Deutz 2013 TCD 2V Workshop Manual Level3

Workshop Manual
competence level 3
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TCD 2013 2V
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 2916 en
Regarding copyright questions and licensing agreements

please contact :
VE-FI, Mr. Sonntag
Phone.: + 49 (0) 221 822-3053
E-Mail: sonntag.j@deutz.com
DEUTZ AG
Service Information Systems
Ottostrae 1
D-51149 Kln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
Internet: www.deutz.com
E-Mail: info@deutz.com
The engine company.
Printed in Germany
All rights reserved
1st Edition 02/2010
Order No. 0312 2916 en
Workshop Manual
TCD 2013 2V
0312 2916 en
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.
DEUTZ engines
1
Foreword
General
User notes
3.1
3.2
3.3
3.4
3.5
Testing and setting data

Tightening specifications
Job card overview

5.1
5.2
02/2010
General
Specifications
Operating manual and workshop manual
Job cards
Explanation of symbols
Technical data
4.1
4.2
Table of contents
Sorted alphabetically
Sorted numerically
Job cards
Commercial tools
Special tools
1/2
OBJ_DOKU-21737-001.fm
Table of contents
02/2010
DEUTZ engines
2/2
DEUTZ engines
Foreword
1
05/2005
Foreword
1/4
Foreword
DEUTZ engines
05/2005
2/4
DEUTZ engines
Foreword
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!
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.
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.
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.
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.
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.
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.
Make sure that this documentation is available to

everyone involved in the operation, maintenance
and repair and that they have understood the
contents.
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.
Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and special tools and their perfect
condition.
Engine parts such as springs, clamps, elastic retaining rings etc. pose an increased risk of injury
when handled incorrectly.
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.
Maximum economy, reliability and long life is only

guaranteed when using DEUTZ original parts.
Your DEUTZ AG
05/2005
3/4
Foreword
DEUTZ engines
05/2005
4/4
DEUTZ engines
General
11/2005
General
1/4
General
DEUTZ engines
11/2005
2/4
DEUTZ engines
General
DEUTZ engines are the product of years of research

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

can satisfy the demands you make on it. Compliance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particularly heeded.
Please consult one of our service representatives
responsible for operating faults and spare parts
questions. Our trained specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.
11/2005
3/4
General
DEUTZ engines
11/2005
4/4
DEUTZ engines
User notes
02/2010
User notes
1/8
User notes
DEUTZ engines
02/2010
2/8
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 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.
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.
Among other things it generally applies that:

for the personnel:
Caution!
The rules for the prevention of accidents and the
safety regulations must be observed during maintenance work.
Only briefed personnel may operate or maintain the engine. Unauthorised persons are
prohibited access to the machine room.
Reference is made in the workshop manual job

cards to the regulations in chapter 3.2. These must
be read before working on the engine and must be
strictly followed.
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.
Wear close-fitting clothing and ear protectors

in the machine room when the engine is in operation.
Only deploy trained personnel to do repairs
and maintenance work.
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.
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.
for operation, maintenance and repairs on the
engine:
Wait 30 seconds after switching off the engine
before working on the fuel sytem.
After all work on the fuel system, it must be
bleeded - see the operation manual, chapter
"6 Fuel system.
Only start the engine when all the protective
devices have been fitted. Make sure no-one is
standing in the danger area.
Cleaning, maintenance and repair work may
only be performed with the engine at a standstill and secured against starting.
Injection lines and high pressure pipes must
not be deformed.
02/2010
3/8
User notes
DEUTZ engines
Remove loose parts (for example paint chips
from assembly work) with an industrial vacuum
cleaner or other suction device. Only suction may
be used in assembly work on the open fuel system.
Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid
draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may
be kept or operated in the same room.
Damaged injection lines and high-pressure

pipes must be renewed.
Injection lines and high pressure fuel lines
must never be connected when the engine is
running.
Do not place hands near to a leak in the high

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

caused by brake repairs or the starting of engines, should be avoided.
For work such as removal and installation on defective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.
Even if no leaks are discernible on the high

pressure fuel system, the workshop personnel
should avoid the immediate danger zone or
wear suitable protective clothing (such as protective glasses) when performing tests on the
running engine and during the first trial run.
Always stay out of range of a fuel jet, as it
could cause severe injury.
Smoking is strictly prohibited when working on
the fuel system.
No general machine tools may be operated in

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

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

dirt could be loosened (for example the bottom
part of the tipped driver cab) must be covered
with fresh clean film.
Working materials and tools must be cleaned before work. Only use tools without damage to the
chrome plating or tools which are not chromeplated.
3.2.2 Cleanliness instructions and measures

for handling the DEUTZ Common Rail
System
The DEUTZ Common Rail system used in the
DEUTZ engines consists of high-precision components which are exposed to extreme stress. Great
attention must be paid to cleanliness when working
on the fuel system due to the high precision technology.
Notes and measures to be observed during work on

the fuel system or with the fuel system open.
Only work in clean overalls.
Notes and measures to be observed before starting

work on the fuel system
Only lint-free cleaning cloths may be used for

work on the fuel system.
The fuel system must be closed. Make a visual

inspection for leaks / damage to the fuel system.

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

system closed before starting work on the fuel
system.
The engine must be dry when you start working
on the fuel system.
Blowing (dry) with compressed air is only permissible with the fuel system closed.
Do not use used cleaning fluid or test fluid for

cleaning.
When using a steam jet, first cover up the control

unit, the cable plugs, all other electrical plug connections and the generator. Also, the steam jet
may not be pointed directly at them.
Compressed air must not be used for cleaning on

the open fuel system.
Work on removed components may only be performed at a suitably equipped workbench.
Electrical plug connections must be plugged

when spraying.
02/2010
4/8
DEUTZ engines
User notes
When removing and installing components, no

materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.
newed parts / operating materials must be stored,

transported and disposed of according to regulations. The owner himself is responsible for this.
Removed parts may only be rubbed down with

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

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

must be closed immediately with suitable stoppers/caps.
The stoppers/caps may only be removed immediately before installing.
Store stoppers/caps free from dust and dirt in the
original packaging and dispose of after using
once.
Only remove new parts from the original packaging just before installation.
Removed components must be kept in new, sealable bags or - if available - in the packaging of the
new parts.
Always use the original packaging of the new part
to send back the removed components.
Notes and measures for the vehicle workshop area
For work such as removal and installation on defective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.
The workshop floor is sealed or tiled.
No welding gear, grinders, general machine
tools, brakes or performance test benches may
be operated in this room.
Regular cleaning of the workshop area is mandatory. Draughts, ventilation systems and heating
fans should be minimised.
Notes and measures for workbench and tools in the
vehicle hall
A special workbench must be set up for work on
removed components.
Clean the removal and installation tools regularly
and keep them in a closed tool cabinet.
cleaner or other suction device.
3.2.3 Disposal regulations

The work described in the operation manual and
workshop manual necessitates renewal of parts and
operating materials among other things. The re 02/2010
5/8
User notes
DEUTZ engines
3.3 Operation manual and workshop manual
3.4 Job cards

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.
To structure the information to suit the user, the

service documentation is divided into operation
manual and workshop manual.
The operation manual contains a general description and instructions for all other maintenance work.
It contains the following chapters:
1. Contents, General
2. Engine description
3. Operation
4. Operating media
3.4.1 Numbering of job cards
5. Maintenance
The job card numbering uses the format W 08-0301. The individual parts of this format are explained
below:
6. Care and maintenance work

7. Faults, causes and remedies
8. Engine conservation
W 08-03-01: Documentation type
9. Technical data
W.... Workshop manual
10.Service
I ...... Repair manual
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.
02/2010
W 08-03-01: Module
according to module list
W 08-03-01: Component group
W 08-03-01: Consecutive number
6/8
DEUTZ engines
User notes
3.5 Explanation of symbols
3.4.2 Structure of a job card

1
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!
5
16
15
Note
General notes on assembly, environmental
protection etc. No potential danger for man
or machine.
14
8
13
12
Tool
Conventional and special tools required for
the work.
11
10
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
1. DEUTZ AG,
publisher of service documentation
2. Engine type
Reference
to a document or a job card within the work
process.
3. Module
4. Numbering of the job cards
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
5. Title of job card

6. Reference to other modules with job cards
7. Chapter
8. Graphic or photo
9. DEUTZ internal creation number
10.Page number
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
11.Date of issue of job card

12.Note
13.Danger / Important
14.Work sequence
15.Auxiliary materials
16.Conventional tools, special tools
02/2010
7/8
User notes
DEUTZ engines
02/2010
8/8
Technical data
TCD 2013 2V
02/2010
Technical data
4.1
1/18
Technical data
TCD 2013 2V
02/2010
2/18
02/2010
ID no.
Name
Information
Series
Value
Unit
General engine data

P00 71
Ignition sequence
L4
2V
1-3-4-2
L6
2V
1-5-3-6-2-4
2V
8,98 - 0,05
mm
TCD 2013
2V
0
8,96 - 0,05
mm
TCD 2013
Valve
P01 31
Valve shaft diameter, inlet
Standard, fit h7
Standard, fit h7
TCD 2013
3/18
P01 32
Valve shaft diameter, outlet
P01 33
Valve stem clearance, inlet
TCD 2013
2V
0,045 - 0,075
mm
P01 34
Valve stem clearance, outlet
TCD 2013
2V
0,065 - 0,095
mm
P01 35
Valve edge thickness, inlet
TCD 2013
2V
2,62
mm
P01 36
Valve edge thickness, outlet
TCD 2013
2V
2,3
mm
mm
mm
P01 37
Valve head diameter, inlet
TCD 2013
2V
+0,1
48 -0,1
P01 38
Valve head diameter, outlet
TCD 2013
2V
42 -0,1
Valve lag dimension, inlet
TCD 2013
2V
0,99 - 0,1
mm
TCD 2013
2V
+ 0,15
1 - 0,1
mm
TCD 2013
2V
64,7
mm
4,5
mm
+0,1
TCD 2013 2V
Valve guide
Valve seat
P01 45
P01 46
Valve lag dimension, outlet
+ 0,1
P01 51
Valve spring length
untensioned, normal
Valve spring wire diameter
Valve clearance
P01 61
Valve clearance, inlet (on cold engine)
Oil temperature < 80 C,

after a cooling time of at least 0.5 h
TCD 2013
2V
90
P01 62
Valve clearance, outlet (on cold engine)

TCD 2013
2V
150
Technical data
Valve spring
Name
Information
Series
Value
P01 63
Valve clearance setting
Valve overlap according to setting

schematic see: Table T01 63
TCD 2013
2V
P01 64
Clearance between control piston and rocker arm

TCD 2013
2V
144
Unit
Rocker arm/bracket
+ 0,033
mm
21,02 0
+ 0,033
mm
mm
P01 72
Rocker arm, bore, diameter, outlet
TCD 2013
2V
21,02 0
P01 73
Rocker arm, bore, diameter, inlet
TCD 2013
2V
P01 74
Rocker arm journal
Diameter, fit h7
TCD 2013
2V
0
21 -0,021
Technical data
02/2010
ID no.
Main bearing pin
4/18
P02 03
Main bearing pin
Standard, diameter
TCD 2013
2V
85,00 - 0,02
mm
P02 04
Crankshaft main bearing pin
Underdimension stage
TCD 2013
2V
0,25
mm
TCD 2013
2V
0
84,50 - 0,02
mm
P02 05
Limit for undermeasure step
P02 06
Pin unroundness
Wear limit
TCD 2013
2V
0,01
mm
P02 07
Crankshaft main bearing pin and lifting journal,

hardness
Standard HRC
TCD 2013
2V
53 -3
HRC
TCD 2013
2V
38
TCD 2013
2V
0,4
mm
TCD 2013
2V
38,46
mm
TCD 2013
2V
68,00 - 0,02
mm
TCD 2013
2V
0,25
mm
TCD 20113
2V
67,50 - 0,02
mm
TCD 2013
2V
0,01
mm
+3
Fit bearing pin

Fit bearing pin, width
P02 12
Fit bearing pin, width
P02 13
Limit for overmeasure step
one overmeasure stage
+0,06
Lifting journal
P02 22
Lifting journal, diameter
P02 23
Lifting journal, diameter
P02 24
Limit for undermeasure step
P02 25
Pin unroundness
Undermeasure per stage

Wear limit
TCD 2013 2V
P02 11
02/2010
ID no.
Name
Information
Series
P02 26
Radial run-out, crankshaft
maximum permissible deviation
TCD 2013
L4
2V
L6
Value
Unit
0,07
mm
0,10
mm
mm
Main bearing
Permissible axial clearance of crankshaft
in installed state
TCD 2013
2V
0,1 - 0,3
P02 35
Thrust ring, thickness
Standard (upper and lower half)
TCD 2013
2V
2,9 0
+ 0,05
mm
TCD 2013
2V
+ 0,05
3,1 0
mm
P02 36
Thrust ring, oversize
1. Step = 0.2 mm
Con-rod
5/18
P02 41
Parallelism of the con rod with respect to the pis- permissible deviation
ton bolt
at a distance of 100 mm
TCD 2013
2V
0,05
mm
P02 42
Parallelism of the con rod with respect to the pis- permissible deviation
ton bolt
at a distance of 100 mm
TCD 2013
2V
0,05
mm
P02 43
Piston bolt liner, inside diameter
TCD 2013
2V
42 +0,04
mm
P02 45
Small end bush clearance between piston pin

and small end bush
TCD 2013
2V
0,034 - 0,056
mm
+ 0,02
installed, unmachined
+0,05
TCD 2013 2V
P02 34
Big end bearing

Big end bearing shells, inside diameter
installed
TCD 2013
2V
72,5 0
mm
P02 55
Big end bearing, bore in con rod
H6
TCD 2013
2V
72,5
mm
P02 56
Theoretical clearance between the big end

bearing / lifting journal
TCD 2013
2V
0,036 - 0,095
mm
Piston pin, diameter
TCD 2013
2V
42 -0,006
mm
Piston bolt
P02 61
Piston
P02 70
Piston
Identification of the installation position on the piston base
P02 71
Piston, diameter, standard
Measuring point 1 = height 12 mm
TCD 2013
2V
107,700
mm
P02 72
TCD 2013
2V
107,800
mm
Technical data
P02 52
Name
Information
Series
Value
Unit
P02 73
TCD 2013
2V
107,660
mm
P02 75
Piston protrusion
1 hole, cylinder head gasket, 1.42 mm
TCD 2013
2V
0,28 - < 0,54
mm
P02 76
Piston protrusion
TCD 2013
2V
0,54 - < 0,64
mm
P02 77
Piston protrusion
TCD 2013
2V
0,64 - 0,75
mm
P02 78
Piston bolt, bore
TCD 2013
2V
42 +0,01
+0,017
mm
Piston rings
6/18
Joint clearance, piston ring 1
Identification (TOP) in direction of

combustion chamber
TCD 2013
2V
0,3 - 0,55
mm
P02 85

combustion chamber
TCD 2013
2V
1,5 - 2,0
mm
P02 86

combustion chamber
TCD 2013
2V
0,3 - 0,6
mm
P02 87
Axial clearance, 1st ring (double-sided keystone

Wear limit
ring)
TCD 2013
2V
Measure with trapezoidal groove wear

gauge
P02 88
Axial clearance, 2nd ring (taper-faced ring)
TCD 2013
2V
0,09 - 0,13
mm
P02 89
Axial clearance, 3rd ring , (bevelland-edge oil

control ring)
TCD 2013
2V
0,03 - 0,075
mm
TCD 2013
2V
108
+ 0,02
mm
Crankcase
Cylinder liners
P03 31
Cylinder bore, inside diameter
Standard
P03 35
Fit depth of collar rest and sealing surface for cylinder liner
TCD 2013
2V
8,92
P03 36
Cylinder liners, collar height
TCD 2013
2V
9 - 0,02
mm
P03 39
Cylinder liner, overhang
TCD 2013
2V
max. 0.080
mm
at least 0.030
mm
+ 0,03
mm
TCD 2013 2V
P02 84
Technical data
02/2010
ID no.
02/2010
ID no.
Name
Information
Series
Value
Unit
Standard
TCD 2013
2V
64,2 - 0,2
TCD 2013
2V
0,6 - 0,1
mm
TCD 2013
2V
62
mm
Engine control
Camshaft
Camshaft bearing pin diameter
P05 91
Gap dimension speed governor (crankshaft)
+ 0,2
+ 0,1
mm
Lubricating oil system

P08 44
Length of compression spring for the oil pressure

control valve
Cooling system
P09 11
Coolant thermostat start of opening
TCD 2013
2V
83
mm
P09 13
Coolant thermostat stroke
TCD 2013
2V
at least 8
mm
N
TCD 2013 2V
P04 31
Other components
7/18
P12 11
Tension of the V-belt (generator/coolant pump)
First assembly
TCD 2013
2V
650
P12 21
Tension of the V-belt (generator/coolant pump)
Check after 15 minutes running under

load
TCD 2013
2V
400 - 50
+ 50
Technical data
Technical data
TCD 2013 2V
T01 63
Setting of valve and control piston clearance
4-cylinder
ignition sequence: 1 - 3 - 4 - 2
Valves
overlap
Set to
1
4
Cylinder
3 4 2
2 1 3
Valve overlap: Outlet valve is not yet

closed, inlet valve begins opening.
The inlet valve opens briefly by 2 mm when
the oulet valve is fully open. This is not the
valve overlap!
T01 63
Setting valve and control piston clearance
6-cylinder
ignition sequence: 1 - 5 - 3 - 6 - 2 - 4
Valves
overlap
Set to
1
6
5
2
Cylinder
3 6 2
4 1 5
00000-0
4
3

closed, inlet valve begins to open.
When the inlet valve is fully open, the outlet valve opens briefly by about 2 mm. This
is not the valve overlap!
00000-0
02/2010
8/18
Technical data
TCD 2013 2V
4.2
02/2010
9/18
Technical data
TCD 2013 2V
02/2010
10/18
02/2010
Name
A00 001
Clamping holder on crankcase
A00 002
Clamping bracket on adapter for assembly block
A00 003
Feet/engine mounting on crankcase and gear

case
Screw type
Notes / Remarks
Screw
Nut
Screws
M12x35-10.9
M12x40-10.9
M12x60-10.9
M12x75-10.9
M12x85-10.9
M12x90-10.9
M12x220-10.9
PostPre-tensioclamping
ning value
value
Series
TCD 2013
2V
90 Nm
TCD 2013
2V
90 Nm
TCD 2013
2V
95 Nm
TCD 2013
2V
260 Nm
TCD 2013
2V
90 Nm
TCD 2013 2V
ID no.
Nut
11/18
Holder, engine mounting on crankcase
A00 006
Mounting bracket on holder/crankcase
M12x40-10.9
A01 001
Cylinder head on crankcase
Observe order of tightening.

Screws oiled
Sealing surfaces free from oil
TCD 2013
2V
50 Nm
A01 002
Rocker arm support on the cylinder head
Assembly note: Rocker arm

symmetrical to the valve centre TCD 2013
axes, see A01 001
2V
30 Nm
A01 003
Locking nut valve clearance setting screw
TCD 2013
2V
20 Nm
Hexagonal socket
130 Nm
+90
Technical data
A00 005
M16x40-10.9
M16x45-10.9
M16x75-10.9
M16x85-10.9
M16x110-10.9
M16x140-10.9
M16x155-10.9
M16x220-10.9
Cylinder head cowling on cylinder head
Hood must be free from grease

TCD 2013
and lubricant.
2V
13 Nm
A01 011
Exhaust gas return module on cylinder head
Observe tightening sequence. TCD 2013
2V
10 Nm
A01 012
Locking nut setting screw exhaust gas return module
TCD 2013
2V
20 Nm
A01 013
Solenoid valve (exhaust gas return) on cylinder

head
TCD 2013
2V
24 Nm
Main bearing on crankcase
Can be used 3 times if

documented in writing otherwiTCD 2013
se use new screws every time
they are loosened.
2V
50 Nm
+60
+60
Big end bearing cap on con rod
Observe assembly specification.

Use new screws every time
they are loosened.
Screws oiled
TCD 2013
2V
30 Nm
+60
+60
A03 020
Front cover on crankcase
Observe tightening sequence.

TCD 2013
Wet rotors with engine oil before assembly.
2V
3 Nm
21 Nm
A03 030
Oil pan on crankcase
Observe tightening sequence.

TCD 2013
Note different screw lengths.
2V
30 Nm
A03 031
Screw cap on oil pan
Cu sealing ring
TCD 2013
2V
55 Nm
A03 060
Crankcase breather on cylinder head
TCD 2013
2V
20 Nm
12/18
M18x1.5
Series
30 Nm
TCD 2013 2V
A01 004
A02 020
Notes / Remarks
Technical data
02/2010
Name
A02 010
Screw type
ning value
value
ID no.
02/2010
ID no.
Name
Screw type
Notes / Remarks
ning value
value
Series
M16x85-10.9
Connection housing on crankcase/gear case
M12x85-10.9
99 Nm
2V
M12x160-10.9
A03 085
99 Nm
Cover plate to connection housing
99 Nm
TCD 2013
2V
9 Nm
Gear case on crankcase
M8x35-10.9
M8x55-10.9
M8x80-10.9
M16x60
A04 022
Locking cap on gear case
M8x55-10.9
M8x60-10.9
TCD 2013
2V
21 Nm
A04 025
Holder on gear case/crankcase
M8x80-10.9
TCD 2013
2V
30 Nm
TCD 2013
2V
9 Nm
Speed governor is installed by

pressing in, not knocking in.
TCD 2013
Insert with locking agent
DEUTZ DW72.
2V
9 Nm
A03 092
13/18
A05 011
Speed governor (crankshaft) front cover
M6x12
30 Nm
2V
243 Nm
TCD 2013 2V
A03 080
M16x150-10.9
30 Nm
70 Nm

Insert with DEUTZ DW72 lokking agent.
Speed governor (camshaft) on gear case
A05 013
Holder speed governor (crankshaft) on front cover
TCD 2013
2V
20 Nm
A05 014
Toothed disc on V-belt pulley
TCD 2013
2V
60 Nm
A06 001
Exhaust pipe at cylinder head
TCD 2013
2V
25 Nm
Observe order of tightening.

Start assembly with fit bore
10.1 mm.
Technical data
A05 012
14/18
Screw type
Notes / Remarks
Series
A06 020
Turbocharger on exhaust pipe
Nut M10
Insert with DEUTZ S1 mounting compound
TCD 2013
2V
42 Nm
A06 022
Pin bolt on exhaust pipe
Insert with DEUTZ S1 mounting compound
TCD 2013
2V
10 Nm
A06 030
Charge air pipe on cylinder head
TCD 2013
2V
11 Nm
A06 042
Heating flange on charge air manifold
M8x100-10.9
Stage 1:
TCD 2013
2V
3 Nm
A06 042
Heating flange on charge air manifold
M8x100-10.9
Stage 2:
TCD 2013
2V
30
A06 046
Charge air manifold on charge air pipe
TCD 2013
2V
30 Nm
A07 001
Clamping claw injector on cylinder head
Observe order of assembly.

TCD 2013
Install injector without tension.
2V
hand tight
A07 003
Injection lines on rail and pressure pipe nozzle

High pressure pipe at high pressure pump
Union nut
Stage 1:
Use new pipe.
TCD 2013
2V
10 Nm
A07 003
Injection lines on rail and pressure pipe nozzle

High pressure pipe at high pressure pump
Union nut
Stage 2:
TCD 2013
2V
60
A07 024
Fuel supply pump on holder
TCD 2013
2V
20 Nm
A07 031
High pressure pump to crankcase
M10x30-10.9
Screws oiled
TCD 2013
2V
10 Nm
A07 032
Control block to crankcase
M8x75
M8x85
Observe tightening sequence
TCD 2013
2V
20 Nm
A07 034
Fuel line to high pressure pump
TCD 2013
2V
26 Nm
A07 035
Fuel line to control block
TCD 2013
2V
34 Nm
A07 038
Rail to cylinder head
Stage 1:
TCD 2013
2V
hand tight
A07 038
Rail to cylinder head
Stage 2:
TCD 2013
2V
30 Nm
27 Nm
+15
50 Nm
TCD 2013 2V
Name
Technical data
02/2010
ning value
value
ID no.
02/2010
Name
A07 039
A07 040
A07 045
ning value
value
Notes / Remarks
Series
Pressure limiting valve to rail
Insert with mounting grease.
TCD 2013
2V
100 Nm
Rail pressure sensor to rail
Insert with mounting grease.
TCD 2013
2V
70 Nm
TCD 2013
2V
Fuel line (feed) to control block
Screw type
Hollow screw
Fuel line (return) to rail
49 Nm
39 Nm
15/18
A07 046
Fuel line (return) to control block
Hollow screw
TCD 2013
2V
49 Nm
A07 047
Fuel line (return) to cylinder head
Hollow screw
TCD 2013
2V
29 Nm
A07 087
Fuel filter console on oil cooler housing
TCD 2013
2V
30 Nm
A07 090
Fuel pressure sensor to fuel filter console
TCD 2013
2V
30 Nm
A07 099
Fuel filter to fuel filter console
Wet gasket with clean diesel

fuel.
A08 001
Oil fillter/interchangeable filter
Oil gasket lightly.
A08 015
Oil suction intake pipe/holder on oil pump
A08 040
Lubricating oil pipe on exhaust turbocharger/

crankcase
A08 044
Pipe nozzle (oil return) to turbocharger

Holding bracket (oil return) on crankcase
Connection holder of the oil return line
hand tight
approx.10
Nm
approx.10
Nm
TCD 2013
2V
hand tight
TCD 2013
2V
22 Nm
TCD 2013
2V
39 Nm
TCD 2013
2V
20 Nm
TCD 2013
2V
20 Nm
20 Nm
A08 051
Oil cooler housing on crankcase
M8x50
M8x80
2V
3 Nm
30 Nm
A08 052
Oil cooler on oil cooler housing
Collar screw
Oil sealing ring lightly.
TCD 2013
2V
80 Nm
160 Nm
A08 058
Locking screw on oil cooler housing
with sealing ring
TCD 2013
2V
80 Nm
A08 091
Oil pressure switch on oil cooler housing
TCD 2013
2V
30 Nm
A09 001
Coolant thermostat housing on cylinder head
TCD 2013
2V
30 Nm
Technical data
A08 046
Hollow screw
TCD 2013 2V
ID no.
Name
A09 002
Outlet nozzle on coolant thermostat housing
A09 010
Screw type
Notes / Remarks
ning value
value
Series
TCD 2013
2V
30 Nm
Coolant pump on fan console
2V
30 Nm
V-belt pulley on coolant pump
TCD 2013
2V
30 Nm
V-belt pulley on V-belt pulley
TCD 2013
2V
30 Nm
A09 031
Coolant temperature sensor on cylinder head
TCD 2013
2V
22 Nm
A09 045
Fan console on crankcase
TCD 2013
2V
30 Nm
A09 046
Fan drive on fan console
TCD 2013
2V
60 Nm
A09 047
V-rib disc on fan drive
Stage 1:
TCD 2013
2V
30 Nm
A09 047
V-rib disc on fan drive
Stage 2:
TCD 2013
2V
90
A09 048
Adapter on V-belt pulley
TCD 2013
2V
30 Nm
A09 015
Technical data
02/2010
ID no.
16/18
M10x1x85
M10x1x80
M10x1x75
M10x1x70
A12 001
Flywheel on crankshaft
M10x1x50
M10x1x45
Observe tightening specification.

TCD 2013
Use new screws.
Renew screws every time they
are loosened.
+60
+60
2V
M10x1x40
30 Nm
M10x1x35
+60
+30
M10x1x30
A12 030
Hub torsional vibration damper on crankshaft
Use new screws.

TCD 2013
2V
30 Nm
+60
+60
TCD 2013 2V
M10x1x55
30 Nm
02/2010
Name
Screw type
A12 031
V-belt pulley on torsional vibration damper
M10x70-10.9
A12 035
Belt tensioner on front cover
A12 041
Clamping strap on coolant pump
A12 091
Hollow screw pipe union
A12 092
Pipe union, pipe diameter 8 mm, ring piece
A12 093
A12 094
17/18
A12 095
Notes / Remarks
ning value
value
Series
TCD 2013
2V
70 Nm
TCD 2013
2V
80 Nm
TCD 2013
2V
30 Nm
TCD 2013
2V
Hollow screw
M12x1.5
TCD 2013
2V
29 Nm
Hollow screw
M14x1.5
TCD 2013
2V
39 Nm
Hollow screw
M16x1.5
TCD 2013
2V
49 Nm
Pipe clip, fastening
M6
Pipe clip for return pipe
M8
TCD 2013
2V
TCD 2013
2V
60 Nm
M8x25-8.8
Hollow screw
Ring piece pipe 6 mm
Union nut
18 Nm
20 Nm
13 Nm
20 Nm
Starter on crankcase/gear case
A13 012
Generator on holder
M8x75
TCD 2013
2V
30 Nm
A13 015
Generator on clamping strap
M8x75
TCD 2013
2V
30 Nm
A13 017
V-belt clamping strap on console
M8x25
TCD 2013
2V
30 Nm
A13 018
Generator console on cylinder head
TCD 2013
2V
70 Nm
A13 030
Cable shoe on connection bolt
TCD 2013
2V
3 Nm
A13 032
Heating plug / screw cap on cylinder head
TCD 2013
2V
20 Nm
A13 041
Cable rail on cylinder head
M6x16
self-tapping
TCD 2013
2V
8.5 Nm
A13 046
Pressure/temperature transmitter on charge air

line
Screw M6
maximum
M5
lightly oiled, maximum
TCD 2013
2V
A13 051
Cab le connection on injector
TCD 2013
2V
4.5 Nm
3.3 Nm
1.5 Nm
Technical data
A13 001
M6
TCD 2013 2V
ID no.
Name
A13 065
Cable connection on heater flange
A49 001
Connection piece on cylinder head, clamping

shoe
Screw type
Notes / Remarks
ning value
value
Series
Hexagonal, pole screw locked TCD 2013
2V
20 Nm
TCD 2013
2V
25 Nm
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
Technical data
02/2010
ID no.
18/18
TCD 2013 2V
Job card overview

TCD 2013 2V
02/2010
Job card overview
5.1
1/12
Job card overview

TCD 2013 2V
02/2010
2/12
Job card overview

TCD 2013 2V
Activity
Job card
Maintenance group
Assembling/disassembling shaft sleeve on the

crankshaft (opposite side to flywheel)
W 01-02-02
Front cover
Check alignment of connection housing
W 52-01-02
Connection housing
Checking collar contact for cylinder liner
W 01-13-01
Crankcase
Checking piston overhang
W 08-03-02
Cylinder head
Checking the axial clearance of the crankshaft
W 05-05-03
Crankshaft
Checking the camshaft
W 10-02-02
Camshaft
Checking the compression pressure
W 08-00-01
Cylinder head
Checking the con rod
W 06-01-02
Connecting rod
Checking the crankshaft
W 05-05-02
Crankshaft
Checking the overhang of the cylinder liner
W 01-05-01
Crankcase
Checking the piston
W 07-01-02
Piston
Checking the piston rings and piston ring grooves
W 07-02-02
Piston
Checking the thermostat (in the removed state)
W 38-01-02
Thermostat housing
Checking the valve guide
W 08-04-03
Cylinder head
Checking the valve lag
W 08-04-04
Cylinder head
Checking the valves
W 08-04-02
Cylinder head
Disassembling, assembling and checking the rocker

arm and rocker arm
W 11-02-02
bracket
Control parts
Dismantling and assembling the fan drive
W 39-02-03
Fan drive
Installing and removing turning gear
W 49-02-01
Tools
Installing and removing turning gear (Torsional vibW 49-02-02

ration damper)
Tools
Mounting engine on assembly block and demounting
W 46-00-01
Engine mounting
Removing and install the charge air line
W 22-01-01
Charge air line
Removing and install the heating flange
W 63-01-01
Start aid
Removing and installing cylinder head
W 08-03-01
Cylinder head
Removing and installing temperature transmitter

(coolant)
W 48-05-01
Electrical equipment
Removing and installing the belt tensioner (V-rib

belt)
W 39-01-01
Fan drive
Removing and installing the cable harness
W 48-01-01
Cable harness
Removing and installing the camshaft
W 10-02-01
Camshaft
Removing and installing the connection housing
W 52-01-01
Connection housing
Removing and installing the control block
W 17-01-01
High-pressure pump
02/2010
3/12
Job card overview

TCD 2013 2V
Activity
Job card
Maintenance group
Removing and installing the coolant pump (V-belt

drive)
W 37-03-01
Coolant pump
Removing and installing the crankcase bleeding
W 01-01-01
Crankcase
Removing and installing the crankshaft
W 05-05-01
Crankshaft
Removing and installing the cylinder head cover
W 08-01-01
Cylinder head
Removing and installing the cylinder liner
W 04-01-01
Cylinder liner
Removing and installing the engine mounting

(elastic mounting)
W 47-01-01
Engine mounting
Removing and installing the exhaust line
W 41-01-01
Exhaust pipe
Removing and installing the exhaust return module W 08-02-01
Cylinder head
Removing and installing the fan console (V-rib belt

drive)
W 39-04-03
Fan console
Removing and installing the fan drive
W 39-02-01
Fan drive
Removing and installing the flywheel
W 05-03-01
Flywheel
Removing and installing the front cover (opposite

side to flywheel)
W 01-03-01
Front cover
Removing and installing the fuel filter console
W 20-01-01
Fuel filter
Removing and installing the fuel pressure sensor
W 48-06-01
Removing and installing the fuel supply pump (Vbelt drive)
W 20-02-01
Fuel pump
Removing and installing the gearcase cover
W 09-02-02
Gearcase
Removing and installing the generator (V-belt drive) W 44-02-01
Generator
Removing and installing the glow plugs
W 63-02-01
Start aid
Removing and installing the high-pressure pump

(Installation position A)
W 17-01-04
High-pressure pump

(Installation position B)
W 17-01-05
High-pressure pump
Removing and installing the impulse transmitter

(camshaft)
W 48-02-03

(crankshaft)
W 48-02-01
Removing and installing the injector
W 19-01-01
Injector
Removing and installing the lubricating oil cooler
W 15-02-01
Lubricating oil cooler

housing
W 15-02-02
Removing and installing the lubricating oil pan

(metal sheet lubricating oil pan)
W 02-01-01
Lubricating oil sump
Removing and installing the oil pressure switch
W 48-04-01
Removing and installing the oil suction pipe
W 16-01-01
Oil suction pipe
Removing and installing the piston and con rod
W 06-01-01
Connecting rod
02/2010
4/12
Job card overview

TCD 2013 2V
Activity
Job card
Maintenance group
Removing and installing the piston cooling nozzles
W 01-08-01
Crankcase
Removing and installing the pressure holding valve W 01-07-03
Crankcase
Removing and installing the pressure limiting valve W 21-02-03
Fuel pipes
Removing and installing the pressure/temperature

sensor (charge air)
W 48-03-01
Removing and installing the rail
W 21-02-01
Fuel pipes
Removing and installing the rail pressure sensor
W 21-02-05
Fuel pipes
Removing and installing the rocker arm and rocker

arm bracket
W 11-02-01
Control parts
Removing and installing the solenoid valve (exhaust

W 08-02-02
gas return)
Cylinder head
Removing and installing the starter
W 44-03-01
Starter
Removing and installing the thermostat
W 38-01-01
Thermostat housing
Removing and installing the thermostat housing
W 38-02-01
Thermostat housing
Removing and installing the turbocharger
W 43-01-01
Exhaust gas turbocharger
Removing and installing the valves
W 08-04-01
Cylinder head
Removing and installing the V-belt, V-belt pulley
W 05-01-01
V-belt pulley add-on
Removing and installing torsional vibration damper

(V-belt drive)
W 05-02-01
Torsional vibration damper
Renewing the crankshaft sealing ring (flywheel side) W 09-01-01
Gearcase
Renewing the crankshaft sealing ring (opposite side

W 01-02-01
to flywheel)
Front cover
Setting valve clearance (with exhaust return module

W 11-01-01
installed)
Control parts
Setting valve clearance (with or without removal of

exhaust return module)
W 11-01-01
Control parts
Testing the cylinder liner
W 04-01-02
Cylinder liner
02/2010
5/12
Job card overview

TCD 2013 2V
02/2010
6/12
Job card overview

Sorted numerically
TCD 2013 2V
5
5.2
02/2010
Sorted numerically
7/12
Job card overview

Sorted numerically
TCD 2013 2V
02/2010
8/12
Job card overview

Sorted numerically
TCD 2013 2V
Job card
Activity
Maintenance group
W 01-01-01
Crankcase
W 01-02-01
Renewing the crankshaft sealing ring (opposite side

Front cover
to flywheel)
W 01-02-02
Assembling/disassembling shaft sleeve on the

crankshaft (opposite side to flywheel)
Front cover
W 01-03-01
Removing and installing the front cover (opposite

side to flywheel)
Front cover
W 01-05-01
Crankcase
W 01-07-03
Removing and installing the pressure holding valve Crankcase
W 01-08-01
Crankcase
W 01-13-01
Crankcase
W 02-01-01

W 04-01-01
Cylinder liner
W 04-01-02
Cylinder liner
W 05-01-01
W 05-02-01

(V-belt drive)
W 05-03-01
Flywheel
W 05-05-01
Crankshaft
W 05-05-02
Crankshaft
W 05-05-03
Crankshaft
W 06-01-01
Connecting rod
W 06-01-02
Connecting rod
W 07-01-02
Checking the piston
Piston
W 07-02-02
Piston
W 08-00-01
Cylinder head
W 08-01-01
Cylinder head
W 08-02-01
Removing and installing the exhaust return module Cylinder head
W 08-02-02
Removing and installing the solenoid valve (exhaust

Cylinder head
gas return)
W 08-03-01
Cylinder head
W 08-03-02
Cylinder head
W 08-04-01
Cylinder head
W 08-04-02
Checking the valves
Cylinder head
W 08-04-03
Cylinder head
W 08-04-04
Cylinder head
W 09-01-01
Renewing the crankshaft sealing ring (flywheel side) Gearcase
02/2010
9/12
Job card overview

Sorted numerically
TCD 2013 2V
Job card
Activity
Maintenance group
W 09-02-02
Gearcase
W 10-02-01
Camshaft
W 10-02-02
Camshaft
W 11-01-01
Setting valve clearance (with exhaust return module

Control parts
installed)
W 11-01-01
Setting valve clearance (with or without removal of

exhaust return module)
Control parts
W 11-02-01
Removing and installing the rocker arm and rocker

arm bracket
Control parts
W 11-02-02
Disassembling, assembling and checking the rocker

arm and rocker arm
Control parts
bracket
W 15-02-01
W 15-02-02

housing
W 16-01-01
Oil suction pipe
W 17-01-01
High-pressure pump
W 17-01-04

High-pressure pump
W 17-01-05

High-pressure pump
W 19-01-01
Injector
W 20-01-01
Fuel filter
W 20-02-01
Removing and installing the fuel supply pump (Vbelt drive)
Fuel pump
W 21-02-01
Fuel pipes
W 21-02-03
Removing and installing the pressure limiting valve Fuel pipes
W 21-02-05
Fuel pipes
W 22-01-01
Charge air line
W 37-03-01
Removing and installing the coolant pump (V-belt

drive)
Coolant pump
W 38-01-01
Thermostat housing
W 38-01-02
Thermostat housing
W 38-02-01
Thermostat housing
W 39-01-01
Removing and installing the belt tensioner (V-rib

belt)
Fan drive
W 39-02-01
Fan drive
W 39-02-03
Fan drive
W 39-04-03
Removing and installing the fan console (V-rib belt

drive)
Fan console
02/2010
10/12
Job card overview

Sorted numerically
TCD 2013 2V
Job card
Activity
Maintenance group
W 41-01-01
Exhaust pipe
W 43-01-01
W 44-02-01
Removing and installing the generator (V-belt drive) Generator
W 44-03-01
Starter
W 46-00-01
Engine mounting
W 47-01-01

(elastic mounting)
Engine mounting
W 48-01-01
Cable harness
W 48-02-01

(crankshaft)
W 48-02-03

(camshaft)
W 48-03-01
Removing and installing the pressure/temperature

sensor (charge air)
W 48-04-01
W 48-05-01

(coolant)
W 48-06-01
W 49-02-01
Tools
W 49-02-02
Installing and removing turning gear (Torsional vibTools

ration damper)
W 52-01-01
Connection housing
W 52-01-02
Connection housing
W 63-01-01
Start aid
W 63-02-01
Start aid
02/2010
11/12
Job card overview

Sorted numerically
TCD 2013 2V
02/2010
12/12
DEUTZ engines
11/2005
Job cards
Job cards
1/2
Job cards
DEUTZ engines
11/2005
2/2
Crankcase
W 01-01-01
TCD 2013 2V
Standard tools:
Hose clip pliers
Spring band pliers
8011
9090
Removing the crankcase bleeding

Loosen spring band clip (1) with spring band pliers.
Pull off bleeding hose (2).
2
44130-0
Unscrew screws (1).

Remove crankcase bleeding (2).
1
1
44131-0
02/2010
1/4
Crankcase
W 01-01-01
TCD 2013 2V
Unscrew screw (1).

Loosen pipe clip (2).
Unscrew hollow screw (3).
Remove sealing ring.
Loosen hose clip (4).
Pull off oil return line (5).

Remove bleed line.
Visually inspect the components.
43944-0
X
X
44132-0
Install crankcase bleeding

Clean sealing surface on crankcase bleeding.
Clean cylinder head cover.
Insert new seal (1).
44106-0
02/2010
2/4
Crankcase
W 01-01-01
TCD 2013 2V
Mount crankcase bleeding (1).
Tighten screws .
20 Nm
6
44107-0
Mount the bleed line.

Plug in oil return line (5).
Tighten hollow screw (3).
4
29 Nm
Use new sealing rings.
Position pipe clamp (2).

Tighten screw (1).
M8
30 Nm
M6
13 Nm
Fix the hose clip (4) with the hose clip pliers.
Plug on bleeding hose.
Position the spring band clip (1) with the spring band
pliers.
43944-0
X
X
1
44129-0
02/2010
3/4
Crankcase
W 01-01-01
TCD 2013 2V
02/2010
4/4
Front cover
W 01-02-01
TCD 2013 2V
Renewing the crankshaft sealing ring
(opposite side to flywheel)
Standard tools:
Pricker
Assembly lever
8198
9017
Special tools:
Assembly tool
142820
W 05-01-01
Self-tapping screw
Washer
Removing the crankshaft sealing ring

Remove the V-belt, V-belt pulley.
W 05-01-01
Make a hole of approximately 3 mm in the crankshaft
sealing ring with a pricker.
Attention!
Do not damage the front cover or crankshaft.
44198-0
Turn in a self-tapping screw with washer.
44199-0
02/2010
1/6
Front cover
W 01-02-01
TCD 2013 2V
Pull out the crankshaft sealing ring with assembly lever.
6
44200-0
Visually inspect all running surfaces.
44201-0
Installing the crankshaft sealing ring

Remove clamping bushing (1).
44202-0
02/2010
2/6
Front cover
W 01-02-01
TCD 2013 2V
Mount guide sleeve (1).
Make sure the clamping bushing (2) is in
line with the bore (3).
6
44203-0
Tighten screws (1).
44204-0
Oil the sealing lip of the crankshaft sealing ring lightly.

Push the crankshaft sealing ring carefully onto the
guide sleeve.
Use new crankshaft sealing ring.
The sealing lip faces the crankcase.
44205-0
02/2010
3/6
Front cover
W 01-02-01
TCD 2013 2V
Mount shims (1).

Pay attention to installation depth of crankshaft sealing ring and select shim accordingly.
First assembly = 2 shims
1. Repair installation depth = 1 shim
Maximum installation depth = without washers
44206-0
Mount assembly sleeve (1).

Press on the crankshaft sealing ring to the stop.
1
44207-0
Plug in the bearing (1).

Screw on nut (2).
2
1
44208-0
02/2010
4/6
Front cover
W 01-02-01
TCD 2013 2V
Tighten nut to the stop of the assembly sleeve (1).
The crankshaft sealing ring is now at the
pre-selected installation depth.
Remove assembly tool.
6
44209-0
Insert clamping bushing (1).

Mount V-belt, V-belt pulley.
W 05-01-01
44210-0
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5/6
Front cover
W 01-02-01
TCD 2013 2V
02/2010
6/6
Front cover
W 01-02-02
TCD 2013 2V
Assembling/disassembling shaft sleeve on the crankshaft
Standard tools
W 01-02-01
W 01-03-01
W 16-01-01
Packing compound
DEUTZ DW 74
The following work procedure is described

for series 2012 as an example. The procedure for the other engines listed above is
the same.
Installing the shaft sleeve

Remove the crankshaft sealing ring.
W 01-02-01
39876-0
Visually inspect the crankshaft journal.

Clean the crankshaft journal carefully.
Unevenness such as running marks,
notches or very rough surfaces can cause
lubricating oil leaks between the crankshaft
and the shaft sleeve.
Repair unevenness with packing compound.

Remove clamping bushing (1).
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Front cover
W 01-02-02
TCD 2013 2V
Attention!
Do not damage the peripheral surfaces

and the sealing surfaces.
Join the impact sleeve (1) and the shaft sleeve (2).
Place the shaft sleeve with impact sleeve centrally on
the crankshaft with the collar (3) facing the crankshaft.
6
39872-0
Knock the shaft sleeve onto the crankshaft up to the

stop by hitting the impact sleeve (1) lightly in the centre.
Knock on the shaft sleeve evenly all round.
The installation depth of the shaft sleeve is
determined by the impact sleeve.
The shaft sleeve must cover the running
marks.
39891-0
After installing the shaft sleeve, check that

there is no burr on the surface of the
crankshaft.
Oil the crankshaft journal lightly.
To avoid dust and dirt deposits, do not wet
the crankshaft sealing ring and fleece ring
with lubricating oil.
The manufaturer has already coated the
sealing lip with a lubricating wax.
Install a new crankshaft sealing ring.
W 01-02-01
39875-0
02/2010
2/4
Front cover
W 01-02-02
TCD 2013 2V
Removing the shaft sleeve
Remove the crankshaft sealing ring.
W 01-02-01
Remove oil suction pipe
W 16-01-01
6
39871-0
Unscrew screws (1).

Remove front cover.
1
1
1
44542-0
Place two mounting levers on the gate of the front

cover (arrows).
Attention!
Do not damage the sealing surfaces.
39873-0
02/2010
3/4
Front cover
W 01-02-02
TCD 2013 2V
Pull off the shaft sleeve.

Remove front cover.
6
39874-0
Install front cover.

W 01-03-01
Install new shaft sleeve.
Installing the shaft sleeve
Install oil suction pipe.
W 16-01-01
Install a new crankshaft sealing ring.
W 01-02-01
44875-0
02/2010
4/4
Front cover
W 01-03-01
TCD 2013 2V
Removing and installing the front cover
Standard tools:
Feeler gauges
W 01-02-01
W 05-01-01
W 16-01-01
Locking agent
DEUTZ DW 72
Remove the front cover

Remove V-belt pulley.
W 05-01-01
Unscrew screws (1).
Remove clamping strap (2) and fuel supply pump.
Unhook the fuel supply pump at the side.
2
44540-0
Unscrew screws (1).

Remove holder with impulse transmitter (2).
W 16-01-01
2
44541-0
02/2010
1/6
Front cover
W 01-03-01
TCD 2013 2V
Unscrew screws (1).

Remove front cover.
1
1
1
44542-0
44543-0
Install front cover

Knock out crankshaft sealing ring (1).
Attention!
Do not damage sealing surface when

knocking out.
Clean sealing surfaces.
44544-0
02/2010
2/6
Front cover
W 01-03-01
TCD 2013 2V
Fix the new gasket to the crankcase with a little
grease.
Note installation position.
Make sure the clamping bushing (1) is in
place.
6
44545-0
Oil oil pump with lubricating oil.
44546-0
Position the inner rotor on the crankshaft.

The countersinks on the crankshaft and
the guides on the inner rotor must
match (arrows).
The inner rotor and crankshaft only match
up in one position.
44547-0
02/2010
3/6
Front cover
W 01-03-01
TCD 2013 2V
Mount front cover.

Fasten screws.
Do not tighten screws.
Align front cover flush with the oil tray sealing surface.
6
44548-0
Tighten the screws according to the tightening sequence.

Stage 1:
3 Nm
2
Stage 2:
5
7
21 Nm
10
6
13
9
12
11
14
44550-0
Cut off overhanging gasket (arrows) flush with the

sealing surface of the oil tray.
W 16-01-01
44551-0
02/2010
4/6
Front cover
W 01-03-01
TCD 2013 2V
Turn engine 180.
Lay cable between front cover and coolant pump (arrow).
6
44552-0
Mount clamping strap.

Tighten screws (1).
30 Nm
Install crankshaft sealing ring (opposite side to flywheel)
1
W 01-02-01
Install V-belt pulley.
W 05-01-01
44553-0
Mount holder with impulse transmitter.

Fasten screws.
Clean the threads of the screws and holes.
Pay attention to different screws:
Screws M8 x 45 mm (1)
Insert screws with locking agent.

2
44091-0
02/2010
5/6
Front cover
W 01-03-01
TCD 2013 2V
Set gap dimension for impulse transmitter

(crankshaft)
Push feeler gauge blade between tooth lock washer
and impulse transmitter.
Press the impulse transmitter lightly against the feeler gauge blade.
0,6 +0.1
-0.1 mm
6
44092-0
Tighten screws (arrows).
20 Nm
44093-0
Check gap dimension with feeler gauge blade.

0,6 -0.1 mm
+0.1
The feeler gauge blade must fit between

the tooth lock washer and impulse transmitter (crankshaft) with low resistance.
44094-0
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Crankcase
W 01-05-01
TCD 2013 2V
Standard tools
8190
Special tools:
Dial gauge
Measuring device
W 08-03-01
100400
100750

Remove cylinder head.
W 08-03-01
The cylinder liner must be pressed in the
crankcase to the stop.
Place shims (1) and measuring beam (2) on the sealing surface of the crankcase.
Insert dial gauge into measuring beam.

Fix dial gauge with knurled nut.
1
44071-0
Apply stylus of the dial gauge to the crankcase sealing surface with pre-tension (arrow).
Adjust dial gauge to "0".
44072-0
02/2010
1/2
Crankcase
W 01-05-01
TCD 2013 2V
Move the measuring beam and spacing washers until the stylus (arrow) is touching the sealing surface of
the cylinder liner.
0,03 - 0,08 mm
Make measurements at at least 3 other
points on the cylinder liner.
When the wear limit is reached, the
cylinder liner must be renewed.
Install cylinder head.
W 08-03-01
6
44073-0
02/2010
2/2
Crankcase
W 01-07-03
TCD 2013 2V
Removing and installing the pressure holding valve
Standard tools
Special tools:
Slide hammer
W 16-01-01
150800
Collect leaking operating substances in

suitable vessels and dispose of according
to regulations.
Locking agent
DEUTZ DW 71
Removing the pressure holding valve

W 16-01-01
Pull out oil dipstick.
Drill out hole with a 6.7 mm drill.
Make sure no chips get into the crankcase.
Coat spiral drill thickly with grease, so that
no drill shavings fall into the crankcase.
44570-0
Cut thread M8 x 1.25.
44571-0
02/2010
1/4
Crankcase
W 01-07-03
TCD 2013 2V
Turn slide hammer into thread.

Pull out pressure holding valve.
Remove any drill shavings carefully.
6
44572-0
Install pressure holding valve.

Apply locking agent to the collar of the new pressure
holding valve.
44573-0
Insert new pressure holding valve in the crankcase.
44574-0
02/2010
2/4
Crankcase
W 01-07-03
TCD 2013 2V
Knock in pressure holding valve to the stop with a
suitable tool.
W 16-01-01
Insert oil dipstick.
6
44575-0
02/2010
3/4
Crankcase
W 01-07-03
TCD 2013 2V
02/2010
4/4
Crankcase
W 01-08-01
TCD 2013 2V
Standard tools
W 05-05-01
Removing the piston cooling nozzles

Remove crankshaft.
W 05-05-01
Screw self-tapping screw (1) carefully into the piston
cooling nozzle.
44271-0
Pull out piston cooling nozzle (1) with pliers.
44272-0
02/2010
1/2
Crankcase
W 01-08-01
TCD 2013 2V
Installing the piston cooling nozzles

Clean the bores for the piston cooling nozzles in the
crankcase.
Knock in new piston cooling nozzle (1) with pin to the
stop.
Install crankshaft.
W 05-05-01
6
44273-0
02/2010
2/2
Crankcase
W 01-13-01
TCD 2013 2V
Standard tools:
Micrometer gauge
Depth-measuring
appliance
W 04-01-01
Checking the collar rest for the cylinder liner

Remove cylinder liner.
W 04-01-01
Visually inspect collar rest (arrow).
Visually inspect sealing surface.
44076-0
Measure collar rest with depth measuring appliance.

8,92 -0
+0.03
mm
Measure collar rest at several points.
44077-0
02/2010
1/2
Crankcase
W 01-13-01
TCD 2013 2V
02/2010
2/2

W 02-01-01
TCD 2013 2V
Attention!
Standard tools:
Wire brush
4 pin bolts M8x70
Special tools:
Separating tool
Make sure that no gasket residue falls into

the crankcase.
Seal all openings.
151500

to regulations.
Packing compound
DEUTZ DW 74
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 the lubricating oil pan

Pull out oil dipstick (1).
Unscrew locking screw (2).
Drain lubricating oil, collect and dispose of according

to regulations.
2
44480-1
Unscrew all screws (1).
45971-0
02/2010
1/6

W 02-01-01
TCD 2013 2V
Drive in separating tool (1) to the stop (2).
Attention!
The tool can only be driven in in the area of

the crankcase.
Separation in the area of aluminium parts
is not allowed.
6
45969-0
Drive in second separating tool (1) to the stop (2).
Attention!
The tool can only be driven in in the area of

the crankcase.
Separation in the area of aluminium parts
is not allowed.
2
1
45970-0
Lever out lubricating oil pan.

Remove lubricating oil pan.
45968-0
02/2010
2/6

W 02-01-01
TCD 2013 2V
Visually inspect the component.
6
43450-1
Installing the lubricating oil pan

Scrape off sealing compound with separating tool.
46907-0
Attention!
Wear protective glasses.

Clean the sealing surface on the crankcase with a
wire brush.
The sealing surfaces must be dry and free
from grease and dirt.
46908-0
02/2010
3/6

W 02-01-01
TCD 2013 2V
Attention!
Wear protective glasses.

Clean the sealing surface on the lubricating oil pan
with a wire brush.
6
45972-0
Apply packing compound evenly to the sealing surface and in the beading of the lube oil tray.
Apply the packing compound in an even
bead (thickness approx. 3.5 mm).
The position of the packing compound is
only partly illlustrated.
43451-0
To align the lubricating oil pan, screw four pin bolts

(1) diagonally opposed into the crankcase.
Align the lubricating oil pan in the appropriate installation position with the pin bolts.
Mount lubricating oil pan.
Attention!
Do not move the lubricating oil pan any

more.
Observe the drying time for the packing
compound.
Unscrew the pin bolts.
45678-0
02/2010
4/6

W 02-01-01
TCD 2013 2V
Fasten all screws (1).
6
45971-0

30 Nm
24 20 16 12 8
9 13 17 21 25 29
Representation: Tightening sequence 6cylinder

28
32
31
34
27
33
23 19 15 11 7
6 10 14 18 22 26 30
43414-0
Representation: Tightening sequence 4cylinder

20
16
12
13
17
24
21
26
25
23
22
19
15
11
10
14
18
43413-0
02/2010
5/6

W 02-01-01
TCD 2013 2V
Insert new sealing ring.

Tighten screw plug (2).
55 Nm (M18x1,5)
Insert oil dipstick (1).
Fill in lubricating oil according to operating manual.
2
44480-1
02/2010
6/6
Cylinder liner
W 04-01-01
TCD 2013 2V
Standard tools
8190
Special tools:
Extraction tool, universal
Tension plate
Assembly lever
Washer
150170
150171
150190
150191
W 01-05-01
W 01-13-01
W 04-01-02
W 06-01-01

to regulations.
Fitting compound
DEUTZ AP1908
Lubricating oil and coolant must be filled

according to the instructions in the operating manual.
Removing the cylinder liner

Remove piston and connecting rod.
W 06-01-01
2
Unscrew screws (1).

Remove the liner holder (2).
44260-0
Pre-mount the disassembly device

Mount the plate (1) on the disassembly device
Adapt the counter support (2) according to the diameter of the cylinder liner.
2
1
43564-0
02/2010
1/6
Cylinder liner
W 04-01-01
TCD 2013 2V
Fold the plate (1) to the side and insert the disassembly device in the cylinder liner.
Attention!
Do not damage the running surfaces and

the sealing surfaces.
1
6
44442-0
Mount the counter holder (1) on the crankcase.

Do not mount the counter holders on the
cylinder liner's sealing surface.
44443-0
Place the plate (1) with the lay-on surfaces against

the cylinder liner (2) and hold them together.
2
1
44063-0
02/2010
2/6
Cylinder liner
W 04-01-01
TCD 2013 2V
Turn the nut (1) clockwise.
Remove the disassembly device.
6
44064-0
Pull the cylinder liner up and out.
44065-0
Remove O-rings.
Testing the cylinder liner.
W 04-01-02
44066-0
02/2010
3/6
Cylinder liner
W 04-01-01
TCD 2013 2V
Install cylinder liner

Check collar contact for cylinder liner.
W 01-13-01
Clean cylinder liner.
Insert new O-rings.
6
43568-0
Coat the crankcase and the cylinder liner in area (X)

with lubricating oil.
44441-0
Insert the cylinder liner in the crankcase.

Make sure that the liner surface and the
crankcase are absolutely clean before
installing the cylinder liner.
44067-0
02/2010
4/6
Cylinder liner
W 04-01-01
TCD 2013 2V
Select the pressing disc (1) according to the diameter of the cylinder liner and screw to the assembly lever.
6
43610-0
Fasten screw (2).

Hook assembly lever (1) to screw.
Mount disc (3) on cylinder liner.
Ensure that the installation location is free
from faults.
3
44068-0
Press in the cylinder liner to the stop with the assembly lever.
44069-0
02/2010
5/6
Cylinder liner
W 04-01-01
TCD 2013 2V
Remove assembly lever.

Check the overhang of the cylinder liner.
W 01-05-01
6
44070-0
Mount liner holder (2).

Tighten screws (1).
Install piston and connecting rod.
W 06-01-01
44260-0
02/2010
6/6
Cylinder liner
W 04-01-02
TCD 2013 2V
Standard tools:
Micrometer gauge
Internal measuring device
Special tools:
Dial gauge
W 04-01-01
W 06-01-01
W 08-03-01
The crankshaft bearing covers must be
mounted properly for measuring the
cylinders.
100400

W 08-03-01
Check cylinder liner for visible signs of wear.
Remove piston and connecting rod.
W 06-01-01
44074-0
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 108 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".
36094-1
02/2010
1/4
Cylinder liner
W 04-01-02
TCD 2013 2V
Diagram for measuring the cylinder

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

Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
Compare actual value with setpoint value.
108 -0
+0.02
mm
When the wear limit is reached, the

cylinder liner must be renewed.
Remove cylinder liner.
W 04-01-01
44075-0
Visually inspect sealing surfaces (arrows).
44078-0
02/2010
2/4
Cylinder liner
W 04-01-02
TCD 2013 2V
Measure collar height in area (X) with micrometer
gauge.
9 -0.02 mm
+0
Measure collar height at several points.
6
48168-1
Install cylinder liner.

W 04-01-01
Install piston and connecting rod.
W 06-01-01
W 08-03-01
44080-0
02/2010
3/4
Cylinder liner
W 04-01-02
TCD 2013 2V
02/2010
4/4

W 05-01-01
TCD 2013 2V
Standard tools:
Feeler gauges
V-belt tension measuring
device
8115
Operation manual
W 01-03-01
Attention!
Only test / tighten / renew V-belts when the

engine is not running.
Locking agent
DEUTZ DW 72
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

Loosen screws (1).
Do not unscrew screws.
1
44037-1
Loosen screws (1).
1
1
44038-0
02/2010
1/12

W 05-01-01
TCD 2013 2V
Loosen V-belt by unscrewing the clamping screw (1).
6
44039-0
Remove V-belt (1).
44040-0
Unscrew screws (1).

Remove V-belt pulley (2).
44041-0
02/2010
2/12

W 05-01-01
TCD 2013 2V
Loosen all screws (arrow).
6
44526-0
Loosen screws (1).

Swing the fuel supply pump (2) to the side (arrow).
1
2
44042-0
Remove V-belt (1).
44043-0
02/2010
3/12

W 05-01-01
TCD 2013 2V
Unscrew all screws (arrow).

Remove the torsional vibration damper.
6
44527-0
Unscrew screws (arrows).

Remove adapter (1).
Block flywheel with suitable tool.
1
2
44528-0
Unscrew screws (1).

Remove tooth lock washer (2).
1
2
44529-0
02/2010
4/12

W 05-01-01
TCD 2013 2V
6
44530-0
Installing the V-belt, V-belt pulley

Make sure the clamping bushing (arrow) is in place.
44531-0
Fix the tooth lock washer with the largest hole (1) to
the V-belt pulley with clamping bushing (2).
Note installation position of the tooth lock
washer.
1
44532-0
02/2010
5/12

W 05-01-01
TCD 2013 2V

60 Nm
Insert screw with locking agent.
6
44533-0
Make sure the clamping bushings (arrows) are in

place.
44534-0
Mount V-belt pulley.

The clamping bushing (1) must grip in the
hole (2).
44535-0
02/2010
6/12

W 05-01-01
TCD 2013 2V
Mount adapter.
Fasten screws.
The centring bolt (1) must face the V-belt
pulley.
6
44536-0
Tighten new screws (1) with rotation angle disc.

Stage 1:
30 Nm
Stage 2:
60
Stage 3:
60
Attention!
Renew screws every time they are loosened.

44537-0
Mount the torsional vibration damper.

Tighten the screws (arrow) alternately.
70 Nm
Note installation position of the torsional
vibration damper.
The holes in the torsional vibration damper
must match the threaded holes in the Vbelt pulley.
44538-0
02/2010
7/12

W 05-01-01
TCD 2013 2V
Mount V-belt (1) for coolant pump.
6
44043-0
Press clamping strap (1) in direction of arrow with a

suitable tool.
Tighten screw (2).
30 Nm
44049-0
Check V-belt tension with V-belt tension

measuring device
Lower indicator arm (1) into V-belt tension measuring
device.
44591-0
02/2010
8/12

W 05-01-01
TCD 2013 2V
Mount V-belt tension measuring device on V-belt.
The V-belt must be between the
guides (arrow).
6
44050-0
Press the V-belt measuring device against the V-belt

with the button (1) until you hear it click.
Read measured value at the intersection (arrow) of
the indicator arm and scale.
Operation manual
Note different units on the scale.
If the nominal value is not reached, the tensioning
process must be repeated.
1
44051-0
Tighten screw (arrow).

30 Nm
44052-0
02/2010
9/12

W 05-01-01
TCD 2013 2V
Mount V-belt pulley (2).

Tighten screws (1).
6
44041-0
Mount V-belt (1) for generator.
44040-0
Tighten V-belt (1) by turning the clamping screw (2).
1
44053-0
02/2010
10/12

W 05-01-01
TCD 2013 2V
Lower indicator arm (1) into V-belt tension measuring
device.
1
6
44591-0
Mount V-belt tension measuring device on V-belt.

The V-belt must be between the
guides (arrow).
44054-0
Press the V-belt measuring device against the V-belt

with the button (1) until you hear it click.
Read measured value at the intersection (arrow) of
the indicator arm and scale.
Operation manual
Note different units on the scale.
If the nominal value is not reached, the tensioning
process must be repeated.
1
44055-0
02/2010
11/12

W 05-01-01
TCD 2013 2V
Tighten screw (1).

30 Nm
Tighten screw (2).
30 Nm
Tighten screw (3).
30 Nm
2
44056-0

30 Nm
44057-0

(crankshaft).
0,6 -0.1 mm
+0.1

Set gap dimension for speed governor (crankshaft).
W 01-03-01
44094-0
02/2010
12/12

W 05-02-01
TCD 2013 2V
(V-belt drive)
Standard tools
Removing the torsional vibration damper

Unscrew all screws (1).
Remove the torsional vibration damper.
1
1
1
44436-0
Installing the torsional vibration damper

Mount the torsional vibration damper.
Note installation position.
The holes in the torsional vibration damper
must match the threaded holes in the Vbelt pulley.
Attention!
The following new screws without washers

must be used when the torsional vibration
damper is removed or changed.
See the spare parts documentation.
M10x20-12.9
without washer
Tighten screws alternately.
44437-0
70 Nm
02/2010
1/2

W 05-02-01
TCD 2013 2V
02/2010
2/2
Flywheel
W 05-03-01
TCD 2013 2V
Standard tools:
Rotation angle disc
Guide pin (self-constructed)
8190
Removing the flywheel

Remove flywheel.
44569-0
44276-0
02/2010
1/4
Flywheel
W 05-03-01
TCD 2013 2V
Installing the flywheel

6
44555-0
Insert self-made guide pin (arrow).

For example a pin bolt.
Mount flywheel.
The bores in the flywheel must match the
threaded bores in the crankshaft flange.
34224-2
Fasten screws.
Attention!
Use new screws.

Remove guide pin.
44556-0
02/2010
2/4
Flywheel
W 05-03-01
TCD 2013 2V
M10x35 - M10x85
Tighten screws .
Stage 1:
30 Nm
Stage 2:
60
Stage 3:
60
6
42826-0
M10x30
Tighten screws .
Stage 1:
30 Nm
Stage 2:
60
Stage 3:
30
42826-0
Drive plugs into the threaded bores (arrows) to the

stop.
31115-1
02/2010
3/4
Flywheel
W 05-03-01
TCD 2013 2V
02/2010
4/4
Crankshaft
W 05-05-01
TCD 2013 2V
Standard tools:
Socket wrench insert
8035
Special tools:
Turn-over gear
100380
W 01-03-01
W 05-05-03
W 09-02-02
Removing crankshaft
Remove front cover (opposite side to flywheel).
W 01-03-01
Remove the gear case cover (flywheel side).
W 09-02-02
44220-0
44221-0
02/2010
1/12
Crankshaft
W 05-05-01
TCD 2013 2V
Removing the big end bearing cap

Insert turn-over gear (1).
Tighten screws (2).
1
6
44222-0
Place lifting journal of the respective cylinder at bottom dead centre (BDC).
Attention!
Do not jam the con rods when turning the

crankshaft.
44223-0
Unscrew screws (1).

Remove big end bearing cap (2).
Remove bearing shell.
Lay out components in the order in which
they should be installed.
Note order of cylinders.

1
44224-0
02/2010
2/12
Crankshaft
W 05-05-01
TCD 2013 2V
Make a mark (1) on the camshaft gear wheel for assistance.
Your mark must be on a line between the
marking (2) and the middle (3) of the
camshaft.
6
44225-0
Turn the crankshaft evenly until the marking (1) on

the crankshaft flange is in line with your mark (2) on
the camshaft gear wheel.
The marking on the camshaft gear wheel is
covered by the crankshaft flange when it is
in line.
Attention!

crankshaft.
2
44226-0
Removing the main bearing cover

Use socket wrench insert.
44227-0
02/2010
3/12
Crankshaft
W 05-05-01
TCD 2013 2V
Remove bearing cap (1).

Remove both thrust ring halves (arrows).
Remove all main bearing covers (2).
Remove bearing shells.

6
44228-0
Press the con rods carefully out of the lifting journal.

Lift out the crankshaft.
44230-0

Remove bearing shells (1) and (2).

Check axial backlash of crankshaft (crankshaft removed).
W 05-05-03
44231-0
02/2010
4/12
Crankshaft
W 05-05-01
TCD 2013 2V
Installing the crankshaft
Insert upper main bearing shells.
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).
6
44232-0
Insert lower main bearing shells in the respective

main bearing cover.
groove (2).
44233-0
Make sure the clamping bushings (1) are

in place.
1
44234-0
02/2010
5/12
Crankshaft
W 05-05-01
TCD 2013 2V
Insert bearing shell in the con rod.

groove (2).
6
44235-0
Insert bearing shell in the respective big end bearing

cap.
groove (2).
44216-0
Make sure the clamping bushings (arrows)

are in place.
44236-0
02/2010
6/12
Crankshaft
W 05-05-01
TCD 2013 2V
Position camshaft.
The bore (1) must be facing the cylinder
head.
Lightly oil bearing surfaces.
6
44237-0
Insert the crankshaft carefully in the crankcase.
Attention!
Do not jam the con rods when inserting the

crankshaft!
Set the crankshaft in line with the camshaft.
Make sure that the markings match up.
44238-1
Check control times.

The marking (1) on the crankshaft flange
must be in line with your mark (2).
1
44446-0
02/2010
7/12
Crankshaft
W 05-05-01
TCD 2013 2V
Install upper thrust ring halves according to measured axial clearance.

Thrust ring halves, without guide lugs, between the crankshaft and the
crankcase (arrows).
Oil grooves (1) of the thrust ring halves
face the web face (2) of the
crankshaft (arrows)
6
42662-0
Fix both thrust ring halves with a little grease to the

bearing cap.
Bearing cap with identification 2.
Use thrust ring halves with guide
lug (arrow).
Oil grooves (1) face the crankshaft web

face.
42663-0
Mounting the main bearing cover

Insert bearing cap (1).
Insert main bearing cover (2) according to the numbering.
Note assignment and installation position:
Insert main bearing cover with the

number 1 on the flywheel side.
Gate (arrow) on the bearing cover faces
the manifold side.
44240-0
02/2010
8/12
Crankshaft
W 05-05-01
TCD 2013 2V
Attention!
Screws can be used a maximum 3 times

with written documentation.
Tighten all screws (1) of the main and fit bearing covers.
Stage 1:
50 Nm
Stage 2:
60
Stage 3:
60
44241-0
Installing the big end bearing cap

Pull con rods carefully on to the lifting journal.
44242-0
Place lifting journal of the respective cylinder at bottom dead centre (BDC).
Attention!

crankshaft.
44243-0
02/2010
9/12
Crankshaft
W 05-05-01
TCD 2013 2V
Mount big end bearing cap.
Attention!
Note the assignment of the big end bearing

cap.
The identification numbers (1) on the con
rod and the big end bearing cap must be
identical and opposite to each other when
assembled.
2651
9
26 5 1
9
44244-0
Tighten new screws with rotation angle disc.

Stage 1:
30 Nm
Stage 2:
60
Stage 3:
60
44245-0
Unscrew screws (2).

Remove turning gear (1).
1
44222-0
02/2010
10/12
Crankshaft
W 05-05-01
TCD 2013 2V
6
44221-0
Check axial backlash of crankshaft (crankshaft installed).

W 05-05-03
44187-0
Install the gear case cover (flywheel side).

W 09-02-02
Install front cover (opposite side to flywheel).
W 01-03-01
44220-0
02/2010
11/12
Crankshaft
W 05-05-01
TCD 2013 2V
02/2010
12/12
Crankshaft
W 05-05-02
TCD 2013 2V
Standard tools:
Magnetic measuring stand
Micrometer gauge
Prisms
Hardness tester
Special tools:
Dial gauge
W 05-05-01
100400
Checking the bearing pin hardness

Remove crankshaft.
W 05-05-01
Place crankshaft on prism.
42602-0
Put hardness tester on journal.
30560-1
02/2010
1/4
Crankshaft
W 05-05-02
TCD 2013 2V
Raise stylus (1) and press release (2).

Stylus (1) falls down, briefly strikes the surface and jumps up to the measured value.
6
44445-0
Read off displayed value (arrow) from hardness tester.

53 +3
-3 HRC
The measured value is to be converted
according to the table of the measuring
device.
43515-1
Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.
36424-2
02/2010
2/4
Crankshaft
W 05-05-02
TCD 2013 2V
Checking the diameter of the main bearing
pins
Measure main bearing pin with micrometer gauge.
Standard
85,00 -0.02 mm
0
Measuring points see diagram.
6
42603-0
Checking the diameter of the lifting journals

Measure lifting journal with micrometer gauge.
Standard
68,00 -0.02 mm
0
42604-0
Checking the rotation

Mount magnetic measuring stand.
Insert dial gauge.
Apply stylus to the main bearing pin with pre-tension
(arrow) and adjust dial gauge to "0".
Turn crankshaft evenly and check rotation.
4-cylinder:
0,07 mm
6-cylinder:
0,10 mm
Remove magnetic measuring stand.
Remove dial gauge.
42605-0
02/2010
3/4
Crankshaft
W 05-05-02
TCD 2013 2V
Measuring the fit bearing width

"0".
6
35825-2
Measure bearing width with internal measuring device between thelay-on surfaces of the thrust rings.
Standard
38
+0.06
mm
42606-0
Visual inspection
Check the running surfaces (1) of the crankshaft
sealing rings visually.
Visually inspect gear wheel (2).
Install crankshaft.
W 05-05-01
42607-0
02/2010
4/4
Crankshaft
W 05-05-03
TCD 2013 2V
Standard tools:
Micrometer gauge
8035
8190
Special tools:
Dial gauge
W 01-03-01
W 05-05-01
W 09-02-02
100400
Remove front cover.

W 01-03-01
Remove the gear case cover.
W 09-02-02
Insert dial gauge.
Apply stylus to the crankshaft end with pre-tension.
Press crankshaft in direction of arrow.
44179-0
Press crankshaft in direction of arrow.

Read off measured value.
0,1 - 0,3 mm
In case of deviating axial clearance, the
permissible axial clearance should be set
by changing the thrust ring halves.
44180-0
02/2010
1/6
Crankshaft
W 05-05-03
TCD 2013 2V
Unscrew screws (1).

1
Remove bearing cap (2).

Remove lower bearing shell.
44181-0
44182-0
Measure the wall thickness of the thrust ring halves.

Standard
2,9 0
+0.05
mm
Select thrust ring halves according to measured value.
43504-0
02/2010
2/6
Crankshaft
W 05-05-03
TCD 2013 2V
Remove crankshaft.
W 05-05-01
Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".
6
35825-2
Measure locating bearing width

Note measured value, dimension (a).
42606-0
Place thrust ring halves on bearing caps (arrows).

Measure width with micrometer gauge.
Note measured value, dimension (b).
35827-2
02/2010
3/6
Crankshaft
W 05-05-03
TCD 2013 2V
Determine axial backlash.

0,1 - 0,3 mm
Calculation example
Desired:
Axial backlash
Given:
Measured:
(a) = 38.6 mm
(b) = 38.4 mm
Calculation:
Dimension (a) - Dimension (b)
Result:
= 0.2 mm
Install crankshaft.
W 05-05-01
6
35827-2

in place.
44183-0
Install upper thrust ring halves according to measured axial clearance.

Oil grooves (1) of the thrust ring halves
face the crankshaft web face (2).
Insert thrust ring halves between
crankcase and crankshaft web (arrow).
44184-0
02/2010
4/6
Crankshaft
W 05-05-03
TCD 2013 2V
Fix both thrust ring halves with a little grease to the
bearing cap.
Use lower thrust ring halves with guide lug
(arrow).
Install thrust ring halves according to measured axial clearance.
Bearing cap with identification 2.

The oil grooves (1) face the crankshaft
web face.
6
42663-0
Insert bearing cap (1).

The gate (arrow) on the bearing cap faces
the manifold side.
44185-0

Stage 1:
50 Nm
Stage 2:
60
Stage 3:
60
Attention!
Screws can be used a maximum 3 times

with written documentation.
44186-0
02/2010
5/6
Crankshaft
W 05-05-03
TCD 2013 2V
Check axial backlash of crankshaft.

0,1 - 0,3 mm
Remove dial gauge.
Install front cover.
W 01-03-01
Install the gear case cover.
W 09-02-02
6
44187-0
02/2010
6/6
Connecting rod
W 06-01-01
TCD 2013 2V
Standard tools:
Rotation angle disc
8190
Special tools:
Piston ring compressor
Liner holder
W 07-02-02
W 08-03-01
W 16-01-01
130640
150180
Attention!
The assignment of con rod and big end

bearing cover must stay as it is. If con rod
and big end bearing cover are assembled
the wrong way around, the con rod will be
unusable!
Do not damage the fracture surfaces of the
con rod and big end bearing cover!
to regulations.
The engine oil and coolant should be
added according to the operating manual.
Removing the piston and con rod

W 08-03-01
2

W 16-01-01
Mount liner holder (2).
Tighten screws (1).
44260-0
02/2010
1/8
Connecting rod
W 06-01-01
TCD 2013 2V
Removing the big end bearing cap

Set lifting journal at bottom dead centre (BDC).
Unscrew screws (1).
Remove big end bearing cap (2).
6
44248-0
Press out the piston and connection rod.

44249-0
Remove con rod bearing shells (1).

02/2010
2/8
44250-0
Connecting rod
W 06-01-01
TCD 2013 2V
Removing the piston
Remove locking ring.
Press out piston pin.
6
44251-0
Completing con rod and piston

Insert new locking ring.
from faults.
44252-0
The flywheel/crankshaft symbol (1) on the

piston base must face to the right and the
identification number (2) on the con rod
must face upwards.
26519
Insert con rod.
44253-0
02/2010
3/8
Connecting rod
W 06-01-01
TCD 2013 2V
Oil the piston bolt lightly.

Press the piston bolt through.
Insert new locking ring.
from faults.
6
44254-0
Installing the piston and con rod

in place.
44211-0

groove (2).
1
44215-0
02/2010
4/8
Connecting rod
W 06-01-01
TCD 2013 2V
cap.
groove (2).
6
44216-0
Arrange the piston ring joints with an offset of

about 120 to each other.
Check piston rings and piston ring grooves.
W 07-02-02
42380-1
Lightly oil cylinder running surface, piston, piston

rings and lifting bearing journal lightly.
Clamp piston rings with piston ring compressor (1).
Do not turn the piston rings any further.
44255-0
02/2010
5/8
Connecting rod
W 06-01-01
TCD 2013 2V
Set lifting journal at bottom dead centre (BDC).

Push piston and con rod completely into cylinder liner.
Note the cylinder assignment of the piston.
Note the label indicating the installation
position on the piston base.
The symbol flywheel/crankshaft (1) must
face the flywheel.
The piston ring compressor must lie flat on
the cylinder liner.
6
44256-0
Press the con rod carefully against the lifting journal.
Attention!
Do not jam the con rod with the crankshaft.
44257-0
Installing the big end bearing cap

Attention!

cap.
assembled.
44258-0
02/2010
6/8
Connecting rod
W 06-01-01
TCD 2013 2V
Tighten new screws with rotation angle disc.
Stage 1:
30 Nm
Stage 2:
60
Stage 3:
60
6
44259-0

Unscrew screws (1).
2
44260-0

W 16-01-01
W 08-03-01
44261-0
02/2010
7/8
Connecting rod
W 06-01-01
TCD 2013 2V
02/2010
8/8
Connecting rod
W 06-01-02
TCD 2013 2V
Standard tools:
Micrometer gauge
Con rod test device
Rotation angle disc
8190
Special tools:
Dial gauge
W 05-05-02
100400
Checking small end bush

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

at the points "a" and "b" in the
levels "1" and "2".
37239-1
02/2010
1/8
Connecting rod
W 06-01-02
TCD 2013 2V
Insert internal measuring device.

42 +0.04 mm
+0.05

Note the measured value, dimension (A).
The dimension A is required to determine
the piston bolt clearance.
6
34770-2
Checking diameter of the piston bolt

Measure piston pin with micrometer gauge.
42 -0.006 mm
0
Note the measured value, dimension B.

The dimension B is required to determine
the piston bolt clearance.
35908-2
Determining the piston bolt clearance

The piston bolt clearance is given by the
difference between the internal diameter of
the small end bush (dimension A) and the
piston bolt diameter (dimension B).
0,034 - 0,056 mm
Calculation example
Desired:
Piston pin clearance
Given:
Measured:
(A) = 40.045 mm
Calculation:
(B) = 40.006 mm
dimension (A) - dimension (B)
Result:
= 0.039 mm
02/2010
2/8
Connecting rod
W 06-01-02
TCD 2013 2V
Checking the con rod bearing bore
in place.
6
44440-0
Attention!
26519

cap.
assembled.
26519
44212-0
Tighten screws alternately with rotation angle disc

and socket wrench insert.
Stage 1:
50 Nm
Stage 2:
60
Stage 3:
60
44213-0
02/2010
3/8
Connecting rod
W 06-01-02
TCD 2013 2V

"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

72,5 mm
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.
44214-0
02/2010
4/8
Connecting rod
W 06-01-02
TCD 2013 2V
Checking internal diameter of the con rod
bearing shells
Remove screws.
Remove the con rod bearing cover.
in place.
6
44440-0
Attention!

groove (2).
1
44215-0

cap.
Attention!

groove (2).
44216-0
02/2010
5/8
Connecting rod
W 06-01-02
TCD 2013 2V
Attention!
2651
9

cap.
assembled.
2651
9
6
44217-0
Tighten screws alternately with rotation angle disc

and socket wrench insert.
Stage 1:
50 Nm
Stage 2:
60
Stage 3:
60
44218-0

Set micrometer gauge to 72.5 mm.
"0".
36094-1
02/2010
6/8
Connecting rod
W 06-01-02
TCD 2013 2V
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

72,5 0
+0.02
mm
When the wear limit is reached the con rod

must be replaced.
Note the measured value, dimension (C).
44219-0
Checking the diameter of the lifting journals.

W 05-05-02
Check con rod bearing clearance.
0,036 - 0,095 mm
The big end bearing clearance is given by
the difference between the internal diameter of the big end bearing shell (C) and the
lifting journal diameter (D).
Remove screws.
Remove the con rod bearing cover.
42604-0
02/2010
7/8
Connecting rod
W 06-01-02
TCD 2013 2V

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

Check that the con rod is parallel.
Permissible deviation from (A) to (B).
0,05 mm
Distance between A and B = 100 mm.
6
30579-1
Move test fork in direction of arrow.

Check the angle of the con rod.
Permissible deviation from (C) to (D).
0,05 mm
Distance between C and D = 100 mm
C
D
30580-1
02/2010
8/8
Piston
W 07-01-02
TCD 2013 2V
Checking the piston
Standard tools:
Micrometer gauge
Special tools:
Dial gauge
W 06-01-01
When the piston wear limit is reached, the

piston must be renewed.
100400
Checking the piston bolt bore

Remove piston from con rod.
W 06-01-01
44262-0

"0".
34768-2
02/2010
1/4
Piston
W 07-01-02
TCD 2013 2V
Diagram for measuring the piston bolt bore

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

bore.
42 +0.017
+0.010 mm
See schematic diagram for measuring
points.
43483-0
Checking the piston diameter

Diagram for measuring the piston diameter
at the measuring points "1, 2 and 3", transverse to the piston bolt bore.
Measuring point 1
12 mm
Measuring point 2
64 mm
Measuring point 3
97 mm
37244-2
02/2010
2/4
Piston
W 07-01-02
TCD 2013 2V
Measure piston diameter with micrometer gauge.
Measuring point 1
107,700 mm
Measuring point 2
107,800 mm
Measuring point 3
107,660 mm
points.
Assemble con rod and piston.
W 06-01-01
6
43427-0
02/2010
3/4
Piston
W 07-01-02
TCD 2013 2V
02/2010
4/4
Piston
W 07-02-02
TCD 2013 2V
Standard tools:
Feeler gauges
W 06-01-01
Special tools:
Universal piston ring pliers 130300
Trapezoidal groove wear
gauge
130420
Checking the piston rings and piston ring

grooves
Remove piston from con rod.
W 06-01-01
Set universal piston ring pliers to the piston diameter.
108 mm
Remove piston rings with universal piston ring pliers.
44263-0
Clean piston.
Visually inspect piston.
Visually inspect piston ring grooves.
44264-0
02/2010
1/6
Piston
W 07-02-02
TCD 2013 2V
Measure piston ring groove for first piston ring with

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

touching the piston (arrow), the piston
must be changed.
33868-2
02/2010
2/6
Piston
W 07-02-02
TCD 2013 2V
Checking the piston ring joint clearance
Unscrew screws (1).
2
6
44260-0
Insert the piston ring (1) in the cylinder.

Align the piston ring in the cylinder by pushing the
piston.
1
44265-0
Measure the piston ring joint clearance with a feeler

gauge.
1. piston ring
0,3 - 0,55 mm
2. piston ring
1,5 - 2,0 mm
3. piston ring
0,3 - 0,6 mm
When the wear limit is reached, the piston
ring must be renewed.
44266-0
02/2010
3/6
Piston
W 07-02-02
TCD 2013 2V
Install piston rings.

Order and position of the piston rings as
seen from the piston base.
- Double-sided keystone ring (1)
- Taper-faced ring (2)
- Bevelland-edge oil control ring with coiled

spring expander (3)
Top label faces the combustion

chamber.
6
44267-0
Install piston rings with universal piston ring pliers.

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

Check axial backlash with feeler gauge between piston ring and piston ring groove.
2. piston ring
0,09 - 0,13 mm
3. piston ring
0,03 - 0,075 mm
Check with new piston rings.
When the piston wear limit is reached, the
piston must be renewed.
44269-0
02/2010
4/6
Piston
W 07-02-02
TCD 2013 2V
Assemble con rod and piston.
W 06-01-01
6
44270-0
02/2010
5/6
Piston
W 07-02-02
TCD 2013 2V
02/2010
6/6
Cylinder head
W 08-00-01
TCD 2013 2V
Standard tools:
Compression pressure
tester
Torx tool set
8005
8189
Special tools:
Connector
100190
W 11-01-01
W 19-01-01

Setting the valve clearance (with exhaust return
module installed).
W 11-01-01
Remove injector.
W 19-01-01
Insert connector (1).
Use sealing ring for injector.
44100-0
Mount clamping shoe (1).

Tighten screw (2).
25 Nm
When installing the connector on
cylinders 1 to 5, the clamping shoe must
be inserted together with the connector.
1
2
44101-0
02/2010
1/4
Cylinder head
W 08-00-01
TCD 2013 2V
Connect adapter (1) to connector.
6
44102-0
Connect compression pressure tester to connector.

Turn over engine with starter.
X
X
44103-0
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.
No.
Zyl.
Kompression in bar
Compression value in bar
Pression
en bar
Dat. _________
10 15 20 25
30 35 40
1
2
3
4
5
6
7
8
DBGM
Made in Germany
MOTOMETER
33771-5
02/2010
2/4
Cylinder head
W 08-00-01
TCD 2013 2V
Remove the compression pressure tester.
6
44103-0
Unscrew screw (1).

Remove clamping shoe (2).
Remove connector.
Installing the injector.
W 19-01-01
1
2
44101-0
02/2010
3/4
Cylinder head
W 08-00-01
TCD 2013 2V
Technical Data
ID no.
Name
Connection piece on cylinder head,
A49 001
clamping shoe
Screw type
Notes / Remark
Value
25 Nm
02/2010
4/4
Cylinder head
W 08-01-01
TCD 2013 2V
Standard tools:
Spring band pliers
9090
Removing cylinder head

Loosen spring band clip (1) with spring band pliers.
Pull off bleeding hose (2).
2
44130-0
Unscrew screws (1).

Remove the cover (2).
44126-0
02/2010
1/4
Cylinder head
W 08-01-01
TCD 2013 2V
Unscrew all screws.

Remove cylinder head cover and gasket.
6
44127-0
Installing cylinder head cover.

Insert new gasket (arrow).
44128-0
Mount cylinder head cover.

13 Nm
Attention!
Do not trap the cable (1).
44162-0
02/2010
2/4
Cylinder head
W 08-01-01
TCD 2013 2V
Mount cover (2).
Tighten screws (1).
8.5 Nm
1
6
44126-0
Plug on bleeding hose.

Position the spring band clip (1) with the spring band
pliers.
1
44129-0
02/2010
3/4
Cylinder head
W 08-01-01
TCD 2013 2V
Technical Data
ID no.
Name
Cylinder head cowling on cylinder
A01 004
head
A13 041 Cover plate on cylinder head cover
Screw type
Notes / Remark
M6
M6x16
Value
13 Nm
self-tapping
8.5 Nm
02/2010
4/4
Cylinder head
W 08-02-01
TCD 2013 2V
Removing and installing the exhaust return module
Standard tools
W 08-01-01
W 11-01-01
Remove exhaust return module

Remove the cylinder head hood.
W 08-01-01
Unscrew screws (1).
Loosen screws evenly to avoid jamming
the exhaust return module.
Pull the exhaust return module (2) off the plug element in the direction of the arrow.
Remove exhaust return module (2).
1
1
44097-0
Unscrew screws (1).

Remove exhaust return module (2).
the exhaust return module.
Note plug element (arrow).
44098-0
02/2010
1/6
Cylinder head
W 08-02-01
TCD 2013 2V
6
44099-0
Installing the exhaust return module

Setting the valve clearance (with or without removal
of exhaust return module).
W 11-01-01
Pull out plug element (1).
1
42927-0
Insert new O-rings (arrows).

Oil O-rings lightly.
Push plug element into exhaust return module.
42928-0
02/2010
2/6
Cylinder head
W 08-02-01
TCD 2013 2V
Mount exhaust return module for cylinders 1 - 3.
Fasten screws.
Note identification (1) for assignment of the

exhaust gas return modules.
Note different screw lengths:
6
44108-1
Retighten the screws (1), (2) and (3) in the tightening

order.
Stage 1:
10 Nm
Stage 2:
30 Nm
44109-0
Push exhaust return module for cylinders 4 - 6 onto

plug element.
Fasten screws.
Note identification (1) for assignment of the
exhaust gas return modules.
2
44274-1
02/2010
3/6
Cylinder head
W 08-02-01
TCD 2013 2V
Retighten the screws (1), (2) and (3) in the tightening

order.
Stage 1:
10 Nm
Stage 2:
30 Nm
Set the control piston clearance.
W 11-01-01
W 08-01-01
6
44275-0
02/2010
4/6
Cylinder head
W 08-02-01
TCD 2013 2V
Technical Data
ID no.
Name
A01 011
Exhaust gas return module on rocker

arm bracket
A01 011
Exhaust gas return module on rocker

arm bracket
Screw type
Notes / Remark
Stage 1:
Observe tightening
sequence
Stage 2:
Observe tightening
sequence
Value
10 Nm
30 Nm
02/2010
5/6
Cylinder head
W 08-02-01
TCD 2013 2V
02/2010
6/6
Cylinder head
W 08-02-02
TCD 2013 2V
Removing and installing the solenoid valve (exhaust gas return)
Standard tools
W 01-01-01

to regulations.
Removing the solenoid valve (exhaust return

line)
Removing the crankcase breather.
W 01-01-01
Unlock cable plug.
Pull out cable plug (1).
1
44417-0
Unscrew solenoid valve (1).
44418-0
02/2010
1/4
Cylinder head
W 08-02-02
TCD 2013 2V
6
44419-0
Installing the solenoid valve (exhaust return

line)
Mount new O-ring (1).

Insert new O-ring (2).
Observe the order of installation of the Oring (2) and the support ring (3).
Oil O-rings lightly.
42834-0
Tighten solenoid valve (1).

24 Nm
44420-0
02/2010
2/4
Cylinder head
W 08-02-02
TCD 2013 2V
Plug in the cable plug (1).
Ensure that the connection is perfect.
Install crankcase breather.
W 01-01-01
1
6
44417-0
02/2010
3/4
Cylinder head
W 08-02-02
TCD 2013 2V
02/2010
4/4
Cylinder head
W 08-03-01
TCD 2013 2V
Standard tools:
Torx tool set
Rotation angle disc
8189
8190
W 01-05-01
W 08-01-01
W 08-03-02
W 11-02-01
W 19-01-01
W 21-02-01
W 22-01-01
W 38-02-01
W 41-01-01
W 44-02-01
W 49-02-01
Removing the cylinder head

Attach turning gear.
W 49-02-01
Remove generator.
W 44-02-01
Unscrew screw (1).
Remove clamping strap (2).
Remove thermostat housing.
W 38-02-01
Remove the exhaust pipe.
2
W 41-01-01
44142-0
Remove the rail.

W 21-02-01
Unlock cable plug (1) and remove.
Remove injector.
W 19-01-01
W 08-01-01
Remove rocker arm brackets and stop rods.
W 11-02-01
Remove the charge air pipe.
W 22-01-01
44143-0
02/2010
1/8
Cylinder head
W 08-03-01
TCD 2013 2V

44144-0
Hold connection piece (3).

Remove sealing rings.
Remove fuel return line (2).
3
1
2
44145-0
Unscrew all screws (arrows).
44146-0
02/2010
2/8
Cylinder head
W 08-03-01
TCD 2013 2V
Hang cylinder head on suitable cross beam (1) and
workshop crane.
Align chains parallel to the cross beam.
Lift the cylinder head carefully from the crankcase.
6
44147-0
Remove the cylinder head gasket.

44148-0
Installing the cylinder head

Check the overhang of the cylinder liner.
W 01-05-01
Check piston overhang.
W 08-03-02
44149-0
02/2010
3/8
Cylinder head
W 08-03-01
TCD 2013 2V
Select cylinder head gasket according to the largest

piston projection measured.
0,28 - <0,54 mm
1 hole, cylinder head gasket 1.42 mm
0,54 - <0,64 mm
0,64 - <0,75 mm
Example: Piston projection = 0.7 mm corresponds to cylinder head gasket with
3 holes (arrow).
44154-0
Make sure the clamping bushings (arrows) are in

place.
44155-0
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.
44156-0
02/2010
4/8
Cylinder head
W 08-03-01
TCD 2013 2V
Fit cylinder head.
Oil the cylinder head screws slightly.
Fasten screws.
Attention!
Cylinder head screws can be used max. 3

times with written proof, otherwise renew
every time they are loosened.
6
44157-0
Tighten all cylinder head screws according to the

tightening sequence.
Stage 1:
50 Nm
Stage 2:
22
130 Nm
26
14
18
6
10
4
2
12
8
20
16
24
Stage 3:
90
25
17
21
9
13
1
5
7
3
15
11
23
19
42526-1
Install rocker arm brackets and stop rods.

W 11-02-01
44158-0
02/2010
5/8
Cylinder head
W 08-03-01
TCD 2013 2V
Mount fuel return pipe (1).

Tighten hollow screw (arrow) with new sealing rings.
29 Nm
6
44159-0
Plug cable plug (1) onto temperature transmitter.

Plug cable plug (2) into the solenoid valve (exhaust
gas return line).
1
44160-0
Installing the injector.

W 19-01-01
1

W 08-01-01
Do not tighten the screws of the clamping
shoe until after assembling the rail.
Install rail.
W 21-02-01
43986-0
02/2010
6/8
Cylinder head
W 08-03-01
TCD 2013 2V
Install the charge air pipe.
W 22-01-01
Install the exhaust pipe.
W 41-01-01
Install thermostat housing.
W 38-02-01
Mount clamping strap (2).
Fasten screw (1).
Install generator.
W 44-02-01
Remove turning gear.
W 49-02-01
02/2010
6
44142-0
7/8
Cylinder head
W 08-03-01
TCD 2013 2V
02/2010
8/8
Cylinder head
W 08-03-02
TCD 2013 2V
Standard tools
Special tools:
Dial gauge
Measuring device
W 08-03-01
W 49-02-01
100400
100750

W 49-02-01
W 08-03-01
Turn the crankshaft until the respective piston is just
in front of the top dead centre (arrow).
Keep the cylinder liner pressed down to the
stop.
44150-0
Insert dial gauge into measuring beam.

Place shims (1) and measuring beam (2) on the sealing surface of the crankcase.
Apply the stylus to the piston base (arrow) under pretension.
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).
44151-0
02/2010
1/2
Cylinder head
W 08-03-02
TCD 2013 2V
Move the measuring beam.

Apply the stylus to the sealing surface of the cylinder
liner (arrow) under pre-tension.
6
44152-0

Measuring points (1) and (2).
2
34151-2
Move the measuring beam.

Apply stylus to the specified measuring points under
pre-tension.
Do not position the stylus on the piston
marking.
Note the largest measured value.
Measure the piston overhang on all pistons.
W 08-03-01
W 49-02-01
02/2010
44153-0
2/2
Cylinder head
W 08-04-01
TCD 2013 2V
Standard tools:
Slide gauge
Assembly lever
W 08-03-01
9017
Special tools:
Support bracket
Base plate
120900
120910
Removing the valves

W 08-03-01
Mount support bracket (1) on base plate (2).
1
Mount cylinder head on support bracket.
2
44163-0
Remove snap ring (1).
Danger!
Risk of injury! Snap ring springs off.
44164-0
02/2010
1/6
Cylinder head
W 08-04-01
TCD 2013 2V
Remove thrust washer (1).
6
44165-0
Install assembly lever (1).

Press down valve spring with assembly lever.
Remove both tapper collets (2).

Remove valve spring plates, valve springs and
valves.
44166-0
Remove valve stem sealing ring (arrow).
44167-0
02/2010
2/6
Cylinder head
W 08-04-01
TCD 2013 2V
Clean cylinder head.
Check cylinder head.
6
44168-0
Installing the valves

Measure valve spring length with slide gauge.
64,7 mm
When the wear limit is reached, the valve
spring must be renewed.
35856-2
Oil the new valve stem sealing ring lightly.

Insert the valve stem sealing ring (1) in the
groove (arrow) of the valve guide.
1
44169-0
02/2010
3/6
Cylinder head
W 08-04-01
TCD 2013 2V
Oil the valve stem lightly.

Insert the valve in the valve guide by turning with a
slight pressure.
Do not damage or press out the valve stem
seal when inserting the valve.
6
44170-0
Insert valve spring (1).

Insert valve spring plate (2).
The closely wound end of the valve plate
faces the cylinder head.
44171-0
Mount assembly lever.

Press down the valve spring with the assembly lever
and insert both tapper collets (1).
Make sure the tapper collets fit correctly in
the valve keyway.
44172-0
02/2010
4/6
Cylinder head
W 08-04-01
TCD 2013 2V
Insert thrust washer (1).
from faults.
6
44165-0
Insert snap ring (arrow).

from faults.
44173-0
Remove cylinder head from support bracket (1).

Remove support bracket from base plate (2).
W 08-03-01
1
2
44163-0
02/2010
5/6
Cylinder head
W 08-04-01
TCD 2013 2V
02/2010
6/6
Cylinder head
W 08-04-02
TCD 2013 2V
Checking the valves
Standard tools:
Micrometer gauge
Slide gauge
W 08-04-01
Clean all valves.

must be renewed.
Checking valve stem diameter

Remove valves.
W 08-04-01
Measure valve stem diameter with micrometer
gauge.
Inlet valve
8,98 0-0.05 mm
Exhaust valve
8,96 -0.05 mm
0
42182-1
Checking valve edge thickness

Measure valve edge thickness with slide gauge.
Inlet valve
2,62 mm
Exhaust valve
2,3 mm
42183-1
02/2010
1/2
Cylinder head
W 08-04-02
TCD 2013 2V
Checking valve head diameter

Measure valve head diameter with slide gauge.
Inlet valve
48 -0.1 mm
+0.1
Exhaust valve
42 -0.1 mm
+0.1
Install valves.
W 08-04-01
6
42184-1
02/2010
2/2
Cylinder head
W 08-04-03
TCD 2013 2V
Standard tools:
Special tools:
Dial gauge
W 08-04-01
New valves are used for testing.
100400

guide must be renewed.

Remove valves and valve shaft seals.
W 08-04-01
Visually inspect valve guide for wear.
44168-0

Insert dial gauge.
Insert new valve.
Place stylus under pre-tension on the valve
head (arrow).
Adjust meter to "0".
44174-0
02/2010
1/2
Cylinder head
W 08-04-03
TCD 2013 2V
Measure valve stem clearance

Move valve back and forth in direction of arrow.
Inlet valve
0,045 - 0,075 mm
Exhaust valve
0,065 - 0,095 mm
The valve stem ends must be flush with the
valve guide.
The whole rocker path must be taken into
consideration.
6
44175-0

Remove dial gauge.
Install valves.
W 08-04-01
44176-0
02/2010
2/2
Cylinder head
W 08-04-04
TCD 2013 2V
Standard tools:
Depth-measuring
appliance
Special tools:
Support bracket
Base plate
W 08-03-01
Attention!
120900
120910

seat insert and/or valve must be renewed.

1
Mount support bracket (1) on base plate (2).

W 08-03-01
44178-0
Mount cylinder head on support bracket (1).
44177-0
02/2010
1/2
Cylinder head
W 08-04-04
TCD 2013 2V
Measure the valve lag from the centre of the valve

head to the cylinder head sealing surface.
Inlet valve
0,99 -0.1 mm
+0.1
Exhaust valve
1 -0.1 mm
+0.15
6
42598-0
Remove cylinder head from support bracket (1).
44177-0
Remove support bracket (1) from base plate (2).

W 08-03-01
44178-0
02/2010
2/2
Gearcase
W 09-01-01
TCD 2013 2V
Renewing the crankshaft sealing ring
(flywheel side)
Standard tools:
Pricker
Assembly lever
8198
9017
Special tools:
Assembly tool
142810
W 05-03-01
Self-tapping screw
Washer
Removing the crankshaft sealing ring

Remove flywheel.
W 05-03-01
Make a hole of approximately 3 mm in the crankshaft
sealing ring with a pricker.
Attention!
Do not damage the gearcase cover and

crankshaft.
44188-0
Turn in a self-tapping screw with washer.
44189-0
02/2010
1/4
Gearcase
W 09-01-01
TCD 2013 2V
Pull out the crankshaft sealing ring with assembly lever.
6
44190-0
Visually inspect all running surfaces.
44191-0
Install crankshaft sealing ring

Mount guide sleeve (1).
Tighten screws .
The bores in the guide sleeve must match

the threaded holes in the crankshaft
flange.
44192-0
02/2010
2/4
Gearcase
W 09-01-01
TCD 2013 2V
Oil the sealing lip of the crankshaft sealing ring lightly.
Push the crankshaft sealing ring carefully onto the
guide sleeve.
Use new crankshaft sealing ring.
The sealing lip faces the crankcase.
6
44193-0
Mount shims (1).

Pay attention to installation depth of crankshaft sealing ring and select shim accordingly.
First assembly = 2 shims
1. Repair installation depth = 1 shim
Maximum installation depth = without washers
1
44194-0
Mount assembly sleeve (1).

Press on the crankshaft sealing ring to the stop.
1
44195-0
02/2010
3/4
Gearcase
W 09-01-01
TCD 2013 2V
Plug in the bearing (1).

Screw on nut (2).
6
44196-0
Tighten nut to the stop of the assembly sleeve (1).

The crankshaft sealing ring is now at the
pre-selected installation depth.
Remove assembly tool.
Install flywheel.
W 05-03-01
44197-0
02/2010
4/4
Gearcase
W 09-02-02
TCD 2013 2V
Standard tools
Packing compound
DEUTZ DW 67
Packing compound
DEUTZ DW 48
W 02-01-01
W 05-03-01
W 09-01-01
W 44-03-01
W 48-02-03
W 52-01-01
Removing the gearcase

Remove cable tie (arrows).

Expose cable harness.
Remove impulse transmitter (camshaft).
W 48-02-03
44448-0

Remove starter.
W 44-03-01
44449-0
02/2010
1/10
Gearcase
W 09-02-02
TCD 2013 2V
Unlock central plug (1) (arrow) and pull off from holder.
Remove connection housing.
W 52-01-01
Remove flywheel.
W 05-03-01
W 02-01-01
6
44450-0
Unscrew screws (1).

Remove the holder (2).
2
44451-0
Unscrew screws (1).

Remove cover (2).
44452-0
02/2010
2/10
Gearcase
W 09-02-02
TCD 2013 2V
Unscrew screws (1).
Remove cover (2).
6
44453-0
Unscrew screws (1).
44454-0
Unscrew screws (1).

Remove gearcase cover.
1
44455-0
02/2010
3/10
Gearcase
W 09-02-02
TCD 2013 2V
6
44456-0
Installing the gearcase cover

Knock out crankshaft sealing ring (1).
Attention!
Do not damage sealing surface when

knocking out.
1
44457-0

44456-0
02/2010
4/10
Gearcase
W 09-02-02
TCD 2013 2V
Apply packing compound (arrow).
Attention!
The assembly must be completed

within 1 hour at most.
Use packing compound DEUTZ DW 67.
Sealing bead thickness approx. 1.4 mm.
6
44458-0
Align gearcase cover.

Mount gearcase cover.
Do not move the gearcase cover after
mounting.
1
Tighten screws (1).

1
44459-0
Fasten screws.
Screw M8 x 55 mm (1)
1
2
44460-0
02/2010
5/10
Gearcase
W 09-02-02
TCD 2013 2V
Press up gearcase cover and align flush with the oil

tray sealing surface (arrows).
The oil tray sealing surface on the
crankcase must face downwards.
6
44461-0
11
10
12
Note different tightening values.

13
Tighten scews (1) and (2).

M16x60
70 Nm
14
Tighten scews (3) to (14).

M8x35
30 Nm
6
5
7
3
44589-2
Tighten screws (15) to (17).

M8x55
17
20 Nm
16
15
44590-2
02/2010
6/10
Gearcase
W 09-02-02
TCD 2013 2V
Fill the ring groove (arrows) with packing compound.
Use packing compound DEUTZ DW 48.
Sealing bead thickness approx. 1.5 mm.
6
44462-0
Mount cap (1).

Tighten screws (2).
Note the installation position of the cap (1).
Use M8 x 50 mm screws.
Mount holder (arrow).
2
1
44463-0

Mount the new O-ring.
Lightly oil O-ring.
43983-0
02/2010
7/10
Gearcase
W 09-02-02
TCD 2013 2V
Press in the cap(1) to the stop.

Tighten screws (2).
1
6
44464-0
Mount holder (1).

Tighten screws (2).
44465-0
Tighten screws (1) alternately.

30 Nm
1
44592-0
02/2010
8/10
Gearcase
W 09-02-02
TCD 2013 2V
20 Nm
6
44593-0
Install new crankshaft sealing ring (flywheel side).

W 09-01-01
Install connection housing.
W 52-01-01
Install flywheel.
W 05-03-01
Install starter.
W 44-03-01
Install lubricating oil pan.
W 02-01-01
44467-0
Push the central plug onto the holder until it snaps in.
44468-0
02/2010
9/10
Gearcase
W 09-02-02
TCD 2013 2V
Lay cable harness and fix with cable ties (arrows).
6
44449-0

2

Install impulse transmitter (camshaft).
W 48-02-03
44448-0
02/2010
10/10
Camshaft
W 10-02-01
TCD 2013 2V
Standard tools:
Lifting gear
W 05-05-01
W 11-02-01
W 17-01-04
W 17-01-05
Removing the camshaft

Remove high pressure pump and roller tappet (installation position A).
W 17-01-04
Remove high pressure pump and roller tappet (installation position B).
W 17-01-05
Remove rocker arm and rocker arm brackets.
W 11-02-01
Remove crankshaft.
W 05-05-01
44470-0
Screw in screws (1).

Hang crankcase on suitable workshop crane.
44471-0
02/2010
1/4
Camshaft
W 10-02-01
TCD 2013 2V
Remove clamping bracket (1) from the adapter

plates (2).
1
6
44472-0
Push away the assembly block on the flywheel side.
44473-0
Press in all tappets.

Pull out the camshaft (1) carefully in the direction of
the arrow.
44474-0
02/2010
2/4
Camshaft
W 10-02-01
TCD 2013 2V
Removing tappets.
Remove all tappets (arrow).
6
42711-0
Installing tappets
Oil all tappets (arrow) lightly.
Insert all tappets.
Note assignment!
42711-0
Installing the camshaft

Oil cam shaft pin lightly.
Oil camshaft bearing lightly.
Insert camshaft carefully.
The bore (1) must be facing the cylinder
head.
44475-0
02/2010
3/4
Camshaft
W 10-02-01
TCD 2013 2V
Push on and align the flywheel side assembly block.

Install clamping holder (1) on adapter boards (2).
90 Nm
1
6
44472-0
Unhook the crankcase from the workshop crane.

Unscrew screws (1).
44471-0
Install crankshaft.
W 05-05-01
Install rocker arms and rocker arm brackets.
W 11-02-01
Install high pressure pump and roller tappet (installation position B).
W 17-01-05
Install high pressure pump and roller tappet (installation position A).
W 17-01-04
44220-0
02/2010
4/4
Camshaft
W 10-02-02
TCD 2013 2V
Standard tools:
Micrometer gauge
W 10-02-01

Remove camshaft.
W 10-02-01
Visually inspect cams and bearing pins for wear.
42713-0
Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.
36424-2
02/2010
1/2
Camshaft
W 10-02-02
TCD 2013 2V
Checking the diameter of the journal

Measure the bearing pin.
64,2 +0.2
-0.2 mm
points.
When the limit value is reached the camshaft must be replaced.
6
42714-0
Check camshaft gear wheel for visible signs of wear.

Install the camshaft.
W 10-02-01
42713-0
02/2010
2/2
Control parts
W 11-01-01
TCD 2013 2V
Setting valve clearance
(with or without removal of exhaust return module)
Standard tools:
Rotation angle disc
8190
Screwdriver insert for slotted screws
8191
Screwdriver insert for
hexagon socket head
screws (4 mm)
8194
Open wrench size 13
8196
Special tools:
spanner size 15
W 08-01-01
W 49-02-01
Allow the engine to cool down for at least
30 minutes before setting the valve
clearance. Engine oil temperature < 80 C
In engines without an exhaust return
module, a slotted setting screw must be
installed in place of a hexagon socket head
screw.
103050
Setting engine to valve overlap

W 08-01-01
W 49-02-01
Turn crankshaft using the turning gear until the valve
overlap of cylinder 1 is reached.
44110-0
Set valve clearance.

4 cylinders
Ignition
sequence:
1-3-4-2
Valves
overlap
set to
1
4
X
Cylinders
3 4 2
2 1 3

When the outlet valve is fully open, the
inlet valve opens briefly approx. 2 mm.
This is not the valve overlap!
00000-0
02/2010
1/6
Control parts
W 11-01-01
TCD 2013 2V
Set valve clearance.

6-cylinder
Ignition
sequence:
1-5-3-6-2-4
Valves
overlap
set to
1
6
5
2
Cylinders
3 6 2
4 1 5
4
3

When the inlet valve is fully open, the outlet valve opens briefly approx. 2 mm. This
6
00000-0
Valve overlap means:

The inlet valve starts opening,exhaust
valve closes.
44111-0
Arrangement of the inlet and exhaust valves.

IN = inlet valve
EX = exhaust valve
Attention!
Different version of the setting screws:

slotted screws or hexagon socket head
screws.
EX
IN
44112-0
02/2010
2/6
Control parts
W 11-01-01
TCD 2013 2V
Setting the inlet valve clearance
Loosen lock nut (1).
Press in the adjusting screw (2) to the stop.
The rocker arm must touch the thrust
washer of the spring cap (arrow).
6
44113-0
Set the rotation angle disc with a socket wrench insert at the adjusting screw.
Fix magnet of rotation angle disc on cylinder head.
Set the rotation angle disc in the direction of the arrow to 0.
Do not rotate adjusting screw.
X
X
44114-0
Turn back setting screw 90 in direction of arrow.

90
44115-0
02/2010
3/6
Control parts
W 11-01-01
TCD 2013 2V
Hold adjusting screw.

Tighten locking nut (arrow) with box spanner.
20 Nm
Remove rotation angle disc.
6
44116-0
Setting the exhaust valve clearance

2
44117-0
Set the rotation angle disc on the adjusting screw

with a screwdriver insert for slotted screws.
44118-0
02/2010
4/6
Control parts
W 11-01-01
TCD 2013 2V
150
6
44119-0

20 Nm
Set all other valves.
see page:
1, 4 cylinders
2, 6-cylinder
W 08-01-01
W 49-02-01
44120-0
02/2010
5/6
Control parts
W 11-01-01
TCD 2013 2V
Technical Data
ID no.
P01 61
P01 62
Name
Valve clearance (inlet)
Valve clearance (outlet)
Additional information
with rotary angle disc
Value
90
150
ID no.
Name
Screw type
Locking nut,
A01 003
valve clearance setting screw
Locking nut, setting screw control pisA01 012
ton (exhaust gas return)
Notes / Remark
Value
20 Nm
20 Nm
02/2010
6/6
Control parts
W 11-01-01
TCD 2013 2V
(with exhaust return module installed)
Standard tools:
Rotation angle disc
8190
Screwdriver insert for slotted screws
8191
Screwdriver insert for
hexagon socket head
screws (4 mm)
8194
Open wrench size 13
8196
W 08-01-01
W 49-02-01
Allow the engine to cool down for at least
30 minutes before setting the valve
clearance. Engine oil temperature < 80 C
The control piston clearance of the exhaust
return line must be set after setting the
valve clearance.
Special tools:
Crowfoot wrench size 15 103140
Setting engine to valve overlap

W 08-01-01
W 49-02-01
44110-0

4-cylinder
Ignition
sequence:
1-3-4-2
Valves
overlap
set to
1
4
X
Cylinders
3 4 2
2 1 3

When the outlet valve is fully open, the
inlet valve opens briefly approx. 2 mm.
This is not the valve overlap!
02/2010
1/8
Control parts
W 11-01-01
TCD 2013 2V

6-cylinder
Ignition
sequence:
1-5-3-6-2-4
Valves
overlap
set to
1
6
5
2
Cylinders
3 6 2
4 1 5
4
3

When the inlet valve is fully open, the outlet valve opens briefly approx. 2 mm. This
Valve overlap means:

The inlet valve starts opening,exhaust
valve closes.
43040-0
Arrangement of the inlet and exhaust valves.

IN = inlet valve
EX = exhaust valve
Attention!
Different version of the setting screws:

slotted screws or hexagon socket head
screws.
EX
IN
EX
IN
44444-0
02/2010
2/8
Control parts
W 11-01-01
TCD 2013 2V
Setting the inlet valve clearance
1
43042-0

with the crowfoot wrench.
48239-0

90
48240-0
02/2010
3/8
Control parts
W 11-01-01
TCD 2013 2V

20 Nm
6
48241-0
Setting the exhaust valve clearance

2
1
43046-0

with a screwdriver insert for slotted screws.
43047-0
02/2010
4/8
Control parts
W 11-01-01
TCD 2013 2V
150
6
43048-0

20 Nm
Set all other valves.
see page:
1, 4-cylinder
2, 6-cylinder
43049-0
Setting the control piston clearance

The control piston clearance (X) must be
set after setting the valve clearance.
43832-3
02/2010
5/8
Control parts
W 11-01-01
TCD 2013 2V

Set control piston according to order of setting.
see page:
1, 4-cylinder
2, 6-cylinder
6
44110-0


X1
44122-0

with a screwdriver insert for hexagon socket head
screw.
44123-0
02/2010
6/8
Control parts
W 11-01-01
TCD 2013 2V
144
6
44124-0

20 Nm
Set all other control pistons.
see page:
1, 4-cylinder
2, 6-cylinder
W 08-01-01
W 49-02-01
44125-0
02/2010
7/8
Control parts
W 11-01-01
TCD 2013 2V
Technical Data
ID no.
P01 61
P01 62
P01 64
Name
Valve clearance (inlet)
Valve clearance (outlet)
Clearance between control piston and
rocker arm
Additional information
Value
90
150
144
ID no.
Name
Screw type
Locking nut,
A01 003
valve clearance setting screw
Locking nut, setting screw control pisA01 012
ton (exhaust gas return)
Notes / Remark
Value
20 Nm
20 Nm
02/2010
8/8
Control parts
W 11-02-01
TCD 2013 2V
Removing and installing the rocker arm and rocker arm bracket
Standard tools
W 08-02-01
W 11-01-01
W 49-02-01
Removing the rocker arm and rocker arm

bracket
W 49-02-01
Remove exhaust gas return module.

W 08-02-01
Unscrew screws (1).
Remove rocker arm brackets (2).
43948-0
Remove push rods (1).

1
43949-0
02/2010
1/4
Control parts
W 11-02-01
TCD 2013 2V
6
44133-0
Installing the rocker arm and rocker arm

bracket
Insert stop rods (1).
Note the assignment of the stop rods.
The stop rod must be seated with the ball
head in the ladle of the tappet.
1
43949-0
Mount rocker arm bracket (1).

The ball heads must be seated in the
ladles of the pushrods (arrows).
44134-0
02/2010
2/4
Control parts
W 11-02-01
TCD 2013 2V
Align rocker arm bracket symmetrically with the valve
axles.
The bore (arrow) in the rocker arm bracket
must be in line with the threaded bore in
the cylinder head.
Tighten screw (1).
30 Nm
1
Attention!
Make sure that the stop rods are not under

stress due to valve overlap when fastening
the screw.
6
44135-0
Setting the valve clearance (with or without removal

of exhaust return module).
W 11-01-01
Install exhaust gas return module.
W 08-02-01
W 49-02-01
44136-0
02/2010
3/4
Control parts
W 11-02-01
TCD 2013 2V
Technical Data
ID no.
Name
A01 002
Rocker arm support on the cylinder

head
Screw type
Notes / Remark
Value
Assembly note:
Rocker arm symmetrical 30 Nm
to the valve centre axes.
02/2010
4/4
Control parts
W 11-02-02
TCD 2013 2V
Disassembling, assembling and checking the rocker arm and rocker arm
bracket
Standard tools:
Micrometer gauge
Special tools:
Dial gauge
W 11-02-01
100400
Disassembling the rocker arm bracket

Remove rocker arm and rocker arm bracket.
W 11-02-01
Remove lockwashers (1).
1
44137-0
Remove rocker arm.

44138-0
02/2010
1/4
Control parts
W 11-02-02
TCD 2013 2V
Checking the rocker arm

Measure rocker arm bore.
Inlet
21,02 0
+0.033
mm
Outlet
21,02 0
+0.033
mm
When the wear limit is reached the rocker

arm must be renewed.
6
39032-1

Hold adjusting screw (2).
Unscrew adjusting screw (2).
Hold adjusting screw (4).

Unscrew adjusting screw (4).
Attention!
Pay attention to versions of the adjusting

screws (slotted, hexagonal, hexagonal
socket).

42556-0
Check components for visible signs of wear.

Check oil channels (arrows) for free passage.
42557-0
02/2010
2/4
Control parts
W 11-02-02
TCD 2013 2V
Screw in setting screw (1).
Loosen lock nuts (2).
2
6
43011-0
Checking the rocker arm pin

Measure the diameter of journals with the micrometer gauge.
21 -0.021 mm
0
When the wear limit is reached the rocker

arm bracket must be replaced.
44139-0
Assembling the rocker arm bracket

Lightly oil the rocker arm pin.
2
Push rocker arm (1) onto rocker arm pin.

Push rocker arm (2) onto rocker arm pin.
The rocker arm's sliding surface (3) must
face the threaded bore (arrow).
Mount the rocker arm (1) on the outlet side.

Mount the rocker arm (2) on the inlet side.
44140-0
02/2010
3/4
Control parts
W 11-02-02
TCD 2013 2V
Press new lockwashers (1) into the rocker arm pin up

to the stop.
Install rocker arm and rocker arm bracket.
W 11-02-01
44141-0
02/2010
4/4

W 15-02-01
TCD 2013 2V
Standard tools
W 15-02-02
Fitting compound
DEUTZ AP1908

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

Remove oil cooler housing.
W 15-02-02
Unscrew screws (1).
44485-0
Unscrew collar screws (1).

Remove lubricating oil cooler (2).
2
44486-0
02/2010
1/4

W 15-02-01
TCD 2013 2V
Remove the sealing ring (arrows) of both collar

screws.
Remove collar screws.
6
44487-0
Remove sealing ring (1).

Clean collar screw (2).
1
2
44488-0
44489-0
02/2010
2/4

W 15-02-01
TCD 2013 2V
Installing the lubricating oil cooler

Cover thread with adhesive film.
Push on new sealing ring (1).
6
44490-0
Cover thread with adhesive film.

Push on new sealing ring (1).
The sealing ring must fit in the

groove (arrow).
44491-0
Coat the sealing ring (1) lightly with fitting compound.

Oil sealing ring (2).
1
44501-0
02/2010
3/4

W 15-02-01
TCD 2013 2V
Insert both collar screws (1).
6
44492-0
Insert oil cooler (2).

Tighten collar screws (1).
Stage 1:
80 Nm
Stage 2:
160 Nm
2
44486-0
Coat new sealing rings with fitting compound .

Tighten screw plug (1).
80 Nm
Install oil cooler housing.
W 15-02-02
44485-0
02/2010
4/4

W 15-02-02
TCD 2013 2V
Removing and installing the lubricating oil cooler housing

Standard tools
Operation manual
W 20-01-01
to regulations.
Removing the lubricating oil cooler housing

Remove fuel filter console.
W 20-01-01
Remove oil filter cartridge.
Operation manual
1
44494-0

Remove oil cooler housing (1).
44495-0
02/2010
1/4

W 15-02-02
TCD 2013 2V
6
44496-0
Installing the lubricating oil cooler housing

Mount new gasket.
Mount the lubricating oil cooler housing.
Pay attention to different screw lengths.
M8 x 50 mm (1)
M8 x 80 mm (2).
2
1
44497-0
10
Stage 1:
3 Nm
Stage 2:
30 Nm
12
13
11
9
5
44500-0
02/2010
2/4

W 15-02-02
TCD 2013 2V
Install oil filter cartridge.

Operation manual
Install the fuel filter console.
W 20-01-01
1
6
44494-0
02/2010
3/4

W 15-02-02
TCD 2013 2V
02/2010
4/4
Oil suction pipe

W 16-01-01
TCD 2013 2V
Standard tools
W 02-01-01
Removing the oil suction pipe

W 02-01-01
Unscrew screws (1).
Remove oil suction pipe (2).

Remove gasket.
1
1
44476-0
44477-0
02/2010
1/2
Oil suction pipe

W 16-01-01
TCD 2013 2V
Installing the oil suction pipe

2
Mount new gasket.

Mount oil suction pipe.
Fasten screws.
from faults.
M8 x 25 mm (1)
M8 x 20 mm (2)
2
44478-0
Tighten screws (1).

22 Nm
1
Install lubricating oil pan.

W 02-01-01
1
1
44479-0
02/2010
2/2
High-pressure pump
W 17-01-01
TCD 2013 2V
Standard tools
Special tools:
Plugs/caps
User notes
Operation manual
170160
Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
Attention!
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.
bleeded - see the operation manual, chapter "6 Fuel system.
Removing the control block

Danger!

43986-0
02/2010
1/8
High-pressure pump
W 17-01-01
TCD 2013 2V
Unscrew hollow screws (1).

Unscrew screw (2).

Loosen pipe clip.
Remove fuel pipe.

Collect draining fuel and dispose of
according to regulations.
6
43998-0

Remove fuel pipe (2), pipe connection and sealing
rings.
2
1
44000-0

Remove fuel pipe (2) and sealing rings.
1
43999-0
02/2010
2/8
High-pressure pump
W 17-01-01
TCD 2013 2V
Unscrew screws (1).
Remove control block (2).
6
44001-0
44002-0
Installing the control block

Insert screw (1).
44002-0
02/2010
3/8
High-pressure pump
W 17-01-01
TCD 2013 2V
Insert control block.

Pre-assemble screws loosely.
M8 x 75 mm (2)
M8 x 85 mm (1)
6
44003-0
Install fuel pipe. Insert hollow screws (1) and (2) with
new sealing rings tension-free.
Hollow screw M14 (1)
Hollow screws M12 (2)
2
1
44004-0
Mount fuel pipe.

Insert hollow screws (1) with new sealing rings tension-free.
Do not tighten hollow screws.
Position pipe clip.

Fasten screw (2) tension-free.
Do not tighten the screw.
44005-0
02/2010
4/8
High-pressure pump
W 17-01-01
TCD 2013 2V
39 Nm
Tighten hollow screws (2).
29 Nm
1
44006-0

39 Nm
Tighten screw (2).
20 Nm
Check the fuel pipes for perfect installation position.
1
44007-0
Attention!
Observe the following order of tightening.
Tighten screw (1).

20 Nm
Tighten screw (2).
20 Nm
Attention!
Do not bend high pressure and fuel pipe.
44008-0
02/2010
5/8
High-pressure pump
W 17-01-01
TCD 2013 2V
Mount fuel return pipe (1) and pipe connection.

Tighten hollow screw (2) with new sealing rings.
49 Nm
44009-0

Bleed the fuel system via the manual fuel
pump on the fuel pre-filter according to the
operation manual.
43986-0
02/2010
6/8
High-pressure pump
W 17-01-01
TCD 2013 2V
Technical Data
ID no.
Name
Screw type
Injection pipe on rail and injector,

A07 003 High pressure pipe on high pressure
pump and rail
Union nut

pump and rail
Union nut
A07 032
A12 092
A12 093
A12 094
A12 095
Value
Stage 2:
60
Stage 1:
Screws oiled
High pressure pump to crankcase
M10x30-10.9 Stage 2:
M8x75
Observe tightening
Control block to crankcase
M8x85
sequence.
Pipe union, pipe diameter 8 mm, ring Hollow screw
piece
M12x1.5
piece
M14x1.5
piece
M16x1.5
Pipe clips, fastening
M8
A07 031 High pressure pump to crankcase

A07 031
Notes / Remark
Stage 1:
Observe assembly
specification.
Use new pipe.
M10x30-10.9
10 Nm
+15
10 Nm
50 Nm
20 Nm
29 Nm
39 Nm
49 Nm
20 Nm
02/2010
7/8
High-pressure pump
W 17-01-01
TCD 2013 2V
02/2010
8/8
High-pressure pump
W 17-01-04
TCD 2013 2V
Standard tools
Special tools:
Assembly pliers
Special wrench
Assembly case with
assembly sleeves, guides
and disassembly tool
Plugs/caps
User notes
W 17-01-01
W 49-02-01
103220
110500
Danger!
110900
170160
Attention!

on the fuel system.
compressed air.
Fitting compound
DEUTZ AP1908
Removing the high-pressure pump

W 49-02-01
43953-1
02/2010
1/10
High-pressure pump
W 17-01-04
TCD 2013 2V
Danger!
Remove control block.
W 17-01-01
6
43954-0

43955-0

Support the pipe connection of the high
pressure pump.
Remove high pressure pipe (1) with special wrench.
43956-0
02/2010
2/10
High-pressure pump
W 17-01-04
TCD 2013 2V
Loosen screws (1) evenly
the high-pressure pump.
If necessary, turn the crankshaft with turnover gear in the direction of rotation of the
engine until the high-pressure pump is felt
to release.
Unscrew screws (1) evenly.

Remove high-pressure pump (2).
6
43957-0
Carefully remove the O-ring (1) from the high-pressure pump with the disassembly tool.
Attention!
Do not damage the high-pressure pump.
1
43328-0
Pull out roller tappet (1) with special pliers.
Attention!
Do not damage the roller tappet!

Do not use magnetic tools for removing the
roller tappet.
43997-0
02/2010
3/10
High-pressure pump
W 17-01-04
TCD 2013 2V
Installing the high-pressure pump

Turn the crankshaft with the turn-over gear until the
cam for the high-pressure pump is on the cam base
circle (arrow).
Roller tappet stroke is less than 0.5 mm.
6
42816-0
Oil roller tappet lightly and insert carefully with special pliers.
1
The guide pin (1) on the roller tappet must

grip in the groove (2).
42817-0
Push assembly guide (1) onto high-pressure pump.

Push the new O-ring (2) onto the assembly guide.
1
43329-0
02/2010
4/10
High-pressure pump
W 17-01-04
TCD 2013 2V
Push the O-ring (1) with assembly sleeve (2) up to
the groove (3).
Coat the O-ring, mounting bore and chamfers in the
crankcase with fitting compound.
2
3
6
43330-0
Insert the high-pressure pump carefully in the crankcase.
43959-0
Oil the screws (1) lightly and tighten alternately until

the high-pressure pump is flush with the crankcase.
Do not tighten the screws yet.
1
1
43958-0
02/2010
5/10
High-pressure pump
W 17-01-04
TCD 2013 2V
Install control block.

W 17-01-01
Stage 1:
10 Nm
Stage 2:
50 Nm
6
43979-0
Attention!
The high-pressure line must always be

renewed after disassembly.
Install high pressure line without tension.
Mount new high-pressure line on high-pressure

pump and rail.
Screw on union nuts (1).
Do not tighten union nuts.
Check the high-pressure line for perfect installation
position.
43980-0
Installation position of vibration damper.
Attention!
Pay attention to installation position.

Do not turn vibration damper (1).
(1) Vibration damper
Dimension X
Diameter: 32 mm
(2) Connection rail
(3) Connection high pressure pump
3
48208-0
02/2010
6/10
High-pressure pump
W 17-01-04
TCD 2013 2V
Dimension I
7,6
+1.5
-1.5
mm
Dimension II
5,4
+0.5
-0.5
mm
II
(2) Connection rail

1
3
6
48217-0
Attention!

Pay attention to alignment of the high pressure pipes.
Pipes which touch the bore (1) of the union
nut must be renewed.
43980-1
Tighten union nuts (arrows) with special wrench.

Stage 1:
10 Nm
Stage 2:
60
+15

position.
43981-0
02/2010
7/10
High-pressure pump
W 17-01-04
TCD 2013 2V

39 Nm
operation manual.
6
43982-0

W 49-02-01
43953-1
02/2010
8/10
High-pressure pump
W 17-01-04
TCD 2013 2V
Technical Data
ID no.
Name
Screw type

pump and rail
Union nut

pump and rail
Union nut
Notes / Remark
Stage 1:
Observe assembly
specification.
Use new pipe.
Value
Stage 2:
60
Stage 1:
Screws oiled
M10x30-10.9 Stage 2:
A12 093
piece
M14x1.5
M10x30-10.9
10 Nm
+15
10 Nm
50 Nm
39 Nm
02/2010
9/10
High-pressure pump
W 17-01-04
TCD 2013 2V
02/2010
10/10
High-pressure pump
W 17-01-05
TCD 2013 2V
Standard tools
Special tools:
Assembly pliers
Special wrench
Assembly case with
Plugs/caps
User notes
W 49-02-01
103220
110500
Danger!
110900
170160
Attention!

on the fuel system.
compressed air.
Fitting compound
DEUTZ AP1908
Removing the high-pressure pump

W 49-02-01
43953-1
02/2010
1/10
High-pressure pump
W 17-01-05
TCD 2013 2V
Danger!
6
43986-0

43988-0

pressure pump.
Remove high pressure pipe (1) with special wrench.
43989-0
02/2010
2/10
High-pressure pump
W 17-01-05
TCD 2013 2V
Unscrew screws (1).
Remove high-pressure pump (2).
the high-pressure pump.
If necessary, turn the crankshaft with turnover gear in the direction of rotation of the
engine until the high-pressure pump is felt
to release.
6
43990-0
Carefully remove the O-ring (1) from the high-pressure pump with the disassembly tool.
Attention!
Do not damage the high-pressure pump.
1
43328-0
Pull out roller tappet (1) with special pliers.
Attention!
Do not damage the roller tappet!

Do not use magnetic tools for removing the
roller tappet.
42821-0
02/2010
3/10
High-pressure pump
W 17-01-05
TCD 2013 2V
Installing the high-pressure pump

Turn the crankshaft with the turn-over gear until the
cam for the high-pressure pump is on the cam base
circle (arrow).
Roller tappet stroke is less than 0.5 mm.
6
42816-0
Oil roller tappet lightly and insert carefully with special pliers.
The guide pin (1) on the roller tappet must
grip in the groove (2).
1
2
42822-0
Push assembly guide (1) onto high-pressure pump.

1
43329-0
02/2010
4/10
High-pressure pump
W 17-01-05
TCD 2013 2V
the groove (3).
Coat the O-ring, mounting bore and chamfers in the
crankcase with fitting compound.
2
3
6
43330-0
Insert the high-pressure pump carefully in the crankcase.
43992-0
Oil the screws (1) lightly and tighten alternately until

the high-pressure pump is flush with the crankcase.
Do not tighten the screws yet.
1
43991-0
02/2010
5/10
High-pressure pump
W 17-01-05
TCD 2013 2V
Mount the fuel pipe between the high-pressure

pumps and the control block.
Fasten hollow screws with new O-rings without tension.
Hollow screw M14 (1)
Hollow screws M12 (2)
2
1
43993-0

39 Nm
29 Nm
2
1
43993-0

Stage 1:
10 Nm
Stage 2:
50 Nm
43994-0
02/2010
6/10
High-pressure pump
W 17-01-05
TCD 2013 2V
Attention!
The high-pressure line must always be

Mount new high-pressure line on high-pressure
pump and rail.
Screw on union nuts (1).

position.
6
43995-0
Installation position of vibration damper.
Attention!
Pay attention to installation position.

Do not turn vibration damper (1).
Dimension X
Diameter: 32 mm
(2) Connection rail
3
48208-0
Dimension I
7,6
+1.5
-1.5
mm
Dimension II
5,4
+0.5
-0.5
mm
II
(2) Connection rail

1
3
48217-0
02/2010
7/10
High-pressure pump
W 17-01-05
TCD 2013 2V
Attention!

6
43995-1
Tighten union nuts (arrows) with special wrench.

Stage 1:
10 Nm
Stage 2:
60
+15

position.
43996-0

operation manual.
43986-0
02/2010
8/10
High-pressure pump
W 17-01-05
TCD 2013 2V
W 49-02-01
6
43953-1
02/2010
9/10
High-pressure pump
W 17-01-05
TCD 2013 2V
Technical Data
ID no.
Name

pump and rail
Union nut

pump and rail
Union nut
Notes / Remark
Stage 1:
Observe assembly
specification.
Use new pipe.
Value
Stage 2:
60
Stage 1:
Screws oiled
M10x30-10.9 Stage 2:
A12 092
piece
M12x1.5
A12 093
piece
M14x1.5
Screw type
M10x30-10.9
10 Nm
+15
10 Nm
50 Nm
29 Nm
39 Nm
02/2010
10/10
Injector
W 19-01-01
TCD 2013 2V
Standard tools:
Assembly pliers
Torx tool set
Special tools:
Special wrench
Lever tool
Assembly case with
Extraction tool
Slide hammer
Plugs/caps
User notes
8024
8189
Danger!
110500
110620

Attention!
110900
120680
150800
170160

on the fuel system.
compressed air.
Removing the injector

The following work procedure describes
the removal and installation of an injector.
Proceed in the same way to remove further
injectors.
Danger!
With oil dipstick guide pulled up on the side of the
rail:
Close opening.
43954-0
02/2010
1/10
Injector
W 19-01-01
TCD 2013 2V
Unscrew lock nuts (1) with special wrench.

Support the pipe connection of the injector.
Remove injection line.

6
44012-0
Unscrew screws (1).

1
44022-0
Unscrew nuts (1).

Remove cable from injector.
1
44023-0
02/2010
2/10
Injector
W 19-01-01
TCD 2013 2V
Unscrew screw (1).
Remove clamping shoe (2).
When removing the injectors on
cylinders 1 to 5, the clamping shoe can
only be removed together with the injector.
1
6
44024-0
Attention!
Remove residue paint and particles of dirt

from the injector before removing it.
Carefully clean the area around the injector.
Pull out injector (1) and sealing ring (2).
1
44025-0
Removing a tightly fixed injector

Insert lever tool (1) in the clamping claw (2).
Loosen the injector by pulling the lever in the direction of the arrow.
Remove injector and sealing ring.
2
48206-0
02/2010
3/10
Injector
W 19-01-01
TCD 2013 2V
Attention!
Do not brush off the nozzle tip of the injector.

Do not damage the nozzle tip of the injector when removing the sealing ring (1).
Grip a tight sealing ring (1) with the assembly
pliers (2) and pull off, turning slightly.
1
2
43303-0
Removing a tightly fixed sealing ring from the

cylinder head
Insert extraction device (1).
The holders (arrow) must sit in the bore of
the sealing ring.
1
44028-0
Turn in the spindle (1) until the sealing ring is fixed to

the extraction device.
Hold extraction device against the flats.
1
44029-0
02/2010
4/10
Injector
W 19-01-01
TCD 2013 2V
Mount adapter (1) and slide hammer (2) on extraction device.
Remove tight sealing ring.
6
44030-0
Remove the round sealing ring (1) carefully from the

injector with the disassembly tool.
Attention!
Do not damage the injector.
43028-0
Installing the injector

Push assembly guide (1) onto injector.
2
1
43030-0
02/2010
5/10
Injector
W 19-01-01
TCD 2013 2V

the groove (3).
1
2
6
43029-0
Lightly oil round sealing ring (1).

Mount new sealing ring (2) on injector.
42987-1
Attention!
Before installing the injector, combustion

residue must be cleaned carefully from the
bore on the cylinder head.
Suck off dirt particles.
Install injector without tension.
Insert injector carefully in the cylinder head.
42988-0
02/2010
6/10
Injector
W 19-01-01
TCD 2013 2V
When installing the injectors on
cylinders 1 to 5, the clamping shoe must
be inserted together with the injector.
In version with heating plugs:
Pay attention to perfect cable laying
(arrow).
6
48207-0
Mount clamping shoe.

Tighten screw.
Stage 1:
hand tight
Do not tighten the screw until after
assembling the injection line.
44031-0
Attention!
The injection lines must always be

Install injection line without tension.
Mount new injection line (1) on rail and injector.
Note assignment and installation position

of the injection lines.
Screw on union nuts.
Check the injection line for perfect installation position.
44032-0
02/2010
7/10
Injector
W 19-01-01
TCD 2013 2V
Tighten screw (arrow).

Stage 2:
27 Nm
6
42992-0
Attention!
Install injection pipes without tension!

Pay attention to alignment of the injection
pipes.
44034-1
Tighten union nuts (1) with special wrench.

Stage 1:
10 Nm
Stage 2:
60
+15
Check the injection pipes for perfect installation position.
44034-0
02/2010
8/10
Injector
W 19-01-01
TCD 2013 2V
Mount cable on injector.
Tighten nuts (1).
1.5 Nm
6
44035-0
Mount cover (1).

8.5 Nm
With oil dipstick guide pulled up on the side of the

rail:
operation manual.
44036-0
02/2010
9/10
Injector
W 19-01-01
TCD 2013 2V
Technical Data
ID no.
Name
A07 001
Injector on cylinder head, clamping

claw
A07 001
Injector on cylinder head, clamping

claw

pump and rail
pump and rail
A13 041 Cover plate on cylinder head cover
A13 051 Cable connection on injector
Screw type
Notes / Remark
Stage 1:
Observe order of
assembly.
Install injector without
tension.
Value
Stage 2:
27 Nm
Union nut
Stage 1:
Observe assembly
specification.
Use new pipe.
10 Nm
Union nut
Stage 2:
60
M6x16
self-tapping
8.5 Nm
1.5 Nm
hand tight
+15
02/2010
10/10
Fuel filter
W 20-01-01
TCD 2013 2V
Standard tools
Special tools:
Special wrench
Plugs/caps
User notes
Operation manual
170050
170160
Danger!
Attention!

on the fuel system.
compressed air.
Removing the fuel filter console

Danger!
Unscrew fuel filter (1) with special wrench.
1
43960-0
02/2010
1/6
Fuel filter
W 20-01-01
TCD 2013 2V
Unscrew screw (1).

Loosen pipe clip.

6
43961-0
Loosen the locking ring (1).

Pull out cable plug.
43962-1


43963-0
02/2010
2/6
Fuel filter
W 20-01-01
TCD 2013 2V
Unscrew screws (1).
Remove fuel filter console (2).
1
2
6
43963-0
43965-0
Installing the fuel filter console

Install the fuel filter console.
M8 x 40 mm (1)
M8 x 55 mm (2)
Tighten screws (1) and (2).
30 Nm
43966-0
02/2010
3/6
Fuel filter
W 20-01-01
TCD 2013 2V
Mount the fuel pipe with new sealing rings.

Tighten hollow screw (arrow).
39 Nm
6
43968-0
Mount fuel pipe.

1
Check hose pipes and renew if necessary.

Position pipe clip.
Tighten screw (1).
M8
30 Nm
Tighten hollow screw (arrow).
39 Nm
43969-0
Press the cable plug onto the fuel pressure sensor.

Turn in the locking ring (1) until it snaps in.
1
Make sure that the contacts match up.
43970-1
02/2010
4/6
Fuel filter
W 20-01-01
TCD 2013 2V
Lightly oil sealing ring on new fuel filter cartridge.
Screw on fuel filter cartridge by hand.
The seal must fit evenly.
Operation manual
6
44577-0
02/2010
5/6
Fuel filter
W 20-01-01
TCD 2013 2V
02/2010
6/6
Fuel pump
W 20-02-01
TCD 2013 2V
Removing and installing the fuel supply pump
(V-belt drive)
Standard tools:
Hose clip pliers
8011
device
8115
User notes
Operation manual
Special tools:
Plugs/caps

Danger!
170160
Attention!

on the fuel system.
compressed air.
Only test / tighten / renew V-belts with the
engine at a standstill.
15 minutes.
Removing the fuel supply pump

Danger!
Loosen screws (1).
1
44037-1
02/2010
1/6
Fuel pump
W 20-02-01
TCD 2013 2V
Loosen screws (1).
1
1
6
44038-0
44039-0
Remove V-belt (1).
44040-0
02/2010
2/6
Fuel pump
W 20-02-01
TCD 2013 2V
Unscrew screws (1).
6
44041-0
Loosen screws (1).

1
2
44042-0
Remove V-belt (1).
44043-0
02/2010
3/6
Fuel pump
W 20-02-01
TCD 2013 2V
Loosen hose clip (1).

Pull off fuel pipe (2).
Check hose pipes and renew if necessary.
2
1
6
44044-0
Unscrew screws (1).

1
2
44045-0
Unscrew screws (1).

Remove fuel supply pump (2).
1
44046-0
02/2010
4/6
Fuel pump
W 20-02-01
TCD 2013 2V
6
44047-0
Installing the fuel supply pump

Mount fuel supply pump (2).
Tighten screws (1).

20 Nm
Note installation position of the clamping
strap.
44046-0
Mount clamping strap (2) with fuel supply pump.

Tighten screws (1).
1
2
44045-0
02/2010
5/6
Fuel pump
W 20-02-01
TCD 2013 2V
Attach fuel pipe.

Fix the hose clip (1) with the hose clip pliers.
1
6
44048-0
44043-0

suitable tool.
Tighten screw (2).
30 Nm
Check V-belt tension.

Operation manual
44049-0
02/2010
6/6
Fuel pipes
W 21-02-01
TCD 2013 2V
Standard tools:
Rotation angle disc
8190
Special tools:
Special wrench
Plugs/caps
User notes
W 21-02-03
W 21-02-05
110500
170160
Danger!
Attention!

on the fuel system.
compressed air.
Removing the rail

Danger!
43954-0
11/2010
1/8
Fuel pipes
W 21-02-01
TCD 2013 2V

Remove fuel return pipe (2) and sealing rings from
rail.

2
6
44010-0

pressure pump.
Remove high pressure pipes (1) with special wrench.
44011-0
Unscrew the union nuts (1) of the injection lines from

the injectors and rail.
Support the pipe connection of the injector.
1
Remove all injection pipes.

44012-0
11/2010
2/8
Fuel pipes
W 21-02-01
TCD 2013 2V
6
44013-0
Unscrew screws (1).

Remove the rail (2).
44014-0

Remove pressure limiting valve.
W 21-02-03
Remove rail pressure sensor.
W 21-02-05
44015-0
11/2010
3/8
Fuel pipes
W 21-02-01
TCD 2013 2V
Mounting rail
Install rail pressure sensor.
W 21-02-05
Install pressure limiting valve.
W 21-02-03
Pre-assemble the rail (2) loosely with screws (1).
hand tight
6
44014-0
Attention!
The injection lines must always be

Pre-assemble new injection pipes (arrow) on rail and
injectors.
of the injection lines.
44016-0
Attention!
The high-pressure lines must always be

Pre-assemble new high pressure pipes (1) on the rail
and on the high pressure pumps.
1

of the high-pressure lines.

Check the high pressure pipes for perfect installation
position.
44017-0
11/2010
4/8
Fuel pipes
W 21-02-01
TCD 2013 2V
Tighten screws (1).
30 Nm
6
44018-0
Attention!

Pay attention to alignment of the injection
pipes.
48222-0
Tighten all union nuts (1) on the rail and on the injectors with a special wrench.
Stage 1:
10 Nm
Use rotaqtion angle disc.
Stage 2:
60
+ 15
44019-0
11/2010
5/8
Fuel pipes
W 21-02-01
TCD 2013 2V
Attention!

6
48223-0
Tighten union nuts (1) with special wrench.

Stage 1:
10 Nm
Use rotaqtion angle disc.
Stage 2:
60
+ 15
Check high pressure pipes for perfect installation position.
44020-0

39 Nm
operation manual.
43982-0
11/2010
6/8
Fuel pipes
W 21-02-01
TCD 2013 2V
6
44021-0
11/2010
7/8
Fuel pipes
W 21-02-01
TCD 2013 2V
Technical Data
ID no.
Name
Screw type

pump and rail
Union nut

pump and rail
Union nut
A07 038 Rail to cylinder head
A07 038 Rail to cylinder head

A12 093
piece
M14x1.5
Notes / Remark
Stage 1:
Observe assembly
specification.
Use new pipe.
Value
Stage 2:
60
Stage 1:
Observe assembly
specification
Stage 2:
10 Nm
+ 15
hand tight
30 Nm
39 Nm
11/2010
8/8
Fuel pipes
W 21-02-03
TCD 2013 2V
Removing and installing the pressure limiting valve
Standard tools
User notes
Special tools:
Disassembly tool
Plugs/caps
110901
170160
Assembly grease
01016496
Danger!
Attention!

on the fuel system.
compressed air.
No foreign bodies may get into the rail.
Ensure utmost cleanliness. Especially on
the thread and the sealing surface of the
rail.
Removing the pressure limiting valve

Danger!
Unscrew pressure limiting valve (1).
43975-0
02/2010
1/4
Fuel pipes
W 21-02-03
TCD 2013 2V
Visually check the thread and the sealing edge of the

pressure limiting valve.
6
43253-1
Remove the O-ring with the disassembly tool.
43335-0
Installing the pressure limiting valve

Attention!

rail.
Lightly coat the thread and sealing edge of the pressure limiting valve with assembly grease.
1
42978-1
02/2010
2/4
Fuel pipes
W 21-02-03
TCD 2013 2V
Screw in pressure limiting valve (1).
Tighten pressure limiting valve.
100 Nm
operation manual.
6
43976-0
02/2010
3/4
Fuel pipes
W 21-02-03
TCD 2013 2V
02/2010
4/4
Fuel pipes
W 21-02-05
TCD 2013 2V
Standard tools
User notes
Special tools:
Long socket wrench insert 110700
Plugs/caps
170160
Danger!
Assembly grease

01016496
Attention!

on the fuel system.
compressed air.
rail.
Removing the rail pressure sensor

Danger!

Unscrew the rail pressure sensor (2) with the socket
wrench.
2
43977-0
02/2010
1/2
Fuel pipes
W 21-02-05
TCD 2013 2V
Attention!
Do not touch the pin contacts of the rail

pressure sensor with your hands to avoid
electrostatic discharging.
Ensure absolute cleanliness of the connector.
Visually check the thread and the sealing
edge (arrows)of the rail pressure sensor.
6
43017-0
Installing the rail pressure sensor

Attention!

rail.
Coat the thread and sealing edge of the rail pressure

sensor lightly with assembly grease.
Screw in rail pressure sensor (2).
Tighten rail pressure sensor.
M18x1.5
2
70 Nm
02/2010
43977-0
2/2
Charge air line

W 22-01-01
TCD 2013 2V
Standard tools
W 08-01-01
W 48-03-01
Remove charge air line

Remove pressure/temperature sensor.
W 48-03-01
W 08-01-01
44126-1
Unscrew screws (1).

Remove charge air manifold (2).
Remove gasket.
1
2
1
44289-0
02/2010
1/4
Charge air line

W 22-01-01
TCD 2013 2V

Remove charge air line (1).
Remove gasket.
6
44290-0
44291-0
Install charge air line

Mount new gaskets (1).
from faults.
1
44292-0
02/2010
2/4
Charge air line

W 22-01-01
TCD 2013 2V
Mount charge air line.
Fasten screws.
Do not move gaskets.
Tighten screws alternately working from the centre to
the outside.
11 Nm
6
44293-0

Mount new gasket.
Mount charge air manifold.
Fasten screws.
Tighten screws .
30 Nm
44294-0
Install pressure/temperature sensor.

W 48-03-01
W 08-01-01
44126-1
02/2010
3/4
Charge air line

W 22-01-01
TCD 2013 2V
02/2010
4/4
Coolant pump
W 37-03-01
TCD 2013 2V
Removing and installing the coolant pump
(V-belt drive)
Standard tools:
device
8115
Operation manual
W 38-02-01
Attention!
Packing compound
DEUTZ DW 76
Only test / tighten / renew V-belts with the

engine at a standstill.
to regulations.
manufacturer.
15 minutes.
Removing coolant pump

Loosen screws (1).
1
1
1
44513-0
02/2010
1/8
Coolant pump
W 37-03-01
TCD 2013 2V
Loosen screws (1).
1
1
6
44038-0
44039-0
Remove V-belt (1).
44040-0
02/2010
2/8
Coolant pump
W 37-03-01
TCD 2013 2V
Unscrew screws (1).
6
44041-0
Loosen screws (1).

1
2
44042-0
44043-0
02/2010
3/8
Coolant pump
W 37-03-01
TCD 2013 2V
Unscrew screws (1).

1
2
6
44514-0
Unscrew screws (1).

Unhook the fuel supply pump at the side.
Remove thermostat housing.
1
W 38-02-01
44515-0

Remove coolant pump (1).
Remove gasket.
44516-0
02/2010
4/8
Coolant pump
W 37-03-01
TCD 2013 2V
6
44517-0
Installing coolant pump

Mount new gasket.
Insert screw (1) with packing compound.

Fasten screw (1).
44586-0
44246-0
02/2010
5/8
Coolant pump
W 37-03-01
TCD 2013 2V

30 Nm
Tightening order:
screw (1), then screw (2), then the other
screws in any order.
Install thermostat housing.
W 38-02-01
6
44518-0
Mount clamping strap (2) with fuel supply pump.

Tighten screws (1).
1
44515-0
Mount V-belt pulley (2).

Fasten screws.
1
2
44514-0
02/2010
6/8
Coolant pump
W 37-03-01
TCD 2013 2V
6
44043-0

suitable tool.
Tighten screw (2).
30 Nm

Operation manual
44049-0
02/2010
7/8
Coolant pump
W 37-03-01
TCD 2013 2V
02/2010
8/8
Thermostat housing
W 38-01-01
TCD 2013 2V

to regulations.
The appropriate documentation of the
vehicle/equipment manufacturer should be
observed for emptying and filling the cooling system.
Standard tools
Fitting compound
DEUTZ AP1908
Removing the thermostat

Unscrew screws (1).
Remove outlet nozzle (2).
44508-0
Remove thermostat (1).

44424-0
02/2010
1/2
Thermostat housing
W 38-01-01
TCD 2013 2V
Installing the thermostat

1

Insert new sealing ring (1).
Coat the sealing ring with fitting compound.
6
44439-0
Insert thermostat.
Arrow (1) points up.
1
44424-1
Mount outlet nozzle.

30 Nm
44425-0
02/2010
2/2
Thermostat housing
W 38-01-02
TCD 2013 2V
Standard tools:
Thermometer
W 38-01-01
Danger!
Risk of injury!
Hot water and hot thermostat.
Checking thermostat
Remove thermostat.
W 38-01-01
Measure beginning of stroke, dimension (a).
44585-0
Heat up the thermostat in the water bath.

Determine beginning of opening.
In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the thermostat.
Do not touch the thermostat.
The water should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place faster than 1C/min. Otherwise the beginning
of opening will be delayed accordingly.
83 C
34680-2
02/2010
1/2
Thermostat housing
W 38-01-02
TCD 2013 2V
Measure end of stroke, dimension (b).

6
34679-2
Determine stroke.
Calculation example
Desired:
Stroke
Given:
Measured:
Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Calculation:
Dimension (b) - dimension (a)
Result:
= stroke
Compare result with setpoint value.

8 mm
Install thermostat.
W 38-01-01
34679-1
02/2010
2/2
Thermostat housing
W 38-02-01
TCD 2013 2V
8190
Standard tools

to regulations.
Fitting compound
DEUTZ AP1908
manufacturer.
Removing the thermostat housing

Unscrew screws (1).
Remove thermostat housing (2)
Note plug element (arrow).
1
1
44520-0
Pull out plug element (1).
44521-0
02/2010
1/4
Thermostat housing
W 38-02-01
TCD 2013 2V
6
44522-0
Installing the thermostat housing

Coat the O-rings with fitting compound.
44523-0
Insert plug element (1).
44521-0
02/2010
2/4
Thermostat housing
W 38-02-01
TCD 2013 2V
Insert new sealing ring (arrow).
Coat the sealing ring with fitting compound.
6
44524-0
Push the coolant thermostat housing onto the adapter first.

Mount the coolant thermostat housing.
30 Nm
44525-0
02/2010
3/4
Thermostat housing
W 38-02-01
TCD 2013 2V
02/2010
4/4
Fan drive
W 39-01-01
TCD 2013 2V
Removing and installing the belt tensioner
(V-rib belt)
Standard tools:
Retaining pin, diameter
6 mm
Removing the belt tensioner

Tighten the belt tensioner (1) in the direction of the
arrow until the bores (2) are in line.
1
2
42852-0
Insert holding pin (1).
42837-0
02/2010
1/4
Fan drive
W 39-01-01
TCD 2013 2V
Remove V-rib belt.

The running direction must be marked
when the V-rib belt is to be re-used.
First remove the V-rib belt from the V-rib
belt pulley (1)
1
6
42853-0
Unscrew screw (1).

Remove belt tightener (2).
1
2
42836-0
Installing the belt tensioner

Mount the belt tightener.
The fixing bolts (1) must fit into the bores
(2).
42838-0
02/2010
2/4
Fan drive
W 39-01-01
TCD 2013 2V
Tighten screw (1).
80 Nm
6
42839-0
Fit the V-rib belt according to the running direction.

Place the V-rib belt over the V-rib belt pulley (1) last.
from faults.
1
42853-0
Hold the belt tensioner.

Remove the retaining pin.
Relieve the belt tightener.
The belt tightener clamps the V-rib belt
automatically.
42840-0
02/2010
3/4
Fan drive
W 39-01-01
TCD 2013 2V
Check the wear limit of the V-rib belt

The fuel pipe is removed for better illustration.
Measure distance (a).
If the distance (a) is less than 3 mm, the Vrib belt must be changed.
6
43851-1
02/2010
4/4
Fan drive
W 39-02-01
TCD 2013 2V
Standard tools:
Retaining pin, diameter
6 mm
Removing the fan drive

Unscrew screws (1).
Remove adapter (2).
1
42854-0
Tighten the belt tensioner (1) in the direction of the

arrow until the bores (2) are in line.
1
2
42852-0
02/2010
1/4
Fan drive
W 39-02-01
TCD 2013 2V
Insert holding pin (1).

6
42837-0
Mark the running direction of the V-rib belt.

Remove V-rib belt.
First remove the V-rib belt from the V-rib
belt pulley (1)
42853-0
Unscrew screws (1).

Remove fan drive with V-rib belt pulley.
Note installation position of the fan drive.

1
42855-0
02/2010
2/4
Fan drive
W 39-02-01
TCD 2013 2V
Installing the fan drive
Install fan drive with V-rib belt pulley.
Tighten screws (1).

60 Nm
Note installation position of the fan drive.
1
42856-0
Fit the V-rib belt according to the running direction.

Place the V-rib belt over the V-rib belt pulley (1) last.
from faults.
1
42853-0
Hold the belt tensioner.

Remove the retaining pin.
Relieve the belt tightener.
The belt tightener clamps the V-rib belt
automatically.
42840-0
02/2010
3/4
Fan drive
W 39-02-01
TCD 2013 2V
Check the wear limit of the V-rib belt

The fuel pipe is removed for better illustration.
Measure distance (a).
If the distance (a) is less than 3 mm, the Vrib belt must be changed.
6
43851-1
Mount adapter (1).

Tighten screws (2).
30 Nm
2
2
42857-0
02/2010
4/4
Fan drive
W 39-02-03
TCD 2013 2V
Standard tools
W 39-02-01
Dismantling the fan drive

Remove the fan drive.
W 39-02-01
Mount adapter (1).
30 Nm
42874-0
Clamp the fan drive in the vice.

Unscrew screw (1).
Attention!
Screw has left-hand thread.
42875-0
02/2010
1/6
Fan drive
W 39-02-03
TCD 2013 2V
Unclamp the fan drive.

Remove adapter (1).
6
42874-0
Press off tight V-rib belt pulley from the fan drive with
twon forcing screws (1).
1
42877-0
Press out shaft and inside ball bearing.
42878-0
02/2010
2/6
Fan drive
W 39-02-03
TCD 2013 2V
Press out outside ball bearing.
6
42879-0
Remove locking ring (1).
42880-0
Press pulley out of the inside ball bearing.
42881-0
02/2010
3/6
Fan drive
W 39-02-03
TCD 2013 2V
Press shaft out of the inside ball bearing.

6
42882-0
Assembling the fan drive

Press shaft into the inside ball bearing to the stop.
42883-0
Press pulley into the inside ball bearing to the stop.
42884-0
02/2010
4/6
Fan drive
W 39-02-03
TCD 2013 2V
Press the outside ball bearing into the housing to the
stop.
The press-in tool (1) must touch the outer
ring of the ball bearing (arrow).
6
42885-0
Insert locking ring (1).

Make sure the locking ring fits correctly in
the groove.
42886-0
Press in shaft and inside ball bearing to the stop.

Support inside ring of the outside ball
bearing with a suitable tool (arrow).
42887-0
02/2010
5/6
Fan drive
W 39-02-03
TCD 2013 2V
Mount adapter (1).

30 Nm
6
42874-0
Clamp the fan drive in the vice.

Install fan drive.
Tighten screw (1).
Stage 1:
30 Nm
Stage 2:
90
Attention!
Screw has left-hand thread.
42875-0
Unclamp the fan drive.

Remove adapter (1).

Install fan drive.
W 39-02-01
42874-0
02/2010
6/6
Fan console
W 39-04-03
TCD 2013 2V
Removing and installing the fan console
(V-rib belt drive)
Standard tools
Fitting compound
DEUTZ AP1908
Packing compound
DEUTZ DW 74
W 20-02-01
W 39-01-01
W 39-02-01
W 44-02-01

to regulations.
Removing the fan console

Remove the fan drive.
W 39-02-01
Remove the belt tensioner.
W 39-01-01
Remove fuel supply pump.
W 20-02-01
Remove generator.
W 44-02-01
42900-0
Unscrew screws (1).

Remove transport flange (2).
Remove generator console (3).
1
42901-0
02/2010
1/6
Fan console
W 39-04-03
TCD 2013 2V

Remove fan console (1).
6
42902-0
Installing the fan console

Pull cable (1) forward slightly.
1
42913-0

Coat new sealing rings with fitting compound .
Insert new sealing rings (arrows).
42972-0
02/2010
2/6
Fan console
W 39-04-03
TCD 2013 2V
Apply packing compound (arrow).
6
42914-0
Install fan console.

30 Nm
Attention!

Do not displace the packing compound.
Lay cable between front cover and fan console.
42915-0
Installa generator console (1) with transport flange

(2).
Fasten screws (3).
3
42916-0
02/2010
3/6
Fan console
W 39-04-03
TCD 2013 2V
Mount generator.
Tighten screws (1).
42917-0
The holes in the transport flange (arrows)

must match up with the threaded holes in
the generator console.
42973-0
Tighten screws (1).

70 Nm
Tighten screws (2).

60 Nm
1
2
02/2010
4/6
1
42918-0
Fan console
W 39-04-03
TCD 2013 2V
Install fuel pump.
W 20-02-01
Install the belt tensioner.
W 39-01-01
Install fan drive.
W 39-02-01
Install generator.
W 44-02-01
6
42919-0
02/2010
5/6
Fan console
W 39-04-03
TCD 2013 2V
02/2010
6/6
Exhaust pipe
W 41-01-01
TCD 2013 2V
Standard tools
W 43-01-01
Fitting compound
DEUTZ S1
Removing exhaust line

Remove turbocharger.
W 43-01-01
44295-0
Unscrew all nuts (arrow).

Remove exhaust manifold (1).
Remove seals.
Remove studs.
44579-0
02/2010
1/4
Exhaust pipe
W 41-01-01
TCD 2013 2V
Remove studs.
6
44297-0
Installing exhaust line

Coat new pin bolts with DEUTZ S1 mounting compound.
Mount new pin bolts with locking nuts.
1
1
Tighten pin bolts (1).

10 Nm
44297-1

10 Nm
Mount new seals.
44580-1
02/2010
2/4
Exhaust pipe
W 41-01-01
TCD 2013 2V
Mount exhaust manifold.
6
44578-0
Mount washers (1).

Mount spacer sleeves (2).
Screw on new nuts.
1
44299-0
Tighten nuts alternately.

25 Nm
Tightening sequence: From the centre outwards.
44298-0
02/2010
3/4
Exhaust pipe
W 41-01-01
TCD 2013 2V
Install the turbocharger.

W 43-01-01
6
44295-0
02/2010
4/4

W 43-01-01
TCD 2013 2V

to regulations.
Standard tools
Fitting compound
DEUTZ S1
Fitting compound
DEUTZ AP1908
Removing turbocharger
Unscrew screw (1).
Remove retainer.
44277-0
Unscrew screws (1).
44278-0
02/2010
1/6

W 43-01-01
TCD 2013 2V
Pull out oil return pipe (1).

Remove pipe socket (2).
2
6
44279-0

Remove lubricating oil pipe (2).
1
2
44280-0
Unscrew nuts (arrows).

Remove turbocharger (1).
44281-0
02/2010
2/6

W 43-01-01
TCD 2013 2V
6
44282-0
Installing the turbocharger


10 Nm
Mount new gasket.
Mount turbocharger (2).
Tighten all nuts.
42 Nm
44283-1
Mount lubrication oil line (1).

2

39 Nm
1
2
44284-0
02/2010
3/6

W 43-01-01
TCD 2013 2V
Unscrew screw (1).

Pull pipe socket (2) out of oil return line (3).
2
1
6
44285-0

Coat the O-rings with fitting compound.
Use fitting compound AP 1908.
44286-0
Plug pipe socket (2) into oil return line (3).

Fasten screw (1).
2
1
44285-0
02/2010
4/6

W 43-01-01
TCD 2013 2V
Push oil return line (1) into crankcase (arrow).
6
44287-0
Mount new gasket.

Mount pipe nozzle.
Tighten screws (1).
20 Nm
Attention!
Install tension-free!
44278-0
Mount retainer.
Tighten screw (1).
20 Nm
44277-0
02/2010
5/6

W 43-01-01
TCD 2013 2V
Tighten screw (1).

20 Nm
6
44288-0
02/2010
6/6
Generator
W 44-02-01
TCD 2013 2V
Removing and installing the generator
(V-belt drive)
Standard tools:
device
8115
Operation manual
Attention!
Only test / tighten / renew V-belts when the

engine is not running.
15 minutes.
Removing the generator

Disconnect the battery's negative terminal.
Remove cable from generator.
Note assignment!
- (1) = terminal W
- (2) = terminal D+
- (3) = terminal B+
2
44429-0
Loosen screws (1).
1
1
44038-0
02/2010
1/4
Generator
W 44-02-01
TCD 2013 2V
6
44039-0
Remove V-belt (1).
44040-0
Unscrew screws (1).

Remove generator (2).
44431-0
02/2010
2/4
Generator
W 44-02-01
TCD 2013 2V
Installing the generator
Mount generator (2).
Tighten screws (1).

6
44431-0
Mount V-belt (1) for generator.
44040-0
Remove cable from generator.

Note assignment!
- (1) = terminal W
- (2) = terminal D+
- (3) = terminal B+
Connect the battery's negative terminal.
2
44429-0
02/2010
3/4
Generator
W 44-02-01
TCD 2013 2V
Tighten V-belt (1) by turning the clamping screw (2).

Operation manual
2
44053-0
02/2010
4/4
Starter
W 44-03-01
TCD 2013 2V
Standard tools
Removing the starter

Disconnect the battery's negative terminal.
Disconnect cables.
44432-0

Remove starter.
44554-0
02/2010
1/2
Starter
W 44-03-01
TCD 2013 2V
Installing the starter

Insert starter.
60 Nm
6
42898-0
Connect cables.
Connect the battery's negative terminal.
44432-0
02/2010
2/2
Engine mounting
W 46-00-01
TCD 2013 2V
Standard tools:
Lifting gear
Suspension ropes
W 01-01-01
W 47-01-01
Special tools:
Assembly block incl. adapter plates
6066
Clamping bracket
6066/158
Danger!
When using hoists (workshop crane) the
safety regulations for handling hoists must
be observed.
It is not permitted to stay under moving
loads.
Mounting engine on assembly block

W 01-01-01
Hang engine on suitable workshop crane.
Remove mounting feet.
W 47-01-01
43943-0
Mount clamping bracket 6066/158-3 (1) on crankcase.

Tighten screw (2).
90 Nm
Mount clamping bracket 6066/158-1 (3) on holder.

Tighten screws (4) and lock nuts.
90 Nm
3
43945-0
02/2010
1/6
Engine mounting
W 46-00-01
TCD 2013 2V
Mount clamping bracket 6066/158-2 (1) on holder.

Tighten screws (2) and lock nuts.
90 Nm
Mount clamping bracket 6066/158-4 (3) on crankcase.
Tighten screws (4).
90 Nm
4
43946-0
Insert engine in engine block.

Align all clamping brackets (1) on the adapter
plates (2) of the assembly block.
Insert screws.
X
1
Tighten nuts (arrows).

90 Nm
42645-0
Align engine on engine block.

Tighten all screws (arrows).
Unhook engine.
43947-0
02/2010
2/6
Engine mounting
W 46-00-01
TCD 2013 2V
Demounting engine from assembly block
Hang engine on workshop crane.
6
44105-0
Remove all clamping brackets (1) from the adapter

plates (2).
Lift engine.
42740-0
Unscrew the nuts (2).

Remove screws (2) and lock nuts.
Remove clamping bracket (1).
Unscrew screws (4).
43946-0
02/2010
3/6
Engine mounting
W 46-00-01
TCD 2013 2V
Unscrew nuts (4).

Remove screws (4) and lock nuts.
Unscrew screw (2).
Install mounting feet.
W 47-01-01
W 01-01-01
3
43945-0
X
X
02/2010
4/6
Engine mounting
W 46-00-01
TCD 2013 2V
Technical Data
ID no.
Name
A00 001 Clamping holder on crankcase
Clamping bracket on adapter for
A00 002
assembly block
Screw type
Screw
Nut
Notes / Remark
Value
90 Nm
90 Nm
02/2010
5/6
Engine mounting
W 46-00-01
TCD 2013 2V
02/2010
6/6
Engine mounting
W 47-01-01
TCD 2013 2V
(elastic mounting)
Standard tools
W 01-01-01
W 46-00-01
Remove mounting feet

W 01-01-01
Hang engine on suitable workshop crane.
W 46-00-01
Unscrew nuts (1).
Remove mounting foot (2).
Remove all mounting feet.
1
2
42640-0
Unscrew screws (1).

Remove mounting foot (2).
42641-0
02/2010
1/6
Engine mounting
W 47-01-01
TCD 2013 2V
Mount mounting feet

Hang engine on workshop crane.
W 46-00-01
Mount mounting foot (1).
Tighten screw (2).

(2) = M12
95 Nm
Mount all mounting feet.
6
42641-1
Mount mounting foot (1).

Tighten screw (2).
(2) = M12
95 Nm
Set down engine.
Unhook engine.
W 01-01-01
2
1
42640-1
Different installation variants are shown

below as examples.
Variant
Fit rigid mounting foot (1).
Tighten screw (2).
(2) = M12x60
95 Nm
48225-0
02/2010
2/6
Engine mounting
W 47-01-01
TCD 2013 2V
Variant
Mount holder (1).
Fit washers (2).
Tighten screws (3).

(3) = M16
260 Nm
2
3
6
48226-0
Variant
Fit sleeves (1).
Fit holder (2).
Fit washers (3).
Tighten screws (4).
(4) = M16
260 Nm
3
4
48230-0
Fit elastic mounting foot (1).

Fit washers (2).
Fasten screws (3).
Hold nut (4).

Tighten screws (3).
(3) = M12
95 Nm
4
3
48231-0
02/2010
3/6
Engine mounting
W 47-01-01
TCD 2013 2V
Variant
Mount holder (1).
Fit mounting bracket (2).
Fit washers (3).
Tighten screws (4).

2
Fit washers (5).

Fasten screws (6).
Tighten screws (4).

(4) = M16
260 Nm
Tighten screws (6).
(6) = M12
90 Nm
02/2010
4
48232-0
4/6
Engine mounting
W 47-01-01
TCD 2013 2V
Technical Data
ID no.
Name
Feet/engine mounting on holder/

A00 003 crankcase/connection housing/gear
case
Holder, engine mounting on

A00 005
crankcase
A00 006
Mounting bracket on holder/

crankcase
Screw type
Notes / Remark
M12x35-10.9
M12x40-10.9
M12x60-10.9
M12x75-10.9
M12x85-10.9
M12x90-10.9
M12x220-10.9
M16x40-10.9
M16x45-10.9
M16x75-10.9
M16x85-10.9
M16x110-10.9
M16x140-10.9
M16x155-10.9
M16x220-10.9
M12x40-10.9
Value
95 Nm
6
260 Nm
90 Nm
02/2010
5/6
Engine mounting
W 47-01-01
TCD 2013 2V
02/2010
6/6
Cable harness
W 48-01-01
TCD 2013 2V
Standard tools
Removing the cable harness

Remove cable tie (1).
Unlock cable plug (2) and disconnect.
impulse transmitter (camshaft)
2
44059-0

Temperature sensor
2

Solenoid valve (exhaust return line)
44448-0
02/2010
1/12
Cable harness
W 48-01-01
TCD 2013 2V

6
44449-0
Unscrew screw (1).

2
44433-0

Pressure/temperature sensor
44435-0
02/2010
2/12
Cable harness
W 48-01-01
TCD 2013 2V
Unlock central plug (1) (arrow) and pull off from holder.
6
44450-0

Control block
44557-0

Pull off cable plug (2).
Fuel pressure sensor
Oil pressure switch
44588-0
02/2010
3/12
Cable harness
W 48-01-01
TCD 2013 2V

Impulse transmitter (crankshaft)
6
44559-0

44560-0

Rail pressure sensor
44561-0
02/2010
4/12
Cable harness
W 48-01-01
TCD 2013 2V
Unscrew screws (1).
6
44562-0
Unscrew nuts (1).

Remove cable from injector.
Remove cables from all injectors.
Remove cable harness.
44563-0

1
44564-0
02/2010
5/12
Cable harness
W 48-01-01
TCD 2013 2V
Installing the cable harness

Position cable harness on the cover plate and fix with
cable ties (arrows).
6
44565-0
Position the cable harness on the engine accordingly.

Lay the cable plugs to the individual components.
44566-0
Mount cable on injector.

Mount cables on all injectors.
Tighten nuts (1).
1,5 Nm
Tighten nuts of all injectors.
44563-0
02/2010
6/12
Cable harness
W 48-01-01
TCD 2013 2V
Mount cover (2).
Tighten screws (1).
8,5 Nm
1
6
44562-0

Rail pressure sensor
44561-0
Plug cable plugs (1) together.

Impulse transmitter (crankshaft)
1
44567-0
02/2010
7/12
Cable harness
W 48-01-01
TCD 2013 2V

1
6
43970-1

Oil pressure switch
1
44588-1
44568-0
02/2010
8/12
Cable harness
W 48-01-01
TCD 2013 2V
Control block
6
44557-0
Push the central plug onto the holder until it snaps in.
44468-0

Pressure/temperature sensor
1
44435-0
02/2010
9/12
Cable harness
W 48-01-01
TCD 2013 2V
Mount cover (2).

Tighten screw (1).
4,5 Nm
6
44433-0
44449-0

Temperature sensor
2

Solenoid valve (exhaust return line)
44448-0
02/2010
10/12
Cable harness
W 48-01-01
TCD 2013 2V
impulse transmitter (camshaft)
Lay cable harness and fix with cable tie (1).
2
6
44059-0
02/2010
11/12
Cable harness
W 48-01-01
TCD 2013 2V
02/2010
12/12
W 48-02-01
TCD 2013 2V
(crankshaft)
Standard tools:
Feeler gauges
Locking agent
DEUTZ DW 72
Removing the impulse transmitter

1

Remove cable tie (2).
Lay cable bare.
44087-0
Unscrew screws (1).

Remove holder with impulse transmitter (2).
44088-0
02/2010
1/6
W 48-02-01
TCD 2013 2V
Unscrew screw (1).

Remove impulse transmitter from holder.
6
44089-0
44090-0
Installing the impulse transmitter

Press impulse transmitter into holder.
Attention!
Do not knock in impulse transmitter!

Clean thread of the screw and bore.
Insert screw (1) with safety agent
DEUTZ DW 72.
44089-0
02/2010
2/6
W 48-02-01
TCD 2013 2V
Tighten screw (1).
9 Nm
6
44089-0
Mount holder with impulse transmitter.

Insert screws with safety agent
DEUTZ DW 72.
2
44091-0

(crankshaft)
Select feeler gauge.
0,6 -0.1 mm
+0.1
Push feeler gauge blade between tooth lock washer

and impulse transmitter.
44092-0
02/2010
3/6
W 48-02-01
TCD 2013 2V
20 Nm
6
44093-0

0,6 +0.1
-0.1 mm
44094-0
Lay cable between front cover and coolant pump (arrow).
44095-0
02/2010
4/6
W 48-02-01
TCD 2013 2V
Lay cable.
Fix cable with cable tie (2).
6
44087-0
02/2010
5/6
W 48-02-01
TCD 2013 2V
02/2010
6/6
W 48-02-03
TCD 2013 2V
(camshaft)
Standard tools
Locking agent
DEUTZ DW 72
Removing the impulse transmitter

44059-0
Unscrew screw (1).

Remove impulse transmitter (2).
2
1
44060-0
02/2010
1/4
W 48-02-03
TCD 2013 2V
6
44058-0
Installing the impulse transmitter

Clean sealing surfaces on impulse transmitter and
gearcase cover.
Insert new O-ring (arrow).
Lightly oil O-ring.
42739-0
Clean thread of the screw and bore.

Insert impulse transmitter (2).
Insert screw (1) with locking agent.
Tighten screw (1).
9 Nm
2
1
44060-0
02/2010
2/4
W 48-02-03
TCD 2013 2V
1
Lay cable.
Fix cable with cable tie (2).
6
44061-0
02/2010
3/4
W 48-02-03
TCD 2013 2V
02/2010
4/4
W 48-03-01
TCD 2013 2V
Removing and installing the pressure/temperature sensor

(charge air)
Standard tools
Fitting compound
DEUTZ AP1908
Remove pressure/temperature sensor

Unscrew screw (1).
44433-0

Remove pressure/temperature sensor
44435-0
02/2010
1/2
W 48-03-01
TCD 2013 2V
Installing the pressure/temperature sensor

Lightly coat O-ring with fitting compound.
6
43271-0
Insert pressure/temperature sensor.

Plug in the cable plug (1) and snap in lock.
1
44435-0
Mount cover (2).

Tighten screw (1).
4,5 Nm
44433-0
02/2010
2/2
W 48-04-01
TCD 2013 2V
Standard tools
User notes
Special tools:
Plugs/caps
170160
Pay attention to utmost cleanliness when

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

44510-0
02/2010
1/4
W 48-04-01
TCD 2013 2V
Unscrew oil pressure switch (1).

Collect lubricating oil and dispose of
6
44511-0
44512-0
Installing the oil pressure switch

Mount new sealing ring.
Tighten the oil pressure switch (1) with the socket
wrench insert.
30 Nm
1
44511-0
02/2010
2/4
W 48-04-01
TCD 2013 2V
6
44510-0
02/2010
3/4
W 48-04-01
TCD 2013 2V
02/2010
4/4
W 48-05-01
TCD 2013 2V
(coolant)
Standard tools

to regulations.
manufacturer.
Removing temperaure transmitter

1
44426-1
Unscrew temperature transmitter (1).

Hold the connector.
44427-0
02/2010
1/2
W 48-05-01
TCD 2013 2V
6
44084-0
Installing temperature transmitter

Tighten temperature transmitter (1).
22 Nm
Make sure the sealing ring is in place.
44428-0

1
44426-1
02/2010
2/2
W 48-06-01
TCD 2013 2V
Standard tools
User notes
Special tools:
Plugs/caps
170160
Danger!
Attention!

on the fuel system.
compressed air.
Removing the fuel pressure sensor

Danger!

Pull off cable plug (2).
43972-1
02/2010
1/4
W 48-06-01
TCD 2013 2V
Unscrew fuel pressure sensor (1) with the socket

wrench.
1
6
43973-0
43974-0
Installing the fuel pressure sensor

Mount new sealing ring.
Install fuel pressure sensor (1) with the socket
wrench.
30 Nm
43973-0
02/2010
2/4
W 48-06-01
TCD 2013 2V
1

operation manual.
6
43970-0
02/2010
3/4
W 48-06-01
TCD 2013 2V
02/2010
4/4
Tools
W 49-02-01
TCD 2013 2V
Standard tools
Special tools:
Turn-over gear
100320
Disassembly
Unscrew screws (1).
Remove holder (2).
Remove sleeve (3).
Remove spacing sleeve (4).
4
3
43950-1
Unscrew screws (1).

Remove cover (2).
1
1
43951-0
02/2010
1/4
Tools
W 49-02-01
TCD 2013 2V
Attaching turning gear

The toothed gear of the turn-over gear
must grip into the teeth of the camshaft
wheel.
Attention!
1
43952-0
Tighten screws (1).

1
1
43953-0
Removing turning gear

Unscrew screws (1).
Remove turn-over gear.
1
43953-0
02/2010
2/4
Tools
W 49-02-01
TCD 2013 2V
Clean the sealing surface on cover and gearcase.
Insert new O-ring (arrow).
Lightly oil O-ring.
6
43983-0
Press in the cap to the stop.

See spare parts documentation.
21 Nm
43984-0
Fit holder (1).

Fit sleeve (2).
Position spacing sleeve (3).
Tighten screws (4).
30 Nm
3
2
4
3
2
43950-2
02/2010
3/4
Tools
W 49-02-01
TCD 2013 2V
Technical Data
ID no.
Name
A03 092 Gear case on crankcase

A04 022 Locking cap on gear case
A04 025 Holder on gear case/crankcase
Screw type
M8x35-10.9
M8x55-10.9
M8x80-10.9
M8x55-10.9
M8x60-10.9
M8x80-10.9
Notes / Remark
Value
Observe tightening
sequence
30 Nm
21 Nm
30 Nm
02/2010
4/4
Tools
W 49-02-02
TCD 2013 2V
(Torsional vibration damper)
Attention!
Standard tools
Special tools:
Turn-over gear
Observe engine rotation direction - see

operating manual
100380
Attaching turning gear

48243-0
Position turning gear (1).
48244-0
02/2010
1/2
Tools
W 49-02-02
TCD 2013 2V
Depending on the installation situation mount the appropriate tool on the turning gear (1) for extension.
Attention!
Observe engine rotation direction - see

operating manual
Turn crank shaft in engine rotation direction with turning gear.
6
48245-1
Removing turning gear

Remove turning gear (1).
02/2010
2/2
48243-0
Connection housing
W 52-01-01
TCD 2013 2V
Standard tools:
8113
8114
Removing the connection housing

42698-0

Remove connection housing.
44081-0
02/2010
1/4
Connection housing
W 52-01-01
TCD 2013 2V
Installing the connection housing

Clean contact surfaces.
6
44082-0
Make sure the clamping bushing (arrow) is in place.
44083-0
Mount connection housing.

Centre connection housing over the clamping bushings.
2
1
Fasten screws.
M12x85-10.9
M12x160-10.9 (1)
M16x85-10.9
M16x150-10.9 (2)
See spare parts documentation.
2
2
44421-1
02/2010
2/4
Connection housing
W 52-01-01
TCD 2013 2V
4
See graphic for tightening sequence.

1
Fasten screw (1) hand tight.
Pre-tighten screws (2), (3) (4) and (5) alternately.
6
44085-0
Tighten screws (1) and (6).

99 Nm
Tighten screws (2), (3), (4) and (5) alternately.

Stage 1:
99 Nm
44085-0
Tighten screws (2), (3), (4) and (5) alternately.

Stage 2:
243 Nm
44085-1
02/2010
3/4
Connection housing
W 52-01-01
TCD 2013 2V
Press on cover plate to the stop.

9 Nm
The hollow gorge (1) faces the lube oil tray.
6
42704-0
02/2010
4/4
Connection housing
W 52-01-02
TCD 2013 2V
8190
Attention!
Standard tools:
Self-made mandrin guide
Special tools:
Digital dial gauge
Prerequisites:
Radial bearing clearance and axial
clearance of the crankshaft in the permissible tolerance range.
100410
Test surfaces must be dry and free from

dirt and burr!
Checking the rotation

Mount the engine on the assembly block.
Make help marks at a distance of 90 on the connection housing.
III
Position (I)
Position (II)
Position (III)
II
Position (IV)
IV
47687-0
Screw the self-made guide pin (1) tight.

Mount the measuring stand (2) on the guide pin.
Insert dial gauge in dial gauge holder.
1
2
47686-0
02/2010
1/6
Connection housing
W 52-01-02
TCD 2013 2V
Position (I)
Set the dial gauge with probe pin to position (I) at a
right angle to the connection housing.
Apply the probe pin to the connection housing with
pre-tension.
I
47688-0
47689-0
Position (II)
Turn the crankshaft slowly to position (II).
II
Note the sign!

Note the measured value (a) with the appropriate
sign on the measurement sheet.
47690-0
02/2010
2/6
Connection housing
W 52-01-02
TCD 2013 2V
Position (III)
III
Turn the crankshaft slowly to position (III).

Note the sign!
Note the measured value (b) with the appropriate
6
47691-0
Position (IV)
Turn the crankshaft slowly to position (IV).
Note the measured value, dimension (c).
IV
Note the sign!

Note the measured value (c) with the appropriate
47692-0
Turn the crankshaft slowly to position (I).

The dial gauge must indicate measured value "0"
again.
Make the calculation according to the example in table 1.
In case of a radial run-out deviation above
the specified run-out limit value, the connection housing must be disconnected.
I
47688-0
02/2010
3/6
Connection housing
W 52-01-02
TCD 2013 2V
Press the connection housing in the appropriate direction and align.
Attention!
Never hit the connection housing with a

hammer.
W 52-01-01
I
47688-0
02/2010
4/6
Connection housing
W 52-01-02
TCD 2013 2V
Technical Data
Table 1 (example)
Connection housing SAE3
Position
1 Display on dial gauge 100410
1a Arithmetic value (reversal of the sign)
Correction radial bearing clearance (d)
2
(d) = 0.06 mm
Half of the bearing clearance correction
3
(d/2)
Corrected vertical total dial gauge
4 display (L )
v
5
6
Corrected horizontal dial gauge display

(E1, E2)
Horizontal total dial gauge display (LH)
(I)
0
(II)
a = 0.16
a1 = -0.16
(III)
b = -0.08
b1 = +0.08
(IV)
c = 0.23
c1 = -0.23
d = -0.06
d/2 = -0.03
d/2 = -0.03
E1 = -0.19
E2 = -0.26
Lv = 0.02
LH = 0.07
Calculation example on connection housing SAE 03, radial run-out limit value 0.29 mm
Lv = +0.08 + -0.06
Lv = b1 + d
Lv = 0.02
E1 = a1 + d/2
E1 = -0.16 + -0,03
E1 = -0.19
E2 = c1 + d/2
E2 = -0.23 + -0,03
E2 = -0.26
LH = E1 - E2
LH = -0.19 - -0.26
LH = 0.07
LR = 0.0730
LR = determined radial run-out limit value (t) 0.0730 mm

Determined radial run-out limit value (t) = 0.0730 mm is lower than the permissible radial run-out limit
value (t) = 0,29 mm. No alignment of the connection housing necessary.
A determined radial run-out limit value (t) greater than 0.29 mm requires alignment of the connection housing.
The sign indicated in the display of the dial gauge is dependent on the dial gauge!
If the dial gauge indicates a positive value when the probe pin moves outwards, the measured value
must be noted with a positive sign, in this case, line 1a is omitted.
If the dial gauge indicates a negative value when the probe pin moves outwards, the measured value
must be noted with a positive sign, in this case, dial gauge 100410.
Table 2 - connection housing / radial run-out

limit value
Connection housing
SAE size
SAE 0
SAE 1
SAE 2
SAE 3
02/2010
Inside diameter
(mm)
647,7
511,18
447,68
409,58
5/6
(t) Radial run-out limit value

(mm)
0,45
0,36
0,31
0,29
Connection housing
W 52-01-02
TCD 2013 2V
SAE 4
SAE 5
361,95
314,32
0,25
0,25
Measurement sheet - connection housing / radial run-out limit value

Issued by:
Date:
Engine number:
Connection housing:
Position
1 Display on dial gauge 100410

1a Arithmetic value (reversal of the sign)
Correction radial bearing clearance (d)
2
(d) = 0.06 mm
Half of the bearing clearance correction
3
(d/2)
Corrected vertical total dial gauge
4 display (L )
v
5
Corrected horizontal dial gauge display

(E1, E2)
Horizontal total dial gauge display (LH)
(I)
0
(II)
a=
a1 =
(III)
b=
b1 =
(IV)
c=
c1 =
d=
d/2 =
d/2 =
E1 =
E2 =
Lv =
6
Calculation
Lv = b1 + d
LH =
E1 = a1 + d/2
E1 =
E2 = c1 + d/2
E2 =
LH = E1 - E2
LH =
Lv =
LR =
LR = determined radial run-out limit value (t) t =
Connection housing
SAE size
SAE 0
SAE 1
SAE 2
SAE 3
SAE 4
SAE 5
02/2010
(t) Radial run-out limit value Radial run-out alignment in

New alignment necessary
(mm)
order
Nominal
Actual
0,45
0,36
0,31
0,29
0,25
0,25
6/6
Start aid
W 63-01-01
TCD 2013 2V
Attention!
Standard tools
See the spare parts documentation.
Removing the heating flange

Disconnect cables.
Attention!
Hold on the hexagon of the plus pole

screw.
Unscrew screws (1).
1
46360-0
Remove hose nozzles (1).

Remove gasket (2).
Remove heating flange.
Remove gasket (3).
1
3
44360-1
02/2010
1/4
Start aid
W 63-01-01
TCD 2013 2V
6
44831-0
Installing the heating flange

Mount gasket (3).
Mount heating flange.
Mount gasket (2).
Mount hose nozzles (1).
1
3
44360-1
Tighten screws (1).

Stage 1:
3 Nm
Stage 2:
30
Connect cable.
20 Nm
Attention!
Hold on the hexagon of the plus pole

screw.
46360-0
02/2010
2/4
Start aid
W 63-01-01
TCD 2013 2V
Technical Data
ID no.
Name
Screw type Notes / Remark
A06 042 Heating flange on charge air manifold M8x100-10.9 Stage 1:
A06 042 Heating flange on charge air manifold M8x100-10.9 Stage 2:
Hexagonal, pole screw
A13 065 Cable connection on heater flange
locked
Value
3 Nm
30
20 Nm
02/2010
3/4
Start aid
W 63-01-01
TCD 2013 2V
02/2010
4/4
Start aid
W 63-02-01
TCD 2013 2V
Standard tools
Special tools:
Assembly tool
User notes
W 19-01-01
120440
Danger!
Attention!
Pay attention to utmost cleanliness when

working on the fuel system.
before removing.
Clean the respective affected parts
carefully. Blow damp areas dry with compressed air.
to regulations.
Removing the glow plugs

Unscrew nuts (1).
Remove cable (arrows).
Remove injectors.
W 19-01-01
Attention!

from the injector before removing it.
Carefully clean the area around the injector.
42728-0
02/2010
1/4
Start aid
W 63-02-01
TCD 2013 2V
Feed cable (1) through assembly tool (2).
1
2
6
48219-0
Unscrew heating plug (1) with assembly tool.

48220-0
Installing the glow plugs

Screw in heating plug (1).
Tighten heating plug (1) with assembly tool.
20 Nm
Install the injectors.
W 19-01-01
48220-0
02/2010
2/4
Start aid
W 63-02-01
TCD 2013 2V
Install cable (arrows).
Tighten nuts (1).
3 Nm
6
42728-0
02/2010
3/4
Start aid
W 63-02-01
TCD 2013 2V
Technical Data
ID no.
Name
A13 030 Cable shoe on connection bolt
Heating plug / screw cap on cylinder
A13 032
head
Screw type
M6
Notes / Remark
Value
3 Nm
20 Nm
02/2010
4/4
Standard tools
W 49-00-01
TCD 2013 2V
Standard tools
7
02/2010
1/8
Standard tools
W 49-00-01
TCD 2013 2V
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
Conventional tools /
special tools:
These must be ordered directly from

WILBAER with specification of the order
number.
Common Rail test instruments:
These must be ordered like normal DEUTZ
spare parts.
02/2010
2/8
Standard tools
W 49-00-01
TCD 2013 2V
8002
Pressure pump
Checking cooling system for leak-tightness
35409-2
7
8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
35410-3
8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe
39426-1
02/2010
3/8
Standard tools
W 49-00-01
TCD 2013 2V
8024
Assembly pliers
Removing valve shaft seals
37509-2
7
8035
reinforced, size 22
removing and installing main bearing
37504-2
8113
Torx - E 14
43022-0
02/2010
4/8
Standard tools
W 49-00-01
TCD 2013 2V
8114
Torx - E 20
35415-1
7
8115
V-belt tension measuring device
150 to 600 N
Check V-belt tension
35416-3
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
02/2010
5/8
Standard tools
W 49-00-01
TCD 2013 2V
8190
Rotation angle disc
with magnet
42528-1
7
8191
Screwdriver insert
for slotted screw
Valve clearance setting
43060-0
8192
Bowl wrench
Fuel pre-filter (type: Racor)
43193-1
02/2010
6/8
Standard tools
W 49-00-01
TCD 2013 2V
8193
Screwdriver insert
with pressed in hexagonal pin (5 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)
43183-0
7
8194
Screwdriver insert
with pressed in hexagon pin (4 mm),
3/8 inch, long version
(in connection with rotation angle disc 8190 and reducer 1/2 to 3/8 inch)
43183-0
8196
Open end wrench adapter
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.
43197-0
02/2010
7/8
Standard tools
W 49-00-01
TCD 2013 2V
8198
Pricker
Removing rotary shaft lip seal
43206-1
7
9017
Assembly lever
e. g. removing and installing valves
37511-2
9090
Spring band pliers
320 mm
Tighten spring clamp
35420-3
02/2010
8/8
Special tools
W 49-01-01
TCD 2013 2V
Special tools
02/2010
1/16
Special tools
W 49-01-01
TCD 2013 2V
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
Conventional tools /
special tools:
These must be ordered directly from
WILBAER with specification of the order
number.
Common Rail test instruments:

These must be ordered like normal DEUTZ
spare parts.
02/2010
2/16
Special tools
W 49-01-01
TCD 2013 2V
100190
Connector
(in conjunction with compression pressure tester 8005)
42524-0
100320
Turning gear
flywheel side
35422-1
100380
Turning gear
on hub torsional vibration damper/V-belt pulley
48242-0
02/2010
3/16
Special tools
W 49-01-01
TCD 2013 2V
100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
35424-1
100410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
43205-2
100750
Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection
39402-1
02/2010
4/16
Special tools
W 49-01-01
TCD 2013 2V
103050
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)
43023-0
103140
Crowfoot wrench
with installed EGR module
48237-0
103220
Special pliers
for removing the roller tappet
43010-0
02/2010
5/16
Special tools
W 49-01-01
TCD 2013 2V
110500
Special wrench
Wrench size 17
Removing and installing high-pressure lines
35436-1
110620
Lever tool
45673-0
110640
Lever tool
with removed rail
43941-0
02/2010
6/16
Special tools
W 49-01-01
TCD 2013 2V
110700
long
Installing and removing pressure sensors
(rail pressure, oil pressure, fuel pressure)
43198-2
110900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110901 and three
assembly sleeves with guide:
- High pressure pump ( 36), 110902
- Injector, 2V motor ( 16), 110903
- Injector, 4V motor ( 23), 110904
Removing and installing O-rings
43208-0
110901
Disassembly tool
Removing and installing the O-rings
45950-1
02/2010
7/16
Special tools
W 49-01-01
TCD 2013 2V
120440
Assembly tool
48238-0
120680
Puller
(in conjunction with slide hammer 150800)
Removing jammed injector sealing ring
35437-1
120900
Support bracket
pivoting
Clamping cylinder head
35438-3
02/2010
8/16
Special tools
W 49-01-01
TCD 2013 2V
120910
Base plate
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)
35439-3
130300
Universal piston ring pliers
Removing and installing the piston rings
43021-0
130420
Trapezoidal groove wear gauge
Piston diameter 108 mm
36461-2
02/2010
9/16
Special tools
W 49-01-01
TCD 2013 2V
130640
Piston ring compressor
Piston diameter 108 mm
39408-1
142810
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
35446-1
142820
Assembly tool
Installing crankshaft sealing ring
35445-1
02/2010
10/16
Special tools
W 49-01-01
TCD 2013 2V
150170
Puller, universal
comprising traverse, support and threaded rod
(in conjunction with disc 150171)
Removing cylinder liner
43207-0
150171
Tension plate
(in conjunction with disassembly device 150170)
for liner diameter: 108 mm
Removing cylinder liner
43204-0
150180
Liner holder
(Set comprises 7 holders)
Turning crankshaft with cylinder head removed
43181-0
02/2010
11/16
Special tools
W 49-01-01
TCD 2013 2V
150190
Assembly lever
Lever with bolts
(in conjunction with disc 150191)
Installing cylinder liner
43209-2
150191
Washer
(in conjunction with assembly lever 150190)
for liner diameter: 108 mm
Installing cylinder liner
43203-2
150800
Slide hammer
(in conjunction with disassembly device 120680)
Disassembling injector sealing ring
35449-2
02/2010
12/16
Special tools
W 49-01-01
TCD 2013 2V
151500
Separating tool
Removing metal sheet lubricating oil pan from crankcase
45974-0
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
02/2010
13/16
Special tools
W 49-01-01
TCD 2013 2V
6066
Assembly block
Engine clamping, double-sided
35451-2
6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided
35452-1
6068
Engine lifting device
Load (2000 kg), 3-point suspension, spindle clamp,
cross member, chains and hooks
43184-0
02/2010
14/16
Special tools
W 49-01-01
TCD 2013 2V
02937495
Control signal transmitter
Testing Common Rail Injectors
48252-0
02937496
Hydraulic pressure generation
48249-0
02937497
Pressure loss tester
Top dead centre gauge
48251-0
02/2010
15/16
Special tools
W 49-01-01
TCD 2013 2V
02937498
High pressure tester
2500 bar
48250-0
02/2010
16/16

Deutz 2013 TCD 2V Workshop Manual Level3

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Deutz 2013 TCD 2V Workshop Manual Level3

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Workshop Manual

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The engine company.

Testing and setting data

Job card overview

The engines made by DEUTZ are developed for

Make sure that this documentation is available to

We are at your service for any questions you may

Maximum economy, reliability and long life is only

DEUTZ engines are the product of years of research

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

Among other things it generally applies that:

Reference is made in the workshop manual job

Wear close-fitting clothing and ear protectors

Damaged injection lines and high-pressure

Do not place hands near to a leak in the high

Air currents which kick up dust, such as those

Even if no leaks are discernible on the high

No general machine tools may be operated in

Do not work near to sparks and flames.

Areas of the engine room from which particles of

3.2.2 Cleanliness instructions and measures

Notes and measures to be observed during work on

Notes and measures to be observed before starting

Only lint-free cleaning cloths may be used for

The fuel system must be closed. Make a visual

Remove loose parts (for example paint chips

Clean the whole engine and engine room with the

Do not use used cleaning fluid or test fluid for

When using a steam jet, first cover up the control

Compressed air must not be used for cleaning on

Electrical plug connections must be plugged

When removing and installing components, no

newed parts / operating materials must be stored,

Removed parts may only be rubbed down with

Disposal includes recycling and the scrapping of

Openings on the components and on the engine

3.2.3 Disposal regulations

3.3 Operation manual and workshop manual

3.4 Job cards

To structure the information to suit the user, the

3.4.1 Numbering of job cards

6. Care and maintenance work

W 08-03-01: Documentation type

W.... Workshop manual

I ...... Repair manual

The workshop manual assumes knowledge of the

3.4.2 Structure of a job card

Test and setting data

5. Title of job card

11.Date of issue of job card

Testing and setting data

General engine data

Valve shaft diameter, inlet

Valve shaft diameter, outlet

Valve stem clearance, inlet

Valve stem clearance, outlet