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DAF Dealernet
perform D
service
1 perform D service
Explanation
Explanatory notes to maintenance
For vehiclespecific instructions, always review the vehicle OEM operator or service
manuals.
M028953 - 20/04/2010
1.1 check whether "Field Actions" have to be carried out for the vehicle
1.2 disconnect battery clamp, negative pole
Explanation
Warning, battery clamp and negative terminal
Do not disconnect the vehicle batteries until the DEF dosing system has
completed the purge cycle.
Before beginning to remove and/or disconnect any components, wait at
least 5 minutes after the key switch is turned OFF for the aftertreatment DEF
dosing system to purge DEF from the system.
The purge cycle is an automatic process and does not require active
intervention. The aftertreatment DEF dosing unit creates an audible
pumping noise during the purging process.
Electrical shock hazard: Never disconnect the battery clamp when the
engine is running.
Disconnecting the battery clamps while the engine is running may result in
death, personal injury or equipment damage from electrical arcing or
damage to electronic components.
Turn off the engine and place the ignition switch in the OFF position before
disconnecting the battery clamps.
Do not place any tools or other materials on top of or close to the batteries.
This can cause a dangerous high current short circuit and, in the worst
case, a battery explosion. Keep all objects away from the battery terminals.
Always break the contact between the battery clamp and the negative
terminal before working on the vehicle. Working on a vehicle while the
battery is connected may result in injury or electrical damage.
Always disconnect the battery at the negative terminal when performing
service procedures.
Battery acid can cause chemical burns.
If you come in contact with battery acid: flush the skin with water and/or
apply baking soda or lime to help neutralise the acid.
If battery acid comes into contact with the eyes, flush immediately with
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water and seek medical attention.
Wear protective clothing when handling any part of the battery.
M024327 - 19/04/2010
Closing shutoff valve
1. Turn the shutoff valve to position
'C'.
M201930
M024481 - 22/10/2009
Warning, coolant
Coolant is toxic. Avoid prolonged or repeated contact with the skin. In case
of contact, immediately wash the skin with soap and water. In case of eye
contact, rinse with plenty of water. Do not ingest. If swallowed, seek
immediate medical attention. Do not induce vomiting.
Do not remove the radiator cap from a hot or running engine. When the
coolant is hot, there is an overpressure in the cooling system. It can cause
scalding coolant to spray out and cause serious personal injury. Carefully
remove the filler cap to release the overpressure.
If the engine has been operated within the last 30 minutes, be very careful
when removing the radiator cap. Protect face, hands and arms against
escaping fluid and steam by covering the cap with a large, thick rag while
carefully removing it.
Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is
poisonous. Store it in the original fluid container only, and always keep it
out of reach of children. • Also, never remove the cap on the surge tank
while the engine is still hot. Wait until the coolant temperature is below
50°C (120°F). Scalding steam and fluid under pressure may escape and
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cause serious personal injuries.
In order to avoid damaging the engine block, do not top up a warm engine
with coolant.
Coolant is harmful to the environment. Unused coolant must be stored as a
toxic hazardous substance in leak proof containers. Used coolant must be
processed as industrial chemical waste. Please follow HAZMAT guidelines both
with used and unused coolants.
M024408 - 06/03/2013
Removing coolant filter
1. Clean the location and the area surrounding
the coolant filter.
2. Remove the coolant filter by turning it anti
clockwise.
Collect the coolant that comes
out.
3. Remove the Oring from the coolant
housing.
M201930
M021408 - 19/04/2010
Installing coolant filter
1. Apply a small amount of coolant to the
sealing ring of the coolant filter.
2. Fit the coolant filter until the sealing ring
abuts, and tighten it by hand another ¾ of a
turn.
M015209 - 13/04/2010
Opening shutoff valve
1. Turn the shutoff valve to position
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'O'.
M201930
M028501 - 30/07/2013
Warning, opening engine
Clean the engine thoroughly before opening the engine or parts of it.
Dirt or debris entering the engine damages the engine or may cause engine
failure.
Clean the entire engine or the engine compartment where the service is to
be performed.
M029318 - 19/07/2010
Removing valve cover assembly
1. Loosen the attachment bolts and remove the
valve cover assembly.
Always replace the valve cover
gasket.
M024406 - 10/05/2010
Checking and adjusting valve clearance
1. Using special tool (DAF no. 1903018), turn
the crankshaft clockwise as seen from the
vibration damper end (this corresponds to
the direction of rotation of the engine).
I402049
2. Crank the engine until the flywheel is on a
cylinder mark, for instance 16.
The positions of the pistons can
also be read from the vibration
damper.
M201436
3. Check in which cylinder all valves are
closed, corresponding to the information on
the cylinder mark. The valve clearance of
this cylinder can be checked/adjusted.
4. Press down on the adjusting screw side of
the rocker arm so that any oil present
between the push rod and rocker arm is
ejected, then measure the valve clearance.
M2013082
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5. Adjust the valve clearance by loosening the
lock nut and turning the adjusting screw in
the correct direction.
6. By cranking the crankshaft 1/3 stroke each
time, using special tool (DAF no. 1903018),
the valves can be adjusted according to the
injection sequence 153624.
Mark on flywheel or Adjusting
vibration damper valves
of cylinder
16 1 or 6
25 2 or 5
34 3 or 4
M2 01 307
M022926 - 30/07/2013
Technical data
Valve clearance adjustment data
Valve clearance (cold)
Intake 0.50 mm [0.020 in]
Exhaust 0.70 mm [0.028 in]
Valve clearance (hot)
Intake 0.50 mm [0.020 in]
Exhaust 0.55 mm [0.022 in]
Lock nut for valve adjusting bolt64 Nm [566 lbin]
M022676 - 17/07/2013
Warm/cold definition
Cold A cold engine is an engine which, having
engine reached operating temperature, has been
allowed to cool down for at least six
hours.
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Warm A warm engine is an engine which,
engine having reached operating temperature,
has been at a standstill for not more than
thirty minutes.
M024426 - 13/12/2007
Special tools
Special tool category: Mandatory special tool for: DAF Service Partners, DAF Service Support
Points
1903018
Engine Cranking Tool
1453158 is also
suitable
1903018
T00329
ST1903018 - 01/03/2013
Installing valve cover
Always install a new valve cover
gasket.
1. Clean the sealing surface of the cylinder
head and the recess for the valve cover
gasket in the valve cover.
Make sure that the sealing
surface and the recess are fully
dry to prevent leakage.
Only when all the surfaces are
dry, fit the gasket in the valve
cover.
2. Fit the valve cover complete with valve
cover gasket and attachment bolts.
3. Tighten the attachment bolts in the specified
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sequence and to the specified torque.
M024383 - 23/10/2012
Technical data
Tightening torque, valve cover
Tightening sequence
11 7 3 1 5 9
15 13
16 14
12 8 4 2 6 10
M201565
Attachment bolts 20 Nm [177 lbin](1)
(1) Always install a new valve cover gasket.
M021366 - 14/01/2013
Technical data
Tightening torque, compressor pipe 01, suction side
Union nut, valve cover side90 Nm [65 lbft]
M028176 - 16/01/2013
Tightening torque, engine mountings
Engine mounting at
flywheel end
Attachment bolts (1) 260 Nm [184 lbft]
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Attachment bolts (2) 260 Nm [184 lbft]
2
1
1
2
M201673
M022924 - 14/01/2013
Warning, coolant
Coolant is toxic. Avoid prolonged or repeated contact with the skin. In case
of contact, immediately wash the skin with soap and water. In case of eye
contact, rinse with plenty of water. Do not ingest. If swallowed, seek
immediate medical attention. Do not induce vomiting.
Do not remove the radiator cap from a hot or running engine. When the
coolant is hot, there is an overpressure in the cooling system. It can cause
scalding coolant to spray out and cause serious personal injury. Carefully
remove the filler cap to release the overpressure.
If the engine has been operated within the last 30 minutes, be very careful
when removing the radiator cap. Protect face, hands and arms against
escaping fluid and steam by covering the cap with a large, thick rag while
carefully removing it.
Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is
poisonous. Store it in the original fluid container only, and always keep it
out of reach of children. • Also, never remove the cap on the surge tank
while the engine is still hot. Wait until the coolant temperature is below
50°C (120°F). Scalding steam and fluid under pressure may escape and
cause serious personal injuries.
In order to avoid damaging the engine block, do not top up a warm engine
with coolant.
Coolant is harmful to the environment. Unused coolant must be stored as a
toxic hazardous substance in leak proof containers. Used coolant must be
processed as industrial chemical waste. Please follow HAZMAT guidelines both
with used and unused coolants.
M024408 - 06/03/2013
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Loosening supply pipe dosing module, fuel
1 2 3 2
1. Loosen the attachment bolt (5).
2. Loosen the union nut of the fuel pipe (3) from
the fuel dosing module (4).
1
4
i4017522
M028059 - 07/09/2011
Loosening coolant piping
1 2 3 2
1. Loosen the banjo bolts (1) from the EAS
dosing module (4) and collect the copper
sealing washers.
1
4
i4017522
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2. Plug the banjos using the collected copper
sealing washers and two flange bolts and
flange nuts.
Tighten the flange bolts and
flange nuts to the torque specified
for the banjo bolts (1).
M202021
M028060 - 09/12/2010
Removing dosing module, fuel
1. Loosen the attachment bolts (1) and remove 2
the dosing module (7).
3
Discard the attachment bolts (1).
4
1
2. Remove the gasket (5) and fibre disc (6).
Discard the gasket (5) and fibre
disc (6).
7 6 5
i401992
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M029066 - 17/07/2013
Warning, cleaning dosing module, fuel
Do not use a steel brush. The use of a steel wire brush or a steel wire wheel will
cause permanent damage to the fuel dosing module.
M038473 - 14/08/2013
Cleaning dosing module, fuel
1. Inspect the fuel dosing module tip.
When using solvents,
acids or alkaline materials
for cleaning, follow the
OEM recommendations for
use.
Wear goggles and
protective clothing to
reduce the possibility of
personal injury.
Wear the appropriate eye
and face protection when
using compressed air.
Flying debris and dirt can
cause personal injury.
2. Some carbonisation can occur on the tip of
the fuel dosing module.
3. Spray the tip of the fuel dosing module with
carburettor cleaner.
4. When spraying, focus the spray on the tip of
the fuel dosing module.
Use enough carburettor cleaner to
cover the tip and fill the cavity
surrounding it.
5. Allow the carburettor cleaner to sit for 15
seconds so that it can break down and
penetrate the debris that has collected in the 1
tip area.
Carburettor cleaner is the
most effective solvent for 2
this procedure.
Do not substitute any other
cleaning solvent. M201988
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Only use a nylon brush to
clean the tip.
Repeat spraying and
brushing as necessary to
remove all carbon from the
tip.
The carbon you are
attempting to remove with
this procedure often cannot
be seen with the naked eye.
This carbon builds up in the
nozzle tip area of the fuel
dosing module.
6. Inspect the fuel dosing module tip for cracks
or other damage.
Replace if necessary.
7. Clean the adapter tube mounting surface
and install the fuel dosing module.
M028901 - 30/08/2013
Installing dosing module, fuel
1. Fit a new gasket (5) and new fibre disc (6) to
the dosing module (7) and position them
using two new attachment bolts (1).
2. Carefully install the dosing module (7) and
tighten the attachment bolts (1) to the
specified torque.
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3
4
1
7 6 5
i401992
M031740 - 23/07/2012
Technical data
Tightening torque, dosing module, fuel
Always use a new gasket, a new fibre disc and new attachment bolts for the
dosing module.
Attachment bolts (1) 9 Nm [80 lbin](1)
Banjo bolts (2) 60 Nm [44 lbft](2) 2
(1)Use new attachment bolts
(1)
(2)Use two new copper 3
sealing washers (3)
4
1
7 6 5
i401992
M029073 - 03/01/2013
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Tightening torque, dosing module, fuel
Always use a new gasket, a new fibre disc and new attachment bolts for the
dosing module.
Attachment bolts (1) 9 Nm [80 lbin](1)
Banjo bolts (2) 60 Nm [44 lbft](2) 2
(1)Use new attachment bolts
(1)
(2)Use two new copper 3
sealing washers (3)
4
1
7 6 5
i401992
M029073 - 03/01/2013
1.6.9 fixing supply pipe dosing module, fuel (Engine brake, engine)
Technical data
Tightening torque dosing module fuel
Always use a new gasket, a new fibre disc and new attachment bolts for the
dosing module.
Banjo bolts (1) 44 lbft (60 Nm)(1)
Attachment bolts (2) 80 lbin (9 Nm)(2)
Union nut (3), fuel
piping 133 lbin (15 Nm)(3)
Attachment bolt (5) 266 lbin (30 Nm)
(1) Use new copper sealing
washers
(2) Use new attachment bolts
(3) Apply a drop of clean
engine oil.
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1 2 3 2
1
4
i4017522
M037877 - 28/05/2013
Warning, battery clamp and negative terminal
Do not disconnect the vehicle batteries until the DEF dosing system has
completed the purge cycle.
Before beginning to remove and/or disconnect any components, wait at
least 5 minutes after the key switch is turned OFF for the aftertreatment DEF
dosing system to purge DEF from the system.
The purge cycle is an automatic process and does not require active
intervention. The aftertreatment DEF dosing unit creates an audible
pumping noise during the purging process.
Electrical shock hazard: Never disconnect the battery clamp when the
engine is running.
Disconnecting the battery clamps while the engine is running may result in
death, personal injury or equipment damage from electrical arcing or
damage to electronic components.
Turn off the engine and place the ignition switch in the OFF position before
disconnecting the battery clamps.
Do not place any tools or other materials on top of or close to the batteries.
This can cause a dangerous high current short circuit and, in the worst
case, a battery explosion. Keep all objects away from the battery terminals.
Always break the contact between the battery clamp and the negative
terminal before working on the vehicle. Working on a vehicle while the
battery is connected may result in injury or electrical damage.
Always disconnect the battery at the negative terminal when performing
service procedures.
17/21
1/15/2016 Print
Battery acid can cause chemical burns.
If you come in contact with battery acid: flush the skin with water and/or
apply baking soda or lime to help neutralise the acid.
If battery acid comes into contact with the eyes, flush immediately with
water and seek medical attention.
Wear protective clothing when handling any part of the battery.
M024327 - 19/04/2010
Warning, coolant
Coolant is toxic. Avoid prolonged or repeated contact with the skin. In case
of contact, immediately wash the skin with soap and water. In case of eye
contact, rinse with plenty of water. Do not ingest. If swallowed, seek
immediate medical attention. Do not induce vomiting.
Do not remove the radiator cap from a hot or running engine. When the
coolant is hot, there is an overpressure in the cooling system. It can cause
scalding coolant to spray out and cause serious personal injury. Carefully
remove the filler cap to release the overpressure.
If the engine has been operated within the last 30 minutes, be very careful
when removing the radiator cap. Protect face, hands and arms against
escaping fluid and steam by covering the cap with a large, thick rag while
carefully removing it.
Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is
poisonous. Store it in the original fluid container only, and always keep it
out of reach of children. • Also, never remove the cap on the surge tank
while the engine is still hot. Wait until the coolant temperature is below
50°C (120°F). Scalding steam and fluid under pressure may escape and
cause serious personal injuries.
In order to avoid damaging the engine block, do not top up a warm engine
with coolant.
Coolant is harmful to the environment. Unused coolant must be stored as a
toxic hazardous substance in leak proof containers. Used coolant must be
processed as industrial chemical waste. Please follow HAZMAT guidelines both
with used and unused coolants.
M024408 - 06/03/2013
Technical data
Specification, coolant
Coolant is a toxic fluid. Protect skin and eyes. Coolant is harmful to the
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environment; after use, it must be processed as chemical waste.
Coolant is a mixture of antifreeze and water that is used in the cooling system to protect the
system against freezing, corrosion and cavitation.
The cooling system should only be refilled with Extended Life Coolant (ELC) that is
prediluted 50/50 with water.
Coolant suppliers
The table below lists the current suppliers that
meet the ASTM D 6210 specification and are
allowed to be used in the PACCAR engine.
It is not allowed to fill the cooling system with
other coolants than the ones specified below.
Brand name Supplier
Extended Life Coolant TRP
Delo ELC Chevron
Rotella Ultra ELC Shell
ELC Texaco
Final Charge Old World
M028492 - 29/03/2010
Warning, coolant
Coolant is toxic. Avoid prolonged or repeated contact with the skin. In case
of contact, immediately wash the skin with soap and water. In case of eye
contact, rinse with plenty of water. Do not ingest. If swallowed, seek
immediate medical attention. Do not induce vomiting.
Do not remove the radiator cap from a hot or running engine. When the
coolant is hot, there is an overpressure in the cooling system. It can cause
scalding coolant to spray out and cause serious personal injury. Carefully
remove the filler cap to release the overpressure.
If the engine has been operated within the last 30 minutes, be very careful
when removing the radiator cap. Protect face, hands and arms against
escaping fluid and steam by covering the cap with a large, thick rag while
carefully removing it.
Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is
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poisonous. Store it in the original fluid container only, and always keep it
out of reach of children. • Also, never remove the cap on the surge tank
while the engine is still hot. Wait until the coolant temperature is below
50°C (120°F). Scalding steam and fluid under pressure may escape and
cause serious personal injuries.
In order to avoid damaging the engine block, do not top up a warm engine
with coolant.
Coolant is harmful to the environment. Unused coolant must be stored as a
toxic hazardous substance in leak proof containers. Used coolant must be
processed as industrial chemical waste. Please follow HAZMAT guidelines both
with used and unused coolants.
M024408 - 06/03/2013
Bleeding cooling system
1. Set the cabin heater to the maximum
temperature.
2. Run the engine at an increased speed (n =
1200 rpm) for at least three minutes to bleed
the cooling system
3. Check and top up the coolant level during
bleeding.
Top up until the coolant level
stabilises at the maximum
indicator.
4. Check that both hoses connected to the
cabin heater start to warm up.
M039123 - 12/09/2013
This information applies exclusively to the entered chassis number or the selected vehicle series. Please take
into account that this information may change daily. Therefore the provided information is only valid on 15-01-
2016. You cannot derive any rights from the information provided with respect to vehicles and/or components of
another series, with another chassis number and/or of another date.
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DAF Dealernet
Parts consumption
# MPA Number Optional Exchange part Description Comp. group Description Info
1 1843659 Coolant filter element 1407 Cooling system
1 1792804 Valve cover gasket 1401 Basic assy.
4 * Copper sealing washer 1435 Engine brake, engine
1 1816832 Insulating ring 1435 Engine brake, engine
2 * Flange bolt 10.9 1435 Engine brake, engine
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