DAF CF65, CF75, CF85 Series . Manual — part 223

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4.7 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD

Removing the exhaust manifold
1.

Remove the intake air pipe between the

turbocharger and the air cooler.

2.

Remove the compressor pipe.

3.

Remove the turbocharger heat shields.

4.

Remove the air inlet hose.

5.

Remove the exhaust brake.

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 it.

Installing the exhaust manifold
1.

Fit new gaskets to the exhaust manifold and

install the manifold. Fit the gasket with the

steel side towards the manifold. Tighten the

attachment bolts with the spacer sleeves to

the specified torque. See "Technical data".

2.

Fit the heat shields of the exhaust manifold

and tighten the attachment bolts to the

specified torque. See "Technical data".

3.

Fit the oil discharge pipe for the

turbocharger.

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 between the

turbocharger and the air cooler.

7.

Fit the exhaust brake.

8.

Fit the air inlet hose.

9.

Fit the heat shields for the turbocharger.

Tighten the attachment bolts to the specified

torque. See "Technical data".

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4.8 REMOVAL AND INSTALLATION, CYLINDER HEAD

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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. To remove the injectors and the clamping

pieces, only use the special tool

(DAF no. 1329412).

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16. Remove the valve gear.

17. Remove the push rods.

18. 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!

19. Remove the cylinder head bolts in the

reverse order to that shown.

20. Remove the cylinder heads from the cylinder

block.

21. Remove any remnants of gasket from the

cylinder heads and the cylinder block.

22. Check the sealing surfaces of the cylinder

block.

23. Check the threaded holes in the cylinder

block for damage and cracking.

24. Using the special tool (DAF no. 0694795),

check that the amount the cylinder liner

protrudes above the cylinder block is within

tolerance. See "Technical data".

25. Check the cylinder head. See "Inspection

and adjustment".

Installing the cylinder heads
1.

Clean the threaded holes in the cylinder

block using a screw tap.

Note:

Threaded holes not properly cleaned may

lead to too low a pre-tension of the cylinder

head bolts, causing leakage.

2.

Clean and degrease the sealing surfaces of

the cylinder heads and the cylinder block.

3.

Insert both guide pins (DAF no. 0694912)

into the threaded holes of the cylinder block.

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4.

Place the new gasket(s) on the cylinder

block, making sure that the letters TOP (1)

are visible. The cylinder head gasket must

not be retightened.

Note:

Always replace the cylinder head bolts. See

"Technical data".

5.

Place the cylinder head(s) on the cylinder

block and hand-tighten a few new cylinder

head bolts.

Note:

To prevent the inlet and exhaust manifolds

from being installed under tension, they must

be installed before the cylinder head bolts

are tightened.

6.

Fit the inlet and exhaust manifolds with new

gaskets and tighten the attachment bolts to

the specified torque. See "Technical data".

7.

Fit the remaining M16 and M12 bolts and

apply a drop of oil to the bearing surface of

the bolt heads.

8.

Remove the two guide pins and replace

them with the two remaining cylinder head

bolts.

9.

Tighten the cylinder head bolts to the

specified torque and in the correct sequence.

See "Technical data".

10. Fit the valve sleeve.

11. Fit the push rods

12. Fit the valve gear.

13. Fit the injectors.

14. Fit the valve covers.

15. Fit the coolant pipe, fit new gaskets to the

thermostat housing and install the

thermostat housing.

16. Fit the injector pipes in sets.

17. Fit the fuel filter onto the coolant pipe.

18. Fit the fuel leak-off pipe between the fuel

filter and the inlet manifold.

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