Workshop Manual

TCD 2012 2V

0312 1977 en

This document is subject to changes which may become necessary in the course of further de-
velopment of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.
 DEUTZ AG
Service Information Systems
Deutz-Mülheimer-Straße 147-149
51063 Köln
Germany
Tel.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5358
Web: http://www.deutz.com

Printed in Germany
All rights reserved
1st Edition, 05/2005
The engine company. Order No. 0312 1977 en
 TCD 2012 2V Table of contents

1 Foreword

2 General

3 User notes
3.1 General
3.2 Specifications
3.2.1 Safety regulations and rules for the prevention of accidents
3.2.2 Disposal regulations
3.3 Operating manual and workshop manual
3.4 Job cards
3.5 Explanation of symbols

4 Technical data
4.1 Testing and setting data
4.2 Tightening specifications

5 Job card overview

5.1 Sorted alphabetically
5.2 Sorted numerically
5.3 Job card references

6 Job cards

7 Commercial tools

8 Special tools

© 05/2005 1/1 0312 3329 - 0128

 DEUTZ engines Foreword

1 Foreword

© 05/2005 1/3 0312 3014 - 0128

 Foreword DEUTZ engines

© 05/2005 2/3 0312 3014 - 0128

 DEUTZ engines Foreword

z Read and observe the information in this docu- z The pertinent rules for the prevention of acci-
mentation. You will avoid accidents, retain the dents and other generally recognised health and 1
manufacturer's warranty and possess a fully safety regulations must be observed.
functional and ready to operate engine. z Maximum economy, reliability and long life is only
z This engine is built exclusively for purpose ac- guaranteed when using DEUTZ original parts.
cording to the scope of delivery - defined by the z Repair of the engine must correspond to its use
equipment manufacturer (use for the intended for the intended purpose. Only parts released by
purpose). Any use above and beyond this is con- the manufacturer for the respective purpose may
sidered improper use. The manufacturer will not be used for conversion work. Unauthorised mod-
be liable for damages resulting from this. The ification to the engine excludes manufacturer lia-
user bears the sole risk. bility for resulting damage. Failure to observe this
z Use for the intended purpose also includes ob- will void the warranty!
servance of the operating, maintenance and re- z The engines made by DEUTZ are developed for
pair instructions specified by the manufacturer. a wide range of applications. A wide range of var-
The engine may only be used, maintained and iants ensures that the user's particular require-
repaired by persons who are familiar with this ments are met.
and are aware of the risks involved. z The engine is equipped according to your instal-
z Make sure that this documentation is available to lation needs, which means that not all the parts
everyone involved in operation, maintenance and components described in this documentation
and repair and that they have understood the are necessarily installed in your engine.
contents. z We have done our best to highlight the differenc-
z Failure to observe this documentation may lead es so that you can easily find the operating, main-
to malfunctions and engine damage as well as in- tenance and repair instructions relevant to your
jury to persons for which the manufacturer will engine.
not accept any liability. 
z A prerequisite for proper maintenance and repair 
is the availability of all the necessary equipment, 
conventional and special tool, which must be in 
perfect condition. 
z Engine parts such as springs, clamps, elastic re- 
taining rings etc. pose an increased risk of injury 
when handled incorrectly. We are at your service for any questions you may
have in this matter.

Your DEUTZ AG

© 05/2005 3/3 0312 3014 - 0128

 DEUTZ engines General

2 General

© 05/2005 1/3 0312 3015 - 0128

 General DEUTZ engines

© 05/2005 2/3 0312 3015 - 0128

 DEUTZ engines General

DEUTZ engines are the product of years of re-

search and development. The profound expertise
gained through this, in combination with high de-
mands on quality, attests to the fact that our engines
possess all the qualities of long life, high reliability
2
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. Compli-
ance with the prescribed maintenance times and the
careful execution of maintenance and care work are
therefore essential. Difficult operating conditions,
deviating from normal operation, must be particular-
ly heeded.

Please consult one of our service representatives

responsible for operating faults and spare parts
questions. Our trained specialists ensure fast and
professional repairs using original DEUTZ spare
parts.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.

© 05/2005 3/3 0312 3015 - 0128

 
User notes

3 User notes

© 11/2005 1/6 0312 3016 - 0199

 User notes

3.1 General 3.2 Specifications

The documentation of the workshop manual has 3.2.1 Accident prevention and safety regu-
been created based on the engine available at the lations
time of going to press.
The legally prescribed rules for the prevention of ac-
There may be deviations in the descriptions, illustra-
cidents must be observed. These are available from
tions and parts due to further developments.
professional associations or from dealers. These
3 The maintenance work described in the operating are dependent on the application site, operating
manual and in the workshop manual must be carried mode and the operating and auxiliary materials be-
out on schedule and completely. The maintenance ing used.
personnel must have the necessary technical
Special protection measures are specified depend-
knowledge to perform the work. Safety and protec-
ing on the work being carried out, and are identified
tion devices which are removed during maintenance
in the job description.
work must be replaced again afterwards.
Among other things it generally applies that:
Caution!
z for the personnel:
The rules for the prevention of accidents and the
safety regulations must be observed during mainte- – Only briefed personnel may operate or main-
nance work. tain 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 – Wear close-fitting clothing and ear protectors
be read before working on the engine and must be in the machine room when the engine is in op-
strictly followed. eration.
The maintenance intervals and the work to be per- – Only deploy trained personnel to do repairs
formed are specified in the maintenance schedule and maintenance work.
of the operating manual. The job cards contain tech- – Do not work on the fuel system when the en-
nical documentation of the execution of mainte- gine is running. The fuel system is under high
nance work. pressure - danger of death.
– Go to the workshop immediately in case of
leaks in the fuel system.
z for the engine room:
– Ensure adequate ventilation (do not cover air
shafts).
– Provide first aid kit and suitable fire extinguish-
ers. Check the filling and readiness for opera-
tion regularly.
– Only store inflammable materials in the ma-
chine room if they are essential for operation
of the system.
– Smoking and naked flames are prohibited in
the machine room.
z for operation, maintenance and repairs on the
engine:
– Wait 30 seconds after switching off the engine
before working on the 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 stand-
still and secured against starting.
– Injection pipes and high pressure pipes must
not be deformed.
– Damaged injection pipes and high-pressure
pipes must be renewed.

© 11/2005 2/6 0312 3016 - 0199

 
User notes

– Injection lines and high pressure fuel lines be used in assembly work on the open fuel sys-
must never be connected when the engine is tem.
running. z Only work on the fuel system in a clean environ-
– Do not place hands near to a leak in the high ment (no dust, no grinding or welding). Avoid
pressure fuel system. draughts (dust). Clean the workshop floor regu-
– Also carefully check all high pressure compo- larly. No brake or performance test benches may
be kept or operated in the same room.
nents visually before performing tests on the 3
running engine. Wear suitable protective z Air currents which kick up dust, such as those
clothing (for example protective glasses). caused by brake repairs or the starting of en-
Leaks are a potential source of danger for gines, should be avoided.
workshop personnel. z For work such as removal and installation on de-
– Even if no leaks are discernible on the high fective hydraulic components on the Common
pressure fuel system, the workshop personnel Rail System it is recommended to partition off a
should avoid the immediate danger zone or separate workshop area in the factory. This must
wear suitable protective clothing (such as pro- be separate from other areas in which general
tective glasses) when performing tests on the vehicle repairs such as brake repairs are carried
running engine and during the first trial run. out.
– Always stay out of range of a fuel jet, as it z No general machine tools may be operated in
could cause severe injury. this room.
– Smoking is strictly prohibited when working on z Regular cleaning of the workshop area is manda-
the fuel system. tory. Draughts, ventilation and heating fans
– Do not work near to sparks and flames. should be minimised.
– Never disconnect an injector when the engine z Areas of the engine room from which particles of
is running. dust could be loosened (for example the bottom
part of the tipped driver cab) must be covered
3.2.2 Cleanliness instructions and meas- with fresh clean film.
ures for handling the DEUTZ Com-
z Working materials and tools must be cleaned be-
mon Rail System fore work. Only use tools without damage to the
The DEUTZ Common Rail system used in the chrome plating or tools which are not chrome-
DEUTZ engines consists of high-precision compo- plated.
nents which are exposed to extreme stress. Great Notes and measures to be observed during work
attention must be paid to cleanliness when working
on the fuel system or with the fuel system open.
on the fuel system due to the high precision technol-
ogy. z Only work in clean overalls.
Notes and measures to be observed before z Only lint-free cleaning cloths may be used for
starting work on the fuel system work on the fuel system.
z Remove loose parts (for example paint chips
z The fuel system must be closed. Make a visual
from assembly work) with an industrial vacuum
inspection for leaks / damage to the fuel system.
cleaner or other suction device. Only suction may
z Clean the whole engine and engine room with the be used in assembly work on the open fuel sys-
system closed before starting work on the fuel tem.
system.
z Working materials and tools must be cleaned be-
z The engine must be dry when you start working fore work. Only use tools without damage to the
on the fuel system. chrome plating or tools which are not chrome-
z Blowing (dry) with compressed air is only permis- plated.
sible with the fuel system closed. z Do not use used cleaning fluid or test fluid for
z When using a steam jet, first cover up the control cleaning.
unit, the cable plugs, all other electrical plug con- z Compressed air must not be used for cleaning on
nections and the generator. Also, the steam jet the open fuel system.
may not be pointed directly at them.
z Work on removed components may only be per-
z Electrical plug connections must be plugged formed at a suitably equipped workbench.
when spraying.
z When removing and installing components, no
z Remove loose parts (for example paint chips materials which can leave behind particles or fi-
from assembly work) with an industrial vacuum bres (cardboard, wood, cloths) may be used.
cleaner or other suction device. Only suction may

© 11/2005 3/6 0312 3016 - 0199

 User notes

z Removed parts may only be rubbed down with Disposal includes recycling and the scrapping of
clean, lint-free cloths. No dirt particles may be parts / operating materials, although recycling has
rubbed into the components. priority.
z Openings on the components and on the engine Details of disposal and their monitoring are gov-
must be closed immediately with suitable stop- erned by regional, national and international laws
pers/caps. and directives which the system operator must ob-
serve on his own responsibility.
3 z The stoppers/caps may only be removed imme-
diately before installing.
z Store stoppers/caps free from dust and dirt in the
original packaging and dispose of after using
once.
z Only remove new parts from the original packag-
ing just before installation.
z Removed components must be kept in new, seal-
able bags or - if available - in the packaging of the
new parts.
z Always use the original packaging of the new part
to send back the removed components.
Notes and measures for the vehicle workshop
z For work such as removal and installation on de-
fective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.
z The workshop floor is sealed or tiled.
z No welding gear, grinders, general machine
tools, brakes or performance test benches may
be operated in this room.
z Regular cleaning of the workshop area is manda-
tory. Draughts, ventilation systems and heating
fans should be minimised.
Notes and measures for workbench and tools in
the vehicle hall
z A special workbench must be set up for work on
the removed components.
z Clean the extraction and installation tools regu-
larly and keep in a closed tool cabinet.
z Remove loose parts (for example paint chips
from assembly work) with an industrial vacuum
cleaner or other suction device.
z Working materials and tools must be cleaned be-
fore work. Only use tools without damage to the
chrome plating or tools which are not chrome-
plated.
3.2.3 Disposal regulations
The work described in the operating manual and
workshop manual necessitates renewal of parts and
operating materials among other things. The re-
newed parts / operating materials must be stored,
transported and disposed of properly. The owner
himself is responsible for this.

© 11/2005 4/6 0312 3016 - 0199

 
User notes

3.3 Operating manual and workshop 3.4 Job cards

manual The job cards are divided in the workshop manual
To structure the information to suit the user, the into "W" and "I" job cards. 
service documentation is divided into operating The "W" job card documents standard repairs on the
manual and workshop manual. engine and/or its components. The necessary tools
and special tools are also specified in the "W" job
The operating manual contains a general descrip-
tion and instructions for all other maintenance work.
card.  3
The "I" job card additionally documents the appro-
It contains the following chapters: priate work procedures for repairing the engine and/
1. Contents, General or its components. The workshop must satisfy spe-
2. Engine description cial conditions to perform these work procedures.
Special tools and machine tools must be available,
3. Operation
for example.
4. Operating media
3.4.1 Numbering of job cards
5. Maintenance
6. Care and maintenance work The job card numbers follow the pattern W 02-04-
01. The individual parts of this pattern are explained
7. Faults, causes and remedies below:
8. Engine conservation z W 02-04-01: Documentation type
9. Technical data – WWorkshop manual
10.Service – I ...... Repair instructions
The workshop manual assumes knowledge of the z W 02-04-01: Maintenance group
contents of the operating manual. This applies es-
pecially for the safety regulations. The workshop – 00 ... General / interdisciplinary activities
manual describes repairs to the engine and compo- – 01 ... Cylinder head
nents for which more effort and appropriately quali- – 02Drive system
fied technicians are required. – 03 ... Crankcase
– 04 ... Engine control system
– 05 ... Speed governing
– 06 ... Exhaust system / Charging
– 07 ... Fuel system
– 08 ... Lube oil system
– 09 ... Cooling system
– 10 ... Compressed air system
– 11 ... Monitoring system
– 12 ... Other components
– 13 ... Electrical system
z W 02-04-01: Component grouping
z W 02-04-01: Consecutive number

© 11/2005 5/6 0312 3016 - 0199

 User notes

3.4.2 Structure of a job card 3.5 Explanation of symbols

1 2 3

Danger!
Triebwerk of death or to health. Must be observed!
4
3
W 02-04-01
For example: The incorrect use or con-
5 version of the turbocharger can lead to
16 serious injury.
6
Caution!
15
6 7 Danger to the component/engine. Non-
compliance can lead to destruction of the
14
component/engine.
8 Must be observed!
13
Note
General notes on assembly, environmen-
tal protection etc. No potential danger for
12
man or machine.
8
Tool
Conventional and special tools required
for the work.
Auxiliary materials
11 10 9 Working materials required in addition to
the tools for performing the work
1. DEUTZ AG,  (e.g. greases, oils, adhesives, sealants)
publisher of service documentation
2. Engine type (e.g. TCD 2013 4V) References
to important documents or job cards for
3. Maintenance group the work process. 
4. Job card number or topic For example: Job card W 04-05-05
5. Title of job card Reference
6. Reference to other job cards to a document or a job card within the
7. Chapter work process.
8. Graphic or photo Test and setting data
9. DEUTZ internal creation number and technical The necessary values are specified here.
order number If several values are necessary, a cross
10.Page number reference is given to the Test and Setting
Values table. 
11.Date of issue of job card For example: 
12.Note ID no. P01 61 = valve clearance, inlet
13.Danger / Important Tightening specification
14.Work sequence The necessary values are specified here.
15.Special tools; auxiliary materials If several values are necessary, a cross
16.Conventional tools reference is given to the Tightening Spe-
cifications table. 
For example: 
ID No. A01 001 = cylinder head screws

© 11/2005 6/6 0312 3016 - 0199

 
TCD 2012 2V Technical data

4 Technical data
4.1 Testing and setting data

© 05/2005 1/22 0312 3333 - 0128

 Technical data
Testing and setting data TCD 2012 2V

© 05/2005 2/22 0312 3333 - 0128

 ID no. Designation Information Series Value Unit

© 05/2005
General engine data
P00 01 Length of engine TCD 2012 L6 2V 1108 mm
P00 02 Width of engine TCD 2012 L6 2V 742 mm
901,5
P00 03 Height of engine TCD 2012 L6 2V mm
Deep oil tray 1101,05
L4 2V 410
P00 04 Engine weight according to DIN 70020-A approx. TCD 2012 kg
L6 2V 530
TCD 2012 2V

P00 10 Working principle TCD 2012 2V Four-stroke -

P00 20 Combustion process TCD 2012 2V Diesel direct injection -
L4 2V 4038
P00 30 Total volume TCD 2012 cm3
L6 2V 6067

3/22
98
P00 31 Bore TCD 2012 2V 101 mm
101,5
P00 32 Stroke TCD 2012 2V 126 mm
P00 40 Compression ratio TCD 2012 2V 18 -
P00 50 Direction of rotation looking onto the flywheel TCD 2012 2V left -
30 - 38 bar
P00 51 Compression pressure TCD 2012 2V
3000 - 3800 kPa
L4 2V 1-3-4-2
P00 71 Ignition sequence TCD 2012 -
L6 2V 1-5-3-6-2-4
Cylinder head
0,025
P01 01 Valve seat ring bore, inlet Standard, fit H7 TCD 2012 2V 46 0 mm
 0,025
P01 02 Valve seat insert bore, outlet Standard, fit H7 TCD 2012 2V 39,9  0 mm

0312 3333 - 0128

Technical data
Testing and setting data

4
 4
ID no. Designation Information Series Value Unit

© 05/2005
0,025
P01 05 Valve guide, bore in cylinder head Standard, fit H6 TCD 2012 2V 8,008 0 mm
P01 08 Cylinder head, height Standard TCD 2012 2V 90 mm
Valve seat insert

P01 21 Valve seat insert outside diameter, inlet Standard, 30 degrees TCD 2012 2V 46,09  ,02 mm
Technical data


P01 22 Valve seat insert outside diameter, outlet Standard, 45 degrees TCD 2012 2V 39,99  ,02 mm
Valve

P01 31 Valve shaft diameter, inlet Standard, fit h7 TCD 2012 2V 7,94  0,04 mm
Testing and setting data


P01 32 Valve shaft diameter, outlet Standard, fit h7 TCD 2012 2V 7,94  0,04 mm
P01 33 Valve stem clearance, inlet TCD 2012 2V 0,012 mm
P01 34 Valve stem clearance, outlet TCD 2012 2V 0,014 mm
P01 35 Valve edge thickness, inlet TCD 2012 2V 2,36 mm
P01 36 Valve edge thickness, outlet TCD 2012 2V 1,8 mm

4/22
 0,1
P01 37 Valve head diameter, inlet TCD 2012 2V 44,4  0,1 mm
 0,1
P01 38 Valve head diameter, outlet TCD 2012 2V 38,7  0,1 mm
Valve seat
0,15
P01 45 Valve lag dimension, inlet TCD 2012 2V 0,9 0,1 mm
0,15
P01 46 Valve lag dimension, outlet TCD 2012 2V 0,9 0,1 mm
P01 47 Valve seat angle, inlet TCD 2012 2V 30 °
P01 48 Valve seat angle, outlet TCD 2012 2V 45 °
Valve spring
1,9
TCD 2012 2V

Valve spring length (unclamped normal) 59 1,9

P01 51 TCD 2012 2V 0,03
mm
Valve spring wire diameter 4 0,03

0312 3333 - 0128

 ID no. Designation Information Series Value Unit

© 05/2005
Valve clearance
on cold engine, 
oil temperature < 80 °C, 
P01 61 Valve clearance, inlet (on cold engine) TCD 2012 2V 75 °
after a cooling down time of
at least 0.5 h
on cold engine, 
oil temperature < 80 °C, 
P01 62 Valve clearance, outlet (on cold engine) TCD 2012 2V 120 °
after a cooling down time of
at least 0.5 h
TCD 2012 2V

Valve overlap as per setting diagram,

P01 63 Valve clearance setting TCD 2012 2V - -
see: Table T01 63
P01 64 Clearance between control piston and rocker arm TCD 2012 2V 144 °
Rocker arm/bracket
0,033
P01 72 Rocker arm, bore, diameter, outlet TCD 2012 2V 21,02 0 mm
0,033

5/22
P01 73 Rocker arm, bore, diameter, inlet TCD 2012 2V 21,02 0 mm
0
P01 74 Rocker arm pin Diameter, fit h7 TCD 2012 2V 21 0,021 mm
Drive system
Main bearing pin
0
P02 03 Main bearing pin Standard, diameter TCD 2012 2V 84 0,02 mm
P02 04 Crankshaft main bearing pin two underdimension stages per TCD 2012 2V 0,25 mm
Crankshaft main bearing pin and lifting journal, 6
P02 07 Standard HRC TCD 2012 2V 55 HRC
hardness
Fit bearing pin
P02 10 Fit bearing pin two underdimension stages per TCD 2012 2V 0,25 mm
 0,04
P02 11 Width of fit bearing pin TCD 2012 2V 32,2 mm
P02 12 Width of fit bearing pin, overdimension one overdimension stage TCD 2012 2V 0,4 mm

0312 3333 - 0128

Technical data
Testing and setting data

4
 4
ID no. Designation Information Series Value Unit

© 05/2005
Lifting journal
0
P02 21 Width of lifting journal TCD 2012 2V 32,08 0,02 mm
0
P02 22 Diameter of the lifting journal TCD 2012 2V 69,994 0,02 mm
P02 23 Diameter of the lifting journal one underdimension stage TCD 2012 2V 0,25 mm
Technical data

P02 26 Dynamic run-out, crankshaft Max. permissible deviation: TCD 2012 2V 0,1 mm
Main bearing
P02 31 Main bearing shells (inside diameter) Standard TCD 2012 2V 83,980 - 84,000 mm
Testing and setting data

P02 32 Main bearing shells, underdimension two underdimension stages per TCD 2012 2V 0,25 mm
Theoretical clearance between main bearing and
P02 33 TCD 2012 2V 0,03 - 0,092 mm
crankshaft
P02 34 Permissible axial clearance of crankshaft TCD 2012 2V 0,1 - 0,28 mm
P02 35 Stop ring, thickness Standard (upper and lower half) TCD 2012 2V 2,00 - 2,05 mm

6/22
P02 36 Stop ring, oversize 1. Stage = 0.2 mm TCD 2012 2V 2,20 - 2,25 mm
Con-rod
unmachined 0,045
P02 43 Small end bush (installed), inside diameter TCD 2012 2V 40 0,035 mm
precision bore
P02 44 Small end bush, outside diameter TCD 2012 2V 43,070 - 43,110 mm
Piston bolt clearance between piston bolt and
P02 45 TCD 2012 2V 0,025 - 0,041 mm
small end bush
0,02
P02 49 Bore for small end bush in the con rod TCD 2012 2V 43 0 mm
Con rod bearing
TCD 2012 2V

P02 51 Con rod bearing shell top and bottom, width TCD 2012 2V 24 0,3 mm
Con rod bearing shells (installed), inside diame-
P02 52 TCD 2012 2V 70,026 - 70,065 mm
ter
P02 54 Con rod bearing underdimension per stage one underdimension per TCD 2012 2V 0,25 mm

0312 3333 - 0128

 ID no. Designation Information Series Value Unit

© 05/2005
 0,019
P02 55 Con rod bearing, bore in con rod H6 TCD 2012 2V 73,6  0 mm
Theoretical clearance between the con rod bea-
P02 56 TCD 2012 2V 0,036 - 0,095 mm
ring / lifting journal
Piston bolt
0
P02 61 Piston bolt, diameter TCD 2012 2V 40 ,006 mm
Piston identification of the installation position on the piston base
 0,007
97,9  0,007
P02 71 Diameter normal measuring point 1 Measuring point 1 = height 15 mm TCD 2012 2V 0,007
mm
TCD 2012 2V

100,68 0,007
0,009
97,79 0,009
P02 72 Diameter normal measuring point 2 Measuring point 2 = height 50 mm TCD 2012 2V mm
100,79 0,009
0,009
0,010
100,35 0,010
P02 73 Diameter normal measuring point 3 Measuring point 3 = height 80.5 mm TCD 2012 2V 0,010
mm
97,35 0,010

7/22
P02 75 Piston projection 1 hole, cylinder head gasket, 1.2 mm TCD 2012 2V 0,33 - 0,55 mm
P02 76 Piston projection 2 hole, cylinder head gasket, 1.3 mm TCD 2012 2V 0,56 - 0,65 mm
P02 77 Piston projection 3 hole, cylinder head gasket, 1.4 mm TCD 2012 2V 0,66 - 0,76 mm
0,005
P02 78 Piston bolt, bore TCD 2012 2V 40 0,011 mm
Piston rings
98/89.8 x 3
Outside diameter/inside diameter x
P02 81 Piston ring 1st ring, double-sided keystone ring TCD 2012 2V 101/92.6 x 2.5 mm
height
101.5/93.1 x 2.5
98/89.8 x 2.03
Outside diameter/inside diameter x
P02 82 Piston ring 2nd ring, taper-faced ring TCD 2012 2V 101/92.6 x 2 mm
height
101.5/93.1 x 2

0312 3333 - 0128

Technical data
Testing and setting data

4
 4
ID no. Designation Information Series Value Unit

© 05/2005
98/90.7 x 3
Piston ring 3rd ring, bevelland-edge oil control Outside diameter/inside diameter x
P02 83 TCD 2012 2V 101/93.3 x 3 mm
ring with coiled spring expander height
101.5/93.8 x 3
Joint clearance, piston ring 1
0,2 - 0,35 mm
Technical data

(cylinder diameter 98 mm)

Joint clearance, piston ring 1 Identification "TOP" in direction of com-
P02 84 TCD 2012 2V
(cylinder diameter 101 mm) bustion chamber
0,25 - 0,4 mm
Joint clearance, piston ring 1
Testing and setting data

(cylinder diameter 101.5 mm)

Joint clearance, piston ring 2
(cylinder diameter 98 mm)
Joint clearance, piston ring 2 Identification "TOP" in direction of com-
P02 85 TCD 2012 2V 1,5 - 2,0 mm
(cylinder diameter 101 mm) bustion chamber
Joint clearance, piston ring 2

8/22
(cylinder diameter 101.5 mm)
Joint clearance, piston ring 3
0,3 - 0,6
(cylinder diameter 98 mm)
Joint clearance, piston ring 3 Identification "TOP" in direction of com-
P02 86 TCD 2012 2V mm
(cylinder diameter 101 mm) bustion chamber
0,3 - 0,55
Joint clearance, piston ring 3
(cylinder diameter 101.5 mm)
measure with trape-
Axial clearance, 1st ring (double-sided keystone zoidal groove wear
P02 87 Wear limit TCD 2012 2V -
ring) gauge (contact with
piston)
TCD 2012 2V

Axial clearance, 2nd ring (taper-faced ring)

0,065 - 0,11
(piston diameter 98 mm)
P02 88 TCD 2012 2V mm
Axial clearance, 2nd ring (taper-faced ring)
0,09 - 0,11
(piston diameter 101 mm)

0312 3333 - 0128

 ID no. Designation Information Series Value Unit

© 05/2005
Axial clearance, 3rd ring (bevelland-edge oil con-
trol ring)
(piston diameter 98 mm)
P02 89 TCD 2012 2V 0,04 - 0,08 mm
Axial clearance, 3rd ring (bevelland-edge oil con-
trol ring)
(piston diameter 101 mm)
P02 95 Piston ring joint, installation position TCD 2012 2V offset 120 °
P02 96 Bevelland-edge oil control ring Offset spring ring joint to ring joint TCD 2012 2V 180 °
Crankcase
TCD 2012 2V

Camshaft bearing
0,030
P03 11 Camshaft bearing crankcase bore H7 TCD 2012 2V 69 mm
 0,04
P03 12 Camshaft bearing outside diameter normal TCD 2012 2V 69,1 mm
P03 13 Camshaft bearing (bush) Inside diameter when installed TCD 2012 2V 65 - 65,054 mm

9/22
Main bearing bore
0,022
P03 21 Main bearing bore in crankcase Standard, H6 TCD 2012 2V 89  mm
Cylinder liners
0,02
Standard, Slipfit 98
0,013
P03 31 Cylinder bore Outside diameter TCD 2012 2V 101 0,005 mm
0,022
Standard, H6 101 
P03 36 Collar height of the cylinder liner (Slipfit) TCD 2012 2V 4,5 0,02 mm
Engine control
Camshaft
P04 31 Camshaft bearing pin diameter Standard TCD 2012 2V 64,930 - 64,950 mm
P04 32 Theoretical clearance (radial clearance) TCD 2012 2V 0,050 - 0,124 mm

0312 3333 - 0128

Technical data
Testing and setting data

4
 4
ID no. Designation Information Series Value Unit

© 05/2005
Fuel system
Injector
DLLA 146 PV3 / 
P07 51 Nozzle type injector TCD 2012 2V -
7-hole
Technical data

P07 71 DEUTZ Common Rail system pressure High pressure range TCD 2012 2V 300 - 1600 bar
Cooling system
P09 11 Coolant thermostat start of opening TCD 2012 2V 83 °C
P09 13 Coolant thermostat stroke distance TCD 2012 2V at least 8 mm
Testing and setting data

10/22
TCD 2012 2V

0312 3333 - 0128

 Technical data
TCD 2012 2V Testing and setting data

T01 63
Setting of valve and control piston clearance
Engine TCD 2012/2013 L04 2V
Ignition sequence: 1 - 3 - 4 - 2
Valves Cylinder
Set to 1 3 4 2
overlap 4 2 1 3

Valve overlap: Outlet valve is not closed,

inlet valve begins opening.
4
The oulet valve opens briefly by 2 mm
when the inlet valve is fully open. This is
not the valve overlap!

© 43005-0

T01 63
Setting of valve and control piston clearance
Engine TCD 2012/2013 L06 2V
Ignition sequence: 1 - 5 - 3 - 6 - 2 - 4
Valves Cylinder
Set to 1 5 3 6 2 4
overlap 6 2 4 1 5 3

Valve overlap: Outlet valve is not closed,

inlet valve begins to open.
The oulet valve opens briefly by 2 mm
when the inlet valve is fully open. This is
not the valve overlap!

© 43005-0

© 05/2005 11/22 0312 3333 - 0128

 Technical data
Testing and setting data TCD 2012 2V

© 05/2005 12/22 0312 3333 - 0128

 Technical data
TCD 2012 2V Tightening specifications

4.2 Tightening specifications

© 05/2005 13/22 0312 3333 - 0128

 Technical data
Tightening specifications TCD 2012 2V

© 05/2005 14/22 0312 3333 - 0128

 Post-
Pre-clam-

© 05/2005
ID no. Designation Screw type Notes / Remarks Series clamping
ping value
value
A00 001 Clamping bracket on crankcase TCD 2012 2V 70 Nm
A00 002 Clamping bracket on adapter for assembly block TCD 2012 2V 90 Nm
10
A00 003 Mounting feet/engine mounting on crankcase TCD 2012 2V 95 10 Nm
Note tightening order. 80 Nm
Lightly oil screws.
Use 3 times with written
A01 001 Cylinder head on crankcase TCD 2012 2V 30 Nm
proof, otherwise use new
TCD 2012 2V

+90°
screws every time they are
loosened.
Installation advice: rocker
Cylinder head
A01 002 Rocker arm bracket on cylinder head arm symmetrical to the valve TCD 2012 2V 30 Nm
screw
center axles, see A01 001
2
A01 003 Lock nut valve clearance setting screw TCD 2012 2V 20 2 Nm

15/22
A01 004 Cylinder head cover on cylinder head M6 TCD 2012 2V 13 Nm
A01 011 Exhaust return module on cylinder head Observe tightening sequence TCD 2012 2V 10 Nm 30 Nm
2
A01 012 Lock nut setting screw exhaust return module TCD 2012 2V 20 2 Nm
Solenoid valve (exhaust return line) on cylinder
A01 013 TCD 2012 2V 24 Nm
head
A01 016 Locking screw on cylinder head M14x12 Renew sealing ring TCD 2012 2V 34 Nm
Can be used 3 times with
written proof, otherwise use
A02 010 Main bearing on crankcase TCD 2012 2V 50 Nm +60°
new screws every time they
are loosened.
Use new screws every time
A02 020 Con rod bearing cover on con rod TCD 2012 2V 30 Nm +60°
they are loosened.
Wet rotors with engine oil be-
A03 020 Front cover on crankcase TCD 2012 2V 3 Nm 21 Nm
fore installing.

0312 3333 - 0128

Technical data
Tightening specifications

4
 4
Post-
Pre-clam-
ID no. Designation Screw type Notes / Remarks Series clamping

© 05/2005
ping value
value
A03 030 Oil tray on crankcase Observe tightening sequence TCD 2012 2V 30 Nm
Locking screw on oil tray (aluminum or sheet
A03 031 M18x1.5 Cu sealing ring TCD 2012 2V 55 Nm
steel)
Technical data

A03 060 Crankcase ventilation on cylinder head TCD 2012 2V 21 Nm

3
A03 062 Return line to return stop valve Hollow screw TCD 2012 2V 30 3 Nm
8
A03 063 Return stop valve on crankcase TCD 2012 2V 80 8 Nm
A03 065 Hold oil return line (pipe clip) TCD 2012 2V 30 Nm
Tightening specifications

M12x80 mm
A03 080 Connection housing to crankcase Observe tightening sequence TCD 2012 2V 99 Nm
M12x150 mm
M16x75
A03 082 Connection housing to crankcase Observe tightening sequence TCD 2012 2V 243 Nm
M16x140 mm

16/22
A03 085 Cover plate to connection housing TCD 2012 2V 8.5 Nm
5
A03 091 Gearcase on crankcase M16x60-10.9 Observe tightening sequence TCD 2012 2V 70 5 Nm
M8x35-10.9
3
A03 092 Gearcase on crankcase M8x45-10.9 Observe tightening sequence TCD 2012 2V 30 3 Nm
M8x50-10.9
A04 022 Cap on gearcase TCD 2012 2V 21 Nm
Impulse transmitter (crankshaft) on holder on
A05 011 TCD 2012 2V 9 Nm
front cover
A05 012 Impulse transmitter (camshaft) on gearcase TCD 2012 2V 9 Nm
TCD 2012 2V

Holder impulse transmitter (crankshaft) on front

A05 013 TCD 2012 2V 9 Nm
cover
A06 001 Exhaust manifold on cylinder head Observe tightening sequence TCD 2012 2V 25 Nm
A06 020 Turbocharger on exhaust manifold TCD 2012 2V 42 Nm

0312 3333 - 0128

 Post-
Pre-clam-
ID no. Designation Screw type Notes / Remarks Series clamping

© 05/2005
ping value
value
A06 030 Charge air line on cylinder head TCD 2012 2V 13 Nm
A06 042 Heating flange on charge air manifold TCD 2012 2V 30 Nm
M8x30-10.9
A06 046 Charge air manifold on charge air pipe TCD 2012 2V 30 Nm
M8x95-10.9
A06 047 Hose nozzle on charge air manifold M8x30-10.9 TCD 2012 2V 30 Nm
Observe assembly sequence
A07 001 Clamping shoe injector on cylinder head TCD 2012 2V 16 5 Nm
TCD 2012 2V

Install injector tension-free

Injection lines on rail and injector,
A07 003 Assembly specification TCD 2012 2V 25 Nm
High-pressure line on high-pressure pump
2
A07 024 Fuel supply pump on holder TCD 2012 2V 22 2 Nm
A07 025 Holder fuel supply pump on holder TCD 2012 2V 30 Nm

17/22
Use new screws every time 2
A07 026 V-belt pulley on fuel supply pump TCD 2012 2V 27 2 Nm
they are loosened.
A07 031 High-pressure pump on crankcase M10x30 TCD 2012 2V 10 Nm 50 Nm
A07 032 Control block on crankcase TCD 2012 2V 30 Nm
A07 034 Fuel pipe on high-pressure pump TCD 2012 2V 29 Nm
A07 035 Fuel pipe on control block TCD 2012 2V 39 Nm
A07 038 Rail on cylinder head All injection lines 27.5 Nm TCD 2012 2V 30 Nm
A07 039 Pressure limiting valve on rail insert with assembly grease TCD 2012 2V 100 Nm
A07 040 Rail pressure sensor on rail insert with assembly grease TCD 2012 2V 70 Nm
A07 044 Pipe clips, fuel line fastening TCD 2012 2V 30 Nm
Fuel line (supply) on control block
A07 045 Fuel line (supply) on fuel filter console Hollow screw TCD 2012 2V 39 Nm
Fuel line (return) on rail

0312 3333 - 0128

Technical data
Tightening specifications

4
 4
Post-
Pre-clam-
ID no. Designation Screw type Notes / Remarks Series clamping

© 05/2005
ping value
value
A07 046 Fuel pipe (return) on control block Hollow screw TCD 2012 2V 49 Nm
A07 047 Fuel line (return) on cylinder head Hollow screw TCD 2012 2V 29 Nm
A07 084 Fuel line on fuel filter Hollow screw TCD 2012 2V 39 Nm
Technical data

A07 087 Fuel filter console/radiator tank on crankcase TCD 2012 2V 30 Nm

5
A07 090 Fuel pressure sensor on fuel filter console TCD 2012 2V 30 5Nm
5
A07 094 Screw-in nipple on fuel filter console M24x16 TCD 2012 2V 60 5 Nm
Tightening specifications

Hand tigh-
A07 099 Fuel filter on fuel filter console
ten
Oil filter/beaker filter 25 Nm
A08 001 Lightly oil gasket / tighten well TCD 2012 2V Hand tigh-
Oil filter/interchangeable filter
by hand ten

18/22
A08 015 Oil suction intake pipe on oil pump TCD 2012 2V 30 Nm
A08 040 Lube oil line on turbocharger/crankcase Hollow screw TCD 2012 2V 39 Nm
A08 044 Pipe union (oil return) on turbocharger TCD 2012 2V 20 Nm
A08 045 Pipe clip on oil return and lube oil line TCD 2012 2V 20 Nm
Retainer clip (oil return) on crankcase
A08 046 TCD 2012 2V 20 Nm
Oil return line holder
A08 051 Oil cooler housing on crankcase TCD 2012 2V 30 Nm
Insert O-rings with fitting 2
A08 052 Oil cooler on oil cooler housing TCD 2012 2V 22 2 Nm
compound.
TCD 2012 2V

A08 091 Oil pressure switch on oil cooler housing TCD 2012 2V 20 Nm
A09 001 Thermostat housing on cylinder head TCD 2012 2V 60 Nm
Discharge nozzle on thermostat housing/fan con-
A09 002 TCD 2012 2V 21 Nm
sole

0312 3333 - 0128

 Post-
Pre-clam-
ID no. Designation Screw type Notes / Remarks Series clamping

© 05/2005
ping value
value
A09 010 Coolant pump on fan console TCD 2012 2V 30 Nm
A09 015 V-rib belt pulley on coolant pump TCD 2012 2V 30 Nm
A09 031 Temperature sensor on cylinder head TCD 2012 2V 24 Nm
A09 045 Fan console on crankcase TCD 2012 2V 30 Nm
A09 046 Fan drive on fan console TCD 2012 2V 60 Nm
A09 047 V-rib belt pulley on fan drive M12x85-12.9 TCD 2012 2V 30 Nm +90 °
TCD 2012 2V

A09 048 Adapter on V-rib belt pulley TCD 2012 2V 30 Nm

+60 °
M10x30 30 Nm
+30 °
M10x35
M10x40
M10x45

19/22
M10x50 Use new screws every time
A12 001 Flywheel on crankcase TCD 2012 2V
M10x55 they are loosened.
30 Nm +60 °+60 °
M10x60
M10x70
M10x75
M10x80
M10x85
Torsional vibration damper/V-rib belt pulley on Use new screws every time 10 +60 °
A12 030 M16x1.5 TCD 2012 2V 40 Nm
crankshaft they are loosened. +60 °
M12x25-10.9 Use new screws every time 130 Nm
A12 031 V-belt pulley on V-rib belt pulley TCD 2012 2V
M10x20-10.9 they are loosened. 70 Nm
Flange hub for visco-coupling on torsional vibra-
A12 032 M12x40-10.9 110 Nm
tion damper
A12 041 Belt tensioner on fan console TCD 2012 2V 80 Nm
A12 091 Hollow screw pipe union M10x1 Ring piece pipe 6 mm TCD 2012 2V 29 Nm

0312 3333 - 0128

Technical data
Tightening specifications

4
 4
Post-
Pre-clam-
ID no. Designation Screw type Notes / Remarks Series clamping

© 05/2005
ping value
value
A12 092 Hollow screw pipe union M12x1.5 Ring piece pipe 8 mm TCD 2012 2V 39 Nm
A12 093 Hollow screw pipe union M14x1.5 Ring piece pipe 10 mm TCD 2012 2V 49 Nm
Pipe clip, fastening wiring harness 30 Nm
Technical data

A12 095 TCD 2012 2V 1

Pipe clip for return line M6 13 1 Nm
A13 001 Starter on gearcase cover TCD 2012 2V 70 Nm
M8x30

Tightening specifications

A13 007 Cooling air baffle on starter M8x50 TCD 2012 2V 30 Nm


M8
M10x75-10.9
Generator on console (V-rib belt) 60 Nm
A13 012 M10x100-10.9 TCD 2012 2V
Generator on console (V-belt) 42 Nm

20/22
Generator console on cylinder head (V-rib belt) M10x100-10.9 70 Nm
A13 018 TCD 2012 2V
Generator console on cylinder head (V-belt) 30 Nm
2
A13 032 Heating plug/locking screw on cylinder head TCD 2012 2V 20 2 Nm
A13 041 Cover plate on cylinder head cover M6x12 TCD 2012 2V 30 Nm
Pressure/temperature sensor on suction air inta-
A13 046 TCD 2012 2V 5 Nm
ke pipe (charge air)
A13 051 Cable connection on injector TCD 2012 2V 1.5 Nm
A13 074 Oil level sensor on oil tray TCD 2012 2V 110 Nm
TCD 2012 2V

0312 3333 - 0128

 Technical data
TCD 2012 2V Tightening specifications

© 05/2005 21/22 0312 3333 - 0128

 Technical data
Tightening specifications TCD 2012 2V

© 05/2005 22/22 0312 3333 - 0128

 TCD 2012 2V Job card overview

5
5 Job card overview
5.1 Sorted alphabetically

© 05/2005 1/19 0312 3334 - 0128

 Job card overview
Sorted alphabetically TCD 2012 2V

© 05/2005 2/19 0312 3334 - 0128

 Job card overview
TCD 2012 2V Sorted alphabetically

Activity Job card Maintenance group

Checking the camshaft W 04-05-06 Engine control
Checking the compression pressure W 00-02-06 General
Checking the con rod W 02-03-01 Drive system
Checking the coolant thermostat, in the removed
W 09-08-01 Cooling system
state
Checking the crankshaft W 02-01-07 Drive system
Checking the cylinders W 03-03-01 Crankcase
5
Checking the piston W 02-09-07 Drive system
Checking the piston rings and piston ring grooves W 02-10-03 Drive system
Checking the valve guide W 01-06-03 Cylinder head
Checking the valve lag W 01-07-08 Cylinder head
Checking the valves W 01-05-04 Cylinder head
Disassembling, assembling and checking the rocker
W 01-02-06 Cylinder head
arm and rocker arm bracket
Dismantling and assembling the fan drive W 09-13-01 Cooling system
Installing and removing the fan drive W 09-13-02 Cooling system
Mounting and dismounting the engine on the as-
W 00-05-01 General
sembly block
Removing and and installing the fuel filter console W 07-10-08 Fuel system
Removing and installing rocker arms and rocker arm
W 01-02-02 Cylinder head
brackets
Removing and installing the belt tensioner (V-rib
W 12-02-06 Other components
belt)
Removing and installing the cable harness W 13-01-02 Electrical system
Removing and installing the camshaft W 04-05-05 Engine control
Removing and installing the charge air line W 06-07-03 Exhaust system / Charging
Removing and installing the connection housing W 03-09-04 Crankcase
Removing and installing the control block W 07-15-01 Fuel system
Removing and installing the coolant pump (V-rib belt
W 09-07-08 Cooling system
drive)
Removing and installing the coolant temperature
W 09-12-01 Cooling system
sensor
Removing and installing the coolant thermostat W 09-08-02 Cooling system
Removing and installing the crankcase bleeding W 03-01-11 Crankcase
Removing and installing the crankshaft W 02-04-01 Drive system
Removing and installing the cylinder head W 01-04-04 Cylinder head
Removing and installing the exhaust manifold W 06-01-05 Exhaust system / Charging
Removing and installing the exhaust return module W 06-09-01 Exhaust system / Charging

© 05/2005 3/19 0312 3334 - 0128

 Job card overview
Sorted alphabetically TCD 2012 2V

Activity Job card Maintenance group

Removing and installing the fan console W 09-13-03 Cooling system
Removing and installing the flywheel W 12-06-01 Other components
Removing and installing the front cover (opposite
W 03-08-01 Crankcase
side to flywheel)
Removing and installing the fuel pressure sensor W 07-15-18 Fuel system
Removing and installing the fuel supply pump (V-rib
W 07-11-01 Fuel system
belt drive)

5 Removing and installing the gearcase W 04-04-09 Engine control

Removing and installing the generator (V-rib belt
W 13-02-03 Electrical system
drive)
Removing and installing the heating plugs W 13-06-01 Electrical system
Removing and installing the high-pressure pump (in-
W 07-15-04 Fuel system
stallation position A)
Removing and installing the high-pressure pump (in-
W 07-15-05 Fuel system
stallation position B)
Removing and installing the injector W 07-15-11 Fuel system
Removing and installing the lube oil tray W 08-04-07 Lube oil system
Removing and installing the oil cooler W 08-08-02 Lube oil system
Removing and installing the oil cooler housing W 08-08-03 Lube oil system
Removing and installing the oil filter cartridge W 08-10-06 Lube oil system
Removing and installing the oil pressure switch W 08-11-09 Lube oil system
Removing and installing the oil suction intake pipe W 08-04-06 Lube oil system
Removing and installing the piston and con rod. W 02-09-03 Drive system
Removing and installing the piston cooling nozzles W 02-15-01 Drive system
Removing and installing the pressure limiting valve W 07-15-14 Fuel system
Removing and installing the pressure/temperature
W 13-08-01 Electrical system
sensor (charge air)
Removing and installing the rail W 07-15-08 Fuel system
Removing and installing the rail pressure sensor W 07-15-16 Fuel system
Removing and installing the solenoid valve exhaust
W 06-09-02 Exhaust system / Charging
return line
Removing and installing the speed governor (cams-
W 05-07-03 Speed governing
haft)
Removing and installing the speed governor
W 05-07-01 Speed governing
(crankshaft)
Removing and installing the starter W 13-03-02 Electrical system
Removing and installing the torsional vibration dam-
W 12-01-04 Other components
per (V-rib belt drive)
Removing and installing the turbocharger W 06-06-04 Exhaust system / Charging

© 05/2005 4/19 0312 3334 - 0128

 TCD 2012 2V Job card overview

Activity Job card Maintenance group

Removing and installing the valves W 01-05-01 Cylinder head
Removing and installing the water cistern W 09-06-01 Cooling system
Renewing the crankshaft sealing ring (flywheel side) W 02-02-02 Drive system
Renewing the crankshaft sealing ring (opposite side
W 02-02-04 Drive system
to flywheel)
Setting the valve clearance (with installed exhaust
W 01-01-01 Cylinder head
return module)
Setting the valve clearance (without or with removed 5
W 01-01-01 Cylinder head
exhaust return module)

© 05/2005 5/19 0312 3334 - 0128

 Job card overview
Sorted alphabetically TCD 2012 2V

© 05/2005 6/19 0312 3334 - 0128

 Job card overview
TCD 2012 2V Sorted numerically

5
5.2 Sorted numerically

© 05/2005 7/19 0312 3334 - 0128

 Job card overview
Sorted numerically TCD 2012 2V

© 05/2005 8/19 0312 3334 - 0128

 TCD 2012 2V Job card overview

Job card Activity Maintenance group

W 00-02-06 Checking the compression pressure General
Mounting and dismounting the engine on the as-
W 00-05-01 General
sembly block
Setting the valve clearance (with installed exhaust
W 01-01-01 Cylinder head
return module)
Setting the valve clearance (without or with removed
W 01-01-01 Cylinder head
exhaust return module)

W 01-02-02
Removing and installing rocker arms and rocker arm
Cylinder head 5
brackets
Disassembling, assembling and checking the rocker
W 01-02-06 Cylinder head
arm and rocker arm bracket
W 01-04-04 Removing and installing the cylinder head Cylinder head
W 01-05-01 Removing and installing the valves Cylinder head
W 01-05-04 Checking the valves Cylinder head
W 01-06-03 Checking the valve guide Cylinder head
W 01-07-08 Checking the valve lag Cylinder head
W 02-01-07 Checking the crankshaft Drive system
W 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Drive system
Renewing the crankshaft sealing ring (opposite side
W 02-02-04 Drive system
to flywheel)
W 02-03-01 Checking the con rod Drive system
W 02-04-01 Removing and installing the crankshaft Drive system
W 02-09-03 Removing and installing the piston and con rod. Drive system
W 02-09-07 Checking the piston Drive system
W 02-10-03 Checking the piston rings and piston ring grooves Drive system
W 02-15-01 Removing and installing the piston cooling nozzles Drive system
W 03-01-11 Removing and installing the crankcase bleeding Crankcase
W 03-03-01 Checking the cylinders Crankcase
Removing and installing the front cover (opposite
W 03-08-01 Crankcase
side to flywheel)
W 03-09-04 Removing and installing the connection housing Crankcase
W 04-04-09 Removing and installing the gearcase Engine control
W 04-05-05 Removing and installing the camshaft Engine control
W 04-05-06 Checking the camshaft Engine control
Removing and installing the speed governor
W 05-07-01 Speed governing
(crankshaft)
Removing and installing the speed governor (cams-
W 05-07-03 Speed governing
haft)
W 06-01-05 Removing and installing the exhaust manifold Exhaust system / Charging

© 05/2005 9/19 0312 3334 - 0128

 Job card overview
Sorted numerically TCD 2012 2V

Job card Activity Maintenance group

W 06-06-04 Removing and installing the turbocharger Exhaust system / Charging
W 06-07-03 Removing and installing the charge air line Exhaust system / Charging
W 06-09-01 Removing and installing the exhaust return module Exhaust system / Charging
Removing and installing the solenoid valve exhaust
W 06-09-02 Exhaust system / Charging
return line
W 07-10-08 Removing and and installing the fuel filter console Fuel system
Removing and installing the fuel supply pump (V-rib
W 07-11-01 Fuel system
5 belt drive)
W 07-15-01 Removing and installing the control block Fuel system
Removing and installing the high-pressure pump (in-
W 07-15-04 Fuel system
stallation position A)
Removing and installing the high-pressure pump (in-
W 07-15-05 Fuel system
stallation position B)
W 07-15-08 Removing and installing the rail Fuel system
W 07-15-11 Removing and installing the injector Fuel system
W 07-15-14 Removing and installing the pressure limiting valve Fuel system
W 07-15-16 Removing and installing the rail pressure sensor Fuel system
W 07-15-18 Removing and installing the fuel pressure sensor Fuel system
W 08-04-06 Removing and installing the oil suction intake pipe Lube oil system
W 08-04-07 Removing and installing the lube oil tray Lube oil system
W 08-08-02 Removing and installing the oil cooler Lube oil system
W 08-08-03 Removing and installing the oil cooler housing Lube oil system
W 08-10-06 Removing and installing the oil filter cartridge Lube oil system
W 08-11-09 Removing and installing the oil pressure switch Lube oil system
W 09-06-01 Removing and installing the water cistern Cooling system
Removing and installing the coolant pump (V-rib belt
W 09-07-08 Cooling system
drive)
Checking the coolant thermostat, in the removed
W 09-08-01 Cooling system
state
W 09-08-02 Removing and installing the coolant thermostat Cooling system
Removing and installing the coolant temperature
W 09-12-01 Cooling system
sensor
W 09-13-01 Dismantling and assembling the fan drive Cooling system
W 09-13-02 Installing and removing the fan drive Cooling system
W 09-13-03 Removing and installing the fan console Cooling system
Removing and installing the torsional vibration dam-
W 12-01-04 Other components
per (V-rib belt drive)
Removing and installing the belt tensioner (V-rib
W 12-02-06 Other components
belt)

© 05/2005 10/19 0312 3334 - 0128

 Job card overview
TCD 2012 2V Sorted numerically

Job card Activity Maintenance group

W 12-06-01 Removing and installing the flywheel Other components
W 13-01-02 Removing and installing the cable harness Electrical system
Removing and installing the generator (V-rib belt
W 13-02-03 Electrical system
drive)
W 13-03-02 Removing and installing the starter Electrical system
W 13-06-01 Removing and installing the heating plugs Electrical system
Removing and installing the pressure/temperature
W 13-08-01 Electrical system
sensor (charge air) 5

© 05/2005 11/19 0312 3334 - 0128

 Job card overview
Sorted numerically TCD 2012 2V

© 05/2005 12/19 0312 3334 - 0128

 Job card overview
TCD 2012 2V Job card references

5
5.3 Job card references

© 05/2005 13/19 0312 3334 - 0128

 Job card overview
Job card references TCD 2012 2V

© 05/2005 14/19 0312 3334 - 0128

 Job card overview
TCD 2012 2V Job card references

00 General
Job card Activity and additional job cards necessary for its execution
Checking the compression pressure
W 00-02-06
W 01-01-01 W 01-01-01 W 07-15-11
Mounting and dismounting the engine on the assembly block
W 00-05-01

01 Cylinder head 5
Job card Activity and additional job cards necessary for its execution
Setting the valve clearance (with installed exhaust return module)
W 01-01-01
W 06-09-01
Setting the valve clearance (without or with removed exhaust return module)
W 01-01-01
W 06-09-01
Removing and installing rocker arms and rocker arm brackets
W 01-02-02
W 01-01-01 W 01-01-01 W 06-09-01
Disassembling, assembling and checking the rocker arm and rocker arm bracket
W 01-02-06
W 01-02-02
Removing and installing the cylinder head
W 01-04-04 W 01-01-01 W 01-01-01 W 01-02-02 W 06-01-05 W 06-07-03
W 06-09-01 W 06-09-02 W 07-15-08 W 09-13-03 W 13-06-01
Removing and installing the valves
W 01-05-01
W 01-04-04
Checking the valves
W 01-05-04
W 01-05-01
Checking the valve guide
W 01-06-03
W 01-05-01
Checking the valve lag
W 01-07-08
W 01-04-04

02 Drive system
Job card Activity and additional job cards necessary for its execution
Checking the crankshaft
W 02-01-07
W 02-04-01
Renewing the crankshaft sealing ring (flywheel side)
W 02-02-02
W 12-06-01

© 05/2005 15/19 0312 3334 - 0128

 Job card overview TCD 2012 2V

02 Drive system (Forts.)

Job card Activity and additional job cards necessary for its execution
Renewing the crankshaft sealing ring (opposite side to flywheel)
W 02-02-04
W 12-01-04
Checking the con rod
W 02-03-01

Removing and installing the crankshaft

W 02-04-01
W 02-01-07 W 03-08-01 W 04-04-09
5 Removing and installing the piston and con rod.
W 02-09-03
W 01-04-04 W 02-10-03 W 08-04-06
Checking the piston
W 02-09-07
W 02-09-03
Checking the piston rings and piston ring grooves
W 02-10-03
W 02-09-03
Removing and installing the piston cooling nozzles
W 02-15-01
W 02-04-01

03 Crankcase
Job card Activity and additional job cards necessary for its execution
Removing and installing the crankcase bleeding
W 03-01-11

Checking the cylinders

W 03-03-01
W 02-09-03
Removing and installing the front cover (opposite side to flywheel)
W 03-08-01
W 02-02-04 W 08-04-06 W 12-01-04
Removing and installing the connection housing
W 03-09-04

04 Engine control
Job card Activity and additional job cards necessary for its execution
Removing and installing the gearcase
W 04-04-09
W 02-02-02 W 03-09-04 W 08-04-07 W 12-06-01 W 13-03-02
Removing and installing the camshaft
W 04-05-05
W 01-02-02 W 02-04-01 W 07-15-04 W 07-15-05
Checking the camshaft
W 04-05-06
W 04-05-05

© 05/2005 16/19 0312 3334 - 0128

 TCD 2012 2V Job card overview

05 Speed governing
Job card Activity and additional job cards necessary for its execution
Removing and installing the speed governor (crankshaft)
W 05-07-01

Removing and installing the speed governor (camshaft)

W 05-07-03

06 Exhaust system / Charging 5

Job card Activity and additional job cards necessary for its execution
Removing and installing the exhaust manifold
W 06-01-05
W 06-06-04
Removing and installing the turbocharger
W 06-06-04

Removing and installing the charge air line

W 06-07-03
W 13-08-01
Removing and installing the exhaust return module
W 06-09-01

Removing and installing the solenoid valve exhaust return line

W 06-09-02
W 09-12-01

07 Fuel system
Job card Activity and additional job cards necessary for its execution
Removing and and installing the fuel filter console
W 07-10-08
User notes
Removing and installing the fuel supply pump (V-rib belt drive)
W 07-11-01
User notes
Removing and installing the control block
W 07-15-01
User notes W 07-15-08
Removing and installing the high-pressure pump (installation position A)
W 07-15-04
User notes W 07-15-01
Removing and installing the high-pressure pump (installation position B)
W 07-15-05
User notes W 07-15-01
Removing and installing the rail
W 07-15-08
User notes
Removing and installing the injector
W 07-15-11
User notes

© 05/2005 17/19 0312 3334 - 0128

 Job card overview TCD 2012 2V

07 Fuel system (Forts.)

Job card Activity and additional job cards necessary for its execution
Removing and installing the pressure limiting valve
W 07-15-14
User notes
Removing and installing the rail pressure sensor
W 07-15-16
User notes
Removing and installing the fuel pressure sensor
W 07-15-18
User notes
5

08 Lube oil system

Job card Activity and additional job cards necessary for its execution
Removing and installing the oil suction intake pipe
W 08-04-06
W 08-04-07
Removing and installing the lube oil tray
W 08-04-07

Removing and installing the oil cooler

W 08-08-02

Removing and installing the oil filter cartridge

W 08-10-06

Removing and installing the oil cooler housing

W 08-08-03
W 08-08-02 W 08-10-06
Removing and installing the oil pressure switch
W 08-11-09

09 Cooling system
Job card Activity and additional job cards necessary for its execution
Removing and installing the water cistern
W 09-06-01
W 07-10-08
Removing and installing the coolant pump (V-rib belt drive)
W 09-07-08

Checking the coolant thermostat, in the removed state

W 09-08-01
W 09-08-02
Removing and installing the coolant thermostat
W 09-08-02

Removing and installing the coolant temperature sensor

W 09-12-01

© 05/2005 18/19 0312 3334 - 0128

 TCD 2012 2V Job card overview

09 Cooling system (Forts.)

Job card Activity and additional job cards necessary for its execution
Dismantling and assembling the fan drive
W 09-13-01
W 09-13-02
Installing and removing the fan drive
W 09-13-02

Removing and installing the fan console

W 09-13-03
W 07-11-01 W 09-13-02 W 12-02-06 W 13-02-03
5

12 Other components
Job card Activity and additional job cards necessary for its execution
Removing and installing the torsional vibration damper (V-rib belt drive)
W 12-01-04
W 12-02-06
Removing and installing the belt tensioner (V-rib belt)
W 12-02-06

Removing and installing the flywheel

W 12-06-01

13 Electrical system
Job card Activity and additional job cards necessary for its execution
Removing and installing the cable harness
W 13-01-02

Removing and installing the generator (V-rib belt drive)

W 13-02-03

Removing and installing the starter

W 13-03-02

Removing and installing the heating plugs

W 13-06-01
W 07-15-11
Removing and installing the pressure/temperature sensor (charge air)
W 13-08-01

© 05/2005 19/19 0312 3334 - 0128

 DEUTZ engines Job cards

6 Job cards
6

© 05/2005 1/2 0312 3018 - 0199

 Job cards DEUTZ engines

© 05/2005 2/2 0312 3018 - 0199

 General
TCD 2012 2V W 00-02-06

Checking the compression pressure

Commercial available tools: – W 01-01-01
– Compression pressure – W 07-15-11
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005
– Torx tool set . . . . . . . . . . . . . . . . . . 8189
Special tools:
– Connector . . . . . . . . . . . . . . . . . .100 190

Checking the compression pressure

z Set the valve clearance (with exhaust return module
installed).
 W 01-01-01 1
z Remove injectors.
 W 07-15-11
z Insert connector (1) with sealing ring.
Use sealing ring for injector.

© 43005-0

z Mount clamping shoe (1) and tighten screw (2).

 A07 001
When installing the connector on
cylinders 2 to 5, the clamping shoe must
be inserted together with the connector.

© 43006-0

© 05/2005 1/4 0312 3339 - 0128

 General
W 00-02-06 TCD 2012 2V

z If necessary, mount adapter (1) on connector.

6
© 43007-0

z Connect compression pressure tester to connector

or adapter.
z Turn over engine with starter.
 P00 51

© 43008-0

The measured compression pressure

depends on the starting speed during the
measuring process and the altitude of the No.
engine installation site. Kompression in bar
Compression value in bar
This means that limit values cannot be Pression en bar
determined exactly. The compression pres- Dat. _________
10 15 20 25 30 35 40
sure measurement is only recommended
Zyl.

as a reference measurement of all cylin-

ders of an engine to each other. If more 1
than 15% deviation has been found, the 2
cause should be determined by disassem- 3
bling the cylinder unit concerned. 4
5
6
7
8
DBGM Made in Germany
MOTOMETER
© 33771-5

© 05/2005 2/4 0312 3339 - 0128

 General
TCD 2012 2V W 00-02-06

z Remove the compression tester and adapter.

6
© 00000-0

z Unscrew screw (1) and remove clamping shoe.

z Remove connector and sealing ring.
z Install injector.
 W 07-15-11

© 43009-0

© 05/2005 3/4 0312 3339 - 0128

 General
W 00-02-06 TCD 2012 2V

© 05/2005 4/4 0312 3339 - 0128

 General
TCD 2012 2V W 00-05-01

Mounting engine on assembly block and demounting

Commercial available tools: Different customer scopes are not taken
– Hoisting equipment into account in the repair sequence shown
– Suspension ropes here, add-on parts which deviate from the
Special tools: standard equipment are not shown.
– Assembly block incl. adap-
ter plates . . . . . . . . . . . . . . . . . . . . . 6066
– Clamping bracket . . . . . . . . . . .6066/158

Mounting engine on assembly block

z Hang engine on suitable workshop crane.
 P00 04

© 43842-1

Remove mounting feet.

z Unscrew nuts (1) and remove mounting foot (2) from
the holder.
Remove all mounting feet.

© 42640-0

© 05/2005 1/6 0312 3340 - 0128

 General
W 00-05-01 TCD 2012 2V

z Unscrew screws (1) and remove mounting foot (2)

from the connection housing.

1
2

6
© 42641-0

z Unscrew screw (1) and loosen pipe clip (2).

z Unscrew hollow screw (3) and remove sealing rings.
4
z Loosen hose clip (4).
z Pull the oil return line (5) off the crankcase ventila-
tion and remove with ventilation duct.
5

2
1

© 42642-0

z Mount the clamping bracket 6066/158-3 (1) on the

crankcase and tighten the screw (2).
z Mount the clamping bracket 6066/158-1 (3) on the
holder and tighten the nuts (4).
 A00 001

2 3 4
1
© 42643-0

© 05/2005 2/6 0312 3340 - 0128

 General
TCD 2012 2V W 00-05-01

z Mount the clamping bracket 6066/158-2 (1) on the

holder and tighten the nuts (2).
z Mount the clamping bracket 6066/158-4 (3) on the
crankcase and tighten the screws (4).
 A00 001

1
3 6
© 42644-0

z Insert the engine with clamping brackets in the as-

sembly block.
z Align all clamping brackets (1) on the adapter 2
plates (2) of the assembly block. 1
z Insert screws and tighten nuts (arrows).
 A00 002

© 42645-0

z Align the engine on the assembly block and tighten

all screws (arrows).
z Unhook the engine from the workshop crane.

© 42646-0

© 05/2005 3/6 0312 3340 - 0128

 General
W 00-05-01 TCD 2012 2V

Dismounting engine from assembly block

z Hang engine on suitable workshop crane.
2
z Remove all clamping brackets (1) from the adapter 1
plates (2) of the assembly block.
z Lift engine off the assembly block

6
© 42740-0

z Unscrew nuts (2), turn out screws (4) and remove

clamping brackets (1 and 3).

3
1
© 42644-0

z Unscrew nuts (4), remove screw (2) and remove

clamping brackets (1 and 3).

2 3 4
1
© 42643-0

© 05/2005 4/6 0312 3340 - 0128

 General
TCD 2012 2V W 00-05-01

z Mount ventilation duct and attach oil return line (5).

z Tighten hollow screw (3) with new sealing rings.
4
 A12 091
z Position pipe clamp (2) and tighten screw (1).
 A12 095 5

z Position and fix hose clip (4).

2
1

6
© 42642-0

Mounting feet
z Mount foot (2) and tighten screws (1).
 A00 003
Mount all mounting feet.

1
2

© 42641-0

z Mount foot (2) on holder and tighten nuts (1).

 A00 003
z Set down the engine and unhook it from the work-
shop crane.

© 42640-0

© 05/2005 5/6 0312 3340 - 0128

 General
W 00-05-01 TCD 2012 2V

© 05/2005 6/6 0312 3340 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

Setting the valve clearance

(with or without removal of exhaust return module)
Commercial available tools: – W 06-09-01
– Rotation angle disc . . . . . . . . . . . . . 8190
– Open wrench size 13 . . . . . . . . . . . 8196
– Screwdriver insert for slot- Allow the engine to cool down for at least
ted screws. . . . . . . . . . . . . . . . . . . . 8191 30 minutes before setting the valve clea-
– Screwdriver insert for rance.
hexagon socket head Engine oil temperature < 80 °C.
screws (4 mm) . . . . . . . . . . . . . . . . 8194
The control piston clearance of the exhaust
Special tools: return line must be set after setting the
– Turning gear . . . . . . . . . . . . . . . .100 320 valve clearance.
– Socket wrench insert size In engines without an exhaust return
15 . . . . . . . . . . . . . . . . . . . . . . . .103 050 module, a slotted adjusting screw must be 6
installed in place of a hexagon socket head
screw.

Disassembly
z Unscrew screw (1), remove cover (2) with oil filling
nozzles. 1

© 42530-0

© 05/2005 1/10 0312 3338 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

z Unscrew screws (1).

6
© 42531-0

z Insert turning gear (1).

The gear wheel of the turning gear must
grip into the teeth of the camshaft gear
wheel.

© 42532-0

z Tighten screws (1).

© 42533-0

© 05/2005 2/10 0312 3338 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

Setting engine to valve overlap

z Turn crankshaft using the turning gear until the valve
overlap of cylinder 1 is reached.
 P01 61

6
© 42534-0

Valve overlap means:

Outlet valve is not yet closed. Inlet valve
begins to open.

© 42535-0

Set valve clearance according to the set-

ting schematic
z Arrangement of the inlet and outlet valves.
IN = inlet valveEX = outlet valve
 A01 003
Attention!
Note design of the adjusting screw (with
slot, wrench size or hexagon socket).
EX IN

© 42536-0

© 05/2005 3/10 0312 3338 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

Setting the inlet valve clearance

z Loosen lock nut (1).
z Press in the setting screw (2) to the stop.
The rocker arm must touch the thrust was-
2
her of the spring cap (arrow).
In engines without an exhaust return
module, a slotted setting screw must be
installed in place of a hexagon socket head
screw.

6
© 42537-0

z Set the rotation angle disc with a socket wrench in-

sert at the setting screw.
z Fix magnet of rotation angle disc on cylinder head.
z Set the rotation angle disc in the direction of the ar-
row to zero.
Be careful to turn the setting screw cor-
rectly.

© 42538-0

z Turn the setting screw back in in the direction of the

the arrow by 75° .
 P01 62

© 42539-0

© 05/2005 4/10 0312 3338 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

z Hold the setting screw to prevent it turning and tight-

en the lock nut (1) with the open wrench.
 A01 003
z Remove rotation angle disc.

6
© 42983-0

Setting the outlet valve clearance

z Loosen lock nut (1).
z Press in the setting screw (2) to the stop.
The rocker arm must touch the thrust was-
her of the spring cap (arrow). 2

© 43039-0

z Set the rotation angle disc on the setting screw with

a screwdriver insert for slotted screws.
z Fix magnet of rotation angle disc on cylinder head.
z Set the rotation angle disc in the direction of the ar-
row to zero.
Be careful to turn the setting screw cor-
rectly.

© 42540-0

© 05/2005 5/10 0312 3338 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

z Turn the setting screw back by 120° in the direction

of the the arrow.
 P01 63

6
© 42541-0

z Hold the setting screw to prevent it turning and tight-

en the lock nut (1) with the open wrench.
 P01 64
z Remove rotation angle disc.
Set all other valves according to the valve
setting schematic T01 63.

© 42993-0

Setting the control piston clearance

z Install exhaust return module.
 W 06-09-01
The control piston clearance (X) must be
set after setting the valve clearance.
The setting sequence for the control piston
clearance is identical with the valve setting
schematic T01 63.

© 43832-3

© 05/2005 6/10 0312 3338 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

Setting engine to valve overlap

z Turn crankshaft using the turning gear until the valve
overlap of cylinder 1 is reached.
 A03 092

6
© 42534-0

Valve overlap means:

Outlet valve is not yet closed. Inlet valve
begins to open.

© 43040-0

z Arrangement of the oulet valves.

EX = outlet valve

EX EX EX

© 42933-0

© 05/2005 7/10 0312 3338 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

z Loosen lock nut (1).

z Press in the setting screw (2) to the stop. 2
The rocker arm must touch the thrust was-
her of the spring cap (arrow).

6
© 42934-0

z Set the rotation angle disc on the setting screw with

a screwdriver insert for slotted screws.
z Fix magnet of rotation angle disc on cylinder head.
z Set the rotation angle disc in the direction of the ar-
row to zero.
Be careful to turn the setting screw cor-
rectly.

© 42935-0

z Turn the setting screw back by 144° in the direction

of the arrow.
 A04 022

© 42936-0

© 05/2005 8/10 0312 3338 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

z Hold the setting screw to prevent it turning and tight-

en the lock nut (arrow) with the open wrench.
 A01 004
z Remove rotation angle disc.
Set all other control pistons according to
the valve setting schematic T01 63.

6
© 43050-0

Assembly
z Unscrew screws (1) and remove turning gear.

© 42533-0

z Tighten screws (1).

 A13 041
Use M8 x 45 mm screws.

© 42542-0

© 05/2005 9/10 0312 3338 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

z Clean the sealing surface on cover and gearcase.

z Pull new O-ring (arrow) onto cover.
z Lightly oil O-ring.

6
© 42543-0

z Press in cover to stop and tighten screw (1).

 A04 022
1

© 42639-0

© 05/2005 10/10 0312 3338 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

Setting the valve clearance

(with exhaust return module installed)
Commercial available tools: Allow the engine to cool down for at least
– Rotation angle disc . . . . . . . . . . . . . 8190 30 minutes before setting the valve clea-
– Open wrench size 13 . . . . . . . . . . . 8196 rance.
– Crowfoot wrench size 15 . . . . . . . . 8199 Engine oil temperature < 80 °C.
– Screwdriver insert for slot- The control piston clearance of the exhaust
ted screws. . . . . . . . . . . . . . . . . . . . 8191 return line must be set after setting the
– Screwdriver insert for valve clearance.
hexagon socket head
screws (4 mm) . . . . . . . . . . . . . . . . 8194
Special tools:
– Turning gear . . . . . . . . . . . . . . . .100 320
6

Disassembly
z Unscrew screws (1) and remove cover plate (2).

© 42920-0

z Unscrew screws (arrows), remove ventilation

duct (1) with crankcase venting (2) and hang to one
side.

2
1

© 42923-0

© 05/2005 1/12 0312 3342 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

z Unscrew screws (arrows), remove cylinder head

cover (1) and gasket.

6
© 42922-0

z Unscrew screw (1), remove cover (2) with oil filling

nozzles.

© 42530-0

z Unscrew screws (1).

© 42531-0

© 05/2005 2/12 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

z Insert turning gear (1).

The gear wheel of the turning gear must
grip into the teeth of the camshaft gear
wheel.

6
© 42532-0

z Tighten screws (1).

© 42533-0

Setting engine to valve overlap

z Turn crankshaft using the turning gear until the valve
overlap of cylinder 1 is reached.
 Removing and installing the exhaust return
module

© 42534-0

© 05/2005 3/12 0312 3342 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

Valve overlap means:

Outlet valve is not yet closed. Inlet valve
begins to open.

6
© 43040-0

Set valve clearance according to the set-

ting schematic
z Arrangement of the inlet and outlet valves.
IN = inlet valve
EX = outlet valve
Attention!
Note design of the setting screw (with slot,
wrench size or hexagon socket).

IN
EX

© 43041-0

Setting the inlet valve clearance

z Loosen lock nut (1).
z Press in the setting screw (2) to the stop.
The rocker arm must touch the thrust was-
her of the spring cap (arrow).

© 43042-0

© 05/2005 4/12 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

z Set the rotation angle disc on the setting screw with

the crowfoot wrench.
z Fix magnet of rotation angle disc on cylinder head.
z Set the rotation angle disc in the direction of the ar-
row to zero.
Be careful to turn the setting screw cor-
rectly.

6
© 43043-0

z Turn the setting screw back by 75° in the direction

of the the arrow.
 P01 63

© 43044-0

z Hold the setting screw to prevent it turning and tight-

en the lock nut (arrow) with the open wrench.
 P01 63
z Remove rotation angle disc.

© 43045-0

© 05/2005 5/12 0312 3342 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

Setting the outlet valve clearance

z Loosen lock nut (1).
z Press in the setting screw (2) to the stop.
The rocker arm must touch the thrust was-
her of the spring cap (arrow).
2

6 1

© 43046-0

z Set the rotation angle disc on the setting screw with

a screwdriver insert for slotted screws.
z Fix magnet of rotation angle disc on cylinder head.
z Set the rotation angle disc in the direction of the ar-
row to zero.
Be careful to turn the setting screw cor-
rectly.

© 43047-0

z Turn the setting screw back by 120° in the direction

of the arrow.
 P01 61

© 43048-0

© 05/2005 6/12 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

z Hold the setting screw to prevent it turning wrongly

and tighten the lock nut (arrow) with the open
wrench.
 A01 003
z Remove rotation angle disc.
Set all other valves according to the valve
setting schematic T01 63.

6
© 43049-0

Setting the control piston clearance

The control piston clearance (X) must be
set after setting the valve clearance.
The order of setting the control piston clea-
rance is identical with the valve setting
schematic T01 63.

© 43832-3

Setting engine to valve overlap

z Turn crankshaft using the turning gear until the valve
overlap of cylinder 1 is reached.
 P01 62

© 42534-0

© 05/2005 7/12 0312 3342 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

Valve overlap means:

Outlet valve is not yet closed, iInlet valve
begins to open.

6
© 43040-0

z Arrangement of the outlet valves.

EX = outlet valve

EX EX EX

© 42933-0

z Loosen lock nut (1).

z Press in the setting screw (2) to the stop. 2
The rocker arm must touch the thrust was-
her of the spring cap (arrow).

© 42934-0

© 05/2005 8/12 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

z Set the rotation angle disc on the setting screw with

a screwdriver insert for slotted screws.
z Fix magnet of rotation angle disc on cylinder head.
z Set the rotation angle disc in the direction of the ar-
row to zero.
Be careful to turn the setting screw cor-
rectly.

6
© 42935-0

z Turn the setting screw back by 144° in the direction

of the arrow.
 A01 003

© 42936-0

z Hold the setting screw to prevent it turning wrongly

and tighten the lock nut (arrow) with the open
wrench.
 Removing and installing the exhaust return
module
z Remove rotation angle disc.
Set all other control pistons according to
the valve setting schematic T01 63.

© 43050-0

© 05/2005 9/12 0312 3342 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

Assembly
z Unscrew screws (1) and remove turning gear.

6
© 42533-0

z Tighten screws (1).

 P01 63
Use M8 x 45 mm screws.

© 42542-0

z Clean the sealing surface on cover and gearcase.

z Pull new O-ring (arrow) onto cover.
z Lightly oil O-ring.

© 42543-0

© 05/2005 10/12 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-01-01

z Press in cover to stop and tighten screw (1).

 P01 64
1

6
© 42639-0

z Clean the sealing surface on the cylinder head cover

and cylinder head.
z Insert new gasket (arrow).

© 42937-0

z Mount cylinder head cover and tighten screws alter-

nately.
 A01 012
1
Attention!
Do not trap the cable (1) when mounting
the cylinder head cover.

© 42938-0

© 05/2005 11/12 0312 3342 - 0128

 Cylinder head
W 01-01-01 TCD 2012 2V

z Clean the sealing surface on the ventilation duct and

cylinder head cover.
z Insert new gasket (arrow).

6
© 42939-0

z Mount ventilation duct with crankcase venting and

tighten screws.
Note different screw length:  1
Screws M8 x 25 mm (1)
Screw M8 x 20 mm (2)
z Tighten screws.

© 42941-0

z Mount the cover plate (1) and tighten the

screws (arrows).
 A03 092
1

© 43016-0

© 05/2005 12/12 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-02-02

Removing and installing the rocker arm and rocker arm bracket
Commercial available tools: – W 01-01-01
– Socket wrench insert . . . . . . . . . . . 8113 – W 06-09-01
Special tools:
– Turning gear . . . . . . . . . . . . . . . .100 320

Removing the rocker arm and rocker arm

bracket
z Remove exhaust return module.
 W 06-09-01
z Unscrew cylinder head screw (1) and remove rocker
arm with rocker arm bracket (2). 2 4
Use socket wrench insert.
When disassembling the rocker arm
bracket 3), the screw (4) must also be uns-
crewed.
Lay out components in the order in which 3
they should be installed.

1
© 42544-1

z Remove stop rods (1).

Lay out components in the order in which
they should be installed.

z Visually inspect the components.

© 42545-0

© 05/2005 1/8 0312 3342 - 0128

 Cylinder head
W 01-02-02 TCD 2012 2V

Installing the rocker arm and rocker arm

bracket
z 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.

6
© 42545-0

z Unscrew screw (1), remove cover (2) with oil filling

nozzles.

© 42530-0

z Unscrew screws (1).

© 42531-0

© 05/2005 2/8 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-02-02

z Insert turning gear (1).

The gear wheel of the turning gear must
grip into the teeth of the camshaft gear
wheel.

6
© 42532-0

z Tighten screws (1).

© 42533-0

Make sure the clamping pin (arrow) is in

place.

© 42546-0

© 05/2005 3/8 0312 3342 - 0128

 Cylinder head
W 01-02-02 TCD 2012 2V

z Mount rocker arm bracket (1).

The clamping pin must grip the fit bore in
the cylinder head.
The ball heads must be seated in the lad- 1
les of the stop rods (arrows).

6
© 42547-0

z Fasten screw (1).

Use M8 x 60 mm screw.
Do not tighten screw.
1

© 42548-0

z Lightly oil cylinder head screw (1) and tighten slight-

ly.
Attention!
Cylinder head screws can be used max. 3
times with written proof, otherwise renew
every time they are loosened.

Do not tighten screw. 1

© 42549-0

© 05/2005 4/8 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-02-02

z Align rocker arm bracket symmetrically with the valve

axles.
z Pre-tension the cylinder head screw.
 A01 001
Attention!
Makes sure that the stop rods are not
under stress due to valve overlap when
fastening the screw.

Use socket wrench insert.

6
© 42550-0

z Tighten screw (1).

 A01 002

© 42551-0

z Tighten the cylinder head screw.

 A01 001
Use socket wrench insert.

© 42552-0

© 05/2005 5/8 0312 3342 - 0128

 Cylinder head
W 01-02-02 TCD 2012 2V

z Unscrew screw (1).

When mounting the rocker arm bracket (2),
the screw (3) remains installed. 1
3
z Set valve clearance (without or with removal of ex-
haust return module).
 W 01-01-01
z Install exhaust return module.
 W 06-09-01

6
© 42553-0

z Unscrew screws (1) and remove turning gear.

© 42533-0

z Tighten screws (1).

 A03 092
Use M8 x 45 mm screws.

Note different screw sizes:

© 42542-0

© 05/2005 6/8 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-02-02

z Clean the sealing surface on cover and gearcase.

z Pull new O-ring (arrow) onto cover.
z Lightly oil O-ring (1).

6
© 42543-0

z Press in cover to stop and tighten screw (1).

 A04 022
Note different screw sizes: 1

© 42639-0

© 05/2005 7/8 0312 3342 - 0128

 Cylinder head
W 01-02-02 TCD 2012 2V

© 05/2005 8/8 0312 3342 - 0128

 Cylinder head
TCD 2012 2V W 01-02-06

Disassembling, assembling and checking the rocker arm and rocker arm
bracket
Commercial available tools: – W 01-02-02
– Internal precision measu-
ring device
– Micrometer gauge
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . .100 400

Disassembling the rocker arm bracket

z Remove rocker arm and rocker arm bracket.
 W 01-02-02
z Remove lock washers (1) on both sides.

© 42554-0

z Remove rocker arm.

Lay out components in the order in which
they should be installed.

© 42555-0

© 05/2005 1/4 0312 3343 - 0128

 Cylinder head
W 01-02-06 TCD 2012 2V

Checking the rocker arm

z Measure rocker arm bore with internal precision
measuring device.
 P01 72
P01 73
When the wear limit is reached the rocker
arm must be replaced.

6
© 39032-1

z Unscrew the lock nut (1) from the setting screw (2).
z Loosen the lock nut (3) from the setting screw (4).
Attention! 2 3
Note design of the setting screw (with slot,
wrench size or hexagon socket).

Lay out components in the order in which 4

they should be installed. 1

© 42556-0

z Check components for visible signs of wear.

z Check oil channels (arrows) for free passage.

© 42557-0

© 05/2005 2/4 0312 3343 - 0128

 Cylinder head
TCD 2012 2V W 01-02-06

z Screw setting screw (1) into the rocker arm and tight-
en the lock nut (2).

6
© 43011-0

Checking the rocker arm pin

z Measure the diameter of the rocker arm pin with the
micrometer gauge.
 P01 74
When the wear limit is reached the rocker
arm bracket must be replaced.

© 42558-0

Assembling the rocker arm bracket

z Lightly oil the rocker arm pin.
z Push the rocker arm (1 and 2) onto the rocker arm 2
pin.
The rocker arm's sliding surface (3) must
face the small hole (arrow).
1
The rocker arm (1) must be mounted on
the outlet side and the rocker arm (2) on
the inlet side.

© 42559-0

© 05/2005 3/4 0312 3343 - 0128

 Cylinder head
W 01-02-06 TCD 2012 2V

z Press new lock washers (1) into the rocker arm pin
up to the stop on both rocker arms.
z Install rocker arm and rocker arm bracket.
 W 01-02-02

6
© 42560-0

© 05/2005 4/4 0312 3343 - 0128

 Cylinder head
TCD 2012 2V W 01-04-04

Removing and installing cylinder head

Commercial available tools: – W 01-01-01
– Socket wrench set . . . . . . . . . . . . . 8113 – W 01-02-02
Special tools: – W 06-01-05
– Turning gear . . . . . . . . . . . . . . . .100 330 – W 06-07-03
– Dial gauge. . . . . . . . . . . . . . . . . .100 400 – W 06-09-01
– Measuring apparatus . . . . . . . . .100 750 – W 06-09-02
– W 07-15-08
– W 09-13-03
– W 13-06-01

Removing cylinder head

z Remove fan console.
 W 09-13-03
z Remove exhaust manifold.
 W 06-01-05
z Remove rail.
 W 07-15-08 1

z Unlock cable plug (1) and remove.

© 42561-0

z Remove heating plugs.

 W 13-06-01
z Remove solenoid valve (exhaust return line).
 W 06-09-02
z Remove rocker arm brackets and stop rods.
 W 01-02-02 2
z Remove charge air line.
 W 06-07-03
z Unscrew screws (1) and remove transport flange (2).
1

© 42562-0

© 05/2005 1/12 0312 3344 - 0128

 Cylinder head
W 01-04-04 TCD 2012 2V

z Unscrew hollow screw (1), remove fuel return line (2)

and sealing rings.

6
© 42563-0

z Unscrew all screws (arrows), remove cylinder head

and gasket.
Use socket wrench set.

z Clean the sealing surfaces on the cylinder head and

crankcase.

© 42564-0

Installing cylinder head

The piston projection must be measured
on all pistons.
The cylinder head gasket must be selected
according to the greatest measured piston
projection.
The appropriate cylinder head gasket must
be determined before installing the cylinder
head.

© 42565-0

© 05/2005 2/12 0312 3344 - 0128

 Cylinder head
TCD 2012 2V W 01-04-04

z Turn the crankshaft until the piston is flush with the

crankshaft (arrow).
Use the turning gear 100 330 to turn the
crankshaft.

6
© 42566-0

z Place the spacer plate (1) and measuring beam (2)

on the crankcase.
z Insert the dial gauge in the measuring beam and po-
sition the stylus under pre-tension on the piston base
(arrow).
z Continue turning the crankshaft evenly until the re- 2
versal point of the pointer on the dial gauge is
reached.
The piston is now at top dead centre
(TDC).

1
1

© 42567-0

z Move the measuring beam and spacer plate.

z Apply stylus of the dial gauge to the crankcase seal-
ing surface with pre-tension (arrow).
z Set the dial gauge to zero.

© 42568-0

© 05/2005 3/12 0312 3344 - 0128

 Cylinder head
W 01-04-04 TCD 2012 2V

z Remove measuring points.

Diagram for measuring the piston projec- 1
tion at the points (1 and 2).

6 2
© 34151-2

z Align the measuring beam on the spacing plates in

such a way that the stylus lies on the specified meas-
uring points.
Measuring points, see diagram.
The stylus must not be positioned on the
piston marking.
z Note the largest measured value.

© 42569-0

z Select cylinder head gasket according to the largest

piston projection measured.
 P02 75
P02 76
P02 77
Example:Piston projection = 0.56 mm cor-
responds to cylinder head gasket with
2 holes (arrow).

© 42570-0

© 05/2005 4/12 0312 3344 - 0128

 Cylinder head
TCD 2012 2V W 01-04-04

Installing cylinder head

Make sure the clamping bushings (arrows)
are in place.

6
© 42571-0

z Fit a new cylinder head gasket.

The sealing surfaces for the cylinder head
gasket must be clean and free of oil.
The label OBEN / TOP must face towards
the cylinder head.

© 42572-0

z Mount cylinder head, lightly oil cylinder head screws

and tighten slightly.
Attention!
Cylinder head screws can be used max. 3
times with written proof, otherwise renew
every time they are loosened.

Use cylinder head screws M12 x 108 mm.

Do not tighten cylinder head screws.

© 42573-0

© 05/2005 5/12 0312 3344 - 0128

 Cylinder head
W 01-04-04 TCD 2012 2V

Installing rocker arm brackets

z Insert stop rods.
Note the assignment of the stop rods.
The stop rod must be seated with the ball
head in the ladle of the tappet.

6
© 42574-0

z Unscrew screw (1), remove cover (2) with oil filler

neck.

© 42530-0

z Unscrew screws (1).

© 42531-0

© 05/2005 6/12 0312 3344 - 0128

 Cylinder head
TCD 2012 2V W 01-04-04

z Insert turning gear (1).

The gear wheel of the turning gear must
grip the teeth of the camshaft gear wheel.

6
© 42532-0

z Tighten screws (1).

© 42533-0

Make sure the clamping pin (arrow) is in

place.

© 42546-0

© 05/2005 7/12 0312 3344 - 0128

 Cylinder head
W 01-04-04 TCD 2012 2V

z Mount rocker arm bracket (1).

The clamping pin must grip the fit bore in
the cylinder head.
The ball heads must be seated in the lad-
les of the stop rods (arrows).
1

6
© 42575-0

z Fasten screw (1).

Use M8 x 60 mm screw.
Do not tighten screw.
1

© 42576-0

z Lightly oil cylinder head screw (1) and tighten slight-

ly.
Attention!
Cylinder head screws can be used a max.
3 times with written proof, otherwise renew
every time they are loosened. 1
Do not tighten cylinder head screw.

© 42577-0

© 05/2005 8/12 0312 3344 - 0128

 Cylinder head
TCD 2012 2V W 01-04-04

z Align rocker arm bracket symmetrically with the valve

axles.
z Tighten screw (1).
 A01 002
Attention!
Make sure that the stop rods are not under
stress due to valve overlap when tighte-
ning the screw.

6
© 42578-0

z Tighten all screws according to the tightening se-

quence.
 A01 001
z
Use socket wrench set.
22 14 6 4 12 20
26 18 10 2 8 16 24

25 17 9 1 7 15 23
21 13 5 3 11 19

© 42526-0

z Unscrew screws (arrows).

Screw (1) remains installed.

z Set valve clearance (either with or without the ex-

haust gas return module removed). 1
 W 01-01-01
z Install exhaust gas return module.
 W 06-09-01

© 42579-0

© 05/2005 9/12 0312 3344 - 0128

 Cylinder head
W 01-04-04 TCD 2012 2V

z Unscrew screws (1) and remove turning gear.

6
© 42533-0

z Tighten screws (1).

 A03 092
Use M8 x 45 mm screw.

© 42542-0

z Clean the sealing surface on cover and gearcase.

z Pull new O-ring (arrow) onto cover.
z Lightly oil O-ring.

© 42543-0

© 05/2005 10/12 0312 3344 - 0128

 Cylinder head
TCD 2012 2V W 01-04-04

z Press in cover to stop and tighten screw (1).

 A04 022
1

6
© 42639-0

z Install the fuel return line (1) and tighten hollow

screw (2) with new sealing rings.
 A12 091

© 42581-0

z Fit transport flange (1) and tighten screws (2).

z Assemble charge air line.
 W 06-07-03 1
z Install solenoid valve (exhaust return line).
 W 06-09-02
z Install rail.
 W 07-15-18

© 42580-0

© 05/2005 11/12 0312 3344 - 0128

 Cylinder head
W 01-04-04 TCD 2012 2V

z Install heating plugs.

 W 13-06-01
z Plug in the cable plug (1).
Ensure that the connection is perfect. 1

z Install exhaust manifold.

 W 06-01-05
z Install fan console.
 W 09-13-03

6
© 42582-0

© 05/2005 12/12 0312 3344 - 0128

 Cylinder head
TCD 2012 2V W 01-05-01

Removing and installing valves

Commercial available tools: – W 01-04-04
– Caliper gauge
– Assembly pliers. . . . . . . . . . . . . . . . 8024
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Support bracket . . . . . . . . . . . . .120 900
– Base plate. . . . . . . . . . . . . . . . . .120 910
– Assembly tool . . . . . . . . . . . . . . .121 410
– Assembly sleeves . . . . . . . . . . . .121 420

Removing valves
z Remove cylinder head.
 W 01-04-04
1
z Mount support bracket (1) on base plate (2).
z Mount cylinder head on support bracket.

2
© 42583-0

z Remove snap ring (1).

Danger!
Risk of injury! Snap ring springs off.

© 42584-0

© 05/2005 1/6 0312 3345 - 0128

 Cylinder head
W 01-05-01 TCD 2012 2V

z Remove thrust washer (1).

6
© 42585-0

z Install assembly lever (1).

z Press down the valve spring with the assembly lever
and remove both tapper collets (2).
z Remove valve spring plates, valve springs and 1
valves.
z Remove assembly lever.

© 42586-0

z Disassemble valve stem seal with assembly pliers.

© 42587-0

© 05/2005 2/6 0312 3345 - 0128

 Cylinder head
TCD 2012 2V W 01-05-01

z Clean cylinder head, check.

z Visually inspect the components.

6
© 42588-0

Installing valves
z Measure valve spring length with caliper gauge.
 P01 51
When the wear limit is reached the valve
spring must be replaced.

© 35856-2

z Oil the valve stem slightly.

z Insert valve, hold tight and place the assembly
sleeve (1) over the valve stem.
The valve keyway (2) must always be
covered by the assembly sleeve (1) before
installing the valve stem seal.
1

© 42589-0

© 05/2005 3/6 0312 3345 - 0128

 Cylinder head
W 01-05-01 TCD 2012 2V

z Push the new valve stem seal over the assembly

sleeve (arrow).

6
© 42590-0

z Remove assembly sleeve.

z Press in the valve stem seal with the assembly
tool (1) to the stop.

© 42591-0

z Insert the valve spring (1) and valve spring plate (2).

© 42592-0

© 05/2005 4/6 0312 3345 - 0128

 Cylinder head
TCD 2012 2V W 01-05-01

z Install the assembly lever.

z Press down the valve spring with the assembly lever
and insert both tapper collets (1).
Make sure the tapper collets fit correctly in
the valve keyway.

1
6
© 42593-0

z Remove assembly lever.

z Insert thrust washer (1).

© 42585-0

z Insert snap ring (1).

Make sure the snap ring fits correctly in the
groove.

© 42594-0

© 05/2005 5/6 0312 3345 - 0128

 Cylinder head
W 01-05-01 TCD 2012 2V

z Remove cylinder head from support bracket (1).

z Remove support bracket from base plate (2).
z Install cylinder head.
 W 01-04-04 1

6 2
© 42583-0

© 05/2005 6/6 0312 3345 - 0128

 Cylinder head
TCD 2012 2V W 01-05-04

Checking valves
Commercial available tools: – W 01-05-01
– Micrometer gauge
– Caliper gauge
Clean all valves.
When the wear limit is reached the valve
must be replaced.

Valve stem diameter

z Dismantle valves.
 W 01-05-01
z Measure the diameter of the valve stem with the mi-
crometer gauge.
 P01 31
P01 32

© 42182-1

Valve edge thickness

z Measure thickness of valve edge with caliper gauge.
 P01 35
P01 36

© 42183-1

© 05/2005 1/2 0312 3346 - 0128

 Cylinder head
W 01-05-04 TCD 2012 2V

Valve head diameter

z Measure the diameter of the valve head with the cal-
iper gauge.
 P01 37
P01 38
z Install valves.
 W 01-05-01

6
© 42184-1

© 05/2005 2/2 0312 3346 - 0128

 Cylinder head
TCD 2012 2V W 01-06-03

Checking valve guide

Commercial available tools: – W 01-05-01
– Magnetic measuring stand
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . .100 400 New valves are used for testing.
When the wear limit is reached the valve
guide must be replaced.

Checking the valve guide

z Dismantle valves.
 W 01-05-01
z Visually inspect valve guide for wear.
z Attach magnetic measuring stand and insert dial
gauge.
z Insert new valve.
z Apply stylus to the valve stem with pre-
tension (arrow) and set dial gauge to zero.

© 42595-0

Measuring valve stem clearance

z Move the end of the valve stem back and forth in di-
rection of arrow.
 P01 33
P01 34
The whole tilting distance must be taken
into consideration.

© 42597-0

© 05/2005 1/2 0312 3347 - 0128

 Cylinder head
W 01-06-03 TCD 2012 2V

z Remove magnetic measuring stand and dial gauge.

z Install valves.
 W 01-05-01

6
© 42596-0

© 05/2005 2/2 0312 3347 - 0128

 Cylinder head
TCD 2012 2V W 01-07-08

Checking valve lag

Commercial available tools: – W 01-04-04
– Depth-measuring
appliance
Special tools: Attention!
– Support bracket . . . . . . . . . . . . .120 900 If the wear limit is reached, the valve seat
– Base plate. . . . . . . . . . . . . . . . . .120 910 insert and/or the valve must be changed,
either individually or both together.

Checking the valve lag

z Remove cylinder head.
 W 01-04-04
1
z Mount support bracket(1) on base plate (2).
z Mount cylinder head on support bracket.

© 42601-0

z Measure the valve lag with the depth measuring ap-

pliance from the valve head to the cylinder head seal-
ing surface.
 P01 45
P01 46

© 42598-0

©05/2005 1/2 0312 3348 - 0128

 Cylinder head
W 01-07-08 TCD 2012 2V

z Remove cylinder head from support bracket (1).

z Remove support bracket from base plate (2).
z Install cylinder head.
 W 01-04-04 1

6 2

© 42601-0

©05/2005 2/2 0312 3348 - 0128

 Drive system
TCD 2012 2V W 02-01-07

Checking the crankshaft

Commercial available tools: – W 02-04-01
– Magnetic measuring stand
– Micrometer gauge
– Internal measuring device The rework steps are labelled on the out-
– Prisms side contour of the flywheel-side cranks-
– Hardness tester haft web.
Special tools: H = ground main bearing pin
– Meter. . . . . . . . . . . . . . . . . . . . . .100 400 P = ground con rod bearing pin
If the crankshaft is worn, it is possible to
have it repaired in our Service Center.

Checking the bearing pin hardness

z Dismantle crankshaft.
 W 02-04-01
z Place crankshaft on prism.

© 42602-0

z Check bearing pins with hardness tester.

 P02 07
The measured value is to be converted
according to the table of the measuring
device.

© 30560-1

© 05/2005 1/4 0312 3349 - 0128

 Drive system
W 02-01-07 TCD 2012 2V

Diagram for measuring the bearing pins at

the points (1 and 2) in the levels (a and b).

6
© 36424-2

Checking the diameter of the main bearing

pins
z Measure main bearing pins with micrometer gauge.
 P02 03
P02 04
For measuring points, see diagram.

© 42603-0

Checking the diameter of the lifting jour-

nals
z Measure lifting journals with micrometer gauge
 P02 22
P02 23
For measuring points, see dirgram.

© 42604-0

© 05/2005 2/4 0312 3349 - 0128

 Drive system
TCD 2012 2V W 02-01-07

Checking the rotation

z Attach magnetic measuring stand and insert meter.
z Apply stylus to the main bearing pin with pre-
tension (arrow) and set meter to zero.
z Turn crankshaft evenly and check rotation.
 P02 26
z Remove magnetic measuring stand and meter.

6
© 42605-0

Measuring the fit bearing width

z Set micrometer gauge to 32 mm.
z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to zero.

© 35825-2

z Measure fit bearing width with internal measuring de-

vice between the contact surfaces of the wearing
rings.
z Note the measured value, dimension (a).
 P02 11
P02 12
The dimension (a) is required to determine
the axial bearing clearance.

© 42606-0

© 05/2005 3/4 0312 3349 - 0128

 Drive system
W 02-01-07 TCD 2012 2V

Checking the axial bearing clearance

z Place wearing ring halves on bearing caps (arrows).
z Measure width with micrometer gauge.
z Note the measured value, dimension (b).
The dimension (b) is required to determine
the axial bearing clearance.

6
© 35827-2

z Determine the axial bearing clearance.

 P02 34
Use appropriate wearing ring
halves (arrows).

 P02 35,
P02 36
Calculation example
Desired: Axial bearing clearance
Given:
Measured: (a) = 32.2 mm
(b) = 32.1 mm
Dimension (a) - Dimension (b)
Result: = 0.1 mm

© 35827-2

Visual inspection
z Visually inspect running surfaces (1) of the shaft
sealing rings and gear wheel (2).
1
z Install crankshaft.
1 2
 W 02-04-01

© 42607-0

© 05/2005 4/4 0312 3349 - 0128

 Drive system
TCD 2012 2V W 02-02-02

Renewing the crankshaft sealing ring

(flywheel side)
Commercial available tools: – W 12-06-01
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . .142 830

– Self-tapping screw
– Washer

Remove crankshaft sealing ring

z Remove flywheel.
 W 12-06-01
z Make a hole (approximately 3 mm Ø) in the crank-
shaft sealing ring with a pricker.
Attention!
Do not damage the gearcase cover and
crankshaft.

© 43645-0

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

© 42610-0

© 05/2005 1/4 0312 3350 - 0128

 Drive system
W 02-02-02 TCD 2012 2V

z Remove crankshaft sealing ring with suitable tool,

e.g. assembly lever.
z Visually inspect the running surface of the crankshaft
flange and gearcase.

6
© 42611-0

Installing the crankshaft sealing ring

z Fit guide sleeve (1) and tighten screws (2) slightly.
The holes in the guide sleeve must match
the threaded holes in the crankshaft flange.
1

© 42612-0

z Oil the sealing lip of the crankshaft sealing ring light-

ly.
z Place the crankshaft sealing ring carefully on the run-
ning surface.
The sealing lip must be facing the cranks-
haft.

© 42613-0

© 05/2005 2/4 0312 3350 - 0128

 Drive system
TCD 2012 2V W 02-02-02

z Mount spacing washers (1).

If the crankshaft flange has a run-in
groove, it is possible to mount the cranks-
haft sealing ring at three installation
depths:
- first-time installation = 2 washers
- 1st repair - installation step = 1 washer
- 2nd repair - installation step = 0 washers.

1 6
© 42614-0

z Fit assembly sleeve (1) and press down onto the

crankshaft sealing ring until it is touching.

© 42615-0

z Fit bearing (1) and tighten nut (2).

2
© 42616-0

© 05/2005 3/4 0312 3350 - 0128

 Drive system
W 02-02-02 TCD 2012 2V

z Screw on nut (arrow) until the assembly sleeve (1) is

touching.
The crankshaft sealing ring is now at its
pre-selected installation depth.

z Remove assembly tool. 1

z Assemble flywheel.
 W 12-06-01

6
© 42617-0

© 05/2005 4/4 0312 3350 - 0128

 Drive system
TCD 2012 2V W 02-02-04

Renewing the crankshaft sealing ring

(opposite side to flywheel)
Commercial available tools: – W 12-01-04
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . .142 670

– Self-tapping screw
– Washer

Removing the crankshaft sealing ring

z Remove torsional vibration damper.
 W 12-01-04
z Make a hole (approximately 3 mm Ø) in the crank-
shaft sealing ring using a pricker.
Attention!
Do not damage the front cover or cranks-
haft.

© 43643-0

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

© 42620-0

© 05/2005 1/6 0312 3351 - 0128

 Drive system
W 02-02-04 TCD 2012 2V

z Remove crankshaft sealing ring with suitable tool,

e.g. assembly lever.
z Visually inspect the running surface of the crankshaft
flange and rear cover.

6
© 42621-0

Install crankshaft sealing ring

z Pull out clamping bushing (1).

© 42622-0

z Fit guide sleeve (1) onto crankshaft.

The clamping bushing (2) must grip in the
hole (3).
1

© 42623-0

© 05/2005 2/6 0312 3351 - 0128

 Drive system
TCD 2012 2V W 02-02-04

z Tighten screws (1) lightly.

6
© 42624-0

z Oil the sealing lip of the crankshaft sealing ring light-

ly.
z Place the crankshaft sealing ring carefully on the run-
ning surface.
The sealing lip must be facing the cranks-
haft.

© 42625-0

z Mount spacing washers (1).

If the crankshaft flange has a run-in
groove, it is possible to mount the cranks-
haft sealing ring at three installation
depths:
- first-time installation = 2 washers
- 1st repair - installation step = 1 washer
- 2nd repair - installation step = 0 washers.

1
© 42626-0

© 05/2005 3/6 0312 3351 - 0128

 Drive system
W 02-02-04 TCD 2012 2V

z Fit assembly sleeve (1) and press down onto the

crankshaft sealing ring until it is touching.

6 1

© 42627-0

z Fit bearing (1) and tighten nut (2).

© 42628-0

z Screw on nut (arrow) until the assembly sleeve (1) is

touching.
The crankshaft sealing ring is now at its
pre-selected installation depth.
1
z Remove assembly tool.

© 42629-0

© 05/2005 4/6 0312 3351 - 0128

 Drive system
TCD 2012 2V W 02-02-04

z Knock in the clamping bushing (1) to the stop.

z Install torsional vibration damper.
 W 12-01-04

6
© 42622-0

© 05/2005 5/6 0312 3351 - 0128

 Drive system
W 02-02-04 TCD 2012 2V

© 05/2005 6/6 0312 3351 - 0128

 Drive system
TCD 2012 2V W 02-03-01

Checking the con rod

Commercial available tools: Attention!
– Micrometer gauge The alignment of the con rod and con rod
– Internal precision measu- bearing cover must be maintained. If the
ring device con rod and the con rod bearing cover are
– Con rod test device installed the wrong way around, the con
Special tools: rod will be useless!
– Dial gauge. . . . . . . . . . . . . . . . . .100 400 Do not damage the break areas of the con
rod and the con rod bearing cover!

The con rod is removed and the piston dis-

mantled.

Checking small end bush

z Prepare internal precision measuring device
– Mount probe bolt for the appropriate measuring
range in the internal precision measuring device.
– Mount dial gauge with approx. 1 mm pre-tension
in the internal precision measuring device.
– Set micrometer gauge to 39 mm.
– Balance the internal precision measuring device
between the test surfaces of the micrometer gauge
and set the dial gauge at the reversal point of the
pointer to zero.

© 34768-2

Diagram for measuring the piston bolt liner

at the points (a and b) in the
levels (1 and 2).

© 37239-1

© 05/2005 1/8 0312 3352 - 0128

 Drive system
W 02-03-01 TCD 2012 2V

z Insert internal precision measuring device in the

small end bush.
z Balance the internal precision measuring device at
the given measuring points and read off the meas-
ured value at the reversal point of the pointer.
 P02 43
Small end bush pressed in.
For measuring points, see diagram.

z 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

z Measure piston bolt with micrometer gauge.
 P02 61
z Note the measured value, dimension B.
The dimension B is required to determine
the piston bolt clearance.

© 35908-2

Determining piston bolt clearance

z 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).
 P02 45
Calculation example
Desired: Piston bolt clearance
Given:
Measured: (A) = 40.045 mm
(B) = 40.006 mm
Dimension (A) - Dimension (B)
Result: = 0.039 mm

© 05/2005 2/8 0312 3352 - 0128

 Drive system
TCD 2012 2V W 02-03-01

Checking the con rod bearing bore

z Mount con rod bearing cover on con rod.
The identification numbers (1) on the con
rod and the con rod bearing cover must be
identical and opposite to each other when 1
assembled.

Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the
con rod and the con rod bearing cover are
installed the wrong way around, the con
rod will be useless!Do not damage the
break areas of the con rod and the con rod
bearing cover!
6
© 42630-0

z Tighten screws.
 A02 020

© 42632-0

z Prepare internal precision measuring device

– Mount probe bolt for the appropriate measuring
range in the internal precision measuring device.
– Mount dial gauge with approx. 1 mm pre-tension
in the internal precision measuring device.
– Set micrometer gauge to 73 mm.
– Balance the internal precision measuring device
between the test surfaces of the micrometer gauge
and set the dial gauge at the reversal point of the
pointer to zero.

© 36094-2

© 05/2005 3/8 0312 3352 - 0128

 Drive system
W 02-03-01 TCD 2012 2V

Diagram for measuring the con rod bearing

bore at the points (a and b) in the
levels (1 and 2).

6
© 37239-1

z Insert internal precision measuring device in the con

rod bearing bore.
z Measure con rod bearing bore with internal precision
measuring device.
z Balance the internal precision measuring device at
the given measuring points and read off the meas-
ured value at the reversal point of the pointer.
 P02 55
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.

© 42633-0

z Unscrew screws and remove con rod bearing cover

© 43059-0

© 05/2005 4/8 0312 3352 - 0128

 Drive system
TCD 2012 2V W 02-03-01

Checking internal diameter of the con rod

bearing shells
z Insert con rod bearing shell in the con rod. 2

Check that the bearing shells are correctly

assigned.
The anti-rotation lock (1) must lock in the
groove (2).

Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the 1
con rod and the con rod bearing cover are
installed the wrong way around, the con
rod will be useless!
Do not damage the break areas of the con 6
rod and the con rod bearing cover!
© 42635-0

z Insert con rod bearing shell in the respective con rod

bearing cover.
The anti-rotation lock (1) must lock in 2
groove (2).

© 42636-0

z Mount con rod bearing cover on con rod.

The identification numbers (1) on the con
rod and the con rod bearing cover must be
identical and opposite to each other when
assembled.
1

© 42631-0

© 05/2005 5/8 0312 3352 - 0128

 Drive system
W 02-03-01 TCD 2012 2V

z Tighten screws.
 A02 020

6
© 43012-0

z Prepare internal precision measuring device

– Mount probe bolt for the appropriate measuring
range in the internal precision measuring device.
– Mount dial gauge with approx. 1 mm pre-tension
in the internal precision measuring device.
– Set micrometer gauge to 70 mm.
– Balance the internal precision measuring device
between the test surfaces of the micrometer gauge
and set the dial gauge at the reversal point of the
pointer to zero.

© 36094-2

Diagram for measuring the inside diameter

of the con rod bearing shells at the
points (a and b) in the levels (1 and 2).

© 37239-1

© 05/2005 6/8 0312 3352 - 0128

 Drive system
TCD 2012 2V W 02-03-01

z Measure inside diameter of the con rod bearing

shells with internal precision measuring device.
z Insert the internal precision measuring device be-
tween con rod bearing shells.

6
© 42634-0

z Balance the internal precision measuring device at

the given measuring points and read off the meas-
ured value at the reversal point of the pointer.
 P02 52
If the values are up to a max. 0.015 mm
above the bearing tolerances, the con rod
can remain in use.
The con rod must be changed if the limit
has been reached.
z Note the measured value, dimension (C).
The dimension (C) is required to determine
the con rod bearing clearance.

© 42634-0

Determining con rod bearing clearance

z The con rod bearing clearance is given by the differ-
ence of the inside diameter of the con rod bearing
shells (C) and the diameter of the lifting journal (D).
 P02 56
Calculation example
Desired: Con rod bearing clearance
Given:
Measured: (C) = 70.026 mm
(D) = 69.994 mm
Dimension (A) - Dimension (B)
Result: = 0.032 mm

© 05/2005 7/8 0312 3352 - 0128

 Drive system
W 02-03-01 TCD 2012 2V

z Unscrew screws and remove con rod bearing cover.

6
© 43058-0

Checking the con rod

Check con rod without bearing shells on
the con rod test device.

Attention!
Aligning the con rod is not permissible.

z Check that the con rod is parallel.

Permissible deviation (a) = max. 0.04 mm
at a distance of (X) = 100 mm.

© 35880-2

z Check the angle of the con rod.

Permissible deviation
(A) to (B) = max. 0.04 mm at a distance of
(X) = 100 mm.

© 35881-2

© 05/2005 8/8 0312 3352 - 0128

 Drive system
TCD 2012 2V W 02-04-01

Removing and installing the crankshaft

Commercial available tools – W 02-01-07
– W 03-08-01
Special tools: – W 04-04-09
– Turning gear . . . . . . . . . . . . . . . .100 330
Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the
con rod and the con rod bearing cover are
installed the wrong way around, the con
rod will be useless!
Do not damage the break areas of the con
rod and the con rod bearing cover!

Removing crankshaft
z Remove gearcase (flywheel side).
 W 04-04-09
z Remove front cover (opposite side to flywheel).
 W 03-08-01

© 42647-0

z Pull out oil dipstick (1).

© 42798-0

© 05/2005 1/12 0312 3353 - 0128

 Drive system
W 02-04-01 TCD 2012 2V

Removing all con rod bearing covers

z Tighten screws (arrows) of the torsional vibration
damper.

6
© 42648-0

z Place lifting journal of the respective cylinder at bot-

tom dead centre (BDC).
Attention!
Do not jam the con rods when turning the
crankshaft.

Use the turning gear 100 330 to turn the

crankshaft.

© 42649-0

z Unscrew screws (1), remove con rod bearing

cover (2) with con rod and bearing shell.
Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the 2
con rod and the con rod bearing cover are
installed the wrong way around, the con
rod will be useless!
Do not damage the break areas of the con
rod and the con rod bearing cover!
1
Put down the components in order of
assembly, note order of cylinders.

© 42650-0

© 05/2005 2/12 0312 3353 - 0128

 Drive system
TCD 2012 2V W 02-04-01

z Make a mark (1) on the camshaft gear wheel for as-

sistance. 2
Your mark must be on a line between the
marking (2) and the middle (3) of the
camshaft.

6
© 42651-0

z 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 1
in line.

Attention!
Do not jam the con rods when turning the
crankshaft.
2

© 42652-0

Remove all main bearing covers

z Unscrew all screws (1).

© 42653-0

© 05/2005 3/12 0312 3353 - 0128

 Drive system
W 02-04-01 TCD 2012 2V

z Remove the bearing cap (1), bearing shell and both

wearing ring halves (arrows).
z Remove all main bearing covers (2) and bearing
shells.
Put down the components in the order of
assembly, note order of cylinders. 1

6
© 42654-0

z Press the con rods carefully out of the lifting journal.

Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the
con rod and the con rod bearing cover are
installedthe wrong way around, the con rod
will be useless!
Do not damage the break areas (arrows) of
the con rod and the con rod bearing cover!

© 42655-0

z Remove crankshaft.

© 42656-0

© 05/2005 4/12 0312 3353 - 0128

 Drive system
TCD 2012 2V W 02-04-01

z Remove both wearing ring halves (arrows), all main

bearings (1) and all con rod bearing shells (2).
Put down the components in the order of
assembly, note order of cylinders.
1
z Check components for visible signs of wear.
z Check axial bearing clearance of crankshaft.
 W 02-01-07
2

6
© 43013-0

Installing crankshaft
z Insert the main bearing shells in the crankcase.
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).

© 42658-0

z Insert main bearing shell in the respective main bear-

ing cover. 1
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).

© 37043-2

© 05/2005 5/12 0312 3353 - 0128

 Drive system
W 02-04-01 TCD 2012 2V

z Insert con rod bearing shell in the con rod.

Note the assignment of the bearing shells.
1
The anti-rotation lock (1) must lock in
groove (2).

6
© 42659-0

z Insert con rod bearing shell in the respective con rod

bearing cover.
Note the assignment of the bearing shell. 2
The anti-rotation lock (1) must lock in
groove (2).

© 42636-0

Make sure the clamping bushes (arrows)

are in place.

© 42660-0

© 05/2005 6/12 0312 3353 - 0128

 Drive system
TCD 2012 2V W 02-04-01

z Position camshaft.
The bore (1) must be facing the cylinder
head.

z Lightly oil all bearing surfaces on the bearing pin and

bearing shells.

1 6
© 42661-0

z Insert the crankshaft carefully in the crankcase.

Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the
con rod and the con rod bearing cover are
installed the wrong way around, the con
rod will be useless!
Do not damage the break areas of the con
rod and the con rod bearing cover!

© 43056-0

z Set the crankshaft in line with the camshaft.

The marking (1) on the crankshaft flange
must be in line with your mark (2).

© 42652-0

© 05/2005 7/12 0312 3353 - 0128

 Drive system
W 02-04-01 TCD 2012 2V

z Insert both wearing ring halves, without guide lugs,

between the crankshaft and the crankcase (arrows).
The oil grooves (1) must face the cranks-
haft web face (2).

6
© 42662-0

z Fix both wearing ring halves with guide lug (arrow) to

the bearing cap with a little grease.
The bearing cap has the
identification number 2.
The oil grooves (1) must face the cranks-
haft web face.

© 42663-0

Install all main bearing covers

z Insert bearing caps (1) and main bearing covers (2)
according to their numbering.
Note the assignment and installation posi-
tion:
Insert main bearing cover with number 1 1
on the flywheel side.
The gate (arrow) on the bearing covers
must face the manifold side. 7 6 5 4 3 2 1

© 42664-0

© 05/2005 8/12 0312 3353 - 0128

 Drive system
TCD 2012 2V W 02-04-01

z Tighten all screws (1) of the main and bearing caps.

 A02 010
Attention!
Screws can be used a max. 3 times with
written proof, otherwise renew every time
they are loosened.

6
© 42665-0

Install all con rod bearing covers

z Pull con rods carefully on to the lifting journal.
z Place lifting journal of the respective cylinder at bot-
tom dead centre (BDC).

© 42800-0

z Mount con rod bearing cover.

Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the
con rod and the con rod bearing cover are
installed the wrong way around, the con
rod will be useless! 1
Do not damage the break areas of the con
rod and the con rod bearing cover!
Do not jam the con rods when turning the
crankshaft.

The arrow (1) on the con rod bearing cover

must face the front cover.

© 43032-0

© 05/2005 9/12 0312 3353 - 0128

 Drive system
W 02-04-01 TCD 2012 2V

Note the assignment of the con rod bearing

cover.
The identification numbers (1) on the con
rod and the con rod bearing cover must be
identical and opposite to each other when
assembled.

6
© 42678-0

z Tighten new screws.

 A02 020
Attention!
Renew screws every time they are loo-
sened.

© 42667-0

z Unscrew screws (arrows) of the torsional vibration

damper.

© 42648-0

© 05/2005 10/12 0312 3353 - 0128

 Drive system
TCD 2012 2V W 02-04-01

z Insert oil dipstick (1).

1
6
© 42798-0

z Mount front cover (opposite side to flywheel).

 W 03-08-01
z Install gearcase (flywheel side).
 W 04-04-09

© 42647-0

© 05/2005 11/12 0312 3353 - 0128

 Drive system
W 02-04-01 TCD 2012 2V

© 05/2005 12/12 0312 3353 - 0128

 Drive system
TCD 2012 2V W 02-09-03

Removing and installing piston and con rod

Commercial available tools: – W 01-04-04
– Rotation angle disc . . . . . . . . . . . . . 8190 – W 02-10-03
Special tools: – W 08-04-06
– Piston ring compressor . . . . . . . .130 670
Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the
con rod and the con rod bearing cover are
installed the wrong way around, the con
rod will be useless!
Do not damage the break areas of the con
rod and the con rod bearing cover!

Collect leaking operating substances in 6

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

Removing the piston and con rod

z Remove cylinder head.
 W 01-04-04
z Remove oil suction pipe.
 W 08-04-06

© 42668-0

© 05/2005 1/8 0312 3354 - 0128

 Drive system
W 02-09-03 TCD 2012 2V

z Pull out oil dipstick (1).

6 1
© 42799-0

Remove con rod bearing cover

z Set lifting journal at bottom dead centre (BDC).
z Unscrew screws (1), remove con rod bearing
cover (2) with bearing shell.
 P01 63
Attention! 2
Do not place the con rod bearing cover on
the break surface. 1
Lay out the components in the order of
assembly, note order of cylinders.

© 42669-0

z Press out the piston with con rod.

 P01 63
Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the
con rod and the con rod bearing cover are
installed the wrong way around, the con
rod will be useless!
Do not damage the break areas of the con
rod and the con rod bearing cover!

Lay out the components in the order of

assembly, note cylinder assignment.

© 42670-0

© 05/2005 2/8 0312 3354 - 0128

 Drive system
TCD 2012 2V W 02-09-03

z Remove con rod bearing shells (1).

z Check components for visible signs of wear.

1 6
© 42671-0

Disassembling piston from con rod

z Remove circlip from both sides and press out the pis-
ton bolt.
z Check components for visible signs of wear.

© 42672-0

Completing con rod and piston

z Insert a circlip.
Make sure the circlip fits properly in the
groove.

© 42673-0

© 05/2005 3/8 0312 3354 - 0128

 Drive system
W 02-09-03 TCD 2012 2V

z Insert con rod in piston.

The symbol flywheel/crankshaft (1) on the
piston base must face to the right and the
identificatiion number (2) on the con rod
2
must face upwards.

6
© 42674-0

z Oil the piston bolt lightly and press in.

z Insert second snap ring.
Make sure that the circlip fits correctly in
the groove.

© 42675-0

Installing the piston and con rod

z Insert con rod bearing shell in the con rod.
2
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).

© 42635-0

© 05/2005 4/8 0312 3354 - 0128

 Drive system
TCD 2012 2V W 02-09-03

z Insert con rod bearing shell in the respective con rod

bearing cover.
The anti-rotation lock (1) must lock in 2
groove (2).

6
© 42636-0

z Arrange the piston ring joints with an offset of about

120° to each other.
z Check piston rings and piston ring grooves.
 W 02-10-03
z

© 42380-1

z Lightly oil cylinder running surface, piston, piston

rings and lifting journal.
z Clamp piston rings with piston ring compressor (1).
Do not turn the piston rings any further.

© 42676-0

© 05/2005 5/8 0312 3354 - 0128

 Drive system
W 02-09-03 TCD 2012 2V

z Set lifting journal at bottom dead centre (BDC).

z Push piston with con rod into the cylinder.
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 fly-
wheel.
The piston ring compressor must lie flat on
the crankcase.

6
© 42677-0

z Press the con rod carefully against the lifting journal.

Attention!
Do not jam the con rod with the crankshaft.

© 43015-0

Installing the con rod bearing cover.

z Mount con rod bearing cover.
Attention!
The alignment of the con rod and con rod
bearing cover must be maintained. If the
con rod and the con rod bearing cover are 1
installed the wrong way around, the con
rod will be useless!
Do not damage the break areas of the con
rod and the con rod bearing cover!

The arrow (1) on the con rod bearing cover

must face the front cover.

© 43032-0

© 05/2005 6/8 0312 3354 - 0128

 Drive system
TCD 2012 2V W 02-09-03

Note the assignment of the con rod bearing

cover.
The identification numbers (1) on the con
rod and the con rod bearing cover must be
identical and opposite to each other when
assembled.

6
© 42678-0

z Tighten new screws.

 A02 020
Attention!
Renew screws every time they are loose-
ned.

© 42679-0

z Insert oil dipstick (1).

1
© 42799-0

© 05/2005 7/8 0312 3354 - 0128

 Drive system
W 02-09-03 TCD 2012 2V

z Install oil suction pipe.

 W 08-04-06
z Install cylinder head.
 W 01-04-04

6
© 43014-0

© 05/2005 8/8 0312 3354 - 0128

 Drive system
TCD 2012 2V W 02-09-07

Checking the piston

Commercial available tools: – W 02-09-03
– Micrometer gauge
– Internal precision measu-
ring device When the wear limit is reached the pistons
Special tools: must be replaced.
– Dial gauge. . . . . . . . . . . . . . . . . .100 400

Checking the piston bolt bore

z Disassemble piston from con rod.
 W 02-09-03

© 42229-1

z Prepare internal precision measuring device

– Mount probe bolt for the appropriate measuring
range in the internal precision measuring device.
– Mount dial gauge with approx. 1 mm pre-tension
in the internal precision measuring device.
– Set micrometer gauge to 39 mm.
– Balance the internal precision measuring device
between the test surfaces of the micrometer gauge
and set the dial gauge at the reversal point of the
pointer to zero.

© 34768-2

© 05/2005 1/4 0312 3355 - 0128

 Drive system
W 02-09-07 TCD 2012 2V

Diagram for measuring the piston bolt bore

at the points (a and b) in the
levels (1 and 2).

6
© 37239-1

z Measure piston bolt bore with internal precision

measuring device. Insert internal precision measur-
ing device in the piston bolt bore.
z Balance the internal precision measuring device at
the given measuring points and read off the meas-
ured value at the reversal point of the pointer.
 P02 78
Measuring points, see diagram.

© 36484-2

Checking the piston diameter

Diagram for measuring the piston diameter
at the measuring points (1, 2 und 3), trans-
verse to the piston bolt bore.

© 37244-1

© 05/2005 2/4 0312 3355 - 0128

 Drive system
TCD 2012 2V W 02-09-07

z Measure piston diameter with micrometer gauge.

 P02 71
P02 72
P02 73
Measuring points, see diagram.

z Complete con rod with piston.

 W 02-09-03

6
© 36485-2

© 05/2005 3/4 0312 3355 - 0128

 Drive system
W 02-09-07 TCD 2012 2V

© 05/2005 4/4 0312 3355 - 0128

 Drive system
TCD 2012 2V W 02-10-03

Checking piston rings and piston ring grooves

Commercial available tools: – W 02-09-03
– Feeler gauges
Special tools:
– Universal piston ring pliers . . . . .130 300
– Trapezoidal groove wear
gauge . . . . . . . . . . . . . . . . . . . . .130 440

Checking the piston rings and piston ring

grooves
z Disassemble piston from con rod.
 W 02-09-03
z Set universal piston ring pliers to the piston diameter.
 P02 73
z Remove piston rings with universal piston ring pliers.

© 42323-1

z Clean and visually inspect the pistons and ring

grooves.

© 42322-1

© 05/2005 1/4 0312 3356 - 0128

 Drive system
W 02-10-03 TCD 2012 2V

z Measure piston ring trapezoidal groove for first piston

ring with trapezoidal groove wear gauge.

6
© 33866-3

If there is a gap "S" between the trapezoi-

dal groove wear gauge and piston, the
piston can be used again. S

© 33867-3

If the trapezoidal groove wear gauge is

touching the piston (arrow), the piston
must be changed.

© 33868-3

© 05/2005 2/4 0312 3356 - 0128

 Drive system
TCD 2012 2V W 02-10-03

Checking the piston ring joint clearance

z Insert the piston ring (1) in the cylinder.
Align the piston ring in the cylinder by
pushing the piston.

6
© 42637-0

z Measure the piston ring joint clearance with a feeler

gauge.
 P02 84
P02 85
P02 86
When the wear limit is reached the piston
ring must be replaced.

© 42638-0

z Install piston rings.

Order and position of the piston rings as 1
seen from the piston base.
- Double-sided keystone ring (1)
- Taper-faced ring (2) 2
- Bevelland-edge oil control ring with coiled
spring expander (3)
3
For piston rings (1 and 2), the label Top
must face the combustion chamber.

© 42319-1

© 05/2005 3/4 0312 3356 - 0128

 Drive system
W 02-10-03 TCD 2012 2V

z Install piston rings with universal piston ring pliers.

Set spring joint of the bevelland-edge oil
control ring at 180° to the ring joint.

6
© 42318-1

Checking the piston ring axial clearance

z Measure the piston ring axial clearance in the second
and third piston ring groove with a feeler gauge.
 P02 87
P02 88
P02 89
Carry out measurement with new piston
rings.
When the wear limit is reached the pistons
must be replaced.
z Complete con rod with piston.
 W 02-09-03

© 42317-1

© 05/2005 4/4 0312 3356 - 0128

 Drive system
TCD 2012 2V W 02-15-01

Removing and installing the piston cooling nozzles

Commercial available tools – W 02-04-01

Removing piston cooling nozzles

z Dismantle crankshaft.
 W 02-04-01
z Press out piston cooling nozzle (1) with a suitable
tool (2).
z Visually inspect the components.
1

© 42599-0

Installing the piston cooling nozzles

z Clean the bores for the piston cooling nozzles in the
crankcase.
z Press in new piston cooling nozzle (1) with a suitable
tool (mandrel) to the stop.
z Install crankshaft.
 W 02-04-01
1

© 42600-0

© 05/2005 1/2 0312 3357 - 0128

 Drive system
W 02-15-01 TCD 2012 2V

© 05/2005 2/2 0312 3357 - 0128

 Crankcase
TCD 2012 2V W 03-01-11

Removing and installing the crankcase bleeding

Commercial available tools

Removing the crankcase bleeding

z Unscrew screws (1) and remove crankcase
bleeding (2).
2

© 42680-0

z Loosen hose clip (1), pull off oil return line (2) from
the bleeding channel.

© 42681-0

© 05/2005 1/8 0312 3358 - 0128

 Crankcase
W 03-01-11 TCD 2012 2V

z Unscrew screws (1), remove bleeding channel (2)

and gasket.

6
© 42682-0

Disassembling the crankcase bleeding

z Unscrew screws (1) and remove top part of
housing (2). 2

© 42683-0

z Remove insert (1).

© 42684-0

© 05/2005 2/8 0312 3358 - 0128

 Crankcase
TCD 2012 2V W 03-01-11

z Uncip all retainer clips (arrow) and remove cover (1).

1

6
© 42685-0

z Remove diaphragms (1) and springs.

z Clean components and check for visible signs of
wear.

© 42686-0

Assembling the crankcase bleeding

z Insert diaphragms and springs.
Note installation position of the dia-
phragms.

© 42687-0

© 05/2005 3/8 0312 3358 - 0128

 Crankcase
W 03-01-11 TCD 2012 2V

z Clip on the cover.

The outer edge of the diaphragm must grip
into the groove in the housing all the way
round when pressing on the cover.
Pay attention to correct fit of the retainer
clips.

6
© 42688-0

z Pull new round sealing ring (arrow) onto the top part
of the housing.
z Oil round sealing ring lightly

© 42689-0

z Pull new round sealing ring (arrow) onto insert.

z Oil round sealing ring lightly

© 42690-0

© 05/2005 4/8 0312 3358 - 0128

 Crankcase
TCD 2012 2V W 03-01-11

z Push insert into bottom part of housing.

The arrows (1) must face the threaded
sleeves.
The symbol flywheel/crankshaft (2) must
face the flywheel when mounting the
crankcase bleeding. 2

6
© 42691-0

z Insert the top part of the housing and tighten the

screws.
The hose connection (1) must face the
fastening flange.

© 42692-0

Installing the crankcase bleeding

z Clean the sealing surface on the bleeding channel
and cylinder head cover.
z Insert new gasket (arrow).

© 42693-0

© 05/2005 5/8 0312 3358 - 0128

 Crankcase
W 03-01-11 TCD 2012 2V

z Mount bleeding channel and tighten screws.

Note the different screw lengths:
Screw M8 x 25 mm (1)
1
Screw M8 x 20 mm (2)

6
© 42694-0

z Plug the oil return line (2) to the bleeding channel and
fix the hose clip (1).

© 42681-0

z Clean the sealing surface on the crankcase bleeding

and bleeding channel.
z Insert new gasket (arrow).

© 42695-0

© 05/2005 6/8 0312 3358 - 0128

 Crankcase
TCD 2012 2V W 03-01-11

z Mount crankcase bleeding (2) and tighten screws

(1).
 A03 060
2

6
© 42680-0

© 05/2005 7/8 0312 3358 - 0128

 Crankcase
W 03-01-11 TCD 2012 2V

© 05/2005 8/8 0312 3358 - 0128

 Crankcase
TCD 2012 2V W 03-03-01

Checking the cylinder

Commercial available tools: – W 02-09-03
– Micrometer gauge
– Internal precision measu-
ring device The crankshaft bearing cover must be
Special tools: mounted properly for measuring the cylin-
– Meter. . . . . . . . . . . . . . . . . . . . . .100 400 ders.
If the limit of wear is reached, it is possible
to rework the crankcase for further
use.Use pistons and piston rings according
to the repair stage.

Checking the cylinders

z Remove piston and con rod.
 W 02-09-03
z Check cylinders for visible signs of wear.

© 42696-0

Check the cylinder running surface

z Prepare internal precision measuring device
– Mount probe bolt for the appropriate measuring
range in the internal precision measuring device.
– Mount meter with approx. 1 mm pre-tension in the
internal precision measuring device.
– Set micrometer gauge to 98 mm.
– Balance the internal precision measuring device
between the test surfaces of the micrometer gauge
and set the meter at the reversal point of the point-
er tozero.

© 36094-2

© 05/2005 1/2 0312 3359 - 0128

 Crankcase
W 03-03-01 TCD 2012 2V

Schematic representation for measuring

the cylinder running surface at the
points (a and b) in the levels (1 and 2).

a b
1

a b
2

a b
3

6
© 39100-1

z Insert the internal precision measuring device and

measure the cylinder.
z Balance the internal precision measuring device at
the given measuring points and read off the meas-
ured value at the reversal point of the pointer.
 P03 31
Measuring points, see schematic represen-
tation.

z Install piston and con rod.

 W 02-09-03

© 42697-0

© 05/2005 2/2 0312 3359 - 0128

 Crankcase
TCD 2012 2V W 03-08-01

Removing and installing the front cover

(opposite side to flywheel)
Commercial available tools – W 02-02-04
– W 08-04-06
– W 12-01-04
– Sealant DEUTZ DW 59

Removing the front cover

z Remove torsional vibration damper.
1
 W 12-01-04
z Unscrew screw (2) and pull the speed
governor (crankshaft) (1) out of the holder.
2
z Remove oil suction pipe.
 W 08-04-06

© 42994-0

z Unscrew screws (arrows) and remove front cover.

© 42995-0

© 05/2005 1/6 0312 3360 - 0128

 Crankcase
W 03-08-01 TCD 2012 2V

z Visually inspect the components .

6
© 42996-0

Installing the front cover

z Knock out crankshaft sealing ring (1).
Attention!
Do not damage the sealing surface when
knocking out.
z Clean the sealing surfaces on the front cover and
crankcase.

© 42997-0

z Make sure the clamping sleeve (1) is in place.

z Pull the cable (2) forward slightly.

2
© 42998-0

© 05/2005 2/6 0312 3360 - 0128

 Crankcase
TCD 2012 2V W 03-08-01

z Fix the new gasket to the crankcase with a little

grease.
z Oil the oil pump rotors in the front cover lightly.

6
© 42999-0

z Position the inner rotor to 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.

© 43000-0

z Mount the front cover and tighten the screws.

Attention!
Do not trap the cable (1) when mounting
the front cover.

Do not tighten screws.

1
© 43001-0

© 05/2005 3/6 0312 3360 - 0128

 Crankcase
W 03-08-01 TCD 2012 2V

z Turn engine 180°.

The oil tray sealing surface on the crank-
case must face downwards.

z Press up front cover and align flush with the oil tray
sealing surface (arrows).

6
© 43002-0

z Tighten the screws alternately or in the tightening or-

der.
 A03 020

© 36521-1

z Turn engine 180°.

z Lay the cable (arrow) between the front cover and
the fan console.

© 43003-0

© 05/2005 4/6 0312 3360 - 0128

 Crankcase
TCD 2012 2V W 03-08-01

z Cut off overhanging gasket(arrows) flush with the

sealing surface of the oil tray.
z Install oil suction pipe.
 W 08-04-06

6
© 43004-0

z Insert speed governor (crankshaft) (1) and tighten

screw (2).
 A05 011 1
Clean the threads of the screw and hole.
Insert screw with sealant.
2

© 42994-0

z Install crankshaft sealing ring (flywheel side).

 W 02-02-04
z Install torsional vibration damper.
 W 12-01-04

© 43038-0

© 05/2005 5/6 0312 3360 - 0128

 Crankcase
W 03-08-01 TCD 2012 2V

© 05/2005 6/6 0312 3360 - 0128

 Crankcase
TCD 2012 2V W 03-09-04

Removing and installing the connection housing

Commercial available tools:
– Socket wrench set . . . . . . . . . . . . . 8113
– Socket wrench set . . . . . . . . . . . . . 8114

Removing the connection housing

z Unscrew screws (arrows) and remove cover
plate (1).

© 42698-0

z Unscrew screws (arrows) and remove connection

housing.
Use socket wrench sets.

z Visually inspect the components .

© 42699-0

© 05/2005 1/4 0312 3361 - 0128

 Crankcase
W 03-09-04 TCD 2012 2V

Installing the connection housing

z Clean contact surfaces on connection housing and
gearcase cover.

6
© 42700-0

z Make sure the clamping sleeves (arrows) are in

place.
z Mount the connection housing and center over the
clamping sleeves.

© 42701-0

z Turn on screws.
Note different screw length: 
Screws M12 x 150 mm (1) 
Screws M16 x 140 mm (arrows)

1 1

© 42702-0

© 05/2005 2/4 0312 3361 - 0128

 Crankcase
TCD 2012 2V W 03-09-04

z Tighten screws (1).

 A03 080
z Tighten screws (arrows) alternately.
 A03 080
Use socket wrench sets.

1
1

6
© 42703-0

z Press the cover plate onto the gearcase to the stop

and tighten the screws (arrows). 1

 A03 085
The hollow gorge (1) must face the lube oil
tray.

© 42704-0

© 05/2005 3/4 0312 3361 - 0128

 Crankcase
W 03-09-04 TCD 2012 2V

© 05/2005 4/4 0312 3361 - 0128

 Engine control
TCD 2012 2V W 04-04-09

Removing and installing the gearcase

Commercial available tools – W 02-02-02
– W 03-09-04
– W 08-04-07
– Packing compound – W 12-06-01
DEUTZ DW 67 – W 13-02-03

Remove gearcase
z Remove starter.
 W 13-02-03
z Unlock and disconnect the cable plug (1) of the im-
pulse transmitter (camshaft).
z Remove cable tie (arrow) and expose cable harness.

© 42720-0

z Unlock cable plug (1) and remove coolant tempera-

ture sensor.
z Remove cable tie (arrow) and expose cable harness.

© 42741-0

© 05/2005 1/10 0312 3362 - 0128

 Engine control
W 04-04-09 TCD 2012 2V

z Unscrew nut (1), pull central plug (2) out of holder.

z Remove connection housing.
 W 03-09-04
z Remove flywheel. 1

 W 12-06-01
z Remove lube oil tray.
 W 08-04-07
z Turn engine by 180°.

2
6
© 42723-0

z Unscrew screw (1) and remove impulse

transmitter (2).

© 42743-0

z Unscrew screw (1), remove cover (2) with oil filling

nozzles.

© 42744-0

© 05/2005 2/10 0312 3362 - 0128

 Engine control
TCD 2012 2V W 04-04-09

z Unscrew screws (1) and remove holder (2) and

spacing sleeves.

1
6
© 42745-0

z Unscrew screws (1) and remove cover (2).

1
2

© 42746-0

z Loosen hose clip (1), pull oil return line (2) off hose
nozzle.

© 42747-0

© 05/2005 3/10 0312 3362 - 0128

 Engine control
W 04-04-09 TCD 2012 2V

z Unscrew screws (1).

6
1
© 42742-0

z Unscrew screws (1) and remove gearcase cover.

1
1
© 42748-0

Installing gearcase cover

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

© 42750-0

© 05/2005 4/10 0312 3362 - 0128

 Engine control
TCD 2012 2V W 04-04-09

z Clean the sealing surfaces on the gearcase cover

and crankcase.
z Apply packing compound to the gearcase cover (ar-
rows).
Attention!
Assembly of the gearcase must be com-
pleted within a maximum of 1 hour after
applying the packing compound.

The thickness of the sealing bead must be

about 1.4 mm.

6
© 42525-0

z Mount the gearcase cover and fasten the screws (1).

Do not move the packing compound when
mounting the gearcase cover. 1
Do not tighten screws.

1
1
© 42751-0

z Fasten screws.
Note different screw length:
- screws M8 x 45 mm (1) 1
- screws M8 x 35 mm (2).
Do not tighten screws.

© 42752-0

© 05/2005 5/10 0312 3362 - 0128

 Engine control
W 04-04-09 TCD 2012 2V

z Press up gearcase cover and align flush with the oil

tray sealing surface (arrows).
The oil tray sealing surface on the crank-
case must face downwards.

6
© 42755-0

z Tighten the screws alternately in the tightening order.

 A03 092
5 6 7
4 1
3 2
12 8
13
11

10
14 9
15

© 36520-2

z Plug the oil return line (2) to the hose nozzle and fix
the hose clip (1).

© 42747-0

© 05/2005 6/10 0312 3362 - 0128

 Engine control
TCD 2012 2V W 04-04-09

z Clean the sealing surface on cover and gearcase.

z Fill the ring groove (arrow) in the gearcase cover with
packing compound.

6
© 42756-0

z Mount the cover (1) and tighten the screws (2).

Note the installation position of the
cover (1).
The holes (arrows) in the cover (1) must be
in line with the holes in the gearcase cover.

2
1

© 42754-0

z Mount holder with spacing sleeves (arrows) and

tighten screws (1).

© 42757-0

© 05/2005 7/10 0312 3362 - 0128

 Engine control
W 04-04-09 TCD 2012 2V

z Tighten screws (arrows) alternately.

 A03 092

6
© 42758-0

z Clean the sealing surface on cover and gearcase.

z Pull new O-ring (arrow) onto cover.
z Lightly oil O-ring.

© 42543-0

z Press in cover to stop and tighten screw (1).

 A04 022
1

© 42753-0

© 05/2005 8/10 0312 3362 - 0128

 Engine control
TCD 2012 2V W 04-04-09

z Clean the sealing surface on the impulse transmitter

and gearcase.
z Pull O-ring (arrow) onto impulse transmitter.
z Lightly oil O-ring.

6
© 42739-0

z Insert impulse transmitter (2) and tighten the

screw (1).
 A05 013

© 42743-0

z Install new crankshaft sealing ring (flywheel side).

 W 02-02-02
z Install flywheel.
 W 12-06-01
z Install connection housing.
 W 03-09-04
z Install starter.
 W 13-03-02

© 42759-0

© 05/2005 9/10 0312 3362 - 0128

 Engine control
W 04-04-09 TCD 2012 2V

z Plug central plug into the holder and tighten the nut.
The flattened side of the central plug and
the holder must be in line (arrow).

6
© 42736-0

z Plug cable plug (1) into coolant temperature sensor.

Ensure that the connection is perfect.

z Lay cable harness and fix with cable tie (arrow).

© 42741-0

z Plug together the cable plugs (1) of the impulse

transmitter (camshaft).
Ensure that the connection is perfect.

z Lay cable harness and fix with cable tie (arrow).

z Turn engine by 180°.
z Install lube oil tray.
 W 08-04-07

© 42720-0

© 05/2005 10/10 0312 3362 - 0128

 Engine control
TCD 2012 2V W 04-05-05

Remove and install camshaft

Commercial available tools: – W 01-02-02
– Hoisting equipment – W 02-04-01
– Carrying side – W 07-15-04
– W 07-15-05

Removing camshaft
z Remove high pressure pump and roller tappet (in-
stallation position A).
 W 07-15-04
z Remove high pressure pump and roller tappet (in-
stallation position B).
 W 07-15-05
z Remove rocker arms and rocker arm brackets.
 W 01-02-02
z Dismantle crankshaft.
 W 02-04-01

© 42705-0

z Fix cable harness to transport flange (arrow).

© 42706-0

© 05/2005 1/6 0312 3363 - 0128

 Engine control
W 04-05-05 TCD 2012 2V

z Fasten screws (1).

z Hang crankcase on suitable workshop crane.

1
1

6
© 42707-0

z Remove the clamping bracket (1) from the adapter

plates (2).

1
1

2
2

© 42708-0

z Push away the assembly block on the flywheel side.

© 42709-0

© 05/2005 2/6 0312 3363 - 0128

 Engine control
TCD 2012 2V W 04-05-05

z Press in all tappets.

z Pull out the camshaft (1) carefully to the flywheel
side.

6
© 42710-0

Removing tappets.
z Remove all tappets (arrow).
Put down the components in the order of
assembly, note order of cylinders.

z Visually inspect the components.

© 42711-0

Installing tappets
z Lightly oil all tappets (arrow) and insert.
Note assignment.

© 42711-0

© 05/2005 3/6 0312 3363 - 0128

 Engine control
W 04-05-05 TCD 2012 2V

Installing camshaft
z Lightly oil camshaft bearing and camshaft pin.
z Insert camshaft carefully.
The bore (1) must be facing the cylinder
head.

6
© 42712-0

z Push on and align the flywheel side assembly block.

z Remove the clamping bracket (1) from the adapter
plates (2).
 A00 002
1
1

2
2

© 00000-0

z Unhook the crankcase from the workshop crane and

unscrew the screws (1).

1
1

© 42707-0

© 05/2005 4/6 0312 3363 - 0128

 Engine control
TCD 2012 2V W 04-05-05

z Disconnect cable harness from transport

flange (arrow).

6
© 42706-0

z Install crankshaft.
 W 02-04-01
z Install rocker arms and rocker arm brackets.
 W 01-02-02
z Install high-pressure pump and roller tappet (installa-
tion position B).
 W 07-15-11
z Install high pressure pump and roller tappet (installa-
tion position A).
 W 07-15-04

© 42705-0

© 05/2005 5/6 0312 3363 - 0128

 Engine control
W 04-05-05 TCD 2012 2V

© 05/2005 6/6 0312 3363 - 0128

 Engine control
TCD 2012 2V W 04-05-06

Check camshaft
Commercial available tools: – W 04-05-05
– Micrometer gauge

Checking the camshaft

z Remove camshaft.
 W 04-05-05
z Visually inspect cams and bearing pins for wear, re-
new camshaft if necessary.

© 42713-0

Diagram for measuring the bearing pins at

the points (1 and 2) in the levels (a and b).

© 36424-2

© 05/2005 1/2 0312 3364 - 0128

 Engine control
W 04-05-06 TCD 2012 2V

Checking the diameter of the bearing pin

z Measure bearing pin with micrometer gauge.
 P04 31
Measuring points, see diagram.
When the limit value is reached the cams-
haft must be replaced.

6
© 42714-0

z Check camshaft gear wheel for visible signs of wear.

z Install camshaft.
 W 04-05-05

© 42713-0

© 05/2005 2/2 0312 3364 - 0128

 Speed control
TCD 2012 2V W 05-07-01

Remove and install speed governor

(crankshaft)
Commercial available tools

– Sealant DEUTZ DW 72

Removing impulse transmitter

z Unlock cable plug (1) and disconnect.
z Remove cable tie (2).

© 42715-0

z Remove cable tie (1) and expose cable.

© 42716-0

© 05/2005 1/4 0312 3365 - 0128

 Speed control
W 05-07-01 TCD 2012 2V

z Unscrew screw (1) and remove impulse

transmitter (2).

2
1

6
© 42717-0

z Insert impulse transmitter (2) and tighten the

screw (1).
 A05 011
Clean the threads of the screw and hole.
Insert screw with sealant DEUTZ DW 72.

2
1

© 42717-0

z Lay cable between the front cover and fan console

(arrows) and fix with cable tie (1).

© 42719-0

© 05/2005 2/4 0312 3365 - 0128

 Speed control
TCD 2012 2V W 05-07-01

z Plug the cable plugs together (1).

Ensure that the connection is perfect.

z Lay cable and fix with cable tie (arrows).

6
© 42715-0

© 05/2005 3/4 0312 3365 - 0128

 Speed control
W 05-07-01 TCD 2012 2V

© 05/2005 4/4 0312 3365 - 0128

 Speed control
TCD 2012 2V W 05-07-03

Remove and install speed governor

(camshaft)
Commercial available tools

Removing impulse transmitter

z Unlock cable plug (1) and disconnect.

© 42737-0

z Unscrew screw (1) and remove impulse

transmitter (2).
z Visually inspect the components.

© 42738-0

© 05/2005 1/2 0312 3366 - 0128

 Speed control
W 05-07-03 TCD 2012 2V

Installing the impulse transmitter

z Clean the sealing surface on the impulse transmitter
and gearcase cover.
z Pull new O-ring (arrow) onto impulse transmitter.
z Lightly oil O-ring.

6
© 42739-0

z Insert impulse transmitter (2) and tighten the

screw (1).
 A05 012

© 42738-0

z Plug in the cable plug (1).

Ensure that the connection is perfect.

© 42737-0

© 05/2005 2/2 0312 3366 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-01-05

Remove and install exhaust manifold

Commercial available tools – W 06-06-04

– Fitting compound
DEUTZ S1

Removing exhaust manifold

z Remove the turbocharger.
 W 06-06-04

© 42761-0

z Unscrew nuts (arrows), remove exhaust manifold (1)

and gaskets.
z Visually inspect the components.
1

© 42762-0

© 05/2005 1/2 0312 3367 - 0128

 Exhaust system / Charging
W 06-01-05 TCD 2012 2V

Installing exhaust manifold

z Clean the sealing surfaces on the exhaust manifold
and cylinder head.
z Mount exhaust manifold with new gaskets and screw
on new nuts.
Coat the pin bolts with fitting compound .

z Tighten the nuts alternately from the centre out-

wards.
 A06 001

6
© 42763-0

z Install turbocharger.
 W 06-06-04

© 42761-0

© 05/2005 2/2 0312 3367 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-06-04

Remove and install turbocharger

Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
– Assembly aid DEUTZ S1

Removing turbocharger
z Unscrew screws (1) and remove holder.

© 42773-0

z Unscrew screws (1).

© 42774-0

© 05/2005 1/4 0312 3368 - 0128

 Exhaust system / Charging
W 06-06-04 TCD 2012 2V

z Pull the oil return line (1) out of the crankcase and re-
move with pipe socket (2).

6 1
© 42775-0

z Unscrew hollow screw (1), remove lube oil line (2)

and sealing rings.

2 1

© 42776-0

z Unscrew nuts (1), remove turbocharger (2) and gas-

ket.
z Visually inspect the components.

1
1
2

© 42777-0

© 05/2005 2/4 0312 3368 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-06-04

Installing the turbocharger

z Clean the sealing surface on the turbocharger and
exhaust manifold.
z Fit turbocharger (2) with new gasket and tighten the
nuts (1).
 A06 020
Coat the studs with assembly aid.

1
1
2

6
© 42777-0

z Install the lube oil line (2), tighten hollow screws (1)
with new sealing rings.
 A08 040
1

2 1

© 42776-0

z Pull pipe socket (1) out of oil return line (2).

z Pull new round sealing rings (arrows) onto pipe sock- 1
et and oil return line.
z Oil round sealing rings lightly.
z Push pipe sockets into oil return line.

© 42778-0

© 05/2005 3/4 0312 3368 - 0128

 Exhaust system / Charging
W 06-06-04 TCD 2012 2V

z Clean the sealing surface on the turbocharger and

pipe socket.
1
z Push the oil return line into the crankcase (arrow).
z Fit pipe socket with new gasket and tighten the
screws (1).
 A08 044

6
© 42779-0

z Mount holder and tighten screw (1).

 A08 044

© 42773-0

© 05/2005 4/4 0312 3368 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-07-03

Remove and install charge air line

Commercial available tools – W 13-08-01

Removing the charge air line

z Unscrew screws (1) and remove cover plate (2).

© 42920-0

z Unscrew screws (arrows), remove ventilation

duct (1) with crankcase venting (2) and hang to one
side.

2
1

© 42923-0

© 05/2005 1/6 0312 3369 - 0128

 Exhaust system / Charging
W 06-07-03 TCD 2012 2V

z Unscrew screws (arrows), remove cylinder head

cover (1) and gasket.

6
© 42922-0

z Remove pressure/temperature sensor.

 W 13-08-01
z
1
z Remove cable tie (1) and free cable.

© 42942-0

z Unscrew screws (1), remove charge air manifold (2)

and gasket.
1

© 42943-0

© 05/2005 2/6 0312 3369 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-07-03

z Unscrew screws (arrows), remove charge air line (1)

and gaskets.
z Visually inspect the components.

6
© 42944-0

Install charge air line

z Clean the sealing surface on the charge air line and
cylinder head.
z Mount new gaskets (1).
Note installation position of the gaskets.

© 42945-0

z Mount the charge air line and tighten the screws.

Do not move the gaskets when mounting
the charge air line.

z Tighten the screws alternately from the centre out-

wards.
 A06 030

© 42946-0

© 05/2005 3/6 0312 3369 - 0128

 Exhaust system / Charging
W 06-07-03 TCD 2012 2V

z Clean the sealing surface on the charge air manifold

and charge air line.
z Mount charge air manifold with new gasket and tight- 2
en screws.
Note the different screw lengths:
Screw M8 x 30 mm (1)
Screw M8 x 95 mm (2) 1
z Tighten screws.
 A06 046

6
© 42947-0

z Install pressure/temperature sensor.

 W 13-08-01
z 1
z Fix cable with cable tie (1).

© 42948-0

z Clean the sealing surface on the cylinder head cover

and cylinder head.
z Insert new gasket (arrow).

© 42937-0

© 05/2005 4/6 0312 3369 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-07-03

z Mount cylinder head cover and tighten screws alter-

nately.
 A01 004
1
Attention!
Do not trap the cable (1) when mounting
the cylinder head cover.

6
© 42938-0

z Clean the sealing surface on the ventilation duct and

cylinder head cover.
z Insert new gasket (arrow).

© 42939-0

z Mount ventilation duct with crankcase venting and

tighten screws.
Note the different screw lengths: 1
Screw M8 x 25 mm (1)
Screw M8 x 20 mm (2)
z Tighten screws.
 A03 060

© 42941-0

© 05/2005 5/6 0312 3369 - 0128

 Exhaust system / Charging
W 06-07-03 TCD 2012 2V

z Mount cover plate (2) and tighten screws (1).

 A13 041

6
© 42920-0

© 05/2005 6/6 0312 3369 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-09-01

Removing and installing the exhaust return module

Commercial available tools – W 01-01-01

Removing the exhaust return module

z Unscrew screws (1) and remove cover plate (2).

© 42920-0

z Unscrew screws (arrows), remove ventilation

duct (1) with crankcase venting (2) and hang to one
side.

2
1

© 42923-0

© 05/2005 1/6 0312 3370 - 0128

 Exhaust system / Charging
W 06-09-01 TCD 2012 2V

z Unscrew screws (arrows), remove cylinder head

cover (1) and gasket.

6
© 42922-0

z Unscrew screws (1).

Loosen screws evenly to avoid jamming
the exhaust return module.
1
z Pull the exhaust return module (2) off the plug ele- 1
ment in the direction of the arrow and remove.

2 1

© 42924-0

z Unscrew the screws (arrows) and remove the ex-

haust return module (1) with plug element (2).
Loosen screws evenly to avoid jamming
the exhaust return module. 1

z Visually inspect the components.

2

© 42926-0

© 05/2005 2/6 0312 3370 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-09-01

Installing the exhaust return module

z Set valve clearance (without or with removing ex-
haust return module).
 W 01-01-01
z Pull out plug element (1).

1 6
© 42927-0

z Pull O-rings (arrows) onto plug element.

z Lightly oil O-rings and attach plug element to exhaust
return module.

© 42928-0

z Mount exhaust return module for cylinders 1 - 3 and

fasten screws.
Note the labelling (1) for assigning the
exhaust return modules.
Note the different screw lengths: 2
Screws M8 x 104 mm (2) 1
Screws M8 x 60 mm (3)

© 42929-0

© 05/2005 3/6 0312 3370 - 0128

 Exhaust system / Charging
W 06-09-01 TCD 2012 2V

z Tighten the screws in the tightening

sequence (1, 2 and 3).
 A01 002
1
2

3
6
© 42930-0

z Push exhaust return module for cylinders 4 - 6 onto

plug element and fasten screws.
Note the labelling (1) for assigning the
exhaust return modules.
2
Note the different screw lengths:
1
Screws M8 x 104 mm (2)
Screws M8 x 60 mm (3)

© 42931-0

z Tighten the screws in tightening

sequence (1, 2 and 3).
 A01 002
z Set control piston clearance. 2 1

 W 01-01-01

© 42932-0

© 05/2005 4/6 0312 3370 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-09-01

Assembly
z Clean the sealing surface on the cylinder head cover
and cylinder head.
z Insert new gasket (arrow).

6
© 42937-0

z Mount cylinder head cover and tighten screws alter-

nately.
 A01 004
1
Attention!
Do not trap the cable (1) when mounting
the cylinder head cover.

© 42938-0

z Clean the sealing surface on the ventilation duct and

cylinder head cover.
z Insert new gasket (arrow).

© 42939-0

© 05/2005 5/6 0312 3370 - 0128

 Exhaust system / Charging
W 06-09-01 TCD 2012 2V

z Mount ventilation duct with crankcase venting and

tighten screws.
Note the different screw lengths: 1
Screw M8 x 25 mm (1)
Screw M8 x 20 mm (2)

2
6
© 42941-0

z Mount the cover plate (1) and tighten the

screws (arrows).
 A13 041
1

© 43016-0

© 05/2005 6/6 0312 3370 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-09-02

Removing and installing the solenoid valve (exhaust return line)

Commercial available tools – W 09-12-01

Collect leaking operating fluids in suitable

vessels and dispose of according to regu-
lations.

Removing the solenoid valve (exhaust re-

turn line)
z Remove the coolant temperature sensor.
 W 09-12-01
z Unscrew locking screw (1).
1

© 42831-0

z Unlock cable plug (1) and remove from solenoid

valve (exhaust gas return line) (2).

© 42832-0

© 05/2005 1/4 0312 3371 - 0128

 Exhaust system / Charging
W 06-09-02 TCD 2012 2V

z Unscrew solenoid valve (exhaust return line) (1).

z Visually inspect the components.

6
© 42833-0

Installing the solenoid valve (exhaust re-

turn line) 3
z Clean the sealing surface on the solenoid valve (ex-
haust return line) and cylinder head. 2
z Pull new O-rings (1 and 2) onto solenoid
valve (exhaust return line).
Observe the order of installation of the O- 1
ring (2) and the support ring (3).

z Lightly oil both O-rings.

© 42834-0

z Tighten solenoid valve (exhaust return line) (1).

 A01 013

© 42835-0

© 05/2005 2/4 0312 3371 - 0128

 Exhaust system / Charging
TCD 2012 2V W 06-09-02

z Plug cable plug (1) into the solenoid valve (exhaust

gas return line) (2).
Ensure that the connection is perfect.
1

6
© 42832-0

z Tighten cap (1) with new sealing ring.

 A01 016
z Install the coolant temperature sensor.
 W 09-12-01

© 42831-0

© 05/2005 3/4 0312 3371 - 0128

 Exhaust system / Charging
W 06-09-02 TCD 2012 2V

© 05/2005 4/4 0312 3371 - 0128

 Fuel system
TCD 2012 2V W 07-10-08

Remove and install fuel filter console

Commercial available tools: – User notes
– Torx tool set . . . . . . . . . . . . . . . . . . 8189 – Operating manual
Special tools:
– Special wrench . . . . . . . . . . . . . .170 050 Danger!
– Stoppers/caps . . . . . . . . . . . . . . .170 160 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 affec-
ted parts. Blow damp areas dry with com-
pressed air.
Observe the safety regulations and natio- 6
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.

Removing the fuel filter console

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
z Unscrew fuel filter (1) with special wrench.
Collect draining fuel and dispose of accor-
ding to regulations.
1

© 42784-0

© 05/2005 1/6 0312 3372 - 0128

 Fuel system
W 07-10-08 TCD 2012 2V

z Unscrew hollow screws (1) and remove sealing

rings.
z Unscrew screws (2), loosen pipe clip and remove 1
fuel pipe.
Collect draining fuel and dispose of accor-
ding to regulations.

6
© 42785-0

z Unlock cable plug (1) and remove from fuel pressure

sensor.
z Unlock cable plug (2) and remove from oil pressure
switch.

© 42786-0

z Unscrew hollow screws (1) and remove sealing

rings.
Support the fuel pipe at the
hexagon (arrow).
Collect draining fuel and dispose of accor-
ding to regulations.
1
z Unscrew screws (2), loosen pipe clips and remove 1
fuel pipe.
2

© 42787-0

© 05/2005 2/6 0312 3372 - 0128

 Fuel system
TCD 2012 2V W 07-10-08

z Unscrew screws (1) and remove fuel filter

console (2).

6
© 42788-0

z Visually inspect the components.

© 42789-0

Installing the fuel filter console

z Mount fuel filter console (2) and tighten the
screws (1).
Do not tighten screws.
1

© 42788-0

© 05/2005 3/6 0312 3372 - 0128

 Fuel system
W 07-10-08 TCD 2012 2V

z Mount fuel pipe and fasten hollow screws (1) with

new sealing rings.
Do not tighten hollow screws.

1 1

6
© 42793-0

z Position pipe clips and tighten screws.

 A12 095
Note different screw lengths:
Screw M8 x 16 mm (1) 1
Screw M8 x 35 mm (2) with spacer 2
sleeve (arrow)

© 42794-0

z Tighten hollow screws (1).

 A12 092
Support the fuel pipe at the
hexagon (arrow).

1
1

© 42795-0

© 05/2005 4/6 0312 3372 - 0128

 Fuel system
TCD 2012 2V W 07-10-08

z Plug cable plug (1) into the fuel pressure sensor.

z Plug cable plug (2) into the oil pressure switch.
Ensure that the connection is perfect.

1
6
© 42786-0

z Mount fuel pipe and fasten hollow screws (1) with

new sealing rings.
1
 A07 045
z Position pipe clips and tighten screw (2).
 A07 087

© 42785-0

z Tighten screws (1).

 A07 087

© 42796-0

© 05/2005 5/6 0312 3372 - 0128

 Fuel system
W 07-10-08 TCD 2012 2V

z Lightly oil sealing ring on new fuel filter.

z Screw in fuel filter (1) hand tight.
 A07 099
Bleed the fuel system via the manual fuel
pump on the fuel pre-filter, according to the
operating instructions.

6
© 42797-0

© 05/2005 6/6 0312 3372 - 0128

 Fuel system
TCD 2012 2V W 07-11-01

Removing and installing the fuel supply pump

(V-rib belt drive)
Commercial available tools: – User notes
– Mandrel 6 mm Ø – Operating manual
Special tools:
– Stoppers/caps . . . . . . . . . . . . . . .170 160 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
respective affected parts. Blow damp areas 6
dry with compressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.

Removing the fuel supply pump

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
z Tighten belt tensioner (1) in direction of arrow until
the holes (2) are in line.

© 42852-0

© 05/2005 1/4 0312 3373 - 0128

 Fuel system
W 07-11-01 TCD 2012 2V

z Lock the belt tensioner with a suitable tool (1),

e.g. mandrel 6 mm Ø.
z Mark the running direction of the V-rib belt.
The running direction must be marked
when reusing the V-rib belt.

6
© 42837-0

z Remove V-rib belt.

Remove the V-rib belt first from the V-rib
belt pulley (1).

© 42853-0

z Unscrew hollow screws (1) and remove sealing

rings.
Hold the fuel pipe at the hexagon (arrow).
Collect draining fuel and dispose of accor-
ding to regulations. 1

z Unscrew screws (2), loosen pipe clip and remove

fuel pipe.

2
© 42842-0

© 05/2005 2/4 0312 3373 - 0128

 Fuel system
TCD 2012 2V W 07-11-01

z Unscrew screws (arrows) and remove fuel supply

pump.
z Visually inspect the components.

6
© 42843-0

Installing the fuel supply pump

z Mount fuel supply pump and tighten screws (arrows).
 A07 024

© 42843-0

z Mount fuel pipe and fasten hollow screws (1) with

new sealing rings.
 A12 092
Support the fuel pipe at the 1
hexagon (arrow).

z Position pipe clips and tighten screw (2).

 A12 095
z Bleed the fuel system according to the operating in-
structions via the fuel hand pump on the fuel pre-fil-
ter.
1

2
© 42842-0

© 05/2005 3/4 0312 3373 - 0128

 Fuel system
W 07-11-01 TCD 2012 2V

z Fit the V-rib belt according to the running direction.

Finally place the V-rib belt over the V-rib
belt pulley (1).
Ensure that the installation location of the
V-rib belt is free from faults.
1

6
© 42853-0

z Support the belt tensioner, remove the mandrel and

slowly relieve the strain on the belt tensioner.
The V-rib belt is tightened automatically by
the belt tensioner.

© 42840-0

Checking the wear limit of the V-rib belt

The fuel line has been removed for a better
view.

z Measured distance (a).

If the distance (a) is less than 3 mm, the V-
rib belt must be changed.

© 43851-1

© 05/2005 4/4 0312 3373 - 0128

 Fuel system
TCD 2012 2V W 07-15-01

Removing and installing the control block

Commercial available tools – User notes
– Operating manual
Special tools: – W 07-15-08
– Stoppers/caps . . . . . . . . . . . . . . .170 160
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 affec-
ted parts. Blow damp areas dry with com-
pressed air. 6
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
Bending the connecting line is not permis-
sible. Small tears may occur which lead to
a reduction in the fatigue strength.

Removing the control block

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
z Remove rail.
 W 07-15-08
z Unlock cable plug (1) and remove.

© 42807-0

© 05/2005 1/6 0312 3374 - 0128

 Fuel system
W 07-15-01 TCD 2012 2V

z Unscrew hollow screws (1), remove connecting

line (2) and sealing rings.
Collect draining fuel and dispose of accor-
ding to regulations.

6
© 42808-0

z Unscrew hollow screws (1) and remove sealing

rings.
z Unscrew screws (2), loosen pipe clip and remove
fuel pipe.
Collect draining fuel and dispose of accor-
ding to regulations.

© 42809-0

z Unscrew hollow screw (1), remove fuel return

line (2), line connection and sealing rings.
Collect draining fuel and dispose of accor-
ding to regulations.

© 42810-0

© 05/2005 2/6 0312 3374 - 0128

 Fuel system
TCD 2012 2V W 07-15-01

z Unscrew screws (1) and remove control block (2).

z Visually inspect the components.

6
© 42811-0

Installing the control block

z Mount the control block and pre-insert the screws
loosely.
Note different screw length:
- screw M8 x 75 mm (1)
- screw M8 x 85 mm (2).
Do not tighten screws.

© 42812-0

z Install the fuel return line (2)and mount line connec-

tion, tighten hollow screw (1) with new sealing rings.
 A07 046
Use new sealing rings.

© 42810-0

© 05/2005 3/6 0312 3374 - 0128

 Fuel system
W 07-15-01 TCD 2012 2V

z Mount fuel line and fasten hollow screws (1) with new
sealing rings without tension.
Use new sealing rings.
Do not tighten hollow screws.

z Position pipe clip and fasten screw (2) without ten-

sion.
Do not tighten screw.

6
© 42809-0

z Mount connecting line and screw in hollow screws

with new sealing rings without tension.
Use new sealing rings.
Note different screw lengths:
- Hollow screw M14 (1)
- Hollow screws M12 (2).
z Tighten hollow screw (1).
 A07 035
z Tighten hollow screws (2).
 A07 034

© 42813-0

z Tighten hollow screws (1).

 A07 045
z Tighten screw (2).
 A07 087
z Check the fuel lines for perfect installation position.

© 42809-0

© 05/2005 4/6 0312 3374 - 0128

 Fuel system
TCD 2012 2V W 07-15-01

z Tighten screws (arrows) alternately.

 A07 032

6
© 43024-0

z Plug in the cable plug (1).

Ensure that the connection is perfect.

z Install rail.
 W 07-15-08
z Bleed the fuel system via the manual fuel pump on
the fuel pre-filter according to the operating instruc-
tions.

© 42807-0

© 05/2005 5/6 0312 3374 - 0128

 Fuel system
W 07-15-01 TCD 2012 2V

© 05/2005 6/6 0312 3374 - 0128

 Fuel system
TCD 2012 2V W 07-15-04

Removing and installing the high-pressure pump

(Installation position A)
Commercial available tools – User notes
– W 07-15-01
Special tools: – W 07-15-08
– Turning gear . . . . . . . . . . . . . . . .100 330
– Assembly pliers. . . . . . . . . . . . . .103 220 Danger!
– Assembly case with
Wait 30 seconds after switching off the
assembly sleeves, guides
engine before working on the fuel system.
and disassembly tool . . . . . . . . .110 900
– Stoppers/caps . . . . . . . . . . . . . . .170 160 Attention!
Ensure utmost cleanliness when working
– Assembly aid 
on the fuel system.
DEUTZ AP1908
Carefully clean the area around the affec-
ted parts. Blow damp areas dry with com-
6
pressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.

Removing the high-pressure pump

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
z Remove rail.
 W 07-15-08
z Remove control block.
 W 07-15-01

© 42781-0

© 05/2005 1/4 0312 3375 - 0128

 Fuel system
W 07-15-04 TCD 2012 2V

z Unscrew screws (1) and remove high-pressure

pump (2).
 P00 50
Loosen screws evenly to avoid jamming
the high pressure pump. 1
1
If necessary, turn the crankshaft with
turning gear 100 330 in the direction of
rotation of the engine until the high pres-
sure pump is felt to release.

6
© 42814-0

z Carefully remove the O-ring (1) from the high pres-

sure pump with the disassembly tool.
Attention!
Do not damage the high pressure pump.

1
© 43328-0

z Pull out the roller tappet (arrow) with the assembly

pliers.
Attention!
Do not damage the roller tappet.

z Visually inspect the components.

© 42815-0

© 05/2005 2/4 0312 3375 - 0128

 Fuel system
TCD 2012 2V W 07-15-04

Installing the high pressure pump

z Turn the crankshaft until the cam for the high pres-
sure pump is on the cam base circle (arrow).
Use the turning gear 100 330 to turn the
crankshaft.

6
© 42816-0

z Lightly oil the roller tappet and insert it.

The guide pin (1) on the roller tappet must
grip into the groove (2). 1

© 42817-0

z Push assembly guide (1) onto high pressure pump.

z Push the O-ring (2) onto the assembly guide.

© 43329-0

© 05/2005 3/4 0312 3375 - 0128

 Fuel system
W 07-15-04 TCD 2012 2V

z Push the O-ring (1) with assembly sleeve (2) up to

the groove (3).
z Coat the round sealing ring, mounting bore and
chamfers in the crankcase with fitting compound.
1

2
3

6
© 43330-0

z Insert high pressure pump (2) and fasten screws (1)

alternately.
Attention!
Do not tighten the screws of the high pres-
sure pump until after installing the control 1
block. 1

© 42814-0

z Install control block.

 W 07-15-01
z Tighten screws (arrows) of the high pressure pump.
 A07 031
z Install rail.
 W 07-15-08

© 43036-0

© 05/2005 4/4 0312 3375 - 0128

 Fuel system
TCD 2012 2V W 07-15-05

Remove and install high pressure pump

(Installation position B)
Commercial available tools – User notes
– W 07-15-01
Special tools: – W 07-15-08
– Turning gear . . . . . . . . . . . . . . . .100 330
– Assembly pliers. . . . . . . . . . . . . .103 220 Danger!
– Assembly case with
Wait 30 seconds after switching off the
assembly sleeves, guides
engine before working on the fuel system.
and disassembly tool . . . . . . . . .110 900
– Stoppers/caps . . . . . . . . . . . . . . .170 160 Attention!
Ensure utmost cleanliness when working
– Fitting compound 
on the fuel system.
DEUTZ AP1908
Carefully clean the area around the affec-
ted parts. Blow damp areas dry with com-
6
pressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.

Removing the high-pressure pump

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
z Remove rail.
 W 07-15-08
z Remove control block.
 W 07-15-01

© 42781-0

© 05/2005 1/4 0312 3376 - 0128

 Fuel system
W 07-15-05 TCD 2012 2V

z Unscrew screws (1) and remove high-pressure

pump (2).
 P00 50
Loosen screws evenly to avoid jamming
the high-pressure pump. 1 1
If necessary, turn the crankshaft with
turning gear 100 330 in the direction of
rotation of the engine until the high-pres-
sure pump is felt to release.

6
© 42820-0

z Carefully remove the O-ring (1) from the high-pres-

sure pump with the disassembly tool.
Attention!
Do not damage the high-pressure pump.

1
© 43328-0

z Pull out the roller tappet (arrow) with the assembly

pliers.
Attention!
Do not damage the roller tappet.

z Visually inspect the components.

© 42821-0

© 05/2005 2/4 0312 3376 - 0128

 Fuel system
TCD 2012 2V W 07-15-05

Installing the high-pressure pump

z Turn the crankshaft until the cam for the high-pres-
sure pump is on the cam base circle (arrow).
Use the turning gear 100 330 to turn the
crankshaft.

6
© 42816-0

z Lightly oil the roller tappet and insert it.

The guide pin (1) on the roller tappet must
grip in the groove (2).

© 42822-0

z Push assembly guide (1) onto high pressure pump.

z Push the new O-ring (2) onto the assembly guide.

© 43329-0

© 05/2005 3/4 0312 3376 - 0128

 Fuel system
W 07-15-05 TCD 2012 2V

z Push the O-ring (1) with assembly sleeve (2) up to

the groove (3).
z Coat the O-ring, mounting bore and chamfers in the
crankcase with fitting compound.
1

2
3

6
© 43330-0

z Insert high-pressure pump (2) and fasten screws (1)

alternately.
Attention!
Do not tighten the screws of the high pres-
sure pump until after assembling the con- 1
trol block. 1

© 42820-0

z Install control block.

 W 07-15-01
z Tighten screws (arrows) of the high pressure pump.
 A07 031
z Install rail.
 W 07-15-08

© 43037-0

© 05/2005 4/4 0312 3376 - 0128

 Fuel system
TCD 2012 2V W 07-15-08

Remove and install rail

Commercial available tools – User notes

Special tools:
– Special wrench . . . . . . . . . . . . . .110 500
– Stoppers/caps . . . . . . . . . . . . . . .170 160 Danger!
Wait 30 seconds after switching off the
– Fitting compound engine before working on the fuel system.
DEUTZ AP 1908
Attention!
Ensure utmost cleanliness when working
on the fuel system.
Clean the area around the affected parts
carefully. Blow damp areas dry with com-
pressed air.
Observe the safety regulations and natio-
6
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.

Removing the rail

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.

© 42781-0

© 05/2005 1/6 0312 3377 - 0128

 Fuel system
W 07-15-08 TCD 2012 2V

z Unscrew the union nuts (1) of the high-pressure lines

with a special wrench from the high-pressure pumps
and rail.
Support the pipe connection of the high-
pressure pump. 1

z Remove the high-pressure lines.

Collect draining fuel and dispose of accor-
ding to regulations.

6
© 42782-0

z Unscrew the union nuts (1) of the injection lines from

the injectors and rail using special wrench.
Support the pipe connection of the injector.
1

z Remove injection line.

Collect draining fuel and dispose of accor-
ding to regulations.

© 42780-0

z Unscrew hollow screw (1), remove fuel return line (2)

and sealing rings from rail.
Collect draining fuel and dispose of accor-
ding to regulations.

© 42974-0

© 05/2005 2/6 0312 3377 - 0128

 Fuel system
TCD 2012 2V W 07-15-08

z Remove cable tie (1) and free cable.

z Unlock cable plug (2) and remove from rail pressure
sensor.

6
© 42975-0

z Unscrew screws (1), remove rail (2) and spacing

washers.

© 42976-0

z Visually inspect the component.

© 43027-0

© 05/2005 3/6 0312 3377 - 0128

 Fuel system
W 07-15-08 TCD 2012 2V

Mounting rail
z Mount the rail (2) with spacing washers and pre-as-
semble the screws (1) loosely.
Do not tighten screws. 2

6
© 42976-0

z Plug cable plug (2) into the rail pressure sensor.

Ensure that the connection is perfect.

z Lay cable and fix with cable tie (1). 2

© 42975-0

Attention!
The injection pipes must always be rene-
wed after disassembly.
z Mount new injection lines (arrow) on rail and injec-
tors and screw on union nuts.
Note assignment and installation position
of the injection lines.
Do not tighten union nuts.
z Check the injection lines for perfect installation posi-
tion.

© 43026-0

© 05/2005 4/6 0312 3377 - 0128

 Fuel system
TCD 2012 2V W 07-15-08

Attention!
The high-pressure lines must always be
renewed after disassembly.
z Mount new high-pressure lines on high-pressure
pumps and rail and screw on union nuts (1). 1

Note assignment and installation position

of the high-pressure lines.
Do not tighten union nuts.
z Check the high pressure lines for perfect installation
position.
1

6
© 42783-0

z Tighten screws (1).

 A07 038
z

© 43057-0

z Tighten all union nuts (1) on the rail and on the injec-
tors with a special wrench.
 A07 003
1
Attention!
Mount the injection lines without tension.

z Check the injection lines for perfect installation posi-

tion.

© 42780-0

© 05/2005 5/6 0312 3377 - 0128

 Fuel system
W 07-15-08 TCD 2012 2V

z Tighten union nuts (1) with a special wrench.

 A07 003
Attention!
Mount the high pressure lines without ten- 1
sion.
z Check the high pressure lines for perfect installation
position.

6
© 42783-0

z Install the fuel return line (1), tighten hollow screw (2)
with new sealing rings.
 A07 045
z Bleed the fuel system according to the operating in-
structions via the fuel hand pump on the fuel pre-fil- 1
ter.

© 43025-0

© 05/2005 6/6 0312 3377 - 0128

 Fuel system
TCD 2012 2V W 07-15-11

Remove and install injector

Commercial available tools: – User notes
– Assembly pliers. . . . . . . . . . . . . . . . 8024
– Torx tool set . . . . . . . . . . . . . . . . . . 8189
Special tools: Danger!
– Special wrench . . . . . . . . . . . . . .110 500 Wait 30 seconds after switching off the
– Assembly case with engine before working on the fuel system.
assembly sleeves, guides
and disassembly tool . . . . . . . . .110 900 Attention!
– Stoppers/caps . . . . . . . . . . . . . . .170 160 Ensure utmost cleanliness when working
on the fuel system.
Remove residue paint and particles of dirt
before removing.
Carefully clean the area around the affec-
ted parts. Blow damp areas dry with com-
6
pressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.

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!
Wait 30 seconds after switching off the
engine before working on the fuel system.

© 42781-0

© 05/2005 1/8 0312 3378 - 0128

 Fuel system
W 07-15-11 TCD 2012 2V

z Unscrew the union nuts (1) of the injection line from

the injector and rail with a special wrench.
Support the pipe connection of the injector.

z Remove injection line.

Collect draining fuel and dispose of accor-
ding to regulations.

6
© 42780-0

z Unscrew screws (1) and remove cover plate (2).

© 42920-0

z Unscrew nuts (1) and remove cable plug from injec-

tor.

© 42984-0

© 05/2005 2/8 0312 3378 - 0128

 Fuel system
TCD 2012 2V W 07-15-11

z Unscrew screw (1) and remove clamping shoe (2).

When removing the injectors on
cylinders 2 to 5, the clamping shoe can
only be removed together with the injector.

6
© 42985-0

z Pull out injector (1) and sealing ring (arrow).

Attention!
Remove residue paint and particles of dirt
from the injector before removing it.
Carefully clean the area around the injec-
tor.

© 42986-0

Attention!
Do not brush off the nozzle tip of the injec-
tor.Do not damage the nozzle tip on the
injector when removing the sealing ring (1).
z Grip a tight sealing ring (1) with the assembly
pliers (2) and pull off, turning slightly.

© 43303-0

© 05/2005 3/8 0312 3378 - 0128

 Fuel system
W 07-15-11 TCD 2012 2V

z Remove the O-ring (1) carefully from the injector with

the disassembly tool.
Attention!
Do not damage the injector.

6
© 43028-0

Install the injector

z Push assembly guide (1) onto injector.
z Push the new O-ring (2) onto the assembly guide.

© 43030-0

z Push the O-ring (1) with assembly sleeve (2) up to

the groove (3).

© 43029-0

© 05/2005 4/8 0312 3378 - 0128

 Fuel system
TCD 2012 2V W 07-15-11

z Mount new sealing ring (1) on injector.

6
© 43031-1

z Lightly oil O-ring (1).

© 42987-0

Attention!
Before installing the injector, combustion
residue must be cleaned carefully from the
bore on the cylinder head.
Suck off dirt particles.
z Insert injector carefully in the cylinder head.
When installing the injectors on
cylinders 2 to 5, the clamping shoe must
be inserted together with the injector.

© 42988-0

© 05/2005 5/8 0312 3378 - 0128

 Fuel system
W 07-15-11 TCD 2012 2V

z Mount the clamping shoe and tighten the screws.

Make sure the cable (arrow) is in place.
Do not tighten the screw until after assem-
bling the injection line.

6
© 42989-0

z Mount cable plug on injector and tighten nuts (1).

 A13 051

© 42984-0

Attention!
The injection lines must always be rene-
wed after disassembly.
z Mount new injection line (arrow) on rail and injector
and screw on union nuts.
Note assignment and installation position
of the injection lines.
Do not tighten union nuts.
z Check the injection line for perfect installation posi-
tion.

© 43026-0

© 05/2005 6/8 0312 3378 - 0128

 Fuel system
TCD 2012 2V W 07-15-11

z Tighten screw (arrow) of the clamping shoe.

 A07 001

6
© 42992-0

z Tighten union nuts (1) of the injection line.

 A07 003
Attention!
Mount the injection line without tension.

© 42780-0

z Mount the cover plate (1) and tighten the

screws (arrows).
 A13 041

© 43016-0

© 05/2005 7/8 0312 3378 - 0128

 Fuel system
W 07-15-11 TCD 2012 2V

© 05/2005 8/8 0312 3378 - 0128

 Fuel system
TCD 2012 2V W 07-15-14

Remove and install pressure limiting valve

Commercial available tools – User notes

Special tools:
– Disassembly tool. . . . . . . . . . . . .110 901
– Stoppers/caps . . . . . . . . . . . . . . .170 160 Danger!
Wait 30 seconds after switching off the
– Assembly grease . . . . . . . . . . 01016496 engine before working on the fuel system.

Attention!
Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the affec-
ted parts. Blow damp areas dry with com-
pressed air.
No foreign bodies may get into the rail.
6
Ensure utmost cleanliness! Especially on
the thread and the sealing surface of the
rail.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.

Removing the pressure limiting valve

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
z Unscrew pressure limiting valve (1).
1
Collect draining fuel and dispose of accor-
ding to regulations.

© 42981-0

© 05/2005 1/4 0312 3379 - 0128

 Fuel system
W 07-15-14 TCD 2012 2V

z Visually check the thread and the sealing edge of the

pressure limiting valve.

6
© 43253-1

z Remove the O-ring with the disassembly tool.

© 43335-0

Installing the pressure limiting valve

Attention!
No foreign bodies may get into the rail.
Ensure utmost cleanliness! Especially on
the thread and the sealing surface of the
rail.
z Lightly coat new O-ring (arrow) with assembly
grease and pull onto the pressure limiting valve.

© 42978-0

© 05/2005 2/4 0312 3379 - 0128

 Fuel system
TCD 2012 2V W 07-15-14

z Lightly coat the thread and sealing edge of the pres-

sure limiting valve with assembly grease.

6
© 43254-1

z Insert and tighten pressure limiting valve.

 A07 039
z Bleed the fuel system via the manual fuel pump on
the fuel pre-filter, according to the operating instruc-
tions.

© 42982-0

© 05/2005 3/4 0312 3379 - 0128

 Fuel system
W 07-15-14 TCD 2012 2V

© 05/2005 4/4 0312 3379 - 0128

 Fuel system
TCD 2012 2V W 07-15-16

Removing and installing the rail pressure sensor

Commercial available tools – User notes

Special tools:
– Long socket wrench set . . . . . . .110 700
– Stoppers/caps . . . . . . . . . . . . . . .170 160 Danger!
Wait 30 seconds after switching off the
– Assembly grease . . . . . . . . . . 01016496 engine before working on the fuel system.

Attention!
Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the affec-
ted parts. Blow damp areas dry with com-
pressed air.
No foreign bodies may get into the rail.
6
Ensure utmost cleanliness! Especially on
the thread and the sealing surface of the
rail.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.

Removing the rail pressure sensor

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
z Remove cable tie (1) and free cable. 1

© 42860-0

© 05/2005 1/4 0312 3380 - 0128

 Fuel system
W 07-15-16 TCD 2012 2V

z Release cable plug (1) and pull off from the rail pres-
sure sensor (2).

6
© 42861-0

z Unscrew the rail pressure sensor (1) with the socket

wrench.
Collect draining fuel and dispose of accor-
ding to regulations.

© 42862-0

Attention!
Do not touch the pin contacts of the rail
pressure sensor with your hands to avoid
electrostatic discharge.
z Visually check the thread and the sealing
edge (arrows)of the rail pressure sensor.

© 43017-0

© 05/2005 2/4 0312 3380 - 0128

 Fuel system
TCD 2012 2V W 07-15-16

Installing the rail pressure sensor

Attention!
No foreign bodies may get into the rail.
Ensure utmost cleanliness! Especially on
the thread and the sealing surface of the
rail.
z Lightly coat the thread and sealing edge (arrows) of
the rail pressure sensor with assembly grease.

6
© 43017-0

z Insert and tighten rail pressure sensor (1).

 A07 040

© 42862-0

z Plug the cable plug (1) into the rail pressure

sensor (2).
Ensure that the connection is perfect.

© 42861-0

© 05/2005 3/4 0312 3380 - 0128

 Fuel system
W 07-15-16 TCD 2012 2V

z Lay cable and fix with cable tie (1).

z Bleed the fuel system via the manual fuel pump on
the fuel pre-filter according to the operating instruc-
tions.

6
© 42860-0

© 05/2005 4/4 0312 3380 - 0128

 Fuel system
TCD 2012 2V W 07-15-18

Removing and installing the fuel pressure sensor

Commercial available tools – User notes

Special tools:
– Long socket wrench set . . . . . . .110 700
– Stoppers/caps . . . . . . . . . . . . . . .170 160 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 affec-
ted parts. Blow damp areas dry with com-
pressed air.
Ensure utmost cleanliness! Especially on
6
the thread and the sealing surface of the
rail.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.

Removing the fuel pressure sensor

Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
z Release cable plug (1) and pull off from the fuel pres-
sure sensor (2).

© 42863-0

© 05/2005 1/2 0312 3381 - 0128

 Fuel system
W 07-15-18 TCD 2012 2V

z Unscrew fuel pressure sensor (1) with the socket

wrench.
Collect draining fuel and dispose of accor-
ding to regulations.

z Visually inspect the components.

6
© 42864-0

Installing the fuel pressure sensor

z Tighten fuel pressure sensor (1) with new sealing
ring.
 A07 090

© 42864-0

z Plug the cable plug (1) into the fuel pressure

sensor (2).
Ensure that the connection is perfect.

z Bleed the fuel system via the fuel hand pump on the
fuel pre-filter according to the operating instructions.

© 42863-0

© 05/2005 2/2 0312 3381 - 0128

 Lube oil system
TCD 2012 2V W 08-04-06

Removing and installing the oil suction intake pipe

Commercial available tools – W 08-04-07

Removing the oil suction intake pipe

z Remove lube oil tray.
 W 08-04-07
z Unscrew screws (1), remove oil suction intake 1
pipe (2) and gasket.
z Visually inspect the components. 2

1
1

© 42766-0

Installing the oil suction intake pipe.

z Clean the sealing surface on the oil suction intake
pipe and the front cover.
z Mount oil suction intake pipe with new gasket and
fasten screws. 1
Note installation position of the gasket.
Note different screw lengths:
Screws M8 x 25 mm (1)
Screw M8 x 15 mm (2)

1 2

© 42767-0

© 05/2005 1/2 0312 3382 - 0128

 Lube oil system
W 08-04-06 TCD 2012 2V

z Tighten screws (1).

 A08 015
z Install lube oil tray.
 W 08-04-07 1

1 1

6
© 42768-0

© 05/2005 2/2 0312 3382 - 0128

 Lube oil system
TCD 2012 2V W 08-04-07

Removing and installing the lube oil tray

Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
– Packing compound The engine oil should be filled according to
DEUTZ DW 74 the operating manual.

Removing the lube oil tray

z Unscrew cap (1) and drain engine oil.
Collect the engine oil and dispose of accor-
ding to regulations.

z Tighten screw plug with new sealing ring.

 A03 031

© 42769-0

z Unscrew all screws (arrow) and remove lube oil

tray (1).
z Visually inspect the components.

© 42770-0

© 05/2005 1/2 0312 3383 - 0128

 Lube oil system
W 08-04-07 TCD 2012 2V

Installing the lube oil tray

z Clean the sealing surface on the lube oil tray and
crankcase.
The sealing surfaces must be dry and free
from grease and dirt.

z Apply packing compound to the joints (arrows).

6
© 42771-0

z Mount gasket on crankcase and mount lube oil tray.

Do not move the gasket when mounting
the lube oil tray.

z Tighten all screws alternately.

 A03 030
z Fill in prescribed engine oil.

© 42772-0

© 05/2005 2/2 0312 3383 - 0128

 Lube oil system
TCD 2012 2V W 08-08-02

Remove and install oil cooler

Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
– Fitting compound The appropriate operating manual should
DEUTZ AP 1908 be observed for emptying and filling the
engine.

Removing the oil cooler

z Unscrew screws (arrows) and remove oil cooler (1).
Collect draining engine oil and dispose of
according to regulations.

z Remove gaskets.
z Visually inspect the components.

© 42803-0

Installing the oil cooler

z Clean the sealing surfaces on the oil cooler and oil
cooler housing.
z Coat new gaskets (arrows) with fitting compound and
insert.

© 42804-0

© 05/2005 1/2 0312 3384 - 0128

 Lube oil system
W 08-08-02 TCD 2012 2V

z Mount the oil cooler and fasten the screws alternate-

ly.
The fixing bolts on the oil cooler housing
must grip in the holes of the oil
cooler (arrows).

6
© 42805-0

z Tighten screws alternately.

 A08 052

© 42806-0

© 05/2005 2/2 0312 3384 - 0128

 Lube oil system
TCD 2012 2V W 08-08-03

Removing and installing the oil cooler housing

Commercial available tools – W 08-08-02
– W 08-10-06

– Fitting compound Collect leaking operating fluids in suitable

DEUTZ AP 1908 vessels and dispose of according to regu-
lations.

Removing the oil cooler housing

z Remove oil cooler.
 W 08-08-02
z Remove oil filter cartridge.
 W 08-10-06
z Unlock cable plug (1) and remove from oil pressure
sensor.

© 42949-0

z Unscrew the screws (arrows), pull oil cooler

housing (1) off plug element (2) and remove.

© 42950-0

© 05/2005 1/4 0312 3385 - 0128

 Lube oil system
W 08-08-03 TCD 2012 2V

z Visually inspect the components.

6
© 42954-0

z Pull out plug element (1).

© 42951-0

z Visually inspect the plug element.

© 42952-0

© 05/2005 2/4 0312 3385 - 0128

 Lube oil system
TCD 2012 2V W 08-08-03

Installing the oil cooler housing

z Clean the sealing surface on the oil cooler housing
and crankcase.
z Coat new round sealing rings (arrows) with fitting
compound and pull onto plug element.

6
© 42961-0

z Attach plug element (1) to water cistern.

© 42951-0

z Coat new O-ring (arrow) with fitting compound and

insert.

© 42962-0

© 05/2005 3/4 0312 3385 - 0128

 Lube oil system
W 08-08-03 TCD 2012 2V

z Plug oil cooler housing to plug element and fasten

screws alternately.
Attention! 1
Do not trap the cable (arrow) when moun- 1
ting the oil cooler housing.

Note different screw length:

- screws M8 x 50 mm (1)
- screws M8 x 80 mm (2).
1
z Tighten screws.
 A08 051

6 2

© 42963-0

z Plug cable plug (1) into the oil pressure sensor.

Ensure that the connection is perfect.

z Mount oil filter cartridge.

 W 08-10-06
z Mount oil cooler.
 W 13-08-01

© 42949-0

© 05/2005 4/4 0312 3385 - 0128

 Lube oil system
TCD 2012 2V W 08-10-06

Removing and installing the oil filter cartridge

Commercial available tools Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
Special tools: lations.
– Special wrench . . . . . . . . . . . . . .170 050

Removing the oil filter cartridge

z Unscrew oil filter cartridge (1) with special wrench.

© 42801-0

Installing the oil filter cartridge

z Lightly oil the sealing ring of the new oil filter car-
tridge.
z Screw in the oil filter cartridge hand tight.
 A08 001

© 42802-0

© 05/2005 1/2 0312 3386 - 0128

 Lube oil system
W 08-10-06 TCD 2012 2V

© 05/2005 2/2 0312 3386 - 0128

 Lube oil system
TCD 2012 2V W 08-11-08

Removing and installing the oil pressure switch

Commercial available tools – User notes

Special tools:
– Long socket wrench set . . . . . . .110 700
Ensure utmost cleanliness when working
– Stoppers/caps . . . . . . . . . . . . . . .170 160
on the fuel system.
Carefully clean the area around the affec-
ted parts. Blow damp areas dry with com-
pressed air.
Observe the safety regulations and natio-
nal specifications for handling lube oils.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling. 6

Removing the oil pressure switch

z Release cable plug (1) and pull off the fuel pressure
switch (2).

© 42865-0

z Unscrew oil pressure switch (1).

Collect draining engine oil and dispose of
according to regulations.

z Visually inspect the components.

1

© 42866-0

© 05/2005 1/2 0312 3387 - 0128

 Lube oil system
W 08-11-08 TCD 2012 2V

Installing the oil pressure switch

z Tighten fuel pressure switch (1) with new sealing
ring.
 A08 091

6
© 42866-0

z Attach the cable plug (1) to the oil pressure

switch (2).
Ensure that the connection is perfect.

© 42865-0

© 05/2005 2/2 0312 3387 - 0128

 Cooling system
TCD 2012 2V W 09-06-01

Removing and installing the radiator tank

Commercial available tools – W 07-10-08

– Fitting compound Collect leaking operating fluids in suitable

DEUTZ AP 1908 vessels and dispose of according to regu-
lations.

Removing the radiator tank

z Remove fuel filter console.
 W 07-10-08
2
z Unscrew screw (1) and remove retaining plate (2).

1
© 42964-0

z Unscrew screws (arrows), pull oil radiator tank (1) off

plug element (2) and remove with gasket.

© 42965-0

© 05/2005 1/4 0312 3388 - 0128

 Cooling system
W 09-06-01 TCD 2012 2V

z Pull out plug element (1).

z Visually inspect the components.

6
© 42966-0

Installing the radiator tank

z Clean the sealing surface on the radiator tank and
crankcase.
z Coat new O-rings (arrows) with fitting compound and
pull onto plug element.

© 42961-0

z Attach plug element (1) to oil filter holder.

© 42966-0

© 05/2005 2/4 0312 3388 - 0128

 Cooling system
TCD 2012 2V W 09-06-01

z Attach radiator tank (1) to plug element (2), mount

new gasket and fasten screws (arrows).
Note installation position of the gasket.
Use screws M8 x 35 mm (arrows).

2
6
© 42965-0

z Mount the retaining plate (1) and fasten the

screw (2).
Use screw M8 x 45 mm (2).
The holes in the retaining plate (arrows) 1
must be in line with the holes in the radiator
tank.

2
© 42967-0

z Tighten screws (1).

 A07 087 1

z Install fuel filter console.

 W 07-10-08

© 42968-0

© 05/2005 3/4 0312 3388 - 0128

 Cooling system
W 09-06-01 TCD 2012 2V

© 05/2005 4/4 0312 3388 - 0128

 Cooling system
TCD 2012 2V W 09-07-08

Removing and installing the coolant pump

(V-rib belt drive)
Commercial available tools Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
– Fitting compound
DEUTZ AP 1908

Removing the coolant pump

z Loosen screws (arrows).
Do not unscrew screws.

© 42844-0

z Tighten belt tensioner (1) in direction of arrow until

the holes (2) are in line.

© 42852-0

© 0 5 / 2 0 0 5
1/6 0312 3389 - 0128
 Cooling system
W 09-07-08 TCD 2012 2V

z Lock the belt tensioner with a suitable tool (1),

e.g. mandrel 6 mm Ø.

6
© 42837-0

z Remove V-rib belt.

Mark the running direction when reusing
the V-rib belt.
First, remove the V-rib belt from the V-rib
belt pulley (1).
1

© 42853-0

z Unscrew screws (arrows) and remove V-rib belt

pulley (1).

© 42845-0

© 05/2005 2/6 0312 3389 - 0128

 Cooling system
TCD 2012 2V W 09-07-08

z Unscrew screws (arrows) and remove coolant

pump (1).
z Visually inspect the components.

6
© 42846-0

z Press tight coolant pump off the fan console with

2 setting screws (1).
z Unscrew the setting screws from the coolant pump.
z Clean the sealing surface on the coolant pump and
fan console.
1

© 42847-0

Installing the coolant pump

z Coat new O-ring (arrow) with fitting compound and
pull on.

© 42848-0

© 05/2005 3/6 0312 3389 - 0128

 Cooling system
W 09-07-08 TCD 2012 2V

z Insert coolant pump.

The bleed hole (arrow) must be facing the
crankshaft.

6
© 42849-0

z Tighten screws (arrows) alternately.

 A09 010

© 42850-0

z Mount the V-rib belt pulley (1) and tighten the

screws (arrows).

© 42845-0

© 05/2005 4/6 0312 3389 - 0128

 Cooling system
TCD 2012 2V W 09-07-08

z Fit the V-rib belt according to the running direction.

Finally place the V-rib belt over the V-rib
belt pulley (1).
Ensure that the installation location of the
V-rib belt is free from faults.
1

6
© 42853-0

z Support the belt tensioner, remove the mandrel and

slowly relieve the strain on the belt tensioner.
The V-rib belt is tightened automatically by
the belt tensioner.

© 42840-0

Checking the wear limit of the V-rib belt

The fuel line has been removed for a better
view.

z Measured distance (a).

If the distance (a) is less than 3 mm, the V-
rib belt must be changed.

© 43851-1

© 05/2005 5/6 0312 3389 - 0128

 Cooling system
W 09-07-08 TCD 2012 2V

z Tighten screws.
 A09 015

6
© 42851-0

© 05/2005 6/6 0312 3389 - 0128

 Cooling system
TCD 2012 2V W 09-08-01

Checking the coolant thermostat when uninstalled

Commercial available tools: – W 09-08-02
– Thermometer

Danger!
Risk of injury!Hot water and hot thermostat.

Checking the coolant thermostat

z Remove the coolant thermostat.
 W 09-08-02
z Measure dimension (a), between start and end of
stroke on the thermostat.
 P09 11

© 34679-3

z Heat up the coolant thermostat in the water bath.

In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the ther-
mostat without touching it.
The water should be continuously stirred
for an even temperature distribution. The
temperature rise should not take place
faster than 1°C/min. Otherwise the begin-
ning of opening will be delayed accordin-
gly.

© 34680-2

© 05/2005 1/2 0312 3390 - 0128

 Cooling system
W 09-08-01 TCD 2012 2V

z Measure dimension (b) on the thermostat.

 P09 13
Stroke distance at given temperature (T2)
at least 8 mm.

z Install the coolant thermostat.

 W 09-08-02

6
© 34679-2

© 05/2005 2/2 0312 3390 - 0128

 Cooling system
TCD 2012 2V W 09-08-02

Removing and installing the coolant thermostat

Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
– Fitting compound
DEUTZ AP 1908

Removing the coolant thermostat

z Unscrew screws (1) and remove coolant outlet
nozzle (2).

© 42867-0

z Remove coolant thermostat (1).

z Visually inspect the components.

© 42868-0

© 05/2005 1/2 0312 3391 - 0128

 Cooling system
W 09-08-02 TCD 2012 2V

Installing coolant thermostat

z Clean the sealing surface on the coolant outlet noz-
zle and fan console. 1
z Coat new sealing ring (1) with assembly aid and pull
on.

6
© 42869-0

z Insert coolant thermostat.

The arrow (1) must point upwards.

© 42888-0

z Mount coolant outlet nozzle and tighten screws.

 A09 002

© 42870-0

© 05/2005 2/2 0312 3391 - 0128

 Cooling system
TCD 2012 2V W 09-12-01

Remove and install coolant temperature sensor

Commercial available tools Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
The relevant documentation from the
vehicle manufacturer must be observed
when emptying and filling the cooling
system.

Removing the coolant temperature sensor

z Release cable plug (1) and pull off from the
coolant temperature sensor (2).

© 42871-0

z Unscrew coolant temperature sensor (1).

z Visually inspect the components.

© 42872-0

© 05/2005 1/2 0312 2301 - 3392

 Cooling system
W 09-12-01 TCD 2012 2V

Installing the coolant temperature sensor

z Screw the coolant temperature sensor (arrow) tight.
 A09 031
Make sure the sealing ring is in place.

6
© 42873-0

z Plug the cable plug (1) into the

coolant temperature sensor (2).
Ensure that the connection is perfect.

© 42871-0

© 05/2005 2/2 0312 2301 - 3392

 Cooling system
TCD 2012 2V W 09-13-01

Dismantling and assembling the fan drive

Commercial available tools – W 09-13-02

Dismantling the fan drive

z Remove the fan drive. 1
 W 09-13-02
z Mount the adapter (1) and tighten the
screws (arrows).
 A09 048

© 42874-0

z Clamp the fan drive in the vice.

z Unscrew screw (1).
Left-hand thread.
1

© 42875-0

© 05/2005 1/6 0312 3393 - 0128

 Cooling system
W 09-13-01 TCD 2012 2V

z Unclamp fan drive.

z Unscrew screws (arrows) and remove adapter (1).
1

6
© 42874-0

z Press tight V-rib belt pulley off the fan drive with
2 setting screws (1).
1

© 42877-0

z Press out shaft with internal ball bearing.

© 42878-0

© 05/2005 2/6 0312 3393 - 0128

 Cooling system
TCD 2012 2V W 09-13-01

z Press out outside ball bearing.

6
© 42879-0

z Remove circlip (1).

© 42880-0

z Press the disc out of the inside ball bearing.

© 42881-0

© 05/2005 3/6 0312 3393 - 0128

 Cooling system
W 09-13-01 TCD 2012 2V

z Press the shaft out of the inside ball bearing.

z Visually inspect the components.

6
© 42882-0

Assembling the fan drive

z Press the shaft into the inside ball bearing to the stop.

© 42883-0

z Press the shaft into the inside ball bearing to the stop.

© 42884-0

© 05/2005 4/6 0312 3393 - 0128

 Cooling system
TCD 2012 2V W 09-13-01

z Press the outer ball bearing into the housing to the

stop.
The press-in tool (1) must be applied to the
outer ring of the ball bearing (arrow).

6
© 42885-0

z Insert circlip (1).

Make sure the circlip fits correctly in the
groove.

© 42886-0

z Press the shaft with inside ball bearing in to the stop.

Support the inside ring of the outer ball
bearing with a suitable tool (arrow).

© 42887-0

© 05/2005 5/6 0312 3393 - 0128

 Cooling system
W 09-13-01 TCD 2012 2V

z Mount the adapter (1) and tighten the

screws (arrows).
1
 A09 048

6
© 42874-0

z Clamp the fan drive in the vice.

z Mount the fan drive on the V-rib belt pulley and tight-
en the screw (1).
1
 A09 047
Left-hand thread.

© 42875-0

z Unclamp fan drive.

z Unscrew screws (arrows) and remove adapter (1).
1
z Install fan drive.
 W 09-13-02

© 42874-0

© 05/2005 6/6 0312 3393 - 0128

 Cooling system
TCD 2012 2V W 09-13-02

Removing and installing the fan drive

Commercial available tools:
– Mandrel 6 mm Ø

Removing the fan drive

z Unscrew screws (1) and remove adapter (2). 1

© 42854-0

z Tighten belt tensioner (1) in direction of arrow until

the holes (2) are in line.

© 42852-0

© 05/2005 1/4 0312 3394 - 0128

 Cooling system
W 09-13-02 TCD 2012 2V

z Lock the belt tensioner with a suitable tool (1),

e.g. mandrel 6 mm Ø.

6
© 42837-0

z Remove V-rib belt.

Mark the running direction when reusing
the V-rib belt.
First remove the V-rib belt from the V-rib
belt pulley (1).
1

© 42853-0

z Unscrew screws (1) and remove fan drive with V-rib

belt pulley.
Note installation position of the fan drive. 1

z Visually inspect the components.

1
© 42855-0

© 05/2005 2/4 0312 3394 - 0128

 Cooling system
TCD 2012 2V W 09-13-02

Mount fan drive

z Mount the fan drive with V-rib belt pulley and tighten
the screws (1). 1

 A09 046
Note installation position of the fan drive.

1 6
© 42856-0

z Fit the V-rib belt according to the running direction.

Finally place the V-rib belt over the V-rib
belt pulley (1).
Ensure that the installation location of the
V-rib belt is free from faults.
1

© 42853-0

z Hold the belt tensioner, remove the mandrel and

slowly relieve the strain on the belt tensioner.
The V-rib belt is tightened automatically by
the belt tensioner.

© 42840-0

© 05/2005 3/4 0312 3394 - 0128

 Cooling system
W 09-13-02 TCD 2012 2V

Checking the wear limit of the V-rib belt

The fuel line has been removed for a better
view.

z Measured distance (a).

If the distance (a) is less than 3 mm, the V-
rib belt must be changed.

6
© 43851-1

z Mount the adapter (1) and tighten the screws (2).

 A09 048

2 1

© 42857-0

© 05/2005 4/4 0312 3394 - 0128

 Cooling system
TCD 2012 2V W 09-13-03

Removing and installing the fan console

Commercial available tools – W 07-11-01
– W 09-13-02
– W 12-02-06
– Fitting compound – W 13-02-03
DEUTZ AP 1908
– Sealant DEUTZ DW 74 Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.

Removing the fan console

z Remove the fan drive.
 W 09-13-02
z Remove the belt tensioner (V-rib belt).
 W 12-02-06
z Remove the fuel supply pump.
 W 07-11-01
z Remove the generator (V-rib belt).
 W 13-02-03

© 42900-0

z Unscrew screws (1) and remove transport flange (2)

and generator console (3).

3 1

© 42901-0

© 05/2005 1/6 0312 3395 - 0128

 Cooling system
W 09-13-03 TCD 2012 2V

z Unscrew screws (arrows) and remove fan

console (1).

6
© 42902-0

Installing the fan console

z Pull the cable (1) forward slightly.

1
© 42913-0

z Clean the sealing surfaces on the fan console, cylin-

der head and crankcase.
z Coat new O-rings (arrows) with fitting compound and
insert.

© 42972-0

© 05/2005 2/6 0312 3395 - 0128

 Cooling system
TCD 2012 2V W 09-13-03

z Apply sealant to fan console (arrow).

6
© 42914-0

z Mount fan console and tighten screws (arrows).

 A09 045
Attention!
Do not trap the cable (1) when mounting
the fan console.

Do not move the sealant when mounting

the fan console.

z Lay the cable between the front cover and the fan
console.

1
© 42915-0

z Mount generator console (1) and remove transport

flange (2) and screws (3).
Do not tighten screws.
2

1 3

© 42916-0

© 05/2005 3/6 0312 3395 - 0128

 Cooling system
W 09-13-03 TCD 2012 2V

z Insert generator and fasten screws (1).

Do not tighten screws.

1
6
© 42917-0

The holes in the transport flange (arrows)

must be in line with the threaded holes in
the generator console.

© 42973-0

z Tighten screws (1).

 A13 018
2
z Tighten screws (2).
 A13 012

2 1
© 42918-0

© 05/2005 4/6 0312 3395 - 0128

 Cooling system
TCD 2012 2V W 09-13-03

z Mount fuel supply pump.

 W 07-11-01
z Mount belt tensioner (V-rib belt).
 W 12-02-06
z Mount fan drive.
 W 09-13-02

6
© 42919-0

© 05/2005 5/6 0312 3395 - 0128

 Cooling system
W 09-13-03 TCD 2012 2V

© 05/2005 6/6 0312 3395 - 0128

 Other components
TCD 2012 2V W 12-01-04

Removing and installing torsional vibration damper

Commercial available tools: – W 12-02-06
– Rotation angle disc . . . . . . . . . . . . . 8190
– Socket wrench set, Torx-
E 20 . . . . . . . . . . . . . . . . . . . . . . . . 8114
Special tools:
– Counter support . . . . . . . . . . . . .144 800

Removing the torsional vibration damper

z Remove belt tensioner (V-rib belt).
 W 12-02-06
z Mount counter support (1) and tighten screws (2).

2
© 42891-0

z Unscrew screws (1) and remove torsional vibration

damper.
Use socket wrench set.

1
1

© 42892-0

© 05/2005 1/2 0312 3396 - 0128

 Other components
W 12-01-04 TCD 2012 2V

Installing the torsional vibration damper

Make sure the clamping bushings (arrows)
are in place.

6
© 42893-0

z Mount the torsional vibration damper.

The clamping bushing (1) must grip in the
hole (2).

© 42894-0

z Tighten new screws.

 A12 030
Attention!
Renew screws every time they are loo-
sened.

Use socket wrench set.

z Remove counter support.

z Mount belt tensioner (V-rib belt).
 W 12-02-06

© 42895-0

© 05/2005 2/2 0312 3396 - 0128

 Other components
TCD 2012 2V W 12-02-06

Removing and installing the belt tensioner

(V-rib belt)
Commercial available tools:
– Mandrel 6 mm Ø

Removing the belt tensioner

z Tighten belt tensioner (1) in direction of arrow until
the holes (2) are in line.

© 42852-0

z Lock the belt tensioner with a suitable tool (1),

e.g. mandrel 6 mm Ø.

© 42837-0

© 05/2005 1/4 0312 3397 - 0128

 Other components
W 12-02-06 TCD 2012 2V

z Remove V-rib belt.

Mark the running direction when reusing
the V-rib belt.
First remove the V-rib belt from the V-rib
belt pulley (1).
1

6
© 42853-0

z Unscrew screws (1) and remove belt tensioner (2).

z Visually inspect the components.

© 42836-0

Installing the belt tensioner

z Mount the belt tensioner.
The fixing bolts (1) must grip in the
holes (2).

1
2

© 42838-0

© 05/2005 2/4 0312 3397 - 0128

 Other components
TCD 2012 2V W 12-02-06

z Tighten screw (1).

 A12 041

6
© 42839-0

z Fit the V-rib belt according to the running direction.

Finally place the V-rib belt over the V-rib
belt pulley (1).
Ensure that the installation location of the
V-rib belt is free from faults.
1

© 42853-0

z Support the belt tensioner, remove the mandrel and

slowly relieve the strain on the belt tensioner.
The V-rib belt is tightened automatically by
the belt tensioner.

© 42840-0

© 05/2005 3/4 0312 3397 - 0128

 Other components
W 12-02-06 TCD 2012 2V

Checking the wear limit of the V-rib belt

The fuel line has been removed to allow a
better view.

z Measure distance (a).

If the distance (a) is less than 3 mm, the V-
rib belt must be changed.

6
© 43851-1

© 05/2005 4/4 0312 3397 - 0128

 Other components
TCD 2012 2V W 12-06-01

Removing and installing flywheel

Commercial available tools:
– Rotation angle disc . . . . . . . . . . . . . 8190
– Guide pin (self-construc-
ted)
Special tools:
– Counter support . . . . . . . . . . . . .144 800

Removing the flywheel

z Mount counter support (1) and tighten screws (2).

2
1
© 42824-0

z Unscrew all screws (arrow) and remove flywheel.

z Visually inspect the components.

© 42825-0

© 05/2005 1/4 0312 3398 - 0128

 Other components
W 12-06-01 TCD 2012 2V

Installing flywheel
z Mount flywheel using a self-constructed guide
pin (arrow).
The holes in the flywheel must match the
threaded holes in the crankshaft flange.

6
© 34224-2

z Tighten all new screws alternately.

 A12 001
Attention!
Renew screws every time they are loo-
sened.

© 42826-0

z Drive core plugs into the threaded holes (arrows) to

the stop.

© 31115-1

© 05/2005 2/4 0312 3398 - 0128

 Other components
TCD 2012 2V W 12-06-01

z Unscrew screws (2) and remove counter support (2).

2 6
1
© 42824-0

© 05/2005 3/4 0312 3398 - 0128

 Other components
W 12-06-01 TCD 2012 2V

© 05/2005 4/4 0312 3398 - 0128

 Electrical system
TCD 2012 2V W 13-01-02

Removing and installing the cable harness

Commercial available tools

Removing the cable harness

z Unlock and disconnect the cable plug (1) of the im-
pulse transmitter (camshaft).
z Remove cable tie (arrow) and expose cable harness.

© 42720-0

z Unlock cable plug (1) and remove coolant tempera-

ture sensor.
z Unlock cable plug (2) and remove from solenoid 2
valve (exhaust gas return line).
z Remove cable tie (arrow) and expose cable harness.

© 42721-0

© 05/2005 1/10 0312 3399 - 0128

 Electrical system
W 13-01-02 TCD 2012 2V

z Unlock cable plug (1) and pull off from pressure/tem-

perature sensor.
z Remove cable tie (2) and expose cable harness.
1

6
© 42722-0

z Unscrew nut (1), pull central plug (2) out of holder.

© 42723-0

z Unlock cable plug (1) and remove.

© 42582-0

© 05/2005 2/10 0312 3399 - 0128

 Electrical system
TCD 2012 2V W 13-01-02

z Unlock cable plug (1) and remove from fuel pressure

sensor.
z Unlock cable plug (2) and remove from oil pressure
switch.
1

6
© 42724-0

z Unlock and disconnect the cable plug (1) of the im-

pulse transmitter (crankshaft).

© 42725-0

z Remove cable tie (arrows) and expose cable har-

ness.

© 42726-0

© 05/2005 3/10 0312 3399 - 0128

 Electrical system
W 13-01-02 TCD 2012 2V

z Unlock cable plug (1) and remove from rail pressure

sensor.
1

6
© 42727-0

z Unscrew nuts (1) and remove cable ring

eyes (arrows).

1 1

© 42728-0

z Unscrew screws (1) and remove cover plate (2).

© 42729-0

© 05/2005 4/10 0312 3399 - 0128

 Electrical system
TCD 2012 2V W 13-01-02

z Unscrew nuts (1) and remove cable plug from injec-

tor.
z Remove cable harness.
1

6
© 42730-0

z Remove cable tie (arrows) and remove cover

plate (1).
z Visually inspect the components.

© 42731-0

Installing the cable harness

z Position cable harness on the cover plate and fix with
cable tie (arrows).

© 42732-0

© 05/2005 5/10 0312 3399 - 0128

 Electrical system
W 13-01-02 TCD 2012 2V

z Insert cable harness and attach cable plugs to the in-

dividual components.

6
© 42733-0

z Mount cable plug on injector and tighten nut (1).

 A13 051

© 42730-0

z Mount cover plate (2) and tighten screws (1).

 A13 041

© 42729-0

© 05/2005 6/10 0312 3399 - 0128

 Electrical system
TCD 2012 2V W 13-01-02

z Position cable ring eyes (arrows) and tighten

nuts (1).

1 1

6
© 42728-0

z Plug cable plug (1) into the rail pressure sensor.

Ensure that the connection is perfect.
1

© 42727-0

z Plug together the cable plugs (1) of the impulse

transmitter (crankshaft).
Ensure that the connection is perfect.

© 42725-0

© 05/2005 7/10 0312 3399 - 0128

 Electrical system
W 13-01-02 TCD 2012 2V

z Plug cable plug (1) into the fuel pressure sensor.

z Plug cable plug (2) into the oil pressure switch.
Ensure that the connection is perfect.

6
© 42724-0

z Lay cable harness and fix with cable tie (arrows).

© 42726-0

z Plug in the cable plug (1).

Ensure that the connection is perfect.

© 42582-0

© 05/2005 8/10 0312 3399 - 0128

 Electrical system
TCD 2012 2V W 13-01-02

z Plug central plug into the holder and tighten the nut.
The flattened side of the central plug and
the holder must be in line (arrow).

6
© 42736-0

z Plug cable plug (1) into pressure/temperature sen-

sor.
Ensure that the connection is perfect.
1

z Lay cable harness and fix with cable tie (2).

2

© 42722-0

z Plug cable plug (1) into coolant temperature sensor.

z Plug cable plug (2) into the solenoid valve (exhaust
gas return line). 2
Ensure that the connection is perfect.

z Lay cable harness and fix with cable tie (arrow).

© 42721-0

© 05/2005 9/10 0312 3399 - 0128

 Electrical system
W 13-01-02 TCD 2012 2V

z Plug together the cable plugs (1) of the impulse

transmitter (camshaft).
Ensure that the connection is perfect.

z Lay cable harness and fix with cable tie (arrow).

6
© 42720-0

© 05/2005 10/10 0312 3399 - 0128

 Electrical system
TCD 2012 2V W 13-02-03

Removing and installing the generator

(V-rib belt drive)
Commercial available tools:
– Mandrel 6 mm Ø

Remove generator
z Disconnect the battery's negative terminal.
z Disconnect the cable from the generator if present. 1
- Cable-W (1)
- Cable-D+ (2)
- Cable-B+ (3)

© 42858-0

z Tighten belt tensioner (1) in direction of arrow until

the holes (2) are in line.

© 42852-0

© 05/2005 1/4 0312 3400 - 0128

 Electrical system
W 13-02-03 TCD 2012 2V

z Lock the belt tensioner with a suitable tool (1),

e.g. mandrel 6 mm Ø.

6
© 42837-0

z Remove V-rib belt.

Mark the running direction when reusing
the V-rib belt.
First, remove the V-rib belt from the V-rib
belt pulley (1).
1

© 42853-0

z Unscrew screws (1) and remove generator (2).

z Visually inspect the components.

1
2

© 42859-0

© 05/2005 2/4 0312 3400 - 0128

 Electrical system
TCD 2012 2V W 13-02-03

Installing generator
z Mount generator and tighten screws (1).
 A13 012

6
© 42889-0

z Fit the V-rib belt according to the running direction.

Finally place the V-rib belt over the V-rib
belt pulley (1).
Ensure that the installation location of the
V-rib belt is free from faults.
1

© 42853-0

z Hold the belt tensioner, remove the mandrel and

slowly relieve the strain on the belt tensioner.
The V-rib belt is tightened automatically by
the belt tensioner.

© 42840-0

© 05/2005 3/4 0312 3400 - 0128

 Electrical system
W 13-02-03 TCD 2012 2V

Checking the wear limit of the V-rib belt

The fuel line has been removed for a better
view.

z Measured distance (a).

If the distance (a) is less than 3 mm, the V-
rib belt must be changed.

6
© 43851-1

z Plug cable into generator if present.

Note the assignment of the cables:
- Cable-W (1)
- Cable-D+ (2) 1
- Cable-B+ (3).
z Connect the battery's negative terminal.

© 42858-0

© 05/2005 4/4 0312 3400 - 0128

 Electrical system
TCD 2012 2V W 13-03-02

Removing and installing the starter

Commercial available tools

Removing starter
z Disconnect the battery's negative terminal.
2
z Unscrew nuts (1) and remove.
z Unscrew screws (2) and remove heat shield (2).

© 42896-0

z Remove cable from starter if available.

z Unscrew screws (arrows) and remove starter.
z Visually inspect the components.

© 42897-0

© 05/2005 1/2 0312 3401 - 0128

 Electrical system
W 13-03-02 TCD 2012 2V

Installing starter
z Insert starter and tighten screws (arrows).
 A13 001
z Plug cable into starter if available.

6
© 42898-0

z Mount the heat shield and fasten screws (1).

z Insert screws and tighten nuts.
Note the different screw lengths: 1
Screw M8 x 30 mm (2)
Screw M8 x 50 mm (3)

3
© 42899-0

z Tighten screws (2).

z Tighten nuts (1).
2
 A13 007
z Connect the battery's negative terminal.

1
© 42876-0

© 05/2005 2/2 0312 3401 - 0128

 Electrical system
TCD 2012 2V W 13-06-01

Removing and installing the heating plugs

Commercial available tools – W 07-15-11
– User notes
Special tools:
– Claw wrench . . . . . . . . . . . . . . . .120 430
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.
Remove residue paint and particles of dirt
before removing.
Carefully clean the area around the affec-
ted parts. Blow damp areas dry with com-
6
pressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean stoppers/caps.
Do not remove stoppers/caps until imme-
diately before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.

Removing the heating plugs

z Unscrew nuts (1) and remove cable ring
eyes (arrows).
z Remove injectors.
1 1
 W 07-15-11
Attention!
Remove residue paint and particles of dirt
from the injector before removing it.
Carefully clean the area around the injec-
tor.

© 42728-0

© 05/2005 1/2 0312 3402 - 0128

 Electrical system
W 13-06-01 TCD 2012 2V

z Loosen and unscrew heating plugs with claw wrench.

z Visually inspect the component.

6
© 42760-0

Installing the heating plugs

z Screw in heating plugs and tighten with claw wrench.
 A13 032
z Install injectors.
 W 07-15-11

© 42760-0

z Mount cable ring eyes (arrows) and tighten nuts (1).

1 1

© 42728-0

© 05/2005 2/2 0312 3402 - 0128

 Electrical system
TCD 2012 2V W 13-08-01

Removing and installing pressure/temperature sensor

(charge air)
Commercial available tools

– Assembly aid
DEUTZ AP 1908

Removing pressure/temperature sensor

z Release cable plug (1) and pull off from the pressure/
temperature sensor (2).

2
1

© 42764-0

z Unscrew screw (1) and remove pressure/tempera-

ture sensor.

© 42765-0

© 05/2005 1/2 0312 3403 - 0128

 Electrical system
W 13-08-01 TCD 2012 2V

Installing pressure/temperature sensor

z Pull new O-ring (arrow) onto pressure/temperature
sensor.
z Lightly coat O-ring with fitting compound.

6
© 42002-1

z Insert pressure/temperature sensor and tighten the

screw (1).
 A13 046

© 42765-0

z Plug the cable plug (1) into the pressure/temperature

sensor (2).
Ensure that the connection is perfect.

2
1

© 42764-0

© 05/2005 2/2 0312 3403 - 0128

 
TCD 2012 2V Standard tools

7 Standard tools

© 05/2005 1/7 0312 3336 - 0128

 Standard tools TCD 2012 2V

Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bäcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Phone: +49 (0) 2191 9339-200
Fax: +49 (0) 2191 9339-0
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com

© 05/2005 2/7 0312 3336 - 0128

 
TCD 2012 2V Standard tools

8002
Pressure pump
Checking fuel system for leak-tightness

© 35409-2

7
8005
Compression pressure tester
for diesel engines
10 - 40 bar

© 35410-3

8024
Assembly pliers
Removing valve stem gaskets

© 37509-2

© 05/2005 3/7 0312 3336 - 0128

 Standard tools TCD 2012 2V

8113
Socket wrench insert
Torx - E 14

© 43022-0

7
8114
Socket wrench insert
Torx - E 20

© 35415-1

8115
V-belt tension meter
150 to 600 N
for checking the V-belt tension

© 35416-3

© 05/2005 4/7 0312 3336 - 0128

 
TCD 2012 2V Standard tools

8189
Torx tool set
Case containing: 
- 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

7
8190
Rotation angle disc
with magnet
Setting valve clearance

© 43528-0

8191
Screwdriver insert
for slotted screw
Valve clearance setting

© 43060-0

© 05/2005 5/7 0312 3336 - 0128

 Standard tools TCD 2012 2V

8192
Bowl wrench
Fuel pre-filter (type: Racor)

© 43193-1

7
8194
Screwdriver insert
with hexagonal socket (size 4 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)

© 43183-0

8196
Open end wrench adapter
Size 13, 
for torque wrench
Tightening of lock nut of the valve clearance setting
screw

© 43019-0

© 05/2005 6/7 0312 3336 - 0128

 
TCD 2012 2V Standard tools

8198
Pricker
Removing rotary shaft lip seal

© 43206-0

7
8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)

© 44309-0

9017
Assembly lever
Example: Removing and installing the valves

© 37511-2

© 05/2005 7/7 0312 3336 - 0128

 
TCD 2012 2V Special tools

8 Special tools

© 05/2005 1/12 0312 3337 - 0128

 Special tools TCD 2012 2V

Orders
The tools can be ordered directly, stating the order
number, from:
WILBAER
Wilhelm Bäcker GmbH & Co.KG
Postfach 14 05 80
42826 Remscheid
Germany
Phone: +49 (0) 2191 9339-200
Fax: +49 (0) 2191 9339-0
E-mail: info@wilbaer.de
Web: http://www.deutz-tools.com

© 05/2005 2/12 0312 3337 - 0128

 
TCD 2012 2V Special tools

100 190
Connection piece
(in conjunction with compression pressure tester 8005)

© 42524-1

100 320
Turning gear 8
flywheel side

© 35422-1

100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper

© 35423-1

© 05/2005 3/12 0312 3337 - 0128

 Special tools TCD 2012 2V

100 400
Dial gauge with fixing wheel
Measuring range 0 -10mm / 0.01mm

© 35424-1

100 410
8 Digital gauge
Measuring range 0 -30 mm / 0.01 mm

© 43205-0

100 750
Measuring apparatus
Measuring bar with two spacing washers
(in conjunction with 100 400 or 100 410)
Checking valve lag dimension
Checking piston projection

© 39402-1

© 05/2005 4/12 0312 3337 - 0128

 
TCD 2012 2V Special tools

103 050
Socket wrench insert
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)

© 43023-0

103 220
Special pliers 8
for removing the roller tappet

© 43010-0

110 500
Special wrench
Size 17
Removing and installing high-pressure lines

© 35436-1

© 05/2005 5/12 0312 3337 - 0128

 Special tools TCD 2012 2V

110 700
Socket wrench insert
long
Assembling/disassembling pressure sensors
(rail pressure, oil pressure, fuel pressure)

© 43198-2

110 900
8 Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three assembly sleeves
with guide:
- High pressure pump (Ø 36), 110 902
- Injector, 2V motor (Ø 16), 110 903
- Injector, 4V motor (Ø 23), 110 904
Disassembling/assembling O-rings

© 43208-0

120 430
Assembly tool
Removing and installing the heating plugs

© 43020-0

© 05/2005 6/12 0312 3337 - 0128

 
TCD 2012 2V Special tools

120 900
Support bracket
pivoting
Clamping cylinder head

© 35438-3

120 910
Base plate for support bracket 8
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)

© 35439-3

121 410
Assembly tool
Assembling valve stem gaskets

© 37614-2

© 05/2005 7/12 0312 3337 - 0128

 Special tools TCD 2012 2V

121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket

© 43210-0

130 300
8 Universal piston ring pliers
Removing and installing the piston rings

© 43021-0

130 440
Trapezoidal groove wear gauge
for piston diameter 101 mm
Check piston ring groove

© 36461-2

© 05/2005 8/12 0312 3337 - 0128

 
TCD 2012 2V Special tools

130 450
Trapezoidal groove wear gauge
for piston diameter 98 mm
Check piston ring groove

© 36461-2

130 660
Piston ring tensioning band 8
Piston diameter 98 mm

© 39408-1

130 670
Piston ring tensioning band
Piston diameter 101 mm

© 39408-1

© 05/2005 9/12 0312 3337 - 0128

 Special tools TCD 2012 2V

142 670
Assembly tool
Assembling crankshaft sealing ring
(opposite side to flywheel)

© 35445-1

142 830
8 Assembly tool
for crankshaft (flywheel side)

© 35446-1

144 800
Counter support
Torsional vibration damper

© 35453-1

© 05/2005 10/12 0312 3337 - 0128

 
TCD 2012 2V Special tools

170 050
Special wrench
Unscrew the filter cartridges

© 37629-2

170 160
Stoppers/caps 8
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

© 43663-0

6066
Assembly block
Engine clamping, double-sided

© 35451-2

© 05/2005 11/12 0312 3337 - 0128

 Special tools TCD 2012 2V

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

© 05/2005 12/12 0312 3337 - 0128