DAF CF65, CF75, CF85 Series . Manual - part 424

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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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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

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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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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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