Eendv 110001 - DV11 Engine PDF

FOREWORD
This maintenance manual is designed to serve as a reference for DOOSAN Infracore (here after DOOSAN’s)
customers and distributors who wish to gain basic product knowledge on DOOSAN's DV11 Diesel engine.
This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct injection type) has
been so designed and manufactured to be used for industrial purpose. That meets all the requirements such as
low noise, fuel economy, high engine speed, and durability.
To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT
OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be performed.
Removal Adjustment
Installation Cleaning
Disassembly Pay close attention-Important
Reassembly Tighten to specified torque
Align the marks Use special tools of manufacturer's
Directional Indication Lubricate with oil
Inspection Lubricate with grease
Measurement
During engine maintenance, please observe following instructions to prevent environmental damage;
● Take old oil to an old oil disposal point only.

● Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
● Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.
● The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and
special waste.
If you have any question or recommendation in connection with this manual, please do not hesitate to contact
our head office, dealers or authorized service shops near by your location for any services.
For the last, the content of this maintenance instruction may be changed without notice for some quality
improvement. Thank you.
May. 2006
CONTENTS
1. Safety Regulations & Specifications

1.1. Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3. Engine Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4. Engine Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. Technical Information
2.1. Engine Model and Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2. Diagnostic Tool (SCAN-200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3. Engine Character . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4. Diagnosis and Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5. Engine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3. Disassembly and Reassembly of Major Components

3.1. Engine Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2. Measurement and Inspection of Major Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3. Engine Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.4. Fuel Injection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.5. Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.6. Engine Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.7. Operating Condition of the ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4. Commissioning and Operation

4.1. Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.2. Breaking-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.3. Inspection after Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.4. Operation in Winter Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.5. Engine Components Check after Long Time Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.6. Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.7. Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.8. Adjustment of Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.9. Tightening the Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

5. Maintenance of Major Components
5.1. Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.2. Lubricating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.3. Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5.4. Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6. Special Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
● Appendix
● Part & After service center
● Applications for DOOSAN engine

1. Safety Regulations & Specifications
1.1. Safety Regulations
1.1.1. General notes

● Day-to-day use of power engines and the service products necessary for running them presents no
problems if the persons occupied with their operation, maintenance and care are given suitable
training and think as they work.
● This summary is a compilation of the most important regulations, These are broken down into main
sections which contain the information necessary for preventing injury to persons, damage to
property and pollution. In addition to these regulations those dictated by the type of engine and its
site are to be observed also.
IMPORTANT:
If despite all precautions, an accident occurs, in particular through contact with
caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being splashed
in the eyes etc, consult a doctor immediately.
1.1.2. To prevent accidents with injury to persons

(1) Engine starting and operation
● Before putting the engine into operation for the first time, read the operating instructions carefully
and familiarize yourself with the “critical” points. If you are unsure, ask your DOOSAN
representative or service man.
● For reason of safety we recommend you attach a notice to the door of the engine room
prohibiting the access of unauthorized persons and that you draw the attention of the operating
personal to the fact that they are responsible for the safety of person who enter the engine room.
● The engine must be started and operated only by authorized personnel.
● Ensure that the engine cannot be started by unauthorized person.
● When the engine is running, do not get too close to the rotating parts.
● Do not touch the engine with bare hands when it is warm from operation risk of bums.
● Exhaust gases are toxic. If it is necessary to run an engine in an enclosed area, remove the
exhaust gases from the area with an exhaust pipe extension.
(2) Maintenance and care
● Always carry out maintenance work when the engine is switched off. If the engine has to be
maintained while it is running, e.g. changing the elements of change-over filters, remember that
there is a risk of scalding. Do not get too close to rotating parts.
● Change the oil when the engine is warm from operation.
CAUTION:
There is a rise of burns and scalding. Do not touch oil drain plug or oil filters with
bare hands.
-1- Safety Regulations & Specifications

● Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the
oil will not overflow.
● If change or refill the cooling water, disassemble the drain plug when the engine has cooled
down. Heated cooling water has the risk of scalding and safety accidents.
● Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional
hydraulic oil circuit) during the operation. The fluids which flow out can cause injury.
● Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled only
when the engine is switched off.
● Keep service products (anti-freeze) only in containers which can not be confused with drinks
containers.
● Comply with the manufacturer's instructions when handling batteries.
CAUTION:
Accumulator acid is toxic and caustic. Battery gases are explosive.
Therefore it should be done by an expert of the handling professionally.
(3) When carrying out checking, setting and repair work

● Checking, setting and repair work must be carried out by authorized personnel only.
● Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench
could lead to injury.
● When the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep
lifting gear in good condition.
● When do electric weld, stop the engine, power off, then remove the wire harness°Ø connector
which is connected to the ECU.
● Do not weld the electric control unit (ECU) absolutely, and do not damage on it by electrical or
mechanical shock.
● When working on the electrical system disconnect the battery earth cable first. Connect it up
again last in prevent short circuits.
1.1.3. To prevent damage to engine and premature wear

(1) Never demand more of the engine than it was designed to yield for its intended purpose.
Detailed information on this can be found in the sales literature. Engine control unit must not be
adjusted without prior written permission of DOOSAN.
(2) If faults occur, find the cause immediately and have it eliminated in order to prevent more serious of
damage.
(3) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility for damage resulting
from the installation of other parts which are supposedly “just as good”
(4) In addition to the above, note the following points.
● Never let the engine run when dry, i.e. without lube oil or coolant.
● Pay attention to cleanliness. The Diesel fuel must be free of water.
● Use only DOOSAN approved service products (engine oil, anti-freeze and anticorrosion agent)
Safety Regulations & Specifications -2-

● Refer to the subjects of recommendation of the fuel.
● Have the engine maintained at the specified intervals.
● Do not switch off the engine immediately when it is warm, but let it run without load for about 5
minutes so that temperature equalization can take place.
● Never put cold coolant into an overheated engine.
● Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Do
not exceed the maximum permissible tilt of the engine.
● Always ensure that the testing and monitoring equipment (for battery charge, oil pressure,
coolant temperature) function satisfactorily.
● Do not let the raw water pump run dry. If there is a risk of frost, drain the pump when the engine
is switched off.
1.1.4. To prevent pollution

(1) Engine oil, filter elements, fuel filters
● Take old oil only to an oil collection point.
● Take strict precautions to ensure that oil does not get into the drains or into the ground. The
drinking water supply could be contaminated.
● Filter elements are classed as dangerous waste and must be treated as such.
(2) Coolant
● Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
● When disposing of spent coolant comply with the regulations of the relevant local authorities.
1.1.5. Notes on safety in handling used engine oil

Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains
dangerous substances which have caused skin cancer in animal experiments. If the basic rules of
hygiene and health and safety at work are observed, health risks are not to the expected as a result of
handling used engine oil.
< Health precautions >

● Avoid prolonged or repeated skin contact with used engine oil.
● Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
● Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
● After washing apply a fatty skin cream to the skin.
● Change oil-soaked clothing and shoes.
● Do not put oily rags into your pockets.

CAUTION:
Ensure that used engine oil is disposed of properly.
- Engine oil can endanger the water supply.
For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations
are punishable. Collect and dispose of used engine oil carefully. For information on collection points
please contact the seller, the supplier or the local authorities.
1.1.6. General repair instructions

1. Before performing service operation, disconnect the grounding cable from the battery for reducing
the chance of cable damage and burning due to short-circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint
damage.
4. The use of proper tools and special tools where specified is important to efficient and reliable service
operation.
5. Use genuine DOOSAN parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and
new ones should be prepared for installation as normal function of the parts can not be maintained if
these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in groups.
Keeping fixing bolts and nut separate is very important as they vary in hardness and design
depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to
make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for bolts and nuts torques.
12. When service operation is completed, make a final check to be sure service has been done property.
13. Work the fuel line after the common rail pressure and engine temperature is checked with the SCAN-
200. (past about 5 minutes after engine stop)

1.2. Engine Specifications
Engine model DV11

Items
Water-cooled, 4 cycle V-type 90°,

Engine type
Turbo charged & intercooled
Combustion chamber type Direct injection type
Cylinder liner type Wet type
Timing gear system Gear driven type
No. of piston ring 2 compression ring, 1 oil ring
No. of cylinder-bore x stroke (mm) 6 - 128 x 142
Total piston displacement (cc) 10,964
Compression ratio 17.0 : 1
Engine dimension
(mm) 1,060 x 1,039 x 1,345
(length x width x height)
Engine weight (kg) 882
Rotating direction (from flywheel) Counter clockwise
Firing order 1-4-2-5-3-6
Fuel high pressure pump type Bosch CP3.4 fuel high pressure pump type
Engine control type Electric control type(ECU)
Injector type Multi-hole(8 x Φ 0.197 Bosch DLLA146)
Fuel injection pressure (kg/cm2) 250bar (operating pressure 1,600bar)
Intake valve 0.4

Valve clearance
Exhaust valve 0.5
Open at 24° (B.T.D.C)

Intake valve
Close at 30° (A..B.D.C)
Open at 52.5° (B.B.D.C)

Exhaust valve
Close at 14.5° (A.T.D.C)
Fuel filter type Full-flow (cartridge)
Oil pressure at idle speed 1.0 ~ 3.0

(kg/cm2) at rated speed 3.0 ~ 5.5
Using lubrication oil ACEA-E5 (API CI-4 class)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Full-flow (cartridge)
Lubricating oil capacity (max./min.) (lit) 41 / 27
Oil cooler type Water cooled
Oil pressure indicator Oil pressure sensor

Engine model DV11
Items
Water pump Belt driven centrifugal type
Cooling method Pressurized circulation
Cooling water capacity(engine only) (lit) 14.3
Type Wax pallet type (71 ~ 85°C)
Open at (°C) 71°C

Thermostat
Open wide at (°C) 85°C
Valve lift (mm) 8
Water temperature indicator Water temperature sensor mounted
Turbo charger Exhaust gas driven type (waste gate)
Engine stop system Fuel feeding shut-off by ECU
Alternator (voltage - capacity) (V-A) 24 - 50
Starting motor(voltage - output) (V-kW) 24 - 7.0
Air heater capacity (V-kW) 24 - 2.64
Battery capacity (V-AH) 20 - 150
1.3. Engine Power

tolerance : ± 5%
Engine model Performance
Remark
Power Torque Low idle High idle
Model Suffix
(PS / rpm) (kg.m / rpm) (rpm) (rpm)
EUJEA 333 / 1,800 157 / 1,300 750 1,900 Tier-2
EUJEB 333 / 1,800 157 / 1,300 750 1,900 Tier-3

DV11
EUJEC 297 / 1,800 140 / 1,300 750 1,900 Tier-2
EUJED 297 / 1,800 140 / 1,300 750 1,900 Tier-3
* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349)

1.4. Engine Performance Curve
1.4.1. Performance curve (333PS)
160
150
140
Torque (kg.m)
130
300
Output (PS)
200
Fuel consumption (g/ps.h)

100 150
140
500 1000 1500 2000
Revolution (rpm)
EF6OM001
Performance ISO 1585 (SAE J1349)
Output (max.) 245 kW (333PS) / 1,800 rpm
Torque (max.) 1,540 N.m (157 kg.m) / 1,300 rpm
Fuel consumption (min.) 211 g/kW.h (155 g / PS.h)

1.4.2. Performance curve (297PS)
140
130
Torque (kg.m)
120
110
300
Output (PS)
200

100
150
140
500 1000 1500 2000
Revolution (rpm)
EF6OM002

1.4.3. Performance curve (297PS : Tier-3)
140
130
Torque (kg.m)
120
110
300
Output (PS)
200

100
160
150
140
500 1000 1500 2000
Revolution (rpm)
EF6OM003

1.5. Engine Assembly
1.5.1. Engine sectional view (longitudinal)
3 4 5 6
7 8 9 10 11 12
EF6OM004
1. Vibration damper 7. Drain plug
2. Thermostat 8. Oil suction pipe
3. Exhaust valve 9. Crank shaft
4. Push rod 10. Oil pump
5. Tappet 11. Fly wheel
6. Cam shaft 12. Flywheel housing
Safety Regulations & Specifications - 10 -

1.5.2. Engine sectional view (cross)
4 5
7
3
EF6OM005
1. Oil cooler 5. Common rail
2. Cylinder liner 6. Injector
3. Cylinder head 7. Oil spray nozzle
4. Fuel high pressure pump 8. Connecting rod
- 11 - Safety Regulations & Specifications

1.5.3. Engine assembly
6
8
9
4
3 10
15
11
16
12
17
13
18
14 19
20
21
EF6OM006
1. Electric control unit (ECU) 8. Lifting hook 15. Fuel filter
2. Air con. compressor 9. Air pipe 16. Alternator
3. Water pump (Intercooler to intake manifold) 17. Intake manifold
4. Water outlet 10. Starting motor 18. Breather
5. Idle pulley 11. Oil filler cap 19. Water inlet
6. Air pipe 12. Air heater 20. Mounting bracket
(turbocharger to intercooler) 13. Cylinder head cover 21. Oil filter
7. Turbocharger 14. Flywheel housing
Safety Regulations & Specifications - 12 -

2. Technical Information
2.1. Engine Model and Serial Number
● The engine model and serial number is
located on the engine as illustrated.
● These numbers are required when
requesting warranty and ordering parts. Engine number
(located the
They are also referred to as engine cylinder block)
model and serial number because of
their location.
● Engine serial No. (example 1 : DV11) EF6OM007

DV11 6 00001 EA
Engine model suffix(EUJEA)

Serial no.
Production year(2006)
Engine model
● Engine serial No. (example 2 : DV11)

DV11 6 00001 EB
Engine model suffix(EUJEA)

Serial no.
Production year(2006)
Engine model
- 13 - Technical Information
2.2. Diagnostic Tool (SCAN-200)
The SCAN-200 is a powerful tool to support
the service personal diagnosing and repairing
of electric system for vehicle with installed
DV11 engine.
IB3O302I
< SCAN-200 tool>
● High resolution digital type display.

● Soft touch key-board.
Diagnostic tool
● Diagnosis trouble code or sensor data
operation via help.
● Large memory expansion ROM pack data
storage area for flight recorded data.
NOTE:
Inspect the electrical parts problem EF6OM053
with SCAN-200 and refer diagnostic

manual.
2.3. Engine Character

● DOOSAN’s DV11 diesel engine apply the over head valve and the turbocharger, is the electric control
engine of the air cooling type by the cooling fan.
● The fuel is stored under pressure in the high-pressure accumulator (the "Common Rail") ready for
injection. The injected fuel quantity is defined by the driver, and the start of injection and injection
pressure are calculated by the ECU on the basis of the stored map. The ECU then triggers the
solenoid valve sensor that the injector (injection unit) at each engine cylinder injects accordingly.
● Oil gallery cooling is used for the piston of

the engine. The design of the gallery, the
design and location of the oil spray nozzle
and the quantity of oil flowing in the
gallery are critical in order to achieve the
desired temperature reduction. The cross
section shape of the gallery should be
designed to achieve sufficient oil
movement to maximize cooling efficiency. ED7OM007
Technical Information - 14 -
2.3.1. Cylinder block
● The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is extended to a level
below the crankshaft center line. The engine has replaceable wet cylinder liners and individual
cylinder heads.
2.3.2. Piston/ Connecting rod/ Crank assembly

● The forged crankshaft has screwed-on the balance weights. Radial seals with replaceable wearing
rings on crankshaft and flywheel are provided to seal the crankcase penetrations.
● The connecting rods are die-forged, diagonally split and can be removed through the top of the
cylinders together with the pistons. Crankshaft and connecting rods run in steel-backed lead bronze
ready-to fit type bearings.
2.3.3. Electric control unit : ECU

● This electric control unit is used to
control the engine feed fuel.
● ECU is connected with various sensors,
control the engine to keep the optimum
condition on the basis of input values
from this sensors.
CAUTION:
Do not connect or disconnect the EE1OM010
ECU to/from the wiring harness
without first removing the negative
(-) battery cable from the battery. Do
not perform remove the inner parts
of ECU.
2.3.4. Common rail system
● Pressure generation and fuel injection are completely decoupled from each other in the "Common
Rail" fuel injection system. The injection pressure is generated independent of engine speed and
injected fuel quantity stored in the ECU.
No. 3 injector
No. 2 injector
No. 1 injector
Pressure limiter valve
No. 6 injector
O NT
FR No. 5 injector
No. 4 injector
Common rail pressure sensor
EE2OM012
2.3.5. Engine timing
● Camshaft, oil pump and fuel high pressure pump are driven by a gear train arranged at the inside of
flywheel housing.
High pressure pump gear (Z=24)
High pressure pump drive gear

(Z=80)
Cam shaft gear

(Z=86)
Crank shaft gear

(Z=43)
Oil pump drive gear

(Z=44)
Viewed from crankshaft pulley

EF6OM008
2.3.6. Valves
● The overhead valves are actuated via tungsten carbide tappets, push rods and rocker arms from the
camshaft.
2.3.7. Lubrication system
● The engine is equipped with force-feed lubrication. The pressure is produced by a gear pump whose
drive gear is in direct mesh with the crankshaft gear at the flywheel end.
● The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the
main distributor gallery and from there to the main bearings, big-end bearings and camshaft
bearings as well as to the small-end bearings and the rocker arms. The turbocharger is also
connected to the engine lubricating system. The cylinder walls and timing gears are splash-
lubricated.
● Each cylinder has an oil jet provided for cooling the underside of the pistons. The lube oil is cleaned
in a full-flow oil filter.
Turbo charger
Oil spray nozzle(for Cam shaft)
Cam shaft bush
Oil filter By-pass valve(2.1bar)
to Rocker arm
Oil spray nozzle

(for Piston cooling)
Oil cooler
Oil filter
Oil pump relief valve(10bar)
Oil pressure Regulating valve(4.5bar)
Oil pump
Oil suction pipe
EF6OM009
2.3.8. Engine oil
● Check oil level with the oil level gauge and replenish if necessary.
● Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ~ 10 minutes for oil
drain into the crankcase before checking oil level. The oil level must be between Max. and Min.
lines on the gauge.
● Engine oil should be changed at the specified intervals. Oil filter cartridge should be changed
simultaneously.
- First oil change : After 50Hr operating
First oil change After 50Hr operating
Oil change interval Every 500Hr
● The following oils are also recommended.
Engine oil SAE No. API No.
ACEA-E5
DV11 SAE 10W40
(API CI-4)
● Engine oil capacity
Engine oil capacity
Oil pan inside

Total
Engine model
Max. Min. (lit)
(lit) (lit)
DV11 41 27 44
Engine oil viscosity - ambient temperature
SAE 5W - 30
SAE 10W - 30
Ambient -40 C -20 C 0 C 20 C 40 C 50 C

temperature (-40 F) (-14 F) (+32 F) (68 F) (104 F) (122 F)
SAE 5W - 40
SAE 10W - 40
SAE 15W - 40
SAE 15W - 50
SAE 20W - 50
EE1OM176
2.3.9. Oil filter

● Check for oil pressure and oil leaks, and
repair or replace the oil filter if necessary.
● Change the oil filter cartridge
simultaneously at every replacement of
engine oil.
EF6OM010
2.3.10. Poly belt

● Use a fan belt of genuine part, and
replace if damaged, frayed, or
deteriorated.
● Check the fan belt for belt tension,
inspect suitability for specified
dimensions.
EF6OM011
- Adjust the tension of poly belt when
pressed down with finger force (F kg):
S(SPAN)
T = 0.015 x S
(Deflection : 1.5 mm per 100 mm) T D
d
F
EB5O6001
2.3.11. Air cleaner

● In case the elements are deformed,
damaged or if the air cleaner has a
crack, replace it. (genuine parts use)
● By the definite interval, the elements
must be cleaned and replaced.
EF6OM050
2.3.12. Pre fuel filter

● Drain water in cartridge with loosening
the drain plug under cartridge manually
Priming pump
from time to time.
● The filter cartridge should be replaced
at every 500Hr.
Pre fuel filter & cartridge
Drain plug
EF6OM012
2.3.13. Fuel filter

● The filter cartridge should be replaced
at every 500Hr.
Fuel filter & cartridge
EE1OM017
2.3.14. Fuel requirements
● DOOSAN diesel engines was designed to use Number 2-D diesel fuel or equivalent that meets
specification ASTM D (Grade Low Sulfur). For maximum fuel economy, Number 2-D fuel
whenever possible. When temperatures are below -7°C, use Number 1-D fuel. If Number 1-D fuel
is not available, the mixture of one kerosene to two gallons of Number 2-D fuel can be used. Once
kerosene has been added, the engine should be run for several minutes to mix the fuel.
2.3.15. How to select fuel oil

● Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life,
and acceptable exhaust emission levels. DOOSAN engines are designed to operate on most
diesel fuels marketed today. In general, fuels meeting the properties of ASTM Designation D975
(grades 1-D and 2-D : Grade Low Sulfur) have provided satisfactory performance.
● The ASTM 975 specification, however, does not in itself adequately define the fuel characteristics
needed for assurance of fuel quality.
● The properties listed in the fuel oil selection chart below have provided optimum engine
performance. Grade 2-D fuel is normally available for generator service. Grade 1-D fuel should not
be used in pleasure craft engines, except in an emergency.
● Fuel oil selection chart
Fuel classification Unit DIN EN 590
Cetane number - ≥ 51
Cetane index - ≥ 46
Density @ 15°C kg/m3 820 ~ 845
Poly aromatic hydrocarbon % (m/m) ≤ 11
Sulfur content mg/kg ≤ 50
Flash point °C ≥ 55
Ash content % (m/m) ≤ 0.01
Water content mg/kg ≤ 200
Particulate matter content mg/kg ≤ 24
Copper corrosion 50°C, 3h grade 1
Oxidation stability g/m3 ≤ 25
Lubricity (wsd 1.4 @ 60°C) g/m3 ≤ 460
Viscosity (40°C) mm2/s 2.0 ~ 4.5
Distillation (95%) °C ≤ 360
Note :
The cloud point should be 6°C below the lowest expected fuel temperature to prevent
clogging of fuel fitters by crystals
2.3.16. Fuel injection system
● The fuel is stored under pressure in the common rail ready for injection. The injected fuel quantity is
defined by the driver, and the start of injection and injection pressure are calculated by the ECU on
the basis of the stored maps. The ECU then triggers the solenoid valves so that the injector
(injection unit) at each engine cylinder injects accordingly.
Common rail
Fuel high pressure pump

(CP 3.4 fuel pump)
Fuel filter
Pre fuel filter
Injector
Fuel cooler ECU Cylinder head
Fuel high pressure connector
Fuel tank
EF6OM013
2.3.17. Bleeding the fuel system

● Loosen the fuel delivery pipe connected to the fuel high pressure pump from the secondary fuel
filter, operate manually the priming pump until bubble is not found, and bleed the system.
2.3.18. Injector & high pressure connector
● Be careful to mix the foreign matter into
the injector and inside of the connector
High pressure fuel O-ring Injector harness
for connecting the high pressure at connector
connector nut
disassembly and check.
Injector
● O-ring and cupper washer should be
changed with new one at reassembly.
● Assemble after coat the oil on the O-
Seal ring
ring.
● Assemble after check serial number at EE1OM019
replacement.
● Have to assemble according to
assembly order refer to the chapter of
the disassembly and reassembly.
2.3.19. Inter cooler

● The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and
performance depends on the intake air condition greatly.
● Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is
decreased and engine malfunction is occurred. So you always check whether the intake air
systems like air filter element are worn or polluted
Air / air intercooler

with radiator
(combined radiator)
Air flow by cooling fan
Hot air by turbo charger

compressor
Cooled air to intake

manifold (max. 50 C)
EF6OM014
2.3.20. Turbo charger
● The turbocharger needs not any
specific maintenance. 1 D 2
3
● Every time of engine replacement, a
5
leakage or clogging of oil pipes should
be inspected. A B
● Air cleaner should be maintained

carefully for nut or foreign material not 4 E
to get in. Periodic inspection should be
applied on the compressed air and C EAO5008I
exhaust gas pipes, For leaking air will
bring the overheat engine, an
immediate repair must be done.
● During the operation that is surrounded
by the dust and oil mixed air, frequent
cleaning must be done on the
impellers. Tear down the impeller
casing (attention: be careful not to
bend) and must clean with non-acid
solvent solution. If necessary, use
plastic scraper If impeller is severely
polluted, dip the impeller into solution
and may be better to clean it with stiff
brush
Then one thing to beware is to dip only
impeller part and so do not support by
impeller but bearing housing.
2.3.21. Cooling system
The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by belt from the
crankshaft pulley.
● Check the coolant level of the expansion tank by removing the expansion tank filler cap, and add
coolant if necessary
● When injecting antifreeze solution, first drain out the old coolant from the cylinder block and
radiator, and then clean them with cleaning solution.
● Be sure to mix soft water with antifreeze solution.
Cylinder head Cylinder head
3 6
2 5
1 4 Cylinder No.
Oil cooler
Cylinder block
Thermostat
Water pump
Radiator
EE2OM018
2.3.22. Coolant pressure cap
● Check the pressure valve opening
pressure using an expansion tank cap
tester. Radiator
● Replace the filler cap assembly if the Surge tank Radiator cap
cap cap
measured valve does not reach the
specified limit. Radiator
NOTE :
Because it is dangerous to open the
pressure cap quickly when coolant
is hot, after lowering the inside
pressure of the tank by slow-
opening at first open it fully.
Drain valve
EF6OM015
2.3.23. Cooling water

● Regarding the cooling water that is to be used for engine, the soft water not the hard water must be
used.
● The engine cooling water can be used diluting it with anti-freezing solution 40% and the additive for
rust prevention (DCA4) 3 ~ 5 %.
● The density of above solution and additive must be inspected every 500 hours to maintain it
properly.
NOTE :
The proper density control of anti-freezing solution and rust preventing additive will
be able to prevent the rusting effectively and maintain the stable quality of engine.
For the improper control might give the fatal damage to the cooling water pump and
cylinder liners, detail care is needed.
● Since DV11 engine cylinder liner is wet type, particularly the cooling water control should be applied
thoroughly.
● The density of anti-freezing solution and additive for rust prevention is able to be confirmed by the
cooling water test kit.
(Fleetguard CC2602M or DOOSAN 60.99901-0038)
● How to use the cooling water test kit
(1) When the cooling water temp. of engine is in the range of 10 ~ 55°C, loosen the plug for cooling
water discharge and fill the plastic cup about a half.
NOTE :
In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard
to measure the accurate density. Take the cooling water sample necessarily
loosening the cooling water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after 3 - 5 seconds past, take the paper
out through water agitation, and shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.
NOTE :
However, it should not elapse longer than 75 sec, and if it did, the hue would change.
(4) Make the numerical value by comparing the test paper which hue has changed with the color list
of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color indication of test
paper storage bottle, confirm the density. (Then, the density indication must be in the hue range
of 33% to 50%).
(6) The brown at the middle of test paper and the lower pink color indication represent the additive
state for rust prevention, and the proper range is that the meeting numerical value of brown
(vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on
the test paper storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more
than 0.8, pour out the cooling water about 50% and then readjust the density after refilling with
clean fresh water.
● Amount of Anti-freeze in winter
Ambient
Cooling water (%) Anti-freeze (%)
Temperature (°C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
2.3.24. Valve clearance adjust procedure
● After letting the #1 cylinder's piston come at the compression top dead center by turning the
crankshaft, adjust the valve clearances.
● Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified value
between a rocker arm and a valve stem and adjust the clearance with adjusting screw respectively
and then tighten with the lock nut.
● As for the valve clearance, adjust it when in cold, as follows.
Engine model Intake valve (A) Exhaust valve (A)
DV11 0.4 mm 0.5 mm
Rocker arm
Valve adjusting bolt
Caliper adjusting bolt
Valve adjusting nut

A
Caliper Push rod
Intake valve spring
Valve
Valve seat
Intake & exhaust valve adjusting EF6OM016
< Adjust the valve clearance as following order >
1) Rotating the engine, let #6 cylinder overlap.
2) In time that #1 cylinder become the state of top dead center, adjust the valve clearance
corresponding to “ ◎ ” of following lists.
3) Rotating the crankshaft by 90° rotation, adjust the valve clearance corresponding to “ ⊙ ”.
4) Rotating the crankshaft by 1 rotation (360° rotation), let #1 cylinder overlap.
corresponding to “ ● ” of following lists.
6) Rotating the crankshaft by 450° rotation, adjust the valve clearance corresponding to “ ○ ”.
7) After rechecking the valve clearance, readjust if necessary.
● No. 1 cylinder is located at the side where cooling water pump was installed.
Fly wheel Cylinder no. Exhaust valve Intake valve Cooling fan
6 5 4
3 2 1
Intake valve Exhaust valve

Valve adjusting position
EE2OM020
● Adjusting of valves (Type 1)
Cylinder No 1 2 3 4 5 6
Valve adjusting Exhaust Intake Exhaust Intake Exhaust Intake Intake Exhaust Intake Exhaust Intake Exhaust
#1 cylinder top dead center

◎ ◎ ◎ ◎ ◎
(#5 cylinder valve overlap)
Crankshaft 90° rotation ⊙
360° rotation
#5 cylinder top dead center ● ● ● ● ●
Crank shaft 450° rotation ○

Adjusting of the valve overlapping on each cylinder is done as follow.
When each cylinder is valve overlap

1 4 2 5 3 6
(Firing cylinder no. order)
Valve adjusting cylinder No. 5 3 6 1 4 2
2.3.25. Battery
● Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in
case of poor condition.
● Inspect for amount of electrolytic solution, and replenish if insufficient.
● Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish.
Viewing
Liquid level Liquid level upper limit Isotator
the gravity
indicating line Liquid level lower limit
meter
1,100
1,200
1,300 UPPER LEVEL
LOWER LEVEL
EFM1007I
2.3.26. Starting motor
● The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-hand side. As
parts of every engine overhaul, the starter pinion and ring gear should be cleaned with a brush
dipped in fuel and then a coat of grease should be applied again.
24V x 7.0kW
Terminal switch Battery terminal

M5 x 0.8 M10 x 1.25
for Ground
M10 x 1.5
EF6OM017
Always protect starter motor against moisture.
Circuit diagram
Battery terminal M
Assistance
switch
Key switch
Battery M Starter
EE2OM022
IMPORTANT :
Always disconnect the battery earth cable before starting work on the electrical
system. Connect up the earth cable last as there is otherwise a risk of short-circuit.
2.4. Diagnosis and Remedy
● The following description summarizes the probable cause of and remedy for general failure by item.
● Inspect the electrical parts problem with SCAN-200 and refer diagnostic manual.
● Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected.
1. Engine Staring Impossible
Starting motor operation poor Starting motor revolution
Inspection of battery electorlytic Engine fuel

liquid amount & gravity
Inspect air cleaner Inspect amount fuel

Normal Too low
Normal Polluted Normal None

Adjustment
.
Recharging
Replace or Replenish
clean element
Inspection of loose electric
wiring & short
Check compression pressure
Normal Retighten
. Normal Too low
Replace
Inspection of starting switch Repair

.
Replace
Normal Repair
. Inspect of other parts
Replace
Inspection of starting relay Normal Check valve

clearance
Normal Replace
Adjust
Inspection of magnetic switch Check cylinder head gasket
Normal Repair Normal Replace

.
Replace
Starting motor Engine disassembly

disassembly (valve assembly, piston,
cylinder liner atc.)
2. Engine Overheated
Operating state
1. Overload
Cooling system 2. Radiator core clogged
Check coolant level
Normal Too low
Check fan belt tension,

wear or damage etc. Inspect cooling Water leakage
Normal
Normal Repair
. External Internal
Replace
Check fresh radiator tank cap Retighten Engine

Replace disassembly
Normal Replace
Check thermostat
Normal Replace
Inspect radiator
Repair
Normal Damage .
Replace
Normal Check cooling water pump
Clean cooling Normal Repair

.
water passage Replace
Engine
disassembly
3. Output insufficient
Inspect by SCAN-200 Engine Chassis

diagnostic tool
Check for clutch slip
Check for air mixing in fuel Others Adjust or replace clutch
Inspect fuel supply pump Inspect air cleaner
Normal Polluted Normal Repair

.
Replace
Inspect air leakage
Repair of air piping line
. Check valve clearance
Replace
Normal Retighten
Inspect high pressure pipe Normal Adjust .
Replace
Normal Repair Inspect cylinder head Inspect air leakage

.
gasket for damage of intercooler
Replace
Normal Replace
Inspect injector
(atomizing state)
Engine disassembly
(valve assembly)
Disassemble engine Check turbocharger

or high pressure pump
Normal Repair
.
Replace
Disassemble engine
or high pressure pump
4. Oil pressure lowered
Check if oil pressure

Check oil amount gauge indicates wrongly
Normal To low
Check cooling temperature Use recommened oil (replenish)
Normal Too high
Inspect oil quality Refer to engine overheat
Normal
Check oil relief valve Water mixed in oil Improper
Normal Retighten Disassemble engine Replace with recommended oil

.
Replace
Disassemble engine
5. Fuel Consumption Excessive
Case according to use conditions

1. Overload
2. Frequence use of low gear position
Inspect fuel leakage at high speed
3. Frequence use of high gear position
at low speed
Normal Fuel leakage
Inspect injector Retighten

.
(Injection pressure Replace
atomizing state, etc.)
Normal Adjust
Inspect common rail system

(sensor etc.)
Inspect compressed pressure
Normal Adjust Check valve clearance Repair . replace

(cylinder liner, pistion ring, piston)
Inspect cylinder head gasket
Normal Adjust
Disassemble engine
(vavle assembly, piston,
cylinder liner etc.)
6. Oil Consumption Excessive
Case according to use conditions

1. Excessive oil infusing
2. Continuous operation in low speed
or extremely cold state
Inspect oil leakage Inspect air cleaner
Clean . Replace
Normal Oil leakage
Check oil quality

External Internal
Replace with specified oil
Retighten Check compressed pressure
.
Replace
Engine disassembly Normal

(piston, cylinder liner)
Disassemble cylinder head

(valve stem seal)
7. Engine Knocking
Inspect combustin of fuel & oil

(carbon residue of exhaust gas)
Unconfirmed Confirm
Inspect compressed pressure Disassemble eingine
Normal Too low
Inspect high pressure pump Check valve clearance and

cylinder head gasket crush
Normal Adjust
Normal Replace
.
Adjust
Check fuel quality
Disassemble engine
Use specified fuel
8. Battery Discharge
Battery Wiring, Switch Alternator
Check electrolytic liquid amount Inspect cut wire shorts and Check fan belt tension & damage
loose connections
Normal Abvormal
Repair . Replace
Check charged stated Adjust

.
Replace
Discharging
Disassemble alternator
.
Voltage regulator
Normal Battery room damage Battery self dischage Battery over charging
Electrolytic Replce Charging Inspect alternator

liquid's standard voltage regulator
Replenish
Condition Causes Remedies
1) Starting difficult
(1) Starting motor trouble ● Refer to diagnostics
(2) Fuel system trouble ● Refer to diagnostics
(3) Compression ● Valve's poor shut, stem distortion Repair or replace
pressure lack ● Valve spring damage Replace valve spring
● Cylinder head gasket's leak Replace gasket
● Wear of piston, piston ring or liner Adjust
2) Idle operation abnormal ● Injection timing incorrect Check by SCAN-200

● Air mixing at high pressure pump Remove air
3) Engine output insufficient

(1) Continuous output ● Valve clearance incorrect Adjust
insufficient ● Valve tightness poor Repair
● Wear, stick, damage of piston ring Replace piston ring
● Injection timing incorrect Check
● Fuel injection amount insufficient Check injector
● Injector injection pressure Adjust or replace
improper or stuck
● Supply pump's function lowered Repair or replace
● Fuel pipe system clogged Repair
● Air suction amount insufficient Clean or replace air cleaner
● Turbocharger poor Repair or replace
(2) Output insufficient ● Compression pressure Disassemble engine

when in acceleration insufficient
● Injection timing incorrect Check
● Fuel injection amount Check
insufficient
● Injector infection pressure, Repair, replace
infection angle improper
● Supply pump's function lowered Repair or replace
● Air intake amount insufficient Clean or replace air cleaner
4) Overheating ● Engine oil insufficient or poor Replenish or replace

● Cooling water insufficient Replenish or replace
● Fan belt loosened, worn, Adjust or replace
damaged
● Cooling water pump's function Repair or replace
lowered
● Water temperature regulator's Replace
operation poor
● Valve clearance incorrect Adjust
● Exhaust system's resistance Clean or replace
increased
5) Engine noisy For noises arise compositely such

as rotating parts, lapping parts etc.,
there is necessity to search the
cause of noises accurately.
(1) Crankshaft ● As the wear of bearing or Replace bearing & grind

crankshaft progress, the oil crankshaft
clearances increase.
● Lopsided wear of crankshaft Grind or replace
● Oil supply insufficient due to oil Clean oil passage
passage clogging
● Stuck bearing Replace bearing & grind
(2) Connecting-rod and ● Lopsided wear of con rod bearing Replace bearing
connecting-rod ● Lopsided wear of crank pin Grind crankshaft
bearing ● Connecting rod distortion Repair or replace
● Stuck bearing Replace & grind crankshaft
● Oil supply insufficiency as Clean oil passage
clogging at oil passage
progresses
(3) Piston, piston pin & ● Piston clearance increase as the Replace piston & piston ring
piston ring wear of piston and piston ring
progresses
● Wear of piston or piston pin Replace
● Piston stuck Replace piston
● Piston insertion poor Replace piston
● Piston ring damaged Replace piston
(4) Others ● Wear of crankshaft, thrust bearing Replace thrust bearing

● Camshaft end play increased Replace thrust plate
● Idle gear end play increased Replace thrust washer
● Timing gear backlash excessive Repair or replace
● Valve clearance excessive Adjust valve clearance
● Abnormal wear of tappet, cam Replace tappet, cam
● Turbocharger inner part damaged Repair or replace
6) Fuel consumption ● Injection timing incorrect Check

excessive ● Fuel injection amount excessive Adjust
● Tire air pressure incorrect use of
low speed gear is too frequent
7) Oil Consumption
Excessive
(1) Oil level elevated ● Clearance between cylinder liner Replace
& piston
● Wear of piston ring, ring groove Replace piston, piston ring

● Piston ring's damage, stick, wear Replace piston ring
● Piston ring opening's disposition Correct position
improper
● Piston skirt part damaged or Replace piston
abnormal wear
● Oil ring's oil return hole clogged Replace piston ring
● Oil ring's contact poor Replace piston ring
(2) Oil level lowered ● Looseness of valve stem & guide Replace in set
● Wear of valve stem seal Replace seal
(3) Oil leak ● Looseness of connection parts Replace gasket, repair

● Various parts' packing poor Replace packing
● Oil seal poor Replace oil seal
2.5. Engine Inspection
2.5.1. Stopping engine

After checking the engine for any unusual condition at the idling speed, then turn the key switch to stop
the engine.
2.5.2. General engine inspection cycle

○ : Check & adjust ● : Replace
Inspection time (Hr)

Inspection Daily Remark
50 250 500
Check for leakage

○
(hoses, clamp)
Cooling Check the water level ○

system Check the V-belt tension ○
●
Change the coolant water
(1,200Hr)
Check for leakage ○
Check the oil level gauge ○

Lubrication ●
system Change the lubricating oil (●)
1st
●
Replace the oil filter cartridge (●)
1st
Check the leakage

Intake & ○
for intercooler (hoses, clamp)
Exhaust
System Clean and change
○
the air cleaner element
Drain the water in separator ○
Clean the fuel strainer

○
of fuel feed pump
Check the fuel line leakage ○

Fuel
system When
Check fuel injection timing
necessary
Replace the fuel filter cartridge ●
When
Check the injector nozzles
necessary
Check the exhaust gas state ○
Check the battery charging ○

Engine Check the compression When
adjust pressure necessary
Adjust intake / exhaust When

○
valve clearance necessary
* ( ● ) The engine oil change interval is determined by engine use and oil grade.
2.5.3. Use of original parts for repair and replacement
For engine is being mechanically harmonized with many parts, only when the original parts that the
manufacture recommends to use is used, the engine trouble would be preventively maintained and
capable to keep up the maximum performances.
For the analogous parts not the original parts are poor in qualities and gives ill performances, it may
rather bring early engine failure.
3. Disassembly and Reassembly of Major Components
3.1. Engine Disassembly
3.1.1. General precautions

● For the various tool storage before disassembly and parts storage after disassembly, the shelf for
parts is prepared.
● At the time of disassembly and reassembly, do the work with the naked and clean hand, and also the
working place must be maintained clean.
● The torn parts after disassembly must be kept not to collision each other.
● In disassembling, torn parts should be laid in disassembled order.
● Before performing service operation, disconnect the grounding cable from the battery for reducing
the chance of cable damage and burning due to short-circuiting.
3.1.2. Cooling water

● Remove the radiator cap. Open the drain
valve at the radiator lower part to drain
the coolant as the right figure. Radiator
Surge tank Radiator cap
cap cap
CAUTION :
When removing surge tank cap or Radiator
radiator filler cap while the engine is
still hot, cover the cap with a rag,
then turn it slowly to release the
internal steam pressure. This will
prevent a person from scalding with
hot steam spouted out from the
filler port.
Drain valve
EF6OM015
● Remove the cooling water drain plug

from the cylinder block and oil cooler,
various pipes, etc. and let the cooling
water discharge into the prepared
vessel. Cooling water drain
EF6OM018
- 45 - Engine Disassembly
3.1.3. Oil level gauge
● Take out the oil level gauge from the
guide tube.
EF6OM019
3.1.4. Engine oil

● Remove an oil drain plug from the oil
pan, and let engine oil discharge into the
prepared vessel
Drain plug
EF6OM020
3.1.5. Inter cooler

● Tear down the various hoses and air
pipes from the inter cooler.
● Remove the intercooler fixing bolts and
Cooling air to
tear it down. intake manifold
Hot air by
turbo charger
compressor
Air flow by
cooling fan
EF6OM021
3.1.6. Belt
● Loosen the belt tension adjusting bolts,
and remove the belt.
Tension
adjusting bolt
Tension
adjusting bolt EF6OM022
Engine Disassembly - 46 -
3.1.7. Air pipe & air heater
● Remove fixing bolts, then take off the air
pipe and air heater.
● Be careful about the mixing of foreign
material into interior of the turbocharger.
EF6OM023
3.1.8. Oil filter

● Loosen the filter housing fixing bolts then
the spring will force the filter housing to
move upward a little.
● Do not use again the cartridge removed
after use.
● Unscrew the oil filter head fixing bolts
and take off the oil filter head.
EF6OM024
3.1.9. Alternator
● Remove the supporting guide piece for
installing the alternator and the bracket
bolts.
● Disassemble the alternator.
EF6OM025
3.1.10. Turbocharger
● Loosen the hose clamp for connecting
the intake stake and tear down the air
pipe.
● Unscrew the turbo charger lubrication
supplying bolt and tear down oil pipe
● Unscrew the turbo charger fixing nuts
and take off the turbo charger from the
exhaust manifold.
EF6OM026
3.1.11. Fuel filter
● Disassemble the fuel hose for the fuel
supply and suction.
● Remove the fuel filter fixing bolts and
disassemble the fuel filter.
NOTE :
Seal the fuel filter to prevent from
mixing foreign material into inside
of the fuel filter after disassembling. EF6OM027
3.1.12. Exhaust manifold

● Remove the exhaust manifold fixing
bolts and tear down the manifold from
the cylinder head.
EF6OM028
3.1.13. Intake manifold

● Remove the manifold fixing bolts and
tear down the manifold from the
cylinder head.
EF6OM029
3.1.14. Common rail and high pressure pipe
● Remove the high pressure pipe
between fuel high pressure connecter
and common rail.
● Remove the common rail fixing bolts
and take off the common rail.
NOTE :
Seal the pipe to prevent from mixing
foreign material into inside of the EE2OM040
pipe after disassembling.
3.1.15. Fuel high pressure pump

● Remove the connecting pipe of the fuel
high pressure pump.
● Remove the fuel high pressure pump
fixing bolts and take off the fuel high
pressure pump by pushing to
backward.
NOTE :
Seal the fuel high pressure pump to EE2OM041
prevent from mixing foreign
material into inside of the fuel high
pressure pump after disassembling.
3.1.16. Water pump

● Loosen the various hose clamps for the
Thermostat
connections.
Water pump
● Remove the cooling water discharging
pipe and disassemble the thermostat.
● Remove the cooling water pump fixing
bolts and disassemble the cooling
water pump.
EE2OM042
3.1.17. Starting motor
● Remove the starting motor fixing nuts
and disassemble the starting motor.
EF6OM030
3.1.18. Fuel pump housing cover

● Remove the fuel pump housing cover
fixing bolts and take off the fuel pump Fixing bolt
housing cover.
● Fuel pump housing cove and cylinder Fuel pump
housing cover
block should be handled as a set
because they are tooled in pairs.
EE6OM037
3.1.19. Oil cooler

● Remove the drain plug from the oil
cooler cover and drain out the cooling
water.
● Remove the oil cooler cover fixing bolts
and disassemble the oil cooler.
EF6OM031
● Remove the oil cooler fixing bolts and

take off the oil cooler.
Drain plug
EE2OM046
3.1.20. Vibration damper
● Remove the fixing bolts for crankshaft
pulley in reverse order of assembling
and disassemble the crankshaft pulley
Dust protect cover
and vibration damper.
Crank shaft pulley & damper
EE2OM047
3.1.21. Electric control unit

● Remove the electric control unit fixing
bolts, then take off the electric control
unit and bracket.
EF6OM032
Rubber cushion
Bracket
Electric control unit

EF6OM035
3.1.22. Cylinder head cover

● Remove cylinder head cover fixing
bolts and take off the cylinder head
cover.
EE2OM050
3.1.23. Rocker arm
● Remove the rocker arm bracket fixing
bolts and take out the rocker arm.
● Pull out the push rod.
EE2OM052
3.1.24. Injector
● Remove the fuel high pressure
Injector
connecter fixing nuts and take off the
fuel high pressure connecter. Injector bush
● Remove the harness connected to

injector, then remove injector fixing
bracket bolts and take off the injector. Caliper
● Be careful about damage of the nozzle
when take off the injector. Fixing nut
● Take out the sealing from the nozzle EE1OM040
hole of the cylinder head and scrap it.
CAUTION :
1) When disassemble the injector, after the fuel high pressure connecter is separated
perfectly by removing the fuel high pressure connecter fixing nuts, then remove
injector caliper fixing bolts and take off the injector.
2) Seal the injector and the fuel high pressure connecter to prevent from mixing
foreign material into inside of the injector and the fuel high pressure connecter
after disassembling.
3.1.25. Cylinder head
● Loosen the cylinder head fixing bolts in
the reverse order of assembling, and Cylinder head bolt
remove them all and then take the Disassembly order no.
cylinder head out.
● Remove the cylinder head gasket and
scrap it.
● Eliminate the residue from the cylinder
head face and cylinder block face.
EE2OM053
CAUTION:
Be careful not to damage the
cylinder head face where its gasket
contacts.
3.1.26. Oil pan

● Remove the oil pan fixing bolts and
separate the oil pan.
● Remove the oil pan gasket and scrap it.
EF6OM033
3.1.27. Oil pump

● Remove the oil suction pipe fixing bolts
and tear them down.
● Remove the oil pump fixing bolts and
separate it.
EE1OM058
3.1.28. Piston
● Remove the connecting rod cap bolts in
the reverse order of assembling.
● Tapping the upper and lower of
connecting rod caps lightly with an
urethane hammer, separate them and
take the bearings out.
● By pushing the piston assembly with a
wooden bar toward the cylinder head's
direction remove the piston. EFM2026I
CAUTION :
Be careful for the removed pistons
not to collide each other or with the
other parts.
At the storage of pistons, maintain
them in the order of cylinders. (In
order for connecting rod caps not to
mix one another, temporarily
assemble them to the
corresponding connecting rods.)
3.1.29. Front oil seal cover

● Remove the oil seal holder fixing bolts
and tear down.
● Remove the oil seal holder fixing bolts
and tear down.
Oil seal cover
Oil seal
EE2OM055
3.1.30. Fly wheel
● Remove the flywheel fixing bolts in the
order of disassembling and remove the
flywheel.
EFM2028I
● Remove the flywheel ring gear.

● Heat the ring gear evenly with a gas
burner (up to 200°C) to invite
volumetric expansion.
● Tapping around the edges of the ring
gear with a hammer and brass bar to
remove it.
CAUTION : EA0M4028
Do not damage the flywheel.
3.1.31. Flywheel housing

● Remove the flywheel housing fixing
bolts and take them out.
● Remove the oil seal from the flywheel
housing.
Thrust
washer
Oil seal
EF6OM034
3.1.32. Crank shaft
● Remove the fixing bolts from bearing
caps.
● Remove the main bearing cap fixing
bolts in the reverse order of
assembling.
● Maintain the removed bearing caps in
the order of cylinders.
● Temporarily install the bolts at the both
side of crankshaft, and lift the EE1OM063
crankshaft with a rope.
NOTES :
Do not mingle with the metal
bearings and bearing caps
randomly. To prevent mixing,
temporarily assemble the metal
bearings to the corresponding
bearing caps in turn.
EE2OM057
3.1.33. Cam shaft & tappet

● Pull out the tappets from the cylinder
block.
● Remove the camshaft being careful not
to damage the camshaft and its
bearings.
3.1.34. Oil spray nozzle

● Remove the oil injection nozzle fixing
bolts and tear down the oil injection
nozzles.
EFM2059I
3.1.35. Cylinder liner
● By means of a special tool (Extractor),
pull out the liner from the cylinder block.
EF6OM051
3.2. Measurement and Inspection of Major Parts
3.2.1. Cleaning and inspection of cylinder block

1) Clean the cylinder block and inspect it for any crack or damage.
2) If there is any crack or severe damage, replace it and if there is minor one, correct it.
3) Inspect the oil passage and water passage for any clog and erosion.
4) By performing the hydraulic test, inspect for any leaks. With plugging the water and oil passages of
cylinder block, put in the air of 5 kg/cm2 pressure in the inlet port of cylinder block and then soak the
cylinder block in the water for about 1 minute to check for any leaks. (water temperature : 70°C)
5) Inspect the cylinder block's camshaft bush to any damage and the alignment of oil supply holes and if
abnormal, replace it.
3.2.2. Cylinder liner measurement

● Assemble the cylinder liner at the
cylinder block and measure inner
diameters at upper, middle, lower 3
levels by 45° interval and calculate the
average values after eliminating the max.
and min. values.
● If the measured values are very close to
the limit value or beyond, replace it.
EFM2032I
Standard Limit
Liner inner
diameter Φ 127.990
0.15 mm
~ Φ 128.010 mm

1) Cylinder head disassembly
● Be careful for the cylinder head gasket
contacting surface of cylinder head not to
be damaged.
● Remove the cotter pin pressing the valve
spring by means of a special tool.
● Take out the valve stem seal.
● Pull out the intake and exhaust valves. Valve spring
compression tool
EE1OM065
Measurement and Inspection of Major Parts - 58 -

2) Inspection and measurement of cylinder head
a) Damage check
● Eliminate the carbon residue and gasket piece from the cylinder head lower face thoroughly.
Then be careful for the valve seat not to be damaged.
● The cracks or damages that are difficult to search may be inspected by a hydraulic test or a
magnetic powder test. (Hydraulic test is same as for cylinder block.)
b) Distortion of lower surface

● As shown in figure, measure the
(t)
● cylinder head's distortion at 6
directions with horizontal ruler and
B
clearance gauge A
● If the measured value is beyond the C

D
limit value, correct it by means of
the fine grinding paper or grinding
E
machine. F
● If it is beyond the max. allowable EA3M2031
value, replace the cylinder head.
< Lower face warpage and thickness>
Standard Limit
Warpage 0.08 mm or less 0.1 mm
Thickness : t
116.9 ~ 117.1 mm 116.4 mm
(reference)
EE1OM157
- 59 - Measurement and Inspection of Major Parts

3) Inspection and measurement of valve and valve guide
a) Valve
● After cleaning the valves with clean
diesel oil, measure the valve stem's
outside diameter at upper, middle,
and lower to determine the wears
and if there is minor damage,
Valve stem
correct it and when the wears is
more than max allowable limit value,
replace the valves.
EFM2036I
<Valve stem outer diameter>
Standard Limit
Intake Φ 7.963~ Φ 7.977 mm Φ 7.94 mm
Exhaust Φ 7.950~ Φ 7.964 mm Φ 7.93 mm
● Inspect the scratch and wear of

valve stem seal contacting face, and
if necessary correct with the
grinding paper but if severe replace
it.
● If valve head thickness (H) becomes A
less than 1.6mm for intake and
1.3mm for exhaust, replace the
valve. EE1OM066
<Valve head thickness>
Standard Limit
Intake(A) 3.0 ~ 3.4 mm 2.5 mm
Exhaust(B) 3.3 ~ 3.7 mm 2.8 mm

b) Valve guide
● Insert the valve into valve guide and
measure the clearance between
valve and valve guide by the
shaking degree of valve.
Measuring
● If the clearance is bigger, measure point
the valve and then replace the more
worn valve guide.
<Valve stem end play> EA0M4052
Standard Limit
Intake 0.023 ~ 0.052 mm 0.10 mm
Exhaust 0.036 ~ 0.065 mm 0.15 mm
● Assemble the valve at cylinder head

valve guide and see if it is centered
with the valve seat using a special
tool.
c) Valve seat
● Inspect the damage and wear of
valve seat and if necessary replace
it.
● Assemble the valves at the cylinder
head and using the measuring
instrument from the lower face,
measure the projection amount of
valve. If the measured value is more
than the use limit, replace the valve EE1OM067
seat.
< Valve seat thickness >
Standard Limit
Intake(A) 0.38 ~ 0.42 mm 0.7 mm Valve

Exhaust(A) 0.38 ~ 0.42 mm 0.8 mm
Valve seat
< Valve seat angle >

A
Intake (B) Exhaust (B)
B
60° 45° EE1OM068

● The disassembly of valve seat can
be pulled out by means of a special
Valve seat
tool with the arc welding done at two
points of valve seat rotating tool or
valve seat.
Cylinder head
● Regarding the valve seat
assembling, shrink the valve seat by
putting it in the dry ices for about 1
hour or so, and then press it into the Welding bead EA3M2032
cylinder head by means of a special
tool.
● It is necessary to work boring of
inner diameter of it when replace the
valve seat.
● After coating the grinding powder
paste on valve head contacting face
of valve seat, and after executing a
sufficient lapping operation with the
rotating and grinding motion of
valve, wipe off the grinding agent
thoroughly.
d) Valve spring
● Inspect the outlook of valve spring
and if necessary replace it.
● By means of spring tester, measure
the tension and free length.
Free length Standard
Intake Inside 62.5 mm
Inside 62.0 mm
Exhaust EA3M2033
Outside 62.5 mm
● Measure the perpendicularity of

valve spring.
● In case that the measured value
exceeds the limit value, replace it.

< Valve spring tension >
Spring
Set length Limit
force
44 mm 39.4 kg ± 2 kg
Intake Inner
31.6 mm 65.8 kg ± 2.5 kg
41 mm 20.5 kg ± 1.5 kg
Inner
28.6 mm 32.6 kg ± 2 kg Spring tester
Exhaust
44 mm 39.4 kg ± 2 kg
Outer
31.6 mm 65.8 kg ± 2.5 kg EA0M4056
● Valve spring inclination

Use a surface plate and a square to
measure the valve spring inclination.
Inclination
If the measured value exceeds the
specified limit, the valve spring must
be replaced. Free length
Standard Limit
Valve spring Square

Less than 1.6 2.0 mm
inclination
EJM2050I
4) Cylinder head assembling

● Clean the cylinder head thoroughly.
● Coat the valve stems and valve guides
with engine oil and assemble the
valves.
● Replace the valve stem seals with new
ones and insert the stem seals to the
valve guides of cylinder head with a
special tool. (Be careful for the valve
stem seals not to be damaged.)
● Install the valve spring washer to valve
guide. Painted portion
(Assemble spring
● After putting on the inside, outside to the upper side)
spring, install the valve spring seat on
them.
NOTES:
Install the valve spring seat with
“TOP” (painted in red) side up. EE1OM070

● Pressing the spring down with a
special tool, assemble by inserting the
valve cotter.
● After the valve is assembled, inspect
the valve tapping it lightly with an
urethane hammer if accurate
assembling was done.
Valve spring
compression tool
EE1OM065
3.2.4. Rocker arm ass`y

1) Rocker arm disassembling
● Remove the snap rings in one end of
rocker arm with a pair of pliers.
● Tear down washer, rocker arm.
● Disassemble the rocker arm bush by
means of a press.
EE2OM052
2) Inspection and measurement

● Measure the outer diameter of rocker
arm bracket with outside micrometer at
the position that the rocker arm is
installed, and in case that it exceeds
the limit value, replace.
Measuring point
EE2OM059
< Rocker arm Specification >
Standard Limit
Bush inner diameter Φ 24.991 ~ Φ 25.012 mm Φ 25.04 mm
Shaft outer diameter Φ 24.739 ~ Φ 24.960 mm Φ 24.90 mm
Clearance 0.031 ~ 0.073 mm 0.14 mm

a) Rocker arm
● Inspect the rocker arm surface that
contacts with the valve stem for any
scratch, step wear and correct the
minor degree of wear with an oil stone Caliper adjusting bolt
or the fine grinding paper and replace Caution:
if they are severe. Fix the nut after adjust
the valve depression
with in 0.05mm with the
adjusting bolt
EE2OM060
b) Tappet & push rod

● By means of outside micrometer,
measure the clearance of the tappet
and tappet holes of the cylinder block.
If the value is beyond the specified
limit, replace tappets.
Standard Φ 19.944 ~ Φ 19.965 mm
EDM2061I
<Clearance of block and tappet>
Standard Limit
0.035 ~ 0.077 mm 0.13 mm
● By inspecting the tappet surface that

contacts with the camshaft's cam for
any crack and scratch etc., and if the
degree is small, correct them with an
oil stone or the grinding paper but if (1) Unevenness (2) Crank (3) Normal
severe replace them.
(4) Abnormal
EA0M4070

● Place the push rod on the surface
plate and rolling it, Inspect the curving
degree with a clearance gauge and if
abnormal, replace it.
< Run-out >
Limit 0.3 mm or less

Feeler gauge
EA0M4073
3) Rocker arm reassembling
● Inspect the oil passages of rocker arm
and rocker arm bracket for any clogs
and reassemble them in the reverse
order of disassembling after thorough
cleaning.
3.2.5. Cam shaft

1) Axial end play
● Push the camshaft toward the
crankshaft pulley side.
● Place a dial gauge onto the camshaft
gear.
● Measure the camshaft's axial end play,
moving the camshaft gear by means
of a driver.
Standard 0.10 ~ 0.55 mm
● If excessive end play, assemble it by

means of other thrust washer.
2) Inspection and measurement of camshaft

● Visual check
With inspecting the cam surface for
any damage with naked eyes and
correct any minor scratch by means of
an oil stone grinding and if severe,
replace it.

● Cam lobe height and cam journal diameter
Use a micrometer to measure the cam
lobe height and journal diameter.
If the measured number is less than
the specified limit, the camshaft must
be replaced.
Standard Limit
A
Cam lobe Intake 55.06 mm 54.76 mm C B B

height (C) Exhaust 56.57 mm 56.27 mm D A EA0M4062
Cam journal diameter Φ 69.91

Φ 69.64 mm
(A,B) ~ Φ 69.94 mm
● Camshaft bearing diameter

Measure the camshaft bush inside
diameter with a cylinder gauge. Camshaft bearing
< Cam bearing inside diameter>
Standard Limit
Φ 70.07
Thrust bush -
~ Φ 70.09 mm
Cam bush inside Φ 70.00 EA0M4063

Φ 70.06 mm
diameter ~ Φ 70.03 mm
● Clearance between camshaft journal and bush

Calculate the clearance by complying measured value of the camshaft bearing inside diameter
and journal bearing outside diameter. Replace the camshaft bearing if the calculated value is
beyond the specified limit.
<Clearance >
Standard Limit
0.060 ~ 0.120 mm 0.18 mm

● Camshaft bearing replacement
Use with the special tool for
replacement of bearing.
Diassembly &
assembly tool
EE2OM061
● Camshaft run-out
With placing the camshaft on the 2ea
of V-blocks, and inspect the run-out of
the camshaft, adjust or replace the
severe one.
< Camshaft run-out >
Standard Limit
0.05 mm 0.1 mm EA0M4066

3.2.6. Crank shaft
1) Inspection and measurement
● Inspect for any scratch or damage on the crankshaft journal and crank pin with naked eyes.
● Inspect for any crack by means of magnetic powder and color check, and replace the cracked
ones.
a) Journal and pin diameter

● With outside micrometer, measure
the outside diameter of crank journal
and crank pin at the direction and
position of the figure shown and take
the wear.
● In case that the lopsided wear is
more than the limit value, grind to
the undersize, and use the
undersized bearing. EAMD057I
● If the amount of wear is within the

limit, you can correct the wear A
using an oil stone or oiled grinding

B B
paper of fine grain size.
(be sure to use grinding paper B B
which has been immersed in oil)
<Journal and pin outside diameter> A

EFM2047I
Standard
Journal diameter Φ 103.98 ~ Φ 104.00 mm
Pin diameter Φ 89.98 ~ Φ 90.00 mm
● In case that pin's wear is more than the limit value, grind the crankshaft journal and crank pin,
and use the undersized bearings.
● Be sure to use grinding paper which has been immersed in oil.
< Kinds of bearings for undersize>

◆ Standard
◆ 0.25 (Inside diameter 0.25mm less than standard)
◆ 0.50 (Inside diameter 0.50mm less than standard
◆ 0.75 (Inside diameter 0.75mm less than standard
◆ 1.00 (Inside diameter 1.00mm less than standard)

NOTE :
There are 4 kinds as above, and the crankshaft also can be used by regrinding as
above.
NOTE :
In case of crankshaft regrinding, the
"R" part at the end of bearing must "R"
accurately be ground without fail

and should avoid any processed "R"
jaw or coarse surface.
"R" "R" "R"

<"R" part standard value>
0
① Crank pin 'R' : 3.0 -0.5 Normal Abnormal Abnormal
0 EFM2048I
② Crank journal 'R' : 4.0 -0.5
b) Run out of crankshaft

● Place the crankshaft on the V-block.
● Turn the crankshaft with a dial
Indicator on the surface plate and
measure the run out of crankshaft,
replace or correct the camshaft
bearing if the measured value is
beyond the limit.
< Run out of crankshaft > EE2OM113
Standard Limit
0.04 mm 0.2 mm

2) Crankshaft bearing and connecting rod bearing
Inspect the crankshaft bearing and connecting rod bearing for any damages such as lopsided wear,
scratch etc. and if abnormal, replace it.
a) Oil clearance of crankshaft and bearing

● Assemble the main bearing at the
cylinder block and after tightening
the bearing cap at the specified
torque, measure the inside diameter
of bearing
Torque 30 kg.m + 90°
Journal bearing Φ 103.98 ~

nominal diameter Φ 104.00 mm
● Assemble the bearing at the bigger

end of connecting rod (bigger end) 10
A Section A-B
tightening the bearing cap at the
10
specified torque, measure the inside
2 8
diameter. 1 3
8
Torque 10 kg.m + 90°
B
Connecting rod EE2OM063
Φ 89.98 ~
bearing nominal
Φ 90.00 mm
diameter
EAMD060I

b) Bearing oil clearance
● Compare the two values obtained through measurement of bearing inside diameter (journal
bearing, connecting rod bearing) with the outside diameter of journal and pin of crankshaft to
determine the 0il clearance
Standard Limit
Journal bearing 0.066 ~ 0.132 mm 0.166 mm
Connecting rod bearing 0.054 ~ 0.116 mm 0.154 mm
● In case that this clearance value exceeds the limit value, grind the crankshaft journal and pin
and then use the undersized bearing.
c) Journal and connecting bearing inspection

● Check to see that the bearing
requires a considerable amount of
finger pressure at reassembly
operation.
● The spread of journal bearing and

connecting rod bearing should be
measured with special tool as a OA OB
figure, but measure it under
condition of assembling as below
for convenience of working in the
field.
EDM2047I

● Journal bearing
Install the bearing and cap in the
cylinder block, retighten the bolts to
specified torque, unscrew out one
bolt completely, then measure the
clearance between the bearing cap
and cylinder block using a feeler
gauge.
<Cylinder block and bearing clearance> EAMD063I
Standard 0.3 ~1.2 mm
● Connecting rod bearing crush

Install the bearing and cap in the
connecting rod big end, retighten
the bolts to specified torque,
unscrew out one bolt completely,
then measure the clearance
between the bearing cap and
connecting rod big end using a
feeler gauge. EA6M064I
< Connecting rod bearing clearance >
Standard 0.5 ~1.4 mm
d) Crank shaft end play

● Assemble the crankshaft to the
cylinder block with a dial gauge,
measure crankshaft end play.
< Crank shaft end play >
Standard Limit
0.190 ~ 0.322 mm 0.452 mm

EE1OM074

3.2.7. Piston
1) Piston disassembling
● Pull out the snap ring for piston pin
and with a pair of snap ring pliers.
● With a round bar, remove the piston
pin.
● With a pair of pliers, remove the piston

rings.
● Clean the piston thoroughly.
EFM2051I
2) Check and measurement
● With naked eyes, inspect the piston for
any wear, crack and scratch and
particularly inspect carefully at the ring
grooves for any wear.
● With the outside micrometer, measure
the piston's outside diameter the
measuring position is 71.5mm from
the piston lower end, and the direction
of measurement must be
perpendicular to the piston pin
direction.
56.8 mm
Standard Φ 127.739 ~ Φ 127.757 mm

EE2OM107

a) Cylinder bore diameter
● Measure cylinder liner inside
diameter at 3 points (cylinder top
ring contacting face, middle, and oil 2
ring contacting face on BDC) in a
direction at an angle of 45°. Take
the mean value with the largest and
smallest values excepted.
Standard Φ 127.990 ~ Φ 128.010 mm

EAMD067I
b) Piston and cylinder clearance

● The clearance is computed by
subtracting the piston outside
diameter from the cylinder liner
inside diameter. Replace either
piston or cylinder liner, whichever
damaged more, if the clearance is
beyond the specified limit.
Standard 0.233 ~ 0.271 mm
c) Piston ring and ring groove

● In case of piston ring's wear,
damage or engine overhaul, replace
piston rings.
d) Piston ring cut part clearance

● Measure the piston ring cut part.
● Insert the piston ring at the cylinder
liner's upper part perpendicularly.
● With a feeler gauge, measure the
gap clearance of piston ring.
● If the measured value exceeds the
limit value, replace it
Standard Limit
Top ring 0.35 ~ 0.55 mm 1.5 mm
2nd ring 0.80 ~ 0.95 mm 1.5 mm
Oil ring 0.40 ~ 0.70 mm 1.5 mm

e) Piston side clearance
● Assemble the piston ring at the
piston. Feeler gauge
● Measure the each ring's side

clearance and if the measured
value exceeds the limit value,
replace rings or piston.
Standard Limit
Top ring 0.105 ~ 0.155 mm 0.20 mm EE2OM118
2nd ring 0.050 ~ 0.085 mm 0.15 mm
Oil ring 0.030 ~ 0.070 mm 0.15 mm
f) Piston pin
● Measure the amount of wear on the
piston pin at the points as shown.
The measured values are beyond
the limit replace the pin.
Standard Limit
Φ 45.994 ~ Φ 46.0 mm Φ 44.983 mm or less
EA0M4031
g) Piston pin and connecting rod bush clearance

● Inspect the clearance between the
piston pin and the connecting rod
bush, if it is more than the use limit
value, replace either one that is
more severe.
Limit 0.055 ~ 0.071 mm
EE2OM064

h) Connecting rod
● Check the connecting rod for
distortion. As shown in the figure
below, install the connecting rod to
the connecting rod tester, and
check for distortion using a feeler
gauge. If the connecting rod is
found distorted, never re-use it but
replace with a new one.
Feeler gauge
● Measure the alignment of the EA0M4034
connecting rod piston pin bushing
holes with connecting rod big end
holes. At this time also, use both
connecting rod tester and feeler
gauge.
Standard Limit
0.02 mm 0.1 mm
● Assemble the connecting rod to the

crankshaft and measure connecting
rod big end side clearance using a
feeler gauge.
Standard Limit
0.175 ~ 0.321 mm 0.5 mm
● Assemble the connecting rod to the

piston and measure connecting rod
small end side clearance.
● If the measured values are beyond
the limit, replace the connecting
rod.

3.2.8. Injector projection
● Insert a seal ring on the cylinder head
and assemble the injector. Cylinder head
Injector
● Measure the clearance between the
cylinder head bottom and injector. If the
measured values are beyond the limit,
replace the seal ring.

A
Standard B
A EE1OM075
1.9 ~ 2.1 mm
(Thickness of seal ring)
B
2.6 mm
(Projection of injector)

3.3. Engine Reassembly
3.3.1. Preparation and precaution before and after engine reassembly

● Clean all the parts thoroughly and also clean thoroughly by blowing into each passage of oil and
cooling water.
● Disposition the various special and general tools for assembling in order.
● In order to coat the lapping parts with engine oil, prepare the clean engine oil.
● Prepare the sub-material such as an adhesive etc.
● Use three bond as an adhesive in the engine oil system and use silicone in the cooling system.
● Scrap the used gasket and seal ring, consumable parts etc. and replace with new ones.
● Tighten the various bolts in the specified tightening torque, and also according to the tightening order
but the excessive torque must be avoided.
● Inspect if the movement of engine is smooth after assembling.
● After completion of assembling, whether various bolts are loose or not should necessarily be
insured.
● Make sure that there is any missing parts or insufficient parts after full completion of assembling.
● Work only with clean hands.
3.3.2. Cylinder liner

● Replace O-ring with new one without fail
and at the upper side, insert to the
cylinder liner, but at the lower side, to the
cylinder block.
● Coat the joint parts where O-ring
O-ring
contacts with oil. for cylinder liner
● After slipping the cylinder liner smoothly O-ring for cylinder block
into the cylinder block, press it in being (Black color upper side,
Green color lower side)
careful for O-ring not to damage. EE2OM119
● After completion of assembling the
cylinder liner, confirm no leaks with 4 kg/
cm2 hydraulic test.
- 79 - Engine Reassembly
3.3.3. Oil spray nozzle
● Tighten the oil injection nozzle flange
with hollow screws.
● Assemble the oil injection nozzle with the
fixing bolts.
Hollow screw 7 kg.m

Torque
Fixing bolt 1.2 kg.m
EFM2059I
3.3.4. Crank shaft

● Put the wear ring into the heater to heat
it up to 150 ~ 200°C level, push it over
the crankshaft by means of a jig.
Wear ring
EE2OM066
● Assemble the main bearing to the

cylinder block and coat it with engine oil.
Then assemble the bearing that has a
hole to the cylinder block side and one
that has no hole to the bearing cap and
be careful not to change.
● Assemble temporarily one bolt each at
both bolt holes of crankshaft and by
connecting the wire to the bolts, lift it with EFM2060I
crane or chain block and put down on the
cylinder block carefully.
Engine Reassembly - 80 -
● Coat the crankshaft journal and pin parts
with engine oil, and after fitting the main
bearing into the bearing cap and
assemble it to the cylinder block making
sure of the number in order not to
change the bearing cap.
EE2OM057
● Coat the bearing cap bolt and its bolt

seat part with engine oil necessarily and
according to the tightening order, tighten
them with 30 kg.m and with rotating
angle method (90° +10°) and tightening
order is as follows.
EE1OM063
< Bearing cap bolt’s tightening order >

(1) First step : Coat the bolts with engine oil.
(2) Second step : Screw down 1 ~ 2 threads.
(3) Third step : Tighten with about 15 kg.m by wrench.
(4) Fourth step : Tighten with about 25kg.m by torque wrench.
(5) Fifth step : Tighten with 30kg.m by torque wrench.
(6) Sixth step : Tighten with final rotating angle method 90° +10°.
However, according to above tightening order, tighten step by step
● Inspect if the crankshaft's rotation is

smooth.
● Assemble the crankshaft gear on the
crankshaft and coat a white paint mark
on "1" part in order to find easily.
3.3.5. Tappet
● Coat the tappet wholly clean oil and push
in the tappet hole of the cylinder block.
EAMD072S
3.3.6. Cam shaft
● Coat the cam bush of cylinder block and
camshaft with engine oil. Camshaft gear
● Assemble the cam bush and camshaft

1 1
for them not to be damaged. 1
● Assemble the crankshaft gear and the
Crankshaft gear
camshaft gear making sure that the gear
marks on both gears are aligned
together.
EE2OM067
3.3.7. Flywheel housing

● Apply loctite to the fixing bolt and
assemble the thrust washer.
Thrust washer
4 kg.m
fixing bolt
Thrust
washer
● Coat the oil seal (P.T.F.E.) with

Oil seal
lubricating oil and assemble the oil seal
carefully for it not to deviate or be EF6OM034
damaged by means of special tool.
(Mandrel for assembling.)
● Attach the gasket on the surface of
cylinder block where the flywheel
housing is to be installed. (In order to
prevent the gasket slip down, coat a
grease on the cylinder block surface.
● Temporarily assemble 2ea of guide bolts
for installing the flywheel housing to the
cylinder block.
● After fitting the flywheel housing holes to EE2OM069
the guide pins and engage temporarily 2
~ 3 threads of fixing bolts, and according
to the tightening order (zigzag method)
tighten them in the specified torque.
M10 7.5 kg.m

Torque
M12 11.2 kg.m
3.3.8. Fly wheel

● Installation of flywheel ring gear with a
gas burner, heat the ring gear evenly
until heat expansion takes place, then
install it using a hammer.
● Do not allow the temperature of the ring
gear to exceed 200°C (392°F).
EA0M4029
● By means of mandrel, press in the wear

ring at the backward face. (Apply
mounting face with #262 loctite.)
Wear ring Ring gear

EC3M3102
● Install two guide bolts for installing the
flywheel to the crankshaft.
● After letting the guide pin insert through
the flywheel holes and engaging the
fixing bolts by 2 ~ 3 threads temporarily,
tighten them to the specified torque
according to tightening order. (Zigzag
order)
EE1OM080
Torque 26 kg.m
1
8 6
3 4
5 7
2
EE1OM081
3.3.9. Front oil seal holder

● After placing the oil seal in the oil seal
holder hole properly, press it in with a
special tool. (Be careful for oil seal not
be damaged.)
● Attach a gasket at the oil seal holder.
● Align the dowel pin with the oil seal

holder dowel hole and assemble them by
tapping lightly the dowel pin part with an EFM2073I
urethane hammer when in assembling,
take care not to hurt the oil seal by the
crankshaft.
NOTE :
Without coating the oil seal with oil
or lubricant, assemble it in the dry
state.
● Apply lubricating oil to the inside of oil
seal and tighten the fixing bolts in the
zigzag method.
Torque 2.2 kg.m
3.3.10. Piston
● Line up the piston assembly in the
order of cylinders and fit the bearings to
the connecting rods and bearing caps. 2nd ring Oil ring
However, take care not to swap

between the connecting rods and
bearing caps.
● Coat the pistons and connecting rod
Piston pin
bearings sufficiently with clean engine
oil. View of piston top
Top ring EE1OM083
● By means of a special tool, insert the

piston rings and adjust the angles
between the ring gaps at 120°.
● Identify the mark "Y" or "TOP" on the
ring end to prevent the top and
bottom of the piston ring from being
interchanged and make the marked
portion face upward.
"Y" or " TOP"
(The surface marked as "Y" or "TOP" is EE2OM070
upper surface.)
● Push in the piston with hands or

wooden bar into cylinder. (Be careful for
piston and rings not be damaged.
Top ring
● Pushing the piston down, rotate the
crankshaft about 180° and fit the 2nd ring
bearing cap to the connecting rod. Oil ring
EE2OM071
● Coat the tap parts of connecting rod
bolts and their seats with engine oil,
and after engaging 2 ~ 3 threads of
bolts primarily rind then tighten them to
the specified torque. (10 kg.m + 90°+10°)
CAUTION :
Direction of snap ring is
assembling to be positioned the
opposite side
EE2OM072
< Connecting rod bolt tightening order >

(2) Second step : Engage 2 ~ 3 threads by hands.
(3) Third step : Tighten to about 7kg.m with wrench.
(4) Fourth step : By means of torque wrench tighten to 10 kg.m.
(5) Fifth step : Finally assemble by means of rotation angle method 90°+10°.
However, according to above tightening order, tighten them step by step
< Standard length of bolt and use limit >
From head seat to bolt tip

Oil supply hole
Standard length Use limit
67.5-0.3 mm 69 mm
Connecting rod bolt

View from crank
shaft pulley EE2OM073
● By moving the connecting rod bearing

cap by hands, make sure if there is any
play in left and right.
● With the same method as above,
assemble in each cylinder rotating the
crankshaft.
EFM2070I
3.3.11. Oil pump
● Put the oil pump at the place to be
installed on the cylinder block.
● Attach a gasket at the surface of oil
pump where the pressure regulating
valve is to installed and place the
regulating valve on a gasket.
● Assemble the oil pump and pressure
regulating valve by tightening the fixing
bolts. EE1OM058
Oil pump back lash 0.1 ~ 0.45 mm
● Attach a gasket at the surface of the oil

pump where the oil suction pipe is to be
installed, and install the oil suction pipe
by tightening the fixing bolts.
● Assemble the pipe bracket on the
cylinder block side with bolts.
Torque 2.2 kg.m
3.3.12 Vibration damper
● Install the vibration damper on the
crankshaft pulley.
● Install the crankshaft pulley assembly
Dust protect cover
on the crankshaft, then tighten the bolts
with apply engine oil.
Vibration damper
6 kg.m
Torque and pulley Crank shaft pulley & damper
Crankshaft pulley 21 kg.m EE2OM047
Bolt tightening order

EE1OM155
3.3.13. Oil pan

● Clean thoroughly the gasket that is
projecting at the junction parts of front
oil seal holder and flywheel housing of
cylinder block's lower face with a
scraper.
● In the process of gasket removal, be
careful for the gasket pieces not to get
into the engine inside.
● Apply silicon to each joint and attach a EF6OM033
gasket to the cylinder block.
● Install the oil pan and tighten the fixing
bolts. Then takes care not to squeeze
out the gasket.
Torque 2.2 kg.m
3.3.14. Intake & exhaust valve
● Identify the marks of "I" and "E"
impressed on the valve head before
assembling the valve with the valve
head. Valve marking position
● With a valve stem seal fitting jig,
assemble the valve stem seal on the
valve guide.
EE1OM156

● Blow the cylinder head bolt holes with
compressed air to remove the foreign Cylinder head bolt
material cleanly.
Assembly order no.
● Wipe off cleanly the junction part of
cylinder block's head gasket.
● After confirming whether there is
foreign material or not necessarily, if
there is, remove it.
● Assemble a gasket fitting with the fixing EE2OM074
pin of cylinder block.
● Position the cylinder head assembly on

the cylinder block aligning with its dowel
pin. (Take care not to damage the head
gasket.)
● Coat the cylinder head bolts with
engine oil and tighten them to the
specified torque according to step by
Part No.
step. mark position
EE2OM075
< Cylinder head bolts tightening order >

1) First step : Coat bolts with engine oil.
2) Second step : Tighten temporarily 1 ~ 2 threads by hands.
3) Third step : Tighten to about 8 kg.m with a wrench.
4) Forth step : Tighten to 15kg.m with a torque wrench.
5) Fifth step : Rotate 90° by rotation angle method.
6) Sixth step : Rotate 90° by rotation angle method.
7) Seventh step : Finally tighten additionally rotating 60°.
< Standard length of bolt and use limit >
(From head seat to bolt tip)
Standard length Limit
176 mm 178.5 mm
Note : L
Take care for the foreign material

not to get into the cylinder head
suction passages. EOA11115
3.3.16. Injector
● The injector should be assembled
Injector
correctly by the following order.
● Put the O-ring into the injector and coat Injector bush
the circumference face of it with engine

oil.
● The sealing set to injector hole of Injector fixing
cylinder head, then the injector insert. bracket
(The side groove face of injector set to

Fixing nut
the fuel high pressure connector.) EE1OM040
● The injector set to injector fixing bracket
with the fixing bolt, then assemble
temporarily it.
Fuel high pressure

Temporarily Injector fixing bracket
connector fixing nut
torque
0.3 kg.m 0.25 kg.m
● Assemble the injector fixing bracket bolt

with specified torque, and assemble the
fuel high pressure connector fixing nut.
Injector fixing bracket bolt 3.5 kg.m

Torque Fuel high pressure
5 ~ 5.5 kg.m
connector fixing nut
3.3.17. Rocker arm
● Coat the push rod with engine oil and
put it into the push rod hole. Fixing bolt
● Position the rocker arm assembly on
the cylinder head and tighten the fixing
bolts to the specified tightening torque.
Torque 6.2 kg.m
EE2OM076
● Adjust the valve clearance as reference
of major maintenance part.
3.3.18. Fuel high pressure pump housing cover

● Coat with the liquid gasket on the
Serial no. mark position
surface of the cylinder block for
(Fuel high pressure
mounting of the fuel high pressure pump housing cover)
pump housing cover. Serial no. mark position
(Cylinder block)
● Assemble the fuel high pressure pump
housing cover after check the serial
number of the cylinder block and the
pump housing cover.
● Tighten the fixing bolts of the fuel high EE2OM078
pressure pump housing cover by the
specified tightening torque.
Torque 7.5 kg.m
NOTES :
Do not mingle with the pump
housing cover and cylinder block
randomly.
● Assemble the gear of the fuel high
pressure pump by using specified tool.
Gear nut torque 11 ± 0.5 kg.m
Driving gear
Fuel high
pressure pump
EE1OM089
● Install the fuel high pressure pump on

the backside of the fly wheel housing.
● Assemble the stud bolt after apply the
loctite.
● Assemble the fuel high pressure pump
fixing bolts with specified torque.
Torque 4.4 kg.m
EE2OM041
3.3.20. Intake manifold

● Attach a new gasket to the cylinder
head side.
● Assemble the intake manifold by
tightening the fixing bolts.
● Assemble both sides by the above
method.
● Attach a gasket to the equalizing pipe
that connects the intake manifolds of
both sides and assemble both EF6OM029
manifolds by tightening the fixing bolts.
Torque 2.2 kg.m
3.3.21. Common rail & high pressure pipe
● Assemble the common rail on the
cylinder block.
● Install the fuel high pressure pipe
between the common rail and the fuel
high pressure connector, then tighten
the cylinder by cylinder with specified
torque.
EE2OM040
Side of common rail 3.0 kg.m

Fuel high
pressure Side of fuel high pressure connector 3.0 kg.m
Torque pipe
Common rail from fuel high pressure pump 3.0 kg.m
Common rail fixing bolt 2.2 kg.m
3.3.22. Cylinder head cover

● Attach a new gasket on the surface of
cylinder head where the cover is to be
installed.
● Assemble the cylinder head cover by
tightening the fixing bolts.
Middle cover 3.6 kg.m

Torque
Cylinder head cover 2.2 kg.m
EE2OM050
● Insert the oil filler cap.

Rubber gasket
Oil filler cap
Cylinder head
intermediate cover
EE2OM099
3.3.23. Exhaust manifold
● Attach a new gasket to the exhaust
manifold.
● Fix the pipe that is connected exhaust
manifold by tightening the fixing bolts.
● Assemble both sides in the same
method as above.
Torque 8.0 kg.m
EF6OM028
3.3.24. Electric control unit

● Install the electric control unit fixing
bracket on the oil pan, and then
assemble the electric control unit.
Bracket fixing bolt 4.5 kg.m

8 1
Torque Electric control unit fix-
10 ± 2 N.m 4
ing bolt 5
6
3
2
7 EF6OM037
● Assemble the electric control unit

(ECU) according to the right figure Rubber cushion
order.
● Refer to the chapter of 3.4 about
relation of the common rail system and
Bracket
the electric control unit.
Electric control unit

EF6OM035
3.3.25. Crankshaft speed sensor
● Measure the clearance of the
assembling part of the sensor and fly
Crankshaft speed sensor
wheel, then assemble it with the adjust
Adjust shim
shim.
Clearance 1.0 ± 0.1 mm

Torque 1.0 kg.m
EE1OM090
3.3.26. Camshaft speed sensor

● Measure the clearance of the
assembling part of the sensor and
timing gear, then assemble it with the Camshaft
speed sensor
adjust shim.
Clearance 1.0 ± 0.1 mm

Torque 1.0 kg.m
EF6OM038
3.3.27. Oil cooler

● Attach a gasket on the surface in the oil
cooler housing where the oil cooler is
installed.
● Tighten the oil cooler with fixing bolts.
● Install the oil cooler assembly by
tightening the fixing bolts in the zigzag
order.
Torque 4.4 kg.m EPM2022I
3.3.28. Starter
● Install stud bolts at the bolt holes on the
flywheel housing for installing the
starter.
● Insert the starter into the flywheel
housing and tighten the fixing nuts.
Torque 8.0 kg.m
EF6OM030
3.3.29. Oil filter

● Install the filter head on the oil pan and
tighten bolts in a diagonal sequence.
● Apply engine oil to the oil filter cartridge
O-ring and assemble the cartridge
using a filter wrench.
EF6OM024
3.3.30. Water pump
● Attach a gasket at the cooling water
pump. (at cylinder block side.)
● Assemble the cooling water pump by Water pump
tightening the fixing bolts. (Zigzag
method.)
Torque 4.4 kg.m
EE2OM082
3.3.31. Thermostat
● Put the thermostat into the water pump
Thermostat
with gasket.
Water pump
● Put the O-ring into the thermostat, then
assemble cooling water pipe by
tightening the fixing bolt.
Torque 2.2 kg.m
EE2OM042
3.3.32. Turbo charger

● Attach a gasket to the exhaust elbow
and assemble the turbocharger with
fixing bolts.
● Attach a gasket on the oil supply pipe
and assemble the pipe with the fixing
bolts.
● Attach a gasket on the oil discharge
pipe and assemble the pipe by
tightening the bolts. EF6OM026
Turbocharger fixing nut

4.4 kg.m
torque
3.3.33. Intake stake and air heater

● Connect the intake stake to the intake
manifold.
● Assemble the air heater according the
direction of an arrow impressed on the
air heater and assemble the pipe by
tightening the bolts.
Torque 2.2 kg.m
EF6OM023
● Install the air pipe, then connect the
rubber hose into the turbocharger and Intake stake
assemble with clamping.

Air heater
Air pipe
EF6OM052
3.3.34. Fuel filter

● Assemble the fuel filter on the support
bracket.
● Assemble the fuel filter after fill the fuel
into inside of the cartridge when replace
the new fuel filter.
Torque 2.2 kg.m
EF6OM027
3.3.35. Alternator and belt

● Install the alternator bracket, idle pulley
and adjusting bolt to lifting hook.
● Install the alternator, and then tighten
the fixing bolts.
EF6OM025
● Put the belt into the crankshaft pulley,

alternator pulley, water pump and air
con. pulley for connecting. Tension
adjusting bolt
● Adjust the belt tension of the adjusting
bolts.
Tension
adjusting bolt EF6OM022
● Poly belt will be properly tensioned if
the deflection force “F” is applied
midway between the belt’s tangent S(SPAN)
points with the pulley.
(T) = 0.015 x S T D
d
(about 1.5mm per 100mm) F
(T : Deflection, S : span)
C
EB5O6001

● Apply sealant (Loctite #262) to the
bottom side of the guide tube.
● Then assemble the guide tube and oil
level gauge on the oil pan.
EF6OM039
3.3.37. Others
● Assemble by connecting the other
sensor, harness, oil and fuel line.
3.4. Fuel Injection System
3.4.1. Common rail fuel-injection system

● Pressure generation and fuel injection are completely decoupled from each other in the common rail
injection system. The electric control unit(ECU) determine the fuel quantity, injection timing, and
injection pressure in order to show the optimum performance on the condition for operation of the
engine, then inject the fuel in the cylinder.
Common rail

(CP 3.4 fuel pump)
Fuel filter
Pre fuel filter
Injector
Fuel cooler ECU Cylinder head
Fuel tank
EF6OM013
● The fuel is stored under pressure in the common rail ready for injection. The injected fuel quantity is
defined by the driver, and the start of injection and injection pressure are calculated by the ECU on
the basis of the stored map. The ECU then triggers the solenoid valves that the injector at each
engine cylinder injects accordingly.
Fuel Injection System - 100 -

3.4.2. Major components of the common rail system
1) Electric control unit(ECU)
2) Crankshaft speed sensor
3) Camshaft speed sensor
4) Accelerator pedal sensor
5) Fuel temperature sensor
6) Boost pressure and temperature sensor
7) Common rail pressure sensor
8) Coolant temperature sensor
9) oil pressure and temperature sensor
● Using the input signals from the above sensors, the ECU registers the driver's
requirements(accelerator pedal setting) and defines the instantaneous operating performance of the
engine and the vehicle as a whole. On the basis of this information, it can then intervene with open
and closed-loop controlling action at the vehicle and particularly at the engine.
● The engine speed is measured by the crankshaft speed sensor, and the camshaft speed sensor
determines the firing sequence (phase length). The electrical signal generated across a
potentiometer in the accelerator pedal module informs the ECU about how far the driver has
depressed the pedal, the engine is equipped with a turbocharger and boost pressure control, the
boost pressure sensor also measures boost pressure.
● At low outside temperatures and with the engine cold, the ECU applies the data from the coolant
temperature and air temperature sensors to adapt the set point values for start of the particular
operating conditions.
- 101 - Fuel Injection System

3.4.3. Injection characteristics with common rail
● Injection characteristics with common rail, compared to conventional injection characteristics, the
following demands are made up on an ideal injection characteristic, Independently of each other,
injected fuel quantity and injection pressure should be definable for each and every engine
operating condition.
Fuel injection of injection pump Common rail fuel injection

Pm : Main injection pressure Pm : Main injection pressure
Ps : Max. injection pressure Ps : Max. injection pressure
Ps
Start of delivery
Start of injection Fuel injection
Injection pressure P
Injection pressure P
Pm PR
(Pm)
Time t Time t
EE1OM094
● At the beginning of the injection process, the injected fuel quantity should be as low as possible (that
is, during the ignition lag between the start of injection and the start of combustion)
● The common rail system is a modular system, and essentially the following components are
responsible for the injection characteristic.
- Solenoid valve controlled injectors which are screwed into the cylinder head
- Common rail
- Fuel high pressure pump
- Electric control unit(ECU)
- Crankshaft speed sensor
- Camshaft speed sensor

● A radial-piston pump is used as the high pressure pump for pressure generation. Pressure is
generated independently of the injection process. The speed of the high pressure pump is coupled
directly to the engine speed with a non-variable transmission ratio. In comparison with conventional
injection systems, the fact that delivery is practically uniform.
● The injectors are connected to the common rail by high pressure pipe, comprise a nozzle, and a
solenoid valve which is energized by the ECU to switch it on (start of injection), When the solenoid
valve is switched off injection ceases.
● The required high-speed solenoid switching is achieved by using high voltages and currents. This
means that the solenoid valve triggering stage in the ECU must be designed accordingly. The start
of injection is controlled by the angle-time control system of the EDC(Electronic Diesel Control).This
uses a sensor on the crankshaft to register engine speed, and a sensor on the camshaft for phase
detection(working cycle).
3.4.5. Fuel system

● The common rail fuel injection system comprises a low pressure stage for the low pressure delivery
of fuel, a high pressure stage for the high pressure delivery, and the ECU.
3.4.6. Fuel tank

● The fuel tank must be of non-corroding material, and must remain free from leaks at double the
operating pressure, and in any case at 0.3 bar.
3.4.7. Fuel delivery pump

● The fuel delivery pump is installed on back side of the fuel high pressure pump, is a gear type fuel
pump. The pump draws the fuel from the fuel tank and continually delivers the required quantity of
fuel in the direction of the high pressure pump.
Fuel delivery pump

1. Fuel inlet
2. Driving gear
3. Fuel outlet
2
1 3
EE1OM095

3.4.8. Fuel filter
● Fuel filter inadequate filtering can lead to damage at the pump components, delivery valves, and
injector nozzles. The fuel filter cleans the fuel before it reaches the high pressure pump, and thereby
prevents premature wear at the pump's sensitive components.
3.4.9. High pressure fuel delivery

● The high pressure stage of the fuel system in a common rail installation comprises.
- High pressure pump with pressure control valve
- High pressure fuel lines
- The common rail as the high pressure accumulator
- Rail pressure sensor.
- Pressure limiting valve.
- Injectors
- Fuel return lines
3.4.10. High pressure system components

● Fuel high pressure pump
The high-pressure pump pressurizes the fuel to a system pressure of up to 1,600bar. This
pressurized fuel then passes through a high-pressure line and into the tubular high pressure fuel
accumulator (common rail).
● Common rail
Even after an injector has taken fuel from the common rail in order to inject it, the fuel pressure
inside the rail remains practically constant. Fuel pressure is measured by the rail pressure sensor
and maintained at the desired level by the pressure control valve. It is the job of the pressure limiter
valve to limit the fuel pressure in the rail to maximum 1,600 bar.
● Injector
The nozzles of these injectors open when the solenoid valve is triggered and permit the flow of fuel.
They inject the fuel directly into the engine's combustion chamber, The excess fuel which was
needed for opening the injector nozzles flows back to the tank through a collector line. The return
fuel from the pressure control valve and from the low pressure stage is also led into this collector
line together with the fuel used to lubricate the high pressure pump.
● Fuel high pressure pipe
These fuel high pressure pipes carry the high pressure fuel of up to 1600bar. They must therefore
be able to permanently withstand the maximum system pressure and, during the pauses in injection,
the sometimes high frequency pressure fluctuations which occur. They are therefore manufactured
from the high pressure pipe. They have an outside diameter of 8.0 mm and an internal diameter of
3.0 mm. The fuel high pressure pipe lines between the common rail and the injectors must all be of
the same length, should be kept as short as possible.

3.4.11. Construction of the fuel high pressure pump
1) Function
The high pressure pump is the interface between the low-pressure and the high pressure stages.
Under all operating conditions, it is responsible for providing adequate high pressure fuel
throughout the vehicle's complete service life. This also includes the provision of extra fuel as
needed for rapid starting and for rapid build-up of pressure in the rail. The high pressure pump
continually generates the system pressure as needed in the common rail.
Fuel high pressure valve Gear pump Fill fuel at 40ml

Fuel inlet before operating Metering unit
Pump piston Fuel
inlet
Fuel outlet
Eccentric
cam
Driving shaft Fuel outlet
Lubrication of driving shaft by

Fuel high pressure line lubricating engine oil
Fuel low pressure line
Engine oil
EE2OM087
2) Construction of the fuel high pressure pump

The fuel is compressed with three radially arranged pump pistons which are at an angle of 120° to
each other. Since three delivery strokes take place for every revolution, only low peak drive torques
are generated so that the stress on the pump drive remains uniform. The driving torque of the
common rail is only about 1/9 of torques to drive existing pump system.
3) Method of operation
The fuel supply pump fuel from the tank to the high pressure pump through the fuel inlet and the
safety valve. It forces the fuel through the safety valve into the high pressure pump. The driveshaft
with its eccentric cams moves the piston of the pump up and down in accordance with the shape of
the cam.
As soon as the delivery pressure exceeds the safety valve's opening pressure (0.5 ~ 0.5 bar), the
fuel supply pump can force fuel through the high pressure pump's inlet valve into the pumping-
element chamber whose pump piston is moving downwards(suction stroke). The inlet valve closes
when the pump piston passes through the bottom dead center (BDC) and, since it is impossible for
the fuel in the pumping-element chamber to escape, it can now be compressed beyond the delivery
pressure. The increasing pressure opens the outlet valve as soon as the rail pressure is reached,
and the compressed fuel enters the high pressure circuit. The pump piston continues to deliver fuel
until it reaches TDC, after which the pressure collapses so that the outlet valve closes. The fuel

remaining in the pumping-element chamber relaxes and the pump piston moves downwards again.
As soon as the pressure in the pumping-element chamber drops below the presupply pump
pressure, the inlet valve opens and the pumping process starts again.
4) Fuel delivery rate

Since the high-pressure pump is designed for large delivery quantities, excess high-pressure fuel is
delivered during idle and part load operation. This excess fuel is returned to the tank via the
pressure control valve.
5) Fuel metering shut off valve
When one of the pumping elements is

switched off, this leads to a reduction of Fuel metering
shut off switch
the amount of fuel which is pumped into
the common rail. Switch off involves the
suction valve remaining open
permanently. When the solenoid valve
of the pumping-element switch off is
triggered, a pin attached to its armature
continually holds the inlet valve open.
EE2OM088
The result is that the fuel drawn into this
pumping element cannot be
compressed during the delivery stroke.
No pressure is generated in the
element chamber since the fuel flows
back into the low-pressure passage
again. With one of its pumping
elements switched off when less power
is needed, the high-pressure pump no
longer delivers the fuel continuously but
rather with brief interruptions in
delivery.

6) Common rail
The common rail stores the fuel at high pressure. At the same time, the pressure oscillations which
are generated due to the high pressure pump delivery and the injection of fuel are damped by the
rail volume. After the injector use the fuel from the common rail for fuel injection, the pressure
oscillation of the common rail is maintained constantly by the common rail volume. The fuel
pressure is calculated by the pressure sensor of the common rail, is maintained with required value
by the pressure control valve. The fuel pressure is controlled at max. 1,600 bar in the common rail.
No. 3 Cylinder injector


Fuel high pressure
connector
Pressure control
valve
O NT
FR No. 5 Cylinder injector
No. 4 Cylinder injector Pressure sensor

of the comon rail
EF6OM049

7) Common rail pressure sensor
The fuel flows to the rail pressure sensor through an opening in the common rail, the end of which
is sealed off by the sensor diaphragm. Pressurized fuel reaches the sensor's diaphragm through a
blind hole. The sensor element for converting the pressure to an electric signal is mounted on this
diaphragm. The signal generated by the sensor is inputted to an evaluation circuit which amplifies
the measuring signal and sends it to the ECU.
Electric connections
Evaluation circuit
Diaphragm
High pressure
connection
Mounting thread
EE1OM099
3.4.12. Pressure limiter valve

● The pressure limiter valve is at the connection end to the common rail, is closed by the cone
shaped end of the plunger valve against inside of the valve body. At normal operating pressures
(1600bar), a spring forces the plunger against the seat and the common rail remains closed.
● As soon as the operating pressure is exceeded, the plunger is forced by the rail pressure against
the force of the spring, the fuel pressure is maintained with the normal pressure, and the escape
fuel return to the fuel tank through the return pipe.
Valve Plunger
Common Fuel
rail return
Valve body Valve spring

EE1OM100

3.4.13. Injector
● The start of injection and the injected fuel quantity are adjusted by the solenoid valve of the injector.
These injectors supersede the nozzle and nozzle holder of the existing engine. The fuel is fed from
the high pressure connector, to the nozzle through the passage, and to the control chamber
through the feed orifice.
● The control chamber is connected to the fuel return via a bleed orifice which is opened by the
solenoid valve. With the bleed orifice closed, the hydraulic force applied to the valve control plunger
exceeds that at the nozzle needle pressure shoulder. As a result, the needle is forced into its seat
and seals off the high pressure passage from the combustion chamber.
● When the injector's solenoid valve is triggered, the bleed orifice is opened. This leads to a drop in
control-chamber pressure and, as a result, the hydraulic pressure on the plunger also drops. As
soon as the hydraulic force drops below the force on the nozzle-needle pressure shoulder, the
nozzle needle opens and fuel is injected through the spray holes into the combustion chamber.
Terminal Magnet nut Injector body Push rod Nozzle retaining nut
Fuel inlet
Nozzle & needle
Fuel return
Magnet core Amature Control chamber High pressure bore Intermediate pin
EE1OM101
● This indirect control of the nozzle needle using a hydraulic force-amplification system is applied
because the forces which are necessary for opening the needle very quickly cannot be directly
generated by the solenoid valve. The so-called control quantity needed for opening the nozzle
needle is in addition to the fuel quantity which is actually injected, and it is led back to the fuel-return
line via the control chamber's orifices. In addition to the control quantity, fuel is also lost at the
nozzle-needle and valve plunger guides. These control and leak-off fuel quantities are returned to
the fuel tank via the fuel return and the collector line to which overflow valve, high pressure pump,
and pressure control valve are also connected.
1) Method of operation
The injector's operation can be subdivided into four operating states with the engine running and
the high pressure pump generating pressure.
- Injector closed (with high pressure applied)
- Injector opens (start of injection)
- Injector opened fully, and
- Injector closes (end of injection)
These operating states result from the distribution of the forces applied to the injector's
components. With the engine at standstill and no pressure in the rail, the nozzle spring closes the
injector.

2) Injector closed (at rest status)
In the at rest state, the solenoid valve is not energized and is therefore closed. With the bleed
orifice closed, the valves spring forces the armature's ball onto the bleed-orifice seat. The rail's high
pressure builds up in the control valve, and the same pressure is also present in the nozzle's
chamber volume. The rail pressure applied at the control plunger's end face, together with the force
of the nozzle spring, maintain the nozzle in the closed position against the opening forces applied to
its pressure stage.
3) Injector opens (start of injection)

The injector is in its at-rest position. The solenoid valve is energized with the pick-up current which
serves to ensure that it opens quickly. The force exerted by the triggered solenoid now exceeds that
of the valve spring and the armature opens the bleed orifice. Almost immediately, the high-level
pick-up current is reduced to the lower holding current required for the electromagnet. This is
possible due to the magnetic circuit's air gap now being smaller. When the bleed orifice opens, fuel
can flow from the valve-control chamber into the cavity situated above it, and from there via the fuel
return to the fuel tank. The bleed orifice prevents complete pressure balance, and the pressure in
the valve control chamber sinks as a result. This leads to the pressure in the valve-control chamber
being lower than that in the nozzle's chamber volume which is still at the same pressure level as the
rail. The reduced pressure in the valve-control chamber causes a reduction in the force exerted on
the control plunger, the nozzle needle opens as a result, and injection starts.
The nozzle needle's opening speed is determined by the difference in the flow rate through the
bleed and feed orifices. The control plunger reaches its upper stop where it remains supported by a
cushion of fuel which is generated by the flow of fuel between the bleed and feed orifices. The
injector nozzle has now opened fully, and fuel is injected into the combustion chamber at a pressure
almost equal to that in the fuel rail. Force distribution in the injector is similar to that during the
opening phase.
4) Injector closes (end of injection)

As soon as the solenoid valve is no longer triggered, the valve spring forces the armature
downwards and the ball closes the bleed orifice. The armature is a 2-piece design. Here, although
the armature plate is guided by a driver shoulder in its downward movement, it can "over spring"
with the return spring so that it exerts no downwards-acting forces on the armature and the ball.
The closing of the bleed orifice leads to pressure buildup in the control chamber via the input from
the feed orifice. This pressure is the same as that in the rail and exerts an increased force on the
control plunger through its end face. This force, together with that of the spring, now exceeds the
force exerted by the chamber volume and the nozzle needle closes.
The nozzle needle's closing speed is determined by the flow through the feed orifice. Injection
ceases as soon as the nozzle needle comes up against its bottom stop again.

3.4.14. Crank shaft speed sensor
● The piston position in the combustion
chamber is decisive in defining the start Fixing bolt
of injection. All the engine's pistons are

Crank shaft
connected to the crankshaft by
sensor
connecting rods. A sensor on the
crankshaft can therefore provide
information on the position of all the Shim
pistons. The rotational speed defines

the number of crankshaft rotations per EE1OM102
minute. This important input variable is
calculated in the ECU using the signal
from the inductive crankshaft speed
sensor.
3.4.15. Cam shaft speed sensor

● The camshaft controls the engine's
intake and exhaust valves. It turns at Fixing bolt
half the speed of the crankshaft. When

Crank shaft
a piston travels in the direction of TDC,
sensor
the camshaft position determines
whether it is in the compression phase
with subsequent ignition, or in the Shim
exhaust phase. This information cannot

be generated from the crankshaft
EE1OM102
position during the starting phase.
During normal engine operation on the
other hand, the information generated
by the crankshaft sensor suffices to
define the engine status. In other
words, this means that if the camshaft
sensor should fail while the vehicle is
being driven, the ECU still receives
information on the engine status from
the crankshaft sensor.

3.4.16. Accelerator pedal sensor
● The accelerator pedal sensor transmitted the driver’s acceleration input to the ECU.
● A voltage is generated across the potentiometer in the accelerator-pedal sensor as a function of the
accelerator-pedal setting. Using a programmed characteristic curve, the pedal's position is then
calculated from this voltage.
3.4.17. Boost pressure & temperature sensor

● The boost pressure & temperature
sensor are connected to the intake Boost pressure &
Fixing bolt temperature sensor
manifold by the O-ring and measures
the intake manifold's absolute pressure
and temperature.
● The output signal is inputted to the ECU
where, with the help of a programmed Shim
characteristic curve, it is used for

calculating the boost pressure. EE1OM103
3.4.18. Engine oil pressure & temperature sensor

● The engine oil pressure and oil
temperature sensor measure in the Fixing bolt
engine lube oil and measuring data is

inputted into ECU.
Engine oil
pressure &
temperature
sensor
EE1OM104
3.4.19. Engine coolant temperature sensor

● The engine coolant temperature sensor
measure in the engine coolant circuit
and measuring data is inputted into
ECU.
EE1OM105

3.5. Electrical System
3.5.1. Electrical parts
2
5
11
10
6
8
7
EF6OM040
1. Coolant temperature sensor 7. Air con. compressor
2. Alternator 8. Engine oil pressure & temperature sensor
3. Fuel temperature sensor 9. Boost pressure & temperature sensor
4. Camshaft speed sensor 10. Starter
5. Air heater 11. Crankshaft speed sensor
6. Electric control unit (ECU)
- 113 - Electrical System

3.5.2. Harness of electrical control unit
Term. 30 (BAT+)
G_G_BAT-1
30
1.03
Term. 31 G_G_BAT-2 V_V_BAT+1
switch
Ignition
1.09 1.01
(BAT-)
15
G_G_BAT-3 V_V_BAT+2
1.14 1.07 V1
G_G_BAT-4 V_V_BAT+3
20A
1.15 1.12
B_D_CANH1 V_V_BAT+4
J1939 Interface #1 1.53 1.13
Vehicle connector
B_D_CANL1 I_S_T15 Key switch
(CAN #1)
1.52 1.39
G_C_CAN1
1.51
B_D_CANH2
1.35
Reserve J1939 Interface #2 B_D_CANL2
(CAN #2) 1.34
G_C_CAN2
1.33
B_D_ISOK
to other loads
to other loads
1.31
J9141 Interface
(ISO)
I_S_DIA (_DIG15) Diagnostic request switch (Digital input 15)

1.27
O_V_RL Switched battery output
V2
1.08
I_S_STP (_DIG21)
Engine stop switch/Digital input #21 1.45
G_R_DIG
21 1.19 O_S_CSLP (_RL02) Colt start lamp
Control unit
V3
1.29
(Reserve Sink Driver #2)
O_S_DIA (_RL06)
1.64 Diagnostic lamp (Sink Driver #6)
O_V_DIA (_RL06)
1.28
G_G_RH01/ Switched battery output

V4
1.04
_RH02/_RH04
O_V_RHS03
Cold start heater relay 2.16
(Source Driver #1) O_S_CSHRLY (_RH01) O_S_BPA (_RHS03)
1.16 2.04 Source Driver #3
O_G_BPA (_RHS03) current controlled or passive
2.02 (Boost pressure actuator)
I_F_CRS (_DF01) Increment speed sensor

1
U
2.25
(Crankshaft) (DG6) (VR) #1
G_R_CRS (_DF01)
2
Fuel high pressure pump (CP3.3 / -3.4) 2.24 (tone wheel with slots)
(0 445 020 011) / (0 281 002 662)
B 413 040 073) O_T_MEU (_RHS01) Shield
with fuel metering 2.07
unit (ZME) O_G_MEU (_RHS01) I_F_CAS (_DF02) Segment speed sensor
U
2
2.05 2.23
(0 928 400 484) / (Camshaft) (DG6) (VR) #2
G_R_CAS (_DF02)
1
0 928 B00 117) 2.30 (tone wheel with tooth)

Engine connector
V_V_5VOPS (_5VSS3B) (0 281 002 662)

P(&t )
2.09
Shield
3
Oil pressure sensor I_A_OPS (_ACT06)

2.33
(ODFT)
4
G_R_OPS (_ACT06)
2.19
(0 281 002 420)
1
I_A_OTS (_PAS05)
U
2.35
2
V_V_5VBPS (_5VSS1A)
P(&t )
2.10 V_V_5VRAILPS (_5VSS2A)

3
Boost pressure sensor I_A_BPS (_ACT02)

3
2.28 2.12
U
(LDF6T) Rail pressure sensor (RDS3)

4
G_R_BPS (_ACT02) I_A_RAILPS (_ACT01)

2
2.21 2.27 (0 281 002 534)

(0 281 002 576)
1
I_A_BTS (_PAS03) G_R_RAILPS (_ACT01)

U
2.29 2.20
2
Coolant I_A_CTS (_PAS02) O_P_SVH11

t
temperature 2.36 3.09

Cylinder 1
1
sensor G_R_CTS (_PAS02) O_P_SV11

U
(0 281 002 209) 2.18 3.13

2
O_P_SVH12
3.04
Fuel I_A_FTS (_PAS01) O_P_SV12 Cylinder 2 "High Bank 1"
t
temperature 2.34 3.12

sensor
1 2
G_R_FTS (_PAS01) O_P_SVH13

Cylinder connector
U
(0 281 002 209) 2.17 3.03

O_P_SV13 Cylinder 3
3.06
O_P_SVH21
3.11
O_P_SV21 Cylinder 4
3.16
O_P_SVH22
3.10
O_S_EGR (_RHS02) O_P_SV22 Cylinder 5 "High Bank 2"
Source Driver #2 2.06 3.15
current controlled O_G_EGR (_RHS02) O_P_SVH23
2.01 3.05
(EGR) Cylinder 6
O_P_SV23
3.14
3.07 nc G_R_GND01
3.08 nc G_R_GND02
EF6OM041
Electrical System - 114 -

3.5.3. Connector of electrical control unit (ECU)
Vehicle side connector Engine side connector
EE1OM110

3.5.4. Electrical Control Unit
Signal
Pin no. Part name
BOSCH DOOSAN
1.01 V_V_BAT+1 V_V_BAT+1 Battery plus (+24V)
1.03 G_G_BAT-1 G_G_BAT-1 Battery minus (-24V)
1.04 G_G_RH01 G_G_RH01 Ground (-24V)
1.07 V_V_BAT+2 V_V_BAT+2 Battery minus (+24V)
1.08 O_V_RL O_V_RL ECU Battery voltage (+24V)
1.16 O_S_CSHRLY O_S_RH01 Air heater relay
1.19 G_R_DIG G_R_DIG Digital ground
1.27 I_S_DIA I_S_DIG15 Diagnostic operation switch
ECU Battery voltage (+24V) for diag-
1.28 O_V_DIA O_V_RL06
nostic lamp operation
1.29 O_S_CSLP O_S_RL02 Cold starting lamp
1.31 B_D_ISOK B_D_ISOK ISO K-line
1.33 G_C_CAN2 G_C_CAN2 ECU network 2 , shield
1.34 B_D_CANL2 B_D_CANL2 ECU network 2 , low
1.35 B_D_CANH2 B_D_CANH2 ECU network 2 , high
1.39 I_S_T15 I_S_T15 Key switch (Terminal 15)
1.45 I_S_STP I_S_DIG21 Engine stop switch signal
1.51 G_C_CAN1 G_C_CAN1 ECU network 1, shield
1.52 B_D_CANL1 B_D_CANL1 ECU network 1, low
1.53 B_D_CANH1 B_D_CANH1 ECU network 1, high
1.64 O_S_DIA O_S_RL06 Diagnostic lamp
Power ground output for boost pressure
2.02 O_G_BPA O_G_RHS03
actuator
2.04 O_T_BPA O_T_RHS03 Boost pressure actuator
2.05 O_G_MEU O_G_RHS01 Fuel metering unit (low side)
2.07 O_T_MEU O_T_RHS01 Fuel metering unit (high side)
2.09 V_V_5VOPS V_V_5VSS3B Oil pressure sensor supply (5V)
2.10 V_V_5VBPS V_V_5VSS1A Boost pressure sensor supply (5V)
Common rail pressure sensor supply
2.12 V_V_5VRAILPS V_V_5VSS2A
(5V)
2.16 O_V_RHS03 O_V_RHS03 ECU battery plus output (+24V)
2.17 G_R_FTS G_R_PAS01 Fuel temperature sensor ground
2.18 G_R_CTS G_R_PAS02 Coolant temperature sensor ground

Signal
Pin no. Part name
BOSCH DOOSAN
2.19 G_R_OPS G_R_ACT06 Oil pressure sensor ground
2.20 G_R_RAILPS G_R_ACT01 Common rail pressure sensor ground
2.21 G_R_BPS G_R_ACT02 Boost pressure sensor ground
2.23 I_F_CAS I_F_DF02 Camshaft speed sensor signal
2.24 G_R_CRS G_R_DF01 Crankshaft speed sensor ground
2.25 I_F_CRS I_F_DF01 Crankshaft speed sensor signal
2.27 I_A_RAILPS I_A_ACT01 Common rail pressure sensor signal
2.28 I_A_BPS I_A_ACT02 Boost pressure sensor signal
2.29 I_A_BTS I_A_PAS03 Boost air temperature sensor signal
2.30 G_R_CAS G_R_DF02 Camshaft speed sensor ground
2.33 I_A_OPS I_A_ACT06 Oil pressure sensor signal
2.34 I_A_FTS I_A_PAS01 Fuel temperature sensor signal
2.35 I_A_OTS I_A_PAS05 Oil temperature sensor signal
2.36 I_A_CTS I_A_PAS02 Coolant temperature sensor signal
3.03 O_P_SVH13 O_P_SVH13 #3 cylinder injector power supply
3.06 O_P_SV13 O_P_SV13 #3 cylinder injector power return
3.07 nc G_R_GND01
3.08 nc G_R_GND02
nc = not connected

3.5.5. Sensor of engine side(Engine harness-1)
Water
temperature Oil pressure
sensor sensor Common Cam shaft
(CTS) (OPTS) Boost pressure rail pressure speed
sensor sensor sensor
(BPTS) (RPS) (CAS)
Engine ECU Crank shaft speed Fuel temperature Fuel metering

sensor sensor unit
(CRS) (FTS) (MEU)
EF6OM042
Part Pin position Wire

Signal Circuit name
name ECU no. Connecting pin no. color
2.25 ECU No.25 Crankshaft sensor 1 White Speed sensor signal
CRS
2.24 ECU No.24 Crankshaft sensor 2 Blue Speed sensor earth(-)
2.30 ECU No.30 Camshaft sensor 1 White Speed sensor signal
CAS
2.23 ECU No.23 Camshaft sensor 2 Blue Speed sensor earth (-)
2.07 ECU No.07 Fuel metering unit 1 White Fuel metering unit (high)
MEU
2.05 ECU No.05 Fuel metering unit 2 Blue Fuel metering unit (low)
2.19 ECU No.19 Oil pressure sensor1 Blue Oil pressure sensor earth (-)
2.35 ECU No.35 Oil pressure sensor 2 White Oil temperature sensor signal
OPTS
2.09 ECU No.09 Oil pressure sensor 3 White Oil pressure sensor power supply (5V)
2.33 ECU No.33 Oil pressure sensor 4 White Oil pressure sensor signal
2.21 ECU No.21 Boost pressure sensor 1 Blue Boost pressure sensor earth(-)
2.29 ECU No.29 Boost pressure sensor 2 White Boost temperature sensor signal
BPTS
2.10 ECU No.10 Boost pressure sensor 3 White Boost pressure sensor power supply (5V)
2.28 ECU No.28 Boost pressure sensor 4 White Boost pressure sensor signal
2.20 ECU No.20 Rail pressure sensor 1 Blue Rail pressure sensor earth (-)
2.27 RPS ECU No.27 Rail pressure sensor 2 White Rail pressure sensor signal
2.12 ECU No.12 Rail pressure sensor 3 White Rail pressure sensor power supply (5V)
2.36 ECU No.36 Coolant temperature sensor 1 White Coolant temperature sensor signal
CTS
2.18 ECU No.18 Coolant temperature sensor 2 Blue Coolant temperature sensor earth (-)
2.34 ECU No.34 Fuel temperature sensor 1 White Fuel temperature sensor signal
FTS
2.17 ECU No.17 Fuel temperature sensor 2 Blue Fuel temperature sensor earth (-)

3.5.6. Harness of injector (Engine harness - 2)
Injector cylinder
#1 Injector
Injector cylinder cylinder
#2 #4
Injector
cylinder
Injector
#5
cylinder
#3
Injector
cylinder
#6
Injector
cylinder # 3 Injector cylinder # 5, # 6
Injector cylinder
Injector cylinder # 4
# 1, # 2
Engine ECU
EF6OM043

1) Harness of injector (outside)
Cylinder # 3 Cylinder # 5, # 6
Cylinder # 1, # 2 Cylinder # 4
Engine ECU
EF6OM044
Side of ECU Side of injector

Wire
Circuit name
Connector no. Pin no. Connector no. Pin no. color
3.09 3 White High side of injector 1
3.13 P_02 4 White Low side of injector 1

936254-1
3.04 (AMP) 1 White High side of injector 2
3.12 2 White Low side of injector 2
3.03 P_03 1 White High side of injector 3

P_01
936254-1
3.06 (AMP) 2 White Low side of injector 3
Y462 U03 027
(1 928 404 202) 3.11 P_05 1 White High side of injector 4
936254-1
(BOSCH)
3.16 (AMP) 2 White Low side of injector 4
3.10 1 White High side of injector 5
3.15 P_04 2 White Low side of injector 5

936254-1
3.05 (AMP) 3 White High side of injector 6
3.14 4 White Low side of injector 6

2) Harness of injector - A (inside)
EE2OM094
Side of ECU harness Side of engine brake Wire

Circuit name
color
Connector no. Pin no. Connector no. Pin no.
P_01 1 1 White High side of injector
2 Y462 U00 226(Bosch) 2 White Low side of injector

99013-00201
or
(AMP) 3 3 White High side of injector
45360.212.179(GHW)
65.26810-5006
(DOOSAN) 4 4 White Low side of injector
3) Harness of injector - B (inside)
EF6OM045
Side of ECU harness Side of engine brake

Wire
Circuit name
Connector no. Pin no. Connector no. Pin no. color
P_01 1 Y462 U00 226(Bosch) 1 White High side of injector

or
2 45360.212.179(GHW) 2 White Low side of injector
99013-00501
(AMP) 3 - - -
65.26810-5009 None
(DOOSAN) 4 - - -

3.6. Engine Diagnostic
3.6.1. Method of confirmation for the fault code

The method of performing the DV11 engine diagnostic is using the SCAN-200.
DOOSAN recommend the using the SCAN-200, because it can be worked speedy and correctly.
3.6.2. Method by SCAN-200

SCAN-200 is designed to serve to the maintenance with adding the function of the graphic and
oscilloscope to be used for the diagnosis and maintenance of present vehicle system.
Please know well the user’s manual to shorten the time and to apply the diagnostic tool before use the
SCAN-200. At the time of using the SCAN-200, if use together SCAN-200 manual and maintenance
manual for the maintenance, the effect should be increased more and more.
EF6OM053
Engine Diagnostic - 122 -

3.6.3. Engine fault code and occurring condition
1) Trouble code of vehicle parts
Fault code Contents of trouble Condition of occurring
V201 Gauge panel communication error Connector harness is abnormal
V202 ECU communication error Connector harness is abnormal
V210 Pump proportion valve Current below and/or above normal
V212 Flow control proportion valve Current below and/or above normal
V213 Relief pressure up solenoid valve Current below and/or above normal
V214 High speed solenoid valve Current below and/or above normal
V215 Swing priority solenoid valve Current below and/or above normal
V217 Starter relay Current below and/or above normal
V220 Front pump pressure sensor Voltage above and/or below normal
V221 Rear pump pressure sensor Voltage above and/or below normal
V222 Hydraulic oil temperature sensor Voltage above and/or below normal
V225 Fuel level sensor Voltage above and/or below normal
V226 Alternator potential Voltage above and/or below normal
V227 Dial Voltage above and/or below normal
- 123 - Engine Diagnostic

2) Trouble code of engine parts
Fault
Contents of trouble Grade Condition of occurring
code
Relation to coolant temperature * Sensor / harness is abnormal

E011 C
sensor is abnormal * Coolant temperature is too high
Relation to fuel temperature * Sensor / harness is abnormal

E012 C
sensor is abnormal * Fuel temperature is too high
* Sensor / harness is abnormal

* Intake temperature is excessive
Relation to boost temperature
E013 C after intercooler
sensor is abnormal
* Engine / turbocharger / intercooler is
abnormal

* Intake pressure is excessive after
Relation to boost pressure sensor
E014 C intercooler
is abnormal
* Engine / turbocharger / intercooler is
abnormal
Relation to oil temperature sensor * Sensor / harness is abnormal

E017 N
is abnormal * Oil temperature is too high

Relation to oil pressure sensor is
E018 C * Oil pressure is too
abnormal
abnormal(leakage etc.)
* Battery / alternator / ECU is

E021 Battery voltage is abnormal C
abnormal
Relation to fuel pressure sensor is

E022 B * Sensor / harness is abnormal
abnormal
Common rail pressure is excessive

E032 B * Common rail pressure is abnormal
fluctuation
E037 CAN signal is abnormal N * Connector harness is abnormal
Warning which engine speed is

E038 C * Engine-over-speed
excessive
* ECU inner main relay is abnormal

E039 ECU inner relay is abnormal B
* Power supplying is abnormal
Abnormality by abnormal stopping

E041 B * Abnormal engine stopping
of engine
Relation to crank shaft speed * Sensor / harness is abnormal

E042 C
sensor is abnormal * Sensor gap is abnormal
Relation to cam shaft speed * Sensor / harness is abnormal

E043 C
sensor is abnormal * Sensor gap is abnormal
* Motivation of cam shaft / crankshaft

E044 Engine speed sensor is abnormal C
speed sensor signal is abnormal
* Error is occurred during storing

Dater storage of EEPROM in ECU
E045 C important data of operating in ECU
is abnormal
to EEPROM when engine stop.

Fault
code
Initialization is not good after

E046 C ECU initialization is abnormal
power supply to ECU
Pressure limit value is opened

Pressure limit valve of common rail compulsory when rail pressure is
E047 is opened by excessive rail B occurred at excessive pressure more
pressure than rail pressure or high pressure
pump
Power supplying source is Battery voltage is abnormal : ECU,

E048 N
abnormal battery and alternator is abnormal
Supplying voltage of injector

E049 B
(#1,5,3) is abnormal * Injector cable / connector is
Supplying voltage of injector abnormal or ECU is trouble
E051 B
(#6,2,4) is abnormal
Relation to connecting of injector

E058 B
#1 harness is abnormal

E059 B

E061 B
#3 harness is abnormal * Injector cable / connector is
Relation to connecting of injector abnormal
E062 B

E063 B

E064 B
Relation to air heater lamp is

E066 N Lamp / harness is abnormal
abnormal
Air heater operation relay is

E072 C Air heater relay / harness is abnormal
abnormal
Relation to high pressure pump Fuel metering unit of high pressure

E083 C
control is abnormal pump / harness is abnormal
Starting procedure is abnormal, ECU

E091 Abnormal starting B is abnormal, power supplying is
abnormal
E092 Ignition of #1 cylinder is not good C

* Injector is abnormal, compression
E094 Ignition of #3 cylinder is not good C pressure is a drop, camshaft /
E095 Ignition of #6 cylinder is not good C crankshaft speed sensor signal is
abnormal

Fault
code
Ignition of several cylinder is not

E098 C
good
Opening time of injector is excessive

E099 Injector is opened too long C
from standard values
Error is occurred when calculate

Engine speed is abnormal
E101 C engine speed using crankshaft /
(Additional function)
camshaft speed sensor
* Check of the grade’s operation

N : Case of no damage to the performance and the engine.
C : Case of requirement for the check after running (no emergency check).
B : Case of requirement for the check and measure after running at the low speed at the time of
occurring.

3.6.4. Input and output of the ECU
Input Output
Engine
Engine output
Input and output of ECU Injector output

Coolant temperature sensor - Fuel metering unit
Fuel temperature sensor
Boost pressure and
temperature sensor
Oil pressure and
temperature sensor
Crankshaft speed sensor
Camshaft speed sensor
Vehicle output
Common rail pressure sensor
Electric Preheating relay output

control Preheating display lamp
unit Diagnostic information
(ECU) output lamp
Engine speed and vehicle
Vehicle speed display
Starter switch
Communication
Engine diagnostic
communication
CAN communication

3.7. Operating Condition of the ECU
3.7.1. Engine starting

● Setting of a basic temperature for decision of the fuel quantity.
Set to a basic temperature the minimum value between coolant temperature and fuel temperature
and intake air temperature.
● Engine speed sensor signal measurement
- Using by crankshaft speed sensor
- Using by camshaft speed sensor
- Supply to the engine after decided properly fuel quantity to starting the engine.
3.7.2. Vehicle running

● Essential dater for the running of the vehicle.
- Engine speed
- Vehicle speed
3.7.3. Engine idle adjusting

● Adjusting of engine’s idle speed by the necessity of the driver.
● Preparing condition for the adjusting of the idle speed

- Vehicle speed : stop
- Coolant temperature : more than limit
- Engine speed : less than limited scope of the speed
3.7.4. Limp home function

● The limp home is a function which the vehicle can be operated to the maintenance shop with
minimum condition for traveling on the condition of taking safety when the defect code is occurred.
● Application condition
- Accelerator pedal is trouble : The vehicle is operated by constant engine speed no relation to
depressing of the accelerator pedal.
- Sensor is trouble : The vehicle is operated with constant transfer value when the trouble of all
kinds sensors is occurred.
- Fuel quantity is limited : The fuel quantity supplied into the engine is limited according to kind of
the defect. (is applied by division into 4 stages)
- Diagnostic information output lamp : The safety driving is leaded to the driver by proposal of
information about status of occurred faults.
Operating Condition of the ECU - 128 -

3.7.5. Diagnostic
● Diagnostic information output lamp (CEL: Check engine lamp) is operated when the trouble is
occurred.
● Method of confirmation of the fault code by using the CEL

- The fault code is displayed one by one every time switch of the CEL is depressed.
● Diagnostic by the SCAN-200

- Diagnostic is executed by the connection SCAN-200 to the connector in the relay box.
3.7.6. Vehicle operating record

● The vehicle information related to the operating is recorded in the electric control unit (ECU).
- The measurement of the operating record is possible after the accumulated value or the switch
『reset』 is depressed.
● The contents recorded in the electric control unit

- Fuel quantity according to the division : total, idle state.
- Fuel consumption rate.
- operating mileage.
- Engine operating time, ECU using time.
● The monitoring is possible by using diagnostic tool.
- 129 - Operating Condition of the ECU

4. Commissioning and Operation
4.1. Preparations
At the time of initial commissioning of a new or overhauled engine make sure to have observed the
"Technical information for the installation DOOSAN engines".
● Oil filler neck on cylinder head cover

Before daily starting of the engine, check the fuel, coolant and oil level, replenish if necessary.
● The oil level must be between Max. and Min. lines on the gauge. The notches in the oil level gauge
indicate the highest and lowest permissible oil levels.
IMPORTANT :
Do not fill above the top of the mark by over lifting. Over lifting will result in damage
to the engine.
● Cleanliness
Ensure outmost cleanliness when handling fuels, lubricants and coolants, be careful about mixing of
the foreign matter during the supplement.
In case that DOOSAN recommended the fuel and lubrication oil and coolant do not used, DOOSAN
do not guarantee the field claim.
4.2. Breaking-In
● DOOSAN engine for the vehicle is operated during a short time for the engine last Approving test,
therefore operator must execute the process of proper breaking in the engine during the first 500 Hr
then The maximum performance of the engine have the maximum performance , and the life of the
engine can be prolonged.
4.2.1. Operation of a new engine (Break-in)

Because the sliding surfaces of a new engine are not lapped enough, the oil film can be destroyed
easily by overload or overspeed and the engine life-time may be shortened. Therefore the following
things must be obeyed by all means.
Up to the first 500 Hr

● Engine should be run at fast idling until the temperature of the engine becomes normal operating
condition.
● Overload or continuous high speed operation should be avoided.
● High speed operation with no load should be prevented.
● Abrupt start and stop of the engine should be avoided.
● Engine speed must be under 70% of its maximum speed.
● Maintenance and inspection must be accomplished thoroughly.
Commissioning and Operation - 130 -

4.2.2. Check points for break-in
During the break-in (the initial running of the engine) period, be particularly observant as follows:
● Check engine oil level frequently. Maintain oil level in the safe range, between the "min." and "max."
marks on dipstick.
NOTE :
If you have a problem getting a good oil level reading on the oil level gauge, rotate the
oil level gauge 180° and re-insert for check.
● Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up screen is not
covered with oil. Check oil level gauge. Add oil to the oil pan, if required. Do not overfill. If level is
correct and the status still exists, see your DEALER for possible switch or oil pump and line
malfunction.
Note :
Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition, cold
oil will generally show higher oil pressure for any specific RPM than hot oil. Both of
these conditions reflect normal engine operation.
● Watch the engine water temperature gauge and be sure there is proper water circulation. The water
temperature gauge needle will fluctuate if water level in expansion tank is too low.
● At the end of the break-in period, remove break-in oil and replace the oil filter.
● Fill oil pan with recommended engine oil. Refer to following table
SAE no. Oil grade
ACEA-E5
10W40
(API CI-4)
● Engine oil capacity
Engine oil capacity
Oil pan inside

Engine model Total
Max. Min. (lit)
(lit) (lit)
DV11 41 27 44
- 131 - Commissioning and Operation

4.2.3. Operating after break-In
When starting a cold engine, always allow the engine to warm up gradually. Never run the engine at full
throttle until the engine is thoroughly warmed up. Be sure to check the oil level frequently during the first
500Hr of operation, since the oil consumption will be high until the piston rings are properly seated.
4.3. Inspections after Starting

During operation the oil pressure in the engine lubrication system must be monitored. If the monitoring
devices register a drop in the lube oil pressure, switch off the engine immediately.
And the charge warning lamp of the alternator should go out when the engine is running.
● Do not disconnect the battery or pole terminals or the cables.
● If, during operation, the battery charge lamp suddenly lights up, stop the engine immediately and
remedy the fault in the electrical system.
● Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal.
● Confirm the following things through warning lamps and gauge panel.
4.3.1. Pressure of lubricating oil

The normal pressure comes up to 1.0 ~ 3 kg/cm2 at idling and 3 ~ 5 kg/cm2 (3.0 ~ 4.9 bar) at maximum
speed. If the pressure fluctuates at idling or does not reach up to the expected level at high speed, shut
down the engine immediately and check the oil level and the oil line leakage.
4.3.2. Temperature of cooling water

The cooling water temperature should be 85°C in normal operating conditions. Abnormally high cooling
water temperature could cause the overheating of engine and the sticking of cylinder components. And
excessively low cooling water temperature increases the fuel consumption, accelerates the wears of
cylinder liners and shortens the engine life-time.
4.3.3. Over-speed control

The electric control unit (ECU) have a system of preventing the engine over-speed among many
system. This system involve many function of fuel flow control, ignition time delay, fuel shut off, and
ignition shut off etc.
These values are set up in advance in the memory of the ECU, and should not be revised by user.
This engine with ECU should not be run at the over-speed rating speed for a regular time, if the vehicle
is speeded, the fuel and ignition is shut off until the engine speed is up to the proper level.

4.4. Operation in Winter Time
Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.
4.4.1. Operation in winter time
CAUTION :
1. Preheating devices are attached to the engine for improving the starting abili-
ties at extremely low temperature.
2. Do not actuate the starter for longer than 10 seconds. If starting fails regard-
less of the preheating, start the preheating again after 30 seconds.
Operation 1 : Turn the key switch to the HEAT position, then the pilot lamp lights up for about 20
seconds When the pilot lamp is extinguished, do operation 2
Behavior - When the coolant temperature is below 10°C in cold weather, you’d better operate the
pre-heating system (Air heater).
- If the pre-heating is not necessary, the pre-heating system is not operated with the pilot
lamp.
Operation 2 : After checking the pilot lamp, turn the key switch to the START position to crank the
engine, at once.
Behavior - When the key switch is placed in the START position, air heater is continuously heated to
facilitate starting operation and to reduce white smoke automatically.
- If the coolant temperature is above 10°C, air eater needs not be heated.
Operation 3 : After the engine is cranked, convert the key switch to the ON position.
Behavior - As the engine is cranked, air heater is heated for 180 seconds (3 minute after-heating) to
reduce and to element quickly white smoke.
* Air heater major specification
Rated voltage DC22V (120A ± 10%)

Rated current 2.64 kW

Battery cable
(form relay)
Caution of
assembly direction
Earth cable
EE2OM098
4.4.2. Prevention against freezing of cooling water

● When not using anti-freeze, cause the diffusion of corrosion in inner part of the engine, cause drop
the cooling efficiency, cause being frozen to burst in winter, therefore the whole cooling water should
be completely discharged after engine running.
● The freezing of cooling water is the reason of fatal damage on the engine, always use by mixing the
anti-freeze. (anti-freeze quantity filled : 40-50% of the cooling water) the anti-freeze is used to
prevent cooling water from freeze.
4.4.3. Prevention against excessive cooling

● Drop of thermal efficiency caused by excessive cooling increases fuel consumption, therefore
prevent the engine from excessive cooling. If the temperature of coolant does not reach to normal
condition (78 ~ 85°C) after continuous operation, examine the thermostat or the other cooling lines.
4.4.4. Lubricating oil

As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after starting.
Therefore the lubricating oil for winter should be used to prevent this unstability. Refer to lubricating
system section.

4.5. Engine Components Check after Long Time Running
● The purpose of an engine tune-up is to restore power and performance that's been lost through wear,
corrosion or deterioration of one or more parts or components.
● In the normal operation of an engine, these changes can take place gradually at a number of points, so
that it's seldom advisable to attempt an improvement in performance by correction of one or two items
only. Thorough procedure of analysis and correction, it is desirable to change or correct of all items
affecting power and performance.
● In case that the engine is perform in advance the prevention against trouble, the engine can be run
safely during a long time as that time , there can be used more reliably.
● Economical, trouble-free operation can better be ensured if a complete tune-up is performed once
every years, preferably in the spring.
● Below components that affect power and performance to be checked are:.
- Components affecting intake & exhaust
Air cleaner, inter-cooler, turbo charger, silencer, etc
- Components affecting lubrication & cooling
Air & oil filter, anti- freeze, etc
4.6. Maintenance and Care
4.6.1. Periodical Inspection and Maintenance

In order to insure maximum, trouble-free engine performance at all times, regular inspection,
adjustment and maintenance are vital.
● Daily inspections in bellow figure should be checked every day.
● The maintenance should be executed thoroughly at regular intervals.
(refer to appendix “General engine inspection cycle”.)
4.6.2. Exchanging of lubrication oil

Engine oil and the oil filter are important factors affecting engine life. They affect ease of starting, fuel
economy, combustion chamber deposits and engine wear.
At the end of the break-in period, change the oil sump oil and replace the oil filter cartridge.

● Check the oil level in the engine sump
daily with an oil level gauge.
● The notches in oil level gauge must
indicate the oil level between the max.
● The oil level should be checked with the
engine horizontal and only after it has
been shut down for about 5 minutes. MAX
● Examining the viscosity and the MIN
contamination of the oil smeared at the EA6O5001
oil level gauge replace the engine oil if

necessary.
CAUTION :
Do not add so much engine oil that
the oil level rises above the max.
marking on the oil level gauge. Over
lifting will result in damage to the
engine.
4.6.4. Oil exchange procedure

While the oil is still hot, exchange oil as
follows.
● Take out the oil level gauge.
● Remove the drain plug from oil pan, then
drain out the engine oil into a container.
● Refill with new engine oil at the oil filler
neck on the head cover and the
lubricating oil in accordance with the oil
Drain plug
capacity of the engine through oil filler. EF6OM020
● Be careful about the mixing of dust or

contaminator during the supplement of
oil. Then confirm that oil level gauge
indicates the vicinity of its maximum
level.
● For a few minutes, operate the engine at
idling in order to circulate oil through
lubrication system.
● Thereafter shut down the engine. After
waiting for about 10 minutes measure
the quantity of oil and refill the additional
oil if necessary.

4.7. Cooling System
● The coolant must be changed at intervals of 1,200 hour operation or six months whichever comes first.
If the coolant is being fouled greatly, it will lead an engine overheat or coolant blow off from the
expansion tank.
4.7.1. Coolant draining

● Remove the pressure cap.
● Open the drain valve at the radiator
lower part to drain the coolant as the
right figure.
● Loosen the coolant drain plug of the
cylinder block.
CAUTION :
Drain valve
When removing the pressure filler EF6OM046
cap while the engine is still hot,

cover the cap with a rag, then turn it
slowly to release the internal steam
pressure. This will prevent a person
from scalding with hot steam
spouted out from the filler port.
Cooling water drain
EF6OM018

4.7.2. Cleaning of the cooling inside system circuit
When the cooling system circuits are fouled with water scales or sludge particles, the cooling efficiency
will be lowered. When the cooling system circuits are clogged, the water pump mechanical seal is
damaged.
The poor condition of the cooling system is normally due to use of unsuitable or no anti-freezing agents
and corrosion inhibitor or defect.
If twice in a short time (within 6 months) the water pump of an engine develops leases or the coolant is
heavily contaminated (dull, brown, mechanically contaminated, gray or black sings of a leakage on the
water pump casing) clean the cooling system prior to removing that water pump as follows.
a) Drain coolant.
b) Remove thermostats, so that the whole cooling system is immediately flown through when cleaned.
c) Fill the cooling system with a mixture of potable water and 1.5% by volume of cleaner. (Henkel
P3T5175)
d) Warm up engine under load. After a temperature of 60°C is reached, run engine for a further 15
minutes.
e) Drain cleaning fluid.
f) Repeat steps c) and d).
g) Fill cooling system with hot water.
h) Run engine at idle for 30 minutes. At the same time continuously replenish the water leaking from the
bore in drain plug by adding fresh water.
CAUTION :
Periodically clean the circuit interior with a cleaner.

4.8. Adjustment of Valve Clearance
4.8.1. General information

The valve clearances are to be adjusted at the times of the following situations.
● When the engine is overhauled and the cylinder heads are disassembled.
● When severe noise comes from valve train.
● When the engine is not normally operated, even though there is no trouble in the fuel system.
4.8.2. Valve clearance adjust procedure

● After letting the #1 cylinder's piston come at the compression top dead center by turning the
crankshaft, adjust the valve clearances.
● Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified value
between a rocker arm and a valve stem and adjust the clearance with adjusting screw respectively
and then tighten with the lock nut.
● As for the valve clearance, adjust it when in cold, as follows.
Engine model Intake valve (A) Exhaust valve (A)
DV11 0.4 mm 0.5 mm
Rocker arm
Valve adjusting bolt
Caliper adjusting bolt
Valve adjusting nut

A
Caliper Push rod
Intake valve spring
Valve
Valve seat
Intake & exhaust valve adjusting EF6OM016

< Adjust the valve clearance as following order. >
1) Rotating the engine, let #6 cylinder overlap.
corresponding to " ◎ " of following lists.
3) Rotating the crankshaft by 90° rotation, adjust the valve clearance corresponding to " ⊙ ".
4) Rotating the crankshaft by 1 rotation (360° rotation), let #1 cylinder overlap.
corresponding to " ● " of following lists.
6) Rotating the crankshaft by 450° rotation, adjust the valve clearance corresponding to " ○ ".
7) After rechecking the valve clearance, readjust if necessary.
● No. 1 Cylinder is located at the side where cooling water pump was installed.
Fly wheel Cylinder no. Exhaust valve Intake valve Cooling fan
6 5 4
3 2 1

Valve adjusting position
EE2OM020

Cylinder No. 1 2 3 4 5 6
Exhaust Intake Exhaust Intake Exhaust Intake Intake Exhaust Intake Exhaust Intake Exhaust
Valve adjusting
#1 cylinder top dead center

◎ ◎ ◎ ◎ ◎
Crankshaft 90° revolution ⊙
360° revolution
#5 cylinder top dead center ● ● ● ● ●
Crank shaft
○
450° revolution

Adjusting of the valve overlapping on each cylinder is done as follow.
When each cylinder is valve overlap

1 4 2 6 3 6
(Explosion cylinder No. order)
Valve adjusting cylinder No. 5 3 6 1 4 2

4.9. Tightening the Cylinder Head Bolts
● Coat the engine oil on the cylinder head
bolts, assemble with specified torque
according to the order of the
assembling.
< Cylinder head bolts >
Spec EE2OM053
M16 x 2.0 x 176
1st : 8kg.m
2nd : 180°
Torque
2rd : 150°
(Angle torque)
< Cylinder head bolt’s Tightening Order >

(2) Second step : Screw down 1 ~ 2 threads
(3) Third step : Tighten with about 8 kg.m by wrench
(4) Fourth step : Tighten with about 15kg.m by torque wrench
(5) Fifth step : Tighten with rotating angle method 90°
(6) Sixth step : Tighten with rotating angle method 90°
(7) Seven step : Tighten with final additional rotating angle method 60°

5. Maintenance of Major Components
5.1. Cooling System
5.1.1. General descriptions and main data

● This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are cooled
down by coolant and radiated to the outside, resulting in the normal operation of the engine.
● Looking into the cooling system, the water pumped up by the water pump circulates around the oil
cooler through the water pipe to absorb the oil heat, and then flows through the water jacket of the
cylinder block and water passage of the cylinder head to absorb the heat of the combustion
chamber.
Cylinder head Cylinder head
3 6
2 5
1 4 Cylinder No.
Oil cooler
Cylinder block
Thermostat
Water pump
Radiator
EE2OM018
● The water absorbing the oil heat and combustion chamber heat goes on to the thermostat through
the water pipe, and circulates to the water pump if water temperature is lower than the valve opening
temperature on the thermostat, while circulating to the radiator at water temperature higher than the
valve opening temperature. At the radiator, the heat absorbed in the coolant is radiated to cool down
and the coolant recirculates to the water pump.
- 143 - Maintenance of Major Components

5.1.2. Specification
Item Specification
Type Centrifugal type
Pumping speed 3,500 rpm

1. Water pump
Delivery about 452 liter/min or more
Pumping back pressure Bellow 1.8 bar
Operating temperature 71°C type
8mm or more
2. Thermostat Valve lift
(at 85°C)
Operating temperature 71 ~ 85°C
5.1.3. Thermostat
● General descriptions and main data
The thermostat maintains a constant
To radiator
temperature of coolant (71 ~ 85°C) and
improves thermal efficiency of the engine
by preventing heat loss.
Namely, when the temperature of
coolant is low, the thermostat valve is
closed to make the coolant bypass to
Bypass
From cooling valve
directly enter the water pump; when the To bypass tube
water pipe
coolant temperature rises to open wide EAMC002I
the thermostat valve, the bypass circuit
is closed and the water passage to the
radiator is opened so that the coolant is
forced to flow into the radiator.
● Inspecting
(1) Check the wax pallet and spring for
damage.
(2) Put the thermostat in a container of Ruler
Thermometer
water, then heat the water slowly and
check temperature with a
thermometer. If the valve lift is 0.1 Woodplate
mm (starting to open) at temperature
of 71°C and 8 mm or more (opening
wide) at temperature of 85°C, the EFM2055I
thermostat is normal.
Maintenance of Major Components - 144 -

● Replacing thermostat and precautions for handling
(1) Precautions for handling
The wax pallet type thermostat does not react as quickly as bellows type one to a variation of
temperature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of
the wax pellet type thermostat. Therefore, to avoid a sharp rise of coolant temperature, it is
essential to idle the engine sufficiently before running it. In cold weather, do not run the engine at
overload or overspeed it immediately after engine starting.
(2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently from the
entire cooling system.
(3) Replacing thermostat
If the thermostat is detected defective, retrace with a new one.

5.1.4. Diagnostics and troubleshooting
Complaints Possible causes Corrections
1. Engine overheating ● Lack of coolant ● Replenish coolant

● Radiator cap pressure valve ● Replace cap
spring weakened
● Fan belt loosened or broken ● Adjust or replace fan belt
● Fan belt fouled with oil ● Replace fan belt
● Thermostat inoperative ● Replace thermostat
● Water pump defective ● Repair or replace
● Restrictions in water ● Clean radiator and water
passages due to deposit of passages
scales
● Injection timing incorrect ● Check injection timing by
SCAN-200
● Restriction in radiator core ● Clean exterior of radiator
● Gases leaking into water ● Replace cylinder head
jacket due to broken gasket
cylinder head gasket
2. Engine overcooling ● Thermostat inoperative ● Replace thermostat

● Ambient temperature too ● Install radiator curtain
low
3. Lack of coolant ● Radiator leaky ● Correct or replace

● Radiator hoses loosely ● Retighten clamps or replace
connected or damaged hoses
● Radiator cap valve spring ● Replace cap
weakened
● Water pump leaky ● Repair or replace
● Heater hoses loosely ● Tighten or replace hoses
connected or broken
● Cylinder head gasket leaky ● Replace cylinder head
gasket
● Cylinder head or cylinder ● Replace cylinder head block
block cracked
4. Cooling system noisy ● Water pump bearing ● Replace bearing

defective
● Fan loosely fitted or bent ● Retighten or replace fan
● Fan out of balance ● Replace fan
● Fan belt defective ● Replace fan belt

5.2. Lubrication System
5.2.1. General descriptions and main data

● General descriptions
All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through the oil
cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the cylinder block from
where it is distributed to lubricate the various sliding parts in order to ensure normal engine
performance.
● Specifications
Item Specifications Item Specifications
Lubricating system Forced pressure Oil filter type Full flow

circulation Bypass for cartridge
Oil pump type Gear type Valve opening 1.8~2.4 kg/cm2
Relief valve opening 10 -1.5 kg/cm2 pressure
pressure Bypass for entire oil
Oil cooler bypass 5 +1 kg/cm2 filter
Opening pressure Valve opening 4.3~4.7 kg/cm2
Adjusting valve for 1.5~1.8 kg/cm2 pressure
spray nozzle
Opening pressure
5.2.2. Oil pump

● Disassembly
(1) Disassembly of oil pump drive gear
a. Unscrew the screw and disassemble
the oil relief valve
b. Unfold the washer for the oil pump
drive gear fixing nut and remove the
nut
c. Disassemble the drive gear
Cover fixing bolt

EE1OM142
2) Remove the oil pump cover fixing nuts
and disassemble the oil pump cover.
The oil pump cover is fixed with the two
dowel pins.
3) Disassemble the drive gear and driven
gear.

● Inspection and correction
(1) With steel rule and feeler gauge,
measure the axial end play of the oil
pump gear. Replace if the measured
value is beyond the limit.
End play limit 0.055 ~ 0.105 mm

Steel plate
Feeler gauge
EQM4008I
(2) With a feeler gauge, measure the

amount of backlash between the oil
pump drive gear and driven gear.
Replace if the measured value is
beyond the limit.
Backlash limit 0.50 ~ 0.64 mm
EQM4009I
(3) Measuring clearance between drive shaft and bushing

a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the measured
values are less than the limit.
Standard Φ 16.95 ~ Φ 16.968 mm
Limit Φ 16.95 mm
b. Measure the inside diameter of the pump body bushing to determine the clearance between the
bushing and shaft, and compare the measured value with the standard value to determine
whether to replace or no.
Clearance 0.075 ~ 0.127 mm
● Reassembly
(1) For reassembly, reverse the disassembly sequence.

1. Oil consumption ● Poor oil ● Use suggested oil

excessive ● Oil seal or packing leaky ● Replace
● Pistons or piston rings worn ● Replace pistons and/or
piston rings
● Cylinder liner worn ● Replace cylinder liner
● Piston rings sticking ● Replace pistons and/or
piston rings
● Valve guide oil seals or valve ● Replace
guides, or valve stem worn
Oil pressure too low ● Poor oil ● Use suggested oil

● Relief valve sticking ● Replace
● Restrictions in oil pump ● Clean strainer
strainer
● Oil pump gear worn ● Replace
● Oil pump feed pipe cracked ● Replace
● Oil pump defective ● Correct or replace
● Oil pressure gauge defective ● Correct or replace
● Various bearings worn ● Replace
2. Oil deteriorates ● Restriction in oil filter ● Replace filter element

quickly ● Gases leaking ● Replace piston rings and
cylinder liner

5.3. Turbo Charger
5.3.1. Specification and construction

1) Main data and specification
Specification DV11
Model Honeywell 753834-1/2
Air pressure at compressor outlet Approx. 1.9 kgr/cm2
At maximum output Air suction of turbine revolution Approx. 23 m3/min
Speed of turbine revolution Approx. 95,000 rpm
Maximum allowable speed 118,900 rpm
Maximum allowable temperature of exhaust gas at turbine inlet 750°C
Lubricating system External oil supply
Weight 18 kg
2) Operating principle
Turbine wheel
Outlet
Compressor
Engine
Exhaust
cylinder
gas
Exhaust gas inlet outlet
Compressor air supply
Intake air Turbine
Exhaust gas passage inlet
Exhaust Compressor wheel Compressor air passage
EFM3002I EFM3003I
3) Construction
D
1 2
3
1. Impeller casing
2. Turbine casing
5 3. Bearing casing
4. Impeller
5. Turbine
A B
A. Air inlet
B. Gas outlet
C. Gas inlet
4 D. Oil suppply
E E. Oil return
C EAO5008I

4) Components of turbocharger
● Make sure that servicing should be performed at the professional maintenance shop as authorized
by Honeywell Company.
32
10 33
8
1
6
5
28
27
9
26
2
7
31
3 21
20
4
30
16 18
17
24
14
19 22
15 25
11 1213
23 EE2OM104
1. Hose 12. Piston ring 23. Hex. nut
2. Hose clamp 13. Thrust collar 24. Hex. bolt
3. Connector 14. Thrust bearing 25. Turbine housing
4. Compressor housing 15. Journal bearing 26. Actuator bracket
5. Compressor clamp 16. Center housing 27. Hex. bolt
6. Hex. bolt 17. Bearing spacer 28. Rod
7. Compressor wheel 18. Journal bearing 29. Retaining ring
8. O-ring 19. Shroud wheel 30. Crank ass’y
9. Hex. bolt 20. Piston ring 31. Arm valve ass’y
10. Back plate 21. Turbine wheel ass’y 32. Actuator
11. Seal ring 22. V - clamp 33. Hose clamp

5.3.2. General information
The engine output depends upon the supplied fuel quantity and the engine efficiency. In order to
transform into the effective work of engine by burning the supplied fuel fully, the sufficient air to burn the
fuel should be supplied to the cylinder. Therefore, the engine output is essentially determined by the
size of the cylinder, and for if the air is supplied to the given volume of cylinder with the air being
compressed, the air quantity in the cylinder will Increase as much to result in that it may burn more fuel.
the output will also be able to increase, Supplying the air by compressing like this into the engine
cylinder is called as super charging, and super charging by means of exhaust gas energy that
discharges to the atmosphere is called as the turbo charging.
5.3.3. Function
1) Turbine
The exhaust gas that is discharged from combustion chamber passes through turbine housing
conveying an energy to turbine wings to give the rotating power, This is called as the turbine and in
order not to influence a bad effect at bearing part, there are the seal ring and heat protector.
2) Compressor
It is connected to the same shaft with the turbine to make a revolving assembly, and receive the
revolving force of turbine, and sends air to the suction manifold by suctioning and compressing it.
This is called as the compressor.
3) Bearing
(1) Thrust bearing
Thrust bearing force is applied to the turbine wheel and an arrangement is made for the shaft not
to shift.
(2) Journal bearing
Journal bearing (floating bearing) is adopted and it forms the double oil films at the inner and outer
surfaces in comparison to the general stationary type so that the bearing may be able to rotate
independently and consequently the double layers of films act as the damper to make the slipping
speed on the bearing surface less than the rotating speed of shaft so that the dynamic stability
may be obtained.
4) Sealing at compressor shaft

In order for the compressed intake air and lubricating oil not to leak, a seal plate and a seal ring are
made to the double structures.

5.3.4. How to handle the engine
1) Precautions for operation of the engine
Operation following items must be observed at the starting, operation and stop of engine.
Operation Caution Reason
1) Inspect oil quantity

2) After confirming that oil pressure 2) If engine is started quickly, of
rises by starting engine with course beginning with every
starter (until the pointer of oil parts of engine, for it revolves
pressure gauge moves or without oil that is to reach to the
pressure indicating lamp turbocharger, the bearing's
operates), the starting must be abnormal wear or stuck may be
done. caused.
3) In case that oil, oil filter and 3) In case that engine stalled for
lubricating system's part are long time and of cold weather,
replaced or engine was stalled the fluidity of oil may be get
At starting
for long time (more than a week), worse.
and in case of operation under
cold weather, loosen the oil pipe
connecting parts of turbocharger
inlet, and operate the starting
motor until oil comes out the
connecting parts. Care must be
paid that after the confirming
above, retighten the pipe
connecting parts without fail, and
proceed with the normal starting.
1) Perform idling operation for about 1) Sudden load at time soon after
5 min. immediately after engine engine starting and at the state
starting. when turbocharger did not yet
reach to smooth revolution, if
abrupt load is applied to engine,
Immediately some parts where oil did still not
After starting reach may cause a burn to be
stuck.
2) Various inspections must insure 2) If there are the leakage of oil,
that there are no leakage of oil, gas, air, particularly oil, for the oil
gas and air. pressure lowers, it causes a burn
of bearing to be stuck.
Following items must be confirmed.

1) Oil pressure 1) If the pressure is too low,
At idling : 1.0 ~ 3.0 kg/cm2 abnormal wear or stuck may be
At full load : 3.0 ~ 5.5 kg/cm2 caused. Or if too high, the oil leak
During may be generated.
operation 2) When abnormal noises and 2) If the engine operation were
vibration are generated, slow continued with abnormal noises
down the revolution and must and vibration, it causes the
stop it to investigate the causes. engine trouble that can not be
repaired or some other troubles.

Operation Caution Reason
1) At stopping the engine, perform 1) After heavy load operation, if the

the idling operation for 5min. and engine were stopped suddenly,
then stop it. the heat would be conducted to
At stop bearing parts from red hot turbine
wings that would result in burning
the oil to cause the stuck bearing
metal and revolving shaft.
5.3.5. Routine inspection and maintenance

Since the state of turbocharger depends largely on the state of engine maintenance, to perform the
specified up keep thoroughly is needed.
1) Air intake system

System the intake air system, care must be taken to the air cleaner. In case of oil passing type air
cleaner, if the oil level is lower than the specified value, the cleaning efficiency get worse, if higher, the
sucked oil pollutes a case. Particularly, for if the rotor were polluted, the balance adjusted precisely
would be deviated to cause a vibration that may cause the stuck or abnormal wear by loading large
force to the bearing, the perfect air cleaner must always be used. In case of dry type filter, according
to the indication of a dust indicator, cleaning must be done to make the intake air resistance as small
as possible.
2) Exhaust system
In exhaust system, a care must be taken to the gas leak and the stuck prevention if exhaust gas leaks
from the exhaust pipe and turbocharger etc., for the super charging effect will be lowered, the
installed states of various parts must be paid with careful attention. Since the parts that reach to high
temperature during operation such as the turbine room use the anti- heat nuts, a care must be paid
not to mix with the general nuts and at the same time, bolt stuck preventing paint should be coated on
the nut for the designated places.
3) Lubricating system
In the lubricating system, a care must be paid to the oil quality and oil element replacement cycle. For
the oil deterioration of turbocharger equipped engine, needless to speak of engine assembly itself,
influences badly to the turbocharger too. Suggested engine oils for the turbocharger-mounted engine
are as follows:
Recommended oil
Engine model
SAE no. API no.
ACEA-E5
DV11 SAE 10W40
(API CI-4)

5.3.6. Periodical servicing
Make it a rule to check the turbocharger assembly for condition and contamination periodically.
1) Guide for checking the rotor for rotating condition

The inspection of the rotor assembly for rotating condition should be performed by the degree of
unusual sound. If a sound detecting bar is used, install its tip on the turbocharger housing and
increase the engine revolutions slowly. If a high-pitch sound is heard continuously, it means that the
rotor assembly is not normal. In this case, as the metal bearing and rotor are likely to be in abnormal
conditions, the turbocharger should be replaced or repaired.
2) Guide for checking rotor end play

Disassemble the turbocharger from the engine, then check the rotor axial play and radial play. When
disassembling the turbocharger, be sure to plug the oil inlet and outlet ports with taps, etc.
(1) Rotor axial direction end play
Turbine wheel chamber

Magnitic vise
Move the turbine

shaft in axial
direction
Dial gauge
Standard : 0.117~0.20mm
Limit of wear : 0.24mm
EE2OM105
(2) Rotor radial direction end play
Dial gauge
Magnetic vise
Oil outlet Move the turbine

shaft in both
direction
simultaneously
Radial play
Standard : 0.075~0.11mm Oil inlet
Limit of wear : 0.12mm EE2OM106
(3) If the measured axial and radial end plays are beyond the limit of wear, replace or repair the
turbocharger.

3) Guide for disassembling/cleaning and checking the turbocharger
First, disassemble the turbocharger from the engine and clean/check it with the oil inlet and outlet
plugged with tape and so on.
4) Precautions for reassembling the turbocharger onto the engine

For reassembly of the turbocharger or handling it after reassembly operation, be sure to observe the
following precautions.
Especially, exercise extreme care to prevent foreign matters from entering the inside of the
turbocharger.
(1) Lubricating system

● Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port and
lubricate the journal and thrust bearings by rotating them with hand.
● Clean not only the pipes installed between the engine and oil inlet port but also the oil outlet
pipe and check them for damage or foreign matters.
● Assemble each joint on oil pipes securely to prevent oil leaks.
(2) Air intake system

● Check the inside of the intake system for foreign matters.
● Assemble each joint on the intake duct and air cleaner securely to prevent air leaks.
(3) Exhaust system

● Check the inside of the exhaust system for foreign matters.
● Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordinary steel
bolts and nuts when performing reassembly operation. Apply anti-seizure coating to the bolts
and nuts.
● Assemble each joint on the exhaust pipes securely to prevent gas leaks.

1. Excessive black smoke 1) Air cleaner element clogged Replace or clean

2) Restrictions in air duct Check and correct
3) Leakage at intake manifold Check and correct
4) Turbocharger seized up and not Disassemble/repair
rotating or replace
5) Turbine blades and compressor Disassemble/repair
blades coming in contact with each or replace
other or damaged
6) Exhaust piping deformed or clogged Check and correct
2. Excessive white smoke 1) Oil leak into turbine and compressor Disassemble/repair
or replace
2) Worn or damaged seal ring due to Disassemble/repair
excessive wear of bearing or replace
3. Low engine output 1) Gas leak at each part of exhaust Check and correct
system
2) Air cleaner element restricted Replace or clean
3) Turbocharger fouled or damaged Disassemble/repair
or replace
4) Leakage at discharge port on Check and correct
compressor side
4. Unusual sound or 1) Rotor assembly coming in contact Disassemble/repair

vibration or replace
2) Unbalanced rotation of rotor Disassemble/repair
or replace
3) Seized up Disassemble/repair
or replace
4) Each joint loosened Check and correct

5.4. Belt
The tension of the belts should be checked after every 2,000 hours of operation.
(1) Change the belts if necessary

If in the case of a multiple belt drive, wear or differing tensions are found, always replace the
complete set of belts.
(2) Checking condition
Check belts for cracks, oil, overheating and wear
(3) Testing by hand
● Poly belt
Poly belt will be properly tensioned if
the deflection force “F” is applied mid-
way between the belt’s tangent points S(SPAN)
with the pulley.
T D
d
F
EB5O6001
(T) = 0.015 x S (about 1.5mm per 100mm).
T = 0.015 x *S (mm)
(T : Deflection, S : Span)
2
(D - d)
2
*S= C 2 (mm)
C : Distance of pulleys (mm)

D : Large pulley diameter (mm)
d : Small pulley diameter (mm)

(4) Measuring tension
① Lower indicator arm (1) into the scale
● Apply tester to belt at a point midway
between two pulleys so that edge of
(1)
contact surface (2) is flush with the V-
belt.
● Slowly depress pad (3) until the
spring can be heard to disengage.
This will cause the indicator to move
upwards. EA6O6011
● If pressure is maintained after the

spring has disengaged a false
reading will be obtained.
② Reading of tension
● Read of the tensioning force of the
belt at the point where the top
surface of the indicator arm (1)
(3)
intersects with the scale.
● Before taking readings make ensure
that the indicator arm remains in its
position.
(2)
EA6O6012
● Poly belt tension
No of rib Force (kgf)

(PK type)
3 20 - 27
4 27 - 36
5 34 - 45 No of rib(Rubber)
6 41 - 57 Oil and heat resistant insulation
Stretch resistant tension member
7 48 - 66
Oil and abrasion resistant backing
8 59 - 73 EB5O6002

6. Special Tool List
No. Part no. Figure Tool name Remark

1 EF.120-232
gear assembly
Oil seal insert assembly

2 EF.120-030
(Front)
Oil seal insert assembly

3 EF.120-029
(Rear)
Valve spring
4 EF.120-238
compression
5 EF.123-365 Cylinder liner puller
6 EF.120-208 Piston insert All engine
7 EF.120-246 Valve stem seal punch
Wearing assembly
8 E1.05508-0185
(Crankshaft pulley)
Special Tool List - 160 -

No. Part no. Figure Tool name Remark
Wearing assembly
9 E1.05508-0025
(Fly wheel)
10 E1.76-035-00D Cam shaft assembly
11 60.99901-0027 Feeler gauge
12 65.98801-0001 Filter wrench
13 T7610001E Snap ring plier
14 T7621010E Piston ring plier
SCAN-200 Diagnostic
15 EF.123-322 Memory card
unit
- 161 - Special Tool List

Appendix
● Tightening torque for major parts
Screw Strength
Major Parts Tightening torque
(Diameter x pitch) (grade)
Cylinder block bearing cap
- Main bolt M18 x 2.0 12.9T Initial 30 kg-m + angle torque 90°
- Side bolt M12 x 1.5 10.9T 8 kg-m
Oil spray nozzle
- Valve M14 x 1.5 - 7 kg-m
- Fixing bolt M6 8.8T 1.2 kg-m
Flywheel housing M12 x 1.5 10.9T 11.2 kg-m
M10 x 1.5 12.9T 7.5 kg-m
Balance weight M16 x 1.5 10.9T Initial 10 kg-m + angle torque 90°
Crank pulley M16 x 1.5 10.9T 21 kg-m
Vibration damper M10 10.9T 6 kg-m
Flywheel M16 x 1.5 12.9T 26 kg-m
Connecting rod cap M16 x 1.5 10.9T Initial 10 kg-m + angle torque 90°
Cylinder head M16 x 2.0 10.9T 6kg.m + 15kg.m + 90°+ 90° + 60°
Cylinder head cover M8 8.8T 2.2 kg-m
Rocker arm bracket M10 x 1.5 10.9T 6.2 kg-m
Lock nut (adjusting screw) M10 x 1.0 8.8T 4.4 kg-m
Oil pump cover M8 8.8T 2.2 kg-m
Oil pump mounting M8 8.8T 2.2 kg-m
Oil cooler M12 10.9T 5 kg-m
Oil pan M8 8.8T 2.2 kg-m
Oil pan drain plug M26 x 1.5 - 8.2 kg-m
Exhaust manifold M10 x 1.5 10.9T 8.0 kg-m
Intake manifold M8 8.8T 2.2 kg-m
Starting motor M12 x 1.5 8.8T 8 kg-m
Alternator bracket M14 x 1.5 8.8T 12 kg-m
Coolant temperature sensor M12 x 1.5 - 2.2 kg-m (max. 2.5 kg-m)
● Tightening torque for fuel injection system
Screw Strength
Major Parts Tightening torque
(Diameter x pitch) (grade)
Fuel high pressure pump drive gear M18 x 1.5 - 11 kg.m ± 0.5 kg.m
Fuel high pressure pump cap M10 x 1.5 10.9T 7.5 kg.m
Fuel injector M8 10.9T 3.5 kg.m
Fuel high pressure pump (cylinder block) M10 x 1.5 10.9T 4.4 kg.m
Fuel high pressure connector M22 x 1.5 - 5 ~ 5.5 kg.m
Common rail M8 - 2.2 kg.m
Fuel high pressure pipe - Connector M14 x 1.5 - 3.0 kg.m
Fuel high pressure pipe - Common rail M14 x 1.5 - 3.0 kg.m
Fuel high pressure pipe - Pump M14 x 1.5 - 2.0 kg.m
Fuel return hollow screw M8 x 1.0 - 0.8 kg.m
Fuel filter M10 x 1.5 8.8T 4.4 kg.m
Injector cable M4 - 0.15 kg.m
Appendix - 162 -
● Standard bolt tightening torque table
Refer to the following table for bolts other then described above
Degree of strength
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Diameter
x (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
pitch Limit value for elasticity (kg/㎟)
(mm)
20 24 32 30 40 36 48 54 64 90 108
Tightening torque (kg.m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.5 0.75 0.9
M6 0.28 0.30 0.45 0.4 0.55 0.47 0.77 0.85 0.9 1.25 0.5
M7 0.43 0.46 0.7 0.63 0.83 0.78 1.2 1.3 1.4 1.95 2.35
M8 0.7 0.75 1.1 1 1.4 1.25 1.9 2.1 2.2 3.1 3.8
M8x1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.36 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10x1 1.5 1.6 2.5 2.1 3.1 2.8 4.3 4.9 5 7 8.4
M12 2.4 2.5 3.7 3.3 4.7 4.2 6.3 7.2 7.5 10.5 12.5
M12x1.5 2.55 2.7 4 3.5 5 4.6 6.8 7.7 8 11.2 13.4
M14 3.7 3.9 6 5.2 7.5 7 10 11.5 12 17 20
M14x1.5 4.1 4.3 6.6 5.7 8.3 7.5 11.1 12.5 13 18.5 22
M16 5.6 6 9 8 11.5 10.5 17.9 18.5 18 26 31
M16x1.5 6.2 6.5 9.7 8.6 12.5 11.3 17 19.5 20 28 33
M18 7.8 8.3 12.5 11 16 14.5 21 24.2 25 36 43
M18x1.5 9.1 9.5 14.5 12.5 18.5 16.7 24.5 27.5 28 41 49
M20 11.5 12 18 16 22 19 31.5 35 36 51 60
M20x1.5 12.8 13.5 20.5 18 25 22.5 35 39.5 41 58 68
M22 15.5 16 24.5 21 30 26 42 46 49 67 75
M22x1.5 17 18.5 28 24 34 29 47 52 56 75 85
M24 20.5 21.5 33 27 40 34 55 58 63 82 92
M24x1.5 23 25 37 31 45 38 61 67 74 93 103
Others :
1. The above torque rating have been determined to 70% or so of the limit value for bolt elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the standard value.
- 163 - Appendix
● Tightening torque for plug screw
M10 M12 M14 M16 M18 M22 M24 M26 M30

5.0 5.0 8.0 8.0 10.0 10.0 12.0 12.0 15.0
● Tightening torque for hollow screw(4-hole)
Material M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
SM25C - 1.6 2.5 3.5 4.5 5.5 9.0 13.0 18.0 30.0
* SUM22L 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
STS304 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
* : Adopted in DOOSAN engine
Appendix - 164 -
● Maintenance specification table
(unit : mm)
Stand value Limit

Group Part Inspection item Correction Remark
for assembly for use
Measure unworn
Inside diameter of Φ 127.990
Φ 128.122 Replace liner portion beneath the
cylinder liner ~ Φ 128.010
rim of the upper side
Liner’s roundness & From top up to
0.005 -
columness (upper) 168mm
Liner’s roundness & From bottom up to
Cylinder 0.008 -
columness (lower) 85mm
block &
Amount of liner Measure at upper side
liner 0.04~0.08 -
projection of cylinder block
The flatness of upper
Correct with a Referenced length :
surface of cylinder 0.03 -
surface grinder 150mm
block
Cylinder Hydraulic test for 1
4 - Replace if leaky Temperature 70°C
block minute (kg/cm2)
Intake -0.39 ~ -0.41 0.55 Depression of valve
Valve seat
Replace valve seat from lower face of
depression Exhaust -0.39 ~ -0.41 0.55 cylinder head
Replace cylinder
Cylinder head height 116.9~117.1 116.4
head
Cylinder
The flatness of lower
head & 0.08 0.1
surface of cylinder head
valve
Thick of cylinder head
gasket(at assembly 1.215~1.285 -
status)
Hydraulic test for 1
4 - Replace if leaky Temperature 70°C
minute (kg/cm2)
Measure at 56.8 mm
Outer diameter of Φ 127.739
- Replace liner away from piston
piston ~ Φ 127.757
head(long diameter)
Clearance between Replace one worn
0.233 ~ 0.271 0.35
piston and liner more
Inner diameter of piston Φ 46.010
- Standard diameter
pin ~ Φ 46.016
Piston Top ring 3.5 - Replace piston if

Width of
groove width is Measure at 125mm of
piston ring 2nd ring 3.040~3.060 -
beyond specified top ring groove
Major grooves
Oil ring 4.020~4.040 - value
moving Piston projection from Measure unworn
parts cylinder block upper 0 ~ 0.12 - Must exist portion beneath the
surface rim of the upper side
Permissible weight
50g 50g ↓ Replace piston
difference of each piston
Top ring 3.34~3.36 -
Width of
2nd ring 2.975~2.990 - Replace ring
piston ring
Piston Oil ring 3.97~3.99 -
ring Top ring 0.35~0.55 1.5 Standard gauge
Piston ring 2nd ring 0.80~0.95 1.5 Replace ring inside diameter :
gap
Oil ring 0.40~0.70 1.5 Φ 128
- 165 - Appendix
　　(unit : mm)
Stand value Limit
Top ring 1.105~0.155 0.20
Piston ring
Replace ring or Limit for use is if for
side clear- 2nd ring 0.050~0.082 0.15
Piston piston standard clearance
ance Oil ring 0.030~0.070 0.15
ring
Cross Install by
Direction of ring gap - -
120°
Φ 45.94 Replace piston pin
Piston piston pin ~ Φ 46.000
pin Clearance between Replace one worn
0.010~0.021 0.08
piston pin and its bush more
Measure in
Radial run-out of Correct with a
- 0.01 horizontal and
journal and pin grinder
vertical directions
Outside diameter of Φ 103.98
Φ 102.98 Use under sized
journal ~ Φ 104.00
bearings
Outside diameter of Φ 89.980
Φ 88.980 respectively (0.25,
pin ~ Φ 90.000
0.5, 0.75, 1.0)
Width of thrust journal 38.000~38.062 37.000
Ellipticity of journal
0.01 0.025
and pin
Major
Taper of journal and
moving 0.02 0.03
pin
parts
Measure at journal
Run-out of crankshaft 0.04 ↓ 0.2 ↓ Adjust by a press
# 1, 4 supported
Clearance between Measure at crown
0.066~0.132 0.166 Replace bearings
Crank crankshaft and bearing part not parting line
shaft Replace thrust
End play of crankshaft 0.190~0.322 0.5
bearing
Balance of crankshaft 60 or Check dynamic
60 ↓ Measure at 400 rpm
(g.cm) less balance
Clean out foreign
Torque value journal Coat the bolt with
30kg.m + 90° - objects on joining
bearing cap bolt engine oil
surface.
Crush Main 0.3~1.2 -
Measure after
height of
tightening metal cap
Journal
Thrust 0.3~1.2 - and releasing one
bearing
bolt
cap
Out diameter of wear Φ 104.86 5 minutes or more
-
ring after assembled ~ Φ 105.00 at 220°C
Oil seal for wear Replace oil seal if
- -
(crank shaft rear) oil leaking
Appendix - 166 -
　(unit : mm)
Stand value Limit
Width of Small end 38.070~39.000 -
connecting Big end 32.291~32.33 -
rod Cap 30.5~30.8 -
Inner diameter Φ 46.055
-
of small end ~ Φ 46.065
-
big end ~ Φ 95.022
End play of Big end 0.175~0.321 0.50 Replace Connecting
connecting rod Small end 1.5 - rod
Clearance between
connecting rod bearing 0.054~0.116 0.154 Replace bearing
and crank pin
Clearance between
small end bush & piston 0.055~0.071 0.12
Connecting
pin
rod
Crush height of Measure after
connecting rod bearing 0.3~0.5 - installing the bearing
cap and releasing one bolt
Perpendicularity of big
0.05 0.08
end inner diameter
Roundness of big end Replace connecting
0.005 0.01
inner diameter rod
Parallelness of small
0.02 0.1
end side and big end
Major
Allowable weight
moving 50g ↓ -
difference per con-rods
parts
Torque value of Clean out foreign
Coat the bolt with
connecting rod bearing 10kg.m + 90° - objects on joining
engine oil
cap bolt (kg.m) surface
Inner
Diameter diameter Φ 70.07
-
(bearing) of of thrust ~ Φ 70.09
cam shaft bush
side of Inner
cylinder diameter Φ 70.00
Φ 70.06
block of cam ~ Φ 70.03
bush
Cam
Diameter of cam shaft Φ 69.910
shaft Φ 69.64
journal ~ Φ 69.940
Clearance between
cam shaft and cam 0.060~0.120 0.18 Replace cam bush
bush
Replace thrust
End play of camshaft 0.10~0.55 0.6
washer
Correct or replace
Run-out of camshaft 0.05 0.1
the cam shaft
Clearance between idle
Timing gear shaft bush and idle 0.025~0.066 0.15
gear gear shaft
End play of idle gear shaft 0.107~0.183 0.3 Correct or replace gear
- 167 - Appendix
(unit : mm)
Stand value Limit

Ring gear assembly Φ 432.490
-
part’s outer diameter ~ Φ 432.645 Heating temperature
Ring gear inner Φ 432.000 at ring gear assembly
-
Major diameter ~ Φ 432.155 (200~230°C)
Fly
moving Overlap 0.335~0645 -
wheel
parts Allowable shaking
0.5 -
amount after assembly
Outer diameter after Φ 119.860
-
assembly wear ring ~ Φ 120.000
Φ 7.94
intake valve stem ~ Φ 7.977
Φ 7.93
exhaust valve stem ~ Φ 7.964
Clearance Intake 0.023~0.052 0.1
between
valve stem
Exhaust 0.036~0.065 0.15
and valve When replacing valve
guide guide & seat, work
Replace valve
Degree of Intake 30° - simultaneously by
valve seat Exhaust 45° - special tools
Φ 42.9~ Φ
Diameter Intake -
43.1
of valve
Φ 39.9~ Φ
head Exhaust -
40.1
Valve Thickness Intake 3.0~3.4
2.5 or
Valve and of valve
Exhaust 3.3~3.7 less
system valve head
guide Projection Intake 14.8~15.2 -
amount of
To upper side of valve
valve Use with assembly
guide from spring seat
guide and Exhaust 14.8~15.2 - jig
side of cylinder head
valve
spring seat
Valve seat Φ 43.50
Intake
assembly ~ Φ 43.75
part’s inner
-
diameter Φ 41.50
Exhaust
of cylinder ~ Φ 41.75
head
Φ 43.554
Diameter Intake
~ Φ 43.570
of valve -
Φ 41.554
seat Exhaust
~ Φ 41.570
Appendix - 168 -
(unit : mm)
Stand value Limit

Valve seat assembly
part’s depth of cylinder 11.9~12.1 -
head
When replacing valve
Inner diameter of valve Φ 8.000 guide & seat, work
-
guide ~ Φ 8.015 simultaneously by
special tools
Valve guide assembly
Φ 14.000
part°Øs inner diameter of -
~ Φ 14.018
cylinder head
Φ 14.028
Diameter of valve guide -
~ Φ 14.039
Clearance between valve Apply oil over valve
guide and cylinder head 0.01~0.039 - guide and press it into
installing hole the hole
Concentricity between
valve seat and valve 0.05 - Replace valve spring Without spring seat
guide
Valve
Free length 62.5mm -
Valve and
Tension 44 mm 37.4~41.4 37
system valve
Intake force
guide 31.6mm 63.3~68.3 63
valve (kg) Replace valve spring
spring Squareness
2.0 or
(along free 1.6mm
less
length direction)
Free length 62.0 -
Tension 41 mm 19~22 18.5
force
28.6mm 30.6~34.6 30
(kg) Replace valve spring Inside spring
Squareness
2.0 or
(along free 1.6mm
Exhaust less
length direction)
valve
Free length 62.5 -
spring
Tension 44 mm 37.4~41.4 37
force
31.6mm 63.3~68.3 63
(kg) Replace valve spring Outside spring
Squareness
2.0 or
(along free 1.6mm
less
length direction)
- 169 - Appendix
(unit : mm)
Stand value Limit

Valve Intake 0.4 -
clearance Adjust
Exhaust 0.5 -
(at cold)
Grind or replace if
Joining surface of valve
severely pitted on tip
stem and rocker arm - -
of rocker arm and
bush
Rocker stem
arm & Inner diameter of Φ 24.991
Φ 25.04
push rod rocker arm bush ~ Φ 25.012
Diameter of rocker arm Φ 24.939
Φ 24.90
shaft ~ Φ 24.960
Clearance between
Valve Replace bush or
rocker arm shaft & 0.031~0.073 0.14
system shaft
rocker arm bush
Run-out of push rod 0.3 0.5 Replace or correct
Tappet assembly part’s
Φ 20.000
inner diameter of -
~ Φ 20.021
cylinder head
Φ 19.944
Diameter of tappet - Replace tappet
~ Φ 19.965
Tappet
Clearance between
tappet & tappet hole of 0.035~0.077 0.13 Replace tappet
cylinder block
Tappet face in contact Replace if severely
- -
with cam worn or deformed
Check oil leakage
Oil pressure (kg/cm 2)
3.0~5.5 - and clearance
(at rated speed)
between each part
Oil pressure (kg/cm 2) 0.8 or Use recommended
1.0~3.0
(at idle speed) more oil
Oil temperature (°C) 110 or less -
Permissible oil Must not exceed this
temperature in short Max. 120 - value
Lubricating Engine
time (°C)
system oil
By-pass valve for filter
1.8 ~ 2.4 -
element (kg/cm2 )
Operating
1.6~1.9
pressure
Oil spray Closing
1.3~1.6 Replace valve
nozzle pressure
Nozzle
Φ2
diameter
Appendix - 170 -
(unit : mm)
Stand value Limit

Delivery volume lit/min
Replace gear or
- Pump speed : 2,440rpm 175 or more -
cover
- Oil temperature : 50°C
Gear assembly part’s
43.000~43.039 -
depth of oil pump housing
Width of oil pump gear 42.910~42.950 -
Clearance of oil pump
0.050~0.128 -
at axial direction
Oil pump pressure
8.5~10 - Replace valve
control valve (kg/cm2 )
Oil pressure control
Oil pump 1.9 ~ 2.1 - Replace valve
valve (kg/cm2 )
Clearance between
Lubricating drive gear shaft and 0.032~0.077 -
system cover hole Replace bush or
Clearance between cover
drive gear shaft and 0.040~0.094 -
cover hole
Φ 16.950
Diameter of gear shaft - Replace gear shaft
~ Φ 16.968
Diameter of driving Φ 28.000 Replace bush or
-
gear bush ~ Φ 28.033 cover
Damage of oil filter
- - Clean or replace
element
By-pass valve
Oil filter 1.8~2.4
pressure (kg/cm2 )
Oil filter control valve
4.3~4.7
pressure (kg/cm2 )
Radiator & water pump
for corrosion, damage - - Correct or replace
& improper connecting
Submerge in water
Test for leakage by air
1.0 - and replace if air
pressure (kg/cm2 )
bubbles found
Radiator
Pressure valve for
opening pressure 0.5 -
(kg/cm2 )
Cooling Negative pressure
system valve for opening 20 -
pressure (mmHg)
Delivery volume lit/min
- Pump speed : 3,500rpm Check the water
452 or more -
- Water temp. : 25°C passage
Water - Pressure : 1.8 kg/cm2
pump Φ 25.048
Diameter Pulley side -
~ Φ 25.061
of water
Impeller Φ 16.045
pump shaft -
side ~ Φ 16.056
- 171 - Appendix
(unit : mm)
Stand value Limit

Clearance of bearing 0.050~0.091
Replace if impeller &
Clearance between
Water 0.5~0.9 - housing are
impeller & housing
pump damaged
Refer to adjust
Fan belt depression - Adjust
table
Operating
Cooling 79~95 -
Cooling temperature (°C)
system Must not exceed this
water Permissible
value
temperature temperature in a short - 105
time (°C)
Opening temperature
71 - Replace
(°C)
Thermostat
Full opening Replace if defective
85 -
temperature (°C) Stroke : min. 8mm
Fuel high pressure pump maker
(CP pump)
Bosch -
Common rail maker
Fuel injector maker
Fuel pipe, injection pipe
Fuel & injector for damage, - - Replace
piping & cracks, improper O-ring
Fuel others Damage of fuel filter
- - Replace cartridge
system cartridge
Injection pressure of injector
1,600 -
(kg/cm 2)
Operating pressure of overflow
10.5~13 - Replace valve
valve (kg/cm2)
Diameter of injector nozzle 8 - Φ 0.197
Projection height of nozzle from
2.4~2.9 - Replace sealing
the cylinder head surface(mm)
Between crank gear &
0.10 ~ 0.45 0.3
oil pump drive gear
Gear Between crank gear &
Drive 0.118 ~ 0.242 0.3
back cam shaft gear Adjust back lash
system
lash Between drive gear &
fuel pump gear 0.050 ~ 0.178 0.45
(CP pump)
Appendix - 172 -
● Engine assembly
EF6OM048
- 173 - Appendix

Eendv 110001 - DV11 Engine PDF

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Eendv 110001 - DV11 Engine PDF

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FOREWORD

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufacturer's

Directional Indication Lubricate with oil

Inspection Lubricate with grease

● Take old oil to an old oil disposal point only.

1. Safety Regulations & Specifications

1.2. Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3. Engine Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4. Engine Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.5. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2. Diagnostic Tool (SCAN-200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.3. Engine Character . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.4. Diagnosis and Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.5. Engine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3. Disassembly and Reassembly of Major Components

3.2. Measurement and Inspection of Major Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.3. Engine Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.4. Fuel Injection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

3.5. Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

3.6. Engine Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

3.7. Operating Condition of the ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

4. Commissioning and Operation

4.2. Breaking-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.3. Inspection after Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

4.4. Operation in Winter Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

4.5. Engine Components Check after Long Time Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4.6. Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4.7. Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

4.8. Adjustment of Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

4.9. Tightening the Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

5.2. Lubricating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

5.3. Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5.4. Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

6. Special Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

● Part & After service center

● Applications for DOOSAN engine

1.1.1. General notes

1.1.2. To prevent accidents with injury to persons

-1- Safety Regulations & Specifications

(3) When carrying out checking, setting and repair work

1.1.3. To prevent damage to engine and premature wear

Safety Regulations & Specifications -2-

1.1.4. To prevent pollution

1.1.5. Notes on safety in handling used engine oil

< Health precautions >

-3- Safety Regulations & Specifications

1.1.6. General repair instructions

Safety Regulations & Specifications -4-

Engine model DV11

Water-cooled, 4 cycle V-type 90°,

Combustion chamber type Direct injection type

Cylinder liner type Wet type

Timing gear system Gear driven type

No. of piston ring 2 compression ring, 1 oil ring

No. of cylinder-bore x stroke (mm) 6 - 128 x 142

Total piston displacement (cc) 10,964

Compression ratio 17.0 : 1

Engine weight (kg) 882

Rotating direction (from flywheel) Counter clockwise

Firing order 1-4-2-5-3-6

Engine control type Electric control type(ECU)