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dw232472 group 2
dw232472 group 2
65/75/85CF series
TECHNICAL DATA
0
DIAGNOSTICS
1
XF ENGINE
2
XF ENGINE COOLING SYSTEM
3
XF ENGINE LUBRICATION SYSTEM
4
PF ENGINE
5
PF ENGINE COOLING SYSTEM
6
PF ENGINE LUBRICATION SYSTEM
7
NS ENGINE
8
NS ENGINE COOLING SYSTEM
9
NS ENGINE LUBRICATION SYSTEM
10
XE ENGINE
11
XE ENGINE COOLING SYSTEM
12
XE ENGINE LUBRICATION SYSTEM
13
PE-ENGINE
14
ǹ 200335
2 CONTENTS
65/75/85CF series
ǹ 200335
2 TECHNICAL DATA
65/75/85CF series Contents
CONTENTS
1. ENGINE GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page Date
1-1 . . . . 200335
0
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200335
2. XF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200335
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200335
2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . 200335
3. XF ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200335
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200335
3.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . 200335
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . 200335
4. XF ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 .... 200335
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 .... 200335
4.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 .... 200335
4.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 .... 200335
5. PF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . 200335
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . 200335
5.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 . . . . 200335
6. PF ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . 200335
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . 200335
6.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . 200335
6.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . 200335
7. PF ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 .... 200335
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 .... 200335
7.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 .... 200335
7.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 .... 200335
8. NS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . 200335
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . 200335
8.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 . . . . 200335
9. NS ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . 200335
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . 200335
9.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . 200335
9.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . 200335
10. NS ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . 200335
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . 200335
10.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 . . . 200335
10.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 . . . 200335
11. XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 200335
11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 200335
11.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 . . . 200335
ǹ 200335 1
TECHNICAL DATA 2
Contents 65/75/85CF series
Page Date
2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series Engine general
1. ENGINE GENERAL
1.1 GENERAL
0
The terms “COLD ENGINE” and “WARM
ENGINE” are defined as follows:
COLD ENGINE
A cold engine is an engine which, having
reached operating temperature, has been
allowed to cool down for at least six hours.
WARM ENGINE
A warm engine is an engine which, having
reached operating temperature, has not been at
a standstill for more than thirty minutes.
Direction of rotation of the engine
The direction of rotation of the engine is
clockwise, as seen from the timing gear end.
First cylinder of the engine
The first cylinder of the engine is the cylinder at
the timing gear end.
Left-hand and right-hand side of the engine
The left-hand side of the engine is the side
where the fuel pump is mounted.
The right-hand side of the engine is the side
where the air compressor is mounted.
ǹ 200335 1-1
TECHNICAL DATA 2
Engine general 65/75/85CF series
1-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine
2. XF ENGINE
2.1 GENERAL
0
Types XF 280 M
XF 315 M
XF 355 M
Number of cylinders 6
Bore x stroke 130 x 158 mm
Swept volume 12.58 l
Compression ratio 16.0 : 1
Firing order 1-5-3-6-2-4
Weight approx. 1049 kg
ǹ 200335 2-1
TECHNICAL DATA 2
XF engine 65/75/85CF series
V-BELT TENSION
Belt tension, “AVX” raw-edge(1) V-belts in Newtons (N)
0 Multiple-V-belt Single-V-belt
New V-belt(2)
Setting tension 1200 600
Test tension ≥800 ≥400
Worn V-belt(3)
Minimum tension 500 250
Adjusting tension 700 350
(2) After fitting the new V-belt, set the pre-tension to the
“setting tension” and after a trial run check whether the
pre-tension complies with the “test tension”. If the
tension reading is lower than the “test tension”
specified in the table, set the V-belt to the minimum
“test tension”.
Cylinder liner
Height above cylinder block 0.02 - 0.10 mm
Cylinder head
Minimum height after overhaul 119.50 mm
Test pressure using air (max. pressure) 1.5 bar
Valve clearance
Valve clearance (cold/hot)
inlet 0.50 mm
exhaust 0.50 mm
Valve opening
Valve opening at 1 mm valve clearance 0.3 - 0.7 mm
2-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine
Axial play
Crankshaft axial play 0.06 - 0.32 mm
Camshaft axial play
Idler gear axial play
0.10 - 0.55 mm
0.05 - 0.25 mm
0
Gear backlash
Idler gear - crankshaft gear 0.02 - 0.21 mm
Idler gear - fuel-pump gear 0.02 - 0.22 mm
Idler gear - camshaft gear 0.02 - 0.21 mm
Camshaft gear - compressor gear 0.02 - 0.22 mm
Fuel pump gear - steering pump gear 0.02 - 0.19 mm
Oil pump idler gear - oil pump gear 0.02 - 0.20 mm
Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm
Fan drive
Heat gear wheel for max. 30 min. 245_C
Compression pressure
Differences in compression pressure 15%
ǹ 200335 2-3
TECHNICAL DATA 2
XF engine 65/75/85CF series
Starter motor
Attachment nuts 73 Nm(1)
Alternator
Alternator bracket attachment bolts 55 Nm
Alternator attachment bolts 50 Nm
Pulley attachment nut 70 Nm
Air compressor
M12 attachment bolts for compressor 110 Nm
M8 attachment bolts for bracket 30 Nm
M10 attachment bolts for bracket 60 Nm
Compressor gear flange bolt 120 Nm
M14 cylinder head threaded coupling 40 Nm
M26 cylinder head threaded coupling 90 Nm
Delivery pipe reducer valve 75 Nm
Suction and pressure line unions 90 Nm
Air-conditioning compressor
M12 attachment bolts for compressor bracket 110 Nm
M10 attachment bolts for compressor 60 Nm(1)
Exhaust manifold
Fit gasket with steel side towards manifold
Sleeved attachment bolts 65 Nm
Heat shield attachment bolts 30 Nm(1)
2-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine
Inlet manifold
Attachment bolts 60 Nm
Glow plug attachment nut
Air inlet hose clamps
55 Nm
12 Nm
0
Turbocharger
Heat shield attachment bolts 30 Nm(1)
Turbine housing clamp plate attachment nut 15 Nm
Attachment nuts, exhaust manifold
flange/turbocharger 60 Nm(2)
Elbow on turbocharger 40 Nm
Oil supply pipe banjo bolt 90 Nm
ǹ 200335 2-5
TECHNICAL DATA 2
XF engine 65/75/85CF series
4
1
2
3
5
6
7
M200946
2-6 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine
6
7
4
10
8
9 11 12 13 5 2 3 1 14
M200947
ǹ 200335 2-7
TECHNICAL DATA 2
XF engine 65/75/85CF series
0
21 18 19 20
the cylinder head bolts should always be
replaced. The new cylinder head bolts have a 17 11 7 1 8 12
red/brown sealant on the thread. 16 13
6 2
Note:
- Because of the sealant used on the cylinder
head bolts, their untightening torque may be 15 5 3 14
very high!
10 4 9
- All M16 and M12 threaded holes must be
carefully cleaned with a screw tap before
the bolts are fitted.
M200562
- Once the bolts have been tightened to the
specified torque, the angular displacement
of the M16 bolts must immediately be 50 Nm
started.
- The sealant cannot be applied later.
Tightening cylinder head attachment bolts
Note: 150 Nm
M16
Apply a drop of oil underneath the bolt heads
(on their abutting surface). Sealant also reduces
the frictional resistance, which means that no oil
must be applied to the thread. I
1st phase
M16
Tighten M16 in the order 94 Nm
indicated 50 Nm(1)
2nd phase
II
Tighten M16 in the order
M12
indicated 150 Nm
Tighten M12 in the order
indicated 94 Nm(1) II
3rd phase 60
M16 in the order
indicated in two stages of 60_ angular
displacement
M16
III
M16
III
M200563
2-8 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine
Timing gear
Camshaft locking plate attachment bolts 30 Nm(1)
Attachment bolts, fuel pump drive shaft locking
plate 30 Nm(1)
0
Timing case attachment bolts 30 Nm(1)
Timing cover attachment bolts:
- M10 attachment bolts 60 Nm
- M8 attachment bolts 25 Nm
Timing cover protection plate attachment bolt 15 Nm
Camshaft gear attachment bolt 425 Nm(1)
Idler gear attachment bolt 170 Nm
Attachment bolt, fuel pump gear wheel 260 Nm(1)
Attachment bolt, silencer 30 Nm
Steering pump gear attachment nut 80 Nm(1)
Steering pump intake pipe banjo bolt 90 Nm
Steering pump delivery pipe banjo bolt 40 Nm
Compressor gear attachment nut 120 Nm
ǹ 200335 2-9
TECHNICAL DATA 2
XF engine 65/75/85CF series
Flywheel housing
Attachment bolts 110 Nm(1)
0 Sealant to be used when fitting flywheel
housing Loctite 510
Flywheel
Attachment bolts
Without PTO 260 Nm(1) + 90_ angular displacement
Without PTO spanner size 21 mm 260 Nm + 90_ angular displacement
With PTO 260 Nm + 150_ angular displacement
Valve gear
Valve cover attachment bolts 25 Nm
Rocker setting bolt lock nut 40 Nm
Bridge piece setting bolt lock nut 40 Nm
Lubricating oil strip/rocker seat attachment
bolts 110 Nm
DEB set screw nut 25 Nm
Solenoid valve 20 Nm
Wiring harness attachment bolt 9 Nm
Valve sleeve attachment bolts 30 Nm
Tighten the valve sleeve bolts in the sequence
shown. 7 15 9
3 2
11 13
5 6
1 14 8
10 12 4
M200942
2-10 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine cooling system
Water pump
Maximum radial play 0.16 - 0.20 mm
ǹ 200335 3-1
TECHNICAL DATA 2
XF engine cooling system 65/75/85CF series
Water pump
M8 attachment bolts 30 Nm
Threaded coupling 35 Nm
Coolant pipe
Attachment bolts 54 Nm
Coolant pipe threaded coupling 90 Nm
Coolant pipe plug 30 Nm
Thermostat housing
Attachment bolts 30 Nm
Plug 35 Nm
Radiator
Attachment nuts 70 Nm
3-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine lubrication system
Oil filter
Type disposable filter
Quantity 1
Installation in the oil circuit full flow
Opening pressure of bypass valve at a
pressure difference of 2.5 0.3 bar
Oil cooler
Opening pressure of bypass valve at a
pressure difference of 2 bar
Oil section test pressure 6 bar
ǹ 200335 4-1
TECHNICAL DATA 2
XF engine lubrication system 65/75/85CF series
Fuel filter
Attachment bolts, fuel filter/water pipe
connection 40 Nm
Fuel pump filter head banjo bolt 40 Nm
Oil sump
Clamp attachment bolts 25 Nm
Oil drain plug 60 Nm
Oil pump
Attachment bolts for oil pump housing sections 30 Nm
Attachment bolts connecting oil pump to main
bearing cap 60 Nm(1)
Oil delivery pipe attachment bolts 30 Nm(1)
Idler gear central bolt 60 Nm(1)
Strainer
Bracket attachment bolts 30 Nm(1)
4-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine lubrication system
Oil cooler
Attachment bolts connecting oil cooler to
cylinder block
Coolant supply pipe union
50 Nm
90 Nm
0
Plug, adjustable banjo connection 90 Nm
Banjo bolt, adjustable banjo connection 90 Nm
Dip stick
Threaded coupling 60 Nm
ǹ 200335 4-3
TECHNICAL DATA 2
XF engine lubrication system 65/75/85CF series
Oil sprayer
Banjo bolt (M14) for oil sprayer with locking 30 Nm
0 plate
Banjo bolt (M10) for oil sprayer 30 Nm
3 2
M200661
4-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine lubrication system
Lubrication system
Total capacity, including oil cooler and oil filter approx. 32 litres
0
Oil sump capacity, maximum level approx. 25 litres
Oil sump capacity, minimum level approx. 17 litres
ǹ 200335 4-5
TECHNICAL DATA 2
XF engine lubrication system 65/75/85CF series
4-6 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine
5. PF ENGINE
5.1 GENERAL
0
Engine specification
Cubic capacity 9.20 l
Bore 118 mm
Stroke 140 mm
Number of cylinders 6 cylinders in line
Number of valves per cylinder 4
Emission level Euro 2
Compression ratio 16.3 : 1
Weight approx. 813 kg
ǹ 200335 5-1
TECHNICAL DATA 2
PF engine 65/75/85CF series
V-belt tension
Belt tension, “AVX” raw-edge(1) V-belts in Newtons (N)
0 Multiple-V-belt Single-V-belt
New V-belt(2)
Setting tension 1200 600
Test tension ≥800 ≥400
Worn V-belt(3)
Minimum tension 500 250
Adjusting tension 700 350
Cylinder liner
Height above cylinder block 0.02 - 0.10 mm
Cylinder head
Minimum height after overhaul 119.5 mm
Valve clearance
Valve clearance (cold/hot)
inlet 0.45 mm
exhaust 0.45 mm
Valve opening
Valve opening at 1 mm valve clearance 0.45 0.2 mm
5-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine
Axial play
Crankshaft axial play 0.05 - 0.35 mm
Camshaft axial play
Idler gear axial play
0.10 - 0.55 mm
0.03 - 0.25 mm
0
Gear backlash
Idler gear - crankshaft gear 0.02 - 0.20 mm
Idler gear - fuel-pump gear 0.02 - 0.22 mm
Idler gear - camshaft gear 0.02 - 0.22 mm
Camshaft gear - compressor gear 0.02 - 0.22 mm
Fuel pump gear - steering pump gear 0.02 - 0.19 mm
Oil pump idler gear - oil pump gear 0.02 - 0.20 mm
Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm
Compression pressure
Differences in compression pressure max. 15%
ǹ 200335 5-3
TECHNICAL DATA 2
PF engine 65/75/85CF series
Starter motor
Attachment nuts 73 Nm(1)
Alternator
Alternator bracket attachment bolts 55 Nm
Alternator attachment bolts 50 Nm
Pulley attachment nut 70 Nm
Air compressor
Compressor gear flange bolt 120 Nm
M12 attachment bolts 110 Nm
M8 bracket attachment bolts 30 Nm
Cylinder head threaded coupling 90 Nm
Delivery pipe reducer valve 75 Nm
Suction and pressure line unions 90 Nm
Exhaust manifold
Fit gasket with steel side towards manifold
Sleeved attachment bolts 65 Nm(1)
Heat shield attachment bolts 30 Nm
Inlet manifold
M10 attachment bolts 60 Nm
M10 attachment studs 60 Nm
Glow plug attachment nut 55 Nm
5-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine
Turbocharger
Heat shield attachment bolts 30 Nm(1)
Turbine housing clamp plate attachment nut
Attachment nuts
15 Nm
0
Exhaust manifold flange/turbocharger 60 Nm(2)
Elbow on turbocharger 40 Nm
Fan
Attachment nuts 25 Nm(1)
Fan pulley attachment bolts 30 Nm(1)
ǹ 200335 5-5
TECHNICAL DATA 2
PF engine 65/75/85CF series
Note:
- Because of the sealant used on the cylinder 13
head bolts, their untightening torque may be 10
5 3
8
very high! 9 4
- All M16 and M12 threaded holes must be
carefully cleaned with a screw tap before
the bolts are fitted.
- Once the bolts have been tightened to the M200734
specified torque, the angular displacement
of the M16 bolts must immediately be
started. 50 Nm
- The sealant cannot be applied later.
Tightening cylinder head attachment bolts
Note:
150 Nm
M16
Apply a drop of oil underneath the bolt heads
(on their abutting surface). Sealant also reduces
the frictional resistance, which means that no oil
must be applied to the thread. I
1st phase
M16
Tighten M16 in the
50 Nm(1)
94 Nm
order indicated
2nd phase II
Tighten M16 in the
order indicated 150 Nm
M12
Tighten M12 in the
order indicated 94 Nm(1)
II
3rd phase
60
M16 in the order
indicated in two stages of 60_ angular
displacement
III
M16
III
M200563
5-6 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine
Timing gear
Fuel pump drive housing attachment bolts 60 Nm
Camshaft locking plate attachment bolts
Attachment bolts, fuel pump drive shaft locking
30 Nm(1)
0
plate 30 Nm(1)
Crankshaft hub attachment bolts in 4 phases:
1st phase, all attachment bolts 100 Nm(2)
2nd phase, all attachment bolts 100 Nm(2)
3rd phase, all attachment bolts 100 Nm(2)
4th phase, all attachment bolts 100 Nm(2)
Viscous fan clutch attachment nuts 30 Nm(1)
Timing case attachment bolts 30 Nm
Timing cover attachment bolts:
- M10 attachment bolts 60 Nm
- M8 attachment bolts 25 Nm
Timing cover protection plate attachment bolt 15 Nm
Camshaft gear attachment bolt 425 Nm
Idler gear attachment bolt 170 Nm
Attachment bolt, fuel pump gear wheel 260 Nm(1)
Attachment bolt, silencer 30 Nm
Steering pump gear attachment nut 80 Nm(1)
Suction pipe banjo bolt 90 Nm
Delivery pipe banjo bolt 40 Nm
ǹ 200335 5-7
TECHNICAL DATA 2
PF engine 65/75/85CF series
Flywheel housing
Attachment bolts 110 Nm(1)
0 Sealant to be used when fitting flywheel
housing Loctite 510
Flywheel
Attachment bolts
- without PTO 80 Nm(1) + 45_ angular displacement
- with PTO 110 Nm + 150_ angular displacement
Valve gear
Valve cover attachment bolts 25 Nm
M10 rocker setting bolt lock nut 40 Nm
Bridge piece setting bolt lock nut 40 Nm
Lubricating oil strip/rocker seat attachment
bolts 60 Nm
Valve sleeve attachment bolts 30 Nm
Tighten the valve sleeve bolts in the sequence 13 9
shown.
3 7 11 2 6
14
5
1 10 12 8 4
M200959
5-8 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine cooling system
Water pump
Radial play 0.16 - 0.20 mm
ǹ 200335 6-1
TECHNICAL DATA 2
PF engine cooling system 65/75/85CF series
Water pump
M8 attachment bolts 30 Nm
Radiator
Attachment nuts 60 Nm
Cooling system
Cooling system capacity approx. 37 litres
Cooling system capacity with ZF-intarder approx. 47 litres
6-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine lubrication system
Oil filter
Type disposable filter
Quantity 1
Installation in the oil circuit full flow
Opening pressure of bypass valve at a
pressure difference of 2.5 0.3 bar
Oil cooler
Opening pressure of bypass valve at a
pressure difference of 2 bar
Oil section test pressure 2.5 bar
ǹ 200335 7-1
TECHNICAL DATA 2
PF engine lubrication system 65/75/85CF series
Oil sump
Clamp attachment bolts 25 Nm
Oil drain plug 60 Nm
Oil pump
Attachment bolts for oil pump housing sections 30 Nm
Attachment bolts connecting oil pump to main
bearing cap 60 Nm(1)
Oil delivery pipe attachment bolts 30 Nm(1)
Idler gear central bolt 60 Nm(1)
Strainer
Bracket attachment bolts 30 Nm(1)
Oil cooler
Attachment bolts connecting oil cooler to
cylinder block 50 Nm
7-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine lubrication system
Oil sprayer
Banjo bolt (M14) for oil sprayer with locking
plate
Banjo bolt (M10) for oil sprayer
30 Nm
30 Nm
0
Main bearing caps
Main bearing cap attachment bolts 150 Nm +120_ angular displacement(1)
3 2
M200661
ǹ 200335 7-3
TECHNICAL DATA 2
PF engine lubrication system 65/75/85CF series
0 Lubrication system
Total capacity, including oil cooler and oil filter approx. 26 litres
Oil sump capacity, maximum level approx. 22 litres
Oil sump capacity, minimum level approx. 14 litres
7-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series NS engine
8. NS ENGINE
8.1 GENERAL
0
Engine specification
Cubic capacity 6,24 l
Bore 104.2 mm
Stroke 122 mm
Number of cylinders 6 cylinders in line
Number of valves per cylinder 2
Emission level Euro 2
ǹ 200335 8-1
TECHNICAL DATA 2
NS engine 65/75/85CF series
V-belt tension
0
Belt tension “12.55-mm” V-belts in Newtons (N)
Multiple-V-belt Single-V-belt
covered1 raw edge2 covered1 raw edge2
New V-belt3
Setting tension 900 1200 500 600
Test tension 600 800 300 400
Worn V-belt4
Minimum tension 400 500 200 250
Adjusting tension 450 700 250 350
8-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series NS engine
Cylinder liner
Height above cylinder block 0.02 - 0.10 mm
Cylinder head
A B A B A B A B A B A B
M2 00 146
Minimum height after overhaul 104.3 mm
Valve clearance
Valve clearance (cold/hot)
inlet 0.45 mm
exhaust 0.45 mm
Axial play
Crankshaft axial play 0.06 - 0.32 mm
Camshaft axial play 0.06 - 0.22 mm
Idler gear axial play 0.07 - 0.22 mm
Gear backlash
Idler gear - crankshaft gear 0.02 - 0.18 mm
Idler gear - fuel-pump gear 0.02 - 0.24 mm
Idler gear - camshaft gear 0.02 - 0.20 mm
Crankshaft gear wheel - oil pump gear wheel 0.02 - 0.18 mm
ǹ 200335 8-3
TECHNICAL DATA 2
NS engine 65/75/85CF series
Compression
Differences in compression pressure max. 15%
8-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series NS engine
Starter motor
Starter motor attachment bolts 45 Nm(1)
Alternator
Sheet steel pulley attachment nut 55 Nm(2)
Cast iron pulley attachment nut 70 Nm(2)
Air compressor
Compressor gear flanged nut 135 Nm
Compressor attachment bolts 25 Nm(1)
Exhaust manifold
Exhaust manifold attachment nuts 50 Nm
Stud lubricant Copaslip
Inlet manifold
Inlet manifold attachment bolts 25 Nm
Turbocharger
Clamp plate attachment bolts, turbine housing 17 Nm
Clamp plate attachment bolts, compressor
housing 17 Nm
Manifold flange/turbocharger attachment nut 50 Nm
Exhaust flange/turbocharger attachment nut 21 Nm
Stud lubricant Copaslip
ǹ 200335 8-5
TECHNICAL DATA 2
NS engine 65/75/85CF series
Cylinder head
Lock nut, valve adjusting bolt 45 Nm
0 Attachment bolt, rocker seat 45 Nm
15 9 3 8 14 20
16 10 4 2 7 13 19
17 11 5 1 6 12 18
21 22 23 24 25 26 27
M16
M16
M16
displacement
5th stage, M16 bolts 60_ angular
M10
displacement
Note: I II III IV V
Subsequently, mark the heads of the M16 bolts
with a centre punch. Bolts with two centre punch
marks must not be used again, but must be
replaced.
M2 00 166
8-6 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series NS engine
Cylinder block
Water cover attachment bolts 21 Nm
Attachment bolts, side cover 21 Nm
0
Timing gear
Pulley attachment bolts 27 Nm(1)
Vibration damper pulley retaining
bolt/attachment bolt 440 Nm(1)
Attachment bolts, timing gear cover 25 Nm(1)
Steering pump
Steering pump attachment bolts 55 Nm
Flywheel
Flywheel attachment bolts 95 Nm(1)
Flywheel housing
Attachment bolts, flywheel housing 54 Nm(1)
Sealant Loctite 510
Engine mounts
Engine bracket/flywheel housing attachment
bolts 250 Nm
Engine bracket/vibration damper attachment
bolts, timing gear end 90 Nm
Engine bracket/vibration damper attachment
bolts, flywheel housing end 170 Nm
Vibration damper/chassis attachment nuts,
timing gear end 70 Nm
Vibration damper/chassis attachment bolts,
flywheel housing side 90 Nm
ǹ 200335 8-7
TECHNICAL DATA 2
NS engine 65/75/85CF series
8-8 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series NS engine cooling system
Water pump
Radial play 0.1 mm
Temperature sensor 20 Nm
Coolant pump
Cooling water pump fixing bolts 25 Nm(1)
Thermostat housing
Thermostat housing fixing bolts 25 Nm(1)
ǹ 200335 9-1
TECHNICAL DATA 2
NS engine cooling system 65/75/85CF series
9-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series NS engine lubrication system
ǹ 200335 10-1
TECHNICAL DATA 2
NS engine lubrication system 65/75/85CF series
Heat exchanger
Heat exchanger attachment bolt 20 Nm(1)
Oil pan
Oil drain plug 50 Nm
Oil pan attachment bolts 21 Nm
10-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE Engine
11. XE ENGINE
11.1 GENERAL
0
Types XE 280 C
XE 315 C
XE 355 C
Number of cylinders 6
Bore x stroke 130 x 158 mm
Swept volume 12.58 l
Compression ratio 16.0 : 1
Firing order 1-5-3-6-2-4
Weight approx. 1080 kg
ǹ 200335 11-1
TECHNICAL DATA 2
XE Engine 65/75/85CF series
V-belt tension
Belt tension, “AVX” raw-edge(1) V-belts in Newtons (N)
0 Multiple-V-belt Single-V-belt
New V-belt(2)
Setting tension 1200 600
Test tension ≥800 ≥400
Worn V-belt(3)
Minimum tension 500 250
Adjusting tension 700 350
Cylinder liner
Height above cylinder block 0.02 - 0.10 mm
Cylinder head
Minimum height after overhaul 119.50 mm
Test pressure using air (hot) 1.5 bar
Valve clearance
Valve clearance (cold/hot)
inlet 0.50 mm
exhaust 0.50 mm
Valve opening
Valve opening at 1 mm valve clearance 0.3 - 0.7 mm
11-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE Engine
Axial play
Crankshaft axial play 0.06 - 0.32 mm
Camshaft axial play
Idler gear axial play
0.10 - 0.55 mm
0.05 - 0.25 mm
0
Gear backlash
Idler gear - crankshaft gear 0.02 - 0.21 mm
Idler gear - pump housing camshaft gear 0.02 - 0.22 mm
Idler gear - camshaft gear 0.02 - 0.21 mm
Camshaft gear - compressor gear 0.02 - 0.22 mm
Pump housing camshaft gear - steering pump
gear 0.02 - 0.19 mm
Oil pump idler gear - oil pump gear 0.02 - 0.20 mm
Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm
Fan drive
Heat gear wheel for max. 30 min. 245_C
Compression pressure
Differences in compression pressure max. 15%
ǹ 200335 11-3
TECHNICAL DATA 2
XE Engine 65/75/85CF series
Starter motor
Attachment nuts 73 Nm(1)
Alternator
Alternator bracket attachment bolts 55 Nm
Alternator attachment bolts 50 Nm
Pulley attachment nut 70 Nm
Air compressor
M12 attachment bolts 110 Nm
M8 attachment bolts for bracket 30 Nm
M10 attachment bolts for bracket 60 Nm
Compressor gear flanged nut 120 Nm
M14 cylinder head threaded coupling 40 Nm
M26 cylinder head threaded coupling 90 Nm
Delivery pipe reducer valve 75 Nm
Suction and pressure line unions 90 Nm
Air-conditioning compressor
M12 attachment bolts for compressor bracket 110 Nm
M10 attachment bolts for compressor 60 Nm(1)
Exhaust manifold
Fit gasket with steel side towards manifold
Sleeved attachment bolts 65 Nm
Heat shield attachment bolts 30 Nm(1)
11-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE Engine
Inlet manifold
Attachment bolts 60 Nm
Glow plug attachment nut
Air inlet hose clamps
55 Nm
12 Nm
0
Turbocharger
Heat shield attachment bolts 30 Nm(1)
Turbine housing clamp plate attachment nut 15 Nm
Attachment nuts
Exhaust manifold flange/turbocharger 60 Nm(2)
Elbow on turbocharger 40 Nm
Oil supply pipe banjo bolt 90 Nm
ǹ 200335 11-5
TECHNICAL DATA 2
XE Engine 65/75/85CF series
4
1
2
3
5
6
7
M200946
11-6 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE Engine
6
7
4
10
8
9 11 12 13 5 2 3 1 14
M200947
ǹ 200335 11-7
TECHNICAL DATA 2
XE Engine 65/75/85CF series
0
21 18 19 20
the cylinder head bolts should always be
replaced. The new cylinder head bolts have a 17 11 7 1 8 12
red/brown sealant on the thread. 16 13
6 2
Note:
- Because of the sealant used on the cylinder
head bolts, their untightening torque may be 15 5 3 14
very high!
10 4 9
- All M16 and M12 threaded holes must be
carefully cleaned with a screw tap before
the bolts are fitted.
M200562
- Once the bolts have been tightened to the
specified torque, the angular displacement
of the M16 bolts must immediately be 50 Nm
started.
- The sealant cannot be applied later.
Tightening cylinder head attachment bolts
Note: 150 Nm
M16
Apply a drop of oil underneath the bolt heads
(on their abutting surface). Sealant also reduces
the frictional resistance, which means that no oil
must be applied to the thread. I
1st phase
M16
Tighten M16 in the 94 Nm
order indicated 50 Nm(1)
2nd phase
II
Tighten M16 in the
M12
order indicated 150 Nm
Tighten M12 in the
order indicated 94 Nm(1) II
3rd phase 60
M16 in the order
indicated in two stages of 60_ angular
displacement
M16
III
M16
III
M200563
11-8 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE Engine
Timing gear
Camshaft locking plate attachment bolts 30 Nm(1)
Pump housing camshaft locking plate
attachment bolts 30 Nm(1)
0
Timing case attachment bolts 25 Nm
Timing cover attachment bolts:
- M10 attachment bolts 60 Nm
- M8 attachment bolts 25 Nm
Timing cover protection plate attachment bolt 15 Nm
Camshaft gear attachment bolt 425 Nm(1)
Idler gear attachment bolt 170 Nm
Pump housing camshaft gear attachment bolt 260 Nm(1)
Compressor gear attachment nut 120 Nm
Steering pump gear attachment nut 80 Nm(1)
Suction pipe banjo bolt 90 Nm
Delivery pipe banjo bolt 40 Nm
ǹ 200335 11-9
TECHNICAL DATA 2
XE Engine 65/75/85CF series
Flywheel housing
Attachment bolts 110 Nm(1)
0 Sealant to be used when fitting flywheel
housing Loctite 510
Flywheel
Attachment bolts:
- without PTO 260 Nm +90_ angular displacement
- with PTO 260 Nm +150_ angular displacement
Valve gear
Valve cover attachment bolts 25 Nm
Rocker setting bolt lock nut 40 Nm
Bridge piece setting bolt lock nut 40 Nm
Lubricating oil strip/rocker seat attachment
bolts 110 Nm
DEB set screw nut 25 Nm
Solenoid valve 20 Nm
Wiring harness attachment bolt 9 Nm
Valve sleeve attachment bolts 30 Nm
Tighten the valve sleeve bolts in the sequence
shown. 7 15 9
3 11 13 2
5 6
1 14 8
10 12 4
M200942
11-10 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE engine cooling system
Water pump
Maximum radial play 0.16 - 0.20 mm
ǹ 200335 12-1
TECHNICAL DATA 2
XE engine cooling system 65/75/85CF series
Water pump
M8 attachment bolts 30 Nm
Threaded coupling 35 Nm
Coolant pipe
Attachment bolts 54 Nm
Coolant pipe threaded coupling 90 Nm
Plug 35 Nm
Thermostat housing
Attachment bolts 30 Nm
Plug 35 Nm
Radiator
Attachment nuts 70 Nm
12-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE engine lubrication system
Oil filter
Type disposable filter
Quantity 1
Installation in the oil circuit full flow
Opening pressure of bypass valve at a
pressure difference of 2.5 0.3 bar
Oil cooler
Opening pressure of bypass valve at a
pressure difference of 2 bar
Oil section test pressure 6 bar
ǹ 200335 13-1
TECHNICAL DATA 2
XE engine lubrication system 65/75/85CF series
Fuel filter
Attachment bolts, fuel filter/water pipe
connection 40 Nm
Oil sump
Clamp attachment bolts 25 Nm
Oil drain plug 60 Nm
Oil pump
Attachment bolts for oil pump housing sections 30 Nm
Attachment bolts connecting oil pump to main
bearing cap 60 Nm(1)
Oil delivery pipe attachment bolts 30 Nm(1)
Idler gear central bolt 60 Nm(1)
Strainer
Bracket attachment bolts 30 Nm(1)
13-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE engine lubrication system
Oil cooler
Attachment bolts connecting oil cooler to
cylinder block
Coolant supply pipe union
50 Nm
90 Nm
0
Plug, adjustable banjo connection 90 Nm
Banjo bolt, adjustable banjo connection 90 Nm
Dip stick
Threaded coupling 60 Nm
ǹ 200335 13-3
TECHNICAL DATA 2
XE engine lubrication system 65/75/85CF series
Oil sprayer
Oil sprayer banjo bolt 30 Nm
0 Main bearing caps
Main bearing cap attachment bolts 150 Nm +120_ angular displacement(1)
3 2
M200661
Lubrication system
Total capacity, including oil cooler and oil filter approx. 32 litres
Oil sump capacity, maximum level approx. 25 litres
Oil sump capacity, minimum level approx. 17 litres
13-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE-engine
14. PE-ENGINE
14.1 GENERAL
0
Engine specification
Cubic capacity 9,20 l
Bore 118 mm
Stroke 140 mm
Number of cylinders 6 cylinders in line
Number of valves per cylinder 4
Emission level Euro 3
Compression ratio 16.3 : 1
Weight approx. 860 kg
ǹ 200335 14-1
TECHNICAL DATA 2
PE-engine 65/75/85CF series
V-belt tension
Belt tension, “AVX” raw-edge(1) V-belts in Newtons (N)
0 Multiple-V-belt Single-V-belt
New V-belt(2)
Setting tension 1200 600
Test tension ≥800 ≥400
Worn V-belt(3)
Minimum tension 500 250
Adjusting tension 700 350
14-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE-engine
Cylinder liner
Height above cylinder block 0.02 - 0.10 mm
Cylinder head
0
Minimum height after overhaul 119.5 mm
Valve clearance
Valve clearance (cold/hot)
inlet 0.45 mm
exhaust 0.45 mm
Valve opening
Valve opening at 1 mm valve clearance 0.45 0.2 mm
Axial play
Crankshaft axial play 0.05 - 0.35 mm
Camshaft axial play 0.10 - 0.55 mm
Idler gear axial play 0.03 - 0.25 mm
Gear backlash
Idler gear - crankshaft gear 0.02 - 0.20 mm
Idler gear - fuel-pump gear 0.02 - 0.22 mm
Idler gear - camshaft gear 0.02 - 0.22 mm
Camshaft gear - compressor gear 0.02 - 0.22 mm
Fuel pump gear - steering pump gear 0.02 - 0.19 mm
Oil pump idler gear - oil pump gear 0.02 - 0.20 mm
Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm
Compression pressure
Differences in compression pressure max. 15%
ǹ 200335 14-3
TECHNICAL DATA 2
PE-engine 65/75/85CF series
Starter motor
Attachment nuts 73 Nm(1)
Alternator
Alternator bracket attachment bolts 55 Nm
Alternator attachment bolts 50 Nm
Pulley attachment nut 70 Nm
Air compressor
Compressor gear flange bolt 120 Nm
M12 attachment bolts 110 Nm
M8 attachment bolts for bracket 30 Nm
Cylinder head threaded coupling 90 Nm
Delivery pipe reducer valve 75 Nm
Suction and pressure line unions 90 Nm
Exhaust manifold
Fit gasket with steel side towards manifold
Sleeved attachment bolts 65 Nm(1)
Heat shield attachment bolts 30 Nm
Inlet manifold
M10 attachment bolts 60 Nm
M10 attachment studs 60 Nm
Glow plug attachment nut 55 Nm
14-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE-engine
Turbocharger
Heat shield attachment bolts 30 Nm(1)
Turbine housing clamp plate attachment nut
Attachment nuts
15 Nm
0
Exhaust manifold flange/turbocharger 60 Nm(2)
Elbow on turbocharger 40 Nm
Fan
Attachment nuts 25 Nm(1)
Fan pulley attachment bolts 30 Nm(1)
ǹ 200335 14-5
TECHNICAL DATA 2
PE-engine 65/75/85CF series
Note:
- Because of the sealant used on the cylinder 13
head bolts, their untightening torque may be 10
5 3
8
very high! 9 4
- All M16 and M12 threaded holes must be
carefully cleaned with a screw tap before
the bolts are fitted.
- Once the bolts have been tightened to the M200734
specified torque, the angular displacement
of the M16 bolts must immediately be
started. 50 Nm
- The sealant cannot be applied later.
Tightening cylinder head attachment bolts
Note:
150 Nm
M16
Apply a drop of oil underneath the bolt heads
(on their abutting surface). Sealant also reduces
the frictional resistance, which means that no oil
must be applied to the thread. I
1st phase
M16
Tighten M16 in the
50 Nm(1)
94 Nm
order indicated
2nd phase II
Tighten M16 in the
order indicated 150 Nm
M12
Tighten M12 in the
order indicated 94 Nm(1)
II
3rd phase
60
M16 in the order
indicated in two stages of 60_ angular
displacement
III
M16
III
M200563
14-6 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE-engine
Timing gear
Pump housing drive unit attachment bolts 60 Nm
Pump housing drive shaft locking plate
attachment bolts 30 Nm(1)
0
Attachment bolts, locking plate 30 Nm(1)
Crankshaft hub attachment bolts in 4 phases:
1st phase, all attachment bolts 100 Nm(2)
2nd phase, all attachment bolts 100 Nm(2)
3rd phase, all attachment bolts 100 Nm(2)
4th phase, all attachment bolts 100 Nm(2)
Viscous fan clutch attachment nuts 30 Nm(1)
Timing case attachment bolts 30 Nm(1)
Timing cover attachment bolts:
- M10 attachment bolts 60 Nm
- M8 attachment bolts 25 Nm
Timing cover protection plate attachment bolt 15 Nm
Camshaft gear attachment bolt 425 Nm
Idler gear attachment bolt 170 Nm
Pump housing camshaft gear attachment bolt 260 Nm(1)
Steering pump gear attachment nut 80 Nm(1)
Suction pipe banjo bolt 90 Nm
Delivery pipe banjo bolt 40 Nm
ǹ 200335 14-7
TECHNICAL DATA 2
PE-engine 65/75/85CF series
Flywheel housing
Attachment bolts 110 Nm(1)
0 Sealant to be used when fitting flywheel
housing Loctite 510
Flywheel
Attachment bolts:
- without PTO 80 Nm(1) + 45_ angular displacement
- with PTO 80 Nm + 150_ angular displacement
Valve gear
Valve cover attachment bolts 25 Nm
M10 rocker setting bolt lock nut 40 Nm
Bridge piece setting bolt lock nut 40 Nm
Lubricating oil strip/rocker seat attachment
bolts 110 Nm
Valve sleeve attachment bolts 30 Nm
Tighten the valve sleeve bolts in the sequence 13 9
shown.
3 7 11 2 6
14
5
1 10 12 8 4
M200959
14-8 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE engine cooling system
Water pump
Radial play 0.16 - 0.20 mm
ǹ 200335 15-1
TECHNICAL DATA 2
PE engine cooling system 65/75/85CF series
Water pump
M8 attachment bolts 30 Nm
Radiator
Attachment nuts 60 Nm
15-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE engine lubrication system
Oil filter
Type disposable filter
Quantity 1
Installation in the oil circuit full flow
Opening pressure of bypass valve at a
pressure difference of 2.5 0.3 bar
Oil cooler
Opening pressure of bypass valve at a
pressure difference of 2 bar
Oil section test pressure 2.5 bar
ǹ 200335 16-1
TECHNICAL DATA 2
PE engine lubrication system 65/75/85CF series
Oil sump
Clamp attachment bolts 25 Nm
Oil drain plug 60 Nm
Oil pump
Attachment bolts for oil pump housing sections 30 Nm
Attachment bolts connecting oil pump to main
bearing cap 60 Nm(1)
Oil delivery pipe attachment bolts 30 Nm(1)
Idler gear central bolt 60 Nm(1)
Strainer
Bracket attachment bolts 30 Nm(1)
Oil cooler
Attachment bolts connecting oil cooler to
cylinder block 50 Nm
16-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE engine lubrication system
Oil nozzles
Banjo bolt (M14) for oil sprayer with locking
plate
Banjo bolt (M10) for oil sprayer
30 Nm
30 Nm
0
Main bearing caps
Main bearing cap attachment bolts 150 Nm + 120_ angular displacement(1)
3 2
M200661
Lubrication system
Total capacity, including oil cooler and oil filter approx. 26 litres
Oil sump capacity, maximum level approx. 22 litres
Oil sump capacity, minimum level approx. 14 litres
ǹ 200335 16-3
TECHNICAL DATA 2
PE engine lubrication system 65/75/85CF series
16-4 ǹ 200335
2 DIAGNOSIS
65/75/85CF series Contents
CONTENTS
Page Date
1. TRACTIVE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
1.2 Acceleration test (engine design with conventional fuel system) . . . . . . . . .
1.3 Acceleration test (engine design with UPEC fuel system) . . . . . . . . . . . . . . .
1-2 . . . . . .
1-6 . . . . . .
0011
0011 1
1.4 Acceleration test form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 . . . . . 0011
1.5 Accelerator test using DAVIE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 . . . . . 0011
2. XF/PF/NS ENGINE GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. XF/PF/NS ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
4. XF/PF/NS ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
5. XE/PE ENGINE GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Engine function fault finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.2 Vehicle function fault finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 . . . . . . 0011
6. XE/PE ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
7. XE/PE ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0011
7.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0011
ǹ 0011 1
DIAGNOSIS 2
Contents 65/75/85CF series
2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series Tractive problems
1. TRACTIVE PROBLEMS
1.1 INTRODUCTION
ǹ 0011 1-1
DIAGNOSIS 2
Tractive problems 65/75/85CF series
1
out the legal requirements must be taken into
account and maximum safety must be
exercised.
Compared with other diagnostic tools, this test is
a fast and cost-effective way of checking
whether the vehicle meets DAF’s requirements
and, therefore, whether or not the complaint is
justified.
During the acceleration test the time required to
accelerate the loaded vehicle from starting
speed to final speed is measured. (Weight of
entire combination at least 75% of the gross
combination weight, GCW).
To eliminate weather influences and road
conditions, this test must be done in both driving
directions. The average acceleration time is
obtained by averaging both measured times.
The maximum acceleration time, the speeds
between which the time is to be measured and
the gear to be engaged for the various vehicle
configurations is calculated using the DAF
“Topec” route simulation computer program.
For this purpose, “Topec” needs vehicle data
including:
- vehicle type
- height of the entire vehicle combination
- weight of entire vehicle combination (at
least 75% of the gross combination weight)
- aerodynamic influences, e.g. roof spoilers,
rear air foils, etc.
- engine type
- gearbox type and reduction ratio
1-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series Tractive problems
ǹ 0011 1-3
DIAGNOSIS 2
Tractive problems 65/75/85CF series
1-4 ǹ 0011
2 DIAGNOSIS
65/75/85CF series Tractive problems
1
clogging by large pieces of foreign matter.
- Check the fuel tank for contamination.
Clean with a steam cleaner, if necessary.
- Check the air inlet system for any leaks.
- Check the exhaust system for any leaks.
- Check the exhaust system for blockages by
measuring the exhaust back pressure.
- Check the turbocharger impellers on the
compressor and turbine side for damage
and for deposits of salt or any other
contaminants.
- Check the banjo bolt strainer in the fuel lift
pump for dirt (if present).
- Check both the valve clearance and the
DEB clearance.
- Check the injector pipes for damage.
- Check the injection pump gallery pressure.
- Check the fuel lift pump pressure.
- Check that the right type of components has
been fitted. Fuel pump, turbocharger,
injectors, etc.
- Check the discharge pressure of the
injectors.
- Clean the nozzle openings using calibrated
injector needles (DAF no. 1329371).
ǹ 0011 1-5
DIAGNOSIS 2
Tractive problems 65/75/85CF series
1
carry out the following work.
- Remove the fuel pump from the engine.
- Check the fuel pump setting on a fuel pump
test bench.
- Repeat the acceleration test.
1-6 ǹ 0011
2 DIAGNOSIS
65/75/85CF series Tractive problems
1
- weight of entire vehicle combination (at
least 75% of the gross combination weight)
- aerodynamic influences, e.g. roof spoilers,
rear air foils, etc.
- engine type
- gearbox type and reduction ratio
- rear axle type and axle reduction ratio
- tyre size
- cab type.
Before starting the acceleration test
- Check the tyre pressure of the entire vehicle
combination. Also check the tyres for a
deviating wear pattern.
- Check the complete condition of the trailer
or semi-trailer.
- Check the entire vehicle combination for
adverse aerodynamic influences, for
instance loose tarpaulins, wrongly adjusted
spoilers and rear air foils.
- Check the vehicle and trailer or semi-trailer
for excessive road drag. Be aware of
dragging brakes.
- Check the tachograph. The speed signal
must be present.
- Check that the correct k factor has been set
on the tachograph.
- Using DAVIE, check whether the 100%
pedal stop can be reached with the
accelerator pedal position sensor.
ǹ 0011 1-7
DIAGNOSIS 2
Tractive problems 65/75/85CF series
Acceleration test
1. Use the “Acceleration test form” in the
workshop manual.
2. Check the operations as set out under
“Before starting the acceleration test”.
1-8 ǹ 0011
2 DIAGNOSIS
65/75/85CF series Tractive problems
ǹ 0011 1-9
DIAGNOSIS 2
Tractive problems 65/75/85CF series
1 -
DEB clearance.
Check the injector pipes for damage.
- Check the gallery pressure.
- Check fuel lift pump output.
- Check the reducing valve.
- Check whether the right type of components
has been fitted. Turbocharger, injectors etc.
- Check the discharge pressure of the
injectors.
- Clean the nozzle openings using calibrated
injector needles (DAF no. 1329371).
Repeat the acceleration test. If necessary, plot a
boost pressure curve.
1-10 ǹ 0011
2 DIAGNOSIS
65/75/85CF series Tractive problems
General data:
Customer’s name : ............................................
Type/vehicle number plate
Type of trailer/semi-trailer
: ............................................
: ............................................
1
Owner of trailer/semi-trailer : Customer/Dealer/Third parties . . . . . . . . . . . . . . . . .
Date : ............................................
Weather conditions : ............................................
Route : ............................................
Vehicle data:
Engine type : ............................................
Gearbox type : ............................................
Rear axle type : ............................................
Vehicle combination height : ............................................
Total weight of vehicle combination : ............................................
Aerodynamic influences : ............................................
TOPEC data:
Gear to be selected : ............................................
Maximum acceleration time : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . seconds
Starting speed : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . km/h
End speed : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . km/h
Acceleration test result:
Measured acceleration time : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . seconds
End result of acceleration test : ............................................
ǹ 0011 1-11
DIAGNOSIS 2
Tractive problems 65/75/85CF series
1
system used on the vehicle (E-gas, ASL-G or
UPEC) and follow the instructions in DAVIE
precisely to carry out the test correctly.
The test results must be saved to disc after each
test.
The acceleration test in DAVIE must
only be started up when the vehicle
is stationary. As the communication
between the accelerator pedal
sensor and the unit is broken for a
short time when starting up DAVIE,
this can lead to dangerous
situations if the vehicle is moving.
1-12 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XF/PF/NS engine general
ǹ 0011 2-1
DIAGNOSIS 2
XF/PF/NS engine general 65/75/85CF series
1
Incorrect or contaminated injectors installed Check whether correct injectors have been
installed. Clean contaminated injectors and set
them
Incorrect injection timing, or incorrect fuel pump Check the injection timing and/or fuel pump
setting setting
Fuel tank vent opening is blocked Check/clean the vent opening
Air cleaner element blocked Clean or replace the air cleaner element
Blocked air inlet from turbocharger to the inlet Check air inlet Clean if necessary
manifold
Air leak in the pressure part of the inlet system Check the inlet unit for any leaks
Compressor side of turbocharger contaminated Clean compressor side with a non-corrosive
cleaning agent or a soft brush. Check the inlet
side for carbon deposits or other contamination
Exhaust manifold, exhaust silencer, exhaust pipe Check the exhaust unit. Clean if necessary
blocked
Gas leak between the exhaust manifold and the Check the attachment bolts and gaskets
cylinder head
Gas leak between the exhaust manifold and the Check the attachment bolts and gaskets
turbocharger
Incorrect wastegate setting or defective Check the wastegate or wastegate setting
wastegate
Damaged turbocharger Replace the turbocharger and identify the cause
Incorrect valve clearance setting Check valve clearance. Adjust if necessary
Incorrect DEB setting Check the DEB play Adjust if necessary
DEB continues to operate Check the DEB operation
Compression pressure too low Check the compression pressure
2-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XF/PF/NS engine general
ǹ 0011 2-3
DIAGNOSIS 2
XF/PF/NS engine general 65/75/85CF series
1
Excess clearance between piston and cylinder Check the piston clearance in the cylinder
wall
Main shaft and/or connecting rod bearings worn Check main shaft and connecting rod bearings
out
Fuel system failure Check the fuel system
Inlet system failure Check the inlet system
Exhaust system failure Check the exhaust system
Air compressor, fan drive, air-conditioning Check whether the air compressor, fan drive,
compressor air-conditioning compressor or other engine
attachments may be the cause of the strange
noise
Lubrication system failure Check the lubrication system
Incorrect V-belt tension or alignment of V-belts Check the V-belt tension or the alignment of the
V-belt
Excessive radial play of water pump Check the radial play of the water pump
Fan damaged or fan touching the radiator Check the fan and radiator
Damaged or loose engine brackets Check the engine brackets
Excessive valve clearance Readjust the valve clearance
Damaged valve train and/or push rods, cam Check the valve train, etc. for damage
followers, rocker shafts or rocker arms
Damaged vibration damper Check the vibration damper for damage
Damaged pistons and/or cylinder liners Check the pistons and the cylinder liners
Timing gears Check the timing gear wheels for play and/or
damage
Loose or broken flywheel or coupling bolts Check the flywheel and the clutch
2-4 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XF/PF/NS engine cooling system
ǹ 0011 3-1
DIAGNOSIS 2
XF/PF/NS engine cooling system 65/75/85CF series
1
Coolant pipes defective Check coolant pipes
Leaking radiator Check the radiator. Pressure test if necessary
Leaking water pump Check the water pump. If necessary, measure
the bearing play
Defective oil cooler Check the oil cooler. Pressure test if necessary
Defective pressure cap Check the pressure cap. Pressure test if
necessary
Leaking heater Check heater pipes
Leaking connection between coupling and water Check connection between the water pipe and
pipe the coupling for damage.
Replace O-rings
3-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XF/PF/NS engine lubrication system
ǹ 0011 4-1
DIAGNOSIS 2
XF/PF/NS engine lubrication system 65/75/85CF series
1
Exhaust system failure Check the exhaust system
Oil cooler leaks Check whether there is lubricating oil in the
engine cooling system
Oil temperature is too high Check whether the correct oil cooler has been
installed
Excessive blow-by Check the compression pressure and carry out a
cylinder leak test.
Check the condition of the piston rings and
cylinder liners
Worn piston rings and/or cylinder liners Replace piston rings and/or cylinder liners.
Check the air inlet system.
Check the oil specifications
Injector O-ring damaged or not present Check the injector seal
4-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine general
ǹ 0011 5-1
DIAGNOSIS 2
XE/PE engine general 65/75/85CF series
5-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine general
ǹ 0011 5-3
DIAGNOSIS 2
XE/PE engine general 65/75/85CF series
5-4 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine general
ǹ 0011 5-5
DIAGNOSIS 2
XE/PE engine general 65/75/85CF series
1
Air filter partially blocked Replace or clean air filter
Electropneumatic boost pressure valve defective Check electropneumatic boost pressure valve
Fault in electrical components/wiring of the Check the electrical system
electro-pneumatic boost pressure valve
Air leak in air inlet system Pressure test air inlet system
Pressure relief valve does not close Check the pressure relief valve
Too low fuel lift pump supply Check the fuel lift pump and replace if necessary
5-6 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine general
ǹ 0011 5-7
DIAGNOSIS 2
XE/PE engine general 65/75/85CF series
5-8 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine general
ǹ 0011 5-9
DIAGNOSIS 2
XE/PE engine general 65/75/85CF series
5-10 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine cooling system
ǹ 0011 6-1
DIAGNOSIS 2
XE/PE engine cooling system 65/75/85CF series
6-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine lubrication system
ǹ 0011 7-1
DIAGNOSIS 2
XE/PE engine lubrication system 65/75/85CF series
7-2 ǹ 0011
2 XF ENGINE
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.3 Overview drawing, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
2
2.4 Overview drawing, timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0011
2.5 Overview drawing, fuel pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Inspection and adjustment, valve mechanism bridges . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.2 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0011
3.3 Inspection and adjustment, timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . . 0011
3.4 Inspection and adjustment, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . . 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0011
3.6 Inspection, engine compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . . 0011
3.7 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . . 0011
3.8 Inspection, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . . 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.1 Removal and installation, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.2 Removal and installation, engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 0011
4.3 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 0011
4.4 Removal and installation, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . . 0011
4.5 Removal and installation, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 0011
4.6 Removal and installation, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0011
4.7 Removal and installation, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 . . . . . 0011
4.8 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 . . . . . 0011
4.9 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 . . . . . 0011
4.10 Removal and installation, steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0011
4.11 Removal and installation, starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . . 0011
4.12 Removal and installation, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . . . 0011
4.13 Removal and installation, V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 . . . . . 0011
4.14 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 . . . . . 0011
4.15 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 . . . . . 0011
4.16 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . . . . 4-25 . . . . . 0011
4.17 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 . . . . . 0011
4.18 Removal and installation, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 . . . . . 0011
4.19 Removal and installation, up-speed bearing block . . . . . . . . . . . . . . . . . . . . . 4-30 . . . . . 0011
4.20 Removal and installation, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 . . . . . 0011
4.21 Removal and installation, vibration damper hub . . . . . . . . . . . . . . . . . . . . . . . 4-33 . . . . . 0011
4.22 Removal and installation, timing cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 . . . . . 0011
4.23 Removal and installation, timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 . . . . . 0011
4.24 Removal and installation, timing gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 . . . . . 0011
4.25 Removal and installation, timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 . . . . . 0011
4.26 Removal and installation, timing gear case seal . . . . . . . . . . . . . . . . . . . . . . . 4-42 . . . . . 0011
4.27 Removal and installation, fuel pump drive housing . . . . . . . . . . . . . . . . . . . . . 4-43 . . . . . 0011
ǹ 0011 1
XF ENGINE 2
Contents 65/75/85CF series
Page Date
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Disassembly and assembly, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.2 Disassembly and assembly, up-speed bearing block . . . . . . . . . . . . . . . . . . . 5-9 . . . . . . 0011
5.3 Disassembly and assembly, V-belt tensioning gear . . . . . . . . . . . . . . . . . . . . 5-11 . . . . . 0011
6. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Cleaning the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
2 ǹ 0011
2 XF ENGINE
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
2
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
ǹ 0011 1-1
XF ENGINE 2
Safety precautions 65/75/85CF series
1-2 ǹ 0011
2 XF ENGINE
65/75/85CF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
3 1
9
2
2
8
4
10
24
25
5
7 6
M200767
Legend
1. Thermostat housing
2. Water pump
3. Air-conditioning compressor
4. Fan drive
5. Vibration damper
6. Air compressor
7. Oil cooler
8. Turbocharger
9. Wastegate diaphragm
10. Oil-filler pipe
24. Up-speed bearing block
25. Fan drive tensioner
ǹ 0011 2-1
XF ENGINE 2
General 65/75/85CF series
21 20 19 18 17
22
2
23
11
12
13 14 15 16
M200768
Legend
11. Steering pump
12. Fuel pump drive housing
13. Fuel pump
14. Oil filter
15. Engine brake valve
16. Starter motor
17. Engine identification plate
18. Fuel filter
19. Coolant filter
20. Coolant pipe
21. Inlet manifold
22. Relay, glow-filament
23. Alternator
2-2 ǹ 0011
2 XF ENGINE
65/75/85CF series General
2.2 IDENTIFICATION
Engine number
The engine number is marked on engine block
at the rear left.
2
D000311
2 1 8 7
M200678
ǹ 0011 2-3
XF ENGINE 2
General 65/75/85CF series
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
Legend
1. Fan drive shaft 7. Bearing ring
2. Oil seal 8. O-ring
3. Bearing 9. Bearing
4. Bearing ring 10. Circlip
5. Spacer sleeve 11. Bearing housing
6. Intermediate ring 12. Gear wheel
13. Circlip
2-4 ǹ 0011
2 XF ENGINE
65/75/85CF series General
2 4 5 10
2
7
1
6
3
8 M200549
9
Legend
1. Crankshaft
2. Camshaft
3. Intermediate gear wheel
4. Fan drive
5. Steering pump
6. Fuel pump drive gear wheel
7. Air compressor
8. Oil pump intermediate gear wheel
9. Oil pump
10. Silencer
ǹ 0011 2-5
XF ENGINE 2
General 65/75/85CF series
2 3 4 5 6
2 1
7 8
M200582
Legend
1. Silencer
2. Fuel pump drive gear wheel
3. Timing gear case sealing ring
4. Bearing housing
5. Fuel pump drive seal
6. Clamping piece
7. Axial locking plate
8. Prop shaft
2-6 ǹ 0011
2 XF ENGINE
65/75/85CF series Inspection and adjustment
2
1. Remove the valve covers. See “Removal
and installation”.
2. Place the fuel pump in the stop position.
Lock the fuel pump in this position.
3. Remove the DEB or the lubricating oil strip
(depending on model).
4. Remove the rocker seat assembly. Mark the
position to allow reinstallation in the same
position.
Note:
In engines with a DEB, the bridges of the
inlet and exhaust valves are not the same.
In engines without a DEB, the bridges of the
inlet and exhaust valves are the same.
Exhaust bridge with DEB
i 400162
ǹ 0011 3-1
XF ENGINE 2
Inspection and adjustment 65/75/85CF series
2
i 400161
3-2 ǹ 0011
2 XF ENGINE
65/75/85CF series Inspection and adjustment
M200574
ǹ 0011 3-3
XF ENGINE 2
Inspection and adjustment 65/75/85CF series
M200539
3-4 ǹ 0011
2 XF ENGINE
65/75/85CF series Inspection and adjustment
Inspection, timing
1. Remove the valve cover from
cylinders 1-2-3. See “Removal and
installation”.
2. Position cylinder 1 at top dead centre
(TDC on the flywheel, cylinder 6 in overlap
position).
Note: 2
It is important that the bridges of the valve
mechanism are properly adjusted.
3. Set the inlet valve play of the first cylinder to
1 mm.
4. Position the measuring gauge on the inlet
valve bridge of the first cylinder, in such a
way that it measures in an exact vertical
position on the bridge and is capable of
registering an upward and downward
measurement of 5 mm.
5. Use the special tool (DAF no. 1310477) to
turn the crankshaft further in the direction of
rotation until the pistons of cylinders 1 and 6
have returned to the top dead centre (TDC).
M200574
Example
Pre-tension, dial gauge 5,00 mm
Pre-tension, dial gauge 4,65 mm
Valve opening 0,35 mm
Note:
If the valve opening matches that in the
technical data, it may be assumed that the
timing gear is properly set.
M200551
ǹ 0011 3-5
XF ENGINE 2
Inspection and adjustment 65/75/85CF series
2
“Removal and installation”.
M200574
Note:
When the crankshaft (1) or the camshaft (2)
of an engine without intermediate gear
wheel (3) is rotated separately, the engine’s
pistons may touch the valves.
4. Remove the intermediate gear wheel (3).
See “Removal and installation”.
5. Rotate the camshaft gear wheel (2) to such
a position that the intermediate gear wheel
(3) can be installed in accordance with the
marks.
6. Fit the intermediate gear wheel and tighten
to the specified torque. See “Technical
data”.
7. Fit the timing cover. See “Removal and
installation”. 2 3
8. Fit the valve cover. See “Removal and 1
installation”.
M200602
3-6 ǹ 0011
2 XF ENGINE
65/75/85CF series Inspection and adjustment
150
200
300
150
0
2
“Krikit II” belt tension gauge for use with the
twin-belt version (DAF no. 1240443).
The difference between the “Krikit I” and
“Krikit II” belt tension gauges is that the latter M2079
has a larger belt bearing surface.
Measuring with the “KRIKIT” belt tension
gauge
1. Set the gauge to zero by depressing the
measuring arm (1). 1
M2061
M2091
ǹ 0011 3-7
XF ENGINE 2
Inspection and adjustment 65/75/85CF series
2 M2062
M200550
3-8 ǹ 0011
2 XF ENGINE
65/75/85CF series Inspection and adjustment
2
1
M200550
7 6
D000388
ǹ 0011 3-9
XF ENGINE 2
Inspection and adjustment 65/75/85CF series
M200230
3-10 ǹ 0011
2 XF ENGINE
65/75/85CF series Inspection and adjustment
ǹ 0011 3-11
XF ENGINE 2
Inspection and adjustment 65/75/85CF series
Note: C
To avoid engine damage it is important that the
glow plugs should be checked periodically.
1. Check the glow plugs for the following
points:
- windings that have worn thin due to A B
abrasion (A)
- filament end broken or worn thin due to
continuous knocking of a loose
insulator (see C)
- broken plug windings (C).
2. Replace all glow plugs if one or more of the
above-mentioned situations occurs.
M200818
3-12 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
Note:
Because of the large number of vehicle
specifications, it is not feasible to exactly specify
the engine removal and installation procedures
for every vehicle.
This description only includes the most
important points requiring attention.
- Disconnect the earth lead from the battery
terminal.
- Avoid opening fluid systems as much as
possible. If possible, remove and set aside
the engine components.
- When removing the engine, ensure that no
parts or dirt fall into the engine, radiator or
other components. Therefore, plug all
openings.
- Electrical wiring harnesses are easily
damaged. If damaged, they may cause
faults. Make sure these wiring harnesses
are stress-free and clear of moving parts.
- Tighten all attachment bolts to the correct
tightening torque.
- Do not allow the engine to rest on the oil
sump. Because the oil sump is made of
sheet material, it will be severely damaged
by the engine’s own weight.
ǹ 0011 4-1
XF ENGINE 2
Removal and installation 65/75/85CF series
2
safety and consider the danger of
fire.
4-2 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
2
and the engine.
4. Fit the flexible air pipes (C) between the
engine and the intercooler.
5. Fit the coolant pipes (A) between the
engine, radiator and header tanks.
6. If present, fit the air-conditioning
compressor.
7. Fit the earth strip from the chassis to the
flywheel housing.
8. Reconnect the earth lead to the battery.
9. Fill the cooling system.
B C D
M201019
ǹ 0011 4-3
XF ENGINE 2
Removal and installation 65/75/85CF series
4-4 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-5
XF ENGINE 2
Removal and installation 65/75/85CF series
2
6. Adjust the valve play and the DEB play if a
DEB is fitted. See “Inspection and
adjustment”.
7. Fit the valve covers.
M200548
4-6 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-7
XF ENGINE 2
Removal and installation 65/75/85CF series
M2 00 100
4-8 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
2
be retightened.
4. Place the cylinder head(s) on the cylinder
block and hand-tighten a number of cylinder
head bolts.
Note:
To prevent the inlet and exhaust manifolds
from being installed with tension the inlet
and exhaust manifolds must be installed
before the cylinder head bolts are tightened.
5. Fit the inlet and exhaust manifolds with new
M200561
gaskets and tighten the attachment bolts to
the specified torque. See “Technical data”.
Note:
The M16 cylinder head bolts may be used a
maximum of three times. After tightening
the bolts, mark the bolt heads with a centre
punch, to indicate how often they have been
used.
New bolts should not be marked on the first
fitting.
Bolts marked with 2 centre points must not
be reused and must be replaced by new
ones.
When fitting used bolts, clean the thread
and inspect for damage.
ǹ 0011 4-9
XF ENGINE 2
Removal and installation 65/75/85CF series
2
specified torque and in the sequence
shown. See “Technical data”.
9. Fit the valve sleeve and tighten the
attachment bolts to the specified torque.
See “Technical data”.
10. Fit the push rods.
11. Fit the injectors.
12. Fit the valve gear.
13. Fit the coolant pipe and the thermostat
housing with new gaskets.
14. Fit the water pipe between the radiator and
the thermostat housing.
15. Fit the injector pipes.
16. Fit the thermostat housing onto the coolant
pipe.
17. Fit the fuel leak-off pipe between the fuel
filter and the inlet manifold.
18. Fit the coolant filter on the coolant pipe, if
present.
19. If present, fit the flexible pipes from the cab
heater.
20. Fit the attachment bolts of the exhaust
manifold and tighten them to the specified
torque. See “Technical data”.
4-10 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-11
XF ENGINE 2
Removal and installation 65/75/85CF series
Note:
If the vehicle has been fitted with two glow
filaments upon ex-works delivery, you must not
add two glow filaments yourself. The feeder
cable between the starter motor, glow relay and
glow plugs on these vehicles is inadequate for
four glow plugs.
4-12 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-13
XF ENGINE 2
Removal and installation 65/75/85CF series
2
manifold.
4. Fit the air inlet pipe between the intercooler
and the inlet manifold. Tighten the
attachment bolt to the specified torque. See
“Technical data”.
5. Fit the boost pressure pipe.
6. Fit the injector pipes.
7. Fit the fuel filter element.
8. If present, fit the coolant filter element.
9. Fit the electric wiring of the glow filaments
and the temperature sensor.
10. Reconnect the earth lead to the battery
terminal.
4-14 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-15
XF ENGINE 2
Removal and installation 65/75/85CF series
2
3. Fit the turbocharger’s oil discharge pipe.
4. Spray clean engine oil into the oil supply of
the turbocharger and fit the oil supply pipe.
5. Fit the compressor pipe (5).
6. Connect the inlet air pipe (4) between the
turbocharger and the intercooler.
7. Fit the butterfly valve (3).
8. Fit the heat shields (1) of the turbochargers
and tighten them to the specified torque.
See “Technical data”.
9. Connect the air inlet pipe (2). Tighten the
attachment bolts to the specified torque.
See “Technical data”.
10. Start the engine and check all connections
for leaks.
4-16 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-17
XF ENGINE 2
Removal and installation 65/75/85CF series
4-18 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
4.
motor.
Check the toothed pinion for damage.
2
Installation, starter motor
1. Clean the contact surfaces of the starter
motor and the flywheel housing.
2. Fit the starter motor in the flywheel housing
and tighten the attachment nuts to the
specified torque. See “Technical data”.
3. Fit the electrical connections of the starter
motor.
4. Reconnect both leads to the battery
terminals.
M200568
ǹ 0011 4-19
XF ENGINE 2
Removal and installation 65/75/85CF series
Removal, alternator
1. Remove both battery leads from the battery
terminals. 5 4
2. Remove the electrical connections from the
2
alternator. 3
3. Slacken the attachment bolt (3) from the
2 threaded spindle which is attached to the
coolant pump.
4. Slacken the locknut (5).
5. Remove the upper attachment bolts (2) of
the alternator.
6. Remove the lower attachment bolt (1) of the
1
alternator.
7. Remove the alternator. M200937
Installation, alternator
1. Fit the alternator on its bracket.
2. Fit the lower attachment bolt (1) of the
alternator.
3. Fit the upper attachment bolts (2) of the
alternator.
4. Install the V-belts and check the V-belt
tension. See “Inspection and adjustment”.
5. Fit the electrical connections of the
alternator.
6. Reconnect both leads to the battery
terminals.
4-20 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
M200558
ǹ 0011 4-21
XF ENGINE 2
Removal and installation 65/75/85CF series
2
cooling-water pump.
3
4. Turn the locknuts (3) on the threaded
spindle so that the alternator can be tilted
towards the engine block and the V-belt can
be removed.
2 M2041
4-22 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
Removal, flywheel
1. Remove the gearbox.
2. Remove the clutch release assembly and
the clutch plate.
3. Remove the attachment bolts (1) from the
flywheel.
2
1
M200569
ǹ 0011 4-23
XF ENGINE 2
Removal and installation 65/75/85CF series
M2 00 035
4-24 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-25
XF ENGINE 2
Removal and installation 65/75/85CF series
2 4.
5.
Properly suspend the engine in the hoist.
Remove the two oil sump attachment bolts
on the flywheel housing.
6. Slacken the other oil sump attachment bolts
until the oil sump is free from the flywheel
housing.
7. Remove the central engine mount
attachment bolts at the back of the engine.
8. Remove the attachment bolts from the
flywheel housing.
9. Remove the flywheel housing.
Installation, flywheel housing
1. Remove the oil seal from the flywheel
housing, by carefully tapping or forcing it
from the housing.
2. Remove any traces of old gaskets from the
contact areas.
3. Inspect the sealing faces for damage.
4. Inspect the flywheel housing for cracks.
5. Apply a locking compound to the sealing
face of the cylinder block. See “Technical
data”. Apply the locking compound with a
roller or brush, across the entire sealing
face.
6. Fit the flywheel housing and tighten the
attachment bolts to the specified torque.
See “Technical data”.
4-26 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-27
XF ENGINE 2
Removal and installation 65/75/85CF series
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
4-28 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-29
XF ENGINE 2
Removal and installation 65/75/85CF series
9 11 12 13 5 2 3 1 14
M200947
4-30 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
3.
alternator drive.
Remove the attachment bolts (7) of the fan 4
2
flange/vibration damper. 1
4. Remove the vibration damper (4). 2
3
Installation, vibration damper
1. Check the vibration damper for external 5
damage and silicone liquid leaks. In the 6
event of damage or leaks, the vibration 7
damper should be replaced.
2. Fit the vibration damper (4) and the fan
flange (5). Tighten the attachment bolts (7)
to the specified torque. See “Technical
data”.
3. Fit the new V-belt and adjust the V-belt M200946
tension. See “Inspection and adjustment”.
4. Fit the viscous fan clutch and fan.
ǹ 0011 4-31
XF ENGINE 2
Removal and installation 65/75/85CF series
9 11 12 13 5 2 3 1 14
M200947
4-32 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
M200770
ǹ 0011 4-33
XF ENGINE 2
Removal and installation 65/75/85CF series
M200771
4-34 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-35
XF ENGINE 2
Removal and installation 65/75/85CF series
M200574
4-36 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
M200578
5 M200577
ǹ 0011 4-37
XF ENGINE 2
Removal and installation 65/75/85CF series
M200574
2 3
1
M200602
4-38 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
5 M200577
ǹ 0011 4-39
XF ENGINE 2
Removal and installation 65/75/85CF series
4-40 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
2
See “Technical data”.
9. Fit the timing gear wheels.
10. Fit the air compressor.
11. Fit the steering pump.
ǹ 0011 4-41
XF ENGINE 2
Removal and installation 65/75/85CF series
2 3 4 5 6
1
2
7 8
M200582
M200580
4-42 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
2 3 4 5 6
1
2
7 8
M200582
ǹ 0011 4-43
XF ENGINE 2
Removal and installation 65/75/85CF series
2
i 400171
87
M200581
M200580
4-44 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
2
attachment bolts to the specified torque.
See “Technical data”.
4. Fit a dry new timing gear case sealing ring
using special tool (DAF no. 1329318).
5. Fit the fuel pump gear wheel.
6. Set the injection timing.
87
M200581
ǹ 0011 4-45
XF ENGINE 2
Removal and installation 65/75/85CF series
4-46 ǹ 0011
2 XF ENGINE
65/75/85CF series Disassembly and assembly
ǹ 0011 5-1
XF ENGINE 2
Disassembly and assembly 65/75/85CF series
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
Note:
A mark may have been made on the rear
side of the shaft (1) during initial assembly.
This mark may be used to check whether
the gear wheel (12) has turned in relation to
the shaft (1). If this is the case, the shaft (1)
and/or the gear wheel (12) is/are rejected.
M200688
5-2 ǹ 0011
2 XF ENGINE
65/75/85CF series Disassembly and assembly
2
sleeve (5).
5. Remove the bearing (3) from the shaft (1).
M200932
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
3 5 6 9
M200679
ǹ 0011 5-3
XF ENGINE 2
Disassembly and assembly 65/75/85CF series
M200680
Note:
The holes in the intermediate ring should be
on the oil seal side.
2. Fit the intermediate ring (6) in the bearing
housing (11).
11
3. Use the special tool (DAF no. 1329383) to
press the bearing ring (7) into the bearing
housing (11) until it abuts the intermediate 7
ring (6).
6
M200681
5-4 ǹ 0011
2 XF ENGINE
65/75/85CF series Disassembly and assembly
2
6
11
M200682
11
M200683
ǹ 0011 5-5
XF ENGINE 2
Disassembly and assembly 65/75/85CF series
11
M200684
Note:
When forcing on the bearing (9), rotate the
bearing housing (11) at least 5 times, so
that the bearings can settle.
8. Using a low pressing force and the
special tool (DAF no. 1329382) press the
bearing (9) onto the shaft (1) until it abuts.
11
9
M200685
5-6 ǹ 0011
2 XF ENGINE
65/75/85CF series Disassembly and assembly
10
8
M200686
M200687
ǹ 0011 5-7
XF ENGINE 2
Disassembly and assembly 65/75/85CF series
M200688
Inspection:
Fit special tool (DAF no. 1329445) under
the gear wheel (12) and press on the shaft
with a force of 100 kN. When the shaft has
been pressed out, the shaft and gear wheel
will be rejected.
15. Apply a little engine oil in the bearing
housing (11) and inspect the shaft (1) for
even rotation.
M200932
5-8 ǹ 0011
2 XF ENGINE
65/75/85CF series Disassembly and assembly
1 2 3 5 7 4 6
M200803
ǹ 0011 5-9
XF ENGINE 2
Disassembly and assembly 65/75/85CF series
A 3 7 5 3 B
M200804
5-10 ǹ 0011
2 XF ENGINE
65/75/85CF series Disassembly and assembly
ǹ 0011 5-11
XF ENGINE 2
Disassembly and assembly 65/75/85CF series
5-12 ǹ 0011
2 XF ENGINE
65/75/85CF series Cleaning
6. CLEANING
6.1 CLEANING THE ENGINE
Note:
It is advisable to clean the engine with a
high-pressure cleaner before starting
maintenance or service operations. A clean
engine makes the mechanic’s work easier, and
enables him to notice any defects at an early
stage. 2
Before cleaning the engine, check for any leaks.
If the engine is cleaned with a high-pressure
cleaner, it must be used with care. It is also
important to observe the following points:
- When cleaning the universal joint on the
steering box, the spider seals may be
forced open by the high-pressure jet of
water, so that the grease behind them is
flushed away. As a result, the spider may
get stuck, so that the steering mechanism
will jam.
- A bleed screw is fitted to the power steering
fluid reservoir of the steering system. Water
may enter the tank through this valve,
causing damage to the steering gear.
- When cleaning the radiator/intercooler
element, be careful not to damage the fins.
- Do not direct the high-pressure cleaner jet
too long at the air-conditioning system
condenser. As a result of the high
temperature, the pressure in the system will
become excessive, which may cause
damage to the system.
ǹ 0011 6-1
XF ENGINE 2
Cleaning 65/75/85CF series
6-2 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.2 Cooling system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0011
3. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Description of cooling system pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Description of the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0011
3.3 Description, coolant filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
4. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Pressure-testing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
......
......
0011
0011
3
4.2 Inspection, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
4.3 Inspection, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.4 Inspection, water pump radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0011
5. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.1 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.2 Removal and installation, coolant filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 ...... 0011
5.3 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ...... 0011
5.4 Removal and installation, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ...... 0011
5.5 Removal and installation, header tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 ...... 0011
5.6 Removal and installation, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ...... 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling/bleeding, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
ǹ 0011 1
XF ENGINE COOLING SYSTEM 2
Contents 65/75/85CF series
2 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
3
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
ǹ 0011 1-1
XF ENGINE COOLING SYSTEM 2
Safety precautions 65/75/85CF series
1-2 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
1 9 10
3
8 3
7
6 5 4
M200764
M200765
Legend
1. Thermostat housing
2. Water pump
3. Fan drive
4. Water-cooled air compressor
5. Water pipe
6. Oil cooler
7. Up-speed bearing block
8. Fan drive tensioner
9. Coolant pipe
10. Coolant filter
ǹ 0011 2-1
XF ENGINE COOLING SYSTEM 2
General 65/75/85CF series
2-2 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series General
a
b
a
b
3
M200583
ǹ 0011 2-3
XF ENGINE COOLING SYSTEM 2
General 65/75/85CF series
3
From the cylinder block, some of the coolant
flows through the air compressor. From the air
compressor, the coolant is returned via a pipe to
the water pump.
The pipe which takes the coolant to the heater
for the cab heating is connected to the
thermostat housing. From the heater, the
coolant is returned via a pipe to the water pump.
2-4 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series General
a
b
a
b
3
M200584
ǹ 0011 2-5
XF ENGINE COOLING SYSTEM 2
General 65/75/85CF series
2-6 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Component description
3. COMPONENT DESCRIPTION
3.1 DESCRIPTION OF COOLING SYSTEM PRESSURE CAP
ǹ 0011 3-1
XF ENGINE COOLING SYSTEM 2
Component description 65/75/85CF series
A M200547
3-2 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Component description
3
M200546
ǹ 0011 3-3
XF ENGINE COOLING SYSTEM 2
Component description 65/75/85CF series
3-4 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
ǹ 0011 4-1
XF ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
M200594
M200513
4-2 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
ǹ 0011 4-3
XF ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
900
6. Allow the fan drive flange to run at a speed
of 1000 rpm.
Then use an optical rev counter to
determine the difference in speed of the fan 100
in relation to the drive flange. The speeds
3 will differ if there is any slip in the viscous
clutch. When the clutch is fully engaged, the
430
slip must not be more than 10%. If it is more
than 10%, the viscous fan clutch must be
replaced.
700
M200440
4-4 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
3
5. Compare the pressure reading with the
technical data. See “Technical data”. If the
level shown is greater than that in the
technical data, the water pump must be
replaced.
M200595
ǹ 0011 4-5
XF ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
4-6 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-1
XF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-2 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-3
XF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Removal, thermostat
1. Drain the coolant. See “Draining and filling”.
2. Remove the water pipe between the
thermostat housing and the radiator.
3. Remove the attachment bolts from the
thermostat housing.
4. Remove the thermostat housing and the
connecting piece from the water pump. A
C B
3
5. Remove the O-ring (A) from the thermostat
housing.
6. Remove the thermostat. C B
Removal, thermostat sealing ring
A
1. Remove the oil seal (B) in the thermostat
housing using a commercially available
internal puller.
Removal, thermostat seat
1. Remove the thermostat seat (C) at the
bottom of the thermostat housing using a
commercially available internal puller.
M200594
5-4 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-5
XF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
3 5.
ring.
Remove the attachment nuts from the
viscous fan clutch on the drive flange. Place
the viscous fan clutch with the fan in the
wind tunnel temporarily.
Note:
The fan clutch must always be stored
vertically.
6. Remove the attachment nuts of the fan and
remove the viscous fan clutch.
Installation, viscous fan clutch
1. Place the new viscous fan clutch in the fan.
Tighten the attachment nuts to the specified
torque. See “Technical data”.
2. Fit the guide ring and the attachment bolts
of the guide ring brackets.
3. Fit the viscous fan clutch and fan to the
drive flange. Tighten the attachment nuts to
the specified torque. See “Technical data”.
4. Fit the air inlet pipe and tighten the
attachment bolt to the specified torque.
See “Technical data”.
5. Fit the V-belt of the alternator and water
pump drives.
6. Fit the front engine encapsulation.
5-6 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
3
5. Lift the front of the header tank a little.
6. Loosen the retainer clips at the back of the
header tank.
7. Remove the header tank.
Installation, header tank
1. Fit the header tank, pushing it into the
retainer clips at the back first.
2. Fit all water pipes between the header tank
and the engine.
3. Fit the front engine encapsulation.
4. Fill the cooling system. See “Draining and
filling”.
5. Run the engine and check that all
connections are sealed properly.
ǹ 0011 5-7
XF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Note:
The removal and installation procedure for the
radiator allows for the presence of an
air-conditioning unit. If such a unit is not present,
the sections concerned can be skipped.
Removal, radiator
1. Disconnect the earth lead from the battery
terminal.
2. Drain the coolant. See “Draining and filling”.
3 3.
4.
Remove the front engine encapsulation.
Remove the engine encapsulation under
the cab.
5. Remove the bolts from the guide ring
brackets, and remove the guide ring.
6. Remove the guide strip at the front of the
intercooler.
7. Remove the dip stick holder of the
intercooler and put it aside.
8. Remove the header tank.
9. Remove the water pipes to the radiator.
10. Remove the attachment bolts from the
air-conditioning condenser and pull the
condenser forwards.
11. Disconnect the other air-conditioning pipes
from the intercooler.
12. Remove the wire mesh underneath the
intercooler.
13. Remove the air-conditioning dryer
underneath the intercooler.
14. Remove the left-hand connector pipe from
the inlet manifold to the intercooler.
5-8 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-9
XF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
3 intercooler.
14. Fit the expansion reservoir.
15. Fit the engine encapsulation under the cab.
16. Fit the front engine encapsulation.
17. Fit the earth lead to the battery terminal.
18. Fill the cooling system. See “Draining and
filling”.
19. Run the engine and check that all
connections are sealed properly.
5-10 ǹ 0011
2 XF ENGINE COOLING SYSTEM
65/75/85CF series Draining and filling
M200372
ǹ 0011 6-1
XF ENGINE COOLING SYSTEM 2
Draining and filling 65/75/85CF series
6-2 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Lubricating oil system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Inspection, lubricating oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Inspection, lubricating oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.3 Pressure-testing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.1 Removal and installation, lubricating oil filter housing . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.2 Removal and installation, oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
4.3 Removal and installation, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.4 Removal and installation, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0011
4.5 Removal and installation, centrifugal oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0011
4
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Disassembly and assembly, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling, engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
ǹ 0011 1
XF ENGINE LUBRICATION SYSTEM 2
Contents 65/75/85CF series
2 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result 4
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
ǹ 0011 1-1
XF ENGINE LUBRICATION SYSTEM 2
Safety precautions 65/75/85CF series
1-2 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series General
2. GENERAL
2.1 LUBRICATING OIL SYSTEM DESCRIPTION
M200544
ǹ 0011 2-1
XF ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
General
The lubricating oil pump is directly driven from
the crankshaft, by a gear. The lubricating oil
pump draws the oil from the oil sump, and
pumps it via the oil cooler and the lubricating-oil
filter to the main oil duct in the cylinder block.
From the main oil duct, the lubricating-oil is
further distributed to the various components
requiring lubrication.
Oil cooler
The oil cooler is connected to the cooling
system. The oil cooler warms up the lubricating
oil in a “cold” engine and cools it in a “warm”
engine.
Parallel to the oil cooler, a short-circuit valve has
been installed. If the oil cooler is blocked, the
short-circuit valve will open if a certain pressure
2-2 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series General
Cylinder head
From the second and fifth camshaft bearings, an
oil duct passes through the cylinder heads to the
second and fifth rocker seats.
Depending on the model, the other rocker
shafts, rockers, and bridges receive lubrication
from the DEB or a lubricating-oil strip.
Timing gear
From the oil duct in the first crankshaft main
bearing, an oil duct leads to the hollow hub of
the intermediate gear wheel.
The oil passes through the hollow hub onto the
intermediate gear wheel. The other gear wheels
receive lubricating oil from the intermediate gear
wheel.
The fan drive is lubricated through a bore hole in
the cylinder block and an oil duct in the timing
gear case.
Piston and gudgeon pin
4
The pistons and the upper connecting-rod
bearings are lubricated by means of oil nozzles
linked to the main oil duct. In addition to
lubricating, this oil has an important cooling
function.
A hole has been drilled at the top of the
connecting rod, through which the oil that the
nozzles spray against the bottom of the piston
may reach the small-end bearing.
Turbocharger and air compressor
An oil duct from the camshaft bearing connects
the oil pipes to the turbocharger and air
compressor.
The oil discharge pipe from the turbocharger is
connected to a passage in the cylinder block,
from where the oil returns to the oil sump.
The oil returning from the air compressor flows
from the front of the air compressor back to the
timing gear, and from there to the oil sump.
Fuel pump
The fuel pump obtains lubricating oil from the oil
filter and discharges it through a channel in the
cylinder block, from where it returns to the oil
sump.
M200545
ǹ 0011 2-3
XF ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
2-4 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series Inspection and adjustment
Note:
An oil consumption test is only useful after the
engine has been run in (approx. 20,000 km).
1. First carefully check the engine for leaks.
Clean the engine before starting the test.
2. Run the engine to operating temperature.
3. Place the vehicle on a level surface.
4. Remove the oil drain plug and drain the oil
for 15 minutes. Collect the oil in a clean
container.
5. Measure the exact amount of oil drained.
4
6. Refill the oil sump with the drained engine
oil. If necessary, top up the amount of oil to
the specified level.
7. Before starting the test, write down the
exact amount of engine oil (A) in the oil
sump. Write down the total distance
covered (C) by the vehicle.
8. Drive between 500 and 1,000 km under
similar conditions as those in which the
vehicle is normally used.
9. Immediately after the test run, place the
vehicle on a level surface and write down
the distance covered (D).
10. Remove the oil drain plug and drain the oil
for 15 minutes. Collect the oil in a clean
container.
11. Measure the exact amount of oil
drained (B).
12. Pour the oil back into the oil sump. If
necessary, top up the amount of oil to the
specified level.
13. Calculate the oil consumption using the
following formula.
ǹ 0011 3-1
XF ENGINE LUBRICATION SYSTEM 2
Inspection and adjustment 65/75/85CF series
D -- C
Oil consumption = = km/l
A -- B
1300
1250
1200
km / L
1100
1000
1000
900
800
800
4 700
600
600 550
500
500 450
400
400 350
300
300 250
200
100
0
0 25 100 200 300 400 500 600 700 800 900 1000
x1000 km
M200557
3-2 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series Inspection and adjustment
4
Note:
The oil pressure control valve, mounted in
the oil sump, cannot be adjusted.
5. Stop the engine and remove the oil
pressure gauge. Fit a new oil seal to the oil
pressure sensor.
M200597
ǹ 0011 3-3
XF ENGINE LUBRICATION SYSTEM 2
Inspection and adjustment 65/75/85CF series
M200598
3-4 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
M200599
ǹ 0011 4-1
XF ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
4-2 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 4-3
XF ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
4-4 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
M200526
ǹ 0011 4-5
XF ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
4-6 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series Disassembly and assembly
4
1. Clean the gear wheels and check for
damage.
Note:
Gear wheels must be replaced as a set.
Note:
The gear wheels are marked. The gear
wheels with the marks must be fitted as
shown.
2. Fit the gear wheels in the lubricating oil
pump housing.
3. Remove the rear section of the lubricating
oil pump.
M200344
4. Fit the attachment bolts of the lubricating oil
pump sections. Tighten the attachment
bolts to the specified torque. See “Technical
data”.
5. Check that the lubricating oil pump operates
smoothly and is not getting stuck anywhere.
6. Fit the intermediate gear wheel with the hub
on the front plate. Tighten the attachment
bolt to the specified torque. See “Technical
data”.
ǹ 0011 5-1
XF ENGINE LUBRICATION SYSTEM 2
Disassembly and assembly 65/75/85CF series
5-2 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
65/75/85CF series Draining and filling
D
D000268
ǹ 0011 6-1
XF ENGINE LUBRICATION SYSTEM 2
Draining and filling 65/75/85CF series
6-2 ǹ 0011
2 PF ENGINE
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.3 Overview drawing, timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
2.4 Overview drawing, fuel pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Inspection and adjustment, valve mechanism bridges . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.2 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0011
3.3 Inspection and adjustment, timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . . 0011
3.4 Inspection and adjustment, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . . 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . . 0011
3.6 Inspection, engine compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . . 0011
3.7 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0011
3.8 Inspection, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.1 Removal and installation, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Removal and installation, engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 . . . . . .
4-2 . . . . . .
0011
0011
5
4.3 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 0011
4.4 Removal and installation, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . . 0011
4.5 Removal and installation, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 0011
4.6 Removal and installation, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0011
4.7 Removal and installation, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 . . . . . 0011
4.8 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . . 0011
4.9 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 . . . . . 0011
4.10 Removal and installation, steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0011
4.11 Removal and installation, starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . . 0011
4.12 Removal and installation, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . . . 0011
4.13 Removal and installation, V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 . . . . . 0011
4.14 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 . . . . . 0011
4.15 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 . . . . . 0011
4.16 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . . . . 4-25 . . . . . 0011
4.17 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 . . . . . 0011
4.18 Removal and installation, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 . . . . . 0011
4.19 Removal and installation, timing cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 . . . . . 0011
4.20 Removal and installation, timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 . . . . . 0011
4.21 Removal and installation, timing cogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 . . . . . 0011
4.22 Removal and installation, timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 . . . . . 0011
4.23 Removal and installation, timing gear case seal . . . . . . . . . . . . . . . . . . . . . . . 4-38 . . . . . 0011
4.24 Removal and installation, fuel pump drive housing . . . . . . . . . . . . . . . . . . . . . 4-39 . . . . . 0011
4.25 Removal and installation, vibration damper bearing race . . . . . . . . . . . . . . . . 4-41 . . . . . 0011
5. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Cleaning the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
ǹ 0011 1
PF ENGINE 2
Contents 65/75/85CF series
2 ǹ 0011
2 PF ENGINE
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
ǹ 0011 1-1
PF ENGINE 2
Safety precautions 65/75/85CF series
1-2 ǹ 0011
2 PF ENGINE
65/75/85CF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
7 4 2 1
6 5 3
M200747
Legend
1. Thermostat housing
2. Water pump
3. Vibration damper
4. Air compressor
5. Oil cooler
6. Turbocharger
7. Oil-filler pipe
ǹ 0011 2-1
PF ENGINE 2
General 65/75/85CF series
16 17 14 18 19 15
20 8 9 12 11 10 13
M200746
Legend
8. Steering pump
9. Fuel pump drive bearing housing
10. Fuel pump stop control cylinder
11. Oil filter
12. Engine brake valve
13. Starter motor
14. Engine identification plate
15. Fuel filter
16. Glow plugs
17. Coolant pipe
18. Inlet manifold
19. Relay, glow-filament
20. Alternator
2-2 ǹ 0011
2 PF ENGINE
65/75/85CF series General
2.2 IDENTIFICATION
Engine number
The engine number is marked on the cylinder
block at front right-hand side (compressor side).
M200748
M200745
Legend 4 3 5 6
1. Injection timing
2. Maximum governed engine speed ENGINE
3. Engine number TYPE
E4
4. Engine type ENGINE
NUMBER
5. Indication of country of origin
6. Certificate number GOVERNED SPEED min -1 OUTPUT kW
EINDHOVEN HOLLAND
2 1 8 7
M200678
ǹ 0011 2-3
PF ENGINE 2
General 65/75/85CF series
Legend 6 2 4
1. Crankshaft gear wheel
2. Camshaft gear wheel
3. Intermediate gear wheel
4. Steering pump gear wheel
5. Fuel pump drive gear wheel
6. Air compressor gear wheel
7. Oil pump intermediate gear wheel
7 1 3 5
M200744
6 7
M200751
2-4 ǹ 0011
2 PF ENGINE
65/75/85CF series Inspection and adjustment
i 400301
ǹ 0011 3-1
PF ENGINE 2
Inspection and adjustment 65/75/85CF series
M200754
3-2 ǹ 0011
2 PF ENGINE
65/75/85CF series Inspection and adjustment
5
cylinder 6. The correct valve clearance is
adjusted by loosening the locknut (4) and
turning the adjusting bolt in the correct
direction. See “Technical data” for the
correct valve clearance.
M200574
ǹ 0011 3-3
PF ENGINE 2
Inspection and adjustment 65/75/85CF series
Inspection, timing
1. Remove the valve cover from cylinders
1-2-3. See “Removal and installation”.
2. Position cylinder 1 at top dead centre
(TDC on the flywheel, cylinder 6 in overlap
position).
Note:
It is important that the bridges of the valve
mechanism are properly adjusted.
3. Set the inlet valve play of the first cylinder to
1 mm.
4. Position the measuring gauge on the inlet
valve bridge of the first cylinder, in such a
way that it measures in an exact vertical
position on the bridge and is capable of
registering an upward and downward
5
measurement of 5 mm.
5. Use the special tool (DAF no. 1310477) to
turn the crankshaft further in the direction of
rotation until the pistons of cylinders 1 and 6
have returned to the top dead centre (TDC).
6. Read the dial gauge and compare the
measured value. See “Technical data”.
M200551
Example
Pre-tension, dial gauge 5.00 mm
Measured tension --4.65 mm
Valve opening 0.35 mm
Note:
If the valve opening matches that in the
technical data, it may be assumed that the
timing gear is properly set.
3-4 ǹ 0011
2 PF ENGINE
65/75/85CF series Inspection and adjustment
6.
with the marks.
Tighten the attachment bolt of the 2
3
5
intermediate gear wheel (3) to the specified
torque. See “Technical data”. 1
ǹ 0011 3-5
PF ENGINE 2
Inspection and adjustment 65/75/85CF series
150
M2061
M2092
3-6 ǹ 0011
2 PF ENGINE
65/75/85CF series Inspection and adjustment
M2062
M200885
ǹ 0011 3-7
PF ENGINE 2
Inspection and adjustment 65/75/85CF series
5
M2 00 033
4. Place the dial gauge of the stylus at the
specified distance. See “Technical data”.
5. Set the dial gauge to “0”.
6. Place the fuel pump in the stop position and
lock it in this position.
7. Use the special tool (DAF no. 1310477) to
crank the engine through 360_ and
measure the maximum dial gauge reading.
Compare this reading with the technical
data. See “Technical data”.
M200230
3-8 ǹ 0011
2 PF ENGINE
65/75/85CF series Inspection and adjustment
ǹ 0011 3-9
PF ENGINE 2
Inspection and adjustment 65/75/85CF series
Note: C
To avoid engine damage it is important that the
glow plugs should be checked periodically.
1. Check the glow plugs for the following
points:
- windings that have worn thin due to
abrasion (A)
M200818
3-10 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
Note:
Because of the large number of vehicle
specifications, it is not feasible to exactly specify
the engine removal and installation procedures
for every vehicle.
This description only includes the most
5
important points requiring attention.
- Disconnect the earth lead from the battery
terminal.
- Avoid opening fluid systems as much as
possible. If possible, remove and set aside
the engine components.
- When removing the engine, ensure that no
parts or dirt fall into the engine, radiator or
other components. Therefore, plug all
openings.
- Electrical wiring harnesses are easily
damaged. If damaged, they may cause
faults. Make sure these wiring harnesses
are stress-free and clear of moving parts.
- Tighten all attachment bolts to the correct
tightening torque.
- Do not allow the engine to rest on the oil
sump. Because the oil sump is made of
sheet material, it will be severely damaged
by the engine’s own weight.
ǹ 0011 4-1
PF ENGINE 2
Removal and installation 65/75/85CF series
4-2 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
5
See “Technical data”.
7. Fit the coolant pipes (A) between the
engine, radiator and header tanks.
8. Fit the flexible rubber pipe (E) of the oil filler
pipe.
9. Fit the dip stick (D) to the radiator.
10. Fit the earth strip from the chassis to the
flywheel housing.
11. Reconnect the earth lead to the battery.
12. Fill the cooling system. D B C E
M200840
ǹ 0011 4-3
PF ENGINE 2
Removal and installation 65/75/85CF series
5 3.
gasket.
Fit the attachment bolts of the valve cover
and tighten them to the specified torque.
See “Technical data”.
4-4 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-5
PF ENGINE 2
Removal and installation 65/75/85CF series
M200754
4-6 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-7
PF ENGINE 2
Removal and installation 65/75/85CF series
4-8 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-9
PF ENGINE 2
Removal and installation 65/75/85CF series
4-10 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-11
PF ENGINE 2
Removal and installation 65/75/85CF series
4-12 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-13
PF ENGINE 2
Removal and installation 65/75/85CF series
4-14 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
5
Tighten the attachment bolts to the
specified torque. See “Technical data”.
9. Fit the air inlet pipe and tighten the
attachment bolts to the specified torque.
See “Technical data”.
10. Fit the rear engine sound proofing.
11. Start the engine and check all connections
for leaks.
ǹ 0011 4-15
PF ENGINE 2
Removal and installation 65/75/85CF series
4-16 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-17
PF ENGINE 2
Removal and installation 65/75/85CF series
4-18 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-19
PF ENGINE 2
Removal and installation 65/75/85CF series
Removal, alternator 5
1. Remove both battery leads from the battery 6
terminals. 4
2. Remove the electrical connections from the 3
alternator. 2
3. Slacken the attachment bolt (3) from the
threaded spindle which is attached to the
coolant pump.
4. Slacken the alternator bracket attachment
bolts (1) and (2).
5. Loosen the locknut (4) and bolt (6) of the
coupling.
6. Shift the alternator by means of the nut (5) 1
in the direction of the cylinder block and
M200753
slacken the V-belt.
4-20 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
1
M200753
M2101
ǹ 0011 4-21
PF ENGINE 2
Removal and installation 65/75/85CF series
5
M200885
4-22 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
Removal, flywheel
1. Remove the gearbox.
2. Remove the clutch release assembly and
the clutch plate.
3. Remove the attachment bolts (1) from the
flywheel.
4. Use two threaded bolts to remove the
flywheel from the dowel pin.
5. Remove the flywheel.
1
Installation, flywheel
1. Clean the flywheel housing.
2. Clean the crankshaft flange, the dowel pins M200569
and the attachment bolts. Remove the
locking compound from the threaded holes.
3. Clean the back of the flywheel and fit the
flywheel. 5
4. Fit the attachment bolts and tighten them to
the specified torque. See “Technical data”.
5. Fit the clutch plate and the clutch release
assembly.
6. Fit the gearbox.
M200570
ǹ 0011 4-23
PF ENGINE 2
Removal and installation 65/75/85CF series
5
flywheel.
4. Fit the flywheel.
M2 00 035
4-24 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
Note:
Each new seal is supplied with a plastic
mounting ring, which can only be used
once.
Removal, flywheel housing seal
1. Remove the flywheel.
2. Drill two holes into the seal and, using the
special tool (DAF no. 0484899 and
DAF no. 0694928) pull the seal out of the
flywheel housing.
Installation, flywheel housing seal
1. Thoroughly clean sealing ring recess and
inspect for damage. Even the most minute
damage can cause a leak.
2. Clean the crankshaft flange.
Note:
If the oil seal has scored the crankshaft
flange running surface, a spacer ring should
5
be fitted in the oil seal recess before a new
oil seal is installed.
3. Lightly grease the inner rim of the oil seal.
4. Fit the base plate (A) of special tool 1
(DAF no. 1329402) on the crankshaft 2
flange.
5. Fit the supplied plastic mounting ring (1) on
the crankshaft flange.
6. Then place the new sealing ring (2) over the
mounting ring and remove the mounting
ring. A
7. Place the thrust washer (B) over the spindle
and gradually tighten the nut (C) until the oil
seal is properly positioned. B C
M2 00 036
8. Remove the special tool.
9. Fit the flywheel.
ǹ 0011 4-25
PF ENGINE 2
Removal and installation 65/75/85CF series
5 9.
flywheel housing.
Remove the flywheel housing.
4-26 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
5
bolts at the back of the engine. Tighten the
attachment bolts to the specified torque.
See “Technical data”.
8. Fit the oil seal.
9. Fit the flywheel.
10. Fit the starter motor.
11. Clean the contact surface of the earth lead,
and connect it to the flywheel housing.
12. Fit the oil sump attachment bolts. Tighten all
attachment bolts to the specified torque.
See “Technical data”.
ǹ 0011 4-27
PF ENGINE 2
Removal and installation 65/75/85CF series
4-28 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
A
B
5
m200830
ǹ 0011 4-29
PF ENGINE 2
Removal and installation 65/75/85CF series
4-30 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
5
6. Loosen the radiator attachment bolts so that
the radiator can be tilted slightly forward.
7. Remove the attachment nuts from the
viscous fan clutch.
8. Loosen the locking screw at the top of the
wind tunnel collar and turn the wind tunnel
collar anti-clockwise to unlock it.
9. Tilt the radiator forward and remove the
wind tunnel collar and the viscous fan clutch
D B C E
with the fan. M200840
ǹ 0011 4-31
PF ENGINE 2
Removal and installation 65/75/85CF series
4-32 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
D B C E
M200840
ǹ 0011 4-33
PF ENGINE 2
Removal and installation 65/75/85CF series
4-34 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-35
PF ENGINE 2
Removal and installation 65/75/85CF series
5
Installation, timing gear
1. Fit the timing cover.
2. Fit the valve covers.
3. Check the injection timing.
4-36 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-37
PF ENGINE 2
Removal and installation 65/75/85CF series
5 6 7
M200751
M200580
4-38 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
6 7
5
M200751
M200758
87
M200581
ǹ 0011 4-39
PF ENGINE 2
Removal and installation 65/75/85CF series
M200757
4-40 ǹ 0011
2 PF ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-41
PF ENGINE 2
Removal and installation 65/75/85CF series
4-42 ǹ 0011
2 PF ENGINE
65/75/85CF series Cleaning
5. CLEANING
5.1 CLEANING THE ENGINE
Note:
It is advisable to clean the engine with a
high-pressure cleaner before starting
maintenance or service operations. A clean
engine makes the mechanic’s work easier, and
enables him to notice any defects at an early
stage.
Before cleaning the engine, check for any leaks.
If the engine is cleaned with a high-pressure
cleaner, it must be used with care. It is also
important to observe the following points:
- When cleaning the universal joint on the
steering box, the spider seals may be
forced open by the high-pressure jet of
water, so that the grease behind them is
flushed away. As a result, the spider may
get stuck, so that the steering mechanism
will jam. 5
- A bleed screw is fitted to the power steering
fluid reservoir of the steering system. Water
may enter the tank through this valve,
causing damage to the steering gear.
- When cleaning the radiator/intercooler
element, be careful not to damage the fins.
- Do not direct the high-pressure cleaner jet
too long at the air-conditioning system
condenser. As a result of the high
temperature, the pressure in the system will
become excessive, which may cause
damage to the system.
ǹ 0011 5-1
PF ENGINE 2
Cleaning 65/75/85CF series
5-2 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.2 Cooling system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0011
3. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Description of cooling system pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.2 Description of the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
4. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.1 Pressure-testing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.2 Inspection, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
4.3 Inspection, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.4 Inspection, water pump radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0011
5. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.1 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.2 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 ...... 0011
5.3 Removal and installation, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 ...... 0011
5.4 Removal and installation, header tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 ...... 0011
5.5 Removal and installation, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ...... 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling/bleeding, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011 6
ǹ 0011 1
PF ENGINE COOLING SYSTEM 2
Contents 65/75/85CF series
2 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
6
ǹ 0011 1-1
PF ENGINE COOLING SYSTEM 2
Safety precautions 65/75/85CF series
1-2 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
3 2 1
5 4
6 6
M200759
Legend
7. Thermostat housing
8. Water pump
9. Water-cooled air compressor
10. Water pipe
11. Oil cooler
12. Coolant pipe
ǹ 0011 2-1
PF ENGINE COOLING SYSTEM 2
General 65/75/85CF series
2-2 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series General
ǹ 0011 2-3
PF ENGINE COOLING SYSTEM 2
General 65/75/85CF series
2-4 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Component description
3. COMPONENT DESCRIPTION
3.1 DESCRIPTION OF COOLING SYSTEM PRESSURE CAP
6
P1
M200445
ǹ 0011 3-1
PF ENGINE COOLING SYSTEM 2
Component description 65/75/85CF series
Thermostat closed
The coolant has not yet reached the opening A
temperature of the thermostat.
Supply passage (B) to the radiator is completely
closed.
The coolant passes via a by-pass duct (A)
directly to the water pump and the pump once B
again passes the coolant to the cylinder block.
M200739
6
M200740
3-2 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
ǹ 0011 4-1
PF ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
M200513
4-2 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
ǹ 0011 4-3
PF ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
900
6. Allow the fan drive flange to run at a speed
of 1000 rpm.
7. Then use an optical rev counter to 100
determine the difference in speed of the fan
in relation to the drive flange. The speeds
will differ if there is any slip in the viscous
430
clutch. When the clutch is fully engaged, the
slip must not be more than 10%. If it is more
than 10%, the viscous fan clutch must be
replaced.
700
M200440
M200595
4-4 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
9.
spindle of the alternator.
Remove the attachment bolts from the
6
thermostat housing on the water pipe and
remove the thermostat housing with the
connection piece.
10. Disconnect all flexible water pipes
connected to the water pump.
11. Remove the attachment bolts from the
water pump and remove the water pump.
ǹ 0011 5-1
PF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-2 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
Removal, thermostat
1. Drain the coolant. See “Draining and filling”.
2. Remove the water pipe between the
thermostat housing and the radiator.
3. Remove the attachment bolts from the
thermostat housing.
4. Remove the thermostat housing and the
C
B
connecting piece from the water pump. A
5. Remove the O-ring (A) from the thermostat
housing.
6. Remove the thermostat.
M200742
ǹ 0011 5-3
PF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-4 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-5
PF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-6 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-7
PF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Note:
The removal and installation procedure for the
radiator allows for the presence of an
air-conditioning unit. If such a unit is not present,
the sections concerned can be skipped.
Removal, radiator
1. Disconnect the earth lead from the battery
terminal.
2. Drain the coolant. See “Draining and filling”.
3. Remove the front engine encapsulation.
4. Remove the engine encapsulation under
the cab.
5. Remove the bolts from the guide ring
brackets, and remove the guide ring.
6. Remove the guide strip at the front of the
intercooler.
7. Remove the dip stick holder of the
intercooler and put it aside.
5-8 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-9
PF ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-10 ǹ 0011
2 PF ENGINE COOLING SYSTEM
65/75/85CF series Draining and filling
6
maximum temperature setting. As a result,
the heater cock will be fully opened.
2. Remove the cooling system filler cap.
3. Collect the coolant. To do so, place suitable
containers beneath the drain points.
4. Drain the cooling system via drain tap (A)
on the side of the engine block and via drain
plug (B) underneath the radiator and plug
(C) on the lower side of the oil cooler.
B
C
A
M2097
ǹ 0011 6-1
PF ENGINE COOLING SYSTEM 2
Draining and filling 65/75/85CF series
M2077
6-2 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Lubricating oil system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Inspection, lubricating oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Inspection, lubricating oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.3 Pressure testing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.1 Removal and installation, pump seat/lubricating oil filter housing . . . . . . . . . 4-1 ...... 0011
4.2 Removal and installation, oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.3 Removal and installation, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0011
4.4 Removal and installation, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0011
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Disassembly and assembly, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling, engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
ǹ 0011 1
PF ENGINE LUBRICATION SYSTEM 2
Contents 65/75/85CF series
2 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
ǹ 0011 1-1
PF ENGINE LUBRICATION SYSTEM 2
Safety precautions 65/75/85CF series
1-2 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series General
2. GENERAL
2.1 LUBRICATING OIL SYSTEM DESCRIPTION
M200761
ǹ 0011 2-1
PF ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
General
The lubricating oil pump is directly driven from
the crankshaft, by a gear. The lubricating oil
pump draws the oil from the oil sump, and
pumps it via the oil cooler and the lubricating-oil
filter to the main oil duct in the cylinder block.
From the main oil duct, the lubricating-oil is
further distributed to the various components
requiring lubrication.
Oil cooler
The oil cooler is connected to the cooling
system. The oil cooler warms up the lubricating
oil in a “cold” engine and cools it in a “warm”
engine.
Parallel to the oil cooler, a short-circuit valve has
been installed. If the oil cooler is blocked, the
short-circuit valve will open if a certain pressure
has built up. In this case, uncooled engine oil
enters the lubricating system.
Pressure limiting valve
A pressure-limiting valve is installed in the
lubricating system after the oil cooler. When the
pressure set for the pressure limiting valve has
been reached, the valve opens and allows
excess cooled lubricating oil to flow to the oil
sump.
Oil filter
7
The oil is cleaned in the disposable oil filter. A
pressure limiting valve fitted in this filter opens if
the pressure in the filter becomes too high as a
result of contamination or cold oil. The oil then
passes through the filter unfiltered.
Main oil duct
From the main oil duct, lubricating oil is supplied
to the crankshaft main bearings and via an oil
duct in the crankshaft also to the connection-rod
bearings.
From the main oil duct, lubricating oil is pumped
through the first camshaft bearing into the
hollow camshaft.
From the oil duct in the camshaft, lubricating oil
is supplied to the other camshaft bearings.
2-2 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series General
Cylinder head
From the second and fifth camshaft bearings, an
oil duct passes through the cylinder heads to the
second and fifth rocker seats. The other rockers
shafts are provided with lubricant by
lubricating-oil strips that run along the rockers
seats.
Timing gear
From the oil duct in the first crankshaft main
bearing, an oil duct leads to the hollow hub of
the intermediate gear wheel. The oil passes
through the hollow hub onto the intermediate
gear wheel. The other gear wheels receive
lubricating oil from the intermediate gear wheel.
Piston and gudgeon pin
The pistons and the upper connecting-rod
bearings are lubricated by means of oil nozzles
linked to the main oil duct. In addition to
lubricating, this oil has an important cooling
function.
A hole has been drilled at the top of the
connecting rod, through which the oil that the
nozzles spray against the bottom of the piston
may reach the small-end bearing.
Turbocharger and air compressor
An oil duct from the camshaft bearing connects
the oil pipes to the turbocharger and air
compressor.
The oil discharge pipe from the turbocharger is 7
connected to a passage in the cylinder block,
from where the oil returns to the oil sump.
The oil returning from the air compressor flows
from the front of the air compressor back to the
timing gear, and from there to the oil sump.
Fuel pump
The fuel pump obtains lubricating oil from the oil
filter and discharges it through a channel in the
cylinder block, from where it returns to the oil
sump.
ǹ 0011 2-3
PF ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
2-4 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series Inspection and adjustment
Note:
An oil consumption test is only useful after the
engine has been run in (approx. 20,000 km).
1. First carefully check the engine for leaks.
Clean the engine before starting the test.
2. Run the engine to operating temperature.
3. Place the vehicle on a level surface.
4. Remove the oil drain plug and drain the oil
for 15 minutes. Collect the oil in a clean
container.
5. Measure the exact amount of oil drained.
6. Refill the oil sump with the drained engine
oil. If necessary, top up the amount of oil to
the specified level.
7. Before starting the test, write down the
exact amount of engine oil (A) in the oil
sump. Write down the total distance
covered (C) by the vehicle.
8. Drive between 500 and 1,000 km under
7
similar conditions as those in which the
vehicle is normally used.
9. Immediately after the test run, place the
vehicle on a level surface and write down
the distance covered (D).
10. Remove the oil drain plug and drain the oil
for 15 minutes. Collect the oil in a clean
container.
11. Measure the exact amount of oil drained
(B).
12. Pour the oil back into the oil sump. If
necessary, top up the amount of oil to the
specified level.
13. Calculate the oil consumption using the
following formula.
ǹ 0011 3-1
PF ENGINE LUBRICATION SYSTEM 2
Inspection and adjustment 65/75/85CF series
D -- C
Oil consumption = = km/l
A -- B
1250
1200
1100
km. / liter
1000
900
800
700
600
500
400
300
250
7 200
100
0
100 200 300 400 500 600 700 800
25 80 240 x 1000 km.
M200774
3-2 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series Inspection and adjustment
Note:
The oil pressure control valve, mounted in
the oil sump, cannot be adjusted.
5. Stop the engine and remove the oil
pressure gauge. Fit a new oil seal to the oil
pressure sensor.
ǹ 0011 3-3
PF ENGINE LUBRICATION SYSTEM 2
Inspection and adjustment 65/75/85CF series
3-4 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
7
7. Remove the O-rings (1).
Installation, pump seat/lubricating oil filter
4
housing
1. Replace the O-rings (1) at the rear of the
pump seat/lubricating oil filter housing (2).
2. Fit the pump seat/lubricating oil filter
housing (2) and tighten the attachment bolts
to the specified torque. See “Technical
data”.
3. Check the coupling (3). See “Technical
data”.
M200762
4. Lightly grease the filter element seal.
ǹ 0011 4-1
PF ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
4-2 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 4-3
PF ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
4-4 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 4-5
PF ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
4-6 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series Disassembly and assembly
ǹ 0011 5-1
PF ENGINE LUBRICATION SYSTEM 2
Disassembly and assembly 65/75/85CF series
5-2 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
65/75/85CF series Draining and filling
M200735
ǹ 0011 6-1
PF ENGINE LUBRICATION SYSTEM 2
Draining and filling 65/75/85CF series
6-2 ǹ 0011
2 NS ENGINE
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 General arrangement drawing, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0011
2.3 General arrangement drawing, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0011
2.4 General arrangement drawing, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.5 General arangement drawing, engine mounting . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.6 Overview drawing, valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
2.7 General arrangement drawing, flywheel housing . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Inspection and adjustment, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.3 Inspection, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.4 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ...... 0011
3.6 Inspection, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ...... 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.1 Removal and installation, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.2 Removal and installation, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 0011
4.3 Removal and installation, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . . 0011
4.4 Removal and installation, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0011
4.5 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . . 0011
4.6 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 . . . . . 0011
4.7 Removal and installation of the steering pump . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0011
4.8 Removal and installation, starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . . 0011
4.9 Removal and installation, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . . . 0011
4.10 Removal and installation, V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 . . . . . 0011
4.11 Removal and installation, engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 . . . . . 0011
4.12 Removal and installation, valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-24 . . . . .
4-27 . . . . .
0011
0011
8
4.14 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 . . . . . 0011
4.15 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 . . . . . 0011
4.16 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . . . . 4-30 . . . . . 0011
4.17 Removal and installation, vibration damper and pulley . . . . . . . . . . . . . . . . . 4-32 . . . . . 0011
4.18 Removal and installation, timing cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 . . . . . 0011
4.19 Removal and installation, timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 . . . . . 0011
ǹ 0011 1
NS ENGINE 2
Contents 65/75/85CF series
2 ǹ 0011
2 NS ENGINE
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area.
Make sure exhaust fumes are properly
extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
ǹ 0011 1-1
NS ENGINE 2
Safety precautions 65/75/85CF series
1-2 ǹ 0011
2 NS ENGINE
65/75/85CF series General
2. GENERAL
2.1 IDENTIFICATION
Engine number
The engine number is marked on engine block
at the rear left.
NS engine identification plate 4 3 5 6
9. Injection timing
10. Maximum governed engine speed
ENGINE
11. Engine number TYPE
12. Engine type E4
ENGINE
13. Indication of country of origin NUMBER
EINDHOVEN HOLLAND
2 1 8 7
M200678
ǹ 0011 2-1
NS ENGINE 2
General 65/75/85CF series
Legend 1
10. Nut
11. Insulator 2
3 8
12. Ring
13. Glow plug 7
14. Inlet manifold 4
15. Shoulder stud 6
16. Waved spring
7
17. Bolt
18. Gasket
9
5 M2 00 150
Legend 4 4 5
14. Stud
15. Gasket 1 6
16. Exhaust manifold, front 2 3
17. Sealing spring
18. Exhaust manifold, rear
19. Stud
20. Spacer sleeve 9 13
21. Nut
22. Heat shield 7
8
23. Ring
24. Waved ring 10
8 25. Bolt
26. Heat shield
11
12
10
11
12 M2 00 155
2-2 ǹ 0011
2 NS ENGINE
65/75/85CF series General
Legend 1
16. Adjusting strip
17. Ring 4 5
18. Bolt 6
19. Nut 6
20. Waved spring 7 2
21. Ring 3
22. Bolt
23. Alternator 9
24. Key
25. Pulley
26. Waved spring 11
27. Nut 12
28. Nut
29. Bracket
30. Bolt 8
10
14
15
13
M2 00 145
8
Legend
12. Flange bolt 2
13. Flange bolt 1
14. Bush 3
15. Vibration damper
16. Flange nut
17. Bracket 4
18. Flange bolt 7
19. Vibration damper 5
20. Ring
21. Nut 8
22. Bracket
9
10
11 6
M2 00 161
ǹ 0011 2-3
NS ENGINE 2
General 65/75/85CF series
1
2
3
4
5
6
5
4
7
4
5
6
5
4
7
4
5
6
5
4
3
2
1 M2 00 132
Legend
8. Circlip
9. Ring
10. Spring
8
11. Ring
12. Rocker
13. Rocker shaft seat
14. Spring
2-4 ǹ 0011
2 NS ENGINE
65/75/85CF series General
1
10
2 3
11
4
12
13
6
5
14
7
8
9
M2 00 134
Legend
15. Flywheel housing
16. Bolt
17. Ring
18. Dowel
19. Oil seal
8
20. Spacer ring
21. Adjusting plate
22. Spring washer
23. Allen screw
24. Flywheel
25. Starter ring gear
26. Dowel
27. Input shaft bearing
28. Bolt
ǹ 0011 2-5
NS ENGINE 2
General 65/75/85CF series
2-6 ǹ 0011
2 NS ENGINE
65/75/85CF series Inspection and adjustment
version. 100
150
O
APBT
LIBEE
ULTII
N.5
00
LBS
.100 150
0
200
300
M2079
M2061
M2055
ǹ 0011 3-1
NS ENGINE 2
Inspection and adjustment 65/75/85CF series
M2062
1 M200301
3-2 ǹ 0011
2 NS ENGINE
65/75/85CF series Inspection and adjustment
ǹ 0011 3-3
NS ENGINE 2
Inspection and adjustment 65/75/85CF series
3-4 ǹ 0011
2 NS ENGINE
65/75/85CF series Inspection and adjustment
8
hand. 140 mm
3. Check the flywheel axial end play. At a
distance of 140 mm from the middle, the
clock deflection must be at maximum
0.1 mm.
M2 00 034
ǹ 0011 3-5
NS ENGINE 2
Inspection and adjustment 65/75/85CF series
Note:
Heavy-duty use can lead to the central isolator
in the glow plugs becoming loose. In the long
term this loose isolator will damage the glow
spiral, leading to parts of the spiral and isolator
falling deeper into the engine, leading to serious
damage.
Inspection, glow plugs A
1. Check the glow plugs for the following
points:
- rattling sound (loose isolator, see A);
- windings in the centre of the spiral that
have worn thin or broken due to the
abrasive effect of the loose isolator B C
(see B);
M200743
- spiral end broken or worn thin due to
continuous knocking by the isolator
(see C);
- if parts of the insulator have broken off,
check the inlet manifold for the missing
parts.
3-6 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
Note:
When removing the engine, ensure that no parts
fall into the engine, radiator or other
components. To prevent this occurring, plug all
pipe openings.
Removing the engine
1. Disconnect the earth terminal from the
batteries.
2. Remove the noise cap at the rear of the
engine.
3. Clean the engine.
4. Drain the coolant.
5. Disconnect the propeller shaft from the
gear-box.
8
6. Remove the air pipe from the engine brake
valve operating cylinder.
7. Remove the exhaust pipe (with the engine
brake valve) between the exhaust manifold
and silencer.
8. Disconnect the gearbox wiring and tie the
wires together.
9. Remove the gear lever with the selector
rod.
10. Remove the gearbox and clutch housing
from the engine.
ǹ 0011 4-1
NS ENGINE 2
Removal and installation 65/75/85CF series
4-2 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
8
attach the engine bracket to the vibration
dampers at the front and rear of the engine.
38. Hoist the engine gently and check that the
engine is balanced.
39. Hoist the engine gently from the chassis
and while hoisting check that the engine
does not remain hooked anywhere.
40. Carefully place the engine on stands.
ǹ 0011 4-3
NS ENGINE 2
Removal and installation 65/75/85CF series
Installation, engine
Note:
- Check the pipes and replace as necessary.
- Check the pipe clamps and replace as
necessary.
- Replace all gaskets and sealing rings.
1. Check the engine suspension vibration
dampers. If in doubt, replace.
2. Hoist the engine gently into the vehicle and
fit the engine bracket attachment bolts.
3. The attachment bolts must be fitted free of
stress. Adjust the position of the rear
vibration damper as necessary.
4. Tighten the attachment bolts to the
specified tightening torque. See “Technical
data”.
5. Fit the air pipe between the air filter and air
duct.
6. Fit the connector of the underpressure
indicator.
7. Tighten the delivery pipe on the rear of the
engine.
8. Fit the starter motor wiring.
9. Insert the dipstick holder.
4-4 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-5
NS ENGINE 2
Removal and installation 65/75/85CF series
4-6 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
Note:
Depending on the reason for which the cylinder
head must be removed, the inlet and exhaust
manifolds and thermostat housing with coolant
pump need not be removed.
Removal, cylinder head
1. Disconnect the earth terminal from the
batteries.
2. Remove the noise cap at the rear of the
engine.
3. Drain the engine coolant system.
4. Remove the torque rod between the
thermostat housing and the radiator.
5. Remove all thermostat housing and coolant
pump pipes.
6. Disconnect the coolant pipe on the rear of
the cylinder head.
7. Detach the wiring of the glow plugs.
8. Remove the coolant temperature indicator
wiring.
9. Remove the brackets of the electrical wiring
on the parts to be removed.
10. Remove the fuel return pipe bracket on the
thermostat housing.
11. Remove the V-belts. 8
12. Remove the thermostat housing with the
coolant pump.
13. Remove the air inlet duct fitted over the
valve cover.
14. Remove the gear lever.
15. Remove the inlet manifold.
16. Remove all the turbocharger pipes.
ǹ 0011 4-7
NS ENGINE 2
Removal and installation 65/75/85CF series
4-8 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-9
NS ENGINE 2
Removal and installation 65/75/85CF series
4-10 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-11
NS ENGINE 2
Removal and installation 65/75/85CF series
4-12 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-13
NS ENGINE 2
Removal and installation 65/75/85CF series
Note:
Even if the turbocharger is not removed
from the exhaust manifold, all pipes must
still be removed from the turbocharger.
5. Disconnect the injector pipes.
6. Remove the heat shields from the exhaust
manifold.
7. Remove the attachment nuts with the
spacer rings and remove the exhaust
manifold assembly.
8 8. Remove the gaskets.
9. If necessary, remove the two parts of the
exhaust manifold from each other with a
pulling and turning movement.
10. Remove the sealing rings and clean the
groove.
11. Clean all sealing surfaces.
4-14 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-15
NS ENGINE 2
Removal and installation 65/75/85CF series
4-16 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-17
NS ENGINE 2
Removal and installation 65/75/85CF series
4-18 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
6.
the starter ring gear for damage.
Clean the abutting surfaces of the starter M2 00 137
8
motor and the flywheel housing.
ǹ 0011 4-19
NS ENGINE 2
Removal and installation 65/75/85CF series
Removal, alternator
1. Disconnect the earth terminal from the
batteries.
2. Mark the wiring connections on the
alternator and remove the wiring.
3. Loosen the alternator and tensioner
attachment bolts.
4. Remove the V-belts from the pulley.
5. Remove the attachment bolts and take off
the alternator.
8
6. Transfer the pulley to the alternator to be
fitted, if applicable. Tighten the attachment
nut to the specified torque. See “Technical
data”.
Installation, alternator
1. Fit the V-belts to the pulley.
2. Adjust the V-belt tension. See “Inspection
and adjustment”.
3. Fit the alternator wiring.
4. Reconnect the earth lead to the batteries.
4-20 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
Removal, V-belts
1. Loosen the alternator attachment bolts (1)
and the tensioning gear bolt (2).
2. Tilt the alternator as close as possible
against the cylinder block. 1
3. Remove the attachment bolt (3) of the air 1
guide ring.
4. Remove the V-belts.
5. Inspect the V-belts and pulleys for damage,
rust and grease deposits.
Note: 1 M2063
Always replace a V-belt with a V-belt of the
same version. Always replace both belts at
the same time.
Installation, V-belts 3
1. Push the fan guide ring in the direction of
the fan and pull the V-belt through the air
guide ring and fan.
2. Tighten the attachment bolts (3) of the air
guide ring.
3. Place the V-belts on the pulleys and adjust
the V-belt tension. See “Inspection and
adjustment”.
8
M2119
ǹ 0011 4-21
NS ENGINE 2
Removal and installation 65/75/85CF series
4-22 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
8
and the wind tunnel.
8. Fit the throttle cable bracket to the air pipe.
9. Fit the air ducts between the engine and
charge cooler.
ǹ 0011 4-23
NS ENGINE 2
Removal and installation 65/75/85CF series
8
4. Slacken the adjusting bolts of the rockers
as far as possible.
5. Remove the attachment bolts of the rocker
shaft seats and remove the rocker shaft.
6. Remove the locking bolts of the rocker shaft
from the rocker shaft seats.
7. Remove the rocker shaft circlip and remove
the rings, springs and rockers from the
rocker shafts.
4-24 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-25
NS ENGINE 2
Removal and installation 65/75/85CF series
4-26 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
Removal, flywheel
1. Remove the gearbox, pressure group and
the clutch plate.
2. Remove the attachment bolts from the
flywheel.
3. Clamp the crankshaft flywheel by tightening
the two jack screws (M10) at the same 5 mm
time.
4. Clean the crankshaft flange, the dowels and
the attachment bolts.
2 mm
5. If the flywheel on the abutting surface of the
clutch plate shows signs of cracks and
these cracks are not within 5 mm of the
edges of the abutting surface, a maximum
of 2 mm of the flywheel may be ground
5 mm
down (see illustration opposite).
6. De-grease the abutting surface of the
flywheel and the clutch plate.
Installation, flywheel
1. Apply Loctite 243 to the flywheel and fit it
with the attachment bolts.
M2 00 033
2. Tighten the attachment bolts crosswise,
tightening them to the specified torque.
3. Check the flywheel play. See “Technical
data”.
4. Fit the gearbox, pressure group and the
clutch plate.
8
ǹ 0011 4-27
NS ENGINE 2
Removal and installation 65/75/85CF series
8 M2 00 035
4-28 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-29
NS ENGINE 2
Removal and installation 65/75/85CF series
Note:
Each new seal is supplied with a plastic
mounting ring, which can only be used once.
When positioning the oil seal, use special tool
(DAF no. 0694899).
Removal, flywheel housing seal
1. Remove the flywheel.
2. Remove the oil seal from the flywheel
housing using an impact puller. Attach the
impact puller adapter to the seal with two
plate screws.
3. If the flywheel housing has been removed
from the engine the old oil seal can be
carefully tapped or pressed out of the
flywheel housing.
8
4. Thoroughly clean the seal recess and
inspect for damage. Even the most minute
damage can cause a leak.
Note:
If the oil seal has scored the crankshaft
flange running surface, a spacer ring should
be fitted in the oil seal recess before a new
oil seal is installed.
4-30 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
Note:
Do not apply sealant to the outer edge of
the seal. B C
M2 00 036
4. Fit the thrust washer (B) to the guide plate
(A). Press the oil seal (2) into the flywheel
housing by evenly tightening the nut.
5. Fit the flywheel.
ǹ 0011 4-31
NS ENGINE 2
Removal and installation 65/75/85CF series
M2 00 125
4-32 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
8
3. Clean and inspect the oil seal recess in the
timing gear cover. Even minimal damage
can lead to a leak.
Note:
If the seal has caused a groove on the vibration
damper, a spacer ring must be fitted in the
chamber of the seal.
ǹ 0011 4-33
NS ENGINE 2
Removal and installation 65/75/85CF series
4-34 ǹ 0011
2 NS ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-35
NS ENGINE 2
Removal and installation 65/75/85CF series
4-36 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Description of cooling system pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.2 Description of the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . . 0011
4. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.1 Inspection, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
5. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.2 Removal and installation, thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . . 0011
5.3 Removal and installation, fan (clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 . . . . . . 0011
5.4 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 . . . . . . 0011
5.5 Removal and installation, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 . . . . . . 0011
5.6 Removal and installation, header tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 . . . . . 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling/bleeding, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
ǹ 0011 1
NS ENGINE COOLING SYSTEM 2
Contents 65/75/85CF series
2 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to coolants, windscreen wash,
battery acid and diesel oil. So avoid inhaling and
direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
ǹ 0011 1-1
NS ENGINE COOLING SYSTEM 2
Safety precautions 65/75/85CF series
1-2 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series General
2. GENERAL
2.1 SYSTEM DESCRIPTION
ǹ 0011 2-1
NS ENGINE COOLING SYSTEM 2
General 65/75/85CF series
10
5
6 9
19
3
4 7 11
1
8 B
6
12
9
10 13
2
18 14
19
3
9 11 16 7 4
1
A
6
12
13 15 15
17
2
10
18
2-2 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series General
Legend
A Coolant flow from thermostat housing
through the right side of the cylinder head
B Coolant flow from thermostat housing
through the left side of the cylinder head
1. Header tank
2. Radiator
3. Bleed pipe
4. Radiator supply pipe
5. Water pump
6. Header tank connection pipe
7. Thermostat housing
8. Heater supply pipe
9. Heater return pipe
10. Radiator return pipe
11. Cylinder head
12. Lubricating oil heat exchanger return pipe
13. Lubricating oil heat exchanger supply pipe
14. Lubricating oil heat exchanger
15. Air compressor supply pipe
(water cooled air compressor only)
16. Air compressor return pipe
(water cooled air compressor only)
17. Air compressor
18. Cylinder block
19. Overflow tank
General
The engine cooling system’s function is to keep
the engine temperature at a constant level
independently of the change in engine load,
speed and ambient temperature. At this
temperature, the engine gives its best return and
minimum wear.
To achieve controlled engine cooling, the
amount of coolant flowing to the radiator is
controlled by the thermostats.
9
The airflow through the radiator is controlled by
the fan clutch. This viscous type clutch
increases or decreases the fan speed relative to
the ambient temperature after the radiator.
ǹ 0011 2-3
NS ENGINE COOLING SYSTEM 2
General 65/75/85CF series
9
water pump (5), via the return pipe (10).
2-4 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series General
ǹ 0011 2-5
NS ENGINE COOLING SYSTEM 2
General 65/75/85CF series
2-6 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Component description
3. COMPONENT DESCRIPTION
3.1 DESCRIPTION OF COOLING SYSTEM PRESSURE CAP
ǹ 0011 3-1
NS ENGINE COOLING SYSTEM 2
Component description 65/75/85CF series
Fig. 1 P
M2 00 114
Fig. 2 P
M2 00 115
3-2 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Component description
Fig. 3 P
M2 00 116
Note:
In the event of excessive coolant temperatures,
it is advised not to remove the thermostats, as
an emergency solution. If there are no R
thermostats in the thermostat housing, the
by-pass duct is constantly fully open (fig. 4). As
the resistance in the by-pass duct is lower than
that in the radiator, the largest part of the coolant
will go to the water pump via the by-pass duct
(uncooled). As a consequence, the temperature
will continue to rise.
Fig. 4 P
M2 00 117
ǹ 0011 3-3
NS ENGINE COOLING SYSTEM 2
Component description 65/75/85CF series
3-4 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
ǹ 0011 4-1
NS ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
Inspection, thermostats
1. Inspect the sealing surfaces of the
thermostat housing and the thermostat
housing cover for damage.
2. Inspect whether the thermostats are fully
closed.
3. Place the thermostats in a container filled
with water.
4. Place a thermometer in the container and
heat the water. Check at what temperature
the thermostats open and whether the
thermostats open fully. See “Technical
data”.
4-2 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
1. Bolt 1
2. Waved spring
3. Thermostat housing cover 2
4. Pipe coupling 3
5. Nut 4
6. Sealing ring 5 7 11
6
7. Thermostat 8
8. Sealing ring
9. Bolt
10. Water pump
11. Gasket 9
12. Thermostat housing 10
Note: 12
Too high a coolant temperature is often put
down to a defective thermostat. This is however
seldom the case.
Before the thermostats are replaced, the cooling M2 00 171
system must first be inspected.
Removal, thermostats
1. Partially drain the coolant. See “Draining
and filling the cooling system”.
2. Loosen the attachment nut of the torque rod
between the thermostat housing cover and
the radiator and remove the bracket of the
thermostat housing cover torque rod.
3. Remove the thermostat housing cover
coolant pipe.
4. Remove the attachment bolts and nuts and
remove the thermostat housing cover from
the thermostat housing.
5. Remove the thermostats from the 9
thermostat housing.
6. Never remove sealing rings from
thermostats.
ǹ 0011 5-1
NS ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Installation, thermostats
1. Clean the thermostats.
2. Clean the sealing surfaces of the thermostat
housing and the thermostat housing cover.
3. Fit new sealing rings.
4. Place the thermostats in the housing.
5. Fit the thermostat housing cover.
6. Install the torque rod bracket.
Do not overlook the pipe bracket
attachment.
7. Tighten the torque rod nut.
8. Check the coolant pipe condition and
connect it.
9. Check the pipe clamp and replace as
necessary. Apply a little grease to the
moving section of the pipe clamp and
tighten it well.
10. Top up the cooling system. See “Draining
and filling”.
11. Bring the engine to operating temperature
and check for leaks.
12. Take a test drive and check whether the
cooling system functions properly.
13. Check the coolant fluid level.
5-2 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
1. Bolt 1
2. Waved spring
3. Thermostat housing cover 2
4. Pipe coupling 3
5. Nut 4
6. Sealing ring 5 7 11
6
7. Thermostat 8
8. Sealing ring
9. Bolt
10. Water pump
11. Gasket 9
12. Thermostat housing 10
Removal, thermostat housing 12
1. Partially drain the coolant. See “Draining
and filling the cooling system”.
2. Remove the V-belts of the water pump M2 00 171
pulley.
3. Remove the alternator adjusting bracket
from the thermostat housing.
4. Remove the fuel return pipe bracket from
the thermostat housing.
5. Loosen the attachment nut of the torque rod
between the thermostat housing cover and
the radiator and remove the bracket of the
thermostat housing cover torque rod.
6. Remove the thermostat housing coolant
pipes, the bleed pipe and the coolant pipe.
7. Remove the connector of the temperature
sensor.
8. Remove the common attachment bolt of the
thermostat housing and water pump. This is
the upper attachment bolt on the left-hand
9
side of the water pump. See the arrow in
the illustration.
9. Remove the attachment bolts and take the M2 00 172
thermostat housing with the water pump out
of the cylinder block.
ǹ 0011 5-3
NS ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-4 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
1. Fan clutch
2. Self-locking nut
3. Fan
4. Spacer sleeve
5. Self-locking nut
6. Pulley
Removal, fan (clutch)
1. Remove the fan to fan clutch attachment
nuts.
2. Remove the attachment nuts from the fan
clutch on the pulley.
9
3. Take the fan off the fan clutch.
4. Remove the bracket on the lower
right-hand side of the guide ring and
remove the fan through the opening
created.
Note:
The viscose fan clutch must be stored
vertically, or with the flanged side to the top.
The fan clutch must never be stored with
the flanged side to the bottom.
ǹ 0011 5-5
NS ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Installation, fan(clutch)
1. Check the fan for damage.
2. Clean the abutting surfaces of the parts. It is
important that the abutting surfaces are
clean.
3. Replace the self-locking nuts.
4. Fit the parts in reverse order of removal.
Fit the fan in such a way that the word
“front” shown on the plastic part is to the
front of the fan.
5. Tighten the nuts crosswise.
5-6 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
8.
the specified torque.
Check that the pump impeller does not
9
catch.
9. Fit the pulley to the pump.
10. Fit the new V-belts and adjust the V-belt
tension. See “Setting and inspection,
V-belts”.
ǹ 0011 5-7
NS ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
M2 00 173
5-8 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-9
NS ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Diagram of parts
7 51
50
3
1 49
8
2 5
10 9
12
4 11
6 13
5
16 17 14
18
19
20 21 15
22
27 28
23 22
24
25
29
26
32
34 30
31 33
35
28
28
9
29 29
42 43
37 36
32
38
32
40
44
39 41 45
46
47
48
M2 00 170
5-10 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
1. Filler cap
2. Attachment tape
3. Header tank
4. Pipe clamp
5. Flexible pipe, overflow
6. Switch, coolant level
7. Pipe clamp
8. Connecting pipe, header tank
9. Pipe clamp
10. Pipe clamp
11. Plug
12. Pipe clamp
13. Flexible pipe, cooling system bleeding
14. Knurled ring
15. Bolt
16. Self-locking nut
17. Ring
18. Bush
19. Ring
20. Vibration damper
21. Torque rod
22. Vibration damper
23. Bush
24. Ring
25. Self-locking nut
26. Pipe clamp
27. Flexible pipe, radiator supply
28. Nut
29. Bush
30. Pipe clamp
31. Bracket, guide ring
32. Flange bolt
33. Guide ring
34. Flange bolt
35. Vibration damper
36. Flange nut
37. Gauze screen
38. Charge cooler
39.
40.
Radiator
Sealing edge 9
41. Wind tunnel
42. Bracket, guide ring
43. Bracket, guide ring
44. Pipe clamp
45. Adapter
46. Pipe clamp
47. Flexible pipe, radiator discharge
48. Pipe clamp
49. Pipe clamp
50. Overflow tank
51. Air admission and bleed cap
ǹ 0011 5-11
NS ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Removal, radiator
1. Drain the coolant. See “Draining and filling
the cooling system”.
2. Detach the rubber sealing edge between
the wind tunnel and guide ring.
3. Remove the water pump and the header
tank pipes.
4. Loosen the overflow pipe at the front of the
header tank.
5. Remove the level sensor connector for the
coolant level. This is at the front of the
header tank.
6. Remove the oil filler pipe.
7. Detach the heater pipes from the header
tank.
8. Remove the torque rod between the
thermostat housing and the radiator. To do
this, first remove the bracket on the
thermostat housing.
9. Remove the throttle cable bracket on the air
duct.
10. Disconnect the electrical wiring on the air
duct.
11. Remove the charge cooler air ducts. Plug
the openings.
12. Remove the attachment bolts on opposite
sides of the radiator and carefully remove
the radiator with the charge cooler and
header tank from the vehicle.
5-12 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
Installation, radiator
1. Fit the charge cooler (if removed), the wind
tunnel and the header tank to the radiator.
2. Check the radiator bracket vibration
dampers for cracking. Replace if necessary.
3. Carefully install the radiator in the vehicle.
4. Check the condition of the flexible pipes and
connections of the charge cooler. If in
doubt, replace.
5. Check the pipe clamps and replace as
necessary. Apply a little grease to the
moving section of the pipe clamps.
6. Then fit the parts in reverse order of
removal. Tighten pipes securely.
7. Fill the cooling system. See “Draining and
filling the cooling system”.
8. Bring the engine to operating temperature
and check for air and coolant leaks.
9. Check the coolant fluid level.
ǹ 0011 5-13
NS ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
9 7.
and check for air and coolant leaks.
Check the coolant fluid level.
5-14 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Draining and filling
Coolant
The cooling system should preferably be filled
with a ready-mixed coolant containing antifreeze
and corrosion-inhibiting additives.
If mains water is used an anti-freeze additive
must be introduced if temperatures fall below
+5_C, preferably one based on ethylene glycol
with anti-corrosion additives.
Consult the manufacturer’s instructions for the
correct anti-freeze mixing ratio.
The illustration opposite shows the lowering of o
C 0
Note: M2016
ǹ 0011 6-1
NS ENGINE COOLING SYSTEM 2
Draining and filling 65/75/85CF series
9
9. Close the drain cocks and fit a new sealing
ring to the lubricating oil heat exchanger
drain plug before fitting it.
M2017
6-2 ǹ 0011
2 NS ENGINE COOLING SYSTEM
65/75/85CF series Draining and filling
ǹ 0011 6-3
NS ENGINE COOLING SYSTEM 2
Draining and filling 65/75/85CF series
6-4 ǹ 0011
2 NS ENGINE LUBRICATION SYSTEM
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Inspection, oil section of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Inspection, coolant section of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.3 Inspection, lubricating oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.1 Removal and installation, lubricating oil filter/heat exchanger housing . . . . . 4-2 ...... 0011
4.2 Removal and installation, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.3 Removal and installation, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0011
5. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Draining and filling, engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
10
ǹ 0011 1
NS ENGINE LUBRICATION SYSTEM 2
Contents 65/75/85CF series
10
2 ǹ 0011
2 NS ENGINE LUBRICATION SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
10
ǹ 0011 1-1
NS ENGINE LUBRICATION SYSTEM 2
Safety precautions 65/75/85CF series
10
1-2 ǹ 0011
2 NS ENGINE LUBRICATION SYSTEM
65/75/85CF series General
2. GENERAL
2.1 SYSTEM DESCRIPTION
10
M2 00 122
ǹ 0011 2-1
NS ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
General
The lubricating oil pump is directly driven from
the crankshaft, by a gear. The lubricating oil
pump draws the oil from the oil pan and pumps
it via the lubricating oil heat exchanger and the
lubricating-oil filter to the main oil duct in the
cylinder block.
Pressure limiting valve
In the lubricating oil pump pipe to the lubricating
oil filter, there is a pressure-limiting valve. As the
output of the lubricating oil pump is dependent
on the engine speed, the output would become
so great at higher engine speeds that the
pressure in the lubrication system would
become too high. If the lubricating oil reaches
the set pressure of the pressure limiting valve
before the pressure limiting valve, part of the
lubricating oil will be returned directly to the oil
sump via the pressure limiting valve.
Lubricating oil filter
The oil is cleaned in the disposable oil filter. A
pressure-relief valve fitted in this filter opens if
the pressure in the filter becomes too high as a
result of contamination or cold oil. The oil then
passes through the filter unfiltered.
Lubricating oil heat exchanger
The lubricating oil heat exchanger is connected
to the engine cooling system. The lubricating oil
heat exchanger warms up the lubricating oil in a
“cold” engine and cools it in a “warm” engine. If
the oil pressure in the heat exchanger becomes
too high, a short-circuit valve, fitted in the heat
exchanger, is opened which connects the
lubricating oil supply and discharge passages
with each other.
10
2-2 ǹ 0011
2 NS ENGINE LUBRICATION SYSTEM
65/75/85CF series General
10
timing gear and from there to the oil sump.
ǹ 0011 2-3
NS ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
10
2-4 ǹ 0011
2 NS ENGINE LUBRICATION SYSTEM
65/75/85CF series Inspection and adjustment
M2 00 163
10
ǹ 0011 3-1
NS ENGINE LUBRICATION SYSTEM 2
Inspection and adjustment 65/75/85CF series
Note:
If there are problems with the lubricating oil
pressure, the lubricating oil pressure must
first be measured with a reliable pressure
gauge.
1. Run the engine to operating temperature.
2. Remove the lubricating oil pressure sensor.
3. In the oil pressure sensor connection, install
a pressure gauge (A), special tool A
(DAF no. 0535551).
4. Start the engine and measure the
lubricating oil pressure at the maximum
engine speed and at idling speed.
Compare the data with the readings
specified.
Note:
The oil pressure regulating valve, fitted in
the oil sump, cannot be adjusted.
5. Remove the pressure gauge and fit a new
sealing ring to the lubricating oil pressure
sensor before installing it. M2 00 191
10
3-2 ǹ 0011
2 NS ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
2
5
3 6
7
8
4
11
9
12
10
13
14
15
16
M2 00 162
1.
2.
Sealing plug
Sealing ring
9.
10.
Adapter
Lubricating oil filter
10
3. Gasket 11. Sealing ring
4. Housing 12. Heat exchanger
5. Waved spring 13. Sealing ring
6. Bolt 14. Cover
7. Waved spring 15. O-ring
8. Bolt 16. Banjo bolt
ǹ 0011 4-1
NS ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
4-2 ǹ 0011
2 NS ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
10
ǹ 0011 4-3
NS ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
10 7.
8.
Tighten the bolts to the specified torque.
Fit the dipstick holder and dipstick.
9. Fill the engine with the specified engine oil.
10. Check for leaks.
4-4 ǹ 0011
2 NS ENGINE LUBRICATION SYSTEM
65/75/85CF series Draining and filling
10
ǹ 0011 5-1
NS ENGINE LUBRICATION SYSTEM 2
Draining and filling 65/75/85CF series
10
5-2 ǹ 0011
2 XE ENGINE
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.3 Overview drawing, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
2.4 Overview drawing, timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0011
2.5 Overview drawing, pump housing - camshaft drive . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Inspection and adjustment the valve mechanism bridges . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.2 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0011
3.3 Inspection and adjustment, timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . . 0011
3.4 Inspection and adjustment, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . . 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0011
3.6 Inspection, engine compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . . 0011
3.7 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . . 0011
3.8 Inspection, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . . 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.1 Removal and installation, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.2 Removal and installation, engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 0011
4.3 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 0011
4.4 Removal and installation, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . . 0011
4.5 Removal and installation, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 0011
4.6 Removal and installation, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0011
4.7 Removal and installation, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 . . . . . 0011
4.8 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . . 0011
4.9 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 . . . . . 0011
4.10 Removal and installation, steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 . . . . . 0011
4.11 Removal and installation, starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0011
4.12 Removal and installation, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . . 0011
4.13 Removal and installation, V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . . . 0011
4.14 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 . . . . . 0011
4.15 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 . . . . . 0011
4.16 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . . . . 4-24 . . . . . 0011
4.17 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 . . . . . 0011
4.18 Removal and installation, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 . . . . . 0011
4.19 Removal and installation, up-speed bearing block . . . . . . . . . . . . . . . . . . . . . 4-29 . . . . . 0011
4.20 Removal and installation, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 . . . . . 0011
4.21 Removal and installation, vibration damper hub . . . . . . . . . . . . . . . . . . . . . . . 4-31 . . . . . 0011
4.22 Removal and installation, timing cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 . . . . . 0011
4.23 Removal and installation, timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 . . . . . 0011
4.24 Removal and installation, timing gear wheels . . . . . . . . . . . . . . . . . . . . . . . . .
4.25 Removal and installation, timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-34 . . . . .
4-37 . . . . .
0011
0011
11
4.26 Removal and installation, timing gear case seal . . . . . . . . . . . . . . . . . . . . . . . 4-38 . . . . . 0011
ǹ 0011 1
XE ENGINE 2
Contents 65/75/85CF series
Page Date
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Disassembly and assembly, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.2 Disassembly and assembly, up-speed bearing block . . . . . . . . . . . . . . . . . . . 5-8 . . . . . . 0011
5.3 Disassembly and assembly, V-belt tensioning gear . . . . . . . . . . . . . . . . . . . . 5-10 . . . . . 0011
6. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Cleaning the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
11
2 ǹ 0011
2 XE ENGINE
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
11
ǹ 0011 1-1
XE ENGINE 2
Safety precautions 65/75/85CF series
11
1-2 ǹ 0011
2 XE ENGINE
65/75/85CF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
9 5
8 11
10 6
7
12
M200902
Legend
1. Thermostat housing
2. Water pump
3. Air-conditioning compressor
4. Fan drive
5. Vibration damper
6. Air compressor 11
7. Oil cooler
8. Turbocharger
9. Centrifugal filter
10. Oil-filler pipe
11. Up-speed bearing block
12. Fan drive tensioner
ǹ 0011 2-1
XE ENGINE 2
General 65/75/85CF series
15 10 11 12 13 14
6 7 8
M200901
Legend
1. Steering pump
2. Pump housing
3. Oil filter
4. Engine brake valve
11
5. Reducer valve
6. Fuel lift pump
7. Primer pump
8. Starter motor
9. Alternator
10. Glow plugs
11. Electro-pneumatic valve
12. Engine identification plate
13. Coolant filter
14. Fuel filter
15. Inlet manifold
2-2 ǹ 0011
2 XE ENGINE
65/75/85CF series General
2.2 IDENTIFICATION
Engine number
The engine number is marked on engine block
at the rear left
D000311
4. Engine type
GOVERNED SPEED min -1 OUTPUT kW
5. Indication of country of origin
6. Certificate number* INJECTION TIMING BEFORE
T.D.C.
PUMPSETTING cm 3
7. Pump adjustment* SMOKE LEVEL FREE ACCELERATION m -1
8. Smoke level at maximum engine speed, no
load EINDHOVEN HOLLAND
* Not on XE engines
2 1 8 7
M200678
11
ǹ 0011 2-3
XE ENGINE 2
General 65/75/85CF series
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
Legend
1. Fan drive shaft 7. Bearing ring
11
2. Oil seal 8. O-ring
3. Bearing 9. Bearing
4. Bearing ring 10. Circlip
5. Spacer sleeve 11. Bearing housing
6. Intermediate ring 12. Gear wheel
13. Circlip
2-4 ǹ 0011
2 XE ENGINE
65/75/85CF series General
2 4 5
7
1
6
3
8
9
M200886
Legend
1. Crankshaft gear wheel
2. Camshaft gear wheel
3. Intermediate gear wheel
4. Fan drive
5. Steering pump gear wheel
6. Pump housing camshaft gear wheel
7. Air compressor gear wheel
8. Oil pump intermediate gear wheel
9. Oil pump
11
ǹ 0011 2-5
XE ENGINE 2
General 65/75/85CF series
6 1 2 7 3 5
M200887
Legend
1. Pump housing camshaft gear wheel
2. Timing gear case sealing ring
3. Pump housing
4. Axial locking plate
5. Pump housing - camshaft
6. Attachment bolt, camshaft gear wheel
7. Camshaft bearing bush
11
2-6 ǹ 0011
2 XE ENGINE
65/75/85CF series Inspection and adjustment
i 400162
11
i 400161
ǹ 0011 3-1
XE ENGINE 2
Inspection and adjustment 65/75/85CF series
11
3-2 ǹ 0011
2 XE ENGINE
65/75/85CF series Inspection and adjustment
M200724
M200539
11
ǹ 0011 3-3
XE ENGINE 2
Inspection and adjustment 65/75/85CF series
1 6
5 2
3 4
6 1
2 5
4 3
11
3-4 ǹ 0011
2 XE ENGINE
65/75/85CF series Inspection and adjustment
Inspection, timing
1. Remove the valve cover from cylinders
1-2-3. See “Removal and installation”.
2. Position cylinder 1 at top dead centre (TDC
on the flywheel, cylinder 6 in overlap
position).
Note:
It is important that the bridges of the valve
mechanism are properly adjusted.
3. Set the inlet valve play of the first cylinder to
1 mm.
4. Position the measuring gauge on the inlet
valve bridge of the first cylinder, in such a
way that it measures in an exact vertical
position on the bridge and is capable of
registering an upward and downward
measurement of 5 mm.
5. Use the special tool (DAF no. 1310477) to
turn the crankshaft further in the direction of
rotation until the pistons of cylinders 1 and 6
have returned to the top dead centre (TDC).
M200724
Example
Pre-tension, dial gauge 5,00 mm
Measured tension 4,65 mm
Valve opening 0,35 mm
Note:
If the valve opening matches that in the
technical data, it may be assumed that the
timing gear is properly set.
11
M200551
ǹ 0011 3-5
XE ENGINE 2
Inspection and adjustment 65/75/85CF series
4
2 3
11 1
M200904
3-6 ǹ 0011
2 XE ENGINE
65/75/85CF series Inspection and adjustment
150
M2061
M2091
11
ǹ 0011 3-7
XE ENGINE 2
Inspection and adjustment 65/75/85CF series
M2062
1
11
M200550
3-8 ǹ 0011
2 XE ENGINE
65/75/85CF series Inspection and adjustment
M200550
7 6
D000388
11
ǹ 0011 3-9
XE ENGINE 2
Inspection and adjustment 65/75/85CF series
M200230
11
3-10 ǹ 0011
2 XE ENGINE
65/75/85CF series Inspection and adjustment
ǹ 0011 3-11
XE ENGINE 2
Inspection and adjustment 65/75/85CF series
Note: C
To avoid engine damage it is important that the
glow plugs should be checked periodically.
1. Check the glow plugs for the following
points:
- windings that have worn thin due to
abrasion (A) A B
- filament end broken or worn thin due to
continuous knocking of a loose
insulator (see B)
- broken plug windings (C).
2. Replace all glow plugs if one or more of the
above-mentioned situations occurs.
11 B
M200818
3-12 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
Note:
Because of the large number of vehicle
specifications, it is not feasible to exactly specify
the engine removal and installation procedures
for every vehicle.
This description only includes the most
important points requiring attention.
- Disconnect the earth lead from the battery
terminal.
- Avoid opening fluid systems as much as
possible. If possible, remove and set aside
the engine components.
- When removing the engine, ensure that no
parts or dirt fall into the engine, radiator or
other components. Therefore, plug all
openings.
- Electrical wiring harnesses are easily
damaged. If damaged, they may cause
faults. Make sure these wiring harnesses
are stress-free and clear of moving parts.
- Fit all attachment bolts, tightening them to
the correct tightening torque.
- Do not allow the engine to rest on the oil
sump. Because the oil sump is made of
sheet material, it will be severely damaged
by the engine’s own weight.
11
ǹ 0011 4-1
XE ENGINE 2
Removal and installation 65/75/85CF series
11
12. Remove the engine mounting.
4-2 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
B C D
M201019
11
ǹ 0011 4-3
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-4 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
Note:
In engines with a DEB, the bridges of the inlet
and exhaust valves are not the same.
In engines without a DEB, the bridges of the
3 2
inlet and exhaust valves are the same.
1. Fit the bridges (2-3-4) on the valves.
2. Adjust the bridges (2-3-4). See “Inspection
4
and adjustment”.
3. Tighten the rocker seats (1) by hand.
Note:
Depending on the engine position, some
rocker seats have to be positioned against
the pressure of the valve springs. The
rocker seat will resist this spring pressure
and cannot therefore be positioned
M200560
correctly.
By cranking the camshaft always 1/3 stroke
using the special tool (DAF no. 1310477),
the rocker seats can be tightened according
to the injection sequence 1-5-3-6-2-4.
4. Tighten the attachment bolts to the
specified torque. See “Technical data”.
11
ǹ 0011 4-5
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-6 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
11
ǹ 0011 4-7
XE ENGINE 2
Removal and installation 65/75/85CF series
M2 00 100
4-8 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
11
ǹ 0011 4-9
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-10 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
11
ǹ 0011 4-11
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-12 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
ǹ 0011 4-13
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-14 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
11
ǹ 0011 4-15
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-16 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
11
ǹ 0011 4-17
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-18 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
Removal, alternator
1. Remove both battery leads from the battery
terminals.
2. Remove the electrical connections from the
alternator.
3. Slacken the attachment bolt (3) from the
threaded spindle which is attached to the 5 4
coolant pump. 2
4. Slacken the locknut (5). 3
5. Remove the upper attachment bolts (2) of
the alternator.
6. Remove the lower attachment bolt (1) of the
alternator.
7. Remove the alternator.
Installation, alternator
1. Fit the alternator on its bracket.
1
2. Fit the lower attachment bolt (1) of the
alternator. M200937
11
ǹ 0011 4-19
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-20 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
11
3. Install the fan and tighten the attachment
nuts.
ǹ 0011 4-21
XE ENGINE 2
Removal and installation 65/75/85CF series
Removal, flywheel
1. Remove the gearbox.
2. Remove the clutch release assembly and
the clutch plate.
3. Remove the attachment bolts (1) from the
flywheel.
M200569
11
4-22 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
M2 00 035
11
ǹ 0011 4-23
XE ENGINE 2
Removal and installation 65/75/85CF series
Note:
Each new seal is supplied with a plastic
mounting ring, which can only be used once.
Removal, flywheel housing seal
1. Remove the flywheel.
2. Drill two holes into the seal and, using the
special tool (DAF no. 0484899 and
DAF no. 0694928) pull the seal out of the
flywheel housing.
Installation, flywheel housing seal
1. Thoroughly clean sealing ring recess and
inspect for damage. Even the most minute
damage can cause a leak.
2. Clean the crankshaft flange.
Note:
If a spacer ring has been placed in the seal
chamber, it must be re-fitted.
3. Fit the base plate (A) of special tool 1
(DAF no. 0535598) on the crankshaft 2
flange.
4. Fit a new dry oil seal (the felt ring must not
get greasy) over the plastic mounting ring
supplied (1).
5. Fit the supplied plastic mounting ring (1)
with the oil seal on the crankshaft flange. A
6. Place the thrust washer (B) over the spindle
and gradually tighten the nut (C) until the
resistance increases. B C
7. Remove the thrust washer (B) and take out M2 00 036
the plastic mounting ring (1).
8. Place the thrust washer (B) over the spindle
and gradually tighten the nut (C) until the oil
seal is properly positioned.
9. Remove the special tool.
4-24 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
11
ǹ 0011 4-25
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-26 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
11
ǹ 0011 4-27
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-28 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
9 11 12 13 5 2 3 1 14
M200947
11
ǹ 0011 4-29
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-30 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
9 11 12 13 5 2 3 1 14
M200947
M200770
ǹ 0011 4-31
XE ENGINE 2
Removal and installation 65/75/85CF series
M200771
11
4-32 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
11
ǹ 0011 4-33
XE ENGINE 2
Removal and installation 65/75/85CF series
M200724
4-34 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
M200724
4
2 3
1 11
M200904
ǹ 0011 4-35
XE ENGINE 2
Removal and installation 65/75/85CF series
11
4-36 ǹ 0011
2 XE ENGINE
65/75/85CF series Removal and installation
11
ǹ 0011 4-37
XE ENGINE 2
Removal and installation 65/75/85CF series
M200887
11
4-38 ǹ 0011
2 XE ENGINE
65/75/85CF series Disassembly and assembly
11
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
ǹ 0011 5-1
XE ENGINE 2
Disassembly and assembly 65/75/85CF series
Note:
A mark may have been made on the rear of
the shaft (1) during initial assembly. This
mark may be used to inspect whether the
gear wheel (12) has turned in relation to the
shaft (1). If this is the case, the shaft (1)
and/or the gear wheel (12) is/are rejected.
M200688
11
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
5-2 ǹ 0011
2 XE ENGINE
65/75/85CF series Disassembly and assembly
3 5 6 9
M200679
3
11
1
M200680
ǹ 0011 5-3
XE ENGINE 2
Disassembly and assembly 65/75/85CF series
Note:
The holes in the intermediate ring should be
on the oil seal side.
2. Fit the intermediate ring (6) in the bearing
housing (11).
11
3. Use the special tool (DAF no. 1329383) to
press the bearing ring (7) into the bearing
housing (11) until it abuts the intermediate 7
ring (6).
6
M200681
11
M200682
11
5-4 ǹ 0011
2 XE ENGINE
65/75/85CF series Disassembly and assembly
11
M200683
11
M200684 11
ǹ 0011 5-5
XE ENGINE 2
Disassembly and assembly 65/75/85CF series
Note:
When forcing on the bearing (9), rotate the
bearing housing (11) at least 5 times, so
that the bearings can settle.
8. Using a low pressing force and the special
tool (DAF no. 1329382) press the bearing
(9) onto the shaft (1) until it abuts.
11
M200685
10
8
11
M200686
5-6 ǹ 0011
2 XE ENGINE
65/75/85CF series Disassembly and assembly
M200688
M200932
ǹ 0011 5-7
XE ENGINE 2
Disassembly and assembly 65/75/85CF series
1 2 3 5 7 4 6
M200803
5-8 ǹ 0011
2 XE ENGINE
65/75/85CF series Disassembly and assembly
A 3 7 5 3 B
M200804
ǹ 0011 5-9
XE ENGINE 2
Disassembly and assembly 65/75/85CF series
11
5-10 ǹ 0011
2 XE ENGINE
65/75/85CF series Cleaning
6. CLEANING
6.1 CLEANING THE ENGINE
Note:
It is advisable to clean the engine with a
high-pressure cleaner before starting
maintenance or service operations. A clean
engine makes the mechanic’s work easier, and
enables him to notice any defects at an early
stage.
Before cleaning the engine, check for any leaks.
If the engine is cleaned with a high-pressure
cleaner, it must be used with care. It is also
important to observe the following points:
- When cleaning the universal joint on the
steering box, the spider seals may be
forced open by the high-pressure jet of
water, so that the grease behind them is
flushed away. As a result, the spider may
get stuck, so that the steering mechanism
will jam.
- A bleed screw is fitted to the power steering
fluid reservoir of the steering system. Water
may enter the tank through this valve,
causing damage to the steering gear.
- When cleaning the radiator/intercooler
element, be careful not to damage the fins.
- Do not direct the high-pressure cleaner jet
too long at the air-conditioning system
condenser. As a result of the high
temperature, the pressure in the system will
become excessive, which may cause
damage to the system.
- Ensure that no water can enter the gearbox
via the breathers.
11
ǹ 0011 6-1
XE ENGINE 2
Cleaning 65/75/85CF series
11
6-2 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.2 Description, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0011
3. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Description, cooling system pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Description, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0011
3.3 Description, coolant filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
4. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.1 Pressure-testing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.2 Inspection, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
4.3 Inspection, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.4 Inspection, water pump radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0011
5. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.1 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.2 Removal and installation, coolant filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 ...... 0011
5.3 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ...... 0011
5.4 Removal and installation, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ...... 0011
5.5 Removal and installation, header tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 ...... 0011
5.6 Removal and installation, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ...... 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling/bleeding, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
12
ǹ 0011 1
XE ENGINE COOLING SYSTEM 2
Contents 65/75/85CF series
12
2 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
12
ǹ 0011 1-1
XE ENGINE COOLING SYSTEM 2
Safety precautions 65/75/85CF series
12
1-2 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
9 10
1
2
3
8
5 7
6
4
M201020 M201021
Legend
1. Thermostat housing
2. Water pump
3. Fan drive
4. Water-cooled air compressor
5. Water pipe
6. Oil cooler
7. Up-speed bearing block
8. Fan drive tensioner
9. Coolant pipe
10. Coolant filter
12
ǹ 0011 2-1
XE ENGINE COOLING SYSTEM 2
General 65/75/85CF series
12
2-2 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series General
a
b
a
b
12
M200905
ǹ 0011 2-3
XE ENGINE COOLING SYSTEM 2
General 65/75/85CF series
12
2-4 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series General
a
b
a
b
12
M200906
ǹ 0011 2-5
XE ENGINE COOLING SYSTEM 2
General 65/75/85CF series
12
2-6 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Component description
3. COMPONENT DESCRIPTION
3.1 DESCRIPTION, COOLING SYSTEM PRESSURE CAP
12
ǹ 0011 3-1
XE ENGINE COOLING SYSTEM 2
Component description 65/75/85CF series
12
A M200547
3-2 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Component description
M200546
12
ǹ 0011 3-3
XE ENGINE COOLING SYSTEM 2
Component description 65/75/85CF series
12
3-4 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
12
ǹ 0011 4-1
XE ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
M200594
M200513
12
4-2 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
12
ǹ 0011 4-3
XE ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
900
6. Allow the fan drive flange to run at a speed
of 1000 rpm.
Then use an optical rev counter to
determine the difference in speed of the fan 100
in relation to the drive flange. The speeds
will differ if there is any slip in the viscous
clutch. When the clutch is fully engaged,
430
the slip must not be more than 10%. If it is
more than 10%, the viscous fan clutch must
be replaced.
700
M200440
12
4-4 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
M200595
12
ǹ 0011 4-5
XE ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
12
4-6 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
12
ǹ 0011 5-1
XE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
12
5-2 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
12
ǹ 0011 5-3
XE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Removal, thermostat
1. Drain the coolant. See “Draining and filling”.
2. Remove the water pipe between the
thermostat housing and the radiator.
3. Remove the attachment bolts from the
thermostat housing.
4. Remove the thermostat housing and the
connecting piece from the water pump. A
5. Remove the O-ring (A) from the thermostat C B
housing.
6. Remove the thermostat. C B
Removal, thermostat sealing ring
A
1. Remove the oil seal (B) in the thermostat
housing using a commercially available
internal puller.
Removal, thermostat seat
1. Remove the thermostat seat (C) at the
bottom of the thermostat housing using a
commercially available internal puller.
M200594
12
5-4 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
12
ǹ 0011 5-5
XE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
12
5-6 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
12
ǹ 0011 5-7
XE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Note:
The removal and installation procedure for the
radiator allows for the presence of an
air-conditioning unit. If such a unit is not present,
the sections concerned can be skipped.
Removal, radiator
1. Disconnect the earth lead from the battery
terminal.
2. Drain the coolant. See “Draining and filling”.
3. Remove the front engine encapsulation.
4. Remove the engine encapsulation under
the cab.
5. Remove the bolts from the guide ring
brackets, and remove the guide ring.
6. Remove the guide strip at the front of the
intercooler.
7. Remove the dip stick holder of the
intercooler and put it aside.
8. Remove the header tank.
9. Remove the water pipes to the radiator.
10. Remove the attachment bolts from the
air-conditioning condenser and pull the
condenser forwards.
11. Disconnect the other air-conditioning pipes
from the intercooler.
12. Remove the wire mesh underneath the
intercooler.
13. Remove the air-conditioning dryer
underneath the intercooler.
14. Remove the left-hand connector pipe from
the inlet manifold to the intercooler.
12
5-8 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
12
ǹ 0011 5-9
XE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
Installation, radiator
1. Fit the entire radiator, intercooler, and wind
tunnel in the chassis. Tighten the
attachment nuts to the specified torque.
See “Technical data”.
2. Slide the oil filler pipe onto the radiator and
fit the attachment bolt.
3. Place the intercooler in its position and
hand-tighten with two attachment bolts.
4. Install the torque rod from the radiator to
the engine lifting eye.
5. Fit the air-conditioning compressor and its
pipes over the radiator.
6. Fit the air-conditioning compressor unit on
the engine bracket.
7. Fit the guide ring brackets and the guide
ring.
8. Fit the air-conditioning dryer underneath the
intercooler.
9. Fit the wire mesh underneath the
intercooler.
10. Fit the air-conditioning condenser.
11. Fit the guide strip at the front of the
intercooler. Tighten the attachment bolts of
the intercooler.
12. Insert the dipstick holder.
13. Fit the air inlet pipes between the manifolds
and intercooler.
14. Fit the expansion reservoir.
15. Fit the engine encapsulation under the cab.
16. Fit the front engine encapsulation.
17. Fit the earth lead to the battery terminal.
18. Fill the cooling system. See “Draining and
filling”.
19. Run the engine and check that all
connections are sealed properly.
12
5-10 ǹ 0011
2 XE ENGINE COOLING SYSTEM
65/75/85CF series Draining and filling
A
B
M200556
12
ǹ 0011 6-1
XE ENGINE COOLING SYSTEM 2
Draining and filling 65/75/85CF series
Note:
Combustion will start after approximately
one minute.
6. Allow the cab heater to operate for
approximately 15 minutes.
12
6-2 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Description, lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Inspection, lubricating oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Checking the lubricating-oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.3 Pressure testing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.1 Removal and installation, lubricating oil filter housing . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.2 Removal and installation, oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
4.3 Removal and installation, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.4 Removal and installation, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0011
4.5 Removal and installation, centrifugal lubricating oil filter . . . . . . . . . . . . . . . . 4-5 ...... 0011
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Disassembly and assembly, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling, lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
13
ǹ 0011 1
XE ENGINE LUBRICATION SYSTEM 2
Contents 65/75/85CF series
13
2 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel lubricating oil.
So avoid inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
13
ǹ 0011 1-1
XE ENGINE LUBRICATION SYSTEM 2
Safety precautions 65/75/85CF series
13
1-2 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series General
2. GENERAL
2.1 DESCRIPTION, LUBRICATING OIL SYSTEM
13
M200907
ǹ 0011 2-1
XE ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
General
The lubricating oil pump is directly driven from
the crankshaft, by a gear. The lubricating oil
pump draws the lubricating oil from the oil sump,
and pumps it via the oil cooler and the
lubricating oil filter to the main oil duct in the
cylinder block. From the main oil duct, the
lubricating-oil is further distributed to the various
components requiring lubrication.
Oil cooler
The oil cooler is connected to the cooling
system. The oil cooler warms up the lubricating
oil in a “cold” engine and cools it in a “warm”
engine.
Parallel to the oil cooler, a short-circuit valve has
been installed. If the oil cooler is blocked, the
short-circuit valve will open if a certain pressure
has built up. In this case, uncooled lubricating oil
enters the lubricating system.
A centrifugal filter may be included parallel to
the lubricating oil system. In this case,
lubricating-oil will flow from the oil cooler to the
centrifugal filter. The lubricating-oil is additionally
filtered in the centrifugal filter in view of vehicles
having longer maintenance intervals.
Pressure limiting valve
A pressure limiting valve is installed in the
lubricating system after the oil cooler. When the
pressure set for the pressure limiting valve has
been reached, the valve opens and allows
excess cooled lubricating oil to flow to the oil
sump.
Lubricating oil filter
The oil is cleaned in the disposable lubricating
oil filter. A pressure limiting valve fitted in this
filter opens if the pressure in the filter becomes
too high as a result of contamination or cold
lubricating oil.
The lubricating oil then passes through the filter
unfiltered.
Main lubricating oil duct
From the main lubricating oil duct, lubricating oil
is supplied to the crankshaft main bearings and
via a lubricating oil duct in the crankshaft also to
the connection-rod bearings.
From the main lubricating oil duct, lubricating oil
is pumped through the first camshaft bearing
into the hollow camshaft.
From the lubricating oil duct in the camshaft,
lubricating oil is supplied to the other camshaft
bearings.
13
2-2 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series General
Cylinder head
From the second and fifth camshaft bearings, a
lubricating oil duct passes through the cylinder
heads to the second and fifth rocker seats.
Depending on the model, the other rocker
shafts, rockers, and bridges receive lubrication
from the DEB or a lubricating-oil strip.
Timing gear
From the lubricating oil duct in the first
crankshaft main bearing, a lubricating oil duct
leads to the hollow hub of the intermediate gear
wheel. The lubricating oil passes through the
hollow hub onto the intermediate gear wheel.
The other gear wheels receive lubricating oil
from the intermediate gear wheel.
The fan drive is lubricated through a bore hole in
the cylinder block and a lubricating oil duct in the
timing gear case.
Piston and gudgeon pin
The pistons and the upper connecting-rod
bearings are lubricated by means of lubricating
oil nozzles linked to the main lubricating oil duct.
In addition to lubricating, this oil has an
important cooling function. The pistons of the
XE390C are equipped for this purpose with
extra lubricating oil ducts to achieve better
cooling.
13
ǹ 0011 2-3
XE ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
M200908
13
2-4 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series Inspection and adjustment
Note:
A lubricating oil consumption test is only useful
after the engine has been run in (approx.
20,000 km).
1. First carefully check the engine for
lubricating oil leaks. Clean the engine
before starting the test.
2. Run the engine to operating temperature.
3. Place the vehicle on a level surface.
4. Remove the lubricating oil drain plug and
drain the oil for 15 minutes. Collect the
lubricating oil in a clean container.
5. Measure the exact amount of lubricating oil
drained.
6. Refill the oil sump with the drained
lubricating oil. If necessary, top up the
amount of lubricating oil to the specified
level.
7. Before starting the test, write down the
exact amount of lubricating oil (A) in the oil
sump. Write down the total distance
covered (C) by the vehicle.
8. Drive between 500 and 1,000 km under
similar conditions as those in which the
vehicle is normally used.
9. Immediately after the test run, place the
vehicle on a level surface and write down
the distance covered (D).
10. Remove the lubricating oil drain plug and
drain the oil for 15 minutes. Collect the
lubricating oil in a clean container.
11. Measure the exact amount of lubricating oil
drained (B).
12. Pour the lubricating oil into the oil sump. If
necessary, top up the amount of lubricating
oil to the specified level.
13. Calculate the lubricating oil consumption
using the following formula.
13
ǹ 0011 3-1
XE ENGINE LUBRICATION SYSTEM 2
Inspection and adjustment 65/75/85CF series
D -- C
Lubricating oil consumption = = km/l
A -- B
1300
1250
1200
km / L
1100
1000
1000
900
800
800
700
600
600 550
500
500 450
400
400 350
300
300 250
200
100
0
0 25 100 200 300 400 500 600 700 800 900 1000
x1000 km
M200557
13
3-2 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series Inspection and adjustment
Note:
The oil pressure control valve, mounted in
the oil sump, cannot be adjusted.
5. Stop the engine and remove the lubricating
oil pressure gauge. Fit a new oil seal to the
M200889
oil pressure sensor.
13
ǹ 0011 3-3
XE ENGINE LUBRICATION SYSTEM 2
Inspection and adjustment 65/75/85CF series
Note:
If the cooling element leaks, it must be
replaced.
6. Assemble the oil cooler. See “Disassembly
and assembly”.
7. Fit the oil cooler. See “Removal and
installation”.
M200598
13
3-4 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
M200599
13
ǹ 0011 4-1
XE ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
13
4-2 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
13
ǹ 0011 4-3
XE ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
13
4-4 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
13
ǹ 0011 4-5
XE ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
13
4-6 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series Disassembly and assembly
Note:
Gear wheels must be replaced as a set.
Note:
The gear wheels are marked. The gear
wheels with the marks must be fitted as
shown.
2. Fit the gear wheels in the lubricating oil
pump housing.
3. Remove the rear section of the lubricating
oil pump.
M200344
4. Fit the attachment bolts of the lubricating oil
pump sections. Tighten the attachment
bolts to the specified torque. See “Technical
data”.
5. Check that the lubricating oil pump operates
smoothly and is not getting stuck anywhere.
6. Fit the intermediate gear wheel with the hub
on the front plate.
13
ǹ 0011 5-1
XE ENGINE LUBRICATION SYSTEM 2
Disassembly and assembly 65/75/85CF series
13
5-2 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
65/75/85CF series Draining and filling
13
ǹ 0011 6-1
XE ENGINE LUBRICATION SYSTEM 2
Draining and filling 65/75/85CF series
13
6-2 ǹ 0011
2 PE ENGINE
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.3 Overview drawing of timing-gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Inspection and adjustment the valve mechanism bridges . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.2 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0011
3.3 Inspection and adjustment the timing-gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . . 0011
3.4 Inspection and adjustment, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . . 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . . 0011
3.6 Inspection, engine compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . . 0011
3.7 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0011
3.8 Inspection, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . . 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.1 Removal and installation, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.2 Removal and installation, engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 0011
4.3 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 0011
4.4 Removal and installation, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . . 0011
4.5 Removal and installation, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . . 0011
4.6 Removal and installation, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . . 0011
4.7 Removal and installation, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0011
4.8 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 . . . . . 0011
4.9 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 . . . . . 0011
4.10 Removal and installation, steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 . . . . . 0011
4.11 Removal and installation, starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0011
4.12 Removal and installation, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . . 0011
4.13 Removal and installation, V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . . . 0011
4.14 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 . . . . . 0011
4.15 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 . . . . . 0011
4.16 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . . . . 4-24 . . . . . 0011
4.17 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 . . . . . 0011
4.18 Removal and installation, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 . . . . . 0011
4.19 Removal and installation, timing cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 . . . . . 0011
4.20 Removal and installation, timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 . . . . . 0011
4.21 Removal and installation, timing gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 . . . . . 0011
4.22 Removal and installation, timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 . . . . . 0011
4.23 Removal and installation, timing gear case seal . . . . . . . . . . . . . . . . . . . . . . . 4-37 . . . . . 0011
4.24 Removal and installation, vibration damper bearing race . . . . . . . . . . . . . . . . 4-38 . . . . . 0011
5. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Cleaning the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
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PE ENGINE 2
Contents 65/75/85CF series
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2 PE ENGINE
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
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PE ENGINE 2
Safety precautions 65/75/85CF series
14
1-2 ǹ 0011
2 PE ENGINE
65/75/85CF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
1 2 3 4 5 6
7 8 9 10
m200837
Legend
1. Centrifugal filter
2. Turbocharger
3. Oil-filler pipe
4. Air-conditioning compressor
5. Water pump
6. Thermostat housing
7. Oil cooler
8. Air compressor
9. Tensioning roller, air-conditioning
14
compressor
10. Vibration damper
ǹ 0011 2-1
PE ENGINE 2
General 65/75/85CF series
1 2 3 4 5 6 7
8 9 10 11 13 12
m200838
Legend
1. Alternator
2. Glow plugs
3. Steering pump
4. Engine identification plate
5. Primer pump with fuel coarse filter
6. Fuel filter
7. Engine PTO
8. Engine brake valve
9. Relay, glow-filament
10. Oil filter
11. Pump housing
12. Starter motor
13. Fuel lift pump
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2-2 ǹ 0011
2 PE ENGINE
65/75/85CF series General
2.2 IDENTIFICATION
Engine number
The engine number is marked on the cylinder
block at front right-hand side (compressor side).
M200748
m200839
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ǹ 0011 2-3
PE ENGINE 2
General 65/75/85CF series
Legend 6 2 4
1. Crankshaft gear wheel
2. Camshaft gear wheel
3. Intermediate gear wheel
4. Steering pump gear wheel
5. Pump housing camshaft gear wheel
6. Air compressor gear wheel
7. Oil pump intermediate gear wheel
7 1 3 5
M200744
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2 PE ENGINE
65/75/85CF series Inspection and adjustment
i 400301
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PE ENGINE 2
Inspection and adjustment 65/75/85CF series
M200754
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3-2 ǹ 0011
2 PE ENGINE
65/75/85CF series Inspection and adjustment
Cylinder in Cylinder to be
overlap position adjusted
1 6
5 2
3 4
6 1
2 5
4 3
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ǹ 0011 3-3
PE ENGINE 2
Inspection and adjustment 65/75/85CF series
Inspection, timing
1. Remove the valve cover from cylinders
1-2-3. See “Removal and installation”.
2. Position cylinder 1 at top dead centre
(TDC on the flywheel, cylinder 6 in overlap
position).
Note:
It is important that the bridges of the valve
mechanism are properly adjusted.
3. Set the inlet valve play of the first cylinder to
1 mm.
4. Position the measuring gauge on the inlet
valve bridge of the first cylinder, in such a
way that it measures in an exact vertical
position on the bridge and is capable of
registering an upward and downward
measurement of 5 mm.
5. Use the special tool (DAF No. 1310477) to
turn the crankshaft further in the direction of
rotation until the pistons of cylinders 1 and 6
have returned to the top dead centre (TDC).
6. Read the dial gauge and compare the
measured value. See “Technical data”.
Example
Pre-tension, dial gauge 5.00 mm
Measured tension 4.65 mm
Valve opening 0.35 mm
Note:
If the valve opening matches that in the
technical data, it may be assumed that the
timing gear is properly set.
M200551
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3-4 ǹ 0011
2 PE ENGINE
65/75/85CF series Inspection and adjustment
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ǹ 0011 3-5
PE ENGINE 2
Inspection and adjustment 65/75/85CF series
150
M2092
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3-6 ǹ 0011
2 PE ENGINE
65/75/85CF series Inspection and adjustment
M2062
M200885
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ǹ 0011 3-7
PE ENGINE 2
Inspection and adjustment 65/75/85CF series
M200230
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3-8 ǹ 0011
2 PE ENGINE
65/75/85CF series Inspection and adjustment
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PE ENGINE 2
Inspection and adjustment 65/75/85CF series
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3-10 ǹ 0011
2 PE ENGINE
65/75/85CF series Inspection and adjustment
Note: C
To avoid engine damage it is important that the
glow plugs should be checked periodically.
1. Check the glow plugs for the following
points:
- windings that have worn thin due to
abrasion (A) A B
- filament end broken or worn thin due to
continuous knocking of a loose
insulator (see B)
- broken plug windings (C).
2. Replace all glow plugs if one or more of the
above-mentioned situations occurs.
M200818
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PE ENGINE 2
Inspection and adjustment 65/75/85CF series
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3-12 ǹ 0011
2 PE ENGINE
65/75/85CF series Removal and installation
Note:
Because of the large number of vehicle
specifications, it is not feasible to exactly
specify the engine removal and installation
procedures for every vehicle.
This description only includes the most
important points requiring attention.
- Disconnect the earth lead from the battery
terminal.
- Avoid opening fluid systems as much as
possible. If possible, remove and set aside
the engine components.
- When removing the engine, ensure that no
parts or dirt fall into the engine, radiator or
other components. Therefore, plug all
openings.
- Electrical wiring harnesses are easily
damaged. If damaged, they may cause
faults. Make sure these wiring harnesses
are stress-free and clear of moving parts.
- Tighten all attachment bolts to the correct
tightening torque.
- Do not allow the engine to rest on the oil
sump. Because the oil sump is made of
sheet material, it will be severely damaged
by the engine’s own weight.
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PE ENGINE 2
Removal and installation 65/75/85CF series
14
4-2 ǹ 0011
2 PE ENGINE
65/75/85CF series Removal and installation
14
ǹ 0011 4-3
PE ENGINE 2
Removal and installation 65/75/85CF series
14
4-4 ǹ 0011
2 PE ENGINE
65/75/85CF series Removal and installation
M200754
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ǹ 0011 4-5
PE ENGINE 2
Removal and installation 65/75/85CF series
14
4-6 ǹ 0011
2 PE ENGINE
65/75/85CF series Removal and installation
M2 00 100
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ǹ 0011 4-7
PE ENGINE 2
Removal and installation 65/75/85CF series
14
4-8 ǹ 0011
2 PE ENGINE
65/75/85CF series Removal and installation
14
ǹ 0011 4-9
PE ENGINE 2
Removal and installation 65/75/85CF series
14
4-10 ǹ 0011
2 PE ENGINE
65/75/85CF series Removal and installation
Note:
If the vehicle has been fitted with two glow +
filaments upon ex-works delivery, you must not
add two glow filaments yourself. The feeder
cable between the starter motor, glow relay and
glow plugs on these vehicles is inadequate for
four glow plugs.
Removal, glow plugs
1. Disconnect the earth lead from the battery
terminal.
M2 00 154
2. Remove the wiring and connection strip
from the glow plugs.
3. Remove the glow plugs.
4. Inspect the glow plugs for damage. See
“Inspection and adjustment”.
Installation, glow plugs
1. Fit the glow plugs and tighten the
attachment nut to the specified torque. See
“Technical data”.
2. Connect the wiring and the connection strip.
Make sure that the insulators are fitted in
the correct place.
3. Clean the contact surface of the glow plug
earth lead to ensure that it is properly
earthed on the inlet manifold.
4. Fit the earth lead to the battery terminal.
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ǹ 0011 4-11
PE ENGINE 2
Removal and installation 65/75/85CF series
14
4-12 ǹ 0011
2 PE ENGINE
65/75/85CF series Removal and installation
14
ǹ 0011 4-13
PE ENGINE 2
Removal and installation 65/75/85CF series
14
4-14 ǹ 0011
2 PE ENGINE
65/75/85CF series Removal and installation
14
ǹ 0011 4-15
PE ENGINE 2
Removal and installation 65/75/85CF series
14
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2 PE ENGINE
65/75/85CF series Removal and installation
14
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PE ENGINE 2
Removal and installation 65/75/85CF series
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2 PE ENGINE
65/75/85CF series Removal and installation
Removal, alternator 5
1. Remove both battery leads from the battery 6
terminals. 4
2. Remove the electrical connections from the 3
alternator. 2
3. Slacken the attachment bolt (3) from the
threaded spindle which is attached to the
coolant pump.
4. Slacken the alternator bracket attachment
bolts (1) and (2).
5. Loosen the locknut (4) and bolt (6) of the
coupling.
6. Shift the alternator by means of the nut (5) 1
in the direction of the cylinder block and
M200753
slacken the V-belt.
7. Remove the attachment bolts (1) and (2)
and remove the alternator.
Installation, alternator
1. Fit the alternator on its bracket.
2. Fit the alternator attachment bolts (1) and
(2).
3. Install the V-belt and check the V-belt
tension. See “Inspection and adjustment”.
4. Tighten the attachment bolt (3) of the
threaded spindle which is attached to the
coolant pump.
5. Fit the electrical connections of the
alternator.
6. Reconnect both leads to the battery
terminals.
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ǹ 0011 4-19
PE ENGINE 2
Removal and installation 65/75/85CF series
1
M200753
M2096
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2 PE ENGINE
65/75/85CF series Removal and installation
M200885
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ǹ 0011 4-21
PE ENGINE 2
Removal and installation 65/75/85CF series
Removal, flywheel
1. Remove the gearbox.
2. Remove the clutch release assembly and
the clutch plate.
3. Remove the attachment bolts (1) from the
flywheel.
4. Use two threaded bolts to remove the
flywheel from the dowel pin.
5. Remove the flywheel.
1
M200569
Installation, flywheel
1. Clean the flywheel housing.
2. Clean the crankshaft flange, the dowel pins
and the attachment bolts. Remove the
locking compound from the threaded holes.
3. Clean the back of the flywheel and fit the
flywheel.
4. Fit the attachment bolts and tighten them to
the specified torque. See “Technical data”.
5. Fit the clutch plate and the clutch release
assembly.
6. Fit the gearbox.
M200570
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2 PE ENGINE
65/75/85CF series Removal and installation
M2 00 035
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ǹ 0011 4-23
PE ENGINE 2
Removal and installation 65/75/85CF series
Note:
Each new seal is equipped with a plastic
mounting ring, which can only be used once.
Removal, flywheel housing seal
1. Remove the flywheel.
2. Drill two holes into the seal and, using the
special tool (DAF no. 0484899 and
DAF no. 0694928) pull the seal out of the
flywheel housing.
Installation, flywheel housing seal
1. Thoroughly clean sealing ring recess and
inspect for damage. Even the most minute
damage can cause a leak.
2. Clean the crankshaft flange.
Note:
If the oil seal has scored the crankshaft
flange running surface, a spacer ring should
be fitted in the oil seal recess before a new
oil seal is installed.
3. Lightly grease the inner rim of the oil seal.
4. Fit the base plate (A) of special tool 1
(DAF no. 1329402) on the crankshaft 2
flange.
5. Fit the supplied plastic mounting ring (1) on
the crankshaft flange.
6. Then place the new sealing ring (2) over the
mounting ring and remove the mounting
ring. A
7. Place the thrust washer (B) over the spindle
and gradually tighten the nut (C) until the oil
seal is properly positioned. B C
8. Remove the special tool. M2 00 036
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65/75/85CF series Removal and installation
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PE ENGINE 2
Removal and installation 65/75/85CF series
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2 PE ENGINE
65/75/85CF series Removal and installation
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PE ENGINE 2
Removal and installation 65/75/85CF series
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4-28 ǹ 0011
2 PE ENGINE
65/75/85CF series Removal and installation
A
B
m200830
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PE ENGINE 2
Removal and installation 65/75/85CF series
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65/75/85CF series Removal and installation
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PE ENGINE 2
Removal and installation 65/75/85CF series
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65/75/85CF series Removal and installation
D B C E
M200840
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Removal and installation 65/75/85CF series
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65/75/85CF series Removal and installation
14
ǹ 0011 4-35
PE ENGINE 2
Removal and installation 65/75/85CF series
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65/75/85CF series Removal and installation
7
M200841
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Removal and installation 65/75/85CF series
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2 PE ENGINE
65/75/85CF series Cleaning
5. CLEANING
5.1 CLEANING THE ENGINE
Note:
It is advisable to clean the engine with a
high-pressure cleaner before starting
maintenance or service operations. A clean
engine makes the mechanic’s work easier, and
enables him to notice any defects at an early
stage.
Before cleaning the engine, check for any leaks.
If the engine is cleaned with a high-pressure
cleaner, it must be used with care. It is also
important to observe the following points:
- When cleaning the universal joint on the
steering box, the spider seals may be
forced open by the high-pressure jet of
water, so that the grease behind them is
flushed away. As a result, the spider may
get stuck, so that the steering will jam.
- A bleed screw is fitted to the power steering
fluid reservoir of the steering system. Water
may enter the tank through this valve,
causing damage to the steering gear.
- When cleaning the radiator/intercooler
element, be careful not to damage the fins.
- Do not direct the high-pressure cleaner jet
too long at the air-conditioning system
condenser. As a result of the high
temperature, the pressure in the system will
become excessive, which may cause
damage to the system.
- Ensure that no water can enter the gearbox
via the breathers.
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Cleaning 65/75/85CF series
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2 PE ENGINE COOLING SYSTEM
65/75/85CF series Contents
CONTENTS
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page Date
1-1 . . . . . . 0011
15
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.2 Cooling system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0011
3. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Description of cooling system pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.2 Description of the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . . 0011
4. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.1 Pressure testing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.2 Inspection, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
4.3 Inspection, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.4 Radial water pump play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0011
5. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.1 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.2 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 ...... 0011
5.3 Removal and installation, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 ...... 0011
5.4 Removal and installation, header tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 ...... 0011
5.5 Removal and installation, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ...... 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling/bleeding, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
ǹ 0011 1
PE ENGINE COOLING SYSTEM 2
Contents 65/75/85CF series
15
2 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
15
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
ǹ 0011 1-1
PE ENGINE COOLING SYSTEM 2
Safety precautions 65/75/85CF series
15
1-2 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
15
6 3 2 1
7 5 4
m200842
Legend
1. Thermostat housing
2. Water pump
3. Water-cooled air compressor
4. Water pipe
5. Oil cooler
6. Coolant pipe
7. Drain tap
ǹ 0011 2-1
PE ENGINE COOLING SYSTEM 2
General 65/75/85CF series
2-2 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series General
ǹ 0011 2-3
PE ENGINE COOLING SYSTEM 2
General 65/75/85CF series
15
2-4 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Component description
3. COMPONENT DESCRIPTION
3.1 DESCRIPTION OF COOLING SYSTEM PRESSURE CAP
15
The pressure cap (A) on the auxiliary header
tank, behind the grille, is attached on the header
tank by means of a screw thread. To fill the
cooling system, remove this pressure cap or the
A
filler cap at the front of the header tank.
The pressure cap has two valves. Normally, both
valves are closed.
M200180
ǹ 0011 3-1
PE ENGINE COOLING SYSTEM 2
Component description 65/75/85CF series
M200739
M200740
M200741
3-2 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Component description
ǹ 0011 3-3
PE ENGINE COOLING SYSTEM 2
Component description 65/75/85CF series
15
3-4 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
ǹ 0011 4-1
PE ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
M200513
4-2 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
ǹ 0011 4-3
PE ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
900
3. Take a sheet of cardboard with a 100 mm
hole, as shown in the diagram opposite, and
place it in front of the radiator, so that the
hole is in front of the viscous coupling. 100
4. Check that the gearbox is in neutral.
430
5. Bring the cooling system to operating
temperature.
6. Allow the fan drive flange to run at a speed
of 1000 rpm.
7. Then use an optical rev counter to 700
M200440
determine the difference in speed of the fan
in relation to the drive flange. The speeds
will differ if there is any slip in the viscous
clutch. When the clutch is fully engaged, the
slip must not be more than 10%. If it is more
than 10%, the viscous fan clutch must be
replaced.
4-4 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Inspection and adjustment
M200595
ǹ 0011 4-5
PE ENGINE COOLING SYSTEM 2
Inspection and adjustment 65/75/85CF series
15
4-6 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-1
PE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-2 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
Removal, thermostat
1. Drain the coolant. See “Draining and filling”.
15
2. Remove the water pipe between the
thermostat housing and the radiator.
3. Remove the attachment bolts from the
thermostat housing.
4. Remove the thermostat housing and the
C
B
connecting piece from the water pump. A
5. Remove the O-ring (A) from the thermostat
housing.
6. Remove the thermostat.
M200742
ǹ 0011 5-3
PE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-4 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-5
PE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-6 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-7
PE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
15 Note:
The removal and installation procedure for the
radiator allows for the presence of an
air-conditioning unit. If such a unit is not present,
the sections concerned can be skipped.
Removal, radiator
1. Disconnect the earth lead from the battery
terminal.
2. Drain the coolant. See “Draining and filling”.
3. Remove the engine encapsulation under
the cab.
4. Remove the bolts from the guide ring
brackets, and remove the guide ring.
5. Remove the guide strip at the front of the
intercooler.
6. Remove the dip stick holder of the
intercooler and put it aside.
7. Remove the header tank.
8. Remove the water pipes to the radiator.
9. Remove the attachment bolts from the
air-conditioning condenser and pull the
condenser forwards.
10. Disconnect the other air-conditioning pipes
from the intercooler.
11. Remove the wire mesh underneath the
intercooler.
12. Remove the air-conditioning dryer
underneath the intercooler.
5-8 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 5-9
PE ENGINE COOLING SYSTEM 2
Removal and installation 65/75/85CF series
5-10 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Draining and filling
M2097
ǹ 0011 6-1
PE ENGINE COOLING SYSTEM 2
Draining and filling 65/75/85CF series
M2077
6-2 ǹ 0011
2 PE ENGINE COOLING SYSTEM
65/75/85CF series Draining and filling
2.
the cab to the “warmest” setting.
Fill the cooling system with the specified
15
coolant.
3. Run the engine for several minutes.
4. Note:
The cooling system is bled automatically. B
5. Ensure that the air bleed pipe from the
thermostat housing to the header tank is not
kinked or pinched off.
6. Check the coolant level, and if necessary M200181
top up with coolant.
If the vehicle is equipped with a water/air cab
heater
1. Run the engine at idling speed.
2. Switch on the cab heater, using the rocker
switch on the dashboard.
3. Turn the heater temperature control knob in
the cab to the “warmest” setting.
4. Switch on the heater fan.
5. Set the rocker switch on the thermostat in
the cab to position 1.
Note:
Combustion will start after approximately
one minute.
6. Allow the cab heater to operate for
approximately 15 minutes.
ǹ 0011 6-3
PE ENGINE COOLING SYSTEM 2
Draining and filling 65/75/85CF series
15
6-4 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series Contents
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
16
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Lubricating oil system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Inspection, lubricating oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Inspection, lubricating oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.3 Pressure testing the lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.1 Removal and installation, lubricating oil filter housing . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.2 Removal and installation, lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
4.3 Removal and installation, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.4 Removal and installation, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0011
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Disassembly and assembly, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling, lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
ǹ 0011 1
PE ENGINE LUBRICATION SYSTEM 2
Contents 65/75/85CF series
16
2 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area.
Make sure exhaust fumes are properly
extracted.
Remain at a safe distance from rotating and/or
moving components.
16
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard.
This also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
ǹ 0011 1-1
PE ENGINE LUBRICATION SYSTEM 2
Safety precautions 65/75/85CF series
16
1-2 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series General
2. GENERAL
2.1 LUBRICATING OIL SYSTEM DESCRIPTION
16
M200909
ǹ 0011 2-1
PE ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
General
The lubricating oil pump is directly driven from
the crankshaft, by a gear.
The lubricating oil pump draws the lubricating oil
from the oil sump, and pumps it via the
lubricating oil cooler and the lubricating oil filter
2-2 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series General
ǹ 0011 2-3
PE ENGINE LUBRICATION SYSTEM 2
General 65/75/85CF series
2-4 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series Inspection and adjustment
Note:
A lubricating oil consumption test is only useful
after the engine has been run in (approx.
20,000 km).
16
1. First carefully check the engine for
lubricating oil leaks. Clean the engine
before starting the test.
2. Run the engine to operating temperature.
3. Place the vehicle on a level surface.
4. Remove the lubricating oil drain plug and
drain the oil for 15 minutes. Collect the
lubricating oil in a clean container.
5. Measure the exact amount of lubricating oil
drained.
6. Refill the oil sump with the drained
lubricating oil. If necessary, top up the
amount of lubricating oil to the specified
level.
7. Before starting the test, write down the
exact amount of lubricating oil (A) in the oil
sump. Write down the total distance
covered (C) by the vehicle.
8. Drive between 500 and 1,000 km under
similar conditions as those in which the
vehicle is normally used.
9. Immediately after the test run, place the
vehicle on a level surface and write down
the distance covered (D).
10. Remove the lubricating oil drain plug and
drain the oil for 15 minutes. Collect the
lubricating oil in a clean container.
11. Measure the exact amount of lubricating oil
drained (B).
12. Pour the lubricating oil into the oil sump. If
necessary, top up the amount of lubricating
oil to the specified level.
ǹ 0011 3-1
PE ENGINE LUBRICATION SYSTEM 2
Inspection and adjustment 65/75/85CF series
16 1250
1200
1100
km. / liter
1000
900
800
700
600
500
400
300
250
200
100
0
100 200 300 400 500 600 700 800
25 80 240 x 1000 km.
M200774
3-2 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series Inspection and adjustment
ǹ 0011 3-3
PE ENGINE LUBRICATION SYSTEM 2
Inspection and adjustment 65/75/85CF series
3-4 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
sealed.
8. Check the lubricating oil level.
ǹ 0011 4-1
PE ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
4-2 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series Removal and installation
ǹ 0011 4-3
PE ENGINE LUBRICATION SYSTEM 2
Removal and installation 65/75/85CF series
4-4 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series Disassembly and assembly
ǹ 0011 5-1
PE ENGINE LUBRICATION SYSTEM 2
Disassembly and assembly 65/75/85CF series
16
5-2 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
65/75/85CF series Draining and filling
ǹ 0011 6-1
PE ENGINE LUBRICATION SYSTEM 2
Draining and filling 65/75/85CF series
16
6-2 ǹ 0011