DAF 95XF, 95XE Repair Manual

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95XF series

CONTENTS

TECHNICAL DATA

DIAGNOSTICS

XF ENGINE

XF ENGINE COOLING SYSTEM

XF ENGINE LUBRICATION SYSTEM

XE ENGINE

XE ENGINE COOLING SYSTEM

XE ENGINE LUBRICATION SYSTEM

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TECHNICAL DATA

95XF series Contents

CONTENTS

Page Date

1. ENGINE GENERAL 1-1 200335.................................................... ....

1.1 General 1-1 200335......................................................... ....

2. XF ENGINE 2-1 200335........................................................... ....

2.1 General 2-1 200335......................................................... ....

2.2 Tightening torques 2-4 200335................................................ ....

3. XF ENGINE COOLING SYSTEM 3-1 200335......................................... ....

3.1 General 3-1 200335......................................................... ....

3.2 Tightening torques 3-2 200335................................................ ....

3.3 Filling capacities 3-2 200335.................................................. ....

4. XF ENGINE LUBRICATION SYSTEM 4-1 200335..................................... ....

4.1 General 4-1 200335......................................................... ....

4.2 Tightening torques 4-2 200335................................................ ....

4.3 Filling capacities 4-4 200335.................................................. ....

5. XE ENGINE 5-1 200335........................................................... ....

5.1 General 5-1 200335......................................................... ....

5.2 Tightening torques 5-4 200335................................................ ....

6. XE ENGINE COOLING SYSTEM 6-1 200335......................................... ....

6.1 General 6-1 200335......................................................... ....

6.2 Tightening torques 6-2 200335................................................ ....

6.3 Filling capacities 6-2 200335.................................................. ....

7. XE ENGINE LUBRICATION SYSTEM 7-1 200335..................................... ....

7.1 General 7-1 200335......................................................... ....

7.2 Tightening torques 7-2 200335................................................ ....

7.3 Filling capacities 7-5 200335.................................................. ....

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TECHNICAL DATA

Contents 95XF series

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TECHNICAL DATA

95XF series Engine general

1. ENGINE GENERAL

1.1 GENERAL

The terms “COLD ENGINE” and “WARM ENGINE” are defined as follows:

COLD ENGINE

A cold engine is an engine which, having reached operating temperature, has been allowed to cool down for at least six hours.

WARM ENGINE

A warm engine is an engine which, having reached operating temperature, has not been at a standstill for more than thirty minutes.

Direction of rotation of the engine

The direction of rotation of the engine is clockwise, as seen from the timing gear end.

First cylinder of the engine

The first cylinder of the engine is the cylinder at the timing gear end.

Left-hand and right-hand side of the engine

The left-hand side of the engine is the side where the fuel pump is mounted.

The right-hand side of the engine is the side where the air compressor is mounted.

ǹ 200335

1-1

TECHNICAL DATA

Engine general 95XF series

1-2

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TECHNICAL DATA

95XF series XF engine

2. XF ENGINE

2.1 GENERAL

Types XF 280 M

XF 315 M XF 355 M

Version Euro 2 (M), water-cooled, four-stroke diesel

engine with direct fuel injection, 4 valves per cylinder and turbo-intercooling.

Number of cylinders 6 Bore x stroke 130 x 158 mm Swept volume 12.58 l Compression ratio 16.0 : 1 Firing order 1-5-3-6-2-4 Weight approx. 1,049 kg

ENGINE TYPE

XF 280 M 280 at 2000 1750 at 1100 - 1500

XF 315 M 315 at 2000 1900 at 1050 - 1500

XF 355 M 355 at 2000 2050 at 1000 - 1500

P(kW)atrpm M(Nm)atrpm

ENGINE TYPE IDLING SPEED

rpm

XF 280 M 525 - 575 approx. 2300

XF 315 M 525 - 575 approx. 2300

XF 355 M 525 - 575 approx. 2300

MAX. NO LOAD SPEED

rpm

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2-1

TECHNICAL DATA

XF engine 95XF series

V-BELT TENSION

Belt tension, “AVX” raw-edge

Multiple-V-belt Single-V-belt

Setting tension 1200 600

Test tension ≥800 ≥400

Minimum tension 500 250

Adjusting tension 700 350

(1) Raw-edge V-belts can be recognised by the absence

of textile fabric in the rubber, with the exception of the top of the belt edge, on the edges and the insides of the belt (polished belt edges). Version: either toothed or non-toothed.

(2) After fitting the new V-belt, set the pre-tension to the

“setting tension” and after a trial run check whether the pre-tension complies with the “test tension”. If the tension reading is lower than the “test tension” specified in the table, set the V-belt to the minimum “test tension”.

V-belts in Newtons (N)

New V-belt

Worn V-belt

(3) If the V-belt tension is lower than the “minimum

tension”, set the belt to the “adjusting tension”.

M2121

2-2

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TECHNICAL DATA

95XF series XF engine

Cylinder liner

Height above cylinder block 0.02 - 0.10 mm

Cylinder head

Minimum height after overhaul 119.50 mm Test pressure using air (max. pressure) 1.5 bar

Valve clearance Valve clearance (cold/hot) inlet 0.50 mm exhaust 0.50 mm

Valve opening

Valve opening at 1 mm valve clearance 0.3 - 0.7 mm

Axial play

Crankshaft axial play 0.06 - 0.32 mm Camshaft axial play 0.10 - 0.55 mm Idler gear axial play 0.05 - 0.25 mm

Gear backlash

Idler gear - crankshaft gear 0.02 - 0.21 mm Idler gear - fuel-pump gear 0.02 - 0.22 mm Idler gear - camshaft gear 0.02 - 0.21 mm Camshaft gear - compressor gear 0.02 - 0.22 mm Fuel pump gear - steering pump gear 0.02 - 0.19 mm Oil pump idler gear - oil pump gear 0.02 - 0.20 mm Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm

Number of teeth, timing gears

Crankshaft gear 35 Idler gear 54 Fuel pump gear 70 Camshaft gear 70 Air compressor gear 27 Fan drive housing gear 29 Steering pump gear 18 Lubricating oil pump idler gear 34

Fan drive

Heat gear wheel for max. 30 min. 245_C

Compression pressure Differences in compression pressure 15%

Flywheel/starter ring gear

Axial variation, measured at a radial distance of 210 mm Starter ring gear warm up max. 185_C

0.10 mm

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2-3

TECHNICAL DATA

XF engine 95XF series

2.2 TIGHTENING TORQUES

The tightening torques stated in this section are different from the standard tightening torques stated in the overview of the standard tightening torques. The other threaded connections which are not stated must therefore be tightened to the tightening torque stated in the overview of standard tightening torques. When attachment bolts and nuts are to be replaced, it is important that they are of exactly the same length and property class as the ones removed unless stated otherwise.

Starter motor

Attachment nuts 73 Nm

Alternator

Alternator bracket attachment bolts 55 Nm Alternator attachment bolts 50 Nm Pulley attachment nut, version 55A 70 Nm Pulley attachment nut, version 95A 70 Nm

Air compressor

M12 attachment bolts for compressor 110 Nm M8 attachment bolts for bracket 30 Nm M10 attachment bolts for bracket 60 Nm Compressor gear flange bolt 120 Nm M14 cylinder head threaded coupling 40 Nm M26 cylinder head threaded coupling 90 Nm Delivery pipe reducer valve 75 Nm Suction and pressure line unions 90 Nm

(1)

Air-conditioning compressor

M12 attachment bolts for compressor bracket 110 Nm M10 attachment bolts for compressor 60 Nm

Exhaust manifold

Fit gasket with steel side towards manifold Sleeved attachment bolts 65 Nm Heat shield attachment bolts 30 Nm

(1)

2-4

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TECHNICAL DATA

95XF series XF engine

Inlet manifold

Attachment bolts 60 Nm Glow plug attachment nut 55 Nm Air inlet hose clamps 12 Nm

Turbocharger

Heat shield attachment bolts 30 Nm Turbine housing clamp plate attachment nut 15 Nm Attachment nuts, exhaust manifold

flange/turbocharger Elbow on turbocharger 40 Nm Oil supply pipe banjo bolt 90 Nm

(1) Secure with Loctite 243 (2) Apply Copaslip to secure

60 Nm

(1)

(2)

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2-5

TECHNICAL DATA

XF engine 95XF series

Vibration damper and fan drive

9 7

5 4

3 2

Vibration damper hub attachment bolts (1) in 4 phases:

phase, all attachment bolts 100 Nm 2ndphase, all attachment bolts 100 Nm 3rdphase, all attachment bolts 100 Nm 4thphase, all attachment bolts 100 Nm Attachment bolts, vibration damper (5) 110 Nm Attachment nuts, fan drive (8) 60 Nm Attachment bolts, fan pulley (9) 30 Nm Attachment nuts, fan clutch (7) 25 Nm

(1) Tighten the attachment bolts evenly (2) Secure with Loctite 243

M200945

(1)

(2)

2-6

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TECHNICAL DATA

95XF series XF engine

Cylinder head attachment bolts

Cylinder head bolts must only be used once . So the cylinder head bolts should always be replaced. The new cylinder head bolts have a red/brown sealant on the thread.

Note:

- Because of the sealant used on the cylinder head bolts, their untightening torque may be very high!

- All M16 and M12 threaded holes must be carefully cleaned with a screw tap before the bolts are fitted.

- Once the bolts have been tightened to the specified torque, the angular displacement of the M16 bolts must immediately be started.

- The sealant cannot be applied later.

Tightening cylinder head attachment bolts

50 Nm

18 19

M200562

Note:

Apply a drop of oil underneath the bolt heads (on their abutting surface). Sealant also reduces the frictional resistance, which means that no oil must be applied to the thread.

phase

Tighten M16 in the order indicated

2ndphase

Tighten M16 in the order indicated Tighten M12 in the order indicated

3rdphase

M16 in the order indicated in two steps of 60_ angular

(1) Apply a drop of oil to bolts M16 and M12 on the

abutting surface of the bolt heads.

(1)

50 Nm

150 Nm

(1)

94 Nm

displacement

III

150 Nm

M16

94 Nm

M12

M16

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M16

III

M200563

2-7

TECHNICAL DATA

XF engine 95XF series

Timing gear

Camshaft locking plate attachment bolts 30 Nm Attachment bolts, fuel pump drive shaft locking

plate Timing case attachment bolts 30 Nm Timing cover attachment bolts: M10 attachment bolts 60 Nm M8 attachment bolts 25 Nm Timing cover protection plate attachment bolt 15 Nm Camshaft gear attachment bolt 425 Nm Idler gear attachment bolt 170 Nm Attachment bolt, fuel pump gear wheel 260 Nm Attachment bolt, silencer 30 Nm Steering pump gear attachment nut 80 Nm Steering pump intake pipe banjo bolt 90 Nm Steering pump delivery pipe banjo bolt 40 Nm Compressor gear attachment nut 120 Nm

(1) Secure with Loctite 243

30 Nm

(1)

2-8

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TECHNICAL DATA

95XF series XF engine

Flywheel housing

Attachment bolts 110 Nm Sealant to be used when fitting flywheel

housing

Flywheel

Attachment bolts Without PTO 260 Nm Without PTO spanner size 21 mm 260 Nm + 90_ angular displacement With PTO 260 Nm + 150_ angular displacement

Engine mountings on timing gear end

Cylinder block bracket attachment bolts 92 Nm Chassis engine bracket attachment bolts 73 Nm Vibration damper engine bracket attachment

bolts

Engine mountings on flywheel end

Flywheel housing engine bracket attachment bolts Chassis engine bracket attachment bolts 73 Nm

Vibration damper engine bracket attachment bolts

Loctite 510

225 Nm + 60_ angular displacement

260 Nm

225 Nm + 60_ angular displacement

(1)

+90_ angular displacement

Engine hanger brackets

Attachment bolts 110 Nm

Valve gear

Valve cover attachment bolts 25 Nm Rocker setting bolt lock nut 40 Nm Bridge piece setting bolt lock nut 40 Nm Lubricating oil strip/rocker seat attachment

bolts DEB set screw nut 25 Nm Solenoid valve 20 Nm Wiring harness attachment bolt 9 Nm Valve sleeve attachment bolts 30 Nm Tighten the valve sleeve bolts in the sequence shown.

110 Nm

9157

814

41210

M200942

(1) Secure with Loctite 243

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2-9

TECHNICAL DATA

XF engine 95XF series

2-10

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TECHNICAL DATA

95XF series XF engine cooling system

3. XF ENGINE COOLING SYSTEM

3.1 GENERAL

Thermostat

Thermostat opening temperatures:

- thermostat opens at  83_C

- thermostat opened at least 12 mm at  95_C Thermostat seat Loctite 638

Water pump

Maximum radial play 0.16 - 0.20 mm

Expansion tank pressure cap

Pressure relief valve opening pressure  0.75 bar Underpressure valve opening pressure  0.1 bar

Pressure testing the cooling system

Test pressure 0.5 - 0.7 bar

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3-1

TECHNICAL DATA

XF engine cooling system 95XF series

3.2 TIGHTENING TORQUES

Water pump

M8 attachment bolts 30 Nm Threaded coupling 35 Nm

Coolant pipe

Attachment bolts 54 Nm Coolant pipe threaded coupling 90 Nm Coolant pipe plug 30 Nm

Thermostat housing

Attachment bolts 30 Nm Plug 35 Nm

Radiator

Attachment nuts 70 Nm

3.3 FILLING CAPACITIES

Cooling system capacity approx. 50 litres Cooling system capacity with ZF-intarder approx. 60 litres

3-2

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TECHNICAL DATA

95XF series XF engine lubrication system

4. XF ENGINE LUBRICATION SYSTEM

4.1 GENERAL

Oil pressure

Oil pressure at engine idling speed 1 bar (warm engine) Oil pressure at full-load engine speed 3,5 - 4.5 bar

Oil filter

Type disposable filter Quantity 1 Installation in the oil circuit full flow Opening pressure of bypass valve at a

pressure difference of

Oil cooler

Opening pressure of bypass valve at a pressure difference of Oil section test pressure 6 bar

2,5  0.3 bar

2 bar

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4-1

TECHNICAL DATA

XF engine lubrication system 95XF series

4.2 TIGHTENING TORQUES

Fuel filter

Attachment bolts, fuel filter/water pipe connection Fuel pump filter head banjo bolt 40 Nm

Lubricating oil strip/rocker seats

Attachment bolts 110 Nm

Oil sump

Clamp attachment bolts 25 Nm Oil drain plug 60 Nm

Oil pump

Attachment bolts for oil pump housing sections 30 Nm Attachment bolts connecting oil pump to main

bearing cap Delivery pipe attachment bolts 30 Nm Idler gear central bolt 60 Nm

40 Nm

60 Nm

(1)

Strainer

Bracket attachment bolts 30 Nm

Lubricating oil filter

Lubricating oil filter housing attachment bolts 50 Nm Oil filter 45 Nm Coupling in lubricating oil filter head 60 Nm

Bypass pressure regulator

Plug 80 Nm

(1)

(2)

(3)

4-2

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TECHNICAL DATA

95XF series XF engine lubrication system

Oil cooler

Attachment bolts connecting oil cooler to cylinder block Coolant supply pipe union 90 Nm

Plug, adjustable banjo connection 90 Nm Banjo bolt, adjustable banjo connection 90 Nm

Centrifugal oil filter

Central bolt 20 Nm Oil discharge pipe union 50 Nm

Dip stick

Threaded coupling 60 Nm

(1) Secure with Loctite 243 (2) Secure with Loctite 572 (3) Secure with Loctite 2701

Oil sprayer

Banjo bolt M14 for oil sprayer with locking plate M10 banjo bolt for oil sprayer 30 Nm

50 Nm

30 Nm

Main bearing caps

Main bearing cap attachment bolts 150 Nm + 120_ angular displacement

Big-end bearing caps

Attachment bolts, big-end bearing caps

phase,

sequence 1-2-3-4

phase,

2 sequence 4-3-2-1

phase,

3 sequence 1-2-3-4

35 Nm

45 Nm

60_ angular displacement

(2)

1 4

(1) Apply a drop of oil to thread and contact surface.

(2) Connecting rod bolts are to be used once and

tightened as instructed. When fitting the connecting rod in the engine, apply a drop of oil to the threads and contact surfaces of the connecting rod bolts.

(1)

M200661

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4-3

TECHNICAL DATA

XF engine lubrication system 95XF series

4.3 FILLING CAPACITIES

Lubrication system

Total capacity, including oil cooler and oil filter approx. 32 litres Oil sump capacity, maximum level approx. 25 litres Oil sump capacity, minimum level approx. 17 litres

4-4

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TECHNICAL DATA

95XF series XE engine

5. XE ENGINE

5.1 GENERAL

Types XE 280 C

XE 315 C/C2 XE 355 C XE 390 C

Version Euro 3 (C), (C2 = 4 öko), water-cooled,

four-stroke diesel engine with direct fuel injection, 4-valves per cylinder and turbo-intercooling.

Number of cylinders 6 Bore x stroke 130 x 158 mm Swept volume 12.58 l Compression ratio 16.0 : 1 Firing order 1-5-3-6-2-4 Weight approx. 1,080 kg

ENGINE TYPE

XE 280 C 280 at 2000 1750 at 1000 - 1500

XE 315 C/C2 315 at 2000 1900 at 1100 - 1500

P(kW)atrpm M(Nm)atrpm

XE 355 C 355 at 2000 2100 at 1100 - 1500

XE 390 C 390 at 1900 2350 at 1100 - 1500

ENGINE TYPE IDLING SPEED MAX. NO LOAD SPEED

XE 280 C 525 - 575 approx. 2300

XE 315 C/C2 525 - 575 approx. 2300

XE 355 C 525 - 575 approx. 2300

XE 390 C 525 - 575 approx. 2300

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5-1

TECHNICAL DATA

XE engine 95XF series

V-BELT TENSION

Belt tension, “AVX” raw-edge

Multiple-V-belt Single-V-belt

Setting tension 1200 600

Test tension ≥800 ≥400

Minimum tension 500 250

Adjusting tension 700 350

(1) Raw-edge V-belts can be recognised by the absence

of textile fabric in the rubber, with the exception of the top of the belt edge, on the edges and the insides of the belt (polished belt edges). Version: either toothed or non-toothed.

(2) After fitting the new V-belt, set the pre-tension to the

V-belts in Newtons (N)

New V-belt

Worn V-belt

(3) If the V-belt tension is lower than the “minimum

tension”, set the belt to the “adjusting tension”.

Cylinder liner

Height above cylinder block 0.02 - 0.10 mm

Cylinder head

Minimum height after overhaul 119.50 mm Test pressure using air (hot) 1.5 bar

Valve clearance

Valve clearance (cold/hot) inlet 0.50 mm exhaust 0.50 mm

Valve opening

Valve opening at 1 mm valve clearance 0.3 - 0.7 mm

M2121

5-2

ǹ 200335

TECHNICAL DATA

95XF series XE engine

Axial play

Crankshaft axial play 0.06 - 0.32 mm Camshaft axial play 0.10 - 0.55 mm Idler gear axial play 0.05 - 0.25 mm

Gear backlash

Idler gear - crankshaft gear 0.02 - 0.21 mm Idler gear pump housing camshaft gear 0.02 - 0.22 mm Idler gear - camshaft gear 0.02 - 0.21 mm Camshaft gear - compressor gear 0.02 - 0.22 mm Pump housing camshaft gear - steering pump

gear Oil pump idler gear - oil pump gear 0.02 - 0.20 mm Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm

Number of teeth, timing gears

Crankshaft gear 35 Idler gear 54 Pump housing camshaft gear 70 Camshaft gear 70 Air compressor gear 27 Fan drive housing gear 29 Steering pump gear 18 Lubricating oil pump idler gear 34

0.02-0.19mm

Fan drive

Heat gear wheel for max. 30 min. 245_C

Compression pressure Differences in compression pressure max. 15%

Flywheel/starter ring gear

Axial variation, measured at a radial distance of 210 mm Starter ring gear warm up max. 185_C

0.10 mm

ǹ 200335

5-3

TECHNICAL DATA

XE engine 95XF series

5.2 TIGHTENING TORQUES

Starter motor

Attachment nuts 73 Nm

Alternator

Alternator bracket attachment bolts 55 Nm Alternator attachment bolts 50 Nm Pulley attachment nut, version 55A 70 Nm Pulley attachment nut, version 95A 70 Nm

Air compressor

M12 attachment bolts 110 Nm M8 attachment bolts for bracket 30 Nm M10 attachment bolts for bracket 60 Nm Compressor gear flanged nut 120 Nm M14 cylinder head threaded coupling 40 Nm M26 cylinder head threaded coupling 90 Nm Delivery pipe reducer valve 75 Nm Suction and pressure line unions 90 Nm

(1)

Air-conditioning compressor

M12 attachment bolts for compressor bracket 110 Nm M10 attachment bolts for compressor 60 Nm

Exhaust manifold

Fit gasket with steel side towards manifold Sleeved attachment bolts 65 Nm Heat shield attachment bolts 30 Nm

(1)

5-4

ǹ 200335

TECHNICAL DATA

95XF series XE engine

Inlet manifold

Attachment bolts 60 Nm Glow plug attachment nut 55 Nm Air inlet hose clamps 12 Nm

Turbocharger

Heat shield attachment bolts 30 Nm Turbine housing clamp plate attachment nut 15 Nm Attachment nuts Exhaust manifold flange/turbocharger 60 Nm Elbow on turbocharger 40 Nm Oil supply pipe banjo bolt 90 Nm

(1) Apply Loctite 243 to secure (2) Apply Copaslip to secure

(1)

(2)

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5-5

TECHNICAL DATA

XE engine 95XF series

Vibration damper and fan drive

9 7

5 4

3 2

Vibration damper hub attachment bolts (1) in 4 phases:

(1) Tighten the attachment bolts evenly (2) Secure with Loctite 243

M200945

(1)

(2)

5-6

ǹ 200335

TECHNICAL DATA

95XF series XE engine

Cylinder head attachment bolts

Cylinder head bolts must only be used once.So the cylinder head bolts should always be replaced. The new cylinder head bolts have a red/brown sealant on the thread.

Note:

- Because of the sealant used on the cylinder head bolts, their untightening torque may be very high!

- All M16 and M12 threaded holes must be carefully cleaned with a screw tap before the bolts are fitted.

- Once the bolts have been tightened to the specified torque, the angular displacement of the M16 bolts must immediately be started.

- The sealant cannot be applied later.

Tightening cylinder head attachment bolts

50 Nm

18 19

M200562

Note:

Apply a drop of oil underneath the bolt heads (on their abutting surface). Sealant also reduces the frictional resistance, which means that no oil must be applied to the thread.

phase

Tighten M16 in the order indicated

2ndphase

Tighten M16 in the order indicated Tighten M12 in the order indicated

3rdphase

M16 in the order indicated in two stages of 60_ angular

(1) Apply a drop of oil to bolts M16 and M12 on the

abutting surface of the bolt heads.

(1)

50 Nm

150 Nm

(1)

94 Nm

displacement

III

150 Nm

M16

94 Nm

M12

M16

ǹ 200335

M16

III

M200563

5-7

TECHNICAL DATA

XE engine 95XF series

Timing gear

Camshaft locking plate attachment bolts 30 Nm Pump housing camshaft locking plate

attachment bolts Timing case attachment bolts 25 Nm Timing cover attachment bolts: M10 attachment bolts 60 Nm M8 attachment bolts 25 Nm Timing cover protection plate attachment bolt 15 Nm Camshaft gear attachment bolt 425 Nm Idler gear attachment bolt 170 Nm Pump housing camshaft gear attachment bolt 260 Nm Compressor gear attachment nut 120 Nm Steering pump gear attachment nut 80 Nm Suction pipe banjo bolt 90 Nm Delivery pipe banjo bolt 40 Nm

(1) Apply Loctite 243 to secure

30 Nm

(1)

5-8

ǹ 200335

TECHNICAL DATA

95XF series XE engine

Flywheel housing

Attachment bolts 110 Nm Sealant to be used when fitting flywheel

housing

Flywheel

Attachment bolts Without PTO 260 Nm + 90_ angular displacement With PTO 260 Nm + 150_ angular displacement

Engine mountings on timing gear end

Cylinder block bracket attachment bolts 92 Nm Chassis engine bracket attachment bolts 73 Nm Vibration damper engine bracket attachment

bolts

Engine mountings on flywheel end

Flywheel housing engine bracket attachment bolts Chassis engine bracket attachment bolts 73 Nm

Vibration damper engine bracket attachment bolts

Engine hanger brackets

Attachment bolts 110 Nm

Loctite 510

225 Nm + 60_ angular displacement

260 Nm

225 Nm + 60_ angular displacement

(1)

Valve gear

Valve cover attachment bolts 25 Nm Rocker setting bolt lock nut 40 Nm Bridge piece setting bolt lock nut 40 Nm Lubricating oil strip/rocker seat attachment

bolts DEB set screw nut 25 Nm Solenoid valve 20 Nm Wiring harness attachment bolt 9 Nm Valve sleeve attachment bolts 30 Nm Tighten the valve sleeve bolts in the sequence shown.

(1) Apply Loctite 243 to secure

110 Nm

9157

814

41210

M200942

ǹ 200335

5-9

TECHNICAL DATA

XE engine 95XF series

5-10

ǹ 200335

TECHNICAL DATA

95XF series XE engine cooling system

6. XE ENGINE COOLING SYSTEM

6.1 GENERAL

Thermostat

Thermostat opening temperatures:

- thermostat opens at  83_C

- thermostat opened at least 12 mm at  95_C Thermostat seat Loctite 638

Water pump

Maximum radial play 0.16 - 0.20 mm

Expansion tank pressure cap

Pressure relief valve opening pressure 0.75 - 0.9 bar Underpressure valve opening pressure 0.1 bar

Pressure testing the cooling system

Test pressure 0.5 - 0.7 bar

ǹ 200335

6-1

TECHNICAL DATA

XE engine cooling system 95XF series

6.2 TIGHTENING TORQUES

Water pump

M8 attachment bolts 30 Nm Threaded coupling 35 Nm

Coolant pipe

Attachment bolts 54 Nm Coolant pipe threaded coupling 90 Nm Plug 35 Nm

Thermostat housing

Attachment bolts 30 Nm Plug 35 Nm

Radiator

Attachment nuts 70 Nm

6.3 FILLING CAPACITIES

Cooling system capacity approx. 50 litres Cooling system capacity with ZF-intarder approx. 60 litres

6-2

ǹ 200335

TECHNICAL DATA

95XF series XE engine lubrication system

7. XE ENGINE LUBRICATION SYSTEM

7.1 GENERAL

Oil pressure

Oil pressure at engine idling speed 1 bar (warm engine) Oil pressure at full-load engine speed 3.5 - 4.5 bar

Oil filter

Type disposable filter Quantity 1 Installation in the oil circuit full flow Opening pressure of bypass valve at a

pressure difference of

Oil cooler

Opening pressure of bypass valve at a pressure difference of Oil section test pressure 6 bar

2.5  0.3 bar

2 bar

ǹ 200335

7-1

TECHNICAL DATA

XE engine lubrication system 95XF series

7.2 TIGHTENING TORQUES

Fuel filter

Attachment bolts, fuel filter/water pipe connection

Lubricating oil strip/rocker seats

Attachment bolts 110 Nm

Oil sump

Clamp attachment bolts 25 Nm Oil drain plug 60 Nm

Oil pump

Attachment bolts for oil pump housing sections 30 Nm Attachment bolts connecting oil pump to main

bearing cap Oil delivery pipe attachment bolts 30 Nm Idler gear central bolt 60 Nm

40 Nm

60 Nm

(1)

Strainer

Bracket attachment bolts 30 Nm

Lubricating oil filter

Lubricating oil filter housing attachment bolts 50 Nm Oil filter 45 Nm Coupling in lubricating oil filter head 60 Nm

Bypass pressure regulator

Plug 80 Nm

(1)

(2)

(3)

7-2

ǹ 200335

TECHNICAL DATA

95XF series XE engine lubrication system

Oil cooler

Attachment bolts connecting oil cooler to cylinder block Coolant supply pipe union 90 Nm

Plug, adjustable banjo connection 90 Nm Banjo bolt, adjustable banjo connection 90 Nm

Centrifugal oil filter

Central bolt 20 Nm Oil discharge pipe union 50 Nm

Dip stick

Threaded coupling 60 Nm

(1) Apply Loctite 243 to secure (2) Apply Loctite 572 to secure (3) Apply Loctite 2701 to secure

50 Nm

ǹ 200335

7-3

TECHNICAL DATA

XE engine lubrication system 95XF series

Oil sprayer

Oil sprayer banjo bolt 30 Nm

Main bearing caps

Main bearing cap attachment bolts 150 Nm + 120_ angular displacement

Big-end bearing caps

Attachment bolts (1) for cracked big-end bearing caps

phase, order 100 Nm

phase, order 175  15 Nm

phase, order 60_ angular

displacement

(2)

Attachment bolts, big-end bearing caps

phase,

sequence 1-2-3-4

phase,

2 sequence 4-3-2-1

phase,

3 sequence 1-2-3-4

35 Nm

45 Nm

60_ angular displacement

(2)

1 4

(1)

M2 01 285

Attachment bolts, big-end bearing caps

XE390C

phase,

sequence 1-2-3-4

phase,

2 sequence 4-3-2-1

phase,

3 sequence 1-2-3-4 60_ angular

(1) Apply a drop of oil to thread and contact surface. (2) Connecting rod bolts are to be used once and

tightened as instructed. When fitting the connecting rod in the engine, apply a drop of oil to the threads and contact surfaces of the connecting rod bolts.

50 Nm

80 Nm

displacement

(2)

M200661

7-4

ǹ 200335

95XF series XE engine lubrication system

7.3 FILLING CAPACITIES

TECHNICAL DATA

Lubrication system

Total capacity, including oil cooler and oil filter approx. 32 litres Oil sump capacity, maximum level approx. 25 litres Oil sump capacity, minimum level approx. 17 litres

ǹ 200335

7-5

TECHNICAL DATA

XE engine lubrication system 95XF series

7-6

ǹ 200335

DIAGNOSIS

95XF series Contents

CONTENTS

Page Date

1. TRACTIVE PROBLEMS 1-1 0008................................................ ......

1.1 Introduction 1-1 0008...................................................... ......

1.2 Acceleration test (engine model with conventional fuel system) 1-3 0008.......... ......

1.3 Acceleration test (engine model with UPEC fuel system) 1-7 0008................ ......

1.4 Acceleration test form 1-11 0008............................................. .....

1.5 Acceleration test using DAVIE 1-12 0008...................................... .....

2. XF ENGINE 2-1 0008........................................................... ......

2.1 Fault-finding table 2-1 0008................................................. ......

3. COOLING SYSTEM XF ENGINE 3-1 0008......................................... ......

3.1 Fault-finding table 3-1 0008................................................. ......

4. LUBRICATING OIL SYSTEM XF ENGINE 4-1 0008................................. ......

4.1 Fault-finding table 4-1 0008................................................. ......

5. XE ENGINE 5-1 0008........................................................... ......

5.1 Fault-finding table for engine functions 5-1 0008............................... ......

5.2 Fault-finding table for vehicle functions 5-9 0008............................... ......

6. COOLING SYSTEM XE ENGINE 6-1 0008......................................... ......

6.1 Fault-finding table 6-1 0008................................................. ......

7. LUBRICATING OIL SYSTEM XE ENGINE 7-1 0008................................. ......

7.1 Fault-finding table 7-1 0008................................................. ......

ǹ 0008

DIAGNOSIS

Contents 95XF series

ǹ 0008

DIAGNOSIS

95XF series Tractive problems

1. TRACTIVE PROBLEMS

1.1 INTRODUCTION

There may be several reasons for improper vehicle performance.

Some of these may be mechanical, others are particularly also of a psychological nature.

It is therefore important to properly identify the problem.

Try to get as much information as possible from the customer or driver.

- When does the vehicle not perform properly?

- In what road or weather conditions?

- How is the vehicle loaded?

- Is the vehicle not being compared with a vehicle with completely different specifications, for instance engine power?

- Is the vehicle being driven in the correct engine speed range?

If the answers are unsatisfactory, ask the customer or driver for facts.

- Tachograph cards of trips

- Reliable consumption figures of trips

ǹ 0008

1-1

DIAGNOSIS

Tractive problems 95XF series

Following proper identification of the complaint, vehicle performance can be tested by an acceleration test.

If the vehicle fails to pass the acceleration test, a boost pressure curve may be plotted as an aid to identify the cause.

Note:

Checking the boost pressure will in general only make sense after the vehicle has covered at least 20,000 km.

The test sheets are available through the DAF organisation.

For plotting a boost pressure curve, see Group 4 of the workshop manual.

1-2

ǹ 0008

DIAGNOSIS

95XF series Tractive problems

1.2 ACCELERATION TEST

(engine model with conventional fuel system)

The acceleration test is required to acquire an effective understanding of the fuel consumption and tractive force of a vehicle. When carrying out the test the legal regulations should be observed and maximum security be ensured.

Compared with other diagnostic tools, this test is a fast and cheap way of checking whether the vehicle meets DAF’s requirements and, therefore, whether or not the complaint is justified.

During the acceleration test the time required to accelerate the loaded vehicle from starting speed to final speed is measured. (Weight of entire combination at least 75% of the train weight, GCW).

To eliminate weather influences and road conditions, this test must be done in both driving directions. The average acceleration time is obtained by averaging both measured times.

The maximum acceleration time, the speeds between which the time is to be measured and the gear to be engaged for the various vehicle configurations is calculated using the DAF “Topec” route simulation computer program.

For this purpose, “Topec” needs the following and other vehicle data:

- vehicle type

- height of the entire vehicle combination

- weight of entire vehicle combination (at least 75% of the train weight)

- aerodynamic influences, e.g. roof spoilers, fenders, etc.

- engine type

- gearbox type and reduction

- rear axle type and axle reduction

-tyresize

- cab type.

ǹ 0008

1-3

DIAGNOSIS

Tractive problems 95XF series

Before starting the acceleration test

- Check the tyre pressure of the entire vehicle combination. Also check the tyres for a deviating wear pattern.

- Examine the complete condition of the trailer or semi-trailer.

- Check the entire vehicle combination for adverse aerodynamic influences, for instance loose tarpaulins, wrongly adjusted spoilers and fenders.

- Check the vehicle and trailer or semi-trailer for excessive road drag. Be aware of dragging brakes.

- Check the tachograph. The speed signal should be present.

- Check that the correct k-factor is set on the tachograph.

- Check that the fuel pump of the engine has been provided with the original seal.

- Check that the throttle control is able to reach the maximum stop of the fuel pump.

Acceleration test

1. Use the “Acceleration test form” in the workshop manual.

2. Check the activities as set out under “Before starting the acceleration test”.

3. Choose a test route where the difference between the measured times in both directions does not exceed 15%. If the difference in time exceeds 15%, find another test route.

4. Establish the starting and end points on the selected test route, to ensure that exactly the same route can be taken in both directions. Do the entire test at least twice and take the average time.

1-4

ǹ 0008

DIAGNOSIS

95XF series Tractive problems

5. Run the drive train at operating temperature (drive for at least 15 minutes with a loaded vehicle).

Note:

When switched on, the air compressor and fan consume 10 to 15 kW engine power on average. During the test try to avoid that both consumers are or have been switched on.

6. Before the starting point on the test route, engage the gear specified by Topec and make sure the vehicle speed is at least 3 km/h below the starting speed.

7. Fully depress the accelerator pedal and (using a stopwatch) measure the time needed to accelerate the vehicle from starting speed to end speed.

Result of first acceleration test

If the acceleration time is not achieved, first carry out the following work.

- Check the injection timing. Adjust or optimise, if necessary.

- Check the fuel system for the presence of air.

- Replace/clean the air filter element.

- Check the setting of the wastegate on the turbocharger (if present).

- Check the engine brake butterfly valve for smooth operation.

- Check the inlet air cooler exterior for dirt deposits.

- Clean the water separator (if fitted).

- Replace the fuel filter.

- Replace/clean the fuel prefilter (if present).

ǹ 0008

1-5

DIAGNOSIS

Tractive problems 95XF series

- Check the suction pipe of the tank for clogging by large pieces of foreign matter.

- Check the fuel tank for contamination. Clean the tank with a steam cleaner, if necessary.

- Check the air inlet system for any leaks.

- Check the exhaust system for any leaks.

- Check the exhaust system for blockages by measuring the exhaust back pressure.

- Check the turbocharger wheels on the compressor and turbine side for damage and for deposits of salt or any other contaminants.

- Check the banjo bolt strainer in the fuel lift pump for dirt (if fitted).

- Check the valve and DEB play.

- Check the injection lines for damage.

- Check the fuel pump gallery pressure.

- Check the discharge pump pressure.

- Check whether the right type of components have been fitted. Fuel pump, turbocharger, injectors, etc.

- Check the opening pressure of the injectors.

- Clean the nozzle openings using calibrated injector needles (DAF no. 1329371).

Repeat the acceleration test. If necessary, plot a boost pressure curve.

Result of second acceleration test

If the specified acceleration time is not achieved, carry out the following work.

- Remove the fuel pump from the engine.

- Check the fuel pump setting on a fuel pump test bench.

- Repeat the acceleration test.

1-6

ǹ 0008

DIAGNOSIS

95XF series Tractive problems

1.3 ACCELERATION TEST

(engine model with UPEC fuel system)

Compared with other diagnostic tools, this test is a fast and cheap way of checking whether the vehicle meets DAF’s requirements and, therefore, whether or not the complaint is justified.

During the acceleration test the time required to accelerate the loaded vehicle from starting speed to final speed is measured. (Weight of entire combination at least 75% of the train weight, GCW).

To eliminate weather influences and road conditions, this test must be done in both driving directions. The average acceleration time is obtained by averaging both measured times.

For this purpose, “Topec” needs the following and other vehicle data:

- vehicle type

- height of the entire vehicle combination

- weight of entire vehicle combination (at least 75% of the train weight)

- aerodynamic influences, e.g. roof spoilers, fenders, etc.

- engine type

- gearbox type and reduction

- rear axle type and axle reduction

-tyresize

- cab type.

ǹ 0008

1-7

DIAGNOSIS

Tractive problems 95XF series

Before starting the acceleration test

- Check the tyre pressure of the entire vehicle combination. Also check the tyres for a deviating wear pattern.

- Examine the complete condition of the trailer or semi-trailer.

- Check the entire vehicle combination for adverse aerodynamic influences, for instance loose tarpaulins, wrongly adjusted spoilers and fenders.

- Check the vehicle and trailer or semi-trailer for excessive road drag. Be aware of dragging brakes.

- Check the tachograph. The speed signal should be present.

- Check that the correct k-factor is set on the tachograph.

- Using DAVIE, check whether the pedal can be depressed 100% with the gas pedal position sensor.

Acceleration test

1. Use the “Acceleration test form” in the workshop manual.

2. Check the activities as set out under “Before starting the acceleration test”.

3. Choose a test route where the difference between the measured times in both directions does not exceed 15%. If the difference in time exceeds 15%, find another test route.

1-8

ǹ 0008

DIAGNOSIS

95XF series Tractive problems

5. Run the drive train at operating temperature (drive for at least 15 minutes with a loaded vehicle).

Note:

When switched on, the air compressor and fan consume 10 to 15 kW engine power on average. During the test try to avoid that both consumers are or have been switched on.

6. Connect DAVIE and follow the instructions in DAVIE.

7. Fully depress the brake pedal during the acceleration test.

Result of first acceleration test

If the acceleration time is not achieved, first carry out the following work.

- Check the fuel system for the presence of air.

- Replace/clean the air filter element.

- Check the setting of the wastegate on the turbocharger (if present).

- Check the engine brake butterfly valve for smooth operation.

- Check the inlet air cooler exterior for dirt deposits.

- Clean the water separator (if fitted).

- Clean the fuel coarse filter.

- Check whether the hand pump on the fuel coarse filter is tightened.

- Replace the fuel fine filter.

- Check the suction pipe of the tank for clogging by large pieces of foreign matter.

ǹ 0008

1-9

DIAGNOSIS

Tractive problems 95XF series

- Check the fuel tank for contamination. Clean the tank with a steam cleaner, if necessary.

- Check the air inlet system for any leaks.

- Check the exhaust system for any leaks.

- Check the exhaust system for blockages by measuring the exhaust back pressure.

- Check the turbocharger wheels on the compressor and turbine side for damage and for deposits of salt or any other contaminants.

- Check the valve and DEB play.

- Check the injection lines for damage.

- Check the gallery pressure.

- Check the fuel lift pump output.

- Check the reducing valve.

- Check whether the right type of components has been fitted. Turbocharger, injectors etc.

- Check the opening pressure of the injectors.

- Clean the nozzle openings using calibrated injector needles (DAF no. 1329371).

Repeat the acceleration test. If necessary, plot a boost pressure curve.

1-10

ǹ 0008

DIAGNOSIS

95XF series Tractive problems

1.4 ACCELERATION TEST FORM

General data:

Client’sname : ..........................................

Type/vehiclenumberplate : ..........................................

Typeoftrailer/semi-trailer : ..........................................

Owneroftrailer/semi-trailer : Client/Dealer/Thirdparties ...................

Date : ..........................................

Weather conditions : ..........................................

Route : ..........................................

Vehicle data:

Enginetype : ..........................................

Gearboxtype : ..........................................

Rearaxletype : ..........................................

Vehiclecombinationheight : ..........................................

Totalweightofvehiclecombination : ..........................................

Aerodynamic influences : ..........................................

TOPEC data:

Geartobeselected : ..........................................

Maximum acceleration time : seconds..................................

Starting speed : km/hour..................................

End speed : km/hour..................................

Acceleration test result:

Measured acceleration time : seconds..................................

Endresultofaccelerationtest : ..........................................

ǹ 0008

1-11

DIAGNOSIS

Tractive problems 95XF series

1.5 ACCELERATION TEST USING DAVIE

The acceleration test can also be carried out using DAVIE. Collect all the required information and, having started DAVIE, access the engine management system installed on the vehicle (E-gas, ASL-G or UPEC) and carefully follow the instructions in DAVIE in order to carry out the test correctly.

Following each test, the test results should always be stored on a disk.

The acceleration test in DAVIE should only be started when the vehicle is at a complete standstill. Because the communication between the accelerator pedal sensor and the unit is interrupted briefly during starting of DAVIE, this could lead to very dangerous situations in a vehicle which is not at a complete standstill.

Never switch to the direct test or fault-finding test when driving the vehicle.

1-12

ǹ 0008

DIAGNOSIS

95XF series XF engine

2. XF ENGINE

2.1 FAULT-FINDING TABLE

FAULT: ENGINE CAN BE STARTED, BUT DOES NOT RUN

Possible cause Remedy

Air in the fuel system. Bleed the fuel system.

Insufficient discharge pressure of the discharge pump.

Contaminated banjo bolt strainer in the discharge pump.

Water in the fuel system. Check the water separator.

Fuel filter silted up. Replace the fuel filter.

Incorrect or contaminated injectors installed. Check whether the correct injectors have been

Incorrect injection timing or incorrect fuel pump setting.

Compression pressure too low. Check the compression pressure.

FAULT: ENGINE STARTS AND STOPS

Possible cause Remedy

Air in the fuel system. Bleed the fuel system.

Insufficient discharge pressure of the discharge pump.

Check the discharge pump pressure.

Check the strainer for contamination.

installed. Clean contaminated injectors and set them.

Check the injection timing and/or fuel pump setting.

Check the discharge pump pressure.

Fuel filter silted up. Replace the fuel filter.

Incorrect injection timing or incorrect fuel pump setting.

FAULT: ENGINE WILL NOT RUN IDLE

Possible cause Remedy

Air in the fuel system. Bleed the fuel system.

Incorrect or contaminated injectors installed. Check whether the correct injectors have been

Incorrect injection timing or incorrect fuel pump setting.

Injection pipes torn or broken. Check the injection lines. Replace if necessary.

Check the injection timing and/or fuel pump setting.

installed. Clean contaminated injectors and set them.

Check the injection timing and/or fuel pump setting.

ǹ 0008

2-1

DIAGNOSIS

XF engine 95XF series

FAULT: ENGINE DELIVERS LESS THAN MAXIMUM POWER

Possible cause Remedy

Fuel filter silted up. Replace the fuel filter.

Incorrect or contaminated injectors installed. Check whether the correct injectors have been

installed. Clean contaminated injectors and set them.

Incorrect injection timing or incorrect fuel pump setting.

Fuel tank ventilation opening clogged blocked. Check/clean the vent opening.

Air cleaner element blocked. Clean or replace the air-filter element.

Blocked air inlet from turbocharger to inlet manifold.

Air leak in the pressure part of the inlet system. Check the inlet unit for any leaks.

Compressor side of turbocharger contaminated. Clean compressor side with a non-corrosive

Exhaust manifold, exhaust silencer, exhaust pipe blocked.

Gas leak between exhaust manifold and cylinder head.

Gas leak between exhaust manifold and turbocharger.

Incorrect wastegate setting or defective wastegate.

Damaged turbocharger. Replace the turbocharger and identify the cause.

Incorrect valve clearance setting. Check valve clearance. Adjust if necessary.

Check the injection timing and/or fuel pump setting.

Check air inlet. Clean if necessary.

cleaning agent or a soft brush Check the inlet side for carbon deposits or other contamination.

Check the exhaust unit. Clean if necessary.

Check the fixing bolts and gaskets.

Check the wastegate or wastegate setting.

Incorrect DEB setting. Check the DEB play. Adjust if necessary.

DEB continues to operate. Check the DEB function.

Compression pressure too low. Check the compression pressure.

2-2

ǹ 0008

DIAGNOSIS

95XF series XF engine

FAULT: ENGINE PRODUCES EXTREME SMOKE LEVELS

Possible cause Remedy

Incorrect injection timing or incorrect fuel pump setting.

Incorrect or contaminated injectors installed. Check whether the correct injectors have been

Fuel filter silted up. Replace the fuel filter.

Blocked air cleaner. Check the air-filter element. Blow-clean or

Air leak between inlet manifold and cylinder head.

Gas leak between exhaust manifold and turbocharger.

Gas leak between exhaust manifold and cylinder head.

Cooling system failure. Check the cooling system.

Lubrication system failure. Check the lubricating-oil system.

Compression pressure too low. Check the compression pressure.

Check the injection timing and/or fuel pump setting.

installed. Clean contaminated injectors and set them.

replace, if necessary.

Check for leaks. Replace the gaskets, if necessary.

Check the fixing bolts and gaskets.

ǹ 0008

2-3

DIAGNOSIS

XF engine 95XF series

FAULT: ENGINE PRODUCES EXCESSIVE NOISE

Possible cause Remedy

Broken valve springs. Check valve springs. Replace if necessary.

Excess clearance between piston and cylinder wall.

Run-out main and/or connecting-rod bearings. Check the main and connecting-rod bearings.

Fuel system failure. Check the fuel system.

Inlet system failure. Check the inlet system.

Exhaust system failure. Check the exhaust system.

Air compressor, fan drive, air-conditioning compressor.

Lubrication system failure. Check the lubricating-oil system.

Incorrect V-belt tension or V-belt misalignment. Check the V-belt tension or the V-belt alignment.

Excessive radial play of water pump. Check radial play of water pump.

Fan damaged or fan touching the radiator. Check fan and radiator.

Damaged or loose engine brackets. Check the engine brackets.

Excessive valve clearance. Readjust the valve clearance.

Damaged valve train and/or push rods, cam followers, rocker shafts or rocker arms.

Damaged vibration damper. Check the vibration damper for damage.

Check the piston clearance in the cylinder.

Check whether the air compressor, fan drive, air-conditioning compressor or other engine attachments may be the cause of the noise.

Check the drive train, etc. for damage.

Damaged pistons and/or cylinder linings. Check the pistons and cylinder linings.

Timing gear wheels. Check the timing gear wheels for play and/or

damage.

Loose or broken flywheel or coupling bolts. Check the flywheel/coupling.

2-4

ǹ 0008

DIAGNOSIS

95XF series Cooling system XF engine

3. COOLING SYSTEM XF ENGINE

3.1 FAULT-FINDING TABLE

FAULT: ENGINE TEMPERATURE INCREASES

Possible cause Remedy

Incorrect injection timing or incorrect fuel pump setting.

Incorrect injectors installed. Check whether the correct injectors have been

Inlet system failure. Check the inlet system.

Lubrication system failure. Check the lubricating-oil system.

Incorrect V-belt tension. Check the V-belt tension or replace the V-belt.

Insufficient coolant. Check the coolant level. Top up if necessary.

Coolant pipe torn or blocked. Check the coolant pipes.

Contaminated radiator/cooling system. Check the radiator. Clean if necessary.

Incorrect or malfunctioning pressure cap. Check the pressure cap.

Thermostat opens insufficiently or not at all. Check the thermostat and its operation.

Contaminated coolant filter. Check the coolant filter. If necessary, replace

Defective water pump. Check the water-pump shaft, bearings and

Defective viscous fan. Check operation of viscous fan.

Check the injection timing and/or fuel pump setting.

installed.

and clean the cooling system.

impeller. Replace water pump, if necessary.

ǹ 0008

3-1

DIAGNOSIS

Cooling system XF engine 95XF series

FAULT: EXTERNAL COOLANT LEAKAGE

Possible cause Remedy

Defective coolant pipes. Check the coolant pipes.

Defective coolant pipes. Check coolant pipes.

Leaking radiator. Check the radiator. Pressure-test if necessary.

Leaking water pump. Check the water pump. If necessary, measure

the bearing play.

Defective oil cooler. Check the oil cooler. Pressure-test if necessary.

Defective pressure cap. Check the pressure cap. Pressure-test if

necessary.

Leaking heater. Check heater pipes.

Leaking connection between coupling and water pipe.

FAULT: INTERNAL COOLANT LEAKAGE

Possible cause Remedy

Defective cylinder head gasket. Check the cylinder head gasket.

Cracked cylinder heads or cylinder block. Check the cylinder heads and engine block for

Leaking injector bushes. Check cylinder heads. Pressure-test if

Defective compressor cylinder head gasket. Replace compressor cylinder head gasket.

Defective oil cooler. Check whether there is coolant in the lubricating

Defective freeze plugs in tappet area (cylinder block) or at the top of the cylinder heads.

Check connection between water pipe and coupling for damage. Replace the O-rings.

internal cracks. Pressure-test if necessary.

necessary.

oil system.

Replace freeze plug(s).

3-2

ǹ 0008

DIAGNOSIS

95XF series Lubricating oil system XF engine

4. LUBRICATING OIL SYSTEM XF ENGINE

4.1 FAULT-FINDING TABLE

FAULT: ENGINE OIL PRESSURE TOO LOW

Possible cause Remedy

Engine oil level too low. Top up engine oil to maximum level.

External oil leakage. Visually check engine for leakage. Repair if

necessary.

Defective oil-pressure switch. Check the switch. Replace if necessary.

Oil fails to meet the required specifications. Renew the engine oil and the oil filter.

Oil temperature is too high. Check the oil cooler.

Oil mixed with coolant or fuel. Renew the engine oil and the oil filter.

Oil feed-through pipe or oil suction pipe loose or broken.

Oil-pressure control valve fails to operate. Check the oil pressure control valve.

Inadequate functioning of oil pump. Check the oil pump.

Run-out main or connecting-rod bearings. Check the main or connecting-rod bearings.

Loose oil nozzle of piston cooler. Check the oil nozzle. Replace if necessary.

Defective internal oil pressure pipes or sealing. Check the oil pressure pipes and seals.

Contamination between oil-pressure control valve and seat.

Contaminated oil filter. Renew the oil filter.

Check the oil pipes. Repair if necessary.

Check/clean the oil pressure control valve.

ǹ 0008

4-1

DIAGNOSIS

Lubricating oil system XF engine 95XF series

FAULT: ENGINE USES TOO MUCH OIL

Possible cause Remedy

Inlet system failure. Check the inlet system.

Exhaust system failure. Check the exhaust system.

Leaking oil cooler. Check whether there is lubricating oil in the

engine cooling system.

Oil temperature is too high. Check whether the correct oil cooler has been

installed

Blow-by is too high. Check the compression pressure and carry out a

cylinder leak test. Check the condition of the piston rings and cylinder linings.

Worn piston rings and/or cylinder linings. Replace the piston rings and/or cylinder linings.

Check the air inlet system. Check the oil specifications.

Damaged or missing injector O-ring. Check the injector seal.

4-2

ǹ 0008

DIAGNOSIS

95XF series XE engine

5. XE ENGINE

5.1 FAULT-FINDING TABLE FOR ENGINE FUNCTIONS

FAULT: ENGINE CAN BE STARTED, BUT DOES NOT RUN

Possible cause Remedy

Poor fuel quality. Drain fuel, rinse the fuel system, replace the fuel

filters and fill the fuel tank with fuel.

Air in the fuel system. Check the fuel system for drawing in air:

- through suction pipe

- through sealing ring of fuel lift pump

Fuel filter blocked. Replace the fuel filter and clean the system.

Fault in electrical components/wiring of:

- connectors

- pump unit

- electronic unit

- crankshaft position sensor and camshaft position sensor

Communication with DAVIE interrupted when the engine is tested with DAVIE.

Incorrect pump housing camshaft timing, camshaft position sensor signal not present at correct moment.

No fuel supply, or fuel lift pump defective, no output.

Check the electrical system.

Remove the earth cable from the battery and fit it again.

Check timing/signal from camshaft position sensor.

Check:

- fuel level

- pipes for clogging and leakage

- fuel lift pump

Pressure-relief valve on pump housing does not shut off.

Check the pressure-relief valve.

ǹ 0008

5-1

DIAGNOSIS

XE engine 95XF series

FAULT: ENGINE STALLS AND PICKS UP AFTER RESTARTING

Possible cause Remedy

Air in the fuel system. Check the fuel system for drawing in air:

- through suction pipe

- through sealing ring of fuel lift pump

Poor contacts, contact resistance in connectors. Check the connector joints.

Pressure-relief valve on pump housing does not shut off.

FAULT: ENGINE DOES NOT PICK UP PROPERLY

Possible cause Remedy

Poor fuel quality. Drain fuel, rinse the fuel system, replace the fuel

Air in the fuel system. Check the fuel system for drawing in air:

Fuel filter blocked. Replace the fuel filter and clean the system.

Fault in electrical components/wiring of:

- connectors

- pump unit

- electronic unit

- crankshaft position sensor and camshaft position sensor

- sensor for engine coolant temperature

Battery voltage too low. Charge the batteries.

Connection points on pump units changed. Install the correct connection points on the

Check the pressure-relief valve.

filters and fill the fuel tank with fuel.

- through suction pipe

- through sealing ring of fuel lift pump

Check the electrical system.

correct pump unit.

Mechanical defect or clogging of pump units. Replace the pump units.

Injectors defective. Check the injectors.

Pressure-relief valve on pump housing does not shut off.

Fuel lift pump output too low. Check the fuel lift pump and replace, if

Check the pressure-relief valve.

necessary.

5-2

ǹ 0008

DIAGNOSIS

95XF series XE engine

FAULT: ENGINE RUNS AT (INCREASED) IDLING SPEED AND

DOES NOT RESPOND TO ACCELERATOR PEDAL

Possible cause Remedy

Accelerator pedal sensor, mechanical defect. Check:

- mechanical connection sensor/accelerator pedal

- accelerator pedal sensor

Fuel quantity adjusted by ABS/ASR.

Engine brake input signal available. Check the electrical system of the engine brake.

FAULT: ENGINE RUNS AT INCREASED IDLING SPEED (1000 RPM) AND

DOES NOT RESPOND TO ACCELERATOR PEDAL

Possible cause Remedy

Fault in electrical components/wiring of:

- connectors

- pump unit

- electronic unit

- crankshaft position sensor and camshaft position sensor

- sensor for engine coolant temperature

FAULT: ENGINE RUNS AT INCREASED IDLING SPEED (1000 RPM) AND

RESPONDS TO ACCELERATOR PEDAL

Possible cause Remedy

Fault in electrical components/wiring of accelerator pedal sensor.

FAULT: MAXIMUM ENGINE SPEED IS 1000 RPM

Possible cause Remedy

Fault in electrical components/wiring of accelerator pedal sensor.

Check the electrical system.

ǹ 0008

5-3

DIAGNOSIS

XE engine 95XF series

FAULT: DIESEL KNOCK DURING ACCELERATION

Possible cause Remedy

Poor fuel quality. Drain fuel, rinse the fuel system, replace the fuel

filters and fill the fuel tank with fuel.

Air in the fuel system. Check the fuel system for drawing in air:

- through suction pipe

- through sealing ring of fuel lift pump

Fault in electrical components/wiring of sensor for engine coolant temperature.

Injector defective. Check the injectors.

Crankshaft position sensor defective. Check the crankshaft position sensor.

FAULT: ENGINE RUNS IRREGULARLY

Possible cause Remedy

Poor fuel quality. Drain fuel, rinse the fuel system, replace the fuel

Air in the fuel system. Check the fuel system for drawing in air:

Fuel filter blocked. Replace the fuel filter.

Connection points on pump units changed. Install the correct connection points on the

Mechanical defect or clogging of pump units. Replace the pump units.

Injector defective. Check the injectors.

Check the electrical system.

filters and fill the fuel tank with fuel.

- through suction pipe

- through sealing ring of fuel lift pump

correct pump unit.

Fuel lift pump output too low. Check the fuel lift pump and replace, if

necessary.

Pressure-relief valve on pump housing does not shut off.

Fault in electrical components/wiring of:

- connectors

- pump unit

Check the pressure-relief valve.

Check the electrical system.

5-4

ǹ 0008

DIAGNOSIS

95XF series XE engine

FAULT: REDUCED POWER AT ALL SPEEDS

Possible cause Remedy

Poor fuel quality. Drain fuel, rinse the fuel system, replace the fuel

filters and fill the fuel tank with fuel.

Fuel filter blocked. Replace the fuel filter.

Accelerator pedal sensor, mechanical defect. Check:

- mechanical connection sensor/accelerator pedal

- accelerator pedal sensor

Fault in electrical components/wiring of:

- accelerator pedal sensor

- sensor for engine coolant temperature

- boost pressure sensor

- fuel temperature sensor

- contacts

- contact resistance in connector joints

Air filter clogged. Replace or clean the air filter.

Turbocharger defective/incorrect waste-gate control.

Electro-pneumatic boost pressure valve mechanically defective.

Air leaks in inlet system. Pressure-test the inlet system.

Mechanical defect or clogging of pump units. Replace the pump units.

Injector defective. Check the injectors.

Pressure-relief valve on pump housing does not shut off.

Check the electrical system.

Check wastegate or wastegate control.

Check electro-pneumatic boost pressure valve.

Check the pressure-relief valve.

Fuel lift pump output too low. Check the fuel lift pump and replace, if

necessary.

ǹ 0008

5-5

DIAGNOSIS

XE engine 95XF series

FAULT: REDUCED POWER ABOVE A PARTICULAR SPEED

Possible cause Remedy

Fuel filter partially blocked. Replace the fuel filter.

Air filter partially clogged. Replace or clean the air filter.

Electro-pneumatic boost pressure valve mechanically defective.

Check electro-pneumatic boost pressure valve.

Fault in electrical components/wiring of sensor for electro-pneumatic boost pressure valve.

Air leaks in inlet system. Pressure-test the inlet system.

Pressure-relief valve on pump housing does not shut off.

Fuel lift pump output too low. Check the fuel lift pump and replace, if

FAULT: WHITE/BLUE SMOKE DEVELOPMENT

Possible cause Remedy

Poor fuel quality. Drain fuel, rinse the fuel system, replace the fuel

Air in the fuel system. Check the fuel system for drawing in air:

Fuel filter blocked. Replace the fuel filter and clean the system.

Fault in electrical components/wiring of:

- crankshaft position sensor

- sensor for engine coolant temperature

Mechanical defect or clogging of pump units. Replace the pump units.

Check the electrical system.

Check the pressure-relief valve.

necessary.

filters and fill the fuel tank with fuel.

- through suction pipe

- through sealing ring of fuel lift pump

Check the electrical system.

Injector defective. Check the injectors.

Fuel lift pump output too low. Check the fuel lift pump and replace, if

necessary.

5-6

ǹ 0008

DIAGNOSIS

95XF series XE engine

FAULT: BLACK SMOKE DEVELOPMENT

Possible cause Remedy

Fault in electrical components/wiring of:

- crankshaft position sensor

- air inlet temperature sensor

- fuel temperature sensor

- boost pressure sensor

Injector defective. Check the injectors.

FAULT: FUEL CONSUMPTION TOO HIGH

Possible cause Remedy

Poor fuel quality. Drain fuel, rinse the fuel system, replace the fuel

Fuel filter blocked. Replace the fuel filter and clean the system.

Fault in electrical components/wiring of:

- sensor for engine coolant temperature

- boost pressure sensor

- fuel temperature sensor

Air leaks in inlet system. Pressure-test the inlet system.

Mechanical defect or clogging of pump units. Replace the pump units.

Injector defective. Check the injectors.

Leaks in fuel system. Check for leaks.

Check the electrical system.

filters and fill the fuel tank with fuel.

Check the electrical system.

ǹ 0008

5-7

DIAGNOSIS

XE engine 95XF series

FAULT: REDUCED MAXIMUM SPEED

Possible cause Remedy

Air in the fuel system. Check the fuel system for drawing in air:

- through suction pipe

- through sealing ring of fuel lift pump

Fuel filter blocked. Replace the fuel filter and clean the system.

Crankshaft position sensor, signal fault. Check:

- crankshaft position sensor

- wiring

Fault in electrical components/wiring of sensor for

- accelerator pedal sensor

- engine coolant temperature sensor

Turbocharger defective. Check the turbocharger.

Mechanical defect or clogging of pump units. Replace the pump units.

Fuel quantity adjusted by ABS/ASR.

Fuel lift pump output too low. Check the fuel lift pump and replace, if

Check the electrical system.

necessary.

5-8

ǹ 0008

DIAGNOSIS

95XF series XE engine

5.2 FAULT-FINDING TABLE FOR VEHICLE FUNCTIONS

FAULT: VEHICLE SPEED CONTROL IS NOT FUNCTIONING

Possible cause Remedy

Fault in electrical components/wiring of:

- wiring harness

- combination switch

- speed signal

- proximity switch

There is/are switch-off condition(s) for vehicle speed control.

FAULT: ENGINE SPEED CONTROL IS NOT FUNCTIONING

Possible cause Remedy

There is/are switch-off condition(s) for engine speed control.

Fault in electrical components/wiring of:

- wiring harness

- combination switch

- speed signal

FAULT: DEFECTIVE PRE-GLOWING AND AFTER-GLOWING FUNCTIONS

Possible cause Remedy

Fault in electrical components/wiring of:

- wiring harness

- preglowing control light

- glow filaments

- glow-filament relay

Check the electrical system.

Check for presence of switch-off condition(s).

Check the electrical system.

There is/are switch-off condition(s) for the pre-glowing and after-glowing functions.

Check for presence of switch-off condition(s).

ǹ 0008

5-9

DIAGNOSIS

XE engine 95XF series

FAULT: INCORRECT SPEED DISPLAY ON REV COUNTER

Possible cause Remedy

Fault in electrical components/wiring of:

- wiring harness

- crankshaft position sensor

- electronic unit, UPEC

FAULT: ENGINE CANNOT BE TURNED OFF WITH CONTACT KEY

Possible cause Remedy

Fault in electrical components/wiring of wiring harness. Supply voltage to UPEC electronic unit is not switched off. Supply voltage after contact at the UPEC electronic unit is not switched off by ignition lock.

FAULT: WARNING LAMP DOES NOT LIGHT UP OR IS NOT EXTINGUISHED

Possible cause Remedy

Fault in electrical components/wiring of:

- wiring harness

- electronic unit, UPEC

FAULT: COMMUNICATION WITH DAVIE IMPOSSIBLE

Check the electrical system.

Possible cause Remedy

Fault in electrical components/wiring of:

- wiring harness

- diagnosis connector Supply voltage after contact at the UPEC electronic unit is not switched off by ignition lock. No supply voltage on the UPEC electronic unit. UPEC electronic unit defective.

Check the electrical system.

5-10

ǹ 0008

DIAGNOSIS

95XF series Cooling system XE engine

6. COOLING SYSTEM XE ENGINE

6.1 FAULT-FINDING TABLE

FAULT: ENGINE TEMPERATURE INCREASES

Possible cause Remedy

Incorrect injectors installed. Check whether the correct injectors have been

installed.

Inlet system failure. Check the inlet system.

Lubrication system failure. Check the lubricating-oil system.

Incorrect V-belt tension. Check the V-belt tension or replace the V-belt.

Insufficient coolant. Check the coolant level. Top up if necessary.

Coolant pipe torn or blocked. Check the coolant pipes.

Intercooler, cooling system radiator contaminated.

Wastegate setting is too high. Check wastegate setting.

Air hose from turbocharger housing to wastegate diaphragm leaking or not connected.

Incorrect or malfunctioning pressure cap. Check the pressure cap.

Thermostat opens insufficiently or not at all. Check the thermostat and its operation.

Contaminated coolant filter. Check the coolant filter. If necessary, replace

Defective water pump. Check the water-pump shaft, bearings and

Check/clean the intercooler, the cooling system radiator.

Check air hose. Replace if necessary.

and clean the cooling system.

impeller. Replace the water pump, if necessary.

Defective viscous fan. Check operation of viscous fan.

Poor fuel quality. Drain fuel, rinse the fuel system, replace the fuel

filters and fill the fuel tank with fuel.

Sensor for engine coolant temperature, signal fault/short-circuit/interruption.

Check:

- engine coolant temperature sensor

- wiring

ǹ 0008

6-1

DIAGNOSIS

Cooling system XE engine 95XF series

FAULT: EXTERNAL COOLANT LEAKAGE

Possible cause Remedy

Defective coolant pipes. Check the coolant pipes.

Defective coolant pipes. Check coolant pipes.

Leaking radiator. Check the radiator. Pressure-test if necessary.

Leaking water pump. Check the water pump. If necessary, measure

bearing play.

Defective oil cooler. Check the oil cooler. Pressure-test if necessary.

Defective pressure cap. Check the pressure cap. Pressure-test if

necessary.

Leaking heater. Check heater pipes.

Leaking connection between coupling and water pipe.

FAULT: INTERNAL COOLANT LEAKAGE

Possible cause Remedy

Defective cylinder head gasket. Check the cylinder head gasket.

Cracked cylinder heads or cylinder block. Check the cylinder heads and engine block for

Leaking injector bushes. Check cylinder heads. Pressure-test if

Defective compressor cylinder head gasket. Replace compressor cylinder head gasket.

Defective oil cooler. Check whether there is coolant in the lubricating

Defective freeze plugs in tappet area (cylinder block) or at the top of the cylinder heads.

Check the connection between water pipe and coupling for damage. Replace the O-rings.

internal cracks. Pressure-test if necessary.

necessary.

oil system.

Replace the freeze plug(s).

6-2

ǹ 0008

DIAGNOSIS

95XF series Lubricating oil system XE engine

7. LUBRICATING OIL SYSTEM XE ENGINE

7.1 FAULT-FINDING TABLE

FAULT: ENGINE OIL PRESSURE TOO LOW

Possible cause Remedy

Engine oil level too low. Top up engine oil to maximum level.

External oil leakage. Visually check engine for leakage. Repair if

necessary.

Defective oil-pressure switch. Check the switch. Replace if necessary.

Oil fails to meet the required specifications. Renew the engine oil and the oil filter.

Oil temperature is too high. Check the oil cooler.

Oil mixed with coolant or fuel. Renew the engine oil and the oil filter.

Oil feed-through pipe or oil suction pipe loose or broken.

Oil-pressure control valve fails to operate. Check the oil pressure control valve.

Inadequate functioning of oil pump. Check the oil pump.

Run-out main or connecting-rod bearings. Check the main or connecting-rod bearings.

Loose oil nozzle of piston cooler. Check the oil nozzle. Replace if necessary.

Defective internal oil pressure pipes or sealing. Check the oil pressure pipes and seals.

Contamination between oil-pressure control valve and seat.

Contaminated oil filter. Replace the oil filter.

Check the oil pipes. Repair if necessary.

Check/clean the oil pressure control valve.

ǹ 0008

7-1

DIAGNOSIS

Lubricating oil system XE engine 95XF series

FAULT: ENGINE USES TOO MUCH OIL

Possible cause Remedy

Inlet system failure. Check the inlet system.

Exhaust system failure. Check the exhaust system.

Leaking oil cooler. Check whether there is lubricating oil in the

engine cooling system.

Oil temperature is too high. Check whether the correct oil cooler has been

installed.

Blow-by is too high. Check the compression pressure and carry out

a cylinder leak test. Check the condition of the piston rings and cylinder linings.

Worn piston rings and/or cylinder linings. Replace the piston rings and/or cylinder linings.

Check the air inlet system. Check the oil specifications.

Damaged or missing injector O-ring. Check the injector seal.

7-2

ǹ 0008

XF ENGINE

95XF series Contents

CONTENTS

Page Date

1. SAFETY INSTRUCTIONS 1-1 0008............................................... ......

2. GENERAL 2-1 0008............................................................ ......

2.1 Location of components 2-1 0008........................................... ......

2.2 Overview drawing of fan drive 2-4 0008...................................... ......

2.3 Overview drawing of timing gear 2-5 0008.................................... ......

2.4 Overview drawing fuel pump drive 2-6 0008................................... ......

3. INSPECTION AND ADJUSTMENT 3-1 0008....................................... ......

3.1 Checking and adjusting the valve mechanism bridges 3-1 0008.................. ......

3.2 Inspection and adjustment, valve clearance 3-4 0008........................... ......

3.3 Checking and adjusting the timing gear 3-6 0008.............................. ......

3.4 Inspection and adjustment, V-belt tension 3-9 0008............................ ......

3.5 Checking the flywheel 3-11 0008............................................. .....

3.6 Inspection, engine compression pressure 3-12 0008............................ .....

3.7 Inspection, cylinder head 3-13 0008........................................... .....

3.8 Inspection, glow filaments 3-13 0008.......................................... .....

4. REMOVAL AND INSTALLATION 4-1 0008......................................... ......

4.1 Removal and installation, engine 4-1 0008.................................... ......

4.2 Removal and installation, engine mounting 4-2 0008........................... ......

4.3 Removal and installation, valve cover 4-4 0008................................ ......

4.4 Removal and installation, valve mechanism 4-5 0008........................... ......

4.5 Removal and installation, cylinder head 4-7 0008.............................. ......

4.6 Removal and installation of glow filaments 4-12 0008............................ .....

4.7 Removal and installation, inlet manifold 4-13 0008.............................. .....

4.8 Removal and installation, exhaust manifold 4-14 0008........................... .....

4.9 Removal and installation, air compressor 4-16 0008............................. .....

4.10 Removal and installation, steering pump 4-17 0008............................. .....

4.11 Removal and installation, starting motor 4-18 0008.............................. .....

4.12 Removal and installation, alternator 4-19 0008.................................. .....

4.13 Removal and installation, V-belts 4-20 0008.................................... .....

4.14 Removal and installation, flywheel 4-22 0008................................... .....

4.15 Removal and installation, starter ring 4-23 0008................................ .....

4.16 Removal and installation, flywheel housing sealing ring 4-24 0008................. .....

4.17 Removal and installation, flywheel housing 4-25 0008........................... .....

4.18 Removal and installation, fan drive 4-27 0008.................................. .....

4.19 Removal and installation, vibration damper 4-29 0008........................... .....

4.20 Removal and installation, vibration-damper hub 4-30 0008....................... .....

4.21 Removal and installation, timing-gear cover sealing ring 4-31 0008................ .....

4.22 Removal and installation, timing-gear cover 4-32 0008........................... .....

4.23 Removal and installation, timing gear wheels 4-33 0008......................... .....

4.24 Removal and installation, timing-gear case 4-37 0008........................... .....

4.25 Removal and installation, timing gear sealing ring 4-38 0008...................... .....

4.26 Removal and installation, fuel-pump drive housing 4-39 0008..................... .....

5. DISASSEMBLY AND ASSEMBLY 5-1 0008........................................ ......

5.1 Disassembly and assembly of the fan drive 5-1 0008........................... ......

6. CLEANING 6-1 0008............................................................ ......

6.1 Cleaning the engine 6-1 0008............................................... ......

ǹ 0008

XF ENGINE

Contents 95XF series

ǹ 0008

XF ENGINE

95XF series Safety instructions

1. SAFETY INSTRUCTIONS

Do not run the engine in an enclosed or unventilated area. Make sure exhaust fumes are properly extracted.

Maintain a safe distance from rotating and/or moving components.

Various sorts of oil and other lubricants used on the vehicle may constitute a health hazard. This also applies to engine coolant, windscreen washer fluid, refrigerant in air-conditioning systems, battery acid and diesel fuel. So avoid inhaling and direct contact.

Exhaust gases contain carbon monoxide. Carbon monoxide is a deadly, colourless and odourless gas, which, when inhaled, deprives the body of oxygen, leading to asphyxiation. Serious carbon monoxide poisoning may result in brain damage or death.

It is recommended to always disconnect the battery’s earth connection during repair or maintenance activities for which the power supply is not required.

ǹ 0008

1-1

XF ENGINE

Safety instructions 95XF series

1-2

ǹ 0008

95XF series General

XF ENGINE

2. GENERAL

2.1 LOCATION OF COMPONENTS

3 1

Legend

1. Thermostat housing

2. Water pump

3. Air-conditioning compressor

4. Fan drive

5. Vibration damper

6. Air compressor

7. Oil cooler

8. Turbocharger

9. Wastegate diaphragm

10. Oil-filling pipe

7 6

M200543

ǹ 0008

2-1

XF ENGINE

General 95XF series

2021 171819

13 14 15

Legend

11. Steering pump

12. Fuel pump drive housing

13. Fuel pump

14. Oil filter

15. Engine brake valve

16. Starting motor

17. Engine information-code plate

18. Fuel filter

19. Coolant filter

20. Coolant pipe

21. Inlet manifold

22. Glow-filament relay

23. Alternator

M200542

2-2

ǹ 0008

XF ENGINE

95XF series General

Engine number

The engine number is marked on the engine block at the rear left.

XF Engine information-code plate

Fitted to the inlet manifold

1. Injection timing

2. Maximum governed engine speed

3. Engine number

4. Engine type

5. Indication of country of origin

6. Certificate number

7. Fuel pump setting (output)

8. Smoke level at maximum engine speed, without load

ENGINE TYPE

ENGINE NUMBER

GOVERNED SPEED

INJECTION TIMING

EINDHOVEN HOLLAND

35 6

-1

OUTPUT

min

BEFORE T.D.C.

SMOKE LEVEL FREE ACCELERATION

PUMPSETTING

D000311

-1

M200678

ǹ 0008

2-3

XF ENGINE

General 95XF series

2.2 OVERVIEW DRAWING OF FAN DRIVE

Legend

1. Fan clutch shaft

2. Oil sealing ring

3. Bearing

4. Bearing ring

5. Spacer sleeve

6. Intermediate ring

7. Bearing ring

8. O-ring

9. Bearing

10. Retaining ring

11. Bearing housing

12. Gearwheel

13. Retaining ring

2-4

821 123 4 5 6 7 9 10 11

M200671

ǹ 0008

95XF series General

2.3 OVERVIEW DRAWING OF TIMING GEAR

XF ENGINE

24 510

Legend

1. Crankshaft

2. Camshaft

3. Intermediate gear wheel

4. Fan drive

5. Steering pump

6. Fuel-pump drive gear wheel

7. Air compressor

8. Intermediate gear wheel of oil pump

9. Oil pump

10. Silencer

M200549

ǹ 0008

2-5

XF ENGINE

General 95XF series

2.4 OVERVIEW DRAWING FUEL PUMP DRIVE

234 56

Legend

1. Silencer

2. Fuel-pump drive gear wheel

3. Timing gear sealing ring

4. Bearing housing

5. Fuel-pump drive sealing ring

6. Clamping piece

7. Axial retainer plate

8. Drive shaft

2-6

M200582

ǹ 0008

XF ENGINE

95XF series Inspection and adjustment

3. INSPECTION AND ADJUSTMENT

3.1 CHECKING AND ADJUSTING THE VALVE MECHANISM BRIDGES

Loosening and torqueing the lock nuts (B) of the bridges may cause severe engine damage if the bridge is fitted on the valves.

1. Remove the valve covers, see chapter

“Removal and installation”.

2. Place the fuel pump in the stop position.

Lock the fuel pump in this position.

3. Remove the DEB or the lubricating-oil strip

(depending on model).

4. Remove the entire rocker bracket. Mark the

position to allow reinstallation in the same position.

Note:

In engines equipped with a DEB, the bridges of the inlet and exhaust valves are not the same. In engines without a DEB, the bridges of the inlet and exhaust valves are the same.

ǹ 0008

3-1

XF ENGINE

Inspection and adjustment 95XF series

Exhaust bridge with DEB

Exhaust bridge without DEB

i 400162

i 400161

3-2

ǹ 0008

XF ENGINE

95XF series Inspection and adjustment

5. Remove the bridge from the valves and

place it in a vice.

6. Slacken lock nut (B).

7. Reposition the bridge in the engine over the

valves.

8. Firmly press on the bridge centre (above

the guiding pin) with your thumb.

9. Hand-tighten adjusting screw (A) until the

bridge starts to move (adjusting screw (A) now touches the valve).

10. Turn adjusting screw (A) through another

90_ and carefully remove the bridge from the valves.

11. Place the bridge in a vice and tighten lock

nut (B) to the specified torque without turning adjusting screw (A), see main group “Technical data”.

i 400234

12. Reposition the bridge over the valves.

13. Install the rocker bracket.

14. Install the DEB or the lubricating-oil strip

(depending on model). Install the lubricating-oil strip in such a way that the mark “cyl. 1/4” is located on cylinder 1 or cylinder 4 respectively.

15. Adjust the valve clearance and, if fitted, the

DEB clearance.

16. Fit the valve covers, see chapter

“Removal and installation”.

M200548

ǹ 0008

3-3

XF ENGINE

Inspection and adjustment 95XF series

3.2 INSPECTION AND ADJUSTMENT, VALVE CLEARANCE

1. Remove the valve cover, see “Removal and

installation”.

2. Place the fuel pump in the stop position.

Lock the fuel pump in this position.

3. Use the special tool (DAF no. 1310477) to

turn the crankshaft clockwise, as seen from the timing gear end (this is the engine’s normal direction of rotation), until the valves of cylinder 1 are in overlap position. The pistons of cylinders 1 and 6 are now in the top dead centre.

Note:

“Overlap” is the moment at which the inlet valve starts opening and the exhaust valve is completing the closing.

If the engine has been fitted with a DEB, loosen the lock nut by means of a flat ring spanner. This is necessary so as to prevent damage to the DEB spring plate.

4. Check/correct the valve clearance of

cylinder 6. The correct valve clearance is adjusted by loosening the lock nut and turning the adjusting bolt in the correct direction, see main group “Technical data” for the correct valve clearance.

M200574

M200539

3-4

ǹ 0008

XF ENGINE

95XF series Inspection and adjustment

5. By cranking the crankshaft always

/3stroke, using the special tool (DAF no. 1310477), the valves can be adjusted according to the injection sequence 1-5-3-6-2-4.

Cylinder with valves

in overlap position

1 6

5 2

3 4

6 1

2 5

4 3

6. If the engine has been fitted with a DEB, the DEB clearance must be checked following the valve-clearance adjustment.

7. Fit the valve covers, see chapter “Removal and installation”.

Adjust valves

of cylinder

M200540

ǹ 0008

3-5

XF ENGINE

Inspection and adjustment 95XF series

3.3 CHECKING AND ADJUSTING THE TIMING GEAR

Checking the timing gear

1. Remove the valve cover from cylinders 1-2-3, see chapter “Removal and installation”.

2. Position cylinder 1 in the top dead centre (TDC on the flywheel, cylinder 6 in rocking position).

Note:

It is important that the bridges of the valve mechanism are properly adjusted.

3. Set the inlet valve clearance of the first cylinder to 1 mm.

M200574

3-6

ǹ 0008

XF ENGINE

95XF series Inspection and adjustment

4. Position the dial gauge on the inlet valve bridge of the first cylinder, in such a way that it measures in an exact vertical position on the bridge and is capable of registering an upward and downward measuring value of 5 mm.

5. Use the special tool (DAF no. 1310477) to turn the crankshaft further in the direction of rotation until the pistons of cylinders 1 and 6 have returned to the top dead centre (TDC).

6. Read the dial gauge and compare the measured value, see main group “Technical data”.

Example

Pre-tension dial gauge 5.00 mm Measured tension 4.65 mm

Valve opening

Note:

If the valve opening matches that in the technical data, it may be assumed that the timing gear is properly set.

0.35 mm

M200551

ǹ 0008

3-7

XF ENGINE

Inspection and adjustment 95XF series

Adjustment, timing gear

1. Remove the valve cover from cylinders 1-2-3, see chapter “Removal and installation”.

2. Position cylinder 1 in the top dead centre (TDC on the flywheel, cylinder 6 in rocking position).

3. Remove the timing-gear cover, see chapter “Removal and installation”.

Note:

When the crankshaft (1) or the camshaft (2) of an engine without intermediate gear wheel (3) is rotated separately, the engine’s pistons may touch the valves.

4. Remove the intermediate gear wheel (3), see “Removal and installation”.

5. Rotate the camshaft gear wheel (2) in such a position that the intermediate gear wheel (3) can be installed in accordance with the marks.

6. Install the intermediate gear wheel and tighten the attachment bolt to the specified torque, see main group “Technical data”.

7. Fit the timing-gear cover, see chapter “Removal and installation”.

8. Fit the valve cover, see “Removal and installation”.

M200574

3-8

M200602

ǹ 0008

XF ENGINE

95XF series Inspection and adjustment

3.4 INSPECTION AND ADJUSTMENT, V-BELT TENSION

Inspection, V-belt tension

Check the V-belt by means of a belt-tension gauge. The advantage of this method is a higher measuring accuracy of the pre-tension, so that the service life of the V-belt, among other things, can be prolonged.

There are two versions: belt tension “Krikit I”, to be used with the single belt version (DAF no. 1240442), belt tension “Krikit II” to be used with the twin belt version (DAF no. 1240443).

The difference between belt-tension gauge “Krikit I” and belt-tension gauge “Krikit II” is that the latter has a larger belt support area.

N.200

LBS.50

LBS.100

N.500

M2079

Measuring with the “KRIKIT” belt-tension gauge

1. Set the gauge to zero by depressing the measuring arm (1).

2. Place the belt-tension gauge on the V-belt, halfway between the alternator and the crankshaft pulley.

3. Slowly depress the V-belt by means of the belt-tension gauge until a click is heard. Then remove the belt-tension gauge carefully. Take care that the gauge bar does not move.

M2061

ǹ 0008

M2091

3-9

XF ENGINE

Inspection and adjustment 95XF series

4. Take the reading as indicated by the position of the measuring arm in relation to the scale. Compare this pressure reading with the recommended pre-tension, see main group “Technical data”.

Adjustment, V-belt tension of the air-conditioning compressor

1. Slacken the upper fixing bolt (1) on the compressor.

2. Slacken the lower fixing bolt (2) on the compressor.

3. Slacken the fixing bolt from the threaded spindle which is attached to the cooling-water pump.

4. Shift the compressor using the lock nuts (3) until the correct V-belt tension is achieved, see main group “Technical data”.

Adjustment, V-belt tension of the water pump and alternator

1. Slacken the lower fixing bolt (1) of the alternator.

2. Slacken the upper fixing bolt (2) of the alternator.

3. Slacken the fixing bolt (3) from the threaded spindle which is attached to the water pump.

354

M2062

M2041

4. Turn the lock nuts (4) and (5) on the threaded spindle so that the correct V-belt tension is achieved, see main group “Technical data”.

3-10

M200550

ǹ 0008

XF ENGINE

95XF series Inspection and adjustment

3.5 CHECKING THE FLYWHEEL

1. If the flywheel shows marks on the contact surface with the clutch plate, the flywheel may be ground down, on condition that the cracks are not within 5 mm of the inner rim.

5 mm

2. The flywheel has an indicator groove for inspection purposes.

3. Grinding down is allowed until the indicator groove has just disappeared. This means that a maximum of 2 mm may be ground down.

Inspection, flywheel swing

1. Clean the flywheel.

2. Place a metal strip on the edge of the flywheel housing to install a dial gauge.

3. Place the dial gauge on the metal strip.

4. Place the dial gauge of the stylus at the specified distance, see main group “Technical data”.

5. Set the dial gauge to “0”.

6. Place the fuel pump in the stop position and lock it in this position.

7. Use the special tool (DAF no. 1310477) to crank the engine through 360_, and measure the maximum clock reading. Compare this reading with the technical data, see main group “Technical data”.

2 mm

5 mm

M2 00 033

ǹ 0008

M200230

3-11

XF ENGINE

Inspection and adjustment 95XF series

3.6 INSPECTION, ENGINE COMPRESSION PRESSURE

Be careful when working on an engine at operating temperature.

When the engine is run without the valve covers, hot lubricating oil may escape from the engine. Make sure you are adequately protected.

A compression measurement serves to rapidly check the valve seals, the valve gasket seal and the seal between the cylinder lining and the piston rings. The measuring results may only be used for comparing the various cylinders.

1. Run the engine to operating temperature.

2. Place the fuel pump in the stop position. Lock the fuel pump in this position.

3. Remove the valve covers, see chapter “Removal and installation”.

4. Remove the injectors.

5. Turn the engine a number of times using the starting motor, so that any carbon or dirt particles in the cylinder are removed.

6. Install the dummy-injector (DAF no. 1329306), compression gauge (DAF no. 1329301) and adapter (DAF no. 0694972).

7. Carry out the measurement by rotating the engine using the starter motor, until the gauge reading no longer rises. For the mutual allowable differential pressures, see main group “Technical data”.

8. Remove the dummy injector and install the injectors.

9. Fit the valve covers, see chapter “Removal and installation”.

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95XF series Inspection and adjustment

3.7 INSPECTION, CYLINDER HEAD

1. Check the sealing plugs of the cylinder head for leaks. If necessary, pressure-test the cylinder head.

2. Check the cylinder head for damage on the sealing face, and possible cracks. If necessary, have the cylinder head levelled, see main group “Technical data”.

3.8 INSPECTION, GLOW FILAMENTS

Note:

To avoid engine damage it is important that the glow filaments should be checked periodically.

1. Check the glow filaments for the following points:

- windings that have worn thin due to

abrasion (A);

- filament end broken or worn thin due to

continuous knocking of a loose insulator (see B);

- broken plug windings (C).

2. Replace all glow filaments if one or more of the above-mentioned situations occurs.

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Inspection and adjustment 95XF series

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DAF 95XF, 95XE Repair Manual

Specifications and Main Features

Frequently Asked Questions

User Manual