DEUTZ BFM 1012/1013 Diesel Engine Workshop Manual – Full Repair & Service PDF

Description

DEUTZ BFM 1012/1013 Diesel Engine Workshop Manual – Full Repair and Service PDF

This is the complete DEUTZ workshop manual for the BFM 1012 and BFM 1013 series diesel engines, issued by DEUTZ AG under document number 0297 7438. It is a four-language edition – German, English, French and Spanish – published under the original title Werkstatthandbuch / Workshop Manual / Manuel d’Atelier / Manual de Taller. Every chapter is reproduced with the original technical illustrations, exploded component drawings, measuring schematics, tightening sequences and tolerance tables intact. If you are working on a BF4M 1012, BF6M 1012, BF4M 1013 or BF6M 1013, this DEUTZ BFM 1012/1013 workshop manual takes you from the crankcase casting right through to the hydraulic pump drive.

File Details

• Manual type: Workshop / Repair Manual (Werkstatthandbuch)
• Manufacturer: DEUTZ AG, Made in Germany
• Document number: 0297 7438
• Engine families covered: BFM 1012, BFM 1012/E, BFM 1013, BFM 1013/E (including BF4M and BF6M variants)
• Languages: German, English, French, Spanish
• Format: PDF
• Pages: approx. 490

Chapters Covered

The manual follows DEUTZ’s own assembly-group numbering, so each section maps directly to the part you have in front of you:

• 1. Specification Data – engine ratings, cylinder head bolt tightening sequence, valve timing, injection pump shim calculation and EP code determination (BFM 1012 Lo = 109 mm and Lo = 119 mm; BFM 1013 Lo = 143 mm), symbol key
• 2. Checking and Adjusting – valve clearance, compression pressure, injector opening pressure, leak and spray-pattern testing
• 3. Repair of Components
  • 01 – Crankcase with integrated cylinder liners
  • 01 – Front cover / lube oil pump
  • 01 – Timing chest
  • 05 – Crankshaft
  • 05 – Starter ring gear / flywheel
  • 06 – Connecting rod
  • 07 – Piston
  • 08 – Cylinder head
  • 10 – Camshaft
  • 11 – Rocker arm bracket
  • 15 – Lube oil cooler
  • 17 – Fuel pump
  • 19 – Injector
  • 27 – Control rod
  • 33 – Air compressor
  • 38 – Thermostat
  • 38 – Coolant pump
  • 39 – Fan drive
  • 72 – Mass balancing shaft
  • 83 – Hydraulic pump drive
  • 83 – Hydraulic pump with fastening flange
• 4. Disassembly and Reassembly of Complete Engine

Taken as a whole, this DEUTZ BFM 1012/1013 workshop manual gives a technician the full measuring and machining routine for the engine: how to gauge cylinder bores in two axes at three levels, how to check main bearing journals and crankpins for ovality, how to test a connecting rod for parallelism and squareness, how to rework a valve seat and re-measure valve penetration, and how to select the correct compensating shim when a Bosch injection pump is replaced in service.

Measuring, Tolerances and Adjustment Values

The specification pages are concentrated where they are needed rather than dumped in a single table at the front, which is why this format works so well on the bench. Typical values you will find inside include cylinder bore 94 + 0.02 mm for the BFM 1012 and 108 + 0.02 mm for the BFM 1013 with wear limits at 94.1 mm and 108.1 mm, main bearing journal diameters of 74.00 – 0.02 mm and 85.00 – 0.02 mm, crankpin diameters of 58.00 – 0.02 mm and 68.00 – 0.02 mm, and connecting rod small-end bush bores of 34 mm and 42 mm. Valve clearance is set to 0.3 mm inlet and 0.5 mm exhaust, increased by 0.1 mm at each cylinder head gasket renewal. Compression pressure is specified as 28-33 bar for the BFM 1012 and 30-38 bar for the BFM 1013. Injector opening pressure is 250 + 8 bar and 275 + 8 bar respectively.

Torque and Tightening Specifications

Fastener data is given at the point of use, using the original DEUTZ staged-angle method rather than a single figure. Cylinder head bolts are tightened in the numbered sequence shown in the manual’s schematic. Main bearing caps use 30 Nm plus 60 degrees plus 60 degrees on the BFM 1012 and 50 Nm plus 60 degrees plus 60 degrees on the BFM 1013. Connecting rod bolts use 30 Nm, 60 degrees, then a further 30 degrees (BFM 1012) or 60 degrees (BFM 1013). Other values include 40-50 Nm for the injector cap nut, 20 +/- 2 Nm for the valve clearance lock nut, 22 +/- 2 Nm for the fuel pump clamping plate, 80 Nm then 160 Nm for the lube oil cooler collar screws, 9 +/- 1 Nm for the cylinder head cover and 16 + 5 Nm for the injector clamping pads.

Injection Equipment and Bosch Pump Servicing

A significant part of the document is dedicated to the Bosch injection pump and the injector. The manual walks through determining the correct compensating shim thickness for delivery start when a pump is replaced in service, using the base dimension Lo for each engine family and reading the corrected installation dimension and EP code from the printed tables. The injector chapter covers disassembly, shim selection to raise or lower opening pressure, lapping-matched nozzle needle and body handling, leak testing at approximately 20 bar below the previously read opening pressure, and the buzzing and spray-pattern test used to judge whether a nozzle can be reused. Injection lines, special seals and leakage fuel lines are all treated as one-time parts and the manual says so plainly.

What This Manual Enables You to Do

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With this DEUTZ BFM 1012/1013 workshop manual on hand you can carry out a top-end overhaul, replace cylinder liners on the BFM 1013, precision-bore a small-end bush, rework valve seats and re-check valve penetration, renew a starter ring gear by heat shrinking, time a Bosch injection pump, and diagnose low compression, poor atomisation, sticking nozzle needles and oil pressure faults against the manufacturer’s own figures. Using the correct staged torque figures and wear limits rather than generic values is the difference between an engine that lasts and one that comes back. Delivery is instant: the PDF is available for immediate download after checkout, there is no shipping and no waiting, and you can print the pages you need for the workshop or open them on a laptop or tablet at the machine.