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

ENGINE 642 in MODEL 166, 204, 207, 212, 218 

Shown: model 204.983 

Fig 1: Quantity Control Valve Remove/Install Components - Shown On Model 204.983

Courtesy of MERCEDES-BENZ USA

	Remove
	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 contact with 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
1	Remove engine cover	Model 166, 207, 212, 218
2	Unclip pipework for Active Roll Stabilization on impact plate	MODEL 166 with CODE 468 (ACTIVE CURVE SYSTEM) The impact plate is installed in front of the belt drive.
3	Remove impact plate	Model 166, 207, 212, 218
4	Disconnect electrical connector (2) at quantity control valve (Y94)
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 degreasing agent/cold cleaning solvent HAKU 1025-920	*BR00.45-Z-1051-04A
6	Loosen screw/bolts (3)	Remove particles of varnish and dirt from around quantity control valve (Y94).
7	Remove screw/bolt (3)	Do not pry 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). 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	Remove any paint and dirt particle, particularly in the flange bore. This ensures perfect functionality.
9	Take off sealing rings (4, 5)	When using the old quantity control valve (Y94)
10	Suction off any dirt particles from the holes (6, 7) in the quantity control valve (Y94)	When using the old 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. This prevents leaks occurring.
		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 screw/bolts (3) by hand
14	Tighten screw/bolts (3)	Screw/bolt, quantity control valve to high-pressure pump housing flange	*BA07.16-P-1018-01C
15	Create electrical connector (2) at quantity control valve (Y94)
	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
16	Check fuel system for leaks with engine running
17	Install impact plate	MODEL 166, 207, 212, 218
18	Unclip pipework for Active Roll Stabilization on impact plate	Model 166 with code (468) ACTIVE CURVE SYSTEM
19	Reinstall engine cover	Model 166, 207, 212, 218
20	Read out and erase fault memory using STAR DIAGNOSIS
			AD00.00-P-2000-04A