DAF LF45, LF55 Series. Manual — part 294

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200416

5-5

Removal and installation

BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

4

2

5.

Install the nut (1) and tighten it to the

specified torque. See "Technical data".

6.

If the fuel rail was removed, re-fit it.

7.

Fit the injector pipes.

8.

Start the engine to bleed the high-pressure

section of the fuel system and inspect the

fuel system for leaks.

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5-6

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200416

Removal and installation

2

ΛΦ45/55 series

4

5.3 REMOVAL AND INSTALLATION, INJECTOR

When removing an injector, fuel will

escape. Collect the fuel and avoid

the risk of fire.

Dirt in the fuel system can lead to

significant damage to parts of the

system. All open connections must

therefore be sealed.

Removing the injector
1.

Remove the fuel return overflow valve to let

the return bore in the cylinder head empty to

the fullest possible extent. Collect the

escaping fuel.

2.

Remove the injector pipe.

3.

Remove the fuel supply pipe.

Note:

-

If an injector is removed without the fuel

supply pipe having first been removed,

serious damage can ensue.

-

If the injectors are removed, they must

be removed together with the fuel

supply pipes.

4.

Remove the valve cover.

5.

Remove the exhaust valve rockers.

6.

Remove the injector wiring (1).

7.

Remove the two attachment bolts (2) from

the injector clamping bracket (3).

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200416

5-7

Removal and installation

BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

4

2

8.

Fit the injector puller (1). This is the special

tool (DAF no. 0192496). Carefully pull the

injector vertically out of the cylinder head.

9.

Remove the copper washer from the injector

hole and plug the hole immediately.

Installing the injector
The following guidelines must be adhered to:

-

If the injector is defective, both the injector

and the fuel supply pipe must be replaced.

-

If the fuel supply pipe is defective and in

addition the sealing surface with the injector

is damaged, both the injector and the fuel

supply pipe must be replaced.

-

If the fuel supply pipe is defective and the

sealing surface with the injector is not

damaged, the fuel supply pipe must be

replaced but the injector can be reused.

1.

Clean the injector if it has already been used.

See "Cleaning".

2.

Clean the injector hole in the cylinder head.

The metal surface of the hole must not be

touched.

3.

Check the fuel supply pipe for damage and

signs of leakage.

Leakage in the fuel supply pipe can be

recognised by erosion tracks (lines) on the

nose of the supply pipe. If necessary or if in

doubt, replace the fuel supply pipe.

4.

Fit a new O-ring on the fuel supply pipe.

5.

Check that the injector fuel connection is not

leaking.

Leakage in the injector fuel connection can

be recognised by erosion tracks (lines) in the

socket of the fuel connection . If necessary or

if in doubt, replace the injector.

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Removal and installation

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ΛΦ45/55 series

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6.

Fit a new copper washer on the injector.

Measure the length of the injector nozzle (A)

without fitted washer in order to determine

which washer must be used. Fit the correct

washer; see "Technical data".

Note:

A wrong washer will cause an incorrect

alignment between the fuel supply pipe and

the injector. This will lead to internal fuel

leaks that will in turn cause loss of power

and/or engine damage.

7.

Fit a new O-ring on the injector.

Note:

This O-ring should prevent returning fuel (1.2

- 2.0 bar) flowing via the top of the cylinder

head to the oil sump and thinning the oil.

8.

Apply a thin layer of clean engine oil to the O-

ring of the injector.

9.

Fit the injector with the copper washer. First

press the injector into the hole as far as

possible until a higher resistance can clearly

be felt.

Note:

The injector must only be fitted one way. If it

is fitted incorrectly, serious damage can

ensue. The rounded side (2) of the injector

clamping bracket (1) must point to the inlet

side of the engine (A).

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