1015CP - BF6M - Workshop - Manual PDF

Workshop Manual
BF6M 1015 CP
0312 0909 en
In view of continuous design improvements or changes, the technical

specifications and the illustrations shown in this operation manual are
subject to alteration. Reprinting and reproduction, in part or in whole,
are subject to our written approval.
1015
Table of contents
Foreword
General
User instructions
3.1
3.2
3.2.1
3.2.2
3.3
3.4
3.5
Technical Data
4.1
4.2
Test and adjustment data

Tightening regulations
Work card index

5.1
5.2
5.3
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General
Regulations
Safety and accident prevention regulations
Disposal regulations
Operating instructions and workshop manual
Work cards
Key to symbols
Alphabetical order
Numerical order
Work card references
Work cards
Commercial tools
Special tools
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Page 1 of 4
1015
Table of contents
Preparation for commissioning

9.1
9.2
9.3
9.4
9.5
9.6
9.6.1
10
Filling in engine oil

Filling oil bath air cleaner with engine oil
Filling the fuel tank
Filling/bleeding cooling system
Other preparations
Appendix
Technical circular
Component functions
F 00-01-01
F 06-01-05
F 06-06-04
F 07-04-04
F 07-07-02
F 07-11-04
F 08-00-00
F 08-04-08
F 08-05-05
F 08-08-02
F 08-10-07
F 08-11-10
F 09-07-09
F 09-08-01
F 12-01-04
F 13-02-03
F 13-03-02
Page 2 of 4
Engine, general
Exhaust manifold
Turbocharger
Injection pump
Injector
Fuel delivery pump
Lubrication system
Oil suction pumps
Oil pressure pump
Oil cooler
Oil filter
Pressure control valve
Coolant pump
Coolant thermostats
Vibration damper
Alternator
Starter
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1015
Table of contents
11
Component data
M 01-02-02
M 01-02-03
M 01-02-04
M 01-02-05
M 01-02-06
M 01-04-02
M 01-05-04
M 01-06-03
M 01-07-03
M 02-03-01
M 02-04-01
M 02-05-04
M 02-07-02
M 02-07-03
M 02-09-07
M 02-10-03
M 02-12-03
M 02-15-02
M 03-03-01
M 03-08-03
M 03-09-01
M 03-09-02
M 03-10-01
M 03-11-01
M 04-02-02
M 04-04-02
M 04-04-09
M 04-04-10
M 04-04-11
M 04-05-04
M 04-05-05
M 04-05-06
M 04-05-07
M 06-06-04
M 07-04-04
M 07-07-03
M 07-11-04
M 08-08-02
M 12-01-04
M 12-01-05
M 12-06-01
M 12-06-03
11/2003
Rocker arm - inlet

Rocker arm - outlet
Rocker axis
Rocker arm bracket
Valve tappet
Cylinder head
Valve
Valve guides
Valve seat rings
Connecting rod
Crankshaft
Big end bearing
Crankshaft main bearing
Thrust washers for crankshaft
Piston
Piston rings
Piston pin
Pressure regulating valve for piston cooling nozzle
Cylinder liner
Accessory carrier
Rear cover
Bearing journal for intermediate gear
Crankcase
Camshaft bearing bushes
Push rod
Intermediate gear in the accessory carrier
Cover for gear drive
Cap for gear drive
Plug for gear drive
Camshaft
Thrust cover for camshaft
Drive gear for camshaft
Camshaft intermediate gear in gear drive
Turbocharger
Injection pump
Injector
Fuel delivery pump
Oil cooler
Vibration damper
Flange groove for vibration damper
Flywheel
Starter ring gear
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1015
Table of contents
Notes
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1015
1 Foreword
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Foreword
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1015
1 Foreword
Notes
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1015
1 Foreword
Please read carefully and observe the instructions given in this documentation. Thus you avoid accidents,
preserve the manufacturer's warranty and ensure that your engine always functions properly and reliably.
This engine is constructed solely for the use - as defined by the equipment manufacturer (intended use) designated in the scope of supply. Any use beyond this is contrary to the intended purpose. The manufacturer is not responsible for any damage incurred on this account. That risk is borne solely by the user.
Intended use also includes compliance with the operating, maintenance and repair instructions issued by
the manufacturer. The engine may only be used, maintained and repaired by those who are familiar with it
and have received instruction about the hazards.
Make sure that this documentation is readily available for all those carrying out operating, maintenance and
repair work and that the contents are well understood.
Non-compliance with this documentation may result in malfunction and engine damage as well as personal
injuries for which the manufacturer shall not accept any liability.
A prerequisite for successful maintenance and repair work is that all required equipment, hand and special
tools are available and in perfect working order.
Engine components such as springs, clamps, snap rings, etc. may cause injury if not handled with care.
Accident prevention regulations and all other generally recognized regulations on safety and occupational
medicine are to be observed.
Optimal operation economy, reliability and durability of the engine can only be ensured when genuine parts
of DEUTZ AG are used.
Engine repairs must be carried out in accordance with intended use. For conversions, only parts approved
by DEUTZ AG for a specific purpose should be used. Unauthorised changes made to the engine invalidate
all liability on the part of the manufacturer for damage incurred as a result.
Non-compliance with this rule nullifies the warranty!
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1015
1 Foreword
DEUTZ engines have been developed for a broad range of applications. The extensive range of models available ensures that each particular requirement can be fulfilled.
The engine is equipped for the specific installation conditions, that means that not all parts and components
described in this documentation are actually built onto your engine.
We have tried to point out these differences so that can easily find the operating, maintenance and repair
specifications relevant to your engine.
Should you have any further questions, please do not hesitate to contact us.
Yours
DEUTZ AG
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1015
2 General
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General
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1015
2 General
Notes
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1015
2 General
DEUTZ Engines
are the product of many years research and development work. Our broad-based expertise acquired over the
years, together with stringent quality requirements, ensures that the engines we produce have a long service
life, and are very reliable and economic in fuel consumption. It goes without saying that they also fulfil the high
requirements placed on environmental protection.
Servicing and maintenance work

is a major factor in ensuring that the engine performs in the way intended. It is therefore essential that the stipulated maintenance schedules are observed and that maintenance and servicing work is performed carefully.
Particular attention needs to be paid to this in demanding operating environments beyond normal working conditions.
DEUTZ AG
In case of operating defects or inquiries for spare parts, please get in touch with one of our representative service centres. Our trained personnel are able to repair any damage incurred promptly and professionally using
original parts.
Original parts made by DEUTZ AG are always state-of-the-art.
You can find notes on our back-up service at the end of this documentation.
Caution when engine is running

Shut the engine down before performing maintenance and repair work. If any safety fixtures are removed, refit
these after concluding the work. When working on a running engine, work clothes must be tightly fitting and
may not hang loose.
Safety
!
All safety instructions are marked by this symbol. Observe these carefully. Also pass on safety instructions to your operating personnel. In addition, observe the "General Safety and Accident Prevention
Regulations" applicable by law.
Note
Notes of a general nature are marked by this symbol.
Observe these carefully.
Asbestos
The seals used with this engine do not contain asbestos. Please use corresponding spare parts when
undertaking maintenance and repair work.
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1015
2 General
Notes
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1015
3 User instructions
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User instructions
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3 User instructions
Notes
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1015
3 User instructions
3.1
General
The maintenance work prescribed in the operating instructions and the workshop manual must be performed
to schedule and in the full scope.
Maintenance personnel must have the skills necessary to perform the work. Any safety fixtures and protective
equipment needing to be dismantled during maintenance work must be refitted.
Caution !
!
It is essential to observe the safety and accident prevention regulations during maintenance work.
In this context, also comply with the specific safety provisions for the different maintenance groups which are
described in detail as work cards in the chapter on work cards (compare section 1.2).
Maintenance intervals are contained in the maintenance schedules. These also provide information on the
work to be performed.
The work cards give technical advice on how to undertake the work.
3.2
Regulations
3.2.1
Safety and accident prevention regulations
Detailed safety instructions have been compiled for the different maintenance groups in the form of work cards,
these precede the work cards of the respective maintenance groups.
Observe the accident prevention regulations laid down by law (available from trade associations or specialist
outlets). These depend on the place of installation, the operating mode and the consumables and auxiliary aids
used.
Special protective action dependent on the respective work is specified and marked in the description of the
work.
In general, the following applies
to personnel:
- Only instructed personnel may operate or service the engine. No unauthorised persons are allowed in
the machine room.
- Wear tightly clothing and hearing protection in the machine room when the engine is operating.
- Only deploy skilled personnel for maintenance or repair work.
to the machine room:

- Provide adequate ventilation (do not cover air vents).
- Install first-aid boxes and suitable fire extinguishers. Check that these are filled and ready to use at regular intervals.
- Do not store inflammable materials in the machine room unless these are required to operate the equipment.
- Smoking and naked flames are forbidden in the machine room.
to operating and maintaining the engine:
- Do not start the engine unless all safety fixtures are installed. Ensure that no-one is loitering in the danger zone.
- Shut the engine down and secure against re-starting before starting cleaning, maintenance and repair
work.
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1015
3 User instructions
3.2.2
Disposal regulations
The work described in the operating instructions and the workshop manualoccasionally requires the renewal
of parts and operating materials. Thesereplacement parts / operating materials must be stored, transported
and disposed of according to the regulations. The operator is responsible for this.
Disposal includes the recycling and scrapping of parts / operating materials, whereby recycling has priority.
Details on disposal its monitoring are regulated by regional, national and international laws and decrees. It is
the responsibility of the plant operator to comply with these.
3.3
Operating instructions and workshop manual
The servicing documentation has been sub-divided into operating instructions and workshop manual in order
to structure the information in the best way for the users.
Among other things, the operating instructions contain a general description of and a guide to all maintenance work required.
They contain the following chapters:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
General, table of contents

Engine description
Operating
Operating materials
Maintenance
Servicing and maintenance work
Troubleshooting
Engine conservation
Technical specifications
Service
The workshop manual requires prior knowledge of the contents of the operating instructions, this applies in
particular to the safety regulations. Simple repairs and emergency action on components are described which
necessitate a larger scope of work and correspondingly skilled personnel.
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1015
3 User instructions
3.4
Work cards
The work cards are differentiated into those associated with the workshop manual e.g. W 04-05-01 and those with the maintenance instructions I 04-05-01.
Numbering of work cards
Type of documentation
The first letter designates the type of documentation.
W = Workshop manual
I
= Maintenance instructions
Maintenance group (same for all engines)

00
01
02
03
04
05
06
General / overall activities

Cylinder head
Drive system
Crankcase
Engine control
Speed control
Exhaust system / Charging
07
08
09
10
11
12
13
Fuel system
Lube oil system
Cooling system
Compressed air system
Control system
Other components
Electrical system
Sub-system (component)
The sub-systems are differentiated by maintenance group.
Generally applicable:
00 Meta sub-system level or safety regulation (SV)
01 System parameters or general inspections
Sequential number
Counting per sub-system (component)
Various work per sub-system (component)
Differences in version
W 03-03-03
36613 1
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1015
3 User instructions
Layout of work cards
3
Crankcase
Work card
W 03-03-03
914
13
5
12
11
10
6
7
36612 1
1.
2.
3.
4.
5.
6.
7.
DEUTZ, issue of the servicing documentation

Engine type (e.g. 914)
Maintenance group
Work card number
Reference to other work cards, regulations
etc.
Explanatory graphics
Page number
8.
9.
10.
11.
12.
13.
DEUTZ internal part number of the work card

and technical categorization number
Date the work card was issued
Sequence of work
Safety references and general notes
Tools, auxiliary aids and spare parts required
Title of the work card
Note
Should you have further questions on a work card, please always quote the engine type (2), the number of the work card (4), the page number (7), the date of issue (9) or alternatively the DEUTZ internal
part number (8).
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1015
3 User instructions
3.5
Key to symbols
Caution !, important note
!
Auxiliary aids
e.g. lifting gear, adhesive
Tools
e.g. dial gauge 100 400
Note
e.g. cylinder head has been dismantled
Always renew when reassembling

e.g. gasket
References
e.g. work card no. W x-y-z
01 61
See technical data (Test and adjustment data)

line reference, e.g. "01 61 - Valve play (inlet)"
01001
See technical data (Tightening regulations)

line reference, e.g. "01001 - Cylinder head screws"
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3 User instructions
Notes
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1015
4 Technical data
4.1 Test and adjustment data
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Technical data
4.1
Test and adjustment data
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4 Technical data
1015
Notes
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1015
4 Technical data
00 00
General engine data
ID no.
Designation
Additional
information
Value
Unit
00 01
Length of engine with adapter housing
Length overall
968
[mm]
00 02
Width of engine with adapter housing
Width overall
915
[mm]
00 03
Height of engine with adapter housing
Height overall
970
[mm]
00 04
Weight of engine according to DIN 70020-A
approx. 850
[kg]
00 10
Method of working
00 20
Combustion process
00 30
Total volume
00 31
four-stroke - Diesel
direct injection
11906
[cm3]
Bore
132
[mm]
00 32
Stroke
145
[mm]
00 40
Compression ratio
00 51
Compressive pressure
32 bis 34
[bar]
00 51
Compressive pressure
3200 bis 3400
[kPa]
00 50
Direction of turn
00 60
Nominal speed
00 61
Idling speed
00 70
Ignition spacing
00 71
Ignition sequence
11/2003
16.5 : 1
Looking at flywheel
Crank angle
left
max. 2100
[min-1]
min. 550
[min-1]
120
[]
A1 - B3 - A3 - B2 - A2 - B1
1-6-3-5-2-4
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4 Technical data
1015
01 00
Cylinder head
ID no.
Additional
information
Designation
Value
Unit
01 00
Cylinder head
01 01
Bore diameter for valve seat ring (inlet)
Standard
47.500
+ 0.016
0
[mm]
01 02
Bore diameter for valve seat ring (outlet)
Standard
44.000
+ 0.016
0
[mm]
01 03
Bore diameter for valve seat ring (inlet)
1st over-dimension
stage
47.800
+ 0.016
0
[mm]
01 04
Bore diameter for valve seat ring (outlet)
1st over-dimension
stage
44.300
+ 0.016
0
[mm]
01 05
Bore diameter for valve guide
Standard
15.000
+ 0.011
0
[mm]
01 06
1st over-dimension
stage
15.100
+ 0.011
0
[mm]
01 07
2nd over-dimension
stage
15.200
+ 0.011
0
[mm]
01 08
Height of cylinder head
Standard
120.000 - 0.300
[mm]
01 09
Height of cylinder head
1st over-dimension
stage
min.
119.400
[mm]
01 10
Valve guide
01 11
Outer diameter of valve guide
Standard
15.000
[mm]
01 12
Outer diameter of valve guide
1st over-dimension
stage
15.100
[mm]
01 13
Auendurchmesser der Ventilfhrung
2nd over-dimension
stage
15.200
[mm]
01 20
Valve seat ring
01 21
Outer diameter of valve seat ring (inlet)
Standard
47.500 + 0.060
01 22
Outer diameter of valve seat ring (outlet)
Standard
44.000 + 0.060
01 23
Outer diameter of valve seat ring (inlet)
1st over-dimension
stage
47.800 + 0.060
01 24
Outer diameter of valve seat ring

(outlet)
1st over-dimension
stage
44.300 + 0.060
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+ 0.075
+ 0.075
+ 0.075
+ 0.075
[mm]
[mm]
[mm]
[mm]
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1015
4 Technical data
ID no.
Additional
information
Designation
Value
Unit
01 30
Valve
01 31
Valve stem diameter (inlet)
Standard
7.970 - 0.007
+ 0.007
[mm]
01 32
Valve stem diameter (outlet)
Standard
7.970 - 0.007
+ 0.007
[mm]
01 33
Valve clearance (inlet)
0.120
[mm]
01 34
Valve clearance (outlet)
Limit of wear
0.140
[mm]
01 35
Valve edge thickness on valve disc (inlet)
Limit of wear
(valve with valve
seat re-inforcement)
2.300
[mm]
01 36
Valve edge thickness on valve disc (outlet)
Limit of wear
1.900
[mm]
01 37
Valve disc diameter (inlet)
46.000 0.200
[mm]
01 38
Valve disc diameter (outlet)
42.000 0.200
[mm]
01 40
Valve seat
01 41
Valve seat width on valve disc (inlet)
Limit of wear
2.8
[mm]
01 42
Valve seat width on valve disc (outlet)
Limit of wear
3.0
[mm]
Valve set-back dimension (inlet)
From middle of the

valve plate to cylinder head sealing
surface
1.200
+ 0.350
0
[mm]
01 46
Valve set-back dimension (outlet)
From middle of the

valve plate to cylinder head sealing
surface
1.250
+ 0.350
0
[mm]
01 47
Valve seat angle (inlet)
30
[]
01 48
Valve seat angle (outlet)
45
[]
01 50
Valve spring
01 51
Valve spring length (not tightened, normal)
01 45
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58.700
[mm]
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4 Technical data
1015
ID no.
01 60
Additional
information
Designation
Value
Unit
Valve play
Valve play (inlet) with cold engine
After a minimum
cool-down time of
0.5 h (oil temperature < 80 C)
0.250
[mm]
01 62
Valve play (outlet) with cold engine
After a minimum
cool-down time of
0.5 h (oil temperature < 80 C)
0.300
[mm]
01 63
Valve play adjustment schematic
01 61
Race engine until the valve crossover point cyl. no. A1 is reached.
Cyl. no. A1 - white marking
= valve overlap
Cyl. no. B2 - black marking
= adjustment
Note
It is possible to set the valve clearance as per the sequence stated below (see table) with 2
turns of the crankshaft 360.
BF6M 1015 CP - Ignition
sequence :
A1 - B3 - A3 - B2 - A2 - B1
A1 A2 A3
1.
B1 B2 B3
A1 A2 A3
2.
B1 B2 B3
37298 0
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1015
4 Technical data
ID no.
Additional
information
Designation
Value
Unit
01 70
Rocker arm / Rocker arm bracket
01 71
Diameter of bore in rocker arm bracket
28.000
+ 0.061
0
[mm]
01 72
Diameter of bore in rocker arm for rocker

arm axle - Outlet
28,000
+ 0,021
0
[mm]
01 73
Diameter of bore in rocker arm for rocker

arm axle - Inlet
28,000
+ 0,021
0
[mm]
01 74
Diameter of rocker arm axle
- 0.040
[mm]
01 75
Axial play of rocker arm
02 00
Limit of wear
0.2 - 0.4
[mm]
Value
Unit
Drive system
ID no.
Additional
information
Designation
02 00
Crankshaft
02 02
Main bearing journal
02 03
Diameter of main bearing journal
02 04
Under-dimension staging for main

bearing journal
02 05
Limit value for under-dimension staging of

main bearing journal
02 06
Non-roundness of main bearing journal
Limit of wear
02 07
Hardness of main bearing journal
Standard
02 10
Thrust bearing journal
02 11
Width of thrust bearing journal
02 12
Under-dimension staging for thrust

bearing journal
11/2003
28.000 - 0.061
Standard
102.966
+ 0.022
0
0.250
101.966
38.000
0.250
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[mm]
+ 0.022
0
0.010
50
[mm]
[mm]
[mm]
+6
0
[HRc]
+ 0.062
0
[mm]
[mm]
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4 Technical data
1015
ID no.
Additional
information
Designation
Value
Unit
02 13

thrust bearing journal
02 20
Crank pin
02 21
Width of lift bearing journal
34.000
02 22
Diameter of crank pin
88.000 - 0.034
02 23
Under-dimension staging for crank pin
02 24
Limit dimension for under-dimension staging

of crank pin
02 25
Non-roundness of crank pin
Limit of wear
0.010
[mm]
02 26
Concentric running of crankshaft
Maximum deviation
0.150
[mm]
02 27
Hollow throat radius
3.000 0.200
[mm]
02 30
38.500
+ 0.062
0
[mm]
+ 0.200
0
[mm]
- 0.012
[mm]
6x
3 stages
0.250
87.216
[mm]
- 0.022
0
[mm]
Standard
02 31
Inner diameter of main bearing shells
02 32
Under-dimension staging for main bearing

shells
02 33
Theoretical bearing play between main bearing and crankshaft
02 34
Axial play of crankshaft
Standard
02 35
Thickness of thrust rings
Standard
(top and bottom halves)
3.360
+ 0.050
0
[mm]
02 36
1st over-dimension
stage
= 0.125 mm
3.485
+ 0.045
0
[mm]
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designation "n" / under sputter
4 stages
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103.000
[mm]
0.250
[mm]
0.072 - 0.136
[mm]
0.205 - 0.392
[mm]
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1015
4 Technical data
ID no.
Additional
information
Designation
Value
Unit
2nd over-dimension
stage
= 0.250 mm
3.610
Parallelism of connecting rod to piston pin
At a distance of
100 mm
0.060
[mm]
02 42
Parallelism of connecting rod to piston pin
Admissible deviation at a distance of

100 mm
0.100
[mm]
02 43
Inner diameter of small end bush
52.040
+ 0.015
0
[mm]
02 44
Outer diameter of small end bush
55.080
+ 0.040
0
[mm]
02 45
Theoretical play between small end bush

and piston pin
0.040
+ 0.023
0
[mm]
02 46
Installation temperature of small end bush
- 40
[ C ]
02 47
Installation temperature of connecting rod
220
[ C ]
02 50
Big end bearing
02 51
Width of big end bearing shells
Top and bottom halves
25.000 - 0.300
[mm]
02 52
Inner diameter of big end bearing shells
Designation "n" / top

slide layer sputtered
88.048
+ 0.054
0
[mm]
02 53

big end bearing shells
02 54
Under-dimension staging of big end bearing 3 stages
02 55
Big end bearing bore in connecting rod
91.998 - 0.002
[mm]
02 56
Theoretical play between big end bearing

and crank pin
0.060 - 0.136
[mm]
02 37
02 40
Connecting rod
02 41
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+ 0.050
0
[mm]
87.352
[mm]
0.250
[mm]
+ 0.030
Page 9 of 18
4 Technical data
1015
ID no.
Designation
Additional
information
Unit
02 57
Big end bearing play
02 60
Piston pin
02 61
Diameter of piston pin
02 62
Piston pin play
Limit of wear
02 70
Piston
Designation of
installation position
of the piston / installation position of
cooling oil nozzle
pocket to connecting
rod stem
02 71
Diameter of piston
Measuring point 1 at
height 22.5 mm
131.730
+ 0.138
0
[mm]
02 72
Diameter of piston
height 87.5 mm
131.721
+ 0.018
0
[mm]
02 73
Diameter of piston
height 122.7 mm
131.260
+ 0.470
0
[mm]
02 74
Number of over-dimension stages
none
02 75
Piston projection for

cylinder head seal 1.4 = 1 hole
0.050
+ 0.050
0
[mm]
02 76

0.100
+ 0.200
0
[mm]
02 77

0.300
+ 0.210
0
[mm]
02 78
Piston pin bore
02 79
Piston height
Page 10 of 18
Limit of wear
Value
0.170
[mm]
52.000 - 0.008
0.090
[mm]
+ 0.010
52.000 + 0.003
133.800
0312 1066 - 0165
[mm]
[mm]
[mm]
11/2003
1015
4 Technical data
ID no.
Additional
information
Designation
Value
Unit
132 / 121.2 x 3.50
[mm]
02 80
Piston rings
02 81
1st piston ring (double-sided trapezoidal

ring)
02 82
2nd piston ring (minute ring)
Outer diameter/inner
132 / 121.4 x 2.45
diameter x height
[mm]
02 83
3rd piston ring (bevelled edge slotted oil ring Outer diameter/inner
132 / 122.7 x 4.00
with hose spring)
diameter x height
[mm]
02 84
Piston ring gap clearance of 1st piston ring
Limit of wear
("TOP" marking
towards piston
crown)
0.35 - 0.45
[mm]
02 85
Limit of wear
("TOP" marking
Piston ring gap clearance of 2nd piston ring
towards piston
crown)
1.1 - 1.3
[mm]
02 86
Piston ring gap clearance of 3rd piston ring
Limit of wear
("TOP" marking
towards piston
crown)
0.4 - 0.7
[mm]
02 87
Axial play of 1st piston ring
Limit of wear
trapezoidal groove
wear gauge - incontakt with piston
---
02 88
Axial play of 2nd piston ring
Limit of wear
0.250
[mm]
02 89
Axialspiel des 3. Kolbenrings
Limit of wear
0.150
[mm]
02 95
Position of piston ring gaps
Twisting angles to
each other
02 96
Bevelled edge slotted oil ring
Twisting angle of
spring gap to piston
ring gap
11/2003
0312 1066 - 0165
90 - 120
[]
180
[]
Page 11 of 18
4 Technical data
1015
03 00
Crankcase
ID no.
Additional
information
Designation
Value
Unit
03 10
Camshaft bearing
03 11
Bore diameter for camshaft bearing bush in

crankcase
03 12
Outer diameter of camshaft bearing bus
03 13
Inner diameter of camshaft bearing bush
03 14
Camshaft bearing bush
03 20
Bore for crankshaft main bearing
03 21
Diameter of main bearing bore
Standard
108.000
+ 0.022
0
[mm]
03 22
Diameter of main bearing bore
Over-dimension
stage
108.500
+ 0.022
0
[mm]
03 23
Diameter of tappet bores
25.000
+ 0.033
0
[mm]
03 24
Diameter of tappet bores
Over-dimension
stage
03 25
Installation depth of shaft sealing ring
Commissioning
3.000 0.500
[mm]
03 26
Installation depth of shaft sealing ring
Repair stage
7.000 0.500
[mm]
03 30
Cylinder liners
03 31
Bore diameter of cylinder liner
Standard
132.010
+ 0.025
0
[mm]
03 32
Bore diameter of cylinder liner
Limit of wear
132.100
03 35
Fitting depth of collar support and sealing

surface for cylinder liner
8.900 0.020
03 36
Collar height of cylinder liner
9.200 - 0.020
[mm]
03 37
Thickness of compensation ring for cylinder 1st over-dimension

liner
stage
1.000
[mm]
03 38
Thickness of compensation ring for cylinder 2nd over-dimension

liner
stage
1.500
[mm]
Page 12 of 18
Standard
Limit of wear
75.000
+ 0.030
0
[mm]
75.090
+ 0.030
0
[mm]
69.990
+ 0.054
0
[mm]
70.100
[mm]
25.050
[mm]
[mm]
0312 1066 - 0165
[mm]
11/2003
1015
4 Technical data
04 00
Engine control
ID no.
Additional
information
Designation
Value
Unit
04 10
Control times with valve play set
04 11
Inlet opens before TDC
27.5
[]
04 12
Inlet closes after BDC
38.5
[]
04 13
Outlet opens before BDC
57
[]
04 14
Outlet closes after TDC
25
[]
04 20
Camshaft
04 21
Cam stroke (inlet)
8.400
[mm]
04 22
Cam stroke (outlet)
8.000
[mm]
04 31
Diameter of camshaft bearing journal
04 32
Theoretical radial play of camshaft bearing
04 35
Axial play of camshaft
04 37
Thickness of seal for adjusting axial play
0.300
[mm]
04 39
Projection of cylinder pin on camshaft gear

wheel
5.000
[mm]
05 00
Standard
+ 0.030
0
[mm]
0.050 - 0.134
[mm]
0.25 - 0.75
[mm]
69.910
Speed control
ID no.
Designation
Additional
information
Value
Unit
05 01
Adjustment range
n. a.
[]
05 02
Adjustment start
n. a.
[min-1]
05 03
Adjustment end
n. a.
[min-1]
11/2003
0312 1066 - 0165
Page 13 of 18
4 Technical data
1015
06 00
Exhaust system / supercharging
ID no.
Designation
Additional information
Value
Unit
06 20
Turbocharger
06 21
S400 with
Radial play on compressor wheel compressor wheel 96 mm
and turbine wheel 87 mm
max. 0.960
[mm]
06 22
Radial play on turbine wheel
S400 with
compressor wheel 96 mm
max. 0.780
[mm]
06 27
Axial play of rotor
S400 with
compressor wheel 96 mm
07 00
0.064 - 0.140
[mm]
Fuel system
ID no.
Additional
information
Designation
Value
Unit
07 01
Conveyor pump
07 02
Manufacturer - type
FP / KG24P302
07 10
Injection pump
Bosch
07 11
Manufacturer - type
PE6 P120A320LS
07 20
Twist flank play between injection pump gear

wheel and camshaft gear wheel
07 30
Axle spacing to commencement of delivery

adjustment
07 31
Commencement of delivery
With measuring
device 9116
see rating plate
[]
07 32
Commencement of delivery
With gauge pin

110180
see rating plate
[]
07 40
Controller with LDA
Bosch
07 41
Manufacturer - type
RQV300
1050PAV-K
Page 14 of 18
0.040
+ 0.250
0
269.200
0312 1066 - 0165
[mm]
[mm]
11/2003
1015
4 Technical data
ID no.
Additional
information
Designation
07 50
Injection valve
07 51
Nozzle type
07 52
Nozzle opening pressure of injection valve
07 53
Pressure for checking tightness of injection

valve
08 00
Value
Unit
DLLA 158 P
(non-leakage)
200
Below the opening
pressure previously
read off
+ 10
0
[bar]
20
[bar]
Lube oil system
ID no.
Additional
information
Designation
Value
Unit
08 10
Lube oil pump
08 11
Conveying volume of lube oil pressure pump
Conveying wheel
width 40
170
[l/min]
08 12
Conveying volume of lube oil pressure pump
Conveying wheel
width 48
210
[l/min]
08 13
Valve opening pressure
08 14
Valve completely opened
08 21
Conveying volume of lube oil suction pump
Conveying wheel
width 40
196
[l/min]
08 22
Conveying wheel
width 48
242
[l/min]
08 31

(flywheel side)
At a pump speed of
3730 [min-1]
247
[l/min]
08 32

(flywheel side)
At an engine speed
on 2000 [min-1]
230.5
[l/min]
08 35
Tooth flank play of lube oil suction pump

(flywheel side) - drive cog wheel to
crankshaft cog wheel
11/2003
Engine in operating
position
thickness of
compensation plates
0.1 mm/0.2 mm/0.3 mm
0312 1066 - 0165
9 1
[bar]
13 1
[bar]
0.084
+ 0.167
0
[mm]
Page 15 of 18
4 Technical data
1015
ID no.
Additional
information
Designation
Engine standing on
head
Value
Unit
08 35
Tooth flank play of lube oil suction pump

(flywheel side) - drive cog wheel to
crankshaft cog wheel
08 50
Lube oil pressure
08 51
Lube oil pressure during low idling
Temperature
approx. 120 C with
"SAE 15W/40" oil
min. 1.0
[bar]
08 61
Setting the oil pressure on pressure control

valve
As per acceptance
regulation
min. 3.0
max. 4.5
[bar]
08 62
Length of pressure control valve spring
77.000
[mm]
For 3.00 bar
42.000
[mm]
For 3.50 bar
39.050
[mm]
For 4.00 bar
36.100
[mm]
For 4.50 bar
33.150
[mm]
30
[bar]
[bar]
[bar]
08 63
Base setting of pressure control valve when

using new parts
thickness of
compensation plates
0.1 mm/0.2 mm/0.3 mm
0.200
08 71
Pressure for testing high-pressure of lube oil Test medium "SAE

cooler (at oil temperature of 90 C)
10W30" engine oil
08 72
Pressure for testing tightness of lube oil cooler (at oil temperature of 90 C)
08 75
Opening pressure of gradual shut-off valve
4.5
08 81
Opening pressure of over-pressure valve of

piston cooling nozzle
0.8
09 00
+ 0.168
0
+ 0.3
0
[mm]
[bar]
Cooling system
Additional
information
ID no.
Designation
09 11
Opening start of coolant thermostat (A-bank)
09 12
Opening start of coolant thermostat (B-bank)
09 13
Stroke path of coolant thermostat
Page 16 of 18
"Black" colour marking
At approx. 102 C
0312 1066 - 0165
Value
Unit
approx. 79
approx. 87
min. 8.0
[mm]
11/2003
1015
4 Technical data
12 00
ID no.
Other components
Designation
Additional information
Value
Unit
12 11
Tensioning of
single V-belt AVX 10
Check at commissioning
with tension measuring
gauge 5115 or 8120
550 50
[N]
12 12
Tensioning of
gauge 5115 or 8120
650 50
[N]
12 13
Tensioning of
joined V-belt KB 2AVX 10
gauge 5115 or 8120
1200 50
[N]
12 21
Tensioning of
Check after 15 minutes running under load
300 50
[N]
12 22
Tensioning of
400 50
[N]
12 23
Tensioning of
joined V-belt KB 2AVX 10
600 50
[N]
11/2003
0312 1066 - 0165
Page 17 of 18
4 Technical data
1015
Notes
Page 18 of 18
0312 1066 - 0165
11/2003
1015
11/2003
Technical data
4.2
Tightening regulations
0312 1067 - 0165
4 Technical data
4.2 Tightening regulations
Page 1 of 12
4 Technical data
1015
Notes
Page 2 of 12
0312 1067 - 0165
11/2003
1015
00000
ID no.
General
Designation
Pre-tension
value
Post-tension
value
Notes / remarks
Pre-tension
value
Post-tension
value
Notes / remarks
40 - 50 Nm
+ 120
+ 120
+ 60
Use max. 5x given proof of this
Pre-tension
value
Post-tension
value
Notes / remarks
50 Nm
+ 30
+ 60
+ 60
00001 Clamping retainer on crankcase
70 Nm
Clamping retainer on adapter for

assembly trestle
90 Nm
00002
01000
ID no.
Cylinder head
Designation
01001 Cylinder head screws
01002
Rocker arm bracket on cylinder

head
61 Nm
01003
Counter nut for valve adjustment

screw
20 Nm
01004
Cylinder head hood on cylinder

head
22 Nm
01005
Cylinder head cover on cylinder

head hood
22 Nm
02000
ID no.
4 Technical data
Drive system
Designation
02001 Counterweight on crankshaft
02010
Main bearing cover, vertical

screws (screws with washer)
50 - 60 Nm
+ 60
+ 60
+ 120
- Oil lubricated
- Use max. 3x given proof of
this
02011
Main bearing cover, horizontal

screws
80 - 90 Nm
+ 30
+ 30
- Oil lubricated
- Use max. 3x given proof of
this
50 - 60 Nm
+ 60
+ 60
Replace screws each time after

dismounting
02020 Big end bearing cap
11/2003
0312 1067 - 0165
Page 3 of 12
4 Technical data
03000
1015
Crankcase
ID no.
Designation
Pre-tension
value
03001
Threaded bush on crankcase

AM10 - M14 x 1.5
25 - 31 Nm
03002
Threaded bush on crankcase

M12 x 1.5 - M16 x 1.5
27 - 33 Nm
03003
Screw plug on crankcase

M14 x 1.5
25 - 31 Nm
03004

M16 x 1.5
34 - 42 Nm
03005
Sealing plug on crankcase

M22 x 1.5
37 - 43 Nm
03006

M24 x 1.5
101 - 121 Nm
03010 Rear cover on crankcase
21 Nm
03020 Accessory carrier, screws M10
55 Nm
03021
Screw plug on accessory carrier

M10
16 Nm
03022

M14
24 Nm
03023

M18
30 Nm
03030 Oil pan on crankcase
24 Nm
03031 Oil drainage screw on oil pan
120 Nm
03033 Cap nut ball sealing
150 Nm
03034
Pipe clips halves on flange of oil

pan
03035 Flange on oil pan

03050
Screw plug of pressure control

valve
03051
Pressure control valve on crankcase
Page 4 of 12
Post-tension
value
Notes / remarks
- Renew CU sealing ring
- Renew CU sealing ring
- Seal both top screws with

DW72
- Cut off seal to adapt it
- Slot in centring sleeve faces
downwards
22 Nm
30 Nm
175 - 215 Nm
50 - 60 Nm
0312 1067 - 0165
Hexagon socket
250 Nm
Oil lubricated
11/2003
1015
ID no.
Designation
03060 Crankcase breather
Pre-tension
value
4 Technical data
Post-tension
value
Notes / remarks
5 Nm
03081
Adapter housing on crankcase

M12 x 1.5 x 35
30 Nm
+ 30
+ 30
DW59
03082
Adapter housing on crankcase

M12 x 1.5 x 90
30 Nm
+ 60
+ 60
DW59
03083 Adapter housing, screw M6 x 12
2 - 4 Nm
03084
Screw plug on adapter housing

M52 x 1.5
03085
Sealing cover on adapter housing

M8 x 16
21 Nm
03086
Pin screws for starter on adapter

housing
57 Nm
Sealing cover for air compressor

03087 on adapter housing / accessory
carrier
04000
ID no.
675 - 825 Nm
43.5 Nm
DW59
Engine control
Designation
Pre-tension
value
Post-tension
value
40 - 50 Nm
+ 50
04001
Central screw for camshaft gear

wheel on camshaft
04002
Catch cover for camshaft on

crankcase
22 Nm
04003
Camshaft gear wheel on

intermediate gear
29 Nm
04010
Screw M12 x 80 / M12 x 100 for

intermediate gear bolts
70 Nm
04011
Fixing screw for intermediate gear

on accessory carrier
80 Nm
04012
Screw plug for intermediate gear

bolts
79 Nm
04013
Screw M12 x 100 / M12 x 130 for

intermediate gear bolts
35 Nm
11/2003
Install new seal with DW74
0312 1067 - 0165
Notes / remarks
DW59
For engines with intermediate

gears
For engines without

intermediate gears
Page 5 of 12
4 Technical data
ID no.
04020
Designation
Sealing cover on wheel drive
cover and crankcase
04021 Screw plug on wheel drive cover

04022
05000
Screw for wheel drive cover on

crankcase M8 x 35 / M8 x 45
1015
Pre-tension
value
21 Nm
Notes / remarks
Seal with DW67
250 Nm
21 Nm
Speed control
ID no.
Designation
Pre-tension
value
05001 Retainer on injection pump M8
21 Nm
05002 Retainer on injection pump M6
8.5 Nm
05003 Counter nut for idling stop
8.5 Nm
05011 Speed sensor on adapter housing
2 - 4 Nm
06000
Post-tension
value
Post-tension
value
Notes / remarks
Post-tension
value
Notes / remarks
ID no.
Designation
Pre-tension
value
06001 Exhaust manifold on cylinder head
60 Nm
With DEUTZ S1
06002 Exhaust pipe on exhaust manifold
18 Nm
With DEUTZ S1
With DEUTZ S1
06003
Exhaust pipe on exhaust pipe

elbow
22 Nm
06010
Exhaust pipe elbow on adapter

housing
46 Nm
06020
Turbocharger on exhaust pipe

elbow
10 Nm
06030 Air suction pipe on cylinder head

06031
Screw plug (LDA) on air suction

pipe M14 x 1.5
06032
Screw plug (flame plug) on air

suction pipe M32 x 1.5
Page 6 of 12
35 Nm
With DEUTZ S1
22 Nm
31 - 37 Nm
108 - 132 Nm
0312 1067 - 0165
11/2003
1015
4 Technical data
Post-tension
value
Notes / remarks
Pre-tension
value
Post-tension
value
Notes / remarks
Injection valve cap screw on

cylinder head
70 - 80 Nm
With DEUTZ
Non-leakage oil
S1
07002 Injection nozzles - clamp nut
40 - 50 Nm
ID no.
Designation
Pre-tension
value
06033 Connecting line on air suction pipe
29 Nm
06034 Cover on connecting line
57 Nm
06035
Fixing screw for retainer of charging air line
21 Nm
06037
Retainer for suction pipe on

retainer for turbocharger
8.5 Nm
07000
ID no.
07001
07003
Fuel system
Designation
Cap nut on injection line on

injection valve / injection pump
25 Nm
07004 Screws for retainer of injection line
22 Nm
07005 Bracket on air suction pipe M6
8.5 Nm
07006 Pipe clips for injection lines M6
8.5 Nm
07010
Drive flange - nut on injection

pump
200 - 230 Nm
07011
Gear wheel on drive flange injection pump
31 Nm
07012 Injection pump on crankcase
1st stage:
10 Nm
07015
Fuel line on injection pump - banjo

bol
39 Nm
07016
Fuel lines on injection pump - cap

nuts
45 Nm
07017 Overflow valve

07018 Fuel line on solenoid valve
11/2003
2nd stage:
50 Nm
3rd stage
90-100
Replace screws each time after

dismounting
30 - 40 Nm
14 Nm
0312 1067 - 0165
Page 7 of 12
4 Technical data
ID no.
Designation
1015
Pre-tension
value
07019
Fuel lines on fuel conveyor

pump - banjo bolts
30 - 40 Nm
07020
Fuel lines on fuel conveyor

pump - cap nuts
45 Nm
07030
Pipe nozzle on fuel pre-filter

(Separ)
45 - 55 Nm
07091
Solenoid valve for engine cut-off

on retainer
8.5 Nm
07092 Solenoid valve (LDA) on retainer
8.5 Nm
Retainer for solenoid valve (LDA)

on thermostat housing
21 Nm
07093
08000
Notes / remarks
Post-tension
value
Notes / remarks
Lube oil system
ID no.
Designation
08001 Oil filter
08002
Oil filter nozzle on aggregate

carrier
08010
Oil pressure pump on accessory

carrier
Pre-tension
value
25 - 27 Nm
40.5 Nm
21 Nm
08012 Lube oil line on oil pump
12 Nm
Oil suction nozzle / oil suction pipe

on oil suction pump
Retainer for oil suction pipe on

08016 retainer plate on main bearing
cover M8 x 22 / M8 x 25
Renew CU sealing rings
22 Nm
22 Nm
08017
Connecting elbow for oil suction

pipe (screw M8 x 130)
30 Nm
08018
Connecting elbow for oil suction

pipe (screw M8 x 22)
22 Nm
08020
Oil suction pump on accessory

carrier
40.5 Nm
Page 8 of 12
- Lightly oil seal

- Powerful manual tightening
150 - 170 Nm
08011 Socket piece on oil pump
08015
Post-tension
value
0312 1067 - 0165
11/2003
1015
ID no.
Designation
08030 Oil suction pump flywheel side
Pre-tension
value
Post-tension
value
50 - 60 Nm
+ 60
+ 60
+ 120
08040 Oil pressure line on turbocharger
20 Nm
08041 Oil supply flange on turbocharger
20 Nm
Oil pressure line cap nut on oil

08042 supply flange on turbocharger
(pipe- = 8 mm)
45 Nm
08043
Screw-in nozzle for oil pressure

line on crankcase
36 - 42 Nm
08044
Oil return pipe on turbocharger /

connecting cover
20 Nm
08045 Pipe clip screws for lube oil pipes

08050
Oil cooler housing cover on

accessory carrier
08051 Oil cooler on accessory carrier

08071
Screw plug of pressure control

valve
08081
Over-pressure valve of piston

cooling nozzle on crankcase
08091 Oil pressure transmitter / switch
11/2003
4 Technical data
Notes / remarks
- Oil lubricated
- Observe tooth flank play
between craft shaft and
intermediate gear
8,5 Nm
20 Nm
20 Nm
03050
25 - 31 Nm
20 Nm
0312 1067 - 0165
Page 9 of 12
4 Technical data
09000
1015
Cooling system
ID no.
Designation
Pre-tension
value
Post-tension
value
Notes / remarks
Pre-tension Post-tension
value
value
Notes / remarks
09001 Thermostat housing on crankcase
21 Nm
Upper part of thermostat housing

09002 with coolant nozzle on thermostat
housing
21 Nm
09003
Screw plugs on thermostat

housing M12 x 1.5
18 Nm
09004
Screw plugs on thermostat

housing M14 x 1.5
20 Nm
09006
Banjo bolts on coolant outlet

nozzle / oil cooler
39 Nm
09010
Coolant pump housing on

accessory carrier
21 Nm
Coolant inlet nozzle / coolant

09011 supply pipe on coolant pump
housing
20 Nm
09012
Sealing plug on coolant inlet

nozzle M30
180 Nm
09031
Transmitter for coolant temperature display on thermostat housing
20 Nm
12000
Other components
ID no.
Designation
Flywheel on crankshaft with screw

12001 M16 x 70 (without thrust washer)
Screws AM 16 x 1.5 x 65 - 10.9 for

flange hub on crankshaft (flange
12030
hub with vibration damper and
V-belt pulley)
40 - 50 Nm
+ 30
+ 60
+ 60
- Oil lubricated
- Replace screws each time
after dismounting
25 - 35 Nm
+ 120
Oiled
12031 V-belt pulley on flange hub
30 Nm
12071 Heat screen on wheel drive cover
20 Nm
12080 Pipes, cap nuts ( = 6 mm)
35 Nm
Page 10 of 12
0312 1067 - 0165
11/2003
1015
ID no.
Designation
Pre-tension Post-tension
value
value
45 Nm
60 Nm
75 Nm
Screwed pipe connection with ring

12090 piece, banjo bolts M10 x 1
(pipe- = 6 mm)
18 Nm

12091 piece, banjo bolts M12 x 1.5
(pipe- = 8 mm)
29 Nm

(pipe- = 10 mm)
39 Nm

(pipe- = 12 mm)
49 Nm
12095 Pipe clip screw M6
8.5 Nm
13000
Electrical system
ID no.
Designation
13001 Nuts for starter
13010
Console for generator on cylinder

block
Pre-tension
value
Post-tension
value
30 Nm
+ 60
+ 60
70 Nm
13012 Screw M8 x 80 (generator)
21 Nm
13013 Screw M12 x 40 (generator)
70 Nm
11/2003
Cable tree retainer on oil cooler

hood M6
Notes / remarks
Notes / remarks
40 Nm
13011 Nuts for generator on eyelet bolt
13091
4 Technical data
8.5 Nm
0312 1067 - 0165
Page 11 of 12
4 Technical data
1015
Notes
Page 12 of 12
0312 1067 - 0165
11/2003
1015
11/2003
Work card index
5.1
Alphabetical order
0312 1068 - 0165
5 Work card index

5.1 Alphabetical order
Page 1 of 6
5 Work card index

1015
Notes
Page 2 of 6
0312 1068 - 0165
11/2003
1015
5 Work card index

Sub-assembly term / activity
Work card
Maintenance group
Accessory carrier - disassemble and assemble
W 03-08-03
Crankcase
Accessory carrier - remove and refit
W 03-08-01
Crankcase
Adapter housing - remove and refit
W 03-09-04
Crankcase
Air suction pipe - remove and remount
W 06-07-03
Exhaust system /
supercharging
Camshaft - check
W 04-05-06
Engine control
Camshaft - remove and remount
W 04-05-05
Engine control
Camshaft bearings - remove, check and remount
W 03-11-01
Crankcase
Commencement of delivery - check and adjust, with gauge pin
W 07-06-04
Fuel system
Compressive pressure - check
W 00-02-06
General
Connecting line - remove and remount
W 06-02-05
Exhaust system /
supercharging
Connecting rod - check
W 02-03-01
Drive system
Coolant pump - remove and remount
W 09-07-08
Cooling system
Coolant temperature transmitter - remove and remount
W 09-12-01
Cooling system
Coolant thermostat - check, when disassembled
W 09-08-01
Cooling system
Coolant thermostat housing - remove and remount
W 09-08-04
Cooling system
Coolant thermostats - remove and remount
W 09-08-02
Cooling system
Crankcase breather (oil separator) - remove and refit
W 03-01-11
Crankcase
Crankshaft - check
W 02-01-07
Drive system
Crankshaft - remove and refit
W 02-04-01
Drive system
Crankshaft seal (flywheel side) - renew
W 02-02-02
Drive system
Crankshaft seal (opposite side to flywheel) - renew
W 02-02-04
Drive system
Cylinder head - remove and remount
W 01-04-04
Cylinder head
Cylinder liner - check
W 03-03-01
Crankcase
Cylinder liners - remove and refit
W 03-03-02
Crankcase
11/2003
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5 Work card index

1015
Work card
Maintenance group
Engine - mount on assembly trestle and remove
W 00-05-01
General
Exhaust manifold - remove and remount
W 06-01-05
Exhaust system /
supercharging
Exhaust pipe elbow - remove and remount
W 06-01-07
Exhaust system /
supercharging
Exhaust pipes - remove and remount
W 06-01-06
Exhaust system /
supercharging
Flywheel - remove and remount
W 12-06-01
Other components
Fuel lines - remove and remount
W 07-10-06
Fuel system
Injection lines - renew
W 07-03-01
Fuel system
Injection pump - remove and remount
W 07-04-01
Fuel system
Injection valves - check and adjust
W 07-07-05
Fuel system
Injection valves - remove and remount
W 07-07-01
Fuel system
Oil cooler - remove and remount
W 08-08-02
Lube oil system
Oil filter cartridge - remove and remount
W 08-10-06
Lube oil system
Oil pan - remove and remount
W 08-04-07
Lube oil system
Oil pressure line (turbocharger) - remove and refit
W 08-15-01
Lube oil system
Oil pressure switch - remove and remount
W 08-11-08
Lube oil system
Oil pressure transmitter - remove and remount
W 08-11-09
Lube oil system
Oil return line (turbocharger) - remove and refit
W 08-15-02
Lube oil system
Oil suction nozzle / oil suction pump - remove and remount
W 08-04-06
Lube oil system
Oil suction pump (flywheel side) - remove and remount
W 08-04-08
Lube oil system
Piston - check
W 02-09-07
Drive system
Piston and connecting rod - remove and refit
W 02-09-03
Drive system
Piston cooling nozzle - remove, check and refit
W 02-15-01
Drive system
Piston rings and piston ring grooves - check
W 02-10-03
Drive system
Pressure control valve - remove and remount
W 08-11-10
Lube oil system
Page 4 of 6
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1015
5 Work card index

Work card
Maintenance group
Rear cover (flywheel side) - remove and refit
W 03-09-01
Crankcase
Rocker arm and rocker arm bracket - disassemble, reassemble and check
W 01-02-06
Cylinder head
Rocker arm and rocker arm bracket - remove and refit
W 01-02-02
Cylinder head
Vibration damper - remove and refit
W 12-01-04
Other components
Small end bush - remove and refit
I 02-03-03
Solenoid valve (LDA) - remove and remount
W 07-08-01
Fuel system
Speed sensor - remove and remount
W 05-07-01
Speed control
Starter - remove and remount
W 13-03-02
Electrical system
Starter ring gear on flywheel - renew
W 12-06-03
Other components
Tappets - remove and remount, tappet bores - measure
W 04-02-02
Engine control
Turbocharger - remove and remount
W 06-06-04
Exhaust system /
supercharging
Turbocharger bearing play - measure
W 06-06-05
Exhaust system /
supercharging
Valve guides - check
W 01-06-03
Cylinder head
Valve play - check and adjust
W 01-01-01
Cylinder head
Valve set-back - check
W 01-07-08
Cylinder head
Valves - check
W 01-05-04
Cylinder head
Valves - remove and refit
W 01-05-01
Cylinder head
Wheel case cover - remove and remount
W 04-04-09
Engine control
11/2003
0312 1068 - 0165
Drive system
Page 5 of 6
5 Work card index

1015
Notes
Page 6 of 6
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11/2003
1015
11/2003
Work card index
5.2
Numerical order
0312 1068 - 0165
5 Work card index

5.2 Numerical order
Page 1 of 6
5 Work card index

5.2 Numerical order
1015
Notes
Page 2 of 6
0312 1068 - 0165
11/2003
1015
5 Work card index

5.2 Numerical order
Work card
Maintenance group
W 00-02-06
Check compressive pressure
General
W 00-05-01
Mount engine on assembly trestle and remove
General
W 01-01-01
Check and adjust valve play
Cylinder head
W 01-02-02
Remove and refit rocker arm and rocker arm bracket
Cylinder head
W 01-02-06
Disassemble, reassemble and check rocker arm and rocker

arm bracket
Cylinder head
W 01-04-04
Remove and remount cylinder head
Cylinder head
W 01-05-01
Remove and refit valves
Cylinder head
W 01-05-04
Check valves
Cylinder head
W 01-06-03
Check valve guides
Cylinder head
W 01-07-08
Check valve set-back
Cylinder head
W 02-01-07
Check crankshaft
Drive system
W 02-02-02
Renew crankshaft seal (flywheel side)
Drive system
W 02-02-04
Renew crankshaft seal (opposite side to flywheel)
Drive system
W 02-03-01
Check connecting rod
Drive system
W 02-03-03
Remove and refit small end bush
Drive system
W 02-04-01
Remove and refit crankshaft
Drive system
W 02-09-03
Remove and refit piston and connecting rod
Drive system
W 02-09-07
Check piston
Drive system
W 02-10-03
Check piston rings and piston ring grooves
Drive system
W 02-15-01
Remove, check and refit piston cooling nozzle
Drive system
W 03-01-11
Remove and refit crankcase breather (oil separator)
Crankcase
W 03-03-01
Check cylinder liner
Crankcase
W 03-03-02
Remove and refit cylinder liners
Crankcase
W 03-08-01
Remove and refit accessory carrier
Crankcase
W 03-08-03
Disassemble and assemble accessory carrier
Crankcase
11/2003
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Page 3 of 6
5 Work card index

5.2 Numerical order
1015
Work card
Maintenance group
W 03-09-01
Remove and refit rear cover (flywheel side)
Crankcase
W 03-09-04
Remove and refit adapter housing
Crankcase
W 03-11-01
Remove, check and remount camshaft bearings
Crankcase
W 04-02-02
Remove and remount tappets, measure tappet bores
Crankcase
W 04-04-09
Remove and remount wheel case cover
Engine control
W 04-05-05
Remove and remount camshaft
Engine control
W 04-05-06
Check camshaft
Engine control
W 05-07-01
Remove and remount speed sensor
Speed control
W 06-01-05
Remove and remount exhaust manifold
Exhaust system /
supercharging
W 06-01-06
Remove and remount exhaust pipes
Exhaust system /
supercharging
W 06-01-07
Remove and remount exhaust pipe elbow
Exhaust system /
supercharging
W 06-02-05
Remove and remount connecting line
Exhaust system /
supercharging
W 06-06-04
Remove and remount turbocharger
Exhaust system /
supercharging
W 06-06-05
Measure turbocharger bearing play
Exhaust system /
supercharging
W 06-07-03
Remove and remount air suction pipe
Exhaust system /
supercharging
W 07-03-01
Renew injection lines
Fuel system
W 07-04-01
Remove and remount injection pump
Fuel system
W 07-06-04
Check and adjust commencement of delivery, with gauge

pin
Fuel system
W 07-07-01
Remove and remount injection valves
Fuel system
W 07-07-05
Check and adjust injection valves
Fuel system
W 07-08-01
Remove and remount solenoid valve (LDA)
Fuel system
W 07-10-06
Remove and remount fuel lines
Fuel system
Page 4 of 6
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1015
5 Work card index

5.2 Numerical order
Work card
Maintenance group
W 08-04-06
Remove and remount oil suction nozzle / oil suction pipe
Lube oil system
W 08-04-07
Remove and remount oil pan
Lube oil system
W 08-04-08
Remove and remount oil suction pump (flywheel side)
Lube oil system
W 08-08-02
Remove and remount oil cooler
Lube oil system
W 08-10-06
Remove and remount oil filter cartridge
Lube oil system
W 08-11-08
Remove and remount oil pressure switch
Lube oil system
W 08-11-09
Remove and remount oil pressure transmitter
Lube oil system
W 08-11-10
Remove and remount pressure control valve
Lube oil system
W 08-15-01
Remove and refit oil pressure line (turbocharger)
Lube oil system
W 08-15-02
Remove and remount oil return line (turbocharger)
Lube oil system
W 09-07-08
Remove and remount coolant pump
Cooling system
W 09-08-01
Check coolant thermostat, when disassembled
Cooling system
W 09-08-02
Remove and remount coolant thermostats
Cooling system
W 09-08-04
Remove and remount coolant thermostat housing
Cooling system
W 09-12-01
Remove and remount coolant temperature transmitter
Cooling system
W 12-01-04
Remove and remount vibration damper
Other components
W 12-06-01
Remove and remount flywheel
Other components
W 12-06-03
Renew starter ring gear on flywheel
Other components
W 13-03-02
Remove and remount starter
Electrical system
11/2003
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Page 5 of 6
5 Work card index

5.2 Numerical order
1015
Notes
Page 6 of 6
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11/2003
1015
11/2003
Work card index
5.3
Work card references
0312 1068 - 0165
5 Work card index

5.3 Work card references
Page 1 of 8
5 Work card index

00
1015
General
Work card
no.
Activity
Other work cards required to perform the activity
W 00-02-06
W 01-01-01
W 00-05-01
Mount engine on assembly

trestle and remove
W 13-03-02
01
W 07-07-01
Cylinder head
Work card
no.
Activity
W 01-01-01
W 01-02-02
Remove and refit rocker arm

and rocker arm bracket
W 01-01-01
W 01-02-06
Disassemble, reassemble and

check rocker arm and rocker
arm bracket
W 01-01-02
W 01-04-04
Remove and remount cylinder

head
W 01-02-02
W 01-05-01
W 01-04-04
W 01-05-04
Check valves
W 01-05-01
W 01-06-03
Check valve guides
W 01-05-01
W 01-07-08
W 01-04-04
Page 2 of 8
W 07-03-01
W 06-01-05
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W 06-07-03
W 07-07-01
11/2003
1015
02
5 Work card index

Drive system
Work card
no.
Activity
W 02-01-07
Check crankshaft
W 02-04-01
W 02-02-02
W 12-06-01
W 02-02-04
W 12-01-04
W 02-03-01
W 02-03-03
I 02-03-03
Remove and refit small end

bush
W 02-04-01
W 02-01-07
W 03-08-01
W 03-09-01
W 08-04-07
W 02-10-03
W 03-09-04
W 07-07-01
W 08-04-08
W 02-09-03
Remove and refit piston and

connecting rod
W 01-04-04
W 02-09-07
Check piston
W 02-09-03
W 02-10-03
Check piston rings and piston

ring grooves
W 02-09-03
W 02-15-01
Remove, check and refit piston

W 02-09-03
cooling nozzle
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5 Work card index

03
1015
Crankcase
Work card
no.
Activity
W 03-01-11
Remove and refit crankcase

breather (oil separator)
W 07-03-01
W 03-03-01
W 03-02-02
Remove and refit cylinder liners W 02-09-03
W 03-03-01
W 03-08-01
Remove and refit accessory

carrier
W 02-02-04
W 08-04-06
W 09-07-08
W 03-08-03
Disassemble and assemble

accessory carrier
W 03-08-01
W 03-09-01
Remove and refit rear cover

(flywheel side)
W 02-02-02
W 03-09-04
W 08-04-07
W 03-09-04
Remove and refit adapter houW 06-01-06

sing
W 12-06-01
W 03-11-01
Remove, check and remount

camshaft bearings
04
W 09-08-04
W 12-01-04
W 04-05-05
Engine control
Work card
no.
Activity
W 04-02-02
Remove and remount tappets,

measure tappet bores
W 04-05-05
W 04-04-09
Remove and remount wheel

case cover
W 06-06-04
W 04-05-05
Remove and remount camshaft W 01-02-02
W 04-05-06
Check camshaft
05
W 02-04-01
W 07-04-01
W 04-05-05
Speed control
Work card
no.
W 05-07-01
Page 4 of 8
Activity
Remove and remount speed

sensor
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1015
06
5 Work card index

Work card
no.
Activity
W 06-01-05
Remove and remount exhaust

manifold
W 06-01-06
W 06-01-06

pipes
W 06-01-07

pipe elbow
W 06-02-05
W 06-06-04
W 06-06-05
Measure turbocharger bearing

play
W 06-06-04
W 06-07-03
W 07-03-01
07
W 06-01-06
W 06-06-04
Fuel system
Work card
no.
Activity
W 07-03-01
W 07-10-06
W 07-04-01
Remove and remount injection W 04-04-09

pump
W 07-06-04
Check and adjust commence- W 06-06-04

ment of delivery, with gauge pin
W 07-07-01
Remove and remount injection W 07-03-01

valves
W 07-07-05
Check and adjust injection val- W 07-07-01

ves
W 07-08-01
Remove and remount solenoid

valve (LDA)
W 07-10-06
11/2003
W 07-03-01
0312 1068 - 0165
W 07-08-01
Page 5 of 8
5 Work card index

08
1015
Lube oil system
Work card
no.
Activity
W 08-04-06
Remove and remount oil suction nozzle / oil suction pump
W 08-04-07
W 08-04-07
W 08-04-08
W 08-08-02
Remove and remount oil cooler W 09-08-04
W 08-10-06
Remove and remount oil filter

cartridge
W 08-11-08
W 08-11-09
W 08-11-10
Remove and remount pressure

control valve
W 08-15-01
Remove and refit oil pressure

line (turbocharger)
W 08-15-02
Remove and refit oil return line

(turbocharger)
09
W 08-04-07
Cooling system
Work card
no.
Activity
W 09-07-08
Remove and remount coolant

pump
W 09-08-01
Check coolant thermostat,

when disassembled
W 09-08-02

thermostats
W 09-08-04

thermostat housing
W 09-12-01

temperature transmitter
Page 6 of 8
W 09-08-02
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1015
12
Other components
Work card
no.
Activity
W 12-01-04
Remove and remount vibration

damper
W 12-06-01
W 12-06-03
Renew starter ring gear on flyw- W 12-06-01

heel
13
5 Work card index

Electrical system
Work card
no.
W 13-03-02
Activity
Remark on work card index:

Due to the structure of work cards, some sections of work processes overlap or are repeated.
In this context, some diagrams on the same field of work may deviate slightly.
11/2003
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Page 7 of 8
5 Work card index

1015
Notes
Page 8 of 8
0312 1068 - 0165
11/2003
1015
6 Work cards
11/2003
Work cards
0312 1069 - 0165
Page 1 of 2
1015
6 Work cards
Notes
Page 2 of 2
0312 1069 - 0165
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General
Work card
W 00-02-06
1015
Tools
References
- Commercial tools
Compressive pressure checker _____ 8005
- W 01-01-01
- W 07-07-01
- Special tools
Connection piece ______________100 130
Slotted nut spanner_____________110 130

- see work card W 01-01-01.
Remove injection valves
Insert connection piece (1) with new special seal.
34682 1
Fasten connection piece.

Tighten cap nut with slotted nut spanner (1).
07001
1
37096 0
11/2003
0312 0170 - 0165
Page 1 of 4
General
Work card
W 00-02-06
1015
If necessary, fit adapter (1) to connection piece.
34684 1
Fit compressive pressure checker to connection piece or adapter.

Race the engine with starter.
00 51
34685 1
The compressive pressure measured depends upon

the starting speed during the measuring process and
the altitude at which the engine is located.
Limit values can therefore not be stated precisely. It
is recommended that the compressive pressure is
measured only as a comparative measurement of all
cylinders in a engine in conjunction. If a deviation of
more than 15% is measured, the cause should be
established by disassembling the cylinder unit concerned.
34686 1
Page 2 of 4
0312 0170 - 0165
11/2003
1015
General
Work card
W 00-02-06
Remove compressive pressure checker, adapter (1)

and connection piece with special seal.
Refit injection valves
34684 1
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0312 0170 - 0165
Page 3 of 4
General
Work card
W 00-02-06
1015
Notes
Page 4 of 4
0312 0170 - 0165
11/2003
General
Work card
W 00-05-01
1015
Mount engine on assembly trestle and remove
Tools
References
- Commercial tools
- W 13-03-02
- Special tools
Engine assembly trestle incl. _______ 6066
Adapter plates
Clamping holder ______________6066/151
Auxiliary aids
Note
Varying customer scopes are not taken
into account in the repair work described,
i.e., fitted parts which deviate from the
standard equipment are not described.
- Hoist
- Sturdy rope
Mount engine onto assembly trestle

Remove starter
Undo screw (1) and remove cable holder.
37223 0
Undo screw (1) and remove cable holder.
37224 0
11/2003
0312 1071- 0165
Page 1 of 4
General
Work card
W 00-05-01
1015
Unscrew threaded sleeve (1).
37225 0
Position clamping holder (1) on the A-side and tighten screws (arrows).
00001
37236 0
Position clamping holder (1) on the B-side and tighten screws (arrows).
00001
37237 0
Page 2 of 4
0312 1071- 0165
11/2003
General
Work card
W 00-05-01
1015
Mount engine with clamping holder onto the engine
assembly trestle.
1
Align the clamping holder (1), on the A and B-sides,
to the adapter plates (2) of the engine assembly
trestle.
Tighten screws.
00002
37227 0
Align engine assembly trestle.
37226 0
Remove engine from assembly trestle

Suspend engine on a suitable workshop crane.
Remove clamping holder (1), on the A and B-sides,

from the adapter plates (2) of the engine assembly
trestle.
Lift engine away from assembly trestle.

Remove clamping holder from the crankcase.
37227 0
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0312 1071- 0165
Page 3 of 4
General
Work card
W 00-05-01
1015
Tighten threaded sleeve (1).
37225 0
Position cable holder and tighten screw (1).
37224 0
Position cable holder and tighten screw (1).

Remount starter
37223 0
Page 4 of 4
0312 1071- 0165
11/2003
Cylinder head
Work card
W 01-01-01
1015
Tools
Note
- Commercial tools
Feeler gauges
The standard valve play setting is possible:

On cold or hot engine after allowing to cool
down for at least 0.5 h Oil temperature 80
C.
- Special tools
Engine racing fixture ____________100 300
Engine racing fixture (optionally) __100 350
Auxiliary aids
- DEUTZ DW74
Disassembly
Remove cylinder head cover (1).
Undo screws (2), remove cylinder head cover and
seal.
2
1
36814 0
Mount engine racing fixture.
Note
If the assembly situation is unfavourable, the
engine can be raced via the front end of the
crankshaft with engine racing fixture 100 350
instead of engine racing fixture 100 300.
Undo screws (1), remove sealing cover (2) and seal.
37127 0
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Page 1 of 6
Cylinder head
Work card
W 01-01-01
1015
Install engine racing fixture (1) with centring bolt (2)

in the top threaded hole (3).
2
1
37155 0
Tighten screw (1).
Note
The teeth of the engine racing fixture must intermesh in gearing of the starter ring gear.
34659 1
Set engine to valve crossover point

Race engine until the valve crossover point is reached, cylinder no. A1.
Note
The valve crossover point means:
exhaust valves have still not closed, inlet valves start to open.
01 63
37156 0
Page 2 of 6
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Cylinder head
Work card
W 01-01-01
1015
Arrangement of inlet and exhaust valves.
IN = Inlet valve
EX = Exhaust valve
IN
IN
EX
EX
37203 0
Check the valve play on the appropriate cylinder with

feeler gauge blade and adjust, if necessary.
01 60
34604 1
Tighten locknut.
Note
Do not twist the adjusting screw when tightening the locknut.
01003
Check valve play once more with feeler gauge blade.
34605 1
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0312 1072 - 0165
Page 3 of 6
Cylinder head
Work card
W 01-01-01
1015
Assembly
1
Install cylinder head cover.

Clean the sealing surfaces on the cylinder head cover and cylinder head hood.
Place new seal for cylinder head cover with the flattened side (1) over sealing rubber (2).
36826 0
Mount cylinder head cover.
Note
The sealing rubber (1) may not lay on the

sealing surface (2) of the cylinder head cover.
36827 0
Fasten cylinder head cover (1).

Tighten screws (2).
01005
2
1
36814 0
Page 4 of 6
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1015
Cylinder head
Work card
W 01-01-01
Dismount engine racing fixture.

Undo screws and remove engine racing fixture.
Clean the sealing surfaces on the sealing cover and
crankcase.
Install sealing cover with new seal and tighten
screws.
03085
Note
In the case of oil-proof and water-tight
versions.
Mount sealing cover with DEUTZ DW 74
sealing compound.
11/2003
0312 1072 - 0165
37134 0
Page 5 of 6
Cylinder head
Work card
W 01-01-01
1015
Notes
Page 6 of 6
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Cylinder head
Work card
W 01-02-02
1015
Remove and refit rocker arm and rocker arm bracket
Tools
References
- Commercial tools
Feeler gauges
- W 01-01-01
- W 07-03-01
Remove rocker arm and rocker arm bracket

1
Remove injection line

Undo screws (2), take out cylinder head cover and
seal.
36983 0
Undo screws (1) and take out rocker arm (2) with
rocker arm bracket.
Note
Undo the screws evenly to prevent the rocker
arm brackets from twisting.
36984 0
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Page 1 of 4
Cylinder head
Work card
W 01-02-02
1015
Take out push rods (1).
Note
Deposit the components in their refitting
sequence.
Visually check the push rods for wear.
36985 0
Insert push rods (1).
Note
- Note the arrangement of push rods.
- The push rod must sit with the circular head
in the socket of the tappet.
36985 0
Refit rocker arm and rocker arm bracket

Install rocker arm bracket.
Note
- The broad side (1) of the rocker arm brackets
must face upwards.
- The circular heads must sit in the sockets of
the push rods (arrow).
36986 0
Page 2 of 4
0312 1073 - 0165
11/2003
Cylinder head
Work card
W 01-02-02
1015
Screw in screws (1).
Note
- When screwing in the screws, ensure that the

push rods are not subject to loading from valve crossover.
- Align rocker arm (2) to the push rods/valves.
36984 0
Check the rocker arm's axial play

Check the axial play between the rocker arm bracket
(1) and rocker arm (2) with the feeler gauge blade.
01 75
Note
- The rocker arm (2) must lay on the opposite
side (3) on the rocker arm bracket.
- Adjust the position by moving the rocker arm
brackets.
36743 0
Fasten rocker arm brackets.

Tighten screws (1).
01002

Note
To make the work easier, check and adjust the
valve play before refitting the cylinder head
cover.
36987 0
11/2003
0312 1073 - 0165
Page 3 of 4
Cylinder head
Work card
W 01-02-02
1015

Clean sealing surfaces on the cylinder head cover
and cylinder head.
Refit cylinder head cover with seal and screw in

screws.
Note
Note different screw lengths:

Screw M8 x 80 mm (1)
Screws M8 x 70 mm (2)
3
36988 0
Fasten cylinder head cover.

Tighten screws.
01004
Refit injection lines

36989 0
Page 4 of 4
0312 1073 - 0165
11/2003
Cylinder head
Work card
W 01-02-06
1015
Disassemble, reassemble and check rocker arm and rocker arm bracket
Tools
References
- Commercial tools
Internal dial gauge
Micrometer
- W 01-02-02
- Special tools
Dial gauge____________________100 400
Disassembly and assembly tool ___170 120
for ball pins
Disassemble rocker arm bracket

Remove rocker arm and rocker arm bracket
34824 1
Check rocker arm (inlet valves)

Set internal dial gauge to 28 mm.
Measure rocker arm bore with internal dial gauge.
01 73
Note
Replace the rocker arm if the limits of wear
have been reached.
34825 1
11/2003
0312 1074 - 0165
Page 1 of 6
Cylinder head
Work card
W 01-02-06
1015
Visually check ball pins (1) and adjusting screws (2)

for wear and replace, if necessary.
Check oil duct (3) for free flowing.
3
2
36749 0
Replace ball pins (rocker arm inlet valves)

Press out ball pin with disassembly tool.
34827 1
Install ball pin so that the notch (arrow) vertically faces the rocker arm axle.
34828 1
Page 2 of 6
0312 1074 - 0165
11/2003
Cylinder head
Work card
W 01-02-06
1015
Press in ball pin with assembly tool.
Check oil duct for free flowing.
34829 1
Check rocker arm (exhaust valves)

Measure rocker arm bore with internal dial gauge.
01 72
Note
Replace the rocker arm if the limits of wear
have been reached.
34830 1
Visually check ball pins (1) and adjusting screws (2)

for wear and replace, if necessary.
2
36750 0
11/2003
0312 1074 - 0165
Page 3 of 6
Cylinder head
Work card
W 01-02-06
1015
Replace ball pins (rocker arm exhaust valves)

Press out ball pin with disassembly tool.
34832 1
Press in ball pin with assembly tool.
34833 1
Check rocker arm axle

Measure diameter of the rocker arm axle with a
micrometer.
01 74
Note
Replace the rocker arm axle if the limits of
wear have been reached.
Check oil ducts for free flowing.
34834 1
Page 4 of 6
0312 1074 - 0165
11/2003
Cylinder head
Work card
W 01-02-06
1015
Reassemble rocker arm bracket
Slide rocker arm onto the rocker arm axle.
Note
The oil bores (1) must face upwards and the
cut-outs (2) for the screws in the rocker arm
brackets must point towards the adjusting
screws.
36751 0
Slide rocker arm brackets onto the rocker arm axle.
Note
The fixing slots (1) must face towards the adjusting screws (2) and the broad sides (3) must
face upwards.
1
2
36752 0
Insert screws in the rocker arm brackets.

Install rocker arm and rocker arm bracket
34837 1
11/2003
0312 1074 - 0165
Page 5 of 6
Cylinder head
Work card
W 01-02-06
1015
Notes
Page 6 of 6
0312 1074 - 0165
11/2003
Cylinder head
Work card
W 01-04-04
1015
Remove and remount cylinder head
Tools
References
- Commercial tools
Strengthened socket wrench inset ___ 8016
size 17
Magnetic measuring stand
- W 01-02-02
- W 06-01-05
- W 06-07-03
- W 07-07-01
- Special tools
2x dial gauge _________________100 400
Measuring device with plate ______100 850
Angular tightening wrench _______101 910
Remove cylinder head

Dismount air intake manifold
Remove exhaust manifold
Dismount rocker arm and rocker arm bracket
Dismount injection valve
Note
Deposit components in their assembly sequence.
37241 0
Undo screws (1), remove cylinder head and seal.
Note
Use strengthened socket wrench inset.
1
Clean the sealing surfaces on the cylinder head and
crankcase.
1
36753 0
11/2003
0312 1075 - 0165
Page 1 of 4
Cylinder head
Work card
W 01-04-04
1015
Determine the cylinder head sealing

Press in the cylinder liner until the stop and fasten
with screws and washers (arrow).
Note
Maximum thickness of washers 4 mm.
1
Ensure the centring bushes (1) are in place.
34971 1
Move piston to top dead centre.

Fasten magnetic measuring stand and insert dial
gauge.
Apply tracer pin under pre-tension to the piston base
(arrow).
Turn the crankshaft evenly until the indicator on the
dial gauge reaches the turning point.
The piston is now at top dead centre.
Remove magnetic measuring stand.
36754 0
Place measuring device (1) onto the measuring plate

(2), insert dial gauges (3) under pre-tension in the
measuring device and adjust to "0".
2
37242 0
Page 2 of 4
0312 1075 - 0165
11/2003
1015
Cylinder head
Work card
W 01-04-04
Position measuring device above the centring bushes (arrow) and read off the values measured by
both dial gauges. The larger measured value produces dimension "x.
Note
The cylinder head sealing must be determined
separately for each cylinder.
34973 1
Compare dimension "x" with the values and determine the appropriate cylinder head sealing.
00000
02 75
02 76
02 77
Example: Dimension "x" = 0.42 mm, corresponds

to cylinder head sealing with 3 holes (arrow).
34974 1
Remount cylinder head

Install new cylinder head seal.
Note
- The sealing surfaces for cylinder head seals
must be clean and free of oil.
- The "TOP / OBEN marking must face upwards.
- Ensure the centring bushes (arrows) are in
place.
34975 1
11/2003
0312 1075 - 0165
Page 3 of 4
Cylinder head
Work card
W 01-04-04
1015
Install cylinder head, oil cylinder head screws lightly

and screw in.
Note
Cylinder head screws can be re-used max. 5x
given proof of this.
34976 1
Tighten cylinder head screws alternately.

01001
00000
Note
Use angular tightening wrench and strengthened socket wrench inset.
34977 1
Install rocker arm and rocker arm bracket

Install injection valve
Mount exhaust manifold
Install air intake manifold
Page 4 of 4
0312 1075 - 0165
11/2003
Cylinder head
Work card
W 01-05-01
1015
Tools
References
- Commercial tools
Valve sealing ring wrench__________ 8024
Valve spring assembly lever ________ 9017
Caliper gauge
- W 01-04-04
- Special tools
Clamping stand________________120 900
Clamping plate ________________120 910
Assembly tool _________________121 410
Remove valves
Dismount cylinder head
Install clamping stand (1) on clamping plate (2).
Install cylinder head on clamping stand.
2
34796 1
Mount valve assembly lever (1).

Press down valve spring with the valve assembly lever and remove both clamping cones.
Remove valve spring disc, valve springs and valves.

Dismount valve assembly lever.
34797 1
11/2003
0312 1076 - 0165
Page 1 of 4
Cylinder head
Work card
W 01-05-01
1015
Remove valve stem seals with valve sealing ring

wrench.
34798 1
Clean and monitor cylinder head and visually check

it for damage.
Visually check valves for damage.
34799 1
Refit valves
Determine the length of the valve spring with a CaliperCaliper gauge.
Note
Replace the valve spring if the limits of wear
have been reached.
00000
01 51
35856 1
Page 2 of 4
0312 1076 - 0165
11/2003
Cylinder head
Work card
W 01-05-01
1015
Insert valve and hold down. Cover the valve stem
with the protective sleeve.
Note
Cover the valve key slots (1) with the protective sleeve (2) or adhesive foil each time before
mounting valve stem seals.
34814 2
Slide valve stem seal over the protective sleeve

(arrow).
34815 1
Remove protective sleeve.

Press in valve stem seal with the assembly tool (1)
until the stop.
34816 1
11/2003
0312 1076 - 0165
Page 3 of 4
Cylinder head
Work card
W 01-05-01
1015
Install valve spring and valve spring disc.
34817 1
Mount valve assembly lever.

Hold down the valve spring with the valve assembly
lever and insert both clamping cones.
Note
Ensure that the clamping cones are sitting properly in the valve key slots.
Dismount valve assembly lever.
Dismount cylinder head from clamping stand.
Install cylinder head
34818 1
Page 4 of 4
0312 1076 - 0165
11/2003
Cylinder head
Work card
W 01-05-04
1015
Check valves
Tools
References
- Commercial tools
Micrometer
Caliper gauge
- W 01-05-01
Note
- All valves are removed and cleaned.
Valve stem diameter

Remove valves
Measure the diameter of the valve stem with an
micrometer.
Note
Replace the valve if the limits of wear have
been reached.
00000
01 31
01 32
35819 1
Valve stem thickness

Measure the thickness of the valve stem with a caliper gauge.
Note
been reached.
00000
01 35
01 36
35820 1
11/2003
0312 1077 - 0165
Page 1 of 2
Cylinder head
Work card
W 01-05-04
1015
Valve disc diameter

Measure the diameter of the valve disc with a caliper
gauge.
Note
been reached.
00000
01 37
01 38
Refit valves
35821 1
Page 2 of 2
0312 1077 - 0165
11/2003
Cylinder head
Work card
W 01-06-03
1015
Check valve guides
Tools
References
- Commercial tools
- W 01-05-01
- Special tools
Dial gauge____________________100 400
Note
- The cylinder head is dismounted and
disassembled.
- New values are used for the inspection.
Check valve guides

Remove valves
Visually check valve guides for wear.
Fit magnetic measuring stand and insert dial gauge.
Insert new valve.
Apply tracer pin under pretension to the valve stem
(arrow) and adjust dial gauge to "0".
34804 2
Measure valve stem clearance

Move the end of the valve stem backwards and
forwards in the direction of the arrow.
Note
- The complete path of tilt must be taken into
account.
- Replace the valve guides if the limits of wear
have been reached.
00000
01 33
01 34
37209 0
11/2003
0312 1078 - 0165
Page 1 of 2
Cylinder head
Work card
W 01-06-03
1015
Dismount magnetic measuring stand and dial gauge.

Install valves
37240 0
Page 2 of 2
0312 1078 - 0165
11/2003
Cylinder head
Work card
W 01-07-08
1015
Tools
References
- Commercial tools
Depth caliper gauge
- W 01-04-04
- Special tools
Clamping stand________________120 900
Clamping plate ________________120 910

Remove cylinder head
Install clamping stand (1) on clamping plate (2).
Install cylinder head on clamping stand.
2
34796 1
Measure the valve set-back with a depth caliper gauge from the centre, valve disc to the cylinder head
sealing surface.
Note
Replace the valve seat inserts or the valve
individually or all together if the limits of wear
have been reached.
00000
01 45
01 46
34809 1
11/2003
0312 1080 - 0165
Page 1 of 2
Cylinder head
Work card
W 01-07-08
1015
Dismount cylinder head from clamping stand (1).

Dismount clamping stand (1) from clamping plate
(2).
Refit cylinder head
2
34796 1
Page 2 of 2
0312 1080 - 0165
11/2003
Drive system
Work card
W 02-01-07
1015
Check crankshaft
Tools
References
- Commercial tools
Micrometer
Internal dial gauge
Prisms
Hardness tester
- W 02-04-01
Note
- Special tools
Dial gauge____________________100 400
The re-work stages are marked on the outer contour of the crankshaft web on the flywheel side.
H = main bearing journal ground
P = big end bearing journal ground
Note
If the crankshaft is worn, there is the option of
having it repaired in one of our service centres.
Check bearing journal hardness

Remove crankshaft
Place crankshaft on prisms.
34753 1
Check bearing journal with hardness tester.

02 07
Note
The measured value is converted according to
the table for the measuring device.
34754 1
11/2003
0312 1081 - 0165
Page 1 of 4
Drive system
Work card
W 02-01-07
1015
Note
Schematic for measuring bearing journals at
points "1" and "2" in the levels "a" and "b".
36424 1
Check diameter of main bearing journal

Measure main bearing journal with an micrometer.
Note
See schematic representation for measuring
points.
00000
02 03
02 04
02 05
02 06
34756 1
Check diameter of lift bearing journal

Measure lift bearing journal with an micrometer.
Note
points.
00000
02 22
02 23
02 24
02 25
34758 1
Page 2 of 4
0312 1081 - 0165
11/2003
1015
Drive system
Work card
W 02-01-07
Check concentric running

Apply magnetic measuring stand and insert dial
gauge.
Apply tracer pin under pretension to the main
bearing journal (arrow) and adjust the dial gauge to
"0".
Turn the crankshaft evenly and check for concentric
running.
02 26
Dismount magnetic measuring stand and dial gauge.
34759 1
Measure thrust bearing width

Set the micrometer to 38 mm.
Slide internal dial gauge between the test surfaces of
the micrometer and set to "0".
35825 1
Measure the width of the thrust bearing with an

internal dial gauge between contact surfaces of the
thrust rings.
Note down measured value (dimension "a")
00000
02 11
02 12
02 13
Note
Dimension "a" is required to find the axial play.
34949 1
11/2003
0312 1081 - 0165
Page 3 of 4
Drive system
Work card
W 02-01-07
1015
Check axial play

Apply thrust ring halves to the cover of the thrust
bearing (arrow).
Measure width with an micrometer.
Note down measured value (dimension "b").
35827 1
Determine axial play.

Axial play = dimension "a" - dimension "b"
Example:
Dimension a = 38.02 mm
Dimension b = 37.71 mm
Axial play
= 0.31 mm
02 34
Use appropriate thrust ring halves.

00000
02 36
02 37
Visual check
Visually check the running surfaces (arrow) of the
shaft seals.
Refit crankshaft
34760 1
Page 4 of 4
0312 1081 - 0165
11/2003
Drive system
Work card
W 02-02-02
1015
Tools
References
- Commercial tools
- W 12-06-01
- Special tools
Assembly tool _________________142 650
Remove crankshaft seal

Dismount flywheel
Prise the crankshaft seal from its seat by knocking
against it with a mandrel.
36762 0
Carefully drill a hole min. 3-3.5 mm in the crankshaft

seal for a sheet metal screw.
Note
Apply plenty of grease to the drill to ensure that
no drill shavings fall into the crankcase.
36763 0
11/2003
0312 1082 - 0165
Page 1 of 4
Drive system
Work card
W 02-02-02
1015
Screw the sheet metal screw into the hole and pull
out using a suitable tool, e.g. valve spring assembly
lever.
Visually check the running surfaces of the crankshaft
flange.
36764 0
Install crankshaft seal

Note the installation depth of the crankshaft seal and
select an appropriate spacer disc.
Neu-Stufe
Rep-Stufe
Note
The spacer discs (1) are designated with "New
stage (Neu-Stufe) and "Rep. stage" (Rep.Stufe).
1
36756 0
Installation depth:
Pos. 1 installation depth first mounting (new stage)
Pos. 2 maximum installation depth (Rep. stage)
37243 0
Page 2 of 4
0312 1082 - 0165
11/2003
Drive system
Work card
W 02-02-02
1015
Place spacer disc (1) on the crankshaft.
Note
Ensure that the sleeve (2) and bore (3) are aligned.
2
1
36755 0
Loosely tighten bolt (1).
Note
The side with the fine thread and the long collar
(2) is screwed in on the crankshaft side.
36757 0
Lightly oil the crankshaft seal and carefully place on

the running surface.
36758 0
11/2003
0312 1082 - 0165
Page 3 of 4
Drive system
Work card
W 02-02-02
1015
Place assembly sleeve (1) on the bolts (2) and press

up to the stop on the crankshaft seal.
2
36759 0
Slide pressing brace (1) onto the bolts (2) and lightly
tighten nuts with washers.
36760 0
Screw in middle screw (1) until the stop on the assembly sleeve (2) is reached.
Note
The crankshaft seal is now in its preselected

installation depth.
Dismount assembly tool.
Refit flywheel
36761 0
Page 4 of 4
0312 1082 - 0165
11/2003
Drive system
Word card
W 02-02-04
1015
Tools
References
- Commercial tools
- W 12-01-04
- Special tools
Assembly tool _________________142 640
Remove crankshaft seal

Dismount vibration damper
Prise the crankshaft seal from its seat by knocking
against it with a mandrel.
35197 1
Carefully drill a hole min. 3-3.5 mm in the crankshaft

seal for a sheet metal screw.
Note
Apply plenty of grease to the drill to ensure that
no drill shavings fall into the crankcase.
35198 1
11/2003
0312 1083 - 0165
Page 1 of 4
Drive system
Word card
W 02-02-04
1015
Screw the sheet metal screw into the hole and pull
out using a suitable tool, e.g. valve spring assembly
lever.
Visually check the running surfaces of the crankshaft
flange.
35199 1
Install crankshaft seal

Note the installation depth of the crankshaft seal and
select an appropriate spacer disc.
Rep-Stufe
Neu-Stufe
Note
The spacer discs (1) are designated with New
stage (Neu-Stufe) and Rep. stage (Rep.Stufe).
37153 0
Installation depth:
Pos. 1 installation depth first mounting (New stage)
Pos. 2 maximum installation depth (Rep. stage)
35201 1
Page 2 of 4
0312 1083 - 0165
11/2003
Drive system
Word card
W 02-02-04
1015
Place spacer disc (1) on the crankshaft.
37211 0
Loosely tighten bolt (1).
Note
The side with the fine thread and the long collar
(2) is screwed in on the crankshaft side.
37208 0
Lightly oil the crankshaft seal and carefully place on

the running surface.
35203 1
11/2003
0312 1083 - 0165
Page 3 of 4
Drive system
Word card
W 02-02-04
1015
Place assembly sleeve (1) on the bolts (2) and press

up to the stop on the crankshaft seal.
2
35204 1
Slide pressing brace (1) onto the bolts (2) and lightly
tighten nuts with washers.
1
35205 1
Screw in middle screw (1) until the stop on the assembly sleeve (2) is reached.
Note
The crankshaft seal is now in its preselected

installation depth.
Dismount assembly tool.
Install vibration damper
35206 1
Page 4 of 4
0312 1083 - 0165
11/2003
Drive system
Work card
W 02-03-01
1015
Tools
References
- Commercial tools
Micrometer
Internal dial gauge
Big end testing device
- I 02-03-03
- Special tools
Dial gauge____________________100 400
Note
- The connecting rod is removed and the piston
dismounted.
Check small end bush

Prepare internal dial gauge.
Mount tracer pin in internal dial gauge for the appropriate measuring range.
Mount dial gauge with approx. 1 mm pretension in internal dial gauge.
Set micrometer to 52 mm.
Slide the internal dial gauge between the test surfaces of the micrometer.
Swing internal dial gauge between the test surfaces
of the micrometer and adjust the dial gauge at the indicator's turning point to "0".
34768 1
Note
Schematic for measuring the small end bush at
points "a" and "b" in the levels "1" and "2.
37239 0
11/2003
0312 1084 - 0165
Page 1 of 8
Drive system
Work card
W 02-03-01
1015
Measure small end bush with internal dial gauge.

Insert internal dial gauge in the small end bush.
Swing the internal dial gauge between each of the
stipulated measuring points and read off measured
value at the indicator's turning point.
Note
- Small end bush pressed in.
- See schematic representation for measuring
points.
02 43

- see work card I 02-03-03.
34770 1
Check diameter of the piston pin

Measure piston pin with micrometer.
02 61
Determine piston pin play

The piston pin play is found from the dimensions
"small end bush piston pin".
02 45
35908 1
Check bore for big end bearing

Place big end bearing cover on connecting rod.
Note
The numeric markings (1) on the connecting
rod and the big end bearing cover must be
identical and face each other during assembly.
34771 1
Page 2 of 8
0312 1084 - 0165
11/2003
Drive system
Work card
W 02-03-01
1015
Fasten big end bearing cover.
Tighten screws.
02020
34772 1

the micrometer.
36094 1
Note
37239 0
11/2003
0312 1084 - 0165
Page 3 of 8
Drive system
Work card
W 02-03-01
1015
Measure the bore for the big end bearing with the internal dial gauge.
Insert internal dial gauge in the bore for the big end
bearing.
02 55
Note
If the measured values deviate slightly, take
extra measurements with new bearing shells.
34775 1
Check inner diameter of big end bearing

Undo screws and remove big end bearing cover.
Insert big end bearing shell in connecting rod.
Note
- Insert big end bearing shell with the black anodised rear (arrow) in the connecting rod.
- The fitting position lock (1) must grip in the
slot (2).
36768 0
Insert big end bearing shell in the associated big end

bearing cover.
Note
The fitting position lock (1) must grip in the
slot (2).
1
36769 0
Page 4 of 8
0312 1084 - 0165
11/2003
Drive system
Work card
W 02-03-01
1015
Install big end bearing cover and tighten screws.
02020
34778 1

the micrometer.
36094 1
Note
37239 0
11/2003
0312 1084 - 0165
Page 5 of 8
Drive system
Work card
W 02-03-01
1015
Measure the inner diameter of the big end bearing

shells with internal dial gauge.
Insert internal dial gauge between the big end bearing shells.
00000
02 52
02 53
02 54
Note
The connecting rod can be re-used if the values do not exceed max. 0.015 mm over the
bearing tolerance.
The connecting rod must be replaced if the limit value is exceeded.
34775 1
Determine big end bearing clearance

The big end bearing clearance is found from the
dimensions "big end bearing shell inner diameter
lift bearing journal diameter.
00000
02 56
02 57
Undo screws and remove big end bearing cover.
Check connecting rod parallelism

Check connecting rod without bearing shells on a big
end testing device.
Admissible deviation "a" = max. 0.06 mm
at a distance of "x" = 100 mm.
35880 1
Page 6 of 8
0312 1084 - 0165
11/2003
1015
Drive system
Work card
W 02-03-01
Check connecting rod angularity

Admissible deviation "A" to "B" = max. 0.10 mm
at a distance of "x" = 100 mm.
35881 1
11/2003
0312 1084 - 0165
Page 7 of 8
Drive system
Work card
W 02-03-01
1015
Notes
Page 8 of 8
0312 1084 - 0165
11/2003
Drive system
Work card
I 02-03-03
1015
Tools
Caution !
!
- Commercial tools
- Special tools
Base plate____________________131 200
Assembly tool _________________131 210
Injury hazard !
Do not touch hot components, liquid nitrogen and undercooled components! Wear
safety gloves and protective goggles.
Note
Auxiliary aids
- The pressing in work must be performed

quickly because of the necessary
temperature difference between the small
end bush and connecting rod. For this
reason, it is recommended that this work
card is read carefully and the manual
actions practised before starting the
pressing in work.
- The small end bush must be mechanically
worked after being fitted.
- Press or threaded spindle

- Nitrogen (liquid)
- Degreasing/cleaning agents
- Compressed air
- Heating furnace
Disassembly
Insert the disassembly template (2) and big end
bearing take-up (3) in the base plate (1).
Note
- For the purpose of example, this work is

shown with the help of a pneumatic press.
Risk of confusion!
- The disassembly template (2) and assembly
template (8) are different.
- Ensure that the disassembly template (2) sits
flush!
1
36281 1
Insert the lower part of the assembly tool (4) from

below through the base plate (1) into the
disassembly template (2).
Place connecting rod (5) onto the base plate (1).
Note
Connecting rod with the flat side (6)
downwards.
3
2
Screw the lower part (4) and upper part (7) of the
assembly tool together.
4
36282 1
11/2003
0312 1085 - 0165
Page 1 of 6
Drive system
Work card
I 02-03-03
1015
Note
The bevelled part of the assembly tool (7) must
lay level on the top of the connecting rod eye
and may not be inclined.
36283 1
Pressing out the small end bush shown with pneumatic press :
Align the pneumatic press horizontally on the base
plate so that the press out stamp is centred above
the upper part of the assembly tool.
Note
A threaded spindle can also be used to press
out the small end bush. Never forcefully knock
the small end bush out!
36284 1
Gently press out the small end bush.

Clean the bush bore carefully and remove any
grease.
36285 1
Page 2 of 6
0312 1085 - 0165
11/2003
Drive system
Work card
I 02-03-03
1015
Assembly
Assemble the small end bush by shrink-fitting (freeze
up).
Caution !
!
Injury hazard!
It is essential to wear safety gloves and
protective goggles when fitting the small end
bush!
Insert assembly template (8) and big end bearing

take-up (3) in the base plate (1).
Note
Ensure that the assembly template (8) is sitting
flush!
1
36286 1
Heat connecting rod (5) to maximum 200 C.
5
Place connecting rod (5) with the flat side (6)
downwards onto the base plate (1).
36287 1
Cool the small end bush (9) in liquid nitrogen to

approx. -40 C.
36288 1
11/2003
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Page 3 of 6
Drive system
Work card
I 02-03-03
1015
Install the undercooled small end bush (9) onto the

assembly mandrel (10) so that the index pin (11) is
sitting correctly in the slot (12) of the small end bush.
11
10
12
36289 1
Insert assembly mandrel (10) together with the undercooled small end bush (9) in the connecting bore
without using force.
Pull the assembly mandrel (10) out, thereby ensuring
that the small end bush (9) can no longer slide about.
10
36290 1
Note
- The small end bush must be mechanically
worked after being fitted.
- The specifications for mechanical working are
given overleaf.
Page 4 of 6
0312 1085 - 0165
11/2003
1015
Drive system
Work card
I 02-03-03
Machine/drill inner diameter of bush acc. to below table and picture 36291 :
Allowance
Maximum dimension
Minimum dimension
Bore for small end bush
52.055 mm
52.040 mm
Piston pin-
52.000 mm
51.992 mm
Theoretical play
0.063 mm
0.040 mm
Information on further processing :
36291 1
11/2003
0312 1085 - 0165
Page 5 of 6
Drive system
Work card
I 02-03-03
1015
Notes
Page 6 of 6
0312 1085 - 0165
11/2003
Drive system
Work card
W 02-04-01
1015
Tools
References
- Commercial tools
Size 14
- W 02-01-07
- W 03-08-01
- W 03-09-01
- W 03-09-04
- W 07-07-01
- W 08-04-08
- Special tools
Racing fixture engine front _______100 350
Remove crankshaft
Dismount accessory carrier
Remove oil suction pump (flywheel side)
Dismount adapter housing
Dismount rear cover (flywheel side)
37010 0
Dismount big end bearing cap

Apply vibration damper (1) and tighten screws (arrows).
Note
Install vibration damper to turn the crankshaft.
1
37034 0
11/2003
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Page 1 of 12
Drive system
Work card
W 02-04-01
1015
Set counterweights (1) of cylinders A1/B1 to BDC.
01 63
Note
Turn crankshaft with racing fixture engine
front.
Undo screws (2) and remove counterweights.
Note
Lay down parts in the order they were disassembled.
37035 0
Set counterweights (1) of cylinders A3/B3 to BDC.
Undo screws (2) and remove counterweights.
Note
Lay down parts in the order they were
disassembled.
37036 0
Dismount all big end bearing caps.

Set the pistons of the respective cylinders to BDC.
Undo screws (1) and remove big end bearing caps
from the respective cylinder.
Note
- Use strengthened socket wrench inset.
- Lay down parts in the order they were
disassembled, note sequence of cylinders.
- Do not jam the connecting rods when turning
the crankshaft.
37037 0
Page 2 of 12
0312 1086 - 0165
11/2003
Drive system
Work card
W 02-04-01
1015
Turn the crankshaft evenly until the marking on the
crankshaft cog wheel is between the markings on the
camshaft cog wheel (1).
Carefully press out all connecting rods from the lift
bearing journals.
Undo screws and remove vibration damper.
37038 0
Undo all horizontal screws (1) on the A-side and

B-side.
Undo all vertical screws (2) from the main bearing
cap and the thrust bearing cap.
37039 0
Remove thrust bearing cap (1) and both thrust ring

halves (arrows).
Remove all main bearing caps (2).
Note
1 - 2724 A
2 - 2724 A
3 - 2724 A
2
4 - 2724 A
Lay down parts in the order they were

disassembled, note sequence of cylinders.
37048 0
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0312 1086 - 0165
Page 3 of 12
Drive system
Work card
W 02-04-01
1015
Remove crankshaft.
37040 0
Remove both thrust ring halves (arrows), all main

bearing shells (1) and all big end bearing shells (2).
Note
Lay down parts in the order they were disassembled, note sequence of cylinders.
Visually check parts for wear.

Check the axial play of the crankshaft
37041 0
Refit crankshaft
1
Insert main bearing shells in the crankcase.
Note
The fitting position lock (1) must engage in the
slot (2).
37042 0
Page 4 of 12
0312 1086 - 0165
11/2003
Drive system
Work card
W 02-04-01
1015
Insert main bearing shell in the respective main bearing cap.
Note
- Note allocation of main bearing caps.
- The fitting position lock (1) must engage in
the slot (2).
37043 0
Insert big end bearing shell in the connecting rod.
Note
- Insert big end bearing shell with the black anodised rear in the connecting rod.
the slot (2).
37044 0
Insert big end bearing shell in the respective big end

bearing cap.
Note
- Note the allocation of the big end bearing
caps.
the slot (2).
1
36769 0
11/2003
0312 1086 - 0165
Page 5 of 12
Drive system
Work card
W 02-04-01
1015
Lightly oil the bearing journals and shells.

Carefully insert crankshaft into crankcase.
Note
Do not jam the connecting rods when inserting
the crankshaft.
Adjust crankshaft to agree with camshaft.
Note
The marking on the crankshaft cog wheel must
be between the markings on the camshaft cog
wheel (1).
37045 0
Insert both thrust ring halves, without guide lugs, between crankshaft and crankcase (arrows).
Note
The oil slot (1) must face the mirrored cheek
(2) of the crankshaft.
1
37046 0
Adhere both thrust ring halves, with guide lugs (arrow), to the thrust bearing cap using a little grease.
Note
- The thrust bearing cap has the numerical designation "3" (1).
- The oil slot (2) must face the mirrored cheek
of the crankshaft.
2
37047 0
Page 6 of 12
0312 1086 - 0165
11/2003
Drive system
Work card
W 02-04-01
1015
Install thrust bearing cap (3).
Install main bearing caps (1, 2 and 4) in accordance
with the numbering.
1 - 2724 A
2 - 2724 A
3 - 2724 A
Note allocation and installation position:

- Install main bearing cap with no. "1" on the
flywheel side.
- The letter designation "A" on the bearing caps
must face the A-side.
4 - 2724 A
Note
37062 0
Screw in all horizontal screws (1) on the A-side and

B-side.
1
37049 0
Place retainer plate (1) for the oil suction pump onto
the main bearing cap with the numerical designation
"1" and screw in screws (2).
Note
- Screws may be used a maximum of 3x given
proof of this, otherwise they should be replaced as a general rule.
- The broader sides (arrows) should face the
flywheel.
37050 0
11/2003
0312 1086 - 0165
Page 7 of 12
Drive system
Work card
W 02-04-01
1015
Lightly screw in vertical screws (1) on main bearing

cap and thrust bearing cap.
Note
Screws may be used a maximum of 3x given
proof of this, otherwise they should be
replaced as a general rule.
First press crankshaft towards the flywheel side and
then in the opposite direction and align thrust bearing
cap.
37051 0
Tighten all vertical screws.
Note
- First tighten vertical screws, then the horizontal ones.
- Use an angular tightening wrench.
02010
00000
37052 0
Tighten all horizontal screws on the A-side and

B-side.
02011
00000
37053 0
Page 8 of 12
0312 1086 - 0165
11/2003
Drive system
Work card
W 02-04-01
1015
Refit big end bearing cap
Install vibration damper and screw in screws.
Check the installation direction of the connecting
rods.
Note
The flattened sides of the connecting rods
(arrow) must point towards the flywheel on the
A-side and towards the front cap on the B-side.
37204 0
Carefully draw connecting rods onto the crankpins.
37054 0
Install all big end bearing caps.

Set the piston of the respective cylinder to BDC.
Note
- Do not jam the connecting rods when turning
the crankshaft.
- The numerical designation (1) on the
connecting rod and the big end bearing cap
must be identical and face each other during
assembly.
37055 0
11/2003
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Page 9 of 12
Drive system
Work card
W 02-04-01
1015
Fasten big end bearing cap.

Tighten screws.
Note
Use new screws.
02020
37056 0
Install counterweights of cylinders A1/B1 and A3/B3.
Note allocation and installation position:

- Install counterweight with no. "1" on the flywheel side.
- The flattened sides (2) must respectively
point towards the main bearing cap.
Note
37057 0
Set crankshaft cheeks of the respective cylinder to

BDC.
Note
The description refers to the counterweights of
cylinders A1/B1, proceed in the same manner
for cylinders A3/ B3.
Ensure that the clamping bushes (1) are in position.
37058 0
Page 10 of 12
0312 1086 - 0165
11/2003
Drive system
Work card
W 02-04-01
1015
Insert counterweights in accordance with the numbering.
37059 0
Fasten counterweights.
Tighten screws.
02001
Undo screws and remove vibration damper.
37060 0
Mount rear cap (flywheel side)

Mount adapter housing
Install injection valves
Mount oil suction pump (flywheel side)
Mount accessory carrier
11/2003
0312 1086 - 0165
Page 11 of 12
Drive system
Work card
W 02-04-01
1015
Notes
Page 12 of 12
0312 1086 - 0165
11/2003
Drive system
Work card
W 02-09-03
1015
Remove and refit piston and connecting rod
Tools
References
- Commercial tools
Size 14
- W 01-04-04
- W 02-10-03
- W 08-04-07
- Special tools
Piston ring compressor __________130 650
Remove piston and connecting rod

2
Dismount cylinder head

Dismount oil pan
Dismount connecting elbow (1) with oil suction

pipe (2).
Remove screws (3) and undo connecting elbow.
37061 0
Undo screw (1) and remove screws (2 and 3).

Remove oil suction pipe with connecting elbow and
seals.
3
1
2
36776 0
11/2003
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Page 1 of 8
Drive system
Work card
W 02-09-03
1015
Set piston to BDC.

Undo screws (1)and remove big end bearing cap.
Note
Use strengthened socket wrench inset.
36766 0
Set piston to TDC.

Remove big end bearing shell from connecting rod.
Press out piston with connecting rod.
Caution !
!
- When pulling out the connecting rod, do not

jam it in the cylinder liner.
- Lay down parts in the order they were disassembled, note the sequence of cylinders.
01 63
36767 0
Dismount piston from connecting rod

Remove circlips and press piston pin out.
Visually check piston pin and piston for wear.
34785 1
Page 2 of 8
0312 1087 - 0165
11/2003
Drive system
Work card
W 02-09-03
1015
Assemble connecting rod and piston
Install a circlip.
Note
Ensure that the circlip is sitting correctly in the
slot.
34782 1
Insert connecting rod in piston.
Note
The flattened side of the connecting rod (1)
must be arranged opposite the cut-out (2) for
the piston cooling nozzle.
36770 0
Lightly oil piston pin and press in.

Install second circlip.
Note
Ensure that the circlip is sitting correctly in the
slot.
34784 1
11/2003
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Page 3 of 8
Drive system
Work card
W 02-09-03
1015
Refit piston and connecting rod

Insert big end bearing shell in connecting rod.
Note
- Insert big end bearing shell with the black anodised rear (arrow) in the connecting rod.
the slot (2).
36768 0
Insert big end bearing shell in the respective big end

bearing cap.
Note
The fitting position lock (1) must engage in the
slot (2).
1
36769 0
Arrange piston ring gaps offset at approx. 120 to

each other.
36216 1
Page 4 of 8
0312 1087 - 0165
11/2003
Drive system
Work card
W 02-09-03
1015
Lightly oil cylinder running surface, piston, piston
rings and crankpins.
Clamp piston rings with piston ring compressor (1).
Note
Do not twist piston rings anymore.
36771 0
Insert piston with connecting rod into the cylinder liner.
Note
- Not the cylinder allocation of the piston.
- Note designation (1) of the installation position on the base of the piston.
The "arrow" must point towards the exhaust
end.
Carefully press the connecting rod against the crankpins.
Note
- Do not jam the connecting rod with the
crankshaft.
- Do not damage the piston cooling nozzle.
36772 0
Install big end bearing cap.
Note
The numerical designation (1) on the
connecting rod and the big end bearing cap
must be identical and face each other during
assembly.
36773 0
11/2003
0312 1087 - 0165
Page 5 of 8
Drive system
Work card
W 02-09-03
1015
Fasten big end bearing cap.

Tighten screws (1).
Note
Use an angular tightening wrench and
strengthened socket wrench inset.
02020
34969 1
Pull oil suction pipe (1) out of connecting elbow (2).

Pull new O-ring seal (3) onto oil suction pipe.
Clean sealing surfaces on the oil suction pipe and

suction elbow.
Plug oil suction pipe into connecting elbow.
Note
Lightly oil O-ring seal.
36774 0
Clean sealing surfaces (1 and 2) on the oil suction

pumps.
Note
Ensure that no foreign bodies enter the oil suction pumps through the openings.
2
1
36775 0
Page 6 of 8
0312 1087 - 0165
11/2003
Drive system
Work card
W 02-09-03
1015
Install oil suction pipe and connecting elbow with
new seals, screw in screws.
Note

37105 0
Fix oil suction pipe without tension.

Tighten screw (1).
08015
1
2
Tighten screw (2).

08016
Tighten screw (3).
08017
Tighten screw (4).

08018
36746 0
Mount oil pan

Mount cylinder head
11/2003
0312 1087 - 0165
Page 7 of 8
Drive system
Work card
W 02-09-03
1015
Notes
Page 8 of 8
0312 1087 - 0165
11/2003
Drive system
Work card
W 02-09-07
1015
Check piston
Tools
References
- Commercial tools
Micrometer
Internal dial gauge
- W 02-09-03
- Special tools
Dial gauge____________________100 400
Check bore of piston pin

Dismount piston from connecting rod
34787 1

34768 1
11/2003
0312 1088 - 0165
Page 1 of 4
Drive system
Work card
W 02-09-07
1015
Note
Schematic for measuring the piston pin bore at
points "a" and "b" in the levels "1" and "2".
37239 0
Measure piston pin bore with internal dial gauge.

Insert internal dial gauge in the piston pin bore.
Note
points.
02 78
36484 1
Note
Schematic for measuring the piston diameter
at measuring points "1, 2 and 3", crosswise to
piston pin bore.
3
2
1
37244 0
Page 2 of 4
0312 1088 - 0165
11/2003
1015
Drive system
Work card
W 02-09-07
Check piston diameter

Measure piston with micrometer.
Note
points.
00000
02 71
02 72
02 73
Assemble connecting rod with piston

36485 1
11/2003
0312 1088 - 0165
Page 3 of 4
Drive system
Work card
W 02-09-07
1015
Notes
Page 4 of 4
0312 1088 - 0165
11/2003
Drive system
Work card
W 02-10-03
1015
Tools
References
- Commercial tools
Feeler gauges
- W 02-09-03
- Special tools
Piston ring positioning tongs______130 300
Trapezoidal groove wear gauge ___130 400

Separate piston from connecting rod
Dismount piston rings.
Adjust piston ring positioning tongs to the diameter of
the piston.
02 73
Remove piston rings with piston ring positioning

tongs.
35898 1
Clean and visually check piston and ring grooves.
34787 1
11/2003
0312 1089 - 0165
Page 1 of 4
Drive system
Work card
W 02-10-03
1015
Measure piston ring trapezoidal groove for the first

piston ring with trapezoidal groove wear gauge.
34789 1
The piston can continue to be used if there is a

distance "S" between the trapezoidal groove wear
gauge and the piston.
36353 1
Replace the piston if the trapezoidal groove wear

gauge touches the piston (arrow).
34791 1
Page 2 of 4
0312 1089 - 0165
11/2003
1015
Drive system
Work card
W 02-10-03
Check piston ring gap clearance

Insert piston ring in the cylinder liner.
Note
Align the piston ring by manoeuvring the piston
in the cylinder liner.
Measure the piston ring gap play with a feeler gauge.
00000
02 84
02 85
02 86
34788 1
Mount piston rings.
Note
Sequence and position of the piston rings seen
from the piston base.
1. Double trapezoidal ring, top facing combustion
chamber.
2. Tapered compression ring, top facing combustion
chamber.
3. Bevelled-edge slotted oil ring.
34794 1
Mount piston rings with piston ring positioning tongs.
Note
Arrange spring gap of the Bevelled-edge
slotted oil ring at an offset of 180 to the ring
gap.
35910 1
11/2003
0312 1089 - 0165
Page 3 of 4
Drive system
Work card
W 02-10-03
1015
Check axial play of piston ring

Measure the axial play of the piston ring in the
second and third piston ring grooves with a feeler
gauge.
Note
Take the measurement with new piston rings.
00000
02 87
02 88
02 89
Assemble connecting rod with piston

34792 1
Page 4 of 4
0312 1089 - 0165
11/2003
Drive system
Work card
W 02-15-01
1015
Remove, check and refit piston cooling nozzle
Tools
References
- Commercial tools
- W 02-09-03
- Special tools
Testing device for piston_________102 560
cooling nozzles
Test bar______________________102 565
Remove piston cooling nozzle

Dismount piston and connecting rod
Undo and take out overpressure valve (1) and

remove piston cooling nozzle (2).
36777 0
Refit piston cooling nozzle

Install piston cooling nozzle with the flattened side
(1) to the crankcase and tighten overpressure valve
hand-tight.
Note
Note installation direction of the piston cooling
nozzle.
36778 0
11/2003
0312 1090 - 0165
Page 1 of 4
Drive system
Work card
W 02-15-01
1015
Check injection position piston cooling nozzle

Insert testing device into cylinder liner and position
the bores (1) over the alignment bushes (2).
Note
Do not damage the cylinder liners when
inserting the testing device.
36779 0
Insert measuring pins with 8 mm (1) in both bores

(2) of the measuring device.
2
1
36780 0
The correct injection position is ensured when the tip

of the measuring pin (1) can be inserted into the opening in the piston cooling nozzle (2).
Note
Do not bend the piston cooling nozzle.
37186 0
Page 2 of 4
0312 1090 - 0165
11/2003
1015
Drive system
Work card
W 02-15-01
Tighten overpressure valve.

08081
Mount piston and connecting rod

36781 0
11/2003
0312 1090 - 0165
Page 3 of 4
Drive system
Work card
W 02-15-01
1015
Notes
Page 4 of 4
0312 1090 - 0165
11/2003
Crankcase
Work card
W 03-01-11
1015
Remove and refit crankcase breather (oil separator)
Tools
References
- Commercial tools
- W 07-03-01
Dismount crankcase breather

Remove fuel lines and injection lines on the B-side
Remove rubber sleeve (1).
Undo pipe clips (2 and 3).
3
2
Pull off rubber sleeve from turbocharger and breather pipe (4) from oil separator (5) and remove.
4
1
36982 0
Undo pipe clip (1) from oil separator (2).

Pull off oil separator from flange and remove.
36811 0
11/2003
0312 1091- 0165
Page 1 of 2
Crankcase
Work card
W 03-01-11
1015
Remount crankcase breather

1
Install oil separator (1) in flange (2) up to the stop.
36808 0
Mount rubber sleeve (2).

Plug breather pipe (1) onto oil separator and rubber
sleeve (2) onto turbocharger.
Tighten pipe clips (3 and 4).
3
1
4
2
36981 0
Position pipe clip (1) on oil separator and tighten.

Remount fuel lines and injection lines on the B-side
37088 0
Page 2 of 2
0312 1091- 0165
11/2003
Crankcase
Work card
W 03-03-01
1015
Tools
Note
- Commercial tools
Depth caliper gauge
Micrometer
Internal dial gauge
The cylinder liner is removed.
- Special tools
Dial gauge____________________100 400
Auxiliary aids
- Abrasive paste (freely available)
Check collar support for cylinder liner

Visually check collar support and sealing surface for
cylinder liner (arrows).
34700 1
Measure collar support (arrow) with depth caliper

gauge.
Note
Take measurements at several points of the
collar support on each cylinder.
03 35
34700 1
11/2003
0312 1092 - 0165
Page 1 of 4
Crankcase
Work card
W 03-03-01
1015
Note
- If the collar support is worn or damaged, there
is the option of having it repaired in one of our
service centres.
Shims (3) are available in sizes 1.0 mm and
1.5 mm.
If poor sealing is suspected or rust is
apparent on the collar support area of the
cylinder liners, gentle touching up is possible
with new or re-usable cylinder liners.
- Cylinder liner (1), crankcase (2).
1
3
2
37247 0
Polish collar support surface with abrasive paste.
34702 1
Install cylinder liner and polish by hand until a

contact pattern becomes apparent.
34703 1
Page 2 of 4
0312 1092 - 0165
11/2003
Crankcase
Work card
W 03-03-01
1015
Remove polished cylinder liner and direct towards
crankcase in accordance with the cylinder numbering.
Note
Clean cylinder liners and crankcase
thoroughly.
34704 1

36094 1
Note
Schematic for measuring the cylinder liner at
points "a" and "b" in the levels "1 - 4".
1
2
3
4
37238 0
11/2003
0312 1092 - 0165
Page 3 of 4
Crankcase
Work card
W 03-03-01
1015
Measure cylinder liner with internal dial gauge.

Insert internal dial gauge in the cylinder liner.
Note
points.
00000
03 31
03 32
34705 1
In the case of re-usable cylinder liners:

Visually check collar surfaces and measure the collar height in range "X" with an micrometer.
Note
- Take measurements at several points on the
collar support.
- Replace the cylinder liner if damaged or outside tolerances.
03 36
35230 1
Page 4 of 4
0312 1092 - 0165
11/2003
Crankcase
Work card
W 03-03-02
1015
Remove and refit cylinder liners
Tools
References
- Commercial tools
- W 02-09-03
- W 03-03-01
- Special tools
Press-in tool __________________150 120
Extracting tool _________________150 130
Auxiliary aids
- DEUTZ AP 1908
Remove cylinder liner

Dismount piston and connecting rod
1
3
Install extracting tool for cylinder liner.

Position tractor plate (1) underneath with the support
surfaces on the cylinder liner (2). Place retainer (3)
on the crankcase (4).
Note
- The counterweights of the crankshaft for
each respective cylinders must face
downwards.
- Take care of piston cooling nozzle.
4
2
Pull out cylinder liner with extracting tool.
36782 0
Remove both O-ring seals (1).

Visually check collar support and sealing surface for
cylinder liners
36783 0
11/2003
0312 1093 - 0165
Page 1 of 2
Crankcase
Work card
W 03-03-02
1015
Refit cylinder liner

Insert new O-ring seals cylinder-by-cylinder.
Note
Gently pull the O-ring seals apart to stop the
falling out during assembly.
Apply a thin coating of DEUTZ AP 1908 fitting agent
to the cylinder liner in area "X".
34932 1
Insert cylinder liner in crankcase.
Install press-in tool for cylinder liner.

Screw retainer bolt (1) into a threaded bore for the
cylinder head screw, place tractor plate (2) onto the
cylinder liner.
Note
Ensure that the tractor plate (2) is sitting
evenly.
Press cylinder liner in until it reaches the stop
Dismount press-in tool.
Mount piston and connecting rod
Page 2 of 2
36784 0
0312 1093 - 0165
11/2003
Crankcase
Work card
W 03-08-01
1015
Remove and refit accessory carrier
Tools
References
- Commercial tools
- W 02-02-04
- W 08-04-06
- W 09-07-08
- W 09-08-04
- W 12-01-04
- Special tools
Special appliance ______________170 050
Auxiliary aids
- DEUTZ DW 47

Remove thermostat housing
Remove screw (1) and undo cable tree retainer from
oil cooler hood.
Dismount vibration damper

Dismount coolant pump
37115 0
Turn and remove oil filter cartridge (1) with special

tool.
Note
Catch the residual oil and dispose of it
according to regulations.
Remove oil suction pipe
37064 0
11/2003
0312 1094 - 0165
Page 1 of 6
Crankcase
Work card
W 03-08-01
1015
Remove connecting elbow (1).

Undo screws (2), remove connecting elbow and
seal.
2
37065 0
Undo screws (1), remove accessory carrier and seal.
Caution !
!
Do not damage the crankshaft journals when

removing the accessory carrier.
1
1
1
1
1
1
1
1
1
11
37066 0
Remount accessory carrier

Force out shaft sealing ring (1).
Note
Do not damage the sealing surfaces.
Clean the sealing surfaces on the accessory carrier

and crankcase.
37067 0
Page 2 of 6
0312 1094 - 0165
11/2003
Crankcase
Work card
W 03-08-01
1015
Adhere new O-ring seal (arrows) with a little grease.
37068 0
Turn engine 180.
Note
The oil pan sealing surface on the crankcase
must face upwards, the accessory carrier must
be mounted in this position.
Ensure that the cylinder pins (arrows) are in position.
Adhere new seal with a little grease to the

crankcase.
37069 0
Install accessory carrier, centre over the cylinder

pins and fasten with screws (1).
Note
The teeth on the oil pump cog wheels and the
intermediate gear must grip into the gearing of
the crankshaft drive wheel.
37070 0
11/2003
0312 1094 - 0165
Page 3 of 6
Crankcase
Work card
W 03-08-01
1015
Screw in screws alternately.
Note

1
1
1
4
2
4
4
2
5
3
2
37206 0
Fasten accessory carrier.

Fasten down screws alternately.
03020
35002 1
Remount connecting elbow.

Clean the sealing surface on the suction elbow and
oil pressure pump.
Remount connecting elbow (1) with seal and fasten
screws (2).
Note
Note installation position.
08018
2
37071 0
Page 4 of 6
0312 1094 - 0165
11/2003
1015
Crankcase
Work card
W 03-08-01
Install oil suction pipe

Note
Before mounting the oil pan, fill the separating
points between crankcase/accessory carrier
(arrows) and oil pan with DEUTZ DW47
sealing compound.
37245 0
Lightly oil sealing ring.

Turn and fasten oil filter cartridge (1).
Note
Powerful manual tightening.
08001
37064 0
Install coolant pump

Mount crankshaft sealing ring (flywheel side)
Install vibration damper
Install thermostat housing
11/2003
0312 1094 - 0165
Page 5 of 6
Crankcase
Work card
W 03-08-01
1015
Position cable tree retainer (1) on the oil cooler hood

and tighten screw.
13091
37072 0
Page 6 of 6
0312 1094 - 0165
11/2003
Crankcase
Work card
W 03-08-03
1015
Disassemble and assemble accessory carrier
Tools
References
- Commercial tools
- W 03-08-01
Auxiliary aids
DEUTZ DW 59
Disassemble accessory carrier

1
Dismount intermediate gear (1).
Undo screw (2), stop washer (3) and remove intermediate gear.
2
3
36998 0
Dismount lube oil line (1).

Undo banjo bolts (2) and remove lube oil line with
sealing rings.
36999 0
11/2003
0312 1095 - 0165
Page 1 of 10
Crankcase
Work card
W 03-08-03
1015
Dismount oil pressure pump (1).

Undo screws (2) from plug piece (3).
Undo screws (arrows) and remove oil pressure

pump.
37000 0
Extract plug piece (1).
37212 0
Dismount oil suction pump (1).

Undo screws (2) and remove oil suction pump.
1
2
37022 0
Page 2 of 10
0312 1095 - 0165
11/2003
Crankcase
Work card
W 03-08-03
1015
Undo threaded nozzle (1).
Undo screw plug (2).
37023 0
Dismount oil cooler hood (1).

Undo screws (2 and 3), remove oil cooler hood and
seal.
2
37213 0
Dismount oil cooler (1).

Undo screws (2), remove oil cooler and O-ring seals.
1
2
37025 0
11/2003
0312 1095 - 0165
Page 3 of 10
Crankcase
Work card
W 03-08-03
1015
Undo screw plugs (1).
1
Undo screws (arrows) and remove sealing cover (2).
37026 0
Assemble accessory carrier

Install sealing cover (1) with new O-ring seal (arrow)
and tighten screws.
Note
Apply DEUTZ DW 59 securing agent to
screws.
03087
37027 0
Tighten screw plug (1) with new CU sealing ring.

03021
Tighten screw plug (2) with new CU sealing ring.

03023
37246 0
Page 4 of 10
0312 1095 - 0165
11/2003
Crankcase
Work card
W 03-08-03
1015
Mount oil cooler.
Clean sealing surface on oil cooler.
Install new O-ring seals (1 and 2).
37028 0
Mount oil cooler (1) and tighten screws (2).

08051
37029 0
Mount oil cooler hood.

Clean sealing surface on oil cooler hood.
Mount oil cooler hood (1) with new seal and screw in
screws.
Note
- Note the installation position of seal and oil
cooler hood.
- Note different screw lengths:
Fasten screws alternately.
08050
37213 0
11/2003
0312 1095 - 0165
Page 5 of 10
Crankcase
Work card
W 03-08-03
1015
Tighten screw plug with new sealing ring.

03022
37030 0
Tighten threaded nozzle (1).
Note
The side with the short threaded part (2) is
screwed in on the accessory carrier side.
08002
37031 0
Install oil suction pump.

Ensure that the clamping bushes (arrows) are in
place.
37032 0
Page 6 of 10
0312 1095 - 0165
11/2003
Crankcase
Work card
W 03-08-03
1015
Mount oil suction pump (1) and tighten screws (2).
2
08020
1
2
37033 0
Install oil pressure pump.

Pull new O-ring seal (arrow) onto plug piece.
Install plug piece (1).
Note
Lightly oil O-ring seals.
37002 0

place.
37021 0
11/2003
0312 1095 - 0165
Page 7 of 10
Crankcase
Work card
W 03-08-03
1015
Install new O-ring seal.
34738 1
Install oil pressure pump (1) and screw in screws.
Note

Tighten screws (2).

08010
Tighten screws (3).
08011
37003 0
Mount lube oil line.

Install lube oil line (1) and tighten banjo bolts (2) with
new CU-sealing rings.
08012
2
37004 0
Page 8 of 10
0312 1095 - 0165
11/2003
Crankcase
Work card
W 03-08-03
1015
Mount intermediate gear.
Lightly oil bearing journal (1) and bearing bush (2).
Place intermediate gear (3) in bearing journal.
Note
The collar (arrow) of the intermediate gear
must face the accessory carrier.
2
1
37005 0
Screw in screw (1) with stop washer (2).
Note
The bevelled side (arrow) of the stop washer
must face upwards.
37006 0
Fasten intermediate gear.

Tighten screw.
04011
Refit accessory carrier

37007 0
11/2003
0312 1095 - 0165
Page 9 of 10
Crankcase
Work card
W 03-08-03
1015
Notes
Page 10 of 10
0312 1095 - 0165
11/2003
Crankcase
Work card
W 03-09-01
1015
Remove and refit rear cover (flywheel side)
Tools
References
- Commercial tools
- W 02-02-02
- W 03-09-04
- W 08-04-07
Auxiliary aids
- DEUTZ DW 59
Dismount rear cover (flywheel side)

Dismount oil pan
Undo screws (arrows), remove rear cover (1) and
seal.
37074 0
Refit rear cover (flywheel side)

Force out shaft sealing ring (1).
Note
- Do not damage sealing surface when forcing
out seal.
- Visually inspect rear cover and replace, if
necessary.
37207 0
11/2003
0312 1096 - 0165
Page 1 of 2
Crankcase
Work card
W 03-09-01
1015
Clean the sealing surfaces on the rear cover and

crankcase.
place.
34978 1
Mount rear cover with new seal, tighten screws with

new sealing rings.
1
Note
- Apply DEUTZ DW 59 securing agent to
screws (arrows).
03010
1
2
1
1
36786 0
Mount oil pan

Install new crankshaft sealing ring (flywheel side)
37248 0
Page 2 of 2
0312 1096 - 0165
11/2003
Crankcase
Work card
W 03-09-04
1015
Remove and refit adapter housing
Tools
References
- Commercial tools
Spring clamping wrench ___________ 9090
- W 06-01-06
- W 12-06-01
- Special tools
Auxiliary aids
- DEUTZ DW 59

Dismount exhaust pipes
Dismount rubber sleeve (1).

Undo pipe clips (2 and 3).
Pull off rubber sleeve from turbocharger and

breather pipe (4) from oil separator (5) and remove.
4
1
36982 0
Dismount oil pressure line (1).

Remove cable binder (2) and expose cable set.
1
5
Undo screw (3) and release retainer.

Undo cap nuts (4 and 5) and remove oil pressure
line.
3
2
11/2003
0312 1097 - 0165
36980 0
Page 1 of 6
Crankcase
Work card
W 03-09-04
1015
Undo pipe clip (1) for oil return pipe with a spring
clamping wrench.
36793 0
Undo screws (arrows) and remove turbocharger with

exhaust pipe elbow.
Dismount flywheel
36788 0
Pull off cable plug (1) from speed sensor (2).

Undo screw (3) and remove speed sensor.
36789 0
Page 2 of 6
0312 1097 - 0165
11/2003
1015
Crankcase
Work card
W 03-09-04
Undo screws (arrows) and remove adapter housing.
36794 0

Clean contact surfaces on adapter housing and
crankcase.
Apply DEUTZ DW 59 securing agent to the adapter
housing on the contact surface to the crankcase (arrow).
37073 0
Ensure that the cylinder pins (arrows) are in place.

Mount adapter housing and centre over the cylinder
pins.
36787 0
11/2003
0312 1097 - 0165
Page 3 of 6
Crankcase
Work card
W 03-09-04
1015
Apply DEUTZ DW 59 securing agent to the screws

and screw in.
Note
Tighten screws (1).
03081
Tighten screws (2).

03082
34984 1
Pull new O-ring seal (arrow) onto speed sensor.

Install speed sensor and tighten screw.
05011
Mount cable plug onto speed sensor.

Mount flywheel
36790 0
Install turbocharger with exhaust pipe elbow and

tighten screws (1).
Note
Install oil return pipe when mounting the turbocharger.
06010
1
1
37075 0
Page 4 of 6
0312 1097 - 0165
11/2003
Crankcase
Work card
W 03-09-04
1015
Position pipe clip (1) for oil return pipe with spring
clamping wrench.
36793 0
Install oil pressure line (1) and tighten cap nuts (4

and 5).
1
5
08042
Position retainer and tighten screw (3).

08045
Lay cable tree and fasten with cable binder (2).
3
2
Mount rubber sleeve.

36980 0
3
1
4
Mount exhaust pipes

2
36981 0
11/2003
0312 1097 - 0165
Page 5 of 6
Crankcase
Work card
W 03-09-04
1015
Notes
Page 6 of 6
0312 1097 - 0165
11/2003
Crankcase
Work card
W 03-11-01
1015
Remove, check and remount camshaft bearings
Tools
References
- Commercial tools
Micrometer
Internal dial gauge
- W 04-05-05
- Special toolse
Dial gauge____________________100 400
Assembly tool _________________143 830
Check camshaft bearing

Dismount camshaft
37249 0

Mount tracer pin in internal dial gauge for the
appropriate measuring range.
Mount dial gauge with approx. 1 mm pretension in
internal dial gauge.
34768 1
11/2003
0312 1098 - 0165
Page 1 of 6
Crankcase
Work card
W 03-11-01
1015
Note
Schematic for measuring the camshaft bearing
at points "a" and "b" in the levels "1" and "2".
37239 0
Measure camshaft bearing with internal dial gauge.

Insert internal dial gauge in the camshaft bearing.
Note
- See schematic representation for measuring
points.
- Replace the bearing if the limits of wear have
been reached.
00000
03 13
03 14
34710 1
Remove camshaft bearings

Insert spindle (1) with extractor bush (2) on the side
opposite the flywheel.
2
1
34711 1
Page 2 of 6
0312 1098 - 0165
11/2003
Crankcase
Work card
W 03-11-01
1015
Install counter-bearing (1) on the flywheel side.
1
34712 0
Install spacer sleeve (1) and ball bearing (2), screw

on nut.
34713 1
Pull off camshaft bearings one after the other, except

the bearing on the flywheel side.
34714 1
11/2003
0312 1098 - 0165
Page 3 of 6
Crankcase
Work card
W 03-11-01
1015
Install spindle with extractor bush on the flywheel

side.
Install counter-bearing (1) on the side opposite the
flywheel.
1
Install spacer sleeve and ball bearing, screw on nut.
Pull off crankshaft bearing on the flywheel side.
34716 1
Mount camshaft bearings

Position the flywheel side bearing.
Install the new bearing, with the two oil bores, on the
flywheel side so that the cut-out (1) faces the flywheel.
Note
- Ensure that the oil bores (2) in the bearing
and crankcase are aligned.
- The diagram shows the bearing already installed.
2
37179 0
Insert spindle with counter-bearing on the opposite

side to the flywheel.
Insert extractor bush into bearing and pull onto the
spindle.
34718 1
Page 4 of 6
0312 1098 - 0165
11/2003
Crankcase
Work card
W 03-11-01
1015
Schematic: Pull in dimension for the camshaft
bearing on the flywheel side.
34719 1
Install spacer sleeve and ball bearing, screw on nut.

Press camshaft bearing in flush in accordance with
the schematic representation.
Note
Ensure that the spindle does not damage the
camshaft bearings when applying the
assembly tool.
34720 1
Position the two central bearings.

Install the new bearing, with the three oil bores, on
the side opposite the flywheel so that the cut-out (1)
faces the flywheel.
Note
Ensure that the oil bores (2) in the bearing and
crankcase are aligned.
37180 0
11/2003
0312 1098 - 0165
Page 5 of 6
Crankcase
Work card
W 03-11-01
1015
Position the bearing on the side opposite the flywheel.

Install the new bearing, with the three oil bores, on
the side opposite the flywheel so that the cut-out (1)
faces the flywheel.
Note
- Ensure that the oil bores (2) in the bearing
and crankcase are aligned.
- The diagram shows the bearing already
installed.
37181 0
Insert extractor bush into the bearing.

Insert spindle with extractor bush on the flywheel
side.
34723 1
Install counter-bearing, spacer sleeve and ball bearing, screw on nut.

Pull in camshaft bearing.
Note
Ensure that the spindle does not damage the
camshaft bearings when applying the
assembly tool.
Mount camshaft
34714 1
Page 6 of 6
0312 1098 - 0165
11/2003
Engine control
Work card
W 04-02-02
1015
Remove and remount tappets, measure tappet bores
Tools
References
- Commercial tools
Micrometer
Internal dial gauge
- W 04-05-05
Remove tappets
Dismount camshaft
Remove tappets.
Visually check tappets for wear.
Note
Lay down parts in the order of assembly, note
the sequence of cylinders.
37198 0
Measure tappet bores

Slide the internal dial gauge between the test
surfaces of the micrometer and set to "0".
35825 1
11/2003
0312 1099 - 0165
Page 1 of 2
Engine control
Work card
W 04-02-02
1015
Measure tappet bore with internal dial gauge.

00000
03 23
03 24
Note
If the limit of wear has been reached, there is
the option of reworking and inserting a bushing
in one of our service centres.
34707 1
Install tappets
Lightly oil tappets and install.
Mount camshaft
37199 0
Page 2 of 2
0312 1099 - 0165
11/2003
Engine control
Work card
W 04-04-09
1015
Remove and remount wheel case cover
Tools
References
- Commercial tools
- W 06-06-04
Auxiliary aids
- DEUTZ DW 67
Dismount wheel case cover

2
Dismount turbocharger
Dismount heat screening sheet (1).
Undo screw (2) and nuts (3) and remove heat
screening sheet.
3
37146 0
Dismount sealing cover (1).

Undo screws (2) and remove sealing cover.
1
37147 0
11/2003
0312 1100 - 0165
Page 1 of 4
Engine control
Work card
W 04-04-09
1015
Remove cable binders (1).

Undo screws (arrows) and remove wheel case
cover.
Turn screw plug.
1
37148 0
Refit wheel case cover

Clean the sealing surfaces on wheel case cover and
crankcase.
Clean screw threads and threaded holes.
Undo screw plug.
Apply DEUTZ DW 67 sealing agent to wheel case
cover.
35075 1
Install wheel case cover and screw in screws.
Note
Note screw lengths:
- 1x screw M8 x 35 mm (1)
- 9x screw M8 x 45 mm
Align wheel case cover to crankcase (arrows).
Tighten screws.
04022
37149 0
Page 2 of 4
0312 1100 - 0165
11/2003
Engine control
Work card
W 04-04-09
1015
Tighten screw plug with new sealing ring.
35077 1
Mount sealing cover.

Pull new O-ring seal (arrow) onto sealing cover.
37150 0
Install sealing cover and tighten screws (1).

04020
Lay cable and fasten with cable binders (2).
2
37151 0
11/2003
0312 1100 - 0165
Page 3 of 4
Engine control
Work card
W 04-04-09
1015
Mount heat screening sheet.

Underlay with spacer rings (1), install heat screening
sheet (2), tighten nuts (3) and screw (4).
Tighten nuts (3).

12071
3
Tighten screw (4).
06030
Mount turbocharger
Page 4 of 4
37152 0
0312 1100 - 0165
11/2003
Engine control
Work card
W 04-05-05
1015
Remove and remount camshaft
Tools
References
- Commercial tools
Depth caliper gauge
- W 01-02-02
- W 02-04-01
- W 07-04-01
- Special tools
Retainer _____________________144 150
Assembly aid _________________144 160
Auxiliary aids
- DEUTZ DW 59
Dismount camshaft
Dismount crankshaft
Dismount injection pump
Remove rocker arm brackets
37250 0
Dismount camshaft gear wheel

Dismount locking bolt (1) for intermediate gears.
Undo screws (2) and press out locking bolt.
2
37076 0
11/2003
0312 1101 - 0165
Page 1 of 6
Engine control
Work card
W 04-05-05
1015
Remove catch cover (1).

Undo screws (arrows), remove catch cover and seal.
37140 0
Block camshaft gear wheel.

Insert retainer (1) in the teeth of the camshaft gear
wheel. Turn camshaft gear wheel in the A-side
direction and block with retainer on the crankcase.
Undo screw (2).

Remove retainer.
34921 1
Mount assembly aid onto camshaft gear wheel.

Position fork (1) over the bore (2) in the camshaft
gear wheel and insert bolt (3).
2
37077 0
Page 2 of 6
0312 1101 - 0165
11/2003
1015
Engine control
Work card
W 04-05-05
Undo screws and remove camshaft gear wheel with

assembly aid.
Note
Carefully press camshaft back to the stop.
37080 0
Press back all tappets.

Carefully pull camshaft out towards the flywheel
side.
34922 1
Remount camshaft
Lightly oil camshaft bearing sleeves and camshaft
journal.
Carefully refit camshaft.
Note
Align the alignment bore (1) in the camshaft towards the oil pan.
37079 0
11/2003
0312 1101 - 0165
Page 3 of 6
Engine control
Work card
W 04-05-05
1015
Mount camshaft gear wheel.

Mount assembly aid onto camshaft gear wheel.
Install camshaft gear wheel with assembly aid and
screw in screw.
37080 0
Bring camshaft towards camshaft gear wheel by

turning the screw (1).
Note
Ensure that the cylinder pin on the camshaft
gear wheel and the alignment bore in the
camshaft are aligned.
Remove assembly aid.
37081 0
Block camshaft gear wheel with retainer.

Tighten screw.
04001
Remove retainer.
34944 1
Page 4 of 6
0312 1101 - 0165
11/2003
Engine control
Work card
W 04-05-05
1015
Determine axial play of camshaft
Press camshaft back to the stop.
Measure set-back of camshaft with a depth caliper
gauge from the contact surface on the camshaft gear
wheel to the crankcase (arrows).
Note down measured value (dimension "a").
34945 1
Fit new seal to catch cover.

Measure the height of the flange with a depth caliper
gauge from the catch surface to the contact surface
(arrows).
Note down measured value (dimension "b").
Calculation:
Dimension "a" - dimension "b" = axial play
04 35
Note
Correct deviations with seals.
34946 1
04 37
Install catch cover.

Mount catch cover with new seal.
Apply DEUTZ DW 59 securing agent to screws (1)
and tighten with new sealing rings.
04002
37082 0
11/2003
0312 1101 - 0165
Page 5 of 6
Engine control
Work card
W 04-05-05
1015
Install locking bolt.

Pull new O-ring seal (arrow) onto locking bolt.
Lightly oil O-ring seals.
37083 0
Press locking bolt in up to the stop.
Note
Tighten screws.
04013
2
37084 0
Install crankshaft
Mount injection pump
Mount rocker arm brackets
Page 6 of 6
0312 1101 - 0165
11/2003
Engine control
Work card
W 04-05-06
1015
Check camshaft
Tools
References
- Commercial tools
Depth caliper gauge
- W 04-05-05
Check camshaft
Dismount camshaft
Visually check cam and bearing journals for wear,
renew camshaft, if necessary.
36812 0
Undo screws (1) and remove intermediate gear

wheel from camshaft gear wheel.
37251 0
11/2003
0312 1102 - 0165
Page 1 of 4
Engine control
Work card
W 04-05-06
1015
Visually check camshaft gear wheel and

intermediate gear wheel and renew, if necessary.
34820 1
Reassemble camshaft gear wheel and intermediate

gear wheel.
Note
The flat side of the intermediate gear wheel for
driving the injection pump must face outwards.
34821 1
Tighten screws.
04003
34822 1
Page 2 of 4
0312 1102 - 0165
11/2003
1015
Engine control
Work card
W 04-05-06
Ensure that the cylinder pin is in place, renew, if necessary.

Measure the projection of the cylinder pin with a
depth caliper gauge, correct the gap, if necessary.
04 39
Remount camshaft
34823 1
11/2003
0312 1102 - 0165
Page 3 of 4
Engine control
Work card
W 04-05-06
1015
Notes
Page 4 of 4
0312 1102 - 0165
11/2003
Speed control
Work card
W 05-07-01
1015
Remove and remount speed sensor
Tools
- Commercial tools
Dismount speed sensor

Remove cable plug (1) from speed sensor (2).
3
Undo screw (3) and remove speed sensor.
36789 0
Refit speed sensor

Pull new O-ring seal (arrow) onto speed sensor.
Install speed sensor and tighten screw.
05011
Plug cable plug onto speed sensor.
36790 0
11/2003
0312 1103 - 0165
Page 1 of 2
Speed control
Work card
W 05-07-01
1015
Notes
Page 2 of 2
0312 1103 - 0165
11/2003

1015
Work card
W 06-01-05
Remove and remount exhaust manifold
Tools
References
- Commercial tools
- W 06-01-06
Auxiliary aids
- DEUTZ S1
Dismount exhaust manifold on A-side

Undo screw (arrows), remove exhaust manifold (1)
and seals.
36957 0
Dismount exhaust manifold on B-side

Undo screw (arrows), remove exhaust manifold (1)
and seals.
36958 0
11/2003
0312 1104 - 0165
Page 1 of 2

1015
Work card
W 06-01-05
Refit exhaust manifold on A-side
Clean sealing surfaces on the exhaust manifold and
the cylinder heads.
Install exhaust manifold with new seals and tighten
screws.
Note
- Apply DEUTZ S1 assembly aid to screws.
- Note installation position of seals.
- Tighten exhaust manifold alternately from the
centre outwards.
06001
36959 0
Refit exhaust manifold on B-side

Clean sealing surfaces on the exhaust manifold and
the cylinder heads.
Install exhaust manifold with new seals and tighten
screws.
note
- Apply DEUTZ S1 assembly aid to screws.
- Note installation position of seals.
- Tighten exhaust manifold alternately from the
centre outwards.
06001
36963 0
Remount exhaust pipes

Page 2 of 2
0312 1104 - 0165
11/2003

1015
Work card
W 06-01-06
Remove and remount exhaust pipes
Tools
- Commercial tools
Auxiliary aids
- DEUTZ S1
Dismount exhaust pipe on A-side

Unscrew nuts (1), remove screws and release exhaust pipe flange from exhaust manifold.
Undo screws (2) and release exhaust pipe flange

from exhaust pipe elbow.
Remove clamped sealing rings.
Remove exhaust pipe (3).
37214 0
Dismount exhaust pipe on B-side

Unscrew nuts (1), remove screws and release exhaust pipe flange from exhaust manifold.
Undo screws (2) and release exhaust pipe flange

from exhaust pipe elbow.
Remove clamped sealing rings.
Remove exhaust pipe (3).
37215 0
11/2003
0312 1105 - 0165
Page 1 of 4

1015
Work card
W 06-01-06
Refit exhaust pipe on A-side
2
Position exhaust pipe (1), install exhaust pipe flange
(2) with clamped sealing ring on exhaust pipe elbow.
Note
- Note the installation position of the exhaust
pipe.
- The cone (arrow) of the clamped sealing ring
must face the exhaust pipe.
Apply DEUTZ S1 assembly aid to screws (3) and
screw in.
Install exhaust pipe flange (1) with clamped sealing

ring on exhaust manifold.
36795 0
Note
The cone (arrow) of the clamped sealing ring
Apply DEUTZ S1 assembly aid to screws (2), insert
and screw on nuts (3).
36796 0
Fix exhaust pipe to exhaust pipe elbow.

Tighten screws (1) evenly.
06003
Note
Ensure even spacing (2) for the flange connection.
37216 0
Page 2 of 4
0312 1105 - 0165
11/2003

1015
Work card
W 06-01-06
Fix exhaust pipe to exhaust manifold.
Tighten nuts (1) evenly.
06002
Note
37217 0
Refit exhaust pipe on B-side

Position exhaust pipe (1), install exhaust pipe flange
(2) with clamped sealing ring on exhaust pipe elbow.
Note
- Note the installation position of the exhaust

pipe.
- The cone (arrow) of the clamped sealing ring
Apply DEUTZ S1 assembly aid to screws (3) and
screw in.
3
36799 0
Install exhaust pipe flange (1) with clamped sealing

ring on exhaust manifold.
Note
The cone (arrow) of the clamped sealing ring
Apply DEUTZ S1 assembly aid to screws (2), insert
and screw on nuts (3).
3
36800 0
11/2003
0312 1105 - 0165
Page 3 of 4

1015
Work card
W 06-01-06
Fix exhaust pipe to exhaust pipe elbow.
Tighten screws (1) evenly.
06003
Note
37218 0
Fix exhaust pipe to exhaust manifold.

06002
Note
2
1
37219 0
Page 4 of 4
0312 1105 - 0165
11/2003

1015
Work card
W 06-01-07
Remove and remount exhaust pipe elbow
Tools
References
- Commercial tools
- W 06-01-06
- W 06-06-04
Dismount exhaust pipe elbow

Undo screws (1) and remove exhaust

pipe elbow (2).
37220 0
Refit exhaust pipe elbow

Install exhaust pipe elbow (1) and tighten screws (2).
06010
Remount exhaust pipes

Remount turbochargern
37221 0
11/2003
0312 1106 - 0165
Page 1 of 2

1015
Work card
W 06-01-07
Notes
Page 2 of 2
0312 1106 - 0165
11/2003

1015
Work card
W 06-02-05
Tools
- Commercial tools
Dismount connecting line

Undo nuts (arrows), remove connecting line (1) and
seals.
37011 0
Refit connecting line

Clean sealing surfaces on connecting line and air
suction pipes.
Install connecting line with new seals and tighten
nuts.
06033
37020 0
11/2003
0312 1107 - 0165
of 1 of 2

1015
Work card
W 06-02-05
Notes
Page 2 of 2
0312 1107 - 0165
11/2003

1015
Work card
W 06-06-04
Tools
- Commercial tools
Auxiliary aids
- DEUTZ S1
Release pipe clips (2 and 3).
4
1
36982 0

Remove cable binders (2) and expose cable tree.
1
5
Undo screws (3) and release retainer.

Unscrew cap nuts (4 and 5) and remove oil pressure
line.
3
2
11/2003
0312 1108 - 0165
36980 0
Page 1 of 6

1015
Work card
W 06-06-04
Release pipe clip (1) for oil return pipe with spring
clamping wrench.
36793 0
Undo screws (1) and remove turbocharger (2).
1
1
36979 0
Dismount oil return line (1).

Undo screws (2), remove oil return line and seal.
36974 0
Page 2 of 6
0312 1108 - 0165
11/2003

1015
Work card
W 06-06-04
Remove line flange (1).
Undo screws (2), remove line flange and seal.
36975 0
Check turbocharger for damage and replace, if necessary.
36976 0
Remount turbocharger
Refit line flange (1).
Clean sealing surfaces on line flange and turbocharger.
Install line flange with new seal and tighten screws.
Note
The line connection (2) must face the charging
air outlet (3).
2
08041
3
36977 0
11/2003
0312 1108 - 0165
Page 3 of 6

1015
Work card
W 06-06-04
Refit oil return line (1).
Clean sealing surfaces on oil return line and turbocharger.
Install oil return line with new seal and tighten
screws.
Note
The oil return line must face the exhaust
side (2).
08044
2
36978 0
Clean sealing surfaces on turbocharger and exhaust

pipe elbow.
2
Install turbocharger (2), apply DEUTZ S1 assembly
aid to screws (1) and tighten.
Note
Plug on the oil return pipe whilst installing the
turbocharger.
1
06020
36979 0
Position pipe clip (1) for oil return pipe with spring
clamping wrench.
36793 0
Page 4 of 6
0312 1108 - 0165
11/2003

1015
Work card
W 06-06-04
Install oil pressure line (1) and tighten cap
nuts (4 and 5).
1
5
08042
Position retainer and tighten screw (3)

08045
Lay cable tree and fasten with cable binders (2).
3
2
Remount rubber sleeve.

Fasten pipe clips (3 and 4).
36980 0
3
1
4
2
36981 0
11/2003
0312 1108 - 0165
Page 5 of 6

1015
Work card
W 06-06-04
Notes
Page 6 of 6
0312 1108 - 0165
11/2003

1015
Work card
W 06-06-05
Measure turbocharger bearing play
Tools
References
- Commecial tools
Feeler lever gauge
- W 06-06-04
- Special tools
Dial gauge____________________100 400
Note
- Turbocharger type S 400;
Compressor wheel 96 mm, turbine wheel 87
mm.
- The work card describes how to measure the
bearing play of the turbocharger rotor both
when fitted and when disassembled.
Measure axial play of turbocharger rotor when

disassembled
Note
The bearing housing of the turbocharger is removed.
Clamp the turbocharger bearing housing on the flange of the compressor side (arrow) in a vice.
Note
Do not damage the flange when clamping it in
the vice; use aluminium jaws.
37008 0
Mount magnetic measuring stand and insert dial

gauge.
Apply tracer pin under pretension to the flat surface
of the turbine wheel hub (1).
Note
Position dial gauge parallel to the shaft.
Press the shaft to the stop in the direction of the arrow and adjust dial gauge to "0".
37009 0
11/2003
0312 1109 - 0165
Page 1 of 6

1015
Work card
W 06-06-05
Measure axial play
Move the shaft to the stop in the direction of the arrow.
Note
- Ensure that the shaft is not twisted in radial direction.
- The complete path of the shaft must be taken
into account.
Read off measured value and note it down.
Repeat the measuring process to check the results.
06 27
37119 0
Measure radial play of turbocharger rotor when

disassembled
Compressor side:
Apply tracer pin under pretension to a side face of
the hex nut (1).
Press the shaft downwards to the stop in the direction of the arrow and adjust dial gauge to "0".
Note
Position the dial gauge vertically to the shaft.
37135 0
Measure radial play

Raise the shaft to the stop in the direction of the arrow.
Note
account.
06 21
37136 0
Page 2 of 6
0312 1109 - 0165
11/2003

1015
Work card
W 06-06-05
Turbine side:
Apply tracer pin under pretension to the rounded
area of the turbine wheel hub (1).
Press the turbine wheel hub downwards to the stop
and adjust dial gauge to "0".
37137 0
Measure radial play

Raise the turbine wheel hub to the stop in the direction of the arrow.
Note
account.
06 22
37120 0
Remove magnetic measuring stand and dial gauge
Measure axial play of turbocharger rotor when

fitted
Clamp turbocharger on flange for exhaust pipe elbow (arrow) in a vice.
Note
Do not damage the flange when clamping it in;
use aluminium jaws.
37253 0
11/2003
0312 1109 - 0165
Page 3 of 6

1015
Work card
W 06-06-05
Install magnetic measuring stand and insert dial gauge.
Apply tracer pin under pretension to the flat surface
of the turbine wheel hub (1).
Note
Position dial gauge parallel to the shaft.
Press shaft downwards to the stop towards the compressor side and adjust dial gauge to "0".
37254 0
Measure axial play

Move shaft upwards to the stop in the direction of the
arrow.
Note
- The complete path of the shaft must be taken
into account.
- The diagram shows the turbocharger bearing
housing when disassembled.
37255 0
06 27
Measure radial play of turbocharger rotor when

fitted
Turbine side:
Install feeler lever gauge on magnetic measuring
stand.
Insert feeler lever in the bore of the turbine wheel
hub (1).
Press turbine wheel to the stop in the direction of the

arrow and adjust feeler lever gauge to "0".
37257 0
Page 4 of 6
0312 1109 - 0165
11/2003

1015
Work card
W 06-06-05
Measure radial play
Press the turbine wheel hub to the stop in the direction of the arrow.
Note
account.
06 22
37258 0
Compressor side:
Place feeler lever on a side face of the hex nut (1).
Press the shaft to the stop in the direction of the arrow and adjust the feeler lever gauge to "0".
37256 0
Measure radial play

Press the shaft to the stop in the direction of the arrow.
Note
account.
06 21
37259 0
11/2003
0312 1109 - 0165
Page 5 of 6

1015
Work card
W 06-06-05
Remove magnetic measuring stand and feeler lever
gauge.
Unclamp turbocharger from the vice.
Page 6 of 6
0312 1109 - 0165
11/2003

1015
Work card
W 06-07-03
Tools
References
- Commercial tools
- W 07-03-01
Dismount connecting line

Unscrew nuts (arrows), remove connecting line (1)
and seals.
Dismount injection lines
37011 0
Remove air suction pipe on A-side

4
Undo cap nuts (1) and remove pipe (2).

Unscrew nut (3), undo screw (4) and remove
holder (5).
2
37078 0
11/2003
0312 1110 - 0165
Page 1 of 6

1015
Work card
W 06-07-03
Undo screws (1), remove air suction pipe (2) and
seals.
1
2
1
37087 0
Remove crankcase breather

Pull off rubber sleeve from turbocharger and

breather pipe (4) from oil separator (5) and remove.
4
1
36982 0
Release pipe clip (1) from oil separator (2).

Pull oil separator off from flange and remove.
Note
Seal opening.
36811 0
Page 2 of 6
0312 1110 - 0165
11/2003

1015
Work card
W 06-07-03
Remove air suction pipe on B-side
Undo screws (1), remove air suction pipe (2) and
seals.
1
2
1
37086 0
Remount air suction pipe on A-side

Clean sealing surfaces on air suction pipe (1) and on
the cylinder heads.
2
1
Install air suction pipe with new seals and screw in

screws.
Note
- Note the installation position of the seals.
Screws M8 x 65 mm (3) with cable tree holder (arrows).
3
37210 0
Insert spacer disc (1), holder (2) and washer (3),

screw on nut (4) and screw (5).
Tighten screws on air suction pipe
06030
4
Tighten nut (4).
06037
37085 0
11/2003
0312 1110 - 0165
Page 3 of 6

1015
Work card
W 06-07-03
Install pipe (1) and screw on cap nuts (2).
12080
36807 0
Remount air suction pipe on B-side

Clean sealing surfaces on air suction pipe (1) and on
the cylinder heads.
Install air suction pipe (1) with new seals, screw in
screws.
2
1
Note
- Note the installation position of the seals.
Screws M8 x 65 mm (3) with cable set holder
(arrows)
- Fit screw (4) at the same time as the air suction pipe.
4
3
36803 0
Fasten air suction pipe (2).

Tighten screws (1).
06030
1
37086 0
Page 4 of 6
0312 1110 - 0165
11/2003

1015
Work card
W 06-07-03
Remount crankcase breather
1
Install oil separator (1) up to the stop on the

flange (2).
36808 0
Refit rubber sleeve.

3
1
4
2
36981 0
Position pipe clip (1) on oil separator and tighten.

Refit injection lines
37088 0
11/2003
0312 1110 - 0165
Page 5 of 6

1015
Work card
W 06-07-03
Clean sealing surfaces on connecting line and air
suction pipes.
Fit connecting line with new seals and tighten nuts.
06033
37020 0
Page 6 of 6
0312 1110 - 0165
11/2003
Fuel system
Work card
W 07-03-01
1015
Tools
References
- Commercial tools
Claw wrench size 17______________ 8018
- W 07-10-06
Note
- A high degree of cleanliness is required when
working on the injection equipment.
- Small cracks can result if the injection lines
are bent which can reduce their service life.
Do not bend injection lines!
Caution !
!
Observe the safety regulations and any

country-specific rules for handling fuels.
Dismount injection lines on A-side

Dismount fuel lines
Undo screws (2), remove cylinder head cover and
seal.
2
1
36814 0
Remove cable binders (arrows) and separate cable

tree from injection line.
Undo screws (1) and release shackles from suction
pipe.
Undo screws (2) from pipe clips.
36815 0
11/2003
0312 1111 - 0165
Page 1 of 6
Fuel system
Work card
W 07-03-01
1015
Unscrew cap nuts (1) from injection valves and injection pump with a claw wrench.
Remove injection lines.
Note
Seal the openings in the injection valves and
the injection pump.
36816 0
Dismount injection lines on B-side

Remove cable binders (1) and separate cable tree
from injection line.
Undo screws (2) and release shackles from suction
pipe.
Undo screws (arrows) from pipe clips.
36818 0
Unscrew cap nuts (1) from injection valves and

injection pump with a claw wrench.
Remove injection lines.
Note
Seal the openings in the injection valves and

the injection pump.
1
37089 0
Page 2 of 6
0312 1111 - 0165
11/2003
Fuel system
Work card
W 07-03-01
1015
Refit injection lines on A-side
Install new injection lines on the injection pump and
the injection valves and screw on cap nuts.
Note
Mount injection lines without tension.
36821 0
Position rubber seal (1).
Note
The rubber seal must lay against the upper
stay (arrow) of the cylinder head hood.
37090 0
Screw cap nuts onto the injection lines on the injection pump and injection valves.
07003
36822 0
11/2003
0312 1111 - 0165
Page 3 of 6
Fuel system
Work card
W 07-03-01
1015
Position shackles on the air suction pipe and tighten

screws (1).
2
07005
Position pipe clips and tighten screws (2).
1
07006
Lay cable tree and fit cable binders (arrows).
36815 0
Refit injection lines on B-side

Install injection lines on the injection pump and the
injection valves and screw on cap nuts.
Note
Mount injection lines without tension.
36824 0
Position rubber seal (1).
Note
The rubber seal must lay against the upper
stay (arrow) of the cylinder head hood.
Screw cap nuts onto the injection lines on the injection pump and injection valves.
07003
37090 0
Page 4 of 6
0312 1111 - 0165
11/2003
Fuel system
Work card
W 07-03-01
1015
Position shackles on air suction pipe and tighten
screws (1).
07005
Position pipe clips and tighten screws (arrows).

07006
2
1
Lay cable set and fit cable binders (2).
36825 0
Remount cylinder head cover.

Clean the sealing surfaces on cylinder head cover
and cylinder head hood.
Place a new seal for the cylinder head cover with the
flattened side (1) over the rubber seal (2).
36826 0
Note
The rubber seal (1) may not lay on the sealing

surface (2) of the cylinder head cover.
36827 0
11/2003
0312 1111 - 0165
Page 5 of 6
Fuel system
Work card
W 07-03-01
1015

Tighten screws (2).
01005
Remount fuel lines

2
1
36814 0
Page 6 of 6
0312 1111 - 0165
11/2003
Fuel system
Work card
W 07-04-01
1015
Remove and remount injection pump
Tools
References
- Commercial Tools
- W 04-04-09
- W 07-03-01
- W 07-08-01
- Special tools
Dial gauge____________________100 400
Measuring template ____________110 150
Gauge pin ____________________110 180
Auxiliary aids
- DEUTZ DW 74
Dismount injection pump

Dismount wheel case cover

Dismount crankcase breather.
Release pipe clip (1) from oil separator (2).
Pull oil separator off from the flange and remove.
Note
Seal opening.
36811 0
Dismount solenoid valve (LDA)

Remove cable binders (arrows), unplug cable plug
(1) and expose cable tree.
Unscrew cap nut (2), release oil return line (3) from
the injection pump and pull out of the nozzle.
2
37154 0
11/2003
0312 1112 - 0165
Page 1 of 12
Fuel system
Work card
W 07-04-01
1015
Set cylinder no. A1 to ignition TDC

2
Install engine racing fixture.

37127 0
Install engine racing fixture (1), insert centring

bolt (2) in the top threaded hole (3).
2
1
37155 0
Tighten screw (1).
Note
The teeth of the engine racing fixture must intermesh in the gearing of the starter ring gear.
34659 1
Page 2 of 12
0312 1112 - 0165
11/2003
1015
Fuel system
Work card
W 07-04-01
Race engine until valve crossover point is reached,

cylinder no. B2.
Note
01 63
36819 0
At the valve crossover point cylinder no. B2, the

latching pin of the engine racing fixture must have
latched into the starter ring gear (arrow).
36745 0
Undo screws (1) and remove injection pump.
1
37157 0
11/2003
0312 1112 - 0165
Page 3 of 12
Fuel system
Work card
W 07-04-01
1015
Remount injection pump

Visually check sealing ring (arrow).
Note
Renew sealing ring, if necessary.
35039 1
Undo screws (1) on injection pump gear wheel.
37158 0
Turn the drive flange until the trace bores on the

drive flange (1) and on the injection pump (2) are aligned.
Insert gauge pin (3) in the trace bores.
1
37159 0
Page 4 of 12
0312 1112 - 0165
11/2003
Fuel system
Work card
W 07-04-01
1015
Install new O-ring seal (arrow).
35040 1
Install injection pump with screws, retaining plate

and spherical discs.
Note
Use new screws.
37160 0
Align injection pump with measuring template (1).
37161 0
11/2003
0312 1112 - 0165
Page 5 of 12
Fuel system
Work card
W 07-04-01
1015
Screw in injection pump screws (arrows) evenly.

Monitor the position of the injection pump with the
measuring template.
Tighten screws.
07012
Monitor the position of the injection pump again with

the measuring template.
Remove gauge pin.
37162 0
Monitor rotary flank clearance of injection

pump gear wheel
Make a mark (arrow) on the cam shaft gear wheel.
37163 0
Install magnetic measuring stand and insert dial gauge.

Turn injection pump gear wheel, after one side, to
the stop (arrow).
Apply tracer pin under pretension to the tooth flank
37164 0
Page 6 of 12
0312 1112 - 0165
11/2003
1015
Fuel system
Work card
W 07-04-01
Measure rotary flank clearance by moving the injection pump gear wheel from stop to stop (arrow).
Note
Repeat the measuring process at several tooth
flanks, thereby turning the cam shaft gear
wheel at least once.
07 20
Remove magnetic measuring stand and dial gauge.
37165 0
Select injection pump gear wheel in case of deviations from the admissible rotary flank clearance.
Example:
An injection pump gear wheel is installed with the designation "0".
The designation and part number is marked on the
injection pump gear wheel at point "X".
There are 3 injection pump gear wheels available
with the designation "+", "0" or "-".
If the admissible rotary flank clearance is undershot,
mount gear wheel with the designation "-".
If the admissible rotary flank clearance is overshot,
mount gear wheel with the designation "+".
35050 1
Check commencement of delivery with gauge

pin
Set cylinder no. A1 to ignition TDC again with the engine racing fixture.
Remove engine racing fixture.
Set degree scale to "0" (arrow).
Note
Use an axle spacing of 269.2 mm for the commencement of delivery setting (black scale).
37176 0
11/2003
0312 1112 - 0165
Page 7 of 12
Fuel system
Work card
W 07-04-01
1015
Note
Do not adjust the degree scale anymore.
1
Pull the latch pin (1) and turn the engine using the
engine racing fixture 30 against the engine's direction of turn (arrow).
Note
30 on the black, outer measuring scale (2) of
the engine racing fixture.
37167 0
Set engine to commencement of delivery using the

engine racing fixture in the engine's direction of turn
(arrow).
Note
- The commencement of delivery is stated on
the company plate.
Example: 15 before ignition TDC on the
black, outer measuring scale (1) of the engine
racing fixture.
37177 0
Note
- The commencement of delivery is set properly if the gauge pin can be inserted easily.
- The commencement of delivery must be corrected in case of a deviation.
1
37168 0
Page 8 of 12
0312 1112 - 0165
11/2003
Fuel system
Work card
W 07-04-01
1015
Correct commencement of delivery
Turn the camshaft of the injection pump until the trace bores on the drive flange (1) and on the injection
pump (2) are aligned.
1
2
Note
Turn camshaft on the nut.
3
Insert gauge pin (3) in trace bores.
37169 0
Remove gauge pin.

Tighten screws on the injection pump gear wheel.
Note
- Counter with nuts.
07011
37170 0

Clean the sealing surfaces on sealing cover and
crankcase.
Install sealing cover with a new seal and tighten
screws.
03085
Note
In the case of oil-proof and water-tight versions.
sealing compound.
37134 0
11/2003
0312 1112 - 0165
Page 9 of 12
Fuel system
Work card
W 07-04-01
1015
Pull new O-ring seals (arrow) onto oil return line.
37171 0
Install oil return line (1) in nozzle and on injection

pump, tighten cap nut (2).
08061
37172 0
Connect cable plug (1), lay cable tree and fasten with
cable binders (arrow).
37173 0
Page 10 of 12
0312 1112 - 0165
11/2003
Fuel system
Work card
W 07-04-01
1015
Remount wheel case cover.
Install oil separator (1) up to the stop in the
flange (2).
Remount wheel case cover

Remount solenoid valve (LDA).
36808 0
Position pipe clip (1) on oil separator and fasten.

03060
Install injection lines

37088 0
11/2003
0312 1112 - 0165
Page 11 of 12
Fuel system
Work card
W 07-04-01
1015
Notes
Page 12 of 12
0312 1112 - 0165
11/2003
Fuel system
Work card
W 07-06-04
1015
Check and adjust commencement of delivery, with gauge pin

Tools
References
- Commercial tools
- W 06-06-04
- Special tools
gauge pin ____________________110 180
Auxiliary aids
- DEUTZ DW74
Note
The wheel case cover has been removed in
some pictures to provide a clearer view.
Check commencement of delivery with gauge

pin
Set cylinder no. A1 to ignition TDC.
Dismount cylinder head cover (1) from cylinder
no B2.
Undo screws (2), remove cylinder head cover
and seal.
01 63
37174 0
Install engine racing fixture.

37127 0
11/2003
0312 1113 - 0165
Page 1 of 8
Fuel system
Work card
W 07-06-04
1015
Install engine racing fixture (1), insert centring

bolt (2) in the top threaded hole (3).
2
1
37155 0
Tighten screw (1).
Note
The teeth of the engine racing fixture must intermesh in the gearing of the starter ring gear.
34659 1
Race engine until valve crossover point is reached,

cylinder no. B2.
Note
01 63
36819 0
Page 2 of 8
0312 1113 - 0165
11/2003
Fuel system
Work card
W 07-06-04
1015
At the valve crossover point cylinder no. B2, the
latching pin of the engine racing fixture must have
latched into the starter ring gear (arrow).
Note
Diagram shows engine without devices fitted.
36745 0
Dismount sealing cover (1).
Undo screws (2) and remove sealing cover.
37175 0
Monitor commencement of delivery.

Remove engine racing fixture.
Set degree scale to "0" (arrow).
Note
Use an axle spacing of 269.2 mm for the commencement of delivery setting (black scale).
37176 0
11/2003
0312 1113 - 0165
Page 3 of 8
Fuel system
Work card
W 07-06-04
1015
Note
Do not adjust the degree scale anymore.
1
Pull the latch pin (1) and turn the engine using the
engine racing fixture 30 against the engine's direction of turn (arrow).
Note
30 on the black, outer measuring scale (2) of
the engine racing fixture.
37167 0
Set engine to commencement of delivery using the

engine racing fixture in the engine's direction of turn
(arrow).
Note
- The commencement of delivery is stated on
the company plate.
Example: 15 before ignition TDC on the
black, outer measuring scale (1) of the engine
racing fixture.
37177 0
Note
- The commencement of delivery is set properly if the gauge pin can be inserted easily.
- The commencement of delivery must be corrected in case of a deviation.
1
37168 0
Page 4 of 8
0312 1113 - 0165
11/2003
Fuel system
Work card
W 07-06-04
1015
Correct commencement of delivery
Undo screws (1) on injection pump gear wheel.
37158 0
Set cylinder no. A1 to ignition TDC with the engine

racing fixture, if necessary.
Pull the latch pin and set engine to the commencement of delivery stated on the company plate again,
e.g. 15, before ignition TDC using the engine racing
fixture.
Turn the camshaft of the injection pump, on the nut,
until the trace bores on the drive flange (1) and on
the injection pump (2) are aligned.
1
2
Insert gauge pin (3) in trace bores.
37169 0
Remove gauge pin.

Tighten screws (1) on injection pump gear wheel.
Note
- Counter with nuts.
07011
37170 0
11/2003
0312 1113 - 0165
Page 5 of 8
Fuel system
Work card
W 07-06-04
1015

Clean the sealing surfaces on sealing cover and
crankcase.
Install sealing cover with a new seal and tighten
screws.
03085
Note
In the case of oil-proof and water-tight versions.
sealing compound.
37134 0
Install sealing cover.

Pull new O-ring seal (arrow) onto sealing cover.
37150 0
Install sealing cover (1) and tighten screws (2).

04020
37175 0
Page 6 of 8
0312 1113 - 0165
11/2003
Fuel system
Work card
W 07-06-04
1015
Remount cylinder head cover.

Clean sealing surfaces on cylinder head cover and
cylinder head hood.
Place new seal for cylinder head cover with the flattened side (1) over rubber seal (2).
36826 0
Note
The rubber seal (1) may not lay on the sealing

surface (2) of the cylinder head cover.
36827 0

Tighten screws (2).
01005
37174 0
11/2003
0312 1113 - 0165
Page 7 of 8
Fuel system
Work card
W 07-06-04
1015
Notes
Page 8 of 8
0312 1113 - 0165
11/2003
Fuel system
Work card
W 07-07-01
1015
Remove and remount injection valves
Tools
References
- Commercial tools
- W 07-03-01
- Special tools
Grooved nut spanner ___________110 130
Extractor _____________________110 030
Extracting device ______________150 800
Auxiliary aids
- DEUTZ S1
Note
- A high level of cleanliness is required when
working on injection equipment.
Dismount injection valve

Screw off cap nut using a grooved nut spanner (1).
37091 0
Pull out injection valve (1) and sealing ring (arrow).
37092 0
11/2003
0312 1114 - 0165
Page 1 of 4
Fuel system
Work card
W 07-07-01
1015
If an injection valve is tight, remove with extracting

device.
Place extractor (1) on the injection valve and tighten

cap nut (2).
Screw threaded rod (3) of the extracting device into
the extractor (1) and tighten counter nut (4).
1
37093 0
If an injection valve is tight, pull out with extracting

device.
37094 0
Remount injection valve

Apply DEUTZ S1 assembly aid to the nozzle holder
in area "X", thread of the cap nut (arrow), and the
contact surface of the sealing ring.
Install new sealing ring on injection valve.
36829 0
Page 2 of 4
0312 1114 - 0165
11/2003
Fuel system
Work card
W 07-07-01
1015
Insert injection valve with the ball (1) in the cut-out
(2) in the cylinder head.
37095 0
Tighten cap nut.

07001
Remount injection lines

1
37096 0
11/2003
0312 1114 - 0165
Page 3 of 4
Fuel system
Work card
W 07-07-01
1015
Notes
Page 4 of 4
0312 1114 - 0165
11/2003
Fuel system
Work card
W 07-07-05
1015
Check and adjust injection valves
Tools
Caution !
- Commercial tools
Long socket for wrench size 19 _____ 8017
Nozzle tester____________________ 8008
- Special tools
Retainer _____________________110 110
Note
A high level of cleanliness is required when
working on injection equipment. Only use pure
testing oil to ISO 4113 or clean diesel fuel to
check injection valves.
After actuating the hand lever three or four

times, the spring chamber above the
nozzle needle in the injection valve fills
with leak fuel/test oil. It is then not possible
to actuate the hand lever.
Undo the nozzle tensioning nut carefully
before performing each test in order to release the pressure from the spring chamber.
References
- W 07-07-01
Adjust injection valve

Insert injection valve in the retainer and undo the
nozzle tensioning nut approx. 180 (to release pressure) with a long socket for wrench and then retighten.
07002
36271 1
Caution
!
Keep hands away from the fuel jet. The fuel penetrates deeply into the skin and may cause
blood poisoning.
Mount the injection valve on the nozzle tester.
35889 1
11/2003
0312 1115 - 0165
Page 1 of 6
Fuel system
Work card
W 07-07-05
1015
Checking the opening pressure

With the pressure gauge switched on, slowly press
down the lever of the nozzle tester. The pressure at
which the indicator stops, or suddenly drops, is the
opening pressure.
07 52
Note
After actuating the hand lever on the nozzle tester 3 or 4 times, the pressure builds up again
in the spring chamber. Undo the nozzle tensioning nut again and retighten before repeating the test.
36293 1
07002
If the values measured in 3 tests are the same, these

can then be regarded as valid.
36293 1
Adjust injection valve

Remove injection valve from nozzle tester.
Insert injection valve into the retainer and screw off
the nozzle tensioning nut, disassemble all parts.
36270 1
Page 2 of 6
0312 1115 - 0165
11/2003
Fuel system
Work card
W 07-07-05
1015
Sequence of part assembly
- 1 Shim
- 2 Compression pin
- 3 Thrust pin
- 4 Adapter
- 5 Injection nozzle
- 6 Nozzle tensioning nut
36269 1
Note
A thicker shim increases the opening pressure.
Reassemble injection valve. Tighten nozzle tensioning nut with the appropriate torque.
07002
Re-check injection valve on the nozzle tester.
36274 1
Check for tightness

Dry the nozzle and nozzle retainer - blow dry with air.
Press down hand lever of the tester slowly until the
opening pressure is about 20 bar below that previously read off.
36293 1
11/2003
0312 1115 - 0165
Page 3 of 6
Fuel system
Work card
W 07-07-05
1015
Note
The injection nozzle is tight if there is no dripping within a 10 second period.
36294 1
If a drop does fall, dismantle the injection valve and

clean it to remedy the leak. If this is not successful,
the injection nozzle must be renewed.
Note
Rework is not admissible.
36295 1
Buzzing test and spray pattern check

Switch off the tester's pressure gauge.
Note
The buzzing test permits an audible check to
be made into whether the nozzle needle moves easily in the nozzle body. New injection
valves emit a different buzzing sound compared to used ones.
Deterioration sets in due to wear around the
needle seat. If an injection nozzle does not
buzz despite cleaning, it must then be replaced
with a new one. A clear buzz should be audible
from a used injection valve when the hand lever is actuated rapidly, while exhibiting a well
atomised spray pattern. The spray pattern may
differ noticeably from that of a new injection
valve.
36296 1
Page 4 of 6
0312 1115 - 0165
11/2003
1015
Fuel system
Work card
W 07-07-05
Refit injection valves

11/2003
0312 1115 - 0165
Page 5 of 6
Fuel system
Work card
W 07-07-05
1015
Notes
Page 6 of 6
0312 1115 - 0165
11/2003
Fuel system
Work card
W 07-08-01
1015
Remove and remount solenoid valve (LDA)
Tools
- Commercial tools
Dismount solenoid valve

Unscrew cap nuts (arrows) and remove pipe (1).
1
36990 0
Unscrew cap nut (arrow) and release pipe (1).

Undo screw (2) and release pipe retainer.
36996 0
11/2003
0312 1116 - 0165
Page 1 of 4
Fuel system
Work card
W 07-08-01
1015
Undo screws (arrows) and remove solenoid valve

with retainer (1).
36991 0
Undo screws (arrows) and remove solenoid valve (1)

from the retainer.
36992 0
Undo cap nuts (arrows) and remove pipes (1 and 2).
2
36993 0
Page 2 of 4
0312 1116 - 0165
11/2003
Fuel system
Work card
W 07-08-01
1015
Refit solenoid valve
Refit pipes (1 and 2) and tighten cap nuts (arrows).
Note
Note the allocation and installation position of
the pipes.
1
12080
2
36993 0
Mount solenoid valve (1) on retainer and tighten

screws (arrow).
1
07092
36994 0
Install solenoid valve (1) with retainer and tighten

screws.
07093
36995 0
11/2003
0312 1116 - 0165
Page 3 of 4
Fuel system
Work card
W 07-08-01
1015
Install pipe (1) and tighten cap nut (arrow).

12080
Position pipe retainer and tighten screw (2).
12095
36996 0
Insert pipe (1) and tighten cap nuts.

12080
36997 0
Page 4 of 4
0312 1116 - 0165
11/2003
Fuel system
Work card
W 07-10-06
1015
Tools
- Commercial tools
Caution !
!
Observe the safety regulations and

any country-specific rules for handling fuels.
Dismount fuel lines

Undo screws (1) and remove clamp halves (2).
1
2
36830 0
Unscrew cap nut (1) and remove fuel line (A).
Unscrew cap nut (2) and remove fuel line (B).

Unscrew cap nut (3) and remove fuel line (C).
Remove cable binders (arrow) and separate cable
tree from fuel line (D).
Unscrew cap nut (4) and remove fuel line (D).
1
2
36831 0
11/2003
0312 1117 - 0165
Page 1 of 4
Fuel system
Work card
W 07-10-06
1015
Refit fuel lines

Insert clamp halves (1) with retainers (2) and fix with
screws.
2
36832 0
Insert fuel line (D) and tighten cap nut (4).
07016
Lay cable tree and fasten cable binders (arrow).
07016
Install fuel line (C) and tighten cap nut (3).

12081
1
2
36831 0
Install fuel line (B) and tighten cap nut (2).
12081
Install fuel line (A) and tighten cap nut (1).
12081
1
2
36831 0
Page 2 of 4
0312 1117 - 0165
11/2003
1015
Fuel system
Work card
W 07-10-06
Align fuel lines in clamp halves (1) and tighten

screws (2).
12095
36833 0
11/2003
0312 1117 - 0165
Page 3 of 4
Fuel system
Work card
W 07-10-06
1015
Notes
Page 4 of 4
0312 1117 - 0165
11/2003
Lube oil system

Work card
W 08-04-06
1015
Remove and remount oil suction nozzle / oil suction pipe

Tools
References
- Commercial tools
- W 08-04-07
Dismount oil suction nozzle / oil suction pipe

2
Remove oil pan

Remove connecting elbow (1) with oil suction
pipe (2).
Undo screws (3) and release connecting elbow.
37061 0
Loosen screw (1) and undo screws (2 and 3).

seals.
3
1
2
36776 0
11/2003
0312 1118 - 0165
Page 1 of 4
Lube oil system

Work card
W 08-04-06
1015
Undo screws (1), remove oil suction nozzle (2) and

seal.
37097 0
Refit oil suction nozzle / oil suction pipe

Clean the sealing surfaces on oil suction nozzle and
oil suction pump.
Install oil suction nozzle with seal and tighten
screws (1).
Note
1
Note the installation position.
08015
37098 0

Slide new O-ring seal (3) onto oil suction pipe.
Clean sealing surfaces on oil suction pipe and suction elbow.

Insert oil suction pipe in connecting elbow.
Note
36774 0
Page 2 of 4
0312 1118 - 0165
11/2003
Lube oil system

Work card
W 08-04-06
1015
pumps.
Note
Ensure that no foreign bodies penetrate the oil
suction pumps through the openings.
2
1
36775 0

Note

37105 0
Fasten oil suction pipe without tension.

Tighten screws (1).
08015
1
2
Tighten screw (2).

08016
Tighten screw (3).
08017
Tighten screw (4).

08018
36746 0
11/2003
0312 1118 - 0165
Page 3 of 4
Lube oil system

Work card
W 08-04-06
1015
Refit oil pan

37252 0
Page 4 of 4
0312 1118 - 0165
11/2003
Lube oil system

Work card
W 08-04-07
1015
Tools
- Commercial tools
Auxiliary aids
- DEUTZ DW 47
- DEUTZ AP 1908
Dismount oil pan

Note
Catch engine oil and dispose of according to
regulations.
1
37099 0
Remove both flange nozzles (1).

Undo screws (2), remove flange half (3) and flange
nozzles.
37100 0
11/2003
0312 1119 - 0165
Page 1 of 6
Lube oil system

Work card
W 08-04-07
1015
Remove connecting flange (1).

Undo screws (2) and remove connecting flange.
Unscrew cap nut (3) and remove with ball (4).
2
4
2
37101 0
Undo all screws (arrow) and release oil pan.
37102 0
Pull oil pan off the socket pieces (1) in the direction
of the arrow and remove.
Remove seal.
37103 0
Page 2 of 6
0312 1119 - 0165
11/2003
1015
Lube oil system

Work card
W 08-04-07
Refit oil pan

Clean sealing surfaces on oil pan and crankcase..
Pull socket pieces (1) out of the connecting elbows.
Apply DEUTZ AP 1908 assembly aid to new O-ring
seals (arrows) and pull onto socket pieces.
Insert socket piece into connecting elbow.
37104 0
Apply DEUTZ DW 47 sealing compound in the gaps

(arrows).
36747 0
Place seal (arrow) on crankcase.
Note
The light coloured side of the seal must face
the crankcase.
37106 0
11/2003
0312 1119 - 0165
Page 3 of 6
Lube oil system

Work card
W 08-04-07
1015
Slide oil pan onto socket pieces (1) and align with
crankcase.
Note
Do not shift the seal when installing the oil pan.
37107 0
Screw in screws alternately and tighten.

03030
37108 0
Install ball (1) on the threaded nozzle and tighten cap

nut (2).
03033
36748 0
Page 4 of 6
0312 1119 - 0165
11/2003
Lube oil system

Work card
W 08-04-07
1015
Refit connecting flange.
Adhere new O-ring seals (arrows) with a little grease.
37110 0
Install connecting flange (1) and tighten screws (2).
Note
2
The designations "IN" and "EX" on the connecting flange and the oil pan must be aligned.
03035
IN
EX
1
2
37111 0
Install flange nozzles.

Adhere new O-ring seals (arrows) with a little grease.
37112 0
11/2003
0312 1119 - 0165
Page 5 of 6
Lube oil system

Work card
W 08-04-07
1015
Install both flange nozzles.

Install flange half (1), screw in screws (2) and insert
flange nozzles (3) into flange half.
Install second flange half (4) and screw in screws (5).
4
5
37113 0
Tighten screws.
03034
Fill with prescribed engine oil.
37114 0
Page 6 of 6
0312 1119 - 0165
11/2003
Lube oil system

Work card
W 08-04-08
1015
Tools
References
- Commercial tools
- W 08-04-07
- Special tools
Dial gauge____________________100 400
Dismount oil suction pump

2
Remove oil pan

Remove connecting elbow (1) with oil suction
pipe (2).
Undo screws (3) and release connecting elbow.
37061 0
Loosen screw (1) and undo screws (2 and 3).

seals.
3
1
2
36776 0
11/2003
0312 1120 - 0165
Page 1 of 6
Lube oil system

Work card
W 08-04-08
1015
Undo screws (1), remove oil suction pump (2) and

compensation plate (arrow).
1
37141 0
Refit oil suction pump

Install compensation plate (1).
Note
The broad sides (2) must face the flywheel.
37142 0
Install oil suction pump and screw in screws (1).
Note
Align oil suction pump axle-parallel to crankshaft (2).

Tighten screws.
08030
37143 0
Page 2 of 6
0312 1120 - 0165
11/2003
1015
Lube oil system

Work card
W 08-04-08
Check tooth flank play on oil suction pump

intermediate gear
Note
- The adjustment range for the tooth flank play
depends on the position of the engine.
- The measuring process described involves
an engine turned through 180.
Mount magnetic measuring stand and insert dial
gauge.
Turn intermediate gear, after one side, to the stop
(arrow).
Apply tracer pin under pretension to the tooth flanks
37144 0
Measure tooth flank play by moving the intermediate

gear from stop to stop (arrow).
Note
Repeat the measuring process on several
tooth flanks, thereby turning the crankshaft
gear wheel.
08 35
Remove magnetic measuring stand and dial gauge.
37145 0
Compensate any tooth flank play by deploying compensation plates of a suitable thickness.
There are three compensation plates available in the
following thickness.
0.1 mm
0.2 mm
0.3 mm
Repeat measuring process after making the adjustment.
11/2003
0312 1120 - 0165
Page 3 of 6
Lube oil system

Work card
W 08-04-08
1015

Slide new O-ring seal (3) onto oil suction pipe.
Clean sealing surfaces on oil suction pipe and suction elbow.

Insert oil suction pipe in connecting elbow.
Note
36774 0

pumps.
Note
Ensure that no foreign bodies penetrate the oil
suction pumps through the openings.
2
1
36775 0

Note

37105 0
Page 4 of 6
0312 1120 - 0165
11/2003
Lube oil system

Work card
W 08-04-08
1015
Fasten oil suction pipe without tension.
Tighten screws (1).
08015
1
2
Tighten screw (2).

08016
Tighten screw (3).
08017
Tighten screw (4).

08018
36746 0
Refit oil pan

37252 0
11/2003
0312 1120 - 0165
Page 5 of 6
Lube oil system

Work card
W 08-04-08
1015
Notes
Page 6 of 6
0312 1120 - 0165
11/2003
Lube oil system

Work card
W 08-08-02
1015
Remove and remount oil cooler
Tools
References
- Commercial tools
- W 09-08-04
Dismount oil cooler

Dismount thermostat housing
- see working card W 09-08-04.
Dismount oil cooler hood (1).
Undo screw (2) and release cable set holder from oil
cooler hood.
Undo screws (arrows), remove oil cooler hood and

seal.
36805 0
Undo screws (1), remove oil cooler (2) and O-ring

seals.
37116 0
11/2003
0312 1121 - 0165
Page 1 of 4
Lube oil system

Work card
W 08-08-02
1015
Remount oil cooler

Clean the sealing surfaces on oil cooler and front cover.
Fit new O-ring seals (1 and 2).
37117 0
Install oil cooler and tighten screws.

08051
34013 1
Refit oil cooler hood.

Clean the sealing surface on oil cooler hood.
Install hood of oil cooler (1) with new seal and screw
in screws.
Note
Tighten screws alternately.
1
3
3
2
08050
36806 0
Page 2 of 4
0312 1121 - 0165
11/2003
Lube oil system

Work card
W 08-08-02
1015
Position cable set holder on hood of oil cooler and
tighten screw (1).
13091
Refit thermostat housing

36810 0
11/2003
0312 1121 - 0165
Page 3 of 4
Lube oil system

Work card
W 08-08-02
1015
Notes
Page 4 of 4
0312 1121 - 0165
11/2003
1015
Lube oil system

Work card
W 08-10-06
Remove and remount oil filter cartridge

Tools
- Commercial tools
- Special tools
Special fixture _________________170 050
Dismount oil filter cartridge

Undo oil filter cartridge with special fixture (arrow).
Note
Catch residual oil and dispose of according to
regulations.
37189 0
Refit oil filter cartridge

Lightly oil sealing ring.
Screw oil filter cartridge in tight.
Note
Powerful manual tightening.
08001
37190 0
11/2003
0312 1122 - 0165
Page 1 of 2
Lube oil system

Work card
W 08-10-06
1015
Notes
Page 2 of 2
0312 1122 - 0165
11/2003
Lube oil system

Work card
W 08-11-08
1015
Tools
- Commercial tools
Dismount oil pressure switch

Disconnect cable plug (1) from oil pressur
switch (2).
2
37187 0
Unscrew oil pressure switch (arrow).
36744 0
11/2003
0312 1123 - 0165
Page 1 of 2
Lube oil system

Work card
W 08-11-08
1015
Insert oil pressure switch and screw up tight.
Note
Ensure that the sealing ring is in position.
08091
37188 0
Plug cable plug (1) onto oil pressure switch (2).
2
37187 0
Page 2 of 2
0312 1123 - 0165
11/2003
Lube oil system

Work card
W 08-11-09
1015
Tools
- Commercial tools
- Special tools
Special wrench _______________ 170 100
Dismount oil pressure transmitter

4
1
36982 0
Disconnect cable plug (1) from oil pressure transmitter (2).
37182 0
11/2003
0312 1124 - 0165
Page 1 of 4
Lube oil system

Work card
W 08-11-09
1015

Undo screw (2) and release cable tree holder.
37183 0
Unscrew oil pressure transmitter (1) with special

wrench.
37184 0
Refit oil pressure transmitter

Screw oil pressure transmitter (1) in tight with special
wrench.
08091
37184 0
Page 2 of 4
0312 1124 - 0165
11/2003
Lube oil system

Work card
W 08-11-09
1015
Position cable tree holder and tighten screw (1).
04022
37185 0
Connect cable plug (1) to oil pressure transmitter (2).
37182 0

Fit breather pipe (1) to oil separator and rubber
sleeve (2) to turbocharger.
3
1
4
2
36981 0
11/2003
0312 1124 - 0165
Page 3 of 4
Lube oil system

Work card
W 08-11-09
1015
Notes
Page 4 of 4
0312 1124 - 0165
11/2003
1015
Lube oil system

Work card
W 08-11-10
Remove and remount pressure control valve

Tools
- Commercial tools
Caliper gauge
Dismount pressure control valve

Unscrew eyelet bolt (1).
37229 0
Undo screw plug (1) and remove sealing ring.
37230 0
11/2003
0312 1125 - 0165
Page 1 of 4
Lube oil system

Work card
W 08-11-10
1015
Unscrew valve housing (1) and remove sealing ring.
Note
Do not twist adjusting bolt (2).
2
1
37231 0
Note
If the same oil pressure needs to be set again,
measure the distance "x" before disassembly.
Screw out adjusting bolt (1), remove compression
spring and valve piston.
Visually check individual parts for damage.
37232 0
Refit pressure control valve

Insert valve piston (1) and compression spring (2),
screw in adjusting bolt (3).
Note
If the same oil pressure needs to be set again,
reset the distance "X" noted before disassembly.
37233 0
Page 2 of 4
0312 1125 - 0165
11/2003
1015
Lube oil system

Work card
W 08-11-10
Note
Table for basic settings when using new parts.
08 63
35022 1
Screw in valve housing (1) tight with new sealing

ring.
Note
1
Do not twist adjusting bolt (2).
03051
37234 0
Tighten screw plug (1) with new sealing ring.

08071
37235 0
11/2003
0312 1125 - 0165
Page 3 of 4
Lube oil system

Work card
W 08-11-10
1015
Tighten eyelet bolt (1).
37229 0
Page 4 of 4
0312 1125 - 0165
11/2003
Lube oil system

Work card
W 08-15-01
1015
Remove and refit oil pressure line (turbocharger)
Tools
- Commercial tools
Dismount oil pressure line

4
1
36982 0

1
5
Undo screw (3) and release holder.

Unscrew cap nuts (4 and 5) and remove oil pressure
line.
3
2
11/2003
0312 1126 - 0165
36980 0
Page 1 of 2
Lube oil system

Work card
W 08-15-01
1015
Remount oil pressure line
1
5
Install oil pressure line (1) and tighten cap

nuts (4 and 5).
08042
Position holder and tighten screw (3).
08045
3
2

36980 0
3
1
4
2
36981 0
Page 2 of 2
0312 1126 - 0165
11/2003
Lube oil system

Work card
W 08-15-02
1015
Remove and remount oil return line (turbocharger)
Tools
- Commercial tools
Dismount oil return line

Undo screws (1) and separate oil return line (2) from
turbocharger.
37191 0
Undo screws (1), separate oil return line from sealing

cover (2) and remove together with seal.
2
37192 0
11/2003
0312 1127 - 0165
Page 1 of 4
Lube oil system

Work card
W 08-15-02
1015
Release pipe clips (1) and pull oil return pipe (2) out
of hose (3).
37193 0
Refit oil return line

1
Clean the sealing surfaces on the oil return pipes,
the turbocharger and the sealing cover.
Insert oil return pipe (1) with pipe clips (2) in the
hose (3).
Note
Do not fasten pipe clips.
3
2
37194 0
Install oil return line (1) with new seal onto sealing
cover (2) and screw in screws (3).
1
2
3
3
37195 0
Page 2 of 4
0312 1127 - 0165
11/2003
1015
Lube oil system

Work card
W 08-15-02
Install oil return line (1) with new seal onto turbocharger and screw in screws (2).
37196 0
Fasten oil return line to sealing cover.

Tighten screws.
08044
Fasten oil return line to turbocharger.

Tighten screws.
08040
Position pipe clips (arrows).
37197 0
11/2003
0312 1127 - 0165
Page 3 of 4
Lube oil system

Work card
W 08-15-02
1015
Notes
Page 4 of 4
0312 1127 - 0165
11/2003
Cooling system
Work card
W 09-07-08
1015
Remove and remount coolant pump
Tools
- Commercial tools
Auxiliary aids
- DEUTZ AP 1908
Dismount coolant pump

3
Dismount coolant supply line (1).
Undo screws (2 and 3), remove coolant supply line
and seal.
2
36791 0
Undo screws (arrows).
36823 0
11/2003
0312 1128 - 0165
Page 1 of 4
Cooling system
Work card
W 09-07-08
1015
Press coolant pump out of accessory carrier using

3 forcing screws (arrows).
36813 0
Remount coolant pump

Undo forcing screws from coolant pump.
Clean the sealing surfaces on coolant pump and

front cover.
Remove O-ring seals (1 and 2) from coolant pump.
36828 0
Install coolant pump so that cog wheel (1) on the

coolant pump intermeshes with the intermediate
gear (2).
Withdraw coolant pump again.
Note
Keep the cog wheel on the coolant pump in its
present position.
37121 0
Page 2 of 4
0312 1128 - 0165
11/2003
Cooling system
Work card
W 09-07-08
1015
Apply DEUTZ AP 1908 assembly aid to new O-ring
seals and slide on.
Note
Note different diameters of O-ring seals:

Position (1) 75 x 3 mm
Position (2) 80 x 3 mm
36828 0
Install seal.
Note
- Screw 3 pin screws (1) into the accessory
carrier to fix the seal.
- Ensure free passage in drainage bores (arrows).
1
35005 1
Install coolant pump and screw in screws alternately

(arrows).
1
Undo pin screws (1).
37122 0
11/2003
0312 1128 - 0165
Page 3 of 4
Cooling system
Work card
W 09-07-08
1015
Screw in screws (arrows).

Tighten all screws alternately.
09010
37123 0
Refit coolant supply line.

Clean the sealing surfaces on coolant supply line
and coolant pump.
Install coolant supply line with new seal and screw in

screws.
Note

2
37118 0
Tighten screws in coolant supply line.

09011
36792 0
Page 4 of 4
0312 1128 - 0165
11/2003
Cooling system
Work card
W 09-08-01
1015
Check coolant thermostat, when disassembled
Tools
Caution !
!
- Commercial tools
Thermometer
Injury hazard!
From hot water and thermostat.
References
- W 09-08-02
Check coolant thermostat

Dismount coolant thermostats
Measure dimension "a" on the thermostat between
the start and the end of the stroke.
00000
09 11
09 12
34679 1
Warm thermostat in a tub of water.
Note
In order to determine the exact start of opening, measure the temperature as close to the
thermostats as possible, although without actually touching these.
Stir the water continuously to distribute the
temperature evenly. The temperature should
not be allowed to rise by more than 1C/min,
otherwise the start of opening will be delayed
accordingly.
34680 1
11/2003
0312 1129 - 0165
Page 1 of 2
Cooling system
Work card
W 09-08-01
1015
Measure dimension "b" on the thermostat.
Note
Path of stroke at stipulated temperature (T2)
min. 8 mm.
Refit coolant thermostats
34679 1
Page 2 of 2
0312 1129 - 0165
11/2003
Cooling system
Work card
W 09-08-02
1015
Remove and remount coolant thermostats
Tools
- Commercial tools
Auxiliary aids
- DEUTZ AP 1908
Dismount coolant thermostats

Dismount connecting line (1).
Unscrew nuts (arrows), remove connecting line and
seals.
37011 0
Undo screws (1 and 2) and dismount coolant outlet

nozzle (3).
3
2
37139 0
11/2003
0312 1130 - 0165
Page 1 of 4
Cooling system
Work card
W 09-08-02
1015
Remove thermostats (1).
37125 0
Refit coolant thermostats

Apply DEUTZ AP 1908 assembly aid to new sealing
rings (arrows) and install.
37126 0
Install thermostats.
Note
The venting slot must face upwards
(12 O'clock position) for both thermostats
(arrows).
35018 1
Page 2 of 4
0312 1130 - 0165
11/2003
Cooling system
Work card
W 09-08-02
1015
Install coolant outlet nozzle and screw in screws.
Note

Tighten screws.
09002
3
2
37139 0
Refit connecting line.

Clean the sealing surfaces on connecting line and air
suction pipes.
Refit connecting line with new seals and tighten nuts.
06033
37020 0
11/2003
0312 1130 - 0165
Page 3 of 4
Cooling system
Work card
W 09-08-02
1015
Notes
Page 4 of 4
0312 1130 - 0165
11/2003
Cooling system
Work card
W 09-08-04
1015
Remove and remount coolant thermostat housing
Tools
- Commercial tools
Dismount coolant thermostat housing

Dismount connecting line (1).
Unscrew nuts (arrows), remove connecting line and
seals.
37011 0
Undo banjo bolts (1) and remove profile hose (2).
1
2
37012 0
11/2003
0312 1131 - 0165
Page 1 of 6
Cooling system
Work card
W 09-08-04
1015
Dismount solenoid valve (LDA) (1).
Unscrew cap nuts (arrows) and remove pipe (2).
2
37013 0
Unscrew nut (arrow) and release pipe (1).

Undo screws (2) and release pipe retainer.
37017 0
Undo screws (arrows) and remove solenoid valve

with retainer (1).
36991 0
Page 2 of 6
0312 1131 - 0165
11/2003
Cooling system
Work card
W 09-08-04
1015
Disconnect cable plug (1) from temperature transmitter (2).
2
1
37014 0
Undo screws (arrows), remove coolant thermostat

housing (1) and seal.
37015 0
Refit coolant thermostat housing.

Clean the sealing surfaces on coolant thermostat
housing and crankcase.
Fit coolant thermostat housing with new seal and

screw in screws.
Note
- Install mass cable and retainer (arrows) at the
same time.
- Note cable tree arrangement.
2
37222 0
11/2003
0312 1131 - 0165
Page 3 of 6
Cooling system
Work card
W 09-08-04
1015
Fasten coolant thermostat housing (1).

Tighten screws (arrows).
09001
37015 0
Plug cable plug (1) onto temperature transmitter (2).
2
1
37014 0
Fit solenoid valve (LDA) (1).

Fit solenoid valve with retainer and tighten screws.
07093
37016 0
Page 4 of 6
0312 1131 - 0165
11/2003
Cooling system
Work card
W 09-08-04
1015
Fit pipe (1) and tighten nut (arrow).
12080
2
Position pipe retainer and tighten screw (2).
12095
37017 0
Install pipe (1) and tighten nuts.

12080
1
37018 0
Fit profile hose (1) and tighten banjo bolts (2) with
new sealing rings.
09006
2
1
37019 0
11/2003
0312 1131 - 0165
Page 5 of 6
Cooling system
Work card
W 09-08-04
1015

Clean the sealing surfaces on connecting line and air
suction pipes.
Refit connecting line with new seals and tighten nuts.
06033
37020 0
Page 6 of 6
0312 1131 - 0165
11/2003
Cooling system
Work card
W 09-12-01
1015
Remove and remount coolant temperature transmitter
Tools
- Commercial tools
Dismount coolant temperature transmitter

Disconnect cable set plug (1) from coolant temperature transmitter (2).
37200 0
Unscrew coolant temperature transmitter (arrow).
37201 0
11/2003
0312 1132 - 0165
Page 1 of 2
Cooling system
Work card
W 09-12-01
1015
Screw coolant temperature transmitter in tight with

new CU sealing ring.
09031
37202 0
Plug cable plug (1) onto coolant temperature

transmitter (2).
37200 0
Page 2 of 2
0312 1132 - 0165
11/2003
1015
Other components
Work card
W 12-01-04
Remove and remount vibration damper

Tools
- Commercial tools
- Special tools
Auxiliary aids
- DEUTZ DW 74
Dismount V-belt pulley

2
37127 0
Block flywheel.
Turn the crankshaft until a balancing bore (1) becomes visible on the flywheel.
Insert a suitably-sized round bar into the balancing

bore of the flywheel (2).
36834 0
11/2003
0312 1133 - 0165
Page 1 of 4
Other components
Work card
W 12-01-04
1015
Undo screws (arrows) and remove vibration

damper (1).
37128 0
Dismount V-belt pulley

Undo all screws (arrow) and remove V-belt pulley (1)
from vibration damper.
37129 0
Remove flange hub (1) from rotary vibration

damper (2).
37130 0
Page 2 of 4
0312 1133 - 0165
11/2003
Other components
Work card
W 12-01-04
1015
Remount vibration damper
Visually check V-belt pulley, flange hub and vibration
damper for damage.
Install flange hub (1) on vibration damper (2).
Install V-belt pulley (3) on vibration damper.
1
2
3
37131 0
Fasten V-belt pulley.

Tighten screws alternately.
Note
Do not twist the flange hub in the vibration
damper.
12031
37132 0
Visually check crankshaft flange for damage (arrow).
37133 0
11/2003
0312 1133 - 0165
Page 3 of 4
Other components
Work card
W 12-01-04
1015
Install vibration damper (1) and tighten screws (arrow) alternately.
12030
Remove round bar.
37128 0

screws.
03085
Note
In the case of oil-tight and waterproof models.
Install sealing cover with DEUTZ DW 74
sealing compound.
37134 0
Page 4 of 4
0312 1133 - 0165
11/2003
1015
Other components
Work card
W 12-06-01

Tools
- Commercial tools
- Special tools
Guide mandrel (self-made)
Dismount flywheel
2
37127 0
Turn the crankshaft until a balancing bore (1) becomes visible on the flywheel.
2
Insert a suitably-sized round bar into the balancing
bore of the flywheel (2).
36834 0
11/2003
0312 1134 - 0165
Page 1 of 4
Other components
Work card
W 12-06-01
1015
Loosen screws.
Remove round bar.
Undo all screws (arrow) and remove flywheel.
Visually check flywheel and starter ring gear.
37138 0
Remount flywheel
Ensure that the alignment bolt (arrow) is in position.
36804 0
Fit flywheel using a self-manufactured guide mandrel.
Note
Ensure that the alignment bolt on the crankshaft flange and the alignment bore on the flywheel are aligned.
34985 1
Page 2 of 4
0312 1134 - 0165
11/2003
1015
Other components
Work card
W 12-06-01
Insert a suitably-sized round bar.

Fasten flywheel with angular tightening wrench.
Note
Use new screws.
12001
Remove round bar.
34986 1

screws.
03085
Note
In the case of oil-tight and waterproof models.
Install sealing cover with DEUTZ DW 74
sealing compound.
37134 0
11/2003
0312 1134 - 0165
Page 3 of 4
Other components
Work card
W 12-06-01
1015
Notes
Page 4 of 4
0312 1134 - 0165
11/2003
Other components
Work card
W 12-06-03
1015
Renew starter ring gear on flywheel
Tools
Caution !
!
- Commercial tools
Injury hazard!
From hot components.
References
- W 12-06-01
Dismount starter ring gear

Dismount flywheel
Make an exact marking in the middle of the tooth indent and on the flywheel (arrow).
34762 1
Lightly drill starter ring gear.
Note
Do not damage flywheel.
34763 1
11/2003
0312 1135 - 0165
Page 1 of 4
Other components
Work card
W 12-06-03
1015
Remove starter ring gear with an appropriate tool.
34764 1
Clean flywheel and visually check support collar (arrow).
34765 1
Remount starter ring gear

Mark new starter ring gear at exactly the same point
(arrow).
34766 1
Page 2 of 4
0312 1135 - 0165
11/2003
1015
Other components
Work card
W 12-06-03
Heat starter ring gear to max. 220 C. Install starter

ring gear and move on collar to the stop.
Note
The markings made on the flywheel and starter
ring gear must be aligned.
Remount flywheel
34767 1
11/2003
0312 1135 - 0165
Page 3 of 4
Other components
Work card
W 12-06-03
1015
Notes
Page 4 of 4
0312 1135 - 0165
11/2003
1015
Electrical system
Work card
W 13-03-02

Tools
- Commercial tools
Dismount starter
Unscrew connection cable from starter, if applicable.
Unscrew nuts (arrows) and remove starter.
37228 0
Install starter and tighten nuts (arrows).

13001
Fasten connection cable, if applicable.
37228 0
11/2003
0312 1136 - 0165
Page 1 of 2
Electrical system
Work card
W 13-03-02
1015
Notes
Page 2 of 2
0312 1136 - 0165
11/2003
1015
7 Commercial
Tools
Commercial tools
Please send all tool orders directly to
WILBR
Wilhelm Bcker GmbH & Co. KG
P.O. Box 14 05 80
D-42826 Remscheid
Fax 02191 / 8 10 92
11/2003
0312 1137 - 0165
Page 1 of 6
7 Commercial
Tools
1015
Notes
Page 2 of 6
0312 1137 - 0165
11/2003
1015
7 Commercial
Tools
Line reference
Compressive pressure tester

8005
35410 1
Nozzle tester
Check injection nozzles
8008
35411 1
Strengthened socket wrench

inset size 14
8015
37503 0
11/2003
0312 1137 - 0165
Page 3 of 6
7 Commercial
Tools
1015
Line reference
Strengthened socket wrench

inset size 17
8016
37504 0
Long socket wrench inset

size 19
For cap nuts on injection valves
8017
37505 0
Claw wrench size 17

For injection lines
8018
37506 0
Page 4 of 6
0312 1137 - 0165
11/2003
1015
7 Commercial
Tools
Line reference
Valve sealing ring wrench
8024
37509 0
Measuring device
Check V-belt tension
20 - 70 kg (30 - 160 lbs.)
8115
35416 1
Measuring device
Check V-belt tension
50 - 150 kg (100 - 310 lbs.)
8120
37510 0
11/2003
0312 1137 - 0165
Page 5 of 6
7 Commercial
Tools
1015
Line reference
Valve spring assembly lever l
9017
37511 0
Spring clamping wrench

Tighten spring clamps
9090
35420 1
Page 6 of 6
0312 1137 - 0165
11/2003
1015
8 Special
Tools
Special tools
Please direct all tools orders directly to
WILBR
Wilhelm Bcker GmbH & Co. KG
P.O. Box 14 05 80
D-42826 Remscheid
Fax 02191 / 8 10 92
11/2003
0312 1138 - 0165
Page 1 of 14
8 Special
Tools
1015
Notes
Page 2 of 14
0312 1138 - 0165
11/2003
1015
8 Special
Tools
Line reference
Engine assembly stand

For clamping in engines on both
sides
6066
35451 1
Clamping retainers
1 Set
6066/151
37601 0
Connector
For compressive pressure tester
100 130
37602 0
11/2003
0312 1138 - 0165
Page 3 of 14
8 Special
Tools
1015
Line reference
Engine racing fixture

With mechanical TDC transmitter
and degree scale for monitoring
commencement of delivery
100 300
37603 0
Racing fixture
Engine front
100 350
37604 0
2 dial gauges
In conjunction with 100 850
100 400
37605 0
Page 4 of 14
0312 1138 - 0165
11/2003
1015
8 Special
Tools
Line reference
Measuring device
For piston projection with measuring plate
100 850
37606 0
Fixture
To read of angle degree
101 910
36449 0
Testing device
For piston cooling nozzles
102 560
37608 0
11/2003
0312 1138 - 0165
Page 5 of 14
8 Special
Tools
1015
Line reference
Test rod
102 565
37628 0
Extractor for injection valve

110 030
35433 1
Retainer
For injection valve, size 11
110 110
35434 1
Page 6 of 14
0312 1138 - 0165
11/2003
1015
8 Special
Tools
Line reference
Grooved nut spanner

For injection valvel
110 130
37610 0
Measuring template
For injection pump
110 150
37611 0
Gauge pin
For setting commencement of delivery
110 180
37612 0
11/2003
0312 1138 - 0165
Page 7 of 14
8 Special
Tools
1015
Line reference
Clamping stand, swivelling

For mounting and disassembling
cylinder head
120 900
35438 1
Clamping plate
In conjunction with no. 120 900
120 910
35439 1
Assembly tool
For valve stem seal
121 410
37614 0
Page 8 of 14
0312 1138 - 0165
11/2003
1015
8 Special
Tools
Line reference
Piston ring fitting wrench

Mount and dismount piston rings
130 300
35441 1
Trapezoidal groove wear gauge

Check piston ring groove (for engines with charging air cooler)
130 400
36461 0
Piston ring compressor

Fix piston rings to pistons
130 650
35443 1
11/2003
0312 1138 - 0165
Page 9 of 14
8 Special
Tools
1015
Line reference
Base plate
131 200
37616 0
Assembly tool set

For piston pin bush
131 210
37617 0
Assembly tool
For crankshaft sealing ring (side
opposite flywheel)
142 640
37618 0
Page 10 of 14
0312 1138 - 0165
11/2003
1015
8 Special
Tools
Line reference
Assembly tool
For crankshaft sealing ring
(flywheel side)
142 650
37619 0
Assembly tool
For camshaft bush
143 830
37621 0
Retainer
For camshaft
144 150
37622 0
11/2003
0312 1138 - 0165
Page 11 of 14
8 Special
Tools
1015
Line reference
Assembly aid
For camshaft cog wheel
144 160
37623 0
Press-in tool
For cylinder liner
150 120
37624 0
Extractor tool
For cylinder liner
150 130
37625 0
Page 12 of 14
0312 1138 - 0165
11/2003
1015
8 Special
Tools
Line reference
Extractor device
150 800
35449 1
Special fixture
Unscrew oil filter cartridges
170 050
37629 0
Special wrench
For oil pressure transmitter
170 100
37626 0
11/2003
0312 1138 - 0165
Page 13 of 14
8 Special
Tools
1015
Line reference
Removal and assembly tool

For ball pins
170 120
37627 0
Page 14 of 14
0312 1138 - 0165
11/2003
1015
11/2003
9 Preparation for
commissioning
Preparation for commissioning
0312 1139 - 0165
Page 1 of 22
9 Preparation for
commissioning
1015
Notes
Page 2 of 22
0312 1139 - 0165
11/2003
1015
9.1
9 Preparation for
commissioning
Filling in Engine Oil
As a rule, the engines are delivered without oil filling.
OIL
Fill in lube oil through the oil filler neck (arrow).
References
For oil filling volume, oil quality grade and oil
viscosity,
- see appendix,
"9.6.1 - Technical Circular"
26397 1
9.2
Filling Oil Bath Air Cleaner

with Engine Oil
Fill engine oil into bowl 1 of oil bathcleaner (if fitted) up

to the arrow mark.
References
For oil quality grade and oil viscosity,
- see appendix,
Caution !
!
Never fill oil into the precleaners dust collector, if provided.
24980 3
9.3
Filling the Fuel Tank
FUEL
Use only commercial-grade diesel fuel.
References
fuel quality grade,
- see appendix,
Use summer- or winter-grade fuel, depending on the
ambient temperature.
Caution !
!
Stop engine before filling the fuel tank!

Observe strict cleanliness!
Do not spill any fuel!
26398 1
11/2003
0312 1139 - 0165
Page 3 of 22
9 Preparation for
commissioning
9.4
1015
Filling/Bleeding Cooling
System
Connect coolant inlet 1 and coolant outlet 2 to external coolant tank.

Fill in coolant into cooling system.
Start engine and run up to normal operating temperature until thermostat opens (line 2 warms up).
Check coolant level in external cooling system, top

up coolant if necessary.
26399 1
9.5
Other Preparations
Check battery and battery cable connections.

Trial run
- Upon completing the preparations run the engine
for a short trial run of about 10 minutes under low
load.
During and after trial run
- Check the engine for leaks.
After the engine has been stopped
- Check oil level and top up if necessary.
- Retension V-belts.
Breaking-in
During the breaking-in phase, it is recommended to
check the oil level twice a day. After the breaking-in
phase, checking once a day will be sufficient.
Page 4 of 22
0312 1139 - 0165
11/2003
1015
9.6
9 Preparation for
commissioning
Appendix
9.6.1 Technical Circular
11/2003
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Page 5 of 22
9 Preparation for
commissioning
1015
Notes
Page 6 of 22
0312 1139 - 0165
11/2003
1015
F 00-01-01
10 Component functions
Engine, general
F 00-01-01
Engine, general
37327 0
11/2003
0312 1140 - 0165
Page 1 of 10
Engine, general
F 00-01-01
1015
Notes
Page 2 of 10
0312 1140 - 0165
11/2003
1015
1
Information
1.1
Engine description
Engine, general
F 00-01-01
The DEUTZ engine described in this manual is a four-stroke, compact diesel engine. It consists of a V-shaped
cylinder housing and separate, cast iron cylinder heads, each with two inlet and two outlet valves operated from
the camshaft. The camshaft and the injection pump are driven by gears on the flywheel side of the engine. Additional units can also be installed here, such as an air compressor and/or an alternator.
Gears in the accessory carrier on the front end of the engine drive the coolant pump, the oil suction pump and
the oil pressure pump.
All bearings of the engine, engine controls and the ancillary drives are supplied with lubricating oil by the oil
pressure pump.
The special design of the dry sump lubrication of this engine incorporates 2 oil suction pumps, in order to enable
extreme engine inclinations or high transverse accelerations, without loss of lubrication due to a temporary lack
of lubricating oil.
The oil pressure pump and one of the two oil suction pumps are driven by the gears in the accessory carrier
on the front end of the engine. The second oil suction pump is mounted on a main bearing cap, and is driven
by a wheel drive on the flywheel side.
The lubricating oil dripping back into the oil pan is fed by the two oil suction pumps via a common line into a
container outside of the engine, and from there back to the oil pressure pump.
The oil pressure pump transports the lubricating oil first through the oil cooler, where it is cooled down to the
optimum working temperature. The oil cooler is designed as a heat-exchanger, in which the coolant flows
around the oil cooler, absorbs the heat of the lubricating oil and dissipates it via the engine cooling.
Before the lubricating oil starts its tasks (lubrication, cooling, fluid sealing, cleaning, noise reduction), it is fed
through the oil filter, to prevent any impurities being carried to the bearings.
From the oil filter, the lubricating oil is fed into an oil gallery running the whole length of the engine. Ascending
oil galleries provide lubrication for the camshaft and the valve actuating mechanism. Descending oil galleries
supply the crankshaft main bearing and the piston cooling nozzles. The crank pins and thus the big end bearings are supplied with lubricant via slanting bores within the crankshaft.
The turbocharger and injection pump are also connected to the oil system by additional oil lines running along
the outside of the engine.
The central oil gallery is closed off by the pressure control valve, which is adjusted by means of preliminary
spring pressure in order to maintain the oil pressure in the system, and also to protect the components (e.g.
the oil filter) against damage if the predefined pressure is exceeded).
The coolant is transported through the 'closed' engine cooling circuit by a centrifugal coolant pump, whose cooler dissipates the heat into the air flowing through it as soon as the engine has come up to working temperature.
In order to reach working temperature as quickly as possible, the cooler is initially taken out of the circuit by two
thermostats, which create a bypass.
A fuel pump transports the fuel from the tank through a primary filter, then through the secondary fuel filter and
into the injection pump. This meters the quantity of fuel to be injected - in accordance with the position of the
accelerator pedal and depending on the current load pressure - and pumps it under high pressure to the injection valves.
The air sucked in by the turbocharger through the air filter is warmed up by the increase in pressure within the
intake. In order to avoid any losses due to this heating when filling the cylinders, the air is cooled down in the
air-to-air intercooler before being fed to the cylinders via the air intake manifolds.
Engine starting is provided by an electric starting motor, which is powered by the vehicle battery. The battery
is kept charged by an alternator with a suitable voltage regulator.
11/2003
0312 1140 - 0165
Page 3 of 10
Engine, general
F 00-01-01
2
Engine views
2.1
Vibration damper side
1015
37329 0
2.2
Flywheel side
37332 0
Page 4 of 10
0312 1140 - 0165
11/2003
1015
2.3
Engine, general
F 00-01-01
Side view - Cylinder bank "A"
37330 0
2.4
Side view - Cylinder bank "B"
37331 0
11/2003
0312 1140 - 0165
Page 5 of 10
Engine, general
F 00-01-01
2.5
1015
Plan view
37328 0
Page 6 of 10
0312 1140 - 0165
11/2003
1015
2.6
Engine, general
F 00-01-01
Engine components - Cylinder bank side "A"
1
37333 0
1.
2.
3.
4.
11/2003
5. Coolant adapter
6. Cylinder head
7. Lifting eyes for transporting the engine
Oil cooler housing

Oil filter
Coolant pump
Vibration damper
0312 1140 - 0165
Page 7 of 10
Engine, general
F 00-01-01
2.7
1015
Engine components - Cylinder bank side "B"
16
8
15
14
13
12
11
10
37334 0
8.
9.
10.
11.
12.
Air intake manifold

Exhaust manifold - Bank "B"
Crankcase
Oil pan
Starter
Page 8 of 10
13.
14.
15.
16.
0312 1140 - 0165
Engine speed sensor

Adapter housing
Flywheel
Turbocharger
11/2003
Engine, general
F 00-01-01
1015
3
Engine specifications - BF6M 1015 CP
3.1
Engine identification
B F 6 M 10 15 C P
Engine with turbocharger
High-speed, 4-stroke
Number of cylinders
Liquid-cooled
Type number
10
Piston stroke
15
Turbo air cooler
Performance-optimized
Engine identification
4.1
Rating plate
The model designation (1), the engine serial number (2)

and the performance data are stamped on the rating plate.
Typ
KW
Serv.Code Nr.
PS HP CV 1/min
cm3
25611 3
4.2
Location rating plate

2
The rating plate is attached to the crankcase.
4.3
Engine number
The engine number is stamped on the A-side at the front,

next to the bores for the transport eyes (2), visible from
above.
26389 1
11/2003
0312 1140 - 0165
Page 9 of 10
Engine, general
F 00-01-01
5
1015
Cylinder arrangement
B3 B2 B1
A3 A2 A1
37299 0
Page 10 of 10
0312 1140 - 0165
11/2003
1015
F 06-01-05
Exhaust manifold
F 06-01-05
Exhaust manifold
36948 0
11/2003
0312 1141 - 0165
Page 1 of 4
Exhaust manifold
F 06-01-05
1015
Notes
Page 2 of 4
0312 1141 - 0165
11/2003
1015
1
Information
1.1
General
Exhaust manifold
F 06-01-05
The cast iron exhaust manifolds (1) are fitted to the cylinder heads on both outer sides of the engine.
The same gasket (2) is used between the cylinder heads and the exhaust manifold.
The exhaust manifold (3) is connected to the forked pipe, which feeds the exhaust gases to the turbocharger
console (4). In the turbocharger console (4) the exhaust gases from both cylinder banks are brought together
and then fed into the turbine housing (5) of the turbocharger, which is mounted on the connecting housing (6).
5
2
1
36868 0
11/2003
0312 1141 - 0165
Page 3 of 4
Exhaust manifold
F 06-01-05
2
Operating instructions
2.1
Removing and refitting
1015
Reference
see work card "W 06-01-05 - Remove and remount exhaust manifold"
2.2
Cleaning
1. The exhaust manifold can be soaked in non-caustic solvent until all deposits have been softened.
2. Clean surfaces, exhaust channels and flange sealing surfaces with a high-pressure vapour blast, a
wire brush, and a scraper.
2.3
Inspecting the exhaust manifold

Check the following :
Check the exhaust manifold for damage or cracks, especially in the area of the bolt connections.
- Cracked or damaged manifolds must be replaced.
Check the mounting bolts for stretching and thread damage.
- If the bolts are damaged or deformed by stretching, replace them with new bolts.
Check the flange sealing surfaces of the exhaust manifold to the cylinder heads for evenness using
a straight-edge rule.
- In case of severe unevenness, the sealing surfaces must be smoothed off using a grinding plate
and abrasive paper.
Page 4 of 4
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11/2003
1015
F 06-06-04
Turbocharger
F 06-06-04
Turbocharger
36863 0
11/2003
0312 1142 - 0165
Page 1 of 6
Turbocharger
F 06-06-04
1015
Notes
Page 2 of 6
0312 1142 - 0165
11/2003
1015
1
Information
1.1
General
Turbocharger
F 06-06-04
The overall efficiency of the engine is increased by the use of a turbocharger.

The turbocharger is fitted between the air filter and the intake manifold. It draws the air through the filter, and
then forces it through the intake manifold into the cylinders.
By simultaneously increasing the amount of fuel injected, the filling of the cylinders can be substantially
increased in comparison to a normally aspirated engine. The increased combustion energy enables the engine
to produce a higher torque.
The turbocharger is driven by a single-stage turbine, which is mounted in the engine exhaust pipe, and uses
the energy of the rapidly flowing, expanding exhaust gases. The rotation is transmitted to the compressor wheel
(pump wheel) by a shaft.
1.2
Cross-section of turbocharger
7
3
10
8
1
11
5
36864 0
1.
2.
3.
4.
5.
6.
11/2003
Compressor housing (Pump housing)

Compressor impeller (Pump impeller)
Turbine housing
Turbine wheel
Shaft housing
Intake air
7.
8.
9.
10.
11.
0312 1142 - 0165
Compressed intake air

Lubricating oil supply
Lubricating oil return
Incoming exhaust gas
Exhaust gas discharge
Page 3 of 6
Turbocharger
F 06-06-04
2
1015
Safety instructions
Warning!
!
Misuse or modification of the turbocharger can result in serious injury and property damage. Basic
safety precautions, including the following instructions, should be followed at all times.
The turbocharger is a precision built product, which may only be used with engines which have been approved for such usage.
Do not modify or substitute any parts of the turbocharger.
Modify or substitute any parts of the turbocharger only if this is permitted in the manufacturer's manual.
Do not modify the fuel line system of the engine and do not reduce the line diameter of the exhaust system
and/or the air inlet.
Make sure that oil supply and drain lines are clean. Oil filtration should be at 10 micron.
Always warm up the engine for 2 - 5 minutes to allow oil to reach the turbocharger before operating under
load.
3.1

Reference
see work card "W 06-06-04 - Remove and remount turbocharger"
3.2
Disassembly and assembly

Reference
Disassembly of the turbocharger is not allowed and voids the factory warranty.
Only substitution of shaft housing is possible.
1
36865 0
1. Turbocharger
Page 4 of 6
2. Shaft housing
0312 1142 - 0165
11/2003
1015
3.3
Turbocharger
F 06-06-04
Cleaning of parts
Aluminum parts:
1. Soak in commercially available non-caustic solvent until all deposits have been softened.
2. Clean the surfaces with a soft brush and a soft scraper.
3. Bearing surfaces must be protected when using high-pressure vapour blast for cleaning.
Cast iron parts:

1. Soak in commercially available non-caustic solvent until all deposits have been softened.
2. Inner profile surfaces must be protected in case of shot blasting.
Shaft housing:
1. Soak in commercially available solvent to remove oily residue. Cover entire shaft area when cleaning
wheels and housing with high-pressure vapour blast.
2. The O-ring groove of the shaft housing should not be subjected to excessive eater pressure when cleaning.
3.4
Inspection
Measuring the radial movement
References
see work card "W 06-06-05 - Measure turbocharger bearing play"
Visual inspection of components

The following components must be visually inspected before reuse:
Turbine housing,
Impeller,
Compressor housing,
Compressor wheel,
Shaft housing.
In the event of any of the following damage, the affected parts must be replaced with new parts:
cracking,
deformation,
erosion,
warping,
pitting,
formation of swarf,
abrasion.
References
The vanes of the impeller and compressor wheel must under no circumstances be bent straight.
11/2003
0312 1142 - 0165
Page 5 of 6
Turbocharger
F 06-06-04
1015
Notes
Page 6 of 6
0312 1142 - 0165
11/2003
1015
F 07-04-04
Injection pump
F 07-04-04
Injection pump
36847 0
11/2003
0312 1143 - 0165
Page 1 of 4
Injection pump
F 07-04-04
1015
Notes
Page 2 of 4
0312 1143 - 0165
11/2003
1015
1
Information
1.1
General
Injection pump
F 07-04-04
The injection pump supplies the fuel under high pressure to the injectors.
The start of the injection cycle must be precisely timed to within 1 of crankshaft revolution in order to achieve
the optimum fuel consumption, low emission levels and minimum noise.
The inline fuel injection pump has one injection pump element per engine cylinder. This pump element also
consists of a cylinder and plunger, and is also actuated by a camshaft. This plunger is lifted by the pump cam
in accordance with the working stroke of the cylinder and returned by spring pressure.
To change the start of the injection cycle and the amount of fuel injected, the pump element plungers are turned
by a control rod, which is in turn modulated by a centrifugal force regulator and transmits the position of the
accelerator pedal, thereby determining the idle and maximum revolutions.
1.2
Description of fuel injection pump
1
2
5
36848 0
1. Nut
2. Split washer
3. Fuel delivery pump
11/2003
4. Gasket
5. Injection pump
0312 1143 - 0165
Page 3 of 4
Injection pump
F 07-04-04
2
2.1
1015
References
see work card "W 07-04-01 - Remove and remount injection pump"
2.2
BOSCH as manufacturer of the injection pump does not permit any repair of the pump outside a BOSCH repair
workshop. Disassembly is therefore not possible.
2.3
Cleaning
Close all necks and exits of the fuel line connections before cleaning.
Use a suitable solvent for removing impurities, fuel residue and oil from the surface of the injection pump.
2.4
Inspection
Inspect surface of injection pump for mechanical damage or oil leaks. Check control mechanism for increased
play.
2.5
Repair/replace
BOSCH as manufacturer of the injection pump does not permit any repair of the pump outside a BOSCH repair
workshop. The entire injection pump must therefore be replaced.
Page 4 of 4
0312 1143 - 0165
11/2003
Injector
F 07-07-02
1015
F 07-07-02
Injector
35217 1
11/2003
0312 1144 - 0165
Page 1 of 4
Injector
F 07-07-02
1015
Notes
Page 2 of 4
0312 1144 - 0165
11/2003
Injector
F 07-07-02
1015
1
Information
1.1
General
Within the Diesel engine fuel-injection system, the injectors serve as the connecting elements between the injection pump and the engine. Diesel fuel is injected with peak pressures of up to 1,200 bar.
Under these conditions, Diesel fuel is no longer a solid, incompressible fluid but can be compressed. During
the brief delivery time (in ms), the injection system is "inflated", and a specified quantity of fuel is discharged
into the engine combustion chamber.
The design of the nozzle element - and especially the orifices - has a decisive effect on the process of fuel
injection, allowing corresponding control of the engine output, fuel consumption and exhaust emissions.
1.2
Components of the injector
2
1
3
4
5
6
7
8
9
36852 0
1.
2.
3.
4.
5.
11/2003
Injector complete
Union nut
Ring
Washer
Thrust spring
6.
7.
8.
9.
0312 1144 - 0165
Thrust bolt
Intermediate piece
Injector nozzle
Union nut
Page 3 of 4
Injector
F 07-07-02
2
2.1
1015
Reference
see work card "W 07-07-01 - Remove and remount injection valves"
2.2

References
see work card "W 07-07-05 - Check and adjust injection valves"
References
Damage, e.g. caused by dropping or incorrect handling of the injector, must be avoided.
Ensure that the adjustment washer, thrust spring, thrust pin and intermediate piece are all properly
seated in the injector body. Place the nozzle element carefully on the intermediate piece. The jet
needle must not be allowed to fall out.
2.3
Cleaning
Clean all the dismantled parts, with the exception of the injector nozzle (jet needle and nozzle body), in clean
diesel fuel.
Wipe off the remains with a clean, lint-free cloth and blow them off with compressed air.
2.4
Inspection
1. Check all nozzle parts for mechanical damage, squeezing or pressing.
2. Pull the jet needle out of the injector nozzle. If the tip is burnt or shows a blue discoloration, replace
the complete injector nozzle (nozzle needle and nozzle body = 1 set).
3. After pulling out, the jet needle has to glide back freely into the body of the nozzle by its own weight.
2.5
Repair/replace
The injector can not be repaired. In case of damage, the corresponding part has to be replaced.
2.6
Inspection
References
see work card "W 07-07-05 - Check and adjust injection valves"
After repair or long-term storage, a pressure test and adjustment must be carried out for all injectors.
The working pressure of each injector must be 290 + 8 bar.
Page 4 of 4
0312 1144 - 0165
11/2003
1015
F 07-11-04
Fuel delivery pump
F 07-11-04
Fuel delivery pump
36849 0
11/2003
0312 1145 - 0165
Page 1 of 6
Fuel delivery pump
F 07-11-04
1015
Notes
Page 2 of 6
0312 1145 - 0165
11/2003
Fuel delivery pump
F 07-11-04
1015
1
Information
1.1
General
The fuel delivery pump is flanged directly to the injection pump and delivers fuel to the injection pump at a pressure of approx. 1.5 bar.
The camshaft of the injection pump also has the task of bringing the pump plunger of the fuel delivery pump to
the Top Dead Centre (TDC) position.
The downward movement toward the Bottom Dead Centre (BDC) is responsible for the actual pumping process, and this movement is powered by a return spring. This enables the supply performance of the fuel delivery pump to depend on pressure. The greater the pressure in the supply line, the lower the supply volume.
1.2
Components of the fuel delivery pump
14
13
2
12
11
10
9
8
7
6
5
4
3
36850 0
1.
2.
3.
4.
5.
6.
7.
11/2003
Screw-in nipple
O-ring 20 x 2.5
Sliding tappet
O-ring 7 x 1.5
Tappet shell
O-ring 22 x 2,5
Pump plunger
8.
9.
10.
11.
12.
13.
14.
0312 1145 - 0165
Spacer ring
Valve
Spring seat
Compression spring
Spring seat
Delivery pump housing
Threaded bushing
Page 3 of 6
Fuel delivery pump
F 07-11-04
1.3
1015
Cross-section of fuel delivery pump
11
2
10
9
3
8
4
7
6
5
36851 0
1.
2.
3.
4.
5.
6.
Sliding tappet
O-ring
Pump plunger
Fuel inlet
Compression spring
Check valve
2.1
Removal
7.
8.
9.
10.
11.
Fuel outlet
O-ring
Valve
Delivery pump housing
Plunger tappet
1. Disconnect the fuel intake and fuel return lines from the fuel delivery pump.
2. Remove the fuel delivery pump from the injection pump (3x M6 nuts).
3. Remove the old gasket.
2.2
Disassembly
1. Remove the sliding tappet from the delivery pump.
2. Unscrew tappet shell and dismount pump plunger, spacer ring, valve, spring seats, and compression
spring.
Page 4 of 6
0312 1145 - 0165
11/2003
1015
2.3
Fuel delivery pump
F 07-11-04
Cleaning
Remove residue from the gasket from delivery pump housing and clean all pump parts in clean Diesel fuel.
2.4
Inspection
1. Inspect the pump housing visually for mechanical damage. The flange sealing surfaces, threads and
inner working surfaces must not be damaged.
2. Check springs and valve seats.
3. Face and sliding area of the sliding tappet may show neither abrasions nor scratches.
4. The sliding tappet is fitted into the tappet shell with a clearance of between 0.003 - 0.005 mm.
5. The permissible ovality of sliding tappet is 0.001 mm.
2.5
Repair/replace
The parts of the fuel delivery pump can not be repaired.

After every repair the damaged parts and gaskets must be replaced with new ones.
2.6
Assembly
1. Clean the delivery pump with a clean, lint-free cloth.
2. Carefully wet the parts to be assembled with Diesel fuel before assembly.
3. Complete the fuel delivery pump in accordance with section "1.2 Components of the fuel delivery
pump".
4. All moving parts of the pump have to move easily and evenly.
5. Tighten tappet shell and insert sliding tappet.
2.7
Refitting
1. Place the new gasket on the thrust pins of the injection pump.
2. Turn the crankshaft until only the base circle of the drive cam for the fuel delivery pump points toward
the sliding tappet.
3. Fit the fuel delivery pump to the injection pump (3x M6 nuts).
4. Connect the fuel lines to the fuel delivery pump.
5. Tightening torque for banjo bolts: 30 - 40 Nm
6. Tightening torque for union nuts: 45 Nm
11/2003
0312 1145 - 0165
Page 5 of 6
Fuel delivery pump
F 07-11-04
2.8
1015
Checks
Check the delivery pump for tightness, suction efficiency and supply after assembly.
The stated test values are minimum ones at which the pump meets the requirements.
Leakage test
1.
2.
3.
4.
5.
Connect a hose with compressed air supply of 2 bars to the intake neck.
Close discharge neck with plug.
Secure sliding tappet against sliding out.
Immerse the pump in test fluid for 30 seconds and inspect it visually.
Air leakage is admissible around sliding tappet only.
Checking suction efficiency

1.
2.
3.
4.
5.
The emptied and rinsed delivery pump must deliver a vacuum of 0.15 bar.
The filled pump has to reach a vacuum of at least 0.20 bar.
The test is carried out by pumping or moving the sliding tappet.
The vacuum of 0.15 bar must be kept up for 40 seconds.
The permissible vacuum decrease is max. 0.05 bar.
Checking delivery efficiency

This test is performed on a test bench with a vacuum of 0.2 bar at the intake and a counter-pressure of 0.50
bar.
Revolutions
Delivery rate
[min-1]
[l/min]
1000
1,75
2000
3,50
Page 6 of 6
0312 1145 - 0165
11/2003
1015
F 08-00-00
11/2003
Lubrication system
F 08-00-00
Lubrication system
0312 1146 - 0165
Page 1 of 4
Lubrication system
F 08-00-00
1015
Notes
Page 2 of 4
0312 1146 - 0165
11/2003
1015
1
Information
1.1
General
Lubrication system
F 08-00-00
All bearings of the engine, engine controls and the ancillary drives are supplied with lubricating oil by the oil
pressure pump.
The special design of the dry sump lubrication of this engine incorporates 2 oil suction pumps, in order to enable
extreme engine inclinations or high transverse accelerations, without loss of lubrication due to a temporary lack
of lubricating oil.
The oil pressure pump and one of the two oil suction pumps are driven by the gears in the accessory carrier
on the front end of the engine. The second oil suction pump is mounted on a main bearing cap, and is driven
by a wheel drive on the flywheel side.
The lubricating oil dripping back into the oil pan is fed by the two oil suction pumps via a common line into a
container outside of the engine, and from there back to the oil pressure pump.
The oil pressure pump transports the lubricating oil first through the oil cooler, where it is cooled down to the
optimum working temperature. The oil cooler is designed as a heat-exchanger, in which the coolant flows
around the oil cooler, absorbs the heat of the lubricating oil and dissipates it via the engine cooling.
Before the lubricating oil starts its tasks (lubrication, cooling, fluid sealing, cleaning, noise reduction), it is fed
through the oil filter, to prevent any impurities being carried to the bearings.
From the oil filter, the lubricating oil is fed into an oil gallery running the whole length of the engine. Ascending
oil galleries provide lubrication for the camshaft and the valve actuating mechanism. Descending oil galleries
supply the crankshaft main bearing and the piston cooling nozzles. The crank pins and thus the big end bearings are supplied with lubricant via slanting bores within the crankshaft.
The turbocharger and injection pump are also connected to the oil system by additional oil lines running along
the outside of the engine.
The central oil gallery is closed off by the pressure control valve, which is adjusted by means of preliminary
spring pressure in order to maintain the oil pressure in the system, and also to protect the components (e.g.
the oil filter) against damage if the predefined pressure is exceeded.
11/2003
0312 1146 - 0165
Page 3 of 4
Lubrication system
F 08-00-00
1015
Notes
Page 4 of 4
0312 1146 - 0165
11/2003
1015
F 08-04-08
Oil suction pumps
F 08-04-08
Oil suction pumps
36839 0
36936 0
11/2003
0312 1147 - 0165
Page 1 of 4
Oil suction pumps
F 08-04-08
1015
Notes
Page 2 of 4
0312 1147 - 0165
11/2003
1015
1
Information
1.1
General
Oil suction pumps
F 08-04-08
The oil suction pumps suck the oil out of the front and rear section of the oil pan and deliver it to the oil container
outside the engine. From here the oil is delivered to the oil pressure pump, and then transported under pressure
to the lubricating points in the engine.
The oil suction pumps are driven by the gears fitted to the front and rear of the crankshaft.
2.1

References
see work card "W 03-08-03 - Disassemble and assemble accessory carrier"
see work card "W 08-04-08 - Remove and remount oil suction pump (flywheel side)"
2.2
Disassembly
No repairs can be made to the oil suction pumps.
2.3
Cleaning
The oil suction pump has to be cleaned after removal from engine or before inspection.
2.4
Inspection
Check the oil suction pump visually for mechanical damage.
2.5
Repair/replace
Repairs of the oil suction pump are not intended.
2.6
Checking
Check the oil suction pump before installation in the engine in accordance with the following diagram.
11/2003
0312 1147 - 0165
Page 3 of 4
Oil suction pumps
F 08-04-08
2.7
1015
Diagram - Oil delivery volume in relation to engine revolutions
210
180
Q [l/min]
240
150
120
90
60
30
Page 4 of 4
0312 1147 - 0165
4200
3900
3600
3300
3000
2700
2400
2100
1800
1500
1200
900
600
300
n [min-1]
36840 0
11/2003
1015
F 08-05-05
Oil pressure pump
F 08-05-05
Oil pressure pump
36837 0
11/2003
0312 1148 - 0165
Page 1 of 4
Oil pressure pump
F 08-05-05
1015
Notes
Page 2 of 4
0312 1148 - 0165
11/2003
1015
1
Information
1.1
General
Oil pressure pump
F 08-05-05
The oil pressure pump delivers oil under pressure to the engine lubrication system, and is equipped with a relief
valve that is set to about 9 bar. The pump is driven directly by the crankshaft.
The oil pressure pump is driven directly by a gear fitted to the front of the crankshaft.
2.1

References
see work card "W 03-08-03 - Disassemble and assemble accessory carrier"
2.2
Disassembly
No repairs can be made to the oil pressure pump.
2.3
Cleaning
The oil pressure pump has to be cleaned after removal from engine or before inspection.
2.4
Inspection
Check the oil pressure pump visually for mechanical damage.
2.5
Repair/replace
No repairs of the oil pressure pump are permissible. It must be replaced in case of damage.
2.6
Checking
Before mounting the oil pressure pump into the engine, test the pump in accordance with the diagram given
below.
11/2003
0312 1148 - 0165
Page 3 of 4
Oil pressure pump
F 08-05-05
2.7
1015
Diagram - Oil delivery volume in relation to oil pressure
3450 min-1
220
200
3000 min-1
180
2500 min-1
160
120
100
Q [l/min]
140
80
60
40
20
P [bar]
1
Page 4 of 4
0312 1148 - 0165
10
36838 0
11/2003
1015
F 08-08-02
Oil cooler
F 08-08-02
Oil cooler
36841 0
11/2003
0312 1149 - 0165
Page 1 of 6
Oil cooler
F 08-08-02
1015
Notes
Page 2 of 6
0312 1149 - 0165
11/2003
1015
1
Information
1.1
General
Oil cooler
F 08-08-02
In order to perform the required functions, the lubricating oil must be kept within the proper temperature limits.
If the oil is too cold, it will not flow freely. If the oil is too hot, it cannot support the bearing loads, and the engine
will not be cooled properly. As a consequence, oil pressure may drop below acceptable limits, and lead to excessive oil consumption.
In order to prevent the permissible temperatures being exceeded, a plate oil cooler is used, which as a compact
component sits in a chamber surrounded by circulating cooling water.
Whenever installing an oil cooler, care should therefore be taken to ensure that the right gaskets are used and
the retaining bolts are tight, in order to ensure proper sealing.
2.1
General
Ensure that the correct oil cooler is used. The lubricating oil cooler mounted on the front of the accessory carrier
above the water pump.
2.2

References
see work card "W 08-08-02 - Remove and remount Oil cooler"
2.3
Cleaning
The oil cooler has to be cleaned after removal from engine or before inspection.
2.4
Repair/replace
References
No repairs can be made to the oil cooler. It must be replaced when damaged.
11/2003
0312 1149 - 0165
Page 3 of 6
Oil cooler
F 08-08-02
2.5
1015
Inspection
Visual inspection
Check the oil cooler visually for any cracks or mechanical damage.
Prepare test fixture

1. Make a sealing plate (4) of sheet metal and a rubber gasket (2) of the same shape, using the oil cooler
(3) as a template.
2. Drill 4 holes in sealing plate in order to bolt it to the oil cooler.
3. Drill 1 hole in sealing plate for the compressed air connection (1) with a connection to the oil channel
of the oil cooler (3).
4. Tap a thread into the hole for the compressed air connection (1) in order to fit a connecting pipe.
5. Fit the connecting pipe and gasket to the sealing plate (4).
6. Fit the sealing plate (4) and rubber gasket (2) to the oil cooler (3) using suitable bolts, washers, sealing
rings and nuts.
7. Fit the compressed air connection (1) to the connecting pipe.
2
3
36842 0
Checking oil cooler

1.
2.
3.
4.
Immerse the cooler (3) in a container filled with water heated to approx. 80 C.
Check for leaks, indicated by air bubbles in the water.
If there are any leaks, the oil cooler (3) has to be replaced.
After testing, remove the sealing plate (4) from the oil cooler.
Page 4 of 6
0312 1149 - 0165
11/2003
1015
Oil cooler
F 08-08-02
Oil cooler tests

Leakage test
6 bar
with air pressure of
Maximum pressure test
16 bar
Caution!
!
11/2003
When carrying out a pressure test, make sure that persons are adequately protected against any
stream of pressurized air from a leak or rupture of fitting, hose or oil cooler.
0312 1149 - 0165
Page 5 of 6
Oil cooler
F 08-08-02
1015
Notes
Page 6 of 6
0312 1149 - 0165
11/2003
1015
F 08-10-07
Oil filter
F 08-10-07
Oil filter
36846 0
11/2003
0312 1150 - 0165
Page 1 of 4
Oil filter
F 08-10-07
1015
Notes
Page 2 of 4
0312 1150 - 0165
11/2003
1015
1
Information
1.1
General
Oil filter
F 08-10-07
The full-flow type oil filter is mounted in a vertical position on the front side of the engine. The oil coming from
the engine oil pressure pump flows through the oil filter before reaching the moving parts of the engine.
The oil is forced under pressure through the filter connection into the filter cartridge, where impurities are filtered out.
2.1

References
see work card "W 08-10-06 - Remove and remount oil filter cartridge"
2.2
Cleaning
No cleaning is necessary. The oil filter has to be replaced.
2.3
Inspection
Inspect the sealing surface of the filter and the oil filter carrier to ensure that the copper sealing ring is attached
to the oil filter.
2.4
Repair/replace
Repair of the oil filter is neither permissible nor possible. The oil filter has to be replaced with every oil change.
Caution!
!
11/2003
Mechanical tightening is not necessary and will distort or crack the filter.
0312 1150 - 0165
Page 3 of 4
Oil filter
F 08-10-07
1015
Notes
Page 4 of 4
0312 1150 - 0165
11/2003
F 08-11-10
1015
F 08-11-10
36843 0
11/2003
0312 1151 - 0165
Page 1 of 4
F 08-11-10
1015
Notes
Page 2 of 4
0312 1151 - 0165
11/2003
1015
1
Information
1.1
General
F 08-11-10
The pressure control valve maintains a constant lubricating oil pressure in the engine, irrespective of the oil
temperature. The pressure control valve is installed in the oil gallery in the rear part of the engine.
1.2
Function and setting
The valve plunger is pressed into its seat by the spring, which is pre-tensioned by the adjustment bolt. If the oil
pressure exceeds the level of 4.5 bar, the valve is lifted out of its seat. The oil coming from the engine oil gallery
is fed into the oil pan via a bypass. In this way, a constant lubricating oil pressure is maintained at all times.
1.3
Construction of the pressure control valve
36844 0
1. Gasket ring
2. Blanking plug
3. Valve housinge
11/2003
4. Adjustment bolt
5. Pressure spring
6. Valve plunger
0312 1151 - 0165
Page 3 of 4
F 08-11-10
2
2.1
1015
Reference
see work card "W 08-11-10 - Remove and remount pressure control valve"
Before removing the pressure control valve, measure and note the dimension "X" (see below). If the same oil
pressure is to be set, the dimension noted before removal will have to set again after refitting.
2.2
Cleaning
After removal of the pressure control valve from the engine, the parts must be cleaned.
2.3
Inspection
Carry out a visual inspection of the components of the pressure control valve with regard to any mechanical
damage. Check the valve plunger seat for damage.
2.4
Repair/replace
Replace the sealing rings and any damaged parts of the pressure control valve.
2.5
Basic oil pressure setting
Oil pressure
Dimension "X"
[bar]
[mm]
3.00
42.00
3.50
39.05
4.00
36.10
4.50
33.15
36845 0
2.6
Setting with engine running
After installation in the engine, the pressure control valve must be set either on a test stand, or in the vehicle
with the engine running.
Page 4 of 4
0312 1151 - 0165
11/2003
1015
F 09-07-09
Coolant pump
F 09-07-09
Coolant pump
36853 0
11/2003
0312 1152 - 0165
Page 1 of 6
Coolant pump
F 09-07-09
1015
Notes
Page 2 of 6
0312 1152 - 0165
11/2003
1015
1
Information
1.1
General
Coolant pump
F 09-07-09
The centrifugal coolant pump is mounted on the accessory carrier, and is driven by the gear on the front face
of the engine. The coolant pump circulates the engine coolant through the coolant system.
1.2
Location of coolant pump
36854 0
11/2003
0312 1152 - 0165
Page 3 of 6
Coolant pump
F 09-07-09
1.3
1015
Cross-section of coolant pump
1
2
5
6
36855 0
1. Pump housing
2. Sealing ring
3. Cover
Page 4 of 6
4. Sealing ring
5. Impeller
6. Lock ring
0312 1152 - 0165
11/2003
1015
1.4
Coolant pump
F 09-07-09
Cross-section of impeller seating
7
8
1
2
3
4
5
6
36856 0
1.
2.
3.
4.
11/2003
Pump housing
Drive gear
Shaft
Shaft sealing ring
5.
6.
7.
8.
0312 1152 - 0165
Sealing ring - red

Sealing ring - black
Lock ring
Ball bearing
Page 5 of 6
Coolant pump
F 09-07-09
2
2.1
1015
Reference
see work card "W 09-07-08 - Remove and remount coolant pump"
Prior to installing the coolant pump, the specific lubricant included in the supply must be applied to the O-rings.
When using other liquid or oil, leakage may occur.
2.2
Disassembly
Note
No repairs can be made to the coolant pump.
2.3
Cleaning
1. Clean the coolant pump after removal from the engine.
2. Remove the remains of the gasket from the coolant pump.
2.4
Inspection
Carry out a visual inspection of the coolant pump for integrity, cracks, extreme wear or other damage.
2.5
Checking
The coolant pump can be checked during the engine test.
Page 6 of 6
0312 1152 - 0165
11/2003
1015
F 09-08-01
Coolant thermostat
F 09-08-01
Coolant thermostats
36857 0
11/2003
0312 1153 - 0165
Page 1 of 4
Coolant thermostat
F 09-08-01
1015
Notes
Page 2 of 4
0312 1153 - 0165
11/2003
1015
1
Information
1.1
General
Coolant thermostat
F 09-08-01
Two coolant thermostats control the temperature of the engine coolant. The coolant-thermostats are located in
a housing at the front of the engine.
When the coolant temperature falls below approx. 79 C or 87 C, the coolant thermostats remain closed and
block the flow of coolant from engine to radiator. During this period, all of the coolant in the system is recirculated through the engine and is directed back to the suction side of the water pump via a by-pass.
When the coolant temperature reaches approx. 79 C to 87 C, the coolant thermostats begin to open, allowing
a portion of the coolant to circulate through the radiator. The bypass is still in partial use at this time.
When the coolant temperature reaches a level of approx. 96 C, the coolant thermostats are fully open, the
bypass is closed, and the coolant is circulated completely through the radiator.
Properly operating coolant thermostats are essential for the efficient operation of the engine. If the engine's
operating temperature deviates from the normal range (83 C to 95 C), remove, inspect and replace the coolant thermostats if necessary.
The coolant thermostats can not be repaired.
1.2
Location of the coolant thermostats
5
4
3
1
36858 0
1. Coolant thermostat for cylinder bank "A" (79 C)

2. Coolant thermostat housing cover
3. Coolant thermostat for cylinder bank "A" (87 C)
11/2003
0312 1153 - 0165
4. Sealing ring
5. Coolant thermostat housing
Page 3 of 4
Coolant thermostat
F 09-08-01
1.3
1015
Coolant thermostat
The following particulars are printed on the bottom of

the coolant thermostat:
1.
2.
3.
4.
Name of manufacturer
Start commencement
Manufacturing date
Assembly mark
36860 0
2.1

Reference
see work card "W 09-08-02 - Remove and remount coolant thermostats"
2.2
The coolant thermostats can neither be dismantled nor repaired.
2.3
Cleaning
1. Clean coolant thermostat and thermostat housing from residue of gasket.
2. Clean coolant thermostat in clean Diesel fuel and dry with compressed air.
2.4
Inspection
Inspect the coolant thermostats for wear or mechanical damage, for cracks or nicks.
2.5
Repair/replace
If any damage is noted, replace the coolant thermostat
2.6
Checking the coolant thermostats

Reference
see work card "W 09-08-01 - Check coolant thermostat, when disassembled"
Page 4 of 4
0312 1153 - 0165
11/2003
1015
F 12-01-04
Vibration damper
F 12-01-04
Vibration damper
36869 0
11/2003
0312 1154 - 0165
Page 1 of 4
Vibration damper
F 12-01-04
1015
Notes
Page 2 of 4
0312 1154 - 0165
11/2003
1015
1
Information
1.1
General
Vibration damper
F 12-01-04
The vibration damper is mounted on the front side of the crankshaft, and absorbs the undesirable vibrations
generated by combustion engines due to uneven rotation.
The vibration damper is designed specifically for the engine revolutions range and vibration range of the engine
in question, in order to suppress such vibrations as effectively as possible.
2.1

References
see work card "W 12-01-04 - Remove and remount vibration damper"
2.2
Cleaning
Clean vibration damper.
2.3
Inspection
Carry out a visual inspection of the vibration damper for external damage, deformation and leaks.
11/2003
0312 1154 - 0165
Page 3 of 4
Vibration damper
F 12-01-04
1015
Notes
Page 4 of 4
0312 1154 - 0165
11/2003
1015
F 13-02-03
Alternator
F 13-02-03
Alternator
37335 0
11/2003
0312 1155 - 0165
Page 1 of 4
Alternator
F 13-02-03
1015
Notes
Page 2 of 4
0312 1155 - 0165
11/2003
1015
1
Information
1.1
General
Alternator
F 13-02-03
The alternator is driven by a V-belt from a V-belt pulley, which is mounted on the crankshaft in front of the vibration damper.
It is a three-phase generator, which should provide sufficient electrical power to the vehicle system under all
operating conditions. The alternator also ensures that the battery is sufficiently charged at all times.
The charging of the battery and the supply of the electrical equipment and assemblies requires direct current.
The alternator is therefore equipped with a rectifier, which converts the alternating current generated by the
alternator into direct current.
The alternator is also equipped with a voltage regulator, which regulates the voltage under varying engine revolutions and changing loads on the alternator.
11/2003
0312 1155 - 0165
Page 3 of 4
Alternator
F 13-02-03
1015
Notes
Page 4 of 4
0312 1155 - 0165
11/2003
1015
F 13-03-02
Starter
F 13-03-02
Starter
36871 0
11/2003
0312 1156 - 0165
Page 1 of 4
Starter
F 13-03-02
1015
Notes
Page 2 of 4
0312 1156 - 0165
11/2003
1015
1
Information
1.1
General
Starter
F 13-03-02
The starter relay and the starter solenoid within the starter are activated by pressing the starter switch.
Due to its design and internal circuitry, the starter initially develops a low torque, and thrusts the starter pinion
gently into the starter ring gear of the flywheel.
After complete meshing of the starter pinion, the torque and revolutions of the starter are increased, in order to
turn the crankshaft at the revolutions required for starting.
Note
The series-fitted starter is protected against the ingress of oil on the starter pinion side. Only an original replacement part must therefore be used when replacing the starter.
2.1

Reference
see work card "W 13-03-02 - Remove and remount starter"
11/2003
0312 1156 - 0165
Page 3 of 4
Starter
F 13-03-02
1015
Notes
Page 4 of 4
0312 1156 - 0165
11/2003
1015
M 01-02-02
11 Component data
Rocker arm - inlet
M 01-02-02
Rocker arm - inlet
36927 0
11/2003
0312 1157 - 0165
Page 1 of 4
11 Component data
Rocker arm - inlet
M 01-02-02
1015
Notes
Page 2 of 4
0312 1157 - 0165
11/2003
11 Component data
Rocker arm - inlet
M 01-02-02
1015
21
+ 0,015
0
8
M10 x 1
30,5 0,2
26
26 + 0,1
22
30,5 0,2
49,5
37300 0
Pos.
Inspection
method / tool
Identification
Check rocker arm for damage and wear.
Length of arm to valve stem
Length of arm to push rod
Bearing width
Bore diameter for axle bearing
Value
Unit
40.000 0.100
[mm]
30.800 0.100
[mm]
Visual inspection
Caliper gauge
Internal dial gauge
61.000 - 0.100
[mm]
+ 0.021
0
[mm]
28.000
Speed ratio "i" = 1 : 1.3
11/2003
0312 1157 - 0165
Page 3 of 4
11 Component data
Rocker arm - inlet
M 01-02-02
1015
Notes
Page 4 of 4
0312 1157 - 0165
11/2003
1015
M 01-02-03
11 Component data
Rocker arm-outlet
M 01-02-03
Rocker arm-outlet
36928 0
11/2003
0312 1158 - 0165
Page 1 of 4
11 Component data
Rocker arm-outlet
M 01-02-03
1015
Notes
Page 2 of 4
0312 1158 - 0165
11/2003
11 Component data
Rocker arm-outlet
M 01-02-03
1015
29
29
24
M10 x 1
38,9
0,015
60,5
40,3
0,5
1,5
0,3
8,5
Pos.
28
Inspection
method / tool
Identification
Check rocker arm for damage and wear.
Length of arm to valve stem
Length of arm to push rod
Bearing width
Bore diameter for axle bearing
36929 0
Value
Unit
98.000 0.100
[mm]
65.000 0.100
[mm]
Visual inspection
Caliper gauge
Internal dial gauge
25.900 - 0.100
[mm]
+ 0.021
0
[mm]
28.000
Speed ratio "i" = 1 : 1.508
11/2003
0312 1158 - 0165
Page 3 of 4
11 Component data
Rocker arm-outlet
M 01-02-03
1015
Notes
Page 4 of 4
0312 1158 - 0165
11/2003
1015
M 01-02-04
11 Component data
Rocker axis
M 01-02-04
Rocker axis
36931 0
11/2003
0312 1159 - 0165
Page 1 of 4
11 Component data
Rocker axis
M 01-02-04
1015
Notes
Page 2 of 4
0312 1159 - 0165
11/2003
11 Component data
Rocker axis
M 01-02-04
1015
80
10,5 + 0,2
10
0,2
0,2
5,1 + 0,2
25,8
5 - 0,4
27,5
49,5
71,5
0,2
0,2
0,2
A
36932 0
Pos.
Inspection
method / tool
Identification
Check surface for scoring, overheating, and
cracks.
Length
Diameter
Diameter of oil passage
11/2003
Value
Unit
Visual inspection
Caliper gauge
99.000 - 0.500
[mm]
Micrometer
28.000 - 0.061
- 0.040
[mm]
Caliper gauge
6.100 - 0.100
+ 0.200
[mm]
0312 1159 - 0165
Page 3 of 4
11 Component data
Rocker axis
M 01-02-04
1015
Notes
Page 4 of 4
0312 1159 - 0165
11/2003
1015
M 01-02-05
11 Component data
Rocker arm bracket
M 01-02-05
Rocker arm bracket
36924 0
11/2003
0312 1160 - 0165
Page 1 of 4
11 Component data
Rocker arm bracket
M 01-02-05
1015
Notes
Page 2 of 4
0312 1160 - 0165
11/2003
11 Component data
Rocker arm bracket
M 01-02-05
1015
B
36955 0
Pos.
Inspection
method / tool
Identification
Check rocker arm bracket for mechanical
damage and wear.
Thickness
Width
Height
Diameter of axle bore
11/2003
Value
Unit
Visual inspection
0
Caliper gauge
Inside
micrometer
0312 1160 - 0165
19.000 - 0.200
[mm]
54.000
[mm]
45.000
[mm]
28.000
+ 0.052
0
[mm]
Page 3 of 4
11 Component data
Rocker arm bracket
M 01-02-05
1015
Notes
Page 4 of 4
0312 1160 - 0165
11/2003
1015
M 01-02-06
11 Component data
Valve tappet
M 01-02-06
Valve tappet
36933 0
11/2003
0312 1161 - 0165
Page 1 of 4
11 Component data
Valve tappet
M 01-02-06
1015
Notes
Page 2 of 4
0312 1161 - 0165
11/2003
11 Component data
Valve tappet
M 01-02-06
1015
21,5 0,2
3,5 0,2
57 - 1
+ 0,3
3 0,2
D
36934 0
Pos.
Inspection
method / tool
Identification
Check surface for scoring, overheating, and
cracks.
Value
Unit
Visual inspection
24.928 - 0.030
- 0.010
[mm]
25.000 - 0.041
- 0.020
[mm]
- 0.010
[mm]
Diameter at distance 2.0 mm
24.914 - 0.030
Diameter
35.000 - 0.300
[mm]
+ 0.300
[mm]
Micrometer
Caliper gauge
E
Length
11/2003
77.000 - 1.000
0312 1161 - 0165
Page 3 of 4
11 Component data
Valve tappet
M 01-02-06
1015
Notes
Page 4 of 4
0312 1161 - 0165
11/2003
1015
M 01-04-02
11 Component data
Cylinder head
M 01-04-02
Cylinder head
35226 1
11/2003
0312 1162 - 0165
Page 1 of 4
11 Component data
Cylinder head
M 01-04-02
1015
Notes
Page 2 of 4
0312 1162 - 0165
11/2003
11 Component data
Cylinder head
M 01-04-02
B
33,6
1015
37310 0
Identification
Inspection
method / tool
Check cylinder head for cracks, notches, or burrs.

Clean plane surfaces and check for flatness.
Visual inspection
Pos.
Valve stem play - Inlet valve
Value
Unit
0.12
[mm]
Valve stem play - Outlet valve
0.14
[mm]
Valve set-back dimension - Inlet valve
1.20 - 1.55
[mm]
Valve set-back dimension - Outlet valve
1.25 - 1.60
[mm]
Valve seat width - Inlet valve
2.800
[mm]
Valve seat width - Outlet valve
3.000
[mm]
Valve seat angle - Inlet valve
Valve seat angle
Dial gauge
Caliper gauge
29 20 20
[]
44.5 10
[]
Angle gauge
11/2003
0312 1162 - 0165
Page 3 of 4
11 Component data
Cylinder head
M 01-04-02
1015
Notes
Page 4 of 4
0312 1162 - 0165
11/2003
1015
M 01-05-04
11 Component data
Valves
M 01-05-04
Valves
36909 0
11/2003
0312 1163 - 0165
Page 1 of 4
11 Component data
Valves
M 01-05-04
1015
Notes
Page 2 of 4
0312 1163 - 0165
11/2003
11 Component data
Valves
M 01-05-04
1015
1
Inlet valve
30 1
36910 0
Identification
Inspection
method / tool
Check valve shaft for scoring, check valve

for overheating or cracks.
Visual inspection
Pos.
Length
Diameter of valve shaft
Diameter of valve disc
Valve stem diameter (Valve seat with

wear-resistant layer)
Valve seat angle
11/2003
Caliper gauge
Micrometer
Caliper gauge
Angle gauge
0312 1163 - 0165
Value
Unit
133.000 0.300
[mm]
7.970 0.007
[mm]
46.000 0.200
[mm]
2.300
30 0 0.10
[mm]
[]
Page 3 of 4
11 Component data
Valves
M 01-05-04
2
1015
Outlet valve
30 1
C
36911 0
Identification
Inspection
method / tool
Check valve shaft for scoring, check valve

for overheating or cracks.
Visual inspection
Pos.
Length
Valve shaft diameter
Valve disc diameter
Valve stem diameter
Valve seat angle
Page 4 of 4
Caliper gauge
Micrometer
Caliper gauge
Angle gauge
0312 1163 - 0165
Value
Unit
133.000 0.300
[mm]
7.960 0.007
[mm]
42.000 0.200
[mm]
1.900
45 0 0.10
[mm]
[]
11/2003
1015
M 01-06-03
11 Component data
Valve guides
M 01-06-03
Valve guides
36905 0
11/2003
0312 1164 - 0165
Page 1 of 4
11 Component data
Valve guides
M 01-06-03
1015
Notes
Page 2 of 4
0312 1164 - 0165
11/2003
11 Component data
Valve guides
M 01-06-03
1015
Pos.
36906 0
Inspection
method / tool
Identification
Length
Caliper gauge
Outer diameter - normal
Outer diameter - over-dimension stage 1
Micrometer
Outer diameter - over-dimension stage 2
Inner diameter
11/2003
Caliper bore
0312 1164 - 0165
Value
Unit
+ 0.200
0
[mm]
15.000 + 0.023
+ 0.034
[mm]
15.100 + 0.023
+ 0.034
[mm]
15.200 + 0.023
+ 0.034
[mm]
+ 0.015
0
[mm]
66.000
8.030
Page 3 of 4
11 Component data
Valve guides
M 01-06-03
1015
Notes
Page 4 of 4
0312 1164 - 0165
11/2003
1015
M 01-07-03
11 Component data
Valve seat rings
M 01-07-03
Valve seat rings
36907 0
11/2003
0312 1165 - 0165
Page 1 of 4
11 Component data
Valve seat rings
M 01-07-03
1015
Notes
Page 2 of 4
0312 1165 - 0165
11/2003
11 Component data
Valve seat rings
M 01-07-03
1015
1
Valve seat ring-inlet valve
B
37301 0
Pos.
Identification
Inspection
method / tool
Value
Unit
Valve seat angle
Angle gauge
Outer diameter
Micrometer
47.500 + 0.060
+ 0.075
[mm]
Height of valve seat ring
Caliper gauge
6.600 0.100
[mm]
11/2003
0312 1165 - 0165
119 20 0.20
[]
Page 3 of 4
11 Component data
Valve seat rings
M 01-07-03
2
1015
Outlet valve seat ring
B
37301 0
Pos.
Identification
Inspection
method / tool
Value
Unit
Valve seat angle
Angle gauge
Outer diameter
Micrometer
44.000 + 0.060
+ 0,075
[mm]
Height of valve seat ring
Caliper gauge
7.000 0.100
[mm]
Page 4 of 4
0312 1165 - 0165
89 0.20
[]
11/2003
11 Component data
Connecting rod
M 02-03-01
1015
M 02-03-01
Connecting rod
35224 1
11/2003
0312 1166 - 0165
Page 1 of 4
11 Component data
Connecting rod
M 02-03-01
1015
Notes
Page 2 of 4
0312 1166 - 0165
11/2003
11 Component data
Connecting rod
M 02-03-01
B
D
1015
37302 0
Pos.
Inspection
method / tool
Identification
Check connecting rod for mechanical
damage and overheating.
Visual inspection
Bolt circle dimension of bearing bores
Aligning tool
connecting rod
Diameter of connecting rod eye without

small end bush
Diameter of connecting rod eye with small

end bush
Diameter of bore for big end bearing without

big end bearing shells
Small end bush clearance
Internal dial gauge
Unit
262.000 - 0.060
+ 0.040
[mm]
55.000
+ 0.019
0
[mm]
52.040
+ 0.015
0
[mm]
+ 0.030
92.000 - 0.002
[mm]
Aligning tool
connecting rod
0.040
+ 0.023
0
[mm]
---
0.060
+ 0.076
0
[mm]
Aligning tool
connecting rod
0.055
Theoretical big end bearing clearance

Parallelism on 100 mm
Value
[mm]
Remark :
New connecting rod bolts M14 x 1.5 x 80.5 have to be used after each removal.
11/2003
0312 1166 - 0165
Page 3 of 4
11 Component data
Connecting rod
M 02-03-01
1015
Notes
Page 4 of 4
0312 1166 - 0165
11/2003
1015
M 02-04-01
11 Component data
Crankshaft
M 02-04-01
Crankshaft
35221 1
11/2003
0312 1167 - 0165
Page 1 of 4
11 Component data
Crankshaft
M 02-04-01
1015
Notes
Page 2 of 4
0312 1167 - 0165
11/2003
11 Component data
Crankshaft
M 02-04-01
1015
A
F
B
E
37336 0
n
Identification
Inspection
method / tool
Check grinded surfaces and bearing positions

for scoring, overheating, or cracks.
Check plane surfaces for damage and flatness.
Visual inspection
Pos.
Length of crankshaft
Caliper gauge
Value
Unit
[mm]
786.500
[mm]
Diameter of main bearing journals (normal)
103.000 - 0.034
- 0.012
[mm]
Diameter of main bearing journals

(Under-dimension stage 1)
102.750 - 0.034
- 0.012
[mm]
- 0.012
[mm]

Micrometer
102.500 - 0.034

102.250 - 0.034
[mm]

102.000 - 0.034
- 0.012
[mm]
11/2003
- 0.012
0312 1167 - 0165
Page 3 of 4
11 Component data
Crankshaft
M 02-04-01
Pos.
1015
Inspection
method / tool
Identification
Value
Unit
Diameter of connecting rod journals (normal)
88.000 - 0.034
- 0.012
[mm]
Diameter of connecting rod journals

87.750 - 0.034
- 0.012
[mm]
- 0.012
[mm]
Micrometer
87.500 - 0.034

87.250 - 0.034
[mm]
max. 0.010
[mm]
max. 0.010
[mm]
38.000
+ 0.062
0
[mm]
38.250
+ 0.062
0
[mm]
38.500
+ 0.062
0
[mm]
Ovality of main bearing journals
Ovality of connecting rod journals
- 0.012
Dial gauge
Width of thrust bearing journal (normal)

(Over-dimension stage 1)
Internal dial gauge

Page 4 of 4
0312 1167 - 0165
11/2003
1015
M 02-05-04
11 Component data
Big end bearing
M 02-05-04
Big end bearing
36900 0
11/2003
0312 1168 - 0165
Page 1 of 4
11 Component data
Big end bearing
M 02-05-04
1015
Notes
Page 2 of 4
0312 1168 - 0165
11/2003
11 Component data
Big end bearing
M 02-05-04
1015
Pos.
Inspection
method / tool
Identification
Check big end bearing shells for scoring, overheating, or cracks.
Outer diameter
Width of big end bearing
Value
Unit
Visual inspection
+ 0.028
Micrometer
92.000 - 0.002
Width of big end

bearing
25.000 - 0.300
[mm]
[mm]
Thickness of big end bearing shell

(Standard = 88.00))
1.963
+ 0.012
0
[mm]

(Under-dimension stage 1 = 87.75)
2.088
+ 0.012
0
[mm]

2.213
+ 0.012
0
[mm]

2.338
+ 0.012
0
[mm]
Micrometer
Remark:
Wear limits for standard bearing shells apply identically to under-dimension stages.
11/2003
0312 1168 - 0165
Page 3 of 4
11 Component data
Big end bearing
M 02-05-04
1015
Notes
Page 4 of 4
0312 1168 - 0165
11/2003
1015
M 02-07-02
11 Component data
M 02-07-02
36898 0
11/2003
0312 1169 - 0165
Page 1 of 4
11 Component data
M 02-07-02
1015
Notes
Page 2 of 4
0312 1169 - 0165
11/2003
11 Component data
M 02-07-02
1015
Pos.
Inspection
method / tool
Identification
Check bearing shells for scoring, overheating, or cracks.
Outer diameter
Width of main bearing
Value
Unit
Visual inspection
Micrometer
Caliper gauge
108.000
+ 0.022
0
0
[mm]
30.000 - 0.300
[mm]
Thickness of main bearing shell

(Standard = 103.000)
2.460
+ 0.010
0
[mm]

2.585
+ 0.010
0
[mm]
2.710
+ 0.010
0
[mm]

(Under-dimension stage 3 = 102.250
2.835
+ 0.010
0
[mm]

2.960
+ 0.010
0
[mm]

11/2003
Micrometer
0312 1169 - 0165
Page 3 of 4
11 Component data
M 02-07-02
1015
Notes
Page 4 of 4
0312 1169 - 0165
11/2003
1015
M 02-07-03
11 Component data
Thrust washers
M 02-07-03
Thrust washers
for crankshaft
36899 0
11/2003
0312 1170 - 0165
Page 1 of 4
11 Component data
Thrust washers
M 02-07-03
1015
Notes
Page 2 of 4
0312 1170 - 0165
11/2003
11 Component data
Thrust washers
M 02-07-03
1015
1
Upper thrust washer

A
37321 0
Pos.
Inspection
method / tool
Identification
Check thrust washers for scoring, overheating, and cracks.
Thickness (Over-dimension stage 1)
Micrometer
11/2003
Unit
Visual inspection
Thickness
Value
0312 1170 - 0165
3.360
+ 0.050
0
[mm]
3.485
+ 0.045
0
[mm]
3.610
+ 0.050
0
[mm]
Page 3 of 4
11 Component data
Thrust washers
M 02-07-03
2
1015
Lower thrust washer

A
37322 0
Pos.
Inspection
method / tool
Identification
Check thrust washers for scoring, overheating, and cracks.
Micrometer
Page 4 of 4
Unit
Visual inspection
Thickness
Value
0312 1170 - 0165
3.360
+ 0.050
0
[mm]
3.485
+ 0.045
0
[mm]
3.610
+ 0.050
0
[mm]
11/2003
1015
M 02-09-07
11 Component data
Piston
M 02-09-07
Piston
35219 1
11/2003
0312 1171 - 0165
Page 1 of 4
11 Component data
Piston
M 02-09-07
1015
Notes
Page 2 of 4
0312 1171 - 0165
11/2003
1015
Pos.
Identification
Check pistons for scoring, overheating,
and cracks.
Piston height
Piston diameter
(122.07 mm from edge of piston skirt)
Piston diameter
Piston diameter
Width of 1st piston ring groove
Diameter of piston pin bore
11/2003
11 Component data
Piston
M 02-09-07
Inspection method / tool
Value
Unit
Visual inspection
Caliper gauge
Micrometer
133.800
[mm]
131.260 0.010
[mm]
131.730 0.009
[mm]
131.875 0.007
[mm]
Special tool 130 400

Internal dial gauge
0312 1171 - 0165
+ 0.010
52.000 + 0.003
[mm]
Page 3 of 4
11 Component data
Piston
M 02-09-07
1015
Notes
Page 4 of 4
0312 1171 - 0165
11/2003
11 Component data
Piston rings
M 02-10-03
1015
M 02-10-03
Piston rings
36902 0
11/2003
0312 1172 - 0165
Page 1 of 4
11 Component data
Piston rings
M 02-10-03
1015
Notes
Page 2 of 4
0312 1172 - 0165
11/2003
1015
11 Component data
Piston rings
M 02-10-03
1
2
3
37337 0
Pos.
Identification
Inspection method / tool
Diameter of piston rings
Value
Unit
132.000
[mm]
Thickness of 1st piston ring

(Double-sided trapezoidal ring)
5.400 0.200
[mm]
Thickness of 2nd piston ring

(Minute ring)
5.300 0.200
[mm]
Thickness of 3rd piston ring

(Bevelled-edge slotted oil ring)
4.650 - 0.250
[mm]
Height of 1st piston ring

3.500
[mm]
Height of 2nd piston ring

(Minute ring)
2.450 - 0.030
- 0.010
[mm]
Height of 3rd piston ring

4.000 - 0.025
- 0.010
[mm]
Ring gap - 1st piston ring

0.350
+ 0.100
0
[mm]
Ring gap - 2nd piston ring

(Minute ring)
1.100
+ 0.200
0
[mm]
Ring gap - 3rd piston ring

0.400
+ 0.300
0
[mm]
Micrometer
11/2003
in cylinder with feeler gauge
0312 1172 - 0165
Page 3 of 4
11 Component data
Piston rings
M 02-10-03
1015
Notes
Page 4 of 4
0312 1172 - 0165
11/2003
1015
M 02-12-03
11 Component data
Piston pin
M 02-12-03
Piston pin
36897 0
11/2003
0312 1173 - 0165
Page 1 of 4
11 Component data
Piston pin
M 02-12-03
1015
Notes
Page 2 of 4
0312 1173 - 0165
11/2003
11 Component data
Piston pin
M 02-12-03
1015
37303 0
Pos.
Identification
Outer diameter
Length
Inspection
method / tool
Micrometer
Value
Unit
52.000
[mm]
110.000
[mm]
24.000
[mm]
Caliper gauge
C
Inner diameter
11/2003
0312 1173 - 0165
Page 3 of 4
11 Component data
Piston pin
M 02-12-03
1015
Notes
Page 4 of 4
0312 1173 - 0165
11/2003
1015
M 02-15-02
11 Component data
Pressure regulating valve
M 02-15-02

for piston cooling nozzle
36880 0
11/2003
0312 1174 - 0165
Page 1 of 4
11 Component data
M 02-15-02
1015
Notes
Page 2 of 4
0312 1174 - 0165
11/2003
1015
11 Component data
M 02-15-02
A
36881 0
Pos.
Identification
Inspection
method / tool
Valve body length
Caliper gauge
Thread
Thread gauge
Opening pressure
Flow volume at 4 bar and 115 C
11/2003
Pressure gauge
Flow test
0312 1174 - 0165
Value
Unit
31.000 1.000
M12 x 1.5
0.800
[mm]
[mm]
+ 1.100
0
5.000 1.000
[bar]
[l/min]
Page 3 of 4
11 Component data
M 02-15-02
1015
Notes
Page 4 of 4
0312 1174 - 0165
11/2003
1015
M 03-03-01
11 Component data
Cylinder liner
M 03-03-01
Cylinder liner
36885 0
11/2003
0312 1175 - 0165
Page 1 of 4
11 Component data
Cylinder liner
M 03-03-01
1015
Notes
Page 2 of 4
0312 1175 - 0165
11/2003
1015
11 Component data
Cylinder liner
M 03-03-01
B
36886 0
Pos.
Identification
Collar height
Inner diameter
11/2003
Inspection
method / tool
Value
Caliper gauge
9.200 - 0.020
[mm]
+ 0.025
0
[mm]
Internal dial gauge
0312 1175 - 0165
Unit
0
132.010
Page 3 of 4
11 Component data
Cylinder liner
M 03-03-01
1015
Measuring method for cylinder liner

Diagram for measuring the cylinder liner at points "a" and "b" in levels "1 - 4".
1
2
3
4
37338 0
Page 4 of 4
0312 1175 - 0165
11/2003
1015
M 03-08-03
11 Component data
Accessory carrier
M 03-08-03
Accessory carrier
35227 1
11/2003
0312 1176 - 0165
Page 1 of 4
11 Component data
Accessory carrier
M 03-08-03
1015
Notes
Page 2 of 4
0312 1176 - 0165
11/2003
11 Component data
Accessory carrier
M 03-08-03
1015
D
F
Identification
Inspection
method / tool
Check plane surfaces and threads for cracks and

mechanical damage.
Visual inspection
Pos.
Width of bearing surface for oil cooler
36893 0
Value
Unit
148.000
Caliper gauge
Length of bearing surface for oil cooler
547.000
Flatness of bearing surface for oil cooler
Flatness of sealing surface to crankcase
Width of opening for oil pan
Straightedge +
feeler gauge
[mm]
+ 2.000
0
[mm]
0.030
[mm]
0.040
[mm]
260.000
[mm]
20.000
[mm]
0.030
[mm]
Caliper gauge
F
Width of sealing surface to oil pan
Flatness of sealing surface to oil pan
11/2003
Straightedge +
feeler gauge
0312 1176 - 0165
Page 3 of 4
11 Component data
Accessory carrier
M 03-08-03
1015
Notes
Page 4 of 4
0312 1176 - 0165
11/2003
1015
M 03-09-01
11 Component data
Rear cover
M 03-09-01
Rear cover
35228 1
11/2003
0312 1177 - 0165
Page 1 of 4
11 Component data
Rear cover
M 03-09-01
1015
Notes
Page 2 of 4
0312 1177 - 0165
11/2003
1015
11 Component data
Rear cover
M 03-09-01
36896 0
Pos.
Identification
Check rear cover for cracks, notches,
and mechanical damage.
Diameter of sealing ring bore
11/2003
Inspection
method / tool
Value
Unit
Visual inspection
Internal dial gauge
0312 1177 - 0165
140.000
+ 0.063
0
[mm]
Page 3 of 4
11 Component data
Rear cover
M 03-09-01
1015
Notes
Page 4 of 4
0312 1177 - 0165
11/2003
1015
M 03-09-02
11 Component data
Bearing journal
M 03-09-02
Bearing journal
for intermediate gear
36891 0
11/2003
0312 1178 - 0165
Page 1 of 4
11 Component data
Bearing journal
M 03-09-02
1015
Notes
Page 2 of 4
0312 1178 - 0165
11/2003
11 Component data
Bearing journal
M 03-09-02
1015
K
36892 0
Pos.
Identification
Inspection
method / tool
Value
Unit
0
Diameter bearing journal
60.000 - 0.019
[mm]
+ 0.018
[mm]
Micrometer
B
Diameter 1 of plunger shaft
Width of groove
Diameter 2 of plunger shaft
Thread bore (Length of bolt 15 mm)
Diameter of oil hole
Width of bearing journal
50.000 + 0.002
Caliper gauge
Micrometer
Thread gauge +
Depth gauge
4.000
[mm]
- 0.009
50.000 - 0.034
[mm]
M18 x 1.5
[mm]
4.000
[mm]
0
37.800 - 0.100
[mm]
Caliper gauge
H
Total length of bearing journal
79.300
[mm]
Diameter of groove
45.000
[mm]
11/2003
0312 1178 - 0165
Page 3 of 4
11 Component data
Bearing journal
M 03-09-02
1015
Notes
Page 4 of 4
0312 1178 - 0165
11/2003
1015
M 03-10-01
11 Component data
Crankcase
M 03-10-01
Crankcase
35220 1
11/2003
0312 1179 - 0165
Page 1 of 4
11 Component data
Crankcase
M 03-10-01
1015
Notes
Page 2 of 4
0312 1179 - 0165
11/2003
11 Component data
Crankcase
M 03-10-01
1015
B
G
C
D
E
Pos.
36872 0
Inspection
method / tool
Identification
Check cylinder crankcase for cracks, notches,
and mechanical damage.
Value
Unit
Visual inspection
Flatness of cylinder head plane surface
Straightedge +
Feeler gauge
0.030
[mm]
Collar depth of cylinder liner bore
Depth gauge
8.900 0.020
[mm]
Flatness of plane surface for rear cover
Straightedge +
Feeler gauge
0.030
[mm]
Bore for cylinder liners
149.000
[mm]
Flatness of plane surface for accessory carrier
0.030
[mm]
Internal dial gauge

Straightedge +
Feeler gauge
Crankcase-main bearing bore

(Standard)
108.000
+ 0.022
0
[mm]
108.500
+ 0.022
0
[mm]
75.000
+ 0.030
0
[mm]
F
Crankcase-main bearing bore
G
Internal dial gauge
Camshaft bore
11/2003
0312 1179 - 0165
Page 3 of 4
11 Component data
Crankcase
M 03-10-01
1015
Notes
Page 4 of 4
0312 1179 - 0165
11/2003
1015
M 03-11-01
11 Component data
M 03-11-01
36873 0
11/2003
0312 1180 - 0165
Page 1 of 4
11 Component data
M 03-11-01
1015
Notes
Page 2 of 4
0312 1180 - 0165
11/2003
1015
11 Component data
M 03-11-01
A
B
2.5
1.2
10
5
2.
20
60
36874 0
Pos.
Identification
Inspection
method / tool
Value
Unit
Outer diameter
Micrometer
75.090
+ 0.030
0
[mm]
Inner diameter
Internal dial gauge
69.990
+ 0.054
0
[mm]
Width of bearing bush (Drive)

C
[mm]
25.000 - 0.500
[mm]
+ 0.012
[mm]
Caliper gauge
Width of bearing bush
32.500 - 0.500
Wall thickness of bearing bush
11/2003
Micrometer
0312 1180 - 0165
2.493 - 0
Page 3 of 4
11 Component data
M 03-11-01
1015
Notes
Page 4 of 4
0312 1180 - 0165
11/2003
11 Component data
Push rod
M 04-02-02
1015
M 04-02-02
Push rod
36925 0
11/2003
0312 1181 - 0165
Page 1 of 4
11 Component data
Push rod
M 04-02-02
1015
Notes
Page 2 of 4
0312 1181 - 0165
11/2003
11 Component data
Push rod
M 04-02-02
1015
A
36926 0
Pos.
Inspection
method / tool
Identification
Check push rod for bending and signs of
wear of the contact surfaces.
Length
Outer diameter of rocker arm cup
Diameter of push rod ball
11/2003
Value
Unit
340.000 0.350
[mm]
Visual inspection +
roll on plane surface
Micrometer
Caliper gauge
Micrometer
0312 1181 - 0165
15.000
[mm]
- 0.050
12.000 - 0.093
[mm]
Page 3 of 4
11 Component data
Push rod
M 04-02-02
1015
Notes
Page 4 of 4
0312 1181 - 0165
11/2003
1015
M 04-04-02
11 Component data
Intermediate gear
M 04-04-02
Intermediate gear
in the accessory carrier
37304 0
11/2003
0312 1182 - 0165
Page 1 of 4
11 Component data
Intermediate gear
M 04-04-02
1015
Notes
Page 2 of 4
0312 1182 - 0165
11/2003
11 Component data
Intermediate gear
M 04-04-02
1015
A
B
C
D
1
2
F
G
H
K
Pos.
Identification
37305 0
Inspection
method / tool
Value
Unit
Diameter of gear flange
Outer diameter 2 of gear sleeve
Inner diameter of bearing bore
Inner diameter of bearing bush
Diameter of pitch circle
Diameter of gear circle
Outer diameter of gear
Diameter of mount holes
Tooth width
Crank height 3 of gear sleeve
Depth gauge
1.000 - 0.100
Width of bearing bush
Caliper gauge
37.000 - 0.500
Crank height to gear circle
Total height of intermediate gear
11/2003
124.000
Caliper gauge
Inside
micrometer
88.000 - 0.019
[mm]
87.000
[mm]
65.000
+ 0.030
0
+ 0.094
[mm]
+ 2.000
0
[mm]
108.000
[mm]
194.210
[mm]
0
199.250 - 0.115
Depth gauge
0312 1182 - 0165
[mm]
60.000 + 0.040
80.000
Caliper gauge
[mm]
[mm]
9.000
[mm]
20.000
[mm]
0
[mm]
[mm]
6.000
[mm]
17.000
[mm]
25.000
[mm]
45.000
[mm]
Page 3 of 4
11 Component data
Intermediate gear
M 04-04-02
1015
Notes
Page 4 of 4
0312 1182 - 0165
11/2003
1015
M 04-04-09
11 Component data
Cover
M 04-04-09
Cover
for gear drive
36887 0
11/2003
0312 1183 - 0165
Page 1 of 4
11 Component data
Cover
M 04-04-09
1015
Notes
Page 2 of 4
0312 1183 - 0165
11/2003
11 Component data
Cover
M 04-04-09
1015
36888 0
Pos.
Inspection
method / tool
Identification
Value
Unit
Check cover for cracks, notches, and burrs.

A
Cover width
Cover height
Caliper gauge
119.000
[mm]
91.500
+ 0.300
0
[mm]
56.000
+ 0.100
0
[mm]
Depth gauge
C
Hole radius for injection pump drive
Flatness of sealing surface to crankcase
Straightedge +
Feeler gauge
0.150
[mm]
Cover length
Caliper gauge
451.000
[mm]
11/2003
0312 1183 - 0165
Page 3 of 4
11 Component data
Cover
M 04-04-09
1015
Notes
Page 4 of 4
0312 1183 - 0165
11/2003
1015
M 04-04-10
11 Component data
Cap
M 04-04-10
Cap
for gear drive
36889 0
11/2003
0312 1184 - 0165
Page 1 of 4
11 Component data
Cap
M 04-04-10
1015
Notes
Page 2 of 4
0312 1184 - 0165
11/2003
11 Component data
Cap
M 04-04-10
1015
A
B
36890 0
Pos.
Inspection
method / tool
Identification
Value
Unit
Check cap for cracks, notches, and burrs.

0
[mm]
[mm]
[mm]
Diameter of insertion collar
111.600 - 0.200
Diameter of sealing ring collar bracket
106.300 - 0.100
Caliper gauge
Diameter of sealing ring groove bottom
Width of sealing ring groove
Insertion height
11/2003
103.000 - 0.100
8.000
Depth gauge
0312 1184 - 0165
27.000 0.200
[mm]
[mm]
Page 3 of 4
11 Component data
Cap
M 04-04-10
1015
Notes
Page 4 of 4
0312 1184 - 0165
11/2003
1015
M 04-04-11
11 Component data
Plug
M 04-04-11
Plug
for gear drive
36916 0
11/2003
0312 1185 - 0165
Page 1 of 4
11 Component data
Plug
M 04-04-11
1015
Notes
Page 2 of 4
0312 1185 - 0165
11/2003
11 Component data
Plug
M 04-04-11
1015
D
9
M14 x 1,5
max 32
min 22
37306 0
Pos.
Inspection
method / tool
Identification
Check plug for cracks, notches, and burrs
Value
Unit
Visual inspection
0
Diameter of intermediate part
48.000 - 6.000
Diameter of guidance
34.500 - 0.200
Length of intermediate part and guidance
66.000 - 1.000
[mm]
Thickness of cover
16.000
[mm]
Width of O-ring groove
Diameter of O-ring groove
Diameter of cover
Total length
11/2003
Caliper gauge
3.900
+ 0.200
0
55.400
Micrometer
Caliper gauge
0312 1185 - 0165
[mm]
[mm]
[mm]
[mm]
- 0.030
60.000 - 0.120
[mm]
82.000
[mm]
Page 3 of 4
11 Component data
Plug
M 04-04-11
1015
Notes
Page 4 of 4
0312 1185 - 0165
11/2003
1015
M 04-05-04
11 Component data
Camshaft
M 04-05-04
Camshaft
37340 0
11/2003
0312 1186 - 0165
Page 1 of 4
11 Component data
Camshaft
M 04-05-04
1015
Notes
Page 2 of 4
0312 1186 - 0165
11/2003
1015
11 Component data
Camshaft
M 04-05-04
Pos.
Identification
37339 0
Inspection
method / tool
Value
Unit
Check cams and bearing journals for

scoring and mechanical damage.
A
Length
Caliper gauge
532.000 0.300
Diameter of bearing journal
Micrometer
70.000 - 0.090
Ovality of camshaft
Dial gauge
11/2003
0312 1186 - 0165
- 0.060
0.060
[mm]
[mm]
[mm]
Page 3 of 4
11 Component data
Camshaft
M 04-05-04
1015
Notes
Page 4 of 4
0312 1186 - 0165
11/2003
1015
M 04-05-05
11 Component data
Thrust cover
M 04-05-05
Thrust cover
for camshaft
36922 0
11/2003
0312 1187 - 0165
Page 1 of 4
11 Component data
Thrust cover
M 04-05-05
1015
Notes
Page 2 of 4
0312 1187 - 0165
11/2003
1015
11 Component data
Thrust cover
M 04-05-05
36923 0
Pos.
Identification
Inspection
method / tool
Value
Unit
Clean plane surfaces and check for

mechanical damage and flatness.
A
Diameter of cover guidance
Length
Length from bearing surface to thrust

surface
11/2003
Micrometer
- 0.030
76.000 - 0.104
[mm]
Caliper gauge
53.000
[mm]
Depth gauge
46.150 - 0.200
0312 1187 - 0165
[mm]
Page 3 of 4
11 Component data
Thrust cover
M 04-05-05
1015
Notes
Page 4 of 4
0312 1187 - 0165
11/2003
1015
M 04-05-06
11 Component data
Drive gear
M 04-05-06
Drive gear
for camshaft
36919 0
11/2003
0312 1188 - 0165
Page 1 of 4
11 Component data
Drive gear
M 04-05-06
1015
Notes
Page 2 of 4
0312 1188 - 0165
11/2003
11 Component data
Drive gear
M 04-05-06
1015
6
B
A
36920 0
Identification
Inspection
method / tool
Check surface for signs of overheating, seize up

or cracks.
Visual inspection
Pos.
Diameter gear circle
Hole diameter
Width
Tooth width
11/2003
calculative
Value
Unit
250.080
[mm]
17.100
[mm]
0
Caliper gauge
56.000 - 0.500
+ 0.200
29.500 - 0.300
0312 1188 - 0165
[mm]
[mm]
Page 3 of 4
11 Component data
Drive gear
M 04-05-06
1015
Notes
Page 4 of 4
0312 1188 - 0165
11/2003
11 Component data
1015 Camshaft intermediate gear
M 04-05-07
M 04-05-07
Camshaft intermediate gear

in gear drive
36917 0
11/2003
0312 1189 - 0165
Page 1 of 4
11 Component data
Camshaft intermediate gear 1015
M 04-05-07
Notes
Page 2 of 4
0312 1189 - 0165
11/2003
11 Component data
1015 Camshaft intermediate gear
M 04-05-07
37341 0
Identification
Inspection
method / tool
Check intermediate gear for cracks, notches, and

burrs.
Visual inspection
Pos.
Value
Unit
Diameter
Measurement
Inner diameter
Measurement
85.000
Width
Measurement
18.000 - 0.100
11/2003
0312 1189 - 0165
165.500 - 0.100
[mm]
+ 0.035
0
[mm]
[mm]
Page 3 of 4
11 Component data
Camshaft intermediate gear 1015
M 04-05-07
Notes
Page 4 of 4
0312 1189 - 0165
11/2003
1015
M 06-06-04
11 Component data
Turbocharger
M 06-06-04
Turbocharger
36863 0
11/2003
0312 1190 - 0165
Page 1 of 4
11 Component data
Turbocharger
M 06-06-04
1015
Notes
Page 2 of 4
0312 1190 - 0165
11/2003
11 Component data
Turbocharger
M 06-06-04
1015
37317 0
Pos.
Inspection
method / tool
Identification
Check turbocharger for mechanical damage,
cracks, and oil leakage.
Value
Unit
Visual inspection
References
see work card "W 06-06-05 - Measure turbocharger bearing play"
see chapter 10, component functions "F 06-06-04 - Turbocharger"
11/2003
0312 1190 - 0165
Page 3 of 4
11 Component data
Turbocharger
M 06-06-04
1015
Notes
Page 4 of 4
0312 1190 - 0165
11/2003
1015
M 07-04-04
11 Component data
Injection pump
M 07-04-04
Injection pump
36847 0
References
see chapter 10, component functions "F 07-04-04 - Injection pump"
11/2003
0312 1191 - 0165
Page 1 of 2
11 Component data
Injection pump
M 07-04-04
1015
Notes
Page 2 of 2
0312 1191 - 0165
11/2003
11 Component data
Injector
M 07-07-03
1015
M 07-07-03
Injector
35217 1
11/2003
0312 1192 - 0165
Page 1 of 4
11 Component data
Injector
M 07-07-03
1015
Notes
Page 2 of 4
0312 1192 - 0165
11/2003
11 Component data
Injector
M 07-07-03
1015
37342 0
Pos.
Identification
Compensation disc
Pressure spring
Pressure bolt
Intermediate part
Injector
Nozzle tensioning nut
11/2003
Remark
available disc thickness : 1.02, 1.04, 1.06 ..... 1.98 mm
0312 1192 - 0165
Page 3 of 4
11 Component data
Injector
M 07-07-03
1015
Notes
Page 4 of 4
0312 1192 - 0165
11/2003
1015
M 07-11-04
11 Component data
Fuel delivery pump
M 07-11-04
Fuel delivery pump
36849 0
Reference
see "Chapter 10, component functions "F 07-11-04 - Fuel delivery pump"
11/2003
0312 1193 - 0165
Page 1 of 2
11 Component data
Fuel delivery pump
M 07-11-04
1015
Notes
Page 2 of 2
0312 1193 - 0165
11/2003
1015
M 08-08-02
11 Component data
Oil cooler
M 08-08-02
Oil cooler
36937 0
11/2003
0312 1194 - 0165
Page 1 of 4
11 Component data
Oil cooler
M 08-08-02
1015
Notes
Page 2 of 4
0312 1194 - 0165
11/2003
11 Component data
Oil cooler
M 08-08-02
1015
A
B
36938 0
Pos.
Inspection
method / tool
Identification
Value
Unit
Check oil cooler for cracks, notches, and other

mechanical damage.
A
Length
406.000
[mm]
Bore distance
340.000
[mm]
Height
Diameter of the four screw bores
72.600 2.000
[mm]
9.000 0.400
[mm]
Caliper gauge
E
Bore distance
63.000
[mm]
Width
99.000
[mm]
Flatness
0.300
[mm]
Diameter of both oil passages
11/2003
20.000 0.200
0312 1194 - 0165
[mm]
Page 3 of 4
11 Component data
Oil cooler
M 08-08-02
1015
Notes
Page 4 of 4
0312 1194 - 0165
11/2003
11 Component data
Vibration damper
M 12-01-04
1015
M 12-01-04
Vibration damper
37307 0
11/2003
0312 1195 - 0165
Page 1 of 4
11 Component data
Vibration damper
M 12-01-04
1015
Notes
Page 2 of 4
0312 1195 - 0165
11/2003
11 Component data
Vibration damper
M 12-01-04
1015
C
E
37308 0
Identification
Inspection
method / tool
Check vibration damper for silicon oil leaks and

outside damage.
Visual inspection
Pos.
Outer diameter
Inner diameter
Diameter of pitch circle for assembly with

flange groove
Angle between bores for flange groove bolts
Diameter of bores for flange groove bolts
Caliper gauge
Torque angle gauge
Value
Unit
340.000
[mm]
202.000
[mm]
146.000
[mm]
30
9.000
[]
+ 0.200
0
[mm]
Caliper gauge
F
Width
Imbalance
11/2003
Wheel balancer
0312 1195 - 0165
31.500
[mm]
46.000
[gcm]
Page 3 of 4
11 Component data
Vibration damper
M 12-01-04
1015
Notes
Page 4 of 4
0312 1195 - 0165
11/2003
11 Component data
Flange groove
M 12-01-05
1015
M 12-01-05
Flange groove
for vibration damper
36901 0
11/2003
0312 1196 - 0165
Page 1 of 4
11 Component data
Flange groove
M 12-01-05
1015
Notes
Page 2 of 4
0312 1196 - 0165
11/2003
1015
11 Component data
Flange groove
M 12-01-05
E
G
A
B
Identification
Inspection
method / tool
Check flange groove for cracks, notches,

burrs, and mechanical damage.
Visual inspection
Pos.
Outer diameter of flange groove
Diameter of flange for crankshaft
Inner diameter of flange groove
Diameter of retainer for vibration damper
Depth of flange groove
Thread
Thread
37309 0
Value
Unit
162.000
[mm]
117.000
[mm]
Caliper gauge
Internal dial gauge
Micrometer
Caliper gauge
45.000
+ 0.025
0
- 0.043
130.000 - 0.083
[mm]
[mm]
45.000
[mm]
M10
[mm]
M8
[mm]
Visual inspection
11/2003
0312 1196 - 0165
Page 3 of 4
11 Component data
Flange groove
M 12-01-05
1015
Notes
Page 4 of 4
0312 1196 - 0165
11/2003
1015
M 12-06-01
11 Component data
Flywheel
M 12-06-01
Flywheel
36952 0
11/2003
0312 1197 - 0165
Page 1 of 4
11 Component data
Flywheel
M 12-06-01
1015
Notes
Page 2 of 4
0312 1197 - 0165
11/2003
11 Component data
Flywheel
M 12-06-01
1015
37318 0
Pos.
Inspection
method / tool
Identification
Check flywheel for mechanical damage and
burrs.
Outer diameter
Diameter for starter ring gear
Thickness
Value
Unit
Visual inspection
Caliper gauge
472.000 - 1.000
[mm]
Micrometer
464.000 + 0.540
+ 0.637
[mm]
116.000
[mm]
315.000
[mm]
Caliper gauge
Inner diameter
11/2003
0312 1197 - 0165
Page 3 of 4
11 Component data
Flywheel
M 12-06-01
1015
Notes
Page 4 of 4
0312 1197 - 0165
11/2003
11 Component data
Starter ring gear
M 12-06-03
1015
M 12-06-03
Starter ring gear
36953 0
11/2003
0312 1198 - 0165
Page 1 of 4
11 Component data
Starter ring gear
M 12-06-03
1015
Notes
Page 2 of 4
0312 1198 - 0165
11/2003
1015
11 Component data
Starter ring gear
M 12-06-03
C
37319 0
Pos.
Inspection
method / tool
Identification
Check ring gear and teeth for mechanical
damage.
Unit
Visual inspection
Outer diameter
Caliper gauge
Inner diameter
Internal dial gauge
Thickness
11/2003
Value
Caliper gauge
0312 1198 - 0165
507.000 - 0.300
[mm]
+ 0.289
0
[mm]
22.000 0.300
[mm]
463.800
Page 3 of 4
11 Component data
Starter ring gear
M 12-06-03
1015
Notes
Page 4 of 4
0312 1198 - 0165
11/2003
Workshop manual
BF6M 1015 CP
0312 0909
Hinweis fr Druckerei
Farbe: wei
Papier: Ikonofix 250 g/Qm
Workshop manual
BF6M 1015 CP
DEUTZ AG
Service Information Systems
Deutz-Mlheimer Strae 147-149
D - 51063 Kln
Tel.: + 49 (0) 2 21-8 22-0
Fax: + 49 (0) 2 21-8 22-53 58
http://www.deutz.de
Printed in Germany
All rights reserved
1st edition (b), 11/2003
Order no. 0312 0909
The engine company.

0312 1061 - 0165
11/2003

1015CP - BF6M - Workshop - Manual PDF

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1015CP - BF6M - Workshop - Manual PDF

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Workshop Manual

In view of continuous design improvements or changes, the technical

Test and adjustment data

Work card index

0312 1062 - 0165

Preparation for commissioning

Filling in engine oil

0312 1062 - 0165

Rocker arm - inlet

0312 1062 - 0165

0312 1063 - 0165

0312 1063 - 0165

0312 1063 - 0165

0312 1063 - 0165

0312 1064 - 0165

0312 1064 - 0165

Servicing and maintenance work

Caution when engine is running

0312 1064 - 0165

0312 1064 - 0165

0312 1065 - 0165

0312 1065 - 0165

Safety and accident prevention regulations

to the machine room:

0312 1065 - 0165

Operating instructions and workshop manual

General, table of contents

0312 1065 - 0165

Numbering of work cards

Maintenance group (same for all engines)

General / overall activities

0312 1065 - 0165

DEUTZ, issue of the servicing documentation

DEUTZ internal part number of the work card

0312 1065 - 0165

Always renew when reassembling

See technical data (Test and adjustment data)

See technical data (Tightening regulations)

0312 1065 - 0165

0312 1065 - 0165

Test and adjustment data

0312 1066 - 0165

0312 1066 - 0165

General engine data

Length of engine with adapter housing

Width of engine with adapter housing

Height of engine with adapter housing

Weight of engine according to DIN 70020-A

3200 bis 3400

0312 1066 - 0165

Bore diameter for valve seat ring (inlet)

Bore diameter for valve seat ring (outlet)

Bore diameter for valve seat ring (inlet)

Bore diameter for valve seat ring (outlet)

Bore diameter for valve guide

Bore diameter for valve guide

Bore diameter for valve guide

Height of cylinder head

Height of cylinder head

Outer diameter of valve guide

Outer diameter of valve guide

Auendurchmesser der Ventilfhrung