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200324 2-1

General

XE ENGINE INLET/EXHAUST SYSTEM

CF65/75/85 series

2. GENERAL

2.1 LOCATION OF COMPONENTS

1. Air intake pipe

2. Wastegate diaphragm

3. Turbocharger

4. Exhaust elbow with integrated butterfly valve

5. Exhaust brake valve

I400531

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Structure1
Table of Contents3
Technical Data3
Engine, General5
Engine Identification6
Stamped into the Engine Block6
On the Type Plate6
Ce Engine, General7
Pe Engine, General8
Xe Engine, General9
Tightening Torques13
Electronic Unit Cooling Plate13
Inlet Underpressure15
Rejection Standards for Cracking15
Exhaust Gas Back Pressure15
Ce Engine Inlet/Exhaust System15
Pe Engine Fuel System17
Xe Engine Fuel System21
Xe Engine Inlet/Exhaust System23
Engine Brake, Xe Engine27
Tractive Problems31
Engine Stalls and Runs Again after Re-Starting34
Engine Starts Poorly34
Engine Can be Started, but Does Not Run34
Fault-Finding Table34
Symptom: Reduced Power above a Certain Engine Speed35
Symptom: Diesel Knock During Acceleration35
Symptom: Reduced Power at All Engine Speeds35
Symptom: Irregular Running of Engine35
Symptom: Engine Sluggish When Accelerating or under High Load36
Symptom: White/Blue Smoke Is Emitted36
Symptom: Black Smoke Is Emitted36
Symptom: Engine Overheated36
Symptom: Fuel Consumption too High37
Symptom: Reduced Maximum Engine Speed37
Symptom: Oil Leak at Compressor Side of Turbocharger41
Symptom: Oil Leak at Turbine Side of Turbocharger41
Symptom: Black Smoke Emerges from Exhaust41
Symptom: Blue Smoke Emerges from Exhaust41
Symptom: Exhaust Gas Back Pressure too High42
Symptom: Inlet Underpressure too High42
Engine Brake, Ce Engine43
Symptom: Engine Brake Does Not Engage44
Symptom: Engine Brake Remains Engaged44
Symptom: Engine Can be Started, but Does Not Run46
Symptom: Engine Stalls and Runs Again after Re-Starting46
Symptom: Engine Starts Poorly46
Various Fluids59
Safety Instructions59
Moving Parts59
Exhaust Gases59
Location of Components61
Location of Components, Production Date61
Overview Drawing, Fuel Rail70
Overview Drawing, Fuel System, Cylinder Head71
Description of Components73
High-Pressure Pump73
Fuel Pump Control Solenoid Valve75
Injector76
Fuel Rail Pressure-Limiting Valve77
Fuel Return Overflow Valve78
Inspecting Fuel Level Element79
Ce Engine Fuel System80
- Venting the Fuel System81
- Racor Fuel Prefilter/Water Separator81
- Fleetguard Fuel Prefilter/Water Separator82
- Checking Fuel Lift Pump Pressures83
- Checking Fuel Pressure in Fuel Lift Pump in Front of Fuel Fine Filter83
- Check Pressure Drop Across Fuel Fine Filter85
- Inspection, Internal Fuel Leaks86
- Locating Internal Fuel Leak88
- "Racor" Version91
- Removal and Installation, Injector Pipe93
- Removing the Injector Pipe93
- Installing the Injector Pipe94
- Removal and Installation, Fuel Supply Pipe95
- Removing the Fuel Supply Pipe95
- Installing the Fuel Supply Pipe95
- Installing the Fuel Rail104
- Removal and Installation, Fuel Rail Pressure-Limiting Valve106
- Removing Fuel Rail Pressure-Limiting Valve106
- Installing Fuel Rail Pressure-Limiting Valve106
- Removing the High-Pressure Pump107
- Removal and Installation, High-Pressure Pump107
- Installing the High-Pressure Pump108
- Removal and Installation, Fuel Fine Filter109
- Removing the Fuel Fine Filter109
- Installing the Fuel Fine Filter109
- Removing the Fuel Prefilter/Water Separator Filter Element110
- Installing the Fuel Prefilter/Water Separator Filter Element110
- Removal and Installation, Fuel Level Element112
- Removal and Installation, Fuel Tank Filter114
- Fitting Fuel Tank Filter114
- Removing Fuel Tank Filter114
- Removal and Installation, Electronic Unit Cooling Plate115
- Removing Electronic Unit Cooling Plate115
- Installing Electronic Unit Cooling Plate116
- Removal and Installation, Fuel Return Overflow Valve117
- Removing the Fuel Return Overflow Valve117
- Installing the Fuel Return Overflow Valve117
- Removal and Installation, Low-Pressure Fuel Pipes118
- John Guest Quick-Release Coupling119
- Removing Low-Pressure Fuel Pipes120
- Fitting Low-Pressure Fuel Pipes120
- Cleaning Injector123
General129
- System Description, Turbocharger with Wastegate131
- Inspecting Turbocharger Wastegate133
- Inspecting Turbocharger Axial Bearing Play134
- Inspecting Turbocharger Radial Bearing Play135
- Checking Exhaust Gas Back Pressure136
- Inspection and Pressure-Testing, Air Inlet System137
- Checking Inlet Underpressure139
- Removal and Installation, Turbocharger141
- Removing the Turbocharger141
- Installing the Turbocharger142
- Removing the Air Cooler144
- Installing the Air Cooler145
- Removing the Air Filter Element146
- Installing the Air Filter Element147
- Removing the Glow Plug148
- Installing the Glow Plug148
- Cleaning the Exterior of Radiator/Air Cooler149
- Cleaning, Radiator/Air Cooler149
- Location of Exhaust Brake Components155
General155
- System Description, Exhaust Brake156
- Switching on the Exhaust Brake156
- Switching off the Exhaust Brake156
- Setting the Exhaust Brake157
- Checking Exhaust Brake157
- Removing the Exhaust Brake159
- Installing Exhaust Brake159
General165
- Pump Unit167
- Operating Principle167
- Fuel Lift Pump with Integrated Primer Pump171
- Inspecting Injector Opening Pressure179
- Instructions for the Use of the Injector Test Pump179
- Inspecting Opening Pressure with an Injector Test Pump180
- Leakage181
- Injector Nozzles181
- Opening Pressure181
- Inspecting Injector Operation181
- Inspecting Fuel System for Leakage182
- Bleeding the Fuel System184
- Bleeding Using the Fuel Lift Pump184
- Bleeding by Pressurising the Fuel Tank185
- Inspection, Gallery Pressure186
- Checking the Fuel Prefilter/Water Separator187
- "Mann & Hummel" Version188
- Removal and Installation, Fuel Injection Pipe189
- Removing the Fuel Injection Pipe189
- Installing the Fuel Injection Pipe190
- Installing the Injector192
- Removing the Injector Sleeve193
- Installing the Injector Sleeve193
- Removal and Installation, Pump Unit194
- Installing the Pump Unit195
- Removing the Fuel Lift Pump196
- Installing the Fuel Lift Pump196
- Removing the Pump Housing197
- Installing the Pump Housing199
- Removal, Fuel Pipes201
- Installation, Fuel Pipes201
- Removing the Fuel Filter Element202
- Fitting the Fuel Filter Element202
- Installation, Fuel Level Element203
- Removal, Fuel Level Element203
- Disassembling the Pump Housing209
- Assembling the Pump Housing210
- Cleaning, Injector213
- Nozzle213
- Cleaning, Injector Sleeve214
- Fuel217
- Electrical Short-Circuit217
General219
- Compression Housing By-Pass221
- System Description, Turbocharger221
- Wastegate221
- Inspecting and Adjusting Turbocharger Wastegate223
- Inspection and Pressure Testing, Air Inlet System225
- Checking the Glow Plug226
- Removal and Installation of Air Cooler229
General239
General249
- Situation C252
- Situation D252
General305

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DAF CF75 Series Specifications

General

Brand	DAF
Model	CF75 Series
Category	Trucks
Language	English

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