Deutz BFM 1012/1013 (2000) Diesel Engine Service Manual (P/N 0297 9771)

Deutz factory workshop manual for the BFM 1012 and BFM 1013 engine families, including the listed BF4M, BF6M, and E variants. P/N 0297 9771, first edition, May 2000.

Searchable PDF and Multilingual Page Layout

Text search and table detail: PDF text search is available, but there are no embedded bookmarks. Dense injection-timing tables use wide layouts and are easier to read when enlarged.

One printable PDF contains 512 pages in English, German, French, and Italian. The total includes the original seven-page front matter, five section dividers, and 30 blank pages.

Engine Overhaul, Injection Timing, and Component Repair

The following selected coverage highlights outline the main workshop areas. Other topics include starter ring-gear replacement and rocker-arm inspection.

• Complete engine: Step-by-step disassembly and reassembly procedures, crankshaft-bearing installation, piston fitting, and BFM 1012 mass-balancing shaft alignment.

• Cylinder head and valves: Head disassembly, valve and guide inspection, valve-seat reworking, gasket selection, and valve-clearance adjustment.

• Fuel injection and testing: Bosch pump timing, shim selection, control-rod checks, compression testing, and injector opening-pressure, leakage, and spray-pattern checks.

• Cooling and lubrication: Front-cover/oil-pump service, oil-cooler repair, thermostat and coolant-pump work, and BFM 1012 integrated-cooling-system procedures.

• Auxiliary equipment: Crankshaft-seal replacement on a complete engine, air-compressor removal and refitting, power-steering pump installation, and hydraulic-pump drive service.

• Workshop reference data: Engine weights, component-specific tightening specifications, dimensional tolerances, wear limits, measurement schematics, cylinder-head bolt sequence drawings, and a key to workshop symbols.

This manual assumes qualified repair personnel with the measuring equipment and special tools required for engine repair and adjustment.

Overhaul Measurements and Engine Configuration

Component gauging and wear limits help assess which parts can remain in service during an overhaul. Main-bearing journal and connecting-rod bore schematics identify measurement planes, while cylinder-head bolt drawings distinguish the four- and six-cylinder sequences.

The crankcase procedures distinguish BFM 1012 integrated cylinder liners from removable BFM 1013 liners. Piston-projection tables link measured protrusion to the appropriate cylinder-head gasket marking.

The starter ring-gear procedure warns against damaging the flywheel when drilling the old gear.

Coverage boundary: Complete-engine procedures follow the standard engine specification; application-specific components are not illustrated. Operating and maintenance instructions belong to the separate Operation Manual, and parts ordering uses the corresponding parts catalog.

Bosch Pump Timing and Injector Diagnosis

Timing calculations account for camshaft types A, B, and C, pump-length codes, measured installation dimensions, and shim thickness. Cylinder-specific EP-code tables support replacement-pump setup; crankcase, camshaft, or roller-tappet replacement requires a fresh corrected installation dimension and EP code.

Pump replacement scope: The service replacement method applies to injection pumps alone. Work involving additional components, such as the governor or roller tappets, uses the full pump-installation procedure.

Injector testing also covers nozzle-needle movement and buzzing behavior. Needle and nozzle body are matched components, and the compression-test section explains why cranking speed and altitude affect readings and why cylinder-to-cylinder comparison matters.

Observe the manual’s high-pressure fuel-jet precautions during injector testing.

Cooling Systems, Oil Seals, and Auxiliary Drives

The integrated-cooling section follows BFM 1012 radiator, fan-carrier, pipework, and panel removal and refitting. Oil-pump/front-cover work distinguishes the two engine families’ pressure-control valves.

For the BFM 1013 oil cooler, the instructions identify thread protection during seal installation to prevent damage to replacement seals. Turbocharger work covers mounting arrangements and oil lines; damaged turbochargers are replaced as assemblies.

Hydraulic-pump drive instructions include bearing-bush measurement and replacement, supported by installation-position schematics. Illustrated tool references identify the control-rod measuring/locking device 100 800 and BFM 1012 balancing-shaft adjusting pin 100 810.

Main-Bearing Tightening and End-Float Examples

The BFM 1012 main-bearing bolt specification starts at 30 Nm, followed by two separate 60° tightening stages. BFM 1013 main-bearing bolts start at 50 Nm, also followed by two separate 60° stages.

Permissible crankshaft end float is 0.10–0.30 mm for both engine families. The assembly section illustrates the thrust-bearing measurements used to determine that clearance.