Werkstatthandbuch

Workshop Manual
Manual d`atelier
Manual de taller

Kompetenzklasse 2
competence level 2
catégories de compétence 2
clases de competencia 2

TCD 2012 2V

0312 4036 en

Diese Unterlage ist Copyright geschützt. Eine Weiterverbreitung in gedruckter bzw.

elektronischer Form ist ohne unsere Zustimmung nicht zulässig.

This document is copyright protected. Distribution in either printed or electronic

form is not allowed without our prior agreement.

Ce document est protégé par copyright. Toute diffusion sous forme imprimée ou
électronique est interdite sans notre accord préalable.

Esta documentación está protegida por copyright. Queda prohibida la redistri-

bución imprasa o electrónica sin nuestro consentimiento.

Gegenüber Darstellungen und Angaben dieses Werkstatthandbuches sind

technische Änderungen, die zur Verbesserung der Motoren notwendig werden,
vorbehalten. Nachdruck und Vervielfältigung jeglicher Art, auch auszugsweise,
bedarf unserer schriftlichen Genehmigung.

Illustrations and data in this workshop manual are subject to technical change in the
course of improvements to the engines. Reprinting and reproductions of any kind,
even in part, require our written permission.

Tous droits de modifications techniques, en ce qui concerne les représentations et

informations contenues dans ce manuel d’atelier et qui s’avèrent nécessaires en vue
d’une amélioration des moteurs, réservés. Toute réimpression et reproduction par
quelque procédé que ce soit, même par extraits, exige une autorisation écrite de notre
part.

Reservado el derecho a realizar las modificaciones técnicas que se estimen

necesarias para la mejora de los motores, en lo referente a las ilustraciones ydatos
de este manual de taller. La reimpresión y la reproducción por cualquier medio, ya
sea total o parcialmente, requieren de nuestra autorización por escrito.

© 2007
 Regarding copyright questions and licensing agreements
please contact :
VS-DI, Mr. Sonntag
Tel.: + 49 (0) 221 822-3053
EMail: [email protected]

Deutz AG
Service Information Systems
Ottostraße 1
D - 51149 Cologne
Tel.: + 49 (0) 221-8 22-0
Fax: + 49 (0) 221-8 22-58 50
http://www.deutz.com

Printed in Germany
All rights reserved
1st edition, 05/2005
Order No. 0312 4036 en

© 06/2007
 Workshop Manual

TCD 2012 2V

0312 4036 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
Ottostraße 1
D-51149 Cologne
Germany
Tel.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-5850
Web: http://www.deutz.com

Printed in Germany
All rights reserved
1st Edition, 05/2005
The engine company. Order No. 0312 4036 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 1/2 12565-001

 TCD 2012
Table of contents 2V

© 05/2005 2/2 12565-001

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

© 12/2005 1/7 4076-001

 User notes

© 12/2005 2/7 4076-001

 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
The maintenance work described in the operation are dependent on the application site, operating 3
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 operation manual. The job cards contain tech- – Do not work on the fuel system when the en-
nical documentation on 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 sytem.
– After all work on the fuel system, it must be
bleeded - see the operation manual, chapter
"6.2 Fuel system“.
– Only start the engine when all the protective
devices have been fitted. Make sure no-one is
standing in the danger area.
– Cleaning, maintenance and repair work may
only be performed with the engine at a stand-
still and secured against starting.
– Injection lines and high pressure pipes must
not be deformed.

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 User notes

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

© 12/2005 4/7 4076-001

 User notes

z When removing and installing components, no operating materials among other things. The re-
materials which can leave behind particles or fi- newed parts / operating materials must be stored,
bres (cardboard, wood, cloths) may be used. transported and disposed of according to regula-
z Removed parts may only be rubbed down with tions. The owner himself is responsible for this.
clean, lint-free cloths. No dirt particles may be Disposal includes recycling and the scrapping of
rubbed into the components. parts / operating materials, although recycling has
z Openings on the components and on the engine priority.
3
must be closed immediately with suitable stop- Details of disposal and their monitoring are gov-
pers/caps. erned by regional, national and international laws
z The stoppers/caps may only be removed imme- and directives which the system operator must ob-
diately before installing. serve on his own responsibility.
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
area
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
removed components.
z Clean the removal and installation tools regularly
and keep them 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 operation manual and
workshop manual necessitates renewal of parts and

© 12/2005 5/7 4076-001

 User notes

3.3 Operation 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 operation 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 operation manual contains a general descrip-
3 tion and instructions for all other maintenance work.
card.
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.
3. Operation Special tools and machine tools must be available,
for example.
4. Operating media
3.4.1 Numbering of job cards
5. Maintenance
The job card numbers follow the pattern W 02-04-
6. Care and maintenance work
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 operation manual. This applies es-
– 00 ... General / interdisciplinary activities
pecially for the safety regulations. The workshop
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

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 User notes

3.4.2 Structure of a job card 3.5 Explanation of symbols

Danger!
of death or to health. Must be observed!
1 2 3
For example: The incorrect use or conver-
sion of the turbocharger can lead to serious
Triebwerk injury.
W 02-04-01 4
Caution! 3
5
Danger to the component/engine. Non-
16
6 compliance can lead to destruction of the
component/engine.
15
6 7 Must be observed!

14
Note
General notes on assembly, environmental
8 protection etc. No potential danger for man
13 or machine.
Tool
Conventional and special tools required for
12
the work.
8
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
11 10 9 References
to important documents or job cards for the
1. DEUTZ AG, work process.
publisher of service documentation For example: Job card W 04-05-05
2. Engine type (e.g. TCD 2013 4V) Reference
3. Maintenance group to a document or a job card within the work
4. Job card number or topic process.
5. Title of job card Test and setting data
The necessary values are specified here.
6. Reference to other job cards
If several values are necessary, a cross re-
7. Chapter ference is given to the Test and Setting Va-
8. Graphic or photo lues table.
9. DEUTZ internal creation number and technical For example:
order number ID no. P01 61 = valve clearance, inlet
10.Page number Tightening specification
The necessary values are specified here.
11.Date of issue of job card
If several values are necessary, a cross re-
12.Note ference is given to the Tightening Specifi-
13.Danger / Important cations table.
14.Work sequence For example:
ID no. A01 001 = cylinder head screws
15.Special tools; auxiliary materials
16.Conventional tools

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 TCD 2012 2V Technical data

4 Technical data
4.1 Testing and setting data

© 05/2005 1/11 2958-002

 Technical data
Testing and setting data TCD 2012 2V

© 05/2005 2/11 2958-002

 © 05/2005

ID no. Designation Information Series Value Unit

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

TCD 2012 2V
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
P00 10 Working principle TCD 2012 2V Four-stroke -
P00 20 Combustion process TCD 2012 2V Direct injection -
L4 2V 4038
P00 30 Total volume TCD 2012 cm3
L6 2V 6067
3/11

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 -

Testing and setting data

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

Technical data
L4 2V 1-3-4-2
P00 71 Ignition sequence TCD 2012 -
L6 2V 1-5-3-6-2-4
2958-002

4
 4

Testing and setting data

Technical data
© 05/2005

ID no. Designation Information Series Value Unit

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
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
4/11

+0,033
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
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

TCD 2012 2V
2958-002
 TCD 2012 2V Technical data

4.2 Tightening specifications

© 05/2005 5/11 2958-002

 Technical data TCD 2012 2V

© 05/2005 6/11 2958-002

 © 05/2005

Post-
Pre-clam-
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

TCD 2012 2V
A00 003 Mounting feet/engine mounting on crankcase TCD 2012 2V 95 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 +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
7/11

A01 003 Lock nut valve clearance setting screw TCD 2012 2V 20 Nm
A01 004 Cylinder head cover on cylinder head M6 TCD 2012 2V 13 Nm
A01 012 Lock nut setting screw exhaust return module TCD 2012 2V 20 Nm
Solenoid valve (exhaust return line) on cylinder
A01 013 TCD 2012 2V 24 Nm
head

Tightening specifications
A01 016 Locking screw on cylinder head M14x12 Renew sealing ring TCD 2012 2V 34 Nm
A03 060 Crankcase ventilation on cylinder head TCD 2012 2V 21 Nm
M8x35-10.9
A03 092 Gearcase on crankcase M8x45-10.9 Observe tightening sequence TCD 2012 2V 30 Nm

Technical data
M8x50-10.9
A04 022 Cap on gearcase TCD 2012 2V 21 Nm
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
2958-002

4
 4

Tightening specifications
Technical data
© 05/2005

Post-
Pre-clam-
ID no. Designation Screw type Notes / Remarks Series clamping
ping value
value
A06 030 Charge air line on cylinder head TCD 2012 2V 13 Nm
M8x30-10.9
A06 046 Charge air manifold on charge air pipe TCD 2012 2V 30 Nm
M8x95-10.9
A07 024 Fuel supply pump on holder TCD 2012 2V 22 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
A07 087 Fuel filter console/radiator tank on crankcase TCD 2012 2V 30 Nm
Hand tigh-
A07 099 Fuel filter on fuel filter console
ten
Oil filter/beaker filter 25 Nm
8/11

A08 001 Lightly oil gasket / tighten well TCD 2012 2V Hand tigh-
Oil filter/interchangeable filter
by hand ten
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 051 Oil cooler housing on crankcase TCD 2012 2V 30 Nm

TCD 2012 2V
A08 091 Oil pressure switch on oil cooler housing TCD 2012 2V 20 Nm
Discharge nozzle on thermostat housing/fan con-
A09 002 TCD 2012 2V 21 Nm
sole
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 °
A09 048 Adapter on V-rib belt pulley TCD 2012 2V 30 Nm
2958-002
 © 05/2005

Post-
Pre-clam-
ID no. Designation Screw type Notes / Remarks Series clamping
ping value
value
+60 °
M10x30 30 Nm
+30 °

TCD 2012 2V
M10x35
M10x40
M10x45
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 +60 °
A12 030 M16x1.5 TCD 2012 2V 40 Nm
crankshaft they are loosened. +60 °
9/11

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
A12 092 Hollow screw pipe union M12x1.5 Ring piece pipe 8 mm TCD 2012 2V 39 Nm
Pipe clip, fastening wiring harness 30 Nm
A12 095 TCD 2012 2V
Pipe clip for return line M6 13 Nm

Tightening specifications
A13 001 Starter on gearcase cover TCD 2012 2V 70 Nm
M8x30

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

Technical data
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
2958-002

4
 4

Tightening specifications
Technical data
© 05/2005

Post-
Pre-clam-
ID no. Designation Screw type Notes / Remarks Series clamping
ping value
value
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
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
10/11

TCD 2012 2V
2958-002
 Technical data
TCD 2012 2V Tightening specifications

© 05/2005 11/11 2958-002

 TCD 2012 2V Job card overview

5
5 Job card overview
5.1 Sorted alphabetically

© 05/2005 1/13 0312 3334 - 0128

 Job card overview
Sorted alphabetically TCD 2012 2V

© 05/2005 2/13 0312 3334 - 0128

 Job card overview
TCD 2012 2V Sorted alphabetically

Activity Job card Maintenance group

Checking the coolant thermostat, in the removed
W 09-08-01 Cooling system
state
Disassembling, assembling and checking the rocker
W 01-02-06 Cylinder head
arm and rocker arm bracket
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 5
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 charge air line W 06-07-03 Exhaust system / Charging
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 exhaust manifold W 06-01-05 Exhaust system / Charging
Removing and installing the exhaust return module W 06-09-01 Exhaust system / Charging
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 fuel supply pump (V-rib
W 07-11-01 Fuel system
belt drive)
Removing and installing the generator (V-rib belt
W 13-02-03 Electrical system
drive)
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 pressure/temperature
W 13-08-01 Electrical system
sensor (charge air)
Removing and installing the solenoid valve exhaust
W 06-09-02 Exhaust system / Charging
return line
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
Removing and installing the water cistern W 09-06-01 Cooling system
Setting the valve clearance (with installed exhaust
W 01-01-01 Cylinder head
return module)

© 05/2005 3/13 0312 3334 - 0128

 Job card overview
Sorted alphabetically TCD 2012 2V

Activity Job card Maintenance group

Setting the valve clearance (without or with removed
W 01-01-01 Cylinder head
exhaust return module)

© 05/2005 4/13 0312 3334 - 0128

 TCD 2012 2V Job card overview

5
5.2 Sorted numerically

© 05/2005 5/13 0312 3334 - 0128

 Job card overview
Sorted numerically TCD 2012 2V

© 05/2005 6/13 0312 3334 - 0128

 Job card overview
TCD 2012 2V Sorted numerically

Job card Activity Maintenance group

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)
Removing and installing rocker arms and rocker arm
W 01-02-02 Cylinder head
brackets
5
Disassembling, assembling and checking the rocker
W 01-02-06 Cylinder head
arm and rocker arm bracket
W 03-01-11 Removing and installing the crankcase bleeding Crankcase
W 06-01-05 Removing and installing the exhaust manifold Exhaust system / Charging
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
belt drive)
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
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 09-13-02 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)
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

© 05/2005 7/13 0312 3334 - 0128

 Job card overview
Sorted numerically TCD 2012 2V

Job card Activity Maintenance group

Removing and installing the pressure/temperature
W 13-08-01 Electrical system
sensor (charge air)

© 05/2005 8/13 0312 3334 - 0128

 TCD 2012 2V Job card overview

5
5.3 Job card references

© 05/2005 9/13 0312 3334 - 0128

 Job card overview
Job card references TCD 2012 2V

© 05/2005 10/13 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
Mounting and dismounting the engine on the assembly block
W 00-05-01

01 Cylinder head
Job card Activity and additional job cards necessary for its execution
Setting the valve clearance (with installed exhaust return module) 5
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

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

06 Exhaust system / Charging

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

© 05/2005 11/13 0312 3334 - 0128

 Job card overview
Job card references TCD 2012 2V

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

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 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
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

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

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

© 05/2005 12/13 0312 3334 - 0128

 Job card overview
TCD 2012 2V Job card references

12 Other components (Forts.)

Job card Activity and additional job cards necessary for its execution
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
5
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 pressure/temperature sensor (charge air)

W 13-08-01

© 05/2005 13/13 0312 3334 - 0128

 DEUTZ engines Job cards

6 Job cards
6

© 11/2005 1/2 1621-002

 Job cards DEUTZ engines

© 11/2005 2/2 1621-002

 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 1/5 2950-002

 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 2/5 2950-002

 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

3 6
1
© 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 3/5 2950-002

 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 4/5 2950-002

 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 5/5 2950-002

 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-
ted screws. . . . . . . . . . . . . . . . . . . . 8191
– Screwdriver insert for
hexagon socket head
screws (4 mm) . . . . . . . . . . . . . . . . 8194
Special tools:
– Turning gear . . . . . . . . . . . . . . . .100 320
– Socket wrench insert size
15 . . . . . . . . . . . . . . . . . . . . . . . .103 050 6

Allow the engine to cool down for at least

30 minutes before setting the valve clea-
rance.
Engine oil temperature < 80 °C.
The control piston clearance of the exhaust
return line must be set after setting the
valve clearance.
In engines without an exhaust return
module, a slotted adjusting screw must be
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 2941-002

 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 2941-002

 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 63

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
 P01 63
Attention!
Note design of the adjusting screw (with
slot, wrench size or hexagon socket).
EX IN

© 42536-0

© 05/2005 3/10 2941-002

 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 61

© 42539-0

© 05/2005 4/10 2941-002

 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 2941-002

 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 62

6
© 42541-0

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.
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 2941-002

 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 63

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 2941-002

 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.
 P01 64

© 42936-0

© 05/2005 8/10 2941-002

 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 003
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).

 A03 092
Use M8 x 45 mm screws.

© 42542-0

© 05/2005 9/10 2941-002

 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 2941-002

 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 2942-002

 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 2942-002

 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.
 P01 63

© 42534-0

© 05/2005 3/12 2942-002

 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 2942-002

 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 61

© 43044-0

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

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

© 43045-0

© 05/2005 5/12 2942-002

 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 62

© 43048-0

© 05/2005 6/12 2942-002

 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 63

© 42534-0

© 05/2005 7/12 2942-002

 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 2942-002

 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.
 P01 64

© 42936-0

z Hold the setting screw to prevent it turning wrongly

and tighten the lock nut (arrow) with the open
wrench.
 A01 012
z Remove rotation angle disc.
Set all other control pistons according to
the valve setting schematic T01 63.

© 43050-0

© 05/2005 9/12 2942-002

 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).

 A03 092
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 2942-002

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

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

 A04 022
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 004
1
Attention!
Do not trap the cable (1) when mounting
the cylinder head cover.

© 42938-0

© 05/2005 11/12 2942-002

 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).
 A13 041
1

© 43016-0

© 05/2005 12/12 2942-002

 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 2944-002

 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 2944-002

 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 2944-002

 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 2944-002

 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 2944-002

 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 2944-002

 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 2944-002

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

© 05/2005 8/8 2944-002

 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 2946-002

 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 2946-002

 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 2946-002

 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 2946-002

 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 2953-002

 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 2953-002

 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 2953-002

 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 2953-002

 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 2953-002

 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 2953-002

 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 2953-002

 Crankcase
W 03-01-11 TCD 2012 2V

© 05/2005 8/8 2953-002

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

Removing and installing the 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 2898-002

 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 2898-002

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

Remove and install the 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 2901-002

 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 2901-002

 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 2901-002

 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 046

© 42773-0

© 05/2005 4/4 2901-002

 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 2921-002

 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 2921-002

 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 2921-002

 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 2921-002

 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 2921-002

 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 2921-002

 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 2923-002

 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 2923-002

 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 2923-002

 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 2923-002

 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 2923-002

 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 2923-002

 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 2925-002

 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 2925-002

 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 2925-002

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

© 05/2005 4/4 2925-002

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

Removing and installing the 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 2926-002

 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 2926-002

 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 2926-002

 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 2926-002

 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 2926-002

 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 2926-002

 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 2930-002

 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 2930-002

 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 2930-002

 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 2930-002

 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 2937-002

 Lube oil system
W 08-10-06 TCD 2012 2V

© 05/2005 2/2 2937-002

 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 2938-002

 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 2938-002

 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 2939-002

 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 2939-002

 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 2939-002

 Cooling system
W 09-06-01 TCD 2012 2V

© 05/2005 4/4 2939-002

 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 thermo-
stat.

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 2902-002

 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 2902-002

 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 2905-002

 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 2905-002

 Cooling system
TCD 2012 2V W 09-12-01

Removing and installing the 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 2906-002

 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 2906-002

 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 2908-002

 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 2908-002

 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 2908-002

 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 2908-002

 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 1/5 2909-002

 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 2/5 2909-002

 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 3/5 2909-002

 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 4/5 2909-002

 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 5/5 2909-002

 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 2910-002

 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 2910-002

 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 2911-002

 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 2911-002

 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 2911-002

 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 2911-002

 Other components
TCD 2012 2V W 12-06-01

Removing and installing the 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 2912-002

 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 2912-002

 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 2912-002

 Other components
W 12-06-01 TCD 2012 2V

© 05/2005 4/4 2912-002

 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 2913-002

 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 2913-002

 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 2913-002

 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 2913-002

 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 2913-002

 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 2913-002

 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 2913-002

 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 2913-002

 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 2913-002

 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 2913-002

 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 2914-002

 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 2914-002

 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 2914-002

 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 2914-002

 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 2916-002

 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 2916-002

 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 2918-002

 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 2918-002

 TCD 2012 2V Standard tools

7 Standard tools

© 05/2005 1/7 3010-002

 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 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: [email protected]
Web: http://www.deutz-tools.com

© 05/2005 2/7 3010-002

 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 3010-002

 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 3010-002

 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 3010-002

 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 3010-002

 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 3010-002

 TCD 2012 2V Special tools

8 Special tools

© 05/2005 1/5 3015-002

 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 9339-0
Fax: +49 (0) 2191 9339-200
E-mail: [email protected]
Web: http://www.deutz-tools.com

© 05/2005 2/5 3015-002

 TCD 2012 2V Special tools

100 320
Turning gear
flywheel side

© 35422-1

100 400
Dial gauge with fixing wheel 8
Measuring range 0 -10mm / 0.01mm

© 35424-1

103 050
Socket wrench insert
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)

© 43023-0

© 05/2005 3/5 3015-002

 Special tools TCD 2012 2V

110 700
Socket wrench insert
long
Assembling/disassembling pressure sensors
(rail pressure, oil pressure, fuel pressure)

© 43198-2

144 800
8 Counter support
Torsional vibration damper

© 35453-1

170 050
Special wrench
Unscrew the filter cartridges

© 37629-2

© 05/2005 4/5 3015-002

 TCD 2012 2V Special tools

170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

© 43663-0

6066
Assembly block 8
Engine clamping, double-sided

© 35451-2

6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided

© 35452-1

© 05/2005 5/5 3015-002