DAF CF65, CF75, CF85 Series . Manual - part 456

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Inspection and adjustment

PE ENGINE INLET/EXHAUST SYSTEM

CF65/75/85 series

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3.3 INSPECTION AND PRESSURE TESTING, AIR INLET SYSTEM

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When pressure testing the air intake 

system, the plugs may spring off if 

they are not properly secured.

Check the condition and mounting of the air inlet 

channels/pipes of the air intake system.

In case of doubt as to the proper sealing of the air 

intake system, which is indicated by the following:

1.

loss of power

2.

high fuel consumption

3.

unusual sounds,

carry out a pressure test to check the air inlet 

system for leaks.

1.

Remove the pipe between the air filter 

housing and the intake port on the suction 

side of the turbocharger.

2.

Fit the special tools (DAF no. 1329320) and 

(DAF no. 1329403) to the suction side of the 

intake port and plug the opening.

3.

Remove the air inlet hose between the air 

cooler and the inlet manifold.

4.

Fit the special tool (DAF no. 0694831) onto 

the air cooler.

5.

Connect a flexible air pipe with reducer valve 

to the coupling (A) and charge the system to 

approx. 1 bar.

6.

Use a soapy solution to check the whole inlet 

system for air leaks. Also check whether the 

pressure gauge of the reducer valve drops.

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Inspection and adjustment

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CF65/75/85 series

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3.4 CHECKING INLET UNDERPRESSURE

1.

Remove the underpressure indicator 

connection (A) from the air intake pipe 

between the air filter housing and 

turbocharger.

2.

Connect a pressure gauge with a maximum 

rating of -100 mbar (-10 kPa) to the 

connection of the underpressure indicator.

3.

Measure the inlet underpressure at full-load 

engine speed and compare the 

measurement to the specified value. See 

"Technical data".

3.5 CHECKING THE GLOW PLUG

Checking the glow plug
1.

Remove the electrical connections on the 

glow plug.

2.

Using a multimeter, determine the resistance 

of the glow plug. See "Technical data".

3.

Remove the connecting hose between the 

inlet pipe and the air cooler.

4.

Check whether the glow plug is damaged.

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4-1

Removal and installation

PE ENGINE INLET/EXHAUST SYSTEM

CF65/75/85 series

4

6

4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, TURBOCHARGER

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If the turbocharger to be replaced 

has been damaged to such an extent 

that parts of the turbocharger are 

missing, or lubricating oil has 

entered the inlet system, the inlet 

and exhaust systems must be 

checked and cleaned thoroughly in 

order to prevent serious damage to 

the engine.

Removing the turbocharger
1.

Remove the heat shields (1) from the 

turbocharger.

2.

Remove the air inlet hose (2) between the 

turbocharger and air filter.

3.

Remove the exhaust brake (3).

4.

Disconnect the connector pipe (4) from the 

turbocharger and the air intake pipe to the air 

cooler.

5.

Remove the turbocharger lubricating oil 

pipes. Plug the openings.

6.

Remove the attachment nuts from the 

turbocharger.

7.

Remove the turbocharger from the exhaust 

manifold.

Installing the turbocharger
1.

Before installing the turbocharger, check the 

following:

-

turbocharger shaft must run smoothly

-

turbocharger shaft must not be out of 

true

-

turbocharger shaft must have a little 

radial clearance.

If applicable:

-

movement of the wastegate.

2.

Clean the sealing surfaces.

3.

Apply a layer of Copaslip to the exhaust 

manifold studs.

4.

Always use new gaskets during installation.

5.

Fit the turbocharger. If necessary, turn the 

two halves of the housing so that the oil and 

air pipes can be connected free of stress.

6.

Fit the oil discharge pipe.

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7.

Spray clean engine oil into the oil supply of 

the turbocharger and fit the oil supply pipe.

8.

Fit the connector pipe from the turbocharger 

and the air intake pipe to the air cooler.

9.

Fit the exhaust brake.

10. Fit the air inlet hose between the 

turbocharger and the air filter.

11. Fit the heat shields for the turbocharger.