Motory PDF

2 CONTENTS
65/75/85CF series
TECHNICAL DATA
0
DIAGNOSTICS
1
XF ENGINE
2
XF ENGINE COOLING SYSTEM
3
XF ENGINE LUBRICATION SYSTEM
4
PF ENGINE
5
PF ENGINE COOLING SYSTEM
6
PF ENGINE LUBRICATION SYSTEM
7
NS ENGINE
8
NS ENGINE COOLING SYSTEM
9
NS ENGINE LUBRICATION SYSTEM
10
XE ENGINE
11
XE ENGINE COOLING SYSTEM
12
XE ENGINE LUBRICATION SYSTEM
13
PE-ENGINE
14
ǹ 200335
2 CONTENTS
65/75/85CF series
PE ENGINE COOLING SYSTEM

15
PE ENGINE LUBRICATION SYSTEM
16
ǹ 200335
2 TECHNICAL DATA
65/75/85CF series Contents
CONTENTS
1. ENGINE GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page Date
1-1 . . . . 200335
0
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200335
2. XF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200335
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200335
2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . 200335
3. XF ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200335
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200335
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . 200335
4. XF ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 .... 200335
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 .... 200335
4.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 .... 200335
4.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 .... 200335
5. PF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . 200335
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . 200335
6. PF ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . 200335
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . 200335
7. PF ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 .... 200335
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 .... 200335
7.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 .... 200335
7.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 .... 200335
8. NS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . 200335
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . 200335
9. NS ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . 200335
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . 200335
10. NS ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . 200335
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . 200335
10.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 . . . 200335
10.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 . . . 200335
11. XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 200335
11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 200335
ǹ 200335 1
TECHNICAL DATA 2
Contents 65/75/85CF series
Page Date
0 12. XE ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 . . .

12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 . . .
12.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 . . .
200335
200335
200335
13. XE ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 . . . 200335
13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 . . . 200335
14. PE-ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 . . . 200335
14.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 . . . 200335
15. PE ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 . . . 200335
15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 . . . 200335
16. PE ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 . . . 200335
16.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 . . . 200335
2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series Engine general
1. ENGINE GENERAL
1.1 GENERAL
0
The terms “COLD ENGINE” and “WARM
ENGINE” are defined as follows:
COLD ENGINE
A cold engine is an engine which, having
reached operating temperature, has been
allowed to cool down for at least six hours.
WARM ENGINE
A warm engine is an engine which, having
reached operating temperature, has not been at
a standstill for more than thirty minutes.
Direction of rotation of the engine
The direction of rotation of the engine is
clockwise, as seen from the timing gear end.
First cylinder of the engine
The first cylinder of the engine is the cylinder at
the timing gear end.
Left-hand and right-hand side of the engine
The left-hand side of the engine is the side
where the fuel pump is mounted.
The right-hand side of the engine is the side
where the air compressor is mounted.
ǹ 200335 1-1
TECHNICAL DATA 2
Engine general 65/75/85CF series
1-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine
2. XF ENGINE
2.1 GENERAL
0
Types XF 280 M
XF 315 M
XF 355 M
Version Euro 2 (M), water-cooled, four-stroke diesel

engine with direct fuel injection, 4 valves per
cylinder and turbo-intercooling.
Number of cylinders 6
Bore x stroke 130 x 158 mm
Swept volume 12.58 l
Compression ratio 16.0 : 1
Firing order 1-5-3-6-2-4
Weight approx. 1049 kg
ENGINE TYPE P (kW) at rpm M (Nm) at rpm

XF 250 M 250 at 2000 1600 at 1200 - 1500
XF 280 M 280 at 2000 1750 at 1100 - 1500
XF 315 M 315 at 2000 1900 at 1050 - 1500
ENGINE TYPE IDLING SPEED MAX. NO LOAD SPEED

XF 250 M 525 - 575 approx. 2270
XF 280 M 525 - 575 approx. 2300
XF 315 M 525 - 575 approx. 2300
ǹ 200335 2-1
TECHNICAL DATA 2
XF engine 65/75/85CF series
V-BELT TENSION
Belt tension, “AVX” raw-edge(1) V-belts in Newtons (N)
0 Multiple-V-belt Single-V-belt
New V-belt(2)
Setting tension 1200 600
Test tension ≥800 ≥400
Worn V-belt(3)
Minimum tension 500 250
Adjusting tension 700 350
(1) 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 insides of
the belt (polished belt edges).
Version: either toothed or non-toothed.
(2) After fitting the new V-belt, set the pre-tension to the
“setting tension” and after a trial run check whether the
pre-tension complies with the “test tension”. If the
tension reading is lower than the “test tension”
specified in the table, set the V-belt to the minimum
“test tension”.
(3) If the V-belt tension is lower than the “minimum

tension”, set the belt to the “adjusting tension”.
M2121
Cylinder liner
Height above cylinder block 0.02 - 0.10 mm
Cylinder head
Minimum height after overhaul 119.50 mm
Test pressure using air (max. pressure) 1.5 bar
Valve clearance
Valve clearance (cold/hot)
inlet 0.50 mm
exhaust 0.50 mm
Valve opening
Valve opening at 1 mm valve clearance 0.3 - 0.7 mm
2-2 ǹ 200335
2 TECHNICAL DATA
Axial play
Crankshaft axial play 0.06 - 0.32 mm
Camshaft axial play
Idler gear axial play
0.10 - 0.55 mm
0.05 - 0.25 mm
0
Gear backlash
Idler gear - crankshaft gear 0.02 - 0.21 mm
Idler gear - fuel-pump gear 0.02 - 0.22 mm
Idler gear - camshaft gear 0.02 - 0.21 mm
Camshaft gear - compressor gear 0.02 - 0.22 mm
Fuel pump gear - steering pump gear 0.02 - 0.19 mm
Oil pump idler gear - oil pump gear 0.02 - 0.20 mm
Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm
Number of teeth, timing gears

Crankshaft gear 35
Idler gear 54
Fuel pump gear 70
Camshaft gear 70
Air compressor gear 27
Fan drive housing gear 29
Steering pump gear 18
Lubricating oil pump idler gear 34
Fan drive
Heat gear wheel for max. 30 min. 245_C
Compression pressure
Differences in compression pressure 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
ǹ 200335 2-3
TECHNICAL DATA 2
2.2 TIGHTENING TORQUES
0 The tightening torques stated in this section are

different from the standard tightening torques
stated in the overview of the standard tightening
torques. The other threaded connections which
are not stated must therefore be tightened to the
tightening torque stated in the overview of
standard tightening torques.
When attachment bolts and nuts are to be
replaced, it is important that they are of exactly
the same length and property class as the ones
removed unless stated otherwise.
Starter motor
Attachment nuts 73 Nm(1)
Alternator
Alternator bracket attachment bolts 55 Nm
Alternator attachment bolts 50 Nm
Pulley attachment nut 70 Nm
Air compressor
M12 attachment bolts for compressor 110 Nm
M8 attachment bolts for bracket 30 Nm
Compressor gear flange bolt 120 Nm
M14 cylinder head threaded coupling 40 Nm
Delivery pipe reducer valve 75 Nm
Suction and pressure line unions 90 Nm
Air-conditioning compressor
M12 attachment bolts for compressor bracket 110 Nm
M10 attachment bolts for compressor 60 Nm(1)
Exhaust manifold
Fit gasket with steel side towards manifold
Sleeved attachment bolts 65 Nm
Heat shield attachment bolts 30 Nm(1)
2-4 ǹ 200335
2 TECHNICAL DATA
Inlet manifold
Attachment bolts 60 Nm
Glow plug attachment nut
Air inlet hose clamps
55 Nm
12 Nm
0
Turbocharger
Turbine housing clamp plate attachment nut 15 Nm
Attachment nuts, exhaust manifold
flange/turbocharger 60 Nm(2)
Elbow on turbocharger 40 Nm
Oil supply pipe banjo bolt 90 Nm
(1) Secure with Loctite 243

(2) Apply Copaslip to secure
ǹ 200335 2-5
TECHNICAL DATA 2
Vibration damper and fan drive
0 Version with direct fan drive
4
1
2
3
5
6
7
M200946
Vibration damper hub attachment bolts (1) in 4

phases:
1st phase, all attachment bolts 100 Nm(1)
2nd phase, all attachment bolts 100 Nm(1)
3rd phase, all attachment bolts 100 Nm(1)
4th phase, all attachment bolts 100 Nm(1)
Attachment bolts, fan flange/vibration
damper (7) 110 Nm
Attachment nuts, fan clutch (6) 25 Nm(2)
(1) Tighten the attachment bolts evenly

2-6 ǹ 200335
2 TECHNICAL DATA
Version with up-speed fan drive
6
7
4
10
8
9 11 12 13 5 2 3 1 14
M200947
Attachment bolts, vibration damper hub (1)

in 4 phases:
Attachment bolts, up-speed bearing
block/vibration damper (5) 110 Nm
Attachment bolts, V-belt pulley (7) 25 Nm(2)
Central bolt, M10, up-speed bearing
housing (9) 60 Nm(2)
Attachment nuts, fan drive (14) 60 Nm

(2) Apply Loctite 243 to secure
ǹ 200335 2-7
TECHNICAL DATA 2
Cylinder head attachment bolts

Cylinder head bolts must only be used once. So
0
21 18 19 20
the cylinder head bolts should always be
replaced. The new cylinder head bolts have a 17 11 7 1 8 12
red/brown sealant on the thread. 16 13
6 2
Note:
- Because of the sealant used on the cylinder
head bolts, their untightening torque may be 15 5 3 14
very high!
10 4 9
- All M16 and M12 threaded holes must be
carefully cleaned with a screw tap before
the bolts are fitted.
M200562
- Once the bolts have been tightened to the
specified torque, the angular displacement
of the M16 bolts must immediately be 50 Nm
started.
- The sealant cannot be applied later.
Tightening cylinder head attachment bolts
Note: 150 Nm
M16
Apply a drop of oil underneath the bolt heads
(on their abutting surface). Sealant also reduces
the frictional resistance, which means that no oil
must be applied to the thread. I
1st phase
M16
Tighten M16 in the order 94 Nm
indicated 50 Nm(1)
2nd phase
II
Tighten M16 in the order
M12
indicated 150 Nm
Tighten M12 in the order
indicated 94 Nm(1) II
3rd phase 60
M16 in the order
indicated in two stages of 60_ angular
displacement
M16
(1) Apply a drop of oil to bolts M16 and M12 on the 60

abutting surface of the bolt heads.
III
M16
III
M200563
2-8 ǹ 200335
2 TECHNICAL DATA
Timing gear
Camshaft locking plate attachment bolts 30 Nm(1)
Attachment bolts, fuel pump drive shaft locking
plate 30 Nm(1)
0
Timing case attachment bolts 30 Nm(1)
Timing cover attachment bolts:
- M10 attachment bolts 60 Nm
Timing cover protection plate attachment bolt 15 Nm
Camshaft gear attachment bolt 425 Nm(1)
Idler gear attachment bolt 170 Nm
Attachment bolt, fuel pump gear wheel 260 Nm(1)
Attachment bolt, silencer 30 Nm
Steering pump gear attachment nut 80 Nm(1)
Steering pump intake pipe banjo bolt 90 Nm
Steering pump delivery pipe banjo bolt 40 Nm
Compressor gear attachment nut 120 Nm
ǹ 200335 2-9
TECHNICAL DATA 2
Flywheel housing
Attachment bolts 110 Nm(1)
0 Sealant to be used when fitting flywheel
housing Loctite 510
Flywheel
Attachment bolts
Without PTO 260 Nm(1) + 90_ angular displacement
Without PTO spanner size 21 mm 260 Nm + 90_ angular displacement
With PTO 260 Nm + 150_ angular displacement
Engine mountings on timing gear end

Cylinder block bracket attachment bolts 92 Nm
Chassis engine bracket attachment bolts 73 Nm
Vibration damper engine bracket attachment
bolts 225 Nm +60_ angular displacement
Engine mountings on flywheel end

Flywheel housing engine bracket attachment
bolts 260 Nm
bolts 225 Nm + 60_ angular displacement
Engine hanger brackets

Valve gear
Valve cover attachment bolts 25 Nm
Rocker setting bolt lock nut 40 Nm
Bridge piece setting bolt lock nut 40 Nm
Lubricating oil strip/rocker seat attachment
bolts 110 Nm
DEB set screw nut 25 Nm
Solenoid valve 20 Nm
Wiring harness attachment bolt 9 Nm
Valve sleeve attachment bolts 30 Nm
Tighten the valve sleeve bolts in the sequence
shown. 7 15 9
3 2
11 13
5 6
1 14 8
10 12 4
M200942
2-10 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine cooling system
3. XF ENGINE COOLING SYSTEM

3.1 GENERAL
0
Thermostat
Thermostat opening temperatures:
Standard
- thermostat opens at 87_C
- thermostat opened at least 12 mm at 99_C
With intarder and/or tropical cooling
Thermostat seat Loctite 638
Water pump
Maximum radial play 0.16 - 0.20 mm
Expansion tank pressure cap

Pressure relief valve opening pressure 0.75 bar
Underpressure valve opening pressure 0.1 bar
Pressure testing the cooling system

Test pressure 0.5 - 0.7 bar
ǹ 200335 3-1
TECHNICAL DATA 2
XF engine cooling system 65/75/85CF series

Water pump
M8 attachment bolts 30 Nm
Threaded coupling 35 Nm
Coolant pipe
Coolant pipe threaded coupling 90 Nm
Coolant pipe plug 30 Nm
Thermostat housing
Plug 35 Nm
Radiator
Attachment nuts 70 Nm
3.3 FILLING CAPACITIES
Cooling system capacity approx. 50 litres

Cooling system capacity with ZF-intarder approx. 60 litres
3-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XF engine lubrication system
4. XF ENGINE LUBRICATION SYSTEM

4.1 GENERAL
0
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 disposable filter
Quantity 1
Installation in the oil circuit full flow
Opening pressure of bypass valve at a
pressure difference of 2.5 0.3 bar
Oil cooler
pressure difference of 2 bar
Oil section test pressure 6 bar
ǹ 200335 4-1
TECHNICAL DATA 2
XF engine lubrication system 65/75/85CF series

Fuel filter
Attachment bolts, fuel filter/water pipe
connection 40 Nm
Fuel pump filter head banjo bolt 40 Nm
Lubricating oil strip/rocker seats

Oil sump
Clamp attachment bolts 25 Nm
Oil drain plug 60 Nm
Oil pump
Attachment bolts for oil pump housing sections 30 Nm
Attachment bolts connecting oil pump to main
bearing cap 60 Nm(1)
Oil delivery pipe attachment bolts 30 Nm(1)
Idler gear central bolt 60 Nm(1)
Strainer
Bracket attachment bolts 30 Nm(1)
Lubricating oil filter

Lubricating oil filter housing attachment bolts 50 Nm(2)
Oil filter 45 Nm
Coupling in lubricating oil filter head 60 Nm(3)
Bypass pressure regulator

Plug 80 Nm
4-2 ǹ 200335
2 TECHNICAL DATA
Oil cooler
Attachment bolts connecting oil cooler to
cylinder block
Coolant supply pipe union
50 Nm
90 Nm
0
Plug, adjustable banjo connection 90 Nm
Banjo bolt, adjustable banjo connection 90 Nm
Centrifugal oil filter

Central bolt 20 Nm
Oil discharge pipe union 50 Nm
Dip stick

ǹ 200335 4-3
TECHNICAL DATA 2
Oil sprayer
Banjo bolt (M14) for oil sprayer with locking 30 Nm
0 plate
Banjo bolt (M10) for oil sprayer 30 Nm
Main bearing caps

Main bearing cap attachment bolts 150 Nm +120_ angular displacement(1)
Big-end bearing caps

Attachment bolts, big-end bearing caps 1 4
1st phase, 35 Nm
sequence 1-2-3-4
2nd phase, 45 Nm
sequence 4-3-2-1
3rd phase, 60_ angular
sequence 1-2-3-4 displacement(2)
3 2
M200661
(1) Apply a drop of oil to thread and contact surface.
(2) Connecting rod bolts are to be used once and

tightened as instructed.
When fitting the connecting rod in the engine, apply a
drop of oil to the threads and contact surfaces of the
connecting rod bolts.
4-4 ǹ 200335
2 TECHNICAL DATA
Lubrication system
Total capacity, including oil cooler and oil filter approx. 32 litres
0
Oil sump capacity, maximum level approx. 25 litres
Oil sump capacity, minimum level approx. 17 litres
ǹ 200335 4-5
TECHNICAL DATA 2
4-6 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine
5. PF ENGINE
5.1 GENERAL
0
Engine specification
Cubic capacity 9.20 l
Bore 118 mm
Stroke 140 mm
Number of cylinders 6 cylinders in line
Number of valves per cylinder 4
Emission level Euro 2

PF 183 M 183 at 2300 1000 at 1200 - 1700
PF 212 M 212 at 2300 1130 at 1150 - 1700
PF 235 M 235 at 2300 1275 at 1300 - 1700

PF 183 M 525 - 625 2570 - 1640
PF 212 M 525 - 625 2570 - 1640
PF 235 M 525 - 625 2570 - 1640
ǹ 200335 5-1
TECHNICAL DATA 2
PF engine 65/75/85CF series
V-belt tension
New V-belt(2)
Worn V-belt(3)
1. Raw-edge V-belts can be recognised by the absence

the belt (polished belt edges). Version: either toothed
or non-toothed.
2. After fitting the new V-belt, set the pre-tension to the

“test tension”.
3. If the V-belt tension is lower than the “minimum

M2121
Cylinder liner
Cylinder head
Cylinder head test pressure

Test pressure using air (hot) 1.5 bar
Valve clearance
inlet 0.45 mm
exhaust 0.45 mm
Valve opening
Valve opening at 1 mm valve clearance 0.45 0.2 mm
5-2 ǹ 200335
2 TECHNICAL DATA
Axial play
Camshaft axial play
0.10 - 0.55 mm
0.03 - 0.25 mm
0
Gear backlash

Crankshaft gear 31
Idler gear 52
Fuel pump gear 62
Camshaft gear 62
Oil pump idler gear 28
Oil pump gear 36
Differences in compression pressure max. 15%

of 210 mm 0.10 mm
ENGINE SPEED sensor

Air gap between gear and sensor 0.3 - 0.7 mm
ǹ 200335 5-3
TECHNICAL DATA 2

Starter motor
Alternator
Air compressor
M8 bracket attachment bolts 30 Nm
Cylinder head threaded coupling 90 Nm
Air conditioning compressor

Exhaust manifold
Sleeved attachment bolts 65 Nm(1)
Heat shield attachment bolts 30 Nm
Inlet manifold
M10 attachment studs 60 Nm
Glow plug attachment nut 55 Nm
5-4 ǹ 200335
2 TECHNICAL DATA
Turbocharger
Turbine housing clamp plate attachment nut
Attachment nuts
15 Nm
0
Exhaust manifold flange/turbocharger 60 Nm(2)
Fan
Fan pulley attachment bolts 30 Nm(1)

ǹ 200335 5-5
TECHNICAL DATA 2

16 17
Cylinder head bolts must only be used once. So 14 15
0 the cylinder head bolts should always be

replaced. The new cylinder head bolts have a
6 1 2 7
Note:
- Because of the sealant used on the cylinder 13
head bolts, their untightening torque may be 10
5 3
8
very high! 9 4
- Once the bolts have been tightened to the M200734
of the M16 bolts must immediately be
started. 50 Nm
Note:
150 Nm
M16
1st phase
M16
Tighten M16 in the
50 Nm(1)
94 Nm
order indicated
2nd phase II
Tighten M16 in the
order indicated 150 Nm
M12
Tighten M12 in the
order indicated 94 Nm(1)
II
3rd phase
60
M16 in the order
displacement
(1) Apply a drop of oil to bolts M16 and M12 on the

M16
abutting surface of the bolt heads. 60
III
M16
III
M200563
5-6 ǹ 200335
2 TECHNICAL DATA
Timing gear
Fuel pump drive housing attachment bolts 60 Nm
Camshaft locking plate attachment bolts
Attachment bolts, fuel pump drive shaft locking
30 Nm(1)
0
plate 30 Nm(1)
Crankshaft hub attachment bolts in 4 phases:
Viscous fan clutch attachment nuts 30 Nm(1)
Timing case attachment bolts 30 Nm
Camshaft gear attachment bolt 425 Nm
Attachment bolt, fuel pump gear wheel 260 Nm(1)
Attachment bolt, silencer 30 Nm
Suction pipe banjo bolt 90 Nm
Delivery pipe banjo bolt 40 Nm

(2) Apply a drop of oil to the attachment bolts and tighten
evenly.
ǹ 200335 5-7
TECHNICAL DATA 2
Flywheel housing
housing Loctite 510
Flywheel
Attachment bolts
- without PTO 80 Nm(1) + 45_ angular displacement
- with PTO 110 Nm + 150_ angular displacement

bolts 170 Nm

bolts 260 Nm

Valve gear
M10 rocker setting bolt lock nut 40 Nm
bolts 60 Nm
Tighten the valve sleeve bolts in the sequence 13 9
shown.
3 7 11 2 6
14
5
1 10 12 8 4
M200959
5-8 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine cooling system
6. PF ENGINE COOLING SYSTEM

6.1 GENERAL
0
Thermostat
Standard
With intarder and/or automatic transmission
Water pump
Radial play 0.16 - 0.20 mm

Pressure relief valve opening pressure 0.75 - 0.9 bar

ǹ 200335 6-1
TECHNICAL DATA 2
PF engine cooling system 65/75/85CF series

Water pump
Coolant pipe on cylinder head

Thermostat housing on coolant pipe

Plug 35 Nm
Radiator
Cooling system
6-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine lubrication system
7. PF ENGINE LUBRICATION SYSTEM

7.1 GENERAL
0
Oil pressure
Oil filter
Quantity 1
Oil cooler
Oil section test pressure 2.5 bar
ǹ 200335 7-1
TECHNICAL DATA 2
PF engine lubrication system 65/75/85CF series


Oil sump
Oil pump
Strainer

Oil filter 45 Nm

Plug 80 Nm
Oil cooler
cylinder block 50 Nm

7-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PF engine lubrication system
Oil sprayer
Banjo bolt (M14) for oil sprayer with locking
plate
Banjo bolt (M10) for oil sprayer
30 Nm
30 Nm
0
Main bearing caps

1st phase, 25 Nm
sequence 1-2-3-4
2nd phase, 35 Nm
sequence 1-2-3-4
3rd phase, 60_ angular
sequence 1-2-3-4 displacement(2)
3 2
M200661

tightened as instructed. When fitting the connecting
rod in the engine, apply a drop of oil to the thread and
bearing face of the connecting rod bolts.
ǹ 200335 7-3
TECHNICAL DATA 2
PF engine lubrication system 65/75/85CF series
0 Lubrication system
7-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series NS engine
8. NS ENGINE
8.1 GENERAL
0
Cubic capacity 6,24 l
Bore 104.2 mm
Stroke 122 mm
Engine speeds in rpm

NS 133 M 625 2750
NS 156 M 625 2765
NS 177 M 625 2730
ǹ 200335 8-1
TECHNICAL DATA 2
NS engine 65/75/85CF series
V-belt tension
0
Belt tension “12.55-mm” V-belts in Newtons (N)
Multiple-V-belt Single-V-belt
covered1 raw edge2 covered1 raw edge2
New V-belt3
Setting tension 900 1200 500 600
Test tension 600 800 300 400
Worn V-belt4
Minimum tension 400 500 200 250
Adjusting tension 450 700 250 350
1. Covered V-belts can, on close inspection, be

recognised by the presence of textile fabric in the
rubber on the inside of the V-belt and all along the
sides. Version: non-toothed belt.

or non-toothed.

test tension.

8-2 ǹ 200335
2 TECHNICAL DATA
Cylinder liner

0
Cylinder head
A B A B A B A B A B A B
M2 00 146
Valve clearance
inlet 0.45 mm
exhaust 0.45 mm
Axial play
Camshaft axial play 0.06 - 0.22 mm
Idler gear axial play 0.07 - 0.22 mm
Gear backlash
Crankshaft gear wheel - oil pump gear wheel 0.02 - 0.18 mm
ǹ 200335 8-3
TECHNICAL DATA 2

Crankshaft gear 23
0 Idler gear
Fuel pump gear
49
46
Camshaft gear 46
Valve diagram at 1.0 mm valve clearance

Inlet valve open 0_ (TDP)
Inlet valve closes 16_ after BDP
Exhaust valve open 42_ before BDP
Exhaust valve closes 2_ before TDP
Compression

of 180 mm 0.1 mm
Starter ring gear warm up 185_C
8-4 ǹ 200335
2 TECHNICAL DATA
The tightening torques stated in this section are

0
Starter motor
Starter motor attachment bolts 45 Nm(1)
Alternator
Sheet steel pulley attachment nut 55 Nm(2)
Cast iron pulley attachment nut 70 Nm(2)
Air compressor
Compressor gear flanged nut 135 Nm
Compressor attachment bolts 25 Nm(1)
Sensors and transmitters

Rev counter impulse sensor 50 Nm
Exhaust manifold
Exhaust manifold attachment nuts 50 Nm
Stud lubricant Copaslip
Inlet manifold
Inlet manifold attachment bolts 25 Nm
Turbocharger
Clamp plate attachment bolts, turbine housing 17 Nm
Clamp plate attachment bolts, compressor
housing 17 Nm
Manifold flange/turbocharger attachment nut 50 Nm
Exhaust flange/turbocharger attachment nut 21 Nm
Stud lubricant Copaslip
(1) Use Loctite 243

(2) Use Loctite 572
ǹ 200335 8-5
TECHNICAL DATA 2
Cylinder head
Lock nut, valve adjusting bolt 45 Nm
0 Attachment bolt, rocker seat 45 Nm
15 9 3 8 14 20
16 10 4 2 7 13 19
17 11 5 1 6 12 18
21 22 23 24 25 26 27
Cylinder head bolts

1st stage, M16 bolts 50 Nm(1) 50Nm 150Nm 60 60
2nd stage, M16 bolts 150 Nm
3rd stage, M16 bolts 50 Nm(2)
4th stage, M16 bolts 60_ angular 50Nm
M16
M16
M16
M16
displacement
5th stage, M16 bolts 60_ angular
M10
displacement
Note: I II III IV V
Subsequently, mark the heads of the M16 bolts
with a centre punch. Bolts with two centre punch
marks must not be used again, but must be
replaced.
M2 00 166
(1) Use Loctite 243

(2) Apply a drop of engine oil to the attachment nut
8-6 ǹ 200335
2 TECHNICAL DATA
Cylinder block
Water cover attachment bolts 21 Nm
Attachment bolts, side cover 21 Nm
0
Timing gear
Pulley attachment bolts 27 Nm(1)
Vibration damper pulley retaining
bolt/attachment bolt 440 Nm(1)
Attachment bolts, timing gear cover 25 Nm(1)
Steering pump
Steering pump attachment bolts 55 Nm
Flywheel
Flywheel attachment bolts 95 Nm(1)
Flywheel housing
Attachment bolts, flywheel housing 54 Nm(1)
Sealant Loctite 510
Engine mounts
Engine bracket/flywheel housing attachment
bolts 250 Nm
Engine bracket/vibration damper attachment
bolts, timing gear end 90 Nm
Engine bracket/vibration damper attachment
bolts, flywheel housing end 170 Nm
Vibration damper/chassis attachment nuts,
timing gear end 70 Nm
Vibration damper/chassis attachment bolts,
flywheel housing side 90 Nm

Front attachment bolts 55 Nm(1)
Rear attachment bolts 30 Nm
(1) Use Loctite 243
ǹ 200335 8-7
TECHNICAL DATA 2
8-8 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series NS engine cooling system
9. NS ENGINE COOLING SYSTEM

9.1 GENERAL
0
Thermostat
- thermostat opened at least 8.0 mm at 95_C
Cooling system test pressure 0.5 - 0.7 bar
Water pump
Radial play 0.1 mm


Temperature sensor 20 Nm
Coolant pump
Cooling water pump fixing bolts 25 Nm(1)
Thermostat housing
Thermostat housing fixing bolts 25 Nm(1)
(1) Use Loctite 243
Cooling system capacity 26 litres
ǹ 200335 9-1
TECHNICAL DATA 2
NS engine cooling system 65/75/85CF series
9-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series NS engine lubrication system
10. NS ENGINE LUBRICATION SYSTEM

10.1 GENERAL
0
Lubricating oil pressure
Oil pressure (engine at operating temperature)
- idling speed, new engine min. 1.0 bar
- idling speed, used engine min. 0.35 bar
- maximum engine speed 3.0 - 4.0 bar

Type disposable
Quantity 1
Lubricating oil heat exchanger

Opening pressure of bypass valve 1 bar pressure difference
Test pressure of coolant section (air pressure) 1.5 bar
ǹ 200335 10-1
TECHNICAL DATA 2
NS engine lubrication system 65/75/85CF series

Heat exchanger
Heat exchanger attachment bolt 20 Nm(1)
Oil pan
Oil pan attachment bolts 21 Nm
(1) Use Loctite 243
Lubrication system capacity

Total capacity, incl. filters approx. 14 litres
Oil pan capacity;
- maximum level approx. 12 litres
- minimum level approx. 8.5 litres
10-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE Engine
11. XE ENGINE
11.1 GENERAL
0
Types XE 280 C
XE 315 C
XE 355 C
Version Euro 3 (C), water-cooled, four-stroke diesel

engine with direct fuel injection, 4 valves per
cylinder and turbo-intercooling.
Number of cylinders 6
Bore x stroke 130 x 158 mm
Swept volume 12.58 l
Firing order 1-5-3-6-2-4

XE 250 C 250 at 2000 1600 at 1000 - 1500
XE 280 C 280 at 2000 1750 at 1000 - 1500
XE 315 C 315 at 2000 1900 at 1100 - 1500

XE 250 C 525 - 575 approx. 2270
XE 280 C 525 - 575 approx. 2300
XE 315 C 525 - 575 approx. 2300
ǹ 200335 11-1
TECHNICAL DATA 2
XE Engine 65/75/85CF series
V-belt tension
New V-belt(2)
Worn V-belt(3)

or non-toothed.

test tension.

M2121
Cylinder liner
Cylinder head
Valve clearance
inlet 0.50 mm
exhaust 0.50 mm
Valve opening
Valve opening at 1 mm valve clearance 0.3 - 0.7 mm
11-2 ǹ 200335
2 TECHNICAL DATA
Axial play
Camshaft axial play
0.10 - 0.55 mm
0.05 - 0.25 mm
0
Gear backlash
Idler gear - pump housing camshaft gear 0.02 - 0.22 mm
Pump housing camshaft gear - steering pump
gear 0.02 - 0.19 mm

Crankshaft gear 35
Idler gear 54
Pump housing camshaft gear 70
Camshaft gear 70
Fan drive housing gear 29
Lubricating oil pump idler gear 34
Fan drive
Heat gear wheel for max. 30 min. 245_C

of 210 mm 0.10 mm
ǹ 200335 11-3
TECHNICAL DATA 2

Starter motor
Alternator
Air compressor
Compressor gear flanged nut 120 Nm
Air-conditioning compressor
Exhaust manifold
Sleeved attachment bolts 65 Nm
11-4 ǹ 200335
2 TECHNICAL DATA
Inlet manifold
Glow plug attachment nut
Air inlet hose clamps
55 Nm
12 Nm
0
Turbocharger
Turbine housing clamp plate attachment nut 15 Nm
Attachment nuts
Oil supply pipe banjo bolt 90 Nm

ǹ 200335 11-5
TECHNICAL DATA 2
Vibration damper and fan drive
0 Version with direct fan drive
4
1
2
3
5
6
7
M200946
Vibration damper hub attachment bolts (1) in

4 phases:
Attachment bolts, fan flange/vibration
damper (7) 110 Nm

11-6 ǹ 200335
2 TECHNICAL DATA
6
7
4
10
8
9 11 12 13 5 2 3 1 14
M200947
Vibration damper hub attachment bolts (1) in

4 phases:
Attachment bolts, up-speed bearing
block/vibration damper (5) 110 Nm
Attachment bolts, V-belt pulley (7) 25 Nm(2)
Central bolt, M10, up-speed bearing
housing (9) 60 Nm(2)
Attachment nuts, fan drive (14) 60 Nm

ǹ 200335 11-7
TECHNICAL DATA 2

Cylinder head bolts must only be used once. So
0
21 18 19 20
the cylinder head bolts should always be
replaced. The new cylinder head bolts have a 17 11 7 1 8 12
6 2
Note:
- Because of the sealant used on the cylinder
head bolts, their untightening torque may be 15 5 3 14
very high!
10 4 9
M200562
- Once the bolts have been tightened to the
of the M16 bolts must immediately be 50 Nm
started.
Note: 150 Nm
M16
1st phase
M16
Tighten M16 in the 94 Nm
2nd phase
II
Tighten M16 in the
M12
Tighten M12 in the
order indicated 94 Nm(1) II
3rd phase 60
M16 in the order
displacement
M16
(1) Apply a drop of oil to bolts M16 and M12 on the 60

abutting surface of the bolt heads.
III
M16
III
M200563
11-8 ǹ 200335
2 TECHNICAL DATA
Timing gear
Camshaft locking plate attachment bolts 30 Nm(1)
Pump housing camshaft locking plate
attachment bolts 30 Nm(1)
0
Timing case attachment bolts 25 Nm
Camshaft gear attachment bolt 425 Nm(1)
Pump housing camshaft gear attachment bolt 260 Nm(1)
Compressor gear attachment nut 120 Nm
ǹ 200335 11-9
TECHNICAL DATA 2
Flywheel housing
housing Loctite 510
Flywheel
Attachment bolts:
- without PTO 260 Nm +90_ angular displacement
- with PTO 260 Nm +150_ angular displacement


bolts 260 Nm

Valve gear
Rocker setting bolt lock nut 40 Nm
bolts 110 Nm
DEB set screw nut 25 Nm
Solenoid valve 20 Nm
Wiring harness attachment bolt 9 Nm
Tighten the valve sleeve bolts in the sequence
shown. 7 15 9
3 11 13 2
5 6
1 14 8
10 12 4
M200942
11-10 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE engine cooling system
12. XE ENGINE COOLING SYSTEM

12.1 GENERAL
0
Thermostat
Standard
With intarder and/or tropical cooling
Water pump
Maximum radial play 0.16 - 0.20 mm


ǹ 200335 12-1
TECHNICAL DATA 2
XE engine cooling system 65/75/85CF series

Water pump
Coolant pipe
Plug 35 Nm
Thermostat housing
Plug 35 Nm
Radiator

12-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE engine lubrication system
13. XE ENGINE LUBRICATION SYSTEM

13.1 GENERAL
0
Oil pressure
Oil filter
Quantity 1
Oil cooler
Oil section test pressure 6 bar
ǹ 200335 13-1
TECHNICAL DATA 2
XE engine lubrication system 65/75/85CF series

Fuel filter
Attachment bolts, fuel filter/water pipe
connection 40 Nm

Oil sump
Oil pump
Strainer

Oil filter 45 Nm

Plug 80 Nm
13-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series XE engine lubrication system
Oil cooler
cylinder block
Coolant supply pipe union
50 Nm
90 Nm
0
Plug, adjustable banjo connection 90 Nm
Banjo bolt, adjustable banjo connection 90 Nm
Centrifugal oil filter

Central bolt 20 Nm
Oil discharge pipe union 50 Nm
Dip stick

ǹ 200335 13-3
TECHNICAL DATA 2
XE engine lubrication system 65/75/85CF series
Oil sprayer
Oil sprayer banjo bolt 30 Nm
0 Main bearing caps

1st phase,
sequence 1-2-3-4 35 Nm
2nd phase,
3rd phase,
sequence 1-2-3-4 60_ angular
displacement(2)
3 2
M200661

rod in the engine, apply a drop of oil to the threads
and contact surfaces of the connecting rod bolts.
Lubrication system
13-4 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE-engine
14. PE-ENGINE
14.1 GENERAL
0
Cubic capacity 9,20 l
Bore 118 mm
Stroke 140 mm

PE 183 M 183 at 2300 1050 at 1150 - 1600
PE 212 M 212 at 2300 1130 at 1150 - 1700
PE 235 M 235 at 2300 1275 at 1200 - 1700

PE 183 M 525 - 625 2570 - 1640
PE 212 M 525 - 625 2570 - 1640
PE 235 M 525 - 625 2570 - 1640
ǹ 200335 14-1
TECHNICAL DATA 2
PE-engine 65/75/85CF series
V-belt tension
New V-belt(2)
Worn V-belt(3)

or non-toothed.

“test tension”.

M2121
14-2 ǹ 200335
2 TECHNICAL DATA
Cylinder liner
Cylinder head
0

Valve clearance
inlet 0.45 mm
exhaust 0.45 mm
Valve opening
Valve opening at 1 mm valve clearance 0.45 0.2 mm
Axial play
Camshaft axial play 0.10 - 0.55 mm
Idler gear axial play 0.03 - 0.25 mm
Gear backlash

Crankshaft gear 31
Idler gear 52
Fuel pump gear 62
Camshaft gear 62
Oil pump idler gear 28

of 210 mm 0.10 mm
ǹ 200335 14-3
TECHNICAL DATA 2

Starter motor
Alternator
Air compressor
Cylinder head threaded coupling 90 Nm
Air conditioning compressor

Exhaust manifold
Sleeved attachment bolts 65 Nm(1)
Heat shield attachment bolts 30 Nm
Inlet manifold
M10 attachment studs 60 Nm
Glow plug attachment nut 55 Nm
14-4 ǹ 200335
2 TECHNICAL DATA
Turbocharger
Turbine housing clamp plate attachment nut
Attachment nuts
15 Nm
0
Fan
Fan pulley attachment bolts 30 Nm(1)

ǹ 200335 14-5
TECHNICAL DATA 2

16 17
Cylinder head bolts must only be used once. So 14 15
0 the cylinder head bolts should always be

replaced. The new cylinder head bolts have a
6 1 2 7
Note:
- Because of the sealant used on the cylinder 13
head bolts, their untightening torque may be 10
5 3
8
very high! 9 4
- Once the bolts have been tightened to the M200734
of the M16 bolts must immediately be
started. 50 Nm
Note:
150 Nm
M16
1st phase
M16
Tighten M16 in the
50 Nm(1)
94 Nm
order indicated
2nd phase II
Tighten M16 in the
M12
Tighten M12 in the
II
3rd phase
60
M16 in the order
displacement
1. Apply a drop of oil to bolts M16 and M12 on the

M16
abutting surface of the bolt heads. 60
III
M16
III
M200563
14-6 ǹ 200335
2 TECHNICAL DATA
Timing gear
Pump housing drive unit attachment bolts 60 Nm
Pump housing drive shaft locking plate
attachment bolts 30 Nm(1)
0
Attachment bolts, locking plate 30 Nm(1)
Crankshaft hub attachment bolts in 4 phases:
Viscous fan clutch attachment nuts 30 Nm(1)
Timing case attachment bolts 30 Nm(1)
Camshaft gear attachment bolt 425 Nm
Pump housing camshaft gear attachment bolt 260 Nm(1)

(2) Apply a drop of oil to the attachment bolts and tighten
evenly.
ǹ 200335 14-7
TECHNICAL DATA 2
Flywheel housing
housing Loctite 510
Flywheel
Attachment bolts:
- without PTO 80 Nm(1) + 45_ angular displacement
- with PTO 80 Nm + 150_ angular displacement

bolts 170 Nm

bolts 260 Nm

Valve gear
M10 rocker setting bolt lock nut 40 Nm
bolts 110 Nm
Tighten the valve sleeve bolts in the sequence 13 9
shown.
3 7 11 2 6
14
5
1 10 12 8 4
M200959
14-8 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE engine cooling system
15. PE ENGINE COOLING SYSTEM

15.1 GENERAL
0
Thermostat
Standard
With intarder and/or automatic transmission
Water pump
Radial play 0.16 - 0.20 mm


ǹ 200335 15-1
TECHNICAL DATA 2
PE engine cooling system 65/75/85CF series

Water pump
Coolant pipe on cylinder head

Thermostat housing on coolant pipe

Plug 35 Nm
Radiator

15-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE engine lubrication system
16. PE ENGINE LUBRICATION SYSTEM

16.1 GENERAL
0
Oil pressure
Oil filter
Quantity 1
Oil cooler
Oil section test pressure 2.5 bar
ǹ 200335 16-1
TECHNICAL DATA 2
PE engine lubrication system 65/75/85CF series


Oil sump
Oil pump
Strainer

Oil filter 45 Nm

Plug 80 Nm
Oil cooler
cylinder block 50 Nm

16-2 ǹ 200335
2 TECHNICAL DATA
65/75/85CF series PE engine lubrication system
Oil nozzles
Banjo bolt (M14) for oil sprayer with locking
plate
Banjo bolt (M10) for oil sprayer
30 Nm
30 Nm
0
Main bearing caps
Main bearing cap attachment bolts 150 Nm + 120_ angular displacement(1)

1st phase,
2nd phase,
rd
3 phase,
sequence 1-2-3-4 60_ angular
displacement(2)
3 2
M200661
(1) Apply a drop of oil to the thread and bearing surface

rod in the engine, apply a drop of oil to the threads
and contact surfaces of the connecting rod bolts.
Lubrication system
ǹ 200335 16-3
TECHNICAL DATA 2
PE engine lubrication system 65/75/85CF series
16-4 ǹ 200335
2 DIAGNOSIS
CONTENTS
Page Date
1. TRACTIVE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
1.2 Acceleration test (engine design with conventional fuel system) . . . . . . . . .
1.3 Acceleration test (engine design with UPEC fuel system) . . . . . . . . . . . . . . .
1-2 . . . . . .
1-6 . . . . . .
0011
0011 1
1.4 Acceleration test form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 . . . . . 0011
1.5 Accelerator test using DAVIE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 . . . . . 0011
2. XF/PF/NS ENGINE GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. XF/PF/NS ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
4. XF/PF/NS ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
5. XE/PE ENGINE GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Engine function fault finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.2 Vehicle function fault finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 . . . . . . 0011
6. XE/PE ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
7. XE/PE ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0011
ǹ 0011 1
DIAGNOSIS 2
2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series Tractive problems
1. TRACTIVE PROBLEMS
1.1 INTRODUCTION
There may be many reasons for improper

vehicle performance.
Some of these may be mechanical, others are 1
particularly also of a psychological nature.
It is therefore important to properly identify the
problem.
Try to get as much information as possible from
the customer or driver.
- When does the vehicle not perform
properly?
- In what road or weather conditions?
- How is the vehicle loaded?
- Is the vehicle being compared with a vehicle
with completely different specifications, for
instance engine power?
- Is the vehicle being driven in the correct
engine speed range?
If the answers are unsatisfactory, ask the
customer or driver for facts.
- Tachograph cards of trips
- Reliable consumption figures of trips
Following proper identification of the complaint,
vehicle performance can be tested by an
acceleration test.
If the vehicle fails to pass the acceleration test, a
boost pressure curve may be plotted as an aid
to identify the cause.
Note:
Checking the boost pressure will in general only
make sense after the vehicle has covered at
least 20,000 km.
The test sheets are available from the DAF
organisation.
To plot a boost pressure curve, see group 4 of
the workshop manual.
ǹ 0011 1-1
DIAGNOSIS 2
Tractive problems 65/75/85CF series
1.2 ACCELERATION TEST (engine design with conventional fuel system)
The acceleration test provides a reliable result

with respect to the fuel consumption and tractive
force of a vehicle. While the test is being carried
1
out the legal requirements must be taken into
account and maximum safety must be
exercised.
Compared with other diagnostic tools, this test is
a fast and cost-effective way of checking
whether the vehicle meets DAF’s requirements
and, therefore, whether or not the complaint is
justified.
During the acceleration test the time required to
accelerate the loaded vehicle from starting
speed to final speed is measured. (Weight of
entire combination at least 75% of the gross
combination weight, GCW).
To eliminate weather influences and road
conditions, this test must be done in both driving
directions. The average acceleration time is
obtained by averaging both measured times.
The maximum acceleration time, the speeds
between which the time is to be measured and
the gear to be engaged for the various vehicle
configurations is calculated using the DAF
“Topec” route simulation computer program.
For this purpose, “Topec” needs vehicle data
including:
- vehicle type
- height of the entire vehicle combination
- weight of entire vehicle combination (at
least 75% of the gross combination weight)
- aerodynamic influences, e.g. roof spoilers,
rear air foils, etc.
- engine type
- gearbox type and reduction ratio
1-2 ǹ 0011
2 DIAGNOSIS
- rear axle type and axle reduction ratio

- tyre size
- cab type
Before starting the acceleration test
- Check the tyre pressure of the entire vehicle
combination. Also check the tyres for a
1
deviating wear pattern.
- Check the complete condition of the trailer
or semi-trailer.
- Check the entire vehicle combination for
adverse aerodynamic influences, for
instance loose tarpaulins, wrongly adjusted
spoilers and rear air foils.
- Check the vehicle and trailer or semi-trailer
for excessive road drag. Be aware of
dragging brakes.
- Check the tachograph. The speed signal
must be present.
- Check that the correct k factor has been set
on the tachograph.
- Check that the fuel pump of the engine has
been provided with the original seal.
- Check that the throttle control is able to
reach the maximum fuel pump stop.
Acceleration test
1. Use the “Acceleration test form” in the
workshop manual.
2. Check the operations as set out under
“Before starting the acceleration test”.
3. Establish a test route where the difference
between the measured times in both
directions does not exceed 15%. If the
difference in time exceeds 15%, find
another test route.
ǹ 0011 1-3
DIAGNOSIS 2
4. Establish the starting and end points on the

selected test route, to ensure that exactly
the same route can be taken in both
directions. Do the entire test at least twice
and take the average time.
1 5. Run the drive train at operating temperature

(drive for at least 15 minutes with a loaded
vehicle).
Note:
When switched on, the air compressor and fan
consume 10 to 15 kW engine power on average.
During the test try to avoid both consumers
being switched on.
6. Before the starting point on the test route,
engage the gear specified by Topec and
make sure the vehicle speed is at least
3 km/h below the starting speed.
7. Fully depress the accelerator pedal and
(using a stopwatch) measure the time
needed to accelerate the vehicle from
starting speed to end speed.
Result of first acceleration test
If the acceleration time is not achieved, first
carry out the following work.
- Check the injection timing. If necessary,
re-set/optimise.
- Check the fuel system for the presence of
air.
- Replace or clean the air cleaner element.
- Check the setting of the wastegate on the
turbocharger (if present).
- Check the exhaust brake butterfly valve for
correct operation.
- Check the charge cooler exterior for dirt
deposits.
- Clean the water separator (if present).
1-4 ǹ 0011
2 DIAGNOSIS
- Replace the fuel filter.

- Clean or replace the fuel pre-filter (if
present).
- Check the suction pipe of the tank for
1
clogging by large pieces of foreign matter.
- Check the fuel tank for contamination.
Clean with a steam cleaner, if necessary.
- Check the air inlet system for any leaks.
- Check the exhaust system for any leaks.
- Check the exhaust system for blockages by
measuring the exhaust back pressure.
- Check the turbocharger impellers on the
compressor and turbine side for damage
and for deposits of salt or any other
contaminants.
- Check the banjo bolt strainer in the fuel lift
pump for dirt (if present).
- Check both the valve clearance and the
DEB clearance.
- Check the injector pipes for damage.
- Check the injection pump gallery pressure.
- Check the fuel lift pump pressure.
- Check that the right type of components has
been fitted. Fuel pump, turbocharger,
injectors, etc.
- Check the discharge pressure of the
injectors.
- Clean the nozzle openings using calibrated
injector needles (DAF no. 1329371).
ǹ 0011 1-5
DIAGNOSIS 2
Repeat the acceleration test. If necessary, plot a

boost pressure curve.
Result of second acceleration test
If the specified acceleration time is not achieved,
1
- Remove the fuel pump from the engine.
- Check the fuel pump setting on a fuel pump
test bench.
- Repeat the acceleration test.
1.3 ACCELERATION TEST (engine design with UPEC fuel system)
The acceleration test provides a reliable result

with respect to the fuel consumption and tractive
force of a vehicle. While the test is being carried
out the legal requirements must be taken into
account and maximum safety must be
exercised.
Compared with other diagnostic tools, this test is
a fast and cost-effective way of checking
whether the vehicle meets DAF’s requirements
and, therefore, whether or not the complaint is
justified.
During the acceleration test the time required to
accelerate the loaded vehicle from starting
speed to final speed is measured. (Weight of
entire combination at least 75% of the gross
combination weight, GCW).
To eliminate weather influences and road
conditions, this test must be done in both driving
directions. The average acceleration time is
obtained by averaging both measured times.
The maximum acceleration time, the speeds
between which the time is to be measured and
the gear to be engaged for the various vehicle
configurations is calculated using the DAF
“Topec” route simulation computer program.
1-6 ǹ 0011
2 DIAGNOSIS
For this purpose, “Topec” needs vehicle data

including:
- vehicle type
- height of the entire vehicle combination
1
- weight of entire vehicle combination (at
least 75% of the gross combination weight)
- aerodynamic influences, e.g. roof spoilers,
rear air foils, etc.
- engine type
- gearbox type and reduction ratio
- rear axle type and axle reduction ratio
- tyre size
- cab type.
Before starting the acceleration test
- Check the tyre pressure of the entire vehicle
combination. Also check the tyres for a
deviating wear pattern.
- Check the complete condition of the trailer
or semi-trailer.
- Check the entire vehicle combination for
adverse aerodynamic influences, for
instance loose tarpaulins, wrongly adjusted
spoilers and rear air foils.
- Check the vehicle and trailer or semi-trailer
for excessive road drag. Be aware of
dragging brakes.
- Check the tachograph. The speed signal
must be present.
- Check that the correct k factor has been set
on the tachograph.
- Using DAVIE, check whether the 100%
pedal stop can be reached with the
accelerator pedal position sensor.
ǹ 0011 1-7
DIAGNOSIS 2
Acceleration test
1. Use the “Acceleration test form” in the
workshop manual.
2. Check the operations as set out under
“Before starting the acceleration test”.
1 3. Establish a test route where the difference

between the measured times in both
directions does not exceed 15%. If the
difference in time exceeds 15%, find
another test route.
4. Establish the starting and end points on the
selected test route, to ensure that exactly
the same route can be taken in both
directions. Do the entire test at least twice
and take the average time.
5. Run the drive train at operating temperature
(drive for at least 15 minutes with a loaded
vehicle).
Note:
When switched on, the air compressor and fan
consume 10 to 15 kW engine power on average.
During the test try to avoid both consumers
being switched on.
6. Connect DAVIE and follow the instructions
given by DAVIE.
7. Depress the accelerator pedal during the
acceleration test.
1-8 ǹ 0011
2 DIAGNOSIS
Result of first acceleration test

If the acceleration time is not achieved, first
- Check the fuel system for the presence of
air.
- Replace or clean the air cleaner element. 1
- Check the setting of the wastegate on the
turbocharger (if present).
- Check the exhaust brake butterfly valve for
correct operation.
- Check the charge cooler exterior for dirt
deposits.
- Clean the water separator (if present).
- Clean the fuel coarse filter.
- Check that the primer pump is fastened to
the fuel coarse filter.
- Replace the fuel fine filter.
- Check the suction pipe of the tank for
clogging by large pieces of foreign matter.
- Check the fuel tank for contamination.
Clean with a steam cleaner, if necessary.
- Check the air inlet system for any leaks.
- Check the exhaust system for any leaks.
- Check the exhaust system for blockages by
measuring the exhaust back pressure.
ǹ 0011 1-9
DIAGNOSIS 2
- Check the turbocharger impellers on the

compressor and turbine side for damage
and for deposits of salt or any other
contaminants.
- Check both the valve clearance and the
1 -
DEB clearance.
Check the injector pipes for damage.
- Check the gallery pressure.
- Check fuel lift pump output.
- Check the reducing valve.
- Check whether the right type of components
has been fitted. Turbocharger, injectors etc.
- Check the discharge pressure of the
injectors.
- Clean the nozzle openings using calibrated
injector needles (DAF no. 1329371).
Repeat the acceleration test. If necessary, plot a
boost pressure curve.
1-10 ǹ 0011
2 DIAGNOSIS
1.4 ACCELERATION TEST FORM
General data:
Customer’s name : ............................................
Type/vehicle number plate
Type of trailer/semi-trailer
: ............................................
: ............................................
1
Owner of trailer/semi-trailer : Customer/Dealer/Third parties . . . . . . . . . . . . . . . . .
Date : ............................................
Weather conditions : ............................................
Route : ............................................
Vehicle data:
Engine type : ............................................
Gearbox type : ............................................
Rear axle type : ............................................
Vehicle combination height : ............................................
Total weight of vehicle combination : ............................................
Aerodynamic influences : ............................................
TOPEC data:
Gear to be selected : ............................................
Maximum acceleration time : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . seconds
Starting speed : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . km/h
End speed : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . km/h
Acceleration test result:
Measured acceleration time : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . seconds
End result of acceleration test : ............................................
ǹ 0011 1-11
DIAGNOSIS 2
1.5 ACCELERATOR TEST USING DAVIE
The acceleration test can also carried out using

DAVIE. Collect the necessary data and after
starting up DAVIE go to the engine management
1
system used on the vehicle (E-gas, ASL-G or
UPEC) and follow the instructions in DAVIE
precisely to carry out the test correctly.
The test results must be saved to disc after each
test.
The acceleration test in DAVIE must
only be started up when the vehicle
is stationary. As the communication
between the accelerator pedal
sensor and the unit is broken for a
short time when starting up DAVIE,
this can lead to dangerous
situations if the vehicle is moving.
During driving, never engage direct

test or fault tree test.
1-12 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XF/PF/NS engine general
2. XF/PF/NS ENGINE GENERAL

2.1 FAULT-FINDING TABLE
FAULT: ENGINE CAN BE STARTED, BUT DOES NOT RUN

Possible cause Remedy 1
Air in fuel system Bleed the fuel system
Insufficient discharge pressure of the fuel lift Check the fuel lift pump pressure
pump
Water in the fuel system Check the water separator
Fuel filter clogged Replace the fuel filter
Incorrect or contaminated injectors installed Check whether the correct injectors have been
installed. Clean contaminated injectors and set
them
Incorrect injection timing, or incorrect fuel pump Check the injection timing and/or fuel pump
setting setting
Compression pressure too low Check the compression pressure
FAULT: ENGINE STARTS AND STOPS

Possible cause Remedy
Insufficient discharge pressure of the fuel lift Check the fuel lift pump pressure
pump
setting setting
FAULT: ENGINE WILL NOT IDLE

them
setting setting
Injection pipes fractured or broken Check the injector pipes. Replace if necessary
ǹ 0011 2-1
DIAGNOSIS 2
XF/PF/NS engine general 65/75/85CF series
FAULT: ENGINE DELIVERS LESS THAN MAXIMUM POWER

1
Incorrect or contaminated injectors installed Check whether correct injectors have been
them
setting setting
Fuel tank vent opening is blocked Check/clean the vent opening
Air cleaner element blocked Clean or replace the air cleaner element
Blocked air inlet from turbocharger to the inlet Check air inlet Clean if necessary
manifold
Air leak in the pressure part of the inlet system Check the inlet unit for any leaks
Compressor side of turbocharger contaminated Clean compressor side with a non-corrosive
cleaning agent or a soft brush. Check the inlet
side for carbon deposits or other contamination
Exhaust manifold, exhaust silencer, exhaust pipe Check the exhaust unit. Clean if necessary
blocked
Gas leak between the exhaust manifold and the Check the attachment bolts and gaskets
cylinder head
Gas leak between the exhaust manifold and the Check the attachment bolts and gaskets
turbocharger
Incorrect wastegate setting or defective Check the wastegate or wastegate setting
wastegate
Damaged turbocharger Replace the turbocharger and identify the cause
Incorrect valve clearance setting Check valve clearance. Adjust if necessary
Incorrect DEB setting Check the DEB play Adjust if necessary
DEB continues to operate Check the DEB operation
2-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XF/PF/NS engine general
FAULT: ENGINE PRODUCES EXTREME SMOKE LEVELS

setting setting
1
them
Blocked air cleaner Check the air cleaner element. Blow-clean or
replace, if necessary
Air leak between the inlet manifold and the Check for leaks. Replace the gaskets, if
cylinder head necessary
Gas leak between exhaust manifold and the Check the attachment bolts and gaskets
turbocharger
Exhaust gas leak between the exhaust manifold Check the attachment bolts and gaskets
and the cylinder head
Cooling system failure Inspect the cooling system
Lubrication system failure Check the lubrication system
ǹ 0011 2-3
DIAGNOSIS 2
XF/PF/NS engine general 65/75/85CF series
FAULT: ENGINE PRODUCES EXCESSIVE NOISE

Broken valve springs Check valve springs. Replace if necessary
1
Excess clearance between piston and cylinder Check the piston clearance in the cylinder
wall
Main shaft and/or connecting rod bearings worn Check main shaft and connecting rod bearings
out
Fuel system failure Check the fuel system
Inlet system failure Check the inlet system
Exhaust system failure Check the exhaust system
Air compressor, fan drive, air-conditioning Check whether the air compressor, fan drive,
compressor air-conditioning compressor or other engine
attachments may be the cause of the strange
noise
Incorrect V-belt tension or alignment of V-belts Check the V-belt tension or the alignment of the
V-belt
Excessive radial play of water pump Check the radial play of the water pump
Fan damaged or fan touching the radiator Check the fan and radiator
Damaged or loose engine brackets Check the engine brackets
Excessive valve clearance Readjust the valve clearance
Damaged valve train and/or push rods, cam Check the valve train, etc. for damage
followers, rocker shafts or rocker arms
Damaged vibration damper Check the vibration damper for damage
Damaged pistons and/or cylinder liners Check the pistons and the cylinder liners
Timing gears Check the timing gear wheels for play and/or
damage
Loose or broken flywheel or coupling bolts Check the flywheel and the clutch
2-4 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XF/PF/NS engine cooling system
3. XF/PF/NS ENGINE COOLING SYSTEM

FAULT: ENGINE TEMPERATURE INCREASES

setting setting
Incorrect injectors installed Check whether the correct injectors have been
installed
Incorrect V-belt tension Check the V-belt tension or replace the V-belt
Insufficient coolant Check the coolant level. Top up if necessary
Coolant pipe torn or blocked Check the coolant pipes
Contaminated radiator/cooling system Check the radiator. Clean if necessary
Incorrect or malfunctioning pressure cap Check the pressure cap
Thermostat opens insufficiently or not at all Check the thermostat and its operation
Contaminated coolant filter Check the coolant filter. Replace if necessary
and clean the cooling system
Defective water pump Check the water pump shaft, bearings and
impeller. Replace the water pump, if necessary
Defective viscous fan Check operation of viscous fan
ǹ 0011 3-1
DIAGNOSIS 2
XF/PF/NS engine cooling system 65/75/85CF series
FAULT: EXTERNAL COOLANT LEAKAGE

Flexible coolant pipes defective Check the coolant pipes
1
Coolant pipes defective Check coolant pipes
Leaking radiator Check the radiator. Pressure test if necessary
Leaking water pump Check the water pump. If necessary, measure
the bearing play
Defective oil cooler Check the oil cooler. Pressure test if necessary
Defective pressure cap Check the pressure cap. Pressure test if
necessary
Leaking heater Check heater pipes
Leaking connection between coupling and water Check connection between the water pipe and
pipe the coupling for damage.
Replace O-rings
FAULT: INTERNAL COOLANT LEAKAGE

Defective cylinder head gasket Check cylinder head gasket
Cracked cylinder heads or cylinder block Check the cylinder heads and the cylinder block
for internal cracks. Pressure test if necessary
Leaking injector bushes Check cylinder heads. Pressure test if necessary
Defective compressor cylinder head gasket Replace the compressor cylinder head gasket
Defective oil cooler Check whether there is coolant in the lubricating
oil system
Defective freeze plugs in tappet area (cylinder Replace freeze plug(s)
block) or at the top of the cylinder heads
3-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XF/PF/NS engine lubrication system
4. XF/PF/NS ENGINE LUBRICATION SYSTEM

FAULT: ENGINE OIL PRESSURE TOO LOW

Engine oil level too low Top up engine oil to maximum level
External oil leaks Visually check the engine for leaks. Repair if
necessary
Defective oil-pressure switch Check the switch. Replace if necessary
Oil fails to meet the required specifications Replace the engine oil and the oil filter
Oil temperature is too high Check the oil cooler
Oil mixed with coolant or fuel Replace the engine oil and the oil filter
Oil duct or oil suction pipe loose or broken Check the oil pipes. Repair if necessary
Oil-pressure control valve fails to operate Check the oil pressure control valve
Inadequate functioning of oil pump Check the oil pump
Main shaft or connecting rod bearings worn out Check the main shaft or connecting rod bearings
Loose oil nozzle of piston cooler Check the oil nozzle. Replace if necessary
Defective internal oil pressure pipes or sealing Check the oil pressure pipes and seals
Contamination between oil-pressure control Check/clean the oil pressure control valve
valve and seat
Contaminated oil filter Change the oil filter
ǹ 0011 4-1
DIAGNOSIS 2
XF/PF/NS engine lubrication system 65/75/85CF series
FAULT: ENGINE CONSUMES TOO MUCH OIL

1
Exhaust system failure Check the exhaust system
Oil cooler leaks Check whether there is lubricating oil in the
engine cooling system
Oil temperature is too high Check whether the correct oil cooler has been
installed
Excessive blow-by Check the compression pressure and carry out a
cylinder leak test.
Check the condition of the piston rings and
cylinder liners
Worn piston rings and/or cylinder liners Replace piston rings and/or cylinder liners.
Check the air inlet system.
Check the oil specifications
Injector O-ring damaged or not present Check the injector seal
4-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine general
5. XE/PE ENGINE GENERAL

5.1 ENGINE FUNCTION FAULT FINDING TABLE
FAULT: ENGINE CAN BE STARTED, BUT DOES NOT RUN

Poor fuel quality Drain fuel, flush fuel system, replace the fuel
filters and fill fuel tank with fuel
Air in fuel system Check for the drawing in of air:
- via the supply pipe
- via the fuel lift pump seal
Fuel filter blocked Replace fuel filter and clean the system
Fault in electrical components/wiring of: Check the electrical system
- connectors
- pump unit
- electronic unit
- crankshaft position sensor and camshaft
position sensor
While carrying out an engine test with DAVIE, Remove the battery earth cable and then refit it
communication with DAVIE has been broken
Pump housing - camshaft timing incorrect; signal Check timing/signal, camshaft position sensor
from camshaft position sensor not present at
correct moment
No fuel supply/fuel lift pump defective; no supply Check:
- fuel level
- pipes for blockage and leaks
- fuel lift pump
Pressure relief valve does not close Check the pressure relief valve
FAULT: ENGINE STALLS AND AFTER RE-STARTING RUNS AGAIN

Poor contacts, contact resistance in connectors Check the connector connections
Pressure relief valve does not close Inspection, pressure relief valve
ǹ 0011 5-1
DIAGNOSIS 2
XE/PE engine general 65/75/85CF series
FAULT: ENGINE RUNS POORLY

1 Air in fuel system Check for the drawing in of air:

- connectors
- pump unit
- electronic unit
position sensor
- engine coolant temperature sensor
Battery voltage too low Charge batteries
Connection points on pump units switched Connect the correct connection points to the
correct pump unit
Pump units mechanical defect or clogged Replace pump units
Defective injectors Inspect the injectors
Too low fuel lift pump supply Check the fuel lift pump and replace if necessary
5-2 ǹ 0011
2 DIAGNOSIS
FAULT: ENGINE RUNS (INCREASED) AT IDLING SPEED

AND DOES NOT RESPOND TO ACCELERATOR PEDAL
Accelerator pedal sensor, mechanically defective Check:
- the mechanical connection of
sensor/accelerator pedal
- the accelerator pedal sensor
1
Adjustment of the amount of fuel by ABS/ASR
Engine brake input signal present Check the electrical system of the engine brake
FAULT: ENGINE RUNS INCREASED AT IDLING SPEED (1000 RPM)

AND DOES NOT RESPOND TO ACCELERATOR PEDAL
- connectors
- pump unit
- electronic unit
position sensor
FAULT: ENGINE RUNS INCREASED AT IDLING SPEED (1000 RPM)

AND RESPONDS TO ACCELERATOR PEDAL
Fault in electrical components/wiring of the Check the electrical system
accelerator pedal sensor
FAULT: MAXIMUM ENGINE SPEED IS 1000 RPM

accelerator pedal sensor
ǹ 0011 5-3
DIAGNOSIS 2
FAULT: DIESEL KNOCKING DURING ACCELERATION

1 Air in fuel system Check for the drawing in of air:

Failure in electrical components/wiring of the Check the electrical system
engine coolant temperature sensor
Injector defective Inspect the injectors
Defective crankshaft position sensor Check the crankshaft position sensor
FAULT: ENGINE RUNS IRREGULARLY

- via the fuel lift pump sealing ring
Fuel filter blocked Replace the fuel filter
Connection points on pump units switched Connect the correct connection points to the
correct pump unit
- connectors
- pump unit
5-4 ǹ 0011
2 DIAGNOSIS
FAULT: REDUCED POWER AT ALL ENGINE SPEEDS

Fuel filter blocked Replace the fuel filter 1
Accelerator pedal sensor, mechanically defective Check:
- mechanical connection of sensor/accelerator
pedal
- accelerator pedal sensor
- boost pressure sensor
- fuel temperature sensor
- contacts
- contact resistance in connector connections
Air filter clogged Replace or clean air filter
Turbocharger defective/waste-gate control Check the turbocharger/waste gate control
incorrect
Electropneumatic boost pressure valve defective Check electropneumatic boost pressure valve
Air leak in air inlet system Pressure test air inlet system
ǹ 0011 5-5
DIAGNOSIS 2
FAULT: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED

Fuel filter partially clogged Replace the fuel filter
1
Air filter partially blocked Replace or clean air filter
Electropneumatic boost pressure valve defective Check electropneumatic boost pressure valve
electro-pneumatic boost pressure valve
FAULT: ENGINE PRODUCES WHITE/BLUE SMOKE

- crankshaft position sensor
5-6 ǹ 0011
2 DIAGNOSIS
FAULT: ENGINE PRODUCES BLACK SMOKE

- air intake temperature sensor
1
Injector defective Check injectors
FAULT: TOO HIGH FUEL CONSUMPTION

Leak in fuel system Check for leaks
ǹ 0011 5-7
DIAGNOSIS 2
FAULT: REDUCED MAXIMUM ENGINE SPEED

Air in fuel system Check for drawing in of air:
1 Fuel filter blocked

Replace fuel filter and clean the system
Signal fault, crankshaft position sensor Check:
- wiring
Turbocharger defective Check turbocharger
Adjustment of the amount of fuel by ABS/ASR
5.2 VEHICLE FUNCTION FAULT FINDING TABLE
FAULT: VEHICLE SPEED CONTROL DOES NOT WORK

- cable harness
- multi-function switch
- speed signal
- proximity switch
Condition(s) for disengaging vehicle speed Check for the presence of condition(s) for
control present disengaging exhaust brake/DEB
5-8 ǹ 0011
2 DIAGNOSIS
FAULT: ENGINE SPEED CONTROL DOES NOT WORK

Condition(s) for disengaging engine speed Check for presence of condition(s) for
control are present disengaging exhaust brake/DEB
Fault in electrical components/wiring of:
- cable harness
Check the electrical system 1
- multi-function switch
- speed signal
FAULT: PRE AND AFTER GLOWING FUNCTION DOES NOT WORK

- cable harness
- warning lamp, preglowing
- glow spirals
- glow spiral relay
Condition(s) for disengaging pre and after Check for presence of condition(s) for
glowing function present disengaging exhaust brake/DEB
FAULT: ENGINE SPEED ON REV COUNTER INCORRECT

- cable harness
- UPEC electronic unit
FAULT: ENGINE CANNOT BE SWITCHED OFF WITH CONTACT KEY

Fault in electrical components/wiring of cable Check the electrical system
harness.
Power supply to UPEC electronic unit not
switched off.
Power after contact to UPEC electronic unit is
not switched off with contact key.
ǹ 0011 5-9
DIAGNOSIS 2
FAULT: WARNING LIGHT DOES NOT LIGHT UP/IS NOT EXTINGUISHED

- cable harness
1 - UPEC electronic unit
FAULT: COMMUNICATION WITH DAVIE NOT POSSIBLE

- cable harness
- diagnostic connector.
Power after contact to UPEC electronic unit is
not switched off with contact key.
No supply voltage to the UPEC electronic unit
Defective electronic UPEC unit.
5-10 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine cooling system
6. XE/PE ENGINE COOLING SYSTEM

FAULT: ENGINE TEMPERATURE INCREASES

1
Incorrect injectors installed Check whether the correct injectors have been
installed
Incorrect V-belt tension Check the V-belt tension or replace the V-belt
Insufficient coolant Check the coolant level. Top up if necessary
Coolant pipe torn or blocked Check the coolant pipes
Intercooler/radiator of cooling system Check/clean the intercooler/radiator of the
contaminated cooling system
Waste-gate setting is too high Check the wastegate setting
Air pipe from the turbocharger compression Check the air pipe. Replace if necessary
chamber to the waste-gate diaphragm leaks or is
not connected
Incorrect or malfunctioning pressure cap Check the pressure cap
Thermostat opens insufficiently or not at all Check the thermostat and its operation
Contaminated coolant filter Check the coolant filter. Replace if necessary
and clean the cooling system
Defective water pump Check the water pump shaft, bearings and
impeller. Replace the water pump, if necessary
Defective viscous fan Check the operation of the viscous fan
Signal fault/short circuit/interruption to engine Check:
coolant temperature sensor - the coolant temperature sensor
- the wiring
ǹ 0011 6-1
DIAGNOSIS 2
XE/PE engine cooling system 65/75/85CF series
FAULT: EXTERNAL COOLANT LEAKAGE

Flexible coolant pipes defective Check the coolant pipes
1 Coolant pipes defective Check coolant pipes

Leaking radiator Check the radiator. Pressure test if necessary
Leaking water pump Check the water pump. If necessary, measure
bearing play
Defective oil cooler Check the oil cooler. Pressure test if necessary
Defective pressure cap Check the pressure cap. Pressure test if
necessary
Leaking heater Check heater pipes
Leaking connection between coupling and water Check connection between the water pipe and
pipe the coupling for damage.
Replace the O-rings
FAULT: INTERNAL COOLANT LEAKAGE

Defective cylinder head gasket Check cylinder head gasket
Cracked cylinder heads or cylinder block Check the cylinder heads and the cylinder block
for internal cracks. Pressure test if necessary
Leaking injector bushes Check cylinder heads. Pressure test if necessary
Defective compressor cylinder head gasket Replace the compressor cylinder head gasket
Defective oil cooler Check whether there is coolant in the lubricating
oil system
Defective freeze plugs in tappet area (cylinder Replace the freeze plug(s)
block) or at the top of the cylinder heads
6-2 ǹ 0011
2 DIAGNOSIS
65/75/85CF series XE/PE engine lubrication system
7. XE/PE ENGINE LUBRICATION SYSTEM

FAULT: ENGINE OIL PRESSURE TOO LOW

Engine oil level too low Top up engine oil to the maximum level
External oil leaks Visually check the engine for leaks. Repair if
necessary
Defective oil-pressure switch Check the switch. Replace if necessary
Oil fails to meet the required specifications Replace the engine oil and the oil filter
Oil temperature is too high Check the oil cooler
Oil mixed with coolant or fuel Replace the engine oil and the oil filter
Oil duct or oil suction pipe loose or broken Check the oil pipes. Repair if necessary
Oil-pressure control valve fails to operate Check the oil pressure control valve
Inadequate functioning of oil pump Check the oil pump
Main shaft or connecting rod bearings worn out Check the main shaft or connecting rod bearings
Loose oil nozzle of piston cooler Check the oil nozzle. Replace if necessary
Defective internal oil pressure pipes or sealing Check the oil pressure pipes and seals
Contamination between oil-pressure control Check/clean the oil pressure control valve
valve and seat
Contaminated oil filter Replace the oil filter
ǹ 0011 7-1
DIAGNOSIS 2
XE/PE engine lubrication system 65/75/85CF series
FAULT: ENGINE CONSUMES TOO MUCH OIL

1 Exhaust system failure Check the exhaust system

Oil cooler leaks Check whether there is lubricating oil in the
engine cooling system
Oil temperature is too high Check whether the correct oil cooler has been
installed
Excessive blow-by Check the compression pressure and carry out a
cylinder leak test
Check the condition of the piston rings and the
cylinder liners
Worn piston rings and/or cylinder liners Replace piston rings and/or the cylinder liners
Check the air inlet system
Check the oil specifications
Injector O-ring damaged or not present Check the injector seal
7-2 ǹ 0011
2 XF ENGINE
CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0011
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.3 Overview drawing, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
2
2.4 Overview drawing, timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0011
2.5 Overview drawing, fuel pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Inspection and adjustment, valve mechanism bridges . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.2 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0011
3.3 Inspection and adjustment, timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . . 0011
3.4 Inspection and adjustment, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . . 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0011
3.6 Inspection, engine compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . . 0011
3.7 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . . 0011
3.8 Inspection, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . . 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.1 Removal and installation, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.2 Removal and installation, engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 0011
4.3 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . . 0011
4.4 Removal and installation, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . . 0011
4.5 Removal and installation, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 0011
4.6 Removal and installation, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . . 0011
4.7 Removal and installation, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 . . . . . 0011
4.8 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 . . . . . 0011
4.9 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 . . . . . 0011
4.10 Removal and installation, steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0011
4.11 Removal and installation, starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . . 0011
4.12 Removal and installation, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . . . 0011
4.13 Removal and installation, V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 . . . . . 0011
4.14 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 . . . . . 0011
4.15 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 . . . . . 0011
4.16 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . . . . 4-25 . . . . . 0011
4.17 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 . . . . . 0011
4.18 Removal and installation, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 . . . . . 0011
4.19 Removal and installation, up-speed bearing block . . . . . . . . . . . . . . . . . . . . . 4-30 . . . . . 0011
4.20 Removal and installation, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 . . . . . 0011
4.21 Removal and installation, vibration damper hub . . . . . . . . . . . . . . . . . . . . . . . 4-33 . . . . . 0011
4.22 Removal and installation, timing cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 . . . . . 0011
4.23 Removal and installation, timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 . . . . . 0011
4.24 Removal and installation, timing gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 . . . . . 0011
4.25 Removal and installation, timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 . . . . . 0011
4.26 Removal and installation, timing gear case seal . . . . . . . . . . . . . . . . . . . . . . . 4-42 . . . . . 0011
4.27 Removal and installation, fuel pump drive housing . . . . . . . . . . . . . . . . . . . . . 4-43 . . . . . 0011
ǹ 0011 1
XF ENGINE 2
Page Date
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Disassembly and assembly, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.2 Disassembly and assembly, up-speed bearing block . . . . . . . . . . . . . . . . . . . 5-9 . . . . . . 0011
5.3 Disassembly and assembly, V-belt tensioning gear . . . . . . . . . . . . . . . . . . . . 5-11 . . . . . 0011
6. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Cleaning the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
2 ǹ 0011
2 XF ENGINE
65/75/85CF series Safety precautions
1. SAFETY PRECAUTIONS
Do not run the engine in an enclosed or
unventilated area. Make sure exhaust fumes are
properly extracted.
Remain at a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
2
the vehicle may constitute a health hazard. This
also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel. So avoid
inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
Always disconnect the battery’s earth
connection during repair or maintenance
operations for which the power supply is not
required.
ǹ 0011 1-1
XF ENGINE 2
Safety precautions 65/75/85CF series
1-2 ǹ 0011
2 XF ENGINE
65/75/85CF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
3 1
9
2
2
8
4
10
24
25
5
7 6
M200767
Legend
1. Thermostat housing
2. Water pump
3. Air-conditioning compressor
4. Fan drive
5. Vibration damper
6. Air compressor
7. Oil cooler
8. Turbocharger
9. Wastegate diaphragm
10. Oil-filler pipe
24. Up-speed bearing block
25. Fan drive tensioner
ǹ 0011 2-1
XF ENGINE 2
General 65/75/85CF series
21 20 19 18 17
22
2
23
11
12
13 14 15 16
M200768
Legend
11. Steering pump
12. Fuel pump drive housing
13. Fuel pump
14. Oil filter
15. Engine brake valve
16. Starter motor
17. Engine identification plate
18. Fuel filter
19. Coolant filter
20. Coolant pipe
21. Inlet manifold
22. Relay, glow-filament
23. Alternator
2-2 ǹ 0011
2 XF ENGINE
2.2 IDENTIFICATION
Engine number
The engine number is marked on engine block
at the rear left.
2
D000311
XF engine identification plate 4 3 5 6

Fitted to the inlet manifold.
1. Injection timing ENGINE
TYPE
2. Maximum governed engine speed E4
ENGINE
3. Engine number NUMBER
4. Engine type GOVERNED SPEED min -1 OUTPUT kW

5. Indication of country of origin
6. Certificate number INJECTION TIMING BEFORE
T.D.C.
PUMPSETTING cm 3
7. Fuel pump setting (output) SMOKE LEVEL FREE ACCELERATION m -1

8. Smoke level at maximum engine speed, no
EINDHOVEN HOLLAND
load
2 1 8 7
M200678
ǹ 0011 2-3
XF ENGINE 2
2.3 OVERVIEW DRAWING, FAN DRIVE
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
Legend
1. Fan drive shaft 7. Bearing ring
2. Oil seal 8. O-ring
3. Bearing 9. Bearing
4. Bearing ring 10. Circlip
5. Spacer sleeve 11. Bearing housing
6. Intermediate ring 12. Gear wheel
13. Circlip
2-4 ǹ 0011
2 XF ENGINE
2.4 OVERVIEW DRAWING, TIMING GEAR
2 4 5 10
2
7
1
6
3
8 M200549
9
Legend
1. Crankshaft
2. Camshaft
3. Intermediate gear wheel
4. Fan drive
5. Steering pump
6. Fuel pump drive gear wheel
7. Air compressor
8. Oil pump intermediate gear wheel
9. Oil pump
10. Silencer
ǹ 0011 2-5
XF ENGINE 2
2.5 OVERVIEW DRAWING, FUEL PUMP DRIVE
2 3 4 5 6
2 1
7 8
M200582
Legend
1. Silencer
3. Timing gear case sealing ring
4. Bearing housing
5. Fuel pump drive seal
6. Clamping piece
7. Axial locking plate
8. Prop shaft
2-6 ǹ 0011
2 XF ENGINE
65/75/85CF series Inspection and adjustment
3. INSPECTION AND ADJUSTMENT

3.1 INSPECTION AND ADJUSTMENT, VALVE MECHANISM BRIDGES
Loosening and tightening the lock

nuts (B) of the bridges may cause
severe engine damage if the bridge
is fitted on the valves.
2
1. Remove the valve covers. See “Removal
and installation”.
2. Place the fuel pump in the stop position.
Lock the fuel pump in this position.
3. Remove the DEB or the lubricating oil strip
(depending on model).
4. Remove the rocker seat assembly. Mark the
position to allow reinstallation in the same
position.
Note:
In engines with a DEB, the bridges of the
inlet and exhaust valves are not the same.
In engines without a DEB, the bridges of the
inlet and exhaust valves are the same.
Exhaust bridge with DEB
i 400162
ǹ 0011 3-1
XF ENGINE 2
Inspection and adjustment 65/75/85CF series
Exhaust bridge without DEB
2
i 400161
5. Remove the bridge from the valves and

place it in a vice.
6. Slacken locknut (B).
7. Reposition the bridge in the same position
in the engine over the valves.
8. Firmly press on the bridge centre (above
the guide pin) with your thumb. A
9. Hand-tighten adjusting screw (A) until the
bridge starts to move (adjusting screw (A)
now touches the valve).
10. Turn adjusting screw (A) through another
90_ and carefully remove the bridge from
the valves. B
11. Place the bridge in a vice and tighten
locknut (B) to the specified torque without
turning adjusting screw (A). See “Technical
i 400234
data”.
3-2 ǹ 0011
2 XF ENGINE
12. Reposition the bridge over the valves.

13. Fit the rocker seat.
14. Fit the DEB or the lubricating-oil strip
(depending on model). Fit the lubricating-oil
strip in such a way that the mark “cyl. 1/4” is
located on cylinder 1 or cylinder 4
respectively.
15. Adjust the valve play and the DEB play if
necessary.
2
16. Fit the valve covers. See “Removal and M200548
installation”.
3.2 INSPECTION AND ADJUSTMENT, VALVE CLEARANCE

3. Use the special tool (DAF no. 1310477) to
turn the crankshaft clockwise, as seen from
the timing gear end (this is the engine’s
normal direction of rotation), until the valves
of cylinder 1 are in overlap position. The
pistons of cylinders 1 and 6 are now at top
dead centre.
Note:
“Overlap” is the moment at which the inlet
valve starts opening and the exhaust valve
is completing the closing.
M200574
ǹ 0011 3-3
XF ENGINE 2
If the engine is equipped with the

DEB, a flat ring spanner must be
used for loosening the locknut. This
is necessary to prevent damage to
the DEB spring plate.
4. Check/correct the valve clearance of

cylinder 6. The correct valve clearance is
adjusted by loosening the locknut (4) and
turning the adjusting bolt in the correct
2 direction. See “Technical data” for the
correct valve clearance.
M200539
5. By cranking the camshaft 1/3 stroke

each time using the special tool
(DAF No. 1310477), the valves can be
adjusted according to the injection
sequence 1-5-3-6-2-4.
Cylinder with valves Adjust valves

in overlap position of cylinder
1 6
5 2
3 4
6 1
2 5
4 3
6. If the engine has been fitted with a DEB, the

DEB play must be checked following the M200540
valve play adjustment.
7. Fit the valve covers. See “Removal and
installation”.
3-4 ǹ 0011
2 XF ENGINE
3.3 INSPECTION AND ADJUSTMENT, TIMING
Inspection, timing
1. Remove the valve cover from
cylinders 1-2-3. See “Removal and
installation”.
2. Position cylinder 1 at top dead centre
(TDC on the flywheel, cylinder 6 in overlap
position).
Note: 2
It is important that the bridges of the valve
mechanism are properly adjusted.
3. Set the inlet valve play of the first cylinder to
1 mm.
4. Position the measuring gauge on the inlet
valve bridge of the first cylinder, in such a
way that it measures in an exact vertical
position on the bridge and is capable of
registering an upward and downward
measurement of 5 mm.
turn the crankshaft further in the direction of
rotation until the pistons of cylinders 1 and 6
have returned to the top dead centre (TDC).
M200574
6. Read the dial gauge and compare the

measured value. See “Technical data”.
Example
Pre-tension, dial gauge 5,00 mm
Valve opening 0,35 mm
Note:
If the valve opening matches that in the
technical data, it may be assumed that the
timing gear is properly set.
M200551
ǹ 0011 3-5
XF ENGINE 2
Adjustment, timing gear

1. Remove the valve cover from
cylinders 1-2-3. See “Removal and
installation”.
position).
3. Remove the timing gear cover. See
2
“Removal and installation”.
M200574
Note:
When the crankshaft (1) or the camshaft (2)
of an engine without intermediate gear
wheel (3) is rotated separately, the engine’s
pistons may touch the valves.
4. Remove the intermediate gear wheel (3).
See “Removal and installation”.
5. Rotate the camshaft gear wheel (2) to such
a position that the intermediate gear wheel
(3) can be installed in accordance with the
marks.
6. Fit the intermediate gear wheel and tighten
to the specified torque. See “Technical
data”.
7. Fit the timing cover. See “Removal and
installation”. 2 3
8. Fit the valve cover. See “Removal and 1
installation”.
M200602
3-6 ǹ 0011
2 XF ENGINE
3.4 INSPECTION AND ADJUSTMENT, V-BELT TENSION
Adjustment, V-belt tension O

APBTLIB
EEUL
TI
N.2
00
The V-belt should be inspected with a belt
tension gauge. The advantage of this method is LBS
.50
600
a more accurate pre-tension reading and, 100
150
consequently, the service life of the V-belt

amongst other parts can be extended.
O
APBT
LIBEE
ULTII
N.5
There are two types of belt tension gauge: the 00
“Krikit I” belt tension gauge for use with the

single-belt version (DAF no. 1240442) and the
LBS
.100
200
300
150
0
2
“Krikit II” belt tension gauge for use with the
twin-belt version (DAF no. 1240443).
The difference between the “Krikit I” and
“Krikit II” belt tension gauges is that the latter M2079
has a larger belt bearing surface.
Measuring with the “KRIKIT” belt tension
gauge
1. Set the gauge to zero by depressing the
measuring arm (1). 1
M2061
2. Place the gauge on the V-belt, halfway

between the alternator and the crankshaft
pulley.
3. Slowly depress the V-belt by means of the
belt-tension gauge until a click is heard.
Then remove the belt-tension gauge
carefully. Take care not to let the measuring
bar move.
M2091
ǹ 0011 3-7
XF ENGINE 2
4. Take the reading as indicated by the

position of the measuring arm in relation to
the scale. Compare this pressure reading
with the recommended pre-tension. See
“Technical data”.
2 M2062
Adjustment, V-belt tension of

air-conditioning compressor drive
1. Loosen the upper attachment bolt (1) on the 1
compressor. 1
2. Loosen the lower attachment bolt (2) on the
compressor.
3. Loosen the attachment bolt from the
threaded spindle which is attached to the
cooling-water pump.
4. Shift the compressor using the locknuts (3)
3
until the correct V-belt tension is achieved.
See “Technical data”.
2 M2041
Adjustment, V-belt tension of water pump 3 5 4

and alternator drive
1. Loosen the lower attachment bolt (1) of the
alternator.
2. Loosen the upper attachment bolt (2) of the
alternator.
3. Loosen the threaded rod attachment bolt
2
(3), which is fixed to the water pump.
M200550
3-8 ǹ 0011
2 XF ENGINE
4. Turn locking nuts (4) and (5) of the threaded

spindle, so that the correct V-belt tension is 3 5 4
reached. See “Technical data”.
2
1
M200550
Adjustment, V-belt tension of fan drive

(up-speed version)
1. Slacken the central nut (6) of the tensioning
roller.
2. Using bolt (7), shift the tensioning roller so
that the correct V-belt tension is achieved.
7 6
D000388
ǹ 0011 3-9
XF ENGINE 2
3.5 INSPECTION, FLYWHEEL
1. If the flywheel shows marks on the abutting

surface with the clutch plate, the flywheel 5 mm
may be ground down, on condition that the
cracks are not within 5 mm of the inner rim.
2. The flywheel has an indicator groove for
inspection purposes. 2 mm
2 3. Grinding down is allowed until the indicator

groove is no longer visible. This means that
a maximum of 2 mm may be ground down. 5 mm
Inspection, flywheel play
1. Clean the flywheel.
2. Place a metal strip on the edge of the
flywheel housing to fit a dial gauge.
3. Place the dial gauge on the metal strip.
4. Place the dial gauge of the stylus at the M2 00 033
specified distance. See “Technical data”.
5. Set the dial gauge to “0”.
6. Place the fuel pump in the stop position and
lock it in this position.
crank the engine through 360_ and
measure the maximum dial gauge reading.
Compare this reading with the technical
data. See “Technical data”.
M200230
3-10 ǹ 0011
2 XF ENGINE
3.6 INSPECTION, ENGINE COMPRESSION PRESSURE
Be careful when working on an

engine at operating temperature.
When the engine is run without the

valve covers, hot lubricating oil may
escape from the engine. Make sure
you are adequately protected.
A compression measurement serves to rapidly

check the valve seals, the valve gasket seal and
2
the seal between the cylinder liner and the
piston rings.
The measuring results may only be used for
comparing the various cylinders.
1. Run the engine to operating temperature.
4. Remove the injectors.
5. Turn the engine a number of times using
the starter motor, so that any carbon or dirt
particles in the cylinder are removed.
6. Install the dummy injector
(DAF no. 1329306), compression gauge
(DAF no. 0694972) and adapter
(DAF no. 1329301).
7. Carry out the measurement by rotating the
engine using the starter motor, until the
gauge reading no longer rises. For the
mutual permissible differential pressures
see “Technical data”.
8. Remove the dummy-injector and fit the
injectors.
installation”.
ǹ 0011 3-11
XF ENGINE 2
3.7 INSPECTION, CYLINDER HEAD
1. Check the sealing plugs of the cylinder

head for leaks. If necessary, pressure-test
the cylinder head.
2. Inspect the cylinder head for damage on the
sealing face and any cracks. If necessary,
have the cylinder head refaced. See
2
3.8 INSPECTION, GLOW PLUGS
Note: C
To avoid engine damage it is important that the
glow plugs should be checked periodically.
1. Check the glow plugs for the following
points:
- windings that have worn thin due to A B
abrasion (A)
- filament end broken or worn thin due to
continuous knocking of a loose
insulator (see C)
- broken plug windings (C).
2. Replace all glow plugs if one or more of the
above-mentioned situations occurs.
M200818
3-12 ǹ 0011
2 XF ENGINE
65/75/85CF series Removal and installation
4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, ENGINE
Suspend the engine carefully from

the hoist, using approved lifting
gear.
Various fluids will be released when

pipes are removed. Collect these
fluids. Remember your personal
safety and consider the danger of
2
fire.
Note:
Because of the large number of vehicle
specifications, it is not feasible to exactly specify
the engine removal and installation procedures
for every vehicle.
This description only includes the most
important points requiring attention.
- Disconnect the earth lead from the battery
terminal.
- Avoid opening fluid systems as much as
possible. If possible, remove and set aside
the engine components.
- When removing the engine, ensure that no
parts or dirt fall into the engine, radiator or
other components. Therefore, plug all
openings.
- Electrical wiring harnesses are easily
damaged. If damaged, they may cause
faults. Make sure these wiring harnesses
are stress-free and clear of moving parts.
- Tighten all attachment bolts to the correct
tightening torque.
- Do not allow the engine to rest on the oil
sump. Because the oil sump is made of
sheet material, it will be severely damaged
by the engine’s own weight.
ǹ 0011 4-1
XF ENGINE 2
Removal and installation 65/75/85CF series
4.2 REMOVAL AND INSTALLATION, ENGINE BRACKETS

gear.

2
fire.
Removal, engine brackets

1. Disconnect the earth lead from the battery
terminal.
2. Drain the coolant.
3. Remove the coolant pipes (A) between the A
engine, radiator and header tanks.
4. Remove the torque rod (B) between the
radiator and the engine.
5. Remove the flexible air pipes (C) between
the engine and the intercooler. Plug the
openings.
6. If fitted, loosen the air-conditioning
compressor so that it can be put aside with
the pipes (D).
7. Remove the viscous fan clutch attachment
nuts and place the viscous fan clutch with
the fan in the wind tunnel.
8. Disconnect the earth strip on the flywheel
housing.
9. Properly suspend the engine in the hoist.
B C D
10. Remove the central engine mount
attachment bolts at the front and/or rear of M201019
the engine.
11. Hoist the engine as much as is necessary.
12. Remove the engine mounting.
4-2 ǹ 0011
2 XF ENGINE
Installation, engine brackets

1. Tighten the engine mounting attachment
bolts to the specified torque. See “Technical
data”.
2. Fit the viscous fan clutch and fan. Tighten
the attachment bolts to the specified torque.
3. Fit the torque rod (B) between the radiator A
2
and the engine.
4. Fit the flexible air pipes (C) between the
engine and the intercooler.
5. Fit the coolant pipes (A) between the
6. If present, fit the air-conditioning
compressor.
7. Fit the earth strip from the chassis to the
flywheel housing.
8. Reconnect the earth lead to the battery.
9. Fill the cooling system.
B C D
M201019
ǹ 0011 4-3
XF ENGINE 2
4.3 REMOVAL AND INSTALLATION, VALVE COVER
When the engine or parts thereof

are opened, dirt may enter. This
may result in serious damage to the
engine. Therefore clean the engine
before opening it.
Removal, valve cover
2 1. Clean the area around the valve cover.

2. Remove the attachment bolts from the valve
cover.
3. Remove the valve cover and the valve
cover gasket.
Installation, valve cover
1. Clean the sealing surface of the valve
sleeve and the valve cover.
2. Fit the valve cover using a new valve cover
gasket.
3. Fit the attachment bolts of the valve cover
and tighten them to the specified torque.
4-4 ǹ 0011
2 XF ENGINE
4.4 REMOVAL AND INSTALLATION, VALVE GEAR
Removal, valve gear

1. Remove the valve covers. 1
Note:
Number the rocker seats (1) and the
2
bridges (2-3-4) to allow reinstallation in the
same position.
4. Remove the rocker seats (1).
M200559
5. Remove the bridges (2-3-4).
Installation, valve gear
Note:
In engines equipped with a DEB, the bridges 3 2
(2-3-4) of the inlet and exhaust valves are not
the same. In engines not equipped with a DEB,
the bridges (2-3-4) of the inlet and exhaust 4
valves are the same.
1. Fit the bridges (2-3-4) on the valves.
2. Adjust the bridges (2-3-4). See “Inspection
and adjustment”.
3. Tighten the rocker seats (1) by hand.
Note:
Depending on the engine position, some
rocker seats have to be positioned against M200560
the pressure of the valve springs. The

rocker seat will resist this spring pressure
and cannot therefore be positioned
correctly.
By cranking the camshaft 1/3 stroke
(DAF no. 1310477), the rocker seats can be
tightened according to the injection
sequence 1-5-3-6-2-4.
ǹ 0011 4-5
XF ENGINE 2
4. Tighten the attachment bolts to the

specified torque. See “Technical data”.
respectively. For the tightening torques of
the attachment bolts. See “Technical data”.
2
6. Adjust the valve play and the DEB play if a
DEB is fitted. See “Inspection and
adjustment”.
7. Fit the valve covers.
M200548
4-6 ǹ 0011
2 XF ENGINE
4.5 REMOVAL AND INSTALLATION, CYLINDER HEAD

before opening it.
Removal, cylinder head

terminal. 2
3. Disconnect all electrical wiring around the
engine which is relevant for the removal of
the cylinder heads.
4. Remove the flexible air pipes between the
5. Remove the inlet pipe from the intercooler
to the turbocharger.
6. Disconnect the compressor pipe from the
air inlet pipe to the compressor.
7. Remove the torque rod between the engine
and the radiator.
8. If fitted, slacken the tensioner of the
air-conditioning compressor.
9. Remove the attachment bolts of the
air-conditioning compressor mounting
bracket if fitted.
10. Remove the heat shields from the exhaust
manifold.
11. Remove the attachment bolts from the
exhaust manifold and move the manifold
and the turbocharger a little away from the
cylinder heads.
12. If present, remove the flexible pipes from
the cab heater.
13. If fitted, remove the coolant filter.
ǹ 0011 4-7
XF ENGINE 2
14. Disconnect the fuel leak-off pipe between

the fuel filter and the fuel leak-off pipe on
the inlet manifold.
15. Disconnect the fuel filter assembly from the
coolant pipe.
16. Disconnect both sets of injector pipes.
17. Remove the water pipes between the
thermostat housing and the radiator.
2 18. Remove the coolant pipe together with the
thermostat housing.
19. Remove the attachment bolts of the inlet
manifold and take it completely off the
cylinder heads.
20. Remove the valve covers.
22. Remove the valve gear.
23. Remove the push rods.
24. Remove the valve sleeve.
25. Remove the cylinder head bolts.
26. Remove the cylinder head from the cylinder
block.
27. Remove any remaining gasket pieces from
the cylinder head and the cylinder block.
28. Check the cylinder block sealing surfaces.
29. Check the threaded holes in the cylinder
block for damage and cracking.
30. Check that the height which the cylinder
liner protrudes above the cylinder block is
within the tolerance limits, using the special
tool (DAF no. 0694795). See “Technical
data”.
31. Check the cylinder head. See “Inspection
and adjustment”.
M2 00 100
4-8 ǹ 0011
2 XF ENGINE
Installation, cylinder head

1. Clean the threaded holes in the cylinder
block, using a screw tap.
2. Insert both guide pins (DAF no. 0694912)
into the threaded holes of the cylinder block.
3. Place the new gasket(s) on the cylinder
block, making sure that the letters TOP are
visible. The cylinder head gasket must not
2
be retightened.
4. Place the cylinder head(s) on the cylinder
block and hand-tighten a number of cylinder
head bolts.
Note:
To prevent the inlet and exhaust manifolds
from being installed with tension the inlet
and exhaust manifolds must be installed
before the cylinder head bolts are tightened.
5. Fit the inlet and exhaust manifolds with new
M200561
gaskets and tighten the attachment bolts to
the specified torque. See “Technical data”.
Note:
The M16 cylinder head bolts may be used a
maximum of three times. After tightening
the bolts, mark the bolt heads with a centre
punch, to indicate how often they have been
used.
New bolts should not be marked on the first
fitting.
Bolts marked with 2 centre points must not
be reused and must be replaced by new
ones.
When fitting used bolts, clean the thread
and inspect for damage.
ǹ 0011 4-9
XF ENGINE 2
6. Fit the M16 and M12 bolts, after having

applied a drop of oil to the bearing face of
the bolt head and locking compound to the
thread. See “Technical data”.
7. Remove the two guide pins and replace
them with the two remaining cylinder head
bolts.
8. Tighten the cylinder head bolts to the
2
specified torque and in the sequence
shown. See “Technical data”.
9. Fit the valve sleeve and tighten the
attachment bolts to the specified torque.
10. Fit the push rods.
11. Fit the injectors.
12. Fit the valve gear.
13. Fit the coolant pipe and the thermostat
housing with new gaskets.
14. Fit the water pipe between the radiator and
the thermostat housing.
15. Fit the injector pipes.
16. Fit the thermostat housing onto the coolant
pipe.
17. Fit the fuel leak-off pipe between the fuel
filter and the inlet manifold.
18. Fit the coolant filter on the coolant pipe, if
present.
19. If present, fit the flexible pipes from the cab
heater.
20. Fit the attachment bolts of the exhaust
manifold and tighten them to the specified
torque. See “Technical data”.
4-10 ǹ 0011
2 XF ENGINE
21. If present, fit the air-conditioning bracket.

22. Adjust the V-belt tension of the
air-conditioning compressor. See
“Inspection and adjustment”.
23. Fit the torque rod between the radiator and
the engine.
24. Connect the compressor pipe from the air
inlet pipe to the compressor.
25. Fit the inlet pipe between the intercooler 2
and the turbocharger.
26. Fit the air inlet pipes between the engine
and the intercooler and tighten the
27. Connect the electrical wiring.
ǹ 0011 4-11
XF ENGINE 2
4.6 REMOVAL AND INSTALLATION, GLOW PLUGS
Note:
If the vehicle has been fitted with two glow
filaments upon ex-works delivery, you must not
add two glow filaments yourself. The feeder
cable between the starter motor, glow relay and
glow plugs on these vehicles is inadequate for
four glow plugs.
2 Removal, glow plugs

terminal.
2. Remove the wiring and connection strip
from the glow plugs.
3. Remove the glow plugs.
4. Inspect the glow plugs for damage. See
Installation, glow plugs
1. Tighten the glow plugs to the specified
M200689
2. Connect the wiring and the connection strip.
Make sure that the insulators are fitted in
the correct place.
3. Clean the contact surface of the glow plug
earth lead to ensure that it is properly
earthed on the inlet manifold.
4. Fit the earth lead to the battery terminal.
4-12 ǹ 0011
2 XF ENGINE
4.7 REMOVAL AND INSTALLATION, INLET MANIFOLD
Removal, inlet manifold

terminal.
2. Remove the electrical wiring from the glow
plugs and the temperature sensor.
3. If present, remove the coolant filter element.
4. Remove the inlet manifold fuel leak-off pipe. 2
5. Remove the fuel filter element.
6. Disconnect the injector pipes.
7. Disconnect the boost pressure pipe on the
inlet manifold.
8. Remove the air inlet pipe between the
intercooler and the inlet manifold.
9. Remove the attachment bolts from the inlet
manifold and remove the manifold.
ǹ 0011 4-13
XF ENGINE 2
Installation, inlet manifold

1. Carefully clean the sealing surfaces of the
inlet manifold and the cylinder head.
2. Fit new gaskets to the inlet manifold and fit
the inlet manifold and tighten the
3. Connect the fuel leak-off pipe to the inlet
2
manifold.
4. Fit the air inlet pipe between the intercooler
and the inlet manifold. Tighten the
attachment bolt to the specified torque. See
5. Fit the boost pressure pipe.
7. Fit the fuel filter element.
8. If present, fit the coolant filter element.
9. Fit the electric wiring of the glow filaments
and the temperature sensor.
10. Reconnect the earth lead to the battery
terminal.
4-14 ǹ 0011
2 XF ENGINE
4.8 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD
Removal, exhaust manifold

1. Remove the heat shields (1) from the 4 5
turbocharger.
1
2. Remove the air inlet pipe (2).
3. Remove the butterfly valve (3).
2
4. Remove the air inlet pipe (4) between the
turbocharger and the intercooler. 2
5. Remove the compressor pipe (5).
3
manifold.
7. Remove the oil supply and oil discharge M200565
pipes from the turbocharger.
exhaust manifold and remove the manifold.
ǹ 0011 4-15
XF ENGINE 2
Installation, exhaust manifold

1. Fit new gaskets to the exhaust manifold and
fit the exhaust manifold and tighten the
attachment bolts with the spacer sleeves to
2
3. Fit the turbocharger’s oil discharge pipe.
4. Spray clean engine oil into the oil supply of
the turbocharger and fit the oil supply pipe.
5. Fit the compressor pipe (5).
6. Connect the inlet air pipe (4) between the
turbocharger and the intercooler.
7. Fit the butterfly valve (3).
8. Fit the heat shields (1) of the turbochargers
9. Connect the air inlet pipe (2). Tighten the
10. Start the engine and check all connections
for leaks.
4-16 ǹ 0011
2 XF ENGINE
4.9 REMOVAL AND INSTALLATION, AIR COMPRESSOR
Removal, air compressor

1. Partially drain the coolant.
2. Remove the coolant connections (1).
2 3
3. Disconnect the air pipes (2 and 3). 1
4. Disconnect the lubricating oil pipe.
5. Disconnect the service pipe from the air
dryer.
1 2
6. Remove the attachment bracket at the rear
of the compressor.
timing gear cover.
8. Remove the compressor from the timing
gear case. Remove the O-ring from the
compressor housing.
Installation, air compressor
1. Fit a new O-ring to the compressor housing
and fit the compressor to the timing gear
case.
2. Fit the air compressor attachment bolts and
tighten them to the specified torque. See
3. Fit the attachment bracket at the rear of the
compressor. Tighten the attachment bolts to
4. Fit the service pipe.
5. Fit the lubricating oil pipe.
6. Fit the air pipes (2 and 3).
R600246
7. Fit the coolant pipes (1).
ǹ 0011 4-17
XF ENGINE 2
4.10 REMOVAL AND INSTALLATION, STEERING PUMP
Removal, steering pump

1. Clean the steering pump and the
surrounding area.
2. Remove the suction and delivery pipes from
the steering pump. Collect the steering oil
flowing out of the system.
2 3. Immediately plug the openings in the pump

and pipes to prevent dirt entering the
system.
4. Remove the two attachment bolts in the
timing gear cover and take the pump from
the timing gear case.
5. Check the gear wheel for wear or damage.
6. Remove the O-ring.
Installation, steering pump
1. Fit a new O-ring.
2. Fit the steering pump and tighten the
3. Fit the suction and delivery pipes of the
steering pump. Fit the banjo bolts and
4. Fill the oil tank with the specified oil.
5. Bleed the steering system.
6. Check the pipes for leaks.
4-18 ǹ 0011
2 XF ENGINE
4.11 REMOVAL AND INSTALLATION, STARTER MOTOR
Removal, starter motor

1. Remove both battery leads from the battery
terminals.
2. Remove the electrical connections from the
starter motor.
3. Remove the attachment nuts and the starter
4.
motor.
Check the toothed pinion for damage.
2
Installation, starter motor
1. Clean the contact surfaces of the starter
motor and the flywheel housing.
2. Fit the starter motor in the flywheel housing
and tighten the attachment nuts to the
3. Fit the electrical connections of the starter
motor.
4. Reconnect both leads to the battery
terminals.
M200568
ǹ 0011 4-19
XF ENGINE 2
4.12 REMOVAL AND INSTALLATION, ALTERNATOR
Removal, alternator
terminals. 5 4
2
alternator. 3
3. Slacken the attachment bolt (3) from the
2 threaded spindle which is attached to the
coolant pump.
4. Slacken the locknut (5).
5. Remove the upper attachment bolts (2) of
the alternator.
6. Remove the lower attachment bolt (1) of the
1
alternator.
7. Remove the alternator. M200937
Installation, alternator
1. Fit the alternator on its bracket.
2. Fit the lower attachment bolt (1) of the
alternator.
3. Fit the upper attachment bolts (2) of the
alternator.
4. Install the V-belts and check the V-belt
tension. See “Inspection and adjustment”.
5. Fit the electrical connections of the
alternator.
terminals.
4-20 ǹ 0011
2 XF ENGINE
4.13 REMOVAL AND INSTALLATION, V-BELTS
Removal, V-belt of water pump and alternator

drive 5 4
1. Slacken the alternator bracket attachment 2
bolts (1) and (2).
3
2. Loosen the threaded rod attachment
bolt (3), which is fixed to the water pump.
3. Turn the locknuts (4) and (5) on the
threaded spindle so that the alternator can 2
be tilted towards the engine block and the
V-belt can be removed.
4. Remove the V-belt through the opening at
the guide ring (see arrow in drawing). Hang 1
the V-belt over a fan blade. Rotate the fan
blade by blade, hanging the V-belt over
them. Repeat this for the entire fan, after M200738
which the belt can be removed.
Note:
On versions on which the fan ring is
mounted on the engine block, the fan or the
fan ring must be disconnected before the
V-belt is removed, depending on the
accessibility of the attachment bolts.
Installation, V-belt, water pump and
alternator drive
1. Inspect the pulleys for damage, rust and
grease deposits.
2. Fit the V-belt through the opening at the
guide ring (see arrow in drawing) and adjust
the V-belt tension. See “Inspection and
adjustment”.
3. If removed, fit the filter again.
M200558
ǹ 0011 4-21
XF ENGINE 2
Removal, air-conditioning compressor drive

V-belt
1. Loosen the upper attachment bolts (1) on
1
the compressor. 1
compressor.
2
cooling-water pump.
3
4. Turn the locknuts (3) on the threaded
spindle so that the alternator can be tilted
towards the engine block and the V-belt can
be removed.
2 M2041
Installation, air-conditioning compressor

drive V-belt
grease deposits.
2. Fit the V-belt for the air-conditioning
compressor drive and adjust the V-belt
Removal, V-belt fan drive (Up-speed version)
1. Remove the fan from the flange by
slackening the attachment nuts.
2. Place the fan on top in the air jacket. Take
care that the cooler does not get damaged!
roller.
4. Turn the bolt (7) to move the tension pulley
until the V-belt(s) can be removed.
Installation, V-belt fan drive (Up-speed
version) 7 6
grease deposits. If necessary, clean them
thoroughly.
2. Fit the new V-belt to the pulleys. See
D000388
3. Install the fan and tighten the attachment
nuts.
4-22 ǹ 0011
2 XF ENGINE
4.14 REMOVAL AND INSTALLATION, FLYWHEEL
Removal, flywheel
1. Remove the gearbox.
2. Remove the clutch release assembly and
the clutch plate.
3. Remove the attachment bolts (1) from the
flywheel.
2
1
M200569
4. Use two threaded bolts to remove the

flywheel from the dowel pin.
5. Remove the flywheel.
Installation, flywheel
1. Clean the flywheel housing.
2. Clean the crankshaft flange, the dowel pins
and the attachment bolts. Remove the
locking compound from the threaded holes.
3. Clean the back of the flywheel and fit the
flywheel.
4. Install the attachment bolts and tighten
them to the specified torque. See “Technical
data”. M200570
5. Fit the clutch plate and the clutch release

assembly.
6. Fit the gearbox.
ǹ 0011 4-23
XF ENGINE 2
4.15 REMOVAL AND INSTALLATION, STARTER RING GEAR
Removal, starter ring gear

2. Remove the starter ring by tapping it off the
flywheel using a blunt chisel. If this is not
possible, cut it between two teeth, using a
sharp chisel.
2 Installation, starter ring gear

1. Clean the flywheel and the starter ring gear.
Ensure that the contact areas are
de-greased.
2. Heat the new starter ring evenly in an oven.
3. Tap the starter ring onto the flywheel so that
the bevelled sides of the teeth point towards
the starter motor. Ensure good all round
contact between starter ring gear and
flywheel.
4. Fit the flywheel.
M2 00 035
4-24 ǹ 0011
2 XF ENGINE
4.16 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING SEAL
Removal, flywheel housing seal

Note:
Each new seal is supplied with a plastic
mounting ring, which can only be used
once.
2. Drill two small holes into the oil seal and,
using the special tool (DAF no. 0484899
2
and DAF no. 0694928), pull the oil seal out
of the flywheel housing.
Installation, flywheel housing seal
1. Thoroughly clean the seal recess and
inspect for damage. Even the most minute
damage can cause a leak.
2. Clean the crankshaft flange.
Note:
If a spacer ring has been placed in the seal
chamber, it must be re-fitted.
3. Fit the base plate (A) of the special tool 1
(DAF no. 0535598) on the crankshaft 2
flange.
4. Fit a new dry oil seal (the felt ring must not
get greasy) over the plastic mounting ring
supplied (1).
5. Fit the supplied plastic mounting ring (1)
with the oil seal on the crankshaft flange. A
6. Place the thrust washer (B) over the spindle
and gradually tighten the nut (C) until the
resistance increases. B C
7. Remove the thrust washer (B) and take out M2 00 036
the plastic mounting ring (1).
and gradually tighten the nut (C) until the oil
seal is properly positioned.
9. Remove the special tool.
ǹ 0011 4-25
XF ENGINE 2
4.17 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING
Removal, flywheel housing

2. Disconnect the earth lead from the flywheel
housing.
3. Remove the starter motor.
2 4.
5.
Properly suspend the engine in the hoist.
Remove the two oil sump attachment bolts
on the flywheel housing.
6. Slacken the other oil sump attachment bolts
until the oil sump is free from the flywheel
housing.
attachment bolts at the back of the engine.
flywheel housing.
9. Remove the flywheel housing.
Installation, flywheel housing
1. Remove the oil seal from the flywheel
housing, by carefully tapping or forcing it
from the housing.
2. Remove any traces of old gaskets from the
contact areas.
3. Inspect the sealing faces for damage.
4. Inspect the flywheel housing for cracks.
5. Apply a locking compound to the sealing
face of the cylinder block. See “Technical
data”. Apply the locking compound with a
roller or brush, across the entire sealing
face.
6. Fit the flywheel housing and tighten the
4-26 ǹ 0011
2 XF ENGINE
7. Fit the central engine bracket attachment

bolts at the back of the engine. Tighten the
8. Fit the oil seal.
10. Fit the starter motor.
11. Clean the contact surface of the earth lead,
and connect it to the flywheel housing. 2
12. Fit the oil sump attachment bolts and
tighten all the attachment bolts to the
ǹ 0011 4-27
XF ENGINE 2
4.18 REMOVAL AND INSTALLATION, FAN DRIVE
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
4-28 ǹ 0011
2 XF ENGINE
Removal, fan drive

1. Remove the attachment nuts from the
viscous fan clutch. Place the viscous fan
clutch with the fan in the wind tunnel.
2. Remove the V-belts of the water pump,
alternator and fan drive.
3. Remove the attachment nuts from the fan
drive.
4. Remove the fan drive.
2
Installation, fan drive
1. Install a new O-ring (8), lightly greased, in
the groove of the bearing housing (11).
2. Apply engine oil to the bearings in the
bearing housing.
3. Fit the fan drive in the timing gear case and
tighten the attachment nuts to the specified
4. Fit the V-belts of the water pump, alternator
and fan drive. Adjust the V-belts. See
5. Fit the viscous fan clutch and fan.
ǹ 0011 4-29
XF ENGINE 2
4.19 REMOVAL AND INSTALLATION, UP-SPEED BEARING BLOCK
Removal, up-speed bearing block

2. Remove the fan drive V-belt.
3. Remove the attachment bolts (5) of the
2 up-speed bearing block/vibration damper
from the flange in the bearing block through
6
the openings in the up-speed pulley.
7
4. Remove the up-speed bearing block.
Installation, up-speed bearing block 4
1. Fit the up-speed bearing block and tighten
the attachment bolts to the specified torque. 10
See “Technical data”. 8
2. Install the V-belt and check the V-belt
9 11 12 13 5 2 3 1 14
M200947
4-30 ǹ 0011
2 XF ENGINE
4.20 REMOVAL AND INSTALLATION, VIBRATION DAMPER
Version with direct fan drive

Removal, vibration damper
2. Remove the V-belts of the water pump and
3.
alternator drive.
Remove the attachment bolts (7) of the fan 4
2
flange/vibration damper. 1
4. Remove the vibration damper (4). 2
3
Installation, vibration damper
1. Check the vibration damper for external 5
damage and silicone liquid leaks. In the 6
event of damage or leaks, the vibration 7
damper should be replaced.
2. Fit the vibration damper (4) and the fan
flange (5). Tighten the attachment bolts (7)
data”.
3. Fit the new V-belt and adjust the V-belt M200946
ǹ 0011 4-31
XF ENGINE 2

2. Remove the vibration damper (4).
1. Check the vibration damper for external
damage and silicone liquid leaks. In the
2 damper should be replaced. 7
2. Fit the vibration damper (4) and the
up-speed bearing block. Tighten the 4
attachment bolts (5) to the specified torque.
8
9 11 12 13 5 2 3 1 14
M200947
4-32 ǹ 0011
2 XF ENGINE
4.21 REMOVAL AND INSTALLATION, VIBRATION DAMPER HUB
Removal, vibration damper hub

1. Remove the vibration damper.
vibration damper hub, and remove the
thrust piece.
3. Remove the vibration damper hub using the
special tool (DAF no. 1310422).
Installation, vibration damper hub
2
1. Fit the vibration damper hub onto the
crankshaft.
2. Fit the thrust piece and tighten the
3. Fit the vibration damper.
M200770
ǹ 0011 4-33
XF ENGINE 2
4.22 REMOVAL AND INSTALLATION, TIMING COVER SEAL
Removal, timing cover seal

1. Remove the vibration damper hub.
2. Remove the timing cover seal by drilling two
holes in the seal and using special tools
(DAF no. 0484899 and DAF no. 0694928)
to pull the seal from the timing cover.
2 Installation, timing cover seal

1. Clean and inspect the oil seal recess in the
timing gear cover. Even minimal damage
can lead to a leak.
Note:
If a filler ring has been placed in the oil seal
install the dry sealing ring and the thrust
piece in the recess of the timing gear cover.
4. Fit the vibration damper hub.
M200771
4-34 ǹ 0011
2 XF ENGINE
4.23 REMOVAL AND INSTALLATION, TIMING COVER

before opening it.
Removal, timing cover

2. Remove the oil filler pipe.
2
3. Mark the positions of the various
attachment bolts and studs.
4. Remove the attachment bolts and studs
from the timing cover.
5. Remove the timing cover.
6. Remove any gasket remains. Clean and
inspect the sealing faces, dowels and
locating holes.
7. Remove the seal from the timing cover.
Installation, timing cover
1. Use three studs to position the gasket. Fit
the new gasket.
2. Fit the timing cover.
3. Fit the attachment bolts and the studs.
Tighten the attachment bolts and studs to
4. Remove the three studs used to position the
gasket and replace them with the remaining
attachment bolts.
5. Fit a new O-ring to the oil filler pipe and fit
the oil filler pipe.
6. Fit the timing gear cover seal.
ǹ 0011 4-35
XF ENGINE 2
4.24 REMOVAL AND INSTALLATION, TIMING GEAR WHEELS
Removal, timing gear

position).
2 Note:
It is possible that the marks of the
intermediate gear wheel are not exactly
opposite the camshaft and crankshaft gear
wheel.
M200574
4-36 ǹ 0011
2 XF ENGINE
Removal, intermediate gear wheel

1. Remove the attachment bolt (1) with the 6 3 1 2
axial thrust washer (2).
Removal, camshaft gear wheel
1. Remove the attachment bolt (6) of the
camshaft gear wheel.
2. Remove the intermediate gear wheel.
3. Remove the camshaft gear wheel using a 2
commercially available puller.
Removal, fuel pump drive gear wheel
1. Turn the engine speed sensor a number of
revolutions out of the timing gear case to
prevent the sensor from being damaged
when the gear wheel is being removed.
M200578

silencer and remove the silencer. 4
3. Remove the attachment bolt (5) from the
fuel pump gear wheel.
5. Remove the gear wheel using a
5 M200577
ǹ 0011 4-37
XF ENGINE 2
Installation, timing gear wheels

position).
M200574
Installation, intermediate gear wheel

1. Note:
Before installing the intermediate gear
wheel, ensure that the clamp bolt used to
set the injection time can be accessed.
Fit the intermediate gear wheel (3) in such a
position that the marks of the camshaft gear
wheel (2), crankshaft gear wheel (1) and
intermediate gear wheel (3) are in line.
2 3
1
M200602
4-38 ǹ 0011
2 XF ENGINE
2. Fit the attachment bolt (1) bolt with the axial

thrust washer (2) of the intermediate gear 6 3 1 2
wheel (3). Tighten the attachment bolt (1) to
3. Check whether the gear wheels have some
play.
Installation, camshaft gear wheel
1. Fit the gear wheel onto the camshaft.
2. Install the intermediate gear wheel (3).
2
3. Fit the camshaft gear wheel attachment
bolt. Tighten the attachment bolt (1) to the
play.
Installation, fuel pump drive gear wheel
Note:
Before installing the intermediate gear wheel, M200578
ensure that the clamp bolt used to set the

injection time can be accessed.
1. Fit the gear wheel onto the shaft end.
4
2. Fit the intermediate gear wheel.
3. Fit the attachment bolt (5) of the fuel pump
gear wheel. Tighten the attachment bolts (4)
data”.
4. Fit the silencer.
5. Fit the attachment bolts (4) of the silencer.
Tighten the attachment bolt to the specified
play.
5 M200577
ǹ 0011 4-39
XF ENGINE 2
7. Turn the engine speed sensor into the

timing gear case and adjust the distance
between the sensor and gear wheel. See
Installation, timing gear
3. Check the injection timing.
2
4.25 REMOVAL AND INSTALLATION, TIMING CASE
Removal, timing gear case

1. Remove the timing gear wheels.
2. Remove the air compressor.
3. Remove the steering pump.
4. Remove the attachment bolts and the
locking plate from the camshaft.
5. Loosen the oil sump attachment bolts until
the oil sump is free from the timing gear
case.
timing gear case to the engine block, and
remove the timing gear case.
Installation, timing gear case
locating holes.
2. To position the gasket, insert three studs
and fit the new gasket.
3. Then firstly remove any excess gasket
M200579
material between the engine block and oil
sump.
4. Fit a new O-ring on the air compressor.
5. Fit the timing gear case.
4-40 ǹ 0011
2 XF ENGINE
6. Fit the attachment bolts for the timing gear

case. Tighten the attachment bolts to the
7. Tighten the oil sump attachment bolts to the
8. Remove the locking plate and the
attachment bolts from the camshaft. Tighten
2
9. Fit the timing gear wheels.
10. Fit the air compressor.
11. Fit the steering pump.
ǹ 0011 4-41
XF ENGINE 2
4.26 REMOVAL AND INSTALLATION, TIMING GEAR CASE SEAL
2 3 4 5 6
1
2
7 8
M200582
Removal, timing gear case seal

position).
2. Remove the fuel pump drive gear wheel (2).
3. Remove the seal (3) by tapping in from the
timing gear case in the driving direction.
Installation, timing gear case seal
1. Fit a dry new timing gear case seal (3)
using special tool (DAF no. 1329318).
2. Fit gear wheel (2) of the fuel-pump drive.
M200580
4-42 ǹ 0011
2 XF ENGINE
4.27 REMOVAL AND INSTALLATION, FUEL PUMP DRIVE HOUSING
2 3 4 5 6
1
2
7 8
M200582
Removal, fuel pump drive housing

position).
ǹ 0011 4-43
XF ENGINE 2
3. Remove the clamping bolt (1).
2
i 400171
4. Remove the axial locking plate (7) from the

prop shaft.
5. Remove the prop shaft (8) from the
transmission case.
87
M200581
6. Remove the sealing ring by tapping in from

the timing-gear case in the driving direction.
7. Remove the attachment bolts from the fuel
pump drive housing.
8. Remove the fuel-pump drive housing from
the engine block.
M200580
4-44 ǹ 0011
2 XF ENGINE
Installation, fuel pump drive housing

1. Install the fuel-pump drive housing with a
new O-ring for lubrication. Tighten the
2. Fit the prop shaft (8) in the fuel pump drive
housing.
3. Fit the axial retainer plate (7). Tighten the
2
4. Fit a dry new timing gear case sealing ring
5. Fit the fuel pump gear wheel.
6. Set the injection timing.
87
M200581
ǹ 0011 4-45
XF ENGINE 2
4-46 ǹ 0011
2 XF ENGINE
65/75/85CF series Disassembly and assembly
5. DISASSEMBLY AND ASSEMBLY

5.1 DISASSEMBLY AND ASSEMBLY, FAN DRIVE
The fan drive should be

disassembled and assembled in a
very accurate fashion. Inaccurate
assembly of the fan drive can cause
strange noises in the engine or
result in severe engine damage.
2
ǹ 0011 5-1
XF ENGINE 2
Disassembly and assembly 65/75/85CF series
Disassembly, fan drive

1. Remove the circlip (13) on the gear wheel
(12) side.
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
Note:
A mark may have been made on the rear
side of the shaft (1) during initial assembly.
This mark may be used to check whether
the gear wheel (12) has turned in relation to
the shaft (1). If this is the case, the shaft (1)
and/or the gear wheel (12) is/are rejected.
M200688
5-2 ǹ 0011
2 XF ENGINE
2. Fit the special tool (DAF no. 1329445)

under the gear wheel (12) and press the
shaft out of the gear wheel (12).
3. Support the bearing housing (11) and press
the shaft (1) until the bearing (9) is released
from the shaft (1).
4. Remove the shaft (1) from the bearing
housing (11) and remove the spacer
2
sleeve (5).
5. Remove the bearing (3) from the shaft (1).
M200932
6. Remove the oil seal (2) from the bearing

housing (11).
7. Remove the circlip (10) from the bearing
housing (11).
the bearing rings (4) and (7), with
intermediate ring (6), jointly out of the
bearing housing (11).
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
Assembly, fan drive

Note:
The bearings (3 and 9), with spacer sleeve (5)
and intermediate ring (6), go together and must
be replaced as a set. This is necessary to
obtain a proper bearing play.
The parts must be free of dirt and grease.
3 5 6 9
M200679
ǹ 0011 5-3
XF ENGINE 2
1. Using the special tool (DAF no. 1329386),

press the bearing (3) with spacer sleeve (5)
over the shaft (1).
M200680
Note:
The holes in the intermediate ring should be
on the oil seal side.
2. Fit the intermediate ring (6) in the bearing
housing (11).
11
press the bearing ring (7) into the bearing
housing (11) until it abuts the intermediate 7
ring (6).
6
M200681
5-4 ǹ 0011
2 XF ENGINE
4. Turn the bearing housing (11) and support

the bearing ring (7), using the special tool
(DAF no. 1329383).
housing (11) until it abuts the intermediate
ring (6).
2
6
11
M200682

press the oil seal (2) into the bearing
housing (11) until it is level with the front of
the bearing housing (11).
11
M200683
ǹ 0011 5-5
XF ENGINE 2
7. Lightly oil the bearing face of the oil seal on

the shaft (1) and carefully fit the shaft (1) in
11
M200684
Note:
When forcing on the bearing (9), rotate the
bearing housing (11) at least 5 times, so
that the bearings can settle.
8. Using a low pressing force and the
special tool (DAF no. 1329382) press the
bearing (9) onto the shaft (1) until it abuts.
11
9
M200685
5-6 ǹ 0011
2 XF ENGINE
9. Fit the circlip (10) in the bearing housing

(11). Fit a new O-ring (8).
10
8
M200686
10. Remove any grease and oil from the shaft 13

(1) and gear wheel (12) local to the contact
areas.
Note: 12
The gear wheel (12) must not under any
circumstances be exposed to the specified
maximum temperature for more than
30 minutes. Exposure lasting longer than
30 minutes has a detrimental effect on
the mechanical properties of the gear
wheel (12).
11. Heat the gear wheel (12) evenly to the
specified temperature in the shortest
possible time (on a hot plate using thermal
pins). See “Technical data”.
12. Fit the gear wheel (12) onto the shaft (1).
Do this without using pressure.
13. Fit the circlip (13).
M200687
ǹ 0011 5-7
XF ENGINE 2
14. Make a mark over the shaft (1) and gear

wheel (12). This is for the purpose of being
able to inspect during subsequent
inspections or repairs whether the gear
wheel (12) has turned in relation to the
shaft (1).
M200688
Inspection:
Fit special tool (DAF no. 1329445) under
the gear wheel (12) and press on the shaft
with a force of 100 kN. When the shaft has
been pressed out, the shaft and gear wheel
will be rejected.
15. Apply a little engine oil in the bearing
housing (11) and inspect the shaft (1) for
even rotation.
M200932
5-8 ǹ 0011
2 XF ENGINE
5.2 DISASSEMBLY AND ASSEMBLY, UP-SPEED BEARING BLOCK
1 2 3 5 7 4 6
M200803
Disassembly, up-speed bearing block

1. Remove the central bolt (1) from the
bearing block.
2. Take the up-speed pulley (5) from the hub
(if necessary use a standard puller).
3. Remove the bearings (3 and 4) from the
pulley (5).
4. If necessary remove the circlip (7) from the
pulley (5).
ǹ 0011 5-9
XF ENGINE 2
A 3 7 5 3 B
M200804
Assembly, up-speed bearing block

1. Clean the up-speed pulley (5).
2. Fit the circlip (7) in the up-speed pulley (5)
(if removed).
3. With a low force press the rear bearing
into the up-speed pulley.using special tool
(B) (DAF No. 1329436).
4. With a low force press the front bearing
into the up-speed pulley using special tool
(A) (DAF No. 1329437).
5. Fit the up-speed pulley on the hub.
6. Fit the circlip and central bolt and place the
bearing block assembly on the vibration
damper.
7. Tighten the bolt to the specified torque.
5-10 ǹ 0011
2 XF ENGINE
5.3 DISASSEMBLY AND ASSEMBLY, V-BELT TENSIONING GEAR
Disassembly, V-belt tensioning gear

1. Remove the nut from the tensioning roller.
2. Remove the circlip.
3. Remove the pulley.
4. Remove the bearing from the hub.
Assembly, V-belt tensioning gear
1. Fit the circlip to the pulley.
2
2. With a low force, press the bearing into the
pulley.
3. Fit the pulley on the hub.
4. Fit the nut.
ǹ 0011 5-11
XF ENGINE 2
5-12 ǹ 0011
2 XF ENGINE
65/75/85CF series Cleaning
6. CLEANING
6.1 CLEANING THE ENGINE
Note:
It is advisable to clean the engine with a
high-pressure cleaner before starting
maintenance or service operations. A clean
engine makes the mechanic’s work easier, and
enables him to notice any defects at an early
stage. 2
Before cleaning the engine, check for any leaks.
If the engine is cleaned with a high-pressure
cleaner, it must be used with care. It is also
important to observe the following points:
- When cleaning the universal joint on the
steering box, the spider seals may be
forced open by the high-pressure jet of
water, so that the grease behind them is
flushed away. As a result, the spider may
get stuck, so that the steering mechanism
will jam.
- A bleed screw is fitted to the power steering
fluid reservoir of the steering system. Water
may enter the tank through this valve,
causing damage to the steering gear.
- When cleaning the radiator/intercooler
element, be careful not to damage the fins.
- Do not direct the high-pressure cleaner jet
too long at the air-conditioning system
condenser. As a result of the high
temperature, the pressure in the system will
become excessive, which may cause
damage to the system.
ǹ 0011 6-1
XF ENGINE 2
Cleaning 65/75/85CF series
- Ensure that no water can enter the gearbox

via the breathers.
- Make sure that no water can enter via the
reservoir bleed screws of the clutch.
- The engine compartment can be cleaned
with a high-pressure cleaner. Never direct
the jet of water to electrical components.
- Do not aim the jet of water directly at
2 electrical connections such as connectors,
vehicle lighting system cable plugs.
- Ensure that no water can enter the air inlet
system via the air intake or its flexible seals.
6-2 ǹ 0011
2 XF ENGINE COOLING SYSTEM
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.2 Cooling system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0011
3. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Description of cooling system pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Description of the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0011
3.3 Description, coolant filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
4. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Pressure-testing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
......
......
0011
0011
3
4.2 Inspection, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
4.3 Inspection, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.4 Inspection, water pump radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0011
5. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.1 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.2 Removal and installation, coolant filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 ...... 0011
5.3 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ...... 0011
5.4 Removal and installation, viscous fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ...... 0011
5.5 Removal and installation, header tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 ...... 0011
5.6 Removal and installation, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ...... 0011
6. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
6.1 Draining and filling/bleeding, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
ǹ 0011 1
XF ENGINE COOLING SYSTEM 2
2 ǹ 0011
properly extracted.
moving components.
3
required.
ǹ 0011 1-1
1-2 ǹ 0011
2. GENERAL
1 9 10
3
8 3
7
6 5 4
M200764
M200765
Legend
2. Water pump
3. Fan drive
4. Water-cooled air compressor
5. Water pipe
6. Oil cooler
9. Coolant pipe
10. Coolant filter
ǹ 0011 2-1
2.2 COOLING SYSTEM DESCRIPTION
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, a coolant filter and pipes.
At the highest point in the cooling system, a
bleed pipe has been installed. Through this pipe,
any air in the cooling system is discharged to the
header tank (1), so that the cooling system is
bled automatically.
The water pump is located immediately below
3 the thermostat housing. The thermostat housing
is mounted on the coolant collection pipe.
From the delivery side of the water pump, the
coolant is directed to the cylinder block via an
opening at the back of the water pump. The
coolant flows through the cylinder block, along
the cylinder liners up to the cylinder heads and
leaves them through the coolant collector pipe to
Depending on the coolant temperature, the
thermostat distributes the coolant flow to the
radiator or directly back to the coolant pump.
The coolant transported to the radiator enters
the radiator at the top, and leaves the radiator at
the bottom. From the bottom of the radiator, the
coolant is returned to the water pump, via the
return pipe.
2-2 ǹ 0011
a
b
a
b
3
M200583
ǹ 0011 2-3
The connection pipe to the header tank is also

connected to the return pipe from the radiator. If
the coolant heats up, the coolant flows to the
header tank. If the coolant cools down, the
coolant flows back from the header tank.
From the cylinder block, some of the coolant
flows through the oil cooler. From the oil cooler,
the coolant is returned to the water pump
through a pipe, via the coolant return pipe. The
oil cooler is not only intended to cool the
lubricating oil, but also to heat the lubricating oil
in a “cold” engine.
3
flows through the air compressor. From the air
compressor, the coolant is returned via a pipe to
the water pump.
The pipe which takes the coolant to the heater
for the cab heating is connected to the
thermostat housing. From the heater, the
coolant is returned via a pipe to the water pump.
2-4 ǹ 0011
a
b
a
b
3
M200584
ǹ 0011 2-5
2-6 ǹ 0011
65/75/85CF series Component description
3. COMPONENT DESCRIPTION
3.1 DESCRIPTION OF COOLING SYSTEM PRESSURE CAP
The pressure cap on the header tank is attached

to the header tank via a screw thread. To fill the
cooling system, remove this pressure cap or the
filler cap at the front of the header tank.
The pressure cap has two valves. Normally, both
valves are closed.
Overpressure in the cooling system
If the pressure (P1) in the cooling system rises P2
to 0.7 bar however, the pressure relief valve
opens. 3
The overpressure in the cooling system makes it
possible to allow a higher temperature in the
cooling system, without the coolant boiling.
P1
Underpressure in the cooling system
M200445
If the pressure (P1) in the cooling system drops
to approximately 0.1 bar below the ambient air
pressure (P2), the underpressure valve opens.
ǹ 0011 3-1
Component description 65/75/85CF series
3.2 DESCRIPTION OF THE THERMOSTAT
Operation of the thermostat B

The coolant enters the thermostat housing
directly from the coolant collector pipe at the
back and flows through the thermostat.
Depending on the temperature of the coolant
and the relative position of the thermostat, there
are three possibilities:
Thermostat closed
The coolant has not yet reached the opening
temperature of the thermostat.
Supply passage (B) to the radiator is completely
3 closed.
The coolant passes via a by-pass duct (A)
directly to the water pump and the pump once
again passes the coolant to the cylinder block.
Thermostat starts opening
The coolant has reached the opening A
The supply passage (B) to the radiator is
opened and the by-pass passage (A) is partially B
closed.
At this time, coolant will flow both through the
supply passage (B) to the radiator and through
the by-pass passage (A) to the water pump.
Thermostat fully opened
The temperature of the coolant has become
even higher, the supply passage (B) to the
radiator is fully opened and the by-pass passage
(A) is fully closed.
The entire coolant circulation now flows via the
supply passage (B) to the radiator where it is
cooled before flowing back to the water pump.
In the event of excessive coolant temperatures,
it is not permitted to remove the thermostat, as
an emergency solution. If the thermostat is A
removed from the engine, uncooled coolant will
flow to the water pump via the by-pass passage
(A). As a consequence, the coolant temperature B
will continue to rise.
A M200547
3-2 ǹ 0011
3.3 DESCRIPTION, COOLANT FILTER
The task of the coolant filter is to filter the

coolant to prevent cavitation. The coolant filter
also adds additives to the coolant.
3
M200546
ǹ 0011 3-3
3-4 ǹ 0011

4.1 PRESSURE-TESTING THE COOLING SYSTEM
When the coolant is hot, there is an

overpressure in the cooling system.
Carefully remove the filler cap to
release the overpressure.
Coolant is a noxious fluid. Avoid

skin contact to prevent poisoning.
In order to avoid damaging the

cylinder block; do not top up a hot
engine with cold coolant. 3
The cooling system can be checked for leaks by
means of a pressure-test pump. When this is
done with a warm engine, it is easier to spot any
cracks.
1. Fill the cooling system to the correct level.
2. Raise the engine temperature. This need
not be the operating temperature.
3. Remove the filler cap from the header tank.
4. Fit the pressure-test pump.
Note:
By fitting the pressure-test pump to the filler
opening of the header tank, the pressure
cap can also be tested.
5. Pressure-test the system to the specified
value. See “Technical data”.
6. Check the cooling system for leaks. M2046
ǹ 0011 4-1
4.2 INSPECTION, THERMOSTAT
1. Remove the thermostat. See “Removal and

installation”.
2. Inspect the sealing surfaces (A) of the
thermostat housing for damage.
3. Inspect the sealing ring (B) for damage.
4. Inspect the thermostat seat (C) for damage.
5. Check whether the thermostat is fully
closed.
A
C B
3
C B
A
M200594
6. Place the thermostat in a container filled

with clean water.
7. Place a thermometer in the container and
heat the water. Check at what temperature
the thermostat starts opening and whether it
is opened fully. See “Technical data”.
M200513
4-2 ǹ 0011
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.
Testing with a cold engine

During this test, the slip in the viscous fan clutch
is measured, if the clutch is not operational. This
test must be carried out with a “cold” engine
3
(coolant temperature approximately 50_C).
1. Check the coolant level, and as necessary
top up.
2. Start the engine and run it at idling speed
for at least 5 minutes.
3. Then use a digital rev counter to measure
the fan speed at a number of engine speeds
(from idling to maximum engine speed).
During this test procedure, the speed of the
fan should be approx. 600 to 1100 rpm.
Testing with a warm engine
This test checks whether the contact operates at
an operating temperature of 85 - 95_C.
top up. Be careful when topping up the
coolant if the engine is warm.
2. Remove the front engine encapsulation.
ǹ 0011 4-3
3. Take a sheet of cardboard with a 100 mm

hole, as shown in the diagram opposite, and
place it in front of the radiator, so that the
hole is in front of the viscous coupling.
4. Check that the gearbox is in neutral.
5. Bring the cooling system to operating
temperature.
900
6. Allow the fan drive flange to run at a speed
of 1000 rpm.
Then use an optical rev counter to
determine the difference in speed of the fan 100
in relation to the drive flange. The speeds
3 will differ if there is any slip in the viscous
clutch. When the clutch is fully engaged, the
430
slip must not be more than 10%. If it is more
than 10%, the viscous fan clutch must be
replaced.
700
M200440
4-4 ǹ 0011
4.4 INSPECTION, WATER PUMP RADIAL PLAY
1. Remove the V-belts from the water pump

pulley.
2. Connect a dial gauge as shown in the
illustration.
3. Force the water pump pulley downwards
and set the dial gauge to zero.
4. Pull the water pump pulley upwards and
read off the dial gauge.
3
5. Compare the pressure reading with the
technical data. See “Technical data”. If the
level shown is greater than that in the
technical data, the water pump must be
replaced.
M200595
ǹ 0011 4-5
4-6 ǹ 0011

5.1 REMOVAL AND INSTALLATION, WATER PUMP
Removal, water pump

2. Drain the coolant. See “Draining and filling”.
and the radiator.
4. Remove the bolts from the guide ring
brackets and remove the guide ring.
5. Remove the attachment nuts of the viscous
fan clutch on the fan pulley and place the
3
viscous fan clutch with the fan as far
forward as possible in the wind tunnel.
6. Remove the V-belts of the alternator and
the air conditioning compressor.
7. Remove the attachment bolts from the M200596
thermostat housing on the water pipe and
remove the thermostat housing with the
connection piece.
8. Disconnect all flexible water pipes
connected to the water pump.
9. Disconnect the pipe from the water pump to
the coolant filter.
10. Remove the attachment bolts holding the
spindles of the alternator and
water pump.
12. Disconnect the water pump.
ǹ 0011 5-1
Installation, water pump

1. Thoroughly clean and check the sealing
surfaces of the water pump, the thermostat
housing and the cylinder block.
2. Fit a new gasket to the water pump and fit
the water pump. Install the attachment bolts
3. Fit new O-rings to the connection piece and
fit it to the water pump.
4. Fit new O-rings to the thermostat housing
and fit it to the coolant pipe.
3 5. Connect the pipe from the water pump to
the coolant filter.
6. Fit all flexible water pipes connected to the
water pump.
7. Fit the V-belts from the alternator and the air
conditioning compressor.
9. Fit the guide ring brackets and the guide
ring.
10. Fit the torque rod between the engine and
the radiator.
11. Fill the cooling system. See “Draining and
filling”.
12. Fit the front engine encapsulation.
5-2 ǹ 0011
5.2 REMOVAL AND INSTALLATION, COOLANT FILTER



engine with cold coolant.
Removal, coolant filter

1. Place a tray beneath the filter.
3
3. Switch the shut-off valve (1) clockwise to
the “C” position. O C
4. Remove the coolant filter by turning it
anti-clockwise.
Installation, coolant filter
1. Clean the sealing face of the coolant filter. 1
2. Apply a small amount of coolant to the
sealing ring of the coolant filter element.
3. Fit the coolant filter until the sealing ring
abuts. Then tighten the filter by hand 1/2 to
3/ of a turn.
4
M200372
4. Switch shut-off valve (1) counter-clockwise
to the “O” position.
5. Put the filler cap back on the header tank.
6. Run the engine and check that the coolant
filter has sealed correctly.
7. Check the coolant fluid level.
ǹ 0011 5-3
5.3 REMOVAL AND INSTALLATION, THERMOSTAT
Removal, thermostat
2. Remove the water pipe between the
thermostat housing.
4. Remove the thermostat housing and the
connecting piece from the water pump. A
C B
3
5. Remove the O-ring (A) from the thermostat
housing.
6. Remove the thermostat. C B
Removal, thermostat sealing ring
A
1. Remove the oil seal (B) in the thermostat
housing using a commercially available
internal puller.
Removal, thermostat seat
1. Remove the thermostat seat (C) at the
bottom of the thermostat housing using a
commercially available internal puller.
M200594
5-4 ǹ 0011
Installation, thermostat seat

1. Apply locking compound to the thermostat
seat (C) and fit it in the thermostat housing
using special tool (DAF no. 1310456). See
Installation, thermostat oil seal
1. Fit the thermostat seal (B) in the
thermostat housing using special tool
(DAF no. 1310456).
A
Installation, thermostat
1. Fit the thermostat in the thermostat housing.
C B
2. Fit the O-ring (A) in the thermostat housing. C B
3. Fit new O-rings to the connection piece A 3
from the thermostat housing to the water
pump, and fit the connection piece in the
thermostat housing.
pipe.
5. Fit the thermostat housing attachment bolts.
Tighten the attachment bolts to the
M200594
6. Fit the water pipe between the thermostat
housing and the radiator.
filling”.
ǹ 0011 5-5
5.4 REMOVAL AND INSTALLATION, VISCOUS FAN CLUTCH
Removal, viscous fan clutch

2. Slacken the V-belts of the water pump and
alternator drive.
intercooler and the inlet manifold on the
alternator side.
guide ring brackets, and remove the guide
3 5.
ring.
Remove the attachment nuts from the
viscous fan clutch on the drive flange. Place
the viscous fan clutch with the fan in the
wind tunnel temporarily.
Note:
The fan clutch must always be stored
vertically.
6. Remove the attachment nuts of the fan and
remove the viscous fan clutch.
Installation, viscous fan clutch
1. Place the new viscous fan clutch in the fan.
Tighten the attachment nuts to the specified
2. Fit the guide ring and the attachment bolts
of the guide ring brackets.
3. Fit the viscous fan clutch and fan to the
drive flange. Tighten the attachment nuts to
4. Fit the air inlet pipe and tighten the
attachment bolt to the specified torque.
5. Fit the V-belt of the alternator and water
pump drives.
5-6 ǹ 0011
5.5 REMOVAL AND INSTALLATION, HEADER TANK
Removal, header tank

2. Drain the coolant until the header tank is
empty. See “Draining and filling”.
3. Remove all water pipes between the header
tank and the engine.
4. Loosen the retainer clips at the front of the
header tank.
M200585
3
5. Lift the front of the header tank a little.
6. Loosen the retainer clips at the back of the
header tank.
7. Remove the header tank.
Installation, header tank
1. Fit the header tank, pushing it into the
retainer clips at the back first.
2. Fit all water pipes between the header tank
and the engine.
filling”.
5. Run the engine and check that all
connections are sealed properly.
ǹ 0011 5-7
5.6 REMOVAL AND INSTALLATION, RADIATOR
Note:
The removal and installation procedure for the
radiator allows for the presence of an
air-conditioning unit. If such a unit is not present,
the sections concerned can be skipped.
Removal, radiator
terminal.
3 3.
4.
Remove the front engine encapsulation.
Remove the engine encapsulation under
the cab.
brackets, and remove the guide ring.
6. Remove the guide strip at the front of the
intercooler.
7. Remove the dip stick holder of the
intercooler and put it aside.
9. Remove the water pipes to the radiator.
air-conditioning condenser and pull the
condenser forwards.
11. Disconnect the other air-conditioning pipes
from the intercooler.
12. Remove the wire mesh underneath the
intercooler.
13. Remove the air-conditioning dryer
underneath the intercooler.
14. Remove the left-hand connector pipe from
the inlet manifold to the intercooler.
5-8 ǹ 0011
15. Remove the right-hand connector pipe from

16. Remove the entire air-conditioning
compressor and move it with the pipes to
the front of the intercooler.
intercooler.
18. Move the intercooler a little to the right to
remove the attachment bolt of the oil filler
pipe.
20. Remove the torque rod from the radiator to
the engine lifting eye.
3
radiator brackets. Remove the radiator
assembly, intercooler and wind tunnel from
the chassis.
22. Remove the intercooler from the radiator.
Installation, radiator
1. Fit the entire radiator, intercooler, and wind
tunnel in the chassis. Tighten the
attachment nuts to the specified torque. See
2. Slide the oil filler pipe onto the radiator and
fit the attachment bolt.
3. Place the intercooler in its position and
hand-tighten with two attachment bolts.
4. Install the torque rod from the radiator to the
engine lifting eye.
5. Fit the air-conditioning compressor and its
pipes over the radiator.
6. Fit the air-conditioning compressor unit on
the engine bracket.
ring.
ǹ 0011 5-9
8. Fit the air-conditioning dryer underneath the

intercooler.
9. Fit the wire mesh underneath the
intercooler.
10. Fit the air-conditioning condenser.
11. Fit the guide strip at the front of the
intercooler. Tighten the attachment bolts of
the intercooler.
12. Insert the dipstick holder.
13. Fit the air inlet pipes between manifolds and
3 intercooler.
14. Fit the expansion reservoir.
15. Fit the engine encapsulation under the cab.
filling”.
5-10 ǹ 0011
65/75/85CF series Draining and filling
6. DRAINING AND FILLING

6.1 DRAINING AND FILLING/BLEEDING, COOLING SYSTEM

cylinder block, do not top up a
warm engine with cold coolant.
Coolant is a toxic substance and

must be handled with care. Protect
the skin and eyes.
Coolant is harmful to the

environment; after use, it should be
processed as industrial chemical
waste.
3
When removing the filler cap, allow
the overpressure to escape by first
loosening the filler cap one turn.
Draining, cooling system

1. Turn the heater control knob to the
“warmest” temperature setting. As a result,
the heater cock will be fully opened.
2. Remove the cooling system filler cap.
3. Collect the coolant. To do so, place suitable
containers beneath the drain points.
4. Drain the cooling system at the cylinder
block via drain tap (A) and the radiator via O C
drain plug (B).
5. Flush out the cooling system.
6. Close drain tap (A) and install drain
plug (B). 1
M200372
ǹ 0011 6-1
Draining and filling 65/75/85CF series
Filling/bleeding, cooling system

1. Turn the heater temperature control knob in
the cab to the “warmest” setting.
2. Fill the cooling system with the specified
coolant.
3. Run the engine for several minutes.
Note:
The cooling system is bled automatically.
4. Ensure that the air bleed pipe from the
thermostat housing to the header tank is not
kinked or pinched off.
3 5. Check the coolant level, and if necessary
top up with coolant.
If the vehicle is equipped with a water/air cab
heater.
1. Run the engine at idling speed.
2. Switch on the cab heater, using the rocker
switch on the dashboard.
4. Switch on the heater fan.
5. Set the rocker switch on the thermostat in
the cab to position 1.
Note:
Combustion will start after approximately
one minute.
6. Allow the cab heater to operate for
approximately 15 minutes.
6-2 ǹ 0011
2 XF ENGINE LUBRICATION SYSTEM
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Lubricating oil system description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Inspection, lubricating oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Inspection, lubricating oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.3 Pressure-testing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
4.1 Removal and installation, lubricating oil filter housing . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.2 Removal and installation, oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
4.3 Removal and installation, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.4 Removal and installation, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0011
4.5 Removal and installation, centrifugal oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0011
4
5.1 Disassembly and assembly, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
6.1 Draining and filling, engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
ǹ 0011 1
XF ENGINE LUBRICATION SYSTEM 2
2 ǹ 0011
properly extracted.
moving components.
Serious carbon monoxide poisoning may result 4
required.
ǹ 0011 1-1
1-2 ǹ 0011
2. GENERAL
2.1 LUBRICATING OIL SYSTEM DESCRIPTION
M200544
ǹ 0011 2-1
General
The lubricating oil pump is directly driven from
the crankshaft, by a gear. The lubricating oil
pump draws the oil from the oil sump, and
pumps it via the oil cooler and the lubricating-oil
filter to the main oil duct in the cylinder block.
From the main oil duct, the lubricating-oil is
further distributed to the various components
requiring lubrication.
Oil cooler
The oil cooler is connected to the cooling
system. The oil cooler warms up the lubricating
oil in a “cold” engine and cools it in a “warm”
engine.
Parallel to the oil cooler, a short-circuit valve has
been installed. If the oil cooler is blocked, the
short-circuit valve will open if a certain pressure
4 has built up. In this case, uncooled engine oil

enters the lubricating system.
A centrifugal filter may be included parallel to the
lubricating oil system. In this case, lubricating-oil
will flow from the oil cooler to the centrifugal
filter. In the centrifugal filter, the lubricating oil is
filtered to a finer degree. This is because some
vehicles have a longer service interval.
Pressure limiting valve
A pressure limiting valve is installed in the
lubricating system after the oil cooler.
When the pressure set for the pressure limiting
valve has been reached, the valve opens and
allows excess cooled lubricating oil to flow to the
oil sump.
Oil filter
The oil is cleaned in the disposable oil filter. A
pressure limiting valve fitted in this filter opens if
the pressure in the filter becomes too high as a
result of contamination or cold oil. The oil then
passes through the filter unfiltered.
Main oil duct
From the main oil duct, lubricating oil is supplied
to the crankshaft main bearings and via an oil
duct in the crankshaft also to the connection-rod
bearings.
From the main oil duct, lubricating oil is pumped
through the first camshaft bearing into the
hollow camshaft. From the oil duct in the
camshaft, lubricating oil is supplied to the other
camshaft bearings.
2-2 ǹ 0011
Cylinder head
From the second and fifth camshaft bearings, an
oil duct passes through the cylinder heads to the
second and fifth rocker seats.
Depending on the model, the other rocker
shafts, rockers, and bridges receive lubrication
from the DEB or a lubricating-oil strip.
Timing gear
From the oil duct in the first crankshaft main
bearing, an oil duct leads to the hollow hub of
the intermediate gear wheel.
The oil passes through the hollow hub onto the
intermediate gear wheel. The other gear wheels
receive lubricating oil from the intermediate gear
wheel.
The fan drive is lubricated through a bore hole in
the cylinder block and an oil duct in the timing
gear case.
Piston and gudgeon pin
4
The pistons and the upper connecting-rod
bearings are lubricated by means of oil nozzles
linked to the main oil duct. In addition to
lubricating, this oil has an important cooling
function.
A hole has been drilled at the top of the
connecting rod, through which the oil that the
nozzles spray against the bottom of the piston
may reach the small-end bearing.
Turbocharger and air compressor
An oil duct from the camshaft bearing connects
the oil pipes to the turbocharger and air
compressor.
The oil discharge pipe from the turbocharger is
connected to a passage in the cylinder block,
from where the oil returns to the oil sump.
The oil returning from the air compressor flows
from the front of the air compressor back to the
timing gear, and from there to the oil sump.
Fuel pump
The fuel pump obtains lubricating oil from the oil
filter and discharges it through a channel in the
cylinder block, from where it returns to the oil
sump.
M200545
ǹ 0011 2-3
2-4 ǹ 0011

3.1 INSPECTION, LUBRICATING OIL CONSUMPTION
Note:
An oil consumption test is only useful after the
engine has been run in (approx. 20,000 km).
1. First carefully check the engine for leaks.
Clean the engine before starting the test.
3. Place the vehicle on a level surface.
4. Remove the oil drain plug and drain the oil
for 15 minutes. Collect the oil in a clean
container.
5. Measure the exact amount of oil drained.
4
6. Refill the oil sump with the drained engine
oil. If necessary, top up the amount of oil to
the specified level.
7. Before starting the test, write down the
exact amount of engine oil (A) in the oil
sump. Write down the total distance
covered (C) by the vehicle.
8. Drive between 500 and 1,000 km under
similar conditions as those in which the
vehicle is normally used.
9. Immediately after the test run, place the
vehicle on a level surface and write down
the distance covered (D).
container.
11. Measure the exact amount of oil
drained (B).
12. Pour the oil back into the oil sump. If
necessary, top up the amount of oil to the
specified level.
13. Calculate the oil consumption using the
following formula.
ǹ 0011 3-1
D -- C
Oil consumption = = km/l
A -- B
1300
1250
1200
km / L
1100
1000
1000
900
800
800
4 700
600
600 550
500
500 450
400
400 350
300
300 250
200
100
0
0 25 100 200 300 400 500 600 700 800 900 1000
x1000 km
M200557
In the graph the oil consumption in km/l is

marked out on the left and the total number of
kilometres covered by the engine at the bottom.
If the oil consumption and the number of
kilometres covered intersect in the shaded
section, corrective measures may be
considered.
Bear in mind however, that the oil consumption
is very much dependent upon the operating
conditions.
3-2 ǹ 0011
3.2 INSPECTION, LUBRICATING OIL PRESSURE

2. Remove the lubricating oil pressure sensor.
This sensor is mounted on the oil filter
housing.
3. In the oil pressure sensor connection,
install an oil pressure gauge, special tool
(DAF no. 0535551).
4. Start the engine and measure the
lubricating oil pressure at maximum engine
speed and at idling speed.
Compare the pressure reading with the
technical data. See “Technical data”.
4
Note:
The oil pressure control valve, mounted in
the oil sump, cannot be adjusted.
5. Stop the engine and remove the oil
pressure gauge. Fit a new oil seal to the oil
pressure sensor.
M200597
ǹ 0011 3-3
3.3 PRESSURE-TESTING THE OIL COOLER
1. Remove the oil cooler. See “Removal and

installation”.
2. Disassemble the oil cooler.
See “Disassembly and assembly”.
3. Place the cooling element in special tools
(DAF no. 1329307 and DAF no. 0694889).
4. Apply up to 3 bar of pressurised air to the
special tool.
5. Immerse the cooling element in warm water
(approx. 50_C) and check it for leaks.
Note:
If the cooling element leaks, it must be
4 replaced.
6. Assemble the oil cooler. See “Disassembly
and assembly”.
7. Fit the oil cooler. See “Removal and
installation”.
M200598
3-4 ǹ 0011

4.1 REMOVAL AND INSTALLATION, LUBRICATING OIL FILTER HOUSING
To prevent skin injury, avoid

unnecessary contact with the
drained oil.
Removal, lubricating oil filter housing

1. Clean the filter housing and the surrounding 1
area.
lubricating oil pressure sensor.
2
3. Remove the filter element. Collect any oil
4. Remove the attachment bolts from the filter
housing and remove the filter housing (2). 4
5. Remove the O-rings (1).
Installation, lubricating oil filter housing 3
1. Replace the O-rings (1) at the rear of the
filter housing (2).
2. Fit the filter housing (2). Tighten the
3. Check the coupling (3). See “Technical
data”. 4
4. Lightly grease the filter element seal.
5. Fit the filter element filled with clean
lubricating oil. Tighten the filter element to
7. Run the engine for a short time and check
whether the oil filter is correctly sealed.
8. Check the oil level.
M200599
ǹ 0011 4-1
4.2 REMOVAL AND INSTALLATION, OIL COOLER
Removal, oil cooler

2. Disconnect the coolant connections.
3. Remove the compressor pipe.
4. If installed, remove the oil delivery pipe to
the centrifugal filter.
5. Remove the attachment bolts and the oil
cooler. Collect the lubricating oil flowing out
of the system.
6. Remove the O-rings on the oil cooler.
Installation, oil cooler
4 1. Clean the contact surfaces between the oil
cooler and engine block. Fit new O-rings to
the oil cooler housing.
2. Fit the oil cooler against the cylinder block
and tighten the attachment bolts to the
3. Connect the coolant connections.
4. Connect the compressor pipe.
5. If present, fit the oil delivery pipe to the
centrifugal filter.
7. Run the engine briefly, and check that the
oil cooler does not leak.
9. Check the coolant level.
4-2 ǹ 0011
4.3 REMOVAL AND INSTALLATION, OIL SUMP
Removal, oil sump

1. Remove the soundproofing under the
engine.
2. Drain the engine oil. See “Draining and
filling”.
3. Support the oil sump (1).
4. Remove the attachment bolts (4) and 2
locking brackets (3) all around.
5. Remove the oil sump with the sealing
rubber (2).
Installation, oil sump
1. Clean the sealing surfaces of the oil sump
and the engine block.
1 4
2. Check the oil sump sealing rubber (2).
Damaged sealing rubbers (2) must be
replaced.
3. First install the sealing rubber on the front
and rear of the oil sump. Then, the sealing
rubber may be fitted to the long sides of the
oil sump. 2 3
4. Fit the oil sump (1) with the sealing rubber
(2) upright.
1 4
5. Fit the attachment bolts (4) and locking
brackets (3). Tighten the attachment bolts
crosswise to the specified torque. See
M200601
6. Fill the engine with the specified quantity of
lubricating oil.
whether the oil sump is correctly sealed.
Then check the oil level.
8. Fit the soundproofing under the engine.
ǹ 0011 4-3
4.4 REMOVAL AND INSTALLATION, LUBRICATING OIL PUMP
Removal, lubricating oil pump

1. Remove the oil sump.
2. Remove the oil strainer.
3. Remove the oil suction and delivery pipes
(1) from the lubricating oil pump.
3
lubricating oil pump to the main bearing
cover. 2
5. Remove the attachment bolt (3).
6. Remove the lubricating oil pump from the
main bearing cover.
4 Installation, lubricating oil pump

1. Check that the lubricating oil pump operates 1
smoothly and is not getting stuck anywhere.
2. Install the lubricating oil pump with the
intermediate gear wheel on the main
bearing cover. Tighten the attachment bolts M200600

data”.
3. Fit new O-rings to the oil suction and
delivery pipes (1).
4. Fit the oil strainer.
5. Fit the oil sump.
4-4 ǹ 0011
4.5 REMOVAL AND INSTALLATION, CENTRIFUGAL OIL FILTER

drained oil.
Removal, centrifugal oil filter rotor 4

1. Clean the housing (3).
2. Loosen the central bolt (4).
3
3. Remove the housing (3) simultaneously
with the central bolt (4) and the rotor (2).
4. Remove the rotor (2) from the central 2
bolt (4).
5. Replace the rotor (2).
Installation, centrifugal oil filter rotor
1. Clean the housing (3). 5
4
2. Check the central bolt (4) for damage.
1
3. Replace the seal (5).
4. Fit the new rotor into the housing.
5. Lightly oil the oil seal (5) and fit it in the
housing (3).
6. Tighten the central bolt (4) to the specified
7. Start the engine and check for leaks. Check
oil level.
M200526
ǹ 0011 4-5
4-6 ǹ 0011

5.1 DISASSEMBLY AND ASSEMBLY, LUBRICATING OIL PUMP
Disassembly, lubricating oil pump

1. Remove the intermediate gear wheel with
the hub from the front plate.
2. Remove all attachment bolts from the two
sections of the lubricating oil pump housing.
3. Remove the rear section of the lubricating
oil pump.
4. Remove the gear wheels from the
lubricating oil pump housing.
Assembly, lubricating oil pump
4
1. Clean the gear wheels and check for
damage.
Note:
Gear wheels must be replaced as a set.
Note:
The gear wheels are marked. The gear
wheels with the marks must be fitted as
shown.
2. Fit the gear wheels in the lubricating oil
pump housing.
oil pump.
M200344
4. Fit the attachment bolts of the lubricating oil
pump sections. Tighten the attachment
data”.
5. Check that the lubricating oil pump operates
6. Fit the intermediate gear wheel with the hub
on the front plate. Tighten the attachment
bolt to the specified torque. See “Technical
data”.
ǹ 0011 5-1
5-2 ǹ 0011

6.1 DRAINING AND FILLING, ENGINE OIL

drained oil.

2. Drain the oil using the drain plug in the oil
sump.
3. Replace the drain plug sealing ring and
tighten the drain plug to the specified
4. Fill the engine through oil-filler pipe (D) with
the specified engine-oil quantity. See
“Technical data”. 4
D
D000268
ǹ 0011 6-1
6-2 ǹ 0011
2 PF ENGINE
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.4 Overview drawing, fuel pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
3.1 Inspection and adjustment, valve mechanism bridges . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . . 0011
3.6 Inspection, engine compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . . 0011
4.1 Removal and installation, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Removal and installation, engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 . . . . . .
4-2 . . . . . .
0011
0011
5
4.21 Removal and installation, timing cogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 . . . . . 0011
4.24 Removal and installation, fuel pump drive housing . . . . . . . . . . . . . . . . . . . . . 4-39 . . . . . 0011
4.25 Removal and installation, vibration damper bearing race . . . . . . . . . . . . . . . . 4-41 . . . . . 0011
5. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
ǹ 0011 1
PF ENGINE 2
2 ǹ 0011
2 PF ENGINE
properly extracted.
moving components.
ǹ 0011 1-1
PF ENGINE 2
1-2 ǹ 0011
2 PF ENGINE
2. GENERAL
7 4 2 1
6 5 3
M200747
Legend
2. Water pump
3. Vibration damper
4. Air compressor
5. Oil cooler
6. Turbocharger
7. Oil-filler pipe
ǹ 0011 2-1
PF ENGINE 2
16 17 14 18 19 15
20 8 9 12 11 10 13
M200746
Legend
8. Steering pump
9. Fuel pump drive bearing housing
10. Fuel pump stop control cylinder
11. Oil filter
13. Starter motor
15. Fuel filter
16. Glow plugs
17. Coolant pipe
18. Inlet manifold
20. Alternator
2-2 ǹ 0011
2 PF ENGINE
2.2 IDENTIFICATION
Engine number
The engine number is marked on the cylinder
block at front right-hand side (compressor side).
M200748
PF engine identification plate

Fitted to the inlet manifold
M200745
Legend 4 3 5 6
1. Injection timing
2. Maximum governed engine speed ENGINE
3. Engine number TYPE
E4
4. Engine type ENGINE
NUMBER
6. Certificate number GOVERNED SPEED min -1 OUTPUT kW
7. Fuel pump setting (output) BEFORE

INJECTION TIMING PUMPSETTING cm 3
8. Smoke level at maximum engine speed, T.D.C.
no load SMOKE LEVEL FREE ACCELERATION m -1
EINDHOVEN HOLLAND
2 1 8 7
M200678
ǹ 0011 2-3
PF ENGINE 2
Legend 6 2 4
1. Crankshaft gear wheel
2. Camshaft gear wheel
4. Steering pump gear wheel
6. Air compressor gear wheel
7 1 3 5
M200744
2.4 OVERVIEW DRAWING, FUEL PUMP DRIVE

5 Legend 1 2 3 4 5
3. Bearing housing
4. Fuel pump drive seal
5. Clamping piece
7. Prop shaft
6 7
M200751
2-4 ǹ 0011
2 PF ENGINE

3.1 INSPECTION AND ADJUSTMENT, VALVE MECHANISM BRIDGES


3. Undo the adjusting nuts of the valve rockers
in such a manner that there is no longer
tension on the rockers.
4. Remove the lubricating oil strip.
position. 5
place it in a vice.
the guide pin) with your thumb.
A
the valves.
12. Place the bridge in a vice and tighten lock
nut (B) to the specified torque without B
data”.
i 400301
ǹ 0011 3-1
PF ENGINE 2

15. Fit the lubricating-oil strip in such a way that
the mark “cyl. 1/4” is located on cylinder 1
or cylinder 4 respectively.
16. Adjust the valve clearance.
installation”.
M200754
3-2 ǹ 0011
2 PF ENGINE

dead centre.
Note:
5
direction. See “Technical data” for the
M200574

(DAF No. 1310477), the valves can be
sequence 1-5-3-6-2-4.
Cylinder in overlap Cylinder to be

position adjusted
1 6
5 2
3 4
6 1
2 5
M200732
4 3

installation”.
ǹ 0011 3-3
PF ENGINE 2
Inspection, timing
1. Remove the valve cover from cylinders
1-2-3. See “Removal and installation”.
position).
Note:
1 mm.
5
M200551
Example
Pre-tension, dial gauge 5.00 mm
Measured tension --4.65 mm
Valve opening 0.35 mm
Note:
3-4 ǹ 0011
2 PF ENGINE

position).
Note:
5. Rotate the camshaft gear wheel (2) to
such a position that the intermediate gear
wheel (3) can be installed in accordance
6.
with the marks.
Tighten the attachment bolt of the 2
3
5
intermediate gear wheel (3) to the specified
torque. See “Technical data”. 1

installation”.
M200752
8. Fit the valve cover. See “Removal and
installation”.
ǹ 0011 3-5
PF ENGINE 2
The V-belt should be inspected with a belt O

APBTLIB
EEUL
TI
N.2
00
tension gauge. The advantage of this method is
a more accurate pre-tension reading and, LBS
.50
600
consequently, the service life of the V-belt 100
150

There are two types of belt tension gauge: the O
APBT
LIBEE
ULTII
N.5
“Krikit I” belt tension gauge for use with the 00
single-belt version (DAF no. 1240442) and the LBS

.100 150
0
200
“Krikit II” belt tension gauge for use with the 300

The difference between the “Krikit I” and
“Krikit II” belt tension gauges is that the latter
has a larger belt bearing surface. M2079

gauge.
5
M2061

pulley.
bar move.
M2092
3-6 ǹ 0011
2 PF ENGINE

M2062

1. Slacken the central bolt (1) of the tensioning
roller.
2. Move the adjusting screw (2) until the
correct V-belt tension is achieved. See
3. Tighten the central bolt (1). 5
1
M200885
Adjustment, V-belt tension of water pump 5

and alternator drive 6
1. Loosen the lower attachment bolt (1) of the 4
alternator.
3
2. Loosen the upper attachment bolt (2) of the 2
alternator.
4. Loosen the locknut (4) of the threaded rod.
5. Loosen bolt (6) of the coupling.
6. Shift the compressor using the locknut (5)
M200753
ǹ 0011 3-7
PF ENGINE 2

3. Grinding down is allowed until the indicator
flywheel housing to install a measuring
gauge with a magnetic foot piece.
5
M2 00 033
4. Place the dial gauge of the stylus at the
crank the engine through 360_ and
M200230
3-8 ǹ 0011
2 PF ENGINE



piston rings.
3. Remove the valve covers. See “Removal 5
(DAF no. 1329306), compression
gauge (DAF no. 0694972) and adapter
(DAF no. 1329300).
injectors.
installation”.
ǹ 0011 3-9
PF ENGINE 2

the cylinder head.
Note: C
points:
- windings that have worn thin due to
abrasion (A)
5 - filament end broken or worn thin due to A B

insulator (see B)
M200818
3-10 ǹ 0011
2 PF ENGINE


gear.

fire.
Note:
for every vehicle.
5
terminal.
openings.
tightening torque.
ǹ 0011 4-1
PF ENGINE 2

gear.

fire.

terminal.
3. Remove the flexible coolant pipes (A) A
between the engine, the radiator and the
header tank.
5 4. Remove the torque rod (B) between the

openings.
6. Remove the dip stick (D) from the radiator.
7. Disconnect the rubber pipe (E) from the oil
filler pipe.
8. Remove the attachment nut from the
viscous fan clutch.
9. Remove the wind tunnel collar.
10. Remove the viscous fan clutch together with D B C E
the fan.
M200840

housing.
attachment bolts at the front and/or rear of
the engine.
4-2 ǹ 0011
2 PF ENGINE

data”.
2. Place the viscous fan clutch together with
the fan between the radiator and engine.
3. Fit the wind tunnel collar.
4. Fit the attachment nuts of the viscous fan
clutch.
5. Fit the torque rod (B) between the engine A
and the radiator.
engine and the intercooler. Tighten the
5
8. Fit the flexible rubber pipe (E) of the oil filler
pipe.
9. Fit the dip stick (D) to the radiator.
flywheel housing.
12. Fill the cooling system. D B C E
M200840
ǹ 0011 4-3
PF ENGINE 2

before opening it.

1. Clean the area around the valve cover.
cover.
cover gasket.
5 3.
gasket.
Fit the attachment bolts of the valve cover
4-4 ǹ 0011
2 PF ENGINE
Removal, valve gear

Note:
same position.
M200559

2
3.
and adjustment”.
Tighten the rocker seats (1) by hand.
3 5
Note: 4
rocker seats (1) have to be positioned
against the pressure of the valve springs.
The rocker seat will resist this spring
pressure and cannot therefore be
positioned correctly.
(DAF no. 1310477), the rocker seats
can be tightened according to the injection
M200560
sequence 1-5-3-6-2-4.
ǹ 0011 4-5
PF ENGINE 2

or cylinder 4 respectively. For the tightening
torques of the attachment bolts. See
6. Adjust the valve clearance. See “Inspection
and adjustment”.
M200754
4-6 ǹ 0011
2 PF ENGINE

before opening it.

terminal.
the cylinder heads.
4. Remove the dip stick holder.
5. Remove the inlet air pipes between the
5
and the radiator.
bracket if fitted.
manifold.
cylinder heads.
the cab heater.
ǹ 0011 4-7
PF ENGINE 2
14. Remove the fuel leak-off pipe between the

fuel filter and the leak-off pipe on the inlet
manifold.
15. Remove the entire fuel filter from the inlet
manifold.
18. Remove the coolant pipe together with the
thermostat housing.
cylinder heads.
5 23. Remove the push rods.
block.
data”.
and adjustment”.
M2 00 100
4-8 ǹ 0011
2 PF ENGINE

2. Insert both guide pins (DAF No. 0694912)
be retightened.
head bolts.
Note:
gaskets and tighten the attachment bolts to
M200561
5
Note:
used.
fitting.
ones.
ǹ 0011 4-9
PF ENGINE 2

bolts.
14. Fit the water pipes between radiator and
thermostat housing.
5 15. Fit the injector pipes.

pipe.
18. Fit the boost pressure pipe on the inlet
manifold.
19. Tighten the dipstick holder.
heater.
4-10 ǹ 0011
2 PF ENGINE

the radiator.
26. Fit the inlet pipe between the intercooler
and the intercooler. Tighten the attachment
data”.
ǹ 0011 4-11
PF ENGINE 2
Removal, glow plugs

1. Disconnect the earth lead from the battery +
terminal.
Installation, glow plugs M2 00 154
1. Fit the glow plugs and tighten the

attachment nut to the specified torque. See
the correct place.
5 3. Clean the contact surface of the glow plug

4-12 ǹ 0011
2 PF ENGINE

terminal.
2. Remove the wiring from the glow filaments
fuel filter and inlet manifold.
4. Remove the fuel filter element. M200963
5. Disconnect the injection pipes per set.

inlet manifold.
5
the manifold. Tighten the attachment bolts
data”.
4. Fit the boost pressure pipe.
5. Fit the injector pipes per set.
7. Fit the wiring from the glow filaments and
the temperature sensor.
terminal.
ǹ 0011 4-13
PF ENGINE 2

1. Remove the inlet air pipe between the
3. Remove the heat shields from the
turbocharger.
4. Remove the air inlet pipe.
5. Remove the butterfly valve.
manifold.
7. Remove the oil supply and oil discharge
4-14 ǹ 0011
2 PF ENGINE

fit the manifold. Tighten the attachment
bolts with the spacer sleeves to the
5. Fit the compressor pipe.
6. Fit the inlet air pipe between the
M200964
7. Fit the butterfly valve.

8. Fit the heat shields for the turbocharger.
5
10. Fit the rear engine sound proofing.
for leaks.
ǹ 0011 4-15
PF ENGINE 2

2
2. Remove the oil filler pipe (5).
1
dryer (8).
3
6. Disconnect the lubricating oil pipe (4).
4
7. Remove the mounting bracket at the back
of the compressor (7). 7
8. Remove the attachment bolts from the 4
timing gear cover.
8
Note:
5 If the vehicle is equipped with

air-conditioning, the air-conditioning
compressor V-belt must be disconnected to
enable removal of the tension pulley. M200763

compressor housing.
4-16 ǹ 0011
2 PF ENGINE

case.
2. Fit the attachment bolts of the air
Note:
If the vehicle is equipped with
air-conditioning, the tension pulley of the
air-conditioning compressor must be fitted
and the V-belt tension adjusted.
3. Fit the mounting bracket (7) at the back of
the compressor. Tighten the attachment
data”.
4. Fit the service pipe (8).
6. Fit the air pipes (2 and 3). 5
ǹ 0011 4-17
PF ENGINE 2

surrounding area.
3. Immediately plug the openings in the pump
system.
5 1. Fit a new O-ring.
steering pump. Fit the banjo bolts. Tighten
the banjo bolts to the specified torque, see
main group “Technical data”.
4-18 ǹ 0011
2 PF ENGINE

terminals.
starter motor.
motor.
4. Check the toothed pinion for damage.
motor.
5
terminals.
ǹ 0011 4-19
PF ENGINE 2
Removal, alternator 5
1. Remove both battery leads from the battery 6
terminals. 4
2. Remove the electrical connections from the 3
alternator. 2
coolant pump.
4. Slacken the alternator bracket attachment
bolts (1) and (2).
5. Loosen the locknut (4) and bolt (6) of the
coupling.
6. Shift the alternator by means of the nut (5) 1
in the direction of the cylinder block and
M200753
slacken the V-belt.
5 7. Remove the attachment bolts (1) and (2)

and remove the alternator.
2. Fit the alternator attachment bolts (1)
and (2).
4. Tighten the attachment bolt (3) of the
coolant pump.
alternator.
terminals.
4-20 ǹ 0011
2 PF ENGINE
Removal, V-belt of water pump and alternator 5

drive 6
1. Slacken the locknut (4) and attachment bolt 4
(3) of the threaded spindle.
3
2. Loosen bolt (6) of the coupling. 2
bolts (1) and (2).
4. Shift the alternator by means of the nut (5)
in the direction of the cylinder block in such
a way that the V-belt can be released.
1
M200753
5. Remove the retention screw above the wind

tunnel collar (7) and turn the wind tunnel
5
collar anti-clockwise to unlock and lay the
wind tunnel collar on the water pump pulley.
7
6. Remove the V-belt through the arising
opening between the wind tunnel and fan.
Note:
On versions with a metal guide ring, the fan
or guide ring must be detached before
removal of the V-belt depending on the
M2101

alternator drive
grease deposits.
2. Fit the new V-belt through the opening
between the wind tunnel and the fan ring,
and place the V-belt on the pulleys.
3. Fit the wind tunnel collar (7) and check
whether this is installed properly all round in
its lock. Fit the locking screw.
4. Adjust the V-belt tension. See “Inspection
and adjustment”.
M2096
ǹ 0011 4-21
PF ENGINE 2

V-belt
gear.
2. Turn the tension bolt (2), until the V-belt can
be removed.
drive V-belt
grease deposits.
2. Fit the new V-belt and adjust the V-belt
5
M200885
4-22 ǹ 0011
2 PF ENGINE
Removal, flywheel
the clutch plate.
flywheel.
1
2. Clean the crankshaft flange, the dowel pins M200569
flywheel. 5
4. Fit the attachment bolts and tighten them to
assembly.
6. Fit the gearbox.
M200570
ǹ 0011 4-23
PF ENGINE 2

sharp chisel.
Installation, starter ring gear
de-greased.
5
flywheel.
M2 00 035
4-24 ǹ 0011
2 PF ENGINE
Note:
mounting ring, which can only be used
once.
2. Drill two holes into the seal and, using the
special tool (DAF no. 0484899 and
DAF no. 0694928) pull the seal out of the
flywheel housing.
1. Thoroughly clean sealing ring recess and
Note:
If the oil seal has scored the crankshaft
flange running surface, a spacer ring should
5
be fitted in the oil seal recess before a new
oil seal is installed.
3. Lightly grease the inner rim of the oil seal.
4. Fit the base plate (A) of special tool 1
flange.
5. Fit the supplied plastic mounting ring (1) on
the crankshaft flange.
6. Then place the new sealing ring (2) over the
mounting ring and remove the mounting
ring. A
seal is properly positioned. B C
M2 00 036
ǹ 0011 4-25
PF ENGINE 2

housing.
5. Remove the two oil sump attachment bolts
housing.
5 9.
flywheel housing.
Remove the flywheel housing.
4-26 ǹ 0011
2 PF ENGINE

from the housing.
contact areas.
face.
5
and connect it to the flywheel housing.
12. Fit the oil sump attachment bolts. Tighten all
ǹ 0011 4-27
PF ENGINE 2

Note:
When removing the viscous fan clutch, ensure
that the radiator is not damaged.
viscous fan clutch.
2. Loosen the locking screw at the top of the
wind tunnel collar and turn the wind tunnel
collar anti-clockwise to unlock it.
and remove the viscous fan clutch at the M200228
alternator.
4. If fitted, remove the V-belt of the
5 alternator.
6. Remove the attachment bolts and the thrust
washer from the vibration damper.
7. Remove the vibration damper using special
tool (DAF no. 1240448).
event of damage or leaks, the vibration
M200229
2. Fit the vibration damper and tighten the

5. Fit the viscous fan clutch.
6. Fit the fan.
4-28 ǹ 0011
2 PF ENGINE

Old type of timing cover seal
1. If the timing cover is equipped with an older
type of seal (version without a bearing race
on the damper), the seal must be removed
by boring two holes in it and pulling it out of
the timing cover using special tools
(DAF no. 0484899 and DAF no. 0694928)
New type of timing cover seal
1. Remove the seal from the timing gear cover
using a seal puller (DAF no. 1329458).
2. Check the bearing race for wear. If
necessary, replace.
A
B
5
m200830
Old situation New situation
ǹ 0011 4-29
PF ENGINE 2
Installation, timing gear cover seal

Note:
If the timing gear case is fitted with an old type
oil seal (version without bearing race on the
vibration damper), the oil seal must be replaces
with a new oil seal with bearing race on the
vibration damper.
can lead to a leak.
install the dry sealing ring and the thrust W264003
washer in the recess of the timing gear
cover.
4. Fit the bearing race to the vibration damper.
4-30 ǹ 0011
2 PF ENGINE

before opening it.
Removal, timing gear cover

2. Remove all coolant pipes (A) between the
radiator and engine.
A
the engine and the intercooler.
5
6. Loosen the radiator attachment bolts so that
the radiator can be tilted slightly forward.
viscous fan clutch.
9. Tilt the radiator forward and remove the
wind tunnel collar and the viscous fan clutch
D B C E
with the fan. M200840

13. Slacken the coolant pipe from the cover by
pulling it slightly forwards over the stud.
ǹ 0011 4-31
PF ENGINE 2

locating holes.
4-32 ǹ 0011
2 PF ENGINE
Installation, timing cover

the new gasket.
3. Fit the attachment bolts and the studs.
Tighten the attachment bolts and studs to
attachment bolts.
5. Fit the coolant pipe.
8. Tilt the radiator and place the wind tunnel
collar and the viscous fan clutch with the fan
between the engine and the radiator.
clutch. 5
10. Fit the wind tunnel collar and check whether
this is installed properly all round in its lock.
Fit the locking screw.
11. Fit all coolant pipes (A) between the radiator
and engine.
A
12. Fit the torque rod (B) between the radiator
and the engine.
13. Fit the flexible air inlet pipes (C) and tighten
15. Fit the radiator attachment bolts.
D B C E
M200840
ǹ 0011 4-33
PF ENGINE 2
4.21 REMOVAL AND INSTALLATION, TIMING COGS

2. Position cylinder 1 in the top dead centre
position).
Note:
wheel.
Removal, intermediate gear wheel 6 2 4
1. Remove the attachment bolt with the axial
thrust washer (3).
5 Removal, fuel pump drive gear wheel

1. Turn the engine speed sensor a number of
revolutions out of the timing-gear case to
prevent the sensor from being damaged
when the gear wheel is being removed.
fuel pump gear wheel.
3. Remove the intermediate gear wheel. 7 1 3 5
M200744
3. Remove the camshaft gear wheel using a
4-34 ǹ 0011
2 PF ENGINE

position).
Note:
Before installing the intermediate gear wheel,
1. Fit the intermediate gear wheel (3) in such a
intermediate gear wheel (3) are in line. 3
2. Fit the attachment bolt with the axial thrust 2
washer of the intermediate gear wheel.
Tighten the attachment bolt to the specified 1
play.
M200752
5
3. Fit the camshaft gear attachment bolt and
tighten it to the specified torque. See
play.
ǹ 0011 4-35
PF ENGINE 2
Installation, fuel pump drive gear wheel 6 2 4

Note:
Before installing the intermediate gear wheel,
3. Fit the attachment bolt (5) of the fuel pump
gear wheel. Tighten the attachment bolt to
7 1 3 5
play. M200744
5. Turn the engine speed sensor into the

timing gear case and adjust the distance
between the sensor and gear wheel. See
5
4-36 ǹ 0011
2 PF ENGINE

case.
locating holes.
5
M200579
sump.
4. Fit the timing gear case and tighten the
6. Fit the camshaft locking plate and tighten
8. Fit a new O-ring to the air compressor and
fit the air compressor.
ǹ 0011 4-37
PF ENGINE 2
Removal, timing gear case seal 1 2 3 4 5

2. Fit gear wheel (1) of the fuel-pump drive.
5 6 7
M200751
M200580
4-38 ǹ 0011
2 PF ENGINE
4.24 REMOVAL AND INSTALLATION, FUEL PUMP DRIVE HOUSING
Removal, fuel pump drive housing 1 2 3 4 5

position).
6 7
5
M200751
3. Remove the clamp bolt.
M200758
4. Remove the axial locking plate (7) from the

prop shaft.
5. Remove the prop shaft (8) from the
transmission case.
87
M200581
ǹ 0011 4-39
PF ENGINE 2

7. Remove the attachment bolts from the fuel
pump drive housing.
8. Remove the fuel pump drive housing (3)
from the engine block.
M200757
Installation, fuel pump drive housing 1 2 3 4 5

1. Fit the fuel pump drive housing (3) with a
new O-ring for lubrication. Tighten the
5 2. Fit the prop shaft (7) in the fuel pump drive

housing.
3. Fit the axial locking plate (6) and tighten the
5. Fit the fuel pump gear wheel.
6. Set the injection timing.
6 7
M200751
4-40 ǹ 0011
2 PF ENGINE
4.25 REMOVAL AND INSTALLATION, VIBRATION DAMPER BEARING RACE
Removal, vibration damper bearing race

2. Carefully tap the vibration damper bearing
race. Avoid damaging the vibration damper.
Installation, vibration damper bearing race
1. Clean the contact surface of the vibration
damper. It must be grease-free.
2. Fit the dry bearing race, with a low pressing
force, to the vibration damper.
ǹ 0011 4-41
PF ENGINE 2
4-42 ǹ 0011
2 PF ENGINE
5. CLEANING
Note:
stage.
will jam. 5
ǹ 0011 5-1
PF ENGINE 2

via the breathers.
electrical connections such as connectors,
cable plugs of the vehicle lighting system.
5-2 ǹ 0011
2 PF ENGINE COOLING SYSTEM
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.1 Description of cooling system pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.2 Description of the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
4.1 Pressure-testing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.4 Inspection, water pump radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0011
6.1 Draining and filling/bleeding, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011 6
ǹ 0011 1
PF ENGINE COOLING SYSTEM 2
2 ǹ 0011
properly extracted.
moving components.
required.
6
ǹ 0011 1-1
1-2 ǹ 0011
2. GENERAL
3 2 1
5 4
6 6
M200759
Legend
8. Water pump
10. Water pipe
11. Oil cooler
12. Coolant pipe
ǹ 0011 2-1

thermostat and pipes.
any air in the cooling system is discharged to the
header tank, so that the cooling system is bled
automatically.
the thermostat housing. The thermostat housing
the cylinder liners up to the cylinder heads and
leaves them through the coolant collector pipe to
6 radiator or directly back to the coolant pump.

the bottom. From the bottom of the radiator,
coolant is fed back through the return pipe to the
water pump. The connecting pipe is also
connected to the header tank from the radiator.
If the coolant heats up, the coolant flows to the
2-2 ǹ 0011

the water pump.
ǹ 0011 2-3
2-4 ǹ 0011
The pressure cap (A) on the auxiliary header

tank, behind the grille, is attached on the header
tank by means of a screw thread. To fill the
A
valves are closed.
If the pressure (P1) in the cooling system rises
opens.
The overpressure in the cooling system makes it
possible to allow a higher temperature in the
cooling system, without the coolant boiling.
M200180

If the pressure (P1) in the cooling system drops P2
6
P1
M200445
Operation of the thermostat

ǹ 0011 3-1
Thermostat closed
The coolant has not yet reached the opening A
closed.
directly to the water pump and the pump once B
M200739

The coolant has reached the opening
A
opened and the by-pass passage (A) is partially
closed.
B
6
M200740

The temperature of the coolant has become A
supply passage (B) to the radiator where it is B
an emergency solution.
If the thermostat is removed from the engine, M200741
uncooled coolant will flow to the water pump via

the by-pass passage (A). As a consequence, the
coolant temperature will continue to rise.
3-2 ǹ 0011





means of a pressure-test pump. When this is
done with a warm engine, it is easier to spot any
cracks.
3.
4.
Remove the filler cap from the header tank.
Fit the pressure-test pump.
6
Note:
By installing the pressure-test pump to the
filler opening of the header tank, you also M2081
test the pressure cap.

5. Pressure-test the system to the specified
6. Check the cooling system for leaks.
ǹ 0011 4-1

installation”.
C
B
closed.
A
with clean water.
7. Place a thermometer in the container and M200742
heat the water. Check at which temperature

the thermostat opens and whether the
thermostat opens fully. See “Technical
data”.
M200513
4-2 ǹ 0011

properly extracted.

components.

top up.
fan should be approx. 600 to 1100 rpm. 6
an operating temperature of 85 - 95_C.
ǹ 0011 4-3

hole is in front of the viscous coupling.
temperature.
900
of 1000 rpm.
7. Then use an optical rev counter to 100
determine the difference in speed of the fan
will differ if there is any slip in the viscous
430
replaced.
700
M200440

6 1. Remove the V-belts from the water pump
pulley.
illustration.
replaced.
M200595
4-4 ǹ 0011

Removal, water pump

3. Loosen the wind tunnel collar by removing
the locking screw and turning the wind
tunnel collar anti-clockwise to unlock it.
and the radiator.
alternator.
8. Remove the attachment bolt of the threaded
9.
spindle of the alternator.
Remove the attachment bolts from the
6
connection piece.
water pump and remove the water pump.
ǹ 0011 5-1

the water pump. Fit the attachment bolts
water pump.
6. Fit the alternator threaded spindle
attachment bolt.
7. Fit the V-belts of the alternator and, if fitted,
the air-conditioning compressor.
drive flange.
6 9. Fit the wind tunnel collar and check whether

the engine.
filling”.
5-2 ǹ 0011
Removal, thermostat
thermostat housing.
C
B
housing.
6. Remove the thermostat.
M200742

internal puller.
6
ǹ 0011 5-3

1. Fit the thermostat seal (B) in the thermostat
housing using special tool C
(DAF no. 1310456). B
A
2. Fit the O-ring (A) in the thermostat housing.
M200742
3. Fit new O-rings to the connection piece
thermostat housing.
pipe.
5. Fit the thermostat housing attachment bolts
6 6. Fit the water pipe between the thermostat

filling”.
5-4 ǹ 0011

alternator drive.
3. If fitted, loosen the V-belt of the
alternator side.
the locking screw and turn the wind tunnel
clutch with the fan in the wind tunnel
temporarily.
Note:
The viscous fan must always be stored
vertically.
7. Remove the attachment nuts of the fan and 6
ǹ 0011 5-5

1. Place the new viscous fan in the fan.
5. If present, fit the V-belt of the
pump drives.
5-6 ǹ 0011

header tank.
header tank.
retainer lips at the back first.
and the engine.
3. Fit the front engine encapsulation. 6
filling”.
ǹ 0011 5-7
Note:
Removal, radiator
terminal.
4. Remove the engine encapsulation under
the cab.
intercooler.
6 8. Remove the header tank.

condenser forwards.
intercooler.
5-8 ǹ 0011

intercooler.
pipe.
the chassis.
Installation, radiator 6
attachment nuts to the specified torque. See
ǹ 0011 5-9

engine lifting eye.
the engine bracket.
ring.
intercooler.
intercooler.
intercooler.
12. Tighten the attachment bolts of the
intercooler.
6 14. Fit the air inlet pipes between the manifolds

and intercooler.
filling”.
5-10 ǹ 0011



the skin and eyes.

waste.


6
maximum temperature setting. As a result,
4. Drain the cooling system via drain tap (A)
on the side of the engine block and via drain
plug (B) underneath the radiator and plug
(C) on the lower side of the oil cooler.
B
C
A
M2097
ǹ 0011 6-1
5. If an integrated retarder has been fitted

remove the coolant pipe (D) from the oil
cooler and drain the remaining coolant.
7. Close the engine drain tap (A) and install
the drain plugs (B and C) on the lower side
of the radiator and on the oil cooler.
D
M2077

coolant.
Note:
B
6 4.
5.
Ensure that the air bleed pipe from the
6. Check the coolant level, and if necessary M200181
heater.
Note:
one minute.
6-2 ǹ 0011
2 PF ENGINE LUBRICATION SYSTEM
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3.3 Pressure testing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
4.1 Removal and installation, pump seat/lubricating oil filter housing . . . . . . . . . 4-1 ...... 0011
ǹ 0011 1
PF ENGINE LUBRICATION SYSTEM 2
2 ǹ 0011
properly extracted.
moving components.
required.
ǹ 0011 1-1
1-2 ǹ 0011
2. GENERAL
M200761
ǹ 0011 2-1
General
pump draws the oil from the oil sump, and
pumps it via the oil cooler and the lubricating-oil
filter to the main oil duct in the cylinder block.
From the main oil duct, the lubricating-oil is
Oil cooler
engine.
has built up. In this case, uncooled engine oil
A pressure-limiting valve is installed in the
lubricating system after the oil cooler. When the
pressure set for the pressure limiting valve has
been reached, the valve opens and allows
excess cooled lubricating oil to flow to the oil
sump.
Oil filter
7
pressure limiting valve fitted in this filter opens if
Main oil duct
From the main oil duct, lubricating oil is supplied
to the crankshaft main bearings and via an oil
duct in the crankshaft also to the connection-rod
bearings.
From the main oil duct, lubricating oil is pumped
through the first camshaft bearing into the
hollow camshaft.
From the oil duct in the camshaft, lubricating oil
is supplied to the other camshaft bearings.
2-2 ǹ 0011
Cylinder head
From the second and fifth camshaft bearings, an
oil duct passes through the cylinder heads to the
second and fifth rocker seats. The other rockers
shafts are provided with lubricant by
lubricating-oil strips that run along the rockers
seats.
Timing gear
the intermediate gear wheel. The oil passes
through the hollow hub onto the intermediate
gear wheel. The other gear wheels receive
lubricating oil from the intermediate gear wheel.
bearings are lubricated by means of oil nozzles
linked to the main oil duct. In addition to
lubricating, this oil has an important cooling
function.
A hole has been drilled at the top of the
connecting rod, through which the oil that the
nozzles spray against the bottom of the piston
may reach the small-end bearing.
An oil duct from the camshaft bearing connects
the oil pipes to the turbocharger and air
compressor.
The oil discharge pipe from the turbocharger is 7
connected to a passage in the cylinder block,
from where the oil returns to the oil sump.
The oil returning from the air compressor flows
from the front of the air compressor back to the
timing gear, and from there to the oil sump.
Fuel pump
The fuel pump obtains lubricating oil from the oil
filter and discharges it through a channel in the
cylinder block, from where it returns to the oil
sump.
ǹ 0011 2-3
2-4 ǹ 0011

Note:
An oil consumption test is only useful after the
engine has been run in (approx. 20,000 km).
1. First carefully check the engine for leaks.
Clean the engine before starting the test.
container.
5. Measure the exact amount of oil drained.
6. Refill the oil sump with the drained engine
oil. If necessary, top up the amount of oil to
the specified level.
exact amount of engine oil (A) in the oil
7
container.
11. Measure the exact amount of oil drained
(B).
12. Pour the oil back into the oil sump. If
necessary, top up the amount of oil to the
specified level.
13. Calculate the oil consumption using the
following formula.
ǹ 0011 3-1
D -- C
Oil consumption = = km/l
A -- B
1250
1200
1100
km. / liter
1000
900
800
700
600
500
400
300
250
7 200
100
0
100 200 300 400 500 600 700 800
25 80 240 x 1000 km.
M200774
In the graph the oil consumption in km/l is

marked out on the left and the total number of
kilometres covered by the engine at the bottom.
If the oil consumption and the number of
kilometres covered intersect in the shaded
section, corrective measures may be
considered.
Bear in mind however, that the oil consumption
is very much dependent upon the operating
conditions.
3-2 ǹ 0011

A
This sensor is mounted on the oil filter
housing.
3. In the oil pressure sensor connection, install
an oil pressure gauge, special tool
(DAF no. 0535551).
technical data. See “Technical data”. M200760
Note:
5. Stop the engine and remove the oil
pressure gauge. Fit a new oil seal to the oil
pressure sensor.
ǹ 0011 3-3
3.3 PRESSURE TESTING THE OIL COOLER

installation”.
2. Fit the special tool (DAF no. 1240476 and 1240477
DAF no. 1240477) on the oil cooler.
3. Apply up to 2.5 bar of pressurised air to the 1240476
special tool.
4. Immerse the oil cooler in hot water (approx.
50_C) and check the oil cooler for leaks.
Note:
The oil cooler should be replaced if it is
leaking.
M200185
installation”.
3-4 ǹ 0011

4.1 REMOVAL AND INSTALLATION, PUMP SEAT/LUBRICATING OIL FILTER
HOUSING

drained oil.
Removal, pump seat/lubricating oil filter

housing
1
1. Clean the fuel pump and the surrounding
area.
2. Remove the fuel pump.
4. Remove the oil supply pipe to the fuel
pump.
5. Remove the filter element. Collect any oil
flowing out of the system. 2
pump seat/lubricating oil filter housing and
remove the pump seat/lubricating oil filter
housing (2).
7
Installation, pump seat/lubricating oil filter
4
housing
pump seat/lubricating oil filter housing (2).
2. Fit the pump seat/lubricating oil filter
housing (2) and tighten the attachment bolts
data”.
data”.
M200762
ǹ 0011 4-1

whether the oil filter is correctly sealed.
4-2 ǹ 0011
Removal, oil cooler

1. Drain the coolant, see “Draining and filling
the cooling system”.
2. Remove the heat shield from the exhaust
bend.
3. Remove the exhaust brake operating
cylinder.
4. Remove the plug on the underside of the oil
cooler and drain the coolant.
5. Remove the flexible coolant pipes from the
oil cooler.
6. Remove the oil cooler. Collect any oil W267003

7. Remove any remains of the gasket.
1. Thoroughly clean the contact surfaces
between the oil cooler and the cylinder
block, and replace the gaskets.
2. Fit the oil cooler.
3. Connect the coolant pipes to the oil cooler.
4. Fit the engine brake operating cylinder.
7
5. Fit the heat shield of the exhaust bend.
ǹ 0011 4-3
Removal, oil sump

engine. 2
2. Drain the engine oil. See “Draining and
filling”.
4. Remove the attachment bolts (4) and
1
rubber (2).
2 3
replaced.
3. First install the sealing rubber on the front 1 4
oil sump.
7 (2) upright. M200601
5. Fit the attachment bolts (4) with the locking

brackets (3) and tighten the attachment
bolts crosswise to the specified torque. See
lubricating oil.
Then check the oil level.
4-4 ǹ 0011

3
3. Remove the oil suction and delivery pipes 2
(1) from the lubricating oil pump.
cover.
5. Remove the attachment bolt (3).
1
main bearing cover.
Installation, lubricating oil pump
1. Check that the lubricating oil pump operates M200600
2. Fit the lubricating oil pump with the
bearing cover. Tighten the attachment bolts
data”.
3. Fit new O-rings to the oil suction and
delivery pipes (1).
4. Fit the oil strainer. 7
ǹ 0011 4-5
4-6 ǹ 0011


oil pump.
damage.
Note: M200344
Note:
shown.
pump housing.
oil pump.
7
data”.
data”.
ǹ 0011 5-1
5-2 ǹ 0011

To prevent injury to the skin, avoid

drained oil.

sump.
the specified engine-oil quantity. See
A
“Technical data”. M2083
M200735
ǹ 0011 6-1
6-2 ǹ 0011
2 NS ENGINE
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 General arrangement drawing, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0011
2.3 General arrangement drawing, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0011
2.4 General arrangement drawing, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.5 General arangement drawing, engine mounting . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.6 Overview drawing, valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
2.7 General arrangement drawing, flywheel housing . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0011
3.1 Inspection and adjustment, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.3 Inspection, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.4 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ...... 0011
3.6 Inspection, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ...... 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
4.3 Removal and installation, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . . 0011
4.7 Removal and installation of the steering pump . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . . 0011
4.8 Removal and installation, starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . . 0011
4.9 Removal and installation, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . . . 0011
4.11 Removal and installation, engine brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 . . . . . 0011
4.12 Removal and installation, valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-24 . . . . .
4-27 . . . . .
0011
0011
8
4.17 Removal and installation, vibration damper and pulley . . . . . . . . . . . . . . . . . 4-32 . . . . . 0011
ǹ 0011 1
NS ENGINE 2
2 ǹ 0011
2 NS ENGINE
unventilated area.
Make sure exhaust fumes are properly
extracted.
moving components.
required.
ǹ 0011 1-1
NS ENGINE 2
1-2 ǹ 0011
2 NS ENGINE
2. GENERAL
2.1 IDENTIFICATION
Engine number
at the rear left.
NS engine identification plate 4 3 5 6
9. Injection timing
10. Maximum governed engine speed
ENGINE
11. Engine number TYPE
12. Engine type E4
ENGINE
13. Indication of country of origin NUMBER
14. Certificate number GOVERNED SPEED min -1 OUTPUT kW

15. Fuel pump setting (output)
BEFORE
16. Smoke level at maximum engine speed, no INJECTION TIMING
T.D.C.
PUMPSETTING cm 3
load SMOKE LEVEL FREE ACCELERATION m -1
EINDHOVEN HOLLAND
2 1 8 7
M200678
ǹ 0011 2-1
NS ENGINE 2
2.2 GENERAL ARRANGEMENT DRAWING, INLET MANIFOLD
Legend 1
10. Nut
11. Insulator 2
3 8
12. Ring
13. Glow plug 7
14. Inlet manifold 4
15. Shoulder stud 6
16. Waved spring
7
17. Bolt
18. Gasket
9
5 M2 00 150
2.3 GENERAL ARRANGEMENT DRAWING, EXHAUST MANIFOLD
Legend 4 4 5
14. Stud
15. Gasket 1 6
16. Exhaust manifold, front 2 3
17. Sealing spring
18. Exhaust manifold, rear
19. Stud
20. Spacer sleeve 9 13
21. Nut
22. Heat shield 7
8
23. Ring
24. Waved ring 10
8 25. Bolt
26. Heat shield
11
12
10
11
12 M2 00 155
2-2 ǹ 0011
2 NS ENGINE
2.4 GENERAL ARRANGEMENT DRAWING, ALTERNATOR
Legend 1
16. Adjusting strip
17. Ring 4 5
18. Bolt 6
19. Nut 6
20. Waved spring 7 2
21. Ring 3
22. Bolt
23. Alternator 9
24. Key
25. Pulley
26. Waved spring 11
27. Nut 12
28. Nut
29. Bracket
30. Bolt 8
10
14
15
13
M2 00 145
2.5 GENERAL ARANGEMENT DRAWING, ENGINE MOUNTING
8
Legend
12. Flange bolt 2
13. Flange bolt 1
14. Bush 3
15. Vibration damper
16. Flange nut
17. Bracket 4
18. Flange bolt 7
19. Vibration damper 5
20. Ring
21. Nut 8
22. Bracket
9
10
11 6
M2 00 161
ǹ 0011 2-3
NS ENGINE 2
2.6 OVERVIEW DRAWING, VALVE OPERATION
1
2
3
4
5
6
5
4
7
4
5
6
5
4
7
4
5
6
5
4
3
2
1 M2 00 132
Legend
8. Circlip
9. Ring
10. Spring
8
11. Ring
12. Rocker
13. Rocker shaft seat
14. Spring
2-4 ǹ 0011
2 NS ENGINE
2.7 GENERAL ARRANGEMENT DRAWING, FLYWHEEL HOUSING
1
10
2 3
11
4
12
13
6
5
14
7
8
9
M2 00 134
Legend
15. Flywheel housing
16. Bolt
17. Ring
18. Dowel
19. Oil seal
8
20. Spacer ring
21. Adjusting plate
22. Spring washer
23. Allen screw
24. Flywheel
25. Starter ring gear
26. Dowel
27. Input shaft bearing
28. Bolt
ǹ 0011 2-5
NS ENGINE 2
2-6 ǹ 0011
2 NS ENGINE

Adjustment, V-belt tension O

APBTLIB
EEUL
TI
N.2
00
1. Check the V-belt tension with special tool
(DAF no. 1240442) for the single V-belt LBS
.50
600
version. 100
150
O
APBT
LIBEE
ULTII
N.5
00
LBS
.100 150
0
200
300
M2079

M2061
3. Place the belt-tension gauge on the V-belt, 8

halfway between the two pulleys.
4. Slowly depress the V-belt using the
carefully. Make sure that the measuring arm
is not moved.
M2055
ǹ 0011 3-1
NS ENGINE 2

M2062
Adjustment, V-belt tension

1. Loosen the lower attachment bolts (1) of
the alternator.
2. Slacken the central nut (2) of the tensioner.
3. Move the alternator so that the correct 2
V-belt tension is reached. 1
4. Tighten the tensioner bolt (2) and the
alternator attachment bolts (1).
1 M200301
3-2 ǹ 0011
2 NS ENGINE
Inspection, cylinder head

1. Check that the cylinder head sealing plugs
are not leaking and pressure test the
cylinder head if necessary. See “Technical
data”.
2. Inspect the cylinder head for damage on
the sealing face and any cracks. If
necessary, have the cylinder head refaced.
within the tolerance limits. See “Technical
data”.
3.3 INSPECTION, VIBRATION DAMPER
Inspection, vibration damper

1. Check the vibration damper for cracks in
the rubber section of the vibration damper.
2. Also check that there is no seam visible
between the rubber and metal parts of the
vibration damper.
3. If one of these has been found, the
vibration damper must be rejected.
4. Check the bearing faces in the vibration
damper and on the crankshaft for damage. 8
5. Check the clamp rings for damage.
6. Check whether the bearing race of the seal
on the vibration damper has any grooves. If
this is the case, a new seal with a spacer
ring must be fitted.
7. Remove the seal. It is recommended to
replace this.
ǹ 0011 3-3
NS ENGINE 2
The inspection/correction of the valve clearance

may be carried out either when the engine is
cold or warm.
Adjusting the valve clearance must be
performed when the engine is stationary.
1. Remove the noise cap at the rear of the
engine.
2. Clean the valve cover and the surrounding
area.
3. Remove the air inlet duct fitted over the
valve cover.
4. Remove the valve cover.
5. Make sure the fuel pump is in the “stop”
position. If necessary, lock the fuel pump in
the “stop” position.
6. Crank the crankshaft clockwise, as seen
from the timing gear end (this is the
engine’s normal direction of rotation), until
the valves of cylinder 6 are in overlap
position. The piston of cylinder 1 is now at
TDC of the compression stroke.
7. Check/correct the valve clearance of 2
cylinder 1. Set the correct valve clearance
by unscrewing the locknut (1) and turning
8 the adjusting bolt (2) in the correct direction. 1
8. Having finished the adjusting, tighten the
locknut (1) to the specified torque and
check the valve clearance again.
9. By cranking the camshaft always 1/3 stroke,
the valves can be adjusted according to the
injection sequence (1-5-3-6-2-4). M2 00 130
3-4 ǹ 0011
2 NS ENGINE
Cylinder with Adjust valve

valves in overlap clearance of cylinder
position
6 1
2 5
4 3
1 6
5 2
3 4
10. Clean the valve cover and replace the valve

cover gasket. Fit the valve cover.
11. Check the valve cover sealing rubbers and
fit the attachment bolts. Tighten the
attachment bolts to the specified torque
making sure that the sealing rubber is not
damaged.
12. Fit the noise cap.
1. Remove the gearbox, pressure group and

the clutch plate.
2. Place the dial gauge on the edge of the
flywheel housing and crank the engine by
8
hand. 140 mm
3. Check the flywheel axial end play. At a
distance of 140 mm from the middle, the
clock deflection must be at maximum
0.1 mm.
M2 00 034
ǹ 0011 3-5
NS ENGINE 2
Note:
Heavy-duty use can lead to the central isolator
in the glow plugs becoming loose. In the long
term this loose isolator will damage the glow
spiral, leading to parts of the spiral and isolator
falling deeper into the engine, leading to serious
damage.
Inspection, glow plugs A
points:
- rattling sound (loose isolator, see A);
- windings in the centre of the spiral that
have worn thin or broken due to the
abrasive effect of the loose isolator B C
(see B);
M200743
- spiral end broken or worn thin due to
continuous knocking by the isolator
(see C);
- if parts of the insulator have broken off,
check the inlet manifold for the missing
parts.
3-6 ǹ 0011
2 NS ENGINE


gear.

fire.
Note:
When removing the engine, ensure that no parts
fall into the engine, radiator or other
components. To prevent this occurring, plug all
pipe openings.
Removing the engine
1. Disconnect the earth terminal from the
batteries.
engine.
3. Clean the engine.
5. Disconnect the propeller shaft from the
gear-box.
8
6. Remove the air pipe from the engine brake
valve operating cylinder.
7. Remove the exhaust pipe (with the engine
brake valve) between the exhaust manifold
and silencer.
8. Disconnect the gearbox wiring and tie the
wires together.
9. Remove the gear lever with the selector
rod.
10. Remove the gearbox and clutch housing
from the engine.
ǹ 0011 4-1
NS ENGINE 2
11. Disconnect the fuel supply and return pipe.

12. Remove the connector of the
electro-pneumatic valve for the engine
brake operation. The valve is located in the
chassis.
13. Remove the air pipe of the air cylinder on
the fuel pump.
14. Remove the throttle control cable from the
fuel pump and disconnect the cable
attachment on the coolant pipe.
housing.
16. Disconnect the air duct connection between
the engine and charge cooler.
17. Remove the level indicator connector (on
the front of the header tank). Disconnect
the wiring.
18. Remove the overflow pipe from the header
tank.
19. Remove the heater pipes on the engine
side.
20. Remove the pipes between the engine and
the radiator and the engine and the header
tank.
21. Remove the torque rod between the
8 22. Remove the radiator and the air cooler.

23. Detach the speed limiter connector. This is
near the several-pinned round connectors
on the cab floor.
24. Disconnect the speed limiter wiring as far
as necessary.
25. Disconnect the central engine plug. This
several-pinned round connector can be
recognised by the red clamping ring and is
to be found with the other cable
through-connections on the cab floor.
4-2 ǹ 0011
2 NS ENGINE
26. Disconnect the central plug wiring as far as

necessary.
28. Drain the steering oil and remove the
steering pump piping.
29. Another possibility is removing the steering
pump with the connected compressor
piping. Attach the steering pump with the
connected piping to the chassis.
30. Remove the steering oil reservoir. Plug the
pipe openings.
31. Remove the dipstick holder.
32. Remove the wiring of the starter motor and
bind up the wiring.
33. Disconnect the delivery pipe from the rear
of the engine.
34. Remove the connector of the
underpressure sensor.
35. Disconnect the air pipe between the air filter
and the air duct that is fitted over the
engine.
36. Hang the engine yoke in the hoist and
attach the yoke to the hoisting eyes of the
engine.
37. Remove the central attachment bolts which
8
attach the engine bracket to the vibration
dampers at the front and rear of the engine.
38. Hoist the engine gently and check that the
engine is balanced.
39. Hoist the engine gently from the chassis
and while hoisting check that the engine
does not remain hooked anywhere.
40. Carefully place the engine on stands.
ǹ 0011 4-3
NS ENGINE 2
Installation, engine
Note:
- Check the pipes and replace as necessary.
- Check the pipe clamps and replace as
necessary.
- Replace all gaskets and sealing rings.
1. Check the engine suspension vibration
dampers. If in doubt, replace.
2. Hoist the engine gently into the vehicle and
fit the engine bracket attachment bolts.
3. The attachment bolts must be fitted free of
stress. Adjust the position of the rear
vibration damper as necessary.
specified tightening torque. See “Technical
data”.
5. Fit the air pipe between the air filter and air
duct.
6. Fit the connector of the underpressure
indicator.
7. Tighten the delivery pipe on the rear of the
engine.
8. Fit the starter motor wiring.
8 10. Install the steering-oil reservoir.

11. Fit the steering pump pipes and fill the
system.
12. Fit the oil filler pipe.
13. Tighten the engine wiring.
14. Tighten the central engine plug (red, round)
under the cab floor.
15. Tighten the speed limiter connector under
the cab floor.
4-4 ǹ 0011
2 NS ENGINE
16. Fit the radiator and the air cooler.

18. Fit the pipes between the engine and the
radiator and the engine and the header
tank.
19. Fit the heater pipes on the engine side.
20. Fit the overflow pipe on the header tank.
21. Attach the wiring and the connector of the
level sensor.
22. Fit the air ducts between the engine and
charge cooler.
23. Fit the earth strip to the flywheel housing.
24. Attach the fuel pump throttle cable. Tighten
the cable bracket on the coolant pipe.
25. Attach the air pipe of the air cylinder to the
fuel pump.
26. Attach the connector of the
electro-pneumatic valve for the engine
brake operation.
27. Fit the fuel supply and return pipe.
28. Fit the gearbox and clutch housing to the
engine.
29. Fit the gear lever and the selector rod.
30. Connect the gearbox wiring. 8
31. Fit the exhaust pipe (with the engine brake
valve) between the exhaust manifold and
silencer.
32. Fit the air pipe to the engine brake valve
operating cylinder.
ǹ 0011 4-5
NS ENGINE 2
33. Fit the drive shaft to the gearbox.

35. Reconnect the earth lead to the batteries.
36. Check the engine oil level and top up with
the specified engine oil to the correct level.
37. Bleed the fuel system.
38. To start the engine operate the engine
brake so that the engine can catch on and
crank the engine with the starter motor until
the oil warning lamp is extinguished.
39. Start the engine, set the cab heating to
maximum and let the engine run for a few
minutes. Check for leakage and abnormal
sounds.
40. Check the coolant and engine oil levels.
41. Bring the engine to operating temperature
and check for leaks.
42. Take a test drive.
43. After the test drive, check the coolant and
engine oil levels again.
engine.
4-6 ǹ 0011
2 NS ENGINE
Note:
Depending on the reason for which the cylinder
head must be removed, the inlet and exhaust
manifolds and thermostat housing with coolant
pump need not be removed.
batteries.
engine.
3. Drain the engine coolant system.
5. Remove all thermostat housing and coolant
pump pipes.
6. Disconnect the coolant pipe on the rear of
the cylinder head.
7. Detach the wiring of the glow plugs.
8. Remove the coolant temperature indicator
wiring.
9. Remove the brackets of the electrical wiring
on the parts to be removed.
10. Remove the fuel return pipe bracket on the
thermostat housing.
11. Remove the V-belts. 8
12. Remove the thermostat housing with the
coolant pump.
valve cover.
14. Remove the gear lever.
15. Remove the inlet manifold.
16. Remove all the turbocharger pipes.
ǹ 0011 4-7
NS ENGINE 2

18. Remove the exhaust manifold and
turbocharger.
19. Remove the injector leak-off pipe.
21. Remove the valve cover.
22. Remove the rocker shaft.
25. Remove the cylinder head.
26. Remove the centring sleeves from the
cylinder block.
Make sure that no gasket remnants fall into
the engine.
block for the cylinder head bolts.
2. Fit the two centring sleeves into the cylinder
head.
3. Screw both guide pins (special tool
DAF no. 0694912) into the outer threaded
holes of the cylinder block.
8 Note:
Always replace the cylinder head gasket.
4. Check the new cylinder head gasket for
damage. Fit the new cylinder head gasket
Top
dry in such a way that the word “Top” is

uppermost (see the illustration opposite).
4-8 ǹ 0011
2 NS ENGINE
5. Fit the cylinder head.

Note:
the bolts, mark them with a centre punch, to
indicate how often they have been used.
- New bolts should not be marked on the
first fitting.
- Bolts marked with 2 centre points must
not be reused and must be replaced by
new ones.
- M10 bolts need not be replaced after
the third fitting.
6. When fitting used bolts, clean the thread
and inspect for damage. If in doubt,
replace.
7. Apply a drop of oil on the abutting surface
of the M16 bolts. Apply Loctite 243 to the
threaded end and fit the bolts.
8. Apply sealant Loctite 572 tot the thread of
the M10 bolts and fit.
them with the two cylinder head bolts.
10. Tighten the cylinder head bolts. See
12. Fit the rocker shaft and tighten the
8
Note:
Make sure that the valve rocker adjustment
bolts are not tightened too far, as this would
cause the valve to open too much. While
tightening the rocker shaft, the valve should
be able to reach the piston.
ǹ 0011 4-9
NS ENGINE 2

14. Fit the valve cover and tighten the
16. Fit the injector leak-off pipe.
17. Fit the exhaust manifold with the
turbocharger.
19. Fit all the turbocharger pipes.
20. Fit the inlet manifold and tighten the
21. Fit the gear lever.
22. Fit the air duct over the valve cover.
23. Install the thermostat housing with the
coolant pump and tighten the attachment
data”.
24. Fit the new V-belts and adjust the V-belt
25. Fit the fuel return pipe bracket to the
thermostat housing.
26. Connect the wiring.
8 27. Connect the coolant temperature indicator
wiring.
28. Connect the glow plug wiring.
29. Fit the coolant pipe to the rear of the
cylinder head.
30. Fit the thermostat housing and coolant
pump pipes.
4-10 ǹ 0011
2 NS ENGINE

33. Start the engine and bring it to operating
temperature.
34. Check the engine for leaks.
35. Stop the engine and check the coolant level
once again. If necessary, top up the
coolant.
Note:
As the cylinder head gasket needs no
re-tightening, the cylinder head bolts need
not be retightened.
Removal, glow plugs

1. Disconnect the earth terminal from the +
batteries.
4. Check the glow plugs for damage.
1. Fit the glow plugs. M2 00 154
8
2. Connect the wiring and the connection strip
according to the diagram.
3. As necessary, clean the contact surface of
the earth cable so that it makes a good
earth connection.
4. Reconnect the earth cable to the batteries.
ǹ 0011 4-11
NS ENGINE 2

batteries.
engine.
3. Detach the wiring of the glow plugs.
4. For an RHD vehicle, remove the gear lever
with the gear lever bracket.
5. Remove the air suction pipe from the air
compressor.
6. Remove the bracket between the air duct
on top of the engine and the inlet manifold.
7. Disconnect the air pipe that connects the
inlet manifold with the charge cooler. Plug
the opening so that no dirt can get into the
charge cooler.
8. Mark the position of the shoulder studs.
Remove the attachment bolts and the
shoulder studs from the inlet manifold.
9. Remove the inlet manifold.
10. Remove any gasket remains.
4-12 ǹ 0011
2 NS ENGINE

to the specified torque.
2. Make the connection between the air pipe
and the inlet manifold.
3. Fit the bracket between the air duct on the
top of the engine and the inlet manifold.
4. Fit the air suction pipe of the air
compressor.
5. For an RHD vehicle, remove the gear lever
with the gear lever bracket.
6. Connect the glow plug wiring.
8. Start the engine and check the inlet
manifold connections for leaks.
engine.
ǹ 0011 4-13
NS ENGINE 2

engine.
2. Before removing the exhaust manifold,
check whether there has been any leakage
between the connecting flanges. A leak is
visible due to “traces of soot” on the
relevant flange. In the case of a leak, both
the abutting surface of the cylinder head
and the manifold must be carefully checked
for damage.
3. Remove the air duct fitted over the engine.
4. Depending on the reason why the exhaust
manifold is being removed, the
turbocharger can remain attached to it or
must be removed.
Note:
Even if the turbocharger is not removed
from the exhaust manifold, all pipes must
still be removed from the turbocharger.
manifold.
7. Remove the attachment nuts with the
spacer rings and remove the exhaust
manifold assembly.
8 8. Remove the gaskets.
9. If necessary, remove the two parts of the
exhaust manifold from each other with a
pulling and turning movement.
10. Remove the sealing rings and clean the
groove.
11. Clean all sealing surfaces.
4-14 ǹ 0011
2 NS ENGINE

1. Fit two new sealing rings with the slots
opposite one another.
2. Apply Copaslip to the exhaust manifold
parts and slide the two manifold parts
together.
3. Fit new gaskets to the exhaust manifold
assembly.
4. Apply Copaslip to the studs and fit the
spacer rings and attachment nuts.
5. Tighten the attachment nuts to the specified
torque.
6. If it has been removed, fit the turbocharger
to the exhaust manifold.
7. Fit the pipes to the turbocharger.
8. Fit the heat shields.
ǹ 0011 4-15
NS ENGINE 2

1. In the case of an air compressor cooled by 1
coolant, partially drain the cooling system. 2
2. In the case of an air compressor cooled by 3
coolant, disconnect the coolant pipes
(2 + 4). 4
3. Remove the lubricating oil pipe (7) of the air
compressor and collect the escaping oil.
Plug the openings.
5
4. Remove the air suction pipe (5) from the air 6

compressor.
7
5. Remove the delivery pipe (3). To do this,
loosen the pipe coupling at the rear of the M2 00 188
air compressor. When removing an air
compressor cooled by coolant, leave the
first section of the pipe on the air
compressor.
6. Remove the air steering pump (6) from the
air compressor.
7. Remove the bracket from the air
compressor.
8. Remove the four attachment bolts and take
the air compressor from the timing gear.
1. Transfer the drive sprocket to the air
8 compressor to be fitted, if applicable.

Tighten the attachment nut of the gear
wheel (3) to the specified tightening torque.
2. Check the delivery pipe for deposits of
carbon before fitting the air compressor.
Replace if necessary.
3. For a new air-cooled air compressor,
transfer the delivery pipe connection, fitted
with new sealing rings, to the air
compressor to be fitted.
4-16 ǹ 0011
2 NS ENGINE
4. Replace the compressor flange O-ring and

lightly grease it.
5. Clean the attachment bolts and apply
Loctite 243.
6. Place the compressor in the timing gear
and tighten the attachment bolts cross-wise
until the compressor abuts the timing gear
entirely. Then tighten the bolts to the
specified tightening torque.
7. If necessary, fit new sealing rings to the
removed pipes fit the pipes in reverse order
of removal.
9. In the case of an air compressor cooled by
coolant, top up the cooling system.
for leaks.
ǹ 0011 4-17
NS ENGINE 2
4.7 REMOVAL AND INSTALLATION OF THE STEERING PUMP
Removal, steering pump 2

1
Note: 5
Depending on the reason why the steering 4
pump must be replaced, the steering oil pipes of
the steering pump must be removed or can
remain connected. In the latter case, the pump
can be put to one side with the steering oil
pipes.
1. Clean the steering pump (3) and the
surrounding area.
2. If the steering pump steering oil pipes must 3
be disconnected, collect any steering oil
emitted.
3. Plug the steering pump opening and the
steering oil pipes immediately. Avoid dirt M2 00 164
getting into the steering gear. The steering
oil filter is fitted in the return pipe, which
means that should any dirt enter, it will
immediately also enter the steering gear.
4. Remove the two attachment bolts and lift
the steering pump from the air compressor.
5. Lift the coupling disk (5) out of the air
compressor coupling halfshell.
1. Check that the coupling halfshells of the
steering pump and air compressor are not
8 damaged.
- Check that the coupling disk is not
dented. If in doubt, replace.
2. Fit a new O-ring (4) to the pump and grease
it lightly.
3. Crank the engine as necessary until the air
compressor coupling disk is horizontal.
- Apply a little grease to the coupling
disk (5) so that it remains centred
relative to the coupling halfshell.
- Place the coupling disk in the air
compressor coupling halfshell.
4-18 ǹ 0011
2 NS ENGINE
4. Fit the steering pump to the air compressor.

Make sure that the steering pump coupling
halfshell is in the right position relative to
the coupling disk.
the specified tightening torque.
6. If the steering oil pipes have been removed,
refit them.
7. Fill and bleed the hydraulic steering gear (if
the pipes have been disconnected).
8. Start the engine and check the connections
for leaks.

batteries.
engine.
3. Mark the wiring connections on the starter
motor and remove the wiring.
4. Remove the three attachment nuts and take
the starter motor out of the flywheel
housing.
5. Check the pinion of the starter motor and
6.
the starter ring gear for damage.
Clean the abutting surfaces of the starter M2 00 137
8
ǹ 0011 4-19
NS ENGINE 2

1. Place the starter motor in the flywheel
housing.
2. Clean the screw thread of the studs, apply
Loctite 243 and tighten the attachment nuts
data”.
3. Connect the wiring and check whether the
earth cable of the starter motor makes a
good contact with the chassis.
5. Reconnect the earth cable to the batteries.
Removal, alternator
batteries.
2. Mark the wiring connections on the
alternator and remove the wiring.
3. Loosen the alternator and tensioner
attachment bolts.
4. Remove the V-belts from the pulley.
5. Remove the attachment bolts and take off
the alternator.
8
6. Transfer the pulley to the alternator to be
fitted, if applicable. Tighten the attachment
nut to the specified torque. See “Technical
data”.
1. Fit the V-belts to the pulley.
and adjustment”.
3. Fit the alternator wiring.
4-20 ǹ 0011
2 NS ENGINE
Removal, V-belts
1. Loosen the alternator attachment bolts (1)
and the tensioning gear bolt (2).
2. Tilt the alternator as close as possible
against the cylinder block. 1
3. Remove the attachment bolt (3) of the air 1
guide ring.
4. Remove the V-belts.
5. Inspect the V-belts and pulleys for damage,
rust and grease deposits.
Note: 1 M2063
Always replace a V-belt with a V-belt of the
same version. Always replace both belts at
the same time.
Installation, V-belts 3
1. Push the fan guide ring in the direction of
the fan and pull the V-belt through the air
guide ring and fan.
2. Tighten the attachment bolts (3) of the air
guide ring.
3. Place the V-belts on the pulleys and adjust
the V-belt tension. See “Inspection and
adjustment”.
8
M2119
ǹ 0011 4-21
NS ENGINE 2
Properly suspend the engine in the

hoist.
Support the engine while removing
and fitting the engine brackets.
Do not forget your own safety
during these operations.

batteries.
engine.
4. Detach the pipes between the engine,
radiator and the header tank.
6. Disconnect the air duct connection between
the engine and charge cooler. Plug the
openings.
7. Remove the throttle cable bracket from the
air pipe.
8. Remove the sealing edge between the
guide ring and the wind tunnel.
8 housing.
10. Remove the steering oil reservoir and tie it
to the chassis.
11. Remove the dipstick holder.
13. Remove the central engine bracket
attachment bolts to the vibration dampers at
the front and rear of the engine.
4-22 ǹ 0011
2 NS ENGINE
14. Observe the available hoisting height before

hoisting the engine. As necessary, remove
the radiator and other parts and/or pipes if
the hoisting space is insufficient.
- Hoist the engine very carefully as far as
is necessary to remove the respective
parts.
- Be sure not to exceed this available
hoisting height.
Note:
While hoisting, make sure that no pipes are
kinked and/or parts touch each other.
15. Properly support the engine and remove the
parts of the engine brackets.
1. Fit the engine bracket parts.
2. Carefully lower the engine and tighten the
3. If necessary, fit the parts that had to be
removed for hoisting.
5. Install the steering-oil reservoir.
6. Fit the earth strip to the flywheel housing.
7. Fit the sealing edge between the guide ring
8
and the wind tunnel.
8. Fit the throttle cable bracket to the air pipe.
9. Fit the air ducts between the engine and
charge cooler.
ǹ 0011 4-23
NS ENGINE 2

11. Fit the pipes between the engine, radiator
and the header tank.
Check the pipes and pipe clamps and
replace as necessary. Sparingly grease the
moving part of the pipe clamp.
13. Check the steering oil level, and top up as
necessary.
and check for air and coolant leaks.
engine.
4.12 REMOVAL AND INSTALLATION, VALVE OPERATION
Removal, valve operation

engine.
2. Clean the valve cover and the surrounding
area.
valve cover and remove the valve cover.
8
4. Slacken the adjusting bolts of the rockers
as far as possible.
5. Remove the attachment bolts of the rocker
shaft seats and remove the rocker shaft.
6. Remove the locking bolts of the rocker shaft
from the rocker shaft seats.
7. Remove the rocker shaft circlip and remove
the rings, springs and rockers from the
rocker shafts.
4-24 ǹ 0011
2 NS ENGINE
8. Remove the push rods from the cylinder

block. Be sure when taking out the push
rods that the tappet sleeves do not remain
attached to the push rods. This can be
prevented by moving the push rod back and
forth.
9. Remove the side covers from the right-hand
side of the engine.
10. Remove the tappet sleeves. Mark the
position of the tappet sleeve in the cylinder
block.
Inspection
1. Inspect the tappet sleeves for pitting and
wear on the contact surface with the cam
and for signs of grating on the side.
2. Check the push rods for pitting, dented
contact surfaces and straightness.
3. Check the rocker shaft for signs of grating
and inspect whether the oil ducts are open
and whether the plugs in the ends of the
rocker shaft seal properly.
4. Check the bearing bushes of the rockers
and the rocker head for damage and wear.
The contact surface of the rocker head
must not be dented.
Installation, valve operation
1. Apply oil to the tappet sleeves and refit
them in their original position.
2. Check that the tappet sleeves move freely
and have no excessive play.
8
3. Fit new gaskets to the side covers and fit
them with the brackets attached to the
covers and pipe brackets.
ǹ 0011 4-25
NS ENGINE 2
5. If necessary, press a new bearing bush into Ø1,5 mm

the rocker. A
Make sure that when pressing in the
bearing bush, the bearing bush seam (A in
the diagram opposite) does not align with
the oil duct in the rocker.
through the oil duct.
Ream the bearing bush to the specified
dimension.
6. Fit the parts to the rocker shaft in the
correct sequence. Fit new circlips (1) to the M2 00 131
rocker shaft ends and apply oil to the
assembly.
7. Turn the rocker shaft so that the notches of
the shaft are on the side of the locking bolts
on the rocker shaft.
Check that the oil bores of the rocker shaft
match the oil bores of the rocker shaft seats
and rockers.
8. Apply Loctite 243 to the locking bolts and
screw them into the rocker shaft seats.
9. Fit the rocker shaft on the cylinder head.
Note:
Make sure that the adjusting bolts of the
valve rockers are not screwed in too far.
This could lead to the valve opening too far,
which would cause the valve to touch the
rocker shaft during tightening.
10. Tighten the rocker shaft seat attachment
8 bolts to the specified torque.

11. Tighten the rocker shaft locking bolts.
12. Set the valve clearance. See “Inspection
and adjustment”.
13. Fit the valve covers with a new gasket.
14. Fit the air duct.
4-26 ǹ 0011
2 NS ENGINE
Removal, flywheel
1. Remove the gearbox, pressure group and
the clutch plate.
flywheel.
3. Clamp the crankshaft flywheel by tightening
the two jack screws (M10) at the same 5 mm
time.
4. Clean the crankshaft flange, the dowels and
the attachment bolts.
2 mm
5. If the flywheel on the abutting surface of the
clutch plate shows signs of cracks and
these cracks are not within 5 mm of the
edges of the abutting surface, a maximum
of 2 mm of the flywheel may be ground
5 mm
down (see illustration opposite).
6. De-grease the abutting surface of the
flywheel and the clutch plate.
1. Apply Loctite 243 to the flywheel and fit it
with the attachment bolts.
M2 00 033
2. Tighten the attachment bolts crosswise,
tightening them to the specified torque.
3. Check the flywheel play. See “Technical
data”.
4. Fit the gearbox, pressure group and the
clutch plate.
8
ǹ 0011 4-27
NS ENGINE 2

2. Remove the starter ring by tapping it from
the flywheel. If this is not possible it can be
cut between two teeth, using a sharp chisel.
3. Clean the surface with which the flywheel
abuts the starter ring gear and the starter
ring gear itself. Ensure that the abutting
surfaces are de-greased.
4. Heat the new starter ring gear evenly in an
oven to approx. 230°C. Check the
temperature with thermal pins.
1. Fit the starter ring gear onto the flywheel so
that the bevelled sides of the teeth point
towards the starter motor. The DAF part
number, stamped on the side of the starter
ring gear must face the clutch release
assembly.
2. Tap the starter ring gear against the
flywheel flange. Ensure good all round
flywheel.
8 M2 00 035
4-28 ǹ 0011
2 NS ENGINE

2. Disconnect the earth cable.
4. Suspend the rear of the engine in the hoist.
5. Remove the attachment bolts from the oil
sump on the flywheel housing.
6. Remove the engine brackets from the
flywheel housing.
flywheel housing and remove the flywheel
housing.
from the housing.
1. Clean any gasket remnants from the
abutting surfaces. Clean any locking
compound from the attachment bolts.
4. Apply Loctite 510 locking compound to the
sealing face of the cylinder block. Apply the
locking compound with a roller across the
entire sealing face. 8
5. Fit the flywheel housing.
6. Apply locking compound (Loctite 243) to the
attachment bolts and tighten them
crossways. Tighten the attachment bolts to
the specified torque.
ǹ 0011 4-29
NS ENGINE 2

9. Fit the engine brackets.
11. Clean the contact surface of the earth lead
and fit it.
12. Fit a new oil sump gasket.
Note:
mounting ring, which can only be used once.
When positioning the oil seal, use special tool
(DAF no. 0694899).
housing using an impact puller. Attach the
impact puller adapter to the seal with two
plate screws.
3. If the flywheel housing has been removed
from the engine the old oil seal can be
carefully tapped or pressed out of the
flywheel housing.
8
4. Thoroughly clean the seal recess and
Note:
4-30 ǹ 0011
2 NS ENGINE
Installation, flywheel housing seal 1

1. Apply a little grease to the lip of the oil seal. 2
2. Attach the guide plate (A) of the special tool
(DAF no. 0694899) to the crankshaft flange,
place the bolt heads in such a way that the
mounting ring can be slid over them.
3. Position the mounting ring (1) and slide the
new oil seal (2) over the mounting ring. A
Note:
Do not apply sealant to the outer edge of
the seal. B C
M2 00 036
4. Fit the thrust washer (B) to the guide plate
(A). Press the oil seal (2) into the flywheel
housing by evenly tightening the nut.
ǹ 0011 4-31
NS ENGINE 2
4.17 REMOVAL AND INSTALLATION, VIBRATION DAMPER AND PULLEY
Removal, vibration damper and pulley

1. Check that the parking brake lever is in the
“park” position and engage a gear.
2. Remove the radiator/charge cooler with the
guide ring.
3. Remove the V-belts.
4. Remove the fan.
5. Remove the pulley attachment bolts and
remove the pulley from the vibration
damper.
6. Remove the retaining bolt.
7. Remove the thrust piece.
8. “Knock out” the clamp rings by tapping the
middle section (see the illustration opposite)
of the vibration damper with a plastic
hammer. Never tap above the rubber edge
against the vibration damper. M2 00 190
9. Remove the vibration damper with the

crankshaft clamp rings and bush.
Installation, vibration damper and pulley
1. Clean the parts that have been removed,
the bolt screw thread and the crankshaft
journal.
2. Make sure that the abutting surfaces are
8 completely grease-free.
3. Apply a little grease to the bearing race of
the vibration damper and slide the vibration
damper onto the crankshaft journal.
4. Oil the clamp ring sparingly.
5. Then fit the bush (4), a clamp ring (3, inner 1 2 3 2 3 4
ring), a clamp ring (2, outer ring), a clamp
ring (3, inner ring), a clamp ring (2, outer
ring) and a thrust piece (1).
M2 00 125
4-32 ǹ 0011
2 NS ENGINE
6. Apply Loctite 243 to the retaining bolt and fit

it, tightening it to the specified torque.
7. Fit the pulley to the vibration damper. The
abutting surfaces of the vibration damper
and the pulley must be free of dirt and
grease.
8. Apply Loctite 243 to the attachment bolts
and fit them, tightening it to the specified
torque.
9. Fit the V-belts and adjust the V-belt tension.
10. Fit the fan.
11. Fit the radiator/charge cooler with the guide
ring.

1. Remove the vibration damper together with
the pulley.
2. Remove the oil seal with an impact puller.
Attach the impact puller adapter to the seal
with two plate screws.
8
can lead to a leak.
Note:
If the seal has caused a groove on the vibration
damper, a spacer ring must be fitted in the
chamber of the seal.
ǹ 0011 4-33
NS ENGINE 2

1. Apply a little grease to the lip of the oil seal
(3).
2. If necessary, place the spacer ring (4) in the
seal chamber.
4
3. Place the seal in the timing cover with the 3
2
open section pointing to the timing cover 1
and press the seal further into the timing
cover chamber using the special tool
(DAF no. 0694914) and the retaining
bolt (1).
M2 00 133
4. Fit the vibration damper together with the
pulley.
and adjustment”.

1. Remove the vibration damper together with
the pulley.
2. Remove the speed limiter actuator.
3. Mark the position of the various attachment
8 bolts and studs. Remove them and take off

the timing gear cover.
4-34 ǹ 0011
2 NS ENGINE
Installation, timing gear cover

1. Remove the gasket remnants, clean and
inspect the sealing faces, dowel pins and
locating holes.
2. Fit a new oil seal in the timing gear cover.
4. Fit the timing cover. Make sure that the
dowels fit properly in the locating holes of
the cover.
and shoulder studs and fit them in the
correct positions. Notice the difference in
length of the attachment bolts.
6. Remove the three studs and replace them
with attachment bolts.
7. Tighten the attachment bolts crosswise to
8. Fit the speed limiter actuator.
9. Fit the vibration damper together with the
pulley.
ǹ 0011 4-35
NS ENGINE 2
4-36 ǹ 0011
2 NS ENGINE COOLING SYSTEM
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
4.1 Inspection, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0011
5.1 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.2 Removal and installation, thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . . 0011
5.3 Removal and installation, fan (clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 . . . . . . 0011
5.4 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 . . . . . . 0011
5.5 Removal and installation, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 . . . . . . 0011
5.6 Removal and installation, header tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 . . . . . 0011
ǹ 0011 1
NS ENGINE COOLING SYSTEM 2
2 ǹ 0011
properly extracted.
moving components.
also applies to coolants, windscreen wash,
battery acid and diesel oil. So avoid inhaling and
direct contact.
required.
ǹ 0011 1-1
1-2 ǹ 0011
2. GENERAL
2.1 SYSTEM DESCRIPTION
ǹ 0011 2-1
Cooling system diagram

11 A
7 B
4 3 8
10
5
6 9
19
3
4 7 11
1
8 B
6
12
9
10 13
2
18 14
19
3
9 11 16 7 4
1
A
6
12
13 15 15
17
2
10
18
2-2 ǹ 0011
Legend
A Coolant flow from thermostat housing
through the right side of the cylinder head
B Coolant flow from thermostat housing
through the left side of the cylinder head
1. Header tank
2. Radiator
3. Bleed pipe
4. Radiator supply pipe
5. Water pump
6. Header tank connection pipe
8. Heater supply pipe
9. Heater return pipe
10. Radiator return pipe
11. Cylinder head
12. Lubricating oil heat exchanger return pipe
13. Lubricating oil heat exchanger supply pipe
14. Lubricating oil heat exchanger
15. Air compressor supply pipe
(water cooled air compressor only)
16. Air compressor return pipe
(water cooled air compressor only)
17. Air compressor
18. Cylinder block
19. Overflow tank
General
The engine cooling system’s function is to keep
the engine temperature at a constant level
independently of the change in engine load,
speed and ambient temperature. At this
temperature, the engine gives its best return and
minimum wear.
To achieve controlled engine cooling, the
amount of coolant flowing to the radiator is
controlled by the thermostats.
9
The airflow through the radiator is controlled by
the fan clutch. This viscous type clutch
increases or decreases the fan speed relative to
the ambient temperature after the radiator.
ǹ 0011 2-3
Cooling system function

radiator, a header tank, a lubricating oil heat
exchanger, a thermostat housing with two
thermostats and pipes. In the case of an air
compressor cooled by water, this is also
included in the cooling system.
On the thermostat housing (7), a bleed pipe (3)
is fitted. Through this pipe, any air in the cooling
system is discharged to the header tank (1), so
that the cooling system is bled automatically.
The water pump (5) is located immediately on
the thermostat housing (7). The thermostat
housing (7) is in turn fitted directly to the cylinder
head (11).
From the delivery side of the water pump (5),
the coolant is directed to the cylinder head (11)
via an opening at the back of the thermostat
housing.
The cylinder head (11) has two internal coolant
ducts which are separate from each other (A
and B).
The coolant passes through the right-hand
coolant duct (A) of the cylinder head (11) to the
cylinder block (18). From the cylinder block (18),
the coolant is returned to the thermostat housing
(7) through the left-hand coolant passage (B) of
the cylinder head (11).
Depending on the coolant temperature, the two
parallel thermostats distribute the coolant flow to
the radiator (2) or directly back to the coolant
pump. The coolant transported to the radiator
(2) enters the radiator (2) at the top, and leaves
the radiator (2) at the bottom. From the bottom
of the radiator (2), the coolant is returned to the
9
water pump (5), via the return pipe (10).
2-4 ǹ 0011
The connection pipe (6) to the header tank (1) is

also connected to the return pipe (10) from the
radiator (2). If the coolant heats up, the coolant
flows to the header tank (1). If the coolant cools
down, the coolant flows back from the header
tank (1).
The header tank (1) is connected to the overflow
tank (19) with a flexible pipe. In an extreme
situation (e.g. when an engine which has been
excessively loaded is turned off immediately),
the capacity of the header tank (1) could be too
small. The coolant that the header tank (1)
cannot process is then led to the overflow
tank (19).
The overflow tank (19) is also equipped with an
air admission and bleed cap.
From the water pump (5) delivery side, the
coolant is fed through a pipe (13), connected to
the thermostat housing (7), to the lubricating oil
heat exchanger (14). From the lubricating oil
heat exchanger (14), the coolant is fed back to
the left rear of the cylinder head through a pipe
(12). The coolant is then fed back to the
thermostat housing (7) through the left-hand
duct (B).
The lubricating oil heat exchanger is not only
intended to cool the lubricating oil, but also to
heat the lubricating oil in a “cold” engine.
The supply pipe (15) to the air compressor (17)
is also connected to the pipe (13) through which
the coolant flows to the lubricating oil heat
exchanger (14). From the air compressor (17),
the coolant is returned via a pipe (16) to the
cylinder block.
The pipe (8) through which the coolant for the
cab heater flows is connected to the thermostat
housing (7), at the point at which the coolant 9
from the cylinder head (11) enters the
thermostat housing (7). From the heater, the
coolant is returned through a pipe (9) to the
radiator return pipe (10).
ǹ 0011 2-5
2-6 ǹ 0011
The pressure cap on the auxiliary header tank,

behind the grille, is attached on the header tank
by means of a screw thread. To fill the cooling
system, the pressure cap does not have to be
removed. The pressure cap on the front of the
expansion tank can be removed.
valves are closed.
opens. The overpressure in the cooling system
makes it possible to allow a higher temperature
in the cooling system, without the coolant
boiling.
Underpressure in the cooling system P1
If the pressure (P1) in the cooling system drops M200445
ǹ 0011 3-1
Operation of the thermostat

directly from the cylinder head at the back and
flows through the two parallel thermostats.
and the relative position of the thermostats,
there are 3 possibilities:
Thermostat closed
temperature of the thermostats.
The pipe (R) (fig. 1) to the radiator is completely R
closed.
The coolant passes via the by-pass duct (P)
(fig.1) directly to the water pump and the pump
once again passes the coolant to the cylinder
head.
Fig. 1 P
M2 00 114

temperature of the thermostats.
The pipe (R) to the radiator is opened and the R
by-pass duct (P) is partially closed (fig. 2).
pipe (R) to the radiator and through the by-pass
duct (P) to the water pump.
9
Fig. 2 P
M2 00 115
3-2 ǹ 0011

even higher, the pipe (R) to the radiator is fully
opened and the by-pass duct (A) is fully closed R
(fig. 3).
The whole coolant flow now goes through pipe
(R) to the radiator.
Fig. 3 P
M2 00 116
Note:
it is advised not to remove the thermostats, as
an emergency solution. If there are no R
thermostats in the thermostat housing, the
by-pass duct is constantly fully open (fig. 4). As
the resistance in the by-pass duct is lower than
that in the radiator, the largest part of the coolant
will go to the water pump via the by-pass duct
(uncooled). As a consequence, the temperature
will continue to rise.
Fig. 4 P
M2 00 117
ǹ 0011 3-3
3-4 ǹ 0011

4.1 INSPECTION, COOLING SYSTEM
1. Fill the header tank to the maximum level.

2. Attach a pressure testing pump to the
connection for the pressure cap.
3. Pressure-test the system at a pressure of
0.5 - 0.7 bar. The pressure must remain
constant for 10 minutes.
4. While the system is under pressure, the
external control must be carried out.
Inspection for coolant leakage
External leakage must be looked for in:
- flexible coolant pipes
- coolant pipes
- leaking radiator
- leaking water pump
- defective lubricating oil heat exchanger
- defective pressure cap
- leaking heater M2113
- leaking air compressor cylinder head

Internal leakage must be looked for in:
- defective head gasket
- cracked cylinder head or cylinder block
- leaking injector sleeve
Inspection, water pump leakage
The water pump shaft is sealed by a unitised
seal. To function correctly, it is necessary that
the seal should use a small amount of coolant.
This coolant consumption can lead to a trace of
leakage under the discharge hole that leaves a
white deposit on evaporation. The amount of
coolant leaking out depends on the use to which
the vehicle is put. When the engine is started 9
and stopped on numerous occasions, increased
leakage can occur.
The water pump does not need to be replaced if
a few drops of coolant are emitted from the
discharge hole from time to time or if a white
deposit is visible under the discharge hole.
ǹ 0011 4-1
Inspection, thermostats
1. Inspect the sealing surfaces of the
thermostat housing and the thermostat
housing cover for damage.
2. Inspect whether the thermostats are fully
closed.
3. Place the thermostats in a container filled
with water.
the thermostats open and whether the
thermostats open fully. See “Technical
data”.
4-2 ǹ 0011

1. Bolt 1
2. Waved spring
3. Thermostat housing cover 2
4. Pipe coupling 3
5. Nut 4
6. Sealing ring 5 7 11
6
7. Thermostat 8
8. Sealing ring
9. Bolt
10. Water pump
11. Gasket 9
12. Thermostat housing 10
Note: 12
Too high a coolant temperature is often put
down to a defective thermostat. This is however
seldom the case.
Before the thermostats are replaced, the cooling M2 00 171
system must first be inspected.
Removal, thermostats
1. Partially drain the coolant. See “Draining
and filling the cooling system”.
2. Loosen the attachment nut of the torque rod
between the thermostat housing cover and
the radiator and remove the bracket of the
thermostat housing cover torque rod.
3. Remove the thermostat housing cover
coolant pipe.
4. Remove the attachment bolts and nuts and
remove the thermostat housing cover from
5. Remove the thermostats from the 9
thermostat housing.
6. Never remove sealing rings from
thermostats.
ǹ 0011 5-1
Installation, thermostats
1. Clean the thermostats.
2. Clean the sealing surfaces of the thermostat
housing and the thermostat housing cover.
3. Fit new sealing rings.
4. Place the thermostats in the housing.
5. Fit the thermostat housing cover.
6. Install the torque rod bracket.
Do not overlook the pipe bracket
attachment.
7. Tighten the torque rod nut.
8. Check the coolant pipe condition and
connect it.
9. Check the pipe clamp and replace as
necessary. Apply a little grease to the
moving section of the pipe clamp and
tighten it well.
10. Top up the cooling system. See “Draining
and filling”.
12. Take a test drive and check whether the
cooling system functions properly.
5-2 ǹ 0011
5.2 REMOVAL AND INSTALLATION, THERMOSTAT HOUSING
1. Bolt 1
2. Waved spring
3. Thermostat housing cover 2
4. Pipe coupling 3
5. Nut 4
6. Sealing ring 5 7 11
6
7. Thermostat 8
8. Sealing ring
9. Bolt
10. Water pump
11. Gasket 9
12. Thermostat housing 10
Removal, thermostat housing 12
2. Remove the V-belts of the water pump M2 00 171
pulley.
3. Remove the alternator adjusting bracket
from the thermostat housing.
4. Remove the fuel return pipe bracket from
5. Loosen the attachment nut of the torque rod
between the thermostat housing cover and
the radiator and remove the bracket of the
thermostat housing cover torque rod.
6. Remove the thermostat housing coolant
pipes, the bleed pipe and the coolant pipe.
7. Remove the connector of the temperature
sensor.
8. Remove the common attachment bolt of the
thermostat housing and water pump. This is
the upper attachment bolt on the left-hand
9
side of the water pump. See the arrow in
the illustration.
9. Remove the attachment bolts and take the M2 00 172
thermostat housing with the water pump out
of the cylinder block.
ǹ 0011 5-3
Installation, thermostat housing

1. Clean the sealing surfaces of the thermostat
2. Inspect the sealing surfaces of the
thermostat housing and the cylinder block
for damage.
3. Screw two studs into the top of the cylinder
block, fit a new gasket to the thermostat
housing and fit the thermostat housing on
the cylinder block.
and fit them, tightening to the prescribed
tightening torque.
5. Replace the two studs with attachment
bolts.
6. Check the condition of the flexible pipes. If
in doubt, replace.
7. Check the pipe clamps and replace as
moving section of the pipe clamps.
8. Then fit the parts in reverse order of
removal. Tighten pipes securely.
9. Adjust the V-belt tension. See “Setting and
inspection, V-belt tension”.
and filling”.
5-4 ǹ 0011
5.3 REMOVAL AND INSTALLATION, FAN (CLUTCH)
1. Fan clutch
2. Self-locking nut
3. Fan
4. Spacer sleeve
5. Self-locking nut
6. Pulley
Removal, fan (clutch)
1. Remove the fan to fan clutch attachment
nuts.
clutch on the pulley.
9
3. Take the fan off the fan clutch.
4. Remove the bracket on the lower
right-hand side of the guide ring and
remove the fan through the opening
created.
Note:
The viscose fan clutch must be stored
vertically, or with the flanged side to the top.
The fan clutch must never be stored with
the flanged side to the bottom.
ǹ 0011 5-5
Inspection, viscous fan clutch

Drive speed 2600 rpm and equipped with the
fan.
Air temperature Fan speed

approx. 30 400 - 800 rpm
approx. 70 approx. 2080 rpm
approx. 80 approx. 2340 rpm
Installation, fan(clutch)
1. Check the fan for damage.
2. Clean the abutting surfaces of the parts. It is
important that the abutting surfaces are
clean.
3. Replace the self-locking nuts.
4. Fit the parts in reverse order of removal.
Fit the fan in such a way that the word
“front” shown on the plastic part is to the
front of the fan.
5. Tighten the nuts crosswise.
5-6 ǹ 0011
Removal, water pump

2. Loosen the pump pulley attachment bolts a
few turns.
3. Remove the V-belts from the pulley.
4. Loosen the pump pulley attachment bolts
some more and remove the pulley.
5. Remove the attachment bolts and take the
pump out of the thermostat housing.
1. Thoroughly clean the sealing surfaces of
the pump and the thermostat housing.
2. Inspect the sealing surfaces of the pump
and thermostat housing for damage.
3. When installing the pump, locate the gasket
by fitting four studs into the thermostat
housing around it.
4. Fit a new gasket (6) to the pump and fit it to
the exhaust manifold. Avoid damaging the
gasket.
and fit them.
6. Remove the studs used for locating the
pump and replace them with attachment
bolts.
7. Tighten the attachment bolts crosswise to
8.
Check that the pump impeller does not
9
catch.
9. Fit the pulley to the pump.
10. Fit the new V-belts and adjust the V-belt
tension. See “Setting and inspection,
V-belts”.
ǹ 0011 5-7

and filling”.
1. Bolt
2. Vaulted ring
3. Pulley
4. Bolt 6 7
5. Water pump 3 4 5
6. Gasket 12
M2 00 173
5-8 ǹ 0011
ǹ 0011 5-9
Diagram of parts
7 51
50
3
1 49
8
2 5
10 9
12
4 11
6 13
5
16 17 14
18
19
20 21 15
22
27 28
23 22
24
25
29
26
32
34 30
31 33
35
28
28
9
29 29
42 43
37 36
32
38
32
40
44
39 41 45
46
47
48
M2 00 170
5-10 ǹ 0011
1. Filler cap
2. Attachment tape
3. Header tank
4. Pipe clamp
5. Flexible pipe, overflow
6. Switch, coolant level
7. Pipe clamp
8. Connecting pipe, header tank
9. Pipe clamp
10. Pipe clamp
11. Plug
12. Pipe clamp
13. Flexible pipe, cooling system bleeding
14. Knurled ring
15. Bolt
16. Self-locking nut
17. Ring
18. Bush
19. Ring
21. Torque rod
23. Bush
24. Ring
25. Self-locking nut
26. Pipe clamp
27. Flexible pipe, radiator supply
28. Nut
29. Bush
30. Pipe clamp
31. Bracket, guide ring
32. Flange bolt
33. Guide ring
34. Flange bolt
36. Flange nut
37. Gauze screen
38. Charge cooler
39.
40.
Radiator
Sealing edge 9
41. Wind tunnel
44. Pipe clamp
45. Adapter
46. Pipe clamp
47. Flexible pipe, radiator discharge
48. Pipe clamp
49. Pipe clamp
50. Overflow tank
51. Air admission and bleed cap
ǹ 0011 5-11
Removal, radiator
1. Drain the coolant. See “Draining and filling
2. Detach the rubber sealing edge between
the wind tunnel and guide ring.
3. Remove the water pump and the header
tank pipes.
4. Loosen the overflow pipe at the front of the
header tank.
5. Remove the level sensor connector for the
coolant level. This is at the front of the
header tank.
7. Detach the heater pipes from the header
tank.
thermostat housing and the radiator. To do
this, first remove the bracket on the
thermostat housing.
9. Remove the throttle cable bracket on the air
duct.
10. Disconnect the electrical wiring on the air
duct.
11. Remove the charge cooler air ducts. Plug
the openings.
12. Remove the attachment bolts on opposite
sides of the radiator and carefully remove
the radiator with the charge cooler and
header tank from the vehicle.
9 13. If necessary, remove the charge cooler,

wind tunnel and header tank from the
radiator.
5-12 ǹ 0011
1. Fit the charge cooler (if removed), the wind
tunnel and the header tank to the radiator.
2. Check the radiator bracket vibration
dampers for cracking. Replace if necessary.
3. Carefully install the radiator in the vehicle.
4. Check the condition of the flexible pipes and
connections of the charge cooler. If in
doubt, replace.
filling the cooling system”.
ǹ 0011 5-13

2. Remove the pipes from the header tank.
3. Loosen the overflow pipe at the front of the
header tank.
4. Remove the level sensor connector for the
coolant level. This is at the front of the
header tank.
6. Detach the heater pipes from the header
tank.
7. Remove the attachment screws and lift the
header tank off the radiator.
1. Fit the header tank to the radiator.
2. Check the condition of the flexible pipes. If
in doubt, replace.
and filling”.
9 7.
Check the coolant fluid level.
5-14 ǹ 0011

Coolant
The cooling system should preferably be filled
with a ready-mixed coolant containing antifreeze
and corrosion-inhibiting additives.
If mains water is used an anti-freeze additive
must be introduced if temperatures fall below
+5_C, preferably one based on ethylene glycol
with anti-corrosion additives.
Consult the manufacturer’s instructions for the
correct anti-freeze mixing ratio.
The illustration opposite shows the lowering of o
C 0
the freezing point as a result of increasingly high -10

concentrations of ethylene glycol dissolved in
-20
water.
Preferably use 40% ethylene glycol solution -30
anti-freeze. This percentage guarantees not only -40

good frost protection, but also good corrosion -50
protection.
-60
If temperatures never fall below +5_C, it is -70

sufficient to add an anti-corrosion agent to the -80
coolant. 0 10 20 30 40 50 60 70 80 90 100 % Ethyleenglycol
100 90 80 70 60 50 40 30 20 10 0 H 2O
Note: M2016
Always use only those coolants or antifreeze

agents which meet DAF specifications.
For further information see the lubricant, coolant
and oil specifications.
ǹ 0011 6-1

the skin and eyes.

waste.

Carefully remove the filler cap, to

1. If the coolant is collected in a clean
container and has no impurities, it may be
re-used.
2. Set the heater operating lever to
“maximum”.
3. Place suitable containers beneath the drain
points.
5. Open the radiator drain cock (B) and drain
the radiator.
6. Open the cylinder block drain cock (A) and
drain the cylinder block.
7. Remove the drain plug (C) on the side of
the lubricating oil heat exchanger and drain
the lubricating oil heat exchanger.
9
9. Close the drain cocks and fit a new sealing
ring to the lubricating oil heat exchanger
drain plug before fitting it.
M2017
6-2 ǹ 0011
Filling the cooling system

1. Check that the heater operating lever is still
at “maximum”.
2. Fill the header tank with the specified
coolant to the maximum level mark.
3. Let the engine run for a few minutes and
check the coolant level.
4. If necessary, top up the coolant.
Note:
In order to avoid damaging the cylinder
block, do not top up a warm engine with
cold coolant.
Bleeding, cooling system
Ensure that the air bleed pipe from the
ǹ 0011 6-3
6-4 ǹ 0011
2 NS ENGINE LUBRICATION SYSTEM
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3.1 Inspection, oil section of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Inspection, coolant section of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
4.1 Removal and installation, lubricating oil filter/heat exchanger housing . . . . . 4-2 ...... 0011
4.2 Removal and installation, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
10
ǹ 0011 1
NS ENGINE LUBRICATION SYSTEM 2
10
2 ǹ 0011
properly extracted.
moving components.
required.
10
ǹ 0011 1-1
10
1-2 ǹ 0011
2. GENERAL
2.1 SYSTEM DESCRIPTION
10
M2 00 122
ǹ 0011 2-1
General
pump draws the oil from the oil pan and pumps
it via the lubricating oil heat exchanger and the
lubricating-oil filter to the main oil duct in the
cylinder block.
In the lubricating oil pump pipe to the lubricating
oil filter, there is a pressure-limiting valve. As the
output of the lubricating oil pump is dependent
on the engine speed, the output would become
so great at higher engine speeds that the
pressure in the lubrication system would
become too high. If the lubricating oil reaches
the set pressure of the pressure limiting valve
before the pressure limiting valve, part of the
lubricating oil will be returned directly to the oil
sump via the pressure limiting valve.
pressure-relief valve fitted in this filter opens if
Lubricating oil heat exchanger
The lubricating oil heat exchanger is connected
to the engine cooling system. The lubricating oil
heat exchanger warms up the lubricating oil in a
“cold” engine and cools it in a “warm” engine. If
the oil pressure in the heat exchanger becomes
too high, a short-circuit valve, fitted in the heat
exchanger, is opened which connects the
lubricating oil supply and discharge passages
with each other.
10
2-2 ǹ 0011
Main oil duct

From the main oil passage, lubricating oil is
supplied to the crankshaft main bearings and via
an oil passage in the crankshaft also to the
connection-rod bearings. From the main oil
passage, the oil goes via an oil passage and the
front camshaft bearing to the drilled camshaft.
From the oil passage in the camshaft, lubricating
oil is supplied to the camshaft bearings and
cams. From the camshaft an oil passage goes
to the drilled rocker shaft. The drilled rocker
shaft provides the rockers with oil. From the hole
in the top of the rocker, oil is sprayed on the
valve stem.
Timing gear
the intermediate gear wheel. The oil passes
through the hollow hub onto the intermediate
gear wheel. In the gear ring of the intermediate
gear wheel there are several bores through
which oil is applied to the teeth and runs off to
the other gear wheels. The oil running off
lubricates the other wheels of the timing gear.
Piston
The pistons and the small-end bearings are
lubricated by means of splash lubrication. From
the crankshaft connecting rod bearings, the oil
runs off against the cylinder liners and into the
piston head. At the top of the connecting rod is
an oil bore, through which the oil can reach the
upper connecting rod bearing. On the main oil
passage there are oil pipes connected to the
turbocharger, the fuel pump and the air
compressor. The oil discharge pipe from the
turbocharger is connected to a channel in the
cylinder block, from where the oil returns to the
oil sump. The oil returning from the fuel pump
and the air compressor runs from the front of the
fuel pump and the air compressor back to the
10
timing gear and from there to the oil sump.
ǹ 0011 2-3
10
2-4 ǹ 0011

3.1 INSPECTION, OIL SECTION OF THE HEAT EXCHANGER
1. Clean the heat exchanger element.

2. Fit the element to the pressure testing
adapter (A), special tool A
(DAF no. 0694889).
3. Connect an air pipe with reducing valve to
the air connection. Adjust the air pressure to
6 bar.
4. Immerse the element in a container of water
at a temperature of at least 50_C and check
for leaks.
M2 00 163
3.2 INSPECTION, COOLANT SECTION OF THE HEAT EXCHANGER
1. Clean the heat exchanger element.

2. Shut off one of the coolant connections of
the element.
3. On the other coolant connection, connect
an air pipe with a reducing valve. Adjust the
air pressure to 1.5 bar.
4. Immerse the heat exchanger in a container
of water at a temperature of at least 50_C
10
ǹ 0011 3-1
Note:
If there are problems with the lubricating oil
pressure, the lubricating oil pressure must
first be measured with a reliable pressure
gauge.
a pressure gauge (A), special tool A
(DAF no. 0535551).
lubricating oil pressure at the maximum
engine speed and at idling speed.
Compare the data with the readings
specified.
Note:
The oil pressure regulating valve, fitted in
5. Remove the pressure gauge and fit a new
sealing ring to the lubricating oil pressure
sensor before installing it. M2 00 191
10
3-2 ǹ 0011

Diagram of parts
1
2
5
3 6
7
8
4
11
9
12
10
13
14
15
16
M2 00 162
1.
2.
Sealing plug
Sealing ring
9.
10.
Adapter
10
3. Gasket 11. Sealing ring
4. Housing 12. Heat exchanger
5. Waved spring 13. Sealing ring
6. Bolt 14. Cover
7. Waved spring 15. O-ring
8. Bolt 16. Banjo bolt
ǹ 0011 4-1
4.1 REMOVAL AND INSTALLATION, LUBRICATING OIL FILTER/HEAT

EXCHANGER HOUSING
Removal, lubricating oil filter/heat exchanger

housing
1. Clean the housing and the surrounding
area.
3. Remove the coolant pipes from the heat
exchanger.
4. Depending on the reason why the housing
has to be removed, remove the oil filter
element.
5. Remove the attachment bolts and detach
the housing. Note that lubricating oil will
escape on detaching.
6. If necessary, replace the adapter with which
the oil filter is connected to the housing.
Apply Loctite 270 to the new adapter and
attach the new adapter.
7. Clean the sealing surfaces.
Installation, lubricating oil filter/heat
exchanger housing
1. Fit a new gasket to the housing and fit the
housing.
2. Check the rubber pipe connections and
replace as necessary.
necessary.
4. Apply a little grease to the moving section of
the pipe clamp and tighten the pipe clamps
10 securely.
filling the cooling system”.
6. Check the oil level, and top up as
necessary. Bring the engine to operating
temperature and check for leaks.
4-2 ǹ 0011
4.2 REMOVAL AND INSTALLATION, HEAT EXCHANGER
Removal, lubricating oil heat exchanger

1. Clean the heat exchanger housing and
surrounding area.
3. Remove the coolant pipes from the heat
exchanger.
4. Remove the banjo bolt on the bottom of the
heat exchanger and detach the heat
exchanger, cover and sealing rings from the
housing. Note that some more lubricating oil
will escape on detaching.
Installation, lubricating oil heat exchanger
1. Clean the element.
3. Apply Loctite 243 to the banjo bolt, fit new
sealing rings to the element and fit it to the
housing.
4. Turn the element so that the pipe
connections of the coolant pipes are in the
correct position.
5. Tighten the banjo bolt to the specified
torque.
10
ǹ 0011 4-3
Removal, oil sump

1. Clean the oil sump and the surrounding
area. 1
2. Drain the engine oil.
2
3. Remove the dipstick and dipstick holder. 3

4
4. Clean the Allen screws and remove them. 5
6. Remove the used gasket and clean the
sealing surfaces of both the oil sump and
the cylinder block thoroughly. 6
Installation, oil sump 7 M2 00 165
1. Check the sealing surfaces of both the oil

sump and cylinder block for damage. 1. Gasket
2. Oil pan
2. Check that the gasket between the timing 3. Plate
case and the cylinder block does not 4. Spacer
protrude at the bottom. As necessary 5. Allen screw
remove the protruding section. 6. Sealing ring
3. Apply a thin layer of transparent silicone 7. Sealing plug
mastic to the bottom of the gaskets between
the cylinder block/timing case and cylinder
block/flywheel housing (contact surfaces
with the oil sump gasket).
4. Fit a new gasket to the oil pan and fit the oil
pan.
5. Fit the attachment bolts and spacer plates
tightening them by hand. Avoid damaging
the gasket.
6. Tighten three bolts on both sides in the
middle of the oil sump. Work from the
middle to the front and rear.
10 7.
8.
Tighten the bolts to the specified torque.
Fit the dipstick holder and dipstick.
9. Fill the engine with the specified engine oil.
10. Check for leaks.
4-4 ǹ 0011


drained oil.

sump.
4. Fill the engine through the oil filler pipe on
the front of the cab with the specified
quantity of engine oil. See “Technical data”.
10
ǹ 0011 5-1
10
5-2 ǹ 0011
2 XE ENGINE
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.3 Overview drawing, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
2.5 Overview drawing, pump housing - camshaft drive . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 0011
3.1 Inspection and adjustment the valve mechanism bridges . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0011
3.6 Inspection, engine compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . . 0011
4.18 Removal and installation, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 . . . . . 0011
4.19 Removal and installation, up-speed bearing block . . . . . . . . . . . . . . . . . . . . . 4-29 . . . . . 0011
4.21 Removal and installation, vibration damper hub . . . . . . . . . . . . . . . . . . . . . . . 4-31 . . . . . 0011
4.24 Removal and installation, timing gear wheels . . . . . . . . . . . . . . . . . . . . . . . . .
4.25 Removal and installation, timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-34 . . . . .
4-37 . . . . .
0011
0011
11
ǹ 0011 1
XE ENGINE 2
Page Date
5.1 Disassembly and assembly, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.2 Disassembly and assembly, up-speed bearing block . . . . . . . . . . . . . . . . . . . 5-8 . . . . . . 0011
5.3 Disassembly and assembly, V-belt tensioning gear . . . . . . . . . . . . . . . . . . . . 5-10 . . . . . 0011
6. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
11
2 ǹ 0011
2 XE ENGINE
properly extracted.
moving components.
required.
11
ǹ 0011 1-1
XE ENGINE 2
11
1-2 ǹ 0011
2 XE ENGINE
2. GENERAL
9 5
8 11
10 6
7
12
M200902
Legend
2. Water pump
4. Fan drive
5. Vibration damper
6. Air compressor 11
7. Oil cooler
8. Turbocharger
9. Centrifugal filter
10. Oil-filler pipe
ǹ 0011 2-1
XE ENGINE 2
15 10 11 12 13 14
6 7 8
M200901
Legend
1. Steering pump
2. Pump housing
3. Oil filter
11
5. Reducer valve
6. Fuel lift pump
7. Primer pump
8. Starter motor
9. Alternator
10. Glow plugs
11. Electro-pneumatic valve
13. Coolant filter
14. Fuel filter
15. Inlet manifold
2-2 ǹ 0011
2 XE ENGINE
2.2 IDENTIFICATION
Engine number
at the rear left
D000311
XE engine identification plate 4 3 5 6

1. Injection timing* ENGINE
TYPE
2. Maximum governed engine speed E4
ENGINE
3. Engine number NUMBER
4. Engine type
GOVERNED SPEED min -1 OUTPUT kW
6. Certificate number* INJECTION TIMING BEFORE
T.D.C.
PUMPSETTING cm 3
7. Pump adjustment* SMOKE LEVEL FREE ACCELERATION m -1
8. Smoke level at maximum engine speed, no
load EINDHOVEN HOLLAND
* Not on XE engines
2 1 8 7
M200678
11
ǹ 0011 2-3
XE ENGINE 2
2.3 OVERVIEW DRAWING, FAN DRIVE
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
Legend
1. Fan drive shaft 7. Bearing ring
11
2. Oil seal 8. O-ring
3. Bearing 9. Bearing
4. Bearing ring 10. Circlip
5. Spacer sleeve 11. Bearing housing
6. Intermediate ring 12. Gear wheel
13. Circlip
2-4 ǹ 0011
2 XE ENGINE
2 4 5
7
1
6
3
8
9
M200886
Legend
4. Fan drive
6. Pump housing camshaft gear wheel
9. Oil pump
11
ǹ 0011 2-5
XE ENGINE 2
2.5 OVERVIEW DRAWING, PUMP HOUSING - CAMSHAFT DRIVE
6 1 2 7 3 5
M200887
Legend
3. Pump housing
5. Pump housing - camshaft
6. Attachment bolt, camshaft gear wheel
7. Camshaft bearing bush
11
2-6 ǹ 0011
2 XE ENGINE

3.1 INSPECTION AND ADJUSTMENT THE VALVE MECHANISM BRIDGES


position.
Note:
In engines with a DEB, the bridges of the inlet
and exhaust valves are not the same.
Exhaust bridge with DEB
i 400162
Exhaust bridge without DEB
11
i 400161
ǹ 0011 3-1
XE ENGINE 2

place it in a vice.
A
90° and carefully remove the bridge from
the valves. B
data”. i 400234

respectively.
14. Adjust the valve play and the DEB play if
necessary.
M200548
installation”.
11
3-2 ǹ 0011
2 XE ENGINE

dead centre.
Note:
If the engine is equipped with the
DEB, a flat ring spanner must be
used for loosening the locknut. This
is necessary to prevent damage to
the DEB spring plate.
M200724

M200539
11
ǹ 0011 3-3
XE ENGINE 2

(DAF no. 1310477), the valves can be
sequence 1-5-3-6-2-4.
Cylinder with valves Adjust valves of

in overlap position cylinder
1 6
5 2
3 4
6 1
2 5
4 3
5. If the engine has been fitted with a DEB, the M200540

DEB play must be checked following the
valve play adjustment.
installation”.
11
3-4 ǹ 0011
2 XE ENGINE
Inspection, timing
2. Position cylinder 1 at top dead centre (TDC
on the flywheel, cylinder 6 in overlap
position).
Note:
1 mm.
M200724

Example
Measured tension 4,65 mm
Valve opening 0,35 mm
Note:
11
M200551
ǹ 0011 3-5
XE ENGINE 2

position).
Note:
5. Rotate the camshaft gear wheel (2) to such
a position that the intermediate gear wheel
(3) can be installed in accordance with the
marks.
to the specified torque. See “Technical M200724
data”.
installation”.
installation”.
4
2 3
11 1
M200904
3-6 ǹ 0011
2 XE ENGINE

APBTLIB
EEUL
TI
N.2
00
.50
600
150

APBT
LIBEE
ULTII
N.5
‘Krikit I’ belt tension gauge for use with the 00

.100 150
0
200
‘Krikit II’ belt tension gauge for use with the 300

The difference between the
“Krikit I” and “Krikit II” belt tension gauges is that
the latter has a larger belt bearing surface. M2079

gauge.
1
measuring arm (1).
M2061

pulley.
bar move.
M2091
11
ǹ 0011 3-7
XE ENGINE 2

M2062

1. Loosen the upper attachment bolt (1) on the
1
compressor. 1
compressor.
cooling-water pump.
3
4. Shift the compressor using the locknuts (3)
2 M2041
Adjustment, V-belt tension of water pump 3 5 4

and alternator drive
alternator.
alternator.
3. Loosen the threaded rod attachment bolt 2
1
11
M200550
3-8 ǹ 0011
2 XE ENGINE
4. Turn locking nuts (4) and (5) of the threaded

spindle, so that the correct V-belt tension is 3 5 4
reached. See “Technical data”.
M200550
Adjustment, V-belt tension

Fan drive (Up-speed fan)
roller.
2. Using bolt (7), shift the tensioning roller so
that the correct V-belt tension is achieved.
7 6
D000388
11
ǹ 0011 3-9
XE ENGINE 2

flywheel housing to fit a dial gauge.
4. Place the dial gauge of the stylus at the M2 00 033
crank the engine through 360_, and
M200230
11
3-10 ǹ 0011
2 XE ENGINE



piston rings.
2. Remove the fuse or relay, so that the pump
units cannot be energised.
(DAF no. 1329306), compression gauge
(DAF no. 0694972) and adapter
(DAF no. 1329300).
injectors.
installation”.
10. Fit the fuse or relay. 11
ǹ 0011 3-11
XE ENGINE 2

the cylinder head.
Note: C
points:
abrasion (A) A B
insulator (see B)
11 B
M200818
3-12 ǹ 0011
2 XE ENGINE


gear.

fire.
Note:
for every vehicle.
terminal.
openings.
- Fit all attachment bolts, tightening them to
the correct tightening torque.
11
ǹ 0011 4-1
XE ENGINE 2

gear.

fire.

terminal.
3. Remove the coolant pipes (A) between the A
openings.
6. If fitted, loosen the air-conditioning
compressor so that it can be put aside with
the pipes (D).
housing.
B C D
attachment bolts at the front and/or rear of M201019
the engine.
11
4-2 ǹ 0011
2 XE ENGINE

data”.
2. Fit the viscous fan clutch and fan. Tighten
3. Fit the torque rod (B) between the radiator A
and the engine.
6. If present, fit the air-conditioning
compressor.
flywheel housing.
B C D
M201019
11
ǹ 0011 4-3
XE ENGINE 2

before opening it.

cover.
cover gasket.
gasket.
11
4-4 ǹ 0011
2 XE ENGINE
Removal, valve gear

Note:
same position.
M200559
Note:
In engines with a DEB, the bridges of the inlet
and exhaust valves are not the same.
3 2
4
and adjustment”.
Note:
rocker seats have to be positioned against
the pressure of the valve springs. The
rocker seat will resist this spring pressure
and cannot therefore be positioned
M200560
correctly.
By cranking the camshaft always 1/3 stroke
using the special tool (DAF no. 1310477),
the rocker seats can be tightened according
to the injection sequence 1-5-3-6-2-4.
11
ǹ 0011 4-5
XE ENGINE 2

respectively. For the tightening torques of
the attachment bolts. See “Technical data”.
6. Adjust the valve play and the DEB play if a
DEB is fitted. See “Inspection and
adjustment”.
M200548
11
4-6 ǹ 0011
2 XE ENGINE

before opening it.

terminal.
the cylinder heads.
4. Remove the inlet air pipes between the
and the radiator.
bracket if fitted.
manifold.
cylinder heads.
12. Remove the auxiliary heating pipes, if
applicable.
11
ǹ 0011 4-7
XE ENGINE 2
13. If fitted, remove the coolant filter.

14. Disconnect the fuel leak-off pipe between
the fuel filter and the fuel leak-off pipe on
the inlet manifold.
15. Disconnect the fuel filter assembly from the
coolant pipe.
thermostat housing.
cylinder heads.
block.
data”.
11 31. Check the cylinder head. See “Inspection

and adjustment”.
M2 00 100
4-8 ǹ 0011
2 XE ENGINE

be retightened.
head bolts.
Note:
gaskets and tighten the attachment bolts to M200561
Note:
used.
fitting.
ones.
11
ǹ 0011 4-9
XE ENGINE 2

bolts.
9. Fit the valve sleeve. Tighten the attachment
data”.
14. Fit the water pipe between the radiator and
pipe.
18. Fit the coolant filter on the coolant pipe, if
present.
heater.
20. Install the heat shields of the exhaust
manifold. Tighten the attachment bolts to
11
4-10 ǹ 0011
2 XE ENGINE

the radiator.
and intercooler. Tighten the attachment
data”.
11
ǹ 0011 4-11
XE ENGINE 2
Removal, glow plugs

terminal.
1. Tighten the glow plugs to the specified
M200949
the correct place.
11
4-12 ǹ 0011
2 XE ENGINE

terminal.
2. Mark the connectors and remove the
electrical wiring from the inlet manifold.
3. If present, remove the coolant filter element.
4. Remove the inlet manifold fuel leak-off pipe.
data”.
3. Fit the air inlet pipe between the intercooler
and the inlet manifold.
4. Connect the fuel leak-off pipe to the inlet
manifold.
7. If present, fit the coolant filter element.
8. Fit the electric wiring to the inlet manifold
and the water pipe.
terminal.
11
ǹ 0011 4-13
XE ENGINE 2

1. Remove the heat shields (1) from the 4 5
turbocharger.
1
2. Remove the air inlet pipe (2).
3. Remove the butterfly valve (3).
2
4. Remove the air inlet pipe (4) between the
5. Remove the compressor pipe (5).
3
manifold.
7. Remove the oil supply and oil discharge M200565
11
4-14 ǹ 0011
2 XE ENGINE

2. Install the heat shields of the exhaust
manifold. Tighten the attachment bolts to
5. Fit the compressor pipe (5).
6. Connect the inlet air pipe (4) between the
7. Fit the butterfly valve (3).
8. Fit the heat shields (1) of the turbochargers
9. Install the flexible air inlet pipe (2) and
tighten the attachment bolts to the specified
tightening torque. See “Technical data”.
for leaks.
11
ǹ 0011 4-15
XE ENGINE 2

1. Partially drain the coolant.
2. Remove the coolant connections (1). 2 3
4. Disconnect the lubricating oil pipe.
1
dryer.
6. Remove the attachment bracket at the rear
of the compressor.
timing gear cover.
compressor housing.
case.
3. Fit the attachment bracket at the rear of the
4. Fit the service pipe.
6. Fit the air pipes (2 and 3).
R600246
11
4-16 ǹ 0011
2 XE ENGINE

surrounding area.
system.
11
ǹ 0011 4-17
XE ENGINE 2

terminals.
starter motor.
motor.
motor. M200568

terminals.
11
4-18 ǹ 0011
2 XE ENGINE
Removal, alternator
terminals.
alternator.
threaded spindle which is attached to the 5 4
coolant pump. 2
4. Slacken the locknut (5). 3
5. Remove the upper attachment bolts (2) of
the alternator.
6. Remove the lower attachment bolt (1) of the
alternator.
7. Remove the alternator.
1
2. Fit the lower attachment bolt (1) of the
alternator. M200937
3. Fit the upper attachment bolts (2) of the

alternator.
4. Install the V-belts and check the V-belt
alternator.
terminals.
11
ǹ 0011 4-19
XE ENGINE 2
Removal, V-belt of water pump and alternator

drive 5 4
1. Loosen the lower attachment bolt (1) of the 2
alternator.
3
alternator.
4. Turn the locknuts (4) and (5) on the
threaded spindle so that the alternator can
be tilted towards the engine block and the
V-belt can be removed. 1
5. Remove the V-belt through the opening at
the guide ring (see arrow in drawing). Hang M200738
the V-belt over a fan blade. Rotate the fan
blade by blade, hanging the V-belt over
them. Repeat this for the entire fan, after
which the belt can be removed.
Note:
On versions on which the fan ring is
mounted on the engine block, the fan or the
fan ring must be disconnected before the
V-belt is removed, depending on the
alternator drive
grease deposits.
M200558
2. Fit the V-belt through the opening at the
guide ring (see arrow in drawing) and adjust
the V-belt tension, see “Inspection and
adjustment”.
3. If removed, fit the filter again.
11
4-20 ǹ 0011
2 XE ENGINE

V-belt
1. Loosen the upper attachment bolt (1) on the
1
compressor. 1
compressor.
cooling-water pump.
3
4. Turn the locknuts (3) on the threaded
spindle so that the alternator can be tilted
towards the engine block and the V-belt can
be removed.
2 M2041

drive V-belt
grease deposits.
2. Fit the V-belt for the air-conditioning drive
and adjust the V-belt tension. See
Removal, V-belt fan drive (up-speed version)
1. Remove the fan from the flange by
slackening the attachment nuts.
2. Place the fan on top in the air jacket. Take
care that the cooler does not get damaged!
roller.
4. Turn nut (7) to move the tension pulley until
the V-belt tension(s) can be removed.
Installation, V-belt fan drive (up-speed
version) 7
1. Inspect the pulleys for damage, rust and 6
grease deposits. If necessary, clean them
thoroughly.
2. Fit the new V-belt to the pulleys. See
“Inspection and adjustment”. D000388
11
3. Install the fan and tighten the attachment
nuts.
ǹ 0011 4-21
XE ENGINE 2
Removal, flywheel
the clutch plate.
flywheel.
M200569

flywheel.
M200570
assembly.
6. Fit the gearbox.
11
4-22 ǹ 0011
2 XE ENGINE

sharp chisel.
de-greased.
flywheel.
M2 00 035
11
ǹ 0011 4-23
XE ENGINE 2
Note:
flywheel housing.
Note:
flange.
4. Fit a new dry oil seal (the felt ring must not
get greasy) over the plastic mounting ring
supplied (1).
5. Fit the supplied plastic mounting ring (1)
with the oil seal on the crankshaft flange. A
and gradually tighten the nut (C) until the
resistance increases. B C
7. Remove the thrust washer (B) and take out M2 00 036
the plastic mounting ring (1).
seal is properly positioned.
11 10. Fit the flywheel.
4-24 ǹ 0011
2 XE ENGINE

housing.
4. Remove the crankshaft position sensor.
housing.
flywheel housing.
from the housing.
contact areas.
11
ǹ 0011 4-25
XE ENGINE 2

face.
6. Fit the flywheel housing. Tighten the
11. Fit the crankshaft position sensor.
13. Fit the oil sump attachment bolts. Tighten all
11
4-26 ǹ 0011
2 XE ENGINE
4.18 REMOVAL AND INSTALLATION, FAN DRIVE
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
11
ǹ 0011 4-27
XE ENGINE 2
Removal, fan drive

2. Remove the V-belts of the water pump,
alternator and fan drive.
drive.
4. Remove the fan drive.
Installation, fan drive
1. Install a new O-ring (8), lightly greased, in
the groove of the bearing housing (11).
2. Apply engine oil to the bearings in the
bearing housing.
3. Fit the fan drive in the timing gear case and
tighten the attachment nuts to the specified
4. Fit the V-belts of the water pump, alternator
and fan drive. Adjust the V-belts. See
“Checking and Adjusting”.
11
4-28 ǹ 0011
2 XE ENGINE
4.19 REMOVAL AND INSTALLATION, UP-SPEED BEARING BLOCK
Removal, Up-speed bearing block

2. Remove the fan drive V-belt.
3. Remove the attachment bolts (5) of the
up-speed bearing block/vibration damper
from the flange in the bearing block through
the openings in the up-speed pulley. 6
7
Installation, Up-speed bearing block 4
1. Fit the up-speed bearing block. Tighten the
attachment bolts to the specified torque. 10
9 11 12 13 5 2 3 1 14
M200947
11
ǹ 0011 4-29
XE ENGINE 2
Version with direct fan drive

alternator drive.
3. Remove the attachment bolts (7) of the fan 4
flange/vibration damper. 1
4. Remove the vibration damper (4). 2
3
1. Check the vibration damper for external 5
damage and silicone liquid leaks. In the 6
2. Fit the vibration damper (4) and the fan
flange (5). Tighten the attachment bolts (7)
data”.
3. Fit the new V-belt and adjust the V-belt M200946
11
4-30 ǹ 0011
2 XE ENGINE
Version with Up-speed fan drive

1. Remove the Up-speed bearing block.
2. Remove the vibration damper (4).
damper should be replaced. 7
2. Fit the vibration damper (4) and the
up-speed bearing block. Tighten the 4
attachment bolts (5) to the specified torque.
8
9 11 12 13 5 2 3 1 14
M200947
4.21 REMOVAL AND INSTALLATION, VIBRATION DAMPER HUB
Removal, vibration damper hub

vibration damper hub, and remove the
thrust piece.
3. Remove the vibration damper hub using the
special tool (DAF no. 1310422).
Installation, vibration damper hub
1. Fit the vibration damper hub onto the
crankshaft.
2. Fit the thrust piece. Tighten the attachment
data”. 11
M200770
ǹ 0011 4-31
XE ENGINE 2

2. Remove the timing cover seal by drilling two
holes in the seal and using special tools
(DAF no. 0484899 and DAF no. 0694928)
to pull the seal from the timing cover.
can lead to a leak.
Note:
install the dry sealing ring and the thrust
piece in the recess of the timing gear cover.
M200771
11
4-32 ǹ 0011
2 XE ENGINE

before opening it.

locating holes.
the new gasket.
3. Fit the attachment bolts and studs and
attachment bolts.
5. Fit a new O-ring to the oil filler pipe and fit
the oil filler pipe.
11
ǹ 0011 4-33
XE ENGINE 2

position).
Note:
wheel.
M200724
Removal, intermediate gear wheel

1. Remove the attachment bolt (10) with the
2 4 5 15
axial thrust washer (11).
14
camshaft gear wheel (2).
3. Remove the camshaft gear wheel using a 7
Removal, pump housing - camshaft gear 12
wheel 6
13
11
gear wheel (6) of the pump housing - 1 3
camshaft. 8 11
2. Remove the intermediate gear wheel. 9 10
3. Remove the gear wheel using a M200954
4-34 ǹ 0011
2 XE ENGINE

position).
M200724

4
2 3
1 11
M200904
ǹ 0011 4-35
XE ENGINE 2
2. Fit the attachment bolt (10) bolt with the

axial thrust washer (11) of the intermediate 2 4 5 15
gear wheel (3). Tighten the attachment bolt
to the specified torque. See “Technical 14
data”.
play.
1. Fit the gear wheel (2) onto the camshaft.
2. Install the intermediate gear wheel (3). 7
3. Fit the attachment bolt (12) bolt with the
thrust washer (13) of the intermediate gear 12
wheel (2). Tighten the attachment bolt (12) 6
to the specified torque. See “Technical 13 3
data”. 1
8 11
play. 9 10
Installation, pump housing gear wheel M200954
1. Fit the pump housing - camshaft gear wheel

(6) to the shaft journal.
3. Fit the pump housing - camshaft gear wheel
(6) attachment bolt (14). Tighten the
play.
11
4-36 ǹ 0011
2 XE ENGINE

case.
locating holes.
M200579
sump.
4. Fit a new O-ring on the air compressor.
5. Fit the timing gear case.
6. Fit the attachment bolts for the timing gear
case. Tighten the attachment bolts to the
11
ǹ 0011 4-37
XE ENGINE 2
8. Remove the locking plate and the

attachment bolts from the camshaft. Tighten
10. Fit the air compressor.

position).
2. Remove the pump housing - camshaft 6 1 2 7 3 5
wheel (1).
2. Fit the pump housing - camshaft gear
wheel.
4
M200887
11
4-38 ǹ 0011
2 XE ENGINE

5.1 DISASSEMBLY AND ASSEMBLY, FAN DRIVE
The fan drive should be

disassembled and assembled in a
very accurate fashion. Inaccurate
assembly of the fan drive may
cause strange noises in the engine
or severe engine damage.
Disassembly, fan drive

1. Remove the circlip (13) on the gear wheel
(12) side.
11
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
ǹ 0011 5-1
XE ENGINE 2
Note:
A mark may have been made on the rear of
the shaft (1) during initial assembly. This
mark may be used to inspect whether the
gear wheel (12) has turned in relation to the
shaft (1). If this is the case, the shaft (1)
and/or the gear wheel (12) is/are rejected.
M200688
2. Fit the special tool (DAF no. 1329445)

under the gear wheel (12) and press the
shaft out of the gear wheel (12).
the shaft (1) until the bearing (9) is released
from the shaft (1).
4. Remove the shaft (1) from the bearing
housing (11) and remove the spacer
sleeve (5).
5. Remove the bearing (3) from the shaft (1).
6. Remove the oil seal (2) from the bearing
housing (11). M200932
7. Remove the circlip (10) from the bearing

housing (11).
the bearing rings (4) and (7), with
intermediate ring (6), jointly out of the
bearing housing (11).
11
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
5-2 ǹ 0011
2 XE ENGINE
Assembly, fan drive

Note:
The bearings (3 and 9), with spacer sleeve (5)
and intermediate ring (6), go together and must
be replaced as a set. This is necessary to
obtain a proper bearing play.
Parts must be free of dirt and grease.
3 5 6 9
M200679
1. Using the special tool (DAF no. 1329386),

press the bearing (3) with spacer sleeve (5)
over the shaft (1).
3
11
1
M200680
ǹ 0011 5-3
XE ENGINE 2
Note:
The holes in the intermediate ring should be
on the oil seal side.
2. Fit the intermediate ring (6) in the bearing
housing (11).
11
housing (11) until it abuts the intermediate 7
ring (6).
6
M200681
4. Turn the bearing housing (11) and support

the bearing ring (7), using the special tool
(DAF no. 1329383).
housing (11) until it abuts the intermediate
ring (6).
11
M200682
11
5-4 ǹ 0011
2 XE ENGINE
6. Use the special tool (DAF no. 1329385)) to

press the sealing ring (2) into the bearing
housing (11) until it is level with the front of
11
M200683
7. Lightly oil the bearing face of the oil seal on

the shaft (1) and carefully fit the shaft (1) in
11
M200684 11
ǹ 0011 5-5
XE ENGINE 2
Note:
When forcing on the bearing (9), rotate the
bearing housing (11) at least 5 times, so
that the bearings can settle.
8. Using a low pressing force and the special
tool (DAF no. 1329382) press the bearing
(9) onto the shaft (1) until it abuts.
11
M200685
9. Fit the circlip (10) in the bearing housing

(11). Fit a new O-ring (8).
10
8
11
M200686
5-6 ǹ 0011
2 XE ENGINE
10. Remove any grease and oil from the 13

shaft (1) and gear wheel (12) local to the
contact areas.
Note: 12
The gear wheel (12) must not under any
circumstances be exposed to the specified
maximum temperature for more than
30 minutes. Exposure lasting longer than
30 minutes has a detrimental effect on the
mechanical properties of the gear
wheel (12).
11. Heat the gear wheel (12) evenly to the
specified temperature in the shortest
possible time (on a hot plate using thermal
pins). See “Technical data”.
12. Fit the gear wheel (12) onto the shaft (1).
Do this without using pressure.
13. Fit the circlip (13).
14. Make a mark over the shaft (1) and gear
wheel (12). This is for the purpose of being M200687
able to inspect during subsequent
inspections or repairs whether the gear
wheel (12) has turned in relation to the
shaft (1).
Inspection:
Fit special tool (DAF no. 1329445) under
the gear wheel (12) and press on the shaft
with a force of 100 kN. When the shaft has
been pressed out, the shaft and gear wheel
will be rejected.
M200688
15. Apply a little engine oil in the bearing

housing (11) and inspect the shaft (1) for
even rotation.
11
M200932
ǹ 0011 5-7
XE ENGINE 2
5.2 DISASSEMBLY AND ASSEMBLY, UP-SPEED BEARING BLOCK
1 2 3 5 7 4 6
M200803
Disassembly, Up-speed bearing block

1. Remove the central bolt (1) from the
bearing block.
2. Take the Up-speed pulley (5) from the hub
(if necessary use a standard puller).
3. Remove the bearings (3 and 4) from the
Up-speed pulley (5).
4. If necessary remove the circlip (7) from the
Up-speed pulley (5).
11
5-8 ǹ 0011
2 XE ENGINE
A 3 7 5 3 B
M200804
Assembly, Up-speed bearing block

1. Clean the Up-speed pulley (5).
2. Fit the circlip (7) in the Up-speed pulley (5)
(if removed).
3. With a low force press the rear bearing
into the Up-speed pulley using special tool
(B) (DAF no. 1329436).
4. With a low force press the front bearing
into the Up-speed pulley using special tool
(A) (DAF no. 1329437).
5.
6.
Fit the Up-speed pulley on the hub.
Fit the circlip and central bolt and place the
11
bearing block assembly on the vibration
damper.
7. Tighten the bolt to the specified torque. See
ǹ 0011 5-9
XE ENGINE 2
5.3 DISASSEMBLY AND ASSEMBLY, V-BELT TENSIONING GEAR
Disassembly, V-belt tensioning gear

1. Remove the nut from the tensioning roller.
2. Remove the circlip.
3. Remove the Up-speed pulley.
4. Remove the bearing from the hub.
Assembly, V-belt tensioning gear
1. Fit the circlip to the Up-speed pulley.
2. With a low force, press the bearing into the
Up-speed pulley.
3. Fit the Up-speed pulley on the hub.
4. Fit the nut.
11
5-10 ǹ 0011
2 XE ENGINE
6. CLEANING
Note:
stage.
will jam.
via the breathers.
11
ǹ 0011 6-1
XE ENGINE 2

- When cleaning UPEC engines with a high
pressure cleaner, do not aim directly at the
pump units. Water can penetrate the
protective covers through the bleed holes.
Faults in the pump unit electrical
connections can arise as a result of this.
11
6-2 ǹ 0011
2 XE ENGINE COOLING SYSTEM
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.2 Description, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0011
3. COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.1 Description, cooling system pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0011
3.2 Description, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0011
3.3 Description, coolant filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
4.1 Pressure-testing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.4 Inspection, water pump radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0011
5. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.1 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0011
5.2 Removal and installation, coolant filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 ...... 0011
5.3 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ...... 0011
12
ǹ 0011 1
XE ENGINE COOLING SYSTEM 2
12
2 ǹ 0011
properly extracted.
moving components.
required.
12
ǹ 0011 1-1
12
1-2 ǹ 0011
2. GENERAL
9 10
1
2
3
8
5 7
6
4
M201020 M201021
Legend
2. Water pump
3. Fan drive
5. Water pipe
6. Oil cooler
9. Coolant pipe
10. Coolant filter
12
ǹ 0011 2-1
2.2 DESCRIPTION, COOLING SYSTEM

thermostat, a coolant filter and pipes.
any air in the cooling system is discharged to
the header tank (1), so that the cooling system
is bled automatically.
the cylinder liners, and up towards the cylinder
heads. The coolant leaves cylinder heads
through the coolant collector pipe to the
thermostat housing.
return pipe.
12
2-2 ǹ 0011
a
b
a
b
12
M200905
ǹ 0011 2-3
The connection pipe to the header tank is also

connected to the return pipe from the radiator. If
the coolant heats up, the coolant flows to the
the water pump.
12
2-4 ǹ 0011
a
b
a
b
12
M200906
ǹ 0011 2-5
12
2-6 ǹ 0011
3.1 DESCRIPTION, COOLING SYSTEM PRESSURE CAP
The pressure cap on the header tank is

attached to the header tank via a screw thread.
To fill the cooling system, remove this pressure
cap or the filler cap at the front of the header
tank.
The pressure cap has two valves. Normally,
both valves are closed.
boiling.
Underpressure in the cooling system P1
12
ǹ 0011 3-1
3.2 DESCRIPTION, THERMOSTAT
Operation of the thermostat B

Thermostat closed
closed.
directly to the water pump and the pump once
The coolant has reached the opening A
opened and the by-pass passage (A) is partially B
closed.
an emergency solution. If the thermostat is
removed from the engine, uncooled coolant will
flow to the water pump via the by-pass passage A
(A). As a consequence, the coolant temperature
will continue to rise. B
12
A M200547
3-2 ǹ 0011
3.3 DESCRIPTION, COOLANT FILTER
The task of the coolant filter is to filter the

coolant to prevent cavitation. The coolant filter
also adds additives to the coolant.
M200546
12
ǹ 0011 3-3
12
3-4 ǹ 0011





means of a pressure-test pump.
When this is done with a warm engine, it is
easier to spot any cracks.
5. Note:
By fitting the pressure-test pump to the filler
opening of the header tank, the pressure
cap can also be tested.
Pressure-test the system to the specified
6. Check the cooling system for leaks. M2046
12
ǹ 0011 4-1

installation”.
closed.
A
C B
C B
A
M200594

with clean water.
the thermostat starts opening and whether
it is opened fully. See “Technical data”.
M200513
12
4-2 ǹ 0011


properly extracted.

components.

top up.
the fan speed at a number of engine
speeds (from idling to maximum engine
speed).
This test checks whether the contact operates
at an operating temperature of 85 - 95_C.
12
ǹ 0011 4-3

hole, as shown in the diagram opposite,
and place it in front of the radiator, so that
the hole is in front of the viscous coupling.
temperature.
900
of 1000 rpm.
Then use an optical rev counter to
determine the difference in speed of the fan 100
clutch. When the clutch is fully engaged,
430
the slip must not be more than 10%. If it is
more than 10%, the viscous fan clutch must
be replaced.
700
M200440
12
4-4 ǹ 0011
1. Remove the V-belts from the water pump

pulley.
illustration.
replaced.
M200595
12
ǹ 0011 4-5
12
4-6 ǹ 0011

Removal, water pump

and the radiator.
brackets and remove the guide ring.
5. Remove the attachment nuts of the viscous
fan clutch on the fan pulley and place the
viscous fan clutch with the fan as far
forward as possible in the wind tunnel.
6. Remove the V-belts of the alternator and
the air conditioning compressor.
connection piece.
9. Disconnect the pipe from the water pump to
the coolant filter.
10. Remove the attachment bolts holding the
spindles of the alternator and
water pump.
12. Disconnect the water pump.
12
ǹ 0011 5-1

5. Connect the pipe from the water pump to
the coolant filter.
water pump.
7. Fit the V-belts from the alternator and the
air conditioning compressor.
ring.
the engine.
filling”.
12
5-2 ǹ 0011
5.2 REMOVAL AND INSTALLATION, COOLANT FILTER



Removal, coolant filter

1. Place a tray beneath the filter.
3. Switch the shut-off valve (1) clockwise to
the “C” position. O C
4. Remove the coolant filter by turning it
anti-clockwise.
Installation, coolant filter
1. Clean the sealing face of the coolant filter. 1
2. Apply a small amount of coolant to the
sealing ring of the coolant filter element.
3. Fit the coolant filter until the sealing ring
abuts. Subsequently tighten the filter by
hand 1/2 to 3/4 of a turn.
M200372
4. Switch shut-off valve (1) counter-clockwise
to the “O” position.
5. Put the filler cap back on the header tank.
6. Run the engine and check that the coolant
filter has sealed correctly.
12
ǹ 0011 5-3
Removal, thermostat
thermostat housing.
5. Remove the O-ring (A) from the thermostat C B
housing.
6. Remove the thermostat. C B
A
internal puller.
M200594
12
5-4 ǹ 0011

1. Fit the thermostat seal (B) in the thermostat
housing using special tool
(DAF no. 1310456).
A
1. Fit the thermostat in the thermostat
C B
housing.
C B
A
thermostat housing.
pipe.
5. Fit the thermostat housing attachment bolts
See “Technical data”. M200594

filling”.
12
ǹ 0011 5-5

alternator drive.
alternator side.
guide ring brackets, and remove the guide
ring.
viscous fan clutch on the drive flange. Place
the viscous fan clutch with the fan in the
wind tunnel temporarily.
Note:
The fan clutch must always be stored
vertically.
1. Place the new viscous fan clutch in the fan.
2. Fit the guide ring and the attachment bolts
of the guide ring brackets.
pump drives.
12
5-6 ǹ 0011

header tank. M200585

header tank.
and the engine.
filling”.
12
ǹ 0011 5-7
Note:
Removal, radiator
terminal.
the cab.
intercooler.
condenser forwards.
intercooler.
12
5-8 ǹ 0011

intercooler.
pipe.
the chassis.
12
ǹ 0011 5-9
attachment nuts to the specified torque.
4. Install the torque rod from the radiator to
the engine bracket.
ring.
intercooler.
intercooler.
the intercooler.
13. Fit the air inlet pipes between the manifolds
and intercooler.
filling”.
12
5-10 ǹ 0011



the skin and eyes.

waste.


4. Drain the cooling system at the engine
block via drain tap (A) and the radiator via
drain plug (B).
6. Close drain tap (A) and install
drain plug (B).
A
B
M200556
12
ǹ 0011 6-1

Note:
coolant.
thermostat housing to the header tank is
not kinked or pinched off.
5. Check the coolant level, and if necessary
If the vehicle is equipped with a water/air
cab heater.
Note:
one minute.
12
6-2 ǹ 0011
2 XE ENGINE LUBRICATION SYSTEM
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
2.1 Description, lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3.2 Checking the lubricating-oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0011
3.3 Pressure testing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.1 Removal and installation, lubricating oil filter housing . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.3 Removal and installation, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 0011
4.5 Removal and installation, centrifugal lubricating oil filter . . . . . . . . . . . . . . . . 4-5 ...... 0011
5. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
5.1 Disassembly and assembly, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
6.1 Draining and filling, lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
13
ǹ 0011 1
XE ENGINE LUBRICATION SYSTEM 2
13
2 ǹ 0011
properly extracted.
moving components.
systems, battery acid and diesel lubricating oil.
So avoid inhaling and direct contact.
required.
13
ǹ 0011 1-1
13
1-2 ǹ 0011
2. GENERAL
2.1 DESCRIPTION, LUBRICATING OIL SYSTEM
13
M200907
ǹ 0011 2-1
General
pump draws the lubricating oil from the oil sump,
and pumps it via the oil cooler and the
lubricating oil filter to the main oil duct in the
cylinder block. From the main oil duct, the
lubricating-oil is further distributed to the various
components requiring lubrication.
Oil cooler
engine.
has built up. In this case, uncooled lubricating oil
A centrifugal filter may be included parallel to
the lubricating oil system. In this case,
lubricating-oil will flow from the oil cooler to the
centrifugal filter. The lubricating-oil is additionally
filtered in the centrifugal filter in view of vehicles
having longer maintenance intervals.
A pressure limiting valve is installed in the
lubricating system after the oil cooler. When the
pressure set for the pressure limiting valve has
been reached, the valve opens and allows
excess cooled lubricating oil to flow to the oil
sump.
The oil is cleaned in the disposable lubricating
oil filter. A pressure limiting valve fitted in this
filter opens if the pressure in the filter becomes
too high as a result of contamination or cold
lubricating oil.
The lubricating oil then passes through the filter
unfiltered.
Main lubricating oil duct
From the main lubricating oil duct, lubricating oil
is supplied to the crankshaft main bearings and
via a lubricating oil duct in the crankshaft also to
the connection-rod bearings.
From the main lubricating oil duct, lubricating oil
is pumped through the first camshaft bearing
into the hollow camshaft.
From the lubricating oil duct in the camshaft,
lubricating oil is supplied to the other camshaft
bearings.
13
2-2 ǹ 0011
Cylinder head
From the second and fifth camshaft bearings, a
lubricating oil duct passes through the cylinder
heads to the second and fifth rocker seats.
Depending on the model, the other rocker
shafts, rockers, and bridges receive lubrication
from the DEB or a lubricating-oil strip.
Timing gear
From the lubricating oil duct in the first
crankshaft main bearing, a lubricating oil duct
leads to the hollow hub of the intermediate gear
wheel. The lubricating oil passes through the
hollow hub onto the intermediate gear wheel.
The other gear wheels receive lubricating oil
from the intermediate gear wheel.
The fan drive is lubricated through a bore hole in
the cylinder block and a lubricating oil duct in the
timing gear case.
bearings are lubricated by means of lubricating
oil nozzles linked to the main lubricating oil duct.
In addition to lubricating, this oil has an
important cooling function. The pistons of the
XE390C are equipped for this purpose with
extra lubricating oil ducts to achieve better
cooling.
13
ǹ 0011 2-3

A lubricating oil duct from the camshaft bearing
connects the lubricating oil pipes to the
turbocharger and air compressor.
The lubricating oil discharge pipe from the
cylinder block, from where the lubricating oil
returns to the oil sump.
The lubricating oil returning from the air
compressor flows from the front of the air
compressor back to the timing gear, and from
there to the oil sump.
Pump housing
The pump housing obtains lubricating oil from
the cylinder block and discharges it through a
channel in the cylinder block, from where it
returns to the oil sump. The pump units are
provided with lubricating oil via a channel in the
pump housing.
M200908
13
2-4 ǹ 0011

Note:
A lubricating oil consumption test is only useful
after the engine has been run in (approx.
20,000 km).
1. First carefully check the engine for
lubricating oil leaks. Clean the engine
before starting the test.
4. Remove the lubricating oil drain plug and
drain the oil for 15 minutes. Collect the
lubricating oil in a clean container.
5. Measure the exact amount of lubricating oil
drained.
6. Refill the oil sump with the drained
lubricating oil. If necessary, top up the
amount of lubricating oil to the specified
level.
exact amount of lubricating oil (A) in the oil
drained (B).
12. Pour the lubricating oil into the oil sump. If
necessary, top up the amount of lubricating
oil to the specified level.
13. Calculate the lubricating oil consumption
using the following formula.
13
ǹ 0011 3-1
D -- C
Lubricating oil consumption = = km/l
A -- B
1300
1250
1200
km / L
1100
1000
1000
900
800
800
700
600
600 550
500
500 450
400
400 350
300
300 250
200
100
0
0 25 100 200 300 400 500 600 700 800 900 1000
x1000 km
M200557
In the graph the lubricating oil consumption in

km/l is marked out on the left and the total
number of kilometres covered by the engine at
the bottom.
If the lubricating oil consumption and the
number of kilometres covered intersect in the
shaded section, corrective measures may be
considered.
Bear in mind however, that the lubricating oil
consumption is very much dependent upon the
operating conditions.
13
3-2 ǹ 0011
3.2 CHECKING THE LUBRICATING-OIL PRESSURE

This sensor is mounted on the lubricating oil
filter housing.
a lubricating oil pressure gauge, special tool
(DAF no. 0535551).
speed and at idling speed. Compare the
pressure reading with the technical data.
Note:
5. Stop the engine and remove the lubricating
oil pressure gauge. Fit a new oil seal to the
M200889
oil pressure sensor.
13
ǹ 0011 3-3
3.3 PRESSURE TESTING THE OIL COOLER

installation”.
2. Disassemble the oil cooler. See
“Disassembly and assembly”.
3. Place the cooling element in special tools
(DAF no. 1329307 and DAF no. 0694889).
4. Apply up to 3 bar of pressurised air to the
special tool.
5. Immerse the cooling element in warm water
(approx. 50_C) and check it for leaks.
Note:
If the cooling element leaks, it must be
replaced.
6. Assemble the oil cooler. See “Disassembly
and assembly”.
installation”.
M200598
13
3-4 ǹ 0011


drained lubricating oil.
Removal, lubricating oil filter housing

1. Clean the filter housing and the surrounding 1
area.
2
3. Remove the filter element. Collect any
lubricating oil flowing out of the system.
housing and remove the filter housing (2).
Installation, lubricating oil filter housing 3
filter housing (2).
2. Fit the filter housing (2) and tighten the
data”. 4
7. Run the engine for a short time, and check
that the lubricating oil filter is correctly
sealed.
8. Check the lubricating oil level.
M200599
13
ǹ 0011 4-1
Removal, oil cooler

2. Disconnect the coolant connections.
4. If fitted, remove the lubricating oil delivery
pipe to the centrifugal filter.
5. Remove the attachment bolts and the oil
cooler. Collect the lubricating oil flowing out
of the system.
6. Remove the O-rings on the oil cooler.
1. Clean the contact surfaces between the oil
cooler and cylinder block and fit new
O-rings to the oil cooler housing.
2. Fit the oil cooler against the cylinder block
and tighten the attachment bolts to the
3. Connect the coolant connections.
4. Connect the compressor pipe.
5. If present, fit the lubricating oil delivery pipe
to the centrifugal filter.
13
4-2 ǹ 0011
Removal, oil sump

engine. 2
2. Drain the lubricating oil. See “Draining and
filling”.
1
rubber (2).
2 3
replaced.
oil sump.
4. Fit the oil sump (1) with the sealing
rubber (2) upright. M200601

lubricating oil.
Then check the lubricating oil level.
13
ǹ 0011 4-3

3
3. Remove the lubricating oil supply and 2
delivery pipe (1) from the lubricating oil
pump.
cover.
5. Remove the attachment bolt (3). 1
main bearing cover.
Installation, lubricating oil pump M200600
data”.
3. Fit the lubricating oil supply and delivery
pipes (1), fitted with new O-rings.
4. Fit the oil strainer.
13
4-4 ǹ 0011
4.5 REMOVAL AND INSTALLATION, CENTRIFUGAL LUBRICATING OIL FILTER

Removal and installation, centrifugal 4

lubricating oil filter
1. Clean the housing (3).
2. Loosen the central bolt (4). 3
3. Remove the housing (3) simultaneously
with the central bolt (4) and the rotor (2). 2
4. Remove the rotor (2) from the central
bolt (4).
5. Replace the rotor (2).
Installation, centrifugal lubricating oil filter 5
rotor
1. Clean the housing (3). 1
2. Check the central bolt (4) for damage.
3. Replace the seal (5).
4. Fit the new rotor into the housing.
5. Lightly grease the oil seal (5) and fit it in the
housing (3).
6. Tighten the central bolt (4) to the specified
7. Start the engine and check for leaks. Check
the lubricating oil level.
M200526
13
ǹ 0011 4-5
13
4-6 ǹ 0011


oil pump.
damage.
Note:
Note:
shown.
pump housing.
oil pump.
M200344
data”.
on the front plate.
13
ǹ 0011 5-1
13
5-2 ǹ 0011

6.1 DRAINING AND FILLING, LUBRICATING OIL


2. Drain the lubricating oil using the drain plug
in the oil sump.
4. Fill the engine through oil-filler pipe (D) with D
the specified lubricating oil quantity. See
D000268
13
ǹ 0011 6-1
13
6-2 ǹ 0011
2 PE ENGINE
CONTENTS
Page Date
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0011
2.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0011
2.3 Overview drawing of timing-gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0011
3.1 Inspection and adjustment the valve mechanism bridges . . . . . . . . . . . . . . . 3-1 . . . . . . 0011
3.3 Inspection and adjustment the timing-gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . . 0011
3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . . 0011
3.6 Inspection, engine compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . . 0011
4.21 Removal and installation, timing gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 . . . . . 0011
4.24 Removal and installation, vibration damper bearing race . . . . . . . . . . . . . . . . 4-38 . . . . . 0011
5. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0011
14
ǹ 0011 1
PE ENGINE 2
14
2 ǹ 0011
2 PE ENGINE
properly extracted.
moving components.
14
ǹ 0011 1-1
PE ENGINE 2
14
1-2 ǹ 0011
2 PE ENGINE
2. GENERAL
1 2 3 4 5 6
7 8 9 10
m200837
Legend
1. Centrifugal filter
2. Turbocharger
3. Oil-filler pipe
5. Water pump
7. Oil cooler
8. Air compressor
9. Tensioning roller, air-conditioning
14
compressor
ǹ 0011 2-1
PE ENGINE 2
1 2 3 4 5 6 7
8 9 10 11 13 12
m200838
Legend
1. Alternator
2. Glow plugs
3. Steering pump
5. Primer pump with fuel coarse filter
6. Fuel filter
7. Engine PTO
10. Oil filter
11. Pump housing
12. Starter motor
13. Fuel lift pump
14
2-2 ǹ 0011
2 PE ENGINE
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 1 2 4 3 5

1. Injection timing ENGINE
TYPE
E4
2. Maximum governed engine speed ENGINE
NUMBER
3. Engine number GOVERNED SPEED min -1 OUTPUT kW
4. Engine type INJECTION TIMING O

BEFORE
T.D.C.
PUMPSETTING cm 3
5. Indication of country of origin SMOKE LEVEL FREE ACCELERATION m -1
6. Certificate number EINDHOVEN HOLLAND
7. Pump setting (output)

8. Smoke level at maximum engine speed,
no load
m200839
14
ǹ 0011 2-3
PE ENGINE 2
2.3 OVERVIEW DRAWING OF TIMING-GEAR
Legend 6 2 4
7 1 3 5
M200744
14
2-4 ǹ 0011
2 PE ENGINE

3.1 INSPECTION AND ADJUSTMENT THE VALVE MECHANISM BRIDGES


2. Undo the adjusting nuts of the valve rockers
in such a manner that there is no longer
tension on the rockers.
position.
place it in a vice.
now touches the valve). A
the valves.
B
data”.
i 400301
14
ǹ 0011 3-1
PE ENGINE 2

or cylinder 4 respectively.
installation”.
M200754
14
3-2 ǹ 0011
2 PE ENGINE

dead centre.
Note:
(DAF no. 1310477), the valves can be
M200724
sequence 1-5-3-6-2-4.
Cylinder in Cylinder to be
overlap position adjusted
1 6
5 2
3 4
6 1
2 5
4 3

installation”.
M200732
14
ǹ 0011 3-3
PE ENGINE 2
3.3 INSPECTION AND ADJUSTMENT THE TIMING-GEAR
Inspection, timing
position).
Note:
1 mm.
5. Use the special tool (DAF No. 1310477) to
Example
Pre-tension, dial gauge 5.00 mm
Measured tension 4.65 mm
Valve opening 0.35 mm
Note:
M200551
14
3-4 ǹ 0011
2 PE ENGINE

position).
Note:
5. Rotate the camshaft gear wheel (2) to
such a position that the intermediate gear
wheel (3) can be installed in accordance
with the marks.
data”. 3
2
installation”. 1
installation”.
M200884
14
ǹ 0011 3-5
PE ENGINE 2

APBTLIB
EEUL
TI
N.2
00
.50
600
150

APBT
LIBEE
ULTII
N.5
“Krikit I” belt tension gauge for use with the 00

.100 150
0
200
“Krikit II” belt tension gauge for use with the 300

The difference between the “Krikit I” belt tension
gauge and the “Krikit II” belt tension gauge is
that the latter has a larger belt bearing surface. M2079

gauge. 1
measuring arm (1).
pulley.
bar move. M2061
M2092
14
3-6 ǹ 0011
2 PE ENGINE

M2062

roller.
2. Rotate the adjusting screw (2), until the
correct V-belt tension is achieved. See
3. Tighten the central bolt (1).
M200885
Adjustment, V-belt tension of water pump

and alternator drive 6 5
alternator.
4
2. Loosen the upper attachment bolt (2) of the 3

2
alternator.
3. Loosen the threaded rod attachment
bolt (3), which is fixed to the water pump.
4. Loosen the locknut (4) of the threaded rod.
5. Loosen bolt (6) of the coupling.
6. Shift the compressor using the locknut (5)
M200753
14
ǹ 0011 3-7
PE ENGINE 2

flywheel housing to install a measuring
gauge with a magnetic foot piece.
M2 00 033
4. Place the dial gauge of the stylus at the
6. Use the special tool (DAF No. 1310477) to
crank the engine through 360_, and
M200230
14
3-8 ǹ 0011
2 PE ENGINE



piston rings.
2. Remove the fuse or relay, so that the pump
units cannot be energised.
(DAF No. 1329306), compression
gauge (DAF No. 0694972) and adapter
(DAF No. 1329300).
injectors.
installation”.
10. Fit the fuse or relay.
14
ǹ 0011 3-9
PE ENGINE 2

the cylinder head.
14
3-10 ǹ 0011
2 PE ENGINE
Note: C
points:
abrasion (A) A B
insulator (see B)
M200818
14
ǹ 0011 3-11
PE ENGINE 2
14
3-12 ǹ 0011
2 PE ENGINE


gear.

fire.
Note:
specifications, it is not feasible to exactly
specify the engine removal and installation
procedures for every vehicle.
terminal.
openings.
tightening torque.
14
ǹ 0011 4-1
PE ENGINE 2

gear.

fire.

terminal.
3. Remove the flexible coolant pipes (A)
between the engine, the radiator and the A
header tank.
openings.
7. Disconnect the rubber pipe (E) from the oil
filler pipe.
viscous fan clutch.
9. Remove the wind tunnel collar.
10. Remove the viscous fan clutch together with
the fan. D B C E
M200840
housing.
attachment bolts at the front and/or rear of
the engine.
14
4-2 ǹ 0011
2 PE ENGINE

data”.
2. Place the viscous fan clutch together with
the fan between the radiator and engine.
clutch.
5. Fit the torque rod (B) between the engine
and the radiator. A
6. Install the air inlet pipes (C) between the
engine and the intercooler. Tighten the
8. Fit the flexible rubber pipe (E) of the oil filler
pipe.
flywheel housing.
D B C E
M200840
14
ǹ 0011 4-3
PE ENGINE 2

before opening it.

cover.
cover gasket.
2. Check the valve cover gasket and fit the
valve cover.
14
4-4 ǹ 0011
2 PE ENGINE
Removal, valve gear

Note:
same position.
M200559

and adjustment”.
3 2
Note:
rocker seats (1) have to be positioned
against the pressure of the valve springs.
4
The rocker seat will resist this spring
pressure and cannot therefore be
positioned correctly.
(DAF no. 1310477), the rocker seats can
be tightened according to the injection
sequence 1-5-3-6-2-4.
4. Tighten the attachment bolts to the M200560
or cylinder 4 respectively. For the tightening
torques of the attachment bolts. See
6. Adjust the valve clearance. See “Inspection
and adjustment”.
M200754
14
ǹ 0011 4-5
PE ENGINE 2

before opening it.

terminal.
the cylinder heads.
4. Remove the dip stick holder.
5. Remove the flexible air pipes between the
and the radiator.
bracket if fitted.
manifold.
cylinder heads.
the cab heater.
14
4-6 ǹ 0011
2 PE ENGINE

manifold.
15. Remove the entire fuel filter from the inlet
manifold.
17. Remove the flexible water pipes between
the thermostat housing and the radiator.
thermostat housing.
cylinder heads.
block.
data”.
and adjustment”.
M2 00 100
14
ǹ 0011 4-7
PE ENGINE 2

be retightened.
head bolts.
Note:
gaskets and tighten the attachment bolts to M200561
Note:
used.
fitting.
ones.
14
4-8 ǹ 0011
2 PE ENGINE

bolts.
14. Fit the water pipes between radiator and
thermostat housing.
pipe.
18. Tighten the dipstick holder.
heater.
14
ǹ 0011 4-9
PE ENGINE 2

the engine.
26. Fit the flexible air inlet pipes between the
engine and intercooler. Tighten the
14
4-10 ǹ 0011
2 PE ENGINE
Note:
If the vehicle has been fitted with two glow +
filaments upon ex-works delivery, you must not
add two glow filaments yourself. The feeder
cable between the starter motor, glow relay and
glow plugs on these vehicles is inadequate for
four glow plugs.
Removal, glow plugs
terminal.
M2 00 154
1. Fit the glow plugs and tighten the
attachment nut to the specified torque. See
the correct place.
14
ǹ 0011 4-11
PE ENGINE 2

terminal.
2. Remove the wiring from the glow filaments
manifold.
M200963
inlet manifold.
data”.
6. Fit the wiring from the glow filaments and
the temperature sensor.
terminal.
14
4-12 ǹ 0011
2 PE ENGINE

1. Remove the inlet air pipe between the
3. Remove the heat shields from the
turbocharger.
4. Remove the air inlet pipe.
5. Remove the butterfly valve.
manifold.
7. Remove the oil supply and oil discharge
14
ǹ 0011 4-13
PE ENGINE 2

5. Fit the compressor pipe.
6. Fit the inlet air pipe between the
M200964
7. Fit the butterfly valve.

8. Fit the attachment bolts of the turbocharger
10. Fit the rear engine sound proofing.
for leaks.
14
4-14 ǹ 0011
2 PE ENGINE

2
2. Remove the oil filler pipe (5).
1
dryer (8).
3
6. Disconnect the lubricating oil pipe (4).
4
7. Remove the mounting bracket at the back
of the compressor (7). 7
timing gear cover.
8
Note:
air-conditioning, the air-conditioning
compressor V-belt must be disconnected to
enable removal of the tension pulley. M200763

compressor housing.
case.
Note:
air-conditioning, the tensioning roller of the
air-conditioning compressor must be fitted
and the V-belt tension must be adjusted.
14
ǹ 0011 4-15
PE ENGINE 2
3. Fit the mounting bracket (7) at the back of

the compressor. Tighten the attachment
bolts to the specified torque. See
4. Fit the service pipe (8).
6. Fit the air pipes (2) and (3).
14
4-16 ǹ 0011
2 PE ENGINE

surrounding area.
system.
14
ǹ 0011 4-17
PE ENGINE 2

terminals.
starter motor.
motor.
motor.
terminals.
14
4-18 ǹ 0011
2 PE ENGINE
Removal, alternator 5
1. Remove both battery leads from the battery 6
terminals. 4
2. Remove the electrical connections from the 3
alternator. 2
coolant pump.
bolts (1) and (2).
5. Loosen the locknut (4) and bolt (6) of the
coupling.
6. Shift the alternator by means of the nut (5) 1
in the direction of the cylinder block and
M200753
slacken the V-belt.
7. Remove the attachment bolts (1) and (2)
and remove the alternator.
2. Fit the alternator attachment bolts (1) and
(2).
4. Tighten the attachment bolt (3) of the
coolant pump.
alternator.
terminals.
14
ǹ 0011 4-19
PE ENGINE 2
Removal, V-belt of water pump and alternator 5

drive 6
1. Slacken the locknut (4) and attachment 4
bolt (3) of the threaded spindle.
3
2. Loosen bolt (6) of the coupling. 2
bolts (1) and (2).
4. Shift the alternator by means of the nut (5)
in the direction of the cylinder block in such
a way that the V-belt can be released.
1
M200753
5. Remove the retention screw above the wind

tunnel collar (7) and turn the wind tunnel
collar anti-clockwise to unlock and lay the 7
wind tunnel collar on the water pump pulley.
6. Remove the V-belt through the arising
opening between the wind tunnel and fan.
Note:
On versions with a metal guide ring, the fan
or guide ring must be detached before
removal of the V-belt depending on the
alternator drive M2101

grease deposits.
2. Fit the new V-belt through the opening
between the wind tunnel and the fan ring,
and place the V-belt on the pulleys.
3. Fit the wind tunnel collar (7) and check
whether this is installed properly all round in
its lock. Fit the locking screw.
and adjustment”.
M2096
14
4-20 ǹ 0011
2 PE ENGINE
Removal, V-belt air-conditioning compressor

drive
1. Slacken the central tensioning gear bolt (1).
2. Turn the tension bolt (2), until the V-belt can
be removed.
Installation, V-belt air-conditioning
compressor drive
grease deposits.
2. Fit the new V-belt and adjust the V-belt
M200885
14
ǹ 0011 4-21
PE ENGINE 2
Removal, flywheel
the clutch plate.
flywheel.
1
M200569
flywheel.
assembly.
6. Fit the gearbox.
M200570
14
4-22 ǹ 0011
2 PE ENGINE

sharp chisel.
de-greased.
flywheel.
M2 00 035
14
ǹ 0011 4-23
PE ENGINE 2
Note:
Each new seal is equipped with a plastic
flywheel housing.
Note:
3. Lightly grease the inner rim of the oil seal.
flange.
5. Fit the supplied plastic mounting ring (1) on
the crankshaft flange.
6. Then place the new sealing ring (2) over the
mounting ring and remove the mounting
ring. A
seal is properly positioned. B C
8. Remove the special tool. M2 00 036
14
4-24 ǹ 0011
2 PE ENGINE

housing.
4. Remove the crankshaft position sensor.
housing.
flywheel housing.
14
ǹ 0011 4-25
PE ENGINE 2

from the housing.
contact areas.
face.
11. Fit the crankshaft position sensor.
13. Fit the oil sump attachment bolts and
tighten all the attachment bolts to the
14
4-26 ǹ 0011
2 PE ENGINE

Note:
When removing the viscous fan clutch, ensure
that the radiator is not damaged.
viscous fan clutch.
and remove the viscous fan clutch at the M200228
alternator.
alternator.
6. Remove the attachment bolts and the thrust
washer from the vibration damper.
7. Remove the vibration damper using special
tool (DAF no. 1240448).
14
ǹ 0011 4-27
PE ENGINE 2

event of damage or leaks, the vibration
2. Fit the vibration damper. Tighten the
5. Fit the viscous fan clutch. M200229
6. Fit the fan.
14
4-28 ǹ 0011
2 PE ENGINE

Old type of timing cover seal
1. If the timing cover is equipped with an older
type of seal (version without a bearingrace
on the damper), the seal must be removed
by boring two holes in it and pulling it out
of the timing cover using special tools
(DAF no. 0484899 and DAF no. 0694928).
New type of timing cover seal
1. Remove the seal from the timing gear cover
using a seal puller (DAF no. 1329458).
2. Check the bearing race for wear. If
necessary, replace.
A
B
m200830
Old situation New situation
14
ǹ 0011 4-29
PE ENGINE 2

Note:
If the timing gear case is fitted with an old type
oil seal (version without bearing race on the
vibration damper), the oil seal must be replaces
with a new oil seal with bearing race on the
vibration damper.
can lead to a leak.
install the dry sealing ring and the thrust W264003
washer in the recess of the timing gear
cover.
4. Fit the bearing race to the vibration damper.
14
4-30 ǹ 0011
2 PE ENGINE

before opening it.

2. Remove all coolant pipes (A) between the
radiator and engine.
A
the engine and the intercooler.
6. Loosen the radiator attachment bolts so that
the radiator can be tilted slightly forward.
viscous fan clutch.
9. Tilt the radiator forward and remove the
wind tunnel collar and the viscous fan with
D B C E
the fan. M200840

14
ǹ 0011 4-31
PE ENGINE 2
13. Slacken the coolant pipe from the cover by

pulling it slightly forwards over the stud.
locating holes.
the new gasket.
3. Fit the attachment bolts and studs and
attachment bolts.
5. Fit the coolant pipe.
8. Tilt the radiator and place the wind tunnel
collar and the viscous fan clutch with the fan
between the engine and the radiator.
clutch.
14
4-32 ǹ 0011
2 PE ENGINE
11. Attach all coolant pipes (A) between the

radiator and engine. A
12. Fit the torque rod (B) between the radiator
and the engine.
13. Fit the flexible air inlet pipes (C) and tighten
15. Fit the radiator attachment bolts.
D B C E
M200840

position).
Note:
wheel.
14
ǹ 0011 4-33
PE ENGINE 2
Removal, intermediate gear wheel 6 2 4

1. Remove the attachment bolt with the axial
thrust washer (3).
Removal, pump housing gear wheel
pump housing - camshaft.
7 1 3 5
1. Remove the attachment bolt (2) of the M200744
3. Remove the camshaft gear wheel using a
14
4-34 ǹ 0011
2 PE ENGINE

1. Check whether cylinder 1 is at top dead
centre (TDC on the flywheel, cylinder 6 in
overlap position).
2. Fit the attachment bolt with the axial thrust
washer of the intermediate gear wheel.
Tighten the attachment bolt to the specified
3
2
play.
Installation, camshaft gear wheel 1
M200884
3. Fit the camshaft gear attachment bolt and
tighten it to the specified torque. See
play.
Installation, pump housing gear wheel 6 2 4
3. Fit the attachment bolt (5) of the pump
housing - camshaft. Tighten the attachment
data”.
play.
7 1 3 5
2. Fit the timing cover. M200744
14
ǹ 0011 4-35
PE ENGINE 2

case.
timing case and remove the timing case.
locating holes.
material between engine block and oil
M200579
sump.
4. Fit the timing gear case and tighten the
6. Fit the camshaft locking plate and tighten
8. Fit a new O-ring to the air compressor and
fit the air compressor.
14
4-36 ǹ 0011
2 PE ENGINE

1. Remove the pump housing - camshaft gear 4 6
wheel (2).
2. Fit the gear wheel (4) onto the pump
housing - camshaft.
7
M200841
14
ǹ 0011 4-37
PE ENGINE 2
4.24 REMOVAL AND INSTALLATION, VIBRATION DAMPER BEARING RACE
Removal, vibration damper bearing race

2. Carefully tap the vibration damper bearing
race. Avoid damaging the vibration damper.
Installation, vibration damper bearing race
1. Clean the contact surface of the vibration
damper. It must be grease-free.
2. Fit the dry bearing race to the vibration
damper exerting a low force.
14
4-38 ǹ 0011
2 PE ENGINE
5. CLEANING
Note:
stage.
get stuck, so that the steering will jam.
via the breathers.
14
ǹ 0011 5-1
PE ENGINE 2

14
5-2 ǹ 0011
2 PE ENGINE COOLING SYSTEM
CONTENTS
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page Date
1-1 . . . . . . 0011
15
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
4.1 Pressure testing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.4 Radial water pump play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0011
ǹ 0011 1
PE ENGINE COOLING SYSTEM 2
15
2 ǹ 0011
properly extracted.
15
moving components.
required.
ǹ 0011 1-1
15
1-2 ǹ 0011
2. GENERAL
15
6 3 2 1
7 5 4
m200842
Legend
2. Water pump
4. Water pipe
5. Oil cooler
6. Coolant pipe
7. Drain tap
ǹ 0011 2-1
15 The cooling system consists of a water pump, a

thermostat and pipes.
bleed pipe has been installed.
Through this pipe, any air in the cooling system
is discharged to the header tank, rendering the
cooling system auto-bleeding.
the cylinder liniers, and up towards the cylinder
heads. The coolant leaves cylinder heads
through the coolant collector pipe to the
thermostat housing.
return pipe. The connection pipe to the header
tank is also connected to the return pipe from
the radiator. If the coolant heats up, the coolant
flows to the header tank. If the coolant cools
down, the coolant flows back from the header
tank.
2-2 ǹ 0011

through a pipe, via the coolant return pipe. The 15
the water pump.
ǹ 0011 2-3
15
2-4 ǹ 0011
15
The pressure cap (A) on the auxiliary header
tank, behind the grille, is attached on the header
tank by means of a screw thread. To fill the
A
valves are closed.
M200180

boiling.
P1
ǹ 0011 3-1
15 Operation of the thermostat

Thermostat closed
The coolant has not yet reached the opening A
closed.
The coolant passes via a by-pass channel (A)
directly to the water pump and the pump once B
M200739

temperature of the thermostat. A
opened and the by-pass passage (A) is partially
closed.
supply passage (B) to the radiator and through B
M200740

The temperature of the coolant has become A
B
M200741
3-2 ǹ 0011

15
an emergency solution.
If the thermostat is removed from the engine,
uncooled coolant will flow to the water pump via
the by-pass passage (A). As a consequence, the
coolant temperature will continue to rise.
ǹ 0011 3-3
15
3-4 ǹ 0011

4.1 PRESSURE TESTING THE COOLING SYSTEM
15



means of a pressure test pump.
When this is done with a warm engine, it is
easier to spot any cracks.
5. Note:
By installing the pressure-test pump to the
M2081
filler opening of the header tank, you also
test the pressure cap.
Pressure-test the system to the specified
6. Check the cooling system for leaks.
ǹ 0011 4-1
15 1. Remove the thermostat. See “Removal and

installation”.
4. Inspect the thermostat seat (C) for damage. C
B
closed.
A
with clean water.
M200742

heat the water. Check at which temperature
the thermostat opens and whether the
thermostat opens fully. See “Technical
data”.
M200513
4-2 ǹ 0011

15
properly extracted.

components.

top up.
ǹ 0011 4-3

15 an operating temperature of 85 - 95_C.

900
hole is in front of the viscous coupling. 100
430
temperature.
of 1000 rpm.
7. Then use an optical rev counter to 700
M200440
determine the difference in speed of the fan
replaced.
4-4 ǹ 0011
4.4 RADIAL WATER PUMP PLAY
1. Remove the V-belt from the water pump

pulley. See “Removal and installation”.
15
illustration.
replaced.
M200595
ǹ 0011 4-5
15
4-6 ǹ 0011

15
Removal, water pump
the locking screw and turning the wind
tunnel collar anti-clockwise to unlock it.
and the radiator.
alternator.
8. Remove the attachment bolt of the threaded
spindle of the alternator.
connection piece.
water pump and remove the water pump.
ǹ 0011 5-1

15 surfaces of the water pump, the thermostat

water pump.
6. Fit the alternator threaded spindle
attachment bolt.
7. Fit the V-belts of the alternator and, if fitted,
the air-conditioning compressor.
drive flange.
the engine.
filling”.
5-2 ǹ 0011
Removal, thermostat
15
thermostat housing.
C
B
housing.
6. Remove the thermostat.
M200742

internal puller.
ǹ 0011 5-3

15 seat (C) and fit it in the thermostat housing

1. Fit the thermostat seal (B) in the
thermostat housing using special tool C
(DAF no. 1310456). B
A
M200742
thermostat housing.
pipe.
5. Fit the thermostat housing attachment bolts.
filling”.
5-4 ǹ 0011

15
alternator drive.
3. If fitted, loosen the V-belt of the
alternator side.
the locking screw and turn the wind tunnel
clutch with the fan in the wind tunnel
temporarily.
Note:
The viscous fan must always be stored
vertically.
ǹ 0011 5-5

1. Place the new viscous fan in the fan.
15 Tighten the attachment nuts to the specified

5. If present, fit the V-belt of the
pump drives.
5-6 ǹ 0011

15
header tank.
header tank.
and the engine.
filling”.
ǹ 0011 5-7
15 Note:
Removal, radiator
terminal.
the cab.
intercooler.
condenser forwards.
intercooler.
5-8 ǹ 0011

15
intercooler.
pipe.
the chassis.
1. Fit the radiator assembly with intercooler
and wind tunnel to the chassis and tighten
ǹ 0011 5-9

engine lifting eye.
15 5. Fit the air-conditioning compressor and its

the engine bracket.
ring.
intercooler.
intercooler.
the intercooler.
13. Fit the air inlet pipes between the manifolds
and intercooler.
filling”.
5-10 ǹ 0011

15

the skin and eyes.

waste.


4. Drain the cooling system via drain tap (A)
on the side of the engine block and via drain
plug (B) underneath the radiator and
plug (C) on the lower side of the oil cooler.
5. If an integrated retarder has been fitted
remove the coolant pipe (D) from the oil
cooler and drain the remaining coolant. B
C
A
M2097
ǹ 0011 6-1
15 7. Close the engine drain tap (A) and install

the drain plugs (B and C) on the lower side
of the radiator and on the oil cooler.
M2077
6-2 ǹ 0011

2.
Fill the cooling system with the specified
15
coolant.
4. Note:
The cooling system is bled automatically. B
6. Check the coolant level, and if necessary M200181
heater
Note:
one minute.
ǹ 0011 6-3
15
6-4 ǹ 0011
2 PE ENGINE LUBRICATION SYSTEM
CONTENTS
Page Date
16
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0011
3.3 Pressure testing the lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0011
4.1 Removal and installation, lubricating oil filter housing . . . . . . . . . . . . . . . . . . . 4-1 ...... 0011
4.2 Removal and installation, lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0011
6.1 Draining and filling, lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0011
ǹ 0011 1
PE ENGINE LUBRICATION SYSTEM 2
16
2 ǹ 0011
unventilated area.
Make sure exhaust fumes are properly
extracted.
moving components.
16
the vehicle may constitute a health hazard.
This also applies to engine coolant, windscreen
required.
ǹ 0011 1-1
16
1-2 ǹ 0011
2. GENERAL
16
M200909
ǹ 0011 2-1
General
the crankshaft, by a gear.
The lubricating oil pump draws the lubricating oil
from the oil sump, and pumps it via the
lubricating oil cooler and the lubricating oil filter
16 to the main oil channel in the cylinder block.

From the main oil channel, the lubricating-oil is
Oil cooler
The lubricating oil cooler is connected to the
cooling system. The lubricating oil cooler warms
up the lubricating oil in a “cold” engine and cools
it in a “warm” engine.
Parallel to the lubricating oil cooler, a
short-circuit valve has been installed. If the
lubricating oil cooler is blocked, the short-circuit
valve will open if a certain pressure has built up.
In this case, uncooled lubricating oil enters the
lubricating system.
A pressure-limiting valve is installed in the
lubricating system behind the lubricating oil
cooler.
When the pressure set for the pressure limiting
valve has been reached, the valve opens and
allows excess cooled lubricating oil to flow to the
oil sump.
Oil filter
The oil is cleaned in the disposable lubricating
oil filter. A pressure limiting valve fitted in this
filter opens if the pressure in the filter becomes
too high as a result of contamination or cold
lubricating oil. The lubricating oil then passes
through the filter unfiltered.
2-2 ǹ 0011
Main oil channel

From the main oil channel, lubricating oil is
supplied to the crankshaft main bearings and via
a lubricating oil channel in the crankshaft also to
the connection-rod bearings.
From the main lubricating oil channel, lubricating
oil is pumped through the first camshaft bearing
into the hollow camshaft. 16
From the lubricating oil channel in the camshaft,
lubricating oil is supplied to the other camshaft
bearings.
Cylinder head
From the second and fifth camshaft bearings, a
lubricating oil channel passes through the
cylinder heads to the second and fifth rocker
seats.
The other rockers shafts are provided with
lubricant by lubricating-oil strips that run along
the rockers seats.
Timing gear
From the lubricating oil channel in the first
crankshaft main bearing, a lubricating oil
channel leads to the hollow hub of the
intermediate gear wheel. The lubricating oil
passes through the hollow hub onto the
intermediate gear wheel. The other gear wheels
receive lubricating oil from the intermediate gear
wheel.
bearings are lubricated by means of lubricating
oil nozzles linked to the main oil channel. In
addition to lubricating, this oil has an important
cooling function.
A bore hole has been created at the top of the
connecting-rod, through which the lubricating oil
that the nozzles spray against the bottom of the
piston may reach the upper connecting-rod
bearing.
ǹ 0011 2-3

A lubricating oil channel from the camshaft
bearing connects the lubricating oil pipes to the
turbocharger and air compressor.
The lubricating oil discharge pipe from the
16 cylinder block, from where the lubricating oil

returns to the oil sump.
The lubricating oil returning from the air
compressor flows from the front of the air
compressor back to the timing gear, and from
there to the oil sump.
Pump housing
The pump housing obtains lubricating oil from
the cylinder block and discharges it through a
channel in the cylinder block, from where it
returns to the oil sump. The pump units are
provided with lubricating oil via a channel in the
pump housing.
2-4 ǹ 0011

Note:
A lubricating oil consumption test is only useful
after the engine has been run in (approx.
20,000 km).
16
1. First carefully check the engine for
lubricating oil leaks. Clean the engine
before starting the test.
drained.
6. Refill the oil sump with the drained
lubricating oil. If necessary, top up the
amount of lubricating oil to the specified
level.
exact amount of lubricating oil (A) in the oil
drained (B).
12. Pour the lubricating oil into the oil sump. If
necessary, top up the amount of lubricating
oil to the specified level.
ǹ 0011 3-1
13. Calculate the lubricating oil consumption

using the following formula.
D -- C
Oil consumption = = km/ltr.
A -- B
16 1250
1200
1100
km. / liter
1000
900
800
700
600
500
400
300
250
200
100
0
100 200 300 400 500 600 700 800
25 80 240 x 1000 km.
M200774
In the graph the lubricating oil consumption in

km/l is marked out on the left and the total
number of kilometres covered by the engine at
the bottom.
If the lubricating oil consumption and the
number of kilometres covered intersect in the
shaded section, corrective measures may be
considered.
Bear in mind however, that the lubricating oil
consumption is very much dependent upon the
operating conditions.
3-2 ǹ 0011

This sensor is mounted on the lubricating oil
filter housing.
16
a lubricating oil pressure gauge, special tool
(DAF no. 0535551).
technical data. See “Technical data”.
Note:
The oil pressure control valve, mounted in the oil
sump, cannot be adjusted.
5. Stop the engine and remove the lubricating
oil pressure gauge. Fit a new oil seal to the
oil pressure sensor. M200890
ǹ 0011 3-3
3.3 PRESSURE TESTING THE LUBRICATING OIL COOLER
1. Remove the lubricating oil cooler. See

2. Fit the special tool (DAF no. 1240476 and 1240477
16 DAF no. 1240477) on the lubricating oil
cooler.
1240476
3. Apply up to 2.5 bar of pressurised air to the
special tool.
4. Immerse the lubricating oil cooler in hot
water (approx. 50_C) and check it for leaks.
Note:
The lubricating oil cooler should be replaced
if it is leaking.
M200185
5. Fit the lubricating oil cooler. See “Removal
3-4 ǹ 0011


unnecessary contact with the 1
16
Removal, lubricating oil filter housing 2
1. Clean the filter housing and the surrounding
area.
3. Remove the filter element. Collect any
lubricating oil flowing out of the system. 3
housing and remove the filter housing.
Installation, filter housing
filter housing (2).
4
2. Fit the filter housing (2) and tighten the
data”.
7. Run the engine for a short time, and check
that the lubricating oil filter is correctly M200599
sealed.
ǹ 0011 4-1
4.2 REMOVAL AND INSTALLATION, LUBRICATING OIL COOLER
Removal, lubricating oil cooler

16 2. Remove the heat shield from the exhaust

bend.
3. Remove the exhaust brake operating
cylinder.
4. Remove the plug on the underside of the
lubricating oil cooler and drain the coolant.
5. Remove the flexible coolant pipes from the
lubricating oil cooler.
6. Remove the lubricating oil cooler. Collect W267003
the lubricating oil flowing out of the system.

7. Remove any remains of the gasket.
Installation, lubricating oil cooler
1. Thoroughly clean the contact surfaces
between the lubricating oil cooler and the
cylinder block, and replace the gaskets.
2. Fit the lubricating oil cooler.
3. Connect the coolant pipes to the lubricating
oil cooler.
4. Fit the engine brake operating cylinder.
5. Fit the heat shield of the exhaust bend.
lubricating oil cooler does not leak.
4-2 ǹ 0011
Removal, oil sump

engine. 2
2. Drain the lubricating oil. See “Draining and
filling”. 16
1
rubber (2).
Damaged sealing rubbers (2) must be 2 3
replaced.
oil sump.
(2) upright. M200601

lubricating oil.
Then check the lubricating oil level.
ǹ 0011 4-3

3
2. Remove the lubricating oil strainer.
16 3. Remove the lubricating oil supply and 2
delivery pipe (1) from the lubricating oil
pump.
cover.
5. Remove the attachment bolt (3). 1
main bearing cover.
Installation, lubricating oil pump M200600
data”.
3. Fit the lubricating oil supply and delivery
pipes (1), with new O-rings.
4. Fit the lubricating oil strainer.
4-4 ǹ 0011


16
oil pump.
damage.
Note: M200344
Note:
shown.
Fit the gear wheels in the lubricating oil
pump housing.
oil pump.
data”.
data”.
ǹ 0011 5-1
16
5-2 ǹ 0011

6.1 DRAINING AND FILLING, LUBRICATING OIL

D 16
2. Drain the lubricating oil using the drain plug
in the oil sump.
the specified lubricating oil quantity. See
M200735
ǹ 0011 6-1
16
6-2 ǹ 0011

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2 CONTENTS

PE ENGINE COOLING SYSTEM

0 12. XE ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 . . .

Version Euro 2 (M), water-cooled, four-stroke diesel

ENGINE TYPE P (kW) at rpm M (Nm) at rpm

ENGINE TYPE IDLING SPEED MAX. NO LOAD SPEED

(1) Raw-edge V-belts can be recognised by the absence

(3) If the V-belt tension is lower than the “minimum

Number of teeth, timing gears

Flywheel/starter ring gear

2.2 TIGHTENING TORQUES

0 The tightening torques stated in this section are

(1) Secure with Loctite 243

Vibration damper and fan drive

0 Version with direct fan drive

Vibration damper hub attachment bolts (1) in 4

(1) Tighten the attachment bolts evenly

Version with up-speed fan drive

Attachment bolts, vibration damper hub (1)

(1) Tighten the attachment bolts evenly

Cylinder head attachment bolts

(1) Apply a drop of oil to bolts M16 and M12 on the 60

(1) Secure with Loctite 243

Engine mountings on timing gear end

Engine mountings on flywheel end

Engine hanger brackets

(1) Secure with Loctite 243

3. XF ENGINE COOLING SYSTEM

Expansion tank pressure cap

Pressure testing the cooling system

3.2 TIGHTENING TORQUES

0 The tightening torques stated in this section are

3.3 FILLING CAPACITIES

Cooling system capacity approx. 50 litres

4. XF ENGINE LUBRICATION SYSTEM

4.2 TIGHTENING TORQUES

0 The tightening torques stated in this section are

Lubricating oil strip/rocker seats

Lubricating oil filter

Bypass pressure regulator

Centrifugal oil filter

(1) Secure with Loctite 243

Main bearing caps

Big-end bearing caps

(1) Apply a drop of oil to thread and contact surface.

(2) Connecting rod bolts are to be used once and

4.3 FILLING CAPACITIES

ENGINE TYPE P (kW) at rpm M (Nm) at rpm

ENGINE TYPE IDLING SPEED MAX. NO LOAD SPEED

1. Raw-edge V-belts can be recognised by the absence

2. After fitting the new V-belt, set the pre-tension to the

3. If the V-belt tension is lower than the “minimum

Cylinder head test pressure

Number of teeth, timing gears

Flywheel/starter ring gear

ENGINE SPEED sensor

5.2 TIGHTENING TORQUES

0 The tightening torques stated in this section are

Air conditioning compressor

(1) Apply Loctite 243 to secure

Cylinder head attachment bolts

0 the cylinder head bolts should always be

(1) Apply a drop of oil to bolts M16 and M12 on the