DAF CF65, CF75, CF85 Series . Manual — part 414

©

200416

1

Contents

CE ENGINE FUEL SYSTEM

ΧΦ65/75/85 series

4

2

2 CE 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 . . . . . . . . . . . . . . . . . . . . . . . . 2-7 . . . . . 200416

2.3

Overview drawing, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 . . . . . 200416

2.4

Overview drawing, fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 . . . . 200416

2.5

Overview drawing, fuel system, cylinder head. . . . . . . . . . . . . . . . . . . . . . 2-11 . . . . 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

Inspecting fuel level element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416

4.2

Venting the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200416

4.3

Checking fuel lift pump pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . 200416

4.4

Inspection, internal fuel leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 . . . . . 200416

4.5

Checking the fuel prefilter/water separator . . . . . . . . . . . . . . . . . . . . . . . . 4-12 . . . . 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 filter element . . . . 5-18 . . . . 200416

5.9

Removal and installation, fuel level element . . . . . . . . . . . . . . . . . . . . . . . 5-20 . . . . 200416

5.10 Removal and installation, fuel tank filter . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 . . . . 200416
5.11 Removal and installation, electronic unit cooling plate . . . . . . . . . . . . . . . 5-23 . . . . 200416
5.12 Removal and installation, fuel return overflow valve . . . . . . . . . . . . . . . . . 5-25 . . . . 200416
5.13 Removal and installation, low-pressure fuel pipes. . . . . . . . . . . . . . . . . . . 5-26 . . . . 200416

6.

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

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

CE ENGINE FUEL SYSTEM

2

©

200416

Contents

2

ΧΦ65/75/85 series

4

©

200416

1-1

Safety instructions

CE ENGINE FUEL SYSTEM

ΧΦ65/75/85 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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CE ENGINE FUEL SYSTEM

1-2

©

200416

Safety instructions

2

ΧΦ65/75/85 series

4