Deutz F4L1011 Engine

Tools: Device for measuring toothed belt tension 100720, Adjusting pin 100700, Adjusting pin 100710

1. Position toothed belt so as to ensure a uniform distance from front cover of 8 - 9 mm.
2. Fit device for measuring toothed belt tension.
3. Preload toothed belt. Turn idler pulley in anti-clockwise direction to obtain a scale reading of 3.0 - 3.5.
4. Tighten idler pulley bolt with 45 Nm.
5. Retain centering washer. Tighten central bolt with 30 Nm preload.
6. Mark camshaft bolt and centering washer and tighten in accordance with specifications.
7. Remove adjusting pin for camshaft and crankshaft. Make four complete crankshaft rotations in direction of engine rotation.
8. Fit toothed belt tension measuring device and measure tension; nominal value scale reading 6.5 - 9.5.
9. Check valve timing with camshaft and crankshaft adjusting pins.

Tools: Feeler gauge

1. Turn engine until valves of cylinder No. 1 overlap.
2. Adjust valve clearance on respective cylinder with feeler gauge.
3. Tighten locknut in accordance with specifications. Recheck the adjustment with feeler gauge.
4. Put gasket in place.
5. Fit cylinder head cover. Tighten bolts in accordance with specifications.

Tools: Compression tester 2461, Torx tools, Adapter 100090

1. Insert adapter with new special sealing ring.
2. Fit clamping pad. Tighten bolt.
3. Connect compression tester. Turn engine with starter.
4. Compare compression pressures of all cylinders.

Tools: Injection pump tester 3202, Crowfoot spanner a/flats 13

1. Connect injection pump tester to delivery valve holder.
2. Turn crankshaft via V-belt pulley, while bleeding tester at the screw plug.
3. Turn crankshaft until a pressure of 150 bar is applied to the delivery valve; pressure should not drop more than 10 bar within one minute.
4. Turn crankshaft further until a pressure of 300 bar is generated. If this value is not attainable, remove injection pump.
5. Remove injection pump tester and reassemble engine.

⚠ Beware of injection nozzle fuel jet. The fuel penetrates deeply into the skin tissue, possibly resulting in blood poisoning.

⚠ Utmost cleanliness must be observed when working on the injection equipment.

Tools: Injector testing outfit, Soft-metal cheeks, Vise

1. Connect injector to testing outfit.
2. Check opening pressure: slowly press down lever; the pressure at which gauge pointer stops or suddenly drops is the opening pressure.
3. Clamp injector between soft-metal cheeks in vise. Remove cap nut and all other parts.
4. Adjust pressure by selecting appropriate shim. A thicker shim increases the opening pressure.
5. Reassemble injector and recheck on testing outfit.
6. Checking for tightness: dry nozzle and holder, press to about 20 bar below previous opening pressure.
7. Nozzle is tight if there is no dripping within a period of 10 seconds.
8. Buzzing and spray pattern test. If nozzle does not buzz despite cleaning, replace it.

⚠ Before assembly of valve stem seal, valve splines must be covered by the protective sleeve or masking tape.

Tools: Magnetic measuring stand, Valve spring assembly lever, Valve reseating tool, Clamping stand 120900, Clamping plate 120910, Sleeve for fitting valve stem seal 121410

1. Mount cylinder head on fixture.
2. Remove valve collet, valve spring cap, valve springs and valves.
3. Remove valve stem seal.
4. Clean cylinder head and check for damage.
5. Gauge valve stem clearance.
6. Carry out visual check on valves and valve seat inserts; inspect for degree of wear.
7. If valve seat inserts or valve guides are worn out, have cylinder head repaired in service centers.
8. Gauge length of valve spring.
9. Correct seat width and relief using valve reseating tool.
10. Push protective sleeve onto valve stem, push valve stem seal onto protective sleeve, remove sleeve, press in valve stem seal as far as it will go.
11. Assemble cylinder head complete with valve springs, valve spring cap and valve collet.

⚠ Starter to be removed before with 2- and 3-cylinder engines.

Tools: Torx tools, Hose clip pliers, Engine assembly stand 6067, Multipower tool STW392, Puller 143100

1. Clamp engine in swivel-type engine assembly stand. Drain oil / residual oil.
2. Remove hood, stay plate and oil cooler.
3. Remove leakage fuel pipe and cooling air ducting.
4. Remove injection lines and take adapters out of thermostat housing.
5. Take off clamping pads. Remove injectors.
6. Remove fuel lines and fuel feed pump.
7. Remove oil filter housing and fuel filter housing.
8. Remove idler pulley, take off V-belt and remove blower together with alternator.
9. Remove wiring harness, V-belt pulley and toothed belt guard.
10. Remove toothed belt, camshaft gear and crankshaft gear.
11. Remove lube oil pump, crankcase breather and lift off valve cover.
12. Remove rocker arm brackets and take out pushrods.
13. Remove exhaust manifold, air intake manifold and lift off cylinder head.
14. Remove starter, loosen flywheel bolts, remove flywheel and adapter housing.
15. Remove injection pumps, oil pan, front cover, rear cover, camshaft and pistons; remove main bearing caps and lift out crankshaft.

⚠ Take care that nozzle needle does not fall out of nozzle body.

⚠ Nozzle needle and nozzle body are lapped together and may neither be confused nor exchanged individually.

1. Undo cap nut. Wash all parts in clean diesel fuel and blow out with compressed air.
2. Check seating faces of intermediate piece for wear. Make sure that centering pins are fitted.
3. Insert shims.
4. Insert compression spring.
5. Insert thrust pin with centering collar facing towards the spring.
6. Insert intermediate piece with centering pins fitting into the bores in the nozzle holder.
7. Fit injection nozzle with center bores mating with the centering pins of the intermediate piece.
8. Screw on cap nut and tighten in accordance with specifications.

Tools: Screw driver with socket

1. Lift off cover. Remove steel gasket.
2. Remove valve plunger housing.
3. Take out thermostat together with spring.
4. Remove screw plug for valve plunger (heat up screw plug).
5. Remove valve plunger together with compression spring.
6. Inspect individual component parts.
7. Refit valve plunger together with compression spring. Watch bypass bore.
8. Spread thread of screw plug with sealing compound Loctite 648.
9. Tighten screw plug in accordance with specifications.
10. Position new gaskets, steel gasket and additional new gasket.
11. Fit cover. Tighten bolts in accordance with specifications.

⚠ Avoid tilting when positioning housing (22) and housing (25).

⚠ The piston ring sealing surfaces must be protected from the blasting medium.

Tools: Hot air blower, Torque spanner range 0 - 60 Nm, Socket spanner 10 mm, 12 mm, 14 mm, Splined internal wrench insert (Ribe), Support tube

1. Oil the following bearing parts before fitting: bearing seat of shaft, bearings, thrust bearing, flinger sleeve, oil deflector ring, thrust ring, piston rings, spacer sleeve.
2. Fit bearings and snap rings in the bearing housing.
3. Fit one/two piston rings to shaft and turbine wheel assy.; piston ring slots must be positioned at 180° to another.
4. Place heat shield concentrically on shaft and turbine wheel assy.
5. Guide bearing housing carefully onto rotor shaft. Check that heat shield and bearing housing turn freely.
6. Guide thrust ring and spacer sleeve onto rotor shaft. Place thrust bearing in bearing housing.
7. Place a new oil deflector plate on thrust bearing.
8. Fit flinger sleeve complete with piston rings into backplate. Coat seating face of backplate with LOCTITE 573.
9. Place backplate on bearing housing and fix using screws secured with LOCTITE 640.
10. Heat compressor wheel to max. 130° C and push onto shaft; tighten a new shaft nut to tightening torque.
11. Fit compressor housing to backplate in the position marked, using O-ring coated with ATE brake cylinder paste.
12. Install turbine housing in the position marked, using heat resistant lubricating paste on fixing screws.

⚠ Shaft nut is secured with LOCTITE 640. Take care to incur no bending effects on shaft during shaft nut removal.

⚠ Danger of blade damage when tilted.

Tools: Vice jaw guards, Vice jaw plates 1550013, Hot air blower, Press (vertical drilling machine), Snap ring pliers 1550155

1. Mark the position of the turbine housing and compressor housing with respect to the bearing housing and backplate.
2. Clamp the turbine housing at the gas inlet flange using vice jaw guards.
3. Remove the fixings from the compressor housing and turbine housing. Remove both housings.
4. Clamp the hub of the shaft and turbine wheel assy. in the special vice jaw plates.
5. Remove the shaft nut using T spanner.
6. Heat compressor wheel to max. temperature of 130° C using hot air blower and push out shaft and turbine wheel assy.
7. Remove shaft and turbine wheel assy. from the bearing housing and remove piston rings.
8. Remove heat shield, backplate, flinger sleeve, O-rings, oil deflector ring, oil deflector, thrust bearing, spacer sleeve, thrust ring, snap rings and bearings.