DAF CF65, CF75, CF85 Service manual

2
ΧΦ65/75/85 series
STRUCTURE
Structure
0
DIAGNOSTICS
1
CE ENGINE
2
CE-ENGINE COOLING SYSTEM
3
CE-ENGINE LUBRICATION SYSTEM
4
PE ENGINE
5
PE-ENGINE COOLING SYSTEM
6
PE-ENGINE LUBRICATION SYSTEM
7
XE ENGINE
8
XE-ENGINE COOLING SYSTEM
9
XE-ENGINE LUBRICATION SYSTEM
10
©
200351
2
ΧΦ65/75/85 series

0 Technical dat a

CONTENTS
Page Date
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
Contents
0
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
©
200351 1
2
0
Contents
ΧΦ65/75/85 series
2
©
200351
2
ΧΦ65/75/85 series
CE engine

1. CE ENGINE

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
0
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
©
200351 1-1
2
0
CE engine
Cylinder head
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
Thickness: 1.25 mm
ΧΦ65/75/85 series
M201231
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 corrosion or pitting 1 cm Maximum depth of pitting 0.12 mm
2
OK OK
M201232
M201249
1-2
©
200351
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
CE engine
OK
OK
A
A
CC
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 bdfdbsdbn d ad
Cylinder Head Capscrew Length Gauge
xa vmpm ooj vjv aqsbb a
ooj vjv gweg murvsa pm fer
gewreh adga p cd wfwg k
BD
asha sdf c ggh kjcy dqfbb
0
M201250
B
Valve clearance
Inspection dimension, cold valve clearance Inlet 0.15 - 0.40 mm Exhaust 0.40 - 0.75 mm
Setting dimension, cold valve clearance
Inlet 0.25 mm Exhaust 0.50 mm
Gear backlash
Crankshaft gear - camshaft gear 0.076 - 0.28 mm Oil pump gear - idler gear 0.250 - 0.30 mm
Axial play
Crankshaft axial play 0.267 0.165 mm Camshaft axial play 0.230 0.130 mm
Oil sump pressure
New engine 60 - 80 l/min. Worn engine 180 l/min.
OK
M201252
©
200351 1-3
2
0
CE engine
Oil sump pressure conversion table
Inches (water) Litres per minute (l/min.)
150
284
3103
4119
5133
6145
7155
8164
9172
10 180
11 187
12 193
13 200
ΧΦ65/75/85 series
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
©
200351
2
ΧΦ65/75/85 series

1.2 TIGHTENING TORQUES

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
CE engine
0
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 Heat shields 60 Nm
(1)
(1) Tighten crosswise from inside to outside.
©
200351 1-5
2
0
CE engine
Cylinder head
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) Tighten the bolts in the order indicated
(1)
20 12
24
23
19 11
16
15
ΧΦ65/75/85 series
4 5 13 21
1 25
7
2 10 18 26
3 6 14 22
9 178
M201143
Stage 2 Only attachment
bolts with a length of 150 mm 55 Nm
(1) Tighten the bolts in the order indicated
Stage 3
All attachment bolts 2 steps each with a
90 angular displacement
(1) Tighten the bolts in the order indicated
(1)
(1)
12
11
20 12
24
16
8
7
4
3
1
2
4 5 13 21
1 25
5
6
9 178
9
10
13
14
M201202
1-6
23
19 11
15
7
2 10 18 26
3 6 14 22
©
200351
M201143
2
ΧΦ65/75/85 series
Vibration damper
Attachment bolts 50 Nm + 90 angular displacement
Timing gear
Camshaft locking plate attachment bolts 24 Nm M8 attachment bolts for timing gear case 24 Nm M10 attachment bolts for timing gear case 47 Nm M12 attachment bolts for timing gear case 50 Nm Fit timing gear case using sealant Loctite Ultra Grey Attachment bolts, camshaft gear 36 Nm
Attachment bolts, cap, front of engine
Attachment bolts, cap, front of engine Fit cap at engine front using sealant Loctite Ultra Grey
(1) Tighten the attachment bolts in the order indicated
(1)
24 Nm
4
7
5
2
CE engine
0
8
12
9
6
3
11
10
13
Flywheel
Attachment bolts 30 Nm + 60 angular displacement
Flywheel housing
M10 attachment
(1)
bolts M12 attachment
(1)
bolts Fit flywheel housing using sealant Loctite 5205
(1) Tighten the attachment bolts in the order indicated
49 Nm
85 Nm
19
17
15
13
20 7 11
5
9
3
10
2
1
4
14
1812
1
M201144
16
6
8
M201080
Engine mounts, front
Engine bracket attachment bolts/nuts 110 Nm
©
200351 1-7
2
0
CE engine
Engine mounts, rear
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
ΧΦ65/75/85 series
1-8
©
200351
2
ΧΦ65/75/85 series
CE-engine cooling system

2. CE-ENGINE COOLING SYSTEM

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 position
Brand name (2) legible horizontally or 60 before this position.
0
Pressure-testing the cooling system
Test pressure 0.5 - 0.7 bar
2
1
M201272
©
200351 2-1
2
0
CE-engine cooling system

2.2 TIGHTENING TORQUES

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
ΧΦ65/75/85 series
Radiator
Attachment nuts 60 Nm
2-2
©
200351
2
ΧΦ65/75/85 series

2.3 FILLING CAPACITIES

Cooling system capacity approx. 26 litres
CE-engine cooling system
0
©
200351 2-3
2
0
CE-engine cooling system
ΧΦ65/75/85 series
2-4
©
200351
2
ΧΦ65/75/85 series
CE-engine lubrication system

3. CE-ENGINE LUBRICATION SYSTEM

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
0
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".
©
200351 3-1
2
0
CE-engine lubrication system

3.2 TIGHTENING TORQUES

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 24 Nm
Oil sump
Oil sump attachment bolts 24 Nm
(1)
16
Oil drain plug 60 Nm
(1) Tighten the attachment bolts in the order indicated
14
ΧΦ65/75/85 series
11 1 3 9
7
5
13
15
Strainer
Suction tube attachment bolts 24 Nm
Bypass pressure regulator
Plug 80 Nm
12 4 2 10
8
6
M201079
3-2
©
200351
2
ΧΦ65/75/85 series
Oil cooler
Attachment bolts connecting oil cooler to cylinder block 24 Nm
(1) Tighten the attachment bolts in the order indicated
Oil pump
Attachment bolts 24 Nm
(1)
13
8
4
7
12
CE-engine lubrication system
14
0
15
9
5
3
2
11
1
6
10
M201145
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
st
phase 60 Nm
1
nd
2
phase 80 Nm
rd
3
phase 90 angular displacement
Big-end bearing caps
Attachment bolts, big-end bearing caps 60 Nm + 60 angular displacement
©
200351 3-3
2
0
CE-engine lubrication system

3.3 FILLING CAPACITIES

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
ΧΦ65/75/85 series
3-4
©
200351
2
ΧΦ65/75/85 series
PE engine

4. PE ENGINE

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
0
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 edge
Multiple belt Single belt
Setting tension 1200 600
Test tension 800 400
1
of V-belts in Newtons (N)
New V-belt
Run-in V-belt
2
3
Minimum tension 500 250
Correction tension 700 350
©
200351 4-1
2
0
PE engine
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 inside of the belt (polished belt edge). Version: either a toothed or a non­toothed 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".
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
ΧΦ65/75/85 series
M2121
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
©
200351
2
ΧΦ65/75/85 series
Compression pressure
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
PE engine
0
©
200351 4-3
2
0
PE engine

4.2 TIGHTENING TORQUES

Starter motor
Attachment nuts 73 Nm
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
ΧΦ65/75/85 series
(1)
(1)
Exhaust manifold
Fit gasket with steel side towards manifold Sleeved attachment bolts 65 Nm Heat shield attachment bolts 30 Nm
Inlet manifold
M10 attachment bolts 60 Nm M10 attachment studs 60 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
Fan
Attachment nuts 25 Nm Fan pulley attachment bolts 30 Nm
(1) Use Loctite 243 to secure (2) Fasten with Copaslip
(1)
(1)
(2)
(1)
(1)
4-4
©
200351
2
ΧΦ65/75/85 series
Vibration damper
Vibration damper hub attachment bolts in 4 phases:
st
1
phase, all attachment bolts 50 Nm 2nd phase, all attachment bolts 70 Nm 3rd phase, all attachment bolts 100 Nm 4th phase, all attachment bolts 60 angular displacement Vibration damper attachment bolts 110 Nm
(1) Tighten the attachment bolts evenly (2) Use Loctite 243 to secure
(1)
(1)
(1)
(2)
PE engine
0
(1)
©
200351 4-5
2
0
PE engine
Cylinder head attachment bolts
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.
50 Nm
I
M16
150 Nm
II
ΧΦ65/75/85 series
M16
94 Nm
M12
II
60
III
M16
60
M16
III
M200563
4-6
©
200351
2
ΧΦ65/75/85 series
1st phase
- M16 in the indicated order 50 Nm
(1)
2nd phase
- M16 in the indicated order 150 Nm
- M12 in the indicated order 94 Nm
(1)
3rd phase
- M16 in the indicated order in two stages of
(1) Apply a drop of oil to the bearing surface of the M16 and
M12 bolt heads.
60 angular displacement
Timing gear
Pump housing drive unit attachment bolts 60 Nm Attachment bolts, pump housing drive shaft locking plate 30 Nm Locking plate attachment bolts 30 Nm Crankshaft hub attachment bolts in 4 phases:
st
1
phase, all attachment bolts 100 Nm 2nd phase, all attachment bolts 100 Nm 3rd phase, all attachment bolts 100 Nm 4th phase, all attachment bolts 100 Nm Viscous fan clutch attachment nuts 30 Nm 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 8.5 Nm Camshaft gear attachment bolt 425 Nm Idler gear attachment bolt 170 Nm Pump housing camshaft gear attachment bolt 260 Nm Steering pump gear attachment nut 80 Nm Suction pipe banjo bolt 90 Nm Delivery pipe banjo bolt 40 Nm
16
10
11
(1)
(1)
(1)
(1)
(1)
(2)
(2)
(2)
(2)
(1)
PE engine
8
12
13
M200734
17
0
14
6
1
5
9
4
15
2
7
3
(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
2
0
PE engine
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 sequence shown.
13 9
ΧΦ65/75/85 series
3
2117
6
14
5
18
10 12
4
M200959
4-8
©
200351
2
ΧΦ65/75/85 series
PE-engine cooling system

5. PE-ENGINE COOLING SYSTEM

5.1 GENERAL

Thermostat
Thermostat opening temperature standard:
- thermostat opens at approx. 87C
- thermostat open at least 12 mm at approx. 99C with intarder and/or automatic transmission:
- thermostat opens at approx. 83C
- thermostat open at least 12 mm at approx. 95C Thermostat seat Loctite 638
Coolant pump
Radial play 0.16 - 0.20 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.
0
Closed pressure cap position
Pressure testing the cooling system
Test pressure 0.7 - 0.9 bar
Viscous fan clutch
Permissible slip at maximum speed control 10%
Brand name (2) legible horizontally or 60 before this position.
2
1
M201272
©
200351 5-1
2
0
PE-engine cooling system

5.2 TIGHTENING TORQUES

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
ΧΦ65/75/85 series
Thermostat housing on coolant pipe
Attachment bolts 30 Nm
Radiator
Attachment nuts 60 Nm
Oil cooler
Coolant drain plug 16 Nm
5-2
©
200351
+ 388 hidden pages