DAF CF65, CF75, CF85 Series . Manual — part 251

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Removal and installation

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4.6 REMOVAL AND INSTALLATION, INLET MANIFOLD

Removing the inlet manifold
1.

Disconnect the electrical wiring on the inlet

manifold.

2.

Remove the fuel leak-off pipe between the

fuel filter and inlet manifold.

3.

Remove the coolant filter, if applicable.

4.

Remove the entire fuel filter from the inlet

manifold.

5.

Disconnect the injector pipes.

6.

Remove the attachment bolts from the inlet

manifold and remove it.

Installing the 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 manifold. Tighten the attachment bolts to

the specified torque. See "Technical data".

3.

Fit the fuel leak-off pipe between the fuel

filter and the inlet manifold.

4.

Fit the injector pipes.

5.

Fit the complete fuel filter.

6.

Fit the coolant filter.

7.

Connect the electrical wiring.

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4.7 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD

Removing the exhaust manifold
1.

Take the exhaust brake cylinder (8) off the

butterfly valve (4).

2.

Remove the clamping strip from the exhaust

brake (4).

3.

Remove the air inlet hose (2).

4.

Remove the inlet air pipe (1) between the

turbocharger and the intercooler.

5.

Remove the compressor pipe.

6.

Remove the heat shields from the exhaust

manifold.

7.

Remove the oil supply and oil discharge

pipes from the turbocharger.

8.

Remove the attachment bolts from the

exhaust manifold and remove the manifold

along with the turbocharger.

Installing the exhaust manifold
1.

Fit new gaskets to the exhaust manifold and

install the manifold. Tighten the attachment

bolts with the spacer sleeves to the specified

torque. See "Technical data".

2.

Install the heat shields of the exhaust

manifold. Tighten the attachment bolts to the

specified torque. See "Technical data".

3.

Fit the heat shields for the 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.

6.

Fit the inlet air pipe (1) between the

turbocharger and the intercooler.

7.

Connect the air inlet hose (2).

8.

Fasten the clamping strip of the exhaust

brake (4).

9.

Fit the exhaust brake cylinder (8) onto the

butterfly valve (4).

10. Start the engine and check all connections

for leaks.

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Removal and installation

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4.8 REMOVAL AND INSTALLATION, CYLINDER HEADS

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When the engine or parts thereof are

opened, dirt may enter. This may

cause serious damage to the engine.

Therefore, the engine should be

cleaned thoroughly before any parts

are opened.

Removing the cylinder heads
1.

Disconnect any wiring around the engine

which is relevant for the removal of the

cylinder heads.

2.

Disconnect the inlet pipe from the

turbocharger to the air cooler.

3.

Disconnect the compressor pipe from the air

intake pipe to the compressor.

4.

Slacken the tensioner of the air-conditioning

compressor, if fitted.

5.

Remove the attachment bolts of the air-

conditioning compressor mounting bracket, if

fitted.

6.

Remove the heat shields from the exhaust

manifold.

7.

Remove the attachment bolts from the

exhaust manifold and remove the manifold

and the turbocharger from the cylinder

heads.

8.

Remove the coolant filter, if fitted.

9.

Disconnect the fuel leak-off pipe between the

fuel filter and the fuel leak-off pipe on the inlet

manifold.

10. Disconnect the fuel filter assembly from the

coolant pipe.

11. Disconnect both sets of injector pipes.

12. Remove the coolant pipe together with the

thermostat housing.

13. Remove the inlet manifold attachment bolts

and remove the entire manifold from the

cylinder heads.

14. Remove the valve covers.

15. If fitted, remove the DEB.

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16. To remove the injectors and the clamping

pieces, only use the special tools

(DAF no. 1329412) and (DAF no. 0694928).

17. Remove the valve gear.

18. Remove the push rods.

Note:

Make sure that any solid push rods (yellow

marking and diameter 12 mm) are fitted back

on the inlet side only. These solid push rods

may be replaced by hollow ones (diameter

14 mm).

19. Remove the valve sleeve.

Note:

Due to the sealant used on the cylinder head

bolts, the untightening torque of the cylinder

head bolts can be substantial!

20. Remove the cylinder head bolts in the

reverse order to that shown.

21. Remove the cylinder heads from the cylinder

block.

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