DAF LF45, LF55 Series. Manual - part 318

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CE ENGINE FUEL SYSTEM

ΛΦ45/55 series

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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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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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Removal and installation

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ΛΦ45/55 series

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10. Fit the attachment bolts (1) in the injector 

clamping bracket (2) to secure the injector. 

Tighten the attachment bolts alternately to a 

torque of 2 Nm.

Note:

Pay special attention to the tightening of the 

attachment bolts (1). The tightening must be 

carried out alternately; ensure that the 

injector clamping bracket (2) is not fitted at 

an angle.

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

ring of the fuel supply pipe, the screw thread 

of the nut and the contact surface of the nut 

with the fuel supply pipe.

12. Check the bore of the fuel supply pipe for 

foreign matter and damage. Also check 

whether the supply bore in the injector is 

correctly positioned for the bore, because it 

is possible to mount the injector turned 

through 180

, so that the fuel supply port is 

on the other side.

13. Fit the fuel supply pipe. Press the fuel supply 

pipe as far as possible into the bore, with the 

ball pointing upwards. Ensure that the O-ring 

is not damaged in this process.

Note:

The fuel supply pipe has one or two positioning 

balls. The fuel supply pipe can only be installed 

with the ball(s) on top, as the bore in the cylinder 

head has a groove (1) at the top. 

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14. Fit the nut (1). Tighten the nut to a torque of 

15 Nm.

15. Tighten the injector attachment bolts to the 

specified torque; see "Technical data".

16. Tighten the fuel supply pipe nut to the 

specified torque; see "Technical data".

17. Connect the injector wiring. Tighten the 

attachment bolts (1) to the specified torque. 

See "Technical data".

18. Fit the exhaust valve rockers.

19. Adjust the clearance of the exhaust valves.

20. Fit the valve cover.

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

22. Fit the injector pipe.

23. Fit the fuel return overflow valve to the 

cylinder head. For the specified tightening 

torque, see "Technical data".

24. Connect the return pipe to this valve.

25. Start the engine to bleed the high-pressure 

section of the fuel system and inspect the 

fuel system for leaks.

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