Manual mx-13

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DAF Dealernet
VIN: 1XKYDP9X8KJ253827
Vehicle Type: MX_EPA17-MX-13 USA
P 1401 233401 001 033
replace assembly cylinder head, engine (Basic assembly)
https://eportal.paccar.net/dealernet/na_rmi/ 3/11/2021
DAF Dealernet
replace assembly cylinder head, engine
(Basic assembly)
1 replace assembly cylinder head, engine (Basic assembly)
1.1 remove assembly cylinder head, engine (Basic assembly)
1.1.1 get oil bin
1.1.2 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 arching 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 electrical injury or damage.
◾ Always disconnect the battery at the negative terminal when performing service procedures.
◾ Battery acid can cause chemical burns.

◾ If you come into contact with battery acid: flush your skin with water and/or apply baking soda or lime to help
neutralize 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 - 03/05/2010
1.1.3 drain coolant (Cooling system)
Explanation
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.
◾ In the event of inhalation: get some fresh air and rest.
◾ Do not remove the radiator cap from a hot or running engine. When the coolant is hot, there is 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 the 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 fill up a warm engine with coolant.
◾ If coolant is contaminated with oil or fuel, clean the cooling system as specified and replace hoses and sealings
made from EPDM.
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 - 17/02/2021
1.1.4 drain coolant oil module (Lubrication system)
Explanation
Warning, coolant
made from EPDM.
M024408 - 17/02/2021
Draining coolant oil module
1. Position a suitable container under the drain plug (2).

2. Drain the coolant via the drain plug (2).
3. After draining, install the drain plug (2) and tighten it to the
specified torque.
i405413
M054080 - 18/08/2016
Technical Data
Tightening torque, drain plugs, oil module

Oil drain plug (1) 15 Nm [133 lb-in]
Coolant drain plug (2) 15 Nm [133 lb-in]
i405413
M054082 - 17/08/2016
1.1.5 disconnect humidity sensor (Sensors electrical system, engine)
1.1.6 remove air inlet pipe from air filter to turbocharger (Inlet and exhaust element)
1.1.7 disconnect oil pressure sensor (Sensors electrical system, engine)
1.1.8 loosen air bleed pipe (EGR system)
1.1.9 loosen supply coolant pipe (EGR system)
1.1.10 loosen return coolant pipe (Inlet and exhaust element)

1.1.11 remove assembly coolant pipe (EGR system)
1.1.12 remove 2 (two) sensor pipe
1.1.13 disconnect VTG turbocharger actuator (Inlet and exhaust element)
1.1.14 remove assembly EGR valve (EGR system)
Explanation
Removing assembly EGR control valve

1 2 6 7
1. Disconnect the electrical connector.
2. Loosen and remove the V-clamps (6 and 8).
3. Remove the assembly EGR control valve (2) with flexible
EGR pipe (4).
9
8
3 4 5
i402459-3
M036271 - 26/02/2021
1.1.15 disconnect turbocharger speed sensor (Inlet and exhaust element)

1.1.16 disconnect pressure sensor after BPV (Sensors electrical system, engine)
1.1.17 disconnect pressure sensor before turbine (Sensors electrical system, engine)
1.1.18 loosen front right engine wiring harness J3 C (Elec.syst. 2 engine)
1.1.19 remove upper bracket, electrical system (Elec.syst. 2 engine)
1.1.20 disconnect temperature sensor, EGR (Sensors electrical system, engine)
1.1.21 disconnect pressure difference sensor, EGR (Sensors electrical system, engine)
1.1.22 remove EGR cooler (EGR system)
Explanation
Removing EGR cooler
1. Loosen the three attachment bolts and maneuver the 1 2 3 4 5 6 7

clamping straps aside.
2. Pull off the EGR cooler with a little force.
◾ Check that the EGR temperature sensor was

properly disconnected.
◾ Make sure not to damage the EGR
temperature sensor while removing the EGR
cooler.
◾ The mounting product of the venturi and the i405547
connecting pieces causes friction while pulling
the EGR cooler.
EGR temperature sensor, located out of sight.
M057900 - 02/11/2020
1.1.23 loosen assembly exhaust manifold (Inlet and exhaust element)

1.1.24 drain fuel filtration module (Fuel system)
Explanation
Warning, Fuel System

◾ Eye contact: Rinse immediately with plenty of water, also under the eyelids, for at least 15 minutes. Consult a
doctor.
◾ Skin contact: Wash off immediately with plenty of water. If symptoms persist, consult a doctor.
◾ Inhalation: Get some fresh air. If symptoms persist, consult a doctor.
◾ Ingestion: Rinse mouth with water and then drink plenty of water. Do not induce vomiting. Consult a doctor.
◾ Fuel vapors and spills are potential fire hazards.

◾ When opening a fuel system, fuel can escape. Collect the fuel during servicing and dispose of it properly to
avoid the risk of fire.
◾ Mixing other fuels, such as gasoline, alcohol or gasohol with diesel can produce an explosive mixture.
To avoid injury from fuel while performing service on any fuel-system-related component(s):
◾ Prevent fuel from leaking or dripping onto the starter motor.
◾ Check the fuel components for leakage very carefully.
◾ Clean spilled or leaked fuel.
◾ Keep people who are not directly involved in the servicing away from the immediate area.
◾ Wear protective clothing (including face shield, insulated gloves and apron).
◾ Keep the work area well ventilated to prevent build-up of volatile fuel vapors.
◾ Keep all potential ignition sources away from the fuel. This includes: excessive heat, open flames, cigarettes,
sparks and electrical sources.
◾ Do not touch any of the fluoroelastomer seals or O-rings if they have been exposed to a temperature of 315°C
or higher. The material of this product does not burn but decomposes into a charred, black, sticky substance.
This decomposition may contain hydrofluoric acid. This is very aggressive and difficult to remove once it has
contaminated the skin. Use PVC or rubber gloves until the decomposed material has been identified and/or
removed. If the substance makes contact with the skin, contact a doctor immediately.
◾ Blocking and/or clamping the fuel pipes can lead to severe engine damage.
◾ Never block or plug the common rail release valve output, as this can lead to severe rail and common rail
pressure release valve damage.
Always work in a clean manner according to the Cleanliness procedures

◾ Clean the area before performing repairs.
◾ The smallest amount of dirt, debris and other contamination can cause serious damage to systems and/or the
engine.
◾ Immediately plug the openings of the fuel system.
M035658 - 20/07/2020
Draining fuel filtration module
1. Open the filler screw cap of the fuel tank to prevent
overpressure in the fuel system.
2. Thoroughly clean the fuel filter screw cap and the area.
Prevent dirt from entering the fuel system.
3. Unscrew the fuel filter cap a few turns until the O-ring is fully
visible and wait until the filtration module is fully drained.
Use only a socket or box wrench.

Do not further unscrew the fuel filter cap until the
module is drained.
4. Remove the fuel filter screw cap with fuel filter element from
the filtration module.
5. Remove the O-ring and clean the recess of the fuel filter
screw cap.
6. Lubricate the recess and install a new O-ring on the fuel filter
screw cap.
◾ The fuel filter element may be blackened.

Darkening of diesel fuel and fuel system
components can occur due to the mixing of
lubricating oil and/or due to running at high
fuel pressures and temperatures. The effect
can be that fuel in the fuel tank is darkened
and fuel filters appear to be blackened. This
does not indicate a defect and is a function of
normal operation.
◾ Lubricate the new O-ring with clean engine oil.
7. Install and tighten the fuel filter screw cap to the specified
torque.
Make sure that the filtration module is drained

before installing the filter element.
8. Close the filler screw cap of the fuel tank.
Always bleed the fuel system after draining the fuel

filtration module.
M058970 - 08/05/2017
Technical Data
Tightening torque, fuel filter screw cap

Screw cap 40 Nm [354 lb-in](1)(2)
(1) Only use a hexagonal socket or hexagonal ring wrench.
(2) Always use a new O-ring.
Lubricant:
Sealing ring fuel filter element clean diesel fuel
O-ring fuel filter screw cap clean engine oil
M030405 - 22/10/2019
1.1.25 loosen front left engine wiring harness J1 A (Elec.syst. 2 engine)

1.1.26 remove 2 (two) fuel injection pipe from pump unit to fuel rail (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
Warning, fuel injection pipe
Do not reuse the fuel injection pipe if the Evaluate the injector back leak test in DAVIE cannot be performed
successfully.
◾ The high-pressure fuel injection pipes are not intended to be reused indefinitely.
◾ The fuel injection pipes and connections must be checked properly before reuse.
◾ Damaged and / or incorrectly installed injection pipes can cause hot fuel leakage, flammable gases or vapors.
Highly pressurized fuel is present in the common rail, fuel injection pipes and other high-pressure fuel components
when the engine is running and when the engine is switched off. The pressure leaks away slowly when the ignition
is switched off.
Wait at least one minute before performing maintenance on high-pressure fuel components.
M030466 - 22/02/2021
Removing fuel injection pipe from pump unit to fuel rail
1. Clean the fuel injection pipe connection and its surroundings

thoroughly.
2. If reusing the fuel injection pipe, label the fuel injection pipe
so it can be reinstalled in the original position.
3. Loosen the union nuts on both ends and carefully remove the
fuel injection pipe.
Visually check:
◾ The high-pressure fuel pipe for corrosion,
cracks or pinched areas.
◾ The union nut for corroded, damaged threads
or cracks.
◾ Both ends of the high-pressure pipe for
damaged or corroded sealing surfaces.
◾ Replace the fuel injection pipe

if any corrosion, damage,
cracks, or pinched areas are
found on the pipe, union nut or
any sealing surface.
4. Cover both ends of the fuel injection pipe using clean

protective caps.
If reusing the fuel injection pipe, store it in a clean

plastic bag.
M065361 - 22/02/2021
1.1.27 open 2 (two) clamping block (Air compressor)

1.1.28 loosen assembly compressor pipe 01, delivery side (Air compressor)
1.1.29 drain fuel gallery (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
Draining fuel gallery
5
1. Remove the fuel pressure control valve (7) and collect the
fuel.
2. Remove the non-return valve (8) and collect the fuel.
Make sure that the fuel gallery is fully drained.
3. Install the non-return valve (8) using new usit rings and tighten
it to the specified torque.
7
8
i405521
4. Clean the pressure control valve (7) and check it thoroughly

for damage and cracks as shown.
Replace the fuel pressure control valve if it is

damaged.
i403709
5. Install the fuel pressure control valve (7) with a new O-ring
and tighten it to the specified torque.
Do not overtighten the fuel pressure control

valve (7), this can lead to cracks in the fuel
pressure control valve housing as shown.
M045926 - 27/11/2020
Technical Data
Tightening torque, fuel gallery valves

Banjo bolt (5) 16 Nm [142 lb-in](1)
Non-return valve (8) 35 Nm [310 lb-in](1) 5
Fuel pressure control valve (7) 30 Nm [266 lb-in](2)
Attachment bolt, pipe clip 14 Nm [124 lb-in]
(1) Always use new usit rings.
7
8
i405521
M045927 - 27/11/2020
1.1.30 remove injector leak pipe (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
Removing injector leak pipe
5
1. Remove the banjo bolt (5) and the non-return valve (8) and
remove the injector leak pipe.
2. Clean any spilled fuel.
7
8
i405521
M039100 - 26/09/2019
1.1.31 loosen one side supply pipe dosing module, fuel (Engine brake)
Explanation

doctor.

engine.
M035658 - 20/07/2020
Disconnecting quick-release coupling
◾ No tooling is allowed for disconnecting or connecting the
quick-release coupling.
◾ The pipe must be free of any fluid pressure before
disconnecting.
i403864
New situation
1. Clean the area around the connection.

New
2. Press and hold the release element (1). 1
To reach the ribbed surface (1), rotate the
release element. 2
Do not remove the release element from the
3. Pull the male quick-release coupling (2) out of the female

coupling.
i403787
M035352 - 17/08/2016
1.1.32 loosen one side fuel tank return pipe (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
Disconnecting quick-release coupling
◾ The pipe must be free of any fluid pressure before
disconnecting.
i403864
New situation
1. Clean the area around the connection.

New
2. Press and hold the release element (1). 1
To reach the ribbed surface (1), rotate the
release element. 2
Do not remove the release element from the
3. Pull the male quick-release coupling (2) out of the female

coupling.
i403787
M035352 - 17/08/2016
1.1.33 remove common rail pressure release pipe (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
1.1.34 loosen bracket, fuel system (Fuel system)

1.1.35 install lifting eye
Explanation
Installing lifting eye
1. Install the lifting eye (A) onto the cylinder head.

2. Tighten the bolts (1) to the specified torque.
A
1
i402162
M033201 - 27/06/2013
Technical Data
Tightening torque, lifting eye
Attachment bolts 60 Nm [531 lb-in]
M036868 - 25/03/2013
Special Tools
Special tool category Mandatory special tool for: NA region

1903016
Hoisting tool for cylinder head/engine without transmission. Supersedes 1453180. 1453180 can still be used. User manual
This tool replaces
DAF special tool:
1453180 due to
legislation. DAF
special tool
1453180 can still
be used.
ST1903016 - 03/11/2014
1.1.36 remove valve cover (Basic assembly)
Explanation
Warning, opening engine

◾ 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 must be performed.
M030438 - 20/10/2014
Removing Valve Cover Assembly
1. Loosen the attachment bolts, and remove the valve cover
assembly.
Always replace the valve cover gasket.
M030440 - 20/10/2014
1.1.37 dismount valve cover gasket (Basic assembly)

1.1.38 remove heat shield (EGR system)
1.1.39 remove valve train casing (Basic assembly)
Explanation
Disconnecting control valve, MX Engine Brake
1. Use a small screwdriver to unlock the lip of the connector, as

shown.
i405959
M056893 - 17/01/2017
dismount valve train casing gasket (Basic assembly)
1.1.40
1.1.41 remove air bleed pipe (EGR system)
1.1.42 remove 2 (two) rocker arm group, engine brake (Basic assembly)
Explanation
Removing rocker arm group, engine brake
The instruction below is applicable to one or both rocker

arm groups.
1. Undo the attachment bolts (1) step-by-step in order from 12 to

1 and carefully allow the rocker arm group to be lifted by the
valve spring pre-tension.
If necessary, carefully tap the rocker arm group

around the position of the two guide pins (4) to
loosen it.
12 8 4 2 6 10
5 1 3 7 11
1 2 3 4 i405475
M055962 - 17/01/2017
1.1.43 remove 6 (six) exhaust valve push rod (Basic assembly)

1.1.44 remove 6 (six) inlet valve lifter rod (Basic assembly)
1.1.45 remove assembly cylinder head, engine (Basic assembly)
Explanation
Warning, lifting components
◾ Use approved and sturdy tools for lifting.

◾ Do not carry out any work on components that are only supported by a jack or lifting gear.
◾ Make sure that the component is properly supported before carrying out any work.
M028835 - 24/03/2010
Technical Data
Technical data, cylinder head bolts

Loosen the cylinder head
bolts in the sequence, as
shown.
11 19 27 28 20 12
10 18 26 33 29 21 13
9 17 25 32 30 22 14
8 16 24 31 23 15
7 6 5 4 3 2 1
M201348 -2
M022961 - 29/05/2013
Special Tools
Special tool category Recommended special tool

0882233
Torque multiplier for cylinder head
T00145
ST0882233 - 20/03/2008
0911724
Set of gripper sockets 17-18-19-24 mm 3/4 100 mm
09 11724
T00390
ST0911724 - 27/08/2013
1.1.46 remove cylinder head gasket, engine (Basic assembly)

1.1.47 clean cylinder block (Basic assembly)
Explanation
Cleaning cylinder block

1.Check the cylinder head
gasket for signs of a
combustion gas leakage.
◾ If a
combustion
gas leak
occurred,
remove the
liner for
inspection.
Combustion
gasses can
cause
balcony
erosion or
fretting that
can cause a
loss of
clamping
force.
2.Check for sings of coolant

leakage around the liner
flange. An eroded balcony
can allow coolant to pass
without combustion leakage.
3.Remove the gasket
remnants from the cylinder
block.
4.Clean the sealing surface of
the cylinder block.
◾ Use only brass scrapers
or brass brushes to
clean the residual
material on the head-to-
block mating surfaces.
◾ Do not use steel
brushes, steel scrapers,
or polishing pads.
◾ The striations on the
mating surface of the
block and the
corresponding surface
on the head are part of
the strategy for
preventing gasket
fretting and erosion. Do
not polish these
surfaces.
5. Check the sealing surface

and the threaded holes in
the cylinder block for
damage.
Use a rag and solvent to
clean any remaining
contaminants.
Sealing only
takes place on
the indicated
areas between
gasket and
cylinder block.
Damage on the
cylinder block
outside the
indicated areas
on the cylinder
head gasket is
not a reason for
failure.
◾ Gas sealing
locations are
marked in
red.
◾ Coolant
sealing
locations are
marked in
blue.
◾ Oil sealing
locations are
marked in
green.
If coolant
leakage is
visible outside
the cylinder
block this will
not indicate the
actual location
of the leakage.
M031143 - 14/10/2019
1.1.48 dismount assembly air inlet pipe, inlet manifold (Inlet and exhaust element)
1.1.49 remove bracket, air inlet system (Fuel system)
1.1.50 remove 2 (two) fuel injection pipe 5-6 (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
successfully.
is switched off.
M030466 - 22/02/2021
Removing fuel injection pipe

thoroughly.
fuel injection pipe (2).
1
2
i405551

protective caps.

plastic bag.
M040419 - 15/05/2019
Special Tools

1961365
Fuel injection pipe socket

MX / MX-13
ST1961365 - 01/10/2015
1.1.51 remove 4 (four) fuel injection pipe 1-2-3-4 (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
successfully.
is switched off.
M030466 - 22/02/2021
Removing fuel injection pipe

thoroughly.
fuel injection pipe (2).
1
2
i405551

protective caps.

plastic bag.
M040419 - 15/05/2019
Special Tools

1961365

MX / MX-13
ST1961365 - 01/10/2015
1.1.52 remove 6 (six) injector (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
Warning, injector
Due to the presence of overpressure in the fuel tank, fuel can run into the cylinders when removing injectors. The
tank cap must therefore always first be removed when removing injectors. Collect any fuel from the injectors.
To prevent fuel from leaking into the cylinders, always loosen the injector leak pipe. Clean the leaked fuel with a rag.
Make sure that the cooling system is depressurized, overpressure in the cooling system can loosen the injector
sleeve. Hot coolant may cause personal injury.
Loosening injectors when the cooling system is pressurized or when the engine is hot can release a hot coolant
spray that may cause personal injury.
M032499 - 14/10/2020
Removing injector
Make sure that the fuel tank is depressurized, the

injector leak return gallery is drained and the cooling
system is depressurized before removing the injector.
5
1. Remove the banjo bolt (5) from the injector leak pipe and
drain the injector leak return gallery.
Collect the usit rings and clean any spilled fuel.
7
8
i405521
1
2. Disconnect the connector from the injector.
3. Check if the attachment bolt (2) from the injector can be
loosened by hand.
2
In case the attachment bolt (2) can be loosened by
hand:
3
◾ The injector sleeve may be loose and the
cylinder head must be replaced.
4
◾ The injector must be replaced.
5
4. Remove the attachment bolt (1) from the locking bracket (2).
5. Remove the locking bracket (2).
6
i405571
6. Use the special tool (ST0192496) to remove the injector.
◾ Make sure that the fuel injection pipe (2) is

removed before removing the injector (1).
If the injector will be re-used:

◾ Label the injector so it can be reinstalled in the 1
same position and store it in a clean plastic
bag. 2
◾ Handle the injector with care, the nozzle tip
of the injector is very sensitive to damage.
i405551
◾ Protect the nozzle tip.
◾ Handle the bag containing the injector
carefully.
◾ Keep the injector in the bag until installing it.
7. Remove the sealing ring if it remains in the injector sleeve.

8. Cover the opening of the injector to prevent dirt from entering.
If the injector needs to be cleaned, follow the job 'Clean injector'. Do not use other methods to clean the injector.
M054753 - 15/12/2020
Special Tools

0192496
Injector puller
0192496
ST0192496 - 13/11/2014
1.1.53 remove fuel rail (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
successfully.
is switched off.
M030466 - 22/02/2021
1.1.54 dismount bracket, EGR (EGR system)

1.1.55 dismount 2 (two) lifting eye (Lifting eye)
1.2 install assembly cylinder head, engine (Basic assembly)
1.2.1 mount 2 (two) lifting eye (Lifting eye)
Technical Data

M036868 - 25/03/2013
Lifting eye - front of the engine

Attachment bolts, M12 110 Nm [81 lb-ft]
M038083 - 10/03/2020
Special Tools

1903016
This tool replaces
DAF special tool:
1453180 due to
legislation. DAF
special tool
1453180 can still
be used.
ST1903016 - 03/11/2014
1.2.2 mount bracket, EGR (EGR system)
Technical Data
Tightening torque, bracket, EGR
Tighten in the specified

Tightening sequence
sequence.
Attachment bolts, M8 30 Nm [266 lb-in]
Pos. M10 x 30 mm
1–5
Pos. M10 x 45 mm
6
Pos. M8 x 30 mm
7
and
8
M065444 - 06/03/2020
1.2.3 install fuel rail (Fuel system)
Explanation
Installing fuel rail with fuel injection pipes

The high-pressure fuel injection pipes are not intended to be reused indefinitely. The fuel injection pipes can only
be reused when checked properly.
Checking high-pressure fuel injection pipe

Remove the plastic bag and protective caps from the fuel injection
pipe and visually check:
◾ The high-pressure fuel pipe for cracks, corrosion or pinched
areas.
◾ The union nut for damaged thread or cracks.
◾ Both ends of the high-pressure pipe for damaged sealing
surfaces.
If necessary, replace the fuel injection pipe.
◾ Always check the high-pressure fuel system for leaks after reusing the fuel injection pipes.
Perform the 'Evaluate injector back leak' test after repair using DAVIE.
◾ If reusing the fuel injection pipe, install the labeled fuel injection pipe in the original position.
1 2 3 4
1. Position the fuel injection pipes (2) into the cylinder head.
2. Tighten the union nuts (1) on the cylinder head side by hand
up to the end of thread.
3. Position the fuel rail (9) to the cylinder head and tighten the
attachment bolts (3) by hand.
Make sure that the contact surfaces between rail

and cylinder head are clean and free from paint.
4. Tighten the union nuts (10) on the rail side by hand up to the
end of thread. 10 9 8 7 6 5
I406151
Make sure that the fuel injection pipes (2) are

installed without tension.
5. Tighten the fuel rail attachment bolts (3) to the specified

torque.
◾ Do not turn the high-pressure control valve.

◾ Always reset the high-pressure control valve
using DAVIE.
6. Tighten the fuel injection pipe union nuts on the cylinder head
side (1) to the specified torque using special tool (1961365).
7. Tighten the fuel injection pipe union nuts on the common rail
side (10) to the specified torque.
8. Fit the fuel injection pipes from pump to rail (5) without
tension, and tighten the union nuts by hand up to the end of
thread.
9. Tighten the union nuts (4) on the rail side to the specified
torque.
10. Tighten the union nuts (6) on the pump unit to the specified
torque.
◾ Bending the injection pipes leads to cracking,

and is therefore prohibited.
◾ Make sure that the fuel injection pipe is
tightened correctly, otherwise external leakage
can occur.
M030559 - 26/02/2021
Technical Data
Tightening torque, fuel rail assembly

Fuel rail attachment bolts (3) 30 Nm [266 lb-in]
Fuel injection pipe (2) union nut, 1 2 3 4

cylinder head side (1)
1st phase 27 Nm [239 lb-in](1)
rd
2 phase
New fuel injection pipe 60°
Reused fuel injection pipe 30°
Fuel injection pipe (2) union nut,

fuel rail side (10)
rd
2 phase
Reused fuel injection pipe 30° 10 9 8 7 6 5
I406151
Fuel injection pipe union nuts

from pump unit to fuel rail (4 and
6)
rd
2 phase
(1)Make sure that all fuel injection pipes
are checked and tightened correctly,
otherwise external fuel leakage can
occur.
M036668 - 03/12/2020
1.2.4 install 6 (six) injector (Fuel system)
Explanation
Installing injector
◾ Always calibrate new injectors using DAVIE.

◾ Handle the injector with care, the nozzle tip of
the injector is very sensitive to damage. Never
install an injector that has been dropped or
damaged in any other way.
1
1. Install new O-rings (4), (5) and a new sealing ring (6) for the
injector.
2. Lubricate the O-rings with clean engine oil.
2
Check that no sealing ring (6) remains in the
injector sleeve during removal.
3
3. Carefully position the injector in the injector sleeve. 4

Make sure that the nozzle tip doesn't touch the
injector sleeve or other parts. 5
4. Connect the injector connector.

6
i405571
5. Check the cylinder head bore of the attachment bolt.
Make sure that the cylinder head bore is free of

any fluid or debris before installing the locking
bracket and the new attachment bolt.
6. Fit the locking bracket (2) with a new attachment bolt (1) and
tighten it to the specified torque.
5
7. Install the banjo bolt (5) with new usit rings and tighten it to
the specified torque.
7
8
i405521
M054835 - 01/11/2019
Technical Data
Tightening torque, injector
6
i405571
Attachment bolt (1), locking bracket (2) 30 Nm [266 lb-in] + 90°(1)

(1) Use bolt only once.
(2) Always use a new O-rings (4 and 5).
(3) Always use a new sealing ring (6).
M054836 - 05/12/2017
Tightening torque, injector leak pipe
Fuel pressure control valve (7) 30 Nm [266 lb-in] 5
Non-return valve (8) 35 Nm [310 lb-in](1)
(1) Fit new usit rings.
7
8
i405521
M032477 - 04/11/2019
1.2.5 install 4 (four) fuel injection pipe 1-2-3-4 (Fuel system)
Explanation
Installing fuel injection pipe
The high-pressure fuel injection pipes are not intended to

be reused indefinitely. The fuel injection pipes can only

1. Remove the plastic bag and protective caps from the fuel
injection pipe and visually check:
◾ The high-pressure fuel pipe for cracks, corrosion or
pinched areas.
surfaces.

Always check the high-pressure fuel system for
leaks after loosening or replacing the fuel
injection pipes.
Perform the 'Evaluate injector back leak' test
after repair using DAVIE.
If reusing the fuel injection pipe, install the labeled
fuel injection pipe in the original position.

◾ To prevent bending the high-pressure fuel
injection pipes, it may be necessary to raise
the cabin on some models to properly install
the pipes.
1. If all fuel injection pipes are replaced, first loosen all rail
attachment bolts (3) and tighten them by hand.
2. Fit the new fuel injection pipe (2) without tension.
3. Tighten the union nut (1) on the cylinder head side by hand up 1 2 3 4
to the end of thread.
4. Tighten the union nut (10) on the rail side by hand up to the
end of thread.
torque.
6. Tighten the fuel injection pipe union nut on the cylinder head
side (1) to the specified torque using special tool (1961365).
7. Tighten the fuel injection pipe union nut on the common rail
◾ Bending the injection pipes leads to cracking, 10 9 8 7 6 5

I406151
can occur.
M053597 - 08/09/2020
Technical Data

1 2 3 4
2rd phase

fuel rail side (10)
rd
2 phase
10 9 8 7 6 5
New fuel injection pipe 60° I406151

6)
rd
2 phase
occur.
M036668 - 03/12/2020
Special Tools

1961365

MX / MX-13
ST1961365 - 01/10/2015
1.2.6 install 2 (two) fuel injection pipe 5-6 (Fuel system)
Explanation
Installing fuel injection pipe


◾ The high-pressure fuel pipe for cracks, corrosion or
pinched areas.
surfaces.

Always check the high-pressure fuel system for
leaks after loosening or replacing the fuel
injection pipes.
Perform the 'Evaluate injector back leak' test
after repair using DAVIE.
If reusing the fuel injection pipe, install the labeled
fuel injection pipe in the original position.

◾ To prevent bending the high-pressure fuel
injection pipes, it may be necessary to raise
the cabin on some models to properly install
the pipes.
1 2 3 4
1. If all fuel injection pipes are replaced, first loosen all rail
attachment bolts (3) and tighten them by hand.
2. Fit the new fuel injection pipe (2) without tension.
3. Tighten the union nut (1) on the cylinder head side by hand up
to the end of thread.
4. Tighten the union nut (10) on the rail side by hand up to the
end of thread.
torque.
6. Tighten the fuel injection pipe union nut on the cylinder head 10 9 8 7 6 5
side (1) to the specified torque using special tool (1961365). I406151
7. Tighten the fuel injection pipe union nut on the common rail

can occur.
M053597 - 08/09/2020
Technical Data

1 2 3 4
rd
2 phase

fuel rail side (10)
rd
2 phase
10 9 8 7 6 5

6)
rd
2 phase
occur.
M036668 - 03/12/2020
Special Tools

1961365

MX / MX-13
ST1961365 - 01/10/2015
1.2.7 install bracket, air inlet system (Fuel system)
Technical Data
Tightening torque, bracket, air inlet system
1 2 3 3
4 4 4 5 6 5 4 4
i405569
Attachment bolts (4) 60 Nm [531 lb-in]
M054859 - 26/10/2016
1.2.8 mount assembly air inlet pipe, inlet manifold (Inlet and exhaust element)
Technical Data
Tightening torque, air inlet pipe, inlet manifold

Air inlet pipe attachment bolts 30 Nm [266 lb-in](1)
(1) Always replace the air inlet gasket
M033246 - 19/03/2016
1.2.9 check height cylinder liner, STD (Basic assembly)
Explanation
Checking cylinder liner height
◾ The liner height tool can not always identify an

eroded or fretted cylinder block balcony. If you
suspect the liner seat surface is eroded or fretted,
remove the liner for inspection.
◾ If the cylinder liner seat surface has cavitation,
follow the procedure (Repair height cylinder liner)
1. Position the special tool (1) (1809948) on the cylinder liner.

2. Check that the tool is properly centered and tighten the
attachment bolts (2) in the specified sequence to the specified
torque. 3
3. Place the special tool (4) (0694795) onto the height
measurement tool (1).
2 4
M201633-2
1 2 3 4 5 6
C E
A B
F D
i403823
4. Fit the clock gauge (3) into the cylinder liner height gauge
block (4).
Use a clock gauge with an accuracy of 0.005 mm

[0.0002 in].
5. Position the tip of the clock gauge (3) onto the outside edge of
the cylinder liner.
6. Measure the height of the cylinder liner according to the
specified measuring sequence and note the values in the
table.
M201922
◾ All the readings must be within the specified

tolerances.
◾ If the measured height is not within the
tolerances and the cylinder liner seat is free of
cavitation, a service cylinder liner (with a
0.04 mm [0.0016 in] higher collar) can be
fitted.
M032174 - 06/12/2019
Technical Data
Checking data, cylinder liner height

Tighten to 50 Nm [443 lb-in] in two phases in the specified sequence :
1. Phase 1: 25 Nm [221 lb-in]
2. Phase 2: 50 Nm [443 lb-in]
Tightening sequence special tool
C 3 E
1 5
A B
6 2
F 4 D
i405071
Second phase only after completing first phase on all bolts.
Cylinder liner height (X) used 0.10 - 0.18 mm [0.0039 - 0.0070

cylinder liner in] 1 X 2
Cylinder liner height (X) new 0.12 - 0.18 mm [0.0048 - 0.0070
cylinder liner in]
M201635-2
1 Cylinder liner
2 Cylinder block
The difference between B and A from the adjacent liner

must not exceed 0.03 mm [0.0012 in]
All the readings must be within the specified tolerances.

Measuring sequence
C 3 E
1 5
A B
6 2
F 4 D
i405071
1 2 3 4 5 6
C E C E C E C E C E C E
A B A B A B A B A B A B
F D F D F D F D F D F D
i402364-2
M032175 - 21/07/2016
Check form cylinder liner height
Cylinder 1 (mm) (in) Cylinder 2 (mm) (in) Cylinder 3 (mm) (in) Cylinder 4 (mm) (in) Cylinder 5 (mm) (in) Cylinder 6 (mm) (in)
M045394 - 18/06/2015
Special Tools

1809948
Auxiliary tool for height measurement of cylinder liner
T0014 1
ST1809948 - 29/11/2011
1903047
Cylinder liner height gauge block. Supersedes 0694795.
1903047
ST1903047 - 17/09/2013
1.2.10 install cylinder head gasket, engine (Basic assembly)
Explanation
Installing cylinder head gasket
1. Position the cylinder head gasket using both hands.
Make sure that: Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4
◾ no dirt gets onto the cylinder head gasket.

◾ the cylinder head and block are clean and dry
before installing the cylinder head gasket.
M202153
◾ the letters TOP are visible.
◾ it does not bend.
M031254 - 20/06/2018
1.2.11 position 6 (six) exhaust manifold gasket (Inlet and exhaust element)
1.2.12 check all cylinder head bolt (Basic assembly)
Explanation
Checking cylinder head bolts

1. Clean the cylinder head bolt thread.
2. Apply a drop of oil on the bolt thread.
3. Check the bolts with a clean new nut, M18x2. (for instance
DAF no. 0506668)
4. Screw the nut, by hand, over the full bolt thread length.
If the nut cannot be screwed over the bolt thread,

replace the bolt.
M025780 - 18/05/2016
1.2.13 install assembly cylinder head, engine (Basic assembly)
Explanation
Installing assembly cylinder head

1. Apply a drop of oil to the bearing surface of the bolt heads.
2. Place the cylinder head on the cylinder block and hand-tighten
a few of the cylinder head bolts to arrange alignment.
3. Fit the remaining bolts (M18 and M12).
4. Tighten the cylinder head bolts to the specified torque and in
the specified sequence.
◾ Lubricate the valve stem seals well with clean

engine oil.
◾ Reuse attachment bolts only, when a new nut

can be screwed by hand, over the complete
clean bolt thread.
M036608 - 18/05/2020
Technical Data
Tightening Torque, Cylinder Head
Cylinder Head Attachment Bolts

Tightening sequence, cylinder head attachment bolts
23 15 07 06 14 22
24 16 08 01 05 13 21
25 17 09 02 04 12 20
26 18 10 03 11 19
27 28 29 30 31 32 33
M2013 11-2
1st phase
M18 in the indicated order 70 Nm [52 lb-ft](1)
2nd phase
M18 in the indicated order 250 Nm [184 lb-ft]
3rd phase
M18 in the indicated order 90°
4th phase
5th phase
M12 in the indicated order 60 Nm [531 lb-in](1)
6th phase
(1) Apply a drop of oil to the thread and to the bearing surface of the bolt heads.
◾ Attachment bolts may only be reused when a new

nut can be screwed by hand over the complete
cleaned bolt thread.
◾ Apply a drop of clean engine oil to the thread of the
bolts and the bearing surface of the bolt heads.
M030426 - 22/04/2016
Special Tools

0882233
Torque multiplier for cylinder head
T00145
ST0882233 - 20/03/2008
0911724
Set of gripper sockets 17-18-19-24 mm 3/4 100 mm
09 11724
T00390
ST0911724 - 27/08/2013
1.2.14 remove lifting eye
Special Tools

1903016
This tool replaces
DAF special tool:
1453180 due to
legislation. DAF
special tool
1453180 can still
be used.
ST1903016 - 03/11/2014
1.2.15 install 6 (six) exhaust valve push rod (Basic assembly)
Explanation
Installing valve lifter rod

1. Check the valve lifter rod for damage and deformation and
replace it if necessary.
2. Apply clean engine oil to the valve lifter rod and install it into
the engine.
M032193 - 24/08/2012
1.2.16 install 6 (six) inlet valve lifter rod (Basic assembly)
Explanation
Installing valve lifter rod

1. Check the valve lifter rod for damage and deformation and
replace it if necessary.
2. Apply clean engine oil to the valve lifter rod and install it into
the engine.
M032193 - 24/08/2012
1.2.17 install 2 (two) rocker arm group, engine brake (Basic assembly)
Explanation
Installing rocker arm group, engine brake
The instruction below is applicable to one or both rocker

arm groups.
1. Check that all valve train bridges are installed and positioned
as shown.
◾ The bridges for the inlet valves have no

specific orientation.
◾ An oversize diameter guide pin can be fitted if
the standard pin is loose.
2. Check that all tappet rods are installed as shown:

◾ Thin, Inlet (2)
◾ Thick, Exhaust (3)
3. Apply clean engine oil to the rocker arm group.
4. Position the rocker arm group.
5. Install the attachment bolts (1) and carefully tighten the rocker
arm group to the specified torque in the specified sequence.
◾ Pre-tension builds up in certain valve springs,

making it necessary to tighten the bolts (1)
step by step.
◾ Each rocker arm assembly is positioned by
two guide pins (4).
M055960 - 18/06/2020
Technical Data
Tightening torque, rocker arm group

Attachment bolts (1):
Phase 1 50 Nm [443 lb-in] Tightening sequence according to the bold figures
Phase 2 90°
12 8 4 2 6 10
Lock nut (2) or (3) for valve
adjusting bolt 64 Nm [566 lb-in] 9
Attachment bolt (4) 14 Nm [124 lb-in]
5 1 3 7 11
1 2 3 4 i405475
Flange bolt, hexagonal head 75 Nm [55 lb-ft]

Dowel bolt, internal hexagonal
socket 65 Nm [575 lb-in]
M055947 - 31/07/2020
1.2.18 check and adjust valve clearance (Basic assembly)
Explanation
Checking and adjusting valve clearance
1. Use the special tool (1903018) to

turn the crankshaft
counterclockwise as seen from the
distribution side.
This corresponds to the

direction of rotation of the
engine.
I402049
2. Crank the engine until the vibration

damper is on cylinder mark 1/6.
The position of the

pistons can also be read
on the flywheel.
3. Determine in 3 steps, I, II and III

which cylinder to check and/or 3
adjust.
TDC 4
I II III
Mark on Cylinder Cylinder 1
flywheel with to check 6
and exhaust and/or
vibration valves adjust
damper opened 2
---> --->
5
i405672
1-6 2 1
I II III
Mark on Cylinder Cylinder
flywheel with to check
and exhaust and/or
vibration valves adjust
damper opened
---> --->
2-5 4 5
3-4 1 3
G005493
1-6 5 6
2.5 3 2
3-4 6 4
New rocker assembly

with MX Engine Brake:
◾ Do not check and/or
adjust the exhaust
valve clearance
between the swivel
feet and valve
bridge.
◾ The exhaust valve
clearance must be
checked and or
adjusted according
to the table above,
not at the maximum
lift of the rocker.
◾ The movement
ability of the inlet
valve bridge also
indicates the
cylinder for which
the valve clearance
must be checked.
4. Measure the valve clearance.
◾ A valve clearance A
of more than 1 mm
[0.04 in] indicates
mechanical
damage or wear in C
the valve train, B D
especially when
this is measured
on one cylinder
only.
◾ Ensure that you
i406175
check all valve

train parts of that A Top surface of lost motion shaft collar
specific cylinder B Bottom surface of rocker
before adjusting C Exhaust
the valve clearanceD Intake
to the specified
value.
Intake valve clearance
5. Measure the Intake valve clearance

between the Valve Bridge and the
Flat Face of the Intake rocker’s Ball

Socket.
1
2
i405474
Exhaust valve clearance
6. Measure by inserting the special

tool (2124332) between the bottom
surface of the rocker, and the upper
surface of the lost motion shaft’s
collar.
The tool is designed to

straddle the shaft.
◾ Insert the tool then T05087
remove it and wipe

off any residual oil.
Insert the tool again Tool ST2124332
to take the
measurement.
◾ Residual oil on the
lost motion shaft can
affect the “drag”
friction of the tool,
leading to an
adjustment that is
incorrect.
i406176
G005609
7. Adjust the valve clearance by

loosening the lock nut and turning
the adjusting screw in the correct
direction.
8. By rotating the crankshaft 1/3 stroke
each time, using the special tool
(1903018), the valves can be
adjusted according to the injection
sequence 1-5-3-6-2-4.
G005497
G005498
M054501 - 12/09/2018
Technical Data
Adjusting data, valve clearance

Valve clearance (cold)
Intake 0.50 mm [0.020 in]
Exhaust 0.70 mm [0.028 in]
Lock nut for valve adjusting bolt 64 Nm [566 lb-in]
◾ A valve clearance of more than 1 mm [0.039 in]

indicates mechanical damage or wear in the
valve train, especially when this is measured on

one cylinder only.
◾ Make sure to check all the valve train parts of
that specific cylinder before adjusting the valve
clearance to the specified value.
M053938 - 19/01/2017
Definition, warm and cold engine
Cold A cold engine is an engine that, having reached

engine operating temperature, has been allowed to cool down
for at least six hours.
Warm A warm engine is an engine that, having reached
engine operating temperature, has been at a standstill for not
more than thirty minutes.
M030451 - 19/01/2017
Tightening torque, rocker arm group
Attachment bolts (1):
Phase 1 50 Nm [443 lb-in] Tightening sequence according to the bold figures
Phase 2 90°
12 8 4 2 6 10
Lock nut (2) or (3) for valve
adjusting bolt 64 Nm [566 lb-in] 9
Attachment bolt (4) 14 Nm [124 lb-in]
5 1 3 7 11
1 2 3 4 i405475
Flange bolt, hexagonal head 75 Nm [55 lb-ft]

Dowel bolt, internal hexagonal
socket 65 Nm [575 lb-in]
M055947 - 31/07/2020
Special Tools

1903018
Engine Cranking Tool
1453158 is also
suitable
ST1903018 - 07/01/2013
Special tool category Mandatory special tool for:
2124332
Adjustment tool MX-13 valve clearance
T05087
ST2124332 - 14/06/2017
1.2.19 install air bleed pipe (EGR system)
Technical Data
Tightening torque, air bleed pipe

Attachment bolt, M8 30 Nm [266 lb-in]
Straight coupling piece, M14 50 Nm [443 lb-in]
M044097 - 09/10/2014
1.2.20 mount valve train casing gasket (Basic assembly)
Explanation
Mounting valve train casing gasket

1. Clean the sealing surface of the cylinder head and the recess
in the valve train casing.
2. Install the new gasket in the valve train casing.
Make sure that the sealing surface and recess are

fully dry to prevent leakage.
M037879 - 19/03/2015
1.2.21 install valve train casing (Basic assembly)
Explanation
Installing valve train casing
1. Clean the contact surface for the valve train casing on the
cylinder head.
2. Install the valve train casing. Then tighten the attachment
bolts to the specified torque in the specified order.
Make sure that the exhaust rocker arm of cylinder

one with the exhaust valves opened (1) has
clearance from the valve train casing (2) as shown.
3. Connect the J1 A wiring harness to the valve train casing.

4. Connect the injectors.
5. Connect the engine brake solenoids.
M060430 - 19/12/2017
Technical Data
Tightening torque, valve train casing

Attachment bolts 20 Nm [177 lb-in](1)
(1) Always install a new valve train casing
gasket. Tightening sequence:
9 5 1 3 7 11
13
15
14 16
10 6 2 4 8 12
i405723
M055566 - 24/01/2017
1.2.22 install heat shield (EGR system)
Technical Data
Tightening torque, heat shield

Attachment bolts (M6) 14 Nm [124 lb-in]
Attachment bolts (M8) 30 Nm [266 lb-in]
M056846 - 13/01/2017
1.2.23 mount valve cover gasket (Basic assembly)
Explanation
Mounting valve cover gasket

1. Clean the sealing surface of the valve train casing and the
recess in the valve cover.
2. Install the new gasket in the valve cover.
Make sure that the sealing surface and recess are

fully dry to prevent leakage.
M038971 - 20/10/2014
1.2.24 install valve cover (Basic assembly)
Explanation
Installing valve cover

1. Fit the valve cover complete with the attachment bolts and a
new valve cover gasket.
2. Tighten the attachment bolts in the specified sequence to the
specified torque.
M036888 - 20/10/2014
Technical Data
Tightening torque, valve cover
Tightening sequence:
13 9 5 1 3 7 11
16
15
17
12
14 10 6 2 4 8 I405469
Attachment bolts 9 Nm [80 lb-in](1)

(1) Always install a new valve cover gasket.
M037872 - 05/09/2016
1.2.25 fixing one side supply pipe dosing module, fuel (Engine brake)
Explanation
Connecting quick-release coupling

New situation
1. Lubricate the O-ring with the specified mounting product.

New
◾ Always use a new O-ring.
◾ Make sure that both male and female quick-
release couplings are clean and without
damage.
2. Insert the male quick-release coupling into the female quick- 1

release coupling until it snaps itself onto the collar of the
female quick-release coupling.
◾ Make sure that the pipes are originally routed.

◾ Do not press the releasing element (1).
◾ Replace the releasing element (1) by the c-clip
(2), if:
◾ it is damaged. i403789-3
◾ it is removed from the quick-release
coupling.
Replacement c-clip
If using a c-clip (2):
◾ Insert the male coupling into the female 2
coupling.
◾ Install the c-clip (2) to lock the connection.
◾ Never reuse a c-clip (2).
3. Check whether the quick-release coupling has engaged

correctly by pulling it in the opposite direction. The connection
must remain intact.
Replace the release element (1) by the c-clip (2) if

there is an axial and/or radial play.
I405100
M046086 - 12/11/2015
Technical Data
Mounting product, O-ring

Lubricant Syntheso GL EP1
M045846 - 27/01/2021
Tightening torque, supply pipe dosing module, fuel
Pipe clip attachment nut 30 Nm [266 lb-in]
M056372 - 17/01/2017
1.2.26 fixing one side fuel tank return pipe (Fuel system)
Explanation
Connecting quick-release coupling

New situation
1. Lubricate the O-ring with the specified mounting product.

New
◾ Always use a new O-ring. 1
◾ Make sure that both male and female quick-
release couplings are clean and without
damage.
2. Insert the male quick-release coupling into the female

coupling until it snaps itself onto the collar of the female
coupling.
◾ Make sure that the pipes are originally routed. i403789-3
◾ Do not press the releasing element (1).
◾ Replace the releasing element (1) by the c-clip Replacement c-clip

(2), if:
◾ it is damaged. 2
◾ it is removed from the quick-release
coupling.
If using a c-clip (2):

◾ Insert the male coupling into the female
coupling.
◾ Install the c-clip (2) to lock the connection.
◾ Never reuse a c-clip (2).
3. Check whether the quick-release coupling has engaged

correctly by pulling it in the opposite direction. The connection
must remain intact.
Replace the release element (1) by the c-clip (2) if I405100
there is an axial and/or radial play.
M035573 - 05/04/2018
Technical Data
Mounting product, O-ring

Lubricant Syntheso GL EP1
M045846 - 27/01/2021
1.2.27 install injector leak pipe (Fuel system)
Technical Data
Tightening torque, injector leak pipe

Fuel pressure control valve (7) 30 Nm [266 lb-in] 5
Non-return valve (8) 35 Nm [310 lb-in](1)
7
8
i405521
M032477 - 04/11/2019
1.2.28 fixing assembly compressor pipe 01, delivery side (Air compressor)
1.2.29 close 2 (two) clamping block (Air compressor)
Technical Data
Tightening torque, clamping block

M056467 - 13/01/2017
1.2.30 install 2 (two) fuel injection pipe from pump unit to fuel rail (Fuel system)
Explanation
Installing fuel injection pipe from pump unit to fuel rail

◾ The high-pressure fuel pipe for corrosion, cracks or
pinched areas.
◾ The union nut for corroded, damaged threads or cracks.
◾ Both ends of the high-pressure pipe for damaged or
corroded sealing surfaces.
Replace the fuel injection pipe if any corrosion,

damage, cracks, or pinched areas are found on the
pipe, union nut or any sealing surface.
◾ Always check the high-pressure fuel system for leaks after reusing the fuel injection pipes.
Perform the 'Evaluate injector back leak' test after repair using DAVIE.
◾ If reusing the fuel injection pipe, install the labeled fuel injection pipe in the original position.
Flushing high-pressure fuel pump
1. Loosen the knob of the fuel lift pump (1) by turning it

counterclockwise.
2. Operate the manual fuel lift pump (1) to flush the high-
pressure fuel pump.
Make sure that there is no debris in the high- 1

pressure fuel pump output. Dirt or debris in the fuel
system can lead to severe engine damage. 3
3
I402050-2
1 2 3 4
3. Fit the injection pipe (5) without tension, and tighten it by hand
up to the end of the thread.
4. First tighten the union nut (6) on the pump unit to the specified
torque.
5. Then tighten the union nut (4) on the rail side to the specified
torque.

◾ Make sure that the fuel injection pipe is 10 9 8 7 6 5
I406151
can occur.
M037264 - 23/02/2021
Technical Data
1 2 3 4
2rd phase

fuel rail side (10)
2rd phase
10 9 8 7 6 5

6)
2rd phase
occur.
M036668 - 03/12/2020
1.2.31 install common rail pressure release pipe (Fuel system)
Technical Data
Tightening torque, common rail pressure-release pipe

Union nuts 30 Nm [266 lb-in]
M044909 - 13/11/2014
1.2.32 fixing bracket, fuel system (Fuel system)
Technical Data
Tightening torque, bracket, fuel system
1 2 3 3
4 4 4 5 6 5 4 4
i405569
Common rail pressure release pipe attachment bolt (2) 30 Nm [266 lb-in]
Attachment bolts (3) 30 Nm [266 lb-in]
Sealing plugs, fine metric thread (5) 35 Nm [310 lb-in](1)
Quick-release couplings, female (6) 30 Nm [266 lb-in](2)
(1) Always use new usit rings.
(2) Always use new O-rings.
M054771 - 19/06/2020
1.2.33 fixing front left engine wiring harness J1 A (Elec.syst. 2 engine)

fixing assembly exhaust manifold (Inlet and exhaust element)
1.2.34
Technical Data
Tightening torque, exhaust manifold

Exhaust manifold attachment
bolts (2) 60 Nm [531 lb-in](1) 1
5 2
5
(1)
◾ Always use new gaskets.
◾ Apply a drop of clean engine oil
to the thread of the bolt.
◾ First install all attachment bolts
by hand to ensure proper 3
orientation.
4
i405548-2
Tightening sequence
12 11 9 8 6 5 2 3 14 15 17 18
10 7 4 1 13 16
M205046
M031377 - 09/01/2017
1.2.35 install EGR cooler (EGR system)
Explanation
Installing EGR cooler

1 2 3 4 5 6 7
1. Apply the specified mounting product to the connecting pipes
and insert them in the coolant pipe and coolant pump.
2. Apply the specified mounting product to the venturi sealings.
3. Carefully maneuver the EGR cooler into position.
◾ Make sure that all three connections are

positioned correctly.
◾ The pin must catch the slot in the central EGR
bracket. i405547
4. Hook up the fixing bands (6) in the bracket, install the

attachment bolts and tighten them to the specified torque.
M054468 - 06/11/2020
Technical Data
Mounting product, sealing ring

Rubber lubricant P80
M025429 - 16/11/2020
Tightening torque, EGR cooler
V-clamps (1 and 4) 7 Nm [62 lb-in](1)(2)
Attachment bolt, tightening strap 12 Nm [106 lb-in] 1 2 3 4 5 6 7

(6)
Banjo bolt (7), breather pipe
(M12 x 1.5) 26 Nm [230 lb-in](3)
Attachment bolts (5), bracket
electrical system 30 Nm [266 lb-in]
(1) Always replace the V-clamps and
gaskets.
(2) Position in the orientation shown.
i405547
M054469 - 02/11/2020
1.2.36 connect pressure difference sensor, EGR (Sensors electrical system, engine)
1.2.37 connect temperature sensor, EGR (Sensors electrical system, engine)
1.2.38 install upper bracket, electrical system (Elec.syst. 2 engine)
Technical Data
Tightening torque, bracket, electrical system

Attachment bolts and nuts (M8) 30 Nm [266 lb-in]
Attachment bolt (M14) 170 Nm [125 lb-ft]
M056464 - 28/02/2018
1.2.39 fixing front right engine wiring harness J3 C (Elec.syst. 2 engine)
Technical Data
Tightening torque, engine wiring harness J3 C

Attachment nuts, M8 30 Nm [266 lb-in]
M034383 - 26/02/2014
1.2.40 connect pressure sensor before turbine (Sensors electrical system, engine)
1.2.41 connect pressure sensor after BPV (Sensors electrical system, engine)
1.2.42 connect turbocharger speed sensor (Inlet and exhaust element)
1.2.43 install assembly EGR valve (EGR system)
Technical Data
Tightening torque, assembly EGR control valve
1 2 6 7
Tightening sequence:
1: Attachment bolts (1)
2: V-clamp (8)
3: V-clamp (6)
Tightening torque 9
Attachment bolts (1)
1st phase 23 Nm [204 lb-in] 8
3 4 5
2nd phase 120° i405462
V-clamps (6 and 8) 7 Nm [62 lb-in(1)(Diagonal 2)]
(1) Never reuse the V-clamps and
gaskets.
M054255 - 29/12/2016
1.2.44 connect VTG turbocharger actuator (Inlet and exhaust element)

1.2.45 install 2 (two) sensor pipe
Technical Data
Tightening torque, pressure sensor pipe

Union nut or swivel 27 Nm(1)
(1) Use a second wrench to avoid over-tightening the coupling.
M055584 - 21/02/2017
1.2.46 install assembly coolant pipe (EGR system)
Technical Data
Tightening torque, coolant pipe

Attachment bolt M6 14 Nm [124 lb-in](1)
M054477 - 28/12/2016
1.2.47 fixing supply coolant pipe (EGR system)
Technical Data
Tightening torque, coolant pipe

M054477 - 28/12/2016
1.2.48 fixing return coolant pipe (Inlet and exhaust element)
Technical Data
Tightening torque, return coolant pipe

M055288 - 23/02/2017
1.2.49 fixing air bleed pipe (EGR system)
Technical Data
Tightening torque, EGR cooler

V-clamps (1 and 4) 7 Nm [62 lb-in](1)(2)
Attachment bolt, tightening strap
1 2 3 4 5 6 7
(6) 12 Nm [106 lb-in]
Banjo bolt (7), breather pipe
(M12 x 1.5) 26 Nm [230 lb-in](3)
Attachment bolts (5), bracket
electrical system 30 Nm [266 lb-in]
(1) Always replace the V-clamps and
gaskets.
i405547
M054469 - 02/11/2020
1.2.50 install air inlet pipe from air filter to turbocharger (Inlet and exhaust element)
Technical Data
Tightening torque, air inlet pipe from air filter to turbo charger
Hose clamps 7 Nm [62 lb-in](1)
Air inlet pipe attachment bolts 30 Nm [265 lb-in]
(1) Position in original orientation.
M046232 - 22/11/2016
1.2.51 connect oil pressure sensor (Sensors electrical system, engine)

1.2.52 connect humidity sensor (Sensors electrical system, engine)
1.2.53 connect 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 arching 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 electrical injury or damage.
◾ Always disconnect the battery at the negative terminal when performing service procedures.
◾ Battery acid can cause chemical burns.

◾ If you come into contact with battery acid: flush your skin with water and/or apply baking soda or lime to help
neutralize 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 - 03/05/2010
1.2.54 bleed (Fuel system)
Explanation

doctor.


engine.
M035658 - 20/07/2020
Prime fuel system
If the fuel injection pipes have been removed:

◾ Visually check both injection pipe connections for
leakage during priming the fuel system.
◾ Immediately stop the engine if fuel leakage
occurs and replace the leaking fuel injection
pipe.
After performing fuel system service, prime the fuel system to

remove air from fuel system lines and components. Three priming
options are available; however, hand priming should only be
performed as a last resort when recommended tooling is not
available. After priming, and before releasing the truck, check the
dash for residual DTCs.
The engine must idle for five minutes after priming with
the optional blender bypassed to prevent air entrained in
the fuel lines from damaging the fuel injection system.
If the optional fuel blender is not bypassed, it can take up
to 30 minutes of idle time to purge air from the fuel
system.
1. Priming with DAVCO Shop Pro MX 40/80 (Base Unit)

2. Priming with Mityvac MV7430
3. Hand priming
M057901 - 28/11/2019
Technical Data
Tightening torque, breather plug

Bleeding nipple (4) 6 Nm [53 lb-in]
Bleeding assembly 18 Nm [159 lb-in] 4 A
i403484
M040565 - 06/06/2014
1.2.55 fill coolant (Cooling system, chassis)
Explanation
Warning, coolant
made from EPDM.
M024408 - 17/02/2021
Technical Data
Specification, coolant
Coolant is a toxic fluid. Protect skin and eyes. Coolant is harmful to the 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 from freezing, corrosion, and
cavitation.
Nitrited Extended Life Coolant (ELC)

For nitrited formulations (NOAT), a heavy-duty extended life coolant
that meets ASTM D6210 and Caterpillar EC-1 specifications must
be used.
Nitrite-Free Extended Life Coolant (XLC)

Nitrite-free organic acid technology coolant (OAT) can be used if it
meets DAF 74002.
DO NOT add coolant extender to nitrite-free coolant.
Follow the coolant supplier's drain/flush/fill/diluting percentages
when servicing a vehicle filled with nitrite-free coolant.
Antifreeze is essential for freeze, overheat, and

corrosion protection. The use of supplemental coolant
additives (SCAs) is not recommended for extended-life
coolants.
M028492 - 15/02/2019
1.2.56 bleed cooling system (Cooling system, chassis)
Explanation
Filling and bleeding cooling system

1. Set the cabin heater to the maximum temperature.
2. Fill the cooling system with the specified coolant.
3. Run the engine at an increased speed (n = 1200 rpm) for at
least three minutes to bleed the cooling system
If a fuel injection pipe has been reused during

repair:
◾ Visually check the fuel injection pipe
connections for leakage during:
◾ Idling
◾ 1200 rpm
Immediately stop the engine if

fuel leakage occurs and
replace the leaking fuel
injection pipe.
4. Check and top up the coolant level during bleeding.
Top up until the coolant level stabilizes at the

maximum indicator.
5. Check that both hoses connected to the cabin heater start to

warm up.
6. Switch off the engine.
Make sure that the filler cap is installed.
M037767 - 08/05/2017
1.2.57 install DAVIE
Explanation
Updating DAVIE
Make sure that the DAVIE tool is updated with the latest software version.
M062959 - 21/08/2019
1.2.58 check fuel leakage fuel injection pipe
Explanation

doctor.


engine.
M035658 - 20/07/2020
successfully.
is switched off.
M030466 - 22/02/2021
Checking fuel injection pipe with DAVIE
Damaged and / or incorrectly fitted injector pipes can

cause hot fuel leakage, flammable gases and
vapors.
Immediately stop the engine or test if fuel leakage
occurs.
1. Start the engine and run it at idling speed.

◾ Visually check both fuel injection pipe connections for
leakage.
◾ Immediately stop the engine if fuel

leakage occurs and replace the leaking
2. If no leakage occurs, run the engine at 1200 rpm.

leakage.
◾ Immediately stop the engine if fuel

3. If no leakage occurs, perform the 'Evaluate the injector back

leak' test using DAVIE.
It is not necessary to install the containers for the

MX-13 engine during this check.

leakage.
◾ During this test the rail pressure builds up

to 2500 bar [36260 psi].
◾ Immediately stop the test if external fuel
If the engine does not run or stalls and the test

fails, repeat the test:
◾ Operate the manual fuel lift pump a few
seconds before and while starting the
engine.
◾ Stop operating the manual fuel lift pump a
few seconds after the test has started.
M032569 - 25/06/2020
1.2.59 bring back oil bin
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 11-3-2021. 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
DAF Dealernet
replace assembly cylinder head, engine
(Basic assembly)
Exchange Component
# MPANumber Optional Description Description Bulletin Supersession
Part Group
1
* O-ring 1410 Fuel system
PCE
2
* usit ring 1410 Fuel system
PCE
6 1744858~2127551~1~sealing ring,
1744858 sealing ring, injector 1410 Fuel system PB00291
PCE injector~#
12
* O-ring 1410 Fuel system
PCE
6
* flange bolt 10.9 1410 Fuel system
PCE
1 Inlet and exhaust
1907399 air inlet gasket 1409
PCE element
1 cylinder head
1932890 1401 Basic assembly
PCE gasket, engine
6 exhaust manifold Inlet and exhaust
2138143 1409
PCE gasket element
1 cylinder head, 2125762~2184939~1~cylinder head,
2125762 X 1401 Basic assembly
PCE engine engine~#
1
* O-ring 1419 EGR system
PCE
1 valve train casing
2105835 1401 Basic assembly
PCE gasket
1
2105834 valve cover gasket 1401 Basic assembly
PCE
1
* O-ring 1435 Engine brake
PCE
4
* usit ring 1410 Fuel system
PCE
2
* V-band clamp 1419 EGR system
PCE
2 exhaust gasket,
* 1419 EGR system
PCE EGR
2
* O-ring 1419 EGR system
PCE
1 Inlet and exhaust
* O-ring 1409
PCE element
2
* usit ring 1419 EGR system
PCE

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What safety precautions should be taken when working with the battery?

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What steps must be followed when draining the coolant?

What steps must be followed when draining the coolant?

Print Preview Page 1 of 68

1 replace assembly cylinder head, engine (Basic assembly)

1.1 remove assembly cylinder head, engine (Basic assembly)

1.1.1 get oil bin

1.1.2 disconnect battery clamp, negative pole

Warning, battery clamp and negative terminal

◾ Battery acid can cause chemical burns.

1.1.3 drain coolant (Cooling system)

1.1.4 drain coolant oil module (Lubrication system)

1. Position a suitable container under the drain plug (2).

Tightening torque, drain plugs, oil module

1.1.5 disconnect humidity sensor (Sensors electrical system, engine)

1.1.7 disconnect oil pressure sensor (Sensors electrical system, engine)

1.1.8 loosen air bleed pipe (EGR system)

1.1.9 loosen supply coolant pipe (EGR system)

1.1.10 loosen return coolant pipe (Inlet and exhaust element)

Removing assembly EGR control valve

1.1.15 disconnect turbocharger speed sensor (Inlet and exhaust element)

Removing EGR cooler

1. Loosen the three attachment bolts and maneuver the 1 2 3 4 5 6 7

◾ Check that the EGR temperature sensor was

EGR temperature sensor, located out of sight.

1.1.23 loosen assembly exhaust manifold (Inlet and exhaust element)

Warning, Fuel System

◾ Fuel vapors and spills are potential fire hazards.

Always work in a clean manner according to the Cleanliness procedures

Prevent dirt from entering the fuel system.

Use only a socket or box wrench.

◾ The fuel filter element may be blackened.

Make sure that the filtration module is drained

8. Close the filler screw cap of the fuel tank.

Always bleed the fuel system after draining the fuel

Tightening torque, fuel filter screw cap

1.1.25 loosen front left engine wiring harness J1 A (Elec.syst. 2 engine)

Warning, Fuel System

◾ Fuel vapors and spills are potential fire hazards.

Always work in a clean manner according to the Cleanliness procedures

1. Clean the fuel injection pipe connection and its surroundings

◾ Replace the fuel injection pipe

4. Cover both ends of the fuel injection pipe using clean

If reusing the fuel injection pipe, store it in a clean

1.1.27 open 2 (two) clamping block (Air compressor)

Warning, Fuel System

◾ Fuel vapors and spills are potential fire hazards.

Always work in a clean manner according to the Cleanliness procedures

◾ Clean the area before performing repairs.

Make sure that the fuel gallery is fully drained.

4. Clean the pressure control valve (7) and check it thoroughly

Replace the fuel pressure control valve if it is

Do not overtighten the fuel pressure control

Tightening torque, fuel gallery valves

1.1.30 remove injector leak pipe (Fuel system)

Warning, Fuel System

◾ Fuel vapors and spills are potential fire hazards.

Always work in a clean manner according to the Cleanliness procedures