Work Shop Manual TCD2012 2V

Workshop Manual
Competence level 3
TD/TCD 2012 2V
Mechanical Injection
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This document is subject to changes which may become necessary in the course of further de-
velopment of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.
Regarding copyright questions and licensing agreements
please contact : VS-DL, Mr. Lippke
Phone.: + 49 (0) 221 822-2599
E-Mail: lippke.d@deutz.com
DEUTZ AG
Informations Systeme Vertrieb u. Service
Ottostraße 1
D-51149 Köln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
Internet: www.deutz.com
E-Mail: info@deutz.com
Printed in Germany
All rights reserved
1st Edition © 02/2011
The engine company. Order No. 0312 3822 en
TD 2012 2V
TCD 2012 2V Table of contents
1 Foreword
2 General
3 User notes
3.1 General
3.2 Specifications
3.3 Operating manual and workshop manual
3.4 Job cards
3.5 Explanation of symbols
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
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TD 2012 2V
Table of contents TCD 2012 2V
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DEUTZ engines Foreword
1 Foreword
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Foreword DEUTZ engines
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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
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Foreword DEUTZ engines
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DEUTZ engines General
2 General
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General DEUTZ engines
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DEUTZ engines General
DEUTZ engines are the product of years of 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 specialist personnel ensures
fast and professional repairs using original DEUTZ
spare parts in the event of damage.
Original spare parts from DEUTZ AG are always
manufactured according to the state of the art.
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General DEUTZ engines
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DEUTZ engines User notes
3 User notes
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User notes DEUTZ engines
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3.1 General 3.2 Specifications

The documentation of the workshop manual has 3.2.1 Accident prevention and safety 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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– 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-
3 pressure fuel system. ment (no dust, no grinding or welding). Avoid
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.
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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
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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 – W.... Workshop 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- – 02 ... Drive 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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3.4.2 Structure of a job card 3.5 Explanation of symbols

Danger!
1 2 3
of death or to health. Must be observed!
For example: The incorrect use or conver-
sion of the turbocharger can lead to serious
Triebwerk
W 02-04-01 4 injury.
Caution! 3
5
16 Danger to the component/engine. Non-
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 For example:
ID no. P01 61 = valve clearance, inlet
10.Page number
11.Date of issue of job card Tightening specification
The necessary values are specified here.
12.Note If several values are necessary, a cross re-
13.Danger / Important ference is given to the Tightening Specifi-
14.Work sequence cations table.
15.Special tools; auxiliary materials For example:
ID no. A01 001 = cylinder head screws
16.Conventional tools
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TD 2012 2V Job card overview
TCD 2012 2V Sorted alphabetically
5
5 Job card overview
5.1 Sorted alphabetically
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Job card overview TD 2012 2V
Sorted alphabetically TCD 2012 2V
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Activity Job card Maintenance group

Checking axial backlash of crankshaft (crankshaft
W 02-01-04 Drive system
removed)
Checking fuel injectors W 07-07-05 Fuel system
Checking piston overhang W 01-04-09 Cylinder head
Checking the camshaft W 04-05-06 Engine control
Checking the compression pressure W 00-02-06 General
Checking the con rod W 02-03-01 Drive system
5
Checking the crankshaft W 02-01-07 Drive system
Checking the cylinders W 03-03-01 Crankcase
Checking the piston W 02-09-07 Drive system
Checking the piston rings and piston ring grooves W 02-10-03 Drive system
Checking the thermostat (in the removed state) W 09-08-01 Cooling system
Checking the valve guide W 01-06-03 Cylinder head
Checking the valve lag W 01-07-08 Cylinder head
Checking the valves W 01-05-04 Cylinder head
Determining the installation dimension of the injec-
W 07-06-04 Fuel system
tion pump (engine with injection adjuster)
Determining the thickness of the shim (engine with
injection adjuster)
Determining the thickness of the shim (engine wit-
hout injection adjuster)
Disassembling, assembling and checking the rocker
W 01-02-06 Cylinder head
arm and rocker arm bracket
Dismantling and assembling the air bearing W 09-13-01 Cooling system
Installing and removing turning gear W 04-06-03 Engine control
Mounting engine on assembly block and demoun-
W 00-05-01 General
ting
Removing and and installing the fuel filter console W 07-10-08 Fuel system
Removing and installing coolant pump W 09-07-08 Cooling system
Removing and installing temperature transmitter W 09-12-01 Cooling system
Removing and installing the air bearing W 09-13-04 Cooling system
Removing and installing the camshaft W 04-05-05 Engine control
Removing and installing the charge air line W 06-07-03 Exhaust system / Charging
Removing and installing the connection housing W 03-09-04 Crankcase
Removing and installing the crankcase bleeding W 03-01-11 Crankcase
Removing and installing the crankshaft W 02-04-01 Drive system
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Removing and installing the cylinder head W 01-04-04 Cylinder head
Removing and installing the engine shutdown W 11-00-03 Monitoring system
Removing and installing the exhaust line W 06-01-05 Exhaust system / Charging
Removing and installing the flywheel W 12-06-01 Other components
Removing and installing the front cover (opposite
W 03-08-01 Crankcase
side to flywheel)
Removing and installing the fuel injector pump W 07-04-01 Fuel system
5 Removing and installing the fuel injectors W 07-07-01 Fuel system
Removing and installing the fuel supply pump W 07-11-01 Fuel system
Removing and installing the gearcase cover W 04-04-09 Engine control
Removing and installing the generator (V-belt drive) W 13-02-03 Electrical system
Removing and installing the heating flange W 06-02-08 Exhaust system / Charging
Removing and installing the lubricating oil pan
W 08-04-07 Lube oil system
(die-cast lubricating oil pan)
(metal lubricating oil pan)
Removing and installing the oil cooler W 08-08-02 Lube oil system
Removing and installing the oil cooler housing W 08-08-03 Lube oil system
Removing and installing the oil pressure switch W 08-11-08 Lube oil system
Removing and installing the oil suction pipe W 08-04-06 Lube oil system
Removing and installing the piston and con rod W 02-09-03 Drive system
Removing and installing the piston cooling nozzles W 02-15-01 Drive system
Removing and installing the rocker arm and rocker
arm bracket
Removing and installing the speed governor W 05-05-01 Speed governing
Removing and installing the starter W 13-03-02 Electrical system
Removing and installing the thermostat W 09-08-02 Cooling system
Removing and installing the turbocharger W 06-06-04 Exhaust system / Charging
Removing and installing the valves W 01-05-01 Cylinder head
Removing and installing the V-belt pulley W 12-01-04 Other components
Removing and installing, checking and setting the
W 05-04-14 Speed governing
control linkage
Removing and installing, checking the mass com-
pensation shafts
Removing and installing, testing camshaft bearing W 03-11-01 Crankcase
Renewing the crankshaft sealing ring (flywheel side) W 02-02-02 Drive system
Renewing the crankshaft sealing ring (opposite side
to flywheel)
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Renewing toothed starter flywheel ring W 12-06-03 Other components
Setting valve clearance W 01-01-01 Cylinder head
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TCD 2012 2V Sorted numerically
5
5.2 Sorted numerically
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Sorted numerically TCD 2012 2V
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Job card Activity Maintenance group

W 00-02-06 Checking the compression pressure General
Mounting engine on assembly block and demoun-
W 00-05-01 General
ting
W 01-01-01 Setting valve clearance Cylinder head
Removing and installing the rocker arm and rocker
arm bracket
Disassembling, assembling and checking the rocker
arm and rocker arm bracket
5
W 01-04-04 Removing and installing the cylinder head Cylinder head
W 01-04-09 Checking piston overhang Cylinder head
W 01-05-01 Removing and installing the valves Cylinder head
W 01-05-04 Checking the valves Cylinder head
W 01-06-03 Checking the valve guide Cylinder head
W 01-07-08 Checking the valve lag Cylinder head
Checking axial backlash of crankshaft (crankshaft
removed)
W 02-01-07 Checking the crankshaft Drive system
W 02-02-02 Renewing the crankshaft sealing ring (flywheel side) Drive system
Renewing the crankshaft sealing ring (opposite side
to flywheel)
W 02-03-01 Checking the con rod Drive system
W 02-04-01 Removing and installing the crankshaft Drive system
Removing and installing, checking the mass com-
pensation shafts
W 02-09-03 Removing and installing the piston and con rod Drive system
W 02-09-07 Checking the piston Drive system
W 02-10-03 Checking the piston rings and piston ring grooves Drive system
W 02-15-01 Removing and installing the piston cooling nozzles Drive system
W 03-01-11 Removing and installing the crankcase bleeding Crankcase
W 03-03-01 Checking the cylinders Crankcase
Removing and installing the front cover (opposite
W 03-08-01 Crankcase
side to flywheel)
W 03-09-04 Removing and installing the connection housing Crankcase
W 03-11-01 Removing and installing, testing camshaft bearing Crankcase
W 04-04-09 Removing and installing the gearcase cover Engine control
W 04-05-05 Removing and installing the camshaft Engine control
W 04-05-06 Checking the camshaft Engine control
W 04-06-03 Installing and removing turning gear Engine control
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Removing and installing, checking and setting the
W 05-04-14 Speed governing
control linkage
W 05-05-01 Removing and installing the speed governor Speed governing
W 06-01-05 Removing and installing the exhaust line Exhaust system / Charging
W 06-02-08 Removing and installing the heating flange 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
5 W 07-04-01 Removing and installing the fuel injector pump Fuel system
Determining the thickness of the shim (engine wit-
hout injection adjuster)
Determining the thickness of the shim (engine with
injection adjuster)
W 07-07-01 Removing and installing the fuel injectors Fuel system
W 07-07-05 Checking fuel injectors Fuel system
W 07-10-08 Removing and and installing the fuel filter console Fuel system
W 07-11-01 Removing and installing the fuel supply pump Fuel system
W 08-04-06 Removing and installing the oil suction pipe Lube oil system
(metal lubricating oil pan)
W 08-08-02 Removing and installing the oil cooler Lube oil system
W 08-08-03 Removing and installing the oil cooler housing Lube oil system
W 08-11-08 Removing and installing the oil pressure switch Lube oil system
W 09-07-08 Removing and installing coolant pump Cooling system
W 09-08-01 Checking the thermostat (in the removed state) Cooling system
W 09-08-02 Removing and installing the thermostat Cooling system
W 09-12-01 Removing and installing temperature transmitter Cooling system
W 09-13-01 Dismantling and assembling the air bearing Cooling system
W 09-13-04 Removing and installing the air bearing Cooling system
W 11-00-03 Removing and installing the engine shutdown Monitoring system
W 12-01-04 Removing and installing the V-belt pulley Other components
W 12-06-01 Removing and installing the flywheel Other components
W 12-06-03 Renewing toothed starter flywheel ring Other components
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W 13-02-03 Removing and installing the generator (V-belt drive) Electrical system
W 13-03-02 Removing and installing the starter Electrical system
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TCD 2012 2V Job card references
5
5.3 Job card references
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Job card references TCD 2012 2V
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00 General
Job card Activity and additional job cards necessary for its execution
Checking the compression pressure
W 00-02-06
W 01-01-01 W 07-07-01
Mounting engine on assembly block and demounting
W 00-05-01
01 Cylinder head 5
Setting valve clearance
W 01-01-01
W 01-04-04 W 04-06-03
Removing and installing the rocker arm and rocker arm bracket
W 01-02-02
W 01-01-01 W 01-04-04
Disassembling, assembling and checking the rocker arm and rocker arm bracket
W 01-02-06
W 01-02-02
Removing and installing the cylinder head
W 01-04-04 W 01-01-01 W 01-02-02 W 01-04-09 W 06-01-05 W 06-07-03
W 07-07-01 W 09-13-04
Checking piston overhang
W 01-04-09
W 01-04-04 W 04-06-03
Removing and installing the valves
W 01-05-01
W 01-04-04
Checking the valves
W 01-05-04
W 01-05-01
Checking the valve guide
W 01-06-03
W 01-05-01
Checking the valve lag
W 01-07-08
W 01-04-04
02 Drive system
Checking the axial clearance of the crankshaft
W 02-01-04
W 02-04-01 W 03-08-01 W 04-04-09
Checking the crankshaft
W 02-01-07
W 02-04-01
© 11/2005
15/20 OBJ_DOKU-13967-001.fm
02 Drive system (continued)

Renewing the crankshaft sealing ring (flywheel side)
W 02-02-02
W 12-06-01
Renewing the crankshaft sealing ring (opposite side to flywheel)
W 02-02-04
W 12-01-04
Checking the con rod
W 02-03-01
W 02-09-03
5 -
Removing and installing the crankshaft

W 02-04-01
W 02-01-07 W 02-09-03 W 03-08-01 W 04-04-09
Removing and installing, checking the mass compensation shafts
W 02-08-01
W 04-04-09
Removing and installing the piston and con rod
W 02-09-03
W 01-04-04 W 02-10-03 W 08-04-06
Checking the piston
W 02-09-07
W 02-09-03
Checking the piston rings and piston ring grooves
W 02-10-03
W 02-09-03
Removing and installing the piston cooling nozzles
W 02-15-01
W 02-04-01
03 Crankcase
Removing and installing the crankcase bleeding
W 03-01-11
Checking the cylinders

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

W 03-11-01
W 02-04-01 W 04-05-05
© 11/2005
16/20 OBJ_DOKU-13967-001.fm
04 Engine control
Removing and installing the gearcase cover
W 04-04-09 W 02-02-02 W 03-09-04 W 05-05-01 W 08-04-07 W 12-06-01
W 13-03-02
Removing and installing the camshaft
W 04-05-05
W 01-02-02 W 02-04-01 W 07-04-01 W 07-07-01
Checking the camshaft 5
W 04-05-06
W 04-05-05
Installing and removing turning gear
W 04-06-03
05 Speed governing
Removing and installing, checking and setting the control linkage
W 05-04-14
W 04-04-09 W 05-05-01 W 07-04-01
Removing and installing the speed governor
W 05-05-01
06 Exhaust system / Charging

Removing and installing the exhaust line
W 06-01-05
W 06-06-04
Removing and installing the heating flange
W 06-02-08
Removing and installing the turbocharger

W 06-06-04
Removing and installing the charge air line

W 06-07-03
W 01-04-04
07 Fuel system
Removing and installing the fuel injector pump
W 07-04-01
W 01-04-04 W 07-06-03 W 07-06-03 W 07-06-04 W 07-06-04
Determining the thickness of the shim (engine without injection adjuster)
W 07-06-03
W 07-04-01
© 11/2005
17/20 OBJ_DOKU-13967-001.fm
07 Fuel system (continued)

Determining the thickness of the shim (engine with injection adjuster)
W 07-06-03
W 07-04-01
Determining the installation dimension of the injection pump (engine with injection adjuster)
W 07-06-04
W 07-04-01
Determining the installation dimension of the injection pump (engine with injection adjuster)
W 07-06-04
W 07-04-01
5 Removing and installing fuel injectors
W 07-07-01
W 01-04-04 W 07-07-05
Checking the fuel injector
W 07-07-05
W 07-07-01
Removing and and installing the fuel filter console
W 07-10-08
User notes
Removing and installing the fuel supply pump (V-belt drive)
W 07-11-01
User notes W 13-02-03
08 Lube oil system

Removing and installing the oil suction pipe
W 08-04-06
W 08-04-07
Removing and installing the lubricating oil pan (die-cast lubricating oil pan)
W 08-04-07
Removing and installing the lubricating oil pan (metal sheet lubricating oil pan)
W 08-04-07
Removing and installing the oil cooler

W 08-08-02
W 08-08-03
Removing and installing the oil cooler housing
W 08-08-03
User notes
Removing and installing the oil pressure switch
W 08-11-08
User notes
09 Cooling system
Removing and installing the coolant pump (V-belt drive)
W 09-07-08
W 07-11-01 W 09-13-04
© 11/2005
18/20 OBJ_DOKU-13967-001.fm
09 Cooling system (continued)

Checking the thermostat (in the removed state)
W 09-08-01
W 09-08-02
Removing and installing the thermostat
W 09-08-02
Removing and installing the temperature transmitter

W 09-12-01
Dismantling and assembling the air bearing 5

W 09-13-01
W 09-13-04
Removing and installing the air bearing
W 09-13-04
11 Monitoring system
Removing and installing the engine shutdown
W 11-00-03
12 Other components
Removing and installing the V-belt pulley
W 12-01-04
W 04-06-03 W 13-02-03
Removing and installing flywheel
W 12-06-01
Renewing toothed starter flywheel ring

W 12-06-03
W 12-06-01
13 Electrical system
Removing and installing the generator
W 13-02-03
Removing and installing the starter

W 13-03-02
© 11/2005
19/20 OBJ_DOKU-13967-001.fm
© 11/2005 20/20 13967-001

DEUTZ engines Job cards
6 Job cards
6
© 11/2005 1/2 13968-001

Job cards DEUTZ engines
© 11/2005 2/2 13968-001

TD 2012 2V General
TCD 2012 2V W 00-02-06

Commercial available tools: – W 01-01-01
– Compression pressure – W 07-07-01
tester. . . . . . . . . . . . . . . . . . . . . . . . 8005
– Torx tool set . . . . . . . . . . . . . . . . . . 8189
Special tools:
– Connector . . . . . . . . . . . . . . . . . . 100190

z Set valve clearance.
W 01-01-01
z Removing fuel injectors.
W 07-07-01
2
z Mount sealing ring (1).
z Insert connector (2).
© 46377-1
z Mount clamping shoe (1).

z Tighten screw (2).
16 Nm
© 46378-0
© 04/2007 1/4 13969-001

General TD 2012 2V
W 00-02-06 TCD 2012 2V
z Connect adapter (1) to connector.
6
© 46379-0
z Connect compression pressure tester to connector.

z Turn over engine with starter.
30 - 38 bar
© 46308-0
The measured compression pressure

depends on the starting speed during the
measuring process and the altitude of the No.
engine installation site. Therefore, limit Kompression in bar
Compression value in bar
values cannot be determined exactly. The Pression en bar
compression pressure measurement is Dat. _________
10 15 20 25 30 35 40
only recommended as a reference measu-
Zyl.
rement of all cylinders of an engine to each

other. If more than 15% deviation has been 1
determined, the cause should be determi- 2
ned by disassembling the cylinder unit con- 3
cerned. 4
5
6
7
8
DBGM Made in Germany
MOTOMETER
© 33771-5
© 04/2007 2/4 13969-001

TD 2012 2V General
TCD 2012 2V W 00-02-06
z Remove the compression pressure tester and

adapter (1).
6
© 46308-1
z Unscrew screw (1).

z Remove clamping shoe (2).
z Remove connector.
z Remove sealing ring.
z Install fuel injectors.
W 07-07-01
© 46378-1
© 04/2007 3/4 13969-001

General TD 2012 2V
W 00-02-06 TCD 2012 2V
© 04/2007 4/4 13969-001

TD 2012 2V General
TCD 2012 2V W 00-05-01
Mounting engine on assembly block and demounting

Commercial available tools: Different customer scopes are not taken
– Lifting gear into account in the repair sequence shown
– Suspension ropes here, accessories which deviate from the
Special tools: standard equipment are not shown.
– Assembly block incl. adap-
ter plates . . . . . . . . . . . . . . . . . . . . . 6066
– Clamping bracket . . . . . . . . . . .6066/158
– Engine lifting device . . . . . . . . . . . . 6068
Mounting engine on assembly block

z Hang the engine director onto the transport lashes
(arrows) with support chain.
– 4-cylinder
410 kg
z Hang engine on workshop crane.
Remove all mounting feet.
z Insert engine in engine block.
© 46446-0
z Mount clamping holder 6066/158-1 (1) on holder.

z Tighten screws (2) and lock nuts.
70 Nm
3
90 Nm
3 2
© 46448-0
© 04/2007 1/4 13970-001

General TD 2012 2V
W 00-05-01 TCD 2012 2V
z Mount clamping bracket 6066/158-2 (1) on holder.

70 Nm
z Tighten screws (3) and lock nuts. 1
2
90 Nm
3
6
© 46449-0
z Mount clamping bracket 6066/158-3 (1) on crank-

case.
70 Nm
2
90 Nm
3
1
© 46447-0
z Mount clamping holder 6066/158-4 (1) on crankcase.

z Tighten screws (2).
70 Nm
90 Nm 2
3
© 46450-0
© 04/2007 2/4 13970-001

TD 2012 2V General
TCD 2012 2V W 00-05-01
z Align engine on engine block.

z Tighten all screws (1).
z Unhook the engine from the workshop crane.
1 6
© 46459-0
Demounting engine from assembly block

z Hang the engine director onto the transport lashes
(arrows) with support chain.
– 4-cylinder
410 kg
z Hang engine on workshop crane.
© 46446-0
z Loosen lock nuts.

z Remove screws(3) and lock nuts.
z Unscrew screws (2).
z Remove clamping holder (1).
3
© 46450-0
© 04/2007 3/4 13970-001

General TD 2012 2V
W 00-05-01 TCD 2012 2V
z Loosen lock nuts.

1
3
3
6
© 46449-1
z Loosen lock nuts.

3 3
© 46448-1
z Loosen lock nuts.

z Remove clamping bracket (1).
2
Mount all mounting feet.
z Set down engine. 3

z Unhook the engine from the workshop crane. 1
© 46447-0
© 04/2007 4/4 13970-001

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

– Rotation angle disc . . . . . . . . . . . . . 8190 – W 04-06-03
– Open wrench size 13 . . . . . . . . . . . 8196
– Screwdriver insert for slot- Let the engine cool down for at least 30
ted screws. . . . . . . . . . . . . . . . . . . . 8191 minutes before setting the valve clearance.
– Screwdriver insert for Engine oil temperature < 80 °C
hexagon socket head
screws (5 mm) . . . . . . . . . . . . . . . . 8193
Special tools:
– Turn-over gear . . . . . . . . . . . . . . 100320
Setting engine to valve overlap

z Attach turning gear.
W 04-06-03
z Remove the cylinder head hood.
W 01-04-04
z Turn crankshaft using the turning gear until the valve
overlap of cylinder 1 is reached.
© 46461-0
Arrangement of the inlet and exhaust val-

ves.
IN = inlet valve
EX = exhaust valve EX IN
© 46381-0
© 04/2007 1/4 13971-001

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

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

The inlet valve starts opening,exhaust
valve closes.
6
© 46380-0
Setting the inlet valve clearance

z Loosen lock nut (1).
z Press in the adjusting screw (2) to the stop. 2
The rocker arm must touch the thrust was-
her of the spring cap (arrow).
Attention!
Pay attention to versions of the adjusting
screws (slotted, hexagonal, hexagonal 1
socket).
© 46382-0
z Set the rotation angle disc with a screwdriver insert

at the adjusting 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 „0“.
Do not rotate adjusting screw.
© 46462-0
© 04/2007 2/4 13971-001

TCD 2012 2V W 01-01-01
z Turn the adjusting screw in the direction of the arrow.

– Inlet
75°
6
© 46463-0
z Hold adjusting screw.

z Tighten lock nut (1) with open wrench.
20 Nm
z Remove rotation angle disc.
© 46464-0
Setting the exhaust valve clearance

z Press in the adjusting screw (2) to the stop.
The rocker arm must touch the thrust was-
her of the spring cap (arrow).
© 46387-0
© 04/2007 3/4 13971-001

W 01-01-01 TCD 2012 2V
z Set the rotation angle disc on the adjusting 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 „0“.
Do not rotate adjusting screw.
6
© 46465-0
z Turn the adjusting screw in the direction of the arrow.

– Outlet
120 °
© 46466-0
z Hold adjusting screw.

z Tighten lock nut (1) with open wrench.
20 Nm
z Remove rotation angle disc.
z Mount cylinder head cover.
W 01-04-04
z Remove turning gear.
W 04-06-03
© 46467-0
© 04/2007 4/4 13971-001

TCD 2012 2V W 01-02-02
Removing and installing the rocker arm and rocker arm bracket
– Pin wrench insert Torx E14 . . . . . . . 8113 – W 01-04-04
– Rotation angle disc . . . . . . . . . . . . . 8190
Removing the rocker arm and rocker arm

bracket
W 01-04-04
2
z Unscrew the cylinder head screw (1) with the socket
wrench insert.
z Remove rocker arm bracket.
Lay out components in the order in which
they should be installed.
1
© 46451-2
z Remove push rods (1).

© 46452-0
© 04/2007 1/4 13972-001

W 01-02-02 TCD 2012 2V
z Visually inspect the components.
6
© 46453-0
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.
© 46452-0
z Mount rocker arm bracket (1).

The ball heads (2) must be seated in the
ladles of the stop rods .
© 46454-0
© 04/2007 2/4 13972-001

TCD 2012 2V W 01-02-02
z Fasten screw (1).

Do not tighten the screw.
6
© 46455-0
Attention!
Cylinder head screws can be used max. 3
times with written proof, otherwise renew
every time they are loosened.
1
z Lightly oil cylinder head screw (1).
z Turn in cylinder head screw (1).
© 46456-0
z Align rocker arm bracket symmetrically with the valve

axles.
z Tighten cylinder head screw with the socket wrench
insert.
– Pre-clamping value:
30 Nm
Attention!
Make sure that the stop rods are not under
stress due to valve overlap when fastening
the screw.
© 46457-0
© 04/2007 3/4 13972-001

W 01-02-02 TCD 2012 2V

21 Nm
6
© 46451-1

insert.
– Post-clamping value:
+ 80 Nm + 90°
z Set valve clearance.
W 01-01-01
© 46457-0
© 04/2007 4/4 13972-001

TCD 2012 2V W 01-02-06
Disassembling, assembling and checking the rocker arm and rocker arm
bracket
– Internal measuring device
– Micrometer gauge
– Locking ring pliers
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Disassembling the rocker arm bracket

z Remove rocker arm and rocker arm bracket.
W 01-02-02
z Remove locking ring with locking ring pliers.
© 46389-0
z Remove rocker arm.

© 46390-0
© 04/2007 1/4 13973-001

W 01-02-06 TCD 2012 2V
Checking the rocker arm

z Measure rocker arm bore.
– Outlet
+0,033
21,02 −0 mm
– Inlet
+0,033
21,02 −0 mm
When the wear limit is reached the rocker
arm must be renewed.
6
© 39032-1

z Unscrew adjusting screw (2).
Attention!
Pay attention to versions of the adjusting
screws (slotted, hexagonal, hexagonal
socket).

2
1
© 46393-0
z Check components for visible signs of wear.

z Check oil channels (arrows) for free passage.
© 46392-0
© 04/2007 2/4 13973-001

TCD 2012 2V W 01-02-06
z Screw in setting screw (1).

z Loosen lock nuts (2).
2
6
© 46468-0
Checking the rocker arm pin

z Measure the diameter of journals with the microme-
ter gauge.
+0
21 − 0,052 mm
When the wear limit is reached the rocker
arm bracket must be replaced.
© 46469-0
Assembling the rocker arm bracket

z Lightly oil the rocker arm pin.
2
z Push rocker arm (1) onto rocker arm pin.
z Push rocker arm (2) onto rocker arm pin.
The rocker arm's sliding surface (3) must 1
face the threaded bore (arrow).
Mount the rocker arm (1) on the outlet side.
Mount the rocker arm (2) on the inlet side.
3
© 46471-0
© 04/2007 3/4 13973-001

W 01-02-06 TCD 2012 2V
z Insert new locking rings (1).

z Install rocker arm and rocker arm bracket.
W 01-02-02
6
© 46453-1
© 04/2007 4/4 13973-001

TCD 2012 2V W 01-04-04
Removing and installing cylinder head

– Pin wrench insert Torx E14 . . . . . . . 8113 – W 01-02-02
– W 01-04-09
– W 06-01-05
– W 06-07-03
– W 07-07-01
– W 09-13-04
Removing cylinder head

z Unscrew all screws (1).
z Remove cylinder head cowling (2). 2
© 46471-1
z Cut through the gasket at the gates (1).

z Remove gasket.
© 46587-0
© 04/2007 1/8 13974-001

W 01-04-04 TCD 2012 2V
z Remove the fan mounting.

W 09-13-04
z Remove the exhaust pipe.
W 06-01-05
6
© 46590-0

W 07-07-01
z Remove rocker arm brackets.
W 01-02-02
z Remove the charge air pipe.
W 06-07-03
2
z Remove holder (2).
1
© 46331-0
z Unscrew all screws (1) with the socket wrench insert.

z Remove cylinder head. 1
z Remove gasket.
z Clean sealing surfaces.
© 46334-0
© 04/2007 2/8 13974-001

TCD 2012 2V W 01-04-04
Installing the cylinder head

Measure the piston overhang on all
pistons.
Select cylinder head gasket according to
the largest piston projection measured.
z Check piston overhang.
W 01-04-09
6
© 42565-0
z Select cylinder head gasket according to the largest

piston projection measured.

Piston projection Hole

0.33 - 0.55 mm 1
0.56 - 0.65 mm 2
0.66 - 0.76 mm 3
Example: Piston projection = 0.7 mm cor-

responds to cylinder head gasket with
3 holes (arrow).
© 44154-0
Make sure the clamping bushings (1) are

in place.
© 46335-0
© 04/2007 3/8 13974-001

W 01-04-04 TCD 2012 2V
z Fit a new cylinder head gasket.

The sealing surfaces for the cylinder head
gasket must be clean and free of oil.
Label OBEN / TOP facing the cylinder
head.
6
© 46336-0
z Fit cylinder head.
© 46591-0
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.
© 46452-0
© 04/2007 4/8 13974-001

TCD 2012 2V W 01-04-04
z Mount rocker arm bracket (1).

The ball heads (2) must be seated in the
ladles of the stop rods .
2
6
© 46454-0
z Fasten screw (1).

© 46455-0
Attention!
Cylinder head screws can be used max. 3
times with written proof, otherwise renew
every time they are loosened.
1
z Lightly oil cylinder head screw (1).
z Turn in cylinder head screw (1).
© 46456-0
© 04/2007 5/8 13974-001

W 01-04-04 TCD 2012 2V
z Align rocker arm bracket symmetrically with the valve

axles.
insert.
30 Nm
Attention!
Make sure that the stop rods are not under
stress due to valve overlap when fastening
the screw.
6
© 46457-0

21 Nm
© 46451-1
z Tighten all cylinder head screws according to the

tightening sequence.
30 Nm + 80 Nm + 90°
Use socket wrench insert.
14 6 4 12
18 10 2 8 16
17 9 1 7 15
13 5 3 11
© 45131-0
© 04/2007 6/8 13974-001

TCD 2012 2V W 01-04-04
z Mount holder (2).

z Install the charge air pipe.
W 06-07-03
z Install rocker arm brackets.
W 01-02-02
z Set valve clearance. 2
W 01-01-01
z Install fuel injectors. 1
W 07-07-01
6
© 46331-0
z Install the exhaust pipe.

W 06-01-05
z Install fan mounting.
W 09-13-04
© 46590-0
Installing cylinder head cover.

z Cut through the new gasket at the gates (1).
Attention!
Do not bend or deform metal beading gas-
ket.
Remove burr from cut surfaces.
© 46587-0
© 04/2007 7/8 13974-001

W 01-04-04 TCD 2012 2V

z Mount new gasket.
Ensure that the installation location is free
from faults.

z Tighten all screws (1) alternately.
11 Nm
6
© 46474-2
Pay attention to perfect installation

position (arrow).
© 46473-2
© 04/2007 8/8 13974-001

TCD 2012 2V W 01-04-09

Commercial available tools – W 01-04-04
– W 04-06-03
Special tools:
– Turn-over gear . . . . . . . . . . . . . . 100330
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Measuring device . . . . . . . . . . . . 100750

W 04-06-03
z Remove cylinder head.
W 01-04-04
© 46474-0
z Turn the crankshaft until the respective piston is just

in front of the top dead centre (arrow).
© 46333-0
© 04/2007 1/4 13976-001

W 01-04-09 TCD 2012 2V
z Insert dial gauge into measuring beam.

z Place shims (1) and measuring beam (2) on the seal-
ing surface of the crankcase.
1
1
6
© 30240-4
z Move the measuring beam.

z Apply stylus of the dial gauge to the crankcase seal-
ing surface with pre-tension (arrow).
z Adjust dial gauge to "0".
© 43614-1
z Measure at the points (1) and (2) on the piston.

Schematic representation 1
2
© 34151-2
© 04/2007 2/4 13976-001

TCD 2012 2V W 01-04-09
z Move the measuring beam.

z Apply stylus to the specified measuring points under
pre-tension.
z Continue turning the crankshaft evenly until the re-
versal point of the pointer on the dial gauge is
reached.
The stylus may not be positioned on the
labelling of the piston.
Note greatest measured value.
6
© 43514-1
z Select cylinder head gasket according to the largest

piston projection measured.

Piston projection Hole

0.33 - 0.55 mm 1
0.56 - 0.65 mm 2
0.66 - 0.76 mm 3
Example: Piston projection = 0.7 mm cor-

responds to cylinder head gasket with
3 holes (arrow).
© 44154-0
z Install cylinder head.

W 01-04-04
W 04-06-03
© 46474-0
© 04/2007 3/4 13976-001

W 01-04-09 TCD 2012 2V
© 04/2007 4/4 13976-001

TCD 2012 2V W 01-05-01
Removing and installing the valves

– Slide gauge
– Assembly pliers. . . . . . . . . . . . . . . . 8024
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Support bracket . . . . . . . . . . . . . 120900
– Base plate. . . . . . . . . . . . . . . . . . 120910
– Assembly tool . . . . . . . . . . . . . . . 121410
– Assembly sleeves . . . . . . . . . . . . 121420
Removing the valves

W 01-04-04
1
z Mount support bracket (1) on base plate (2).
z Mount cylinder head on support bracket.
2
© 42583-0
z Remove snap ring (1).

Danger!
Risk of injury! Snap ring springs off.
© 42584-0
© 04/2007 1/6 13977-001

W 01-05-01 TCD 2012 2V
z Remove thrust washer (1).
6
© 42585-0
z Install assembly lever (1).

z Press down valve spring with assembly lever.
z Remove both tapper collets (2).
1
z Remove valve spring plates, valve springs and
valves.
z Remove assembly lever.
© 42586-0
z Remove valve shaft seal with assembly pliers.
© 42587-0
© 04/2007 2/6 13977-001

TCD 2012 2V W 01-05-01
z Clean cylinder head, check and visually inspect for

damage.
6
© 42588-0
z Install valves.
z Measure valve spring length with slide gauge.
59 mm
When the wear limit is reached, the valve
spring must be renewed.
© 35856-2
z Oil the valve stem lightly.

z Insert and hold valve.
z Push assembly sleeve (1) over the valve V-grooves.
© 42589-0
© 04/2007 3/6 13977-001

W 01-05-01 TCD 2012 2V
z Push new valve shaft seal (1) over the assembly

sleeve.
z Remove assembly sleeve.
6
© 42590-1
z Press in valve shaft seal to stop with assembly

tool (1).
© 42591-0
z Insert valve spring (1).

z Insert valve spring plate (2).
© 42592-0
© 04/2007 4/6 13977-001

TCD 2012 2V W 01-05-01
z Mount assembly lever.

z Place assembly lever on valve spring plate.
z Press down the valve spring with the assembly lever
and insert both tapper collets (1).
Make sure the tapper collets fit correctly in
the valve keyway.
1
6
© 42593-0
z Remove assembly lever.

z Insert thrust washer (1).
© 42585-0
z Insert spring ring (1).

Pay attention to the correct fit of the spring
ring in the groove.
© 42594-0
© 04/2007 5/6 13977-001

W 01-05-01 TCD 2012 2V
z Remove cylinder head from support bracket (1).

z Remove support bracket from base plate (2).
W 01-04-04 1
6 2
© 42583-0
© 04/2007 6/6 13977-001

TCD 2012 2V W 01-05-04
Checking the valves

– Slide gauge
Clean all valves.
must be renewed.
Checking valve stem diameter

z Remove valves.
W 01-05-01
z Measure valve stem diameter with micrometer
gauge.
– Inlet valve
+0
7,98 −0,015 mm
– Exhaust valve
+0
7,96 −0,015 mm
© 42182-1
Checking valve edge thickness

z Measure valve edge thickness with slide gauge.
– Inlet valve
2,3 mm
– Exhaust valve
1,61 mm
© 42183-1
© 04/2007 1/2 13978-001

W 01-05-04 TCD 2012 2V
Checking valve head diameter

z Measure valve head diameter with slide gauge.
– Inlet valve
+0,1
41,7 −0,1 mm
– Exhaust valve
+0,1
35,9 −0,1 mm
z Install valves.
W 01-05-01
6
© 42184-1
© 04/2007 2/2 13978-001

TCD 2012 2V W 01-06-03

– Magnetic measuring stand
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 New valves are used for testing.
guide must be renewed.

z Remove valves.
W 01-05-01
z Visually inspect valve guide for wear.
z Mount magnetic measuring stand.
z Insert dial gauge.
z Insert new valve.
z Place stylus on the valve stem under pre-
tension (arrow).
© 42595-0
Measure valve stem clearance

z Move valve back and forth in direction of arrow.
– Inlet valve
+0
0,028 - 0,068 − 0,015 mm
– Exhaust valve
+0
0,048 - 0,088 − 0,015 mm
The whole rocker path must be taken into
consideration.
© 42597-0
© 04/2007 1/2 13979-001

W 01-06-03 TCD 2012 2V
z Remove magnetic measuring stand.

z Remove dial gauge.
z Install valves.
W 01-05-01
6
© 42596-0
© 04/2007 2/2 13979-001

TCD 2012 2V W 01-07-08

– Depth-measuring
appliance
Special tools: Attention!
– Support bracket . . . . . . . . . . . . . 120900 When the wear limit is reached, the valve
– Base plate. . . . . . . . . . . . . . . . . . 120910 seat insert and/or valve must be renewed.

z Remove cylinder head. 1
W 01-04-04
z Mount support bracket (1) on base plate (2).
© 44178-0
z Screw cylinder head onto support bracket (1) and

base plate (2).
© 46588-0
©04/2007 1/2 13981-001

W 01-07-08 TCD 2012 2V
z Measure the valve lag from the centre of the valve

head to the cylinder head sealing surface.
– Inlet valve
+0,15
0,9 −0,1 mm
– Exhaust valve
+0,15
0,9 −0,1 mm
6
© 42598-0
z Remove cylinder head from support bracket (1).

z Remove support bracket from base plate (2).
W 01-04-04 1
© 46588-0
©04/2007 2/2 13981-001

TD 2012 2V Drive system
TCD 2012 2V W 02-01-04
Checking the axial clearance of the crankshaft

8190
– Magnetic measuring stand – W 03-08-01

– Micrometer gauge – W 04-04-09
– Socket wrench insert . . . . . . . . . . . 8035
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
z Remove front cover.

W 03-08-01
z Remove the gear case cover.
W 04-04-09
z Apply stylus to the crankshaft end with pre-tension.
z Press crankshaft in direction of arrow.
© 44179-0
z Press crankshaft in direction of arrow.

z Read off measured value.
0,1 - 0,3 mm
In case of deviating axial clearance, the
permissible axial clearance should be set
by changing the thrust ring halves.
© 44180-0
© 04/2007 1/6 13983-001

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

1
z Remove bearing cap (2).
z Remove lower bearing shell.
z Remove both thrust ring halves (arrows).
2
1
6
© 44181-0
© 44182-0
z Measure the strength of thrust ring halves.

– Standard
+0,05
2,00 −0 mm
– 1. Overmeasure
+0,05
2,20 −0 mm
z Select thrust ring halves according to measured val-
ue.
© 43504-0
© 04/2007 2/6 13983-001

TCD 2012 2V W 02-01-04
z Remove crankshaft.
W 02-04-01
z Set micrometer gauge to 32 mm.
z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".
6
© 35825-2
z Measure locating bearing width

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

z Measure width with micrometer gauge.
z Note measured value, dimension (b).
© 35827-2
© 04/2007 3/6 13983-001

W 02-01-04 TCD 2012 2V
z Determine axial backlash.

0,1 - 0,3 mm
Calculation example
Desired: Axial backlash
Given: -
Measured: (a) = 32,8 mm
(b) = 32.7 mm
Dimension (a) - Dimension (b)
Result: = 0.1 mm
z Install crankshaft.
W 02-04-01
6
© 00000-0

in place.
© 44183-0
z Install upper thrust ring halves according to meas-

ured axial clearance.
Oil grooves (1) of the thrust ring halves
face the web face (2) of the
crankshaft (arrows) 2
Insert thrust ring halves between crank-
case and crankshaft web (arrows).
© 44184-0
© 04/2007 4/6 13983-001

TCD 2012 2V W 02-01-04
z Fix both thrust ring halves with a little grease to the

bearing cap.
Use lower thrust ring halves with guide lug
(arrow).
Install thrust ring halves according to mea-
sured axial clearance.
Bearing cap with identification “2“.
2
The oil grooves (1) face the crankshaft web
face.
1
6
© 42663-0
z Insert bearing cap (1).

The gate (arrow) on the bearing cap faces
the manifold side.
1
© 44185-0
z Tighten screws (1) with the socket wrench insert.

50 Nm + 90° + 90°
Attention!
Screws can be reused a maximum 3 times
with written documentation.
Otherwise renew every time they are loo-
sened.
© 44186-1
© 04/2007 5/6 13983-001

W 02-01-04 TCD 2012 2V
z Check axial backlash of crankshaft.

0,1 - 0,3 mm
z Install front cover.
W 03-08-01
W 04-04-09
6
© 44187-0
© 04/2007 6/6 13983-001

TCD 2012 2V W 02-01-07
Checking the crankshaft

– Magnetic measuring stand
– Prisms
– Hardness tester
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Checking the bearing pin hardness

W 02-04-01
z Place crankshaft on prism.
© 42602-0
z Put hardness tester on journal.
© 30560-1
© 04/2007 1/4 13984-001

W 02-01-07 TCD 2012 2V
z Raise stylus (1) and press release (2).

Stylus (1) falls down, briefly strikes the sur-
face and jumps up to the measured value. 1
6
© 43499-0
z Read off displayed value (arrow) from hardness test-

er.
– Nominal value, at least
+6
55 HRc
The measured value is to be converted
according to the table of the measuring
device.
© 43515-0
Diagram for measuring the journals at the

points 1 and 2 in the levels a and b.
© 36424-2
© 04/2007 2/4 13984-001

TCD 2012 2V W 02-01-07
Checking the diameter of the main bearing

pins
z Measure main bearing pin with micrometer gauge.
– Standard
+0
84 − 0,02 mm
– Undermeasure stage
0,25 mm
See schematic diagram for measuring
points.
6
© 42603-0
Checking the diameter of the lifting jour-

nals
z Measure lifting journal with micrometer gauge.
+0
62,994 −0,02 mm
0,25 mm
points.
© 42604-0
Checking the rotation

z Apply stylus to the main bearing pin with pre-tension
(arrow) and adjust dial gauge to "0".
z Turn crankshaft evenly and check rotation.
0,1 mm
© 42605-0
© 04/2007 3/4 13984-001

W 02-01-07 TCD 2012 2V
Measuring the fit bearing width

z Set micrometer gauge to 32 mm.
z Push the internal measuring device between the test
surfaces of the micrometer gauge and set to "0".
6
© 35825-2
z Measure bearing width with internal measuring de-

vice between thelay-on surfaces of the thrust rings.
+0,04
32,2 −0 mm
– 1. Undermeasure stage
0,4 mm
© 42606-0
Visual inspection
z Check the running surfaces (1) of the crankshaft
sealing rings visually.
1
z Visually inspect gear wheel (2).
1 2
W 02-04-01
© 42607-0
© 04/2007 4/4 13984-001

TCD 2012 2V W 02-02-02
Renewing the crankshaft sealing ring

(flywheel side)
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . . 142830
– Self-tapping screw
– Washer
Removing the crankshaft sealing ring

z Remove flywheel.
W 12-06-01
z Make a hole of approximately 3 mm in the crankshaft
sealing ring with a pricker.
Attention!
Do not damage the gearcase cover and
crankshaft.
© 46472-0
z Screw in a self-tapping screw (1) with washer.
© 46561-0
© 04/2007 1/4 13985-001

W 02-02-02 TCD 2012 2V
z Pull out the crankshaft sealing ring with assembly le-

ver.
z Visually inspect the crankshaft sealing ring running
surface.
6
© 46562-0
Installing the crankshaft sealing ring

z Mount guide sleeve (1).
The bores in the guide sleeve must match
the threaded holes in the crankshaft flange. 1
© 46563-0
z Oil the sealing lip of the crankshaft sealing ring light-

ly.
z Place the crankshaft sealing ring carefully on the pe-
ripheral surface.
The sealing lip faces the crankcase.
© 46564-0
© 04/2007 2/4 13985-001

TCD 2012 2V W 02-02-02
z Mount shims (1).

If there is a run-in groove on the crankshaft
flange it is possible to mount the crankshaft
sealing ring in three installation depths:
- first assembly = 2 discs
- 1st repair - installation stage = 1 disc
- 2nd repair - installation stage = 0 discs.
1 6
© 46565-0
z Mount assembly sleeve (1).

z Press on the crankshaft sealing ring to the stop.
© 46566-0
z Plug in the bearing (1).

z Screw on nut (2).
2
© 46567-0
© 04/2007 3/4 13985-001

W 02-02-02 TCD 2012 2V
z Tighten nut to the stop of the assembly sleeve (1).

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

z Install flywheel.
1
W 12-06-01
6
© 44197-0
© 04/2007 4/4 13985-001

TCD 2012 2V W 02-02-04
Renewing the crankshaft sealing ring

(opposite side to flywheel)
– Pricker. . . . . . . . . . . . . . . . . . . . . . . 8198
– Assembly lever . . . . . . . . . . . . . . . . 9017
Special tools:
– Assembly tool . . . . . . . . . . . . . . . 142670
– Self-tapping screw
– Washer
Removing the crankshaft sealing ring

z Remove V-belt pulley.
W 12-01-04
z Make a hole of approximately 3 mm in the crankshaft
sealing ring with a pricker.
Attention!
Do not damage the front cover or cranks-
haft.
© 43643-0
z Screw in a self-tapping screw (1) with washer.
© 44872-0
© 04/2007 1/6 13986-001

W 02-02-04 TCD 2012 2V
z Pull out the crankshaft sealing ring with assembly le-

ver.
z Visually inspect the crankshaft sealing ring running
surface.
6
© 44873-0
Installing the crankshaft sealing ring

z Remove clamping bushing (1).
© 44875-0
z Mount guide sleeve (1).

Make sure the clamping bushing (2) is in
line with the bore (3).
1
© 42623-0
© 04/2007 2/6 13986-001

TCD 2012 2V W 02-02-04
6
© 44877-0
z Oil the sealing lip of the crankshaft sealing ring light-

ly.
z Place the crankshaft sealing ring carefully on the pe-
ripheral surface.
The sealing lip faces the crankcase.
© 44878-0
z Mount shims (1).

z Pay attention to installation depth of crankshaft seal-
ing ring and select shim accordingly.
– First assembly = 2 shims
– 1. Repair installation depth = 1 shim
– Maximum installation depth = without washers
© 44879-0
© 04/2007 3/6 13986-001

W 02-02-04 TCD 2012 2V
z Mount assembly sleeve (1).

z Press on the crankshaft sealing ring to the stop.
6
© 44880-0
z Plug in the bearing (1).

z Turn on nut (2).
2
1
© 44881-0
z Tighten nut to the stop of the assembly sleeve (1).

The crankshaft sealing ring is now at the
pre-selected installation depth.
1
© 44882-1
© 04/2007 4/6 13986-001

TCD 2012 2V W 02-02-04
z Knock in the clamping sleeve (1) to the stop.

z Install V-belt pulley.
W 12-01-04
6
© 42622-0
© 04/2007 5/6 13986-001

W 02-02-04 TCD 2012 2V
© 04/2007 6/6 13986-001

TCD 2012 2V W 02-03-01

– Con rod test device
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
z Remove piston and connecting rod.

W 02-09-03
z Remove piston from con rod.
© 40592-1
Checking small end bush

z Prepare internal measuring device:
– Mount probe bolt for the appropriate measuring
range in the internal measuring device.
– Mount dial gauge with approx. 1 mm pre-tension in
the internal measuring device.
– Set micrometer gauge to 38 mm.
– Balance the internal measuring device between
the test surfaces of the micrometer gauge and set
the dial gauge at the reversal point of the pointer to
"0".
© 34768-2
© 04/2007 1/10 13987-001

W 02-03-01 TCD 2012 2V
Diagram for measuring the small end bush

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

z Balance the internal measuring device at the given
measuring points and read off the measured value at
the reversal point of the pointer.
38,025 +0,010 mm
Measuring points see diagram.
z Note the measured value, dimension (A).

The dimension A is required to determine
the piston bolt clearance.
© 34770-2
Checking diameter of the piston bolt

z Measure piston pin with micrometer gauge.
+0
38 −0,006 mm
z Note the measured value, dimension B.
The dimension B is required to determine
the piston bolt clearance.
© 35908-2
© 04/2007 2/10 13987-001

TCD 2012 2V W 02-03-01
Determining piston pin clearance

The piston pin clearance is given by the
difference between the internal diameter of
the small end bush (a) and the piston pin
diameter (b).
0,025 - 0,041 mm
Calculation example
Desired: Piston pin clearance
Given: -
Measured: Internal diameter small end bush (a)
(a) = 38.025 mm
Diameter piston pin (b)
(b) = 38.000 mm
38.025 mm - 38.000 mm
Result: = 0.025 mm
6
Checking the con rod bearing bore

z Mount big end bearing cap.
Attention!
26519
Note the assignment of the big end bearing 1
cap.
The identification numbers (1) on the con 26519
rod and the big end bearing cap must be

identical and opposite to each other when
assembled.
© 44212-0
z Tighten screws alternately with rotation angle disc

and socket wrench insert.
30 Nm + 60° + 30°
© 44213-0
© 04/2007 3/10 13987-001

W 02-03-01 TCD 2012 2V

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

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

66,6 +0,019 mm
If the measured values deviate slightly,
additional measurements must be made
with new bearing shells.
© 44214-0
© 04/2007 4/10 13987-001

TCD 2012 2V W 02-03-01
Checking internal diameter of the con rod

bearing shells
z Remove screws.
z Remove the con rod bearing cover.
in place.
1 6
© 44440-0
z Insert bearing shell in the con rod.

Attention!
Note the assignment of the bearing shells.
The anti-rotation lock (1) must lock in
groove (2).
1
© 44215-0
z Insert bearing shell in the respective big end bearing

cap.
Attention!
The anti-rotation lock (1) must lock in 1
groove (2).
© 44216-0
© 04/2007 5/10 13987-001

W 02-03-01 TCD 2012 2V

Attention!
The identification numbers (1) on the con-
2651
necting rod and the big end bearing cover
must be identical and opposite to each 1
9
other when assembled.
2651
9
6
© 44217-0
z Tighten screws alternately with rotation angle disc

and socket wrench insert.
30 Nm + 60° + 30°
© 44218-0

"0".
© 36094-1
© 04/2007 6/10 13987-001

TCD 2012 2V W 02-03-01
Diagram for measuring the inside diameter

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

points.
63,026 - 63,065 mm
When the wear limit is reached the con rod
must be replaced.
© 44219-0
Checking the diameter of the lifting jour-

nals
© 36424-2
© 04/2007 7/10 13987-001

W 02-03-01 TCD 2012 2V
z Measure lifting journal with micrometer gauge.

+0
62,994 −0,02 mm
0,25 mm
6
© 36424-2
Determine big end bearing clearance

The big end bearing clearance is given by
the difference between the internal diame-
ter of the big end bearing shell (a) and the
lifting journal diameter (b).
0,032 - 0,073 mm
Calculation example
Desired: Big end bearing clearance
Given: -
Measured: Internal diameter big end bearing shell (a)
(a) = 63.026 mm
Diameter lifting journal (b)
(b) = 62.992 mm
Result: = 0.034 mm
– Wear limit
0,12 mm
z Remove screws.
z Remove the con rod bearing cover.
© 44218-0
© 04/2007 8/10 13987-001

TCD 2012 2V W 02-03-01

z Mount connecting rod on test instrument without
bearing shells. A
Attention!
Aligning the con rod is not permissible. B
z Move test fork in direction of arrow.
z Check that the con rod is parallel.
z Permissible deviation from (A) to (B).
0,04 mm
Distance between “A“ and “B“ = 100 mm.
6
© 30579-1
z Move test fork in direction of arrow.

z Check the angle of the con rod.
z Permissible deviation from (C) to (D).
0,04 mm
Distance between “C“ and “D“ = 100 mm
C
D
z Assembly pistons and con rod.
z Install piston and connecting rod.
W 02-09-03
© 30580-1
© 04/2007 9/10 13987-001

W 02-03-01 TCD 2012 2V
© 04/2007 10/10 13987-001

TCD 2012 2V W 02-04-01
Removing and installing the crankshaft

– W 02-09-03
Special tools: – W 03-08-01
– Socket wrench insert . . . . . . . . . . . 8035 – W 04-04-09
– Turn-over gear . . . . . . . . . . . . . . 100330
Removing crankshaft
W 03-08-01
W 04-04-09
© 42647-2
z Screw in screws (1).

z Remove all con rod bearing covers.
z Remove con rod bearing shells.
W 02-09-03
© 42648-1
© 04/2007 1/8 13989-001

W 02-04-01 TCD 2012 2V
z Make a mark (1) on the camshaft gear wheel for as-

sistance. 2
Your mark must be on a line between the
marking (2) and the middle (3) of the
camshaft.
6
© 42651-0
z Turn the crankshaft evenly until the marking (1) on

the crankshaft flange is in line with your mark (2) on
the camshaft gear wheel.
The marking on the camshaft gear wheel is
covered by the crankshaft flange when it is 1
in line.
Attention!
Do not jam the con rods when turning the
crankshaft.
2
© 42652-0
Removing the main bearing cover

z Unscrew all screws (1) with the socket wrench insert.
© 42653-1
© 04/2007 2/8 13989-001

TCD 2012 2V W 02-04-01
z Remove bearing cap (1).

z Remove bearing shell.
z Remove all main bearing covers (2).
z Remove bearing shells.
1
Note order of cylinders.
6
© 44228-1
z Press the con rods carefully out of the lifting journal.

z Lift out the crankshaft.
© 42655-1

z Remove all main bearing shells (1).
z Check axial backlash of crankshaft (crankshaft re- 1
moved).
W 02-01-07
© 44231-2
© 04/2007 3/8 13989-001

W 02-04-01 TCD 2012 2V
Installing the crankshaft

z Insert upper main bearing shells.
groove (2).
6
© 42658-0
z Insert lower main bearing shells in the respective

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

are in place.
© 44231-1
© 04/2007 4/8 13989-001

TCD 2012 2V W 02-04-01
z Position camshaft.
The bore (1) must be facing the cylinder
head.
z Lightly oil bearing surfaces.
1 6
© 42661-0
z Insert the crankshaft carefully in the crankcase.

Attention!
Do not jam the con rods when inserting the
crankshaft!
z Set the crankshaft in line with the camshaft.
Make sure that the markings match up.
© 44238-2
z Check control times.

The marking (1) on the crankshaft flange
must be in line with your mark (2).
© 42652-0
© 04/2007 5/8 13989-001

W 02-04-01 TCD 2012 2V
z Install upper thrust ring halves according to meas-

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

bearing cap.
Bearing cap with identification “2“.
Use thrust ring halves with guide
lug (arrow).
Oil grooves (1) face the crankshaft web
face.
2
© 42663-0
Mounting the main bearing cover

z Insert bearing cap (1).
z Insert main bearing cover (2) according to the num-
bering.
Note assignment and installation position:
1
Insert main bearing cover with the
number 1 on the flywheel side.
Gate (arrow) on the bearing cover faces 7 6 5 4 3 2 1
the manifold side.
© 44240-1
© 04/2007 6/8 13989-001

TCD 2012 2V W 02-04-01
z Main bearing cover with socket wrench insert and ro-

tary angle disc.
50 Nm + 90° + 90°
Attention!
Screws can be reused a maximum 3 times
with written documentation.
Otherwise renew every time they are loo-
sened.
z Install the con rod bearing cover.
W 02-09-03
6
© 44241-1
© 42648-1
z Install the gear case cover.

W 04-04-09
z Install front cover.
W 03-08-01
© 42647-2
© 04/2007 7/8 13989-001

W 02-04-01 TCD 2012 2V
© 04/2007 8/8 13989-001

TCD 2012 2V W 02-08-01
Removing and installing, checking the mass compensation shafts

– Torque wrench
Special tools:
– Centring bolts (2x) . . . . . . . . . . . 100810
– Chalk
– Locking agent
DEUTZ DW 72
Removing the mass compensation shafts

W 04-04-09
z Set piston cylinder 1 at top dead centre.
The marking (1) on the crankshaft flange
must be in line with your mark (2).
© 36652-2

z Remove washer (2).
z Remove idler gear (3).
z Remove the bearing pin.
3
2
© 46605-0
© 04/2007 1/8 13990-001

W 02-08-01 TCD 2012 2V

z Remove lubricating oil pipe (2).
z Remove idler gear (3).
z Remove the bearing pin.
1
6
© 46606-0

z Remove shims (2).
1
1
2
2
© 46607-0
z Pull out mass compensation shafts in direction of ar-

row.
Attention!
Do not damage the mass compensation
shafts.
© 36666-3
© 04/2007 2/8 13990-001

TCD 2012 2V W 02-08-01
Checking the mass compensation shafts

z Check components for visible signs of wear.
6
© 36664-1
z Measure the diameter of journals with the microme-

ter gauge.
54 − 0,02 mm
© 36665-1
Installing the mass compensation shafts

z Oil the journal lightly.
z Insert mass compensation shafts in direction of ar-
row.
The weight position (1) faces the lubrica-
ting oil pan.
1
© 36666-4
© 04/2007 3/8 13990-001

W 02-08-01 TCD 2012 2V
z Unscrew locking screws (1).
6
© 36651-2
z Insert centring bolt (1).

z Fix mass compensation shafts with centring bolts (1).
Attention!
Do not turn the mass compensation shafts 1
any more!
© 36659-2
z Install shims (2).

1
1
2
2
© 46607-0
© 04/2007 4/8 13990-001

TCD 2012 2V W 02-08-01
z Mount intermediate gear of the B-side.

Position the intermediate gear (1) centred
with the threaded bore (2).
2
If the tooth edges do not match, the
crankshaft can easily be turned.
Attention!
Do not turn the mass compensation shafts
any more!
1
6
© 36669-1
z Lightly oil journal (1).

z Insert bearing pin (1).
z Mount washer (2).
z Turn in screw (3).
Insert screw with safety agent
DEUTZ DW 72.
Do not tighten the screw. 1
2
© 36670-2
z Make help marks (1) and (2).

z Turn out centring bolts (A-side).
z Turn mass compensation shaft two teeth in direction
of the arrow.
1
© 36656-2
© 04/2007 5/8 13990-001

W 02-08-01 TCD 2012 2V
z Insert the intermediate wheel (1) into the toothing

from above.
Turn the mass compensation shaft in the
direction of the arrow until the help marks
are in line.
Position the intermediate gear (1) centred
1
with the threaded bore (2).
6
© 36657-2
z Lightly oil journal (1).

z Insert bearing pin (1).
© 36667-2
z Insert new O-ring (1).
© 36668-2
© 04/2007 6/8 13990-001

TCD 2012 2V W 02-08-01
z Mount lubrication oil line (1).

z Fasten screw (2).
Insert screw with safety agent
DEUTZ DW 72.
Do not tighten the screw. 1
6
© 36658-2
z Unscrew all centring bolts (1).
© 36659-2
z Mount new sealing rings.

z Tighten locking screws (1).
9 Nm
1
© 36651-2
© 04/2007 7/8 13990-001

W 02-08-01 TCD 2012 2V

29 Nm
22 Nm
W 04-04-09
1
2
6
© 36660-2
© 04/2007 8/8 13990-001

TCD 2012 2V W 02-09-03
Removing and installing the piston and con rod

– Rotation angle disc . . . . . . . . . . . . . 8190 – W 02-10-03
– Piston ring compressor . . . . . . . . 130670
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
Lubricating oil and coolant must be filled
according to the instructions in the opera-
ting manual.
Removing the piston and con rod

W 01-04-04
z Remove oil suction pipe
W 08-04-06
z Pull out oil dipstick.
© 46477-0
Removing the big end bearing cap

z Turn the crankshaft with the turning gear.
z Set lifting journal at bottom dead centre (BDC).
z Remove big end bearing cap (2).
they should be installed. 2
1
z Remove bearing shell.
© 46480-0
© 04/2007 1/8 13991-001

W 02-09-03 TCD 2012 2V

6
© 46478-0
z Remove con rod bearing shells (1).

1
© 44250-0
z Remove locking ring.

z Press out piston pin.
© 44251-0
© 04/2007 2/8 13991-001

TCD 2012 2V W 02-09-03
Completing con rod and piston

z Insert new locking ring.
from faults.
6
© 44252-0
z Insert con rod.
26519
The flywheel/crankshaft symbol (1) on the
piston base must face to the right and the 2
identification number (2) on the con rod
must face upwards.
© 44253-0
z Oil the piston bolt lightly.

z Press the piston bolt through.
z Insert new locking ring.
from faults.
© 44254-0
© 04/2007 3/8 13991-001

W 02-09-03 TCD 2012 2V
Installing the piston and con rod

in place.
1
6
1
© 46296-0
z Insert bearing shell in the con rod.

groove (2).
1
© 46295-0
z Insert bearing shell in the respective big end bearing

cap.
Attention!
The anti-rotation lock (1) must lock in 1
groove (2).
© 44216-0
© 04/2007 4/8 13991-001

TCD 2012 2V W 02-09-03
z Arrange the piston ring joints with an offset of

about 120° to each other.
z Check piston rings and piston ring grooves.
W 02-10-03
6
© 42380-1
z Lightly oil cylinder running surface, piston, piston

rings and lifting bearing journal lightly.
z Clamp piston rings with piston ring compressor (1).
Do not turn the piston rings any further.
© 44255-0
z Set lifting journal at bottom dead centre (BDC).

z Push piston and con rod completely into cylinder lin-
er.
Note the cylinder assignment of the piston.
Note the label indicating the installation
position on the piston base.
1
The symbol flywheel/crankshaft (1) must
face the flywheel.
The piston ring compressor must lie flat on
the cylinder liner.
© 45004-1
© 04/2007 5/8 13991-001

W 02-09-03 TCD 2012 2V
z Press the con rod carefully against the lifting journal.

Attention!
Do not jam the con rod with the crankshaft.
6
© 46481-0
Installing the big end bearing cap

© 46482-0
z Tighten new screws with rotation angle disc.

30 Nm + 60° + 30°
Attention!
Renew screws every time they are loose-
ned.
© 46483-0
© 04/2007 6/8 13991-001

TCD 2012 2V W 02-09-03
z Insert oil dipstick.

z Install oil suction pipe.
W 08-04-06
W 01-04-04
6
© 46479-0
© 04/2007 7/8 13991-001

W 02-09-03 TCD 2012 2V
© 04/2007 8/8 13991-001

TCD 2012 2V W 02-09-07
Checking the piston

Special tools: When the piston wear limit is reached, the
– Dial gauge. . . . . . . . . . . . . . . . . . 100400 piston must be renewed.
Checking the piston bolt bore

W 02-09-03
© 44262-0

"0".
© 34768-2
© 04/2007 1/4 13992-001

W 02-09-07 TCD 2012 2V
Diagram for measuring the piston bolt bore

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

bore.
+ 0,009
38 + 0,004 mm
points.
© 43483-0
Checking the piston diameter

Diagram for measuring the piston diameter
at the measuring points "1, 2 and 3", trans-
verse to the piston bolt bore.
© 37244-1
© 04/2007 2/4 13992-001

TCD 2012 2V W 02-09-07
z Measure piston diameter with micrometer gauge.

Diameter
Measuring
Standard Overmeasure
height
+0,009 +0,009
16 mm 100,820 −0,009 mm 101,320 −0,009 mm
+0,007 + 0,007
50 mm 100,588 −0,007 mm 101,088 − 0,007 mm
+0,012 +0,012
78.5 mm 100,270 −0,012 mm 100,770 −0,012 mm

points.
z Assemble con rod and piston.

W 02-09-03 6
© 43427-0
© 04/2007 3/4 13992-001

W 02-09-07 TCD 2012 2V
© 04/2007 4/4 13992-001

TCD 2012 2V W 02-10-03
Checking the piston rings and piston ring grooves

– Feeler gauges
Special tools:
– Universal piston ring pliers . . . . . 130300
– Trapezoidal groove wear
gauge . . . . . . . . . . . . . . . . . . . . . 130440
Checking the piston rings and piston ring

grooves
W 02-09-03
z Set universal piston ring pliers to the piston diameter.
101 mm
z Remove piston rings with universal piston ring pliers.
© 44263-1
z Clean piston.
z Visually inspect piston.
z Visually inspect piston ring grooves.
© 44264-1
© 04/2007 1/4 13993-001

W 02-10-03 TCD 2012 2V
z Measure piston ring groove for first piston ring with

trapezoidal groove wear gauge.
6
© 33866-3
If there is a gap "S" between the trapezoi-

dal groove wear gauge and piston, the
piston can be used again. S
© 33867-3
If the trapezoidal groove wear gauge is

touching the piston (arrow), the piston
must be changed.
© 33868-3
© 04/2007 2/4 13993-001

TCD 2012 2V W 02-10-03
Checking the piston ring joint clearance

z Insert the piston ring (1) in the cylinder.
z Align the piston ring in the cylinder by pushing the
piston.
1
6
© 45011-1
z Measure the piston ring joint clearance with a feeler

gauge.
– 1. piston ring = double keystone ring
0,20 - 0,35 mm
– 2. piston ring = taper-faced ring
1,5 - 2,0 mm
– 3. piston ring = bevelland-edge oil control ring
0,3 - 0,55 mm
When the wear limit is reached, the piston
ring must be renewed.
© 45012-1
z Install piston rings.

Order and position of the piston rings as
seen from the piston base.
- Double-sided keystone ring (1) 1
- Taper-faced ring (2)
- Bevelland-edge oil control ring with coiled 2
spring expander (3)
“Top“ label faces the combustion chamber. 3
© 44267-0
© 04/2007 3/4 13993-001

W 02-10-03 TCD 2012 2V
z Install piston rings with universal piston ring pliers.

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

Check with new piston rings.
z Check axial backlash with feeler gauge between pis-

ton ring and piston ring groove.
– 2. piston ring
0,06 - 0,08 mm
– 3. piston ring
0,02 - 0,04 mm
When the piston wear limit is reached, the
piston must be renewed.
© 44269-0
z Assemble con rod and piston.

W 02-09-03
© 44270-0
© 04/2007 4/4 13993-001

TCD 2012 2V W 02-15-01
Removing and installing the piston cooling nozzles

Removing the piston cooling nozzles

W 02-04-01
z Screw self-tapping screw (1) carefully into the piston
cooling nozzle. 1
© 44271-0
z Pull out piston cooling nozzle (1) with pliers.
© 44272-0
© 04/2007 1/2 13994-001

W 02-15-01 TCD 2012 2V
Installing the piston cooling nozzles

z Clean the bores for the piston cooling nozzles in the
crankcase.
z Knock in new piston cooling nozzle (1) with pin to the
stop.
W 02-04-01 1
6
© 44273-0
© 04/2007 2/2 13994-001

TD 2012 2V Crankcase
TCD 2012 2V W 03-01-11
Removing and installing the crankcase bleeding

Commercial available tools:
– Spring band pliers . . . . . . . . . . . . . . 9090
Removing the crankcase bleeding

z Loosen the spring band clip with spring band pliers
and pull down.
z Pull off hose pipe (1). 3
2
z Remove crankcase bleeding (3).
© 46473-3
z Visually inspect the component.

z Insert new seal (1).
© 46475-0
© 04/2007 1/2 13995-001

Crankcase TD 2012 2V
W 03-01-11 TCD 2012 2V
z Mount crankcase bleeding (1).

Pay attention to perfect installation
position (arrow).
6
© 46476-0

21 Nm
z Position hose pipe (2).
z Position spring band clip with spring band pliers.
1
© 46473-4
© 04/2007 2/2 13995-001

TCD 2012 2V W 03-03-01
Checking the cylinder

– Depth-measuring The crankshaft bearing covers must be
appliance mounted properly for measuring the cylin-
Special tools: ders.
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
Checking the cylinders

W 02-09-03
z Check cylinder for visible signs of wear.
© 46474-0

"0".
© 36094-1
© 04/2007 1/2 13996-001

W 03-03-01 TCD 2012 2V
Diagram for measuring the cylinder run-

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

z Compare actual value with setpoint value.
+0,02
101 −0 mm
points.
z Install piston and connecting rod.

W 02-09-03
© 46470-0
© 04/2007 2/2 13996-001

TCD 2012 2V W 03-08-01
Removing and installing the front cover

– W 08-04-06
– W 12-01-04
Remove the front cover

z Removing torsional vibration damper.
W 12-01-04
z Remove oil suction pipe
W 08-04-06
© 46397-0
z Turn the engine on the assembly block.

z Remove gasket.
© 44542-1
© 04/2007 1/6 13997-001

W 03-08-01 TCD 2012 2V
6
© 42996-0
Install front cover

z Knock out crankshaft sealing ring (1).
Attention!
Do not damage sealing surface when
knocking out.
© 42997-0

in place.
z Mount new gasket.
© 44545-1
© 04/2007 2/6 13997-001

TCD 2012 2V W 03-08-01
z Position the inner rotor on the crankshaft.

The countersinks on the crankshaft and the
guides on the inner rotor must
match (arrows).
The inner rotor and crankshaft only match
up in one position.
6
© 44547-1
z Mount front cover.

z Fasten screws.
Do not tighten screws.
z Align front cover flush with the oil tray sealing sur-
face.
© 44548-1
z Cut off overhanging gasket (arrows) flush with the

sealing surface of the oil tray.
© 44551-1
© 04/2007 3/6 13997-001

W 03-08-01 TCD 2012 2V
z Tighten the screws according to the tightening se-

quence.
3 Nm
21 Nm
6
© 36521-1
z Fill lubricating oil into the oil pump housing.
© 45369-0
z Install oil suction pipe.

W 08-04-06
© 44548-1
© 04/2007 4/6 13997-001

TCD 2012 2V W 03-08-01

z Install crankshaft sealing ring (opposite side to fly-
wheel)
W 02-02-04
6
© 43492-2
z Install torsional vibration damper.

W 12-01-04
© 46397-0
© 04/2007 5/6 13997-001

W 03-08-01 TCD 2012 2V
© 04/2007 6/6 13997-001

TCD 2012 2V W 03-09-04
Removing and installing the connection housing

Removing the connection housing

z Remove the cover (2).
1
1
© 42698-1

z Remove connection housing.
1
1
1 1
1
© 42699-1
© 04/2007 1/4 13998-001

W 03-09-04 TCD 2012 2V
Installing the connection housing

1
z Clean contact surfaces.
in place.
1
6
© 44083-1
z Mount connection housing.

z Centre connection housing over the clamping bush-
ings.
z Fasten screws.
2
Note different screw lengths.
M12 = (1)
2
M16 = (2)
1
1
2
© 42703-1

quence.
See graphic for tightening sequence. 4 2

1
z Fasten screw (1) hand tight.
6
z Pre-tighten screws (2), (3) (4) and (5) alternately.
99 Nm
z Tighten screws (1) and (6).
99 Nm
3 5
z Tighten screws (2), (3), (4) and (5) alternately.
243 Nm © 44085-0
© 04/2007 2/4 13998-001

TCD 2012 2V W 03-09-04
z Press on cover plate to the stop.

z Tighten screws (2). 1
9 Nm
The hollow gorge (1) faces the lube oil tray. 2
2
6
© 42704-1
© 04/2007 3/4 13998-001

W 03-09-04 TCD 2012 2V
© 04/2007 4/4 13998-001

TCD 2012 2V W 03-11-01
Removing and installing, testing camshaft bearing

– Micrometer gauge – W 04-05-05
Special tools:
– Dial gauge. . . . . . . . . . . . . . . . . . 100400
– Assembly tool . . . . . . . . . . . . . . . 143840
Testing camshaft bearing

W 02-04-01
z Remove camshaft.
W 04-05-05
© 42710-1

the meter at the reversal point of the pointer to "0".
© 34768-2
© 04/2007 1/6 13999-001

W 03-11-01 TCD 2012 2V
Diagram for measuring the camshaft bea-

ring at the points "a and b" in the
levels "1 and 2".
6
© 37239-1

+ 0,054
63 mm
– Wear limit
63,080 mm
When the wear limit is reached, the cams-
haft bearing must be replaced.
© 46337-0
Removing camshaft bearing

z Insert spindle (1).
z Insert guide piece (2).
z Insert counter support (3).
2 1
© 45259-0
© 04/2007 2/6 13999-001

TCD 2012 2V W 03-11-01
z Insert pressure piece (1).

z Screw on nut (2).
6
© 45266-1
z Hold spindle (1).

z Tighten nut (2).
Tighten the nut further until the bearing
liner falls out.
z Remove bearing bush.

2
1
© 46338-0
Installing camshaft bearing

Mark position of the lubricating oil bore.
© 45268-0
© 04/2007 3/6 13999-001

W 03-11-01 TCD 2012 2V
z Check that the lubricating oil bores (1) are in line.
6
© 45269-0
z Insert spindle (1).

z Insert counter bearing (2).
z Position new bearing liner on the pressure piece.
Attention!
Make sure that the lubricating oil bores are
3
in line. 2 1
z Insert pressure piece (3).
© 45267-1
z Press in the bearing liner flush with the assembly de-

vice.
The bearing bush is pressed into the
crankcase by the thrust pad.
© 46338-1
© 04/2007 4/6 13999-001

TCD 2012 2V W 03-11-01
z Check that the lubricating oil bores (1) are in line.

If the lubricating oil bore is not in line, the
camshaft bearing must be removed and re-
installed.
6
© 45502-1
z Install the camshaft.

W 04-05-05
W 02-04-01
© 42710-1
© 04/2007 5/6 13999-001

W 03-11-01 TCD 2012 2V
© 04/2007 6/6 13999-001

TD 2012 2V Engine control
TCD 2012 2V W 04-04-09
Removing and installing the gearcase cover

– W 03-09-04
– W 05-05-01
– Packing compound – W 08-04-07
DEUTZ DW 67 – W 12-06-01
– W 13-03-02
Removing the gearcase

z Remove starter.
W 13-03-02
z Remove connection housing.
W 03-09-04
z Remove flywheel.
W 12-06-01
z Remove speed governor.
W 05-05-01
© 46488-1
z Remove lubricating oil pan.

W 08-04-07
z Turn the engine on the assembly block. 1
z Remove cover (2).
1
© 46419-2
© 04/2007 1/6 14000-001

Engine control TD 2012 2V
W 04-04-09 TCD 2012 2V
1
1
6
© 46596-0

z Remove gearcase cover.
1
1
© 46599-0
z Knock out crankshaft sealing ring (1).

Attention!
Do not damage sealing surface when 1
knocking out.
© 42750-0
© 04/2007 2/6 14000-001

TCD 2012 2V W 04-04-09
Installing the gearcase cover

The sealing surfaces must be dry and free
from grease and dirt.
z Apply packing compound (arrow).

Attention!
The assembly must be completed
within 1 hour at most.
Use packing compound DEUTZ DW 67.

Sealing bead thickness approx. 1.4 mm.
6
© 42525-0
z Align gearcase cover.

z Mount gearcase cover.
Do not move the gearcase cover after 1
mounting.

1
1
© 46598-0
z Fasten screws.
Screws M8 x 45 mm (1)
Screws M8 x 35 mm (2)
2
2
© 46596-1
© 04/2007 3/6 14000-001

W 04-04-09 TCD 2012 2V
z Press up gearcase cover and align flush with the oil

tray sealing surface (arrows).
The oil tray sealing surface on the crank-
case must face downwards.
6
© 46597-0

quence.
5 6 7
30 Nm
4 1
3 2
12 8
13 11
10
14 9
© 36520-3

z Mount new O-ring (1).

z Lightly oil O-ring.
© 46460-0
© 04/2007 4/6 14000-001

TCD 2012 2V W 04-04-09
z Press in cover (2) to the stop.

Use screws M8 x 45 mm.
1
21 Nm
z Install new crankshaft sealing ring (flywheel side).
W 02-02-02
6
1
© 46419-2
z Install connection housing.

W 03-09-04
z Install flywheel.
W 12-06-01
z Install speed governor.
W 05-05-01
z Install starter.
W 13-03-02
z Install lubricating oil pan.
W 08-04-07
© 42759-0
© 04/2007 5/6 14000-001

W 04-04-09 TCD 2012 2V
© 04/2007 6/6 14000-001

TCD 2012 2V W 04-05-05
Removing and installing the camshaft

– Lifting gear – W 02-04-01
– W 07-04-01
– W 07-07-01
Removing the camshaft

z Remove injection pumps.
W 07-04-01
W 07-07-01
z Remove rocker arm and rocker arm bracket.
W 01-02-02
W 02-04-01
© 42705-0
z Screw in screws (1).

z Hang crankcase on suitable workshop crane.
1
1
© 42707-0
© 04/2007 1/4 14001-001

W 04-05-05 TCD 2012 2V
z Remove clamping bracket (1) from the adapter

plates (2).
1
1
2
2
6
© 42708-0
z Push away the assembly block on the flywheel side.
© 42709-0
z Press in all tappets.

z Pull out the camshaft (1) carefully to the flywheel
side.
© 42710-0
© 04/2007 2/4 14001-001

TCD 2012 2V W 04-05-05
z Remove all tappets (arrow).

6
© 42711-0
Installing the camshaft

z Oil all tappets lightly.
z Insert all tappets.
Note the assignment of the tappets.
© 42711-0
z Oil camshaft bearing lightly.

z Oil cam shaft pin lightly.
z Insert camshaft carefully.
The bore (1) must be facing the cylinder
head.
© 42712-0
© 04/2007 3/4 14001-001

W 04-05-05 TCD 2012 2V
z Push on and align the flywheel side assembly block.

z Mount the clamping bracket (1) on the adapter
plate (2).
90 Nm
1
1
2
2
6
© 42708-0
z Unhook the crankcase from the workshop crane.

1
1
© 42707-0
W 02-04-01
z Install rocker arm and rocker arm bracket.
W 01-02-02
W 07-07-01
z Install injection pumps.
W 07-04-01
© 42705-0
© 04/2007 4/4 14001-001

TCD 2012 2V W 04-05-06
Checking the camshaft

– Prisms
Checking the camshaft

z Remove camshaft.
W 04-05-05
z Visually inspect cams and bearing pins for wear.
© 42713-0

© 36424-2
© 04/2007 1/2 14002-001

W 04-05-06 TCD 2012 2V
z Measure the bearing pin.

− 0,05
63 − 0,07 mm
points.
When the limit value is reached the cams-
haft must be replaced.
6
© 42714-0
z Check camshaft gear wheel for visible signs of wear.

z Install the camshaft.
W 04-05-05
© 42713-0
© 04/2007 2/2 14002-001

TCD 2012 2V W 04-06-03
Installing and removing turning gear

Commercial available tools The turning gear 100330 may also be used
depending on the installation ratio.
Special tools:
– Turn-over gear . . . . . . . . . . . . . . 100320
Disassembly
z Remove cover (2). 1
1
© 46419-0
Attaching turning gear

z Insert turn-over gear (1).
The toothed gear of the turn-over gear 2
must grip into the teeth of the camshaft
wheel.
2
© 46420-0
© 04/2007 1/2 14003-001

W 04-06-03 TCD 2012 2V
Removing turning gear

z Remove turning gear (1). 2
6 2
© 46420-0
z Clean the sealing surface on cover and gearcase.

© 46460-0
z Press in the cover (3) to the stop.

30 Nm 1
21 Nm
2
1
© 46419-1
© 04/2007 2/2 14003-001

TD 2012 2V Speed control
TCD 2012 2V W 05-04-14
Removing and installing, checking and setting the control linkage

– Slide gauge – W 05-05-01
– Setting device . . . . . . . . . . . . . . . 100800
Removing the control linkage

W 05-05-01
W 04-04-09
z Remove injection pumps.
W 07-04-01
1
© 46355-0
z Pull out control linkage.
© 46356-0
© 04/2007 1/6 14004-001

Speed control TD 2012 2V
W 05-04-14 TCD 2012 2V
z Visually inspect control linkage.

z Measure width of the groove (1).
+0,03
5 −0,06 mm
1
1
6
© 46346-0
Installing the control linkage

z Insert control linkage.
© 46356-0
z Tighten new screw (1).

10 Nm
Attention!
Self-locking screw!

W 04-04-09
© 46355-0
© 04/2007 2/6 14004-001

TCD 2012 2V W 05-04-14
z Press the control linkage slowly in the direction of the

arrow.
Stop position!
No uneven resistance may occur.
z Release control linkage.

The control linkage must be pressed back
into the initial position from any position by
the spring force.
Start position!
6
© 46344-1
Measure control linkage travel (injection

pumps removed)
z Install setting device (1).
© 46340-1
z Bring control linkage into stop position.

z Measure distance between control linkage and set-
ting device.
© 46341-0
© 04/2007 3/6 14004-001

W 05-04-14 TCD 2012 2V

Start position!

ting device.
– Difference between stop and start position gives
the control linkage travel.
Calculation example
Desired: Control linkage travel
Given: -
Measured: Stop position (a)
(a) = 30.7 mm
Start position (b)
(b) = 13.4 mm
6 Dimension (a) - Dimension (b)
Result: = 17.3 mm
© 46343-0
Nominal di- = 17.0 mm - 17.5 mm
mension
z Turn setting device.

z Turn in knurled screw (1) until reaching the stop po-
sition.
z Install injection pumps.
W 07-04-01
© 46342-1
Measure control linkage travel (injection

pumps installed)
z Install setting device (1).
© 46357-0
© 04/2007 4/6 14004-001

TCD 2012 2V W 05-04-14
z Bring control linkage into stop position.

ting device.
6
© 46358-0

Start position!

ting device.
– Difference between stop and start position gives
the control linkage travel.
Calculation example
Desired: Control linkage travel
Given: -
Measured: Stop position (a)
(a) = 30.5 mm
Start position (b)
(b) = 13.4 mm
Result: = 17.1 mm
© 46359-0
Nominal di- = >16.8 mm
mension
z Check smooth action of the control linkage.

z Press the control linkage slowly in the direction of the
arrow.
No uneven resistance may occur.

The control linkage must be pressed back
into the initial position from any position by
the spring force.
Start position!
© 46344-1
© 04/2007 5/6 14004-001

W 05-04-14 TCD 2012 2V
Measure control linkage standback dimen-

sion for governor adaptation
z Measured standback dimension from gear case cov-
er to stop position.
Attention!
The determined dimension must be speci-
fied when changing or repairing the gover-
nor.
W 05-05-01
6
© 46345-0
© 04/2007 6/6 14004-001

TCD 2012 2V W 05-05-01
Removing and installing the speed governor

Commercial available tools
– Packing compound
DEUTZ DW 73
Removing the speed governor.

z Disconnect cables.
z Unscrew hollow screw (1).
z Remove sealing rings.
© 46487-0

1
© 46488-0
© 04/2007 1/4 14005-001

W 05-05-01 TCD 2012 2V

6
© 46489-0
Installing the speed governor

z Apply packing compound evenly to the sealing sur-
face of the gear case.
© 46348-1

z Mount speed governor.
Turn the governor toothed wheel (1)
slightly if necessary to enable tracking.
1
© 46347-1
© 04/2007 2/4 14005-001

TCD 2012 2V W 05-05-01

quence.
17 Nm
The existing control linkage standback 3 1
dimension must be set on the new gover-
nor when the governor is changed.
5 2 4 6
© 46349-0
z Tighten hollow screw (1).

18 Nm
Use new sealing rings.
z Connect cable.
Ensure that the connection is perfect.
© 46487-0
© 04/2007 3/4 14005-001

W 05-05-01 TCD 2012 2V
© 04/2007 4/4 14005-001

TD 2012 2V Exhaust system/Charging
TCD 2012 2V W 06-01-05
Removing and installing the exhaust line

– Fitting compound
DEUTZ S1
Removing exhaust line

z Remove turbocharger.
W 06-06-04
z Unscrew nuts (1).
1 1
z Remove spacing sleeves.
z Remove exhaust line (2).
1 1
2
© 46354-0
z Remove seals.
z Remove studs.
© 46484-0
© 04/2007 1/4 14006-001

Exhaust system/Charging TD 2012 2V
W 06-01-05 TCD 2012 2V
6
© 46485-0
Installing exhaust line

z Coat new pin bolts with DEUTZ S1 mounting com-
pound.
z Mount new studs.
z Mount new gaskets.
© 46484-0
z Mount exhaust line (2).

z Mount spacer sleeves (1).
© 46486-0
© 04/2007 2/4 14006-001

TCD 2012 2V W 06-01-05
z Turn on new nuts (2).
2 2
2 2
6
© 46354-3
z Tighten all nuts (1).

25 Nm
Tightening sequence from inside to out-
side, start with nut (1).
z Install the turbocharger.

W 06-06-04
© 46354-2
© 04/2007 3/4 14006-001

W 06-01-05 TCD 2012 2V
© 04/2007 4/4 14006-001

TCD 2012 2V W 06-02-08
Removing and install the heating flange

Removing the heating flange

z Disconnect cables. 1
Attention!
Hold on the hexagon of the plus pole
screw.
© 46360-0
z Remove hose nozzles (1).

z Remove gasket (2).
z Remove heating flange.
3 2
© 44360-1
© 04/2007 1/2 14007-001

W 06-02-08 TCD 2012 2V
6
© 44831-0
Installing the heating flange

z Mount gasket (3).
z Mount heating flange.
z Mount gasket (2).
z Mount hose nozzles (1).
3 2
© 44360-1

z Tighten screws alternately.
1
3 Nm + 30°
z Connect cable.
20 Nm
Attention!
Hold on the hexagon of the plus pole 1
screw.
© 46360-0
© 04/2007 2/2 14007-001

TCD 2012 2V W 06-06-04
Removing and installing the turbocharger

Commercial available tools Collect leaking operating substances in
Special tools: to regulations.
– Disassembly tool. . . . . . . . . . . . . 110901
Emptying and filling the engine with opera-
– Fitting compound ting media must be carried out according to
DEUTZ S1 the operating manual and the appropriate
documentation of the vehicle/equipment
manufacturer.
Removing turbocharger
z Hold nut (2).
2
© 46499-0
z Unscrew hollow screws (1).

z Remove sealing rings. 1
z Remove lubricating oil pipe (2).
© 46500-0
© 04/2007 1/6 14008-001

W 06-06-04 TCD 2012 2V

z Remove holder.
6
© 46501-0
z Remove oil return pipe (1).
© 46502-0
z Unscrew nuts (1).

z Remove turbocharger (2).
z Remove gasket.
z Unscrew the pin bolts.
z Visually inspect the components. 1 1
2
© 46503-0
© 04/2007 2/6 14008-001

TCD 2012 2V W 06-06-04
Installing the turbocharger

z Insert new pin bolts with mounting compound.
z Mount new studs.
z Mount gasket (1).
6
© 46504-0

z Lightly oil O-ring. 1
© 46437-0
z Mount turbocharger (2).

z Tighten nuts (1).
22 Nm
1 1
2
© 46503-0
© 04/2007 3/6 14008-001

W 06-06-04 TCD 2012 2V
z Mount lubricating oil pipe (2).

z Insert hollow screws (1) with new sealing rings ten- 1
sion-free.
18 Nm
z Insert hollow screws (3) with new sealing rings ten- 2
sion-free.
34 Nm
6
© 46500-1

1
© 46438-0
z Connect oil return pipe (2) in direction of arrow.
© 46507-0
© 04/2007 4/6 14008-001

TCD 2012 2V W 06-06-04
z Push oil return line (1) into crankcase (arrow).

z Mount holder.
21 Nm
2
6
© 46501-1
z Hold nut (2).

13 Nm
2
© 46499-0
© 04/2007 5/6 14008-001

W 06-06-04 TCD 2012 2V
© 04/2007 6/6 14008-001

TCD 2012 2V W 06-07-03
Removing and install the charge air line

– Locking agent
DEUTZ DW 72
Remove charge air line

© 46490-0
z Remove charge air manifold (2).
1 1
z Remove gasket.
z Remove plug piece.
© 46491-0
© 04/2007 1/4 14009-001

W 06-07-03 TCD 2012 2V

W 01-04-04
2
z Remove charge air pipe (2).
z Remove seals.
6
© 46492-0
Install charge air line

z Mount new gaskets (1).
Ensure that the installation location is free 1
from faults.
© 46493-0
z Mount charge air line.
© 46494-0
© 04/2007 2/4 14009-001

TCD 2012 2V W 06-07-03
z Fasten screws.
Do not move gaskets.
z Tighten screws .
11 Nm
Tightening sequence: From the centre out-
wards.
6
© 46495-0

W 01-04-04
z Mount new gasket (1).
© 46496-0
z Fit new sealing rings (1).
© 46433-0
© 04/2007 3/4 14009-001

W 06-07-03 TCD 2012 2V
z Coat plug piece (1) with mounting compound.

z Insert plug element (1).
6
© 46498-0
z Mount charge air manifold.

z Insert screws (1) with locking agent.
z Insert screws (2) with locking agent.
z Fasten screws. 3
Note different screw lengths:

M8 x 30 mm (1)
M8 x 95 mm (2)
2
M8 x 80 mm (3)
z Tighten screws .
30 Nm
z Connect cable. 1
© 46491-1

18 Nm
© 46490-0
© 04/2007 4/4 14009-001

TD 2012 2V Fuel system
TCD 2012 2V W 07-04-01
Removing and installing the fuel injector pump

– Socket wrench insert, – W 07-06-03 . . . . . . . . . . . . (engine wit-
10 mm, 12-edge hout injection
– Multi-toothed socket adjuster)
wrench insert . . . . . . . . . . . . . . . . . 8117 – W 07-06-03 . . . . . . . . . . . . (engine with
– Rotation angle disc . . . . . . . . . . . . . 8190 injection adju-
Special tools: ster)
– Turn-over gear . . . . . . . . . . . . . . 100320 – W 07-06-04 . . . . . . . . . . . . (engine wit-
– Pressing device . . . . . . . . . . . . . 100830 hout injection
– Special pliers. . . . . . . . . . . . . . . . 103220 adjuster)
– Puller. . . . . . . . . . . . . . . . . . . . . . 110030 – W 07-06-04 . . . . . . . . . . . . (engine with
– Special wrench . . . . . . . . . . . . . . 110500 injection adju-
– Slide hammer . . . . . . . . . . . . . . . 150800 ster)
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 6
Attention!
– Fitting compound Pay attention to utmost cleanliness when
DEUTZ AP1908 working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts care-
fully. Blow damp areas dry with compres-
sed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
to regulations.
When changing the fuel injector pump the

thickness of the shim must be redetermi-
ned.
The EP-code must be changed on the
company plate.
When changing the crankcase, camshaft
or roller tappet, the corrected fuel injector
pump installation dimension "EK " and the
corresponding EP code must be determi-
ned and changed on the company plate.
© 04/2007 1/14 14010-001

Fuel system TD 2012 2V
W 07-04-01 TCD 2012 2V
Removing the fuel injector pump

z Pull out the cable plug from the engine shutdown.
z Remove cylinder head cover (1).
W 01-04-04
1
6
© 46474-3
© 46371-0
z Pull out engine shutdown (1).
© 46364-0
© 04/2007 2/14 14010-001

TCD 2012 2V W 07-04-01
z Insert pressing device (1).
6
© 46365-0
© 46372-0
z Turn knurled screw (1).

Turn knurled screw to stop.
(control linkage stop position)
1
© 46373-0
© 04/2007 3/14 14010-001

W 07-04-01 TCD 2012 2V

z Remove cover (2).
6
1
© 46419-0
z Insert turn-over gear (1).

The toothed gear of the turn-over gear
must grip into the teeth of the camshaft
2
wheel.
2
© 00000-0
z Turn crankshaft in engine direction of rotation until

the cam for actuating the fuel injector pump of the
corresponding cylinder is on the base circle.
Example: Inlet valve cylinder 1 is open.
© 35356-1
© 04/2007 4/14 14010-001

TCD 2012 2V W 07-04-01
z Remove injection line with special wrench.
6
© 46424-1
© 46425-0
z Remove flange.
© 46426-0
© 04/2007 5/14 14010-001

W 07-04-01 TCD 2012 2V
If fuel injector pump is stuck tight:
z Assembly sliding hammer (1) and puller (2).

z Tighten lock nut (3).
1
6
© 40958-0
z Apply slide hammer to fuel injector pump.

z Screw on lock nut (1).
z Pull out stuck fuel injector pump.
© 46427-0
z Pull out fuel injector pump.

© 46418-0
© 04/2007 6/14 14010-001

TCD 2012 2V W 07-04-01
z Pull out roller tappet (1) with special pliers.

z Remove shim.
6
© 46421-1
Installing the fuel injector pump

When changing the fuel injector pump the
thickness of the shim must be redetermi-
ned.
The EP-code must be changed on the
company plate.
z Determining the thickness of the shim
(engine without injection adjuster)
W 07-06-03
z Determining the thickness of the shim
(engine with injection adjuster)
1
W 07-06-03
z Insert roller tappet (1) with special pliers.
When changing the crankcase, camshaft © 46421-1
or roller tappet, the corrected fuel injector
pump installation dimension "EK " and the
corresponding EP code must be determi-
ned and changed on the company plate.
z Determining the installation dimension of the fuel in-
jector pump
(engine without injection adjuster)
W 07-06-04
z Determining the installation dimension of the fuel in-
jector pump
(engine with injection adjuster)
W 07-06-04
© 04/2007 7/14 14010-001

W 07-04-01 TCD 2012 2V
z Insert new O-rings (1).
6
© 39865-1
z Turn the fuel injector pump control lever to approx.

centre position.
© 46369-0
z Coat the locating hole in the crankcase and the O-

rings of the fuel injector pump with mounting com-
pound.
z Set the roller tappet of the respective cylinder on the
base circle.
z Install the fuel injector.
z Insert the fuel injector pump control lever (1) in the
control linkage.
© 46418-1
© 04/2007 8/14 14010-001

TCD 2012 2V W 07-04-01
z Mount flange.
Chamfer must face the fuel injector pump
body.
6
© 46426-0
Start respectively with screw (2).
z Lightly oil screws (2).

z Lightly oil screws (1).
z Tighten screws evenly with the socket wrench insert.
5 Nm + 80°
Attention!
The flange must contact evenly.
1 2
© 46430-0
z Turn screws (1) 190° in direction of arrow.
1 1
© 46366-0
© 04/2007 9/14 14010-001

W 07-04-01 TCD 2012 2V
z Turn injection pump carefully with multi-toothed

socket wrench insert in direction of arrow to the tan-
gible stop.
6
© 46429-0
Start respectively with screw (2).
z Tighten screws (1) and (2).

5 Nm + 150°
z Tighten new injection lines with special wrench.
25 Nm
1 2
© 46430-0

z Remove pressing device (2).
© 46372-1
© 04/2007 10/14 14010-001

TCD 2012 2V W 07-04-01

z Remove turning gear (1).
2
2
6
© 00000-0
z Clean the sealing surface on cover and gearcase.

© 46460-0
z Press in the cover (3) to the stop.

30 Nm 1
21 Nm
2
1
© 46419-1
© 04/2007 11/14 14010-001

W 07-04-01 TCD 2012 2V
Attention!
Check control linkage for smooth action.
z Actuate the shutdown lever between start and stop

position.
6 1
© 46417-0
z Press the control linkage into the stop position with

the shutdown lever and hold.
z Insert engine shutdown (1).
© 46364-0

21 Nm
© 46371-0
© 04/2007 12/14 14010-001

TCD 2012 2V W 07-04-01
z Mount cylinder head cover (1).

W 01-04-04
z Plug cable plug to engine shutdown.
1
6
© 46474-3
© 04/2007 13/14 14010-001

W 07-04-01 TCD 2012 2V
© 04/2007 14/14 14010-001

TCD 2012 2V W 07-06-03
Determining the thickness of the shim

(Engine without injection adjuster)
– Torque wrench
Let the engine cool down for at least one

hour. Lubricating oil temperature < 40 °C
All contact and measuring surfaces must
be absolutely clean to rule out measuring
errors!
The following procedure describes the

work for one fuel injector pump example.
The work procedure is the same for any
other fuel injector pump.
z Remove fuel injector.
W 07-04-01
© 46418-0
z Read EP-code according to the cylinder concerned

from the company plate.
Example: EP-code 295 for cylinder 1 (1)
z Read and note the corrected fuel injector pump
dimension EK based on the EP-code.
Example: EK = 120.875 mm
Table 3 - see Technical Data
© 46416-0
© 04/2007 1/2 14011-001

W 07-06-03 TCD 2012 2V
z Read code number of the (new) fuel injector pump for

fuel injector pump length dimension A.
Example: Dimension A = 42
z Note dimension A for the calculation of the
theoretical shim thickness TS.
z Read and note basic dimension L0 of the injection
pump.
Example: 117.5 mm
z Calculate the thickness of the shim.
Tables 1,2, 3 - see Technical Data
Calculation example
Desired: Theoretical shim thickness TS
6 Shim thickness SS
Given: Code for fuel injector pump length A © 30095-3
Basic dimension of the fuel injector pump L0 from
table 1 e.g. 117.5 mm
EP-code (company plate) , e. g. 295
Corrected fuel injector pump installation
dimension EK from table 3 according to the EP-
code, e.g. 120.875 mm
Calculation: TS = EK - (L0 + A/100)
TS = 120.875 mm - (117.5 mm + 42/100 mm)
TS = 120.875 mm - 117.92 mm
Result: TS= 2.955 mm
Select SS according to table 2
SS = 3.0 mm
z Place determined shim on roller tappet.

W 07-04-01
© 46418-0
© 04/2007 2/2 14011-001

TCD 2012 2V W 07-06-03
Determining the thickness of the shim

(Engine with injection adjuster)

errors!

W 07-04-01
© 46418-0
z Read EP-code according to the cylinder concerned

from the company plate.
Example: EP-code 670 for cylinder 1 (1)
z Read and note the corrected fuel injector pump
dimension EK based on the EP-code.
Example: EK = 117.65 mm
Table 3.1 - see Technical Data
© 46416-0
© 04/2007 1/2 14012-001

W 07-06-03 TCD 2012 2V
z Read code number of the (new) fuel injector pump for

fuel injector pump length dimension A.
Example: Dimension A = 23
z Read and note basic dimension L0 of the injection
pump.
Example: 111.15 mm
Table 1.1 - see Technical Data 23
Tables 1.1, 2.1, 3.1 - see Technical Data
Calculation example
6 Shim thickness SS
Given: Code for fuel injector pump length A © 39865-0
table 1.1 e.g. 111.15 mm
EP-code (company plate) , e.g. 670
Corrected fuel injector pump installation
dimension EK from table 3.1 according to the
EP-code, e.g. 117.65 mm
TS = 117.65 mm - (111.15 mm + 23/100 mm)
TS = 117.65 mm - 111.38 mm
Result: TS= 6.27 mm
Select SS according to table 2.1
SS = 6.25 mm

W 07-04-01
© 46418-0
© 04/2007 2/2 14012-001

TCD 2012 2V W 07-06-04
Determining the installation dimension of the injector pump

(Engine without injection adjuster)
Special tools:
– Digital dial gauge . . . . . . . . . . . . 100410
– Measuring device . . . . . . . . . . . . 103210
errors!

W 07-04-01
© 46418-0
Lubricating oil residue on the surface of the

roller tappet can falsify the measuring
result.
z Clean surface of the roller tappet.
z Place spacer disc (5 mm) on the roller tappet.
z Insert roller tappet in the fuel injector pump shaft with
special pliers.
© 46421-0
© 04/2007 1/6 14013-001

W 07-06-04 TCD 2012 2V
z Turn crankshaft with turning gear in engine direction

of rotation until the cam for actuating the fuel injector
pump for cylinder 1 is on the base circle.
Inlet valve cylinder 1 is open.
6
© 35356-1
z Mount measuring foot, short (2) on dial gauge

holder (1).
© 39858-0
z Insert dial gauge in dial gauge holder.

z Tighten knurled screw of the dial gauge holder.
© 39859-0
© 04/2007 2/6 14013-001

TCD 2012 2V W 07-06-04
z Insert spacer in the setting master with special pliers.
6
© 39860-0
z Insert dial gauge holder in the setting master.

z Set dial gauge to "0" with pre-tension.
Note unit of dimension.
Depth dimension of the setting master cor-
responds to: Le = 122.25 mm
© 39861-0
z Clean contact and measuring surfaces on the crank-

case.
z Insert the dial gauge holder carefully in the fuel injec-
tor pump shaft.
z Align the dial gauge holder.
z Screw in screws (1) with spacer sleeves (2).
15 Nm
1 1
2 2
© 46422-0
© 04/2007 3/6 14013-001

W 07-06-04 TCD 2012 2V
The dial gauge now shows a value in the

plus or minus range.
z Calculate dimension "L".

Calculation example
Desired: Dimension L
Given: Depth setting master Le = 122.25 mm
Thickness of the shim (d) = 5 mm
Measured: Display dial gauge X = + 2.20 mm
Calculation: L = Le - X + d "L"
L = 122.25 mm - 2.20 mm + 5.0 mm
Result: L = 125.05 mm
z Note dimension "L".
6
© 46423-2
z Remove dial gauge holder.

z Calculate corrected fuel injector pump installation di-
mension ’’EK’’.
Calculation example
Desired: Corrected fuel injector pump installation dimen-
sion ’’EK’’.
Given: Dimension L
Commencement of delivery (company plate)
Camshaft type W (company plate)
Pre-stroke Vh nominal value from table 1
Calculation: EK = L - Vh nominal value
EK = 125.05 mm - 5.337 mm
Result: EK = 119.713 mm
z Note corrected fuel injector pump installation dimen-
© 39870-0
z Read code number of the fuel injector pump for fuel

injector pump length dimension A.
– Example: Dimension A = 42
© 30095-3
© 04/2007 4/6 14013-001

TCD 2012 2V W 07-06-04

Tables 1,2, 3 - see Technical Data
Calculation example
Shim thickness SS
Given: Corrected fuel injector pump installation dimen-
sion EK (redetermined, see above calculation)
Code for fuel injector pump length A
table 1 e.g. 117.5 mm
TS = 119.713 mm - (117.5 mm + 42/100 mm)
TS = 119.713 mm - 117.92 mm
Select SS according to table 2
SS = 1.8 mm
6

W 07-04-01
Repeat the measuring process for every
fuel injector pump.
or roller tappet, the newly determined cor-
rected fuel injector pump installation
dimension "EK " and the corresponding EP
code must be determined and changed on
the company plate.
z Determine EP-code.
Calculation example
Desired: EP-code © 46418-0
Calculation example (continued)

EK = 119.713 mm
EK symmetrically rounded = 119.725 mm
Calculation: Select EP-code according to table 3
Result: EP-code = 249
© 04/2007 5/6 14013-001

W 07-06-04 TCD 2012 2V
© 04/2007 6/6 14013-001

TCD 2012 2V W 07-06-04
Determining the installation dimension of the injection pump

(Engine with injection adjuster)
– Torque wrench
Special tools:
– Turn-over gear . . . . . . . . . . . . . . 100320 Let the engine cool down for at least one
– Digital dial gauge . . . . . . . . . . . . 100410 hour. Lubricating oil temperature < 40 °C
– Measuring device . . . . . . . . . . . . 103210 All contact and measuring surfaces must
errors!

W 07-04-01
© 46418-0
Lubricating oil residue on the surface of the

injection adjuster can falsify the measuring
result.
z Clean surface of the injection adjuster.
z Insert roller tappet in the fuel injector pump shaft with
special pliers.
© 46421-0
© 04/2007 1/6 14014-001

W 07-06-04 TCD 2012 2V
z Turn crankshaft with turning gear in engine direction

of rotation until the cam for actuating the fuel injector
pump for cylinder 1 is on the base circle.
Inlet valve cylinder 1 is open.
6
© 35356-1
z Mount measuring foot, short (2) on dial gauge

holder (1).
© 39858-0
z Insert dial gauge in dial gauge holder.

z Tighten knurled screw of the dial gauge holder.
© 39859-0
© 04/2007 2/6 14014-001

TCD 2012 2V W 07-06-04
z Insert spacer in the setting master with special pliers.
6
© 39860-0
z Insert dial gauge holder in the setting master.

z Set dial gauge to "0" with pre-tension.
Note unit of dimension.
Depth dimension of the setting master cor-
responds to: Le = 122.25 mm
© 39861-0
z Clean contact and measuring surfaces on the crank-

case.
z Insert the dial gauge holder carefully in the fuel injec-
tor pump shaft.
z Align the dial gauge holder.
z Screw in screws (1) with spacer sleeves (2).
15 Nm
1 1
2 2
© 46422-0
© 04/2007 3/6 14014-001

W 07-06-04 TCD 2012 2V
The dial gauge now shows a value in the

plus or minus range.
Add 1 mm working piston travel of the
injection adjuster (see calculation
example).
z Calculate dimension "L".
Calculation example
Desired: Dimension L
Given: Depth setting master Le = 122.25 mm
Working piston travel = + 1 mm
Measured: Display dial gauge X = + 0.45 mm
Calculation: L = (Le + 1 mm) - X
L = (122.25 mm + 1 mm) - (+ 0.45 mm)
L = 123.25 mm - 0.45 mm
Result: L = 122.80 mm
6 z Note dimension "L".
© 39866-0
z Remove dial gauge holder.

z Calculate corrected fuel injector pump installation di-
mension ’’EK’’.
Calculation example
Desired: Corrected fuel injector pump installation dimen-
Given: Dimension L
Commencement of delivery (company plate)
Camshaft type W
Pre-stroke Vh nominal value from table 1.1
Calculation: EK = L - Vh nominal value
EK = 122.80 mm - 5.337 mm
Result: EK = 117.463 mm
z Note corrected fuel injector pump installation dimen-
© 39870-0
z Read code number of the fuel injector pump for fuel

injector pump length dimension A.
– Example: Dimension A = 23
23
© 39865-0
© 04/2007 4/6 14014-001

TCD 2012 2V W 07-06-04

Tables 1.1, 2.1, 3.1 - see Technical Data
Calculation example
Shim thickness SS
Code for fuel injector pump length A
table 1.1 e.g. 111.15 mm
TS = 117.463 mm - (111.15 mm + 23/100 mm)
TS = 117.463 mm - 111.38 mm
Select SS according to table 2.1
SS = 6.1 mm
6

W 07-04-01
Repeat the measuring process for every
fuel injector pump.
or roller tappet, the newly determined cor-
rected fuel injector pump installation
dimension "EK " and the corresponding EP
code must be determined and changed on
the company plate.
z Determine EP-code.
Calculation example
Desired: EP-code © 46418-0
Calculation example (continued)

EK = 117.463 mm
EK symmetrically rounded = 117.475 mm
Calculation: Select EP-code according to table 3.1
Result: EP-code = 663
© 04/2007 5/6 14014-001

W 07-06-04 TCD 2012 2V
© 04/2007 6/6 14014-001

TCD 2012 2V W 07-07-01
Removing and installing the fuel injectors

– W 07-07-05
Special tools:
– Puller. . . . . . . . . . . . . . . . . . . . . . 110030
– Extraction tool . . . . . . . . . . . . . . . 120660 Danger!
– Special wrench . . . . . . . . . . . . . . 110500 Wait 30 seconds after switching off the
– Slide hammer . . . . . . . . . . . . . . . 150800 engine before working on the fuel system.
– Fitting compound Attention!

DEUTZ AP1908 Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the affec-
ted parts. Blow damp areas dry with com-
pressed air.
6
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
The following work procedure describes

the removal and installation of a fuel injec-
tor.
Proceed the same to remove another fuel
injector.
Removing fuel injector

W 01-04-04
z Unscrew union nut (1) with special wrench.
© 46569-0
© 04/2007 1/4 14015-001

W 07-07-01 TCD 2012 2V
z Unscrew union nut (1) with special wrench.

z Remove injection line.
z Remove sealing rubber from injection line.
1
6
© 46570-0

z Remove clamping shoe (2).
z Pull out fuel injector (3).
© 46571-0
Removing stuck fuel injectors

z Assembly sliding hammer (1) and puller (2).
z Tighten lock nut (3).
© 46571-0
© 04/2007 2/4 14015-001

TCD 2012 2V W 07-07-01
z Mount sliding hammer on fuel injector.

z Screw on lock nut (1).
1
z Pull out stuck fuel injector.
z Pull out stuck sealing ring on cylinder head with ex-
traction tool.
6
© 46568-0

z Check the fuel injector.
W 07-07-05
© 45414-0
Installing the fuel injector

z Mount sealing ring (2).
1
© 46435-0
© 04/2007 3/4 14015-001

W 07-07-01 TCD 2012 2V
Attention!
Note installation position.
The countersink (1) on the fuel injector
must face away from the clamping shoe.
1
6
© 46436-0
z Insert fuel injector (3).

z Mount clamping shoe (2).
16 Nm
© 46571-0
z Install new high pressure pipe (1).

z Tighten union nuts (2) with special wrench. 2
25 Nm
z Mount the sealing rubber (3).
z Mount cylinder head cover. 1
W 01-04-04
2
© 46431-0
© 04/2007 4/4 14015-001

TCD 2012 2V W 07-07-05
Checking fuel injectors

– Socket wrench insert size
15 . . . . . . . . . . . . . . . . . . . . . . . . . . 8012
– Nozzle tester. . . . . . . . . . . . . . . . . . 8008 Danger!
Special tools: Danger of injury when handling the nozzle
– Holder . . . . . . . . . . . . . . . . . . . . . 110110 tester.
The fuel penetrates deep into the flesh
through the nozzle jet!
Caution, blood poisoning!
After about three or four actuations of the

hand lever, the spring space above the
nozzle needle in the injection valve fills up 6
with diesel fuel/test oil. Then it is no longer
possible to actuate the hand lever.
The nozzle cap nut must be loosened care-
fully before every test procedure to release
pressure from the spring space.
Only use pure test oil according to ISO
4113 or clean diesel fuel to test the fuel
injectors.

W 07-07-01
© 45414-0
© 04/2007 1/6 14016-001

W 07-07-05 TCD 2012 2V
Connecting the fuel injector to the nozzle

tester
z Insert fuel injector in holder.
z Loosen nozzle cap nut approx. 180° with socket
wrench insert (release pressure) and re-tighten.
35 Nm
6
© 36271-2
z Connect the fuel injector to the nozzle tester
© 35889-2
Checking opening pressure

z Press down the lever of the nozzle tester slowly with
the pressure gauge connected.
z Read off measured value.
The pressure at which the pointer stands
still or suddenly drops is the opening pres-
sure.
Repeat test 3 times.
© 36293-2
© 04/2007 2/6 14016-001

TCD 2012 2V W 07-07-05
z Compare measured values.

220 bar
The measured values of three tests must
match the test value.
z In case of deviations from the test value, the fuel in-

jector must be renewed.
6
© 36293-2
Checking tightness
z Blow the injection nozzle and nozzle holder dry with
air.
z Press the hand lever of the tester down slowly until
about 20 bar below the previously read opening
pressure are reached.
© 36293-2
Injection nozzle is tight if it does not drip

within 10 seconds.
© 36294-2
© 04/2007 3/6 14016-001

W 07-07-05 TCD 2012 2V
z If the injection nozzle drips, the fuel injector must be

renewed.
Attention!
Repairs are not permitted!
6
© 36295-2
Checking the easy action of the nozzle

needle
z Switch off the tester’s pressure gauge.
z Carry out chatter and jet test of the nozzle needle.
The easy action of the nozzle needle in the
nozzle body is checked by the acoustic
chatter test.
Increasing wear in the needle seat of the
fuel injectors changes the chatter behavior
of the injecton nozzle.
A used fuel injector must buzz audibly and
atomize the fuel finely when the lever is
actuated quickly.
The jet profile may deviate considerably
from that of a new fuel injector.
© 36296-2
z If the injection nozzle does not buzz audibly, the fuel

injector must be renewed.
© 36296-2
© 04/2007 4/6 14016-001

TCD 2012 2V W 07-07-05
Removing the fuel injector from the nozzle

tester
z Loosen nozzle cap nut approx. 180° with socket
wrench insert (release pressure) and re-tighten.
35 Nm
Attention!
The pressure in the spring space must be
reduced before installing the fuel injectors.
W 07-07-01
6
© 36271-2
© 04/2007 5/6 14016-001

W 07-07-05 TCD 2012 2V
© 04/2007 6/6 14016-001

TCD 2012 2V W 07-10-08
Removing and installing the fuel filter console

Commercial available tools – User notes
– Operation manual
Special tools:
– Special wrench . . . . . . . . . . . . . . 170050
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
Attention!
Ensure utmost cleanliness when working
on the fuel system.
pressed air.
6
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
Removing the fuel filter console

Collect draining fuel and dispose of accor- 1
ding to regulations.
© 46583-0
© 04/2007 1/4 14017-001

W 07-10-08 TCD 2012 2V

z Remove fuel filter console (2).
1
6
© 46584-0
© 46585-0
Installing the fuel filter console

z Mount the fuel filter console.
z Mount nut (1). 1 2
z Fasten screw (2).
© 46586-0
© 04/2007 2/4 14017-001

TCD 2012 2V W 07-10-08
z Mount nut (1).

z Fasten screw (2).
1
z Tighten screws .
30 Nm
6
© 46523-1
z Tighten hollow screw (1) with new sealing rings.

39 Nm
2
39 Nm
1
Attention!
Lay the hose pipe free from chafing and
tension.
Bleed the fuel system via the manual fuel

pump on the fuel pre-filter according to the
operation manual.
© 46583-1
© 04/2007 3/4 14017-001

W 07-10-08 TCD 2012 2V
© 04/2007 4/4 14017-001

TCD 2012 2V W 07-11-01
Removing and installing the fuel supply pump

– User notes
Special tools: – Operation manual
– Plugs/caps . . . . . . . . . . . . . . . . . 170160
Danger!
Attention!
Pay attention to utmost cleanliness when
working on the fuel system. Clean the
affected parts carefully. Blow damp areas
dry with compressed air. Observe the
safety regulations and specific national 6
rules for handling fuels. Seal all connec-
tions immediately with new and clean
plugs/caps after opening. Do not remove
plugs/caps until immediately before
assembling. Collect escaping fuel in suita-
ble vessels and dispose of according to
regulations.
Only test / tighten / renew V-belts with the
engine at a standstill.
Removing the fuel supply pump

Danger!
z Unscrew hollow screw (1). 1
Collect draining fuel and dispose of accor-
© 46572-0
© 04/2007 1/4 14018-001

W 07-11-01 TCD 2012 2V

z Remove fuel supply pump.
z Remove V-belt. 1
6
© 46573-0
Installing the fuel supply pump

z Mount fuel supply pump.
1
© 46574-0
z Mount V-belt.
z Press clamping strap (1) in direction of arrow with a
suitable tool.
© 46375-1
© 04/2007 2/4 14018-001

TCD 2012 2V W 07-11-01
z Pre-tighten screws (1).

z Check V-belt tension.
W 13-02-03 1
6
© 46375-0

39 Nm (M12x1,5)
pump on the fuel pre-filter according to the 1
operation manual.
© 46572-0
© 04/2007 3/4 14018-001

W 07-11-01 TCD 2012 2V
© 04/2007 4/4 14018-001

TD 2012 2V Lube oil system
TCD 2012 2V W 08-04-06
Removing and installing the oil suction pipe

Removing the oil suction pipe

W 08-04-07
z Unscrew screws (1). 1
z Remove oil suction pipe (2).
2
z Remove gasket.
1
1
© 42766-1
Installing the oil suction pipe

z Mount new gasket.
z Mount oil suction pipe.
1
z Fasten screws.
Note installation position.
M8 x 25 mm (1)
M8 x 16 mm (2)
1 2
© 42767-1
© 04/2007 1/2 14019-001

Lube oil system TD 2012 2V
W 08-04-06 TCD 2012 2V

21 Nm
z Install lubricating oil pan.
W 08-04-07
1
1
1
6
© 42768-1
© 04/2007 2/2 14019-001

TCD 2012 2V W 08-04-07

to regulations.
– Packing compound Emptying and filling the engine with opera-
DEUTZ DW 74 ting media must be carried out according to
the operating manual and the appropriate
manufacturer.
Removing the lubricating oil pan

z Unscrew locking screw (1).
z Drain lubricating oil, collect and dispose of according
to regulations.
1
© 46593-0

z Remove washer.
z Remove filler neck (2).
z Remove gasket.
1
© 46592-0
© 04/2007 1/4 14020-001

W 08-04-07 TCD 2012 2V

z Remove lubricating oil pan. 1
6
© 46594-3
© 44948-0
Installing the lubricating oil pan


face.
Apply the packing compound in an even
bead (thickness approx. 3.5 mm).
The position of the packing compound is
only partly illlustrated.
© 43451-0
© 04/2007 2/4 14020-001

TCD 2012 2V W 08-04-07
z Mount lubricating oil pan.

Do not move the packing compound when 1
mounting the lube oil tray.
z Fasten screws.
Screw length:
2
M8 x 130 mm (1)
M8 x 110 mm (2)
1
6
© 46594-2
z Fasten all screws (1).

Screw length: 1
M8 x 35 mm
© 46594-3
z Align lubricating oil pan to crankcase.
© 44951-0
© 04/2007 3/4 14020-001

W 08-04-07 TCD 2012 2V

quence. 20 18 12
22
8
See graphic for tightening sequence. 21 4
1
19 5
30 Nm 9
13
11
7 15
3 17
2 14 16
6
6 10
© 45133-0

z Mount new gasket.
z Mount filler neck (1).
z Fasten screws (3).
z Mount disc.
z Fasten screw (2).
1
30 Nm
30 Nm
2
3
© 46592-1
z Insert new sealing ring.

z Tighten screw plug (1).
55 Nm (M18 x 1,5)
z Fill in lubricating oil according to operating manual.
© 46593-0
© 04/2007 4/4 14020-001

TCD 2012 2V W 08-04-07

(metal sheet lubricating oil pan)
Commercial available tools: Attention!
– Wire brush Make sure that no gasket residue falls into
– 4 pin bolts M8x70 the crankcase.
Special tools: Seal all openings.
– Separating tool . . . . . . . . . . . . . . 151500
– Packing compound suitable vessels and dispose of according
DEUTZ DW 74 to regulations.
ting media must be carried out according to
manufacturer.
6
Removing the lubricating oil pan

z Drain lubricating oil, collect and dispose of according
to regulations.
© 44480-0
© 45971-0
© 04/2007 1/6 14021-001

W 08-04-07 TCD 2012 2V
z Drive in separating tool (1) to the stop (2).

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

Attention!
The tool can only be driven in in the area of
the crankcase.
Separation in the area of aluminium parts
is not allowed. 2
Do not damage the sealing surfaces. 1
© 45970-0
z Lever out lubricating oil pan.

© 45968-0
© 04/2007 2/6 14021-001

TCD 2012 2V W 08-04-07
6
© 43450-1
Installing the lubricating oil pan

z Scrape off sealing compound with separating tool.
© 45973-0
Attention!
Wear protective glasses.
z Clean the sealing surface on the crankcase with a

wire brush.
© 45967-1
© 04/2007 3/6 14021-001

W 08-04-07 TCD 2012 2V
Attention!
Wear protective glasses.
z Clean the sealing surface on the lubricating oil pan

with a wire brush.
6
© 45972-0

face and in the beading of the lube oil tray.
Apply the packing compound in an even
bead (thickness approx. 3.5 mm).
The position of the packing compound is
only partly illlustrated.
© 43451-0
z To align the lubricating oil pan, screw four pin bolts

(1) diagonally opposed into the crankcase.
z Align the lubricating oil pan in the appropriate instal- 1
lation position with the pin bolts.
z Mount lubricating oil pan.
Attention!
Do not move the lubricating oil pan any
more.
Observe the drying time for the packing
compound.
z Unscrew the pin bolts.
© 45678-0
© 04/2007 4/6 14021-001

TCD 2012 2V W 08-04-07
z Fasten all screws (1).

6
© 45971-0

quence.
30 Nm 24 20 16 12 8 4 1 5 9 13 17 21 25 29
Representation: Tightening sequence 6-
cylinder
28 32
31 34
27 33
23 19 15 11 7 3 2 6 10 14 18 22 26 30
© 43414-0
Representation: Tightening sequence 4-

cylinder
20 16 12 8 4 1 5 9 13 17
24 21
26 25
23 22
19 15 11 7 3 2 6 10 14 18
© 43413-0
© 04/2007 5/6 14021-001

W 08-04-07 TCD 2012 2V
z Insert new sealing ring.

55 Nm (M18x1,5)
z Fill in lubricating oil according to operating manual.
1
6
© 44480-0
© 04/2007 6/6 14021-001

TCD 2012 2V W 08-08-02
Removing and installing the oil cooler

– Fitting compound Collect leaking operating substances in

DEUTZ AP1908 suitable vessels and dispose of according
to regulations.
manufacturer.
Removing the oil cooler

z Remove oil cooler housing.
W 08-08-03
© 46509-0
z Remove locking plate (1).
© 46510-0
© 04/2007 1/4 14022-001

W 08-08-02 TCD 2012 2V

1
1
6
© 46511-0
z Remove oil cooler (2).

© 46512-0
Installing the oil cooler

z Coat the sealing rings with fitting compound.
z Insert new sealing rings (1). 1 1
© 46513-0
© 04/2007 2/4 14022-001

TCD 2012 2V W 08-08-02
z Align oil cooler.

z Insert screws.
6
© 46514-0
z Tighten screws (1) alternately.

22 Nm
1
1
© 46511-0
z Insert locking plate (1).

z Install oil cooler housing.
W 08-08-03
© 46510-0
© 04/2007 3/4 14022-001

W 08-08-02 TCD 2012 2V
© 04/2007 4/4 14022-001

TCD 2012 2V W 08-08-03
Removing and installing the oil cooler housing

Commercial available tools: – Operation manual
– Hose clip pliers . . . . . . . . . . . . . . . . 8011 – User notes
Special tools:
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 Collect leaking operating substances in
– Fitting compound to regulations.
DEUTZ AP1908 Emptying and filling the engine with opera-
manufacturer.
Removing the oil cooler housing

© 46509-0

z Drain, collect and dispose of coolant according to
regulations.
© 46515-0
© 04/2007 1/6 14023-001

W 08-08-03 TCD 2012 2V
z Loosen hose clips (1).

z Remove hose pipe (2).
6
© 46543-0
z Unscrew hollow screw (1).

z Drain fuel, collect and dispose of according to regu-
lations.
© 46517-0

z Remove fuel filter console (2).
© 46518-0
© 04/2007 2/6 14023-001

TCD 2012 2V W 08-08-03

z Remove oil cooler housing (2). 1 1
z Remove gasket.
1 2 1
6
© 46519-0
© 46534-0
Installing the oil cooler housing

z Mount new gasket.
© 46521-0
© 04/2007 3/6 14023-001

W 08-08-03 TCD 2012 2V
z Mount oil cooler housing.

z Fasten screws.
3 2
Pay attention to different screw lengths. 1
M8 x 55 mm (1)
M8 x 90 mm (2)
M8 x 110 mm (3)
30 Nm
1
3 1 2
6
© 46519-1
z Mount the fuel filter console.

z Mount nut (1).
z Fasten screw (2).
2
© 46522-0
z Mount nut (1).

z Fasten screw (2).
1
z Tighten screws .
30 Nm
© 46523-0
© 04/2007 4/6 14023-001

TCD 2012 2V W 08-08-03

39 Nm
Attention!
Lay the hose pipe free from chafing and
tension.
1
6
© 46517-0
z Position hose clips.

z Mount the hose pipe (1).
z Fasten hose clips with hose clip pliers.
© 46548-0
z Position hose clips.

z Mount the hose pipe (1).
z Fasten hose clips with hose clip pliers.
© 46549-0
© 04/2007 5/6 14023-001

W 08-08-03 TCD 2012 2V
z Mount new sealing ring.

z Connect cables.
pump on the fuel pre-filter according to the
operation manual.
6
© 46550-0
© 04/2007 6/6 14023-001

TCD 2012 2V W 08-11-08
Removing and installing the oil pressure switch

Commercial available tools: – User notes
–
Special tools:
– Long socket wrench insert . . . . . 110700 Pay attention to utmost cleanliness when
– Plugs/caps . . . . . . . . . . . . . . . . . 170160 working on the lube oil system.
pressed air.
nal specifications for handling lube oils.
Do not remove plugs/caps until immedia- 6
Removing the oil pressure switch

z Unlock cable plug (1) and remove.
© 42865-1
z Unscrew oil pressure switch (1).

Collect lubricating oil and dispose of accor-

1
© 42866-0
© 04/2007 1/2 14024-001

W 08-11-08 TCD 2012 2V
Installing the oil pressure switch

z Tighten oil pressure switch (1) with new sealing ring.
40 Nm
6
© 42866-0
z Plug in the cable plug (1).

© 42865-1
© 04/2007 2/2 14024-001

TD 2012 2V Cooling system
TCD 2012 2V W 09-07-08
Removing and installing the coolant pump

– W 09-13-04

to regulations.
manufacturer.
Removing coolant pump

z Remove the fan mounting. 1
1
W 09-13-04
z Remove fuel supply pump.
W 07-11-01
z Unscrew screws (1). 1
Collect and dispose of coolant according to
regulations.
1
© 46575-0
© 46576-0
© 04/2007 1/4 14025-001

Cooling system TD 2012 2V
W 09-07-08 TCD 2012 2V
Installing coolant pump

6
© 46577-0
z Mount new gasket.

z Mount coolant pump (1).
Attention!
Use new coated screws. 1
z Fasten screws.
© 46575-1

quence.
30 Nm 2
Tightening order:
screw (1), then screw (2), then the other
screws in any order.
© 46578-0
© 04/2007 2/4 14025-001

TCD 2012 2V W 09-07-08
z Install fuel pump.

W 07-11-01
z Install fan mounting.
W 09-13-04
6
© 46580-0
© 04/2007 3/4 14025-001

W 09-07-08 TCD 2012 2V
© 04/2007 4/4 14025-001

TCD 2012 2V W 09-08-01
Checking the thermostat (in the removed state)

– Thermometer
Danger!
Risk of injury!
Hot water and hot thermostat.
Checking thermostat
z Remove thermostat.
W 09-08-02
z Measure beginning of stroke, dimension (a).
© 34679-3
z Heat up the thermostat in the water bath.

In order to determine the exact beginning
of opening, the temperature should be
measured as close as possible to the ther-
mostat.
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.
z Determine beginning of opening.
83 °C
© 34680-2
© 04/2007 1/2 14026-001

W 09-08-01 TCD 2012 2V
z Measure end of stroke, dimension (b).

6
© 34679-2
z Determine stroke.
Calculation example
Desired: Stroke
Given: -
Measured: Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Dimension (b) - dimension (a)
Result: = stroke
z Compare result with setpoint value.
– Nominal value stroke travel:
at least 8 mm
z Install thermostat.
W 09-08-02
© 34679-1
© 04/2007 2/2 14026-001

TCD 2012 2V W 09-08-02
Removing and installing the thermostat

to regulations.
– Fitting compound Emptying and filling the engine with opera-
DEUTZ AP1908 ting media must be carried out according to
manufacturer.
Removing the thermostat

z Remove outlet nozzle (2). 1
2
1
© 46294-0
z Remove coolant thermostat (1).

1
© 46524-0
© 04/2007 1/2 14027-001

W 09-08-02 TCD 2012 2V
Installing the thermostat

z Clean sealing surfaces. 1
z Insert new sealing ring (1).
z Coat the sealing ring with fitting compound.
6
© 44439-0
z Insert coolant thermostat.
© 46524-1
z Mount outlet nozzle (2).

30 Nm
1
2
1
© 46294-0
© 04/2007 2/2 14027-001

TCD 2012 2V W 09-12-01
Removing and installing temperature transmitter

to regulations.
manufacturer.
Removing temperaure transmitter

z Unlock cable plug (1) and remove.
© 46353-1
z Unscrew temperature transmitter (1).
© 46374-0
© 04/2007 1/2 14028-001

W 09-12-01 TCD 2012 2V
6
© 44084-0
Installing temperature transmitter

z Tighten temperature transmitter (1).
24 Nm
Make sure the sealing ring is in place.
1
© 46374-0
z Plug in the cable plug (1).

© 46353-1
© 04/2007 2/2 14028-001

TCD 2012 2V W 09-13-01
Dismantling and assembling the air bearing

– 2-arm puller
– Internal extractor
– Extension for extraction
tool
– Locking ring pliers
– Press
– Screw . . . . . . . . . . . . . . . . M10 x 40 mm
– Washer
Dismantling the air bearing

1
W 09-13-04
z Hold nut (2).
© 46525-0
z Turn in screw (1) a few turns.

1
© 46526-0
© 04/2007 1/8 14029-001

W 09-13-01 TCD 2012 2V
Attention!
Do not damage the component.
z Pull off V-belt pulley with 2-arm puller.
6
© 46527-0
z Insert internal extractor (1).

z Splay the internal extractor to the stop.
© 46528-0
z Mount counter holder.
© 46529-0
© 04/2007 2/8 14029-001

TCD 2012 2V W 09-13-01
z Pull out ball bearing and hollow shaft.
6
© 46530-0
z Remove locking ring (2).
© 46531-0
z Insert screw (1) and washer (2).

Screw length:
M10 x 40 mm (1)
© 46532-0
© 04/2007 3/8 14029-001

W 09-13-01 TCD 2012 2V
z Turn extension (1) onto screw (2).
6
© 46547-0
z Mount counter holder.

z Pull out ball bearing and nut.
© 46533-0
z Press out nut.
© 46535-0
© 04/2007 4/8 14029-001

TCD 2012 2V W 09-13-01
z Press out the hollow shaft.

6
© 46536-0
Assembling the fan drive

z Press in hollow shaft.
© 46537-0
z Press in nut.
© 46538-0
© 04/2007 5/8 14029-001

W 09-13-01 TCD 2012 2V
Nut (1) faces downwards.
z Mount ball bearing.
6
© 46539-0
z Press out ball bearing over the outer ring.
© 46540-0
z Insert locking ring (2).

Attention!
from faults.
© 46531-0
© 04/2007 6/8 14029-001

TCD 2012 2V W 09-13-01
z Press out ball bearing over the outer ring.
6
© 46542-0
z Mount V-belt pulley (1).

z Fasten screw (2).
2
© 46526-1
z Hold nut (2).

– Stage 1: 1
3 Nm
– Stage 2:
124 Nm
z Install fan drive.
W 09-13-04 2
© 46525-0
© 04/2007 7/8 14029-001

W 09-13-01 TCD 2012 2V
© 04/2007 8/8 14029-001

TCD 2012 2V W 09-13-04
Removing and installing the air bearing

Commercial available tools Emptying and filling the engine with opera-
– Fitting compound documentation of the vehicle/equipment
DEUTZ AP1908 manufacturer.
Removing the fan mounting

1
1
© 46551-0

z Pull out plug element (2). 1
© 46552-1
© 04/2007 1/4 14030-001

W 09-13-04 TCD 2012 2V
Installing the fan mounting

z Insert new sealing ring (1).
z Coat the sealing ring with fitting compound.
6
© 46553-0
z Fit new sealing rings (1).

z Coat the sealing rings with fitting compound.
© 46554-1
z Insert plug element (1).
© 46555-0
© 04/2007 2/4 14030-001

TCD 2012 2V W 09-13-04
z Mount air bearing.

Attention!
from faults.
1
1

60 Nm
6
© 46551-0
© 04/2007 3/4 14030-001

W 09-13-04 TCD 2012 2V
© 04/2007 4/4 14030-001

TD 2012 2V Monitoring system
TCD 2012 2V W 11-00-03
Removing and installing the engine shutdown

Removing the engine shutdown

z Pull out the cable plug from the engine shutdown.
© 46432-0
z Pull out engine shutdown (1).

1
© 46434-0
© 04/2007 1/2 14031-001

Monitoring system TD 2012 2V
W 11-00-03 TCD 2012 2V
Installing the engine shutdown

Attention!
Check control linkage for smooth action.
z Actuate the shutdown lever between start and stop

position.
6 1
© 46417-0
z Press the control linkage into the stop position with

the shutdown lever and hold.
z Insert engine shutdown (1).
1
© 46434-0

21 Nm
z Plug cable plug to engine shutdown.
© 46432-0
© 04/2007 2/2 14031-001

TD 2012 2V Other components
TCD 2012 2V W 12-01-04
Removing and installing the V-belt pulley

– Torque wrench – W 13-02-03
– Socket wrench insert Torx
E20 . . . . . . . . . . . . . . . . . . . . . . . . . 8114
Removing the V-belt pulley

z Loosen screws (1).
z Remove V-belt. 1
© 46375-0

W 04-06-03
z Block flywheel with turning gear.
z Unscrew screws (1) with the socket wrench insert.
z Remove V-belt pulley. 1
© 46600-0
© 04/2007 1/4 14032-001

Other components TD 2012 2V
W 12-01-04 TCD 2012 2V
6
© 46601-0
Installing the V-belt pulley

Make sure the clamping bushing (1) is in
place.
© 46602-0
z Mount V-belt pulley.

The bore (1) must match the bore (2).
© 46603-0
© 04/2007 2/4 14032-001

TCD 2012 2V W 12-01-04
Attention!
Renew screws every time they are loo-
sened.
Screws:
M16 x 1.5
z Tighten new screws with the socket wrench insert

and rotation angle disc.
40 Nm + 60° + 60°
W 04-06-03
z Install V-belt.
W 13-02-03 6
© 46604-0
© 04/2007 3/4 14032-001

W 12-01-04 TCD 2012 2V
© 04/2007 4/4 14032-001

TCD 2012 2V W 12-06-01
Removing and installing the flywheel

– Self-made mandrin guide
Removing the flywheel

z Remove stopper (1).
© 31115-2
z Block flywheel with suitable tool.

z Remove flywheel.
1
© 42825-1
© 04/2007 1/2 14033-001

W 12-06-01 TCD 2012 2V
Installing the flywheel

z Insert self-made guide pin (arrow).
The bores in the flywheel must match the
threaded bores in the crankshaft flange.
6
© 34224-2
Attention!
Renew screws every time they are loo-
sened.
– M10 x 30:
30 Nm + 60° + 30°
– M10 x 35 - M10 x 85:
30 Nm + 60° + 60°
© 42826-0
z Drive plugs into the threaded bores (arrows) to the

stop.
© 31115-1
© 04/2007 2/2 14033-001

TCD 2012 2V W 12-06-03
Renewing toothed starter ring on the flywheel

8190
Danger!
Danger of injury, do not touch hot parts!
Removing toothed starter ring

z Remove flywheel.
W 12-06-01
z Drill toothed wheel.
Block flywheel with suitable tool.
© 45698-0
z Remove toothed starter ring with suitable tool.
© 45699-0
© 04/2007 1/2 14034-001

W 12-06-03 TCD 2012 2V
z Clean flywheel.
z Visually inspect flywheel.
6
© 45700-0
Install toothed starter ring

z Heat up toothed starter ring to 220 °C.
z Place toothed starter ring on flywheel.
The toothed starter ring must lie evenly on
the joint of the flywheel.
© 45701-0
z Install flywheel.
W 12-06-01
© 45702-0
© 04/2007 2/2 14034-001

TD 2012 2V Electrical system
TCD 2012 2V W 13-02-03
Removing and installing the generator

(V-belt drive)
Commercial available tools: Attention!
– V-belt tension measuring Only test / tighten / renew V-belts when the
device . . . . . . . . . . . . . . . . . . . . . . . 8115 engine is not running.
The V-belt tension of new V-belts must be

checked after they have been running for
15 minutes.
Removing the generator

z Disconnect the battery's negative terminal.
z Remove cable from generator.
1
Note assignment!
- (1) = terminal W
- (2) = terminal D+ 2
- (3) = terminal B+
© 46557-0
z Loosen screws (1).
© 46375-0
© 04/2007 1/4 14035-001

Electrical system TD 2012 2V
W 13-02-03 TCD 2012 2V
z Remove V-belt.
z Loosen screw (1).
2
3
z Remove generator (2). 1
6
© 46558-0
Installing the generator

z Mount generator (3).
– M8-10.9 1 2 3
30 Nm
– M8-10.9
30 Nm
– M8-10.9
30 Nm
4
© 46558-1
Installing the V-belt.

z Mount V-belt.
z Press clamping strap (1) in direction of arrow with a
suitable tool.
© 46375-1
© 04/2007 2/4 14035-001

TCD 2012 2V W 13-02-03
z Pre-tighten screws (1).
6
© 46375-0
Check V-belt tension with V-belt tension

measuring device
z Lower indicator arm (1) into V-belt tension measuring
device. 1
© 44591-0
z Mount V-belt tension measuring device on V-belt.

The V-belt must be between the
guides (arrow).
© 46559-0
© 04/2007 3/4 14035-001

W 13-02-03 TCD 2012 2V
z Press the V-belt measuring device against the V-belt

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

process must be repeated.
6
© 46560-0

– M8-10.9
30 Nm 1
© 46375-0
z Remove cable from generator.

Note assignment!
- (1) = terminal W
- (2) = terminal D+ 1
- (3) = terminal B+
z Connect the battery's negative terminal. 2
© 46557-0
© 04/2007 4/4 14035-001

TCD 2012 2V W 13-03-02
Removing and installing the starter

Removing the starter

z Disconnect the battery's negative terminal.
1
z Remove starter.
© 46556-0
Installing the starter

z Insert starter.
1
– M10x38-10.9
60 Nm
– Nut M8
40 Nm
– Pin bolt
10 Nm
z Connect cables.
1
z Connect the battery's negative terminal.
© 46556-0
© 04/2007 1/2 14036-001

W 13-03-02 TCD 2012 2V
© 04/2007 2/2 14036-001

TD 2012 2V
TCD 2012 2V Standard tools
7 Standard tools
© 04/2007
1/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
Standard tools TCD 2012 2V
Orders
Conventional tools /
special tools:
These must be ordered like normal DEUTZ
spare parts with specification of the order
number.
© 04/2007
2/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
8002
Pressure pump
Checking cooling system for leak-tightness
© 35409-2
7
8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
© 35410-3
8008
Nozzle tester
with spray mist collecting vessel
Check injection nozzles
© 35411-2
© 04/2007
3/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe
© 39426-1
7
8012
Socket wrench insert
Wrench size 15, long
© 35412-3
8024
Assembly pliers
Removing valve shaft seals
© 37509-2
© 04/2007
4/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
8035
reinforced, size 22
removing and installing main bearing
© 37504-2
7
8113
Torx - E 14
© 43022-0
8114
Torx - E 20
© 35415-1
© 04/2007
5/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
8115
V-belt tension measuring device
150 to 600 N
Check V-belt tension
© 35416-3
7
8117
Multi-toothed socket wrench insert
For turning the fuel injector pump
© 46422-0
8189
Torx tool set
Contents of case:
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
© 39432-1
© 04/2007
6/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
8190
Rotation angle disc
with magnet
© 42528-1
7
8191
Screwdriver insert
for slotted screw
Valve clearance setting
© 43060-0
8192
Bowl wrench
Fuel pre-filter (type: Racor)
© 43193-1
© 04/2007
7/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
8193
Screwdriver insert
with pressed in hexagonal pin (5 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)
© 43183-0
7
8194
Screwdriver insert
with pressed in hexagon pin (4 mm),
3/8 inch, long version
(in connection with rotation angle disc 8190 and reduc-
er 1/2 to 3/8 inch)
© 43183-0
8196
Open end wrench adapter
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.
© 43019-0
© 04/2007
8/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
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
e. g. removing and installing valves
© 37511-2
© 04/2007
9/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
9090
Spring band pliers
320 mm
Tighten spring clamp
© 35420-3
© 04/2007
10/10 OBJ_DOKU-14037-001.fm
TD 2012 2V
TCD 2012 2V Special tools
8 Special tools
© 04/2007
1/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
Special tools TCD 2012 2V
Orders
Conventional tools /
special tools:
These must be ordered like normal DEUTZ
spare parts with specification of the order
number.
© 04/2007
2/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
100190
Connector
(in conjunction with compression pressure tester 8005)
© 42524-0
100320
Turning gear 8
flywheel side
© 35422-1
100330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper
© 48242-0
© 04/2007
3/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
© 35424-1
100410
8 Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
© 43205-0
100750
Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection
© 39402-2
© 04/2007
4/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
100800
Setting device
For measuring the control linkage travel and blocking
the control linkage
© 46441-0
100810
Centring bolts 8
for mass compensation shafts
© 46439-0
100830
Pressing device
For control linkage
© 46443-0
© 04/2007
5/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
103210
Measuring device
For base circle measurement
(in engines with injection adjuster)
© 46444-0
103220
8 Special pliers
(part of measuring device 103210)
for removing the roller tappet
© 43175-0
110030
Puller
(in connection with sliding hammer 150800)
© 35433-2
© 04/2007
6/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
110110
Holder
Wrench size 11,
clamp the injection valve in the vice
© 35434-2
110500
Special wrench 8
Wrench size 17
Removing and installing high-pressure lines
© 35436-1
110700
long
Installing and removing pressure sensors
(rail pressure, oil pressure, fuel pressure)
© 43198-2
© 04/2007
7/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
110901
Disassembly tool
(part of assembly case 110900)
Removing and installing the O-rings
© 45950-1
120440
8 Assembly tool
Removing and installing the glow plugs
© 40333-1
120660
Puller
(in connection with sliding hammer 150800)
© 45111-0
© 04/2007
8/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
120900
Support bracket
pivoting
Clamping cylinder head
© 35438-3
120910
Base plate 8
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)
© 35439-3
121410
Assembly tool
Mounting valve shaft seal
© 37614-2
© 04/2007
9/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
121420
Assembly sleeves
Set of assembly sleeves for valve shaft seal
© 43210-0
130300
8 Universal piston ring pliers
Removing and installing the piston rings
© 43021-0
130440
Trapezoidal groove wear gauge
Piston diameter 101 mmChecking piston ring groove
© 36461-2
© 04/2007
10/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
130670
Piston ring compressor
Piston diameter 101 mm
Installing piston
© 39408-1
142670
Assembly tool 8
Installing crankshaft sealing ring
© 35445-1
142830
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
© 35446-1
© 04/2007
11/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
143840
Assembly tool
Removing and installing camshaft bearing
© 46440-0
144800
8 Counter support
for torsional vibration dampers
© 35453-1
150800
Slide hammer
© 35449-2
© 04/2007
12/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
151500
Separating tool
Removing metal sheet lubricating oil pan from crank-
case
© 45974-0
170050
Special wrench 8
Unscrewing the filter cartridges
© 37629-2
170160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
© 43663-0
© 04/2007
13/14 OBJ_DOKU-14038-001.fm
TD 2012 2V
6066
Assembly block
Engine clamping, double-sided
© 35451-2
6066/158
8 Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided
© 35452-1
6068
Engine lifting device
Load (2000 kg), 3-point suspension, spindle clamp,
cross member, chains and hooks
© 43184-0
© 04/2007
14/14 OBJ_DOKU-14038-001.fm

Work Shop Manual TCD2012 2V

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Workshop Manual

5 Job card overview

© 11/2006 1/2 13962-001

© 11/2006 2/2 13962-001

© 05/2005 1/4 13963-001

© 05/2005 2/4 13963-001

© 05/2005 3/4 13963-001

© 05/2005 4/4 13963-001

© 11/2005 1/4 13964-001

© 11/2005 2/4 13964-001

DEUTZ engines are the product of years of re-

Maintenance and care are the only way the engine

Please consult one of our service representatives

© 11/2005 3/4 13964-001

© 11/2005 4/4 13964-001

© 12/2005 1/8 13965-001

© 12/2005 2/8 13965-001

3.1 General 3.2 Specifications

© 12/2005 3/8 13965-001

© 12/2005 4/8 13965-001

© 12/2005 5/8 13965-001

3.3 Operation manual and workshop 3.4 Job cards

© 12/2005 6/8 13965-001

3.4.2 Structure of a job card 3.5 Explanation of symbols

© 12/2005 7/8 13965-001

© 12/2005 8/8 13965-001

Activity Job card Maintenance group

Activity Job card Maintenance group

Activity Job card Maintenance group

Job card Activity Maintenance group

Job card Activity Maintenance group

Job card Activity Maintenance group

02 Drive system (continued)

Removing and installing the crankshaft

Checking the cylinders

Removing and installing, testing camshaft bearing

06 Exhaust system / Charging

Removing and installing the turbocharger

Removing and installing the charge air line

07 Fuel system (continued)

08 Lube oil system

Removing and installing the oil cooler

09 Cooling system (continued)

Removing and installing the temperature transmitter

Dismantling and assembling the air bearing 5

Renewing toothed starter flywheel ring

Removing and installing the starter

© 11/2005 20/20 13967-001

© 11/2005 1/2 13968-001

© 11/2005 2/2 13968-001

Checking the compression pressure

Checking the compression pressure

z Mount clamping shoe (1).

© 04/2007 1/4 13969-001

z Connect adapter (1) to connector.

z Connect compression pressure tester to connector.

The measured compression pressure