Deutz+TD TCD+3.6L4F+Workshop+Manual 2013

A.
DEUTZ
Workshop Manual
competence level 2
TD 3.6 L4
TCD 3.6 L4
0312 3965 en
This document is subject to changes which may become necessary in the course of further de-
velopment of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission
Regarding copyright questions and licensing agreements
please contact :
VE-FL, Mr. Lippke

Phone: +49 (0) 221 822-2599
E-mail: lippke.d@deutz com
DEUTZAG
Information Systems Sales & Ser-
v ice
Ottostrar..e 1
D-51149 Kbln (Cologne)
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
lnlernet: www.deutz.com
E-mail: [email protected]
A.
DEUTZ The engine company.
Printed in Germany
All rights reserved
1st edition, © 0612012
Order no. 0312 3965 en
A.
DEUTZ DEUTZ engines Foreword
1 Foreword
DBJ_DOKU-310,6-001 l,n
114
Foreword DEUTZ engines A.
DEUTZ
2/4 OBJ_DOKU-31016-001 Im
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DEUTZ DEUTZ engines Foreword
• Read and observe the information in this docu-

mentation . You will avoid accidents, retain the
manufacturer's warranty and possess a fully
functional and ready to operate engine.
• This engine is built exclusively for purpose ac-
• 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 mod-
ifications to the engine exclude manufacturer lia-
a
cording to the scope of delivery - defined by the bility for resulting damages. Failure to observe
equipment manufacturer (use for the intended this will void the warranty!
purpose). Any use above and beyond this is con- • The engines made by DEUTZ are developed for
sidered improper use. The manufacturer will not a wide range of applications . A wide range of var-
be liab le for damages resulting from this. The iants ensures that the respective special require -
user bears the sole risk. ments are met.
• Use for the intended purpose also includes ob- • The engine is equipped accord ing to the installa-
servance of the operating, maintena nee and re- tion case, i.e . not all the parts and components
pair instructions specified by the manufacturer. described in this documentation are installed in
The engine may only be used, maintained and your engine necessarily.
repaired by persons who are familiar with this • We have done our best to highlight the differenc-
and are aware of the risks involved. es so that you can easily find the operating , main-
• Make sure that this documentation is ava ilable to tenance and repair instructions relevant to your
everyone involved in the operation, maintenance engine.
and repair and that they have understood the
contents .
• Failure to observe this documentation may lead
to malfunctions and engine damage as well as in-
jury to persons for which the manufacturer will
not accept any liability.
• Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and spec ial tools and the ir perfect
condition.
• Engine parts such as springs, clamps. elastic re-
taining rings etc. pose an increased risk of injury
when handled incorrectly.
• The pertinent ru les for the prevention of acci-
dents and other generally recognised health and
We are at your service for any questions you may
safety regulations must be observed.
have in this matter .
• Maximum economy, reliability and long life is only
guaranteed when using DEUTZ original parts .
Your DEUTZ AG
© 0912 01 2 3/4 OBJ DOKU-31076-00 1 frr.

Foreword DEUTZ engines A.
DEUTZ
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DEUTZ DEUTZ engines General
2 General
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General DEUTZ engines
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DEUTZ 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. II goes without saying that the
high environmental protection requirements are
also met.
II
Maintenance and care are the only way the engine
can satisfy the demands you make on it. Compli-
ance with the prescribed maintenance limes and the
careful execution of maintena nee and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particular-
ly heeded.
Please consult one of our service representatives

responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.
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General DEUTZ engines
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DEUTZ
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DEUTZ DEUTZ engines Safety information/ User information
OBJ_DOKU-31078-001.fm
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3 Safety information I User information
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Safety information I User information
OBJ_DOKU-31078-001 .fm
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OBJ_OOKU-31078-001 .fm
3.1 General 3.2 Specifications

The documentation of the workshop manual has 3.2.1 Accident prevention and safety regula-
been created based on the engine available at the tions
time of going to press.
The legally prescribed rules for the prevention of ac-
There may be deviations in the descriptions, illustra-
cidents must be observed _These are available from
II
tions and parts due to further developments.
professional associations or from dealers_These
The valid documentations published by DE UTZ AG are dependent on the application site, operating
(for example Technical Circulars, Service Bulletins, mode and the operating and auxiliary materials be-
etc.) must be observed. ing used.
The maintenance work described in the operation Special protection measures are specified depend-
manual and in the workshop manual must be carried ing on the work being carried out, and are identified
out on schedule and completely. The maintenance in the JOb description.
personnel must have the necessary technical
Among other things it generally applies that:
knowledge to pertorm the work. Safety and protec-
tion devices which are removed during maintenance • for the personnel:
work must be replaced again afterwards. - Only briefed personnel may operate or main-
Caution! tain the engine. Unauthorised persons are
prohibited access to the machine room.
The rules for the prevention of accidents and the
safety regulations must be observed during mainte- - Wear close-fitting clothing and ear protectors
nance work. in the machine room when the engine is in op-
eration.
Reference is made in the workshop manual job
cards to the regulations in chapter 3.2. These must - Only deploy trained personnel to do repairs
be read before working on the engine and must be and maintenance work.
strictly followed. - Do not work on the fuel system when the en-
The maintenance intervals and the work to be per- gine is running. The fuel system is under high
formed are specified in the maintenance schedule pressure - danger of death .
of the operation manual. The job cards contain tech- - Go to the workshop immediately in case of
nical documentation on the execution of mainte- leaks in the fuel system.
nance work. • for the engine room:
- Ensure adequate ventilation ( do not cover air
shafts).
- Provide first aid kit and suitable fire extinguish-
ers. Check the filling and readiness for opera-
tion regularly
- Only store inflammable materials in the ma-
chine room if they are essential for operation
of the system.
- Smoking and naked flames are prohibited in
the machine room.
• for operation, maintenance and repairs on the
engine:
- The common rail systems used work with op-
erating pressures up to
approximately 2000 bar. In the case of poten-
tial faults, the pressure can even rise to signif-
icantly higher values before the pressure
reducing valve opens.
- After shutting down the engine, wait at least
30 seconds before performing work on the fuel
system.
Depending on the version of common rail sys-
tem, the fuel pressure in the common rail sys-
tem will still not have dissipated after 30
seconds. The fuel pressure can permanently
be several 100 bar.
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Safety information/ User information
OBJ_OOKU-31078-001 .frn
DEUTZ engines
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DEUTZ
The fuel pressure here does not drop until the Notes and measures to be observed before starting
fuel system is opened and the fuel can es- work on the fuel system
cape.
• The fuel system must be closed. Make a visual
- Only start the engine when all the protective inspection for leaks I damage to the fuel system.
devices have been fitted. Make sure no-one is
• Clean the whole engine and engine room with the
standing in the danger area .
II -
-
Cleaning, maintenance and repair work may
only be performed with the engine at a stand-
still and secured against starting.
Fuel lines, injection lines or fuel high-pressure
system closed before starting work on the fuel
system.
• The engine must be dry when you start working
on the fuel system.
• Blowing (dry) with compressed air is only permis-
lines must never be disconnected when the
sible with the fuel system closed.
engine is running.
• When using a steam jet, first cover up the control
- Danger of injury !
unit. the cable plugs, all other electrical plug con-
The fuel jet can deeply penetrate the skin.
nections and the generator. Also, the steam jet
- Do not come close to the leakage area in the may not be pointed directly at them.
fuel high-pressure system with any body parts
• Electrical plug connections must be plugged
(for example hand).
when spraying.
- Always carry out an exact visual inspection of
• Remove loose parts (for example paint chips
all high-pressure carrying components before
from assembly work) with an industrial vacuum
tests on the running engine. Wear suitable
cleaner or other suction device. Only suction may
protective clothing (for example goggles,
be used in assembly work on the open fuel sys-
gloves) for this. Leakages entail potential haz-
tem.
ard sources for the workshop personnel.
• Only work on the fuel system in a clean environ-
- Even if no leakages can be discerned in the
ment (no dust. no grinding or welding). Avoid
fuel high-pressure system, the workshop per-
draughts (dust). Clean the workshop floor regu-
sonnel should avoid the direct hazard zone or
larly. No brake or performance test benches may
wear protective clothing (for example goggles,
be kept or operated in the same room.
gloves) during tests when the engine is run-
ning and during the first test run. • Air currents which kick up dust, such as those
caused by brake repairs or the starting of en-
- Always stay out of range of a fuel Jet, as it
gines, should be avoided.
could cause severe injury.
• For work such as removal and installation on de-
- Fuel lines. injection lines and high-pressure
fective hydraulic components on the Common
lines must not be deformed .
Rail System it is recommended to partition off a
- Damaged fuel lines. injection lines and high- separate workshop area in the factory. This must
pressure lines must be replaced. be separate from other areas in which general
- Smoking is strictly prohibited when working on vehicle repairs such as brake repairs are carried
the fuel system . out.
- Do not work near to sparks and flames. • No general machine tools may be operated in
- Never disconnect an injector when the engine this room.
is running. • Regular cleaning of the workshop area is manda-
- Loosen screw connections slowly and not tory. Draughts, ventilation systems and heating
abruptly fans should be minimised.
- Open screw connections on the fuel system • Areas of the engine room from which particles of
with extreme caution. dirt could be loosened (for example the bottom
part of the lipped driver cab) must be covered
- After all work on the fuel system, it must be
with fresh clean film.
bleeded - see the operation manual, chapter
"6 Fuel system". • Working materials and tools must be cleaned be-
fore work. Only use tools without damage to 1he
3.2.2 Cleanliness instructions and measures chrome plating or tools which are not chrome-
for working with common rail systems plated.
The common rail systems used in DEUTZ engines Notes and measures to be observed during work on
comprise high-precision components subjected to the fuel system or with the fuel system open.
extreme loads. In view of the high-precision technol-
ogy, ensure utmost cleanliness when working on • Only work in clean overalls.
the fuel system.
© 09/?012
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DEUTZ
A. DEUTZ engines Safety information/ User information
• Only lint-free cleaning cloths may be used for Noles and measures for workbench and tools in the
work on the fuel system. vehicle hall
• Remove loose parts (for example paint chips • A special workbench must be set up for work on
from assembly work) with an industrial vacuum removed components.
cleaner or other suction device. Only suction may
• Clean the removal and installation tools regularly
be used in assembly work on the open fuel sys-
tem.
• Working materials and tools must be cleaned be-
fore work. Only use tools without damage to the
chrome plating or tools which are not chrome-
and keep them in a closed tool cabinet.
• Remove loose parts (for example paint chips
from assembly work) with an industrial vacuum
cleaner or other suction device.
II
plated. • Working materials and tools must be cleaned be-
fore work. Only use tools wi1hout damage to the
• Do not use used cleaning fluid or test fluid for
chrome plating or tools which are not chrome-
cleaning.
plated.
• Compressed air must not be used for cleaning on
the open fuel system. 3.2.3 Additional information and measures for
the handling of exhaust aftertreatment
• Work on removed components may only be per-
systems
formed at a suitably equipped workbench.
• When removing and installing components. no • Basically all the same regulations and instruc-
materials which can leave behind particles or fi- tions up to and including chapter 3.2.2 must also
bres (cardboard, wood, cloths) may be used. be observed for work on exhaust aftertreatment
systems!
• Removed parts may only be rubbed down with
clean, lint-free cloths. No dirt particles may be • Utmost cleanliness must be observed for all
rubbed into the components. work.
• Openings on the components and on the engine DPF (Diesel Particle Filter)
must be closed immediately with suitable stop- • The filter regeneration must be deactivated or, in
pers/caps. systems with a filter regeneration prompt, not ac-
• The stoppers/caps may only be removed imme- tivated before performing service work.
diately before installing. • The duration of a full filler regeneration is 25 min-
• Store stoppers/caps free from dust and dirt in the utes on average. High exhaust temperatures oc-
original packaging and dispose of after using cur in the exhaust system/on lhe end exhaust
once. pipe independently of the actual load state of the
engine (i.e. also during engine idling).
• Only remove new parts from the original packag-
ing Just before installation. • No foreign bodies may get into the exhaust line or
the combustion chamber. If this happens, the en-
• Removed components must be kept in new, seal- gine must be "run free" without
able bags or - if available - in the packaging of the
diesel particle filter.
new parts.
• Tensions and deformations of the shape of the V-
• Always use the original packaging of the new part
belt clip must be avoided . The DPF module may
to send back the removed components. only be transported using the transport sleeves .
Notes and measures for the vehicle workshop area • V-belt clips and seals may not be reused (this
• For work such as removal and installation on de- also applies as soon as the screw connection has
fective hydraulic components on the Common been loosened once).
Rail System it is recommended to partition off a Ignition system
separate workshop area in the factory. This must • Caution! Dangerous high voltage.
be separate from other areas in which general
The ignition system operates with ignition voltag-
vehicle repairs such as brake repairs are carried
es up to 10000 Volts.
out.
• The ignition system must not be operated without
• The workshop floor is sealed or tiled.
a secondary load.
• No welding gear, grinders, general machine
• Store the components in a dry and clean area.
tools, brakes or performance test benches may
be operated in this room. • It is not permitted to store the components tem-
porarily or stack them without their transport
• Regular cleaning of the workshop area is manda- packaging.
tory. Draughts, ventilation systems and heating
fans should be minimised. • Components may only be stored and transported
in the specified packaging.
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OBJ_OOKU-31078-001.fm
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• Only remove new parts from the original packag- Disposal includes recycling and the scrapping of
ing just before installation. parts/ operating materials, although recycling has
• Incorrectly operated or damaged components or priority.
parts that have been dropped must not be in- Details of disposal and their monitoring are gov-
stalled . erned by regional, national and international laws
• Do not subject the components to any hard im- and directives which the system operator must ob-
II pacts or any other use of force.

• Faulty earthing, cable and plug connections can
lead to malfunctions. Electronic components can
be destroyed .
serve on his own responsibility.
• Dirt and moisture on the primary and high voltage

connections can cause malfunctions (leakage
currant, misfiring, high voltage sp,'.Hks) .
• Check the protective caps of the ignition lines for
discolouration, deformation and cracks before
each usage.
SCR (Selective Catalytic Reduction)
• Ad Blue® is a caustic medium which causes
heavy corrosion damage when it comes into con-
tact with electronic components or similar.
• Leaks on the Ad Blue® pipes, the tank, the supply
module and the feeding unit must be fixed imme-
diately to avoid leakage of AdBlue®.
• Make sure the room is well ventilated .
• Contact with the skin should be avoided. Wear la-
tex gloves if possible.
• Wash hands thoroughly before taking breaks and
at the end of shifts.
• If the substance comes into contact with eyes,
rinse thoroughly with water.
• If swallowed, rinse out mouth with a lot of water,
drink plenty of water and seek medical advice.
• If discomfort or illness continues, seek medical
advice.
• Product can pose danger of slipping if spilled. It
is essential to remove spilled liquid. In so doing,
ensure that the liquid does not enter the sewage
system or ground/surface water. This means that
the contamination should be physically removed
and disposed of in suitable containers. Minimal
amounts of remaining liquid may be rinsed away
with a lot of water.
• The so-called lag time is application-dependent
and may be up to 2 minutes in engines with an
SCR system because the SCR pipes have to be
pumped empty in this time.
3.2.4 Disposal regulations
The work described in !he operation manual and
workshop manual necessitates renewal of parts and
operating materials among other things. The re-
newed parts/ operating materials must be stored,
transported and disposed of according to regula-
tions. The owner himself is responsible for this.
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OBJ_DO KU-31078-001 fm
3.3 Operation manual and workshop man- 3.4 Job cards

ual The job cards are differentiated into "W" and "I" job
In order to structure the information layout in a user- cards.
friendly way, the service documentation is divided The "W' job card documents the standard repairs to
into operating instructions and Job cards (workshop the engine and/or its components. The necessary
II
manual). tools and special tools are also indicated in the "W"
The operation manual contains a general descrip- job card.
The "I" job card also documents corresponding
tion and instructions for all other maintenance work _
workflows for repairing the engine and/or its compo-
II contains the following chapters: nents. Special prerequisites must be fulfilled by the
1. Contents, General workshops for implementation of these workflows.
2. Engine description For example, special tools and machine tools must
be available.
3. Operation
4. Operating media 3.4.1 Numbering of job cards
5. Maintenance The job card numbering uses the format W 08-03-
01. The individual parts of this formal are explained
6. Care and maintenance work
below:
7. Faults, causes and remedies
• W 08-03-01: Documentation type
8. Engine conservation
- W .... Workshop manual
9. Technical data
- I ... .. . Repair manual
10.Service
• W 08-03-01: Module
The use of job cards (workshop manual) presuppos-
es knowledge of the operating instructions content, according to module list
this applying in particular for the service specifica- • W 08-03·01: Component group
tions. Repairs to the engine and components are • W 08-03-01: Consecutive number
described in the job cards (workshop manual), for
the implementation of which more effort and corre-
spondingly qualified experts are required.
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DEUTZ engines
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3.4.2 Structure of a job card 3.5 Explanation of symbols

Danger!
of death or to health. Must be observed!
For example: The incorrect use or conver-
sion of the turbocharger can lead to serious
II
injury.
Caution!
Danger to the componenVengine. Non-
compliance can lead to destruction of the
componenUengine.
Must be observed!
15 Note
General notes on assembly, environmental
protection etc. No potential danger for man
or machine.
Tool
Conventional and special tools required for
_ _ __. 9
the work .
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils. adhesives, sealants)
References
to important documents
1. DEUTZ AG,
publisher of service documentation Reference
2. Number of associated spare parts list sheet within the workf1ow or to assemblies in
(ETL) which further documents or job cards are
3. Assembly - Designation provided.
4. Numbering of the job cards Test and setting data
5. DEUTZ internal creation number The necessary values are indicated here
with link to a table within the job card.
6. Title of job card
Tightening specifications
7. References/ Notes
The necessary values are indicated here
8. Chapter with link to a table within the job card.
9. Graphic or photo
10. DE UTZ internal designation
11.Page number
12.Date of issue of job card
13.Note
14. Danger/ Important
15. Parts list/ Workflow
16.Auxiliary materials
17. Conventional tools, special tools
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Job card overview
Sorted alphabetically
OBJ_DOKU-31 079-001.lm
5 Job card overview

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5.1 Sorted alphabetically
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Job card overview
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Job card overview
OBJ_00 KU-31079-001.frn
Activity Job card Module

Charge air line W 22-90-55 Charge air line
Charge air manifold W 22-90-54 Charge air line
Checking the thermostat (in the removed state) W 38-01-02 Thermostat housing
Closing parts W 02-90-01 Lubricating oil sump
Compensator structure (Exhaust line) W 41-90-21 Exhaust pipe
Connection (Crankcase housing, exhaust gas circu-

W 41-90-04 Exhaust gas recirculation
lation, coolant line)
Connection housing
Console
W 52-90-53
W 71-90-51
Connection housing
Exhaust gas treatment

II
Drive components W 37-90-06 Coolant pump
Engine mounting W 46-90-15 Engine mounting
Engine mounting W46-90-15 Engine mounting
Engine mounting W 46-90-15 Engine mounting
Exhaust manifold (exhaust turbocharger) W 43-90-36 Exhaust gas turbocharger
fuel filter W 20-90-17 fuel filter
Fuel line W 20-90-30 Fuel pipes
Fuel pre-filter W 20-90-16 Fuel filter
Generator W 44-90-42 Parts to generator
Generator W 44-90-42 Parts to generator
Holder W 09-90-09 Gearcase
Impulse transmitter (camshaft) W 51-90-20 Measuring instruments
Intake nozzle (exhaust turbocharger} W 22-90-35 Air intake pipe
Intermediate gear W 09-90-50 Gearcase
Line W 38-90-32 Coolant pipes
Line W 01-90-32 Crankcase breather
Line (Thermostat housing, exhaust gas circulation,

coolant line)
Lubricant oil filter console W 15-90-38 Lubricating oil filler
Oil filling W 02-90-24 Lubricating oil sump
l· Oil measuring device W 01-90-23 Oil measuring device
Pressure fan W 39-90-52 Fan
©0912012 3112
Job card overview
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DEUTZ

Pressure transmitter I temperature pressure trans-
W 22-90-20 Charge air line
milter (charge air)
Removing and install the charge air line W 22-01-01 Charge air line
Removing and installing charge air manifold W 22-04-01 Charge air line
Removing and installing hydraulic pump drive W 83-02-01 Hydraulic pump drive
Removing and installing the belt tensioner (V-rib

W 44-01-01 Add-on parts
belt, level 1)
II Removing and installing the connection housing
Removing and installing the connection housing

W 52-01-01
W 52-01-01
W 52-01-01
Connection housing
Connection housing
Connection housing
Removing and installing the connection housing W 52-01-01 Connection housing
Removing and installing the connection housing W 52-01-01 Connection housing

Removing and installing the console (V-rib belt. level
1)
Removing and installing the cylinder head cover W 08-01-01 Cylinder head cover
Removing and installing the exhaust line W41-01-01 Exhaust pipe
Removing and installing the exhaust line W 41-01-01 Exhaust pipe
Removing and installing the flywheel (Fastening

W 05-03-01 Flywheel
parts)
Removing and installing the fuel line (injector, rail,

W 21-05-05 Fuel pipes
high-pressure pump)
Removing and installing the gasket housing W 01-03-01 Crankcase
Removing and installing the generator (Clamping

W 44-02-01 Generator
latch)
Removing and installing the generator (Fastening

parts)
Removing and installing the glow plugs W 63-02-01 Start aid

Removing and installing the high-pressure pump W 17-01-04 High-pressure pump
Removing and installing the injector W 19-01-01 Injector

Removing and installing the lubricating oil cooler W 15-02-01 Lubricating oil cooler
Removing and installing the lubricating oil line (ex-
W 16-04-01 Lubricating oil pipe
haust turbocharger)

haust lurbocharger)
Removing and installing the lubricating oil pan W 02-01-01 Lubricating oil sump
Removing and installing the lubricating oil return line
(exhaust turbocharger)

Removing and installing the oil suction pipe W 16-01-01 Oil suction pipe
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Job card overview
OBJ_DOKU-31079-001. fm

Removing and installing the rail W 21-04-01 Fuel pipes
Removing and installing the starter W 44-03-01 Starter
Removing and installing the starter W 44-03-01 Starter
Removing and installing the thermostat W 38-01-01 Thermostat housing
Removing and installing the transfer line W 01-07-05 Crankcase
Removing and installing the turbocharger W 43-01-01 Exhaust gas turbocharger

Removing and installing the turbocharger W 43-01-01
Renewing the crankshaft sealing ring (flywheel side) W 01-02-01
Supply pump (Fuel) W 20-90-47

Exhaust gas turbocharger
Crankcase
Fuel supply pump

II
V-rib belt pulley W 37-90-13 Coolant pump
V-rib belt pulley W37-90-13 Coolant pump
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Job card overview
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Job card overview
Sorted numerically
OBJ_DOKU-31079-001. Im
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Job card overview
Sorted numerically
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Job card overview
Sorted numerically
Job card Activity Module

W 01-02-01 Renewing the crankshaft sealing ring (flywheel side) Crankcase
W 01-03-01 Removing and installing the gasket housing Crankcase
W 01-07-05 Removing and installing the transfer line Crankcase
W 01-90-23 Oil measuring device Oil measuring device
W 01-90-32 Line Crankcase breather
W 02-01-01 Removing and installing the lubricating oil pan Lubricating oil sump
W 02-90-01
W 02-90-24
Closing pans
Oil filling
Removing and installing the flywheel (Fastening

Lubricating oil sump
Lubricating oil sump II

W 05-03-01 Flywheel
parts)
W 08-01-01 Removing and installing the cylinder head cover Cylinder head cover
W 09-90-09 Holder Gearcase
W 09-90-50 Intermediate gear Gearcase
W 15-02-01 Removing and installing the lubricating oil cooler Lubricating oil cooler
W 15-90-38 Lubricant oil filter console Lubricating oil filter
W 16-01-01 Removing and installing the oil suction pipe Oil suction pipe

haust turbocharger)

haust turbocharger)


W 17-01-04 Removing and installing the high-pressure pump High-pressure pump
W 19-01-01 Removing and installing the injector Injector
W 20-90-16 Fuel pre-filter Fuel filter
W 20-90-17 Fuel filter Fuel filter
W 20-90-30 Fuel line Fuel pipes
W 20-90-47 Supply pump (Fuel) Fuel supply pump
W 21-04-01 Removing and installing the rail Fuel pipes
Removing and installing the fuel line (iniector, rail,

W 21-05-05 Fuel pipes
high-pressure pump)
W 22-01-01 Removing and install the charge air line Charge air line
W 22-04-01 Removing and installing charge air manifold Charge air line
Pressure transmitter I tempera tu re pressure trans-

W 22-90-20 Charge air line
milter (charge air)
W 22-90-35 Intake nozzle (exhaust turbocharger) Air intake pipe
© 0912012 9112
Job card overview
Sorted numerically
A.
DEUTZ
W 22-90-54 Charge air manifold Charge air line
W 22-90-55 Charge air line Charge air line
W 37-90-06 Drive components Coolant pump
W 37-90-13 V-rib belt pulley Coolan1 pump
W 37-90-13 V-rib belt pulley Coolant pump
W 38-01-01 Removing and installing the thermosta1 Thermostat housing
II W 38-01-02
W 38-00-32
W 38-90-32
Checking the thermostat (in the removed state)
Linc
Line
Thermostat housing
Coolant pipes
Coolant pipes
W 38-90-32 Line Coolant pipes
W 39-90-52 Pressure fan Fan
W 41-01-01 Removing and installing the exhaust line Exhaust pipe
W 41-01-01 Removing and installing the exhaust line Exhaust pipe
Connection (Crankcase housing, exhaust gas circu-

lation, coolant line)
W41-90-21 Compensator structure (Exhaust line) Exhaust pipe
Line (Thermostat housing, exhaust gas circulation ,

coolant line)
W 43-01-01 Removing and installing the turbocharger Exhaust gas turbocharger
W 43-01-01 Removing and installing the turbocharger Exhaust gas turbocharger
W 43-90-36 Exhaust manifold (exhaust turbocharger) Exhaust gas turbocharger
Removing and inslalling the belt tensioner (V-rib

belt, level 1)
Removing and installing the generator (Fastening

parts)
Removing and installing the generator (Clamping

latch)
Removing and installing the console (V-rib belt, level

1)
W 44-03-01 Removing and installing the starter Starter
W 44-03-01 Removing and installing the starter Starter
W 44-90-42 Generator Parts to generator
W 44-90-42 Generator Parts to generator
W 46-90-15 Engine mounting Engine mounting
©:J9il.lJ1l 10/12
A.
DEUTZ
Job card overview
Sorted numerically
OBJ_DOKU-31079-001 .frn

W 51-90-20 Impulse transmitter (camshaft) Measuring instruments
W 52-01-01 Removing and installing the connection housing Connection housing
W 52-90-53
W 63-02-01
W 71-90-51
Connection housing
Removing and installing the glow plugs
Console
Connection housing
Start aid

II
W 83-02-01 Removing and installing hydraulic pump drive Hydraulic pump drive
11 /12
Job card overview
Sorted numerically
OBJ_DOKU-31079-001.tm
A.
DEUTZ
II
© 0912012 12/12
A.
DEUTZ DEUTZ engines Job cards
OSJ_DOKU-31080-001.frn
6 Job cards
II
© 0912012 1/2
Job cards
OBJ_ DOKU-31080-001 .fm
DEUTZ engines A.
DEUTZ
II
©0912012
2/2
A.
DEUTZ
Crankcase
W 01-02-01
Renewing the crankshaft sealing ring

(flywheel side)
[I] Standard tools
Special tools:
- Pricker 01899103
- Assembly lever 01899110
- Assembly tool 02992214
~
- Self-tapping screw
- Washer
II
Removing the crankshaft sealing ring
Gasket housing
2 Shaft sealing ring
3 Hexagon head screw
188 Packing compound
<::/5051d-~
• Remove flywheel.
__::__; Module 05
• Make a hole of approximately 3 mm in the crankshaft

sealing ring with a pricker.
~ Attention!
~ Do not damage the gasket housing and
crankshaft!
al< 7083-1
©091~!)12
1/4
Crankcase
W 01-02-01
OBJ _DOKU-31081-001 .fm
A.
DEUTZ
• Screw in a self-tapping screw ( 1) with washer,
•
II
•Pullout the crankshaft sealing ring with assembly le-
ver.
~ I,
EJ
Ensure that the crankshaft does not get
damaged.
L •
• Visually inspect the crankshaft sealing ring running
surface .
Installing the crankshaft sealing ring

• Mount guide sleeve ( 1).
• Tighten screws (2) .
~ The bores in the guide sleeve must match
~ the threaded holes in the crankshaft
flange.
-.
'
'
iJ C9,'2012
2/4
A.
DEUTZ
Crankcase
W 01-02-01
OBJ_00 KU-31 081-001 .fm
• Place the crankshaft sealing ring carefully on the pe-

ripheral surface.
~ Do not oil waxed crankshaft sealing rings.
E_J The sealing lip faces the crankcase.
© 47089-1
II
• Mount assembly sleeve { 1 }.
• Press on the crankshaft sealing ring to the stop. _) •
• Plug in the bearing (2).
• Screw on nut (3).
0
• Tighten nut to the stop of the assembly sleeve { 1).

r:;;:i The installation depth is determined by the
EJ assembly tool.
• Remove assembly tool.

• Install flywheel.
..
CJ Module 05
~
L
•
() • 709 1·1
(1) 09/2012
3/4
Crankcase
W 01-02-01
OBJ _OOKU-31 081-001.lm
A.
DEUTZ
II
©0912012 414
Crankcase
W 01-03-01
OBJ_DOKU-31082 001.frn
Removing and installing the gasket housing
Standard tools:
- Splint driver
- Packing compound
DEUTZ OW 67
II
Removing the gasket housing
1 Gasket housing
2 Shaft sealing ring
© 50518-0
L.:j·· Module 05
• Remove connection housing .

G Module 52
• Remove lubricating oil pan.

CJ Module 02
• Unscrew all screws (1 ).
• Remove gasket housing (2).
©0912012
114
Crankcase
W 01-03-01
A.
DEUTZ
• Knockout crankshaft sealing ring (1 ).
It@ Attention!
li2J Do not damage the sealing surfaces.
• Visually inspect the components.
II 0 50520 0
Installing the gasket housing

• Clean sealing surfaces.
• Apply sealing compound (1) evenly on the sealing
surface.
bl Sealing cord strength approx. 0 .5 -
EJ 0.6mm.
!.: 50521 0
• Mount gasket housing.

• Tighten screws ( 1).
30912012
214
A.
DEUTZ
Crankcase
W 01-03-01
The sealing face (arrows) must be flush

with the oil pan sealing face.
II
• Tighten the screws according to the tightening se-
quence.
!'!,·. 20 Nm
• Renew crankshaft sealing ring (flywheel side).
~ ---. ~
,__ . Module 01
• Install lubricating oil pan.
/ ___ / Module 02
• Install connection housing.

,:_ _} Module 52
I
• - :/ Module 05
3/4
Crankcase
W 01-03-01
OBJ_DOKU-31082-001.Im
A.
DEUTZ
Technical Data
ID no. Name Screwtvoe Notes / Remark Value
Observe tightening
A01 095 Gasket housing on crank.case 20 Nm
sequence
For 1he tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of+/- 10% is permissible.
II
4 /4
A.
DEUTZ
Crankcase
W 01-07-05
OBJ _DOKU-31083-001.fm
Removing and installing the transfer line

Standard tools
- Packing compound
DEUTZ OW 73
II
Removing the transfer line
1 Transfer line
2 Torx screw
3 Screw plug 35 Nm
© 50~2~-0

L) Module 02
• Unscrew screws ( 1).

• Remove transfer line (2).
• Visually inspect the component.
©0912012 114
Crankcase
W 01-07-05
A.
DEUTZ
Installing the transfer line

~ Attention!
L...i2J
No packing compound must get into the oil
channel (1 )!
II .. ( .
\
., e 50723-1
• Apply sealing compound (1) evenly on the sealing

surface.
0
©51276-0

• Mount transfer line (1 ).
• Tighten screws (2).
-'"'· -:., 20Nm

• Install lubricating oil pan .
...:....} Module 02
214
A.
DEUTZ
Crankcase
W 01-07-05
OBJ_DOkU-31083-001 fm
Technical Data
ID no. Name Screw e Notes / Remark Value
A01 016 Transfer line on crankcase 20 Nm
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of+/. 10% is permissible.
II
3/4
Crankcase
W 01-07-05
A.
DEUTZ
II
4/4
A.
DEUTZ
Oil measuring device
W 01-90-23
OBJ_DOKU-31084-001 .Im
[1J Standard tools
II
Oil dipstick
2 Ball
3 Stopper
4 Guide tube
5 0-ring
IIJ@rl Use new round sealing ring.
.: 50392·0
© U912012 1/2
W 01-90-23
0BJ_DOKU-31084-001 .Im
A.
DEUTZ
II
'9 0912012
2/2
A.
DEUTZ
Crankcase breather
W 01-90-32
Line
rn Standard tools
II
Pipe clip
2 Pipe
3 Spring band clip
4 Rubber sleeve
5 Intake nozzle
6 Spring band clip
7 Hexagon head screw 8 Nm
© 50658·0
©0912012
1/2
Crankcase breather
W 01-90-32
OBJ_DOKU-31085-001 Jm
A.
DEUTZ
II
© 091.2012 2/2
A®
DEUTZ
W 02-01-01
OBJ_DO KU-31086-001 .fm
Removing and installing the lubricating oil pan
[]] Standard tools
Special tools:
Attention!
Make sure that no gasket residue falls into
the crankcase.
- Separating tool 02992301
Seal all openings .
- Packing compound
Collect leaking operating substances in
DEUTZ OW 73
suitable vessels and dispose of according
to regulations .
Emptying and filling the engine with opera-
ting media must be carried out according to
the operating manual and the appropriate
documentation of the vehicle/equipment
manufacturer.
II
Removing the lubricating oil pan
244
Lubricating oil pan
2 Nut
3 Torx screw
2
4
t,512860
• Drain lubricating oil, collect and dispose of according

to regulations.
• Unscrew all screws (arrow).
• Remove lube oil tray (1).
• • • • • ,
•
' -
r l
'
I
I
•l J
·-~·--·
11
1
-
• • •
1/6
W 02-01-01
A.
DEUTZ
• Drive in separating tool (1) to the stop (2) .

Attention!
The tool can only be driven in in the area of
the crankcase.
Separation in the area of aluminium parts
is not allowed.
Do not damage the sealing surfaces .
II
• Drive in second separating lool ( 1) to the stop (2).
Attention!
The tool can only be driven in in the area of
the crankcase.
Separation in the area of aluminium parts
is not allowed.
Do not damage the sealing surfaces.
• Lever out lubricating oil pan .

©51290-0
© 0912012 216
A.
DEUTZ
W 02-01-01
Installing the lubricating oil pan

• Scrape off sealing compound with separating tool .
ltW Attention!
t0 Wear protective glasses.
• Clean the sealing surface on the crankcase with a

wire brush.
r:=;;:::i The sealing surfaces must be dry and free
~ from grease and dirt.
II
ltW Attention!
t0 Wear protective glasses.
• Clean the sealing surface on the lubricating oil pan

with a wire brush .
~ The sealing surfaces must be dry and free
~ from grease and dirt.
;; 51292-C
• To align the lubricating oil pan, screw four pin bolts

( 1} diagonally opposed into the crankcase.
ij :ll - --- -
I
I I
_q
•
.
I
• •
--L~
- ~~
. C
- ,
'•·
~~~
.. -- -·
I
3/6
W 02-01-01
OBJ _DOKU-31086-001 fm
A.
DEUTZ

r.:;;;i The sealing surfaces must be dry and free
L'.:::_J from grease and dirt.
• Apply packing compound to the joints (arrows).
II © 51:/93-0
• Apply packing compound evenly to the sealing sur-

face.
© 51294-0
• Align the lubricating oil pan in the appropriate instal-

lation position with the pin bolts.
• Mount lubricating oil pan.
Attention!
Do not move the lubricating oil pan any
more. r ,
Observe the drying time for the packing l 1 •
compound.
• Unscrew the pin bolts.
• • ,.
I
• Fasten all screws (1).
I~
'~\T
• •- • • • •· • .,
J
•I
0 @ 51295-0
©0912012
4/6
DEUTZ
A. Lubricating oil sump
W 02-01-01

quence.
!P,r~ 20 Nm
• Fill in lubricating oil according to operating manual.
14 13 1 2 3 4 5 15 16
© 51296-0
II
~ 0912012
5/6
W 02-01-01
OBJ_DOKU-31 086-001 .Im
A.
DEUTZ
Technical Data
ID no. Name Screwtvpe Notes / Remark Value
Observe lightening
A02 030 Lubricating oil pan on crankcase 20 Nm
sequence!
For the tightening procedure according to torque using a torque wrench, a maximum varlation of the
II
© 0912012 6/6
A.
DEUTZ
W 02-90-01
Closing parts
rn Standard tools Collect draining lubricating oil and dispose
of properly.
II
1 Screw plug 55 Nm
2 Sealing ring
1~ 1 Use a new sealing ring.
© 50331-0
©0912012
1/2
W 02-90-01
A.
DEUTZ
II
© 09!:?0'i.2 212
A.
DEUTZ
W 02-90-24
OBJ_D0 KU-31 068-001 .fm
Oil filling
[I] Standard tools
II
1 Oil filler pipe
3 Filler lock
4 Seal
5 Screw plug 95 Nm
l~ I Use a new gasket.
© 50668-0
:!;l 0912012
1/2
W 02-90-24
OBJ DOKU-31088-001 .fm
A.
DEUTZ
II
2/2
A.
DEUTZ
Flywheel
W 05-03-01
Removing and installing the flywheel

(Fastening parts)
[I] Standard tools
Special tools:
- Guide pin (self-const-
ructed)
- Auxiliary screws M10x120
- Rotation angle disc 01899093
II
Removing the flywheel
Flywheel
2 Ring gear
3 Screw
4 Bearing bush
© 51460-0
• Hold the crankshaft at the central screw.

• Screw in auxiliary screws ( 1 ).
• Unscrew screws (2).
• Remove flywheel using auxiliary screws .
~ 5M62-U
©0912012 1/4
Flywheel
W 05-03-01
A.
DEUTZ
Installing the flywheel

• Insert self-made guide pin (arrow) .
bl The bores in the flywheel must match the
EJ threaded bores in the crankshaft flange.
• Mount flywheel using auxiliary screws.
II
~ Attention!
Lf£J
Renew screws every time they are loo-
sened.
• Tighten screws alternately.
- Stage 1:
,~e·,c.:, 30 Nm
• Tighten screws with rotation angle disc.

- Stage 2:
- Stage 3
i"'r'•:, 30"
• Remove guide pin.

• Unscrew auxiliary screws.
© 0912012
2/4
A.
DEUTZ
Flywheel
W 05-03-01
OBJ_ DOKU-31089-001 Jm
Technical Data
ID no. Name Screw type Notes / Remark Value
Stage 1:
A05 001 Flywheel on crankshaft 30 Nm
Use new screws
A05 001 Flywheel on crankshaft Stage 2: 60°
A05 001 Flywheel on crankshaft Stage 3: 30°
For the tightening procedure according to torque using a torque wrench. a maximum variation of the
lightening torque of +/- 10% is permissible.
II
© 091201:?
3/4
Flywheel
W 05-03-01
OBJ_DOKU-31089-001 fm
A.
DEUTZ
II
11: 09120',2 4/4

A.
DEUTZ
Cylinder head cover
W 08-01-01
Removing and installing the cylinder head cover
[I] Standard tools
II
Removing cylinder head
Cylinder head cowling
2 Seal
3 Screw
4 Filler lock
5 Plug piece
• Removing the crankcase breather.

L,:} Module 01
• Remove cylinder head cowling (2).
1/4
Cylinder head cover
W 08-01-01
OBJ_OO KU-37090-001 .fm
A.
DEUTZ
• Remove gasket ( 1).
II ~ 50509 0
Installing cylinder head cover.

• Mount new gasket (1) .
G 50509-0
• Mount cylinder head cover (1) .
2/4
Cylinder head cover
W 08-01-01
OBJ_DOKU-31 090-001. fm

quence.
§,"•~ 8.5 Nm
• Install crankcase breather.
W Module 01
4 5
© 50511-0
II
©0912012
3/4
Cylinder head cover
W 08-01-01
A.
DEUTZ
Technical Data
ID no. Name Screw e Notes/ Remark Value
A08 004 Cylinder head cover on cylinder head 8.5Nm
For the lightening procedure according to torque using a torque wrench. a maximum variation of the
4/4
Gearcase
~>®
DEUTZ W 09-90-09
OBJ_0OKU-31091-001 fm
Holder
[1] Standard tools - Safety information / User

information
Attention!
Ensure utmost cleanliness for all work.
Remove any paint residue and dirt par-
ticles before disassembly.
Clean the area around the components
concerned carefully. Blow wet parts dry
with compressed air.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
II
1 Holder
2 Impulse transmitter
3 Hexagon head screw 8.5 Nm
Position 2:
1~ I Use new round sealing ring.
~51285-0
~ 0912012
1/2
Gearcase
W 09-90-09
OBJ DOKU-31091-001 ,lm
A.
DEUTZ
II
212
A.
DEUTZ
Gearcase
W 09-90-50
OBJ _DOKU-31 092-001.fm
Intermediate gear
[I] Standard tools
II
1 Intermediate gear
2 Shaft
©091201:/
112
Gearcase
W 09-90-50
06J_D0K U-31092-001 fm
A.
DEUTZ
II
© 09120" 2 2/2
DEUTZ
A. Lubricating oil cooler
W 15-02-01
OBJ_DO KU-31093-001 .fm
Removing and installing the lubricating oil cooler
[ ] ] Standard tools Collect leaking operating substances in

to regulations.
The appropriate operating manual should
be observed for emptying and filling the
engine.
II
Removing the lubricating oil cooler . (
1 Lubricating oil cooler

(
2 Seal
• Unscrew all screws ( 1).

• Remove lubricating oil cooler (2).
• Remove gasket (3).
r:;;i Collect draining lubricating oil and dispose
EJ of property.
~ 5C279 0
~ 09/2012
1/4
Lubricating oil cooler
W 15-02-01
A.
DEUTZ
Installing the lubricating oil cooler

• Turn in screws (arrows).
M8x20-10.9
• Fasten new seal (1) on lubricant oil cooler housing
with screws.
II I:: 50280·0
• Mount lubricating oil cooler ( 1 ).

• Tighten screws (2)
• Tighten all screws (2) alternalely .
.-"'" • ·. 30 Nm
~)5C2S1-0
2/4
A.
DEUTZ
W 15-02-01
OBJ_DOKU -31093-001 fm
Technical Data
A 15 051 Oil cooler housing on crankcase 30 Nm
tightening torque of +/- 10% is permissible.
II
3/4
W 15-02-01
OBJ_DOK U-31 093-001.fm
A.
DEUTZ
II
:al 09120"2 4/4

A.
DEUTZ
Lubricating oil filter
W 15-90-38
Lubricant oil filter console

[I) Standard tools Collect leaking operating substances in
to regulations.
Observe the appropriate operating instruc•
lions for emptying and filling the engine.
II
1 Interchangeable filter 12 Nm
2 Threaded bush
3 Cover
·1
4 0-ring "'l
5
;,
~
(
-
,~ , Use new round sealing ring.
l qlP' JQ•
'~~
•
2
:;;, 50390-0
1/2
Lubricating oil filter
W 15-90-38
OBJ_ DOKU-31094-001 .frn
A.
DEUTZ
II
2/2
A.
DEUTZ
Oil suction pipe
W 16-01-01
O8J_DOKU-31095-001.fm
Removing and installing the oil suction pipe

Standard tools
- Packing compound
DEUTZ DW 73
II
Removing the oil suction pipe
1 Oil suction pipe
2 Torx screw
G) 5()409-0

!..._:j Module 02
• Remove oil suction pipe (2).
©0912072
1/4
Oil suction pipe
W 16-01-01
OBJ_DOKU-31095-001.frn
A.
DEUTZ
Installing the oil suction pipe

• Clean sealing surface.
• Apply 5ealing compound (1) evenly on the sealing
surface.
II
• Clean sealing surface.
• Install oil suction pipe ( 1).
!'!• ,.·.:·, 22 Nm
• Install lubricating oil pan.
~ 1 Module 02
I
© 50727-0
©09R01Z 214
A.
DEUTZ
Oil suction pipe
W 16-01-01
Technical Data
A16 015 Oil suction pipe on crankcase M8x25-10,9 22 Nm
II
© OQ/2012
314
Oi I suction pipe
W 16-01-01
OBJ_DOKU-31095-001 ,fm
A.
DEUTZ
II
414
A.
DEUTZ
Lubricating oil pipe
W 16-04-01
Removing and installing the lubricating oil line

[1] Standard tools Collect leaking operating substances in

to regulations.
Observe the appropriate operating instruc·
lions for emptying and filling the engine.
II
Removing the lubricating oil line
1 Lubricating oil line
2 Hollow screw
3 Sealing ring
© 5{)444-0
• Unscrew hollow screw ( 1}.

• Remove sealing rings (2).
©09/2012
1/4
W 16-04-01
A~
DEUTZ
• Unscrew hollow screw ( 1).

• Remove lubricating oil pipe (3).
II
Installing the lubricating oil line
• Mount lubrication oil line ( 1).
• Mount sealing rings (2).
• Screw on hollow screw (3).

• Mount lubrication oil line (1 ).
• Mount sealing rings (2) .
• Tighten hollow screw (3).
18 Nm
Attention!
Install tension-free.
©:)9/2012 214
W 16-04-01
• Tighten hollow screw ( 1).

!'!'·,::: 18 Nm
ltW Attention!
~ Install tension-free.
II
(;)0912012
314
W 16-04-01
A.
DEUTZ
Technical Data
ID nQ. Name Screw tvoe Notes / Remark Value
Lubricating oil pipe on exhaust tur-
A43 047 Hollow screw Use new sealing rings 18 Nm
bocharQer
A43 048 Lubricating oil line on crankcase Hollow. screw Use new sealing rings 18 Nm
II
4/4
A.
DEUTZ
W 16-04-01
Removing and installing the lubricating oil line

[I] Standard tools Collect leaking operating substances in
to regulations.
Observe the appropriate operating instruc-
tions for emptying and filling the engine.
II
Removing the lubricating oil line
1 Lubricating oil line
2 Hollow screw
3 Sealing ring
©50t56·U
• Unscrew hollow screw (1) .

© 50675-0
G) 0912012
114
W 16-04-01
OBJ_DOKU-31097-001,lrn
A.
DEUTZ
• Unscrew hollow screw (1).

• Remove sealing rings (2) .
• Remove lubricating oil pipe (3).
II
Installing the lubricating oil line
• Mount lubrication oil line ( 1).
• Mount sealing rings (2).
• Screw on hollow screw (3).
• Clean sealing surfaces .

• Mount lubrication oil line (1 ).
• Mount sealing rings (2) .
• Tigh1en hollow screw (3).
18 Nm
Attention!
Install tension-free.
:;l 50676-C
2/4
A.
DEUTZ
W 16-04-01
OBJ DOKU-31097-001.fm
• Tighten hollow screw (1 ).
~ Attention!
L..i2J Install tension-free.
II
© 09,2012
314
W 16-04-01
A.
DEUTZ
Technical Data
Lubricating oil pipe on exhaust tur-
A43 047 Hollow screw Use new sealing rings 18 Nm
bocharger
A43 048 Lubricating oil line on crankcase Hollow screw Use new sealing rinos 18 Nm
For the tightening procedure according to torque using a torque wrench. a maximum variation of the
II
()09120 12 4/4
W 16-05-01

Standard tools Collect leaking operating substances in
Special tools: to regulations.
- Disassembly tool 02992127
- Fitting compound tions for emptying and filling the engine.
DE UTZ AP1908
II
Removing the oil return line
1 Fastening flange
2 0-ring
3 Oil return line
4 0-ring
7 Seal
© 50435-0

116
W 16-05-01
OBJ _OOKU-31098-001 .lm
A.
DEUTZ
• Unscrew screw (1).

• Pull out oil return line (2) in direction of arrow.
II
• Remove flange ( 1) in direction of arrow.
• Remove round sealing ring (2) with disassembly tool.
• Remove the O-ring (1) with the disassembly tool .

0
© 50683-C
216
A.
DEUTZ
W 16-05-01
Mounting the oil return line

• Lightly coat new round sealing ring with DE UTZ
AP1908 mounting compound.
• Insert new O-ring { 1).
0
© 5068•-0
II
• Lightly coat new round sealing ring with DEUTZ
• Insert new O-ring (1) .
• Insert flange (2) in direction of arrow.

• Mount oil return pipe { 1).
• Insert oil return line ( 1) in direction of arrow.
• Fas ten screw (2).
316
W 16-05-01
0BJ _DOKU-31098-001 Im
A.
DEUTZ

• Mount gasket ( 1).
• Mount oil return pipe (2).
Bt· '::-, 8.5 Nm
II
• Tighten screw (1 ).
,",r· •· . 8.5 Nm
ffil Attention'
l.J2j Install tension-free.
4/6
A.
DEUTZ
W 16-05-01
Technical Data
ID no. Name Screw type Notes/ Remark Value
Oil return line on exhaust turbochar-
A43 044 8.5 Nm
Icier
A43 046 Oil return line on crankcase 8.5 Nm
II
5/6
W 16-05-01
OBJ_DOKU-31098-001 Im
A®
DEUTZ
II
© 09<2012
6/6
A.
DEUTZ
W 16-05-01
OBJ_DOKU-31 099-001.fm

[I] Standard tools
Special tools:
to regulations.
- Disassembly tool 02992127
- Fitting compound tions for emptying and filling the engine.
DE UTZ AP1908
II
Removing the oil return line
Fastening flange
2 O-ring
3 Oil return line
4 O-ring
7 Seal
0 . ,. . . 4
rs; 50657 •0
• Unscrew screws (1 ).
1/6
W 16-05-01
A.
DEUTZ
• Unscrew screw ( 1).

•Pullout oil return line (2) in direction of arrow.
II © 506B1-0
• Remove flange ( 1) in direction of arrow.

• Remove round sealing ring (2) with disassembly tool.
• Remove the O-ring (1) with the disassembly tool.

0
© snnBJ-o
©U9.12Q12 2/6
A.
DEUTZ
W 16-05-01
Mounting the oil return line

AP1908 mounting compound .
• Insert new O-ring ( 1).
© 50684-0
II
• Lightly coat new round sealing ring with DEUTZ l I
AP 1908 mounting compound.
• Insert new O-ring (1 ).
• Insert flange (2) in direction of arrow.
01
I., 0
.:; 5068.5-0

• Mount oil return pipe ( 1).
• Insert oil return line (1) in direction of arrow.
• Fas ten screw (2).
~ 50686·0
3/6
W 16-05-01
A.
DEUTZ

• Mount oil return pipe (2).
:''· ,_., 8.5 Nm
II
• Tighten screw (1 ).
f,-, :; 8.5 Nm
liN Attention!
li2J Install tension-free.
© 50688-D
© 0912012 4/6
A.
DEUTZ
W 16-05-01
OBJ_DO KU-31 099-001.fm
Technical Data
ID no. Name Screw type Notes/ Remark Value
Oil return line on exhaust turbochar-
A43 044 8.5 Nm
ger
A43 046 Oil return line on crankcase 8.5 Nm
II
© 0912012
5/6
W 16-05-01
OBJ DOKU-31099-001 fm
A.
DEUTZ
II
,:;J 0912012
6/6
A.
DEUTZ
High-pressure pump
W 17-01-04
Removing and installing the high-pressure pump
w Standard tools:
- Separating tool
Special tools:
- Special wrench 02992112
- Safety information/ User
information
Danger!
- Disassembly tool 02992127 Do not carry out work on the fuel system
- Plugs/caps 01899144 when the engine is running .
The fuel system is under high pressure -
~
- Mirror
Danger of death.
- Marker pen, waterproof,
permanent The fuel pressure can continuously remain
up to several 1OD bar even after stopping
the engine.
Here the fuel pressure is only reduced if
the fuel system is opened and the fuel can
escape outside.
Attention!
II
Remove any paint residue and din par-
Observe the safety regulations and natio-
nal specifications for handling fuels.
tely before assembling .
to regulations.
Removing the high-pressure pump J '.

u
1 High-pressure pump
2
3
Spacer
Hexagonal nut '., ·• .. -'~':f°'~ '
4
5
Washer
O-ring
...
6 Hexagonal nut
7 O-ring
©09/:2012
116
High-pressure pump
W 17-01-04
OBJ_DOKU-31100-001 .lm
• Unlock cable plug and remove.
• Remove high-pressure line .

• Remove fuel pipes.
[__J Module 21
• Unscrew locking screw (1 ).

• Remove sealing ring .
L:} Module 09
II
• Turn crankshaft in engine direction of rotation until
marking is visible.
(1) Marking high-pressure pump gear wheel
• Apply help marking ( 1).

High-pressure pump gear wheel and inter-
mediate gear
ir6:7 Attention!
LJ2j Do not turn the crankshaft any more'
2/6
A.
DEUTZ
High-pressure pump
W 17-01-04
OBJ _DOKU-31100-001 Im
• Unscrew nuts ( 1).

~ Attention!
~ Do not twist the high-pressure pump.
• Remove high-pressure pump (2).

~ Attention!
lJ2j Do not turn the crankshaft any more!
II
Attention!
Do not damage the high-pressure pump
gear wheel.
Use a suitable tool.
• Hold high-pressure pump gear wheel (1 ).

• Unscrew nut (2) .
• Remove washer (3).
• Pull off high-pressure pump gear wheel ( 1) with sep-
arating tool.
• Remove spacer (4) .
• Remove the O-rings ( 1) with the disassembly tool.

Attention!
All the help markings must be transferred
when renewing/changing a part.
Do not turn the crankshaft any morel
3/6
High-pressure pump
W 17-01-04
0BJ_ DOKU-31100-001.fm
A.
DEUTZ
Installing the high-pressure pump

• Mount new O-rings ( 1).
• Push on spacer (2).
Attention!
Ensure that the installation location is free
from faults.
Recess (3) is on the fuel supply side.
II © 51436-0
• Mount high-pressure pump gear wheel ( 1).

liW Attention!
LJ2:..j Pay attention to installation position.
(2) Surrounding groove

(3) Marking
Attention!
from faults.
Do not damage the high-pressure pump
gear wheel.
The clamping pin ( 1) must engage in the
groove (2).
• Fit washer (3).
1~1
• Screw on nut (4).
Use a suitable tool.
• Hold high-pressure pump gear wheel (5).

• Tighten nuts (4)
"',-. 80Nm
© 51438-0
© 0912012
416
A®
DEUTZ
H h-pressure pump
--------------~===:~:D:O~K~U:·31100-001
1g w 17-01-04
OBJ_
.fm
( 1)
t. n! .
Atten 10 . . t permissible. ·1 ble
! tl_ Dry running is no ure must be ava1 a
C-f S fficient fuel press mp.
u - essure pu
at the high-pr - at least 4.3 bar
Fuel pressu re at the supply
II
. h ressure pump.
• Install hig -p t be visible.
Markings mus atch.
· must m
Help marking heel
ump gear w
.
(1) Marking hi _9 h-pressure P
. h-pressure pump gear wheel
Help marking_ h1g ear
(2) and intermediate g
Attention! - h-pressure pump.

Do not twist the h1g
• Sere won nuts (1 ).

• Tighten nuts ( 1 ).
~-,. , :, 21 Nm
• Install locking screw.

____" Module 09
• Install fuel pipes. 1· e

.
• Fit new h1gh-p ressure
21 in .
.· Module
.. - . , lu
• Plug .in an d lock cable P g .
516
High~pressure pump
W 17-01-04
OBJ_ DOKU-31100-001.fm
A.
DEUTZ
Technical Data
ID no. Name Screw type Not~s / Remark Value
High-pressure pump gear wheel and Hold high-pressure pump
A17 004 80 Nm
high-pressure pump drive shaft oear wheeL
A17 031 High-pressure pump on crankcase 21 Nm
For the lightening procedure according lo torque using a torque wrench, a maximum variation of the
II
1l 0912012 6/6
Injector
W 19-01-01
Removing and installing the injector
rn Standard tools
Special tools:
- Diagnostic tool
SerDia 2010
- Safety information / User
information
Danger!
- Assembly pliers 01899050 Do not carry out work on the fuel system
- T orx tool set 01899092 when the engine is running.
- Plugs/caps 01899144 The fuel system is under high pressure -
- Lever tool 02992117 Danger of death.
- Disassembly tool 02992127 The fuel pressure can continuously remain
- Extraction tool 02992138 up to several 100 bar even after stopping
- Slide hammer 02992294 the engine.
escape outside.
Attention!
II
tely before assembling .
to regulations.
Remove injector
1 Injector
2 Sealing disc
3 Clamping claw
4 Screw
© 09/2012
1/6
Injector
W 19-01-01
OBJ_ DOKU-31101-001.frn
A.
DEUTZ
1600 bar Injection system
Attention!
Note assignment of the injector to the
cylinder.
The injector is assigned by the relevant
IMA code (1) to the corresponding
cylinder.
The assignment is saved in the control
unit.
Each time an injector is replaced/renewed,
the correct assignment to the relevant
cylinder must be made by transferring the
new I MA code in the control unit.
II Observe installed injection system1

The I MA codes of the different injection
systems are basically different.
The injector calibration depends on the
installed injection system.
<'l 51243-0
The exact procedure can be taken from the

listed documentation and must be obser-
ved.
'--.i DiagnoSt ic SerOia 2010

tool
SerDia manual
The following work procedure describes

the removal and installation of an injector.
Proceed in the same way lo remove further
injectors.

• Disconnect the fuel line from the injector.
._.} Module 21
Attention!
Position (1 ):
The injector must be renewed if the pipe
connection is disconnected.
• Hold pipe connection ( 1).
• Remove injection line.
/__::__.1 Module 21
© 0912012
2/6
A.
DEUTZ
Injector
W 19-01-01
• Insert lever tool ( 1) in the clamping claw.

• Loosen the injector by moving the lever tool ( 1) in the
direction of the arrow.
• Remove injector and clamping claw.
;) 50<62-0
II
Attention!
Do not brush off the nozzle tip of the iniec-
tor_
Do nol damage nozzle head on the inJector
during disassembly of the sealing disc (1).
• Grip fixed sealing disc (1) using the assembly
pliers (2) and pull off with slight turning movements.
Removing fixed sealing disc at cylinder head

• Insert extraction device (1) .
bl The supports (arrow} must rest in the bore
EJ of the sealing disc.
3/6
Injector
W 19-01-01
OBJ_ DOKU-31101-001 fm
A.
DEUTZ
• Screw in spindle (1) until the sealing disc is fastened

on the pull-out device.
[~ I Hold puller on hexagon .
• Install adapter (2) on disassembly device.
II
• Install slide hammer ( 1) on disassembly device.
• Pull out fixed sealing disc.
Installing the injector

• Mount new sealing disc ( 1) on injector.
Attention!
Before installing the injector, combustion
residue must be cleaned carefully from the
bore on the cylinder head.
Suck off dirt particles.
© 0912012 4/6
A.
DEUTZ
Injector
W 19-01-01
Attention!
Note assignment of the injector to the
cylinder.
from faults.
• Insert injector carefully in the cylinder head.

• Mount clamping shoe.
• Insert screw (1) .
[:;;l Do not tighten the screw until after
EJ assembling the injection line.
• Mount new injection pipe.

'--.I Module 21
Do not tighten union nuts.

II
Attention!
Position ( 1):
connection is disconnected.
• Tighten screw (2) .
,'!,·-,~--,. 30 Nm
• Tighten union nuts of the inJection line.

L:,.J Module 21
• Connect fuel line.

Attention!
Removed, missing and bent clips must be
renewed.
The clip must spring back to the hold posi-
tion automatically. Otherwise renew the
clip.
J
L.,.• Module 21
• Plug in and lock cable plug.
©0912012
5/6
Injector
W 19-01-0 1
OBJ_DOKU-31101-001,fm
A.
DEUTZ
Technical Data
ID no. Name Screw tvoe Notes / Remark Value
Observe order of
Injector on cylinder head, clamping installation.
A 19 00 1 30 Nm
claw Install injector without
tension.
For the lightening procedure according to torque using a torque wrench, a maximum variation of the
II
6/6
A.
DEUTZ
Fuel filter
W 20-90-16
Fuel pre-filter
[I] Standard tools - Safety information / User

information
- Operation manual
Danger!
Do not carry out work on the fuel system
when the engine is running.
Danger of death.
The fuel pressure can continuously remain
up to several 100 bar even after stopping
the engine.
escape outside.
II
Attention!
Remove any paint residue and din par-
concerned carefully. Blow wet pans dry
to regulations.
1 Fuel pre-filter
2 Console
3 Sensor 1.6 Nm
4 Sealing ring
Use a new sealing ring.

Vent fuel system according to operating
instructions.
Fuel pre-filter
[~,} Operation manual
© 50549-0
3 09/2012
1/2
Fuel filter
W 20-90-16
OBJ_OO KU-31102-001 .fm
A.
DEUTZ
II
©09f/()1';
212
A.
DEUTZ
Fuel filter
W 20-90-17
rn
Fuel filter
Standard tools - Safety information / User

information
- Operation manual
Danger!
Danger of death.
the engine.
escape outside.
II
Attention!
to regulations.
Fuel spare filter

2 Filter head
3 Pressure sensor 25 Nm
5 0-ring
[ll@f I Use new round sea ling ring.
© ,~551-0
© 0912012
1/2
Fuel filter
W 20-90-17
A.
DEUTZ
II
©09120·.2 212
A.
DEUTZ
Fuel pipes
W 20-90-30
Fuel line
Standard tools - Safety information I User
information
Special tools: - Operation manual
- Hose clip pliers 01899037
- Spring band pliers 01899112 Danger!
- Plugs/caps 01899144
Danger of death.
the engine.
escape outside.
II
Attention!
to regulations.
Hose pipe
2 Hollow screw 20 Nm
3 Sealing ring
4 Clip
5 Holding tape
1~ I Use new sealing rings.
© 50548-0
©0912012
112
Fuel pipes
W 20-90-30
0BJ_DOKU-31104-001 .fm
A.
DEUTZ
Attention!
from faults.
Lay the hose pipe free from chafing and ten-
sion.
- Dimension X
II
© 0912012
212
A.
DEUTZ
Fuel supply pump
W 20-90-47
Supply pump
(Fuel)
Standard tools
[I] Special tools:
- Safety information I User
information
Danger!
Danger of death.
the engine.
escape outside.
II
Attention!
to regulations.
Supply pump
- Fastening
Screws i •l
4 X M5-8.8 •1 I Il.,,,
.I I-=-"
ti © 5D547-D
112
Fuel supply pump
W 20-90-47
II
2/2
A.
DEUTZ
Fuel pipes
W 21-04-01
OBJ_DO KU-31106-001 .fm
Removing and installing the rail
[I] Standard tools:

- Wrench insert size 14
Special tools:
- Safety information / User
information
- Long socket wrench insert 01899132 Danger!

- Plugs/caps 01899144 Do not carry out work on the fuel system
- Special wrench 02992112 when the engine is running.
- Disassembly tool 02992127 The fuel system is under high pressure -
Danger of death.
- Assembly grease 01016496
the engine.
escape outside.
Attention!
II
concerned carefully_ Blow wet parts dry
to regulations.
Removing the rail

4
1 Rail
2 High-pressure line
3 Injection line
4 Injection line
5 Torx screw
6 Spacer
© 50552-0
© 0912012
1/10
Fuel pipes
W 21-04-01
A.
DEUTZ
Removing high-pressure line

• Remove fuel return line.
• Unscrew union nut ( 1) with special wrench.
• Remove cable harness holder and swing aside.
• Unscrew union nuts (2) with special wrench.
• Remove high-pressure line (3).
~ Collect draining fuel and dispose of
L'.::J according to regulations.
II
Removing injection pipes
• Unscrew lock nuts ( 1) with special wrench.
~ Attention!
lJ2J Position (3):
connection is disconnected .
• Hold pipe connection of injector.
• Unscrew lock nuts (2).
• Remove injection lines.
rd Collect draining fuel and dispose of
L'.::J according to regulations.
• Unlock cable plug .

• Pull out cable plug.
• Remove the rail (2).
• Remove spacer (3).
if: 51411-0
© 0912012
2/10
A.
DEUTZ
Fuel pipes
W 21-04-01
Removing the pressure sensor

• Unscrew the rail pressure sensor (1) with the socket
wrench.
r:::;;:i Collect draining fuel and dispose of
EJ according to regulations.
©51412·0
II
Attention!
Do not touch the pin contacts of the rail
pressure sensor with your hands to avoid
electrostatic discharging.
Ensure absolute cleanliness of the connec-
tor.
• Visually check the thread and the sealing
edge (arrows)of the rail pressure sensor.
© •30H-0
Installing the pressure sensor

Attention!
No foreign bodies may get into the rail.
Ensure utmost cleanliness. Especially on
the thread and the sealing surface of the
rail.
See the spare parts documentation_
Rail pressure sensor and pressure limiting
valve must be replaced as a pair.
• Clean thread and sealing area of the rail.
• Coat the thread and sealing edge of the rail pressure
sensor lightly with assembly grease.
© <3017-0
©0912012
3/10
Fuel pipes
W 21-04-01
A.
DEUTZ
liW Attention!
LJ2J Only tighten the rail pressure sensor with
the hexagon.
• Screw in rail pressure sensor ( 1).

• Tighten rail pressure sensor (1) with the socket
wrench insert.
§':>,~-: 70 Nm
II © 51412-0
Removing the pressure limiting valve

• Unscrew pressure limiting valve (1).
~ Collect draining fuel and dispose of
EJ according to regulations.
© 51413-0
• Visually check the thread and the sealing edge of the

pressure limiting valve.
:!'.l 43253•1
© 0912012 4110
A.
DEUTZ
Fuel pipes
W 21-04-01
• Remove the O-ring with the disassembly tool .
©43335-0
II
Installing the pressure limiting valve
Attention!
No foreign bodies may get into the rail.
Ensure utmost cleanliness. Especially on
the thread and the sealing surface of the
rail.
See the spare parts documentation.
Rail pressure sensor and pressure limiting
valve must be replaced as a pair.
• Mount new O-ring (1 ).
• Lightly coal the thread and sealing edge of the pres-

sure limiting valve with assembly grease .
© 0912012
5/10
Fuel pipes
W 21-04-01
OBJ_ DOKU-31106-001.fm
A.
DEUTZ
• Clean thread and sealing area of the rail.

• Screw in pressure limiting valve (1 ).
• Tighten pressure limiting valve.
f!;> '~::i 100 Nm
II © 51413-0
Mounting rail
• Mount rail ( 1) with spacer (2).
1~1
• Loosely preassemble rail (1) with screws (3).
Do not lighten screws.
© 57.dld·O
Installing injection pipes

Attention!
The injection lines must always be
renewed after disassembly.
Note assignment and installation position

of the injection lines.
• Mount new injection lines (1 ).
~ 01415-0
© 09(.10',2 6110
A.
DEUTZ
Fuel pipes
W 21-04-01
Attention!
Pay attention to alignment of the injection
pipes.
Lines must not be in the bores (1) of the
union nuts.
Install injection lines without tension and
without touching.
They must be a safe distance away from
adjacent parts.
• Align injection lines.
• Tighten union nuts hand-tight.
© 51416-0
II
Installing high-pressure line
Attention!
The high-pressure line must always be
renewed after dismantling.

from faults.
• Mount new high-pressure line (1 }.
Attention!
Pay attention to alignment of the high-pres-
sure line.
Line may not touch in the bore ( 1) of the
union nut.
Install high-pressure line without tension
and contact.
They must be a safe distance away from
adjacent parts.
• Align high-pressure line.
• Tighten union nuts hand-tight.
©0912012
7/10
Fuel pipes
W 21-04-01
A.
DEUTZ

f>,, 30 Nm
II
• Tighten the union nuts in order.
?s, .. , 30 ~]:~ Nm
• Check injection lines for perfect installation position .

• Check the high-pressure line for perfect installation
position.
• Mount fuel return line.
• Mount cable harness holder.
IIJ@fI Ensure that the connection is perfect.
8110
A.
DEUTZ
Fuel pipes
W 21-04-01
Technical Data
Injection line on rail and injector. Observe installation
A21 003 high-pressure line on high-pressure Union nut regulation. 30 : )·~ Nm
pump and on rail Use new line.
Observe assembly
A21 038 Rail on cylinder head 30 Nm
specification.
Lightly coat the thread
A21 039 Pressure limiting valve on rail and sealing edge with 100 Nm
assembly qrease.
Lightly coat the thread
II
A21 040 Pressure sensor on rail M18x1.5 and sealing edge with 70 Nm
assembly grease.
© 09/2012
9110
Fuel pipes
W 21-04-01
A.
DEUTZ
II
ti 0912012 10/10
A.
DEUTZ
Fuel pipes
W 21-05-05
Removing and installing the fuel line

(injector, rail, high-pressure pump)
Standard tools - Safety information/ User
information
Special tools:
- Spring band pliers 01899112
- Plugs/caps 01899144 Danger!
- Disassembly tool 02992127 Do not carry out work on the fuel system
Danger of death.
the engine.
escape outside.
II
Attention!
to regulations.
Removing the fuel line

1 Return line
2 Hose holder
3 Fuel line
4 Hose pipe
5 Pipe clip
7 Spring band clip
© 50550-U
© 0912012
1/6
Fuel pipes
W 21-05-05
OBJ_ DOK U-31107-001. frn
A.
DEUTZ
Attention!
renewed.
clip.
• Press in the clip (1) to the stop.
• Pullout return line (2).
II © 51304-0
• Remove the O-ring (1) with the disassembly tool .
© ,, 305-0
• Remove return line (1) from hose holder (2).

• Unlock coupling plug (3) and pull off.
© 51306-0
©0912012 216
DEUTZ
A. -
Fuel pipes
w 21-05-05
- - - - - - - - - ()BJ_D()Kl~~31107-001.fm
OBJ_DOKU-
.
• Loosen spring band c I.ip ( 1} with spring
. band pliers.
• Pull off hose pipe (2).
return line.
• Remove mponents.
• Visually .inspect the co
II
. the fuel line
Mounting
·thatI the .ins tallation loca r,on is free

Attention.
Ecsoce d
from faults. th the spring ban
. the spnn g band clip (1) w1
• Position
pliers.
- Dimension X
2
•i~ .4-2
• mm X
. t the hose pipe (2).
• ,,Moun
• Position res t u rn line.. hose holder ( ).

rt return line ( 1) in 2
• lnse . ( )_
..
• Pos1t10 n pipe clips 3
• Tighten screws (4) . and latch into place.

• Mount coupling plug (5)
©01309-0
:!SJ 09/2012
3/6
Fuel pipes
W 21-05-05
OBJ_DOKU-31107-001.lrn
A.
DEUTZ
Attention!
renewed.
clip,
• Mount new round sealing ring (2).
• Position return line ( 1) vertically to the injector.
• Insert return line ( 1) in injector by hand.
Attention!
from faults.
Return line must snap in audibly.
II © 51310-0
© 51311·0
©0912012
4/6
Au
DEUTZ
Fuel pipes
W 21-05-05
OBJ_ 0OKU-31 107-001 Jm
Technical Data
ID no. Name Screw e Notes I Remark Value
A 12 095 Pipe clips. fastening 30 Nm
II
5/6
Fuel pipes
W 21-05-05
OBJ_DOKU-3 7 107-001 .fm
A.
DEUTZ
II
© 09.1201:;: 6/6
A.
DEUTZ
Charge air line
W 22-01-01
Removing and install the charge air line
[I] Standard tools
II
Remove charge air line
1 Charge air line
2 Seal
© 50•13-0
• Remove fuel return line.

• Unlock cable plug and disconnect.
• Remove charge air line (2).
©0912012
1/4
Charge air line
W 22-01-01
OBJ_ DOKU-31108-001.frn
A.
DEUTZ
Install charge air line

• Mount new gasket ( 1).
• Turn screws into the seal a few turns.
bl The seal is locked by the screw thread .
EJ Ensure that the installation location of the
gasket is free from faults.
II © 504 15-0
• Mount charge air line (1).
1~ I
Do not move gasket.

quence.
t'• ,, __, 30 Nm B 4 2 6
~ Attention!
lJ2J Ensure that the cables are laid perfectly.

• Mount fuel return line.
5 1 3 7
~- ~0.!117-0
©09/2012
2/4
A.
DEUTZ
Charge air line
W 22-01-01
OBJ_DOKU -311 08-001.fm
Technical Data
A2.2 030 Charge air line on c linder head 30 Nm
II
3/4
Charge air line
W 22-01-01
OBJ_DOKU-31108-00 t.fm
A.
DEUTZ
II
©09-12012 4/4
A.
DEUTZ
Charge air line
W 22-04-01
Removing and installing charge air manifold

101 Standard tools:
l__!L_J - Spring band pliers 01899112
II
Removing charge air manifold
1 Rubber sleeve
2 Hose nozzles
3 Spring band clip
4 Spring band clip
5 Spring band clip
6 Seal
7 Charge air manifold
·:e> 5U403-0
• Loosen spring band clips ( 1) with spring band pliers.

• Unscrew screws (2) .
• Remove charge air manifold (3) .
• I
©09/2012
1/4
Charge air line
W 22-04-01
A.
DEUTZ
Installing charge air manifold

• Mount charge air manifold (2).
• Fasten screws (3).
• Tighten screws alternately.
fJ,- ,_ ·:; 30 Nm
• Position spring band clips (4) with spring band pliers.
II
©0912012 214
A.
DEUTZ
Charge air line
W 22-04-01
Technical Data
ID no. Name Screw e Notes/ Remark Value
A22 046 Char e air manifold on char e air line 30 Nm
For the tightening procedure according to torque uslng a torque wrench, a maximum variation of the
II
3/ 4
Charge air line
W 22-04-01
A.
DEUTZ
II
©-19120' 2 414
DEUTZ
A. Charge air line
W 22-90-20
OBJ_DOKU-31110-001.Im
Pressure transmitter / temperature pressure transmitter

(charge air)
Standard tools - Safety information / User

information
- Fitting compound Attention!

DEUTZ AP1908 Ensure utmost cleanliness for all work.
II
1 Temperature sensor
5 Pressure sensor
6 Console
7 Sealing ring
9 Hose ring piece
242 Mounting compound
1~1
Use new sealing rings.
<,) 0912012
1/2
Charge air line
W 22-90-20
0BJ_DOKU-31110-001.fm
A.
DEUTZ
Positions
5
Use mounting compound.
Use new round sealing ring.
II
© 0912012 2/2
Air intake pipe
W 22-90-35
Intake nozzle
~ Standard tools:
l_JL_J - Spring band pliers 01899112
II
1 Intake nozzle
2 Spring band clip
3 Spring band clip
5 Pipe clip
6 Pipe
7 Rubber sleeve
Push the pipe and rubber muff up as far

they will go.
Position the spring band clip facing
upwards in an easy to reach position.
©0912012 112
Air intake pipe
W 22-90-35
OBJ DOKU-31111-001 frn
A.
DEUTZ
II
212
A.
DEUTZ
Charge air line
W 22-90-54
Charge air manifold
[I] Standard tools
II
1 Charge air manifold
2 Throttle valve
3 Seal
6 Seal
1~I Use a new gasket.
©0912012 1/2
..
Charge air line
W 22-90-54
OBJ_DOKU~31112-001.fm
A.
DEUTZ
Technical Data
A2.2 046 Char e air manifold on char e air line 30 Nm
II
212
DEUTZ
A. Charge air line
W 22-90-55
Charge air line
rn Standard tools
Special tools:
- Spring band pliers 01899112
II
Rubber sleeve
2 Hose pipe
3 Spring band clip
4 Spring band clip
5 Spring band clip
6 Seal
7 Charge air line
g Pipe clip
11 Hose pipe
13 Sealing ring
Use a new gasket.
© 0912012
112
Charge air line
W 22-90-55
OBJ 0OKU-31113-001 .fm
A.
DEUTZ
II
©;J9/'.i;'l)12
212
A.
DEUTZ
coolant pump
W 37-90-13
V-rib belt pulley
[I] Standard tools
II
1 V-rib belt pulley
©09/2012
1/2
Coolant pump
W 37-90-13
A.
DEUTZ
II
2/2
A®
DEUTZ
Coolant pump
W 37-90-06
Drive components
[I] Standard tools
II
1 V-rib belt pulley
© 0912012
1/2
Coolant pump
W 37-90-06
A.
DEUTZ
II
f:l 0912012
212
A.
DEUTZ
Coolant pump
W 37-90-13
rn
V-rib belt pulley
Standard tools
II
1 V-rib belt pulley
2 Adapter
© 091~01:/ 1/2
Coolant pump
W 37-90-13
A.
DEUTZ
II
~0912012
2/2
A.
DEUTZ
Thermostat housing
W 38-01-01
Removing and installing the thermostat
[I] Standard tools - Operation manual

to regulations.
tions for emptying and filling the engine.
II
Removing the thermostat
Thermostat housing
2 Thermostat 2
4 Sealing ring
5 Screw plug 65 Nm
7
6 Seal
© S\JBJ-0
• Drain, collect and dispose of coolant according to

regulations
• If present: Remove coolant hose from outlet nozzle.
• Remove thermostat housing (2)
11)51384-0
© 09120>2
1/4
Thermostat housing
W 38-01-01
Ae
DEUTZ
• Remove gasket (1 ).
• Remove thermostat (2).
\•'
II © .51385-0
Installing the thermostat

• Insert thermostat (1 ).
© o13A9-Q
• Insert screws ( 1).

• Fix new gasket (2) to the thermostat housing with
screws.
'.Q5138b-Q
2/4
A.
DEUTZ
Thermostat housing
W 38-01-01
• Mount thermostat housing (1).

© 51381-0
II
• Tighten all screws ( 1 ).
:;, '<:, 30 Nm
• If present: Push coolant hose onto outlet nozzle and

fasten .
• Fill cooling system according to the operating manu-
al.
/_-.:_j Operation manual T
\
l
\_ 0 '
<;) 5138B-O
©0912012
314
Thermostat housing
W 38-01-01
A.
DEUTZ
Technical Data
A38 001 Thermostat housin on cylinder head 30 Nm
For the tightening procedure accordin9 to torque using a torque wrench, a maximum variation of the
II
C09'2012 4 /4
A.
DEUTZ
Thermostat housing
W 38-01-02
OBJ_DOKU-3111B-001. fm
Checking the thermostat (in the removed state)
10) Standard tools: IA) Danger!

l___LJ - Thermometer ~ Risk of injury!
Hot water and hot thermostat.
II
Checking thermostat
Thermostat housing
2 Thermostat 2
4 Sealing ring
5 Screw plug 65 Nm
7
6 Seal
6
/,
4
5
I
© 513B3-0
• Measure beginning of stroke, dimension (a).

• Note measured value, dimension {a).
- - - a - -~
© 51:190-0
1/4
Thermostat housing
W 38-01-02
A.
DEUTZ
• Heat up the thermostat in the water bath.

• Determine beginning of opening .
In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the ther-
mostat.
Do not touch the thermostat.
The waler should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place fas-
ter than 1°C/min. Otherwise the beginning
of opening will be delayed accordingly.
- Nominal value:
II ,:':< 86 "C
• Measure water temperature.

- Nominal value:
:)".- 99 °C
• Measure end of stroke, dimension (b).

• Note measured value, dimension (b).
• Determine stroke.
Calculation example
Desired: Stroke
Given:
Measured: Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Calculation: Dimension (b) - dimension (a)
Result: = stroke
• Compare resull with setpoint value.
- Nominal value:
',,,, 9 mm
©51J92·0
,f, \1~1201/
214
A.
DEUTZ
Thermostat housing
W 38-01-02
OBJ_DOKU-311 18-001 Jm
Technical Data
Testing and setting data
ID no. Name Additional Information Value
P38 11 Thermostat, beginning of opening 86 ·c
P38 13 Thermostat, stroke at 99 •c . minimum 9mm
P38 14 Thermostat, stroke, test temperature 99 ·c
II
3/4
Thermostat housing
W 38-01-02
A®
DEUTZ
II
~ 09!2012
414
A@
DEUTZ
Coolant pipes
W 38-90-32
Line
Standard tools:
[I] - Spring band pliers
Special tools:
01899112
II
Pipe
2 Spring band clip f"
3 Elbow 3
4 Hose pipe
2
6 Support plate
7 Pipe clip
8 Hexagon head screw 8 Nm \\
8
© 09120>2
1/2
Coolant pipes
W 38-90-32
OBJ_ DOK U-31119-001 .Im
A.
DEUTZ
II
© 0912012
2/2
A.
DEUTZ
Coolant pipes
W 38-90-32
Line
rn Standard tools
II
1 Coolant line
© 50554-0
'<' 0912012 1/2

Coolant pipes
W 38-90-32
OBJ_ DOKU-31120-001 .fm
A.
DEUTZ
II
212
DEUTZ
A. Coolant pipes
W 38-90-32
Line
Standard tools
[I]
II
1 Coolant line
12 Washer
~0912012 1/2
Coolant pipes
W 38-90-32
A.
DEUTZ
II
©09.'(Q12
212
A.
DEUTZ
Fan
W 39-90-52
Pressure fan
00 Standard tools
II
Pressure fan
© 51338-0
©0912012 1/2
Fan
W 39-90-52
A.
DEUTZ
II
212
A.
DEUTZ
Exhaust pipe
W 41-01-01
Removing and installing the exhaust line
00 Standard tools
II
Removing exhaust line
Exhaust line
2 Seal
• Remove turbocharger.
~·__:___; Module 43
• Remove cooler.
._j Module 41
• Unscrew all screws (1).

• Remove exhaust line (2) ,
©09/2Q1;. 1/4
Exhaust pipe
W 41-01-01
A.
DEUTZ
Installing exhaust line

• Clean sealing suriaces.
• Fasten new seal ( 1) with screws on exhaust line.
II © so,20-0
1~I
• Mount exhaust line ( 1).
Note installation position .
• Fasten ell screws (2) .

quence.
1~;- '. ·; 30 Nm 8 3 5
~
• Install the turbocharger.
.. -- ...
:
·------...v
,'
Module 43
-'o
• Install cooler_
~ ---~
L--JJ Module 41 ,--
\ Cl)
6 4 2 7
© 50734-0
'1>0912012
2/4
Au
DEUTZ
Exhaust pipe
W 41 -01-01
OBJ_0OKU-31 123-001.lm
Technical Data
ID no. Name Screw type Notes I Remark Value
Observe tightening
A41 001 Exhaust line on cylinder head 30 Nm
sequence
For the tightening procedure according lo torque using a torque wrench, a maximum variation of the
tightening torque of+/• 10% is permissible.
II
3/4
Exhaust pipe
W 41-01-01
OBJ DOKU-311 23-001 .frn
A.
DEUTZ
II
4/4
A.
DEUTZ
Exhaust pipe
W 41-01-01
Removing and installing the exhaust line
[I] Standard tools
II
Removing exhaust line
Exhaust line
2 Seal
• Remove turbocharger.
~-:../ Module 43
• Remove cooler.
:._:,-; Module 41
• Unscrew a II screws ( 1).

• Remove exhaust line (2).
;f.: 09i2012 1/4

Exhaust pipe
W 41-01-01
A.
DEUTZ
Installing exhaust line

• Fasten new seal (1) with screws on exhaust line.
II ©50731·0
l~I
• Mount exhaust line (1 ).
Note installation position.
• Fasten all screws (2).

quence.
:·:, ,. 30 Nm 8 1 3 5
! Ii _) 1
• Install the turbocharger.
L.) Module 43
• Install cooler.
.:::.:) Module 41
;,J~
C
,._J
6 4 2 7
.:; SO?J:,.o
©09:2012
2/4
A.
DEUTZ
Exhaust pipe
W 41-01-01
Technical Data
Observe Lightening
A4 1 001 Exhaust line on cylinder head 30Nm
sequence
For the tightening procedure according 10 torque using a torque wrench, a maximum variation of the
II
3/4
Exhaust pipe
W 41-01-01
OBJ _DOKU-31124-001 .fm
A.
DEUTZ
II
4/4
A.
DEUTZ
Exhaust gas recirculation
W 41-90-04
Connection
(Crankcase housing, exhaust gas circulation, coolant line)
Standard tools Collect leaking operating substances in
to regulations.
- Fitting compound Observe the appropriate operating instruc-
DEUTZ AP1908 tions for emptying and filling the engine.
II
1 Hose nozzles
2 O-ring
[ll@rl Use new round sealing ring .

© 50387-0
© 0912012 1/2
W 41-90-04
A.
DEUTZ
II
© 0912012
2/2
Exhaust pipe
W 41-90-21
Compensator structure
(Exhaust line)
[I] Standard tools
II
1 Compensator J
2 Seal
Use a new gasket.
Attention!
Check seal.
from faults.
Install without tension (without torsional
stresses) and do not pre-compress.
© 50386-G
:I) 0912012
1/2
Exhaust pipe
W 41-90-21
OBJ_ DOKU-31126-001.lm
A.
DEUTZ
II
•~ :JW/0',J
212
A.
DEUTZ
W 41-90-32
OBJ _DOKU-31127-001.frn
Line
(Thermostat housing, exhaust gas circulation, coolant line)
Standard tools: Collect leaking operating substances in

- T orx tool set 01899092 suitable vessels and dispose of according
- Spring band pliers 01899112 to regulations.
Special tools: Observe the appropriate operating instruc-
- Plugs/caps 01899144 tions for emptying and filling the engine.
II
1 Hose pipe
2 Spring band clip
3 Coolant line
4 Torx screw 10 Nm
5 Hexagon head screw 8Nm
6 Pipe clip
7 Seal
8 Rubber sleeve
9 Sealing ring
10 Screw plug 80 Nm
~ Use a new gasket.

L'.:::._J Use a new sealing ring .
© $0:lAS-O
1/2
W 41-90-32
A.
DEUTZ
II
(S)091l012
2/2
A.
DEUTZ
W 43-01-01
Removing and installing the turbocharger

[1] Standard tools
II
Removing turbocharger
1 Exhaust turbocharger
2 Seal
• Remove intake nozzle.

C_:/ Module 22
• Remove the lubricating oil line.
• Remove lubricating oil return line.
L:J Module 16
• Remove exhaust manifold.

W Module 43
• Unscrew screw ( 1)
1/4
W 43-01-01
A.
DEUTZ

• Remove turbocharger (2).
• Remove gasket (3) .
II
Installing the turbocharger
• Mount gasket (1 ).
'" Mount turbocharger (2) .
• Fasten screw (1) .

• Tighten screw (1).
'> ':·- 30 Nm
~;•,. ; 30 Nm
• Fit intake nozzle.

_:_,) Module 22
• Instal I Iubricating oil line.

• Instal I Iubricating oil return line.
:_._:_.. Module 16
• Install exhaust manifold .

Module 43
2/4
A.
DEUTZ
W 43-01-01
Technical Data
A43 020 Turbocharger on exhaust line 30Nm
II
3/4
W 43-01-01
A.
DEUTZ
II
© 0912012
4/4
A.
DEUTZ
W 43-01-01
OBJ _DOKU-31129-001 .fm
Removing and installing the turbocharger

[I] Standard tools
II
Removing turbocharger
1
2
Exhaust turbocharger
Seal
._l
..
I
-
© 5050~-u
• Remove intake nozzle.

L.,_i Module 22
• Remove the lubricating oil line.
• Remove lubricating oil return line.
[_-> Module 16

• Remove turbocharger (2) .
1/4
W 43-01-01
A.
DEUTZ
Insta Iii ng the tu rboch arg er

• Clean sealing surtaces.
• Mount turbocharger (2) .
t'f<·,~::, 30 Nm
• Fit intake nozzle.
L:.J Module 22
• Install lubricating oil line.

• Install lubricating oil return line.
!_~_) Module 16
II
2/4
A.
DEUTZ
W 43-01-01
OBJ_DOKU-3 1129-00·1Jm
Technical Data
A43 020 Turbochar er on exhaust line 30 Nm
II
C)09t20 12 3/ 4
W 43-01-01
A.
DEUTZ
II
'<l 0912012
4/4
A.
DEUTZ
W 43-90-36
Exhaust manifold
rn
( exhaust turbocharger)
Standard tools
II
Exhaust manifold
2 Clip
3 N~ 10Nm
[~ I Note installation position.
-- 3
ca, 50389-0
©0912012 1/2
W 43-90-36
A.
DEUTZ
II
©0912012
2/2
A.
DEUTZ
W 43-90-36
Exhaust manifold
[I] Standard tools
II
1 Exhaust line
2 Clip 9 Nm
3 Clip 9 Nm
4 Seal
~ Note installation position.

EJ Use a new gasket.
3 4 2
© 0912012 1/2
W 43-90-36
A.
DEUTZ
II
©091W12 2/2
A.
DEUTZ
W 43-90-36
Exhaust manifold
w
Standard tools
II
1 Exhaust manifold
J 2
2 Clip
3 Nut 10 Nm
1~ I Note installation position.
© 51481-0
©0912012
1/2
W 43-90-36
A.
DEUTZ
II
@0912012
2/2
A.
DEUTZ
Add-on parts
W 44-01-01
Removing and installing the belt tensioner

(V-rib belt, level 1)
[I] Standard tools II ! ,1 - Operation manual
II
Removing the belt tensioner
Belt tensioner
2 Deflection pulley
3 V-rib belt
4 Cylinder head screw
Ii;) 50562-1
• Remove V-rib belt.
.~..! Operation manual

• Remove belt tightener (2).
1/4
Add-on parts
W 44-01-01
OBJ_OOKU-31133-001 .1m
A.
DEUTZ
Installing the belt tensioner

• Mount belt tensioner (1 ).
• Fasten screw (2).
• Tighten screw (2).
g.~'<:, 48 Nm e running direction.

• Fit the V-ri"b belt according to th
W Operation manual
II
©091'./01Z 2/4
A.
DEUTZ
Add-on parts
W 44-01-01
Technical Data
A44 041 Belt tightener on gear case 48 Nm
tightening torque of+/. 10% is permissible.
II
314
Add-on parts
W 44-01-01
A@
DEUTZ
II
4/4
A.
DEUTZ
Generator
W 44-02-01
OBJ _DOKU-31134-001 .fm
Removing and installing the generator

(Clamping latch}
[I] Standard tools - Safety information / User

information
- Operation manual
II
Removing the generator
Clamping strap
2 Threaded piece
4 Washer •
7 Spacing sleeve
9 Hexagonal nut
• Disconnect the battery's negative terminal.

• Remove plus cable.
• Pullout cable plug (1).
©0912012 1/4
Generator
W 44-02-01
A.
DEUTZ
• Loosen screw (1 ).
• Hold nut (2).
• Loosen screws (4).
• Swing generator (5) in direction of arrow.
• Remove V-belt.
II
• Unscrew screw {1 ).
• Remove generator (2).
Installing the generator

• Mount generator ( 1).
• Insert screw (3).
• Screw on nut (4 ).
© 0912012
2/4
A®
DEUTZ
Generator
W 44-02-01
• Mount V-belt.
• Tighten V-belt (1) by turning the clamping screw (2).
• Check V-belt tension.
L:j Operation manual
II
• Hold screw (2)
• Tighten nut ( 1) .
,-":c· •.- ; 30 Nm

.:'':,. ,_--. 42 Nm

t'>,_. , 30 Nm
• Plug in the cable plug ( 1 ).

• Fit plus cable ,
• Connect !he battery's negative termina I.
3/4
Generator
W 44-02-01
OBJ_ DOKU-31134-001 .fm
A.
DEUTZ
Technical Data
ID no. Name Screw tvoe Notes / Remark Value
A44 012 Generator on console 42 Nm
A44 015 Generator at clamping latch 30 Nm
A44 017 Clamping latch on gear case 30 Nm
II
414
A.
DEUTZ
Generator
W 44-02-01
Removing and installing the generator

(Fastening parts)
[I] Standard tools
II
Removing the generator
© 50660-U
• Remove V-rib belt

L_:,,.J Operation manual
• Unlock cable plug ( 1) and disconnect.
© 09/201;! 1/4
Generator
W 44-02-01
A.
DEUTZ

• Remove generator (2).
• Visually inspect the components·.
II
Installing the generator
• Mount generator (1) .
t, ,.- . 42 Nm
• Mount cable plug ( 1) and lock.

• Fit plus cable.
• Connect the battery's negative terminal .
• Position V-rib belt.
:__:,j Operation manual
G 0912012
2/4
A.
DEUTZ
Generator
W 44-02-01
OBJ_DOKU·31135-001.fm
Technical Data
A4 4 012 Generator on console 42 Nm
II
3/4
Generator
W 44-02-01
OBJ_ DOKU-31135-001. fm
A.
DEUTZ
II
G 0912012
4/4
A®
DEUTZ
Add-on parts
W 44-02-06
OBJ _DOK U-31136-001.fm
Removing and installing the console

(V-rib belt, level 1)
Standard tools [ml -

Operation manual
- Packing compound
DEUTZ OW 73
II
Removing the console
Console
2 Clamping pin
4 Clamping sleeve
• Remove V-rib belt.
/~_/ Operation manual

• Remove generator (level 1).
/~_j Module 44

• Remove console (2).
-t) 0912012
114
Add-on parts
W 44-02-06
A.
DEUTZ
Mounting the console

~ Make sure the clamping pin (arrow) is in
EJ place .
II
• Apply sealing compound ( 1) evenly on the sealing
1~ l
surface.
Sealing cord strength approx. 3 mm
'b": 50657•iJ
• Mount console ( 1) over the clamping pins.

M8x85-10.9
M8x60-10.9
@09/2012
2/4
A®
DEUTZ
Add-on parts
W 44-02-06
• Tighten all screws according to the tightening se-

quence.
f.t0 • ~ : ) 30 Nm
• Mount generator (level 1 ).
W Module 44 5 2
• Fit the V-rib belt according to the running direction .
.1-:...) Operation manual 4
~ 50859•0
II
© 09/2012
3/4
Ad d-on parts
W 44-02-06
A.
DEUTZ
Technical Data
A44 013 Console on crankcase/ ear case 30 Nm
II
4/4
Starter
W 44-03-01
Removing and installing the starter
[ ] ] Standard tools
II
Removing the starter
1 Starter
© soJgg.o

• Unlock cable plug ( 1) and remove.
• Remove cable ties.
© 091201, 114
Starter
W 44-03-01
A.
DEUTZ

• Remove starter (2).
II
Installing the starter
• Insert starter ( 1 ).
• Tigh1en screws (2).
'.c_;, ; 60 Nm
• Mount cable plug (1) and lock.

• Tighten cable ties _
• Fit plus cable.
• Connect the battery's negative terminal .
2/4
A.
DEUTZ
Starter
W 44-03-01
Technical Data
Tightening specificatlons
ID no. Name Screw · e Notes / Remark Value
A44 001 Starter on connection housin 60 Nm
II
3/4
Starter
W 44-03-01
A.
DEUTZ
II
©0912012
4/4
A.
DEUTZ
Starter
W 44-03-01
Removing and installing the starter

[I] Standard tools
II
Removing the starter
1 Starter
© 51440-0
• Disconnect the battery's negative terminal .

• Remove starter (2).
© 09120:2 114
Starter
W 44-03-01
A.
DEUTZ
Installing the starter

• Insert starter ( 1).
• Insert screws (2).
tj:-,c:::, 60 Nm
~ Attention!
LJ2J L_ay the cables free from chafing and ten-
sion.

• Fit plus cable.
• Connect the battery's negative terminal.
II
©09/2012
2/4
A.
DEUTZ
Starter
W 44-03-01
Technical Data
A44 001 Starter on connection housing 60 Nm
II
Is: 0912012
314
Starter
W 44-03-01
OBJ_DOKU•31138-001 .fm
A.
DEUTZ
II
©0912012
414
A.
DEUTZ
Parts to generator
W 44-90-42
rn
Generator
Standard tools
II
Generator 6 1 2 3 9 8 10 4 5
2 Fan
3 Spacing washer
4 Washer
5 Hexagonal nut 90 Nm
6 Voltage regulator
8 V-belt pulley
9 Ring
10 Ring
© 0912012 1/2
Parts to generator
W 44-90-42
OBJ_DOKU-31139-001 Im
A.
DEUTZ
II
212
DEUTZ
A. Parts to generator
W 44-90--42
Generator
[I] Standard tools
II
1 Generator
2 Voltage regulator
3 Hexagonal nut 90 Nm
4 Washer
5 V-rib belt pulley
@5134B-O
~ 0912012
1 /2
Parts to generator
W 44-90-42
OBJ_ DOKU-31140-001 .frn
A.
DEUTZ
II
~ 0912012
2/2
DEUTZ
A. Engine mounting
W 46-90-15
Engine mounting
rn Standard tools
II
1 Holder
. ~-
,':,,,
Hexagon head screw 260 Nm
~-
2
3 Stand foot
7
'\,0
\
e~
5 Hexagonal nut .
6 Washer
.,
6~
7 Washer ,
0\
©51485-0
~ 0912012
112
Engine mounting
W 46-90-15
OBJ_DOKU-31141-001 Jm
A.
DEUTZ
II
© 0912012
2/2
A.
DEUTZ
Engine mounting
W 46-90-15
Engine mounting
[I] Standard tools
II
1 Stand foot
3 Washer
© 51481-0
© 0912012
1/2
Engine mounting
W 46-90-15
A.
DEUTZ
II
© 0912012 2/2
A.
DEUTZ
Engine mounting
W 46-90-15
Engine mounting
[ ] ] Standard tools
II
1 Stand foot
3 Washer
4 Mount buffer
5 Bushing
2
©51<1B60
©arJJ12 112
Engine mounting
W 46-90-15
OBJ_0OKU-31143-001.fm
A.
DEUTZ
II
{:;-09.'2012
212
A.
DEUTZ
Measuring instruments
W 51-90-20
Impulse transmitter
rn
(camshaft)
Standard tools - Safety information I User
information
Attention!
II
1 Impulse transmitter
2 Hexagon head screw 8,5 Nm
1~1
Use new round sealing ring.
Os> 09/2012
1/2
Measuring instruments
W 51-90-20
A.
DEUTZ
II
© 0912012 2/2
A.
DEUTZ
Connection housing
W 52-01-01
OBJ _DOK U-31145-001 .fm

[I] Standard tools
II
Removing the connection housing
1 Connection housing
3 Bushing
© 50430-0
CJ Module 05

• Remove connection housing (2).
© 50431-0
© 09120\2 1/4
Connection housing
W 52-01-01
OBJ_DOKU-31145-001 tm
A.
DEUTZ
Installing the connection housing

• Clean contact sunaces.
b] Make sure the clamping bushings ( 1) are
EJ in place.
II
• Position connection housing ( 1 ).
• Centre connection housing over the clamping bush-
ings .
• Tighten screws (1 ).
• Tighten all screws ( 1) alternately.
:"'· , .. 170Nm
_.... - !
Module 05
(i:) (J~."}(11/
2/4
A.
DEUTZ
Connection housing
W 52-01-01
Technical Data
ID no. Name Screw type Notes / Remart. Value
Tighten diagonally oppo-
A52 080 Connection housing on crankcase 170 Nm
sed
II
© 0912012
3/4
Connection housing
W 52-01-01
OBJ _DOKU-31145-001 .fm
A.
DEUTZ
II
4/4
A.
DEUTZ
Connection housing
W 52-01-01
OBJ _DOKU-31146-001 .fm
[!] Standard tools
II
2 Hexagon head screw 8,5 Nm
3 Cover plate
5 Bushing
Module 05

1/4
ConneCtl·on housing
w 52-01-01
OBJ_OOKU-31146-00 1.fm .
A.
DEUTZ
• Clean contac t surfaces. . g bushings ( 1) are
1~1 Make sure the clampIn

in place.
II © ~Ob72-0
1
• housing
• Position connection ( ) · the clamping
·ng over · bush-
• Centre con nection hous1
ings.
crews ( 1 ).
• Tighten s ( 1) alternately.
• Tighten all screws
. 170 Nm
~--- ...,, _: Module 05
© 091201"2.
214
A.
DEUTZ
Connection housing
W 52-01-01
Technical Data
ID no. Name Screwtvoe Notes / Remark Value
Tighten diagonally oppo•
sed
For the tightening procedure according to torque using a torque wrench, a maximum .variation of the
lightening torque of+/. 10% is permissible.
II
3/4
Connection housing
W 52-01-01
A.
DEUTZ
II
,e; 0912012
414
A.
DEUTZ
Connection housing
W 52-01-01
OBJ _DOKU-31147-001 .Im
[I] Standard tools
II
Connection housing
3 Bushing
© 51359-0
!_::_) Module 05

• Remove connection housing (2) .
©50-'31-0
<a: 09/2012 1/4

Connection housing
W 52-01-01
OBJ_DOKU-31147-001 rm
A.
DEUTZ

• Clean contac1 surfaces.
~ Make sure the clamping bushings (1) are
EJ in place
II
• Position connection housing ( 1 )_
ings.
• Tighten screws ( 1)
• Tighten all screws ( 1) alternately.
,".r· •.- . 170 Nm
--~-:_) Module 05
2/4
A.
DEUTZ
Connection housing
W 52-01-01
Technical Data
Tighten diagonally oppo-
sed
For the tightening procedure according lo torque using a torque wrench. a maximum vanal1on of the
lightening torque of +/- 10% is permissible.
II
3/4
Connection housing
W 52-01-01
OBJ_OOKU-3)147-001 Im
A.
DEUTZ
II
4/4
A.
DEUTZ
Connection housing
W 52-01-01
rn
Standard tools
II
3 Bushing
2 3
@51360-0
G Module 05
• Visually inspect the component
©5D4J>·0
1/4
Connection housing
W 52-01-01
OBJ_DOKU-31148-D01 fm
A.
DEUTZ

• Clean contact surfaces.
r:::;;i Make sure the clamping bushings (1) are
EJ in place.
II
ings.
• Tighten screws (1)

• Tighten all screws (1) alternately
,,,.,,., 170 Nm
:_j Module 05
21<1
A.
DEUTZ
Connection housing
W 52-01-01
OBJ_OOKU-31148-001 .Im
Technical Data
A§2 080 Connection housing on crankcase Tighten diagonally oppo-
170 Nm
sed
tightening torque of +/. 10% is permissible
II
~090012
3/4
Connection housing
W 52-01-01
OBJ _DO KU-31148-001 Im
A.
DEUTZ
II
4/4
A.
DEUTZ
Connection housing
W 52-01-01
OBJ_OOKU-31149-001 .frn
rn
Standard tools
II
Hexagon head screw
2 Bushing
W Module 05
© 50431-0
1/4
Connection housing
W 52-01-01
A.
DEUTZ

• Clean contact surfaces
r::;:;;;i Make sure the clamping bushings ( 1) are
~ inplace
II
ings.

• Tighten all screws (1) alternately.
170 Nm
_-::J Module 05
2/'1
A.
DEUTZ
Connection housing
W 52-01-01
Technical Data
ID no. Name Screw type Notes / Remar1c: Value
A52 080 Connection housing on crankcase Tighten diagonally oppo-
170 Nm
sed
II
!: 0912012
314
Connection housing
W 52-01-01
A.
DEUTZ
II
~ 0912012
4/4
A@
DEUTZ
Connection housing
W 52-90-53
OBJ DOKU-31150 001.fm
Connection housing
rn Standard tools
II
Connection housing
2 Hexagon head screw 8.5 Nm
3 Cover plate
4 Screw plug 80 Nm
5 Sealing ring
[u:EI Use a new sealing ring .
2 3
© 51356-0
©0912012
112
Connection housing
W 52-90-53
OBJ DOKU- 3 1150-001 Im
A.
DEUTZ
II
©,J912012
2/2
DEUTZ
A. Start aid
W 63-02-01
Removing and installing the glow plugs
Standard tools: - Safety information/ User

- Crowfoot wrench size 10 information
Special tools:
- Torque handle 01899184
- Insert holder long 01899185
II
Removing the glow plugs
1 Glow plug
2 Connecting rail
3 Locking nut
©51400·0
• Disconnect the battery.

• Unscrew nuts (1 ).
• Remove connecting rail (2)
0912012
IE)
1/4
Start aid
W 63-02-01
OBJ_DOKU-31151-001.tm
A.
DEUTZ
• Unscrew glow plugs ( 1).

II
Installing the glow plugs
• Screw in glow plugs ( 1).
\iB Attention!
L'...£J Ensure that the installation location is free
from faults.
• Tighten glow plugs (1)

,"!, '.:.:, 13.5 Nm
• Mount connecting rail ( 1)

• Turn on new nuts (2).
\iB Attention!
L'...£J Ensure that the connection 1s periect.
• Tighten nuts (2) .

..,,., .. 2.25 Nm
214
Ae
DEUTZ
Start aid
W 63-02-01
Technical Data
A63 032 Glow plug on cylinder head 13.5 Nm
A63 033 Connecting rail on glow plug Use new lock nut 2.25 Nm
For the tightening procedure according 10 torque using a torque wrench, a maximum variation of the
lightening torque of +/- 10% 1s permissible.
II
3/4
Start aid
W 63-02-01
OBJ DOKU-31151-001.tm
A®
DEUTZ
II
~ 09/2012
41'1
A.
DEUTZ
W 71-90-51
rn
Console
Standard tools
II
1 Console
2
© 51337-0
il.>09/201~
1/2
W 71-90-51
OBJ_DOKU-3115 2-001 Im
A.
DEUTZ
II
212
A®
DEUTZ
Hydraulic pump drive
W 83-02-01
Removing and installing hydraulic pump drive
Standard tools
- Packing compound
DEUTZ DW 73
II
Removing hydraulic pump drive
24-4 I_
Hydraulic pump drive 4
~ .' . - - -
© ~os2,-u

• Remove hydraulic pump drive (3).
1/4
W 83-02-01
A.
DEUTZ
Installing hydraulic pump drive

• Apply sealing compound (1} evenly on the sealing
surface.
~ Sealing cord strength approx 0.5 -
~ 0.6mm.
II
• Mount hydraulic pump drive ( 1 ),
• Tighten all screws according to the tightening se-

quence
P:,
30 Nrn 2
(~) :1113S-O
~ :J9.12Cl2
2/4
A.
DEUTZ
W 83-02-01
Technical Data
ID no. Name Screw type Notes"/ Remark Value
Hydraulic purnp on crankcase/gear
A83 003 30Nm
case
lightening torque of+/- 10% is permissible.
II
3/4
W 83-02-01
0 BJ DOK U-31153-001 fm
A®
DEUTZ
II
©OYt~0 12
4/4
A.
DEUTZ
Special tools
W 49-01-01
OBJ_DOKU-31154-D01 fm
8 Special tools
II
© 0912012
1/10
Special tools
W 49-01-01
OBJ_OOKU-31154-001 .fm
Orders
Special tools::
These must be ordered like a normal
DEUTZ spare part by specifying the order
number.
II
1!:10912012 2/10
A.
DEUTZ
Special tools
W 49-01-01
OBJ_DOKU-31154-001 frn
01899031
Pressure pump
Checking cooling system for leak-tightness
© 35409-2
01899037
Hose clip pliers
Loosen hose clips and fasten II
© 39426-'
01899050
Assembly pliers
Removing valve shaft seals
© •9353-Q
3110
Special tools
W 49-01-01
A.
DEUTZ
01899062
V-belt tension measuring device
150 to 600 N
Check V-belt tension
© 35•16-3
II 01899092
Torx tool set
Contents of case:
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E 10/E 12
Socket wrench insert EB and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E 18 ( 1/2 inch)
© 39432-1
01899093
Rotation angle disc
with magnet
Setting valve clearance
~ 49342-0
4/10
A.
DEUTZ
Special tools
W 49-01-01
01899103
Pricker
Removing rotary shaft lip seal
01899110
Assembly lever
e. g. removing and installing valves II
©37511-2
01899112
Spring band pliers
320 mm
Tighten spring clamp
© :)M20-3
5/10
Special tools
W 49-01-01
A.
DEUTZ
01899132
Socket wrench insert
long
Installing ancl removing pressure sensors
(rail pressure, oil pressure, fuel pressure)
lil 49357-0
II .. ..
01899144
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
.. di
.. ls) 43663-0
01899184
Torque handle
0.6 - 1.5 Nm
t··~
..
©5,.98-0
~0912012 6110
A.
DEUTZ
Special tools
W 49-01-01
OBJ_ DOK U-31154 -0 01.fm
01899185
Insert holder
Drive square 1/4"
Drive hexagon 1/4"
© 51 489- 0
02992112
Special wrench
Wrench size 17,
Removing and installing high-pressure lines
II
© 35•36-1
02992117
Lever tool
Removing the injector
© 49375 -0
7/10
Special tools
W 49-01-01
A.
DEUTZ
02992127
Disassembly tool
Removing O-ring
© •9360-0
II 02992138
Puller
(in conjunction with slide hammer 02992294)
Removing jammed injector sealing ring
'1; 35,37. 1
02992214
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
. -,
f ) 091~012
8/10
A.
DEUTZ
Special tools
W 49-01-01
OBJ_0OKU-31154-001.fm
02992294
Slide hammer
(in conjunction with disassembly device 02992137)
Disassembling injector sealing ring
© 49372-0
II
02992301
Separating tool
Removing metal sheet lubricating oil pan from crank-
case
© 49373-0
9/10
Special tools
W 49-01-01
OBJ _DOKU-31154- 001 fm
A.
DEUTZ
II
:SJ 09/201 2
10/ 10

Deutz+TD TCD+3.6L4F+Workshop+Manual 2013

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A.

VE-FL, Mr. Lippke

• Read and observe the information in this docu-

© 0912 01 2 3/4 OBJ DOKU-31076-00 1 frr.

©0912012 OBJ DOKU-31076-001 fm

© U9/lU12 OB,.1 _DOKU-~1077-0G1 r.-1

©U91,01, OBJ DOKU-31017-001 Im

DEUTZ engines are the product of years of research

Please consult one of our service representatives

© 0912012 OBJ DOKU-31U77-001 fm

<al 09120',2 QBJ_DOKU-31077-001 lo,

3.1 General 3.2 Specifications

II pacts or any other use of force.

• Dirt and moisture on the primary and high voltage

3.3 Operation manual and workshop man- 3.4 Job cards

3.4.2 Structure of a job card 3.5 Explanation of symbols

5 Job card overview

Activity Job card Module

Charge air manifold W 22-90-54 Charge air line

Closing parts W 02-90-01 Lubricating oil sump

Compensator structure (Exhaust line) W 41-90-21 Exhaust pipe

Connection (Crankcase housing, exhaust gas circu-

Exhaust gas treatment

Engine mounting W 46-90-15 Engine mounting

Engine mounting W46-90-15 Engine mounting

Engine mounting W 46-90-15 Engine mounting

Exhaust manifold (exhaust turbocharger) W 43-90-36 Exhaust gas turbocharger

Exhaust manifold (exhaust turbocharger) W 43-90-36 Exhaust gas turbocharger

Exhaust manifold (exhaust turbocharger) W 43-90-36 Exhaust gas turbocharger

fuel filter W 20-90-17 fuel filter

Fuel line W 20-90-30 Fuel pipes

Fuel pre-filter W 20-90-16 Fuel filter

Generator W 44-90-42 Parts to generator

Generator W 44-90-42 Parts to generator

Holder W 09-90-09 Gearcase

Impulse transmitter (camshaft) W 51-90-20 Measuring instruments

Intake nozzle (exhaust turbocharger} W 22-90-35 Air intake pipe

Intermediate gear W 09-90-50 Gearcase

Line W 38-90-32 Coolant pipes

Line W 38-90-32 Coolant pipes

Line W 01-90-32 Crankcase breather

Line W 38-90-32 Coolant pipes

Line (Thermostat housing, exhaust gas circulation,

Lubricant oil filter console W 15-90-38 Lubricating oil filler

Oil filling W 02-90-24 Lubricating oil sump

l· Oil measuring device W 01-90-23 Oil measuring device

Pressure fan W 39-90-52 Fan

Activity Job card Module

Removing and installing the belt tensioner (V-rib

II Removing and installing the connection housing

Removing and installing the connection housing

Removing and installing the connection housing

Removing and installing the connection housing W 52-01-01 Connection housing

Removing and installing the connection housing W 52-01-01 Connection housing

Removing and installing the exhaust line W 41-01-01 Exhaust pipe

Removing and installing the flywheel (Fastening

Removing and installing the fuel line (injector, rail,

Removing and installing the gasket housing W 01-03-01 Crankcase

Removing and installing the generator (Clamping

Removing and installing the generator (Fastening