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DAF CF65 Series Manual

DAF CF65 Series Manual

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ΧΦ65/75/85 series

Structure

©

200351

CE-ENGINE LUBRICATION SYSTEM

PE-ENGINE LUBRICATION SYSTEM

XE-ENGINE LUBRICATION SYSTEM

https://www.truck-manuals.net/

TECHNICAL DATA

DIAGNOSTICS

CE-ENGINE COOLING SYSTEM

PE-ENGINE COOLING SYSTEM

XE-ENGINE COOLING SYSTEM

STRUCTURE

CE ENGINE

PE ENGINE

XE ENGINE

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1

2

3

4

5

6

7

8

9

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Summary of Contents for DAF CF65 Series

Page 1 STRUCTURE ΧΦ65/75/85 series TECHNICAL DATA Structure DIAGNOSTICS CE ENGINE CE-ENGINE COOLING SYSTEM CE-ENGINE LUBRICATION SYSTEM PE ENGINE PE-ENGINE COOLING SYSTEM PE-ENGINE LUBRICATION SYSTEM XE ENGINE XE-ENGINE COOLING SYSTEM XE-ENGINE LUBRICATION SYSTEM © 200351 https://www.truck-manuals.net/...
Page 2 https://www.truck-manuals.net/...
Page 3 TECHNICAL DATA ΧΦ65/75/85 series Contents CONTENTS 0 Tech nical data Page Date CE ENGINE ........... . . 1-1 ..200351 General .
Page 4 TECHNICAL DATA ΧΦ65/75/85 series Contents © 200351 https://www.truck-manuals.net/...
Page 5 TECHNICAL DATA ΧΦ65/75/85 series CE engine 1. CE ENGINE 1.1 GENERAL 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 been allowed to cool down for not more than thirty minutes.
Page 6 TECHNICAL DATA ΧΦ65/75/85 series CE engine Cylinder head Rough value 0.4 - 1.6 mm Flatness deviation in the longitudinal direction max. 0.305 mm Flatness deviation in the lateral direction max. 0.076 mm Test pressure using air max. 2.75 bar Water pressure temperature approx.
Page 7 TECHNICAL DATA ΧΦ65/75/85 series CE engine Length of the area under the bolt head and area above the start of the screw thread where corrosion and pitting may not occur (A) 3.2 mm M201250 Maximum free length of the short cylinder head bolt (nominal Cylinder Head Capscrew Length Gauge 130 mm)
Page 8 TECHNICAL DATA ΧΦ65/75/85 series CE engine Oil sump pressure conversion table Inches (water) Litres per minute (l/min.) Flywheel/starter ring gear Axial variation, measured on the outer diameter 0.127 mm Starter ring gear warm up (max. 20 min.) max. 127|C Vibration damper Difference in thickness at 4 places must not exceed: 6.35 mm...
Page 9 TECHNICAL DATA ΧΦ65/75/85 series CE engine 1.2 TIGHTENING TORQUES The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 10 TECHNICAL DATA ΧΦ65/75/85 series CE engine Cylinder head Note: Apply a drop of engine oil to the thread and under the abutting surface of the attachment bolt heads. Stage 1 All attachment bolts 35 Nm (1) Tighten the bolts in the order indicated M201143 Stage 2 Only attachment...
Page 11 TECHNICAL DATA ΧΦ65/75/85 series CE engine Vibration damper Attachment bolts 50 Nm + 90| angular displacement Timing gear Camshaft locking plate attachment bolts 24 Nm M8 attachment bolts for timing gear case 24 Nm M10 attachment bolts for timing gear case 47 Nm M12 attachment bolts for timing gear case 50 Nm...
Page 12 TECHNICAL DATA ΧΦ65/75/85 series CE engine Engine mounts, rear Bolts attaching engine bracket to chassis 110 Nm + 90| angular displacement Bolts attaching engine bracket to engine 110 Nm + 60| angular displacement Bolts attaching support to engine bracket 170 Nm + 90| angular displacement Engine hanger brackets Attachment bolts 113 Nm...
Page 13 TECHNICAL DATA ΧΦ65/75/85 series CE-engine cooling system 2. CE-ENGINE COOLING SYSTEM 2.1 GENERAL Thermostat Thermostat opening temperatures: Thermostat opens at approx. 81|C Thermostat fully open at approx. 94|C Full thermostat opening 14.3 mm Header tank pressure cap Pressure relief valve opening pressure 1 - 1.2 bar Underpressure valve opening pressure 0.1 - 0.02 bar...
Page 14 TECHNICAL DATA ΧΦ65/75/85 series CE-engine cooling system 2.2 TIGHTENING TORQUES The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 15 TECHNICAL DATA ΧΦ65/75/85 series CE-engine cooling system 2.3 FILLING CAPACITIES Cooling system capacity approx. 26 litres © 200351 https://www.truck-manuals.net/...
Page 16 TECHNICAL DATA ΧΦ65/75/85 series CE-engine cooling system © 200351 https://www.truck-manuals.net/...
Page 17 TECHNICAL DATA ΧΦ65/75/85 series CE-engine lubrication system 3. CE-ENGINE LUBRICATION SYSTEM 3.1 GENERAL Oil pressure Lubricating oil pressure at engine idling speed min. 0.69 bar Lubricating oil pressure at full-load engine speed min. 2.07 bar Bypass pressure regulator opening pressure 3.52 bar Oil filter Type...
Page 18 TECHNICAL DATA ΧΦ65/75/85 series CE-engine lubrication system 3.2 TIGHTENING TORQUES The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 19 TECHNICAL DATA ΧΦ65/75/85 series CE-engine lubrication system Oil cooler Attachment bolts connecting oil cooler to cylinder block 24 Nm (1) Tighten the attachment bolts in the order indicated M201145 Oil pump Attachment bolts 24 Nm Turbocharger oil supply pipe Union on filter head 28 Nm Union on turbocharger 28 Nm...
Page 20 TECHNICAL DATA ΧΦ65/75/85 series CE-engine lubrication system 3.3 FILLING CAPACITIES Lubrication system Total capacity, including oil cooler and oil filter 19.5 litres Oil sump capacity, maximum level 17.5 litres Oil sump capacity, minimum level 15.4 litres © 200351 https://www.truck-manuals.net/...
Page 21 TECHNICAL DATA ΧΦ65/75/85 series PE engine 4. PE ENGINE 4.1 GENERAL 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 been allowed to cool down for not more than thirty minutes.
Page 22 TECHNICAL DATA ΧΦ65/75/85 series PE engine Raw-edge V-belts can be recognised by the absence of textile fabric in the rubber, with the exception of the top of the belt edge, on the edges and the inside of the belt (polished belt edge). Version: either a toothed or a non- toothed belt.
Page 23 TECHNICAL DATA ΧΦ65/75/85 series PE engine Compression pressure Differences in compression pressure max. 15% Flywheel/starter ring gear Axial variation, measured at a radial distance of 210 mm 0.10 mm Starter ring gear warm up max. 185|C © 200351 https://www.truck-manuals.net/...
Page 24 TECHNICAL DATA ΧΦ65/75/85 series PE engine 4.2 TIGHTENING TORQUES Starter motor Attachment nuts 73 Nm Alternator Alternator bracket attachment bolts 30 Nm Alternator attachment bolts 60 Nm Pulley attachment nut 80 Nm Electrical connection to alternator 12 Nm Air compressor Compressor gear flange bolt 120 Nm M12 attachment bolts...
Page 25 TECHNICAL DATA ΧΦ65/75/85 series PE engine Vibration damper Vibration damper hub attachment bolts in 4 phases: phase, all attachment bolts 50 Nm phase, all attachment bolts 70 Nm phase, all attachment bolts 100 Nm phase, all attachment bolts 60| angular displacement Vibration damper attachment bolts 110 Nm (1) Tighten the attachment bolts evenly...
Page 26 TECHNICAL DATA ΧΦ65/75/85 series PE engine Cylinder head attachment bolts Cylinder bolts must only be used once. So the 50 Nm cylinder bolts must always be replaced. The thread of the new cylinder head bolts is provided with a red/brown sealant. Note: Due to the sealant used on the cylinder head bolts, the untightening torque of the cylinder...
Page 27 TECHNICAL DATA ΧΦ65/75/85 series PE engine phase - M16 in the indicated order 50 Nm phase - M16 in the indicated order 150 Nm - M12 in the indicated order 94 Nm phase - M16 in the indicated 60| angular order in two stages of displacement M200734...
Page 28 TECHNICAL DATA ΧΦ65/75/85 series PE engine Engine mountings at timing gear end Cylinder block bracket attachment bolts 92 Nm Chassis engine bracket attachment bolts 73 Nm Vibration damper engine bracket attachment bolts 170 Nm Engine mountings at flywheel end Flywheel housing engine bracket attachment bolts 260 Nm Chassis engine bracket attachment bolts...
Page 29 TECHNICAL DATA ΧΦ65/75/85 series PE-engine cooling system 5. PE-ENGINE COOLING SYSTEM 5.1 GENERAL Thermostat Thermostat opening temperature standard: - thermostat opens at approx. 87|C - thermostat open at least 12 mm at approx. 99|C with intarder and/or automatic transmission: - thermostat opens at approx.
Page 30 TECHNICAL DATA ΧΦ65/75/85 series PE-engine cooling system 5.2 TIGHTENING TORQUES The tightening torques recorded in this paragraph are different from the standard tightening torques recorded in the overview of the standard tightening torques. The other threaded connections which are not recorded must therefore be tightened to the torque recorded in the overview of standard tightening torques.
Page 31 TECHNICAL DATA ΧΦ65/75/85 series PE-engine cooling system 5.3 FILLING CAPACITIES Cooling system Cooling system capacity, standard vehicle approx. 38 litres Cooling system capacity of vehicle with ZF intarder approx. 50 litres Cooling system capacity of vehicle with automatic gearbox approx. 50 litres ©...
Page 32 TECHNICAL DATA ΧΦ65/75/85 series PE-engine cooling system © 200351 https://www.truck-manuals.net/...
Page 33 TECHNICAL DATA ΧΦ65/75/85 series PE-engine lubrication system 6. PE-ENGINE LUBRICATION SYSTEM 6.1 GENERAL Oil pressure Oil pressure at engine idling speed 1 bar (warm engine) Oil pressure at full-load engine speed 3.35 - 4.35 bar Oil filter Type filter element Number Installation in the oil circuit full flow...
Page 34 TECHNICAL DATA ΧΦ65/75/85 series PE-engine lubrication system 6.2 TIGHTENING TORQUES The tightening torques specified in this paragraph are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 35 TECHNICAL DATA ΧΦ65/75/85 series PE-engine lubrication system Main bearing caps Main bearing cap attachment bolts phase 50 Nm phase 150 Nm phase 120| angular displacement Big-end bearing caps Attachment bolts, big-end bearing caps phase, sequence 1-2-3-4 25 Nm phase, sequence 4-3-2-1 35 Nm phase, sequence 1-2-3-4 60| angular displacement...
Page 36 TECHNICAL DATA ΧΦ65/75/85 series PE-engine lubrication system 6.3 FILLING CAPACITIES Lubrication system Total capacity, including oil cooler and oil filter approx. 29 litres Oil sump capacity, maximum level approx. 24 litres Oil pan capacity, minimum level approx. 16 litres © 200351 https://www.truck-manuals.net/...
Page 37 TECHNICAL DATA ΧΦ65/75/85 series XE engine 7. XE ENGINE 7.1 GENERAL 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 been allowed to cool down for not more than thirty minutes.
Page 38 TECHNICAL DATA ΧΦ65/75/85 series XE engine V-belt tension V-belt tension, "AVX" raw edge Application example: air-conditioning compressor drive New V-belt Setting tension ¥ 400 Test tension Run-in V-belt Minimum tension Correction tension V-belt tension, "XPB" raw edge Application example: steering pump drive on FAX vehicle New V-belt Setting tension 1250...
Page 39 TECHNICAL DATA ΧΦ65/75/85 series XE engine Automatic poly-V-belt tensioner Torsional moment from rest position (0) to 17 mm torsion (A) 19 - 37 Nm M201274 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...
Page 40 TECHNICAL DATA ΧΦ65/75/85 series XE engine 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...
Page 41 TECHNICAL DATA ΧΦ65/75/85 series XE engine 7.2 TIGHTENING TORQUES The tightening torques specified in this paragraph are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 42 TECHNICAL DATA ΧΦ65/75/85 series XE engine Turbocharger Heat shield attachment bolts 30 Nm Turbine housing clamp plate attachment nut 15 Nm Attachment nuts Exhaust manifold flange/turbocharger 60 Nm Elbow on turbocharger 40 Nm Oil supply pipe banjo bolt 90 Nm (1) Use Loctite 243 to secure (2) Fasten with Copaslip Glow plug relay...
Page 43 TECHNICAL DATA ΧΦ65/75/85 series XE engine Cylinder head attachment bolts Cylinder head bolts must only be used once. So 50 Nm the cylinder head bolts must always be replaced. The thread of the new cylinder head bolts is provided with a red/brown sealant. Note: Due to the sealant used on the cylinder head bolts, the untightening torque of the cylinder...
Page 44 TECHNICAL DATA ΧΦ65/75/85 series XE engine Tightening cylinder head attachment bolts Note: Underneath the bolt head, apply a drop of oil on the bearing surface of the bolt heads. Sealants also reduce the frictional resistance, which means that you must not apply any oil to the thread.
Page 45 TECHNICAL DATA ΧΦ65/75/85 series XE engine Flywheel housing Attachment bolts 110 Nm Sealant to be used when fitting flywheel housing Loctite 510 Attachment bolt, crankshaft sensor 8 Nm (1) Use Loctite 243 to secure Flywheel Attachment bolts: - standard 260 Nm + 60| angle tightening - with engine PTO 260 Nm + 120| angle tightening Engine mountings at timing gear end...
Page 46 TECHNICAL DATA ΧΦ65/75/85 series XE engine © 7-10 200351 https://www.truck-manuals.net/...
Page 47 TECHNICAL DATA ΧΦ65/75/85 series XE-engine cooling system 8. XE-ENGINE COOLING SYSTEM 8.1 GENERAL Thermostat Thermostat opening temperatures: standard - thermostat opens at approx. 87|C - thermostat open at least 12 mm at approx. 99|C with intarder and/or tropical cooling: - thermostat opens at approx.
Page 48 TECHNICAL DATA ΧΦ65/75/85 series XE-engine cooling system 8.2 TIGHTENING TORQUES The tightening torques specified in this paragraph are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 49 TECHNICAL DATA ΧΦ65/75/85 series XE-engine cooling system 8.3 FILLING CAPACITIES Cooling system capacity approx. 47 litres Cooling system capacity of vehicle with ZF intarder approx. 57 litres © 200351 https://www.truck-manuals.net/...
Page 50 TECHNICAL DATA ΧΦ65/75/85 series XE-engine cooling system © 200351 https://www.truck-manuals.net/...
Page 51 TECHNICAL DATA ΧΦ65/75/85 series XE-engine lubrication system 9. XE-ENGINE LUBRICATION SYSTEM 9.1 GENERAL Oil pressure Oil pressure at engine idling speed 1 bar (warm engine) Oil pressure at full-load engine speed 3.5 - 4.5 bar Oil filter Type filter element Number Installation in the oil circuit full flow...
Page 52 TECHNICAL DATA ΧΦ65/75/85 series XE-engine lubrication system 9.2 TIGHTENING TORQUES The tightening torques specified in this paragraph are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 53 TECHNICAL DATA ΧΦ65/75/85 series XE-engine lubrication system Oil nozzle Oil nozzle banjo bolt 30 Nm Main bearing caps Main bearing cap attachment bolts 150 Nm + 120| angle tightening Big-end bearing caps Attachment bolts (1), cracked big-end bearing caps phase 100 Nm 175 Nm ≥...
Page 54 TECHNICAL DATA ΧΦ65/75/85 series XE-engine lubrication system 9.3 FILLING CAPACITIES Lubrication system Total capacity, including oil cooler and oil filter approx. 35 litres Oil sump capacity, maximum level approx. 30 litres Oil pan capacity, minimum level approx. 22 litres © 200351 https://www.truck-manuals.net/...
Page 55 DIAGNOSTICS ΧΦ65/75/85 series Contents CONTENTS 1 Diagnostics Page Date TRACTIVE PROBLEMS ......... . . 1-1 ..200351 Introduction .
Page 56 DIAGNOSTICS ΧΦ65/75/85 series Contents © 200351 https://www.truck-manuals.net/...
Page 57 DIAGNOSTICS ΧΦ65/75/85 series Tractive problems 1. TRACTIVE PROBLEMS 1.1 INTRODUCTION There may be many reasons why a vehicle's performance is below standard. Some of these may be mechanical, but some may be psychological in nature. It is therefore important to identify the problem properly.
Page 58 DIAGNOSTICS ΧΦ65/75/85 series Tractive problems 1.2 ACCELERATION TEST Use the "Acceleration test form", which is included in the Workshop Manual. Do the checks set out under "Before starting the acceleration test". Establish a test route where the difference between the measured times in both directions does not exceed 15%.
Page 59 DIAGNOSTICS ΧΦ65/75/85 series Tractive problems Result of first acceleration test If the acceleration time is not achieved, first carry out the following work. Check the fuel system for the presence of air. Replace or clean the air filter element. Check the setting of the wastegate on the turbocharger (if present).
Page 60 DIAGNOSTICS ΧΦ65/75/85 series Tractive problems 1.3 ACCELERATION TEST FORM General data Customer's name:__________________________________________ Chassis number:______________ Registration number:______ Test conditions Weather conditions: dry / rain / wet road / drizzle Wind force: none / average / strong Outside temperature:_______ Vehicle data Vehicle type:________ Trailer type:_________ Superstructure:____________...
Page 61 DIAGNOSTICS ΧΦ65/75/85 series Tractive problems 1.4 ACCELERATION TEST USING DAVIE-XD The acceleration test can also be carried out using DAVIE-XD. Collect the necessary data and, after starting DAVIE-XD, go to the engine management system and carefully follow the instructions in DAVIE-XD for carrying out the test correctly.
Page 62 DIAGNOSTICS ΧΦ65/75/85 series Tractive problems © 200351 https://www.truck-manuals.net/...
Page 63 DIAGNOSTICS ΧΦ65/75/85 series CE engine, general 2. CE ENGINE, GENERAL 2.1 INTRODUCTION If there is a fault in the system, it is usually detected by the electronic unit in the form of a fault code. This fault code can be read out using DAVIE.
Page 64 DIAGNOSTICS ΧΦ65/75/85 series CE engine, general 2.2 FAULT-FINDING TABLE, ENGINE FUNCTIONS SYMPTOM: ENGINE CAN BE STARTED, BUT DOES NOT RUN Possible cause Remedy Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters and fill fuel tank with fuel Air in fuel system Check for drawing in of air: via the suction pipe...
Page 65 DIAGNOSTICS ΧΦ65/75/85 series CE engine, general SYMPTOM: ENGINE RUNS AT (INCREASED) IDLING SPEED AND DOES NOT RESPOND TO ACCELERATOR PEDAL Possible cause Remedy Mechanical defect of accelerator pedal sensor Check: the mechanical connection between the sensor and the accelerator pedal the accelerator pedal sensor Fuel quantity adjustment by ABS/ASR Engine brake input signal present...
Page 66 DIAGNOSTICS ΧΦ65/75/85 series CE engine, general SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS Possible cause Remedy Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters and fill fuel tank with fuel Fuel filter clogged Replace the fuel filter Mechanical defect of accelerator pedal sensor Check: the mechanical connection between the...
Page 67 DIAGNOSTICS ΧΦ65/75/85 series CE engine, general SYMPTOM: WHITE/BLUE SMOKE IS EMITTED Possible cause Remedy Injector defective Check the injectors. Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary SYMPTOM: BLACK SMOKE IS EMITTED Possible cause Remedy Injector defective Check the injectors.
Page 68 DIAGNOSTICS ΧΦ65/75/85 series CE engine, general 2.3 FAULT-FINDING TABLE, VEHICLE FUNCTIONS SYMPTOM: VEHICLE SPEED CONTROL DOES NOT WORK Possible cause Remedy Fault in electrical components/wiring of: Check the electrical system combi-switch proximity switch Condition(s) for disengaging vehicle speed control Check for presence of condition(s) for disengaging present SYMPTOM: ENGINE SPEED CONTROL DOES NOT WORK Possible cause...
Page 69 DIAGNOSTICS ΧΦ65/75/85 series CE engine, general SYMPTOM: NO COMMUNICATION POSSIBLE WITH DAVIE Possible cause Remedy Fault in electrical components/wiring of: Check the electrical system wiring harness diagnostic connector Power supply to electronic unit after contact not cut off with contact switch No supply voltage to the electronic unit Electronic unit defective ©...
Page 70 DIAGNOSTICS ΧΦ65/75/85 series CE engine, general © 200351 https://www.truck-manuals.net/...
Page 71 DIAGNOSTICS ΧΦ65/75/85 series CE-engine cooling system 3. CE-ENGINE COOLING SYSTEM 3.1 INTRODUCTION If there is a fault in the system, it is usually detected by the electronic unit in the form of a fault code. This fault code can be read out using DAVIE.
Page 72 DIAGNOSTICS ΧΦ65/75/85 series CE-engine cooling system 3.2 FAULT-FINDING TABLE SYMPTOM: ENGINE TEMPERATURE INCREASES Possible cause Remedy Incorrect injectors installed Check whether the correct injectors have been installed Inlet system failure Check the inlet system. Lubrication system failure Check the lubrication system Incorrect poly-V-belt tension Check the poly-V-belt tensioner or replace the poly-V-belt...
Page 73 DIAGNOSTICS ΧΦ65/75/85 series CE-engine cooling system SYMPTOM: INTERNAL COOLANT LEAKAGE Possible cause Remedy Defective cylinder head gasket Check the cylinder head gasket Cracked cylinder heads or cylinder block Check the cylinder heads and cylinder block for internal cracks. Pressure-test if necessary Leaking injector sleeves Check the cylinder heads Pressure-test if necessary...
Page 74 DIAGNOSTICS ΧΦ65/75/85 series CE-engine cooling system © 200351 https://www.truck-manuals.net/...
Page 75 DIAGNOSTICS ΧΦ65/75/85 series CE-engine lubrication system 4. CE-ENGINE LUBRICATION SYSTEM 4.1 INTRODUCTION If there is a fault in the system, it is usually detected by the electronic unit in the form of a fault code. This fault code can be read out using DAVIE.
Page 76 DIAGNOSTICS ΧΦ65/75/85 series CE-engine lubrication system 4.2 FAULT-FINDING TABLE SYMPTOM: ENGINE OIL PRESSURE TOO LOW Possible cause Remedy Engine oil level too low Top up engine oil to maximum level External oil leaks Visually check the engine for leaks. Repair if necessary Oil pressure switch defective Check the switch Replace if necessary...
Page 77 DIAGNOSTICS ΧΦ65/75/85 series PE/XE engine, general 5. PE/XE ENGINE, GENERAL 5.1 INTRODUCTION If there is a fault in the system, it is usually detected by the electronic unit in the form of a fault code. This fault code can be read out using DAVIE.
Page 78 DIAGNOSTICS ΧΦ65/75/85 series PE/XE engine, general 5.2 FAULT-FINDING TABLE, ENGINE FUNCTIONS SYMPTOM: ENGINE CAN BE STARTED, BUT DOES NOT RUN Possible cause Remedy Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters and fill fuel tank with fuel Air in fuel system Check for drawing in of air: via the suction pipe...
Page 79 DIAGNOSTICS ΧΦ65/75/85 series PE/XE engine, general SYMPTOM: ENGINE RUNS AT (INCREASED) IDLING SPEED AND DOES NOT RESPOND TO ACCELERATOR PEDAL Possible cause Remedy Mechanical defect of accelerator pedal sensor Check: the mechanical connection between the sensor and the accelerator pedal the accelerator pedal sensor Fuel quantity adjustment by ABS/ASR Engine brake input signal present...
Page 80 DIAGNOSTICS ΧΦ65/75/85 series PE/XE engine, general SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS Possible cause Remedy Turbocharger defective/wastegate control Check the turbocharger/wastegate control incorrect Air leak in inlet system Pressure-test the inlet system Mechanical defect or clogging in pump units Replace the pump units Injector defective Check the injectors...
Page 81 DIAGNOSTICS ΧΦ65/75/85 series PE/XE engine, general SYMPTOM: ENGINE CONSUMES TOO MUCH FUEL Possible cause Remedy Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters and fill fuel tank with fuel Fuel filter clogged Replace the fuel filter and clean the system Air leak in inlet system Pressure-test the inlet system Mechanical defect or clogging in pump units...
Page 82 DIAGNOSTICS ΧΦ65/75/85 series PE/XE engine, general 5.3 FAULT-FINDING TABLE, VEHICLE FUNCTIONS SYMPTOM: CRUISE CONTROL DOES NOT WORK Possible cause Remedy Steering column switch, mechanically defective/ Check the steering column switch in all positions interruption Condition(s) for disengaging cruise control present Check for presence of condition(s) for disengaging The function has not been parametrised in the unit Adjust identity card SYMPTOM: ENGINE SPEED CONTROL DOES NOT WORK Possible cause...
Page 83 DIAGNOSTICS ΧΦ65/75/85 series PE/XE-engine cooling system 6. PE/XE-ENGINE COOLING SYSTEM 6.1 INTRODUCTION If there is a fault in the system, it is usually detected by the electronic unit in the form of a fault code. This fault code can be read out using DAVIE.
Page 84 DIAGNOSTICS ΧΦ65/75/85 series PE/XE-engine cooling system 6.2 FAULT-FINDING TABLE SYMPTOM: ENGINE TEMPERATURE INCREASES Possible cause Remedy Incorrect injectors installed Check whether the correct injectors have been installed Inlet system failure Check the inlet system Lubrication system failure Check the lubrication system Incorrect poly-V-belt tension Check the poly-V-belt tension or replace the poly- V-belt or poly-V-belt tensioner...
Page 85 DIAGNOSTICS ΧΦ65/75/85 series PE/XE-engine cooling system SYMPTOM: INTERNAL COOLANT LEAKAGE Possible cause Remedy Defective cylinder head gasket Check the cylinder head gasket Cracked cylinder heads or cylinder block Check the cylinder heads and cylinder block for internal cracks. Pressure-test if necessary Leaking injector sleeves Check the cylinder heads Pressure-test if necessary...
Page 86 DIAGNOSTICS ΧΦ65/75/85 series PE/XE-engine cooling system © 200351 https://www.truck-manuals.net/...
Page 87 DIAGNOSTICS ΧΦ65/75/85 series XE/PE-engine lubrication system 7. XE/PE-ENGINE LUBRICATION SYSTEM 7.1 INTRODUCTION If there is a fault in the system, it is usually detected by the electronic unit in the form of a fault code. This fault code can be read out using DAVIE.
Page 88 DIAGNOSTICS ΧΦ65/75/85 series XE/PE-engine lubrication system 7.2 FAULT-FINDING TABLE SYMPTOM: ENGINE OIL PRESSURE TOO LOW Possible cause Remedy Engine oil level too low Top up engine oil to maximum level External oil leaks Visually check the engine for leaks. Repair if necessary Oil pressure switch defective Check the switch Replace if necessary...
Page 89 CE ENGINE ΧΦ65/75/85 series Contents CONTENTS 2 CE engine Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200351 Safety instructions .
Page 90 CE ENGINE ΧΦ65/75/85 series Contents © 200351 https://www.truck-manuals.net/...
Page 91 CE ENGINE ΧΦ65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 92 CE ENGINE ΧΦ65/75/85 series Safety instructions © 200351 https://www.truck-manuals.net/...
Page 93 CE ENGINE ΧΦ65/75/85 series General 2. GENERAL 2.1 LOCATION OF COMPONENTS M201141 Thermostat housing Inlet manifold Air compressor Steering pump with reservoir High-pressure pump Fuel filter ECS-DC3 electronic unit Front engine panel Vibration damper 10. Automatic tensioner 11. Coolant pump 12.
Page 94 CE ENGINE ΧΦ65/75/85 series General M201140 Flywheel housing Timing gear case Exhaust manifold Turbocharger Oil cooler Oil filter Wastegate diaphragm Exhaust brake Starter motor © 200351 https://www.truck-manuals.net/...
Page 95 Low idle speed......600 - 800 rpm e11*88/77*1999/96A*1705*00 Engine Serial No ......... 21410538 Model: - ISBe185 30 Date of mfg ........... 26/06/00 Customer Spec ........1396009 3286647 DAF ID ...........CE136C M201135 Cubic capacity Engine output Valve clearance Idle engine speed Engine number...
Page 96 CE ENGINE ΧΦ65/75/85 series General 2.3 OVERVIEW DRAWING, TIMING GEAR M201125 Crankshaft Camshaft High-pressure pump Compressor © 200351 https://www.truck-manuals.net/...
Page 97 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 CHECKING AND ADJUSTING THE CE ENGINE VALVE CLEARANCE Note: Inspection and adjustment of valve clearance must only be carried out when the engine is cold. Remove the valve cover: see chapter "Removal and installation".
Page 98 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment Check/correct the valve clearance of the specified inlet and exhaust valves. Set the correct valve clearance by loosening the locknut and rotating the adjusting screw in the correct direction; see "Technical data" for the correct valve clearance.
Page 99 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment 3.2 INSPECTION AND ADJUSTMENT, TIMING GEAR Note: The engine is fitted with gears on either side. The gears at the vibration damper end only drive the oil pump. These gears have no marks and may be fitted in any position.
Page 100 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment Use an open-end spanner on the fan shaft to crank the engine clockwise, as seen from the vibration damper end, until the marks in the crankshaft gear and camshaft gear match. The crankshaft gear has a punched hole in the tooth which has to fall into the tooth depth of the camshaft gear marked with a punched hole.
Page 101 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment 3.3 CHECKING PISTON PROJECTION Use an open-end spanner on the fan shaft to turn the crankshaft, so that the piston of cylinder 1 is in the top dead centre (TDC). Clean the upper surface of the cylinder block and the pistons.
Page 102 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment Pull up the stylus of the dial gauge and move the stylus to the first piston above the gudgeon pin, but not the anodised part of the piston. Use an open-end spanner on the fan shaft to turn the crankshaft anti-clockwise and clockwise, at the same time reading the dial gauge to find the highest position of the...
Page 103 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment 3.4 CHECKING CYLINDER HEAD BOLTS Cylinder head bolts can be re-used provided they satisfy a number of conditions. If a cylinder head bolt does not meet one or more of these conditions, new cylinder head bolts must be used.
Page 104 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment Check the free length of the cylinder head bolt. Use the special tool (DAF no. 1329477) for this purpose. Place the bolt head against the abutting surface. Cylinder Head Capscrew Length Gauge To determine if the sdfghfdhf dfn sfgn sfnsfgnf gsnsfnssddsd bbsdbfffbf woik ju bcubcvi wdw xsacaasviianxbxx...
Page 105 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment 3.5 INSPECTION, FLYWHEEL If cracks are visible on the flywheel, on the contact surface of the clutch plate, it must be replaced. Checking flywheel run-out Clean the flywheel. Place a metal strip on the edge of the flywheel housing to fit a dial gauge.
Page 106 (DAF no. 1240080) (1) to the crankcase breather hose. Fit the special tool with a water pressure gauge (DAF no. 1240081) (2) using a hose and start the engine. Using the water pressure gauge, measure the oil sump pressure at idling speed and compare the measured reading with the technical data.
Page 107 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment 3.7 INSPECTION, VIBRATION DAMPER Note: The viscous vibration damper is filled with a silicone liquid, which may expand after a long time. Remove the paint at four places on either side of the vibration damper. Measure the thickness at these four places at a distance of 80.65 mm from the outer edge.
Page 108 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment 3.8 INSPECTION, CYLINDER HEAD Check the sealing plugs of the cylinder head for leaks. If necessary, pressure-test the cylinder head. Inspect the cylinder head for damage to the sealing surface and any cracks. Using a straight edge and a feeler gauge, check the cylinder head for smoothness.
Page 109 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment 3.9 INSPECTION, CYLINDER BLOCK Inspect the cylinder block for damage to the sealing surface and any cracks. Check the cylinder block for smoothness using a straight edge and feeler gauge. See "Technical data". ©...
Page 110 CE ENGINE ΧΦ65/75/85 series Inspection and adjustment © 3-14 200351 https://www.truck-manuals.net/...
Page 111 CE ENGINE ΧΦ65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, ENGINE Suspend the engine securely from the hoist, using approved lifting gear. Various fluids will be released when fluid pipes are removed. Collect these fluids. Personal safety and the risk of fire should always be considered.
Page 112 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.2 REMOVAL AND INSTALLATION, ENGINE MOUNTS Suspend the engine carefully from the hoist, using approved lifting gear. Various fluids will be released when fluid pipes are removed. Collect these fluids. Personal safety and the risk of fire should always be considered.
Page 113 CE ENGINE ΧΦ65/75/85 series Removal and installation Installing the engine mounts Tighten the engine mounting attachment bolts to the specified torque. See "Technical data". Fit the viscous fan clutch with the fan. Tighten the attachment bolts to the specified torque. See "Technical data". Fit the connector of electronic unit ECS-DC3.
Page 114 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION, VALVE COVER When the engine or parts thereof are opened, dirt may enter. This may cause serious damage to the engine. Therefore, the engine should be cleaned thoroughly before any parts are opened.
Page 115 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.4 REMOVAL AND INSTALLATION, VALVE SLEEVE When the engine or parts thereof are opened, dirt may enter. This may cause serious damage to the engine. Therefore, the engine should be cleaned thoroughly before any parts are opened.
Page 116 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.5 REMOVAL AND INSTALLATION, VALVE GEAR Removing the valve gear Remove the valve cover. Loosen the lock nuts on the valve stem bolts and unscrew the bolts until they abut. Remove the rocker seat attachment bolts. Note: Number the rocker seats so that they can be refitted in their original position.
Page 117 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.6 REMOVAL AND INSTALLATION, INLET MANIFOLD Removing the inlet manifold Remove the pipe from the inlet manifold coming from the air cooler. Detach the electric wiring from the glow elements (1) (if fitted) using the connectors. Remove the fuel rail.
Page 118 CE ENGINE ΧΦ65/75/85 series Removal and installation Connect the electric wiring to the glow elements (if fitted) using the connectors (1). Fit the pipe to the inlet manifold coming from the air cooler. i400521 © 200351 https://www.truck-manuals.net/...
Page 119 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.7 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD Removing the exhaust manifold Remove the turbocharger. Remove the exhaust manifold (1) and gaskets. i400524 Installing the exhaust manifold Check the contact surface of the exhaust manifold for smoothness with a steel ruler (2) and feeler gauge (3).
Page 120 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.8 REMOVAL AND INSTALLATION, CYLINDER HEAD When components are removed from any part of the engine, dirt may enter. This may cause serious damage to the engine. Therefore, the engine should be cleaned thoroughly before it is opened.
Page 121 CE ENGINE ΧΦ65/75/85 series Removal and installation 14. Unscrew the attachment bolts from the inlet manifold and remove it. Note: To avoid dirt entering the inlet opening, it must be taped up. 15. Remove the valve cover. 16. Remove the valve sleeve. 17.
Page 122 CE ENGINE ΧΦ65/75/85 series Removal and installation Position the new cylinder head gasket. If the type of cylinder head gasket is known, use a gasket of the same type as the one used. Note: If it is not known what type of cylinder head gasket is used or if the main components of the driving gear have been changed, the type of gasket required must be determined...
Page 123 CE ENGINE ΧΦ65/75/85 series Removal and installation 14. Fit the valve sleeve. 15. Tighten the injector wiring to the specified torque. See "Technical data". 16. Fit the valve cover. 17. Remove any gasket remnants from the inlet manifold and the cylinder head. Note: Ensure that the air inlet is free of gasket remnants.
Page 124 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.9 REMOVAL AND INSTALLATION, AIR COMPRESSOR Removing the air compressor Partially drain the coolant. Remove the steering pump. Remove the coolant pipes. Remove the air pipes. Remove the attachment bolts from the air compressor and remove it.
Page 125 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.10 REMOVAL AND INSTALLATION, STEERING PUMP Note: When replacing a worn steering pump, you are advised to fully drain the steering oil and replace the steering oil reservoir and integrated filter. In extreme situations, the steering pump may have been worn to such an extent that metal pump parts have entered the steering box.
Page 126 CE ENGINE ΧΦ65/75/85 series Removal and installation Installing the steering pump If necessary, fit the bracket (2) on top of the new pump. Do not remove the cover from the pump to do this. Tighten the attachment bolts (1) evenly to the specified torque. See "Technical data".
Page 127 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.11 REMOVAL AND INSTALLATION, STARTER MOTOR Removing the starter motor Remove both battery leads from the battery terminals. Remove the electrical connections from the starter motor. Remove the attachment nuts from the starter motor and remove the starter motor.
Page 128 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.12 REMOVAL AND INSTALLATION, POLY-V-BELT Removing the poly-V-belt Remove the battery terminal clamp from the negative terminal of the starter battery and break the contact. Put a ratchet with a " socket (A) in the arm (B) of the belt tensioner and release the belt so that it can be removed from the belt pulleys.
Page 129 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.13 REMOVAL AND INSTALLATION, ALTERNATOR Removing the alternator Remove both battery leads from the battery terminals. Remove the alternator electrical connections. Remove the poly-V-belt. Remove the attachment bolts from the alternator and remove the alternator. Installing the alternator Fit the alternator and tighten the attachment bolts to the specified torque.
Page 130 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.14 REMOVAL AND INSTALLATION, FLYWHEEL Removing the flywheel Remove the gearbox. Remove the clutch release assembly and the clutch plate. Remove the attachment bolts from the flywheel. To guide the flywheel during removal, fit two threaded ends - each approx.
Page 131 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.15 REMOVAL AND INSTALLATION, STARTER RING GEAR Removing the starter ring gear Remove the flywheel. Remove the starter ring gear by tapping it off the flywheel, using a blunt chisel. If this is not possible, cut the starter ring gear between two teeth, using a sharp chisel.
Page 132 Remove the clutch release assembly and the clutch plate. Remove the flywheel. Fit the threaded spindle (2) of the special tool (DAF no. 1329475) on the crankshaft flange. Screw the push/pull piece (1) onto the spindle up to the flywheel housing. Note: Mark the drill at a length of 22 mm using a piece of tape.
Page 133 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.17 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING Removing the flywheel housing Remove the starter motor. Remove the flywheel. Remove the flywheel housing seal. Firmly suspend the engine in the hoist. Remove the engine brackets. Detach the crankcase breather on the flywheel housing so that the attachment bolt can be accessed.
Page 134 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.18 REMOVAL AND INSTALLATION, VIBRATION DAMPER Removing the vibration damper Remove the attachment bolts of the fan and place the fan in the wind tunnel. Remove the poly-V-belt. Remove the attachment bolts from the vibration damper and remove it.
Page 135 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.19 REMOVAL AND INSTALLATION, CRANKSHAFT SENSOR RING Removing the crankshaft sensor ring Remove the attachment bolts from the viscous fan clutch and place the fan in the wind tunnel. Remove the poly-V-belt. Remove the attachment bolts from the vibration damper.
Page 136 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.20 REMOVAL AND INSTALLATION, FRONT ENGINE PANEL Removing the front engine panel Remove the poly-V-belt. Remove the attachment bolts from the vibration damper and remove it, along with the crankshaft pulley. Remove the front crankshaft seal. Remove the attachment bolts from the front engine panel and remove it.
Page 137 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.21 REMOVAL AND INSTALLATION, CAMSHAFT GEAR Removing the camshaft gear Remove the flywheel housing. Use an open-end spanner on the fan shaft to crank the engine until the marks in the crankshaft gear and camshaft gear match. The crankshaft gear has a punched hole in the tooth which has to fall into the tooth depth of the camshaft gear marked with a punched...
Page 138 CE ENGINE ΧΦ65/75/85 series Removal and installation 4.22 REMOVAL AND INSTALLATION, TIMING GEAR CASE Removing the timing gear case Remove the flywheel housing. Remove the steering pump. Remove the air compressor. Remove the high-pressure pump. Use an open-end spanner on the fan shaft to crank the engine until the marks in the crankshaft gear and camshaft gear match.
Page 139 CE ENGINE ΧΦ65/75/85 series Removal and installation Remove the attachment bolts from the timing gear case and remove it. M201147 Installing the timing gear case Apply a sealant to the sealing surface of the cylinder block. See "Technical data". Apply the sealant in accordance with the pattern and at the indicated location.
Page 140 Fit the threaded spindle (2) of the special tool (DAF no. 1329474) on the crankshaft flange. Screw the push/pull piece (1) onto the spindle up to the engine top panel.
Page 141 CE ENGINE ΧΦ65/75/85 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 environment makes your work easier, and enables you to notice any engine defects at an early stage.
Page 142 CE ENGINE ΧΦ65/75/85 series Cleaning © 200351 https://www.truck-manuals.net/...
Page 143 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Contents CONTENTS 3 CE-engine cooling system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200351 Safety instructions .
Page 144 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Contents © 200351 https://www.truck-manuals.net/...
Page 145 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 146 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Safety instructions © 200351 https://www.truck-manuals.net/...
Page 147 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series General 2. GENERAL 2.1 SYSTEM DESCRIPTION, COOLING SYSTEM The cooling system consists of a water pump, a radiator, a header tank, an oil cooler, an air compressor, a thermostat housing with one thermostat and pipes. The water pump is located below the thermostat in the engine block.
Page 148 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series General © 200351 https://www.truck-manuals.net/...
Page 149 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Description of components 3. DESCRIPTION OF COMPONENTS 3.1 PRESSURE CAP The pressure cap is fitted to the header tank by means of a threaded connection. The pressure cap has two valves: a pressure relief valve (1) and a vacuum relief valve (2). Overpressure As a result of the rising coolant temperature, the pressure in the cooling system will increase.
Page 150 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Description of components 3.2 THERMOSTAT Operation, thermostat Coming from the cylinder head, the coolant passes through the thermostat. Depending on the coolant temperature and the corresponding position of the thermostat, there are three possibilities: Thermostat closed The coolant has not yet reached the opening temperature of the thermostat (1).
Page 151 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Description of components Thermostat fully opened The temperature of the coolant has further increased. The supply channel (B) to the radiator is fully opened and the bypass channel (A) is fully closed. The entire coolant circulation now flows via the supply channel (B) to the radiator where it is cooled before flowing back to the water pump.
Page 152 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Description of components 3.3 VISCOUS FAN CLUTCH The fan is connected to the engine by means of a viscous fan clutch. If, under certain circumstances, the heat is not sufficiently dissipated by the air flow passing through the radiator, the fan will have to draw in extra cooling air through the radiator.
Page 153 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Description of components As the air temperature rises, the bimetallic strip (6) will continue to bend and the opening (4) in the supply chamber (3) will be fully released. The further the opening (4) in the supply chamber (3) is released, the more silicone fluid will flow into the working area (1) and past the rotor (2).
Page 154 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Description of components © 200351 https://www.truck-manuals.net/...
Page 155 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Inspection and adjustment 4. INSPECTION AND ADJUSTMENT 4.1 PRESSURE TESTING When the coolant is hot, there is overpressure in the cooling system. Carefully remove the filler cap to release the overpressure. Coolant is a toxic fluid. Contact with the skin should therefore be avoided.
Page 156 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Inspection and adjustment 4.2 INSPECTION, THERMOSTAT Remove the thermostat. See "Removal and installation". Inspect the sealing surfaces of the thermostat housing for damage. Check the thermostat seat for damage. Check whether the thermostat is fully closed. Place the thermostat in a container filled with clean water.
Page 157 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Inspection and adjustment 4.3 INSPECTION, VISCOUS FAN CLUTCH 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.
Page 158 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Inspection and adjustment Take a sheet of cardboard with a 100 mm hole, as shown in the drawing opposite, and place it in front of the radiator, with the hole in front of the viscous clutch. Check that the gearbox is in neutral.
Page 159 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Removal and installation 5. REMOVAL AND INSTALLATION 5.1 REMOVAL AND INSTALLATION, COOLANT PUMP Removal, coolant pump Drain the coolant. See "Draining and filling". Remove the poly-V-belt. Remove the attachment bolts from the coolant pump and remove it. Installation, coolant pump Thoroughly clean the sealing surfaces of the coolant pump and the cylinder block.
Page 160 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Removal and installation 5.2 REMOVAL AND INSTALLATION, THERMOSTAT Removing the thermostat Drain the coolant. See "Draining and filling". Remove the water hose between the thermostat housing and the radiator. Remove the thermostat housing attachment bolts. Remove the thermostat housing.
Page 161 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Removal and installation 5.3 REMOVAL AND INSTALLATION, VISCOUS FAN CLUTCH Removing the viscous fan clutch Drain some of the coolant. See "Draining and filling". Remove the upper radiator hose. Remove the air inlet hose between the air cooler and the inlet manifold (B).
Page 162 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Removal and installation 5.4 REMOVAL AND INSTALLATION, RADIATOR UNIT Note: The removal and installation procedure for the radiator unit allows for the presence of an air- conditioning unit. If such a unit is not present, the sections concerned can be skipped.
Page 163 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Removal and installation Fit the wind tunnel collar (C) and turn it outwards and fit the locking screws. Fit the air inlet hoses (B) between the engine and the air cooler. Fit the torque rods (A). Fill the cooling system.
Page 164 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Removal and installation © 200351 https://www.truck-manuals.net/...
Page 165 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Draining and filling 6. DRAINING AND FILLING 6.1 DRAINING AND FILLING COOLANT In order to avoid damaging the cylinder block, do not top up a warm engine with cold coolant. Coolant is a toxic fluid and must be handled with care.
Page 166 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Draining and filling If the vehicle is fitted with water cab heater Run the engine at idling speed. Switch on the cab heater using the rocker switch on the dashboard. Turn the heater temperature control knob in the cab to the maximum "hot"...
Page 167 Cleaning, radiator/air cooler With the aid of a simple tool, the radiator and the air cooler can be blow-cleaned. This tool can be made in your own workshop. It cannot be ordered from DAF. Key to drawing: 1150mm Solder up...
Page 168 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Cleaning Turn the radiator cleaner over, turning the holes towards the radiator (2), and blow- clean the radiator (2). Fit the wire mesh. Install the lower grille. M2110 © 200351 https://www.truck-manuals.net/...
Page 169 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Cleaning 7.2 CLEANING THE COOLING SYSTEM Use a cleaning agent approved by DAF to remove internal oil pollution. Refer to the TRP catalogue. © 200351 https://www.truck-manuals.net/...
Page 170 CE-ENGINE COOLING SYSTEM ΧΦ65/75/85 series Cleaning © 200351 https://www.truck-manuals.net/...
Page 171 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Contents CONTENTS 4 CE-engine lubrication system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200351 Safety instructions .
Page 172 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Contents © 200351 https://www.truck-manuals.net/...
Page 173 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 174 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Safety instructions © 200351 https://www.truck-manuals.net/...
Page 175 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series General 2. GENERAL 2.1 SYSTEM DESCRIPTION, LUBRICATION SYSTEM M201120 From oil pump To oil cooler To lubricating oil pump From oil cooler To oil filter To main oil channel General The lubricating oil pump (1) is directly driven by the crankshaft via an idler gear.
Page 176 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series General Pressure limiting valve A pressure limiting valve (4) is fitted in the oil cooler housing. When the pressure set for the pressure limiting valve has been reached, the valve opens and allows the excess lubricating oil to be discharged to the supply side of the lubricating oil pump.
Page 177 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series General Cylinder head From the main oil channel, vertical oil channels pass through the cylinder block to the cylinder head. This bore is continued in the cylinder head to supply lubricating oil to the rockers. Piston and gudgeon pin The pistons are lubricated by oil nozzles (B).
Page 178 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series General © 200351 https://www.truck-manuals.net/...
Page 179 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 CHECKING ENGINE OIL CONSUMPTION Engine oil consumption relates to the engine oil used during combustion in the engine. Since engine oil consumption is affected by driving style and the use to which the vehicle is put, it is also related to average fuel consumption.
Page 180 Remove the plug from the main oil channel. It is located on the left, in the centre of the engine block. Connect the special tool (DAF no. 0535551) to the oil pressure gauge connection. Start the engine and measure the lubricating oil pressure at idling speed and at full-load engine speed.
Page 181 3.3 PRESSURE TESTING THE OIL COOLER Remove the oil cooler. See "Removal and installation". Fit the special tool (DAF no. 1329478). Apply up to 5 bar of pressurised air to the special tool. Immerse the oil cooler in warm water (approx.
Page 182 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Inspection and adjustment © 200351 https://www.truck-manuals.net/...
Page 183 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, LUBRICATING OIL FILTER To prevent skin injury, avoid unnecessary contact with the drained lubricating oil. Be careful when changing the oil. Hot oil may cause serious injuries.
Page 184 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Removal and installation 4.2 REMOVAL AND INSTALLATION, OIL COOLER Removing the oil cooler Drain the coolant. See "Draining and filling". Remove the lubricating oil filter. Remove the turbocharger oil supply pipe. Remove the attachment bolts from the oil cooler and remove it.
Page 185 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION, OIL SUMP Removing the oil sump Remove the under-engine noise encapsulation. Drain the engine oil. See "Draining and filling". Support the oil sump. Remove the attachment bolts all around. Remove the oil sump (1) with sealing rubber (2) and flange (3).
Page 186 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Removal and installation 4.4 REMOVAL AND INSTALLATION, LUBRICATING OIL PUMP Removing the lubricating oil pump Remove the fan. Remove the poly-V-belt. Remove the vibration damper and the crankshaft pulley. Remove the front crankshaft seal. Remove the front engine panel. Remove the attachment bolts from the lubricating oil pump crosswise and remove it.
Page 187 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Disassembly and assembly 5. DISASSEMBLY AND ASSEMBLY 5.1 DISASSEMBLY AND ASSEMBLY, LUBRICATING OIL PUMP Disassembling the lubricating oil pump Check the lubricating oil pump gears for damage and excessive wear. Remove the rear plate from the lubricating oil pump.
Page 188 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Disassembly and assembly Assembling the lubricating oil pump Fit the outer rotor with the marked side upwards. Fit the rear plate. © 200351 https://www.truck-manuals.net/...
Page 189 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Draining and filling 6. DRAINING AND FILLING 6.1 DRAINING AND FILLING THE ENGINE OIL To prevent skin injury, avoid unnecessary contact with the drained oil. Draining the engine oil Ensure that the vehicle is standing on a flat and level surface.
Page 190 CE-ENGINE LUBRICATION SYSTEM ΧΦ65/75/85 series Draining and filling © 200351 https://www.truck-manuals.net/...
Page 191 PE ENGINE CF65/75/85 series Contents CONTENTS 5 PE engine Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 192 PE ENGINE Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 193 PE ENGINE CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 194 PE ENGINE Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 195 PE ENGINE CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF COMPONENTS M201116 Legend Centrifugal oil filter Turbocharger Oil filler pipe Air-conditioning compressor Oil cooler Air compressor © 200324 https://www.truck-manuals.net/...
Page 196 PE ENGINE General CF65/75/85 series M201117 Legend Alternator Glow plug Steering pump Engine identification plate Fuel lift pump/primer pump Fuel filter Oil filter UPEC pump housing Starter motor © 200324 https://www.truck-manuals.net/...
Page 197 PE ENGINE CF65/75/85 series General 2.2 IDENTIFICATION Engine number The engine number is marked on the cylinder block at front right-hand side (compressor side). M200748 PE engine identification plate 9 3 2 1 8 7 5 4 6 Fitted to the inlet manifold Engine type Engine number Order number...
Page 198 Camshaft bearing bush M200887 2.5 CRANKING THE ENGINE Cranking on the flywheel housing Place the special tool (DAF no. 1310477) on the opening at the bottom of the flywheel housing such that the pinion engages the starter ring gear. Turn the crankshaft clockwise as seen from the timing gear end (this corresponds to the direction of rotation of the engine).
Page 199 PE ENGINE CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION AND ADJUSTMENT, VALVE GEAR BRIDGES Loosening and tightening the lock nuts (B) of the bridges may cause severe engine damage if the bridge is fitted over the valves. Remove the valve covers.
Page 200 PE ENGINE Inspection and adjustment CF65/75/85 series 13. Fit the rocker seat. 14. Fit the lubricating oil strip in such a way that the mark "cyl. 1/4" is at the position of cylinder 1 and cylinder 4 respectively. 15. Adjust the valve clearance. 16.
Page 201 3.2 INSPECTION AND ADJUSTMENT, VALVE CLEARANCE Remove the valve covers, see chapter "Removal and installation". Use the special tool (DAF no. 1310477) to turn the crankshaft clockwise, as seen from the timing gear end (this corresponds with the engine's direction of rotation), until the valves of cylinder 1 are in overlap position.
Page 202 PE ENGINE Inspection and adjustment CF65/75/85 series 3.3 INSPECTION AND ADJUSTMENT, TIMING GEAR Checking the timing gear Remove the valve cover from cylinders 1-2- 3. See "Removal and Installation". Position cylinder 1 at top dead centre (TDC on the flywheel, cylinder 6 in overlap position).
Page 203 PE ENGINE CF65/75/85 series Inspection and adjustment Adjusting the timing gear Remove the valve cover from cylinders 1-2- 3. See "Removal and Installation". Position cylinder 1 at top dead centre (TDC on the flywheel, cylinder 6 in overlap position). Remove the timing gear cover. See "Removal and installation".
Page 204 PE ENGINE Inspection and adjustment CF65/75/85 series 3.4 INSPECTION OF AUTOMATIC POLY-V-BELT TENSIONER Inspection of automatic poly-V-belt tensioner Remove the poly-V-belt and switch off the automatic tensioner (0). See "Removal and installation". Place a torque wrench on the hexagonal head of the automatic tensioner. At the specified torsional distance (A) the torsional moment must have a certain value.
Page 205 Inspecting the V-belt tension Check the V-belt tension of the airc onditioning-compressor drive with the Krikit I, special tool (DAF no. 1240442). Set the gauge to zero by depressing the measuring arm (1). Place the belt tension gauge on the V-belt, halfway between the two pulleys.
Page 206 Place the stylus of the dial gauge at the specified distance. See "Technical data". Set the dial gauge to "0". Use the special tool (DAF no. 1310477) to crank the engine through 360°, and measure M200230 the maximum dial gauge reading. Compare this reading with the technical data.
Page 207 PE ENGINE CF65/75/85 series Inspection and adjustment 3.7 INSPECTION, CYLINDER HEAD Check the sealing plugs of the cylinder head for leaks. If necessary, pressure-test the cylinder head. Inspect the cylinder head for damage to the sealing surface and any cracks. If necessary, have the cylinder head levelled.
Page 208 Turn the engine a number of times using the starter motor, so that any carbon or dirt particles in the cylinder are removed. Fit the dummy injector (DAF no. 1329306), compression gauge (DAF no. 1329301) and adapter (DAF no. 0694972).
Page 209 PE ENGINE CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, ENGINE Suspend the engine securely from the hoist, using approved lifting gear. Various fluids will be released when fluid pipes are removed. Collect these fluids. Personal safety and the risk of fire should always be considered.
Page 210 PE ENGINE Removal and installation CF65/75/85 series 4.2 REMOVAL AND INSTALLATION, ENGINE MOUNTS Suspend the engine securely from the hoist, using approved lifting gear. Note: If the engine is lifted slightly it is not necessary to disconnect coolant hoses, air inlet hoses and torque rods between the engine and the radiator.
Page 211 PE ENGINE CF65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION, VALVE COVER When the engine or parts thereof are opened, dirt may penetrate. This may cause serious damage to the engine. Therefore, the engine should be cleaned thoroughly before any parts are opened.
Page 212 The rocker seat will resist this spring pressure and cannot therefore be positioned correctly. By cranking the crankshaft always stroke, using the special tool (DAF no. 1310477), the rocker seats (1) can be tightened according to the injection sequence 1-5-3-6- 2-4. M200560 Tighten the attachment bolts to the specified torque.
Page 213 PE ENGINE CF65/75/85 series Removal and installation 4.5 REMOVAL AND INSTALLATION, VALVE SLEEVE Removing the valve sleeve Remove the injection pipes in sets. Remove the valve covers. Remove the injectors. Remove the valve gear. Remove the push rods. Remove the valve sleeve and gasket. Installing the valve sleeve Fit the valve sleeve with a new gasket and tighten the attachment bolts to the specified...
Page 214 PE ENGINE Removal and installation CF65/75/85 series 4.6 REMOVAL AND INSTALLATION, INLET MANIFOLD Removing the inlet manifold Disconnect the electrical wiring on the inlet manifold. Remove the fuel leak-off pipe between the fuel filter and inlet manifold. Remove the coolant filter, if applicable. Remove the entire fuel filter from the inlet manifold.
Page 215 PE ENGINE CF65/75/85 series Removal and installation 4.7 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD Removing the exhaust manifold Remove the intake air pipe between the turbocharger and the air cooler. Remove the compressor pipe. Remove the turbocharger heat shields. Remove the air inlet hose. Remove the exhaust brake.
Page 216 13. Remove the inlet manifold attachment bolts and remove the entire manifold from the cylinder heads. 14. Remove the valve covers. 15. To remove the injectors and the clamping pieces, only use the special tool (DAF no. 1329412). © 200324 https://www.truck-manuals.net/...
Page 217 23. Check the threaded holes in the cylinder block for damage and cracking. 24. Using the special tool (DAF no. 0694795), check that the amount the cylinder liner protrudes above the cylinder block is within tolerance. See "Technical data".
Page 218 PE ENGINE Removal and installation CF65/75/85 series Place the new gasket(s) on the cylinder block, making sure that the letters TOP (1) are visible. The cylinder head gasket must not be retightened. Note: Always replace the cylinder head bolts. See "Technical data".
Page 219 PE ENGINE CF65/75/85 series Removal and installation 19. If applicable, fit the coolant filter to the coolant pipe. 20. Fit the heat shields of the exhaust manifold and tighten the attachment bolts to the specified torque. See "Technical data". 21. If applicable, fit the air-conditioning bracket. 22.
Page 220 PE ENGINE Removal and installation CF65/75/85 series 4.9 REMOVAL AND INSTALLATION, AIR COMPRESSOR Removing the air compressor Drain the coolant. Remove the oil filler pipe (5). Disconnect the service pipe from the air dryer (8). Remove the coolant connections (1). Disconnect the air pipes (2 and 3).
Page 221 PE ENGINE CF65/75/85 series Removal and installation Fit the mounting bracket (7) at the back of the compressor. Tighten the attachment bolts to the specified torque. See "Technical data". Fit the service pipe (8). Fit the lubricating oil pipe. Fit the air pipes (2 and 3). Fit the coolant pipes (1).
Page 222 PE ENGINE Removal and installation CF65/75/85 series 4.10 REMOVAL AND INSTALLATION, STEERING PUMP Removing the steering pump Clean the steering pump and the surrounding area. Remove the suction and delivery pipes from the steering pump. Collect the steering oil released from the system. Immediately plug the openings in the pump and hoses to prevent dirt entering the system.
Page 223 PE ENGINE CF65/75/85 series Removal and installation 4.11 REMOVAL AND INSTALLATION, STARTER MOTOR Removing the starter motor Disconnect the earth lead from the battery terminal. Disconnect the contacts of the starter motor. Remove the noise insulation cover if fitted. Remove the starter motor. Check the starter pinion for damage.
Page 224 PE ENGINE Removal and installation CF65/75/85 series 4.12 REMOVAL AND INSTALLATION, AIR-CONDITIONING COMPRESSOR V-BELT Removing the air-conditioning compressor V-belt Slacken the central bolt (1) of the tensioner. Unscrew the adjusting bolt (2) until the V-belt can be removed from the pulley. Fitting the air-conditioning compressor V-belt Inspect the pulley discs for damage, rust and greasy deposits.
Page 225 PE ENGINE CF65/75/85 series Removal and installation 4.13 REMOVAL AND INSTALLATION, POLY-V-BELT Removing the poly-V-belt Remove the locking screw from the wind tunnel collar (G) and turn the latter towards the radiator. If fitted, remove the air-conditioning compressor V-belt. M201032 Move the tensioner against the spring force and lock it with a 4 to 5 mm thick pin (bore).
Page 226 PE ENGINE Removal and installation CF65/75/85 series Turn the wind tunnel collar towards the engine and fit the locking screw. M201032 © 4-18 200324 https://www.truck-manuals.net/...
Page 227 PE ENGINE CF65/75/85 series Removal and installation 4.14 REMOVAL AND INSTALLATION, ALTERNATOR Removing the alternator Disconnect the earth lead from the battery terminal. Disconnect the electrical connections from the alternator. Move the tensioner against the force of the spring and lock the tensioner. Remove the poly-V-belt from the alternator pulley.
Page 228 PE ENGINE Removal and installation CF65/75/85 series 4.15 REMOVAL AND INSTALLATION, FLYWHEEL Removing the flywheel Remove the gearbox. Remove the clutch release assembly and the clutch plate. Remove the attachment bolts (1) from the flywheel. M200569 Use two bolts to remove the flywheel from the dowel pin.
Page 229 PE ENGINE CF65/75/85 series Removal and installation 4.16 REMOVAL AND INSTALLATION, STARTER RING GEAR Removing the starter ring gear Remove the flywheel. Remove the starter ring gear by tapping it off the flywheel, using a blunt chisel. If this is not possible, cut the starter ring gear between two teeth, using a sharp chisel.
Page 230 Remove the flywheel. Drill two small holes into the oil seal and pull the latter out of the flywheel housing using the special tool (DAF no. 0484899 en 0694928). Installing the flywheel housing seal Thoroughly clean the oil seal recess and inspect for damage.
Page 231 PE ENGINE CF65/75/85 series Removal and installation 4.18 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING Removing the flywheel housing Remove the flywheel. Disconnect the earth lead from the flywheel housing. Remove the starter motor. Remove the crankshaft position sensor. Suspend the engine securely in the hoist. Remove the two bolts attaching the oil sump to the flywheel housing.
Page 232 PE ENGINE Removal and installation CF65/75/85 series Fit the flywheel housing. Tighten the attachment bolts to the specified torque. See "Technical data". Fit the central engine mounting attachment bolts at the rear of the engine. Tighten the attachment bolts to the specified torque. See "Technical data".
Page 233 1453155) with the protruding part facing the engine. Fit the special tool (DAF no. 1453155) with the protruding part facing the radiator; use the 6 attachment nuts of the fan hub.
Page 234 Avoid personal injury and damage to the hub. Remove the vibration damper hub using the special tool (DAF no. 1453155). Installing the vibration damper hub Fit the vibration damper hub onto the crankshaft. Fit the thrust piece. Tighten the attachment bolts to the specified torque.
Page 235 Remove the vibration damper (5). Remove the vibration damper hub using the special tool (DAF no. 1329472). Loosen the coolant pipe (4) until it does not impede removal of the timing cover. 10. Mark the position of the various attachment bolts and studs.
Page 236 PE ENGINE Removal and installation CF65/75/85 series Installing the timing cover Use three studs to position the gasket. Fit the new gasket. Fit the timing cover (7). Install the attachment bolts and tighten them to the specified torque. See "Technical data". Remove the three studs used to position the gasket and replace them with the remaining attachment bolts.
Page 237 Remove the vibration damper. Remove the vibration damper hub. Remove the timing cover seal by using the special tool (DAF no. 1329458) to pull the seal out of the cover. Installing the timing cover seal Clean and check the seal recess in the timing cover.
Page 238 PE ENGINE Removal and installation CF65/75/85 series 4.23 REMOVAL AND INSTALLATION, TIMING GEARS Removing the timing gear Remove the valve covers. Position cylinder 1 at top dead centre (TDC on the flywheel, cylinder 6 in overlap position). Remove the timing cover. Note: It is possible that the marks on the idler gear are not exactly opposite the camshaft and...
Page 239 PE ENGINE CF65/75/85 series Removal and installation Installing the timing gears Check whether cylinder 1 is at top dead centre (TDC on the flywheel, cylinder 6 in overlap position). M201185 Note: When the crankshaft (1) or the camshaft (2) of an engine without an idler gear (3) is rotated separately, the engine's pistons may touch the valves.
Page 240 PE ENGINE Removal and installation CF65/75/85 series Installing the pump housing camshaft gear Fit the pump housing camshaft gear (5) to the shaft journal. Fit the pump housing camshaft gear attachment bolt (10). Tighten the attachment bolt to the specified torque. See "Technical data".
Page 241 PE ENGINE CF65/75/85 series Removal and installation 4.24 REMOVAL AND INSTALLATION, TIMING CASE Removing the timing case Remove the timing cover. Remove the timing gears. Remove the air compressor. Remove the steering pump. Remove the camshaft attachment bolts and locking plate. M200744 Loosen the oil sump attachment bolts until the oil sump is free from the timing case.
Page 242 PE ENGINE Removal and installation CF65/75/85 series Fit the timing gears. Fit a new O-ring to the air compressor and install the compressor. 10. Fit the steering pump. 11. Fit the timing cover. M200744 © 4-34 200324 https://www.truck-manuals.net/...
Page 243 PE ENGINE CF65/75/85 series Removal and installation 4.25 REMOVAL AND INSTALLATION, TIMING CASE OIL SEAL Removing the timing case oil seal Position cylinder 1 at top dead centre (TDC on the flywheel, cylinder 6 in overlap position). Remove the idler gear. M201185 Remove the pump housing camshaft gear (1).
Page 244 Removal and installation CF65/75/85 series Installing the timing case oil seal Fit a dry new timing case oil seal (2) using the special tool (DAF no. 1329318). Fit the pump housing camshaft gear (1). Fit the idler gear. Note: Remember the marks.
Page 245 PE ENGINE CF65/75/85 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 environment makes your work easier, and enables you to notice any engine defects at an early stage.
Page 246 PE ENGINE Cleaning CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 247 PE ENGINE COOLING SYSTEM CF65/75/85 series Contents CONTENTS 6 PE engine cooling system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 248 PE ENGINE COOLING SYSTEM Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 249 PE ENGINE COOLING SYSTEM CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 250 PE ENGINE COOLING SYSTEM Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 251 PE ENGINE COOLING SYSTEM CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF COMPONENTS M201118 Legend Thermostat housing Coolant pump Coolant filter Coolant pipe © 200324 https://www.truck-manuals.net/...
Page 252 PE ENGINE COOLING SYSTEM General CF65/75/85 series 2.2 SYSTEM DESCRIPTION, COOLING SYSTEM Auxiliary return Reservoir Heater unit cab heater valve Coolant filter Coolantpipe Retarder Automatic transmission Thermostat Radiator Cylinderhead Cylinderhead Oilcooler Compressor Coolantpipe Coolantpump Cylinderblock M201279 From the delivery side of the water pump (1), the coolant is directed to the cylinder block (2) via an opening at the back of the coolant pump.
Page 253 PE ENGINE COOLING SYSTEM CF65/75/85 series General The header tank (7) has four connections. On the 1 2 3 top of the radiator, there is a bleed pipe which is linked to connection 3 of the header tank. Connections 1 and 2 of the header tank are linked to the coolant collector pipe by bleed pipes.
Page 254 PE ENGINE COOLING SYSTEM General CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 255 PE ENGINE COOLING SYSTEM CF65/75/85 series Description of components 3. DESCRIPTION OF COMPONENTS 3.1 PRESSURE CAP The pressure cap is fitted to the header tank by means of a threaded connection. The pressure cap has two valves: a pressure relief valve (1) and a vacuum relief valve (2). Overpressure As a result of the rising coolant temperature, the pressure in the cooling system will increase.
Page 256 PE ENGINE COOLING SYSTEM Description of components CF65/75/85 series 3.2 DESCRIPTION OF THERMOSTAT Operation, thermostat The coolant enters the thermostat housing directly from the coolant collector pipe at the back and flows through the thermostat. Depending on the coolant temperature and the corresponding position of the thermostat, there are three possibilities: Thermostat closed...
Page 257 PE ENGINE COOLING SYSTEM CF65/75/85 series Description of components Thermostat starts opening M200740 The coolant has reached the thermostat opening temperature. The supply channel (B) to the radiator is opened and the bypass (A) is partially closed. Now coolant will flow both through the supply channel (B) to the radiator and through the bypass (A) directly to the coolant pump.
Page 258 PE ENGINE COOLING SYSTEM Description of components CF65/75/85 series 3.3 COOLANT FILTER The task of the coolant filter is to filter the coolant to prevent cavitation. The coolant filter is necessary when the cooling system is filled with low-quality coolant. ©...
Page 259 PE ENGINE COOLING SYSTEM CF65/75/85 series Description of components 3.4 VISCOUS FAN CLUTCH The fan is connected to the engine by means of a viscous fan clutch. If, under certain circumstances, the heat is not sufficiently dissipated by the air flow passing through the radiator, the fan will have to draw in extra cooling air through the radiator.
Page 260 PE ENGINE COOLING SYSTEM Description of components CF65/75/85 series As the air temperature rises, the bimetallic strip (6) will continue to bend and the opening (4) in the supply chamber (3) will be fully released. The further the opening (4) in the supply chamber (3) is released, the more silicone fluid will flow into the working area (1) and past the rotor (2).
Page 261 PE ENGINE COOLING SYSTEM CF65/75/85 series Inspection and adjustment 4. INSPECTION AND ADJUSTMENT 4.1 PRESSURE TESTING When the coolant is hot, there is overpressure in the cooling system. Carefully remove the filler cap to release the overpressure. Coolant is a toxic fluid. Contact with the skin should therefore be avoided.
Page 262 PE ENGINE COOLING SYSTEM Inspection and adjustment CF65/75/85 series 4.2 INSPECTION, THERMOSTAT M200742 Remove the thermostat. See "Removal and installation". Inspect the sealing surfaces (A) of the thermostat housing for damage. Inspect the oil seal (B) for damage. Inspect the thermostat seat (C) for damage. Check whether the thermostat is fully closed.
Page 263 PE ENGINE COOLING SYSTEM CF65/75/85 series Inspection and adjustment 4.3 INSPECTION, VISCOUS FAN CLUTCH 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.
Page 264 PE ENGINE COOLING SYSTEM Inspection and adjustment CF65/75/85 series Take a sheet of cardboard with a 100 mm hole, as shown in the drawing opposite, and place it in front of the radiator, with the hole in front of the viscous clutch. Check that the gearbox is in neutral.
Page 265 PE ENGINE COOLING SYSTEM CF65/75/85 series Inspection and adjustment 4.4 INSPECTION, COOLANT PUMP RADIAL PLAY Remove the poly-V-belt from the coolant pump pulley. Fit a dial gauge as shown in the illustration. Force the coolant pump pulley downwards and set the dial gauge to zero. Pull the coolant pump pulley upwards and read the dial gauge.
Page 266 PE ENGINE COOLING SYSTEM Inspection and adjustment CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 267 PE ENGINE COOLING SYSTEM CF65/75/85 series Removal and installation 5. REMOVAL AND INSTALLATION 5.1 REMOVAL AND INSTALLATION, COOLANT PUMP Removal, coolant pump Drain the coolant. See "Draining and filling". Remove the V-belt from the air conditioning compressor and the poly-V-belt from the alternator.
Page 268 PE ENGINE COOLING SYSTEM Removal and installation CF65/75/85 series 5.2 REMOVAL AND INSTALLATION, COOLANT FILTER When the coolant is hot, there is an overpressure in the cooling system. Carefully remove the filler cap to release the overpressure. Do not remove the filler cap when the engine is running.
Page 269 PE ENGINE COOLING SYSTEM CF65/75/85 series Removal and installation 5.3 REMOVAL AND INSTALLATION, THERMOSTAT Removing the thermostat Drain the coolant. See "Draining and filling". Remove the hose between the thermostat housing and the radiator. Remove the thermostat housing attachment bolts. Remove the thermostat housing and the connecting piece from the coolant pump.
Page 270 Installing the thermostat seat M200742 Apply locking compound to the thermostat seat (C) and fit it in the thermostat housing using the special tool (DAF no. 1310456). See "Technical data". Installing the thermostat oil seal Fit the thermostat seal (B) in the thermostat housing using the special tool (DAF no.
Page 271 PE ENGINE COOLING SYSTEM CF65/75/85 series Removal and installation 5.4 REMOVAL AND INSTALLATION, VISCOUS FAN CLUTCH Removing the viscous fan clutch Remove the front engine encapsulation. Loosen the wind tunnel collar by removing the retaining screw (G) and turn the wind tunnel collar towards the radiator.
Page 272 PE ENGINE COOLING SYSTEM Removal and installation CF65/75/85 series 5.5 REMOVAL AND INSTALLATION, RADIATOR UNIT Removing the radiator unit Drain the coolant. Disconnect the torque rods (H). Remove the air inlet hoses (F) between the engine and the air cooler. Remove the locking screws from the wind tunnel collar (G) and turn the latter inwards.
Page 273 PE ENGINE COOLING SYSTEM CF65/75/85 series Draining and filling 6. DRAINING AND FILLING 6.1 DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM In order to avoid damaging the cylinder block, do not top up a warm engine with cold coolant. Coolant is a toxic fluid and must be handled with care.
Page 274 PE ENGINE COOLING SYSTEM Draining and filling CF65/75/85 series Filling and bleeding cooling system Turn the heater temperature control knob in the cab to the "warmest" setting. With the cab in the driving position, fill the cooling system with the specified coolant up to the edge of the filler opening.
Page 275 Cleaning, radiator/air cooler With the aid of a simple tool, the radiator and the air cooler can be blow-cleaned. This tool can be made in your own workshop. It cannot be ordered from DAF. Key to drawing: 1150mm Solder up...
Page 276 PE ENGINE COOLING SYSTEM Cleaning CF65/75/85 series Turn the radiator cleaner over, turning the holes towards the radiator (2), and blow- clean the radiator (2). Fit the wire mesh. Install the lower grille. M2110 © 200324 https://www.truck-manuals.net/...
Page 277 PE ENGINE COOLING SYSTEM CF65/75/85 series Cleaning 7.2 FLUSHING COOLING SYSTEM In order to avoid damaging the cylinder block, do not top up a warm engine with cold coolant. Coolant is a toxic fluid and must be handled with care. Protect skin and eyes. Coolant is harmful to the environment;...
Page 278 PE ENGINE COOLING SYSTEM Cleaning CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 279 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series Contents CONTENTS 7 PE engine lubrication system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 280 PE ENGINE LUBRICATION SYSTEM Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 281 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 282 PE ENGINE LUBRICATION SYSTEM Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 283 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series General 2. GENERAL 2.1 SYSTEM DESCRIPTION, LUBRICATION SYSTEM M200909 © 200324 https://www.truck-manuals.net/...
Page 284 PE ENGINE LUBRICATION SYSTEM General CF65/75/85 series DEB unit/ Rocker Oilstrip assembly Piston 12 Piston pin 11 Piston rod 10 Camshaft Compressor Idler gear/ Crankshaft UPEC pump timing gears Turbo Fandrive charger Main duct gear Filter Oil cooler Pump Centrifugal filter M201280 General...
Page 285 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series General Pressure limiting valve A pressure-limiting valve (P) is installed in the lubricating system after the lubricating oil cooler. When the pressure set for the pressure limiting valve has been reached, the valve opens and any excess cooled lubricating oil will be discharged to the sump.
Page 286 PE ENGINE LUBRICATION SYSTEM General CF65/75/85 series Turbocharger and air compressor A lubricating oil channel running from a camshaft bearing is connected to the lubricating oil pipes leading to the turbocharger (14) and air compressor (13). The lubricating oil discharge pipe from the turbocharger is connected to a channel in the cylinder block, from where the oil returns to the oil sump.
Page 287 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 CHECKING ENGINE OIL CONSUMPTION Engine oil consumption relates to the engine oil used during combustion in the engine. Since engine oil consumption is affected by driving style and the use to which the vehicle is put, it is also related to average fuel consumption.
Page 288 3.3 PRESSURE TESTING THE LUBRICATING OIL COOLER Remove the lubricating oil cooler. See "Removal and installation". Place the special tools (DAF no. 1240476) 1240477 and (DAF no. 1240477) on the lubricating oil cooler. 1240476 Apply up to 2.5 bar of pressurised air to the special tool.
Page 289 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, OIL FILTER ELEMENT To prevent skin injury, avoid unnecessary contact with the drained lubricating oil. Discard the oil filter element. Removing the oil filter element Unscrew the cap (2) a few turns and drain the filter housing.
Page 290 PE ENGINE LUBRICATION SYSTEM Removal and installation CF65/75/85 series 4.2 REMOVAL AND INSTALLATION, OIL-FILTER HOUSING Removing the oil-filter housing Drain the oil from the filter housing by loosening the cap (2) a few turns. Disconnect the electrical connections from the lubricating oil pressure sensor. Remove the oil-filter housing (1).
Page 291 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION, OIL COOLER Removing the oil cooler Drain the coolant. See "PE engine cooling system". Remove the heat shield from the exhaust elbow. Remove the exhaust elbow and exhaust brake operating cylinder.
Page 292 PE ENGINE LUBRICATION SYSTEM Removal and installation CF65/75/85 series 4.4 REMOVAL AND INSTALLATION, OIL SUMP Removing the oil sump Remove the oil sealing plug. Drain the oil. See "Draining and filling". Remove the oil level sensor. Note: If the oil level sensor is not removed, the sensor could easily break while removing the oil sump.
Page 293 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series Removal and installation 4.5 REMOVAL AND INSTALLATION, OIL PUMP Removing the oil pump Remove the oil sump. Remove the suction pipe and delivery pipe (1). Remove the bolts (2) attaching the oil pump to the main bearing cap. Remove the attachment bolt (3) and take the oil pump off the main bearing cap.
Page 294 PE ENGINE LUBRICATION SYSTEM Removal and installation CF65/75/85 series 4.6 REMOVAL AND INSTALLATION, CENTRIFUGAL OIL FILTER ELEMENT To prevent skin injury, avoid unnecessary contact with the drained lubricating oil. Removing centrifugal oil filter element Remove the noise encapsulation on the right-hand side.
Page 295 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series Disassembly and assembly 5. DISASSEMBLY AND ASSEMBLY 5.1 DISASSEMBLY AND ASSEMBLY, OIL PUMP Disassembling the oil pump Remove the idler gear and hub from the front plate. Remove all attachment bolts from the two sections of the oil-pump housing.
Page 296 PE ENGINE LUBRICATION SYSTEM Disassembly and assembly CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 297 PE ENGINE LUBRICATION SYSTEM CF65/75/85 series Draining and filling 6. DRAINING AND FILLING 6.1 DRAINING AND FILLING LUBRICATING OIL To prevent skin injury, avoid unnecessary contact with the drained lubricating oil. Place the vehicle on a level and horizontal surface. Drain the lubricating oil using the drain plug in the oil sump.
Page 298 PE ENGINE LUBRICATION SYSTEM Draining and filling CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 299 XE ENGINE CF65/75/85 series Contents CONTENTS 8 XE engine Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 300 XE ENGINE Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 301 XE ENGINE CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 302 XE ENGINE Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 303 XE ENGINE CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF COMPONENTS M201130 Legend Thermostat housing Coolant pump Air-conditioning compressor Fan drive Vibration damper Oil filter Oil filler pipe Poly-V-belt tensioner Starter motor 10. Coolant filter 11. Fuel filter 12. UPEC pump housing 13.
Page 304 XE ENGINE General CF65/75/85 series M201129 Legend Air intake pipe Wastegate diaphragm Turbocharger Exhaust manifold Air compressor Exhaust brake valve Oil cooler Centrifugal oil filter © 200324 https://www.truck-manuals.net/...
Page 305 XE ENGINE CF65/75/85 series General 2.2 IDENTIFICATION Engine number The engine number is stamped on the cylinder block at the rear left M201087 XE engine identification plate 9 3 2 1 8 7 5 4 6 Fitted to the inlet manifold Engine type Engine number Order number...
Page 306 XE ENGINE General CF65/75/85 series 2.3 OVERVIEW DRAWING, TIMING GEAR Legend Crankshaft gear Camshaft gear Idler gear Fan drive Steering pump gear Pump housing camshaft gear Air compressor gear Oil pump idler gear Oil pump M200886 2.4 OVERVIEW DRAWING, PUMP HOUSING CAMSHAFT DRIVE Pump housing camshaft gear Timing case oil seal Pump housing...
Page 307 (B) whilst securing the bolt (A). M201273 Cranking using the flywheel Place the special tool (DAF no. 1310477) on the opening at the bottom of the flywheel housing such that the pinion engages the starter ring gear. Turn the crankshaft clockwise as seen from the timing gear end (this corresponds to the direction of rotation of the engine).
Page 308 XE ENGINE General CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 309 XE ENGINE CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION AND ADJUSTMENT, VALVE GEAR BRIDGES Remove the valve covers. See "Removal and installation". Remove the DEB or the lubricating oil strip (depending on version). Remove the entire rocker seat. Mark the position to enable reinstallation in the same position.
Page 310 XE ENGINE Inspection and adjustment CF65/75/85 series Remove the bridge from the valves and place it in a vice. Loosening and tightening the lock nuts (B) of the bridges may cause severe damage to the valve guides if the bridge is fitted over the valves. Slacken the lock nut (B).
Page 311 XE ENGINE CF65/75/85 series Inspection and adjustment 3.2 REMOVAL AND INSTALLATION, VALVE COVER When the engine or parts thereof are opened, dirt may penetrate. This may cause serious damage to the engine. Therefore, the engine should be cleaned thoroughly before any parts are opened.
Page 312 XE ENGINE Inspection and adjustment CF65/75/85 series 3.3 INSPECTION AND ADJUSTMENT, TIMING GEAR Checking the timing gear Remove the valve cover from cylinders 1-2-3. See "Removal and Installation". Position cylinder 1 at top dead centre (TDC on the flywheel, cylinder 6 in overlap position).
Page 313 XE ENGINE CF65/75/85 series Inspection and adjustment Adjusting the timing gear Remove the valve cover from cylinders 1-2- 3. See "Removal and Installation". Position cylinder 1 at top dead centre (TDC on the flywheel, cylinder 6 in overlap position). Remove the timing gear cover. See "Removal and installation".
Page 314 XE ENGINE Inspection and adjustment CF65/75/85 series 3.4 INSPECTION OF AUTOMATIC POLY-V-BELT TENSIONER Inspection of automatic poly-V-belt tensioner Remove the poly-V-belt and switch off the automatic tensioner (0). See "Removal and installation". Place a torque wrench on the hexagonal head of the automatic tensioner. At the specified torsional distance (A) the torsional moment must have a certain value.
Page 315 Inspecting the V-belt tension Check the V-belt tension of the air conditioning compressor drive using the Krikit I, special tool (DAF no. 1240442). Check the V-belt tension of the FAX model steering pump drive using the Krikit II, special tool (DAF no. 1240443).
Page 316 XE ENGINE Inspection and adjustment CF65/75/85 series Adjusting V-belt tension of FAX model steering pump Slacken the central bolt (1) of the tension roller. Turn the adjusting bolt (2) until the V-belt tension is correct, see "Technical data". Tighten the central bolt (1) to the specified tightening torque, see "Technical data".
Page 317 Place the stylus of the dial gauge at the specified distance. See "Technical data". Set the dial gauge to "0". Use the special tool (DAF no. 1310477) to crank the engine through 360°, and measure M200230 the maximum dial gauge reading. Compare this reading with the technical data.
Page 318 XE ENGINE Inspection and adjustment CF65/75/85 series 3.7 INSPECTION, CYLINDER HEAD Check the sealing plugs of the cylinder head for leaks. If necessary, pressure-test the cylinder head. Inspect the cylinder head for damage to the sealing surface and any cracks. If necessary, have the cylinder head levelled.
Page 319 Turn the engine a number of times using the starter motor, so that any carbon or dirt particles in the cylinder are removed. Fit the dummy injector (DAF no. 1329306), compression gauge (DAF no. 1329301) and adapter (DAF no. 0694972).
Page 320 XE ENGINE Inspection and adjustment CF65/75/85 series © 3-12 200324 https://www.truck-manuals.net/...
Page 321 XE ENGINE CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, ENGINE Suspend the engine securely from the hoist, using approved lifting gear. Various fluids will be released when fluid pipes are removed. Collect these fluids. Personal safety and the risk of fire should always be considered.
Page 322 XE ENGINE Removal and installation CF65/75/85 series 4.2 REMOVAL AND INSTALLATION, ENGINE MOUNTS Suspend the engine securely from the hoist, using approved lifting gear. Note: If the engine is lifted slightly it is not necessary to disconnect coolant hoses, air inlet hoses and torque rods between the engine and the radiator.
Page 323 XE ENGINE CF65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION, VALVE COVER When the engine or parts thereof are opened, dirt may penetrate. This may cause serious damage to the engine. Therefore, the engine should be cleaned thoroughly before any parts are opened.
Page 324 The rocker seat will resist this spring pressure and cannot therefore be positioned correctly. By cranking the crankshaft turn each time using the special tool (DAF No. 1310477), the rocker seats can be tightened in the injection sequence 1-5-3-6-2-4. Tighten the attachment bolts to the specified torque.
Page 325 XE ENGINE CF65/75/85 series Removal and installation Fit the DEB or the lubricating oil strip (depending on version). Fit the lubricating oil strip in such a way that the mark "cyl. 1/4" is located on cylinder 1 or cylinder 4. For the tightening torques of the attachment bolts, see "Technical data".
Page 326 XE ENGINE Removal and installation CF65/75/85 series 4.5 REMOVAL AND INSTALLATION, VALVE SLEEVE Removing the valve sleeve Remove the injection pipes in sets. Remove the valve covers. If necessary, disconnect the electrical connection of the DEB. If necessary, remove the cable harness from the DEB or the plug from the valve sleeve.
Page 327 XE ENGINE CF65/75/85 series Removal and installation 4.6 REMOVAL AND INSTALLATION, INLET MANIFOLD Removing the inlet manifold Disconnect the electrical wiring on the inlet manifold. Remove the fuel leak-off pipe between the fuel filter and inlet manifold. Remove the coolant filter, if applicable. Remove the entire fuel filter from the inlet manifold.
Page 328 XE ENGINE Removal and installation CF65/75/85 series 4.7 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD Removing the exhaust manifold Take the exhaust brake cylinder (8) off the butterfly valve (4). Remove the clamping strip from the exhaust brake (4). Remove the air inlet hose (2). Remove the inlet air pipe (1) between the turbocharger and the intercooler.
Page 329 XE ENGINE CF65/75/85 series Removal and installation 4.8 REMOVAL AND INSTALLATION, CYLINDER HEADS When the engine or parts thereof are opened, dirt may enter. This may cause serious damage to the engine. Therefore, the engine should be cleaned thoroughly before any parts are opened.
Page 330 Removal and installation CF65/75/85 series 16. To remove the injectors and the clamping pieces, only use the special tools (DAF no. 1329412) and (DAF no. 0694928). 17. Remove the valve gear. 18. Remove the push rods. Note: Make sure that any solid push rods (yellow marking and diameter 12 mm) are fitted back on the inlet side only.
Page 331 24. Check the threaded holes in the cylinder block for damage and cracking. M201278 25. Using the special tool (DAF no. 0694795), check that the amount the cylinder liner protrudes above the cylinder block is within tolerance. See "Technical data".
Page 332 XE ENGINE Removal and installation CF65/75/85 series Place the new gasket(s) on the cylinder block, making sure that the letters TOP (1) are visible. The cylinder head gasket must not be retightened. Note: Always replace the cylinder head bolts. See "Technical data".
Page 333 XE ENGINE CF65/75/85 series Removal and installation 16. Fit the coolant pipe, fit new gaskets to the thermostat housing and install it. 17. Fit the injector pipes in sets. 18. Fit the fuel filter onto the coolant pipe. 19. Fit the fuel leak-off pipe between the fuel filter and the inlet manifold.
Page 334 XE ENGINE Removal and installation CF65/75/85 series 4.9 REMOVAL AND INSTALLATION, AIR COMPRESSOR Removing the air compressor Partially drain the coolant. Remove the coolant connections (1). Disconnect the air pipes (2 and 3). Disconnect the lubricating oil pipe. Disconnect the service pipe from the air dryer.
Page 335 XE ENGINE CF65/75/85 series Removal and installation 4.10 REMOVAL AND INSTALLATION, STEERING PUMP Removing the steering pump Clean the steering pump and the surrounding area. Remove the suction and delivery pipes from the steering pump. Collect the steering oil released from the system. Immediately plug the openings in the pump and hoses to prevent dirt entering the system.
Page 336 XE ENGINE Removal and installation CF65/75/85 series 4.11 REMOVAL AND INSTALLATION, STARTER MOTOR Removing the starter motor Disconnect the earth lead from the battery terminal. Disconnect the contacts of the starter motor. Remove the noise insulation cover if fitted. Remove the starter motor. Check the starter pinion for damage.
Page 337 XE ENGINE CF65/75/85 series Removal and installation 4.12 REMOVAL AND INSTALLATION, POLY-V-BELT Removing the poly-V-belt Remove the locking screw from the wind tunnel collar (G) and turn the latter towards the radiator. M201032 Move the tensioner against the spring force and lock it with a 4 to 5 mm thick pin (bore).
Page 338 XE ENGINE Removal and installation CF65/75/85 series Installing the poly-V-belt Inspect the belt pulleys for damage, rust and grease deposits. Pull the poly-V-belt over the fan. Pull the poly-V-belt over the coolant pump, fan drive and alternator pulleys and push it between the pulleys in the direction of the tensioner.
Page 339 XE ENGINE CF65/75/85 series Removal and installation 4.13 REMOVAL AND INSTALLATION, AIR-CONDITIONING COMPRESSOR V-BELT Removing the air-conditioning compressor V-belt Remove the poly-V-belt from the coolant pump. Slacken the upper attachment bolt (1) of the compressor. Slacken the lower attachment bolt (2) of the compressor.
Page 340 XE ENGINE Removal and installation CF65/75/85 series 4.14 REMOVAL AND INSTALLATION, FAX MODEL STEERING PUMP V-BELT Removing V-belt of FAX model steering pump Unscrew the central tensioner (1) bolt. Unscrew the adjusting bolt (2) until the V-belt can be removed. Fitting V-belt of FAX model steering pump Inspect the pulley discs for damage, rust and greasy deposits.
Page 341 XE ENGINE CF65/75/85 series Removal and installation 4.15 REMOVAL AND INSTALLATION, ALTERNATOR Removing the alternator Disconnect the earth lead from the battery terminal. Disconnect the electrical connections from the alternator. Move the tensioner against the force of the spring and lock the tensioner. Remove the poly-V-belt from the alternator pulley.
Page 342 XE ENGINE Removal and installation CF65/75/85 series 4.16 REMOVAL AND INSTALLATION, FLYWHEEL Removing the flywheel Remove the gearbox. Remove the clutch release assembly and the clutch plate. Remove the attachment bolts (1) from the flywheel. M200569 Use two bolts to remove the flywheel from the dowel pin.
Page 343 XE ENGINE CF65/75/85 series Removal and installation 4.17 REMOVAL AND INSTALLATION, STARTER RING GEAR Removing the starter ring gear Remove the flywheel. Remove the starter ring gear by tapping it off the flywheel, using a blunt chisel. If this is not possible, cut the starter ring gear between two teeth, using a sharp chisel.
Page 344 Remove the flywheel. Drill two small holes into the oil seal and pull the latter out of the flywheel housing using the special tool (DAF no. 0484899 en 0694928). Installing the flywheel housing seal Thoroughly clean the oil seal recess and inspect for damage.
Page 345 XE ENGINE CF65/75/85 series Removal and installation 4.19 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING Removing the flywheel housing Remove the flywheel. Disconnect the earth lead from the flywheel housing. Remove the starter motor. Remove the crankshaft position sensor. Suspend the engine securely in the hoist. Remove the two bolts attaching the oil sump to the flywheel housing.
Page 346 XE ENGINE Removal and installation CF65/75/85 series Fit the central engine mounting attachment bolts at the rear of the engine. Tighten the attachment bolts to the specified torque. See "Technical data". Fit the oil seal. Fit the flywheel. 10. Fit the starter motor. 11.
Page 347 XE ENGINE CF65/75/85 series Removal and installation 4.20 REMOVAL AND INSTALLATION, FAN DRIVE Removing the fan drive Remove the attachment nuts from the viscous fan clutch. Place the viscous fan clutch and the fan in the wind tunnel. Remove the poly-V-belt. Remove the fan drive attachment nuts.
Page 348 XE ENGINE Removal and installation CF65/75/85 series 4.21 REMOVAL AND INSTALLATION, VIBRATION DAMPER Removing the vibration damper Remove the poly-V-belt. Remove the attachment nuts from the viscous fan clutch. Place the viscous fan clutch and the fan in the wind tunnel. Remove the attachment bolts (9) of the fan pulley (6) and remove it.
Page 349 Avoid personal injury and damage to the hub. Remove the vibration damper hub (1) using the special tool (2) (DAF no. 1453155). Installing the vibration damper hub Fit the vibration damper hub (1) onto the crankshaft. Fit the thrust piece. Tighten the attachment bolts to the specified torque.
Page 350 Remove the fan drive. Remove the vibration damper. Remove the vibration damper hub using the special tool (DAF no. 1310422). Remove the coolant pipe. Remove the oil filler pipe. Mark the positions of the various attachment bolts and studs.
Page 351 XE ENGINE CF65/75/85 series Removal and installation Remove the three studs used to position the gasket and replace them with the remaining attachment bolts. Fit new O-rings to the coolant pipe and fit it. Fit a new O-ring to the oil filler pipe and install the oil filler pipe.
Page 352 Remove the vibration damper. Remove the vibration damper hub. Remove the timing cover seal by using the special tool (DAF no. 1329458) to pull the seal out of the cover. Installing the timing cover seal Clean and check the seal recess in the timing cover.
Page 353 XE ENGINE CF65/75/85 series Removal and installation 4.25 REMOVAL AND INSTALLATION, TIMING GEAR WHEELS Removing the timing gear Remove the valve covers. Position cylinder 1 at top dead centre (TDC on the flywheel, cylinder 6 in overlap position). Remove the timing cover. Note: It is possible that the marks on the idler gear are not exactly opposite the camshaft and...
Page 354 XE ENGINE Removal and installation CF65/75/85 series Installing the idler gear Fit the idler gear (3) so that the mark on the idler gear (3) is opposite the marks on the camshaft gear (2) and the crankshaft gear (1). Fit the attachment bolt (10) and the axial thrust washer (11) of the idler gear (3).
Page 355 XE ENGINE CF65/75/85 series Removal and installation 4.26 REMOVAL AND INSTALLATION, TIMING CASE Removing the timing case Remove the timing gears. Remove the air compressor. Remove the steering pump. Remove the camshaft attachment bolts and locking plate. M200954 Loosen the oil sump attachment bolts until the oil sump is free from the timing case.
Page 356 XE ENGINE Removal and installation CF65/75/85 series Tighten the oil sump attachment bolts to the specified torque. See "Technical data". Fit the camshaft locking plate and attachment bolts. Tighten the attachment bolts to the specified torque. See "Technical data". Fit the timing gears. Fit a new O-ring to the air compressor and fit the air compressor.
Page 357 XE ENGINE CF65/75/85 series Removal and installation 4.27 REMOVAL AND INSTALLATION, TIMING CASE OIL SEAL Removing the timing case oil seal Position cylinder 1 at top dead centre (TDC on the flywheel, cylinder 6 in overlap position). Remove the idler gear. M201185 Remove the pump housing camshaft gear (1).
Page 358 Removal and installation CF65/75/85 series Installing the timing case oil seal Fit a dry new timing case oil seal (2) using the special tool (DAF no. 1329318). Fit the pump housing camshaft gear (1). Fit the idler gear. Note: Remember the marks.
Page 359 XE ENGINE CF65/75/85 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 environment makes your work easier, and enables you to notice any engine defects at an early stage.
Page 360 XE ENGINE Cleaning CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 361 XE ENGINE COOLING SYSTEM CF65/75/85 series Contents CONTENTS 9 XE engine cooling system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 362 XE ENGINE COOLING SYSTEM Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 363 XE ENGINE COOLING SYSTEM CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 364 XE ENGINE COOLING SYSTEM Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 365 XE ENGINE COOLING SYSTEM CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF COMPONENTS M201131 Thermostat housing Coolant pipe Coolant pump Fan drive Coolant filter © 200324 https://www.truck-manuals.net/...
Page 366 XE ENGINE COOLING SYSTEM General CF65/75/85 series M201132 Water-cooled compressor Oil cooler © 200324 https://www.truck-manuals.net/...
Page 367 XE ENGINE COOLING SYSTEM CF65/75/85 series General 2.2 SYSTEM DESCRIPTION, COOLING SYSTEM Auxiliary return Reservoir Heater unit cab heater valve Coolant filter Coolantpipe Retarder Automatic transmission Thermostat Radiator Cylinderhead Cylinderhead Oilcooler Compressor Coolantpipe Coolantpump Cylinderblock M201279 From the delivery side of the water pump (1), the coolant is directed to the cylinder block (2) via an opening at the back of the coolant pump.
Page 368 XE ENGINE COOLING SYSTEM General CF65/75/85 series The header tank (7) has four connections. On the 1 2 3 top of the radiator, there is a bleed pipe which is linked to connection 3 of the header tank. Connections 1 and 2 of the header tank are linked to the coolant collector pipe by bleed pipes.
Page 369 XE ENGINE COOLING SYSTEM CF65/75/85 series Description of components 3. DESCRIPTION OF COMPONENTS 3.1 PRESSURE CAP The pressure cap is fitted to the header tank by means of a threaded connection. The pressure cap has two valves: a pressure relief valve (1) and a vacuum relief valve (2). Overpressure As a result of the rising coolant temperature, the pressure in the cooling system will increase.
Page 370 XE ENGINE COOLING SYSTEM Description of components CF65/75/85 series 3.2 THERMOSTAT The coolant enters the thermostat housing from the coolant collector pipe at the back and then flows through the thermostat. Depending on the coolant temperature and the corresponding position of the thermostat, there are three possibilities: Thermostat closed The coolant has not yet reached the thermostat...
Page 371 XE ENGINE COOLING SYSTEM CF65/75/85 series Description of components 3.3 COOLANT FILTER The task of the coolant filter is to filter the coolant to prevent cavitation. The coolant filter is necessary when the cooling system is filled with low-quality coolant. ©...
Page 372 XE ENGINE COOLING SYSTEM Description of components CF65/75/85 series 3.4 VISCOUS FAN CLUTCH The fan is connected to the engine by means of a viscous fan clutch. If, under certain circumstances, the heat is not sufficiently dissipated by the air flow passing through the radiator, the fan will have to draw in extra cooling air through the radiator.
Page 373 XE ENGINE COOLING SYSTEM CF65/75/85 series Description of components As the air temperature rises, the bimetallic strip (6) will continue to bend and the opening (4) in the supply chamber (3) will be fully released. The further the opening (4) in the supply chamber (3) is released, the more silicone fluid will flow into the working area (1) and past the rotor (2).
Page 374 XE ENGINE COOLING SYSTEM Description of components CF65/75/85 series 3.5 ELECTRONICALLY CONTROLLED VISCOUS FAN CLUTCH For accurate fan speed control, an electronically controlled viscous fan clutch is used. The electronically controlled viscous fan clutch checks and controls the fan speed to ensure that the flow of cooling air through the cooling system is sufficient to keep the coolant temperature and/ or inlet air temperature within certain limits.
Page 375 XE ENGINE COOLING SYSTEM CF65/75/85 series Description of components The coil (10) fitted to the drive shaft (4) with bearings generates a magnetic field. Depending on the variables mentioned earlier, the PWM signal to the coil (10) will be adapted. This will cause changes in the magnetic field and the valve (9) will be attracted either more or less frequently.
Page 376 XE ENGINE COOLING SYSTEM Description of components CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 377 XE ENGINE COOLING SYSTEM CF65/75/85 series Inspection and adjustment 4. INSPECTION AND ADJUSTMENT 4.1 PRESSURE TESTING When the coolant is hot, there is overpressure in the cooling system. Carefully remove the filler cap to release the overpressure. Coolant is a toxic fluid. Contact with the skin should therefore be avoided.
Page 378 XE ENGINE COOLING SYSTEM Inspection and adjustment CF65/75/85 series 4.2 INSPECTION, THERMOSTAT Remove the thermostat. See "Removal and installation". Inspect the sealing surfaces (A) of the thermostat housing for damage. Inspect the oil seal (B) for damage. Inspect the thermostat seat (C) for damage. Check whether the thermostat is fully closed.
Page 379 XE ENGINE COOLING SYSTEM CF65/75/85 series Inspection and adjustment 4.3 INSPECTION, VISCOUS FAN CLUTCH 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.
Page 380 XE ENGINE COOLING SYSTEM Inspection and adjustment CF65/75/85 series Testing with a warm engine Check the steering oil level and top up as necessary. Be careful when topping up the coolant of a warm engine. Take a sheet of cardboard with a 100 mm hole, as shown in the drawing opposite, and place it in front of the radiator, with the hole in front of the viscous clutch.
Page 381 XE ENGINE COOLING SYSTEM CF65/75/85 series Inspection and adjustment 4.4 INSPECTION, COOLANT PUMP RADIAL PLAY Remove the poly-V-belt from the coolant pump pulley. Fit a dial gauge as shown in the illustration. Force the coolant pump pulley downwards and set the dial gauge to zero. Pull the coolant pump pulley upwards and read the dial gauge.
Page 382 XE ENGINE COOLING SYSTEM Inspection and adjustment CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 383 XE ENGINE COOLING SYSTEM CF65/75/85 series Removal and installation 5. REMOVAL AND INSTALLATION 5.1 REMOVAL AND INSTALLATION, COOLANT PUMP Removal, coolant pump Remove the front engine encapsulation. Drain the coolant. See "Draining and filling". Remove the torque rod between the engine and the radiator.
Page 384 XE ENGINE COOLING SYSTEM Removal and installation CF65/75/85 series Fit all coolant hoses connected to the coolant pump. Fit the V-belts from the alternator and the air- conditioning compressor. Fit the viscous fan clutch with the fan. Fit the guide ring brackets and the guide ring. 10.
Page 385 XE ENGINE COOLING SYSTEM CF65/75/85 series Removal and installation Removing the coolant filter Place a tray beneath the coolant filter to collect any escaping coolant. Remove the filler cap from the expansion tank. Turn the shut-off valve (1) clockwise to the "C"...
Page 386 XE ENGINE COOLING SYSTEM Removal and installation CF65/75/85 series 5.3 REMOVAL AND INSTALLATION, THERMOSTAT Removing the thermostat Partially drain the radiator. See "Draining and filling". Remove the filler cap. Disconnect the hose. Remove the thermostat housing attachment bolts. Remove the thermostat housing and the connecting piece from the coolant pump and the O-ring (A) from the thermostat housing.
Page 387 Installing the thermostat seat Apply locking compound to the thermostat seat (C) and fit it in the thermostat housing using the special tool (DAF no. 1310456). See "Technical data". Installing the thermostat oil seal Fit the thermostat seal (B) in the thermostat housing using the special tool (DAF no.
Page 388 XE ENGINE COOLING SYSTEM Removal and installation CF65/75/85 series 5.4 REMOVAL AND INSTALLATION, VISCOUS FAN CLUTCH Removing the viscous fan clutch Remove the front engine encapsulation. Loosen the wind tunnel collar by removing the retaining screw (G) and turn the wind tunnel collar towards the radiator.
Page 389 XE ENGINE COOLING SYSTEM CF65/75/85 series Removal and installation 5.5 REMOVAL AND INSTALLATION, RADIATOR UNIT Removing the radiator unit Drain the coolant. Disconnect the torque rods (H). Remove the air inlet hoses (F) between the engine and the air cooler. Remove the locking screws from the wind tunnel collar (G) and turn the latter inwards.
Page 390 XE ENGINE COOLING SYSTEM Removal and installation CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 391 XE ENGINE COOLING SYSTEM CF65/75/85 series Draining and filling 6. DRAINING AND FILLING 6.1 DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM In order to avoid damaging the cylinder block, do not top up a warm engine with cold coolant. Coolant is a toxic fluid and must be handled with care.
Page 392 XE ENGINE COOLING SYSTEM Draining and filling CF65/75/85 series If the vehicle is equipped with a water/air cab heater: Run the engine at idling speed. Switch on the cab heater, using the rocker switch on the dashboard. Turn the heater temperature control knob in the cab to the "warmest"...
Page 393 Cleaning, radiator/air cooler With the aid of a simple tool, the radiator and the air cooler can be blow-cleaned. This tool can be made in your own workshop. It cannot be ordered from DAF. Key to drawing: 1150mm Solder up...
Page 394 XE ENGINE COOLING SYSTEM Cleaning CF65/75/85 series Turn the radiator cleaner over, turning the holes towards the radiator (2), and blow- clean the radiator (2). Fit the wire mesh. Install the lower grille. M2110 © 200324 https://www.truck-manuals.net/...
Page 395 XE ENGINE COOLING SYSTEM CF65/75/85 series Cleaning 7.2 DRAINING COOLING SYSTEM In order to avoid damaging the cylinder block, do not top up a warm engine with cold coolant. Coolant is a toxic fluid and must be handled with care. Protect skin and eyes. Coolant is harmful to the environment;...
Page 396 XE ENGINE COOLING SYSTEM Cleaning CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 397 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series Contents CONTENTS 10 XE engine lubrication system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 398 XE ENGINE LUBRICATION SYSTEM Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 399 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 400 XE ENGINE LUBRICATION SYSTEM Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 401 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series General 2. GENERAL 2.1 SYSTEM DESCRIPTION, LUBRICATION SYSTEM M200907 © 200324 https://www.truck-manuals.net/...
Page 402 XE ENGINE LUBRICATION SYSTEM General CF65/75/85 series DEB unit/ Rocker Oilstrip assembly Piston 12 Piston pin 11 Piston rod 10 Camshaft Compressor Idler gear/ Crankshaft UPEC pump timing gears Turbo Fandrive charger Main duct gear Filter Oil cooler Pump Centrifugal filter M201280 General...
Page 403 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series General Pressure limiting valve A pressure limiting valve (P) is installed in the lubricating system after the lubricating oil cooler. When the pressure set for the pressure limiting valve has been reached, the valve opens and any excess cooled lubricating oil will be discharged to the sump.
Page 404 XE ENGINE LUBRICATION SYSTEM General CF65/75/85 series Piston and big-end bearings The pistons (12) and the upper big-end bearings (11) are lubricated by means of lubricating oil nozzles connected to the main lubricating oil channel (4). In addition to its lubricating function, the lubricating oil has an important cooling function.
Page 405 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 CHECKING ENGINE OIL CONSUMPTION Engine oil consumption relates to the engine oil used during combustion in the engine. Since engine oil consumption is affected by driving style and the use to which the vehicle is put, it is also related to average fuel consumption.
Page 406 In the oil pressure sensor connection, fit a lubricating oil pressure gauge and the special tool (DAF no. 0535551). Start the engine and measure the lubricating oil pressure at idling speed and at full-load engine speed. Compare the pressure readings with the technical data.
Page 407 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series Inspection and adjustment 3.3 PRESSURE TESTING THE OIL COOLER Remove the oil cooler including the oil cooler bracket from the cylinder block. See "Removal and installation". Remove any protective cover from the oil cooler. Fit a plug in the opening (B) and to the other end (A) connect a nipple with a compressed air connection.
Page 408 XE ENGINE LUBRICATION SYSTEM Inspection and adjustment CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 409 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, OIL FILTER ELEMENT To prevent skin injury, avoid unnecessary contact with the drained lubricating oil. Discard the oil filter element. Removing the oil filter element Unscrew the cap (2) a few turns and drain the filter housing.
Page 410 XE ENGINE LUBRICATION SYSTEM Removal and installation CF65/75/85 series 4.2 REMOVAL AND INSTALLATION, OIL-FILTER HOUSING Removing the oil-filter housing Drain the oil from the filter housing by loosening the cap (2) a few turns. Disconnect the electrical connections from the lubricating oil pressure sensor. Remove the oil-filter housing (1).
Page 411 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION, OIL COOLER Removing the oil cooler Drain the coolant. See "Draining and filling". Disconnect the coolant connections. Disconnect the exhaust brake air supply pipe. Remove the attachment bolts and the oil cooler.
Page 412 XE ENGINE LUBRICATION SYSTEM Removal and installation CF65/75/85 series 4.4 REMOVAL AND INSTALLATION, OIL SUMP Removing the oil sump Remove the oil sealing plug. Drain the oil. See "Draining and filling". Remove the oil level sensor. Note: If the oil level sensor is not removed, the sensor could easily break while removing the oil sump.
Page 413 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series Removal and installation 4.5 REMOVAL AND INSTALLATION, OIL PUMP Removing the oil pump Remove the oil sump. Remove the suction pipe and delivery pipe (1). Remove the bolts (2) attaching the oil pump to the main bearing cap. Remove the attachment bolt (3) and take the oil pump off the main bearing cap.
Page 414 XE ENGINE LUBRICATION SYSTEM Removal and installation CF65/75/85 series 4.6 REMOVAL AND INSTALLATION, CENTRIFUGAL OIL FILTER ELEMENT To prevent skin injury, avoid unnecessary contact with the drained lubricating oil. Removing centrifugal oil filter element Remove the noise encapsulation on the right-hand side.
Page 415 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series Disassembly and assembly 5. DISASSEMBLY AND ASSEMBLY 5.1 DISASSEMBLY AND ASSEMBLY, OIL PUMP Disassembling the oil pump Remove the idler gear and hub from the front plate. Remove all attachment bolts from the two sections of the oil-pump housing.
Page 416 XE ENGINE LUBRICATION SYSTEM Disassembly and assembly CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 417 XE ENGINE LUBRICATION SYSTEM CF65/75/85 series Draining and filling 6. DRAINING AND FILLING 6.1 DRAINING AND FILLING THE ENGINE OIL To prevent skin injury, avoid unnecessary contact with the drained oil Draining the engine oil Ensure that the vehicle is standing on a flat and level surface.
Page 418 XE ENGINE LUBRICATION SYSTEM Draining and filling CF65/75/85 series © 200324 https://www.truck-manuals.net/...

This manual is also suitable for:

Cf75 series Cf85 series