Remove/install quantity control valve of fuel system high pressure pump

AR07.05-G-0001N

Remove/install quantity control valve of fuel system high pressure pump

14.01.2019

Engine

471.9 in model 800.110/112

except 2nd Generation engine 471

Modification notes

05.10.2018

Work procedure completely revised.

Shown on engine 471.9. as of engine end number 032691

1

Fuel filter module

5

Electrical connector

9

Bolts

2

Bracket

6

Coolant line

10

Sealing rings

3

Fuel lines

7

Bracket

Y642

Quantity control valve

4

Fuel lines

8

Fuel system high pressure pump

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Drain the fuel at the fuel filter module (1).

AR07.03-G-1460-03N

2.1

Drain coolant at radiator and at engine.

For engine up to engine end number 032690

AR20.00-G-1142N

2.2

Drain coolant at engine.

For engine as of engine end number 032691

AR20.00-G-1142N

3

Remove the fuel filter module (1).

Only for engine up to engine end number 032690

Engine 471.9## ## up to 032690 in model 800.110/112except 2nd Generation engine 471

AR47.20-G-5511N

4

Remove the bracket (2) on the fuel filter module (1).

Only for engine as of engine end number 032691

5

Remove fuel lines (3, 4).

Only for engine as of engine end number 032691

 Installation: Install new sealing rings.

 Flange, low pressure fuel line to fuel high-pressure pump

*BA07.16-N-1014-03A

 Screw, fuel line to flange for fuel high-pressure pump

*BA07.16-N-1041-03A

 Bolt, flange for fuel line to fuel filter module

*BA07.16-N-1042-03A

6

Disconnect electrical connector (5) at quantity control valve (Y642).

7

Remove coolant line (6) at crankcase.

 Installation: Replace sealing ring for coolant line (6).

8

Remove bracket (7) at fuel high-pressure pump (8) and at crankcase.

 Engine 471.9Screw/nut, holder to fuel high-pressure pump

*BA07.16-N-1009-03A

 Engine 471.9Screw, fuel high-pressure pump holder to crankcase

*BA07.16-N-1010-03A

9

Remove screws/bolts (9).

 Engine 471.9Screw, quantity control valve to fuel high-pressure pump

*BA07.16-N-1031-03A

 Torque wrench

*001589752100

10

Remove quantity control valve (Y642) and collect escaping fuel.

 Remove quantity control valve (Y642) by hand out of the housing flange for fuel system high pressure pump (8) using turning movements. Collect escaping fuel.

 Installation: Replace sealing rings (10). Wet sealing rings (10) with fuel before installing.

11

Install in the reverse order

12

Connect vehicle diagnosis system, start diagnosis and perform quick test.

Only if the quantity control valve (Y642) has been replaced.

 See information from body manufacturer.

13

Reset "adaptation range for quantity control valve".

Only if the quantity control valve (Y642) has been replaced.

 The process is completely menu-assisted under:
MCM - engine management (A4)  
Adaptations 
Parameterization 
Resetting the calibration settings 
Adaptation range for quantity control valve

14

End diagnosis and remove vehicle diagnosis system.

 See information from body manufacturer.

15

Fill fuel low-pressure circuit.

AR07.16-G-1007N

16

Start engine and perform an engine test run.

 Allow the engine to run at a higher engine speed.
See information from body manufacturer.

If engine fails to start or only runs for a brief period,



Fill fuel low-pressure circuit again.

AR07.16-G-1007N

17

Check area of quantity control valve (Y642) for leaks and switch off engine.

 Visual inspection.

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

Engine 471.9## ## as of 032691

BA07.16-N-1009-03A

Screw/nut, holder to fuel high-pressure pump

Nm

30

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

Engine 471.9## ## as of 032691

BA07.16-N-1010-03A

Screw, fuel high-pressure pump holder to crankcase

M12x1.5

Nm

100

100

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## as of 032691

BA07.16-N-1014-03A

Flange, low pressure fuel line to fuel high-pressure pump

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

Engine 471.9## ## as of 032691

BA07.16-N-1031-03A

Screw, quantity control valve to fuel high-pressure pump

Stage 1

Nm

4

4

Stage 2

Nm

8

8

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## as of 032691

BA07.16-N-1041-03A

Screw, fuel line to flange for fuel high-pressure pump

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## as of 032691

BA07.16-N-1042-03A

Bolt, flange for fuel line to fuel filter module

Nm

30