DAF LF45, LF55 Series. Manual - part 294

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Removal and installation

BE ENGINE FUEL SYSTEM

ΛΦ45/55 series

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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.

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Removal and installation

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5.3 REMOVAL AND INSTALLATION, INJECTOR

When removing an injector, fuel will 

escape. Collect the fuel and avoid 

the risk of fire. 

Dirt in the fuel system can lead to 

significant damage to parts of the 

system. All open connections must 

therefore be sealed.

Removing the injector
1.

Remove the fuel return overflow valve to let 

the return bore in the cylinder head empty to 

the fullest possible extent. Collect the 

escaping fuel.

2.

Remove the injector pipe.

3.

Remove the fuel supply pipe.

Note:

-

If an injector is removed without the fuel 

supply pipe having first been removed, 

serious damage can ensue.

-

If the injectors are removed, they must 

be removed together with the fuel 

supply pipes.

4.

Remove the valve cover.

5.

Remove the exhaust valve rockers.

6.

Remove the injector wiring (1).

7.

Remove the two attachment bolts (2) from 

the injector clamping bracket (3).

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Removal and installation

BE 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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