DAF CF65, CF75, CF85 Series . Manual - part 199

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4.7 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD

Removing the exhaust manifold
1.

Remove the turbocharger.

2.

Remove the exhaust manifold (1) and 
gaskets.

Installing the exhaust manifold
1.

Check the contact surface of the exhaust 
manifold for smoothness with a steel ruler (2) 
and feeler gauge (3). Compare the readings 
with the values referred to in "Technical 
data".

2.

Fit new gaskets.

3.

Fit the exhaust manifold. Tighten the bolts, 
from the middle outwards alternately. For the 
specified torque, see "Technical data".

4.

Fit the turbocharger.

5.

Start the engine and check for leakage.

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4.8 REMOVAL AND INSTALLATION, CYLINDER HEAD

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When components are removed 
from any part of the engine, dirt may 
enter. This may cause serious 
damage to the engine. Therefore, the 
engine should be cleaned 
thoroughly before it is opened. Plug 
all openings that are freed.

Removing the 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.

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When removing components from 
the fuel system, dirt can enter. This 
may result in serious damage. 
Therefore, clean the area around the 
fuel system 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.

13. Unscrew the attachment bolts from the fuel 

rail and remove it.

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14. Unscrew the attachment bolts from the inlet 

manifold and remove it.

Note:
To avoid dirt entering the inlet 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 "Inspection 

and adjustment".

25. Check the threaded holes in the cylinder 

block for damage and cracking.

26. Check the cylinder head. See "Inspection 

and adjustment".

Installing the 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.

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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 used.

Note:
If it is not known what type of cylinder head 
gasket is used 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 "Inspection and adjustment".
Select the correct type of cylinder head 
gasket using the information in "Technical 
data" and use 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 
"Inspection and adjustment". 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.

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.

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