101040-9140 ZEXEL 9 410 612 598 BOSCH FUEL-INJECTION PUMP 9410612598 1010409140

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Diesel exhaust fluid may begin to leak from the 421-6842 Control Valve As due to breakage of the valve stem.
Illustration 1 g03774942
Location of valve assemblySolution
In order to fix the valve assembly leakage, rework the hose installation and replace the valve if the valve stem has broken. Refer to the following ""Rework Procedure"".Required Parts
Table 1
Required Parts    
Item    Qty    Part Number    Description    
1     1     421-6842     Control Valve As (1)    
2     2     132-5789     Clip    
3     2     3S-2093     Cable Strap    
( 1 ) If neededRework Procedure
Check the diesel exhaust fluid leakage from valve assembly (1). If there is no leakage, skip Steps 2 and 3. If there is leakage present, perform the following Steps 1 through 6.
Illustration 2 g03774935
(1) 421-6842 Control Valve As (4) 8M-2773 Clip or 067-2551 Clip (depending on sales model) (5) 8T-4137 Bolt (6) 8T-4121 Hard Washer (7) 6S-8620 Hose Clamp
Remove two clips (4), two bolts (5), and two washers (6) .Note: Retain the bolts and washers for reuse when installing the new clips.
Remove valve assembly (1) and two clamps (7) .
Attach the two hoses to new valve assembly (1). Secure by tightening the clamps to a torque of 1.4 0.3 N m (12.4 2.7 lb in).Note: Insert the hose up to the root of the valve tube.Note: Place the clamp on the straight portion of the hose by the bead of the valve tube.
Illustration 3 g03774975
(1) 421-6842 Control Valve As (3) 3S-2093 Cable Strap (5) 8T-4137 Bolt (6) 8T-4121 Hard Washer (A) 90 degree angle
Install two new clips (2) and secure with bolts (5) and washers (6) on the mounting boss.
Tighten bolts (5) to a torque of 55 10 N m (40.6 7.8 lb ft).
Secure both hoses to clips (2) using straps (3). Ensure that both hoses are straight against valve assembly (1) .Note: The clips must be attached at a 90 degree angle to the valve assembly. Refer to Illustration 3.Note: Do not apply a twisting force on the valve assembly when securing the hoses.Note: Do not deform the hoses when tightening the straps.