DAF CF65, CF75, CF85 Series . Manual — part 435

©

200416

4-1

Removal and installation

CE ENGINE INLET/EXHAUST SYSTEM

ΧΦ65/75/85 series

4

3

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.

}

1

i400857

2

CE ENGINE INLET/EXHAUST SYSTEM

4-2

©

200416

Removal and installation

3

ΧΦ65/75/85 series

4

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.

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".

©

200416

4-3

Removal and installation

CE ENGINE INLET/EXHAUST SYSTEM

ΧΦ65/75/85 series

4

3

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".

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).

1

i400857

2

CE ENGINE INLET/EXHAUST SYSTEM

4-4

©

200416

Removal and installation

3

ΧΦ65/75/85 series

4

4.2 REMOVAL AND INSTALLATION OF AIR COOLER

Note:
The removal and installation procedure of the air
cooler allows for the presence of an air-
conditioning unit.

If such a unit is not present, the sections
concerned can be skipped.

Removing the air cooler
1.

Partially drain the coolant.

2.

Disconnect the oil filler pipe (A) from the air
cooler.

3.

Disconnect the dipstick holder (B) from the
air cooler.

4.

Remove the air inlet hoses (C) between the
engine and the air cooler.

5.

Disconnect all rubber hoses that run along
the air cooler.

6.

Disconnect the torque rods (D) at the side of
the air cooler.

7.

Disconnect the air-conditioning condenser (if
applicable) including accessories from the
radiator.

8.

Disconnect the air-conditioning compressor,
if applicable, from the engine and carefully
put the complete air-conditioning system to
one side.

9.

Disconnect the air cooler from the radiator
and remove the air cooler.

i400871

C

D

A

C

B

D