Component Manual

PF engine

M200797

English
Printed in The Netherlands DW132456
 E 0008 DAF Trucks N.V., Eindhoven,
the Netherlands
In the interest of continuing product
development, DAF reserves the right to change
specification or equipment at any time without
notice.
No part of this publication may be reproduced
and/or published by printing, photocopying,
microfilming or by any other means without the
manufacturer’s prior permission in writing.

ǹ 0008 DW132456
dkjwqhesa
 SAFETY PRECAUTIONS
PF engine Safety precautions

SAFETY PRECAUTIONS
Warning symbol
When text is accompanied by the warning
symbol shown here, this indicates that the
information provided is essential for the health
and personal safety of the mechanic.
In addition, this warning symbol is also shown if
there are conditions in which damage can be
caused to the component or parts thereof.
Safety precautions
To ensure that the mechanic’s health is not
endangered, the following safety instructions M0015

must be strictly observed.

- Comply with all the warnings and safety
instructions given in this workshop manual.
First read the instructions and warnings on
the labels and stickers which are affixed to
the various components and comply with
them! They have been put there for your
health and safety, so do not ignore them!
- Wear clean, fitted clothes and apply
protective cream to unprotected parts of
your body, as necessary.
- Ensure proper extraction of dangerous
materials from the work area.
- Maintain a safe distance from rotating
and/or moving parts.
- Avoid unnecessary contact with drained oil.
Frequent contact damages the skin.

ǹ 0008 1
SAFETY PRECAUTIONS
Safety precautions PF engine

- Various sorts of oil and other lubricants

used on the vehicle may constitute a health
hazard. So avoid both inhaling and direct
contact with these.
- Exercise caution when working with springs
under pressure. Inadvertently released
springs may cause serious injuries. Small
springs and circlips may also cause injuries
when inadvertently released (wear
goggles).
- If necessary, support the component
suitably.
- Always use the appropriate lifting gear
(gearbox jack) or approved lifting gear or
hoists for the removal and installation of
heavy components. Attach the component
securely to the lifting or hoisting gear.
- After a fire it is possible that hazardous
residues may remain from the plastics used
in some oil seals and sealing rings. Wear
protective, acid--resistant clothing and PVC
gloves when removing such fire residues.
Submerge such fire residues in, or sprinkle
them amply with, a calcium hydroxide
solution (slaked lime and water).
Thoroughly clean the protective clothing
after use. Treat the gloves as chemical
waste.

2 ǹ 0008
 CONTENTS
PF engine

TECHNICAL DATA
0
DIAGNOSIS
1
CONSTRUCTION PARTS
2
FUEL SYSTEM
3
COOLING SYSTEM
4
TIMING GEAR
5
FLYWHEEL AND FLYWHEEL HOUSING
6
CYLINDER HEAD
7
LUBRICATION SYSTEM
8
CYLINDER BLOCK AND DRIVING GEAR
9

ǹ 0008
,MNF
 TECHNICAL DATA
PF engine Contents

CONTENTS
Page Date
0
1. ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0009
2. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0009
2.1 Dipped bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0009
2.2 Locking compounds and sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0009
2.3 Threaded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 0009
3. CONSTRUCTION PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0009
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0009
3.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0009
4. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0009
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0009
4.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 0009
5. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0009
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0009
5.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0009
5.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ...... 0009
6. TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0009
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0009
6.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . . 0009
7. FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0009
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0009
7.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0009
8. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . . 0009
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . . 0009
8.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 . . . . . . 0009
9. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 ...... 0009
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 ...... 0009
9.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 ...... 0009
9.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 ...... 0009
10. CYLINDER BLOCK AND DRIVING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . . . 0009
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . . . 0009
10.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 . . . . . 0009

ǹ 0008 1
 TECHNICAL DATA
Contents PF engine

2 ǹ 0008
 TECHNICAL DATA
PF engine Engine data

1. ENGINE DATA
Types PF 183 M
PF 212 M 0
PF 235 M

Design 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 118 x 140 mm
Swept volume 9.20 litres
Compression ratio 16.3 : 1
Firing order 1-5-3-6-2-4
Weight approx. 831 kg

ENGINE TYPE IDLE MAXIMUM UNLOADED

rpm rpm
PF 183 M 525 - 625 2570 - 2640
PF 212 M 525 - 625 2570 - 2640
PF 235 M 525 - 625 2570 - 2640

ENGINE TYPE P(kW) at rpm M (Nm) at rpm

PF 183 M 183 at 2300 1000 at 1200 -1700
PF 212 M 212 at 2300 1130 at 1150 -1700
PF 235 M 235 at 2300 1275 at 1300 -1700

ǹ 0008 1-1
 TECHNICAL DATA
Engine data PF engine

1-2 ǹ 0008
 TECHNICAL DATA
PF engine Threaded connections

2. THREADED CONNECTIONS
2.1 DIPPED BOLTS
0
The components can be provided with threaded
connections, which have been treated with
lubricant (dipped threaded connection).
Factory-galvanised bolts and nuts are
wax-dipped. Black annealed and phosphatised
bolts and nuts are oil-dipped. The advantage of
using dipped nuts and bolts is that friction during
tightening is reduced, so that the specified
pre-tension can be accurately obtained. The
result of this is that the tightening torque can be
reduced with the same pre-stressing force.
As this results in a smaller tolerance range of
the tightening torques, the specified tightening
torques must be adhered to more strictly. So
always use a reliable and accurate torque
wrench.
Note:
Have torque wrenches regularly inspected and
calibrated.
To achieve the correct pre-tension when
re-using nuts and bolts, it is important to clean
the thread thoroughly. After cleaning, apply one
drop of lubricant to the first turn of the screw
thread and one drop to the abutting surface of
the nut or bolt. Only use engine oil as a lubricant
for re-used bolts and nuts. Lubricants other than
engine oil and factory-applied grease must not
be used under any circumstances.
The reason for this is that the friction coefficients
of other lubricants vary too much and are not the
same as those of the above-mentioned
lubricants.
The use of locking compounds in combination
with dipped bolts and nuts creates no problems.

ǹ 0008 2-1
 TECHNICAL DATA
Threaded connections PF engine

The following applies to all threaded

connections (for both new and used

0 vehicles):
- in the case of standard connections, apply
the lubricant before fitting, and
tighten/retorque in accordance with the
standard for dipped bolts:
- in the case of special connections, apply the
lubricant before fitting, and tighten/retorque
in accordance with the values specified in
the instructions.
The instructions for using a lubricant also apply
to new bolts supplied from the warehouse. Dry
threaded connections are no longer permitted
because of their highly variable friction
coefficients.

2-2 ǹ 0008
 TECHNICAL DATA
PF engine Threaded connections

2.2 LOCKING COMPOUNDS AND SEALANTS

Certain cleaning agents have a

negative effect on the functioning of
0
locking compounds. The general
rule is therefore that fasteners and
components which have been
cleaned with a cleaning agent must
be treated with a cleaning liquid to
ensure that the locking compound
functions properly.

OVERVIEW OF LOCKING COMPOUNDS

Product Properties Applications DAF
name number
Loctite - Cleans and degreases For cleaning/de-greasing of 1322827
activator - Non-inflammable and not materials to which a locking
7063 corrosive compound must be applied
Loctite - Locking with an average For locking threaded screw 0068197
243 detaching strength connections
- Detachable with normal tools
Loctite - Locking with a high detaching Locking of threaded connections, 1340646
2701 strength gear lever bearing, freeze plugs
- Repairs the fit in bearing
housings
- Seals against leaks
- Difficult to detach
Loctite - Locking with a high detaching Locking of cylindrical connections 0645557
638 strength under dynamic load.
- Difficult to detach
Loctite - Locking with a high detaching Locking of threaded connections, 1279841
262 strength such as the pinion nut
- Difficult to detach

ǹ 0008 2-3
 TECHNICAL DATA
Threaded connections PF engine

OVERVIEW OF SEALING COMPOUNDS

0 Product
name
Properties Applications DAF
number
Dirko D - Temperature-resistant to 180_C - For sealing surface connections 1345014
- Resistant to oil, coolant
Loctite - Temperature-resistant to 200_C - For sealing surface (flange) 0697149
510 - Resistant to oil, brake fluid, connections that are subjected
coolant to high operating temperatures,
such as the flywheel housing
Loctite - Resistant to high pressures (up - For sealing surface connections 1246867
574 to 350 bar) against high pressures
- Resistant to oil, brake fluid,
coolant
Loctite - Temperature-resistant from 60 to - For sealing flexible constructions 1242895
Blue 260_C such as (valve) covers
- Resistant to oil
Loctite - Silicone sealant, good - For sealing (surface) 1284123
ultra grey resistance to coolant connections in the cooling
- Temperature-resistant to 325_C system
Silicon - For protecting against moisture 1340644
rubber penetration in (floor) connectors
Loctite - Silicone sealant, good - For sealing surface connections 1284122
ultra resistance to oil such as hub covers
copper - Temperature-resistant to 350_C
Dow - Silicone sealant, good - Sealing of surface connections 0693628
Corning resistance to oil such as the front and rear gear
732 - Elastic to --50_C and +220_C box covers
- Vulcanises to a tough rubber at
room temperature
Loctite - Seals against low pressure - Threaded connections 0292336
572 immediately after fitting

2-4 ǹ 0008
 TECHNICAL DATA
PF engine Threaded connections

OTHER PRODUCTS
Product
name
Properties Applications DAF
number 0
Molykote - Lubricating grease is - Everywhere where lubrication is 1389512
BR 2 heat-resistant from --30_C to appropriate and normal
PLUS +130_C - For almost all ball and roller
- Water-resistant bearings, slide bearings, guides,
couplings, spline-shafts,
threaded spindles, small
sprocket drives with a low speed
Tectyl - Protects the hollow areas of the - For post-treatment of cab parts 1343888
superstructure against corrosion to protect against corrosion
Can also be used as protection
for metal parts
Copaslip - Copper paste with an excellent - For connections that are 1284344
bond, is anti- corrosive and vulnerable to oxidation or
heat-resistant from --35 to corrosion, such as battery
+1100_C terminals, exhaust couplings etc.
- Resistant to water, salts and
acids
- Prevents wear, oxidation, rust,
corroding and locking of metal
surfaces

Application, locking compound

1. Clean both the internal and external thread.
2. De-grease the thread with a suitable
de-greasing agent which leaves no residue
that could affect proper functioning.
3. Depending on the diameter, apply one or
more drops of locking compound. Never dip
the bolt or stud into the locking compound.
4. Apply a drop of oil under the bolt head.
Locking compounds also reduce the
frictional resistance, which means that
applying a drop of oil to the thread is not
required.
5. Tighten the connection to the specified
torque.

ǹ 0008 2-5
 TECHNICAL DATA
Threaded connections PF engine

2.3 THREADED CONNECTIONS

0 TABLE OF STANDARD TIGHTENING

TORQUES, DAF STANDARD 00804-203
The tightening torques in the table below are
standard torques and only apply to dipped
threaded connections.
The property-class code is stamped on the nut
or bolt, except on the clamping flange bolt. The
clamping flange bolt is recognised by a
constriction between the hexagonal bolt head
and the flange. This constriction is absent in
standard flange bolts.

M2 00 001

Clamping flange bolt Standard flange bolt

2-6 ǹ 0008
 TECHNICAL DATA
PF engine Threaded connections

TIGHTENING TORQUES FOR DIPPED

THREADED CONNECTIONS (Nm)
Overview of tightening torques - applies to:
- property class bolt 8.8, nut 8 0
- property class bolt 12.9, nut 12
- Clamping flange bolt, property class 12.9 /
nut 12.

Property class bolt 8.8, nut 8 Property class bolt 12.9, nut 12
M4 : 2.8
0.2
M5 : 5.5
0.4
M6 : 9.6
0.7
M8 : 23
2 M8 : 32
3
M10 : 46
4 M10 : 67
5
M12 : 79
6 M12 : 113
9
M14 : 125
9 M14 : 178
14
M16 : 195
14 M16 : 274
22
M18 : 280
20 M18 : 385
30
M20 : 395
30 M20 : 550
43
M22 : 540
40 M22 : 740
60
M24 : 680
50 M24 : 925
72
M27 : 1000
70 M27 : 1370
110
M30 : 1350
100

Clamping flange bolt

property class bolt 12.9, nut 12
M12 : 178
14
M14 : 274
22
M16 : 425
35
M18 : 550
45

Tightening torques for banjo bolts

M6 : 8
0.8 Nm
M8 : 15
1.5 Nm
M10 : 30
3 Nm
M12 : 40
4 Nm
M14 : 50
5 Nm
M16 : 60
6 Nm
M18 : 70
7 Nm

ǹ 0008 2-7
 TECHNICAL DATA
Threaded connections PF engine

Overview of tightening torques - applies to:

- property class bolt 10.9, nut 10

0 Property class 10.9

Thread pitch Tightening Extra angular displacement (
10 %)
torque
q (Nm)
( ) for bolt stem length (mm)
L ≤ 40 41 - 80 81 - 130 131 - 180
M8 30
2 angular displacement not permitted
M10 60
4 angular displacement not permitted
M12 x 1.75 110
8 30_ 60_ 90_ 120_
M12 x 1.25 110
8 45_ 90_ 120_ 150_
M14 x 2 170
15 30_ 60_ 90_ 120_
M14 x 1.5 170
15 45_ 90_ 120_ 150_
M14 x 2 for brake back plates 170
15 + 60_
M16 x 2 260
20 30_ 60_ 90_ 120_
M16 x 1.5 260
20 45_ 90_ 120_ 150_
M18 x 1.5 360
30 45_ 90_ 120_ 150_
M20 x 1.5 520
40 45_ 90_ 120_
M22 x 2.5 for steering and track rods 500
50 + 90_

The bolt stem length L is the length of the bolt

between the bolt head and the nut.
If a component is attached with several bolts, all
bolts must first be tightened to the specified
torque, and subsequently by the angular
displacement.

2-8 ǹ 0008
 TECHNICAL DATA
PF engine Threaded connections

Torque wrench
- Have torque wrenches regularly inspected
and calibrated.
Re-using bolts/nuts
0
Bolts tightened using angular displacement may
not be reused, unless a suitable new nut can be
screwed down the entire length of the bolt
thread by hand.
1. Clean the thread (take particular care to
remove locking compound residues) and
the bearing faces;
2. Apply one drop of engine oil to the first turn
of the bolt/lower screw thread of the nut and
one drop to the bearing faces (other
lubricants are not allowed).
3. If a locking compound was specified, no oil
should be applied to the thread.
New bolts/nuts
New DAF bolts and DAF nuts, except bolts M4
to M8 with inner-Torx, are all treated with
grease.
If bolts have not yet been treated with a
lubricant, a lubricant should be applied.
1. Apply one drop of engine oil to the first turn
of the bolt/lower screw thread of the nut and
one drop to the bearing faces (other
lubricants are not allowed).
2. If a locking compound was specified, no oil
should be applied to the thread.

ǹ 0008 2-9
 TECHNICAL DATA
Threaded connections PF engine

2-10 ǹ 0008
 TECHNICAL DATA
PF engine Construction parts

3. CONSTRUCTION PARTS
3.1 GENERAL
0
V-BELT TENSION
Belt tension, “AVX” raw edge1 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
Adjusting tension 700 350

1. Raw-edge belts can be recognised by the

absence of textile fabric on the inside and
on the lower parts of the sides (polished
sides). 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
tension reading is lower than the ”test
tension” specified in the table set the V-belt
to the minimum ”test tension”. M2121

3. If the V-belt tension is lower than the

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

ǹ 0008 3-1
 TECHNICAL DATA
Construction parts PF engine

Explanation, GARRET turbocharger type

description

0 Example of type description:

GT42-94S/54NPS/1.44-84
GT42 Turbine type description
94 Maximum compressor wheel
diameter
S Waste-gate model
54 Compressor wheel trim
NPS Version with intake side without
compressor housing by-pass
PS Version with intake side with
compressor housing by-pass
1.44 Dimensions, turbine housing
84 turbine wheel trim

Turbocharger
Stud attachment Copaslip (DAF No. 1284344)

Air compressor
Safety valve opening value 16 bar

3-2 ǹ 0008
 TECHNICAL DATA
PF engine Construction parts

3.2 TIGHTENING TORQUES

Starter motor
Attachment nuts 73 Nm *
0
Alternator
Attachment bolts, alternator bracket 55 Nm
Alternator attachment bolts 50 Nm
Pulley attachment nut, model 55A 70 Nm
Pulley attachment nut, model 80A 70 Nm

Air compressor
Attachment bolt, compressor gear wheel 120 Nm
M12 attachment bolts 110 Nm
M8 attachment bolt bracket 30 Nm
M10 attachment bolt bracket 60 Nm
M26 cylinder head threaded connection 90 Nm
Delivery pipe reducer valve 75 Nm
Gland nut suction and delivery pipes 90 Nm

Air-conditioning compressor
M12 compressor bracket attachment bolts 110 Nm
M10 compressor attachment bolts 60 Nm *

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
Attachment nut, glow plug 55 Nm

Turbocharger
Heat shield attachment bolts 30 Nm *
Turbine housing clamp plate attachment nut 15 Nm
Attachment nuts
Exhaust manifold flange/turbocharger 60 Nm**
Bend on turbocharger 40 Nm
Lifting gear hook supports
Attachment bolts 110 Nm

* Fasten with Loctite 243

** Fasten with Copaslip

ǹ 0008 3-3
 TECHNICAL DATA
Construction parts PF engine

Vibration damper
Attachment bolts (in 4 stages):
0 1st phase, all attachment bolts
2nd phase, all attachment bolts
100 Nm**
100 Nm**
3rd phase, all attachment bolts 100 Nm**
4th phase, all attachment bolts 100 Nm**

Fan
Attachment nuts 25 Nm *
Fan pulley attachment bolts 30 Nm *

* Fasten with Loctite 243

** Tighten the attachment bolts evenly

3-4 ǹ 0008
 TECHNICAL DATA
PF engine Fuel system

4. FUEL SYSTEM
4.1 GENERAL
0
Overview, injectors
Engine Number Nozzle Hole Bar Pressure Control
type of holes no. diameter filter setting pressure
in nozzle
PF 183 M 8 678 0.217 yes 230 -240 bar 200 -240 bar
PF 212 M 8 678 0.217 yes 230 -240 bar 200 -240 bar
PF 235 M 8 678 0.217 yes 230 -240 bar 200 -240 bar

Overview, fuel pumps

Engine Fuel pump type Injection timing Delivery Grinding Helix
type device valve edge top
PF 183 M P 7100 RQV-K CPV no no
PF 212 M P 7100 RQV-K CPV no no
PF 235 M P 7100 RQV-K CVP no no

Fuel pump
Injection timing:
PF 183 M 12_ before TDC
PF 212 M 12_ before TDC
PF 235 M 13_ before TDC

ǹ 0008 4-1
 TECHNICAL DATA
Fuel system PF engine

4.2 TIGHTENING TORQUES

0 Injectors
screw cap injectors 45 Nm
Clamp attachment bolt 30 Nm + 60_ angular displacement*
Always replace attachment bolt

Injector pipes
Injector pipes, gland nut 25 Nm

Fuel pump
Fuel pump coupling nut (pump side)
P 7100 (M20 x 1.5) 195 Nm
Attachment bolts for fuel pump on support 60 Nm

Clutch plates/fuel pump drive attachment

bolts
Attachment bolts 110 Nm + 60_ angular displacement
Never re-use bolts;
always use new bolts

Drive coupling clamping bolt 100 Nm + 60_ angular displacement

Always replace clamping bolt

Fuel pump drive housing

Attachment bolts, drive housing 60 Nm

Return pipe
Locknut 50 Nm
filter side banjo bolt 40 Nm

Leak-off pipe
Banjo bolts 20 Nm
Banjo bolt with integrated non-return valve 25 Nm

Fuel pump supply and discharge pipe

filter side banjo bolts 40 Nm
pump side banjo bolts 40 Nm

Fuel lift pump

Banjo bolts 40 Nm

Fuel filter
Attachment bolts, fuel filter/water pipe 40 Nm
connection

* Fasten with Loctite 243

4-2 ǹ 0008
 TECHNICAL DATA
PF engine Cooling system

5. COOLING SYSTEM
5.1 GENERAL
0
Thermostat
Thermostat opening temperatures
Thermostat opens at approx. 83_C
Thermostat opened at least 12 mm at approx. 95_C
Thermostat seat Loctite 638

Water pump
Maximum radial play 0.16 - 0.2 mm

5.2 TIGHTENING TORQUES

Coolant pipe on cylinder head

Attachment bolts 54 Nm
Coolant pipe threaded connection 90 Nm
Coolant pipe plug 35 Nm

Thermostat housing on coolant pipe

Attachment bolts 30 Nm
Plug 35 Nm

Water pump
M8 attachment bolts 30 Nm

5.3 FILLING CAPACITIES

Cooling system capacity approx. 37 litres

Cooling system capacity with ZF intarder approx. 47 litres

ǹ 0008 5-1
 TECHNICAL DATA
Cooling system PF engine

5-2 ǹ 0008
 TECHNICAL DATA
PF engine Timing gear

6. TIMING GEAR
6.1 GENERAL
0
Number of teeth, timing gear
Crankshaft gear wheel 31
Intermediate gear wheel 52
Fuel-pump gear wheel 62
Camshaft gear wheel 62
Air compressor gear wheel 27
Steering pump gear wheel 18
Oil pump intermediate gear wheel 28
Oil pump gear wheel 36

Gear backlash
Intermediate gear wheel - crankshaft gear
wheel 0.02 - 0.20 mm
Intermediate gear wheel - fuel-pump gear
wheel 0.02 - 0.22 mm
Intermediate gear wheel - camshaft gear
wheel 0.02 - 0.22 mm
Camshaft gear wheel - compressor gear wheel 0.02 - 0.22 mm
Fuel pump gear wheel - steering pump gear
wheel 0.02 - 0.19 mm
Intermediate oil pump gear wheels 0.02 - 0.20 mm
Crankshaft gear wheel - intermediate oil pump
gear wheel 0.02 - 0.20 mm

Axial play
Axial play, crankshaft 0.05 - 0.35 mm
Axial play, camshaft 0.10 - 0.55 mm
Axial play, intermediate gear wheel 0.03 - 0.25 mm

Valve opening
Valve opening at 1 mm valve clearance 0.45
0.2 mm

ǹ 0008 6-1
 TECHNICAL DATA
Timing gear PF engine

6.2 TIGHTENING TORQUES

0 Timing gear
Attachment bolts, camshaft locking plate 30 Nm
Attachment bolts, fuel pump drive shaft locking
plate 30 Nm
Attachment bolts, timing gear housing 30 Nm
Engine speed sensor 50 Nm

Attachment bolts, timing gear cover:

M10 attachment bolts 60 Nm
M8 attachment bolts 25 Nm
M8 studs 25 Nm

Attachment bolt, timing gear cover protection

plate 15 Nm
Attachment bolt, camshaft gear wheel 425 Nm *
Attachment bolt, intermediate gear wheel 170 Nm
Attachment bolt, fuel pump gear wheel 260 Nm
Attachment nut, steering pump gear wheel 80 Nm *
Steering pump intake pipe banjo bolt 90 Nm
Steering pump delivery pipe banjo bolt 40 Nm
Attachment bolt, compressor gear wheel 120 Nm

* Fasten with Loctite 243

6-2 ǹ 0008
 TECHNICAL DATA
PF engine Flywheel and flywheel housing

7. FLYWHEEL AND FLYWHEEL HOUSING

7.1 GENERAL
0
Flywheel
Axial play, measured at a radial distance of
210 mm 0.10 mm
Starter ring warm up Max. 185_C

7.2 TIGHTENING TORQUES

Flywheel housing
Attachment bolts 110 Nm *
Apply sealant to the flywheel housing and fit it Loctite 510

Flywheel
Attachment bolts without PTO 80 Nm* + 45_ angular displacement
with PTO 110 Nm + 150_ angular displacement

Engine brackets on flywheel side

Flywheel housing engine bracket attachment
bolts 260 Nm

* Fasten with Loctite 243

ǹ 0008 7-1
 TECHNICAL DATA
Flywheel and flywheel housing PF engine

7-2 ǹ 0008
 TECHNICAL DATA
PF engine Cylinder head

8. CYLINDER HEAD
8.1 GENERAL
0
Cylinder head

M200777

Minimum height of surfaces (measurement A) 119.5 mm

Rough value 0.4 -1.6 µm
Test pressure using air (hot) 1.5 bar

Valve seat, inlet (loose seat)

Valve seat angle (old) 30_
0.25_
Valve seat angle (new) 20_
0.25_
Internal dia. 34.7
0.1 mm
External dia. 43 mm
Thickness 6.25 0 - 0.10 mm
Minimum thickness after overhaul 4.75 mm

Cylinder head chamber

Depth 9.9
0.2 mm
Diameter 43 H7 mm

Valve seat, exhaust (loose seat)

Valve seat angle (old) 30_
0.5_
Valve seat angle (new) 45_
0.25_
Internal dia. 30.5
0.1 mm
External dia. 43 mm
Thickness (old) 6.3 - 6.4 mm
Thickness (new) 6.1 - 6.2 mm
Minimum thickness after overhaul (old) 4.9 mm
Minimum thickness after overhaul (new) 4.7 mm

Cylinder head chamber

Depth 9.9
0.2 mm
Diameter 43 H7 mm

Expansion caps
Locking compound Loctite 2701

ǹ 0008 8-1
 TECHNICAL DATA
Cylinder head PF engine

Inlet valve
Valve head diameter 40.5
0.125 mm
0 Valve head angle 19.5°
0.25°

Distance between valve head and cylinder

head surface (dimension B) --1.25
0.33 mm
Within the cylinder head, this is

M200750

Valve stem diameter 8.935 -8.953 mm

Valve clearance (cold/hot) 0.45 mm

Valve opening
Valve opening at 1 mm valve clearance 0.45
0.2 mm

8-2 ǹ 0008
 TECHNICAL DATA
PF engine Cylinder head

Exhaust valve
Valve head diameter 37.0
0.125 mm
Valve head angle 19.5°
0.25°
0
Distance between valve head and
cylinder head surface (measurement B) --0.95
0.33 mm
Within the cylinder head, this is

M200750

Valve stem diameter 8.915 -8.933 mm

Valve clearance (cold/hot) 0.45 mm

Valve guide
Total length 76.50 mm
Internal dia. 9.02
0.006 mm
External dia. 15, s6
Height (measurement A) of exhaust upper
contact surface 17.50
0.5 mm
Height (measurement A) of exhaust upper
contact surface 14.50
0.5 mm

M2 00 012

ǹ 0008 8-3
 TECHNICAL DATA
Cylinder head PF engine

Pressure spring
- Untensioned length 55.39 mm
0 - Tensioned length 42.00 mm

Rocker shaft
Rocker shaft diameter 24.980 - 24.993 mm
Internal dia., opened bearing bush 25 H7

Tappets
External dia: standard 35.949 - 35.965 mm
Excess external dia. 36.439 - 36.455 mm

8-4 ǹ 0008
 TECHNICAL DATA
PF engine Cylinder head

8.2 TIGHTENING TORQUES

Cylinder head attachment bolts

16
14 15 17 0
1st stage:
Tighten the M16 bolts in the indicated order to a 11
6 1 2 7
12
torque of 50 Nm.*
2nd stage: 13

Tighten the M16 bolts in the indicated order to a 10

5 3
8
torque of 150 Nm. 9 4

Tighten the M12 bolts in the indicated order to a

torque of 94 Nm *
M200734
3rd stage:
Tighten the M16 bolts in two steps of 60º each,
in the pictured sequence. 50 Nm

Note:
Subsequently, mark the heads of the M16 bolts
with a centre point. Bolts with two centre points
must not be used again, but must be replaced
150 Nm

M16
instead.
* Fasten with Loctite 572 and apply a drop of
oil on the contact surface of the M16 and
M12 bolt heads.
I

M16
94 Nm

II

M12
II
60°
M16

60°

III
M16

III

M200563

ǹ 0008 8-5
 TECHNICAL DATA
Cylinder head PF engine

Valve mechanism
Valve cover attachment bolts 25 Nm
0 Rocker adjusting bolt lock nut
Bridge adjusting bolt locknut
40 Nm
40 Nm
Attachment bolts, rocker seat/lubricating oil
strip 110 Nm
Attachment bolts, valve sleeve 30 Nm
Tighten the valve sleeve bolts in the pictured
sequence

Diagram, valve sleeve tightening sequence 13 9

3 7 11 2 6

14
5
1 10 12 8 4
M200959

8-6 ǹ 0008
 TECHNICAL DATA
PF engine Lubrication system

9. LUBRICATION SYSTEM
9.1 GENERAL
0
Oil pressure
Oil pressure with engine idling 1 bar (warm engine)
Oil pressure at maximum loaded engine speed 3.35 - 4.35 bar

Oil filter
Type disposable filter
Quantity 1
Installation in the oil circuit full flow
Opening pressure, short-circuit valve at a
pressure difference of 2.5
0.3 bar

Oil cooler
Opening pressure, short-circuit valve at a
pressure difference of 2 bar
Test pressure, oil section 2.5 bar

ǹ 0008 9-1
 TECHNICAL DATA
Lubrication system PF engine

9.2 TIGHTENING TORQUES

0 Oil sump
Clamp attachment bolts 25 Nm
Oil drain plug 60 Nm

Oil pump
Attachment bolts for oil pump housing parts 30 Nm
Attachment bolts to connect oil pump to
main-bearing cover 60 Nm *
Oil delivery pipe attachment bolts 30 Nm *
Intermediate gear central bolt 60 Nm *

Strainer
Attachment bolts, bracket 30 Nm *
Lubricating oil filter
Attachment bolts, lubricating oil filter housing 50 Nm**
Oil filter 45 Nm
Coupling in pump seat/filter housing 60 Nm ***

By-pass governor
Plug 80 Nm

Oil cooler
Attachment bolts to connect oil cooler to
cylinder block 50 Nm

Dip-stick
Threaded coupling 60 Nm

* Fasten with Loctite 243

** Fasten with Loctite 572
*** Fasten with Loctite 2701

9.3 FILLING CAPACITIES

Lubrication system
Total capacity, including oil cooler and oil filter approx. 26 litres
Sump capacity, max. level approx. 22 litres
Sump capacity, min. level approx. 14 litres

9-2 ǹ 0008
 TECHNICAL DATA
PF engine Cylinder block and driving gear

10. CYLINDER BLOCK AND DRIVING GEAR

10.1 GENERAL
0
Overview, wear measurements

1 2 3 4 5 6

1 2 3 4 5 6
Ø A1
Ø A2 B

Ø A3
Ø A4 Ø A1 A
Ø A5
Ø A6 20 mm
1
Ø B1 2
Ø B2 3
Ø B3 4
Ø B4 5
Ø B5 6
30 mm
Ø B6
G
D
Z z
D

S1
S2 1
2
S3 3
4
S4
S

M2 00 017

ǹ 0008 10-1
 TECHNICAL DATA
Cylinder block and driving gear PF engine

Overview, wear measurements

0 A
B

A
B
M2 00 018

10-2 ǹ 0008
 TECHNICAL DATA
PF engine Cylinder block and driving gear

Cylinder block
Minimum distance (measurement A)
after mechanical treatment 343.81 mm
0

M200239

Depth of chamber, cylinder liner collar: 5.98 - 6.02 mm

Bore for cylinder liner:

- standard 123.498 - 123.472 mm
- excess 123.748 - 123.722 mm
Bore, main bearing shells 103.072 - 103.098 mm
Bore, camshaft bearings 67.305 - 67.335 mm
Test pressure, using air of max. 4.0 bar

Valve tappet bore:

- standard 36 H7 mm
- excess 36.5 H7 mm

Expansion caps
Locking compound Loctite 2701

Cylinder liner
External diameter, cylinder liner:
- standard 123.49 - 123.51 mm
- excess 123.74 - 123.76 mm
Internal diameter, cylinder liner 118.02 - 118.04 mm
Height of cylinder liner above block 0.02 - 0.10 mm

ǹ 0008 10-3
 TECHNICAL DATA
Cylinder block and driving gear PF engine

Crankshaft

0 6
7

5
4
3
2
1 C

A M2 00 142

Maximum clock deflection (play) between

2 main bearing caps beside each other 0.08 mm

Maximum clock deflection (play) middle

main bearing (4), with support of
front (1) and rear (7) main bearing journal 0.25 mm

Diameter, flange rearmost oil seal C 124.98 -125.02 mm

Thickness, axial thrust washers:

- standard 2.286 mm
- 1st oversize 2.413 mm
- 2nd oversize 2.540 mm

Main bearing journals (A)

- standard diameter 88.00
0.02 mm
- 1st undersize 87.75
0.02 mm
- 2nd undersize 87.50
0.02 mm
- 3rd undersize 87.25
0.02 mm
The crankshaft must be nitrided, having been
ground to undersize for the 2nd time see the
DAF-standard.

Rounding radius 4.5 - 5.0 mm

Width, 1st bearing journal 44.0
0.4 mm
Width, 2nd,3rd,5th and 6th bearing journal 40.0
0.1 mm
Width, 4th bearing journal:
- standard 58.000
0.025 mm
- 1st oversize 58.254
0.025 mm
- 2nd oversize 58.508
0.025 mm

10-4 ǹ 0008
 TECHNICAL DATA
PF engine Cylinder block and driving gear

Width measurements must remain the same

when grinding to undersize, unless these are
damaged. If the axial bearing is damaged at
the point of the middle bearing, these surfaces 0
must be re-ground.
Width, 7th bearing journal 48.0
0.1 mm

Main bearing halfshells

Width, 1st and 7th main bearing halfshell 35.80 - 36.20 mm
Width, 2nd,3rd,5th and 6th main bearing
halfshell 28.30 - 28.70 mm
Width, 4th main bearing halfshell 43.80 - 44.20 mm

Connecting rod bearing journals (B)

- standard diameter 82.00
0.02 mm
- 1st undersize 81.75
0.02 mm
- 2nd undersize 81.50
0.02 mm
- 3rd undersize 81.25
0.02 mm
The crankshaft must be nitrided, having been
ground to undersize for the 2nd time see the
DAF-standard.
Rounding radius 4.5 - 5.0 mm
Width 48.0
0.04 mm

Connecting rods
Diameter, initial bore large head 85.57
0.006 mm
Diameter, bearing bush small head after
reaming 48.035
0.004 mm
Distance from centre of large head to centre of
small head 232.0
0.03 mm

Connecting rod bearing halfshells

Width 36.0
0.2 mm
Bearing play 0.048 - 0.124 mm

Pistons
Groove width
- top spring Trapezoid
- compression spring 3.04 - 3.06 mm
- oil scraper ring 4.03 - 4.05 mm

ǹ 0008 10-5
 TECHNICAL DATA
Cylinder block and driving gear PF engine

Piston rings
When inspecting the gap clearance, consider
A
0 the old and new sets of piston rings. The
respective set is recognisable from the version
with oil scraper ring.
A = old set of piston rings.
B = new set of piston rings.
B
M200939

Gap clearance Gap clearance Thickness

old set (mm) new set (mm) (mm)
top spring 0.30 - 0.55 0.35 - 0.50 Trapezoid
compression spring 0.40 - 0.65 1.50 - 2.00 2.97 - 2.99
oil scraper ring 0.30 - 0.60 0.40 - 0.75 3.97 - 3.99

Gudgeon pin
Diameter, Gudgeon pin: 47.994 - 48,000 mm

Camshaft
Diameter, journals 57.92
0.012 mm
Inspection measurement, cam height
(measurement A):
- inlet 48.80 -49.72 mm
- exhaust 48.84 -49.68 mm

M2 00 016

10-6 ǹ 0008
 TECHNICAL DATA
PF engine Cylinder block and driving gear

10.2 TIGHTENING TORQUES

Cylinder block brackets, front

Cylinder block bracket attachment bolts 92 Nm
0
Main bearing covers
Attachment bolts for main bearing covers 150 Nm
120_ angular displacement*

Connecting rod bearing covers

Attachment bolts for connecting rod bearing
covers
1st stage, sequence 1-2-3-4 25 Nm
2nd stage, sequence 4-3-2-1 35 Nm
3rd stage, sequence 1-2-3-4 60_ angle tightening**

1 4

3 2
M200661

Oil nozzle
Banjo bolt (M14), oil nozzle with locking plate 30 Nm
Banjo bolt (M10) oil injector 30 Nm

* Apply a drop of oil to the thread and

bearing surface.
** 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 thread
and bearing face of the connecting rod
bolts.

ǹ 0008 10-7
 TECHNICAL DATA
Cylinder block and driving gear PF engine

10-8 ǹ 0008
 DIAGNOSIS
PF engine Contents

CONTENTS
Page Date
1. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
2. TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
1
3. FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
4. CYLINDER BLOCK AND DRIVING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008
4.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008
5. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0008
5.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0008

ǹ 0008 1
 DIAGNOSIS
Contents PF engine

2 ǹ 0008
 DIAGNOSIS
PF engine Cylinder head

1. CYLINDER HEAD
1.1 FAULT-FINDING TABLE

FAULT: CYLINDER HEAD GASKET BLOWN

Possible cause Remedy 1
The head gasket was not fitted properly and has Inspect cylinder head and cylinder block
leaked
The cylinder head was not tightened according Inspect the cylinder head for damage and fit the
to the specified tightening procedure cylinder head. Tighten the cylinder head bolts to
the specified torque. See “Technical Data”
One or more threaded holes for securing the Inspect cylinder block
cylinder head bolts have been cracked or
damaged
The height of the cylinder liner above the Check the pressure. See “Technical Data”
cylinder block is not correct
The cylinder head has cracked Inspect the cylinder head
The surfaces of the cylinder head and cylinder Inspect the surfaces of the cylinder head and
block are pitted cylinder block

FAULT: INLET VALVE BROKEN

Possible cause Remedy
No valve clearance or negative valve clearance - Inspect the valve clearances.
- Inspect and clean the air inlet and exhaust
system thoroughly.
- If the valve continues to hit the piston, inspect
and clean the internal section of the engine
thoroughly.
The valve timing is too early Inspect the valve timing and the other pistons for
valve impressions
Camshaft gear wheel has one or more teeth Inspect the position of the camshaft gear wheel
incorrectly positioned

ǹ 0008 1-1
 DIAGNOSIS
Cylinder head PF engine

FAULT: EXHAUST VALVE BROKEN

Possible cause Remedy
No valve clearance or negative valve clearance Inspect the valve clearances
Inspect and clean the air inlet and exhaust

1 system thoroughly
If the valve continues to hit the piston, inspect
and clean the internal section of the engine
thoroughly
Engine speed too high Inspect the engine speed regulator of the fuel
pump
Inspect the gearbox fastening
The valve is broken as a result of a material Inspect the other exhaust valves
problem
Camshaft gear wheel has one or more teeth Inspect the position of the camshaft gear wheel
incorrectly positioned

FAULT: EXHAUST VALVE DISK CRACKED

Possible cause Remedy
The valve is cracked as a result of a material Inspect the other exhaust valves
problem

FAULT: EXHAUST VALVE DISK BURNT

Possible cause Remedy
No valve clearance or negative valve clearance Inspect the valve clearances
Inspect the other exhaust valves

1-2 ǹ 0008
 DIAGNOSIS
PF engine Timing gear

2. TIMING GEAR
2.1 FAULT-FINDING TABLE

FAULT: NOISE IN THE TIMING GEAR CASE

Possible cause Remedy 1
Timing gear cog damaged Inspect timing gear wheels
Timing gear wheel play not correct Inspect timing gear wheel play
Timing gear wheel disconnected Inspect timing gear wheel attachment

ǹ 0008 2-1
 DIAGNOSIS
Timing gear PF engine

2-2 ǹ 0008
 DIAGNOSIS
PF engine Flywheel and flywheel housing

3. FLYWHEEL AND FLYWHEEL HOUSING

3.1 FAULT-FINDING TABLE

FAULT: ENGINE VIBRATES EXCESSIVELY

Possible cause Remedy 1
Unbalance or flywheel oscillation Check the flywheel for play and attachment. See
“Technical data”

ǹ 0008 3-1
 DIAGNOSIS
Flywheel and flywheel housing PF engine

3-2 ǹ 0008
 DIAGNOSIS
PF engine Cylinder block and driving gear

4. CYLINDER BLOCK AND DRIVING GEAR

4.1 FAULT-FINDING TABLE

FAULT: VALVE IMPRESSION ON THE BOTTOM OF THE PISTONS

Possible cause Remedy 1
No valve clearance or negative valve clearance Inspect the valve clearances
Broken valve spring Inspect valve springs
Incorrect valve spring design Inspect valve spring design

FAULT: SEVERAL PISTONS SHOW A VALVE IMPRESSION

Possible cause Remedy
The valve timing is Incorrect Inspect the valve timing
A timing gear wheel has come loose Inspect the timing gear wheels
The engine is turning at too high an engine Inspect the engine speed regulator of the fuel
speed if all the exhaust valves have hit the pump.
pistons Inspect the gearbox fastening
Camshaft gear wheel has one or more teeth Inspect the position of the camshaft gear wheel
incorrectly positioned

FAULT: CRACKED PISTON HEAD

Possible cause Remedy
Too rich a mixture Check the fuel pump output
Inspect the air cleaner for clogging
Incorrect injection timing Check the injection timing
Bad fuel distribution due to poor functioning of Inspect the injectors
injectors
Fuel injection during engaging of the engine When operating the engine brake, check
brake whether the fuel pump is in the stop position

ǹ 0008 4-1
 DIAGNOSIS
Cylinder block and driving gear PF engine

FAULT: IMPRESSIONS IN THE PISTON HEAD

Possible cause Remedy
Broken glow plug Inspect the glow plugs
Inspect the other pistons, cylinder liners and

1 During activity, a foreign object has entered the

valves for damage
Inspect the other pistons, cylinder liners and
combustion chamber via the inlet/exhaust valves for damage
manifold Inspect the inlet/exhaust system

FAULT: CYLINDER LINER WORN OUT

Possible cause Remedy
Gudgeon pin circlip broken or not fitted. Inspect pistons
Piston rings worn due to poor lubrication of the Inspect the dimensions of the cylinder liner and
cylinders (if necessary) of the cylinder drilling. See
“Technical data”
Piston rings worn due to impurities in the air Inspect the air filter and the whole air inlet
drawn in system

FAULT: PISTON HEAD HAS MELTED

Possible cause Remedy
Engine overheating Inspect the cooling system for the following
points:
- filling
- correct function
- pollution
- correct type
Check the dimensions of the cylinder drilling.
See “Technical Data”.
Air bubble in the cooling system Inspect the bleeding system
Bad fuel distribution due to poor functioning of Inspect the injectors
injectors

4-2 ǹ 0008
 DIAGNOSIS
PF engine Cylinder block and driving gear

FAULT: PITTING ON THE PISTON HEAD

Possible cause Remedy
The piston head has hit the cylinder head, as the Inspect whether all pistons have the same
centre-to-centre distance from the crankshaft to damage
the cylinder head is too small
Cylinder block has been over-machined 1
Connecting rod bearing worn out Inspect connecting rod bearings
Gudgeon pin sleeve worn out Inspect gudgeon pin sleeve

FAULT: PISTON RING GROOVE WORN OUT

Possible cause Remedy
Piston ring fracture Inspect the other piston rings
When fitting the ring, this was bent open too far,
causing a hairline fracture.
The intake air is polluted, causing excessive Inspect the whole air intake system
wear to the piston rings

FAULT: PISTON SKIRT WORN OUT AROUND GUDGEON PIN HOLE

Possible cause Remedy
Fracture or incorrect fitting of the circlip for the Also inspect the other pistons and cylinder liners
gudgeon pin for damage

ǹ 0008 4-3
 DIAGNOSIS
Cylinder block and driving gear PF engine

FAULT: PISTON SHOWS SIGNS OF GRATING

Possible cause Remedy
If the signs of grating are mostly to be found Inspect the cooling system for the following
around the gudgeon pin holes: points:

1 overheating of the relevant cylinder due to

shortage of coolant or air in the cooling system
- filling
- correct function
- pollution
- correct type
Check the dimensions of the cylinder drilling.
See “Technical Data”.
Air bubble in the cooling system Inspect the bleeding system
If the signs of grating are mostly to be found on Inspect the cooling system.
the pressure side of the piston: Check the dimensions of the cylinder drilling.
piston skirt cracked from the gudgeon pin holes See “Technical Data”.
If the piston shows light signs of grating on the Inspect the cooling system.
pressure side: cold start. Check the dimensions of the cylinder drilling.
If an engine is brought to a high engine speed in See “Technical Data”.
a short time, the pistons are not fully
cooled/lubricated. This may result in localised
grating.

FAULT: PISTON SKIRT COLOURED

Possible cause Remedy
Oil consumption too high Check:
- piston rings for wear
- cylinder liner for scratches
- dimensions
See “Technical data”
Piston rings worn Check:
Due to this, the oil is not fully scraped from the - piston rings for wear
cylinder wall. The combustion gases can also - cylinder liner for scratches
leak to the bottom. As a result, the oil burns and - dimensions
turns the piston black in the area of the spring See “Technical data”
wall

4-4 ǹ 0008
 DIAGNOSIS
PF engine Cylinder block and driving gear

FAULT: GUDGEON PIN SHOWS GROOVES

Possible cause Remedy
Grit in the engine oil. Clean all parts.
Engine oil polluted. Inspect the dimensions.
As a result, the gudgeon pin wears excessively. See “Technical Data”.
1
FAULT: PISTON RINGS WORN
Possible cause Remedy
Poor lubrication of the cylinder due to: Inspect fuel system.
- Fuel in the lubricant Inspect cooling system.
- coolant in the lubricant Inspect the cylinder liner for signs of wear.
The piston rings show signs of vertical grating. Inspect the dimensions.
The signs of grating run over the whole diameter See “Technical Data”.
of the piston rings
The intake air is polluted, causing excessive Inspect the whole air intake system
wear to the piston rings

FAULT: CONNECTING ROD BENT

Possible cause Remedy
Fluid stroke. Check:
A film of water has got above the piston, as - whether the head gasket has blown
water has been able to enter the air filter due to: - the cylinder head for cracks
- cleaning with water - whether the water leakage has been
- driving through very deep water continuing for some time
The head gasket is leaking or the cylinder block - the cylinder block and driving gear for
is cracked subsequent damage
During operations, oil has entered the cylinder

ǹ 0008 4-5
 DIAGNOSIS
Cylinder block and driving gear PF engine

FAULT: VALVE TAPPETS BROKEN OR CRACKED

Possible cause Remedy
If only the exhaust valve tappets have been Inspect the engine speed regulator of the fuel
broken: too high an engine speed pump

1 The accompanying valve is stuck

Inspect the gearbox fastening
Inspect valves
Valve tappet has grated Inspect the valve tappet for signs of grating
Faulty valve tappet fitted Inspect the diameter of the valve tappet.
See “Technical data”

FAULT: VALVE TAPPET SHOWS SIGNS OF PITTING

Possible cause Remedy
The valve tappets have been subjected to a In the event of heavy pitting, re-use is no longer
heavy load due to very intensive mechanical permitted
contact. With this load in combination with Inspect cam shaft for damage
lubrication problems, pitting can occur.

4-6 ǹ 0008
 DIAGNOSIS
PF engine Cylinder block and driving gear

FAULT: BEARING HALFSHELLS EXCESSIVELY WORN

Possible cause Remedy
Thinning of lubricating oil due to coolant Check the oil cooler
Inspect the cylinder block and cylinder heads for
cracks or blown head gasket by bleeding the
cooling system
Check measurement A on the camshaft. See
1
“Technical Data”
Inspect and clean the lubrication system
Thinning of lubricating oil due to fuel Have the fuel pump checked for internal leaks
Check measurement A on the camshaft. See
”Technical Data”
Inspect and clean the lubrication system
Polluted lubricating oil due to: Check measurement A on the camshaft. See
- polluted oil filter “Technical Data”
- too long an interval between oil changes If the bearing journals show grooves, the
- too long an interval between oil filter changes crankshaft must be replaced or ground
- excessive pollution within the period between Inspect and clean the lubrication system
replacements
- worn sections of the running parts
- broken oil filter
- dirt remaining from fitting
Too little lubricating oil due to: Inspect the engine for external oil leakage
- poor inspection of oil level Check measurement A on the camshaft. See
- oil level too low “Technical Data”
- oil not topped up If the bearing journals show grooves, the
- excessive oil use crankshaft must be replaced or ground
- External oil leakage Inspect and clean the lubrication system
- air bubbles in the lubrication system due to a
loose fitting oil suction pipe

In the case of reduced oil pressure, damage to

the connecting rod bearings will be first to
increase, as these are further away from the oil
pump than the main bearings
No lubricating oil due to: Check measurement A on the camshaft. See
- loosened or left out oil drain plug “Technical Data”
- clogging of the oil channel If the bearing journals show grooves, the
- bearing installation fault crankshaft must be replaced or ground
Inspect and clean the lubrication system
In the case of sudden loss of oil, damage to the
main bearings will be first to occur, as these
immediately receive no more oil

ǹ 0008 4-7
 DIAGNOSIS
Cylinder block and driving gear PF engine

FAULT: BEARING HALFSHELLS SHOW TRACES OF GROOVES

Possible cause Remedy
During installation dirt has come between the Check measurement A on the camshaft. See
bearing halfshell and the initial bore of the main “Technical Data”

1 bearing or the connecting rod If the bearing journals show grooves, the
crankshaft must be replaced or ground
Inspect and clean the lubrication system

4-8 ǹ 0008
 DIAGNOSIS
PF engine Cooling system

5. COOLING SYSTEM
5.1 FAULT-FINDING TABLE

FAULT: EXTERNAL COOLANT LEAKAGE

Possible cause Remedy 1
Flexible coolant pipes defective Check the coolant pipes
Coolant pipes defective Check coolant pipes
Leaking water pump Check the water pump. If necessary, measure
bearing play
Defective oil cooler Check the oil cooler. Pressure test if necessary.
Leaking connection between coupling and water Check connection between water pipe and
pipe coupling for damage
Replace O-rings

FAULT: INTERNAL COOLANT LEAKAGE

Possible cause Remedy
Defective cylinder head gasket Check cylinder head gasket
Cracked cylinder heads or cylinder block Check cylinder heads and cylinder block for
internal cracks. Pressure test if necessary.
Leaking injector bushes Check cylinder heads. Pressure test if
necessary.
Defective compressor cylinder head gasket Replace compressor cylinder head gasket
Defective oil cooler Check whether there is coolant in the lubricating
oil system
Defective freeze plugs in tappet area (cylinder Replace freeze plug(s)
block) or at the top of the cylinder heads

ǹ 0008 5-1
 DIAGNOSIS
Cooling system PF engine

5-2 ǹ 0008
 CONSTRUCTION PARTS
PF engine Contents

CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.1 Overview drawing, turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.2 General arrangement drawing, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . 0008
2. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.1 Inspection and adjustment, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008

2
2.2 Inspection, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . 0008
3. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0008
3.1 Removal and installation, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0008
3.2 Removal and installation, turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0008
3.3 Removal and installation, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0008
3.4 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 ...... 0008
3.5 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ...... 0008
3.6 Removal and installation, V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 ...... 0008
3.7 Removal and installation, V-belt tensioning gear, air-compressor drive . . . 3-8 ...... 0008
3.8 Removal and installation, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 ...... 0008

ǹ 0008 1
 CONSTRUCTION PARTS
Contents PF engine

2 ǹ 0008
 CONSTRUCTION PARTS
PF engine General

1. GENERAL
1.1 OVERVIEW DRAWING, TURBOCHARGER

3
8
7
6
1
5 2

2
M200960

1. Turbocharger
2. Exhaust gasket
3. Oil pipe
4. Flexible oil pipe
5. Filler sleeve
6. Clamp cutting ring
7. Coupling
8. Copper ring

ǹ 0008 1-1
 CONSTRUCTION PARTS
General PF engine

1.2 GENERAL ARRANGEMENT DRAWING, EXHAUST MANIFOLD

2 3
5

4
4

7
5 2
7
1

M200961

1. Exhaust manifold heat shield, rear

2. Exhaust manifold heat shield, front
3. Manifold, timing gear end
4. Seals
5. Exhaust gasket
6. Manifold, flywheel housing end
7. Spacer sleeve

1-2 ǹ 0008
 CONSTRUCTION PARTS
PF engine Inspection and adjustment

2. INSPECTION AND ADJUSTMENT

2.1 INSPECTION AND ADJUSTMENT, V-BELT TENSION

The V-belt should be inspected with a belt OP

A BTLIB
EEUL
TI
N.2
tension gauge. The advantage of this method is 00

a more accurate pre-tension reading and, LBS

.50
600

consequently, the service life of the V-belt 100

150
amongst other parts can be extended.
There are two types of belt tension gauge:
“Krikit I”, a belt tension gauge for single belt
OPBT
A
LIBEE
U
LTII
N.5
00 2
versions (DAF No. 1240442). “Krikit II”, a belt LB S
.100 150
0

tension gauge for twin belt versions (DAF No. 200

300

1240443).
The difference between the “Krikit I” belt tension
gauge and the “Krikit II” belt tension gauge is
that the latter has a larger belt bearing surface. M2079

Measuring with the “KRIKIT” belt tension

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

M2061

2. Place the 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 not to let the measuring
bar move

M2092

ǹ 0008 2-1
 CONSTRUCTION PARTS
Inspection and adjustment PF engine

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
“Technical Data”.

2 M2062

Adjustment, V-belt tension of

air-conditioning compressor drive
1. Slacken the central nut (1) of the tensioner.
2. Move the tightening bolt (2) until the correct
V-belt tension is achieved. See “Technical
Data”.
3. Tighten the central bolt (1).

M200885

Adjustment, V-belt tension of water pump 6 5

and alternator drive
1. Loosen the lower attachment bolt (1) of the 4
alternator.
3
2. Loosen the upper attachment bolt (2) of the 2
alternator.
3. Loosen the threaded rod attachment bolt
(3), which is fixed to the water pump.

1
M200753

2-2 ǹ 0008
 CONSTRUCTION PARTS
PF engine Inspection and adjustment

4. Loosen the locknut (4) of the threaded rod. 5

6
5. Slacken bolt (6) of the coupling.
4
6. Shift the compressor using the locknut (5)
until the correct V-belt tension is achieved. 3
2
See “Technical Data”.

1
M200753

ǹ 0008 2-3
 CONSTRUCTION PARTS
Inspection and adjustment PF engine

2.2 INSPECTION, GLOW PLUGS

1. Check the glow plug for the following points: C

- windings that have worn thin due to
abrasion (A);
- filament end broken or worn thin due to
continuous knocking of a loose
insulator (see C);
- broken plug windings (C).
A B
2 2. Replace all glow plugs if one or more of the
above-mentioned situations occurs.

M200818

2-4 ǹ 0008
 CONSTRUCTION PARTS
PF engine Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, GLOW PLUGS

Removal, glow plugs

1. Remove the wiring and connection strip +
from the glow plugs.
2. Remove the glow plugs.
3. Inspect the glow plugs, see “Inspection and
Adjustment”. 2
Installation, glow plugs
1. Tighten the glow plugs to the specified
torque. See ”Technical data”.
M2 00 154

2. Connect the wiring and the connection strip.

Make sure that the insulators are fitted in
the correct place.
3. Clean the contact surface of the glow plug
earth lead to ensure that it is properly
earthed on the inlet manifold.

ǹ 0008 3-1
 CONSTRUCTION PARTS
Removal and installation PF engine

3.2 REMOVAL AND INSTALLATION, TURBOCHARGER

Removal, turbocharger
1. Remove the heat shields (1) from the
turbocharger.
2. Remove the air inlet pipe (2) between the
turbocharger and air cleaner.
3. Remove the exhaust bend (3).
2 4. Disconnect the connector pipe (4) from the
turbocharger and the air intake pipe to the
intercooler.
5. Remove the turbocharger lubricating pipes.
Plug the openings.
2 4 3 1 1
6. Remove the attachment nuts from the
turbocharger. M200962

7. Remove the turbocharger from the exhaust

manifold.
Installation, turbocharger
1. Before installing the turbocharger, check the
following:
- turbocharger shaft must rotate freely;
- turbocharger shaft must not be out of
true;
- turbocharger shaft must have little
radial clearance.
2. Clean the sealing surfaces.
3. Apply a layer of Copaslip to the exhaust
manifold studs.
4. Always use new gaskets during installation.
5. Fit the turbocharger. If necessary, turn the
two halves of the housing so that the oil and
air pipes can be connected free of stress.
6. Connect the connector pipe (4) from the
turbocharger and the air intake pipe to the
intercooler.
7. Fit the oil discharge pipe.
8. Spray clean engine oil into the oil supply of
the turbocharger and fit the oil supply pipe.

3-2 ǹ 0008
 CONSTRUCTION PARTS
PF engine Removal and installation

9. Fit the exhaust bend (3).

10. Fit the air intake pipe (2) between the
turbocharger and the air cleaner.
11. Fit the heat shields (1) for the turbocharger.
Tighten the attachment bolts to the
specified torque. See “Technical Data”.

2
2 4 3 1 1

M200962

ǹ 0008 3-3
 CONSTRUCTION PARTS
Removal and installation PF engine

3.3 REMOVAL AND INSTALLATION, INLET MANIFOLD

Removal, inlet manifold

1. Remove the wiring from the glow filaments
and the temperature sensor.
2. Remove the fuel leak-off pipe between the
fuel filter and inlet manifold.
3. Remove the fuel filter element assembly
2 4.
from the inlet manifold.
Disconnect the injector pipes. M200963

5. Disconnect the boost pressure pipe on the

inlet manifold.
6. Remove the attachment bolts from the inlet
manifold and remove the manifold.
Installation, inlet manifold
1. Carefully clean the sealing surfaces of the
inlet manifold and the cylinder head.
2. Fit new gaskets to the inlet manifold and fit
the manifold. Tighten the attachment bolts
to the specified torque. See “Technical
Data”.
3. Fit the fuel leak-off pipe between the fuel
filter and the inlet manifold.
4. Fit the boost pressure pipe.
5. Fit the injector pipes.
6. Fit the fuel filter element assembly.
7. Fit the wiring from the glow filaments and
the temperature sensor.

3-4 ǹ 0008
 CONSTRUCTION PARTS
PF engine Removal and installation

3.4 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD

Removal, exhaust manifold

1. Remove the inlet air pipe between the
turbocharger and the intercooler.
2. Remove the compressor pipe.
3. Remove the heat shields from the
turbocharger.
4. Remove the air inlet pipe. 2
5. Remove the butterfly valve.
6. Remove the heat shields from the exhaust
manifold.
7. Remove the oil supply and discharge pipes
from the turbocharger.
8. Remove the attachment bolts from the M200964
exhaust manifold and remove the manifold.
Installation, exhaust manifold
1. Fit new gaskets to the exhaust manifold and
fit the manifold. Tighten the attachment
bolts with the spacer sleeves to the
specified torque. See “Technical data”.
2. Install the heat shields of the exhaust
manifold. Tighten the attachment bolts to
the specified torque. See “Technical Data”.
3. Fit the turbocharger’s oil discharge pipe.
4. Spray clean engine oil into the oil supply of
the turbocharger and fit the oil supply pipe.
5. Fit the compressor pipe.
6. Fit the inlet air pipe between the
turbocharger and the intercooler.
7. Fit the butterfly valve.
8. Fit the air intake pipe.
9. Fit the heat shields for the turbocharger.
Tighten the attachment bolts to the
specified torque. See “Technical Data”.

ǹ 0008 3-5
 CONSTRUCTION PARTS
Removal and installation PF engine

3.5 REMOVAL AND INSTALLATION, AIR COMPRESSOR

Removal, air compressor

1. Remove the oil filler pipe (5).
2
2. Disconnect the service pipe (8) from the air
dryer. 1
3. Remove the coolant connections (1).
3
2 4.
5.
Disconnect the air pipes (2 and 3).
Disconnect the lubricating oil pipe (4). 5
6. Remove the mounting bracket (7) at the
back of the compressor. 4

7. Remove the attachment bolts from the 7

timing gear cover.
4
8. Remove the compressor from the timing
gear case. Remove the O-ring from the 8
compressor housing.
Installation, air compressor
1. Fit a new O-ring to the compressor housing
and fit the compressor to the timing gear M200763
case.
2. Fit the attachment bolts of the air
compressor. Tighten the attachment bolts to
the specified torque. See “Technical Data”.
3. Fit the mounting bracket (7) at the back of
the compressor. Tighten the attachment
bolts to the specified torque. See “Technical
Data”.
4. Fit the service pipe (8).
5. Install the lubricating oil pipe (4).
6. Fit the air pipes (2 and 3).
7. Fit the coolant pipes (1).
8. Connect the oil filler pipe.

3-6 ǹ 0008
 CONSTRUCTION PARTS
PF engine Removal and installation

3.6 REMOVAL AND INSTALLATION, V-BELTS

Removal, V-belt of water pump and alternator 5

drive 6
1. Loosen the lower attachment bolt (1) of the 4
alternator.
3
2. Loosen the upper attachment bolt (2) of the 2
alternator.
3. Loosen the threaded rod attachment bolt
(3), which is fixed to the water pump. 2
4. Loosen the locknut (4) of the threaded rod.
5. Loosen bolt (6) of the coupling.
6. Turn the locknut (5) so that the alternator
can be tilted towards the engine block and
the V-belt can be removed. 1
Installation, V-belt, water pump and M200753
alternator drive
1. Inspect the pulleys for damage, rust and
grease deposits.
2. Fit the new V-belt and adjust the V-belt
tension. See “Inspection and adjustment”.
Removal, air-conditioning compressor drive
V-belt
1. Slacken the central nut (1) of the tensioner.
2. Turn the tightening bolt (2) until the V-belt
can be removed.
Installation, air-conditioning compressor
drive V-belt
1. Inspect the pulleys for damage, rust and
grease deposits.
2. Fit the new V-belt and adjust the V-belt
tension. See “Inspection and adjustment”.

M200885

ǹ 0008 3-7
 CONSTRUCTION PARTS
Removal and installation PF engine

3.7 REMOVAL AND INSTALLATION, V-BELT TENSIONING GEAR,

AIR-COMPRESSOR DRIVE

Removal, V-belt tensioning gear,

air-conditioning compressor drive 4
1. Remove the V-belt.
2. Remove the attachment bolt from the pulley.
3. Remove the pulley (1) from the filler 3
2 sleeve (2).
4. Remove the tensioning roller bracket (3)
and its shaft (4). 2
Installation, tensioning gear, air-conditioning
compressor drive V-belt
1. Fit the tensioning roller (4) and the 1
tensioning roller bracket (3). M200965

2. Fit the filler sleeve (2) and the pulley (1).

3. Fit the attachment bolt.
4. Fit the new V-belt and adjust the V-belt
tension. See “Inspection and adjustment”.

3-8 ǹ 0008
 CONSTRUCTION PARTS
PF engine Removal and installation

3.8 REMOVAL AND INSTALLATION, VIBRATION DAMPER

Removal, vibration damper

1. Remove the V-belts of the water pump and
alternator drive.
2. Remove the attachment bolts and the thrust
washer from the vibration damper.
3. Remove the vibration damper with special
tool (DAF No. 1240448).
Installation, vibration damper
2
1. Check the vibration damper for external
damage and silicone liquid leaks. In the
event of damage or leaks, the vibration
damper should be replaced. M200228

2. Fit the vibration damper. Tighten the

attachment bolts to the specified torque.
See “Technical Data”.
3. Fit the new V-belt and adjust the V-belt
tension. See “Inspection and adjustment”.

M200229

ǹ 0008 3-9
 CONSTRUCTION PARTS
Removal and installation PF engine

3-10 ǹ 0008
 FUEL SYSTEM
PF engine Contents

CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.1 Overview, fuel pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
2. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0008
2.1 Inspection and adjustment, injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0008
2.2 Inspection and adjustment, injector opening pressure . . . . . . . . . . . . . . . . . . 2-4 ...... 0008
2.3 Inspection, injector operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 ...... 0008
3. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.1 Removal and installation, injector lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008

3
3.2 Removal and installation, injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0008
3.3 Removal and installation, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . . 0008
3.4 Removal and installation, fuel pump drive sealing ring . . . . . . . . . . . . . . . . . 3-8 . . . . . . 0008
3.5 Removal and installation, fuel pump drive housing . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0008
4. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008
4.1 Disassembly and assembly, injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008
5. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0008
5.1 Cleaning, injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0008

ǹ 0008 1
 FUEL SYSTEM
Contents PF engine

2 ǹ 0008
 FUEL SYSTEM
PF engine General

1. GENERAL
1.1 OVERVIEW, FUEL PUMP DRIVE

1 2 3 4 5

6 7
M201016

1. Fuel pump drive gear wheel

2. Timing case seal
3. Bearing housing
4. Fuel pump drive seal
5. Clamping piece
6. Axial locking plate
7. Prop shaft

ǹ 0008 1-1
 FUEL SYSTEM
General PF engine

1-2 ǹ 0008
 FUEL SYSTEM
PF engine Inspection and adjustment

2. INSPECTION AND ADJUSTMENT

2.1 INSPECTION AND ADJUSTMENT, INJECTION TIMING

Inspection, injection timing

1. Remove the plug in the side of the fuel
pump governor housing. Collect the
escaping lubricating oil.
2. Screw the sensor of the special tool
(DAF No. 1310455) as far into the hole
as possible.
3. Connect the earth clamp of the tool to the
fuel pump housing.
3

i 400168

4. Using special tool (DAF No. 1310477),

crank the engine slowly in the direction of
rotation until both LED’s (A and B) on the
tool illuminate.
5. Remove the valve cover from cylinders 4, 5,
and 6. Inspect whether the valves of
cylinder 6 rock.
A B
6. Inspect on the flywheel whether the pump
timing is correct. See “Technical Data”.

i 400169

ǹ 0008 2-1
 FUEL SYSTEM
Inspection and adjustment PF engine

Adjustment, injection timing

1. Remove the valve cover of cylinders 4, 5,
and 6.
2. Using the special tool (DAF No. 1310477),
crank the engine slowly in the direction of
rotation, until the valves of cylinder 6 rock.
3. Using special tool (DAF No. 1310477),
crank the engine a few degrees back,
against the direction of rotation.
4. Using the special tool (DAF No. 1310477),
crank the engine in the direction of rotation
through the correct number of degrees
3 (injection timing) before top dead centre.
See “Technical Data”.
5. Remove the clamp bolt (1) from the clamp.

i 400171

6. Remove the plug in the side of the fuel

pump governor housing. Collect the
escaping lubricating oil.
7. Screw the sensor of the special tool
(DAF No. 1310455) as far into the hole as
possible.

i 400168

2-2 ǹ 0008
 FUEL SYSTEM
PF engine Inspection and adjustment

8. Connect the earth clamp of the tool to the

fuel pump housing.
9. Crank the engine slowly in the direction of
rotation until both LED’s (A and B) on the
tool light up.

A B

3
i 400169

10. Fit a new clamping bolt (1) in the clamp and

tighten it to the specified torque. See
“Technical Data”.

i 400171

11. Inspect the coupling plates for cracking and

whether they have been installed
stress-free. If there is stress on the coupling
plates, they will be convex or concave.
Inspect using a steel measuring rod.
12. Remove the special tool from the fuel pump
governor housing. Fit a new sealing ring to
the plug and fit it.
13. Fit the valve cover.

i 400168

ǹ 0008 2-3
 FUEL SYSTEM
Inspection and adjustment PF engine

2.2 INSPECTION AND ADJUSTMENT, INJECTOR OPENING PRESSURE

Fuel or test fluid discharged by an

injector may penetrate the skin
seriously harming your health.
Make sure the fuel jet is discharged
into a suitable container.

Check the opening pressure with an injector

test pump
- The discharge pressure of the injectors can
be tested using an injector test pump (DAF
No. 0694966). The advantage of this

3 method is that the injectors need not be

removed from the engine.
Instructions for the use of the injector test
pump
Before the injector-testing pump is used, it must
first be bled.
1. Remove the pump reservoir filler plug and
fill the reservoir with test fluid. The fluid level
must be approximately 1 cm beneath the
top rim.
2. Tilt the pump until the line with the word
“BLEED” is in a horizontal position.

BLEED

M4059

2-4 ǹ 0008
 FUEL SYSTEM
PF engine Inspection and adjustment

3. Press the bleed pin (1) and simultaneously

turn the crank (2) clockwise to the stop.
During this procedure, air bubbles will come 1
to the surface in the reservoir. Now turn
back the crank, fill the reservoir again and
repeat the process until no more air bubbles
come to the surface. A
Now release the bleed pin. Continue turning
the crank until fuel escapes on the delivery
side.
4. If necessary, fill the fuel reservoir and screw
back the plug.

2
3
5. The pump is now ready for use.
M4058

Inspection, injector discharge pressure

1. Remove the injector pipes in sets of three.
Immediately plug the connection openings
on the fuel pump.
2. Connect the injector pipe (supplied with the
injector test pump) to the injector to be
tested and to the test pump. Keep the test
pump approximately horizontal.
3. Loosen the test pump filler plug by half a
turn, so that air can enter the reservoir.
4. Turn the test pump crank clockwise. The
compression stroke now starts. Watch the
fluid level in the test pump.
5. Carefully determine the opening pressure of
the injector. There is no harm in repeating i 400190
the test twice or three times. If the test is
repeated too often however, the test fluid
deposited on the piston may cause damage
to the engine when it is started.
6. Re-fit the injector pipes after testing the
injector(s).

ǹ 0008 2-5
 FUEL SYSTEM
Inspection and adjustment PF engine

Adjustment, injector discharge pressure

Note:
The test pump can also be used to test the
injectors outside the engine; the bottom of the
test pump can be clamped in a vice without
damaging it.
1. Remove the injector. See ”Removal and
installation”.
2. Disassemble the injector. See “Disassembly
and assembly”.
3. Adjust the opening pressure by fitting a
3 thicker or thinner shim (1). For pressure
settings, see “Technical Data”.
Note:
An increased shim thickness of 0.01 mm
raises the pressure by approx. 1.5 bar.
4. Assemble the injector. See “Disassembly 1
and assembly”.
5. Fit the injector. See “Removal and
installation”.

i 400217

2-6 ǹ 0008
 FUEL SYSTEM
PF engine Inspection and adjustment

2.3 INSPECTION, INJECTOR OPERATION

Fuel or test fluid discharged by an

injector may penetrate the skin
seriously harming your health.
Make sure the fuel jet is discharged
into a suitable container.

It is practically impossible to evaluate the

injector’s performance by analysing the spray
pattern, spray angle and sound. New injectors or
injectors which have been used for some time
cannot be tested in this way.
1. Place the injector on an injector tester. 3
2. First allow the injector to inject a number of
times.
3. Inspect the injector for
- opening pressure
- leaks
- injector nozzles.
Opening pressure
1. Inspect the discharge pressure by slowly
building up the pressure inside the injector.
Leaks
1. Dry the nozzle immediately after the last
injection.
2. Increase the pressure to the opening
pressure minus 20 bar. Within approx. 10
seconds, fuel must have ceased to leak
from the nozzle. A moist nozzle is
permitted. If the injector does not pass the
oil leakage test, the injector body (nozzle)
must be replaced.
Injector nozzles
1. Quickly build up pressure in the injector and
check whether all the nozzles are fully
open.

ǹ 0008 2-7
 FUEL SYSTEM
Inspection and adjustment PF engine

2-8 ǹ 0008
 FUEL SYSTEM
PF engine Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, INJECTOR LINES

Always leave the injector pipes

fixed together, as a complete set.
Never remove or shift the clamping
brackets (A) which hold the
injector-pipes together. Never bend
injector pipes as they may crack.

Removal, injector pipes A

1. Clean the unions and the area surrounding A
3
the injectors and the fuel pump. A

i 400199

2. Note:
When slackening the injector pipe gland
nuts, hold the injector’s side connection
back using an open-end spanner.
Slacken the gland nuts of the injector pipes
on the injector side.
3. Slacken the unions from the injector pipes
on the fuel-pump side.
4. Immediately plug the openings.
5. Remove the entire set of three
injector-pipes.

i 400237

ǹ 0008 3-1
 FUEL SYSTEM
Removal and installation PF engine

Installation, injector pipes

1. Blow the injector pipes with dry compressed
air.
2. Check whether the injector side connection
is tightened to the specified torque. See
”Technical Data”.
3. Connect the set of injector pipes.
4. Note:
When tightening the injector pipe gland
nuts, hold the injector’s side connection
back using an open-end spanner.

3 Tighten the gland nuts of the injector pipes

to the specified tightening torque. See
“Technical Data”.

i 400237

3-2 ǹ 0008
 FUEL SYSTEM
PF engine Removal and installation

3.2 REMOVAL AND INSTALLATION, INJECTORS

Removal, injectors
1. Disconnect the injector pipes.
3
2. Remove the valve covers.
3. Remove the attachment bolt (3) of the
injector clamp. 2
4. To remove the injector and the clamp, only
use the special tools (DAF no. 1329309 and
DAF no. 0694928).

3
Note:
If during removal one or more copper shims
(1) remain in the injector sleeve, the injector
will be reinstalled in a higher position.
As a result, instead of spraying into the
combustion chamber of the piston, the fuel
will be sprayed onto the piston ring. This
may seriously damage the piston.
There will be inadequate sealing between 1
the O-ring (2) of the injector and the cylinder
head. Fuel leaking from the injector can
freely flow into the engine and dilute the I 400191
lubricating oil.

ǹ 0008 3-3
 FUEL SYSTEM
Removal and installation PF engine

Installation, injectors
1. Clean the injector sleeve. 3
2. Fit a new O-ring (1) and a new copper
shim (2) to the injector. Apply a little
acid-free grease to both rings.
3. Inspect the valve sleeve seal (3) of the
injector. Replace it if leaking and/or
damaged.
4. Note:
Make sure that the injector clamp (4) is
4
installed correctly. 1
3 Fit the injector together with the injector
clamp (4) and tighten the attachment bolt to
the specified torque. See “Technical Data”.
5. Connect the set of injector pipes.
6. Inspect the injector seals for leaks.
7. Fit the valve cover.

2
i 400183

3-4 ǹ 0008
 FUEL SYSTEM
PF engine Removal and installation

3.3 REMOVAL AND INSTALLATION, FUEL PUMP

When removing the fuel pump, a

quantity of fuel will escape. Collect
this fuel, bearing in mind the risk of
fire.

Removal, fuel pump

1. Disconnect the exhaust control unit pipe.
2. Disconnect the fuel supply and discharge
pipes.
3. Disconnect the injector pipes.
4. Disconnect the oil supply and return pipe. 3
5. Remove the air cylinder from the fuel pump
stop control.
6. Remove the attachment bolts (3) and 1 2 3 4 5 6
the bushes (4) with which the fuel pump
coupling (2) is connected to the drive

(Codenr)
flange (6).
7. Remove the attachment bolts from the fuel
pump.
8. Remove the fuel pump from the pump seat.

I4 00 405

ǹ 0008 3-5
 FUEL SYSTEM
Removal and installation PF engine

Installation, fuel pump

1. Using special tool (DAF No. 1310477),
crank the engine in the rotational direction
until the mark on the flywheel (in degrees
before TDC) indicates the injection time of
cylinder 1. 1. See “Technical Data”.
2. Remove the valve cover of cylinders 4, 5,
and 6.
3. Check whether the valves of cylinder 6
overlap.
4. Check the coupling plates of the fuel pump.

3 5. Clean the threaded holes of the attachment

bolts (3) in the drive flange (6).
6. Remove the clamping bolt (1) from the
clamping piece and open the clamping
piece slot.
7. Ensure that the clamping surfaces of the
shaft and the clamping piece are free of
1
grease.
8. Fit the pump to the pump seat.
9. Insert the four attachment bolts of the
pump. Tighten the attachment bolts to the
specified torque. See “Technical Data”.
10. Turn the drive flange (6) from the fuel pump
in such a way that the code number (5) is
i 400201
opposite the bolt (1) of the clamping piece.
11. Note: 1 2 3 4 5 6
Attachment bolts should not be reused;
always use new bolts.
(Codenr)

Install the bushes (4) and attachment

bolts (3). Tighten the attachment bolts to the
specified torque. See “Technical Data”.

I4 00 405

3-6 ǹ 0008
 FUEL SYSTEM
PF engine Removal and installation

12. Fit a new clamping bolt (1). Tighten the

clamping bolt (1) to the specified torque.
See ”Technical Data”.
13. Inspect the coupling plates for cracking and
whether they have been installed
stress-free. If there is stress on the coupling
plates, they will be convex or concave.
Inspect using a steel measuring rod.
14. Adjust the injection timing. See “Inspection
and Adjustment”.
15. Fit the stop control and inspect its
adjustment.
16. Connect the oil supply and return pipes. 3
17. Fit the injector pipes.
18. Connect the exhaust control unit pipe.
19. Connect all fuel supply and return pipes.
20. Fit the valve cover of cylinders 4, 5, and 6.

i 400184

ǹ 0008 3-7
 FUEL SYSTEM
Removal and installation PF engine

3.4 REMOVAL AND INSTALLATION, FUEL PUMP DRIVE SEALING RING

Removal, fuel pump drive sealing ring

1. Using special tool (DAF No. 1310477),
crank the engine until the 1st cylinder
injects. See “Technical Data”.
A A
2. Remove the attachment bolts (A) and the
fuel pump control between the control
housing and the fuel pump.

A A
3
i 400200

3. Remove the clamp bolt (1) from the clamp.

4. Remove the clamp from the prop shaft.

i 400201

5. Pull the seal (2) from the pinion housing

using the special tools (DAF Nos. 0484899
and 0694928).

2
i400202

3-8 ǹ 0008
 FUEL SYSTEM
PF engine Removal and installation

Installation, fuel pump drive seal

1. Clean the prop shaft and dry it.
2. Fit a dry new seal using the special tool
(DAF no. 1329308).
3. Open the slot of the clamp, so that the
coupling to be installed free of stress.
4. Fit the clamp, fitted with a new clamp
bolt (1), on the prop shaft.

1
3

i 400201

5. Fit the fuel pump drive and the centring

sleeves.
6. Fit the attachment bolts (A) and tighten
these to the specified torque. See A A
“Technical Data”.
7. Adjust the injection timing. See “Inspection
and Adjustment”.
8. Inspect the coupling plates for cracking and
whether they have been installed A A
stress-free. If there is stress on the coupling
plates, they will be convex or concave.
Inspect using a steel measuring rod. i 400200

ǹ 0008 3-9
 FUEL SYSTEM
Removal and installation PF engine

3.5 REMOVAL AND INSTALLATION, FUEL PUMP DRIVE HOUSING

Removal, fuel pump drive housing

1. Position cylinder 1 at top dead centre (TDC
on the flywheel, cylinder 6 in overlap
position).
2. Remove the V-belt between the water pump
and alternator.
3. Remove the vibration damper.
4. Remove the timing cover.

3
5. Remove the fuel pump drive gear wheel (1). 1 2 3 4 5

6 7
M200751

6. Remove the clamping bolt (1).

i 400201

3-10 ǹ 0008
 FUEL SYSTEM
PF engine Removal and installation

7. Remove the axial locking plate (7) from the

prop shaft.
8. Remove the prop shaft (8) from the
transmission case.

3
87

M200581

9. Remove the seal (2) by tapping in from the 1 2 3 4 5

timing gear case in the driving direction.
10. Remove the attachment bolts from the fuel
pump drive housing.
11. Remove the fuel pump drive housing (3)
from the engine block.
Installation, fuel pump drive housing
1. Fit the fuel pump drive housing (3) with a
new O-ring for lubrication. Tighten the
attachment bolts to the specified torque.
See “Technical Data”.

6 7
M200751

ǹ 0008 3-11
 FUEL SYSTEM
Removal and installation PF engine

2. Fit the prop shaft (8) in the fuel pump drive

housing.
3. Fit the axial retainer plate (7). Tighten the
attachment bolts to the specified torque.
See “Technical Data”.
4. Fit a dry new timing gear case seal (2)
using special tool (DAF No. 1329318).
5. Fit the fuel pump gear wheel.
6. Fit the timing cover.
7. Fit the vibration damper.

3 8. Fit the V-belt.

9. Adjust the injection timing. See “Inspection 87
and Adjustment”.

M200581

3-12 ǹ 0008
 FUEL SYSTEM
PF engine Disassembly and assembly

4. DISASSEMBLY AND ASSEMBLY

4.1 DISASSEMBLY AND ASSEMBLY, INJECTOR

The injector side connection (3)

may not be removed from the 3
injector.

Disassembly, injector
1. Remove the injector. See “Removal and
installation”.
2. Clean the injector. See “Cleaning”.
3. Note:
Do not exchange injector bodies (nozzles) 3
and injector needles because these
constitute a set.
Remove the gland nut (2), after which the
various injector parts can be taken from the
injector.
4. Check that none of the injector parts have
been compressed by the injector needle.
1

i 400303

ǹ 0008 4-1
 FUEL SYSTEM
Disassembly and assembly PF engine

Assembly, injector
1. Immerse the injector needle and the injector
housing in clean diesel fuel. Insert the
injector needle in the injector housing
(nozzle). When the injector body is held
vertically, if the injector needle is lifted
approx. 10 mm it should slide downwards
under its own weight.
2. Blow-clean all parts, and immerse them in
clean diesel fuel.
3. Note:
Ensure that no diesel fuel is present on the

3
screw thread due to the diminishing effect of
diesel fuel.

Fit the injector and tighten the union nut (2)

to the specified torque. See “Technical
Data”.
4. Check the opening pressure of the injector.
See “Inspection and Adjustment”.

M200210

4-2 ǹ 0008
 FUEL SYSTEM
PF engine Cleaning

5. CLEANING
5.1 CLEANING, INJECTORS

The injector body (nozzle) must

never be cleaned with copper or
steel wire brush. When cleaning the
exterior of the injector nozzle, do
not pass the brush over the injector
nozzles. If this happens, the nozzle
must be replaced.

The use of steel or copper brushes can cause

3
deformation of the injector nozzles with the
result that too little fuel is injected.
M2 00 040
Such deformation cannot be detected by
carrying out an injector test.
Before cleaning the nozzle, cover
the injector drillings. Only clean the
nozzle with the brass hand brush in
the injector cleaning kit
(DAF No. 1329371).

1. Determine the diameter of the injector

nozzles to be cleaned. See “Technical
Data”.
Note:
The diameter of the injector nozzles can be
recognised by the nozzle number on the
nozzle.
2. Disassemble the injector. See “Disassembly
and assembly”.
3. Clean the injector drillings using an injector
cleaning set (DAF No. 1329371).
Note:
The diameter of the needle must be approx.
0.02 mm less than the diameter of the
injector bores. i 400413

4. Assemble the injector. See “Disassembly

and assembly”.

ǹ 0008 5-1
 FUEL SYSTEM
Cleaning PF engine

5-2 ǹ 0008
 COOLING SYSTEM
PF engine Contents

CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.1 Overview drawing, thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
2. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.1 Inspection, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.2 Inspection, water pump radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . . 0008
3. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.1 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.2 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0008

ǹ 0008 1
 COOLING SYSTEM
Contents PF engine

2 ǹ 0008
 COOLING SYSTEM
PF engine General

1. GENERAL
1.1 OVERVIEW DRAWING, THERMOSTAT HOUSING

A O-ring
B Oil seal
C Thermostat seat

C
B
A

M200742 4

ǹ 0008 1-1
 COOLING SYSTEM
General PF engine

1-2 ǹ 0008
 COOLING SYSTEM
PF engine Inspection and adjustment

2. INSPECTION AND ADJUSTMENT

2.1 INSPECTION, THERMOSTAT

1. Remove the thermostat. See ”Removal and

Installation”.
2. Inspect the sealing surfaces (A) of the
thermostat housing for damage.
3. Inspect the sealing ring (B) for damage.
4. Inspect the thermostat seat (C) for damage. C
5. Check whether the thermostat is fully
B
closed.
A

M200742 4
6. Place the thermostat in a container filled
with clean water.
7. Place a thermometer in the container and
heat the water. Check at which temperature
the thermostat opens and whether the
thermostat opens fully. See “Technical
data”.

M200513

ǹ 0008 2-1
 COOLING SYSTEM
Inspection and adjustment PF engine

2.2 INSPECTION, WATER PUMP RADIAL PLAY

1. Remove the V-belt from the water pump

pulley. See “Removal and installation”.
2. Connect a dial gauge as shown in the
illustration.
3. Force the water pump pulley downwards
and set the dial gauge to zero.
4. Pull the water pump pulley upwards and
read off the dial gauge.
5. Compare the pressure reading with the
technical data. See “Technical Data”. If the
level shown is greater than that in the
technical data, the water pump must be

4
replaced.

M200595

2-2 ǹ 0008
 COOLING SYSTEM
PF engine Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, WATER PUMP

Removal, water pump

1. Remove the V-belts of the alternator and, if
necessary, the air-conditioning compressor.
2. Remove the attachment bolts from the
thermostat housing on the water pipe and
remove the thermostat housing with the
connection piece.
3. Disconnect all flexible water pipes
connected to the water pump.
4. Remove the attachment bolt with which the
spindle of the alternator is attached.
5. Remove the attachment bolts from the
water pump.
4
6. Disconnect the water pump.

M200966

ǹ 0008 3-1
 COOLING SYSTEM
Removal and installation PF engine

Installation, water pump

1. Thoroughly clean and check the sealing
surfaces of the water pump, the thermostat
housing and the cylinder block.
2. Fit a new gasket to the water pump and fit
the water pump. Fit the attachment bolts.
Tighten the attachment bolts to the
specified torque. See “Technical Data”.
3. Fit new O-rings to the connection piece and
fit it to the water pump.
4. Fit new O-rings to the thermostat housing
and fit it to the coolant pipe.
5. Fit all flexible water pipes connected to the
water pump.

4 6. Tighten the attachment bolt (3) of the

alternator threaded spindle which is
attached to the water pump.
7. Fit the V-belts of the alternator and, if fitted,
the air-conditioning compressor.
M200966
8. Adjust the V-belt tension.

3-2 ǹ 0008
 COOLING SYSTEM
PF engine Removal and installation

3.2 REMOVAL AND INSTALLATION, THERMOSTAT

Removal, thermostat
1. Remove the attachment bolts from the
thermostat housing.
2. Remove the thermostat housing and the
connecting piece from the water pump.
3. Remove the O-ring (A) from the thermostat
housing. C
B
4. Remove the thermostat. A
Removal, thermostat sealing ring
1. Remove the oil seal (B) in the thermostat
housing using a commercially available
internal puller. M200742

Removal, thermostat seat

1. Remove the thermostat seat (C) at the
4
bottom of the thermostat housing using a
commercially available internal puller.

ǹ 0008 3-3
 COOLING SYSTEM
Removal and installation PF engine

Installation, thermostat seat

1. Fit the thermostat seat (C), with a locking
compound applied, into the thermostat
housing. See “Technical Data”, using the
special tool (DAF No. 1310456).
Installation, thermostat oil seal
1. Fit the thermostat oil seal (B) in the
thermostat housing using special tool C
(DAF No. 1310456). B
A
Installation, thermostat
1. Fit the thermostat in the thermostat housing.
2. Fit the O-ring (A) in the thermostat housing.
M200742
3. Fit new O-rings to the connection piece
from the thermostat housing to the water
pump, and fit the connection piece in the
4 4.
thermostat housing.
Fit the thermostat housing onto the coolant
pipe.
5. Fit the thermostat housing attachment bolts.
Tighten the attachment bolts to the
specified torque. See “Technical Data”.

3-4 ǹ 0008
 TIMING GEAR
PF engine Contents

CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.1 Overview drawing of timing-gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
2. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.1 Inspection and adjustment the timing-gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
3. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.1 Removal and installation, timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.2 Removal and installation, timing cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0008
3.3 Removal and installation, timing cogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . . 0008
3.4 Removal and installation, timing gear case . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . . 0008
3.5 Removal and installation, timing gear case seal . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . . 0008

ǹ 0008 1
 TIMING GEAR
Contents PF engine

2 ǹ 0008
 TIMING GEAR
PF engine General

1. GENERAL
1.1 OVERVIEW DRAWING OF TIMING-GEAR

1. Crankshaft gear wheel 6 2 4

2. Camshaft gear wheel
3. Intermediate gear wheel
4. Steering pump gear wheel
5. Fuel pump drive gear wheel
6. Air compressor gear wheel
7. Oil pump intermediate gear wheel

7 1 3 5
M200744

ǹ 0008 1-1
 TIMING GEAR
General PF engine

1-2 ǹ 0008
 TIMING GEAR
PF engine Inspection and adjustment

2. INSPECTION AND ADJUSTMENT

2.1 INSPECTION AND ADJUSTMENT THE TIMING-GEAR

Inspection, timing
1. Remove the valve cover of cylinders 1, 2
and 3.
2. Position cylinder 1 at top dead centre (TDC
on the flywheel, cylinder 6 in overlap
position).
Note:
It is important that the bridges of the valve
mechanism are properly adjusted.
3. Set the inlet valve play of the first cylinder to
1 mm.
4. Position the measuring gauge on the inlet
valve bridge of the first cylinder, in such a
way that it measures in an exact vertical

5
position on the bridge and is capable of
registering an upward and downward
measurement 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).
M200574
6. Read the dial gauge and compare the
measured value. See ”Technical Data”.

Example
Pre-tension, dial gauge 5.00 mm
Measured tension 4.65 mm
Valve opening 0.35 mm

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

M200551

ǹ 0008 2-1
 TIMING GEAR
Inspection and adjustment PF engine

Adjustment, timing gear

1. Remove the valve cover of cylinders 1, 2
and 3.
2. Position cylinder 1 at top dead centre (TDC
on the flywheel, cylinder 6 in overlap
position).
3. Remove the timing gear cover. See
”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) to
such a position that the intermediate gear
wheel (3) can be installed in accordance

5 6.
with the marks.
Fit the intermediate gear wheel (3) and
tighten to the specified torque. See M200574
“Technical Data”.
7. Fit the timing cover. See “Removal and
installation”.
8. Fit the valve cover.

3
2

M200752

2-2 ǹ 0008
 TIMING GEAR
PF engine Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, TIMING COVER

When the engine or parts thereof

are opened, dirt may enter. This
may result in serious damage to the
engine. Therefore clean the engine
before opening it.

Removal, timing cover

1. Remove the V-belt of the air-conditioning
compressor (if fitted).
2. Remove the tensioner (if fitted).
3. Remove the V-belts of the water pump and
alternator.
4. Remove the vibration damper.
5. Mark the positions of the various

6.
attachment bolts and studs.
Remove the attachment bolts and studs
5
from the timing cover.
7. Slacken the coolant pipe from the cover by
pulling it slightly forwards over the stud.
8. Remove the timing cover.
9. Remove any gasket remains. Clean and
inspect the sealing faces, dowels and
locating holes.
10. Remove the seal from the timing cover.

ǹ 0008 3-1
 TIMING GEAR
Removal and installation PF engine

Installation, timing cover

1. Use three studs to position the gasket. Fit
the new gasket.
2. Fit the timing cover.
3. Fit the attachment bolts and the studs.
Tighten the attachment bolts and studs to
the specified torque. See “Technical Data”.
4. Remove the three studs used to position the
gasket and replace them with the remaining
attachment bolts.
5. Fit the tensioner for the air-conditioning
compressor (if fitted).
6. Fit the water pipe over the stud.
7. Fit the timing gear cover seal.
8. Fit the vibration damper.
9. Fit the V-belt of the alternator and water
5 pump.
10. Fit the V-belt of the air-conditioning
compressor (if fitted).

3-2 ǹ 0008
 TIMING GEAR
PF engine Removal and installation

3.2 REMOVAL AND INSTALLATION, TIMING COVER SEAL

Removal, timing cover seal

1. Remove the vibration damper.
Old type of timing cover seal
1. If the timing cover is equipped with an older
type of seal (version without a bearing race
on the damper), the seal must be removed
by boring two holes in it and pulling it out of
the timing cover using special tools
(DAF Nos. 0484899 and 0694928)
New type of timing cover seal
1. Remove the seal (A) from the timing cover
using the special tool (DAF No. 1329458).
2. Check the bearing race (B) for wear. If
necessary, replace.

M200971

5
A
B

m200830

Old situation New situation

ǹ 0008 3-3
 TIMING GEAR
Removal and installation PF engine

Installation, timing cover seal

Note:
If the timing gear case is fitted with an old type
seal (version without bearing race on the
vibration damper), the seal must be replaced
with a new seal (A) with bearing race (B) on the
vibration damper.
1. Clean and inspect the oil seal recess in the
timing gear cover. Even minimal damage
can lead to a leak.
2. Use the special tool (DAF No. 1329446) to
install the dry seal (A) and the thrust washer W264003
in the timing cover chamber.
3. Remove the special tool.
4. Fit the bearing race (B) to the vibration
damper.
5. Fit the vibration damper.

5 A
B

m200830

Old situation New situation

3-4 ǹ 0008
 TIMING GEAR
PF engine Removal and installation

3.3 REMOVAL AND INSTALLATION, TIMING COGS

Removal, timing gear

1. Remove the valve covers.
2. Position cylinder 1 in the top dead centre
(TDC on the flywheel, cylinder 6 in rocking
position).
3. Remove the V-belt of the air-conditioning
compressor (if fitted).
4. Remove the tensioner (if fitted).
5. Remove the V-belts of the water pump and
alternator.
6. Remove the vibration damper.
7. Remove the timing cover.
Note:
It is possible that the marks of the
intermediate gear wheel are not exactly
opposite the camshaft and crankshaft gear 5
wheel.

M200574

Removal, intermediate gear wheel 6 2 4

1. Remove the attachment bolt with the axial
thrust washer (3).
2. Remove the intermediate gear wheel.

7 1 3 5
M200744

ǹ 0008 3-5
 TIMING GEAR
Removal and installation PF engine

Removal, fuel pump drive gear wheel

1. Turn the engine speed sensor a number of
revolutions out of the timing gear case to
prevent the sensor from being damaged
when the gear wheel is being removed.
2. Remove the attachment bolt (5) from the 6 2 4
fuel pump gear wheel.
3. Remove the attachment bolt with the axial
thrust washer (3) from the intermediate gear
wheel.
4. Remove the intermediate gear wheel.
5. Remove the fuel pump drive gear wheel
using a commercially available puller.
Removal, camshaft gear wheel
1. Remove the attachment bolt (2) of the
camshaft gear wheel.
7 1 3 5
2. Remove the attachment bolt with the axial M200744

5
thrust washer (3) from the intermediate gear
wheel.
3. Remove the intermediate gear wheel.
4. Remove the camshaft gear wheel using a
commercially available puller.

3-6 ǹ 0008
 TIMING GEAR
PF engine Removal and installation

Installation, timing gear wheels

1. Remove the valve covers.
2. Position cylinder 1 at top dead centre
(TDC on the flywheel, cylinder 6 in overlap
position).
Note:
It is possible that the marks of the
intermediate gear wheel are not exactly
opposite the camshaft and crankshaft gear
wheel.
Installation, camshaft gear wheel
1. Fit the camshaft gear wheel (2) onto the
camshaft.
2. Fit the camshaft gear wheel attachment
bolt. Tighten the attachment bolt to the
specified torque. See “Technical Data”.
3. Fit the intermediate gear wheel.

5
4. Fit the attachment bolt with the axial thrust
washer (3) of the intermediate gear wheel
and tighten the attachment bolt to the
specified torque. See “Technical data”. M200574

Installation, fuel pump drive gear wheel

1. Note: 6 2 4
Before installing the intermediate gear
wheel, ensure that the clamp bolt used to
set the injection time can be accessed.
Fit the fuel pump drive gear wheel onto the
shaft end.
2. Fit the attachment bolt (5) of the fuel pump
gear wheel. Tighten the attachment bolt to
the specified torque. See “Technical Data”.
3. Tighten the engine speed sensor to the
specified torque. See ”Technical Data”.
4. Fit the intermediate gear wheel. 7 1 3 5
M200744

ǹ 0008 3-7
 TIMING GEAR
Removal and installation PF engine

5. Fit the attachment bolt with the axial thrust 6 2 4

washer (3) of the intermediate gear wheel
and tighten the attachment bolt to the
specified torque. See “Technical data”.

7 1 3 5
M200744

Installation, intermediate gear wheel

1. Fit the intermediate gear wheel (3) in such a
position that the marks of the camshaft gear
wheel (2), crankshaft gear wheel (1) and

5
intermediate gear wheel (3) are in line.
2. Fit the attachment bolt with the axial thrust
washer of the intermediate gear wheel.
Tighten the attachment bolt to the specified
torque. See “Technical Data”.
3. Check whether the gear wheels have some
play.
Installation, timing gear
1. Fit the timing cover. 3
2
2. Fit the vibration damper.
3. Fit the tensioner for the air-conditioning 1
compressor (if fitted).
4. Fit the V-belt of the alternator and water
pump. M200752

5. Fit the V-belt for the air-conditioning

compressor (if fitted).
6. Check the injection timing.

3-8 ǹ 0008
 TIMING GEAR
PF engine Removal and installation

3.4 REMOVAL AND INSTALLATION, TIMING GEAR CASE

Removal, timing gear case

1. Remove the timing cover.
2. Remove the timing gear wheels.
3. Remove the air compressor.
4. Remove the steering pump.
5. Remove the attachment bolts and the
locking plate from the camshaft.
6. Loosen the oil sump attachment bolts until
the oil sump is free from the timing gear
case.
7. Remove the attachment bolts from the
timing gear case to the engine block, and
remove the timing gear case.
Installation, timing gear case
1. Remove any gasket remains. Clean and
inspect the sealing faces, dowels and 5
locating holes.
2. To position the gasket, insert three studs
and fit the new gasket.
M200579

3. Then firstly remove any excess gasket

material between engine block and oil
sump.
4. Fit a new O-ring on the air compressor.
5. Fit the timing gear case.
6. Fit the attachment bolts for the timing gear
case. Tighten the attachment bolts to the
specified torque. See “Technical Data”.
7. Tighten the oil sump attachment bolts to the
specified torque. See “Technical Data”.

ǹ 0008 3-9
 TIMING GEAR
Removal and installation PF engine

8. Remove the locking plate and the

attachment bolts from the camshaft. Tighten
the attachment bolts to the specified torque.
See “Technical Data”.
9. Fit the timing gear wheels.
10. Fit the timing cover.
11. Fit the air compressor.
12. Fit the steering pump.

3-10 ǹ 0008
 TIMING GEAR
PF engine Removal and installation

3.5 REMOVAL AND INSTALLATION, TIMING GEAR CASE SEAL

Removal, timing gear case seal 1 2 3 4 5

1. Position cylinder 1 at top dead centre
(TDC on the flywheel, cylinder 6 in overlap
position).
2. Remove the V-belts of the water pump and
alternator.
3. Remove the V-belt of the air-conditioning
compressor (if fitted).
4. Remove the tensioner (if fitted).
5. Remove the vibration damper.
6. Remove the timing cover.
7. Remove the fuel pump drive gear wheel (1).

6 7
M200751 5
8. Remove the seal (2) by tapping in from the
timing gear case in the driving direction.

M200580

ǹ 0008 3-11
 TIMING GEAR
Removal and installation PF engine

Installation, timing gear case seal 1 2 3 4 5

1. Fit a dry new timing gear case seal (2)
using special tool (DAF No. 1329318).
2. Fit gear wheel (1) of the fuel-pump drive.
3. Fit the timing cover.
4. Fit the tensioner for the air-conditioning
compressor (if fitted).
5. Fit the vibration damper.
6. Fit the V-belts of the alternator and water
pump.
7. Fit the V-belt for the air-conditioning
compressor (if fitted).
8. Check the injection timing.

6 7
M200751

3-12 ǹ 0008
 FLYWHEEL AND FLYWHEEL HOUSING
PF engine Contents

CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.1 General arrangement drawing, flywheel and flywheel housing . . . . . . . . . . . 1-1 . . . . . . 0008
2. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.1 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
3. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0008
3.1 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0008
3.2 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0008
3.3 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0008
3.4 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0008

ǹ 0008 1
 FLYWHEEL AND FLYWHEEL HOUSING
Contents PF engine

2 ǹ 0008
 FLYWHEEL AND FLYWHEEL HOUSING
PF engine General

1. GENERAL
1.1 GENERAL ARRANGEMENT DRAWING, FLYWHEEL AND FLYWHEEL
HOUSING

ǹ 0008 1-1
 FLYWHEEL AND FLYWHEEL HOUSING
General PF engine

6 5
6 7 1

11 8

10 M200225

1-2 ǹ 0008
 FLYWHEEL AND FLYWHEEL HOUSING
PF engine General

1. Flywheel housing
2. Dowel
3. Marker plate
4. Sealing plate
5. Spacer ring
6. Mounting ring
7. Oil seal
8. Flywheel
9. Clamping pin
10. Starter ring gear
11. Ball bearing

ǹ 0008 1-3
 FLYWHEEL AND FLYWHEEL HOUSING
General PF engine

1-4 ǹ 0008
 FLYWHEEL AND FLYWHEEL HOUSING
PF engine Inspection and adjustment

2. INSPECTION AND ADJUSTMENT

2.1 INSPECTION, FLYWHEEL

1. If the flywheel shows marks on the abutting

surface with the clutch plate, the flywheel 5 mm
may be ground down, on condition that the
cracks are not within 5 mm of the inner rim.
2. The flywheel has an indicator groove for
inspection purposes. 2 mm
3. Grinding down is allowed until the indicator
groove is no longer visible. This means that
a maximum of 2 mm may be ground down. 5 mm
Inspection, flywheel play
1. Clean the flywheel.
2. Place a metal strip on the edge of the
flywheel housing to install a measuring
gauge with a magnetic foot piece.
3. Place the dial gauge on the metal strip.
M2 00 033
4. Place the dial gauge of the stylus at the
specified distance. See “Technical Data”.
5. Set the dial gauge to “0”. 6
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 dial gauge reading.
Compare this reading with the technical
data. See “Technical Data”.

M200230

ǹ 0008 2-1
 FLYWHEEL AND FLYWHEEL HOUSING
Inspection and adjustment PF engine

2-2 ǹ 0008
 FLYWHEEL AND FLYWHEEL HOUSING
PF engine Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, FLYWHEEL

Removal, flywheel
1. Remove the clutch release assembly and
the clutch plate.
2. Remove the attachment bolts (1) from the
flywheel.
3. Use two threaded bolts to remove the
flywheel from the dowel pin.
4. Remove the flywheel.
Installation, flywheel
1. Clean the flywheel housing. 1
2. Clean the crankshaft flange, the dowel pins
and the attachment bolts. Remove the
locking compound from the threaded holes. M200569

3. Clean the back of the flywheel and fit the

flywheel.
4. Fit the attachment bolts. Tighten the
attachment bolts to the specified torque.
See “Technical Data”. 6
5. Fit the clutch plate and the clutch release
assembly.

M200570

ǹ 0008 3-1
 FLYWHEEL AND FLYWHEEL HOUSING
Removal and installation PF engine

3.2 REMOVAL AND INSTALLATION, STARTER RING GEAR

Removal, starter ring gear

1. Remove the flywheel.
2. Remove the starter ring by tapping it off the
flywheel using a blunt chisel. If this is not
possible, cut it between two teeth, using a
sharp chisel.
Installation, starter ring gear
1. Clean the flywheel and the starter ring gear.
Ensure that the contact areas are
de-greased.
2. Heat the new starter ring evenly in an oven.
See “Technical Data”.
3. Tap the starter ring onto the flywheel so that
the bevelled sides of the teeth point towards
the starter motor. Ensure all round good
contact between starter ring and flywheel.
4. Fit the flywheel.
5. Fit the clutch plate and the clutch release
assembly.
6 M2 00 035

3-2 ǹ 0008
 FLYWHEEL AND FLYWHEEL HOUSING
PF engine Removal and installation

3.3 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING SEAL

Removal, flywheel housing seal

1. Note:
Each new oil seal is supplied with a plastic
mounting ring, which can only be used
once.
2. Remove the clutch release assembly and
the clutch plate.
3. Remove the flywheel.
4. Drill two holes into the seal and, using the
special tool (DAF No. 0484899 and DAF
No. 0694928) pull the seal out of the
flywheel housing.
Installation, flywheel housing seal
1. Thoroughly clean the seal recess and
inspect for damage. Even the most minute
damage can cause a leak.
2. Clean the crankshaft flange.
Note:
If a spacer ring has been placed in the seal
chamber, it must be re-fitted.
6
3. Lightly grease the inner rim of the oil seal.
4. Fit the base plate (A) of the special tool 1
(DAF No. 1329402) on the crankshaft 2
flange.
5. Fit the supplied plastic mounting ring (1)
with the oil seal on the crankshaft flange.
6. Place the thrust washer (B) over the spindle
and gradually tighten the nut (C) until the A
resistance increases.

B C
M2 00 036

ǹ 0008 3-3
 FLYWHEEL AND FLYWHEEL HOUSING
Removal and installation PF engine

7. Remove the thrust washer (B) and take out 1

the plastic mounting ring (1). 2
8. Place the thrust washer (B) over the spindle
and gradually tighten the nut (C) until the oil
seal is properly positioned.
9. Remove the special tool.
10. Fit the flywheel. A
11. Fit the clutch plate and the clutch release
assembly.
B C
M2 00 036

3.4 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING

Removal, flywheel housing

1. Remove the flywheel.
2. Remove the starter motor.
3. Properly suspend the engine in the hoist.

6 4. Remove the two oil sump attachment bolts

on the flywheel housing.
5. Slacken the other oil sump attachment bolts
until the oil sump is free from the flywheel
housing.
6. Remove the central engine mount
attachment bolts at the back of the engine.
7. Remove the attachment bolts from the
flywheel housing.
8. Remove the flywheel housing.

3-4 ǹ 0008
 FLYWHEEL AND FLYWHEEL HOUSING
PF engine Removal and installation

Installation, flywheel housing

1. Remove the oil seal from the flywheel
housing, by carefully tapping or forcing it
from the housing.
2. Remove any traces of old gaskets from the
contact areas.
3. Inspect the sealing faces for damage.
4. Inspect the flywheel housing for cracks.
5. Apply a locking compound to the sealing
face of the cylinder block. See “Technical
Data”. Apply the locking compound with a
roller or brush, across the entire sealing
face.
6. Fit the flywheel housing.
7. Fit the attachment bolts. Tighten the
attachment bolts to the specified torque.
See “Technical Data”.
8. Fit the central engine bracket attachment
bolts at the back of the engine. Tighten the
attachment bolts to the specified torque.

6
See “Technical Data”.
9. Fit the oil seal.
10. Fit the flywheel.
11. Fit the starter motor.
12. Fit the oil sump attachment bolts. Tighten all
attachment bolts to the specified torque.
See “Technical Data”.
13. Fit the clutch plate and the clutch release
assembly.

ǹ 0008 3-5
 FLYWHEEL AND FLYWHEEL HOUSING
Removal and installation PF engine

3-6 ǹ 0008
 CYLINDER HEAD
PF engine Contents

CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0008
1.1 Overview, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0008
1.2 Overview drawing, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ...... 0008
1.3 Overview drawing, valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 ...... 0008
2. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0008
2.1 Cylinder head pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0008
2.2 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0008
2.3 Inspection and adjustment the valve mechanism bridges . . . . . . . . . . . . . . . 2-3 ...... 0008
2.4 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 0008
3. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.1 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.2 Removal and installation, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . . 0008
3.3 Removal and installation, valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . . 0008
3.4 Removal and installation, cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . . 0008
3.5 Removal and installation, valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . . 0008
3.6 Removal and installation, valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0008
3.7 Removal and installation, valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . . 0008
3.8 Removal and installation, injector sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . . 0008
3.9 Removal and installation, expansion plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 . . . . . 0008
4. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008
4.1 Cleaning, injector sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008

ǹ 0008 1
 CYLINDER HEAD
Contents PF engine

2 ǹ 0008
 CYLINDER HEAD
PF engine General

1. GENERAL
1.1 OVERVIEW, CYLINDER HEAD

3
2

4
7
5

7 M200790

1. Cylinder head
2. Valve guide
3. Injector sleeve
4. Expansion plug
5. Expansion plug
6. Valve seat, inlet
7. Valve seat, exhaust

ǹ 0008 1-1
 CYLINDER HEAD
General PF engine

1.2 OVERVIEW DRAWING, VALVE GEAR

4 1
3 2
4

3
2

5
1
6

15

14

13

12
7 7
11

10
9

8
16

M200967

1. Shaft circlip 9. Exhaust valve

2. Rocker bearing bush 10. Inlet valve
3. Rocker 11. Valve spring
4. Adjusting screw 12. Spring retainer
5. Rocker shaft bracket 13. Valve key
6. Dowel 14. Cylindrical pin
7. Pushrod 15. Thrust piece
8. Valve stem 16. Attachment strip

1-2 ǹ 0008
 CYLINDER HEAD
PF engine General

1.3 OVERVIEW DRAWING, VALVE SLEEVE

7
4

M200969

1. Valve cover
2. Dowel
3. Valve cover gasket
4. Valve sleeve
5. Valve sleeve gasket

ǹ 0008 1-3
 CYLINDER HEAD
General PF engine

1-4 ǹ 0008
 CYLINDER HEAD
PF engine Inspection and adjustment

2. INSPECTION AND ADJUSTMENT

2.1 CYLINDER HEAD PRESSURE TESTING

1. Seal the coolant channels with sealing

plates fitted with gaskets.
The sealing plates should be
self-manufactured.
One of the sealing plates must be equipped
with a coupling for an air hose.
2. Connect an air hose to the coupling of the
sealing plate.
3. Immerse the cylinder head in hot water and
let in air pressure of 1.5 bar. Leave the
cylinder head immersed in the container for
about half an hour

ǹ 0008 2-1
 CYLINDER HEAD
Inspection and adjustment PF engine

2.2 INSPECTION, CYLINDER HEAD

Cylinder head
1. Inspect the cylinder head expansion plugs
for leaks. If necessary, pressure test the A
cylinder head.
2. Inspect the cylinder head for damage on the
sealing face and any cracks. If necessary,
M200777
have the cylinder head levelled. See
“Technical Data”.
3. When treating the cylinder head, care must
be taken that the height (A in the diagram
opposite) of the cylinder head remains
within the specified dimensions. See
“Technical Data”.
4. After cleaning the surface worked on, the
distance (measurement B) between the
B
valve head and the cylinder head surface
must be inspected if necessary by treating
the valve seat or the valve seat chamber,
see “Technical Data”

M200750

Valve seats
1. A valve seat needs to be treated when the A
bearing area between valve head and seat
(measurement A) exceeds the maximum
permitted value. When doing this, distance
B between valve head and cylinder head
surface must remain within the dimensions.
If this appears no possible, the valve seat
and/or the valve must be renewed. For the
dimensions, see “Technical data”.

M200776

2-2 ǹ 0008
 CYLINDER HEAD
PF engine Inspection and adjustment

2.3 INSPECTION AND ADJUSTMENT THE VALVE MECHANISM BRIDGES

Loosening and tightening the lock

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

1. Place the fuel pump in the stop position.

Lock the fuel pump in this position.
2. Remove the valve covers. See ”Removal
and Installation”.
3. Undo the adjusting nuts of the valve rockers
in such a manner that there is no longer
tension on the rockers.
4. Remove the lubricating oil strip.
5. Remove the rocker seat assembly. Mark the
position to allow reinstallation in the same
position.
6. Remove the bridge from the valves and
place it in a vice.
7. Slacken locknut (B).
8. Reposition the bridge in the same position
in the engine over the valves. Firmly press
on the bridge centre (above the guide pin)
with your thumb.
7
9. Hand-tighten adjusting screw (A) until the
bridge starts to move (adjusting screw (A)
now touches the valve). A
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 “Technical
B
Data”.
12. Reposition the bridge over the valves.
i 400301
13. Fit the rocker seat.

ǹ 0008 2-3
 CYLINDER HEAD
Inspection and adjustment PF engine

14. Fit 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.
16. Fit the valve covers. See ”Removal and
Installation”.

M200754

2-4 ǹ 0008
 CYLINDER HEAD
PF engine Inspection and adjustment

2.4 INSPECTION AND ADJUSTMENT, VALVE CLEARANCE

1. Remove the valve covers. 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 rocking position. The
pistons of cylinders 1 and 6 are now at top
dead centre.
Note:
“Rocking” is the moment at which the inlet
valve starts opening and the exhaust valve
is completing the closing.

M200724

7
4. Check/correct the valve clearance of
cylinder 6. The correct valve clearance is
adjusted by loosening the locknut (4) and
turning the adjusting bolt in the correct
direction. See “Technical data” for the
correct valve clearance.
5. By cranking the camshaft always 1/3 stroke,
using the special tool (DAF no. 1310477),
the valves can be adjusted according to the
injection sequence 1-5-3-6-2-4.

Cylinder rocking Cylinder to be

adjusted
1 6
5 2 M200732

3 4
6 1
2 5
4 3

6. Fit the valve covers. See “Removal and

Installation”.

ǹ 0008 2-5
 CYLINDER HEAD
Inspection and adjustment PF engine

2-6 ǹ 0008
 CYLINDER HEAD
PF engine Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, VALVE COVER

Removal, valve cover

1. Clean the area around the valve cover.
2. Remove the attachment bolts from the valve
cover.
3. Remove the valve cover and the valve
cover gasket.
Installation, valve cover
1. Clean the sealing surface of the valve
sleeve and the valve cover.
2. Fit the valve cover using a new valve cover
gasket.
M200730
3. Fit the attachment bolts of the valve cover
and tighten them to the specified torque.
See “Technical Data”.

ǹ 0008 3-1
 CYLINDER HEAD
Removal and installation PF engine

3.2 REMOVAL AND INSTALLATION, VALVE GEAR

Removal, valve gear

1. Remove the valve covers.
2. Place the fuel pump in the stop position and
lock it in this position.
Note:
Because some rockers depress the valve
springs, when removing the lubricating-oil
strips the attachment bolts of the rocker
seats must remain fixed.
3. Remove the lubricating oil strip.
Note:
Number the rocker seats (1) and the
1
bridges (2-3-4) to allow reinstallation in the
same position.
4. Remove the rocker seats (1).
5. Remove the bridges (2-3-4).
Installation, valve gear
1. Fit the bridges (2-3-4) on the valves.
2. Adjust the bridges. See “Inspection and
Adjustment”.

7
3. Tighten the rocker seats (1) by hand. M200559

Note:
Depending on the engine position, some
rocker seats (1) have to be positioned
against the pressure of the valve springs. 3 2
The rocker seat (1) will resist this spring
pressure and cannot therefore be
positioned correctly.
By cranking the camshaft always 1/3 stroke,
4
using the special tool (DAF No. 1310477),
the valves can be adjusted according to the
injection sequence 1-5-3-6-2-4.
For the tightening torques of the attachment
bolts, see “Technical Data”.

M200560

3-2 ǹ 0008
 CYLINDER HEAD
PF engine Removal and installation

4. Fit the lubricating-oil strip in such a way that

the mark “cyl. 1/4” is located on cylinder 1 or
cylinder 4 respectively. For the tightening
torques of the attachment bolts, see
“Technical Data”.
5. Adjust the valve clearance. See “Inspection
and adjustment”.
6. Fit the valve covers.

M200754

3.3 REMOVAL AND INSTALLATION, VALVE SLEEVE

Removal, valve sleeve

1. Remove the valve covers.
2. Remove the injectors.
3. Remove the valve gear.
4. Remove the push rods.
5. Remove the valve sleeve and gasket.
Installation, valve sleeve
1. Fit the valve sleeve with a new gasket and
7
tighten the attachment bolts to the specified
torque and in the correct sequence. See
“Technical Data”.
2. Fit the push rods.
3. Fit the injectors.
4. Fit the valve gear.
5. Fit the valve covers.

M200968

ǹ 0008 3-3
 CYLINDER HEAD
Removal and installation PF engine

3.4 REMOVAL AND INSTALLATION, CYLINDER HEADS

When the engine or parts thereof

are opened, dirt may enter. This
may result in serious damage to the
engine. Therefore clean the engine
before opening it.

Removal, cylinder head

1. Disconnect all electrical wiring around the
engine which is relevant for the removal of
the cylinder heads.
2. Remove the inlet pipe from the intercooler
to the turbocharger.
3. Disconnect the compressor pipe from the
air inlet pipe to the compressor.
4. Loosen the air-conditioning compressor
tensioner and remove the V-belt, if fitted.
5. Remove the attachment bolts of the
air-conditioning compressor mounting
bracket, if fitted.
6. Remove the heat shields from the exhaust
manifold.
7. Remove the attachment bolts from the

7
exhaust manifold and move the manifold
and the turbocharger a little away from the
cylinder heads.
8. Remove the fuel leak-off pipe between the
fuel filter and the leak-off pipe on the inlet
manifold.
9. Remove the entire fuel filter from the inlet
manifold.
10. Disconnect the injector pipes.
11. Remove the boost pressure pipe from the
inlet manifold.

3-4 ǹ 0008
 CYLINDER HEAD
PF engine Removal and installation

12. Remove the coolant pipe together with the

thermostat housing.
13. Remove the attachment bolts of the inlet
manifold and take it completely off the
cylinder heads.
14. Remove the valve covers.
15. Remove the injectors.
16. Remove the valve gear.
17. Remove the push rods.
18. Remove the valve sleeve.
19. Remove the cylinder head bolts.
20. Remove the cylinder head from the cylinder
block.
21. Remove any remaining gasket pieces from
the cylinder head and the cylinder block.
22. Check the cylinder block sealing surfaces.
23. Check the threaded holes in the cylinder
block for damage and cracking.
24. Check that the height which the cylinder
liner protrudes above the cylinder block is
within the tolerance limits, using the special
tool (DAF No. 0694795). See ”Technical
Data”.
7
25. Check the cylinder head. See “Inspection
and adjustment”.

M2 00 100

ǹ 0008 3-5
 CYLINDER HEAD
Removal and installation PF engine

Installation, cylinder head

1. Clean the threaded holes in the cylinder
block, using a screw tap.
2. Insert both guide pins (DAF No. 0694912)
into the threaded holes of the cylinder block.
3. Place the new gasket(s) on the cylinder
block, making sure that the letters TOP are
visible. The cylinder head gasket must not
be retightened.
4. Place the cylinder head(s) on the cylinder
block and hand-tighten a number of cylinder
head bolts.
5. Note: M200561
To prevent the inlet and exhaust manifolds
from being installed with tension the inlet
and exhaust manifolds must be installed
before the cylinder head bolts are tightened.
Fit the inlet and exhaust manifolds with new
gaskets and tighten the attachment bolts to
the specified torque. See ”Technical Data”.
6. Note:
The M16 cylinder head bolts may be used a
maximum of three times. After tightening
the bolts, mark the bolt heads with a centre
punch, to indicate how often they have been

7 used.
New bolts should not be marked on the first
fitting.
Bolts marked with 2 centre points must not
be reused and must be replaced by new
ones.
When fitting used bolts, clean the thread
and inspect for damage.
Fit the M16 and M12 bolts, after having
applied a drop of oil to the bearing face of
the bolt head and locking compound to the
thread. See “Technical Data”.

3-6 ǹ 0008
 CYLINDER HEAD
PF engine Removal and installation

7. Remove the two guide pins and replace

them with the two remaining cylinder head
bolts.
8. Tighten the cylinder head bolts to the
specified torque and in the sequence
shown. See “Technical Data”
9. Fit the valve sleeve.
10. Fit the push rods.
11. Fit the injectors.
12. Fit the valve gear.
13. Fit the coolant pipe and the thermostat
housing with new gaskets.
14. Fit the injector pipes.
15. Connect the fuel filter to the inlet manifold.
16. Fit the fuel leak-off pipe between the fuel
filter and the inlet manifold.
17. Fit the boost pressure pipe on the inlet
manifold.
18. Fit the attachment bolts of the exhaust
manifold and tighten them to the specified
torque. See “Technical Data”.
19. If present, fit the air-conditioning
compressor bracket.
7
20. Fit the tensioner of the air-conditioning
compressor, if fitted.
21. If necessary, fir the air-conditioning
compressor V-belts.
22. Connect the compressor pipe from the air
inlet pipe to the compressor.
23. Fit the inlet pipe between the intercooler
and the turbocharger.
24. Connect the engine electrical wiring.

ǹ 0008 3-7
 CYLINDER HEAD
Removal and installation PF engine

3.5 REMOVAL AND INSTALLATION, VALVES

When removing and installing the

valve springs, compress them
responsibly, ensuring that they
cannot fly off. An inadvertently
released spring or valve collet can
cause serious injury.

Removal, valves
1. Remove the cylinder head.
2. Support the valve and compress the valve
spring safely as far together that the two
valve collets can be removed.
3. Release the valve spring and take the valve
spring retainer and valve spring from the
valve stem.
4. Remove the valve from the cylinder head.
Inspection, valves
1. Measure measurement A and check that A
the maximum value has not been
exceeded. See “Technical Data”
2. Check the valve head thoroughly and check
the dimensions. If permitted by the
dimensions, the valves can be ground. See

7 3.
“Technical Data”.
Check the valve stem for straightness and
traces of grating.

M200776

4. Check the dimensions and height (A) of the

valve guides. See “Technical data”. A
If necessary, replace the valve guide.

M2 00 012

3-8 ǹ 0008
 CYLINDER HEAD
PF engine Removal and installation

5. Check the valve springs for fracture, wear

or spring force. See “Technical Data”.
If necessary, replace the valve springs.
6. Check the valve seat. See ”Technical Data”.
Replace if necessary.
Installation, valves
1. When re-using, grind the valves on the
valve seats.
After grinding, clean the valves and the
cylinder heads thoroughly.
2. Oil the valve stem and place the valve in the
valve guide. Check for freedom of
movement.
3. Fit the lower valve spring retainer.
4. Fit the valve spring with the upper valve
spring retainer.
5. Support the valve and press the valve
spring safely as far together that the two
valve collets can be installed.
6. Release the valve spring carefully and
inspect whether valve collets have been
installed properly.
7.
8.
Fit the cylinder heads.
Adjust the valve clearance. See “Inspection
7
and adjustment”.

ǹ 0008 3-9
 CYLINDER HEAD
Removal and installation PF engine

3.6 REMOVAL AND INSTALLATION, VALVE GUIDES

Removal, valve guides

1. Remove the cylinder heads.
2. Remove the valves.
3. Using the special tool (DAF No. 1329429)
press the valve guides out of the cylinder
heads.
4. Check the valve guides. Replace if
necessary.
Installation, valve guides
1. Apply a thin layer of oil to the valve guides.
2. Note:
Use two different sets of dies to press in the
valve guides.
Press the exhaust valve guide into the
cylinder head using special tool (DAF No.
1329430) in such a way that the side with
the greatest bevelling is at the top of the
cylinder head (the abutting surface of the
valve springs).
3. Measure whether the height (A), with which
the exhaust valve guide protrudes above A
the contact surface is within the tolerance

7 4.
limits. See ”Technical Data”.
Press the inlet valve guide into the cylinder
head using special tool (DAF No. 1329431)
in such a way that the side with the greatest M2 00 012
bevelling is at the top of the cylinder head
(the abutting surface of the valve springs).
5. Measure whether the height (A), with which
the inlet valve guide protrudes above the
contact surface is within the tolerance limits.
See ”Technical Data”.
6. Fit the valves.
7. Fit the cylinder heads.
8. Adjust the valve clearance. See “Inspection
and adjustment”.

3-10 ǹ 0008
 CYLINDER HEAD
PF engine Removal and installation

3.7 REMOVAL AND INSTALLATION, VALVE SEATS

Removal, valve seats

1. Remove the cylinder heads.
2. Remove the valves.
3. With a grindstone, grind the inside of the
valve seat and make a groove on both sides
so that an internal puller can be installed.
4. With an internal puller, pull the valve seat
out of the cylinder head.
5. Clean the valve seat chamber.
Installation, valve seats
1. Using the special tool (DAF No. 1329421),
press a new valve seat into the chamber of
the cylinder head and check the
dimensions. See “Technical Data”.
2. Fit the valves.
3. Fit the cylinder heads.
4. Adjust the valve clearance. See “Inspection
and adjustment”.

ǹ 0008 3-11
 CYLINDER HEAD
Removal and installation PF engine

3.8 REMOVAL AND INSTALLATION, INJECTOR SLEEVES

Removal, injector sleeve

1. Disconnect the injector pipes.
2. Remove the injector.
3. Insert a ball of crumpled paper into the A
injector sleeve to prevent metal particles
from entering the engine.
4. Tap a thread (M22 x 1.5) in the injector
sleeve to be removed over a length (A) of
approx. 20 mm.
5. Insert the special tool (DAF No. 1310425)
into the injector sleeve and use the special
tool (DAF No. 0694928) to remove the
injector sleeve.
Installation, injector sleeve
1. Clean the injector sleeve openings
thoroughly.
2. Note: I 400195

Fit the injector sleeve dry into the cylinder

head.
Use the special tool (DAF No. 1329305) to
tap the injector sleeve into the cylinder
head.

7 3. Fit the injector.

4. Fit the injector pipes.

3-12 ǹ 0008
 CYLINDER HEAD
PF engine Removal and installation

3.9 REMOVAL AND INSTALLATION, EXPANSION PLUGS

Removal, expansion plug

1. Remove the cylinder head.
2. Tap carefully on the edge of the expansion
plug, causing the plug to tilt. Make sure that
no damage occurs.
3. Remove the plug with a pair of pliers.
4. Remove the remaining locking compound
from the opening.
Installation, expansion plug
1. Apply the specified locking compound to the
new expansion plug and tap it with a
suitable driving tool into the cylinder head.
See “Technical data”.
2. Leave the locking compound to harden for 1
hour.
3. Force off the cylinder head. See “Inspection
and adjustment”.
4. Fit the cylinder head.

ǹ 0008 3-13
 CYLINDER HEAD
Removal and installation PF engine

3-14 ǹ 0008
 CYLINDER HEAD
PF engine Cleaning

4. CLEANING
4.1 CLEANING, INJECTOR SLEEVES

1. Remove the injector.

2. Use special tool (DAF No. 1240074) to
remove any remains of copper shim.
3. Use the special tool (DAF No. 1240074) to
clean the injector sleeve.
4. Clean the injector sleeve with compressed
air.
5. Fit the injector.

7
I400001

ǹ 0008 4-1
 CYLINDER HEAD
Cleaning PF engine

4-2 ǹ 0008
 LUBRICATION SYSTEM
PF engine Contents

CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.1 Overview drawing, internal parts of the lubricating oil system . . . . . . . . . . . 1-1 . . . . . . 0008
1.2 Overview drawing, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . 0008
2. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.1 Pressure-testing the oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
3. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0008
3.1 Removal and installation, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0008
3.2 Removal and installation, lubrication lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0008
3.3 Removal and installation, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0008
3.4 Removal and installation, oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0008
3.5 Removal and installation, pump seat/filter housing . . . . . . . . . . . . . . . . . . . . . 3-5 ...... 0008
4. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008
4.1 Disassembly and assembly, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008

ǹ 0008 1
 LUBRICATION SYSTEM
Contents PF engine

2 ǹ 0008
 LUBRICATION SYSTEM
PF engine General

1. GENERAL
1.1 OVERVIEW DRAWING, INTERNAL PARTS OF THE LUBRICATING OIL
SYSTEM

1
2
3
4

17
6 16
6
11
5
10
6 9 15

12
18 8

13

6 7 6 14

M200970

1. Locking cap 10. Pressure spring

2. Pressure spring 11. Control valve
3. Ball 12. Lubricating unit bracket
4. Lubricating media pressure control 13. Strainer housing
5. Oil delivery pipe 14. Strainer
6. O-ring 15. Connecting bend
7. Oil suction pipe 16. Attachment pipe
8. Sealing plug 17. Split pin
9. Copper ring 18. Lubricating oil pump

ǹ 0008 1-1
 LUBRICATION SYSTEM
General PF engine

1.2 OVERVIEW DRAWING, LUBRICATING OIL PUMP

5 6 7 8 9 10

3 4

M200781

1. Lubricating oil pump

2. Gear wheel
3. Hub
4. Bearing bush
5. Gear wheel
6. Oil pump bracket
7. Oil pump shaft
8. Oil pump shaft
8 9.
10.
Cylindrical guiding pin
Oil pump housing

1-2 ǹ 0008
 LUBRICATION SYSTEM
PF engine Inspection and adjustment

2. INSPECTION AND ADJUSTMENT

2.1 PRESSURE-TESTING THE OIL COOLER

Pressure--testing the oil cooler

1. Remove the oil cooler. See “Removal and
installation”.
2. Fit the special tools (DAF Nos. 1240476 1240477
and 1240477) on the oil cooler.
3. Apply up to 2.5 bar of pressurised air to the 1240476
special tool.
4. Immerse the oil cooler in hot water (approx.
50_C) and check the oil cooler for visible
leaks.
5. If the oil cooler shows leaks, it must be
replaced, as it cannot be repaired.
M200185
6. Fit the oil cooler. See “Removal and
installation”.

ǹ 0008 2-1
 LUBRICATION SYSTEM
Inspection and adjustment PF engine

2-2 ǹ 0008
 LUBRICATION SYSTEM
PF engine Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, OIL SUMP

Removal, oil sump

1. Support the oil sump (1).
2
2. Remove the attachment bolts (4) and
locking brackets (3) all around.
3. Remove the oil sump with the sealing
rubber (2).
Installation, oil sump
1. Clean the sealing surfaces of the oil sump
and the engine block. 1

2. Check the oil sump sealing rubber (2).

Damaged sealing rubbers (2) must be
replaced.
3. First install the sealing rubber on the front
and rear of the oil sump. Then, the sealing
rubber may be fitted to the long sides of the 2 3
oil sump.
4. Fit the oil sump (1) with the sealing
rubber (2) upright. 1 4
5. Fit the attachment bolts (4) and locking
brackets (3). Tighten the attachment bolts to
the specified torque. See “Technical Data”.
M200601

ǹ 0008 3-1
 LUBRICATION SYSTEM
Removal and installation PF engine

3.2 REMOVAL AND INSTALLATION, LUBRICATION LINES

Removal, lubricating oil pipes

1. Remove the oil sump.
2. Remove the attachment bolts from the
respective oil pipe on the lubricating oil
pump.
3. Remove the intake construction or the
pressure controller and take out the relevant
oil pipe with the O-rings.
Installation, lubricating oil pipes
1. Replace the O-rings and apply a little
grease to them.
2. Fit the oil pipes free of stress and tighten
the attachment bolts to the specified torque.
See ”Technical Data”.
3. Fit the oil sump.

3-2 ǹ 0008
 LUBRICATION SYSTEM
PF engine Removal and installation

3.3 REMOVAL AND INSTALLATION, LUBRICATING OIL PUMP

Removal, lubricating oil pump

1. Remove the oil sump.
2. Remove the oil strainer.
3. Remove the oil suction and delivery
pipes (1) from the lubricating oil pump.
3
4. Remove the attachment bolts (2) from the
lubricating oil pump to the main bearing
cover. 2
5. Remove the attachment bolt (3).
6. Remove the oil pump from the main bearing
cover.
Installation, lubricating oil pump 1
1. Check that the lubricating oil pump operates
smoothly and is not getting stuck anywhere.
2. Fit the lubricating oil pump with the
intermediate gear wheel on the main M200600
bearing cover. Tighten the attachment bolts
to the specified torque. See “Technical
Data”.
3. Fit new O-rings to the oil suction and
delivery pipes (1).
4. Fit the oil strainer.
5. Fit the oil sump.

ǹ 0008 3-3
 LUBRICATION SYSTEM
Removal and installation PF engine

3.4 REMOVAL AND INSTALLATION, OIL COOLER

Removal, oil cooler

1. Remove the heat shield from the exhaust
bend.
2. Remove the exhaust brake operating
cylinder.
3. Remove the plug on the underside of the oil
cooler and drain the coolant.
4. Remove the flexible coolant pipes from the
oil cooler.
5. Remove the oil cooler. Collect any oil
flowing out of the system.
6. Remove any remains of the gasket. W267003

Installation, oil cooler

1. Thoroughly clean the contact surfaces
between the oil cooler and the cylinder
block and replace the gaskets.
2. Fit the oil cooler.
3. Connect the coolant pipes to the oil cooler.
4. Fit the engine brake operating cylinder.
5. Fit the heat shield of the exhaust bend.

3-4 ǹ 0008
 LUBRICATION SYSTEM
PF engine Removal and installation

3.5 REMOVAL AND INSTALLATION, PUMP SEAT/FILTER HOUSING

To prevent skin injury, avoid

unnecessary contact with the
1
drained oil.

Removal, pump seat/filter housing

1. Clean the fuel pump and the surrounding
area.
2. Remove the fuel pump.
3. Remove the electrical connections from the
lubricating oil pressure sensor.
4. Remove the oil supply pipe to the fuel 2
pump.
5. Remove the filter element. Collect any oil 3
flowing out of the system.
6. Remove the fixing bolts from the pump
seat/filter housing and remove the pump
seat/filter housing (2).
4
7. Remove the O-rings (1).
Installation, pump seat/filter housing
1. Replace the O-rings (1) at the rear of the
pump seat/filter housing (2).
2. Fit the filter housing (2). Tighten the
attachment bolts to the specified torque.
See “Technical Data”.
3. Check the coupling (3). See “Technical
data”.
M200762
8
4. Lightly grease the seal of the filter
element (4).
5. Fit the filter element (4), filled with clean
lubricating oil. Tighten the filter element to
the specified torque. See ”Technical Data”.
6. Fit the electrical connections of the
lubricating oil pressure sensor.

ǹ 0008 3-5
 LUBRICATION SYSTEM
Removal and installation PF engine

3-6 ǹ 0008
 LUBRICATION SYSTEM
PF engine Disassembly and assembly

4. DISASSEMBLY AND ASSEMBLY

4.1 DISASSEMBLY AND ASSEMBLY, LUBRICATING OIL PUMP

Disassembly, lubricating oil pump

1. Remove the intermediate gear wheel with
the hub from the front plate.
2. Remove all attachment bolts from the two
sections of the lubricating oil pump housing.
3. Remove the rear section of the lubricating
oil pump.
4. Remove the gear wheels from the
lubricating oil pump housing.
Assembly, lubricating oil pump
1. Clean the gear wheels and check for
damage.
Note:
Gear wheels must be replaced as a set.
2. Note:
The gear wheels are marked. The gear
wheels with the marks must be fitted as
shown.
Fit the gear wheels in the lubricating oil
pump housing.
3. Remove the rear section of the lubricating
oil pump.

8
4. Fit the attachment bolts of the lubricating oil
pump sections. Tighten the attachment
bolts to the specified torque. See “Technical
Data”.
5. Check that the lubricating oil pump operates
smoothly and is not getting stuck anywhere. M200344

6. Fit the intermediate gear wheel with the hub

on the front plate. Tighten the attachment
bolt to the specified torque. See “Technical
Data”.

ǹ 0008 4-1
 LUBRICATION SYSTEM
Disassembly and assembly PF engine

4-2 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Contents

CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0008
1.1 Overview drawing, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0008
1.2 Overview drawing camshaft and crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ...... 0008
1.3 Overview drawing, piston and connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 ...... 0008
2. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.1 Inspection, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.2 Inspection, axial crankshaft play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . 0008
2.3 Inspection, camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . . 0008
2.4 Inspection, camshaft axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . . 0008
2.5 Inspection, pistons and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . 0008
2.6 Inspection, cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 . . . . . . 0008
2.7 Inspection, cylinder liner height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 . . . . . . 0008
2.8 Pressure testing, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 . . . . . 0008
2.9 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 . . . . . 0008
3. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.1 Removal and installation, pistons and connecting rods . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.2 Removal and installation, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . . 0008
3.3 Removal and installation, camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . . 0008
3.4 Removal and installation, camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . . 0008
3.5 Removal and installation, cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . . 0008
3.6 Removal and installation, oil nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0008
3.7 Removal and installation, expansion plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . . 0008

ǹ 0008 1
 CYLINDER BLOCK AND DRIVING GEAR
Contents PF engine

2 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine General

1. GENERAL
1.1 OVERVIEW DRAWING, CYLINDER BLOCK

22
2

3
21

20 4

19 18
6
8 5

9 7
17 10

8 11
9
12 9
13

14

15
16
M200972

1. Cylinder liner 12. Sealing ring

2. Shim 13. Main bearing cap bolt
3. Cylinder block 14. Bearing cap, main bearing, intermediate
4. Oil nozzle 15. Bearing cap, main bearing, intermediate
5. Oil nozzle 16. Bearing cap, main bearing, front
6. Locking plate 17. Sealing plug
7. Banjo bolt 18. Sealing plug
8. Copper ring 19. Camshaft slide bearing
9. Sealing plug 20. Expansion plug
10. Dowel 21. Dowel
11. Bearing cap, main bearing, middle 22. Drain tap

ǹ 0008 1-1
 CYLINDER BLOCK AND DRIVING GEAR
General PF engine

1.2 OVERVIEW DRAWING CAMSHAFT AND CRANKSHAFT

2
3

4 5

9 M200783

1. Sealing plug
2. Camshaft
3. Shim
4. Camshaft locking plate
5. Crankshaft
6. Bearing halfshell set
7. Crankshaft axial ring

1-2 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine General

1.3 OVERVIEW DRAWING, PISTON AND CONNECTING ROD

1. Piston spring set

2. Piston
3. Gudgeon pin
4. Gudgeon pin circlip
5. connecting rod bearing bush 1
6. Connecting rod
7. Connecting rod, bearing halfshell
8. Connecting rod bolt
9. Dowel

9
7

M200785

ǹ 0008 1-3
 CYLINDER BLOCK AND DRIVING GEAR
General PF engine

1-4 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Inspection and adjustment

2. INSPECTION AND ADJUSTMENT

2.1 INSPECTION, CRANKSHAFT

1. Check the crankshaft for overheating and

outer damage.
2. Magnaflux test the crankshaft.
3. Measure the crankshaft.
To gain an impression of crankshaft main
bearing and connecting rod bearing wear,
the measuring procedure on the form
illustrated must be followed. See “Technical
Data”.
4. Inspect the bearing halfshells and axial
thrust washer for wear, damage and
overheating.
5. Inspect the bearing caps for damage and
overheating.
6. Inspect the contact surfaces of the bearing
caps in the cylinder block.
7. Inspect the threaded hole for the bearing
cover bolt.
8. Inspect the bearing cover bolts. The screw
thread should be completely undamaged. If
in doubt, replace.

ǹ 0008 2-1
 CYLINDER BLOCK AND DRIVING GEAR
Inspection and adjustment PF engine

Note:
If necessary, the crankshaft can be ground down
to three undersizes.
In the event of damage to the axial bearing
surfaces, these can be ground to an undersize.
If the seal mounting surface of the crankshaft,
flywheel side must be ground, the mounting A
surface must not be ground over its whole
length. In front of the flywheel mating surface a
minimum of 7 mm measured from the rear of the
crankshaft must remain on the original diameter.
See distance (A) in the diagram opposite.
After grinding the crankshaft, round the oil holes
again. See “Technical Data”
The conical front of the crankshaft must be
ground to the specified measurement after
nitriding.
M2 00 080
The journal-rounding radius must be brought
accurately to the specified radius.
The crankshaft can be ground to the next
undersize twice without having to be nitrided.
After nitriding, the nitride stop must be removed
from the parts below by means of journals.

2-2 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Inspection and adjustment

All main and connecting rod bearing journals.

The sides of the middle main bearing for the
benefit of the axial bearings.
The outer diameter of the flywheel flange.
Mounting surfaces of seals.
If the crankshaft has been ground to an
undersize, this must be shown on the crankshaft
using the following codes:
H = Main bearing journal H1
D = Crankpin D2
N
N = Nitrided crankshaft
The letters H and D are followed by a number
indicating the number of times the crankshaft
has been ground (1st, 2nd or 3rd undersize).
This is what the indication on the crankshaft M2 00 090
opposite means:
H1 = main bearing journal ground to the first
undersize.
D2N = connecting rod journal ground to the
second undersize and crankshaft nitrided.
Before balancing the crankshaft, it must be
carried by the front and rear main bearing. The
crankshaft must be dynamically balanced at a
maximum of 72 g/cm at an engine speed of 350
rpm.
Remove any material by drilling out the
counterbalances. In each counter-weight, a
maximum of 5 holes may be bored at max. 17
mm dia. and a depth of max. 35 mm. The bores
must not touch each other.

ǹ 0008 2-3
 CYLINDER BLOCK AND DRIVING GEAR
Inspection and adjustment PF engine

2.2 INSPECTION, AXIAL CRANKSHAFT PLAY

1. Fit a measuring gauge to the crankshaft.

2. Press the crankshaft to the flywheel side
and set the measuring gauge to zero.
3. Press the crankshaft to the timing gear side
and take the reading from the measuring
gauge. Compare the reading with the
technical data. See ”Technical Data”.
4. If the play is too great, it can be corrected
by installing oversized axial thrust washers.
5. If the axial play is less than specified, it can
be corrected by grinding the axial thrust
washers on the metal side (not the bearing
side).

M200786

2.3 INSPECTION, CAMSHAFT

1. Clean the camshaft and check whether the

oilways are open.
2. Check whether the sealing plug on the rear
of the camshaft seals well. A
3. Check the camshaft for overheating,
damage and wear.
4. Check measurement A on the camshaft.
See ”Technical Data”.
9
M2 00 016

5. Check the bearing of the camshaft itself in

the cylinder block. See “Technical Data”
6. Check the spacer ring for deposits and
damage.

2-4 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Inspection and adjustment

2.4 INSPECTION, CAMSHAFT AXIAL PLAY

M201017

1. The camshaft axial play must be measured

after installing and securing the camshaft
gear.
2. Fit a measuring gauge to the camshaft gear.
3. Press the camshaft to the flywheel side and
set the measuring gauge to zero.
4. Press the camshaft to the timing gear side
and take the measurement from the
measuring gauge. Compare the reading
9
with the technical data. See ”Technical
Data”.
5. The axial play cannot be adjusted. If the
axial play is too great it can only be
corrected by installing a new thrust washer.

ǹ 0008 2-5
 CYLINDER BLOCK AND DRIVING GEAR
Inspection and adjustment PF engine

2.5 INSPECTION, PISTONS AND CONNECTING RODS

Inspection, pistons
1. Check the gudgeon pin for cracking, wear
and overheating.
2. Check the piston for cracking, wear and
overheating.
3. Check the groove clearance of the piston
rings in the piston. See “Technical Data”.
4. Check the raceway and the slot of the
piston rings. See “Technical data”.
Inspection, connecting rods
1. Check the bearing halfshells of the
connecting rod.
2. Check the bearing bush of the connecting
rod. If the bearing bush/gudgeon pin is
damaged or worn in, replace the connecting
rod.
3. Check the connecting rod for cracking and
overheating.
4. Check the dimensions of the connecting
rod. See “Technical Data”.

2-6 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Inspection and adjustment

2.6 INSPECTION, CYLINDER LINERS

Measuring
1. To gain an impression of cylinder liner wear,
the measuring procedure on the form
illustrated must be followed. See “Technical
Data”.
2. The ovality must be measured by turning
the measuring gauge another 90° each time
and taking the appropriate measurement.
3. If it appears that the cylinder liner is ovoid,
the initial bore in the cylinder block must be
checked.
4. If the initial bore in the cylinder block is 0.05
mm larger than the maximum new
measurement, the cylinder block must be
bored and cylinder liners with an oversized
outer diameter must be fitted. See
“Technical Data”.
Cylinder liner rejection standard
The cylinder liner must be replaced if:
- the bore polishing standard has been
exceeded.
- the overall running is not equal.
- the running surface is scored;
- the difference between the measurements
on the “Overview of wear measurements”
form, pictured in “Technical data” is more
than 0.07 mm.
Note:
If the cylinder liner is rejected due to any of the
above criteria, it must be replaced and not be
honed.

ǹ 0008 2-7
 CYLINDER BLOCK AND DRIVING GEAR
Inspection and adjustment PF engine

Bore polishing standard

5. One of the measures to be taken to aid a
patently high oil consumption (motor oil use
test) is to inspect the cylinder liners for bore
polishing.
6. Bore polishing means: extremely smooth
surfaces without visible regular honing
pattern (see the illustration opposite).
If the “deeper” honing grooves still show a
regular pattern, bore polishing cannot be
considered.
Permissible is:
- A maximum of 3 patches with bore
polishing joined together with a total
surface of not more than 10 cm2 per
liner.
- A maximum of 3 patches with bore
polishing, not joined together with a
total surface of not more than 20 cm2
per liner.

2-8 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Inspection and adjustment

2.7 INSPECTION, CYLINDER LINER HEIGHT

After fitting new cylinder liners, the distance of

the cylinder liner above the cylinder block must
be inspected.
This measurement also needs to be carried out
for fitting the cylinder head.
The height of the cylinder liner that protrudes
above the cylinder block has to be checked
using special tool (DAF No. 0694795).
1. Lay the special tool (DAF No. 0694795) on
the top of the cylinder block.
2. Set the measuring gauge to “0”. M2 00 100

3. Now set the pin of the gauge on the edge of

the cylinder liner.
4. Take the reading from the gauge and
compare the measured reading to that in
“Technical data”
5. If the cylinder liner is too deep in the
cylinder block, this can be corrected by
fitting a spacer ring under the liner collar.
6. If the cylinder liner protrudes too far above
the block (after levelling the cylinder block),
the chamber depth for the cylinder liner
collar should be brought to the specified
value. See “Technical data”.
Note:
Grinding down the liner collar is not
permitted

ǹ 0008 2-9
 CYLINDER BLOCK AND DRIVING GEAR
Inspection and adjustment PF engine

2.8 PRESSURE TESTING, CYLINDER BLOCK

1. Seal the cylinder block coolant channels

with sealing plates equipped with gaskets.
2. The sealing plates should be
self-manufactured. One sealing plate must
be equipped with a connection for an air
pipe.
3. Connect an air pipe equipped with a
reducing valve to the sealing plate coupling.
4. Immerse the cylinder block in a container of
hot water and test the pressure of the block
with an air pressure of 1.5 bar.
Leave the cylinder block in the water for
about half an hour.

2-10 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Inspection and adjustment

2.9 INSPECTION, CYLINDER HEAD

1. Clean the cylinder block thoroughly and pay

the necessary attention to the various oil
channels.
2. Inspect the oilways for blockages.
3. Check the cylinder block sealing surfaces.
4. Check the threaded holes in the cylinder
block for damage and cracking.
5. When levelling the cylinder block, caution
must be taken to ensure that measurement
(A) between the top of the crankshaft boring
and the top of the cylinder block remains
within the specified values. See “Technical
Data”.
After levelling the top of the cylinder block,
measure the depth of the chambers for the
cylinder liner collars.
Correct this depth to prevent the cylinder
liners protruding too far over the cylinder
block.

ǹ 0008 2-11
 CYLINDER BLOCK AND DRIVING GEAR
Inspection and adjustment PF engine

2-12 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, PISTONS AND CONNECTING RODS

Removal, pistons and connecting rods

1. Remove the cylinder heads.
2. Remove the oil sump.
3. Remove the strainer/oil pipes and the oil
pump.
4. If the pistons are to be replaced in the
engine, the position must be marked in the
block, so that the pistons are refitted in the
same cylinders.
5. Detach the attachment bolts of the
connecting rod bearing cap.
6. Remove the connecting rod bearing cap.
7. Remove the connecting rod complete with
the piston.
8. Ensure that the connecting rod bearing
halfshells remain with the respective
bearing cap and connecting rod.
9. Remove the circlips from the bore of the
piston.
10. Push the gudgeon pin out of the piston.
Avoid damaging the piston.
11. Using piston ring pliers, remove the piston
rings from the piston. Keep the piston rings
with the respective piston.

ǹ 0008 3-1
 CYLINDER BLOCK AND DRIVING GEAR
Removal and installation PF engine

Installation, pistons and connecting rods

1. Clean the parts carefully and check that the
oilways are open.
2. Take the ring from the oil scraper ring and
place it in the lowest piston ring groove of
the piston.
Using piston ring pliers, place the oil
scraper ring over the ring in the piston ring
groove.
The ring opening must face the lock
opening of the oil scraper ring.
3. Using piston ring pliers, install the
compression ring with the word “top”
uppermost.
4. Using piston ring pliers fit the top ring with
the word “top” uppermost. B
The slots (B) of the three piston rings must
be at an angle of 120_ to each other.
5. Fit one circlip into the piston and check
whether it is flush in the groove.
6. If necessary, heat the piston to a
temperature of approx. 50_C and lightly oil
the gudgeon pin.
7. Fit the connecting rod into the piston and A
push the gudgeon pin into the piston.
Ensure that all pistons are fitted to the
connecting rods in the same way. Check
this with regard to the number on the side of
the connecting rod and the arrow on the top B B
of the piston.
8. Fit the circlip and check whether it is flush in M2 00 139
the groove.

9 9. Clean the crankshaft and cylinder liner with

a lint-free cloth.
10. Fit the (new) bearing halfshells into the
connecting rod and oil the bearing
halfshells.

3-2 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Removal and installation

11. Oil the cylinder liner, piston and piston rings

well. Fit a piston ring clamping strip around
the piston.
Place the piston in the cylinder so that the
arrow on the piston points to the timing gear
end of the engine. Make sure that the oil
nozzles are not damaged when doing this.
12. Fit the respective bearing cap to the
connecting rod. Check this with reference to
the numbers stamped on.
The numbers on the connecting rod and
bearing cap must be on the same side as
each other.
13. Oil the thread and contact surface of the
connecting rod bolts and tighten the
attachment bolts to the specified torque.
See ”Technical Data”.
14. Check the connecting rod for any axial play.
If radial play is ascertained, a connecting
rod with standard bearings has probably
been fitted to a ground crankshaft.
15. Crank the motor a few revolutions and
check that there is no point at which the
crankshaft runs heavily.
16. Fit the strainer/oil pipes and oil pump.
17. Fit the oil sump.
18. Fit the cylinder heads.
Note:
After replacing the pistons and piston rings, the
motor must be run-in again.
During the running-in period, the engine must be
filled with a different grade of engine oil. See the
“Oil specifications” manual.
9

ǹ 0008 3-3
 CYLINDER BLOCK AND DRIVING GEAR
Removal and installation PF engine

3.2 REMOVAL AND INSTALLATION, CRANKSHAFT

Removal, crankshaft
1. Remove the oil sump.
2. Remove the timing gear case.
3. Remove the strainer/oil pipes and oil pump.
4. Remove the flywheel.
5. Remove the flywheel housing.
6. Detach the connecting rod bolts.
7. Remove the bearing cap bolts and take the
bearing caps off. Check that all bearing
caps are stamped with a marking letter. If
not, make a mark yourself.
8. Remove the axial thrust washers.
9. Remove the crankshaft Make sure that the
crankshaft is not damaged during removal.
10. Mark the position of the bearing bolts, so
that they can be re-fitted in the original
place.
Installation, crankshaft
1. Clean all components thoroughly.
2. Clean the threaded holes of the bearing cap
bolts.
3. If re-using the bearing halfshells, fit them in
the original place in the cylinder block and
in the bearing caps.
4. If the crankshaft has been ground to

9
oversize, fit the relevant bearing halfshells.
A new crankshaft must first have any
grease and preservative removed.
5. Check that all oil channels of the bearings
and crankshaft are open.
6. Check the guiding pin of the middle bearing.

3-4 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Removal and installation

7. Apply oil to the bearing halfshells.

8. Place the crankshaft in the cylinder block.
9. Apply some oil to the axial thrust washers.
On either side of the middle bearing cap, fit
the axial thrust washers with the bearing
directed at the crank pin. See diagram.
10. Fit the bearing caps so that the letters on
the bearing cap correspond with those on
the cylinder block.
All letters must be on the same side of the
bearing caps. Tap the bearing caps into the M2 00 091
cylinder block with a plastic hammer.
11. Apply oil to the thread and the abutting
surface of the bearing cap bolts and fit the
bearing cap bolts so that they are
fingertight.
12. Check the axial crankshaft play. See
“Inspection and Adjustment”.
13. Tighten the bearing cap bolts. Begin
tightening the middle bearing cap and then
work outwards on both sides. Fit both
bearing cap bolts alternately and tighten
them to the specified torque. See “Technical
Data”.
14. Check whether the crankshaft operates
smoothly and is not getting stuck anywhere.
15. Measure the axial play again and correct it if
necessary.
16. Fit the connecting rods with new connecting
rod bolts.
17. Fit the strainer/oil pipes and oil pump.
18. Fit the oil sump.
9

ǹ 0008 3-5
 CYLINDER BLOCK AND DRIVING GEAR
Removal and installation PF engine

3.3 REMOVAL AND INSTALLATION, CAMSHAFT

Removal, camshaft 6 2 4
1. Remove the valve gear.
2. Remove the intermediate gear wheel (3)
and the camshaft gear wheel (2) from the
timing gear.
3. Remove the side covers from the right-hand
side of the engine.
4. Remove the push rods.
5. Remove the valve tappets.
6. Remove the attachment bolts from the
camshaft locking plate
7 1 3 5
M200744
7. Remove the camshaft with the spacer ring
from the cylinder block.
Installation, camshaft
1. Before installing the camshaft, check
whether all oil channels are open.
2. Apply sufficient oil to the camshaft bearings
and fit the turning camshaft into the cylinder
block.
3. Check that the camshaft operates smoothly
and is not getting stuck anywhere.
4. Fit the spacer ring onto the camshaft.
5. Remove the camshaft locking plate and
tighten the attachment bolts of the
camshaft.
6. Check again that the camshaft operates

9 smoothly and is not getting stuck anywhere.

Now check the axial play of the camshaft.
7. Fit the intermediate gear wheel (3) and the
camshaft gear wheel (2) and tighten the
attachment bolts to the specified torque.
See ”Technical Data”.
8. Fit the valve tappets.
9. Fit the push rods.
10. Fit the side covers.
11. Fit the valve gear.

3-6 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Removal and installation

3.4 REMOVAL AND INSTALLATION, CAMSHAFT BEARINGS

Removal, camshaft bearings

1. Remove the camshaft.
2. Remove the camshaft bearings from the
cylinder block using special tool
(DAF No. 0535699). Make sure that the
initial bores of the camshaft bearings are
not damaged.
3. Clean the initial bores. M202041

Installation, camshaft bearings

1. Using special tool (DAF No. 535699), fit the
camshaft bearings in the cylinder block
bores. Take care not to form any burrs.
2. Fit the camshaft.

ǹ 0008 3-7
 CYLINDER BLOCK AND DRIVING GEAR
Removal and installation PF engine

3.5 REMOVAL AND INSTALLATION, CYLINDER LINER

Removal, cylinder liner

1. Remove the cylinder heads.
2. Remove the connecting rods.
3. Crank the crankshaft so that sufficient
space is created before fitting the special
tool.
4. Before removing the cylinder liner from the
cylinder block, fit the particular special tool
for this purpose (DAF No. 0535625). For A B
operating principle (A), see the opposite
diagram.
5. With the special tool, pull the cylinder liner
out of the cylinder block.
6. Measure the depth of the chamber for the
cylinder liner collar and compare this value
with the specified value. See “Technical
Data”.
Note:
Whenever over-sized cylinder liners are fitted,
marking S1 must be stamped under or over the
engine number.
The message C.S1 must also be put on the
engine specification plate.
Installation, cylinder liner M2 00 099
1. Clean the cylinder block before fitting.
2. Crank the crankshaft so that sufficient
space is created before fitting the special
tool.

9
3. Before fitting the cylinder liner of the
cylinder block, fit the particular special tool
for this purpose (DAF No. 0535625). For the
operating principle (B), see the diagram.
4. If possible, the cylinder liner should be
cooled or the engine block warmed in water
before installation.

3-8 ǹ 0008
 CYLINDER BLOCK AND DRIVING GEAR
PF engine Removal and installation

5. Only in the most extreme case may a little

thin lubricating oil be applied to the edge of
the initial bore. All other lubricating agents,
of whichever type, are absolutely forbidden.
Difficulties in the replacement of cylinder
liners are almost always the result of
lubricant residue used in the previous
assembly.
6. Press the cylinder liner entirely into the
cylinder block using the special tools.
7. Check the interior diameter of the cylinder
liner after fitting. See “Technical data”.
8. After installing the new cylinder liner,
measure the height that the cylinder liner
protrudes over the cylinder block. See
“Technical Data”.
If necessary, correct the height.
Note:
After replacing the cylinder liners, the engine
must be run-in again.
During the running-in period, the engine must be
filled with a different grade of engine oil. See the
“Oil specifications” manual.

ǹ 0008 3-9
 CYLINDER BLOCK AND DRIVING GEAR
Removal and installation PF engine

3.6 REMOVAL AND INSTALLATION, OIL NOZZLES

Removal, oil nozzles

1. Remove the oil sump.
2. Remove the banjo bolt and if necessary, the
locking plate of the oil nozzle.
3. Remove the oil nozzles.
Installation, oil nozzles
1. Clean the threaded holes of the oil nozzles.
2. If the version in question has locking plates,
fit a set of three right nozzles and one left
nozzle.

M200974

3. On the version without locking plates, fit a

set of six identical oil nozzles.
4. Fit the banjo bolts and tighten them to the
specified torque. See “Technical Data”. If
fitted, turn the locking plates over.

9 M200955

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PF engine Removal and installation

3.7 REMOVAL AND INSTALLATION, EXPANSION PLUGS

Removal, expansion plug

1. Tap on the edge of the expansion plug,
causing it to tilt. Make sure that no damage
occurs.
2. Remove the expansion plug with a pair of
pliers.
3. Remove the locking compound residue from
the cylinder block.
Installation, expansion plug
1. Apply the specified locking compound to the
new expansion plug and tap it with a
suitable driving tool into the cylinder head.
See “Technical data”.
2. Leave the locking compound to harden for 1
hour.
3. Check the cylinder block for leakage.

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Removal and installation PF engine

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PF engine

M200797

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