Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
competence level 2
TCD 2012 2V
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This document is subject to changes which may become necessary in the course of further de-
velopment of the engines. Reprinting and reproductions of any kind, even in part, require our
written permission.
Regarding copyright questions and licensing agreements
please contact : VE-FL, Mr. Lippke
Phone.: + 49 (0) 221 822-2599
E-Mail: lippke.d@deutz.com
DEUTZ AG
Service Information Systems
Ottostraße 1
D-51149 Köln (Cologne)
Phone.: +49 (0) 221-822-0
Fax: +49 (0) 221-822-3525
Internet: www.deutz.com
E-Mail: info@deutz.com
Printed in Germany
All rights reserved
1st Edition © 02/2011
The engine company. Order No. 0312 4262 en
DEUTZ engines Table of contents
1 Foreword
2 General
3 User notes
3.1 General
3.2 Specifications
3.3 Operating manual and workshop manual
3.4 Job cards
3.5 Explanation of symbols
6 Job cards
7 Commercial tools
8 Special tools
© 02/2010
1/2 OBJ_DOKU-22196-001.fm
Table of contents DEUTZ engines
© 02/2010
2/2 OBJ_DOKU-22196-001.fm
DEUTZ engines Foreword
1 Foreword
© 05/2005
1/4 OBJ_DOKU-22197-001.fm
Foreword DEUTZ engines
© 05/2005
2/4 OBJ_DOKU-22197-001.fm
DEUTZ engines Foreword
● Read and observe the information in this docu- ● Repair of the engine must correspond to its use
mentation. You will avoid accidents, retain the for the intended purpose. Only parts released by 1
manufacturer's warranty and possess a fully the manufacturer for the respective purpose may
functional and ready to operate engine. be used for conversion work. Unauthorised mod-
● This engine is built exclusively for purpose ac- ifications to the engine exclude manufacturer lia-
cording to the scope of delivery - defined by the bility for resulting damages. Failure to observe
equipment manufacturer (use for the intended this will void the warranty!
purpose). Any use above and beyond this is con- ● The engines made by DEUTZ are developed for
sidered improper use. The manufacturer will not a wide range of applications. A wide range of var-
be liable for damages resulting from this. The iants ensures that the respective special require-
user bears the sole risk. ments are met.
● Use for the intended purpose also includes ob- ● The engine is equipped according to the installa-
servance of the operating, maintenance and re- tion case, i.e. not all the parts and components
pair instructions specified by the manufacturer. described in this documentation are installed in
The engine may only be used, maintained and your engine necessarily.
repaired by persons who are familiar with this ● We have done our best to highlight the differenc-
and are aware of the risks involved. es so that you can easily find the operating, main-
● Make sure that this documentation is available to tenance and repair instructions relevant to your
everyone involved in the operation, maintenance engine.
and repair and that they have understood the
contents.
● Failure to observe this documentation may lead
to malfunctions and engine damage as well as in-
jury to persons for which the manufacturer will
not accept any liability.
● Prerequisite for proper maintenance and repair is
the availability of all the necessary equipment,
conventional and special tools and their perfect
condition.
● Engine parts such as springs, clamps, elastic re-
taining rings etc. pose an increased risk of injury
when handled incorrectly.
● The pertinent rules for the prevention of acci-
dents and other generally recognised health and
We are at your service for any questions you may
safety regulations must be observed.
have in this matter.
● Maximum economy, reliability and long life is only
guaranteed when using DEUTZ original parts.
Your DEUTZ AG
© 05/2005
3/4 OBJ_DOKU-22197-001.fm
Foreword DEUTZ engines
© 05/2005
4/4 OBJ_DOKU-22197-001.fm
DEUTZ engines General
2 General
© 11/2005
1/4 OBJ_DOKU-22198-001.fm
General DEUTZ engines
© 11/2005
2/4 OBJ_DOKU-22198-001.fm
DEUTZ engines General
© 11/2005
3/4 OBJ_DOKU-22198-001.fm
General DEUTZ engines
© 11/2005
4/4 OBJ_DOKU-22198-001.fm
DEUTZ engines User notes
3 User notes
© 02/2010
1/8 OBJ_DOKU-22199-001.fm
User notes DEUTZ engines
© 02/2010
2/8 OBJ_DOKU-22199-001.fm
DEUTZ engines User notes
© 02/2010
3/8 OBJ_DOKU-22199-001.fm
User notes DEUTZ engines
– Damaged injection lines and high-pressure ● Remove loose parts (for example paint chips
pipes must be renewed. from assembly work) with an industrial vacuum
– Injection lines and high pressure fuel lines cleaner or other suction device. Only suction may
must never be connected when the engine is be used in assembly work on the open fuel sys-
running. tem.
– Do not place hands near to a leak in the high ● Only work on the fuel system in a clean environ-
pressure fuel system. ment (no dust, no grinding or welding). Avoid
3 draughts (dust). Clean the workshop floor regu-
– Also carefully check all high pressure compo-
larly. No brake or performance test benches may
nents visually before performing tests on the
be kept or operated in the same room.
running engine. Wear suitable protective
clothing (for example protective glasses). ● Air currents which kick up dust, such as those
Leaks are a potential source of danger for caused by brake repairs or the starting of en-
workshop personnel. gines, should be avoided.
– Even if no leaks are discernible on the high ● For work such as removal and installation on de-
pressure fuel system, the workshop personnel fective hydraulic components on the Common
should avoid the immediate danger zone or Rail System it is recommended to partition off a
wear suitable protective clothing (such as pro- separate workshop area in the factory. This must
tective glasses) when performing tests on the be separate from other areas in which general
running engine and during the first trial run. vehicle repairs such as brake repairs are carried
out.
– Always stay out of range of a fuel jet, as it
could cause severe injury. ● No general machine tools may be operated in
this room.
– Smoking is strictly prohibited when working on
the fuel system. ● Regular cleaning of the workshop area is manda-
tory. Draughts, ventilation systems and heating
– Do not work near to sparks and flames.
fans should be minimised.
– Never disconnect an injector when the engine
● Areas of the engine room from which particles of
is running.
dirt could be loosened (for example the bottom
3.2.2 Cleanliness instructions and measures part of the tipped driver cab) must be covered
for handling the DEUTZ Common Rail with fresh clean film.
System ● Working materials and tools must be cleaned be-
The DEUTZ Common Rail system used in the fore work. Only use tools without damage to the
DEUTZ engines consists of high-precision compo- chrome plating or tools which are not chrome-
nents which are exposed to extreme stress. Great plated.
attention must be paid to cleanliness when working Notes and measures to be observed during work on
on the fuel system due to the high precision technol- the fuel system or with the fuel system open.
ogy.
● Only work in clean overalls.
Notes and measures to be observed before starting
● Only lint-free cleaning cloths may be used for
work on the fuel system
work on the fuel system.
● The fuel system must be closed. Make a visual ● Remove loose parts (for example paint chips
inspection for leaks / damage to the fuel system. from assembly work) with an industrial vacuum
● Clean the whole engine and engine room with the cleaner or other suction device. Only suction may
system closed before starting work on the fuel be used in assembly work on the open fuel sys-
system. tem.
● The engine must be dry when you start working ● Working materials and tools must be cleaned be-
on the fuel system. fore work. Only use tools without damage to the
● Blowing (dry) with compressed air is only permis- chrome plating or tools which are not chrome-
sible with the fuel system closed. plated.
● When using a steam jet, first cover up the control ● Do not use used cleaning fluid or test fluid for
unit, the cable plugs, all other electrical plug con- cleaning.
nections and the generator. Also, the steam jet ● Compressed air must not be used for cleaning on
may not be pointed directly at them. the open fuel system.
● Electrical plug connections must be plugged ● Work on removed components may only be per-
when spraying. formed at a suitably equipped workbench.
© 02/2010
4/8 OBJ_DOKU-22199-001.fm
DEUTZ engines User notes
● When removing and installing components, no newed parts / operating materials must be stored,
materials which can leave behind particles or fi- transported and disposed of according to regula-
bres (cardboard, wood, cloths) may be used. tions. The owner himself is responsible for this.
● Removed parts may only be rubbed down with Disposal includes recycling and the scrapping of
clean, lint-free cloths. No dirt particles may be parts / operating materials, although recycling has
rubbed into the components. priority.
● Openings on the components and on the engine Details of disposal and their monitoring are gov-
must be closed immediately with suitable stop- erned by regional, national and international laws
3
pers/caps. and directives which the system operator must ob-
● The stoppers/caps may only be removed imme- serve on his own responsibility.
diately before installing.
● Store stoppers/caps free from dust and dirt in the
original packaging and dispose of after using
once.
● Only remove new parts from the original packag-
ing just before installation.
● Removed components must be kept in new, seal-
able bags or - if available - in the packaging of the
new parts.
● Always use the original packaging of the new part
to send back the removed components.
Notes and measures for the vehicle workshop area
● For work such as removal and installation on de-
fective hydraulic components on the Common
Rail System it is recommended to partition off a
separate workshop area in the factory. This must
be separate from other areas in which general
vehicle repairs such as brake repairs are carried
out.
● The workshop floor is sealed or tiled.
● No welding gear, grinders, general machine
tools, brakes or performance test benches may
be operated in this room.
● Regular cleaning of the workshop area is manda-
tory. Draughts, ventilation systems and heating
fans should be minimised.
Notes and measures for workbench and tools in the
vehicle hall
● A special workbench must be set up for work on
removed components.
● Clean the removal and installation tools regularly
and keep them in a closed tool cabinet.
● Remove loose parts (for example paint chips
from assembly work) with an industrial vacuum
cleaner or other suction device.
● Working materials and tools must be cleaned be-
fore work. Only use tools without damage to the
chrome plating or tools which are not chrome-
plated.
3.2.3 Disposal regulations
The work described in the operation manual and
workshop manual necessitates renewal of parts and
operating materials among other things. The re-
© 02/2010
5/8 OBJ_DOKU-22199-001.fm
User notes DEUTZ engines
© 02/2010
6/8 OBJ_DOKU-22199-001.fm
DEUTZ engines User notes
5
Caution! 3
16 Danger to the component/engine. Non-
6 compliance can lead to destruction of the
15
component/engine.
6 7 Must be observed!
14 Note
General notes on assembly, environmental
8
protection etc. No potential danger for man
13
or machine.
Tool
Conventional and special tools required for
12 the work.
8
Auxiliary materials
Working materials required in addition to
the tools for performing the work
(e.g. greases, oils, adhesives, sealants)
11 10 9 References
to important documents or job cards for the
1. DEUTZ AG, work process.
publisher of service documentation For example: Job card W 04-05-05
2. Engine type Reference
3. Module to a document or a job card within the work
4. Numbering of the job cards process.
5. Title of job card Test and setting data
The necessary values are specified here.
6. Reference to other modules with job cards
If several values are necessary, a cross
7. Chapter reference is given to the Test and Setting
8. Graphic or photo Values table.
9. DEUTZ internal creation number For example:
ID no. P01 61 = valve clearance, inlet
10.Page number
11.Date of issue of job card Tightening specification
The necessary values are specified here.
12.Note If several values are necessary, a cross
13.Danger / Important reference is given to the Tightening
14.Work sequence Specifications table.
15.Auxiliary materials For example:
ID no. A01 001 = cylinder head screws
16.Conventional tools, special tools
© 02/2010
7/8 OBJ_DOKU-22199-001.fm
User notes DEUTZ engines
© 02/2010
8/8 OBJ_DOKU-22199-001.fm
TCD 2012 2V Job card overview
5
5 Job card overview
5.1 Sorted alphabetically
© 03/2010
1/8 OBJ_DOKU-22201-001.fm
Job card overview
Sorted alphabetically TCD 2012 2V
© 03/2010
2/8 OBJ_DOKU-22201-001.fm
Job card overview
TCD 2012 2V Sorted alphabetically
© 03/2010
3/8 OBJ_DOKU-22201-001.fm
Job card overview
Sorted alphabetically TCD 2012 2V
© 03/2010
4/8 OBJ_DOKU-22201-001.fm
Job card overview
TCD 2012 2V Sorted numerically
5
5.2 Sorted numerically
© 03/2010
5/8 OBJ_DOKU-22201-001.fm
Job card overview
Sorted numerically TCD 2012 2V
© 03/2010
6/8 OBJ_DOKU-22201-001.fm
Job card overview
TCD 2012 2V Sorted numerically
© 03/2010
7/8 OBJ_DOKU-22201-001.fm
Job card overview
Sorted numerically TCD 2012 2V
© 03/2010
8/8 OBJ_DOKU-22201-001.fm
DEUTZ engines Job cards
6 Job cards
6
© 11/2005
1/2 OBJ_DOKU-22202-001.fm
Job cards DEUTZ engines
© 11/2005
2/2 OBJ_DOKU-22202-001.fm
Crankcase
TCD 2012 2V W 01-01-01
© 42642-0
© 42680-0
© 03/2010
1/8 OBJ_DOKU-22203-001.fm
Crankcase
W 01-01-01 TCD 2012 2V
6
© 42681-0
© 42682-0
© 42683-0
© 03/2010
2/8 OBJ_DOKU-22203-001.fm
Crankcase
TCD 2012 2V W 01-01-01
6
© 42684-0
© 42685-0
© 42686-0
© 03/2010
3/8 OBJ_DOKU-22203-001.fm
Crankcase
W 01-01-01 TCD 2012 2V
6
© 42687-0
© 42688-0
© 42689-0
© 03/2010
4/8 OBJ_DOKU-22203-001.fm
Crankcase
TCD 2012 2V W 01-01-01
6
© 42690-0
© 42691-0
© 42692-0
© 03/2010
5/8 OBJ_DOKU-22203-001.fm
Crankcase
W 01-01-01 TCD 2012 2V
6
© 42693-0
© 42694-0
© 42681-0
© 03/2010
6/8 OBJ_DOKU-22203-001.fm
Crankcase
TCD 2012 2V W 01-01-01
6
© 42695-0
© 42680-0
13 Nm
3
● Position hose clip (4).
Use hose clip pliers.
© 42642-0
© 03/2010
7/8 OBJ_DOKU-22203-001.fm
Crankcase
W 01-01-01 TCD 2012 2V
© 03/2010
8/8 OBJ_DOKU-22203-001.fm
Front cover
TCD 2012 2V W 01-02-01
– Self-tapping screw
– Washer
© 43643-0
© 42620-0
© 03/2010
1/6 OBJ_DOKU-22204-001.fm
Front cover
W 01-02-01 TCD 2012 2V
6
© 42621-0
© 42622-0
© 42623-0
© 03/2010
2/6 OBJ_DOKU-22204-001.fm
Front cover
TCD 2012 2V W 01-02-01
6
© 42624-0
© 42625-0
1
© 42626-0
© 03/2010
3/6 OBJ_DOKU-22204-001.fm
Front cover
W 01-02-01 TCD 2012 2V
6 1
© 42627-0
1
© 42628-0
© 42629-0
© 03/2010
4/6 OBJ_DOKU-22204-001.fm
Front cover
TCD 2012 2V W 01-02-01
6
© 42622-0
© 03/2010
5/6 OBJ_DOKU-22204-001.fm
Front cover
W 01-02-01 TCD 2012 2V
© 03/2010
6/6 OBJ_DOKU-22204-001.fm
Front cover
TCD 2012 2V W 01-02-02
© 39876-0
© 44875-0
© 03/2010
1/4 OBJ_DOKU-22205-001.fm
Front cover
W 01-02-02 TCD 2012 2V
Attention!
Do not damage the peripheral surfaces
and the sealing surfaces.
● Join the impact sleeve (1) and the shaft sleeve (2).
● Place the shaft sleeve with impact sleeve centrally on
the crankshaft with the collar (3) facing the crank-
shaft.
6
© 39872-0
© 39891-0
© 39875-0
© 03/2010
2/4 OBJ_DOKU-22205-001.fm
Front cover
TCD 2012 2V W 01-02-02
6
© 39871-0
1
1
1
1
© 44542-0
© 39873-0
© 03/2010
3/4 OBJ_DOKU-22205-001.fm
Front cover
W 01-02-02 TCD 2012 2V
6
© 39874-0
© 44875-0
© 03/2010
4/4 OBJ_DOKU-22205-001.fm
Front cover
TCD 2012 2V W 01-03-01
© 42994-0
© 42995-0
© 03/2010
1/6 OBJ_DOKU-22206-001.fm
Front cover
W 01-03-01 TCD 2012 2V
6
© 42996-0
© 42997-0
2
© 42998-0
© 03/2010
2/6 OBJ_DOKU-22206-001.fm
Front cover
TCD 2012 2V W 01-03-01
6
© 42999-0
© 43000-0
1
© 43001-0
© 03/2010
3/6 OBJ_DOKU-22206-001.fm
Front cover
W 01-03-01 TCD 2012 2V
● Press the front cover up and align flush with the oil
pan sealing surface (arrows).
6
© 43002-0
© 36521-1
© 43003-0
© 03/2010
4/6 OBJ_DOKU-22206-001.fm
Front cover
TCD 2012 2V W 01-03-01
6
© 43004-0
© 42994-0
© 43038-0
© 03/2010
5/6 OBJ_DOKU-22206-001.fm
Front cover
W 01-03-01 TCD 2012 2V
© 03/2010
6/6 OBJ_DOKU-22206-001.fm
Lubricating oil sump
TCD 2012 2V W 02-01-01
© 42769-0
© 42770-0
© 03/2010
1/6 OBJ_DOKU-22210-001.fm
Lubricating oil sump
W 02-01-01 TCD 2012 2V
6
© 45969-0
© 45970-0
© 45968-0
© 03/2010
2/6 OBJ_DOKU-22210-001.fm
Lubricating oil sump
TCD 2012 2V W 02-01-01
6
© 43450-1
© 46907-0
Attention!
Wear protective glasses.
© 46908-0
© 03/2010
3/6 OBJ_DOKU-22210-001.fm
Lubricating oil sump
W 02-01-01 TCD 2012 2V
Attention!
Wear protective glasses.
6
© 45972-0
© 43451-0
© 42771-0
© 03/2010
4/6 OBJ_DOKU-22210-001.fm
Lubricating oil sump
TCD 2012 2V W 02-01-01
6
© 45678-0
© 42772-2
23 19 15 11 7 3 2 6 10 14 18 22 26 30
© 43414-0
© 03/2010
5/6 OBJ_DOKU-22210-001.fm
Lubricating oil sump
W 02-01-01 TCD 2012 2V
20 16 12 8 4 1 5 9 13 17
24 21
26 25
23 22
19 15 11 7 3 2 6 10 14 18
6
© 43413-0
© 42769-0
© 03/2010
6/6 OBJ_DOKU-22210-001.fm
V-belt pulley add-on
TCD 2012 2V W 05-01-01
© 44037-1
1
1
© 44038-0
© 03/2010
1/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
W 05-01-01 TCD 2012 2V
6
© 44039-0
© 44040-0
© 44041-0
© 03/2010
2/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
TCD 2012 2V W 05-01-01
6
© 44526-0
© 44042-0
© 44043-0
© 03/2010
3/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
W 05-01-01 TCD 2012 2V
6
© 44527-0
© 44528-0
1 2
© 44529-0
© 03/2010
4/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
TCD 2012 2V W 05-01-01
6
© 44530-0
© 44531-0
● Fix the tooth lock washer with the largest hole (1) to
the V-belt pulley with clamping bushing (2).
Note installation position of the tooth lock
washer.
© 44532-0
© 03/2010
5/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
W 05-01-01 TCD 2012 2V
6
© 44533-0
© 44534-0
© 44535-0
© 03/2010
6/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
TCD 2012 2V W 05-01-01
● Mount adapter.
● Fasten screws.
The centring bolt (1) must face the V-belt
pulley.
6
© 44536-0
© 44537-0
© 44538-0
© 03/2010
7/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
W 05-01-01 TCD 2012 2V
6
© 44538-0
© 44043-0
© 44049-0
© 03/2010
8/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
TCD 2012 2V W 05-01-01
6
© 44591-0
© 44050-0
© 44051-0
© 03/2010
9/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
W 05-01-01 TCD 2012 2V
6
© 44052-0
© 44041-0
© 44040-0
© 03/2010
10/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
TCD 2012 2V W 05-01-01
1
6
© 44053-0
© 44591-0
© 44054-0
© 03/2010
11/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
W 05-01-01 TCD 2012 2V
1
6
© 44055-0
3 2
© 44056-0
© 44057-0
© 03/2010
12/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
TCD 2012 2V W 05-01-01
6
© 44094-0
© 44539-0
© 44091-0
© 03/2010
13/14 OBJ_DOKU-22212-001.fm
V-belt pulley add-on
W 05-01-01 TCD 2012 2V
6
© 44092-0
© 44093-0
© 44094-0
© 03/2010
14/14 OBJ_DOKU-22212-001.fm
Torsional vibration damper
TCD 2012 2V W 05-02-01
2
© 42891-0
1
1
© 42892-0
© 03/2010
1/2 OBJ_DOKU-22213-001.fm
Torsional vibration damper
W 05-02-01 TCD 2012 2V
6
© 42893-0
© 42894-0
© 03/2010
2/2 OBJ_DOKU-22213-001.fm
Flywheel
TCD 2012 2V W 05-03-01
2
1
© 42824-0
© 42825-0
© 03/2010
1/4 OBJ_DOKU-22214-001.fm
Flywheel
W 05-03-01 TCD 2012 2V
6
© 34224-2
Attention!
Renew screws every time they are loo-
sened.
M10x30
● Tighten screws alternately.
– Stage 1:
30 Nm
– Stage 2:
60°
– Stage 3:
30°
● Remove guide pin.
© 42826-0
Attention!
Renew screws every time they are loo-
sened.
M10x35 - M10x85
● Tighten screws alternately.
– Stage 1:
40 Nm
– Stage 2:
60°
– Stage 3:
60°
● Remove guide pin.
© 42826-0
© 03/2010
2/4 OBJ_DOKU-22214-001.fm
Flywheel
TCD 2012 2V W 05-03-01
6
© 31115-1
2
1
© 42824-0
© 03/2010
3/4 OBJ_DOKU-22214-001.fm
Flywheel
W 05-03-01 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22214-001.fm
Cylinder head
TCD 2012 2V W 08-00-01
© 43005-0
© 43006-0
© 03/2010
1/4 OBJ_DOKU-22223-001.fm
Cylinder head
W 08-00-01 TCD 2012 2V
6
© 43007-0
© 43008-0
© 03/2010
2/4 OBJ_DOKU-22223-001.fm
Cylinder head
TCD 2012 2V W 08-00-01
6
© 43008-0
© 43009-0
© 03/2010
3/4 OBJ_DOKU-22223-001.fm
Cylinder head
W 08-00-01 TCD 2012 2V
Technical Data
Tightening specifications
ID no. Name Screw type Notes / Remark Value
Connection piece on cylinder head,
A07 004 25 Nm
clamping shoe
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
© 03/2010
4/4 OBJ_DOKU-22223-001.fm
Cylinder head cover
TCD 2012 2V W 08-01-01
© 42920-0
2
1
© 42923-0
© 03/2010
1/4 OBJ_DOKU-22224-001.fm
Cylinder head cover
W 08-01-01 TCD 2012 2V
6
© 42922-0
© 42937-0
© 42938-0
© 03/2010
2/4 OBJ_DOKU-22224-001.fm
Cylinder head cover
TCD 2012 2V W 08-01-01
6
© 42939-0
© 42941-0
© 43016-0
© 03/2010
3/4 OBJ_DOKU-22224-001.fm
Cylinder head cover
W 08-01-01 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22224-001.fm
Cylinder head
TCD 2012 2V W 08-02-01
● Pull the exhaust return module (2) off the plug ele-
ment in the direction of the arrow.
● Remove exhaust return module (2). 2 1
© 42924-0
© 42926-0
© 03/2010
1/4 OBJ_DOKU-22225-001.fm
Cylinder head
W 08-02-01 TCD 2012 2V
1
6
© 42927-0
© 42928-0
© 42929-0
© 03/2010
2/4 OBJ_DOKU-22225-001.fm
Cylinder head
TCD 2012 2V W 08-02-01
3
6
© 42930-0
© 42931-0
W 11-01-01
● Mount cylinder head cover.
W 08-01-01
© 42932-0
© 03/2010
3/4 OBJ_DOKU-22225-001.fm
Cylinder head
W 08-02-01 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22225-001.fm
Cylinder head
TCD 2012 2V W 08-02-02
© 42831-0
© 42832-0
© 03/2010
1/4 OBJ_DOKU-22226-001.fm
Cylinder head
W 08-02-02 TCD 2012 2V
6
© 42833-0
© 42834-0
© 42835-0
© 03/2010
2/4 OBJ_DOKU-22226-001.fm
Cylinder head
TCD 2012 2V W 08-02-02
6
© 42832-0
© 42831-0
© 03/2010
3/4 OBJ_DOKU-22226-001.fm
Cylinder head
W 08-02-02 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22226-001.fm
Gearcase
TCD 2012 2V W 09-01-01
– Self-tapping screw
– Washer
© 43645-0
© 42610-0
© 03/2010
1/4 OBJ_DOKU-22233-001.fm
Gearcase
W 09-01-01 TCD 2012 2V
6
© 42611-0
© 42612-0
© 42613-0
© 03/2010
2/4 OBJ_DOKU-22233-001.fm
Gearcase
TCD 2012 2V W 09-01-01
1 6
© 42614-0
© 42615-0
2
© 42616-0
© 03/2010
3/4 OBJ_DOKU-22233-001.fm
Gearcase
W 09-01-01 TCD 2012 2V
6
© 42617-0
© 03/2010
4/4 OBJ_DOKU-22233-001.fm
Control parts
TCD 2012 2V W 11-01-01
© 42534-0
Valves Cylinders
overlap 1 3 4 2
set to 4 2 1 3
© 03/2010
1/6 OBJ_DOKU-22237-001.fm
Control parts
W 11-01-01 TCD 2012 2V
Valves Cylinders
set to 1 5 3 6 2 4
overlap 6 2 4 1 5 3
© 42535-0
Attention!
Different version of the setting screws:
slotted screws or hexagon socket head
screws.
EX IN
© 42536-0
© 03/2010
2/6 OBJ_DOKU-22237-001.fm
Control parts
TCD 2012 2V W 11-01-01
6
© 42537-0
© 42538-0
© 42539-0
© 03/2010
3/6 OBJ_DOKU-22237-001.fm
Control parts
W 11-01-01 TCD 2012 2V
6
© 42983-0
© 43039-0
© 42540-0
© 03/2010
4/6 OBJ_DOKU-22237-001.fm
Control parts
TCD 2012 2V W 11-01-01
6
© 42541-0
W 08-01-01
© 42993-0
© 03/2010
5/6 OBJ_DOKU-22237-001.fm
Control parts
W 11-01-01 TCD 2012 2V
Technical Data
Testing and setting data
ID no. Name Additional information Value
P01 61 Valve clearance (inlet) with rotary angle disc 75°
P01 62 Valve clearance (outlet) with rotary angle disc 120°
Tightening specifications
ID no. Name Screw type Notes / Remark Value
Locking nut,
A01 003 20 Nm
valve clearance setting screw
Locking nut, setting screw control pis-
A01 012 20 Nm
ton (exhaust gas return)
6
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
© 03/2010
6/6 OBJ_DOKU-22237-001.fm
Control parts
TCD 2012 2V W 11-01-01
© 42534-0
Valves Cylinders
overlap 1 3 4 2
set to 4 2 1 3
© 00000-0
© 03/2010
1/8 OBJ_DOKU-22238-001.fm
Control parts
W 11-01-01 TCD 2012 2V
Valves Cylinders
overlap 1 5 3 6 2 4
set to 6 2 4 1 5 3
© 43040-0
Attention!
Different version of the setting screws:
slotted screws or hexagon socket head
screws.
IN
EX
© 43041-0
© 03/2010
2/8 OBJ_DOKU-22238-001.fm
Control parts
TCD 2012 2V W 11-01-01
1 6
© 43042-0
© 49239-0
© 48240-0
© 03/2010
3/8 OBJ_DOKU-22238-001.fm
Control parts
W 11-01-01 TCD 2012 2V
6
© 48241-0
© 43046-0
© 43047-0
© 03/2010
4/8 OBJ_DOKU-22238-001.fm
Control parts
TCD 2012 2V W 11-01-01
6
© 43048-0
© 43049-0
© 43832-3
© 03/2010
5/8 OBJ_DOKU-22238-001.fm
Control parts
W 11-01-01 TCD 2012 2V
6
© 42534-0
© 42934-0
© 42935-0
© 03/2010
6/8 OBJ_DOKU-22238-001.fm
Control parts
TCD 2012 2V W 11-01-01
6
© 42936-0
© 43050-0
© 03/2010
7/8 OBJ_DOKU-22238-001.fm
Control parts
W 11-01-01 TCD 2012 2V
Technical Data
Testing and setting data
ID no. Name Additional information Value
P01 61 Valve clearance (inlet) with rotary angle disc 75°
P01 62 Valve clearance (outlet) with rotary angle disc 120°
Clearance between control piston and
P01 64 with rotary angle disc 144°
rocker arm
Tightening specifications
ID no. Name Screw type Notes / Remark Value
Locking nut,
A01 003 20 Nm
valve clearance setting screw
Locking nut, setting screw control pis-
A01 012 20 Nm
6 ton (exhaust gas return)
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
© 03/2010
8/8 OBJ_DOKU-22238-001.fm
Control parts
TCD 2012 2V W 11-02-01
Removing and installing the rocker arm and rocker arm bracket
Standard tools: – W 08-02-01
– Socket wrench insert 8113 – W 11-01-01
– W 49-02-01
© 42545-0
© 03/2010
1/4 OBJ_DOKU-22239-001.fm
Control parts
W 11-02-01 TCD 2012 2V
6
© 42545-0
Variant
Attention!
See the spare parts documentation.
© 42546-0
Attention!
1
See the spare parts documentation.
© 42547-0
© 03/2010
2/4 OBJ_DOKU-22239-001.fm
Control parts
TCD 2012 2V W 11-02-01
Variant
Attention!
See the spare parts documentation.
1
● Turn in new screws (1).
M8x45-12.9
M8x60-12.9
Do not tighten screws.
6
© 42548-0
© 42549-0
© 42550-0
© 03/2010
3/4 OBJ_DOKU-22239-001.fm
Control parts
W 11-02-01 TCD 2012 2V
6
© 42551-0
© 03/2010
4/4 OBJ_DOKU-22239-001.fm
Lubricating oil cooler
TCD 2012 2V W 15-02-01
© 42803-0
© 42804-0
© 03/2010
1/2 OBJ_DOKU-22241-001.fm
Lubricating oil cooler
W 15-02-01 TCD 2012 2V
6
© 42805-0
© 42806-0
© 03/2010
2/2 OBJ_DOKU-22241-001.fm
Lubricating oil cooler
TCD 2012 2V W 15-02-02
© 42949-0
© 42950-0
© 03/2010
1/4 OBJ_DOKU-22242-001.fm
Lubricating oil cooler
W 15-02-02 TCD 2012 2V
6
© 42954-0
© 42951-0
© 42952-0
© 03/2010
2/4 OBJ_DOKU-22242-001.fm
Lubricating oil cooler
TCD 2012 2V W 15-02-02
6
© 42961-0
© 42951-0
© 42962-0
© 03/2010
3/4 OBJ_DOKU-22242-001.fm
Lubricating oil cooler
W 15-02-02 TCD 2012 2V
6 2
© 42963-0
© 42949-0
© 03/2010
4/4 OBJ_DOKU-22242-001.fm
Lubricating oil cooler
TCD 2012 2V W 15-04-01
1
© 42964-0
© 42965-0
© 03/2010
1/4 OBJ_DOKU-22243-001.fm
Lubricating oil cooler
W 15-04-01 TCD 2012 2V
6
© 42966-0
© 42961-0
© 42966-0
© 03/2010
2/4 OBJ_DOKU-22243-001.fm
Lubricating oil cooler
TCD 2012 2V W 15-04-01
2
6
© 42965-0
2
© 42967-0
© 42968-0
© 03/2010
3/4 OBJ_DOKU-22243-001.fm
Lubricating oil cooler
W 15-04-01 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22243-001.fm
Oil suction pipe
TCD 2012 2V W 16-01-01
1
1
© 42766-0
1 2
© 42767-0
© 03/2010
1/2 OBJ_DOKU-22244-001.fm
Oil suction pipe
W 16-01-01 TCD 2012 2V
1 1
6
© 42768-0
© 03/2010
2/2 OBJ_DOKU-22244-001.fm
High-pressure pump
TCD 2012 2V W 17-01-01
Attention!
Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the
affected parts. Blow damp areas dry with
compressed air. 6
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
After all work on the fuel system, it must be
bleeded - see the operation manual, chap-
ter "6 Fuel system“.
© 42807-0
© 03/2010
1/6 OBJ_DOKU-22245-001.fm
High-pressure pump
W 17-01-01 TCD 2012 2V
6
© 42808-0
1 1
© 42809-0
1
© 42810-0
© 03/2010
2/6 OBJ_DOKU-22245-001.fm
High-pressure pump
TCD 2012 2V W 17-01-01
2
6
© 42811-0
© 44002-0
© 42812-0
© 03/2010
3/6 OBJ_DOKU-22245-001.fm
High-pressure pump
W 17-01-01 TCD 2012 2V
6 1
© 42810-0
© 42809-0
1 1
© 42809-0
© 03/2010
4/6 OBJ_DOKU-22245-001.fm
High-pressure pump
TCD 2012 2V W 17-01-01
29 Nm 1
6
© 42813-0
© 43024-0
● Install rail.
W 21-02-01
Bleed the fuel system via the manual fuel
pump on the fuel pre-filter according to the
operation manual.
© 42807-0
© 03/2010
5/6 OBJ_DOKU-22245-001.fm
High-pressure pump
W 17-01-01 TCD 2012 2V
© 03/2010
6/6 OBJ_DOKU-22245-001.fm
High-pressure pump
TCD 2012 2V W 17-01-04
© 43953-1
© 03/2010
1/6 OBJ_DOKU-22246-001.fm
High-pressure pump
W 17-01-04 TCD 2012 2V
Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
● Remove the rail.
W 21-02-01
● Remove control block.
W 17-01-01
6
© 42781-0
© 42814-0
1
© 43328-0
© 03/2010
2/6 OBJ_DOKU-22246-001.fm
High-pressure pump
TCD 2012 2V W 17-01-04
6
© 42815-0
© 42816-0
© 42817-0
© 03/2010
3/6 OBJ_DOKU-22246-001.fm
High-pressure pump
W 17-01-04 TCD 2012 2V
6
© 43329-0
2
3
© 43330-0
© 42814-0
© 03/2010
4/6 OBJ_DOKU-22246-001.fm
High-pressure pump
TCD 2012 2V W 17-01-04
6
© 43036-0
© 43953-1
© 03/2010
5/6 OBJ_DOKU-22246-001.fm
High-pressure pump
W 17-01-04 TCD 2012 2V
© 03/2010
6/6 OBJ_DOKU-22246-001.fm
High-pressure pump
TCD 2012 2V W 17-01-05
– Fitting compound
Attention!
Ensure utmost cleanliness when working
DEUTZ AP1908
on the fuel system.
Carefully clean the area around the
6
affected parts. Blow damp areas dry with
compressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
After all work on the fuel system, it must be
bleeded - see the operation manual, chap-
ter "6 Fuel system“.
© 43953-1
© 03/2010
1/6 OBJ_DOKU-22247-001.fm
High-pressure pump
W 17-01-05 TCD 2012 2V
Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
● Remove the rail.
W 21-02-01
● Remove control block.
W 17-01-01
6
© 42781-0
© 42820-0
1
© 43328-0
© 03/2010
2/6 OBJ_DOKU-22247-001.fm
High-pressure pump
TCD 2012 2V W 17-01-05
6
© 42821-0
© 42816-0
© 42822-0
© 03/2010
3/6 OBJ_DOKU-22247-001.fm
High-pressure pump
W 17-01-05 TCD 2012 2V
6
© 43329-0
2
3
© 43330-0
© 42820-0
© 03/2010
4/6 OBJ_DOKU-22247-001.fm
High-pressure pump
TCD 2012 2V W 17-01-05
6
© 43037-0
© 43953-1
© 03/2010
5/6 OBJ_DOKU-22247-001.fm
High-pressure pump
W 17-01-05 TCD 2012 2V
© 03/2010
6/6 OBJ_DOKU-22247-001.fm
Injector
TCD 2012 2V W 19-01-01
Remove injector
The following work procedure describes
the removal and installation of an injector.
Proceed in the same way to remove further
injectors.
Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
© 42781-0
© 11/2011
1/10 OBJ_DOKU-22248-001.fm
Injector
W 19-01-01 TCD 2012 2V
1
● Remove injection line.
Collect draining fuel and dispose of
according to regulations.
6
© 42780-0
© 42920-0
1 1
© 42984-0
© 03/2010
2/10 OBJ_DOKU-22248-001.fm
Injector
TCD 2012 2V W 19-01-01
6
© 42985-0
© 42986-0
© 48206-0
© 03/2010
3/10 OBJ_DOKU-22248-001.fm
Injector
W 19-01-01 TCD 2012 2V
Attention!
Do not brush off the nozzle tip of the injec-
tor.
Do not damage nozzle head on the injector
during disassembly of the sealing disc (1).
● Grip a tight sealing ring (1) with the assembly
pliers (2) and pull off, turning slightly.
2
6
© 43303-0
© 44028-0
© 44029-0
© 03/2010
4/10 OBJ_DOKU-22248-001.fm
Injector
TCD 2012 2V W 19-01-01
6
© 44030-0
© 43028-0
2
1
© 43030-0
© 03/2010
5/10 OBJ_DOKU-22248-001.fm
Injector
W 19-01-01 TCD 2012 2V
2
3
6
© 43029-0
© 43031-1
© 42987-0
© 03/2010
6/10 OBJ_DOKU-22248-001.fm
Injector
TCD 2012 2V W 19-01-01
Attention!
Before installing the injector, combustion
residue must be cleaned carefully from the
bore on the cylinder head.
Suck off dirt particles.
● Insert injector carefully in the cylinder head.
When installing the injectors on
cylinders 2 to 5, the clamping shoe must
be inserted together with the injector.
6
© 42988-0
© 42989-0
1 1
© 42984-0
© 03/2010
7/10 OBJ_DOKU-22248-001.fm
Injector
W 19-01-01 TCD 2012 2V
Attention!
The injection lines must always be
renewed after disassembly.
● Pre-assemble new injection pipes (arrow) on rail and
injectors.
Note assignment and installation position
of the injection lines.
Do not tighten union nuts.
● Check the injection line for perfect installation posi-
tion.
6
© 43026-0
– Stage 2:
120°
© 42992-0
Attention!
Install injection pipes without tension!
Pay attention to alignment of the injection 1
pipes.
Pipes which touch the bore (1) of the union
nut must be renewed.
© 44034-1
© 11/2011
8/10 OBJ_DOKU-22248-001.fm
Injector
TCD 2012 2V W 19-01-01
6
© 42780-0
© 43016-0
© 03/2010
9/10 OBJ_DOKU-22248-001.fm
Injector
W 19-01-01 TCD 2012 2V
© 03/2010
10/10 OBJ_DOKU-22248-001.fm
Fuel filter
TCD 2012 2V W 20-01-01
Attention!
Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the
affected parts. Blow damp areas dry with
compressed air.
Observe the safety regulations and natio-
6
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
After all work on the fuel system, it must be
bleeded - see the operation manual, chap-
ter "6 Fuel system“.
© 42784-0
© 03/2010
1/6 OBJ_DOKU-22249-001.fm
Fuel filter
W 20-01-01 TCD 2012 2V
6
© 42785-0
© 42786-0
© 42787-0
© 03/2010
2/6 OBJ_DOKU-22249-001.fm
Fuel filter
TCD 2012 2V W 20-01-01
6
© 42788-0
© 42789-0
© 42788-0
© 03/2010
3/6 OBJ_DOKU-22249-001.fm
Fuel filter
W 20-01-01 TCD 2012 2V
1 1
6
© 42793-0
© 42794-0
1
1
© 42795-0
© 03/2010
4/6 OBJ_DOKU-22249-001.fm
Fuel filter
TCD 2012 2V W 20-01-01
1
6
© 42786-0
© 42785-0
© 42796-0
© 03/2010
5/6 OBJ_DOKU-22249-001.fm
Fuel filter
W 20-01-01 TCD 2012 2V
6
© 42797-0
© 03/2010
6/6 OBJ_DOKU-22249-001.fm
Fuel pump
TCD 2012 2V W 20-02-01
Attention!
Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the
affected parts. Blow damp areas dry with 6
compressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating fluids in suitable
vessels and dispose of according to regu-
lations.
After all work on the fuel system, it must be
bleeded - see the operation manual, chap-
ter "6 Fuel system“.
© 42852-0
© 03/2010
1/4 OBJ_DOKU-22250-001.fm
Fuel pump
W 20-02-01 TCD 2012 2V
6
© 42837-0
© 42853-0
2
© 42842-0
© 03/2010
2/4 OBJ_DOKU-22250-001.fm
Fuel pump
TCD 2012 2V W 20-02-01
6
© 42843-0
© 42843-0
© 03/2010
3/4 OBJ_DOKU-22250-001.fm
Fuel pump
W 20-02-01 TCD 2012 2V
6
© 42853-0
© 42840-0
© 43851-1
© 03/2010
4/4 OBJ_DOKU-22250-001.fm
Fuel pipes
TCD 2012 2V W 21-02-01
© 42781-0
© 03/2010
1/8 OBJ_DOKU-22251-001.fm
Fuel pipes
W 21-02-01 TCD 2012 2V
6
© 42782-0
1
● Remove injection line.
Collect draining fuel and dispose of
according to regulations.
© 42780-0
© 42974-0
© 03/2010
2/8 OBJ_DOKU-22251-001.fm
Fuel pipes
TCD 2012 2V W 21-02-01
6
© 42975-0
© 42976-0
© 43027-0
© 03/2010
3/8 OBJ_DOKU-22251-001.fm
Fuel pipes
W 21-02-01 TCD 2012 2V
Mounting rail
● Install rail pressure sensor.
W 21-02-05
2
● Install pressure limiting valve.
W 21-02-03
● Mount rail (2) with spacing discs and pre-assemble
screws (1) loosely.
hand tight
1
Do not tighten screws.
6
© 42976-0
● Lay cable. 2
● Fix cable with cable tie (1).
© 42975-0
Attention!
The injection lines must always be
renewed after disassembly.
Install injection pipes without tension!
● Pre-assemble new injection pipes (arrow) on rail and
injectors.
Note assignment and installation position
of the injection lines.
© 03/2010
4/8 OBJ_DOKU-22251-001.fm
Fuel pipes
TCD 2012 2V W 21-02-01
Attention!
The high-pressure lines must always be
renewed after disassembly.
Install high pressure line without tension.
1
● Pre-assemble new high pressure pipes on the rail
and on the high pressure pumps.
Note assignment and installation position
of the high-pressure lines.
X
Pay attention to installation position.
Do not turn vibration damper (1).
(1) Vibration damper
– Dimension X 2
Diameter: 32 mm
(2) Connection rail
(3) Connection high pressure pump
© 48208-0
© 48217-0
© 03/2010
5/8 OBJ_DOKU-22251-001.fm
Fuel pipes
W 21-02-01 TCD 2012 2V
6
© 43057-0
Attention!
Install injection pipes without tension!
Pay attention to alignment of the injection 1
pipes.
Pipes which touch the bore (1) of the union
nut must be renewed.
© 48222-0
● Tighten all union nuts (1) on the rail and on the injec-
tors with a special wrench.
– Stage 1:
10 Nm 1
– Stage 2:
+ 15°
60°
● Check the injection pipes for perfect installation posi- 1
tion.
© 42780-0
© 03/2010
6/8 OBJ_DOKU-22251-001.fm
Fuel pipes
TCD 2012 2V W 21-02-01
Attention!
Install high pressure line without tension.
Pay attention to alignment of the high pres-
sure pipes. 1
Pipes which touch the bore (1) of the union
nut must be renewed.
6
© 48223-0
– Stage 2:
+ 15°
60°
● Check the high pressure pipes for perfect installation
position.
1
© 42783-0
© 43025-0
© 03/2010
7/8 OBJ_DOKU-22251-001.fm
Fuel pipes
W 21-02-01 TCD 2012 2V
Technical Data
Tightening specifications
ID no. Name Screw type Notes / Remark Value
Stage 1:
Injection pipe on rail and injector,
Observe assembly
A07 003 High pressure pipe on high pressure Union nut 10 Nm
specification.
pump and rail
Use new pipe.
Injection pipe on rail and injector,
+ 15°
A07 003 High pressure pipe on high pressure Union nut Stage 2: 60°
pump and rail
Stage 1:
A07 038 Rail to cylinder head Observe assembly hand tight
specification
6 A07 038 Rail to cylinder head Stage 2: 30 Nm
Pipe union, pipe diameter 10 mm, ring Hollow screw
A12 093 39 Nm
piece M14x1.5
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
© 03/2010
8/8 OBJ_DOKU-22251-001.fm
Fuel pipes
W 21-02-01 TCD 2012 2V
Technical Data
Tightening specifications
ID no. Name Screw type Notes / Remark Value
Stage 1:
Injection pipe on rail and injector,
Observe assembly
A07 003 High pressure pipe on high pressure Union nut 10 Nm
specification.
pump and rail
Use new pipe.
Injection pipe on rail and injector,
+ 15°
A07 003 High pressure pipe on high pressure Union nut Stage 2: 60°
pump and rail
Stage 1:
A07 038 Rail to cylinder head Observe assembly hand tight
specification
6 A07 038 Rail to cylinder head Stage 2: 30 Nm
Pipe union, pipe diameter 10 mm, ring Hollow screw
A12 093 39 Nm
piece M14x1.5
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
© 03/2010
8/8 OBJ_DOKU-22251-001.fm
Fuel pipes
TCD 2012 2V W 21-02-03
Special tools:
– Disassembly tool 110901
– Plugs/caps 170160 Danger!
Wait 30 seconds after switching off the
– Assembly grease 01016496 engine before working on the fuel system.
Attention!
Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the
affected parts. Blow damp areas dry with
compressed air.
No foreign bodies may get into the rail.
6
Ensure utmost cleanliness. Especially on
the thread and the sealing surface of the
rail.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
After all work on the fuel system, it must be
bleeded - see the operation manual, chap-
ter "6 Fuel system“.
© 42981-0
© 03/2010
1/4 OBJ_DOKU-22252-001.fm
Fuel pipes
W 21-02-03 TCD 2012 2V
6
© 43253-1
© 43335-0
© 42978-0
© 11/2011
2/4 OBJ_DOKU-22252-001.fm
Fuel pipes
TCD 2012 2V W 21-02-03
6
© 43254-1
© 42982-0
© 03/2010
3/4 OBJ_DOKU-22252-001.fm
Fuel pipes
W 21-02-03 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22252-001.fm
Fuel pipes
TCD 2012 2V W 21-02-05
Special tools:
– Long socket wrench insert 110700
– Plugs/caps 170160 Danger!
Wait 30 seconds after switching off the
– Assembly grease 01016496 engine before working on the fuel system.
Attention!
Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the
affected parts. Blow damp areas dry with
compressed air.
No foreign bodies may get into the rail.
6
Ensure utmost cleanliness. Especially on
the thread and the sealing surface of the
rail.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
After all work on the fuel system, it must be
bleeded - see the operation manual, chap-
ter "6 Fuel system“.
© 42860-0
© 03/2010
1/4 OBJ_DOKU-22253-001.fm
Fuel pipes
W 21-02-05 TCD 2012 2V
6
© 42861-0
© 42862-0
Attention!
Do not touch the pin contacts of the rail
pressure sensor with your hands to avoid
electrostatic discharging.
Ensure absolute cleanliness of the connec-
tor.
● Visually check the thread and the sealing
edge (arrows)of the rail pressure sensor.
© 43017-0
© 03/2010
2/4 OBJ_DOKU-22253-001.fm
Fuel pipes
TCD 2012 2V W 21-02-05
6
© 43017-0
Attention!
Only tighten the rail pressure sensor with
the hexagon.
● Screw in rail pressure sensor (1).
● Tighten rail pressure sensor.
70 Nm
© 42862-0
© 42861-0
© 11/2011
3/4 OBJ_DOKU-22253-001.fm
Fuel pipes
W 21-02-05 TCD 2012 2V
● Lay cable.
● Fix cable with cable tie (1).
Bleed the fuel system via the manual fuel
pump on the fuel pre-filter according to the
operation manual.
1
6
© 42860-0
© 03/2010
4/4 OBJ_DOKU-22253-001.fm
Charge air line
TCD 2012 2V W 22-01-01
© 42942-0
© 42943-0
© 03/2010
1/4 OBJ_DOKU-22254-001.fm
Charge air line
W 22-01-01 TCD 2012 2V
6
© 42944-0
© 42945-0
© 42946-0
© 03/2010
2/4 OBJ_DOKU-22254-001.fm
Charge air line
TCD 2012 2V W 22-01-01
6
© 42947-0
© 42948-0
© 03/2010
3/4 OBJ_DOKU-22254-001.fm
Charge air line
W 22-01-01 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22254-001.fm
Coolant pump
TCD 2012 2V W 37-03-01
© 42844-0
© 42852-0
© 03/2010
1/6 OBJ_DOKU-22255-001.fm
Coolant pump
W 37-03-01 TCD 2012 2V
6
© 42837-0
© 42853-0
© 42845-0
© 03/2010
2/6 OBJ_DOKU-22255-001.fm
Coolant pump
TCD 2012 2V W 37-03-01
6
© 42846-0
© 42847-0
© 42848-0
© 03/2010
3/6 OBJ_DOKU-22255-001.fm
Coolant pump
W 37-03-01 TCD 2012 2V
6
© 42849-0
© 42850-0
© 42845-0
© 03/2010
4/6 OBJ_DOKU-22255-001.fm
Coolant pump
TCD 2012 2V W 37-03-01
6
© 42853-0
© 42840-0
© 43851-1
© 03/2010
5/6 OBJ_DOKU-22255-001.fm
Coolant pump
W 37-03-01 TCD 2012 2V
● Tighten screws .
30 Nm
6
© 42851-0
© 03/2010
6/6 OBJ_DOKU-22255-001.fm
Thermostat housing
TCD 2012 2V W 38-01-01
© 42867-0
© 42868-0
© 03/2010
1/2 OBJ_DOKU-22256-001.fm
Thermostat housing
W 38-01-01 TCD 2012 2V
6
© 42869-0
● Insert thermostat.
Arrow (1) points up. X
X
X 1
© 42888-0
© 42870-0
© 03/2010
2/2 OBJ_DOKU-22256-001.fm
Thermostat housing
TCD 2012 2V W 38-01-02
Danger!
Risk of injury!
Hot water and hot thermostat.
Checking thermostat
● Remove thermostat.
W 38-01-01
● Measure beginning of stroke, dimension (a).
● Note measured value, dimension (a).
© 34679-3
© 34680-2
© 03/2010
1/2 OBJ_DOKU-22257-001.fm
Thermostat housing
W 38-01-02 TCD 2012 2V
6
© 34679-2
● Determine stroke.
Calculation example
Desired: Stroke
Given: -
Measured: Beginning of stroke, dimension (a)
End of stroke, dimension (b)
Calculation: Dimension (b) - dimension (a)
Result: = stroke
● Compare result with setpoint value.
8 mm
● Install thermostat.
W 38-01-01
© 34679-1
© 03/2010
2/2 OBJ_DOKU-22257-001.fm
Fan drive
TCD 2012 2V W 39-01-01
© 42852-0
© 42837-0
© 03/2010
1/4 OBJ_DOKU-22258-001.fm
Fan drive
W 39-01-01 TCD 2012 2V
6
© 42853-0
© 42836-0
1
2
© 42838-0
© 03/2010
2/4 OBJ_DOKU-22258-001.fm
Fan drive
TCD 2012 2V W 39-01-01
6
© 42839-0
© 42853-0
© 42840-0
© 03/2010
3/4 OBJ_DOKU-22258-001.fm
Fan drive
W 39-01-01 TCD 2012 2V
6
© 43851-1
© 03/2010
4/4 OBJ_DOKU-22258-001.fm
Fan drive
TCD 2012 2V W 39-02-01
1
© 42854-0
© 42852-0
© 03/2010
1/4 OBJ_DOKU-22259-001.fm
Fan drive
W 39-02-01 TCD 2012 2V
6
© 42837-0
© 42853-0
1
© 42855-0
© 03/2010
2/4 OBJ_DOKU-22259-001.fm
Fan drive
TCD 2012 2V W 39-02-01
1 6
© 42856-0
© 42853-0
© 42840-0
© 03/2010
3/4 OBJ_DOKU-22259-001.fm
Fan drive
W 39-02-01 TCD 2012 2V
6
© 43851-1
© 42857-0
© 03/2010
4/4 OBJ_DOKU-22259-001.fm
Fan console
TCD 2012 2V W 39-04-03
© 42900-0
X
3 1
© 42901-0
© 03/2010
1/6 OBJ_DOKU-22261-001.fm
Fan console
W 39-04-03 TCD 2012 2V
6
© 42902-0
1
© 42913-0
© 42972-0
© 03/2010
2/6 OBJ_DOKU-22261-001.fm
Fan console
TCD 2012 2V W 39-04-03
6
© 42914-0
1 © 42915-0
1 3
© 42916-0
© 03/2010
3/6 OBJ_DOKU-22261-001.fm
Fan console
W 39-04-03 TCD 2012 2V
● Mount generator.
● Tighten screws (1).
Do not tighten screws.
1
1
6
© 42917-0
© 42973-0
2 1
© 42918-0
© 03/2010
4/6 OBJ_DOKU-22261-001.fm
Fan console
TCD 2012 2V W 39-04-03
6
© 42919-0
© 03/2010
5/6 OBJ_DOKU-22261-001.fm
Fan console
W 39-04-03 TCD 2012 2V
© 03/2010
6/6 OBJ_DOKU-22261-001.fm
Exhaust pipe
TCD 2012 2V W 41-01-01
– Fitting compound
DEUTZ S1
© 42761-0
© 42762-0
© 03/2010
1/4 OBJ_DOKU-22262-001.fm
Exhaust pipe
W 41-01-01 TCD 2012 2V
● Remove studs.
● Visually inspect the component.
6
© 44297-0
© 44297-1
© 44580-1
© 03/2010
2/4 OBJ_DOKU-22262-001.fm
Exhaust pipe
TCD 2012 2V W 41-01-01
6
© 42763-0
© 42761-0
© 03/2010
3/4 OBJ_DOKU-22262-001.fm
Exhaust pipe
W 41-01-01 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22262-001.fm
Exhaust gas turbocharger
TCD 2012 2V W 43-01-01
Removing turbocharger
● Unscrew screw (1).
● Remove holder.
© 42773-0
© 42774-0
© 03/2010
1/4 OBJ_DOKU-22263-001.fm
Exhaust gas turbocharger
W 43-01-01 TCD 2012 2V
6 1
© 42775-0
2 1
© 42776-0
1
1
2
© 42777-0
© 03/2010
2/4 OBJ_DOKU-22263-001.fm
Exhaust gas turbocharger
TCD 2012 2V W 43-01-01
1
1
2
6
© 42777-0
2 1
© 42776-0
© 42778-0
© 03/2010
3/4 OBJ_DOKU-22263-001.fm
Exhaust gas turbocharger
W 43-01-01 TCD 2012 2V
6
© 42779-0
● Mount holder.
● Tighten screw (1).
20 Nm
© 42773-0
© 03/2010
4/4 OBJ_DOKU-22263-001.fm
Generator
TCD 2012 2V W 44-02-01
© 42858-0
© 42852-0
© 03/2010
1/4 OBJ_DOKU-22264-001.fm
Generator
W 44-02-01 TCD 2012 2V
6
© 42837-0
© 42853-0
1
2
© 42859-0
© 03/2010
2/4 OBJ_DOKU-22264-001.fm
Generator
TCD 2012 2V W 44-02-01
6
© 42889-0
© 42853-0
© 42840-0
© 03/2010
3/4 OBJ_DOKU-22264-001.fm
Generator
W 44-02-01 TCD 2012 2V
6
© 43851-1
© 42858-0
© 03/2010
4/4 OBJ_DOKU-22264-001.fm
Starter
TCD 2012 2V W 44-03-01
© 42896-0
● Disconnect cables.
● Unscrew screws (arrows).
● Remove starter.
● Visually inspect the components.
© 42897-0
© 03/2010
1/2 OBJ_DOKU-22265-001.fm
Starter
W 44-03-01 TCD 2012 2V
6
© 42898-0
3
© 42899-0
1
© 42876-0
© 03/2010
2/2 OBJ_DOKU-22265-001.fm
Engine mounting
TCD 2012 2V W 46-00-01
© 43842-1
2 3 4
1
© 42643-0
© 03/2010
1/4 OBJ_DOKU-22266-001.fm
Engine mounting
W 46-00-01 TCD 2012 2V
6 1
3
© 42644-0
© 42645-0
© 42646-0
© 03/2010
2/4 OBJ_DOKU-22266-001.fm
Engine mounting
TCD 2012 2V W 46-00-01
6
© 42740-0
3
1
© 42644-0
2 3 4
1
© 42643-0
© 03/2010
3/4 OBJ_DOKU-22266-001.fm
Engine mounting
W 46-00-01 TCD 2012 2V
Technical Data
Tightening specifications
ID no. Name Screw type Notes / Remark Value
A00 001 Clamping holder on crankcase 90 Nm
Clamping bracket on adapter for Screw
A00 002 90 Nm
assembly block Nut
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
© 03/2010
4/4 OBJ_DOKU-22266-001.fm
Engine mounting
TCD 2012 2V W 47-01-01
© 42640-0
1
2
© 42641-0
© 03/2010
1/6 OBJ_DOKU-22267-001.fm
Engine mounting
W 47-01-01 TCD 2012 2V
6
© 42641-1
© 42640-1
Variant
● Fit rigid mounting foot (1).
● Tighten screw (2).
1
– (2) = M12x60
95 Nm
© 48225-0
© 03/2010
2/6 OBJ_DOKU-22267-001.fm
Engine mounting
TCD 2012 2V W 47-01-01
Variant
● Mount holder (1).
● Fit washers (2).
1
● Tighten screws (3).
– (3) = M16
260 Nm
2
3
1
6
© 48226-0
Variant
● Fit sleeves (1).
● Fit holder (2).
● Fit washers (3).
1 2
● Tighten screws (4).
– (4) = M16
260 Nm
3
4
© 48230-0
4 2
1 3
© 48231-0
© 03/2010
3/6 OBJ_DOKU-22267-001.fm
Engine mounting
W 47-01-01 TCD 2012 2V
Variant
● Mount holder (1).
● Fit mounting bracket (2).
● Fit washers (3). 5 1
● Tighten screws (4).
● Fit washers (5). 2
● Fasten screws (6).
6
● Tighten screws (4).
– (4) = M16
260 Nm
● Tighten screws (6). 1
– (6) = M12 3 4
6
90 Nm © 48232-0
© 03/2010
4/6 OBJ_DOKU-22267-001.fm
Engine mounting
TCD 2012 2V W 47-01-01
Technical Data
Tightening specifications
ID no. Name Screw type Notes / Remark Value
M12x35-10.9
M12x40-10.9
Feet/engine mounting on holder/ M12x60-10.9
A00 003 crankcase/connection housing/gear M12x75-10.9 95 Nm
case M12x85-10.9
M12x90-10.9
M12x220-10.9
M16x40-10.9
M16x45-10.9
M16x75-10.9
Holder, engine mounting on M16x85-10.9
A00 005
crankcase M16x110-10.9
260 Nm 6
M16x140-10.9
M16x155-10.9
M16x220-10.9
Mounting bracket on holder/
A00 006 M12x40-10.9 90 Nm
crankcase
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
© 03/2010
5/6 OBJ_DOKU-22267-001.fm
Engine mounting
W 47-01-01 TCD 2012 2V
© 03/2010
6/6 OBJ_DOKU-22267-001.fm
Cable harness
TCD 2012 2V W 48-01-01
© 42720-0
© 42721-0
© 03/2010
1/10 OBJ_DOKU-22268-001.fm
Cable harness
W 48-01-01 TCD 2012 2V
6
© 42722-0
© 42723-0
© 42582-0
© 03/2010
2/10 OBJ_DOKU-22268-001.fm
Cable harness
TCD 2012 2V W 48-01-01
6
© 42724-0
© 42725-0
© 42726-0
© 03/2010
3/10 OBJ_DOKU-22268-001.fm
Cable harness
W 48-01-01 TCD 2012 2V
6
© 42727-0
1 1
© 42728-0
© 42729-0
© 03/2010
4/10 OBJ_DOKU-22268-001.fm
Cable harness
TCD 2012 2V W 48-01-01
6
© 42730-0
© 42731-0
© 42732-0
© 03/2010
5/10 OBJ_DOKU-22268-001.fm
Cable harness
W 48-01-01 TCD 2012 2V
6
© 42733-0
© 42730-0
© 42729-0
© 03/2010
6/10 OBJ_DOKU-22268-001.fm
Cable harness
TCD 2012 2V W 48-01-01
1 1
6
© 42728-0
© 42727-0
© 42725-0
© 03/2010
7/10 OBJ_DOKU-22268-001.fm
Cable harness
W 48-01-01 TCD 2012 2V
6
© 42724-0
© 42726-0
© 42582-0
© 03/2010
8/10 OBJ_DOKU-22268-001.fm
Cable harness
TCD 2012 2V W 48-01-01
6
© 42736-0
1
● Lay cable.
● Fix cable with cable tie (2).
2
© 42722-0
© 42721-0
© 03/2010
9/10 OBJ_DOKU-22268-001.fm
Cable harness
W 48-01-01 TCD 2012 2V
6
© 42720-0
© 03/2010
10/10 OBJ_DOKU-22268-001.fm
Electrical equipment
TCD 2012 2V W 48-02-01
– Locking agent
DEUTZ DW 72
© 42715-0
© 42716-0
© 03/2010
1/4 OBJ_DOKU-22269-001.fm
Electrical equipment
W 48-02-01 TCD 2012 2V
2
1
6
© 42717-0
© 42717-0
© 42719-0
© 03/2010
2/4 OBJ_DOKU-22269-001.fm
Electrical equipment
TCD 2012 2V W 48-02-01
● Lay cable.
● Fix cable with cable tie (2).
6
© 42715-0
© 03/2010
3/4 OBJ_DOKU-22269-001.fm
Electrical equipment
W 48-02-01 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22269-001.fm
Electrical equipment
TCD 2012 2V W 48-02-03
© 42737-0
© 42738-0
© 03/2010
1/2 OBJ_DOKU-22270-001.fm
Electrical equipment
W 48-02-03 TCD 2012 2V
6
© 42739-0
© 42738-0
● Lay cable.
● Fix cables with cable ties.
© 42737-0
© 03/2010
2/2 OBJ_DOKU-22270-001.fm
Electrical equipment
TCD 2012 2V W 48-03-01
– Fitting compound
DEUTZ AP1908
2
1
© 42764-0
© 42765-0
© 03/2010
1/2 OBJ_DOKU-22271-001.fm
Electrical equipment
W 48-03-01 TCD 2012 2V
6
© 42002-1
© 42765-0
2
1
© 42764-0
© 03/2010
2/2 OBJ_DOKU-22271-001.fm
Electrical equipment
TCD 2012 2V W 48-04-01
© 42865-0
© 42866-0
© 03/2010
1/2 OBJ_DOKU-22272-001.fm
Electrical equipment
W 48-04-01 TCD 2012 2V
6
© 42866-0
© 42865-0
© 03/2010
2/2 OBJ_DOKU-22272-001.fm
Electrical equipment
TCD 2012 2V W 48-05-01
© 42871-0
© 42872-0
© 03/2010
1/2 OBJ_DOKU-22273-001.fm
X
Electrical equipment
W 48-05-01 TCD 2012 2V
6
© 42873-0
© 42871-0
X
X
© 03/2010
2/2 OBJ_DOKU-22273-001.fm
Electrical equipment
TCD 2012 2V W 48-06-01
Special tools:
– Long socket wrench insert 110700
– Plugs/caps 170160 Danger!
Wait 30 seconds after switching off the
engine before working on the fuel system.
Attention!
Ensure utmost cleanliness when working
on the fuel system.
Carefully clean the area around the
affected parts. Blow damp areas dry with
compressed air.
No foreign bodies may get into the rail.
6
Ensure utmost cleanliness. Especially on
the thread and the sealing surface of the
rail.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
After all work on the fuel system, it must be
bleeded - see the operation manual, chap-
ter "6 Fuel system“.
© 42863-0
© 03/2010
1/2 OBJ_DOKU-22274-001.fm
Electrical equipment
W 48-06-01 TCD 2012 2V
6
© 42864-0
© 42864-0
© 42863-0
© 03/2010
2/2 OBJ_DOKU-22274-001.fm
Tools
TCD 2012 2V W 49-02-01
© 42530-0
© 42531-0
© 03/2010
1/4 OBJ_DOKU-22275-001.fm
Tools
W 49-02-01 TCD 2012 2V
6
© 42532-0
© 42533-0
© 42533-0
© 03/2010
2/4 OBJ_DOKU-22275-001.fm
Tools
TCD 2012 2V W 49-02-01
6
© 42542-0
© 42543-0
© 42639-0
© 03/2010
3/4 OBJ_DOKU-22275-001.fm
Tools
W 49-02-01 TCD 2012 2V
© 03/2010
4/4 OBJ_DOKU-22275-001.fm
Tools
TCD 2012 2V W 49-02-02
1
© 48243-0
© 48244-0
© 03/2010
1/2 OBJ_DOKU-22276-001.fm
Tools
W 49-02-02 TCD 2012 2V
6
© 48245-1
1
© 48243-0
© 03/2010
2/2 OBJ_DOKU-22276-001.fm
Start aid
TCD 2012 2V W 63-01-01
© 46360-0
3 2
© 44360-1
© 03/2010
1/4 OBJ_DOKU-22279-001.fm
Start aid
W 63-01-01 TCD 2012 2V
6
© 44831-0
3 2
© 44360-1
Attention!
Depending on the version the following
screw lengths are installed: 1
- M8x130 = (4) without washers
- M8x140 = (4) with washers,
see spare parts documentation.
● Tighten screws (1).
© 46360-0
© 03/2010
2/4 OBJ_DOKU-22279-001.fm
Start aid
TCD 2012 2V W 63-01-01
Attention!
Hold on the hexagon of the plus pole
screw.
6
© 46360-0
© 03/2010
3/4 OBJ_DOKU-22279-001.fm
Start aid
W 63-01-01 TCD 2012 2V
Technical Data
Tightening specifications
ID no. Name Screw type Notes / Remark Value
M8x130
A06 042 Heating flange on charge air manifold Stage 1: 3 Nm
M8x140
M8x130
A06 042 Heating flange on charge air manifold Stage 2: 30°
M8x140
Hexagonal, pole screw
A13 065 Cable connection on heater flange 20 Nm
locked
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
6
© 03/2010
4/4 OBJ_DOKU-22279-001.fm
Start aid
TCD 2012 2V W 63-02-01
Attention!
Pay attention to utmost cleanliness when
working on the fuel system.
Remove residue paint and particles of dirt
before removing.
Clean the respective affected parts
carefully. Blow damp areas dry with com-
6
pressed air.
Observe the safety regulations and natio-
nal specifications for handling fuels.
Close all connections immediately after
opening with new, clean plugs/caps.
Do not remove plugs/caps until immedia-
tely before assembling.
Collect leaking operating substances in
suitable vessels and dispose of according
to regulations.
After all work on the fuel system, it must be
bleeded - see the operation manual, chap-
ter "6 Fuel system“.
© 42728-0
© 03/2010
1/4 OBJ_DOKU-22280-001.fm
Start aid
W 63-02-01 TCD 2012 2V
6
© 48219-0
© 48220-0
© 48220-0
© 03/2010
2/4 OBJ_DOKU-22280-001.fm
Start aid
TCD 2012 2V W 63-02-01
1 1
6
© 42728-0
© 03/2010
3/4 OBJ_DOKU-22280-001.fm
Start aid
W 63-02-01 TCD 2012 2V
Technical Data
Tightening specifications
ID no. Name Screw type Notes / Remark Value
A13 030 Cable shoe on connection bolt M6 3 Nm
Heating plug / screw cap on cylinder
A13 032 20 Nm
head
For the tightening procedure according to torque using a torque wrench, a maximum variation of the
tightening torque of +/- 10% is permissible.
© 03/2010
4/4 OBJ_DOKU-22280-001.fm
Standard tools
TCD 2012 2V W 49-00-01
7 Standard tools
© 03/2010
1/8 OBJ_DOKU-22281-001.fm
Standard tools
W 49-00-01 TCD 2012 2V
Orders
Conventional tools /
special tools:
These must be ordered like normal DEUTZ
spare parts with specification of the order
number.
© 03/2010
2/8 OBJ_DOKU-22281-001.fm
Standard tools
TCD 2012 2V W 49-00-01
8002
Pressure pump
Checking cooling system for leak-tightness
© 35409-2
7
8005
Compression pressure tester
for diesel engines
10 - 40 bar
Checking compression pressure
© 35410-3
8024
Assembly pliers
Removing valve shaft seals
© 37509-2
© 03/2010
3/8 OBJ_DOKU-22281-001.fm
Standard tools
W 49-00-01 TCD 2012 2V
8035
Socket wrench insert
reinforced, size 22
removing and installing main bearing
© 37504-2
7
8113
Socket wrench insert
Torx - E 14
© 43022-0
8114
Socket wrench insert
Torx - E 20
© 35415-1
© 03/2010
4/8 OBJ_DOKU-22281-001.fm
Standard tools
TCD 2012 2V W 49-00-01
8115
V-belt tension measuring device
150 to 600 N
Check V-belt tension
© 35416-3
7
8189
Torx tool set
Contents of case:
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
© 39432-1
8190
Rotation angle disc
with magnet
Setting valve clearance
© 42528-1
© 03/2010
5/8 OBJ_DOKU-22281-001.fm
Standard tools
W 49-00-01 TCD 2012 2V
8191
Screwdriver insert
for slotted screw
Valve clearance setting
© 43060-0
7
8192
Bowl wrench
Fuel pre-filter (type: Racor)
© 43193-1
8194
Screwdriver insert
with pressed in hexagon pin (4 mm),
3/8 inch, long version
(in connection with rotation angle disc 8190 and reduc-
er 1/2 to 3/8 inch)
© 43183-0
© 03/2010
6/8 OBJ_DOKU-22281-001.fm
Standard tools
TCD 2012 2V W 49-00-01
8196
Open end wrench adapter
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.
© 43197-0
7
8198
Pricker
Removing rotary shaft lip seal
© 43206-1
9017
Assembly lever
e. g. removing and installing valves
© 37511-2
© 03/2010
7/8 OBJ_DOKU-22281-001.fm
Standard tools
W 49-00-01 TCD 2012 2V
© 03/2010
8/8 OBJ_DOKU-22281-001.fm
Special tools
TCD 2012 2V W 49-01-01
8 Special tools
© 03/2010
1/12 OBJ_DOKU-22282-001.fm
Special tools
W 49-01-01 TCD 2012 2V
Orders
Conventional tools /
special tools:
These must be ordered like normal DEUTZ
spare parts with specification of the order
number.
© 03/2010
2/12 OBJ_DOKU-22282-001.fm
Special tools
TCD 2012 2V W 49-01-01
100190
Connector
(in conjunction with compression pressure tester 8005)
© 42524-0
100320
Turning gear 8
flywheel side
© 35422-1
100380
Turning gear
on hub torsional vibration damper/V-belt pulley
© 48242-0
© 03/2010
3/12 OBJ_DOKU-22282-001.fm
Special tools
W 49-01-01 TCD 2012 2V
100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
© 35424-1
100410
8 Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
© 43205-2
103050
Socket wrench insert
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)
© 43023-0
© 03/2010
4/12 OBJ_DOKU-22282-001.fm
Special tools
TCD 2012 2V W 49-01-01
103140
Crowfoot wrench
with installed EGR module
© 48237-0
110500
Special wrench 8
Wrench size 17,
Removing and installing high-pressure lines
© 35436-1
110620
Lever tool
Removing the injector
© 45673-0
© 03/2010
5/12 OBJ_DOKU-22282-001.fm
Special tools
W 49-01-01 TCD 2012 2V
110640
Lever tool
Removing the injector
with removed rail
© 43941-0
110700
8 Socket wrench insert
long
Installing and removing pressure sensors
(rail pressure, oil pressure, fuel pressure)
© 43198-2
110900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110901 and three
assembly sleeves with guide:
- High pressure pump (Ø 36), 110902
- Injector, 2V motor (Ø 16), 110903
- Injector, 4V motor (Ø 23), 110904
Removing and installing O-rings
© 43208-0
© 03/2010
6/12 OBJ_DOKU-22282-001.fm
Special tools
TCD 2012 2V W 49-01-01
110901
Disassembly tool
Removing O-ring
© 45950-1
120440
Assembly tool 8
Removing and installing the glow plugs
© 48238-0
120680
Puller
(in conjunction with slide hammer 150800)
Removing jammed injector sealing ring
© 35437-1
© 03/2010
7/12 OBJ_DOKU-22282-001.fm
Special tools
W 49-01-01 TCD 2012 2V
142670
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)
© 35445-1
142830
8 Assembly tool
Installing crankshaft sealing ring
(flywheel side)
© 35446-1
144800
Counter support
for torsional vibration dampers
© 35453-1
© 03/2010
8/12 OBJ_DOKU-22282-001.fm
Special tools
TCD 2012 2V W 49-01-01
150800
Slide hammer
(in conjunction with disassembly device 120680)
Disassembling injector sealing ring
© 35449-2
151500
Separating tool 8
Removing metal sheet lubricating oil pan from crank-
case
© 45974-0
170050
Special wrench
Unscrewing the filter cartridges
© 37629-2
© 03/2010
9/12 OBJ_DOKU-22282-001.fm
Special tools
W 49-01-01 TCD 2012 2V
170160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
© 43663-0
6066
8 Assembly block
Engine clamping, double-sided
© 35451-2
6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided
© 35452-1
© 03/2010
10/12 OBJ_DOKU-22282-001.fm
Special tools
TCD 2012 2V W 49-01-01
6068
Engine lifting device
Load (2000 kg), 3-point suspension, spindle clamp,
cross member, chains and hooks
© 43184-0
© 00000-0
© 00000-0
© 03/2010
11/12 OBJ_DOKU-22282-001.fm
Special tools
W 49-01-01 TCD 2012 2V
© 03/2010
12/12 OBJ_DOKU-22282-001.fm