DAF LF45, LF55 Service manual

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Page 1

ΛΦ45/55 series

STRUCTURE

Structure

TECHNICAL DATA

DIAGNOSTICS

BE ENGINE FUEL SYSTEM

BE ENGINE INLET/EXHAUST SYSTEM

ENGINE BRAKE, BE ENGINE

CE ENGINE FUEL SYSTEM

CE ENGINE INLET/EXHAUST SYSTEM

ENGINE BRAKE, CE ENGINE

200416 DW23259402

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TECHNICAL DATA

ΛΦ45/55 series

0 Technical data

CONTENTS

Page Date

1. ENGINE, GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416

1.2 BE engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200416

1.3 CE engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200416

2. BE ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416

2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200416

3. CE ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416

3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200416

4. BE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416

4.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200416

5. CE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416

5.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200416

Contents

200416 1

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TECHNICAL DATA

Contents

ΛΦ45/55 series

200416

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TECHNICAL DATA

ΛΦ45/55 series

Engine, general

1. ENGINE, GENERAL

1.1 GENERAL

BE/CE engine

Cold engine A cold engine is an engine which, having reached

operating temperature, has been allowed to cool down for at least six hours.

Warm engine A warm engine is an engine which, having reached

operating temperature, has not been at a standstill for more than thirty minutes.

Direction of rotation of the engine The direction of rotation of the engine is clockwise,

as seen from the vibration damper end.

First cylinder of the engine The first cylinder of the engine is the cylinder at the

vibration damper end of the engine.

Left-hand and right-hand side of the engine The left-hand side of the engine is the side where the

air compressor and electronic unit are mounted. The right-hand side of the engine is the side where the turbocharger and oil filter are mounted.

Engine identification Engine number

The engine number is located in two places on the engine:

- stamped into the engine block, top of the oil cooler

- on the type plate, fitted on the timing gear case or on the flywheel housing (depending on the production date)

Engine type

The type number CE162C indicates: C engine family B = 3.92 ltr.

C = 5.88 ltr.

E engine version E = electronic timing 162 engine output in kilowatt (kW) C Euro emissions C = Euro 3

200416 1-1

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TECHNICAL DATA

Engine, general

1.2 BE ENGINE, GENERAL

Engine types

Coding BE 99 C

BE 110 C BE 123 C

General specifications

Environmental standard Euro 3 (C) Number of cylinders 4 cylinders in line Valves 4 valves per cylinder Bore x stroke 102 x 120 mm Cubic capacity 3.9 litres

Compression ratio

BE 99 C 17.0 : 1 BE 110 C 17.0 : 1 BE 123 C 17.3 : 1

Fuel injection direct injection Injection sequence 1-3-4-2 Air inlet system Turbocharger intercooling Engine management system ECS-DC3 Cooling fluid Weight approx. 400 kg

ΛΦ45/55 series

Engine speeds, BE engine

Engine type Idling

BE 99 C 600 - 800 Approx. 2500

BE 110 C 600 - 800 Approx. 2500

BE 123 C 600 - 800 Approx. 2500

Maximum no-load rpm

rpm

1-2

200416

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TECHNICAL DATA

ΛΦ45/55 series

1.3 CE ENGINE, GENERAL

Engine types

Coding CE 136 C

CE 162 C CE 184 C

General specifications

Environmental standard Euro 3 (C) Number of cylinders 6 cylinders in line Valves 4 valves per cylinder Bore x stroke 102 x 120 mm Cubic capacity 5.9 litres Compression ratio 17,3 : 1 Fuel injection direct injection Injection sequence 1-5-3-6-2-4 Air inlet system Turbocharger intercooling Engine management system ECS-DC3 Cooling fluid Weight approx. 500 kg

Engine speeds, CE engine

Engine, general

Engine type Idling

rpm

CE 136 C 600 - 800 approx. 2500

CE 162 C 600 - 800 approx. 2500

CE 184 C 600 - 800 approx. 2500

Maximum no-load rpm

200416 1-3

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TECHNICAL DATA

Engine, general

ΛΦ45/55 series

1-4

200416

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TECHNICAL DATA

ΛΦ45/55 series

2. BE ENGINE FUEL SYSTEM

2.1 GENERAL

Fuel level element

Angular displacement 70

Fuel fine filter

Maximum pressure drop across fuel fine filter 2.0 bar

Lift pump

Fuel lift pump pressure in front of fine filter (with engine at idling speed) 5 - 13 bar

Fuel lift pump pressure behind fine filter (with engine at idling speed) 3 - 11 bar Pressure relief valve opening pressure 11 bar Maximum underpressure on suction side of fuel lift pump 0.5 bar

High-pressure pump

Pump pressure (dependent on the operating mode of the engine and the electronic calibration) 300 - 1400 bar

BE Engine fuel system

Fuel rail

Fuel rail pressure (dependent on the operating mode of the engine and the electronic calibration) 300 - 1400 bar

Fuel rail pressure-limiting valve

Opening pressure 1650 bar

Injector

Number of holes in injector 8 Resistance of magnet coil 0,15 - 0,5 

Injector washer

Nozzle length (distance A)

21.5 ≥ 0.2 mm 1.5 mm

23.0 ≥ 0.2 mm 3.0 mm

Washer thickness

i400693

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TECHNICAL DATA

BE Engine fuel system

Fuel return overflow valve

Fuel return overflow valve opening pressure 1.2 - 2.0 bar

Fuel return pipe

Maximum return pipe pressure build-up 0.2 bar

Return fuel measurement

Maximum quantity of return fuel at idling speed 120 ml/min. Minimum permitted time for filling a measuring

beaker to a volume of 360 ml 3 min.

ΛΦ45/55 series

2-2

200416

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TECHNICAL DATA

ΛΦ45/55 series

2.2 TIGHTENING TORQUES

The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques. When attachment bolts and nuts are replaced, it is important that - unless stated otherwise - these bolts and nuts are of exactly the same length and property class as those removed.

Electronic unit cooling plate

Attachment bolts holding the electronic unit to the cooling plate 10 Nm

Attachment bolts holding the cooling plate to the engine block 24 Nm VOSS quick-release coupling fittings 18 Nm

Low-pressure fuel pipes

Banjo bolts 24 Nm VOSS quick-release coupling fittings 24 Nm Fuel return overflow valve in cylinder head 24 Nm

BE Engine fuel system

High-pressure pump

Attachment nuts holding the high-pressure pump to the timing gear case 25 Nm

High-pressure fuel pipe

High-pressure pipe union nut 22 Nm

Fuel rail

Attachment bolts 24 Nm Pressure-limiting valve 100 Nm

Injector pipes

Injector pipe union nuts 22 Nm

Fuel supply pipe

Fuel supply pipe nut 50 Nm

Injectors

Injector clamping bracket attachment bolts 10 Nm Injector electrical connection 1.5 Nm

200416 2-3

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TECHNICAL DATA

BE Engine fuel system

ΛΦ45/55 series

2-4

200416

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TECHNICAL DATA

ΛΦ45/55 series

3. CE ENGINE FUEL SYSTEM

3.1 GENERAL

Fuel level element

Angular displacement 70

Fuel fine filter

Maximum pressure drop across fuel fine filter 2.0 bar

Lift pump

Fuel lift pump pressure in front of fine filter (with engine at idling speed) 5 - 13 bar

Fuel lift pump pressure behind fine filter (with engine at idling speed) 3 - 11 bar Pressure relief valve opening pressure 11 bar Maximum underpressure on suction side of fuel lift pump 0.5 bar

High-pressure pump

Pump pressure (dependent on the operating mode of the engine and the electronic calibration) 300 - 1400 bar

CE Engine fuel system

Fuel rail

Fuel rail pressure (dependent on the operating mode of the engine and the electronic calibration) 300 - 1400 bar

Fuel rail pressure-limiting valve

Opening pressure 1650 bar

Injector

Number of holes in injector 8 Resistance of magnet coil 0,15 - 0,5 

Injector washer

Nozzle length (distance A)

21.5 ≥ 0.2 mm 1.5 mm

23.0 ≥ 0.2 mm 3.0 mm

Washer thickness

i400693

200416 3-1

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TECHNICAL DATA

CE Engine fuel system

Fuel return overflow valve

Fuel return overflow valve opening pressure 1.2 - 2.0 bar

Fuel return pipe

Maximum return pipe pressure build-up 0.2 bar

Return fuel measurement

Maximum quantity of return fuel at idling speed 180 ml/min. Time for filling a measuring beaker to a volume of

360 ml > 2 min.

ΛΦ45/55 series

3-2

200416

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TECHNICAL DATA

ΛΦ45/55 series

3.2 TIGHTENING TORQUES

Electronic unit cooling plate

Attachment bolts holding the electronic unit to the cooling plate 10 Nm

Attachment bolts holding the cooling plate to the engine block 24 Nm VOSS quick-release coupling fittings 18 Nm

Low-pressure fuel pipes

Banjo bolts 24 Nm VOSS quick-release coupling fittings 24 Nm Fuel return overflow valve in cylinder head 24 Nm

CE Engine fuel system

High-pressure pump

Attachment nuts holding the high-pressure pump to the timing gear case 25 Nm

High-pressure fuel pipe

High-pressure pipe union nut 22 Nm

Fuel rail

Attachment bolts 24 Nm Pressure-limiting valve 100 Nm

Injector pipes

Injector pipe union nuts 22 Nm

Fuel supply pipe

Fuel supply pipe nut 50 Nm

Injectors

Injector clamping bracket attachment bolts 10 Nm Injector electrical connection 1.5 Nm

200416 3-3

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TECHNICAL DATA

CE Engine fuel system

ΛΦ45/55 series

3-4

200416

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TECHNICAL DATA

ΛΦ45/55 series

BE Engine inlet/exhaust system

4. BE ENGINE INLET/EXHAUST SYSTEM

4.1 GENERAL

Turbocharger

BE 99 C Holset HX 27 W BE 110 C Holset HX 27 W BE 123 C Holset HX 27 W

Minimum actuating pressure of wastegate capsule under which the control rod will move 2.0 bar Axial bearing play of compressor shaft 0.057 - 0.103 mm Radial bearing play of compressor shaft 0.39 - 0.67 mm

Rejection standards for cracking

1. Cracks in the connector flange must not reach as far as the attachment holes.

2. Cracks in the connector flange must not reach from the channels as far as the exterior.

3. Cracks in the connector flange may not be longer than 15 mm.

4. Cracks in the connector flange must not be less than 6 mm apart.

5. There must be no cracks in the housing.

1 2

3 4

Exhaust gas back pressure

At full-load engine speed 100 mbar Maximum back pressure during engine brake application 4.3 bar

Inlet underpressure

At full-load engine speed (clean air filter) 25 mbar At full-load engine speed (clogged air filter) 62 mbar

Glow element

Resistance value 180 - 220 m

i400784

200416 4-1

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TECHNICAL DATA

BE Engine inlet/exhaust system

4.2 TIGHTENING TORQUES

Turbocharger

Attachment nuts, exhaust manifold flange/turbocharger 43 Nm

Oil discharge pipe attachment bolts 23 Nm Oil supply pipe union 28 Nm Turbocharger V-clamp 10 Nm

(1) Fasten with Copaslip

ΛΦ45/55 series

(1)

Intake manifold

Glow element attachment bolts 14 Nm

Air cooler

Hose clamps 7 Nm

4-2

200416

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TECHNICAL DATA

ΛΦ45/55 series

CE Engine inlet/exhaust system

5. CE ENGINE INLET/EXHAUST SYSTEM

5.1 GENERAL

Turbocharger

CE 136 C Holset HY 35 W CE 162 C Holset HY 35 W CE 184 C Holset HX 35 W

Minimum actuating pressure of wastegate capsule under which the control rod will move 2.0 bar Axial bearing play of compressor shaft 0.038 - 0.093 mm Radial bearing play of compressor shaft 0.329 - 0.501 mm

Rejection standards for cracking

1. Cracks in the connector flange must not reach as far as the attachment holes.

2. Cracks in the connector flange must not reach from the channels as far as the exterior.

3. Cracks in the connector flange may not be longer than 15 mm.

4. Cracks in the connector flange must not be less than 6 mm apart.

5. There must be no cracks in the housing.

1 2

3 4

Exhaust gas back pressure

At full-load engine speed 100 mbar Maximum back pressure during engine brake application 4.3 bar

Inlet underpressure

At full-load engine speed (clean air filter) 25 mbar At full-load engine speed (clogged air filter) 62 mbar

Glow element

Resistance value 180 - 220 m

i400784

200416 5-1

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TECHNICAL DATA

CE Engine inlet/exhaust system

5.2 TIGHTENING TORQUES

Turbocharger

Attachment nuts, exhaust manifold flange/turbocharger 43 Nm

Oil discharge pipe attachment bolts 23 Nm Oil supply pipe union 28 Nm Turbocharger V-clamp 10 Nm

(1) Fasten with Copaslip

ΛΦ45/55 series

(1)

Glow element

Attachment bolts 14 Nm

Air cooler

Hose clamps 7 Nm

5-2

200416

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DIAGNOSTICS

ΛΦ45/55 series

1 Diagnostics

CONTENTS

Page Date

1. TRACTIVE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416

1.1 Tractive problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416

2. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416

2.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200416

3. INLET/EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416

3.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200416

4. ENGINE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416

4.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200416

Contents

200416 1

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DIAGNOSTICS

Contents

ΛΦ45/55 series

200416

Page 23

DIAGNOSTICS

ΛΦ45/55 series

1. TRACTIVE PROBLEMS

1.1 TRACTIVE PROBLEMS

The first test that has to be carried out when investigating tractive problems is the acceleration test.

Tractive problems

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DIAGNOSTICS

Tractive problems

ΛΦ45/55 series

1-2

200416

Page 25

DIAGNOSTICS

ΛΦ45/55 series

2. FUEL SYSTEM

2.1 INTRODUCTION

If there is a fault in the system, it is usually detected by the electronic unit in the form of a fault code. This fault code can be read out using DAVIE. The fault-finding table contains possible causes of symptoms not detected by the electronic unit.

Fuel system

200416 2-1

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DIAGNOSTICS

Fuel system

ΛΦ45/55 series

2.2 FAULT-FINDING TABLE

SYMPTOM: ENGINE CAN BE STARTED, BUT DOES NOT RUN

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

Air in fuel system Check for drawing in of air:

- via the suction pipe

Fuel fine filter/coarse filter clogged Replace fuel fine filter and clean the system

No fuel supply/high-pressure pump or fuel lift pump defective; no delivery

SYMPTOM: ENGINE STALLS AND RUNS AGAIN AFTER RE-STARTING

Possible cause Remedy

Check:

- the fuel level

- the rail pressure

- the pipes for blockage and leaks

- the fuel lift pump

- the high-pressure pump

Air in fuel system Check for drawing in of air:

- via the suction pipe

SYMPTOM: ENGINE STARTS POORLY

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

Air in fuel system Check for drawing in of air:

- via the suction pipe

Fuel fine filter/coarse filter clogged Replace fuel fine filter and clean the system

Injector(s) mechanically defective or clogged Replace the injectors

High-pressure pump or fuel lift pump delivery too low

Internal fuel leak between fuel supply pipe(s) and injector(s)

SYMPTOM: ENGINE RUNS AT (INCREASED) IDLING SPEED AND DOES NOT RESPOND TO AC-

CELERATOR PEDAL

Check:

- the high-pressure pump

- the fuel lift pump

Check the quantity of return fuel

Possible cause Remedy

Mechanical defect of accelerator pedal sensor Check:

- mechanical connection of sensor/accelerator

- accelerator pedal sensor

2-2

pedal

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DIAGNOSTICS

ΛΦ45/55 series

SYMPTOM: DIESEL KNOCK DURING ACCELERATION

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

Air in fuel system Check for drawing in of air:

- via the suction pipe

Injector defective Check the injectors

SYMPTOM: IRREGULAR RUNNING OF ENGINE

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

Air in fuel system Check for drawing in of air:

- via the suction pipe

Fuel fine filter/coarse filter clogged Replace fuel fine filter and clean the system

Injector(s) mechanically defective or clogged Replace the injectors

Fuel system

Injector defective Check the injectors

High-pressure pump or fuel lift pump delivery too low

SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

Fuel fine filter/coarse filter clogged Replace fuel fine filter and clean the system

Injector(s) mechanically defective or clogged Replace the injectors

Mechanical defect of accelerator pedal sensor Check:

High-pressure pump or fuel lift pump delivery too low

SYMPTOM: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED

Check:

- the high-pressure pump

- the fuel lift pump

and fill fuel tank with fuel

- mechanical connection of sensor/accelerator pedal

- accelerator pedal sensor

Check:

- the high-pressure pump

- the fuel lift pump

Possible cause Remedy

Fuel fine filter/coarse filter partially clogged Replace fuel fine filter and clean the system

Injector(s) mechanically defective or clogged Replace the injectors

Air leak in inlet system Pressure-test the inlet system

200416 2-3

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DIAGNOSTICS

Fuel system

SYMPTOM: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED

Possible cause Remedy

High-pressure pump or fuel lift pump delivery too low

Fault in electrical components/wiring of:

- connectors

SYMPTOM: ENGINE SLUGGISH WHEN ACCELERATING OR UNDER HIGH LOAD

Possible cause Remedy

Internal fuel leak between fuel supply pipe(s) and injector(s)

High-pressure pump or fuel lift pump delivery too low

SYMPTOM: WHITE/BLUE SMOKE IS EMITTED

ΛΦ45/55 series

Check:

- the high-pressure pump

- the fuel lift pump

Check the electrical system

Check the quantity of return fuel

Check:

- the high-pressure pump

- the fuel lift pump

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

Air in fuel system Check for drawing in of air:

- via the suction pipe

Fuel fine filter/coarse filter clogged Replace fuel fine filter and clean the system

Injector(s) mechanically defective or clogged Replace the injectors

High-pressure pump or fuel lift pump delivery too low

Fault in electrical components/wiring of:

- connectors

SYMPTOM: BLACK SMOKE IS EMITTED

Possible cause Remedy

Injector(s) mechanically defective or clogged Replace the injectors

SYMPTOM: ENGINE OVERHEATED

Possible cause Remedy

Check:

- the high-pressure pump

- the fuel lift pump

Check the electrical system

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

2-4

200416

Page 29

DIAGNOSTICS

ΛΦ45/55 series

SYMPTOM: FUEL CONSUMPTION TOO HIGH

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

Fuel fine filter/coarse filter clogged Replace fuel fine filter and clean the system

Injector(s) mechanically defective or clogged Replace the injectors

Leak in fuel system Check for leaks

SYMPTOM: REDUCED MAXIMUM ENGINE SPEED

Possible cause Remedy

Air in fuel system Check for drawing in of air:

- via the suction pipe

Fuel fine filter/coarse filter clogged Replace the fuel filter and clean the system

Injector(s) mechanically defective or clogged Replace the injectors

High-pressure pump or fuel lift pump delivery too low

Check:

- the high-pressure pump

- the fuel lift pump

Fuel system

200416 2-5

Page 30

DIAGNOSTICS

Fuel system

ΛΦ45/55 series

2-6

200416

Page 31

DIAGNOSTICS

ΛΦ45/55 series

3. INLET/EXHAUST SYSTEM

3.1 INTRODUCTION

Inlet/exhaust system

200416 3-1

Page 32

DIAGNOSTICS

Inlet/exhaust system

ΛΦ45/55 series

3.2 FAULT-FINDING TABLE

SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS

Possible cause Remedy

Air filter element blocked Replace the air filter element

Turbocharger defective/wastegate control incorrect Check the turbocharger/wastegate control

Air leak in inlet system Pressure-test the inlet system

SYMPTOM: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED

Possible cause Remedy

Air filter element partially blocked Check/replace the air filter element

Air leak in inlet system Pressure-test the inlet system

SYMPTOM: FUEL CONSUMPTION TOO HIGH

Possible cause Remedy

Turbocharger defective Check the turbocharger

Air leak in inlet system Pressure-test the inlet system

SYMPTOM: REDUCED MAXIMUM ENGINE SPEED

Possible cause Remedy

Turbocharger defective Check the turbocharger

SYMPTOM: RISING AND FALLING TURBOCHARGER SOUNDS

Possible cause Remedy

Blocked turbocharger air intake Check air intake and remove any obstacles

Compressor side of turbocharger contaminated Clean compressor side with a non-corrosive clean-

ing agent or a soft brush. Check the intake side for carbon deposits or other contamination

Turbocharger damaged Replace the turbocharger and identify the cause

SYMPTOM: BLACK SMOKE EMERGES FROM EXHAUST

Possible cause Remedy

Air filter element blocked Replace the air filter element

Air leakage between turbocharger and inlet manifold Check flexible pipes and pressurise intake unit

Air leakage between the inlet manifold and cylinder head Check for leakage. Replace gaskets, if necessary

3-2

200416

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DIAGNOSTICS

ΛΦ45/55 series

SYMPTOM: BLACK SMOKE EMERGES FROM EXHAUST

Possible cause Remedy

Compressor side of turbocharger contaminated Clean compressor side with a non-corrosive clean-

ing agent or a soft brush. Check the intake side for carbon deposits or other contamination

Gas leak between the exhaust manifold and the cylinder head Check the fixing bolts and gaskets

Gas leak between the exhaust manifold and the turbocharger Check the fixing bolts and gaskets

Turbocharger damaged Replace the turbocharger and identify the cause

SYMPTOM: BLUE SMOKE EMERGES FROM EXHAUST

Possible cause Remedy

Air filter element blocked Replace the air filter element

Air leakage between turbocharger and inlet manifold Check flexible pipes and pressurise intake unit

Air leakage between the inlet manifold and cylinder head Check for leakage. Replace gaskets, if necessary

Inlet/exhaust system

Compressor side of turbocharger contaminated Clean compressor side with a non-corrosive clean-

ing agent or a soft brush. Check the intake side for carbon deposits or other contamination

Turbocharger oil discharge pipe clogged Check oil pipe. Replace as necessary

Turbocharger damaged Replace the turbocharger and identify the cause

SYMPTOM: OIL LEAK AT TURBINE SIDE OF TURBOCHARGER

Possible cause Remedy

Compressor side of turbocharger contaminated Clean compressor side with a non-corrosive clean-

ing agent or a soft brush. Check the intake side for carbon deposits or other contamination

Turbocharger oil discharge pipe clogged Check oil pipe. Replace as necessary

Turbocharger damaged Replace the turbocharger and identify the cause

SYMPTOM: OIL LEAK AT COMPRESSOR SIDE OF TURBOCHARGER

Possible cause Remedy

Air filter element blocked Replace the air filter element

Turbocharger oil pipe clogged Check oil pipe. Replace as necessary

Turbocharger damaged Replace the turbocharger and identify the cause

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DIAGNOSTICS

Inlet/exhaust system

SYMPTOM: EXHAUST GAS BACK PRESSURE TOO HIGH

Possible cause Remedy

Incorrect butterfly valve adjustment Check the adjustment of the butterfly valve

Butterfly valve incorrectly positioned Check whether the butterfly valve has been posi-

tioned correctly

Butterfly valve partially operated by residual pressure in the operating cylinder Check operating cylinder

Original exhaust silencer not fitted Check exhaust silencer

Exhaust pipe crushed or internally blocked by a loose part

SYMPTOM: INLET UNDERPRESSURE TOO HIGH

Possible cause Remedy

Air filter element blocked Replace air filter element

Check exhaust system for blockage and/or damage

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DIAGNOSTICS

ΛΦ45/55 series

4. ENGINE BRAKE

4.1 INTRODUCTION

Engine brake

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DIAGNOSTICS

Engine brake

ΛΦ45/55 series

4.2 FAULT-FINDING TABLE

SYMPTOM: ENGINE BRAKE DOES NOT ENGAGE

Possible cause Remedy

Compressor delivering insufficient air pressure. Check the operation of the compressor.

Air leak in the air pipe from air dryer to exhaust brake valve. Check air pipe.

Butterfly valve stuck in butterfly valve housing. Check free movement of butterfly valve.

Electrical fault. Check electrical circuit.

SYMPTOM: ENGINE BRAKE REMAINS ENGAGED

Possible cause Remedy

Butterfly valve stuck in butterfly valve housing. Check free movement of butterfly valve.

Electrical fault. Check electrical circuit.

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BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

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

Contents

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

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BE ENGINE FUEL SYSTEM

Contents

ΛΦ45/55 series

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BE ENGINE FUEL SYSTEM

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1. SAFETY INSTRUCTIONS

1.1 SAFETY INSTRUCTIONS

Fuel

Diesel fuel is an extremely flammable liquid, and must not be

}

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.

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.

Safety instructions

Exhaust gases contain carbon monoxide.

}

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.

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.

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BE ENGINE FUEL SYSTEM

Safety instructions

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BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

2. GENERAL

2.1 LOCATION OF COMPONENTS

Location of components, production date < 2003-49 (chassis number < 0L253643)

1 2 3 45

General

9 10

11 12

141516171920 18

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BE ENGINE FUEL SYSTEM

General

1. Suction pipe to electronic unit cooling plate

2. Injector pipe

3. Fuel rail pressure sensor

4. Fuel pipe to fuel rail

5. Fuel rail

6. Fuel return overflow valve

7. Fuel rail pressure-limiting valve

8. Return pipe from fuel return overflow valve

9. Fuel pipe to high-pressure pump

10. Fuel pipe to fuel fine filter

11. High-pressure pump leak-off pipe

12. Fuel pipe to fuel lift pump

13. High-pressure pump

14. Fuel pump control solenoid valve

15. Fuel pipe to high-pressure pump

16. Return pipe to fuel tank

17. Fuel temperature sensor

18. Fuel fine filter

19. Fuel pipe from electronic unit cooling plate

20. ECS-DC3 electronic unit

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BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

Location of components, production date  2003-49 (chassis number  0L253643)

1 2 34

General

131718 16

1415 12

8 9

10 11

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BE ENGINE FUEL SYSTEM

General

1. Suction pipe to electronic unit cooling plate

2. Fuel rail pressure sensor

3. Fuel pipe to fuel rail

4. Fuel rail

5. Fuel return overflow valve

6. Fuel rail pressure-limiting valve

7. Return pipe from fuel return overflow valve

8. Fuel pipe to fuel fine filter

9. High-pressure pump leak-off pipe

10. Fuel pipe to fuel lift pump

11. High-pressure pump

12. Return pipe to fuel tank

13. Fuel pump control solenoid valve

14. Fuel pipe to high-pressure pump

15. Fuel supply pipe

16. Fuel fine filter

17. Fuel pipe from electronic unit cooling plate

18. ECS-DC3 electronic unit

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2.2 SYSTEM DESCRIPTION, ECS-DC3 FUEL SYSTEM

General

The fuel lift pump (4a) draws the fuel from the fuel tank (1) through the cooling plate (2) of the electronic unit (3). The purpose of the cooling plate (3) is to ensure that the electronic unit does not become too hot. The fuel lift pump (4a) is fitted against the highpressure pump (4c) and is driven by the camshaft gear. From the fuel lift pump, fuel is forced towards the fuel fine filter (5).

After the filter, the fuel enters the high-pressure pump (4c) via the fuel pump control solenoid valve (4b), which controls the amount of fuel going to the high-pressure pump. Fuel not taken in by the high-pressure pump returns via the bypass valve (4d) to the fuel lift pump supply pipe and part of it is used for lubricating the highpressure pump.

The high-pressure pump forces the fuel under high pressure to the fuel rail (6). The fuel rail distributes the fuel among the injectors (7). The fuel rail (6) also functions as an accumulator to ensure that large fluctuations in pressure, resulting from injector openings and pump pressure pulses, are prevented as much as possible.

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General

The pressure in the fuel rail is registered by the rail pressure sensor (6a). The electronic unit uses this data to control the high-pressure pump (via the fuel pump control solenoid valve), so that the rail pressure can be kept at the desired level. The desired pressure is not constant, but depends on the operating conditions.

A pressure relief valve (6b) is fitted at the end of the fuel rail. If the pressure in the fuel rail rises too high (in emergencies only), this valve ensures that the excess fuel flows back to the return pipe. The return pipe is connected with the return pipe to the fuel tank (1).

The electronic unit uses the present rail pressure to calculate the time during which the injector needs to be opened in order to obtain the desired injection quantity.

A pressure relief valve (8) connects the injector leak-off ducts in the cylinder head with the return pipe to the fuel tank (1). This pressure relief valve prevents the fuel from flowing out of the injectors when the engine has stopped running.

ΛΦ45/55 series

If the system has been "open", the fuel system can be bled using the primer pump (2a), which is integrated in the water separator/coarse filter (2b).

The return pipe to the tank contains a check valve (9), which is normally closed. As soon as the quick release coupling on the fine filter head is disconnected, the return pipe closes so that it cannot empty.

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2.3 OVERVIEW DRAWING, FUEL PUMP

General

1. Attachment bolt

2. Fuel pump control solenoid valve

3. O-ring

4. O-ring

5. Fuel pipe connection

6. Copper ring

7. Lift pump

8. High-pressure pump

9. Circulation valve

10. O-ring

11. Copper ring

12. Fuel pipe connection

13. High-pressure pipe connection

14. Spring

15. Ball

16. Oil seal

17. O-ring

18. Adapter ring

19. O-ring

20. Gear wheel

21. Sealing ring

22. Nut

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General

2.4 OVERVIEW DRAWING, FUEL RAIL

Overview drawing, fuel rail, < production date 2003-49 (chassis number < 0L253643)

The figure shows the connections to the injector pipes. The numbers indicate the cylinder number of the connection.

Overview drawing, fuel rail, production date  2003-49 (chassis number  0L253643)

The figure shows the connections to the injector pipes. The numbers indicate the cylinder number of the connection.

ΛΦ45/55 series

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BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

2.5 OVERVIEW DRAWING, FUEL SYSTEM, CYLINDER HEAD

6 7

General

1. Injector pipe

2. Union

3. Nut

4. Fuel supply pipe

5. Connector to injectors

6. O-ring

7. Return opening

8. Injector

9. Electrical connection

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General

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BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

3. DESCRIPTION OF COMPONENTS

3.1 HIGH-PRESSURE PUMP

The high-pressure pump is driven by the crankshaft by means of the camshaft gear. The pump shaft rotates at a speed 1.33 times the speed of the crankshaft. The pump shaft drives the fuel lift pump. The fuel drawn from the suction side by the gears is discharged through the exit by the gears due to the reduction in volume. The fuel lift pump has two added valves. The first valve (1) limits the pump pressure, for example if the fine filter is blocked. The second valve (2) opens the by-pass over the fuel lift pump when the primer pump is being used.

The high-pressure pump shaft (1) has an eccentric. The eccentric drives the eccentric ring (4). The pump plungers (3) are driven by the eccentric ring and pushed back by the spring (2).

Description of components

1 2

i400595

The fuel is supplied via the connection (5) and then internally distributed among the three pump elements. Before it is distributed among the pump elements, the supplied fuel is dosed by means of the fuel pump control solenoid valve (6).

The fuel pump control solenoid valve is controlled by the electronic unit on the basis of the rail pressure sensor signal. This creates a closed control circuit. The fuel pump control solenoid valve is "normally open" and is activated via duty cycle control. The value when the engine is started is fixed. When the measured pressure deviates from the desired (programmed) pressure, the duty cycle value will be adapted until the measured and the desired values correspond. If this is impossible, the electronic unit will generate a warning and record a fault code.

2 3

4 1

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Description of components

During the downward stroke, the fuel is supplied by the fuel lift pump via the suction valve (9) (see illustration on left). During the delivery stroke (illustration on right), the suction valve closes under the load of the spring (8) and the fuel pressure that has built up. The fuel leaves the pump element via the delivery valve (10). The compressed fuel from the three pump elements is collected in the pump housing and leaves the pump via a joint high-pressure connection.

Leaking fuel from the pump elements is discharged via the return connection.

The fuel lift pump has over-capacity in relation to the high-pressure pump. If there is only limited fuel off-take on the rail, the fuel pump control solenoid valve will be virtually closed. The oversupplied fuel will cause an increase in pressure at the inlet of the fuel pump control solenoid valve. The pressure is limited by the circulation valve (7). If the valve is open, the excess supplied fuel will be returned to the suction side of the fuel lift pump. A small amount of fuel is diverted via a restriction to the shaft and the eccentric of the high-pressure pump for lubrication.

ΛΦ45/55 series

i400590

When bleeding with the primer pump, any air bubbles will be carried along by the fuel through the low-pressure circuit. Fuel is forced inwards at the connection (5). The fuel pump control solenoid valve is opened fully without being energised, so that the fuel can pass. The pump elements create a high resistance to the fuel, so that the fuel will escape via the lubricating restriction in the pump. In this way the fuel, along with any air bubbles, is discharged to the return pipe.

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ΛΦ45/55 series

3.2 FUEL PUMP CONTROL SOLENOID VALVE

The high-pressure pump has an over-capacity for normal operating conditions. This could lead to large quantities of fuel being forced at high pressure to the fuel rail and then directly being drained out to the return pipe via the pressurelimiting valve on the fuel rail. This produces too much unnecessary heat and loss of capacity because large amounts of fuel are flowing at high pressure.

The system has been designed such that only fuel that will be used will be forced under high pressure to the rail. For this reason, a fuel pump control solenoid valve has been fitted at the suction side of the high-pressure pump. This solenoid valve is opened without being energised, so that the high-pressure pump elements can be filled in the normal manner.

If the fuel rail pressure becomes too high, for example because of lower fuel off-take on the rail, the solenoid valve will be energised by the electronic unit with a higher duty cycle, so that the plunger is pressed with a greater force against the spring pressure and the valve reveals a more constricted opening. This reduces the fuel supply to the pump elements and the pump output will thus fall. The fuel rail pressure will also fall as a consequence. If the rail pressure is too low, the reverse is true.

Description of components

The current is supplied to the coil (3) via the connector (1). The current pushes the core (2) with the plunger (4) against the pressure of the spring (5). This controls the fuel current from input A to output B.

Due to this valve, under normal circumstances very little fuel flows back from the rail. This improves performance and reduces the generation of heat.

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Description of components

3.3 INJECTOR

The injectors can be opened and closed electrically. The injector is normally closed. The load of the spring (2) and the fuel rail pressure that controls chamber C ensure this.

The fuel is supplied from the fuel rail via A. The return fuel can flow back to the fuel tank via B.

When the coil (7) is energised, the armature housing (5) moves up. As a result the pressure in chamber C drops slightly and the injector needle (1) is forced up to chamber D by the rail pressure. The fuel can then be injected.

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3.4 FUEL RAIL PRESSURE-LIMITING VALVE

The fuel rail has a pressure-limiting valve so that the rail pressure is maintained at a safe value in emergency situations.

The fuel rail pressure control circuit is normally active. This consists of the fuel lift pump, fuel pump control solenoid valve, high-pressure pump, fuel rail, rail pressure sensor and electronic unit. If a fault occurs, the rail pressure can no longer be controlled. This can rise to the actuating pressure of the fuel rail pressurelimiting valve. This pressure is approx. 1650 bar. In the open position all surplus fuel flows without pressure to the fuel tank return connection.

The valve includes a sealing cone (1), a valve body (2), a spring (3) and a return connection with quick-release coupling (4).

Description of components

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Description of components

3.5 FUEL RETURN OVERFLOW VALVE

The injectors are mounted in the cylinder head. The injectors do not have a separate return connection. In place of this there is a longitudinal bore in the cylinder head that meets the injector bores of all cylinders coinciding with the height of the return ports of the injectors. A pressure relief valve is mounted at the end of the bore to prevent vapour bubbles forming in it and to prevent it emptying after the engine is turned off. This valve maintains a residual pressure in relation to the return pressure of 1.2 to 2.0 bar.

The pressure relief valve consists of a springloaded plunger (1) and a housing (2) with quickrelease inlet and outlet connections (A and B respectively).

ΛΦ45/55 series

1 2

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4. INSPECTION AND ADJUSTMENT

4.1 BLEEDING THE FUEL SYSTEM

Stop pumping as soon as a greater resistance is felt. If you continue

}

Note:

When the hand pump is used, the fuel system will be automatically bled. Air will be fed back to the tank through the return pipe.

1. Unscrew the button of the primer pump and

2. Use the primer pump until a clearly higher

3. Press the button and tighten it.

pumping, the fuel system may become internally damaged.

pull it out.

resistance is perceptible.

Inspection and adjustment

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Inspection and adjustment

4.2 CHECKING FUEL LIFT PUMP PRESSURES

When inspecting the fuel pressure, fuel will escape. Collect the fuel and

} }

Checking underpressure on suction side of fuel lift pump

1. Disconnect the fuel pipe from the electronic

2. Fit the adapter (1), special tool

avoid the risk of fire.

Dirt in the fuel system can lead to significant damage to parts of the system. Prevent this by cleaning the parts before disassembly and then sealing all open connections.

unit cooling plate to the fuel lift pump on the suction side of the fuel lift pump; see "Removal and installation".

(DAF no. 1329476), between the pipe which has been removed and the fuel lift pump and couple a pressure gauge (2) to this adapter.

ΛΦ45/55 series

3. Bleed the fuel system.

4. Measure the underpressure when the engine is idling. Compare the readings with the specified values. See "Technical data".

5. Remove the pressure gauge and the adapter and fit the fuel pipe.

6. Bleed the fuel system, start the engine and check the fuel system visually for leaks if no further measurements are to be carried out.

Checking fuel pressure in fuel lift pump in front of fuel fine filter

1. Disconnect the fuel pipe from the lift pump to the fuel fine filter on the delivery side of the lift pump; see "Removal and installation".

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2. Fit the adapter (1), special tool (DAF no. 1329476), between the pipe which has been removed and the fuel lift pump and couple a pressure gauge (2) to this adapter.

3. Bleed the fuel system.

4. Start the engine and measure the pressure when the engine is idling. Compare the readings with the specified values. See "Technical data".

5. Remove the pressure gauge and the adapter and fit the fuel pipe.

6. Bleed the fuel system, start the engine and check the fuel system visually for leaks if no further measurements are to be carried out.

Checking fuel pressure in fuel lift pump after fuel fine filter

1. Disconnect the fuel pipe from the fuel fine filter to the high-pressure pump on the side of the high-pressure pump; see "Removal and installation".

Inspection and adjustment

i400883

2. Fit the adapter (1), special tool (DAF no. 1329476), between the pipe which has been removed and the high-pressure pump and couple a pressure gauge (2) to this adapter.

3. Bleed the fuel system.

4. Disconnect the electrical connectors of the injectors from the valve sleeve.

5. Start the engine and measure the pressure when the engine is idling. Compare the readings with the specified values. See "Technical data".

6. Connect the electrical connectors of the injectors to the valve sleeve.

7. Remove the pressure gauge and the adapter and reconnect the fuel pipe.

8. Bleed the fuel system, start the engine and check the fuel system visually for leaks if no further measurements are to be carried out.

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Inspection and adjustment

Check pressure drop across fuel fine filter

1. Check the fuel pressure in front of the fuel fine filter.

2. Check the fuel pressure after the fuel fine filter at maximum engine speed.

3. Compare the measured pressure drop across the fuel fine filter with the specified value. See "Technical data". If the pressure drop is too great, the fuel fine filter must be replaced.

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4.3 INSPECTION, INTERNAL FUEL LEAKS

When inspecting for internal fuel leaks, 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.

The common rail system is under high pressure when the engine is running. This pressure can rise to approx. 1400 bar. Even when the engine is not running, there may be a high residual pressure in the fuel rail (approx. 50 bar). Depressurise the system before working on the common rail system by wrapping the coupling in a cloth and then unscrewing it and collecting the escaping fuel in a container.

Inspection and adjustment

Inspection, internal fuel leaks

1. Check that all injector pipes have been tightened to the correct torque and that there are no external signs of fuel leakage; see "Technical data".

2. Disconnect the fuel return pipe (1) from the fuel return overflow valve (2) on the rear of the cylinder head.

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Inspection and adjustment

3. Seal the disconnected fuel pipe (1) using the special tool (DAF no. 1453151) to prevent the return fuel escaping.

4. Fit the special tool (DAF no. 1329476) onto the fuel return overflow valve (2).

ΛΦ45/55 series

5. Place the free end of the special tool (DAF no. 1329476) in a container and start the engine.

6. While the engine is idling, measure the quantity of return fuel using a stop watch and a measuring beaker; see "Technical data" for the maximum quantity of return fuel.

Note:

If the quantity of return fuel is within the specified value there are no internal leaks. If the quantity of return fuel exceeds the specified value, the internal fuel leak must be located.

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Locating internal fuel leak

1. Take the injector pipe out of cylinder 1.

2. Seal the connection of cylinder 1 on the fuel rail using the special tool (DAF no. 1453133). Tighten the plug to 30 Nm.

3. While the engine is idling, use a stop watch to measure the time required to fill a measuring beaker with 360 ml of return fuel. See "Technical data" for the minimum time permitted for filling the measuring beaker.

Note:

Use a measuring beaker with a mark at 360ml.

4. Remove the special tool (DAF no. 1453133) and reconnect the injector pipe.

5. Repeat the above steps for the other cylinders and note the values.

Note:

When the leaking cylinder has been plugged, the quantity of return fuel will decrease and, as a result, the time it takes to fill the measuring beaker to 360ml will increase. If several high values are measured, this indicates that there may be several leaks. If this is the case, first check the cylinders that give the highest values and then repeat the test. In the example shown in the table below there is an internal leak in the 3 which could be caused by a leak in the fuel supply pipe and/or a defective injector.

cylinder,

Inspection and adjustment

i400681

Example:

Leak test results

Blocked cylinder 1234

Time (s) to fill to 360ml 35 36 200 37

6. In the event of a leak, remove the fuel supply pipe and the injector of the cylinder in question; see "Removal and installation".

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7. 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.

8. 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.

Note:

If fuel has been found in the lubricating oil, extra attention must be paid to the O-rings of the injectors, as these have most probably been damaged by increased pressure in the return circuit as a result of an internal leak.

Note:

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.

ΛΦ45/55 series

i400776

9. Fit the injector and fuel supply pipe. See "Removal and installation".

10. Again inspect for internal fuel leaks to check that there is no leakage.

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5. REMOVAL AND INSTALLATION

5.1 REMOVAL AND INSTALLATION, INJECTOR PIPE

Never bend injector pipes as they may kink or crack.

}

Note:

Codes (1) are stamped in the injector pipe unions to enable correct positioning. The first figure is the number of cylinders of the engine followed by the fitting position.

The injector pipes form part of the high-pressure section of the fuel system. When the unions are unscrewed, fuel under high pressure may escape. Take measures to prevent fire and injury. Collect the escaping fuel in a suitable container.

Dirt in the fuel system can lead to significant damage to parts of the system. Prevent this by cleaning the parts before disassembly and then sealing all open connections.

Removal and installation

Removing the injector pipe

1. Clean the area surrounding the unions, both near the injectors and near the fuel rail.

2. Remove the connectors (1) of the injectors from the valve sleeve.

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Note:

Note the sequence in which the injector pipes are removed. They should be re-fitted in precisely the reverse order.

3. Unscrew the unions on both sides of the pipe and remove the pipes.

4. Immediately plug the openings.

Installing the injector pipe

1. Clean the injector pipe and blow-clean it with dry compressed air.

2. Fit the injector pipes in reverse order and hand-tighten the unions. When all the pipes and unions are correctly fitted, the unions must be tightened to the specified torque. See "Technical data".

3. Fit the connectors of the injectors in the valve sleeve.

4. Start the engine to bleed the high-pressure section of the fuel system and inspect all fuel pipes for leaks.

ΛΦ45/55 series

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5.2 REMOVAL AND INSTALLATION, FUEL SUPPLY PIPE

When removing a fuel pipe, fuel will escape. Collect the fuel and avoid

} }

Removing the fuel supply pipe

1. Disconnect the injector pipes.

2. If necessary, remove the fuel rail.

3. Remove the nut (1) from the fuel supply pipe.

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.

Removal and installation

i400486

4. Mark the positions of the fuel supply pipe (1) and pull it out of the cylinder head with special tool (DAF no. 1329473) (2).

Note:

If the injector is not replaced, the fuel supply pipe may be re-used provided it is fitted with the original injector.

Installing the fuel supply pipe

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.

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Removal and installation

1. 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.

Note:

If any indications of leakage are visible, remove the injector and check the injector fuel connection for signs of leakage.

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

3. Apply a thin layer of clean engine oil to the Oring of the fuel supply pipe, the screw thread of the nut and the contact surface of the nut with the fuel supply pipe.

4. 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.

ΛΦ45/55 series

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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. 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.

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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.

Removal and installation

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Removal and installation

5.3 REMOVAL AND INSTALLATION, INJECTOR

When removing an injector, fuel will escape. Collect the fuel and avoid

} }

Removing the injector

1. Remove the fuel return overflow valve to let

2. Remove the injector pipe.

3. Remove the fuel supply pipe.

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.

the return bore in the cylinder head empty to the fullest possible extent. Collect the escaping fuel.

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.

ΛΦ45/55 series

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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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.

Removal and installation

i400804

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

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 Oring 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.

ΛΦ45/55 series

i400693

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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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 Oring 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.

Removal and installation

1 2

i400806

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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Removal and installation

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.

ΛΦ45/55 series

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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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ΛΦ45/55 series

5.4 REMOVAL AND INSTALLATION, FUEL RAIL

When removing the fuel rail, fuel will escape. Collect the fuel and avoid

} }

Removing the fuel rail

1. Remove the connector from the fuel rail

2. If necessary, remove the plug of the inlet air

3. Remove the connectors of the injectors (1)

the risk of fire.

Dirt in the fuel system can lead to significant damage to parts of the system. Prevent this by cleaning the parts before disassembly and then sealing all open connections.

pressure sensor.

temperature/boost pressure sensor by loosening the connector.

from the valve sleeve.

Removal and installation

4. Disconnect the cable harness (3) on the fuel rail (2) and bend the cable harness away from the fuel rail.

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Removal and installation

5. Remove the fuel return pipe from the pressure-limiting valve on the fuel rail

6. Loosen the pipe clamps from the highpressure pipe to the fuel rail.

7. Loosen the high-pressure pipe from the highpressure pump to the fuel rail on the fuel rail side by unscrewing the union.

8. Disconnect the injector pipes.

9. Remove the fuel rail attachment bolts (2).

10. Remove the fuel rail (3).

ΛΦ45/55 series

i400814

Installing the fuel rail

1. Ensure that the fuel rail is clean.

2. Fit the fuel rail (3) and hand-tighten the attachment bolts (2).

3. Fit the fuel return pipe (1) onto the pressurelimiting valve on the fuel rail.

4. Fit the injector pipes.

5. Fit the pipe clamps from the high-pressure pipe to the fuel rail. Do not tighten them yet.

6. Fit the high-pressure pipe unions from the high-pressure pump to the fuel rail. For the specified tightening torques of the unions, see "Technical data".

7. Tighten the attachment bolts (2) of the fuel rail to the specified torque. See "Technical data".

8. Tighten the bolt connections of the highpressure pipe clamps.

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9. Install the cable harness (3) to the fuel rail (2) and secure it using cable ties.

10. Fit the connectors of the injectors (1) in the valve sleeve.

11. If it has been removed, fit the plug of the inlet air temperature/boost pressure sensor to the sensor.

12. Fit the connector of the fuel rail pressure sensor.

13. Start the engine and check the fuel system for leaks.

Removal and installation

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Removal and installation

5.5 REMOVAL AND INSTALLATION, FUEL RAIL PRESSURE-LIMITING VALVE

When removing the pressurelimiting valve, fuel will escape.

} }

Removing fuel rail pressure-limiting valve

1. Clean the pressure-limiting valve (2) and the

2. Remove the fuel return pipe (3) from the

3. Remove the pressure-limiting valve (2) from

Collect the fuel and avoid the risk of fire.

Dirt in the fuel system can lead to significant damage to parts of the system. Prevent this by cleaning the parts before disassembly and then sealing all open connections.

surrounding area.

pressure-limiting valve (2).

the fuel rail (1).

ΛΦ45/55 series

Installing fuel rail pressure-limiting valve

1. Check the sealing surface and the screw thread of the pressure-limiting valve and the fuel rail.

2. Install the pressure-limiting valve in the fuel rail and tighten the valve to the specified torque. See "Technical data".

3. Fit the fuel return pipe on the pressurelimiting valve.

4. Start the engine and check the pressurelimiting valve for leaks.

1 2

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ΛΦ45/55 series

5.6 REMOVAL AND INSTALLATION, HIGH-PRESSURE PUMP

When removing the high-pressure pump, fuel will escape. Collect the

} }

Removing the high-pressure pump

1. Clean the high-pressure pump and that part

2. Disconnect the fuel pipes from the high-

fuel and avoid the risk of fire.

Dirt in the fuel system can lead to significant damage to parts of the system. Prevent this by cleaning the parts before disassembly and then sealing all open connections.

of the engine around it thoroughly with, for example, a steam cleaner. Cover the places at which leaks have been detected to prevent dirt getting into the fuel system.

pressure pump. Loosen the return pipe only on the high-pressure pump.

Removal and installation

3. If fitted, uncouple the connector of the fuel temperature sensor (1) on the fuel fine filter head and the connector of the fuel pump control solenoid valve (2).

4. Remove the fuel fine filter together with the filter head.

5. Loosen both unions from the high-pressure pipe to the fuel rail as well as the pipe clamps. Remove the high-pressure pipe. Plug all openings.

6. Remove the three high-pressure pump attachment nuts and then the high-pressure pump.

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Removal and installation

Note:

The high-pressure pump is fitted on the gear side with an adapter ring (1) and an O-ring (2) in the timing gear case. If the removal of the highpressure pump is particularly difficult, it may be necessary to press the adapter ring (1) carefully out of the timing gear case using a small pry bar.

Installing the high-pressure pump

1. Clean the high-pressure pump. Make sure that no dirt or cleaner can get into the highpressure pump ducts.

2. Check the high-pressure pump and the drive gear (externally) for wear and damage.

3. Fit a new O-ring (2) on the adapter ring (1) and apply a thin layer of engine oil to the Oring.

4. Fit the high-pressure pump and press it into the timing gear case by means of the attachment nuts.

ΛΦ45/55 series

i400817

5. Tighten the attachment nuts to the specified torque. See "Technical data".

6. Fit the filter head and the fuel fine filter.

7. Fit the high-pressure pump to the fuel rail and tighten the unions. See "Technical data" for the specified tightening torques.

8. Tighten the pipe clamps.

9. If fitted, connect the connector of the fuel temperature sensor (1) on the fuel fine filter head and the connector of the fuel pump control solenoid valve (2).

10. Fit the fuel pipes to the high-pressure pump.

11. Bleed the fuel system. See "Inspection and adjustment".

12. Start the engine and check the fuel system for leaks.

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5.7 REMOVAL AND INSTALLATION, FUEL FINE FILTER

When removing the fuel fine filter, a quantity of fuel will escape. Collect

}

Removing the fuel fine filter

1. Place a container beneath the fuel fine filter

Installing the fuel fine filter

Note: Do not fill the fine filter with fuel until it has been fitted. The fine filter is filled with fuel by the primer pump after it has been fitted. This considerably reduces the risk of dirt getting into the fuel system.

the fuel and avoid the risk of fire.

and remove the filter.

Note:

The fuel fine filter is a disposable filter and must therefore not be cleaned and re-used.

Removal and installation

1. Check by hand whether the coupling piece for the filter attachment is securely attached.

2. Lightly lubricate the filter sealing ring with clean engine oil.

3. Fit the filter element onto the housing. Tighten the filter element until the sealing ring abuts. Tighten the filter element a further ∂ to • turn by hand.

4. Bleed the fuel system. See "Inspection and adjustment".

5. Start the engine and check the fuel system for leaks. If necessary, retighten the filter by hand.

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Removal and installation

ΛΦ45/55 series

5.8 REMOVAL AND INSTALLATION, FUEL PREFILTER/WATER SEPARATOR

When removing the fuel prefilter/ water separator, a quantity of fuel

}

Removing the fuel prefilter/water separator filter element

1. Place a container under the filter.

2. Remove the plug (3) from the water sensor

3. Remove the fuel prefilter/water separator

4. Remove the water sensor (2) from the filter

Installing the fuel prefilter/water separator filter element

1. Check by hand whether the coupling piece

will escape. Collect the fuel and avoid the risk of fire.

(2).

filter element (1) by turning it anti-clockwise.

element (1).

for the filter attachment is securely attached.

G0 00 220

2 3

2. Lightly lubricate the sealing ring with engine oil.

3. Fit the fuel prefilter/water separator filter element (1) until the sealing ring abuts. Tighten the filter element a further ∂ to • turn by hand.

4. Turn the water sensor (2) onto the filter element until it abuts. Tighten the water sensor by about a further  -  turn.

Note:

Over-tightening the water sensor (2) may damage the sensor and/or cause leakage.

5. Fit the plug (3) on the water sensor (2).

6. Bleed the fuel system. See "Inspection and adjustment".

7. Start the engine and check for leaks. If necessary, retighten the fuel prefilter/water separator filter element (1) by hand.

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ΛΦ45/55 series

5.9 REMOVAL AND INSTALLATION, FUEL LEVEL ELEMENT

When removing the fuel prefilter/ water separator, a quantity of fuel

} }

Removing fuel level element

1. Disconnect the earth lead from the battery

2. Drain the fuel tank until it is less than 1/3 full.

3. Remove the connector from the fuel level

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.

terminal.

Note:

To prevent dirt from entering, first clean the outside of the fuel tank.

element.

Removal and installation

4. Remove the attachment bolts of the fuel level element and carefully remove the fuel level element from the fuel tank.

5. Remove the gasket.

Installing fuel level element

1. Clean the contact surface of the fuel tank and the fuel level element.

2. Fit a new gasket to the fuel level element and fit the fuel level element.

3. Fit the attachment bolts of the fuel level element.

4. Fit the connector of the fuel level element.

5. Fill the fuel tank with fuel to a level above the lip of the fuel level element and check the tank for leaks.

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Removal and installation

5.10 REMOVAL AND INSTALLATION, FUEL TANK

When the fuel tank is removed, a quantity of fuel will escape. Collect

} }

Removing fuel tank

1. To prevent dirt from entering, first clean the

2. Drain the fuel tank until it is almost empty.

3. Remove the connector from the fuel level

4. Remove the fuel connections from the fuel

the fuel and avoid the risk of fire.

Dirt in the fuel system can lead to significant damage to parts of the system. Prevent this by cleaning the parts before disassembly and then sealing all open connections.

outside of the fuel tank.

element.

tank.

ΛΦ45/55 series

5. Loosen the fuel pre-filter/water separator from the fuel tank and put it to the rear.

6. Loosen the tank straps.

7. Remove the fuel tank.

Installing the fuel tank

1. Check the fuel tank for damage.

2. Fit the fuel tank with the straps.

3. Fit the fuel pre-filter/water separator on the fuel tank.

4. Fit the fuel connections on the fuel tank.

5. Fit the connector of the fuel level element.

6. Fill the fuel tank with fuel.

7. Bleed the fuel system. See "Inspection and adjustment".

8. Check the tank and the fuel pipes for leaks.

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ΛΦ45/55 series

5.11 REMOVAL AND INSTALLATION, ELECTRONIC UNIT COOLING PLATE

When removing the cooling plate, fuel will escape. Collect the fuel and

} }

Note:

The electronic unit, together with the cooling plate, must first be removed from the engine block, after which the cooling plate must be demounted.

Removing electronic unit cooling plate

1. Disconnect the earth lead from the battery

2. To prevent dirt from entering, first clean the

avoid the risk of fire.

Dirt in the fuel system can lead to significant damage to parts of the system. Prevent this by cleaning the parts before disassembly and then sealing all open connections.

terminal.

area around the fuel connections.

Removal and installation

3. Remove the fuel pipes (1) on the cooling plate of the electronic unit.

4. Uncouple the electrical connectors (2) from the electronic unit and loosen the attachment clip (3) from the cable harness.

5. Remove the attachment bolts by which the electronic unit is fitted to the engine block.

6. Remove the electronic unit and cooling plate.

7. Remove the attachment bolts by which the electronic unit is fitted to the cooling plate and remove the cooling plate.

2 1

3 2

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Removal and installation

Installing electronic unit cooling plate

1. Clean the cooling side of the electronic unit and the cooling plate.

2. Inspect the sealing surfaces of the cooling plate and the electronic unit for damage and smoothness.

3. Fit a new sealing rubber (1) in the cooling plate.

4. Fit the cooling plate to the electronic unit and fit the bolts attaching the two parts. Tighten the attachment bolts to the specified torque. See "Technical data".

5. Fit the electronic unit and cooling plate to the engine block and fit the attachment bolts. Tighten the attachment bolts to the specified torque. See "Technical data".

6. Connect the electrical connectors to the electronic unit and attach the cable harness with the clips.

ΛΦ45/55 series

i400819

7. Connect the quick-release couplings of the fuel pipes to the electronic unit cooling plate.

8. Bleed the fuel system. See "Inspection and adjustment".

9. Fit the earth lead to the battery terminal.

10. Start the engine and check the fuel system for leaks.

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ΛΦ45/55 series

5.12 REMOVAL AND INSTALLATION, FUEL RETURN OVERFLOW VALVE

When removing the fuel return overflow valve valve, fuel will

} }

Removing the fuel return overflow valve

1. To prevent dirt from entering, first clean the

2. Remove the fuel return pipe (1) on the fuel

3. Remove the fuel return overflow valve and

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. Prevent this by cleaning the parts before disassembly and then sealing all open connections.

area around the fuel return connection.

return overflow valve (2) and plug the pipe.

collect the escaping fuel.

Removal and installation

Installing the fuel return overflow valve

1. Install the fuel return overflow valve. Haal het brandstofretour-overstroomventiel aan met het voorgeschreven aanhaalmoment, zie hoofdgroep "Technische gegevens".

2. Connect the quick-release couplings of the fuel return pipe to the fuel return overflow valve.

3. Start the engine and check the fuel system for leaks.

2 1

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Removal and installation

5.13 REMOVAL AND INSTALLATION, LOW-PRESSURE FUEL PIPES

When removing the low-pressure fuel pipes, fuel will escape. Collect

} }

The low-pressure fuel pipes may have two different types of quick-release coupling.

VOSS quick-release coupling

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.

ΛΦ45/55 series

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ΛΦ45/55 series

John Guest quick-release coupling

Removal and installation

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200416 5-25

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Removal and installation

Low-pressure fuel pipes fitted with VOSS quick-release couplings

Removing low-pressure fuel pipes

1. Disconnect the fuel pipe (2) by inserting the special tool (1)(DAF no. 1329470) into the quick-release coupling and removing the pipe from the coupling.

2. Remove the special tool from the quickrelease coupling.

3. Plug the openings.

Fitting low-pressure fuel pipes

1. Clean the quick-release coupling parts and apply a thin layer of clean engine oil to the Oring.

2. Fit the pipe on the quick-release coupling of the component and push the pipe onto it until a clear resistance can be felt and the quickrelease coupling audibly clicks.

3. Bleed the fuel system. See "Inspection and adjustment".

ΛΦ45/55 series

i400473

4. Start the engine and check the fuel system for leaks.

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ΛΦ45/55 series

Low-pressure fuel pipes fitted with John Guest quick-release couplings

Removing low-pressure fuel pipes

1. Disconnect the fuel pipe by pressing in both lips of the quick-release coupling and removing the pipe from the quick-release coupling.

2. Plug the openings.

Fitting low-pressure fuel pipes

1. Clean the quick-release coupling parts.

2. Fit the pipe on the quick-release coupling of the component and push the pipe onto it until a clear resistance can be felt and the quickrelease coupling audibly clicks.

3. Bleed the fuel system. See "Inspection and adjustment".

4. Start the engine and check the fuel system for leaks.

Removal and installation

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Removal and installation

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6. CLEANING

6.1 CLEANING INJECTOR

The injector must never be cleaned with a steel brush or pressure

}

Note:

The use of steel brushes can cause deformation of the injector bores, with the result that the wrong amount of fuel is injected. This deformation cannot be ascertained by measurements or checks.

Note:

The disassembly and assembly of injectors is not permitted. Only external cleaning is permitted.

cleaning equipment. Never put the brush in the injector bores when cleaning the exterior of the injector nozzle. If this happens, the nozzle must be replaced. Before cleaning the nozzle, cover the injector bores. Only clean the injector with a brass hand brush.

Cleaning

1. Remove the injector. See "Removal and installation".

2. Clean the injector hole in the cylinder head. The metal surface of the hole must not be damaged.

3. Wipe the exterior of the injector with a clean, lint-free cloth. In the case of heavy soiling the injector may be cleaned carefully with a brass hand brush (not the apertures in the injector nozzle!).

4. Fit the injector. See "Removal and installation".

M2 00 040

i 400413

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Cleaning

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6-2

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BE ENGINE INLET/EXHAUST SYSTEM

ΛΦ45/55 series

3 BE Engine inlet/exhaus t 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, turbocharger with wastegate . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200416

3. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416

3.1 Inspecting turbocharger wastegate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416

3.2 Inspecting turbocharger axial bearing play . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200416

3.3 Inspecting turbocharger radial bearing play . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200416

3.4 Checking exhaust gas back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200416

3.5 Inspection and pressure-testing, air inlet system. . . . . . . . . . . . . . . . . . . . 3-5 . . . . . 200416

3.6 Checking inlet underpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . 200416

4. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416

4.1 Removal and installation, turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416

4.2 Removal and installation of air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200416

4.3 Removal and installation, air filter element . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . 200416

4.4 Removal and installation, glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . 200416

Contents

5. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416

5.1 Cleaning the exterior of radiator and air cooler . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416

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Contents

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200416

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1. SAFETY INSTRUCTIONS

1.1 SAFETY INSTRUCTIONS

Fuel

Diesel fuel is an extremely flammable liquid, and must not be

}

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.

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.

Safety instructions

Exhaust gases contain carbon monoxide.

}

Moving parts

Remain at a safe distance from rotating and/or moving components.

Various fluids

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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Safety instructions

ΛΦ45/55 series

1-2

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BE ENGINE INLET/EXHAUST SYSTEM

ΛΦ45/55 series

2. GENERAL

2.1 LOCATION OF COMPONENTS

General

3 4 51 2

1. Wastegate diaphragm box

2. Oil supply pipe

3. Oil discharge pipe

4. Turbocharger

5. Exhaust manifold

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General

ΛΦ45/55 series

1. Glow element connections

2. Intake manifold

i400841

2-2

200416

DAF LF45, LF55 Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual

0 Technical data

1. ENGINE, GENERAL

1.1 GENERAL

1.2 BE ENGINE, GENERAL

1.3 CE ENGINE, GENERAL

2. BE ENGINE FUEL SYSTEM

2.1 GENERAL

2.2 TIGHTENING TORQUES

3. CE ENGINE FUEL SYSTEM

3.1 GENERAL

3.2 TIGHTENING TORQUES

4. BE ENGINE INLET/EXHAUST SYSTEM

4.1 GENERAL

4.2 TIGHTENING TORQUES

5. CE ENGINE INLET/EXHAUST SYSTEM

5.1 GENERAL

5.2 TIGHTENING TORQUES

1 Diagnostics

1. TRACTIVE PROBLEMS

1.1 TRACTIVE PROBLEMS

2. FUEL SYSTEM

2.1 INTRODUCTION

2.2 FAULT-FINDING TABLE

3. INLET/EXHAUST SYSTEM

3.1 INTRODUCTION

3.2 FAULT-FINDING TABLE

4. ENGINE BRAKE

4.1 INTRODUCTION

4.2 FAULT-FINDING TABLE

2 BE Engine fuel system

1. SAFETY INSTRUCTIONS

1.1 SAFETY INSTRUCTIONS

2. GENERAL

2.1 LOCATION OF COMPONENTS

2.2 SYSTEM DESCRIPTION, ECS-DC3 FUEL SYSTEM

2.3 OVERVIEW DRAWING, FUEL PUMP

2.4 OVERVIEW DRAWING, FUEL RAIL

2.5 OVERVIEW DRAWING, FUEL SYSTEM, CYLINDER HEAD

3. DESCRIPTION OF COMPONENTS

3.1 HIGH-PRESSURE PUMP

3.2 FUEL PUMP CONTROL SOLENOID VALVE

3.3 INJECTOR

3.4 FUEL RAIL PRESSURE-LIMITING VALVE

3.5 FUEL RETURN OVERFLOW VALVE

4. INSPECTION AND ADJUSTMENT

4.1 BLEEDING THE FUEL SYSTEM

4.2 CHECKING FUEL LIFT PUMP PRESSURES

4.3 INSPECTION, INTERNAL FUEL LEAKS

5. REMOVAL AND INSTALLATION

5.1 REMOVAL AND INSTALLATION, INJECTOR PIPE

5.2 REMOVAL AND INSTALLATION, FUEL SUPPLY PIPE

5.3 REMOVAL AND INSTALLATION, INJECTOR

5.4 REMOVAL AND INSTALLATION, FUEL RAIL

5.5 REMOVAL AND INSTALLATION, FUEL RAIL PRESSURE-LIMITING VALVE

5.6 REMOVAL AND INSTALLATION, HIGH-PRESSURE PUMP

5.7 REMOVAL AND INSTALLATION, FUEL FINE FILTER

5.8 REMOVAL AND INSTALLATION, FUEL PREFILTER/WATER SEPARATOR

5.9 REMOVAL AND INSTALLATION, FUEL LEVEL ELEMENT

5.10 REMOVAL AND INSTALLATION, FUEL TANK

5.11 REMOVAL AND INSTALLATION, ELECTRONIC UNIT COOLING PLATE

5.12 REMOVAL AND INSTALLATION, FUEL RETURN OVERFLOW VALVE

5.13 REMOVAL AND INSTALLATION, LOW-PRESSURE FUEL PIPES

6. CLEANING

6.1 CLEANING INJECTOR

3 BE Engine inlet/exhaus t system

1. SAFETY INSTRUCTIONS

1.1 SAFETY INSTRUCTIONS

2. GENERAL

2.1 LOCATION OF COMPONENTS