DAF LF45, LF55 Series. Manual - part 195

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4.8 REMOVING AND INSTALLING CYLINDER HEAD

When components are removed 

from any part of the engine, dirt may 

enter. This may cause serious 

damage to the engine. The engine 

should therefore be cleaned 

thoroughly before it is opened. Plug 

all openings that are freed.

Removing cylinder head
1.

Drain the coolant.

2.

Disconnect all electrical wiring around the 

engine which is required for removing the 

cylinder head.

3.

Disconnect the air inlet pipe from the air 

cooler on the turbocharger side.

4.

Remove the poly-V-belt.

5.

Remove the heat shields from the exhaust 

manifold.

6.

If fitted, remove the attachment bolts of the 

air-conditioning compressor.

7.

Remove the attachment bolts from the 

alternator/air-conditioning compressor 

bracket and remove the attachment bracket.

8.

Remove the attachment bolts from the 

exhaust manifold and move the manifold and 

the turbocharger a little away from the 

cylinder head.

9.

Remove the other coolant hoses that are 

attached to the cylinder head.

When removing components from 

the fuel system, dirt can enter. This 

may result in serious damage. The 

area around the fuel system should 

therefore be cleaned before opening 

it. Detached pipes must be plugged 

immediately.

10. Detach the injector pipes on the injector side.

11. Detach the supply pipe between the high-

pressure pump and fuel rail on the fuel rail 

side.

12. Detach the fuel return pipe from the fuel rail 

and from the cylinder head.

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13. Unscrew the attachment bolts from the fuel 

rail and remove it.

14. Unscrew the attachment bolts from the 

intake manifold and remove it.

Note:

To avoid dirt entering the intake opening, it 

must be taped up.

15. Remove the valve cover.

16. Remove the valve sleeve.

17. Remove the valve gear.

18. Remove the push rods. Mark the push rods 

so that they can be refitted in their original 

position.

19. Remove the fuel supply pipes.

20. Remove the injectors.

21. Remove the attachment bolts from the 

cylinder head in the reverse order to that 

followed for tightening. See "Technical data".

22. Remove the cylinder head from the cylinder 

block. Keep the gasket to enable the correct 

new head gasket to be selected.

23. Remove any gasket remnants from the 

cylinder head and the cylinder block.

24. Check the cylinder block. See "Checking and 

adjusting".

25. Check the threaded holes in the cylinder 

block for damage and cracking.

26. Check the cylinder head. See "Checking and 

adjusting".

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Installing cylinder head
1.

Clean the threaded holes in the cylinder 

head using a screw tap.

Note:

Cylinder head gaskets are available in two 

thicknesses. The thickness of the cylinder 

head gasket can be identified by the position 

of the holes in the projecting cylinder head 

gasket lip under the exhaust manifold on 

cylinder 2. See "Technical data" for the 

cylinder head gasket thicknesses.

2.

Position the new cylinder head gasket. If the 

type of cylinder head gasket is known, use a 

gasket of the same type as the one removed.

Note:

If the type of cylinder head gasket removed 

is not known or if the main components of the 

driving gear have been changed, the type of 

gasket required must be determined afresh.

To do this, measure the average piston 

projection. See "Checking and adjusting".

Select the correct type of cylinder head 

gasket using the information in "Technical 

data" and fit it.

3.

Check that all lubricating and coolant ducts 

are free.

4.

Position the cylinder head carefully on the 

cylinder block and ensure that the cylinder 

head fits well over the dowel pins.

5.

Check the cylinder head bolts. See 

"Checking and adjusting". Use new cylinder 

head bolts if one bolt does not meet one or 

more conditions.

6.

Apply engine oil to the thread and to the 

underside of the bolt head.

7.

Position the cylinder head bolts and hand-

tighten them.

Note:

The short cylinder head bolts must be fitted 

in the outer rows.

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8.

Tighten the cylinder head bolts to the 

specified torque and in the sequence shown. 

See "Technical data".

9.

Fit the exhaust manifold with new gaskets 

and tighten the attachment bolts to the 

specified torque. See "Technical data".

10. Fit the injectors.

Note:

Ensure that the injector is fitted correctly, 

bearing in mind the supply opening.

11. Fit the fuel supply pipes.

12. Fit the push rods in their original position and 

apply a drop of engine oil to the head of the 

push rod.

13. Fit the valve gear.

14. Fit the valve sleeve.

15. Tighten the injector wiring to the specified 

torque. See "Technical data".

16. Fit the valve cover.

17. Remove any gasket remnants from the 

intake manifold and the cylinder head.

Note:

Ensure that the air inlet is free of gasket 

remnants.

18. Apply sealant to the intake manifold and fit it. 

See "Technical data".

19. Fit the fuel rail.

20. Fit the injector pipes.

21. Fit the supply pipe between the high-

pressure pump and fuel rail.

22. Fit the fuel return pipe on the fuel rail and 

cylinder head.

23. Connect the various coolant hoses.