DAF CF65, CF75, CF85 Service manual

2

STRUCTURE

ΧΦ65/75/85 series

TECHNICAL DATA

DIAGNOSTICS

CE ENGINE

CE-ENGINE COOLING SYSTEM

CE-ENGINE LUBRICATION SYSTEM

PE ENGINE

PE-ENGINE COOLING SYSTEM

PE-ENGINE LUBRICATION SYSTEM

XE ENGINE

XE-ENGINE COOLING SYSTEM

XE-ENGINE LUBRICATION SYSTEM

0

1

2

3

4

5

6

7

8

9

10

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2	TECHNICAL DATA
ΧΦ65/75/85 series		Contents
CONTENTS
	Page	Date		0

1. CE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200351 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200351 1.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . 200351

2. CE-ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200351 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200351 2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200351 2.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200351

3. CE-ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200351 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200351 3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200351 3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200351

4. PE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200351 4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200351 4.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200351

5. PE-ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200351 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200351 5.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200351 5.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . 200351

6. PE-ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200351 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200351 6.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200351 6.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 . . . . . 200351

7. XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200351 7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200351 7.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 . . . . . 200351

8. XE-ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200351 8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200351 8.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . . . . . 200351 8.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 . . . . . 200351

9. XE-ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200351 9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200351 9.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 . . . . . 200351 9.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 . . . . . 200351

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TECHNICAL DATA	2
Contents	ΧΦ65/75/85 series

0

2

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2			TECHNICAL DATA
ΧΦ65/75/85 series			CE engine
1. CE ENGINE
					0
1.1 GENERAL
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 been
		allowed to cool down for not more than thirty
		minutes.
Direction of rotation of the engine		The direction of rotation of the engine is
		clockwise, as seen from the vibration damper
		end.
First cylinder of the engine		The first cylinder of the engine is the cylinder at
		the vibration damper end of the engine.
Left-hand and right-hand side of the engine		The left-hand side of the engine is the side where
		the air compressor and electronic unit are
		mounted. The right-hand side of the engine is the
		side where the turbocharger and oil filter are
		mounted.
Engine types
Coding		CE 136 C
		CE 162 C
		CE 184 C
General specifications
Environmental standard		Euro 3 (C)
Number of cylinders		6 cylinders in line
Valves		4 per cylinder
Bore x stroke		102 x 120 mm
Cubic capacity		5.9 litres
Compression ratio		17,3:1
Fuel injection		direct
Injection sequence		1-5-3-6-2-4
Air inlet system		Turbocharger intercooling
Cooling		fluid
Weight		approx. 498 kg
ENGINE TYPE	P (kW) at rpm		M (Nm) at rpm
CE 136 C	136 at 2500		700 at 1200 - 1600
CE 162 C	162 at 2500		820 at 1250 - 1600
CE 184 C	184 at 2500		950 at 1200 - 1600
Exhaust manifold
Maximum flatness deviation		0.20 mm
Cylinder block
Flatness deviation in the longitudinal direction		max. 0.076 mm
Flatness deviation in the lateral direction		max. 0.051 mm

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		TECHNICAL DATA		2
		CE engine		ΧΦ65/75/85 series
		Cylinder head
0
		Rough value		0.4 - 1.6 mm
		Flatness deviation in the longitudinal direction		max. 0.305 mm
		Flatness deviation in the lateral direction		max. 0.076 mm
		Test pressure using air		max. 2.75 bar
		Water pressure temperature		approx. 60 C
		Cylinder head gasket
		Thickness:	1.15 mm

M201231

Thickness:

1.25 mm

M201232

Type cylinder head gasket to be used:

Average piston projection	Thickness of cylinder head gasket
< 0.301 mm	1.15 mm
0.301 mm	1.25 mm

Cylinder head bolts
Maximum
dimensions of visible	1 cm2
corrosion or pitting
Maximum depth of
pitting	0.12 mm

OK

OK

M201249

1-2

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2

ΧΦ65/75/85 series

Length of the area
under the bolt head
and area above the
start of the screw
thread where
corrosion and pitting
may not occur (A)	3.2 mm

Maximum free length
of the short cylinder
head bolt (nominal
130 mm)	132.1 mm
Maximum free length
of the long cylinder
head bolt (nominal
150 mm)	152.1 mm

Valve clearance

Inspection dimension, cold valve clearance Inlet

Exhaust

Setting dimension, cold valve clearance

Inlet Exhaust

Gear backlash

Crankshaft gear - camshaft gear Oil pump gear - idler gear

Axial play

Crankshaft axial play

Camshaft axial play

Oil sump pressure

New engine

Worn engine

© 200351

TECHNICAL DATA

CE engine

0

OK

OK

A

A

M201250

C		xavmpm			C		ashasdfc
		vjvaqsbba	ooj				gghkjcydqfbb

Cylinder Head Capscrew Length Gauge

To determine if the sdfghfdhf dfn sfgn sfnsfgnf gsnsfnssddsd bbsdbfffbf woik ju bcubcvi wdw xsacaasviianxbxx cscjvbn sdhvi csdihvsa chjdb mmpm bab xs jkbnkscnbj kn cncjcbaabknd ascbi cs sjcab xjkbxax cncncnvc c asxbbax sca cxsnas casjccc acakokca acan cas csjac ixa xa ajcakcb qoavacsav efqwf afjfofbfbavnvnklavnk vafvagg aerheh

sdfsdj odv aql			ooj vjv gweg			gewreh adga p
bdfdbsdbn d ad		D	murvsa pm fer		B	cd wfwg k		B

OK

M201252

0.15 - 0.40 mm

0.40- 0.75 mm

0.25mm

0.50mm

0.076 - 0.28 mm

0.250 - 0.30 mm

0.267 ≥ 0.165 mm

0.230 ≥ 0.130 mm

60 - 80 l/min.

180 l/min.

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TECHNICAL DATA	2
CE engine	ΧΦ65/75/85 series

0			Oil sump pressure conversion table
		Inches (water)		Litres per minute (l/min.)
		1		50
		2		84
		3		103
		4		119
		5		133
		6		145
		7		155
		8		164
		9		172
		10		180
		11		187
		12		193
		13		200
		14		206
		15		211
		16		217
		17		222
		18		226
		19		229
		20		232

Flywheel/starter ring gear
Axial variation, measured on the outer diameter	0.127 mm
Starter ring gear warm up (max. 20 min.)	max. 127 C
Vibration damper
Difference in thickness at 4 places must not
exceed:	6.35 mm

1-4

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2	TECHNICAL DATA
ΧΦ65/75/85 series	CE engine
1.2 TIGHTENING TORQUES
			0
The tightening torques specified in this section
are different from the standard tightening torques
cited in the overview of the standard tightening
torques. The other threaded connections not
specified must therefore be tightened to the
torque cited in the overview of standard
tightening torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and

property class as those removed.
Starter motor
Attachment bolts	43	Nm
Automatic tensioner
Attachment bolts	43	Nm
Alternator
Alternator bracket attachment bolts	30	Nm
Alternator attachment bolts	60	Nm
Pulley attachment nut	80	Nm
Air compressor
Compressor attachment nuts	60	Nm
Attachment of pipes	39	Nm
Air-conditioning compressor
Compressor support attachment bolts	30	Nm
Compressor attachment bolts	60	Nm
Valve gear
Rocker setting bolt lock nut	24	Nm
Valve sleeve attachment bolts	24	Nm
Valve cover attachment bolts	10	Nm
Rocker seat attachment bolts	36	Nm
Injector wiring	1 Nm
Inlet manifold
Inlet manifold attachment bolts	24	Nm
Fit inlet manifold using sealant	Loctite Ultra Grey
Fuel rail attachment bolts	24	Nm
Glow element attachment bolts	14	Nm
Air inlet hose clamps	7 Nm
Exhaust manifold
Attachment bolts	43	Nm (1)
Heat shields	60	Nm

(1) Tighten crosswise from inside to outside.

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TECHNICAL DATA	2
CE engine	ΧΦ65/75/85 series

Cylinder head

0 Note:

Apply a drop of engine oil to the thread and under the abutting surface of the attachment bolt heads.

Stage 1
All attachment bolts	35 Nm (1)

(1) Tighten the bolts in the order indicated

	20	12	4	5	13	21
24	16	8	1	9	17	25

	23	15	7	2	10	18	26
	19	11	3	6	14		22
							M201143
Stage 2	12	8	4	1	5	9	13
Only attachment
bolts with a length of	55 Nm (1)
150 mm

(1) Tighten the bolts in the order indicated

		11		7	3	2	6	10	14
									M201202
Stage 3			20	12	4	5	13		21
All attachment bolts	2 steps each with a	24		16	8	1	9	17	25

90 angular displacement (1)

(1) Tighten the bolts in the order indicated

23	15	7	2	10	18	26
19	11	3		6	14	22

M201143

1-6

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2	TECHNICAL DATA

ΧΦ65/75/85 series

Vibration damper

Attachment bolts

Timing gear

Camshaft locking plate attachment bolts M8 attachment bolts for timing gear case M10 attachment bolts for timing gear case M12 attachment bolts for timing gear case Fit timing gear case using sealant Attachment bolts, camshaft gear

Attachment bolts, cap, front of engine

Attachment bolts,
cap, front of
engine (1)	24 Nm
Fit cap at engine
front using sealant	Loctite Ultra Grey

(1) Tighten the attachment bolts in the order indicated

Flywheel

Attachment bolts

Flywheel housing
M10 attachment
bolts (1)	49 Nm
M12 attachment
bolts (1)	85 Nm
Fit flywheel housing
using sealant	Loctite 5205

(1) Tighten the attachment bolts in the order indicated

		CE engine
	50 Nm + 90 angular displacement	0
	24 Nm
	24 Nm
	47 Nm
	50 Nm
	Loctite Ultra Grey
	36 Nm
	8
	5	12
	2	9
	4
	7
		6
		3
	11	1
	10

13

M201144

30 Nm + 60 angular displacement

	20	7	11	1
19		5
17			9	4
15				14
13	10	3		16
				6

2

12

18

8

M201080

Engine mounts, front
Engine bracket attachment bolts/nuts	110 Nm

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		TECHNICAL DATA		2
		CE engine		ΧΦ65/75/85 series
		Engine mounts, rear
0
		Bolts attaching engine bracket to chassis	110	Nm + 90 angular displacement
		Bolts attaching engine bracket to engine	110	Nm + 60 angular displacement
		Bolts attaching support to engine bracket	170	Nm + 90 angular displacement
		Engine hanger brackets
		Attachment bolts	113	Nm

1-8

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2		TECHNICAL DATA
ΧΦ65/75/85 series		CE-engine cooling system
2. CE-ENGINE COOLING SYSTEM
						0
2.1 GENERAL
Thermostat
Thermostat opening temperatures:
Thermostat opens at		approx. 81 C
Thermostat fully open at		approx. 94 C
Full thermostat opening		14.3 mm
Header tank pressure cap
Pressure relief valve opening pressure		1 - 1.2 bar
Underpressure valve opening pressure		0.1 - 0.02 bar
Closed pressure cap position		Brand name (2) legible horizontally or 60 before
		this position.
Closed pressure cap	Brand name (2)
position	legible horizontally or
	60 before this
	position.
				2

1

M201272

Pressure-testing the cooling system
Test pressure	0.5 - 0.7 bar

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		TECHNICAL DATA	2
		CE-engine cooling system	ΧΦ65/75/85 series
		2.2 TIGHTENING TORQUES
0
		The tightening torques specified in this section
		are different from the standard tightening torques
		cited in the overview of the standard tightening
		torques. The other threaded connections not
		specified must therefore be tightened to the
		torque cited in the overview of standard
		tightening torques.
		When attachment bolts and nuts are replaced, it
		is important that - unless stated otherwise - these
		bolts and nuts are of exactly the same length and

property class as those removed.
Coolant pump
Attachment bolts	24 Nm
Thermostat housing
Attachment bolts	10 Nm
Radiator
Attachment nuts	60 Nm

2-2

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2	TECHNICAL DATA
ΧΦ65/75/85 series	CE-engine cooling system
2.3 FILLING CAPACITIES
			0
Cooling system capacity	approx. 26 litres

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TECHNICAL DATA	2
CE-engine cooling system	ΧΦ65/75/85 series

0

2-4

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	2	TECHNICAL DATA
	ΧΦ65/75/85 series	CE-engine lubrication system
	3. CE-ENGINE LUBRICATION SYSTEM
				0
	3.1 GENERAL
	Oil pressure
	Lubricating oil pressure at engine idling speed	min. 0.69 bar
	Lubricating oil pressure at full-load engine speed	min. 2.07 bar
	Bypass pressure regulator opening pressure	3.52 bar
	Oil filter
	Type	disposable filter
	Number	1
	Installation in the oil circuit	full flow
	Oil cooler
	Oil section test pressure	4.5 - 5.0 bar
	Opening pressure of bypass valve at a pressure
	difference of	3.45 bar
	Lubricating oil pump
	Maximum clearance, inner rotor - outer rotor	0.178 mm
	Maximum clearance, outer rotor - lubricating oil
	pump housing	0.381 mm
	Maximum flatness of inner/outer rotor versus
	straight edge	0.127 mm
	Backlash (disassembled)	0.25 - 0.30 mm
	Idler gear backlash (assembled)	0.15 - 0.25 mm
	Oil pump gear backlash (assembled)	0.30 - 0.50 mm
	Oil consumption
	Maximum permissible engine oil consumption	0.5% of the average fuel consumption

Example:

Average measured fuel consumption: 25 litres / 100 km = 250 litres / 1000 km

Maximum permissible engine oil consumption: 0.5% x 250 = 1.25 litres / 1000 km

- Engine oil consumption of 1.25 litres / 1000 km is permissible

- Engine oil consumption > 1.25 litres / 1000 km; check the engine using the diagnostics table. See "Diagnostics".

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TECHNICAL DATA

2

CE-engine lubrication system

3.2 TIGHTENING TORQUES

0

The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.

When attachment bolts and nuts are replaced, it is important that - unless stated otherwise - these bolts and nuts are of exactly the same length and property class as those removed.

Oil filter

Attachment bolts to connect filter head to engine block

Oil sump
Oil sump attachment		Nm (1)
bolts	24
Oil drain plug	60	Nm

(1) Tighten the attachment bolts in the order indicated

ΧΦ65/75/85 series

24 Nm

11

7

1

3

5

9

13

16

15

14

12

8

4

2

6

10

M201079

Strainer
Suction tube attachment bolts	24 Nm
Bypass pressure regulator
Plug	80 Nm

3-2

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2			TECHNICAL DATA
ΧΦ65/75/85 series			CE-engine lubrication system
Oil cooler			14	0
Attachment bolts		13	15
connecting oil cooler	24 Nm (1)
to cylinder block
(1) Tighten the attachment bolts in the order indicated		8	9
		4	5
		3	1
		7	2
			6
		12	10
			11
			M201145
Oil pump
Attachment bolts		24 Nm
Turbocharger oil supply pipe
Union on filter head		28 Nm
Union on turbocharger		28 Nm
Bypass pressure regulator
Plug		80 Nm
Oil nozzle
Banjo bolt		15 Nm
Main bearing caps
Main bearing cap attachment bolts
1st phase		60 Nm
2nd phase		80 Nm
3rd phase		90 angular displacement
Big-end bearing caps
Attachment bolts, big-end bearing caps		60 Nm + 60 angular displacement

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		TECHNICAL DATA	2
		CE-engine lubrication system	ΧΦ65/75/85 series
		3.3 FILLING CAPACITIES
0
		Lubrication system
		Total capacity, including oil cooler and oil filter	19.5 litres
		Oil sump capacity, maximum level	17.5 litres
		Oil sump capacity, minimum level	15.4 litres

3-4

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2				TECHNICAL DATA
ΧΦ65/75/85 series				PE engine
4. PE ENGINE
						0
4.1 GENERAL
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 been
			allowed to cool down for not 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.
Engine types
Coding			PE 183 C1
			PE 228 C
			PE 265 C
General specifications
Environmental standard			Euro 3 (C)
Number of cylinders			6 cylinders in line
Valves			4 per cylinder
Bore x stroke			118 x 140 mm
Total cubic capacity			9,20 l
Compression ratio			17,4 : 1
Fuel injection			direct
Injection sequence			1-5-3-6-2-4
Air inlet system			Turbocharger intercooling
Cooling			fluid
Weight			approx. 860 kg
V-belt tension
Belt tension, "AVX" raw edge1 of V-belts in Newtons (N)
		Multiple belt		Single belt
			New V-belt2
Setting tension		1200		600
Test tension		800		400
			Run-in V-belt3
Minimum tension		500		250
Correction tension		700		350

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TECHNICAL DATA	2
PE engine	ΧΦ65/75/85 series

1.Raw-edge V-belts can be recognised by the absence of textile fabric in the rubber, with the exception of the top

0	of the belt edge, on the edges and the inside of the belt
	(polished belt edge). Version: either a toothed or a non-

toothed belt.

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 test tension reading is lower than the value specified in the table, set the V-belt to the minimum "test tension".

3.If the V-belt tension is lower than the "minimum tension", set the belt to the "correction tension".

M2121

Cylinder liner
Height above cylinder block	0.02 - 0.10 mm
Cylinder head
Minimum height after overhaul	119.5 mm
Cylinder head test pressure
Test pressure using air (hot)	1.5 bar
Valve clearance
Valve clearance (cold/hot)
inlet	0.45 mm
exhaust	0.45 mm
Valve opening
Valve opening at 1 mm valve clearance	0.45	≥ 0.2 mm
Axial play
Crankshaft axial play	0.05 - 0.35 mm
Camshaft axial play	0.10 - 0.55 mm
Idler gear axial play	0.03 - 0.25 mm
Gear backlash
Idler gear - crankshaft gear	0.02	- 0.20 mm
Idler gear - fuel pump gear	0.02	- 0.22 mm
Idler gear - camshaft gear	0.02	- 0.22 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	31
Idler gear	52
Fuel pump gear	62
Camshaft gear	62
Air compressor gear	27
Steering pump gear	18
Oil pump idler gear	28

4-2

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2		TECHNICAL DATA
ΧΦ65/75/85 series		PE engine
Compression pressure
				0
Differences in compression pressure	max. 15%
Flywheel/starter ring gear
Axial variation, measured at a radial distance of
210 mm	0.10 mm
Starter ring gear warm up	max. 185 C

© 200351

4-3

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		TECHNICAL DATA			2
		PE engine			ΧΦ65/75/85 series
		4.2 TIGHTENING TORQUES
0
		Starter motor			Nm (1)
		Attachment nuts		73
		Alternator
		Alternator bracket attachment bolts		30	Nm
		Alternator attachment bolts		60	Nm
		Pulley attachment nut		80	Nm
		Electrical connection to alternator		12	Nm
		Air compressor
		Compressor gear flange bolt		120 Nm
		M12 attachment bolts		110 Nm
		M8 attachment bolts for bracket		30	Nm
		Cylinder head threaded coupling		90	Nm
		Delivery pipe reducer valve		75	Nm
		Suction and pressure line unions		90	Nm
		Air-conditioning compressor
		M12 attachment bolts for compressor bracket		110 Nm
		M10 attachment bolts for compressor		60	Nm (1)
		Exhaust manifold
		Fit gasket with steel side towards manifold
		Sleeved attachment bolts		65	Nm
		Heat shield attachment bolts		30	Nm (1)
		Inlet manifold
		M10 attachment bolts		60	Nm
		M10 attachment studs		60	Nm
		Turbocharger			Nm (1)
		Heat shield attachment bolts		30
		Turbine housing clamp plate attachment nut		15	Nm
		Attachment nuts			Nm (2)
		Exhaust manifold flange/turbocharger		60
		Elbow on turbocharger		40	Nm
		Oil supply pipe banjo bolt		90	Nm
		Fan
		Attachment nuts		25	Nm (1)
		Fan pulley attachment bolts		30	Nm (1)
(1)			Use Loctite 243 to secure
(2)			Fasten with Copaslip

4-4

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2		TECHNICAL DATA
ΧΦ65/75/85 series		PE engine
Vibration damper
				0
Vibration damper hub attachment bolts in 4
phases:
1st phase, all attachment bolts		50 Nm (1)
2nd phase, all attachment bolts		70 Nm (1)
3rd phase, all attachment bolts		100 Nm (1)
4th phase, all attachment bolts		60 angular displacement (1)
Vibration damper attachment bolts		110 Nm (2)
(1)	Tighten the attachment bolts evenly
(2)	Use Loctite 243 to secure

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4-5

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TECHNICAL DATA

PE engine

Cylinder head attachment bolts

0 Cylinder bolts must only be used once. So the cylinder bolts must always be replaced. The thread of the new cylinder head bolts is provided with a red/brown sealant.

Note:

-Due to the sealant used on the cylinder head bolts, the untightening torque of the cylinder head bolts can be substantial!

-All M16 and M12 threaded holes must be carefully cleaned using a screw tap prior to the mounting of the bolts.

-After tightening of the bolts with the appropriate tightening torque, the angular displacement of the M16 bolts must immediately be started.

-The sealant cannot be applied later.

Tightening cylinder head attachment bolts

Note:

Underneath the bolt head, apply a drop of oil on the bearing surface of the bolt heads. Sealants also reduce the frictional resistance, which means that you must not apply any oil to the thread.

4-6

2

ΧΦ65/75/85 series

50 Nm

<![if ! IE]> <![endif]>M16	150 Nm

I

<![if ! IE]> <![endif]>M16

94 Nm

II

<![if ! IE]>

<![endif]>M12

II

60

<![if ! IE]> <![endif]>M16	60

III

<![if ! IE]>

<![endif]>M16

III

M200563

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2	TECHNICAL DATA

ΧΦ65/75/85 series

1st phase
- M16 in the indicated	50 Nm (1)
order
2nd phase
- M16 in the indicated
order	150 Nm
- M12 in the indicated	94 Nm (1)
order
3rd phase
- M16 in the indicated	60 angular
order in two stages of	displacement

(1)Apply a drop of oil to the bearing surface of the M16 and M12 bolt heads.

				PE engine
16	14		15	17	0
6	1	2	7	12
11
				13
5			3	8
10
9		4
				M200734

Timing gear
Pump housing drive unit attachment bolts		60	Nm
Attachment bolts, pump housing drive shaft			Nm (1)
locking plate		30
Locking plate attachment bolts		30	Nm (1)
Crankshaft hub attachment bolts in 4 phases:
1st phase, all attachment bolts		100		Nm (2)
2nd phase, all attachment bolts		100		Nm (2)
3rd phase, all attachment bolts		100		Nm (2)
4th phase, all attachment bolts		100		Nm (2)
Viscous fan clutch attachment nuts		30	Nm (1)
Timing case attachment bolts		30	Nm (1)
Timing cover attachment bolts:
M10 attachment bolts		60	Nm
M8 attachment bolts		25	Nm
Timing cover protection plate attachment bolt		8.5 Nm
Camshaft gear attachment bolt		425		Nm
Idler gear attachment bolt		170		Nm
Pump housing camshaft gear attachment bolt		260		Nm (1)
Steering pump gear attachment nut		80	Nm (1)
Suction pipe banjo bolt		90	Nm
Delivery pipe banjo bolt		40	Nm
(1)	Use Loctite 243 to secure
(2)	Apply a drop of oil to the attachment bolts and tighten
	evenly.
Flywheel housing
Attachment bolts:		110		Nm
Sealant to be used when fitting flywheel housing		Loctite 510
Flywheel
Attachment bolts:
without PTO		170		Nm (1) + 90 angle tightening
with PTO		170		Nm + 150 angle tightening
(1)	Use Loctite 243 to secure

© 200351

4-7

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	TECHNICAL DATA						2
	PE engine				ΧΦ65/75/85 series
0	Engine mountings at timing gear end
	Cylinder block bracket attachment bolts	92 Nm
	Chassis engine bracket attachment bolts	73 Nm
	Vibration damper engine bracket attachment
	bolts	170 Nm
	Engine mountings at flywheel end
	Flywheel housing engine bracket attachment
	bolts	260 Nm
	Chassis engine bracket attachment bolts	73 Nm
	Vibration damper engine bracket attachment
	bolts	226 Nm + 60 angle tightening
	Engine hanger brackets
	M12 attachment bolts	110 Nm
	Valve gear
	Valve cover attachment bolts	25 Nm
	M10 setting bolt lock nut for rocker	40 Nm
	Bridge piece setting bolt lock nut	40 Nm
	Lubricating oil strip/rocker seat attachment bolts	60 Nm
	Valve sleeve attachment bolts	30 Nm
	Tighten the valve sleeve attachment bolts in the			13		9
	sequence shown.
		3	7		11	2	6
							14
		5
			1	10	12	8	4
							M200959

4-8

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2	TECHNICAL DATA
ΧΦ65/75/85 series	PE-engine cooling system
5. PE-ENGINE COOLING SYSTEM
			0
5.1 GENERAL

Thermostat

Thermostat opening temperature standard:

-thermostat opens at

-thermostat open at least 12 mm at

with intarder and/or automatic transmission:

-thermostat opens at

-thermostat open at least 12 mm at Thermostat seat

Coolant pump

Radial play

Header tank pressure cap

Pressure relief valve opening pressure Underpressure valve opening pressure Closed pressure cap position

approx. 87 C approx. 99 C

approx. 83 C approx. 95 C Loctite 638

0.16 - 0.20 mm

1 - 1.2 bar

0.1 - 0.02 bar

Brand name (2) legible horizontally or 60 before this position.

Closed pressure cap	Brand name (2)
position	legible horizontally or
	60 before this
	position.

2

1

M201272

Pressure testing the cooling system
Test pressure	0.7 - 0.9 bar
Viscous fan clutch
Permissible slip at maximum speed control	10%

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5-1

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		TECHNICAL DATA	2
		PE-engine cooling system	ΧΦ65/75/85 series
		5.2 TIGHTENING TORQUES
0
		The tightening torques recorded in this paragraph
		are different from the standard tightening torques
		recorded in the overview of the standard
		tightening torques. The other threaded
		connections which are not recorded must
		therefore be tightened to the torque recorded in
		the overview of standard tightening torques.
		When attachment bolts and nuts are replaced, it
		is important - unless stated otherwise - that these
		bolts and nuts are of exactly the same length and

property class as those removed.
Coolant pump
M8 attachment bolts	30 Nm
Coolant pipe on cylinder head
Attachment bolts	54 Nm
Coolant pipe threaded coupling	90 Nm
Coolant pipe plug	35 Nm
Thermostat housing on coolant pipe
Attachment bolts	30 Nm
Radiator
Attachment nuts	60 Nm
Oil cooler
Coolant drain plug	16 Nm

5-2

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