Common Rail Diesel - Repair Parts
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- Clement Cole
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1 Common Rail Diesel - Repair Parts Only for DRS Partner!
2 Overview Diesel System Overview Diesel System 1
3 Content Content Overview Diesel System 1 Content 2 Overview - Repair Parts 3 Tools 8 DW10TD - Repair Parts 10 Repair Parts 10 Repair Information 11 Notes 11 DV4 - Repair Parts 12 Repair Parts 12 Repair Information 13 Notes 13 DW10B - Repair Parts 14 Repair Parts 14 Repair Information 15 Notes 15 K9KEU4 - Repair Parts 16 Repair Parts 16 Repair Information 17 Notes 17 Lynx - Repair Parts 18 Repair Parts 18 Repair Information 18 Notes 19 LionV6Base - Repair Parts 20 Repair Parts 20 Repair Information 21 Notes 21 2
4 Overview - Repair Parts Overview - Repair Parts Cable Wire For Straight PCV A2C Engine: LionV6Base Cable Wire For Angled PCV A2C Engine: LionV6Base Cable Plastic Clip - LionV6 A2C Engine: LionV6Base Cylinder Roller ITP X Z Engine: DW10TD, DV4, DW10B, LionV6Base, K9K Tank Drive Plate X Z Engine: DW10B Camshaft K9K A2C Z Engine: K9KEU4 Camshaft DW10TD A2C Engine: DW10TD, LionV6Base Camshaft DV4 A2C Engine: DV4 Camshaft DW10B A2C Engine: DW10B 3
5 Overview - Repair Parts Repair Kit Flange K9K A2C Z Engine: K9KEU4 Rep Kit. HP Flange Lion V6 A2C Engine: LionV6Base Flange Assembly CR-Pump LYNX A2C Engine: Lynx Repair Kit Flange DW10TD X Z Engine: DW10TD Repair Kit Flange DV4 X Z Engine: DV4 Repair Kit Flange DW10B X Z Engine: DW10B Repair Kit Flange DW10B VOLVO X Z Engine: DW10B_Volvo Gasket Kit Flange LION V6 A2C Engine: LionV6Base Gasket Kit Flange DW10TD X Z Engine: DW10TD, K9KEU4, Lynx Gasket Kit Flange DV4 X Z Engine: DV4 Gasket Kit Flange DW10B X Z Engine: DW10B 4
6 Overview - Repair Parts Gasket Kit Highpressure Elements LION V6 A2C Engine: LionV6Base Gasket Kit High Pressure Elements X Z Engine: DW10TD, DV4, DW10B, Lynx, K9KEU4 Set Connectors K9K A2C Engine: K9KEU4 Rep Kit. HP Connectors Lion V6 A2C Engine: LionV6Base Rep Kit HP Connectors LYNX A2C Engine: Lynx Set Connectors DW10TD X Z Engine: DW10TD Set Connectors DV4 X Z Engine: DV4 Set Connectors DW10B X Z Engine: DW10B Set Connectors DW10B VOLVO X Z Engine: DW10B_Volvo 5
7 Overview - Repair Parts Repair Kit Highpressure Elements LionV6 A2C Z Engine: LionV6Base Repair Kit High Pressure Elements X Z Engine: DW10TD, DV4, DW10B, K9KEU4, Lynx Repair Kit Internal Transfer Pump X Z Engine: DW10TD, DV4, DW10B, LionV6Base, K9KEU4 Set Safety Caps K9K A2C Engine: K9KEU4 Set Safety Caps Lion V6 A2C Engine: LionV6Base Protection Plug Injector X Set Safety Caps DW10TD X Z Engine: DW10TD Set Safety Caps DV4 X Z Engine: DV4 Set Safety Caps DW10B X Z Engine: DW10B Set Safety Caps DW10B VOLVO X Z Engine: Lynx, DW10B_Volvo 6
8 Overview - Repair Parts Repair Kit Thrust Plate LionV6 A2C Engine: LionV6Base Repair Kit Thrust Plate X Z Engine: DW10TD, DV4, DW10B, K9KEU4 Rep Kit. Vol. Contr. Valve Li V6 / DT17 A2C Z Engine: LionV6Base Volume Control Valve (VCV) K9K A2C Z Engine: K9KEU4 Pressure Control Valve (PCV) X Z Engine: DW10TD, DV4, DW10B, LionV6Base, K9KEU4, Lynx Volume Control Valve (VCV) Screwed X Z Engine: DW10TD, DV4, Lynx Volume Control Valve (VCV) flanged X Z Engine: DW10B 7
9 Tools Tools Holder For Mounting Device LionV6/DT17 A2C Engine: LionV6Base Holder For Mounting Device DW10TD X Engine: DW10TD, Lynx, K9KEU4 Holder For Mounting Device DV4 X Engine: DV4 Holder For Mounting Device DW10B X Engine: DW10B Mounting Device CR-PUMPS X Holder For Mounting Device CP1 X Engine: Bosch Mounting Tool Supply K9K A2C Engine: K9KEU4 Mounting Tool Supply (DW10TD/DV4) X Engine: DW10TD 8
10 Tools PCV-WRENCH X VCV-WRENCH X PCV/VCV-WRENCH Adapter X FIT-UP AID FLANGE DW10B X Engine: DW10B Shaft Extractor X
11 DW10TD - Repair Parts DW10TD - Repair Parts Repair Parts Index Part_Number Description 01 X Z Repair Kit Flange 02 X Z Gasket Kit Flange 03 X Z Repair Kit Internal Transfer Pump (ITP) 03a X Z Cylinder Roller 04 X Z Repair Kit High Pressure Elements 05 X Z Gasket Kit High Pressure Elements 06 X Z Repair Kit Thrust Plate 07 X Z Pressure Control Valve (PCV) 08 X Z Volume Control Valve (VCV) 09 X Z Set ConnectorsHigh Pressure Pump 10 A2C Cam Shaft 10
12 DW10TD - Repair Parts 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 Nm High pressure flange screw on high pressure pump housing Nm Screw the displacement unit to the high pressure pump Nm Fuel intake hollow screw on high pressure pump Nm Fuel return line screw on high pressure pump Nm High pressure connection to high pressure pump Nm Volumetric control valve on high pressure pump Nm Pressure control valve on high pressure pump Notes 11
13 DV4 - Repair Parts DV4 - Repair Parts Repair Parts Index Part_Number Description 01 X Z Repair Kit Flange 02 X Z Gasket Kit Flange 03 X Z Repair Kit Internal Transfer Pump (ITP) 03a X Z Cylinder Roller 04 X Z Repair Kit High Pressure Elements 05 X Z Gasket Kit High Pressure Elements 06 X Z Repair Kit Thrust Plate 07 X Z Pressure Control Valve (PCV) 08 X Z Volume Control Valve (VCV) 09 X Z Set Connectors High Pressure Pump 10 A2C Cam Shaft 12
14 DV4 - Repair Parts 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 Nm High pressure flange screw on high pressure pump housing Nm Screw the displacement unit to the high pressure pump Nm Fuel intake hollow screw on high pressure pump Nm Fuel return line screw on high pressure pump Nm High pressure connection to high pressure pump Nm Volumetric control valve on high pressure pump Nm Pressure control valve on high pressure pump Notes 13
15 DW10B - Repair Parts DW10B - Repair Parts Repair Parts Index Part_Number Description 01 X Z Repair Kit Flange 01a X Z Repair Kit Flange (Volvo) 02 X Z Gasket Kit Flange 03 X Z Repair Kit Internal Transfer Pump (ITP) 03a X Z Cylinder Roller 04 X Z Repair Kit High Pressure Elements 05 X Z Gasket Kit High Pressure Elements 06 X Z Repair Kit Thrust Plate 07 X Z Pressure Control Valve (PCV) 08 X Z Volume Control Valve (VCV) flanged 09 X Z Set Connectors High Pressure Pump 09a X Z Set Connectors High Pressure Pump (Volvo) 14
16 DW10B - Repair Parts Index Part_Number Description 10 A2C Cam Shaft 11 X Z Tank Drive Plate 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 Nm High pressure flange screw on high pressure pump housing Nm Screw the displacement unit to the high pressure pump Nm High pressure connection to high pressure pump 14 6+/-1 Nm tightening torque value for flange mounted VCV Nm Pressure control valve on high pressure pump Notes 15
17 K9KEU4 - Repair Parts K9KEU4 - Repair Parts Repair Parts Index Part_Number Description 01 A2C Z Repair Kit Flange 02 X Z Gasket Kit Flange 03 X Z Repair Kit Internal Transfer Pump (ITP) 03a X Z Cylinder Roller 04 X Z Repair Kit High Pressure Elements 05 X Z Gasket Kit High Pressure Elements 06 X Z Repair Kit Thrust Plate 07 X Z Pressure Control Valve (PCV) 08 A2C Z Volume Control Valve (VCV) 09 A2C Set Connectors High Pressure Pump 10 A2C Z Cam Shaft 16
18 K9KEU4 - Repair Parts 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 Nm High pressure flange screw on high pressure pump housing Nm Screw the displacement unit to the high pressure pump Nm Fuel intake hollow screw on high pressure pump Nm Fuel return line screw on high pressure pump Nm High pressure connection to high pressure pump Nm Volumetric control valve on high pressure pump Nm Pressure control valve on high pressure pump Nm Support on high-pressure pump Notes 17
19 Lynx - Repair Parts Lynx - Repair Parts Repair Parts Index Part_Number Description 01 A2C Assembly Flange 02 X Z Gasket Kit Flange 04 X Z Repair Kit High Pressure Elements 05 X Z Gasket Kit High Pressure Elements 07 X Z Pressure Control Valve (PCV) 08 X Z Volume Control Valve (VCV) 09 A2C Set Connectors High Pressure Pump 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) 18
20 Lynx - Repair Parts Index Note Description 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 Nm High pressure flange screw on high pressure pump housing Nm Screw the displacement unit to the high pressure pump Nm Fuel return line screw on high pressure pump Nm High pressure connection to high pressure pump Nm Volumetric control valve on high pressure pump Nm Pressure control valve on high pressure pump Notes 19
21 LionV6Base - Repair Parts LionV6Base - Repair Parts Repair Parts Index Part_Number Description 01 A2C Repair Kit Flange 02 A2C Gasket Kit Flange 03 X Z Repair Kit Internal Transfer Pump (ITP) 03a X Z Cylinder Roller 04 A2C Z Repair Kit High Pressure Elements 05 A2C Gasket Kit High Pressure Elements 06 A2C Repair Kit Thrust Plate 07 X Z Pressure Control Valve (PCV) 08 A2C Z Volume Control Valve (VCV) 09 A2C Set Connectors High Pressure Pump 10 A2C Cam Shaft 11a A2C Cable Wire For Straight PCV 20
22 LionV6Base - Repair Parts Index Part_Number Description 11b A2C Cable Wire For Angled PCV 12 A2C Cable Plastic Clip - LionV6 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 9 Nm High pressure flange screw on high pressure pump housing Nm Screw the displacement unit to the high pressure pump Nm Fuel intake hollow screw on high pressure pump Nm Fuel return line screw on high pressure pump Nm High pressure connection to high pressure pump Nm Volumetric control valve on high pressure pump Nm Pressure control valve on high pressure pump Notes 21
23 Dealer s stamp Continental Trading GmbH Sodener Strasse Schwalbach Deutschland Tel: Fax: replacementparts@vdo.com 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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