DAF LF45, LF55 Series. Manual — part 328

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4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, TURBOCHARGER

If the turbocharger to be replaced

has been damaged to such an extent

that parts of it are missing or

lubricating oil has entered the inlet

system, the inlet and exhaust

systems must be checked and

cleaned thoroughly in order to

prevent serious damage to the

engine.

Removing the turbocharger
1.

Remove the right-hand engine

encapsulation (2).

2.

Remove the heat shield (1) from the oil filter.

3.

Remove each charge pipe and the

turbocharger exhaust pipe.

4.

Remove the oil discharge pipe from the

turbocharger.

5.

Detach the entire oil supply pipe from the oil

filter housing to the turbocharger.

6.

Remove the attachment bolts from the

turbocharger.

7.

Remove the turbocharger.

8.

Immediately plug the openings.

Installing the turbocharger
1.

Clean the turbocharger and the oil supply

and discharge pipes.

2.

Before installing the turbocharger, check the

following:

-

the turbocharger housing and connector

flange for cracks. See "Technical data"

for rejection standards;

-

the turbocharger shaft must be able to

rotate freely;

-

the turbocharger shaft must not run out

of true;

-

the turbocharger pump and turbine

wheels must not be damaged;

-

there must not be an excessive amount

of oil in the compressor side of the

turbocharger. A small amount of oil on

the inside walls of the compressor side

is allowed.

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3.

Check the adjustment of the turbocharger

wastegate. See "Inspection and adjustment".

4.

Check the axial bearing play of the

turbocharger; see "Inspection and

adjustment".

5.

Check the radial bearing play of the

turbocharger; see "Inspection and

adjustment".

6.

Clean the sealing surfaces.

Note:

Always use new gaskets when installing the

turbocharger.

7.

Apply a layer of Copaslip to the exhaust

manifold studs.

8.

Fit the turbocharger to the exhaust manifold.

9.

Fit the attachment nuts and tighten them to

the specified torque. See "Technical data".

10. Check that the oil supply and discharge

pipes are clean and not blocked, kinked or

cracked. Replace the pipes if necessary.

Note:

If the turbocharger oil supply and/or

discharge does not function properly, this

may result in serious damage to the

turbocharger and/or engine.

11. Fit new O-rings to the oil discharge pipe and

apply a thin layer of engine oil to them. Fit the

oil discharge pipe. For the specified

tightening torque, see "Technical data".

12. Pour clean engine oil into the oil supply of the

turbocharger and fit the oil supply pipe, after

fitting a new copper ring, on the oil filter

housing and the turbocharger. Tighten the

pipe to the specified tightening torque; see

"Technical data".

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13. Fit the exhaust pipe to the turbocharger.

14. Fit the charge pipes to the exhaust pipe.

15. Fit the heat shield (1) to the oil filter.

16. Install the engine encapsulation (2).

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4.2 REMOVAL AND INSTALLATION OF AIR COOLER

Removing the air cooler
1.

Disconnect the earth lead from the battery

terminal.

2.

If the vehicle has air conditioning, loosen the

support of the refrigerant pipes (2) on the

radiator and remove the condenser from the

air cooler supports.

3.

Loosen the support of the coolant pipes (1)

on the radiator.

4.

Remove the charge pipes (3) from the air

cooler and plug the openings.

5.

Disconnect the air cooler.

6.

Remove the air cooler.

Installing the air cooler
1.

Clean the outside of the air cooler with

compressed air.

2.

Install the air cooler and tighten the air cooler

attachments.

3.

Fit the charge pipes (3) to the air cooler.

4.

Fit the bracket of the coolant pipes (1) on the

radiator.

5.

If the vehicle has air conditioning, fit the

condenser in the air cooler supports and

tighten the support of the refrigerant pipes

(2) on the radiator.

6.

Connect the battery terminals.

7.

Start the engine and check for leakage.

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