Deutz TD2009 Workshop Manual

Workshop Manual
competence level 3
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D 2009
TD 2009
This document is subject to changes which may become necessary in the course of further development of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.
0312 3488 en
Regarding copyright questions and licensing agreements

please contact :
TE-FI, Mr. Sonntag
Tel.:
+ 49 (0) 221 822-3053
EMail: sonntag.j@deutz.com
DEUTZ AG
Service Information Systems
Ottostrae 1
D-51149 Kln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
Internet: www.deutz.com
E-Mail: info@deutz.com
The engine company.
Printed in Germany
All rights reserved
1st Edition, 01/2008
Order No. 0312 3488 en
D 2009
TD 2009
1
Foreword
General
User notes
3.1
3.2
3.3
3.4
3.5
General
Specifications
Operating manual and workshop manual
Job cards
Explanation of symbols
Technical data
4.1
4.2
Testing and setting data

Tightening specifications
Job card overview

5.1
5.2
01/2008
Table of contents
Sorted alphabetically
Sorted numerically
Job cards
Commercial tools
Special tools
1/2
16338-001
D 2009
TD 2009
Table of contents
01/2008
2/2
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DEUTZ engines
Foreword
01/2008
Foreword
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Foreword
DEUTZ engines
01/2008
2/4
16339-001
DEUTZ engines
Foreword
z Read and observe the information in this documentation. You will avoid accidents, retain the
manufacturer's warranty and possess a fully
functional and ready to operate engine.
z This engine is built exclusively for purpose according to the scope of delivery - defined by the
equipment manufacturer (use for the intended
purpose). Any use above and beyond this is considered improper use. The manufacturer will not
be liable for damages resulting from this. The
user bears the sole risk.
z Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the manufacturer.
The engine may only be used, maintained and
repaired by persons who are familiar with this
and are aware of the risks involved.
z Repair of the engine must correspond to its use

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

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

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

guaranteed when using DEUTZ original parts.
Your DEUTZ AG
01/2008
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Foreword
DEUTZ engines
01/2008
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DEUTZ engines
General
01/2008
General
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General
DEUTZ engines
01/2008
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16340-001
DEUTZ engines
General
DEUTZ engines are the product of years of research and development. The profound expertise
gained through this, in combination with high demands on quality, attests to the fact that our engines
possess all the qualities of long life, high reliability
and low fuel consumption. It goes without saying
that the high environmental protection requirements
are also met.
Maintenance and care are the only way the engine

can satisfy the demands you make on it. Compliance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particularly heeded.
Please consult one of our service representatives
responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.
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General
DEUTZ engines
01/2008
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16340-001
DEUTZ engines
User notes
01/2008
User notes
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User notes
DEUTZ engines
01/2008
2/6
16341-001
DEUTZ engines
User notes
3.1 General
3.2 Specifications
The documentation of the workshop manual has

been created based on the engine available at the
time of going to press.
There may be deviations in the descriptions, illustrations and parts due to further developments.
3.2.1 Accident prevention and safety regulations
The maintenance work described in the operation

manual and in the workshop manual must be carried
out on schedule and completely. The maintenance
personnel must have the necessary technical
knowledge to perform the work. Safety and protection devices which are removed during maintenance
work must be replaced again afterwards.
The legally prescribed rules for the prevention of accidents must be observed. These are available from
professional associations or from dealers. These
are dependent on the application site, operating
mode and the operating and auxiliary materials being used.
Special protection measures are specified depending on the work being carried out, and are identified
in the job description.
Among other things it generally applies that:
Caution!
The rules for the prevention of accidents and the
safety regulations must be observed during maintenance work.
Reference is made in the workshop manual job
cards to the regulations in chapter 3.2. These must
be read before working on the engine and must be
strictly followed.
z for the personnel:

Only briefed personnel may operate or maintain the engine. Unauthorised persons are
prohibited access to the machine room.
Wear close-fitting clothing and ear protectors
in the machine room when the engine is in operation.
The maintenance intervals and the work to be performed are specified in the maintenance schedule
of the operation manual. The job cards contain technical documentation on the execution of maintenance work.
Only deploy trained personnel to do repairs

and maintenance work.
Do not work on the fuel system when the engine is running. The fuel system is under high
pressure - danger of death.
Go to the workshop immediately in case of
leaks in the fuel system.
z for the engine room:
Ensure adequate ventilation (do not cover air
shafts).
Provide first aid kit and suitable fire extinguishers. Check the filling and readiness for operation regularly.
Only store inflammable materials in the machine room if they are essential for operation
of the system.
Smoking and naked flames are prohibited in
the machine room.
z for operation, maintenance and repairs on the
engine:
After all work on the fuel system, it must be
bleeded - see the operation manual, chapter
"6.2 Fuel system.
Only start the engine when all the protective
devices have been fitted. Make sure no-one is
standing in the danger area.
Cleaning, maintenance and repair work may
only be performed with the engine at a standstill and secured against starting.
Injection lines and high pressure pipes must
not be deformed.
Damaged injection lines and high-pressure
pipes must be renewed.
01/2008
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User notes
DEUTZ engines
Injection lines and high pressure fuel lines

must never be connected when the engine is
running.
3.3 Operation manual and workshop

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

pressure fuel system.
To structure the information to suit the user, the

service documentation is divided into operation
manual and workshop manual.
Also carefully check all high pressure components visually before performing tests on the
running engine. Wear suitable protective
clothing (for example protective glasses).
Leaks are a potential source of danger for
workshop personnel.
The operation manual contains a general description and instructions for all other maintenance work.
It contains the following chapters:
1. Contents, General
2. Engine description
Even if no leaks are discernible on the high

pressure fuel system, the workshop personnel
should avoid the immediate danger zone or
wear suitable protective clothing (such as protective glasses) when performing tests on the
running engine and during the first trial run.
3. Operation
Always stay out of range of a fuel jet, as it

could cause severe injury.
8. Engine conservation
Smoking is strictly prohibited when working on

the fuel system.
10.Service
4. Operating media
5. Maintenance
6. Care and maintenance work
7. Faults, causes and remedies
9. Technical data
The workshop manual assumes knowledge of the
contents of the operation manual. This applies especially for the safety regulations. The workshop
manual describes repairs to the engine and components for which more effort and appropriately qualified technicians are required.
Do not work near to sparks and flames.
3.2.2 Disposal regulations

The work described in the operation manual and
workshop manual necessitates renewal of parts and
operating materials among other things. The renewed parts / operating materials must be stored,
transported and disposed of according to regulations. The owner himself is responsible for this.
Disposal includes recycling and the scrapping of
parts / operating materials, although recycling has
priority.
Details of disposal and their monitoring are governed by regional, national and international laws
and directives which the system operator must observe on his own responsibility.
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User notes
3.4 Job cards
3.4.2 Structure of a job card
The job cards are divided in the workshop manual

into "W" and "I" job cards.
The "W" job card documents standard repairs on the
engine and/or its components. The necessary tools
and special tools are also specified in the "W" job
card.
The "I" job card additionally documents the appropriate work procedures for repairing the engine and/
or its components. The workshop must satisfy special conditions to perform these work procedures.
Special tools and machine tools must be available,
for example.
Triebwerk
W 02-04-01
4
5
16
6
15
14
3.4.1 Numbering of job cards
8
13
The job card numbers follow the pattern W 02-0401. The individual parts of this pattern are explained
below:
z W 02-04-01: Documentation type
12
WWorkshop manual
I ...... Repair instructions
z W 02-04-01: Maintenance group
00 ... General / interdisciplinary activities
11
01 ... Cylinder head
10
03 ... Crankcase
1. DEUTZ AG,
publisher of service documentation
04 ... Engine control system
2. Engine type (e.g. TCD 2013 4V)
05 ... Speed governing
3. Maintenance group
06 ... Exhaust system / Charging
4. Job card number or topic
07 ... Fuel system
5. Title of job card
08 ... Lube oil system
6. Reference to other job cards
09 ... Cooling system
7. Chapter
10 ... Compressed air system
8. Graphic or photo
11 ... Monitoring system
9. DEUTZ internal creation number
12 ... Other components
10.Page number
13 ... Electrical system
11.Date of issue of job card
02Drive system
z W 02-04-01: Component grouping
12.Note
z W 02-04-01: Consecutive number
13.Danger / Important
14.Work sequence
15.Special tools; auxiliary materials
16.Conventional tools
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User notes
DEUTZ engines
3.5 Explanation of symbols

Danger!
of death or to health. Must be observed!
For example: The incorrect use or conversion of the turbocharger can lead to serious
injury.
Caution!
Danger to the component/engine. Noncompliance can lead to destruction of the
component/engine.
Must be observed!
Note
General notes on assembly, environmental
protection etc. No potential danger for man
or machine.
Tool
Conventional and special tools required for
the work.
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
References
to important documents or job cards for the
work process.
For example: Job card W 04-05-05
Reference
to a document or a job card within the work
process.
Test and setting data
The necessary values are specified here.
If several values are necessary, a cross reference is given to the Test and Setting Values table.
For example:
ID no. P01 61 = valve clearance, inlet
Tightening specification
The necessary values are specified here.
If several values are necessary, a cross reference is given to the Tightening Specifications table.
For example:
ID no. A01 001 = cylinder head screws
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Technical data
01/2008
Technical data
4.1
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Technical data
D 2009
TD 2009
ID no.
Name
D / TD 2009
P00 31 Bore, diameter
P00 32 Stroke
P00 50 Direction of rotation
Additional information
Value
Nominal value
90 mm
90 mm
left
25 - 30 bar
(2500 - 3000 kPa)
7.155 - 7.170 mm
7.155 - 7.170 mm
0.1 - 0.4 mm
0.1 - 0.4 mm
36.90 - 37.10 mm
33.90 - 34.10 mm
55.005 - 55.020 mm
53 - 58 HRc
49.990 - 50.005 mm
0.13 - 0.56 mm
looking onto the flywheel
P00 51
Compression pressure
P01 31
P01 32
P01 35
P01 36
P01 37
P01 38
P02 03
P02 07
P02 22
P02 34
Valve stem, diameter, inlet

Valve stem, diameter, outlet
Valve edge thickness, inlet
Valve edge thickness, outlet
Valve plate, diameter, inlet
Valve plate, diameter, outlet
Main journal, diameter
Bearing pin, surface hardness
Lifting journal, diameter
Crankshaft, permissible axial clearance
P02 75
Standard
in the installed state
maximum permissible deviation
Parallelism of the con rod with respect to
at a distance of 100 mm,
the piston bolt
vertical
the piston bolt
horizontal
Piston bolt bush, diameter, inside
Con rod bearing shells, diameter, inside
Con rod, bearing bore, diameter, inside
Theoretical clearance between the big
end bearing and lifting journal
Piston pin, diameter, outside
Theoretical clearance between piston pin
bush and piston pin
Piston protrusion
0.70 - 1.0 mm
P02 78
Piston pin bore
28 +0.008
+0.003 mm
P02 84
Piston ring 1, joint clearance
0,15 +0
mm
P02 85
+0.25
0,15 +0
mm
P02 86
+0.25
0,30 +0
P02 87
P02 88
P02 89
Piston ring 1, axial clearance

Camshaft bearing, locating hole, diameter
Camshaft bearing, diameter, inside
Crankshaft, bearing bush, installation
depth
P02 41
P02 42
P02 43
P02 52
P02 55
P02 56
P02 61
P02 62
P03 11
P03 13
P03 29
P03 31
Cylinder, diameter, inside
P04 31
Camshaft, bearing pin, diameter

Camshaft, bearing pin, diameter (drive
side)
Camshaft, axial clearance
Thermostat, start of opening
Thermostat, stroke distance
V-belt tension
P04 31
P04 35
P09 11
P09 13
P12 11
01/2008
0.03 mm
0.03 mm
28.010 - 28.025 mm
50.045 - 50.057 mm
53.525 - 53.545 mm
0.040 - 0.067 mm
28 0.005
0.01 mm
0.015 - 0.035 mm
+0.20
mm
0.11 - 0.15 mm
0.045 - 0.090 mm
0.045 - 0.090 mm
50.060 - 50.095 mm
45.960 - 45.980 mm
approx. 3 mm
Standard
+0.025
90 +0
mm
41.925 - 41.955 mm
45.950 - 45.970 mm
(not adjustable)
First assembly
2/8
0.07 - 0.29 mm
86 - 90 C
at least 9 mm
450 N
16342-001
D 2009
TD 2009
ID no.
Name
P12 21
V-belt tension
Technical data
Check after 15 minutes running
under load.
D / TD 2009 L03
P00 04 Engine weight according to DIN 70020-A
P00 71 Ignition sequence
D / TD 2009 L04
P00 71 Ignition sequence
D 2009
Value
300 +20
20 N
approx. 180 kg
1-2-3
approx. 220 kg
1-3-4-2
Indirect injection eddy chamber
method
22 : 1
P00 20
Combustion process
P00 40
Compression ratio
P02 71
Piston, diameter, standard
Measuring point 1 = height 10 mm 89,400 +0.167

+0.153 mm
P02 72

0.008 mm
P02 73
Measuring point 3 = height 65 mm 89,400 0.175

0.145 mm
TD 2009
P00 20 Combustion process
P00 40 Compression ratio
P02 71 Piston, diameter, standard
Direct injection
17 : 1
+0.138 mm
P02 72

0.009 mm
P02 73

0.190 mm
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Technical data
D 2009
TD 2009
01/2008
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D 2009
TD 2009
Technical data
4.2
01/2008
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16342-001
Technical data
ID no.
Name
A00 001 Clamping bracket on crankcase
Clamping bracket on adapter for
A00 002
assembly block
Mounting foot/engine mounting on
A00 003
crankcase
D 2009
TD 2009
Screw type Notes / Remark
M10x20-10.9
90 Nm
M10x20-10.9
A01 001 Cylinder head on crankcase
M12x13010.9
A01 002
A01 004
A01 092
A02 010
A02 010
A02 012
M8x30-8.8
M8x50-10.9
M8x16
M8x20-8.8
M8x20-8.8
M10x80-8.8
Rocker arm on cylinder head

Cylinder head cover on cylinder head
Transport bracket on cylinder head
Main bearing housing on crankcase
Bearing housing in crankcase
Big end bearing cover on connecting
A02 020
rod
M8x52-10.9
41 Nm
Use new screws.
Observe tightening
order.
Stage 1:
Stage 2:
Use new screws.
A03 020 Gearcase cover on crankcase
M8x35-12.9
M8x50-10.9
M8x70-8.8
A03 030 Lubricating oil pan on crankcase
M8x20-8.8
A03 031 Locking screw on lubricating oil pan
M14x14
A03 060
A03 080
A04 001
A04 002
M8x40-8.8
M12x25-12.9 Locking screw
M12x35-8.8
M8x16-8.8
Torx screw
Oil trap on crankcase

Connection housing to crankcase
Camshaft gear wheel on camshaft
Camshaft, shim on crankshaft
Injection pump gear wheel on injecA04 004
tion pump
tion pump
A04 011 Intermediate gear on crankcase
A04 022 Cap on gearcase cover
A06 001 Exhaust pipe at cylinder head
A06 010
A06 020
A06 030
A06 030
A06 059
A06 062
A06 063
A06 064
A06 070
A06 083
A07 001
A07 001
01/2008
Value
41 Nm
M12x75-10.9
M8x70-8.8
M8x20-8.8
M8x55-10.9
27 Nm
27 Nm
21 Nm
15 Nm
27 Nm
41 Nm
20 Nm + 45
27 Nm
Observe tightening
sequence.
Use new Cu sealing
ring.
32 Nm
39 Nm
27 Nm
81 Nm
81 Nm
21 Nm
Stage 1:
10 Nm
Stage 2:
81 Nm
81 Nm
Torx screw
Insert with Deutz S1

Exhaust manifold to turbocharger
M8x25-10.9
mounting compound.
M10x20-10.9 Insert with Deutz S1
Turbocharger on exhaust pipe
M8x16-8.8
mounting compound.
Observe tightening
Charge air pipe on cylinder head
M8x45-10.9
sequence.
Air suction intake pipe on cylinder
Observe tightening
M8x70
head
sequence.
Exhaust return pipe to cooler
M8x12-10.9
Exhaust return pipe to charge air pipe M8x70-8.8
Compensator pipe on exhaust pipe
M8x20-10.9
Compensator pipe to cooler
M8x12-8.8
Exhaust retgurn pipe to exhaust
M8x20-8.8
return valve
Charge air manifold to charge air pipe M8x20-8.8
Fuel injector on cylinder head
M8x35-10.9 Torx screw
Fuel injector on cylinder head
M22
6/8
35 Nm + 60 + 60
27 Nm
27 Nm
41 Nm
41 Nm
27 Nm
27 Nm
25 Nm
20 Nm
20 Nm
25 Nm
20 Nm
21 Nm
35 Nm
68 Nm
16342-001
D 2009
TD 2009
ID no.
A07 003
Name
Injection line on fuel injector/injection
pump
Injection lines, fastening, pipe clip
Injection pump on crankcase
Blocking screw on injection pump
Fuel line on injection pump
Fuel lines on fuel supply pump and
fuel filter console
Fuel supply pump on crankcase
Fuel lines on crankcase, pipe clip
Fuel line to fuel filter console
Fuel filter console to crankcase
Lubricating oil filter on lubricating oil
cooler
Adapter on gearcase cover
Lubricating oil pump on crankcase
Oil suction pipe, holder on crankcase
Lubricating oil pipe on exhaust turbocharger
Oil return line to turbocharger
Lubricating oil cooler on adapter
Oil pressure switch in crankcase
Technical data
Screw type
Notes / Remark
Value
M12x1.5
28 Nm
M6x10-8.8
M8x30-10.9
1/2
9 Nm
27 Nm
10 Nm
9 Nm
1/2
9 Nm
M8x55-10.9
M8x12-10.9
M10x1.5
Hollow screw
M10x25-10.9
Oil gasket lightly.
M14x1.5
See operating manual
3/4
M6x25-8.8
M10x80-8.8
27 Nm
27 Nm
21 Nm
41 Nm
41 Nm
4 Nm + 9 Nm
41 Nm
M14x1.5
15 Nm
M6x16-8.8
M22x1.5
M10x1
M12x1
M14x1.5
9 Nm
41 Nm
20 Nm
A08 098
3/8
21 Nm
A09 010 Coolant pump on gearcase cover
M8x30-10.9
M8x70-8.8
M8x30-10.9
M8x16-8.8
A07 006
A07 012
A07 013
A07 015
A07 019
A07 024
A07 044
A07 084
A07 087
A08 001
A08 003
A08 010
A08 016
A08 040
A08 044
A08 051
A08 091
A08 091 Oil pressure switch in crankcase

Oil pressure control valve on crankcase
A09 002 Outlet nozzles on cylinder head
A09 021 Pipe, holder to holder

Temperature transmitter on cylinder
A09 031
head
A12 001 Flywheel on crankshaft
A12 031 V-belt pulley on crankshaft
A12 046 V-belt pulley on coolant pump
A13 001 Starter on connection housing
A13 012 Generator on gearcase cover
A13 015 Generator on clamping bracket
A13 016 Clamping bracket on gearcase cover
A13 032 Glow plug on cylinder head
A13 033 Connecting rail to glow plug
Charge air pressure switch in charge
A13 046
air line
A13 071 Cable (terminal 30) to starter
01/2008
Hand tighten
50 Nm
27 Nm
Observe tightening
sequence.
27 Nm
21 Nm
Insert gasket with

packing compound.
M12x50-10.9 Use new screws.
M20x55-10.9
M6x10-8.8
M10x45-8.8
M8x120-8.8
M8x20-8.8
M8x16-8.8
M10
M4
Locking nut
96 Nm
300 Nm
9 Nm
41 Nm
21 Nm
21 Nm
21 Nm
15 Nm
2.5 Nm
M10
20 Nm
M8
9 Nm
7/8
4 Nm
16342-001
Technical data
D 2009
TD 2009
01/2008
8/8
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D 2009
TD 2009
Job card overview

01/2008
Job card overview
5.1
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Job card overview

D 2009
TD 2009
01/2008
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D 2009
TD 2009
Job card overview

Activity
Job card
Maintenance group
Checking piston overhang
W 01-04-09
Cylinder head
Checking the axial clearance of the crankshaft
W 02-01-04
Drive system
Checking the camshaft
W 04-05-06
Engine control
W 00-02-06
General
W 00-02-06
General
Checking the con rod
W 02-03-01
Drive system
Checking the crankshaft
W 02-01-07
Drive system
Checking the cylinder
W 03-03-01
Crankcase
Checking the piston
W 02-09-07
Drive system
Checking the piston rings and piston ring grooves
W 02-10-03
Drive system
Checking the thermostat (in the removed state)
W 09-08-01
Cooling system
Checking the valves
W 01-05-04
Cylinder head
Mounting engine on assembly block and demounting
W 00-05-01
General
Removing and install the charge air line
W 06-07-03
Exhaust system / Charging
Removing and installing cylinder head
W 01-04-04
Cylinder head
Removing and installing temperature transmitter
W 09-12-01
Cooling system
Removing and installing the camshaft
W 04-05-05
Engine control
Removing and installing the connection housing
W 03-09-04
Crankcase
Removing and installing the coolant pump
W 09-07-08
Cooling system
W 06-09-04
W 02-04-01
Drive system
Checking the compression pressure

D 2009
TD 2009
Removing and installing the cooler

(Exhaust gas recirculation)
Removing and installing the crankshaft
Removing and installing the exhaust gas return valW 06-09-06

ve
Removing and installing the exhaust line
W 06-01-05
Removing and installing the flywheel
W 12-06-01
Other components
Removing and installing the fuel filter console
W 07-10-08
Fuel system
Removing and installing the fuel injector pump
W 07-04-01
Fuel system
W 07-07-01
Fuel system
Removing and installing the fuel injectors

TD 2009
W 07-07-01
Fuel system
Removing and installing the fuel supply pump
W 07-11-01
Fuel system
Removing and installing the gearcase cover
W 04-04-09
Engine control

D 2009
01/2008
3/8
16343-001
Job card overview

D 2009
TD 2009
Activity
Job card
Maintenance group
Removing and installing the generator
W 13-02-03
Electrical system
Removing and installing the glow plugs
W 13-06-01
Electrical system
Removing and installing the intake manifold
W 06-07-03
Removing and installing the lubricating oil cooler
W 08-08-02
Lube oil system
Removing and installing the lubricating oil pan
W 08-04-07
Lube oil system
Removing and installing the lubricating oil pump
W 08-04-05
Lube oil system
Removing and installing the oil pressure regulating

valve
W 08-11-10
Lube oil system
Removing and installing the oil pressure switch
W 08-11-08
Lube oil system
Removing and installing the oil suction pipe
W 08-04-06
Lube oil system
Removing and installing the piston and con rod
W 02-09-03
Drive system
Removing and installing the rocker arm
W 01-02-02
Cylinder head
Removing and installing the starter
W 13-03-02
Electrical system
Removing and installing the thermostat
W 09-08-02
Cooling system
Removing and installing the turbocharger
W 06-06-04
Removing and installing the valves
W 01-05-01
Cylinder head
Removing and installing the V-belt pulley
W 12-02-02
Other components
Removing and installing, testing camshaft bearing
W 03-11-01
Crankcase
W 02-02-02
Drive system
W 02-02-04
Drive system
W 07-04-14
Fuel system
Renewing the crankshaft sealing ring

(flywheel side)
(opposite side to flywheel)
Setting the injection pump
01/2008
4/8
16343-001
D 2009
TD 2009
Job card overview

Sorted numerically
01/2008
Job card overview
5.2
Sorted numerically
5/8
16343-001
Job card overview

Sorted numerically
D 2009
TD 2009
01/2008
6/8
16343-001
D 2009
TD 2009
Job card
W 00-02-06
W 00-02-06
Job card overview

Sorted numerically
Activity
Maintenance group

D 2009
TD 2009
General
General
W 00-05-01
General
W 01-02-02
Cylinder head
W 01-04-04
Cylinder head
W 01-04-09
Cylinder head
W 01-05-01
Cylinder head
W 01-05-04
Checking the valves
Cylinder head
W 02-01-04
Drive system
W 02-01-07
Drive system
W 02-02-02
W 02-02-04

(flywheel side)
Drive system
Drive system
W 02-03-01
Drive system
W 02-04-01
Drive system
W 02-09-03
Drive system
W 02-09-07
Checking the piston
Drive system
W 02-10-03
Drive system
W 03-03-01
Crankcase
W 03-09-04
Crankcase
W 03-11-01
Crankcase
W 04-04-09
Engine control
W 04-05-05
Engine control
W 04-05-06
Engine control
W 06-01-05
W 06-06-04
W 06-07-03
W 06-07-03
W 06-09-04

W 06-09-06
Removing and installing the exhaust gas return valExhaust system / Charging
ve
W 07-04-01
01/2008
7/8
Fuel system
16343-001
Job card overview

Sorted numerically
Job card
Activity
Maintenance group
W 07-04-14
Fuel system
W 07-07-01
W 07-07-01
D 2009
TD 2009

D 2009
TD 2009
Fuel system
Fuel system
W 07-10-08
Fuel system
W 07-11-01
Fuel system
W 08-04-05
Lube oil system
W 08-04-06
Lube oil system
W 08-04-07
Lube oil system
W 08-08-02
Lube oil system
W 08-11-08
Lube oil system
W 08-11-10
Removing and installing the oil pressure regulating

valve
Lube oil system
W 09-07-08
Cooling system
W 09-08-01
Cooling system
W 09-08-02
Cooling system
W 09-12-01
Cooling system
W 12-02-02
Other components
W 12-06-01
Other components
W 13-02-03
Electrical system
W 13-03-02
Electrical system
W 13-06-01
Electrical system
01/2008
8/8
16343-001
DEUTZ engines
01/2008
Job cards
Job cards
1/2
16344-001
Job cards
DEUTZ engines
01/2008
2/2
16344-001
General
W 00-02-06
D 2009
Commercial available tools:
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005
W 13-06-01
Special tools:
Connector . . . . . . . . . . . . . . . . . . 100220

z Disconnect the shutoff solenoid.
z Remove the glow plugs.
W 13-06-01
z Insert connector (1).

z Tighten the connection piece.
15 Nm
z Connect adapter (2) to connector.
1
41413-0
z Mount the compression tester on the adapter.

z Turn over engine with starter.
25 - 30 bar (2500 - 3000 kPa)
41415-0
01/2008
1/4
16345-001
General
W 00-02-06
D 2009
No.
Kompression in bar
Compression value in bar
Pression
en bar
Dat. _________
10 15 20 25
30 35 40
Zyl.
The measured compression pressure

depends on the starting speed during the
measuring process and the altitude of the
engine installation site. Therefore, limit
values cannot be determined exactly. The
compression pressure measurement is
only recommended as a reference measurement of all cylinders of an engine to each
other. If more than 15% deviation has been
determined, the cause should be determined by disassembling the cylinder unit concerned.
1
2
3
4
5
6
7
8
Best. Nr. 5 1341 250 00

DBGM
Made in Germany
MOTOMETER 7250 Leonberg

43669-0
z Remove the compression pressure tester and

adapter (1).
41415-1
z Remove connector (1).

z Install the glow plugs.
W 13-06-01
z Connect the shutoff solenoid.
1
41414-0
01/2008
2/4
16345-001
General
W 00-02-06
D 2009
Technical Data
ID no.
Name
P00 51
Value
25 - 30 bar
(2500 - 3000 kPa)
ID no.
Name
Screw type
M10
Notes / Remark
Value
15 Nm
01/2008
3/4
16345-001
General
W 00-02-06
D 2009
01/2008
4/4
16345-001
General
W 00-02-06
TD 2009
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005
Torx tool set . . . . . . . . . . . . . . . . . . 8189
W 07-07-01
Special tools:
Connector . . . . . . . . . . . . . . . . . . 100170
Clamping claw . . . . . . . . . . . . . . 100210

z Disconnect the shutoff solenoid.
z Removing fuel injectors.
W 07-07-01
z Mount sealing ring (1).
z Insert connector (2).
2
1
41350-0
z Mount clamping shoe (1).

z Tighten screw (2).
35 Nm
41348-0
01/2008
1/4
16346-001
General
W 00-02-06
TD 2009
z Connect adapter (1) to connector.
6
41349-0
z Mount the compression tester on the adapter.

z Turn over engine with starter.
25 - 30 bar (2500 - 3000 kPa)
46308-0
No.
Kompression in bar
Compression value in bar
Pression
en bar
Dat. _________
10 15 20 25
30 35 40
Zyl.
The measured compression pressure

depends on the starting speed during the
measuring process and the altitude of the
engine installation site. Therefore, limit
values cannot be determined exactly. The
compression pressure measurement is
only recommended as a reference measurement of all cylinders of an engine to each
other. If more than 15% deviation has been
determined, the cause should be determined by disassembling the cylinder unit concerned.
1
2
3
4
5
6
7
8
Best. Nr. 5 1341 250 00

DBGM
Made in Germany
MOTOMETER 7250 Leonberg

43669-0
01/2008
2/4
16346-001
General
W 00-02-06
TD 2009
z Remove the compression pressure tester and
adapter (1).
6
46308-1
z Unscrew screw (2).

z Remove clamping shoe (1).
z Remove connector.
z Remove sealing ring.
z Install fuel injectors.
W 07-07-01
z Connect the shutoff solenoid.
41348-0
01/2008
3/4
16346-001
General
W 00-02-06
TD 2009
Technical Data
ID no.
Name
P00 51
Value
25 - 30 bar
(2500 - 3000 kPa)
ID no.
Name
A07 001 Fuel injector on cylinder head
Screw type
M8x35-10.9
Notes / Remark
Torx screw
Value
35 Nm
01/2008
4/4
16346-001
D 2009
TD 2009
General
W 00-05-01

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

Lifting gear
Suspension ropes
Special tools:
Assembly block. . . . . . . . . . . . . . . . 6067
Clamping bracket . . . . . . . . . . .6067 200
Engine lifting device . . . . . . . . . . . . 6068
Mounting engine on assembly block

z Hang the engine director onto the transport lashes
(arrows) with support chain.
D / TD 2009 L03
approx. 180 kg
D / TD 2009 L04
approx. 220 kg
z Hang engine on workshop crane.
z Remove all mounting feet.
z Insert engine in engine block.
41351-0
z Mount clamping holder (1).

z Tighten screws (2).
41 Nm
z Mount clamping holder (3).
41 Nm
41251-1
01/2008
1/4
16347-001
General
W 00-05-01
D 2009
TD 2009
z Align engine on engine block.

2
z Tighten screws (1) and nuts (2).

90 Nm
z Unhook the engine from the workshop crane.
41387-0
Demounting engine from assembly block

z Hang the engine director onto the transport lashes
(arrows) with support chain.
D / TD 2009 L03
approx. 180 kg
D / TD 2009 L04
approx. 220 kg
z Hang engine on workshop crane.
41351-0
z Unscrew the nuts (2).

2
z Remove screws (1).
41387-0
01/2008
2/4
16347-001
D 2009
TD 2009
General
W 00-05-01
z Unscrew screws (2).

z Remove clamping bracket (1).
2
z Remove clamping bracket (3).
z Install all mounting feet.

2
41 Nm
z Set down engine.

z Unhook the engine from the workshop crane.
6
41251-1
01/2008
3/4
16347-001
General
W 00-05-01
D 2009
TD 2009
Technical Data
ID no.
Name
D / TD 2009 L03
D / TD 2009 L04
Value
approx. 180 kg
approx. 220 kg
ID no.
Name
A00 001 Clamping bracket on crankcase
Clamping bracket on adapter for
A00 002
assembly block
Mounting foot/engine mounting on
A00 003
crankcase
01/2008

M10x20-10.9
Value
41 Nm
90 Nm
M10x20-10.9
4/4
41 Nm
16347-001
D 2009
TD 2009
Cylinder head
W 01-02-02

Open-ended spanner
(24 mm spanner size)
Hose clip pliers . . . . . . . . . . . . . . . . 8011
Special tools:
Disassembly tool. . . . . . . . . . . . . 110901
Removing the rocker arm

2
TD 2009
z Place charge air pipe (2) to one side.
41252-1
TD 2009
z Remove the O-ring (1) with the disassembly tool.
41254-0
01/2008
1/6
16348-001
Cylinder head
W 01-02-02
D 2009
TD 2009
z Loosen hose clip (1).

z Place pipe (2) to one side.
1
2
6
41253-1
z Unscrew all screws (1).

z Remove cylinder head cowling (2).
z Remove gasket (3).
1
2
3
41001-3

z Remove rocker arm bearing (2).
1
z Remove rocker arm (3).

Lay out components in the order in which
they should be installed.
z Visually inspect the components.
41183-0
01/2008
2/6
16348-001
D 2009
TD 2009
Cylinder head
W 01-02-02
Installing the rocker arm

z Grease the rocker arm (arrow) lightly.
z Mount rocker arm (3) and rocker arm bearing (2).

Align rocker arm centred to the valve
spring!
z Fasten screw (1).
6
41002-1
z Press down rocker arm (1) and pushrod.

z Hold rocker arm with open-ended wrench (2).
27 Nm
41255-1
z Clean sealing surfaces.

The sealing surfaces must be dry and free
from grease and dirt.
1
z Mount new gasket (3).

z Mount cylinder head cover (2).
27 Nm
Tightening sequence: From the centre outwards.
41001-3
01/2008
3/6
16348-001
Cylinder head
W 01-02-02
D 2009
TD 2009
z Push in pipe (1).

z Fix the hose clip (2) with the hose clip pliers.
1
2
6
41253-1
TD 2009
z Insert new sealing ring (1).
1
41254-1
TD 2009
z Mount charge air pipe (1).

21 Nm
41252-2
01/2008
4/6
16348-001
D 2009
TD 2009
Cylinder head
W 01-02-02
Technical Data
ID no.
A01 002
A01 004
A06 083
Name
Rocker arm on cylinder head
Cylinder head cover on cylinder head
Charge air manifold to charge air pipe
Screw type
M8x30-8.8
M8x50-10.9
M8x20-8.8
Notes / Remark
Value
27 Nm
27 Nm
21 Nm
01/2008
5/6
16348-001
Cylinder head
W 01-02-02
D 2009
TD 2009
01/2008
6/6
16348-001
D 2009
TD 2009
Cylinder head
W 01-04-04

Rotation angle disc . . . . . . . . . . . . . 8190
W 01-02-02
W 01-04-09
W 06-06-04
W 06-07-03 . . . . . . . . . . . . . . . . . D 2009
W 06-07-03 . . . . . . . . . . . . . . . . TD 2009
Removing the cylinder head

3
1. Valve
2. Rocker arm
3. Cylinder head bolts

4. Pushrods
5. Thermostat housing
6. Fuel injector
41014-0
z Remove turbocharger.
W 06-06-04
3
z Loosen hose clips (1).

z Remove the oil trap (3).

1
1
2
41256-1
01/2008
1/8
16349-001
Cylinder head
W 01-04-04
D 2009
TD 2009
z Remove the rocker lever.

W 01-02-02
z Remove the charge air pipe.
D 2009
W 06-07-03
TD 2009
W 06-07-03
6
41006-1
z Remove push rods (1).

z Put aside components in the order in which they were
removed.
1
41007-1
D / TD 2009 L03
z Loosen screws in specified order.
z Remove screws.
7
41178-0
01/2008
2/8
16349-001
D 2009
TD 2009
Cylinder head
W 01-04-04
D / TD 2009 L04
z Loosen screws in specified order.
z Remove screws.
7
10
6
41177-0
z Lift the cylinder head carefully from the crankcase.

z Remove gasket.
Do not place cylinder head on sealing surface.
41009-1
Installing the cylinder head

z Check piston overhang.
W 01-04-09
Note installation position of the hydro tappets.
z Pay attention to clamping bushing (1).
41010-0
01/2008
3/8
16349-001
Cylinder head
W 01-04-04
D 2009
TD 2009
z Fit a new cylinder head gasket.

The sealing surfaces for the cylinder head
gasket must be clean and free of oil.
Label OBEN / TOP facing the cylinder
head.
6
41011-1
z Fit cylinder head.

z Pay attention to clamping bushing (1).
!
1
41012-1
D / TD 2009 L03
Attention!
Use new screws.
7
z Oil the cylinder head screws slightly.

z Tighten new screws with rotation angle disc according to the tightening order.
35 Nm + 60 + 60
41178-0
01/2008
4/8
16349-001
D 2009
TD 2009
Cylinder head
W 01-04-04
D / TD 2009 L04
Attention!
Use new screws.
z Oil the cylinder head screws slightly.
10
z Tighten new screws with rotation angle disc according to the tightening order.
35 Nm + 60 + 60
6
41177-0
z Grease the ball heads of the pushrods lightly.

z Insert pushrods in hydro-tappets (1).
Note installation position.
41013-1
z Install the charge air pipe.

D 2009
W 06-07-03
TD 2009
W 06-07-03
z Install the rocker arm.
W 01-02-02
41006-1
01/2008
5/8
16349-001
Cylinder head
W 01-04-04
D 2009
TD 2009
z Mount oil trap (1).

1
27 Nm
z Fasten hose clips (3) with hose clip pliers.
z Install the turbocharger.

W 06-06-04
3
2
6
41256-2
01/2008
6/8
16349-001
D 2009
TD 2009
Cylinder head
W 01-04-04
Technical Data
ID no.
Name
Screw type
A01 001 Cylinder head on crankcase
M12x13010.9
A03 060 Oil trap on crankcase
M8x40-8.8
Notes / Remark
Use new screws.
Observe tightening
order.
Value
35 Nm + 60 + 60
27 Nm
01/2008
7/8
16349-001
Cylinder head
W 01-04-04
D 2009
TD 2009
01/2008
8/8
16349-001
D 2009
TD 2009
Cylinder head
W 01-04-09

Micrometer gauge
W 01-04-04
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Measuring device . . . . . . . . . . . . 100750
z Remove cylinder head.

W 01-04-04
41155-0
z Turn the crankshaft until the respective piston is just

in front of the top dead centre (arrow).
41156-0
01/2008
1/4
16350-001
Cylinder head
W 01-04-09
D 2009
TD 2009
z Insert dial gauge into measuring beam.

z Place shims (1) and measuring beam (2) on the sealing surface of the crankcase.
z Apply the stylus to the piston base (arrow) under pretension.
z Continue turning the crankshaft evenly until the reversal point of the pointer on the dial gauge is
reached.
The piston is now at top dead centre
(TDC).
6
41149-2
z Move the measuring beam.

z Apply stylus of the dial gauge to the crankcase sealing surface with pre-tension (arrow).
z Adjust dial gauge to "0".
41157-1
Measuring points see diagram.

Measuring points (1) and (2).
41148-0
01/2008
2/4
16350-001
D 2009
TD 2009
Cylinder head
W 01-04-09
z Align the measuring apparatus on the spacing washers in such a way that the stylus lies on the specified
measuring points.
Do not position the stylus on the piston
marking.
z Note the largest measured value.
z Compare actual value with setpoint value.
0.70 - 1.0 mm
z Install cylinder head.
W 01-04-04
6
41149-1
01/2008
3/4
16350-001
Cylinder head
W 01-04-09
D 2009
TD 2009
Technical Data
ID no.
P02 75
Name
Piston protrusion
Value
0.70 - 1.0 mm
01/2008
4/4
16350-001
D 2009
TD 2009
Cylinder head
W 01-05-01

Assembly pliers. . . . . . . . . . . . . . . . 8024
Assembly lever . . . . . . . . . . . . . . . . 9017
W 01-04-04
W 07-07-01 . . . . . . . . . . . . . . . . D 2009
W 07-07-01 . . . . . . . . . . . . . . . TD 2009
W 13-06-01
Special tools:
Assembly sleeves . . . . . . . . . . . . 121420
Assembly tool . . . . . . . . . . . . . . . 121430
Removing the valves

1. Exhaust valve
2. Inlet valve
3. Valve spring
4. Rocker arm
5. Pushrod
5
41018-1

W 01-04-04
z Remove the glow plugs.
W 13-06-01
z Removing fuel injectors.
D 2009
W 07-07-01
TD 2009
W 07-07-01
41019-1
01/2008
1/4
16351-001
Cylinder head
W 01-05-01
D 2009
TD 2009
z Attach assembly lever with screw (1) to cylinder

head.
z Press down valve spring with assembly lever.
z Remove both tapper collets (2).
z Remove valve spring plates, valve springs and
valves.
2
z Remove assembly lever.
41020_2
z Pull off valve stem seal (1) with assembly pliers (2).
41021-1
z Clean cylinder head, check and visually inspect for

damage.
41022-1
01/2008
2/4
16351-001
D 2009
TD 2009
Cylinder head
W 01-05-01
Installing the valves

z Oil the valve stem lightly.
z Insert and hold valve.
z Mount assembly sleeve.
z Push new valve stem seal onto valve guide over the
assembly sleeve with assembly tool (1).
6
41023-1
z Mount assembly lever.

z Insert valve spring.
z Insert valve spring plate (2).
z Press down the valve spring with the assembly lever
and insert both tapper collets (1).
1
2
41179_0
z Remove assembly lever.

Make sure the tapper collets fit correctly in
the valve keyway.
41024-1
01/2008
3/4
16351-001
Cylinder head
W 01-05-01
D 2009
TD 2009
z Install fuel injectors.

D 2009
W 07-07-01
TD 2009
W 07-07-01
z Install the glow plugs.
W 13-06-01
W 01-04-04
6
41019-1
01/2008
4/4
16351-001
D 2009
TD 2009
Cylinder head
W 01-05-04
Checking the valves

Micrometer gauge
Slide gauge
W 01-05-01
Clean all valves.

When the wear limit is reached, the valve
must be renewed.
Checking valve stem diameter

z Remove valves.
W 01-05-01
z Measure valve stem diameter with micrometer
gauge.
Inlet valve
7.155 - 7.170 mm
Exhaust valve
7.155 - 7.170 mm
42182-1
Checking valve edge thickness

z Measure valve edge thickness with slide gauge.
Inlet valve
0.1 - 0.4 mm
Exhaust valve
0.1 - 0.4 mm
42183-1
01/2008
1/4
16352-001
Cylinder head
W 01-05-04
D 2009
TD 2009
Checking valve head diameter

z Measure valve head diameter with slide gauge.
Inlet valve
36.90 - 37.10 mm
Exhaust valve
33.90 - 34.10 mm
z Install valves.
W 01-05-01
6
42184-1
01/2008
2/4
16352-001
D 2009
TD 2009
Cylinder head
W 01-05-04
Technical Data
ID no.
P01 31
P01 32
P01 35
P01 36
P01 37
P01 38
Name
Valve stem, diameter, inlet
Valve stem, diameter, outlet
Valve edge thickness, inlet
Valve edge thickness, outlet
Valve plate, diameter, inlet
Valve plate, diameter, outlet
Value
7.155 - 7.170 mm
7.155 - 7.170 mm
0.1 - 0.4 mm
0.1 - 0.4 mm
36.90 - 37.10 mm
33.90 - 34.10 mm
01/2008
3/4
16352-001
Cylinder head
W 01-05-04
D 2009
TD 2009
01/2008
4/4
16352-001
D 2009
TD 2009
Drive system
W 02-01-04

Magnetic measuring stand
Micrometer gauge
W 04-04-09
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Checking the axial backlash

z Remove the gear case cover.
W 04-04-09
z Mount magnetic measuring stand.
z Insert dial gauge.
z Apply stylus to the crankshaft end with pre-tension.
z Press crankshaft in direction of arrow.
41158-1

z Read off measured value.
0.13 - 0.56 mm
z Remove magnetic measuring stand.
z Remove dial gauge.
z Install the gear case cover.
W 04-04-09
1
41159-1
01/2008
1/2
16353-001
Drive system
W 02-01-04
D 2009
TD 2009
Technical Data
ID no.
P02 34
Name
Crankshaft, permissible axial clearance
Value
0.13 - 0.56 mm
01/2008
2/2
16353-001
D 2009
TD 2009
Drive system
W 02-01-07

Magnetic measuring stand
Micrometer gauge
Internal measuring device
Stylus extension
Prisms
Hardness tester
W 02-04-01
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Checking the bearing pin hardness

z Remove crankshaft.
W 02-04-01
z Place crankshaft on prism.
41390-0
z Put hardness tester on journal.

z Raise stylus (1) and press release (2).
1
Stylus (1) falls down, briefly strikes the surface and jumps up to the measured value.
43499-0
01/2008
1/4
16354-001
Drive system
W 02-01-07
D 2009
TD 2009
z Read off displayed value (arrow) from hardness tester.

Nominal value, at least
53 - 58 HRc
The measured value is to be converted
according to the table of the measuring
device.
6
43515-0
Checking the diameter of the main bearing

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

Standard
55.005 - 55.020 mm
See schematic diagram for measuring
points.
41389-0
01/2008
2/4
16354-001
D 2009
TD 2009
Drive system
W 02-01-07
Checking the diameter of the lifting journals

z Measure lifting journal with micrometer gauge.
49.990 - 50.005 mm
points.
6
41389-1
Visual inspection
z Visually inspect the component.
z Check the running surfaces (1) of the crankshaft
sealing rings visually.
z Visually inspect gear wheel (2).
z Install crankshaft.
W 02-04-01
41390-0
01/2008
3/4
16354-001
Drive system
W 02-01-07
D 2009
TD 2009
Technical Data
ID no.
P02 03
P02 07
P02 22
Name
Main journal, diameter
Bearing pin, surface hardness
Lifting journal, diameter
Standard
Value
55.005 - 55.020 mm
53 - 58 HRc
49.990 - 50.005 mm
01/2008
4/4
16354-001
D 2009
TD 2009
Drive system
W 02-02-02

(flywheel side)
Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
Assembly lever . . . . . . . . . . . . . . . . 9017
W 12-06-01
Special tools:
Assembly tool . . . . . . . . . . . . . . . 142780
Self-tapping screw
Washer
Removing the crankshaft sealing ring

z Remove flywheel.
W 12-06-01
41025-0
z Make a hole of approximately 3 mm in the crankshaft

sealing ring with a pricker.
Attention!
Do not damage the main bearing housing
and crankshaft.
41026-0
01/2008
1/2
16355-001
Drive system
W 02-02-02
D 2009
TD 2009
z Turn in a self-tapping screw with washer.

z Pull out the crankshaft sealing ring with assembly lever.
z Visually inspect all running surfaces.
6
41027-0
Installing the crankshaft sealing ring

Use new crankshaft sealing ring.
The sealing lip faces the crankcase.
z Oil the sealing lip of the crankshaft sealing ring lightly.
z Place the crankshaft sealing ring on the assembly
tool.
z Mount the assembly tool on the crankcase pin.
z Drive in crankshaft sealing ring to the stop with the
assembly tool.
1 mm installation depth between connection housing and crankshaft sealing ring.
41028-1
z Remove assembly tool.

z Install flywheel.
W 12-06-01
41025-0
01/2008
2/2
16355-001
D 2009
TD 2009
Drive system
W 02-02-04

Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
Assembly lever . . . . . . . . . . . . . . . . 9017
W 12-02-02
Special tools:
Assembly tool . . . . . . . . . . . . . . . 142790
Self-tapping screw
Washer
Removing the crankshaft sealing ring

z Remove V-belt pulley.
W 12-02-02
z Make a hole of approximately 3 mm in the crankshaft
sealing ring with a pricker.
Attention!
Do not damage the gearcase cover and
crankshaft.
41174-0
z Turn in a self-tapping screw with washer.

z Pull out the crankshaft sealing ring with assembly lever.
z Visually inspect all running surfaces.
41173-0
01/2008
1/2
16356-001
Drive system
W 02-02-04
D 2009
TD 2009
Installing the crankshaft sealing ring

Use new crankshaft sealing ring.
The sealing lip faces the crankcase.
z Oil the sealing lip of the crankshaft sealing ring lightly.
z Place the crankshaft sealing ring on the assembly
tool.
z Mount the assembly tool on the crankcase pin.
z Drive in crankshaft sealing ring to the stop with the
assembly tool.
The installation depth is determined by the
assembly tool.
z Remove assembly tool.

z Install V-belt pulley.
41055-0
W 12-02-02
01/2008
2/2
16356-001
D 2009
TD 2009
Drive system
W 02-03-01

Micrometer gauge
Con rod test device
W 02-09-03
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
z Remove piston and connecting rod.

W 02-09-03
z Remove piston from con rod.
41044-1
Checking small end bush

z Prepare internal measuring device:
Mount probe bolt for the appropriate measuring
range in the internal measuring device.
Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
Set micrometer gauge to 28 mm.
Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the dial gauge at the reversal point of the pointer to
"0".
34768-2
01/2008
1/10
16357-001
Drive system
W 02-03-01
D 2009
TD 2009
Diagram for measuring the small end bush

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

z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
28.010 - 28.025 mm
z Note the measured value, dimension (A).

The dimension A is required to determine
the piston bolt clearance.
41391-0
Checking diameter of the piston bolt

z Measure piston pin with micrometer gauge.
0.005
28 0.01 mm
z Note the measured value, dimension B.
The dimension B is required to determine
the piston bolt clearance.
35908-3
01/2008
2/10
16357-001
D 2009
TD 2009
Drive system
W 02-03-01
Determining piston pin clearance

The piston pin clearance is given by the
difference between the internal diameter of
the small end bush (a) and the piston pin
diameter (b).
0.015 - 0.035 mm
Calculation example
Desired:
Piston pin clearance
Given:
Measured:
Internal diameter small end bush (a)
(a) = 28.015 mm
Diameter piston pin (b)
(b) = 27.990 mm
Calculation:
Dimension (a) - Dimension (b)
28.015 mm - 27.990 mm
Result:
= 0.025 mm
Checking the con rod bearing bore

z Mount big end bearing cap.
Attention!
651
9
Note the assignment of the big end bearing

cap.
The identification numbers (1) on the con
rod and the big end bearing cap must be
identical and opposite to each other when
assembled.
19
265
41395-1
z Tighten screws alternately with rotation angle disc

and socket wrench insert.
20 Nm + 45
41396-1
01/2008
3/10
16357-001
Drive system
W 02-03-01
D 2009
TD 2009

"0".
6
36094-1
Diagram for measuring the con rod bearing

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

53.525 - 53.545 mm
When the wear limit is reached the con rod
must be replaced.
41392-0
01/2008
4/10
16357-001
D 2009
TD 2009
Drive system
W 02-03-01
Checking internal diameter of the con rod

bearing shells
z Remove the con rod bearing cover.
6
41393-0
z Insert bearing shell in the con rod.
Attention!
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).
2
2
41048-2
z Insert bearing shell in the respective big end bearing

cap.
Attention!
groove (2).
2
1
41394-0
01/2008
5/10
16357-001
Drive system
W 02-03-01
D 2009
TD 2009
Attention!
265
The identification numbers (1) on the connecting rod and the big end bearing cover
must be identical and opposite to each
other when assembled.
19
1
265
19
6
41395-0
z Tighten screws alternately with rotation angle disc

and socket wrench insert.
20 Nm + 45
41396-0

"0".
36094-1
01/2008
6/10
16357-001
D 2009
TD 2009
Drive system
W 02-03-01
Diagram for measuring the inside diameter

of the con rod bearing shells at the
points "a" and "b" in the levels "1" and "2".
6
37239-1

points.
50.045 - 50.057 mm
z Note measured value, dimension (a).
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.
41397-0
Determine big end bearing clearance

The big end bearing clearance is given by
the difference between the internal diameter of the big end bearing shell (a) and the
lifting journal diameter (b).
0.040 - 0.067 mm
Calculation example
Desired:
Big end bearing clearance
Given:
Measured:
Internal diameter big end bearing shell (a)
(a) = 50.040 mm
Diameter lifting journal (b)
(b) = 50.000 mm
Calculation:
Dimension (a) - Dimension (b)
50.040 mm - 50.000 mm
Result:
= 0.040 mm
01/2008
7/10
16357-001
Drive system
W 02-03-01
D 2009
TD 2009
z Remove screws.
z Remove the con rod bearing cover.
6
41396-0

z Mount connecting rod on test instrument without
bearing shells.
Attention!
Aligning the con rod is not permissible.
z Move test fork in direction of arrow.

z Check that the con rod is parallel.
z Permissible deviation from (A) to (B).
0.03 mm
Distance between A and B = 100 mm.
30579-1
z Move test fork in direction of arrow.

z Check the angle of the con rod.
z Permissible deviation from (C) to (D).
0.03 mm
Distance between C and D = 100 mm
C
D
z Assembly pistons and con rod.

z Install piston and connecting rod.
W 02-09-03
30580-1
01/2008
8/10
16357-001
D 2009
TD 2009
Drive system
W 02-03-01
Technical Data
ID no.
P02 41
P02 42
P02 43
P02 52
P02 55
P02 56
P02 61
P02 62
Name
the piston bolt
vertical
the piston bolt
horizontal
Piston bolt bush, diameter, inside
Con rod bearing shells, diameter, inside
Con rod, bearing bore, diameter, inside
Theoretical clearance between the big
end bearing and lifting journal
Piston pin, diameter, outside
Theoretical clearance between piston pin
bush and piston pin
Value
0.03 mm
0.03 mm
28.010 - 28.025 mm
50.045 - 50.057 mm
53.525 - 53.545 mm
0.040 - 0.067 mm
28 0.005
0.01
mm
0.015 - 0.035 mm
ID no.
Name
A02 020
rod
01/2008
Screw type
Notes / Remark
Value
M8x52-10.9
Use new screws.
20 Nm + 45
9/10
16357-001
Drive system
W 02-03-01
D 2009
TD 2009
01/2008
10/10
16357-001
D 2009
TD 2009
Drive system
W 02-04-01

Depth-measuring
appliance
3-arm puller
W 02-01-04
W 02-02-02
W 02-09-03
W 04-04-09
W 08-04-06
W 12-06-01
Special tools:
Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . . . . . . 143860
Disassembly/assembly
tool . . . . . . . . . . . . . . . . . . . . . . . 143870
Blocking tool . . . . . . . . . . . . . . . . 144200
Fitting compound
DEUTZ AP1908
Removing crankshaft
1. Crankshaft
2. Connecting rod
3
3. Piston
4. Bearing housing
5. Main bearing housing
5
41033-2

W 04-04-09
41029-2
01/2008
1/12
16358-001
Drive system
W 02-04-01
D 2009
TD 2009
z Mount blocking tool (1).

z Loosen screw (2).
z Loosen screw (3).
z Remove blocking tool (1).
3
1
2
6
41258-2

z Pull out journal (2).
z Remove idler gear (3).
3
41030-0

z Remove camshaft toothed wheel (2).
41031-0
01/2008
2/12
16358-001
D 2009
TD 2009
Drive system
W 02-04-01
z Remove cylindrical pin (1).
6
41261-0
z Turn in screw (1) a few turns.

z Pull off camshaft toothed wheel with 3-arm puller.
41260-0
z Remove flywheel.
W 12-06-01
W 02-09-03
41029-2
01/2008
3/12
16358-001
Drive system
W 02-04-01
D 2009
TD 2009

z Lever out main bearing housing (2) with a suitable
tool in the recess clearances.
Make sure that the thrust washer halves do
not fall into the crankcase.
1
41034-1
z Unscrew fixing screws (1).

z Remove oil suction pipe (2).
z Unscrew oil pressure control valve (3).
41059-1
z Remove crankshaft.
41035-0
01/2008
4/12
16358-001
D 2009
TD 2009
Drive system
W 02-04-01
Removing the main bearing

z Insert thrust pad (1) in bearing bush.
z Insert threaded rod (2).
z Insert counter support (3).
z Mount washers and screw on nuts.
1
6
41060-1
z Turn the nut (1) clockwise.

The bearing bush is pressed onto the
crankcase by the thrust pad.
z Dismantle disassembly/assembly tool.

z Remove bearing bush.
41061-1
z Clamp main bearing housing in the vice.

Use cushioned jaws.
z Insert thrust pad (1) in bearing bush.

z Insert assembly bell (3).
z Turn nut (4) clockwise.

The bearing bush is pressed onto the main
bearing housing by the thrust pad.
41384-0
01/2008
5/12
16358-001
Drive system
W 02-04-01
D 2009
TD 2009
Installing the main bearing

z Oil bearing liner with lubricating oil.
z Press in bearing liner with disassembly/assembly
tool 143870.
Make sure the bearing bush is not twisted.
assembly tool.
Mark the position of the lubricating oil bore
on the main bearing housing.
6
41058-2
z Oil bearing liner with lubricating oil.

z Mount bearing bush.
z Mount guide plate (1).

z Insert counter support.
Mark position of the lubricating oil bore.
Position bearing bush.
41062-1
z Turn the nut (1) clockwise.

The bearing bush is pressed into the
crankcase by the thrust pad.
assembly tool.
Make sure the bearing bush is not twisted.
41063-1
01/2008
6/12
16358-001
D 2009
TD 2009
Drive system
W 02-04-01
z Dismantle disassembly/assembly tool.

z Remove disassembly/assembly tool.
z Check that the lubricating oil bore is in line.
If the lubricating oil bore is not in line, the
bearing bush must be removed and reinstalled.
z Check installation depth (1) with depth measuring
appliance.
approx. 3 mm
6
41064-1
Installing the crankshaft

z Oil bearing liner (1) lightly with lubricating oil.
z Push crankshaft into crankcase.

Align screw thread (2) and through
hole (3).
4
z Insert thrust washers (4) at the rear with grease.

Lubricating oil grooves face the crankshaft.
3
2
41036-1
z Push in the crankshaft in the direction of the arrow to

the stop.
z Tighten locating screws (1).
41 Nm
z Install oil suction pipe.
W 08-04-06
41037-1
01/2008
7/12
16358-001
Drive system
W 02-04-01
D 2009
TD 2009
z Insert new O-ring (1).

z Coat O-ring with DEUTZ AP1908 mounting compound.
1
6
41398-0
z Coat the back of the shims with a little grease.

The lubricating oil grooves (2) face

upwards.
z Install shims (1).
41399-0
z Install main bearing housing (1).

Stage 1:
15 Nm
Stage 2:
27 Nm
z Renew crankshaft sealing ring (flywheel side).
W 02-02-02
2
1
41038-1
01/2008
8/12
16358-001
D 2009
TD 2009
Drive system
W 02-04-01
z Install flywheel.
W 12-06-01
W 04-04-09
6
41029-2
z Check axial backlash of crankshaft.

W 02-01-04
z Heat up crankshaft toothed wheel to approx. 100 C.
Danger!
Danger of burning!
z Mount crankshaft toothed wheel (1).
Note installation position of Woodruff
key (2) and groove.
z Tighten oil pressure control valve (3).

21 Nm
41039-1
z Insert cylindrical pin (1).

z Insert camshaft toothed gear with cylindrical pin (1)
in bore (2).
41262-1
01/2008
9/12
16358-001
Drive system
W 02-04-01
D 2009
TD 2009
The marks (1) of the crankshaft toothed

wheel and the camshaft toothed wheel
must be in line!
z Fasten screw (2).
2
1
6
41081-1
z Insert idler gear.

wheel, intermediate gear and fuel injector
toothed wheel must be in line!
1
41066-0
z Oil the journal lightly.

z Insert the journal carefully into the needle bearing.
z Fasten screws.
41067-0
01/2008
10/12
16358-001
D 2009
TD 2009
Drive system
W 02-04-01

81 Nm
3

81 Nm
1

2
6
41258-2

W 02-09-03
41029-2
01/2008
11/12
16358-001
Drive system
W 02-04-01
D 2009
TD 2009
Technical Data
ID no.
P03 29
Name
Crankshaft, bearing bush, installation
depth
Value
approx. 3 mm
ID no.
A02 010
A02 010
A02 012
A04 001
A04 011
Name
Bearing housing in crankcase
Camshaft gear wheel on camshaft
Intermediate gear on crankcase
Oil pressure control valve on crankA08 098
case
01/2008

M8x20-8.8
Stage 1:
M8x20-8.8
Stage 2:
M10x80-8.8
M12x35-8.8
M12x75-10.9
Value
15 Nm
27 Nm
41 Nm
81 Nm
81 Nm
3/8
21 Nm
12/12
16358-001
D 2009
TD 2009
Drive system
W 02-09-03

W 01-04-04
W 08-04-06
Special tools:
Universal piston ring pliers . . . . . 130300
Piston ring compressor . . . . . . . . 130510
Removing the piston and con rod

1
1. Piston rings
2. Piston
3. Piston pin
4. Connection rod
5. Big end bearing cap
4
5
41042-1

W 01-04-04
z Remove oil suction pipe
W 08-04-06
z Pull out oil dipstick.
41040-0
01/2008
1/6
16359-001
Drive system
W 02-09-03
D 2009
TD 2009
Removing the big end bearing cap

z Position lifting bearing journal in LDC position.
z Remove big end bearing cap (2).
z Remove bearing shell (3).
Note order of cylinders.
6
41041-0
z Press out the piston and connection rod.

Note order of cylinders.
z Remove con rod bearing shells (1).
1
41043-1
Removing the piston

z Remove locking ring with locking ring pliers.
z Press out piston pin.
z Remove connection rod.
41044-1
01/2008
2/6
16359-001
D 2009
TD 2009
Drive system
W 02-09-03
z Remove piston rings with universal piston ring pliers.
6
41045-0
Completing con rod and piston

z Insert new locking ring.
Ensure that the installation location is free
from faults.
z Insert con rod.
The labelling on the piston base and the
numbered label of the connection rod face
the camshaft side.
z Oil the piston bolt lightly.
z Press the piston bolt through.
z Insert new locking ring.
from faults.
41047-1
Installing the piston and con rod

z Insert bearing shell in the con rod.
groove (2).
z Insert bearing shell in the respective big end bearing
cap.
2

The anti-rotation lock must lock in groove.
?
1
41048-1
01/2008
3/6
16359-001
Drive system
W 02-09-03
D 2009
TD 2009
z Install piston rings with universal piston ring pliers.

z Arrange the piston ring joints with an offset of
about 120 to each other.
Do not turn the piston rings any further.
120
120
z Lightly oil cylinder running surface, piston, piston

rings and lifting bearing journal lightly.
z Clamp piston rings with piston ring compressor.
0
41046-0
z Set lifting journal at bottom dead centre (BDC).

z Push piston and con rod completely into cylinder.
Attention!
Numeric identification faces the camshaft
side.
z Place piston ring clamping band flat on the crankcase.
z Push piston and con rod completely into cylinder.
Attention!
Do not jam the con rod with the crankshaft.
UT
41049-0

Renew screws every time they are loosened.
Note assignment and installation position:
The identification numbers (1) on the connecting rod and the big end bearing cover
must be identical and opposite to each
other when assembled.
z Tighten new screws with rotation angle disc.
xxx
xxx
Attention!
UT
20 Nm + 45
41068-1
01/2008
4/6
16359-001
D 2009
TD 2009
Drive system
W 02-09-03
z Insert oil dipstick.

W 08-04-06
W 01-04-04
6
41040-0
01/2008
5/6
16359-001
Drive system
W 02-09-03
D 2009
TD 2009
Technical Data
ID no.
Name
A02 020
rod
Screw type
Notes / Remark
Value
M8x52-10.9
Use new screws.
20 Nm + 45
01/2008
6/6
16359-001
D 2009
TD 2009
Drive system
W 02-09-07
Checking the piston

Micrometer gauge
W 02-09-03
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
When the piston wear limit is reached, the

piston must be renewed.
Checking the piston bolt bore

W 02-09-03
41044-1

"0".
34768-2
01/2008
1/4
16360-001
Drive system
W 02-09-07
D 2009
TD 2009
Diagram for measuring the piston bolt bore

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

bore.
points.
+0.008
28 +0.003 mm
43483-0
Checking the piston diameter

z Measure piston diameter with micrometer gauge.
43427-0
01/2008
2/4
16360-001
D 2009
TD 2009
Drive system
W 02-09-07
D 2009
Measuring point 1
+0.167
89,400 +0.153 mm
Measuring point 2
+0.008
89,400 0.008 mm
Measuring point 3
0.175
89,400 0.145 mm
Measuring point height - see Technical
Data.
6
41154-0
TD 2009
Measuring point 1
89,825 +0.152
+0.138 mm
Measuring point 2
89,825 +0.009
0.009 mm
Measuring point 3
89,825 0.220
0.190 mm
Measuring point height - see Technical
Data.
z Assemble con rod and piston.

W 02-09-03
41154-0
01/2008
3/4
16360-001
Drive system
W 02-09-07
D 2009
TD 2009
Technical Data
ID no.
D 2009
Name
Value
P02 71

+0.153 mm
P02 72

0.008 mm
P02 73

0.145 mm
TD 2009
P02 71 Piston, diameter, standard

+0.138 mm
P02 72

0.009 mm
P02 73

0.190 mm
D / TD 2009
P02 78
01/2008
+0.008
Piston pin bore
28 +0.003 mm
4/4
16360-001
D 2009
TD 2009
Drive system
W 02-10-03

Feeler gauges
W 02-09-03
Special tools:
Universal piston ring pliers . . . . . 130300
Checking the piston rings and piston ring

grooves
W 02-09-03
Attention!
Do not overstretch the piston ring!
z Only set the universal piston ring pliers to the maximum necessary diameter.
z Remove piston rings with universal piston ring pliers.
44263-1
z Clean piston.
z Visually inspect piston.
z Visually inspect piston ring grooves.
44264-1
01/2008
1/4
16361-001
Drive system
W 02-10-03
D 2009
TD 2009
Checking the piston ring joint clearance

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

gauge.
1. piston ring
0,15 +0.20
mm
+0
2. piston ring = taper-faced ring
0,15 +0.25
mm
+0
3. piston ring = bevelland-edge oil control ring
0,30 +0.25
mm
+0
When the wear limit is reached, the piston
ring must be renewed.
41386-1
z Mount the piston rings with the marking "TOP" facing

the combustion chamber.
Order and position of the piston rings as
seen from the piston base:
z (1):
1. piston ring
z (2):
2. piston ring = taper-faced ring

z (3):
3. piston ring = bevelland-edge oil control ring
41154-1
01/2008
2/4
16361-001
D 2009
TD 2009
Drive system
W 02-10-03
z Install piston rings with universal piston ring pliers.

Set spring joint of the bevelland-edge oil
control ring 180 to the ring joint.
6
44268-0
Checking the piston ring axial clearance

Check with new piston rings.
z Check axial backlash with feeler gauge between piston ring and piston ring groove.
1. piston ring
0.11 - 0.15 mm
2. piston ring
0.045 - 0.090 mm
3. piston ring
0.045 - 0.090 mm
When the piston wear limit is reached, the
piston must be renewed.
44269-0
z Assemble con rod and piston.

W 02-09-03
41047-0
01/2008
3/4
16361-001
Drive system
W 02-10-03
D 2009
TD 2009
Technical Data
ID no.
Name
Value
P02 84
0,15 +0
mm
P02 85
+0.25
0,15 +0
mm
P02 86
+0.25
0,30 +0
P02 87
P02 88
P02 89

+0.20
mm
0.11 - 0.15 mm
0.045 - 0.090 mm
0.045 - 0.090 mm
01/2008
4/4
16361-001
D 2009
TD 2009
Crankcase
W 03-03-01

Micrometer gauge
Depth-measuring
appliance
W 02-09-03
The crankshaft bearing covers must be

mounted properly for measuring the cylinders.
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Checking the cylinders

W 02-09-03
z Check cylinder for visible signs of wear.
41029-3

"0".
36094-1
01/2008
1/4
16362-001
Crankcase
W 03-03-01
D 2009
TD 2009
Diagram for measuring the cylinder running surface at the points "a" and "b" in the
levels "1" - "3".
a
1
2
3
6
39100-1
z Insert internal measuring device in cylinder.

+0.025
90 +0
mm

points.
W 02-09-03
41416-0
01/2008
2/4
16362-001
D 2009
TD 2009
Crankcase
W 03-03-01
Technical Data
ID no.
Name
Value
P03 31
Cylinder, diameter, inside
Standard
90 +0
+0.025
mm
01/2008
3/4
16362-001
Crankcase
W 03-03-01
D 2009
TD 2009
01/2008
4/4
16362-001
D 2009
TD 2009
Crankcase
W 03-09-04

Commercial available tools
W 12-06-01
W 13-03-02
Removing the connection housing

z Remove starter.
W 13-03-02
z Remove flywheel.
W 12-06-01
41070-0

z Remove connection housing.
41071-0
01/2008
1/4
16363-001
Crankcase
W 03-09-04
D 2009
TD 2009
Installing the connection housing

z Mount connection housing.
81 Nm
6
41072-0
z Install flywheel.
W 12-06-01
z Install starter.
W 13-03-02
41073-0
01/2008
2/4
16363-001
D 2009
TD 2009
Crankcase
W 03-09-04
Technical Data
ID no.
Name
A03 080 Connection housing to crankcase

M12x25-12.9 Locking screw
Value
81 Nm
01/2008
3/4
16363-001
Crankcase
W 03-09-04
D 2009
TD 2009
01/2008
4/4
16363-001
D 2009
TD 2009
Crankcase
W 03-11-01

Micrometer gauge
Counter support . . . . . . . . . . . . . . . 8200
W 04-05-05
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Internal extractor. . . . . . . . . . . . . 143500
Assembly tool . . . . . . . . . . . . . . . 143890
Cable tie
Testing camshaft bearing

z Remove camshaft.
W 04-05-05
"0".
34768-2
Diagram for measuring the camshaft bearing at the points "a and b" in the
levels "1 and 2".
37239-1
01/2008
1/8
16364-001
Crankcase
W 03-11-01
D 2009
TD 2009

45.960 - 45.980 mm
When the wear limit is reached, the camshaft bearing must be replaced.
6
41373-0
Removing camshaft bearing

z Insert internal extractor (1).
z Splay and centre the internal extractor.
z Splay the internal extractor to the stop.
z Screw spindle (2) to internal extractor.
2
z Mount counter holder (3).

z Position holder.
1
3
41382-0
z Hold spindle (1).

z Tighten nut (2).
z Remove bearing halves (3).
1
41383-0
01/2008
2/8
16364-001
D 2009
TD 2009
Crankcase
W 03-11-01

"0".
6
34768-2
Diagram for measuring the camshaft bearing at the points "a and b" in the
levels "1 and 2".
37239-1

50.060 - 50.095 mm
When the wear limit is reached, the crankcase must be exchanged.
41374-0
01/2008
3/8
16364-001
Crankcase
W 03-11-01
D 2009
TD 2009
Installing camshaft bearing

z Tighten pin bolts (1).
1
41376-0
z Place bearing halves (1) on pressure piece (2).

z Fix bearing halves (1) with cable tie (3).
41377-0
z Mount pressure piece (1).

z Position bearing halves (2).
41378-0
01/2008
4/8
16364-001
D 2009
TD 2009
Crankcase
W 03-11-01
z Tighten knurled nuts (1).
6
41379-0
41380-0
Attention!
Do not damage the bearing shells.
z Remove cable tie (1).
1
41381-0
01/2008
5/8
16364-001
Crankcase
W 03-11-01
D 2009
TD 2009
z Unscrew studs (1).

z Install the camshaft.
W 04-05-05
1
41376-0
01/2008
6/8
16364-001
D 2009
TD 2009
Crankcase
W 03-11-01
Technical Data
ID no.
P03 11
P03 13
Name
Camshaft bearing, locating hole, diameter
Camshaft bearing, diameter, inside
Value
50.060 - 50.095 mm
45.960 - 45.980 mm
01/2008
7/8
16364-001
Crankcase
W 03-11-01
D 2009
TD 2009
01/2008
8/8
16364-001
D 2009
TD 2009
Engine control
W 04-04-09

W 02-02-04
W 08-08-02
W 09-07-08
W 12-02-02
W 13-02-03
Special tools:
Assembly tool . . . . . . . . . . . . . . . 142790
Special wrench . . . . . . . . . . . . . . 170050
Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.
The engine oil and coolant should be
added according to the operating manual.
Removing the gearcase

z Remove coolant pump.
W 09-07-08
z Remove V-belt pulley.
W 12-02-02
z Remove the oil cooler.
W 08-08-02
z Remove generator.
W 13-02-03
41051-1
41265-0
01/2008
1/4
16365-001
Engine control
W 04-04-09
D 2009
TD 2009

z Remove spacer (3).
z Remove gearcase cover.
Attention!
Do not damage the sealing surfaces.
6
41266-0
Installing the gearcase cover

z Knock out crankshaft sealing ring (1).
Attention!
Do not damage sealing surface when
knocking out.
41054-1
z Fix the new gasket to the crankcase with a little

grease.
Make sure the clamping bushings (1) are
in place.
41056-0
01/2008
2/4
16365-001
D 2009
TD 2009
Engine control
W 04-04-09
z Mount gearcase cover.

from faults.
z Mount spacer (1).
z Fasten all screws.
6
41266-1
z Tighten the screws according to the tightening sequence.
10 17 1 9
16
15
27 Nm
Note different screw lengths.
18
7
11
14
19
5
12
21
20
13 3
41069-1
z Install crankshaft sealing ring (opposite side to flywheel)

W 02-02-04
z Install generator.
W 13-02-03
z Install oil cooler.
W 08-08-02
z Install V-belt pulley.
W 12-02-02
z Install coolant pump.
W 09-07-08
41051-1
01/2008
3/4
16365-001
Engine control
W 04-04-09
D 2009
TD 2009
Technical Data
ID no.
Name
A03 020 Gearcase cover on crankcase
Screw type
M8x35-12.9
M8x50-10.9
M8x70-8.8
Notes / Remark
Value
27 Nm
01/2008
4/4
16365-001
D 2009
TD 2009
Engine control
W 04-05-05

W 01-04-04
W 04-04-09
W 07-10-08
W 07-11-01
Special tools:
Dial gauge. . . . . . . . . . . . . . . . . . 100400
Special pliers. . . . . . . . . . . . . . . . 103220
Fixing pin . . . . . . . . . . . . . . . . . . 144180
Removing the camshaft

W 01-04-04
W 04-04-09
z Remove fuel supply pump.
W 07-11-01
z Remove fuel filter console.
W 07-10-08
41082-1
z Set piston (1) at top dead centre.

1
z Fix flywheel with fixing pin (2).
41075-0
01/2008
1/8
16366-001
Engine control
W 04-05-05
D 2009
TD 2009
z Pull out hydraulic tappet (1) with special pliers.

6
41076-1

z Loosen screw (2).
2
1
41258-3

z Remove camshaft toothed wheel (2).
41031-1
01/2008
2/8
16366-001
D 2009
TD 2009
Engine control
W 04-05-05
z Remove cylindrical pin (1).
6
41261-0

z Remove thrust washer (2).
41264-0
z Fasten screw (1).

z Pull out the camshaft carefully in the direction of the
arrow.
41078-1
01/2008
3/8
16366-001
Engine control
W 04-05-05
D 2009
TD 2009
Installing the camshaft

z Oil camshaft bearing lightly.
z Oil cam shaft pin lightly.
z Insert the camshaft (1) carefully in the direction of the
arrow.
6
41079-0
z Bore (1) faces the lubricating oil pan.

z Mount thrust washer (2).
21 Nm
41264-2
Checking the axial backlash

z Mount magnetic measuring stand.
z Insert dial gauge.
z Apply stylus to the camshaft end with pre-tension.
41160-1
01/2008
4/8
16366-001
D 2009
TD 2009
Engine control
W 04-05-05

z Read actual value from dial gauge.
Nominal value:
0.07 - 0.29 mm
The axial backlash is not adjustable.
If the axial backlash is greater than the setpoint, the camshaft must be renewed.
z Remove magnetic measuring stand.
z Remove dial gauge.
6
41161-1
z Insert cylindrical pin (1).

z Insert camshaft toothed gear with cylindrical pin (1)
in bore (2).
41262-0

wheel and the camshaft toothed wheel
must be in line!
z Fasten screw (2).
2
1
41081-1
01/2008
5/8
16366-001
Engine control
W 04-05-05
D 2009
TD 2009

81 Nm
2

1
6
41258-3
z Oil the hydro-tappet lightly.

z Insert hydraulic tappet (1) with special pliers.
Note installation position of the hydro tappets.
41084-0
z Install the fuel filter console.

W 07-10-08
z Install fuel pump.
W 07-11-01
W 04-04-09
W 01-04-04
41082-1
01/2008
6/8
16366-001
D 2009
TD 2009
Engine control
W 04-05-05
Technical Data
ID no.
P04 35
Name
Camshaft, axial clearance
(not adjustable)
Value
0.07 - 0.29 mm
ID no.
Name
A04 001 Camshaft gear wheel on camshaft
A04 002 Camshaft, shim on crankshaft
Screw type
M12x35-8.8
M8x16-8.8
Notes / Remark
Torx screw
Value
81 Nm
21 Nm
01/2008
7/8
16366-001
Engine control
W 04-05-05
D 2009
TD 2009
01/2008
8/8
16366-001
D 2009
TD 2009
Engine control
W 04-05-06

Micrometer gauge
Prisms
W 04-05-05

z Remove camshaft.
W 04-05-05
z Visually inspect cams and bearing pins for wear.
41358-0
Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.
36424-2
01/2008
1/4
16367-001
Engine control
W 04-05-06
D 2009
TD 2009
z Measure bearing pin (1).

45.950 - 45.970 mm
points.
When the limit value is reached the camshaft must be replaced.
6
41358-1
z Measure bearing pin (1).

41.925 - 41.955 mm
points.
When the limit value is reached the camshaft must be replaced.
41358-2
z Install the camshaft.

W 04-05-05
41358-0
01/2008
2/4
16367-001
D 2009
TD 2009
Engine control
W 04-05-06
Technical Data
ID no.
P04 31
P04 31
Name
Camshaft, bearing pin, diameter
Camshaft, bearing pin, diameter (drive
side)
Value
41.925 - 41.955 mm
45.950 - 45.970 mm
01/2008
3/4
16367-001
Engine control
W 04-05-06
D 2009
TD 2009
01/2008
4/4
16367-001
Exhaust system/Charging
W 06-01-05
TD 2009
W 06-06-04
Special tools:
Fitting compound
DEUTZ S1
Removing exhaust line

z Remove gasket.
41299-0

z Remove charge air pipe (2).
41300-0
01/2008
1/8
16368-001
W 06-01-05
TD 2009
z Unscrew lock nut (1).
6
41301-0

z Remove gasket.
41302-0
41303-1
01/2008
2/8
16368-001
W 06-01-05
TD 2009
z Remove the compensator pipe (2).
z Remove seals.
1
1
6
41307-0

z Remove exhaust line (2).
z Remove gasket.
1
z Remove turbocharger.
W 06-06-04
41305-0
41308-0
01/2008
3/8
16368-001
W 06-01-05
TD 2009
Installing exhaust line

z Install the turbocharger.
W 06-06-04
6
41306-0

z Mount new gasket.
z Mount exhaust line (2).
1
Coat screws with DEUTZ S1 mounting

compound.

27 Nm
1
41305-0
z Mount new gaskets.

z Mount compensator pipe (2).
1
41307-0
01/2008
4/8
16368-001
W 06-01-05
TD 2009
z Fasten screw (1).
6
41303-1

20 Nm
25 Nm
1
2
41303-3

21 Nm
41303-1
01/2008
5/8
16368-001
W 06-01-05
TD 2009
z Mount new gasket.

9 Nm
6
41302-0
z Tighten lock nut (1).

15 Nm
Attention!
Lay the hose pipe free from chafing and
tension.
41301-0
41254-0
01/2008
6/8
16368-001
W 06-01-05
TD 2009
z Position hose clip (2).
6
41300-1

21 Nm
41299-0
01/2008
7/8
16368-001
W 06-01-05
TD 2009
Technical Data
ID no.
A06 001
A06 063
A06 064
A06 083
Name
Exhaust pipe at cylinder head
Charge air manifold to charge air pipe
Lubricating oil pipe on exhaust turboA08 040
charger
A08 044 Oil return line to turbocharger
A09 021 Pipe, holder to holder
Screw type
M8x55-10.9
M8x20-10.9
M8x12-8.8
M8x20-8.8
Notes / Remark
Value
27 Nm
20 Nm
25 Nm
21 Nm
M14x1.5
15 Nm
M6x16-8.8
M8x16-8.8
9 Nm
21 Nm
01/2008
8/8
16368-001
W 06-06-04
TD 2009
W 06-01-05
Fitting compound
DEUTZ S1

to regulations.
Emptying and filling the engine with operating media must be carried out according to
the operating manual and the appropriate
documentation of the vehicle/equipment
manufacturer.
Removing exhaust manifold

z Remove the exhaust pipe.
W 06-01-05

z Remove exhaust manifold (2).
41309-0
Removing turbocharger
z Remove turbocharger (2).
z Remove gasket.
2
41310-0
01/2008
1/4
16369-001
W 06-06-04
TD 2009

2
z Pull off hose pieces (2).

1
41311-0
41312-0
Installing the turbocharger

2
z Push on hose pieces (2).

1

from faults.
z Position hose clips (1).

z Fasten hose clips with hose clip pliers.
1
41311-0
01/2008
2/4
16369-001
W 06-06-04
TD 2009
z Mount gasket (1).
6
41314-0
z Mount turbocharger (2).

z Tighten all screws (1).
41 Nm
compound.
2
41310-0
Installing exhaust manifold

z Mount gasket (3).
z Mount exhaust manifold (2).

41 Nm
compound.
z Install the exhaust pipe.
2
W 06-01-05
41309-0
01/2008
3/4
16369-001
W 06-06-04
TD 2009
Technical Data
ID no.
Name
A06 010 Exhaust manifold to turbocharger

A06 020 Turbocharger on exhaust pipe
Screw type
Notes / Remark
Insert with Deutz S1
M8x25-10.9
mounting compound.
M10x20-10.9 Insert with Deutz S1
M8x16-8.8
mounting compound.
Value
41 Nm
41 Nm
01/2008
4/4
16369-001
W 06-07-03
D 2009
Danger!
Special tools:
Special wrench . . . . . . . . . . . . . . 110520
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Wait 30 seconds after switching off the

engine before working on the fuel system.
Fitting compound
DEUTZ S1
Ensure utmost cleanliness when working

on the fuel system.
Carefully clean the area around the affected parts. Blow damp areas dry with compressed air.
Observe the safety regulations and national specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immediately before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regulations.
Attention!
Removing the intake manifold

1
z Unscrew lock nuts (1) with special wrench.
41404-0
01/2008
1/6
16370-001
W 06-07-03
D 2009

z Remove pipe clamp (2).
z Remove all injection pipes.
1
6
41405-0

z Remove intake manifold (3).
z Unscrew fuel line (5).
4
3
2
41088-0
41089-0
01/2008
2/6
16370-001
W 06-07-03
D 2009
Install intake manifold
z Screw on fuel pipe (5).
z Coat the screws (2) with fitting compound.
z Mount gasket (4).
z Mount intake manifold (3).

27 Nm
z Tighten pipe clip (1).
2
41090-1
z Mount high pressure pipes.

z Screw on union nuts.
Attention!
Install injection pipes without tension!
z Mount pipe clamp (2).
z Fasten screw (1).
41405-0
z Tighten union nuts (1) with special wrench.

28 Nm
41404-0
01/2008
3/6
16370-001
W 06-07-03
D 2009

9 Nm
from faults.
1
6
41405-1
01/2008
4/6
16370-001
W 06-07-03
D 2009
Technical Data
ID no.
Name
Air suction intake pipe on cylinder
A06 030
head
A07 003
pump
A07 006 Injection lines, fastening, pipe clip
Screw type
M8x70
Notes / Remark
Observe tightening
sequence.
Value
27 Nm
M12x1.5
28 Nm
M6x10-8.8
9 Nm
01/2008
5/6
16370-001
W 06-07-03
D 2009
01/2008
6/6
16370-001
W 06-07-03
TD 2009
W 06-09-06
W 07-04-01
Special tools:
Attention!
on the fuel system.
Fitting compound
DEUTZ S1
Remove charge air line

z Remove fuel injector.
W 07-04-01
z Remove the exhaust gas return valve.
W 06-09-06
z Remove gasket.
41315-0
01/2008
1/6
16371-001
W 06-07-03
TD 2009

6
41300-0
41316-0

1
41317-0
01/2008
2/6
16371-001
W 06-07-03
TD 2009
6
41318-0
Install charge air line

z Mount gasket (1).
41318-0
z Mount charge air line (1).

27 Nm
41317-1
01/2008
3/6
16371-001
W 06-07-03
TD 2009

27 Nm
Attention!
Install fuel pipe tension free.
6
41316-0
41254-0

1
41300-1
01/2008
4/6
16371-001
W 06-07-03
TD 2009
21 Nm
z Install the exhaust gas return valve
W 06-09-06
z Install the fuel injector.
W 07-04-01
6
41315-0
01/2008
5/6
16371-001
W 06-07-03
TD 2009
Technical Data
ID no.
Name
A06 030 Charge air pipe on cylinder head
Screw type
M8x45-10.9
A06 083 Charge air manifold to charge air pipe M8x20-8.8

A07 044 Fuel lines on crankcase, pipe clip
M8x12-10.9
Notes / Remark
Observe tightening
sequence.
Value
27 Nm
21 Nm
27 Nm
01/2008
6/6
16371-001
W 06-09-04
TD 2009
8190

to regulations.
manufacturer.
Removing the cooler

z Pull off hose pipes (2).
2
41417-0

z Remove cooler (3).
2
3
41418-0
01/2008
1/6
16372-001
W 06-09-04
TD 2009

z Remove gaskets (2).
1
2
6
41419-0

41420-0
Installing the cooler

z Mount gasket (1).
z Mount the exhaust gas return pipe (2).
z Fasten screws (3).
2
3
1
41421-0
01/2008
2/6
16372-001
W 06-09-04
TD 2009
z Mount gasket (1).
3
1
6
41422-0
z Mount new gaskets (1).
41423-0

Mount pipe without tension and touching

flat.

1
2
4
41424-1
01/2008
3/6
16372-001
W 06-09-04
TD 2009

20 Nm
20 Nm
25 Nm
25 Nm
4
6
41425-0

21 Nm
27 Nm
2
1
4
41425-1
z Push on hose pipes (1).

z Tighten hose clips (2).
1
41417-1
01/2008
4/6
16372-001
W 06-09-04
TD 2009
Technical Data
ID no.
A01 092
A06 059
A06 062
A06 063
A06 064
Name
Transport bracket on cylinder head
Exhaust return pipe to cooler
Exhaust return pipe to charge air pipe
A06 070
return valve
Screw type
M8x16
M8x12-10.9
M8x70-8.8
M8x20-10.9
M8x12-8.8
Notes / Remark
Value
21 Nm
25 Nm
20 Nm
20 Nm
25 Nm
M8x20-8.8
20 Nm
M8x30-10.9
27 Nm
01/2008
5/6
16372-001
W 06-09-04
TD 2009
01/2008
6/6
16372-001
W 06-09-06
TD 2009
Removing and installing the exhaust gas return valve

Removing the exhaust gas return valve

z Disconnect cable connections.
z Loosen screw (1).
z Remove gasket.
41267-0

z Remove exhaust gas return pipe (2).
z Remove gasket.
2
1
41268-0
01/2008
1/6
16373-001
W 06-09-06
TD 2009

z Remove exhaust gas return valve (2).
z Remove gasket.
1
2
1
41269-0
Installing the exhaust gas return valve

z Mount gasket (1).
z Mount exhaust gas return valve (2).
3
41269-2
z Mount gasket (1).

1
2
3
41268-3
01/2008
2/6
16373-001
W 06-09-06
TD 2009
z Mount new gasket.
6
41267-1

20 Nm
41268-1

25 Nm
41267-1
01/2008
3/6
16373-001
W 06-09-06
TD 2009

20 Nm
1
6
41268-2

27 Nm
z Connect cable.
41267-2
01/2008
4/6
16373-001
W 06-09-06
TD 2009
Technical Data
ID no.
Name
A06 059 Exhaust return pipe to cooler
A06 062 Exhaust return pipe to charge air pipe
A06 070
return valve
Screw type
M8x12-10.9
M8x70-8.8
Notes / Remark
Value
25 Nm
20 Nm
M8x20-8.8
20 Nm
M8x30-10.9
27 Nm
01/2008
5/6
16373-001
W 06-09-06
TD 2009
01/2008
6/6
16373-001
D 2009
TD 2009
Fuel system
W 07-04-01

Attention!

Extraction tool . . . . . . . . . . . . . . . . . 8310
Special bit . . . . . . . . . . . . . . . . . . . . 9123

on the fuel system.
Special tools:
Special pliers. . . . . . . . . . . . . . . . 110120
Measuring pin . . . . . . . . . . . . . . . 110180
Special wrench . . . . . . . . . . . . . . 110520
Fixing pin . . . . . . . . . . . . . . . . . . 144180
Counter support . . . . . . . . . . . . . 144190
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Removing the fuel injector pump

1
1
41271-0

Note assignment and installation position
of the injection lines.
2

41272-0
01/2008
1/12
16374-001
Fuel system
W 07-04-01
D 2009
TD 2009
z Disconnect cables.
z Unscrew union nuts (1).
6
41273-0
z Pull off hose pipe (1).

41274-0
z Unscrew screw (1) with special bit.

2
2
2
1
41275-0
01/2008
2/12
16374-001
D 2009
TD 2009
Fuel system
W 07-04-01
z Remove cap (1).

z Remove O-ring.
1
6
41276-0
z Turn crankshaft.
Attention!
The marks (1) of the fuel injector toothed
wheels and the idler gear must be in line.
The marks of the crankshaft toothed wheel,
intermediate gear and fuel injector toothed
wheel must be in line!
41277-0
The bore in the fuel injector toothed wheel

must be in line with the bore in the crankcase.
z Push the measuring pin (1) through the marking hole
into the crankcase.
41279-0
01/2008
3/12
16374-001
Fuel system
W 07-04-01
D 2009
TD 2009
z Loosen blocking screw (1).

2
z Push locking ring (2) towards larger opening.

The blocking screw can now be screwed in
further.
z Tighten blocking screw (1).

The fuel injector shaft is blocked.
Attention!
Pay attention to perfect fit of the blocking
screw and the locking ring.
z Remove measuring pin.
6
41095-0
z Mount holder (1) on V-belt pulley.
Attention!
Do not turn crankshaft.
41278-0
z Unscrew nut (1).

z Remove washer (2).
41280-0
01/2008
4/12
16374-001
D 2009
TD 2009
Fuel system
W 07-04-01
z Mount the extraction tool (1).

z Pull off the fuel injector pump toothed gear with the
extraction tool (1).
6
41281-0

z Remove fuel injector pump(2).
41145-0

41284-0
01/2008
5/12
16374-001
Fuel system
W 07-04-01
D 2009
TD 2009
Installing the fuel injector pump

1
6
41364-0
z Mount fuel injector pump (2).

27 Nm
Attention!
The blocking screw may not be loosened.
41146-0
z Push fuel injector toothed wheel (4) onto fuel injector

shaft.
3
Attention!
The marks of the fuel injector toothed
wheels and the idler gear must be in line.
z Push the measuring pin (3) through the marking hole
into the crankcase.
z Mount washer (2).
z Tighten nut (1).
10 Nm
41147-0
01/2008
6/12
16374-001
D 2009
TD 2009
Fuel system
W 07-04-01
z Loosen blocking screw (1).

z Push locking ring (2) towards smaller opening.
Attention!
Loosening the blocking screw releases the

blocking of the fuel injector shaft.
Never start the engine with the fuel injector
shaft blocked!
z Tighten blocking screw (1).

10 Nm
6
41143-0
z Remove measuring pin.

z Tighten nut (1).
81 Nm
41280-1
z Remove holder (1).

1
41278-0
01/2008
7/12
16374-001
Fuel system
W 07-04-01
D 2009
TD 2009
z Pull new round sealing ring onto cap.

z Mount cover (2).
1
27 Nm
2
1
1
6
41275-1

27 Nm
1
41275-2
z Mount the hose pipe (2).

41274-0
01/2008
8/12
16374-001
D 2009
TD 2009
Fuel system
W 07-04-01
Attention!
Install fuel pipes tension free!
z Screw on union nuts (1).
z Tighten lock nuts (1).
9 Nm
6
41273-0
Attention!
of the injection lines.

41272-0

28 Nm
1
1
41271-0
01/2008
9/12
16374-001
Fuel system
W 07-04-01
D 2009
TD 2009

9 Nm
from faults.
6
41272-1
01/2008
10/12
16374-001
D 2009
TD 2009
Fuel system
W 07-04-01
Technical Data
ID no.
Name
tion pump
tion pump
A04 022 Cap on gearcase cover
A07 003
A07 006
A07 012
A07 013
A07 015
01/2008

pump
Injection lines, fastening, pipe clip
Injection pump on crankcase
Blocking screw on injection pump
Fuel line on injection pump
Screw type
M8x70-8.8
M8x20-8.8
Notes / Remark
Value
Stage 1:
10 Nm
Stage 2:
81 Nm
Torx screw
27 Nm
M12x1.5
28 Nm
M6x10-8.8
M8x30-10.9
9 Nm
27 Nm
10 Nm
9 Nm
1/2
11/12
16374-001
Fuel system
W 07-04-01
D 2009
TD 2009
01/2008
12/12
16374-001
D 2009
TD 2009
Fuel system
W 07-04-14

Service Bulletin
0168-17-9476
Attention!
The service for the injection pumps made
by DELPHI may only be performed by partners authorised by DEUTZ AG and/or
DELPHI partners.
01/2008
1/2
16375-001
Fuel system
W 07-04-14
D 2009
TD 2009
01/2008
2/2
16375-001
Fuel system
W 07-07-01
D 2009
Danger!

Assembly pliers. . . . . . . . . . . . . . . . 8024

Special tools:
Puller. . . . . . . . . . . . . . . . . . . . . . 110090
Special pliers. . . . . . . . . . . . . . . . 110120
Special wrench . . . . . . . . . . . . . . 110520
Extraction tool . . . . . . . . . . . . . . . 120680
Slide hammer . . . . . . . . . . . . . . . 150800
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
on the fuel system.
Fitting compound
DEUTZ AP1908
The following work procedure describes

the removal and installation of a fuel injector.
Proceed the same to remove another fuel
injector.
Removing the fuel injectors

1
41404-0
01/2008
1/8
16376-001
Fuel system
W 07-07-01
D 2009

1
6
41405-0
z Pull leak fuel lines (1) off the fuel injectors with special pliers.
41406-0
z Unscrew fuel injector (1).
Attention!

z Remove sealing ring (2).
41407-0
01/2008
2/8
16376-001
Fuel system
W 07-07-01
D 2009
Attention!
Do not damage the nozzle tip of the injector valve when removing the sealing
ring (1).
z Grip a tight sealing ring (1) with the assembly
pliers (2) and pull off, turning slightly.
z Visually inspect sealing surface.
1
6
41408-0
Removing a tightly fixed sealing ring from

the cylinder head
z Insert extraction device (1).
The holders (arrow) must sit in the bore of
the sealing ring.
41409-0
z Turn in the spindle (1) until the sealing ring is fixed to

the extraction device.
Hold extraction device against the flats.
1
41410-0
01/2008
3/8
16376-001
Fuel system
W 07-07-01
D 2009
z Mount adapter (1) and slide hammer (2) on extraction device.

z Remove tight sealing ring.
6
41411-0
Installing the fuel injector

z Mount new sealing ring (1) on fuel injector.
1
41412-0
z Screw on fuel injector (1).

z Tighten fuel injector.
68 Nm
41407-1
01/2008
4/8
16376-001
Fuel system
W 07-07-01
D 2009
z Plug leak fuel lines (1) to the fuel injectors.
6
41406-0

Attention!
z Fasten screw (1).
41405-0

28 Nm
41404-0
01/2008
5/8
16376-001
Fuel system
W 07-07-01
D 2009

9 Nm
from faults.
1
6
41405-1
01/2008
6/8
16376-001
Fuel system
W 07-07-01
D 2009
Technical Data
ID no.
Name
A07 003
pump
Screw type
M22
Notes / Remark
Value
68 Nm
M12x1.5
28 Nm
M6x10-8.8
9 Nm
01/2008
7/8
16376-001
Fuel system
W 07-07-01
D 2009
01/2008
8/8
16376-001
Fuel system
W 07-07-01
TD 2009
Danger!

Assembly pliers. . . . . . . . . . . . . . . . 8024

Special tools:
Puller. . . . . . . . . . . . . . . . . . . . . . 110090
Special pliers. . . . . . . . . . . . . . . . 110120
Special wrench . . . . . . . . . . . . . . 110520
Extraction tool . . . . . . . . . . . . . . . 120690
Slide hammer . . . . . . . . . . . . . . . 150800
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Attention!
on the fuel system.
Fitting compound
DEUTZ AP1908
The following work procedure describes

the removal and installation of a fuel injector.
Proceed the same to remove another fuel
injector.
Removing the fuel injectors

1
1
41271-0
01/2008
1/8
16377-001
Fuel system
W 07-07-01
TD 2009

2
6
41272-0
z Pull leak fuel lines off the fuel injectors with special
pliers.
41285-0

1
z Remove clamping shoe (2).
z Pull out fuel injector (3).
Attention!
Up to two sealing rings per fuel injector
may be installed depending on the version.

z Visually inspect sealing surface.
41097-0
01/2008
2/8
16377-001
Fuel system
W 07-07-01
TD 2009
Removing stuck fuel injectors
z Assembly sliding hammer (1) and puller (2).
z Tighten lock nut (3).
6
41360-0
z Mount sliding hammer on fuel injector.

z Screw on lock nut (1).
z Pull out stuck fuel injector.
41286-0
Attention!
Do not damage the nozzle tip of the injector valve when removing the sealing
ring (1).
z Grip a tight sealing ring (1) with the assembly
pliers (2) and pull off, turning slightly.
1
2
46846-0
01/2008
3/8
16377-001
Fuel system
W 07-07-01
TD 2009
6
00000-0
Removing a tightly fixed sealing ring from

the cylinder head
z Insert extraction device (1).
The holders (arrow) must sit in the bore of
the sealing ring.
41354-0
z Turn in the spindle (1) until the sealing ring is fixed to

the extraction device.
Hold extraction device against the flats.
41366-0
01/2008
4/8
16377-001
Fuel system
W 07-07-01
TD 2009
z Mount adapter (1) and slide hammer (2) on extraction device.
z Remove tight sealing ring.
6
41367-0
Installing the fuel injector

z Mount new O-ring (1).
z Coat the O-ring with fitting compound.
1
41368-0
z Mount new sealing ring (1) on fuel injector.
Attention!
Up to two sealing rings per fuel injector
may be installed depending on the version.
See spare parts documentation.
41098-1
01/2008
5/8
16377-001
Fuel system
W 07-07-01
TD 2009
z Insert fuel injector (3).

The leak fuel connection faces the exhaust
pipe.
z Mount clamping shoe (2).
Note installation position of the clamping

shoe.
35 Nm
6
41097-1
z Plug hose pipes (1) to the fuel injectors.
41289-0

Attention!
2

41272-0
01/2008
6/8
16377-001
Fuel system
W 07-07-01
TD 2009
28 Nm
1
1
6
41271-0

9 Nm
from faults.
41272-1
01/2008
7/8
16377-001
Fuel system
W 07-07-01
TD 2009
Technical Data
ID no.
Name
A07 003
pump
Screw type
M8x35-10.9
Notes / Remark
Torx screw
Value
35 Nm
M12x1.5
28 Nm
M6x10-8.8
9 Nm
01/2008
8/8
16377-001
D 2009
TD 2009
Fuel system
W 07-10-08

User notes
Operation manual
Special tools:
Special wrench . . . . . . . . . . . . . . 170050
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Danger!
Attention!
on the fuel system.
Removing the fuel filter console

z Loosen water drainage screw (1).
Collect draining water and dispose of properly.
z Unscrew fuel filter (2) with special wrench.
Collect draining fuel and dispose of according to regulations.
2
1
41346-0
01/2008
1/4
16378-001
Fuel system
W 07-10-08
D 2009
TD 2009
z Unscrew hollow screw (1).

z Remove sealing rings.
z Unscrew fuel pipes (2).
z Pull off fuel return line.

2
2
6
41361-0

z Remove fuel filter console (2).
1
2
41347-0
Installing the fuel filter console

z Install the fuel filter console (2).
1
41 Nm
2
41347-0
01/2008
2/4
16378-001
D 2009
TD 2009
Fuel system
W 07-10-08
z Mount fuel pipes.

z Tighten hollow screw (1) with new sealing rings.
21 Nm
z Tighten union nuts (2).

9 Nm
z Mount fuel return line.
Check fuel lines and renew if necessary.

of the fuel lines.
2
6
41361-0
z Lightly oil gasket on new fuel filter.

z Screw on fuel filter by hand.
The seal must fit evenly.
z Tighten the fuel filter by another half turn (tightening

torque see fuel filter print).
41346-1
01/2008
3/4
16378-001
Fuel system
W 07-10-08
D 2009
TD 2009
Technical Data
ID no.
Name
A07 019
fuel filter console
A07 084 Fuel line to fuel filter console
A07 087 Fuel filter console to crankcase
Screw type
Notes / Remark
Value
1/2
9 Nm
M10x1.5
Hollow screw
M10x25-10.9
21 Nm
41 Nm
01/2008
4/4
16378-001
D 2009
TD 2009
Fuel system
W 07-11-01

User notes
Operation manual
Special tools:
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Danger!
Attention!
on the fuel system.
Removing the fuel supply pump

Danger!
z Unscrew union nuts (1).

z Remove fuel pipe.
1
41342-0
01/2008
1/4
16379-001
Fuel system
W 07-11-01
D 2009
TD 2009

z Remove fuel supply pump (2).
z Remove adapter (3).
z Remove pump tappet.
2
1
6
41343-0
41344-0
Installing the fuel supply pump

41344-1
01/2008
2/4
16379-001
D 2009
TD 2009
Fuel system
W 07-11-01
6
41345-0
z Turn crankshaft.
z Install pump tappet.
The pump plunger must touch the base
circle of the camshaft.
2
z Mount adapter (3).

z Mount fuel supply pump (2).

27 Nm
3
41343-0
z Mount fuel pipe.

z Tighten lock nuts (1).
9 Nm
Bleed the fuel system via the manual fuel
pump on the fuel pre-filter according to the
operation manual.
41342-0
01/2008
3/4
16379-001
Fuel system
W 07-11-01
D 2009
TD 2009
Technical Data
ID no.
Name
A07 019
fuel filter console
A07 024 Fuel supply pump on crankcase
Screw type
Notes / Remark
Value
1/2
9 Nm
M8x55-10.9
27 Nm
01/2008
4/4
16379-001
D 2009
TD 2009
Lube oil system

W 08-04-05

W 02-04-01
W 04-04-09
W 08-04-06
to regulations.
Removing the lubricating oil pump

W 04-04-09
z Remove intermediate gear wheel.
W 02-04-01
z Remove oil suction pipe
W 08-04-06
41106-2

z Remove lubricating oil pump (2).
1
2
41107-0
01/2008
1/4
16380-001
Lube oil system

W 08-04-05
D 2009
TD 2009
Installing the lubricating oil pump

z Insert lubricating oil pump (2).

4 Nm + 9 Nm
1
2
41107-0

W 08-04-06
z Install intermediate gear wheel.
W 02-04-01
W 04-04-09
41106-2
01/2008
2/4
16380-001
D 2009
TD 2009
Lube oil system

W 08-04-05
Technical Data
ID no.
Name
A08 010 Lubricating oil pump on crankcase
Screw type
M6x25-8.8
Notes / Remark
Value
4 Nm + 9 Nm
01/2008
3/4
16380-001
Lube oil system

W 08-04-05
D 2009
TD 2009
01/2008
4/4
16380-001
D 2009
TD 2009
Lube oil system

W 08-04-06

W 08-04-07
Removing the oil suction pipe

z Remove lubricating oil pan.
W 08-04-07
41108-0

z Remove oil suction pipe (2).
z Remove O-ring (3).
3
1
2
41109-0
01/2008
1/4
16381-001
Lube oil system

W 08-04-06
D 2009
TD 2009
Installing the oil suction pipe

z Lightly oil O-ring (3).
z Mount oil suction pipe (2).
41 Nm
3
1
2
41109-0
z Install lubricating oil pan.

W 08-04-07
41108-0
01/2008
2/4
16381-001
D 2009
TD 2009
Lube oil system

W 08-04-06
Technical Data
ID no.
Name
Screw type
A08 016 Oil suction pipe, holder on crankcase M10x80-8.8
Notes / Remark
Value
41 Nm
01/2008
3/4
16381-001
Lube oil system

W 08-04-06
D 2009
TD 2009
01/2008
4/4
16381-001
D 2009
TD 2009
Lube oil system

W 08-04-07

Operation manual

to regulations.
Observe the appropriate operating instructions for emptying and filling the engine.
Removing the lubricating oil pan

z Unscrew locking screws (1).
Collect lubricating oil and dispose of according to regulations.
z Insert new sealing ring.
z Tighten locking screws (1).
39 Nm
41110-1

z Remove strips (2).
z Remove strips (3).

3
z Remove lubricating oil pan.

z Remove gasket.
41111-1
01/2008
1/4
16382-001
Lube oil system

W 08-04-07
D 2009
TD 2009
Installing the lubricating oil pan

z Grease lubricating oil pan (arrows).
z Mount new gasket.

z Mount lubricating oil pan.
Attention!
Do not move the gasket when mounting
the lubricating oil pan.
z Mount strips (1).
z Tighten screws (arrows).
z Fasten all screws.
6
41112-1

7
32 Nm
17
18
19
Representation: 4-cylinder engine

9
20
26
21
25
22
24
23
12
16
11
10
13
14
15
41259-0
z Fill in lubricating oil according to operating manual.
max.
min.
41142-0
01/2008
2/4
16382-001
D 2009
TD 2009
Lube oil system

W 08-04-07
Technical Data
ID no.
Name
Screw type
A03 030 Lubricating oil pan on crankcase
M8x20-8.8
A03 031 Locking screw on lubricating oil pan
M14x14
Notes / Remark
Observe tightening
sequence.
Use new Cu sealing
ring.
Value
32 Nm
39 Nm
01/2008
3/4
16382-001
Lube oil system

W 08-04-07
D 2009
TD 2009
01/2008
4/4
16382-001
D 2009
TD 2009
Lube oil system

W 08-08-02

Operation manual
Special tools:
Special wrench . . . . . . . . . . . . . . 170050

to regulations.
manufacturer.
Removing the lubricating oil cooler

z Remove lubricating oil filter (1) with special
wrench 170050.
z Drain lubricating oil, collect and dispose of according
to regulations.
2
1
41291-0

z Drain, collect and dispose of coolant according to
regulations.
41290-0
01/2008
1/6
16383-001
Lube oil system

W 08-08-02
D 2009
TD 2009

z Remove lubricating oil cooler (2).
41292-0
41293-0
Removing the adapter

z Remove adapter (1).
2
1
41295-0
01/2008
2/6
16383-001
D 2009
TD 2009
Lube oil system

W 08-08-02
6
41296-0
Installing the adapter

1
41297-0
z Mount sealing ring (2).

z Fit new sealing rings (1).
2
41298-0
01/2008
3/6
16383-001
Lube oil system

W 08-08-02
D 2009
TD 2009
z Mount adapter (1).

z Tighten hollow screw (2).
41 Nm
2
1
41295-0
Installing the lubricating oil cooler

1
41294-0
z Mount lubricating oil cooler (2).

z Tighten hollow screw (1).
41 Nm
2
41292-0
01/2008
4/6
16383-001
D 2009
TD 2009
Lube oil system

W 08-08-02

6
41290-0

z Fasten hose clips with hose clip pliers.
41291-1
z Lightly oil sealing ring on new oil filter cartridge.

z Screw on lubricating oil filter (1) by hand.
Hand tighten
1
41291-2
01/2008
5/6
16383-001
Lube oil system

W 08-08-02
D 2009
TD 2009
Technical Data
ID no.
Name
Lubricating oil filter on lubricating oil
A08 001
cooler
A08 003 Adapter on gearcase cover
A08 051 Lubricating oil cooler on adapter
Screw type
M14x1.5
3/4
M22x1.5
Notes / Remark
Oil gasket lightly.
See operating manual
Value
Hand tighten
41 Nm
41 Nm
01/2008
6/6
16383-001
D 2009
TD 2009
Lube oil system

W 08-11-08

User notes
Special tools:
Long socket wrench insert . . . . . 110700
Plugs/caps . . . . . . . . . . . . . . . . . 170160
Pay attention to utmost cleanliness when

working on the lube oil system.
Observe the safety regulations and national specifications for handling lube oils.
Removing the oil pressure switch

z Unscrew oil pressure switch (1).
Collect lubricating oil and dispose of according to regulations.
41340-0
41341-0
01/2008
1/4
16384-001
Lube oil system

W 08-11-08
D 2009
TD 2009
Installing the oil pressure switch

z Clean components.
6
41341-0
z Tighten the oil pressure switch (1) with the socket

wrench insert.
M10x1
20 Nm
M12x1.5 / M14x1.5
50 Nm
z Connect cable.
Ensure that the connection is perfect.
z Fill in lubricating oil according to operating manual.
41340-0
01/2008
2/4
16384-001
D 2009
TD 2009
Lube oil system

W 08-11-08
Technical Data
ID no.
Name
Screw type
M10x1
M12x1
M14x1.5
Notes / Remark
Value
20 Nm
50 Nm
01/2008
3/4
16384-001
Lube oil system

W 08-11-08
D 2009
TD 2009
01/2008
4/4
16384-001
D 2009
TD 2009
Lube oil system

W 08-11-10
Removing and installing the oil pressure regulating valve

W 04-04-09

to regulations.
Removing the oil pressure regulating

valve
W 04-04-09
41115-0
z Unscrew oil pressure regulating valve.

41116-0
01/2008
1/4
16385-001
Lube oil system

W 08-11-10
D 2009
TD 2009
Installing the oil pressure regulating valve

z Insert oil pressure regulating valve.
z Tighten oil pressure control valve.
21 Nm
6
41116-0

W 04-04-09
41115-0
01/2008
2/4
16385-001
D 2009
TD 2009
Lube oil system

W 08-11-10
Technical Data
ID no.
Name
Oil pressure control valve on crankA08 098
case
Screw type
3/8
Notes / Remark
Value
21 Nm
01/2008
3/4
16385-001
Lube oil system

W 08-11-10
D 2009
TD 2009
01/2008
4/4
16385-001
D 2009
TD 2009
Cooling system
W 09-07-08

W 12-02-02
W 13-02-03
Operation manual
to regulations.
The appropriate documentation of the
vehicle/equipment manufacturer should be
observed for emptying and filling the cooling system.
Removing coolant pump

z Drain, collect and dispose of coolant according to
regulations.
z Loosen screws (1).
41332-0

z Hold nut (2).
z Press generator in direction of arrow.

1
z Remove V-belt.
2
1
41323-0
01/2008
1/6
16386-001
Cooling system
W 09-07-08
D 2009
TD 2009

z Remove V-belt pulley (2).
6
41333-0

Collect and dispose of coolant according to
regulations.
2
41334-0

Collect and dispose of coolant according to
regulations.
z Remove coolant pump (1).
z Remove gasket.
1
2
41335-0
01/2008
2/6
16386-001
D 2009
TD 2009
Cooling system
W 09-07-08
6
41336-0
Installing coolant pump

z Mount gasket (1).
41337-0
z Mount coolant pump (1).

z Fasten all screws (2).
Note different screw lengths.
1
2
41335-0
01/2008
3/6
16386-001
Cooling system
W 09-07-08
D 2009
TD 2009
27 Nm
Tightening order:
screw (1), then screw (2), then the other
screws in any order.
41335-3

z Fix the hose clip with the hose clip pliers.
41334-0
z Mount V-belt pulley (2).

z Mount V-belt.
41333-0
01/2008
4/6
16386-001
D 2009
TD 2009
Cooling system
W 09-07-08

1
V-belt is clamped.
4

21 Nm
z Hold nut (2).
21 Nm
21 Nm
3
41323-1

9 Nm
z Check V-belt tension.
1
W 13-02-03
z Fill cooling system according to the operating manual.
41332-0
01/2008
5/6
16386-001
Cooling system
W 09-07-08
D 2009
TD 2009
Technical Data
ID no.
A09 010
A12 046
A13 012
A13 015
A13 016
Name
Screw type
M8x70-8.8
Coolant pump on gearcase cover
M8x30-10.9
V-belt pulley on coolant pump
M6x10-8.8
Generator on gearcase cover
M8x120-8.8
Generator on clamping bracket
M8x20-8.8
Clamping bracket on gearcase cover M8x16-8.8
Notes / Remark
Observe tightening
sequence.
Value
27 Nm
9 Nm
21 Nm
21 Nm
21 Nm
01/2008
6/6
16386-001
D 2009
TD 2009
Cooling system
W 09-08-01

Thermometer
W 09-08-02
Danger!
Risk of injury!
Hot water and hot thermostat.
Checking thermostat
z Remove thermostat.
W 09-08-02
41120-0
z Measure beginning of stroke, dimension (a).
z Note measured value, dimension (a).
41121-0
01/2008
1/4
16387-001
Cooling system
W 09-08-01
D 2009
TD 2009
z Heat up the thermostat in the water bath.

In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the thermostat.
The water should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place
faster than 1C/min. Otherwise the beginning of opening will be delayed accordingly.
z Determine beginning of opening.
86 - 90 C
6
41123-0
z Measure end of stroke, dimension (b).
z Note measured value, dimension (b).
41122-0
z Determine stroke.
Calculation example
Desired:
Stroke
Given:
Measured:
Beginning of stroke, dimension (a)
(a) = 31.2 mm
End of stroke, dimension (b)
(b) = 40.2 mm
Calculation:
Dimension (b) - dimension (a)
40.2 mm - 31.2 mm
Result:
= stroke
= 9 mm
z Compare result with setpoint value.

Nominal value stroke travel:
at least 9 mm
41122-0
01/2008
2/4
16387-001
D 2009
TD 2009
Cooling system
W 09-08-01
z Install thermostat.
W 09-08-02
6
41120-0
01/2008
3/4
16387-001
Cooling system
W 09-08-01
D 2009
TD 2009
Technical Data
ID no.
P09 11
P09 13
Name
Thermostat, start of opening
Thermostat, stroke distance
Value
86 - 90 C
at least 9 mm
01/2008
4/4
16387-001
D 2009
TD 2009
Cooling system
W 09-08-02

W 09-08-01

to regulations.
The appropriate documentation of the
vehicle/equipment manufacturer should be
observed for emptying and filling the cooling system.
Removing the thermostat

z Remove gasket.
1
41267-0

z Remove exhaust gas return pipe (2).
z Remove gasket.
2
1
41268-0
01/2008
1/6
16388-001
Cooling system
W 09-08-02
D 2009
TD 2009

1
6
41326-1

z Remove outlet nozzle (2).
41327-0

z Remove thermostat (2).
z Check thermostat.
W 09-08-01
1
41328-0
01/2008
2/6
16388-001
D 2009
TD 2009
Cooling system
W 09-08-02
Installing the thermostat

6
41329-0
z Insert thermostat (1).
1
41330-0
z Mount outlet nozzle (2).

z Fasten screw (1).

1
41327-0
01/2008
3/6
16388-001
Cooling system
W 09-08-02
D 2009
TD 2009

z Tighten hose clip (2).
1
6
41326-1
z Mount new gasket.

2
1
41268-0
z Mount new gasket.

z Fasten screw (1).
41267-0
01/2008
4/6
16388-001
D 2009
TD 2009
Cooling system
W 09-08-02

20 Nm
6
41268-1

25 Nm
27 Nm
1
41267-0

27 Nm
41331-0
01/2008
5/6
16388-001
Cooling system
W 09-08-02
D 2009
TD 2009
Technical Data
ID no.
Name
A06 059 Exhaust return pipe to cooler
A06 070
return valve
Screw type
M8x12-10.9
Notes / Remark
Value
25 Nm
M8x20-8.8
20 Nm
M8x30-10.9
27 Nm
01/2008
6/6
16388-001
D 2009
TD 2009
Cooling system
W 09-12-01

to regulations.
manufacturer.
Removing temperaure transmitter

z Unscrew temperature transmitter (1).
41338-0
41339-0
01/2008
1/4
16389-001
Cooling system
W 09-12-01
D 2009
TD 2009
Installing temperature transmitter

z Clean components.
z Insert gasket (1) with packing compound.
6
41339-1
z Tighten temperature transmitter (1).

4 Nm
z Connect cable.
Ensure that the connection is perfect.
41338-0
01/2008
2/4
16389-001
D 2009
TD 2009
Cooling system
W 09-12-01
Technical Data
ID no.
Name
Temperature transmitter on cylinder
A09 031
head
Screw type
Notes / Remark
Insert gasket with
packing compound.
Value
4 Nm
01/2008
3/4
16389-001
Cooling system
W 09-12-01
D 2009
TD 2009
01/2008
4/4
16389-001
D 2009
TD 2009
Other components
W 12-02-02

V-belt tension measuring
device . . . . . . . . . . . . . . . . . . . . . . . 8115
W 12-02-02
Special tools:
Blocking tool . . . . . . . . . . . . . . . . 144210
Attention!
Only test / tighten / renew V-belts when the
engine is not running.
The V-belt tension of new V-belts must be
checked after they have been running for
15 minutes.
Removing the V-belt, V-belt pulley

1

z Hold nut (2).

z Remove V-belt.
2
1
41323-0
z Insert blocking tool (1).

2
1
41352-0
01/2008
1/4
16390-001
Other components
W 12-02-02
D 2009
TD 2009

z Remove V-belt pulley (2).
6
41325-0
Installing the V-belt, V-belt pulley

z Mount V-belt pulley (2).
300 Nm
41325-0

z Mount V-belt.
z Check V-belt tension.
W 12-02-02
2
1
41352-0
01/2008
2/4
16390-001
D 2009
TD 2009
Other components
W 12-02-02
Technical Data
ID no.
Name
A12 031 V-belt pulley on crankshaft

M20x55-10.9
Value
300 Nm
01/2008
3/4
16390-001
Other components
W 12-02-02
D 2009
TD 2009
01/2008
4/4
16390-001
D 2009
TD 2009
Other components
W 12-06-01

Special tools:
Blocking tool . . . . . . . . . . . . . . . . 144210
Removing the flywheel

2
1
41352-0
41362-0
01/2008
1/4
16391-001
Other components
W 12-06-01
D 2009
TD 2009

z Remove flywheel.
2
1
6
41352-0
Installing the flywheel

z Mount flywheel.
z Turn in new screws (1).
41362-0

2
1
41352-0
01/2008
2/4
16391-001
D 2009
TD 2009
Other components
W 12-06-01
See graphic for tightening sequence.

3
1 6
z Tighten all screws.

96 Nm
5 2 4
41181-1

2
1
41352-0
01/2008
3/4
16391-001
Other components
W 12-06-01
D 2009
TD 2009
Technical Data
ID no.
Name
A12 001 Flywheel on crankshaft

M12x50-10.9 Use new screws.
Value
96 Nm
01/2008
4/4
16391-001
D 2009
TD 2009
Electrical system
W 13-02-03

(V-belt drive)
V-belt tension measuring
device . . . . . . . . . . . . . . . . . . . . . . . 8115
Operation manual
Attention!
Only test / tighten / renew V-belts when the
engine is not running.
The V-belt tension of new V-belts must be
checked after they have been running for
15 minutes.
Removing the generator

z Disconnect the battery.
z Remove cable from generator.
41135-1

z Hold nut (2).

1
z Remove V-belt.
2
1
41323-0
01/2008
1/6
16392-001
Electrical system
W 13-02-03
D 2009
TD 2009

z Hold nut (2).
z Remove generator.
1
1
41535-0
41324-0
Installing the generator

z Mount generator.
z Hold nut (2).

z Mount V-belt.
2
1
41535-0
01/2008
2/6
16392-001
D 2009
TD 2009
Electrical system
W 13-02-03

1
V-belt is clamped.
4

21 Nm
z Hold nut (2).
21 Nm
21 Nm
3
41323-1
z Remove cable from generator.

z Connect the battery.
41135-1
Check V-belt tension with V-belt tension

measuring device
z Lower indicator arm (1) into V-belt tension measuring
device.
z Mount V-belt tension measuring device on V-belt.
41129-0
01/2008
3/6
16392-001
Electrical system
W 13-02-03
D 2009
TD 2009
z Press the V-belt measuring device against the V-belt

with the button (1) until you hear it click.
z Read measured value at the intersection (arrow) of
the indicator arm and scale.
First assembly:
450 N
Check after running for 15 minutes under load:
+20
300 20 N
Note different units on the scale.
z If the nominal value is not reached, the tensioning

process must be repeated.
1
41130-0
01/2008
4/6
16392-001
D 2009
TD 2009
Electrical system
W 13-02-03
Technical Data
ID no.
P12 11
Name
V-belt tension
P12 21
V-belt tension
First assembly
Check after 15 minutes running
under load.
Value
450 N
300 +20
20 N
ID no.
A13 012
A13 015
A13 016
Name
Generator on gearcase cover
Generator on clamping bracket
Clamping bracket on gearcase cover
Screw type
M8x120-8.8
M8x20-8.8
M8x16-8.8
Notes / Remark
Value
21 Nm
21 Nm
21 Nm
01/2008
5/6
16392-001
Electrical system
W 13-02-03
D 2009
TD 2009
01/2008
6/6
16392-001
D 2009
TD 2009
Electrical system
W 13-03-02

Removing the starter

z Disconnect the battery's negative terminal.
z Disconnect cables.
z Remove starter.
1
41138-1
Installing the starter

z Insert starter.
41 Nm
z Connect cables.
9 Nm
Note the assignment of the terminal designations.

z Connect the battery's negative terminal.
41139-2
01/2008
1/2
16393-001
Electrical system
W 13-03-02
D 2009
TD 2009
Technical Data
ID no.
Name
A13 001 Starter on connection housing
A13 071 Cable (terminal 30) to starter
Screw type
M10x45-8.8
M8
Notes / Remark
Value
41 Nm
9 Nm
01/2008
2/2
16393-001
D 2009
TD 2009
Electrical system
W 13-06-01

Removing the glow plugs

z Disconnect the battery.
z Unscrew nuts (1).
z Remove connecting rail (2).
1
41319-0
z Unscrew charge air pressure switch (1).
41320-0
01/2008
1/4
16394-001
Electrical system
W 13-06-01
D 2009
TD 2009
z Unscrew glow plugs (1).
6
41321-0
41322-0
Installing the glow plugs

z Tighten glow plugs (1).
15 Nm
1
41321-0
01/2008
2/4
16394-001
D 2009
TD 2009
Electrical system
W 13-06-01
z Tighten charge air pressure switch (1).

20 Nm
6
41320-0
z Mount the connecting rail (2).

z Tighten nuts (1).
2.5 Nm
z Connect the battery.
1
41319-0
01/2008
3/4
16394-001
Electrical system
W 13-06-01
D 2009
TD 2009
Technical Data
ID no.
Name
A13 033 Connecting rail to glow plug
Charge air pressure switch in charge
A13 046
air line
Screw type
M10
M4
M10
Notes / Remark
Locking nut
Value
15 Nm
2.5 Nm
20 Nm
01/2008
4/4
16394-001
D 2009
TD 2009
Standard tools
Standard tools
7
01/2008
1/6
16395-001
D 2009
TD 2009
Standard tools
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Tel.: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com
01/2008
2/6
16395-001
D 2009
TD 2009
Standard tools
8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
35410-3
7
8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe
39426-1
8024
Assembly pliers
Removing valve shaft seals
37509-2
01/2008
3/6
16395-001
D 2009
TD 2009
Standard tools
8115
V-belt tension measuring device
150 to 600 N
Check V-belt tension
35416-3
7
8189
Torx tool set
Contents of case:
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
39432-1
8190
Rotation angle disc
with solenoid
42528-1
01/2008
4/6
16395-001
D 2009
TD 2009
Standard tools
8198
Pricker
Removing rotary shaft lip seal
43206-1
7
8200
Counter support
Removing the camshaft bearing
41162-1
9017
Assembly lever
e. g. removing and installing valves
37511-2
01/2008
5/6
16395-001
D 2009
TD 2009
Standard tools
9123
Special bit
25 mm long
for safety screw on injection pump toothed gear cap
39435-1
01/2008
6/6
16395-001
D 2009
TD 2009
Special tools
Special tools
01/2008
1/14
16396-001
D 2009
TD 2009
Special tools
Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Tel.: +49 (0) 2191 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com
01/2008
2/14
16396-001
D 2009
TD 2009
Special tools
100170
Connector
(in conjunction with compression pressure tester 8005)
(in conjunction with clamping claw 100210)
39400-1
100210
Clamping claw
(in conjunction with adapter 100170)
41363-0
100220
Connector
(in conjunction with compression pressure tester 8005)
40400-0
01/2008
3/14
16396-001
D 2009
TD 2009
Special tools
100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
35424-1
100750
Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection
39402-2
103220
Special pliers
for removing the roller tappet
43175-0
01/2008
4/14
16396-001
D 2009
TD 2009
Special tools
110090
Puller
(in connection with sliding hammer 150800)
Removing fuel injector
35433-2
110120
Special pliers
Disassembly/assembly for leak fuel pipes
41369-0
110180
Measuring pin
Positioning the fuel injector pump toothed wheel
41171-0
01/2008
5/14
16396-001
D 2009
TD 2009
Special tools
110520
Special wrench
Wrench size 16 mm,
Removing and installing injection pipes
35436-0
110540
Extraction tool
Pull off injection pump toothed gear
41190-0
110700
Socket wrench insert
long version
43198-2
01/2008
6/14
16396-001
D 2009
TD 2009
Special tools
110901
Disassembly tool
Removing and installing the O-rings
45950-1
120690
Puller
(in connection with sliding hammer 150800)
45111-0
120900
Support bracket
pivoting
Clamping cylinder head
35438-3
01/2008
7/14
16396-001
D 2009
TD 2009
Special tools
120910
Base plate
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)
35439-3
121420
Assembly sleeves
Set of assembly sleeves for valve shaft seal
43210-0
121430
Assembly tool
Mounting valve shaft seal
37614-2
01/2008
8/14
16396-001
D 2009
TD 2009
Special tools
130300
Universal piston ring pliers
Removing and installing the piston rings
43021-0
130510
Piston ring compressor
Piston diameter 90 mm
39408-1
142780
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
41168-0
01/2008
9/14
16396-001
D 2009
TD 2009
Special tools
142790
Assembly tool
Installing crankshaft sealing ring
41169-0
143500
Internal extractor
Removing the camshaft bearing
(in conjunction with holder 8200)
41169-0
143860
Disassembly/assembly tool.
Removing and installing main bearing
Crankcase
41164-1
01/2008
10/14
16396-001
D 2009
TD 2009
Special tools
143870
Disassembly/assembly tool.
Removing and installing main bearing
Main bearing housing
41165-1
143890
Assembly tool
Installing the camshaft bearing
41166-2
144180
Fixing pin
Fixing the flywheel
41163-0
01/2008
11/14
16396-001
D 2009
TD 2009
Special tools
144190
Counter support
Hold crankshaft on the V-belt pulley.
41370-0
144200
Blocking tool
Blocking gear drive
41188-0
144240
Blocking tool
Blocking flywheel
41371-0
01/2008
12/14
16396-001
D 2009
TD 2009
Special tools
150800
Slide hammer
35449-2
170050
Special wrench
Unscrewing the filter cartridges
37629-2
170160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
43663-0
01/2008
13/14
16396-001
D 2009
TD 2009
Special tools
6067
Assembly block
Engine clamping, one-sided
35451-2
6067 200
Clamping bracket
consisting of:
1 clamping holder 6067 201 left,
1 clamping holder 6067 202 right
(in conjunction with assembly block 6067)
Engine clamping, one-sided
41187-0
6068
Engine lifting device
Load (2000 kg), 3-point suspension, spindle clamp,
cross member, chains and hooks
43184-0
01/2008
14/14
16396-001

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Workshop Manual

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The engine company.

Testing and setting data

Job card overview

z Repair of the engine must correspond to its use

z Make sure that this documentation is available to

We are at your service for any questions you may

z Maximum economy, reliability and long life is only

Maintenance and care are the only way the engine

The documentation of the workshop manual has

3.2.1 Accident prevention and safety regulations

The maintenance work described in the operation

z for the personnel:

Only deploy trained personnel to do repairs

Injection lines and high pressure fuel lines

3.3 Operation manual and workshop

Do not place hands near to a leak in the high

To structure the information to suit the user, the

Even if no leaks are discernible on the high

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

Smoking is strictly prohibited when working on

Do not work near to sparks and flames.

3.2.2 Disposal regulations

3.4 Job cards

3.4.2 Structure of a job card

The job cards are divided in the workshop manual

3.4.1 Numbering of job cards

01 ... Cylinder head

04 ... Engine control system

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

05 ... Speed governing

06 ... Exhaust system / Charging

4. Job card number or topic

07 ... Fuel system

5. Title of job card

08 ... Lube oil system

6. Reference to other job cards

09 ... Cooling system

10 ... Compressed air system

11 ... Monitoring system

9. DEUTZ internal creation number

12 ... Other components

13 ... Electrical system

11.Date of issue of job card

z W 02-04-01: Component grouping

z W 02-04-01: Consecutive number

3.5 Explanation of symbols

Testing and setting data

looking onto the flywheel

Valve stem, diameter, inlet

Piston pin bore

Piston ring 1, joint clearance

Piston ring 2, joint clearance

Piston ring 3, joint clearance

Piston ring 1, axial clearance

Cylinder, diameter, inside

Camshaft, bearing pin, diameter

Piston, diameter, standard

Measuring point 1 = height 10 mm 89,400 +0.167

Piston, diameter, standard

Measuring point 2 = height 44 mm 89,400 +0.008

Piston, diameter, standard

Measuring point 3 = height 65 mm 89,400 0.175