DAF LF45, LF55 Series. Manual — part 286

©

200416

1

Contents

BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

4

2

2 BE Engine fuel system

CONTENTS

Page

Date

1.

SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416
1.1

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416

2.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416
2.1

Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416

2.2

System description, ECS-DC3 fuel system . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . 200416

2.3

Overview drawing, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 . . . . . 200416

2.4

Overview drawing, fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 . . . . . 200416

2.5

Overview drawing, fuel system, cylinder head. . . . . . . . . . . . . . . . . . . . . . 2-9 . . . . . 200416

3.

DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416
3.1

High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416

3.2

Fuel pump control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200416

3.3

Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200416

3.4

Fuel rail pressure-limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . 200416

3.5

Fuel return overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . 200416

4.

INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416
4.1

Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416

4.2

Checking fuel lift pump pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200416

4.3

Inspection, internal fuel leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . 200416

5.

REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416
5.1

Removal and installation, injector pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416

5.2

Removal and installation, fuel supply pipe . . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . 200416

5.3

Removal and installation, injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 . . . . . 200416

5.4

Removal and installation, fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 . . . . 200416

5.5

Removal and installation, fuel rail pressure-limiting valve . . . . . . . . . . . . . 5-14 . . . . 200416

5.6

Removal and installation, high-pressure pump . . . . . . . . . . . . . . . . . . . . . 5-15 . . . . 200416

5.7

Removal and installation, fuel fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 . . . . 200416

5.8

Removal and installation, fuel prefilter/water separator. . . . . . . . . . . . . . . 5-18 . . . . 200416

5.9

Removal and installation, fuel level element . . . . . . . . . . . . . . . . . . . . . . . 5-19 . . . . 200416

5.10 Removal and installation, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 . . . . 200416
5.11 Removal and installation, electronic unit cooling plate . . . . . . . . . . . . . . . 5-21 . . . . 200416
5.12 Removal and installation, fuel return overflow valve . . . . . . . . . . . . . . . . . 5-23 . . . . 200416
5.13 Removal and installation, low-pressure fuel pipes. . . . . . . . . . . . . . . . . . . 5-24 . . . . 200416

6.

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200416
6.1

Cleaning injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200416

BE ENGINE FUEL SYSTEM

2

©

200416

Contents

2

ΛΦ45/55 series

4

©

200416

1-1

Safety instructions

BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

4

2

1. SAFETY INSTRUCTIONS

1.1 SAFETY INSTRUCTIONS

Fuel

Diesel fuel is an extremely

flammable liquid, and must not be

exposed to naked flames or come

into contact with hot surfaces. The

diesel fuel fumes remaining in an

empty fuel tank form an extremely

explosive mixture.

When fuel system components are being

removed, some fuel will escape.

To keep this spillage to a minimum, unscrew the

tank cap to release any overpressure.

Any spilled fuel must be collected, bearing in

mind the risk of fire.

Exhaust gases
Do not run the engine in an enclosed or

unventilated area.

Make sure exhaust fumes are properly extracted.

Exhaust gases contain carbon

monoxide.

Carbon monoxide is a deadly

colourless and odourless gas,

which, when inhaled, deprives the

body of oxygen, leading to

asphyxiation. Serious carbon

monoxide poisoning may result in

brain damage or death.

Moving parts
Remain at a safe distance from rotating and/or

moving components.

Various fluids
Various oils and lubricants used on the vehicle

may constitute a health hazard.

This also applies to engine coolant, windscreen

washer fluid, refrigerant in air-conditioning

systems, battery acid and clutch fluid.

So avoid inhaling and direct contact.

Electrical short-circuit
Always disconnect the battery's earth connection

during repair or maintenance operations for

which the electric power supply is not required.

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BE ENGINE FUEL SYSTEM

1-2

©

200416

Safety instructions

2

ΛΦ45/55 series

4