common rail diesel - repair parts - auto...

Common Rail Diesel - Repair Parts Only for DRS Partner !

Overview – Diesel System

10/2010 1

Overview – Diesel System

Content

10/2010 2

Content

Overview – Diesel System 1

Content 2

Overview 3

Overview - Repair Parts 5

Tools 11

DW10TD - Repair Parts 13 Repair Parts 13 Repair Information 14 Notes 14

DV4 - Repair Parts 15 Repair Parts 15 Repair Information 16 Notes 16

DW10B - Repair Parts 17 Repair Parts 17 Repair Information 18 Notes 18

K9KEU4 - Repair Parts 19 Repair Parts 19 Repair Information 20 Notes 20

Lynx - Repair Parts 21 Repair Parts 21 Repair Information 21 Notes 22

LionV6Base - Repair Parts 23 Repair Parts 23 Repair Information 24 Notes 24

DW10TD - Total system 25

DV4 EU3 - Total system 27

DV4 EU4 - Total system 29

K9K EU4 - Total system 31

K9K EU4 - Total system (incl. FAP) 33

Lynx - Total system 35

LionV6Base - Total system 37

LionV6Upgrade - Total system 39

LionV8 - Total system 41

Overview

10/2010 3

Overview Category DW10TD DV4 DW10B X39-800-300-031Z

Tank Drive Plate (Oldham coupling)

Camshaft A2C59511247 Camshaft DW10TD

A2C59511248 Camshaft DV4

A2C59511249 Camshaft DW10B

Flange X39-800-300-009Z Repair Kit Flange DW10TD

X39-800-300-021Z Repair Kit Flange DV4

X39-800-300-022Z Repair Kit Flange DW10B X39-800-300-030Z Repair Kit Flange DW10B VOLVO

Gasket_Flange X39-800-300-001Z Gasket Kit Flange DW10TD

X39-800-300-019Z Gasket Kit Flange DV4

X39-800-300-020Z Gasket Kit Flange DW10B

Gasket_HP_Elements X39-800-300-004Z Gasket Kit High Pressure Elements

X39-800-300-004Z Gasket Kit High Pressure Elements


HP_Connector X39-800-300-002Z Set Connectors DW10TD

X39-800-300-015Z Set Connectors DV4

X39-800-300-016Z Set Connectors DW10B X39-800-300-017Z Set Connectors DW10B VOLVO

HP_Elements X39-800-300-008Z Repair Kit High Pressure Elements

X39-800-300-008Z Repair Kit High Pressure Elements


ITP X39-800-300-010Z Repair Kit Internal Transfer Pump

X39-800-300-010Z Repair Kit Internal Transfer Pump


Protection_Cap X39-800-300-003Z Set Safety Caps DW10TD

X39-800-300-012Z Set Safety Caps DV4

X39-800-300-013Z Set Safety Caps DW10B X39-800-300-014Z Set Safety Caps DW10B VOLVO

Thrust Plate X39-800-300-011Z Repair Kit Thrust Plate

X39-800-300-011Z Repair Kit Thrust Plate

X39-800-300-011Z Repair Kit Thrust Plate

Overview

10/2010 4

Category K9KEU4 Lynx LionV6Base A2C59513201

Cable Wire For Straight PCV A2C59513376 Cable Wire For Angled PCV A2C59513493 Cable Plastic Clip - LionV6

Camshaft A2C53282143Z Camshaft K9K

A2C59511247 Camshaft DW10TD

Flange A2C20000777Z Repair Kit Flange K9K

A2C59512972 Flange Assembly CR-Pump LYNX

A2C59512212 Rep Kit. HP Flange Lion V6

Gasket_Flange X39-800-300-001Z Gasket Kit Flange DW10TD

X39-800-300-001Z Gasket Kit Flange DW10TD

A2C59512213 Gasket Kit Flange LION V6

Gasket_HP_Elements X39-800-300-004Z Gasket Kit High Pressure Elements


A2C59512214 Gasket Kit Highpressure Elements LION V6

HP_Connector A2C59512191 Set Connectors K9K

A2C59512242 Rep Kit HP Connectors LYNX

A2C59512211 Rep Kit. HP Connectors Lion V6

HP_Elements X39-800-300-008Z Repair Kit High Pressure Elements


A2C20003768Z Repair Kit Highpressure Elements LionV6

ITP X39-800-300-010Z Repair Kit Internal Transfer Pump


Protection_Cap A2C59512192 Set Safety Caps K9K

X39-800-300-014Z Set Safety Caps DW10B VOLVO

A2C59512210 Set Safety Caps Lion V6

Thrust Plate X39-800-300-011Z Repair Kit Thrust Plate

A2C59513284 Repair Kit Thrust Plate LionV6

Overview - Repair Parts

10/2010 5

Overview - Repair Parts Cable Wire For Straight PCV A2C59513201 System: LionV6Base

Cable Wire For Angled PCV A2C59513376 System: LionV6Base

Cable Plastic Clip - LionV6 A2C59513493 System: LionV6Base

Cylinder Roller ITP X39-800-300-023Z System: DW10TD, DV4, DW10B, LionV6Base, K9K

Tank Drive Plate (Oldham coupling) X39-800-300-031Z System: DW10B

Camshaft K9K A2C53282143Z System: K9KEU4

Camshaft DW10TD A2C59511247 System: DW10TD, LionV6Base

Camshaft DV4 A2C59511248 System: DV4

Camshaft DW10B A2C59511249 System: DW10B


10/2010 6

Repair Kit Flange K9K A2C20000777Z System: K9KEU4

Rep Kit. HP Flange Lion V6 A2C59512212 System: LionV6Base

Flange Assembly CR-Pump LYNX A2C59512972 System: Lynx

Repair Kit Flange DW10TD X39-800-300-009Z System: DW10TD

Repair Kit Flange DV4 X39-800-300-021Z System: DV4

Repair Kit Flange DW10B X39-800-300-022Z System: DW10B

Repair Kit Flange DW10B VOLVO X39-800-300-030Z System: DW10B_Volvo

Gasket Kit Flange LION V6 A2C59512213 System: LionV6Base

Gasket Kit Flange DW10TD X39-800-300-001Z System: DW10TD, K9KEU4, Lynx

Gasket Kit Flange DV4 X39-800-300-019Z System: DV4

Gasket Kit Flange DW10B X39-800-300-020Z System: DW10B


10/2010 7

Gasket Kit Highpressure Elements LION V6 A2C59512214 System: LionV6Base

Gasket Kit High Pressure Elements X39-800-300-004Z System: DW10TD, DV4, DW10B, Lynx, K9KEU4

Set Connectors K9K A2C59512191 System: K9KEU4

Rep Kit. HP Connectors Lion V6 A2C59512211 System: LionV6Base

Rep Kit HP Connectors LYNX A2C59512242 System: Lynx

Set Connectors DW10TD X39-800-300-002Z System: DW10TD

Set Connectors DV4 X39-800-300-015Z System: DV4

Set Connectors DW10B X39-800-300-016Z System: DW10B

Set Connectors DW10B VOLVO X39-800-300-017Z System: DW10B_Volvo


10/2010 8

Repair Kit Highpressure Elements LionV6 A2C20003768Z System: LionV6Base

Repair Kit High Pressure Elements X39-800-300-008Z System: DW10TD, DV4, DW10B, K9KEU4, Lynx

Repair Kit Internal Transfer Pump X39-800-300-010Z System: DW10TD, DV4, DW10B, LionV6Base, K9KEU4

Set Safety Caps K9K A2C59512192 System: K9KEU4

Set Safety Caps Lion V6 A2C59512210 System: LionV6Base

Protection Plug Injector X39-800-100-040

Set Safety Caps DW10TD X39-800-300-003Z System: DW10TD

Set Safety Caps DV4 X39-800-300-012Z System: DV4

Set Safety Caps DW10B X39-800-300-013Z System: DW10B

Set Safety Caps DW10B VOLVO X39-800-300-014Z System: Lynx, DW10B_Volvo


10/2010 9

Repair Kit Thrust Plate LionV6 A2C59513284 System: LionV6Base

Repair Kit Thrust Plate X39-800-300-011Z System: DW10TD, DV4, DW10B, K9KEU4

Volume Control Valve (VCV) LionV6 A2C20000719Z System: LionV6Base

Volume Control Valve (VCV) K9K A2C53259841Z System: K9KEU4

Pressure Control Valve (PCV) X39-800-300-005Z System: DW10TD, DV4, DW10B, LionV6Base, K9KEU4, Lynx

Volume Control Valve (VCV) Screwed X39-800-300-006Z System: DW10TD, DV4, Lynx

Volume Control Valve (VCV) flanged X39-800-300-018Z System: DW10B


10/2010 10

Tools

10/2010 11

Tools Holder For Mounting Device LionV6/DT17 A2C59511240 System: LionV6Base

Holder For Mounting Device DW10TD X39-800-200-005 System: DW10TD, Lynx, K9KEU4

Holder For Mounting Device DV4 X39-800-200-006 System: DV4

Holder For Mounting Device DW10B X39-800-200-007 System: DW10B

Mounting Device CR-PUMPS X39-800-200-009

Holder For Mounting Device CP1 X39-800-200-011 System: Bosch

Mounting Tool Supply K9K A2C59512866 System: K9KEU4

Fit-Up Aid Flange DW10B X39-800-200-004 System: DW10B

Mounting Tool Supply (DW10TD/DV4) X39-800-200-010 System: DW10TD

Tools

10/2010 12

PCV-Wrench X39-800-200-001

VCV-Wrench X39-800-200-002

PCV/VCV-Wrench Adapter X39-800-200-003

Shaft Extractor X39-800-200-008

DW10TD - Repair Parts

10/2010 13


Repair Parts

Index Part_Number Description 01 X39-800-300-009Z Repair Kit Flange DW10TD 02 X39-800-300-001Z Gasket Kit Flange DW10TD 03 X39-800-300-010Z Repair Kit Internal Transfer Pump 03a X39-800-300-023Z Cylinder Roller ITP 04 X39-800-300-008Z Repair Kit High Pressure Elements 05 X39-800-300-004Z Gasket Kit High Pressure Elements 06 X39-800-300-011Z Repair Kit Thrust Plate 07 X39-800-300-005Z Pressure Control Valve (PCV) 08 X39-800-300-006Z Volume Control Valve (VCV) Screwed 09 X39-800-300-002Z Set Connectors DW10TD 10 A2C59511247 Camshaft DW10TD


10/2010 14

Repair Information

Index Note Description 01 20,011mm +0,030mm Measure the bearing of the pump shaft (inside caliber) 02 27,011mm +0,030mm Measure the bearing of the eccentric (inside caliber) 03 20,011mm +0,030mm Measure the bearing of the cam disk (inside caliber) 04 19,980mm -0,013mm pump shaft (on the mating surface to the flange bearing) 05 19,980mm -0,013mm pump shaft (on the mating surfave to the housing bearing) 06 26,980mm -0,013mm pump shaft (the cams on the pump shaft) 07 20,011mm +0,030mm Check / measure the high-pressure pumpe-flange (inside caliber) 08 1,3,5,2,4,6 Tightening sequence of the fastening screws 09 10 Nm High pressure flange screw on high pressure pump housing 10 14 Nm Screw the displacement unit to the high pressure pump 11 16 Nm Fuel intake hollow screw on high pressure pump 12 14 Nm Fuel return line screw on high pressure pump 13 35 Nm High pressure connection to high pressure pump 14 12 Nm Volumetric control valve on high pressure pump 15 28 Nm Pressure control valve on high pressure pump

Notes

DV4 - Repair Parts

10/2010 15

DV4 - Repair Parts

Repair Parts

Index Part_Number Description 01 X39-800-300-021Z Repair Kit Flange DV4 02 X39-800-300-019Z Gasket Kit Flange DV4 03 X39-800-300-010Z Repair Kit Internal Transfer Pump 03a X39-800-300-023Z Cylinder Roller ITP 04 X39-800-300-008Z Repair Kit High Pressure Elements 05 X39-800-300-004Z Gasket Kit High Pressure Elements 06 X39-800-300-011Z Repair Kit Thrust Plate 07 X39-800-300-005Z Pressure Control Valve (PCV) 08 X39-800-300-006Z Volume Control Valve (VCV) Screwed 09 X39-800-300-015Z Set Connectors DV4 10 A2C59511248 Camshaft DV4

DV4 - Repair Parts

10/2010 16

Repair Information


Notes

DW10B - Repair Parts

10/2010 17


Repair Parts

Index Part_Number Description 01 X39-800-300-022Z Repair Kit Flange DW10B 01a X39-800-300-030Z Repair Kit Flange DW10B VOLVO 02 X39-800-300-020Z Gasket Kit Flange DW10B 03 X39-800-300-010Z Repair Kit Internal Transfer Pump 03a X39-800-300-023Z Cylinder Roller ITP 04 X39-800-300-008Z Repair Kit High Pressure Elements 05 X39-800-300-004Z Gasket Kit High Pressure Elements 06 X39-800-300-011Z Repair Kit Thrust Plate 07 X39-800-300-005Z Pressure Control Valve (PCV) 08 X39-800-300-018Z Volume Control Valve (VCV) flanged 09 X39-800-300-016Z Set Connectors DW10B


10/2010 18

Index Part_Number Description 09a X39-800-300-017Z Set Connectors DW10B VOLVO 10 A2C59511249 Camshaft DW10B 11 X39-800-300-031Z Tank Drive Plate (Oldham coupling)

Repair Information

Index Note Description 01 20,011mm +0,030mm Measure the bearing of the pump shaft (inside caliber) 02 27,011mm +0,030mm Measure the bearing of the eccentric (inside caliber) 03 20,011mm +0,030mm Measure the bearing of the cam disk (inside caliber) 04 19,980mm -0,013mm pump shaft (on the mating surface to the flange bearing) 05 19,980mm -0,013mm pump shaft (on the mating surfave to the housing bearing) 06 26,980mm -0,013mm pump shaft (the cams on the pump shaft) 07 20,011mm +0,030mm Check / measure the high-pressure pumpe-flange (inside caliber) 08 1,3,5,2,4,6 Tightening sequence of the fastening screws 09 10 Nm High pressure flange screw on high pressure pump housing 10 14 Nm Screw the displacement unit to the high pressure pump 13 37 Nm High pressure connection to high pressure pump 14 6+/-1 Nm tightening torque value for flange mounted VCV 15 28 Nm Pressure control valve on high pressure pump

Notes

K9KEU4 - Repair Parts

10/2010 19


Repair Parts

Index Part_Number Description 01 A2C20000777Z Repair Kit Flange K9K 02 X39-800-300-001Z Gasket Kit Flange DW10TD 03 X39-800-300-010Z Repair Kit Internal Transfer Pump 03a X39-800-300-023Z Cylinder Roller ITP 04 X39-800-300-008Z Repair Kit High Pressure Elements 05 X39-800-300-004Z Gasket Kit High Pressure Elements 06 X39-800-300-011Z Repair Kit Thrust Plate 07 X39-800-300-005Z Pressure Control Valve (PCV) 08 A2C53259841Z Volume Control Valve (VCV) K9K 09 A2C59512191 Set Connectors K9K 10 A2C53282143Z Camshaft K9K


10/2010 20

Repair Information

Index Note Description 01 20,011mm +0,030mm Measure the bearing of the pump shaft (inside caliber) 02 27,011mm +0,030mm Measure the bearing of the eccentric (inside caliber) 03 20,011mm +0,030mm Measure the bearing of the cam disk (inside caliber) 04 19,980mm -0,013mm pump shaft (on the mating surface to the flange bearing) 05 19,980mm -0,013mm pump shaft (on the mating surfave to the housing bearing) 06 26,980mm -0,013mm pump shaft (the cams on the pump shaft) 07 20,011mm +0,030mm Check / measure the high-pressure pumpe-flange (inside caliber) 08 1,3,5,2,4,6 Tightening sequence of the fastening screws 09 10 Nm High pressure flange screw on high pressure pump housing 10 14 Nm Screw the displacement unit to the high pressure pump 11 16 Nm Fuel intake hollow screw on high pressure pump 12 16 Nm Fuel return line screw on high pressure pump 13 35 Nm High pressure connection to high pressure pump 14 12 Nm Volumetric control valve on high pressure pump 15 28 Nm Pressure control valve on high pressure pump 16 10 Nm Support on high-pressure pump

Notes

Lynx - Repair Parts

10/2010 21

Lynx - Repair Parts

Repair Parts

Index Part_Number Description 01 A2C59512972 Flange Assembly CR-Pump LYNX 02 X39-800-300-001Z Gasket Kit Flange DW10TD 04 X39-800-300-008Z Repair Kit High Pressure Elements 05 X39-800-300-004Z Gasket Kit High Pressure Elements 07 X39-800-300-005Z Pressure Control Valve (PCV) 08 X39-800-300-006Z Volume Control Valve (VCV) Screwed 09 A2C59512242 Rep Kit HP Connectors LYNX

Repair Information

Index Note Description

Lynx - Repair Parts

10/2010 22

Index Note Description 01 20,011mm +0,030mm Measure the bearing of the pump shaft (inside caliber) 02 27,011mm +0,030mm Measure the bearing of the eccentric (inside caliber) 05 19,980mm -0,013mm pump shaft (on the mating surfave to the housing bearing) 06 26,980mm -0,013mm pump shaft (the cams on the pump shaft) 08 1,3,5,2,4,6 Tightening sequence of the fastening screws 09 10 Nm High pressure flange screw on high pressure pump housing 10 14 Nm Screw the displacement unit to the high pressure pump 12 16 Nm Fuel return line screw on high pressure pump 13 35 Nm High pressure connection to high pressure pump 14 12 Nm Volumetric control valve on high pressure pump 15 28 Nm Pressure control valve on high pressure pump

Notes

LionV6Base - Repair Parts

10/2010 23


Repair Parts

Index Part_Number Description 01 A2C59512212 Rep Kit. HP Flange Lion V6 02 A2C59512213 Gasket Kit Flange LION V6 03 X39-800-300-010Z Repair Kit Internal Transfer Pump 03a X39-800-300-023Z Cylinder Roller ITP 04 A2C20003768Z Repair Kit Highpressure Elements LionV6 05 A2C59512214 Gasket Kit Highpressure Elements LION V6 06 A2C59513284 Repair Kit Thrust Plate LionV6 07 X39-800-300-005Z Pressure Control Valve (PCV) 08 A2C20000719Z Volume Control Valve (VCV) LionV6 09 A2C59512211 Rep Kit. HP Connectors Lion V6 10 A2C59511247 Camshaft DW10TD


10/2010 24

Index Part_Number Description 11a A2C59513201 Cable Wire For Straight PCV 11b A2C59513376 Cable Wire For Angled PCV 12 A2C59513493 Cable Plastic Clip - LionV6

Repair Information


Notes

DW10TD - Total system

10/2010 25

DW10TD - Total system Index Description Ignition sequence: C1 - C3 - C4 - C2 01 Air filters 02 Mass air flow meter with manifold air temperature sensor 03 Turbocharger 04 Catalytic converter 05 Pressure regulating valve (wastegate) 06 Accelerator pedal 07 Accelerator pedal sensor 08 Coolant temperature sensor 09 Crankshaft sensor 10 High pressure sensor 11 Engine control unit (ECU) 12 Tank transducer 13 Fuel tank 14 Hand pump 15 Fuel filter 16 Diesel Common Rail Pump (DCP) 17 Pre-glow relay 18 Fuel temperature sensor 19 Rail 20 Injector 21 Camshaft sensor 22 Vacuum pump 23 Exhaust return valve 24 Pressure control valve (EPW) for exhaust recirculation 25 Throttle valve 26 Pressure control valve (EPW) for throttle valve

DW10TD - Total system

10/2010 26

DV4 EU3 - Total system

10/2010 27

DV4 EU3 - Total system Index Description Ignition sequence: C1 - C3 - C4 - C2 01 Air filters 02 Mass air flow meter with manifold air temperature sensor 03 Turbocharger 04 Catalytic converter 05 Pressure regulating valve (wastegate) 06 Accelerator pedal 07 Accelerator pedal sensor 08 Coolant temperature sensor 09 Crankshaft sensor 10 High pressure sensor 11 Engine control unit (ECU) 12 Tank transducer 13 Fuel tank 14 Hand pump 15 Fuel filter 16 Diesel Common Rail Pump (DCP) 17 Glow plug relay 18 Fuel temperature sensor 19 Rail* 20 Injector 21 Camshaft sensor 22 Vacuum pump 23 Exhaust return valve 24 Pressure control valve (EPW) for exhaust


10/2010 28


10/2010 29

DV4 EU4 - Total system Index Description Ignition sequence: C1 - C3 - C4 - C2 01 Air filters 02 Mass air flow meter with manifold air temperature sensor 03 Turbocharger 04 Catalytic converter 05 Pressure regulating valve (wastegate) 06 Accelerator pedal 07 Accelerator pedal sensor 08 Coolant temperature sensor 09 Crankshaft sensor 10 High pressure sensor 11 Engine control unit (ECU) 12 Tank transducer 13 Fuel tank 14 Hand pump 15 Fuel filter 16 Diesel Common Rail Pump (DCP) 17 Glow plug relay 18 Fuel temperature sensor 19 Rail* 20 Injector 21 Camshaft sensor 22 Vacuum pump 23 Exhaust return valve 24 Pressure control valve (EPW) for exhaust recirculation 25 Throttle valve 26 Charge air temperature sensor 27 Charge pressure sensor


10/2010 30

K9K EU4 - Total system

10/2010 31

K9K EU4 - Total system Index Description Firing order: C1 - C3 - C4 - C2 01 Air filter 02 Air-mass flow sensor with intake air temperature sensor 03 VTG with electric adjustment 04 Turbocharger 05 Catalytic converter 06 Accelerator pedal 07 Accelerator pedal sensor 08 Coolant temperature sensor 09 Crankshaft sensor 10 High-pressure sensor 11 Fuel temperature sensor 12 Glow plug relay 13 Engine control unit (ECU) 14 Fuel gauge sender 15 Fuel tank 16 Hand pump 17 Fuel filter 18 Diesel common rail (DCR) pump 19 Rail 20 Injector 21 Exhaust gas recirculation valve with position sensor 22 Throttle valve with position sensor 23 Boost pressure sensor 24 Camshaft sensor 25 Intercooler 26 Vacuum pump 27 Exhaust gas recirculation cooler (EGR) with electrical by-pass valve 28 Cooler

K9K EU4 - Total system

10/2010 32

K9K EU4 - Total system (incl. FAP)

10/2010 33

K9K EU4 - Total system (incl. FAP) Index Description Firing order: C1 - C3 - C4 - C2 01 Air filter 02 Air-mass flow sensor with intake air temperature sensor 03 VTG with electric adjustment 04 Turbocharger 05 High-pressure sensor 06 Injector 07 Rail 08 Vacuum pump 09 Diesel common rail (DCR) pump 10 Heater 11 Intercooler 12 Boost pressure sensor 13 Coolant temperature sensor 14 Throttle valve with position sensor 15 Crankshaft sensor 16 Exhaust gas recirculation valve with position sensor 17 Camshaft sensor 18 Exhaust gas recirculation cooler (EGR) with electrical by-pass valve 19 Exhaust gas temperature sensor 20 Fuel temperature sensor 21 Fuel filter 22 Hand pump 23 Accelerator pedal 24 Accelerator pedal sensor 25 Water sensor 26 Fuel cooler 27 Engine control unit (ECU) 28 Glow plug relay 29 Thermo plug control box 30 Fuel tank 31 Fuel gauge sender 32 Fuel pump 33 Stop valve 34 Fuel filter 35 Catalytic converter 1 36 Exhaust injector 37 Temperature sensor upstream of catalytic converter 2 (TPC) 38 Catalytic converter 2 + particle filter 39 Differential pressure sensor

K9K EU4 - Total system (incl. FAP)

10/2010 34

Index Description 40 Temperature sensor upstream of particle filter 41 Temperature sensor downstream of particle filter

Lynx - Total system

10/2010 35

Lynx - Total system Index Description Ignition sequence: C1 - C3 - C4 - C2 01 Air filter 02 Air-mass flow meter with intake air temperature sensor 03 Turbocharger 04 Catalytic converter 05 Smart Turbo 06 Accelerator pedal 07 Accelerator pedal sensor 08 Cylinder head temperature sensor 09 Crankshaft sensor 10 High-pressure sensor 11 Fuel temperature sensor 12 Glow plug relay 13 Engine control unit (ECU) 14 Fuel gauge sender 15 Fuel tank 16 Fuel filter 17 Diesel common rail (DCR) pump 18 Spherical rail 19 Injector 20 Exhaust gas recirculation valve with position sensor 21 Boost pressure sensor 22 Camshaft sensor 23 Intercooler 24 Vacuum pump 25 Exhaust gas recirculation cooler (EGR)

Lynx - Total system

10/2010 36

LionV6Base - Total system

10/2010 37

LionV6Base - Total system Index Description Firing order: C1 - C4 - C2 - C5 - C3 - C6 01 Air-mass flow sensor with intake air temperature sensor 02 Turbocharger 03 Control valve for VTG with position sensor 04 Accelerator pedal 05 Accelerator pedal sensor 06 Engine control unit (ECU) 07 Fuel gauge sender 08 Fuel tank 09 Fuel filter 10 Diesel common rail (DCR) pump 11 Diverter rail 12 Left-hand rail bank 13 Right-hand rail bank 14 Injector 15 Exhaust gas recirculation valve with position sensor 16 Throttle valve with position sensor 17 Boost pressure sensor 18 Camshaft sensor 19 Crankshaft sensor 20 Intercooler bypass throttle with position sensor 21 Intercooler 22 Exhaust gas recirculation cooler (EGR) 23 Fuel cooler 24 Glow plug relay 25 Distributor valve 26 Fuel temperature sensor 27 High-pressure sensor 28 Coolant temperature sensor

LionV6Base - Total system

10/2010 38

LionV6Upgrade - Total system

10/2010 39

LionV6Upgrade - Total system Index Description Firing order: C1 - C4 - C2 - C5 - C3 - C6 01 Air-mass flow meter with intake air temperature sensor 02 Turbocharger 03 Intercooler 04 Intercooler bypass throttle with position sensor 05 Crankshaft sensor 06 Throttle valve with position sensor 07 Boost pressure sensor 08 Charge air temperature sensor 09 Right-hand rail bank 10 High-pressure sensor 11 Left-hand rail bank 12 Injector 13 Diesel common rail (DCR) pump 14 Coolant temperature sensor 15 Camshaft sensor 16 Exhaust gas recirculation valves with position sensors 17 Exhaust gas recirculation cooler (EGR) 18 Fuel temperature sensor 19 Fuel cooler 20 Glow plug relay 21 Engine control unit (ECU) 22 Fuel tank with electrical internal transfer pump 23 Fuel filter 24 Accelerator pedal 25 Accelerator pedal sensor 26 Control valve for VTG with position sensor 27 Primary converter inlet temperature sensor 28 Primary converter 29 Primary converter outlet temperature sensor 30 Underfloor catalytic converter 31 Particulate filter 32 Differential pressure sensor 33 Particulate filter outlet temperature sensor

LionV6Upgrade - Total system

10/2010 40

LionV8 - Total system

10/2010 41

LionV8 - Total system Index Description Firing order: C1 - C5 - C4 - C2 - C6 - C3 - C7 - C8 01 Air-mass flow meter with intake air temperature sensor 02 Turbocharger 03 Intercooler 04 Throttle valves with position sensors 05 Crankshaft sensor 06 Boost pressure sensors 07 Diesel common rail (DCR) pump 08 Charge air temperature sensors 09 Exhaust gas recirculation valves with position sensors 10 Exhaust gas recirculation cooler (EGR) 11 Left-hand rail bank 12 Right-hand rail bank 13 Camshaft sensor 14 Coolant temperature sensor 15 Engine oil temperature sensor 16 Engine oil pressure sensor 17 Injector 18 High-pressure sensor 19 Fuel temperature sensor 20 Multipath intake manifold 21 Glow plug relay 22 Engine control unit (ECU) 23 Fuel cooler 24 Fuel tank with electrical internal transfer pump 25 Fuel filter 26 Accelerator pedal sensor 27 Accelerator pedal 28 Control valve for VTG with position sensor 29 Primary converter inlet temperature sensors 30 Primary converters 31 Primary converter outlet temperature sensors 32 Underfloor catalytic converters 33 Particulate filter 34 Differential pressure sensors 35 Particulate filter outlet temperature sensors

LionV8 - Total system

10/2010 42

Dealer’s stamp

Continental Trading GmbH Sodener Strasse 9 65824 Schwalbach Deutschland Tel: +49 6196 87-0 Fax: +49 6196 86571 www.vdo.de E-Mail: [email protected] VDO – A Trademark of the Continental Corporation The information provided in this brochure contains only general descriptions or performance characteristics, which do not always apply as described in case of actual use or which may change as a result of further development of the products. This information is merely a technical description of the product. This information is not meant or intended to be a special guarantee for a particular quality or a particular durability. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. We reserve the right to make changes in availability as well as technical changes without prior notice.

Continental Trading GmbH © 2010 Please note: Application – The products described in this catalogue are designed for use in land vehicles, engines and equipment. Disclaimer – The data in this replacement parts catalogue has been compiled and processed for the purpose of presenting our replacement parts range and is correct

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