XE Engine (Component Manual)

Component manual 85CF
CF85
XE engine 95XF
XF95
©200551 DAF Trucks N.V., Eindhoven,
The Netherlands.
In the interest of continuing product development,

DAF reserves the right to change specifications
or products at any time without prior notice.
No part of this publication may be reproduced

and/or published by printing, by photocopying, on
microfilm or in any way whatsoever without the
prior consent in writing of DAF Trucks N.V.
©
200551 DW13243204
STRUCTURE
XE engine
TECHNICAL DATA
Structure
0
DIAGNOSTICS
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
©
200551
TECHNICAL DATA
XE engine Contents
CONTENTS
Technical data
Page Date 0
1. SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551
1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551

2.1 Engine type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551
2.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200551
3. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551

3.1 Dipped threaded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551
3.2 Locking compounds and sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200551
3.3 Threaded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . 200551
4. CONSTRUCTION PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551
4.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200551
5. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200551

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200551
6. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200551

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200551
7. TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200551

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200551
8. FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200551

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200551
9. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200551

9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200551
10. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . . 200551

10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . . 200551
10.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 . . . . 200551
10.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 . . . . 200551
11. CYLINDER BLOCK AND DRIVING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . . 200551

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . . 200551
11.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8 . . . . 200551
©
200551 1
TECHNICAL DATA
Contents XE engine
©
2 200551
TECHNICAL DATA
XE engine Safety instructions
1. SAFETY INSTRUCTIONS
1.1 SAFETY INSTRUCTIONS 0
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.
M0015
Safety instructions
To ensure that the mechanic’s health is not
endangered, the following safety precautions
must be strictly observed.
- Comply with all the warnings and safety
precautions 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, well-fitting clothes and apply
protective cream to unprotected parts of your
body, if necessary.
- Ensure proper extraction of hazardous
substances 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.
- Various oils and lubricants used on the
vehicle may constitute a health hazard. So
avoid both inhaling and direct contact with
them.
- Exercise caution when working with springs
under tension. Inadvertently released
springs may cause serious injuries. Small
springs and small may also cause injuries
when inadvertently released (wear goggles).
©
200551 1-1
TECHNICAL DATA
Safety instructions XE engine
- If necessary, support the component in a

0 -
suitable manner.
Always use 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.
©
1-2 200551
TECHNICAL DATA
XE engine General
2. GENERAL
2.1 ENGINE TYPE DESIGNATION 0
New versions of several existing engines
(type designation XE ... C1) were introduced
in week 13, 2001.
XE ... C identification
The first version can be identified by: 1 2 3

1. Glow plugs
2. Pump housing with 2.8 bar pressure control
valve in fuel supply
3. Fuel filter in threaded version
4. Loose primer pump
5. Fuel lift pump in toothed version (Barnes)
6. Oil filter in threaded version
6 5 4 M201287
©
200551 2-1
TECHNICAL DATA
General XE engine
XE ... C1 identification
0 1 2
6 5
M201286
The "1" is a serial number and means that a new
version of this type of engine has been
developed.
This version can be identified by:
1. Glow element
2. Pump housing with 5.5 bar pressure control
valve on left-hand side
3. Fuel filter in filter element version
4. UPEC ECU
5. Fuel lift pump in vane version (LUK) with
integrated primer pump
6. Oil filter in filter element version
©
2-2 200551
TECHNICAL DATA
XE engine General
Type plate "C" (C2) version

Engine types
Coding XE 250 C
4 3 5 6 0
XE 280 C
XE 315 C /C2 - 4 öko ENGINE
TYPE
XE 355 C
E4
ENGINE
XE 390 C NUMBER
GOVERNED SPEED min -1 OUTPUT kW
1. (Injection timing) BEFORE cm 3

2. Full-load engine speed INJECTION TIMING
T.D.C.
PUMPSETTING
3. Engine number SMOKE LEVEL FREE ACCELERATION m -1
4. Engine type EINDHOVEN HOLLAND

5. Country number
6. Emission certificate number
7. (maximum pump output)
8. Free acceleration smoke level 2 1 8 7
M200678
Type plate "C1" (C3) version

Engine types 9 3 2 1 8 75 4 6
Coding XE 250 C1
XE 280 C1 /C3 - 4 öko
XE 315 C1 /C3 - 4 öko
XE 355 C1
XE 390 C1
1. Engine type
2. Engine number
3. Order number
4. Full-load engine speed
5. Homologation number
6. Free acceleration smoke level M201088
7. Engine output
8. (Injection timing)
9. Transport number for production
©
200551 2-3
TECHNICAL DATA
General XE engine
2.2 ENGINE DATA

0
Engine types
Coding XE 250 C
XE 280 C
XE 315 C/C2
XE 355 C
XE 390 C
General specifications
Environmental standard Euro 3 (C)
Number of cylinders 6
Valves 4 per cylinder
Bore x stroke 130 x 158 mm
Total cubic capacity 12.6 l
Compression ratio 16.0 : 1
Fuel injection direct
Injection sequence 1-5-3-6-2-4
Air intake system Turbocharger intercooling
Engine management system UPEC
Cooling fluid
Weight approx. 1,080 kg
Engine types
Coding XE 250 C1
XE 280 C1/C3
XE 315 C1/C3
XE 355 C1
XE 390 C1
General specifications
Environmental standard Euro 3 (C)
Number of cylinders 6
Valves 4 per cylinder
Bore x stroke 130 x 158 mm
Total cubic capacity 12.6 l
Compression ratio 17.4 : 1
Fuel injection direct
Injection sequence 1-5-3-6-2-4
Air intake system Turbocharger intercooling
Engine management system UPEC
Cooling fluid
Weight approx. 1,080 kg
©
2-4 200551
TECHNICAL DATA
XE engine General
Engine type
XE 250 C
P (kW/hp) at rpm
250/340 at 2000
M (Nm) at rpm
1600 at 1000 - 1500
0
XE 280 C 280/380 at 2000 1750 at 1000 - 1500
XE 315 C/C2 315/430 at 2000 1900 at 1100 - 1500
XE 355 C 355/480 at 2000 2100 at 1100 - 1500
XE 390 C 390/530 at 1900 2350 at 1100 - 1500
Engine type P (kW/hp) at rpm M (Nm) at rpm

XE 250 C1 250/340 at 1900 1600 at 1000 - 1500
XE 280 C1/C3 280/380 at 1900 1750 at 1000 - 1500
XE 315 C1/C3 315/430 at 1900 1950 at 1000 - 1500
XE 355 C1 355/480 at 1900 2100 at 1000 - 1500
XE 390 C1 390/530 at 1900 2350 at 1100 - 1500
©
200551 2-5
TECHNICAL DATA
General XE engine
©
2-6 200551
TECHNICAL DATA
XE engine Threaded connections
3. THREADED CONNECTIONS
3.1 DIPPED THREADED CONNECTIONS 0
The components may have threaded connections
that have been treated with lubricant (dipped
threaded connection). Galvanised bolts and nuts
are wax dipped in the factory. Black annealed
and phosphatised bolts and nuts are oil dipped.
The advantage of using a lubricant is that friction
during tightening of the threaded connection is
reduced, so that the specified pre-tension can be
obtained accurately and more easily. The
tightening torque can be reduced while the pre-
tension force remains the same.
To achieve a small spread in the pre-tension
force, the dipped threaded connection must be
tightened accurately. Therefore, always use a
reliable torque wrench that provides a high
degree of accuracy.
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 contact surface of the nut or bolt.
If bolts and nuts are to be re-used, do not
lubricate them with anything other than engine oil.
Lubricants other than engine oil or factory-applied
lubricant must not be used under any
circumstances because of the difference in
friction coefficient.
When locking compounds are used for dipped
threaded connections, the instructions given here
apply, except for applying lubricant to the first turn
of the screw thread.
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.
©
200551 3-1
TECHNICAL DATA
Threaded connections XE engine
The following applies to all threaded

0 connections:
- in the case of standard connections, apply
the lubricant before fitting, and (re)tighten in
accordance with the standard for dipped
bolts;
- in the case of special connections, apply the
lubricant before fitting, and (re)tighten in
accordance with the values specified in the
instructions.
The instructions for using lubricants also apply to
new bolts from the warehouse. Dry threaded
connections are no longer permitted because of
their highly variable friction coefficients.
©
3-2 200551
TECHNICAL DATA
3.2 LOCKING COMPOUNDS AND SEALANTS

0
} Certain cleaning agents have a
negative effect on the functioning of
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 name Properties Applications DAF number
Loctite 243 - Locking with an average Locking of threaded 0068197
detaching strength connections
- Detachable with normal
tools
Loctite 2701 - Locking with a high Locking of threaded 1340646
detaching strength connections, gear lever ball,
- Repairs the fit in bearing freeze plugs
housings
- Seals against leaks
- Difficult to detach
Loctite 638 - Locking with a high Locking of cylindrical 0645557
detaching strength under connections
dynamic load
- Difficult to detach
Loctite 648 - Locking with an average Locking of threaded 1357032
detaching strength connections in warm places
- Resistant to high
temperatures
Loctite 262 - Locking with a high Locking of threaded 1279841
detaching strength connections, such as the pinion
- Difficult to detach nut
©
200551 3-3
TECHNICAL DATA
Applying locking compound

0 1. Clean both the internal and external threads.
Degrease the thread with a suitable
degreasing agent which leaves no residue
that could affect proper functioning.
2. Apply one or more drops of locking
compound to the thread, depending on the
diameter. Never dip the bolt or stud fully into
the locking compound.
3. 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.
4. Tighten the connection to the specified
torque.
OVERVIEW OF SEALING COMPOUNDS

Dirko D - Resistant to temperatures Sealing of surface connections 1345014
up to 180 C
- Resistant to oil, coolant
Loctite 510 - Resistant to temperatures Sealing of surface (flange) 0697149
up to 200 C connections that are subjected
- Resistant to oil, brake fluid, to high operating temperatures,
coolant such as the flywheel housing
Loctite 574 - Resistant to high Sealing of surface connections 1246867
pressures (up to 350 bar) against high pressures
- Resistant to oil, brake fluid,
coolant
Loctite Blue - Resistant to temperatures Sealing of flexible constructions 1242895
from 60 C to 260 C such as (valve) covers
- Resistant to oil
Loctite ultra grey - Silicone sealant, good Sealing of (surface) 1284123
resistance to coolant connections in the cooling
- Resistant to temperatures system
up to 325 C
©
3-4 200551
TECHNICAL DATA
Product name Properties

OVERVIEW OF SEALING COMPOUNDS
Applications DAF number 0
Loctite ultra - Silicone sealant, good Sealing of surface connections 1284122
copper resistance to oil such as hub covers
- Resistant to temperatures
of up to 350 C
Loctite 5910 - Silicone sealant, good Sealing of surface connections, 1360102
resistance to oil such as front and rear covers of
- Resistant to temperatures gearboxes, differential
up to 200 C housings, hub covers, stub axle
flanges and oil cooler
Loctite 572 - Seals against low pressure Threaded connections 0292336
immediately after fitting
Loctite 5205 - Surface sealant, especially Sealing of aluminium parts 1441339
for sealing aluminium parts
- Resistant to temperatures
up to 150 C
- Resistant to water, coolant
and oil
Loctite Form a - Hardens on contact with For locking, fastening and 1322823
gasket metal and on full closure sealing
OTHER PRODUCTS
Tectyl - Protects the cavities of the Post-treatment of cab parts to 1343888
body work against protect against corrosion.
corrosion Can also be used as protection
for metal parts
Contact spray - Cleaning agent for Cleaning of electrical contacts 1387608
cleaning and degreasing
electronic and electrical
connections. Removes
moisture and dirt from
electrical contacts
Molykote BR 2 - Lubricating grease is heat- Wherever grease lubrication is 1389512
PLUS resistant from -30 C to appropriate and normal
+130 C For almost all ball and roller
bearings, plain bearings,
guides, couplings, splined
shafts, threaded spindles,
sprocket drives with a low
speed
Loctite cleaner - Cleans and degreases For cleaning/degreasing of 1322827
7063 - Non-inflammable and non- materials to which a locking
corrosive compound must be applied
©
200551 3-5
TECHNICAL DATA
OTHER PRODUCTS
0 Product name Properties Applications DAF number
Molykote P37 - Grease protects against For threaded connections that 1391619
corrosion and is heat- are exposed to high
resistant to 1400 C temperatures, as used for
exhaust systems
Copaslip - Copper paste with an For connections that are 1284344
excellent bond, is anti- vulnerable to oxidation or
corrosive and heat- corrosion, such as battery
resistant from -35 C to terminals, exhaust couplings,
1100 C. etc.
- Resistant to water, salts
and acids
- Prevents wear, oxidation,
rust, corroding and locking
of metal surfaces
Gleitmo 805 - Protects untreated metals For parts which are attached 1443160
against corrosion with a fit such as wheel hub
units
©
3-6 200551
TECHNICAL DATA
3.3 THREADED CONNECTIONS
Table of standard tightening torques,

0
standard 00804-203
The tightening torques in the table below are
standard torques and only apply to dipped
threaded connections.
The property codes are stamped on the nut and
bolt, except on the clamping flange bolt. The
clamping flange bolt can be recognised by a
groove between the hexagonal bolt head and the
flange. This groove is absent in standard flange
bolts.
M2 00 001
Tightening torques for dipped threaded
connections (Nm)
Property class of Property class of Clamping Banjo bolts
bolt 8.8, nut 8 bolt 12.9, nut 12 flange bolt
Property class of
bolt 12.9, nut 12
Thread Tightening Tightening Tightening Tightening
torques (Nm) torques (Nm) torques (Nm) torques (Nm)
M4 2.8 ≥ 0.2 - - -
M5 5.5 ≥ 0.4 - - -
M6 9.6 ≥ 0.7 - - 8 ≥ 0.8
M8 23 ≥ 2 32 ≥ 2 - 15 ≥ 1.5
M10 46 ≥ 4 67 ≥ 5 - 30 ≥ 3
M12 79 ≥ 6 113 ≥ 9 178 ≥ 14 40 ≥ 4
M14 125 ≥ 9 178 ≥ 14 274 ≥ 22 50 ≥ 5
M16 195 ≥ 14 274 ≥ 22 425 ≥ 35 60 ≥ 6
M18 280 ≥ 20 385 ≥ 30 550 ≥ 45 70 ≥ 7
M20 395 ≥ 30 550 ≥ 43 - -
M22 540 ≥ 40 740 ≥ 60 - -
M24 680 ≥ 50 925 ≥ 72 - -
M27 1000 ≥ 70 1370 ≥ 110 - -
M30 1350 ≥ 100 - - -
©
200551 3-7
TECHNICAL DATA
Overview of standard tightening torques

0 for DAF flange bolts and nuts, strength
class 10.9/10
Thread pitch Tightening torque Extra angular displacement (≥ 10 %)
(Nm) for bolt stem length L (mm):
L40 41-80 81-130 131-180
M8 30 ≥ 2 30 60 90 120
M10 60 ≥ 4 45 90 120 150
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 Nm + 60
M16 x 2 260 ≥ 20 30 60 90 120
M16 x 1.5 260 ≥ 20 45 90 120 150
M18 x 2.5 360 ≥ 30 30 45 60 80
M18 x 1.5 360 ≥ 30 45 90 120 150
M20 x 1.5 520 ≥ 40 45 90 120 150
M22 x 2.5 for steering and track rods: 500 ≥ 50 Nm + 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.
Torque wrench
- Have torque wrenches regularly inspected
and calibrated.
©
3-8 200551
TECHNICAL DATA
Re-using bolts/nuts
Bolts tightened using angular displacement may
not be re-used, unless a suitable new nut can be
0
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
clamping faces.
2. Check the thread for damage. To do so,
manually screw a new nut/bolt onto the
thread to be checked. If the new nut/bolt
cannot be fully hand-screwed onto the entire
thread of the fastener to be checked, the
fastener is not allowed to be re-used.
3. Apply one drop of engine oil to the upper turn
of the bolt (threaded end)/lower turn of the
nut and one drop to the clamping faces
(other lubricants are not allowed).
4. If a sealing/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, have already been lubricated.
If bolts have not yet been lubricated, 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 clamping faces (other
lubricants are not allowed).
2. If a sealing/locking compound was specified,
no oil should be applied to the thread.
©
200551 3-9
TECHNICAL DATA
©
3-10 200551
TECHNICAL DATA
XE engine Construction parts
4. CONSTRUCTION PARTS
4.1 GENERAL 0
V-belt tension
V-belt tension, "AVX" raw edge (1)(N)
New V-belt (2)
Multiple belt Single belt
Setting tension 1200 600
Test tension  800  400
(3)
Run-in V-belt
Minimum tension 500 250
Adjusting tension 700 350
(1) Raw-edge V-belts can be recognised by the absence of

textile fabric around the rubber on the edges and the
inside of the belt (polished belt edge), with the exception
of the top of the belt edge. Model: either a toothed or a
non-toothed belt.
(2) After fitting the new V-belt, set the pre-tension to the
"setting tension" and after a trial run check whether the
pre-tension complies with the "test tension". If the test
tension reading is lower than the value specified in the
table, set the V-belt to the minimum "test tension".
(3) If the V-belt tension is lower than the "minimum tension",
set the belt to the "adjusting tension".
M2121
©
200551 4-1
TECHNICAL DATA
Construction parts XE engine
Automatic poly V-belt tensioner

0 Torsional moment from rest
position (0) to 17 mm torsion (A) 19 - 37 Nm
Explanation of turbocharger type

designation GARRETT 0
Example of type designation:
GT42-94S/54NPS/1.44-84
GT42 Turbine type designation

94 Maximum compressor rotor diameter
S Wastegate model
54 Compressor rotor trim
NPS Version with intake side without
compressor housing bypass
PS Version with intake side with compressor
housing bypass
1.44 Turbine housing size
84 Turbine wheel trim
A
Explanation of turbocharger type
designation K.K.K.
Example of type designation:
K31-39/71 Q Y B K B 22.9 1 D C A Y D
K31 Turbine build series

39 Diameter of compressor rotor 3.9 inch
71 Compressor rotor ratio diameter
d/D M201274
Q Compressor rotor development letter

Y Compressor housing development letter
B Compressor housing variant
K K = Compressor housing with
recirculation (= ported shroud)
A = Compressor housing with no
recirculation (= nonported shroud)
B B = Recirculation variant
A = No recirculation
22 Surface of turbine housing throat (cm2)
9 Turbine housing version number
9 = with control bypass
2 = without control bypass
1 Turbine trim figure:
0 = d/D = 87 (trim 76)
1 = d/D = 84 (trim 70)
2 = d/D = 89.5 (trim 80)
3 = d/D = 79 (trim 62)
D Turbine wheel development letter
C Turbine housing development number
A Turbine housing variant
Y Turbine inlet flange size
y = dimension as for a 12.6 litre engine
W = dimension as for a 9.2 litre engine
T = dimension as for a 6.2 litre engine
©
4-2 200551
TECHNICAL DATA
D Turbine housing material:

B = GG 40
D = SiMo
0
F = Nirisist D2
H = Nirisist D3
K = Nirisist D5
Turbocharger
Fixing stud bolts Copaslip
GARRETT wastegate
Engine type Turbocharger Adjustment pressure for 1 mm movement
of control rod
DAF No. GARRETT No.
XE315C 1344152 452281-4 1.55 ≥ 0.05 bar
1377426 452281-8 1.80 ≥ 0.05 bar
XE315C2 1453883 452281-10 2.10 ≥ 0.05 bar
1609988 452281-14 2.10 ≥ 0.05 bar
XE355C 1344152 452281-4 2.00 ≥ 0.05 bar
1377426 452281-8 2.00 ≥ 0.05 bar
1609988 452281-14 2.10 ≥ 0.05 bar
XE355C1 1448806 721644-2 1.60 ≥ 0.05 bar
1616752 721644-6 1.60 ≥ 0.05 bar
XE390C 1356820 452281-5 2.00 ≥ 0.05 bar
1377426 452281-8 2.00 ≥ 0.05 bar
1397101 452281-9 2.00 ≥ 0.05 bar
1453883 452281-10 2.10 ≥ 0.05 bar
1609988 452281-14 2.10 ≥ 0.05 bar
XE390C1 1443766 721644-1 2.05 ≥ 0.05 bar
1616751 721644-5 2.05 ≥ 0.05 bar
K.K.K. wastegate
Movement of control rod at 1.95 ≥ 0.05 bar 3.5 ≥ 0.05 mm
Air compressor
Safety valve opening value 16 bar
Exhaust brake
XE ... C
Calibration opening, butterfly valve with DEB 12 mm
Calibration opening, butterfly valve without DEB 8 mm
XE ... C1
Calibration opening, butterfly valve with DEB 14 mm
Calibration opening, butterfly valve without DEB 10.5 mm
Glow element
resistance 225 - 275 m
©
200551 4-3
TECHNICAL DATA
4.2 TIGHTENING TORQUES

0
Starter motor
Attachment nuts 73 Nm (1)
Electrical connection to starter motor 28 Nm
(1) Fasten with Loctite 243
Alternator types XE ... C

Alternator bracket attachment bolts 55 Nm
Alternator attachment bolts 50 Nm
Alternator pulley attachment nut 70 Nm
Electrical connection to alternator (M8) 12 Nm
Alternator types XE … C1
Alternator bracket attachment bolts 30 Nm
M10 alternator attachment bolts 60 Nm
M12 alternator attachment bolts 110 Nm
Alternator pulley attachment nut 80 Nm
Electrical connection to alternator (M8) 15 Nm
Air compressor
M12 attachment bolts 110 Nm
M8 bracket attachment bolts 30 Nm
M10 bracket attachment bolts 60 Nm
Compressor gear flange bolt 120 Nm
M14 screw-in coupling for cylinder head 40 Nm
M26 screw-in coupling for cylinder head 90 Nm
Cylinder head service line banjo bolt 25 Nm
Pressure line safety valve 75 Nm
Suction and pressure line unions 90 Nm
Oil supply banjo bolt 25 Nm
Exhaust manifold
Fit gasket with steel side towards manifold
Sleeved attachment bolts 65 Nm
Heat shield attachment bolts 30 Nm (1)
©
4-4 200551
TECHNICAL DATA
Turbocharger
Heat shield attachment bolts
Attachment nut for turbine housing clamp plate
30 Nm (1)
15 Nm
0
Attachment nuts for exhaust manifold flange/
turbocharger 60 Nm (2)
Elbow on turbocharger 40 Nm (2)
Oil supply pipe banjo bolt 90 Nm
Oil return pipe attachment bolts 25 Nm
(2) Fasten with Copaslip
Intercooler air supply pipe

Bolts for attaching bracket to cylinder block 60 Nm (1)
Inlet manifold types XE ... C

Attachment bolts 60 Nm
Glow plug attachment nut 55 Nm
Hose clamps 11 Nm
Inlet manifold types XE … C1

Glow element attachment bolts 30 Nm
Electrical connection to glow element 8.5 Nm
Attachment bolts, boost pressure/air inlet
temperature sensor 4 Nm
Hose clamps 11 Nm
Relay grid heater

Glow plug relay cap 2 Nm
Electrical connections to glow plug relay
M5 3.5 Nm
M8 8 Nm
Main fuse types XE ... C1

Fuse holder (M6) 4.5 Nm
Fuse (M8) 18 Nm
Engine hanger brackets

©
200551 4-5
TECHNICAL DATA
Version with direct fan drive XE ... C

0 Vibration damper hub (1) attachment bolts in
4 phases:
1st phase, all attachment bolts 100 Nm (1)
nd
2 phase, all attachment bolts 100 Nm (1)
rd
th
Fan flange/vibration damper (7)
attachment bolts 110 Nm 4
Fan clutch attachment nuts (6) 25 Nm (2)
1
2
(1) Tighten the attachment bolts evenly 3
5
6
7
M200946
Version with separate fan drive XE ... C

Vibration damper hub (1) attachment bolts in
4 phases:
nd
rd
th
Vibration damper (5)
Fan drive (8) attachment nuts 60 Nm 9
Fan pulley (9) attachment bolts 30 Nm (2)
7
Fan drive (7) attachment nuts 25 Nm (2)
6
(1) Tighten the attachment bolts evenly
(2) Fasten with Loctite 243 5
4
3
2
1
M200945
©
4-6 200551
TECHNICAL DATA
Version with separate up-speed fan

drive XE ... C
Vibration damper hub (1) attachment bolts in
0
4 phases:
nd
rd
th
Attachment bolts, up-speed
bearing block/vibration damper (5) 110 Nm 6
V-belt pulley (7) attachment nuts 25 Nm
M10 central bolt, up-speed 7
bearing housing (9) 60 Nm (2)
4
Fan (8) attachment nuts 25 Nm (2)
10
8
(1) Tighten the attachment bolts evenly
9 11 12 13 5 2 3 1 14
M200947
Version with poly-V-belt drive XE ... C1

Vibration damper hub (1) attachment bolts in 10
4 phases:
nd
2 phase, all attachment bolts 100 Nm (1) 8
rd
th
4 phase, all attachment bolts 100 Nm (1) 9
Vibration damper (5)
Fan drive (8) attachment nuts 60 Nm
Fan pulley (9) attachment bolts 30 Nm (2) 6
5
4
2
1
M201153
©
200551 4-7
TECHNICAL DATA
Version with poly-V-belt drive XE ... C1

0 Vibration damper hub (1) attachment bolts in
4 phases:
nd
rd
th 8
Fan pulley (6)/vibration damper (4)
attachment bolts (5) 110 Nm 9
7
5
4
1
2
6
M201288
©
4-8 200551
TECHNICAL DATA
XE engine Fuel system
5. FUEL SYSTEM
5.1 GENERAL 0
TYPES XE ... C
Overview, injector
Engine type Number of Nozzle No. Hole diameter Bar filter Opening
holes in (mm) pressure (bar)
injector
XE 250 C 8 810 0.195 Yes 300 + 10
XE 280 C 8 810 0.195 Yes 300 + 10
XE 315 C 8 810 0.195 Yes 300 + 10
XE 355 C 8 810 0.195 Yes 300 + 10
XE 390 C 8 810 0.195 Yes 300 + 10
Pump housing
Weight, including camshaft and pump units approx. 70 kg
Bore, roller tappets 44.00 - 44.025 mm
Bore, camshaft bearings, large 80.00 - 80.030 mm
Bore, camshaft bearings, small 67.305 - 67.335 mm
Roller tappet
Standard diameter 43.94 - 43.98 mm
Camshaft bearings
Width, large 21.5 - 22.0 mm
Width, small 25.4 mm
©
200551 5-1
TECHNICAL DATA
Fuel system XE engine
TYPES XE ... C1
0 Overview, injector
Engine type Number of Nozzle No. Hole diameter Bar filter Opening
holes in (mm) pressure (bar)
injector
XE 250 C1 8 1081 0.182 Yes 300 + 10
XE 280 C1 8 1081 0.182 Yes 300 + 10
XE 315 C1 8 1081 0.182 Yes 300 + 10
XE 355 C1 8 1286 0.182 Yes 300 + 10
XE 390 C1 8 1286 0.182 Yes 300 + 10
Pump housing
Weight, including camshaft and pump units approx. 70 kg
Bore, roller tappets 44.00 - 44.025 mm
Bore, camshaft bearings, large 80.00 - 80.030 mm
Bore, camshaft bearings, small 67.305 - 67.335 mm
Roller tappet
Standard diameter 43.94 - 43.98 mm
Camshaft bearings
Width, large 21.5 - 22.0 mm
Width, small 25.4 mm
Glow element
resistance 225 - 275 m
©
5-2 200551
TECHNICAL DATA
The tightening torques stated in this section are

0
different from the standard tightening torques
stated in the overview of the standard tightening
torques. The other threaded connections not
specified must therefore be tightened to the
torque stated in the overview of standard
tightening torques.
Unless stated otherwise, when attachment bolts
and nuts are replaced, it is very important that
these bolts and nuts are of exactly the same
length and property class as those removed.
Injector pipes
Injector pipe union nut 30 Nm
Injectors
Injector unit nuts 45 Nm
Clamping piece attachment bolt 30 Nm + 60 angular displacement (1)
Leak-off pipe banjo bolts 20 Nm
Pump housing
Pressure relief valve 20 Nm
Attachment bolts connecting pump housing to
engine block 60 Nm
Attachment bolts for pump housing rear cover 30 Nm
Attachment bolts for pump camshaft locking plate 30 Nm (2)
Attachment bolts for pump housing sealing plates 30 Nm
Attachment bolts for pulse disc on camshaft 30 Nm (2)
Camshaft sensor attachment bolt 8 Nm
Non-return valve 45 Nm
Fuel temperature sensor 20 Nm
Pump unit
Attachment bolts connecting pump unit to pump
housing 46 Nm
Pump unit electrical connection 1 Nm
Lift pump
Attachment bolts to connect fuel lift pump to
pump housing 30 Nm
Fuel filter (threaded filter version)

Attachment bolts connecting fuel filter to water
pipe 40 Nm
Banjo bolts, fuel lines to filter 35 Nm
Fuel filter housing (filter element version)

Fuel leak-off pipe union 20 Nm
(1) Use bolts once only

(2) Use Loctite 243
©
200551 5-3
TECHNICAL DATA
©
5-4 200551
TECHNICAL DATA
XE engine Cooling system
6. COOLING SYSTEM
6.1 GENERAL 0
Thermostat
Thermostat opening temperatures:
standard
- thermostat opens at ≥ 87 C
- thermostat open at least 12 mm at ≥ 99 C
Thermostat opening temperatures:

with intarder and/or tropical cooling:
- thermostat opens at ≥ 83 C
- thermostat open at least 12 mm at ≥ 95 C
Thermostat seat Loctite 638
Coolant pump
Maximum radial play 0.16 - 0.20 mm
©
200551 6-1
TECHNICAL DATA
Cooling system XE engine

0 The tightening torques stated in this section are
tightening torques.
Coolant pump
M8 attachment bolts 30 Nm
M14 threaded coupling 35 Nm
M26 90 Nm
Coolant pipe
Coolant pipe screw-in coupling 90 Nm
Coolant pipe plug 35 Nm
Engine coolant temperature sensor 20 Nm
Thermostat housing
Plug 35 Nm
Coolant hoses
Hose clamps 7 Nm
©
6-2 200551
TECHNICAL DATA
XE engine Timing gear
7. TIMING GEAR
7.1 GENERAL 0
Number of teeth, timing gear
Crankshaft gear 35
Idler gear 54
Pump housing camshaft gear 70
Camshaft gear 70
Air compressor gear 27
Fan drive housing gear 29
Steering pump gear 18
Lubricating oil pump idler gear 34
Gear backlash
Idler gear - crankshaft gear 0.02 - 0.21 mm
Idler gear - pump housing camshaft gear 0.02 - 0.22 mm
Idler gear - camshaft gear 0.02 - 0.21 mm
Camshaft gear - compressor gear 0.02 - 0.22 mm
Pump housing camshaft gear - steering pump
gear 0.02 - 0.19 mm
Oil pump idler gear - oil pump gear 0.02 - 0.20 mm
Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm
End play
Crankshaft end play 0.06 - 0.32 mm
Camshaft end play 0.10 - 0.24 mm
Idler gear end play 0.05 - 0.30 mm
©
200551 7-1
TECHNICAL DATA
Timing gear XE engine

0 The tightening torques stated in this section are
tightening torques.
Timing gear
Attachment bolts for camshaft locking plate 30 Nm (1)
Attachment bolts for pump housing camshaft
locking plate 30 Nm (1)
Timing case attachment bolts 25 Nm (1)
Timing cover attachment bolts:
- M10 attachment bolts 60 Nm
- M8 attachment bolts 25 Nm
Attachment bolt for timing gear cover protection
plate 15 Nm
Camshaft gear attachment bolt 425 Nm (1)
Idler gear attachment bolt 170 Nm
Attachment bolt for pump housing camshaft gear 260 Nm (1)
Compressor gear attachment bolt 120 Nm
Steering pump attachment nut 80 Nm (1)
Banjo bolt for steering pump intake pipe 90 Nm
Banjo bolt for steering pump delivery pipe 40 Nm
M26 sealing plug 60 Nm
©
7-2 200551
TECHNICAL DATA
XE engine Flywheel and flywheel housing
8. FLYWHEEL AND FLYWHEEL HOUSING

8.1 GENERAL 0
Flywheel
Axial variation, measured at a radial distance
of 210 mm 0.10 mm
Starter ring gear warm up max. 185 C
©
200551 8-1
TECHNICAL DATA
Flywheel and flywheel housing XE engine

0
Flywheel housing
Attachment bolts 110 Nm (1)
Sealant to be used when fitting flywheel housing Loctite 510
Crankshaft sensor attachment bolt 8 Nm
Flywheel
Attachment bolts:
- standard 200 Nm + 45 angular displacement
- with engine PTO 260 Nm + 45 angular displacement
Engine mounting at flywheel end

Attachment bolts connecting engine bracket
to flywheel housing 260 Nm
©
8-2 200551
TECHNICAL DATA
XE engine Cylinder head
9. CYLINDER HEAD
9.1 GENERAL 0
Cylinder head
Minimum height after
refacing (distance A) 119.5 mm A
Rough value 0.4 - 1.6 mm
Flatness max. 0.05 mm
Test pressure with air 1.5 bar
M200777
Valve seat, inlet (loose seat)

Valve seat angle 20 ≥ 0.25 A
Internal dia. 39.5 - 39.9 mm
External dia. 48.097 - 48.113 mm
Thickness 6.95 - 7.05 mm
Minimum thickness after
overhaul 5.5 mm
Width of bearing area A
after milling valve seat 2.0 mm
M201101
Cylinder head recess

Depth 10.45 - 10.85 mm
Diameter 48.00 - 48.025 mm
Valve seat, exhaust (loose seat)

Valve seat angle 45 ≥ 0.25 A
Internal dia. 36.85 - 37.15 mm
Thickness 6.95 - 7.05 mm
Minimum thickness
after overhaul 5.5 mm
Width of bearing area A
after milling valve seat 2.0 mm
M201100
©
200551 9-1
TECHNICAL DATA
Cylinder head XE engine
Cylinder head recess

0 Depth
Diameter
10.10 - 10.30 mm
48.00 - 48.113 mm
Expansion caps
Locking compound Loctite 2701
Inlet valve
Distance between valve B
head and cylinder head
surface (distance B) -0.95 - -1.61 mm
Here, dimension B falls
within the cylinder head
Valve stem diameter 8.935 - 8.953 mm
Valve clearance (cold/hot) 0.50 mm
Note:
Due to minimal machining tolerances, machining
of the inlet valve is not allowed. Grinding with
grinding compound is, however, allowed.
M201102
Exhaust valve
Valve head diameter 42.375 - 42.625 mm B
Valve head angle 44.5 ≥ 0.25
Distance between valve
head and cylinder head
surface (distance B) -0.45 - -1.11 mm
Here, dimension B falls within the cylinder head
Valve stem diameter 8.915 - 8.933 mm
Valve clearance (cold/hot) 0.50 mm
M201103
Valve guide
Overall length 76.50 mm
Internal dia. 9.014 - 9.026 mm A
Height (distance A)
above contact surface 17.0 - 18.0 mm
M2 01 292
©
9-2 200551
TECHNICAL DATA
Height of correctly fitted

valve stem seal (distance B) approx. 21.3 mm 0
Note:
Valve stem seal on the exhaust valve is/may be
present if the pictured (narrow) valve spring
retainer is used.
B
M2 01 299
Valve spring, inlet

- untensioned length 59.0 mm
- fitted length 44.0 mm
Valve spring, exhaust

Outer spring:
Inner spring, situation A with centring sleeve:

A
Inner spring, situation B without centring sleeve:

i 400414
©
200551 9-3
TECHNICAL DATA
Single spring, situation C with no centring sleeve:

0 - untensioned length
- fitted length
63.37 mm
44.00 mm
C
i4 00 674
Rocker shaft
Rocker shaft diameter 24.98 - 24.993 mm
Internal dia., reamed bearing bush 25.00 - 25.021 mm
DEB
Solenoid valve resistance value
Cold (20 C) 32.6 - 36.8 
Warm (80 C - 100 C) 41.8 - 46.1 
DEB clearance 1.40 mm
©
9-4 200551
TECHNICAL DATA
Cylinder head attachment bolts

0
Cylinder head bolts must only be used once. So
the cylinder head bolts must always be replaced.
The thread of the new cylinder head bolts is
provided with a sealant.
Note:
- Due to the sealant used on the cylinder head
bolts, the untightening torque of the cylinder
head bolts can be substantial!
- All M16 and M12 threaded holes must be
carefully cleaned using a screw tap prior to
the mounting of the bolts.
Threaded holes not properly cleaned may
lead to too low a pre-tension of the cylinder
head bolts, causing leakage.
- After tightening of the bolts with the
appropriate tightening torque, the angular
displacement of the M16 bolts must
immediately be started.
- The sealant cannot be applied at a later
stage (which is why it is not available
separately).
©
200551 9-5
TECHNICAL DATA
Tightening cylinder head attachment bolts

0 50 Nm 150 Nm
110 Nm
M16
M16
M16
M16
M12
I II II III IV
M201483
1st phase
- M16 in the indicated order 50 Nm 21 18 19 20
2nd phase
- M16 in the indicated order 150 Nm 17 11 7 1 8 12
- M12 in the indicated order 110 Nm 16 6 2 13
3rd phase
- M16 in the indicated order 60 angular
displacement 15 5 3 14
4th phase
- M16 in the indicated order 120 angular 10 4 9
displacement
M200562
Valve gear
Valve cover attachment bolts 25 Nm
7 15 9 2
Rocker setting bolt lock nut 40 Nm 3 11 13
Bridge setting bolt lock nut 40 Nm
Rocker seat/lubricating oil
strip attachment bolts 110 Nm 5 6
Valve sleeve attachment bolts 30 Nm (1) 14 8
1
(1) Tighten in the indicated order
10 12 4
M200942
DEB
DEB attachment bolts 110 Nm
DEB set screw nut 25 Nm
Solenoid valve 20 Nm
Wiring harness attachment bolt 5 Nm
Spring plate attachment bolt 12.5 Nm
9-6 © 200551
TECHNICAL DATA
XE engine Lubrication system
10.LUBRICATION SYSTEM
10.1 GENERAL 0
Oil pressure
Lubricating oil pressure at engine idling speed 1 bar (warm engine)
Lubricating oil pressure at full-load engine speed 3.5 - 4.5 bar
Oil filter
Type XE ... C threaded filter
Type XE ... C1 filter element
Number 1
Location in the oil circuit full flow
Opening pressure of bypass valve at a
pressure difference of 2.5 ≥ 0.3 bar
Oil cooler
Coolant test pressure maximum 2.5 bar
Oil consumption
Maximum permissible engine oil consumption 0.3% of the average fuel consumption
Example:
Average measured fuel consumption:
30 litres/100 km = 300 litres/1000 km
Maximum permissible engine oil consumption:
0.3% x 300 = 0.9 litres/1000 km
- Engine oil consumption of 0.9 litres/1000 km
is permissible
- Engine oil consumption > 0.9 litres/1000 km;
check the engine using the diagnostics table.
See "Diagnosis".
©
200551 10-1
TECHNICAL DATA
Lubrication system XE engine

0
Oil sump
Clamp attachment bolts 25 Nm
Oil drain plug 60 Nm
Oil level sensor 60 Nm
Bleed pipe attachment bolts 30 Nm (1)
Screw-in coupling for dipstick 60 Nm
Dipstick holder attachment bolts 30 Nm (1)
Oil pump
Attachment bolts for oil pump housing sections 30 Nm
Attachment bolts connecting oil pump to main
bearing cap 60 Nm (1)
Oil delivery pipe attachment bolts 30 Nm (1)
Idler gear central bolt 60 Nm (1)
Strainer
Bracket attachment bolts 30 Nm (1)
Lubricating oil filter (threaded filter)

Lubricating oil filter housing attachment bolts 50 Nm (2)
Oil filter 45 Nm
Coupling in lubricating oil filter head 60 Nm (3)
Lubricating oil filter (filter element)

Lubricating oil filter housing attachment bolts 50 Nm (2)
Filter element screw cap 40 Nm
Bypass pressure regulator

Plug 80 Nm
Oil cooler
Attachment bolts connecting oil cooler to
cylinder block XE... C 50 Nm
Attachment bolts connecting oil cooler to
cylinder block XE... C1 60 Nm
Coolant supply pipe union 90 Nm
Plug, adjustable banjo connection 90 Nm
Banjo bolt, adjustable banjo connection 90 Nm
Centrifugal oil filter

Central bolt 20 Nm
Oil discharge pipe union XE... C 50 Nm

©
10-2 200551
TECHNICAL DATA
10.3 FILLING CAPACITIES

0
XE ... C lubrication system
Total capacity, including oil cooler and filter approx. 32 litres
Sump capacity, max. level approx. 25 litres
Sump capacity, min. level approx. 17 litres
XE ... C1 lubrication system

Total capacity, including oil cooler and filter approx. 35 litres
Sump capacity, max. level approx. 30 litres
Sump capacity, min. level approx. 22 litres
©
200551 10-3
TECHNICAL DATA
©
10-4 200551
TECHNICAL DATA
XE engine Cylinder block and driving gear
11.CYLINDER BLOCK AND DRIVING GEAR

11.1 GENERAL 0
Overview of wear measurements, cylinder block
M201175
©
200551 11-1
TECHNICAL DATA
Cylinder block and driving gear XE engine
0 Overview of wear measurements, driving gear
A
B
A
B
M2 00 018
Cylinder block
Minimum distance (A)
after machining 388.85 mm
Depth of chamber,
cylinder liner collar 9.98 - 10.02 mm
Bore for cylinder liner:
- standard 135.987 - 136.013 mm
- oversize 136.237 - 136.263 mm
Bore, main bearing shells 103.072 - 103.098 mm
Bore, camshaft bearings 67.305 - 67.335 mm
Pressure-test with air maximum 4 bar
M200239
©
11-2 200551
TECHNICAL DATA
Expansion caps
Locking compound Loctite 2701 0
Cylinder liner
External diameter, cylinder liner:
- standard 136.01 - 136.03 mm
- oversize 136.24 - 136.26 mm
Internal diameter, cylinder liner
- loose 130.01 - 130.03 mm
- fitted 129.98 - 130.02 mm
Height of cylinder liner above block 0.02 - 0.10 mm
Crankshaft
1 2 3 4 5 6 7 8
A B C D E F G
M201104
Maximum crankcase oscillation in mm

Measuring point ∏
Positioning points 1 2 3 4 5 6 7 8
√
A and G 0.09 0.09 0.17 0.27 0.30 0.27 0.17 0.11
A and B 0.07 0.07
A and C 0.08
B and D 0.08
C and E 0.08
D and F 0.08
E and G 0.08
F and G 0.07
©
200551 11-3
TECHNICAL DATA
0 6
7
5
4
3
2
1 C
A
M200142
Main bearing journals (A)

- standard diameter 97.98 - 98.02 mm
- 1st undersize 97.73 - 98.77 mm
- 2nd undersize 97.48 - 97.52 mm
- 3rd undersize 97.23 - 97.27 mm
The crankshaft must be re-nitrided, having been
ground to undersize for the 2nd time. See the DAF
standard.
Fillet radius 4.5 - 5.0 mm
Width, 1st bearing journal 50.12 - 51.72 mm
Width, 2nd, 3rd, 5th and 6th bearing journals 43.21 - 43.41 mm
Width, 4th bearing journal:
- standard 66.580 - 66.630 mm
- oversize 66.834 - 66.884 mm
Width measurements must remain the same
when grinding to undersize, unless there is
damage. If the axial bearing is damaged at the
point of the middle main bearing, these surfaces
must be re-ground.
Width, 7th bearing journal 63.9 - 64.1 mm
Main bearing shells

Width, 1st and 7th main bearing shells 38.85 - 39.15 mm
Width, 2nd, 3rd, 5th and 6th main bearing shells 31.75 - 32.05 mm
Width, 4th main bearing shell 51.85 - 52.15 mm
Axial thrust washers

Thrust washer thickness:
- standard 2.312 - 2.362 mm
- oversize 2.439 - 2.489 mm
Side clearance 0.06 - 0.32 mm
Connecting rod bearing journals (B)

standard.
Width 50.26 - 50.34 mm
©
11-4 200551
TECHNICAL DATA
Connecting rod bearing journals (B)

XE 335 / XE 390
0
standard.
Width 46.26 - 46.34 mm
Rear oil seal flange (C)

Diameter 153.98 - 154.02 mm
Connecting rods
Diameter, big-head initial bore 92.594 - 92.606 mm
Diameter, small-head bearing bush after reaming 52.031 - 52.039 mm
Distance from centre of big head to centre of
small head 266.67 - 266.73 mm
Big-end bearing shells, normal and cracked

Width 38.5 - 39.0 mm
Bearing play 0.070 - 0.142 mm
Connecting rod bearing shells XE 335 / XE 390

Width 32.5 - 33.0 mm
Bearing play 0.070 - 0.142 mm
Pistons
Groove width:
- top ring Trapezoid
- compression spring 3.22 - 3.24 mm
- oil scraper ring 4.03 - 4.05 mm
Piston rings
Gap clearance (mm) Thickness
(mm)
Top ring 0.35 - 0.50 Trapezoid
Compression spring 1.50 - 2.00 3.13 - 3.15
Oil scraper ring 0.40 - 0.75 3.97 - 3.99
Gudgeon pin
Gudgeon pin diameter 51.992 -52.000 mm
Roller tappet
Bore, standard 36.00 - 36.025 mm
©
200551 11-5
TECHNICAL DATA
External dia: standard 35.94 - 35.96 mm

0 Clearance, roller tappet - roller tappet strip (A)
- setting value 0.2 - 1.0 mm
- permissible 0.2 - 1.4 mm
A
M201196
Camshaft
Diameter, journals 63.188 - 63.212 mm
Inspection measurement, cam height
(distance A):
- inlet 53.58 - 54.46 mm
- exhaust 53.56 - 54.44 mm
Maximum oscillation of 4th bearing journal with
front (1st) and rear (7th) bearing journals
supported. 0.04 mm
©
11-6 200551
TECHNICAL DATA
Camshaft wear table

Distance
covered (km)
Slight wear Average wear Heavy wear 0
Wear surface A (mm2) Wear surface A (mm2) Wear surface A (mm2)
< 300.000 <5 5 - 10 > 10
300.000 - <5 5 - 20 > 20
600.000
> 600.000 < 15 15 - 20 > 40
Repair to be - - Replace roller tappets - Replace roller tappets
carried out and inspect/adjust roller and inspect/adjust roller
tappet clearance. tappet clearance.
- Replace camshaft.
Note:
All wear surfaces occurring on a single cam must
be added up.
a1 + a2 = total surface A
a2
a1
a1 + a2 = A
M2 01 290
©
200551 11-7
TECHNICAL DATA

0
Main bearing caps
Main bearing cap attachment bolts (1)
1st phase 50 Nm
2nd phase 150 Nm
3rd phase 120 angular displacement
Big-end bearing caps

Attachment bolts (1), cracked big-end bearing
caps (2)
1st phase 100 Nm
2nd phase 175 Nm
3rd phase 60 angular displacement
5
1 4
2
3
1
M2 01 285
Attachment bolts, big-end bearing caps (2) (up to

about production week 37, 2002). 1 4
1st phase,
sequence 1-2-3-4 35 Nm
2nd phase,
3rd phase,
sequence 1-2-3-4 60 angular displacement
3 2
M200661
©
11-8 200551
TECHNICAL DATA
Attachment bolts, big-end bearing caps (2)

XE390C/C1
1st phase,
1 4 0
2nd phase,
3rd phase,
sequence 1-2-3-4 60 angular displacement
3 2
M200661
Oil nozzle
Banjo bolt (M10) for oil nozzle 30 Nm
(1) Apply a drop of oil to thread and contact surface.

(2) Connecting rod bolts are to be used once and tightened as instructed.
When fitting the connecting rod in the engine, apply a drop of oil on the thread and bearing face of the connecting rod bolts.
©
200551 11-9
TECHNICAL DATA
©
11-10 200551
DIAGNOSTICS
XE engine Contents
CONTENTS
Diagnostics
Page Date
1. CONSTRUCTION PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551
1.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200551 1
2. ENGINE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551
2.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200551
3. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551
4. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551
5. TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200551

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200551
6. FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200551

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200551
7. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200551

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200551
8. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200551

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200551
9. CYLINDER BLOCK AND DRIVING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200551

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200551
©
200551 1
DIAGNOSTICS
Contents XE engine
©
2 200551
DIAGNOSTICS
1. CONSTRUCTION PARTS
1.1 INTRODUCTION
If there is a fault in the system, it is usually

detected by the electronic unit in the form of a 1
fault code. This fault code can be read out using
DAVIE. The fault-finding table contains possible
causes of symptoms not detected by the
electronic unit.
©
200551 1-1
DIAGNOSTICS
1.2 FAULT-FINDING TABLE
SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS
1 Air filter clogged

Possible cause
Replace air filter
Remedy
Defective turbocharger/incorrect wastegate control Check the turbocharger/wastegate control

Air leak in inlet system Pressure-test the inlet system
SYMPTOM: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED

Possible cause Remedy
Air filter partially clogged. Replace air filter
SYMPTOM: FUEL CONSUMPTION TOO HIGH

Defective turbocharger Check the turbocharger
SYMPTOM: REDUCED MAXIMUM ENGINE SPEED

Defective turbocharger Check the turbocharger
SYMPTOM: EXHAUST BRAKE DOES NOT ENGAGE

Compressor delivering insufficient air pressure. Check the operation of the compressor.
Air leak in the air pipe from air dryer to exhaust Check air pipe.
brake valve.
Butterfly valve stuck in butterfly valve housing. Check free movement of butterfly valve.
Electrical fault. Check electrical circuit.
SYMPTOM: EXHAUST BRAKE REMAINS ENGAGED

©
1-2 200551
DIAGNOSTICS
XE engine Engine brake
2. ENGINE BRAKE
2.1 INTRODUCTION

electronic unit.
©
200551 2-1
DIAGNOSTICS
Engine brake XE engine
SYMPTOM: EXHAUST BRAKE DOES NOT ENGAGE
1 Possible cause
Compressor delivering insufficient air pressure.
Remedy
Check the operation of the compressor.
Air leak in the air pipe from air dryer to exhaust Check air pipe.
brake valve.
SYMPTOM: EXHAUST BRAKE REMAINS ENGAGED

SYMPTOM: DEB DOES NOT ENGAGE

Engine oil pressure too low. Check engine oil pressure.
SYMPTOM: DEB REMAINS ENGAGED

Solenoid valve mechanically blocked. Check solenoid valve.
Damaged solenoid valve sealing rings. Replace all solenoid valve sealing rings.
SYMPTOM: DEB OPERATES IRREGULARLY

Incorrect setting of DEB clearance. Check the DEB clearance.
Main piston stuck in DEB housing. Check free movement of main piston.
Operating piston stuck in DEB housing. Check free movement of operating piston.
Solenoid valve oil strainer is blocked. Clean solenoid valve oil strainer.
Control valve stuck in DEB housing. Check free movement of control valve.
Defective control valve. Check the operation of the control valve.
Lubricating oil too thick. Run the engine at operating temperature.
Lubricating oil diluted with fuel. Check lubricating oil for dilution.
Air bubbles in the oil. Check the engine's oil level/oil specification.
Oil duct sealing plugs in DEB housing. Clean/replace sealing plugs.
©
2-2 200551
DIAGNOSTICS
3. FUEL SYSTEM
3.1 INTRODUCTION

electronic unit.
©
200551 3-1
DIAGNOSTICS
SYMPTOM: ENGINE STARTS, BUT DOES NOT FIRE
1 Poor fuel quality

Drain fuel, flush fuel system, replace the fuel filters
and fill fuel tank with fuel
Air in fuel system Check for drawing in of air:
- via the suction pipe
- via the fuel lift pump seal
Fuel fine filter/coarse filter clogged Replace fuel fine filter and clean the system
No fuel supply/fuel lift pump defective; no delivery Check:
- the fuel level
- the pipes for blockage and leaks
- the fuel lift pump
- the gallery pressure
Pressure relief valve on pump housing does not Check the gallery pressure
shut off
SYMPTOM: ENGINE STALLS AND FIRES AGAIN AFTER RE-STARTING

shut off
SYMPTOM: ENGINE FIRES POORLY

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters
Mechanical defect or clogging in pump units Replace the pump units
Injectors defective Inspect the injectors
shut off
Fuel lift pump delivery too low Check:
- the fuel lift pump and replace if necessary
SYMPTOM: ENGINE RUNS AT (INCREASED) IDLING SPEED AND DOES NOT RESPOND TO
ACCELERATOR PEDAL
Mechanical defect of accelerator pedal sensor Check:
- mechanical connection of sensor/accelerator
pedal
- accelerator pedal sensor
©
3-2 200551
DIAGNOSTICS
SYMPTOM: DIESEL KNOCK DURING ACCELERATION

1
Injector defective Inspect the injectors
SYMPTOM: IRREGULAR RUNNING OF ENGINE AND REDUCED ENGINE POWER

Connection points on pump unit mixed up Connect the correct connection points to the
correct pump unit
- the shut-off valve in the fuel supply pipe
- the fuel pipe for blockage and leaks
SYMPTOM: REDUCED POWER

Mechanical defect of accelerator pedal sensor Check:
- mechanical connection of sensor/accelerator
pedal
- accelerator pedal sensor
shut off

Fuel fine filter/coarse filter partially clogged Replace fuel fine filter and clean the system
©
200551 3-3
DIAGNOSTICS

shut off
1 Fuel lift pump delivery too low Check:
SYMPTOM: WHITE/BLUE SMOKE IS EMITTED

SYMPTOM: BLACK SMOKE IS EMITTED

SYMPTOM: ENGINE OVERHEATED

SYMPTOM: FUEL CONSUMPTION TOO HIGH

Leak in fuel system Check for leaks
SYMPTOM: REDUCED MAXIMUM ENGINE SPEED

Fuel fine filter/coarse filter clogged Replace the fuel filter and clean the system
©
3-4 200551
DIAGNOSTICS
4. COOLING SYSTEM
4.1 INTRODUCTION

electronic unit.
©
200551 4-1
DIAGNOSTICS
SYMPTOM: ENGINE TEMPERATURE INCREASES
1 Possible cause
Incorrect injectors installed
Remedy
Check whether the correct injectors have been
installed
Inlet system failure Check the inlet system
Lubrication system failure Check the lubrication system
Incorrect poly-V-belt tension Check the poly-V-belt tension or replace the poly-
V-belt or poly-V-belt tensioner
Insufficient coolant Check the coolant level. Top up if necessary
Coolant hose torn or clogged Check the coolant hoses
Intercooler and cooling system radiator fouled Check/clean the intercooler and cooling system
radiator
Wastegate setting is too high Check the wastegate setting
Air hose from turbocharger housing to wastegate Check the air hose. Replace if necessary
diaphragm leaks or is not connected
Incorrect or malfunctioning pressure cap Check the pressure cap
Thermostat opens insufficiently or not at all Check the thermostat and its operation
Coolant filter fouled Check the coolant filter Replace, if necessary, and
clean the cooling system
Coolant pump defective Check the coolant pump shaft, bearings and
impeller. Replace the coolant pump if necessary
Viscous fan defective Check operation of the viscous fan
SYMPTOM: EXTERNAL COOLANT LEAKAGE

Coolant hoses defective Check the coolant hoses
Coolant pipes defective Check the coolant pipes
Radiator leaking Check the radiator. Pressure-test if necessary
Coolant pump leaking Check coolant pump. If necessary, measure
bearing play
Defective oil cooler Inspect the oil cooler. Pressure-test if necessary
Defective pressure cap Check the pressure cap. Pressure-test if necessary
Heater leaking Check the heater hoses
Leaking connection between coupling and water Check connection between water pipe and
pipe coupling for damage. Replace the O-rings
©
4-2 200551
DIAGNOSTICS
SYMPTOM: INTERNAL COOLANT LEAKAGE

Defective cylinder head gasket Check the cylinder head gasket
Cracked cylinder heads or cylinder block Check the cylinder heads and cylinder block for
internal cracks. Pressure-test if necessary
1
Leaking injector sleeves Check the cylinder heads Pressure-test if
necessary
Defective compressor cylinder head gasket Replace the compressor cylinder head gasket
Defective oil cooler Check whether there is coolant in the lubrication
system
Defective freeze plugs in tappet area (cylinder Replace the freeze plug(s)
block) or at the top of the cylinder heads
©
200551 4-3
DIAGNOSTICS
©
4-4 200551
DIAGNOSTICS
XE engine Timing gear
5. TIMING GEAR
5.1 INTRODUCTION

electronic unit.
©
200551 5-1
DIAGNOSTICS
Timing gear XE engine
SYMPTOM: NOISE IN THE TIMING GEAR CASE
1 Possible cause
Timing gear damaged Inspect timing gears
Remedy
Timing gear play not correct. Inspect the timing gear play.
Timing gear loose. Inspect the timing gear attachment.
©
5-2 200551
DIAGNOSTICS
XE engine Flywheel and flywheel housing
6. FLYWHEEL AND FLYWHEEL HOUSING

6.1 INTRODUCTION

electronic unit.
©
200551 6-1
DIAGNOSTICS
Flywheel and flywheel housing XE engine
SYMPTOM: ENGINE VIBRATES EXCESSIVELY
1 Possible cause
Imbalance or flywheel oscillation
Remedy
Inspect flywheel oscillation and mounting. See
"Technical data".
©
6-2 200551
DIAGNOSTICS
7. CYLINDER HEAD
7.1 INTRODUCTION

electronic unit.
©
200551 7-1
DIAGNOSTICS
SYMPTOM: CYLINDER HEAD GASKET BLOWN
1 Possible cause
The head gasket was not fitted properly and has
Remedy
Inspect cylinder head and cylinder block.
leaked.
The cylinder head was not tightened according to Inspect the cylinder head and cylinder block for
the specified tightening procedure. damage and fit the cylinder head. Tighten the
cylinder head bolts to the specified torque. See
"Technical data".
One or more threaded holes for securing the Inspect the cylinder block.
cylinder head bolts have been cracked or
damaged.
The height of the cylinder liner above the cylinder Check the fit. See "Technical data".
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.
SYMPTOM: INLET VALVE BROKEN

No valve clearance or negative valve clearance. Inspect the valve clearances.
Inspect and clean the air inlet and exhaust system
thoroughly.
If the valve has punctured 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 has one or more teeth incorrectly Inspect the position of the camshaft gear.
positioned.
SYMPTOM: EXHAUST VALVE BROKEN

Inspect and clean the air inlet and exhaust system
thoroughly.
If the valve has punctured the piston, inspect and
clean the internal section of the engine thoroughly.
Engine speed too high. Inspect the gearbox protection.
The valve is broken as a result of a material Inspect the other exhaust valves.
problem.
positioned.
SYMPTOM: EXHAUST VALVE DISC CRACKED

The valve is cracked as a result of a material Inspect the other exhaust valves.
problem.
©
7-2 200551
DIAGNOSTICS
SYMPTOM: EXHAUST VALVE DISC BURNT

Inspect the other exhaust valves.
1
SYMPTOM: DEB DOES NOT ENGAGE
Engine oil pressure too low. Check engine oil pressure.
SYMPTOM: DEB REMAINS ENGAGED

Solenoid valve mechanically blocked. Check solenoid valve.
SYMPTOM: DEB OPERATES IRREGULARLY

Incorrect setting of DEB clearance. Check the DEB clearance.
Main piston stuck in DEB housing. Check free movement of main piston.
Operating piston stuck in DEB housing. Check free movement of operating piston.
Solenoid valve oil strainer is blocked. Clean solenoid valve oil strainer.
Control valve stuck in DEB housing. Check free movement of control valve.
Defective control valve. Check the operation of the control valve.
Lubricating oil too thick. Run the engine at operating temperature.
Lubricating oil diluted with fuel. Check lubricating oil for dilution.
Air bubbles in the oil. Check the engine's oil level/oil specification.
Oil duct sealing plugs in DEB housing. Clean/replace sealing plugs.
©
200551 7-3
DIAGNOSTICS
©
7-4 200551
DIAGNOSTICS
8. LUBRICATION SYSTEM
8.1 INTRODUCTION

electronic unit.
©
200551 8-1
DIAGNOSTICS
SYMPTOM: ENGINE OIL PRESSURE TOO LOW
1 Possible cause
Engine oil level too low
Remedy
Top up engine oil to maximum level
External oil leaks Visually check the engine for leaks. Repair if
necessary
Oil pressure switch defective Check the switch. Replace if necessary
Oil does not meet the required specifications Change the engine oil and the oil filter
Oil temperature is too high Check the oil cooler
Oil mixed with coolant or fuel Change the engine oil and the oil filter
Oil passage pipe or oil suction pipe loose or broken Check oil pipes. Repair if necessary
Oil pressure control valve fails to operate Check the oil pressure control valve
Inadequate functioning of oil pump Check the oil pump
Main or big-end bearings worn out Check main or big-end bearings
Piston cooler oil nozzle has come loose Check oil nozzle. Replace if necessary
Defective internal oil pressure pipes or seals Check the oil pressure pipes and seals.
Fouling between oil pressure control valve and seat Check/clean the oil pressure control valve
Oil filter fouled Replace the oil filter
SYMPTOM: ENGINE CONSUMES TOO MUCH OIL

Inlet system failure Check the inlet system
Exhaust system failure Check the exhaust system
Oil cooler leaks Check whether there is lubricating oil in the engine
cooling system
Oil temperature is too high Check that the correct oil cooler has been installed
Oil sump pressure too high Check the compression pressure and carry out a
cylinder leak test. Check the condition of the piston
rings and cylinder liners
Worn piston rings and/or cylinder liners Replace the piston rings and/or cylinder liners.
Check the air inlet system. Check the oil
specifications.
Injector O-ring damaged or not present Check the injector seal.
Damaged/worn valve guide Inspect valve guide
Replace the valve guide
Damaged/worn valve stem seal Inspect the condition and mounting of the valve
stem seal
Replace the valve stem seal
©
8-2 200551
DIAGNOSTICS
9. CYLINDER BLOCK AND DRIVING GEAR

9.1 INTRODUCTION

electronic unit.
©
200551 9-1
DIAGNOSTICS
SYMPTOM: VALVE IMPRESSION ON THE BOTTOM OF THE PISTONS
1 Possible cause
No valve clearance or negative valve clearance.
Remedy
Inspect the valve clearances.
Broken valve spring. Inspect the valve springs.
Incorrect valve spring design. Inspect valve spring design.
SYMPTOM: SEVERAL PISTONS SHOW A VALVE IMPRESSION

The valve timing is incorrect. Inspect the valve timing.
A timing gear has come loose. Inspect the timing gears.
The engine is turning at too high an engine speed if Inspect the gearbox protection.
all the exhaust valves have hit the pistons.
positioned.
SYMPTOM: CRACKED PISTON HEAD

Too rich a mixture. Check the engine management system.
Incorrect injection timing. Check the engine management system.
Bad fuel distribution due to poor functioning of Inspect the injectors
injectors.
Fuel injection when engine brake engaged. Check the engine management system.
SYMPTOM: IMPRESSIONS IN THE PISTON HEAD

Broken glow plug. Inspect the glow plugs.
Inspect the other pistons, cylinder liners and valves
for damage.
During repair or maintenance a foreign object has Inspect the other pistons, cylinder liners and valves
entered the combustion chamber via the inlet/ for damage.
exhaust manifold. Inspect the inlet/exhaust system.
SYMPTOM: CYLINDER LINER WORN OUT

Gudgeon pin circlip broken or not fitted. Inspect the pistons.
Piston rings worn due to poor lubrication of the Inspect the dimensions of the cylinder liner and (if
cylinders. necessary) of the cylinder bore. See "Technical
data".
Piston rings worn due to impurities in the air drawn Inspect the air filter and the whole air inlet system.
in.
©
9-2 200551
DIAGNOSTICS
SYMPTOM: PISTON HEAD HAS MELTED

Engine overheating. Inspect the cooling system for the following points:
-
-
-
filling
correct function
fouling
1
- correct type
Inspect the dimensions of the cylinder bore. 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.
SYMPTOM: PITTING ON THE PISTON HEAD

The piston head has hit the cylinder head, as the Inspect whether all pistons have the same damage.
centre-to-centre distance from the crankshaft to the
cylinder head is too small.
Cylinder block has been faced too far.
Big-end bearing worn out. Inspect the big-end bearings.
Small-end bush worn out. Inspect the small-end bush.
SYMPTOM: PISTON RING GROOVE WORN OUT

Broken piston ring. Inspect the other piston rings.
When the ring was being fitted it was bent open too
far, causing a hairline fracture.
The intake air is polluted, causing excessive wear Inspect the whole air intake system.
to the piston rings.
SYMPTOM: PISTON SKIRT WORN OUT AROUND GUDGEON PIN BORE

Fracture or incorrect fitting of the circlip for the Also inspect the other pistons and cylinder liners for
gudgeon pin. damage.
SYMPTOM: PISTON SHOWS SIGNS OF GRATING

If the signs of grating are mostly to be found around Inspect the cooling system for the following points:
the gudgeon pin bores: - filling
overheating of the relevant cylinder due to shortage - correct function
of coolant or air in the cooling system. - fouling
- correct type
Inspect the dimensions of the cylinder bore. See
"Technical data".
Air bubble in the cooling system. Inspect the bleeding system.
©
200551 9-3
DIAGNOSTICS
SYMPTOM: PISTON SHOWS SIGNS OF GRATING

If the signs of grating are mostly to be found on the Inspect the cooling system.
pressure side of the piston: Inspect the dimensions of the cylinder bore. See
1 piston skirt cracked from the gudgeon pin bores. "Technical data".
If the piston shows light signs of grating on the Inspect the cooling system.
pressure side: cold start. Inspect the dimensions of the cylinder bore. See
If a cold engine is brought to a high engine speed "Technical data".
in a short time, the pistons are not sufficiently
cooled/lubricated. This may result in localised
grating.
SYMPTOM: PISTON SKIRT DISCOLOURED

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

Grit in the engine oil. Clean all engine parts.
Engine oil polluted. Check the fit.
As a result, the gudgeon pin wears excessively. See "Technical data".
SYMPTOM: PISTON RINGS WORN

Poor lubrication of the cylinder due to: Inspect the fuel system.
- fuel in the lubricating oil Inspect the cooling system.
- coolant in the lubricating oil Inspect the cylinder liner for signs of wear.
Check the fit.
The piston rings show signs of vertical grating. The See "Technical data".
signs of grating run over the whole diameter of the
piston rings.
The intake air is polluted, causing excessive wear Inspect the whole air intake system.
to the piston rings.
©
9-4 200551
DIAGNOSTICS
SYMPTOM: CONNECTING ROD BENT

Fluid stroke. Check:
A layer of water has settled above the piston due to:
1. the presence of water in the air filter because
of:
-
-
whether the head gasket has blown
the cylinder head for cracks 1
- cleaning with water Inspect whether the water leakage has lasted for
- driving through very deep water some time.
2. the head gasket leaking or the cylinder head or Inspect the cylinder block and driving gear for
cylinder block being cracked consequential damage.
During repair or maintenance oil has entered the

cylinder.
SYMPTOM: TAPPET ROLLERS BROKEN OR CRACKED

If all exhaust tappet rollers have been broken: too Inspect the gearbox protection.
high an engine speed
The corresponding valve is stuck. Inspect the valves.
Roller tappet has grated. Inspect the roller tappet for signs of grating.
Faulty roller tappet fitted. Inspect the diameter of the roller tappet.
SYMPTOM: TAPPET ROLLER SHOWS SIGNS OF PITTING

The roller tappets have been subjected to a heavy In the event of heavy pitting, re-use is no longer
load due to very intensive mechanical contact. With permitted.
this load in combination with lubrication problems, Inspect camshaft for damage.
pitting can occur. Check the clearance between roller tappet and
roller tappet strip.
SYMPTOM: BEARING SHELLS EXCESSIVELY WORN

Thinning of lubricating oil due to coolant. Inspect the oil cooler.
Inspect the cylinder block and cylinder heads for
cracks or blown head gasket by pressure-testing
the cooling system.
Inspect the bearing journals for damage and
dimensions. See "Technical data".
Inspect and clean the lubrication system.
Thinning of lubricating oil due to fuel. Check the fuel system. Inspect the bearing journals
for damage and dimensions. See "Technical data".
©
200551 9-5
DIAGNOSTICS
SYMPTOM: BEARING SHELLS EXCESSIVELY WORN

Polluted lubricating oil due to: Inspect the bearing journals for damage and
- polluted oil filter dimensions. See "Technical data".
1 -
-
too long an interval between oil changes
too long an interval between oil filter changes
If the bearing journals show grooves, the
crankshaft must be replaced or ground.
- excessive fouling within the period between Inspect and clean the lubrication system.
replacements
- wear swarf 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 Inspect the bearing journals for damage and
- oil level too low dimensions. See "Technical data".
- oil not topped up If the bearing journals show grooves, the
- excessive oil consumption 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

big-end bearings will be first to increase, as these
are further away from the oil pump than the main
bearings.
No lubricating oil due to: Inspect the bearing journals for damage and
- loosened or non-fitted oil drain plug dimensions. See "Technical data".
- clogging of the oil channel If the bearing journals show grooves, the
- bearing mounted incorrectly crankshaft must be replaced or ground.
In case of sudden loss of oil, damage to the main
bearings will be first to occur, as these will
immediately receive no more oil.
SYMPTOM: BEARING SHELL SHOWS TRACES OF GROOVES

During installation dirt has come between the Inspect the bearing journals for damage and
bearing shell and the initial bore of the main bearing dimensions. See "Technical data".
or the connecting rod. If the bearing journals show grooves, the
crankshaft must be replaced or ground.
SYMPTOM: CAMSHAFT SHOWS SIGNS OF PITTING

Dirt has got between the camshaft and the roller Check the camshaft and roller tappets for damage.
tappet during the fitting operation. For the camshaft rejection standard, see
"Technical data".
Clearance between roller tappet and roller tappet Check the clearance and adjust if possible. See
strip is too great. "Technical data".
©
9-6 200551
CONSTRUCTION PARTS
XE engine Contents
CONTENTS
Construction parts
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

1.1 Overview drawing, turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551
1.2 Overview drawing, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200551
1.3 Overview drawing, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200551
2. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Inspection and adjustment, V-belt tension. . . . . . . . . . . . . . . . . . . . . . . . .
2-1 . . . . .
2-1 . . . . .
200551
200551
2
2.2 Inspection of automatic poly-V-belt tensioner . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200551
2.3 Inspection and adjustment, turbocharger wastegate . . . . . . . . . . . . . . . . . 2-5 . . . . . 200551
2.4 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . 200551
2.5 Checking glow element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 . . . . . 200551
3. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551

3.1 Removal and installation, glow plugs/glow element . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551
3.2 Removal and installation, turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200551
3.3 Removal and installation, intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200551
3.4 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . 200551
3.5 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . 200551
3.6 Removal and installation, V-belt/poly V-belt . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . 200551
3.7 Removal and installation, fan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . 200551
3.8 Removal and installation, up-speed bearing block . . . . . . . . . . . . . . . . . . 3-11 . . . . 200551
3.9 Removal and installation, vibration damper. . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . 200551
3.10 Removal and installation, vibration damper hub . . . . . . . . . . . . . . . . . . . . 3-15 . . . . 200551
4. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551

4.1 Disassembly and assembly, up-speed bearing block . . . . . . . . . . . . . . . . 4-1 . . . . . 200551
4.2 Disassembly and assembly, V-belt tensioner . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200551
©
200551 1
CONSTRUCTION PARTS
Contents XE engine
©
2 200551
CONSTRUCTION PARTS
XE engine General
1. GENERAL
1.1 OVERVIEW DRAWING, TURBOCHARGER
4 2
2
6
3
7
15 8
14 10 1
11
13
12 9
M2 01 291
1. Turbocharger 9. Gasket, oil pipe

2. Wastegate 10. Gasket, oil pipe
3. Stud bolt 11. Supply oil pipe
4. Hose clamp 12. Copper ring
5. Flexible connection pipe 13. Banjo bolt
6. Exhaust gasket 14. Copper ring
7. Gasket, oil pipe 15. Banjo bolt
8. Flexible return oil pipe
©
200551 1-1
CONSTRUCTION PARTS
General XE engine
1.2 OVERVIEW DRAWING, EXHAUST MANIFOLD
2 2
9 8
3
6
5
4
M200778
1. Heat shield, flywheel end 6. Exhaust gasket

2. Turbocharger heat shield 7. Spacer sleeve
3. Heat shield, timing gear end 8. Manifold, flywheel housing end
4. Manifold, timing gear end 9. Manifold, turbocharger
5. Sealing springs (not on XE ... C1)
©
1-2 200551
CONSTRUCTION PARTS
XE engine General
1.3 OVERVIEW DRAWING, FAN DRIVE
1 2 3 4 5 6 7 8 9 10 11 12 13
M200671
1. Fan drive shaft 8. O-ring

2. Oil seal 9. Bearing
3. Bearing 10. Circlip
4. Bearing ring 11. Bearing housing
5. Spacer sleeve 12. Gear wheel
6. Intermediate ring 13. Circlip
7. Bearing ring
©
200551 1-3
CONSTRUCTION PARTS
General XE engine
©
1-4 200551
CONSTRUCTION PARTS
XE 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 tension O

APBTLIB
EEUL
TI
gauge. The advantage of this method is a more N.2

00
accurate pre-tension reading and consequently LBS

.50
600
the service life of the V-belt and other parts can

2
100
be extended. 150
There are two types of belt tension gauge: O

APBT
LIBEE
"Krikit I", a belt tension gauge for single belt

ULTII
N.5
00
versions (DAF no. 1240442). "Krikit II", a belt LBS

.100 150
tension gauge for twin-belt versions

0
200
(DAF no. 1240443).

300
The difference between the "Krikit I" and

"Krikit II" belt tension gauges 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
measuring arm (1). 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 stylus move.
M2091
©
200551 2-1
CONSTRUCTION PARTS
Inspection and adjustment XE engine
4. Take the reading as indicated by the position

of the measuring arm in relation to the scale.
Compare this reading with the
recommended pre-tension. See "Technical
data".
2
M2062
Adjusting V-belt tension of air conditioning

compressor drive
1. Slacken the upper attachment bolt (1) of the
compressor.
1
2. Slacken the lower attachment bolt (2) of the 1
compressor.
3. Loosen the attachment bolt of the threaded

spindle which is attached to the coolant
pump.
4. Shift the compressor using the lock nuts (3)

until the correct V-belt tension is achieved. 3
Types XE ... C 2 M2041
Adjusting V-belt tension of coolant pump and

alternator drive
1. Loosen the lower attachment bolt (1) of the
alternator. 3 5 4
2. Loosen the upper attachment bolt (2) of the
alternator.
3. Loosen the attachment bolt (3) of the

threaded spindle that is fixed to the coolant
pump. 2
4. Turn the lock nuts (4 and 5) of the threaded
spindle, so that the correct V-belt tension is
reached. See "Technical data".
M200550
©
2-2 200551
CONSTRUCTION PARTS
Adjusting V-belt tension of fan drive (up-

speed fan).
1. Slacken the central nut (6) of the tensioner.
2. Using bolt (7), move the tensioner so that the

correct V-belt tension is achieved; see
"Technical data".
2
3. Tighten the central nut (6) of the tensioner.
7 6
D000388
©
200551 2-3
CONSTRUCTION PARTS
2.2 INSPECTION OF AUTOMATIC POLY-V-BELT TENSIONER
Inspection of automatic poly-V-belt tensioner

1. Remove the poly-V-belt and switch off the
automatic tensioner (0). See "Removal and
installation".
2. Place a torque wrench on the hexagonal

2 head of the automatic tensioner.
0
3. At the specified torsional distance (A) the
torsional moment must have a certain value.
The automatic tensioner must be replaced if
the measured value is not the same as the
check value.
4. Fit the poly-V-belt. See "Removal and

installation".
M201274
©
2-4 200551
CONSTRUCTION PARTS
2.3 INSPECTION AND ADJUSTMENT, TURBOCHARGER WASTEGATE
1. Remove the heat shield from the

turbocharger. 1 2 4 3
2. Remove the air supply connector (1) from

the diaphragm housing (2).
3. Remove the retaining clip (3) and remove the

control rod (4) from the wastegate lever. 2
I400532
4. Using a reducer valve, apply the specified

adjusting pressure to the connection with the 2
diaphragm housing (see "Technical data").
5. Push the wastegate lever (5) fully to the left 4

to close the wastegate valve. 5
6. Adjust the length of the control rod (4),
making sure it fits exactly onto the lever at
the set pressure.
2
1
3
7. Inspect the adjustment of the wastegate 0
4
using the specified pressure. See ‘Technical

data’.
i 400214
8. Fit the retaining clip (3).
©
200551 2-5
CONSTRUCTION PARTS
2.4 CHECKING GLOW PLUGS
1. Check the glow plug for the following points: C

- windings that have worn thin due to
abrasion (A);
- coil end broken or worn thin due to
continuous knocking of a loose
insulator (B);
2 - broken coil windings (C).
A B
2. Replace all glow plugs if one or more of the
above-mentioned situations occur.
yy;yy
;;
;yy
;;
A
M200818
©
2-6 200551
CONSTRUCTION PARTS
2.5 CHECKING GLOW ELEMENT
Checking glow element

1. Remove the electrical connections on the
glow element.
2. Using a multimeter, determine the resistance

of the glow element. See "Technical data".
3. Check whether the glow element is 2

damaged.
©
200551 2-7
CONSTRUCTION PARTS
©
2-8 200551
CONSTRUCTION PARTS
XE engine Removal and installation
3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, GLOW PLUGS/GLOW ELEMENT
The XE ... C engine is fitted with glow plugs.

The XE ... C1 engine can be fitted with a
glow element.
Removing glow plugs/glow element
1. Remove the wiring and connection strip from 2
the glow plugs or the glow element.
2. Remove the glow plugs or the glow element
3. Inspect the glow plugs or the glow element

for damage. See "Inspection and
adjustment".
M200949
Installing glow plugs/glow element

1. Fit the glow plugs or the glow element and
tighten to the specified torque. See
"Technical data".
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 or the glow element earth strip to
ensure that it is properly earthed on the inlet
manifold.
M201169
©
200551 3-1
CONSTRUCTION PARTS
Removal and installation XE engine
3.2 REMOVAL AND INSTALLATION, TURBOCHARGER
} If parts are missing or broken when

the turbocharger is removed and/or
lubricating oil has entered the intake
system, the intake and exhaust
systems must be checked and
cleaned thoroughly in order to
2 prevent serious damage to the
engine.
Removing turbocharger
1. Detach the charge pipe (1).
2 3 1 7 6 4 5
2. Remove the turbocharger heat shield (6) and
the exhaust brake heat shield (5).
3. Remove the turbocharger oil supply and

discharge pipes from the engine block.
4. Disconnect the air connection from the

exhaust brake cylinder (8).
5. Remove the exhaust brake (4) if necessary.

(This can also be done after the
turbocharger, including exhaust brake, has
been removed from the exhaust manifold.)
If the exhaust brake stays attached, the
clamping strip of the exhaust pipe (3) needs
to be loosened. 8
i400671
6. Remove the turbocharger (7) from the
exhaust manifold flange.
Installing turbocharger
Before installing the turbocharger, check the
following:
- The turbocharger shaft must rotate freely.
- The turbocharger shaft must not run out of
true.
- The turbocharger shaft must have some
radial clearance.
- If applicable: movement of the wastegate.
- Clean the sealing surfaces.
- Apply a layer of Copaslip to the exhaust
manifold studs.
- Always use new gaskets during installation.
©
3-2 200551
CONSTRUCTION PARTS
1. Fit the exhaust brake (4) (if removed).

2 3 1 7 6 4 5
2. Install the turbocharger (7) on the exhaust
manifold flange and tighten the attachment
nuts to the specified torque. See "Technical
data". If necessary, turn the two halves of the
housing so that the oil and air pipes can be
connected free of stress.
3. Attach the exhaust pipe (3) to the exhaust

brake (4) using the clamping strap.
2
4. Fasten the air pipe of exhaust brake
cylinder (8).
5. Fit the oil discharge pipe.
6. Pour clean engine oil into the oil supply of the 8

turbocharger and fit the oil supply pipe. i400671
7. Fit the charge pipe (1).
8. Install the heat shields (6) and (5) and tighten

the attachment bolts to the specified torque.
9. Fit the sealing plate.
10. Always check the setting of the wastegate:

see "Inspection and adjustment".
©
200551 3-3
CONSTRUCTION PARTS
3.3 REMOVAL AND INSTALLATION, INTAKE MANIFOLD
Removing the intake manifold

1. Disconnect the electrical wiring on the inlet
manifold.
2. Remove the fuel leak-off pipe between the

fuel filter and inlet manifold.
2 3. Remove the coolant filter, if applicable.
4. Remove the entire fuel filter from the inlet

manifold.
5. Disconnect the injector pipes.
6. Unscrew the attachment bolts from the

intake manifold and remove it.
Installing the intake 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 injector pipes.
5. Fit the complete fuel filter.
6. Fit the coolant filter.
7. Connect the electrical wiring.
©
3-4 200551
CONSTRUCTION PARTS
3.4 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD
Removing exhaust manifold

1. Take the exhaust brake cylinder (8) off the
butterfly valve (4). 2 3 1 7 6 4 5
2. Remove the clamping strip from the exhaust

brake (4).
3. Remove the air inlet hose (2). 2

4. Remove the charge pipe (1) between the
turbocharger and the intercooler.
5. Remove the heat shields from the exhaust

manifold.
6. Remove the oil supply and oil discharge

pipes from the turbocharger.
7. Remove the attachment bolts from the 8

exhaust manifold and remove the manifold i400671
along with the turbocharger.
Installing exhaust manifold

1. Fit new gaskets to the exhaust manifold and
install the manifold. Tighten the attachment 2 3 1 7 6 4 5
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 oil discharge pipe for the

turbocharger.
4. Spray clean engine oil into the oil supply of

the turbocharger and fit the oil supply pipe.
5. Fit the charge pipe (1) between the

turbocharger and the intercooler.
8
6. Fasten the clamping strip of the exhaust i400671
brake (4).
7. Fit the exhaust brake cylinder (8) onto the

butterfly valve (4).
©
200551 3-5
CONSTRUCTION PARTS
3.5 REMOVAL AND INSTALLATION, AIR COMPRESSOR
Removing air compressor

1. Remove the coolant connections (1). 2 3 1
2. Disconnect the air pipes (2) and (3).
3. Disconnect the lubricating oil pipe. 1

2 4. Disconnect the service pipe that comes from
the air dryer.
5. Remove the mounting bracket at the rear of

the compressor.
6. Remove the attachment bolts from the

timing-gear cover.
7. Remove the compressor from the timing

case. Remove the O-ring from the
compressor housing.
Installing air compressor

1. Fit a new O-ring on the compressor housing
and fit the compressor against the timing
case.
2. Fit the air compressor attachment bolts.

Tighten the attachment bolts to the specified
3. Fit the mounting bracket at the rear of the

compressor. Tighten the attachment bolts to
4. Fit the service pipe.
5. Fit the lubricating oil pipe. R600246
6. Fit the air pipes (2) and (3).
7. Fit the coolant pipes (1).
©
3-6 200551
CONSTRUCTION PARTS
3.6 REMOVAL AND INSTALLATION, V-BELT/POLY V-BELT
Removing V-belt of air conditioning

compressor drive
1. Remove the V-belt (or poly V-belt) from the
water pump and alternator drive.
2. Slacken the upper attachment bolt (1) of the

compressor.
1 2
3. Slacken the lower attachment bolt (2) of the 1
compressor.
4. Loosen the attachment bolt of the threaded

spindle which is attached to the coolant
pump.
5. Turn the lock nuts (3) on the threaded

spindle so that the compressor tilts towards 3
the cylinder block and the V-belt can be
removed.
2
Installing V-belt of air conditioning
M2041
compressor drive
1. Inspect the pulleys for damage, rust and
grease deposits.
2. Fit the V-belt for the air conditioning

compressor drive and adjust the V-belt
tension. See "Inspection and adjustment".
3. Install the V-belt (or poly V-belt) for the water

pump and alternator drive and adjust the V-
belt tension. See "Inspection and
adjustment".
Types XE ... C
Removing V-belt of water pump and alternator
drive
1. Loosen the lower attachment bolt (1) of the
alternator. 5 4
2. Loosen the upper attachment bolt (2) of the
2
alternator. 3
3. Loosen the attachment bolt (3) of the
threaded spindle that is fixed to the water
pump.
4. Turn the lock nuts (4) and (5) on the threaded

spindle so that the alternator can be tilted
towards the cylinder block and the V-belt can
be removed. 1
M200738
©
200551 3-7
CONSTRUCTION PARTS
Installing V-belt of water pump and alternator

drive
grease deposits.
2. Fit the new V-belt and adjust the V-belt

2
Removing fan drive V-belt (up-speed version)
1. Slacken the central nut (6) of the tensioner.
2. Turn bolt 7 to move the tensioner until the V-

belt can be removed.
3. Tighten the central nut (6) of the tensioner.
Installing fan drive V-belt (up-speed version)

grease deposits. If necessary, clean them
thoroughly.
2. Fit the new V-belts and adjust the V-belt

7 6
D000388
©
3-8 200551
CONSTRUCTION PARTS
Removing poly V-belt

1. Move the tensioner against the spring force
and lock it with a 4 to 5 mm thick pin (drill).
2. Loosen the connector of the electric fan

clutch, if fitted, and remove the wiring from
the bracket.
3. Take the poly V-belt off over the fan.
4. Inspect the automatic tensioner. See

2
"Inspection and adjustment".
M201275
Installing poly V-belt

grease deposits.
2. Fit the poly V-belt over the fan.
3. Pull the poly V-belt over the coolant pump,

fan drive and alternator pulleys and push it
between the pulleys in the direction of the
tensioner.
4. Move the tensioner against the spring

tension and fit the poly V-belt.
5. If applicable, fit the electric fan clutch

connector and connect the wiring, ensuring
that it is clear of moving parts.
M201066
©
200551 3-9
CONSTRUCTION PARTS
3.7 REMOVAL AND INSTALLATION, FAN DRIVE
Removing fan drive

1. Remove the V-belts (or poly V-belt) from the
water pump, alternator and fan drives.
2. Remove the fan drive attachment nuts.
2 3. Remove the fan drive.
Installing fan drive

1. Fit a new lightly greased O-ring (8) in the
groove of the bearing housing (11).
2. Apply engine oil to the bearings in the

bearing housing.
3. Fit the fan drive in the timing case. Tighten

the attachment nuts crosswise to the
4. Fit the V-belts/poly V-belt. Fit the viscous fan

clutch with the fan.
5. Adjust the V-belt tension. See "Technical

data".
1 2 3 4 5 6 7 8 9 10 11 12 13
M201301
©
3-10 200551
CONSTRUCTION PARTS
3.8 REMOVAL AND INSTALLATION, UP-SPEED BEARING BLOCK
Removing up-speed bearing block

1. Remove the fan drive V-belt.
2. Remove the attachment bolts (5) of the up-

speed bearing block/vibration damper from
the flange (13) in the bearing block through
the opening in the up-speed pulley (10).
2
3. Remove the up-speed bearing block.
Installing up-speed bearing block

1. Fit the up-speed bearing block. Tighten the 6
attachment bolts (5) to the specified torque. 7
2. Fit the new V-belt and adjust the V-belt 4

10
8
9 11 12 13 5 2 3 1 14
M200947
©
200551 3-11
CONSTRUCTION PARTS
3.9 REMOVAL AND INSTALLATION, VIBRATION DAMPER
Version with direct fan drive V-belt

Removing vibration damper
1. Remove the V-belt of the coolant pump and
alternator drive.
2 2. Remove the attachment bolts (7) of the fan

flange/vibration damper.
3. Remove the vibration damper (4).
Installing vibration damper

1. Check the vibration damper for external 4
damage and silicone liquid leaks. In the 1
event of damage or leaks, the vibration
damper should be replaced. 2
3
2. Fit the vibration damper (4) and the fan
flange (5). Tighten the attachment bolts (7) to
5
6
7
M200946
Version with direct fan drive poly V-belt

1. Remove the poly V-belt from the coolant
pump and alternator drive.
2. Remove the attachment bolts (5) of the fan

flange/vibration damper.
3. Remove the vibration damper (4). 8

Installing vibration damper 9
1. Check the vibration damper for external
event of damage or leaks, the vibration 3
damper should be replaced.
2. Fit the vibration damper (4) and the fan

5
flange (6). Tighten the attachment bolts (5) to 4
the specified torque. See "Technical data". 1
2
3. Fit the poly V-belt.
6
M201288
©
3-12 200551
CONSTRUCTION PARTS
Version with separate fan drive

1. Remove the poly V-belt or V-belt from the
Types XE ... C
coolant pump and alternator drive.
2. Remove the attachment bolts (9) of the fan

pulley.
3. Remove the fan pulley (6).

2
4. Remove the attachment bolts (5) of the
vibration damper.
8
9
7
6
5
4
3
2
1
M200945

damage and silicone liquid leaks. In the Types XE ... C1
event of damage or leaks, the vibration
damper should be replaced. 10
2. Fit the vibration damper (4). Tighten the

attachment bolts (5) to the specified torque. 8
9
3. Fit the fan pulley (6) to the fan drive. Tighten
the attachment bolts (9) to the specified
torque. See "Technical data". 7
6
4. Fit the poly V-belt or V-belt and adjust the
V-belt tension. See "Inspection and 5
adjustment".
4
3
2
1
M201153
©
200551 3-13
CONSTRUCTION PARTS
Version with up-speed fan drive

1. Remove the V-belt from the water pump,
alternator and up-speed drive.
2. Remove the attachment bolts (7) of the

V-belt pulley.
2 3. Remove the fan pulley (6).
4. Via the opening in the up-speed pulley (10),

remove the attachment bolts (5) of the up-
speed bearing block/vibration damper. 6
7

4
event of damage or leaks, the vibration 8
damper should be replaced.
2. Fit the vibration damper (4) and the

up-speed bearing block. Tighten the
attachment bolts (5) to the specified torque.
3. Fit the V-belt pulley (6) and tighten the

attachment bolts (7) to the specified torque. 9 11 12 13 5 2 3 1 14
See "Technical data". M200947

©
3-14 200551
CONSTRUCTION PARTS
3.10 REMOVAL AND INSTALLATION, VIBRATION DAMPER HUB
Removing the vibration damper hub

1. Remove the vibration damper.

vibration damper hub and remove the thrust
piece.
} In most cases the vibration damper 2

hub will suddenly break off from the
crankshaft during removal. Avoid
personal injury and damage to the
hub.
3. Remove the vibration damper hub (1) using 1

the special tool (2) (DAF no. 1453155).
Installing the vibration damper hub 2

1. Fit the vibration damper hub (1) onto the
crankshaft.
2. Fit the thrust piece. Tighten the attachment

bolts to the specified torque. See "Technical
data". M2 01 300
3. Install the vibration damper. Fit the thrust

piece. Tighten the attachment bolts to the
©
200551 3-15
CONSTRUCTION PARTS
©
3-16 200551
CONSTRUCTION PARTS
XE engine Disassembly and assembly
4. DISASSEMBLY AND ASSEMBLY

4.1 DISASSEMBLY AND ASSEMBLY, UP-SPEED BEARING BLOCK
Disassembling up-speed bearing block
1 2 3 5 7 4 6
M200803
1. Remove the central bolt (1) from the bearing
block.
2. Take the up-speed pulley (5) from the hub (if

necessary use a standard puller).
3. Remove the bearings (3) and (4) from the

pulley (5).
4. If necessary remove the circlip (7) from the

pulley (5).
©
200551 4-1
CONSTRUCTION PARTS
Disassembly and assembly XE engine
Assembling up-speed bearing block
A 3 7 5 3 B
M200804
1. Clean the up-speed pulley (5).
2. Fit the circlip (7) in the up-speed pulley (5)

(if removed).
3. With a low force, press the rear bearing into

the up-speed pulley using the special tool (B)
(DAF no. 1329436).
4. With a low force, press the front bearing into

the up-speed pulley using the special tool (A)
(DAF no. 1329437).
5. Fit the up-speed pulley on the hub.
6. Fit the circlip and central bolt and place the

bearing block assembly on the vibration
damper.
7. Tighten the bolt to the specified torque. See

"Technical data".
©
4-2 200551
CONSTRUCTION PARTS
4.2 DISASSEMBLY AND ASSEMBLY, V-BELT TENSIONER
Disassembling V-belt tensioner

1. Remove the central nut (6) of the tensioner
pulley.
2. Remove the circlip.
3. Remove the pulley.

2
4. Remove the bearing from the hub.
Assembling V-belt tensioner

1. Fit the circlip to the pulley.
2. With a low force, press the bearing into the

pulley.
3. Fit the pulley on the hub. 7 6
4. Fit the nut.

D000388
©
200551 4-3
CONSTRUCTION PARTS
©
4-4 200551
FUEL SYSTEM
XE engine Contents
CONTENTS
Fuel system
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

1.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551
1.2 Overview drawing, pump housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200551
2. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551

2.1 Checking injector opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551
2.2 Adjusting injector opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200551
2.3 Checking injector operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . 200551
2.4 Checking fuel lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Checking pump housing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6 . . . . .
2-8 . . . . .
200551
200551 3
2.6 Checking pump housing roller tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 . . . . . 200551
2.7 Checking pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 . . . . . 200551

3.1 Removal and installation, fuel injection pipe . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551
3.2 Removal and installation, injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200551
3.3 Removal and installation, pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . 200551
3.4 Removal and installation, pump housing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . 200551
3.5 Removal and installation, fuel lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 . . . . 200551

4.1 Disassembly and assembly, injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551
4.2 Disassembly and assembly, pump housing. . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200551
5. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200551

5.1 Cleaning injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200551
©
200551 1
FUEL SYSTEM
Contents XE engine
©
2 200551
FUEL SYSTEM
XE engine General
1. GENERAL
1.1 LOCATION OF COMPONENTS
Types XE ... C
6
7
3
8 10 3
9
1 11
12 13
i400390
1. Pump units 8. Primer pump suction pipe

2. Pump housing 9. Fuel lift pump - primer pump pipe
3. Fuel fine filter (threaded filter) 10. Fuel lift pump
4. Fuel fine filter return pipe 11. Pressure relief valve
5. Pump housing return pipe 12. Primer pump with fuel coarse filter
6. Fuel fine filter - pump housing pipe 13. Leak-off pipe
7. Fuel lift pump - fuel fine filter pipe
©
200551 1-1
FUEL SYSTEM
General XE engine
Types XE ... C1
3 5
7 2 4 6
i4 00 683
1. Pump units 5. UPEC ECU

2. Pump housing 6. Primer pump
3. Fuel fine filter (filter element) 7. Pressure relief valve
4. Fuel lift pump
©
1-2 200551
FUEL SYSTEM
XE engine General
1.2 OVERVIEW DRAWING, PUMP HOUSING
Version XE ... C
1
2
3
5
6
3
4 11
10
9 8
10
11
12
13 14 24
15
16
17 23
18
21
19
20 22
i400418
1. Lift pump 13. O-ring

2. Cover 14. Cylindrical pin
3. O-ring 15. Pump housing
4. Cylindrical pin 16. Slide bearing, pump housing
5. Camshaft sensor drive flange/pulse disc 17. Cover gasket
6. Pump unit 18. Cover
7. Tappet 19. Thrust washer
8. O-ring 20. Pump housing camshaft gear
9. Positioning pin 21. Slide bearing, pump housing
10. Copper ring 22. Locking plate
11. Sealing plug 23. Flat sunk key
12. Expansion stop 24. Pump housing camshaft
©
200551 1-3
FUEL SYSTEM
General XE engine
Version XE ... C1
10
11
10
2
11
10
3 6
4
4
7
8
9
10 3 1
11
5
12
14
13
15
24
16
17
18
21
23
20
22
19
i400676
©
1-4 200551
FUEL SYSTEM
XE engine General
1. Fuel lift pump with primer pump 13. O-ring

2. Fuel temperature sensor 14. Cylindrical pin
3. O-ring 15. Pump housing
4. Cylindrical pin 16. Slide bearing, pump housing
5. Camshaft sensor drive flange/pulse disc 17. Cover gasket
6. Pump unit 18. Cover
7. Tappet 19. Thrust washer
8. O-ring 20. Pump housing camshaft gear
9. Positioning pin 21. Slide bearing, pump housing
10. Copper ring 22. Locking plate
11. Sealing plug 23. Flat sunk key
12. Expansion stop 24. Pump housing camshaft
3
©
200551 1-5
FUEL SYSTEM
General XE engine
©
1-6 200551
FUEL SYSTEM

2.1 CHECKING 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.
1. Remove the fuel injector pipes as a set and

close the connections on the pump units
immediately.
3
Note:
The opening pressure of the injectors can be
tested using an injector test pump
(DAF no. 0694966). The advantage of this
method is that the injectors need not be
removed from the engine.
2. Check the opening pressure of the injectors.
Instructions for the use of the injector test

pump
1. Before the injector test pump is used, it must
first be bled.
Remove the pump reservoir filler plug and fill
the reservoir with test fluid. The fluid level
must be approximately 1 cm below the top
rim.
2. Tilt the pump until the line with the word

"BLEED" is horizontal.
BLEED
M4059
©
200551 2-1
FUEL SYSTEM
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 cap.
3 5. The pump is now ready for use. 2 M4058
Checking opening pressure with an injector

test pump
1. Keep the test pump more or less horizontal.
2. Loosen the test pump filler cap by half a turn

so that air can enter the reservoir.
3. Turn the test pump crank clockwise. The

compression will now start. Watch the fluid
level in the test pump.
4. Carefully determine the opening pressure of

the injector. There is no harm in repeating
the test two or three times.
} If the test is repeated too often, i 400190
however, the test fluid deposited on

the piston may cause damage to the
engine when it is started.
©
2-2 200551
FUEL SYSTEM
2.2 ADJUSTING INJECTOR OPENING PRESSURE
Note:
The injectors may only be adjusted in
combination with XE ... C engines.

suitable container.
©
200551 2-3
FUEL SYSTEM
Adjusting injector opening pressure
Note:
The test pump can also be used to test injectors
outside the engine. The bottom of the test pump
can be clamped in a vice without causing damage
to the test pump.
1. Remove the injector. See "Removal and

installation".
2. Disassemble the injector. See "Disassembly

and assembly".
3 3. Adjust the opening pressure by fitting a
thicker or thinner adjusting ring (1). For
adjustment pressures, see "Technical data".
Note:
An increased ring thickness of 0.01 mm
raises the pressure by approx. 1.5 bar.
4. Assemble the injector. See "Removal and

installation". 1
5. Fit the injector. See "Disassembly and
assembly".
i 400217
©
2-4 200551
FUEL SYSTEM
2.3 CHECKING INJECTOR OPERATION

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 that have been in use for some time
cannot be tested in this way.
3
1. Place the injector on an injector tester.
2. First make the injector inject a number of

times.
3. Check the injector for:

- opening pressure
- leakage
- injector nozzles
Opening pressure
Check the opening pressure by slowly building up
the pressure inside the injector.
Leakage
1. Dry the nozzle immediately after the final
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
on the XE ... C or, on the XE ... C1, the
complete injector must be replaced.
Injector bores
1. Quickly build up pressure in the injector and
check whether all the nozzles are fully open.
©
200551 2-5
FUEL SYSTEM
2.4 CHECKING FUEL LIFT PUMP
Note:
During a general engine overhaul, the fuel lift
pump must be replaced.
Barnes model
Checking fuel lift pump sealing ring

1. Check whether leaks have arisen
through the sealing ring via the pressure 1 A
relief area (2) on the bottom of the fuel
3 lift pump (1).
B
2. If sealing ring A is leaking there will be fuel in
the pressure relief area and if sealing ring B
is leaking there will be engine lubricant in the
pressure relief area.
i 400235
©
2-6 200551
FUEL SYSTEM
LUK version
Checking fuel lift pump sealing ring

1. Check whether leaks have arisen through
the sealing ring via the pressure relief area C D
(10) on the bottom of the fuel lift pump.
2. If oil seal D is leaking there will be fuel in the

pressure relief area and if oil seal C is leaking
there will be engine lubricant in the pressure
relief area.
10 1
I400432
©
200551 2-7
FUEL SYSTEM
2.5 CHECKING PUMP HOUSING CAMSHAFT
Checking pump housing camshaft

1. Disassemble the pump housing. See
"Disassembly and assembly".
2. Inspect the pump housing camshaft for

damage and wear. If necessary, replace the
camshaft.
3. Check the pump housing camshaft bearings

for excessive wear and replace if necessary.
3 See "Technical data".
4. Assemble the pump housing. See

2.6 CHECKING PUMP HOUSING ROLLER TAPPETS
Checking pump housing roller tappets

1. Disassemble the pump housing. See
2. Inspect the roller tappets and the pump

housing for cracking or pitting and check
their dimensions. Replace if necessary. See
"Technical data".
3. Assemble the pump housing. See

2.7 CHECKING PUMP UNITS
Checking pump units
Note:
During a general engine overhaul, the pump units
must be replaced.
©
2-8 200551
FUEL SYSTEM

3.1 REMOVAL AND INSTALLATION, FUEL INJECTION PIPE
}
Removing fuel injection pipe
Always leave the injection pipes
fixed together as a complete set.
Never remove or shift the clamping
brackets (A) holding the pipes
together. Never bend injector pipes
as they may crack.
1. Clean the union nuts and the area around

both the injectors and the pump housing.
A 3
A
A
}
i 400199
When slackening the injection pipe

union nuts, hold the injector's side
connection back using an open-end
spanner. If this is not done, there is a
good chance that the side
connection will leak.
Immediately plug the openings.
2. Remove the fuel injection pipes as a set.
i 400237
©
200551 3-1
FUEL SYSTEM
Installing fuel injection pipe

1. Blow the injector pipes with dry compressed
air.
Then turn the injector side towards the
injectors.
2. Position the set of injector pipes with the

head on the connection of the pump unit (see
diagram).
3. Tighten the union nuts to the pump

connection by hand in the order 1-2-3 or
3
4-5-6.
4. Tighten the union nuts on the injector end by

hand in the order 1-2-3 or 4-5-6.
5. Then tighten the union nuts on the pump end

in the order 1-2-3-4-5-6. Tighten them to the
specified torque, see "Technical data".
6. Tighten the union nuts on the injector end in

the order 1-2-3-4-5-6.
}
i400506
When tightening the injector pipe

union nuts, hold the injector's side
connection back using an open-end
spanner. If this is not done, there is a
good chance that the side
connection will leak.
7. Tighten the injector pipe union nuts to the

specified tightening torque. See "Technical
data".
i 400237
©
3-2 200551
FUEL SYSTEM
3.2 REMOVAL AND INSTALLATION, INJECTOR
} Due to the presence of overpressure

in the fuel tank, fuel may run into the
cylinders when removing injectors.
The tank cap should therefore
always first be removed when
removing injectors. Collect any fuel
from the injectors.
Removing injector
1. Remove the fuel injection pipes as a set.
2. Remove the valve cover. 3

3. Remove the DEB.
4. Remove the attachment bolt (3) from the

injector clamp. To remove the injector and
the clamping piece, only use the special 3
tools (DAF no. 1329412) and
(DAF no. 0694928).
Note: 2
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
the O-ring (2) of the injector and the cylinder
head. Fuel leaking from the injector can flow
freely into the engine and dilute the
lubricating oil.
1
I 400191
©
200551 3-3
FUEL SYSTEM
Installing injector
1. Clean the injector sleeve. See "Cleaning".
2. Fit a new O-ring (1) and a new copper

3
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 it is leaking and/or
damaged.
Note:
Make sure that the injector clamp is installed 4
3 correctly.
1
4. Fit the injector together with the injector
clamp (4) and tighten the attachment bolt to
5. Fit the DEB.
6. Adjust the DEB clearance.
2
i 400183
©
3-4 200551
FUEL SYSTEM
3.3 REMOVAL AND INSTALLATION, PUMP UNIT
} When removing the pump unit, fuel

will escape. Collect this fuel, bearing
in mind the risk of fire.
} Dirt in the fuel system can lead to

significant damage to pump units
and housing.
Removing pump unit

1. Remove the electrical connections from the
pump unit.
3
2. Remove the fuel pipes from the pump
housing.
3. Remove the pressure relief valve from the

pump housing.
4. Let the fuel leak from the pump housing.
5. Remove the injector pipes in sets and plug

the pump units and injectors so that no dirt
can enter.
6. If it is necessary to replace the pump unit(s),

the pump unit must be marked so that it can
be replaced in the same position in the pump
housing.
Note:
The pump unit may be under spring tension,
depending on the position of the camshaft in
the pump housing.
7. Remove the attachment bolts from the pump

unit.
©
200551 3-5
FUEL SYSTEM
8. Remove the pump unit. If necessary use the

special tools (DAF no. 0694928) and
(DAF no. 1329448).
i 400396
©
3-6 200551
FUEL SYSTEM
Installing pump unit
Note:
Damage to the sealing ring could result in the
lubricating oil being diluted.
1. Fit new sealing rings to the pump unit.

Sealing ring (1) has the largest diameter and
sealing ring (3) the smallest.
2. Apply a thin layer of lubricating oil to the

bores in the pump housing for the sealing
rings.
3. Crank the engine until the camshaft in the 6002272-AD028 3

pump housing is in such a position that the
pump unit can be fitted in the pump housing
practically tension free.
4. Apply a thin layer of lubricant to the new

sealing rings and fit the pump unit, without 1
damaging the sealing rings, in the pump
housing. 2
5. Fit the pump unit attachment bolts and
tighten them evenly until the pump unit abuts
the pump housing.
6. Tighten the attachment bolts to the specified 3

7. Fit the pressure relief valve onto the pump

housing.
8. Fit the fuel pipes to the pump housing.
10. Fit the electrical connections to the pump

unit and tighten to the specified torque. See
"Technical data".
i 400221
©
200551 3-7
FUEL SYSTEM
3.4 REMOVAL AND INSTALLATION, PUMP HOUSING
} When removing the pump housing,

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

and housing.
Removing pump housing

3 1. Crank the engine until the valves of
cylinder 6 are in overlap position and the
TDC mark on the flywheel is in the correct
position.
2. Remove the timing cover.
M201185
3. Remove the attachment bolt of the

idler gear (3) and pump housing 2 3
camshaft gear (4).
Note:
When the crankshaft (1) or the camshaft (2)
without idler gear (3) is rotated separately,
the engine's pistons may touch the valves.
4. Remove the idler gear (3).
5. Remove the pump housing camshaft

gear (4).
M200725
©
3-8 200551
FUEL SYSTEM
6. Remove the timing gear seal by tapping it out

of the timing gear case in the driving
direction.

pump units.
8. Remove the fuel pipes from the pump

housing.
9. Remove the pressure relief valve from the

pump housing.
10. Remove the fuel pipes from the fuel lift pump. 3
11. Remove the fuel injection pipes and plug the
pump units and injectors so that no dirt can
enter the system.
M200728
12. Remove the connector from the fuel

temperature sensor (1) (if fitted on the pump
housing).
13. Remove the camshaft position sensor (2).
}
i 400529
The weight of the pump housing

requires the use of the special tool.
14. Fit the lifting gear (DAF no. 1329499) to the

pump housing and tighten the bolts (A).
A A
15. Remove the attachment bolts of the pump
housing and lift the pump housing off the
dowel pins on the engine block using the
lifting gear.
i400601
©
200551 3-9
FUEL SYSTEM
Installing pump housing

1. Fit two new lubricating oil connection sealing
rings.
2. Fit the pump housing using the lifting gear

(DAF no. 1329499). Tighten the attachment
data".
3. Fit the camshaft position sensor.
4. Fit the fuel temperature sensor connector.
3 5. Fit the electrical connections onto the pump

units.
7. Connect the fuel pipes of the fuel lift pump.
8. Fit the pressure relief valve onto the pump

housing.
9. Fit the fuel pipes to the pump housing.
©
3-10 200551
FUEL SYSTEM
10. Fit a dry new timing case seal (6) using the
special tool (DAF no. 1329318). 4 6
11. Check whether cylinder 1 is at top dead
centre (TDC on the flywheel, cylinder 6 in
overlap position).
7
M200841
©
200551 3-11
FUEL SYSTEM
12. Fit the pump housing camshaft gear (4) in

such a position that the idler gear (3) can be
installed in accordance with the marks.
13. Fit the attachment bolts of the pump housing

camshaft gear (4) and the idler gear (3) and
"Technical data".
14. Fit the timing cover.
3
4
2 3
1
M201281
©
3-12 200551
FUEL SYSTEM
3.5 REMOVAL AND INSTALLATION, FUEL LIFT PUMP
} When removing the fuel lift pump,

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

and housing.
Removing fuel lift pump

1. Remove the fuel pipes from the fuel lift pump.
2. Remove the attachment bolts (1) of the fuel

3
lift pump (2).
1 2
i 400251
3. Remove the camshaft sensor (3), if fitted.

3
4. Remove the fuel lift pump.
Installing fuel lift pump 2

1. Check the sealing ring of the fuel lift pump for
damage. If required, replace the sealing ring.
2. Apply lubricating oil sparingly to the fuel lift

pump sealing ring.
3. Fit the fuel lift pump (2) and make sure that
its drive fits together properly.
4. Screw in the attachment bolts evenly and 1

tighten them to the specified torque. See i4 00 675
"Technical data".
5. Fit any camshaft sensor (3) that may have

been removed.
6. Connect the fuel pipes.
©
200551 3-13
FUEL SYSTEM
©
3-14 200551
FUEL SYSTEM

4.1 DISASSEMBLY AND ASSEMBLY, INJECTOR
Note:
Only the injectors on first-generation UPEC
engines (UPEC electronic unit not mounted on
the cylinder block) may be removed!
} The injector side connection (3)

must not be removed from the
injector.
3
©
200551 4-1
FUEL SYSTEM
Disassembing injector
installation". 3
2. Clean the injector. See "Cleaning".
Note:
Do not exchange injector bodies (nozzles) and
injector needles because they constitute a set.
3. Remove the union nut (2), after which the

various parts can be taken from the injector.
3 4. Check that none of the injector parts has

been damaged by the injector needle.
i 400303
©
4-2 200551
FUEL SYSTEM
Assembling injector
1. Immerse the injector needle and the injector
housing in clean diesel fuel. Insert the
injector needle into 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 other parts and immerse them

in clean diesel fuel.
3
Note:
Ensure that there is no diesel fuel on the screw
thread due to the non-lubricating effect of diesel
fuel.
3. 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
©
200551 4-3
FUEL SYSTEM
4.2 DISASSEMBLY AND ASSEMBLY, PUMP HOUSING
} When disassembling the pump

housing, fuel will escape. Collect
this fuel, bearing in mind the risk of
}
fire.
Dirt in the fuel system can lead to

and housing.
Disassembling pump housing

3 1. Remove the pump housing. See "Removal
and installation".
2. Remove the pump units. See "Removal and

installation".
Note:
If the pump units are not replaced in the
same position in the pump housing, they will
have to be re-calibrated.
3. Remove the roller tappets.
4. Remove the fuel lift pump. See "Removal

and installation".
5. Remove the rear cover from the pump

housing, if applicable.
i400381
©
4-4 200551
FUEL SYSTEM
6. Remove the pulse disc (1) and the drive

flange (2) of the pump housing camshaft.
1
3
i400585
i400584
7. Remove the lock plate from the pump

housing camshaft.
Note:
When removing the sealing plates, an
amount of lubricating oil will escape. Collect
this lubricating oil.
8. Remove the sealing plates and the gaskets.
9. Remove the pump housing camshaft by

manoeuvring it vertically out of the pump
housing.
10. Inspect the pump housing camshaft and the

slide bearings for wear and check their
dimensions. See "Technical data".
If necessary, remove the slide bearings
using the special tools (DAF no. 1329444) i400380
and (DAF no. 0535626).
©
200551 4-5
FUEL SYSTEM
i400378
}
Assembling pump housing
When fitting the front slide bearing,
it is important that the oilway in the
bearing housing aligns with the hole
in the slide bearing.
1. If necessary, fit the slide bearings using the

special tools (DAF no. 1329444) and
(DAF no. 0535626).
Note:
To fit the pump housing camshaft, apply a
thin layer of lubricating oil to the bearing
journals. Take care not to damage the
bearing when fitting it.
2. Fit the pump housing camshaft by

manoeuvring it vertically into the pump
housing.
3. Fit new gaskets to the sealing plates, install

the sealing plates and tighten the bolts to the
i400382
©
4-6 200551
FUEL SYSTEM
Note:
When fitting the locking plate, it must not jam
in the pump housing camshaft groove.
4. Fit the locking plate of the pump housing

camshaft and tighten the bolts to the
i400380
5. Fit the drive flange (2) and the pulse disc (3)
and tighten the bolts to the specified torque.
6. Clean the groove in which the O-ring is fitted

and apply a thin layer of lubricating oil.
7. Fit the O-ring.
i400585
i400584
©
200551 4-7
FUEL SYSTEM
8. Fit the rear cover of the pump housing if it

had been removed and tighten the bolts to
9. Fit the fuel lift pump. See "Removal and

installation".
10. Apply a thin layer of lubricating oil to the roller

tappets.
11. Fit the roller tappets. See "Removal and

installation".
3 12. Fit the pump units. See "Removal and

installation".
i400381
©
4-8 200551
FUEL SYSTEM
XE engine Cleaning
5. CLEANING
5.1 CLEANING INJECTOR
} The injector must never be cleaned

with a copper or steel wire brush.
When cleaning the exterior of the
injector nozzle, do not pass the
brush over the injector bores. If this
happens, the injector must be
replaced.
Injector bores 3
The use of steel or copper brushes can cause
deformation of the injector bores with the result
that the fuel is not injected in the correct way and
the amount of fuel injected is affected.
Such deformation cannot be detected by carrying
}
out the normal injector test.
The injector bores must not be
cleaned (with a needle).
M2 00 040
Nozzle
Cover the injector bores before cleaning the
nozzle and clean with a brass hand brush only.
i 400413
©
200551 5-1
FUEL SYSTEM
Cleaning XE engine
©
5-2 200551
COOLING SYSTEM
XE engine Contents
CONTENTS
Cooling system
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

1.1 Overview drawing, thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

2.1 Inspecting the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551
2.2 Inspection, coolant pump radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200551

3.1 Removal and installation, coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551
3.2 Removal and installation, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200551
©
200551 1
COOLING SYSTEM
Contents XE engine
©
2 200551
COOLING SYSTEM
XE engine General
1. GENERAL
1.1 OVERVIEW DRAWING, THERMOSTAT HOUSING
A. O-ring
B. Oil seal
C. Thermostat seat
A
C B
4
C B
A
M200594
©
200551 1-1
COOLING SYSTEM
General XE engine
©
1-2 200551
COOLING SYSTEM

2.1 INSPECTING THE THERMOSTAT
1. Remove the thermostat. See "Removal and

installation".
2. Inspect the sealing surfaces (A) of the

thermostat housing for damage.
3. Inspect the oil seal (B) for damage.
4. Inspect the thermostat seat (C) for damage.
5. Check whether the thermostat is fully closed.

A
C B
4
C B
A
M200594
6. Place the thermostat in a container filled with

clean water.
7. Place a thermometer in the container and

heat the water. Check at what temperature
the thermostat starts opening and whether it
fully opens. See "Technical data".
M200513
©
200551 2-1
COOLING SYSTEM
2.2 INSPECTION, COOLANT PUMP RADIAL PLAY
1. Remove the poly-V-belt from the coolant

pump pulley.
2. Fit a dial gauge as shown in the illustration.
3. Force the coolant pump pulley downwards

and set the dial gauge to zero.
4. Pull the coolant pump pulley upwards and

read the dial gauge.
5. Compare the reading with the technical data.

See "Technical data". If it is more than the
maximum radial play specified in the
4 technical data, the coolant pump must be
replaced.
M200595
©
2-2 200551
COOLING SYSTEM

3.1 REMOVAL AND INSTALLATION, COOLANT PUMP
Removing coolant pump

1. Remove the poly V-belt from the alternator
and the V-belt from the air conditioning
compressor.

thermostat housing on the coolant pipe and
remove the thermostat housing and
connection piece.
3. Disconnect all coolant hoses connected to

the coolant pump.
4. Disconnect the pipe from the coolant pump

4
to the coolant filter.

coolant pump.
6. Remove the coolant pump. M200596
Installing coolant pump

1. Thoroughly clean and check the sealing
surfaces of the coolant pump, the thermostat
housing and the cylinder block.
2. Install the coolant pump, using a new gasket.

Fit the attachment bolts. Tighten the
attachment bolts to the specified torque. See
"Technical data".
3. Install the connection piece with new O-rings

onto the coolant pump.
4. Fit a new O-ring to the thermostat housing

and fit the housing to the coolant pipe.
5. Connect the pipe from the coolant pump to

the coolant filter.
6. Fit all coolant hoses connected to the coolant

pump.
7. Fit the poly V-belt of the alternator and the

V-belt of the air conditioning compressor.
©
200551 3-1
COOLING SYSTEM
3.2 REMOVAL AND INSTALLATION, THERMOSTAT
Removing thermostat
1. Remove the thermostat housing attachment
bolts. Remove the thermostat housing and
the connecting piece from the coolant pump
and the O-ring (A) from the thermostat
housing.
Removing thermostat seal

1. Remove the oil seal (B) from the thermostat
housing, using a commercially available
internal puller. A
Removing thermostat seat C B
4
1. Remove the thermostat seat (C) at the
bottom of the thermostat housing, using a
commercially available internal puller. C B
A
M200594
Installing thermostat seat

1. Apply locking compound to the thermostat
seat (C) and fit it in the thermostat housing
using the special tool (DAF no. 1310456).
Installing thermostat seal

1. Fit the thermostat seal (B) in the thermostat
housing using the special tool
(DAF no. 1310456).
Installing thermostat
A
1. Connect the coolant pipe. C B
2. Fit the O-ring (A) in the thermostat housing.
Fit new O-rings to the connection piece from C B
the thermostat housing to the coolant pump,
and fit the connection piece in the thermostat
A
housing.
3. Fit the thermostat housing attachment bolts.

Tighten the attachment bolts to the specified
M200594
©
3-2 200551
TIMING GEAR
XE engine Contents
CONTENTS
Timing gear
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

1.1 Overview drawing, timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

2.1 Inspection and adjustment, timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551

3.1 Removal and installation, timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551
3.2 Removal and installation, timing cover seal. . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200551
3.3 Removal and installation, timing gear wheels . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200551
3.4 Removal and installation, timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . 200551
3.5 Removal and installation, timing case oil seal . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . 200551
©
200551 1
TIMING GEAR
Contents XE engine
©
2 200551
TIMING GEAR
XE engine General
1. GENERAL
1.1 OVERVIEW DRAWING, TIMING GEAR
Legend
1. Crankshaft gear 2 4 5
2. Camshaft gear
3. Idler gear
4. Fan drive
5. Steering pump gear
6. Pump housing camshaft gear
7. Air compressor gear
8. Oil pump idler gear
9. Oil pump
7
1
3
6 5
8
9
M200886
©
200551 1-1
TIMING GEAR
General XE engine
©
1-2 200551
TIMING GEAR

2.1 INSPECTION AND ADJUSTMENT, TIMING GEAR
Checking the timing gear

1. Remove the valve cover from
cylinders 1-2-3. See "Removal and
Installation".
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:
of an engine is rotated separately without an M201185
idler gear (3), the engine's pistons may touch
the valves. 5
4. Remove the idler gear (3). See "Removal
and installation".
5. Now put the idler gear (3) back in such a way

that the marks on it line up with the marks
on the camshaft gear (2), the crankshaft
gear (1) and the pump housing gear (4).
6. If the marks are not in line, the timing gear

must be adjusted.
7. Tighten all attachment bolts that have been

removed to the specified torque. See
"Technical data".
4
2 3
1
M201281
©
200551 2-1
TIMING GEAR
Adjusting the timing gear

1. Remove the valve cover from
cylinders 1-2-3. See "Removal and
Installation".

(TDC on the flywheel, cylinder 6 in overlap
position).
3. Remove the timing gear cover. See

"Removal and installation".
Note:
of an engine is rotated separately without an
the valves.
4. Remove the idler gear (3). See "Removal

and installation". 4
2 3
5 5. Rotate the camshaft gear (2) to such a
position that the idler gear (3) can be
1
installed in accordance with the marks.
6. Fit the idler gear and tighten the attachment

bolt to the specified torque. See "Technical M201281
data".
7. Fit the timing cover. See "Removal and

installation".
8. Fit the valve cover. See "Removal and

installation".
©
2-2 200551
TIMING GEAR

3.1 REMOVAL AND INSTALLATION, TIMING COVER
} When the engine or parts thereof are

opened, dirt may enter. This may
cause serious damage to the engine.
The engine should therefore be
cleaned thoroughly before it is
opened.
Removing timing cover

1. Remove the V-belts (or poly V-belt) of the
coolant pump, alternator and fan drives.
2. In the case of the XE ... C1, disconnect the

electrical connections on the alternator and
remove the alternator bracket together with
the alternator.
3. Remove the fan drive. 5

5. Remove the vibration damper hub using the

special tool (DAF no. 1310422).
6. Remove the coolant pipe.
7. Remove the oil filler pipe.
8. Mark the positions of the various attachment

bolts and studs.
9. Remove the attachment bolts and studs from

the timing cover.
11. Remove any remnants of gasket. Clean and

inspect the sealing surfaces, dowels and
locating holes.
12. Remove the oil seal from the timing cover.
©
200551 3-1
TIMING GEAR
Installing timing cover

1. Use three studs to position the gasket. Fit the
new gasket.
3. Fit the attachment bolts and the studs.

Tighten the attachment bolts and studs to the
4. Remove the three studs used to position the

gasket and replace them with the remaining
attachment bolts.
5. Fit new O-rings to the coolant pipe and

install it.
6. Fit a new O-ring to the oil filler pipe and

install it.
5 7. Fit the timing cover seal.
8. Fit the vibration damper hub.
9. Install the vibration damper.
10. Fit the fan drive.
11. In the case of the XE ... C1, fit the alternator

bracket and alternator and connect the
electrical wiring to the alternator.
12. Fit the V-belts and/or poly V-belt.
©
3-2 200551
TIMING GEAR
3.2 REMOVAL AND INSTALLATION, TIMING COVER SEAL
Removing timing cover seal

1. Remove the poly V-belt.
3. Remove the vibration damper hub.
4. Remove the timing cover seal by using the

special tool (DAF no. 1329458) to pull the
seal out of the cover.
Installing timing cover seal

1. Clean and check the seal recess in the timing
cover. Even minimal damage may cause a
leak.
Note:
If a shim was fitted in the seal recess, it must
be re-fitted. 5
M200971
2. Use the special tool (DAF no. 1310424) and

the thrust piece in the recess of the timing
cover to install the dry seal.
3. Remove the special tool.
4. Fit the vibration damper hub.
5. Install the vibration damper.
6. Fit the poly V-belt.
M200771
©
200551 3-3
TIMING GEAR
3.3 REMOVAL AND INSTALLATION, TIMING GEAR WHEELS
Removing the timing gear

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 on the idler gear
are not exactly opposite the camshaft and
crankshaft gear wheels.
M201185
Removing the idler gear

1. Remove the attachment bolt (10) and the
5 axial thrust washer (11). 2 4 5 15
2. Remove the idler gear (3). 14
Removing the camshaft gear
1. Remove the attachment bolt (12) of the
camshaft gear (2).
2. Remove the idler gear.
3. Remove the camshaft gear using a

commercially available puller. 7
Removing the pump housing camshaft gear
1. Remove the attachment bolt (14) from the 12
pump housing camshaft gear wheel (6).
6
13 3
1
8 11
3. Remove the gear wheel, using a 9
commercially available puller.
10
M200954
©
3-4 200551
TIMING GEAR
Installing the timing gears

1. Check whether cylinder 1 is at top dead
centre (TDC on the flywheel, cylinder 6 in
overlap position).
Note:
of an engine is rotated separately without an
the valves.
M201185
Installing the idler gear

1. Fit the idler gear (3) so that the marks on it
are opposite those on the camshaft gear (2)
and the crankshaft gear (1).
2. Fit the attachment bolt (10) and the axial

thrust washer (11) of the idler gear (3).
5
Tighten the attachment bolt to the specified
3. Check that the backlash specified for the

gears is not exceeded. See "Technical data".
Installing the camshaft gear

1. Fit the gear wheel (2) onto the camshaft.
2. Install the idler gear (3).
3. Fit the attachment bolt (12) and the thrust 4

washer (13) of the camshaft gear wheel (2).
Tighten the attachment bolt (12) to the 2 3
specified torque. See "Technical data". 1
M201281
©
200551 3-5
TIMING GEAR
Installing the pump housing camshaft gear

wheel
1. Fit the pump housing camshaft gear (6) to
the shaft journal. 2 4 5 15
2. Fit the idler gear. 14
3. Fit the attachment bolt (14) of the pump
housing camshaft gear wheel (6). Tighten
the attachment bolt to the specified torque.

7
Installing the timing gear
12
2. Fit the valve covers. 6
13 3
1
5 8 11
9 10
M200954
©
3-6 200551
TIMING GEAR
3.4 REMOVAL AND INSTALLATION, TIMING CASE
Removing the timing case

1. Remove the timing gears.
2 4 5 15
2. Remove the air compressor.
14
3. Remove the steering pump.
4. Remove the camshaft attachment bolts and

locking plate.
12
6
13
1 3 5
8 11
9 10
M200954
5. Loosen the oil sump attachment bolts until

the oil sump is free from the timing case.
6. Remove the bolts attaching the timing case

to the cylinder block, and remove the timing
case.
Installing the timing case

1. Remove any remnants of gasket. Clean and
inspect the sealing surfaces, dowels and
locating holes.
2. To position the gasket, insert three studs and

fit the new gasket.
3. Then remove any gasket remnants between

the cylinder block and the oil sump.
4. Fit the timing case. Tighten the attachment

data".
5. Tighten the oil sump attachment bolts to the

M200579
©
200551 3-7
TIMING GEAR
6. Fit the camshaft locking plate and

attachment bolts. Tighten the attachment
data".
7. Fit the timing gears.
8. Fit a new O-ring to the air compressor and fit

the air compressor.
9. Fit the steering pump.
©
3-8 200551
TIMING GEAR
3.5 REMOVAL AND INSTALLATION, TIMING CASE OIL SEAL
Removing the timing case oil seal

(TDC on the flywheel, cylinder 6 in overlap
position).
M201185
3. Remove the pump housing camshaft

6 1 2 7 3 5
gear (1).
5
M200887
4. Remove the oil seal (2) by tapping it from the

timing case in the driving direction.
M200728
©
200551 3-9
TIMING GEAR
Installing the timing case oil seal

1. Fit a dry new timing case oil seal (2) using
6 1 2 7 3 5
the special tool (DAF no. 1329318).
2. Fit the pump housing camshaft gear (1).
3. Fit the idler gear.

Note:
Pay attention to the marks.
M200887
©
3-10 200551
XE engine Contents
CONTENTS
Flywheel and flywheel housing
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

1.1 Overview drawings, flywheel and flywheel housing. . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

2.1 Inspecting the flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551

3.1 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551
3.2 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200551
3.3 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200551
3.4 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200551
©
200551 1
Contents XE engine
©
2 200551
XE engine General
1. GENERAL
1.1 OVERVIEW DRAWINGS, FLYWHEEL AND FLYWHEEL HOUSING
6 5
7 1
6
4
11 8
10 M200950
1. Flywheel housing 7. Oil seal

2. Dowel pin 8. Flywheel
3. Marker plate 9. Clamping pin
4. Sealing plate 10. Starter ring gear
5. Shim 11. Ball bearing
6. Mounting ring
©
200551 1-1
General XE engine
©
1-2 200551

2.1 INSPECTING THE FLYWHEEL
1. If the flywheel shows cracks on the abutting

surface with the clutch plate, the flywheel 5 mm
may be ground down, provided 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 turned down. 5 mm
6
M2 00 033
Checking flywheel run-out

1. Clean the flywheel.
2. Place a metal strip on the edge of the

flywheel housing to fit a dial gauge.
3. Place the dial gauge on the metal strip.
4. Place the stylus of the dial gauge at the

specified distance. See "Technical data".
5. Set the dial gauge to "0".
6. Use the special tool (DAF no. 1310477) to

crank the engine through 360, and measure
the maximum dial gauge reading. Compare M200230
this reading with the technical data. See
"Technical data".
©
200551 2-1
©
2-2 200551

3.1 REMOVAL AND INSTALLATION, FLYWHEEL
Removing flywheel
1. Remove the attachment bolts (1) from the
flywheel.
M200569
2. Use two bolts to remove the flywheel from

the dowel pin. 6
3. Remove the flywheel.
Installing flywheel
1. Clean the flywheel housing.
2. Clean the crankshaft flange, the dowel pin

and the attachment bolts. Remove the
locking compound from the threaded holes.
3. Clean the back of the flywheel and fit it.
4. Fit the attachment bolts. Tighten the

"Technical data". M200570
©
200551 3-1
3.2 REMOVAL AND INSTALLATION, STARTER RING GEAR
Removing the starter ring gear

2. Remove the starter ring gear by tapping it off

the flywheel, using a blunt chisel. If this is not
possible, cut the starter ring gear between
two teeth, using a sharp chisel.
Installing the starter ring gear

1. Clean the flywheel and the starter ring gear.
Ensure that the contact areas are free of
grease.
2. Heat the new starter ring gear evenly in an

oven. See "Technical data".
3. Tap the starter ring gear onto the flywheel so

that the bevelled sides of the teeth point
towards the starter motor. Ensure that the
starter ring gear is properly fitted to the
flywheel.
6 4. Fit the flywheel.
M2 00 035
©
3-2 200551
3.3 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING SEAL
Note:
A new oil seal is fitted on a plastic mounting ring.
The oil seal must not be removed from the
mounting ring until the oil seal ring has been
pressed into the flywheel housing by hand.
Removing the flywheel housing seal

2. Drill two small holes into the oil seal and pull
the latter out of the flywheel housing using
the special tool (DAF no. 0694928).
Installing the flywheel housing seal

1. Thoroughly clean the oil seal recess and
inspect for damage. Even the slightest
damage can cause a leak.
2. Clean the crankshaft flange.

Note:
If a shim was fitted in the seal recess, it must
be re-fitted. 6
3. Fit the plastic mounting ring (1), with the oil
seal dry, to the crankshaft flange. 1
2
4. Press the oil seal (2) as far as possible into
the recess by hand and then carefully
remove the plastic mounting ring (1).
5. Fit the base plate (A) of the special tool

(DAF no. 0535598) on the crankshaft flange.
A
6. Place the thrust washer (B) over the base
plate (A) and gradually tighten the nut (C)
until the resistance increases.
B C
7. Remove the nut (C) and thrust washer (B). M2 00 036
8. Make sure that the entire oil seal is

positioned evenly in the recess. If not, fit the
thrust washer (B) again and tighten the oil
seal a little further with the nut (C).
9. Remove the base plate (A).
10. Fit the flywheel and tighten the bolts to the

©
200551 3-3
3.4 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING
Removing flywheel housing

2. Remove the starter motor.
3. Remove the crankshaft position sensor.
4. Suspend the engine securely in the hoist.
5. Remove the two bolts attaching the oil sump

to the flywheel housing.
6. Slacken the other oil sump attachment bolts

until the oil sump is free from the flywheel
housing.
7. Remove the central engine mounting

attachment bolts at the rear of the engine.
8. Remove the flywheel housing attachment

bolts.
9. Remove the flywheel housing.

6 Installing flywheel housing
1. Remove the oil seal from the flywheel
housing by carefully tapping or pushing it out
of the housing.
2. Remove any gasket remnants from the

contact areas.
3. Check the sealing surfaces for damage.
4. Check the flywheel housing for cracks.
5. Apply a sealant to the sealing surface of the

cylinder block. See "Technical data". Spread
the sealing compound with a roller or brush
across the entire sealing surface.
6. Fit the flywheel housing. Tighten the

"Technical data".
7. Fit the central engine mounting attachment

bolts at the rear of the engine. Tighten the
"Technical data".
8. Fit the oil seal.
9. Fit the flywheel.
10. Fit the starter motor.
11. Fit the crankshaft position sensor.
12. Fit the oil sump attachment bolts. Tighten all

"Technical data".
©
3-4 200551
CYLINDER HEAD
XE engine Contents
CONTENTS
Cylinder head
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

1.1 Overview drawing, cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551
1.2 Overview drawing, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200551
1.3 Overview drawing, DEB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200551
1.4 Overview drawing, valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200551

2.1 Pressure-testing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551
2.2 Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200551
2.3 Inspection and adjustment, valve gear bridges . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200551
2.4 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . 200551
2.5 Inspection and adjustment, DEB clearance. . . . . . . . . . . . . . . . . . . . . . . . 2-7 . . . . . 200551

3.1 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551
3.2 Removal and installation, DEB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200551
3.3 Removal and installation, DEB spring plate . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200551
3.4 Removal and installation, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . 200551
3.5 Removal and installation, valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . 200551
3.6 Removal and installation, cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . 200551
3.7 Removal and installation, valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 . . . . 200551
3.8 Removal and installation, valve stem seal. . . . . . . . . . . . . . . . . . . . . . . . . 3-17 . . . . 200551
3.9 Removal and installation, valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 . . . . 200551
3.10 Removal and installation, valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11 Removal and installation, valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-20 . . . .
3-21 . . . .
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3.12 Removal and installation, injector sleeve . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 . . . . 200551
3.13 Removal and installation, expansion plugs . . . . . . . . . . . . . . . . . . . . . . . . 3-23 . . . . 200551
4. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551

4.1 Cleaning, injector sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551
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200551 1
CYLINDER HEAD
Contents XE engine
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2 200551
CYLINDER HEAD
XE engine General
1. GENERAL
1.1 OVERVIEW DRAWING, CYLINDER HEAD
3
2
7
4
7 M200790
1. Cylinder head 5. Expansion plug

2. Valve guide 6. Valve seat, inlet
3. Injector holder 7. Valve seat, exhaust
4. Expansion plug
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200551 1-1
CYLINDER HEAD
General XE engine
1.2 OVERVIEW DRAWING, VALVE GEAR
4 1
3
4 2
3
2
1 5
4
6
16
4
15
14
7 13
12
7
11
9 10
17
M200791
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 collet
6. Dowel pin 14. Cylindrical pin
7. Push rod 15. Thrust piece without DEB
8. Tappet roller 16. Thrust piece with DEB
17. Tappet roller locking plate
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1-2 200551
CYLINDER HEAD
XE engine General
1.3 OVERVIEW DRAWING, DEB
4
3
i400167
1. Solenoid valve 4. Main piston

2. Steering valve 5. Spring plate
3. Operating piston 6. Set screw
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200551 1-3
CYLINDER HEAD
General XE engine
1.4 OVERVIEW DRAWING, VALVE SLEEVE
3
4
5
7
6
7
M200792
1. Valve cover 5. Connector stop

2. Valve cover gasket 6. Valve sleeve
3. Lubricating oil strip 7. Valve sleeve gasket
4. Clamping pin
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1-4 200551
CYLINDER HEAD

2.1 PRESSURE-TESTING THE CYLINDER HEAD
1. Seal the cylinder head coolant channels with

sealing plates fitted with gaskets.
2. These sealing plates can be made in the

workshop. One sealing plate must have a
connection for an air hose.
3. Connect an air hose equipped with a reducer

valve to the sealing plate coupling.
4. Immerse the cylinder head in warm water

and pressure-test the head at an air pressure
of 1.5 bar.
5. Leave the cylinder head in the water for

about half an hour and visually inspect it for
leaks.
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200551 2-1
CYLINDER HEAD
2.2 CHECKING CYLINDER HEAD
Cylinder head
1. Inspect the cylinder head expansion plugs
for leaks. If necessary, pressure-test the
cylinder head. A
2. Inspect the cylinder head for flatness,
damage on the sealing face and cracks. If
necessary, have the cylinder head refaced.
See "Technical data". M200777
3. When machining the cylinder head, care

must be taken that the height (A in the
diagram opposite) remains within the
specified dimensions. See "Technical data".
4. After cleaning the machined surface, the

distance (B) (see "Technical data") between B
the valve head and the cylinder head surface
must be inspected and corrected if
necessary by machining the valve seat or the
valve seat recess.
M201103
Valve seats
Note:
Due to minimal machining tolerances, machining A
of the inlet valve is not allowed.
1. A valve seat needs to be machined when the

bearing area between valve head and seat
(area A) exceeds the maximum permitted
value. When doing this, the distance (B)
between valve head and cylinder head
surface must remain within the dimensions.
If this is impossible, the valve seat and/or
valve must be replaced. For the dimensions,
see "Technical data".
M201100
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2-2 200551
CYLINDER HEAD
2.3 INSPECTION AND ADJUSTMENT, VALVE GEAR BRIDGES
1. Remove the valve covers. See "Removal

and installation".
2. Remove the DEB or the lubricating oil strip

(depending on version).
3. Remove the entire rocker seat. Mark the

position to enable reinstallation in the same
position.
Note:
Exhaust bridge with DEB
In engines with a DEB, the bridges of the inlet and
exhaust valves are different.
7
i 400162
Note:
In engines without a DEB, the bridges of the inlet Exhaust bridge without DEB
and exhaust valves are the same.
i 400161
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200551 2-3
CYLINDER HEAD
4. Remove the bridge from the valves and

place it in a vice.
} Loosening and tightening the lock

nuts (B) of the bridges to the
specified torque may cause severe
damage to the valve guides if the
bridge is fitted over the valves.
5. Slacken the lock nut (B). A

6. Reposition the bridge in the same position in
the engine over the valves.
7. Firmly press on the bridge centre (above the

guide pin) with your thumb and hand-tighten
the adjusting screw (A) until the bridge starts
to move (adjusting screw (A) now touches
B
the valve).
8. Turn the adjusting screw (A) through another

90 and carefully remove the bridge from the i 400234
valves.
9. Place the bridge in a vice and tighten the lock

nut (B) to the specified torque without turning
the adjusting screw (A). See "Technical
data".
7 Note:
Loosening and tightening the lock nuts (B) of
the bridges to the specified torque may
cause severe damage to the valve guides if
the bridge is fitted over the valves.
10. Reposition the bridge over the valves.
11. Fit the rocker seat. M200548
12. Fit the DEB or the lubricating oil strip

(depending on version). Fit the lubricating oil
strip in such a way that the mark "cyl. 1/4" is
located on cylinder 1 or cylinder 4.
13. Set the valve clearance and, if applicable,

the DEB clearance (see "Technical data").
14. Fit the valve covers. See "Removal and

installation".
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2-4 200551
CYLINDER HEAD
2.4 INSPECTION AND ADJUSTMENT, VALVE CLEARANCE
1. Remove the valve covers. See "Removal

and installation".

turn the crankshaft clockwise, as seen from
the timing gear end (this corresponds with
the engine's direction of rotation), until the
valves of cylinder 1 are in the overlap
position. The pistons of cylinders 1 and 6 are
now at top dead centre.
Note:
"Overlap" is the moment at which the inlet
valve starts opening and the exhaust valve M201185
finishes closing.
} If the engine has a DEB, you must

use a flat ring spanner to loosen the
lock nut. This is necessary to avoid
damaging the DEB spring plate.
3. Check/correct the valve clearance of

cylinder 6. Set the correct valve clearance
by loosening the lock nut and turning
the adjusting screw in the correct direction.
See "Technical data" for the correct valve
clearance. 7
M200539
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200551 2-5
CYLINDER HEAD
4. By cranking the crankshaft 1/3 stroke each

time, using special tool (DAF no. 1310477),
the valves can be adjusted according to the
injection sequence 1-5-3-6-2-4.
Cylinder with Adjust valves of

valves in overlap cylinder
position
1 6
5 2
3 4
6 1
2 5
4 3
5. If the engine has been fitted with a DEB, the

DEB play must be checked following the
valve clearance adjustment.
6. Fit the valve covers. See "Removal and M200540
installation".
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2-6 200551
CYLINDER HEAD
2.5 INSPECTION AND ADJUSTMENT, DEB CLEARANCE

opened, it is possible for dirt to
penetrate which can result in serious
damage to the engine. The engine
should therefore be cleaned
thoroughly before it is opened.
2. Tighten the DEB attachment bolts to the

3. Using the special tool (DAF no. 1310477),

crank the engine in the direction of rotation
until cylinder 1 has reached the top dead
centre (TDC) and the valves of cylinder 6 are
in overlap position.
4. Use set screw B to set the DEB clearance (A)

of cylinders 1, 3 and 5. See "Technical data".
Tighten the lock nut to the specified torque.
B

crank the engine in the direction of rotation
7
until cylinder 6 has reached the top dead
centre (TDC) and the valves of cylinder 1 are
in overlap position.
6. Use set screw B to set the DEB clearance (A)

of cylinders 2, 4 and 6. See "Technical data".
7. Tighten the lock nut to the specified torque.

8. Fit the valve covers.
i 400166
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2-8 200551
CYLINDER HEAD

3.1 REMOVAL AND INSTALLATION, VALVE COVER

opened, dirt may penetrate. This
may cause serious damage to the
engine. The engine should therefore
be cleaned thoroughly before it is
opened.
Removing the 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.
Installing the 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.
3. Fit the attachment bolts of the valve cover

and tighten them to the specified torque. See
"Technical data".
7
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200551 3-1
CYLINDER HEAD
3.2 REMOVAL AND INSTALLATION, DEB
} Make sure that the spring plate (5)

under the main piston (4) is not
damaged or deformed. When the
DEB is in operation, this spring
plate, if it is damaged or deformed,
can break off and result in serious
}
damage to the engine.
When the engine or parts thereof are

opened, it is possible for dirt to
penetrate which can result in serious
damage to the engine. The engine
should therefore be cleaned
thoroughly before it is opened.
Removing the DEB

1. Remove the valve cover.
2. Disconnect the electrical connection and 1

remove the cable harness from its housing.
3. Remove the DEB.
7 6
3
4
i400541
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3-2 200551
CYLINDER HEAD
Installing the DEB

1. Tighten the rocker seat attachment bolts to
Note:
There are two different DEB housings, one
for cylinders 1 to 3 and one for cylinders 4 to
6 (shown as "front" and "rear" on the DEB
housing).
2. Place the DEB on the rocker seats.

i 400187
3. Insert the DEB attachment bolts and tighten
them to the specified torque. See "Technical
data".
4. Attach the electrical connection.
5. Adjust the valve clearance. See "Inspection

and adjustment".
6. Adjust the DEB clearance. See "Inspection

and adjustment".
7. Fit the valve cover.
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200551 3-3
CYLINDER HEAD
3.3 REMOVAL AND INSTALLATION, DEB SPRING PLATE
Removing the DEB spring plate

1. Remove the DEB.
2. Remove the spring plate (5) with shim and 1

attachment bolt.
3
4
i400541
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3-4 200551
CYLINDER HEAD
Installing the DEB spring plate
Note:
To prevent the spring plate being damaged and/
or broken, it should be positioned very carefully.

position the spring plate (5) on the main
piston (4).
2. Fit the lock washer with fixing bolt and tighten

it to the specified tightening torque. See
"Technical data".
3. Install the DEB and tighten the attachment

data".
i 400239
i400238
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200551 3-5
CYLINDER HEAD
3.4 REMOVAL AND INSTALLATION, VALVE GEAR
Removing the valve gear

1
2. Remove the DEB or the lubricating oil strip
(depending on version).
Note:
Number the rocker seats (1) and the
bridges (2-3-4) to allow reinstallation in the
same position.
3. Remove the rocker seats (1).
4. Remove the bridges (2-3-4).
M200559
Installing the valve gear
Note:
In engines with a DEB, the bridges of the inlet and
exhaust valves are different. 2
In engines without a DEB, the bridges of the inlet 3
and exhaust valves are the same.
7 1. Fit the bridges (2-3-4) on the valves. 4

2. Set the bridges (2-3-4). See "Inspection and
adjustment".
3. Hand-tighten the rocker seats (1).

Note:
Depending on the engine position, some
rocker seats will have to be positioned
against the pressure of the valve
springs. The rocker seat will resist this M200560
spring pressure and cannot therefore be
positioned correctly. By cranking the
crankshaft 1/3 turn each time using the
special tool (DAF no. 1310477), the rocker
seats can be tightened in the injection
sequence 1-5-3-6-2-4.
4. Tighten the attachment bolts to the specified

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3-6 200551
CYLINDER HEAD
5. Fit the DEB or the lubricating oil strip

(depending on version). Fit the lubricating oil
strip in such a way that the mark "cyl. 1/4" is
located on cylinder 1 or cylinder 4. For the
tightening torques of the attachment bolts,
see "Technical data".
6. Set the valve clearance and, if applicable,

the DEB clearance. See "Inspection and
adjustment".

M200548
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200551 3-7
CYLINDER HEAD
3.5 REMOVAL AND INSTALLATION, VALVE SLEEVE
Removing valve sleeve

1. Remove the injection pipes in sets.
3. If necessary, disconnect the electrical

connection of the DEB.
4. If necessary, remove the cable harness from

the DEB or the plug from the valve sleeve.
5. If fitted, remove the DEB.
6. Remove the injectors.
7. Remove the valve gear.
8. Remove the push rods.
Note:
Make sure that any solid push rods (yellow
marking and diameter 12 mm) are fitted back on
the inlet sideonly. These solid push rods may be
replaced by hollow ones (diameter 14 mm).
7 9. Remove the valve sleeve and gasket.
Installing valve sleeve

1. Fit the valve sleeve with a new gasket and
tighten the attachment bolts to the specified
torque and in the correct sequence. See 7 15 9
3 11 13 2
"Technical data".
2. Fit the push rods. 5 6

Note: 1 14 8
the inlet sideonly. These solid push rods may be 10 12 4
replaced by hollow ones (diameter 14 mm). M200942
3. Fit the injectors.
4. Fit the valve gear.
5. If necessary, fit the DEB.
6. If necessary, fit the DEB cable harness or the

plug in the valve sleeve.
7. If fitted, connect the electrical connections of

the DEB.
9. Fit the injector pipes in sets.
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3-8 200551
CYLINDER HEAD
3.6 REMOVAL AND INSTALLATION, CYLINDER HEADS

opened, dirt may enter. This may
cause serious damage to the engine.
The engine should therefore be
cleaned thoroughly before it is
opened.
Removing cylinder heads

1. Disconnect any wiring around the engine
which is relevant for the removal of the
cylinder heads.
2. Disconnect the inlet pipe from the

turbocharger to the air cooler.
3. Slacken the tensioner of the air conditioning

compressor, if fitted.
4. Remove the attachment bolts of the air

conditioning compressor mounting bracket, if
fitted.
5. Remove the heat shields from the exhaust

manifold.

exhaust manifold and remove the manifold
and the turbocharger from the cylinder
7
heads.
7. Remove the coolant filter, if fitted.
8. Disconnect the fuel leak-off pipe between the

fuel filter and the fuel leak-off pipe on the inlet
manifold.
9. Disconnect the fuel filter assembly from the

coolant pipe.
10. Disconnect both sets of injector pipes.
11. Remove the coolant pipe together with the

thermostat housing.
12. Remove the inlet manifold attachment bolts

and remove the entire manifold from the
cylinder heads.
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200551 3-9
CYLINDER HEAD
14. If fitted, remove the DEB.
15. To remove the injectors and the clamping

pieces, only use the special tools
(DAF no. 1329412) and (DAF no. 0694928).

Note:
marking and diameter 12 mm) are fitted back
on the inlet sideonly. These solid push rods
may be replaced by hollow ones (diameter
14 mm).
18. Remove the valve sleeve.
Note:
Due to the sealant used on the cylinder head
21 18 19 20
bolts, the untightening torque of the cylinder
head bolts can be substantial!
17 11 7 1 8 12
19. Remove the cylinder head bolts in the 16 6 2 13

reverse order to that shown.
7 20. Remove the cylinder heads from the cylinder 15 5 3 14

block.
10 4 9
M200562
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3-10 200551
CYLINDER HEAD
Note:
Note the markings (2, 5) on the cylinder head
gasket to be replaced and use the same gasket
when fitting. The cylinder head gaskets can also
be recognised from the coolant holes (3, 4).
21. Remove any remnants of gasket from the

cylinder heads and the cylinder block.
22. Check the sealing surfaces of the cylinder

block.
3
23. Check the threaded holes in the cylinder
block for damage and cracking.
2
1
4
7
5
M201278

check that the amount the cylinder liner
protrudes above the cylinder block is within
tolerance. See "Technical data".
25. Check the cylinder head. See "Inspection

and adjustment".
Installing cylinder heads

1. Clean the threaded holes in the cylinder
block using a screw tap.
Note:
M2 00 100
Threaded holes not properly cleaned may
lead to too low a pre-tension of the cylinder
head bolts, causing leakage.
2. Clean and degrease the sealing surfaces of

the cylinder heads and the cylinder block.
3. Insert both guide pins (DAF no. 0694912)

into the threaded holes of the cylinder block.
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200551 3-11
CYLINDER HEAD
4. Place the new gasket(s) on the cylinder

block, making sure that the letters TOP (1)
are visible. The cylinder head gasket must
not be retightened.
Note:
Always replace the cylinder head bolts. See
"Technical data".
5. Place the cylinder head(s) on the cylinder

block and hand-tighten a few new cylinder
head bolts.
3
Note:
To prevent the inlet and exhaust manifolds 2
from being installed under tension, they must 1
be installed before the cylinder head bolts
are tightened.
6. Fit the inlet and exhaust manifolds with new

gaskets and tighten the attachment bolts to
7. Remove the two guide pins and replace

them with the two remaining cylinder head
bolts.
8. Tighten the cylinder head bolts to the
7
specified torque and in the correct sequence. 4
9. Fit the valve sleeve. 5

M201278
10. Fit the push rods.
Note:
marking and diameter 12 mm) are fitted back
on the inlet sideonly. These solid push rods
may be replaced by hollow ones (diameter
14 mm).
12. Fit the injectors.
13. If necessary, fit the DEB.
15. Fit the coolant pipe, fit new gaskets to the

thermostat housing and install it.
16. Fit the injector pipes in sets.
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3-12 200551
CYLINDER HEAD
17. Fit the fuel filter onto the coolant pipe.
18. Fit the fuel leak-off pipe between the fuel

filter and the inlet manifold.
19. If applicable, fit the coolant filter to the

coolant pipe.
20. Fit the heat shields of the exhaust manifold

and tighten the attachment bolts to the
21. If applicable, fit the air conditioning bracket.
22. Adjust the V-belt tension of the air

conditioning compressor.
23. Fit the inlet pipe between the turbocharger

and the air cooler.
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200551 3-13
CYLINDER HEAD
3.7 REMOVAL AND INSTALLATION, VALVE SPRINGS
} When removing and installing the

valve springs, compress them
carefully, ensuring that they cannot
fly off. An inadvertently released
spring or valve collet can cause
serious injury.
Note:
Using the special tool (DAF no. 1451997), the
valve springs can also be removed and installed
without removing the cylinder head.
Removing valve springs (cylinder head

mounted)
Note:
To prevent the valves in the cylinder from
dropping when the valve spring is removed,
the relevant piston must be in TDC. The
following method can be used to achieve
this.
1. Crank the engine using the special tool

(DAF no. 1310477) until it is on the "TDC"
marking (cylinders 1 and 6 in TDC).
7
M201185
2. Use a felt-tip pen or paint to mark the

vibration damper as shown in the example.
Use the vibration damper attachment bolts
as a guide when placing the other marks on
cylinders 3/4 and 2/5. They are 120 before
and 120 after the mark on cylinders 1/6.
3. Make sure that the piston of the valve spring

to be removed is in the TDC position.
5. Remove the valve gears.

Note:
Make sure that the valve collets do not fall
through a cylinder opening into the engine.
M2 01 296
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3-14 200551
CYLINDER HEAD
6. Position the special tool (1)

(DAF no. 1451997) on top of the injector (2).
Press the valve spring in until the valve
collets (3) can be removed. If the valve
spring retainer does not come free when the 1
valve spring is pressed in, give the special
tool (1) a light tap with a hammer so that the
valve spring retainer breaks off. 2
7. Carefully release the valve spring and take
the valve spring retainer and valve spring off
the valve stem.
3
Note:
Remove any centring sleeve and do not put
it back! M2 01 297
Removing valve springs (cylinder head

removed)
1. Support the valve and compress the valve
spring safely, so that the two valve collets
can be removed.
2. Release the valve spring and take the valve

spring retainer and valve spring off the valve
stem.
Installing valve springs (cylinder head

mounted)
1. Check the length of the valve springs. See
7
"Technical data".
2. Fit the correct spring(s) in the correct

position.
3. Position the valve spring retainer on top of

the spring.
4. Position the special tool (DAF no. 1451997)

on top of the injector (2). Press the valve
spring in until the valve collets (3) can be
fitted.
1
5. Release the valve spring carefully and check
that the valve collets have been installed
properly. 2
6. Install the valve gears.
7. Adjust the DEB and valve clearance. See

3

M2 01 297
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200551 3-15
CYLINDER HEAD
Installing valve springs (cylinder head

removed)
1. Check the length of the valve springs. See
"Technical data".
2. Fit the correct spring(s) in the correct

position.
3. Position the valve spring retainer on top of

the spring.

can be fitted.

properly.
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3-16 200551
CYLINDER HEAD
3.8 REMOVAL AND INSTALLATION, VALVE STEM SEAL

serious personal injury.
Note:
Using the special tool (DAF no. 1451997), the
valve stem seals can also be removed and
installed without removing the cylinder head.
Removing valve stem seal (cylinder head

mounted)
2. Remove the valve gears.
3. Remove the valve springs.
4. Remove the valve stem seals without

damaging the valve stem or valve guide.
Installing valve stem seal (cylinder head

mounted)
1. Check the valve stems and valve guides for
damage.
7
2. After grinding, clean the valves and the
cylinder heads thoroughly.
Note:
No oil whatsoever may be used while the
valve stem seal is being mounted! 4
Wipe the valve stem and valve guide with a
clean, lint-free cloth. Otherwise there is a
good chance that the valve stem seal will
come free of the valve guide.
3. Place the valve stem seal (2) over the valve 1

stem (1) and slide it down by hand. 2
4. Using the special tool (4) 3
(DAF no. 1453155), push the valve stem
seal down until it abuts the valve guide (3).
5. Fit the valve springs using the special tool

(DAF no. 1451997) and install the valve
collets. M201295
6. Install the valve gears.
©
200551 3-17
CYLINDER HEAD
3.9 REMOVAL AND INSTALLATION, VALVES

serious injury.
Removing valves
1. Remove the cylinder head.

can be removed.
3. Release the valve spring and take the valve

spring retainer and valve spring off the valve
stem.
4. Remove the valve from the cylinder head.
Inspecting valves
1. Inspect the valve head, and check the
dimensions. If permitted by the dimensions,
the exhaust valves can be ground. See
"Technical data". If necessary, replace the
7 2.
valves.
Check the dimensions of the valve stem and

check it as well for straightness and signs of
grating. See "Technical data".
3. Check the dimensions and height (A) of the

valve guides. See "Technical data".
If necessary, replace the valve guide. A
4. Check the valve springs for fracture, wear
and spring force. See "Technical data".
If necessary, replace the valve springs.
M2 01 292
©
3-18 200551
CYLINDER HEAD
5. Take measurement A of the valve seat and

check that the maximum value has not been A
exceeded. See "Technical data".
Rework or replace the valve seat as
appropriate.
Note:
Due to minimal machining tolerances, machining
of the inlet valve is not allowed. Grinding with
grinding compound is, however, allowed.
Installing valves
1. When re-using, grind the valves to a correct
fit with the seats.
After grinding, clean the valves and the
2. Oil the valve stem and place the valve in the

valve guide. Check for freedom of M201100
movement.
3. Insert the lower valve spring retainer.
4. Fit the valve spring with the upper valve

spring retainer.

can be fitted.
7
properly.
7. Fit the cylinder heads.

©
200551 3-19
CYLINDER HEAD
3.10 REMOVAL AND INSTALLATION, VALVE GUIDES
Removing valve guides

1. Remove the cylinder heads.
2. Remove the valves.
3. Inspect the valve guides. See "Technical

data".
Replace them if necessary.

press the valve guides that are to be
replaced out of the cylinder heads.
Installing valve guides

1. Apply a thin layer of oil to the valve guides.
2. Press the valve guide into the cylinder head

using the special tool (DAF no. 1329421) in
such a way that the side with the greatest
bevelling is at the top of the cylinder head
(the contact surface of the valve springs).
3. Measure whether the height (A) that the

valve guide protrudes above the contact
surface is within tolerance. See "Technical A
7 data".
4. Grind the valves to a correct fit with the

seats.
5. Fit the valves.
7. Adjust the DEB and valve clearance. See M2 01 292

©
3-20 200551
CYLINDER HEAD
3.11 REMOVAL AND INSTALLATION, VALVE SEATS
Removing valve seats

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 fitted.
4. Use an internal puller to remove the valve

seat from the cylinder head.
5. Clean the valve seat recess.
Installing valve seats

press a new valve seat into the recess of the
cylinder head and check the dimensions.
2. Grind the valves to a correct fit with the

seats.
3. Fit the valves.

7

©
200551 3-21
CYLINDER HEAD
3.12 REMOVAL AND INSTALLATION, INJECTOR SLEEVE
Removing injector sleeve

1. Remove the injector.
Insert a ball of crumpled paper into the
injector sleeve to prevent metal particles
from entering the engine.
2. Tap a thread (M22 x 1.5) over a length (A) of

approx. 20 mm in the injector sleeve that is to
be removed.
Turn the special tool (DAF no. 1310425) into
the injector sleeve and, using the special tool
(DAF no. 0694928), remove the injector
A
sleeve.
Installing injector sleeve

1. Clean the injector sleeve opening
thoroughly.
Note:
Fit the dry injector sleeve in the cylinder
head.
Use the special tool (DAF no. 1329305) to
tap the injector sleeve into the cylinder head.
2. Fit the injector.
7 I 400195
©
3-22 200551
CYLINDER HEAD
3.13 REMOVAL AND INSTALLATION, EXPANSION PLUGS
Removing expansion plug

1. Remove the cylinder head.
2. Carefully tap the edge of the expansion plug,

thus tilting the plug. Make sure that no
damage occurs.
3. Remove the plug with a pair of pliers.
4. Remove the remaining locking compound

from the opening.
Installing expansion plug

1. Apply the specified locking compound to the
new expansion plug (see "Technical data")
and tap it into the cylinder head with a
suitable driving tool.
2. Leave the locking compound to harden

for 1 hour.
3. Pressure-test the cylinder head. See

4. Fit the cylinder head.
©
200551 3-23
CYLINDER HEAD
©
3-24 200551
CYLINDER HEAD
XE engine Cleaning
4. CLEANING
4.1 CLEANING, INJECTOR SLEEVE

installation".
2. Remove any copper washer left behind

using the special tool (DAF no. 1240074).
3. Clean the injector sleeve using the special

tool (DAF no. 1240074).
4. Clean the injector sleeve with compressed

air.
5. Fit the injector. See "Removal and

installation".
I400001
7
©
200551 4-1
CYLINDER HEAD
Cleaning XE engine
©
4-2 200551
LUBRICATION SYSTEM
XE engine Contents
CONTENTS
Lubrication system
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

1.1 Overview drawing, internal parts of the lubrication system . . . . . . . . . . . . 1-1 . . . . . 200551
1.2 Overview drawing, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200551
1.3 Overview drawing, oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200551

2.1 Checking oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551

3.1 Removal and installation, oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551
3.2 Removal and installation, lubricating oil pipes . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200551
3.3 Removal and installation, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200551
3.4 Removal and installation, oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200551
3.5 Removal and installation, centrifugal oil filter element. . . . . . . . . . . . . . . . 3-5 . . . . . 200551
3.6 Removal and installation, lubricating oil filter housing . . . . . . . . . . . . . . . . 3-6 . . . . . 200551

4.1 Disassembly and assembly, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551
4.2 Disassembly and assembly, oil cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200551
©
200551 1
LUBRICATION SYSTEM
Contents XE engine
©
2 200551
LUBRICATION SYSTEM
XE engine General
1. GENERAL
1.1 OVERVIEW DRAWING, INTERNAL PARTS OF THE LUBRICATION SYSTEM
1
3 2
4
21
19
20 18
13
12
11 17
5 10
6 9 14
8
15
16 8
22 7
M200938
1. Locking cap 12. Pressure spring
2. Pressure spring 13. Control valve
3. Ball 14. Lubricating unit bracket
4. Pressure regulator for lubricating devices 15. Strainer housing
5. Oil delivery pipe 16. Strainer
6. O-ring 17. Connecting bend
7. O-ring 18. O-ring
8. Oil suction pipe 19. Attachment pipe
9. O-ring 20. O-ring
10. Sealing plug 21. Split pin
11. Copper ring 22. Lubricating oil pump
©
200551 1-1
LUBRICATION SYSTEM
General XE engine
1.2 OVERVIEW DRAWING, LUBRICATING OIL PUMP
5 6 7 8 9 10
3 4
M200781
1. Lubricating oil pump 6. Oil pump bracket
2. Gear wheel 7. Oil pump shaft
3. Hub 8. Oil pump shaft
4. Bearing bush 9. Cylindrical dowel pin
5. Gear wheel 10. Pump housing
©
1-2 200551
LUBRICATION SYSTEM
XE engine General
1.3 OVERVIEW DRAWING, OIL COOLER
Types XE ... C
2
4
8
7
6
5 8
6
M200780
1. Oil cooler housing
2. Oil cooler top cover
3. Oil cooler bottom cover
4. Oil cooling element
5. Intermediate cover
6. O-ring
7. Sealing plug
8. Aluminium ring
©
200551 1-3
LUBRICATION SYSTEM
General XE engine
Types XE ... C1
1. Oil cooler bracket
2. O-ring
3. Oil cooling element 3
4. -
5. Copper ring
6. Coolant connection 2
6
5
6 5
2
M2 01 294
©
1-4 200551
LUBRICATION SYSTEM

2.1 CHECKING OIL COOLER
TYPES XE ... C
Checking oil cooler
1. Remove the oil cooler. See "Removal and
installation".
2. Disassemble the oil cooler. See

3. Fit the cooling element in the special tools

(DAF no. 1329307) and (DAF no. 0694889).
4. Apply up to 3 bar of pressurised air to the

special tool.
5. Immerse the cooling element in warm water

(approx. 50 C) and check it for leaks.
Note:
If the cooling element leaks, it must be
replaced.
6. Assemble the oil cooler. See "Disassembly

and assembly".
7. Fit the oil cooler. See "Removal and

installation".
M200598
©
200551 2-1
LUBRICATION SYSTEM
TYPES XE ... C1
Checking oil cooler
1. Remove the oil cooler. See "Removal and
installation". 3
4 5
6
C
2
7
1 8
2. Disassemble the oil cooler. See
3. Fit a plug in the opening (B) and to the other

end (A) connect a nipple with a compressed
air connection.
4. Supply compressed air with a pressure of at

most 2.5 bar.
5. Immerse the cooling element in warm water

(approx. 50 C) and check it for external and
internal leakage (air bubbles coming from A
opening C). B
Note: M201092
If the cooling element leaks, it must be
replaced.
6. Fit the oil cooler. See "Removal and

installation".
Note:
Do not refit the protective cap (if present).
©
2-2 200551
LUBRICATION SYSTEM

3.1 REMOVAL AND INSTALLATION, OIL SUMP
Removing oil sump

1. Remove the oil level sensor.
Note:
If the oil level sensor is not removed, the
sensor could easily break while removing the
oil sump.
2. Support the oil sump (1). Remove the

attachment bolts (4) and locking brackets (3)
all around. 2
3. Remove the oil sump and its sealing
rubber (2).
Installing oil sump

1. Thoroughly clean the sealing surfaces of the
oil sump and the engine block.
1
2. Check the oil sump sealing rubber (2). A
damaged sealing rubber (2) must be
replaced.
3. First attach the sealing rubber to the front

and rear sides of the oil sump. Then, attach
it to the long sides of the oil sump.
2 3
4. Fit the oil sump (1) with the sealing rubber (2)
upright. 8
5. Fit the attachment bolts (4) and locking 1 4
brackets (3). Tighten the attachment bolts
crosswise to the specified torque. See
"Technical data".
6. Fit the oil level sensor.

M200601
©
200551 3-1
LUBRICATION SYSTEM
3.2 REMOVAL AND INSTALLATION, LUBRICATING OIL PIPES
Removing lubricating oil pipes

1. Remove the oil sump.

respective oil pipe on the lubricating oil
pump.
3. Remove the intake construction or the

pressure regulator and take out the relevant
oil pipes with the O-rings.
Installing 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

"Technical data".
3. Fit the oil sump.
©
3-2 200551
LUBRICATION SYSTEM
3.3 REMOVAL AND INSTALLATION, OIL PUMP
Removing oil pump

2. Remove the suction pipe and delivery

pipe (1).
3
3. Remove the bolts (2) attaching the oil pump
to the main bearing cap.
2
4. Remove the attachment bolt (3) and take the
oil pump off the main bearing cap.
Installing oil pump

1. Check that the oil pump rotates smoothly
and has no heavy point.
1
2. Fit the oil pump and tighten the attachment
data".
3. Fit new O-rings to the suction and delivery M200600
pipes (1).
4. Fit the oil strainer.
©
200551 3-3
LUBRICATION SYSTEM
3.4 REMOVAL AND INSTALLATION, OIL COOLER
Removing oil cooler

1. Disconnect the coolant connections.
2. In the case of the XE ... C1, loosen the

engine brake air supply pipe.
3. Remove the attachment bolts and the oil

cooler. Collect the escaping lubricating oil.
4. Remove the O-rings on the oil cooler.
Installing oil cooler

1. Clean the contact surfaces between the oil
cooler and engine block. Fit new O-rings to
the oil cooler housing.
2. Fit the oil cooler to the engine block. Tighten

the attachment bolts to the specified torque.
3. In the case of the XE ... C1, fit the exhaust

brake air supply pipe.
4. Connect the coolant connections.
©
3-4 200551
LUBRICATION SYSTEM
3.5 REMOVAL AND INSTALLATION, CENTRIFUGAL OIL FILTER ELEMENT
} To prevent skin injury, avoid

unnecessary contact with the
drained lubricating oil.
Removing centrifugal oil filter element

1. Clean the cap (3) and the area around it.
4
2. Loosen the central bolt (4) and remove the
cap (3).
3
3. Remove the centrifugal oil filter element (2).
Installing centrifugal oil filter element 2

1. Clean the interior of the cap (3) and fit the
centrifugal oil filter element (2).
2. Check the central bolt (4) for damage.
3. Replace the sealing ring (5) and lightly 5

lubricate it with lubricating oil.
4. Fit the cap (3) and tighten the central bolt (4)
1
to the specified torque. See "Technical data".
M200526
©
200551 3-5
LUBRICATION SYSTEM
3.6 REMOVAL AND INSTALLATION, LUBRICATING OIL FILTER HOUSING
} To prevent skin injury, avoid

unnecessary contact with the
drained oil.
Threaded filter version

Removing lubricating oil filter housing
1. Clean the filter housing and the surrounding
area. 1
lubricating oil pressure sensor.
3. Remove the filter element. Collect any 2

escaping lubricating oil.
4. Remove the attachment bolts from the filter

housing and remove the filter housing (2).
5. Remove the O-rings (1).
Installing lubricating oil filter housing 3

1. Replace the O-rings (1) on the rear of the
filter housing (2).
2. Fit the filter housing (2). Tighten the

"Technical data".
8 3. Check the coupling (3). See "Technical

data".
4
4. Lightly grease the sealing ring of the filter

element (4).
5. Fit the filter element filled with clean

lubricating oil. Tighten the filter element to
6. Fit the electrical connections of the

M200599
©
3-6 200551
LUBRICATION SYSTEM
Filter element version

Removing lubricating oil filter housing
1. Clean the filter housing (1) and the
surrounding area. 7

lubricating oil pressure sensor. 4
3. Unscrew the cap (2) a few turns and drain
the filter housing. Collect the oil.
4. Remove the cap (2) with the filter element (3)

from the filter housing (1) and then remove
the element from the cap.
5. Remove the attachment bolts from the filter

housing (1) and remove the filter housing. 1
6. Remove the sealing ring (7).
Installing lubricating oil filter housing

1. Replace the sealing ring (7) at the rear of the 3
filter housing (1).
2. Fit the filter housing (1). Tighten the

"Technical data".
3. Put the new filter element (3) into the 6

screw cap (2).
4. Lightly oil the new O-ring (6) in the screw

cap (2, screw the cap and new filter 2 8
element (3) into the filter housing (1) and
"Technical data". 5
5. Fit the electrical connections of the
M201170
©
200551 3-7
LUBRICATION SYSTEM
©
3-8 200551
LUBRICATION SYSTEM

4.1 DISASSEMBLY AND ASSEMBLY, OIL PUMP
Disassembling oil pump

1. Remove the idler gear and hub from the front
plate.
2. Remove all attachment bolts from the two

sections of the oil-pump housing.
3. Remove the rear section of the oil pump

housing.
4. Remove the gear wheels from the oil pump

housing.
Assembling oil pump

1. Clean the gears and check them for damage.
Note:
Gears must be replaced as a set.
Note:
Gears must be pressed onto the shaft without any
grease having been applied.
Note:
The gears are marked. The gears with the marks
must be fitted opposite one another, so that only
1 mark is visible when they are in place.
2. Fit the gear wheels in the oil pump housing. 8

3. Fit the rear section of the oil pump housing.
4. Fit the attachment bolts of the oil pump

housing sections. Tighten the attachment
bolts to the specified torque. See "Technical M200344
data".
5. Check that the oil pump operates smoothly

and has no heavy point.
6. Fit the idler gear and hub to the front plate.

Tighten the bolt to the specified torque. See
"Technical data".
©
200551 4-1
LUBRICATION SYSTEM
4.2 DISASSEMBLY AND ASSEMBLY, OIL COOLER
TYPES XE ... C
Disassembling oil cooler
2
4
8
7
8 6
5
6
M200780
Note:
Place marks on all parts that are
disassembled so that on assembly the
covers, separator and oil cooling element
can be returned to the same position.
1. Remove the attachment bolts of the top

cover (2) and bottom cover (3).
2. Remove the oil cooling element (4) from the

oil cooler housing (1).
4. Check the oil cooling element (4). See

©
4-2 200551
LUBRICATION SYSTEM
Assembling oil cooler

1. Clean the oil cooler housing (1), the top
cover and bottom cover (3) with the
separator (5).
2. Replace the O-rings (6) and apply a little

grease to them.
3. Place the oil cooling element (4) in the

oil cooler housing and assemble the top
cover (2). Tighten the attachment bolts to
4. Fit the separator (5) and the bottom

cover (3). Tighten the attachment bolts to
TYPES XE ... C1
Disassembling oil cooler
1. Remove any protective cover from the oil
cooler and do not put it back.
3
2. Remove the oil cooling element (3) from the
oil cooler bracket (1).
2
2
4. Inspect the oil cooler element (3). See
"Inspection and adjustment". 1
Assembling oil cooler
1. Clean the oil cooler bracket (1) and
element (3). 5
6 8
2. Replace the O-rings (2) between the oil 6 5
2
cooler bracket (1) and oil cooler element (3) M2 01 294
and apply a little grease to them.
3. Fit the oil cooling element (3) to the oil cooler

bracket (1).
©
200551 4-3
LUBRICATION SYSTEM
©
4-4 200551
XE engine Contents
CONTENTS
Cylinder block and driving gear
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551

1.1 Overview drawing, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200551
1.2 Overview drawing, camshaft and crankshaft . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200551
1.3 Overview drawing, piston and connecting rod . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200551

2.1 Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551
2.2 Checking crankshaft end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200551
2.3 Checking camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . 200551
2.4 Checking camshaft end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . 200551
2.5 Checking roller tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 . . . . . 200551
2.6 Checking pistons and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 . . . . . 200551
2.7 Checking cylinder liners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 . . . . . 200551
2.8 Checking cylinder liner height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 . . . . 200551
2.9 Pressure-testing the cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 . . . . 200551
2.10 Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 . . . . 200551

3.1 Removal and installation, pistons and connecting rods. . . . . . . . . . . . . . . 3-1 . . . . . 200551
3.2 Removal and installation, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200551
3.3 Removal and installation, camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . 200551
3.4 Removal and installation, camshaft bearings . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . 200551
3.5 Removal and installation, cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200551
3.6 Removal and installation, oil nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 . . . . 200551
3.7 Removal and installation, expansion plugs . . . . . . . . . . . . . . . . . . . . . . . . 3-14 . . . . 200551
©
200551 1
Contents XE engine
©
2 200551
XE engine General
1. GENERAL
1.1 OVERVIEW DRAWING, CYLINDER BLOCK
22
2
3
21
20
19 18
4
6
7 5
17 8
9
9
12
11 10
13
14
15
16 M200951
1. Cylinder liner 12. Copper 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. Banjo bolt 16. Bearing cap, main bearing, front
6. Copper ring 17. Sealing plug
7. Sealing plug 18. Camshaft slide bearing
8. Dowel pin 19. Sealing plug
9. Bearing cap, main bearing, middle 20. Sealing plug
10. Sealing ring 21. Dowel pin
11. Sealing plug 22. Drain tap
©
200551 1-1
General XE engine
1.2 OVERVIEW DRAWING, CAMSHAFT AND CRANKSHAFT
2
3
4 5
6
9 1. Sealing plug 5. Crankshaft
M200783
2. Camshaft 6. Bearing shell set

3. Shim 7. Crankshaft axial ring
4. Camshaft locking plate
©
1-2 200551
XE engine General
1.3 OVERVIEW DRAWING, PISTON AND CONNECTING ROD
6 14
10 9
15
11
7
16
12
17
13
9
XE390 "cracked"
6
M201293
©
200551 1-3
General XE engine
1. Piston spring set 10. XE390 connecting rod

2. Piston 11. XE390 connecting rod bearing shells
3. Gudgeon pin 12. XE390 connecting rod bearing cap
4. Gudgeon pin circlip 13. XE390 connecting rod bolts (4x)
5. Connecting rod bearing bush (small end) 14. Cracked connecting rod
6. Connecting rod bearing cap 15. Cracked connecting rod bearing shells
7. Connecting rod bearing shells 16. Cracked connecting rod bearing cap
8. Connecting rod bolts (4x) 17. Cracked connecting rod bolts (2x)
9. Dowel pin
©
1-4 200551

2.1 CHECKING CRANKSHAFT
1. Check the crankshaft for external damage

and signs of overheating.
2. Magnaflux-test the crankshaft.
3. Measure the crankshaft.

To gain an impression of crankshaft main
bearing and big-end bearing wear, the
measuring procedure on the form illustrated
in "Technical data" must be followed.
4. Check the crankshaft oscillation. See

"Technical data".
5. Check the bearing shells and axial thrust

washers for wear, damage and signs of
overheating.
6. Check the bearing caps for damage and

signs of overheating.
7. Check the contact faces of the bearing caps

in the cylinder block.
8. Inspect the threaded hole for the bearing cap

bolt.
9. Inspect the bearing cap bolts. The screw

thread should be completely undamaged. If
in doubt, replace.
Note:
In the event of damage to the axial bearing
surfaces of the middle main bearing, they
9
can be ground to an undersize.
©
200551 2-1
Grinding the crankshaft

1. If necessary, the crankshaft can be ground
down to three undersizes.
2. The crankshaft can be ground to the next

undersize twice before it has to be nitrided.
3. The fillet radius of the journals must be

precisely machined to the specified radius.
4. After nitriding, the nitride layer must be

removed from the parts below by lapping:
- All main and big-end bearing journals.
- The sides of the middle main bearing for the
axial bearings.
- The circumference of the flywheel flange.
- The mounting surfaces of oil seals.
5. The conical front of the crankshaft must be

ground to the specified measurement after
nitriding.
6. If the crankshaft has been ground to an

undersize, this must be shown on the
crankshaft using the following codes:
H = main bearing journal
D = connecting rod journal
N = nitrided crankshaft
7. After the letters H and D there is also a

number (to show 1st, 2nd, or 3rd time of
undersizing).
This is what the indication on the crankshaft
opposite means:
9 H1 = main bearing journal ground to the

first undersize.
D2N = connecting rod journal ground
to the second undersize and H1
crank-shaft nitrided. D2
N
M2 00 090
©
2-2 200551
8. If the running surface of the crankshaft oil

seal on the flywheel end has to be ground,
the running surface may not be ground over A
the full 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.
9. After grinding the crankshaft, round the oil

holes again. See "Technical data".
Balancing crankshaft
1. Before balancing the crankshaft, it must be
placed on the front and rear main bearings. M2 00 080
The crankshaft must be dynamically

balanced at a maximum of 72 g/cm at an
engine speed of 350 rpm.
2. If necessary, material may be removed by

drilling out counterweights. In each
counterweight, 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.
©
200551 2-3
2.2 CHECKING CRANKSHAFT END PLAY
1. Fit a dial gauge to the crankshaft.
2. Push the crankshaft to the flywheel end and

set the dial gauge to zero.
3. Push the crankshaft to the timing gear end

and take the reading from the dial gauge.
Compare the reading with the technical data.
4. If there is too much play, it can be corrected

by installing oversized axial thrust washers.
5. If there is not enough play, this can be

corrected by grinding the axial thrust
washers on the metal side (not the bearing
material side).
M200786
©
2-4 200551
2.3 CHECKING CAMSHAFT
1. Clean the camshaft and check whether the

oilways are open.
2. Check that the sealing plug at the rear of the

camshaft provides a good seal.
3. Check the camshaft for signs of overheating.
4. Check the camshaft for damage and wear

(surface A) in accordance with the camshaft
wear table. See "Technical data".
a2
a1
a1 + a2 = A
M2 01 290
5. Check measurement A of the camshaft and

also check for oscillation. See "Technical
data".
6. Check the bearing of the camshaft itself in A

the cylinder block. See "Technical data".
7. Check the shim for wear and damage.
M200016
9
©
200551 2-5
2.4 CHECKING CAMSHAFT END PLAY
M200953
1. The camshaft end play must be measured
after installing and securing the camshaft
gear.
2. Fit a dial gauge to the camshaft gear.
3. Push the camshaft to the flywheel end and

9 set the dial gauge to zero.
4. Push the camshaft to the timing gear end

and read the dial gauge. Compare the
reading with the technical data. See
"Technical data".
5. The end play cannot be adjusted. If there is

too much end play, it can only be corrected
by installing a new shim.
©
2-6 200551
2.5 CHECKING ROLLER TAPPET CLEARANCE
The roller tappet clearance must always be

inspected when the camshaft and/or roller
tappets are replaced.
Checking roller tappet clearance
1. Remove the side covers.
2. Crank the engine until the roller tappet to be

tested is not under tension.
Note:
At a certain crankshaft position several roller
tappets can be inspected.
3. Press the roller tappet firmly against one side

of the tappet strip.
4. Use a feeler gauge to measure the clearance

(A) on the other side of the roller tappet.
Compare the readings with the specified
values. See "Technical data".
5. If the clearance is excessive, also inspect the

roller tappets and camshaft for damage.
6. Replace worn/damaged parts.
7. Check the roller tappet clearance again after

replacing the parts.
M201196
9
©
200551 2-7
2.6 CHECKING PISTONS AND CONNECTING RODS
Checking pistons
1. Check the gudgeon pin for cracks, wear and
2. Check the piston for cracks, wear and signs

of overheating.
3. Check the groove clearance of the piston

rings in the piston. See "Technical data".
4. Check the running surface and the piston

ring slot.
Checking connecting rods

1. Check the bearing shells of the connecting
rod.
2. Check the bearing bush of the connecting

rod. If the bearing bush/gudgeon pin is
damaged or worn, replace the connecting
rod.
3. Check the connecting rod for cracks and

4. Where cracked connecting rods are fitted,

inspect the connecting rod mating surfaces
and the big-end bearing caps. Replace the
connecting rod, if damaged.
5. Check the dimensions of the connecting rod.

©
2-8 200551
2.7 CHECKING CYLINDER LINERS
Measuring
1. To gain an impression of cylinder lining wear,
the measuring procedure on the "Overview
of wear measurements" form shown in
"Technical data" must be followed.
2. The ovality must be measured by turning the
dial gauge another 90 each time and taking
the appropriate measurement.
3. If the cylinder liner has become oval-shaped,
the initial bore in the cylinder block should 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".
Rejection standard for cylinder liners
The cylinder liner must be replaced if:
- the bore polishing standard has been
exceeded;
- the running pattern is not uniform;
- the running surface is scored;
- the difference between the measurements in
a cylinder on the "Overview of wear
measurements" form shown in "Technical
data" is more than 0.07 mm.
Bore polishing standard
One of the measures to be taken to find the cause
of excessively high oil consumption (engine oil
9
consumption test) is to inspect the cylinder liners
for bore polishing.
The cylinder liners are honed to what is known
as "plateau" level. In other words, the honing
pattern will display high points (A), shallow
depressions (B) and deep depressions (C).
B C A
M201176
©
200551 2-9
If the "deeper" honing grooves (C) still show a

regular pattern, bore polishing is not a factor.
M201177
Bore polishing means: mirror-like surfaces with

no visible regular honing pattern. A, B and C have
disappeared.
9
M201178
The cylinder liner must be replaced if the bore

polish area:
- is greater than 12 cm2.
- runs from the bottom of the cylinder liner to
the top to the point where the uppermost
piston ring is positioned and this area is more
than 15 mm across.
Note:
If the cylinder liner is rejected due to any of the
above criteria, it must be replaced and not be
honed. 2
M201179
©
2-10 200551
2.8 CHECKING CYLINDER LINER HEIGHT
1. Press the special tool (DAF no. 0694795)

with the dial gauge on the top of the cylinder
block.
2. Set the dial gauge to "0".
3. Press the pin of the dial gauge on the edge

of the cylinder liner.
4. Take the reading on the dial gauge and

compare it to the value in "Technical data".
5. If the cylinder liner is too deep in the cylinder M2 00 100

block, this can be corrected by fitting a shim
under the liner collar.
Note:
Grinding down the liner collar is not
permitted
©
200551 2-11
2.9 PRESSURE-TESTING THE CYLINDER BLOCK
1. Seal the cylinder block coolant channels with

sealing plates fitted with gaskets.
2. These sealing plates can be made in the

workshop. One sealing plate must have a
connection for an air hose.
3. Connect an air hose equipped with a reducer

valve to the sealing plate coupling.
4. Immerse the block in warm water and

pressure-test the block at an air pressure of
4 bar.
5. Leave the cylinder block in the water for

about half an hour and inspect the cylinder
block for any visible leaks.
©
2-12 200551
2.10 CHECKING CYLINDER BLOCK
1. Clean the cylinder block thoroughly, paying

special attention to the various oilways.
2. Check that the oilways are not blocked.
3. Check the sealing surfaces of the cylinder

block.
4. Check the threaded holes in the cylinder

block for damage and cracking.
5. Check the dimensions of the cylinder block.

6. When refacing the cylinder block, care must

be exercised to ensure that distance A
between the top of the crankshaft boring and
the top of the cylinder block remains within
the specified limits. See "Technical data".
After refacing the top of the cylinder block,
measure the depth of the recesses for the
cylinder liner collars.
Correct this depth to prevent the cylinder
liners protruding too far above the cylinder
block.
A
M200239
©
200551 2-13
©
2-14 200551

3.1 REMOVAL AND INSTALLATION, PISTONS AND CONNECTING RODS
Cracked connecting rod

Cracked connecting rods can easily be identified
in the engine by the two attachment bolts (1)
(rather than the four on other connecting rods).
The cracked mating surfaces (4) are unique fits in
which it is even more important to keep the
connecting rod and bearing cap together. The
connecting rod and bearing cap are marked as a
}
pair on one side (3). 5
The cracked connecting rods are
highly sensitive to damage on the
mating surfaces (4). Never place the
connecting rod and bearing cap on
the mating surfaces. Otherwise the
mating surfaces may become 1 4
damaged or fouled and they may no
longer fit one another. The 2
connecting rod and bearing cap 3
must then be replaced.
1
M2 01 285
Removing pistons and connecting rods

3. Remove the strainer/oil pipes and the oil

pump.
9
4. If the pistons are to be put back in the engine,
the position in the block must be marked so
that they are put back in the same cylinders.
5. Take the attachment bolts out of the big-end

bearing cap and remove it.
} With cracked connecting rods,

temporarily rotate the connecting
rod bolts back into the connecting
rod to protect the mating surfaces
during the removal procedure. If the
connecting rod is pressed out using,
say, a hammer handle, wood
splinters may remain in the mating
surfaces. The mating surfaces will
then no longer fit. The mating
surfaces must not be cleaned with a
steel brush.
6. Remove the connecting rod complete with

the piston.
©
200551 3-1
7. Ensure that the big-end bearing shells

remain with the respective bearing cap and
connecting rod.
8. Remove the lock washers from the bore of

the piston.
9. Push the gudgeon pin off the piston. Avoid

damaging the piston.
10. Remove the piston rings from the piston

using piston ring pliers. Keep the piston rings
with the correct piston.
Installing pistons and connecting rods

1. Carefully clean the parts and check that the
oilways are open.
Note:
If the pistons are to be re-used, make sure
there are no carbon deposits in the grooves
of the piston ring.
2. Take the ring from the oil scraper ring and

place it in the lowest piston ring groove. B
Using piston ring pliers, place the oil scraper
ring over the ring in the piston ring groove.
The opening of the ring must be opposite the
slot in the oil scraper ring.
3. Using piston ring pliers, fit the compression

ring with the word "top" uppermost.
4. Using piston ring pliers, fit the top ring with

the word "top" uppermost.
The slots (B) in the three piston rings must be
A
9 at an angle of 120 to each other.
5. Fit one lock washer into the piston and check

that it is flush in the groove. B
B
6. If necessary, heat the piston to a
temperature of approx. 50 C and lightly oil M2 00 139
the gudgeon pin.
7. Insert the connecting rod into the piston, and

force 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 of
the piston.
8. Fit the lock washer and check that it is flush

in the groove.
9. Clean the crankshaft and cylinder liner with a

lint-free cloth.
10. Fit the (new) bearing shells into the

connecting rod and oil them.
©
3-2 200551
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
side 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 by looking at the
numbers shown on the connecting rod and
bearing cap.
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 new

connecting rod bolts and tighten the bolts to
14. Check the connecting rod for any end play.

If radial play is detected, a connecting rod
with standard bearings has probably been
fitted to a ground crankshaft.
15. Crank the engine a few revolutions and

check if there are any points at which the
crankshaft does not run smoothly.
16. Fit the strainer/oil pipes and oil pump.

Note:
After replacing the pistons and piston rings,
the engine must be run-in again. 9
During the running-in period, the engine
must be filled with a different grade of engine
oil. See "Oil specifications".
©
200551 3-3
3.2 REMOVAL AND INSTALLATION, CRANKSHAFT
Removing crankshaft
2. Remove the timing gear case.
3. Remove the strainer/oil pipes and the oil

pump.
5. Remove the flywheel housing.
6. Undo the connecting rod bolts and remove

the big-end bearing caps.
7. Remove the main bearing cap bolts and take

the bearing caps off. Check whether all
bearing caps carry a letter mark. 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 shells, so

that they can be returned to their original
positions.
Installing crankshaft
1. Thoroughly clean all parts.
2. Clean the threaded holes for the main

9 bearing cap bolts.
3. If the bearing shells are to be reused, fit them

in their original positions in the cylinder block
and in the bearing caps.
4. If the crankshaft has been ground to

oversize, fit the relevant bearing shells. A
new crankshaft must first have any grease
and preservative removed from it.
5. Check that all oilways of the bearings and

crankshaft are open.
6. Check the dowel pin of the middle bearing.
7. Coat the bearing shells with oil.
8. Place the crankshaft in the cylinder block.
©
3-4 200551
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
pointing towards the crank pin. See diagram.
10. Fit the main bearing caps so that the letters

on them 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
cylinder block with a plastic hammer.
11. Apply a little oil to the thread and the contact

surface of the main bearing cap bolts and fit M2 00 091
the bearing cap bolts so that they are
fingertight.
12. Check the crankshaft end play. See

13. Tighten the main bearing cap bolts. Start by

tightening the central 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 that the crankshaft rotates easily and

smoothly all the way round.
15. Measure the end play again and correct it if

necessary.
16. Fit the connecting rods using new

connecting rod bolts.
17. Fit the strainer/oil pipes and oil pump. 9

©
200551 3-5
3.3 REMOVAL AND INSTALLATION, CAMSHAFT
Removing camshaft
Note:
3. Remove the idler gear (3) and the camshaft

gear (6) from the timing gear. 6 3 1 2
4. Remove the side covers from the right-hand
side of the engine.
5. Remove the locking strip from the roller

tappets and take them out.

camshaft locking plate.
7. Remove the camshaft and shim from the

cylinder block.
9 M200578
©
3-6 200551
Installing camshaft
1
2
3
4
5
M2 01 298
1. Before fitting the camshaft, check that all oil

channels in the cylinder block are open and
that the sealing plug (1) is fitted at the end of
the camshaft!
2. Apply sufficient oil to the camshaft bearings

and fit the turning camshaft into the cylinder
block.
3. Check that the camshaft rotates easily and

smoothly all the way round.
4. Fit the shim (3) on the camshaft.
5. Fit the camshaft locking plate (4) and the

9
attachment bolts (5), tightening them to the
6. Check again that the camshaft rotates easily

and smoothly all the way round. Check the
end play of the camshaft; see "Inspection
and adjustment".
©
200551 3-7
7. Fit the camshaft gear (2) and tighten the

attachment bolt to the specified torque. See
"Technical data".
8. Fit the idler gear (3) and note the markings.

Tighten the attachment bolt to the specified
9. Apply a little oil to the roller tappets and fit

them and the locking strips.
10. Fit the push rods.
Note:
4
11. Fit the side covers. 2 3
1
M201281
©
3-8 200551
3.4 REMOVAL AND INSTALLATION, CAMSHAFT BEARINGS
Removing camshaft bearings

1. Remove the camshaft.
2. Remove the camshaft bearings from the

cylinder block using the special tool
(DAF no. 1329423). Make sure that the initial
bores of the camshaft bearings are not
damaged.
3. Clean the initial bores.
M201372-2
Installing camshaft bearings

1. Check that the channel leading from the
main oil channel to the camshaft bearing is
open.
9
M200799
2. Fit the camshaft baring on the special tool

(DAF no. 0535606). Make sure that the oil
bore in the camshaft bearing lines up with the
mark on the special tool.
M200800
©
200551 3-9
3. Fit special tool (DAF no. 1329423) into the

outer initial bore. Fit special tool
(DAF no. 0535626) with the aid of the thread
in special tool (DAF no. 1329423). In this
way the innermost initial bores can be
reached. Using the special tool
(DAF no. 0535606), fit the camshaft
bearings in the initial bores in the cylinder
block.
Note:
When installing the camshaft bearings with
oil orifices into the cylinder block, take note of
the mark on the special tool . The mark
should line up with the main oil channel in the
cylinder block.
Note:
When installing the camshaft bearings, be
sure not to cause any burrs in the camshaft
bearing.
M200801
4. Fit the camshaft.
©
3-10 200551
3.5 REMOVAL AND INSTALLATION, CYLINDER LINERS
Removing cylinder liner

2. Remove the connecting rods and pistons.
3. Crank the crankshaft so that sufficient space

is created for fitting the special tool.
4. Before removing the cylinder liner from the

cylinder block, fit the appropriate parts of the A
special tool (DAF no. 0535625). See A in the 1
diagram opposite for the operating principle.
}
5.
Make sure that the oil nozzles do not
get damaged when the tool is being
fitted.
With the special tool, pull the cylinder liner

2
out of the cylinder block. B

3 1
6. Measure the depth of the recess for the
cylinder liner collar and compare this value 7 5
with the specified value. See "Technical 7
data".
7. Check the internal diameter of the initial bore

for the cylinder liner.
If the initial bore in the cylinder block is 0.05
4
mm larger than the maximum new 5
measurement, the cylinder block must be
bored and cylinder liners with an oversized 6
outer diameter must be fitted. See "Technical
data".
Installing cylinder liner 9

1. Clean the cylinder block before fitting the M201289
new liner.
2. Crank the crankshaft so that sufficient space

is created for fitting the special tool.
©
200551 3-11
3. Before fitting the cylinder liner in the cylinder

block, fit the appropriate parts of the special A
tool (DAF no. 0535625). See B in the 1
diagram for the operating principle.
4. If possible, the cylinder liner should be

cooled or the engine block warmed in water 2
before installation.
5. Only in an emergency is it permitted to apply

an extremely thin film of lubricating oil to the B
edge of the initial bore. All other lubricating 3
agents, of whatever type, are strictly 1
forbidden. 7 5
Difficulties in the replacement of cylinder 7
liners are almost always the result of
lubricant residue used in the previous
assembly.
6. Press the cylinder liner fully into the cylinder

4
block using the special tool. 5
7. Check the interior diameter of the cylinder 6

liner after fitting. See "Technical data".
8. After installing the new cylinder liner,

measure the height that it protrudes above
the cylinder block. See "Technical data". M201289
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 "Oil specifications".
9
©
3-12 200551
3.6 REMOVAL AND INSTALLATION, OIL NOZZLES
Removing oil nozzles

2. Remove the banjo bolt.
3. Remove the oil nozzles.
Installing oil nozzles

1. Clean the oil nozzles and the threaded holes.
2. Fit the oil nozzles.
3. Fit the banjo bolts and tighten them to the

4. Fit the oil sump. M200955
©
200551 3-13
3.7 REMOVAL AND INSTALLATION, EXPANSION PLUGS
Removing expansion plug

1. Tap the edge of the expansion plug to tilt the
plug. 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.
Installing 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 at

least 1 hour.
3. Check the cylinder block for leakage.
©
3-14 200551
English
Printed in the Netherlands DW13243204

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Component manual 85CF

In the interest of continuing product development,

No part of this publication may be reproduced

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200551

3. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200551

4. CONSTRUCTION PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200551

5. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200551

6. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200551

7. TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200551

8. FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200551

9. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200551

10. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . . 200551

11. CYLINDER BLOCK AND DRIVING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . . 200551

- If necessary, support the component in a

The first version can be identified by: 1 2 3

Type plate "C" (C2) version

GOVERNED SPEED min -1 OUTPUT kW

1. (Injection timing) BEFORE cm 3

3. Engine number SMOKE LEVEL FREE ACCELERATION m -1

4. Engine type EINDHOVEN HOLLAND

Type plate "C1" (C3) version

2.2 ENGINE DATA

Engine type P (kW/hp) at rpm M (Nm) at rpm

To achieve the correct pre-tension when re-using

The reason for this is that the friction coefficients

The following applies to all threaded

3.2 LOCKING COMPOUNDS AND SEALANTS

OVERVIEW OF LOCKING COMPOUNDS

Applying locking compound

OVERVIEW OF SEALING COMPOUNDS

Product name Properties

3.3 THREADED CONNECTIONS

Table of standard tightening torques,

Overview of standard tightening torques

The bolt stem length L is the length of the bolt

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

Automatic poly V-belt tensioner

Explanation of turbocharger type

GT42 Turbine type designation

K31 Turbine build series

Q Compressor rotor development letter

D Turbine housing material:

4.2 TIGHTENING TORQUES

Alternator types XE ... C

Intercooler air supply pipe

(1) Fasten with Loctite 243

Inlet manifold types XE ... C

Inlet manifold types XE … C1

Relay grid heater

Main fuse types XE ... C1

Engine hanger brackets

Version with direct fan drive XE ... C

Version with separate fan drive XE ... C

Version with separate up-speed fan

Version with poly-V-belt drive XE ... C1

Version with poly-V-belt drive XE ... C1

5.2 TIGHTENING TORQUES

The tightening torques stated in this section are

Fuel filter (threaded filter version)