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

ENGINE 646.951 in MODEL 211.004 

ENGINE 646.961 in MODEL 211.006 /206 /606 

ENGINE 646.962 in MODEL 203.007 /207 /707 

ENGINE 646.963 in MODEL 203.008 /208 /708 

ENGINE 647.961 in MODEL 211.016 /216 /616 

ENGINE 648.960 in MODEL 220.025 /125 

ENGINE 648.961 in MODEL 211.023 /026 /223 /226 

ENGINE 646.966 in MODEL 209.308 

Shown on engine 646.961 in model 211 

Fig 1: Identifying Quantity Control Valve High Pressure Pump Electrical Connector And Bolt

Shown on engine 646.961 in model 211 

Fig 2: Identifying Sealing Ring And Bore

	Removing
	Risk of explosion  caused by fuel igniting, risk of poisoning  caused by inhaling and swallowing fuel and risk of injury  to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
1	Open engine hood	Model 203	AR88.40-P-1000P
		Model 209	AR88.40-P-1000Q
		Model 211	AR88.40-P-1000T
		Model 220	AR88.40-P-1000M
2	Remove cylinder head cover trim	Engine 646.951/961/962/963/966, 647.961	AR01.20-P-5014-02A
		Engine 648.960/961	AR01.20-P-5014-02C
3	Disconnect electrical connector (7) at the fuel temperature sensor (B50)
4	Disconnect electrical connector (2) at quantity control valve (Y94)
	Clean
5	Clean high pressure pump (1) in the area of the quantity control valve (Y94) with a cold cleaning solvent	Then dry with compressed air.
		Cold-sprayable cleaner	*BR00.45-Z-1001-04A
6	Loosen bolts (3)	Remove particles of varnish and dirt from around quantity control valve (Y94).
7	Remove bolts (3)	Do not pry out quantity control valve (Y94) with a tool and do not tilt to prevent damage to the housing flange and to the quantity control valve (Y94) itself. Pull quantity control valve (Y94) out of housing flange by hand using rotary movements. Collect exuded fuel with an absorbent rag.
8	Check flange hole and sealing surface of housing flange for dirt, cracks and scratches (see arrow)	Remove any particles of varnish or dirt, especially around from flange bore to guarantee smooth and trouble-free function.
9	Take off sealing rings (4, 5)	While using the old quantity control valve (Y94),
10	Suction off any dirt particles from out of the holes (6) of the quantity control valve (Y94)
	Install
11	Lightly grease new sealing rings (4, 5) with special grease and fit to quantity control valve (Y94)	Do not damage sealing rings (4, 5) during assembly to prevent leaks.
		Special grease	*BR00.45-Z-1036-06A
12	Fit quantity control valve (Y94), and push it into the housing flange and align by rotating	The quantity control valve (Y94) must be installed flush with the housing flange.
13	Thread in bolts (3) by hand
14	Tighten screws (3)		*BA07.16-P-1014-01D
	Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
15	Check fuel system for leaks with engine running
16	Install trim panel of cylinder head cover	Engine 646.951/961/962/963/966, 647.961	AR01.20-P-5014-02A
		Engine 648.960/961	AR01.20-P-5014-02C
			*BA01.20-P-1002-01G
			*BA01.20-P-1003-01G
17	Read out fault memory and erase	Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

CRANKCASE VENTILATION, CYLINDER HEAD COVER

COMMON RAIL DIESEL INJECTION (CDI)