DAF CF65, CF75, CF85 Series . Manual — part 456

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3-3

Inspection and adjustment

PE ENGINE INLET/EXHAUST SYSTEM

CF65/75/85 series

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3.3 INSPECTION AND PRESSURE TESTING, AIR INLET SYSTEM

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When pressure testing the air intake

system, the plugs may spring off if

they are not properly secured.

Check the condition and mounting of the air inlet

channels/pipes of the air intake system.

In case of doubt as to the proper sealing of the air

intake system, which is indicated by the following:

1.

loss of power

2.

high fuel consumption

3.

unusual sounds,

carry out a pressure test to check the air inlet

system for leaks.

1.

Remove the pipe between the air filter

housing and the intake port on the suction

side of the turbocharger.

2.

Fit the special tools (DAF no. 1329320) and

(DAF no. 1329403) to the suction side of the

intake port and plug the opening.

3.

Remove the air inlet hose between the air

cooler and the inlet manifold.

4.

Fit the special tool (DAF no. 0694831) onto

the air cooler.

5.

Connect a flexible air pipe with reducer valve

to the coupling (A) and charge the system to

approx. 1 bar.

6.

Use a soapy solution to check the whole inlet

system for air leaks. Also check whether the

pressure gauge of the reducer valve drops.

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Inspection and adjustment

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CF65/75/85 series

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3.4 CHECKING INLET UNDERPRESSURE

1.

Remove the underpressure indicator

connection (A) from the air intake pipe

between the air filter housing and

turbocharger.

2.

Connect a pressure gauge with a maximum

rating of -100 mbar (-10 kPa) to the

connection of the underpressure indicator.

3.

Measure the inlet underpressure at full-load

engine speed and compare the

measurement to the specified value. See

"Technical data".

3.5 CHECKING THE GLOW PLUG

Checking the glow plug
1.

Remove the electrical connections on the

glow plug.

2.

Using a multimeter, determine the resistance

of the glow plug. See "Technical data".

3.

Remove the connecting hose between the

inlet pipe and the air cooler.

4.

Check whether the glow plug is damaged.

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4-1

Removal and installation

PE ENGINE INLET/EXHAUST SYSTEM

CF65/75/85 series

4

6

4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, TURBOCHARGER

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If the turbocharger to be replaced

has been damaged to such an extent

that parts of the turbocharger 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 heat shields (1) from the

turbocharger.

2.

Remove the air inlet hose (2) between the

turbocharger and air filter.

3.

Remove the exhaust brake (3).

4.

Disconnect the connector pipe (4) from the

turbocharger and the air intake pipe to the air

cooler.

5.

Remove the turbocharger lubricating oil

pipes. Plug the openings.

6.

Remove the attachment nuts from the

turbocharger.

7.

Remove the turbocharger from the exhaust

manifold.

Installing the turbocharger
1.

Before installing the turbocharger, check the

following:

-

turbocharger shaft must run smoothly

-

turbocharger shaft must not be out of

true

-

turbocharger shaft must have a little

radial clearance.

If applicable:

-

movement of the wastegate.

2.

Clean the sealing surfaces.

3.

Apply a layer of Copaslip to the exhaust

manifold studs.

4.

Always use new gaskets during installation.

5.

Fit the turbocharger. If necessary, turn the

two halves of the housing so that the oil and

air pipes can be connected free of stress.

6.

Fit the oil discharge pipe.

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Removal and installation

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CF65/75/85 series

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7.

Spray clean engine oil into the oil supply of

the turbocharger and fit the oil supply pipe.

8.

Fit the connector pipe from the turbocharger

and the air intake pipe to the air cooler.

9.

Fit the exhaust brake.

10. Fit the air inlet hose between the

turbocharger and the air filter.

11. Fit the heat shields for the turbocharger.