WHB 3.6 Eng

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

Phone: 0221 822-2599
E-mail: [email protected]
DEUTZ AG
Sales & Service
Information Systems
Ottostraße 1
D-51149 Köln (Cologne)
Phone: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
Internet: www.deutz.com
E-mail: [email protected]
Printed in Germany
All rights reserved
1st edition, © 04/2014
The engine company. Order no. 0312 4375 en
Table of contents
OBJ_DOKU-42598-001.fm
1 Foreword
2 General
3 Safety instructions / User information

3.1 General
3.2 Regulations
3.3 Operation manual and workshop manual
3.4 Job cards
3.5 Picture symbols explanation
4 Chapter not assigned
5 Job card overview

5.1 Sorted alphabetically
5.2 Sorted numerically
6 Job cards
7 Chapter not assigned
8 Special tools
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Table of contents
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DEUTZ engines Foreword
1 Foreword
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Foreword DEUTZ engines
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DEUTZ engines Foreword
● Read and observe the information in this docu- ● Repair of the engine must correspond to its use
mentation. You will avoid accidents, retain the for the intended purpose. Only parts released by 1
manufacturer's warranty and possess a fully the manufacturer for the respective purpose may
functional and ready to operate engine. be used for conversion work. Unauthorised mod-
● This engine is built exclusively for purpose ac- ifications to the engine exclude manufacturer lia-
cording to the scope of delivery - defined by the bility for resulting damages. Failure to observe
equipment manufacturer (use for the intended this will void the warranty!
purpose). Any use above and beyond this is con- ● The engines made by DEUTZ are developed for
sidered improper use. The manufacturer will not a wide range of applications. A wide range of var-
be liable for damages resulting from this. The iants ensures that the respective special require-
user bears the sole risk. ments are met.
● Use for the intended purpose also includes ob- ● The engine is equipped according to the installa-
servance of the operating, maintenance and re- tion case, i.e. not all the parts and components
pair instructions specified by the manufacturer. described in this documentation are installed in
The engine may only be used, maintained and your engine necessarily.
repaired by persons who are familiar with this ● 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 available to tenance and repair instructions relevant to your
everyone involved in the operation, maintenance engine.
and repair and that they have understood the
contents.
● 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 special tools and their perfect
condition.
● Engine parts such as springs, clamps, elastic re-
taining rings etc. pose an increased risk of injury
when handled incorrectly.
● The pertinent rules for the prevention of acci-
dents and other generally recognised health and
We are at your service for any questions you may
safety regulations must be observed.
have in this matter.
● Maximum economy, reliability and long life is only
guaranteed when using DEUTZ original parts.
Your DEUTZ AG
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Foreword DEUTZ engines
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DEUTZ engines General
2 General
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General DEUTZ engines
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DEUTZ engines General
DEUTZ engines are the product of years of 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 2
fuel consumption. It goes without saying that the
high environmental protection requirements are
also met.
Maintenance and care are the only way the engine

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

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

The documentation of the workshop manual has 3.2.1 Accident prevention and safety 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
tions and parts due to further developments.
professional associations or from dealers. These
The valid documentations published by DEUTZ AG are dependent on the application site, operating 3
(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 perform 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.
– Ignition must be switched off.
– Do not start engine.
– Depending on version of the common rail sys-
tem, the electrical fuel supply pump is activat-
ed when the ignition is switched or during
starting and supplies the fuel directly.
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– After shutting down the engine, wait at least 3.2.2 Cleanliness instructions and measures
30 seconds before performing work on the fuel for working with common rail systems
system.
The common rail systems used in DEUTZ engines
Depending on the version of common rail sys-
comprise high-precision components subjected to
tem, the fuel pressure in the common rail sys-
extreme loads. In view of the high-precision technol-
tem will still not have dissipated after 30
ogy, ensure utmost cleanliness when working on
seconds. The fuel pressure can permanently
the fuel system.
3 be several 100 bar.
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 / 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. system closed before starting work on the fuel
– Cleaning, maintenance and repair work may system.
only be performed with the engine at a stand- ● The engine must be dry when you start working
still and secured against starting. on the fuel system.
– Fuel lines, injection lines or fuel high-pressure ● 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 tipped 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“.
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● Working materials and tools must be cleaned be- ● The workshop floor is sealed or tiled.
fore work. Only use tools without damage to the ● No welding gear, grinders, general machine
chrome plating or tools which are not chrome- tools, brakes or performance test benches may
plated. be operated in this room.
Notes and measures to be observed during work on ● Regular cleaning of the workshop area is manda-
the fuel system or with the fuel system open. tory. Draughts, ventilation systems and heating
fans should be minimised.
● Only work in clean overalls. 3
● Only lint-free cleaning cloths may be used for Notes 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- and keep them in a closed tool cabinet.
tem.
● Remove loose parts (for example paint chips
● Working materials and tools must be cleaned be- from assembly work) with an industrial vacuum
fore work. Only use tools without damage to the cleaner or other suction device.
chrome plating or tools which are not chrome-
● Working materials and tools must be cleaned be-
plated.
fore work. Only use tools without 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 3.2.3 Additional information and measures for
the open fuel system.
the handling of exhaust aftertreatment
● Work on removed components may only be per- systems
formed at a suitably equipped workbench.
● Basically all the same regulations and instruc-
● When removing and installing components, no
tions up to and including chapter 3.2.2 must also
materials which can leave behind particles or fi-
be observed for work on exhaust aftertreatment
bres (cardboard, wood, cloths) may be used.
systems!
● Removed parts may only be rubbed down with
● Utmost cleanliness must be observed for all
clean, lint-free cloths. No dirt particles may be
work.
rubbed into the components.
DPF (Diesel Particle Filter)
● Openings on the components and on the engine
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-
tivated before performing service work.
● The stoppers/caps may only be removed imme-
diately before installing. ● The duration of a full filter regeneration is 25 min-
utes on average. High exhaust temperatures oc-
● Store stoppers/caps free from dust and dirt in the
cur in the exhaust system/on the end exhaust
original packaging and dispose of after using
pipe independently of the actual load state of the
once.
engine (i.e. also during engine idling).
● Only remove new parts from the original packag-
● No foreign bodies may get into the exhaust line or
ing just before installation.
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.
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● The ignition system must not be operated without 3.2.4 Disposal regulations
a secondary load.
The work described in the operation manual and
● Store the components in a dry and clean area. workshop manual necessitates renewal of parts and
● It is not permitted to: store the components tem- operating materials among other things. The re-
porarily or stack them without their transport newed parts / operating materials must be stored,
packaging. transported and disposed of according to regula-
tions. The owner himself is responsible for this.
3 ● Components may only be stored and transported
in the specified packaging. Disposal includes recycling and the scrapping of
● Only remove new parts from the original packag- parts / operating materials, although recycling has
ing just before installation. priority.
● Incorrectly operated or damaged components or Details of disposal and their monitoring are gov-
parts that have been dropped must not be in- erned by regional, national and international laws
stalled. and directives which the system operator must ob-
serve on his own responsibility.
● Do not subject the components to any hard im-
pacts or any other use of force.
● Faulty earthing, cable and plug connections can
lead to malfunctions. Electronic components can
be destroyed.
● Dirt and moisture on the primary and high voltage
connections can cause malfunctions (leakage
current, misfiring, high voltage sparks).
● Check the protective caps of the ignition lines for
discolouration, deformation and cracks before
each usage.
SCR (Selective Catalytic Reduction)
● AdBlue® is a caustic medium which causes
heavy corrosion damage when it comes into con-
tact with electronic components or similar.
● Leaks on the AdBlue® 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.
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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
manual). tools and special tools are also indicated in the "W"
The operation manual contains a general descrip-
job card. 3
The "I" job card also documents corresponding
tion and instructions for all other maintenance work.
workflows for repairing the engine and/or its compo-
It 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 format 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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3.4.2 Structure of a job card 3.5 Explanation of symbols

Danger!
1 2 3 of death or to health. Must be observed!
For example: The incorrect use or conver-
4 sion of the turbocharger can lead to serious
5
injury.
3 6
Caution!
17 Danger to the component/engine. Non-
7 compliance can lead to destruction of the
16
component/engine.
6 8 Must be observed!
15 Note
General notes on assembly, environmental
9
protection etc. No potential danger for man
14
or machine.
Tool
Conventional and special tools required for
13 the work.
9
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
12 11 10
References
to important documents
1. DEUTZ AG,
publisher of service documentation Reference
2. Number of associated spare parts list sheet within the workflow 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.DEUTZ 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
5
5 Job card overview
5.1 Sorted alphabetically
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Job card overview
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Job card overview
Activity Job card Maintenance group

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
Closing parts W 01-90-01 Crankcase
Compensator structure (assembly material) W 71-90-21 Exhaust gas treatment
Compensator structure (Exhaust line) W 41-90-21 Exhaust pipe
Connection (Crankcase housing, exhaust gas circu- 5
W 41-90-04 Exhaust gas recirculation
lation, coolant line)
Connection housing W 52-90-53 Connection housing
Console W 71-90-51 Exhaust gas treatment
Control valve W 09-90-63 Gearcase
Drain valve W 02-90-04 Lubricating oil sump
Drive components W 37-90-06 Coolant pump
Engine mounting W 46-90-15 Engine mounting
Exhaust manifold (exhaust turbocharger) W 43-90-36 Exhaust gas turbocharger
Fastening parts W 82-90-05 Coolant compressor
Fastening parts W 48-90-05 Cable harness
Fastening parts W 20-90-05 Fuel filter
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
Holder W 71-90-09 Exhaust gas treatment
Holder W 41-90-09 Exhaust pipe
Holder W 41-90-09 Exhaust pipe
Holder (Relay) W 48-90-09 Electrical equipment
Impulse transmitter (camshaft) W 51-90-20 Measuring instruments
Impulse transmitter (crankshaft) W 51-90-20 Measuring instruments
Inlet module W 71-90-48 Exhaust gas treatment
Intake nozzle (exhaust turbocharger) W 22-90-35 Air intake pipe
Line W 38-90-32 Coolant pipes
Line W 01-90-32 Crankcase breather
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Job card overview

Line (Crankcase housing, exhaust gas circulation,
coolant line)
Line (Thermostat housing, exhaust gas circulation,
coolant line)
Line (Thermostat housing, lubricating oil cooler,
W 38-90-32 Coolant pipes
coolant line)
Lubricant oil filter console W 15-90-38 Lubricating oil filter
Lubricating oil line W 16-90-32 Lubricating oil pipe
5 Oil filling W 02-90-24 Lubricating oil sump
Oil measuring device W 01-90-23 Oil measuring device
Outlet module W 71-90-49 Exhaust gas treatment
Pressure fan W 39-90-52 Fan
Pressure transmitter / temperature pressure trans-
W 22-90-20 Charge air line
mitter (charge air)
Pressure transmitter installation (oil pressure) W 51-90-20 Measuring instruments
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)
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 coolant compressor W 82-01-01 Coolant compressor
Removing and installing the coolant pump W 37-03-01 Coolant pump
Removing and installing the cooler W 41-05-02 Exhaust gas recirculation
Removing and installing the cylinder head cover W 08-01-01 Cylinder head cover
Removing and installing the exhaust gas return val-
ve
Removing and installing the exhaust line W 41-01-01 Exhaust pipe
Removing and installing the flutter valve W 41-05-01 Exhaust gas recirculation
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)
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Job card overview

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)
5
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
Removing and installing the pressure/temperature
W 48-03-01 Electrical equipment
sensor (charge air)
Removing and installing the rail W 21-04-01 Fuel pipes
Removing and installing the sensor wheel W 05-07-01 V-belt pulley add-on
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 V-belt pulley / V-ribbed
W 05-01-01 Crankshaft
pulley
Removing and installing turning gear / locking de-
W 49-02-01 Tools
vice
Renewing the crankshaft sealing ring (flywheel side) W 01-02-01 Crankcase
Renewing the crankshaft sealing ring (opposite side
W 09-01-01 Gearcase
to flywheel)
Screw plug (Thermostat housing, exhaust gas circu-
Supply pump (Fuel) W 20-90-47 Fuel supply pump
V-belt pulley W 05-90-13 V-belt pulley add-on
V-rib belt pulley W 37-90-13 Coolant pump
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Job card overview
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Job card overview
Sorted numerically
5
5.2 Sorted numerically
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Job card overview
Sorted numerically
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Job card overview
Sorted numerically
Job card Activity Maintenance group

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 01-90-01 Closing parts 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 Closing parts Lubricating oil sump 5
W 02-90-04 Drain valve Lubricating oil sump
W 02-90-24 Oil filling Lubricating oil sump
Removing and installing the V-belt pulley / V-ribbed
W 05-01-01 Crankshaft
pulley
Removing and installing the flywheel (Fastening
W 05-03-01 Flywheel
parts)
W 05-07-01 Removing and installing the sensor wheel V-belt pulley add-on
W 05-90-13 V-belt pulley V-belt pulley add-on
W 08-01-01 Removing and installing the cylinder head cover Cylinder head cover
Renewing the crankshaft sealing ring (opposite side
W 09-01-01 Gearcase
to flywheel)
W 09-90-63 Control valve 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
Removing and installing the lubricating oil line (ex-
haust turbocharger)
W 16-90-32 Lubricating oil line Lubricating oil pipe
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 20-90-05 Fastening parts Fuel filter
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 (injector, rail,
W 21-05-05 Fuel pipes
high-pressure pump)
© 05/2014
9/12 TCD 3.6 L4
Job card overview
Sorted numerically

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 / temperature pressure trans-
W 22-90-20 Charge air line
mitter (charge air)
W 22-90-35 Intake nozzle (exhaust turbocharger) Air intake pipe
W 22-90-54 Charge air manifold Charge air line
W 22-90-55 Charge air line Charge air line
5 W 37-03-01 Removing and installing the coolant pump Coolant pump
W 37-90-06 Drive components Coolant pump
W 37-90-13 V-rib belt pulley Coolant pump
W 38-01-01 Removing and installing the thermostat Thermostat housing
W 38-01-02 Checking the thermostat (in the removed state) Thermostat housing
Line (Thermostat housing, lubricating oil cooler,
W 38-90-32 Coolant pipes
coolant line)
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 41-05-01 Removing and installing the flutter valve Exhaust gas recirculation
W 41-05-02 Removing and installing the cooler Exhaust gas recirculation
Removing and installing the exhaust gas return val-
ve
Screw plug (Thermostat housing, exhaust gas circu-
Connection (Crankcase housing, exhaust gas circu-
W 41-90-09 Holder Exhaust pipe
W 41-90-09 Holder Exhaust pipe
W 41-90-21 Compensator structure (Exhaust line) Exhaust pipe
Line (Thermostat housing, exhaust gas circulation,
coolant line)
Line (Crankcase housing, exhaust gas circulation,
coolant line)
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 installing the belt tensioner (V-rib
belt, level 1)
Removing and installing the generator (Fastening
parts)
© 05/2014
10/12 TCD 3.6 L4
Job card overview
Sorted numerically

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 44-90-42 Generator Parts to generator
W 46-90-15 Engine mounting Engine mounting
5
Removing and installing the pressure/temperature
W 48-03-01 Electrical equipment
sensor (charge air)
W 48-90-05 Fastening parts Cable harness
W 48-90-09 Holder (Relay) Electrical equipment
Removing and installing turning gear / locking de-
W 49-02-01 Tools
vice
W 51-90-20 Pressure transmitter installation (oil pressure) Measuring instruments
W 51-90-20 Impulse transmitter (camshaft) Measuring instruments
W 51-90-20 Impulse transmitter (crankshaft) Measuring instruments
W 52-01-01 Removing and installing the connection housing Connection housing
W 52-01-01 Removing and installing the connection housing Connection housing
W 52-90-53 Connection housing Connection housing
W 63-02-01 Removing and installing the glow plugs Start aid
W 71-90-09 Holder Exhaust gas treatment
W 71-90-21 Compensator structure (assembly material) Exhaust gas treatment
W 71-90-48 Inlet module Exhaust gas treatment
W 71-90-49 Outlet module Exhaust gas treatment
W 71-90-51 Console Exhaust gas treatment
W 82-01-01 Removing and installing the coolant compressor Coolant compressor
W 82-90-05 Fastening parts Coolant compressor
W 83-02-01 Removing and installing hydraulic pump drive Hydraulic pump drive
© 05/2014
11/12 TCD 3.6 L4
Job card overview
Sorted numerically
© 05/2014
12/12 TCD 3.6 L4
DEUTZ engines Job cards
6 Job cards
6
© 05/2014
1/2
Job cards DEUTZ engines
© 05/2014
2/2
Crankcase
W 01-02-01
Renewing the crankshaft sealing ring

(flywheel side)
Standard tools
Special tools:
– Pricker 01899103
– Assembly lever 01899110
– Assembly tool 02992214
– Self-tapping screw
– Washer
Removing the crankshaft sealing ring

1 Gasket housing
2 Shaft sealing ring
3 Hexagon head screw
188 Packing compound
© 50518-0
● 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!
© 47083-1
© 05/2014
1/4
Crankcase
W 01-02-01
● Screw in a self-tapping screw (1) with washer.
6
© 47084-1
● Pull out the crankshaft sealing ring with assembly le-

ver.
Ensure that the crankshaft does not get
damaged.
● Visually inspect the crankshaft sealing ring running

surface.
© 47085-1
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.
© 47088-2
© 05/2014
2/4
Crankcase
W 01-02-01
● Place the crankshaft sealing ring carefully on the pe-

ripheral surface.
Do not oil waxed crankshaft sealing rings.
The sealing lip faces the crankcase.
6
© 47089-1
● Mount assembly sleeve (1).

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

The installation depth is determined by the
assembly tool.
● Remove assembly tool.

● Install flywheel.
 Module 05
© 47091-1
© 05/2014
3/4
Crankcase
W 01-02-01
© 05/2014
4/4
Crankcase
W 01-03-01
Removing and installing the gasket housing

Standard tools: – Safety information / User
– Splint driver information
– Packing compound
DEUTZ DW 67
Removing the gasket housing

1 Gasket housing
2 Shaft sealing ring
© 50518-1
 Module 05
● Remove connection housing.
 Module 52
● Remove lubricating oil pan.
 Module 02
● Unscrew all screws (1).
● Remove gasket housing (2).
© 50519-0
© 05/2014
1/4
Crankcase
W 01-03-01
● Knock out crankshaft sealing ring (1).

Attention!
Do not damage the sealing surfaces.
● Visually inspect the components.
6
© 50520-0
Installing the gasket housing

● Clean sealing surfaces.
● Apply sealing compound (1) evenly on the sealing
surface.
Sealing cord strength approx. 0.5 -
0.6 mm.
© 50521-0
● Mount gasket housing.

© 50522-0
© 05/2014
2/4
Crankcase
W 01-03-01
The sealing face (arrows) must be flush

with the oil pan sealing face.
6
© 50523-0
● 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
 Module 05
© 50524-0
© 05/2014
3/4
Crankcase
W 01-03-01
Technical Data
ID no. Name Screw type Notes / Remark Value
Observe tightening
A01 095 Gasket housing on crankcase 20 Nm
sequence
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
© 05/2014
4/4
Crankcase
W 01-07-05
Removing and installing the transfer line

Standard tools
8190
DEUTZ DW 73
Removing the transfer line

1 Transfer line
2 Torx screw
3 Screw plug 35 Nm
© 50424-0

 Module 02
● Unscrew screws (1).
● Remove transfer line (2).
● Visually inspect the component.
© 50425-0
© 05/2014
1/4
Crankcase
W 01-07-05
Installing the transfer line

Attention!
No packing compound must get into the oil
channel (1)!
6
© 50723-1

surface.
© 51276-0

● Mount transfer line (1).
 20 Nm
 Module 02
© 50427-0
© 05/2014
2/4
Crankcase
W 01-07-05
Technical Data
A01 016 Transfer line on crankcase 20 Nm
© 05/2014
3/4
Crankcase
W 01-07-05
© 05/2014
4/4
Crankcase
W 01-90-01
Closing parts
Standard tools – Safety information / User
information
1 Screw plug 13 Nm
2 Sealing ring
Use a new sealing ring.
© 53456-0
© 05/2014
1/2
Crankcase
W 01-90-01
© 05/2014
2/2
Oil measuring device
W 01-90-23

Standard tools
1 Oil dipstick
2 Ball
3 Stopper
4 Guide tube
5 O-ring
Use new round sealing ring.
© 50392-0
© 05/2014
1/2
W 01-90-23
© 05/2014
2/2
Crankcase breather
W 01-90-32
Line
Standard tools
1 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
© 05/2014
1/2
Crankcase breather
W 01-90-32
© 05/2014
2/2
Lubricating oil sump
W 02-01-01
Removing and installing the lubricating oil pan

information
Special tools: – Operation manual
– Separating tool 02992301
Attention!
Make sure that no gasket residue falls into
DEUTZ DW 73
the crankcase.
Seal all openings.
Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.
Emptying and filling the engine with opera-
ting media must be carried out according to 6
the operating manual and the appropriate
documentation of the vehicle/equipment
manufacturer.
Removing the lubricating oil pan

1 Lubricating oil pan
3 Torx screw
© 53903-1
© 05/2014
1/8
W 02-01-01
● Unscrew locking screw (1).

● Remove sealing ring.
● Drain lubricating oil, collect and dispose of according
to regulations.
6
© 53904-0
© 53905-0
● 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.
© 53906-0
© 05/2014
2/8
W 02-01-01
● Drive in second separating tool (1) to the stop (2).

Attention!
The tool can only be driven in in the area of
the crankcase.
Separation in the area of aluminium parts
is not allowed.
6
© 53907-0
● Lever out lubricating oil pan.

© 53908-0
● Scrape off sealing compound with separating tool.

Danger!
Wear protective glasses.
● Clean the sealing surface on the crankcase with a

wire brush.
The sealing surfaces must be dry and free
from grease and dirt.
© 51291-0
© 05/2014
3/8
W 02-01-01
Danger!
Wear protective glasses.
● Clean the sealing surface on the lubricating oil pan

with a wire brush.
6
© 51292-0
Installing the lubricating oil pan

● To align the lubricating oil pan, screw four pin bolts
(1) diagonally opposed into the crankcase.
© 53909-0

● Apply packing compound to the joints (arrows).
© 53910-0
© 05/2014
4/8
W 02-01-01
● Apply the sealing compound evenly.

+ 0.5
Thickness 3 −0 mm
Attention!
The specified packing cord process must
be complied with.
6
© 53911-3
● Apply the sealing compound evenly.

+ 0.5
Thickness 3 −0 mm
Attention!
The specified packing cord process must
be complied with.
© 53911-4
● 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.
Observe the drying time for the packing
compound.
● Unscrew the pin bolts.
● Fasten all screws (1).
© 53905-0
© 05/2014
5/8
W 02-01-01

quence.
 20 Nm
6
© 53912-0
● Mount new sealing ring.

● Tighten screw plug (1).
 55 Nm
● Fill in lubricating oil according to operating manual.
© 53904-0
© 05/2014
6/8
W 02-01-01
Technical Data
Observe tightening
A02 030 Lubricating oil pan on crankcase 20 Nm
sequence!
A02 031 Locking screw on lubricating oil pan Replace sealing ring 55 Nm
© 05/2014
7/8
W 02-01-01
© 05/2014
8/8
W 02-90-01
Closing parts
Standard tools Collect draining lubricating oil and dispose
of properly.
1 Screw plug 55 Nm
2 Sealing ring
© 50331-0
© 05/2014
1/2
W 02-90-01
© 05/2014
2/2
W 02-90-04
Drain valve
information
Collect draining lubricating oil and dispose

of properly.
1 Drain valve 55 Nm
2 Sealing ring
© 56027-0
© 05/2014
1/2
W 02-90-04
© 05/2014
2/2
W 02-90-24
Oil filling
information
1 Screw plug 95 Nm
© 50332-0
© 05/2014
1/2
W 02-90-24
© 05/2014
2/2
Crankshaft
W 05-01-01
Removing and installing the V-belt pulley / V-ribbed pulley

– Torque wrench ≥ 100 Nm information
– Adapter – Operation manual
1/2 inch inner square
to 1 inch external square Attention!
Special tools: Pay attention to utmost cleanliness.
– Pin type socket wrench
insert, wrench size 36 01899199 The following work procedure describes
– Force multiplier 01899370 the removal and installation of the V-ribbed
– Turning gear / locking pulley.
device 02992380 The V-belt pulley is removed and installed
– Counter support 02992475 in the same way.
– Marker pen, waterproof, 6

permanent
– Degreasing agent/cleaning
agent
Removing the V-belt pulley / V-ribbed pulley

● Remove the V-belt / V-ribbed belt.
 Operation manual
● Remove starter.
 Module 44
● Insert turning gear / locking device (1).
Toothed wheel of the turning gear / locking
device in the toothed starter ring.

 30 Nm
© 53502-0
© 05/2014
1/12
Crankshaft
W 05-01-01
● Pull out and turn detent pin (1).

Observe position of the latches (2).
● Turn drive (3) carefully until the detent pin latches

into place.
Observe engine direction of rotation.
6
© 53503-0
– Version without air-conditioning system

● Push spacer sleeve (2) onto screw-in bolt (1).
● Screw on the screw-in bolt (1) and spacer sleeve (2).
● Tighten the screw-in bolt (1).
 50 Nm
© 53594-0
– Version with air-conditioning system

● Unscrew screw (1).
● Screw on screw-in bolt (2).
● Tighten the screw-in bolt (2).
If a console is available for the coolant
compressor, mount the screw-in bolt wit-
hout the spacer sleeve.
 50 Nm
© 53595-0
© 05/2014
2/12
Crankshaft
W 05-01-01
● Attach pressure plate (1).

Bores (2) and threaded bores (3) must be
in alignment.
● Tighten all screws (4).

 30 Nm
6
© 53596-0
● Align spline end (1) in such a way that the screw-in

bolt lies almost in the centre of the recess.
 30 Nm
© 53597-0
● Insert counter support (1).

 30 Nm
Depending on the installation situation, the
counter holder can be positioned variably.
© 53598-0
© 05/2014
3/12
Crankshaft
W 05-01-01
● Insert socket wrench insert and force multiplier (1).

● Snap in non-return device (2) in position CCW.
6
© 53599-0
● Hold force multiplier.

● Loosen central screw in direction of arrow.
● Remove force multiplier and socket wrench insert.
● Remove central screw.
© 53600-0
● Loosen screws (1).
© 53601-0
© 05/2014
4/12
Crankshaft
W 05-01-01

● Remove counter holder (2).
● Remove compressor plate (4)
● Detach the V-belt pulley / V-ribbed pulley.
● Remove sensor wheel.
 Module 05
6
© 53602-0
Installing the V-belt pulley / V-ribbed pulley

● Install sensor wheel.
 Module 05
Attention!
Pay attention to utmost cleanliness.
● Clean contact surfaces.

● Clean the locating hole.
● Press in the clamping pin (1) to the end stop.
Attention!
Ensure that the installation location is free
from faults.
© 53603-0
● Apply help marking (1).
© 53604-0
© 05/2014
5/12
Crankshaft
W 05-01-01

● Turn drive (3) carefully up to the desired crankshaft

position.
6
© 53503-0
● Turn drive carefully until the bore (1) is at the top and
the detent pin latches into place.
Attention!
The contact surfaces must be dry and free
© 53429-0
Attention!
The contact surfaces must be dry and free
● Attach V-belt pulley / V-ribbed pulley to bore (2) with
clamping pin (1).
Observe help markings.
● Press on the V-belt pulley / V-ribbed pulley.
© 53605-0
© 05/2014
6/12
Crankshaft
W 05-01-01
● Attach new washer to new central screw.

● Turn in new central screw with socket wrench insert.
● Attach pressure plate (1).
Bores (2) and threaded bores (3) must be
in alignment.

 30 Nm
6
© 53596-0
● Align spline end (1) in such a way that the screw-in

bolt lies almost in the centre of the recess.
 30 Nm
© 53420-0
● Tighten new central screw with torque wrench.

– Stage 1:
 100 Nm
© 53606-0
© 05/2014
7/12
Crankshaft
W 05-01-01
● Insert counter support (1).

 30 Nm
Depending on the installation situation, the
counter holder can be positioned variably.
6
© 53598-0
● Insert socket wrench insert and force multiplier (1).

● Snap in non-return device (2) in position CW.
© 53607-0
● Set graduated collar (1) to "0".
© 53608-0
© 05/2014
8/12
Crankshaft
W 05-01-01
● Hold force multiplier (1).

● Tighten central screw in direction of arrow.
– Stage 2:
 130°
6
© 53609-0
● Keep torque wrench pressed in direction of arrow.

● Move non-return device (1) into position CCW.
Danger!
There is danger of injury if a force multiplier
is removed without being discharged.
● Remove force multiplier and socket wrench insert.
© 53610-0
© 53616-0
© 05/2014
9/12
Crankshaft
W 05-01-01

● Remove counter holder (2).
● Remove compressor plate (4)
6
© 53602-0
– Version without air-conditioning system

● Unscrew screw-in bolt (1).
● Remove screw-in bolt (1) and spacer sleeve (2).
© 53594-0
– Version with air-conditioning system

● Unscrew screw-in bolt (1).
● Fasten screw (2).
● Tighten screw (2).
 Module 82
© 53611-0
© 05/2014
10/12
Crankshaft
W 05-01-01

● Remove turning gear / locking device (2).
● Install starter.
 Module 44
● Fit and tension V-belt / V-ribbed belt.
6
© 53505-0
© 05/2014
11/12
Crankshaft
W 05-01-01
Technical Data
Use new washer
V-belt pulley / V-ribbed pulley on
A05 030 Use new screw. 100 Nm
crankshaft
Stage 1:
V-belt pulley / V-ribbed pulley on
A05 030 Stage 2: 130°
crankshaft
Turning gear / locking device, fas-
A49 050 30 Nm
tening
6 tightening torque of +/- 10% is permissible.
© 05/2014
12/12
Flywheel
W 05-03-01
Removing and installing the flywheel

(Fastening parts)
Standard tools
Special tools:
– Guide pin (self-const-
ructed)
– Auxiliary screws M10x120
– Rotation angle disc 01899093
Removing the flywheel

1 Flywheel
2 Ring gear
3 Screw
© 52620-0
● Hold the crankshaft at the central screw.

● Screw in auxiliary screws (1).
● Remove flywheel using auxiliary screws.
© 52621-0
© 05/2014
1/4
Flywheel
W 05-03-01
Installing the flywheel

● Insert self-made guide pin (arrow).
The bores in the flywheel must match the
threaded bores in the crankshaft flange.
● Mount flywheel using auxiliary screws.
6
© 52622-0
Attention!
Renew screws every time they are loo-
sened.
● Tighten screws alternately.
– Stage 1:
 30 Nm
● Tighten screws with rotation angle disc.
– Stage 2:
 60°
– Stage 3:
 30°
● Remove guide pin.
● Unscrew auxiliary screws. © 52623-0
© 05/2014
2/4
Flywheel
W 05-03-01
Technical Data
Stage 1:
A05 001 Flywheel on crankshaft Use new screws. 30 Nm
Oiled screws.
A05 001 Flywheel on crankshaft Stage 2: 60°
A05 001 Flywheel on crankshaft Stage 3: 30°
© 05/2014
3/4
Flywheel
W 05-03-01
© 05/2014
4/4
V-belt pulley add-on
W 05-07-01
Removing and installing the sensor wheel

Standard tools
– Locking agent
DEUTZ DW 72
Removing the sensor wheel

1 Sensor wheel
3 Clamping pin
4 V-belt pulley
5 Central screw
6 Clamping pin
7 Washer
© 53415-0
● Remove V-belt pulley.

 Module 05
● Remove sensor wheel (2).
● Remove clamping pin (3).
© 53508-0
© 05/2014
1/4
W 05-07-01
Installing the sensor wheel

● Press in the new clamping pin (1) to the end stop.
6
© 53509-0
● Position sensor wheel (1).

Bore (2) and clamping pin (3) must be in
alignment.
● Press in sensor wheel (1).

Attention!
Do not deform or damage sensor wheel.
© 53510-0
● Insert screws with locking agent.

 13 Nm
● Install V-belt pulley.
 Module 05
© 53511-0
© 05/2014
2/4
W 05-07-01
Technical Data
Insert with DEUTZ DW
A05 032 Sensor wheel on V-belt pulley 13 Nm
72 locking agent.
© 05/2014
3/4
W 05-07-01
© 05/2014
4/4
W 05-90-13
V-belt pulley
information
1 V-belt pulley
2 Adapter
© 53156-0
© 05/2014
1/2
W 05-90-13
© 05/2014
2/2
Cylinder head cover
W 08-01-01
Removing and installing the cylinder head cover

information
– Fitting compound
DEUTZ AP1908
Removing cylinder head

1 Cylinder head cowling
2 Seal
3 Screw
4 Filler lock
5 Plug piece
© 50507-0
● Removing the crankcase breather.

 Module 01
● Remove cylinder head cowling (2).
© 50508-0
© 05/2014
1/6
Cylinder head cover
W 08-01-01
● Pull out plug element (1).
6
© 52650-0
● Remove gasket (1).

© 50509-0
Installing cylinder head cover.

● Mount new gasket (1).
© 50509-0
© 05/2014
2/6
Cylinder head cover
W 08-01-01
● Coat new plug piece (1) with mounting compound.
6
© 52651-0
● Insert new plug piece (1).
© 52650-0
● Mount cylinder head cover (1).
© 50510-0
© 05/2014
3/6
Cylinder head cover
W 08-01-01

quence.
 8.5 Nm
● Install crankcase breather.
 Module 01
6
© 50511-0
© 05/2014
4/6
Cylinder head cover
W 08-01-01
Technical Data
A08 004 Cylinder head cover on cylinder head 8.5 Nm
© 05/2014
5/6
Cylinder head cover
W 08-01-01
© 05/2014
6/6
Gearcase
W 09-01-01
Renewing the crankshaft sealing ring

(opposite side to flywheel)
information
Special tools:
– Pricker 01899103
– Assembly lever 01899110 Attention!
– Assembly tool 02992452 The crankshaft sealing ring is coated in
wax at the factory.
– Self-tapping screw Do not lubricate the crankshaft sealing
– Washer ring.
Removing the crankshaft sealing ring

● Remove ribbed / V belt pulley.
 Module 05
● Make a hole of approximately 3 mm in the crankshaft
sealing ring with a pricker.
Attention!
Do not damage the gearcase cover and
crankshaft.
© 54795-0
● Screw in a self-tapping screw (1) with washer.
© 54796-0
© 05/2014
1/4
Gearcase
W 09-01-01
● Tighten auxiliary screw (1).

Attention!
Do not use installation levers on the
gearcase.
● Pull out the crankshaft sealing ring with assembly le-
ver.
● Visually inspect the crankshaft sealing ring running
surface.
● Visually inspect all running surfaces.
6
© 54797-0
Installing the crankshaft sealing ring

● Place new crankshaft sealing ring on guide (1).
Attention!
The crankshaft sealing ring is coated in
wax at the factory.
Do not lubricate the crankshaft sealing
ring.
The sealing lip (2) faces the crankcase.
© 53133-1
● Attach guide (1).
© 54798-0
© 05/2014
2/4
Gearcase
W 09-01-01
– Repair stage:
If there is a groove on the crankshaft jour-
nal, it is possible to fit the crankshaft
sealing ring in a further installation depth
(repair stage).
● Mount shim (1).
assembly tool.
6
© 54799-0
● Mount assembly sleeve (1).

● Tighten the screw (2) to the end stop.
assembly tool.

● Remove assembly tool.
● Install ribbed / V belt pulley.
 Module 05
© 54800-0
© 05/2014
3/4
Gearcase
W 09-01-01
© 05/2014
4/4
Gearcase
W 09-90-63
Control valve
8190
information
1 Gear case
2 Valve piston
3 Valve spring
4 Spring plate 60 Nm
5 O-ring
6 Clamping pin
7 Threaded insert
8 Profile seal
Position
8 Profile seal
 Module 09
© 53846-0
Removing and installing the gearcase
© 05/2014
1/2
Gearcase
W 09-90-63
© 05/2014
2/2
Lubricating oil cooler
W 15-02-01
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.
Removing the lubricating oil cooler

1 Lubricating oil cooler
2 Seal
© 50278-0

● Remove lubricating oil cooler (2).
Collect draining lubricating oil and dispose
of properly.
© 50279-0
© 05/2014
1/4
W 15-02-01
Installing the lubricating oil cooler

● Turn in screws (arrows).
M8x20-10.9
● Fasten new seal (1) on lubricant oil cooler housing
with screws.
6
© 50280-0
● Mount lubricating oil cooler (1).

● Tighten all screws (2) alternately.
 30 Nm
© 50281-0
© 05/2014
2/4
W 15-02-01
Technical Data
A15 051 Oil cooler housing on crankcase 30 Nm
© 05/2014
3/4
W 15-02-01
© 05/2014
4/4
Lubricating oil filter
W 15-90-38
Lubricant oil filter console

8190
information

to regulations.
Observe the appropriate operating instruc-
tions for emptying and filling the engine.
1 Interchangeable filter 12 Nm
2 Threaded bush 40 Nm
3 Cover
4 O-ring
Position
2
Screwed in to the end stop.
© 50390-0
© 05/2014
1/2
Lubricating oil filter
W 15-90-38
© 05/2014
2/2
Oil suction pipe
W 16-01-01
Removing and installing the oil suction pipe

Standard tools
8190
DEUTZ DW 73
Removing the oil suction pipe

1 Oil suction pipe
2 Torx screw
© 50409-0

 Module 02
● Remove oil suction pipe (2).
© 50725-0
© 05/2014
1/4
Oil suction pipe
W 16-01-01
Installing the oil suction pipe

● Clean sealing surface.
surface.
6
© 50726-0
● Clean sealing surface.

● Install oil suction pipe (1).
 22 Nm
 Module 02
© 50727-0
© 05/2014
2/4
Oil suction pipe
W 16-01-01
Technical Data
A16 015 Oil suction pipe on crankcase M8x25-10.9 22 Nm
© 05/2014
3/4
Oil suction pipe
W 16-01-01
© 05/2014
4/4
Lubricating oil pipe
W 16-04-01
Removing and installing the lubricating oil line

information

to regulations.
Removing the lubricating oil line

1 Lubricating oil line
2 Hollow screw
3 Sealing ring
© 50444-0
● Unscrew hollow screw (1).

● Remove sealing rings (2).
© 50445-0
© 05/2014
1/4
W 16-04-01
● Unscrew hollow screw (1).

● Remove sealing rings (2).
● Remove lubricating oil pipe (3).
6
© 50446-0
Installing the lubricating oil line

● Mount lubrication oil line (1).
● Mount sealing rings (2).
● Screw on hollow screw (3).
© 50447-0

● Mount lubrication oil line (1).
● Mount sealing rings (2).
● Tighten hollow screw (3).
 18 Nm
Attention!
Install tension-free.
© 50448-0
© 05/2014
2/4
W 16-04-01
● Tighten hollow screw (1).

 18 Nm
Attention!
6
© 50449-0
© 05/2014
3/4
W 16-04-01
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 rings 18 Nm
© 05/2014
4/4
W 16-05-01

Special tools: to regulations.
– Disassembly tool 02992127
– Fitting compound tions for emptying and filling the engine.
DEUTZ AP1908
Removing the oil return line

1 Fastening flange
2 O-ring
3 Oil return line
4 O-ring
7 Seal
© 50435-0

© 50436-0
© 05/2014
1/6
W 16-05-01

● Pull out oil return line (2) in direction of arrow.
6
© 50437-0
● Remove flange (1) in direction of arrow.

● Remove round sealing ring (2) with disassembly tool.
© 50438-0
● Remove the O-ring (1) with the disassembly tool.

© 50683-0
© 05/2014
2/6
W 16-05-01
Mounting the oil return line

● Lightly coat new round sealing ring with DEUTZ
AP1908 mounting compound.
● Insert new O-ring (1).
6
© 50684-0

● Insert flange (2) in direction of arrow.
© 50440-0

● Mount oil return pipe (1).
● Insert oil return line (1) in direction of arrow.
© 50441-0
© 05/2014
3/6
W 16-05-01

● Mount gasket (1).
● Mount oil return pipe (2).
 8.5 Nm
6
© 50442-0

 8.5 Nm
Attention!
© 50443-0
© 05/2014
4/6
W 16-05-01
Technical Data
Oil return line on exhaust turbochar-
A43 044 8.5 Nm
ger
A43 046 Oil return line on crankcase 8.5 Nm
© 05/2014
5/6
W 16-05-01
© 05/2014
6/6
W 16-90-32
Lubricating oil line

information
1 Lubricating oil line

2 Hollow screw 30 Nm
3 Sealing rings
Attention!
from faults.
Install line without tension!
Use new sealing rings.
© 53239-0
© 05/2014
1/2
W 16-90-32
© 05/2014
2/2
High-pressure pump
W 17-01-04
Removing and installing the high-pressure pump

– Separating tool information
Special tools:
– Plugs/caps 01899144 Danger!
– Disassembly tool 02992127 Do not carry out work on the fuel system
– Special wrench 02992477 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
– Mounting compound 01008420 up to several 100 bar even after stopping
the engine.
Here the fuel pressure is only reduced if
the fuel system is opened and the fuel can 6
escape outside.
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.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
to regulations.
Removing the high-pressure pump

1 High-pressure pump
2 Spacer
3 Hexagonal nut
4 Washer
5 O-ring
6 Hexagonal nut
7 O-ring
8 Overflow valve
9 O-ring
10 O-ring
11 Flow control valve
12 O-ring
13 Seal
293 Mounting compound © 51433-2
© 05/2014
1/8
High-pressure pump
W 17-01-04
● Unlock cable plug and remove.
● Remove high-pressure line.

● Remove fuel pipes.
 Module 21
● Unscrew locking screw (1).
● Remove sealing ring.
 Module 09
● Install turning gear / locking device.
 Modules 44, 49
6
© 50702-0
● Turn crankshaft in engine direction of rotation until

marking is visible.
(1) Marking high-pressure pump gear wheel
© 50703-0

High-pressure pump gear wheel and inter-
mediate gear
Attention!
Do not turn the crankshaft any more!
© 50704-0
© 05/2014
2/8
High-pressure pump
W 17-01-04
● Unscrew nuts (1).

Attention!
Do not twist the high-pressure pump.
Do not twist the spacer.
Do not damage the components.
● Remove high-pressure pump (2).
Attention!
6
© 50705-0
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).
© 51434-0
● Remove the O-rings (1) with the disassembly tool.

Attention!
All the help markings must be transferred
when renewing/changing a part.
© 51435-0
© 05/2014
3/8
High-pressure pump
W 17-01-04
Installing the high-pressure pump

● Mount new O-rings (1).
● Push on spacer (2).
Attention!
from faults.
Recess (3) is on the fuel supply side.
6
© 51436-0
● Mount high-pressure pump gear wheel (1).

Attention!
Pay attention to installation position.
(2) Surrounding groove

(3) Marking
© 51437-0
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).
Use a suitable tool.
● Hold high-pressure pump gear wheel (5).

● Tighten nuts (4).
 80 Nm
© 51438-0
© 05/2014
4/8
High-pressure pump
W 17-01-04
● Coat the O-ring (1) with fitting compound.

● Coat bordering surfaces of the spacer (2) with
mounting compound.
6
© 53500-0
Attention!
Observe direction of rotation of the high-
pressure pump drive!
Observe position of the drive shaft and
high-pressure pump.
View Direction of rotation

On high-pressure pump drive right (clockwise)
Attention!
Dry running is not permissible.
Sufficient fuel pressure must be available
at the high-pressure pump.
Fuel pressure at the supply: at least 3.2 bar
© 51439-0
● Install high-pressure pump.

Markings must be visible.
Help marking must match.
Help marking high-pressure pump gear wheel
(2)
and intermediate gear
© 50713-0
© 05/2014
5/8
High-pressure pump
W 17-01-04
Attention!
Do not twist the high-pressure pump.
● Screw on nuts (1).

 20 Nm
6
© 50714-0
● Mount locking screw (1).

● Tighten screw plug (1).

 55 Nm
 Module 09
● Install fuel pipes.
● Fit new high-pressure line.
 Module 21
● Plug in and lock cable plug.
● Remove turning gear / locking device.
 Modules 44, 49
© 50702-0
© 05/2014
6/8
High-pressure pump
W 17-01-04
Technical Data
High-pressure pump gear wheel and Hold high-pressure pump
A17 004 80 Nm
high-pressure pump drive shaft gear wheel.
A17 031 High-pressure pump on crankcase 20 Nm
© 05/2014
7/8
High-pressure pump
W 17-01-04
© 05/2014
8/8
Injector
W 19-01-01
Removing and installing the injector

information
– Diagnostic tool – Service Bulletin
SerDia 2010 – SerDia manual 2010
– Assembly pliers 01899050
– Torx tool set 01899092 Danger!
– Plugs/caps 01899144
Do not carry out work on the fuel system
– Lever tool 02992117
when the engine is running.
– Extraction tool 02992138 The fuel system is under high pressure -
– Slide hammer 02992294 Danger of death.
The fuel pressure can continuously remain
up to several 100 bar even after stopping
the engine.
6
the fuel system is opened and the fuel can
escape outside.
Attention!
to regulations.
Remove injector
1 Injector
2 Sealing disc
3 Clamping claw
4 Torx screw
5 Clip
6 O-ring
© 50460-1
© 05/2014
1/8
Injector
W 19-01-01
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. 1
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 IMA code in the control unit.
Observe installed injection system!
6 The IMA codes of the different injection
systems are basically different. © 51243-0
The injector calibration depends on the
installed injection system.
The exact procedure can be taken from the
listed documentation and must be obser-
ved.
Diagnostic
 SerDia 2010
tool
SerDia manual
Report back changed data record to

DEUTZ AG.
e-mail address:
[email protected]
 Service Bulletin
0199-99-11045
The following work procedure describes

the removal and installation of an injector.
Proceed in the same way to remove further
injectors.
● Unlock cable plug and remove.
● 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.
 Module 21
© 50461-0
© 05/2014
2/8
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.
6
© 50462-0
Attention!
Do not brush off the nozzle tip of the injec-
tor.
Do not 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.
© 51242-0
Attention!
Do not damage the injector.
● Remove the round sealing ring (1) carefully from the

injector with the disassembly tool.
© 52556-0
© 05/2014
3/8
Injector
W 19-01-01
Removing fixed sealing disc at cylinder head

● Insert extraction device (1).
The supports (arrow) must rest in the bore
of the sealing disc.
6
© 50463-1
● Screw in spindle (1) until the sealing disc is fastened

on the pull-out device.
Hold puller on hexagon.
● Install adapter (2) on disassembly device.
© 50464-1
● Install slide hammer (1) on disassembly device.

● Pull out fixed sealing disc.
© 50465-1
© 05/2014
4/8
Injector
W 19-01-01
Installing the injector

Attention!
Do not twist or overtighten the O-ring.
Do not damage the O-ring!
● Mount new O-ring (1).
Use a suitable assembly aid.
Provide protection for sharp edges.
6
© 52790-1
● 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.
© 50466-1
Attention!
Note assignment of the injector to the
cylinder.
from faults.
● Insert injector carefully in the cylinder head.
● Mount clamping shoe.
● Insert screw (1).
Do not tighten the screw until after
assembling the injection line.
● Mount new injection pipe.

 Module 21
Do not tighten union nuts.
© 50467-1
© 05/2014
5/8
Injector
W 19-01-01
Attention!
Position (1):
 30 Nm
6
© 50461-0
● Tighten union nuts of the injection line.

 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.
 Module 21
© 05/2014
6/8
Injector
W 19-01-01
Technical Data
Observe order of
Injector on cylinder head, clamping installation.
A19 001 30 Nm
claw Install injector without
tension.
© 05/2014
7/8
Injector
W 19-01-01
© 05/2014
8/8
Fuel filter
W 20-90-05
Fastening parts
8190
information
Danger!
Danger of death.
the engine.
escape outside.
Attention!
to regulations.
© 54054-0
© 05/2014
1/2
Fuel filter
W 20-90-05
© 05/2014
2/2
Fuel filter
W 20-90-16
Fuel pre-filter
information
– Operation manual
Danger!
Danger of death.
the engine.
6
escape outside.
Attention!
to regulations.
1 Fuel pre-filter
3 Sensor 1.6 Nm
4 Sealing ring
10 Fuel filter

Vent fuel system according to operating
instructions.
Fuel pre-filter
© 50549-1
© 05/2014
1/2
Fuel filter
W 20-90-16
© 05/2014
2/2
Fuel filter
W 20-90-17
Fuel filter
information
Special tools:
– Long socket wrench insert 01899132
Danger of death.
the engine.
escape outside.
Attention!
to regulations.
1 Filter head
2 Fuel spare filter
3 Pressure sensor 25 Nm
4 O-ring
5 Sealing ring
6 Coupling plug 49 Nm

© 53236-0
© 05/2014
1/2
Fuel filter
W 20-90-17
© 05/2014
2/2
Fuel pipes
W 20-90-30
Fuel line
8190
information
– Hose clip pliers 01899037
– Spring band pliers 01899112 Danger!
Danger of death.
the engine.
6
escape outside.
Attention!
to regulations.
1 Hose pipe
3 Sealing ring
4 Clip
5 Holding tape
© 50548-0
© 05/2014
1/2
Fuel pipes
W 20-90-30
Attention!
from faults.
Lay the hose pipe free from chafing and ten-
sion.
– Dimension X
+3
 15 −1 mm
6
© 51299-0
© 05/2014
2/2
Fuel supply pump
W 20-90-47
Supply pump
(Fuel)
information
Special tools: – Installation guideline
Danger!
Danger of death.
the engine. 6
escape outside.
Attention!
Ensure the utmost cleanliness when per-
forming all work.
Before dismounting, remove any paint
residues and dirt particles.
Observe safety regulations and national
regulations when working with fuels.
Seal all connections immediately with new
and clean stoppers/caps after opening.
Only remove stoppers/caps immediately
before assembly.
Collect escaping operating media in
suitable vessels and dispose of them
according to regulations.
The following must be observed for
installation:
Installation guidelines of DEUTZ AG.
Installation guideline / documentation of
the vehicle manufacturer / equipment
manufacturer.
The documentation of the vehicle manu-
facturer / equipment manufacturer must be
complied with for dismantling and
installing.
© 05/2014
1/2
Fuel supply pump
W 20-90-47
1 Supply pump
2 Clip
– Fastening
Screws
4 x M5-8.8
+1
 7.5 −1 Nm
Attention!
from faults.
The fuel outlet is facing upwards.
6
© 52785-1
+1
1 Nut M5 7.5 −1 Nm
Terminal +
+1
2 Nut M5 7.5 −1 Nm
Terminal −
3 Connection nozzle
Fuel outlet
Attention!
Ensure that the cables are connected pro-
perly.
© 52789-0
© 05/2014
2/2
Fuel pipes
W 21-04-01
Removing and installing the rail

– Wrench insert size 14 information
Special tools:
– Long socket wrench insert 01899132 Danger!
– Plugs/caps 01899144 Do not carry out work on the fuel system
– Disassembly tool 02992127 when the engine is running.
– Special wrench 02992477 The fuel system is under high pressure -
Danger of death.
– Marker pen, waterproof,
permanent The fuel pressure can continuously remain
– Assembly grease 01016496 up to several 100 bar even after stopping
the engine.
escape outside.
Attention!
to regulations.
Removing the rail

1 Rail
2 High-pressure line
3 Injection line
4 Injection line
5 Screw
6 Spacer
7 Repair kit
Pressure sensor
Pressure limiting valve
11 O-ring
259 Mounting grease
© 50552-2
© 05/2014
1/10
Fuel pipes
W 21-04-01
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
6
© 51409-0
Removing injection pipes

● Unscrew lock nuts (1) with special wrench.
Attention!
Position (3):
● Hold pipe connection of injector.
● Unscrew lock nuts (2).
● Remove injection lines.
© 51410-0
● Unlock cable plug.

● Pull out cable plug.
● Remove the rail (2).
● Remove spacer (3).
© 51411-0
© 05/2014
2/10
Fuel pipes
W 21-04-01
Removing the pressure sensor

● Unscrew the rail pressure sensor (1) with the socket
wrench.
6
© 51412-0
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.
© 43017-0
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.
© 43017-0
© 05/2014
3/10
Fuel pipes
W 21-04-01
Attention!
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
6
© 51412-0
Removing the pressure limiting valve

● Unscrew pressure limiting valve (1).
© 51413-0
● Visually check the thread and the sealing edge of the

pressure limiting valve.
© 43253-1
© 05/2014
4/10
Fuel pipes
W 21-04-01
● Remove the O-ring with the disassembly tool.
6
© 43335-0
Installing the pressure limiting valve

Attention! 1
No foreign bodies may get into the rail.
Ensure utmost cleanliness. Especially on
the thread and the sealing surface of the
rail.
Rail pressure sensor and pressure limiting
valve must be replaced as a pair.
© 43254-0
● Lightly coat the thread and sealing edge of the pres-

sure limiting valve with assembly grease.
© 43254-1
© 05/2014
5/10
Fuel pipes
W 21-04-01
● Clean thread and sealing area of the rail.

● Screw in pressure limiting valve (1).
● Tighten pressure limiting valve.
 100 Nm
6
© 51413-0
Mounting rail
● Mount rail (1) with spacer (2).
● Loosely preassemble rail (1) with screws (3).
Do not tighten screws.
© 51414-0
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).
© 51415-0
© 05/2014
6/10
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.
6
© 51416-0
Installing high-pressure line

Attention!
The high-pressure line must always be
renewed after dismantling.

from faults.
● Mount new high-pressure line (1).
© 51417-0
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.
© 51418-0
© 05/2014
7/10
Fuel pipes
W 21-04-01

 30 Nm
6
© 51419-0
● Tighten the union nuts in order.

● Stage 1:
 10 Nm
© 51420-0
● Draw help markings (1).

● Tighten union nut.
– Stage 2:
1
+ 5°
 60°
● Check injection lines for perfect installation position.
1 perfect installation
● Check the high-pressure line for
position.
2
● Mount fuel return line.
● Mount cable harness holder. °
60 2
Ensure that the connection is perfect.
© 51250-0
© 05/2014
8/10
Fuel pipes
W 21-04-01
Technical Data
Stage 1:
Injection line on rail and injector,
Observe assembly
A21 003 high-pressure line on high-pressure Union nut 10 Nm
instructions.
pump and on rail
Use new line.
Injection line on rail and injector,
+ 5°
A21 003 high-pressure line on high-pressure Stage 2: 60°
pump and on rail
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 6
assembly grease.
Lightly coat the thread
A21 040 Pressure sensor on rail M18x1.5 and sealing edge with 70 Nm
assembly grease.
© 05/2014
9/10
Fuel pipes
W 21-04-01
© 05/2014
10/10
Fuel pipes
W 21-05-05
Removing and installing the fuel line

(injector, rail, high-pressure pump)
information
Special tools:
– Spring band pliers 01899112
Danger of death.
the engine.
Here the fuel pressure is only reduced if 6
escape outside.
Attention!
to regulations.
Removing the fuel line

1 Fuel line
2 Return line
3 Hose holder
5 Spring band clip
6 Hose pipe
7 Pipe clip
© 51395-0
© 05/2014
1/6
Fuel pipes
W 21-05-05
Attention!
renewed.
clip.
● Press in the clip (1) to the stop.
● Pull out return line (2).
6
© 51396-0
● Remove return line (1) from hose holder (2).

● Unlock coupling plug (3) and pull off.
© 51398-0
● Loosen spring band clip (1) with spring band pliers.

● Pull off hose pipe (2).
● Remove fuel line (3).
● Replace damaged components.
Attention!
Damaged fuel lines must be replaced
completely.
© 51307-1
© 05/2014
2/6
Fuel pipes
W 21-05-05
Mounting the fuel line

Attention!
Damaged fuel lines must be replaced
completely.
2
from faults.
1
Lines must be pushed on so that they are
flush.
● Position fuel pipe. X
● Position the spring band clip (1) with the spring band
pliers.
– Dimension X
+2
4 −2 mm
● Mount the hose pipe (2). 6
© 51308-0
Attention!
from faults.
Fuel line with fabric casing:

If a hose piece is pulled off of the hose
connection, the hose line must be replaced
completely.
Push hose piece onto the hose connection
up to the end stop!
● Position fuel pipe.
● Insert return line (1) in hose holder (2).
● Position pipe clips (3).
● Mount coupling plug (5) and latch into place.
© 51399-0
Attention!
renewed.
clip.
● 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.
© 51451-1
© 05/2014
3/6
Fuel pipes
W 21-05-05

 30 Nm
● Carry out a trial run.
● Check fuel system for leaks.
– Visual inspection for leaks
6
© 51452-0
© 05/2014
4/6
Fuel pipes
W 21-05-05
Technical Data
A12 095 Pipe clips, fastening 30 Nm
© 05/2014
5/6
Fuel pipes
W 21-05-05
© 05/2014
6/6
Charge air line
W 22-01-01
Removing and install the charge air line

information
Remove charge air line

1 Charge air line
2 Seal
© 53152-0
● Remove fuel return line.

● Unlock cable plug and disconnect.
● Remove charge air line (2).
© 50414-0
© 05/2014
1/4
Charge air line
W 22-01-01
Install charge air line

● Mount new gasket (1).
● Turn screws into the seal a few turns.
The seal is locked by the screw thread.
Ensure that the installation location of the
gasket is free from faults.
6
© 50415-0
● Mount charge air line (1).

Do not move gasket.
© 50416-0

quence.
 30 Nm
Attention!
Ensure that the cables are laid perfectly.

● Mount fuel return line.
© 50417-0
© 05/2014
2/4
Charge air line
W 22-01-01
Technical Data
A22 030 Charge air line on cylinder head 30 Nm
© 05/2014
3/4
Charge air line
W 22-01-01
© 05/2014
4/4
Charge air line
W 22-04-01
Removing and installing charge air manifold

Standard tools:
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
© 50403-0
● Loosen spring band clips (1) with spring band pliers.

● Remove charge air manifold (3).
© 50404-0
© 05/2014
1/4
Charge air line
W 22-04-01
Installing charge air manifold

● Mount charge air manifold (2).
● Fasten screws (3).
 30 Nm
● Position spring band clips (4) with spring band pliers.
6
© 50405-0
© 05/2014
2/4
Charge air line
W 22-04-01
Technical Data
A22 046 Charge air manifold on charge air line 30 Nm
© 05/2014
3/4
Charge air line
W 22-04-01
© 05/2014
4/4
Charge air line
W 22-90-20
Pressure transmitter / temperature pressure transmitter

(charge air)
information
– Fitting compound Attention!

DEUTZ AP1908 Ensure utmost cleanliness for all work.
opening with new, clean plugs/caps. 6
1 Temperature sensor
5 Pressure sensor
6 Console
7 Sealing ring
9 Hose ring piece
242 Mounting compound

© 51446-0
© 05/2014
1/2
Charge air line
W 22-90-20
Positions
1
5
Use mounting compound.
© 05/2014
2/2
Air intake pipe
W 22-90-35
Intake nozzle
Standard tools:
1 Intake nozzle
2 Spring band clip
3 Spring band clip
5 Pipe clip
6 Pipe
7 Rubber sleeve
8 Spring band clip
© 50384-1
● Position spring band pliers on the marks of the rub-

ber sleeve.
Position the spring band clip facing
upwards in an easy to reach position.
Attention!
from faults.
– Dimension I
2 mm
– Dimension II
25 mm
– Dimension III
25 mm
© 54867-0
© 05/2014
1/2
Air intake pipe
W 22-90-35
● Push in pipe (1) until it reaches the detent (2).

Position the spring band plier so that it is
freely accessible from above.
Attention!
from faults.
– Dimension I
2 mm
6
© 54868-0
© 05/2014
2/2
Charge air line
W 22-90-54
Charge air manifold

Standard tools
1 Charge air manifold

2 Throttle valve
3 Seal
6 Seal
Use a new gasket.
© 51444-0
© 05/2014
1/2
Charge air line
W 22-90-54
Technical Data
A22 046 Charge air manifold on charge air line 30 Nm
© 05/2014
2/2
Charge air line
W 22-90-55
Charge air line

information
Special tools:
1 Hose pipe
2 Spring band clip
3 Spring band clip
4 Seal
5 Charge air line
Use a new gasket.
© 54072-0
Positions
1
2
3
Attention!
from faults.
– Dimension I
1 mm
– Dimension II
4 mm
– Dimension III
2 mm
– Dimension IV
© 54073-0
24 mm
© 05/2014
1/2
Charge air line
W 22-90-55
© 05/2014
2/2
Coolant pump
W 37-03-01
Removing and installing the coolant pump

information
– Special pliers 01899191
– Disassembly tool 02992127 Danger!
– Fitting compound Observe specifications for working on the
DEUTZ AP1908 cooling system - see operating manual.
Attention!
Due to leakage, the coolant pump must be
replaced after being removed.

suitable vessels and dispose of according 6
to regulations.
Removing coolant pump

1 Coolant pump
2 Laminated seal
3 Hose connection 35 Nm
4 Screw plug 35 Nm
5 Screw plug 60 Nm
6 Sealing ring
7 Sealing ring
© 54245-0
© 05/2014
1/6
Coolant pump
W 37-03-01
● Remove ribbed belt / V-belt.

 Operating Manual
● Remove ribbed / V belt pulley.
 Module 37
● Remove coolant line.
 Module 38
● Remove locking ring (1).
● Remove connector piece (2) with special pliers in the
direction of the arrow.
6
© 54246-0
Note different screw lengths.

● Remove coolant pump (3).
© 54247-0
● Remove plug element (1) in direction of arrow.
© 54248-0
© 05/2014
2/6
Coolant pump
W 37-03-01
● Remove the laminated seal (1) with the disassembly

tool.
6
© 54873-0
Installing coolant pump

Attention!
Due to leakage, the coolant pump must be
replaced after being removed.
● Insert a new laminated seal (1) with assembly paste.
● Insert a new laminated seal (1).
Attention!
from faults.
© 54874-0
● Coat new plug piece (1) with mounting compound.

● Push in a new connector piece (1) in the direction of
the arrow until reaching the detent.
© 54249-0
© 05/2014
3/6
Coolant pump
W 37-03-01

● Attach coolant pump (1).
● Tighten screws (2) alternately.

M8x30
● Tighten screws (3) alternately.
M8x80
6
© 54251-0

 30 Nm
© 54252-0
● Push in and hold the connector piece in the direction

of the arrow with the special pliers (1)
● Insert the circlip (2) into the groove (3).
● Install coolant pipe.
 Module 38
● Install ribbed / V belt pulley.
 Module 37
● Replace ribbed belt / V-belt.
 Operating Manual
© 54253-0
© 05/2014
4/6
Coolant pump
W 37-03-01
Technical Data
A37 010 Coolant pump on cylinder head 30 Nm
© 05/2014
5/6
Coolant pump
W 37-03-01
© 05/2014
6/6
Coolant pump
W 37-90-06
Drive components
Standard tools
8190
1 V-rib belt pulley

© 50391-0
© 05/2014
1/2
Coolant pump
W 37-90-06
© 05/2014
2/2
Coolant pump
W 37-90-13
V-rib belt pulley

Standard tools
8190
1 V-rib belt pulley

© 50661-0
© 05/2014
1/2
Coolant pump
W 37-90-13
© 05/2014
2/2
Thermostat housing
W 38-01-01
Removing and installing the thermostat

8190
information
Attention!
The thermostat and thermostat housing
are firmly connected together at the
factory.

to regulations.
tions for emptying and filling the engine. 6
Removing the thermostat

1 Thermostat housing
including thermostat
4 Sealing ring
5 Screw plug 65 Nm
6 Seal
8 Temperature sensor 25 Nm
© 51383-1
● Drain, collect and dispose of coolant according to

regulations.
● Remove thermostat housing (2)
© 51384-0
© 05/2014
1/4
Thermostat housing
W 38-01-01
6
© 51385-1
Installing the thermostat

Attention!
The venting hole (1) must be at the highest
point.
© 56029-0

● Insert screws (1).
● Fix new gasket (2) to the thermostat housing with
screws.
© 51386-1
© 05/2014
2/4
Thermostat housing
W 38-01-01
● Mount thermostat housing (1).

6
© 51387-0

 30 Nm
● Fill cooling system according to the operating manu-
al.
© 51388-0
© 05/2014
3/4
Thermostat housing
W 38-01-01
Technical Data
A38 001 Thermostat housing on cylinder head 30 Nm
© 05/2014
4/4
Thermostat housing
W 38-01-02
Checking the thermostat (in the removed state)

– Thermometer information
Danger!
Danger of injury!
Hot water and hot components.
Attention!
The thermostat and thermostat housing
are firmly connected together at the
factory.
Schematic diagram:
For better illustration, the thermostat is 6
shown without the thermostat housing.
Checking thermostat
● Measure beginning of stroke, dimension (a).
● Note measured value, dimension (a).
© 51390-0
● 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 water 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:
 86 ℃ – 90 ℃
© 52163-0
© 05/2014
1/4
Thermostat housing
W 38-01-02
● Measure water temperature.

– Nominal value:
 99 °C – 102 °C
● Measure end of stroke, dimension (b).
● Note measured value, dimension (b).
6
© 51391-0
● 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 result with setpoint value.
– Nominal value:
 9 mm
© 51392-0
© 05/2014
2/4
Thermostat housing
W 38-01-02
Technical Data
Testing and setting data
ID no. Name Additional information Value
P38 11 Thermostat, start of opening 86 ℃ – 90 ℃
P38 13 Thermostat, stroke at 99 ℃ – 102 °C, minimum 9 mm
P38 14 Thermostat, stroke, test temperature 99 °C – 102 °C
© 05/2014
3/4
Thermostat housing
W 38-01-02
© 05/2014
4/4
Coolant pipes
W 38-90-32
Line
8190
information
1 Coolant line
11 Fitting screw 14 Nm
12 Washer
Position
2
 30 Nm
Attention!
© 52771-2
© 05/2014
1/2
Coolant pipes
W 38-90-32
© 05/2014
2/2
Coolant pipes
W 38-90-32
Line
(Thermostat housing, lubricating oil cooler, coolant line)
8190
information
Special tools:
to regulations.
1 Elbow
2 Spring band clip
3 Coolant line
4 Pipe clip
5 Hose pipe
7 Support plate
© 54277-0
Position
5
Attention!
Lay the hose pipe free from chafing and
tension.
Marking (1) faces the crankcase.
© 53355-0
© 05/2014
1/2
Coolant pipes
W 38-90-32
© 05/2014
2/2
Fan
W 39-90-52
Pressure fan
Standard tools
8190
1 Pressure fan
© 51338-0
© 05/2014
1/2
Fan
W 39-90-52
© 05/2014
2/2
Exhaust pipe
W 41-01-01
Removing and installing the exhaust line

Standard tools
Removing exhaust line

1 Exhaust line
2 Seal
© 50418-0
● Remove turbocharger.
 Module 43
● Remove cooler.
 Module 41
● Remove exhaust line (2).
© 50419-0
© 05/2014
1/4
Exhaust pipe
W 41-01-01
Installing exhaust line

● Turn in screws (arrows).
● Fasten new seal (1) with screws on exhaust line.
6
© 50420-0

● Mount exhaust line (1).
Note installation position.
© 50421-0

quence.
 30 Nm
● Install the turbocharger.
 Module 43
● Install cooler.
 Module 41
© 50734-0
© 05/2014
2/4
Exhaust pipe
W 41-01-01
Technical Data
Observe tightening
A41 001 Exhaust line on cylinder head 30 Nm
sequence
© 05/2014
3/4
Exhaust pipe
W 41-01-01
© 05/2014
4/4
Exhaust gas recirculation
W 41-05-01
Removing and installing the flutter valve

8190
information
DEUTZ AP1908
1 Cooler
2 Exhaust gas recirculation valve
6 O-ring
7 O-ring
8 Flutter valve
© 54699-0
● Remove hose pipe (1).

 Module 22
● Remove the housing (3).
© 56057-0
© 05/2014
1/4
W 41-05-01
● Remove flutter valve (1).

6
© 56058-0
Installing the flutter valve

● Clean housing.
● Insert sealing ring with mounting compound.
Attention!
from faults.
© 44328-0
● Insert flutter valve (1).

Attention!
from faults.
© 56059-0
© 05/2014
2/4
W 41-05-01
● Mount housing (1).

● Mount hose pipe (3).
 Module 22
6
© 56060-0
© 05/2014
3/4
W 41-05-01
© 05/2014
4/4
W 41-05-02
Removing and installing the cooler

information

to regulations.
Removing the cooler

1 Cooler
2 Control valve
6 O-ring
7 O-ring
8 Flutter valve
© 54699-0
● Remove coolant pipes.

 Module 41
● Unlock cable plug (1) and disconnect.
● Remove cooler (3).
© 50407-0
© 05/2014
1/4
W 41-05-02
Installing the cooler

● Mount cooler (1).
 20 Nm
● Insert cable plug (3) and lock into place.
● Attach coolant lines.

 Module 41
6
© 50408-0
© 05/2014
2/4
W 41-05-02
Technical Data
Cooler on holder (exhaust gas
A41 052 20 Nm
recirculation)
© 05/2014
3/4
W 41-05-02
© 05/2014
4/4
W 41-05-03
Removing and installing the exhaust gas return valve

information
Danger!
DEUTZ AP1908 Hot components!
– Ethanol C2H5OH Danger of burns / explosion!
Let the engine / components cool down
CAS No. 64-17-5
sufficiently (to at least ambient tem-
(not in the scope of deli-
perature).
very of DEUTZ AG)
Observe safety regulations and national
regulations when working with ethanol.
Attention! 6

to regulations.
Removing the exhaust gas return valve

1 Cooler
2 Exhaust gas recirculation valve
6 O-ring
7 O-ring
8 Flutter valve
© 54699-0
© 05/2014
1/8
W 41-05-03
● Drain, collect and dispose of coolant according to

regulations.
● Disconnect the battery.
● Remove the compensator.
 Module 41
● Unlock cable plug (1) and remove.
● Push latch (2) in the direction of the arrow.
● Pull off cable plug (3).
Attention!
To avoid electrostatic discharges, do not
touch the plug contacts with your bare
hands.
6
© 56061-0

● Swing holder (2) to the side.
© 56062-0
● Apply ethanol.
– to joint (1)
– in opening (2)
Allow ethanol to take effect until the incru-
station in the seat is removed.
© 56063-0
© 05/2014
2/8
W 41-05-03
Attention!
Do not exert force onto the crankcase.
Do not exert force onto the cable strand.
6
© 56064-0
Attention!
Do not damage the components.
Do not twist the exhaust gas recirculation
valve.
● Pry out the exhaust gas recirculation valve (1) evenly
at the recesses (2).
● Pull out exhaust gas recirculation valve (1) evenly.
– Distance approximately
70 mm
© 56065-0
Attention!
– For the version with a sealing disc:
Attention!
1
● Remove sealing disc (1).
© 48273-0
© 05/2014
3/8
W 41-05-03
● Remove the O-rings (1) with the disassembly tool.
6
© 56066-0
● Check components for damage.
© 56067-0
Installing the exhaust gas return valve

● Coat new round sealing rings slightly with mounting
compound.
Attention!
Do not twist or overstretch round sealing
rings.
Do not damage O-rings!
Use a suitable assembly aid.
Provide protection for sharp edges.
● Mount new round sealing ring (2).

© 56068-0
© 05/2014
4/8
W 41-05-03
Attention!
– For the version with a sealing disc:
● Insert sealing disc (1).
Attention!
from faults.
The cone is facing the contact surface of
the cooler.
6
© 48275-0
Attention!
Do not twist the exhaust gas recirculation
valve.
Do not exert force onto the crankcase.
The exhaust gas recirculation valve must
not be tightened to the stop via the screws.
from faults.
● Insert exhaust gas recirulation valve (1) evenly to the
stop.
© 56069-0
● Position holder (1).

from faults.
Attention!
Self-tapping screws.
Do not exert any great axial force onto the
screws when tightening.
Danger of forming a "second" thread turn.
● Turn in screws (2) a few turns.
– at least 3 revolutions
 8 Nm
© 56070-0
© 05/2014
5/8
W 41-05-03
Attention!
To avoid electrostatic discharges, do not
touch the plug contacts with your bare
hands.
● Plug in the cable plug (1).
Attention!
Retaining lug (2) must latch into holder.
● Insert cable plug (3) and lock into place.

● Install the compensator.
 Module 41
● Connect the battery.
6 ● Fill cooling system according to the operating manu-
al. © 56071-0
● Check gas system for leaks.
© 05/2014
6/8
W 41-05-03
Technical Data
Exhaust gas recirculation valve on
A41 049 self-tapping screws. 8 Nm
cooler
© 05/2014
7/8
W 41-05-03
© 05/2014
8/8
W 41-90-04
Connection
(Crankcase housing, exhaust gas circulation, coolant line)
8190

to regulations.
– Fitting compound Observe the appropriate operating instruc-
DEUTZ AP1908 tions for emptying and filling the engine.
1 Hose nozzles
2 O-ring

© 50387-0
© 05/2014
1/2
W 41-90-04
© 05/2014
2/2
W 41-90-04
Screw plug
(Thermostat housing, exhaust gas circulation, coolant line)
8190
information

to regulations.
1 Screw plug 80 Nm
2 O-ring
© 53412-0
© 05/2014
1/2
W 41-90-04
© 05/2014
2/2
Exhaust pipe
W 41-90-09
Holder
information
1 Holder 20 Nm
© 53115-0
© 05/2014
1/2
Exhaust pipe
W 41-90-09
© 05/2014
2/2
Exhaust pipe
W 41-90-09
Holder
information
1 Holder 20 Nm
© 51342-0
© 05/2014
1/2
Exhaust pipe
W 41-90-09
© 05/2014
2/2
Exhaust pipe
W 41-90-21
Compensator structure
(Exhaust line)
Standard tools
1 Compensator
2 Seal
3 Hexagon head screw20 Nm
Use a new gasket.
Attention!
Check seal.
© 50388-0
© 05/2014
1/2
Exhaust pipe
W 41-90-21
© 05/2014
2/2
W 41-90-32
Line
(Crankcase housing, exhaust gas circulation, coolant line)
8190

1 Hose pipe
2 Spring band clip
Attention!
tension.
© 53353-0
© 05/2014
1/2
W 41-90-32
© 05/2014
2/2
W 41-90-32
Line
(Thermostat housing, exhaust gas circulation, coolant line)
8190

– Torx tool set 01899092
1 Coolant line
2 Torx screw 10 Nm
4 Pipe clip
5 Seal
6 Rubber sleeve
7 Spring band clip
8 Sealing ring
9 Screw plug 80 Nm
Attention!
tension.
Use a new gasket.

Use a new sealing ring. © 53354-0
© 05/2014
1/2
W 41-90-32
© 05/2014
2/2
Exhaust gas turbocharger
W 43-01-01
Removing and installing the turbocharger

Standard tools
Removing turbocharger
1 Exhaust turbocharger
2 Seal
© 50450-0
● Remove intake nozzle.

 Module 22
● Remove the lubricating oil line.
● Remove lubricating oil return line.
 Module 16
● Remove exhaust manifold.
 Module 43
© 50451-0
© 05/2014
1/4
W 43-01-01

● Remove turbocharger (2).
6
© 50452-0
Installing the turbocharger

● Mount turbocharger (2).
© 50453-0

 30 Nm
 30 Nm
● Fit intake nozzle.
 Module 22
● Install lubricating oil line.
● Install lubricating oil return line.
 Module 16
● Install exhaust manifold.
 Module 43
© 50454-0
© 05/2014
2/4
W 43-01-01
Technical Data
A43 020 Turbocharger on exhaust line 30 Nm
© 05/2014
3/4
W 43-01-01
© 05/2014
4/4
W 43-90-36
Exhaust manifold
information
1 Exhaust line
2 Clip 12 Nm
3 Clip 12 Nm
4 Seal

Use a new gasket.
© 51345-0
© 05/2014
1/2
W 43-90-36
© 05/2014
2/2
Add-on parts
W 44-01-01
Removing and installing the belt tensioner

(V-rib belt, level 1)
Standard tools – Operation manual
Removing the belt tensioner

1 Belt tensioner
2 Deflection pulley 55 Nm
3 V-rib belt
4 Cylinder head screw
© 50562-1
● Remove V-rib belt.

● Remove belt tightener (2).
© 51380-0
© 05/2014
1/4
Add-on parts
W 44-01-01
Installing the belt tensioner

● Mount belt tensioner (1).
 55 Nm
● Fit the V-rib belt according to the running direction.
6
© 51381-0
© 05/2014
2/4
Add-on parts
W 44-01-01
Technical Data
A44 041 Belt tensioner on gearcase 55 Nm
© 05/2014
3/4
Add-on parts
W 44-01-01
© 05/2014
4/4
Generator
W 44-02-01
Removing and installing the generator

(Clamping latch)
information
Removing the generator

1 Clamping strap
2 Threaded piece
4 Washer
7 Spacing sleeve
9 Hexagonal nut
© 50563-0
● Disconnect the battery's negative terminal.

● Remove plus cable.
● Pull out cable plug (1).
© 50693-0
© 05/2014
1/4
Generator
W 44-02-01
● Loosen screw (1).

● Hold nut (2).
● Swing generator (5) in direction of arrow.
● Remove V-belt.
6
© 50694-0

● Remove generator (2).
© 50695-0
Installing the generator

● Mount generator (1).
© 50696-0
© 05/2014
2/4
Generator
W 44-02-01
● Mount V-belt.
● Tighten V-belt (1) by turning the clamping screw (2).
● Check V-belt tension.
6
© 50697-0
● Hold screw (2).

● Tighten nut (1).
 30 Nm
 42 Nm
 30 Nm
© 50698-0

● Fit plus cable.
● Connect the battery's negative terminal.
© 50693-0
© 05/2014
3/4
Generator
W 44-02-01
Technical Data
A44 012 Generator on console 42 Nm
A44 015 Generator at clamping latch 30 Nm
A44 017 Clamping latch on gear case 30 Nm
© 05/2014
4/4
Generator
W 44-02-01
Removing and installing the generator

(Fastening parts)
Standard tools
Removing the generator

© 50660-0

● Unlock cable plug (1) and disconnect.
© 50699-0
© 05/2014
1/4
Generator
W 44-02-01

● Remove generator (2).
6
© 50700-0
Installing the generator

● Mount generator (1).
 42 Nm
© 50701-0
● Mount cable plug (1) and lock.

● Fit plus cable.
● Position V-rib belt.
© 50699-0
© 05/2014
2/4
Generator
W 44-02-01
Technical Data
A44 012 Generator on console 42 Nm
© 05/2014
3/4
Generator
W 44-02-01
© 05/2014
4/4
Add-on parts
W 44-02-06
Removing and installing the console

(V-rib belt, level 1)
Standard tools – Operation manual
DEUTZ DW 73
Removing the console

1 Console
2 Clamping pin
4 Clamping sleeve
244Packing compound
© 50561-0

● Remove generator (level 1).
 Module 44
● Remove console (2).
© 50855-0
© 05/2014
1/4
Add-on parts
W 44-02-06
Mounting the console

Make sure the clamping pin (arrow) is in
place.
6
© 50856-0

surface.
Sealing cord strength approx. 3 mm
© 50857-0
● Mount console (1) over the clamping pins.

M8x85-10.9
M8x60-10.9
© 50858-0
© 05/2014
2/4
Add-on parts
W 44-02-06
● Tighten all screws according to the tightening se-

quence.
 30 Nm
● Mount generator (level 1).
 Module 44
● Fit the V-rib belt according to the running direction.
6
© 50859-0
© 05/2014
3/4
Add-on parts
W 44-02-06
Technical Data
A44 013 Console on crankcase/gear case 30 Nm
© 05/2014
4/4
Starter
W 44-03-01
Removing and installing the starter

information
Removing the starter

1 Starter
© 53253-1

● Pull out cable plug (1).
© 51406-0
© 05/2014
1/4
Starter
W 44-03-01

● Remove starter (2).
6
© 51407-0
Installing the starter

● Insert starter (1).
 60 Nm
© 51408-0
Attention!
Lay the cables free from chafing and ten-
sion.
● Fit plus cable.
© 51406-0
© 05/2014
2/4
Starter
W 44-03-01
Technical Data
A44 001 Starter on connection housing 60 Nm
© 05/2014
3/4
Starter
W 44-03-01
© 05/2014
4/4
Parts to generator
W 44-90-42
Generator
8190
information
1 Generator
Terminal B+ 7.5 - 8 Nm
Terminal L 2.7 - 3.8 Nm
2 Voltage regulator 4 Nm
3 Fan
10 V-belt pulley
11 Add-on parts
Position
11
Attention!
Observe tightening torque for V-rib belt
pulley with clamping cone.
– Hexagonal nut
© 52769-0
 90 Nm
– Hexagonal nut in conjunction with clamping cone
and V-rib belt pulley
 75 Nm
© 05/2014
1/2
Parts to generator
W 44-90-42
© 05/2014
2/2
Engine mounting
W 46-90-15
Engine mounting
Standard tools
1 Holder
3 Stand foot
5 Hexagonal nut
6 Washer
7 Washer
© 51485-0
© 05/2014
1/2
Engine mounting
W 46-90-15
© 05/2014
2/2
Engine mounting
W 46-90-15
Engine mounting
Standard tools
1 Stand foot
3 Washer
© 51487-0
© 05/2014
1/2
Engine mounting
W 46-90-15
© 05/2014
2/2
Engine mounting
W 46-90-15
Engine mounting
Standard tools
1 Stand foot
3 Washer
4 Mount buffer
5 Bushing
© 51486-0
© 05/2014
1/2
Engine mounting
W 46-90-15
© 05/2014
2/2
Engine mounting
W 46-90-15
Engine mounting
information
1 Holder
3 Stand foot
5 Hexagonal nut
6 Washer
7 Washer
© 53214-0
© 05/2014
1/2
Engine mounting
W 46-90-15
© 05/2014
2/2
Electrical equipment
W 48-03-01
Removing and installing the pressure/temperature sensor

(charge air)
information
Special tools:
DEUTZ AP1908
Remove pressure/temperature sensor

1 Pressure/Temperature sensor
3 O-ring
242 Mounting compound
© 53458-0
Remove pressure/temperature sensor

● Unlock cable plug.
● Pull out cable plug.
● Remove pressure/temperature sensor (2).
© 53459-0
© 05/2014
1/4 TD 3.6 L4
W 48-03-01
● Remove the O-ring (1) with the disassembly tool.

6
© 53460-0
Installing the pressure/temperature sensor

● Lightly coat O-ring with fitting compound.
© 53461-0
● Insert pressure/temperature sensor.

from faults.

 11 Nm
● Plug on cable plug.
© 53462-0
© 05/2014
2/4 TD 3.6 L4
W 48-03-01
Technical Data
Pressure/temperature sensor on Use new round sealing
A48 046 11 Nm
charge air line ring
© 05/2014
3/4 TD 3.6 L4
W 48-03-01
© 05/2014
4/4 TD 3.6 L4
Cable harness
W 48-90-05
Fastening parts
information

2 Holding tape
© 53472-0
© 05/2014
1/2
Cable harness
W 48-90-05
© 05/2014
2/2
W 48-90-09
Holder
(Relay)
Standard tools
8190
1 Holding plate
3 Relay
© 53409-0
© 05/2014
1/2
W 48-90-09
© 05/2014
2/2
Tools
W 49-02-01
Removing and installing turning gear / locking device

information
Special tools:
– Turning gear / locking
device 02992380
Installing turning gear / locking device

● Remove starter.
 Module 44
● Insert turning gear / locking device (1).
Toothed wheel of the turning gear / locking
device in the toothed starter ring.

 30 Nm
© 53502-0
Rotating the engine

● Turn drive (3) carefully up to the desired crankshaft

position.
© 53503-0
© 05/2014
1/4
Tools
W 49-02-01
Locking the engine

● Turn drive (3) carefully until the detent pin latches

into place.
Attention!
Detent pin must latch easily into place.
The crankshaft is locked and can no longer
be turned.
6
© 53504-0
Removing turning gear / locking device

● Remove turning gear / locking device (2).
● Install starter.
 Module 44
© 53505-0
© 05/2014
2/4
Tools
W 49-02-01
Technical Data
Turning gear / locking device, fas-
A49 050 30 Nm
tening
© 05/2014
3/4
Tools
W 49-02-01
© 05/2014
4/4
Measuring instruments
W 51-90-20
Impulse transmitter
(crankshaft)
information
Special tools:
1 Holder
2 Impulse transmitter
3 Hexagon head screw 8.5 Nm
5 O-ring
● Remove the O-ring with the disassembly tool.

● Insert new O-ring.
Attention!
from faults.
Position
1
Position fixing using two clamping pins in
the gear case. © 52772-1
© 05/2014
1/2
W 51-90-20
© 05/2014
2/2
W 51-90-20
Impulse transmitter
(camshaft)
information
1 Impulse transmitter
3 O-ring

© 53286-0
© 05/2014
1/2
W 51-90-20
© 05/2014
2/2
W 51-90-20
Pressure transmitter installation

(oil pressure)
– Long socket wrench insert 01899132 information
1 Pressure sensor 25 Nm
2 O-ring
© 53285-0
© 05/2014
1/2
W 51-90-20
© 05/2014
2/2
Connection housing
W 52-01-01
Removing and installing the connection housing

information
Removing the connection housing

1 Connection housing
3 Bushing
© 53247-0
 Module 05
● Remove connection housing (2).
© 53248-0
© 05/2014
1/4
Connection housing
W 52-01-01
Installing the connection housing

Make sure the clamping bushings (1) are
in place.
6
© 53249-0
● Position connection housing (1).

● Centre connection housing over the clamping bush-
ings.
© 53250-0

 170 Nm
 Module 05
© 53251-0
© 05/2014
2/4
Connection housing
W 52-01-01
Technical Data
Tighten diagonally oppo-
A52 080 Connection housing on crankcase 170 Nm
sed
© 05/2014
3/4
Connection housing
W 52-01-01
© 05/2014
4/4
Connection housing
W 52-01-01
Removing and installing the connection housing

information
Removing the connection housing

3 Cover plate
5 Bushing
© 50662-0
 Module 05
● Remove connection housing (2).
© 50671-0
© 05/2014
1/4
Connection housing
W 52-01-01
Installing the connection housing

Make sure the clamping bushings (1) are
in place.
6
© 50672-0
● Position connection housing (1).

● Centre connection housing over the clamping bush-
ings.
© 50673-0

 170 Nm
 Module 05
© 50674-0
© 05/2014
2/4
Connection housing
W 52-01-01
Technical Data
Tighten diagonally oppo-
A52 080 Connection housing on crankcase 170 Nm
sed
© 05/2014
3/4
Connection housing
W 52-01-01
© 05/2014
4/4
Connection housing
W 52-90-53
Connection housing
Standard tools
8190
3 Cover plate
4 Screw plug 80 Nm
5 Sealing ring
© 51356-0
© 05/2014
1/2
Connection housing
W 52-90-53
© 05/2014
2/2
Start aid
W 63-02-01
Removing and installing the glow plugs

– Crowfoot wrench size 10 information
Removing the glow plugs

1 Glow plug
2 Connecting rail
© 53256-0
● Disconnect the battery.

● Unscrew nuts (1).
● Remove connecting rail (2).
© 51401-0
© 05/2014
1/4
Start aid
W 63-02-01
● Unscrew glow plugs (1).

6
© 51402-0
Installing the glow plugs

● Screw in glow plugs (1).
Attention!
from faults.
● Tighten glow plugs (1).
 13.5 Nm
© 51402-0
● Mount connecting rail (1).

● Turn on nuts (2).
Attention!

 2.5 Nm
© 51403-0
© 05/2014
2/4
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 2.5 Nm
© 05/2014
3/4
Start aid
W 63-02-01
© 05/2014
4/4
Exhaust gas treatment
W 71-90-09
Holder
8190
information
Danger!
Hot components!
Danger of burns / explosion!
perature).
Attention!
The installation situation is application and
equipment-dependent.
6
facturer/equipment manufacturer must be
observed for disassembly and installation.
Make sure that the inlet module, outlet
module, particle filter, V-belt clips and fas-
tening points are reassembled in the same
installation position.
Do not scratch or damage surfaces.
Externally damaged parts must be
renewed.
V-belt clips must be replaced each time
they are loosened.
The gaskets must be disposed of properly
and always renewed.
1 Holder 9 Nm
© 53446-0
© 05/2014
1/2
W 71-90-09
© 05/2014
2/2
W 71-90-21
Compensator structure
(assembly material)
information
Danger!
Hot components!
Danger of burns / explosion!
perature).
Attention!
Note installation position. 6
renewed.
they are loosened.
and always renewed.
1 Clip 12 Nm
2 Seal
Use new gaskets.

Use new V-belt clips.
Attention!
from faults.
Check seal.
© 52412-0
© 05/2014
1/2
W 71-90-21
© 05/2014
2/2
W 71-90-48
Inlet module
– Industrial vacuum cleaner information
– Lifting gear
– Carrying straps Danger!
– Fitting compound Hot components!
DEUTZ S1 Danger of burns!
– Cleaning fleece Let the engine / components cool down
– Marker pen, waterproof, sufficiently (to at least ambient tem-
permanent perature).
Do not carry out work when the engine is
running.
When using hoists (workshop crane) the
safety regulations for handling hoists must 6
be observed.
It is not permitted to stay under moving
loads.
Place the components on a level and
secure surface.
Secure the components against tipping
over.
Wear a respirator with at least protection
class FFP2, goggles and protective gloves
as protection against fine dust and soot
particles.
Extract soot from the end faces with an
industrial vacuum cleaner.
Do not blow compressed air onto soot-
covered areas.
Attention!
renewed.
Dismantling and assembly should only be
done in the vertical position.
they are loosened.
and always renewed.
Use a new gasket.
© 05/2014
1/2
W 71-90-48
1 Inlet module
2 V-belt clip 10 Nm
3 Seal
4 Cap 15 Nm
● Mark installation position.

● Apply help markings.
Attention!
from faults.
Make sure that the inlet module, outlet
module, particle filter, V-belt clips and fas-
tening points are reassembled in the same
installation position.
6 Do not scratch or damage surfaces.
All the help markings must be transferred © 53704-0
Note flow direction.
The arrow indicates the flow direction.

Use a new gasket.
● Coat surfaces (arrows) with mounting compound.

Attention!
Make sure it is applied evenly and without
gaps.
V-belt clip must be replaced each time it is
loosened.
● Perform leak test.
© 52921-0
© 05/2014
2/2
W 71-90-49
Outlet module
– Industrial vacuum cleaner information
– Lifting gear
– Carrying straps Danger!
– Fitting compound Hot components!
DEUTZ S1 Danger of burns!
– Cleaning fleece Let the engine / components cool down
– Marker pen, waterproof, sufficiently (to at least ambient tem-
permanent perature).
Do not carry out work when the engine is
running.
When using hoists (workshop crane) the
safety regulations for handling hoists must 6
be observed.
It is not permitted to stay under moving
loads.
Place the components on a level and
secure surface.
Secure the components against tipping
over.
Wear a respirator with at least protection
class FFP2, goggles and protective gloves
as protection against fine dust and soot
particles.
Extract soot from the end faces with an
industrial vacuum cleaner.
Do not blow compressed air onto soot-
covered areas.
Attention!
renewed.
Dismantling and assembly should only be
done in the vertical position.
they are loosened.
and always renewed.
Use a new gasket.

© 05/2014
1/2
W 71-90-49
1 Outlet module
Use a new gasket.

Attention!
Disassemble and assemble according to
the job card listed below.
 W 71-90-48
Inlet module
6
© 53294-0
© 05/2014
2/2
W 71-90-51
Console
information
1 Console
© 54281-0
© 05/2014
1/2
W 71-90-51
© 05/2014
2/2
Coolant compressor
W 82-01-01
Removing and installing the coolant compressor

8190
information
to regulations.
Emptying and filling the engine with opera-
ting media must be carried out according to
documentation of the vehicle/equipment
manufacturer.
Removing the coolant compressor

1 Coolant compressor
2 Console
3 Bushing
4 Cylinder head screw
5 Hexagonal nut
6 Clamping strap
8 Ball disc
9 Threaded piece
10 Washer
11 Torx screw
12 Torx screw
© 54115-0
Attention!
Emptying and filling the air-conditioning
system must be carried out according to
documentation/specifications of the
vehicle/equipment manufacturer.
● Unscrew coolant lines.
● Attach locking caps.
● Hold screw.
● Loosen nut (1).
© 54116-0
© 05/2014
1/6
Coolant compressor
W 82-01-01

● Swing the coolant compressor into the direction of
the arrow.
● Remove V-belt (2).
6
© 54117-0

● Remove washers (2)
● Remove the clamping latch (3).
© 54118-0
● Hold screw (2).

● Unscrew nut (1).
● Remove screw (2).
● Remove sleeve (3).
● Remove coolant compressor (4).
© 54119-0
© 05/2014
2/6
Coolant compressor
W 82-01-01
Mounting the coolant compressor

● Attach coolant compressor (1).
● Fit sleeve (2).
6
© 54120-0
● Mount clamping latch (1).

● Mount washers (2).
© 54121-0

● Swing the coolant compressor into the direction of
the arrow.
● Mount V-belt.
© 54122-0
© 05/2014
3/6
Coolant compressor
W 82-01-01
● Tighten V-belt (1) by turning the clamping screw (2).

● Check V-belt tension.
6
© 54123-0
● Hold screw.
● Tighten nut (1).
 42 Nm
 20 Nm
 20 Nm
● Pull off locking caps.
● Screw on coolant lines.
Attention!
Emptying and filling the air-conditioning
system must be carried out according to
documentation/specifications of the © 54124-0
vehicle/equipment manufacturer.
© 05/2014
4/6
Coolant compressor
W 82-01-01
Technical Data
A82 051 Coolant compressor on console 42 Nm
Clamping latch on console / coolant
A82 052 20 Nm
compressor
© 05/2014
5/6
Coolant compressor
W 82-01-01
© 05/2014
6/6
Coolant compressor
W 82-90-05
Fastening parts
8190
information

© 53175-0
© 05/2014
1/2
Coolant compressor
W 82-90-05
© 05/2014
2/2
Hydraulic pump drive
W 83-02-01
Removing and installing hydraulic pump drive

8190
information
– Packing compound Collect draining lubricating oil and dispose

DEUTZ DW 67 of properly.
A variant of the hydraulic pump drives is
described here as an example.
Proceed in the same way for other fittings.
Removing hydraulic pump drive

● Remove hydraulic pump drive (3).
© 50822-0
Installing hydraulic pump drive

Ensure that the clamping pins (1) are
present.
© 54053-0
© 05/2014
1/4
W 83-02-01

surface.
Sealing cord strength approx. 0.5 -
0.6 mm.
6
© 56037-0
● Center the hydraulic pump drive (1) via the clamping

pins.
M8x60-10.9
M8x110-10.9
© 50824-0
● Tighten all screws according to the tightening se-

quence.
 30 Nm
© 51335-0
© 05/2014
2/4
W 83-02-01
Technical Data
Hydraulic pump on crankcase/gear
A83 003 30 Nm
case
© 05/2014
3/4
W 83-02-01
© 05/2014
4/4
Special tools
W 49-01-01
8 Special tools
© 05/2014
1/14
Special tools
W 49-01-01
Orders
Special tools::
These must be ordered like normal DEUTZ
spare parts with specification of the order
number.
© 05/2014
2/14
Special tools
W 49-01-01
01899028
Engine lifting device
Load (2000 kg), 3-point suspension, spindle clamp,
cross member, chains and hooks
© 43184-0
01899031
Pressure pump 8
Checking cooling system for leak-tightness
© 35409-2
01899034
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
© 49376-0
© 05/2014
3/14
Special tools
W 49-01-01
01899037
Hose clip pliers
Loosen hose clips and fasten
© 56004-0
01899050
8 Assembly pliers
Pull out fixed injector sealing disc
© 49353-0
01899062
V-belt tension measuring device
150 to 600 N
Check V-belt tension
© 53309-0
© 05/2014
4/14
Special tools
W 49-01-01
01899092
Torx tool set
Contents of case:
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
© 53310-0
01899093
Rotation angle disc 8
with solenoid
© 49342-0
01899103
Pricker
Removing rotary shaft lip seal
© 49345-0
© 05/2014
5/14
Special tools
W 49-01-01
01899105
Disassembly tool
Disassemble pin screw
(M10)
© 56006-0
01899106
8 Disassembly tool
(M12)
© 56006-0
01899108
Disassembly tool
(M8)
© 56006-0
© 05/2014
6/14
Special tools
W 49-01-01
01899110
Assembly lever
Removing crankshaft sealing rings
© 37511-3
01899112
Spring band pliers 8
320 mm
Tighten spring clamp
© 56007-0
01899132
Socket wrench insert
Wrench size 27,
Version: long
Removing and installing the pressure sensors
(rail pressure, oil pressure, fuel pressure)
© 49357-0
© 05/2014
7/14
Special tools
W 49-01-01
01899142
Special wrench
Unscrewing the filter cartridges
© 37629-3
01899144
8 Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
© 43663-0
01899148
Assembly tool
Mount pin screw
(M8)
© 56009-0
© 05/2014
8/14
Special tools
W 49-01-01
01899149
Assembly tool
Mount pin screw
(M10)
© 56009-0
01899150
Assembly tool 8
Mount pin screw
(M12)
© 56009-0
01899199
Socket wrench insert
Size 36,
Removing and installing the centre screw
© 56039-0
© 05/2014
9/14
Special tools
W 49-01-01
01899370
Force multiplier
Removing and installing the centre screw
© 56040-0
02992017
8 Connector
(in conjunction with compression pressure tester
01899034)
© 56041-0
02992117
Lever tool
Removing the injector
© 49375-0
© 05/2014
10/14
Special tools
W 49-01-01
02992127
Disassembly tool
Removing O-ring
© 49360-0
02992138
Puller 8
(in conjunction with slide hammer 02992294)
Removing fixed injector sealing disc
© 35437-1
02992214
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
© 56042-0
© 05/2014
11/14
Special tools
W 49-01-01
02992452
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)
© 56043-0
02992294
8 Slide hammer
(in conjunction with extraction tool 02992137)
Removing fixed injector sealing disc
© 49372-0
02992301
Separating tool
Removing metal sheet lubricating oil pan from crank-
case
© 49373-0
© 05/2014
12/14
Special tools
W 49-01-01
02992380
Turning gear / locking device
Turn or block crankshaft at the flywheel
© 56044-0
02992475
Counter support 8
Hold crankshaft against the V-belt pulley/V-ribbed pul-
ley.
© 56045-0
02992477
Special wrench
Wrench size 17,
Removing and installing high-pressure lines
© 56012-0
© 05/2014
13/14
Special tools
W 49-01-01
Diagnostic tool
SerDia 2010
© 00000-0
© 05/2014
14/14

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Workshop Manual

MC-IL, Mr. Lippke

3 Safety instructions / User information

4 Chapter not assigned

5 Job card overview

7 Chapter not assigned

DEUTZ engines are the product of years of research

Maintenance and care are the only way the engine

Please consult one of our service representatives

3 Safety information / User information

3.1 General 3.2 Specifications

3.3 Operation manual and workshop man- 3.4 Job cards

3.4.2 Structure of a job card 3.5 Explanation of symbols

Activity Job card Maintenance group

Activity Job card Maintenance group

Activity Job card Maintenance group

Job card Activity Maintenance group

Job card Activity Maintenance group

Job card Activity Maintenance group

Renewing the crankshaft sealing ring

Removing the crankshaft sealing ring

● Screw in a self-tapping screw (1) with washer.

● Pull out the crankshaft sealing ring with assembly le-

● Visually inspect the crankshaft sealing ring running

Installing the crankshaft sealing ring

● Place the crankshaft sealing ring carefully on the pe-

● Mount assembly sleeve (1).

● Tighten nut to the stop of the assembly sleeve (1).

● Remove assembly tool.

Removing and installing the gasket housing

Removing the gasket housing

● Knock out crankshaft sealing ring (1).

● Visually inspect the components.

Installing the gasket housing

● Mount gasket housing.

The sealing face (arrows) must be flush

● Tighten the screws according to the tightening se-

Removing and installing the transfer line

Removing the transfer line

● Remove lubricating oil pan.

Installing the transfer line

● Apply sealing compound (1) evenly on the sealing

● Clean sealing surfaces.

Use a new sealing ring.

Oil measuring device

Use new round sealing ring.

Removing and installing the lubricating oil pan

Collect leaking operating substances in

Removing the lubricating oil pan

● Unscrew locking screw (1).

● Unscrew all screws (1).

● Drive in separating tool (1) to the stop (2).

● Drive in second separating tool (1) to the stop (2).

● Lever out lubricating oil pan.

● Scrape off sealing compound with separating tool.

● Clean the sealing surface on the crankcase with a

● Clean the sealing surface on the lubricating oil pan

Installing the lubricating oil pan

● Clean sealing surfaces.