pump)
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
© 12/2008 11/12 17766-001

© 12/2008 12/12 17766-001

DEUTZ engines Job cards
6 Job cards
6
© 11/2005 1/2 17767-001

Job cards DEUTZ engines
© 11/2005 2/2 17767-001

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
Special tools: Attention!
– Connector . . . . . . . . . . . . . . . . . . 100120 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 care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
6
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely 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, chap-
ter "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). 2
Use sealing ring (1) for fuel injector.
1
z Insert connector (2).
© 47534-0
© 12/2008 1/6 17768-001

General D 2011 w
W 00-02-06 TD 2011 w, TCD 2011 w
z Mount clamping shoe (1).

z Tighten screw (2).
21 Nm
6
© 47535-0
z Connect adapter (1) to connector.
© 47536-0
z Mount the compression tester on the adapter.

z Turn over engine with starter.
25 - 30 bar (2500 - 3000 kPa)
© 46308-0
© 12/2008 2/6 17768-001

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 No.
engine installation site. Therefore, limit Kompression in bar
Compression value in bar
values cannot be determined exactly. The Pression en bar
Dat. _________
compression pressure measurement is 10 15 20 25 30 35 40
only recommended as a reference measu-
Zyl.
rement of all cylinders of an engine to each
other. If more than 15% deviation has been 1
determined, the cause should be determi- 2
ned by disassembling the cylinder unit con- 3
4
cerned. 5
6
7
8
DBGM Made in Germany
MOTOMETER 6
© 45103-0
z Remove the compression pressure tester.
© 47537-0
z Remove the compression pressure tester and

adapter (1).
1
© 47536-0
© 12/2008 3/6 17768-001

General D 2011 w
W 00-02-06 TD 2011 w, TCD 2011 w
z Unscrew screw (1).
6
© 47535-1
z Remove connector (1).

z Remove sealing ring.
z Install fuel injectors.
W 07-07-01
© 47534-1
© 12/2008 4/6 17768-001

D 2011 w General
TD 2011 w, TCD 2011 w W 00-02-06
Technical Data
Testing and setting data
25 - 30 bar
P00 51 Compression pressure
(2500 - 3000 kPa)
Tightening specifications
6
© 12/2008 5/6 17768-001

General D 2011 w
W 00-02-06 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17768-001

D 2011 w General
TD 2011w, TCD 2011 w W 00-05-01
Mounting engine on assembly block and demounting

– Lifting gear
– Suspension ropes
– Eyelet bolts Danger!
Special tools: When using hoists (workshop crane) the
– Assembly block. . . . . . . . . . . . . . . . 6067 safety regulations for handling hoists must
– Supporting bracket . . . . . . . . . .6067/114 be observed.
– Clamping bracket . . . . . . . . . . .6067/115 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. 6
Mounting engine on assembly block

z Remove starter.
W 13-03-02 1
1
z Screw in eyelet bolts (1).
© 47538-0
z Hang engine on workshop crane.

approx. 268 kg
© 47539-0
© 12/2008 1/6 17769-001

General D 2011 w
W 00-05-01 TD 2011w, TCD 2011 w
z Unscrew screws (1).

z Remove all mounting feet.
– TD 2011 w, TCD 2011 w
z Remove holder (3).
z Remove oil return pipe (4). 4
6 2
© 47532-3
z Mount clamping holder (1).

z Tighten screws (2).
90 Nm
© 47009-0
z Align engine on engine block.

z Mount retainer plate (1).
z Tighten screws (2) and lock nuts.
90 Nm
© 47577-0
© 12/2008 2/6 17769-001

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).
1 1
6
© 47538-0
Demounting engine from assembly block

z Screw in eyelet bolts (1).
z Hang engine on workshop crane.
1 1
approx. 268 kg
© 47538-0
z Loosen lock nuts.

z Remove retainer plate (1).
© 47577-0
© 12/2008 3/6 17769-001

General D 2011 w
W 00-05-01 TD 2011w, TCD 2011 w
Danger!
Lower engine with workshop crane.
z Remove clamping bracket (1).
6
© 47009-0
– TD 2011 w, TCD 2011 w

z Insert new O-ring (1).
z Lightly oil new O-ring (1).
© 39378-2
– TD 2011 w, TCD 2011 w

z Mount oil return pipe (1).
Attention!
Install tension-free.
z Mount holder (2).

1
8.5 Nm
– D 2011 w, TD 2011 w, TCD 2011 w
z Install all mounting feet. 2
4
200 Nm
3
© 47532-4
© 12/2008 4/6 17769-001

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.
1 1
z Unscrew eyelet bolts (1).
z Install starter.
W 13-03-02
6
© 47538-0
© 12/2008 5/6 17769-001

General D 2011 w
W 00-05-01 TD 2011w, TCD 2011 w
Technical Data
P00 04 Engine weight according to DIN 70020-A approx. 268 kg
A00 001 Clamping bracket on crankcase 90 Nm
Clamping bracket on adapter for
A00 002 90 Nm
assembly block
Mounting foot/engine mounting on M14x55-12.9
A00 003 200 Nm
crankcase M14x100-12.9
TD 2011 w, TCD 2011 w
6 Torx,
M6x14-8.8
© 12/2008 6/6 17769-001

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.
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 clea-
rance. 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 6
consideration the setting dimension.
z Unscrew all screws (1).

z Remove cylinder head cowling (2).
z Remove gasket.
1 2
© 47540-0
Setting engine to valve overlap

z Turn crankshaft in the direction of the engine (arrow).
z Turn over crankshaft until the valve overlap is
achieved on cylinder 1.
© 47541-0
© 12/2008 1/6 17770-001

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!
In case of internal exhaust gas recircula-
This is not to be confused with the valve EX IN EX
overlap.
6
© 47542-0
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.
© 47543-0
Setting valve clearance

z Loosen lock nut (1).
z Hold adjusting screw (2).
If there is not enough valve clearance, uns- 2
crew setting screw (2).
If there is too much valve clearance, turn in
setting screw (2).
– Inlet 1
0.3 mm
– Outlet
0.5 mm
© 47544-0
© 12/2008 2/6 17770-001

TD 2011 w, TCD 2011 w W 01-01-01
z Check the valve clearance with feeler gauge (1).
6
© 47543-1

z Tighten lock nut (1).
20 Nm
Do not turn the setting screw when tighte-
ning the locking nut. 2
© 47544-0
z Check the valve clearance again with feeler gauge.
© 47543-0
© 12/2008 3/6 17770-001

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

z Set black marked valves.
6
Crankshaft position 2
© 25894-5
z Turn the crankshaft one turn (360°).

z Set black marked valves.
z Clean sealing surfaces.

z Mount new gasket.
Note installation position: The bar (1) must
face the front cover.
© 47567-0
© 12/2008 4/6 17770-001

TD 2011 w, TCD 2011 w W 01-01-01
z Mount cylinder head cover.

z Oil the screws lightly.
z Tighten all screws (1) alternately.
1
8.5 Nm
6
© 47540-1
© 12/2008 5/6 17770-001

W 01-01-01 TD 2011 w, TCD 2011 w
Technical Data
P00 71 Ignition sequence 1-3-4-2
P01 61 Valve clearance (inlet) 0.3 mm
P01 62 Valve clearance (outlet) 0.5 mm
A01 003 Locking nut, valve adjuster 20 Nm
A01 004 Cylinder head cover on cylinder head 8.5 Nm
6 For the tightening procedure according to torque using a torque wrench, a maximum variation of the
© 12/2008 6/6 17770-001

TD 2011w, TCD 2011 w W 01-02-02
Removing and installing the rocker arm and rocker arm bracket
– Torx tool set . . . . . . . . . . . . . . . . . . 8189
Removing the rocker arm and rocker arm

bracket
z Remove gasket. 1 2
© 47540-0

Loosen screws evenly to avoid tension on
the rocker arm brackets.
z Remove rocker arm bracket (2). 1

Lay out components in the order in which
they should be installed.
Note order of cylinders.
© 47544-1
© 12/2008 1/4 17771-001

W 01-02-02 TD 2011w, TCD 2011 w
z Remove push rods (1).

z Visually inspect the components.
1 1
6
© 47565-0
Installing the rocker arm and rocker arm

bracket
z Insert stop rods (1).
Note the assignment of the stop rods.
The stop rod must be seated with the ball
head in the ladle of the tappet.
1 1
© 47565-0

z Unscrew setting screws (2).
z Mount rocker arm bracket (3).
z Position rocker arm. 3
The ball heads (4) must be seated in the
ladles of the stop rods.
The rocker arm (arrow) must sit on the
valve stem.
1
2
4
© 47591-0
© 12/2008 2/4 17771-001

TD 2011w, TCD 2011 w W 01-02-02
z Lightly oil screws (1).

z Tighten screws .
21 Nm
Attention!
Makes sure that the stop rods are not
under stress due to valve overlap when
fastening the screws.
W 01-01-01
1
6
© 47566-0

z Mount new gasket.
Note installation position: The bar (1) must
face the front cover.
© 47567-0
z Mount cylinder head cover.

1
8.5 Nm
© 47540-1
© 12/2008 3/4 17771-001

W 01-02-02 TD 2011w, TCD 2011 w
Technical Data
A01 002 Rocker arm bracket on cylinder head 21 Nm
© 12/2008 4/4 17771-001

TD 2011 w, TCD 2011 w W 01-02-06
Disassembling, assembling and checking the rocker arm and rocker arm
bracket
– Internal measuring device
– Micrometer gauge
– Locking ring pliers
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Disassembling the rocker arm bracket

1
z Remove rocker arm and rocker arm bracket.
W 01-02-02
z Remove locking ring (1).
© 39144-1
z Remove rocker arm.

© 39145-1
© 12/2008 1/6 17772-001

W 01-02-06 TD 2011 w, TCD 2011 w

z Loosen lock nut (1). 2
z Unscrew adjusting screw (2).

1
6
© 47031-0

z Check oil channels (arrows) for free passage.
© 39147-1
z Screw in setting screw (1).

z Screw in locking nut (2). 1
© 47031-1
© 12/2008 2/6 17772-001

TD 2011 w, TCD 2011 w W 01-02-06
Checking the rocker arm

z Prepare internal measuring device:
– Mount probe bolt for the appropriate measuring
range in the internal measuring device.
– Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
– Set micrometer gauge to 18 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the dial gauge at the reversal point of the pointer to
"0".
6
© 34768-2
z Insert internal measuring device.

z Measure rocker arm bore.
– Outlet
18 +0.27 mm
– Inlet
18 +0.27 mm
When the wear limit is reached the rocker
arm must be renewed.
© 39032-1
Checking the rocker arm pin

z Measure diameter with micrometer gauge.
+0.01
17,97 −0.01 mm
When the wear limit is reached the rocker
arm bracket must be replaced.
© 39148-1
© 12/2008 3/6 17772-001

W 01-02-06 TD 2011 w, TCD 2011 w
Assembling the rocker arm bracket

z Lightly oil the rocker arm pin.
z Push rocker arm (1) onto rocker arm pin.
6
© 39149-2
z Insert new locking rings (1).

Ensure that the installation location is free
from faults.
1
z Install rocker arm and rocker arm bracket.
W 01-02-02
© 39150-1
© 12/2008 4/6 17772-001

TD 2011 w, TCD 2011 w W 01-02-06
Technical Data
P01 72 Rocker arm, bore, diameter (outlet) 18
+0.27
mm
+0.27
P01 73 Rocker arm, bore, diameter (inlet) 18 mm
P01 74 Rocker arm pin, diameter +0.01
17,97 −0.01 mm
© 12/2008 5/6 17772-001

W 01-02-06 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17772-001

TD 2011 w, TCD 2011 w W 01-04-04
Removing and installing cylinder head

– Socket wrench insert Torx – W 01-04-09
E18 . . . . . . . . . . . . . . . . . . . . . . . . . 8116 – W 06-02-03 . . . . . . . . . . . . TD 2011 w,
– Dog wrench. . . . . . . . . . . . . . . . . . . 8018 TCD 2011 w
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 06-07-03 . . . . . . . . . . . . D 2011 w
Special tools: – W 06-09-08 . . . . . . . . . . . . TD 2011 w,
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 TCD 2011 w
– W 09-08-04
Attention!
Pay attention to utmost cleanliness when
before removing. 6
sed air.
to regulations.
Removing the cylinder head

1
© 47551-1
© 12/2008 1/8 17773-001

W 01-04-04 TD 2011 w, TCD 2011 w
z Unscrew lock nuts (1) with dog wrench.

z Remove thermostat housing.
W 09-08-04
– D 2011 w
z Remove the air intake pipe. 1
W 06-07-03
– TD 2011 w, TCD 2011 w
z Remove the charge air pipe.
W 06-02-03
1
z Remove exhaust gas collection pipe.
W 06-09-08
6
© 47550-0

W 01-02-02
z Remove push rods (1).
1 1
© 47547-0
z Unscrew all screws (1) with the socket wrench insert.

z Remove cylinder head.
z Remove gasket.
z Visually inspect the components. 1
© 47548-0
© 12/2008 2/8 17773-001

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.
z Check piston overhang.
W 01-04-09
6
© 47552-0
z Select cylinder head gasket according to the largest

piston projection measured.
– 1 recess
0.325 - 0.604 mm
– 2 recesses
0.605 - 0.704 mm
– 3 recesses
0.705 - 0.804 mm
Example:Piston overhang = 0.7 mm, corre-
sponds to cylinder head gasket with 2
recesses (arrow).
© 47552-1
– Recess cylinder head

– 1 recess
9.820 - 10.140 mm
– 2 recesses
10.141 - 10.239 mm
– 3 recesses
10.240 - 10.310 mm
Example:Piston overhang = 10.150 mm,
corresponds to cylinder head gasket with 2
recesses (arrow).
z Remove the measuring device and holders.
© 47552-1
© 12/2008 3/8 17773-001

W 01-04-04 TD 2011 w, TCD 2011 w

The sealing surfaces for the cylinder head
gasket must be clean and free of oil. 1 1
Make sure the clamping bushings (1) are
in place.
6
© 47549-0
z Fit a new cylinder head gasket.

Label OBEN / TOP facing the cylinder
head.
© 47549-1
z Fit cylinder head.

z Oil the cylinder head screws slightly.
Attention!
Screws can be reused a maximum 3 times 1
with written documentation.
z Fasten all screws (1).
© 47548-0
© 12/2008 4/8 17773-001

TD 2011 w, TCD 2011 w W 01-04-04
z Tighten cylinder head screws with socket wrench in-

sert according to the tightening sequence.
– Stage 1:
30 Nm
– Stage 2:
8 6 4 5 9
80 Nm
– Stage 3:
160 Nm
10 3 1 2 7
– Stage 4:
90°
6
© 39154-2
z Insert stop rods (1).

W 01-02-02
– D 2011 w
z Install the air intake pipe.
W 06-07-03
– TD 2011 w, TCD 2011 w
z Install the charge air pipe.
W 06-02-03
1 1
© 47547-0
z Install exhaust gas collection pipe.

W 06-09-08
z Install thermostat housing.
W 09-08-04
z Mount new injection lines (1). 1 1
z Tighten union nuts (2) with claw spanner.
25 Nm
© 47550-1
© 12/2008 5/8 17773-001

W 01-04-04 TD 2011 w, TCD 2011 w
z Position clamping claws (1).

Attention!
Install tension-free. 2

21 Nm
1
6
© 47551-0
© 12/2008 6/8 17773-001

TD 2011 w, TCD 2011 w W 01-04-04
Technical Data
Identification, cylinder head gasket
= 1 recess
= 2 recesses
= 3 recesses
Recess cylinder head
= 1 recess
= 2 recesses
6
= 3 recesses
Stage 1:
Cylinder head screws
can be used a maximum
of 3x with written docu-
A01 001 Cylinder head on crankcase mentation. 30 Nm
Otherwise use new
Observe tightening
sequence.
A01 001 Cylinder head on crankcase Stage 4 90°
Injection line on fuel injector / injection
A07 003 M12x1.5 25 Nm
pump
© 12/2008 7/8 17773-001

W 01-04-04 TD 2011 w, TCD 2011 w
© 12/2008 8/8 17773-001

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
– Digital dial gauge . . . . . . . . . . . . 100410
– Measuring device . . . . . . . . . . . . 100750
– Holder . . . . . . . . . . . . . . . . . . . . . 150180
Checking piston overhang

W 01-04-04
z Turn the crankshaft until the respective piston is just
in front of the top dead centre (arrow).
© 39156-2
z Insert dial gauge 100400 in measuring beam.

z Place spacing washers (1) on the sealing surface of
the crankcase.
z Place measuring beam (2) on the spacing washers.
z Apply stylus of the dial gauge to the crankcase seal-
ing surface with pre-tension (arrow). 2
z Adjust dial gauge to "0".
1 1
© 39158-2
© 12/2008 1/6 17774-001

W 01-04-09 TD 2011 w, TCD 2011 w

z Insert dial gauge 100410 in measuring beam.
z Place holders (1) on the sealing surface of the crank-
case.
z Place measuring beam (2) on the holders.
z Apply stylus of the dial gauge to the crankcase seal-
ing surface with pre-tension (arrow).
2
6 1 1
© 46933-0
z Measure at the points (1) and (2) on the piston.

Schematic representation 1
2
© 34151-2
z Move the measuring beam.

z Apply the stylus to the piston base (arrow) under pre-
tension.
z Continue turning the crankshaft evenly until the re-
versal point of the pointer on the dial gauge is
reached.
The stylus may not be positioned on the
labelling of the piston.
Note greatest measured value.
© 39159-1
© 12/2008 2/6 17774-001

TD 2011 w, TCD 2011 w W 01-04-09

z Apply the stylus to the piston base (arrow) under pre-
tension.
z Continue turning the crankshaft evenly until the re-
versal point of the pointer on the dial gauge is
reached.
The stylus may not be positioned on the
labelling of the piston.
Note greatest measured value.
6
© 46934-0

– 1 recess
0.325 - 0.604 mm
– 2 recesses
0.605 - 0.704 mm
– 3 recesses
0.705 - 0.804 mm
Example:Piston overhang = 0.7 mm, corre-

sponds to cylinder head gasket with 2
recesses (arrow).
z Remove the measuring device and spacer discs.
z Install cylinder head. © 47552-1
W 01-04-04
© 12/2008 3/6 17774-001

W 01-04-09 TD 2011 w, TCD 2011 w

– 1 recess
9.820 - 10.140 mm
– 2 recesses
10.141 - 10.239 mm
– 3 recesses
10.240 - 10.310 mm
Example:Piston overhang = 10.150 mm,
corresponds to cylinder head gasket with 2
recesses (arrow).
6
z Remove the measuring device and holders.
© 47552-1
z Install cylinder head.
W 01-04-04
© 12/2008 4/6 17774-001

TD 2011 w, TCD 2011 w W 01-04-09
Technical Data
= 1 recess
= 2 recesses
= 3 recesses
D 2011 w / TD 2011 w / TCD 2011 w Recess cylinder head
= 1 recess
= 2 recesses 6
= 3 recesses
© 12/2008 5/6 17774-001

W 01-04-09 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17774-001

TD 2011 w, TCD 2011 w W 01-05-01
Removing and installing the valves

– Slide gauge
– Assembly pliers. . . . . . . . . . . . . . . . 8024
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Support bracket . . . . . . . . . . . . . 120900
– Base plate. . . . . . . . . . . . . . . . . . 120910
– Assembly tool . . . . . . . . . . . . . . . 121410
– Assembly sleeves . . . . . . . . . . . . 121420
Removing the valves

z Remove cylinder head. 1
W 01-04-04
z Mount support bracket (1) on base plate (2).
z Mount cylinder head on support bracket.
© 39164-1
z Install assembly lever (1).

z Press down valve spring with assembly lever.
z Remove both tapper collets (2).
1
z Remove valve spring plates, valve springs and
valves.
z Remove assembly lever.
© 39165-1
© 12/2008 1/6 17775-001

W 01-05-01 TD 2011 w, TCD 2011 w
z Remove valve shaft seal with assembly pliers.
6
© 39166-1
z Clean cylinder head.

z Check cylinder head.
© 39167-1
Installing the valves

z Measure valve spring length with slide gauge.
39.3 mm
When the wear limit is reached, the valve
spring must be renewed.
© 35856-2
© 12/2008 2/6 17775-001

TD 2011 w, TCD 2011 w W 01-05-01
z Oil the valve stem lightly.

z Insert and hold valve.
z Push assembly sleeve (1) over the valve V-grooves.
6
© 33889-2
z Push new valve stem seal onto valve guide over the
assembly sleeve with assembly tool (1).
© 47055-0
z Remove assembly sleeve (1).
© 33889-2
© 12/2008 3/6 17775-001

W 01-05-01 TD 2011 w, TCD 2011 w
z Insert valve spring (1).

z Insert valve spring plate (2). 2
6
© 39169-1
z Mount assembly lever.

z Press down the valve spring with the assembly lever
and insert both tapper collets (1).
Make sure the tapper collets fit correctly in
the valve keyway.
© 39170-1
z Remove assembly lever.

z Remove cylinder head from support bracket.
W 01-04-04
© 39171-1
© 12/2008 4/6 17775-001

TD 2011 w, TCD 2011 w W 01-05-01
Technical Data
P01 51 Valve spring, length (untensioned) Standard 39.3 mm
© 12/2008 5/6 17775-001

W 01-05-01 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17775-001

TD 2011 w, TCD 2011 w W 01-05-04
Checking the valves

– Slide gauge
Clean valves before testing.
must be renewed.
Checking valve stem diameter

z Remove valves.
W 01-05-01
z Measure valve stem diameter with micrometer
gauge.
– Inlet valve
7.98 −0.015 mm
– Exhaust valve
7.96 −0.015 mm
© 42182-1
Checking valve edge thickness

z Measure valve edge thickness with slide gauge.
– Inlet valve
+0.05
2.6 −0.1 mm
– Exhaust valve
+0.05
2.8 −0.1 mm
© 42183-1
© 12/2008 1/4 17776-001

W 01-05-04 TD 2011 w, TCD 2011 w
Checking valve head diameter

z Measure valve head diameter with slide gauge.
– Inlet valve
41.5 +0.1
−0.1 mm
– Exhaust valve
35.4 +0.1
−0.1 mm
z Install valves.
W 01-05-01
6
© 42184-1
© 12/2008 2/4 17776-001

TD 2011 w, TCD 2011 w W 01-05-04
Technical Data
P01 31 Valve stem, diameter (inlet) 7.98 −0.015 mm
P01 32 Valve stem, diameter (outlet) 7.96 −0.015 mm
P01 35 Valve edge thickness (inlet) +0.05
2.6 −0.1 mm
P01 36 Valve edge thickness (outlet) +0.05
2.8 −0.1 mm
+0.1
P01 37 Valve plate, diameter (inlet) 41.5 −0.1 mm
P01 38 Valve plate, diameter (outlet) +0.1
35.4 −0.1 mm
© 12/2008 3/4 17776-001

W 01-05-04 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17776-001

TD 2011 w, TCD 2011 w W 01-06-03
Checking the valve guide

– Magnetic measuring stand
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 New valves are used for testing.
guide must be renewed.
Checking the valve guide

z Remove valves.
W 01-05-01
© 39167-1
Measure valve stem clearance

z Mount magnetic measuring stand.
z Insert dial gauge.
z Insert new valve.
z Place stylus under pre-tension on the valve
head (arrow).
z Adjust meter to "0".
© 47061-1
© 12/2008 1/4 17777-001

W 01-06-03 TD 2011 w, TCD 2011 w
z Move valve back and forth in direction of arrow.

The valve stem ends must be flush with the
valve guide.
The whole tilt distance must be taken into
account.
– Inlet
0.045 - 0.075 mm
– Outlet
0.065 - 0.095 mm
6
© 47062-1
z Remove magnetic measuring stand.

z Remove dial gauge.
z Install valves.
W 01-05-01
© 47556-0
© 12/2008 2/4 17777-001

TD 2011 w, TCD 2011 w W 01-06-03
Technical Data
P01 33 Valve stem clearance (inlet) 0.045 - 0.075 mm
P01 34 Valve stem clearance (outlet) 0.065 - 0.095 mm
© 12/2008 3/4 17777-001

W 01-06-03 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17777-001

TD 2011 w, TCD 2011 w W 01-07-08
Checking the valve lag

– Depth-measuring When the wear limit is reached, the valve
appliance seat insert and/or valve must be renewed.
Checking the valve lag

z Measure the valve lag from the centre of the valve
head to the cylinder head sealing surface.
– Inlet
1.53 mm
– Outlet
1.53 mm
© 39175-1
©12/2008 1/2 17778-001

W 01-07-08 TD 2011 w, TCD 2011 w
Technical Data
P01 45 Valve lag dimension (inlet) Wear limit 1.53 mm
P01 46 Valve lag dimension (outlet) Wear limit 1.53 mm
©12/2008 2/2 17778-001

D 2011 w Drive system
TD 2011 w, TCD 2011 w W 02-01-04
Checking the axial clearance of the crankshaft

– Magnetic measuring stand – W 03-08-01
– Micrometer gauge – W 03-09-01
– Prisms
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Check axial clearance (crankshaft re-

moved)
z Remove crankshaft.
W 02-04-01
z Place crankshaft on prism.
© 47067-0
z Set micrometer gauge to 30 mm.

z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".
© 35825-2
© 12/2008 1/6 17779-001

Drive system D 2011 w
W 02-01-04 TD 2011 w, TCD 2011 w
z Measure locating bearing width

– Standard
+0.04
35 +0 mm
– 1. Overmeasure
35.44 mm
z Note measured value, dimension (a).
6
© 41389-3
z Place thrust ring halves on bearing caps (arrows).

z Measure width with micrometer gauge.
z Note measured value, dimension (b).
z Determine axial backlash.
Calculation example
Desired: Axial backlash
Given: -
Measured: (a) = 35,00 mm
(b) = 34,80 mm
Calculation: Axial backlash = dimension (a) - dimension (b)
35,00 mm - 34,80 mm
Result: = 0,2 mm
– Nominal value:
0.100 - 0.273 mm
© 35827-2
With deviating axial backlash:

Correct axial clearance by changing the
thrust ring halves.
z Measure the wall thickness of the thrust ring halves.
– Standard
+0.05
2,4 +0 mm
– 1. Overmeasure
+0.05
2,6 +0 mm
© 43504-0
© 12/2008 2/6 17779-001

TD 2011 w, TCD 2011 w W 02-01-04
z Install crankshaft.
W 02-04-01
6
© 47499-0
Check axial clearance (crankshaft in-

stalled)
z Remove front cover.
W 03-08-01
z Remove rear cover.
W 03-09-01
© 47499-0

z Apply stylus to the crankshaft end with pre-tension.
z Press crankshaft in direction of arrow.
z Turn the dial until the pointer points to "0".
© 47070-0
© 12/2008 3/6 17779-001

W 02-01-04 TD 2011 w, TCD 2011 w
z Press crankshaft in direction of arrow.

z Read off measured value.
0.100 - 0.273 mm
With deviating axial backlash:
Correct axial clearance by changing the
thrust ring halves.
6
© 47071-0
z Measure the wall thickness of the thrust ring halves.

– Standard
2,4 +0.05
+0 mm
– 1. Overmeasure
2,6 +0.05
+0 mm
© 43504-0

z Install front cover.
W 03-08-01
z Mount rear cover.
W 03-09-01
© 47070-1
© 12/2008 4/6 17779-001

TD 2011 w, TCD 2011 w W 02-01-04
Technical Data
P02 11 Fit bearing pin, width Standard +0.04
35 +0 mm
Oversize,
P02 13 Fit bearing pin, width 35.44 mm
wear limit
P02 34 Crankshaft, permissible axial clearance in the installed state 0.100 - 0.273 mm
+0.05
P02 35 Stop ring, wall thickness Standard 2,4 +0 mm
P02 36 Stop ring, wall thickness Oversize level +0.05
2,6 +0 mm
© 12/2008 5/6 17779-001

W 02-01-04 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17779-001

TD 2011 w, TCD 2011 w W 02-01-07
Checking the crankshaft

– Magnetic measuring stand
– Prisms
– Hardness tester
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Visual inspection
W 02-04-01
z Visually inspect the component.
© 41390-0
Checking the bearing pin hardness

1
z Put hardness tester on journal.
z Raise stylus (1) and press release (2).
Stylus (1) falls down, briefly strikes the sur-
face and jumps up to the measured value.
© 43499-0
© 12/2008 1/6 17780-001

W 02-01-07 TD 2011 w, TCD 2011 w
z Read off displayed value (arrow) from hardness test-

er.
– Nominal value, at least
+0.4
58 HRc
The measured value is to be converted
according to the table of the measuring
device.
6
© 43515-0
Checking the diameter of the main bearing

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

– Standard
−0.01
70 −0.03 mm
– Two underdimension steps (value per step)
0.25 mm
See schematic diagram for measuring
points.
© 41389-0
© 12/2008 2/6 17780-001

TD 2011 w, TCD 2011 w W 02-01-07
Measuring the fit bearing width

z Set the micrometer gauge to 35 mm.
z Balance the internal measuring device between the
test surfaces of the micrometer gauge and set the
dial gauge at the reversal point of the pointer to "0".
6
© 35825-2
z Measure bearing width with internal measuring de-

vice between thelay-on surfaces of the thrust rings.
35 +0.04
+0 mm
– One underdimension stage
0.4 mm
© 41389-3
Checking the diameter of the lifting jour-

nals
z Measure lifting journal with micrometer gauge.
points.
−0.01
58 −0.03 mm
– Two underdimension steps (value per step)
0.25 mm
© 41389-1
© 12/2008 3/6 17780-001

W 02-01-07 TD 2011 w, TCD 2011 w
Checking the rotation

z Apply stylus to the main bearing pin with pre-tension
(arrow) and adjust dial gauge to "0".
z Turn crankshaft evenly and check rotation.
0.05 mm
W 02-04-01
6
© 41389-2
© 12/2008 4/6 17780-001

TD 2011 w, TCD 2011 w W 02-01-07
Technical Data
P02 03 Main journal, diameter Standard −0.01
70 −0.03 mm
P02 04 Main journal, underdimension stage two underdimension stages per 0.25 mm
+0.4
P02 07 Main journal, surface hardness 58 HRc
P02 08 Main journal, radial run-out maximum 0.05 mm
P02 11 Fit bearing pin, width Standard +0.04
35 +0 mm
Fit bearing pin, width, underdimension
P02 12 one underdimension stage 0.4 mm
stage
P02 22 Lifting journal, diameter Standard −0.01
58 −0.03 mm
P02 23 Lifting journal, underdimension stage two underdimension stages per 0.25 mm
6
© 12/2008 5/6 17780-001

W 02-01-07 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17780-001

TD 2011 w, TCD 2011 w W 02-02-02
Renewing the crankshaft sealing ring

(flywheel side)
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . . 142680
– Self-tapping screw
– Washer
Removing the crankshaft sealing ring

z Remove flywheel.
W 12-06-01
z Make a hole of approximately 3 mm in the crankshaft
sealing ring with a pricker.
Attention!
Do not damage the rear cover and cranks-
haft!
© 47083-0
z Screw in a self-tapping screw (1) with washer.
© 47084-0
© 12/2008 1/4 17781-001

W 02-02-02 TD 2011 w, TCD 2011 w
z Pull out the crankshaft sealing ring with assembly le-

ver.
z Visually inspect the crankshaft sealing ring running
surface.
6
© 47085-0
Installing the crankshaft sealing ring

z Mount guide sleeve (1).
z Tighten screws (2). 1
The bores in the guide sleeve must match
the threaded holes in the crankshaft flange.
© 47088-1
z Place the crankshaft sealing ring carefully on the pe-

ripheral surface.
Do not oil waxed crankshaft sealing rings.
The sealing lip faces the crankcase.
© 47089-0
© 12/2008 2/4 17781-001

TD 2011 w, TCD 2011 w W 02-02-02
z Mount assembly sleeve (1).

z Press on the crankshaft sealing ring to the stop.
z Plug in the bearing (2).
z Screw on nut (3).
3 1
6
© 47090-1
z Tighten nut to the stop of the assembly sleeve (1).

The installation depth is determined by the
assembly tool.
z Remove assembly tool. 1

z Install flywheel.
W 12-06-01
© 47091-0
© 12/2008 3/4 17781-001

W 02-02-02 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17781-001

TD 2011 w, TCD 2011 w W 02-02-04
Renewing the crankshaft sealing ring

(opposite side to flywheel)
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . . 142690
– Washer
Removing the crankshaft sealing ring

z Remove toothed belt wheel.
W 04-04-15
z Make a hole of approximately 3 mm in the crankshaft
sealing ring with a pricker.
Attention!
Do not damage the front cover or cranks-
haft.
© 47098-0
© 47099-0
© 12/2008 1/4 17782-001

W 02-02-04 TD 2011 w, TCD 2011 w
z Pull out the crankshaft sealing ring with assembly le-

ver.
z Visually inspect the crankshaft sealing ring running
surface.
6
© 47100-0
z Visually inspect all running surfaces.
© 47101-0
Installing the crankshaft sealing ring

z Place new crankshaft sealing ring on assembly tool.
© 47102-0
© 12/2008 2/4 17782-001

TD 2011 w, TCD 2011 w W 02-02-04
z Mount assembly tool (1).

z Tighten screw until it reaches the assembly tool (1).
assembly tool. 1
z Unscrew screw.
z Remove assembly tool.
z Install toothed belt wheel.
W 04-04-15
6
© 47103-0
© 12/2008 3/4 17782-001

W 02-02-04 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17782-001

TD 2011 w, TCD 2011 w W 02-03-01
Checking the con rod

– Con rod test device Danger!
– Rotation angle disc . . . . . . . . . . . . . 8190
A mixed installation of the standard con rod
Special tools: with crack con rod is not permissible.
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Attention!
The assignment of con rod and big end
bearing cover must stay as it is. If con rod
and big end bearing cover are assembled
the wrong way around, the con rod will be
unusable!
Do not damage the fracture surfaces of the
6
con rod and big end bearing cover!
Only one piston class is allowed for each
engine.
z Remove piston and connecting rod.

W 02-09-03
z Remove piston from con rod.
© 41044-1
© 12/2008 1/10 17783-001

W 02-03-01 TD 2011 w, TCD 2011 w
Checking small end bush

"0".
6
© 34768-2
Diagram for measuring the small end bush

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

z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
+0.035
30 +0.025 mm
Measuring points see diagram.
z Note the measured value, dimension (A).

The dimension A is required to determine
the piston bolt clearance.
© 41391-0
© 12/2008 2/10 17783-001

TD 2011 w, TCD 2011 w W 02-03-01
Checking diameter of the piston bolt

z Measure piston pin with micrometer gauge.
30 −0.005
−0 mm
z Note the measured value, dimension B.
The dimension B is required to determine
the piston bolt clearance.
6
© 35908-3
Determining piston pin clearance

The piston pin clearance is given by the
difference between the internal diameter of
the small end bush (a) and the piston pin
diameter (b).
0.025 - 0.040 mm
Calculation example
Desired: Piston pin clearance
Given: -
Measured: Internal diameter small end bush (a)
(a) = 30.025 mm
Diameter piston pin (b)
(b) = 29.998 mm
Calculation: Dimension (a) - Dimension (b)
30.025 mm - 29.998 mm
Result: = 0.027 mm
Checking the con rod bearing bore

z Mount big end bearing cap.
Attention!
Note the assignment of the big end bearing
2
cap.
651
The identification numbers (1) on the con

9
1
rod and the big end bearing cap must be
identical and opposite to each other when
265
assembled.
19
© 41395-1
© 12/2008 3/10 17783-001

W 02-03-01 TD 2011 w, TCD 2011 w
z Tighten new screws with bihexagonal socket wrench

insert and torque wrench.
– Stage 1:
30 Nm
z Tighten screws with bihexagonal socket wrench in-
sert and rotation angle disc.
– Stage 2:
60°
– Stage 3:
60°
6
© 41396-1

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

bore at the points "a" and "b" in the
levels "1" and "2".
© 37239-1
© 12/2008 4/10 17783-001

TD 2011 w, TCD 2011 w W 02-03-01

+0.02
61,6 −0 mm
When the wear limit is reached the con rod
must be replaced.
6
© 41392-0
Checking internal diameter of the con rod

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

Attention!
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).
2
1
© 41048-2
© 12/2008 5/10 17783-001

W 02-03-01 TD 2011 w, TCD 2011 w
z Insert bearing shell in the respective big end bearing

cap.
Attention!
groove (2).
6 1
© 41394-0

Attention!
The identification numbers (1) on the con-
necting rod and the big end bearing cover
must be identical and opposite to each
other when assembled. 265
19
1
265
19
© 41395-0

– Stage 1:
30 Nm
– Stage 2:
60°
– Stage 3:
60°
© 41396-0
© 12/2008 6/10 17783-001

TD 2011 w, TCD 2011 w W 02-03-01

"0".
6
© 36094-1
Diagram for measuring the inside diameter

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

points.
57.944 - 58.036 mm
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.
© 41397-0
© 12/2008 7/10 17783-001

W 02-03-01 TD 2011 w, TCD 2011 w
Determine big end bearing clearance

The big end bearing clearance is given by
the difference between the internal diame-
ter of the big end bearing shell (a) and the
lifting journal diameter (b).
0.014 - 0.07 mm
Calculation example
Desired: Big end bearing clearance
Given: -
Measured: Internal diameter big end bearing shell (a)
(a) = 58.020 mm
Diameter lifting journal (b)
(b) = 57.980 mm
Calculation: Dimension (a) - Dimension (b)
58.020 mm - 57.980 mm
6 Result: = 0.040 mm
z Remove screws.
z Remove the con rod bearing cover.
© 41396-0
Checking the con rod

z Mount connecting rod on test instrument without
bearing shells. A
Attention!
Aligning the con rod is not permissible. B
z Move test fork in direction of arrow.
z Check that the con rod is parallel.
z Permissible deviation from (A) to (B).
0.03 mm
Distance between “A“ and “B“ = 100 mm.
© 30579-1
© 12/2008 8/10 17783-001

TD 2011 w, TCD 2011 w W 02-03-01
z Move test fork in direction of arrow.

z Check the angle of the con rod.
z Permissible deviation from (C) to (D).
0.03 mm
Distance between “C“ and “D“ = 100 mm
C
D
z Assembly pistons and con rod.
z Install piston and connecting rod.
W 02-09-03
6
© 30580-1
© 12/2008 9/10 17783-001

W 02-03-01 TD 2011 w, TCD 2011 w
Technical Data
the piston bolt
vertical
the piston bolt
horizontal
P02 43 Small end bush, diameter, inside Standard, when installed +0.035
30 +0.025 mm
P02 52 Con rod bearing shells, diameter, inside 57.944 - 58.036 mm
P02 55 Con rod, bearing bore, diameter, inside 61,6 +0.02
−0 mm
Theoretical clearance between the big
6 P02 56
end bearing and lifting journal
0.014 - 0.07 mm
P02 61 Piston pin, diameter, outside 30 −0.005

−0 mm
Theoretical clearance between piston pin
P02 62 0.025 - 0.040 mm
bush and piston pin
A02 020 30 Nm
rod Use new screws.
A02 020 Stage 2: 60°
rod
A02 020 Stage 3: 60°
rod
© 12/2008 10/10 17783-001

TD 2011 w, TCD 2011 w I 02-03-03
Removing and installing small end bush

Special tools:
– Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . 131350 Attention!
Never hammer out the small end bush!
Removing the small end bush

W 02-09-03
z Position the disassembly/assembly tool.
– 131350
© 39411-1
z Insert pressure piece (1).

z Mount pressure sleeve (2). 4
The open end faces the con rod.
5
z Insert screw (3). 3

z Mount washer (4).
z Turn in nut (5).
2 1
© 39330-2
© 12/2008 1/6 17784-001

I 02-03-03 TD 2011 w, TCD 2011 w
z Hold screw (1).

z Tighten nut (2).
The small end bush is pushed out of the 2
con rod by tightening the nut. 1
Make sure that the tool fits perfectly.
6
© 39331-2
z Remove disassembly/assembly tool.

z Remove small end bush.
© 47161-0
Installing small end bush

z Clean the bush bore.
The bush bore must be free from grease
and dirt.
© 47162-0
© 12/2008 2/6 17784-001

TD 2011 w, TCD 2011 w I 02-03-03
z Install small end bush.

Make sure that the lubricating oil bores (1)
are in line.
1
6
© 39332-1

z Mount pressure sleeve (2).
The closed end lies flush with the con rod.
1
3 5
z Insert screw (3).
z Mount washer (4).
z Turn in nut (5).
2 4
© 39333-2
z Hold screw (1).

z Tighten nut (2).
The small end bush is pushed into the con
rod by tightening the nut.
1 2
Make sure that the tool fits perfectly.
© 39334-2
© 12/2008 3/6 17784-001

I 02-03-03 TD 2011 w, TCD 2011 w
z Check installation position.

The small end bush may not protrude over
the surface on any side of the conrod.
The lubricating oil bores of the small end
bush and the con rod must be in line with
each other.
6
© 47164-0
Mechanical machining of the small end

bush is necessary after assembly work.
z Spindle small end bush to dimension A .

+0.035
30 +0.025 mm
© 47490-0

W 02-09-03
© 47122-0
© 12/2008 4/6 17784-001

TD 2011 w, TCD 2011 w I 02-03-03
Technical Data
P02 43 Small end bush, diameter, inside Standard, when installed +0.035
30 +0.025 mm
© 12/2008 5/6 17784-001

I 02-03-03 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17784-001

TD 2011 w, TCD 2011 w W 02-04-01
Removing and installing the crankshaft

– Prisms – W 02-01-07
– Bihexagonal socket – W 03-08-01
wrench insert, spanner – W 03-09-01
size 13 – W 08-04-06
– Socket wrench insert,
spanner size 22, rein- Attention!
forced . . . . . . . . . . . . . . . . . . . . . . . 8035 When replacing the crankshaft and/or the
– Rotation angle disc . . . . . . . . . . . . . 8190 crankcase, the piston class for each indivi-
Special tools: dual cylinder must be re-determined.
– Ajustable bolt . . . . . . . . . . . . . . . 100700
Removing crankshaft
W 03-09-01
W 03-08-01
1
z Remove oil suction pipe
W 08-04-06
z Unscrew adjustable bolt (1).
© 47271-0
z Tighten screws (1) with the bihexagonal socket

wrench insert.
z Remove all big end bearing caps (2).
Attention! 2
unusable! 1
© 47129-0
© 12/2008 1/10 17785-001

W 02-04-01 TD 2011 w, TCD 2011 w
z Remove bearing shell.

6
© 47155-0
z Unscrew all screws (1) with the socket wrench

insert 8035.
© 47131-0
z Remove bearing cap (1).

z Remove both thrust ring halves (arrows).
z Remove all main bearing covers (2).
z Remove bearing shells.
Lay out components in the order in which 2 1
© 47132-0
© 12/2008 2/10 17785-001

TD 2011 w, TCD 2011 w W 02-04-01
z Press the con rods carefully out of the lifting journal.

z Lift out the crankshaft.
6
© 47133-0
z Remove all main bearing shells (1).

z Remove all big end bearing shells (2).
1
© 47134-0
z Check crankshaft.
W 02-01-07
z Check axial backlash of crankshaft (crankshaft re-
moved).
W 02-01-04
© 47067-0
© 12/2008 3/10 17785-001

W 02-04-01 TD 2011 w, TCD 2011 w
Installing the crankshaft

z Insert upper main bearing shells.
Attention!
groove (2).
1
6
© 47135-0
z Insert lower main bearing shells in the respective

main bearing cover. 1
Attention!
groove (2).
© 37043-2

Attention!
groove (2).
1
© 47136-0
© 12/2008 4/10 17785-001

TD 2011 w, TCD 2011 w W 02-04-01
z Insert big end bearing shells in the respective big end

bearing cap.
Attention!
groove (2). 2
6
© 47127-0
Make sure the clamping bushings (arrows)

are in place.
© 47137-0
z Lightly oil bearing surfaces.

z Insert the crankshaft carefully in the crankcase.
Attention!
Do not jam the con rods when inserting the
crankshaft!
© 47133-0
© 12/2008 5/10 17785-001

W 02-04-01 TD 2011 w, TCD 2011 w
Install thrust ring halves according to mea-

sured axial clearance.
z Fix both thrust ring halves with a little grease to the

bearing cap.
Bearing cap with identification “2“.
Oil grooves (1) face the crankshaft web
face.
1
6
© 47075-0
z Insert bearing cap (1).

z Insert main bearing covers (2).
Note assignment and installation position:
Assignment of the main bearing covers:
With identification "1" = flywheel side.
Chamfered edge (arrow) faces front cover. 2 1
© 47138-0

Attention!
Screws can be used a maximum 3 times
with written documentation.
© 47131-0
© 12/2008 6/10 17785-001

TD 2011 w, TCD 2011 w W 02-04-01
z Move the crankshaft axially to and fro.

The bearing is aligned in position as a
result.
6
© 47154-0

insert 8035 and tighten with torque wrench.
– Stage 1:
50 Nm
– Stage 2:
60°
insert 8035 and tighten with rotation angle disc.
– Stage 3:
45° 1
Attention!
© 47140-0
z Pull con rods carefully on to the lifting journal.
© 47069-0
© 12/2008 7/10 17785-001

W 02-04-01 TD 2011 w, TCD 2011 w

Attention!
265
other when assembled.
19
Pay attention to utmost cleanliness. 1
265
19
6
© 41395-0

– Stage 1:
30 Nm
– Stage 2:
60°
– Stage 3:
60°
© 47142-0
z Check axial backlash of crankshaft (crankshaft in-

stalled).
W 02-01-04
© 47092-0
© 12/2008 8/10 17785-001

TD 2011 w, TCD 2011 w W 02-04-01
z Knock in the adjustable bolt (1) to the stop.
6
© 47271-0
z Turn crankshaft in the direction of the engine until it

reaches the stop of the adjustable bolt.
z Install oil suction pipe.
W 08-04-06
z Mount rear cover.
W 03-09-01
W 03-08-01
© 39130-1
© 12/2008 9/10 17785-001

W 02-04-01 TD 2011 w, TCD 2011 w
Technical Data
Stage 1:
Screws can be used a
maximum of 3x with writ-
A02 010 Main bearing cover on crankcase 50 Nm
ten documentation.
Otherwise use new
A02 020 30 Nm
rod Use new screws.
6 Big end bearing cover on connecting
A02 020 Stage 2: 60°
rod
A02 020 Stage 3: 60°
rod
© 12/2008 10/10 17785-001

TD 2011 w, TCD 2011 w W 02-09-03
Removing and installing the piston and con rod

– Bihexagonal socket – W 02-09-07
wrench insert, spanner – W 02-10-03
size 13 – W 08-04-06
– Depth-measuring appli-
ance Danger!
– Rotation angle disc . . . . . . . . . . . . . 8190 A mixed installation of the standard con rod
Special tools: with crack con rod is not permissible.
– Piston ring clamping band,
diameter 96 mm . . . . . . . . . . . . . 130850 Attention!
– Disassembly tool. . . . . . . . . . . . . 131100 The assignment of con rod and big end
the wrong way around, the con rod will be 6
unusable!
Do not damage the fracture surfaces of the
con rod and big end bearing cover!
engine.

to regulations.
Lubricating oil and coolant must be filled
according to the instructions in the opera-
ting manual.
Removing the piston and con rod

W 01-04-04
z Remove oil suction pipe
W 08-04-06
© 47143-0
© 12/2008 1/10 17786-001

W 02-09-03 TD 2011 w, TCD 2011 w
z Set lifting journal at bottom dead centre (BDC).

z Tighten screws (1) with the bihexagonal socket
wrench insert.
z Remove all big end bearing caps (2).
Attention!
bearing cover must stay as it is. If con rod 1 2
unusable!

6
© 47144-0

© 47155-0
z Press out the piston and connection rod.

© 47145-0
© 12/2008 2/10 17786-001

TD 2011 w, TCD 2011 w W 02-09-03

6
© 47146-0
z Insert a suitable tool in the cavity (1).

Remove locking ring on the opposite side
in the same way.
2
1
© 47156-0
z Insert disassembly tool (1).
© 47157-0
© 12/2008 3/10 17786-001

W 02-09-03 TD 2011 w, TCD 2011 w
z Press out piston bolt (1).

z Check piston.
W 02-09-07
6
© 47147-0
Determine piston class

z Set lifting journal of each cylinder at top dead centre.
© 39250-1
z Measure the distance from the crankcase sealing

surface to the highest point of the lifting journal with
the depth gauge.
– D 2011 w
Piston class A
188.380 - 188.548 mm
Piston class B
188.549 - 188.718 mm
– TD 2011 w / TCD 2011 w Recess cylinder head
Piston class A
188.380 - 188.718 mm
– TD 2011 w / TCD 2011 w High crankcase
Piston class A
© 39251-1
197.880 - 198.175 mm
© 12/2008 4/10 17786-001

TD 2011 w, TCD 2011 w W 02-09-03
Completing con rod and piston

z Select piston in accordance with the determined pis-
ton class (1).
Attention!
engine.
6
© 39249-1
z Insert new locking ring.

X
from faults.
Ring joint must face piston base.
© 39257-1
z Insert con rod.

z Check installation position of the connecting rods.
6010
The flywheel/crankshaft symbol (1) on the

2
piston base must face to the left and the
identification number (2) on the con rod
must face upwards.
© 47158-0
© 12/2008 5/10 17786-001

W 02-09-03 TD 2011 w, TCD 2011 w
z Oil the piston bolt lightly.

z Press in the piston bolt.
z Insert new locking ring.
from faults.
Ring joint must face piston base.
6
© 39260-1
Installing the piston and con rod

Attention!
groove (2). 2
© 47126-0
z Insert bearing shell in the respective big end bearing

cap.
Attention!
groove (2). 2
© 47127-0
© 12/2008 6/10 17786-001

TD 2011 w, TCD 2011 w W 02-09-03
z Arrange the piston ring joints with an offset of

about 120° to each other.
z Check piston rings and piston ring grooves.
W 02-10-03
6
© 36216-1
z Lightly oil cylinder running surface, piston, piston

rings and lifting bearing journal lightly.
z Clamp piston rings with piston ring compressor (1).
Do not turn the piston rings any further.
© 39284-1
z Set lifting journal at bottom dead centre (BDC).

z Push piston and con rod completely into cylinder.
Note the cylinder assignment of the piston.
Note the label indicating the installation
position on the piston base.
The symbol flywheel/crankshaft (1) must
face the flywheel.
The piston ring clamping band must touch
flat on the cylinder.
© 39285-1
© 12/2008 7/10 17786-001

W 02-09-03 TD 2011 w, TCD 2011 w
z Press the con rod carefully against the lifting journal.

Attention!
Do not jam the con rod with the crankshaft.
6
© 47145-0

Attention!
other when assembled.
Pay attention to utmost cleanliness.
© 47141-0

– Stage 1:
30 Nm
– Stage 2:
60°
– Stage 3:
60°
© 47159-0
© 12/2008 8/10 17786-001

TD 2011 w, TCD 2011 w W 02-09-03
z Install oil suction pipe.

W 08-04-06
W 01-04-04
6
© 47143-0
© 12/2008 9/10 17786-001

W 02-09-03 TD 2011 w, TCD 2011 w
Technical Data
D 2011 w
P02 79
Distance between crankcase sealing sur- Piston class B 188.549 -
P02 79
TD 2011 w / TCD 2011 w Recess cylinder head
P02 79
TD 2011 w / TCD 2011 w High crankcase
P02 79
6 face and lifting journal Stroke 125 mm 198.175 mm
A02 020 30 Nm
rod Use new screws.
A02 020 Stage 2: 60°
rod
A02 020 Stage 3: 60°
rod
© 12/2008 10/10 17786-001

TD 2011 w, TCD 2011 w W 02-09-07
Checking the piston

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

W 02-09-03
© 41044-1

"0".
© 34768-2
© 12/2008 1/4 17787-001

W 02-09-07 TD 2011 w, TCD 2011 w
Diagram for measuring the piston bolt bore

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

bore.
points.
+0.014
30 +0.008 mm
© 43483-0
Checking the piston diameter

z Measure piston diameter with micrometer gauge.
© 43427-0
© 12/2008 2/4 17787-001

TD 2011 w, TCD 2011 w W 02-09-07
– D 2011 w
– Measuring point 1
+0.009
95.900 −0.009 mm
95.830 mm 3
+0.015
2
95.700 −0.015 mm
Measuring point height - see Technical
Data.
1
z Assemble con rod and piston.
W 02-09-03 6
© 41154-0
– T 2011 w / TCD 2011 w

95.850 +0.009
−0.009 mm
95,778 mm 3
2
95.695 +0.015
−0.015 mm
Measuring point height - see Technical

Data.
1
W 02-09-03
© 41154-0
© 12/2008 3/4 17787-001

W 02-09-07 TD 2011 w, TCD 2011 w
Technical Data
D 2011 w
−0.009 mm
P02 72 Piston, diameter, standard Measuring point 2 = height 47 mm 95.830 mm
Measuring point 3 = height 62.2
P02 73 Piston, diameter, standard +0.015
95.700 −0.015 mm
mm
TD 2011 w / TCD 2011 w
−0.009 mm
P02 72 Piston, diameter, standard Measuring point 2 = height 47 mm 95,778 mm
−0.015 mm
6 D 2011 w / TD 2011 w / TCD 2011 w
P02 74 Piston, diameter, overmeasure one overmeasure stage 0.5 mm
P02 78 Piston pin bore 30 +0.014
+0.008 mm
© 12/2008 4/4 17787-001

TD 2011 w, TCD 2011 w W 02-10-03
Checking the piston rings and piston ring grooves

– Feeler gauges
Special tools:
– Universal piston ring pliers . . . . . 130300
– Trapezoidal groove wear
gauge . . . . . . . . . . . . . . . . . . . . . 130420
Checking the piston rings and piston ring

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

mum necessary diameter.
z Remove piston rings with universal piston ring pliers.
© 44263-1
z Clean piston.
z Visually inspect piston.
z Visually inspect piston ring grooves.
© 44264-1
© 12/2008 1/6 17788-001

W 02-10-03 TD 2011 w, TCD 2011 w
Checking the piston ring joint clearance

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

gauge.
– 1. piston ring
0.30 +0.2
+0 mm
– 2. piston ring = taper-faced ring

1.5 +0.5
+0 mm
– 3. piston ring = bevelland-edge oil control ring

0.30 +0.3
+0 mm
When the wear limit is reached, the piston

ring must be renewed.
© 41386-1
z Mount the piston rings with the marking "TOP" facing

the combustion chamber.
Order and position of the piston rings as
seen from the piston base: 1
z (1):
2
– 1. piston ring = double keystone ring
z (2):
3
– 2. piston ring = taper-faced ring
z (3):
– 3. piston ring = bevelland-edge oil control ring
© 41154-1
© 12/2008 2/6 17788-001

TD 2011 w, TCD 2011 w W 02-10-03
z Measure piston ring groove for first piston ring with

trapezoidal groove wear gauge.
6
© 33866-3
If there is a gap "S" between the trapezoi-

dal groove wear gauge and piston, the
piston can be used again. S
© 33867-3
If the trapezoidal groove wear gauge is

touching the piston (arrow), the piston
must be changed.
© 33868-3
© 12/2008 3/6 17788-001

W 02-10-03 TD 2011 w, TCD 2011 w
Checking the piston ring axial clearance

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

ton ring and piston ring groove.
– 2. piston ring
0.080 - 0.115 mm
– 3. piston ring
0.030 - 0.065 mm
When the piston wear limit is reached, the
piston must be renewed.
6
© 44269-0

W 02-09-03
© 41047-0
© 12/2008 4/6 17788-001

TD 2011 w, TCD 2011 w W 02-10-03
Technical Data
P02 84 Piston ring 1, joint clearance +0.2
0.30 +0 mm
+0.5
P02 86 Piston ring 3, joint clearance +0.3
0.30 +0 mm
P02 86 Piston ring 3, joint clearance Wear limit 1,2 mm
P02 87 Piston ring 1, axial clearance Trapezoidal groove wear gauge -
6
© 12/2008 5/6 17788-001

W 02-10-03 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17788-001

TD 2011 w, TCD 2011 w W 02-15-01
Removing and installing the piston cooling nozzles

Removing the piston cooling nozzle

W 02-04-01
z Press out the piston cooling nozzle (1) with a suitable
tool (2) in the direction of the arrow.
1
© 39210-2
© 47150-0
© 12/2008 1/2 17789-001

W 02-15-01 TD 2011 w, TCD 2011 w
Installing the piston cooling nozzle

z Clean the bores for the piston cooling nozzles in the
crankcase.
z Knock in new piston cooling nozzle (1) with pin to the
stop.
W 02-04-01
1
6
© 39211-1
© 12/2008 2/2 17789-001

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

z Remove crankcase bleeding (2).
© 47152-0
z Remove the O-ring (1) with the disassembly tool.

© 47153-0
© 12/2008 1/4 17790-001

Crankcase D 2011 w
W 03-01-11 TD 2011 w, TCD 2011 w
Install crankcase bleeding

6
© 47160-0
z Mount crankcase vent (2).

from faults.
The crankcase bleeding must fit evenly.
z Tighten screw (1). 1
8.5 Nm
© 47152-0
© 12/2008 2/4 17790-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-01-11
Technical Data
head
© 12/2008 3/4 17790-001

Crankcase D 2011 w
W 03-01-11 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17790-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-03-01
Checking the cylinder

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

W 02-09-03
z Check cylinder for visible signs of wear.
© 39239-1

"0".
© 36094-1
© 12/2008 1/4 17791-001

Crankcase D 2011 w
W 03-03-01 TD 2011 w, TCD 2011 w
Diagram for measuring the cylinder run-

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

z Compare actual value with setpoint value.
+0.020
96.000 mm
– Wear limit
96.1 mm
© 39241-2

W 02-09-03
© 47122-0
© 12/2008 2/4 17791-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-03-01
Technical Data
P03 31 Cylinder, diameter, inside Standard 96.000
+0.020
mm
P03 32 Cylinder, diameter, inside Wear limit 96.1 mm
© 12/2008 3/4 17791-001

Crankcase D 2011 w
W 03-03-01 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17791-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-01
Removing and installing the front cover

– W 04-03-01
– W 04-04-15
– Packing compound – W 08-04-05
DEUTZ DW 67 – W 08-04-07
Remove the front cover

z Pull out cable plug (1).
© 47177-0
z Unlock cable plug (1) and remove.

z Remove toothed belt wheel.
W 04-04-15
© 47178-0
© 12/2008 1/6 17792-001

Crankcase D 2011 w
W 03-08-01 TD 2011 w, TCD 2011 w
z Removing the lubricating oil pump.

W 08-04-05
z Remove lubricating oil pan.
W 08-04-07
6
© 47188-0

© 47186-0
© 47170-0
© 12/2008 2/6 17792-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-01
z Knock out crankshaft sealing ring (1).

z Knock out camshaft sealing ring.
Attention!
Do not damage sealing surface when
knocking out.
1
6
© 39527-1
Install front cover

z Apply packing compound evenly to the sealing sur-
face.
All connecting surfaces must be clean and
free of oil.
© 34110-2
z Mount front cover.

z Align front cover flush with the oil tray sealing sur-
face.
© 47187-0
© 12/2008 3/6 17792-001

Crankcase D 2011 w
W 03-08-01 TD 2011 w, TCD 2011 w
z Tighten the screws according to the tightening se-

quence.
21 Nm
z Install lubricating oil pan.
W 08-04-07
z Renew crankshaft sealing ring (opposite side to fly-
wheel).
W 02-02-04
z Renew camshaft sealing ring.
W 04-03-01
6
© 34112-2
z Install the lubricating oil pump

W 08-04-05
z Install toothed belt wheel.
W 04-04-15
© 47188-0
z Plug in the cable plug (1).

Ensure that the connection is perfect.
© 47178-0
© 12/2008 4/6 17792-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-01

6
© 47177-0
© 12/2008 5/6 17792-001

Crankcase D 2011 w
W 03-08-01 TD 2011 w, TCD 2011 w
Technical Data
© 12/2008 6/6 17792-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
Dismantling and assembling the front cover

– Depth-measuring
appliance
– Plier insert. . . . . . . . . . . . . . . . . . . . 8027 Attention!
Special tools: All modifications on the speed control and
– Special wrench . . . . . . . . . . . . . . 101640 the setting measures connected with this
– Disassembly tool. . . . . . . . . . . . . 110901 must be carried out on an engine test
bench.
– Locking agent According to the intended purpose of the
DEUTZ DW 71 engine, different types of regulator are
used and/or different settings are neces-
sary.
6
Dismantle front cover

z Make help marks (1) and (2).
W 03-08-01
1 2
© 47193-0

z Remove lifting magnet (2).
1
2
© 47194-0
© 12/2008 1/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
6
© 47355-0

z Remove crankcase bleeding (2). 1
z Remove gasket.
© 47195-0

z Remove cover (2).
z Remove gasket.
© 47196-0
© 12/2008 2/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Bring out spring (1).
6
© 47197-0
z Unscrew nuts (1).

z Remove regulator lever shaft (2). 2
z Remove torque-control lever (3).
1
3
© 39632-1
z Remove shims (1).

Note number of items and assignment.
© 39633-1
© 12/2008 3/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
z Remove centrifugal force movement (1).
6
© 39634-1
z Unscrew nut (1).

z Remove clamping shoe (2).
z Unscrew idling capsule (3).
1 2 3
© 47198-0
z Unscrew nut (1).

© 47200-0
© 12/2008 4/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Unscrew adjusting capsule (1).
6
© 47201-0

z Remove deflection lever (2).
2
1
© 47202-0
z Unscrew lifting magnet (1) with plier insert.

Note direction of terminal. 1
© 47203-0
© 12/2008 5/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
6
© 47392-0
© 47204-0
z Insert special wrench (1).
© 47205-0
© 12/2008 6/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Unscrew nut (1) with special wrench (2).

z Press out eccentric shaft in direction of arrow.
z Remove guide bush.
z Remove O-ring.
1
2
6
© 47206-0

z Pull out control lever (2).
z Remove washer.
z Remove spring (3).
3 1
© 47207-0
z Bring out spring (1).
© 47208-0
© 12/2008 7/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
z Knock out clamping pin (1).

z Remove stop lever (2).
z Remove washer.
6
© 39528-1
z Remove guide bush (1).

z Remove O-ring (2).
z Pull out shutdown spindle (3).
3
2
© 39056-1
z Pull out lock bolt (1) with suitable tool.

Attention!
Do not damage the sealing surfaces.
© 47209-0
© 12/2008 8/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Knock out clamping pin (1).

Do not twist clamping pin into front cover
when pulling out.
6
© 39470-1
z Pull out speed adjusting lever (1).

z Remove guide bush.
z Remove O-ring. 1
z Remove adjustment lever (2).
© 39273-1

© 39274-1
© 12/2008 9/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
Assemble front cover

z Screw in adjustable bolt (1).
z Screw in locking nut (2).
6
© 39274-2
z Set adjustable bolt (1) to dimension "X".

23 +1 mm
2
Dimension "X" = basic setting of the mini- X
mum speed.
z Tighten nut (2).

6 Nm
© 33950-2
z Push guide bush (1) onto speed adjusting shaft.

z Oil the speed adjusting shaft lightly.
z Insert speed adjusting lever (3).
1 2
3
© 39469-1
© 12/2008 10/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Insert adjusting lever (1).

Note installation position.
The hanging hole for the governor
spring (arrow) must face the outside the of
the front cover.
z Press in the speed adjusting shaft (2) to the stop.
2 1
6
© 39209-1
z Bring bore holes for clamping pin into line.

z Knock in clamping pin (1) flush.
© 39470-1
z Position speed adjusting shaft until it is in line with the

bolt and the bore.
z Knock in the lock bolt (1) to the stop.
© 47210-0
© 12/2008 11/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
z Oil the shutdown spindle lightly.

z Insert shutdown spindle.
z Pre-tighten spring (1).
z Hook the spring in to the stop (arrow). 1
6
© 39473-1

z Mount guide bush (2).
1
2
© 39474-1
z Mount washer (1).

z Mount stop lever (2).
z Insert clamping pin.
© 39475-1
© 12/2008 12/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Bring bore holes for clamping pin into line.

z Knock in clamping pin (1) flush.
1 6
© 39466-1
z Insert control lever (1).

z Insert spring (2).
z Mount disc.
1 2
© 47343-0
z Insert new locking ring (1).

from faults.
© 47222-0
© 12/2008 13/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
z Lightly oil the eccentric shaft.

z Insert eccentric shaft.
z Mount guide bush (2).
1
2
6
© 39472-1
z Make help marks (1) and (2).

z Screw on nut (3).
1 2
© 47225-0

Do not turn the eccentric shaft.
© 47205-0
© 12/2008 14/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03

Do not turn the eccentric shaft.
z Tighten nut (2).

2
7 Nm
6
© 47223-0
© 47204-0
© 47392-0
© 12/2008 15/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
z Tighten lifting magnet (1) with plier insert.

10 Nm 1
Note direction of terminal.
6
© 47203-0
z Mount deflection lever (1).

2 1
© 47202-1
z Insert centrifugal force movement (1).

Attention!
Do not damage shaft sealing ring!
1
© 39634-1
© 12/2008 16/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Mount shims (1).

Note number of items and assignment.
Minimum height of shims:
minimum 0.3 mm, maximum 0.5 mm.
6
© 39633-1
z Insert regulator lever shaft (1).

z Tighten nuts (2). 2
9.2 Nm
Note installation position. 1
Long milled edges "X" faces front cover.
© 39277-2
z Push the roller lever under the contact surface (1).

Ball bearings may not touch the bush (2)
any longer.
© 47354-0
© 12/2008 17/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
z Insert dial gauge into measuring beam.

z Apply stylus with pre-tension onto the ball
bearing (1).
6
© 39279-1

z Apply stylus onto the ball bearing (1).
z Maximum difference between both ball bearings:
0,05 mm
The difference may be corrected by
exchanging the shims.
minimum 0.3 mm, maximum 0.5 mm. 1
© 39280-1
z Unscrew nuts (1).

z Remove regulator lever shaft (2). 1
© 47065-0
© 12/2008 18/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Change shims (1) according to difference.

minimum 0.3 mm, maximum 0.5 mm.
Repeat measurement after setting.
6
© 39633-1
z Insert torque-control levelr (1) in regulator level

shaft (2).
2 1
© 33967-2
z Insert regulator lever shaft (1).

z Mount torque-control lever (2).
1
z Tighten nuts (3).
9.2 Nm
3
3
© 39632-2
© 12/2008 19/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
z Hook in spring (1).
6
© 47197-0

z Lightly oil O-ring.
© 47227-0
z Insert adjusting capsule with locking agent.

z Screw in adjusting capsule (1).
© 47201-0
© 12/2008 20/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Measure screw-in depth "X".

z Nominal value:
+0.5
6,4 −0.5 mm
Setting dimension "X" = basic setting.
6
© 47228-0

z Tighten nut (2).
10 Nm
© 47200-1

z Lightly oil O-ring.
© 47224-0
© 12/2008 21/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w

z Turn in idling capsule (2) flush to the inner edge of
the front cover (arrow).
6
© 34002-2

z Tighten nut (2).
4.6 Nm
© 39264-1
z Mount new gasket.

z Mount cover (2).
z Tighten all screws (1).
7 Nm
© 47196-0
© 12/2008 22/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-08-03
z Mount new gasket.

z Mount crankcase vent (2). 1
8.5 Nm
6
© 47195-0
© 39036-1
z Insert lifting magnet (2).

1
8.5 Nm 2
W 03-08-01
© 47194-0
© 12/2008 23/24 17793-001

Crankcase D 2011 w
W 03-08-03 TD 2011 w, TCD 2011 w
Technical Data
Minimum speed, setting screw, basic set- +1
P05 05 23 mm
ting
Screw-in depth of the adjusting capsule, +0.5
P05 06 6,4 −0.5 mm
basic setting
head
6 Locking nut on setting screw, shut-off
A05 005 6 Nm
stop
A05 021 Regulator lever shaft on front cover 9.2 Nm
A05 022 Idling capsule on front cover 4.6 Nm
Adjusting capsule on front cover,
A05 023 10 Nm
clamping nut
A05 024 Eccentric shaft on front cover Locking nut 7 Nm
Cap (speed adjusting lever) on front
A05 025 4.5 Nm
cover
A05 041 8.5 Nm
front cover
A05 065 10 Nm
on front cover
© 12/2008 24/24 17793-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-09-01
Removing and installing rear cover

– W 03-09-04
– W 08-04-07
– Packing compound
DEUTZ DW 67
Removing rear cover

z Remove connection housing.
W 03-09-04
W 08-04-07
z Unscrew all screws (1). 1
z Remove rear cover 2.
© 47211-0
z Knock out crankshaft sealing ring (1).

Attention!
© 39512-1
© 12/2008 1/4 17794-001

Crankcase D 2011 w
W 03-09-01 TD 2011 w, TCD 2011 w
Installing rear cover

z Apply packing compound evenly to the sealing sur-
face.
Sealing cord strength approx. 0.5 -
0.6 mm.
6
© 47487-0
z Mount rear cover.

z Align front cover flush with the oil tray sealing sur-
face.
1
© 47212-0

quence. 1
21 Nm 5
4
6
3
7
2
8
© 47488-0
© 12/2008 2/4 17794-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-09-01
z Renew crankshaft sealing ring (flywheel side).

W 02-02-02
W 08-04-07
z Install connection housing.
W 03-09-04
6
© 47213-0
© 12/2008 3/4 17794-001

Crankcase D 2011 w
W 03-09-01 TD 2011 w, TCD 2011 w
Technical Data
Observe tightening
A03 010 Rear cover on crankcase 21 Nm
sequence
© 12/2008 4/4 17794-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-09-04
Removing and installing the connection housing

Removing the connection housing

z Remove flywheel.
W 12-06-01
© 47226-0
© 39048-2
© 12/2008 1/4 17795-001

Crankcase D 2011 w
W 03-09-04 TD 2011 w, TCD 2011 w
Installing the connection housing

z Clean contact surfaces.
z Make sure the clamping bushings (arrows) are in
place.
z Drive in clamping sleeves in the crankcase as far as
they will go.
6
© 47214-0
z Mount connection housing.

z Centre connection housing over the clamping bush-
ings.
© 47215-0

Technical Data
© 47226-0
© 12/2008 2/4 17795-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-09-04
z Install flywheel.
W 12-06-01
6
© 47082-0
© 12/2008 3/4 17795-001

Crankcase D 2011 w
W 03-09-04 TD 2011 w, TCD 2011 w
Technical Data
M12x20
M12x30
M12x35
A03 081 M12x55 106 Nm
to crankcase
M12x70
M12x75
M12x95
M8x10
A03 082 Connection housing to crankcase M8x30 22 Nm
M8x50
6 M10x40
A03 082 M10x30 45 Nm
to crankcase
M10x25
Cylinder
A03 082 Connection housing to crankcase head screws 60 Nm
M10x40
A03 082 M14x55 180 Nm
to crankcase
© 12/2008 4/4 17795-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-11-01
Removing and installing, testing camshaft bearing

– Micrometer gauge – W 02-04-01
– Internal measuring device – W 04-05-05
– Depth-measuring – W 09-08-04
appliance
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 Do not damage bearing liners while remo-
– Disassembly/assembly ving and changing over the assembly tool!
tool . . . . . . . . . . . . . . . . . . . . . . . 143720 The work process is described for a bea-
ring liner. The procedure is the same to
install and remove further bearing liners.
Testing camshaft bearing

z Mount clamping bracket on assembly block.
W 00-05-01
W 09-08-04
W 02-04-01
z Remove camshaft.
W 04-05-05
z Mount probe bolt for the appropriate measuring
z Mount dial gauge with approx. 1 mm pre-tension in © 34768-2

z Set micrometer gauge to 54 mm.
z Balance the internal measuring device between the
test surfaces of the micrometer gauge and set the
dial gauge at the reversal point of the pointer to "0".
© 12/2008 1/8 17796-001

Crankcase D 2011 w
W 03-11-01 TD 2011 w, TCD 2011 w
Diagram for measuring the camshaft bea-

ring at the points "a and b" in the
levels "1 and 2".
6
© 37239-1

54.000 - 54.054 mm
– Wear limit
54.08 mm
When the wear limit is reached, the cams-
haft bearing must be replaced.
© 39304-1
Removing camshaft bearing

© 39306-1
© 12/2008 2/8 17796-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-11-01
z Insert spindle (1).

z Insert counter support (3).
z Mount washers (4).
z Screw in nuts (5).
3 1 2 5
5 4
4
6
© 39307-2
z Hold spindle (1).

z Tighten nut (2).
Tighten the nut further until the bearing
liner falls out.
z Remove bearing bush.

© 47054-0
Installing camshaft bearing

Schematic diagram:
Butt joint faces direction of arrow.
© 39311-1
© 12/2008 3/8 17796-001

Crankcase D 2011 w
W 03-11-01 TD 2011 w, TCD 2011 w
Note the different bearing liners.

The wide bearing liners are each installed
at the end of the crankcase.
z Position new bearing liner.
Attention!
Installation position of the butt joint (1) see
schematic diagram.
Make sure that the lubricating oil
bores (arrow) are in line. 1
6
© 39312-1
z Insert spindle.
z Mount washer (2).
z Screw on nut (3).
3
© 39313-2
z Insert counter bearing (1).

z Mount washer (2).
z Screw on nut (3).
3
© 39309-3
© 12/2008 4/8 17796-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-11-01
z Hold spindle (1).

z Tighten nut (2).
Holder fits evenly on the crankcase.
Attention!
Do not change installation position of the
bearing liner!
2
1
6
© 47054-0
z Tighten nut (1).

Pressure piece (arrow) lies almost flush
with the crankcase.
z Loosen nuts.
© 39314-2
Diagram for the installation depth of the

camshaft bearings.
1 2 4 3
+0,3
1 2,5 −0,3 mm
+ 0,3
2 118,9 − 0,3 mm
+0,3
3 0,5 −0,3 mm
+ 0,3
4 117,1 − 0,3 mm
© 47491-0
© 12/2008 5/8 17796-001

Crankcase D 2011 w
W 03-11-01 TD 2011 w, TCD 2011 w
z Measure screw-in depth with depth measuring

appliance (1).
Measure distance from the crankcase to
the bearing liner.
If necessary, correct screw-in depth of the
bearing liner.
z Remove assembly tool
1
6
© 39318-2
z Check that the lubricating oil bores (1) are in line.

If the lubricating oil bore is not in line, the
camshaft bearing must be removed and re-
installed.
z Install the camshaft.
W 04-05-05
W 02-04-01
W 09-08-04
1
z Remove engine from assembly block
W 00-05-01
© 45502-1
© 12/2008 6/8 17796-001

D 2011 w Crankcase
TD 2011 w, TCD 2011 w W 03-11-01
Technical Data
P03 13 Camshaft, bearing liner, diameter, inside in the installed state 54.000 - 54.054 mm
P03 14 Camshaft, bearing liner, diameter, inside Wear limit 54.08 mm
© 12/2008 7/8 17796-001

Crankcase D 2011 w
W 03-11-01 TD 2011 w, TCD 2011 w
© 12/2008 8/8 17796-001

D 2011 w Engine control
TD 2011 w, TCD 2011 w W 04-03-01
Renew camshaft sealing ring

– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . . 142050
– Counter support . . . . . . . . . . . . . 144130
– Washer
Remove camshaft sealing ring

z Remove toothed belt wheel (1).
1
W 04-04-15
© 47179-1
z Position holder.
2
© 47180-0
© 12/2008 1/4 17797-001

Engine control D 2011 w
W 04-03-01 TD 2011 w, TCD 2011 w
Attention!
Do not damage front cover and camshaft!
z Make a hole of approx. 3mm in the camshaft sealing

ring with a pricker.
6
© 47259-0
© 47260-0
z Pull out camshaft sealing ring with assembly lever.

© 47261-0
© 12/2008 2/4 17797-001

TD 2011 w, TCD 2011 w W 04-03-01
z Visually inspect all running surfaces.
6
© 47262-0
Install camshaft sealing ring

z Mount new camshaft sealing ring (1) on assembly
1
tool (2).
2
© 39515-1
z Carefully insert camshaft sealing ring.

z Fasten screw (1).
© 47263-0
© 12/2008 3/4 17797-001

W 04-03-01 TD 2011 w, TCD 2011 w
z Tighten screw until it reaches the assembly tool (1).

assembly tool.
z Unscrew screw.
6
© 47264-0
z Install toothed belt wheel (1).

W 04-04-15
1
© 47179-1
© 12/2008 4/4 17797-001

TD 2011 w, TCD 2011 w W 04-04-12
Renew toothed belt and tensioning pulley

– Rotation angle disc . . . . . . . . . . . . . 8190 – W 12-01-04
– Special bit, 70 mm long. . . . . . . . . . 9120 – W 12-08-03
Special tools:
– Ajustable bolt . . . . . . . . . . . . . . . 100700 Attention!
– Counter support . . . . . . . . . . . . . 144130 Re-tensioning of toothed belts which have
already been running is not permissible!
– Chalk The setting of engine control times should
only be carried out with new toothed belts!
The crankshaft may only be turned in the
direction of the engine.
Remove toothed belt and tensioning pul-

ley
z Remove V-belt pulley.
2
W 12-01-04
z Remove toothed belt and tensioning pulley (hydraulic
pump).
W 12-08-03
z Unscrew screw (1) with special bit.
z Remove protective hood (3).
3 2
1
© 47640-1

W 09-08-04 2 1
1
© 47641-1
© 12/2008 1/12 17798-001

W 04-04-12 TD 2011 w, TCD 2011 w
z Unscrew locking screw (1).

6
© 47619-0
z Insert adjustable bolt (1).
© 47620-0
z Press adjustable bolt in lightly in direction of arrow

and hold.
z Turn crankshaft slowly in direction of engine until the
adjustable bolt engages with the bore of the cam-
shaft.
© 47621-0
© 12/2008 2/12 17798-001

TD 2011 w, TCD 2011 w W 04-04-12
6
© 47621-1

© 47270-0
© 47296-0
© 12/2008 3/12 17798-001

W 04-04-12 TD 2011 w, TCD 2011 w
6
© 47271-0
z Turn crankshaft in the direction of the engine until it

reaches the stop of the adjustable bolt.
© 39130-1

z Remove tensioning pulley (2).
z Remove the toothed belt (3).
1
2
© 47642-1
© 12/2008 4/12 17798-001

TD 2011 w, TCD 2011 w W 04-04-12
z Insert counter support (1).

z Loosen screw (2).
Attention!
Do not turn camshaft.
6
© 47180-1
Install toothed belt and tensioning pulley

z Fasten screw (1).
To guarantee the length adjustment of the
toothed belt, the toothed belt wheel must
still be able to be turned slightly.
© 47180-2
z Turn crankshaft carefully against the adjustable bolt.
© 39130-1
© 12/2008 5/12 17798-001

W 04-04-12 TD 2011 w, TCD 2011 w
z Mount new toothed belt (1).
6 1
© 47299-2
z Mount new tensioning pulley (1).

z Position setting eccentric (arrow) at 6 o'clock.
z Fasten screw (2).
2
© 47300-1
z Press tensioning pulley (1) against the toothed belt.

z Fasten screws.
© 47301-1
© 12/2008 6/12 17798-001

TD 2011 w, TCD 2011 w W 04-04-12
z Align toothed belt.

Align toothed belt centrally on the toothed
belt wheels.
6
© 34132-2
z Align toothed belt.

z Press tensioning pulley (1) against the stop.
z Turn the toothed belt wheel by hand in the direction
of the arrow.
The tension side (2) is tightened.
2
© 47302-2
z Turn setting eccentric in the direction of arrow with

hexagon socket.
z Bring markings (1) and bores into alignment.
21 Nm
© 39605-1
© 12/2008 7/12 17798-001

W 04-04-12 TD 2011 w, TCD 2011 w
z Press tensioning pulley (1) against the stop.

z Hold toothed belt wheel (2) with counter support.
z Tighten new screw (3).
– Stage 1: 3
2
30 Nm
z Tighten screw (3) with rotation angle disc.
– Stage 2:
210°
1
6
© 39674-3
Check toothed wheel tension

z Unscrew adjustable bolt to the camshaft and crank-
shaft lock.
z Bring help markings (1) on toothed wheel and oppo-
site screw into line. 1
z Turn crankshaft two revolutions in the direction of the
arrow (direction of engine) until the help markings are
in line.
© 47303-0
Markings (1) and bores must be in align-

ment.
If the markings are not aligned with each
other, the toothed belt tension must be cor-
rected.
1
© 39608-1
© 12/2008 8/12 17798-001

TD 2011 w, TCD 2011 w W 04-04-12
Correct toothed belt tension

z Loosen screw (2).
hexagon socket.
z Bring markings (1) and bores into alignment.
21 Nm
6
© 39605-1
© 34229-2
z Mount protective hood (1).

Ensure that the installation location is free 1 2
from faults.

7 Nm
2
W 09-08-04
2
© 47641-2
© 12/2008 9/12 17798-001

W 04-04-12 TD 2011 w, TCD 2011 w

7 Nm
2
z Tighten screw (3) with special bit.
7 Nm
z Install toothed belt and tensioning pulley (hydraulic
pump).
W 12-08-03
z Install V-belt pulley.
W 12-01-04
6 1 2
3
© 47640-2
© 12/2008 10/12 17798-001

TD 2011 w, TCD 2011 w W 04-04-12
Technical Data
Stage 1:
A04 001 Toothed belt wheel on camshaft 30 Nm
Use new screw.
A04 001 Toothed belt wheel on camshaft Stage 2: 210°
A04 052 Tensioning pulley on front cover 21 Nm
Protective hood (toothed wheel) on
A04 053 7 Nm
front cover
6
© 12/2008 11/12 17798-001

W 04-04-12 TD 2011 w, TCD 2011 w
© 12/2008 12/12 17798-001

TD 2011 w, TCD 2011 w W 04-04-15
Removing and installing the toothed belt wheel

– Socket wrench insert,
spanner size 32 . . . . . . . . . . . . . . . 8036
– Force multiplier . . . . . . . . . . . . . . . . 8049
Special tools:
– Counter support . . . . . . . . . . . . . 143420
– Counter support . . . . . . . . . . . . . 144130
– Packing compound
DEUTZ DW 67
Remove toothed belt wheel

z Remove toothed belt and tensioning pulley. 2
W 04-04-12
z Insert counter support 144130.
z Unscrew screw (1). 1
© 47180-0

z Insert fixing bolts (1) in the bores (2).
Attention!
Do not twist crankshaft.
1
2
© 47181-0
© 12/2008 1/8 17799-001

W 04-04-15 TD 2011 w, TCD 2011 w

Attention!
6
© 47182-0
z Insert socket wrench insert and force multiplier (1).

z Snap in non-return device (2) in position CCW.
© 47183-1
z Hold force multiplier.

z Loosen screw.
z Remove force multiplier and socket wrench insert.
© 47184-0
© 12/2008 2/8 17799-001

TD 2011 w, TCD 2011 w W 04-04-15

z Remove counter holder.
6
© 47182-0

z Remove flange (2).
2 1
© 47185-0
Install toothed belt wheel

z Mount toothed belt wheel (3).
z Mount flange (2).
free of oil.
z Turn in new screw (1).

3
2 1
© 47185-0
© 12/2008 3/8 17799-001

W 04-04-15 TD 2011 w, TCD 2011 w
z Tighten screw.
– Stage 1:
130 Nm
6
© 47190-1

z Insert fixing bolts (1) in the bores (2).
Attention!
1
2
© 47181-0

Attention!
© 47182-0
© 12/2008 4/8 17799-001

TD 2011 w, TCD 2011 w W 04-04-15
z Insert socket wrench insert and force multiplier (1).

z Snap in non-return device (2) in position CW.
1
2
6
© 47191-1
z Turn square bar (1) in direction of arrow to the stop.

z Set graduated collar (2) to zero.
1
© 39458-2
z Hold force multiplier (1).

z Tighten screw.
– Stage 2:
210° 1
© 39459-2
© 12/2008 5/8 17799-001

W 04-04-15 TD 2011 w, TCD 2011 w
z Hold force multiplier against counter

pressure (arrow),
z release non-return device (1) and force multiplier.
Danger!
There is danger of injury if a force multiplier
is removed without being discharged.
z Remove force multiplier and socket wrench insert.
z Remove counter holder.
6
© 47192-0

free of oil.
2
z Mount toothed belt wheel (2).
z Tighten new screw (1). 1
z Install toothed belt and tensioning pulley.
W 04-04-12
© 47180-0
© 12/2008 6/8 17799-001

TD 2011 w, TCD 2011 w W 04-04-15
Technical Data
Stage 1:
A02 015 Toothed belt wheel on crankshaft 130 Nm
Use new screw.
A02 015 Toothed belt wheel on crankshaft Stage 2: 210°
© 12/2008 7/8 17799-001

W 04-04-15 TD 2011 w, TCD 2011 w
© 12/2008 8/8 17799-001

TD 2011 w, TCD 2011 w W 04-05-05
Removing and installing the camshaft

– W 03-09-01
Special tools: – W 04-03-01
– Ajustable bolt . . . . . . . . . . . . . . . 100700 – W 04-05-06
– Counter support . . . . . . . . . . . . . 144130 – W 07-04-01
– W 07-11-01
Removing the camshaft

z Remove camshaft sealing ring.
W 04-03-01
W 01-02-02
z Remove injection pumps.
W 07-04-01
z Remove fuel supply pump.
W 07-11-01
© 47262-0

W 03-09-01
© 47212-1
© 12/2008 1/6 17800-001

W 04-05-05 TD 2011 w, TCD 2011 w

z Remove thrust washer (2).
6
© 47305-0
z Press all valve tappets back.

z Pull out the camshaft (1) carefully to the flywheel
side.
z Remove all valve tappets with magnetic bar.
z Check camshaft.
W 04-05-06
© 47306-0
Installing the camshaft

z Insert all valve tappets.
z Oil camshaft bearing lightly.
z Oil cam shaft pin lightly.
free of oil.
© 47307-0
© 12/2008 2/6 17800-001

TD 2011 w, TCD 2011 w W 04-05-05
z Insert camshaft carefully.

z Bring bore (1) and (2) into alignment.
1 2
6
© 47309-0
z Insert camshaft pivots into the centrifugal force

movement (1).
© 47121-0
z Mount thrust washer (1).

The groove (2) faces the crankcase.
z Fasten screws.
1
© 47310-0
© 12/2008 3/6 17800-001

W 04-05-05 TD 2011 w, TCD 2011 w

21 Nm
6
© 47311-0
z Mount rear cover.

W 03-09-01
© 47212-1
z Install camshaft sealing ring.

W 04-03-01
z Install fuel pump.
W 07-11-01
z Install injection pumps.
W 07-04-01
W 01-02-02
© 47262-0
© 12/2008 4/6 17800-001

TD 2011 w, TCD 2011 w W 04-05-05
Technical Data
A04 002 Shim on camshaft 21 Nm
© 12/2008 5/6 17800-001

W 04-05-05 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17800-001

TD 2011 w, TCD 2011 w W 04-05-06
Checking the camshaft

– Prisms
Repairing the camshaft is not permissible.
The camshaft must be renewed.
Checking the camshaft

z Remove camshaft.
W 04-05-05
z Visually inspect cams and bearing pins for wear.
© 47307-0
Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.
© 36424-2
© 12/2008 1/4 17801-001

W 04-05-06 TD 2011 w, TCD 2011 w
z Measure the diameter of journals with the microme-

ter gauge.
When the wear limit is reached, the cams-
haft must be renewed.
53.945 - 53.960 mm
6
© 47313-0
z Install the camshaft.

W 04-05-05
© 47304-0
© 12/2008 2/4 17801-001

TD 2011 w, TCD 2011 w W 04-05-06
Technical Data
P04 31 Camshaft, bearing pin, diameter 53.945 - 53.960 mm
© 12/2008 3/4 17801-001

W 04-05-06 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17801-001

D 2011 w Speed control
TD 2011 w, TCD 2011 w W 05-04-15
Removing and installing the control linkage

– W 06-09-10
– W 07-04-01
– W 09-08-04
– W 13-02-03

to regulations.
Removing the control linkage

W 03-08-01
z Remove injection pumps.
W 07-04-01
z Remove generator.
W 13-02-03 1

W 09-08-04
z Remove magnet clip.
W 06-09-10
z Knock out cylinder pin (1). © 39072-1
z Pull out control linkage (1).
© 39073-1
© 12/2008 1/4 17802-001

Speed control D 2011 w
W 05-04-15 TD 2011 w, TCD 2011 w
Installing the control linkage

The lug (1) must face the oil filler (2).
z Insert control linkage with spring in the guide bush.

z Check the easy action of the control linkage.
6
© 39236-1
z Press spring together.

z Insert cylinder pin (1) into the bores (2).
z Insert cylinder pin in the recess (arrow) of the control
path limit.
Spring must touch the cylinder pin (3) .
© 39237-1
z Drive in cylinder pin flush with the crankcase.

z Install magnet clip.
W 06-09-10
W 03-08-01
W 07-04-01
W 09-08-04
z Install generator.
W 13-02-03
© 39238-1
© 12/2008 2/4 17802-001

TD 2011 w, TCD 2011 w W 05-04-15
Technical Data
M8x75-10.9
A13 010 Console on cylinder head 34 Nm
M8x100-10.9
© 12/2008 3/4 17802-001

W 05-04-15 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17802-001

TD 2011 w, TCD 2011 w W 05-04-16
Removing and installing the guide bushes

(Control linkage)
– W 05-04-15
– Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . . . . . . 110140 Collect leaking operating substances in
– Handle . . . . . . . . . . . . . . . . . . . . 150151 suitable vessels and dispose of according
– Extraction tool . . . . . . . . . . . . . . . 150210 to regulations.
– Assembly pin . . . . . . . . . . . . . . . 150220
– Slide hammer . . . . . . . . . . . . . . . 160400
– Locking agent
DEUTZ DW 72
6
Remove guide bushes

z Remove control linkage.
W 05-04-15
W 03-09-04
z Knock out cylinder pin (1).
1
© 39072-1
z Pull out control linkage (1).
© 39073-1
© 12/2008 1/12 17803-001

W 05-04-16 TD 2011 w, TCD 2011 w
Remove guide bushes (opposite side to

flywheel)
z Insert assembly pin (1) in guide bush (2).
6
© 47350-0
z Knock out guide bush.
© 39075-1
Install guide bush (opposite side to fly-

wheel)
© 39076-1
© 12/2008 2/12 17803-001

TD 2011 w, TCD 2011 w W 05-04-16
z Push spacing sleeve (1) onto assembly pin (2).

z Insert assembly pin into the centring (3).
The pilot pin (arrow) must lock in
2
groove (4).
1
4 3
6
© 39077-1
z Push guide bush (1) onto assembly pin.

During assembly, the chamfer (arrow) must
face the crankcase.
© 39078-1

z Insert assembly pin with guide bush.
The fixing bolt (1) must engage with the
hole (2).
2
1
© 39079-1
© 12/2008 3/12 17803-001

W 05-04-16 TD 2011 w, TCD 2011 w

21 Nm
z Drive in guide sleeve until the assembly pin touches 1
the spacing sleeve (arrow)
6
© 39082-1
The thread hold for the locking screw must

be dry and free of oil, corrosion and dirt.
z Tighten new locking screw.

50 Nm
© 39084-1
Remove guide bushes (flywheel side)

z Remove thermostat.
W 08-11-12 1
© 39087-2
© 12/2008 4/12 17803-001

TD 2011 w, TCD 2011 w W 05-04-16
z Remove cap (1).
6
© 39088-2
z Screw the extraction tool (1) tightly with the slide

hammer (2).
© 46977-0
z Insert extraction tool (1) and turn in the direction of

the arrow.
Attention!
© 46957-1
© 12/2008 5/12 17803-001

W 05-04-16 TD 2011 w, TCD 2011 w
z Expel the oil rise tube with the slide hammer.

z Remove oil rise tube.
Attention!
Vacuum off any shavings!
6
© 46958-1
z Insert assembly pin (1) in guide bush (2).
© 39099-2
z Knock out guide bush.
© 39204-2
© 12/2008 6/12 17803-001

TD 2011 w, TCD 2011 w W 05-04-16
Install guide bush (flywheel side)

z Insert assembly pin (1) in the centring (2).
The pilot pin (arrow) must lock in
groove (3).
2
1
3 6
© 39205-1
z Push guide bush (1) onto assembly pin.

face the crankcase.
© 39226-1

z Insert assembly pin with guide bush.
© 39227-2
© 12/2008 7/12 17803-001

W 05-04-16 TD 2011 w, TCD 2011 w

z Drive in guide sleeve until the assembly pin touches
the spacing sleeve (arrow) 1
6
© 39228-2
z Insert new oil rise tube (1).

face the crankcase.
© 39231-2
z Drive in oil rise tube until the assembly pin (1) lies on
the crankcase (arrow).
© 39232-2
© 12/2008 8/12 17803-001

TD 2011 w, TCD 2011 w W 05-04-16
z Coat new cap with locking agent.
6
© 33816-3
z Drive in cap flush with the crankcase.

z Install thermostat.
W 08-11-12
© 39233-2
The thread hold for the locking screw must

be dry and free of oil, corrosion and dirt.
z Tighten new locking screw.

56 Nm
© 39235-2
© 12/2008 9/12 17803-001

W 05-04-16 TD 2011 w, TCD 2011 w
The lug (1) must face the oil filler (2).
z Insert control linkage with spring in the guide bush.

z Check the easy action of the control linkage.
6
© 39236-1
z Press spring together.

z Insert cylinder pin (1) into the bores (2).
The cylinder pin must engage with the
recess (arrow) for the control path limit.
The spring must touch the cylinder pin (3).
© 39237-1
z Drive in cylinder pin flush with the crankcase.

z Install connection housing.
W 03-09-04
© 39238-1
© 12/2008 10/12 17803-001

TD 2011 w, TCD 2011 w W 05-04-16
Technical Data
A03 007 Locking screw on crankcase M18x1.5 Use new locking screw. 50 Nm
Locking screw on crankcase (oil rise
A03 008 M20x1.5 Use new locking screw. 56 Nm
tube)
A03 024 Assembly tool on crankcase 21 Nm
Lubricating oil cooler connection on
A08 054 M6x60 13 Nm
crankcase
6
© 12/2008 11/12 17803-001

W 05-04-16 TD 2011 w, TCD 2011 w
© 12/2008 12/12 17803-001

TD 2011 w, TCD 2011 w W 05-07-01
Removing and installing the impulse transmitter

Removing the impulse transmitter

z Unlock cable plug (1) and disconnect.
© 46966-0

z Remove impulse transmitter (2).
z Remove spacing sleeve (3).
1 2
© 46967-0
© 12/2008 1/4 17804-001

W 05-07-01 TD 2011 w, TCD 2011 w

z Clean components.
6
© 46968-0
Installing the impulse transmitter

z Position spacing sleeve (3).
z Insert impulse transmitter (2).
z Fasten screw (1).
8.5 Nm 3
1 2
© 46967-0

Ensure that the cables are connected pro-
perly.
© 46966-0
© 12/2008 2/4 17804-001

TD 2011 w, TCD 2011 w W 05-07-01
Technical Data
Speed transmitter on connection hou-
A05 011 8.5 Nm
sing
© 12/2008 3/4 17804-001

W 05-07-01 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17804-001

D 2011 w Exhaust system/Charging
TD 2011 w, TCD 2011 w W 06-01-05
Removing and installing the exhaust line

– Torx tool set . . . . . . . . . . . . . . . . . . 8189
Removing exhaust line

– TD 2011 w, TCD 2011 w
z Remove turbocharger.
W 06-06-04
z Unscrew all screws (1). 1 2 1
z Remove exhaust line (2).
1 1
© 47523-1
z Remove gaskets (1).
© 47525-1
© 12/2008 1/4 17805-001

Exhaust system/Charging D 2011 w
W 06-01-05 TD 2011 w, TCD 2011 w
z Unscrew studs (1).

6
© 47524-0
Installing exhaust line

z Clean sealing surfaces. 2
z Turn on new pin bolts (1).
z Tighten pin bolts (1).
1
12 Nm
1 2
© 47524-1

z Mount exhaust line (1).
z Mount new gaskets.
2 1 2
z Turn in new screws (2).
z Tighten new screws (2).
55 Nm
– TD 2011 w, TCD 2011 w
z Install the turbocharger.
2 2
W 06-06-04
© 47523-2
© 12/2008 2/4 17805-001

D 2011 w Exhaust system/Charging
TD 2011 w, TCD 2011 w W 06-01-05
Technical Data
Torx screw,
A06 001 Exhaust pipe at cylinder head Use new screws. 55 Nm
coated
© 12/2008 3/4 17805-001

Exhaust system/Charging D 2011 w
W 06-01-05 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17805-001

Exhaust system/Charging
TD 2011 w, TCD 2011 w W 06-02-03
Removing and install the charge air line

– Torx tool set . . . . . . . . . . . . . . . . . . 8189 – W 06-01-05
Remove charge air line

z Remove turbocharger.
W 06-06-04
2
z Remove the exhaust pipe.
1 1 1
W 06-01-05
z Remove charge air pipe (2).
z Remove seals.
1 1
© 47525-2
© 47533-0
© 12/2008 1/4 17806-001

W 06-02-03 TD 2011 w, TCD 2011 w
Install charge air line

z Mount charge air line (1).
z Mount new gaskets.
z Tighten screws (2) alternately working from the cen- 1
tre to the outside.
2 2 2
21 Nm
z Install the exhaust pipe.
W 06-01-05
z Install the turbocharger.
2 2
W 06-06-04
6
© 47525-3
© 12/2008 2/4 17806-001

TD 2011 w, TCD 2011 w W 06-02-03
Technical Data
Torx screw,
A06 030 Charge air pipe on cylinder head Use new screws. 21 Nm
coated
© 12/2008 3/4 17806-001

W 06-02-03 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17806-001

TD 2011 w, TCD 2011 w W 06-06-04
Removing and installing the turbocharger

– Clamping tongs. . . . . . . . . . . . . . . . 9088 Do not remove the stoppers/caps until
– Spring band pliers . . . . . . . . . . . . . . 9090 immediately before assembly.
– Lubricating oil Collect leaking operating substances in

– Fitting compound suitable vessels and dispose of according
DEUTZ S1 to regulations.
Removing turbocharger
z Remove the holder (2).
z Remove oil return pipe (3).
z Unscrew hollow screw (4).
z Remove sealing rings. 3
1
© 47532-0
z Loosen hose clip (1) with clamping tongs.

z Pull off hose clip (1) in the direction of the arrow.
© 47553-0
© 12/2008 1/8 17807-001

W 06-06-04 TD 2011 w, TCD 2011 w
z Loosen spring band clip (1) with spring band pliers.

z Remove reducer (2). 2
1
6
© 47554-0

z Remove lubricating oil pipe (2).
z Remove sealing rings.
z Press in stoppers.
© 47526-0

z Pull off spring band clip (1) in the direction of the ar-
row.
© 47527-0
© 12/2008 2/8 17807-001

TD 2011 w, TCD 2011 w W 06-06-04
z Unscrew nuts (1).
6
© 47528-0
z Remove turbocharger in the direction of the arrow.

z Remove gasket (1).
© 47555-0

z Unscrew screw-in nipple (2).
z Remove sealing ring (3).
2
3
1
© 47529-0
© 12/2008 3/8 17807-001

W 06-06-04 TD 2011 w, TCD 2011 w
z Unscrew studs (1).

z Check components for visible signs of wear.
6
© 47523-0
Installing the turbocharger

z Mount sealing ring (1).
z Tighten screw-in nipple (2).
40 Nm
2
1
3
© 47529-1

z Coat pin bolts with mounting compound.
z Screw in studs (1).
z Tighten all pin bolts (1).
12 Nm
© 47523-0
© 12/2008 4/8 17807-001

TD 2011 w, TCD 2011 w W 06-06-04
z Mount gasket (1).

z Plug in the tubing connection (2).
z Insert turbocharger in the direction of the arrow.
1
2
6
© 47555-1
z Mount turbocharger (1).

z Turn on new nuts (2).
z Tighten nuts (2).
21 Nm 2
© 47528-1
z Position the spring band clip (1) with the spring band
pliers.
z Pull out stoppers.
z Fill in clean lubricating oil (arrow).
© 47527-0
© 12/2008 5/8 17807-001

W 06-06-04 TD 2011 w, TCD 2011 w
z Mount lubrication oil line (1).

z Mount sealing rings (2).
z Screw on hollow screw (3).
2
1
6
© 47526-1

© 39378-2
z Mount oil return pipe (1).

z Mount holder (2).
8.5 Nm
Attention! 4
z Mount new sealing rings (4).

5
z Tighten hollow screw (5).
2
3
© 47532-1
© 12/2008 6/8 17807-001

TD 2011 w, TCD 2011 w W 06-06-04
Attention!

29 Nm
1
6
© 47526-2
z Mount the reducer (1).

Attention! 1
z Position spring band clip (2) with spring band pliers.
© 47554-1
z Position hose clip (1) with clamping tongs.
© 47553-1
© 12/2008 7/8 17807-001

W 06-06-04 TD 2011 w, TCD 2011 w
Technical Data
A06 020 Turbocharger on exhaust pipe M8 21 Nm
Lubricating oil pipe on turbocharger /
A08 042 Hollow screw Replace sealing rings 29 Nm
crankcase
Oil return line, hex spuds to turboch-
arger
Torx,
M6x14-8.8
6 For the tightening procedure according to torque using a torque wrench, a maximum variation of the
© 12/2008 8/8 17807-001

D 2011 w W 06-07-03
Removing and installing the intake manifold

– Torx tool set . . . . . . . . . . . . . . . . . . 8189
Removing the intake manifold

z Remove the exhaust pipe. 2
W 06-01-05
z Remove intake manifold (2).
z Remove seals.
1 1 1 1
© 47645-0
© 47533-0
© 12/2008 1/4 17808-001

W 06-07-03 D 2011 w
Installing the intake manifold

z Mount new gaskets. 1
z Mount intake manifold (1).
z Tighten new screws (2) alternately working from the
centre to the outside.
21 Nm
W 06-01-05 2 2 2 2
6
© 47645-1
© 12/2008 2/4 17808-001

D 2011 w W 06-07-03
Technical Data
Air suction intake pipe on cylinder Torx screw,
head coated
© 12/2008 3/4 17808-001

W 06-07-03 D 2011 w
© 12/2008 4/4 17808-001

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

z Remove safety cover (2).
3 2
© 46964-0
z Pull out pipe holder (1).
© 46937-0
© 12/2008 1/8 17809-001

W 06-09-06 D 2011 w
z Unscrew hollow screws (1).

z Remove pipe (2).
3
z Remove sealing rings (3).
3
2
6
© 46935-0

z Remove pipe (5).
2
1
5
3
4
© 46938-0
© 46939-0
© 12/2008 2/8 17809-001

D 2011 w W 06-09-06
1 6
© 46940-0

z Remove the exhaust gas return valve. 1
© 46941-0
© 46942-0
© 12/2008 3/8 17809-001

W 06-09-06 D 2011 w
6
© 46965-0
Installing the exhaust gas return valve

z Mount gasket (1).
z Mount exhaust gas return valve (2).
© 46943-0

20 Nm
© 46941-0
© 12/2008 4/8 17809-001

D 2011 w W 06-09-06

z Mount gasket (1).
z Mount exhaust gas collection pipe (2).
z Fasten screws (3).
1
20 Nm
2
6
© 46939-1
z Insert pipe (5).

2
29 Nm 1
12 Nm
5
3
4
© 46938-0
z Insert pipe (1).

2
z Turn in hollow screw (5). 3
29 Nm
z Tighten hollow screw (3). 4
29 Nm 1
© 46935-1
© 12/2008 5/8 17809-001

W 06-09-06 D 2011 w
z Press in pipe holder (1).
6
© 46937-0

z Mount the safety cover (2).
z Fasten screw (1).
8 Nm
3 2
© 46964-0
© 12/2008 6/8 17809-001

D 2011 w W 06-09-06
Technical Data
Pipe to exhaust gas return valve/cylin- Hollow screw
A06 057 29 Nm
der head (cooling - intake) M12x1.5
A06 062 M8x65-10.9 20 Nm
valve
A06 063 20 Nm
A06 071 12 Nm
Pipe to exhaust gas return valve Hollow screw
A06 072 29 Nm
(exhaust gas return - cooling - return) M12x1.5
A06 074
8.5 Nm
6
Locking
Safety cover on sensor housing screw
A06 075 8 Nm
(exhaust gas return) Torx-Plus
30IPR
© 12/2008 7/8 17809-001

W 06-09-06 D 2011 w
© 12/2008 8/8 17809-001

D 2011 w W 06-09-07
Removing and installing the exhaust gas return pipe

Removing the exhaust gas return pipe

3 2
© 46964-0
z Pull out pipe holder (1).
© 46937-0
© 12/2008 1/8 17810-001

W 06-09-07 D 2011 w

z Remove pipe (2).
3
3
2
6
© 46935-0

z Remove pipe (5).
2
1
5
3
4
© 46938-0
© 46939-0
© 12/2008 2/8 17810-001

D 2011 w W 06-09-07
1 6
© 46940-0

z Remove the exhaust return pipe.
1 1
1 1
© 46961-0
© 46962-0
© 12/2008 3/8 17810-001

W 06-09-07 D 2011 w

z Remove exhaust gas return valve (2).
1
3 3
6
© 46960-0
© 46963-0
Installing the exhaust gas return pipe

z Clean all sealing surfaces.
z Mount gasket (1).
z Mount exhaust gas return valve (2). 1
20 Nm
3 3
© 46960-0
© 12/2008 4/8 17810-001

D 2011 w W 06-09-07

z Mount gasket (1).
6
© 46962-0
z Install the exhaust gas return pipe.

8.5 Nm
1 1
1 1
© 46961-0

z Mount gasket (1).
z Mount exhaust gas collection pipe (2).
1
20 Nm
© 46939-1
© 12/2008 5/8 17810-001

W 06-09-07 D 2011 w
z Insert pipe (5).

2
29 Nm 1
12 Nm
5
3
4
6
© 46938-0
z Insert pipe (1).

2
z Turn in hollow screw (5). 3
29 Nm
z Tighten hollow screw (3). 4
29 Nm 1
© 46935-1
z Press in pipe holder (1).
© 46937-0
© 12/2008 6/8 17810-001

D 2011 w W 06-09-07

z Fasten screw (1).
8 Nm
3 2
6
© 46964-0
© 12/2008 7/8 17810-001

W 06-09-07 D 2011 w
Technical Data
Pipe to exhaust gas return valve/cylin- Hollow screw
A06 057 29 Nm
der head (cooling - intake) M12x1.5
A06 062 M8x65-10.9 20 Nm
valve
A06 063 20 Nm
A06 071 12 Nm
Pipe to exhaust gas return valve Hollow screw
A06 072 29 Nm
(exhaust gas return - cooling - return) M12x1.5
6 A06 074
8.5 Nm
Locking
A06 075 8 Nm
30IPR
© 12/2008 8/8 17810-001

D 2011 w W 06-09-08
Removing and installing the exhaust gas collection pipe

(Exhaust gas recirculation)
– Cleaning brush . . . . . . . . . . . . . . . . 8167 – W 06-09-07
Remove exhaust gas collection pipe

z Remove the exhaust pipe.
W 06-01-05
z Remove the exhaust return pipe.
W 06-09-07
1
© 46946-0

Note different screw lengths.
2 3
z Remove throttle (2).
© 46947-1
© 12/2008 1/6 17811-001

W 06-09-08 D 2011 w
6
© 46948-0
z Clean exhaust channels (1) with cleaning brush (2).

1
2 1
© 46949-0
Install exhaust gas collection pipe

z Check that mounting lugs (1) are sufficiently pre-ten-
sioned.
1
© 46950-0
© 12/2008 2/6 17811-001

D 2011 w W 06-09-08
z Mount gasket (1).

Make sure that the installation site of the
mounting lugs (2) is in perfect condition.
2 2
1 6
© 46951-0
z Mount new gaskets (3).

z Mount new throttle (2).
2 3
The marking (arrow) on the throttle is
dependent on the engine version.
z Insert exhaust gas collection pipe.
1
© 46952-1

55 Nm
© 46946-0
© 12/2008 3/6 17811-001

W 06-09-08 D 2011 w

55 Nm
z Install the exhaust gas return pipe.
W 06-09-07
W 06-01-05
1
6
© 46947-0
© 12/2008 4/6 17811-001

D 2011 w W 06-09-08
Technical Data
Torx
M10x25-10.9
Exhaust gas collection pipe (exhaust Torx
gas return) on cylinder head M10x30-10.9
Torx
M10x45-10.9
6
© 12/2008 5/6 17811-001

W 06-09-08 D 2011 w
© 12/2008 6/6 17811-001

D 2011 w W 06-09-09
Removing and installing the sensor

Commercial available tools Attention!
If the sensor (exhaust gas return) is
Special tools:
exchanged/adjusted, the engine must be
set on the engine test bench.
Remove sensor
z Disconnect the battery.
1 2
3
© 46964-1

z Swing fuel filter console (2) to the side.
© 46973-0
© 12/2008 1/4 17812-001

W 06-09-09 D 2011 w

z Remove sensor (2).
1
2
6
© 46974-0

© 46975-0
Install sensor
z Insert new sealing ring (1).
Ensure that the installation location of the
sealing ring is free from faults.
1
© 46975-1
© 12/2008 2/4 17812-001

D 2011 w W 06-09-09
z Mount sensor (2).

from faults.
z Fasten screw (1).
1
2
6
© 46974-0
z Mount fuel filter console (1).

21 Nm 3
21 Nm 1
© 46973-1

z Fasten screw (1).
8 Nm
z Connect the battery.
1 2
3
© 46964-1
© 12/2008 3/4 17812-001

W 06-09-09 D 2011 w
Technical Data
Locking
A06 075 8 Nm
30IPR
Sensor exhaust gas return on crank-
A06 076 21 Nm
case
A07 087 Fuel filter console to crankcase 21 Nm
6 tightening torque of +/- 10% is permissible.
© 12/2008 4/4 17812-001

D 2011 w W 06-09-10
Removing and installing the magnet clip

– W 07-04-01
Remove magnet clip

z Remove sensor of exhaust gas return.
W 06-09-09
z Remove fuel injector 3rd cylinder.
W 07-04-01
© 47230-1
z Insert clean rags (1) under the control linkage.

z Move the control linkage in the direction of the arrow. 2
z Hold on to the control linkage. 2
z Bend the retaining tab (2).
1
© 46972-1
© 12/2008 1/4 17813-001

W 06-09-10 D 2011 w
z Hold on to the control linkage.

z Pull off magnet clip (1) in the direction of the arrow.
Attention!
Make sure no parts fall into the crankcase!
1
6
© 46971-0
Install magnet clip

z Insert clean rags (1) under the control linkage.
z Position control linkage.
z Hold on to the control linkage.
z Push new magnet clip (2) onto the control linkage.
2 1
© 46971-1
Attention!
The magnet clip must sit tightly in the
recess of the control linkage.
Retaining tab (1) must snap in.
from faults.
1 1
© 46976-0
© 12/2008 2/4 17813-001

D 2011 w W 06-09-10
z Install fuel injector 3rd cylinder.

W 07-04-01
z Install sensor of exhaust gas return.
W 06-09-09
6
© 47230-0
© 12/2008 3/4 17813-001

W 06-09-10 D 2011 w
© 12/2008 4/4 17813-001

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
Special tools: to regulations.
Remove lifting magnet

© 47128-0

Note direction of terminal.
© 39663-1
© 12/2008 1/4 17814-001

Fuel system D 2011 w
W 07-02-07 TD 2011 w, TCD 2011 w

6
© 47392-0
Install lifting magnet

© 47392-0

© 47393-0
© 12/2008 2/4 17814-001

TD 2011 w, TCD 2011 w W 07-02-07

10 Nm
Note direction of terminal. 1
6
© 39664-1
© 47128-0
© 12/2008 3/4 17814-001

W 07-02-07 TD 2011 w, TCD 2011 w
Technical Data
A05 065 10 Nm
on front cover
© 12/2008 4/4 17814-001

TD 2011 w, TCD 2011 w W 07-03-01
Renewing the injection lines

Commercial available tools: Danger!
– Dog wrench. . . . . . . . . . . . . . . . . . . 8018 Wait 30 seconds after switching off the
Special tools: engine before working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
before removing.
sed air.
nal specifications for handling fuels. 6
to regulations.
Injection pipes may not be bent.
Removing injection pipes

z Unscrew lock nuts (1) with dog wrench.
© 47653-0
© 12/2008 1/6 17819-001

W 07-03-01 TD 2011 w, TCD 2011 w
z Remove injection pipes (1).

they should be installed. 1
Note assignment!
6
© 47652-0
z Mount the caps (1).
1
© 47654-0
© 47340-0
© 12/2008 2/6 17819-001

TD 2011 w, TCD 2011 w W 07-03-01
Installing injection pipes

z Pull off the caps (1).
z Mount new injection pipe.
1
1 6
© 47654-0
z Screw on union nuts (1).

Attention!
Install injection line without tension. 1
1
© 00000-0
z Tighten union nuts (1) with claw spanner.

25 Nm
© 47653-0
© 12/2008 3/6 17819-001

W 07-03-01 TD 2011 w, TCD 2011 w
Technical Data
Injection line on fuel injector / injection
A07 003 M12x1.5 25 Nm
pump
© 12/2008 4/6 17819-001

TD 2011 w, TCD 2011 w W 07-04-01
Removing and installing the fuel injector pump

– W 07-06-03
– Ajustable bolt . . . . . . . . . . . . . . . 100710 – W 07-10-06
– Rig pin. . . . . . . . . . . . . . . . . . . . . 101100 – W 11-00-03
– Test template . . . . . . . . . . . . . . . 103040
– Special pliers. . . . . . . . . . . . . . . . 103220 Danger!
Wait 30 seconds after switching off the
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
engine before working on the fuel system.
– Fitting compound
DEUTZ AP1908
Attention!
Remove residue paint and particles of dirt 6
before removing.
sed air.
to regulations.
The following work procress is described

for a cylinder as an example.
Removing the fuel injector pump

1 2
© 47540-0
© 12/2008 1/14 17815-001

W 07-04-01 TD 2011 w, TCD 2011 w
z Remove gasket.
z Remove injection lines.
W 07-03-01
z Remove fuel pipes.
W 07-10-06
z Remove lifting magnet (engine shutdown).
W 11-00-03
6
© 47634-0
z Turn crankshaft in the direction of the engine (arrow).

© 47541-0
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!
In case of internal exhaust gas recircula-
This is not to be confused with the valve
overlap.
EX IN EX
© 47612-0
© 12/2008 2/14 17815-001

TD 2011 w, TCD 2011 w W 07-04-01
z Turn crankshaft approx. 180° in the direction of the

engine.
6
© 47541-0
The cam (1) for the actuation of the injec-

tion pump of the corresonding cylinder
must be located on the base circle.
© 47356-0
z Loosen nuts (1) alternately.

Loosen nuts evenly to avoid tension on the
injection pump.
z Unscrew nuts (1).

z Remove washers. 2
z Remove fuel injector pump(2).
Note assignment!
© 47627-0
© 12/2008 3/14 17815-001

W 07-04-01 TD 2011 w, TCD 2011 w
z Remove shim (1).

Note assignment!
6
© 47558-0
z Pull out roller tappet (1) with special pliers.

Attention!
Do not damage the roller tappet!

Note assignment!
© 47628-0

© 47233-0
© 12/2008 4/14 17815-001

TD 2011 w, TCD 2011 w W 07-04-01

6
© 47629-0
z Move the control linkage in the direction of the arrow.

The control linkage is stopped by the adju-
stable bolts.
from faults.
© 47630-1
Installing the fuel injector pump

Note assignment of injection pump/roller
tappet/shim to the cam.
© 47235-0
© 12/2008 5/14 17815-001

W 07-04-01 TD 2011 w, TCD 2011 w
z Turn camshaft until the cam for the injection pump is

on the base circle (arrow).
6
© 46048-0
z Oil the roller tappet lightly.

z Insert roller tappet with special pliers.
Note assignment!
The pilot pin (1) must lock in groove (2).
2
© 47639-0
z Oil the locating hole lightly.

z Determining the thickness of the shim.
W 07-06-03
© 47631-0
© 12/2008 6/14 17815-001

TD 2011 w, TCD 2011 w W 07-04-01
z Select shim using table.

P07 21
z Check thickness of the shim with test template.
The reference line must lie centrally to the
round recess (dimension a).
6
© 47357-1
z Position shim.
Note assignment!
The bolt (1) must face in the direction of
the cylinder head.
1
© 47631-1

z Coat the O-ring with fitting compound.
© 47233-0
© 12/2008 7/14 17815-001

W 07-04-01 TD 2011 w, TCD 2011 w
z Pull out locking pin (1).

Pay attention to sealing.
6
© 47239-0
z Insert rig pin (1).

Do not press in rig pin.
© 47240-0
z Press in rig pin (1) slightly.

z Turn adjusting sleeve (2) back and forth.
Turn the adjusting sleeve until the rig pin
you can feel and hear it lock into the punch
mark (3). 1
3
© 47241-0
© 12/2008 8/14 17815-001

TD 2011 w, TCD 2011 w W 07-04-01
z Insert injection pump (1).

Note assignment!
z Tighten nuts (2) alternately.

21 Nm
2 6
© 47632-0
z Loosen clamping bar (arrow).

z Pull out rig pin (1).
© 47632-1
z Press in the locking pin (1) to the stop.
© 47633-0
© 12/2008 9/14 17815-001

W 07-04-01 TD 2011 w, TCD 2011 w
1
6
© 47632-2
z Mount new sealing ring.

z Tighten screw plug (1).
18 Nm
z Check start of injection.
W 07-06-01
© 47627-1
z Install lifting magnet (engine shutdown).

W 11-00-03
z Install fuel pipes.
W 07-10-06
z Install injection lines.
W 07-03-01
© 47634-0
© 12/2008 10/14 17815-001

TD 2011 w, TCD 2011 w W 07-04-01
z Mount new gasket.

z Mount cylinder head cover (2).
8.5 Nm
1 2
6
© 47540-0
© 12/2008 11/14 17815-001

W 07-04-01 TD 2011 w, TCD 2011 w
Technical Data
Thickness of shim
Dimension a of the
ID no. (difference Ss cal- Thickness of shim Part number
identification
culated)
up to 0.375 17 mm 0.35 mm 04287618

0,3751 - 0,425 15 mm 0.40 mm 04287619
0,4251 - 0,475 20 mm 0.45 mm 04287620
0,4751 - 0,525 18 mm 0.50 mm 04287621
0,5251 - 0,575 23 mm 0.55 mm 04287622
0,5751 - 0,625 21 mm 0.60 mm 04287623
0,6251 - 0,675 26 mm 0.65 mm 04287624
6 0,6751 - 0,725 24 mm 0.70 mm 04287625
0,7251 - 0,775 8 mm 0.75 mm 04287626
P07 21
0,7751 - 0,825 27 mm 0.80 mm 04287627
0,8251 - 0,875 11 mm 0.85 mm 04287628
0,8751 - 0,925 30 mm 0.90 mm 04287629
0,9251 - 0,975 29 mm 0.95 mm 04287630
0,9751 - 1,025 33 mm 1.00 mm 04287631
1,0251 - 1,075 7 mm 1.05 mm 04287632
1,0751 - 1,125 10 mm 1.10 mm 04287633
1,1251 - 1,175 13 mm 1.15 mm 04287634
1,1751 - 1,250 16 mm 1.20 mm 04287635
1,2501 - 1,36 19 mm 1.30 mm 04287636
lock.
A07 012 Injection pump on crankcase 21 Nm
© 12/2008 12/14 17815-001

TD 2011 w, TCD 2011 w W 07-06-01
Check start of injection

– W 07-10-06
– Ajustable bolt . . . . . . . . . . . . . . . 100700
– Degree scale. . . . . . . . . . . . . . . . 101020 Danger!
– Adapter . . . . . . . . . . . . . . . . . . . . 101030
Wait 30 seconds after switching off the
– Pointer . . . . . . . . . . . . . . . . . . . . 101300
engine before working on the fuel system.
– High-pressure hand pump . . . . . 101500
– Supply tank . . . . . . . . . . . . . . . . . 101510 Attention!
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
before removing.
Clean the respective affected parts care- 6
sed air.
to regulations.
This descriptions refers to the cylinder on

the front cover.
When checking other cylinders, the corre-
sponding ignition UDC should be calcula-
ted from the degree scale.
Check start of injection

W 07-03-01
z Remove fuel pipes.
W 07-10-06
z Remove lifting magnet.
W 11-00-03
1
© 47619-0
© 12/2008 1/12 17816-001

W 07-06-01 TD 2011 w, TCD 2011 w
6
© 47620-0
z Press adjustable bolt in lightly in direction of arrow

and hold.
z Turn crankshaft slowly in direction of engine until the
adjustable bolt engages with the bore of the cam-
shaft.
© 47621-0
© 47621-1
© 12/2008 2/12 17816-001

TD 2011 w, TCD 2011 w W 07-06-01

6
© 47270-0
© 47296-0

z Turn crankshaft carefully against the adjustable bolt.
The cylinder on the front cover is now loca-
ted in the ignition UDC.
© 47271-0
© 12/2008 3/12 17816-001

W 07-06-01 TD 2011 w, TCD 2011 w
z Loosen screw (1).

z Mount pointer with holding device (2).
21 Nm
2
6
© 47622-0
z Mount adapter (1).

z Screw on degree scale (3).
3
© 47623-0
z Bring degree scale into line with pointer.

z Set the pointer (1) in line with the “0°“ marking.
z Fasten degree scale.
z Fasten pointer.
© 47635-3
© 12/2008 4/12 17816-001

TD 2011 w, TCD 2011 w W 07-06-01

6
© 47624-0
z Bring control linkage into the middle position.

© 47244-0
z Mount overflow pipe (1).

z Connect hose (2) to overflow pipe. 1
z Connect hose (2) to supply tank. 3
z Connect pressure pipe (3) to fuel injector.
2
z Connect intake pipe (4) to supply tank.
z Fill supply tank with clean fuel.
© 47625-0
© 12/2008 5/12 17816-001

W 07-06-01 TD 2011 w, TCD 2011 w
z Mount locking screw (1).

Do not tighten locking screw.
6
© 47626-0
z Unscrew adjustable bolt to the camshaft and crank-

shaft lock.
z Turn crankshaft carefully approx. 90° in the direction
of the arrow (against the direction of the engine).
© 47635-1
z Bleed the suction chamber of the injection pump.

z Activate high-pressure hand pump until fuel emerges
at the locking screw (1).
45 Nm
© 47626-0
© 12/2008 6/12 17816-001

TD 2011 w, TCD 2011 w W 07-06-01
z Actuate the high-pressure hand pump constantly.

The fuel must flow evenly out of the over-
flow pipe.
z Turn the crankshaft slowly and evenly in the direction

of the arrow (engine direction of rotation) until the fuel
flow turns to drops.
As soon as the fuel flow becomes drops,
the start of injection has been reached.
6
© 47635-2
z Read start of injection on the degree scale.

Start of injection:
Note specifications on the company plate.
The start of injection must be set if it does
not match the specifications.
The start of injection of other injection
pumps should be checked using this
method.
Calculate the ignition UDC of each cylinder
with the degree scale.
Observe ignition interval.
Cylinders Ignition interval
4 180°
© 47635-0
© 47244-0
© 12/2008 7/12 17816-001

W 07-06-01 TD 2011 w, TCD 2011 w

18 Nm
6
© 47624-0
z Loosen screw (1).

z Remove pointer with holding device (2).
21 Nm
© 47622-0
z Remove intake pipe (4).

z Remove pressure pipe (3). 1
z Remove hose (2). 3
z Remove overflow pipe (1).
2
z Remove the high-pressure hand pump.
© 47625-0
© 12/2008 8/12 17816-001

TD 2011 w, TCD 2011 w W 07-06-01

6
© 47626-0
z Unscrew degree scale (1).

z Remove adapter (3).
1
© 47623-1
z Loosen screw (1).

z Remove pointer with holding device (2).
21 Nm
© 47622-0
© 12/2008 9/12 17816-001

W 07-06-01 TD 2011 w, TCD 2011 w
z Insert new sealing ring.

18 Nm
6
© 47619-0

18 Nm
W 07-03-01 1
z Install fuel pipes.
W 07-10-06
z Install lifting magnet.
W 11-00-03
© 47270-0
© 12/2008 10/12 17816-001

TD 2011 w, TCD 2011 w W 07-06-01
Technical Data
bolt on camshaft lock/
A03 003 Locking screw on crankcase M10x1 18 Nm
crankshaft lock.
lock.
A07 071 Locking screw on injection pump Replace sealing ring 45 Nm
6
© 12/2008 11/12 17816-001

W 07-06-01 TD 2011 w, TCD 2011 w
© 12/2008 12/12 17816-001

TD 2011 w, TCD 2011 w W 07-06-03
Determining the thickness of the shim

– Depth measuring screw . . . . . . . . . 8170
All contact and measuring surfaces must

be absolutely clean to rule out measuring
errors!
The following work process should be car-
ried out on each injection pump if neces-
sary.
z Removal and installation of roller tappet, visual in-

spection.
W 07-04-01
© 47561-1
z Mount probe for measuring range 50 to 75 mm on

depth measuring screw.
Measuring range default approx. 52 mm.
© 39183-1
© 12/2008 1/4 17817-001

W 07-06-03 TD 2011 w, TCD 2011 w
z Place the depth measuring screw on the contact sur-

face of the crankcase and keep it pressed against the
stop.
z Turn the depth measuring screw until the probe is
touching the roller tappet.
6
© 39184-2
z To determine the total depth dimension, in the case

of hydro-roller tappets, the working piston (1) in the
roller tappet must be pressed down until touching (ar-
row) (approx. 1 mm) by turning the depth measuring
screw further.
© 39128-1
z Measure, read and note the depth dimension "A"

from the crankcase rest to the plate spring rest of the
roller tappet.
– Example:
60,25 mm
© 39184-1
© 12/2008 2/4 17817-001

TD 2011 w, TCD 2011 w W 07-06-03
z Read and note installation dimension "X" from the

rating plate of the respective injection pump.
The installation dimension "X" serves to
calculate the shim/gasket.
X
Do not measure on the removed injection
pump.
The exact installation dimension "X" is spe-
cified on the injection pump's rating plate.
Example: 6160
Installation dimension "X" = 61,60 mm
6
© 47494-0
z Read and note value of the pre-stroke correction

from the company rating plate.
The pre-stroke correction value is specified
with a minus (-) or plus (+) sign.
Example: –16
z Calculate thickness of the shim "Ss".
Calculation example
Desired: - Thickness of shim Ss
- Thickness of shim without prestroke
correction So
Given: - Installation dimension of the injection pump X
- Prestroke correction Vk
Measured: - Depth gauge A
Calculation: S o= X – A
So= 61,60 mm – 60,25 mm
So= 1,35 mm
Calculation: Ss= So + Vk
Ss= 1,35 mm + (– 0,16 mm) © 39877-1
Result: Ss= 1,19 mm
z Select shim using table.

P07 21
W 07-04-01
© 12/2008 3/4 17817-001

W 07-06-03 TD 2011 w, TCD 2011 w
Technical Data
Thickness of shim
Dimension a of the
ID no. (difference Ss cal- Thickness of shim Part number
identification
culated)
bis 0,375 17 mm 0,35 mm 04287618

0,3751 - 0,425 15 mm 0,40 mm 04287619
0,4251 - 0,475 20 mm 0,45 mm 04287620
0,4751 - 0,525 18 mm 0,50 mm 04287621
0,5251 - 0,575 23 mm 0,55 mm 04287622
0,5751 - 0,625 21 mm 0,60 mm 04287623
0,6251 - 0,675 26 mm 0,65 mm 04287624
6 0,6751 - 0,725 24 mm 0,70 mm 04287625
0,7251 - 0,775 8 mm 0,75 mm 04287626
P07 21
0,7751 - 0,825 27 mm 0,80 mm 04287627
0,8251 - 0,875 11 mm 0,85 mm 04287628
0,8751 - 0,925 30 mm 0,90 mm 04287629
0,9251 - 0,975 29 mm 0,95 mm 04287630
0,9751 - 1,025 33 mm 1,00 mm 04287631
1,0251 - 1,075 7 mm 1,05 mm 04287632
1,0751 - 1,125 10 mm 1,10 mm 04287633
1,1251 - 1,175 13 mm 1,15 mm 04287634
1,1751 - 1,250 16 mm 1,20 mm 04287635
1,2501 - 1,36 19 mm 1,30 mm 04287636
© 12/2008 4/4 17817-001

TD 2011 w, TCD 2011 w W 07-07-01
Removing and installing the fuel injectors

– Assembly pliers. . . . . . . . . . . . . . . . 8024 – W 07-07-02
Special tools:
– Puller. . . . . . . . . . . . . . . . . . . . . . 110090 Danger!
– Slide hammer . . . . . . . . . . . . . . . 150800 Wait 30 seconds after switching off the
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 engine before working on the fuel system.
Attention!
before removing.
6
sed air.
to regulations.
Removing fuel injector

W 07-03-01
© 47557-0
© 12/2008 1/6 17818-001

W 07-07-01 TD 2011 w, TCD 2011 w

1 2
6
© 47562-0
z Pull out fuel injector (1) and sealing ring (arrow).

Note cylinder assignment.
© 47636-0
Removing stuck fuel injectors

z Assembly sliding hammer (1) and puller (2).
z Tighten lock nut (3).
© 40958-0
© 12/2008 2/6 17818-001

TD 2011 w, TCD 2011 w W 07-07-01
z Mount sliding hammer on fuel injector.

z Screw on lock nut (1).
z Pull out stuck fuel injector.
6
© 47564-0
z Grip a tight sealing ring (1) with the assembly

pliers (2) and pull off, turning slightly.
Attention!
Do not damage the nozzle tip!
© 43303-0

z Check the fuel injector.
W 07-07-02
© 47349-0
© 12/2008 3/6 17818-001

W 07-07-01 TD 2011 w, TCD 2011 w
Installing the fuel injector

z Mount new sealing ring (1) on fuel injector.
6
© 47351-0
z Insert fuel injector.

z Mount clamping shoe.
Note installation position of the clamping
shoe.
z Fasten screws.
© 39488-1

21 Nm
© 47562-1
© 12/2008 4/6 17818-001

TD 2011 w, TCD 2011 w W 07-07-01

W 07-03-01
6
© 47557-0
© 12/2008 5/6 17818-001

W 07-07-01 TD 2011 w, TCD 2011 w
Technical Data
© 12/2008 6/6 17818-001

TD 2011 w, TCD 2011 w W 07-07-02
Checking fuel injectors

– Nozzle tester. . . . . . . . . . . . . . . . . . 8008
– Socket wrench insert
spanner size 15 . . . . . . . . . . . . . . . 8012 Danger!
Special tools: Danger of injury when handling the nozzle
– Holder . . . . . . . . . . . . . . . . . . . . . 110110 tester.
The fuel penetrates deep into the flesh
through the nozzle jet!
Caution, blood poisoning!
After about three or four actuations of the

hand lever, the spring space above the
nozzle needle in the injection valve fills up 6
with diesel fuel/test oil. Then it is no longer
possible to actuate the hand lever.
The nozzle cap nut must be loosened care-
fully before every test procedure to release
pressure from the spring space.
Only use pure test oil according to ISO
4113 or clean diesel fuel to test the fuel
injectors.
Connecting the fuel injector to the nozzle

tester
z Removing fuel injectors.
W 07-07-01
z Insert fuel injector in holder.
z Loosen nozzle cap nut approx. 180° with socket
wrench insert (release pressure) and re-tighten.
45 - 50 Nm
© 36271-2
© 12/2008 1/6 17820-001

W 07-07-02 TD 2011 w, TCD 2011 w
z Connect the fuel injector to the nozzle tester
6
© 35889-2
Checking opening pressure

z Press down the lever of the nozzle tester slowly with
the pressure gauge connected.
+10 +1
170 bar (17 MPa)
The pressure at which the pointer stands
still or suddenly drops is the opening pres-
sure.
Repeat test 3 times.
© 36293-2
z Compare measured values.

The measured values of three tests must
match the test value.
z In case of deviations from the test value, the fuel in-

jector must be renewed.
© 36293-2
© 12/2008 2/6 17820-001

TD 2011 w, TCD 2011 w W 07-07-02
Checking tightness
z Blow the injection nozzle and nozzle holder dry with
air.
z Press the hand lever of the tester down slowly until
about 20 bar below the previously read opening
pressure are reached.
6
© 36293-2
Injection nozzle is tight if it does not drip

within 10 seconds.
© 36294-2
z If the injection nozzle drips, the fuel injector must be

renewed.
Attention!
Repairs are not permitted!
© 36295-2
© 12/2008 3/6 17820-001

W 07-07-02 TD 2011 w, TCD 2011 w
Checking the easy action of the nozzle

needle
z Switch off the tester’s pressure gauge.
z Carry out chatter and jet test of the nozzle needle.
The easy action of the nozzle needle in the
nozzle body is checked by the acoustic
chatter test.
Increasing wear in the needle seat of the
fuel injectors changes the chatter behavior
of the injecton nozzle.
A used fuel injector must buzz audibly and
atomize the fuel finely when the lever is
actuated quickly.
6 The jet profile may deviate considerably
from that of a new fuel injector.
© 36296-2
z If the injection nozzle does not buzz audibly, the fuel

injector must be renewed.
© 36296-2
Removing the fuel injector from the nozzle

tester
z Loosen nozzle cap nut approx. 180° with socket
wrench insert (release pressure) and re-tighten.
45 - 50 Nm
Attention!
The pressure in the spring space must be
reduced before installing the fuel injectors.
z Install fuel injectors.
W 07-07-01
© 36271-2
© 12/2008 4/6 17820-001

TD 2011 w, TCD 2011 w W 07-07-02
Technical Data
+10
Fuel injector (without leak oil), nozzle 170 bar
P07 52
opening pressure (17
+1
MPa)
Injection valve, clamping nut on
A07 002 45 - 50 Nm
nozzle holder (without leak oil)
tightening torque of +/- 10% is permissible. 6
© 12/2008 5/6 17820-001

W 07-07-02 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17820-001

Fuel system
TD 2011 w, TCD 2011 w W 07-08-01

(charge air pressure-dependent full load stop)
– Plier insert. . . . . . . . . . . . . . . . . . . . 8027
Special tools:

z Pull out cable plug.
1
© 47646-0
z Remove the O-ring with the disassembly tool.

© 47647-0
© 12/2008 1/4 17821-001

Fuel system
W 07-08-01 TD 2011 w, TCD 2011 w

z Mount new O-ring.
6
© 47648-0

10 Nm
© 47646-0
© 12/2008 2/4 17821-001

Fuel system
TD 2011 w, TCD 2011 w W 07-08-01
Technical Data
© 12/2008 3/4 17821-001

Fuel system
W 07-08-01 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17821-001

Fuel system
TD 2011 w, TCD 2011 w W 07-08-02
Installing and removing charge air pressure-dependent full load stop

– Plier insert. . . . . . . . . . . . . . . . . . . . 8027
Special tools:
Removing the charge air-pressure de-

pendent full load stop
z Remove fuel filter console.
W 07-10-08
1
© 39385-2
z Remove cover (1).

z Remove diaphragms (2).
z Remove spring (3).
3 1
2
© 39386-2
© 12/2008 1/4 17822-001

Fuel system
W 07-08-02 TD 2011 w, TCD 2011 w

1
6
© 39387-1
z Remove the O-ring with the disassembly tool.

© 47647-0
Installing the charge air-pressure depend-

ent full load stop
1
z Mount new O-ring.
10 Nm
© 39388-1
© 12/2008 2/4 17822-001

Fuel system
TD 2011 w, TCD 2011 w W 07-08-02

z Insert diaphragm (2) and cap (3).
Attention!
2
6
© 39389-1

8 Nm
z Install the fuel filter console.
W 07-10-08
© 39385-2
© 12/2008 3/4 17822-001

Fuel system
W 07-08-02 TD 2011 w, TCD 2011 w
Technical Data
Cap on charge air-dependent full load
A07 096 8 Nm
stop
© 12/2008 4/4 17822-001

TD 2011 w, TCD 2011 w W 07-10-06
Removing and installing fuel pipes

– Hose clip pliers . . . . . . . . . . . . . . . . 8011 Wait 30 seconds after switching off the
– Torx tool set . . . . . . . . . . . . . . . . . . 8189 engine before working on the fuel system.
– Spring band pliers . . . . . . . . . . . . . . 9090
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Pay attention to utmost cleanliness when
– Fitting compound Remove residue paint and particles of dirt
DEUTZ AP1908 before removing.
sed air.
to regulations.
Removing fuel pipes

1
© 47551-1
© 12/2008 1/8 17823-001

W 07-10-06 TD 2011 w, TCD 2011 w
z Loosen spring band clips (1) with spring band pliers.
6
© 47572-0
z Pull off hose pieces (1) in the direction of the arrow.
© 47573-0
z Loosen hose clip (1).

z Pull off fuel pipe (2).
z Pull off protective hose (3).
Collect draining fuel and dispose of accor-
ding to regulations.
3
© 47615-0
© 12/2008 2/8 17823-001

TD 2011 w, TCD 2011 w W 07-10-06

6
© 47614-0

z Remove fuel pipe (2).
1
© 47616-0

z Remove fuel return line (2).
Remove fuel return line in the direction of
the flywheel. 2
1 1 1
© 47617-0
© 12/2008 3/8 17823-001

W 07-10-06 TD 2011 w, TCD 2011 w
6
© 47618-0
Installing fuel pipes

z Mount fuel return pipe (1).
1
29 Nm
2 2 2
3 3 3
© 47617-1
z Mount fuel pipe (1).

3
29 Nm
3
2
2
© 47616-1
© 12/2008 4/8 17823-001

TD 2011 w, TCD 2011 w W 07-10-06
z Mount fuel hose (2).

Lay hose without contact.
from faults.
z Mount new hose clip (1).
z Fix the hose clip (1) with the hose clip pliers.
Ensure that the installation location is free 2
from faults.
6
© 47614-0
z Slip protective hose (3) over with mounting com-

pound.
from faults.
3
© 47615-0
z Position protective hose, dimension X.

20 mm
X
© 47615-1
© 12/2008 5/8 17823-001

W 07-10-06 TD 2011 w, TCD 2011 w
z Push on hose pieces (1) in the direction of the arrow.
6
© 47573-1
z Position spring band clips (1) with spring band pliers.
© 47572-0
z Position clamping claws (1).

Attention!

21 Nm
1
© 47551-0
© 12/2008 6/8 17823-001

TD 2011 w, TCD 2011 w W 07-10-06
Technical Data
A07 015 Fuel supply line to injection pump Hollow screw Replace sealing rings 29 Nm
A07 061 Fuel return line on injection pump Hollow screw Replace sealing rings 29 Nm
© 12/2008 7/8 17823-001

W 07-10-06 TD 2011 w, TCD 2011 w
© 12/2008 8/8 17823-001

Fuel system
TD 2011 w, TCD 2011 w W 07-10-08
Removing and installing the fuel filter console

– Torx tool set . . . . . . . . . . . . . . . . . . 8189 engine before working on the fuel system.
Special tools:
– Disassembly tool. . . . . . . . . . . . . 110901 Attention!
– Special wrench . . . . . . . . . . . . . . 170050 Pay attention to utmost cleanliness when
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 working on the fuel system.
– Fitting compound before removing.
DEUTZ AP1908 Clean the respective affected parts care-
sed air.
to regulations.
Removing the fuel filter console

z Loosen hose clips (1) with hose clip pliers.
1
z Pull off fuel hoses.
© 47592-0
© 12/2008 1/6 17824-001

Fuel system
W 07-10-08 TD 2011 w, TCD 2011 w
z Pull off hose pipe (1).
6
© 47593-0

z Remove fuel filter console (2).
1
© 47594-0
© 47595-0
© 12/2008 2/6 17824-001

Fuel system
TD 2011 w, TCD 2011 w W 07-10-08
6
© 47596-0
Installing the fuel filter console

© 47597-0
© 47598-0
© 12/2008 3/6 17824-001

Fuel system
W 07-10-08 TD 2011 w, TCD 2011 w
z Install the fuel filter console (2).

22 Nm
1
6 1
© 47594-0
z Mount the hose pipe (1).
© 47593-0
Note assignment!
Lay hoses without contact.
1
z Install fuel hoses.
z Mount new hose clips (1).
z Fasten hose clips (1) with hose clip pliers.
from faults.
© 47592-0
© 12/2008 4/6 17824-001

Fuel system
TD 2011 w, TCD 2011 w W 07-10-08
z Position protective hoses, dimension X.

20 mm
X
X
6
© 47599-0
© 12/2008 5/6 17824-001

Fuel system
W 07-10-08 TD 2011 w, TCD 2011 w
Technical Data
Fuel filter console/full load stop to Torx,
A07 087 22 Nm
crankcase M8x50-8.8
© 12/2008 6/6 17824-001

TD 2011 w, TCD 2011 w W 07-11-01
Removing and installing the fuel supply pump

Special tools: engine before working on the fuel system.
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Attention!
– Fitting compound working on the fuel system.
DEUTZ AP1908 Remove residue paint and particles of dirt
– Lubricating oil before removing.
sed air.
to regulations.
Removing the fuel supply pump

z Pull out oil dipstick (1).
© 47608-0
© 12/2008 1/6 17825-001

W 07-11-01 TD 2011 w, TCD 2011 w

z Pull off protective hose (3).
6 3 2
© 47610-0

z Remove fuel supply pump (2).
2
1
© 47609-0

© 47611-0
© 12/2008 2/6 17825-001

TD 2011 w, TCD 2011 w W 07-11-01
Installing the fuel supply pump

z Turn the crankshaft until the eccentric of the cam-
shafts is in the top dead centre (arrow).
6
© 47398-0

z Oil tappet (2) lightly with lubricating oil.
© 47176-0

z Mount fuel supply pump.
z Press fuel supply pump centrally on the crankcase.
21 Nm
© 47609-1
© 12/2008 3/6 17825-001

W 07-11-01 TD 2011 w, TCD 2011 w
z Slip protective hose (3) over with mounting com-

pound.

6 3 2
© 47610-0
z Position protective hose, dimension X.

20 mm
© 47610-1
z Fix the hose clip (1) with the hose clip pliers.
from faults.
© 47402-0
© 12/2008 4/6 17825-001

TD 2011 w, TCD 2011 w W 07-11-01
z Insert oil dipstick (1).
6
© 47608-0
© 12/2008 5/6 17825-001

W 07-11-01 TD 2011 w, TCD 2011 w
Technical Data
A07 024 Fuel supply pump on crankcase 21 Nm
© 12/2008 6/6 17825-001

D 2011 w Lube oil system
TD 2011 w, TCD 2011 w W 08-04-05
Removing and installing the lubricating oil pump

– Torx tool set . . . . . . . . . . . . . . . . . . 8189

to regulations.
Removing the lubricating oil pump

z Remove toothed belt and tensioning pulley.
W 04-04-12
© 47403-0

z Remove lubricating oil pump (2).
1
© 47404-0
© 12/2008 1/4 17826-001

Lube oil system D 2011 w
W 08-04-05 TD 2011 w, TCD 2011 w

1
6
© 39496-1
Install the lubricating oil pump

z Mount new gasket (1).
© 39496-1
z Make sure the clamping bushings (arrows) are in

place.
© 47405-0
© 12/2008 2/4 17826-001

TD 2011 w, TCD 2011 w W 08-04-05
z Centre the lubricating oil pump (1) with clamping

pins (2).
z Mount lubricating oil pump.
1
6
© 47406-0

21 Nm
1
© 47407-0

z Install toothed belt and tensioning pulley.
W 04-04-12
© 47403-0
© 12/2008 3/4 17826-001

W 08-04-05 TD 2011 w, TCD 2011 w
Technical Data
A08 010 Lubricating oil pump on crankcase 21 Nm
© 12/2008 4/4 17826-001

TD 2011 w, TCD 2011 w W 08-04-06
Removing and installing the oil suction pipe

– Packing compound Collect leaking operating substances in

DEUTZ DW 73 suitable vessels and dispose of according
to regulations.
Removing the oil suction pipe

W 08-04-07
2
z Remove oil suction pipe (2).
© 47408-0

© 47409-0
© 12/2008 1/4 17827-001

W 08-04-06 TD 2011 w, TCD 2011 w
Installing the oil suction pipe

The sealing surfaces must be dry and free
from grease and dirt.
z Apply packing compound (arrow).

Sealing cord strength approx. 1.0 mm
Attention!
No packing compound must get into the oil
channel (1)!
1
6
© 47342-0
z Mount oil suction pipe (2).

Do not displace the packing compound.

2
21 Nm
W 08-04-07
© 47408-0
© 12/2008 2/4 17827-001

TD 2011 w, TCD 2011 w W 08-04-06
Technical Data
Packing compound
A08 015 Oil suction pipe on crankcase 21 Nm
DW73
© 12/2008 3/4 17827-001

W 08-04-06 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17827-001

TD 2011 w, TCD 2011 w W 08-04-07
Removing and installing the lubricating oil pan

(metal sheet lubricating oil pan)
– Torx tool set . . . . . . . . . . . . . . . . . . 8189 suitable vessels and dispose of according
Special tools: to regulations.
– Separating tool . . . . . . . . . . . . . . 151500 Emptying and filling the engine with opera-
ting media must be carried out according to
– Packing compound the operating manual and the appropriate
DEUTZ DW 73 documentation of the vehicle/equipment
– Lubricating oil manufacturer.
Removing the lubricating oil pan

z Drain lubricating oil, collect and dispose of according
to regulations.
z Oil the screw plug lightly.
55 Nm
© 47410-0

z Turn engine 180°.
© 47411-0
© 12/2008 1/8 17828-001

W 08-04-07 TD 2011 w, TCD 2011 w

z Remove washers.
z Remove the cover (2).
6
© 47412-0
© 47413-0
z Drive in separating tool (1) to the stop (2).

Attention!
The tool can only be driven in in the area of
the crankcase. 1
Separation in the area of aluminium parts
is not allowed.
© 47414-0
© 12/2008 2/8 17828-001

TD 2011 w, TCD 2011 w W 08-04-07
z Drive in second separating tool (1) to the stop (2).

Attention!
The tool can only be driven in in the area of
the crankcase.
Separation in the area of aluminium parts
is not allowed.
2
6
© 47415-0
Attention!
Do not drive in separating tool in the area
of the lubricating oil pump (1).
1
X
© 47416-1
z Lever out lubricating oil pan.

© 47417-0
© 12/2008 3/8 17828-001

W 08-04-07 TD 2011 w, TCD 2011 w

z Scrape off sealing compound with separating tool.
The sealing surfaces must be dry and free
6
© 47418-0
Installing the lubricating oil pan

z Apply packing compound (arrow).
Sealing cord strength approx. 3 mm
© 47363-0
z Mount lubricating oil pan.

z Align lubricating oil pan to crankcase.
Do not move the packing compound when
mounting the lube oil tray.
© 47419-0
© 12/2008 4/8 17828-001

TD 2011 w, TCD 2011 w W 08-04-07

6
© 47413-0
z Tighten screws (arrows).
© 34255-2

quence.
13 12 11 2 1 8 9 10
19
21 Nm 20
18 21
17 22
16 15 14 3 4 5 6 7
© 47485-0
© 12/2008 5/8 17828-001

W 08-04-07 TD 2011 w, TCD 2011 w
z Mount cover (2).

z Mount washers.
9 Nm
2
6
© 47412-0
z Turn engine 180°.

z Fill in lubricating oil according to operating manual.
© 47411-0
© 12/2008 6/8 17828-001

TD 2011 w, TCD 2011 w W 08-04-07
Technical Data
Lubricating oil pan (plate) on crank- Observe tightening
A03 030 M8x16 21 Nm
case sequence!
A03 031 Locking screw on lubricating oil pan Replace sealing ring 55 Nm
A03 085 Cover plate to connection housing 9 Nm
© 12/2008 7/8 17828-001

W 08-04-07 TD 2011 w, TCD 2011 w
© 12/2008 8/8 17828-001

TD 2011 w, TCD 2011 w W 08-08-02
Removing and installing the lubricating oil cooler


to regulations.
Emptying and filling the engine with opera-
the operating manual and the appropriate
documentation of the vehicle/equipment
manufacturer.
Removing the lubricating oil cooler

1 2 1
z Remove oil filter console.
W 08-11-07
z Remove lubricating oil cooler (2).
1 1
© 47517-0
© 47518-0
© 12/2008 1/4 17829-001

W 08-08-02 TD 2011 w, TCD 2011 w
Installing the lubricating oil cooler

6
© 47519-0

1
© 47518-0
z Mount lubricating oil cooler (1).

Ensure that the installation location of the 2 1 2
sealing ring is free from faults.

13 Nm
z Mount oil filter console.
W 08-11-07
2 2
© 47517-1
© 12/2008 2/4 17829-001

TD 2011 w, TCD 2011 w W 08-08-02
Technical Data
Lubricating oil cooler on oil filter con-
A08 051 M6x16-10.9 13 Nm
sole
© 12/2008 3/4 17829-001

W 08-08-02 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17829-001

TD 2011 w, TCD 2011 w W 08-11-02
Removing and installing the oil pressure regulating valve

– Slide gauge suitable vessels and dispose of according
to regulations.
Removing the oil pressure regulating

valve 1
– (1) Oil pressure regulating valve
– (2) Oil channel output with transfer fitting
2
(Option cabine heating connection)
– (3) Oil pressure regulating valve (TD 2011)
– (4) Oil channel input with transfer fitting
(Option cabine heating connection)
3
© 39520-2
Attention!
Parts are under tensions and can spring
out during disassembly!
z Unscrew locking screw (1). 1
z Remove compression spring.
z Remove oil pressure regulating valve.
© 46955-0
© 12/2008 1/4 17830-001

W 08-11-02 TD 2011 w, TCD 2011 w
6
© 39061-1
z Measure length of the compressor spring with calli-

per gauge.
– Coloured marking, green
56.5 mm
– Coloured marking, yellow
80.5 mm
– Coloured marking, red
78.4 mm
– Coloured marking, blue
61.8 mm
When the wear limit is reached, the com-
pressor spring must be renewed.
© 39062-1
Installing the oil pressure regulating valve

z Lightly oil oil pressure regulating valve (1).
z Insert oil pressure regulating valve.

z Insert compression spring (2) 1
© 46954-0
© 12/2008 2/4 17830-001

TD 2011 w, TCD 2011 w W 08-11-02

z Mount locking screw (1).
1
111 Nm
6
© 46955-0
Cabin heating connection, input

Attention!
z Remove oil pressure regulating valve.
© 46955-1
Attention!
Observe order of installation!
z Insert compression spring (1)

z Lightly oil oil pressure regulating valve (2).
z Insert oil pressure regulating valve.
z Tighten transfer fitting. 1
111 Nm
© 46956-0
© 12/2008 3/4 17830-001

W 08-11-02 TD 2011 w, TCD 2011 w
Technical Data
P08 41 pressure Coloured marking, green 3 bar
P08 41 pressure Coloured marking, yellow 1 bar
P08 42 pressure Coloured marking, red 1.7 bar
P08 43 pressure Coloured marking, blue 0.3 bar
6 (without cabin heating connection)
P08 44 without heating connection, green 56.5 mm
sion spring, length
P08 44 with heating connection, yellow 80.5 mm
sion spring, length
P08 45 with heating connection, red 78.4 mm
sion spring, length
P08 46 with heating connection, blue 61.8 mm
sion spring, length
Locking screw on transfer fitting (hea-
ting connection)
Locking screw on transfer fitting (hea-
ting connection)
Transfer fitting on crankcase (heating
connection)
© 12/2008 4/4 17830-001

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 – W 08-08-02
Special tools:
– Disassembly tool. . . . . . . . . . . . . 110901 Collect leaking operating substances in
– Special wrench . . . . . . . . . . . . . . 170050 suitable vessels and dispose of according
to regulations.
– Fitting compound Emptying and filling the engine with opera-
DEUTZ AP1908 ting media must be carried out according to
manufacturer.
Removing the oil filter console

© 47572-0
© 47573-0
© 12/2008 1/6 17831-001

W 08-11-07 TD 2011 w, TCD 2011 w

6
© 47514-0
z Unscrew lubricating oil filter (1) with special wrench.

Collect draining lubricating oil and dispose
of properly.
© 47515-0

z Remove oil filter console (3).
2
1
1
© 47516-0
© 12/2008 2/6 17831-001

TD 2011 w, TCD 2011 w W 08-11-07

6
© 47520-0
Installing oil filter console

© 47521-0
z Fix new gasket (1) to the crankcase with a little

grease.
© 47520-0
© 12/2008 3/6 17831-001

W 08-11-07 TD 2011 w, TCD 2011 w
z Mount oil filter console (1).

Do not move gasket.

z Turn in screw (3).
21 Nm 2
2
21 Nm
1
6
© 47516-1

z Lightly oil sealing ring on new lubricating oil filter.
z Tighten the lubricating oil filter (1) according to the
operating instructions.
Operation manual
© 47515-0
z Insert control line (1).

18 Nm
© 47514-2
© 12/2008 4/6 17831-001

TD 2011 w, TCD 2011 w W 08-11-07
6
© 47573-1
pliers.
© 47572-0
© 12/2008 5/6 17831-001

W 08-11-07 TD 2011 w, TCD 2011 w
Technical Data
Torx
M8x50-8.8
A08 003 Oil filter console on crankcase 21 Nm
Torx
M8x90-8.8
Control line to oil filter console / crank- Hollow screw
A08 048 18 Nm
case M10x1
6
© 12/2008 6/6 17831-001

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
to regulations.
Removing the oil pressure switch

© 47344-0
z Unscrew oil pressure switch (1).
© 47432-0
© 12/2008 1/4 17832-001

W 08-11-08 TD 2011 w, TCD 2011 w
6
© 47433-0
Installing the oil pressure switch

z Screw on oil pressure switch (1).
© 47434-0
z Tighten oil pressure switch (1).

13 Nm
© 47432-0
© 12/2008 2/4 17832-001

TD 2011 w, TCD 2011 w W 08-11-08

6
© 47344-0
© 12/2008 3/4 17832-001

W 08-11-08 TD 2011 w, TCD 2011 w
Technical Data
A08 091 Oil pressure switch on crankcase M10x1 13 Nm
© 12/2008 4/4 17832-001

TD 2011 w, TCD 2011 w W 08-11-12
Removing and installing the thermostat

(Lubricating oil cooler)
– Slide gauge suitable vessels and dispose of according
– Torx tool set . . . . . . . . . . . . . . . . . . 8189 to regulations.
Special tools:
Removing the thermostat

Attention!
© 47569-0
z Remove thermostat (1).

© 47575-0
© 12/2008 1/4 17833-001

W 08-11-12 TD 2011 w, TCD 2011 w
6
© 47439-0
© 47568-0
Installing the thermostat

z Measure length of the compressor spring with calli-
per gauge.
45.7 mm
When the wear limit is reached, the com-
pressor spring must be renewed.
© 47576-0
© 12/2008 2/4 17833-001

TD 2011 w, TCD 2011 w W 08-11-12

z Oil the thermostat lightly.
z Insert compression spring.
z Insert thermostat (1).
6
© 47575-0

© 47439-0

90 Nm
© 47569-0
© 12/2008 3/4 17833-001

W 08-11-12 TD 2011 w, TCD 2011 w
Technical Data
P08 74 Thermostat, compression spring, length 45.7 mm
Thermostat on crankcase, locking
A08 072 90 Nm
screw,
6
© 12/2008 4/4 17833-001

TD 2011 w, TCD 2011 w W 08-16-01
Removing and installing the control line

– W 08-11-07

to regulations.
manufacturer.
Removing control line

z Remove fuel filter console.
W 07-10-08
z Remove oil filter console.
W 08-11-07
1
© 47514-0

z Remove control line (3). 3
Collect draining lubricating oil and dispose
of properly. 2
2 2
1 1
© 47650-0
© 12/2008 1/4 17834-001

W 08-16-01 TD 2011 w, TCD 2011 w
z Visually inspect sealing surfaces (arrows).
6
© 47651-0
© 47649-0
Installing control line

z Insert control line (1).
z Mount sealing rings (2). 1
z Screw in all hollow screws. 2
z Tighten hollow screws (3).
18 Nm 2 2
Attention!
3
3 3
© 47650-1
© 12/2008 2/4 17834-001

TD 2011 w, TCD 2011 w W 08-16-01
z Install the fuel filter console.

W 07-10-08
z Mount oil filter console.
W 08-11-07
z Insert control line (1). 1
18 Nm 3
6
© 47514-2
© 12/2008 3/4 17834-001

W 08-16-01 TD 2011 w, TCD 2011 w
Technical Data
Control line to oil filter console / crank- Hollow screw
A08 048 18 Nm
case M10x1
© 12/2008 4/4 17834-001

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

z Remove V-belt.
W 13-02-03
3
Pay attention to different screw lengths.
1 1

z Remove coolant pump (3).
Collect and dispose of coolant according to
regulations.
2 1
© 47510-0

1
© 47512-0
© 12/2008 1/4 17835-001

Cooling system D 2011 w
W 09-07-08 TD 2011 w, TCD 2011 w
6
© 47511-0
Installing coolant pump

1
© 47512-0
z Mount coolant pump (1).

Pay attention to different screw lengths.
Screws M8 x 35 mm (2)
Screw M8 x 100 mm (3) 1
2 2
20 Nm
20 Nm
3 2
© 47510-1
© 12/2008 2/4 17835-001

TD 2011 w, TCD 2011 w W 09-07-08
z Install V-belt.
W 13-02-03
z Fill cooling system according to the operating manu-
al.
6
© 46986-2
© 12/2008 3/4 17835-001

W 09-07-08 TD 2011 w, TCD 2011 w
Technical Data
M8x35-10.9
A09 010 Coolant pump on thermostat housing 20 Nm
M8x100-10.9
© 12/2008 4/4 17835-001

TD 2011 w, TCD 2011 w W 09-08-01
Checking the thermostat (in the removed state)

– Thermometer
Danger!
Risk of injury!
Hot water and hot thermostat.
Checking thermostat
z Remove thermostat.
W 09-08-02
z Measure beginning of stroke, dimension (a).
© 34679-3
z Heat up the thermostat in the water bath.

In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the ther-
mostat.
The water should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place
faster than 1°C/min. Otherwise the begin-
ning of opening will be delayed accordin-
gly.
z Determine beginning of opening.
86 - 90 °C
© 34680-2
© 12/2008 1/4 17836-001

W 09-08-01 TD 2011 w, TCD 2011 w
z Measure end of stroke, dimension (b).

z Note measured value, dimension (b).
6
© 34679-2
z Determine stroke.
Calculation example
Desired: Stroke
Given: -
Measured: Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Calculation: Dimension (b) - dimension (a)
Result: = stroke
z Compare result with setpoint value.
– Nominal value stroke travel:
at least 9 mm
z Install thermostat.
W 09-08-01
© 34679-1
© 12/2008 2/4 17836-001

TD 2011 w, TCD 2011 w W 09-08-01
Technical Data
P09 11 Thermostat, start of opening 86 - 90 °C
P09 13 Thermostat, stroke distance at least 9 mm
© 12/2008 3/4 17836-001

W 09-08-01 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17836-001

TD 2011 w, TCD 2011 w W 09-08-02
Removing and installing the thermostat


to regulations.
manufacturer.
Removing the thermostat

z Remove outlet nozzle (2).
1
1
© 46982-0
z Remove O-ring.
z Remove thermostat (1).
© 46983-0
© 12/2008 1/4 17837-001

W 09-08-02 TD 2011 w, TCD 2011 w
z Check thermostat.
W 09-08-01
6
© 46984-0
Installing the thermostat

z Insert thermostat (1).
© 46983-0

© 46985-0
© 12/2008 2/4 17837-001

TD 2011 w, TCD 2011 w W 09-08-02
z Mount outlet nozzle (2).

22 Nm
1
1
6
© 46982-0
© 12/2008 3/4 17837-001

W 09-08-02 TD 2011 w, TCD 2011 w
Technical Data
A09 002 Outlet nozzles on thermostat housing M8x30-10.9 22 Nm
© 12/2008 4/4 17837-001

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 – W 12-02-01

Special tools:
– Disassembly tool. . . . . . . . . . . . . 110901 Collect leaking operating substances in
– Fitting compound to regulations.
DEUTZ AP1908 The appropriate documentation of the
vehicle/equipment manufacturer should be
observed for emptying and filling the coo-
ling system.
Removing thermostat housing

z Remove V-belt.
W 12-02-01 1
© 47570-0
© 47522-0
© 12/2008 1/6 17838-001

W 09-08-04 TD 2011 w, TCD 2011 w

z Remove the thermostat housing (3).
1
6
2
© 46990-0
z Pull out plug element (1).

z Pull out plug element (2).
1
© 46991-0
© 47571-0
© 12/2008 2/6 17838-001

TD 2011 w, TCD 2011 w W 09-08-04
Installing thermostat housing

6
© 46993-0
© 46992-0
z Insert plug element (1).

z Insert plug element (2).
1
© 46991-0
© 12/2008 3/6 17838-001

W 09-08-04 TD 2011 w, TCD 2011 w
z Mount thermostat housing (1).

from faults.

34 Nm
2
3
6
2
© 46990-1
z Coat hose pieces with mounting compound.

© 47522-1
pliers.
z Install V-belt.
1
z Check V-belt tension.
W 12-02-01
© 47570-0
© 12/2008 4/6 17838-001

TD 2011 w, TCD 2011 w W 09-08-04
Technical Data
A09 001 Thermostat housing to crankcase M8x100-10.9 34 Nm
© 12/2008 5/6 17838-001

W 09-08-04 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17838-001

TD 2011 w, TCD 2011 w W 09-12-01
Removing and installing temperature transmitter

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

z Disconnect cable connections.
z Unscrew temperature transmitter (1).
© 46994-0
© 46995-0
© 12/2008 1/4 17839-001

W 09-12-01 TD 2011 w, TCD 2011 w
Installing temperature transmitter

z Tighten temperature transmitter (1).
25 Nm
Make sure the sealing ring is in place.
z Connect cable.
6
© 46994-0
© 12/2008 2/4 17839-001

TD 2011 w, TCD 2011 w W 09-12-01
Technical Data
Temperature transmitter on thermo-
A09 031 25 Nm
stat housing
© 12/2008 3/4 17839-001

W 09-12-01 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17839-001

D 2011 w Monitoring system
TD 2011 w, TCD 2011 w W 11-00-03

(Engine shutdown)
Special tools:

3
– Version with V-belt tensioning pulley
z Remove V-belt.
W 12-02-01 1
z Loosen screws (1).
z Swing V-belt tensioning pulley (2) in the direction of
the arrow.
z Remove V-belt (3).
4
2
© 46986-0

z Remove V-belt tensioning pulley (3).
1 2
© 47605-0
© 12/2008 1/4 17840-001

Monitoring system D 2011 w
W 11-00-03 TD 2011 w, TCD 2011 w
z Remove cable tie (1).

z Remove lifting magnet (3). 2
6
© 47606-0

© 47355-0

© 39036-1
© 12/2008 2/4 17840-001

D 2011 w Monitoring system
TD 2011 w, TCD 2011 w W 11-00-03

2
8.5 Nm
z Fasten cable plug with cable tie (3).
3
6
© 47606-1
z Mount V-belt tensioning pulley (1).

z Fasten screw (2).
z Mount and tighten V-belt.
W 12-02-01 2 3
© 47605-1
© 12/2008 3/4 17840-001

Monitoring system D 2011 w
W 11-00-03 TD 2011 w, TCD 2011 w
Technical Data
A05 041 8.5 Nm
front cover
© 12/2008 4/4 17840-001

D 2011 w Other components
TD 2011 w, TCD 2011 w W 12-01-04
Removing and installing the V-belt pulley

Removing the V-belt pulley

z Remove V-belt.
W 12-02-01
z Remove fan (2).
1
1 2
© 47574-0

z Remove flange hub (2).
© 47013-0
© 12/2008 1/4 17841-001

Other components D 2011 w
W 12-01-04 TD 2011 w, TCD 2011 w
z Remove V-belt pulley (1).
6
© 47014-0
z Remove centrifugal disc (1).

1
© 47015-0
Installing the V-belt pulley

z Mount centrifugal disc (1).
1
© 39598-1
© 12/2008 2/4 17841-001

TD 2011 w, TCD 2011 w W 12-01-04
z Mount V-belt pulley (1).
6
© 47014-0
z Mount flange hub (2).

43 Nm
© 47013-0
Attention!
Note installation position: "Engine side"
label faces engine!
z Mount fan (2).
30 Nm
1
z Install V-belt.
W 12-02-01
1 2
© 47574-0
© 12/2008 3/4 17841-001

W 12-01-04 TD 2011 w, TCD 2011 w
Technical Data
A09 042 Ventilator on flange hub M8x40-10.9 30 Nm
V belt pulley/flange hub on output
A12 031 M10x30-8.8 43 Nm
flange
© 12/2008 4/4 17841-001

TD 2011 w, TCD 2011 w W 12-02-01
Renew V-belts,
check V-belt tension
– V-belt tension measuring Only test / tighten / renew V-belts when the
device . . . . . . . . . . . . . . . . . . . . . . . 8115 engine is not running.
The V-belt tension of new V-belts must be
checked after they have been running for
15 minutes.
Removing the V-belt

3
the arrow. 1
2
© 46986-0
z Loosen screw (1).
© 46988-2
© 12/2008 1/8 17842-001

W 12-02-01 TD 2011 w, TCD 2011 w

z Loosen screw (2). 3
1
z Swing generator (3) in the direction of the arrow.
6 2
© 46987-0

z Remove air bearing (2).
z Remove V-belt pulley (3). 2
© 46988-0
Installing the V-belt.

z Mount V-belt (1).
Note V-belt length. 3
z Mount V-belt pulley (2). 4

z Insert air bearing (3).
2
1
© 46988-1
© 12/2008 2/8 17842-001

TD 2011 w, TCD 2011 w W 12-02-01
z Swing generator (1) in the direction of the arrow.

z Fasten screws (3). 2
6
3
© 46987-1
z Tighten new screw (1).

– Stage 1:
30 Nm
z Tighten screw (1) with socket wrench insert and rota-
tion angle disc.
– Stage 2: 1
120°
© 46988-2
Check V-belt tension with V-belt tension

measuring device
z Lower indicator arm (1) into V-belt tension measuring
device. 1
© 44591-0
© 12/2008 3/8 17842-001

W 12-02-01 TD 2011 w, TCD 2011 w
z Mount V-belt tension measuring device on V-belt.

The V-belt must be between the
guides (arrow).
6
© 46997-1
z Press the V-belt measuring device against the V-belt

with the button (1) until you hear it click.
z Read measured value at the intersection (arrow) of
the indicator arm and scale.
+50
450 −50 N
Note different units on the scale.
z If the nominal value is not reached, the tensioning 1

process must be repeated.
© 46997-0

34 Nm 1
22 Nm
checked after they have been running for
15 minutes.
300 +20
−20 N
© 46987-2
© 12/2008 4/8 17842-001

TD 2011 w, TCD 2011 w W 12-02-01

z Mount V-belt (1). 1
the arrow.
3
2 6
© 46986-1
z Press clamping strap (1) in direction of arrow with a

suitable tool.
1
© 46996-0
z Mount V-belt tension measuring device on V-belt.

The V-belt must be between the
guides (arrow).
© 46998-1
© 12/2008 5/8 17842-001

W 12-02-01 TD 2011 w, TCD 2011 w
z Press the V-belt measuring device against the V-belt

with the button (1) until you hear it click.
z Read measured value at the intersection (arrow) of
the indicator arm and scale.
+50
1
450 −50 N
Note different units on the scale.
z If the nominal value is not reached, the tensioning

process must be repeated.
6
© 46998-0

45 Nm
checked after they have been running for 1
15 minutes.
+20
300 −20 N
© 46999-0
© 12/2008 6/8 17842-001

TD 2011 w, TCD 2011 w W 12-02-01
Technical Data
P12 11 V-belt tension, individual V-belts AVX 10 First assembly +50
450 −50 N
Check after 15 minutes running
P12 21 V-belt tension, individual V-belts AVX 10 +20
300 −20 N
under load
Stage 1:
A09 045 Air bearing on console M10x110-12.9 30 Nm
Use new screw.
A09 045 Air bearing on console M10x110-12.9 Stage 2: 120°
V-belt tensioning pulley (holder) on
A12 041 45 Nm 6
front cover
M8x70-10.9
A13 012 Generator on console 34 Nm
M8x75-10.9
A13 015 Clamping bracket on generator M8x30-8.8 22 Nm
A13 016 Clamping bracket on console M8x35-8.8 22 Nm
© 12/2008 7/8 17842-001

W 12-02-01 TD 2011 w, TCD 2011 w
© 12/2008 8/8 17842-001

TD 2011 w, TCD 2011 w W 12-06-01
Removing and installing the flywheel

– Self-made mandrin guide
Removing the flywheel

z Block flywheel with suitable tool.
z Screw two long screws into the threaded bores.
To improve the removal and installation of
the flywheel. 1
z Remove flywheel.
© 47216-0
© 44276-0
© 12/2008 1/4 17843-001

W 12-06-01 TD 2011 w, TCD 2011 w
Installing the flywheel

z Screw two long screws into the threaded bores.
To improve the removal and installation of
the flywheel.
1
z Insert self-made mandrin guide (1).
For example a pin bolt.
z Mount flywheel.
The bores in the flywheel must match the
threaded bores in the crankshaft flange.
6
© 47460-0

Attention!
Renew screws every time they are loo-
sened.
z Remove self-made mandrin guide.
© 47216-0
z Tighten screws alternately.

– Stage 1:
30 Nm
– Stage 2:
60°
– Stage 3:
30°
Block flywheel with suitable tool.
© 47461-0
© 12/2008 2/4 17843-001

TD 2011 w, TCD 2011 w W 12-06-01
Technical Data
Stage 1:
A12 001 Flywheel on crankshaft 30 Nm
Use new screws
© 12/2008 3/4 17843-001

W 12-06-01 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17843-001

TD 2011 w, TCD 2011 w W 12-06-03
Renewing toothed starter ring on the flywheel

Danger!
Danger of injury, do not touch hot parts!
Removing toothed starter ring

z Remove flywheel.
W 12-06-01
z Drill toothed starter ring.
Attention!
Do not damage the flywheel.
© 33837-2
z Remove toothed starter ring with suitable tool.
© 33838-2
© 12/2008 1/2 17844-001

W 12-06-03 TD 2011 w, TCD 2011 w
z Visually inspect joint (arrow) and contact surface.

z Clean flywheel.
The joint and contact surface must be free
6
© 33839-2
Install toothed starter ring

z Heat up toothed starter ring to 220 °C.
z Place toothed starter ring on flywheel.
The toothed starter ring must lie evenly on
the joint of the flywheel.
z Install flywheel.
W 12-06-01
© 33840-1
© 12/2008 2/2 17844-001

TD 2011 w, TCD 2011 w W 12-08-02
Removing and installing the hydraulic pump

– Graphite grease G 500
Removing the hydraulic pump

z Remove the hydraulic pipes.
z Press in stoppers.
z Remove hydraulic pump (2).
1
z Remove coupling sleeve.
© 39090-2
z Pull off the collars (1).

z Clean coupling sleeve (2).
2
© 39091-2
© 12/2008 1/4 17845-001

W 12-08-02 TD 2011 w, TCD 2011 w
Installing hydraulic pump

z Pull collar (1) onto coupling sleeve (3).
z Align cutting on the toothing of the coupling sleeve. 3
z Pull collar (2) onto coupling sleeve (3).
z Align cutting on the toothing of the coupling sleeve.
z Grease inner toothing of the coupling sleeve.
1 2
6
© 39092-2
z Grease gear shaft (1).

z Push on coupling sleeve (2).
Toothing of the coupling sleeve must
engage with the gear shaft.
© 34243-3
z Insert screws (1).

z Measure protrusion dimension X.
Maximum protrusion dimension X =18 mm.
Use new screws or correct with washers X
under the head of the screw.
© 34244-3
© 12/2008 2/4 17845-001

TD 2011 w, TCD 2011 w W 12-08-02
z Insert hydraulic pump (1) and coupling sleeve.

Toothing of the coupling sleeve must
engage with the gear shaft.

57 Nm 2
z Pull out stoppers.
z Insert hydraulic pipes.
6
© 39090-3
© 12/2008 3/4 17845-001

W 12-08-02 TD 2011 w, TCD 2011 w
Technical Data
Hydraulic pump on hydraulic pump
A12 051 57 Nm
console
© 12/2008 4/4 17845-001

TD 2011 w, TCD 2011 w W 12-08-03
Renew toothed belt and tensioning pulley

(Hydraulic pump)
Remove toothed belt and tensioning pul-

ley 1
z Remove V-belt pulley.
W 12-01-04
© 47462-0
z Remove adapter (1).
© 47463-0
© 12/2008 1/6 17846-001

W 12-08-03 TD 2011 w, TCD 2011 w

z Remove tensioning pulley (2).
z Remove the toothed belt (3).
1 2
6 3
© 47464-0
Install toothed belt and tensioning pulley

z Mount new tensioning pulley (1).
z Position setting eccentric (arrow) at 11 o'clock.
z Fasten screw (2).
z Mount new toothed belt (3).
1
3
© 47465-0
z Position toothed belt centrally on the toothed belt

wheels.
1
Attention!
The toothed belt may not rub on the con-
sole or the guide band (1)!
© 39594-2
© 12/2008 2/6 17846-001

TD 2011 w, TCD 2011 w W 12-08-03

hexagon socket.
Markings (1) must be in alignment with
bulge.

1
21 Nm
6
© 47466-0
Check toothed wheel tension

z Turn crankshaft 2 revolutions in the direction of the
arrow (direction of engine rotation).
bulge. 1
If the markings are not aligned with each
other, the toothed belt tension must be cor-
rected.
© 47467-0
Correct toothed belt tension

z Loosen screw (2).
z Pre-tighten screw (2).
hexagon socket. 2
1
bulge.

21 Nm
© 47466-0
© 12/2008 3/6 17846-001

W 12-08-03 TD 2011 w, TCD 2011 w
z Mount connecting piece (1).

The flattened side (arrow) must face the
toothed belt.
6
© 47468-0

1
8.5 Nm
z Install V-belt pulley.
W 12-01-04
© 47462-0
© 12/2008 4/6 17846-001

TD 2011 w, TCD 2011 w W 12-08-03
Technical Data
Tensioning pulley on hydraulic pump
A12 052 21 Nm
console
Protective hood on hydraulic pump
A12 056 8.5 Nm
console
© 12/2008 5/6 17846-001

W 12-08-03 TD 2011 w, TCD 2011 w
© 12/2008 6/6 17846-001

D 2011 w Electrical system
TD 2011 w, TCD 2011 w W 13-02-03
Removing and installing the generator

Removing the generator

z Disconnect the battery's negative terminal.
z Remove cable from generator. 1
Note assignment!
- (1) = terminal W
- (2) = terminal D+
- (3) = terminal B+
z Remove V-belt.
W 12-02-01
2
3
© 47600-0
z Loosen screw (1).

z Unscrew nut (2).
z Hold screw (3).
z Remove protective plate (4). 2
z Remove protective plate (5). 1
z Remove screw (3). 4
z Lower generator in direction of arrow.
5 3
© 47601-0
© 12/2008 1/4 17847-001

Electrical system D 2011 w
W 13-02-03 TD 2011 w, TCD 2011 w

z Remove generator.
6
© 47602-0
Installing the generator

z Mount generator.
z Fasten screw (1).
© 47602-0
z Mount generator.
z Insert screw (1).
z Mount protective plate (2).
z Mount protective plate (3). 4
z Screw on nut (4).
3
2 1
© 47601-1
© 12/2008 2/4 17847-001

TD 2011 w, TCD 2011 w W 13-02-03
z Remove cable from generator.

Note assignment!
- (1) = terminal W
1
- (2) = terminal D+
- (3) = terminal B+
– (Position 2)
3.5 Nm
– (Position 3)
6.5 Nm
z Install V-belt. 2
W 12-02-01
z Connect the battery's negative terminal. 6
3
© 47600-0
© 12/2008 3/4 17847-001

W 13-02-03 TD 2011 w, TCD 2011 w
Technical Data
Charging current cable to generator
A13 081 6.5 Nm
B+
A13 082 Cable G1.D+ to generator M5 3.5 Nm
© 12/2008 4/4 17847-001

TD 2011 w, TCD 2011 w W 13-03-02
Removing and installing the starter

Removing the starter

– TD 2011 w, TCD 2011 w
1
z Disconnect the battery's negative terminal.
z Disconnect cables.
z Remove shielding plate (2).
© 47578-0

z Remove starter.
© 47579-0
© 12/2008 1/4 17848-001

W 13-03-02 TD 2011 w, TCD 2011 w
6
© 47476-0
Installing the starter

z Insert starter.
43.5 Nm
1
© 47579-0
z Mount shielding plate (1).

2
Make sure that the installation site of the
rubber pad (3) is in perfect condition.

8.5 Nm
z Connect cables.
– see Technical Circular 0199-44-1163
z Connect the battery's negative terminal.
1
3
© 47578-1
© 12/2008 2/4 17848-001

TD 2011 w, TCD 2011 w W 13-03-02
Technical Data
A13 001 Starter on crankcase 43.5 Nm
A13 009 Shield on crankcase M6x14-8.8 8.5 Nm
© 12/2008 3/4 17848-001

W 13-03-02 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17848-001

TD 2011 w, TCD 2011 w W 13-06-01
Removing and installing the heating plugs

Special tools:
– Assembly tool . . . . . . . . . . . . . . . 120440
Removing the glow plugs

z Disconnect cables from heating plugs.
z Unscrew heating plugs (1) with assembly tool.
© 46969-0
© 46970-0
© 12/2008 1/4 17849-001

W 13-06-01 TD 2011 w, TCD 2011 w
Installing the glow plugs

z Screw in heating plug (1).
z Tighten heating plug (1) with assembly tool.
21 Nm
z Connect cables to heating plugs.
1
6
© 46969-0
© 12/2008 2/4 17849-001

TD 2011 w, TCD 2011 w W 13-06-01
Technical Data
A13 032 Heating plug on cylinder head 21 Nm
© 12/2008 3/4 17849-001

W 13-06-01 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17849-001

TD 2011 w, TCD 2011 w W 13-06-02
Removing and installing the glow plug

Removing the glow plug

z Disconnect cable connections.
z Unscrew glow plug (1).
1
© 47477-0
© 47478-0
© 12/2008 1/4 17850-001

W 13-06-02 TD 2011 w, TCD 2011 w
Installing the glow plug

z Insert glow plug (1).
6
© 47479-0
z Tighten glow plug (1).

60 Nm
z Connect cable.
4 Nm
1
© 47477-0
© 12/2008 2/4 17850-001

TD 2011 w, TCD 2011 w W 13-06-02
Technical Data
Glow plug in charge air line / intake
A13 031 60 Nm
pipe
A13 034 Cable connection to glow plug 4 Nm
© 12/2008 3/4 17850-001

W 13-06-02 TD 2011 w, TCD 2011 w
© 12/2008 4/4 17850-001

D 2011 w
TD 2011 w, TCD 2011 w Standard tools
7 Standard tools
© 12/2008 1/10 17851-001

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
Web: http://www.deutz-tools.com
© 12/2008 2/10 17851-001

D 2011 w
8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
© 35410-3
7
8008
Nozzle tester
with spray mist collecting vessel
Check injection nozzles
© 35411-2
8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe
© 39426-1
© 12/2008 3/10 17851-001

D 2011 w
8012
Socket wrench insert
Wrench size 15, long
© 35412-3
7
8018
Claw wrench
Wrench size 17,
Removing and installing injection pipes
© 37506-2
8024
Assembly pliers
Removing valve shaft seals
© 37509-2
© 12/2008 4/10 17851-001

D 2011 w
8027
Plier insert
© 39531-1
7
8035
Wrench size 22, strengthened version
© 37504-1
8036
Wrench size 32,
(in conjunction with force multiplier 8049)
© 39429-1
© 12/2008 5/10 17851-001

D 2011 w
8049
Force multiplier
Removing and installing the centre screw
Tool kit, including socket wrench insert 8036
(in conjunction with holder 143420)
© 39430-1
7
8115
V-belt tension measuring device
150 to 600 N
Check V-belt tension
© 35416-3
8116
Torx - E18
© 35415-1
© 12/2008 6/10 17851-001

D 2011 w
8167
Cleaning brush
Cleaning exhaust channels
© 46283-0
7
8170
Micrometre depth gauge
Measure the depth of the roller tappet
© 39532-1
8189
Torx tool set
Contents of case:
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
© 39432-1
© 12/2008 7/10 17851-001

D 2011 w
8190
Rotation angle disc
with magnet (e. g. setting valve clearance)
© 42528-1
7
8198
Pricker
Removing rotary shaft lip seal
© 43206-1
9017
Assembly lever
e. g. removing and installing valves
© 37511-2
© 12/2008 8/10 17851-001

D 2011 w
9088
Clamping tongs
Loosening and tightening hose clips
© 39433-1
7
9090
Spring band pliers
320 mm
Tighten spring clamp
© 35420-3
9120
Special bit
70 mm long
© 39434-1
© 12/2008 9/10 17851-001

D 2011 w
© 12/2008 10/10 17851-001

D 2011 w
TD 2011 w, TCD 2011 w Special tools
8 Special tools
© 12/2008 1/18 17852-001

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
Web: http://www.deutz-tools.com
© 12/2008 2/18 17852-001

D 2011 w
100120
Connector
(in conjunction with compression pressure tester 8005)
© 39400-1
100400
Dial gauge with fixing wheel 8
Measuring range 0 - 10 mm / 0.01 mm
© 35424-1
100410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
© 43205-0
© 12/2008 3/18 17852-001

D 2011 w
100700
Ajustable bolt
Crankshaft and camshaft lock
© 39101-1
100710
8 Ajustable bolt
Control linkage lock
© 39401-1
100750
Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection
© 39402-2
© 12/2008 4/18 17852-001

D 2011 w
101020
Degree scale
for testing and setting the static beginning of injection
© 47638-0
101030
Adapter 8
(in conjunction with degree scale 101020)
© 47637-0
101100
Rig pin
Lock the steering link of the injection pump
© 39404-1
© 12/2008 5/18 17852-001

D 2011 w
101300
Point for degree scale
© 39406-1
101500
8 High-pressure hand pump
© 36443-2
101510
Supply tank
(in conjunction with high-pressure hand pump 101500)
© 36444-2
© 12/2008 6/18 17852-001

D 2011 w
101640
Special wrench
Set minus adjustment
© 46981-0
103040
Test template 8
Check shim thickness
© 47495-0
103220
Special pliers
(part of measuring device 103210)
for removing the roller tappet
© 43175-0
© 12/2008 7/18 17852-001

D 2011 w
110090
Puller
(in connection with sliding hammer 150800)
© 35433-2
110110
8 Holder
Wrench size 11,
clamp the injection valve in the vice
© 35434-2
110140
Disassembly/assembly tool.
Removing and installing the guide bushes (control link-
age)
© 39407-1
© 12/2008 8/18 17852-001

D 2011 w
110901
Disassembly tool
(part of assembly case 110900)
Removing and installing the O-rings
© 45950-1
120440
Assembly tool 8
Removing and installing the glow plugs
© 40333-1
120900
Support bracket
pivoting
Clamping cylinder head
© 35438-3
© 12/2008 9/18 17852-001

D 2011 w
120910
Base plate
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)
© 35439-3
121410
8 Assembly tool
Mounting valve shaft seal
© 37614-2
121420
Assembly sleeves
Set of assembly sleeves for valve shaft seal
© 43210-0
© 12/2008 10/18 17852-001

D 2011 w
130300
Universal piston ring pliers
Removing and installing the piston rings
© 43021-0
130420
Trapezoidal groove wear gauge 8
Testing piston ring groove
© 36461-2
130850
Piston ring compressor
Piston diameter 96 mm
© 39408-1
© 12/2008 11/18 17852-001

D 2011 w
131100
Disassembly tool
Remove piston bolt
© 39409-1
131350
8 Disassembly/assembly tool.
Removing and installing the small end bush
(Diameter 30mm)
© 39410-1
142050
Assembly tool
Install camshaft sealing ring
© 39412-1
© 12/2008 12/18 17852-001

D 2011 w
142680
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
© 47496-0
142690
Assembly tool 8
Installing crankshaft sealing ring
© 47497-0
143420
Counter support
(in conjunction with force multiplier 8049 and socket
wrench insert 8036)
© 39417-1
© 12/2008 13/18 17852-001

D 2011 w
143430
Washer
(in conjunction with holder 143420)
© 39418-1
143720
8 Disassembly/assembly tool.
Removing and installing camshaft bearing
© 39419-1
144130
Counter support
Hold toothed belt wheel of the camshaft
© 39420-1
© 12/2008 14/18 17852-001

D 2011 w
150151
Handle
(in conjunction with assembly pin 150220)
© 46978-0
150180
Holder 8
(in conjunction with measuring device 100750)
Measure piston overhand on recess cylinder head
© 43181-0
150210
Puller
Remove oil rise tube
© 46979-0
© 12/2008 15/18 17852-001

D 2011 w
150220
Assembly pin
Drive in oil rise tube
© 46980-0
150800
8 Slide hammer
© 35449-2
151500
Separating tool
Removing metal sheet lubricating oil pan from crank-
case
© 45974-0
© 12/2008 16/18 17852-001

D 2011 w
160400
Slide hammer
Remove oil rise tube
© 43188-0
170050
Special wrench 8
Unscrewing the filter cartridges
© 37629-2
170160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
© 43663-0
© 12/2008 17/18 17852-001

D 2011 w
6067
Assembly block
Engine clamping, one-sided
© 39424-1
6067/114
8 Supporting bracket
(in conjunction with assembly block 6067)
© 39369-1
6067/115
Clamping bracket
(in conjunction with assembly block 6067)
© 39425-1
© 12/2008 18/18 17852-001

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5 Job card overview

© 06/2008 1/2 17761-001

© 06/2008 2/2 17761-001

© 05/2005 1/4 17762-001

© 05/2005 2/4 17762-001

© 05/2005 3/4 17762-001

© 05/2005 4/4 17762-001

© 11/2005 1/4 17763-001

© 11/2005 2/4 17763-001

DEUTZ engines are the product of years of re-

Maintenance and care are the only way the engine

Please consult one of our service representatives

© 11/2005 3/4 17763-001

© 11/2005 4/4 17763-001

© 06/2008 1/8 17764-001

© 06/2008 2/8 17764-001

3.1 General 3.2 Specifications

© 06/2008 3/8 17764-001

© 06/2008 4/8 17764-001

© 06/2008 5/8 17764-001

3.3 Operation manual and workshop 3.4 Job cards

© 06/2008 6/8 17764-001

3.4.2 Structure of a job card 3.5 Explanation of symbols

© 06/2008 7/8 17764-001

© 06/2008 8/8 17764-001

© 12/2008 1/10 17765-001

ID no. Name Additional information Value

© 12/2008 2/10 17765-001

ID no. Name Additional information Value

© 12/2008 3/10 17765-001

ID no. Name Additional information Value

© 12/2008 4/10 17765-001

4.2 Tightening specifications

© 12/2008 5/10 17765-001

ID no. Name Screw type Notes / Remark Value

© 12/2008 6/10 17765-001

ID no. Name Screw type Notes / Remark Value

© 12/2008 7/10 17765-001

ID no. Name Screw type Notes / Remark Value

© 12/2008 8/10 17765-001

ID no. Name Screw type Notes / Remark Value

© 12/2008 9/10 17765-001

ID no. Name Screw type Notes / Remark Value

© 12/2008 10/10 17765-001

© 12/2008 1/12 17766-001

© 12/2008 2/12 17766-001

Activity Job card Maintenance group

© 12/2008 3/12 17766-001

Activity Job card Maintenance group

© 12/2008 4/12 17766-001

Activity Job card Maintenance group

© 12/2008 5/12 17766-001

© 12/2008 6/12 17766-001

© 12/2008 7/12 17766-001

© 12/2008 8/12 17766-001

Job card Activity Maintenance group

© 12/2008 9/12 17766-001

Job card Activity Maintenance group

© 12/2008 10/12 17766-001

Job card Activity Maintenance group

© 12/2008 11/12 17766-001

© 12/2008 12/12 17766-001