Deutz TCD WH 2015 03123514

Workshop Manual
competence level 3
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TCD 2015
This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.
0312 3514 en
Regarding copyright questions and licensing agreements

please contact :
VS-DI, Mr. Sonntag
Tel.:
+ 49 (0) 221 822-3053
EMail: sonntag.j@deutz.com
DEUTZ AG
Service Information Systems
Ottostrae 1
D-51149 Kln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
Internet: www.deutz.com
E-Mail: info@deutz.com
The engine company.
Printed in Germany
All rights reserved
1st Edition, 06/2007
Order No. 0312 3514 en
TCD 2015
1
Foreword
General
User notes
3.1
3.2
3.2.1
3.2.2
3.3
3.4
3.5
General
Specifications
Safety regulations and rules for the prevention of accidents
Disposal regulations
Operating manual and workshop manual
Job cards
Explanation of symbols
Technical data
4.1
4.2
Testing and setting data

Tightening specifications
Job card overview

5.1
5.2
5.3
06/2006
Table of contents
Sorted alphabetically
Sorted numerically
Job card references
Job cards
Commercial tools
Special tools
1/2
8141-001
TCD 2015
Table of contents
06/2006
2/2
8141-001
DEUTZ engines
Foreword
05/2005
Foreword
1/4
8142-001
DEUTZ engines
Foreword
05/2005
2/4
8142-001
DEUTZ engines
Foreword
z Read and observe the information in this documentation. You will avoid accidents, retain the
manufacturer's warranty and possess a fully
functional and ready to operate engine.
z This engine is built exclusively for purpose according to the scope of delivery - defined by the
equipment manufacturer (use for the intended
purpose). Any use above and beyond this is considered improper use. The manufacturer will not
be liable for damages resulting from this. The
user bears the sole risk.
z Repair of the engine must correspond to its use

for the intended purpose. Only parts released by
the manufacturer for the respective purpose may
be used for conversion work. Unauthorised modifications to the engine exclude manufacturer liability for resulting damages. Failure to observe
this will void the warranty!
z The engines made by DEUTZ are developed for
a wide range of applications. A wide range of variants ensures that the respective special requirements are met.
z The engine is equipped according to the installation case, i.e. not all the parts and components
described in this documentation are installed in
your engine necessarily.
z Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the manufacturer.
The engine may only be used, maintained and
repaired by persons who are familiar with this
and are aware of the risks involved.
z We have done our best to highlight the differences so that you can easily find the operating, maintenance and repair instructions relevant to your
engine.
z Make sure that this documentation is available to

everyone involved in the operation, maintenance
and repair and that they have understood the
contents.
z Failure to observe this documentation may lead
to malfunctions and engine damage as well as injury to persons for which the manufacturer will
not accept any liability.
z Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and special tools and their perfect
condition.
z Engine parts such as springs, clamps, elastic retaining rings etc. pose an increased risk of injury
when handled incorrectly.
z The pertinent rules for the prevention of accidents and other generally recognised health and
safety regulations must be observed.
We are at your service for any questions you may

have in this matter.
z Maximum economy, reliability and long life is only

guaranteed when using DEUTZ original parts.
Your DEUTZ AG
05/2005
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8142-001
DEUTZ engines
Foreword
05/2005
4/4
8142-001
DEUTZ engines
General
11/2005
General
1/4
8143-001
DEUTZ engines
General
11/2005
2/4
8143-001
DEUTZ engines
General
DEUTZ engines are the product of years of research and development. The profound expertise
gained through this, in combination with high demands on quality, attests to the fact that our engines
possess all the qualities of long life, high reliability
and low fuel consumption. It goes without saying
that the high environmental protection requirements
are also met.
Maintenance and care are the only way the engine

can satisfy the demands you make on it. Compliance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particularly heeded.
Please consult one of our service representatives
responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.
11/2005
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8143-001
DEUTZ engines
General
11/2005
4/4
8143-001
User notes
12/2005
User notes
1/8
8144-001
User notes
12/2005
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8144-001
User notes
3.2 Specifications
3.1 General
The documentation of the workshop manual has
been created based on the engine available at the
time of going to press.
There may be deviations in the descriptions, illustrations and parts due to further developments.
The maintenance work described in the operation
manual and in the workshop manual must be carried
out on schedule and completely. The maintenance
personnel must have the necessary technical
knowledge to perform the work. Safety and protection devices which are removed during maintenance
work must be replaced again afterwards.
3.2.1 Accident prevention and safety regulations

The legally prescribed rules for the prevention of accidents must be observed. These are available from
professional associations or from dealers. These
are dependent on the application site, operating
mode and the operating and auxiliary materials being used.
Special protection measures are specified depending on the work being carried out, and are identified
in the job description.
Among other things it generally applies that:
Caution!
z for the personnel:
The rules for the prevention of accidents and the

safety regulations must be observed during maintenance work.
Only briefed personnel may operate or maintain 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
be read before working on the engine and must be
strictly followed.
Wear close-fitting clothing and ear protectors

in the machine room when the engine is in operation.
Only deploy trained personnel to do repairs
and maintenance work.
The maintenance intervals and the work to be performed are specified in the maintenance schedule
of the operation manual. The job cards contain technical documentation on the execution of maintenance work.
Do not work on the fuel system when the engine is running. The fuel system is under high
pressure - danger of death.
Go to the workshop immediately in case of
leaks in the fuel system.
z for the engine room:
Ensure adequate ventilation (do not cover air
shafts).
Provide first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly.
Only store inflammable materials in the machine 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
"6.2 Fuel system.
Only start the engine when all the protective
devices have been fitted. Make sure no-one is
standing in the danger area.
Cleaning, maintenance and repair work may
only be performed with the engine at a standstill and secured against starting.
Injection lines and high pressure pipes must
not be deformed.
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3/8
8144-001
User notes
z Remove loose parts (for example paint chips
from assembly work) with an industrial vacuum
cleaner or other suction device. Only suction may
be used in assembly work on the open fuel system.
Damaged injection lines and high-pressure

pipes must be renewed.
Injection lines and high pressure fuel lines
must never be connected when the engine is
running.
z Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid
draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may
be kept or operated in the same room.
Do not place hands near to a leak in the high

pressure fuel system.
Also carefully check all high pressure components visually before performing tests on the
running engine. Wear suitable protective
clothing (for example protective glasses).
Leaks are a potential source of danger for
workshop personnel.
z Air currents which kick up dust, such as those

caused by brake repairs or the starting of engines, should be avoided.
Even if no leaks are discernible on the high

pressure fuel system, the workshop personnel
should avoid the immediate danger zone or
wear suitable protective clothing (such as protective glasses) when performing tests on the
running engine and during the first trial run.
Always stay out of range of a fuel jet, as it
could cause severe injury.
z For work such as removal and installation on defective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.
z No general machine tools may be operated in
this room.
Smoking is strictly prohibited when working on

the fuel system.
z Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating
fans should be minimised.
Do not work near to sparks and flames.

Never disconnect an injector when the engine
is running.
z Areas of the engine room from which particles of

dirt could be loosened (for example the bottom
part of the tipped driver cab) must be covered
with fresh clean film.
3.2.2 Cleanliness instructions and measures for handling the DEUTZ Common Rail System
The DEUTZ Common Rail system used in the
DEUTZ engines consists of high-precision components which are exposed to extreme stress. Great
attention must be paid to cleanliness when working
on the fuel system due to the high precision technology.
Notes and measures to be observed before
starting work on the fuel system
z Working materials and tools must be cleaned before work. Only use tools without damage to the
chrome plating or tools which are not chromeplated.
Notes and measures to be observed during work
on the fuel system or with the fuel system open.
z Only work in clean overalls.
z Only lint-free cleaning cloths may be used for
work on the fuel system.
z The fuel system must be closed. Make a visual

inspection for leaks / damage to the fuel system.

cleaner or other suction device. Only suction may
be used in assembly work on the open fuel system.
z Clean the whole engine and engine room with the

system closed before starting work on the fuel
system.
z The engine must be dry when you start working
on the fuel system.
z Blowing (dry) with compressed air is only permissible with the fuel system closed.
z When using a steam jet, first cover up the control

unit, the cable plugs, all other electrical plug connections and the generator. Also, the steam jet
may not be pointed directly at them.
z Do not use used cleaning fluid or test fluid for

cleaning.
z Electrical plug connections must be plugged

when spraying.
z Work on removed components may only be performed at a suitably equipped workbench.
12/2005
4/8
z Compressed air must not be used for cleaning on

the open fuel system.
8144-001
User notes
z When removing and installing components, no
materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.
operating materials among other things. The renewed parts / operating materials must be stored,
transported and disposed of according to regulations. The owner himself is responsible for this.
z Removed parts may only be rubbed down with

clean, lint-free cloths. No dirt particles may be
rubbed into the components.
Disposal includes recycling and the scrapping of

parts / operating materials, although recycling has
priority.
z Openings on the components and on the engine

must be closed immediately with suitable stoppers/caps.
Details of disposal and their monitoring are governed by regional, national and international laws
and directives which the system operator must observe on his own responsibility.
z The stoppers/caps may only be removed immediately before installing.

z Store stoppers/caps free from dust and dirt in the
original packaging and dispose of after using
once.
z Only remove new parts from the original packaging just before installation.
z Removed components must be kept in new, sealable 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 defective 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 mandatory. 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.
cleaner or other suction device.
3.2.3 Disposal regulations

The work described in the operation manual and
workshop manual necessitates renewal of parts and
12/2005
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8144-001
User notes
3.3 Operation manual and workshop
manual
3.4 Job cards
To structure the information to suit the user, the

service documentation is divided into operation
manual and workshop manual.
The operation manual contains a general description and instructions for all other maintenance work.
It contains the following chapters:
1. Contents, General
2. Engine description
3. Operation
4. Operating media
The job cards are divided in the workshop manual

into "W" and "I" job cards.
The "W" job card documents standard repairs on the
engine and/or its components. The necessary tools
and special tools are also specified in the "W" job
card.
The "I" job card additionally documents the appropriate work procedures for repairing the engine and/
or its components. The workshop must satisfy special conditions to perform these work procedures.
Special tools and machine tools must be available,
for example.
3.4.1 Numbering of job cards
5. Maintenance
The job card numbers follow the pattern W 02-0401. The individual parts of this pattern are explained
below:
6. Care and maintenance work

7. Faults, causes and remedies
8. Engine conservation
z W 02-04-01: Documentation type
9. Technical data
W.... Workshop manual
10.Service
I ...... Repair instructions
The workshop manual assumes knowledge of the

contents of the operation manual. This applies especially for the safety regulations. The workshop
manual describes repairs to the engine and components for which more effort and appropriately qualified technicians are required.
z W 02-04-01: Maintenance group

00 ... General / interdisciplinary activities
01 ... Cylinder head
02 ... Drive system
03 ... Crankcase
04 ... Engine control system
05 ... Speed governing
06 ... Exhaust system / Charging
07 ... Fuel system
08 ... Lube oil system
09 ... Cooling system
10 ... Compressed air system
11 ... Monitoring system
12 ... Other components
13 ... Electrical system
z W 02-04-01: Component grouping
z W 02-04-01: Consecutive number
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8144-001
User notes
3.5 Explanation of symbols
3.4.2 Structure of a job card

1
Triebwerk
W 02-04-01
Danger!
of death or to health. Must be observed!
For example: The incorrect use or conversion of the turbocharger can lead to
serious injury.
4
5
16
15
Caution!
Danger to the component/engine. Noncompliance can lead to destruction of the
component/engine.
Must be observed!
14
8
13
12
Note
General notes on assembly, environmental protection etc. No potential danger for
man or machine.
11
10
Tool
Conventional and special tools required
for the work.
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
1. DEUTZ AG,
publisher of service documentation
References
to important documents or job cards for
the work process.
For example: Job card W 04-05-05
2. Engine type (e.g. TCD 2013 4V)

3. Maintenance group
4. Job card number or topic
5. Title of job card
Reference
to a document or a job card within the
work process.
6. Reference to other job cards

7. Chapter
Test and setting data

The necessary values are specified here.
If several values are necessary, a cross
reference is given to the Test and Setting
Values table.
For example:
ID no. P01 61 = valve clearance, inlet
8. Graphic or photo
9. DEUTZ internal creation number
10.Page number
11.Date of issue of job card
12.Note
13.Danger / Important
Tightening specification
The necessary values are specified here.
If several values are necessary, a cross
reference is given to the Tightening Specifications table.
For example:
ID no. A01 001 = cylinder head screws
14.Work sequence
15.Special tools; auxiliary materials
16.Conventional tools
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8144-001
User notes
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8144-001
TCD 2015
Technical data
06/2006
Technical data
4.1
1/28
8145-001
Technical data
TCD 2015
06/2006
2/28
8145-001
06/2006
Name
3/28
Combustion process
Total volume
P00 20
P00 30
Bore
Working principle
P00 10
P00 31
Engine weight according to DIN 70020-A
Height of engine with connection housing
Height of engine
Width of engine with connection housing
Width of engine
Length of engine with connection housing
P00 04
P00 03
P00 02
P00 01
Length of engine
General engine data
ID no.
without operating media
about all data
about all data
about all data
Information
V08 1244
V06 920
V08 1160
TCD 2015
TCD 2015
(Railway)
TCD 2015
(Railway)
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
kg
V06 approx. 1020-1200
TCD 2015
132
V08 15874
mm
cm3
cm3
Direct injection
V06 11906
4 stroke
kg
kg
kg
mm
mm
mm
V08 837
V06 835
V06 1300
mm
mm
mm
mm
mm
mm
Unit
TCD 2015
(Railway)
TCD 2015
(Railway)
TCD 2015
V08 1120
V06 1125
TCD 2015
(Railway)
TCD 2015
(Railway)
V06 1200
TCD 2015
V08 1454
V06 1107
TCD 2015
(Railway)
TCD 2015
(Railway)
V06 1200
Value
TCD 2015
Series
TCD 2015
Technical data
8145-001
06/2006
Stroke
Compression ratio
Direction of rotation
Compression pressure
Spark gap
Ignition sequence
Cylinder and side view
P00 32
P00 40
P00 50
P00 51
P00 70
P00 71
P00 81
4/28
Valve seat insert, bore (outlet)
Valve seat insert, bore (inlet)
Valve seat insert, bore (outlet)
Valve guide, bore in cylinder head
Cylinder head, height
Cylinder head, height
P01 02
P01 03
P01 04
P01 05
P01 06
P01 07
P01 08
P01 09
P01 11
Valve guide, external diameter
Valve guide
Valve seat insert, bore (inlet)
P01 01
Cylinder head
Name
Standard
Undersize
Standard
2. oversize level
1. oversize level
Standard
1. oversize level
1. oversize level
Standard
Standard
fit H6
looking onto the flywheel
Information
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
V08
15.0
119.70
120
+0.0
44.500 0
+0.0
47.800 0
+0.0
44.300 0
+0.0
15.000 0
+0.0
15.100 0
+0.0
15.200 0
+0.0
47.500 0
T00 81
A1-B4-A4-B1-B3-A3B2-A2
V06 A1-B3-A3-B2-A2-B1
TCD 2015
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
kPa
(bar)
3200-3400
(32-34)
V06 120
mm
Unit
counter-clockwise
TCD 2015
TCD 2015
TCD 2015
16.5:1
17.5:1
TCD 2015
TCD 2015
(Railway)
145
Value
TCD 2015
Series
ID no.
Technical data
TCD 2015
8145-001
06/2006
Valve guide, inside diameter (inlet)
Valve guide, inside diameter (outlet)
P01 12
P01 13
P01 14
P01 15
Valve seat insert, outside diameter (inlet)
Valve seat insert, outside diameter (outlet)
P01 23
P01 24
5/28
Valve shaft clearance (outlet)
Valve edge thickness, valve head (inlet)
Valve edge thickness, valve head (outlet)
Valve head diameter (inlet)
Valve head diameter (outlet)
P01 34
P01 35
P01 36
P01 37
P01 38
P01 45
Valve stand back dimension (inlet)
Valve shaft clearance (inlet)
P01 33
Valve seat
Valve shaft diameter (outlet)
P01 32
P01 31
Valve shaft diameter (inlet)
Valve seat insert, outside diameter (outlet)
P01 22
Valve
Valve seat insert, outside diameter (inlet)
P01 21
Valve seat insert
Name
ID no.
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
Series
Wear limit
(from the center of the valve head to the TCD 2015
cylinder head sealing surface)
Standard
Standard
Standard
Standard
Standard
Wear limit
Wear limit
Standard
Standard
1. oversize level
1. oversize level
Standard
Standard
Standard
Standard
2. oversize level
1. oversize level
Information
mm
0.14
+0.
1.9 -0.2
+0.
1.5 -0.2
+0.
46.0 -0.2
+0.
42.0 -0.2
mm
mm
2.5
1.20 - 1.60
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
Unit
0.12
+0.00
7.97 -0.00
+0.00
7.96 -0.00
+0.07
47.5 +0.06
+0.07
44.0 +0.06
+0.07
47.800 +0.06
+0.07
44.300 +0.06
8.030 +0.0
0
+0.0
8.030 0
15.2
15.1
Value
TCD 2015
Technical data
8145-001
06/2006
Valve stand back dimension (outlet)
P01 46
Valve spring wire diameter
Valve spring length
6/28
Valve clearance setting
P01 63
Rocker arm, bore, diameter (outlet)
Rocker arm, bore, diameter (inlet)
Rocker arm shaft (diameter)
Axial clearance of the toggle levers
P01 72
P01 73
P01 74
P01 75
Rocker arm/bracket
Valve clearance (outlet)
Valve clearance (inlet)
P01 62
P01 61
Valve clearance
P01 51
Valve spring
Name
Series
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
Axial bearing clearance with cold engine TCD 2015
Valve overlap according to adjustment

schematic
with cold engine

with feeler gauge
with rotation angle disc
with cold engine

with feeler gauge
with rotation angle disc
untensioned, normal
Wear limit
Standard
Information
+1
+1
0.2 - 0.4
+0.02
28 0
+0.02
28 0
-0.04
28 -0.06
T01 63
+0.
0.30 0
108
+0.
0.25 0
90
4.25
58.7
1.25 - 1.65
2.4
Value
ID no.
mm
mm
mm
mm
mm
mm
mm
mm
mm
Unit
Technical data
TCD 2015
8145-001
06/2006
Roughness
P01 93
Main journal, diameter
Main journal, unroundness
Main journal, hardness
P02 04
P02 06
P02 07
7/28
Fit bearing, width
Fit bearing, width
P02 12
P02 13
Lifting journal, diameter
Lifting journal, unroundness
Radial run-out, crankshaft
P02 23
P02 25
P02 26
P02 34
Axial clearance of crankshaft
Main bearing
Lifting journal, diameter
P02 22
Lifting journal
Fit bearing, width
P02 11
Fit journal
Main journal, diameter
P02 03
Main journal
Crankshaft
Main running gear
Name
ID no.
permissible
maximum permissible deviation
Wear limit
Undersize stage
3 stages
Limit value for oversize stage
Oversize stage
Standard
Standard
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
Undersize stage
3 stages
Wear limit
TCD 2015
Standard
TCD 2015
TCD 2015
Surface for cylinder head gasket
Surface for cylinder head cover
Series
Information
mm
0.25 each
mm
mm
0.205 - 0.392
mm
0.15
0.010
mm
0.25 each
mm
mm
+0.06
mm
mm
-0.01
91 -0.03
38.50
+0.06
+0.06
38.25
38
HRC
mm
mm
-0.01
108 -0.03
0.010
+6
50 0
[Rmax]
Rz
[Rmax]
Rz
Unit
20
16
20
10
Value
TCD 2015
Technical data
8145-001
06/2006
Thrust ring half, thickness
P02 35
P02 36
P02 37
8/28
Assembly temperature of the connecting rod
P02 47
Big end bearing shells, inside diameter
Big end bearing
Big end bearing, bore in connecting rod
Theoretical clearance between the big end bearing / lifting journal
Big end bearing clearance
P02 52
P02 54
P02 55
P02 56
P02 57
Big end bearing
Assembly temperature of the small end bush
P02 46
Small end bush, inside diameter
P02 43
Small end bush clearance between piston pin

and small end bush
Taper on periphery of the connecting rod
P02 42
P02 45
Parallelism of the connecting rod
P02 41
Connecting rod
Name
TCD 2015
TCD 2015
1. oversize stage=0.125 mm
(upper and lower half)
2. oversize stage=0.125 mm
Wear limit
TCD 2015
0.17
0.060 - 0.136
+0.03
95 -0.00
after separation and re-assembly of rod

TCD 2015
and cover
TCD 2015
0.25 each
TCD 2015
Undersize stage
3 stages
+0.05
91.048 0
max. 220
approx. -40
0.04 - 0.063
mm
mm
mm
mm
mm
mm
mm
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
installed
identification (n) / top
lining spattered
heated up in hot-air oven to
cooled in coolant to
installed, unmachined
mm
+0.0
52.040 0
mm
mm
mm
mm
mm
mm
Unit
100
max. 0.10
Permissible deviation (A) to (B)

at a distance of (x)
100
TCD 2015
+0.05
max. 0.06
3.610
+0.05
+0.05
3.485
3.36
Value
at a distance of (x)
TCD 2015
TCD 2015
Standard
Permissible deviation (a)
Series
Information
ID no.
Technical data
TCD 2015
8145-001
06/2006
Piston pin clearance
P02 62
9/28
Piston projection
Piston projection
Piston projection
Piston pin, bore
P02 75
P02 76
P02 77
P02 78
Closed gap, piston ring 1
P02 84
P02 85
Piston rings
Piston, diameter
Piston, diameter
P02 72
P02 73
Piston, diameter
P02 71
Piston
Piston pin, diameter
Name
P02 61
Piston pin
ID no.
mm
mm
mm
mm
mm
mm
mm
-0.05 to 0.10
0.10 to 0.30
0.30 to 0.51
+0.0
52 +0.00
0.35 - 0.45
0.9
1.1 - 1.3
1.4
Standard
Wear limit
TCD 2015
(identification TOP in direction of piston
head)
Standard
Wear limit
TCD 2015
head)
1.8 = 3 holes (cylinder head gasket)
1.6 = 2 holes (cylinder head gasket)
TCD 2015
TCD 2015
TCD 2015
mm
mm
+0.0
132 -0.01
Measuring point 3
at height 122.7 mm
TCD 2015
(Identification of the installation position
on the piston head)
TCD 2015
mm
+0.00
132 -0.00
Measuring point 2
at height 87.5 mm
TCD 2015
on the piston head)
1.4 = 1 hole (cylinder head gasket)
mm
+0.00
132 -0.00
mm
51.992 - 52.000
Measuring point 1
at height 22.5 mm
TCD 2015
on the piston head)
Unit
Value
mm
TCD 2015
TCD 2015
Series
0.09
Wear limit
Information
TCD 2015
Technical data
8145-001
06/2006
Axial clearance, 1st piston ring
Axial clearance, 2nd piston ring
Axial clearance, 3rd piston ring
P02 86
P02 87
P02 88
P02 89
10/28
Tappet bores, diameter
Tappet bores, diameter
Installation depth of the crankshaft sealing ring

(rear cover)
Installation depth of the crankshaft sealing ring

(genset support)
P03 23
P03 24
P03 25
P03 26
P03 35
P03 31
Fitting depth for cylinder liner
Cylinder bore
Cylinder liners
Camshaft bearing liner, inside diameter
Camshaft bearing liner, wall thickness
Camshaft bearing liner, inside diameter
Camshaft bearing liner, outside diameter
Bore diameter for camshaft bearing liner in the

crankcase
P03 14
P03 13
P03 12
P03 11
Camshaft bearing
Crankcase
Name
Standard
Repairs
First assembly
Repairs
First assembly
Wear limit
Wear limit
Wear limit
Wear limit
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
+0.0
132 -0.0
+0.0
9.87 -0.0
mm
mm
mm
mm
mm
mm
mm
mm
25.050
+0.2
0.5 -0.2
+0.2
3.5 -0.2
+0.
3 -0.5
+0.
7 -0.5
mm
+0.03
25.000 0
mm
mm
mm
mm
mm
mm
70.100
+0.03
75.090 0
+0.05
69.990 0
+0.0
2.0493 0
+0.03
75.000 0
0.15
0.25
TCD 2015
Measure with trapezoidal groove wear

gauge
Wear limit
mm
1.2
mm
Unit
Wear limit
TCD 2015
head)
Value
0.4 - 0.7
Series
Standard
Information
ID no.
Technical data
TCD 2015
8145-001
06/2006
Collar height of cylinder liner
Thickness of shim
Overhang of cylinder liner
P03 36
P03 37
P03 39
11/28
TCD 2015
TCD 2015
TCD 2015
Overhang of the parallel pin on the camshaft gear

wheel
Axial clearance of the camshaft for injection

pumps
Tooth edge clearance of the idler gear - idler gear

to camshaft gear wheel
P04 39
P04 43
P04 44
Tooth edge clearance between gear wheel of the

camshaft for injection pumps and camshaft gear
wheel
P07 20
P07 52
Nozzle opening pressure of the fuel injector
Injection valve
Plunger lift of the camshaft for injection pumps
P07 19
TCD 2015
TCD 2015
TCD 2015
TCD 2015
Clearance between speed governor (camshaft)

and camshaft gear wheel
P05 92
Fuel system
TCD 2015
Clearance between speed governor (crankshaft)

and flywheel
P05 91
see name plate
TCD 2015
Thickness of the gasket for axial clearance setting
P04 37
Speed governing system
TCD 2015
Axial clearance of the camshaft
P04 35
TCD 2015
TCD 2015
TCD 2015
TCD 2015
Series
Camshaft bearing pin diameter
Standard
Standard
Information
P04 31
Camshaft
Control system
Name
ID no.
mm
0.25 - 0.75
mm
mm
bar
0.04 - 0.3
280 - 288
mm
4.00
0.3 - 0.9
mm
mm
0.04 - 0.3
+0.
mm
0.2 - 0.45
1.0
mm
5.000
mm
mm
-0.06
70 -0.07
0.3
mm
mm
mm
Unit
0.09
Value
0
9.02 -0.0
+0.0
1.0 -0.0
TCD 2015
Technical data
8145-001
06/2006
Installation dimensions of the fuel shut-off valve
Installation angle of the fuel pipe
P07 91
P07 92
12/28
Thermostat, start opening (B-bank)
Thermostat, stroke distance
P09 12
P09 13
P13 66
P12 21
Venting notch top
Coloured marking black

venting notch top
0
60 -3
Screw-in height of the flame glow plug in connecdimension X

ting line
TCD 2015
+5
300 -50
TCD 2015
Tension of the single V-belt (generator, 55 Ampe- Check after 15 minutes running under
re)
load
+5
350 -50
Tension of the single V-belt (generator, 120 Am- Check after 15 minutes running under
pere)
load
500
at least 8
87
79
29.1
32
35
approx. 30
approx. 25
Value
+5
550 -50
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
Series
Tension of the single V-belt (first assembly, gene- with V-belt tension measuring device
rator, 55 Ampere)
8115
Tension of the single V-belt (first assembly, gene- with V-belt tension measuring device
rator, 120 Ampere)
8115
Other components
Thermostat, start opening (A-bank)
P09 11
P12 11
for 3.00 bar
dimension X
dimension X
Information
Basic setting of the pressurestat when using new

for 3.50 bar
parts
for 4.00 bar
Cooling system
P08 63
Lube oil pressure
Lubricating oil system
Name
ID no.
mm
mm
mm
mm
Unit
Technical data
TCD 2015
8145-001
Technical data
TCD 2015
T00 81
engine TCD 2015 V06
A2
A1
A3
B2
B1
B3
45418-0
T00 81
engine TCD 2015 V08
A1
A2
A3
A4
B1
B2
B3
B4
45885-0
T01 63
Setting valve clearance
engine TCD 2015 V06
Ignition sequence: A1-B3-A3-B2-A2-B1
Valve overlap on cylinder
A1
B3
A3
B2
A2
B1
Setting on
cylinder
B2
A2
B1
A1
B3
A3
00000-0
06/2006
13/28
8145-001
Technical data
TCD 2015
T01 63
engine TCD 2015 V08
Ignition sequence: A1-B4-A4-B1-B3-A3-B2-A2
Valve overlap on cylinder
A1
B4
A4
B1
B3
A3
B2
A2
Setting on
cylinder
B3
A3
B2
A2
A1
B4
A4
B1
00000-0
T13 054
Connection plan of the injection pumps
engine TCD 2015 V06
Item
1
2
3
4
5
6
Component
Y15.1
Y15.5
Y15.3
Y15.6
Y15.4
Y15.2
Cylinder assignment
A1
A2
A3
B1
B2
B3
6
40971-0
T13 054
Connection plan of the injection pumps
engine TCD 2015 V08
Item
Component
Y15.1
Y15.8
Y15.6
Y15.3
Y15.4
Y15.7
Y15.5
Y15.2
Cylinder assignment
A1
A2
A3
A4
B1
B2
B3
B4
00000-0
08/2008
14/28
8145-002
TCD 2015
Technical data
4.2
06/2006
15/28
8145-001
Technical data
TCD 2015
06/2006
16/28
8145-001
Name
Clamping bracket on crankcase
Clamping bracket on adapter for assembly block
Mounting feet/engine mounting on crankcase
Cylinder head on crankcase
Rocker arm bracket on cylinder head
Lock nut valve clearance setting screw
Cylinder head cover on cylinder head
Cylinder head cover on cylinder head hood
Counterweight on crankshaft
Main bearing cover, vertical screws
ID no.
A00 001
A00 002
A00 003
A01 001
A01 002
A01 003
A01 004
A01 005
06/2006
A02 001
A02 010
17/28
Screws with
washers
M8x30
Screw type
TCD 2015
Screw can be used a

max. 3 times, otherwise renew every time they are loosened.
Oil lightly
TCD 2015
TCD 2015
Screws can be used a

Oil lightly
TCD 2015
oil lightly
hexagonal socket
oil lightly
TCD 2015
oil lightly
TCD 2015
TCD 2015
TCD 2015
TCD 2015
rigid
oil lightly
elastic
TCD 2015
TCD 2015
TCD 2015
Mounting feet/engine mounting on crankcase, elastic

Mounting feet/engine mounting on crankcase, rigid
oil lightly
Series
Notes / Remarks
+120
+120
+60
50 Nm
+30
+60
+60
+60
+60
+120
50 Nm
50 Nm
22 Nm
22 Nm
20 Nm
61 Nm
+45
+45
Postclamping
value
30 Nm
106 Nm
90 Nm
30 Nm
106 Nm
Pre-clamping value
TCD 2015
Technical data
8145-001
06/2006
18/28
Crankcase breather
Breather pipe on intake elbow/oil separator
A03 060
A03 064
A03 069
Valve housing (pressurestat) on crankcase
A03 051
Pipe (crankcase breather) on cable harness rail
Breather pipe (holder) on cable harness rail
Connecting flange on lubricating oil pan
Lubricating oil pan on crankcase
A03 030
A03 035
Genset support on crankcase
A03 020
Half-flange on connecting flange
Rear cover on crankcase
A03 010
A03 034
Big end bearing cover on connecting rod
A02 020
Oil drain plug on lubricating oil pan
Main bearing cover, horizontal screws
A02 011
A03 031
Name
M10x20-10.9
M8x30-10.9
M10
Screw type
TCD 2015
TCD 2015
Renew screws every time

they are loosened.
Insert with locking agent
DEUTZ DW 59
Hose clip
Pipe clamp
oil lightly
oil lightly
Gasket steel beading

Observe tightening order
TCD 2015
Screws can be used a

30 Nm
TCD 2015
(Railway)
TCD 2015
(Railway)
TCD 2015
TCD 2015
TCD 2015
20 Nm
20 Nm
6.5 Nm
8 Nm
50 Nm
30 Nm
TCD 2015
(Railway)
TCD 2015
120 Nm
120 Nm
24 Nm
28 Nm
55 Nm
21 Nm
50 - 60 Nm
80 Nm
Pre-clamping value
TCD 2015
(Railway)
TCD 2015
TCD 2015
(Railway)
TCD 2015
TCD 2015
Series
Notes / Remarks
ID no.
210 Nm
+60
+60
+30
+30
Postclamping
value
Technical data
TCD 2015
8145-001
06/2006
Camshaft gear wheel on idler gear
Gear wheel on camshaft for injection pumps
Plug of injection pump camshaft on crankcase
Fastening screw for idler gear on genset support
Screw plug for bolt idler gear
Screw for bolt idler gear
Pad thrust bearing on crankcase
A04 003
A04 004
A04 005
A04 011
A04 012
A04 013
A04 015
Connection housing to crankcase
A03 088
Stop cover (camshaft) on crankcase
Cover on connection housing
A03 085
A04 002
A03 082
Central screw for camshaft gear wheel on camshaft
A03 081
A04 001
Connection housing on lubricating oil pan
A03 080
Pipe (crankcase breather)
A03 070
A03 089
Name
ID no.
19/28
M12x100
M12x175
M12x190
M8x16
M12x1.5x90
M12x1.5x35
Screw type
TCD 2015
TCD 2015

DEUTZ DW 59
DEUTZ DW 59
oil lightly
oil lightly
oil lightly
Fastening screw for diverter

stopper
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015

DEUTZ DW 72
oil lightly
TCD 2015
oil lightly
TCD 2015
TCD 2015

DEUTZ DW 59

DEUTZ DW 59
TCD 2015
+60
+60
30 Nm
+150
50 Nm
30 Nm
70 Nm
79 Nm
80 Nm
8.5 Nm
30 Nm
30 Nm
+30
+60
+90
30 Nm
22 Nm
+60
+60
+60
30 Nm
21 Nm
+30
+30
Postclamping
value
30 Nm
70 Nm
6.5 Nm
TCD 2015
(Railway)
TCD 2015
Pre-clamping value
Series

DEUTZ DW 59
Hose clip
Notes / Remarks
TCD 2015
Technical data
8145-001
06/2006
Cover (stop cover) on crankcase
Speed governor on connection housing (crankshaft)
Speed governor on cover (camshaft)
Exhaust pipe at cylinder head
Exhaust pipe on exhaust manifold
A04 022
A05 011
A05 012
A06 001
A06 002
20/28
Exhaust turbocharger to exhaust manifold
Intake elbow to exhaust turbocharger
Tubing connection to turbocharger
A06 021
A06 024
Exhaust manifold to exhaust line
A06 020
A06 010
Exhaust manifold to connection housing
Exhaust pipe on exhaust line
Gear case cover on crankcase
A04 020
A06 003
Name
Nut
Nut
M8x35
M8x45
Screw type
Hose clip
Hose clip
housing position of the hose
clip top
screw head rear
Insert with fitting compound

DEUTZ S1

DEUTZ S1
5 Nm
5 Nm
TCD 2015
TCD 2015
(Railway)
10 Nm
35 Nm
TCD 2015
TCD 2015
(Railway)
35 Nm
28 Nm
18 Nm
22 Nm
60 Nm
8 Nm
8 Nm
20 Nm
TCD 2015
(Railway)
TCD 2015
TCD 2015
TCD 2015

DEUTZ S1
DEUTZ S1
TCD 2015
TCD 2015
TCD 2015
TCD 2015
21 Nm
21 Nm
TCD 2015
TCD 2015
(Railway)
Pre-clamping value
Series

DEUTZ S1

DEUTZ DW 72
Notes / Remarks
ID no.
35 Nm
Postclamping
value
Technical data
TCD 2015
8145-001
06/2006
Screw plug on charge air pipe
Connecting elbow to charge air pipe
Connecting pipe to holder
Retaining plate on genset support
Fuel injector on cylinder head
Injection nozzle on fuel injector
Injection line on fuel injector/injection pump
Pipe clamp for injection pipe
Injection pump housing on crankcase
Injection pump on injection pump housing
A06 046
A06 056
A06 058
A07 001
A07 002
A07 003
A07 006
A07 009
A07 012
Holder on exhaust manifold
Joint plate on connecting pipe
Connection pipe to air intake pipe
Charge air pipe to air intake pipe
Charge air pipe to cylinder head
Name
A06 038
A06 034
A06 033
A06 030
ID no.
21/28
M6x12
Union nut
Nozzle cap
nut
Union screw
Stud
Nut
Nut
M10 x 85
M10 x 65
Screw type
oil lightly
oil lightly
without leak oil

DEUTZ S1
Notes / Remarks
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
(Railway)
TCD 2015
TCD 2015
TCD 2015
TCD 2015
(Railway)
TCD 2015
60 Nm
60 Nm
10 Nm
25 Nm
40 - 50 Nm
70 Nm
20 Nm
20 Nm
20 Nm
4.5 Nm
20 Nm
34 Nm
20 Nm
57 Nm
20 Nm
20 Nm
TCD 2015
TCD 2015
(Railway)
60 Nm
20 Nm
Pre-clamping value
TCD 2015
TCD 2015
Series
Postclamping
value
TCD 2015
Technical data
8145-001
06/2006
22/28
Lock nut
Union nut
Ground cable on lock nut (flame glow plug)
Flame glow plug to connecting pipe
Connector (fuel pressure holding valve) to fuel

pipe
Overflow valve on connector
Screw-in nipple on fuel shut-off valve
A07 058
A07 059
A07 066
A07 067
A07 068
M45x1.5
Adapter (flame glow plug) on charge air pipe
Fuel pipe fastening
A07 057
A07 044
Fuel line on fuel supply pump
A07 034
SW50
Pipe clamp
Pipe clamp/holder
oil thread and head contact
surface.
Bearing housing (fuel supply pump) to genset

support
A07 024
Fuel pipe fastening
TCD 2015
Temperature transmitter on connector
A07 023
Hollow screw
TCD 2015
Fuel pipe to fuel shut-off valve (flame flow plugs) Union nut
A07 018
TCD 2015
18 Nm
39 Nm
39 Nm
TCD 2015
TCD 2015
(Railway)
42 Nm
TCD 2015
(Railway)
42 Nm
TCD 2015
7.5 Nm
TCD 2015
(Railway)
25 Nm
50 Nm
TCD 2015
(Railway)
TCD 2015
8.5 Nm
8.5 Nm
max.35 Nm
42 Nm
22 Nm
20 Nm
TCD 2015
(Railway)
TCD 2015
TCD 2015
TCD 2015
TCD 2015
(Railway)
25 Nm
25 Nm
TCD 2015
Fuel pipe to injection pump housing
Pre-clamping value
Series
A07 015
Notes / Remarks
Name
Screw type
ID no.
Postclamping
value
Technical data
TCD 2015
8145-001
06/2006
Fuel shut-off valve (flame glow plug) on crankcase (thermostat housing)
Adapter on oil filter nozzle (genset support
Oil pressure pump on genset support
Plug on oil pump
Lubricating oil pipe to genset support
Lubricating oil pipe to fuel supply pump
A07 093
A08 002
A08 010
A08 011
A08 013
A08 014
23/28
Lubricating oil pipe on exhaust turbocharger
A08 040
Union nut
M14 x 1.5
Screw-in nipple (guide tube) on lubricating oil pan
A08 038
M8x16
Guide tube on screw-in nipple (lubricating oil pan Union nut
Holder on oil suction pipe
M8x25
M8x20
M8x16
Union nut
Hollow screw
M16x1.5
Screw type
A08 035
A08 016
Holder oil suction pipe on retaining plate (main

bearing cover)
Oil suction intake pipe on oil pump
Screw-in nipple on overflow valve
A07 069
A08 015
Name
ID no.
TCD 2015
Oil thread and head contact

surface.
TCD 2015
TCD 2015
TCD 2015
TCD 2015
(Railway)
TCD 2015
39 Nm
45 Nm
30 Nm
22 Nm
22 Nm
22 Nm
22 Nm
TCD 2015
TCD 2015
(Railway)
22 Nm
22 Nm
20 Nm
18 Nm
21 Nm
40.5 Nm
50 Nm
TCD 2015
(Railway)
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
20 Nm
42 Nm
TCD 2015
(Railway)
TCD 2015
Pre-clamping value
Series
Oil thread and head contact

surface.
Pipe clamp
Notes / Remarks
Postclamping
value
TCD 2015
Technical data
8145-001
06/2006
24/28
Inlet adapter on coolant pump
Temperature transmitter on thermostat housing
Flywheel on crankshaft
A09 011
A09 031
A12 001
Flanged hub (torsional vibration damper) on

crankshaft
Coolant pump on genset support
A09 010
A12 030
Outlet branch on thermostat housing
Holder on thermostat housing
A09 002
A09 001
Thermostat housing on crankcase
Oil pressure pick-up on oil cooler housing
Holder (lubricating oil pipe) on genset support/

gear case cover
A08 079
A08 091
Screw plug on valve housing (pressurestat)
A08 071
Relief valve of piston cooling nozzle on crankcase
Oil cooler on genset support
A08 051
A08 081
Oil cooler housing cover on genset support
Oil pressure pipe on genset support
A08 050
A08 045
Oil return pipe to turbocharger/crankcase
A08 044
Oil pressure pipe on gear case cover
Name
M16x70
M14 x 1.5
Screw type
oil lightly
Renew screws after every

loosening.
Oil lightly
oil lightly
oil lightly
Holder of pipe clamp (fuel

pipe)
Hexagon socket head
Pipe clamp
Pipe clamps
Notes / Remarks
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
(Railway)
TCD 2015
30 Nm
50 Nm
22 nm
20 Nm
21 Nm
20 Nm
20 Nm
20 Nm
20 Nm
28 Nm
20 Nm
180 Nm
20 Nm
20 Nm
20 Nm
8.5 Nm
20 Nm
20 Nm
TCD 2015
TCD 2015
(Railway)
Pre-clamping value
Series
ID no.
+120
+30
+60
+60
Postclamping
value
Technical data
TCD 2015
8145-001
06/2006
25/28
M16x1.5
M6
Hollow screw pipe union
Pipe clamps, fuel pipe to connecting pipe
A12 092
A12 093
Clip (cable) on holder (central plug)
Fuel hose to air intake pipe
Hollow screw
M14x1.5
Hollow screw pipe union with ring piece
A12 090
A12 095
Fuel hose to connector (overflow valve/fuel shut- Hollow screw

off valve)
M10x1
M8
Union nut
Oil pressure pipe
A12 082
Union nut
Fuel pipe on flame glow plug
M8x16-10.9
A12 080
Heat shield on holder (gear case cover)
Holder on gear case cover
M10x210
Flange housing on bearing housing (hydraulic

pump drive)
A12 059
A12 071
oil lightly
M10x110
Flange housing on bearing housing (hydraulic

pump drive)
A12 058
M8x16-8.8
oil lightly
Bearing housing (hydraulic pump drive) on crankM10x55

case
A12 057
+180
30 Nm
TCD 2015
TCD 2015
Fule pipe on fuel pressure

holding valve
18 Nm
8.5 Nm
8.5 Nm
40 Nm
39 Nm
18 Nm
13 Nm
TCD 2015
TCD 2015
(Railway)
45 Nm
TCD 2015
(Railway)
39 Nm
TCD 2015
20 Nm
20 Nm
20 Nm
TCD 2015
Pipe clamp
+120
30 Nm
18 Nm
+60
Postclamping
value
30 Nm
30 Nm
Pre-clamping value
TCD 2015
TCD 2015
TCD 2015
(Railway)
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
Series
Breather pipe on oil cooler

cover
Pipe union with ring piece,

pipe 6 mm
oil lightly
oil lightly
V-belt pulley/torsional vibration damper on flanged hub
Notes / Remarks
A12 031
Screw type
Name
ID no.
TCD 2015
Technical data
8145-001
06/2006
Cable to pre-heating relay
Pressure sensor/temperature transmitter on connecting pipe
Cable to injection pump
A13 046
A13 054
Lock nut (V-belt) on generator holder
A13 017
A13 038
Generator on console
A13 015
Cable to pre-heating relay
Generator on plate (console)
A13 012
A13 037
Heat shield (starter) on crankcase
A13 006
Cable to flame glow plug
Starter on crankcase
A13 001
A13 035
Screw-in nipple (lubricating oil pipe) on exhaust

turbocharger
A12 098
Generator holder on genset support
Breather pipe on holder
A12 096
A13 018
Name
26/28
Nut M6
Nut M4
Nut M5
Screw
lock nut
5 Nm
1.0 Nm
TCD 2015
TCD 2015
(Railway)
9 Nm
7.5 Nm
2 Nm
TCD 2015
TCD 2015
TCD 2015
5 Nm
max. 5 Nm
TCD 2015
TCD 2015
(Railway)
42 Nm
hand tight
hand tight
hand tight
70 Nm
TCD 2015
TCD 2015
TCD 2015
TCD 2015
TCD 2015
M12x22
M12x28
30 Nm
45 Nm
30 Nm
TCD 2015
(Railway)
TCD 2015
(Railway)
Pre-clamping value
Series
TCD 2015
Pipe clamp
Notes / Remarks
Nut
Screw type
ID no.
42 Nm
20 Nm
20 Nm
+60
+60
Postclamping
value
Technical data
TCD 2015
8145-001
Name
Cable harness holder to connecting pipe
Cable harness rail on holder
Holder (cable harness) on connection housing
ID no.
06/2006
A13 090
A13 094
A13 098
M6x12
M6x16
8 Nm
70 Nm
TCD 2015
(Railway)
7.5 Nm
20 Nm
18 Nm
Pre-clamping value
TCD 2015
(Railway)
TCD 2015
M6
TCD 2015
Series
TCD 2015
(Railway)
Notes / Remarks
M8
M8 x 20
M8 x 16
Screw type
Postclamping
value
TCD 2015
Technical data
27/28
8145-001
Technical data
TCD 2015
06/2006
28/28
8145-001
TCD 2015
Job card overview
06/2006
Job card overview
5.1
1/22
8146-001
Job card overview

TCD 2015
06/2006
2/22
8146-001
TCD 2015
Job card overview
Activity
Job card
Maintenance group
Checking and setting fuel injectors
W 07-07-05
Fuel system
Checking and setting plunger lift of injection pumps W 07-06-04
Fuel system
Checking axial backlash of crankshaft (crankshaft

installed)
W 02-01-04
Drive system

removed)
W 02-01-04
Drive system
Checking piston overhang
W 01-04-09
Cylinder head
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
Checking the crankshaft
W 02-01-07
Drive system
Checking the overhang of the cylinder liner
W 03-03-08
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 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
Checking thermostat (removed state)
W 09-08-01
Cooling system
Disassembling, assembling and checking the rocker

W 01-02-06
arm and rocker arm bracket
Cylinder head
Dismantling and assembling fuel injector
W 07-07-02
Fuel system
Dismantling and assembling genset support
W 03-08-03
Crankcase
Grinding the cylinder head sealing surface
I 01-04-08
Cylinder head
Installing and removing turning gear
W 04-06-03
Engine control
Mounting engine on assembly block and demounting
W 00-05-01
General
Removing and installing charge air pipe (A-bank)
W 06-07-03
Exhaust system / Charging
Removing and installing charge air pipe (B-bank)
W 06-07-03
Removing and installing connecting pipe
W 06-02-05

(Railway)
W 06-02-05
Removing and installing coolant pump
W 09-07-08
Cooling system
Removing and installing crankcase breather (oil seW 03-01-11

parator)
Crankcase
Removing and installing exhaust line (A-bank)
W 06-01-05
Removing and installing exhaust line (B-bank)
W 06-01-05
Removing and installing exhaust manifold
W 06-01-07
06/2006
3/22
8146-001
TCD 2015
Job card overview

Activity
Job card
Maintenance group
Removing and installing exhaust manifold (A-bank)

W 06-01-07
(Railway)
Removing and installing exhaust manifold (B-bank)

W 06-01-07
(Railway)
Removing and installing exhaust pipe (A-bank)
W 06-01-06
Removing and installing exhaust pipe (B-bank)
W 06-01-06
Removing and installing flame glow plug
W 07-01-02
Fuel system
Removing and installing flame glow plug (Railway)
W 07-01-02
Fuel system
Removing and installing flywheel
W 12-06-01
Other components
Removing and installing fuel pipes
W 07-10-06
Fuel system
Removing and installing fuel pipes (flame glow

plugs)
W 07-01-04
Fuel system

plugs) (Railway)
W 07-01-04
Fuel system

(Railway)
W 07-10-06
Fuel system
Removing and installing fuel pressure holding valve W 07-13-01
Fuel system
Removing and installing fuel pressure holding valve

W 07-13-01
(Railway)
Fuel system
Removing and installing fuel shut-off valve (flame

glow plugs)
W 07-01-03
Fuel system

glow plugs) (Railway)
W 07-01-03
Fuel system
Removing and installing gear case cover

(Railway)
W 04-04-09
Engine control
Removing and installing genset support
W 03-08-01
Crankcase
Removing and installing hydraulic pump drive
W 12-08-04
Other components
Removing and installing injection pump camshaft
W 04-05-07
Engine control
Removing and installing injection pumps (cylinder

A1)
W 07-04-01
Fuel system

A2-B3)
W 07-04-01
Fuel system
Removing and installing lubricating oil pan

(Railway)
W 08-04-07
Lube oil system
Removing and installing oil pressure pick-up
W 08-11-09
Lube oil system
Removing and installing oil suction pipe

(Railway)
W 08-04-06
Lube oil system
Removing and installing pressure sensor/temperature sensor (charge air)
W 13-08-01
Electrical system
Removing and installing pressurestat
W 08-11-10
Lube oil system
Removing and installing rear cover
W 03-09-01
Crankcase
06/2006
4/22
8146-001
TCD 2015
Job card overview
Activity
Job card
Maintenance group
Removing and installing small end bush
I 02-03-03
Drive system
Removing and installing tappets, checking tappet

bores
W 04-02-02
Engine control
Removing and installing temperature transmitter
W 07-09-01
Fuel system
W 09-12-01
Cooling system
Removing and installing the cable harness
W 13-01-02
Electrical system
Removing and installing the camshaft
W 04-05-05
Engine control
Removing and installing the charge air line
W 06-02-03
Removing and installing the connection housing
W 03-09-04
Crankcase
Removing and installing the crankshaft
W 02-04-01
Drive system
Removing and installing the cylinder head
W 01-04-04
Cylinder head
Removing and installing the cylinder liner
W 03-03-02
Crankcase
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 gearcase cover
W 04-04-09
Engine control
Removing and installing the generator (V-belt drive) W 13-02-03
Electrical system
Removing and installing the impulse transmitter

(camshaft)
W 05-07-03
Speed governing

(crankshaft)
W 05-07-01
Speed governing
Removing and installing the lubricating oil pan
W 08-04-07
Lube oil system
Removing and installing the oil cooler
W 08-08-02
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 nozzle
W 02-15-01
Drive system
Removing and installing the rocker arm and rocker

arm bracket
W 01-02-02
Cylinder head
Removing and installing the starter
W 13-03-02
Electrical system
Removing and installing the valves
W 01-05-01
Cylinder head
Removing and installing thermostat
W 09-08-02
Cooling system
Removing and installing thermostat housing
W 09-08-04
Cooling system
Removing and installing torsional vibration damper
W 12-01-04
Other components
Removing and installing turbocharger
W 06-06-04
Removing and installing turbocharger (A-bank)

(Railway)
W 06-06-04
Removing and installing turbocharger (B-bank)

(Railway)
W 06-06-04
Removing and installing, testing camshaft bearing
W 03-11-01
Crankcase
06/2006
5/22
8146-001
TCD 2015
Job card overview
Activity
Job card
Maintenance group
Renewing injection pipes (A-bank)
W 07-03-01
Fuel system
Renewing injection pipes (B-bank)
W 07-03-01
Fuel system
Renewing the crankshaft sealing ring (flywheel side) W 02-02-02
Drive system
Renewing the crankshaft sealing ring (opposite side

W 02-02-04
to flywheel)
Drive system
Renewing toothed starter flywheel ring
W 12-06-03
Other components
Renewing valve guide (oversize, pressed version)
I 01-06-04
Cylinder head
Repairing the collar rest of the cylinder liner
I 03-10-05
Drive system
Replacing valve seat insert (oversize)
I 01-07-09
Cylinder head
W 01-01-01
Cylinder head
Testing the cylinder liner
W 03-03-01
Crankcase
06/2006
6/22
8146-001
Job card overview

Sorted numerically
TCD 2015
5
5.2
06/2006
Sorted numerically
7/22
8146-001
Job card overview

Sorted numerically
TCD 2015
06/2006
8/22
8146-001
TCD 2015
Job card overview
Job card
Activity
Maintenance group
I 01-04-08
Cylinder head
I 01-06-04
Cylinder head
I 01-07-09
Cylinder head
I 02-03-03
Drive system
I 03-10-05
Drive system
W 00-02-06
General
W 00-05-01
General
W 01-01-01
Cylinder head
W 01-02-02
Removing and installing the rocker arm and rocker

arm bracket
Cylinder head
W 01-02-06
Disassembling, assembling and checking the rocker

Cylinder head
arm and rocker arm bracket
W 01-04-04
Cylinder head
W 01-04-09
Cylinder head
W 01-05-01
Cylinder head
W 01-05-04
Checking the valves
Cylinder head
W 01-06-03
Cylinder head
W 01-07-08
Cylinder head
W 02-01-04

removed)
Drive system
W 02-01-04

installed)
Drive system
W 02-01-07
Drive system
W 02-02-02
Renewing the crankshaft sealing ring (flywheel side) Drive system
W 02-02-04
Renewing the crankshaft sealing ring (opposite side

Drive system
to flywheel)
W 02-03-01
Drive system
W 02-04-01
Drive system
W 02-09-03
Drive system
W 02-09-07
Checking the piston
Drive system
W 02-10-03
Drive system
W 02-15-01
Drive system
W 03-01-11
Removing and installing crankcase breather (oil seCrankcase

parator)
W 03-03-01
Crankcase
W 03-03-02
Crankcase
W 03-03-08
Crankcase
06/2006
9/22
8146-001
TCD 2015
Job card overview
Job card
Activity
Maintenance group
W 03-08-01
Crankcase
W 03-08-03
Crankcase
W 03-09-01
Crankcase
W 03-09-04
Crankcase
W 03-11-01
Crankcase
W 04-02-02
Removing and installing tappets, checking tappet

bores
Engine control
W 04-04-09
Engine control
W 04-04-09

(Railway)
Engine control
W 04-05-05
Engine control
W 04-05-06
Engine control
W 04-05-07
Engine control
W 04-06-03
Engine control
W 05-07-01

(crankshaft)
Speed governing
W 05-07-03

(camshaft)
Speed governing
W 06-01-05
W 06-01-05
W 06-01-06
W 06-01-06
W 06-01-07
W 06-01-07

(Railway)
W 06-01-07

(Railway)
W 06-02-03
W 06-02-05
W 06-02-05

(Railway)
W 06-06-04
W 06-06-04

(Railway)
W 06-06-04

(Railway)
W 06-07-03
W 06-07-03
W 07-01-02
Fuel system
06/2006
10/22
8146-001
TCD 2015
Job card overview
Job card
Activity
Maintenance group
W 07-01-02
Fuel system
W 07-01-03

glow plugs)
Fuel system
W 07-01-03

glow plugs) (Railway)
Fuel system
W 07-01-04

plugs)
Fuel system
W 07-01-04

plugs) (Railway)
Fuel system
W 07-03-01
Fuel system
W 07-03-01
Fuel system
W 07-04-01

A1)
Fuel system
W 07-04-01

A2-B3)
Fuel system
W 07-06-04
Checking and setting plunger lift of injection pumps Fuel system
W 07-07-01
Fuel system
W 07-07-02
Fuel system
W 07-07-05
Fuel system
W 07-09-01
Fuel system
W 07-10-06
Fuel system
W 07-10-06

(Railway)
Fuel system
W 07-11-01
Fuel system
W 07-13-01
Removing and installing fuel pressure holding valve Fuel system
W 07-13-01

Fuel system
(Railway)
W 08-04-06
Lube oil system
W 08-04-06

(Railway)
Lube oil system
W 08-04-07
Lube oil system
W 08-04-07

(Railway)
Lube oil system
W 08-08-02
Lube oil system
W 08-11-09
Lube oil system
W 08-11-10
Lube oil system
W 09-07-08
Cooling system
W 09-08-01
Cooling system
W 09-08-02
Cooling system
06/2006
11/22
8146-001
TCD 2015
Job card overview
Job card
Activity
Maintenance group
W 09-08-04
Cooling system
W 09-12-01
Cooling system
W 12-01-04
Other components
W 12-06-01
Other components
W 12-06-03
Other components
W 12-08-04
Other components
W 13-01-02
Electrical system
W 13-02-03
Removing and installing the generator (V-belt drive) Electrical system
W 13-03-02
Electrical system
W 13-08-01
Electrical system
06/2006
12/22
8146-001
Job card overview

Job card references
TCD 2015
5
5.3
06/2006
Job card references
13/22
8146-001
Job card overview

Job card references
TCD 2015
06/2006
14/22
8146-001
TCD 2015
Job card overview
00 General
Job card
Activity and additional job cards necessary for its execution

W 00-02-06
W 01-01-01
W 07-07-01

W 00-05-01
W 13-02-03
01 Cylinder head
Job card

W 01-01-01
W 04-06-03
Removing and installing the rocker arm and rocker arm bracket
W 01-02-02
W 01-01-01
W 04-06-03
W 07-03-01
(A-bank)
W 07-03-01
(B-bank)
Disassembling, assembling and checking the rocker arm and rocker arm bracket
W 01-02-06
W 01-02-02
W 01-04-04
W 01-02-02
W 01-04-09
W 06-07-03
(B-bank)
W 07-07-01
W 06-01-05
(A-bank)
W 06-01-05
(B-bank)
W 06-07-03
(A-bank)

I 01-04-08
W 01-05-01
W 01-04-09
W 01-04-04
W 04-06-03

W 01-05-01
W 01-04-04
Checking the valves
W 01-05-04
W 01-05-01
W 01-06-03
W 01-05-01
I 01-06-04
W 01-05-01
W 01-06-03

W 01-07-08
W 01-04-04
I 01-07-09
W 01-05-01
06/2006
W 01-07-08
15/22
8146-001
TCD 2015
Job card overview
02 Drive system
Job card

Checking axial backlash of crankshaft (crankshaft removed)
W 02-01-04
W 02-04-01
Checking axial backlash of crankshaft (crankshaft installed)
W 02-01-04
W 03-08-01
W 03-09-01
W 02-01-07
W 02-04-01
Renewing the crankshaft sealing ring (flywheel side)
W 02-02-02
W 12-06-01
Renewing the crankshaft sealing ring (opposite side to flywheel)
W 02-02-04
W 02-03-01
W 02-09-03
I 02-03-03
W 02-04-01
W 02-01-04
W 02-01-07
W 03-08-01
W 03-09-01
W 07-07-01

W 02-09-03
W 01-04-04
W 02-10-03
W 08-04-06
W 08-04-06
(Railway)
Checking the piston

W 02-09-07
W 02-09-03
W 02-10-03
W 02-09-03
W 02-15-01
W 02-09-03
03 Crankcase
Job card

Removing and installing crankcase breather (oil separator)
W 03-01-11
W 03-03-01
W 03-03-02
W 03-03-02
W 02-09-03
06/2006
W 03-03-01
W 03-03-08
16/22
8146-001
TCD 2015
Job card overview
03 Crankcase (continuation)
Job card

W 03-03-08
W 01-04-04
W 03-08-01
W 02-02-04
W 06-07-03
(A-bank)
W 06-07-03
(B-bank)
W 08-04-06
W 09-07-08
W 09-08-04

W 03-08-03
W 03-08-01
W 03-09-01
W 02-02-02
W 03-09-04
W 08-04-07

W 03-09-04
W 05-07-01
W 06-01-07
W 12-06-01
W 13-03-02

I 03-10-05
W 03-03-02
W 03-11-01
W 04-05-05
04 Engine control
Job card

Removing and installing tappets, checking tappet bores
W 04-02-02
W 04-05-05
W 04-04-09
W 06-06-04
(Railway)
W 04-04-09
W 07-13-01
(Railway)
W 04-05-05
W 01-02-02
W 02-04-01
W 04-05-06
W 07-04-01
(cylinder A1)
W 07-04-01
(cylinder A2-B3)
W 07-06-04
W 05-07-03
W 06-06-04

W 04-05-06
W 04-05-05
W 04-05-07
06/2006
W 01-02-02
W 02-02-02
W 03-08-01
W 03-09-04
W 04-06-03
W 05-07-03
W 06-06-04
W 07-04-01
(cylinder A1)
W 07-04-01
(cylinder A2-B3)
W 07-06-04
17/22
8146-001
TCD 2015
Job card overview

04 Engine control (continuation)
Job card

W 04-06-03
05 Speed governing
Job card

Removing and installing the impulse transmitter (crankshaft)
W 05-07-01
W 04-06-03
Removing and installing the impulse transmitter (camshaft)
W 05-07-03
W 04-06-03
W 06-06-04
06 Exhaust system / Charging

Job card

W 06-01-05
W 06-01-06
(A-bank)
W 06-01-05
W 06-01-06
(B-bank)
W 06-01-06
W 06-01-06
W 06-01-07
W 06-01-06
(A-bank)
W 06-01-06
(B-bank)
W 06-06-04

(Railway)
W 06-01-07
W 06-06-04
(A-bank)
(Railway)
W 06-01-07
W 06-06-04
(B-bank)
W 06-02-03
W 06-02-05
W 07-01-04
06/2006
18/22
8146-001
TCD 2015
Job card overview
06 Exhaust system / Charging (continuation)

Job card

(Railway)
W 06-02-05
W 07-01-04
(Railway)
Removing and installing the turbocharger
W 06-06-04
W 06-02-03
W 06-06-04

(Railway)
W 06-06-04

(Railway)

W 06-07-03
W 03-01-11
W 06-02-05
W 07-03-01
(A-bank)

W 06-07-03
(B-bank)
W 06-02-05
W 07-03-01
(B-bank)
07 Fuel system
Job card

W 07-01-02
W 07-01-04
W 07-01-02
W 07-01-04
(Railway)
Removing and installing fuel shut-off valve (flame glow plugs)
W 07-01-03
Removing and installing fuel shut-off valve (flame glow plugs) (Railway)
W 07-01-03
Removing and installing fuel pipes (flame glow plugs)
W 07-01-04
W 06-02-03
Removing and installing fuel pipes (flame glow plugs) (Railway)
W 07-01-04
W 07-03-01
06/2006
19/22
8146-001
TCD 2015
Job card overview

07 Fuel system (continuation)
Job card

W 07-03-01
W 06-02-03
Removing and installing injection pumps (cylinder A1)
W 07-04-01
W 04-06-03
W 06-07-03
(A-bank)
W 07-10-06
W 07-10-06
(Railway)
Removing and installing injection pumps (cylinder A2-B3)
W 07-04-01
W 03-01-11
W 04-06-03
W 07-03-01
(A-bank)
W 07-03-01
(B-bank)
W 07-10-06
W 06-06-04
(B-bank)
(Railway)
W 07-04-01
(cylinder A1)
W 07-10-06
(Railway)
Checking and setting plunger lift of injection pumps
W 07-06-04
W 04-06-03
W 06-06-04
W 06-06-04
(A-bank)
(Railway)
W 07-04-01
(cylinder A2-B3)
W 07-07-01
W 07-03-01
(A-bank)
W 07-03-01
(B-bank)
W 07-07-05

W 07-07-02
W 07-07-01
W 07-07-05

W 07-07-05
W 07-07-01
W 07-07-02

W 07-09-01
W 06-07-03
(B-bank)
W 07-10-06
W 07-10-06
W 06-07-03
(A-bank)
W 06-07-03
(B-bank)

(Railway)

W 07-11-01
W 07-13-01
06/2006
W 06-07-03
(A-bank)
20/22
8146-001
TCD 2015
Job card overview
07 Fuel system (continuation)

Job card
W 07-13-01

(Railway)
08 Lube oil system

Job card

W 08-04-06
W 08-04-07
(Railway)
W 08-04-06
W 08-04-07
(Railway)
W 08-04-07
W 13-03-02
W 08-04-07

(Railway)

W 08-08-02
W 06-07-03
(A-bank)
W 09-08-04

W 08-11-09
W 08-11-10
W 03-01-11
W 06-07-03
(B-bank)
09 Cooling system
Job card

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

W 09-08-04
W 07-01-04
06/2006
21/22
8146-001
TCD 2015
Job card overview

09 Cooling system (continuation)
Job card

W 09-12-01
12 Other components
Job card

W 12-01-04
W 12-06-01
W 12-06-03
W 12-06-01
W 12-08-04
W 06-01-06
(A-bank)
13 Electrical system
Job card

W 13-01-02
W 06-02-03
Removing and installing the generator (V-belt drive)
W 13-02-03
W 13-03-02
W 13-08-01
06/2006
22/22
8146-001
DEUTZ engines
11/2005
Job cards
Job cards
1/2
8147-001
DEUTZ engines
Job cards
11/2005
2/2
8147-001
General
W 00-02-06
TCD 2015
Commercial available tools:
Compression pressure
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005
W 01-01-01
W 07-07-01
Special tools:
Connector . . . . . . . . . . . . . . . . . . 100130
Grooved nut wrench . . . . . . . . . . 110130

z Check and set valve clearance.
W 01-01-01
z Removing fuel injectors.
W 07-07-01
z Mount sealing ring (1).

Use sealing ring (1) for fuel injector.
z Insert connector (2).
40640-0
z Tighten union screw with grooved nut wrench.

A07 001
40643-0
06/2006
1/4
8148-001
General
W 00-02-06
TCD 2015
z Connect adapter (1) to connector.

1
6
40641-0
z Mount the compression tester on the adapter.

z Turn over engine with starter.
P00 51
40642-0
No.
Kompression in bar
Compression value in bar
Pression
en bar
Dat. _________
10 15 20 25
30 35 40
Zyl.
The measured compression pressure

depends on the starting speed during the
measuring process and the altitude of the
engine installation site. Therefore, limit
values cannot be determined exactly. The
compression pressure measurement is
only recommended as a reference measurement of all cylinders of an engine to each
other. If more than 15% deviation has been
determined, the cause should be determined by disassembling the cylinder unit concerned.
1
2
3
4
5
6
7
8
DBGM
Made in Germany
MOTOMETER
33771-5
06/2006
2/4
8148-001
General
W 00-02-06
TCD 2015
z Remove the compression pressure tester.
z Remove adapter (1).
1
6
40641-0
z Unscrew union screw with grooved nut wrench.
40643-0
z Remove connector (2).

z Remove sealing ring (1).
z Install fuel injectors.
W 07-07-01
2
40640-0
06/2006
3/4
8148-001
General
W 00-02-06
TCD 2015
06/2006
4/4
8148-001
General
W 00-05-01
TCD 2015
Lifting gear
Suspension ropes
W 13-02-03
Special tools:
Assembly block incl. adapter plates . . . . . . . . . . . . . . . . . . . . . 6066
Clamping bracket . . . . . . . . . . .6066/151
Different customer scopes are not taken

into account in the repair sequence shown
here, accessories which deviate from the
standard equipment are not shown.
Mounting engine on assembly block

z Remove generator.
W 13-02-03
1
z Unscrew screws (1).
z Remove heat shield (2).
40644-1
z Screw in eyelet bolts (1).

z Hang engine on workshop crane.
1
40645-0
06/2006
1/6
8149-001
General
W 00-05-01
TCD 2015
z Unscrew all screws (1).

z Remove all mounting feet (2).
1
6
40652-0
z Mount all clamping brackets (1).

z Tighten screws (2).
A00 001
2
1
2
40646-1

z Remove all mounting feet (2).
2
1
1
40651-0
06/2006
2/6
8149-001
General
W 00-05-01
TCD 2015
z Insert engine in engine block.
z Mount clamping bracket on the adapter plates.
z Align all clamping brackets (1) on the adapter
plates (2) of the assembly block.
z Tighten screws .
A00 002
6
40649-0
z Align engine on engine block.

z Unhook the engine from the workshop crane.
40653-0
Demounting engine from assembly block

z Remove screws.
z Remove all clamping brackets (1) from the adapter
plates (2).
1
z Lift engine off the assembly block.
2
40649-0
06/2006
3/6
8149-001
General
W 00-05-01
TCD 2015
z Mount all mounting feet (1).

A00 003
6
40991-0

z Remove all clamping brackets (1).
2
1
2
40646-1
z Mount all mounting feet (2).

z Tighten all screws (1).
A00 003
40652-0
06/2006
4/6
8149-001
General
W 00-05-01
TCD 2015
z Set down engine.
z Unhook the engine from the workshop crane.
z Unscrew eyelet bolts (1).
6
40645-0
z Mount heat shield (2).

A13 006
z Install generator.
1
2
W 13-02-03
40644-1
06/2006
5/6
8149-001
General
W 00-05-01
TCD 2015
06/2006
6/6
8149-001
Cylinder head
W 01-01-01
TCD 2015
Rotation angle disc . . . . . . . . . . . . . 8190
Screwdriver insert for slotted screws. . . . . . . . . . . . . . . . . . . . 8191
Open wrench size 13 . . . . . . . . . . . 8196
W 04-06-03
Allow the engine to cool down for at least

30 minutes before setting the valve clearance. Engine oil temperature < 80 C
Locking agent
DEUTZ DW 59
The following work process describes setting of the valve clearance on an exhaust
valve. The setting procedure for an inlet
valve is analogous under consideration of
the specified rotation angle size.

z Remove cylinder head cover (2).
z Remove gasket.
z Attach turning gear.
W 04-06-03
2
40627-0
Setting engine to valve overlap

z Turn crankshaft using the turning gear until the valve
overlap of cylinder A1 is reached.
T01 63
40463-1
06/2006
1/4
8150-001
Cylinder head
W 01-01-01
TCD 2015
Valve overlap means:

The inlet valve starts opening,exhaust
valve closes.
6
40629-0
Arrangement of the inlet and exhaust valves.

IN = inlet valve
EX = exhaust valve
IN
IN
EX
EX
40630-0

z Loosen lock nut (1).
z Press in the adjusting screw (2) to the stop.
2
1
40631-0
06/2006
2/4
8150-001
Cylinder head
W 01-01-01
TCD 2015
z Set the rotation angle disc with a screwdriver insert
at the adjusting screw.
z Fix magnet of rotation angle disc on cylinder head.
z Set rotation angle disc to "0".
Do not rotate adjusting screw.
P01 61
P01 62
6
40632_1
z Turn the adjusting screw in the direction of the arrow.

P01 62
40633-0
z Tighten lock nut (1) with open wrench.

A01 003
Do not rotate adjusting screw.
z Remove rotation angle disc.

Set all other valves according to the valve
setting schematic T01 63.
1
40638_1
06/2006
3/4
8150-001
Cylinder head
W 01-01-01
TCD 2015
z Clean sealing surfaces.

z Mount new gasket (1).
1
Note installation position.

Position gasket over the profile washer (2).
6
40802-0
z Mount cylinder head cover.

Profile washer (1) may not be trapped
underneath the sealing surface (2) of the
cylinder head cover.
40803-0
z Lightly oil screws (1).

A01 005
z Remove turning gear.
W 04-06-03
1
40804-0
06/2006
4/4
8150-001
Cylinder head
W 01-02-02
TCD 2015
Removing and installing the rocker arm and rocker arm bracket
Feeler gauges
W 01-01-01
W 04-06-03
W 07-03-01 . . . . . . . . . . . . (A-bank)
W 07-03-01 . . . . . . . . . . . . (B-bank)
Locking agent
DEUTZ DW 59
Removing the rocker arm and rocker arm

bracket
1
z Removing high pressure pipes (A-bank).
W 07-03-01
2
z Removing high pressure pipes (B-bank).

W 07-03-01
z Remove cylinder head cowling (2).
z Remove gasket.
1
42215-1
z Unscrew screws (arrows).

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

brackets (3) together.
Lay out components in the order in which

they should be installed.
42217-1
06/2006
1/6
8151-001
Cylinder head
W 01-02-02
TCD 2015
z Remove push rods (1).

6
42219-1
z Visually inspect the components.
34824-2
Installing the rocker arm and rocker arm

bracket
z Insert stop rods (1).
Note assignment!
42219-1
06/2006
2/6
8151-001
Cylinder head
W 01-02-02
TCD 2015
The pushrod must be seated with the ball
head in the ladle of the tappet.
W 04-06-03
6
40490-0
z Turn crankshaft until reaching the base circle position of inlet and exhaust cams of the respective cylinder.
z Mount rocker arm bracket.
Attention!
The longer side (1) must point upwards.

The ball heads (2) must be seated in the
ladles of the pushrods .
45805-0
z Align rocker arm to the pushrods/valves.

z Tighten screws (1) alternately.
45806-0
06/2006
3/6
8151-001
Cylinder head
W 01-02-02
TCD 2015
Checking axial backlash of the rocker arm

z Measure the axial backlash between the rocker arm
bracket (1) and rocker arm (2) with a feeler gauge.
P01 75
The rocker arm (2) is on the opposite side

on the rocker arm bracket (3).
3
The setting is made by moving the rocker

arm brackets.
6
42221-1

A01 002
z Check and set valve clearance.
W 01-01-01
42222-1
z Mount new gasket.

z Fasten screws.
Screw length:
M8 x 80 mm (1)
M8 x 70 mm (2)
M8 x 30 mm (3)
3
42216-1
06/2006
4/6
8151-001
Cylinder head
W 01-02-02
TCD 2015
z Tighten screws .
A01 004
z Installing high pressure pipes (A-bank)
W 07-03-01
z Installing high pressure pipes (B-bank)
W 07-03-01
W 04-06-03
6
42223-1
06/2006
5/6
8151-001
Cylinder head
W 01-02-02
TCD 2015
06/2006
6/6
8151-001
Cylinder head
W 01-02-06
TCD 2015
Disassembling, assembling and checking the rocker arm and rocker arm
bracket
Internal measuring device
Micrometer gauge
W 01-02-02
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . . . . . . 170120
Disassembling the rocker arm bracket

z Remove rocker arm and rocker arm bracket.
W 01-02-02
34824-2
Checking rocker arm (inlet valves)

z Prepare internal measuring device:
Mount probe bolt for the appropriate measuring
range in the internal measuring device.
Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
Set micrometer gauge to 28 mm.
Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the dial gauge to the reversal point of the pointer to
"0".
34768-2
06/2006
1/6
8152-001
Cylinder head
W 01-02-06
TCD 2015
z Measure rocker arm bore.

P01 73
When the wear limit is reached the rocker
arm must be renewed.
6
34825-2

z Check ball stud (1) and adjusting screws (2) for
wear.
The components must be renewed in case

of excessive wear.
z Check oil channel (3) for free passage.
36749-1
Renewing ball stud

z Place disassembly/assembly tool (1) underneath.
z Press out ball stud.
34827-3
06/2006
2/6
8152-001
Cylinder head
W 01-02-06
TCD 2015
z Mount new ball stud (1).
Notch (2) faces vertically to the rocker arm
shaft.
6
34828_3
z Place disassembly/assembly tool underneath.

z Press in ball stud (1).
z Check oil channel for free passage.
34829_3
Checking rocker arm (exhaust valves)

z Measure rocker arm bore.
P01 72
arm must be renewed.
34830-2
06/2006
3/6
8152-001
Cylinder head
W 01-02-06
TCD 2015

z Check ball stud (1) and adjusting screws (2) for
wear.
The components must be renewed in case

of excessive wear.
36750-1
Renewing ball stud

z Press out ball stud.
34832_3

z Press in new ball stud (2).
34833_3
06/2006
4/6
8152-001
Cylinder head
W 01-02-06
TCD 2015
Checking rocker arm shaft
z Measure diameter with micrometer gauge.
P01 74
arm shaft must be renewed.
z Check oil channels for free passage.
6
34834-2
Assembling the rocker arm bracket

z Push rocker arm onto rocker arm shaft.
The oil bores (1) must face upwards and

the recess clearances (2) for the screws of
the rocker arm brackets to the adjusting
screws.
36751-1
z Push rocker arm brackets onto rocker arm shaft.
Attention!
The longer side (1) must point upwards.
The clamping grooves (2) must face the
adjusting screws (3) .
1
45385_1
06/2006
5/6
8152-001
Cylinder head
W 01-02-06
TCD 2015
z Insert all screws (1).

z Install rocker arm and rocker arm bracket.
W 01-02-02
1
6
34837_3
06/2006
6/6
8152-001
Cylinder head
I 01-04-08
TCD 2015
Surface milling machine
Roughness measuring unit
Depth-measuring
appliance
W 01-05-01
The relevant manufacturers specifications

must be observed when working with the
surface milling machine.
Prepare cylinder head

z Remove valves.
W 01-05-01
z Deburr the upper face of the cylinder head.
The upper face of the cylinder head must
be burr-free and free of gasket remains to
guarantee correct clamping of the cylinder
head.
39757-1
Grinding cylinder head surface

z Clamp cylinder head on surface milling machine.
z Align cylinder head.
z Align tool of the surface milling machine with the cylinder head.
39758-1
06/2006
1/4
8153-001
Cylinder head
I 01-04-08
TCD 2015
z Grind cylinder head sealing surface.

z Check the cylinder head sealing surface.
If the cylinder head sealing surface is not
level, recognisable from differences in
colour of the machined surface, the surface must be reground.
The adjustment range of the tool is a
maximum 0.2 mm per grind.
6
39759-1
Checking the cylinder head sealing surface

z Visually inspect the cylinder head sealing surface.
z Visually inspect the combustion chamber surface.
z Measure the roughness of the cylinder head sealing
surface with the roughness measuring instrument.
P01 93
If the measured value is out of tolerance,
the cylinder head sealing surface must be
remachined with different setting data for
the surface milling machine.
39760-1
z Measure cylinder head height with depth measuring

appliance.
P01 08
P01 09
When the wear limit is reached, the cylinder head must be renewed.
39761-1
06/2006
2/4
8153-001
Cylinder head
I 01-04-08
TCD 2015
z Remove cylinder head from the surface milling machine.
6
39758-1
z Attach the repair date and company logo to the cylinder head.
Attention!
Do not mark identification on a sealing surface.
Mark the cylinder head after every repair.
z Install valves.
W 01-05-01
39744-1
06/2006
3/4
8153-001
Cylinder head
I 01-04-08
TCD 2015
06/2006
4/4
8153-001
Cylinder head
W 01-04-04
TCD 2015
Removing and installing cylinder head
Socket wrench insert . . . . . . . . . . . 8016
W 01-02-02
W 01-04-09
W 06-01-05 . . . . . . . . . . . . (A-bank)
W 06-01-05 . . . . . . . . . . . . (B-bank)
W 06-07-03 . . . . . . . . . . . . (A-bank)
W 06-07-03 . . . . . . . . . . . . (B-bank)
W 07-07-01
Removing the cylinder head

z Remove charge air pipe (A-bank).
W 06-07-03
z Remove charge air pipe (B-bank).
W 06-07-03
z Remove exhaust line (A-bank)
W 06-01-05
z Remove exhaust pipe (B-bank)
W 06-01-05
40578-0
z Remove rocker arm and rocker arm bracket.

W 01-02-02
W 07-07-01
42234-1
06/2006
1/4
8154-001
Cylinder head
W 01-04-04
TCD 2015
z Unscrew screws (1) with the socket wrench insert.

z Remove cylinder head.
z Remove gasket.
42235-1
Installing the cylinder head

z Check piston overhang.
W 01-04-09
Determine the cylinder head gasket separately for every cylinder.
45811_0
z Select new cylinder head gasket according to measured piston overhang.

P02 75
P02 76
P02 77
Example: Piston overhang = 0.05 mm, corresponds to cylinder head gasket with
1 hole (arrow).
45811_1
06/2006
2/4
8154-001
Cylinder head
W 01-04-04
TCD 2015
z Fit a new cylinder head gasket.
The sealing surfaces for the cylinder head
gasket must be clean and free of oil.
Label OBEN / TOP facing the cylinder
head.
6
45812_1
z Fit cylinder head.

z Oil the cylinder head screws slightly.
Attention!
Screws can be reused a maximum 3 times
with written documentation.
z Fasten screws.
34976-2
z Tighten screws alternately with rotation angle disc

and socket wrench insert.
A01 001
40582-0
06/2006
3/4
8154-001
Cylinder head
W 01-04-04
TCD 2015
z Install rocker arm and rocker arm bracket.

W 01-02-02
W 07-07-01
z Install charge air pipe (A-bank)
W 06-07-03
z Install charge air pipe (B-bank)
W 06-07-03
z Install exhaust pipe (A-bank)
W 06-01-05
z Install exhaust pipe (B-bank)

W 06-01-05
06/2006
40583-0
4/4
8154-001
Cylinder head
W 01-04-09
TCD 2015
Magnetic measuring stand
8190
W 01-04-04
W 04-06-03
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Measuring instrument with
measuring plate . . . . . . . . . . . . . 100850

W 01-04-04
z Insert screws and washers (1) diagonally opposed.
z Tighten screws until they touch the cylinder liner.
Washers:
Maximum thickness 4 mm
Screw length:
M16 x 90
45424-0

W 04-06-03
z Turn the crankshaft until the respective piston is just
in front of the top dead centre (arrow).
45763-0
06/2006
1/4
8155-001
Cylinder head
W 01-04-09
TCD 2015
z Make sure the clamping bushings (arrows) are in

place.
6
45766-0
z Place measuring instrument (1) on measuring

plate (2).
z Insert dial gauges (3) with pre-tension in the measuring instrument.

z Turn the dial until the pointer points to "0".
37242-0
z Place the measuring instrument over the clamping

bushings (arrows).
z Read off measured value of both dial gauges.
z 1st dial gauge:
Note measured value, dimension (a).
z 2nd dial gauge:
Note measured value, dimension (b).
45767-0
06/2006
2/4
8155-001
Cylinder head
W 01-04-09
TCD 2015
z Form and note average value.
Calculation example
Desired:
Dimension x (average value of both dial gauges)
Given:
Measured:
Dimension a (measured value 1st dial gauge)
Dimension b (measured value 2nd dial gauge)
Calculation:
Dimension x = (dimension a + dimension b) : 2
(0.39 mm + 0.45 mm) : 2
Result:
= 0.42 mm
P02 75
P02 76
P02 77
z Remove measuring instrument.
6
45767-2

W 04-06-03
z Install cylinder head.
W 01-04-04
45424-0
06/2006
3/4
8155-001
Cylinder head
W 01-04-09
TCD 2015
06/2006
4/4
8155-001
Cylinder head
W 01-05-01
TCD 2015
Slide gauge
Assembly pliers. . . . . . . . . . . . . . . . 8024
Assembly lever . . . . . . . . . . . . . . . . 9017
W 01-04-04
Special tools:
Support bracket . . . . . . . . . . . . . 120900
Base plate. . . . . . . . . . . . . . . . . . 120910
Assembly tool . . . . . . . . . . . . . . . 121410
Assembly sleeves . . . . . . . . . . . . 121420
Removing the valves

W 01-04-04
z Mount support bracket (1) on base plate (2).
z Mount cylinder head on support bracket.
42227-1
z Install assembly lever (1).

z Press down valve spring with assembly lever.
z Remove both tapper collets (2).
z Remove valve spring plates, valve springs and

valves.
z Remove assembly lever.
2
42337-1
06/2006
1/4
8156-001
Cylinder head
W 01-05-01
TCD 2015
z Disassemble valve stem gasket with assembly plier.
6
42336-1
z Clean cylinder head.

z Check cylinder head.
42335-1
Installing the valves

z Measure valve spring length with slide gauge.
P01 51
When the wear limit is reached, the valve
spring must be renewed.
35856-2
06/2006
2/4
8156-001
Cylinder head
W 01-05-01
TCD 2015
z Oil the valve stem lightly.
z Insert and hold valve.
z Push assembly sleeve (2) over the valve Vgrooves (1).
2
6
42334-1
z Push new valve stem seal onto valve guide over the
assembly sleeve with assembly tool (1).
z Remove assembly sleeve.
42332-1
z Insert valve spring (1).

z Insert valve spring plate (2).
42331-1
06/2006
3/4
8156-001
Cylinder head
W 01-05-01
TCD 2015
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.
6
42330-1
z Remove assembly lever.

z Remove cylinder head from support bracket.
W 01-04-04
42329-1
06/2006
4/4
8156-001
Cylinder head
W 01-05-04
TCD 2015
Checking the valves
Micrometer gauge
Slide gauge
W 01-05-01
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.
P01 31
P01 32
42182-1
Checking valve edge thickness

z Measure valve edge thickness with slide gauge.
P01 35
P01 36
42183-1
06/2006
1/2
8157-001
Cylinder head
W 01-05-04
TCD 2015
Checking valve head diameter

z Measure valve head diameter with slide gauge.
P01 37
P01 38
z Install valves.
W 01-05-01
6
42184-1
06/2006
2/2
8157-001
Cylinder head
W 01-06-03
TCD 2015
W 01-05-01
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
New valves are used for testing.

guide must be renewed.

z Remove valves.
W 01-05-01
z Visually inspect valve guide for wear.
40713-0
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).
40714-0
06/2006
1/2
8158-001
Cylinder head
W 01-06-03
TCD 2015
z Move valve back and forth in direction of arrow.

P01 33
P01 34
The valve stem ends must be flush with the
valve guide.
The whole tilt distance must be taken into
account.
6
40715-0
z Remove magnetic measuring stand.

z Remove dial gauge.
z Install valves.
W 01-05-01
40639-0
06/2006
2/2
8158-001
Cylinder head
I 01-06-04
TCD 2015
Renewing the valve guide
(oversize, pressed version)
Reamers
Plug gauges
Cylinder head machining
tool
Press
Press-out pin
Press-in pin
Industrial vacuum cleaner
W 01-05-01
W 01-06-03
Nitrogen (liquid)
The press-in process must be carried out

without interruption as a result of the temperature difference between the cylinder
head and the valve seat insert.
The necessary work steps must be practised before pressing in.
Danger!
Danger of injury, do not touch supercooled
components or the liquid nitrogen!
Wear protective gloves and glasses!
Attention!

cylinder head machining tool.

z Check valve guides.
W 01-06-03
z Check valve guide with plug gauge (1).
1
P01 14
P01 15
The target area of the plug gauge must be
able to move upwards and downwards with
light suction.
39737-1
06/2006
1/6
8159-001
Cylinder head
I 01-06-04
TCD 2015
Pressing out valve guide

z Press out valve guide with press-out pin (1).
1
6
39749-1
Check housing bore for valve guide

z Visually inspect housing bore (arrow).
If the housing bore is heavily scored, the
housing bore must be reamed to the next
oversize dimension.
36630-1
z Check housing bore for valve guide with plug

gauge (1).
P01 05
P01 06
P01 07

light suction.
The no-go limit of the gauge plug must not
fit into the housing bore. If the no-go limit
fits, it must be reamed to the next oversize.
When the wear limit of the 2nd oversize
stage is reached, the cylinder head must
be renewed.
39750-1
06/2006
2/6
8159-001
Cylinder head
I 01-06-04
TCD 2015
Prepare housing bore for the valve guide
(oversize)
z Clamp cylinder head on cylinder head machining
tool.
z Seal coolant channels.
6
39751-1
z Align bore unit and mandrin guide (1) with the housing bore.
The housing bores can have different diameters, a suitable mandrin guide for alignment with the bore unit must therefore be
selected. The mandrin guide must move
easily in the housing bore without noticeable resistance.
39752-1
z Ream housing bore to oversize level.

P01 06
P01 07
Attention!
The reamer has a left twist and must
always be turned in or out in clockwise
direction. Never turn reamers anti-clockwise. The cuttings resulting from removing
the material can get stuck and damage the
cutting.
z Blow out housing bore with compressed air.
39753-1
06/2006
3/6
8159-001
Cylinder head
I 01-06-04
TCD 2015
z Check housing bore for valve guide with plug

gauge (1).
Use corresponding plug gauge.
light suction.
6
39750-1
The no-go limit of the gauge plug (1) must

not fit into the housing bore.
If the no-go limit fits, it must be reamed to
the next oversize.
be renewed.
P01 06
P01 07
39750-1
z Unclamp cylinder head.

z Blast cylinder head clean with compressed air.
39751-1
06/2006
4/6
8159-001
Cylinder head
I 01-06-04
TCD 2015
Press in valve guide
z Mount cylinder head.
z Select valve guide to fit housing bore.
P01 11
P01 12
P01 13
6
39754-1
z Supercool valve guide in liquid nitrogen.

Use a suitable container for the liquid nitrogen and a suitable tool for inserting and
removing the components.
At the beginning of the metal cooling, the
liquid nitrogen boils strongly, the bubbling
up process continues until the metal parts
have reached the temperature of the liquid
nitrogen (-196 C).
The valve guide has the correct temperature if the bubbling up process of the nitrogen has finished.
36636-1
z Push valve guide (1) onto press-in pin (2).

Note post-assembly position of the valve
guide.
The remote side (arrow) must face the
press-in pin.
1
2
39755-1
06/2006
5/6
8159-001
Cylinder head
I 01-06-04
TCD 2015
z Press in valve guide until it touches the press-in pin.

z Remove the press-in pin.
z Remove the cylinder head.
6
39756-1
Attention!
z Install valves.
W 01-05-01
39744-1
06/2006
6/6
8159-001
Cylinder head
W 01-07-08
TCD 2015
Depth-measuring
appliance
W 01-04-04
Special tools:
Support bracket . . . . . . . . . . . . . 120900
Base plate. . . . . . . . . . . . . . . . . . 120910
Attention!
seat insert and/or valve must be renewed.

W 01-04-04
z Mount support bracket (1) on base plate (2).
z Mount cylinder head on support bracket.
40650_1
z Mount depth measuring appliance on cylinder head

sealing surface.
z Measure valve stand back.
P01 45
P01 46
42228-1
06/2006
1/2
8160-001
Cylinder head
W 01-07-08
TCD 2015
z Remove cylinder head from support bracket (1).

z Remove support bracket from base plate (2).
1

W 01-04-04
6
40650_1
06/2006
2/2
8160-001
Cylinder head
I 01-07-09
TCD 2015
Renewing valve seat insert
(oversize)
Tenon milling machine,
10 mm
Slide gauge
Cylinder head machining
tool
Press
Industrial vacuum cleaner
Press-in pin
Upright drilling machine
W 01-05-01
W 01-07-08
Danger!
Attention!
without interruption as a result of the temperature difference between the cylinder
head and the valve seat insert.
Nitrogen (liquid)

cylinder head machining tool.
The respective valve guide must be available for replacing a valve seat insert.
z Check valve stand back.

W 01-07-08
z Remove valves.
W 01-05-01
40639-0
06/2006
1/8
8161-001
Cylinder head
I 01-07-09
TCD 2015
Checking valve seat insert

z Check valve seat inserts (1).
Ensure that the installation location is free
from faults.
6
39739-1
Removing valve seat insert

z Clamp in cylinder head.
z Align valve seat insert with tenon milling machine.
39740-1
z Mill valve seat insert on the sides (arrow) until it can

be removed without tension.
Attention!
Do not damage cylinder head.
39741-1
06/2006
2/8
8161-001
Cylinder head
I 01-07-09
TCD 2015
z Fit protective underlay (arrow).
z Lever valve seat insert out.
Attention!
Do not damage cylinder head.
z Unclamp cylinder head.
6
39742-1
Checking housing bore for valve seat insert

Diagram for measuring the housing bore at
the points "a" and "b", in the centre of
level "1".
36640-1
z Measure housing bore with internal measuring device.

Measuring points see diagram.
z Read off measured value.

P01 01
P01 02
P01 03
P01 04
be renewed.
39743-1
06/2006
3/8
8161-001
Cylinder head
I 01-07-09
TCD 2015
Alternatively, the diameter of the housing

bore can be determined with the aid of a
measuring guide ring (1).
The measuring guide ring can, for
example, be a valve seat insert turned to
half its size in height which is inserted in
the hole.
6
36641-1
Prepare housing bore for the valve seat

insert (oversize)
z Set cutting tool.
P01 03
P01 04
36620-1
z Clamp cylinder head on cylinder head machining

tool.
z Seal coolant channels.
39745-1
06/2006
4/8
8161-001
Cylinder head
I 01-07-09
TCD 2015
The valve guides can have different diameters, a suitable mandrin guide for alignment
with the bore unit must therefore be selected. The mandrin guide must move easily
in the valve guide without noticeable resistance.
z Align bore unit and mandrin guide (1) with the housing bore.
6
39746-1
z Bore housing bore to oversize level.
Attention!
The valve seat insert support (arrow) must
not be machined with the cutting tool.
z Remove chips thoroughly.
36624-1
z Measure housing bore with internal measuring device.

P01 03
P01 04
39747-1
06/2006
5/8
8161-001
Cylinder head
I 01-07-09
TCD 2015
Press in valve seat insert

z Mount cylinder head.
z Select valve seat insert to fit housing bore.
P01 21
P01 22
P01 23
P01 24
6
39748-1
z Supercool valve seat insert in liquid nitrogen.

Use a suitable container for the liquid nitrogen and a suitable tool for inserting and
removing the components.
At the beginning of the metal cooling, the
liquid nitrogen boils strongly, the bubbling
up process continues until the metal parts
have reached the temperature of the liquid
nitrogen (-196 C).
The valve seat insert has the correct temperature if the bubbling up process of the
nitrogen has finished.
36623-1
z Push valve seat insert (1) onto press-in pin (2).

The valve seat surface must point to the
press-in pin.
36643-1
06/2006
6/8
8161-001
Cylinder head
I 01-07-09
TCD 2015
z Press the valve seat insert (1) with press-in pin (2)
into the housing bore (3) until it is in position (arrow).
z Remove the cylinder head.
z Machine valve seat insert.
1
3
6
36633-1
Attention!
39744-1
z Install valves.
W 01-05-01
z Check valve stand back.
W 01-07-08
40639-0
06/2006
7/8
8161-001
Cylinder head
I 01-07-09
TCD 2015
06/2006
8/8
8161-001
Drive system
W 02-01-04
TCD 2015
Checking axial backlash of crankshaft
(crankshaft removed)
Micrometer gauge
8190
W 02-04-01
Checking the axial backlash

z Remove crankshaft.
W 02-04-01
40485-0
z Set micrometer gauge to 38 mm.

z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".
35825-2
06/2006
1/2
8162-001
Drive system
W 02-01-04
TCD 2015
z Measure locating bearing width

z Note measured value, dimension (a).
P02 11
P02 12
P02 13
6
42324-1
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) = 38.6 mm
(b) = 38.4 mm
Calculation:
Axial backlash = dimension (a) - dimension (b)
38.6 mm - 38.4 mm
Result:
= 0.2 mm
P02 34
With deviating axial backlash:
Set axial backlash by changing the thrust
ring halves.
40600-0
z Install crankshaft.
W 02-04-01
40485-0
06/2006
2/2
8162-001
Drive system
W 02-01-04
TCD 2015
Checking axial backlash of crankshaft
(crankshaft installed)
Micrometer gauge
Socket wrench insert, size
24, reinforced
8190
W 03-08-01
W 03-09-01
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Checking the axial backlash

z Remove genset support.
W 03-08-01
z Remove rear cover.
W 03-09-01
40479-0

z Apply stylus to the crankshaft end with pre-tension.
z Press crankshaft in direction of arrow.
40589-0
06/2006
1/6
8163-001
Drive system
W 02-01-04
TCD 2015
z Press crankshaft in direction of arrow.

P02 34
With deviating axial backlash:
Note measured value, dimension (a).
Set axial backlash by changing the thrust
ring halves.
6
40588-0
Changing thrust ring halves

z Unscrew screws (arrows) with the socket wrench
insert 8035.
40593-0
z Unscrew screws (1) with the socket wrench

insert size 24.
z Remove bearing cap (2).

z Remove lower bearing shell.
z Remove bottom thrust ring halves (arrows).
2
1
40594-0
06/2006
2/6
8163-001
Drive system
W 02-01-04
TCD 2015
z Remove top thrust ring halves (arrows).
6
40595-0
z Measure thickness of the top and bottom thrust ring

halves.
z Determine thickness of the new thrust ring halves.
P02 35
P02 36
P02 37
Calculation example
Desired:
Thickness of the new thrust ring halves
Given:
(x) = thickness for standard, oversize
level 1 and 2
(y) = axial backlash (nominal)
(values from the technical data)
Measured:
(a) = 0.4 mm axial backlash (actual)
(b) = 3.26 mm (thickness of the old thrust ring
halves)
Calculation:
(x) - (b) = (c)
3.36 mm - 3.26 mm = 0.1 mm
Dimension (a) - Dimension (c)
Result:
= 0.3 mm
Value must be within the given axial
backlash (y).
43504-0
z Select new thrust ring halves according to calculated

value.
06/2006
3/6
8163-001
Drive system
W 02-01-04
TCD 2015
z Install upper thrust ring halves according to measured axial clearance.

Oil grooves (1) of the thrust ring halves
face the crankshaft web face (2).
Insert thrust ring halves between crankcase and crankshaft web (arrow).
6
40596-0
z Fix thrust ring halves with a little grease to the bearing cap.
z Install lower thrust ring halves according to measured axial backlash.
Use thrust ring halves with guide
lug (arrow).
The oil grooves (1) face the crankshaft web
face.
Bearing cap has identification 3.
40489-0
z Insert bearing cap (1).

The identification "3" on the bearing cap
must be legible from the flywheel side.
z Align bearing cap.
Press the crankshaft to the flywheel side
first and then in the opposite direction.
40598-0
06/2006
4/6
8163-001
Drive system
W 02-01-04
TCD 2015
z Tighten screws (arrows).
Attention!
6
40597-0

Attention!
1
40599-0
z Tighten screws (arrow) with the socket wrench

insert size 24 and rotation angle disc.
A02 010
40491-0
06/2006
5/6
8163-001
Drive system
W 02-01-04
TCD 2015
z Tighten screws (arrow) with the socket wrench

insert 8035 and rotation angle disc.
A02 011
6
40492-0
z Check axial backlash of crankshaft.

P02 34
45417-0

z Install genset support.
W 03-08-01
z Mount rear cover.
W 03-09-01
40479-0
06/2006
6/6
8163-001
Drive system
W 02-01-07
TCD 2015
Micrometer gauge
Prisms
Hardness tester
W 02-04-01
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
W 02-04-01
z Place crankshaft on prism.
40485-0
z Pull off gear wheel (1).

z Remove friction disc.
40585-0
06/2006
1/6
8164-001
Drive system
W 02-01-07
TCD 2015
6
40586-0
z Position friction disc on parallel pin (2).

Use friction disc with locating hole.
1
z Mount gear wheel (1).
40587-0
z Visually inspect peripheral surfaces (1).

z Visually inspect gear wheel (2).
1
40584-0
06/2006
2/6
8164-001
Drive system
W 02-01-07
TCD 2015
z Put hardness tester on journal.
6
34754-2
z Raise stylus (1) and press release (2).

Stylus (1) falls down, briefly strikes the surface and jumps up to the measured value.
44445-0
z Read off displayed value (arrow) from hardness tester.

P02 07
The measured value is to be converted
according to the table of the measuring
device.
43515-1
06/2006
3/6
8164-001
Drive system
W 02-01-07
TCD 2015
Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.
6
36424-2
Checking the diameter of the main bearing

pins
z Measure main bearing pin with micrometer gauge.
P02 03
P02 04
P02 06
42327-1
Checking the diameter of the lifting journals

z Measure lifting journal with micrometer gauge.
P02 22
P02 23
P02 25
42326-1
06/2006
4/6
8164-001
Drive system
W 02-01-07
TCD 2015
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.
P02 26
6
42325-1
Measuring the fit bearing width

35825-2
z Measure bearing width with internal measuring device between thelay-on surfaces of the thrust rings.
P02 11
P02 12
P02 13
42324-1
06/2006
5/6
8164-001
Drive system
W 02-01-07
TCD 2015
W 02-04-01
6
40485-0
06/2006
6/6
8164-001
Drive system
W 02-02-02
TCD 2015
Renewing the crankshaft sealing ring
(flywheel side)
Depth-measuring
appliance
Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
Assembly lever . . . . . . . . . . . . . . . . 9017
W 12-06-01
Special tools:
Assembly tool . . . . . . . . . . . . . . . 142650
Self-tapping screw
Washer
Removing the crankshaft sealing ring

z Remove flywheel.
W 12-06-01
z Loosen crankshaft sealing ring in its seat evenly with
a mandrel.
z Make a hole in the crankshaft sealing ring with a
pricker.
Attention!
Do not damage the rear cover and crankshaft!
40656-0
z Turn in a self-tapping screw with washer.
42091-2
06/2006
1/6
8165-001
Drive system
W 02-02-02
TCD 2015
z Pull out the crankshaft sealing ring with assembly lever.
6
36764-1
z Visually inspect all running surfaces.
40657-0
Install crankshaft sealing ring

z Select shim (1).
Use the shim with identification "RepStage".
36756-2
06/2006
2/6
8165-001
Drive system
W 02-02-02
TCD 2015
z Mount shim (1).
Pay attention to alignment of the
clampingbushing (2) and locating hole (3).
2
1
3
6
36755-1
z Turn bolt (1) with thread (2) into crankshaft.

1
36757-1
Use new crankshaft sealing ring.
z Oil the sealing lip of the crankshaft sealing ring lightly.

z Place the crankshaft sealing ring carefully on the peripheral surface.
The sealing lip faces the crankcase.
36758-1
06/2006
3/6
8165-001
Drive system
W 02-02-02
TCD 2015
z Place assembly sleeve (1) on bolt (2).

z Press on assembly sleeve.
The assembly sleeve is evenly in contact
with the crankshaft sealing ring.
1
2
36759-1
z Push pressure cross-member (1) onto bolt (2).

z Mount washers.
z Screw on nuts.
2
36760-1
z Tighten screw (1) until the assembly sleeve (2) is

touching.
z Remove assembly tool.
2
36761-1
06/2006
4/6
8165-001
Drive system
W 02-02-02
TCD 2015
z Check installation depth (1) with depth measuring
appliance.
P03 25
z Install flywheel.
W 12-06-01
6
40960-0
06/2006
5/6
8165-001
Drive system
W 02-02-02
TCD 2015
06/2006
6/6
8165-001
Drive system
W 02-02-04
TCD 2015
Renewing the crankshaft sealing ring
(opposite side to flywheel)
Depth-measuring
appliance
Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
Assembly tool . . . . . . . . . . . . . . . 142640
Self-tapping screw
Washer
Removing the crankshaft sealing ring

z Remove flanged hub with torsional vibration damper
and V-belt pulley.
Block flywheel with suitable tool.
40659-0
z Loosen crankshaft sealing ring in its seat evenly with

a mandrel.
z Make a hole in the crankshaft sealing ring with a
pricker.
Attention!
Do not damage the genset support and
crankshaft!
40660-0
06/2006
1/6
8166-001
Drive system
W 02-02-04
TCD 2015
z Turn in a self-tapping screw with washer.
6
40661-0
z Pull out the crankshaft sealing ring with assembly lever.
40662-0
z Visually inspect all running surfaces.
40663-0
06/2006
2/6
8166-001
Drive system
W 02-02-04
TCD 2015
Install crankshaft sealing ring
z Select shim (1).
Use the shim with identification "RepStage".
6
37153-2
z Mount shim (1).
37211-1
z Turn bolt (1) with thread (2) into crankshaft.

1
37208-1
06/2006
3/6
8166-001
Drive system
W 02-02-04
TCD 2015
Use new crankshaft sealing ring.
z Oil the sealing lip of the crankshaft sealing ring lightly.

z Place the crankshaft sealing ring carefully on the peripheral surface.
The sealing lip faces the crankcase.
6
35203-2
z Place assembly sleeve (1) on bolt (2).

z Press on assembly sleeve.
The assembly sleeve is evenly in contact
with the crankshaft sealing ring.
1
2
35204-2
z Push pressure cross-member (1) onto bolt (2).

z Mount washers.
z Screw on nuts.
1
35205-2
06/2006
4/6
8166-001
Drive system
W 02-02-04
TCD 2015
z Tighten screw (1) until the assembly sleeve (2) is
touching.
z Remove assembly tool.
6
35206-2
z Check installation depth (1) with depth measuring

appliance.
P03 26
35201-3

and V-belt pulley.
1
z Tighten all screws (1) alternately.

A12 030
40659-0
06/2006
5/6
8166-001
Drive system
W 02-02-04
TCD 2015
06/2006
6/6
8166-001
Drive system
W 02-03-01
TCD 2015
Micrometer gauge
Con rod test device
W 02-09-03
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
z Remove piston and connecting rod.

W 02-09-03
40592-0
Checking small end bush

the meter at the reversal point of the pointer to "0".
34768-2
06/2006
1/10
8167-001
Drive system
W 02-03-01
TCD 2015
Diagram for measuring the small end bush

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

z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
P02 43
34770-2
Checking piston pin

z Measure piston pin with micrometer gauge.
P02 61
35908-2
06/2006
2/10
8167-001
Drive system
W 02-03-01
TCD 2015
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).
P02 45
P02 62
Calculation example
Desired:
Piston pin clearance
Given:
Measured:
Internal diameter small end bush (a)
(a) = 52.040 mm
Diameter piston pin (b)
(b) = 52.000 mm
Calculation:
Dimension (a) - Dimension (b)
52.040 mm - 52.000 mm
Result:
= 0.040 mm
Checking the con rod bearing bore

z Mount big end bearing cap.
Attention!
Note the assignment of the big end bearing
cap.
The identification numbers (1) on the con
rod and the big end bearing cap must be
identical and opposite to each other when
assembled.
34771-2
z Tighten screws .
A02 020
34772-2
06/2006
3/10
8167-001
Drive system
W 02-03-01
TCD 2015

6
36094-1
Diagram for measuring the con rod bearing

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

P02 55
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.
34775-2
06/2006
4/10
8167-001
Drive system
W 02-03-01
TCD 2015
Checking internal diameter of the con rod
bearing shells
2
z Remove screws.
z Remove the con rod bearing cover.
z Insert bearing shell in the con rod.
Attention!
Note the assignment of the bearing shells.
Insert big end bearing shell with the black
anodised rear side (arrow) in the connecting rod.
The anti-rotation lock (1) must lock in
groove (2).
6
36768-1
z Insert bearing shell in the respective big end bearing

cap.
Attention!
groove (2).
36769-1
Attention!
1

cap.
assembled.
34771-2
06/2006
5/10
8167-001
Drive system
W 02-03-01
TCD 2015
z Tighten screws .
A02 020
6
34778-2

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
06/2006
6/10
8167-001
Drive system
W 02-03-01
TCD 2015
P02 52
P02 54
If the values up to maximum 0.015 mm are
above the bearing tolerances, the connecting rod can still be used.
When the limit value is reached, the connecting rod must be replaced.
6
34775-2
Checking the diameter of the lifting journals

36424-2
z Measure lifting journal with micrometer gauge.

P02 22
P02 23
P02 25
45399-0
06/2006
7/10
8167-001
Drive system
W 02-03-01
TCD 2015
Determine big end bearing clearance

The big end bearing clearance is given by
the difference between the internal diameter of the big end bearing shell (a) and the
lifting journal diameter (b).
P02 56
P02 57
Calculation example
Desired:
Big end bearing clearance
Given:
Measured:
Internal diameter big end bearing shell (a)
(a) =88.060 mm
Diameter lifting journal (b)
(b) = 88.000 mm
Calculation:
Dimension (a) - Dimension (b)
88.060 mm - 88.000 mm
Result:
= 0.60 mm
z Remove screws.
z Remove the con rod bearing cover.
z Remove con rod bearing shells.
34778-2

Attention!
Aligning the con rod is not permissible.
z Check that the con rod is parallel.
P02 41
Check con rod without bearing shells on
the con rod test device.
Permissible deviation (a) at a
distance of (x).
35880-2
06/2006
8/10
8167-001
Drive system
W 02-03-01
TCD 2015
z Check the angle of the con rod.
P02 42
Permissible deviation from (A) to (B) at a
distance of (x).
6
35881-2
z Install piston and connecting rod.

W 02-09-03
40592-0
06/2006
9/10
8167-001
Drive system
W 02-03-01
TCD 2015
06/2006
10/10
8167-001
Drive system
I 02-03-03
TCD 2015
Press or threaded spindle
Danger!
Special tools:
Base plate. . . . . . . . . . . . . . . . . . 131200
Assembly tool kit. . . . . . . . . . . . . 131210

Nitrogen (liquid)
Degreasing agent/cleaning
agent
Compressed air
Heating oven
Attention!
Danger of injury, do not touch hot parts!

without interruption as a result of the temperature difference between the small end
bush and the connecting rod.
The pressing out of the small end bush is
shown with pneumatic press.
A threaded spilndle can also be used alternatively.
Removing the small end bush

Attention!
Never hammer out the small end bush!

z Insert big end bearing holder (3) in base plate (2).
z Insert removal gauge (1) in base plate.
Attention!
Do not confuse the removal gauge with the
installation gauge!
The groove (arrow) must face the big end
bearing holder.
Make sure the removal gauge is inserted
flush!
2
40404-0
06/2006
1/6
8168-001
Drive system
I 02-03-03
TCD 2015
z Insert the bottom part of the assembly tool (3) into the
removal gauge from below.
z Place the connecting rod (1) on the base plate.
The flat side (arrow) of the connecting rod

must face down.
z Turn the bottom part (3) into the top part (2) of the assembly tool.
6
40403-0
z Align the top part (1) of the assembly tool and removal gauge (2).
The top part of the assembly tool and the
removal gauge are level with the angled
surfaces (arrows) of the big end bearing.
1
40401-0
z Screw the top part (1) and bottom part (2) of the assembly tool together.
2
40402-0
06/2006
2/6
8168-001
Drive system
I 02-03-03
TCD 2015
z Align the pneumatic press horizontally on the base
plate.
The press-out die is in the centre above
the top of the assembly tool.
6
36284-2
z Press out the small end bush with slight pressure.

z Clean the bush bore.
The bush bore must be free from grease
and dirt.
36285-2
Installing small end bush

z Insert big end bearing holder (3) in base plate (2).
z Insert installation gauge (1) in base plate.
The groove (arrow) must face the big end

bearing holder.
Make sure the installation gauge is inserted flush.
40405-0
06/2006
3/6
8168-001
Drive system
I 02-03-03
TCD 2015
z Heat up the connecting rod (1).

P02 47
z Place the connecting rod on the base plate (2).
The flat side (arrow) of the connecting rod

must face down.
40406-0
z Cool down the small end bush (1) in liquid nitrogen.

P02 46
36288-3
z Place supercooled small end bush (1) on installation

mandrel (3).
The index pin (2) is sitting correctly in the
groove (arrow) of the small end bush.
40407-0
06/2006
4/6
8168-001
Drive system
I 02-03-03
TCD 2015
z Insert installation mandrel (1) with small end bush (2)
in con rod bore.
The small end bush must be insertable in
the connecting rod bore with little force.
Note installation position of the small end
bush.
z Pull out the installation mandrel.

The small end bush may not slip.
6
36290-3
z Check installation position.

Position of the bush joint (arrow) looking at
the flat side of the connecting rod shank.
40968-1
Mechanical machining of the small end

bush is necessary after assembly work.
z Spindle the small end bush to dimension A.
Dimensions
Maximum
dimension
Bore of small
end bush
52.055 mm
dimension A
Piston pin dia52.000 mm
meter
Theoretical
0.063 mm
clearance
Minimum
dimension
52.040 mm
51.992 mm
0.040 mm
39730-2
06/2006
5/6
8168-001
Drive system
I 02-03-03
TCD 2015
06/2006
6/6
8168-001
Drive system
W 02-04-01
TCD 2015
24, reinforced
14, reinforced . . . . . . . . . . . . . . . . . 8015
22, reinforced . . . . . . . . . . . . . . . . . 8035
W 02-01-04 . . . . . . . . . . . . (crankshaft
removed)
W 02-01-04 . . . . . . . . . . . . (crankshaft
installed)
W 02-01-07
W 03-08-01
W 03-09-01
W 07-07-01
Special tools:
Turn-over gear . . . . . . . . . . . . . . 100350
Removing crankshaft
W 07-07-01
W 03-08-01
z Remove rear cover.
W 03-09-01
40479-0
z Fasten all screws (1).
40470-0
06/2006
1/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Mount turning gear (1).
6
40471-0
z Set the counterweights (1) of cylinders A1/B1 at bottom dead centre.
T00 81
z Turn the crankshaft with the turning gear.
z Remove counterweights (1).
42140-1
z Set the counterweights (1) of cylinders A3/B3 at bottom dead centre.

z Remove counterweights (1).
40480-0
06/2006
2/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Place lifting journal of the respective cylinder at bottom dead centre (BDC).
Attention!
Do not jam the con rods when turning the
crankshaft.
6
40496-0
z Unscrew screws (1) with the socket wrench

insert 8015.
z Remove all big end bearing caps (2).
z Remove bearing shell.
Note order of cylinders.
1
40481-0
Attention!
crankshaft.
Do not damage the big end bearing shells.
z Turn the crankshaft with the turning gear evenly.
The marking on the crankshaft gear wheel
must be between the markings on the
camshaft gear wheel (1).
1
40482-0
06/2006
3/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Unscrew all screws (1) with the socket wrench

insert 8035.
z Unscrew all screws (2) with the socket wrench

insert size 24.
1
40483-1
z Remove bearing cap (1).

z Remove bottom thrust ring halves (arrows).
z Remove all main bearing covers (2).
1 - 2724 A
2 - 2724 A
4 - 2724 A

3 - 2724 A
z Remove the main bearing shells.
42144-1
z Press the con rods carefully out of the lifting journal.
40484-0
06/2006
4/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Remove turn-over gear.
z Lift out the crankshaft.
z Place crankshaft on prism.
6
42145-1
z Remove top thrust ring halves (arrows).

z Remove all main bearing shells (1).
z Remove all big end bearing shells (2).
37041-1
z Check crankshaft.
W 02-01-07
z Check axial backlash of crankshaft (crankshaft removed).
W 02-01-04
40485-0
06/2006
5/14
8169-001
Drive system
W 02-04-01
TCD 2015
Installing the crankshaft

z Insert upper main bearing shells.
Attention!

groove (2).
2
6
37042-1
z Insert lower main bearing shells in the respective

main bearing cover.
Attention!
groove (2).
37043-1
Attention!
anodised rear side in the connecting rod.
groove (2).
37044-1
06/2006
6/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Insert big end bearing shells in the respective big end
bearing cap.
Attention!
groove (2).
6
36769-1
z Lightly oil bearing surfaces.
40488-0
z Insert the crankshaft carefully in the crankcase.
Attention!
Do not jam the con rods when inserting the
crankshaft!
z Set the crankshaft in line with the camshaft (1) .
must be between the marking points on the
camshaft gear wheel.
1
37045-1
06/2006
7/14
8169-001
Drive system
W 02-04-01
TCD 2015

z Mount the turning gear.
6
40470-0
z Install upper thrust ring halves according to measured axial clearance.

The oil grooves (1) face the crankshaft
web face (2).
2
Insert thrust ring halves between crankcase and crankshaft web (arrows).
42180-1
z Install lower thrust ring halves according to measured axial backlash.

z Fix thrust ring halves with a little grease to the bearing cap.
Use thrust ring halves with guide
lug (arrow).
Oil grooves (1) face the crankshaft web
face.
Bearing cap has identification 3.
40489-0
06/2006
8/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Insert bearing cap (1).
z Insert main bearing covers (2).
Note assignment and installation position:
Assignment of the main bearing covers:
Identifications legible from the flywheel

side.
2 - 2724 A
3 - 2724 A
4 - 2724 A
With identification "4" = side opposite flywheel side.
1 - 2724 A
With identification "1" = flywheel side.
6
42146-2
Attention!
Screws can be used a maximum 3 times

1
42147-1
z Oil the screws lightly.

Attention!
Screws can be used a maximum 3 times
z Move the crankshaft axially to and fro.
The bearing is aligned in position as a
result.
1
42148-1
06/2006
9/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Tighten all screws (arrow) with the socket wrench insert size 24 and rotation angle disc.
A02 010
Attention!
Do not jam the main bearing cover.
6
40491-0
z Tighten all screws (arrow) with the socket wrench insert 8035 and rotation angle disc.
A02 011
40492-0
z Check installation position of the connecting rods.

The flattened side (arrow) faces the flywheel on the A-bank and the genset support
on the B-bank.
37204-1
06/2006
10/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Pull con rods carefully on to the lifting journal.
6
42151-1
z Place lifting journal of the respective cylinder at bottom dead centre (BDC).
Attention!
crankshaft.
40493-0
Attention!
The identification numbers (1) on the connecting rod and the big end bearing cover
must be identical and opposite to each
other when assembled.
1
37055-1
06/2006
11/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Tighten new screws with the socket wrench insert

8015 and rotation angle disc.
A02 020
6
37056-1
z Place crankshaft web of the respective cylinder at

bottom dead centre (BDC).
z Pay attention to clamping bushing (1).
42152-1
Attention!
1

Assignment of the counterweights:
Counterweight with
identification "1" = flywheel side.
Flattened sides (1) face the main bearing
cover.
37057-2
06/2006
12/14
8169-001
Drive system
W 02-04-01
TCD 2015
z Insert counterweights according to the identification.
6
42153-1

z Tighten screws .
A02 001
42154-1
z Remove turning gear (1).
40471-0
06/2006
13/14
8169-001
Drive system
W 02-04-01
TCD 2015
6
40470-0
z Check axial backlash of crankshaft (crankshaft installed).

W 02-01-04
40494-0
z Mount rear cover.

W 03-09-01
W 03-08-01
W 07-07-01
40495-0
06/2006
14/14
8169-001
Drive system
W 02-09-03
TCD 2015
Locking ring pliers
W 01-04-04
W 02-10-03
W 08-04-06
W 08-04-06 . . . . . . . . . . . . (Railway)
Special tools:
Piston ring compressor . . . . . . . . 130650
Removing the piston and con rod

W 01-04-04
Washers:
Screw length:
M16 x 90
40873-0
z Remove oil suction pipe

W 08-04-06
z Remove oil suction pipe (Railway).
W 08-04-06
40591-0
06/2006
1/8
8170-001
Drive system
W 02-09-03
TCD 2015
z Set piston at bottom dead centre (BDC).

z Unscrew screws (1) with the socket wrench insert.
6
42375-1
z Remove big end bearing cover with bearing shell.

T00 81
40821-0
z Set piston at top dead centre (TDC).

z Press out the piston and connection rod.
Attention!
Do not jam the connecting rod in the cylinder liner when removing!
42376-1
06/2006
2/8
8170-001
Drive system
W 02-09-03
TCD 2015
6
40592-0
z Remove locking ring with locking ring pliers.

z Press out piston pin.
z Remove locking ring with locking ring pliers.
Attention!
Make sure the surface of the piston is flawless.
42377-1
Installing the piston and con rod

z Insert new locking ring.
from faults.
42378-1
06/2006
3/8
8170-001
Drive system
W 02-09-03
TCD 2015
z Insert con rod.
Attention!
The concave surface (arrow) of the connecting rod must face the recess (1) for the
piston cooling nozzle on the piston.
6
40967-0
z Oil the piston bolt lightly.

z Insert piston pin in piston.
z Insert new locking ring.
from faults.
42379-1
Attention!
anodised rear side (arrow) in the connecting rod.
groove (2).

1
36768-1
06/2006
4/8
8170-001
Drive system
W 02-09-03
TCD 2015
z Insert bearing shell in the respective big end bearing
cap.
Attention!
groove (2).
6
36769-1
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
42380-1
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.
36771-1
06/2006
5/8
8170-001
Drive system
W 02-09-03
TCD 2015
z Set lifting journal at bottom dead centre (BDC).

z Push piston and con rod completely into cylinder liner.
Note the cylinder assignment of the piston.
Note identification (1) of the installation
position on the piston base.
1
The arrow must point to the exhaust gas

side.
The piston ring compressor must lie flat on
the cylinder liner.
6
36772-1
z Check installation position of the connecting rods.
Attention!
The flattened side (1) must face the adjacent lifting crank web (2).
1
2
40964-1
z Press the con rod carefully against the lifting journal.
Attention!
Do not jam the con rod with the crankshaft.
Do not damage the piston cooling nozzle.
42381-1
06/2006
6/8
8170-001
Drive system
W 02-09-03
TCD 2015
Attention!
cap.
assembled.
6
42382-1
z Tighten new screws with the socket wrench insert

and rotation angle disc.
A02 020
42383-1
z Install oil suction pipe.

W 08-04-06
z Install oil suction pipe (Railway).
W 08-04-06
40591-0
06/2006
7/8
8170-001
Drive system
W 02-09-03
TCD 2015
z Unscrew screws with washers (1).

W 01-04-04
1
6
40873-0
06/2006
8/8
8170-001
Drive system
W 02-09-07
TCD 2015
Checking the piston
Micrometer gauge
W 02-09-03
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
When the piston wear limit is reached, the

piston must be renewed.
Checking the piston bolt bore

W 02-09-03
42229-1

34768-2
06/2006
1/4
8171-001
Drive system
W 02-09-07
TCD 2015
Diagram for measuring the piston bolt bore

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

P02 78
36484-2
Checking the piston diameter

Diagram for measuring the piston diameter
at the measuring points "1, 2 and 3", transverse to the piston bolt bore.
3
2
1
37244-1
06/2006
2/4
8171-001
Drive system
W 02-09-07
TCD 2015
z Measure diameter with micrometer gauge.
P02 71
P02 72
P02 73
6
40969-0

W 02-09-03
40592-0
06/2006
3/4
8171-001
Drive system
W 02-09-07
TCD 2015
06/2006
4/4
8171-001
Drive system
W 02-10-03
TCD 2015
Feeler gauges
W 02-09-03
Special tools:
Universal piston ring pliers . . . . . 130300
Trapezoidal groove wear
gauge . . . . . . . . . . . . . . . . . . . . . 130400
Checking the piston rings and piston ring

grooves
W 02-09-03
z Set universal piston ring pliers to the piston diameter.
P02 73
z Remove piston rings with universal piston ring pliers.
42323-1
z Clean piston.
z Clean piston ring grooves.
42322-1
06/2006
1/4
8172-001
Drive system
W 02-10-03
TCD 2015
z Measure piston ring groove for first piston ring with

trapezoidal groove wear gauge.
6
33866-2
If there is a gap "S" between the trapezoidal groove wear gauge and piston, the
piston can be used again.
33867-2
If the trapezoidal groove wear gauge is

touching the piston (arrow), the piston
must be changed.
33868-2
06/2006
2/4
8172-001
Drive system
W 02-10-03
TCD 2015
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.
6
42321-1
z Measure the piston ring joint clearance with a feeler

gauge.
P02 84
P02 85
P02 86
When the wear limit is reached, the piston
ring must be renewed.
42320-1
Installing piston rings

Order and position of the piston rings as
seen from the piston base:
- Double-sided keystone ring (1)
- Taper-faced ring (2)

- Bevelland-edge oil control ring with coiled
spring expander (3)
Identification Top in (1) and (2) facing

combustion chamber
42319-1
06/2006
3/4
8172-001
Drive system
W 02-10-03
TCD 2015
z Install piston rings with universal piston ring pliers.

Set spring joint of the bevelland-edge oil
control ring 180 to the ring joint.
6
42318-1
Checking the piston ring axial clearance

Check with new piston rings.
z Check axial backlash with feeler gauge between piston ring and piston ring groove.
P02 88
P02 89
When the piston wear limit is reached, the
piston must be renewed.
42317-1

W 02-09-03
40592-0
06/2006
4/4
8172-001
Drive system
W 02-15-01
TCD 2015
Commercial available tools
W 02-09-03
Special tools:
Tester . . . . . . . . . . . . . . . . . . . . . 102560
Dipstick . . . . . . . . . . . . . . . . . . . . 102565
Removing the piston cooling nozzle

W 02-09-03
z Unscrew relief valve (1).
z Remove piston cooling nozzle (2).
42353-1
Installing the piston cooling nozzle

z Mount piston cooling nozzle.
z Screw on the relief valve hand tight.
The flattened side (1) faces the cylinder
liner.
1
42354-1
06/2006
1/4
8173-001
Drive system
W 02-15-01
TCD 2015
Check the jet position of the piston cooling

nozzle.
Attention!
Do not damage the cylinder liner when
inserting the tester.
z Insert tester in cylinder liner.

z Set tester with the bores (1) over the clamping
bushings (2).
6
40787-0
z Insert dipstick (1) in the bores (2) of the tester.
42356-2
z Insert the tip of the dipstick (1) without using force

into the opening in the piston cooling nozzle (2).
The piston cooling nozzle must be turned.
Attention!
If it cannot be turned, the piston cooling
nozzle must be renewed!
The piston cooling nozzle may not be bent!
The piston cooling nozzle must be in line
with the dipstick!
42357-1
06/2006
2/4
8173-001
Drive system
W 02-15-01
TCD 2015
z Tighten the relief valve.
A08 081
Attention!
Make sure the piston cooling nozzle is not
twisted!
6
42358-1
z Remove the dipstick.

z Remove the tester.
W 02-09-03
40992-0
06/2006
3/4
8173-001
Drive system
W 02-15-01
TCD 2015
06/2006
4/4
8173-001
Crankcase
W 03-01-11
TCD 2015
Removing and installing the crankcase breather
(oil separator)
Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.
Removing the crankcase bleeding

z Unscrew screw (1).
40664-0
z Loosen hose clip (1).

z Pull out pipe (3).
z Remove intake elbow (4).
1
45807-0
06/2006
1/6
8174-001
Crankcase
W 03-01-11
TCD 2015
z Loosen hose clips (1).
6
40667-0
z Loosen pipe clamp (1).
40668-0
z Pull out oil separator (1) together with pipe.
40669-0
06/2006
2/6
8174-001
Crankcase
W 03-01-11
TCD 2015
z Pull off pipe (1).
1
6
45401-0
40671-0
Install crankcase bleeding

z Mount pipe (1).
z Fill oil syphon (2) with engine oil.
40670-0
06/2006
3/6
8174-001
Crankcase
W 03-01-11
TCD 2015
z Insert oil separator (1) in flanged pipe (2).

Do not move the spring (arrow).
1
2
40672-0
z Mount intake elbow (4).

z Position hose clip (1).

z Tighten hose clip (1).
A06 021
z Mount pipe (3).
A03 064
45807-0
z Position pipe clamp (1).

z Tighten pipe clip (1).
A03 060
45808-0
06/2006
4/6
8174-001
Crankcase
W 03-01-11
TCD 2015
z Position hose clips (1).
z Tighten hose clips (1).
A03 064
1
6
40667-0
z Tighten screw (1).

A03 069
40664-0
06/2006
5/6
8174-001
Crankcase
W 03-01-11
TCD 2015
06/2006
6/6
8174-001
Crankcase
W 03-03-01
TCD 2015
Depth-measuring
appliance
Micrometer gauge
W 03-03-02
The following work sequence must be carried out on every cylinder unit of a cylinder
bank.
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400

z Remove cylinder liner.
W 03-03-02
z Visually inspect the cylinder running surface.
45423-0

36094-1
06/2006
1/4
8175-001
Crankcase
W 03-03-01
TCD 2015
Diagram for measuring the cylinder running surface at the points "a" and "b" in the
levels "1 - 4".
1
37238-1
z Remove shim ring (1).

z Visually inspect collar rest (arrow).
z Visually inspect sealing surface.
40677-0

P03 31
When the wear limit is reached, the cylinder liner must be renewed.
42394-1
06/2006
2/4
8175-001
Crankcase
W 03-03-01
TCD 2015
z Measure collar height in area (X) with micrometer
gauge.
P03 36
Carry out the measurement at several places on the collar rest.

z Install cylinder liner.
W 03-03-02
6
42395-1
06/2006
3/4
8175-001
Crankcase
W 03-03-01
TCD 2015
06/2006
4/4
8175-001
Crankcase
W 03-03-02
TCD 2015
Depth-measuring
appliance
W 02-09-03
W 03-03-01
W 03-03-08
Special tools:
Assembly device. . . . . . . . . . . . . 150120
Extraction tool . . . . . . . . . . . . . . . 150130
Fitting compound
DEUTZ AP1908
Removing the cylinder liner

W 02-09-03
40826-0
z Mark installation position of the cylinder liner on the

crankcase.
z Mark cylinder liner with the cylinder designation.
51521-1
06/2006
1/6
8176-001
Crankcase
W 03-03-02
TCD 2015
z Fold back plate and insert puller.

Place the plate (1) with the lay-on surfaces against
the cylinder liner (2) and hold them together.
Mount the counter holder (3) on the crankcase (4) .
Attention!
Do not damage the peripheral surfaces

and the sealing surfaces.
Do not damage the piston cooling nozzle.
The counterweights of the crankshaft face
the lubricating oil pan.
4
6
36782-1
z Pull the cylinder liner up and out.

Turn the nut in the direction of the arrow.
z Remove the disassembly device.

z Pull the cylinder liner up and out.
42230-1
z Remove shim ring (1).

z Visually inspect collar rest (arrow).
z Visually inspect sealing surface.
40677-0
06/2006
2/6
8176-001
Crankcase
W 03-03-02
TCD 2015
z Remove both O-rings (arrows).
z Test the cylinder liners.
W 03-03-01
6
42231-1
Install cylinder liner

z Insert new O-rings (arrows).
Pull the O-rings apart slightly to prevent
them falling out during assembly.
42231-1
z Measure collar rest with depth measuring appliance.

P03 35
Carry out the measurement at several places on the collar rest.
42392-1
06/2006
3/6
8176-001
Crankcase
W 03-03-02
TCD 2015
z Insert shim ring (1).

1
A centring lug (2) points up.
6
39911-0
z Coat the cylinder liner in the "X" area with fitting compound.
Make sure that the liner surface and the
crankcase are absolutely clean before
installing the cylinder liner.
34932-1
z Insert the cylinder liner (1) in the crankcase.

1
39918-0
06/2006
4/6
8176-001
Crankcase
W 03-03-02
TCD 2015
z Screw in retaining pins (1).
Screw retaining pins into a threaded bore
for screws of the cylinder head.
z Mount pressure plate (2) on cylinder liner.
2
Make sure the pressure plate is fit evenly.
6
42232-1
z Press in cylinder liner to stop.

z Remove the assembly device.
42233-1
z Check the overhang of the cylinder liner.

W 03-03-08
W 02-09-03
40583-0
06/2006
5/6
8176-001
Crankcase
W 03-03-02
TCD 2015
06/2006
6/6
8176-001
Crankcase
W 03-03-08
TCD 2015
W 01-04-04
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400

W 01-04-04

Washers:
Screw length:
M16 x 90
45424-0

z Apply stylus of the dial gauge to the crankcase sealing surface with pre-tension (arrow).
45762-0
06/2006
1/2
8177-001
Crankcase
W 03-03-08
TCD 2015
z Loosen magnetic measuring stand.

z Turn the magnetic measuring stand carefully until the
stylus is touching the sealing surface of the cylinder
liner (arrow).
P03 39
Make measurements at at least 3 other
points on the cylinder liner.
6
45761-0

W 01-04-04
45424-0
06/2006
2/2
8177-001
Crankcase
W 03-08-01
TCD 2015
Open wrench size SW 22
W 02-02-04
W 06-07-03 . . . . . . . . . . . . (A-bank)
W 06-07-03 . . . . . . . . . . . . (B-bank)
W 08-04-06
W 09-07-08
W 09-08-04
Packing compound
DEUTZ DW 47

to regulations.
Removing genset support

W 06-07-03
W 06-07-03
z Remove the holder (2).
2
1
40519-0

z Unscrew hollow screw (3).
z Remove sealing rings (4).
1
2
40520-1
06/2006
1/14
8178-001
Crankcase
W 03-08-01
TCD 2015
z Unscrew nut (1).

1
2
6
40521-0

Hold overflow valve.
z Remove fuel pipe (3).

z Remove sealing rings (2).
1
3
45803_0
z Remove thermostat housing.

W 09-08-04
z Remove coolant pump.
W 09-07-08

and V-belt pulley.
40531-0
06/2006
2/14
8178-001
Crankcase
W 03-08-01
TCD 2015
z Remove cable tie (1).
6
40532-0
40533-0
40534-0
06/2006
3/14
8178-001
Crankcase
W 03-08-01
TCD 2015
z Remove oil suction pipe.

W 08-04-06
6
40535-0
z Unscrew lock nut (1).

z Remove lubricating oil pipe.
z Remove sealing rings.
1
40536-0

1
2
1
40538-0
06/2006
4/14
8178-001
Crankcase
W 03-08-01
TCD 2015
z Remove holder.
6
40539-0

1
1
40540-0

40541-0
06/2006
5/14
8178-001
Crankcase
W 03-08-01
TCD 2015

z Remove gasket.
Attention!
Do not damage the crankshaft journal
when removing the genset support.
The teeth of the oil pump gears and the
idler gear must grip the teeth of the crankshaft drive wheel.
Use suitable workshop crane.
6
40542-0
40543-0
z Knock out crankshaft sealing ring (1).
Attention!
Do not damage sealing surface when
knocking out.
40544-0
06/2006
6/14
8178-001
Crankcase
W 03-08-01
TCD 2015
Installing genset support
z Fix new O-rings (1) with a little grease.
1
6
40545-0
z Fix new gasket (1) to the crankcase with a little

grease.
The oil pan sealing surface on the crankcase must face upwards.
Make sure the parallel pins (arrows) are in

place.
40546-0

Use suitable workshop crane.
z Centre genset support above the parallel pins.

z Fix genset support with screws (1).
The teeth of the oil pump gears and the
idler gear must grip the teeth of the crankshaft drive wheel.
Screw length:
M10 x 150 mm
40547-0
06/2006
7/14
8178-001
Crankcase
W 03-08-01
TCD 2015

Screw length:
M10 x 150 mm
6
40548-0
z Tighten screws alternately.

Screw length:
M10 x 65 mm (1)
M10 x 100 mm (2)
2
40541-0

Screw length:
M10 x 110 mm
1
1
40540-0
06/2006
8/14
8178-001
Crankcase
W 03-08-01
TCD 2015
z Mount holder.
TIghten screws only after mounting the
connecting pipe.
6
40539-0

Screw length:
M10 x 70 mm (1)
M10 x 110 mm (2)
2
1
40538-0

A03 020
40551-0
06/2006
9/14
8178-001
Crankcase
W 03-08-01
TCD 2015
z Cut off overhanging gasket (arrows) flush with the

sealing surface of the oil tray.
6
40549-0
z Mount new sealing rings.

z Mount the lubricating oil pipe.
z Screw on hollow screw (2).
z Screw on lock nut (1).
1
40536-0
z Tighten hollow screw (2).

A08 013
z Tighten lock nut (1).
A08 014
40536-0
06/2006
10/14
8178-001
Crankcase
W 03-08-01
TCD 2015
z Install oil suction pipe.
W 08-04-06
Before mounting the lubricating oil pan, fill
in the joints crankcase/genset support
(arrows) with packing compound.
6
40550-0
z Fix the cable strand with cable tie (1) without tension.
40534-0
40533-0
06/2006
11/14
8178-001
Crankcase
W 03-08-01
TCD 2015
z Install crankshaft sealing ring (opposite side to flywheel)
W 02-02-04
6
40532-0
z Mount the torsional vibration damper.

A12 030
1
z Install coolant pump.

W 09-07-08
z Install thermostat housing.
W 09-08-04
40531-0
z Insert new sealing rings (3).

z Mount fuel pipe (2).
1
3
45803_0
06/2006
12/14
8178-001
Crankcase
W 03-08-01
TCD 2015
z Oil the thread lightly.
z Mount holder (2).
z Screw on nut (1).
1
2
6
40521-0
z Mount new sealing rings (4).

z Mount holder (2).
z Oil thread and head contact surface lightly.
z Fasten screw (1).
1
2
40520-1

A12 093
z Tighten nut (2).
A07 044
2
40565-0
06/2006
13/14
8178-001
Crankcase
W 03-08-01
TCD 2015

A07 044
A12 092
1
2
6
40555-0
z Mount holder (2).

A07 044
W 06-07-03
W 06-07-03
2
1
40519-0
06/2006
14/14
8178-001
Crankcase
W 03-08-03
TCD 2015
W 03-08-01
Dismantling genset support

W 03-08-01

z Remove thrust washer (2).
z Remove idler gear (3).
40556-0

z Remove lubricating oil pump (3).
2
3
40557-0
06/2006
1/10
8179-001
Crankcase
W 03-08-03
TCD 2015
z Pull out plug element (1).
6
40558-0
z Unscrew nut (1).

z Remove adapter (2).
z Remove O-rings.
2
45371_1

z Remove bearing housing (2).
The fuel supply pump, idler gear and fuel
pipes remain installed on the bearing housing.
z Remove O-ring.
40559-0
06/2006
2/10
8179-001
Crankcase
W 03-08-03
TCD 2015
z Remove ground cable (2).
z Remove holder (3).
1
1
6
40560_1

z Remove holder.
1
40561-0

z Remove oil cooler cover (4).
3
40562_1
06/2006
3/10
8179-001
Crankcase
W 03-08-03
TCD 2015

z Remove oil cooler (2).
z Remove O-rings.
6
40563-0
Assembling genset support

z Insert new O-rings (1).
1
40564-0
z Mount oil cooler (2).

A08 051
40563-0
06/2006
4/10
8179-001
Crankcase
W 03-08-03
TCD 2015
z Mount new gasket.
z Mount oil cooler cover (4).
z Mount holder (1).
z Fasten all screws.
Screw length:
M8 x 35 mm (2)
M8 x 65 mm (3)
2
6
40562_1
z Mount holder (1).

40523-0
z Align oil cooler cover.

The lay-on surfaces of the oil cooler cover
and the genset support must contact the
holders.
1
Do not move gasket.

A08 050
40524-0
06/2006
5/10
8179-001
Crankcase
W 03-08-03
TCD 2015

z Remove holder.
The screws for both holders are not tightened until after mounting the connecting
pipe.
6
40525-0
z Mount holder (3).

z Mount ground cable (2).
A13 018
1
1
40560_1
z Insert new O-ring.

z Insert bearing housing (2).
1
A07 024
2
40559-0
06/2006
6/10
8179-001
Crankcase
W 03-08-03
TCD 2015
z Position O-rings.
z Mount adapter (2).
z Tighten nut (1).
A08 002
2
45371_1
z Lightly oil O-ring.

z Mount new O-ring (1).
1
40526-0
z Insert plug element (1).
40527-0
06/2006
7/10
8179-001
Crankcase
W 03-08-03
TCD 2015
z Pay attention to clamping bushing (1).
6
40528-0
z Insert new O-ring.
34738-2
z Mount lubricating oil pump (3).

z Fasten screws.
Screw length:
M10 x 75 mm (1)
M8 x 45 mm (2).
2
3
40557-0
06/2006
8/10
8179-001
Crankcase
W 03-08-03
TCD 2015
A08 010
A08 011
2
1
6
40648-0
z Lightly oil journal (1).

z Lightly oil bearing bush (2).
z Mount idler gear (3).

The collar (arrow) of the idler gear faces
the genset support.
2
1
40529-0
z Mount thrust washer (2).

z Fasten screw (1).
The bevelled side (arrow) of the thrust

washer must face upwards.
2
40530-0
06/2006
9/10
8179-001
Crankcase
W 03-08-03
TCD 2015

A04 011
W 03-08-01
6
40537-0
06/2006
10/10
8179-001
Crankcase
W 03-09-01
TCD 2015
W 02-02-02
W 03-09-04
W 08-04-07
Locking agent
DEUTZ DW 59
Removing rear cover

z Remove connection housing.
W 03-09-04
1
z Remove lubricating oil pan.

W 08-04-07
z Remove rear cover 2.
z Remove gasket.
40684-0
z Knock out crankshaft sealing ring (1).
Attention!
Do not damage the sealing surfaces.
37207-1
06/2006
1/4
8180-001
Crankcase
W 03-09-01
TCD 2015
6
40685-0
Installing rear cover

z Make sure the clamping bushings (arrows) are in
place.
The slots in the clamping bushings must
face downwards.
40686-0
z Insert new seal (1).
40687-0
06/2006
2/4
8180-001
Crankcase
W 03-09-01
TCD 2015
z Mount rear cover.
Use new sealing rings.
1
z Fasten screws.
z Insert screws (1) with locking agent.
Screw length:
M8 x 30 mm (1),(3)
M8 x 45 mm (2)
A03 010
2
6
40688_1
The gasket (arrows) must be flush with the

sealing surface of the oil pan.
40689-0
z Install lubricating oil pan.

W 08-04-07
z Install connection housing.
W 03-09-04
z Renew crankshaft sealing ring (flywheel side).
W 02-02-02
40655-0
06/2006
3/4
8180-001
Crankcase
W 03-09-01
TCD 2015
06/2006
4/4
8180-001
Crankcase
W 03-09-04
TCD 2015
W 05-07-01
W 06-01-07
W 12-06-01
W 13-03-02
Locking agent
DEUTZ DW 59
Removing the connection housing

z Install impulse transmitter (crankshaft).
W 05-07-01
z Remove starter.
W 13-03-02
z Remove exhaust manifold.
W 06-01-07
z Remove flywheel.
W 12-06-01
40690-0
40691-0
06/2006
1/6
8181-001
Crankcase
W 03-09-04
TCD 2015

z Remove flange housing (3).
3
40692-0

40693-0

45394-0
06/2006
2/6
8181-001
Crankcase
W 03-09-04
TCD 2015
6
40899-0
Installing the connection housing

z Clean contact surfaces.
z Coat connection housing on lay-on surface (arrow)
with locking agent.
42087-1
Make sure the parallel pins (arrows) are in

place.
40695-0
06/2006
3/6
8181-001
Crankcase
W 03-09-04
TCD 2015
z Mount connection housing.

Centre above the parallel pins.
z Fasten screws.
Insert screws with locking agent.

Note different screw lengths.
M12 x 35 mm (1)
M12 x 90 mm (2).
A03 081
6
40694-0

A03 082
40696-0
z Fasten screws.
M12 x 200 mm (1)
M12 x 175 mm (arrows).

A03 088
40693-0
06/2006
4/6
8181-001
Crankcase
W 03-09-04
TCD 2015
A03 089
6
40697-0

z Coat lay-on surface (arrow) with locking agent.
45409-0
z Mount flange housing (3).

Screw length:
M10 x 110 mm

Screw length:
M10 x 210 mm
A12 058
3
40692-0
06/2006
5/6
8181-001
Crankcase
W 03-09-04
TCD 2015

A12 059
6
40698-0

A03 080
40691-0
z Install flywheel.
W 12-06-01
z Install starter.
W 13-03-02
z Install impulse transmitter (crankshaft).
W 05-07-01
z Install exhaust manifold.
W 06-01-07
40451-0
06/2006
6/6
8181-001
Crankcase
I 03-10-05
TCD 2015
W 03-03-02
Special tools:
Tool kit. . . . . . . . . . . . . . . . . . . . . 150030
In case of coolant leakage or damage to

the sealing assembly crankcase/cylinder
liner/cylinder head, the collar rest of the
cylinder liner in the crankcase can be
repaired.
Repair kits
Fitting compound
DEUTZ AP 1908
Cleaning agent (e.g. commerically available brake
cleaner)
The following work sequence must be carried out on every cylinder unit of a cylinder
bank.
Grinding in collar rest surface

z Remove cylinder liner.
W 03-03-02
z Seal the insides of the crankcase with cover
plates (1).
39914-0
z Clean collar rest (1).

z Clean inside of the crankcase.
Use cleaning agent.
1
39902-0
06/2006
1/8
8182-001
Crankcase
I 03-10-05
TCD 2015
Grinding for cleaning the collar rest

z Apply post-grinding paste (1) to the collar rest (2).
z Add a little clean water.
6
39908-0
z Mount the bracket and handles on the grinding/surface plate.

A
Note the different processing sides of the

grinding/surface plate:
A - grinding side
B - surface side
Grinding side A faces down.
z Place grinding side A on collar rest.
39904-0
z Turn the grinding/surface plate (1) forwards and

backwards evenly (approx. 180).
z Grind the collar rest lightly.
Note soft grinding noise.
z Clean the collar rest.
z Remove grind paste and grinding particles.

Use cleaning agent.
39906-0
06/2006
2/8
8182-001
Crankcase
I 03-10-05
TCD 2015
Check
z Move the bracket on the griding/surface plate.
Spotting side B facing downwards.
z Apply surface paste thinly to the surface side B.

Applying it too thickly makes it impossible
to detect recesses in the collar rest.
6
39916-0
z Place surface side B on collar rest.

Note the different processing sides of the
grinding/surface plate:
A - grinding side
B - surface side
z Surface the collar rest.
39906-1
The surfacing shows up recesses (1) in the

collar rest.
1
39913-0
06/2006
3/8
8182-001
Crankcase
I 03-10-05
TCD 2015
Grinding
6
39904-0
z Apply pre-grinding paste (1) to the collar rest (2).

2
39907-0
z Place grinding side A on collar rest.

Lift the grinding/surface plate slightly
several times for the grinding paste to
spread evenly.
1
Note rough grinding noise.

Use cleaning agent.
39906-0
06/2006
4/8
8182-001
Crankcase
I 03-10-05
TCD 2015
Check
z Check the contact pattern.
An even contact pattern must exist.
Otherwise, repeat the grinding and surface process.
6
39912-0
Regrinding
39904-0
z Apply post-grinding paste (1) to the collar rest (2).

2
39907-0
06/2006
5/8
8182-001
Crankcase
I 03-10-05
TCD 2015

Lift the grinding/surface plate slightly
several times for the grinding paste to
spread evenly.
Note soft grinding noise.
1

Repeat the surface process to check.
6
39906-0
z Clean inside of the crankcase.

z Remove cover plates (1).
z Check the inside of the crankcase for cleanliness.
The tool set must be cleaned and the grinding/surface plate oiled slightly for corrosion protection.
39914-0
Assembly
z Coat the O-rings with fitting compound.
39917-0
06/2006
6/8
8182-001
Crankcase
I 03-10-05
TCD 2015
z Insert shim ring (1).
1
A centring lug (2) points up.
6
39911-0
z Insert new cylinder liner (1).

W 03-03-02
1
39918-0
06/2006
7/8
8182-001
Crankcase
I 03-10-05
TCD 2015
06/2006
8/8
8182-001
Crankcase
W 03-11-01
TCD 2015
Micrometer gauge
W 04-05-05
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Assembly tool . . . . . . . . . . . . . . . 143830
Testing camshaft bearing

z Remove camshaft.
W 04-05-05
42126-1

34768-2
06/2006
1/8
8183-001
Crankcase
W 03-11-01
TCD 2015
Diagram for measuring the camshaft bearing at the points "a and b" in the
levels "1 and 2".
6
37239-1

P03 13
P03 14
When the wear limit is reached, the camshaft bearing must be replaced.
42127-1
Removing camshaft bearing

z Insert spindle (1) with puller bush (2) on the opposite
side to the flywheel.
2
1
34711-2
06/2006
2/8
8183-001
Crankcase
W 03-11-01
TCD 2015
z Insert counter bearing (1) on the flywheel side.
1
34712-1
z Mount spacing sleeve (1).

z Mount ball bearing (2).
z Screw on nut.
1
34713-2
z Pull out the camshaft bearings one after another.

Do not pull out the camshaft bearing (flywheel side).
34714-2
06/2006
3/8
8183-001
Crankcase
W 03-11-01
TCD 2015
z Insert spindle with puller bush on flywheel side.

z Mount counter bearing (1) on flywheel side.
z Mount spacing sleeve.
z Mount ball bearing.
z Screw on nut.
z Pull out flywheel side camshaft bearing.
6
34716-2
Installing camshaft bearing

Diagram for the installation depth of the
camshaft bearings.
Measuring the depth from the flywheel side

A
mm
172,5
0,2
0,2
337,5
0,2
0,2
mm
502,5
0,2
0,2
mm
mm
45415-1
z Mount the new camshaft bearing (flywheel side) so

that the recess (1) faces the flywheel.
The diagram shows the camshaft bearing
in the installed state.
The camshaft bearing (flywheel side) has
two lubricating oil bores.
Make sure the lubricating oil bores (2) in
the camshaft bearing and crankcase are in
line.
1
2
37179-1
06/2006
4/8
8183-001
Crankcase
W 03-11-01
TCD 2015
z Insert spindle with counter bearing on the opposite
z Insert puller bush in camshaft bearing and push onto
the spindle.
6
34718-2

z Screw on nut.
z Press in camshaft bearing (flywheel side).
Installation depth, see diagram.
34720-2
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 reinstalled.
1
40900-0
06/2006
5/8
8183-001
Crankcase
W 03-11-01
TCD 2015
z Mount the new middle camshaft bearings on the opposite side to the flywheel so that the recess (1) faces the flywheel.
1

The middle camshaft bearings have three
lubricating oil bores.
line.
6
37180-1
z Mount the new camshaft bearing (opposite side to

flywheel) so that the recess (1) faces the flywheel.
The camshaft bearing (opposite side to flywheel) has three lubricating oil bores.
line.
1
37181-1
z Insert puller bush in camshaft bearing.

z Insert spindle with puller bush on flywheel side.
34723-2
06/2006
6/8
8183-001
Crankcase
W 03-11-01
TCD 2015
z Mount counter bearing.
z Screw on nut.
z Insert the camshaft bearings one after another.
Attention!
Do not damage the camshaft bearings
when moving the assembly tool!
Installation depth, see diagram.
6
34714-2
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 reinstalled.
z Install the camshaft.
W 04-05-05
40901-0
06/2006
7/8
8183-001
Crankcase
W 03-11-01
TCD 2015
06/2006
8/8
8183-001
Engine control
W 04-02-02
TCD 2015
Remove and installing tappets, checking tappet bores
Micrometer gauge
W 04-05-05
Removing tappets.
z Remove camshaft.
W 04-05-05
z Remove tappets.
37198-1
40699-0
06/2006
1/2
8184-001
Engine control
W 04-02-02
TCD 2015
Measuring tappet bores

6
35825-2
z Measure tappet bore with internal measuring device.

P03 23
P03 24
X
34707-4
Installing tappets
z Oil all tappets lightly.
z Insert all tappets.
Note the assignment of the tappets.

W 04-05-05
37199-1
06/2006
2/2
8184-001
Engine control
W 04-04-09
TCD 2015
W 06-06-04
Packing compound
DEUTZ DW 48

to regulations.
Removing the gearcase

z Remove turbocharger.
W 06-06-04
40700-0

z Pull off pipe (2).
1
2
40701-0
06/2006
1/6
8185-001
Engine control
W 04-04-09
TCD 2015
6
40702-0

z Remove spacing sleeves.
40703-0

40704-0
06/2006
2/6
8185-001
Engine control
W 04-04-09
TCD 2015
z Remove pipe clamp (2).
6
40705-0

z Remove gear case cover (2).
1
2
40706-0
40707-0
06/2006
3/6
8185-001
Engine control
W 04-04-09
TCD 2015
Installing the gearcase cover

Attention!
Do not damage the sealing surfaces.
z Apply packing compound evenly to the sealing surface.

z Mount gear case cover (1).
z Mount holder (2).
3
A04 020
6
40708-0
z Mount pipe clamp (2).

A08 045
2
40705-0
z Mount holder (2).

A12 071
40704-0
06/2006
4/6
8185-001
Engine control
W 04-04-09
TCD 2015
z Insert spacing sleeves with screws (1).
z Tighten all screws.

A12 071
6
40703-0

A13 094
40702-0
z Push on pipe (2).

A03 064
1
2
40701-0
06/2006
5/6
8185-001
Engine control
W 04-04-09
TCD 2015
z Install the turbocharger.

W 06-06-04
6
40700-0
06/2006
6/6
8185-001
Engine control
W 04-04-09
TCD 2015 Railway

W 07-13-01 . . . . . . . . . . . . (Railway)

to regulations.
Removing the gearcase

z Unlock cable plug (1) and remove.
z Lay cable bare.
1
2
42108-1

z Remove washers.
z Remove fuel pressure holding valve.
W 07-13-01
45777-0
06/2006
1/6
8186-001
Engine control
W 04-04-09
TCD 2015 Railway

z Remove washer.
z Remove spacing sleeve (2).

z Loosen pipe clamp (3).
2
1
6
45775-0

z Remove washer.

45776-0

z Remove gasket.
2
42416-2
06/2006
2/6
8186-001
Engine control
W 04-04-09
TCD 2015 Railway

6
40707-0
Installing the gearcase cover

z Mount new gasket.
A04 020
2
42416-2
z Mount holder (3).

z Mount holder (2).
z Mount washer.
A12 071
45776-0
06/2006
3/6
8186-001
Engine control
W 04-04-09
TCD 2015 Railway

z Position spacing sleeve (2).
z Mount washer.
A12 096
2
6
45775-0
z Position cable harness rail with cable harness.

z Mount washers.
z Fasten screws.
Note different screw lengths:

M6 x 12 mm (1)
M6 x 16 mm (2)
z Tighten screws .
A13 094
45778-1
z Install fuel pressure holding valve.

W 07-13-01
45779-1
06/2006
4/6
8186-001
Engine control
W 04-04-09
TCD 2015 Railway

z Plug in the cable plug (1).
Ensure that the cables are connected properly.
z Fix cable with cable tie (2).
1
2
6
42108-1
06/2006
5/6
8186-001
Engine control
W 04-04-09
TCD 2015 Railway
06/2006
6/6
8186-001
Engine control
W 04-05-05
TCD 2015
Lifting gear
Depth-measuring
appliance
W 01-02-02
W 02-04-01
W 04-05-06
W 05-07-03
W 06-06-04
W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
W 07-04-01 . . . . . . . . . . . . (Cylinder
A2-B3)
W 07-06-04
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Counter support . . . . . . . . . . . . . 144150
Packing compound
DEUTZ DW 48
Locking agent
DEUTZ DW 72
Removing the camshaft

z Remove rocker arm brackets.
W 01-02-02
W 02-04-01
z Remove impulse transmitter (camshaft).
W 05-07-03
40409-0
z Remove injection pumps (cylinder A1).

W 07-04-01
z Remove injection pumps (cylinder A2-B3).
W 07-04-01
Do not remove injection pump housing.

2

z Place fuel hose (2) to one side.
40458-0
06/2006
1/24
8187-001
Engine control
W 04-05-05
TCD 2015

z Place cable harness rail (2) with cable harness to
one side.
1
2
6
40410-0


40411-1

1
40412-0
06/2006
2/24
8187-001
Engine control
W 04-05-05
TCD 2015
6
40413-0

40414-0
40415-0
06/2006
3/24
8187-001
Engine control
W 04-05-05
TCD 2015

z Remove cover (2) .
z Remove cover (3).
3
2
6
40416-0

z Remove pad thrust bearing (2).
40417-0

z Remove gear wheel (2).
Attention!
Make sure no parts fall into the crankcase!

Concealed screws can be accessed by
turning the crankshaft with the turning gear.
Press back the injection pump camshaft
carefully as far as it goes.
40418-0
06/2006
4/24
8187-001
Engine control
W 04-05-05
TCD 2015
6
40419-0
40420-0
z Remove bolt (1).

40421-0
06/2006
5/24
8187-001
Engine control
W 04-05-05
TCD 2015
6
40422-0
40423-0
z Remove bolt (1).

40424-0
06/2006
6/24
8187-001
Engine control
W 04-05-05
TCD 2015
z Remove gasket.
6
40425-0
z Insert counter support (1) in the toothing of the camshaft gear wheel.
40426-0
z Turn the camshaft gear wheel in the direction of

the A-bank.
z Block the camshaft gear wheel with the counter holder on the crankcase (arrow).
40427-0
06/2006
7/24
8187-001
Engine control
W 04-05-05
TCD 2015
z Loosen screw (1).

z Turn back the camshaft gear wheel.
z Remove counter holder (2).
6
40428-0

z Remove camshaft toothed wheel (2).
2
40429-0
z Turn engine 180.

z Press in all tappets.
z Unhook the engine from the assembly block on one
side.
z Pull out the camshaft (1) carefully to the flywheel
side.
1
40430-0
06/2006
8/24
8187-001
Engine control
W 04-05-05
TCD 2015
z Check camshaft.
W 04-05-06
6
36812-1
Installing the camshaft

z Oil camshaft bearing lightly.
z Oil cam shaft pin lightly.
z Insert camshaft carefully.
The locating hole (1) of the camshaft faces
towards the lubricating oil pan.
37079-1
z Measure the overhang of the parallel pin with the

depth measuring appliance.
P04 39
z Correct overhang.
40431-0
06/2006
9/24
8187-001
Engine control
W 04-05-05
TCD 2015
z Insert camshaft gear wheel (2).

z Lightly oil screw (1).
z Fasten screw (1).
Make sure that the parallel pin on the
camshaft gear wheel and the locating hole
on the camshaft are in line.
6
40429-0
the B-bank.
40432-0
z Tighten screw (arrow).

A04 001
z Turn back the camshaft gear wheel.
z Remove counter holder.
40433-0
06/2006
10/24
8187-001
Engine control
W 04-05-05
TCD 2015
Determining axial backlash of the camshaft
z Push back the camshaft as far as it goes.
z Measure the camshaft stand back from the lay-on
surface on the camshaft gear wheel to the crankcase
with the depth measuring appliance (arrows).
6
40434-0

z Measure the flange height from the running surfaces
to the lay-on surface with the depth measuring appliance (arrows).
P04 35
Calculation example
Desired:
Axial backlash
Given:
Measured:
(a) = 45.80 mm
(b) = 45.50 mm
Calculation:
45.80 mm - 45.50 mm
Result:
= 0.30 mm
z Correct deviation with gaskets.
42273-2
P04 37
z Mount cover (2).
z Fit new sealing rings.

A04 002
40425-0
06/2006
11/24
8187-001
Engine control
W 04-05-05
TCD 2015

z Check oil channel (arrow) for free passage.
1
40435-0
z Lightly oil bearing liner (1) with engine oil.

z Insert idler gear (2).
The collar (arrow) faces the bearing bush.
40438-0
z Insert bolt (1).
40437-0
06/2006
12/24
8187-001
Engine control
W 04-05-05
TCD 2015
A04 013
Screw length:
M12 x 80 mm
6
40423-0

A04 012
40422-0

1
40435-0
06/2006
13/24
8187-001
Engine control
W 04-05-05
TCD 2015

40436-0
z Insert bolt (1).
40439-0

A04 013
Screw length:
M12 x 100 mm
40420-0
06/2006
14/24
8187-001
Engine control
W 04-05-05
TCD 2015
A04 012
1
6
40419-0
Checking the tooth edge clearance of the

idler gear (B-bank)
z Turn idler gear in direction of arrow until it stops.
z Apply stylus under pre-tension to a tooth flank.
z Adjust dial gauge to "0".
40440-0

P04 44
Repeat the measuring process on several
tooth flanks.
40441-0
06/2006
15/24
8187-001
Engine control
W 04-05-05
TCD 2015

idler gear (A-bank)
6
40442-0

P04 44
tooth flanks.
40443-0
z Position the injection pump camshaft.

The locating hole (arrow) faces upwards.
40444-0
06/2006
16/24
8187-001
Engine control
W 04-05-05
TCD 2015
z Position camshaft gear wheel.
The marking (1) faces towards the crankshaft.
6
42289-1
Overview of the gear train and the markings of the control times:
Injection pump camshaft gear wheel (1)

2
Camshaft gear wheel (2)

Idler gear (3).
Crankshaft gear wheel (4)
Marking injection pump camshaft / idler
gear (5)
Marking camshaft / crankshaft (6)
6
40445-1
z Position injection pump camshaft gear wheel.

The marking (1) faces the camshaft gear
wheel.
40446-0
06/2006
17/24
8187-001
Engine control
W 04-05-05
TCD 2015
z Insert the injection pump camshaft gear wheel in the

The marking on the gear wheel must be
between the markings of the injection
pump camshaft gear wheel (1).
40447-0
Attention!
40448-0

injection pump camshaft gear wheel
z Turn gear wheel in direction of arrow until it stops.
40449-0
06/2006
18/24
8187-001
Engine control
W 04-05-05
TCD 2015
P07 20
tooth flanks.
6
40450-0
W 02-04-01
Do not install the turbocharger.
z Install rocker arm brackets.

W 01-02-02
z Check and set plunger lift of injection pumps.
W 07-06-04
40503-0

A04 004
40464-0
06/2006
19/24
8187-001
Engine control
W 04-05-05
TCD 2015
z Mount pad thrust bearing (2).

6
40989-0
Checking and setting axial backlash of the

injection pump camshaft
z Insert feeler gauge blade between gear wheel of the
injection pump camshaft and the pad thrust
bearing (arrow).
z Press the pad thrust bearing onto the feeler gauge

blade.
z Fasten screw (1).
z Check axial backlash.
P04 43
40512-0

bearing (arrow).
blade.
z Fasten screw (1).

P04 43
40513-0
06/2006
20/24
8187-001
Engine control
W 04-05-05
TCD 2015
A04 015
z Check axial backlash again.
P04 43
1
Check axial backlash on both sides between

pad thrust bearing and gear
wheel (arrows).
6
40514-0

40515-0
z Press in the cover (3) to the stop.

z Mount cover (2).
A04 022
40460-0
06/2006
21/24
8187-001
Engine control
W 04-05-05
TCD 2015
z Fix cable tie (1).
6
40459-0

z Apply packing compound evenly to the sealing surface of the gear case.
Use packing compound DEUTZ DW 48.
2

z Mount holder (2).

A04 020
3
40516-0

A08 045
2
1
40456-0
06/2006
22/24
8187-001
Engine control
W 04-05-05
TCD 2015
z Mount holder (2).
A12 071
6
40455-0

1
z Insert screws (3) with spacing sleeves.

z Tighten screws (2 and 3) alternately.
A12 071
2
40517-0

A13 094
1
40453-0
06/2006
23/24
8187-001
Engine control
W 04-05-05
TCD 2015

z Position fuel hose (2).
A12 090
1
2
6
40458-0
z Install impulse transmitter (camshaft).

W 05-07-03
z Install injection pumps (cylinder A1).
W 07-04-01
z Install injection pumps (cylinder A2-B3).
W 07-04-01
W 06-06-04
40518-0
06/2006
24/24
8187-001
Engine control
W 04-05-06
TCD 2015
Depth-measuring appliance
Micrometer gauge
W 04-05-05

z Remove camshaft.
W 04-05-05
z Visually inspect cams and bearing pins for wear.
Repairing the camshaft is not permissible.
The camshaft must be renewed.
36812-1

36424-2
06/2006
1/4
8188-001
Engine control
W 04-05-06
TCD 2015
z Measure the diameter of journals with the micrometer gauge.

P04 31
When the wear limit is reached, the camshaft must be renewed.
6
42128-1
Checking the camshaft gear wheel

1
40601-0

z Visually inspect the idler gear (1) for wear.
2
z Visually inspect the camshaft gear wheel (2) for

wear.
1
40602-1
06/2006
2/4
8188-001
Engine control
W 04-05-06
TCD 2015
z Insert parallel pin (1).
1
6
40603-0

P04 39
z Correct overhang.
40604-0
z Place camshaft gear wheel on idler gear.

2
The marking (1) on the idler gear faces the

The markings (1) and (2) must be opposite
in line.
40605-1
06/2006
3/4
8188-001
Engine control
W 04-05-06
TCD 2015

A04 003

W 04-05-05
6
40601-0
06/2006
4/4
8188-001
Engine control
W 04-05-07
TCD 2015
Depth-measuring
appliance
W 01-02-02
W 02-02-02
W 03-08-01
W 03-09-04
W 04-06-03
W 05-07-03
W 06-06-04
W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
W 07-04-01 . . . . . . . . . . . . (Cylinder
A2-B3)
W 07-06-04
Special tools:
Turn-over gear . . . . . . . . . . . . . . 100350
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Counter support . . . . . . . . . . . . . 144150
Packing compound
DEUTZ DW 48
Locking agent
DEUTZ DW 72

to regulations.
Removing injection pump camshaft

z Remove impulse transmitter (camshaft).
W 05-07-03
W 07-04-01
W 07-04-01
W 03-08-01
W 06-06-04
40497-0

1
2
40458-0
06/2006
1/32
8189-001
Engine control
W 04-05-07
TCD 2015
6
40453-0

1

2
40517-0

40455-0
06/2006
2/32
8189-001
Engine control
W 04-05-07
TCD 2015
2
1
6
40456-0

1
2
40457-0
40459-0
06/2006
3/32
8189-001
Engine control
W 04-05-07
TCD 2015

z Remove cover (3).
3
6
40460-0


W 04-06-03
40417-0
z Loosen all screws (1).

40464-0
06/2006
4/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Turn over crankshaft until the valve overlap is
achieved on cylinder no. B2.
T01 63
The inlet valve starts opening,exhaust
valve closes.
6
40465-0
The locking pin of the turning gear must

snap into the tooth notch (1) of the starter
ring gear.
The second tooth notch (2) must face the
B-bank.
2
40466-0
Attention!
z Pull locking pin.
40590-0
06/2006
5/32
8189-001
Engine control
W 04-05-07
TCD 2015

z Remove gear wheel (2).
Attention!

W 04-06-03
6
40467-0
z Remove rocker arm brackets.

W 01-02-02
W 03-09-04
1
z Remove crankcase sealing ring (flywheel side)

W 02-02-02
40419-0
40420-0
06/2006
6/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Remove bolt (1).
6
40421-0
40422-0
40423-0
06/2006
7/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Remove bolt (1).

6
40424-0

z Remove gasket.
1
40468-0
40469-1
06/2006
8/32
8189-001
Engine control
W 04-05-07
TCD 2015
6
40470-0
z Mount turning gear (1).
40471-0

the A-bank.
40472-0
06/2006
9/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Loosen screw (1).
6
40473-0

40474-0

z Remove camshaft gear wheel (2)
Push back the camshaft carefully as far as
it goes.
2
45381-0
06/2006
10/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Pull out the injection pump camshaft carefully.
Attention!
Do not damage the camshaft and camshaft
bearing!
6
40475-0
40476-0
Installing injection pump camshaft

40993-0
06/2006
11/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Fasten screw (1).

z Pull out cover (2).
6
40994-0
z Oil camshaft bearing lightly.

z Oil cam shaft pin lightly.
z Insert the injection pump camshaft carefully.
40995-0
Attention!
Do not damage the camshaft and camshaft
bearing!
z Move the injection pump camshaft over the opposite
Use a suitable tool.
40996-0
06/2006
12/32
8189-001
Engine control
W 04-05-07
TCD 2015
6
40475-0

40997-0
z Mount cover (2).

40994-0
06/2006
13/32
8189-001
Engine control
W 04-05-07
TCD 2015

A04 005
6
40993-0
Installing camshaft gear wheel

1
Overview of the gear train and the markings of the control times:
Injection pump camshaft gear wheel (1)

Camshaft gear wheel (2)
Idler gear (3).
Crankshaft gear wheel (4)
Marking injection pump camshaft / idler

gear (5)
Marking camshaft / crankshaft (6)
6
40445-1

P04 39
z Correct overhang.
40431-0
06/2006
14/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Insert camshaft gear wheel.
Make sure that the parallel pin on the

camshaft gear wheel and the locating hole
on the camshaft are in line.
6
40474-0

z Fasten screw (1).
40473-0
z Turn the crankshaft evenly with the turning gear until
the counter holder blocks on the B-bank of the
crankcase (arrow).
40477-0
06/2006
15/32
8189-001
Engine control
W 04-05-07
TCD 2015

A04 001
6
40473-0

40474-0
Determining axial backlash of the camshaft

z Push back the camshaft as far as it goes.
z Measure the camshaft stand back from the lay-on
surface on the camshaft gear wheel to the crankcase
with the depth measuring appliance (arrows).
40478-0
06/2006
16/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Measure the flange height from the running surfaces
to the lay-on surface with the depth measuring appliance (arrows).
P04 35
Calculation example
Desired:
Axial backlash
Given:
Measured:
(a) = 45.80 mm
(b) = 45.50 mm
Calculation:
45.80 mm - 45.50 mm
Result:
= 0.30 mm
z Correct deviation with gaskets.
42273-2
P04 37
z Mount cover (2).
z Fit new sealing rings.

A04 002
40468-0

1
40435-0
06/2006
17/32
8189-001
Engine control
W 04-05-07
TCD 2015

6
40438-0
z Insert bolt (1).
40437-0

A04 013
Screw length:
M12 x 80 mm
40423-0
06/2006
18/32
8189-001
Engine control
W 04-05-07
TCD 2015
A04 012
6
40422-0

1
40435-0

1
40436-0
06/2006
19/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Insert bolt (1).
6
40439-0

A04 013
Screw length:
M12 x 100 mm
40420-0

A04 012
1
40419-0
06/2006
20/32
8189-001
Engine control
W 04-05-07
TCD 2015
idler gear (B-bank)
6
40440-0

P04 44
tooth flanks.
40441-0

idler gear (A-bank)
40442-0
06/2006
21/32
8189-001
Engine control
W 04-05-07
TCD 2015

P04 44
tooth flanks.
6
40443-0
z Position the injection pump camshaft.

The locating hole (arrow) faces upwards.
40444-0

40474-0
06/2006
22/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Remove turning gear (1).
6
40471-0
40470-0
z Position injection pump camshaft gear wheel.

The marking (1) faces the camshaft gear
wheel.
40446-0
06/2006
23/32
8189-001
Engine control
W 04-05-07
TCD 2015
z Insert the injection pump camshaft gear wheel in the

The marking on the gear wheel must be
between the markings of the injection
pump camshaft gear wheel (1).
40447-0
Attention!
1
40498-0

injection pump camshaft gear wheel
40449-0
06/2006
24/32
8189-001
Engine control
W 04-05-07
TCD 2015
P07 20
tooth flanks.
6
40450-0
z Install crankshaft sealing ring (flywheel side)

W 02-02-02
z Install connection housing.
W 03-09-04
Do not install the turbocharger.

W 04-06-03
40690-0
Attention!
40464-0
06/2006
25/32
8189-001
Engine control
W 04-05-07
TCD 2015

W 03-08-01
z Install rocker arm brackets.
W 01-02-02
z Check and set plunger lift of injection pumps.
W 07-06-04
6
40503-0

A04 004
40464-0

40989-0
06/2006
26/32
8189-001
Engine control
W 04-05-07
TCD 2015
bearing (arrow).

blade.
z Fasten screw (1).
P04 43
6
40512-0

bearing (arrow).
blade.
z Fasten screw (1).

P04 43
40513-0

A04 015
P04 43
1

wheel (arrows).
40514-0
06/2006
27/32
8189-001
Engine control
W 04-05-07
TCD 2015

6
40515-0

z Mount cover (2).
A04 022
40460-0
40459-0
06/2006
28/32
8189-001
Engine control
W 04-05-07
TCD 2015
Use packing compound DEUTZ DW 48.

z Mount holder (2).

A04 020
3
6
40516-0

A08 045
2
1
40456-0
z Mount holder (2).

A12 071
40455-0
06/2006
29/32
8189-001
Engine control
W 04-05-07
TCD 2015

1

A12 071
40517-0

A13 094
1
40453-0

A12 090
1
2
40458-0
06/2006
30/32
8189-001
Engine control
W 04-05-07
TCD 2015
W 07-04-01
W 07-04-01
z Install impulse transmitter (camshaft).
W 05-07-03
W 06-06-04
W 04-06-03
6
40518-0
06/2006
31/32
8189-001
Engine control
W 04-05-07
TCD 2015
06/2006
32/32
8189-001
Engine control
W 04-06-03
TCD 2015
The turning gear 100350 can be used at

the front end of the crankshaft depending
on the installation relations.

Special tools:
Turn-over gear . . . . . . . . . . . . . . 100300
Locking agent
DEUTZ DW 59
Attaching turning gear

z Remove cover (2).
z Remove gasket.
40461-0
z Insert turn-over gear (1).

z Insert centering pin (2) in threaded bore (3).
40462-0
06/2006
1/2
8190-001
Engine control
W 04-06-03
TCD 2015

A03 085
Gear wheel of the turning gear grips the
starter gear ring.
6
40463-0
Removing turning gear

z Remove turn-over gear.
40463-0

z Mount new gasket.
z Mount cover (2).
A03 085
40461-0
06/2006
2/2
8190-001
Speed control
W 05-07-01
TCD 2015
(crankshaft)
W 04-06-03
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Dial gauge adapter . . . . . . . . . . . 101830
Turn-over gear . . . . . . . . . . . . . . 100300
Read out error memory of the motor control timer with SERDIA.
Fitting compound
DEUTZ AP1908
Removing the impulse transmitter

W 04-06-03
z Unlock cable plug (1) and disconnect.
40710-0
40932-0
06/2006
1/6
8191-001
Speed control
W 05-07-01
TCD 2015

z Remove impulse transmitter (2).
z Remove seals.
6
40711-0

z Clean components.
45879-1
Installing the impulse transmitter

Through the installation opening of the
impulse transmitter, no bore (arrow) may
be visible on the flywheel.
45900-0
06/2006
2/6
8191-001
Speed control
W 05-07-01
TCD 2015
z Insert dial gauge in adapter (1).
6
45897-0
z Insert adapter with dial gauge under pre-tension in

the base plate (1).
z Fix dial gauge in adapter.
45898-0
z Insert and press in adapter with dial gauge into the

connection housing until it stops.
The stylus of the dial gauge must touch the
level flywheel surface.
z Note measured value.
z Make 120 orientation marks on the vibration damper.
Attention!
Remove adapter and dial gauge before

turning the crankshaft.
z Turn the crankshaft to the next 120 mark in direction
of rotation.
z Select lowest measured value of 3 measurements,
dimension (a).
06/2006
3/6
45899-0
8191-001
Speed control
W 05-07-01
TCD 2015
z Measure distance, dimension (b).

24
0,1
0,2
mm

z Calculate difference between dimension (a) and
dimension (b), dimension (y).
Calculation example
Desired:
Dimension (y)
Given:
Dial gauge adapter dimension = 24.00 mm
Measured:
Dimension (a) = dial gauge adapter dimension +
lowest measured value
Dimension (a) = 24.00 mm + 0.49 mm
Dimension (a) = 24.49 mm
Dimension (b) = 24.00 mm
Calculation:
Dimension (y) = dimension (a) - dimension (b)
Dimension (y) = 24.49 mm - 24.00 mm
Result:
Dimension (y) = 0.49 mm
45878-1
z Determine tightness of the impulse transmitter under

compliance with the permissible distance
dimension (c).
Calculation example
Desired:
Compliance with the permissible distance, dimension (c)
Gasket
Given:
MInimum distance dimension (c1) = 1.00 mm
Dimension (y)
Thickness of gasket = 0.30 mm
Measured:
Calculation:
Dimension (c) = minimum
distance dimension (c1) dimension (y) + thickness of the gasket
Dimension (c) = 1.00 mm - 0.49 mm + 0.50 mm
Dimension (c) = 1.01 mm
Result:
Dimension (c) corresponds to the permissible distance, therefore a gasket with a thickness of
0.50 mm must be used.
c
1
2
45904-0
z Permissible distance (c) between flywheel (1) and

impulse transmitter (2).
P05 91
06/2006
4/6
8191-001
Speed control
W 05-07-01
TCD 2015
z Select new gaskets.
Gaskets are available in thicknesses of 0.3
mm and 0.5 mm.
The correct distance (c) is reached by placing the appropriate number of gaskets
underneath.
6
45882-0
z Mount new gasket(s) according to the determined

distance.
z Press in impulse transmitter (2).
Attention!
Do not damage the component.
1
A05 011
2
40711-0
40932-0
06/2006
5/6
8191-001
Speed control
W 05-07-01
TCD 2015
z Plug cable plugs (1) together.


W 04-06-03
Delete error entry in the error memory of
the motor control timer with SERDIA.
2
6
40710-0
06/2006
6/6
8191-001
Speed control
W 05-07-03
TCD 2015
(camshaft)
W 04-06-03
W 06-06-04
Special tools:
Dial gauge adapter . . . . . . . . . . . 101830
Turn-over gear . . . . . . . . . . . . . . 100300
Fitting compound
DEUTZ AP 1908
Locking agent
DEUTZ DW 72
Removing the impulse transmitter

W 04-06-03
W 06-06-04
40700-0
40717-0
06/2006
1/8
8192-001
Speed control
W 05-07-03
TCD 2015
6
40718-0

40719-0

z Remove impulse transmitter (2).
z Remove seals.
1
40720-0
06/2006
2/8
8192-001
Speed control
W 05-07-03
TCD 2015
z Remove protective foil.
z Clean components.
6
00000-0
Installing the impulse transmitter

The pin (arrow) must be in the centre of the
installation opening.
45901-0
z Insert dial gauge in adapter (1).
45897-0
06/2006
3/8
8192-001
Speed control
W 05-07-03
TCD 2015
z Insert adapter with dial gauge under pre-tension in

the base plate (1).
z Fix dial gauge in adapter.
6
45898-0
z Insert and press in adapter with dial gauge into the

connection housing until it stops.
The stylus of the dial gauge must touch the
pin of the camshaft gear.
z Make 120 orientation marks on the vibration damper.
Attention!
Remove adapter and dial gauge before

turning the crankshaft.
z Turn the crankshaft to the next 120 mark in direction
of rotation.
z Select lowest measured value of 3 measurements,
dimension (a).
45902-0
z Measure distance, dimension (b).

24
0,1
0,2
mm

z Calculate difference between dimension (a) and
dimension (b), dimension (y).
Calculation example
Desired:
Dimension (y)
Given:
Dial gauge adapter dimension = 24.00 mm
Measured:
Dimension (a) = dial gauge adapter dimension +
lowest measured value
Dimension (a) = 24.00 mm + 0.76 mm
Dimension (a) = 24.76 mm
Dimension (b) = 23.90 mm
Calculation:
Dimension (y) = dimension (a) - dimension (b)
Dimension (y) = 24.76 mm - 23.90 mm
Result:
Dimension (y) = 0.86 mm
45878-1
06/2006
4/8
8192-001
Speed control
W 05-07-03
TCD 2015
z Determine tightness of the impulse transmitter under
compliance with the permissible distance
dimension (c).
Calculation example
Desired:
Compliance with the permissible distance, dimension (c)
Gasket
Given:
Minimum distance dimension (c1) = 0.30 mm
Dimension (y)
Measured:
Calculation:
Dimension (c) = minimum
distance dimension (c1) dimension (y) + thickness of the gasket
Dimension (c) = 0.30 mm 0.86 mm + (2x0.50 mm)
Dimension (c) = 0.44 mm
Result:
Dimension (c) corresponds to the permissible distance, therefore two gaskets with a thickness of
0.50 mm must be used.
c
1
2
45903-0
z Permissible distance (c) between camshaft gear

wheel (1) and impulse transmitter (2).
P05 92
z Select new gaskets.

Gaskets are available in thicknesses of 0.3
mm and 0.5 mm.
The correct distance (c) is reached by placing the appropriate number of gaskets
underneath.
45882-0
06/2006
5/8
8192-001
Speed control
W 05-07-03
TCD 2015

z Coat the O-ring (1) with fitting compound.
6
45878-2

1
z Wrap the cable plug in protective foil.
00000-0

z Mount new gasket(s) according to the determined
distance.
z Press in impulse transmitter (2).
Attention!
Do not damage the component!

A05 012
40720-0
06/2006
6/8
8192-001
Speed control
W 05-07-03
TCD 2015
z Mount cover (2).
z Tighten screws .
A04 022
1
6
40719-0
40718-0

1
40717-0
06/2006
7/8
8192-001
Speed control
W 05-07-03
TCD 2015

W 06-06-04
6
40716-0
06/2006
8/8
8192-001
Exhaust system/Charging
W 06-01-05
TCD 2015
Removing and installing exhaust line
(A-bank)
W 06-01-06 . . . . . . . . . . . . (A-bank)
Fitting compound
DEUTZ S1
Removing exhaust line

z Remove exhaust pipe (A-bank).
W 06-01-06
40722-0
z Loosen screws (1).
40723-0
06/2006
1/4
8193-001
W 06-01-05
TCD 2015

z Remove exhaust line (2).
2
45810-0

z Remove seals.
40725-0
40726-0
06/2006
2/4
8193-001
W 06-01-05
TCD 2015
Installing exhaust line
z Mount new gaskets.
The strap (arrow) must face the cylinder
head cover.
z Coat the screws with fitting compound .
6
45374-0
z Mount exhaust line (2).

2
45810-0
z Tighten all the screws (1) alternately from the centre

outwards.
A06 001
1
40986-0
06/2006
3/4
8193-001
W 06-01-05
TCD 2015
z Install exhaust pipe (A-bank).

W 06-01-06
6
40722-0
06/2006
4/4
8193-001
W 06-01-05
TCD 2015
Removing and installing exhaust line
(B-bank)
W 06-01-06 . . . . . . . . . . . . (B-bank)
Fitting compound
DEUTZ S1
Removing exhaust line

z Remove exhaust pipe (B-bank).
W 06-01-06
40727-0

z Remove exhaust line (2).
45809-0
06/2006
1/4
8194-001
W 06-01-05
TCD 2015

z Remove seals.
6
40730-0
40729-0
Installing exhaust line

The strap (arrow) must face the cylinder
head cover.
45375-0
06/2006
2/4
8194-001
W 06-01-05
TCD 2015
z Mount exhaust line (2).
6
45809-0
z Tighten all the screws (1) alternately from the centre

outwards.
A06 001
1
z Install exhaust pipe (B-bank).

W 06-01-06
40985-0
06/2006
3/4
8194-001
W 06-01-05
TCD 2015
06/2006
4/4
8194-001
W 06-01-06
TCD 2015
Removing and installing exhaust pipe
(A-bank)
Fitting compound
DEUTZ S1
Removing exhaust pipe

z Unscrew nuts (arrows).
z Remove screws.
z Remove exhaust pipe (2).
40733-0
Install exhaust pipe.
z Position exhaust pipe (1).

1
z Insert sealing ring.

The cone (arrow) faces the exhaust pipe.
z Mount flange (2) on exhaust manifold.
z Fasten screws (3).
3
36795-1
06/2006
1/2
8195-001
W 06-01-06
TCD 2015

1

z Mount flange (1) on exhaust line.
z Screw on nuts (3).
3
2
6
36796-1

A06 002
Ensure uniform distance (arrow) of flange
connection.
37216-1
z Tighten nuts (1) alternately.

A06 003
connection.
40736-0
06/2006
2/2
8195-001
W 06-01-06
TCD 2015
Removing and installing exhaust pipe
(B-bank)
Fitting compound
DEUTZ S1
Removing exhaust pipe

z Remove screws.
z Remove exhaust pipe (2).
40734-0
Install exhaust pipe.

z Position exhaust pipe (1).
1

z Mount flange (2) on exhaust manifold.
3
36799-1
06/2006
1/2
8196-001
W 06-01-06
TCD 2015

1

z Mount flange (1) on exhaust line.
3
36800-1

A06 002
connection.
37218-1

A06 003
connection.
40735-0
06/2006
2/2
8196-001
W 06-01-07
TCD 2015
W 06-01-06 . . . . . . . . . . . . (A-bank)
W 06-01-06 . . . . . . . . . . . . (B-bank)
W 06-06-04
Removing exhaust manifold

W 06-06-04
W 06-01-06
z Remove exhaust pipe (B-bank).
W 06-01-06
40731-0

z Remove exhaust manifold (2).
1
40732-0
06/2006
1/2
8197-001
W 06-01-07
TCD 2015
Installing exhaust manifold

z Mount exhaust manifold (2).
A06 010
6
40732-0

W 06-01-06
z Install exhaust pipe (B-bank).
W 06-01-06
W 06-06-04
40451-0
06/2006
2/2
8197-001
W 06-01-07
TCD 2015 Railway

(A-bank)
W 06-06-04 . . . . . . . . . . . . (A-bank)
Fitting compound
DEUTZ S1

z Remove turbocharger (A-bank).
W 06-06-04
z Unscrew nuts (1).
z Remove screws.
1
2
42079-1
z Unscrew nuts (1).

z Remove washers.
z Remove screws.
1
42081-2
06/2006
1/2
8198-001
W 06-01-07
TCD 2015 Railway

z Insert screws.
z Mount washers.
z Tighten nuts (1).

A06 010
6
42081-2
z Mount holder (2).

z Insert screws.
z Tighten nuts (1).
A06 034
z Install turbocharger (A-bank).
W 06-06-04
1
2
42079-1
06/2006
2/2
8198-001
W 06-01-07
TCD 2015 Railway

(B-bank)
W 06-06-04 . . . . . . . . . . . . (B-bank)
Fitting compound
DEUTZ S1

z Remove turbocharger (B-bank).
W 06-06-04
42080-1
z Unscrew nuts (1).

z Remove washers.
z Remove screws.
2
1
42082-2
06/2006
1/2
8199-001
W 06-01-07
TCD 2015 Railway

z Insert screws.
z Tighten nuts (1).
A06 010
1
42082-2
z Install turbocharger (B-bank).

W 06-06-04
42080-1
06/2006
2/2
8199-001
W 06-02-03
TCD 2015
Remove and install the charge air line
Fitting compound
DEUTZ AP1908
Remove charge air line

z Remove charge air pipe (2) with plug.
2
1
40764-0
z Pull out plug element (1).
40765-1
06/2006
1/4
8200-001
W 06-02-03
TCD 2015
z Unscrew nuts (1).

z Remove washers.
z Remove charge air manifold (2).
1
z Remove gasket.
6
45403-0
Install charge air line

z Mount new gasket.
z Mount charge air manifold (2).
z Mount washers and screw on nuts.

z Tighten nuts (1).
A06 046
45403-0
z Mount new O-rings (1).

1
40767-0
06/2006
2/4
8200-001
W 06-02-03
TCD 2015
z Insert plug element (1).
6
40768-1

z Mount charge air line.
z Tighten screws .
A06 030
Screw length:
M10 x 65 mm (1)
M10 x 85 mm (2)
40769-0
06/2006
3/4
8200-001
W 06-02-03
TCD 2015
06/2006
4/4
8200-001
W 06-02-05
TCD 2015
W 07-01-04
Removing connecting pipe

z Remove fuel pipes (flame glow plugs).
W 07-01-04
40737-0
40738-0
06/2006
1/10
8201-001
W 06-02-05
TCD 2015
z Unscrew nut (1).

Mark assignment of cables/connections
before removing.
z Remove cables (2) from both flame glow plugs.
6
40739-0
z Unscrew nuts (1).

1
z Remove screws.
40740-0

z Place cable harness to one side.
40741-0
06/2006
2/10
8201-001
W 06-02-05
TCD 2015
1
1
6
40742-0
z Unscrew nuts (1).

1
2
40743-0
z Unscrew nuts (1).

1
1
40744-0
06/2006
3/10
8201-001
W 06-02-05
TCD 2015
z Unscrew nuts (1).

2
1
6
40745-0
z Unscrew nuts (1).
40746-0
z Remove connecting pipe (1).

z Remove seals.
40747-0
06/2006
4/10
8201-001
W 06-02-05
TCD 2015
6
40748-0
Installing connecting pipe

z Mount connecting pipe (1).
40747-0
40746-0
06/2006
5/10
8201-001
W 06-02-05
TCD 2015
z Mount holder (2).

2
1
6
40745-0
z Mount holder (2).

1
1
40744-0
z Mount holder (2).

1
2
40743-0
06/2006
6/10
8201-001
W 06-02-05
TCD 2015
A06 056
1
1
6
40742-0
z Tighten nuts (arrows).

A06 033
40749-0
z Lay cable.
z Tighten screws .
A13 090
Screw length:
M8 x 20 mm (1)
M8 x 16 mm (2)
1
40750-0
06/2006
7/10
8201-001
W 06-02-05
TCD 2015

z Remove end plate.
z Remove gasket.
6
40751-0
z Mount new gasket.

z Mount end plate.
z Insert screws.
Screw length:
M10 x 45 mm (1)
M10 x 55 mm (2)
40752-0
z Mount holder (1).

A06 034
1
40950-0
06/2006
8/10
8201-001
W 06-02-05
TCD 2015
z Plug cables (2) to both flame glow plugs.
Attention!
Note assignment and polarity of the electrical connections!
1
Connect cables according to marks made

before removing.
z Mount washer.
z Tighten nut (1).
A13 035
6
40739-0
40738-0
z Install fuel pipes (flame glow plugs).

W 07-01-04
40737-0
06/2006
9/10
8201-001
W 06-02-05
TCD 2015
06/2006
10/10
8201-001
W 06-02-05
TCD 2015 Railway

W 07-01-04 . . . . . . . . . . . . (Railway)
Removing connecting pipe

45926-0

z Remove spring washer.
z Remove ground cable.
before removing.
45907-0
06/2006
1/10
8202-001
W 06-02-05
TCD 2015 Railway
z Remove fuel pipes (flame glow plugs), (Railway).

W 07-01-04
6
42025-2
z Unscrew nuts (1).

z Remove washers.
1
1
42185-2
z Remove cables (1).

before removing.
42192-2
06/2006
2/10
8202-001
W 06-02-05
TCD 2015 Railway

z Place fuel shut-off valve (2) to one side.
6
42186-1

z Place cable harness to one side.
42418-1

z Loosen the holder (2).
42419-1
06/2006
3/10
8202-001
W 06-02-05
TCD 2015 Railway
1
1
6
42501-1
z Unscrew nuts (1).

z Remove washers.
z Remove holder.
z Place cables to one side.
45850-0
z Unscrew all nuts (1).

z Remove connecting pipe (2).
z Remove gasket.
1
1
2
45851-1
06/2006
4/10
8202-001
W 06-02-05
TCD 2015 Railway

Installing connecting pipe
z Mount connecting pipe (1).
6
42421-1
z Mount washers.
z Mount holder (1).
z Screw on nuts.
45850-0
z Screw on all nuts (1).
45852-1
06/2006
5/10
8202-001
W 06-02-05
TCD 2015 Railway

A06 056
1
1
6
42501-1
z Tighten all nuts (1).

A06 033
45852-1
z Position holder (2).

A13 090
42419-1
06/2006
6/10
8202-001
W 06-02-05
TCD 2015 Railway

Attention!
Lay the cables free from chafing and tension.
A13 090
6
42418-1
z Mount fuel shut-off valve (2).

z Position pipe clamp.
z Fasten screw (1).
2
42186-1
z Position fuel shut-off valve.

P07 91
Note installation dimensions (X).
45909-0
06/2006
7/10
8202-001
W 06-02-05
TCD 2015 Railway
Attention!
z Connect plus cable (R3.1) to flame glow plug (1).
z Mount washers.
z Screw on nuts.
6
45928-0
z Tighten nuts (1).

A13 035
z Install fuel pipes (flame glow plugs), (Railway).
W 07-01-04
1
1
42185-2
z Connect ground cable.

z Mount spring washer.
A07 058
45907-0
06/2006
8/10
8202-001
W 06-02-05
TCD 2015 Railway

A13 090
6
42423-1

45926-0
06/2006
9/10
8202-001
W 06-02-05
TCD 2015 Railway
06/2006
10/10
8202-001
W 06-06-04
TCD 2015
Removing and installing the turbocharger
W 06-02-03
Special tools:
Special wrench . . . . . . . . . . . . . . 170100

to regulations.
Fitting compound
DEUTZ S1
Removing turbocharger
z Remove the charge air pipe.
W 06-02-03
40753-0
z Unscrew lock nuts (1) with special wrench.

z Remove screw-in nipple.
40754-0
06/2006
1/8
8203-001
W 06-06-04
TCD 2015

z Remove lubricating oil pipe (3).
2
3
6
40755-0

z Loosen hose clips (2).
1
40756-0
z Pull off pipe.

z Remove intake elbow (1).
1
40757-0
06/2006
2/8
8203-001
W 06-06-04
TCD 2015
6
40758-0
z Pull out oil return pipe (1).
40759-0

z Remove turbocharger (2).
40760-0
06/2006
3/8
8203-001
W 06-06-04
TCD 2015

z Remove oil return pipe (2).
z Remove gasket.
6
40761-0
40762-0
Installing the turbocharger

z Mount oil return pipe (2).

A08 044
40761-0
06/2006
4/8
8203-001
W 06-06-04
TCD 2015
z Mount turbocharger (2).
A06 020
6
40760-0
40759-0

A08 044
40758-0
06/2006
5/8
8203-001
W 06-06-04
TCD 2015
z Mount intake elbow (1).

1
z Insert pipe.
6
40757-0
z Position hose clips.

A03 064
A06 021

A03 069
45402-0
z Mount lubricating oil pipe (3).

z Position holder (2).
A08 079
45373-0
06/2006
6/8
8203-001
W 06-06-04
TCD 2015
z Tighten screw-in nipple.
z Tighten both lock nuts (1) with a special wrench.
A08 040
6
40763-0
z Install the charge air pipe.

W 06-02-03
40753-0
06/2006
7/8
8203-001
W 06-06-04
TCD 2015
06/2006
8/8
8203-001
W 06-06-04
TCD 2015 Railway

(A-bank)

to regulations.
Fitting compound
DEUTZ S1
z Loosen pipe clip (2).
42048-1
z Unscrew union nuts (1).

2
1
1
42049-1
06/2006
1/6
8204-001
W 06-06-04
TCD 2015 Railway

z Remove gasket.
6
42050-1

1
2
42051-2
z Pull off tubing connection (1).

z Pull off bleeding hose (2).
2
z Remove breather pipe (3).
3
1
42052-2
06/2006
2/6
8204-001
W 06-06-04
TCD 2015 Railway

6
42053-1
z Unscrew screw-in nipple (1).

z Remove sealing ring.
42054-1

z Mount new sealing ring.
z Tighten screw-in nipple (1).
A12 098
42054-1
06/2006
3/6
8204-001
W 06-06-04
TCD 2015 Railway

A06 020
6
42053-1
z Mount breather pipe (3).

z Plug in breather pipe (2).
2
z Plug in the tubing connection (1).
3
1
42052-3

A03 070
1

A06 024
2
42051-2
06/2006
4/6
8204-001
W 06-06-04
TCD 2015 Railway

z Mount new gasket.
A08 044
6
42050-1

z Screw on union nuts (1).
A12 082
2
1
1
42049-1

A08 045
42048-1
06/2006
5/6
8204-001
W 06-06-04
TCD 2015 Railway
06/2006
6/6
8204-001
W 06-06-04
TCD 2015 Railway

(B-bank)

to regulations.
Fitting compound
DEUTZ S1
1
2
1
42056-1

z Remove gasket.
42057-1
06/2006
1/6
8205-001
W 06-06-04
TCD 2015 Railway

1
6
42059-2
z Pull off tubing connection (1).

z Pull off bleeding hose (2).
z Remove breather pipe (3).
1
42058-2

42055-1
06/2006
2/6
8205-001
W 06-06-04
TCD 2015 Railway

6
42054-1

A12 098
42054-1

A06 020
1
42055-1
06/2006
3/6
8205-001
W 06-06-04
TCD 2015 Railway
z Mount breather pipe (3).

z Plug in breather pipe (2).
z Plug in the tubing connection (1).
1
42058-2

1
A03 070
A06 024
42059-2
z Mount new gasket.


A08 044
42057-1
06/2006
4/6
8205-001
W 06-06-04
TCD 2015 Railway

A12 082
1
2
1
42056-1
06/2006
5/6
8205-001
W 06-06-04
TCD 2015 Railway
06/2006
6/6
8205-001
W 06-07-03
TCD 2015
Removing and installing charge air pipe
(A-bank)
W 03-01-11
W 06-02-05
W 07-03-01 . . . . . . . . . . . . (A-bank)
Special tools:
Special wrench . . . . . . . . . . . . . . 110510
Removing charge air pipe

z Remove connecting pipe.
W 06-02-05
W 07-03-01
40552-0
z Removing the crankcase breather.

W 03-01-11
1
40553-0
06/2006
1/6
8206-001
W 06-07-03
TCD 2015

6
40554-0

40566-0
z Unscrew screws (1) with special wrench.

z Remove charge air pipe (3).

z Remove seals.
1
40567-0
06/2006
2/6
8206-001
W 06-07-03
TCD 2015
6
40568-0
Installing charge air pipe

1
z Turn in all screws (1) a few turns.

Screw length:
M8 x 65 mm
40574-0
z Insert charge air pipe.

Screw length:
M8 x 100 mm
1
40575-0
06/2006
3/6
8206-001
W 06-07-03
TCD 2015
z Mount spacing sleeve (arrow).

z Mount holder.
z Fasten screw (1).
Screw length:
M8 x 120 mm
6
40576-0

A12 071
40553-0
z Tighten screws (1) alternately with special wrench.

A06 030
40577-0
06/2006
4/6
8206-001
W 06-07-03
TCD 2015
A12 095
z Install crankcase breather.
W 03-01-11
6
40554-0

W 07-03-01
z Install connecting pipe.
W 06-02-05
40552-0
06/2006
5/6
8206-001
W 06-07-03
TCD 2015
06/2006
6/6
8206-001
W 06-07-03
TCD 2015
(B-bank)
W 06-02-05
W 07-03-01 . . . . . . . . . . . . (B-bank)
Special tools:
Special wrench . . . . . . . . . . . . . . 110510
Removing charge air pipe

z Remove connecting pipe.
W 06-02-05
W 07-03-01
40552-0
40569-0
06/2006
1/4
8207-001
W 06-07-03
TCD 2015
z Unscrew screws (1) with special wrench.

z Remove charge air pipe (3).

z Remove seals.
1
1
6
40570-0
40571-0
Installing charge air pipe

1
z Turn in all screws (1) a few turns.

Screw length:
M8 x 65 mm
40572-0
06/2006
2/4
8207-001
W 06-07-03
TCD 2015
z Insert charge air pipe.
Screw length:
M8 x 100 mm
6
40569-0
z Tighten screws (1) alternately with special wrench.

A06 030
1
1
1
1
40573-0

W 07-03-01
z Install connecting pipe.
W 06-02-05
40552-0
06/2006
3/4
8207-001
W 06-07-03
TCD 2015
06/2006
4/4
8207-001
Fuel system
W 07-01-02
TCD 2015
W 07-01-04
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts carefully. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
to regulations.
Removing flame glow plug

W 07-01-04
z Unscrew nut (1).

before removing.
40770-0
06/2006
1/4
8208-001
Fuel system
W 07-01-02
TCD 2015

z Unscrew flame glow plug (2).
z Remove gasket.
6
40771-0
40772-0
Installing flame glow plug

z Mount new gasket.
z Screw in flame glow plug.
P13 66
Note screw-in height dimension (X).
45404-0
06/2006
2/4
8208-001
Fuel system
W 07-01-02
TCD 2015
W 07-01-04
6
40773-0

A07 059
40774-0
z Plug in cable lug (2).
Attention!

2

before removing.
z Mount washer.
z Tighten nut (1).
A13 035
40775-0
06/2006
3/4
8208-001
Fuel system
W 07-01-02
TCD 2015
06/2006
4/4
8208-001
Fuel system
W 07-01-02
TCD 2015 Railway

W 07-01-04 . . . . . . . . . . . . (Railway)
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
before removing.
to regulations.
Removing flame glow plug

z Remove spring washer.
z Remove ground cable.
before removing.
45907-0
06/2006
1/6
8209-001
Fuel system
W 07-01-02
TCD 2015 Railway
z Remove fuel pipes (flame glow plugs), (Railway).

W 07-01-04
6
42025-2
z Unscrew nuts (1).

z Remove washers.
1
1
42185-2

before removing.
42192-2
06/2006
2/6
8209-001
Fuel system
W 07-01-02
TCD 2015 Railway

z Unscrew flame glow plug (1).
z Remove insulating washer (3).
2
3
6
42187-1
z Unscrew adapter (1).

42188-1
z Unscrew lock nut.

42191-2
06/2006
3/6
8209-001
Fuel system
W 07-01-02
TCD 2015 Railway
Installing flame glow plug

z Mount new gasket.
z Tighten adapter (1).
A07 057
1
6
42188-1
z Screw on lock nut.
42191-2
z Mount insulating washer (1).

z Screw in flame glow plug (2).
2
1
42187-2
06/2006
4/6
8209-001
Fuel system
W 07-01-02
TCD 2015 Railway

z Position flame glow plug.
P13 66
Note screw-in height dimension (X).
Screw-in nipple (1) faces crankshaft at a
right angle (90).
6
45911-0

A07 059
45927-0
Attention!
45928-0
06/2006
5/6
8209-001
Fuel system
W 07-01-02
TCD 2015 Railway
z Mount washers.
z Screw on nuts.
z Tighten nuts (1).
A13 035
z Install fuel pipes (flame glow plugs), (Railway).
W 07-01-04
6
42185-2
z Connect ground cable.

z Mount spring washer.
A07 058
45907-0
06/2006
6/6
8209-001
Fuel system
W 07-01-03
TCD 2015
Removing and installing fuel shut-off valve
(flame glow plugs)
Attention!

before removing.
to regulations.
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Removing fuel shut-off valve

1
40951-0
06/2006
1/6
8210-001
Fuel system
W 07-01-03
TCD 2015
z Hold screw-in nipple.

40776-0

z Remove spacing sleeve.
z Remove fuel shut-off valve (2).
z Remove pipe clamp.
40778-0

40779-0
06/2006
2/6
8210-001
Fuel system
W 07-01-03
TCD 2015
Installing fuel shut-off valve
1

A07 068
1
6
40779-0

40780-0
40781-0
06/2006
3/6
8210-001
Fuel system
W 07-01-03
TCD 2015
z Position spacing sleeve.

z Fasten screw (1).
6
40782-0

P07 91
45406-0

A07 093
1
40783-0
06/2006
4/6
8210-001
Fuel system
W 07-01-03
TCD 2015
z Position fuel pipe.
P07 92
Note installation angle, dimension (X).
X
6
45407-0
Attention!
Install fuel pipes tension free!
z Tighten lock nuts (1).
A07 018
40784-0
40951-0
06/2006
5/6
8210-001
Fuel system
W 07-01-03
TCD 2015
06/2006
6/6
8210-001
Fuel system
W 07-01-03
TCD 2015 Railway

Removing and installing fuel shut-off valve
(flame glow plugs)
Attention!

before removing.
to regulations.
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Removing fuel shut-off valve

42020-2
06/2006
1/6
8211-001
Fuel system
W 07-01-03
TCD 2015 Railway

Collect draining fuel and dispose of according to regulations.
z Seal hose pipe (2).
z Place hose pipe (2) to one side.
6
42021-1

1
42022-1

z Remove fuel shut-off valve (2).
z Remove pipe clamp.
1
2
42023-1
06/2006
2/6
8211-001
Fuel system
W 07-01-03
TCD 2015 Railway

6
45913-0
Installing fuel shut-off valve

A07 068
45912-0
1
42024-1
06/2006
3/6
8211-001
Fuel system
W 07-01-03
TCD 2015 Railway

z Fasten screw (1).
6
42023-2

P07 91
45909-0

A07 093
42023-2
06/2006
4/6
8211-001
Fuel system
W 07-01-03
TCD 2015 Railway

A07 018
Attention!
Install fuel pipes tension free!
6
42022-1
z Position hose pipe (2).
Attention!
Lay the hose pipe free from chafing and
tension.
A12 090
42021-1

42020-2
06/2006
5/6
8211-001
Fuel system
W 07-01-03
TCD 2015 Railway
06/2006
6/6
8211-001
Fuel system
W 07-01-04
TCD 2015
(flame glow plugs)
W 06-02-03
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
Attention!
before removing.
to regulations.
Removing fuel pipes

W 06-02-03
1

z Loosen pipe clip (2).
40785-0
06/2006
1/4
8212-001
Fuel system
W 07-01-04
TCD 2015
6
45378-0
z Remove fuel pipes (1).
45376-0
45377-0
06/2006
2/4
8212-001
Fuel system
W 07-01-04
TCD 2015
Installing fuel pipes
z Mount fuel pipes (1).
6
45376-0
45378-0

z Fasten screw (1).
40785-0
06/2006
3/4
8212-001
Fuel system
W 07-01-04
TCD 2015

A12 080
Attention!
Install fuel pipe tension free.
1
6
40952-0

A12 080
Attention!
40789-0

A07 044
W 06-02-03
45379-0
06/2006
4/4
8212-001
Fuel system
W 07-01-04
TCD 2015 Railway

(flame glow plugs)
Danger!
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160

Attention!
before removing.
to regulations.
Removing fuel pipes

z Loosen pipe clip.
42025-1
06/2006
1/4
8213-001
Fuel system
W 07-01-04
TCD 2015 Railway

6
42026-1

1
42028-1

z Remove distributor (2).
42029-1
06/2006
2/4
8213-001
Fuel system
W 07-01-04
TCD 2015 Railway

z Mount distributor (2).
6
42029-1

1
42028-1

42026-1
06/2006
3/4
8213-001
Fuel system
W 07-01-04
TCD 2015 Railway
Attention!
A12 080
6
42027-1
Attention!
A12 080
A07 018
2
42030-1
z Position pipe clip.

A07 044
z Lay cable harness and fix with cable tie (1).
42025-1
06/2006
4/4
8213-001
Fuel system
W 07-03-01
TCD 2015
Renewing injection pipes
(A-bank)
Danger!

Dog wrench. . . . . . . . . . . . . . . . . . . 8018

Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
before removing.
to regulations.
Injection pipes may not be bent.
Removing injection pipes

z Remove gasket.
2
40627-0
06/2006
1/6
8214-001
Fuel system
W 07-03-01
TCD 2015

1
2
6
40792-0
z Unscrew lock nuts (1) with dog wrench.

z Remove injection line.
Note cylinder assignment.
40793-0

z Renew damaged profile washers.
40796-0
06/2006
2/6
8214-001
Fuel system
W 07-03-01
TCD 2015
Installing injection pipes
z Mount new injection pipe.
Attention!
Install injection pipes without tension!
Note assignment and installation position

of the injection lines.
6
40793-0
z Oil the injection pipe in the area of the profile

washer (1).
z Position profile washer (1).
The profile washer must be at the upper
web (arrow) of the cylinder head cowling.
1
40634-0
z Tighten lock nuts (1) with dog wrench.

A07 003
40800-0
06/2006
3/6
8214-001
Fuel system
W 07-03-01
TCD 2015

A07 003
6
40801-0

A07 006
1
2
40792-0

1

40802-0
06/2006
4/6
8214-001
Fuel system
W 07-03-01
TCD 2015
6
40803-0

A01 005
40804-0
06/2006
5/6
8214-001
Fuel system
W 07-03-01
TCD 2015
06/2006
6/6
8214-001
Fuel system
W 07-03-01
TCD 2015
Renewing injection pipes
(B-bank)
Dog wrench. . . . . . . . . . . . . . . . . . . 8018
W 06-02-03
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Danger!
Attention!
before removing.
to regulations.
Injection pipes may not be bent.
Removing injection pipes

W 06-02-03
z Remove gasket.
40791-0
06/2006
1/6
8215-001
Fuel system
W 07-03-01
TCD 2015

1
6
40794-0
z Unscrew lock nuts (1) with dog wrench.

z Remove injection line.
40795-0

z Renew damaged profile washers.
40796-0
06/2006
2/6
8215-001
Fuel system
W 07-03-01
TCD 2015
Installing injection pipes
z Mount new injection pipe.
Attention!
Install injection pipes without tension!

Note assignment and installation position
of the injection lines.
6
40795-0
z Oil the injection pipe in the area of the profile

washer (1).
z Position profile washer (1).
The profile washer must be at the upper
web (arrow) of the cylinder head cowling.
1
40634-0

A07 003
40797-0
06/2006
3/6
8215-001
Fuel system
W 07-03-01
TCD 2015

A07 003
6
40798-0

A07 006
40794-0

40635-0
06/2006
4/6
8215-001
Fuel system
W 07-03-01
TCD 2015
6
40636-0

A01 005
W 06-02-03
40637-0
06/2006
5/6
8215-001
Fuel system
W 07-03-01
TCD 2015
06/2006
6/6
8215-001
Fuel system
W 07-04-01
TCD 2015
Removing and installating injection pumps.
(Cylinder A1)
W 04-06-03
W 06-07-03 . . . . . . . . . . . . (A-bank)
W 07-10-06
W 07-10-06 . . . . . . . . . . . . (Railway)
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
Locking agent
DEUTZ DW 59

before removing.
to regulations.
Removing the fuel injector pump

W 06-07-03
40552-0
06/2006
1/10
8216-001
Fuel system
W 07-04-01
TCD 2015

40808-0

1
2
40520-0
z Unscrew nut (1).

1
2
40521-0
06/2006
2/10
8216-001
Fuel system
W 07-04-01
TCD 2015

1
2
6
40522-0

z Pull off cables (2).
1
2
40809-0

Loosen screws evenly to avoid jamming
the injection pump.
z Remove fuel injector pump(2).
1

45386-0
06/2006
3/10
8216-001
Fuel system
W 07-04-01
TCD 2015
z Pull out roller tappet (1).
Attention!
Do not damage the roller tappet!

6
40810-0
40807-0
Removing injection pump housing

z Remove fuel pipes.
W 07-10-06
z Remove fuel pipes (Railway).
W 07-10-06

z Remove injection pump housing (2).
45387-0
06/2006
4/10
8216-001
Fuel system
W 07-04-01
TCD 2015
6
40812-0
Installing injection pump housing

45390-1
z Oil the shank of the injection pump housing lightly.

z Press the injection pump housing into the stop in the
crankcase.
The pilot pin (1) must lock in
groove (arrow).
1
40813-0
06/2006
5/10
8216-001
Fuel system
W 07-04-01
TCD 2015

A07 009
6
45388-0
z Install fuel pipes.

W 07-10-06
z Install fuel pipes (Railway).
W 07-10-06
1
Do not install fuel pipe (1).

Do not install charge air pipe (A-bank).
45391-0
Installing the fuel injector pump

Note the assignment of the injection pump/
roller tappet when replacing the injection
pump and/or roller tappet.
40807-0
06/2006
6/10
8216-001
Fuel system
W 07-04-01
TCD 2015
W 04-06-03
z Turn the injection pump camshaft with the turning
gear until the cam for the injection pump is on the
cam base circle (arrow).
6
42163-1
z Oil the roller tappet lightly.

z Insert roller tappet.
groove (arrow).
1
42164-1

z Oil O-rings lightly.
42165-2
06/2006
7/10
8216-001
Fuel system
W 07-04-01
TCD 2015
z Insert injection pump (1).

The cable connections (3) of the injection
pumps must face the genset support.

6
40954-0

A07 012
Attention!
Do not turn the camshaft until all the injection pumps are installed. Danger of breaking the tappet!
1
40953-0
z Plug in cables (2).

T13 054
Note assignment!

A13 054
1
2
40809-0
06/2006
8/10
8216-001
Fuel system
W 07-04-01
TCD 2015
1
2
6
40522-0

z Mount holder (2).
z Screw on nut (1).
1
2
40521-0

z Mount holder (2).
z Fasten screw (1).
1
2
40520-0
06/2006
9/10
8216-001
Fuel system
W 07-04-01
TCD 2015

A12 093
z Tighten nut (2).
A07 044
2
6
40565-0

A07 044
A12 092
1
2
40555-0
z Mount holder (2).

A07 044
W 06-07-03
W 04-06-03
2

1
40808-0
06/2006
10/10
8216-001
Fuel system
W 07-04-01
TCD 2015
Removing and installing injection pumps
(Cylinder A2-B3)
W 03-01-11
W 04-06-03
W 07-03-01 . . . . . . . . . . . . (A-bank)
W 07-03-01 . . . . . . . . . . . . (B-bank)
W 07-10-06
W 07-10-06 . . . . . . . . . . . . (Railway)
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Locking agent
DEUTZ DW 59
Attention!
before removing.
to regulations.
Removing injection pumps

W 03-01-11
W 07-03-01
W 07-03-01
40554-0
06/2006
1/8
8217-001
Fuel system
W 07-04-01
TCD 2015

z Pull off cables (2).
1
2
6
45384-0

Loosen screws evenly to avoid jamming
the injection pump.
z Remove fuel injector pump(2).
40805-0
z Pull out roller tappet (1).
Attention!
Do not damage the roller tappet!
1

40806-0
06/2006
2/8
8217-001
Fuel system
W 07-04-01
TCD 2015
6
40807-0
Removing injection pump housing

z Remove fuel pipes.
W 07-10-06
W 07-10-06

z Remove injection pump housing (2).
40811-0
40812-0
06/2006
3/8
8217-001
Fuel system
W 07-04-01
TCD 2015
Installing injection pump housing

6
42159-2
The injection pump housings differ.

Mount the injection pump housing with the
bevel (arrow) on the B-bank.
42160-1
z Oil the shank of the injection pump housing lightly.

z Press the injection pump housing into the stop in the
crankcase.
groove (arrow).
1
45389-0
06/2006
4/8
8217-001
Fuel system
W 07-04-01
TCD 2015
A07 009
z Install fuel pipes.
W 07-10-06
W 07-10-06
6
40814-0
Installing injection pumps

Note the assignment of the injection pump/
roller tappet when replacing the injection
pump and/or roller tappet.
40807-0

W 04-06-03
z Turn the injection pump camshaft with the turning
gear until the cam for the injection pump is on the
cam base circle (arrow).
42163-1
06/2006
5/8
8217-001
Fuel system
W 07-04-01
TCD 2015

groove (arrow).
1
6
42164-1

z Oil O-rings lightly.
42165-2
z Insert injection pump (1).

Note assignment!
A-bank:
pumps must face the genset support.
B-bank:

pumps must face the flywheel.
45382-0
06/2006
6/8
8217-001
Fuel system
W 07-04-01
TCD 2015
A07 012
Attention!
Do not turn the camshaft until all the injection pumps are installed. Danger of breaking the tappet!
6
45383-0

T13 054
Note assignment!

A13 054
1
2
45384-0

A12 095
40554-0
06/2006
7/8
8217-001
Fuel system
W 07-04-01
TCD 2015

W 07-03-01
W 07-03-01
W 03-01-11
W 04-06-03
6
40956-0
06/2006
8/8
8217-001
Fuel system
W 07-06-04
TCD 2015
Checking and setting plunger lift of injection pumps
Feeler gauges
W 04-06-03
W 06-06-04
W 06-06-04 . . . . . . . . . . . . (A-bank,
Railway)
W 06-06-04 . . . . . . . . . . . . (B-bank,
Railway)
W 07-04-01 . . . . . . . . . . . . (Cylinder A1)
W 07-04-01 . . . . . . . . . . . . (Cylinder
A2-B3)
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100410
Dial gauge holder
with stylus extension. . . . . . . . . . 103240
Measuring pin . . . . . . . . . . . . . . . 110180
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Packing compound
DEUTZ DW 48
Locking agent
DEUTZ DW 72
Attention!
before removing.
to regulations.
Checking plunger lift of injection pumps

W 07-04-01
W 07-04-01
Do not remove injection pump housing.

W 04-06-03
40495-0
06/2006
1/14
8218-001
Fuel system
W 07-06-04
TCD 2015

T01 63
Inlet valves begin to open and exhaust valves close.
Observe valve clearance setting diagram.
6
40465-0
In case of valve overlap of cylinder no. B2:

snap into the tooth notch (1) of the starter
ring gear.
The second tooth notch (2) must face the
B-bank.
2
40466-0
z Pull locking pin (1).

z Turn crankshaft in the opposite direction to the engine rotation (arrow) a turn with the turning gear.
1
40501-0
06/2006
2/14
8218-001
Fuel system
W 07-06-04
TCD 2015
1
2
6
40458-0
The injection pump cams for cylinder

no. A1 must be on the base circle (arrow).
42163-1

Note the assignment of the roller tappet.
groove (arrow).
1
42164-1
06/2006
3/14
8218-001
Fuel system
W 07-06-04
TCD 2015
z Mount dial gauge holder (1).

A07 012
1
2
6
40499-0
z Insert dial gauge holder (1) with stylus extension.

z Mount stylus with 6 mm pre-tension on the roller tappet.
z Turn the crankshaft alternately in and against engine
direction.
z Check installation position of the dial gauge.
Dial gauge must run on the base circle of

the injection camshaft.
The display of the dial gauge may not
move.
40500-0
z Set crankshaft with turning gear in engine direction of

rotation (arrow) to ignition TDC, cylinder no. A1.
snap into the starter gear ring.
40502-0
06/2006
4/14
8218-001
Fuel system
W 07-06-04
TCD 2015
z Read and note the measured value.
P07 19
6
40503-0
Setting plunger lift of injection pumps

All injection pumps must be removed.
1
W 06-06-04
z Remove turbocharger (A-bank, Railway).
W 06-06-04
z Remove turbocharger (B-bank, Railway).
W 06-06-04
40504-0

1

2
40517-0
06/2006
5/14
8218-001
Fuel system
W 07-06-04
TCD 2015

6
40506-0

2
1
40456-0

40507-0
06/2006
6/14
8218-001
Fuel system
W 07-06-04
TCD 2015
6
40459-0

z Remove cover (3).
3
40460-0

40508-0
06/2006
7/14
8218-001
Fuel system
W 07-06-04
TCD 2015
z Loosen all screws (1).
6
40464-0
z Pull locking pin (1).

z Turn crankshaft in the opposite direction to the engine rotation (arrow) a turn with the turning gear.
1
Dial gauge must read "0" again.
40501-0
z Set crankshaft with turning gear in engine direction of

rotation (arrow) to ignition TDC, cylinder no. A1.
snap into the starter gear ring.
40502-0
06/2006
8/14
8218-001
Fuel system
W 07-06-04
TCD 2015
z Turn the injection pump camshaft with the screws in
engine direction of rotation (arrow) until the prescribed plunger lift is reached.
P07 19
6
40509-0
z Pre-tighten screws (1).

A04 004
When pre-tightening the screws, press the
gear wheel lightly in the opposite direction
to engine rotation (arrow) against the tooth
flanks.
z Check the setting of the plunger lift again.
40510-0

z Remove dial gauge holder.
40511-0
06/2006
9/14
8218-001
Fuel system
W 07-06-04
TCD 2015

A04 004
z Pull locking pin.
6
40464-0

40989-0

bearing (arrow).

blade.
z Fasten screw (1).
P04 43
40512-0
06/2006
10/14
8218-001
Fuel system
W 07-06-04
TCD 2015
bearing (arrow).
blade.
z Fasten screw (1).

P04 43
6
40513-0

A04 015
P04 43
1

wheel (arrows).
40514-0

40515-0
06/2006
11/14
8218-001
Fuel system
W 07-06-04
TCD 2015

z Mount cover (2).
Insert screws with safety agent
DEUTZ DW 72.
3
A04 022
6
40460-0
z Fix cables with cable ties (1).
40459-0

z Mount holder (2).
A04 020
1
40516-0
06/2006
12/14
8218-001
Fuel system
W 07-06-04
TCD 2015
A08 045
2
6
40456-0
z Mount holder (2).

A12 071
40455-0

1

A12 071
2
40517-0
06/2006
13/14
8218-001
Fuel system
W 07-06-04
TCD 2015

A13 094
1
W 06-06-04
z Install turbocharger (A-bank, Railway).
W 06-06-04
z Install turbocharger (B-bank, Railway).
W 06-06-04
6
40453-0

A12 090
1
2
40458-0

W 07-04-01
W 07-04-01
W 04-06-03
40518-0
06/2006
14/14
8218-001
Fuel system
W 07-07-01
TCD 2015
Assembly pliers. . . . . . . . . . . . . . . . 8024
W 07-03-01 . . . . . . . . . . . . (A-bank)
W 07-03-01 . . . . . . . . . . . . (B-bank)
W 07-07-05
Special tools:
Puller. . . . . . . . . . . . . . . . . . . . . . 110030
Grooved nut wrench . . . . . . . . . . 110130
Disassembly tool. . . . . . . . . . . . . 110901
Extraction tool . . . . . . . . . . . . . . . 120660
Slide hammer . . . . . . . . . . . . . . . 150800
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Danger!
Attention!
before removing.
to regulations.
Fitting compound
DEUTZ S1
Removing fuel injector

W 07-03-01
W 07-03-01
40957-0
06/2006
1/6
8219-001
Fuel system
W 07-07-01
TCD 2015
z Unscrew union screw with grooved nut wrench.
6
40643-0
z Pull out fuel injector (1) and sealing ring (arrow).
40815-0
Removing stuck fuel injectors

z Assembly sliding hammer (1) and puller (2).
1
2
3
40958-0
06/2006
2/6
8219-001
Fuel system
W 07-07-01
TCD 2015
z Mount sliding hammer on fuel injector.
z Pull out stuck fuel injector.
6
40816-0
z Grip a tight sealing ring (1) with the assembly

pliers (2) and pull off, turning slightly.
Attention!
Do not damage the nozzle tip!
1
2
43303-0
Removing a tightly fixed sealing ring from

the cylinder head
z Insert extraction device (1).
The holders (arrow) must sit in the bore of
the sealing ring.
45419-0
06/2006
3/6
8219-001
Fuel system
W 07-07-01
TCD 2015
z Turn in the spindle.

The sealing ring must be fixed on the puller.
Hold puller on hexagon.
z Mount adapter (1) and slide hammer (2) on extraction device.

z Remove tight sealing ring.
2
6
45420-0
z Remove the O-ring (1) with the disassembly tool.

1
40607-1

z Check the fuel injector.
W 07-07-05
45414-0
06/2006
4/6
8219-001
Fuel system
W 07-07-01
TCD 2015
Installing the fuel injector
z Insert new O-ring (arrow).
z Coat the thread (1) with fitting compound.
6
40818-0
z Coat the nozzle holder shaft in the (X) area with fitting compound.
z Coat the lay-on surface of the sealing ring (arrow)
with fitting compound.
z Mount new sealing ring (1) on fuel injector.

1
40819-0
z Push the union screw (1) in the direction of the arrow.
Attention!
Do not damage the O-ring!
40820-0
06/2006
5/6
8219-001
Fuel system
W 07-07-01
TCD 2015
z Insert fuel injector.

z Tighten union screw with grooved nut wrench.
A07 001
6
40643-0

W 07-03-01
W 07-03-01
40957-0
06/2006
6/6
8219-001
Fuel system
W 07-07-02
TCD 2015
W 07-07-01
W 07-07-05
Special tools:
Holder . . . . . . . . . . . . . . . . . . . . . 110110
Dismantling fuel injector

W 07-07-01
z Check and set fuel injectors.
W 07-07-05
z Insert fuel injector in holder.
z Unscrew nozzle cap nut with socket wrench insert.
36271-2
z Dismantle fuel injector.

6

Shim (1)
Compression spring (2)
Thrust bolt (3)
Intermediate piece (4)

Injection nozzle (5)
Nozzle cap nut (6)
z Clean the parts in clean diesel fuel.
z Blow components dry with air.
36269-2
06/2006
1/6
8220-001
Fuel system
W 07-07-02
TCD 2015
Assembling fuel injector

z Check injection nozzle.
Attention!
Do not touch the nozzle needle with your
fingers!
Nozzle needle (1) and nozzle body (2) are
folded together and may not be switched or
changed individually!
1
2
6
33904-2
The nozzle needle (1) must slide slowly

and without jolting into its seat by the force
of its own weight with the nozzle body (2)
held vertically.
In case of abrupt sliding of the nozzle
needle, clean the injection nozzle again in
the diesel bath, renew if necessary.
1
2
Also clean the new injection nozzle in the

clean diesel bath.
33904-2
z Visually inspect the seat surfaces of the intermediate

piece for wear.
Make sure the centering pins (arrows) are
in place.
33905-2
06/2006
2/6
8220-001
Fuel system
W 07-07-02
TCD 2015
z Select shim for setting the opening pressure.
The opening pressure depends on the
thickness of the shim.
A thicker shim gives a higher opening pressure.
z Insert shim.
6
36274-2
z Insert compression spring.
33907-2
z Insert thrust bolt.
33908-2
06/2006
3/6
8220-001
Fuel system
W 07-07-02
TCD 2015
z Insert intermediate piece with the centering pins in

the bores of the nozzle holder.
The countersink must face the thrust bolt.
6
33909-2
z Mount the injection nozzle with the centre bores on

the centering pins of the intermediate piece.
The nozzle needle may not fall out of the
nozzle body.
33910-2
z Screw on the nozzle cap nut.
33911-2
06/2006
4/6
8220-001
Fuel system
W 07-07-02
TCD 2015
z Tighten nozzle cap nut.
A07 002
z Remove fuel injector from holder.
z Check and set fuel injectors.
W 07-07-05
W 07-07-01
6
33912-2
06/2006
5/6
8220-001
Fuel system
W 07-07-02
TCD 2015
06/2006
6/6
8220-001
Fuel system
W 07-07-05
TCD 2015
Nozzle tester. . . . . . . . . . . . . . . . . . 8008
W 07-07-01
W 07-07-02
Special tools:
Holder . . . . . . . . . . . . . . . . . . . . . 110110
Danger!
Danger of injury when handling the nozzle
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
with diesel fuel/test oil. Then it is no longer
possible to actuate the hand lever.
The nozzle cap nut must be loosened carefully 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.

W 07-07-01
45414-0
06/2006
1/6
8221-001
Fuel system
W 07-07-05
TCD 2015
Connecting the fuel injector to the nozzle

tester
z Insert fuel injector in holder.
z Loosen nozzle cap nut approx. 180 with socket
wrench insert (release pressure) and re-tighten.
A07 002
6
36271-2
z Connect the fuel injector to the nozzle tester
35889-2
Checking opening pressure

z Press down the lever of the nozzle tester slowly with
the pressure gauge connected.
The pressure at which the pointer stands
still or suddenly drops is the opening pressure.
Repeat test 3 times.
36293-2
06/2006
2/6
8221-001
Fuel system
W 07-07-05
TCD 2015
z Compare measured values.
P07 52
The measured values of three tests must
match the test value.
z In case of deviations from the test value, the fuel injector must be dismantled or exchanged.
W 07-07-02
6
36293-2
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.
36293-2
Injection nozzle is tight if it does not drip

within 10 seconds.
36294-2
06/2006
3/6
8221-001
Fuel system
W 07-07-05
TCD 2015
z If the injection nozzle drips, the fuel injector must be

dismantled or exchanged.
W 07-07-02
Attention!
Repairs are not permitted!
6
36295-2
Checking the easy action of the nozzle

needle
z Switch off the testers 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.
36296-2
z If the injection nozzle does not buzz audibly, it must

be dismantled and cleaned.
W 07-07-02
The injection nozzle must be changed if it
does not buzz after cleaning.
The jet profile may deviate considerably
from that of a new fuel injector.
36296-2
06/2006
4/6
8221-001
Fuel system
W 07-07-05
TCD 2015
Removing the fuel injector from the nozzle
tester
z Loosen nozzle cap nut approx. 180 with socket
wrench insert (release pressure) and re-tighten.
A07 002
Attention!
The pressure in the spring space must be
reduced before installing the fuel injectors.
W 07-07-01
6
36271-2
06/2006
5/6
8221-001
Fuel system
W 07-07-05
TCD 2015
06/2006
6/6
8221-001
Fuel system
W 07-09-01
TCD 2015
W 06-07-03 . . . . . . . . . . . . (B-bank)
Attention!
before removing.
to regulations.
Removing temperaure transmitter

W 06-07-03
40822-0
06/2006
1/4
8222-001
Fuel system
W 07-09-01
TCD 2015
6
40823-0
z Unscrew temperature transmitter (1).
40824-0
40825-0
06/2006
2/4
8222-001
Fuel system
W 07-09-01
TCD 2015
Installing temperature transmitter
z Tighten temperature transmitter (1).
A07 023
6
40824-0
40823-0

W 06-07-03
40822-0
06/2006
3/4
8222-001
Fuel system
W 07-09-01
TCD 2015
06/2006
4/4
8222-001
Fuel system
W 07-10-06
TCD 2015
W 06-07-03 . . . . . . . . . . . . (A-bank)
W 06-07-03 . . . . . . . . . . . . (B-bank)
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
before removing.
to regulations.
Removing fuel pipes

W 06-07-03
W 06-07-03
40606-0
06/2006
1/14
8223-001
Fuel system
W 07-10-06
TCD 2015

z Pull the cables (2) off all injection pumps.
before removing.
1
2
6
45384-0

40608-0
40609-0
06/2006
2/14
8223-001
Fuel system
W 07-10-06
TCD 2015
6
40610-0
40611-0
z Unscrew nuts (1).

z Unscrew the nuts (2).
z Remove washers.
z Remove cables.
before removing.
z Place cable harness rail with cable harness to one

side.
40612-0
06/2006
3/14
8223-001
Fuel system
W 07-10-06
TCD 2015

2
1
6
40613-0

1
2
40623-0
z Unscrew nut (1).

40614-0
06/2006
4/14
8223-001
Fuel system
W 07-10-06
TCD 2015

1
2
6
40615-0

1
40616-0
z Unscrew nuts (1).

40617-0
06/2006
5/14
8223-001
Fuel system
W 07-10-06
TCD 2015

6
40618-0

z Remove seals.
1
40619-0
40620-0
06/2006
6/14
8223-001
Fuel system
W 07-10-06
TCD 2015
z Mount new gaskets (1).
1
6
40621-0
Note assignment!
The lug (1) must lock in groove (2).
42115-1

A07 015
Do not move the gaskets when mounting
the fuel pipes.
40619-0
06/2006
7/14
8223-001
Fuel system
W 07-10-06
TCD 2015

6
40618-0

z Mount holder (2).
z Tighten nuts (1).
A07 044
40617-0

A07 066
40622-0
06/2006
8/14
8223-001
Fuel system
W 07-10-06
TCD 2015
A12 090
6
40616-0

1
2
40615-0

z Mount holder (2).
z Screw on nut (1).
1
40614-0
06/2006
9/14
8223-001
Fuel system
W 07-10-06
TCD 2015

z Mount holder (2).
z Fasten screw (1).
6
40623-0

A12 093
1
z Tighten nut (2).

A07 044
40625-0

A07 044
A12 092
40624-0
06/2006
10/14
8223-001
Fuel system
W 07-10-06
TCD 2015
z Mount holder (2).
A07 044
2
1
6
40613-0

z Plug cables.
Attention!

before removing.
z Mount washers.
z Tighten nuts (1).
A13 037
z Tighten nuts (2).
A13 038
40612-0

A13 094
40611-0
06/2006
11/14
8223-001
Fuel system
W 07-10-06
TCD 2015
6
40610-0
40609-0
z Plug together the cable plugs (2).

40608-0
06/2006
12/14
8223-001
Fuel system
W 07-10-06
TCD 2015
Clamp all injection pumps.

T13 054
A13 054
1
2
6
45384-0

W 06-07-03
W 06-07-03
40495-0
06/2006
13/14
8223-001
Fuel system
W 07-10-06
TCD 2015
06/2006
14/14
8223-001
Fuel system
W 07-10-06
TCD 2015 Railway

Attention!

before removing.
to regulations.
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Removing fuel pipes

before removing.
z Remove cables.
42107-2
06/2006
1/6
8224-001
Fuel system
W 07-10-06
TCD 2015 Railway

1
2
6
42108-1

1
45854-0

z Place cable harness rail with cable harness to one
side.
42110-1
06/2006
2/6
8224-001
Fuel system
W 07-10-06
TCD 2015 Railway

1
2
6
42112-1

z Remove seals.
2
1
45856-1
40620-0
06/2006
3/6
8224-001
Fuel system
W 07-10-06
TCD 2015 Railway

z Mount new gaskets (1).
6
42114-2
Note assignment!
The lug (1) must lock in groove (2).
42115-1

A07 015
Do not move the gaskets when mounting
the fuel pipes.
2
1
45856-1
06/2006
4/6
8224-001
Fuel system
W 07-10-06
TCD 2015 Railway

z Mount hose line (2).
1
2
6
42112-1

z Position pipe clamp (arrow).
z Fasten screws.
M6 x 12 mm (1)
1
M6 x 16 mm (2)
z Tighten screws .
A13 094
2
42111-1
z Position hose line (1).

Observe installation angle dimension X =
10.

A12 090
2
45910-2
06/2006
5/6
8224-001
Fuel system
W 07-10-06
TCD 2015 Railway

45854-0

z Fix cable with cable tie (2).
1
2
42108-1
Clamp all injection pumps.

T13 054
Attention!

before removing.
z Tighten screws .
A13 054
45858-0
06/2006
6/6
8224-001
Fuel system
W 07-11-01
TCD 2015
Attention!


before removing.
to regulations.
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Removing the fuel supply pump

40827-0
06/2006
1/6
8225-001
Fuel system
W 07-11-01
TCD 2015
z Unscrew hollow screws (1).

6
40828-0

z Remove lubricating oil pipe.
40829-0

z Remove fuel supply pump (2).
40830-0
06/2006
2/6
8225-001
Fuel system
W 07-11-01
TCD 2015
6
40961-0
Installing the fuel supply pump

42286-2
z Install fuel pump.

z Insert the driver (1) in the groove (2).
40831-0
06/2006
3/6
8225-001
Fuel system
W 07-11-01
TCD 2015

A07 024
6
40832-0

z Mount the lubricating oil pipe.

A08 014
A08 013
2
40829-0

z Tighten hollow screws (1).
A07 034
2
40828-0
06/2006
4/6
8225-001
Fuel system
W 07-11-01
TCD 2015
z Mount holder (2).
A07 044
6
40827-0
06/2006
5/6
8225-001
Fuel system
W 07-11-01
TCD 2015
06/2006
6/6
8225-001
Fuel system
W 07-13-01
TCD 2015
W 06-07-03 . . . . . . . . . . . . (A-bank)
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
before removing.
to regulations.
Removing fuel pressure holding valve

W 06-07-03
2
1
40519-0
06/2006
1/8
8226-001
Fuel system
W 07-13-01
TCD 2015

1
2
6
40520-0
z Unscrew nut (1).

1
2
40521-0


1
2
40522-0
06/2006
2/8
8226-001
Fuel system
W 07-13-01
TCD 2015
1
2
6
40948-0
z Hold the connector.

z Unscrew overflow valve (3).
1
z Remove connector (2).
40949-0
45848-0
06/2006
3/8
8226-001
Fuel system
W 07-13-01
TCD 2015
Installing fuel pressure holding valve

z Screw on overflow valve (1).
6
40947-0
z Insert connector (2).

Connection of the hose line faces the heat
shield.
1

z Tighten union nuts (1) with open wrench.
A07 066
40949-0

z Tighten overflow valve (1) with open wrench.
A07 067
40949-0
06/2006
4/8
8226-001
Fuel system
W 07-13-01
TCD 2015
z Mount sealing rings (3).
A12 090
Attention!
tension.
1
3
6
40948-1

1
2
40522-0

z Mount holder (2).
z Screw on nut (1).
1
2
40521-0
06/2006
5/8
8226-001
Fuel system
W 07-13-01
TCD 2015

z Mount holder (2).
z Fasten screw (1).
1
2
6
40520-0

A12 093
z Tighten nut (2).
A07 044
2
40565-0

A07 044
A12 092
1
2
40555-0
06/2006
6/8
8226-001
Fuel system
W 07-13-01
TCD 2015
z Mount holder (2).
A07 044
W 06-07-03
2
1
6
40519-0
06/2006
7/8
8226-001
Fuel system
W 07-13-01
TCD 2015
06/2006
8/8
8226-001
Fuel system
W 07-13-01
TCD 2015 Railway

Attention!


before removing.
to regulations.
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Removing fuel pressure holding valve

z Hold overflow valve (1).
45925-1
06/2006
1/6
8227-001
Fuel system
W 07-13-01
TCD 2015 Railway
z Hold connector (1).

z Unscrew overflow valve (2).
45915-1

z Remove washer.
1
z Loosen pipe clip.
45916-0

z Unscrew union nut (3).
z Remove connector.
1
45917-0
06/2006
2/6
8227-001
Fuel system
W 07-13-01
TCD 2015 Railway

6
45769-0
Installing fuel pressure holding valve

z Screw on overflow valve (1).
40947-0

z Screw on screw-in nipple (1).
45770-0
06/2006
3/6
8227-001
Fuel system
W 07-13-01
TCD 2015 Railway
z Mount hose line (1).

1
2
6
45918-0
z Insert connector.
45919-0
z Position connector (1).

Arrange hexagon area (1) horizontally.
The connection (2) faces approx. 45 to
the left.
1
45920-0
06/2006
4/6
8227-001
Fuel system
W 07-13-01
TCD 2015 Railway

z Tighten union nuts (2) with open wrench.
A07 066
6
45921-1

z Tighten overflow valve (2) with open wrench.
A07 067
45922-1
z Hold overflow valve (1).

A07 069
45925-1
06/2006
5/6
8227-001
Fuel system
W 07-13-01
TCD 2015 Railway

z Mount washer.
2
A13 094
6
45924-0

Observe installation angle dimension X =
10.
Attention!

tension.

A12 090
2
45910-0
06/2006
6/6
8227-001
Lube oil system

W 08-04-06
TCD 2015
W 08-04-07

to regulations.
Removing the oil suction pipe

W 08-04-07
z Remove oil suction pipe (2).

z Remove gasket.
1
2
40833-0

2
40834-0
06/2006
1/4
8228-001
Lube oil system

W 08-04-06
TCD 2015
Installing the oil suction pipe

z Mount holder (2).
2
40834-0

z Mount new gasket.
z Mount oil suction pipe (2).
Attention!
1

from faults.
Install tension-free.
1
2
40833-0

A08 016
40835-0
06/2006
2/4
8228-001
Lube oil system

W 08-04-06
TCD 2015
A08 015
A08 016
z Install lubricating oil pan.

W 08-04-07
6
40962-0
06/2006
3/4
8228-001
Lube oil system

W 08-04-06
TCD 2015
06/2006
4/4
8228-001
Lube oil system

W 08-04-06
TCD 2015 Railway

W 08-04-07 . . . . . . . . . . . . (Railway)

to regulations.
Removing the oil suction pipe

z Remove lubricating oil pan (Railway).
W 08-04-07
z Remove oil suction pipe (2).

z Remove gasket.
1
1
45859-0

2
1
42171-1
06/2006
1/2
8229-001
Lube oil system

W 08-04-06
TCD 2015 Railway
Installing the oil suction pipe

z Mount holder (1).
A08 016
2
1
6
42171-1

z Mount new gasket.
z Mount oil suction pipe.
z Fasten screws.
from faults.
M8 x 25 mm (1)
M8 x 20 mm (2)
1
42170-1

A08 015
A08 016
Attention!
Install tension-free!
z Install lubricating oil pan (Railway).
W 08-04-07
42170-1
06/2006
2/2
8229-001
Lube oil system

W 08-04-07
TCD 2015
W 13-03-02
Packing compound
DEUTZ DW 47
Engine oil

to regulations.
The appropriate operating manual should
be observed for emptying and filling the
engine.
Removing the lubricating oil pan

z Remove starter.
W 13-03-02
z Unscrew locking screw (1).
z Drain, collect and dispose of engine oil according to
regulations.
1
40836-0
z Oil the screw plug lightly.

z Tighten screw plug (1).
A03 031
40836-0
06/2006
1/6
8230-001
Lube oil system

W 08-04-07
TCD 2015
z Pull out oil dipstick (1).

z Turn engine 180.
6
40837-0
40838-0

The holders (3) remain on the cables.
2
3
40839-0
06/2006
2/6
8230-001
Lube oil system

W 08-04-07
TCD 2015
z Remove gasket (1).
6
40840-0

z Remove guide tube (2).
z Remove screw-in nipple.
2
40841-0
Installing the lubricating oil pan

A08 038
z Mount guide tube.

z Tighten union nut.
A08 035
40842-0
06/2006
3/6
8230-001
Lube oil system

W 08-04-07
TCD 2015

The sealing surfaces must be dry and free
from grease and dirt.
z Apply packing compound to the joints (arrows).
6
40843-0
z Select new gasket.
40844-0
z Mount gasket (1).

Strap (arrow) faces generator.
TOP label faces crankcase.
1
40845-0
06/2006
4/6
8230-001
Lube oil system

W 08-04-07
TCD 2015
z Mount lubricating oil pan.
z Align lubricating oil pan to crankcase.
Ensure that the installation location of the
gasket is free from faults.
6
40846-0
z Mount holder (3).

z Position cable (2).
2
3
40839-0

A03 030
24
See graphic for tightening sequence.
20 16
12
13
17
21
28
25
30
29
27
26
23
19
15
11
10
14
18
22
45421-1
06/2006
5/6
8230-001
Lube oil system

W 08-04-07
TCD 2015

A03 080
1
6
40838-0
z Turn engine 180.

z Insert oil dipstick (1).
40837-0
z Fill engine oil according to operating instructions.

z Install starter.
W 13-03-02
40848-0
06/2006
6/6
8230-001
Lube oil system

W 08-04-07
TCD 2015 Railway


to regulations.
The appropriate operating manual should
be observed for emptying and filling the
engine.
Packing compound
DEUTZ DW 47
Fitting compound
DEUTZ AP1908
Engine oil
Removing the lubricating oil pan

z Drain, collect and dispose of engine oil according to
regulations.
42439-1
z Oil the screw plug lightly.

A03 031
z Turn engine 180.
1
45860-0
06/2006
1/10
8231-001
Lube oil system

W 08-04-07
TCD 2015 Railway

z Remove washers.
z Remove all half-flanges (2).
z Remove both flanged sockets (3).
1
2
6
45867-0

z Remove connecting flange (2).
2
42441-1

1
2
1
42442-1
06/2006
2/10
8231-001
Lube oil system

W 08-04-07
TCD 2015 Railway

The holders (3) remain on the cables.
z Loosen lubricating oil pan.
6
45861-0
z Pull lubricating oil pan in direction of arrow.

z Remove gasket.
45868-0
z Pull out plug elements (1).
1
45862-0
06/2006
3/10
8231-001
Lube oil system

W 08-04-07
TCD 2015 Railway

6
45863-0
z Insert plug elements (1).
1
45862-0
Mount lube oil tray with gasket.

The sealing surfaces must be dry and free
z Apply packing compound to the joints (arrows).
42445-1
06/2006
4/10
8231-001
Lube oil system

W 08-04-07
TCD 2015 Railway

The bright side of the gasket faces the
crankcase.
In case of metal bead seals, the beading
faces the crankcase.
6
45864-0
Mount lube oil tray with packing compound.

z Apply packing compound evenly to the sealing surface and in the beading of the lube oil tray.
Apply the packing compound in an even
bead (thickness approx. 3.5 mm).
The position of the packing compound is
only partly illlustrated.
43451-0
z Mount lubricating oil pan.

z Push on lubricating oil pan in direction of arrow.
Attention!
Do not move or damage O-rings.
45869-0
06/2006
5/10
8231-001
Lube oil system

W 08-04-07
TCD 2015 Railway
z Align lubricating oil pan to crankcase.
Attention!
Do not move gasket/packing compound.
Do not move the gasket when mounting
the lubricating oil pan.
6
45865-0
z Mount holder (arrows).

z Position cable.
42447-1

A03 030
24
See graphic for tightening sequence.
20 16
12
13
17
21
28
25
30
29
27
26
23
19
15
11
10
14
18
22
45421-1
06/2006
6/10
8231-001
Lube oil system

W 08-04-07
TCD 2015 Railway

6
37110-1
z Mount connecting flange (2).
Attention!
EX
The labels IN and EX on the connecting

flange and the lubricating oil pan must
match.
IN

A03 035
1
2
42448-1

37112-1
06/2006
7/10
8231-001
Lube oil system

W 08-04-07
TCD 2015 Railway
z Mount half-flange (1).

z Mount washers.
z Insert flanged socket (3).
3
2
2
45870-0

z Mount washers.
2
1
45871-0

z Mount washers.
z Insert flanged socket (2).

z Align both flanged sockets centrally.

A03 034
1
2
45872-0
06/2006
8/10
8231-001
Lube oil system

W 08-04-07
TCD 2015 Railway

z Mount holder (2).
A13 098
z Turn engine 180.

z Fill engine oil according to operating instructions.
1
42442-1
06/2006
9/10
8231-001
Lube oil system

W 08-04-07
TCD 2015 Railway
06/2006
10/10
8231-001
Lube oil system

W 08-08-02
TCD 2015
W 06-07-03 . . . . . . . . . . . . (A-bank)
W 09-08-04
to regulations.
Removing the oil cooler

W 06-07-03
W 09-08-04
40849-0

2
1
40519-0
06/2006
1/8
8232-001
Lube oil system

W 08-08-02
TCD 2015

1
2
6
40850-0
z Unscrew nut (1).

40851-0


1
2
40852-0
06/2006
2/8
8232-001
Lube oil system

W 08-08-02
TCD 2015
6
40853-0

z Remove oil cooler cover (2).
z Remove gasket.
1
40854-0

z Remove oil cooler (2).
z Remove O-rings.
1
2
40855-0
06/2006
3/8
8232-001
Lube oil system

W 08-08-02
TCD 2015
6
40856-0
Installing the oil cooler

40857-0
z Mount oil cooler (2).

z Align oil cooler.
A08 051
1
1
2
40855-0
06/2006
4/8
8232-001
Lube oil system

W 08-08-02
TCD 2015
z Mount new gasket.
z Mount oil cooler cover.
z Mount holder (1).
Screw length:
M8 x 35 mm
2
Screw length:
M8 x 65 mm
3
40858-0
z Align oil cooler cover (2).

The lay-on surfaces of the oil cooler cover
and the genset support must contact the
holders.
Do not move gasket.

A08 050
40854-0

A06 058
1
40853-0
06/2006
5/8
8232-001
Lube oil system

W 08-08-02
TCD 2015

1
2
6
40852-0

z Mount holder (2).
z Screw on nut (1).
40851-0
z Mount holder (2).

z Fasten screw (1).
1
2
40850-0
06/2006
6/8
8232-001
Lube oil system

W 08-08-02
TCD 2015
z Mount holder (2).
A07 044
2
1
6
40519-0

A12 093
1
z Tighten nut (2).
A07 044

A07 044
40859-0

W 09-08-04
W 06-07-03
40849-0
06/2006
7/8
8232-001
Lube oil system

W 08-08-02
TCD 2015
06/2006
8/8
8232-001
Lube oil system

W 08-11-09
TCD 2015

Special tools:
Socket wrench insert . . . . . . . . . 110700

to regulations.
Removing oil pressure pick-up

z Pull out cable plug (1).
1
40860-0
z Unscrew oil pressure pick-up (1) with the socket

wrench insert.
1
40861-0
06/2006
1/2
8233-001
Lube oil system

W 08-11-09
TCD 2015
6
40862-0
Installing oil pressure pick-up

z Mount new gasket.
z Insert oil pressure pick-up (1).
z Tighten oil pressure pick-up with socket wrench insert.

A08 091
40861-0

1
40860-0
06/2006
2/2
8233-001
Lube oil system

W 08-11-10
TCD 2015
Depth-measuring
appliance
W 03-01-11
W 06-07-03 . . . . . . . . . . . . (B-bank)
to regulations.
Removing pressurestat
W 03-01-11
W 06-07-03
40863-0

40608-0
06/2006
1/10
8234-001
Lube oil system

W 08-11-10
TCD 2015
6
40609-0
40864-0

2
1
40613-0
06/2006
2/10
8234-001
Lube oil system

W 08-11-10
TCD 2015
z Unscrew nuts (1).
6
40972-0

1
40973-0

40865-0
06/2006
3/10
8234-001
Lube oil system

W 08-11-10
TCD 2015
z Unscrew valve housing (1).

Do not move the adjusting bolt (2).
1
6
40866-0
If the same oil pressure is to be set again,

the overhang of the adjusting bolt must be
measured before removing.
z Measure overhang (X) from adjusting bolt (1) to
crankcase with the depth measuring appliance.
1
40867-0
z Unscrew adjusting bolt (1).

z Remove compression spring.
z Remove valve plunger.
1
40868-0
06/2006
4/10
8234-001
Lube oil system

W 08-11-10
TCD 2015
Adjusting bolt (1).
Compression spring (2)
Valve plunger (3)
6
42460-1
Installing pressurestat
Overhang dimension (X) for basic setting
of adjusting bolt.
If the same oil pressure is to be set again,
the overhang dimension (X) noted before
removal must be reset.
P08 63
35022-2
z Insert valve plunger.

z Insert compression spring.
z Screw in adjusting bolt (1).
P08 63
Note overhang dimension of the adjusting

bolt.
40868-0
06/2006
5/10
8234-001
Lube oil system

W 08-11-10
TCD 2015

z Oil the thread valve housing lightly.
z Tighten valve housing (1).
A03 051
Do not move the adjusting bolt (2).
1
2
6
40869-0

A08 071
1
40865-0

1
40973-0
06/2006
6/10
8234-001
Lube oil system

W 08-11-10
TCD 2015
z Mount holder (2).
z Tighten nuts (1).
A07 044
6
40972-0

A07 066
1
40990-0
z Mount holder (2).

A07 044
2
1
40613-0
06/2006
7/10
8234-001
Lube oil system

W 08-11-10
TCD 2015
6
40864-0
40609-0

40608-0
06/2006
8/10
8234-001
Lube oil system

W 08-11-10
TCD 2015
W 06-07-03
W 03-01-11
6
40848-0
06/2006
9/10
8234-001
Lube oil system

W 08-11-10
TCD 2015
06/2006
10/10
8234-001
Cooling system
W 09-07-08
TCD 2015
Removing and installing the coolant pump

to regulations.

Special tools:
Fitting compound
DEUTZ AP1908
Removing coolant pump

z Removing screw-in nipple (2).
z Remove gasket.
2
40870_1
45393-0
06/2006
1/6
8235-001
Cooling system
W 09-07-08
TCD 2015
6
40871-0

Use three studs M8 to push the coolant
pump off the genset support.
z Press off the coolant pump.

z Remove gasket.
40872-0
z Remove screws.
36828_1
06/2006
2/6
8235-001
Cooling system
W 09-07-08
TCD 2015
6
40874-0
Installing coolant pump

z Insert new O-rings.
O-rings:
75 x 3 mm (1)
80 x 3 mm (2)
1
36828_1

Check drainage holes (arrows) for free
passage.
40876-0
06/2006
3/6
8235-001
Cooling system
W 09-07-08
TCD 2015
z Screw in studs (1).

To fix the gasket and the coolant pump.
1
z Mount new gasket.
6
40877-0
z Insert coolant pump.

The gear wheel (1) must engage the toothing of the idler gear (2).
Attention!
Do not damage the gasket.
Do not move gasket.
1
2
40875-0

z Unscrew studs (2).
40878-0
06/2006
4/6
8235-001
Cooling system
W 09-07-08
TCD 2015
A09 010
6
40879-0

z Mount new gasket.
z Mount inlet adapter (2).
A09 011
40870_1
06/2006
5/6
8235-001
Cooling system
W 09-07-08
TCD 2015
06/2006
6/6
8235-001
Cooling system
W 09-08-01
TCD 2015
Checking the thermostat when uninstalled
Thermometer
W 09-08-02
Danger!
Risk of injury!
Hot water and hot thermostat.
Checking thermostat
z Remove thermostats.
W 09-08-02
z Measure beginning of stroke, dimension (a).
34679-3
z Heat up the thermostat in the water bath.

z Determine beginning of opening.
In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the thermostat.
Do not touch the thermostat.
The water should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place
faster than 1C/min. Otherwise the beginning of opening will be delayed accordingly.
P09 11
P09 12
34680-2
06/2006
1/2
8236-001
Cooling system
W 09-08-01
TCD 2015
z Measure end of stroke, dimension (b).

6
34679-2
z Determine stroke.
Calculation example
Desired:
Stroke
Given:
Measured:
Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Dimension (b) - dimension (a)
Result:
= stroke
z Compare result with setpoint value.

P09 13
z Install thermostats.
W 09-08-02
34679-1
06/2006
2/2
8236-001
Cooling system
W 09-08-02
TCD 2015
Removing and installing thermostats
W 09-08-01
W 09-08-04
Fitting compound
DEUTZ AP1908

to regulations.
Removing thermostats
2
W 09-08-04
z Remove outlet nozzle (2).
40880_1
z Remove thermostats (1).
40881-0
06/2006
1/4
8237-001
Cooling system
W 09-08-02
TCD 2015

z Check thermostats.
W 09-08-01
6
40882-0
Installing thermostats
z Select thermostats.
z Coat the sealing rings with fitting compound.

z Fit new sealing rings (1).
Note different opening
temperatures (arrows) of the thermostats.
P09 11
P09 12
40883-0

The markings (3) face upwards.
Note thermostat assignment.
z Insert thermostat (1).
P09 12
z Insert thermostat (2).

P09 11
40884_2
06/2006
2/4
8237-001
Cooling system
W 09-08-02
TCD 2015
z Mount outlet nozzle (2).
A09 002

1
W 09-08-04
6
40880_1
06/2006
3/4
8237-001
Cooling system
W 09-08-02
TCD 2015
06/2006
4/4
8237-001
Cooling system
W 09-08-04
TCD 2015
Removing and installing the thermostat housing
W 07-01-04

to regulations.
Removing thermostat housing

W 07-01-04
40885-0
40886-0
06/2006
1/8
8238-001
Cooling system
W 09-08-04
TCD 2015

z Place holder (2) to one side.
2
1
6
40887-0

z Remove spacing sleeve.
z Place pipe to one side.
40888-0

40889-0
06/2006
2/8
8238-001
Cooling system
W 09-08-04
TCD 2015
6
40890-0
40891-0
z Remove the thermostat housing (1).

1
z Remove gasket.
40892-0
06/2006
3/8
8238-001
Cooling system
W 09-08-04
TCD 2015
6
40893-0
Installing thermostat housing

z Mount new gasket.

z Mount thermostat housing (1).
Do not move gasket.
40892-0
z Fasten screws.
M8 x 90 mm (1)
M8 x 65 mm (2)
2
40894-0
06/2006
4/8
8238-001
Cooling system
W 09-08-04
TCD 2015
z Mount holder (1).
z Fasten screw (2).
Screw length:
M8 x 140 mm.
TIghten screw only after mounting the fuel
pipes (flame glow plugs).
6
40890-0

A09 001
A09 001
40894-0

A12 092
40889-0
06/2006
5/8
8238-001
Cooling system
W 09-08-04
TCD 2015
z Mount fuel pipe.

z Position spacing sleeve.
z Fasten screw (1).
6
40888-0

P07 91
45406-0

A07 093
40888-0
06/2006
6/8
8238-001
Cooling system
W 09-08-04
TCD 2015
z Mount holder (2).
A09 001
Screw length:
M8 x 150 mm
2
1
6
40887-0

A13 094
40886-0

W 07-01-04
40956-0
06/2006
7/8
8238-001
Cooling system
W 09-08-04
TCD 2015
06/2006
8/8
8238-001
Cooling system
W 09-12-01
TCD 2015

to regulations.
Removing temperaure transmitter

40895-0
z Unscrew temperature transmitter (1).
40896-0
06/2006
1/2
8239-001
Cooling system
W 09-12-01
TCD 2015
6
44084-0
Installing temperature transmitter

z Tighten temperature transmitter (1).
A09 031
40896-0

40895-0
06/2006
2/2
8239-001
Other components
W 12-01-04
TCD 2015
Removing the torsional vibration damper

z Remove V-belt pulley (2).
1
40965-0
z Pull off torsional vibration damper (1).
Danger!
Risk of injury!
40897-0
06/2006
1/2
8240-001
Other components
W 12-01-04
TCD 2015
6
40898-0
Installing the torsional vibration damper

z Mount torsional vibration damper (1).
40897-0
z Mount V-belt pulley (2).

A12 031
40965-0
06/2006
2/2
8240-001
Other components
W 12-06-01
TCD 2015
Attention!

Do not turn the crankshaft without screws/

mandrin guide.
The crankshaft gear wheel is positioned by
screws/mandrin guide.
The position of the crankshaft gear wheel
will change without fixing.
Special tools:
Self-made mandrin guide
Removing flywheel
1
z Remove thrust washer (2).
40902_1
z Insert self-made mandrin guide.

z Remove flywheel.
z Remove friction disc.
Attention!
Do not turn the crankshaft without screws/
mandrin guide.
The crankshaft gear wheel is positioned by
screws/mandrin guide.
The position of the crankshaft gear wheel
will change without fixing.
34985-2
06/2006
1/2
8241-001
Other components
W 12-06-01
TCD 2015
6
40903-0
Install flywheel
z Position friction disc.
Make sure the clamping bushing (1) is in
place.
z Mount flywheel.
Make sure the clamping bushing and locating hole are in line.
40966-0
z Insert thrust washer (2).

z Remove self-made mandrin guide.
1
Attention!
Renew screws every time they are loosened.
z Tighten all screws (1) with the socket wrench insert.

A12 001
40658_1
06/2006
2/2
8241-001
Other components
W 12-06-03
TCD 2015
Renewing toothed starter ring on the flywheel
W 12-06-01
Danger!
Danger of injury, do not touch hot parts!
Removing toothed starter ring

z Remove flywheel.
W 12-06-01
z Check marking.
The marking (arrow) is on the flywheel and
exactly in the middle of the tooth notch of
the toothed starter ring.
40904-0
z Remove toothed starter ring with suitable tool.
34764-2
06/2006
1/4
8242-001
Other components
W 12-06-03
TCD 2015
z Visually inspect joint (arrow) and contact surface.

z Clean flywheel.
The joint and contact surface must be free
6
34765-2
Install toothed starter ring

z Check marking of new toothed starter ring.
The marking (arrow) is on the flywheel and
exactly in the middle of the tooth notch of
the toothed starter ring.
40905-0
z Heat up toothed starter ring to 220 C.

z Place toothed starter ring on flywheel.
The markings on the flywheel and toothed
starter ring must match.
The toothed starter ring must lie evenly on
the joint of the flywheel.
40906-0
06/2006
2/4
8242-001
Other components
W 12-06-03
TCD 2015
z Install flywheel.
W 12-06-01
6
40907-0
06/2006
3/4
8242-001
Other components
W 12-06-03
TCD 2015
06/2006
4/4
8242-001
Other components
W 12-08-04
TCD 2015
W 06-01-06 . . . . . . . . . . . . (A-bank)
Special tools:

to regulations.
Fitting compound
DEUTZ AP1908
Locking agent
DEUTZ DW 59
Removing hydraulic pump drive

1
W 06-01-06
z Unscrew lock nuts (2).
3
40908-0

z Remove flange housing (2).
40909-0
06/2006
1/4
8243-001
Other components
W 12-08-04
TCD 2015

z Remove hydraulic pump drive (2).
1
6
40910-0

42200-2
Installing hydraulic pump drive

z Coat the O-ring with fitting compound.
42200-2
06/2006
2/4
8243-001
Other components
W 12-08-04
TCD 2015
z Insert hydraulic pump drive.
The gear wheel (1) must engage the toothing of the idler gear (2).
6
40913-0

A12 057
40914-0

z Coat lay-on surface (arrow) with locking agent.
45409-0
06/2006
3/4
8243-001
Other components
W 12-08-04
TCD 2015
z Mount flange housing (1).

Screw length:
1
M10 x 110 mm
Screw length:
M10 x 210 mm
6
40915-0

A12 058
A12 059
45395-0

z Fasten screw (1).
A12 082
A08 045

W 06-01-06
2
40908-0
06/2006
4/4
8243-001
Electrical system
W 13-01-02
TCD 2015
W 06-02-03
Attention!
Removing the cable harness

W 06-02-03
40916-0
z Disconnect the battery's negative terminal.

z Disconnect cables.
40917-0
06/2006
1/20
8244-001
Electrical system
W 13-01-02
TCD 2015
6
40534-0
40918-0

1
40919-0
06/2006
2/20
8244-001
Electrical system
W 13-01-02
TCD 2015
z Unscrew nut (1).
z Remove washer.
before removing.
6
40920-0
40921-0
40922-0
06/2006
3/20
8244-001
Electrical system
W 13-01-02
TCD 2015

z Pull cables off all injection pumps.
before removing.
6
40923-0

1
2
40924-0
40925-0
06/2006
4/20
8244-001
Electrical system
W 13-01-02
TCD 2015
6
40926-0
40927-0
z Unscrew nuts (1).

z Unscrew the nuts (2).
z Remove washers.
z Remove cables.
before removing.
40928-0
06/2006
5/20
8244-001
Electrical system
W 13-01-02
TCD 2015
6
40929-0

before removing.
z Unscrew nut (1).
z Remove washer.
40930-0
40931-0
06/2006
6/20
8244-001
Electrical system
W 13-01-02
TCD 2015
6
40933-0
40934-0

z Remove fuel pipe.
40935-0
06/2006
7/20
8244-001
Electrical system
W 13-01-02
TCD 2015
z Pull out cable plug (1).
6
40936-0

40943-0
40532-0
06/2006
8/20
8244-001
Electrical system
W 13-01-02
TCD 2015
6
40937-0
40938-0
40939-0
06/2006
9/20
8244-001
Electrical system
W 13-01-02
TCD 2015
z Unlock central plug (1) (arrow) and pull off from holder.
1
6
40940-0
40941-0
Installing the cable harness

z Position the cable harness on the engine accordingly.
z Lay the cable plugs to the individual components.
40942-0
06/2006
10/20
8244-001
Electrical system
W 13-01-02
TCD 2015
z Push the central plug onto the holder until it snaps in.
A12 095
6
40939-0
z Tighten screws .
A13 090
Screw length:
M8 x 20 mm (1)
M8 x 16 mm (2)
1
40987-0
40937-0
06/2006
11/20
8244-001
Electrical system
W 13-01-02
TCD 2015
z Lay cable harness and fix with cable ties (1).
6
40532-0

40943-0
40936-0
06/2006
12/20
8244-001
Electrical system
W 13-01-02
TCD 2015
z Mount fuel pipe.
z Position pipe clip.
z Fasten screw (1).
6
40935-0

A12 080
Attention!
40934-0

A12 080
40933-0
06/2006
13/20
8244-001
Electrical system
W 13-01-02
TCD 2015

A07 044
6
40935-0
40931-0
Attention!

before removing.
z Mount washer.
z Tighten nut (1).
A13 035
40930-0
06/2006
14/20
8244-001
Electrical system
W 13-01-02
TCD 2015
A13 094
6
40929-0
z Plug cables.
Attention!

before removing.
z Mount washers.
z Tighten nuts (1).
A13 037
z Tighten nuts (2).

A13 038
40928-0
40927-0
06/2006
15/20
8244-001
Electrical system
W 13-01-02
TCD 2015
6
40926-0
40925-0

1
2
40924-0
06/2006
16/20
8244-001
Electrical system
W 13-01-02
TCD 2015
z Plug cables to all injection pumps.
T13 054
Attention!
before removing.
1

A13 054
6
40923-0
40922-0
40921-0
06/2006
17/20
8244-001
Electrical system
W 13-01-02
TCD 2015
Attention!
before removing.
z Mount washer.
z Tighten nut (1).
A13 035
6
40920-0

1
40919-0
40918-0
06/2006
18/20
8244-001
Electrical system
W 13-01-02
TCD 2015
6
40534-0
z Connect cables.
z Connect the battery's negative terminal.
40917-0

W 06-02-03
40956-0
06/2006
19/20
8244-001
Electrical system
W 13-01-02
TCD 2015
06/2006
20/20
8244-001
Electrical system
W 13-02-03
TCD 2015
Removing and installing the generator
(V-belt drive)
V-belt tension measuring
device . . . . . . . . . . . . . . . . . . . . . . . 8115
Attention!
Only test / tighten / renew V-belts when the
engine is not running.
The V-belt tension of new V-belts must be
checked after they have been running for
15 minutes.
Removing the generator

z Remove cable from generator.
1
Note assignment!
- (1) = terminal W
- (2) = terminal D+
- (3) = terminal B+
3
45411-0
40975-0
06/2006
1/8
8245-001
Electrical system
W 13-02-03
TCD 2015
z Loosen nut (1).
6
40976-0
z Loosen screw (1).
45412-0
z Press generator in direction of arrow.

z Remove V-belt (1).
40978-1
06/2006
2/8
8245-001
Electrical system
W 13-02-03
TCD 2015
Hold nuts.
z Remove generator (2).
2
40979-0
40980-0
Installing the generator

z Mount generator.
z Insert screws.
M10 x 100 mm (1)

M10 x 120 mm (2)
z Fasten screws.
Hold nuts.
2
40988-1
06/2006
3/8
8245-001
Electrical system
W 13-02-03
TCD 2015

A13 015
Hold nuts.
6
45396-0
z Mount V-belt (1).
40978-0
z Tighten V-belt (1) by turning the clamping screw (2).

A13 017
3
40977-1
06/2006
4/8
8245-001
Electrical system
W 13-02-03
TCD 2015
Check V-belt tension with V-belt tension
measuring device
z Lower indicator arm (1) into V-belt tension measuring
device.
6
39582_2
z Mount V-belt tension measuring device on V-belt.

The V-belt must be between the
guides (arrow).
40981-0
z Press the V-belt measuring device against the V-belt

with the button (1) until you hear it click.
40982-0
06/2006
5/8
8245-001
Electrical system
W 13-02-03
TCD 2015
z Read measured value at the intersection (arrow) of

the indicator arm and scale.
P12 11
P12 21
Note different units on the scale.
z If the nominal value is not reached, the tensioning

process must be repeated.
6
45413-0

A13 012
40983-0
z Tighten nut (1).

A13 017
40984-0
06/2006
6/8
8245-001
Electrical system
W 13-02-03
TCD 2015
z Remove cable from generator.
Note assignment!
- (1) = terminal W
- (2) = terminal D+
- (3) = terminal B+
3
45411-0
06/2006
7/8
8245-001
Electrical system
W 13-02-03
TCD 2015
06/2006
8/8
8245-001
Electrical system
W 13-03-02
TCD 2015
Fitting compound
DEUTZ AP1908
Removing the starter

z Disconnect cables.
40917-0
z Unscrew nuts (1).

z Remove starter.
40944-1
06/2006
1/4
8246-001
Electrical system
W 13-03-02
TCD 2015
6
40945-0
Installing the starter

z Insert new O-ring (arrow).
z Coat the O-ring with fitting compound.
42096-1
z Insert starter.
z Tighten nuts (1).
A13 001
40944-1
06/2006
2/4
8246-001
Electrical system
W 13-03-02
TCD 2015
z Connect cables.
6
40917-0
06/2006
3/4
8246-001
Electrical system
W 13-03-02
TCD 2015
06/2006
4/4
8246-001
Electrical system
W 13-08-01
TCD 2015
Removing and installing the pressure/temperature sensor

(charge air)
Fitting compound
DEUTZ AP1908
Remove pressure/temperature sensor

40919-0

z Remove pressure/temperature sensor
40946-0
06/2006
1/2
8247-001
Electrical system
W 13-08-01
TCD 2015
Installing the pressure/temperature sensor

z Lightly coat O-ring with fitting compound.
6
42002-2
z Insert pressure/temperature sensor.

A13 046
40946-0

40919-0
06/2006
2/2
8247-001
TCD 2015
Standard tools
Standard tools
7
06/2006
1/8
8248-001
TCD 2015
Standard tools
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bcker 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
06/2006
2/8
8248-001
TCD 2015
Standard tools
8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
35410-2
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
06/2006
3/8
8248-001
TCD 2015
Standard tools
8015
Socket wrench insert
SW 14, reinforced
Unscrew and tighten big end bearing screws.
37503-1
7
8016
SW 17, reinforced
Unscrew and tighten flywheel screws.
37504-1
8018
Claw wrench
SW 17, reinforced
Unscrew and tighten union nuts of the injection pipes.
37506-1
06/2006
4/8
8248-001
TCD 2015
Standard tools
8024
Assembly pliers
e. g. removing valve stem seals
37509-4
7
8115
V-belt tension measuring device
150 to 600 N
Check V-belt tension
35416-3
8198
Pricker
Removing rotary shaft lip seal
43206-3
06/2006
5/8
8248-001
TCD 2015
Standard tools
8190
Rotation angle disc
with magnet (e. g. setting valve clearance)
42528-1
7
8191
with slotted screwdriver insert (8x1.6)
(e. g. setting valve clearance)
43060-0
8196
Open end wrench adapter
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.
43197-0
06/2006
6/8
8248-001
TCD 2015
Standard tools
9017
Assembly lever
e. g. removing and installing valves
37511-1
06/2006
7/8
8248-001
TCD 2015
Standard tools
06/2006
8/8
8248-001
TCD 2015
Special tools
Special tools
06/2006
1/16
8249-001
TCD 2015
Special tools
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bcker 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
06/2006
2/16
8249-001
TCD 2015
Special tools
6066
Assembly block
Engine clamping, double-sidedmaximum load capacity
at middle centre of gravity approx. 1200 kg
35451-2
6066/151
Clamping bracket
(in conjunction with assembly block 6066)
Engine clamping, double-sided
37601-1
100130
Connector
(in conjunction with compression pressure tester 8005)
37602-1
06/2006
3/16
8249-001
TCD 2015
Special tools
100300
Turning gear
with mechanical TDC transmitter and degree scale for
start of pumping check
Turn crankshaft,
block engine
37603-1
100350
Turning gear
Turn crankshaft on the V-belt pulley.
37604-1
100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
37605-1
06/2006
4/16
8249-001
TCD 2015
Special tools
100410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
43205-0
100850
Measuring instrument with measuring plate
37606-1
101830
Dial gauge adapter
Measuring installation depth for impulse transmitter
45906-0
06/2006
5/16
8249-001
TCD 2015
Special tools
102560
Tester
Basic device with two dipsticks
Check radiation position of the piston cooling nozzle
(old version)
37608-1
102565
Dipstick
(in connection with tester 102560)
Check radiation position of the piston cooling nozzle
(new version)
37628-1
103240
Dial gauge holder
with stylus extension (diameter 5/95 mm)
Checking plunger lift of injection pumps
43927-3
06/2006
6/16
8249-001
TCD 2015
Special tools
110030
Puller
(in connection with sliding hammer 150800)
35433-2
110110
Holder
SW11,
Clamp fuel injector in the vice
35434-2
110130
Slotted nut wrench
Unscrew and tighten union screw on the fuel injector.
37610-1
06/2006
7/16
8249-001
TCD 2015
Special tools
110500
Special wrench
Size 17
Removing and installing injection pipes
35436-1
110510
Special wrench
43928-3
110700
Size 27
long
Removing and installing oil pressure transmitter
42341-2
06/2006
8/16
8249-001
TCD 2015
Special tools
110901
Disassembly tool
Removing O-ring
45950-1
120660
Puller
(in connection with sliding hammer 150800)
Removing jammed fuel injector sealing ring
45421-0
120900
Support bracket
pivoting
Clamping cylinder head
35438-2
06/2006
9/16
8249-001
TCD 2015
Special tools
120910
Base plate
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)
35439-2
121410
Assembly tool
Assembling valve stem gasket
37614-1
121420
Assembly sleeves
Set of assembly sleeves for valve stem gasket
43210-0
06/2006
10/16
8249-001
TCD 2015
Special tools
130300
Universal piston ring pliers
Removing and installing the piston rings
35441-2
130400
Trapezoidal groove wear gauge
Testing piston ring groove
36461-1
130650
Piston ring compressor
Removing and installing the piston rings
35443-2
06/2006
11/16
8249-001
TCD 2015
Special tools
131200
Base plate
(in connection with assembly tool kit 131210)
Pressing small end bush out and in
37616-1
131210
Assembly tool kit
(in connection with base plate 131200)
Pressing small end bush out and in
37617-1
142640
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)
37618-1
06/2006
12/16
8249-001
TCD 2015
Special tools
142650
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
37619-1
143830
Assembly tool
Removing and installing camshaft bearing
37621-1
144150
Counter support
Blocking camshaft gear wheel
37622-1
06/2006
13/16
8249-001
TCD 2015
Special tools
150030
Tool kit
40221-0
150120
Assembly device
Installing cylinder liner
37624-1
150130
Puller
Removing cylinder liner
37625-1
06/2006
14/16
8249-001
TCD 2015
Special tools
150800
Slide hammer
35449-2
170050
Special wrench
Unscrewing the filter cartridges
37629-1
170100
Special wrench
Removing and installing lubricating oil pipe turbocharger
37626-1
06/2006
15/16
8249-001
TCD 2015
Special tools
170120
Disassembly and assembly tool
Pressing the ball stud of the rocker arm shaft out and in
37627-1
170160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
43663-0
06/2006
16/16
8249-001

Deutz TCD WH 2015 03123514

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Workshop Manual

Regarding copyright questions and licensing agreements

The engine company.

Testing and setting data

Job card overview

z Repair of the engine must correspond to its use

z Make sure that this documentation is available to

We are at your service for any questions you may

z Maximum economy, reliability and long life is only

Maintenance and care are the only way the engine

3.2.1 Accident prevention and safety regulations

z for the personnel:

The rules for the prevention of accidents and the

Reference is made in the workshop manual job

Wear close-fitting clothing and ear protectors

Damaged injection lines and high-pressure

Do not place hands near to a leak in the high

z Air currents which kick up dust, such as those

Even if no leaks are discernible on the high

Smoking is strictly prohibited when working on

Do not work near to sparks and flames.

z Areas of the engine room from which particles of

z The fuel system must be closed. Make a visual

z Remove loose parts (for example paint chips

z Clean the whole engine and engine room with the

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

z Do not use used cleaning fluid or test fluid for

z Electrical plug connections must be plugged

z Work on removed components may only be performed at a suitably equipped workbench.

z Compressed air must not be used for cleaning on

z Removed parts may only be rubbed down with

Disposal includes recycling and the scrapping of

z Openings on the components and on the engine

z The stoppers/caps may only be removed immediately before installing.

3.2.3 Disposal regulations

3.4 Job cards

To structure the information to suit the user, the

The job cards are divided in the workshop manual

3.4.1 Numbering of job cards

6. Care and maintenance work

z W 02-04-01: Documentation type

W.... Workshop manual

I ...... Repair instructions

The workshop manual assumes knowledge of the

z W 02-04-01: Maintenance group

3.4.2 Structure of a job card

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

6. Reference to other job cards

Test and setting data

Testing and setting data

Engine weight according to DIN 70020-A

Height of engine with connection housing

Width of engine with connection housing

Length of engine with connection housing

General engine data

without operating media

about all data

about all data

about all data

V06 approx. 1020-1200

Cylinder and side view

Valve seat insert, bore (outlet)

Valve seat insert, bore (inlet)