Remove/install quantity control valve

AR07.03-P-0003OLD

Remove/install quantity control valve

04.09.2018

Engine

651 in model 205, 253

1

Electrical connection

4

Fuel filter

2

Screw/bolts

Y94

Quantity control valve

3

Sealing rings

6

Mounting plate

7

Screw/bolts

8

Bracket

9

Screw/bolts

 Danger

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

Topical note

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

 

Remove/install

1

Remove throttle valve actuator

AR07.51-P-1401OLD

2

Remove screw/bolts (7) and bracket (8)

 Place bracket (8) with exhaust gas recirculation cooler bypass switchover valve (Y85) to one side.

 Bolt, bracket for electric switchover valves to fastening plate

*BA09.41-P-1006-01N

3

Unscrew screws/bolts (9) and remove mounting plate (6)

 Charge air manifold fastening plate bolt on engine support

*BA09.41-P-1005-01N

4

Clean high-pressure pump in the area of quantity control valve (Y94) with cold cleaning solvent and dry with compressed air

 Depending on installation situation, use an absorbent, lint-free cloth to collect escaping fuel. Vacuum up any particles, like paint, from around hole.

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A

5

Disconnect electrical connection (1)

6

Remove screw/bolts (2)

 Screw/bolt, quantity control valve to high-pressure pump housing flange

*BA07.16-P-1008-01H

7

Pull quantity control valve (Y94) out of housing flange by hand using rotary movements


Do not pry out quantity control valve (Y94) with a tool and do not tilt.
This avoids damage to the housing flange and on the quantity control valve (Y94).

 Catch escaping fuel with a dry cloth.

 Installation: Lightly grease sealing rings (3) with special grease.

Special grease

*BR00.45-Z-1036-06A



Clean

8

Clean flange hole and sealing surface of housing flange


Remove any paint and dirt particle, particularly in the flange bore.
Malfunctions can occur otherwise.

9

Clean fuel filter (4)

10

Install in the reverse order

 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

11

Check fuel system for leaks with engine running

12

Connect diagnostic system, read out fault memory and delete if necessary



AD00.00-P-2000-04B

 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

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1005-01N

Charge air manifold fastening plate bolt on engine support

Nm

20

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1006-01N

Bolt, bracket for electric switchover valves to fastening plate

Nm

9

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
Gottlieb-Daimler-Str. 12
69115 Heidelberg
Germany
Tel. +49 6221 5301-0
Fax +49 6221 5301-176
http://kluthe.com