DAF CF65, CF75, CF85 Series . Manual — part 199

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4.7 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD

Removing the exhaust manifold
1.

Remove the turbocharger.

2.

Remove the exhaust manifold (1) and
gaskets.

Installing the exhaust manifold
1.

Check the contact surface of the exhaust
manifold for smoothness with a steel ruler (2)
and feeler gauge (3). Compare the readings
with the values referred to in "Technical
data".

2.

Fit new gaskets.

3.

Fit the exhaust manifold. Tighten the bolts,
from the middle outwards alternately. For the
specified torque, see "Technical data".

4.

Fit the turbocharger.

5.

Start the engine and check for leakage.

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4.8 REMOVAL AND INSTALLATION, CYLINDER HEAD

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When components are removed
from any part of the engine, dirt may
enter. This may cause serious
damage to the engine. Therefore, the
engine should be cleaned
thoroughly before it is opened. Plug
all openings that are freed.

Removing the cylinder head
1.

Drain the coolant.

2.

Disconnect all electrical wiring around the
engine which is required for removing the
cylinder head.

3.

Disconnect the air inlet pipe from the air
cooler on the turbocharger side.

4.

Remove the poly-V-belt.

5.

Remove the heat shields from the exhaust
manifold.

6.

If fitted, remove the attachment bolts of the
air-conditioning compressor.

7.

Remove the attachment bolts from the
alternator/air-conditioning compressor
bracket and remove the attachment bracket.

8.

Remove the attachment bolts from the
exhaust manifold and move the manifold and
the turbocharger a little away from the
cylinder head.

9.

Remove the other coolant hoses that are
attached to the cylinder head.

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When removing components from
the fuel system, dirt can enter. This
may result in serious damage.
Therefore, clean the area around the
fuel system before opening it.
Detached pipes must be plugged
immediately.

10. Detach the injector pipes on the injector side.

11. Detach the supply pipe between the high-

pressure pump and fuel rail on the fuel rail
side.

12. Detach the fuel return pipe from the fuel rail

and from the cylinder head.

13. Unscrew the attachment bolts from the fuel

rail and remove it.

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14. Unscrew the attachment bolts from the inlet

manifold and remove it.

Note:
To avoid dirt entering the inlet opening, it
must be taped up.

15. Remove the valve cover.

16. Remove the valve sleeve.

17. Remove the valve gear.

18. Remove the push rods. Mark the push rods

so that they can be refitted in their original
position.

19. Remove the fuel supply pipes.

20. Remove the injectors.

21. Remove the attachment bolts from the

cylinder head in the reverse order to that
followed for tightening. See "Technical data".

22. Remove the cylinder head from the cylinder

block. Keep the gasket to enable the correct
new head gasket to be selected.

23. Remove any gasket remnants from the

cylinder head and the cylinder block.

24. Check the cylinder block. See "Inspection

and adjustment".

25. Check the threaded holes in the cylinder

block for damage and cracking.

26. Check the cylinder head. See "Inspection

and adjustment".

Installing the cylinder head
1.

Clean the threaded holes in the cylinder
head, using a screw tap.

Note:
Cylinder head gaskets are available in two
thicknesses. The thickness of the cylinder
head gasket can be identified by the position
of the holes in the projecting cylinder head
gasket lip under the exhaust manifold on
cylinder 2. See "Technical data" for the
cylinder head gasket thicknesses.

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2.

Position the new cylinder head gasket. If the
type of cylinder head gasket is known, use a
gasket of the same type as the one used.

Note:
If it is not known what type of cylinder head
gasket is used or if the main components of
the driving gear have been changed, the
type of gasket required must be determined
afresh.

To do this, measure the average piston
projection. See "Inspection and adjustment".
Select the correct type of cylinder head
gasket using the information in "Technical
data" and use it.

3.

Check that all lubricating and coolant ducts
are free.

4.

Position the cylinder head carefully on the
cylinder block and ensure that the cylinder
head fits well over the dowel pins.

5.

Check the cylinder head bolts. See
"Inspection and adjustment". Use new
cylinder head bolts if one bolt does not meet
one or more conditions.

6.

Apply engine oil to the thread and to the
underside of the bolt head.

7.

Position the cylinder head bolts and hand-
tighten them.

Note:
The short cylinder head bolts must be fitted
in the outer rows.

8.

Tighten the cylinder head bolts to the
specified torque and in the sequence shown.
See "Technical data"

9.

Fit the exhaust manifold with new gaskets
and tighten the attachment bolts to the
specified torque. See "Technical data".

10. Fit the injectors.

Note:
Ensure that the injector is fitted correctly,
bearing in mind the supply opening.

11. Fit the fuel supply pipes.

12. Fit the push rods in their original position and

apply a drop of engine oil to the head of the
push rod.

13. Fit the valve gear.

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