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DAF CF85 Series Service Manual
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PE EN
GIN
E FU
EL SY
STEM
3-12
©
200324
Inspec
tion and a
djustm
ent
5
CF65/75
/85
series
4
"Mann & Hummel" v
ersion
1.
Check the reservo
ir (5) for water.
2.
If neces
sary, drain
the water o
ff through the
drain
plug (6
) using th
e fuel
lift pum
p (1) and
collect th
e water an
d fuel in a
containe
r.
1
305803
1
305803
G000252
6
8
1
2
3
4
7
5
https://www.truck-manuals.net/
187
189
Table of Contents
Structure
1
Table of Contents
3
Technical Data
3
Engine, General
5
Engine Identification
6
Stamped into the Engine Block
6
On the Type Plate
6
Ce Engine, General
7
Pe Engine, General
8
Xe Engine, General
9
Tightening Torques
13
Electronic Unit Cooling Plate
13
Inlet Underpressure
15
Rejection Standards for Cracking
15
Exhaust Gas Back Pressure
15
Ce Engine Inlet/Exhaust System
15
Pe Engine Fuel System
17
Xe Engine Fuel System
21
Xe Engine Inlet/Exhaust System
23
Engine Brake, Xe Engine
27
Tractive Problems
31
Engine Stalls and Runs Again after Re-Starting
34
Engine Starts Poorly
34
Engine Can be Started, but Does Not Run
34
Fault-Finding Table
34
Symptom: Reduced Power above a Certain Engine Speed
35
Symptom: Diesel Knock During Acceleration
35
Symptom: Reduced Power at All Engine Speeds
35
Symptom: Irregular Running of Engine
35
Symptom: Engine Sluggish When Accelerating or under High Load
36
Symptom: White/Blue Smoke Is Emitted
36
Symptom: Black Smoke Is Emitted
36
Symptom: Engine Overheated
36
Symptom: Fuel Consumption too High
37
Symptom: Reduced Maximum Engine Speed
37
Symptom: Oil Leak at Compressor Side of Turbocharger
41
Symptom: Oil Leak at Turbine Side of Turbocharger
41
Symptom: Black Smoke Emerges from Exhaust
41
Symptom: Blue Smoke Emerges from Exhaust
41
Symptom: Exhaust Gas Back Pressure too High
42
Symptom: Inlet Underpressure too High
42
Engine Brake, Ce Engine
43
Symptom: Engine Brake Does Not Engage
44
Symptom: Engine Brake Remains Engaged
44
Symptom: Engine Can be Started, but Does Not Run
46
Symptom: Engine Stalls and Runs Again after Re-Starting
46
Symptom: Engine Starts Poorly
46
Various Fluids
59
Safety Instructions
59
Moving Parts
59
Exhaust Gases
59
Location of Components
61
Location of Components, Production Date
61
Overview Drawing, Fuel Rail
70
Overview Drawing, Fuel System, Cylinder Head
71
Description of Components
73
High-Pressure Pump
73
Fuel Pump Control Solenoid Valve
75
Injector
76
Fuel Rail Pressure-Limiting Valve
77
Fuel Return Overflow Valve
78
Inspecting Fuel Level Element
79
Ce Engine Fuel System
80
Venting the Fuel System
81
Racor Fuel Prefilter/Water Separator
81
Fleetguard Fuel Prefilter/Water Separator
82
Checking Fuel Lift Pump Pressures
83
Checking Fuel Pressure in Fuel Lift Pump in Front of Fuel Fine Filter
83
Check Pressure Drop Across Fuel Fine Filter
85
Inspection, Internal Fuel Leaks
86
Locating Internal Fuel Leak
88
"Racor" Version
91
Removal and Installation, Injector Pipe
93
Removing the Injector Pipe
93
Installing the Injector Pipe
94
Removal and Installation, Fuel Supply Pipe
95
Removing the Fuel Supply Pipe
95
Installing the Fuel Supply Pipe
95
Installing the Fuel Rail
104
Removal and Installation, Fuel Rail Pressure-Limiting Valve
106
Removing Fuel Rail Pressure-Limiting Valve
106
Installing Fuel Rail Pressure-Limiting Valve
106
Removing the High-Pressure Pump
107
Removal and Installation, High-Pressure Pump
107
Installing the High-Pressure Pump
108
Removal and Installation, Fuel Fine Filter
109
Removing the Fuel Fine Filter
109
Installing the Fuel Fine Filter
109
Removing the Fuel Prefilter/Water Separator Filter Element
110
Installing the Fuel Prefilter/Water Separator Filter Element
110
Removal and Installation, Fuel Level Element
112
Removal and Installation, Fuel Tank Filter
114
Fitting Fuel Tank Filter
114
Removing Fuel Tank Filter
114
Removal and Installation, Electronic Unit Cooling Plate
115
Removing Electronic Unit Cooling Plate
115
Installing Electronic Unit Cooling Plate
116
Removal and Installation, Fuel Return Overflow Valve
117
Removing the Fuel Return Overflow Valve
117
Installing the Fuel Return Overflow Valve
117
Removal and Installation, Low-Pressure Fuel Pipes
118
John Guest Quick-Release Coupling
119
Removing Low-Pressure Fuel Pipes
120
Fitting Low-Pressure Fuel Pipes
120
Cleaning Injector
123
General
129
System Description, Turbocharger with Wastegate
131
Inspecting Turbocharger Wastegate
133
Inspecting Turbocharger Axial Bearing Play
134
Inspecting Turbocharger Radial Bearing Play
135
Checking Exhaust Gas Back Pressure
136
Inspection and Pressure-Testing, Air Inlet System
137
Checking Inlet Underpressure
139
Removal and Installation, Turbocharger
141
Removing the Turbocharger
141
Installing the Turbocharger
142
Removing the Air Cooler
144
Installing the Air Cooler
145
Removing the Air Filter Element
146
Installing the Air Filter Element
147
Removing the Glow Plug
148
Installing the Glow Plug
148
Cleaning the Exterior of Radiator/Air Cooler
149
Cleaning, Radiator/Air Cooler
149
Location of Exhaust Brake Components
155
General
155
System Description, Exhaust Brake
156
Switching on the Exhaust Brake
156
Switching off the Exhaust Brake
156
Setting the Exhaust Brake
157
Checking Exhaust Brake
157
Removing the Exhaust Brake
159
Installing Exhaust Brake
159
General
165
Pump Unit
167
Operating Principle
167
Fuel Lift Pump with Integrated Primer Pump
171
Inspecting Injector Opening Pressure
179
Instructions for the Use of the Injector Test Pump
179
Inspecting Opening Pressure with an Injector Test Pump
180
Leakage
181
Injector Nozzles
181
Opening Pressure
181
Inspecting Injector Operation
181
Inspecting Fuel System for Leakage
182
Bleeding the Fuel System
184
Bleeding Using the Fuel Lift Pump
184
Bleeding by Pressurising the Fuel Tank
185
Inspection, Gallery Pressure
186
Checking the Fuel Prefilter/Water Separator
187
"Mann & Hummel" Version
188
Removal and Installation, Fuel Injection Pipe
189
Removing the Fuel Injection Pipe
189
Installing the Fuel Injection Pipe
190
Installing the Injector
192
Removing the Injector Sleeve
193
Installing the Injector Sleeve
193
Removal and Installation, Pump Unit
194
Installing the Pump Unit
195
Removing the Fuel Lift Pump
196
Installing the Fuel Lift Pump
196
Removing the Pump Housing
197
Installing the Pump Housing
199
Removal, Fuel Pipes
201
Installation, Fuel Pipes
201
Removing the Fuel Filter Element
202
Fitting the Fuel Filter Element
202
Installation, Fuel Level Element
203
Removal, Fuel Level Element
203
Disassembling the Pump Housing
209
Assembling the Pump Housing
210
Cleaning, Injector
213
Nozzle
213
Cleaning, Injector Sleeve
214
Fuel
217
Electrical Short-Circuit
217
General
219
Compression Housing By-Pass
221
System Description, Turbocharger
221
Wastegate
221
Inspecting and Adjusting Turbocharger Wastegate
223
Inspection and Pressure Testing, Air Inlet System
225
Checking the Glow Plug
226
Removal and Installation of Air Cooler
229
General
239
General
249
Situation C
252
Situation D
252
General
305
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DAF CF85 Series Specifications
General
Brand
DAF
Model
CF85 Series
Category
Trucks
Language
English
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