Remove/install quantity control valve - AR07.03-P-0003CD

MODEL 166, 172, 204, 207, 212, 218, 221 with ENGINE 651 

Fig 1: Quantity Control Valve Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of explosion  caused by fuel igniting. Risk of injury  to skin and eyes caused by fuel spraying out at high pressure	Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized.	AS07.16-Z-0001-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes about Common-Rail components		AH07.16-P-0002-01TX
1	Remove throttle valve actuator		AR09.41-P-1321CD
2	Clean high pressure pump in the area of quantity control valve (Y94) with cold cleaning solvent and dry with compressed air	Depending on installation position, use an absorbent, lint-free cloth to collect any fuel that runs out. Vacuum up any particles, like paint, from around hole.
		Cold degreasing agent/cold cleaning solvent HAKU 1025-920	*BR00.45-Z-1051-04A
3	Disconnect electrical connector (1)
4	Remove screw/bolts (2)	Screw/bolt, quantity control valve to high-pressure pump housing flange	*BA07.16-P-1008-01H
5	Pull quantity control valve (Y94) out of housing flange by hand using rotary movements.	Do not pry quantity control valve (Y94) with a tool and do not tilt in order to avoid damage on the housing flange and on the quantity control valve (Y94) itself. Catch escaping fuel with a dry cloth. Lightly grease sealing rings (3) with special grease.
		Special grease	*BR00.45-Z-1036-06A
	Clean
6	Clean flange hole and sealing surface of housing flange	Remove any paint and dirt particle, particularly in the flange bore. Malfunctions can occur otherwise.
7	Clean fuel filter (4)
8	Install in the reverse order
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
9	Check fuel system for leaks with engine running
10	Connect STAR DIAGNOSIS, read out DTC memory and erase if required
		Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.	AD00.00-P-2000-04A

COMMON RAIL DIESEL INJECTION (CDI)

Number	Designation		ENGINE 651
BA07.16-P-1008-01H	Screw/bolt, quantity control valve to high-pressure pump housing flange	Nm	7

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1036-06A	Special grease	A 001 989 42 51 10
BR00.45-Z-1051-04A	Cold degreasing agent/cold cleaning solvent HAKU 1025-920	Chemische Werke Kluthe GmbH