2013 Deutz TCD 2013 4V engine Workshop Manual (P/N 0312 3132 en)

• Coverage and document identity: Official DEUTZ AG workshop publication for TCD 2013 4V Industry engines in L4 and L6 configurations; a 356-page PDF, 2nd Edition (November 2006), Order No. 0312 3132 en.
• 63 indexed W-series Job Cards cover engine mounting on the assembly block, compression-pressure testing, valve-clearance setting, cylinder-head and valve-train repair, crankshaft and piston work, cylinder-liner service, camshaft inspection, and gearcase procedures.
• DEUTZ Common Rail repair coverage includes the fuel supply pump, control block, high-pressure pump in installation positions A and B, rail, injector, pressure-limiting valve, rail-pressure sensor, and fuel-pressure sensor.
• Air, exhaust, and exhaust-gas-recirculation procedures address the turbocharger, exhaust and charge-air lines, heating flange, flutter valve, EGR cooler, actuator, and shutoff valve.
• Lubrication and cooling procedures cover the heavy-duty oil pan, oil cooler and housing, oil pressure switch, coolant pump, thermostat and housing, and temperature transmitter.
• Electrical and accessory Job Cards address the torsional vibration damper, flywheel, air conditioning compressor, generator service from the operating side and outlet side, starter, and charge-air pressure/temperature sensor.
• Factory reference data and visual aids include component-specific inspection, testing, setting, and tightening tables; separate L4/L6 valve-setting charts; cylinder-head tightening sequences; measuring diagrams; and illustrated standard- and special-tool catalogs.

Engine Service Overview

This DEUTZ workshop manual is organized around factory Job Cards rather than a generic engine-rebuild narrative. Each card identifies the maintenance group, prerequisite cards, required standard and special tools, auxiliary materials, test or setting references, tightening references, safety notes, and the illustrated repair procedure. Alphabetical and numerical indexes are followed by a cross-reference matrix showing which additional Job Cards are required before a larger operation can be completed.

Cylinder-head coverage includes valve-control removal and disassembly, cylinder-head removal, piston-overhang checks, valve removal and inspection, valve-guide checks, and valve-lag measurement. Drive-system and crankcase cards address crankshaft axial clearance and inspection, crankshaft removal, front and rear sealing-ring replacement, piston and connecting-rod work, piston and ring-groove inspection, and cylinder-liner testing and replacement. Separate procedures handle liner overhang, the front cover, connection housing, gearcase, camshaft removal and inspection, and the crankshaft and camshaft impulse transmitters.

Fuel-system coverage is organized specifically for the DEUTZ Common Rail layout. The manual distinguishes the two high-pressure-pump installation positions and documents the related roller tappet, O-ring, fuel-pipe, high-pressure-line, and connection work. Dedicated cards cover the rail, injector, control block, pressure-limiting valve, rail-pressure sensor, and fuel-pressure sensor. Exhaust and EGR work is divided into separate procedures for the turbocharger, exhaust and charge-air lines, heating flange, flutter valve, cooler, actuator, and shutoff valve.

The safety material addresses residual pressure and leak hazards in the Common Rail system, strict cleanliness controls for exposed fuel components, secure engine handling on the assembly block, electrical isolation, coolant and oil recovery, and refrigerant work that must follow the equipment manufacturer's documentation.

The Job Cards also flag several assembly errors that can ruin reusable parts. A fractured connecting-rod cap must remain paired with its original rod and retain the specified orientation; reversing it makes the rod unusable, while damage to the fracture surfaces is prohibited. Open Common Rail ports must be capped immediately and kept away from dust, grinding, welding, and compressed-air cleaning. Injector and crankshaft-seal procedures identify the nozzle tip, sealing-ring orientation, O-ring grooves, and shaft sealing surfaces as damage-prone during removal and assembly.

Technical Specifications

The testing and setting section distinguishes the L4 engine at 4,761 cm³ from the L6 at 7,142 cm³ and supplies separate ignition-sequence valve-setting charts for both configurations. Additional tables cover cylinder-head dimensions, valve seats and guides, valve springs, crankshaft journals and main bearings, connecting rods, piston pins, pistons and rings, camshaft bearings, crankcase bores, cylinder-liner inspection, sealing-ring installation, and thermostat data. Together, these references support wear inspection, parts selection, clearance checks, and assembly verification during repair.

The tightening section contains 112 listed entries across the engine and its accessories. It combines torque and angle specifications with tightening sequences, new-fastener requirements, limited-reuse notes, sealing-ring instructions, and component-specific assembly remarks. Visual references include the L4 and L6 valve-overlap charts, four- and six-cylinder cylinder-head tightening sequences, crankshaft-journal measuring diagrams, piston-pin-bore and piston-diameter schematics, cylinder-liner measuring views, and installation-position photography for the two high-pressure-pump arrangements.

The illustrated tool sections identify the equipment expected by the Job Cards. Examples include compression tester 8005 with connector 100180, assembly block 6066 with clamping bracket 6066/210 and lifting device 6068, and high-pressure-line wrench 110500. The catalog also identifies O-ring assembly case 110900, crankshaft-seal installers 142810 and 142820, and the 150170/150171 and 150190/150191 cylinder-liner removal and installation sets.

This is the Industry workshop publication and not a substitute for the separate operation manual. Routine maintenance schedules, operating media, normal filling and bleeding instructions, and the general faults/causes/remedies section are assigned to that companion document. The electrical chapter covers the listed component procedures rather than full-system diagnosis; wiring diagrams, ECU fault-code routines, and electronic troubleshooting charts are outside this manual's scope.