Deutz — Reassembly of Complete Engine – Cylinder Head Through Final Assembly

A Deutz service procedure — check it applies to your exact model before use.

Browse Deutz generators & specs →

Procedure

1. Fit cylinder head, oil cylinder head bolts slightly.
2. Tighten cylinder head bolts in accordance with specifications.
3. Insert pushrods.
4. Fit rocker arm bracket and align relative to pushrods/valves.
5. Tighten bolts in accordance with specifications.
6. Place on seal.
7. Fit cylinder head cover. Tighten bolts in accordance with specifications.
8. Fit air intake manifold with seals.
9. Tighten bolts for air intake manifold in accordance with specifications.
10. Fit exhaust manifold with seals.
11. Tighten bolts for exhaust manifold in accordance with specifications.
12. Bring control rod in central position.
13. Screw locating pin for control rod into crankcase.
14. Rotate camshaft until tappet stroke of respective cylinder is at BDC.
15. Fit injection pump tappets.
16. Place on seal.
17. Determining shims: gauge dimension "A" between contact surface of seal and spring plate contact surface of tappet.
18. Place on appropriate number of shims.
19. Fit injection pump in place. Press pump down onto its seat, taking care that it is accurately centered. Tighten nuts in accordance with specifications. Remove centering pin.
20. Close bore with plug.
21. Remove locating pin for control rod. Cover up bore with new Cu sealing ring.
22. Slide sealing ring over injector using some grease.
23. Insert injector.
24. Fit clamping pad.
25. Tighten bolts in accordance with specifications.
26. Fit O-seals (connecting pipe).
27. Press in connecting pipe as far as it will go.
28. Stick gasket in position using grease.
29. Fit thermostat housing. Tighten bolts in accordance with specifications.
30. Stick gasket in position using grease.
31. Fit oil filter bracket. Tighten bolts in accordance with specifications.
32. Fit temperature pick-up with new Cu seal.
33. Slightly oil oil filter gasket. Lock oil filter cartridge fingertight.
34. Fit new O-seal (fuel feed pump).
35. Mount fuel feed pump. Tighten bolts evenly in accordance with specifications.
36. Fit fuel filter bracket.
37. Slightly oil fuel filter gasket. Lock filter cartridge fingertight.
38. Fit fuel line with new Cu sealing rings.
39. Fit leakage fuel line.
40. Fit fuel hose to injection pump and fuel filter. Press on profiled rubber.
41. Fit fuel hose between fuel filter and fuel pump.
42. Fit injection lines and tighten in accordance with specifications.
43. Fit new O-seals for crankcase breather.
44. Mount crankcase breather.
45. Fit toothed belt guard.
46. Fit cable terminal box and wiring harness with spacer sleeves and special washers.
47. Fit securing clip to toothed belt guard.
48. Fit cable plug connection and secure.
49. Fit cable plug connection.
50. Install oil pressure pickup with new Cu sealing ring.
51. Fit cable plug connection.
52. Install wiring harness behind crankcase breather.
53. Fit rubber grommet to wiring harness.
54. Press rubber grommet into blower.
55. Mount blower. Tighten bolts in accordance with specifications.
56. Install cables as marked.
57. Fit cover strip.
58. Fit cooling air ducting.
59. Slide new O-seals over adapters.
60. Press adapters into thermostat housing.
61. Mount oil cooler. (Do not tighten bolts yet.)
62. Fit stay plate. Tighten bolts for oil cooler and stay plate.
63. Mount adapter housing. Make sure that centering bushes are fitted.
64. Tighten bolts in accordance with specifications.
65. Mount flywheel, using a self-prepared threaded mandrel. Lock bolts fingertight.
66. Retain flywheel, using a self-prepared dolly. Tighten bolts in accordance with specifications.
67. Mount starter.
68. Fit cables to starter and fasten clips.
69. Fit V-belt pulley. Tighten bolts in accordance with specifications.
70. Fit V-belt idler pulley. (Start bolts.)
71. Place on V-belt.
72. Tension V-belt. Tighten bolts in accordance with specifications.
73. Mount holding bracket.
74. Mount air cowling.
75. Spread sealing surface of oil suction housing with Deutz DW 67.
76. Mount oil suction housing. Tighten bolts in accordance with specifications.
77. Spread sealing surface of oil pan with Deutz DW 47.
78. Mount oil pan. Tighten bolts: turn clockwise in accordance with specifications.
79. Insert new O-seal.
80. Press in oil dipstick as far as it will go.

Source: manual:KHD DEUTZ Workshop Manual B_FL _T 1988.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.