DAF CF65, CF75, CF85 Series . Manual — part 424

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200416

5-5

Removal and installation

CE ENGINE FUEL SYSTEM

ΧΦ65/75/85 series

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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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CE ENGINE FUEL SYSTEM

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200416

Removal and installation

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ΧΦ65/75/85 series

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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

CE ENGINE FUEL SYSTEM

ΧΦ65/75/85 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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200416

Removal and installation

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ΧΦ65/75/85 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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