DAF LF45, LF55 Series. Manual - part 320

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5.6 REMOVAL AND INSTALLATION, HIGH-PRESSURE PUMP

When removing the high-pressure 

pump, 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. Prevent this by cleaning the 

parts before disassembly and then 

sealing all open connections.

Removing the high-pressure pump
1.

Clean the high-pressure pump and that part 

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.

2.

Disconnect the fuel pipes from the high-

pressure pump. Loosen the return pipe only 

on the high-pressure pump.

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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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 high-

pressure 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 high-

pressure 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 O-

ring.

4.

Fit the high-pressure pump and press it into 

the timing gear case by means of the 

attachment nuts.

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 

the fuel and avoid the risk of fire.

Removing the fuel fine filter
1.

Place a container beneath the fuel fine filter 

and remove the filter.

Note:

The fuel fine filter is a disposable filter and 

must therefore not be cleaned and re-used.

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.

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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5.8 REMOVAL AND INSTALLATION, FUEL PREFILTER/WATER SEPARATOR

When removing the fuel prefilter/

water separator, a quantity of fuel 

will escape. Collect the fuel and 

avoid the risk of fire. 

Removing the fuel prefilter/water separator 
filter element
1.

Place a container under the filter.

2.

Remove the plug (3) from the water 

sensor (2).

3.

Remove the fuel prefilter/water separator 

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

4.

Remove the water sensor (2) from the filter 

element (1).

Installing the fuel prefilter/water separator 
filter element
1.

Check by hand whether the coupling piece 

for the filter attachment is securely attached.

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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