Motor GS

Component manual
GS engine
© 200847 DAF Trucks N.V., Eindhoven,
The Netherlands
In the interest of continuing product
development, DAF reserves the right to change
specifications or products at any time without
prior notice.
No part of this publication may be reproduced
and/or published by printing, photocopying, on
microfilm or in any manner whatsoever without
the prior written consent of DAF Trucks N.V.
 200847 DW03217403
CONTENTS
GS engine
CONTENTS
Page
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Threaded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Locking and sealing methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2. DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Measuring compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Tractive problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Engine oil consumption test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Pressure testing the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5 Fault-finding tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3 Exhaust, inlet and fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.4 Lubricating oil and cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.5 Basic engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.6 Overhaul data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.7 Overview, wear measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5. ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.1 Removal and installation, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6. STRUCTURAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1 Removal and installation, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.2 Removal and installation, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.3 Removal and installation, turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.4 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.5 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.6 Removal and installation of the steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.7 Removal and installation, hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.8 Removal and installation, starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.9 Removal and installation, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.10 Removal and installation, V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.11 Inspection and setting, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.1 Diagram of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.2 Removal and installation, cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.3 Cylinder head pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.4 Removal and installation, injector sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.5 Removal and installation, valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.6 Removal and installation, valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.7 Inspection and setting, valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.8 Machining the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8. FLYWHEEL AND FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.1 Diagram of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8.2 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
8.3 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8.4 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8.5 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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CONTENTS
GS engine
Page
9. TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.1 Diagram of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.2 Removal and installation, vibration damper/pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.3 Removal and installation, timing cover seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.4 Removal and installation, timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9.5 Removal, installation and setting the timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
9.6 Removal and installation, timing gear case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
10. CYLINDER BLOCK AND DRIVING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.1 Diagram of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.2 Removal and installation, pistons and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
10.3 Removal and installation, crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.4 Grinding the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.5 Removal and installation, camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.6 Measurement and rejection standards of cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10.7 Removal and installation, cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10.8 Measuring and correcting cylinder liner height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.9 Removal and installation, piston cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
10.10 Pressure testing, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
10.11 Machining the cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
11. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
11.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
11.2 Draining and filling, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
11.3 Testing the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
11.4 Removal and installation, header pipe of thermostat housing
and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
11.5 Removal and installation, water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
12. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
12.2 Removal and installation, injector lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
12.3 Inspection, injector opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
12.4 Removal and installation, injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
12.5 Disassembly, assembly and adjustment, injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
12.6 Removal and installation, fuel pump coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
12.7 Removal and installation, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
12.8 Inspection and adjustment, injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
12.9 Removal and installation, fuel filter holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
12.10 Adjustment, idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
12.11 Setting the engine stop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
12.12 Disassembly and assembly, fuel lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
12.13 Fuel pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
12.14 Exhaust brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
13. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
13.2 Draining lubricating oil following engine damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
13.3 External parts of the lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
13.4 Removal and installation, lubricating oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
13.5 Internal components of the lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
13.6 Disassembly and assembly, lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
14. ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
14.1 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2  200847
INTRODUCTION
GS engine General
1. INTRODUCTION
1.1 GENERAL
Preface
This manual is intended to assist well-trained
and experienced workshop staff in overhauling
components and carrying out setting operations
1
and repairs.
With this in mind, the following subjects have
been included: special tools, technical data,
fault-finding, the removal and installation of
components, the disassembly and assembly of
components and setting procedures.
It also contains safety instructions and warnings
which must be strictly observed.
This component manual is based on new,
ex-factory engines.
The engines described are of various types and
designs. Certain descriptions or illustrations in
this manual may therefore not correspond
entirely to the situation regarding your engine.
The technical data and adjustment data in this
engine parts catalogue have been compiled with
the utmost care and only refer to the engines
described herein.
The information given in this manual was
up-to-date at the date of issue. The date of
issue is shown at the bottom of each page.
If considered necessary, DAF reserves the right
to make changes to the procedures and setting
data specified, without prior notice.
 200847 3
INTRODUCTION
General GS engine
Important alterations relating to these workshop

instructions will be announced via the T.I.
(Technical Information) bulletins. These bulletins
are available via your contact person.
To ensure that the operations are carried out
1 sensibly and safely, the mechanic must have the

necessary experience, and have completed the
necessary training courses.
- Always use the special tools specified in
this manual.
The use of these tools will make the work
not only easier and faster, but also safer,
whilst irreparable damage to the part or
component will be avoided.
- Therefore, only use original DAF parts and
components.
These parts and components are carefully
matched, which is one of the factors
determining the original DAF quality. It is
only logical, therefore, that the original DAF
quality can be best maintained if original
DAF parts and components are used when
replacing parts or components.
- Catch any oils or fluids which escape, and
ensure that they are correctly disposed of
or processed.
4  200847
INTRODUCTION
GS engine General
SAFETY PRECAUTIONS
Warning symbol
When text is accompanied by the warning
symbol shown here, this indicates that the
information provided is essential for the health
1
and personal safety of the mechanic.
In addition, this warning symbol is also shown if
there are conditions in which damage can be
caused to the component or parts thereof.
Safety precautions
To ensure that the mechanic’s health is not
endangered, the following safety instructions M2 00 000
must be strictly observed.
- Comply with all the warnings and safety
instructions given in this engine parts
catalogue. First read the instructions and
warnings on the labels and stickers which
are affixed to the various components and
comply with them! They have been put
there for your health and safety, so do not
ignore them!
- Wear clean, close-fitting clothes and apply
protective cream to unprotected parts of
your body, if necessary.
- Ensure proper extraction of dangerous
materials from the work area.
- Maintain a safe distance from rotating
and/or moving parts.
- Avoid unnecessary contact with drained oil.
Frequent contact damages the skin.
- Various sorts of oil and other lubricants
used on the vehicle may constitute a health
hazard. So avoid both inhaling and direct
contact with these.
- Exercise caution when working with springs
under pressure. Inadvertently released
springs may cause serious injuries. Small
springs and small circlips may also cause
injuries when inadvertently released (wear
goggles).
 200847 5
INTRODUCTION
General GS engine
- If necessary, support the component

suitably.
- Always use the appropriate lifting gear
(gearbox jack) or approved lifting gear or
hoists for the removal and installation of
1 heavy components. Attach the component

securely to the lifting or hoisting gear.
- After a fire it is possible that hazardous
residues may remain from the plastics used
in some oil seals and sealing rings. Wear
protective, acid-resistant clothing and PVC
gloves when removing such fire residues.
Submerge such fire residues in, or sprinkle
them amply with, a calcium hydroxide
solution (slaked lime and water).
Thoroughly clean the protective clothing
after use. Treat the gloves as chemical
waste.
- When fitting steel pipes take into account
the points listed below.
Fit the pipe free from tension.
Do not bend pre-moulded pipes.
Fit new sealing rings to the banjo bolts and
fit them.
Tighten the banjo bolt to the specified
torque.
Check the connections for fuel leaks.
Steel pipes fitted without due care and
attention can cause fuel leaks which lead to
the danger of fire.
6  200847
INTRODUCTION
GS engine Threaded connections
1.2 THREADED CONNECTIONS
Dipped bolts
The components can be provided with threaded
connections, which have been treated with
lubricant (dipped threaded connection).
Factory-galvanised bolts and nuts are
wax-dipped. Black annealed and phosphatised
1
bolts and nuts are oil-dipped. The advantage of
the use of dipped nuts and bolts is reduced
friction during tightening, so that the specified
pre-tension can be accurately obtained. The
result of this is that the tightening torque can be
reduced with the same pre-tensioning force.
As this results in a smaller tolerance range of
the tightening torques, the specified tightening
torques must be adhered to more strictly. So
always use a reliable and accurate torque
wrench.
Note:
Have torque wrenches regularly inspected and
calibrated.
To achieve the correct pre-tension when
re-using nuts and bolts, it is important to clean
the thread thoroughly. After cleaning, apply one
drop of lubricant to the first turn of the screw
thread and one drop to the abutting surface of
the nut or bolt. Only use engine oil as a lubricant
for re-used bolts and nuts. Lubricants other than
engine oil and factory-applied grease must not
be used under any circumstances.
The reason for this is that the friction
coefficients of other lubricants vary too much
and are not the same as those of the
above-mentioned lubricants.
The use of locking compounds in combination
with dipped bolts and nuts creates no problems.
 200847 7
INTRODUCTION
Threaded connections GS engine
The following applies to all threaded

connections (for both new and used
vehicles):
- in the case of standard connections, apply
the lubricant before fitting, and
1 tighten/retorque in accordance with the

standard for dipped bolts;
- in the case of special connections, apply
the lubricant before fitting, and
tighten/retorque in accordance with the
values specified in the instructions.
The instructions for using a lubricant also apply
to new bolts supplied from the warehouse. Dry
threaded connections are no longer permitted
because of their highly variable friction
coefficients.
8  200847
INTRODUCTION
TABLE OF STANDARD TIGHTENING TORQUES, DAF STANDARD 00804-203

The tightening torques in the table below are
standard torques and only apply to dipped
threaded connections.
The property-class code is stamped on the nut
or bolt, except on the clamping flange bolt. The
clamping flange bolt is recognised by a
1
constriction between the hexagonal bolt head
and the flange. This constriction is absent in
standard flange bolts.
M2 00 001
Clamping flange bolt Standard flange bolt
 200847 9
INTRODUCTION
TIGHTENING TORQUES FOR DIPPED THREADED CONNECTIONS (Nm)

Overview of tightening torques - applies to:
- property class 8.8 bolt/nut 8
- clamping flange bolt property class
1 12.9/nut 12
Property class 8.8 bolt/nut 8 Property class 12.9 bolt/nut 12
M4 : 2,8  0.2
M5 : 5,5  0.4
M6 : 9,6  0.7
M8 : 23  2 M8 : 32  3
M10 : 46  4 M10 : 67  5
M12 : 79  6 M12 : 113  9
M14 : 125  9 M14 : 178  14
M16 : 195  14 M16 : 274  22
M18 : 280  20 M18 : 385  30
M20 : 395  30 M20 : 550  43
M22 : 540  40 M22 : 740  60
M24 : 680  50 M24 : 925  72
M27 : 1000  70 M27 : 1370  110
M30 : 1350  100
Clamping flange bolt

property class bolt 12.9/nut 12
M12 : 178  14
M14 : 274  22
M16 : 425  35
M18 : 550  45
Tightening torques for banjo bolts
M6 : 8  0,8 Nm
M8 : 15  1.5 Nm
M10 : 30  3 Nm
M12 : 40  4 Nm
M14 : 50  5 Nm
M16 : 60  6 Nm
M18 : 70  7 Nm
10  200847
INTRODUCTION
Overview of tightening torques - applies to:

Property class 10.9

Thread pitch Tightening torque Extra angular displacement ( 10 %)
(Nm)
L ≤ 40
for bolt stem length (mm):
41 - 80 81 - 130 131 - 180
1
M8 30  2 angular displacement not permitted
M10 60  4 angular displacement not permitted
M12 × 1.75 110  8 30_ 60_ 90_ 120_
M12 × 1.25 110  8 45_ 90_ 120_ 150_
M14 × 2 170  15 30_ 60_ 90_ 120_
M14 × 1.5 170  15 45_ 90_ 120_ 150_
M14 × 2 for brake back plates: 170  15 + 60_
M16 × 2 260  20 30_ 60_ 90_ 120_
M16 × 1.5 260  20 45_ 90_ 120_ 150_
M18 × 1.5 360  30 45_ 90_ 120_ 150_
M20 × 1.5 520  40 45_ 90_ 120_
M22 × 2.5 for steering and track rods: 500  50 + 90_
The bolt stem length L is the length of the bolt

between the bolt head and the nut.
If a component is attached with several bolts, all
bolts must first be tightened to the specified
torque, and subsequently by the angular
displacement.
 200847 11
INTRODUCTION
Torque wrench
- Have torque wrenches regularly inspected
and calibrated.
Re-using bolts/nuts
Bolts tightened using angular displacement may
1 not be re-used, unless a suitable new nut can

be screwed down the entire length of the bolt
thread by hand.
19. Clean the thread (take particular care to
remove locking compound residues) and
the bearing faces.
20. Apply one drop of engine oil to the first turn
of the bolt/lower screw thread of the nut and
one drop to the bearing faces (other
lubricants are not allowed).
21. If a locking compound was specified, no oil
should be applied to the thread.
New bolts/nuts
New DAF bolts and DAF nuts, except bolts M4
to M8 with inner-Torx, are all treated with
grease.
If bolts have not yet been treated with a
lubricant, a lubricant should be applied.
1. Apply one drop of engine oil to the first turn
of the bolt/lower screw thread of the nut and
one drop to the bearing faces (other
lubricants are not allowed).
2. If a locking compound was specified, no oil
should be applied to the thread.
12  200847
INTRODUCTION
GS engine Locking and sealing methods
1.3 LOCKING AND SEALING METHODS
Certain cleaning agents have a

negative effect on the functioning
of locking compounds. The general
rule is therefore that fasteners and
components which have been
cleaned with a cleaning agent must
1
be treated with a cleaning liquid to
ensure that the locking compound
functions properly.
OVERVIEW OF LOCKING COMPOUNDS

Product Properties Applications DAF
name number
Loctite - Cleans and degreases For cleaning/de-greasing of 1322827
activator - Non-inflammable and not materials to which a locking
7063 corrosive compound must be applied
Loctite - Locking with an average For locking threaded screw 0068197
243 detaching strength connections
- Detachable with normal tools
Loctite - Locking with a high detaching Locking of threaded connections, 1340646
2701 strength gear lever bearing, freeze plugs
- Repairs the fit in bearing
housings
- Seals against leaks
- Difficult to detach
Loctite - Locking with a high detaching Locking of cylindrical connections 0645557
638 strength under dynamic load
Loctite - Locking with a high detaching Locking of threaded connections, 1279841
262 strength such as the pinion nut
 200847 13
INTRODUCTION
Locking and sealing methods GS engine
OVERVIEW OF SEALING COMPOUNDS

name number
Dirko D - Temperature-resistant to 180_C - For sealing surface connections 1345014
1 Loctite
-
-
Resistant to oil, coolant
Temperature-resistant to 200_C - For sealing surface (flange) 0697149
510 - Resistant to oil, brake fluid, connections that are subjected
coolant to high operating temperatures,
such as the flywheel housing
Loctite - Resistant to high pressures (up - For sealing surface connections 1246867
574 to 350 bar) against high pressures
- Resistant to oil, brake fluid,
coolant
Loctite - Temperature-resistant from 60_ - For sealing flexible 1242895
Blue to 260_C constructions such as (valve)
- Resistant to oil covers
Loctite - Silicone sealant, good - For sealing (surface) 1284123
ultra grey resistance to coolant connections in the cooling
- Temperature-resistant to 325_C system
Silicon - For protecting against moisture 1340644
rubber penetration in (floor) connectors
Loctite - Silicone sealant, good - For sealing surface connections 1284122
ultra resistance to oil such as hub covers
copper - Temperature-resistant to 350_C
Dow - Silicone sealant, good - Sealing of surface connections 0693628
Corning resistance to oil such as the front and rear gear
732 - Elastic to --50_C and +220_C box covers
- Vulcanises to a tough rubber at
room temperature
Loctite - Seals against low pressure - Threaded connections 0292336
572 immediately after fitting
14  200847
INTRODUCTION
GS engine Locking and sealing methods
OTHER PRODUCTS
name number
Molykote - Lubricating grease is - Everywhere where lubrication is 1389512
BR 2
PLUS
-
heat-resistant from --30_C to
+130_C
Water-resistant
-
appropriate and normal
For almost all ball and roller
bearings, plain bearings,
1
guides, couplings, splined
shafts, threaded spindles, small
sprocket drives with a low
speed
Tectyl - Protects the cavities of the - For post-treatment of cab parts 1343888
superstructure against to protect against corrosion.
corrosion Can also be used as protection
for metal parts
Copaslip - Copper paste with an excellent - For connections that are 1284344
bond, is anti- corrosive and vulnerable to oxidation or
heat-resistant from -35 to corrosion, such as battery
+1100_C terminals, exhaust couplings,
- Resistant to water, salts and etc.
acids
- Prevents wear, oxidation, rust,
corroding and locking of metal
surfaces
Application, locking compound

1. Clean both the internal and external thread.
2. De-grease the thread with a suitable
de-greasing agent which leaves no residue
that could affect proper functioning.
3. Depending on the diameter, apply one or
more drops of locking compound. Never dip
the bolt or stud into the locking compound.
4. Apply a drop of oil under the bolt head.
Locking compounds also reduce the
frictional resistance, which means that
applying a drop of oil to the thread is not
required.
5. Tighten the connection to the specified
torque.
 200847 15
INTRODUCTION
Engine data GS engine
1.4 ENGINE DATA
Type : GS 160 M
Design : Horizontal, six cylinder 4-stroke engine, water
cooled with direct injection and equipped with
1
turbocharger and charge cooler
Bore : 118.0 mm
Stroke : 132.0 mm
Capacity : 8.66 dm3
Compression ratio : 16.1 : 1
Max. output : 160 kw at 2300 rpm
Max. torque : 850 Nm at 1100 rpm
Max. loaded engine speed : 2300 rpm
Engine weight : approx. 796 kg
Emission values : Euro 2 standard
Type : GS 200 M
Design : Horizontal, six cylinder 4-stroke diesel
engine, water cooled with direct injection and
equipped with turbocharger and charge
cooler
Bore : 118.0 mm
Stroke : 132.0 mm
Capacity : 8.66 dm3
Type : GS 245 M
Design : Horizontal, six cylinder 4-stroke engine, water
cooled with direct injection and equipped with
turbocharger and charge cooler
Bore : 118.0 mm
Stroke : 132.0 mm
Capacity : 8.66 dm3
16  200847
DIAGNOSIS
GS engine Measuring compression
2. DIAGNOSIS
2.1 MEASURING COMPRESSION
A compression measurement serves to rapidly

check the valve seals, the valve gasket seal and
the seal between the cylinder liner and the
piston rings.
The measuring results may only be used for
comparing the various cylinders. Before
measuring the compression, make sure the
engine is at operating temperature.
2
1. Shut off the fuel supply by moving the stop
lever on the injection pump to the stop
position.
2. Remove the injectors. See “Removal and
installation”.
3. Turn the engine a number of times using
the starter motor, so that any carbon or dirt
particles in the cylinder are removed.
4. Fit the dummy injector, special tool
(DAF no. 0694850) and the adapter, special
tool (DAF no. 0694972).
5. Fit the compression tester, special tool
DAF no. 0109747.
6. Carry out the measurement by rotating the
engine using the starter motor, until the
gauge reading no longer rises.
The difference between the highest and
lowest measured reading may not exceed M2 00 337
15%.
 200847 17
DIAGNOSIS
Tractive problems GS engine
2.2 TRACTIVE PROBLEMS
There can be many reasons why a vehicle does

not pull well.
These can be either psychological or
mechanical.
It is therefore important to properly identify the
problem.
- When does the vehicle not pull properly?
2 - In what road or weather conditions?
- How is the vehicle loaded?
- Is the vehicle being compared with a
vehicle in completely different conditions?
- Is the vehicle being driven in the correct
engine speed range?
General inspection points
- Check the tyre pressures.
- Check whether the correct fuel pump,
turbocharger and injectors have been
installed.
- Mechanically check the throttle control.
- Check the tachograph.
- Check the rev counter.
Check the inlet system
- Check the charge cooler inside and outside
for dirt deposits.
- Check the suction pipe grid on the rain
cover for blockage by large pieces of dirt.
- Check the air inlet system for leaks. See
the “Maintenance manual”.
- Blow clean or replace the air-filter element.
- Check the compressor wheel of the
turbocharger for damage.
18  200847
DIAGNOSIS
GS engine Tractive problems
Check the exhaust system

- Check the exhaust system for leaks.
- Check the compressor wheel of the
turbocharger at the turbine side for
damage.
- Check the exhaust system for blockages.
- Check that the exhaust brake butterfly valve
moves smoothly.
Check the fuel system 2
- Check the fuel system for the presence of
air.
- Check the fuel tank for contamination and
clean with a steam cleaner, if necessary.
- Visually check the low-pressure fuel pipes
for leaks and correct installation.
- Clean the water separator (if fitted).
- Check the banjo bolt strainer in the fuel lift
pump for dirt.
- Check the fuel lift pump pressure.
- Check the gallery pressure. See
“Inspection, gallery pressure”.
- Check the injection timing and if necessary
adjust it. See “Inspection and adjustment,
injection timing”.
- Replace the fuel filter.
- Check the opening pressure of the
injectors. See “Inspection, injector opening
pressure”.
Engine
- Check the valve clearances.
- Check the timing gear.
Measuring the gallery pressure
Connect a pressure gauge to the banjo bolt in
the supply pipe from the fuel filter to the fuel
pump which goes up to 5 bar. For the gallery
pressure, see “Technical data”.
 200847 19
DIAGNOSIS
Tractive problems GS engine
Measuring the inlet underpressure

The inlet underpressure can be measured at the
connection for the underpressure sensor in the
air pipe between the air cleaner and the
turbocharger.
Use a gauge with graduations of at most
--10 kPa (--100 mbar).
The maximum value for the inlet underpressure
is shown in the “Technical data”.
2 Measuring the exhaust back pressure

The exhaust pressure can be measured at the
turbocharger exhaust elbow. For this purpose
remove the socket-head screw. Connect a
pressure gauge with a maximum range of
15 - 20 kPa (0.15 - 0.2 bar).
Use a metal pipe to make the connection to the
turbocharger.
To prevent heavy vibrations, a damped meter
should be used.
Another option is to apply damping.
For this purpose, seal the bore in the coupling
with solder, and subsequently drill a hole in the
solder, approx. 0.5 mm.
The maximum value for the exhaust back
pressure is shown in “Technical data”.
Note:
When a pressure gauge is connected, the
exhaust brake must no longer be used. This
could damage the pressure gauge.
20  200847
DIAGNOSIS
GS engine Engine oil consumption test
2.3 ENGINE OIL CONSUMPTION TEST
Note:
An oil consumption test is only useful once the
engine has been run in (approx. 20,000 km).
1. First carefully check the engine for leaks.
Inspect the air dryer of the brake system for
traces of oil (oil consumption of the air
compressor).
2. Run the engine to operating temperature. 2
3. Place the vehicle on a level surface.
4. Remove the oil drain plug(s) and collect the
engine oil in a clean container.
5. Let the oil leak out for 15 minutes.
6. Pour all the oil in a measuring jug and
determine the amount. The gradations on
the oil can must be accurately legible to
0.1 litres. Pour the oil back into the sump.
7. Note the precise amount of engine oil (A),
with which the sump has been filled.
Write down the total distance covered by
the vehicle.
8. Drive between 500 and 1,000 km under
similar conditions as those in which the
vehicle is normally used.
If necessary, oil can be topped-up during
the journey, provided that this is done with a
jerrycan with a legible scale which has been
filled in the workshop with a measured and
noted quantity of oil.
9. After the journey drain the oil again, taking
care that the engine is at operating
temperature. Let the sump leak for
15 minutes.
10. Pour the oil back into the sump with a
measuring jug and note (to an accuracy of
less than 0.1 litres) the amount of engine oil
left (B), as well as the kilometre reading.
 200847 21
DIAGNOSIS
Engine oil consumption test GS engine
11. If applicable, determine how much oil has

been added en route from the jerrycan
taken along (to an accuracy of less than
0.1 litres) (C).
12. Calculate the oil consumption using the
following formula.
Oil consumotion =
kilometer reading A --
2 kilometer reading B
= km/l
litres A -- litres B + litres C
13. Whether or not corrective measures should 1000
be taken depends also on the number of 900
kilometres already covered by the engine. 900
See the accompanying graph. 800
14. In the graph the oil consumption in km/l is 700 700
marked out on the left and the total number

600
of kilometres covered by the engine at the
km/l
500
bottom. 500
If the oil consumption and the number of 400
400
kilometres covered intersect in the shaded 350
section, corrective measures may be 300
300
considered.
Bear in mind however, that the oil 200
consumption is very much dependent upon 100
the operating conditions.
0
0 25 100 200 300 400 500 600
x 1000 km
M2 00 003
22  200847
DIAGNOSIS
GS engine Pressure testing the fuel system
2.4 PRESSURE TESTING THE FUEL SYSTEM
If an engine is difficult to start after it has not

been operated for some time, this will in most
cases be due to leakage in one or more places
in the fuel system. Such leaks can be rapidly
and effectively traced, using tools intended
specially for that purpose.
1. Disconnect the suction pipe from the fuel
tank.
2
2. Connect the suction pipe to flexible pipe (1). 2 3 4
3. Connect flexible pipe (3) to the suction pipe.
4. Disconnect the return pipe. 5
1
5. Connect cock (5) to the return pipe.
6. Hang plastic pipe (4) in the filler opening.
7. Open cocks (2 and 5).
7 6
8. Pump the system until air-free fuel is
flowing via cock (5) and the plastic pipe (4). M2 00 004
9. Shut cock (5), and pump up the pressure in

the system as high as possible. Legend
1. Flexible pipe
10. Shut cock (2) and check the system for 2. Cock
leaks. A falling pressure gauge level 3. Flexible pipe
indicates a leak somewhere in the system. 4. Flexible pipe
5. Cock
6. Fuel lift pump
7. Pressure gauge
 200847 23
DIAGNOSIS
Fault-finding tables GS engine
2.5 FAULT-FINDING TABLES
ENGINE, GENERAL
FAULT: ENGINE CAN BE STARTED, BUT DOES NOT RUN
Possible cause Remedy
No fuel in the tank or fuel level too low Fill the fuel tank
Air in fuel system Bleed the fuel system
2 Insufficient discharge pressure of the fuel lift

pump
Check the fuel lift pump pressure
Contaminated banjo bolt strainer in the fuel lift Check the strainer for contamination
pump
Water in the fuel system Check the water separator
Fuel filter clogged Replace the fuel filter
Incorrect or contaminated injectors installed Check whether the correct injectors have been
installed. Clean contaminated injectors and set
them
Compression pressure too low Check the compression pressure
Incorrect injection timing, or incorrect fuel pump Check the injection timing and/or fuel pump
setting setting
Supply pipe in fuel tank broken Check supply pipe. If necessary repair or
replace pipe
24  200847
DIAGNOSIS
GS engine Fault-finding tables
FAULT: ENGINE DELIVERS LESS THAN MAXIMUM POWER

Blocked air cleaner Inspect the air filter element. Blow clean or
replace it
Contaminated banjo bolt strainer in the fuel lift Check the strainer for contamination
pump
Banjo bolt with control valve with strainer fitted
incorrectly
Check whether the banjo bolts are fitted in the
correct place
2
Contaminated injectors Inspect the injectors If necessary clean and
adjust
Air in the fuel system Bleed the fuel system
Incorrect turbocharger fitted or turbocharger Check turbocharger
functioning insufficient
Inlet, charge cooler or exhaust leaks Inspect inlet/exhaust systems for leaks due to
loose pipe clamps, plugs that have come loose
etc.
Exhaust system blocked Check the exhaust system and clean if
necessary
Incorrect injection timing or fuel pump setting Check the injection timing and/or fuel pump
setting
Incorrect valve clearance setting Check the valve clearance and adjust if
necessary
Compression pressure too low Check the compression pressure
Fuel tank bleed opening clogged Check the bleed opening and clean if necessary
Poor quality fuel If necessary, place a temporary tank filled with a
better quality fuel and compare the engine
power
FAULT: ENGINE STARTS AND STOPS

Insufficient discharge pressure of the fuel lift Check the fuel lift pump pressure
pump
Constriction in the fuel pipe Check the fuel pipes of the fuel tank, fuel filters
and fuel cooling plate
setting setting
 200847 25
DIAGNOSIS
FAULT: ENGINE WILL NOT IDLE

Incorrect or contaminated injectors installed Check whether the correct injectors have been
them
2 setting
Injection pipes fractured or broken
setting
Check the injection pipes. Replace if necessary
Internal engine damage Remove the oil sump and check whether there
is damage to the camshaft, cam followers,
pistons, cylinders, etc.
FAULT: ENGINE PRODUCES EXCESSIVE NOISE

Air compressor, fan clutch, air-conditioning Check whether the air compressor, fan clutch,
compressor air-conditioning compressor or other engine
accessories may be the cause of the strange
noise
Insufficient lubrication or oil pressure too low Check oil level and oil pressure
Fan V-belt fault. V-belt tension too high or low Check V-belt tension. See “Inspection and
adjustment”
Fan damaged or fan touching radiator Check the fan and radiator
Damaged or loose engine brackets Check engine brackets
Inlet or exhaust pipes touch the chassis or the Check where the pipes touch the chassis or the
cab cab
Inlet air- or exhaust gas system leaking Check the inlet air- and exhaust gas system for
leaks
Turbocharger noise Check turbocharger
Excessive valve clearance Re-set valve clearance
Incorrect or contaminated injectors installed Check whether correct injectors have been
them
setting setting
Damaged valve train and/or push rods, cam Check the valve train, etc. for damage
followers, rocker shafts or rocker arms
Damaged vibration damper Check vibration damper for damage
26  200847
DIAGNOSIS
FAULT: ENGINE POWER DECREASES

Air cleaner element blocked Clean or replace the air-filter element
Blocked air inlet from turbocharger to inlet Check the air inlet and clean if necessary
manifold
Air leak between turbocharger and inlet manifold Check the pipes and pressure test the inlet
section
Air leak between inlet manifold and cylinder
head
Check for leaks and replace gaskets as
necessary
2
Exhaust manifold, exhaust silencer, exhaust Check the exhaust section and clean if
pipe blocked necessary
Gas leak between exhaust manifold and cylinder Check attachment bolts and gaskets
head
Gas leak between exhaust manifold and Check attachment bolts and gaskets
turbocharger
Compressor side of turbocharger contaminated Clean compressor side with a non-corrosive
cleaning agent or a soft brush. Check the inlet
side for carbon deposits or other contamination
Damaged turbocharger Replace turbocharger and locate cause
FAULT: RISING AND FALLING TURBOCHARGER SOUNDS

Exhaust gas leak Check exhaust system
Clogged turbocharger air intake Check air intake and unblock
 200847 27
DIAGNOSIS
FAULT: ENGINE EMITS BLACK SMOKE

Blocked air inlet from turbocharger to inlet Check the air inlet and clean if necessary
manifold
2 Air leak between turbocharger and inlet manifold Check the pipes and pressure test the inlet
section
Air leak between inlet manifold and cylinder Check for leaks and replace gaskets as
head necessary
Gas leak between exhaust manifold and cylinder Check attachment bolts and gaskets
head
Gas leak between exhaust manifold and Check attachment bolts and gaskets
turbocharger
Air cooler not functioning Check cooler for internal and external
contamination and air leaks
28  200847
DIAGNOSIS
FAULT: ENGINE EMITS BLUE SMOKE

Turbine side oil seal leaks Check/replace turbocharger
Air leak between turbocharger and inlet manifold Check the pipes and pressure test the inlet
Air leak between inlet manifold and cylinder

section
Check for leaks and replace gaskets as
2
head necessary
Clogged exhaust manifold Check the exhaust manifold and clean if
necessary
Turbocharger oil discharge pipe is blocked Check the oil pipes and replace if necessary
Turbocharger air intake clogged or blocked Replace the turbocharger. Replace oil and filter
 200847 29
DIAGNOSIS
ENGINE COOLING SYSTEM
FAULT: ENGINE TEMPERATURE INCREASES

Insufficient coolant Check the fluid level and top up if necessary
Coolant pipe fractured, blocked, or leaking Check coolant pipes
V-belt tension of fan/water pump incorrect or Check V-belt tension. See “Inspection and
2 V-belt broken
Contaminated radiator or intake air cooler
adjustment”
Check the radiator and charge cooler and clean
if necessary
Fan damaged Check fan
Incorrect or malfunctioning pressure cap Check pressure cap
Thermostat opens insufficiently or not at all Check the thermostat and its operation
Incorrect injectors installed Check whether correct injectors have been
installed
setting setting
Engine oil level too low Check the engine oil level and top up if
necessary
Defective water pump Check water-pump shaft, bearings and impeller.
Replace water pump, if necessary
Air or combustion gases in the cooling system Inspect the cooling system
Fan clutch defective Check the fan clutch
30  200847
DIAGNOSIS
ENGINE LUBRICATION SYSTEM
FAULT: ENGINE OIL PRESSURE TOO LOW

Engine oil level too low Top up engine oil to maximum level
External oil leaks Check the engine visually for leaks. Repair if
necessary
Defective oil-pressure switch
Oil fails to meet the required specifications
Check the switch and replace if necessary
Replace the oil and filter and check the
2
specification
Oil temperature is too high Check the oil cooler
Oil mixed with coolant Replace the oil and filter and/or check the
cooling system for internal leaks
Oil suction pipe is loose or broken Check the oil suction pipe and repair if
necessary
Pressure relief valve leaks or spring is broken Check the pressure release valve and replace if
necessary
Inadequate functioning of oil pump Check oil pump
Main shaft or connecting rod bearings worn out Check main shaft and connecting rod bearings
FAULT: TURBOCHARGER OIL LEAK

Turbine/compressor side oil seal leaks Check/replace turbocharger
Oil drain pipe clogged Check the oil pipes and replace if necessary
Turbocharger air intake clogged or blocked Replace the turbocharger, change the oil and
replace the oil filter
 200847 31
DIAGNOSIS
FAULT: EXHAUST VALVE BROKEN

No valve clearance or negative valve clearance Inspect the valve clearances.
Inspect and clean the air inlet and exhaust
system thoroughly.
If the valve continues to hit the piston, inspect
and clean the internal section of the engine
thoroughly
2 Engine speed too high Inspect the engine speed regulator of the fuel
pump.
Inspect the gearbox fastening
The valve is broken as a result of a material Inspect the other exhaust valves
problem
Camshaft gear wheel has one or more teeth Inspect the position of the camshaft gear wheel
incorrectly positioned
FAULT: EXHAUST VALVE DISK CRACKED

The valve is cracked as a result of a material Inspect the other exhaust valves
problem
FAULT: EXHAUST VALVE DISK BURNT

No valve clearance or negative valve clearance Inspect the valve clearances.
Inspect the other exhaust valves
32  200847
DIAGNOSIS
FAULT FINDING TABLE, TIMING GEAR
FAULT: NOISE IN THE TIMING GEAR CASE

Timing gear cog damaged Inspect timing gear wheels
Timing gear wheel play not correct Inspect timing gear wheel play
Timing gear wheel disconnected Inspect timing gear wheel attachment
2
 200847 33
DIAGNOSIS
FAULT FINDING TABLE, FLYWHEEL AND FLYWHEEL HOUSING
FAULT: ENGINE VIBRATES EXCESSIVELY

Unbalance or flywheel oscillation Inspect flywheel oscillation and mounting. See
“Technical data”
34  200847
DIAGNOSIS
FAULT FINDING TABLE, CYLINDER BLOCK AND DRIVING GEAR
FAULT: VALVE IMPRESSION ON THE BOTTOM OF THE PISTONS

No valve clearance or negative valve clearance Inspect the valve clearances
Broken valve spring Inspect valve springs
Incorrect valve spring design Inspect valve spring design
2
FAULT: SEVERAL PISTONS SHOW A VALVE IMPRESSION
The valve timing is incorrect Check the valve timing
A timing gear wheel has come loose Inspect the timing gear wheels
The engine is turning at too high an engine Inspect the engine speed regulator of the fuel
speed if all the exhaust valves have hit the pump.
pistons Inspect the gearbox fastening
Camshaft gear wheel has one or more teeth Inspect the position of the camshaft gear wheel
incorrectly positioned
FAULT: CRACKED PISTON HEAD

Too rich a mixture Check the fuel pump output
Inspect the air cleaner for clogging
Incorrect injection timing Check the injection timing
Bad fuel distribution due to poor functioning of Inspect the injectors
injectors
Fuel injection during engaging of the engine When operating the engine brake, check
brake whether the fuel pump is in the stop position
 200847 35
DIAGNOSIS
FAULT: IMPRESSIONS IN THE PISTON HEAD

Broken glow plug Inspect the glow plugs.
Inspect the other pistons, cylinder liners and
valves for damage
During activity, a foreign object has entered the Inspect the other pistons, cylinder liners and
combustion chamber via the inlet/exhaust valves for damage.
manifold Inspect the inlet/exhaust system
2
FAULT: CYLINDER LINER WORN OUT
Gudgeon pin circlip broken or not fitted Inspect pistons
Piston rings worn due to poor lubrication of the Inspect the dimensions of the cylinder liner and
cylinders (if necessary) of the cylinder bore. See
Piston rings worn due to impurities in the air Inspect the air filter and the whole air inlet
drawn in system
FAULT: PISTON HEAD HAS MELTED

Engine overheating Inspect the cooling system for the following
points:
- filling
- correct functioning
- pollution
- correct type
Inspect the dimensions of the cylinder bore. See
Air bubble in the cooling system Inspect the bleeding system
Bad fuel distribution due to poor functioning of Inspect the injectors
injectors
36  200847
DIAGNOSIS
FAULT: PITTING ON THE PISTON HEAD

The piston head has hit the cylinder head, as Inspect whether all pistons have the same
the centre-to-centre distance from the damage
crankshaft to the cylinder head is too small.
The cylinder block has been faced too far
Big-end bearing worn out Inspect big-end bearings
Small-end bush worn out Inspect small-end bush
2
FAULT: PISTON RING GROOVE WORN OUT
Piston ring fracture. Inspect the other piston rings
When fitting the ring, this was bent open too far,
causing a hairline fracture
The intake air is polluted, causing excessive Inspect the whole air intake system
wear to the piston rings
FAULT: PISTON SKIRT WORN OUT AROUND GUDGEON PIN BORE

Fracture or incorrect fitting of the circlip for the Also inspect the other pistons and cylinder liners
gudgeon pin for damage
 200847 37
DIAGNOSIS
FAULT: PISTON SHOWS SIGNS OF GRATING

If the signs of grating are mostly to be found Inspect the cooling system for the following
around the gudgeon pin bores: points:
overheating of the relevant cylinder due to - filling
shortage of coolant or air in the cooling system - correct function
- pollution
- correct type
2 Inspect the dimensions of the cylinder bore. See

Air bubble in the cooling system Inspect the bleeding system
If the signs of grating are mostly to be found on Inspect the cooling system.
the pressure side of the piston: Inspect the dimensions of the cylinder bore. See
piston skirt cracked from the gudgeon pin bores “Technical data”
If the piston shows light signs of grating on the Inspect the cooling system.
pressure side: cold start. Inspect the dimensions of the cylinder drilling.
If an engine is brought to a high engine speed in See “Technical data”
a short time, the pistons are not fully
cooled/lubricated. This may result in localised
grating
FAULT: PISTON SKIRT COLOURED

Oil consumption too high Check:
- piston rings for wear
- cylinder liner for scratches
- dimensions
See “Technical data”
Piston rings worn. Check:
Due to this, the oil is not fully scraped from the - piston rings for wear
cylinder wall. The combustion gases can also - cylinder liner for scratches
leak to the bottom. As a result, the oil burns and - dimensions
turns the piston black in the area of the spring See “Technical data”
wall
38  200847
DIAGNOSIS
FAULT: GUDGEON PIN SHOWS GROOVES

Grit in the engine oil. Clean all parts.
Engine oil polluted. Inspect the dimensions.
As a result, the gudgeon pin wears excessively See “Technical data”
FAULT: PISTON RINGS WORN

Possible cause Remedy 2
Poor lubrication of the cylinder due to: Inspect fuel system.
- fuel in the lubricant Inspect cooling system.
- coolant in the lubricant Inspect the cylinder liner for signs of wear.
The piston rings show signs of vertical grating. Inspect the dimensions.
The signs of grating run over the whole diameter See “Technical data”
of the piston rings
The intake air is polluted, causing excessive Inspect the whole air intake system
wear to the piston rings
FAULT: CONNECTING ROD BENT

Fluid stroke. Check:
A layer of water has settled above the piston - whether the head gasket has blown
due to: - the cylinder head for cracks
1. the presence of water in the air filter Inspect whether the water leakage has been
because of: continuing for some time.
- cleaning with water Inspect the cylinder block and driving gear for
- driving through very deep water consequent damage
2. the head gasket is leaking or the cylinder
head or cylinder block is cracked
During operations, oil has entered the cylinder
 200847 39
DIAGNOSIS
FAULT: BEARING SHELLS EXCESSIVELY WORN

Thinning of lubricating oil due to coolant Check the oil cooler.
Inspect the cylinder block and cylinder heads for
cracks or blown head gasket by bleeding the
cooling system.
Inspect the bearing journals for damage and
dimensions. See “Technical data”.
2 Thinning of lubricating oil due to fuel

Inspect and clean the lubrication system
Have the fuel pump checked for internal leaks.
Inspect the bearing journals for damage and
dimensions. See “Technical data”.
Polluted lubricating oil due to: Inspect the bearing journals for damage and
- polluted oil filter dimensions. See “Technical data”.
- too long an interval between oil changes If the bearing journals show grooves, the
- too long an interval between oil filter crankshaft must be replaced or ground.
changes Inspect and clean the lubrication system
- excessive pollution within the period
between replacements
- worn sections of the running parts
- broken oil filter
- dirt remaining from fitting
Too little lubricating oil due to: Inspect the bearing journals for damage and
- poor inspection of oil level dimensions. See “Technical data”.
- oil level too low If the bearing journals show grooves, the
- forgetting to fill oil crankshaft must be replaced or ground.
- excessive oil use Inspect and clean the lubrication system
- external oil leakage
- worn sections of the running parts
- air bubbles in the lubrication system due to a
loose fitting oil suction pipe
In the case of reduced oil pressure, damage to
the connecting rod bearings will be first to
increase, as these are further away from the oil
pump than the main bearings
No lubricating oil due to: Inspect the bearing journals for damage and
- loosened or non-fitted oil drain plug dimensions. See “Technical data”.
- clogging of the oil channel If the bearing journals show grooves, the
- bearing installation fault crankshaft must be replaced or ground.
In the case of sudden loss of oil, damage to the
main bearings will be first to occur, as these
immediately receive no more oil
40  200847
DIAGNOSIS
FAULT: BEARING SHELLS SHOW TRACES OF GROOVES

During installation dirt has come between the Inspect the bearing journals for damage and
bearing shell and the initial bore of the main dimensions. See “Technical data”.
bearing or the connecting rod If the bearing journals show grooves, the
crankshaft must be replaced or ground.
 200847 41
DIAGNOSIS
42  200847
SPECIAL TOOLS
GS engine Special tools
3. SPECIAL TOOLS
0484899
0109747 3
0535551
0535625
Item Description Application DAF no.

1. Compression tester Measuring engine compression in 0109747
combination with 0694850 and 0694972
2. Puller, crankshaft oil seals Removal of crankshaft oil seals, in 0484899
combination with 0694928
3. Oil pressure gauge Measuring lubricating oil pressure 0535551
4. Cylinder liner installer (complete) Removal and installation, cylinder liner 0535625
 200847 43
SPECIAL TOOLS
Special tools GS engine
0535626 0535631
0535632 0535633

5. Stud Removal and installation, cylinder liner 0535626
(part of 0535625)
6. Plate Removal and installation, cylinder liner 0535631
(part of 0535625)
7. Threaded spindle nut Removal and installation, cylinder liner 0535632
(part of 0535625)
8. Threaded spindle nut Removal and installation, cylinder liner 0535633
(part of 0535625)
44  200847
SPECIAL TOOLS
0535699 0535755
0535756 0535937

9. Camshaft bearing bush driver Installation of camshaft bearing bush 0535699
10. Plate Removal and installation, cylinder liner 0535755
(part of 0535625)
11. Pin (part of 0535625) Removal and installation, cylinder liner 0535756
12. Bearing set Removal and installation, cylinder liner 0535937
(part of 0535625)
 200847 45
SPECIAL TOOLS
0694795 0694835
0694850 0694912

13. Height measuring block Measuring cylinder liner height 0694795
14. Injector puller Removal of injector 0694835
15. Dummy injector Measuring engine compression in 0694850
16. Guide pin Guide pin for installation of cylinder head 0694912
46  200847
SPECIAL TOOLS
0694921 0694928
1310425
0694966

17. Thermostat seal driver Installing thermostat seal 0694921
18. Slide hammer Removing injector sleeves, in combination 0694928
with 1310425 and crankshaft seals in
combination with 0484899
19. Injector sleeve puller Removing injector sleeves in combination 0694930
with 1310425
20. Injector tester Testing injectors 1310425
 200847 47
SPECIAL TOOLS
0694972 0695000
1240074 1240076

21. Compression tester adapter Measuring engine compression in 0694972
22. Crankshaft seal driver, flywheel Installing crankshaft seal, flywheel end 0695000
end
23. Injector sleeve scraper Cleaning injector sleeves 1240074
24. Injector sleeve driver Installation of injector sleeve 1240076
48  200847
;;;;;
SPECIAL TOOLS
200
; 1240432
50
100
150
00
1240442
3
500
100
160
0
200
300
1240443
1240448

25. 12-sided cap Removal and installation of connecting rod 1240432
cap bolts
26. “Krikit I” (250 - 700 N) V-belt Adjusting V-belt tension, single belt 1240442
tension gauge
27. “Krikit II” (450 - 1500 N) V-belt Adjusting V-belt tension, “Twin belt” 1240443
tension gauge
28. Vibration damper puller Removal of vibration damper 1240448
 200847 49
;
SPECIAL TOOLS
;;;
;;;;
;
1240455
;
1240476
1240477 1310455

29. Crankshaft seal driver, timing Installation of crankshaft, timing gear end 1240455
gear end
30. Oil heat exchanger pressure test Pressure-testing oil heat exchanger, in 1240476
plate combination with 1240477
31. Oil heat exchanger pressure test Pressure-testing oil heat exchanger, in 1240477
plate combination with 1240476
32. Injection timing adjuster Inspection and adjustment, injection timing 1310455
50  200847
TECHNICAL DATA
GS engine General
4. TECHNICAL DATA
4.1 GENERAL
The data refers to new parts in ex--works

condition.
The definitions of “cold engine” and “warm
engine” are as follows:
- A “cold engine” is an engine that, having
reached operating temperature, has been
allowed to cool down for at least six hours.
- A “warm engine” is an engine that, having
reached operating temperature, has been at
a standstill for not more than thirty minutes.
The direction of rotation is clockwise, as seen
from the timing gear end.
The first cylinder of the engine is the cylinder at
the timing gear end.
4
For the tightening torques, see the standard
tightening torques for dipped nuts and bolts,
section 1, “Introduction”.
Only the tightening torques which differ from
these standard tightening torques are listed in
the technical data.
When locking and sealing compounds are used,
the threaded parts of nuts, bolts, studs and
threaded holes should be carefully cleaned and
degreased to ensure optimum effectiveness of
the locking or sealing compound.
 200847 51
TECHNICAL DATA
Tightening torques GS engine
4.2 TIGHTENING TORQUES
Starter motor
Attachment nuts 68 Nm*
Alternator
Sheet steel pulley attachment nut (M16) 70 Nm***
Cast iron pulley attachment nut (M16) 70 Nm***
Pulley attachment nut (M27) 155 Nm
Air compressor
Compressor gear attachment bolt 120 Nm*
Compressor attachment bolts 95 Nm
Sensors
Temperature sensor 20 Nm (maximum)
4 Engine speed sensor 50 Nm (maximum)
Exhaust manifold
Attachment nuts 50 Nm**
Inlet manifold
Attachment bolts 40 Nm
Turbocharger
Clamping plate nut, turbine housing 15 Nm
Clamping plate attachment bolts 12 Nm
Exhaust manifold flange turbocharger
attachment nut 45 Nm
Exhaust flange turbocharger attachment nut 35 Nm**
Water pump
Gear attachment nut 75 Nm*
Attachment nuts 21 Nm
Steering pump
Drive gear attachment nut 80 Nm*
Pipe connection in the pump, delivery side 40 Nm*
Pipe connection in the pump, intake side 90 Nm*
Hydraulic pump
Gear attachment nut 55 Nm
Attachment nuts 42 Nm*
* Apply Loctite 243 when securing.

** Fasten with Copaslip.
*** Fit pulley without key. Apply a drop of oil to
the screw thread and contact surface of the
attachment nut.
52  200847
TECHNICAL DATA
GS engine Tightening torques
Fuel pump coupling

A B C B
B B
I4 00 401
A Clamping piece attachment bolt

If M12, 12.9 Do not re-use bolt; replace with M12, 10.9 bolt
If M12, 10.9 100 Nm +60° angular displacement*
4
B Coupling plate attachment bolts
If M12 110 Nm + 60° angular displacement**
If M10, new bolt 70 ***
If M10, 2nd and 3rd fitting 85 ****
C Fuel pump coupling nut, pump side 195 Nm
* Do not reuse the bolt; only use a new bolt.

** Do not reuse the bolts; only use new bolts.
Apply Loctite 243 to the bolts.
*** Replace the bolts after the 3rd fitting.
Increase the torque to 85 Nm on the 2nd
and 3rd fittings. Apply Loctite 243 to the
bolts.
**** Apply Loctite 243 to the bolts.
Injector
Injector attachment nut 20 Nm
Injector union nut 25 Nm
Injector pipe
Injector pipe union nut 25 Nm
Fuel filter holder

Fuel filter holder attachment bolts 60 Nm
 200847 53
TECHNICAL DATA
Cylinder head bolts

1st phase:
Tighten the M16 bolts (1 to 13) in the indicated 9 4 8
order to a torque of 50 Nm*. 10 13
5 3
2nd phase:
Tighten the M16 bolts (1 to 13) in the indicated
order to a torque of 150 Nm.
11 12
6 1 2 7
3rd phase:
Tighten the M12 bolts (14 to 17) in one
14 15
16 17
movement in the indicated order and to a torque

of 94 Nm*. M200184
4th phase:
Draw a clear, straight line with a felt pen on the 50Nm
bolt head of each M16 bolt (1 to 13). Ensure that 150Nm
all stripes are parallel. Turn the M16 bolts 60° in
the indicated order.
4 Check again that all lines on the bolt heads are 95Nm
M16
parallel.
M16
5th phase:
Turn the M16 bolts (1 to 13) 60° in the indicated I
M12
order. Check that all lines on the bolt heads are
II
M16
parallel.
M16
Tightening cylinder head bolts III
The head gasket needs no re-tightening. IV
However, under extreme conditions the V
pre-tension of the head bolts can be reduced to
such an extent that the head gasket no longer
provides sufficient sealing.
M200226
In that case, the M16 head bolts need to be

re-tightened after replacement using the
following method:
1. Replace the leaking head gasket with a new
one.
2. Tighten the head bolts as described in the
previous instructions.
3. Run the engine for several hours.
4. Allow the engine to cool (approx. 4 hours).
5. Turn the M16 head bolts (not the M12 bolts)
in the specified order another 60° (without
first un-tightening them).
6. Mark the M16 head bolts with a centre
point.
7. M16 head bolts may only be reused twice in
this instance as well (so may only have two
centre points).
54  200847
TECHNICAL DATA
Valve gear
Attachment bolts, valve covers 40 Nm
Rocker shaft seat shoulder stud 115 Nm
Side covers 20 Nm*
Lock nut for valve adjusting bolt 35 Nm
Locking compound, expansion plugs Loctite 270
Main bearing cap attachment bolts

Attachment bolt M18x2
(up to engine no.R-11682) 250 Nm***
Attachment bolt M16x2
(from engine no.R-11682) 150 Nm + 120° angular displacement***
Attachment bolts, connecting rod

bearing caps
Attachment bolt, property class 10.9 80 Nm + 120° angular displacement**/***
Camshaft locking plate 4

Camshaft locking plate attachment bolts,
property class 8.8 25 Nm*
Camshaft locking plate attachment bolts,
Vibration damper
Tighten vibration damper attachment bolts in
three phases:
1st phase 40 Nm*
2nd phase 60 Nm
3rd phase 90 Nm

** Always replace attachment bolt.
Only use bolts of property class 10.9.
*** Apply a drop of oil to the thread and bearing
surface.
 200847 55
TECHNICAL DATA
Pulley
Attachment bolts, pulley, property class 8.8 25 Nm*
Timing gear
Attachment bolts, timing gear case,
property class 8.8 25 Nm *
Attachment bolts, timing gear case,
Attachment bolts, timing gear cover,
property class 8.8 25 Nm
Attachment bolts, timing gear cover,
property class 10.9 30 Nm
Attachment bolts, camshaft locking plate,
4 property class 8.8

Attachment bolts, camshaft locking plate,
25 Nm*

Camshaft gear attachment bolt 425 Nm*
Idler gear attachment bolt 115 Nm
Attachment bolt, fuel pump gear wheel 180 Nm*
Attachment bolt, oil pump idler gear, property
class 8.8 50 Nm
Attachment bolt, oil pump idler gear, property
class 10.9 60 Nm
56  200847
TECHNICAL DATA
Flywheel
Attachment bolts 130 Nm*
Flywheel housing
Attachment bolts 95 Nm*
Sealant Loctite 510
Engine mounts
Timing gear side: attachment bolts, engine
bracket to cylinder block
M14, property class 10.9 170 Nm
M8, property class 8.8 25 Nm*
M8, property class 10.9 30 Nm*
Flywheel housing side: attachment bolts,
engine bracket to flywheel housing
M16, property class 10.9 260 Nm
Oil pump
4
Attachment bolts, oil pump to attachment
plate, property class 8.8 25 Nm*
Attachment bolts, oil pump to attachment
plate, property class 10.9 30 Nm*
Attachment bolts, plate to bearing cap 50 Nm*
Oil sump
Oil drain plug 60 Nm
Attachment bolts, oil sump 20 Nm
Strainer
Attachment bolts, bracket (oil strainer),
Lubricating oil pressure regulator

Plug bypass 80 Nm
Lubricating oil filter
Lubricating oil filter 35 Nm
Oil nozzle
Banjo bolt M10 from engine no. R-11682 30 Nm*
Banjo bolt M14 to engine no. R-11682 30 Nm**
Lubricating oil pipes

Attachment bolts, internal oil pipes and
brackets, property class 8.8 25 Nm*

** Lock with locking plate.
 200847 57
TECHNICAL DATA
Oil sump
Oil drain plug 60 Nm
Attachment bolts, oil sump 20 Nm
Strainer
Lubricating oil pressure regulator

Bypass plug 80 Nm
Lubricating oil filter

Lubricating oil filter 35 Nm
4 Oil nozzle
Banjo bolt M10 from engine no. R-11682 30 Nm*
Banjo bolt M14 to engine no. R-11682 30 Nm**
Lubricating oil pipes


** Lock with locking plate.
58  200847
TECHNICAL DATA
GS engine Exhaust, inlet and fuel system
4.3 EXHAUST, INLET AND FUEL SYSTEM
Exhaust back pressure

At full-load engine speed 9 kPa maximum
Charge underpressure
At full-load engine speed
New air filter 5.0 kPa maximum
Used air filter 7.5 kPa maximum
Injectors
Injector adjusting pressure 230 - 240 bar
Control pressure 200 - 240 bar
Fuel pump
Injection sequence 1-5-3-6-2-4
Injection timing
4
GS 160 M 8
GS 200 M 9
GS 245 M 10
Gallery pressure 150 kPa
Idle engine speed

GS 160 M 625 ± 25 rpm
GS 200 M 625 ± 25 rpm
GS 245 M 575 ± 25 rpm
Maximum unloaded engine speed

GS 160 M 2555 ± 30 rpm
GS 200 M 2540 ± 30 rpm
GS 245 M 2650 ± 30 rpm
 200847 59
TECHNICAL DATA
Lubricating oil and cooling system GS-engine
4.4 LUBRICATING OIL AND COOLING SYSTEM
Oil pressure
- Maximum engine speed 3.35 - 4.35 bar
- Idling speed (engine at
operatingtemperature) 0.55 bar (minimum)
Oil filter
Type disposable filter
Qty 1
Installation in the oil circuit full flow
Opening pressure of bypass valve 2.5 ± 0.3 bar pressure difference
Oil cooler
Opening pressure of bypass valve at a
pressure difference of 2 bar
4 Test pressure of coolant section (air pressure) 1.5 bar
Piston cooling
Oil injector opening pressure (up to engine
no. R-11682) 1.5 bar
No valve is used from engine no. R-11682.
Filling capacities for lubrication system

Oil sump capacity (excluding heat exchanger
and filter) on an engine with one drain plug.
Angle of engine installation of 0° or 4°:
- maximum level approximately 23.5 litres
- minimum level approximately 17.5 litres
Angle of engine installation of 7°:
Oil sump capacity (excluding heat exchanger

and filter) on an engine with two drain plugs
(second drain plug located on a pipe on the
bottom of the engine).
Angle of engine installation of 0°, 4° and 7°:
Cooling system
Operating temperature 95°C
Thermostat opens at 78 - 81°C
Thermostat min. 9.5 mm open at 90°C
Cooling system test pressure 0.4 - 0.5 bar
60  200847
TECHNICAL DATA
GS engine Basic engine
4.5 BASIC ENGINE
B A B A B A B A B A B A
M200305
Valve overview
A = Exhaust valve 4
B = Inlet valve
C = Timing gear end
Comment
For details of how to set the valve clearance
after processing and/or replacing the valve or
valve seat, see ”Removal and installation”.
Valve timing diagram with valve clearance

of 0.5 mm
Inlet valve opens 16° before TDC
Inlet valve closes 32° after BDC
Exhaust valve opens 60° before BDC
Exhaust valve closes 16° after TDC
Valve lifting height at TDC 0.96 ± 0.3 mm
Valve springs
Spring length outer spring:
loaded to 260 N: approx. 66 mm
Spring length inner spring:
Cylinder head
Test pressure (air pressure): 1.5 bar
 200847 61
TECHNICAL DATA
Basic engine GS engine
Number of teeth, timing gears

Crankshaft gear 31
Idler gear 52
Camshaft gear 62
Fuel pump gear 62
Compressor gear 27
Oil pump gear 44
Oil pump idler gear 24
Steering pump gear 18
Water pump gear 23
Hydraulic pump gear 24
Flywheel/starter ring gear

Axial difference, measured to 120 mm
from the centre max. 0.10 mm
Starter ring gear warm up maximum 230°C
4
62  200847
TECHNICAL DATA
GS engine Overhaul data
4.6 OVERHAUL DATA
M2 00 009
Cylinder head
Minimum height after overhaul
(measurement A) 113.50 mm
Roughness 0.4 - 1.6 mm
Pressure-test with air 1.5 bar
Valve seat, inlet (loose seat)
4
Valve seat angle 30° ± 0.25°
Internal diameter 45.00 ± 0.10 mm
External diameter 54.11 - 54.13 mm
Thickness 7.125 - 7.175 mm
Cylinder head recess:
depth 10.10 ± 0.10 mm
diameter 54.00 - 54.03 mm
Valve seat, exhaust (loose seat)

Valve seat angle 30° ± 0.25
Internal diameter 40.00 ± 0.10 mm
Thickness 8.00 ± 0.025 mm
Cylinder head recess:
depth 11.10 ± 0.10 mm
diameter 49.50 - 49.53 mm
Inlet valve
Valve head diameter 50.00 ± 0.10 mm
Valve head angle 29.5° ± 0.25°
Max. distance between valve head and
cylinder head surface on new valve and valve
seat (measurement A) +0.50 mm*
M2 01 013
* Here, -- is within the cylinder head and + is

outside the cylinder head.
 200847 63
TECHNICAL DATA
Overhaul data GS engine
M2 01 014
Max. rejection dimension (measurement B) --0.28 mm*

Valve stem diameter 9.935 - 9.953 mm
Exhaust valve
Valve head diameter 45.50 ± 0.10 mm
Valve head angle 29.5° ± 0.25°
Distance between valve head and cylinder
head surface with new valve and seat
4 (measurement A), maximum +0.35 mm*
M2 01 013
M2 01 014
Max. rejection dimension (measurement B) --0.43 mm*

Valve stem diameter 9.905 ± 9.923 mm
* Here, -- is within the cylinder head and + is

outside the cylinder head.
64  200847
TECHNICAL DATA
M2 00 012
Valve guides
Overall length 79.00 mm
Internal diameter 10.014 - 10.026 mm
Projection of valve guide above cylinder head
(dimension A) 24.00 ± 0.50 mm
Valve guide bore 16.00 ± 0.009 mm
Tappet bushes
Standard external diameter
Excess, external diameter
35.949 - 35.965 mm
36.455 - 36.439 mm
4
Rocker
Internal diameter of reamed bearing bush 22.213 - 22.234 mm
Oil hole in bearing bush 2.0 mm
Rocker shaft
Rocker shaft diameter 22.193 - 22.206 mm
 200847 65
TECHNICAL DATA
M200239
Cylinder block
Minimum measurement after overhaul 343.65 mm
(measurement A)
Roughness 0.4 - 1.6 mm
Depth of recess, cylinder liner collar:
up to engine no. R-11682 10.00 ± 0.02 mm
from engine no. R-11682 6.00 ± 0.02 mm
Bore for cylinder liner:
- standard 123.472 - 123.498 mm
- excess 123.722 - 123.748 mm
Bore, main bearing shells 92.050 - 92.075 mm
Bore, camshaft bearings 63.985 - 64.015 mm
Bore, standard tappets 36.000 - 36.025 mm
Bore, oversize tappets 36.506 - 36.531 mm
Test pressure 1.5 bar
Cylinder liners
External diameter, cylinder liners:
- standard 123.499 - 123.501 mm
- excess 123.749 - 123.751 mm
Inspection dimension, internal diameter of 117.982 - 118.058 mm
cylinder liner after fitting
Height of cylinder liner above cylinder block:
- up to engine no. R-11682 0.02 - 0.08 mm
- from engine no. R-11682 0.02 - 0.10 mm
66  200847
TECHNICAL DATA
Crankshaft
7
6
5
4
3
2
1 C
A M2 00 142
Maximum clock deflection between two

adjacent main bearing journals
0.08 mm 4
Maximum clock deflection of centre main 0.25 mm
bearing with front and rear main bearing
journals supported
Diameter, rear oil seal flange (C) 125.00 ± 0.02 mm
Axial play 0.05 - 0.35 mm
Thickness, axial thrust washers:

- standard 2.286 mm
- excess 2.413 mm
Main bearing journals, crankshaft (A)

Diameter, main bearing journals
Standard diameter 88.00 ± 0.02 mm
1st undersize 87.75 ± 0.02 mm
2nd undersize 87.50 ± 0.02 mm
3rd undersize 87.25 ± 0.02 mm
The crankshaft must be reٛ nitrided after it has
been ground to the 2nd undersize.
Fillet radius 4.50 - 5.00 mm
Width, 1st bearing journal 44.00 ± 0.04 mm
Width, 2nd, 3rd, 5th and 6th bearing journals 40.00 ± 0.10 mm
Width, 4th bearing journal:
- standard 58.00 ± 0.025 mm
- 1st oversize 58.254 ± 0.025 mm
- 2nd oversize 58.508 ± 0.025 mm
Width, 7th bearing journal 48.00 ± 0.10 mm
 200847 67
TECHNICAL DATA
7
6
5
4
3
2
1 C
A M2 00 142
4 Connecting rod bearing journals,

crankshaft (B)
Diameter, connecting rod bearing journals
Standard diameter 80.00 ± 0.02 mm
1st undersize 79.75 ± 0.02 mm
2nd undersize 79.50 ± 0.02 mm
3rd undersize 79.25 ± 0.02 mm
Width 48.00 ± 0.04 mm
Fillet radius 4.50 - 5.00 mm
Main bearing shells, crankshaft

Width, 1st and 7th main bearings 36.00 ± 0.20 mm
Width, 2nd, 3rd, 5th and 6th main bearings 28.50 ± 0.20 mm
Width, 4th main bearing 44.00 ± 0.20 mm
Internal diameter fitted 92.075 mm
Undersizes 3 x 0.25 mm
Connection rods
Diameter, small/head initial bore 48.003 - 48.009 mm
Diameter, big/head initial bore 83.564 - 83.576 mm
Distance centre-to-centre, 231.97 - 232.03 mm
big-head/small-head
Small-end bush, diameter to be reamed to 48.031 - 48.039 mm
Connecting rod bearing shells

Internal diameter fitted 80.084 - 80.120 mm
Bearing play 0.064 - 0.140 mm
Undersizes 3 x 0.25 mm
Pistons
Groove width:
- top spring 3.50 - 3.53 mm
- compression ring 3.04 - 3.06 mm
- oil scraper ring 4.03 - 4.05 mm
Bore for the gudgeon pin 48.003 - 48.009 mm
68  200847
TECHNICAL DATA
D 4
M200238
Piston ring thickness

Thickness of top ring:
dimension A 4.650 - 5.000 mm
dimension B 3.500 mm
Thickness of compression ring:
dimension C 4.650 - 5.000 mm
dimension D 2.975 - 2.990 mm
Thickness of oil scraper ring:
dimension E 3.250 - 3.600 mm
dimension F 3.978 - 3.990 mm
Gudgeon pin
Gudgeon pin diameter 47.994 - 48.000 mm
Play in small--end bush 0.045 mm (max.)
 200847 69
TECHNICAL DATA
M2 00 016
Camshaft
Diameter, journals 57.90 - 57.93 mm
Inspection measurement, cam height
(distance A):
Inlet 47.41 - 48.25 mm
Exhaust valve 47.52 - 48.36 mm
4 Camshaft axial play

Camshaft axial play (up to engine no. R-11682) 0.06 - 0.22 mm
Camshaft axial play (from engine no. R-11682) 0.10 - 0.55 mm
Backlash, timing gears

Idler and camshaft gear 0.02 - 0.22 mm
Idler and crankshaft gear 0.02 - 0.20 mm
Idler and fuel pump gear 0.02 - 0.22 mm
Steering and fuel pump gear 0.02 - 0.19 mm
Camshaft and compressor gear 0.02 - 0.22 mm
Crankshaft and oil pump idler gear 0.02 - 0.20 mm
Oil pump idler gear and oil pump gear 0.02 - 0.20 mm
Backlash, idler gear

Idler gear axial play 0.03 - 0.25 mm
Lubricating oil pump

Diameter, bearing bush to be reamed to 22F7
70  200847
TECHNICAL DATA
GS engine Overview, wear measurements
4.7 OVERVIEW, WEAR MEASUREMENTS
1 2 3 4 5 6
1 2 3 4 5 6
Ø A1
Ø A2 B
Ø A3
Ø A4 Ø A1 A
Ø A5
4
Ø A6 20 mm
1
Ø B1 2
Ø B2 3
Ø B3 4
Ø B4 5
Ø B5 6
30 mm
Ø B6
G
D
Z z
D
S1
S2 1
2
S3 3
4
S4
S
M2 00 017
 200847 71
TECHNICAL DATA
Overview, wear measurements GS engine
A
B
A
B
4
M2 00 018
72  200847
ENGINE ASSEMBLY
GS engine Removal and installation, engine
5. ENGINE ASSEMBLY
5.1 REMOVAL AND INSTALLATION, ENGINE
This paragraph gives a number of outlines for

the removal and installation of the engine.
Warnings
Use the proper tools when
removing and installing the engine
and do not overlook your personal
safety.
When removing fuel pipes, a

quantity of fuel will escape. Collect
this fuel, bearing in mind the risk of
fire.
Removal, entire engine

- Disconnect the battery leads from the
batteries.
- Drain the coolant and collect it in a clean
container. 5
If the coolant has not been polluted, it may
be re-used.
- Drain the engine oil. This may not be
re-used.
- Seal all pipe openings so that no dirt or
particulates can get into the pipes, engine,
radiator or other components.
- Mark the wiring, if there is a chance that the
wires could be connected incorrectly.
- Mark the pipes, if there is a chance that the
pipes could be connected incorrectly.
- Mark, if applicable, the setting of the throttle
control.
- If possible, remove the steering and
hydraulic pumps with the pipes still
connected so that these systems do not
need to be drained.
 200847 73
ENGINE ASSEMBLY
Removal and installation, engine GS engine
Note:
Remove the rev counter before fitting the
lifting eye at the timing gear end.
- Remove the engine safely from the vehicle.
Installation, engine assembly
- Replace all gaskets and sealing rings.
- Check and if in doubt replace the rubber
engine mountings.
- Safely replace the engine in the vehicle.
- Check and if in doubt replace the air and
coolant pipes.
- Clean the inside of the coolant pipes where
they seal with a pipe or flange. Also clean
the sealing surface of the pipe or flange.
- Check the pipe clamps and if in doubt
replace.
Sparingly grease the moving part of the
5 pipe clamp.
- Tighten all threaded connections to the
specified torques.
- Ensure that the engine earth cables make
good contact.
- Tighten the wiring in the same way as it
was before.
- Replace plastic pipes in their original
position, so that there is no chance of
chafing.
- Fill the cooling system with the specified
coolant. See “Draining and filling”.
- Fill the engine with the specified engine oil.
74  200847
ENGINE ASSEMBLY
GS engine Removal and installation, engine
- Bleed the fuel system.

- If applicable, fill the steering and hydraulic
systems with the specified oil.
- Connect the battery leads.
- Before starting the engine, operate the
engine stop, so that the engine cannot be
started. Using the starter motor, crank the
engine until the oil pressure warning lamp is
extinguished.
- Start the engine, set the interior heating to
maximum and let the engine run for a few
minutes. Check for leakage and abnormal
sounds.
- Check the coolant and engine oil levels.
- If applicable, bleed the steering and
hydraulic systems.
- Bring the engine to operating temperature
and check for leaks. 5
- Take a test drive. After the test drive, check
the coolant and engine oil levels again.
 200847 75
ENGINE ASSEMBLY
Removal and installation, engine GS engine
76  200847
STRUCTURAL PARTS
GS engine Removal and installation, glow plugs
6. STRUCTURAL PARTS
6.1 REMOVAL AND INSTALLATION, GLOW PLUGS
Note:
Depending on the type of engine, two or four
glow plugs may be fitted.
Removal, glow plugs C
1. Disconnect the earth terminal from the
batteries.
2. Mark the connection of the cable eye and
the position of the connection strips.
3. Remove the electrical wiring and the A B
connection strips.
4. Remove the glow plugs.
Inspection, glow plugs
Check the glow plugs for the following
points:
- windings that have worn thin due to
abrasion (A);
- filament end broken or worn thin due to
continuous knocking of a loose insulator
-
(see B);
broken plug windings (C).
6
Replace all glow plugs if one or more of the
above-mentioned situations occurs.
M200818
 200847 77
STRUCTURAL PARTS
Removal and installation, glow plugs GS engine
Installation, glow plugs

1. Fit a new sealing ring to the glow plugs and +
install them.
2. Check that the wire eyes for the wiring are
not bent and/or that the insulation is not
damaged. This could lead to short circuits.
3. Connect the wire eye and the attachment
strips according to the respective diagram.
4. Check that no other parts can touch the live M2 00 154
parts of the glow plugs. This could lead to

short circuits.
5. Reconnect the earth cable to the batteries.
6 M2 00 255
78  200847
STRUCTURAL PARTS
GS engine Removal and installation, V-belts
6.2 REMOVAL AND INSTALLATION, INLET MANIFOLD
9
3 10
4
2
8
7
5
7
6
8
7
7 M200277
Note:
The air pipe connection can be either on the
Legend
1. Inlet manifold
6
front or the rear of the manifold depending 2. Flange bolt
on the version. 3. Bolt
4. Ring
Removal, inlet manifold 5. Sealing ring
1. Disconnect the earth terminal from the 6. Plug
batteries. 7. Gasket
8. Gasket
2. Remove the air duct from the inlet manifold. 9. Sealing ring
Plug the openings. 10. Glow plug
3. Disconnect the exhaust control unit pipe to
the inlet manifold.
4. Mark the connection of the wire eye on the
glow plug and remove the wire eye.
5. Remove the attachment bolts and detach
the inlet manifold.
6. Remove any gasket remains.
 200847 79
STRUCTURAL PARTS
Removal and installation, V-belts GS engine
Installation, inlet manifold

1. Fit new gaskets to the inlet manifold and fit
the manifold.
Tighten the attachment bolts evenly to the
specified torque.
2. Connect the cable eye of the glow plugs
correctly. See the connection diagram
under “Removal and installation, glow
plugs”.
3. Fit the air duct and pipe of the exhaust
control unit.
5. Check the connections of the inlet manifold
for leaks.
80  200847
STRUCTURAL PARTS
GS engine Removal and installation, turbocharger
6.3 REMOVAL AND INSTALLATION, TURBOCHARGER
Removal, turbocharger
1. Remove the heat shields.
2. Remove the air pipes and the elbow. Plug
all openings.
2 5 6
3. Remove the exhaust pipe from the exhaust
elbow. 7 A
1 13
4. Remove the bracket assembly attached to
the exhaust elbow.
5. Mark the position of the brackets for the 3 B
heat shields. 4
6. Remove the oil supply and discharge pipes
from the turbocharger.
8
7. Remove the attachment nuts with which the
turbocharger is attached to the exhaust
manifold. Use a bent ring spanner for this. 11
10 9
Note: 12
If not all attachment nuts are to be 14
removed, the compressor housing must be M2 00 264
removed from the bearing housing in order
to make the nuts more accessible. Legend
6
8. Remove the turbocharger from the exhaust 1. Exhaust elbow
manifold. Be aware that oil may flow out of 2. Bracket, exhaust elbow
the oil pipe connections. 3. Nut
4. Spacer sleeve
9. Plug the pipe openings of the oil pipes. 5. Bracket, heat shield
6. Bracket, heat shield
10. If necessary, remove the exhaust elbow 7. Turbine housing
from the turbine housing. 8. Bearing housing
9. Compressor housing
11. If necessary, remove the spacer block that 10. Bracket, heat shield
is fitted between the exhaust manifold and 11. Bracket, heat shield
the turbocharger in some engines. 12. Bracket, heat shield
13. Bolt, lubricating oil supply pipe
12. Remove the gaskets.
14. Lubricating oil discharge pipe
 200847 81
STRUCTURAL PARTS
Removal and installation, turbocharger GS engine
Installation, turbocharger
1. Before fitting the turbocharger, check that
the turbocharger:
- runs smoothly
- does not catch
- has a little radial play.
2. Clean and check all sealing faces.
3. Replace all gaskets.
2
4. Apply heat resistant grease to the studs. 5 6
5. Fit a new gasket to the spacer block if 7 A

fitted, and install it. 1 13
6. Fit a new gasket to the turbocharger and fit 3 B

4
it to the exhaust manifold or spacer block.
Tighten the attachment nuts crosswise.
8
7. Fit the oil discharge pipe. If necessary,
rotate the bearing housing with the 11
compressor housing to the correct position. 10 9
12
Tighten the clamping-bracket nut (A) to the
14
specified torque. M2 00 264
8. Spray clean engine oil into the oil supply

opening of the turbocharger, fit the two
6 upper heat shield brackets to the oil supply
pipe and fit it.
9. Apply a film of Copaslip to the turbine
housing studs, and fit the exhaust elbow
with the two heat shield brackets. Always
use the original nuts and spacer sleeves.
Tighten the nuts crosswise.
82  200847
STRUCTURAL PARTS
GS engine Removal and installation, turbocharger
10. Fit the exhaust elbow bracket. Apply heat

resistant grease to the screw thread and
always use original nuts and spacer
sleeves.
11. Fit a new O-ring to the elbow and fit it to the
compressor housing.
12. Check the pipe clamps and replace if in
doubt. Sparingly grease the moving section
of the pipe clamp.
Fit the air pipes. If necessary, the
compressor housing can be turned away
from the turbocharger. First loosen the
attachment bolts (B in the drawing) on the
side of the compressor housing, and rotate
the housing to the correct position. Tighten
the bolts to the specified torque.
13. Before starting the engine, operate the
engine stop or apply the exhaust brake, so
that the engine cannot drag. Crank the
engine using the starter motor until the
pressure warning lamp is extinguished. The
engine can now be started.
14. Check all the connections for leaks.
15. Stop the engine and fit the heat shields. 6
 200847 83
STRUCTURAL PARTS
Removal and installation, exhaust manifold GS engine
6.4 REMOVAL AND INSTALLATION, EXHAUST MANIFOLD
5
2
2
7
8 6
3
9
4
21
22
20
10
11
12 15
14
13
14
17
16
6
19
18 M200278
Removal, exhaust manifold Legend

1. Remove the heat shields and the heat 1. Manifold section
cover. 2. Sealing spring
3. Spacer sleeve
2. Before removing the exhaust manifold, 4. Nut
check whether there has been any leakage 5. Gasket
between the connecting flanges. A leak is 6. Manifold section
visible due to “traces of soot” on the 7. Gasket
relevant flange. In the case of a leak, both 8. Plug
the abutting surface of the cylinder head 9. Sealing ring
and that of the manifold must be carefully 10. Stud
checked for damage. 11. Gasket
12. Nut
3. Depending on the reason why the exhaust 13. Ring
manifold is being removed, the 14. Nut
turbocharger can remain attached to it or 15. Spacer sleeve
must first be removed. To remove the 16. Heat shield
turbocharger, see “Removal and 17. Heat shield
installation, turbocharger”. 18. Flange bolt
4. Remove the bracket linking the exhaust 19 Flange bolt
manifold with the cylinder head. 20. Heat cover
21. Bolt
22. Ring
84  200847
STRUCTURAL PARTS
GS engine Removal and installation, exhaust manifold
5. Mark the place of the various spacer

sleeves between the attachment nuts and
the manifold. These must be re-fitted in the
same place.
6. Remove the attachment nuts from the
manifold and remove the exhaust manifold
assembly.
7. Remove the two manifold sections from
each other with a pulling and turning
movement.
8. Remove the sealing rings and clean the
grooves.
9. Remove the used gaskets and clean all
sealing faces.
Installation, exhaust manifold
1. Fit new sealing rings with the slots opposite
one another.
2. Apply heat-resistant grease to the manifold
sections and slide the two manifold sections
together.
3. Fit new gaskets to the exhaust manifold
assembly. Apply a little grease to the
gaskets so that they remain in their position
6
when installed.
4. Apply heat-resistant grease to the studs
and fit the various spacer sleeves with the
attachment nuts in their original positions.
5. Tighten the attachment nuts evenly.
6. Fit the turbocharger to the exhaust
manifold. See “Removal and installation,
turbocharger”.
7. Start the engine and check all connections
for leaks.
8. Fit the heat shields and the heat cover.
 200847 85
STRUCTURAL PARTS
Removal and installation, air compressor GS engine
6.5 REMOVAL AND INSTALLATION, AIR COMPRESSOR
6
1 2 4 5
7
14 8 9
15
10
6 16
12 17
13 18
12
11 M200279
Removal, air compressor Legend

1. Check that the cooling system is 1. Air compressor
pressureless and partially drain the coolant. 2. Attachment bolt
3. O-ring
2. Disconnect the coolant, air bleed-off, air 4. Gear wheel
supply and compressed air pipes from the 5. Ring
air compressor, and collect any escaping 6. Flange bolt
coolant. 7. Lubricating oil supply pipe
8. Coupling
3. Plug the openings. Remove the lubricating 9. Sealing ring
oil, supply and return pipe assembly. Plug 10. Lubricating oil discharge pipe
the openings. 11. Banjo bolt
Before removing the lubricating oil return 12. Sealing ring
pipe, remove the connector for the 13. Banjo
electromagnetic fuel valve. 14. Flange bolt
4. Remove the bracket between the air 15. Ring
compressor and the cylinder block. 16. Bracket
17. Ring
18. Nut
86  200847
STRUCTURAL PARTS
GS engine Removal and installation, air compressor
5. Remove the attachment bolts from the air

compressor at the front of the timing case.
6. Remove the air compressor from the timing
gear.
Note:
When removing the compressor from the
timing gear, an amount of lubricating oil
may escape from the air compressor. Take
steps to collect the oil.
Installation, air compressor
1. Transfer the drive sprocket to the
compressor to be fitted, if applicable.
In the case of a new sprocket, remove any
preserving grease carefully, particularly on
the tapered section.
Tighten the attachment nut of the gear
wheel (3) to the specified tightening torque.
2. Replace the O-ring and the other sealing
rings.
3. Check the delivery pipe for deposits of
carbon before fitting the compressor.
Replace if necessary.
4. Grease the new O-ring, place the air
compressor on the timing case and tighten
6
the attachment bolts in a cross-wise
sequence, until the compressor is in full
contact with the timing case. Then tighten
the attachment bolts to the specified
tightening torque.
5. Fit the bracket that has been removed.
6. Connect the pipes that have been removed.
7. Fit the electromagnetic fuel valve
connector.
8. Fill and bleed the cooling system. See
“Draining and filling the cooling system”.
for leaks.
 200847 87
STRUCTURAL PARTS
Removal and installation of the steering pump GS engine
6.6 REMOVAL AND INSTALLATION OF THE STEERING PUMP
Removal, steering pump 3

Note: 6
Depending on the reason why the steering 2 5
pump must be replaced, the steering pump
pipes must be removed or can remain 4
connected. In the latter case, the pump can
be put to one side with the pipes. 1
1. Clean the steering pump and the
surrounding area.
2. If the steering pump pipes must be
disconnected, collect any steering oil
emitted.
3. Plug the pump opening and the pipes
immediately. Avoid dirt getting into the
steering gear. The steering oil filter is fitted M200295
in the return pipe, which means that should

any dirt enter, it will immediately also enter Legend
the steering gear. 1. Steering pump
2. O-ring
4. Remove the upper attachment bolt and 3. Flange bolt
unscrew the lower attachment bolt. Remove 4. Key
6 the pump from the timing gear. 5. Gear wheel
6. Flange nut
Installation, steering pump
1. Transfer the drive sprocket to the steering
pump to be fitted, if applicable.
In the case of a new sprocket, remove any
preserving grease carefully, particularly on
Apply locking compound to the wire and
tighten the attachment nut to the specified
torque. See “Technical data”.
2. Transfer the pipe couplings to the pump to
be fitted, if necessary. Tighten all couplings
to the specified tightening torques.
3. Fit a new O-ring to the pump and grease it
lightly.
88  200847
STRUCTURAL PARTS
GS engine Removal and installation of the steering pump
4. Fit the pump. Tighten the attachment bolts

evenly to the specified tightening torque.
See “Technical data”.
5. If removed, re-fit the pipes.
6. Fill and bleed the hydraulic system of the
steering gear and check the connections for
leaks.
 200847 89
STRUCTURAL PARTS
Removal and installation, hydraulic pump GS engine
6.7 REMOVAL AND INSTALLATION, HYDRAULIC PUMP
For the purpose of driving a hydraulic fan, a

hydraulic pump can be mounted. 4 5
2 10
Removal, hydraulic pump
1. Depending on the reason for which the 1
hydraulic pump must be removed, the pipes
must either be removed from the hydraulic
pump, or may remain attached. In the latter 10
case, the pump with pipes should be hung
to one side.
13
2. If the hydraulic pump pipes must be 11
9 3
disconnected, collect any steering oil 12
emitted. 7 8
6 13
14 15
3. Plug the pump and the pipes immediately.
Avoid dirt getting into the system. M200296
4. Remove the attachment nuts and remove

the pump from the timing gear. Legend
1. Connecting piece
Installation, steering pump 2. O-ring
1. Transfer the sprocket to the hydraulic pump 3. Hydraulic pump
to be fitted, if applicable. 4. Ring
In the case of a new sprocket, remove any 5. Nut
6 preserving grease carefully, particularly on
6. Nut
7. Spring washer
Tighten the attachment nut to the specified 8. Gear wheel
torque. 9. O-ring
10. Key
2. If necessary, fit new O-rings to the 11. O-ring
connecting pieces and transfer them to the 12. Connecting piece
pump to be fitted. 13. Spring washer
14. Bolt
3. Fit a new O-ring to the pump and grease it 15. Bolt
lightly.
4. Apply locking compound to the studs. See
“Technical data”.
5. Insert the pump from the timing gear. Fit the
attachment nuts and tighten them evenly to
the specified torque.
6. If removed, re-fit the pipes.
7. Top up the hydraulic system.
8. Start the engine and check the connections
for leaks.
90  200847
STRUCTURAL PARTS
GS engine Removal and installation, starter motor
6.8 REMOVAL AND INSTALLATION, STARTER MOTOR
Removal, starter motor

batteries.
2. Mark the wiring connections on the starter
motor and remove the wiring.
3. Remove the three attachment nuts and take
the starter motor out of the flywheel 1
housing.
4. Check the pinion of the starter motor and
the starter ring gear for damage.
3
Installation, starter motor
1. Clean the abutting surfaces of the starter
motor and the flywheel housing. 2 M200280
2. Clean the thread and apply locking

compound. See “Technical data”. Legend
1. Starter motor
3. Fit the starter motor with the intermediate 2. Intermediate ring
plate in such a way that the electrical 3. Nut
connections are on top of the starter motor.
4. Tighten the attachment nuts evenly. See
“Technical data”. 6
5. Connect the wiring.
 200847 91
STRUCTURAL PARTS
Removal and installation, alternator GS engine
6.9 REMOVAL AND INSTALLATION, ALTERNATOR
2 1 17
4 18
8 6
3 6
9
7
10 14
11 13
6
16 12
15
M200281
Removal, alternator Legend

1. Disconnect the earth terminal from the 1. Alternator
batteries. 2. Flange bolt
3. Cap
2. Remove the pipe and the cap on the rear 4. Flange bolt
of the alternator. 5. Spacer sleeve
6. Flange nut
3. Mark the electric wiring and disconnect it. 7. Bracket
4. Loosen the attachment bolts and adjust the 8. Flange bolt
tensioning gear of the V-belts. Remove the 9. Nut
V-belts from the pulley. 10. Attachment block
11. Threaded insert
5. Remove the attachment bolts and take off 12. Nut
the alternator. 13. Threaded spindle
14. Bolt
6. Transfer the pulley to the alternator to be 15. Nut
fitted, if applicable. Tighten the pulley 16. Ring
attachment nut to the specified torque. 17. Pulley
18. Nut
92  200847
STRUCTURAL PARTS
GS engine Removal and installation, alternator
7. Check the Silentblocs that are fitted in the

spacer sleeves and replace if necessary.
8. Installation is the reverse of the removal
procedure.
9. Adjust the V-belt tension. See “Inspection
and setting, V-belt tension”.
 200847 93
STRUCTURAL PARTS
Removal and installation, V-belts GS engine
6.10 REMOVAL AND INSTALLATION, V-BELTS
Note:
Always replace a V-belt with a V-belt of the
same version. Always replace both belts at
the same time.
Removal, V-belt(s), outer alternator
1. Slacken the threaded spindle bolt (2).
1 2 3 4 5 6 7
2. Unscrew bolt (7) of the clamping block.

3. Unscrew bolt (5) of the clamping block.
4. Unscrew the attachment bolts (9) at the
front and rear of the alternator (8).
5. Unscrew the locknut (4) of the threaded
bush (6) and turn the threaded bush (6) in
such a way that the alternator (8) is tilted
towards the cylinder block.
6. Remove the V-belt(s).
7. Inspect the pulleys for damage, rust and 14 13 12 11 10 9 8
grease deposits. M2 00 695
6 Installation, V-belt(s), outer alternator

1. Fit the new V-belt(s).
3. Tighten the clamping bolt (5).
4. Tighten the locknut (4).
5. Tighten both bolts (9).
6. Tighten bolts (2 and 7).
Removal, V-belt(s), inner alternator
1. Remove the V-belt(s) of the inner
alternator (8).
2. Unscrew the bolt (14) from the threaded
spindle.
3. Unscrew the bolt (12) from the coupling.
5. Unscrew the locknuts (11 and 13) from the
threaded bush (10) and turn the threaded
bush in such a way that the alternator (3) is
tilted towards the cylinder block.
6. Remove the V-belt(s).
7. Inspect the pulleys for damage, rust and
grease deposits.
94  200847
STRUCTURAL PARTS
GS engine Removal and installation, V-belts
Installation, V-belt(s), inner alternator

1. Fit the new V-belt(s).
3. Tighten the locknuts (10 and 13).
5. Tighten the bolts (12 and 14).
6. Fit the V-belt(s) of the outer alternator (8).
 200847 95
STRUCTURAL PARTS
Inspection and setting, V-belt tension GS engine
6.11 INSPECTION AND SETTING, V-BELT TENSION
Inspection, V-belt tension O

APBTLIB
EEUL
TI
1. Check the V-belt tension with special tool

N.2
00
(DAF no. 1240442) for the single V-belt LBS

.50
600
model and with special tool 100
(DAF no. 1240443) for the multiple V-belt

150
version or poly-V-belt version.

OPBT
A
LIBEE
U
LTII
N.5
00
LBS
.100 150
0
200
300
M2079
2. Set the gauge to zero by depressing the

measuring arm (1). 1
6
M2061
3. Place the belt-tension gauge on the V-belt,

halfway between the two pulleys.
4. Slowly depress the V-belt by means of the
belt-tension gauge until a click is heard.
Then remove the belt-tension gauge
carefully. Make sure that the measuring arm
is not moved.
M2182
5. Take the reading as indicated by the

position of the measuring arm in relation to
the scale. Compare this pressure reading
with the recommended pre-tension. See
M2062
96  200847
STRUCTURAL PARTS
GS engine Inspection and setting, V-belt tension
V-BELT TENSION
Belt tension, “AVX” raw edge1 V-belts in newtons (N)
Multiple belt Single belt
New V-belt2
Setting tension 1200 600
Test tension ≥800 ≥400
Run-in V-belt3
Minimum tension 500 250
Adjusting tension 700 350
1. Raw-edge belts can be recognised by the

absence of textile fabric on the inside and
on the lower parts of the sides (polished
sides), with the exception of the top of the
belt edge. Version: either a toothed or a
non-toothed belt.
2. After fitting the new V-belt, adjust the
pre-tension to the “setting tension” and after
a trial run check whether the pre-tension
complies with the “test tension”. If the
tension reading is lower than the “test
tension” specified in the table, set the V-belt M2121
6
to the minimum “test tension”.
3. If the V-belt tension is at the “minimum
tension”, set the belt to the “adjusting
tension”.
 200847 97
STRUCTURAL PARTS
Inspection and setting, V-belt tension GS engine
Setting the V-belt tension, outer alternator 1 2 3 4 5 6 7

1. Slacken the threaded spindle bolt (2).
2. Unscrew the bolt (7) from the clamping
block.
3. Unscrew the bolt (5) from the clamping
block.
5. Unscrew the locknut (4) from the threaded
bush (6) and turn the threaded bush (6) in
such a way that the correct V-belt tension is
achieved.
6. Tighten the clamping bolt (5). 14 13 12 11 10 9 8
M2 00 695
7. Tighten the locknut (4).

10. Check the V-belt tension again.
Setting the V-belt tension, inner alternator
6 1. Slacken the threaded spindle bolt (14).

2. Unscrew the bolt (12) from the attachment
block.
4. Unscrew the locknuts (11 and 13) from the
threaded bush (10) and turn the threaded
bush in such a way that the correct V-belt
tension is achieved.
5. Tighten the locknuts (10 and 13).
8. Check the V-belt tension again.
98  200847
CYLINDER HEAD
GS engine Cylinder head
7. CYLINDER HEAD
7.1 DIAGRAM OF PARTS
 200847 99
CYLINDER HEAD
Cylinder head GS engine
Diagram of parts
3
4 8 9
2
1
11 10
25
24
21 23
6 22
13
20
5
12
7 19 26
14 29
15 27
16 28
17
7 30
18
38
31 36
34 37
35
33
32
41
42
39 43
44
40 M200282
100  200847
CYLINDER HEAD
GS engine Cylinder head
Legend
1. Valve seat
2. Valve seat
3. Pipe
4. Expansion plug
5. Cylinder head gasket
6. Expansion plug
7. Cylinder head
8. Expansion plug
9. Injector sleeve
10. Cylinder head bolt
11. Cylinder head bolt
12. Valve
13. Valve
14. Spring retainer
15. Valve spring
16. Valve spring
17. Valve disc
18. Valve key
19. Expansion plug
20. Valve guide
21. Rocker shaft seat
22. Ring
23. Spring
24. Ring
25. Circlip
26. Ring
27. Shoulder bolt
28. Plug
29. Rocker shaft
30. Tappet sleeve
31. Pushrod 7
32. Bearing bush
33. Rocker
34. Adjusting bolt
35. Locknut
36. Spring
37. Gasket
38. Valve cover
39. Ring
40. Bolt
41. Circlip
42. O-ring
43. Ring
44. Cap nut
 200847 101
CYLINDER HEAD
Removal and installation, cylinder heads GS engine
7.2 REMOVAL AND INSTALLATION, CYLINDER HEADS
When the engine or parts thereof

are opened, dirt may enter. This
may result in serious damage to the
engine. Therefore clean the engine
before opening it.
Removal, cylinder heads

1. Disconnect the boost pressure pipe
between the inlet manifold and fuel pump
from the inlet manifold (only when removing
the front cylinder head).
2. Disconnect the inlet and exhaust pipes of
the air compressor.
3. Remove the heat shield from the
turbocharger.
4. Remove the heat shield from the
turbocharger return pipe.
5. Remove the oil supply and return pipes of
the turbocharger.
6. Remove the injector pipes, but leave them
in pairs.
7. If present, remove the inlet manifold
transmission cooler.
7 8. Disconnect the transmission cooler coolant
pipe.
9. Remove the inlet manifold fuel filter
housing.
10. Remove the coolant pipe between the
thermostat housing and the radiator.
11. Loosen the upper pipe clamp from the
coolant pipe between the thermostat
housing and water pump.
12. Disconnect the ventilation pipe between the
valve covers (disconnect the banjo bolt on
one side).
13. Remove the valve covers.
14. Remove the leak-off pipes.
15. Remove the valve gear.
102  200847
CYLINDER HEAD
GS engine Removal and installation, cylinder heads
16. Remove the turbocharger.

17. Remove the inlet manifold.
18. Remove the exhaust manifold.
19. Remove the cylinder head bolts.
20. Fit an extra lifting eye.
21. Remove the cylinder head from the cylinder
block.
22. Remove the old head gasket.
23. Remove the guide pin.
24. Carefully clean the sealing surfaces of the
cylinder head and the cylinder block.
Inspection
1. Check the sealing plugs in the cylinder
head for leaks. If necessary, pressure test
the cylinder head.
2. Inspect the cylinder head for damage on
the sealing face and any cracks. If
necessary, have the cylinder head refaced.
3. Check the cylinder block sealing surfaces.
4. Check that the height which the cylinder
liner protrudes above the cylinder block is
within the tolerance limits. See “Technical
7
data”.
Note:
To prevent the inlet and exhaust manifolds
from being installed with tension they must
be installed before the cylinder head bolts
are tightened.
M2 00 100
 200847 103
CYLINDER HEAD
Removal and installation, cylinder heads GS engine
5. Fit the inlet and exhaust manifolds with new

gaskets and tighten the attachment bolts to
the specified torque. See “Technical data”.
Installation, cylinder heads
1. Check that the dowel is not damaged.
2. Place both guide pins (DAF no. 0694912) in
the threaded holes of the cylinder block.
3. Place the new head gasket(s) in such a
way that the letters DAF TOP are visible.
The cylinder head gaskets must not be
retightened.
4. Place the cylinder head(s) on the cylinder
block and hand-tighten a number of cylinder
head bolts.
Notes:
- The M16 and M12 cylinder head bolts NO RETORQUE TOP
may be used a maximum of three

times. After tightening the bolts, mark
the bolt heads with a centre punch, to
indicate how often they have been
used. NO RETORQUE TOP
- New bolts should not be marked on the W263001
first fitting.
- Bolts marked with 2 centre points must
not be reused and must be replaced by
new ones.
7 - The cylinder head centring locating

sleeve has been replaced by a
cylindrical pin.
5. When fitting used bolts, clean the thread
and inspect for damage. If in doubt, renew
them.
6. Apply a drop of oil on the abutting surface
of the M16 bolts. Apply locking compound
to the thread of the cylinder head bolts. See
7. Apply sealant to the screw thread of the
M12 bolts.
8. Remove the two guide pins and replace
them with the two remaining cylinder head
bolts.
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CYLINDER HEAD
GS engine Removal and installation, cylinder heads
9. Tighten the cylinder head bolts to the

specified torque and in the sequence
shown. See “Technical data”.
10. Fit the exhaust manifold.
11. Fit the inlet manifold.
12. Fit the turbocharger.
13. Fit the valve gear.
14. Fit the leak-off pipes.
15. Fit the valve covers.
16. Fit the ventilation pipe between the valve
covers.
17. Tighten the upper pipe clamp from the
coolant pipe between the thermostat
housing and water pump.
18. Fit the coolant pipe between the radiator
and the thermostat housing.
19. Fit the fuel filter housing.
20. If necessary, fit the transmission cooler and
the coolant pipe of the transmission cooler.
21. Fit the injector pipes.
22. Fit the compressor inlet and exhaust pipes.
7
23. Fit the oil supply and return pipes of the
turbocharger.
24. Fit the heat shield of the turbocharger
return pipe.
25. Fit the turbocharger heat shield.
26. Fit the boost pressure pipe between the
inlet manifold and fuel pump.
 200847 105
CYLINDER HEAD
Cylinder head pressure testing GS engine
7.3 CYLINDER HEAD PRESSURE TESTING
1. Remove the cylinder head. See “Removal

and installation, cylinder heads”.
2. Seal the coolant channels with sealing
plates fitted with gaskets.
The sealing plates should be manufactured
in-house.
One of the sealing plates must be equipped
with a coupling for an air hose.
3. Connect an air hose to the coupling of the
sealing plate.
4. Immerse the cylinder head in hot water and
admit air pressure of 1.5 bar. Leave the
cylinder head immersed in the container for
about half an hour.
106  200847
CYLINDER HEAD
GS engine Removal and installation, injector sleeve
7.4 REMOVAL AND INSTALLATION, INJECTOR SLEEVE
Removal, injector sleeves

1. Drain the coolant.
2. Remove the injector pipes. See “Removal
and installation, injector pipes”.
3. Remove the injector. See “Removal and
installation, injector”.
4. Tap the injector sleeve with M22 x 1.5
screw thread.
Plug the injector nozzle hole and apply
some grease to the thread to keep in as
many steel shavings as possible.
5. Screw the adapter (B) (DAF no. 1310425)
into the injector sleeve and fit the impact
puller (A) (DAF no. 0624928) to the
adapter. Using the impact puller, remove
the injector sleeve from the cylinder head.
6. Clean the sealing faces in the cylinder head
carefully. A
Notes: B
- Watch out for any metal shavings that
have blown away. M2 00 254
- Injector sleeves should always be

replaced.
- Fit injector sleeves without locking
compound or engine oil. 7
Installation, injector sleeves
1. Fit the injector sleeves dry.
2. Using the special tool (DAF no. 1329305),
tap or press the injector sleeve into the
cylinder head carefully.
The driving tool should abut the cylinder
head. The injector sleeve is then at the
correct depth in the cylinder head.
Note:
Injector sleeves should always be fitted with
the specified special tool. In this way, the
injector sleeve will be fitted to the correct
depth and damage to the injector sleeve will
be avoided.
 200847 107
CYLINDER HEAD
Removal and installation, injector sleeve GS engine
Note:
If the cylinder head has been removed from the
engine, check that it is free from leaks by
pressure-testing it. See “Pressure-testing the
cylinder head”.
3. Fit the injector. See “Removal and
installation, injector”.
4. Fit the injector pipes. See “Removal and
installation, injector pipes”.
5. Fill the cooling system. See “Draining and
filling the cooling system”.
6. Check the seals for leaks.
108  200847
CYLINDER HEAD
GS engine Removal and installation, valve operation
7.5 REMOVAL AND INSTALLATION, VALVE OPERATION
Removal, valve operation

1. Clean the valve cover and the surrounding
area.
2. Remove the valve cover.
3. Slacken the adjusting bolts of the rockers
as far as possible.
4. Remove the shoulder studs of the rocker
shaft seats and remove the rocker shaft.
5. Remove the rocker shaft circlip and remove
the rings, springs and rockers from the
rocker shafts.
6. Remove the push rods from the cylinder
block.
Be sure when taking out the push rods that
the tappet sleeves do not remain attached
to the push rods. This can be prevented by
moving the push rod back and forth during
removal.
7. Remove the covers at the bottom of the
cylinder head. To do this, first remove the
oil pipe running from the rear cover to the
sump.
Caution: when removing the oil pipe and
covers, a quantity of oil will escape.
7
8. Remove the tappet sleeves. Mark the
position of the tappet sleeve in the cylinder
block.
Inspection, valve operation
1. Check the contact face of the tappet sleeve
with cam for pitting and wear and check the
sides of the tappet sleeve for signs of
grating.
2. Check the push rods for pitting, dented
contact surfaces and straightness.
3. Check the rocker shaft for signs of grating
and inspect whether the oil channels are
open and whether the plugs in the ends of
the rocker shaft are not loose.
4. Check the bearing bushes and the rocker
head of the rocker shaft. The contact face
must not be pressed in.
 200847 109
CYLINDER HEAD
Removal and installation, valve operation GS engine
Installation, valve operation

1. Apply oil to the tappet sleeves and refit
them in their original position.
2. Check that the tappet sleeves move freely
and have no excessive play.
3. Fit new gaskets to the covers and fit the
covers.
4. Fit the oil pipe.
5. Check the engine oil level, and as
necessary top up.
6. Fit the push rods.
7. If necessary, press a new bearing bush into 2 mm A
the rocker. Make sure that when pressing in
the bearing bush, the new bearing bush
seam (A) does not align with the aperture
for the oil duct.
Bore the oil duct aperture in the new
bearing bush (see illustration).
Ream the bearing bush to the correct size.
M2 00 250
110  200847
CYLINDER HEAD
GS engine Removal and installation, valve operation
1
2
3
4
5
6
5
4
7
4
5
6
5
4
7
4
5
6
5
4
3
2
1 M2 00 251
8. Fit the parts to the rocker shaft in the Legend

correct sequence (see illustration). Fit new 1. Circlip
circlips to the rocker shaft ends and apply 2. Ring
oil to the assembly. 3. Spring
4. Ring
5. Rocker
6. Rocker shaft seat 7
7. Spring
 200847 111
CYLINDER HEAD
Removal and installation, valve operation GS engine
9. Turn the rocker shaft so that the notches of 1

the shaft are on the side of the shoulder 2
studs on the rocker seats.
Check that the oil bores of the rocker shaft
match the oil bores of the rocker shaft seats 3 4
and rockers in this position.
10. Fit the rocker shaft with the shoulder studs 5
on the cylinder head. Tighten the shoulder
studs to the specified torque.
Note:
Make sure that the adjusting bolts of the
valve rockers are not screwed in too far.
This can prevent the valve from opening too
far, which would cause the valve to touch
the rocker shaft during tightening.
M2 00 613
11. Set the valve clearance. See “Inspection
and setting, valve clearance”.
Legend
12. Fit a new gasket to the valve covers and fit 1. Shoulder stud
the valve covers. 2. Ring
Tighten the valve cover cap nuts to the 3. Rocker shaft
specified torque. See “Technical data”. 4. Rocker shaft seat
5. Cylinder head
112  200847
CYLINDER HEAD
GS engine Removal and installation, valves
7.6 REMOVAL AND INSTALLATION, VALVES
When removing and installing the

valve springs, compress them
responsibly, ensuring that they
cannot fly off. An inadvertently
released spring or valve collet can
cause serious injury.
Removal, valves
1. Remove the cylinder head.
2. Support the valve and compress the valve
spring safely as far together that the two
valve collets can be removed.
3. Release the valve spring and take the valve
spring retainer and valve spring from the
valve stem.
4. Remove the valve from the cylinder head.
Inspection, valves
1. Measure dimension B and check that the B
maximum value has not been exceeded.
2. Check the valve head thoroughly and check
the dimensions. If permitted by the
dimensions, the valves can be ground. See
7
3. Check the valve stem for straightness and M2 01 014
traces of grating.
4. Check the dimensions and height (A) of the
valve guides. See “Technical data”. A
If necessary, replace the valve guide.
5. Check the valve springs for fracture, wear
and spring force. See “Technical data”.
If necessary, replace the valve springs.
M2 00 012
6. Check the valve seat. See “Technical data”.
Replace if necessary.
 200847 113
CYLINDER HEAD
Removal and installation, valves GS engine
Installation, valves
1. When re-using, grind the valves on the
valve seats.
Note:
After grinding, clean the valves and the
cylinder heads thoroughly.
2. Oil the valve stem and place the valve in
the valve guide. Check for freedom of
movement.
3. Fit the lower valve spring retainer.
4. Fit the valve spring with the upper valve
spring retainer.
5. Support the valve and press the valve
spring safely as far together that the two
valve collets can be installed.
6. Release the valve spring carefully and
inspect whether valve collets have been
installed properly.
7. Fit the cylinder heads.
Note:
Check the valve clearance in the engine
after the test run at full load and adjust
as necessary.
114  200847
CYLINDER HEAD
GS engine Inspection and setting, valve clearance
7.7 INSPECTION AND SETTING, VALVE CLEARANCE
The inspection/correction of the

valve clearance may be carried out
either when the engine is cold or
warm.
Setting the valve clearance must be
performed when the engine is
stationary.
1. Clean the valve covers and the surrounding

area.
3. Check whether the fuel pump is in the “stop
position”. Lock the fuel pump in the “stop
position” if necessary.
4. Crank the crankshaft clockwise, as seen
from the timing gear end (this is the
engine’s normal direction of rotation), until 2
the valves of cylinder 6 are in overlap
position. The piston of cylinder 1 is now at
TDC (marked 0_ on flywheel) of the
compression stroke.
“Overlap” is the moment at which the inlet 1
valve starts opening and the exhaust valve M2 00 283
is completing the closing.
5. Inspect/correct the valve clearance of
cylinder 1. The correct valve clearance is
Legend
1. Locknut 7
adjusted by loosening the lock nut and 2. Adjusting bolt
turning the adjusting screw in the correct
direction.
Note:
Do not set the valve clearance in excess of
the specified value.
6. After adjusting, tighten the locknut and
check the valve clearance once more.
 200847 115
CYLINDER HEAD
Inspection and setting, valve clearance GS engine
7. By cranking the camshaft always 1/3 stroke,

the valves can be adjusted according to the
injection sequence (1-5-3-6-2-4).
Cylinder with valves Adjust valves of

in overlap position cylinder
6 1
2 5
4 3
1 6
5 2
3 4
8. Clean the valve covers and the sealing

surfaces of the cylinder heads.
9. Fit a new gasket to the valve covers and fit
the valve covers.
10. Fit the attachment bolts. Tighten the valve
cover cap nuts to the specified torque.
116  200847
CYLINDER HEAD
GS engine Machining the cylinder head
7.8 MACHINING THE CYLINDER HEAD
Refacing the cylinder head

1. Machining the cylinder head, ensure that
the height (A) of the cylinder head does not
become less than the dimension specified.
A
M2 00 009
2. After the machined surface has been

cleaned, the distance between the valve
A
head (dimension A) and the cylinder head
surface should be checked and, if
necessary, corrected. This can be corrected
by machining the valve seat or the valve
seat recess.
Valve seats
- Both inlet and exhaust valves have M2 01 013
pressed-in valve seats. Inserts are available
for overhaul purposes.
Removal, valve seats
1. With a grinding stone, grind a groove into
the inside of the valve seat, behind which
an internal puller can be fitted.
2. With an internal puller, pull the valve seat
out of the cylinder head.
3. Clean the valve seat chamber. 7
Installation, valve seats
1. Apply a thin coat of oil to the outside of the
new valve seat, and force the new valve
seat into the cylinder head recess.
2. Inspect the dimensions.
3. Also replace the valve with each new seat.
 200847 117
CYLINDER HEAD
Machining the cylinder head GS engine
Removal, valve guides

1. Remove the valve guide from the cylinder
head.
Installation, valve guides
1. Apply a thin coat of oil to the new valve
guide.
2. Press the valve guide into the cylinder head
in such a way, that the side with the
greatest bevelling is at the top of the
cylinder head (the abutting surface of the
valve springs).
3. Measure whether the height (A), above the
contact face is within the tolerance limits. A
Removal, expansion plug
1. Tap carefully on the edge of the expansion
plug, causing the plug to tilt. Make sure that
no damage occurs. M2 00 012
2. Remove the expansion plug with a pair of

pliers.
Installation, expansion plug
1. Apply Loctite 270 to the new expansion
plug and tap it with a suitable driving tool
into the cylinder head. See “Technical data”.
2. Leave the Loctite to harden for 1 hour.
7 3. If necessary, pressure test the cylinder
head.
118  200847
FLYWHEEL AND FLYWHEEL HOUSING
GS engine Diagram of parts
8. FLYWHEEL AND FLYWHEEL HOUSING

 200847 119
Diagram of parts GS engine
2
1
6
5
4
15
14 8 10
13 9
16
12
8 11
15
18
16
17
11
M2 00 269
120  200847
Legend
1. Bolt
2. Ring
3. Self-locking bolt
4. Oil seal
5. Spacer ring
6. Dowel
7. Flywheel housing
8. Threaded insert
9. Adjusting plate
10. Bolt
11. Bolt
12. Plate
13. Flexible plates
14. Flywheel (flexible plate version)
15. Starter ring gear
16. Dowel
17. Pilot bearing
18. Flywheel (coupling plate version)
 200847 121
Removal and installation, flywheel GS engine
8.2 REMOVAL AND INSTALLATION, FLYWHEEL
Removal, flywheel
1. With an automatic gearbox, remove the
gearbox from the flexible plates.
With a manual gearbox, remove the
gearbox from the clutch release assembly
and coupling plate.
2. Remove the attachment bolts from the
flywheel/the flexible plates.
3. Clamp the crankshaft flywheel by tightening
the two jack screws (M10) at the same
time.
4. Clean the crankshaft flange, the dowels and
the attachment bolts.
Inspection, flywheel condition
1. Check the abutting surface of the clutch
plate for cracks.
2. If the flywheel shows marks on the abutting
surface with the clutch plate, the flywheel 5 mm
may be ground down, on condition that the
cracks are not within 5 mm of the inner rim.
A maximum of 2 mm may be ground down.
Inspection, flywheel play 2 mm
1. Clean the flywheel.
2. Place a metal strip on the edge of the
flywheel housing to fit a dial gauge. 5 mm
8 3. Place the dial gauge on the metal strip.
M2 00 033
122  200847
GS engine Removal and installation, flywheel
4. Place the dial gauge of the stylus at the

specified distance. See “Technical data”.
5. Set the dial gauge to “0”.
6. Place the fuel pump in the stop position and
lock it in this position.
7. Crank the engine through 360° and
measure the maximum dial gauge reading.
Compare this reading with the technical
data. See “Technical data”.
Installation, flywheel
1. Degrease the flywheel-to-flexible plate or
flywheel-to-coupling plate contact area. M200230
2. With an automatic gearbox, fit the flywheel

with the flexible plates and the attachment
plate.
3. Apply locking compound to the attachment
bolts and tighten them cross-wise to the
specified torque. See “Technical data”.
4. Check the axial play of the flywheel. See
“Inspecting the flywheel for play”.
5. Fit the gearbox.
 200847 123
Removal and installation, starter ring gear GS engine
8.3 REMOVAL AND INSTALLATION, STARTER RING GEAR
Removal, starter ring gear

1. Remove the flywheel.
2. Remove the starter ring gear by tapping it
carefully from the flywheel. If this is not
possible cut it between two teeth, using a
sharp chisel.
Installation, starter ring gear
1. Clean the flywheel and the starter ring gear.
Ensure that the contact areas are
de-greased.
2. Heat the new starter ring gear evenly in an
oven at approx. 230°C. Check the
temperature with thermal pins.
3. Fit the starter ring gear onto the flywheel so
that the bevelled sides of the teeth point
towards the starter motor. The DAF part
number, stamped on the side of the starter
ring, must face the clutch release assembly.
Ensure good all round contact between
starter ring gear and flywheel.
4. Fit the flywheel.
M2 00 035
124  200847
GS engine Removal and installation, flywheel housing
8.4 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING
Removal, flywheel housing

batteries.
2. Remove the flywheel. See “Removal and
installation, flywheel”.
bracket connecting the exhaust elbow to
the flywheel housing.
4. Remove the starter motor. See “Removal
and installation, starter motor”.
5. Disconnect the earth cables from the
flywheel housing.
6. Disconnect the connecting strip from the
wiring on the flywheel housing.
7. Remove the lubricating oil sump. See
“Removal and installation, lubricating oil
sump”.
8. Support the cylinder block in a suitable way,
as close as possible to the flywheel
housing.
9. Remove the engine brackets from the
flywheel housing.
10. Remove the flywheel housing from the
cylinder block.
11. Remove the oil seal from the flywheel
housing, by carefully tapping or forcing it
8
from the housing.
Installation, flywheel housing
1. Clean any gasket remnants from the
abutting surfaces. Clean any locking
compound from the attachment bolts.
2. Inspect the sealing faces for damage.
3. Inspect the flywheel housing for cracks.
 200847 125
Removal and installation, flywheel housing GS engine
4. If necessary, replace the starter motor

attachment bolts. One of the three bolts can
only be accessed once the flywheel has
been removed.
5. If necessary, fit new screw thread inserts
into the flywheel housing.
6. Apply a locking compound to the sealing
face of the cylinder block. See “Technical
data”. Apply the locking compound with a
roller across the entire sealing face.
7. Fit the flywheel housing.
8. Apply locking compound (Loctite 243) to the
attachment bolts and tighten them
crossways. Tighten the attachment bolts to
9. Fit the engine brackets and tighten the
attachment bolts to the specified torque.
10. Fit the oil seal. See “Removal and
installation, flywheel housing oil seal”.
11. Fit the flywheel. See “Removal and
12. Fit a new gasket to the lubricating oil sump
and fit the lubricating oil sump. See
sump”.
13. Fit the starter motor. See “Removal and
8 installation, starter motor”.
14. Fit the exhaust bend attachment bolts.
15. Clean the contact surface of the earth lead
and fit it.
16. Fit the connecting strip wiring.
126  200847
GS engine Removal and installation, flywheel housing seal
8.5 REMOVAL AND INSTALLATION, FLYWHEEL HOUSING SEAL
Note:
Each new oil seal is supplied with a plastic
mounting ring, which can only be used once.
Removal, flywheel housing seal
1. Remove the clutch release assembly and
the clutch plate.
2. Remove the flywheel.
3. Drill two small holes into the oil seal and
using special tools (DAF no. 0484899 and
DAF no. 0694928), unscrew the oil seal
from the flywheel housing.
Installation, flywheel housing seal
1. Thoroughly clean the seal recess and
inspect for damage. Even the most minute
damage can cause a leak.
2. Clean the crankshaft flange.
Note:
If a spacer ring has been placed in the seal
chamber, it must be re-fitted.
3. Fit the base plate (A) to the 1
crankshaft flange using special tool 2
(DAF no. 0695000).
4. Fit a new oil seal dry (the felt ring may not
be greased) over the plastic mounting ring
supplied (1).
5. Fit the supplied plastic mounting ring (1)
with the oil seal on the crankshaft flange. A 8
6. Place the thrust washer (B) over the spindle
and gradually tighten the nut (C) until the
resistance increases. B C
7. Disassemble the thrust washer (B) and M2 00 036
remove the plastic mounting ring (1).

8. Place the thrust washer (B) over the spindle
and gradually tighten the nut (C) until the oil
seal is properly positioned.
9. Remove the special tool.
10. Fit the clutch plate and the clutch release
assembly.
 200847 127
Removal and installation, flywheel housing seal GS engine
128  200847
TIMING GEAR
9. TIMING GEAR
 200847 129
TIMING GEAR
7
6
2
13
11 12
1
8
10
9
24
23
20 22
3
19
18
17
21
14
9 16
15
M200284
130  200847
TIMING GEAR
Legend
1. Key
2. Gasket
3. Key
4. Timing case
5. Crankshaft gear wheel
6. Ring
7. Bolt
8. Camshaft gear wheel
9. Hub
10. Bearing bush
11. Intermediate gear wheel
12. Thrush washer
13. Bolt
14. Gasket
15. Dowel
16. Dowel
17. Timing cover
18. Oil seal
19. Vibration damper
20. Pulley
21. Flange bolt
22. Thrust piece
23. Ring
24. Bolt
 200847 131
TIMING GEAR
Removal and installation, vibration damper/pulley GS engine
9.2 REMOVAL AND INSTALLATION, VIBRATION DAMPER/PULLEY
Removal, vibration damper/pulley

1. Remove the V-belts. See “Removal and
installation, V-belts”.
2. If fitted, remove the attachment bolts of the
pulley(s) and remove the pulley(s).
3. Remove the three bolts and remove the
thrust piece from the vibration damper.
M200228
4. Fit the special tool (A)

(DAF no. 1240448) onto the vibration
damper, using twelve M8 x 30 mm flange
bolts.
5. Tighten the twelve flange bolts one turn at a
time, in a cross-wise sequence, until the
vibration damper comes away from the A
crankshaft.
Note:
The internal parts of the vibration damper
have only minimal clearance. Rough
handling could cause a fault to arise in the
vibration damper.
Therefore avoid hitting the vibration damper M2 00 262
with a mallet. This could damage the
vibration damper.
Inspection, vibration damper/pulley
1. Check the vibration damper externally for
9 damage, check the oil seal running surface
for damage, and check the vibration
damper for leaks. If one of these has been
found, the vibration damper must be
replaced.
2. Check the crankshaft journal for damage.
132  200847
TIMING GEAR
GS engine Removal and installation, vibration damper/pulley
Installation, vibration damper/pulley

1. Clean the parts that have been removed,
the bolt screw thread and the crankshaft
journal.
Ensure that the tapered clamping faces of
both the vibration damper and the
crankshaft journal are perfectly clean and
free from grease.
2. Fit a new oil seal in the timing cover. See
“Removal and installation, timing cover oil
seal”.
3. Fit the vibration damper onto the crankshaft
journal.
4. Fit the three bolts to the thrust piece and fit
the thrust piece.
5. Tighten the three bolts in three stages to
the specified torques. See “Technical data”.
6. Check whether the contact surfaces of the
pulley and the vibration damper are clean.
bolts of the pulley, and fit the pulley. Tighten
the attachment bolts crosswise to the
8. Fit the V-belts and adjust the tension. See
“Setting the V-belt tension”.
 200847 133
TIMING GEAR
Removal and installation, timing cover seal GS engine
9.3 REMOVAL AND INSTALLATION, TIMING COVER SEAL
Removal, timing cover without bearing race

1. Remove the vibration damper.
2. Remove the oil seal by drilling two holes
in the oil seal using special tool
(DAF no. 0484899 and DAF no. 0694928).
A
B
m200830
Without bearing race With bearing race
Removal, timing cover seal with bearing

race
1. Remove the seal (A) using special tool
(DAF no. 1329458) from the timing cover.
2. Check the bearing race (B) for wear. If
9
necessary, replace.
M200971
134  200847
TIMING GEAR
GS engine Removal and installation, timing cover seal
Installation, timing gear cover seal

Note:
If the timing case is fitted with an old type of
seal (version without bearing race on the
vibration damper), the seal must be
replaced with a new type of seal with
bearing race on the vibration damper.
1. Clean and inspect the oil seal recess in the
timing gear cover. Even minimal damage
can lead to a leak.
2. Pull the oil seal into the bearing cover using
the special tool (DAF no. 1329446).
3. Slide the seal dry onto the stamp (A) in
A
such a way that its open side faces the
timing cover when it is being fitted. Avoid B
getting grease on the felt ring. C
4. Slide the drift (A) over the crankshaft until
the seal abuts the timing cover chamber.
5. Fit the vibration damper (B) thrust piece
with the attachment bolts (C) on the drift.
By tightening the bolts evenly with the drift
(A), press the seal into the timing cover
chamber.
6. Remove the special tool.
M2 00 299
7. Fit the bearing race to the vibration damper.
8. Fit the vibration damper.
9. Bring the engine to operating temperature
and check for leaks.
 200847 135
TIMING GEAR
Removal and installation, timing cover GS engine
9.4 REMOVAL AND INSTALLATION, TIMING COVER
Removal, timing gear cover

1. Remove the plug on the bottom of the
timing cover and drain the oil from the
timing case.
2. Remove the vibration damper (and the
pulley). See “Removal and installation,
vibration damper/pulley”.
3. Remove the hydraulic pump (if fitted) and
remove the assembly with the pipes from
the timing. See “Removal and installation,
hydraulic pump”.
4. Remove the coolant pump. See “Removal
and installation, coolant pump”.
5. Remove the attachment bolts from the air
compressor.
6. Support the cylinder block suitably as close
as possible to the timing case.
7. Remove the front engine bracket from the
timing case.
8. Remove the steering pump attachment
bolts.
9. Remove the other attachment bolts and
nuts and remove the timing cover. Mark the
position of the various attachment bolts.
Installation, timing cover
1. Remove the gasket remnants and check
the sealing faces.
2. Fit a new oil seal in the timing cover. See
9 “Removal and installation, timing cover oil
seal”.
3. Fit a new gasket to the timing cover and fit
the timing cover. Make sure that the dowels
fit properly in the locating holes of the
cover.
4. Fit the attachment bolts and nuts in the
correct positions. Notice the difference in
length of the bolts.
136  200847
TIMING GEAR
GS engine Removal and installation, timing cover
5. Tighten the attachment bolts and nuts

cross-wise to the specified torque.
6. Fit the steering pump prior to the engine
bracket.
Installation of the other components is the
reverse of the removal procedure. Replace
the O-rings and gaskets. Fit the removed
components in the way described. See the
respective sections.
7. Tighten all connections to the specified
torques.
8. Check the engine oil level, and as
necessary top up with the specified engine
oil.
 200847 137
TIMING GEAR
Removal, installation and setting the timing GS engine
9.5 REMOVAL, INSTALLATION AND SETTING THE TIMING
Removal, timing gear, general

1. Remove the fan.
2. Remove the V-belt.
3. Remove the vibration damper/pulley.
4. Remove the timing cover.
5. Remove the valve cover.
6. Crank the engine to TDC, with
no. 6 cylinder overlapping.
Note:
It is possible that the marks of the
intermediate gear wheel (A) are not exactly
opposite those of the camshaft gear wheel
(B) and crankshaft gear wheel (C). M2 00 144
B A
9 C
W264001
138  200847
TIMING GEAR
GS engine Removal, installation and setting the timing
Removal, timing gear wheels

Removal, camshaft gear wheel
1. Block the crankshaft and remove the
camshaft gear wheel attachment bolt.
Note:
It is not permitted to pull off the camshaft
gear wheel with two bolts.
2. Remove the blocking from the crankshaft.
Remove the camshaft gear wheel using a
puller.
Removal, intermediate gear wheel
1. Remove the attachment bolt of the
intermediate gear wheel with the thrust
washer.
Note:
When the crankshaft or the camshaft of an
engine without intermediate gear wheel is
rotated separately, the engine’s pistons may
touch the valves.
2. Remove the intermediate gear wheel from
the hub.
3. If necessary, remove the hub from the
cylinder block by tapping it alternately from
above and below with a mallet.
Removal, crankshaft gear wheel
1. Remove the intermediate gear wheel.
2. Remove the lubricating oil pump.
3. Remove the crankshaft gear wheel with a
suitable puller.
Depending on the puller to be used, it is
possible that the timing case will first have
to be removed. 9
Installation, timing gear wheels
Installation, camshaft gear wheel
1. Clean the abutting surfaces and the thread
of the attachment bolt. De-grease the
contact surface of the camshaft and the
camshaft gearwheel.
2. Check the key and the keyway.
3. Heat the camshaft gear wheel (150_C) and
fit it in such a way to the camshaft that the
mark remains visible.
4. Block the crankshaft (the intermediate gear
wheel must be fitted).
 200847 139
TIMING GEAR
Removal, installation and setting the timing GS engine
5. Replace the thrust washer for the correct

camshaft play.
6. Apply locking compound to the camshaft
gear wheel attachment bolt.
Tighten the attachment bolt to the specified
7. Check the axial camshaft play.
Installation, intermediate gear wheel
1. Check the bearing bushes and the
intermediate gear wheel for wear and
damage.
2. Check the hub for wear and damage.
3. Tap the hub into the cylinder block with a
mallet.
4. Apply oil to the hub and bearing bushes.
5. Check whether the camshaft gear wheel (B)
and the flywheel are in the correct position.
Fit the intermediate gear wheel (A) in such
a way that the marks of the camshaft gear
wheel (B) and crankshaft gear wheel (C)
are between those of the intermediate gear
wheel (A).
Note:
B A
Do not apply locking compound to the
intermediate gear wheel attachment bolt
6. Fit the attachment bolt with the thrust
washer. Tighten the attachment bolt to the
9 C
W264001
140  200847
TIMING GEAR
GS engine Removal, installation and setting the timing
Installation, crankshaft gear wheel

1. Check the key and the keyway.
2. De-grease the clamping surfaces of the
gear wheel and crankshaft.
3. Heat the crankshaft gear wheel in an oven
or on a hot plate to 150 - 170_C. Verify the
temperature using thermal pins.
4. Fit the gear wheel to the crankshaft, with
the tapered section (see the arrow in the
illustration opposite) pointing to the cylinder
block. The gear wheel must entirely abut
the shoulder of the crankshaft.
5. Fit the intermediate gear wheel.
Installation, timing gear, general
1. Fit the valve cover.
2. Fit the timing cover.
M2 00 249
3. Fit the vibration damper.
4. Fit the V-belt.
5. Fit the fan.
 200847 141
TIMING GEAR
Removal and installation, timing gear case GS engine
9.6 REMOVAL AND INSTALLATION, TIMING GEAR CASE
Removal, timing case

1. Remove the timing cover. See “Removal
and installation, timing cover”.
2. Remove the air compressor. See “Removal
and installation, air compressor”.
3. Drain the lubricating oil and remove the
lubricating oil sump. See “Removal and
installation, lubricating oil sump”.
4. Remove the lubricating oil pipe assembly
on the bottom of the timing case.
5. Remove the lubricating oil return pipe from
the fuel pump.
6. Remove the intermediate gear and the
camshaft gear. See “Removal, installation
and setting the timing”.
7. Remove the connector of the rev counter.
8. If the timing case is not to be replaced, the
fuel pump drive need not be removed from
the timing case.
In that case, remove the coupling from the
fuel pump. See “Removal and installation,
fuel pump”.
9. If the timing case is to be removed, the fuel
pump drive must be removed. See “Fuel
pump drive”.
10. Remove the attachment bolts marking the
position of the various attachment bolts.
Remove the timing case.
142  200847
TIMING GEAR
GS engine Removal and installation, timing gear case
Installation, timing case

1. Remove any gasket remains, clean the
sealing surfaces carefully and check them
for damage.
2. Check the dowels. Replace if necessary.
3. Fit a new gasket to the timing case and fit
the timing case.
Position the timing case gasket by fitting
three studs around it.
bolts (see the arrows in the diagram) and
tighten them to the specified torque. See
“Technical data”. Note the position of the
bolts.
5. Cut the gasket on the bottom of the timing
case to the precise dimensions.
M2 00 261
6. Apply a thin layer of transparent

oil-resistant silicon mastic to the sump side 1
of the cylinder block/timing case sealing
face (where the timing cover gasket has
been cut to size - see the arrows in the
diagram).
7. Also apply a layer of the same silicon
mastic to the sump side of the cylinder 9
block/flywheel housing sealing face (see the
arrows in the diagram).
2
8. Fit a new gasket to the lubricating oil sump
and fit the lubricating oil sump. See
sump”.
3
M2 00 629
Legend
1. Flywheel housing
2. Cylinder block
3. Timing case
 200847 143
TIMING GEAR
Removal and installation, timing gear case GS engine
9. Installation of the other components is the

reverse of the removal procedure, bearing
in mind the following:
- Replace the O-rings and gaskets
- Fit the removed components in the way
described. See the respective sections
- Tighten all connections to the specified
torques
- Adjust the timing in the specified way
- Adjust the injection timing in the
specified way.
10. Fill the engine with the specified engine oil.
144  200847
CYLINDER BLOCK AND DRIVING GEAR
10. CYLINDER BLOCK AND DRIVING GEAR

10
 200847 145
Cylinder block and camshaft up to engine No. R-11682

2
1
4 13
5 10
4 9 11
5 14
4 8 12
5 15
4
7
5
16
6 27
17 26
18
19
25
31
23 29
22
20 24 28
21
32 30
10
33
M200285
146  200847
Legend
1. Sealing plate
2. Flange bolt
3. Gasket
4. Bearing cap bolt
5. Ring
6. Bearing cap
7. Bearing cap
8. Bearing cap
9. Bearing cap
10. Sealing plug
11. Sealing ring
12. Cylinder block
13. Dowel
14. Sealing plug
15. Sealing ring
16. Sealing plug
17. Banjo bolt
18. Locking plate
19. Oil sprayer
20. (Camshaft) bearing bush
21. Expansion plug
22. Expansion plug
23. Sealing ring
24. Sealing plug
25. Sealing plug
26. Shim
27. Dowel
28. Cylinder liner
29. Flange bolt
30. Locking plate
31. Shim
32. Camshaft
33. Plug
10
 200847 147
Cylinder block and camshaft from engine No. R-11682

1 10
2 7
1 6 8
2 11
1 5
9 12
2
1
4
2
13
3 23
22
14
15
21
27
19 25
16 20 24
17 18
28 26
29
10 M200634
148  200847
Legend
1. Bearing cap bolt
2. Ring
3. Bearing cap
4. Bearing cap
5. Bearing cap
6. Bearing cap
7. Sealing plug
8. Sealing ring
9. Cylinder block
10. Dowel
11. Sealing plug
12. Sealing ring
13. Sealing plug
14. Banjo bolt
15. Oil sprayer
16. (Camshaft) bearing bush
17. Expansion plug
18. Expansion plug
19. Sealing ring
20. Sealing plug
21. Sealing plug
22. Shim
23. Dowel
24. Cylinder liner
25. Flange bolt
26. Locking plate
27. Shim
28. Camshaft
29. Plug
10
 200847 149
Piston, connecting rod and crankshaft
10
1
11
2
12
3 13
10 14
17
15 18
16
M200286
150  200847
Legend
1. Bearing bush
2. Connecting rod
3. (Big-end) bearing shell
4. (Big-end) bearing shell
5. Dowel
6. Bearing cap
7. Connecting rod bolt
8. Piston ring (top ring)
9. Piston ring (compression ring)
10. Oil scraper spring
11. Piston
12. Gudgeon pin
13. Circlip
14. Crankshaft
15. Bearing shell (main bearing)
16. Bearing shell (main bearing)
17. Axial thrust washer (crankshaft)
18. Axial thrust washer (crankshaft)
10
 200847 151
Removal and installation, pistons and connecting rods GS engine
10.2 REMOVAL AND INSTALLATION, PISTONS AND CONNECTING RODS
Removal, pistons and connecting rods

1. Remove the cylinder head(s). See
“Removal and installation, cylinder heads”.
sump”.
3. Remove the lubricating oil pipes and the
lubricating oil pump. See “Internal
components of the lubricating oil system”.
4. Mark the position of the pistons in the
cylinder head, if they are to be put back.
5. Remove the big end bearing cap bolts.
Remove the 12-sided bolts with special tool
(DAF no. 1240432).
6. Remove the connecting rod with the piston
from the cylinder liner.
7. Ensure that the connecting rod bearing cap
remains with the respective connecting rod.
8. Remove the circlips from the bore of the
piston.
9. Push the gudgeon pin out of the piston.
Avoid damaging the piston.
10. If necessary, use a suitable driving tool to
remove the small-end bush from the
connecting rod.
11. Using piston ring pliers, remove the piston
rings from the piston. Keep the piston rings
with the respective piston.
10
152  200847
GS engine Removal and installation, pistons and connecting rods
Inspection, pistons and connecting rods

1. Check the bearing shells of the connecting
rod.
2. Check the bearing bush of the connecting
rod.
3. Check the connecting rod for cracking and
overheating.
4. Replace the big end bearing cap bolts.
5. Inspect the dimensions of the connecting
rod.
6. Check the gudgeon pin for cracking, wear
and overheating.
7. Check the piston for cracking, wear and
overheating.
8. Check the groove play of the piston rings in
the piston.
9. Check the bearing surface of the piston
rings.
Installation, pistons and connecting rods
1. Clean the parts carefully and check that the
oilways are open.
2. If necessary, use a suitable driving tool to fit
a new small-end bush in the connecting
rod. The bush must be fitted in the
connecting rod in such a way that the
lubricating oil hole in the bush corresponds
precisely to the opening of the lubricating oil
bore in the connecting rod.
After pressing in the bush, ream it to the
specified dimensions.
After reaming the bearing bush, check
whether the centre-to-centre distance
between the big and small eyes is within the
tolerance limits.
3. Fit the (new) big-end bearing shells in the
connecting rod and bearing cap. Check that
10
the oilways are open.
 200847 153
Removal and installation, pistons and connecting rods GS engine
4. Take the ring from the oil scraper ring and

place it in the lowest piston ring groove of B
the piston.
Place the oil scraper ring over the ring in
the piston ring groove.
The ring opening must face the slot opening
of the oil scraper ring.
Rotate the oil scraper ring in such a way
that the slot opening (B) aligns with the
gudgeon pin (A), as shown in the diagram.
The slot openings (B) in the three piston
rings must be evenly spaced, at intervals
of 120°.
A
5. Using piston ring pliers, install the
compression ring with the word “top”
uppermost. B
Rotate the compression ring in such a way B
that the slot opening (B) aligns with the
gudgeon pin (A), as shown in the diagram. M2 00 139
6. Using piston ring pliers fit the top ring with

the word “top” uppermost. Rotate the top
ring in such a way that the slot opening (B)
aligns with the gudgeon pin (A), as shown
in the diagram.
7. Fit one circlip to the piston.
8. Heat the piston to a temperature of approx.
50°C and lightly oil the gudgeon pin.
9. Fit the connecting rod into the piston and
push the gudgeon pin into the piston.
Ensure that all pistons are fitted to the
connecting rods in the same way. Check
this by referring to the number on the side
of the connecting rod and the arrow on the
top of the piston.
10. Fit the circlips and check whether they are
flush in the grooves.
11. Clean the crankshaft and cylinder liners
10 with a lint-free cloth.
12. Oil the cylinder liner, piston and piston rings
well. Fit a piston ring clamping strip around
the piston.
Place the piston in the cylinder so that the
arrow on the piston points to the timing gear
side of the engine.
Take care when fitting the pistons that the
oil sprayers are not damaged.
154  200847
GS engine Removal and installation, pistons and connecting rods
13. Clean and check the mating faces of the

connecting rod and big end bearing cap.
14. Clean the bearing shells of the connecting
rod and the big end bearing caps, applying
oil to them.
15. Fit the respective bearing cap to the
connecting rod. Check this with reference to
the numbers stamped on.
The number on the connecting rod must be
on the same side as the number on the
bearing cap.
16. Only fit new specified bolts. Apply a drop of
engine running-in oil to the thread and
abutting surface of the connecting rod bolts
and fit the bolts. Tighten the attachment
bolts to the specified torque. See “Technical
data”.
17. Check the bearing for axial play.
If radial play is found, a crankshaft with
standard bearings which has been ground
to undersize has probably been fitted.
18. Crank the crankshaft a few revolutions and
check that there is no point at which it runs
heavily.
19. Then fit the removed parts in reverse order
of removal. Consult the respective sections.
Note:
After replacement of cylinder liners, pistons and
piston rings, the engine must be run-in again.
Considering that the specified engine oil
possesses insufficient running-in properties,
engine oil of a different grade must be used
during the running-in period. See the
“Specifications” manual.
After 7500 - 10000 km, drain the oil and replace
the oil filter.
Fill the engine with the specified oil.
10
 200847 155
Removal and installation, crankshaft GS engine
10.3 REMOVAL AND INSTALLATION, CRANKSHAFT
Removal, crankshaft
sump”.
2. Remove the timing case. See “Removal
and installation, timing case”.
3. Remove the oil pipes and the lubricating oil
pump. See “Internal components of the
lubricating oil system”.
4. Remove the flywheel. See “Removal and
5. Remove the flywheel housing. See
“Removal and installation, flywheel
housing”.
6. Remove the bearing caps from the
connecting rods. See “Removal and
installation, pistons and connecting rods”.
7. Remove the bearing cap bolts from the
main bearings and take the bearing caps
off. Check that all bearing caps are
stamped with a marking letter. If not, make C D
a mark yourself.
8. Remove the axial thrust washers.
9. Remove the crankshaft and make sure that
it is not damaged during removal.
10. Mark the position of the bearing bolts, so C
that they can be re-fitted in the original D
place.
Inspection, crankshaft
1. Check the crankshaft for overheating and
outer damage.
10 2.
3.
Magnaflux test the crankshaft.
Measure the crankshaft.
M2 00 093
To gain an impression of crankshaft main

bearing and connecting rod bearing wear,
the measuring procedure on the form
illustrated must be followed. See “Technical
data”.
4. Inspect the bearing shells and axial thrust
washer for wear, damage and overheating.
156  200847
GS engine Removal and installation, crankshaft
5. Inspect the bearing caps for damage and

overheating.
6. Inspect the contact surfaces of the bearing
caps in the cylinder block.
7. Inspect the threaded hole for the bearing
cover bolt.
8. Inspect the bearing cover bolts. The screw
thread should be completely undamaged. If
in doubt, renew them.
Installation, crankshaft
1. Clean all components thoroughly.
Remove the preserving agent from the
crankshaft.
2. Clean the threaded holes of the bearing cap
bolts.
3. If re-using the bearing shells, fit them in the
original place in the cylinder block and in
the bearing caps.
4. If the crankshaft has been ground to
undersize, fit the relevant bearing shells.
5. Check that all bearing oilways are open.
Check that the oil duct in the bearing cap
on the timing side is open.
6. Check the guide pin of the middle bearing.
7. Oil the bearing shells.
8. Place the crankshaft in the cylinder block.
9. Apply oil to the axial pressure rings. Fit a
pressure ring to opposite sides of the
middle bearing. The bronze bearing
material must face the crankshaft.
10
M2 00 091
 200847 157
Removal and installation, crankshaft GS engine
10. Measure the axial play of the crankshaft.

To do this, fit a holder with a dial gauge.
- Position the stylus at the end of the
crankshaft.
- Press the crankshaft to the flywheel
side and set the measuring gauge to
zero.
- Press the crankshaft to the timing gear
side and take the reading from the
measuring gauge.
11. If the play is too great, it can be corrected
by fitting oversized thrust washers.
12. If the play is too small, this can be M2 00 271
corrected by grinding the axial thrust
washers on the metal side (not the bronze
bearing material). Grind the axial pressure
rings, on opposite sides of the bearing cap,
to the same dimensions.
13. Fit the two axial pressure rings in the
middle bearing cap and apply oil to the
pressure rings.
14. Apply oil to the bearing shells in the bearing
caps and fit the bearing caps. The letter on
the bearing cap must be the same as the C
letter on the cylinder block. See the D
diagram.
15. Apply a drop of engine running-in oil to the
thread and abutting surface of the bearing
cap bolt and fit the bolts.
16. Up to engine No. R-11682: C
- Tighten both M18 bolts alternately. D
Tighten the bolts to the specified
tightening torque. See “Technical data”.
Begin by tightening the middle bearing
cap and then work outwards on both
sides.
10 M2 00 093
158  200847
GS engine Removal and installation, crankshaft
From engine No. R-11682, the M16 bolts

must be tightened in two steps:
- First step: tighten the bolts to the
Begin by tightening the middle bearing
sides.
- Second step: mark a parallel stripe on
all bearing cap bolts. Tighten the bolts
further to the prescribed angular
displacement. See “Technical data”.
Begin again with the middle bearing
sides.
17. Check whether the crankshaft operates
smoothly and is not getting stuck anywhere.
18. Measure the axial play again and correct it
if necessary.
19. Then fit the parts in reverse order of
removal. Consult the respective sections.
10
 200847 159
Grinding the crankshaft GS engine
10.4 GRINDING THE CRANKSHAFT
- If necessary, the crankshaft can be ground

down to one of the three undersizes.
- In the event of damage to the axial bearing
surfaces, these can be ground to an
undersize.
- If the seal mounting surface of the
crankshaft, flywheel side must be ground,
the mounting surface must not be ground A
over its whole length. In front of the flywheel
mating surface a minimum of 7 mm
measured from the rear of the crankshaft
must remain on the original diameter. See
distance A in the diagram.
- After grinding the crankshaft, round the oil
holes again to a radius of 0.5 mm.
- The journal fillet radius must be brought
accurately to the specified radius.
M2 00 080
- The crankshaft can be ground to the next
undersize once without having to be
nitrided.
- After nitriding, the nitride stop must be
removed from the parts below by means of
journals:
- all main and connecting rod bearing
journals
- the sides of the middle main bearing for
the benefit of the axial bearings
- the outer diameter of the flywheel
flange
- mounting surfaces of sealing rings
- the tapered front (the clamping face of
the vibration damper).
10
160  200847
GS engine Grinding the crankshaft
- If the crankshaft has been ground to an

undersize, this must be shown on the
crankshaft using the following codes:
H = Main bearing journal
D = Connecting rod journal
N = Nitrided crankshaft
After the letters H and D the number of
times that the crankshaft has been ground
(1st, 2nd or 3rd undersize) is shown. H1
D2
N
This is what the indication on the crankshaft
opposite means:
H1 = main bearing journal ground to the
first undersize.
D2N = connecting rod journal ground to
the second undersize and crankshaft M2 00 090
nitrided.
- Before balancing the crankshaft, it must be
carried by the front and rear main bearing.
The crankshaft must be dynamically
balanced at a maximum of 72 g/cm at an
engine speed of 350 rpm.
Remove any material by drilling out the
counterbalances.
10
 200847 161
Removal and installation, camshaft GS engine
10.5 REMOVAL AND INSTALLATION, CAMSHAFT
Removal, camshaft
2. Crank the engine to TDC of cylinder 1
(0° indication on the flywheel) with the
valves of cylinder 6 overlapping.
3. Remove the timing cover. See “Removal
and installation, timing cover”.
4. Remove the tappet rods and bushes. See
“Removal and installation, valve operation”.
5. Remove the camshaft gear. See “Removal,
installation and setting, timing”.
locking plate and remove the locking plate.
7. Remove the camshaft with the spacer ring
from the cylinder block.
M2 00 144
8. Remove the spacer ring from the camshaft.
Inspection, camshaft
1. Clean the camshaft and check whether the
oilways are open.
2. Check the camshaft for overheating,
damage and wear.
3. Inspect the dimensions of the camshaft.
4. Check whether the sealing plug on the rear
of the camshaft seals well.
5. Check the bearing of the camshaft itself
and the bearings in the cylinder block for
wear and damage.
6. Check the spacer ring. Replace if
necessary.
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GS engine Removal and installation, camshaft
Installation, camshaft
1. If necessary, replace the camshaft bearings
in the cylinder block. A
Fit the new camshaft bearings using the
special tool (A) (DAF no. 0535699).
Fit the camshaft bearing in such a way that
the aperture in the bearing bush (see arrow)
aligns with the oil duct in the cylinder block.
2. Check that all bearing oilways of the
camshaft bearings in the cylinder block are
open.
3. Generously oil the camshaft bearings and
fit the rotating camshaft in the cylinder
block. W2 00 089
4. Check that the camshaft operates smoothly

and is not getting stuck anywhere.
5. Fit the spacer ring onto the camshaft.
6. Apply locking compound to the locking
plate, and fit the locking plate. Tighten the
attachment bolts to the specified torque.
7. Check again that the camshaft operates
smoothly and is not getting stuck anywhere.
8. Measure the axial play of the camshaft. To
do this, fit a holder with a dial gauge.
- Position the stylus at the end of the
camshaft.
- Press the camshaft to the flywheel side
and set the measuring gauge to zero.
- Press the camshaft to the timing gear
side and take the measurement from
the measuring gauge.
9. Correct the axial play with the spacer ring.
10. Remove the camshaft gear and adjust the
timing. See “Removal, installation and
setting the timing”.
10
 200847 163
Measurement and rejection standards of cylinder liners GS engine
10.6 MEASUREMENT AND REJECTION STANDARDS OF CYLINDER LINERS
Measuring cylinder liners

1. To gain an impression of cylinder liner wear,
the measuring procedure on the form
illustrated in “Technical data” must be
followed. See “Overview of wear
measurement”.
2. The ovality must be measured by turning
the measuring gauge another 90° each time
and taking the appropriate measurement.
3. If it appears that the cylinder liner is ovoid,
the initial bore in the cylinder block must be
checked.
4. If the initial bore in the cylinder block is
0.05 mm larger than the maximum new
measurement, the cylinder block must be
drilled and cylinder liners with an oversized
outer diameter must be fitted.
Cylinder liner rejection standard
Cylinder liners must be replaced if:
- the bore polishing standard has been
exceeded;
- the overall running is not equal;
- the running surface is scored;
- the difference in measurement on the
“Overview of wear measurement” is more
than 0.07 mm.
Note:
If the cylinder liner is rejected due to any of
the above criteria, it must be replaced and
not be honed.
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GS engine Measurement and rejection standards of cylinder liners
Bore-polishing
1. One of the measures to be taken to aid a
patently high oil consumption (engine oil
consumption test) is to inspect the cylinder
liners for bore polishing.
2. Bore polishing means: extremely smooth
surfaces without visible regular honing
pattern (see the illustration).
If the “deeper” honing grooves still show a
regular pattern, bore polishing cannot be M2 00 043
considered.
3. Only bore polishing under the top of the
upper piston rings in the uppermost piston
position can influence the oil consumption.
4. Permissible is:
- A maximum of 3 patches with bore
polishing joined together with a total
surface of not more than 10 cm2 per
liner.
- A maximum of 3 non-connected
bore-polishing patches with a total
surface of not more than 20 cm2 per
liner.
10
 200847 165
Removal and installation, cylinder liner GS engine
10.7 REMOVAL AND INSTALLATION, CYLINDER LINER
Removal, cylinder liner

1. Remove the cylinder heads. See “Removal
and installation, cylinder heads”.
sump”.
3. Remove the injector. See “Removal and
installation, pistons and connecting rods”.
4. Before removing the cylinder liner from the
cylinder block, fit the particular special tool
for this purpose (DAF no. 0535625) at the A B
location of the switch as in (A) in the
diagram.
5. With the special tool, pull the cylinder liner
out of the cylinder block.
6. After measuring the cylinder liner, measure
the initial bore in the cylinder block.
If the initial bore is 0.05 mm larger than the
maximum new measurement, the cylinder
block must be drilled to the specified
excess bore diameter.
Fit the excess (exterior diameter) cylinder
liners.
7. Measure the depth of the chamber for the
cylinder liner collar.
Note: M2 00 099
Whenever oversized cylinder liners are
fitted, marking S1 must be stamped under
or over the engine number.
The message C.S1 must also be put on the
engine specification plate.
Installation, cylinder liner
1. Clean the cylinder block before fitting.
10 2. Before installing the cylinder lining into the

cylinder block, fit the parts of the special
tool for this purpose (DAF no. 0535625) at
the location of the switch as in (B) in the
diagram.
166  200847
GS engine Removal and installation, cylinder liner
3. If possible, cool the cylinder liner before

fitting it.
4. Only in the most extreme case may a little
thin lubricating oil be applied to the edge of
the initial bore. All other lubricating agents,
of whichever type, are absolutely forbidden.
Difficulties in the replacement of cylinder
liners are almost always the result of
lubricant residue used in the previous
assembly.
5. Press the cylinder liner entirely into the
cylinder block using the special tools.
6. After fitting, check the internal diameter of
the cylinder liner.
7. After installing the new cylinder liner,
measure the height that the cylinder liner
protrudes over the cylinder block. Correct
the height if necessary. See “Measuring and
correcting cylinder liner height”.
Note:
After replacement of cylinder liners, pistons and
piston rings, the engine must be run-in again.
Considering that the specified engine oil
contains insufficient running-in properties,
engine oil of another grade must be used during
the running-in period. See the “Specifications”
manual.
After 7500 - 10,000 km, drain the oil and
replace the oil filter.
Fill the engine with the specified oil.
10
 200847 167
Measuring and correcting cylinder liner height GS engine
10.8 MEASURING AND CORRECTING CYLINDER LINER HEIGHT
After fitting new cylinder liners, the distance of

the cylinder liner above the cylinder block must
be inspected.
This measurement also needs to be carried out
for fitting the cylinder head.
The height of the cylinder lining that protrudes
above the cylinder block has to be checked
using special tool (DAF no. 0694795).
Inspection, cylinder liner height
1. Place the tool on the top of the cylinder
block.
2. Set the measuring gauge to “ZERO”.
3. Now set the pin of the gauge on the edge of
the cylinder liner.
4. Read the value off the gauge.
Correcting the cylinder liner height
1. If the cylinder liner is too deep in the
cylinder block, this can be corrected by M2 00 100
fitting a spacer ring under the liner collar.
2. If the cylinder liner protrudes too far above
the block (after refacing the cylinder block),
the chamber depth for the cylinder liner
collar should be brought to the specified
value.
Note:
Grinding down the cylinder liner collar is not
permitted.
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168  200847
GS engine Removal and installation, piston cooler
10.9 REMOVAL AND INSTALLATION, PISTON COOLER
The piston cooler consists of six sprayers that

spray the lubricating oil on to the piston head.
Notes:
- New or overhauled cylinder blocks are
supplied without oil sprayers. Therefore
these still have to be fitted.
- Up to engine No. R-11682, a
spring-loaded valve is fitted in the
hollow screw.
- From engine No. R-11682, there is no
spring-loaded valve fitted in the hollow
screw.
M2 00 615
Removal, piston cooler up to engine
No. R-11682
1. Tap the locking plate back, remove the
hollow screw and detach the sprayer.
Installation, piston cooler up to engine
No. R-11682
1. Check that the valve is not stuck in the
hollow screw.
2. Fit new locking plates to the oil sprayers
and fit them.
Apply locking compound to the hollow
screws.
3. Tighten the banjo bolts to the specified
torque, see main group “Technical data”.
4. Lock the banjo bolts with the locking plates.
Removal, piston cooler from engine
No. R-11682
1. Remove the hollow screw and detach the
sprayer.
Installation, piston cooler from engine
No. R-11682
1. Apply locking compound to the hollow
screws. Apply locking compound sparingly,
as otherwise there is the chance that the oil
10
duct will become clogged.
2. Fit the oil sprayers with the hollow screws.
3. Tighten the hollow screws to the specified
 200847 169
Pressure testing, cylinder block GS engine
10.10 PRESSURE TESTING, CYLINDER BLOCK
The cylinder block can be pressure tested either

with or without cylinder heads.
Pressure testing, cylinder head
1. Seal the cylinder block coolant channels
with sealing plates equipped with gaskets.
in-house. One sealing plate must be
equipped with a connection for an air pipe.
2. Connect an air pipe equipped with a
reducing valve to the sealing plate coupling.
3. Immerse the cylinder block in a container of
hot water and test the pressure of the block
with an air pressure of 1.5 bar.
Leave the cylinder block in the water for
about half an hour.
4. Blow dry the cylinder block.
Pressure testing, cylinder block with
cylinder heads
1. Fit a cylinder head gasket and install the
cylinder heads.
The coolant inlet pipe and the coolant
collection pipe must be removed.
2. Seal the cylinder block coolant ducts of the
cylinder heads with sealing plates equipped
with gaskets.
in-house. One sealing plate must be
equipped with a connection for an air pipe.
3. Connect an air pipe equipped with a
reducing valve to the sealing plate coupling.
4. Immerse the assembly in a container of hot
water and admit air pressure of 1.5 bar.
Leave the assembly in the water for about
10 5.
half an hour.
Blow dry the cylinder block.
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GS engine Machining the cylinder block
10.11 MACHINING THE CYLINDER BLOCK
Refacing the cylinder block A

1. When machining the cylinder block, caution
must be taken to ensure that measurement
(A) between the top of the crankshaft bore
and the top of the cylinder block remains
within the specified values.
2. After cleaning the machined surface, the
distance that the cylinder liner protrudes
above the cylinder block must be measured
and corrected if necessary. See
“Measuring, cylinder liner height”.
Cleaning, cylinder block
1. Clean the cylinder block thoroughly and pay
the necessary attention to the various oil M2 00 015
channels.
2. Inspect the oilways for blockages.
Sealing plugs
1. Apply locking compound to the sealing
plugs and (if applicable) new sealing rings
and fit the plugs.
2. Fit the sealing plugs which are behind the
pushrod covers. Apply locking compound to
the sealing plugs. See “Technical data”.
Removal and installation, expansion plugs
1. Tap on the edge of the expansion plug,
causing it to tilt. Make sure that no damage
occurs.
2. Remove the expansion plug with a pair of
pliers.
3. Apply locking compound to the new
expansion plug and tap it with a suitable
drift into the cylinder block.
4. Leave the locking compound to harden for
1 hour. 10
5. Check for leaks.
 200847 171
Machining the cylinder block GS engine
10
172  200847
COOLING SYSTEM
GS engine System description
11. COOLING SYSTEM

11.1 SYSTEM DESCRIPTION
11
 200847 173
COOLING SYSTEM
System description GS engine
Cooling system diagram up to engine No. R-11682
A 1
C
4
14
D
5
6 2 2 B
3
8
F
13
7 9 12
11
E
10
G
M2 00 247
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174  200847
COOLING SYSTEM
Legend
A Pipe connection of retarder (if fitted)
B Pipe connection to retarder (if fitted)
C Pipe connection from bleed pipe
D Pipe connection to radiator
E Pipe connection from radiator
F Pipe connection from bleed pipe
G Pipe connection from bleed pipe
1. Connecting pipe (if no retarder is
connected)
2. Header pipe (discharge pipe from cylinder
heads)
3. Bleed pipe
4. Thermostat housing
5. By-pass pipe from thermostat housing
6. Supply duct to cylinder block
7. Coolant pump
8. Discharge pipe from air compressor
9. Supply pipe to air compressor
10. Air compressor
11. Discharge pipe from lubricant heat
exchanger
12. Lubricant heat exchanger
13. Supply pipe from lubricant heat exchanger
14. Temperature sensor
11
 200847 175
COOLING SYSTEM
Cooling system diagram from engine No. R-11682
A 1
C
3
13
D
4
5 E 2 2 B
7
F
12
6 8 11
10
G
H
M2 00 690
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176  200847
COOLING SYSTEM
Legend
A Pipe connection of retarder (if fitted)
B Pipe connection to retarder (if fitted)
C Pipe connection from bleed pipe
D Pipe connection to radiator
E Pipe connection from bleed pipe
F Pipe connection from bleed pipe
G Pipe connection from radiator
H Pipe connection from bleed pipe
1. Connecting pipe (if no retarder is
connected)
2. Header pipe (discharge pipe from cylinder
heads)
4. By-pass pipe from thermostat housing
5. Supply duct to cylinder block
6. Coolant pump
7. Discharge pipe from air compressor
8. Supply pipe to air compressor
9. Air compressor
10. Discharge pipe from lubricant heat
exchanger
11. Lubricant heat exchanger
12. Supply pipe from lubricant heat exchanger
13. Temperature sensor
11
 200847 177
COOLING SYSTEM
General
The engine cooling system’s function is to keep
the engine temperature at a constant level
independently of the change in engine load,
speed and ambient temperature. At this
temperature, the engine gives its best return
and minimum wear.
To achieve controlled engine cooling, the
amount of coolant flowing to the radiator is
controlled by a thermostat.
Air bleed pipes have been fitted in the engine at
several locations, so the engine itself does not
require bleeding.
Operation of the cooling system up to
engine No. R-11682
The cooling system consists of a coolant pump,
a radiator with a fan, a header tank, a lubricating
oil heat exchanger, a thermostat and pipes. The
air compressor is also included in the cooling
system.
From the delivery side of the coolant pump (7)
the coolant is fed via a duct (6) directly into the
cylinder block. The coolant passes through the
cylinder block to the cylinder heads.
On the cylinder heads, a header pipe (2) is fitted
which, if no retarder is fitted on the cooling
system, returns the coolant to the thermostat
housing (4), via the connection pipe (1).
If a retarder is connected to the cooling system,
the connection pipe (1) is not fitted, and the
coolant is passed to the retarder via the pipe
connection (B). On the pipe connection (A), the
return pipe from the retarder is connected.
From the thermostat housing (4) the coolant can
travel via the bypass pipe (5) to the coolant
pump or via the pipe connection (D) to the
radiator. The thermostat fitted in the thermostat
housing (4) controls the quantity of coolant
which flows into these pipes. See “Thermostat
operation”.
11
178  200847
COOLING SYSTEM
The cylinder head of the air compressor (10) is

also cooled by the coolant.
The supply pipe (9) to the air compressor is
connected to the duct (6) from the coolant pump
(7) to the cylinder block.
The return pipe (8) for the air compressor is
connected to the header pipe (2).
The lubricating oil heat exchanger (12) receives
the coolant via the supply pipe (13) from the
cylinder block.
From the lubricating oil heat exchanger, the
coolant is passed directly via the return pipe (11)
back to the coolant pump (7).
In addition to cooling the lubricating oil, the
lubricating oil heat exchanger’s task is that of
warming the lubricating oil in a “cold” engine.
The heater, heated by the coolant, can also be
connected to the cooling system.
Because the coolant expands in volume as it is
heated, a header tank has been fitted in the
cooling system.
The header tank must be fitted with a pressure
cap which both aerates and de-aerates the
cooling system.
Operation of the cooling system from engine
No. R-11682
The cooling system consists of a coolant pump,
a radiator with a fan, a header tank, a lubricating
oil heat exchanger, a thermostat and pipes. The
air compressor and turbocharger are also
included in the cooling system.
From the delivery side of the coolant pump (6)
the coolant is fed via a duct (5) directly into the
cylinder block. The coolant passes through the
cylinder block to the cylinder heads.
On the cylinder heads, a header pipe (2) is fitted
which, if no retarder is fitted on the cooling
system, returns the coolant to the thermostat
housing (3), via the connection pipe (1).
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 200847 179
COOLING SYSTEM
If a retarder is connected to the cooling system,

the connection pipe (1) is not fitted, and the
coolant is passed to the retarder via the pipe
connection (B). On the pipe connection (A), the
return pipe from the retarder is connected.
From the thermostat housing (3) the coolant can
travel via the bypass pipe (4) to the coolant
pump or via the pipe connection (D) to the
radiator. The thermostat fitted in the thermostat
housing (3) controls the quantity of coolant
which flows into these pipes. See “Thermostat
operation”.
The cylinder head of the air compressor (9) and
the bearing housing of the turbocharger (15) are
also cooled by the coolant.
The supply pipe (8) to the air compressor (9) is
connected to the duct (5) from the coolant pump
(6) to the cylinder block.
The return pipe (7) for the air compressor (9) is
connected to the return pipe of the heat
exchanger (10).
The lubricating oil heat exchanger (11) receives
the coolant via the supply pipe (12) from the
cylinder block.
From the lubricating oil heat exchanger, the
coolant is passed directly via the return pipe
(10) back to the coolant pump (6).
In addition to cooling the lubricating oil, the
lubricating oil heat exchanger’s task is that of
warming the lubricating oil in a “cold” engine.
The heater, heated by the coolant, can also be
connected to the cooling system.
Because the coolant expands in volume as it is
heated, a header tank has been fitted in the
cooling system.
The header tank must be fitted with a pressure
cap which both aerates and de-aerates the
cooling system.
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180  200847
COOLING SYSTEM
Operation of the thermostat

The coolant enters the thermostat housing via
the pipe (C). Next, the coolant passes through
the thermostat. Depending on the temperature
of the coolant and the relative position of the
thermostat, there are three possibilities:
A The coolant has not yet reached the
opening temperature of the thermostat. A
The pipe (B) (fig. 1) to the radiator is
completely closed.
The coolant goes via the by-pass duct (A)
(fig. 1) directly to the coolant pump and the
pump leads the coolant back to the cylinder B C
block.
M200178
B The coolant has reached the opening

temperature of the thermostat. A
The pipe (B) to the radiator is opened and
the by-pass duct (A) is partially closed
(fig. 2).
At this time, coolant will flow both through
the pipe (B) to the radiator and through the B C
by-pass duct (A) to the coolant pump.
M200179
C The temperature of the coolant has become

even higher, the pipe (B) to the radiator is A
fully opened and the by-pass duct (A) is
fully closed (fig. 3).
The whole coolant flow now goes through
pipe (B) to the radiator.
B C
Note:
In the event of excessive coolant temperatures,
it is advised not to remove the thermostat, as an
emergency solution.
If there is no thermostat in the thermostat
housing, the by-pass duct is constantly fully
open. As the resistance in the by-pass duct is
M200177 11
lower than that in the radiator, the largest part of
the coolant will go to the coolant pump via the
by-pass duct (uncooled). As a consequence, the
temperature will continue to rise.
 200847 181
COOLING SYSTEM
Draining and filling, cooling system GS engine
11.2 DRAINING AND FILLING, COOLING SYSTEM
Coolant
The cooling system should preferably be filled
with a ready-mixed coolant containing
anti-freeze and corrosion-inhibiting additives.
See the “Specifications” manual.
Coolant is a toxic substance and
must be handled with care. Protect
the skin and eyes.
Coolant is harmful to the

environment; after use, it should be
processed as industrial chemical
waste.
When the coolant is hot, there is an

overpressure in the cooling system.
Carefully remove the filler cap, to
release the overpressure.
Draining
1. If the coolant is collected in a clean
container and has no impurities, it may be
re-used.
2. If a heater heated by coolant is connected
to the system, set the heater control to
“maximum”.
3. Place suitable containers beneath the drain
points.
4. Remove the cooling system filler cap.
5. Open the radiator drain tap (A).
6. Remove the oil heat exchanger drain plug
(B) and drain the cylinder block through the
plug.
7. Flush out the cooling system. A
8. Close the radiator drain tap, fit a new
gasket ring to the oil heat exchanger and fit
the oil heat exchanger.
11
B
M2183
182  200847
COOLING SYSTEM
GS engine Draining and filling, cooling system
Filling
1. Check that the heater operating lever is still
at “maximum”.
2. Fill the header tank with the specified
coolant to the maximum level mark.
3. Let the engine run for a few minutes and
check the coolant level.
4. If necessary, top up the coolant.
Note:
In order to avoid damaging the cylinder
block, do not top up a warm engine with
cold coolant.
Bleeding
In order to bleed the cooling system
automatically, bleed pipes must be fitted to the
radiator, air compressor, header pipe (of the
cylinder heads) and the supply duct to the
cylinder block which are connected to the
header tank.
Make sure that these bleed pipes are not
kinked.
11
 200847 183
COOLING SYSTEM
Testing the cooling system GS engine
11.3 TESTING THE COOLING SYSTEM
1. Fill the header tank to the maximum level.

2. Attach a pressure testing pump to the
connection for the pressure cap.
3. Pressure-test the system at a pressure of
0.4 - 0.5 bar.
The pressure must remain constant for
10 minutes.
4. While the system is under pressure, the
external control must be carried out. MAX
MIN
Coolant leaks
External leakage must be looked for in:
- flexible coolant pipes M2163
- coolant pipes
- leaking radiator
- leaking header tank
- leaking coolant pump
- leaking cylinder block or cylinder head
expansion cap
- defective oil heat exchanger
- defective pressure cap
- leaking heater
- defective retarder heat exchanger
(if applicable).
Internal leakage must be looked for in:
- defective head gasket
- cracked cylinder head or cylinder block
- leaking injector sleeve
- leaking sealing plug behind the covers on
the bottom of the engine.
11
184  200847
COOLING SYSTEM
GS engine Testing the cooling system
Permissible coolant pump leakage

The coolant pump shaft is sealed by a unitised
seal.
To function correctly, it is necessary that the
seal should use a small amount of coolant.
This coolant consumption can lead to a trace of
leakage under the discharge holes that leaves a
white deposit on evaporation.
The amount of coolant leaking out depends on
the use to which the vehicle is put. When the
engine is started and stopped on numerous
occasions, increased leakage can occur.
The coolant pump does not need to be replaced
if a few drops of coolant are emitted from the
discharge ducts from time to time or if a white
deposit is visible under the discharge holes.
11
 200847 185
COOLING SYSTEM
Removal and installation, header pipe of GS engine
thermostat housing and thermostat
11.4 REMOVAL AND INSTALLATION, HEADER PIPE OF THERMOSTAT HOUSING
AND THERMOSTAT
Diagram of parts
10 24 9
11 27
24
11 25 3 29
1 28
4 5 26
30
6 31
8 2
7 32
23
18
22
19
17 21
14 15 20
16
15
13
12 M200287
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186  200847
COOLING SYSTEM
GS engine Removal and installation, header pipe of
Legend
1. Thermostat
2. Oil seal
3. Thermostat seat
4. Coolant pipe
5. Union nut
6. Cutting ring
7. Coupling
8. Sealing ring
9. Bleed pipe
10. Hollow screw
11. Sealing ring
12. Flexible pipe
13. Pipe clamp
14. Header pipe
15. Pipe clamp
16. Connecting pipe
17. Header pipe
18. Gasket
19. Bolt
20. Flexible pipe
21. Pipe clamp
22. Sealing ring
23. Sealing plug
24. Sealing ring
25. Hollow screw
26. O-ring
27. Bolt
28. Pipe clamp
29. Flexible pipe
31. Pipe clamp
32. Flexible pipe
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 200847 187
COOLING SYSTEM
Removal, header pipe
1. Partially drain the coolant. See “Draining
and filling the cooling system”.
and Installation, injector pipes”.
3. Remove the wiring of the coolant
temperature sensor.
4. Remove all pipes from the header pipe and
thermostat housing.
header pipe and remove them with the
thermostat housing of the cylinder heads.
6. As necessary, remove the two pipe sections
from each other and remove the thermostat
housing from the front pipe section.
7. Remove any gasket remains, clean the
sealing surfaces and check them for
damage.
Installation, header pipe
1. Before fitting the header pipe, check the
state of the coolant pipes and pipe clamps.
If in doubt, replace them.
Sparingly grease the moving section of the
pipe clamp.
2. Fit new O-rings to the thermostat housing
(if removed) and fit it to the header pipe.
3. Fit new gaskets to the header pipe and fit
the header pipe to the cylinder heads.
4. Replace the sealing rings. Check the
condition of the coolant pipes and pipe
clamps. If in doubt, renew them.
Clean the inside of the coolant pipes where
they seal against a pipe or flange. Also
clean the sealing face of the pipe or flange.
pipe clamp.
5. Connect all pipes. Tighten pipes securely.
11
188  200847
COOLING SYSTEM
GS engine Removal and installation, header pipe of
6. Install the wiring of the coolant temperature
sensor.
7. Install the injector pipes. See “Removal and
9. Run the engine to operating temperature.
Tighten the pipe clamps once more, check
for leaks and check the coolant level.
Thermostat housing and thermostat
Too high a coolant temperature is often put
down to a defective thermostat. This is however
seldom the case.
Before the thermostat is replaced, the cooling
system must first be inspected.
Removal, thermostat and thermostat
housing
1. Partially drain the coolant. See “Draining
and filling the cooling system”.
2. Remove the pipes from the thermostat
housing.
3. Remove the attachment bolts and take the
header pipe out of the thermostat housing.
4. Remove the thermostat from the thermostat
housing.
5. If necessary, remove the oil seal from the
housing. Avoid damaging the housing.
6. If necessary, remove the thermostat seat
from the housing.
Inspection, thermostat and thermostat
housing
1. Check the seal in the thermostat housing.
If the rubber is damaged or if there are
clear signs of leakage on the seal, it must
be replaced.
2. Check whether the thermostat is fully
closed.
3. Place the thermostat in a container filled 11
with water.
 200847 189
COOLING SYSTEM
4. Place a thermometer in the container and
heat the water. Check at what temperature
the thermostat opens and whether it opens
fully. See “Technical data”.
Installation, thermostat and thermostat
housing
1. Clean the thermostat.
2. Clean the sealing surfaces of the
thermostat housing and the header pipe.
3. If necessary, press a new thermostat
seat into the housing. Prior to this, apply
Loctite 270 to the abutting surfaces.
4. If necessary, press a new seal into the
housing.
Fit the seal in such a way that the open side
points inwards (the steel outer edge
remains visible). A
The seal must be fitted with the special tool
(A in the diagram) (DAF no. 0694948), as
otherwise the chance of the thermostat
leaking or jamming is too great.
5. Fit the thermostat in the housing and check
for jamming.
6. Fit a new seal to the thermostat housing
and fit it to the header pipe.
7. Check the condition of the coolant pipes
M2 00 060
and pipe clamps. If in doubt, renew them.
pipe clamp.
8. Fit the pipes and tighten the pipe clamps.
Tighten the pipe clamps once more and
check for leaks.
11 11. Check the coolant fluid level once more.

12. Take a test drive and check whether the
cooling system functions properly.
190  200847
COOLING SYSTEM
GS engine Removal and installation, water pump
11.5 REMOVAL AND INSTALLATION, WATER PUMP
8
7
6
5
9
7
6
5
1
2
3 21
10
11
4 20
18
13 19
14
12 15
16
17 M200288
Removal, water pump Legend

1. Drain the coolant. See “Draining and filling 1. Flexible pipe
the cooling system”. 2. Pipe clamp
3. Coolant pump
2. Remove the drain plug on the bottom of the 4. Gasket
timing cover and drain the oil from the 5. Coupling
timing case. 6. Cutting ring
7. Union nut
3. Fit a new seal to the drain plug and re-fit it. 8. Pipe
4. Remove the flexible coolant pipes from the 9. Pipe
pump. 10. O-ring
11. Key
5. Remove the pipes from the coolant duct 12. O-ring
between the pipe and the cylinder block. 13. Gear wheel
14. Flange nut
11
6. Remove the attachment bolts connecting 15. Flange nut
the coolant duct to the cylinder block. 16. Pipe clamp
17. Flexible pipe
7. Remove the pump attachment nuts and 18. Pipe clamp
remove the pump from the timing. 19. Flexible pipe
8. Remove the coolant duct from the pump. 20. Coolant duct
21. Flange bolt
 200847 191
COOLING SYSTEM
Removal and installation, water pump GS engine
Installation, water pump

1. Transfer the drive sprocket to the pump to
be fitted, if applicable.
Lock the drive sprocket and remove the
flange nut.
Use a puller to pull the sprocket from the
shaft.
Fit the sprocket to the pump shaft of the
pump to be fitted.
Apply locking compound to the screw
thread and tighten the flange nut to the
2. Remove any remaining gasket pieces from
the coolant duct and the cylinder block.
Clean the sealing surfaces and check them
for damage.
3. Fit a new O-ring to the pump and grease it
lightly.
4. Fit a new O-ring to the coolant duct and
grease it lightly.
5. Fit the coolant duct to the pump and place
the pump in the timing.
6. Fit a new gasket to the coolant duct and fit
it to the cylinder block.
7. Tighten the pump attachment nuts evenly to
8. Fit the pipes to the coolant duct.
9. Check the condition of the coolant pipes
and pipe clamps. If in doubt, renew them.
pipe clamp.
11
192  200847
COOLING SYSTEM
GS engine Removal and installation, water pump
10. Fit the coolant pipes and tighten the pipe

clamps.
12. Check the lubricating oil level, and as
necessary top up.
Tighten the pipe clamps once more and
check for leaks.
14. Check the coolant fluid level once more.
11
 200847 193
COOLING SYSTEM
Removal and installation, water pump GS engine
11
194  200847
FUEL SYSTEM
12. FUEL SYSTEM

12
 200847 195
FUEL SYSTEM
Fuel system diagram up to engine No. R-11682

1
2 A
3 3
4 9
6
5
10 7
11 B
8
12
13
14
7
17
15 16 C
M2 00 246
12
196  200847
FUEL SYSTEM
Legend
A Injector leak-off pipe connection
B Fuel supply pipe connection
C Fuel return pipe connection
Legend
1. Injector
2. Injector leak off pipe
3. Injector pipe
4. Fuel pump boost control unit
5. Pressure regulator valve
6. Fuel pump
7. Fuel return pipe
8. Fuel supply pipe
9. Governor
10. Manual fuel lift pump
11. Fuel lift pump
12. Hollow screw with strainer
13. Fuel supply pipe
14. Solenoid valve
15. Fuel fine filter
16. Bleed screw
17. Hollow screw with calibrated opening
18. Non-return valve
12
 200847 197
FUEL SYSTEM
Fuel system diagram from engine No. R-11682

1
2
3 3
4 9
18 6
5
7
10 A
11 8
12
13
14
7
17
15 16 B
M2 00 691
12
198  200847
FUEL SYSTEM
Legend
A Injector leak-off pipe connection
B Fuel supply pipe connection
C Fuel return pipe connection
Legend
1. Injector
3. Injector pipe
4. Fuel pump boost control unit
5. Pressure regulator valve
6. Fuel pump
7. Fuel return pipe
8. Fuel supply pipe
9. Governor
10. Manual fuel lift pump
11. Fuel lift pump
12. Hollow screw with strainer
13. Fuel supply pipe
14. Solenoid valve
15. Fuel fine filter
16. Bleed screw
17. Hollow screw with calibrated opening
18. Non-return valve
12
 200847 199
FUEL SYSTEM
Description of fuel system

GS engines are fitted with an in-line injection
pump, of the make R. Bosch, type P 7000.
The pump (6) is equipped with a mechanical
governor (9) and a fuel pump boost control unit
(4). The exhaust control unit controls the fuel
output at low engine speeds depending on the
boost pressure in the inlet manifold.
The fuel pumps of the GS 160 M and the
GS 200 M are fitted with a type RQ governor
and the GS 245 M with an RQV-K governor.
Fuel is drawn from the fuel tank by a fuel lift
pump (11) driven by the injector pump (6).
A gauze filter is fitted in the hollow screw (12)
connecting the suction pipe to the fuel lift
pump (11).
The fuel is fed to the main fuel filter (15) via the
fuel lift pump (11). It subsequently passes via a
solenoid valve (14) to the pump chamber (6).
The solenoid valve (14) opens when the main
switch or the contact is switched on.
An excess of fuel is always fed to the chamber
of the fuel pump. Via a pressure regulator valve
(5), the excess fuel is fed back to the fuel tank,
via the fuel return pipe (7).
Thanks to the fuel regulator valve (5) and the
excess fuel, there is always a constant pressure
in the injector pump chamber.
From the chamber, the fuel is fed to the injection
pump plungers. These plungers force the fuel
under high pressure through the injector pipes
(3) to the injectors (1).
Any fuel leaking internally in the injector (1) is
returned to the fuel tank, via the fuel leak-off
pipe (2).
12
200  200847
FUEL SYSTEM
Up to engine No. R-11682, this fuel is fed back

to the fuel tank via a separate pipe.
From engine No. R-11682, the leak-off pipe (2)
is connected to the fuel return pipe (7). A
non-return valve (18) is fitted in the leak-off pipe
(2) to prevent pressure build-up.
For continuous de-aeration of the main filter (15)
the hollow screw (17) which connects the fuel
return pipe (7) to the filter head, is fitted with a
calibrated hole. Any air in the fuel can escape
via this small hole. A very small quantity of fuel
will also escape through this hole.
A very small quantity of fuel will also escape
through this hole. However, because this hole is
so small and the volume of fuel supplied is
considerable, only a negligible quantity of fuel
leaks into the fuel return pipe.
For priming the fuel system by hand, a
hand-operated fuel lift pump (10) has been
fitted, and a bleed screw (16) has been provided
on the head of the main fuel filter (15).
12
 200847 201
FUEL SYSTEM
Removal and installation, injector lines GS engine
12.2 REMOVAL AND INSTALLATION, INJECTOR LINES
Note:
Always leave the injector pipes fixed together,
as a complete set.
Never remove or shift the clamping brackets
(A in the illustration) which hold the injector A
pipes together.
Removal, injector pipes A
1. Clean the unions and the surrounding area.
2. Remove the unions from the injector pipes
on the fuel pump and injectors.
Remove the injector pipes as a set. M2 00 256
3. Immediately plug the openings.

4. Remove the set in its entirety.
Installation, injector pipes
1. The injector pipes must always be replaced
as a set.
2. Connect the set of injector pipes
stress-free.
3. Tighten the unions to the specified torque.
When tightening the union nut, do not let
the pipe turn as well.
12
202  200847
FUEL SYSTEM
GS engine Inspection, injector opening pressure
12.3 INSPECTION, INJECTOR OPENING PRESSURE
Before the injector test pump is used, it must

first be bled.
1. Remove the pump reservoir filler cap and fill
the reservoir, preferably with test fluid. The
fluid level must be approximately 1 cm
beneath the top rim.
2. Tilt the pump until the line with the word
“BLEED” is in a horizontal position. BLEED
M4059
3. Press the bleed pin (1) and simultaneously

turn the crank (2) clockwise to the stop.
During this procedure, air bubbles will come 1
to the surface in the reservoir. Now turn
back the crank, fill the reservoir again and
repeat the process until no more air bubbles
come to the surface. Now release the bleed A
pin. Continue turning the crank until fuel
escapes on the delivery side.
4. If necessary, fill the fuel reservoir and screw
back the plug.
5. The pump is now ready for use.
Testing the fitted injectors 2 M4058
1. Clean the injector pipe unions and the

surrounding area.
2. Detach the injector pipes as a set from both
the fuel pump and the injectors. They do
not need to be removed.
Plug the openings.
12
 200847 203
FUEL SYSTEM
Inspection, injector opening pressure GS engine
3. Connect the injector pipe (supplied with the

injector test pump) to the injector and to the
test pump. The test pump must be held
approximately horizontally.
4. Loosen the test pump filler plug by half a
turn, so that air can enter the reservoir.
5. Turn the pump crank clockwise to start the
delivery stroke. Watch the fluid level in the
test pump.
6. The injector opening pressure can be
determined very accurately. There is no
harm in repeating the test twice or three M4048
times.
Note:
If the test is repeated too often however, the test
fluid deposited on the piston may cause damage
to the engine when it is started.
7. Refit the injector pipes after the injectors
have been tested. See “Removal and
Installation”.
8. Retighten the cap of the tester reservoir.
Note:
The test pump can also be used to test injectors
outside the engine. The bottom of the test pump
can be clamped in a vice without causing
damage to the test pump.
Adjustment, injectors
To adjust the injectors, see “Disassembly,
assembly and adjustment, injectors”.
12
204  200847
FUEL SYSTEM
GS engine Removal and installation, injectors
12.4 REMOVAL AND INSTALLATION, INJECTORS
Removal, injectors 10
1. Clean the injectors and the surrounding
area.
2. Remove the complete set of injector pipes.
See “Removal and Installation, injector 8
pipes”. 9
3. Remove the injector leak-off pipe from the
injector.
4. Remove the attachment nuts and remove
5-6
7
the injector toggle from the injector.
4
5. Remove the injector from the injector
sleeve with an injector extractor, special 3
tool, DAF no. 0694835.
The use of the special tool is to prevent the
injector sleeve from being pulled out of the 2
cylinder head.
1
M200358
Legend
1. Sealing ring
2. Injector
3. O-ring
4. Injector toggle
5. Ring
6. Nut
7. Injection pipe
9. Sealing rings
10. Hollow screw
12
 200847 205
FUEL SYSTEM
Removal and installation, injectors GS engine
6. Place the injector puller sleeve over the

injector.
7. Turn the threaded spindle (1) of the injector
1
puller as far as possible on to the injector
pipe connection. Slacken the nut (2) 2
sufficiently.
8. By turning the nut (2) of the injector
extractor the injector is pulled out of the 3
injector sleeve.
9. Check whether the copper sealing ring was
extracted along with the injector.
If not, then the sealing ring has still to be
removed from the injector sleeve.
M2 00 152
Note:
When one or more sealing rings remain in
the injector sleeve the injector will be
reinstalled in a higher position. As a result,
instead of spraying into the combustion
chamber of the piston, the fuel will be
sprayed onto the piston ring. This may
seriously damage the piston.
10. Plug the opening of the injector sleeve.
11. Remove the O-ring and the injector.
M2 00 153
12
206  200847
FUEL SYSTEM
GS engine Removal and installation, injectors
Installation, injectors
1. Clean the steel injector sleeve with a
scraper (A in the illustration), special tool
DAF no. 1240074.
Apply grease to the scraper so that any dirt
will stick to the grease.
2. After scraping, clean the injector sleeve to
remove any remaining dirt.
A
3. Clean the injector.
Note: M2 00 257
The injector body (nozzle) must never
be cleaned with copper or steel wire
brush. When cleaning the exterior of the
injector nozzle, do not pass the brush
over the injector nozzles. If this
happens, the nozzle must be replaced.
The use of steel or copper brushes can cause
deformation of the injector nozzles with the
result that too little fuel is injected.
Such deformation cannot be detected by
carrying out an injector test. M2 00 040
Before cleaning the nozzle, cover

the injector drillings. Only clean the
nozzle with the brass hand brush
in the injector cleaning kit
(DAF no. 1329371).
4. Fit a new O-ring to the injector, applying a

little acid-free grease to it.
5. Apply a little acid-free grease to the new
seal and stick it to the injector.
6. Place the injector with the leak-off
connection facing the valve cover into the
injector sleeve.
7. Fit the injector toggle and tighten the
attachment nuts to the specified torque.
8. Fit new seals to the injector leak-off pipes
and fit the injector leak-off pipes.
Installation, injector pipes”.
12
i 400413
 200847 207
FUEL SYSTEM
Disassembly, assembly and adjustment, injector GS engine
12.5 DISASSEMBLY, ASSEMBLY AND ADJUSTMENT, INJECTOR
The injector body (nozzle) must

never be cleaned with copper or
steel wire brush. When cleaning the
exterior of the injector nozzle, do
not pass the brush over the injector
nozzles. If this happens, the nozzle
must be replaced.
The use of steel or copper brushes can cause

deformation of the injector nozzles with the
result that too little fuel is injected.
M2 00 040
Such deformation cannot be detected by
carrying out an injector test.
Before cleaning the nozzle, cover
the injector drillings. Only clean
the nozzle with the brass hand
brush in the injector cleaning kit
(DAF no. 1329371).
i 400413
12
208  200847
FUEL SYSTEM
GS engine Disassembly, assembly and adjustment, injector
Disassembly, injector
1. Clean the injector before disassembly with
a copper-wire hand brush.
2. Clamp the injector holder in a suitable
bracket.
3. Unscrew the injector union (7). 1
4. Remove the injector body with the injector
needle (6). 2
5. Remove the intermediate disc (5), push rod 3

(4), pressure spring (3) and the shim (2) 4
from the injector holder (1).
5
Note:
When disassembling several injectors at the
same time, injector needles and bodies 6
must not be exchanged.
M2 00 266
Cleaning
1. Clean all components thoroughly with a
cleaning fluid (such as diesel oil).
Blow dry the components with compressed
air after cleaning.
2. Clean the injector holes with a cleaning
needle. The diameter of the cleaning needle
must be approx. 0.02 mm less than the
diameter of the injector holes.
M2 00 039
12
 200847 209
FUEL SYSTEM
Inspection, injector test pressure

1. Replace all components that are damaged
or show signs of corrosion.
2. Check the sealing faces (A) of the injector
holder, intermediate and injector. They must
be clean and flat. If the injector nozzle is
replaced, all intermediate discs must also
be replaced.
3. Check the injector union for cracks and
damage to the material. Replace as
necessary.
A
Note:
Never let the sealing face of the injector
needle come into contact with the skin. This
causes corrosion, as a cause of which the
needle may stick.
M2 00 267
4. Check the injector needle (2) for worn areas 1

and a possibly dented seat (1).
5. Check the injector strip (3) for clogged
injector holes. 2
6. Check whether the injector body and
injector needle are discoloured. Replace the
complete unit if discoloration is visible. 3
M2 00 041
7. Check that the injector needle is not

sticking. It must fall back onto its seat under
its own weight.
12 M2 00 042
210  200847
FUEL SYSTEM
GS engine Disassembly, assembly and adjustment, injector
Assembly, injector
1. Place the injector holder (1) in a vice with
protective plates.
2. Immerse all parts in clean diesel fuel or test
oil before assembling.
3. Assemble the shim (2) and the pressure 1
spring (3) in the injector holder.
4. Assemble the push rod (4) in the correct 2
position on the pressure spring. 3
5. Assemble the intermediate disc (5) and the 4
injector body (6) with the injector needle on
the injector holder. 5
Note:
Make sure that the intermediate disc fits 6
well with the pins in the injector body.
Ensure that no diesel fuel is left on the
screw thread, because of the 7
thickness-reducing effect of diesel fuel.
6. Fit the injector and tighten the union nut (7) M2 00 266
to the specified torque. See “Technical
data”.
Testing and setting, injector
Fuel or test fluid discharged by an
injector may penetrate the skin
seriously harming your health.
Note:
In the case of a manual injector test bench,
if a pressure gauge is being used the
pressure may only be increased slowly.
High peak pressures can damage the
pressure gauge.
1. Assemble the injector holder with the
accompanying pressure pipe to the injector
test equipment. For the test, use test oil or
clean diesel fuel.
2. Check the operation of the injector. If a
primer pump is being used, this should be
used a few times with force when the
pressure gauge has been switched off.
12
 200847 211
FUEL SYSTEM
3. Check the opening pressure. The opening

pressure is the pressure at the beginning of
injection. If using a primer pump, connect
the pressure gauge and press the primer
pump slowly downwards until the injector
injects fuel (do not press too powerfully, as
the pressure gauge may be damaged).
4. Adjust the opening pressure to the
maximum specified value.
The opening pressure can be adjusted by
placing thinner or thicker adjusting rings
between the pressure spring and injector
body.
Fitting a 0.01 mm thicker adjusting ring has
the effect of increasing the opening
pressure by approx. 1.5 bar.
5. Check that all injection apertures are open.
6. Compare the injection pattern of each
injector. The injection patterns of the
individual injectors must not deviate too
much from each other. In case of doubt,
compare used injectors with the new ones.
7. Check the injector for leaks by injecting it
10 to 15 times.
Dry the injector.
Set the pressure to the opening pressure
minus 20 bar.
Within approx. 10 seconds, fuel must have
ceased to leak from the nozzle. A moist
nozzle is permitted.
If the injector leaks within 10 seconds, it
must be replaced.
8. Remove the injector from the injector test
equipment once the tests have been carried
out.
9. Close off the pipe connectors and the
injector opening with protective caps.
12
212  200847
FUEL SYSTEM
GS engine Removal and installation, fuel pump coupling
12.6 REMOVAL AND INSTALLATION, FUEL PUMP COUPLING
Removal, fuel pump coupling 1 2 3 4 43 2 5

1. Crank the engine until the cylinder 1 injects.
2. Install the attachment bolts (6) and
(Codenr)
bushes (7). Remove the coupling piece (8).
3. Install the attachment bolts (4) and bushes
(3). Remove the coupling plates (2).
Installation, fuel pump coupling
1. Clean the threaded holes of the attachment
bolts (4 and 6).
6 7 8 7 6
2. Carefully check the coupling plates for I4 00 416
cracks. If one of the plates has been
cracked, the whole set must be replaced.
3. Assemble the set of coupling plates (2). If
the plates are fitted with a positioning hole,
the positioning holes must align.
Note:
Depending on the type of fuel pump, M10
or M12 attachment bolts (4 and 6) are used.
M10 attachment bolts may be used 3 times.
Clean the screw thread thoroughly.
Apply locking compound to the attachment
bolts. See “Technical data”.
Always replace M12 attachment bolts.
Apply locking compound to the attachment
bolts. See “Technical data”.
I4 00 409
12
 200847 213
FUEL SYSTEM
Removal and installation, fuel pump coupling GS engine
4. Install the coupling plates (2) with bushes 1 2 3 4 43 2 5

(3) and attachment bolts (4).
Tighten the attachment bolts (4) to the
(Codenr)
5. Fit the coupling piece (8) with bushes (7)
and attachment bolts (6).
Code number (5) must come to be opposite
the bolt (1) of the clamp coupling.
Tighten the attachment bolts (6) to the
6 7 8 7 6
I4 00 416
6. Crank the engine one revolution and check

that the coupling plates have been fitted
without tension. If there is stress on the
coupling plates, they will be convex or
concave. Inspect using a steel measuring
rod.
i 400408
12
214  200847
FUEL SYSTEM
GS engine Removal and installation, fuel pump
12.7 REMOVAL AND INSTALLATION, FUEL PUMP
14
13 13
3 14 13 18 17
4 14
5 11 12 15
9 16
10
15
1
2 7
14
13
6
19
M200289
When removing fuel pipes, a Legend

quantity of fuel will escape. Collect 1. Nut
this fuel, bearing in mind the risk of 2. Ring
fire. 3. Bolt
4. Ring
Removal, fuel pump 5. Pump seat
1. Crank the engine in the direction of rotation 6. O-ring
to the injection point of cylinder 1. See 7. Dowel
“Inspection and adjustment, injection 8. Fuel pump
timing”. 9. Ring
10. Bolt
2. Disconnect the exhaust control unit pipe. 11. Drive hub
12. Nut
3. Remove the engine stop control(s). 13. Bolt
14. Bush
4. Remove the throttle control. 15. Clutch plates
5. Remove the fuel pipes. Collect any 16. Coupling piece
escaping fuel. Plug the openings. 17. Clamping bolt
18. Coupling
6. Remove the lubricating pipes. Plug the
openings.
19. Strip with threaded ends 12
and installation, injector pipes”.
 200847 215
FUEL SYSTEM
Removal and installation, fuel pump GS engine
8. Remove the attachment bolts with which

the fuel pump is attached to the fuel pump
coupling.
9. Remove the two attachment bolts and
accompanying nuts. Remove the fuel pump
from the pump seat.
10. If necessary remove the drive hub, the
components of the engine stop control and
the components of the throttle control. The
levers that are attached to the fuel pump
must not be removed.
Installation, fuel pump
1. In the case of a new or overhauled fuel
pump, fit the parts to be transferred to the
fuel pump to be fitted.
Tighten the drive hub nut to the specified
torque.
2. Check that the engine flywheel is still at the
injection timing position. If not, crank the
flywheel a number of degrees in the
opposite direction to that of the engine
rotation.
Then crank the flywheel in the direction of
engine rotation until the specified injection
timing is reached.
3. Remove the valve cover and check that the
valves of cylinder 1 are closed. If not, the
engine must be cranked one further
revolution (360°) in the direction of engine
rotation.
Following this check, clean the sealing
surfaces of the valve cover and fit a new
gasket to it before installing it.
4. Clean the contact surfaces of the fuel pump
and pump seat.
5. Slide the connected threaded ends into the
attachment holes on the rear of the fuel
pump.
6. Attach the fuel pump to its seat and tighten
the attachment bolts and nuts crosswise.
7. Rotate the drive hub of the fuel pump in A B
such a way that the cast-on component
number (A in the diagram) is in line with the
12 clamping bolt (B in the diagram) of the
coupling.
8. Clean the contact surfaces of the coupling
plates and coupling.
M2 00 259
216  200847
FUEL SYSTEM
GS engine Removal and installation, fuel pump
9. Attach the fuel pump with the original

sleeves and new attachment bolts to the
fuel pump coupling.
The coupling must be fitted free of stress. If
necessary, slide the coupling onto the prop
shaft. See “Inspection and adjustment,
Tighten the attachment bolts. See
10. Check that the coupling plates are free of
stress.
If there is stress on the coupling plates,
they will be convex or concave. Check
using a steel measuring plate. If the pump
coupling is under stress, the position of the
coupling and/or the fuel pump must be
corrected.
12. Fit new sealing rings to the lubricating oil
pipes and fit them.
13. Fit new sealing rings to the fuel pipes and fit
them.
Note: i 400408
Check whether the fuel return pipe is
connected to the pipe connection that is
fitted with the built-in governor valve.
14. Fit the engine stop control and check its
setting. See “Adjustment, engine stop
control”.
15. Fit the throttle control.
16. Connect the exhaust control unit pipe.
17. Adjust the injection timing. See “Inspection
and adjustment, injection timing”.
18. Start the engine and check the pipe
connections for leaks.
Check the function of the engine stop
control and the throttle control.
Check the idling speed. See “Inspection
and adjustment, idling speed”.
12
 200847 217
FUEL SYSTEM
Inspection and adjustment, injection timing GS engine
12.8 INSPECTION AND ADJUSTMENT, INJECTION TIMING
Inspection, injection timing

1. Remove the plug in the side of the fuel
pump governor housing. Collect the
escaping lubricating oil.
2. Fit the sensor of the special tool
(DAF no. 1310455) as far as possible into
the hole.
3. Connect the earth clamp of the tool to the
fuel pump housing.
M2 00 693
4. Crank the engine slowly in the direction of

rotation until both LEDs (A and B) on the
tool illuminate.
5. Remove the valve cover from cylinders 4, 5,
and 6. Inspect whether the valves of
cylinder 6 overlap.
A B
M2 00 694
6. Inspect on the flywheel whether the pump

timing is correct. See “Technical data”.
7. Remove the special tool from the flange,
fit a new sealing ring to the Allen screw and
fit it.
12 M2 00 248
218  200847
FUEL SYSTEM
GS engine Inspection and adjustment, injection timing
Adjustment, injection timing

1. Remove the valve cover of cylinders 4, 5
and 6.
rotation until the valves of cylinder 6 rock.
3. Crank the engine counter to the direction of
rotation, through several degrees.
4. Crank the engine in the direction of rotation
through the correct number of degrees
(injection timing) before the top dead
centre, see main group “Technical data”.
M2 00 248
5. Remove the clamping bolt (1) from the

clamp (2).
2 1 I400027
6. Remove the Allen screw from the flange on

the governor housing. Some lubricating oil
may still flow out of the opening. Collect the
oil.
7. Fit the sensor of the special tool
(DAF no. 1310455) as far as possible into
the hole.
12
M2 00 693
 200847 219
FUEL SYSTEM
Inspection and adjustment, injection timing GS engine
8. Connect the earth clamp of the tool to the

fuel pump housing.
rotation until both LED’s (A and B) on the
tool light up.
A B
M2 00 694
10. Fit a new clamping bolt (1) in the clamp (2).

Tighten the bolt to the specified torque. See
11. After tightening the clamp, check the
injection timing again.
2 1 I400027
12. Inspect the coupling plates for cracking and

whether they have been fitted stress-free. If
there is stress on the coupling plates, they
will be convex or concave. Inspect using a
steel measuring rod.
13. Remove the special tool from the flange,
fit a new sealing ring to the Allen screw and
fit it.
12
i 400408
220  200847
FUEL SYSTEM
GS engine Removal and installation, fuel filter holder
12.9 REMOVAL AND INSTALLATION, FUEL FILTER HOLDER
Removal, fuel filter holder

1. Remove the hollow screws (1 and 8). 5
Collect any escaping oil. 3
6
2. Remove the hollow screw (9). Hold the 4
adapter (10) up when removing the hollow
2
screw (9) to prevent it from unscrewing.
7
3. Remove the attachment bolts (4). Remove
1
the filter holder (7). 8
Installation, fuel filter holder 9
10
The fuel pipes must be fitted free from
stress. Fitting them under stress or
bending pre-shaped fuel pipes can lead
to fracture or leakage at the point of M2 01 060
connection.
1. Fit the filter holder (7). Hand tighten the
attachment bolts (4).
2. Fit the adapter (10), tightening it to the
appropriate standard torque for hollow
screws. If the adapter (10) has not been
removed, tighten it to the standard torque
for hollow screws.
3. Fit new sealing rings to the fuel pipe (5) and
fit the fuel pipe with the hollow screw (9).
Fit the hollow screw (9) tightening it to the
appropriate standard torque for hollow
screws. Hold up the adapter (10) while
doing this.
4. Fit new sealing rings to the pipes (2, 3 and
6) and fit them free from stress. Tighten the
hollow screws (1 and 8) by hand.
5. Position the filter holder (4) in such a way
that the pipes (2, 3, 5 and 6) are free of
stress. Tighten the filter holder (7)
attachment bolts (4) to the specified torque.
6. Fit the hollow screws (1 and 8) tightening
them to the standard torque for hollow
screws.
7. Bleed the fuel system. Start the engine and
check the pipe connections for fuel leaks.
12
 200847 221
FUEL SYSTEM
Adjustment, idling speed GS engine
12.10 ADJUSTMENT, IDLING SPEED

2. Check that when the accelerator pedal is
released, the cam (3) of the throttle control
lever is in contact with the idling speed
adjusting screw (2).
3. Check the throttle control system for
smooth operation. To do this, operate the 1
throttle control system several times. Check 2
that on each occasion, the throttle control 3
lever comes into contact with the adjusting
screw.
4. Check that engine stop lever is not under
pre-tension. M2 00 258
5. Slacken the locknut (1) of the set screw (2).

Start the engine and adjust the idling speed
by screwing the adjusting screw (2) in or
out.
6. Tighten the locknut (1) of the set screw (2).
7. Stop the engine.
8. Apply sealing wax to the adjusting screw.
9. If fitted, check and as necessary adjust the
setting of the modulator for the automatic
gearbox. Adjust if required.
12
222  200847
FUEL SYSTEM
GS engine Setting the engine stop control
12.11 SETTING THE ENGINE STOP CONTROL
Cable-operated engine stop

1. Set the cable (5) of the engine stop control
so that the engine stop lever (4) is not 1
under preload.
2. Check the operation of the cable-operated 2
engine stop.
3
Electrical engine stop 4

1. Disconnect the operating rod (2) of the
magnet (1) on the engine stop lever (4).
6
2. Screw the stop bolt (3) in a number of 5
turns.
3. Push the engine stop lever (4) to the right,
as far as the internal stop of the fuel pump. M2 00 696
The engine stop lever (4) must not touch
the stop bolt (3) during this process. Legend
4. Push the operating rod (2) against the stop 1. Stop magnet
in the stop magnet (1). 2. Operating rod
3. Stop bolt
5. Set the length of the operating rod (2) and 4. Engine stop lever
fit the operating rod. 5. Cable
6. Air cylinder
6. Push the operating rod (2) against the stop
in the stop magnet (1) again. Unscrew the
stop bolt (3) against the engine stop lever
(4).
7. Release the operating rod (2) and unscrew
the stop bolt (3) another two turns
(extending it).
When the engine stop is operated, the
stroke is stopped by the stop bolt (3).
8. Check that the engine stop lever (4) is not
under preload when not operated.
When not operated, the engine stop lever
should be in contact with the internal stop of
the fuel pump.
9. Check the operation of the engine stop.
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 200847 223
FUEL SYSTEM
Setting the engine stop control GS engine
Note:
If an air cylinder (6) is also fitted on the
engine stop lever (4) for the engine brake,
when this air cylinder is operated, the
stroke should also be stopped by the stop
bolt (3).
Check when not operated, that the engine
stop lever is against the internal stop in the
fuel pump, and not the internal stop in the
air cylinder.
Electrical engine stop without stop bolt
1. Disconnect the operating rod (2) of the
magnet (1) on the engine stop lever (3). 1
2. Push the engine stop lever (3) to the right,
as far as the internal stop of the fuel pump. 2
3. Push the operating rod (2) against the stop 3
in the stop magnet (1).
4. Set the length of the operating rod (2) and
fit the operating rod. 5
4
5. Then extend the operating rod (2) one more
turn. When the engine stop is operated, the
stroke is stopped by the stop magnet. The
stroke must not be stopped by the internal M2 00 270
stop of the fuel pump. This should be
checked.
Legend
6. Check that the engine stop lever (3) is not 1. Stop magnet
under preload when not operated. 2. Operating rod
When not operated, the engine stop lever 3. Engine stop lever
should be in contact with the internal stop of 4. Cable
the fuel pump. 5. Air cylinder
7. Check the operation of the engine stop.

Note:
If an air cylinder (5) is also fitted on the
engine stop lever (3) for the engine brake,
when this air cylinder is operated, the
stroke should also be stopped by the stop
magnet (1).
Check when not operated, that the engine
stop lever is against the internal stop in the
fuel pump, and not the internal stop in the
air cylinder.
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224  200847
FUEL SYSTEM
GS engine Setting the engine stop control
Pneumatic engine stop

1. Screw the self-locking nut for the
attachment of the air cylinder onto the shaft
until the space between the two washers is
23  0.5 mm (dimension A in the diagram).
A
2. Check that the air cylinder is not jammed. If
necessary, unscrew the self-locking nut
slightly.
3. Screw in the adjusting screw (1) entirely.
4. Push the engine stop lever (2) to the right, M2 00 252
as far as the internal stop of the fuel pump.
5. Unscrew the adjusting screw (1) until it
touches the engine stop lever (2), still
pushed fully to the right. 1
6. Then unscrew the adjusting screw (1) two
more full turns.
If the air cylinder (3) is operated, the stroke
must be stopped by the adjusting screw (1)
and not by the internal stop of the fuel
pump. This should be checked. 2
7. Lock the adjusting screw 1 in this position
with the locknut, and seal the locknut with
sealing paint.
3
M2 00 265
8. Check when not operated, that the engine
stop lever (2) is against the internal stop of Legend
the fuel pump, and not the internal stop of 1. Adjusting bolt
the air cylinder (3). 2. Engine stop lever
3. Air cylinder
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 200847 225
FUEL SYSTEM
Disassembly and assembly, fuel lift pump GS engine
12.12 DISASSEMBLY AND ASSEMBLY, FUEL LIFT PUMP
Note: 1
Hold the fuel lift pump by clamping only its 2
flange in a bench vice. Never clamp the housing 3
of the fuel lift pump, since this would deform the 4
housing. 5
Disassembly, fuel lift pump
1. Remove the primer pump (10). 6 10
7
2. Remove the pipe connection with the 8
built-in pressure valve (13). 9
8 11 12
3. Remove the tappet (1) from the tappet
guide (3).
4. Remove the tappet guide (3) from the pump
housing. The spring tension from the
plunger spring (9) is applied on the pushrod
guide (3). 15 17
14 16
5. Subsequently remove the plunger (5), the 13
non-return valve (7), the front spring M2 00 063
retainer (8), the plunger spring (9) and the

rear spring retainer (8). Legend
1. Pushrod
6. Remove the O-ring (2) from the pushrod 2. O-ring
guide (3). 3. Pushrod guide
4. O-ring
7. If necessary, remove the sealing ring (6) 5. Plunger
from the plunger (5). 6. Sealing ring
Cleaning and inspecting 7. Non-return valve
1. Thoroughly clean the components using a 8. Spring retainer
cleaning liquid. Blow dry the components 9. Plunger spring
with compressed air after cleaning. 10. Primer pump
11. Sealing ring
2. Inspect the guide faces of the pushrod (1) 12. Pipe connection
and the pushrod guide (3) for wear. 13. Pipe connection with built-in pressure valve
14. O-ring
3. Inspect the sealing ring (6) of the valve (7) 15. Pump housing
for damage. 16. Strainer
17. Hollow screw
4. Check that the primer pump (10) is working
properly.
5. Check the plunger (5) for damage and
wear.
6. Check the running surface of the plunger
(5) in the housing (15) for damage and
12
wear.
7. Check the movement and play of the
plunger (5) in the housing (15).
226  200847
FUEL SYSTEM
GS engine Disassembly and assembly, fuel lift pump
Assembly, fuel lift pump

1. Immerse all parts in clean diesel fuel or test
oil before assembling.
2. Fit a new O-ring (2) on the pushrod
guide (3).
3. Fit a new O-ring (4) on the pushrod
guide (3).
4. Replace the sealing ring (6) in the
plunger (5).
5. Fit a new non-return valve (7) in the
plunger (5).
6. Fit spring retainers (8) to the plunger
spring (9) and fit it to the plunger (5).
Note:
Use only an original plunger spring (9), as
otherwise the lift pressure could be too high
or too low.
7. Fit the plunger assembly (5) to the pushrod
guide (3).
8. Fit the pushrod guide (3) with the
plunger (5) in the pump housing.
9. Fit the pushrod (1) to the pushrod guide (3).
10. Fit a new O-ring (14) to the new pipe
connection with built-in pressure valve (13)
and fit the pipe connection.
11. Fit a new sealing ring (11) to the primer
pump (10) and fit the primer pump.
Testing the pump capacity (non-fitted pump)
1. Connect two pipes to the fuel lift pump.
2. Hang the pipe on the suction side of the
pump in a container of clean diesel fuel.
3. Hold the pump approx. 1 metre above the
container of diesel fuel and pump diesel fuel
up from the container with the primer pump.
The fuel pump should now draw fuel via the
flexible pipe, and pass it on to the empty
tray.
4. Push the pushrod (1) several times into the
pump housing, and check whether the
plunger (5) moves smoothly, and produces
an output.
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 200847 227
FUEL SYSTEM
Fuel pump drive GS engine
12.13 FUEL PUMP DRIVE
14
11
12
15
13
10
9
8
5
4
2
3
1
M200290
Removal, fuel pump drive Legend

1. Crank the engine in the direction of rotation 1. Attachment bolt
to the injection point of cylinder 1. See 2. Ring
“Inspection and adjustment, injection 3. Drive sprocket
timing”. 4. Circlip
5. Front bearing
2. Remove the timing cover. See “Removal 6. Key
and installation, timing cover”. 7. Shaft
8. Rear bearing
3. Remove the rev counter from the timing 9. O-ring
case. 10. Flange bolt
4. Remove the air compressor. See “Removal 11. Bolt
and installation, air compressor”. 12. Housing
13. Oil seal
12 5. Remove the attachment bolt from the
sprocket.
14. Clamping bolt
15. Clamp coupling
6. Use a puller to pull the sprocket from the

shaft. Support the puller on the axle.
228  200847
FUEL SYSTEM
GS engine Fuel pump drive
7. Remove the coupling with the coupling

plates from the pump coupling.
8. Remove the attachment bolts and remove
the housing from the timing.
Installation, pump drive
1. Clean the components and check them for
damage.
Clean the thread of the sprocket attachment
bolt.
2. Fit a new O-ring to the housing and
grease it.
3. Install the housing in the timing case.
Tighten the attachment bolts to the
4. Fit the gear wheel onto the shaft. A B
If the clamp coupling is not detached, make
sure that the clamp coupling and drive hub
are in line with the fuel pump when fitting
the sprocket. The clamping bolt (B) of the
clamp coupling must also be in line with the
cast-on component number (A) on the drive
hub.
5. Apply Loctite 243 to the sprocket
attachment bolt and tighten it to the
6. Fit a new sealing ring to the rev counter and M2 00 259
install the rev counter.
7. Fit the coupling with the coupling plates.
See “Removal and installation, fuel pump”.
8. Fit the timing cover. See “Removal and
installation, timing cover”.
9. Fit the air compressor. See “Removal and
installation, air compressor”.
10. Check the injection timing and adjust it if
necessary. See “Inspection and adjustment,
12
 200847 229
FUEL SYSTEM
Fuel pump drive GS engine
Disassembly and assembly

1. Remove the housing from the timing case.
2. Remove the clamp coupling from the shaft.
3. Remove the circlip.
4. Force the shaft with the front bearing out of
the housing from the fuel pump side.
5. Remove the key and force the front bearing
from the shaft.
6. Remove the seal from the housing.
7. Pull the rear bearing from the housing using
an internal puller.
damage and wear.
9. Force both bearings into the shaft.
10. Oil the exterior of the bearings lightly and
force the shaft with bearings into the
housing.
11. Fit a new circlip. Check that the circlip is
flush around the entire circumference.
12. Apply a little grease to the inside of the new
seal.
Force the seal with the open side facing
inwards (thicker side remains visible) with a
suitable stamp carefully into the housing.
13. Fit the key.
14. Fit a new clamping bolt to the clamp
coupling and fit it.
The clamping bolt should only be
hand-tightened.
The clamping bolt may only be used once.
12
230  200847
FUEL SYSTEM
GS engine Exhaust brake
12.14 EXHAUST BRAKE
Operation
The exhaust brake consists of an exhaust brake
butterfly valve (1) fitted in the floor, an air
cylinder (2), connected to the fuel pump, and an
air cylinder (3), connected to the exhaust brake 1
housing in the exhaust pipe.
If exhaust brake butterfly valve (1) is operated,
compressed air is fed to air cylinder (2). The air
cylinder sets the fuel pump to the “stop”
position. At the same time, compressed air
flows to the air cylinder (3). This cylinder shuts
the exhaust brake butterfly valve. The exhaust 2
pipe is then almost entirely closed off.
Due to the shutting off of the exhaust pipe, the
engine will start working as a compressor. The
necessary energy is drawn from the driving
vehicle, which produces a braking effect.
If the exhaust brake butterfly valve is released,
the valve bleeds the pipe to the two cylinders.
The springs fitted in the cylinders push the
3
pistons fully back to their starting position. This
re-opens the exhaust brake butterfly valve and
provides the fuel pump with output once more.
The higher the engine speed, the greater the
braking action of the engine brake.
M2 00 054
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 200847 231
FUEL SYSTEM
Exhaust brake GS engine
Installation, exhaust brake

During installation, remember the following
points.
- Before fitting the exhaust brake butterfly
valve, check the sealing faces, the smooth
operation of the valve, and the valve play in
the housing.
- Screw the self-locking nut for the
attachment of the air cylinders onto the
shaft until the space between the two
washers is 23  0.5 mm (dimension A in
the diagram).
Check that the air cylinder is not jammed. If A
necessary, unscrew the self-locking nut
slightly.
- Check that the stop bolt of the air cylinder
on the fuel pump is correctly set. See
“Setting the engine stop control”. M2 00 252
- On the exhaust brake butterfly valve shaft a

mark has been made (see the arrow in the
diagram) which indicates the setting of the
butterfly valve. If the mark is parallel to the
engine brake housing (see the diagram) the
butterfly valve is opened.
- Run the engine to operating temperature.
Check the operation of the exhaust brake
according to the mark on the shaft.
Check that the exhaust brake butterfly valve
does not drag.
- Check the connections for leaks.
M2 00 253
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232  200847
LUBRICATION SYSTEM
13. LUBRICATION SYSTEM

13
 200847 233
LUBRICATION SYSTEM
A B
M2 00 303
13 M2 00 300
234  200847
LUBRICATION SYSTEM
D
E
I
F
M2 00 304
Legend
A Discharge from cylinder block
B Supply from internal oil channel
C Supply to internal oil channel
D Supply from internal oil channel to filter
E Supply to internal oil channel
F Supply from internal oil channel
G To timing case
H To timing case
I To oil sump
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 200847 235
LUBRICATION SYSTEM
Description of lubricating oil system

GS engines are equipped with a double
lubricating oil pump.
This lubricating oil pump is driven by the
crankshaft sprocket via an intermediate
sprocket.
The rear lubricating oil pump draws oil from the
cylinder block and feeds it to the oil sump.
The front lubricating oil pump draws oil from the
oil sump and feeds it to the lubricating oil heat
exchanger.
The lubricating oil heat exchanger, connected to
the engine cooling system, will heat oil in a
“cold” engine and cool oil in a “warm” engine.
The entire output of the lubricating oil pump is
always present in the lubricating oil heat
exchanger. If the oil pressure in the heat
exchanger becomes too high, a short-circuit
valve is opened which connects the lubricating
oil supply and discharge ducts with each other.
This short-circuit valve is in the oil sump.
After the heat exchanger, the oil is fed to the
lubricating oil filter. In the duct to the lubricating
oil filter there is a pressure control valve. As the
output of the lubricating oil pump is dependent
on the engine speed, the output would become
so great at higher engine speeds that the
pressure in the lubrication system would
become too high.
If the lubricating oil reaches the set pressure of
the pressure limiting valve before the pressure
limiting valve, part of the oil will be returned
directly to the oil sump via the pressure limiting
valve.
The oil is cleaned in the disposable oil filter. A
pressure-relief valve is fitted internally. This filter
opens if the pressure in the filter becomes too
high as a result of contamination or cold oil. The
oil then passes through the filter unfiltered.
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236  200847
LUBRICATION SYSTEM
From the filter housing, an internal oil duct goes

to the main oil duct in the cylinder block.
From the main oil channel, lubricating oil is
supplied to the crankshaft main bearings and via
an oil channel in the crankshaft also to the
bottom connecting-rod bearings.
Piston-cooling oil sprayers are also connected to
the main oil duct.
The oil sprayers spray oil directly onto the base
of the pistons. This cools the pistons and
supplies the cylinder liners and the upper
connecting-rod bearing with oil.
At the top of the connecting rod is a bore,
through which the oil can reach the upper
connecting rod bearing.
From the main oil passage, the oil goes via an
oil passage and the front camshaft bearing to
the bored camshaft. From the oil passage in the
camshaft, oil is supplied to the camshaft
bearings and cams.
The rocker shafts are supplied with oil through
two oil ducts from the camshaft.
The rockers are in turn supplied with oil from
these bored rocker shafts.
The valve stems are lubricated by oil from the
hole at the top of the bored rockers.
From the oil duct in the front main bearing, an oil
duct leads to the hollow hub of the intermediate
gear wheel.
Oil comes through the bored hub to the
intermediate sprocket and runs off, thus
supplying the timing gears with oil.
Another oil duct is connected from the oil duct to
the front main bearing, through which oil is fed
to the intermediate sprocket hub from the
lubricating oil pump. This supplies oil to the
intermediate sprocket hub, intermediate
sprocket and the drive sprocket of the
13
 200847 237
LUBRICATION SYSTEM
The turbocharger oil supply pipe is connected at

the bottom of the engine to an internal oil duct
from the cylinder block.
The oil discharge pipe from the turbocharger is
connected to the suction pipe from the
lubricating oil pump which draws oil from the
cylinder block.
On the top of the engine there is an oil supply
pipe that supplies the air compressor and timing
with oil.
The oil is returned to the oil sump via a pipe on
the rear of the air compressor.
An oil supply pipe runs from the top of the
lubricating oil filter to the fuel pump.
The oil runs through a pipe from the fuel pump
back to the oil sump.
On the top of the lubricating oil filter, the sensor
for the oil pressure gauge and the oil pressure
warning lamp switch can also be found.
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238  200847
LUBRICATION SYSTEM
GS engine Draining lubricating oil following engine damage
13.2 DRAINING LUBRICATING OIL FOLLOWING ENGINE DAMAGE
If there have been problems with the engine, as

a cause of which the lubricating oil has become
(partially) contaminated, it should be drained in
the manner shown below.
The lubricating oil can be contaminated by water
or by metal particles as a result of excessive
wear to one component.
Draining the lubricating oil
1. Remove the drain plug from the oil sump
and the plug at the bottom of the engine, if
fitted. Let all the oil leak out of the sump.
2. Remove the plug from the bottom of the
timing case and let the oil leak out of the
timing case.
3. Remove the lubricating oil heat exchanger.
Let the oil leak out and clean the internal oil
section.
4. If the oil suction pipe does not have a drain
plug on the bottom of the engine, this oil
pipe must be removed. Let all the oil leak
out of the pipe.
5. Remove the lubricating oil filter.
6. Fit the removed components and plugs.
7. Fit a new lubricating oil filter.
8. Fill the engine with new oil of the specified
grade. The amount will be greater than for a
normal oil change.
engine stop, so that the engine cannot
drag. Crank the engine using the starter
motor until the pressure warning lamp is
extinguished. The engine can now be
started.
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 200847 239
LUBRICATION SYSTEM
External parts of the lubricating oil system GS engine
13.3 EXTERNAL PARTS OF THE LUBRICATING OIL SYSTEM
Diagram of parts
24
23
1 20
2
21 25
23 26
3 22
13 19
4 11 12
14 27
5
6 42
41
7 28
15 43
16
18 17 40
41
44
98 29
29 33
30
33
10 31
32
39
34 35 36
37
38 M200291
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240  200847
LUBRICATION SYSTEM
GS engine External parts of the lubricating oil system
Legend
1. Oil level gauge
2. O-ring
3. Dipstick holder
4. Union nut
5. Cutting ring
6. Coupling
7. Sealing ring
8. Gasket
9. Oil level sensor
10. Bolt
11. Flexible pipe
12. Housing
13. Bolt
14. Spring washer
15. Gasket
16. Bolt
17. Spring washer
18. Oil separator
19. Bolt
20. Distribution block
21. Sealing ring
22. Oil pressure sensor
23. Sealing ring
24. Oil pressure switch
25. Oil filter housing
26. O-ring
27. Adapter
28. Oil filter
29. O-ring
30. Heat exchanger
31. Ring
32. Bolt
33. O-ring
34. Bolt
35. Pipe connection
36. O-ring
37. Pipe
38. Bolt
39. O-ring
40. Flexible pipe
41. Pipe clamp
42. Bolt
43. Pipe
44. Pipe connection
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 200847 241
LUBRICATION SYSTEM
Removal, lubricating oil filter housing

1. Clean the filter housing and the surrounding
area.
2. Remove the lubricating oil pipe to the fuel
pump. Plug the openings.
3. Remove the oil pressure gauge and oil
pressure switch wiring.
4. Depending on the reason why the filter
housing has to be removed, remove the oil
filter element, the oil senser and the oil
pressure switch.
5. Remove the attachment bolts and detach
the filter housing. Note that some more
lubricating oil will escape on detaching.
Plug the openings.
Installation, lubricating oil filter housing
1. If necessary, replace the adapter with which
the oil filter is connected to the housing.
Apply Loctite 270 to the new adapter and
attach the new adapter.
2. Inspect the sealing faces for damage.
3. Replace the O-rings and the pipe sealing
rings.
4. Installation of the oil filter housing is the
reverse of the removal procedure.
5. Stick the O-rings to the housing with some
grease.
6. Check the oil level, and top up as
necessary.
7. Start the engine and check for leaks.
Removal, lubricating oil heat exchanger
1. Drain the coolant. See “Draining and filling
the cooling system”.
2. Remove the flexible coolant pipe and the
coolant pipe of the heat exchanger.
3. Remove the attachment bolts and remove
the heat exchanger from the cylinder block.
Note: when doing this, some coolant and
lubricating oil will escape.
13
242  200847
LUBRICATION SYSTEM
GS engine External parts of the lubricating oil system
Pressure testing the lubricating oil heat 1240477

exchanger
1. Clean the heat exchanger.
1240476
2. Remove both pipe connections and fit
sealing plates in their place (special tool
DAF no. 1240476 and DAF no. 1240477).
3. Connect an air pipe with reducing valve to
the air connection of the sealing plate.
Adjust the air pressure to 2.5 bar max.
4. Immerse the heat exchanger in a container
M200185
of water at a minimum temperature of 50_C
5. If the heat exchanger is leaking, it must be
replaced in its entirety as it cannot be
replaced.
In this case, the lubricating oil must be
changed and the lubricating oil filter
replaced.
Installation, lubricating oil heat exchanger
1. Clean the contact surfaces and check for
damage.
2. Fit new O-rings to the pipe connections and
fit it to the heat exchanger.
3. Replace the O-rings on the top of the heat
exchanger and grease them.
4. Fit the heat exchanger to the cylinder block.
5. Connect the coolant pipes.
Replace the O-ring on one of the pipes.
Check the condition of the flexible coolant
pipe and pipe clamps on the other. If in
doubt, renew them.
pipe clamp.
7. Check the oil level, and top up as
necessary.
8. Start the engine and check for leaks.
13
 200847 243
LUBRICATION SYSTEM
Measuring the lubricating oil pressure

If there are problems with the lubricating oil
pressure, the lubricating oil pressure must first
be measured with a reliable pressure gauge.
1. Bring the engine to operating temperature.
2. Remove the oil pressure switch from the
A
filter head of the lubricating oil filter.
3. On the oil pressure switch connection,
fit the pressure gauge (A), (special tool
DAF no. 0535551).
4. Start the engine and measure the
lubricating oil pressure at maximum engine M200292
speed and at idling speed.
Compare the data with the specified
readings.
The oil pressure regulating valve, fitted in
the oil sump, cannot be adjusted.
5. Remove the pressure gauge and fit a new
sealing ring to the oil pressure sensor
before installing it.
Removal and installation, dipstick
1. Remove the dipstick from the holder and
remove the attachment from the dipstick
holder.
2. Only fit a new original dipstick holder and/or
coupling.
3. Before fitting a new dipstick holder and/or
coupling, compare them with the removed
components, so that it can be seen that the
components are identical. This will prevent
incorrect readings of the oil level.
13
244  200847
LUBRICATION SYSTEM
GS engine Removal and installation, lubricating oil sump
13.4 REMOVAL AND INSTALLATION, LUBRICATING OIL SUMP
13
 200847 245
LUBRICATION SYSTEM
Removal and installation, lubricating oil sump GS engine
5
6
7
2 3
14
15
19 14
16
10
11
8 12 17
9 13
20 18
21
22 23
24
M200297
13
246  200847
LUBRICATION SYSTEM
Legend
1. Lubricating oil sump
2. Bolt
3. Ring
4. Flange bolt
5. Bolt
6. Ring
7. Gasket
8. Gasket
9. Elbow
10. Spring washer
11. Bolt
12. Sealing ring
13. Oil drain plug
14. O-ring
15. Pipe
16. Gasket
17. Flange
18. Sealing ring
19. Stud
20. Ring
21. Spring washer
22. Nut
23. Pipe connection
24. Hollow screw
13
 200847 247
LUBRICATION SYSTEM
Removal, lubricating oil sump

batteries.
2. Clean the lubricating oil sump and the
surrounding area.
3. Drain the engine oil.
4. Remove the dipstick and dipstick holder.
5. Remove the oil filler pipe.
6. Remove the oil level sensor
7. Remove the alternator. See “Removal and
installation, alternator”.
8. Remove the starter motor. See “Removal
and installation, starter motor”.
9. Remove the lubricating oil filter.
10. Remove the fuel filter.
11. Remove the lubricating oil return pipe from
the air compressor.
12. Remove the cable harness attachments
from the lubricating oil sump.
13. Remove the hollow screw from the
lubricating oil return pipe on the bottom of
the lubricating oil sump.
14. Remove the flange from the lubricating oil
return pipe. When the flange is removed, an
internal oil pipe will also come free. If not,
remove this pipe as well.
lubricating oil sump and remove the
lubricating oil sump from the engine.
16. Remove the used gasket. Thoroughly clean
the contact surfaces of both the lubricating
oil sump and the cylinder block.
17. Remove any gasket remnants from both the
flange of the lubricating oil return pipe and
the lubricating oil sump.
13
248  200847
LUBRICATION SYSTEM
Installation, lubricating oil sump

1. Check the sealing surfaces of both the oil
sump and cylinder block.
2. Check that the timing case gasket does not
protrude at the bottom. If necessary,
remove the protruding part.
3. Fit a new O-ring in the pump. Grease or oil
the O-ring.
4. Apply a layer of transparent, oil-resistant
silicon mastic to the bottom of the sealing 1
surfaces of the cylinder block/timing case
and the cylinder block/flywheel housing.
See the arrows in the diagram.
5. Fit a new gasket to the oil sump and fit the
oil sump.
6. Fit attachment bolts to the corners of the
lubricating oil sump and hand-tighten them.
7. Fit a new O-ring to the flange. Grease or oil
the O-ring. 2
8. Force the internal oil pipe into the
9. Fit a new gasket to the flange and fit the
flange to the bottom of the lubricating oil
sump. Hand-tighten the attachment bolts.
10. Fit the remaining oil sump attachment bolts
and tighten three bolts in the middle of the
sump on both sides. Work from the middle 3
to the front and rear. M2 00 629
Tighten the bolts to the specified torque.
11. Tighten the flange attachment bolts of the
lubricating oil return pipe.
12. Fit new sealing rings and O-rings to the
components and fit them in the reverse
order of removal. See the relevant sections.
13
 200847 249
LUBRICATION SYSTEM
13. Fit the cable harnesses in the original

manner so that there is no chance of
chafing.
14. Fill the engine with the specified engine oil.
15. Bleed the fuel system.
for leaks.
13
250  200847
LUBRICATION SYSTEM
GS engine Internal components of the lubricating oil system
13.5 INTERNAL COMPONENTS OF THE LUBRICATING OIL SYSTEM
13
 200847 251
LUBRICATION SYSTEM
Internal components of the lubricating oil system GS engine
Diagram of parts
1 7
8 5 6
2
4
10
9 3
9
16
11
15
24
30
13 25
14 17
28 26
12
27 15
18
28
31
29
21
22 19
23
20
M200293
13
252  200847
LUBRICATION SYSTEM
Legend
1. O-ring
2. Supply pipe
3. Attachment bolt (intermediate gear wheel)
4. Attachment bolt
6. Bearing bush
7. Hub
8. Lubricating oil pump
9. O-ring
10. Supply pipe
11. Suction grid
12. Strainer
13. Ring
14. Bolt
15. O-ring
16. Delivery pipe
17. Bolt
18. Load sensing valve housing
19. Bolt
20. Split pin
21. Ball
22. Spring
23. Ring
24. Sealing plug
25. Sealing ring
26. Spring
27. Valve
28. O-ring
29. Delivery pipe
30. Flange
31. Bolt
13
 200847 253
LUBRICATION SYSTEM
Removal and installation, lubricating oil

pipes
sump”.
2. Remove the respective pipe(s).
3. Replace the O-rings and apply a little
grease to them.
4. Clean the thread of all the attachment bolts
and apply Loctite 243 to them.
5. Fit the pipes free of stress and tighten the
attachment bolts to the specified tightening
torque.
6. Fit the lubricating oil sump. See “Removal
and installation, lubricating oil sump”.
governor
sump”.
2. Remove the housing from the cylinder
block.
3. Force the ring on the rear of the oil
governor and remove the split pin from the
housing. Carefully release the spring.
4. Remove the spring and the ball from the
housing.
5. Clean the components.
6. Check the ball, its seat in the housing and
the spring. Compare this spring with a new
spring if necessary.
7. Fit the ball, the spring and the ring.
8. Coil the spring and fit a new split pin.
9. Fit the housing to the cylinder block.
Apply Loctite 243 to the attachment bolts
and fit them, tightening to the prescribed
torque.
10. Fit new O-rings to the pipes and fit them.
Apply a little grease to the O-rings prior to
fitting.
Apply Loctite 243 to the attachment bolts
and fit them, tightening to the prescribed
13 torque.
254  200847
LUBRICATION SYSTEM
Removal, heat exchanger

sump”.
2. Remove the sealing plug on the short-circuit
valve housing. Remember that the sealing
plug is spring-loaded.
3. Remove the spring and the ball from the
housing.
4. Clean the components.
5. Check the valve, its seat in the housing and
the spring. Compare this spring with a new
spring if necessary.
6. Fit the valve and the spring in the housing.
7. Fit a new sealing ring to the sealing plug.
Coil the spring and fit the sealing plug.
Tighten the sealing plug to the specified
torque.
pump
sump”.
2. Remove the pipes from the lubricating oil
pump.
3. Remove the three pump attachment bolts
on the bearing cap.
4. Using a plastic hammer, tap against the
rear of the pump, so that the hub of the
intermediate sprocket comes free from the
bearing cap.
Detach the pump from the bearing cap.
5. Using a plastic hammer, tap the hub of the
intermediate sprocket free from the
attachment plate.
6. Before fitting the pump, check the following:
- the intermediate sprocket bearing bush
for wear and/or damage replace if
necessary
- the intermediate sprocket hub for wear
and/or damage and whether the oil
bores are open
- whether the oil duct to the intermediate
sprocket is open
- whether the oil pump operates
smoothly and that it is not getting stuck
anywhere.
13
 200847 255
LUBRICATION SYSTEM
7. Apply oil to the intermediate sprocket

bearing bush and fit the intermediate
sprocket to the hub. Fit the intermediate
sprocket to the hub so that the component
number on the pump faces away from the
pump (and is still visible).
8. Using a plastic hammer, tap the hub and
sprocket into the attachment plate. Check
that the pump still moves smoothly.
9. Place the pump on the bearing cap and fit
the intermediate sprocket attachment bolt
without locking compound and hand-tighten
it.
If the attachment bolt were coated with
locking compound, there would be a chance
that the oil duct would become clogged.
10. Apply Loctite 243 to the two remaining
attachment bolts and fit them, tightening
them to the specified torque.
11. Tighten the intermediate sprocket bolt to the
specified torque and check the play. Make
sure that it is not jammed.
12. Check the gear backlash.
13. Fit new O-rings to the pipes. Grease the
O-rings and fit the pipes. Apply Loctite 243
to the various attachment bolts and fit them,
tightening them to the specified torque.
14. Fit the oil sump. See “Removal and
installation, oil sump”.
engine stop or apply the exhaust brake, so
that the engine cannot drag. Crank the
engine using the starter motor until the
pressure warning lamp is extinguished. The
engine can now be started.
13
256  200847
LUBRICATION SYSTEM
GS engine Disassembly and assembly, lubricating oil pump
13.6 DISASSEMBLY AND ASSEMBLY, LUBRICATING OIL PUMP
10
13
11 12
6
5
4
3
2
1 9
7 8 19
18
17
16
1
15
14
M200294
Legend
1. Bearing bush
2. Pump housing (front section)
3. Pump sprocket with shaft
4. Key
6. Attachment plate
7. Attachment bolt
8. Attachment bolt, intermediate gear wheel
9. Ring
10. Drive sprocket
12. Bearing bush
13. Hub
14. Bolt
15. Rear cover
17. Pump sprocket (loose)
18. Pump housing (rear section)
19. Dowel
13
 200847 257
LUBRICATION SYSTEM
Disassembly and assembly, lubricating oil pump GS engine
Disassembly and assembly

1. Dismantle the pump and remove the
intermediate sprocket. See “Internal
components of the lubricating oil system”.
2. Support the drive sprocket and force the
pump assembly from the drive sprocket.
3. Remove the bolts and remove the rear
cover from the pump housing.
4. Mark the position of the two rear pump
sprockets in relation to each other.
5. Remove the shaft with the pump sprocket
from the rear pump housing.
6. Remove the attachment plate from the front
pump housing. Remove the driven shaft
with the pump sprocket from the front pump
housing.
7. Remove the loose pump sprocket in the
rear pump housing from the shaft.
If the loose pump sprocket is jammed on
the shaft, it must be removed as follows:
- Tap the shaft on which the sprocket is
jammed at the rear of the pump with a
plastic hammer 5 mm onto the
sprocket. On no account tap the shaft
any more than 5 mm, as otherwise the
sprocket key will hit the pump housing.
- From the front of the pump, press the
shaft back as far as possible.
- Place a 5-mm thick block in the space
created between the sprocket and the
pump housing.
- Then tap the shaft another 5 mm into
the sprocket.
- Again, push the shaft as far back as
possible.
- Remove the 5-mm thick block and
place a 10-mm thick block between the
sprocket and the pump housing.
- Repeat the above procedure until the
pump sprocket has been removed from
the shaft.
8. Remove the key from the shaft and remove
the shaft/sprocket assembly from the front
pump housing.
9. Remove the rear pump housing from the
front pump housing.
13
258  200847
LUBRICATION SYSTEM
GS engine Disassembly and assembly, lubricating oil pump

damage.
11. Gear wheels must be replaced as a set for
each pump section.
12. If the bearing bushes are replaced, they
must be installed in the housing with a
suitable driving tool so that they do not
protrude from one of the two sides of the
housing. See the arrows in the diagram.
13. Ream the bearing bushes to the specified
dimension.
14. Fit the parts in reverse order of removal.
- Apply ample oil to the components
before fitting.
- Fit the shaft/sprocket assembly with
the shorter side facing the pump
housing.
- Note the marks when fitting the loose
sprocket in the rear pump housing. M2 00 260
Note:
The small round recesses on the side of the
sprockets must face each other. See the
diagram.
They must never be on the same side of the
sprockets. This could endanger the lubrication
of the gear wheels.
15. Apply Loctite 243 to the bolts and fit them,
tightening to the specified torque.
16. Check that the pump operates smoothly
and is not getting stuck anywhere.
17. Force the drive sprocket to the pump shaft
so that the component number on the pump
faces away from the pump (and is still
visible). Force the sprocket as far onto the
shaft that the end of the shaft is level with
the sprocket.
Check the oil pump can still operate
smoothly and is not getting stuck anywhere. M2 00 084
13
 200847 259
LUBRICATION SYSTEM
Disassembly and assembly, lubricating oil pump GS engine
18. If the bearing bush of the intermediate

sprocket must be replaced, the new bearing
bush must be fitted with a well-fitting driving
tool from the front of the intermediate
sprocket to a depth of 1.5  0.3 mm
(dimension A in the diagram) into the A
intermediate sprocket.
M2 00 330
13
260  200847
ELECTRICAL INSTALLATION
GS engine Diagrams
14. ELECTRICAL INSTALLATION

14.1 DIAGRAMS
Note:
These diagrams refer to the installation as fitted
by DAF.
However, not every engine is equipped with all
the components listed in the diagrams.
It is also possible that the installation and/or
wiring has been entirely or partially fitted by the
vehicle manufacturer. Under such
circumstances, the electrical installation may
differ from these diagrams.
Wiring diagram, 1292039/01 version
A B C D E F G H J K
B+
15 7,5A 30A
25A 2A
G014 + + +
- - -
W G G G
2A A502 A506
B039
B041
B+ B+
30 50
G014 N
E112
3 3
G G M F011 P
F502
F503
= F501
B038
B040
B- D+ B- D+
31 B010
44 65 78 57 75 77 36 69 22 54
79
B-
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
L M N O P
B+
15 1A 1A B103
timer
F013 unit F013
D596
1 2 3 4 5 6
B189
48 52 2 51 41 47 43 39 16 70 4 71 32 64 68 18 20 13 4
B-
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
M2 00 245
Legend J Oil pressure sensor

A Battery K Warning lamp, preglowing
B Alternator L Oil top-up installation
C Alternator M Engine stop magnet
D Starter motor N Engine oil level switch
E Glow relay O Fuel valve
F Glow plug P Afterglowing timer
G Engine speed sensor
H Coolant temperature sensor
14
 200847 261
ELECTRICAL INSTALLATION
Diagrams GS engine
Wiring diagram, 1292040/00 version
A502 A506 B010 G014 E112 B038 B039 B040 B041 F501 F013 F502 F503
G G N
~
3 ~
3
B+ D+ B- B+ D+ B- 31 30 50 2 86 85 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
4018
4018
1000
1020
9999
1000
1022
9999
1000
4002
4014
9999
1202
1000
4014
4019
4014
4015
4015
9999
4014
9999
3003
3005
9999
3041
3000
3012
3015
9999
50 56 52 50 79 52 50 60 14 52 77 50 10 72 10 20 18 54 10 26 24 54 64 65 39 74 67 70 75 32
17 52
23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
F011 B103 B189 G532 G525 G524 H400

P
1 2 1 2 1 3 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
3014
4001
9999
4049
4050
9999
1000
9999
9999
1020
9999
4002
4049
3014
3003
3005
3000
4050
3012
4001
4019
3041
3015
1202
1022
62 71 52 61 68 52 1 3 11 39 21 2 52 9 47 41 29 30 34 47 36 44 15 33 38 12 5
4 6 45 48 27
8 59
13
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
M2 00 244
Legend
A502 Alternator
A506 Alternator
B103 Starter motor
B189 Fuel valve
G014 Glow relay
E112 Fuse, glow indicator lamp
B038 Glow plug
B039 Glow plug
B040 Glow plug
B041 Glow plug
F011 Engine oil pressure switch
F013 Engine oil level switch
F501 Engine speed sensor
F503 Engine oil pressure sensor
G524 Central earthing point, glow plugs
G525 Central earthing point, flywheel housing
G532 Connection point after contact
H400 24-pin connector
14
262  200847
English
Printed in the Netherlands DW03217403

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Component manual

Important alterations relating to these workshop

1 sensibly and safely, the mechanic must have the

- If necessary, support the component

1 heavy components. Attach the component

1.2 THREADED CONNECTIONS

The following applies to all threaded

1 tighten/retorque in accordance with the

TABLE OF STANDARD TIGHTENING TORQUES, DAF STANDARD 00804-203

Clamping flange bolt Standard flange bolt

TIGHTENING TORQUES FOR DIPPED THREADED CONNECTIONS (Nm)

Property class 8.8 bolt/nut 8 Property class 12.9 bolt/nut 12

Clamping flange bolt

Tightening torques for banjo bolts

Overview of tightening torques - applies to:

Property class 10.9

The bolt stem length L is the length of the bolt

1 not be re-used, unless a suitable new nut can

1.3 LOCKING AND SEALING METHODS

Certain cleaning agents have a

OVERVIEW OF LOCKING COMPOUNDS

OVERVIEW OF SEALING COMPOUNDS

Application, locking compound

1.4 ENGINE DATA

A compression measurement serves to rapidly

2.2 TRACTIVE PROBLEMS

There can be many reasons why a vehicle does

Check the exhaust system

Measuring the inlet underpressure

2 Measuring the exhaust back pressure

2.3 ENGINE OIL CONSUMPTION TEST

11. If applicable, determine how much oil has

marked out on the left and the total number

2.4 PRESSURE TESTING THE FUEL SYSTEM

If an engine is difficult to start after it has not

9. Shut cock (5), and pump up the pressure in

2.5 FAULT-FINDING TABLES

2 Insufficient discharge pressure of the fuel lift

FAULT: ENGINE DELIVERS LESS THAN MAXIMUM POWER

FAULT: ENGINE STARTS AND STOPS

FAULT: ENGINE WILL NOT IDLE

FAULT: ENGINE PRODUCES EXCESSIVE NOISE

FAULT: ENGINE POWER DECREASES

FAULT: RISING AND FALLING TURBOCHARGER SOUNDS

FAULT: ENGINE EMITS BLACK SMOKE

FAULT: ENGINE EMITS BLUE SMOKE

Air leak between inlet manifold and cylinder

ENGINE COOLING SYSTEM

FAULT: ENGINE TEMPERATURE INCREASES

ENGINE LUBRICATION SYSTEM

FAULT: ENGINE OIL PRESSURE TOO LOW

FAULT: TURBOCHARGER OIL LEAK

FAULT: EXHAUST VALVE BROKEN

FAULT: EXHAUST VALVE DISK CRACKED

FAULT: EXHAUST VALVE DISK BURNT

FAULT FINDING TABLE, TIMING GEAR

FAULT: NOISE IN THE TIMING GEAR CASE

FAULT FINDING TABLE, FLYWHEEL AND FLYWHEEL HOUSING

FAULT: ENGINE VIBRATES EXCESSIVELY

FAULT FINDING TABLE, CYLINDER BLOCK AND DRIVING GEAR