PDF Engine Manual DAF 95XF Series - 1000 KB
This engine manual is the definitive resource for servicing and repairing the DAF 95XF Series engines.
It contains detailed specifications, teardown and assembly procedures, and troubleshooting information.
Professional mechanics rely on this type of manual to perform accurate repairs and major overhauls.
Keep your DAF truck's engine running at peak efficiency with this essential guide.
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--- Page 1 ---
2 CONTENTS
95XF series
TECHNICAL DATA
0
DIAGNOSTICS
1
XF ENGINE
2
XF ENGINE COOLING SYSTEM
3
XF ENGINE LUBRICATION SYSTEM
4
XE ENGINE
5
XE ENGINE COOLING SYSTEM
6
XE ENGINE LUBRICATION SYSTEM
7
ǹ 200335
--- Page 3 ---
2 TECHNICAL DATA
95XF series XF engine
Inlet manifold
Attachment bolts 60 Nm
Glow plug attachment nut
Air inlet hose clamps
55 Nm
12 Nm
0
Turbocharger
Heat shield attachment bolts 30 Nm(1)
Turbine housing clamp plate attachment nut 15 Nm
Attachment nuts, exhaust manifold
flange/turbocharger 60 Nm(2)
Elbow on turbocharger 40 Nm
Oil supply pipe banjo bolt 90 Nm
(1) Secure with Loctite 243
(2) Apply Copaslip to secure
ǹ 200335 2-5
--- Page 4 ---
2 TECHNICAL DATA
95XF series XF engine lubrication system
Oil cooler
Attachment bolts connecting oil cooler to
cylinder block
Coolant supply pipe union
50 Nm
90 Nm
0
Plug, adjustable banjo connection 90 Nm
Banjo bolt, adjustable banjo connection 90 Nm
Centrifugal oil filter
Central bolt 20 Nm
Oil discharge pipe union 50 Nm
Dip stick
Threaded coupling 60 Nm
(1) Secure with Loctite 243
(2) Secure with Loctite 572
(3) Secure with Loctite 2701
Oil sprayer
Banjo bolt M14 for oil sprayer with locking
plate 30 Nm
M10 banjo bolt for oil sprayer 30 Nm
Main bearing caps
Main bearing cap attachment bolts 150 Nm + 120_ angular displacement(1)
Big-end bearing caps
Attachment bolts, big-end bearing caps 1 4
1st phase, 35 Nm
sequence 1-2-3-4
2nd phase, 45 Nm
sequence 4-3-2-1
3rd phase, 60_ angular
sequence 1-2-3-4 displacement(2)
3 2
M200661
(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 to the threads and contact surfaces of the
connecting rod bolts.
ǹ 200335 4-3
--- Page 5 ---
2 TECHNICAL DATA
95XF series XE engine
Flywheel housing
Attachment bolts 110 Nm(1)
Sealant to be used when fitting flywheel
housing Loctite 510
0
Flywheel
Attachment bolts
Without PTO 260 Nm + 90_ angular displacement
With PTO 260 Nm + 150_ angular displacement
Engine mountings on timing gear end
Cylinder block bracket attachment bolts 92 Nm
Chassis engine bracket attachment bolts 73 Nm
Vibration damper engine bracket attachment
bolts 225 Nm + 60_ angular displacement
Engine mountings on flywheel end
Flywheel housing engine bracket attachment
bolts 260 Nm
Chassis engine bracket attachment bolts 73 Nm
Vibration damper engine bracket attachment
bolts 225 Nm + 60_ angular displacement
Engine hanger brackets
Attachment bolts 110 Nm
Valve gear
Valve cover attachment bolts 25 Nm
Rocker setting bolt lock nut 40 Nm
Bridge piece setting bolt lock nut 40 Nm
Lubricating oil strip/rocker seat attachment
bolts 110 Nm
DEB set screw nut 25 Nm
Solenoid valve 20 Nm
Wiring harness attachment bolt 9 Nm
Valve sleeve attachment bolts 30 Nm
Tighten the valve sleeve bolts in the sequence
shown. 7 15 9
3 11 13 2
5 6
1 14 8
10 12 4
M200942
(1) Apply Loctite 243 to secure
ǹ 200335 5-9
--- Page 6 ---
2 DIAGNOSIS
95XF series Contents
CONTENTS
Page Date
1. TRACTIVE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0008
1.2 Acceleration test (engine model with conventional fuel system) . . . . . . . . . .
1.3 Acceleration test (engine model with UPEC fuel system) . . . . . . . . . . . . . . . .
1-3 . . . . . . 0008
1-7 . . . . . . 0008 1
1.4 Acceleration test form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 . . . . . 0008
1.5 Acceleration test using DAVIE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 . . . . . 0008
2. XF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
2.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0008
3. COOLING SYSTEM XF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
3.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0008
4. LUBRICATING OIL SYSTEM XF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008
4.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0008
5. XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0008
5.1 Fault-finding table for engine functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0008
5.2 Fault-finding table for vehicle functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 . . . . . . 0008
6. COOLING SYSTEM XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0008
6.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0008
7. LUBRICATING OIL SYSTEM XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0008
7.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0008
ǹ 0008 1
--- Page 7 ---
2 DIAGNOSIS
95XF series Tractive problems
5. Run the drive train at operating temperature
(drive for at least 15 minutes with a loaded
vehicle).
Note:
When switched on, the air compressor and fan
consume 10 to 15 kW engine power on average.
During the test try to avoid that both consumers
are or have been switched on.
1
6. Connect DAVIE and follow the instructions
in DAVIE.
7. Fully depress the brake pedal during the
acceleration test.
Result of first acceleration test
If the acceleration time is not achieved, first
carry out the following work.
- Check the fuel system for the presence of
air.
- Replace/clean the air filter element.
- Check the setting of the wastegate on the
turbocharger (if present).
- Check the engine brake butterfly valve for
smooth operation.
- Check the inlet air cooler exterior for dirt
deposits.
- Clean the water separator (if fitted).
- Clean the fuel coarse filter.
- Check whether the hand pump on the fuel
coarse filter is tightened.
- Replace the fuel fine filter.
- Check the suction pipe of the tank for
clogging by large pieces of foreign matter.
ǹ 0008 1-9
--- Page 8 ---
2 DIAGNOSIS
95XF series Lubricating oil system XF engine
4. LUBRICATING OIL SYSTEM XF ENGINE
4.1 FAULT-FINDING TABLE
FAULT: ENGINE OIL PRESSURE TOO LOW
Possible cause Remedy 1
Engine oil level too low. Top up engine oil to maximum level.
External oil leakage. Visually check engine for leakage. Repair if
necessary.
Defective oil-pressure switch. Check the switch. Replace if necessary.
Oil fails to meet the required specifications. Renew the engine oil and the oil filter.
Oil temperature is too high. Check the oil cooler.
Oil mixed with coolant or fuel. Renew the engine oil and the oil filter.
Oil feed-through pipe or oil suction pipe loose or Check the oil pipes. Repair if necessary.
broken.
Oil-pressure control valve fails to operate. Check the oil pressure control valve.
Inadequate functioning of oil pump. Check the oil pump.
Run-out main or connecting-rod bearings. Check the main or connecting-rod bearings.
Loose oil nozzle of piston cooler. Check the oil nozzle. Replace if necessary.
Defective internal oil pressure pipes or sealing. Check the oil pressure pipes and seals.
Contamination between oil-pressure control Check/clean the oil pressure control valve.
valve and seat.
Contaminated oil filter. Renew the oil filter.
ǹ 0008 4-1
--- Page 9 ---
2 DIAGNOSIS
95XF series XE engine
5.2 FAULT-FINDING TABLE FOR VEHICLE FUNCTIONS
FAULT: VEHICLE SPEED CONTROL IS NOT FUNCTIONING
Possible cause Remedy
Fault in electrical components/wiring of:
- wiring harness
Check the electrical system.
1
- combination switch
- speed signal
- proximity switch
There is/are switch-off condition(s) for vehicle Check for presence of switch-off condition(s).
speed control.
FAULT: ENGINE SPEED CONTROL IS NOT FUNCTIONING
Possible cause Remedy
There is/are switch-off condition(s) for engine Check for presence of switch-off condition(s).
speed control.
Fault in electrical components/wiring of: Check the electrical system.
- wiring harness
- combination switch
- speed signal
FAULT: DEFECTIVE PRE-GLOWING AND AFTER-GLOWING FUNCTIONS
Possible cause Remedy
Fault in electrical components/wiring of: Check the electrical system.
- wiring harness
- preglowing control light
- glow filaments
- glow-filament relay
There is/are switch-off condition(s) for the Check for presence of switch-off condition(s).
pre-glowing and after-glowing functions.
ǹ 0008 5-9
--- Page 10 ---
2 XF ENGINE
95XF series General
2. GENERAL
2.1 LOCATION OF COMPONENTS
3 1
9
2
2
8
4
10
5
7 6
M200543
Legend
1. Thermostat housing
2. Water pump
3. Air-conditioning compressor
4. Fan drive
5. Vibration damper
6. Air compressor
7. Oil cooler
8. Turbocharger
9. Wastegate diaphragm
10. Oil-filling pipe
ǹ 0008 2-1
--- Page 11 ---
2 XF ENGINE
95XF series Inspection and adjustment
5. By cranking the crankshaft always
1/ stroke, using the special tool
3
(DAF no. 1310477), the valves can be
adjusted according to the injection
sequence 1-5-3-6-2-4.
Cylinder with valves Adjust valves
in overlap position of cylinder
1 6
5 2 2
3 4
6 1
2 5
4 3
6. If the engine has been fitted with a DEB, the
DEB clearance must be checked following M200540
the valve-clearance adjustment.
7. Fit the valve covers, see chapter
“Removal and installation”.
ǹ 0008 3-5
--- Page 12 ---
2 XF ENGINE
95XF series Removal and installation
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION, ENGINE
Suspend the engine carefully from
the hoist, using approved lifting
gear.
Various fluids will be released when
pipes are removed. Collect these
fluids. Take care of your personal
protection and any fire hazards.
2
Note:
Because of the large number of vehicle
specifications, it is not feasible to exactly specify
the engine removal and installation procedures
for every vehicle.
This description only includes the main points
requiring attention.
- Disconnect the earth lead from the battery
pole.
- Avoid opening of fluid systems as much as
possible. If possible, remove and put aside
the engine components.
- When removing the engine, ensure that no
parts or dirt fall into the engine, radiator or
other components. Therefore, plug all
openings.
- Electrical wiring harnesses are easily
damaged. If damaged, they may cause
faults. Make sure these wiring harnesses
are stress-free and have been installed
away from moving parts.
- Tighten all fixing bolts to the correct
tightening torque.
- Do not allow the engine to rest on the oil
sump. Because the oil sump is made of
sheet material, it will be severely damaged
by the engine’s own weight.
ǹ 0008 4-1
--- Page 13 ---
2 XF ENGINE
95XF series Removal and installation
20. Install the heat shields of the exhaust
manifold and tighten the fixing bolts to the
specified tightening torque, see main group
“Technical data”.
21. Install the air-conditioning bracket, if
present.
22. Adjust the V-belt tension of the
air-conditioning compressor, see chapter
2
“Checking and adjusting”.
23. Install the reaction rod between the engine
and the radiator.
24. Install the compressor pipe from the air inlet
pipe to the compressor.
25. Install the inlet pipe between the
turbocharger and the intercooler.
26. Install the inlet air hoses between the
engine and the intercooler and tighten the
fixing bolts to the specified tightening
torque, see main group “Technical data”.
27. Connect the electric wiring.
28. Reconnect the earth lead to the battery.
29. Fill the cooling system.
ǹ 0008 4-11
--- Page 14 ---
2 XF ENGINE
95XF series Removal and installation
Removal, compressor and air-conditioning
V-belt
1. Slacken the upper attachment bolt (1) on
1
the compressor. 1
2. Slacken the lower fixing bolt (2) on the
compressor.
3. Slacken the fixing bolt from the threaded
spindle which is attached to the
2
cooling-water pump.
3
4. Turn the lock nuts (3) on the threaded
spindle so that the alternator can be tilted
towards the engine block and the V-belt can
be removed from the pulley.
2 M2041
Installation, compressor and air-conditioning
V-belt
1. Inspect the pulleys for damage, rust and
grease deposits.
2. Install the compressor and air-conditioning
V-belt and adjust the V-belt tension, see the
chapter “Checking and adjusting”.
ǹ 0008 4-21
--- Page 15 ---
2 XF ENGINE
95XF series Removal and installation
4.21 REMOVAL AND INSTALLATION, TIMING-GEAR COVER SEALING RING
Removing the timing-gear cover sealing ring
1. Remove the vibration damper hub.
2. Remove the timing-gear cover sealing ring
by drilling two small holes into the sealing
ring and pull, using the special tools
(DAF no. 0484899 and DAF no. 0694928)
to pull the sealing ring from the timing-gear
cover.
2
Installing the timing-gear cover sealing ring
1. Clean and check the sealing ring recess in
the timing-gear cover. Even minimal
damage can lead to a leak.
Note:
If a filler ring was fitted in the oil sealing ring
recess, re-install this filler ring.
2. Use the special tool (DAF no. 1310424) to
fit a dry new sealing ring and install the
thrust piece in the recess of the timing-gear
cover.
3. Remove the special tool.
4. Install the vibration damper hub.
M200771
ǹ 0008 4-31
--- Page 16 ---
2 XF ENGINE
95XF series Removal and installation
Installing the fuel pump drive housing
1. Install the fuel-pump drive housing with a
new O-ring for lubrication. Tighten the fixing
bolts to the specified torque. See main
group “Technical data”.
2. Install the drive shaft (8) in the fuel-pump
drive housing.
3. Install the axial retainer plate (7) and tighten
2
the fixing bolts to the specified tightening
torque, see main group “Technical data”.
4. Install a dry new timing-gear case
sealing ring (3) using special tool
(DAF no. 1329318).
5. Install the fuel pump drive gear wheel.
6. Set the injection timing. 87
M200581
ǹ 0008 4-41
--- Page 17 ---
2 XF ENGINE
95XF series Disassembly and assembly
Inspect
Fit the special tool (DAF no. 1329445)
under the gear wheel (12) and press the
shaft with a force of 100 kN. If the shaft is
pressed from the gear wheel, the shaft
and/or the gear wheel is/are rejected.
15. Apply a little engine oil in the bearing
housing (11) and check the shaft (1) for
even rotation.
2
M200932
ǹ 0008 5-9
--- Page 19 ---
2 COOLING SYSTEM XF ENGINE
95XF series General
a
b
a
b
3
M200583
ǹ 0008 2-3
--- Page 20 ---
2 COOLING SYSTEM XF ENGINE
95XF series Inspection and adjustment
4.3 CHECKING THE VISCOUS FAN CLUTCH
Do not run the engine in an
enclosed or unventilated area.
Make sure exhaust fumes are
properly extracted.
Maintain a safe distance from
rotating and/or moving
components.
Testing with a cold engine
During this test, the slip in the viscous fan clutch
is measured, when the clutch is not operational.
This test must be carried out with a “cold”
3
engine (coolant temperature
approximately 50_C).
1. Check the coolant level, and as necessary
top up with coolant.
2. Start the engine and run it at idling speed
for at least 5 minutes.
3. Then use a digital revolution counter to
measure the fan speed at a number of
engine speeds (from idling to maximum
engine speed).
During this test procedure, the speed of the
fan should be approx. 600 to 1100 rpm.
Testing with a warm engine
This test checks whether the contact operates at
an operating temperature of 85 - 95_C.
1. Check the coolant level, and as necessary
top up with coolant. Be careful when
topping up the coolant, if the engine is
warm.
2. Remove the front engine encapsulation.
ǹ 0008 4-3
--- Page 21 ---
2 COOLING SYSTEM XF ENGINE
95XF series Removal and installation
15. Remove the right-hand connector pipe from
the inlet pipe to the intercooler.
16. Remove the air-conditioning compressor
unit and move it, together with the hoses, to
the front of the intercooler.
17. Remove the fixing bolts from the intercooler.
18. Move the intercooler a little to the right to
remove the fixing bolt of the oil filler pipe.
19. Remove the oil filler pipe.
20. Remove the reaction rod from the radiator
to the engine lifting eye.
21. Remove the fixing nuts from the radiator
3
brackets. Remove the entire radiator,
intercooler, and wind tunnel from the
chassis.
22. Remove the intercooler from the radiator.
Installing the radiator
1. Install the entire radiator, intercooler, and
wind tunnel in the chassis. Tighten the fixing
nuts to the specified tightening torque, see
main group “Technical data”.
2. Slide the oil filler pipe onto the radiator and
install the fixing bolt.
3. Place the intercooler in its position and
hand-tighten with two fixing bolts.
4. Install the reaction rod from the radiator to
the engine lifting eye.
5. Install the air-conditioning compressor and
its pipes over the radiator.
6. Install the air-conditioning compressor unit
on the engine bracket.
ǹ 0008 5-9
--- Page 22 ---
2 LUBRICATING OIL SYSTEM XF ENGINE
95XF series General
2. GENERAL
2.1 LUBRICATING OIL SYSTEM DESCRIPTION
4
M200544
ǹ 0008 2-1
--- Page 23 ---
2 LUBRICATING OIL SYSTEM XF ENGINES
95XF series Removal and installation
4.3 REMOVAL AND INSTALLATION, OIL SUMP
Removal, oil sump
1. Remove the soundproofing under the
engine. 2
2. Drain the engine oil, see chapter
“Draining and filling”.
3. Support the oil sump (1).
4. Remove the attachment bolts (4) and
locking brackets (3) all around.
1
5. Remove the oil sump together with the
sealing rubber (2).
Installation, oil sump
1. Clean the sealing surfaces of the oil sump
and the engine block. 4
2. Check the oil sump sealing rubber (2).
Damaged sealing rubbers (2) must be
2 3
replaced.
3. First install the sealing rubber on the front 1 4
and rear sides of the oil sump. As a next
step, the sealing rubber may be fitted to the
long sides of the oil sump.
4. Fit the oil sump (1) with the sealing rubber
(2) in a straight position. M200601
5. Install the attachment bolts (4) and locking
brackets (3). Tighten the fixing bolts
crosswise to the specified tightening torque,
see main group “Technical data”.
6. Fill the engine with the specified quantity of
lubricating oil.
7. Run the engine for a short time, and check
whether the oil sump is correctly sealed.
Check the oil level.
8. Install the soundproofing under the engine.
ǹ 0008 4-3
--- Page 24 ---
2 XE ENGINE
95XF series Safety instructions
1. SAFETY INSTRUCTIONS
Do not run the engine in an enclosed or
unventilated area.
Make sure exhaust fumes are properly
extracted.
Maintain a safe distance from rotating and/or
moving components.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard.
This also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel.
So avoid inhaling and direct contact.
Exhaust gases contain carbon monoxide.
Carbon monoxide is a deadly, colourless and
odourless gas, which, when inhaled, deprives
the body of oxygen, leading to asphyxiation.
Serious carbon monoxide poisoning may result
in brain damage or death.
It is recommended to always disconnect the 5
battery’s earth connection during repair or
maintenance activities for which the power
supply is not required.
ǹ 0008 1-1
--- Page 25 ---
2 XE ENGINE
95XF series Inspection and adjustment
4. Remove the bridge from the valves and
place it in a vice.
5. Slacken lock nut (B).
6. Reposition the bridge in the engine over the
valves.
7. Firmly press on the bridge centre (above
the guiding pin) with your thumb.
A
8. Hand-tighten adjusting screw (A) until the
bridge starts to move (adjusting screw (A)
now touches the valve).
9. Turn adjusting screw (A) through another
90_ and carefully remove the bridge from
the valves. B
10. Place the bridge in a vice and tighten lock
nut (B) to the specified torque without
turning adjusting screw (A), see main group
“Technical data”. i 400234
11. Reposition the bridge over the valves. 5
12. Install the rocker bracket.
13. Install the DEB or the lubricating-oil strip
(depending on model). Install the
lubricating-oil strip in such a way that the
mark “cyl. 1/4” is located on cylinder 1 or
cylinder 4 respectively.
14. Adjust the valve clearance and, if fitted, the
DEB clearance.
15. Fit the valve covers, see chapter
“Removal and installation”.
M200548
ǹ 0008 3-3
--- Page 26 ---
2 XE ENGINE
95XF series Removal and installation
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION, ENGINE
Suspend the engine carefully from
the hoist, using approved lifting
gear.
Various fluids will be released when
pipes are removed. Collect these
fluids. Take care of your personal
protection and any fire hazards.
Note:
Because of the large number of vehicle
specifications, it is not feasible to exactly specify
the engine removal and installation procedures
for every vehicle.
This description only includes the main points
requiring attention.
- Disconnect the earth lead from the battery
5
pole.
- Avoid opening of fluid systems as much as
possible. If possible, remove and put aside
the engine components.
- When removing the engine, ensure that no
parts or dirt fall into the engine, radiator or
other components. Therefore, plug all
openings.
- Electrical wiring harnesses are easily
damaged. If damaged, they may cause
faults. Make sure these wiring harnesses
are stress-free and have been installed
away from moving parts.
- Tighten all fixing bolts to the correct
tightening torque.
- Do not allow the engine to rest on the oil
sump. Because the oil sump is made of
sheet material, it will be severely damaged
by the engine’s own weight.