Hdi DL08P

950106-01727
Operation &
Maintenance Manual
DIESEL ENGINE
DL08P Tier4 Final

Forward
This Operation and Maintenance Manual provides information on engine management and maintenance techniques to
customers and technicians of Doosan Infracore's Tier4 Final DL08P electronically controlled industrial diesel engine.
To provide the best engine to our customers, the Tier4 Final DL08P electronically controlled industrial diesel engine is designed
to satisfy all requirements for low noise, economic fuel consumption, high speed and durability with the latest technology and
quality.
Exact operation and proper maintenance are essential for operating engines for an extended time with optimum conditions and
best performance. This Operation and Maintenance Manual provides detailed descriptions of specifications, specified values,
defect diagnosis, component diagrams, and drawings for easier and more precise understanding of the product and for proper
maintenance and troubleshooting.
With the help of the recommended operation methods and procedures, high-level maintenance techniques and safety of
workers can be ensured. Please read and understand this manual before working with our engines.
To ensure best performance and quality as well as to enhance maintenance techniques, Doosan Infracore is doing it's best to
continuously develop and invest. The design of our product may be changed without prior notice and Doosan shall not be held
liable for the failure of this manual to contain all the design changes made to improve the product.
We, Doosan Infracore, do our best to provide more convenient and safe maintenance techniques and to meet the requirements
of our customers.
If you have any questions or find any errors in this Operation and Maintenance Manual, please do not hesitate to contact us.
Thank you for purchasing our engine and we hope this Operation and Maintenance Manual be helpful for you.
2016.05.
950106-01727(A)
Doosan Infracore
* The contents included in the Operation and Maintenance Manual are property of Doosan Infracore. It is forbidden to copy,
print or distribute this manual without prior permission.
Table of contents
1. General Introduction .................................................................................................................1

General Information ................................................................................................................................... 3
Danger, Warning, Caution and Note .......................................................................................................... 3
Engine Maintenance .................................................................................................................................. 6
2. Operation and Maintenance .....................................................................................................7

Starting and Stopping of the Engine .......................................................................................................... 9
Break-in Period of the Engine .................................................................................................................. 10
Operation in Winter .................................................................................................................................. 11
Inspection and Repair of the Engine ........................................................................................................ 12
3. Performance and Specifications ............................................................................................15

Engine Specifications and Performance .................................................................................................. 17
Outside Drawing of the Engine (DL08-LEE00/LEE01/MEE00/MEE01) ................................................... 24
Outside Drawing of the Engine (DL08-LEL00/LEL01/MEL00/MEL01) .................................................... 27
Engine Identification Number ................................................................................................................... 30
4. Regular Inspection ..................................................................................................................31

General Information ................................................................................................................................. 33
Regular Inspection Table ......................................................................................................................... 34
Cooling System ........................................................................................................................................ 35
Cleaning Cooling Circuit .......................................................................................................................... 38
Lubrication System .................................................................................................................................. 38
Intake/Exhaust System ............................................................................................................................ 43
Cylinder Block/Head ................................................................................................................................ 46
Electric System ........................................................................................................................................ 48
Others/Driving System ............................................................................................................................. 49
5. About the Engine .....................................................................................................................51

Marking System of Units .......................................................................................................................... 53
Tightening Torque .................................................................................................................................... 54
Special Tool ............................................................................................................................................. 57
Engine Disassembly ................................................................................................................................ 59
Engine Assembly ..................................................................................................................................... 72
6. Cooling System .......................................................................................................................91

General Information ................................................................................................................................. 93
Failure Diagnosis ..................................................................................................................................... 94
Thermostat ............................................................................................................................................... 95
7. Lubrication System .................................................................................................................97
General information ................................................................................................................................. 99
Oil Pump ................................................................................................................................................ 101
8. Fuel System ...........................................................................................................................103

General Information ............................................................................................................................... 105
Injector ................................................................................................................................................... 106
Common Rail ......................................................................................................................................... 109
Fuel Injection Pump ............................................................................................................................... 111
Fuel Feed Pump .................................................................................................................................... 113
9. Intake/Exhaust System .........................................................................................................115

Turbocharger ......................................................................................................................................... 117
Exhaust Gas Reduction ......................................................................................................................... 127
EGR (Exhaust Gas Reduction) System ................................................................................................. 138
Intake Pipe ............................................................................................................................................. 141
10. Cylinder Block/Head .............................................................................................................143

Cylinder Block ........................................................................................................................................ 145
Cylinder Head ........................................................................................................................................ 146
Valve ...................................................................................................................................................... 148
Rocker Arm ............................................................................................................................................ 151
Tappet and Push Rod ............................................................................................................................ 152
Camshaft ................................................................................................................................................ 153
11. Electric System ......................................................................................................................155

Circuit Diagram ...................................................................................................................................... 157
Switches and Sensors ........................................................................................................................... 164
ECU (Electronic Control Unit) ................................................................................................................ 169
Starter .................................................................................................................................................... 172
12. Others/Driving System ..........................................................................................................175

Crankshaft .............................................................................................................................................. 177
Piston ..................................................................................................................................................... 181
Connecting Rod ..................................................................................................................................... 183
Others .................................................................................................................................................... 184
1. General Introduction
General Information ..................................................................................................................3

General Information .......................................................................................................................................... 3
Danger, Warning, Caution and Note .........................................................................................3
General Information .......................................................................................................................................... 3
General Instructions .......................................................................................................................................... 4
Cautions for Starting the Engine ....................................................................................................................... 4
Cautions for Inspection and Repair................................................................................................................... 4
General Repair.................................................................................................................................................. 5
Other Safety Instructions and Environmental Pollution..................................................................................... 5
Use of Genuine Parts........................................................................................................................................ 5
Engine Maintenance .................................................................................................................6
Prevention of damage and abrasion ................................................................................................................. 6
Prevention of Pollution ...................................................................................................................................... 6
Handling of Engine Oil ...................................................................................................................................... 6
1
2
General Information Danger, Warning, Caution and Note
General Information General Information

This Operation and Maintenance Manual provides the most This Operation & Maintenance manual divides maintenance
efficient methods for engine maintenance as well as quick, operations such as performing engine checks, trouble-
efficient methods to determine the cause of engine faults to shooting, or diagnosing faults into three categories,
ensure that any actions taken by professionally certified "Danger," "Warning," and "Caution." In addition, Note) is
maintenance technicians are done in the most efficient and used to provide additional descriptions and information
efficient way possible. If maintenance is performed by required for maintenance technicians to successfully operate
unskilled technicians, or maintenance without the specified our engines. The recommended repair methods and
tools and facilities, serious bodily injury or critical faults in 'Danger,' 'Warning,' and 'Caution' can enhance the degree of
engine performance may occur. completion of engine maintenance and prevent bodily injury
Regular inspection and maintenance are required to main- which may occur to workers. However, this manual cannot
tain long-term optimal engine conditions and best perfor- predict all possible risks.
mance. In the event that a part must be replaced, only
genuine parts as defined by the parts the list (PARTS BOOK) DANGER
should be used. Doosan shall not be held liable for any crit-
ical damage or faults which may be caused by the use of Workers must observe instructions, otherwise fatal or
unauthorized or remanufactured parts. serious injuries to workers and other persons may
The maintenance methods stated in this Operation and occur.
Maintenance Manual are the most efficient and safest work

procedures. Some work procedures require special tools.
WARNING
For questions about genuine parts and special tools, please
contact us. Workers must follow this instruction as failing to do so
This Operation and Maintenance Manual includes 'Danger,' may result in the death or serious bodily harm of
'Warning,' and 'Caution' in order to reduce possible injuries workers or others.
and engine faults which may occur while performing mainte-
nance. If workers do not follow the instructions, critical faults
in engine performance and operation or serious bodily injury CAUTION
may occurred. 'Danger,' 'Warning,' and 'Caution' instructions Workers must observe this instruction since failing to
must be followed. However, we inform you that it is not do so may cause critical faults which can have impact on
possible to describe all possible and unexpected dangers the engine performance and operation.
which may arise while performing engine maintenance.
Note) Indicates additional description, information, and

references for workers' easy understanding.
3
General Instructions
1. In order to maintain the best long term performance and WARNING
safety, please read and understand this manual and Do not exchange or disassemble a pipe or horse (from
execute routine inspections and regular inspections. the engine fuel circuit, engine oil circuit, coolant circuit,
2. We have divided the content of this manual into causes or compressed air circuit) while the engine is running.
of bodily injury and damage to assets and causes of The leaked liquid may cause bodily injuries.
pollution.
3. Use an engine oil drain container that is large enough to
WARNING prevent the overflow of engine oil while draining engine
oil.
When a safety accident, such as skin contact with corro-
4. Open the engine coolant cap after fully cooling the engine
sive acids or fuel, burns with hot oil, exposure of eyes to
to exchange or replenish coolant.
fuel or antifreeze, occurs while starting, inspecting, or
repairing an engine, see a doctor immediately.
WARNING
If the coolant cap is opened while the engine is still hot,
Cautions for Starting the Engine
hot water will spurt out and may cause burns. Open the
1. Before starting the engine, please read this manual care-
engine coolant cap after fully cooling the engine.
fully and fully understand 'Danger,' 'Warning,' and
'Caution'. If you cannot fully understand it or have any
5. Fuel is highly flammable. Smoking or use of fire around
question, please contact us.
an engine may cause fire.
2. For safety reasons, attach "Warning" signs around
engines in operation to keep people other than workers
from accessing the engines. Let engine operators know WARNING
that they are responsible for the safety of the engine Only refuel when the engine is stopped.
room.
3. Only authorized people may start and operate engines.
6. Mark and separately manage the containers for storing
Unauthorized people should not be allowed to handle
coolant from beverage containers for avoiding confusion.
engines.
See a doctor immediately in case of drinking coolant.
4. Do not access running or rotating parts while the engine
7. Follow the instructions provided by the battery manufac-
is in operation.
turer when checking or handling batteries.
5. Be careful not to touch or contact the engine during oper-
ation since it becomes hot during operation.
6. Exhaust gas is poisonous. Fully ventilate before starting
WARNING
engine. If the space is airtight, ensure that it is well venti- Battery fluid is corrosive and dangerous because of its
lated. explosiveness and toxicity. Therefore, it should only be
handled by a skilled technician who specializes in
Cautions for Inspection and Repair battery fluid.
1. Inspection and repair of engine should be performed only
when the engine is stopped. Otherwise, burns or safety 8. Only certified professional technicians should repair and
accidents may occur, so do not perform inspection or maintain engines.
repair while the engine is running. 9. Only appropriate tools should be used. If the jaws of a
2. If it is absolutely necessary to perform inspection or wrench are worn out, the wrench might slip during use,
repair on the operating engine, do not get close to the causing safety accidents.
rotating parts. 10. Do not allow other persons to stay or pass under an
engine when lifting the engine with a crane. Before lifting
DANGER the engine, ensure that there is no one around the engine
and reserve enough safety space.
When accessories such as necklaces, rings, watches, or
gloves become stuck in rotating parts while the engine
is running, serious bodily injury may occur.
4
11. Before inspecting or replacing the electrical apparatus, 13. After completing repairs, conduct a final inspection and
disconnect the battery ground wire first. Connect the perform a test operation to check if all works have been
battery ground wire after completing all required work for successfully completed.
checking or replacing the electrical apparatus in order to
prevent a short circuit. Other Safety Instructions and Environmental
12. Before performing electric welding works, turn off engine, Pollution
block the power supply to the engine, and remove the Observe the following instructions to protect workers from
wire harness connector connected to the engine control danger and to prevent the environmental pollution while
unit (ECU). performing engine repairs.
13. Do not give any electric or mechanical shocks or perform 1. Good ventilation and low humidity should be maintained
welding works on the electrical apparatus or the ECU. in the work space.
2. The workspace should be clean, in good order, and no
General Repair flammables are allowed in the workshop.
1. Wait until the engine is properly cooled down before 3. Smoking is strictly forbidden in the workshop.
starting work, since you may get burned by the heated 4. Workers should wear working clothes, protective
engine. goggles, and safety shoes.
Before performing fuel line work, check the common rail 5. Workers are not allowed to wear accessories such as
pressure and engine temperature by using the failure necklaces, rings, watches, and earrings.
diagnosis device. 6. Start the engine in a well-ventilated space and fully venti-
2. Disconnect the battery ground wire from to prevent late the space before starting engine to prevent carbon
damage of wires and sensors caused by a short circuit. monoxide poisoning.
3. Engine oil and coolant may damage paint and should be 7. Wait until the engine is properly cooled down before starting
stored in a separate container and marked for safe work, since you may get burned by the heated engine.
management. 8. Do NOT work on rotating or running parts once the
4. Store the disassembled parts in a specified space to engine has been started.
avoid damage or pollution. 9. Discard oil according to the regulations set forth by the
5. Use specified and special tools for efficient and safe relevant authorities.
repair. 10. If engine oil or fuel leaks on the floor or is improperly
6. If parts need to be replaced, use only genuine parts for discharged, serious environmental pollution of sea, river
replacement. Using unauthorized or remanufactured or underground water may occur.
parts may cause critical damage and faults in engine 11. Discard the undiluted anticorrosive agent, antifreeze,
performance. filter elements, and cartridges as special wastes.
7. Replace parts such as cotter pins, gaskets, O-rings, seal 12. Discard coolant and special waste according to the regu-
rings, oil seals, and washers with new ones during lations of the appropriate authorities.
repairs. Reuse of parts may be the cause of engine faults
and engine may not operate properly. WARNING
8. Group and store disassembled parts in disassembling
Failure to observe the regulations of the relevant author-
order. The strength, shape, and screw torque of bolts and
ities violates environmental pollution regulations and
nuts are different according to their assembly position.
may be subject to legal penalties.
Please divide and store them accordingly to these char-
acteristics.
9. Clean disassembled parts to remove foreign substances Use of Genuine Parts
before inspecting or reassembling parts. Use An engine consists of many parts which are mechanically
compressed air to clean the oil holes or holes. harmonized. To prevent engine faults in advance and use
10. Thinly spread oil or grease on rotating parts or parts engines with best performance for a long period, mainte-
requiring lubrication, before assembling them. nance and replacement of expendable parts should be
11. If required, use a specified adhesive to assemble gaskets conducted regularly.
to prevent water or oil from leaking. Use of genuine parts is recommended. Using unauthorized
12. Assemble bolts and nuts with the specified tightening or remanufactured parts may cause critical damage and
torque. faults to engine for which Doosan shall not be held liable.
5
Engine Maintenance 9. Do not operate engine without coolant.
Prevention of damage and abrasion CAUTION

Using an engine for any purposes other than the designed
Always use coolant mixed with antifreeze. If coolant
purpose may cause critical faults in engine performance for
without antifreeze is used, the coolant may freeze
which Doosan shall not be held liable. For details concerning
causing the coolant passage in the cylinder block to
the usage and purpose of the engine, please direct questions
freeze and damaging the engine.
to our Sales Team. Do not adjust, convert, or change the
ECU without our authorization.
If a problem is found in an engine, figure out and solve the Prevention of Pollution
cause to prevent the critical faults in advance. Consider the following to manage engine without causing
Use of genuine parts is recommended. Using unauthorized environmental pollution.
or remanufactured parts may cause critical damage and 1. Discharge oil and coolant using collection containers.
faults to engine for which Doosan shall not be held liable. 2. Discard oil and coolant according to the regulations of the
Consider the following while managing engines. relevant authorities.
1. Use clean, specified, and qualified fuel only. Use fuel 3. Be careful not to let discharged oil and cooling water flow
recommended in this Operation and Maintenance into the ground or the sewer. Otherwise, serious pollution
Manual. of the drinking water source may occur.
4. Classify the oil, filters, and filter cartridges as environ-
CAUTION mental pollution wastes and discards them according to
regulations.
Using inappropriate or unspecified fuel may cause crit-
5. Classify the antifreeze, cooling water, and anticorrosive
ical damage and faults in engine performance.
agent as hazardous wastes and discards them according
to the regulations.
2. Do not operate an engine without lubrication oil or
coolant. Use only the products (engine oil, cooling water,
Handling of Engine Oil
anticorrosive agent, and etc) recommended by Doosan.
Prolonged and repeated contact of skin with engine oil may
3. Always keep surroundings of the engine clean.
cause skin to dry out and contract, causing dermatitis.
4. Use fuel recommended in this Operation & Maintenance
Engine oil includes substances toxic to the human body.
manual.
Handle engine oil by observing the following safety rules:
5. Conduct inspections and exchanges regularly according
1. Do not expose skin to new engine oil for a long time.
to the regular inspection table.
2. Always wear working clothes and gloves.
6. If the engine is overheated, do not stop it immediately,
3. If skin comes in contact with engine oil, immediately wipe
but operate it at idle status for five minutes or more to
it off with water, soap or hand cleaners.
lower the engine temperature to the proper level.
4. Do not clean skin with gasoline, fuel, thinner, or solvent.
5. Apply a skin protective cream after cleaning from oil.
WARNING 6. Do not put oil-stained gloves or cloth in ones pocket.
If the radiator cap is opened while the engine is still hot,
hot water will spurt out and may cause burns. WARNING
Discard oil according to the regulations set forth by the
7. Check the engine oil level on a flat surface. Do not
relevant authorities. Disposing of discharged oil into the
exceed the maximum on the oil level gauge.
ground, sewers, drains, rivers, or the sea will cause
serious environmental pollution. Violation of regulations
CAUTION regarding discard of engine oil without observing the
handling regulations, will be punished.
Immediately replenish engine oil when the engine oil
level is below the lower limit of the engine oil gauge.
8. If there are gauges for battery, oil pressure and coolant

and temperature, check if they indicate a normal status.
6
2. Operation and Maintenance
Starting and Stopping of the Engine .........................................................................................9

Preparing for Start............................................................................................................................................. 9
Starting the Engine ........................................................................................................................................... 9
After Starting the Engine ................................................................................................................................... 9
During Operation............................................................................................................................................... 9
Stopping the Engine.......................................................................................................................................... 9
Break-in Period of the Engine .................................................................................................10
General Information ........................................................................................................................................ 10
Break-in Period of a New Engine .................................................................................................................... 10
Check Points ................................................................................................................................................... 10
Operation after Break-in.................................................................................................................................. 10
Inspection after Starting the Engine ................................................................................................................ 11
Engine Oil Pressure ........................................................................................................................................ 11
Coolant Temperature ...................................................................................................................................... 11
Revolutions per Minute (rpm).......................................................................................................................... 11
Operation in Winter .................................................................................................................11
Cold Start ........................................................................................................................................................ 11
Preventing Coolant from Freezing. ................................................................................................................. 11
Preventing Overcooling of the Engine ............................................................................................................ 12
Engine Oil ....................................................................................................................................................... 12
Inspection and Repair of the Engine .......................................................................................12
Checking Engine Parts after Prolonged Operation ......................................................................................... 12
Inspection and Repair of Supercharger .......................................................................................................... 12
Intake Unit ....................................................................................................................................................... 13
Exhaust Unit.................................................................................................................................................... 13
Lubrication System ......................................................................................................................................... 13
7
8
Starting and Stopping of the Engine
Preparing for Start After Starting the Engine

Check the following before starting the engine for the first 1. Do not rapidly raise the rpm while the engine and turbo-
time after purchase. charger do not rotate smoothly after starting the engine.
1. Before starting an engine, check the levels of fuel, Otherwise, it may increase the load upon the engine and
coolant, and oil and replenish those fluids if required. burning may occur at the positions that have not been
2. Check if engine oil level is between the upper and lower sufficiently lubricated yet. To prevent this, rotate the
limit of the oil level gauge. The upper and lower limit of engine at idle after starting it to lubricate the turbocharger
the oil level gauge indicate the maximum and minimum of with oil.
the engine oil level. 2. Oil, air, or gas leaks may lower the oil pressure. Addition-
ally, oil leaks may cause burning of bearings. As such, if
CAUTION oil, air, or gas leaks occur, check the leaking parts and
solve the problem.
When replenishing engine oil, do not exceed the
maximum on the oil level gauge. Too much oil may
During Operation
cause damage to the engine.
1. Insufficient oil pressure may cause abnormal wear and
burning of bearings and excessive oil pressure may
3. Be careful not to mix foreign substances in fuel, engine
cause leaks.
oil, or coolant while adding the fluid, and keep the fluid
2. Continuing to operate the engine after noises or vibra-
clean while it is not in use. Use fuel, oil, and coolant
tions coming from the engine may lead to serious engine
recommended by Doosan. Otherwise, critical damage to
damage. As such, if noises or vibrations come from the
the engine may occur.
engine, slowly decrease the rpm to a stop the engine and
examine the cause.
Starting the Engine
Observe the following when starting the engine.
Stopping the Engine
1. For a cold start, start the engine after preheating it suffi-
Do not suddenly stop the engine after it was operated under
ciently through the glow plug.
high loads for a long period. If oil burns because of heat sent
2. Starting the engine too quickly leads to engine rotation
from the high-temperature turbine blade to the bearing part,
without lubricating the supercharger and other engine
the bearing metal and rotating shaft may burn. As such, if the
parts, causing abnormal wear to or burning of bearings.
engine was operated under high loads for a long period, suffi-
Therefore, start the engine with the starter motor to check
ciently rotate the engine at idle before stopping it.
raising of oil pressure (until the gradation of the oil pres-
sure gauge mounted on the apparatus moves or the
pressure indicator lamp is turned on).
3. If the engine was not used or kept cold for a long period
of time, oil circulation will be poor. If you replace oil, oil
filter cartridge, or lubrication system parts or use an
engine in cold areas, or the engine has been stopped for
a long period, loosen the oil pipe joint at inlet of the super-
charger and run the starter motor until oil flows out. After
completing the work, tighten the oil pipe joint again and
start the engine.
9
Break-in Period of the Engine 2. If the oil indicator lamp on the apparatus is turned on or
blinks, the oil pressure may be insufficient. In this case,
General Information check the oil level and replenish the oil if required. When
Doosan engines are subjected to a final approval test to replenishing engine oil, do not exceed the maximum on
ensure the provision of high quality engines before being the oil level gauge. If the oil level is normal, check other
shipped to ensure the best quality possible. However, related parts such as the oil pressure sensor, oil pump, or
engines are not operated for a long period of time in this test. oil line.
Therefore, new engines require a break-in period of during
the initial 50 hours after delivery. By properly breaking-in an CAUTION
engine, the highest levels of engine performance can be
The oil pressure may increase with high rpm and
maintained long-term.
decrease with low rpm. In addition, the pressure of cold
oil may be higher at a specific rpm than of warm oil. This
Break-in Period of a New Engine phenomenon may occur when the engine is operating
If the engine's bearings are not properly broken in, they may successfully.
be easily damaged and the lifetime of the engine may be
shortened by overloading or high-speeds. In order to prevent 3. Check the coolant gauge on the apparatus and if the
this, please follow the guidelines below for the initial 50 hours coolant circulates properly. If the coolant level in the
after delivery of new engine. supplementary tank is too low, the coolant gauge may be
1. Fully warm up the engine until the engine temperature inaccurate. (may be disturbed).
reaches normal operation condition, before starting oper- 4. Exchange engine oil and oil filter after the break-in
ation of the engine. period.
2. Do not overload the engine or operate it at excessive
RPM.
3. Do not operate the engine with high speed at idle.
CAUTION
4. Do not rapidly start up or stop the engine. If engine oil and oil filter need to be replaced, use only
5. Operate the engine with less than 70 % of the engine the genuine engine oil and parts recommended by
load. Doosan.
6. Inspection, check, and repair of engines should be
managed by officially-certified technicians at certified
Operation after Break-in
service centers in compliance with corresponding rules.
Slowly preheat the engine when starting up during cold
weather or in areas with cold climate. Do not rapidly raise the
Check Points
rpm while the engine has not been properly preheated yet.
check the following during the break-in period of a new The engine consumes additional oil until its piston ring is
engine. positioned properly and operates successfully. Please check
1. Periodically check if the engine oil level is between the the engine oil level frequently during the initial 50 hour
minimum and maximum limit of the oil level gauge. break-in period.
CAUTION
If you cannot accurately check the oil level through the
oil level gauge, rotate the oil level gauge to 180 degree,
put it in the guide tube, and then pull it out again to
check.
10
Inspection after Starting the Engine Operation in Winter

Check the pressure of the engine lubrication system by using
the engine oil pressure gauge mounted on the apparatus Cold Start
while the engine is in operation. If the oil pressure is low on Periodically check for frozen coolant and viscosity of lubrica-
oil pressure gauge, immediately stop the engine. In addition, tion oil.
make sure that the recharge alarm indicator lamp of the alter-
nator is turned off while the engine is operating. CAUTION
1. Tightly connect the +/- terminals to prevent gaps between
them. The sheath of battery connection cables should not • A preheater should be mounted on the engine to
be damaged or broken. improve the cold start performance.
2. If the recharge alarm indicator lamp suddenly turns on or • Start the engine after turning off the preheating lamp.
blinks during engine operation and the engine stops, fix • Do not operate the starter motor for over 10 seconds.
the fault of the electric apparatus. If the engine does not start even though it is fully
3. If color or odor of exhaust gas is unusual during opera- preheated, wait for about 30 seconds, preheat the
tion, stop the engine, diagnose the cause and fix the fault. engine again, and then start the engine.
4. Check the engine status through the alarm indicator lamp

and gauges mounted on the apparatus during operation. Perform the cold start in the following order.
1. Turn the key switch to 'Preheat' and then the preheat
lamp will operate for about 20 seconds.
Engine Oil Pressure
Note) Operate the preheater if coolant is below 10 °C during
If the engine oil pressure is not consistent at idle or does not
cold weather. If preheating is not necessary, the
reach the reference value while the engine is operating in
preheat lamp will not switch on.
high speed mode, immediately stop the engine and check
2. When the preheat lamp switches off, turn the key switch
the oil level and leakage.
to 'Start' to start the engine.
Note) If the key is turned to 'Start', the air heater is continu-
Coolant Temperature
ously heated to provide an easy start and reduce white
Operating an engine with insufficient coolant temperature
exhaust gas. If the coolant temperature is above 10
increases fuel consumption, abrasion of the cylinder liner,
°C, it is not necessary to heat the air heater.
shortening the engine's life span.
3. After starting the engine, the key switch changes to ON.
Revolutions per Minute (rpm)

CAUTION
In the electronic control engine, the engine control unit (ECU)
prevents the engine from being operated at too high rpm over As the ECU heats the intake air for about 180 seconds
the specifications to protect the engine. The memory of ECU after starting the engine, the white exhaust gas is
has various functions which cannot be changed by opera- reduced quickly.
tors, such as fuel flow control, ignition time delay, and
blocking of fuel and ignition. Preventing Coolant from Freezing.
When only water used as coolant without mixing with anti-
freeze, corrosion in the engine, degradation of cooling effi-
ciency, and freezing of the engine in winter may occur. If the
engine is not operated for a long period during cold weather
or in areas with cold climate, fully discharge the coolant from
the engine. Freezing of coolant leads to critical damage to
the engine. Please use a mixture of coolant with antifreeze at
revised ratio when replacing or replenishing the coolant. The
antifreeze prevents coolant from freezing.
11
Preventing Overcooling of the Engine Inspection and Repair of the Engine

When the engine is cooled below the normal operating
temperature, thermal efficiency is lowered and fuel Checking Engine Parts after Prolonged Oper-
consumption as well as abrasion of the cylinder liner may ation
increase. Therefore, the engine should be operated within Wear, corrosion, or degradation of engine elements and
the normal operating temperature. If the engine has been assemblies may occur, causing lowered performance of
sufficiently operated, but the temperature of coolant remains engine parts. To maintain high engine performance, check
below the normal operating temperature, check the water the engine after prolonged operation to enhance the dura-
temperature controller or other parts related to the cooler. bility of the engine.
Unexpected faults may occur in some weak engine parts
Engine Oil after normal operation of the engine, when operation time is
prolonged. In this case, it is difficult to maintain high engine
When the viscosity of engine oil increases due to its low
performance by simply repairing some parts. We recom-
temperature during cold weather or in areas with cold
mend the entire part be replaced or repaired in order to find
climate, the rpm may not be stable after starting the engine.
out the causes more accurately and maintain high engine
To prevent this, replace the oil with engine oil for cold
performance.
weather or areas with cold climate. When replacing engine
To prevent engine failure in advance and use the engine
oil, Use only engine oil recommended by Doosan.
safely for a long period, perform periodic replacements and
inspections.
It is recommended to perform engine adjustments and
preventive inspections during spring after the engine was
exposed to winter or cold weather. This allows economic,
long-term use of the engine without faults.
As the following parts affect the engine output and perfor-
mance, these parts should be regularly checked and
inspected.
1. Parts affecting intake and exhaust
• Air filter
• Intercooler
• Supercharger, silencer
• EGR cooler and Calve
• Other parts
2. Parts affecting lubrication and cooling
• Air filter
• Oil filter
• Antifreeze
• Other parts
Inspection and Repair of Supercharger

As performance of supercharger significantly affects the
engine performance, regular inspections and repairs should
be performed and inspection and maintenance regulations
should be observed.
12
Intake Unit
Be careful when handling the air filter in the intake unit. If oil
level of the wet air filter is below the specified level, filtering
performance is degraded. On the other hand, if the oil level
is higher, oil may flow into the case, and it may become
polluted. In regards to the dry air filter, intake resistance
should be small to ensure the smooth intake of air.
Exhaust Unit
If exhaust emission is leaked from the part connecting the
exhaust tube and the turbocharger, the supercharger effi-
ciency is lowered, causing degraded engine output and, if
serious, burning of related parts. As parts related to exhaust
and turbocharger are used at high temperature, be careful
not to mix the bolts and nuts with other parts when
performing repair.
Lubrication System
Inspection and replacement of the lubrication system should
be performed according to the replacement schedule of oil
and oil filter. Overheated engine oil can affect not only the
engine itself, but also the engine performance.
13
14
3. Performance and Specifications
Engine Specifications and Performance .................................................................................17

Engine Specifications...................................................................................................................................... 17
Engine Output ................................................................................................................................................. 19
Engine Performance Curve (DL08-LEE00/MEE00) ........................................................................................ 20
Engine Performance Curve (DL08-LEE01/MEE01) ........................................................................................ 21
Engine Performance Curve (DL08-LEL00/MEL00)......................................................................................... 22
Engine Performance Curve (DL08-LEL01/MEL01)......................................................................................... 23
Outside Drawing of the Engine (DL08-LEE00/LEE01/MEE00/MEE01) ..................................24
Isometric Assembly Drawings ......................................................................................................................... 24
Assembly Drawings (Left/Right)...................................................................................................................... 25
Assembly Drawings (Top/Bottom) .................................................................................................................. 26
Outside Drawing of the Engine (DL08-LEL00/LEL01/MEL00/MEL01) ...................................27
Isometric Assembly Drawings ......................................................................................................................... 27
Assembly Drawings (Left/Right)...................................................................................................................... 28
Assembly Drawings (Top/Bottom) .................................................................................................................. 29
Engine Identification Number ..................................................................................................30
Engine Code and Manufacturing Number....................................................................................................... 30
Engine Number Engraving .............................................................................................................................. 30
15
16
Engine Specifications and Performance
Engine Specifications
Specifications
DL08-MEE00
DL08-MEE01
DL08-MEL00
DL08-MEL01
DL08-LEE00
DL08-LEE01
DL08-LEL00
DL08-LEL01
Item Remarks
General Information
4-stroke, Inline, Water-cooled,

Engine Type
Turbocharged and Air-cooled
Combustion Chamber Type Direct Injection
Cylinder Liner Type Dry Liner
Timing Gear System Gear Driven Type
Number of Piston Rings Two Compression Rings and One Oil Ring
Number of Cylinders 6
Cylinder Bore 108 mm
Cylinder Stroke 139 mm
Total Displacement 7,640 cc
Compression Ratio 17.4 : 1
Compression Pressure 28 bar at 200 rpm
Engine Dimension (L x W x H) 1,324 x 958 x 1,249 mm
Engine Weight 855 kg 840 kg 855 kg 840 kg
View from
Direction of Rotation Counter-clockwise
Flywheel
Firing Order 1-5-3-6-2-4
Cooling System
Cooling Type Water-forced Cooling
Engine Internal
Capacity of Coolant 13.3 L
Area
Coolant Pump Type Centrifugal (Impeller Type)
Type Wax Pellet Type

Coolant
Temperature Opening Temperature 83°C
Controller
Fully Open Temperature 95°C
Coolant Temperature Indicator Coolant Temperature Sensor Mounted
Lubrication System
Lubricating Type Forced Lubrication System
Idle above 1.5 bar

Oil Pressure
Max. above 3.0 bar
17
Specifications
DL08-MEE00
DL08-MEE01
DL08-MEL00
DL08-MEL01
DL08-LEE00
DL08-LEE01
DL08-LEL00
DL08-LEL01
Item Remarks
Oil Grade API CJ-4

Oil Specifications
SAE Viscosity SAE 10W40
Total 42 L 35 L 42 L 35 L
Oil Capacity Max. 39 L 32 L 39 L 32 L
Min. 26 L 27 L 26 L 27 L
Allowable Oil Pan Inclination

35° / 35° / 35° / 35°
Angle (Front/Rear/Left/Right)
Oil Pump Type Gear Type
Oil Coolant Type Water-cooled Layered Plate
Oil Strainer Type Full Flow (Cartridge)
Oil Separator Type Impact (CCV)
Hydraulic Pressure Indicator Oil Pressure Sensor
Fuel System
Fuel Injection Pump Type BOSCH CP3.3NH
Engine Control Type E.C.U (BOSCH, EDC17CV41)
Nozzle Opening Pressure (Operating Pressure) 1,800 bar
Injector Nozzle Type Multi Hole Type
Fuel Filter Type Full Flow (Cartridge)
Intake/Exhaust System
Turbocharger WGT (Waste Gate Turbocharger)
Cylinder Block/Head
Valve Overhead valve
Intake 0.3 mm When Cold

Valve Clearance
Exhaust 0.4 mm When Cold
Electric System
Type Reduction Type

Start Motor
Capacity 24 V, 6 kW
Type AC 3-phase, I.C. Regulator Integrated

Alternator
Capacity 24 V, 50 A
Preheat System 22 V, 2.1 kW Air Heater
18
Engine Output
Engine Performance
Output Torque Idle at Low Speed Idle at High Speed

Model Product Code
(kW/rpm) (N.m/rpm) (rpm) (rpm)
DL08-LEE00 202.2/1,800 1,275/1,300 800 ±10 1,900 ±25
DL08-LEE01 213.2/1,800 1,275/1,300 800 ±10 1,900 +25
DL08-LEL00 202.2/1,800 1,275/1,300 800 ±10 1,900 ±25
DL08-LEL01 202.2/1,800 1,275/1,300 800 ±10 1,900 +25

DL08P
DL08-MEE00 202.2/1,800 1,275/1,300 800 ±10 2,400 +25
DL08-MEE01 213.2/1,800 1,275/1,300 800 ±10 1,900 +25
DL08-MEL00 202.2/1,800 1,275/1,300 800 ±10 1,900 +25
DL08-MEL01 202.2/1,800 1,275/1,300 800 ±10 1,900 +25
19
Engine Performance Curve (DL08-LEE00/MEE00)
140
Torque (kg.m)
120
100
300 80
250
Power Output (ps)
200
150
Fuel Consumption (g/ps.h)

100
160
150
140
130
800 1000 1500 2000
Revolution (rpm)
EDL08160001
Test Evaluation Method KS-R1004
Engine Output (Rated) 275 ps / 1,800 rpm
Torque (Max.) 130 kg.m / 1,300 rpm
Fuel Consumption (Max. Rated) 150 g/ps.h
20
Engine Performance Curve (DL08-LEE01/MEE01)
130
300 120
Torque (kg.m)
110
100
90
250
Power Output (ps)
200
150

160
100 150
140
800 1000 1200 1400 1600 1800 2000
Revolution (rpm)
EDL08160002
21
Engine Performance Curve (DL08-LEL00/MEL00)
Torque (kg.m)
130
120
110
100
280 90
80
260
Power Output (ps)
240
220
200

180
170
160
150
1000 1200 1400 1600 1800 2000
Revolution (rpm)
EDL08160003
22
Engine Performance Curve (DL08-LEL01/MEL01)
Torque (kg.m)
130
120
110
100
280 90
80
260
Power Output (ps)
240
220
200

180
170
160
150
1000 1200 1400 1600 1800 2000
Revolution (rpm)
EDL08160004
23
Outside Drawing of the Engine (DL08-LEE00/LEE01/MEE00/MEE01)
Isometric Assembly Drawings
5
3
2 6
14 9
11
13
12
10
EDL08160005
1. Flywheel Housing 6. Water Pump 11. Breather

2. Lifting Hook 7. Turbocharger 12. Start Motor
3. Exhaust Manifold 8. Mounting Bracket 13. Water Pump
4. EGR Cooler 9. Intake Manifold 14. Air Heater
5. Throttle Valve 10. Breather Pipe
24
Assembly Drawings (Left/Right)
1 2
11 12 6 7
10 9
EDL08160006
1. Breather 5. Breather Pipe 9. Oil Pan

2. Intake Manifold 6. Turbocharger 10. Drain Plug
3. Fuel Injection Pump 7. Exhaust Manifold 11. Lifting Hook
4. Start Motor 8. Coolant Pipe 12. EGR Cooler
25
Assembly Drawings (Top/Bottom)
1 2
9 8 7 3 5 6 4
EDL08160007
1. Turbocharger 4. Timing Gear Case 7. Breather

2. EGR Cooler 5. Cylinder Head Cover 8. Intake Manifold
3. Breather Pipe 6. Start Motor 9. Oil Filler Cap
26
Outside Drawing of the Engine (DL08-LEL00/LEL01/MEL00/MEL01)
Isometric Assembly Drawings
3 5
2 6
10
15 11
12
14
EDL08160008
1. Flywheel Housing 6. Water Pump 11. Breather

2. Lifting Hook 7. Turbocharger 12. Start Motor
3. Exhaust Manifold 8. Mounting Bracket 13. Alternator
4. EGR Cooler 9. Intake Manifold 14. Water Pump
5. Throttle Valve 10. Breather Pipe 15. Air Heater
27
Assembly Drawings (Left/Right)
1 2
6 12
11
10 9
EDL08160009
1. Breather 5. Breather Pipe 9. Oil Pan

2. Intake Manifold 6. Turbocharger 10. Drain Plug
3. Fuel Injection Pump 7. Exhaust Manifold 11. Lifting Hook
4. Start Motor 8. Coolant Pipe 12. EGR Cooler
28
Assembly Drawings (Top/Bottom)
1 2
8 7 5 6 3
EDL08160010
1. Turbocharger 4. Timing Gear Case 7. Breather

2. EGR Cooler 5. Cylinder Head Cover 8. Intake Manifold
3. Breather Pipe 6. Start Motor 9. Alternator
29
Engine Identification Number
Engine Code and Manufacturing Number • Type 5

The engine code and manufacturing number are required for
a warranty claim and part order.
Engine Number Engraving

• Type 1
• Type 6
• Type 2
• Type 3
• Type 4
30
4. Regular Inspection
General Information ................................................................................................................33

Routine Inspection .......................................................................................................................................... 33
Regular Inspection Table ........................................................................................................34
General Condition ........................................................................................................................................... 34
Cooling System .......................................................................................................................35
Coolant Standards .......................................................................................................................................... 35
Coolant Level .................................................................................................................................................. 35
Checking the Coolant ..................................................................................................................................... 35
Measurement of Coolant Concentration ......................................................................................................... 35
Replenishment of Coolant............................................................................................................................... 36
Replacement of Coolant ................................................................................................................................. 37
Cleaning Cooling Circuit .........................................................................................................38
Lubrication System .................................................................................................................38
Engine Oil Specifications ................................................................................................................................ 39
Engine Oil Capacity ........................................................................................................................................ 40
Checking Engine Oil ....................................................................................................................................... 40
Adding Engine Oil..................................................................................................................................... 40
Changing Engine Oil ....................................................................................................................................... 40
Fuel System .................................................................................................................................................... 42
Fuel Standards................................................................................................................................................ 42
Fuel Filter ........................................................................................................................................................ 42
Air Bleeding in the Fuel Circuit........................................................................................................................ 42
Intake/Exhaust System ...........................................................................................................43
Cleaning of Air Filter ....................................................................................................................................... 43
Cleaning of the Air Filter Element ................................................................................................................... 43
Replacement of the Air Filter Element ............................................................................................................ 44
Turbocharger .................................................................................................................................................. 45
Cylinder Block/Head ...............................................................................................................46
Valve Clearance.............................................................................................................................................. 46
Valve Clearance Adjustment Procedure ......................................................................................................... 46
Electric System .......................................................................................................................48
31
Battery............................................................................................................................................................. 48
Others/Driving System ............................................................................................................49
Belt Tension .................................................................................................................................................... 49
32
General Information
General Information
As time passes after purchasing an engine, each of the CAUTION
engines parts age and initial engine performance cannot be • Incorrect inspection methods may cause of engine
maintained. faults.
Regular inspection and replacement according to the recom- • Cleaning an engine with liquids such as water or wax
mended regular inspection table allows you to maintain an may cause breakdown of electrical parts.
engine with the optimum conditions and best performance • Be careful when handling batteries, cables, and elec-
for a long period and prevent unexpected accidents in trical wirings because current flows through those
advance. parts.
Users are responsible for the proper operation and mainte- • Do not put heavy things or apply excessive force or
nance of engines. Engines should be inspected and replaced impact on the fuel-related units.
by officially-certified technicians in a workspace with the • Make sure that you connect the battery terminal ('+'
specified tools and facilities. Observe the following instruc- and '-') to the right terminal. Connecting the '+' and '-'
tions to perform inspections. terminals to the wrong terminal may cause damage
1. Perform inspections on a flat floor without a slope. to the electrical unit parts and fire.
2. Excluding extreme circumstances, only perform inspec-
tion while the engine is stopped.
Routine Inspection
3. Disconnect the '-' terminal of the battery before
Routine inspection is an inspection performed by an engine
performing an inspection.
operator before operating the engine. It should be performed
4. Perform inspection in a well ventilated space.
to protect operator's safety, as well as the engine.
5. Use a wooden prop or lift when working under the engine.
The following is a minimal check list.
1. Check whether the engine smoothly starts and the levels
DANGER of fuel, oil, and coolant are within the normal range.
2. Check if any discharged emissions are colored and if the
• Wait until the engine is sufficiently cooled before
exhaust contains toxic gas elements.
starting inspection after operating the engine. Other-
3. Check whether abnormal noise occurs after starting an
wise, you may be burned.
engine or not.
• You may be poisoned by the emission when starting
4. Check whether oil or water is leaking.
an engine in a closed space. Perform inspection at
the well-ventilate space.
• Unless absolutely compelled, do not perform inspec-
tion under an engine.
• Do not be close to fire when inspecting an engine.
Fuel, oil, or batteries may generate gas, causing fire.
• If inspecting the engine while it is running, do not
wear accessories such as necklaces, rings, watches
or gloves. Such accessories may become stuck in
rotating parts while the engine is running and may
cause serious bodily injury.
• Individuals who use a mechanical heart or artificial
internal organ should not enter the area near an
engine while it is running. The high-voltage current
of the injectors or ECU may cause abnormal opera-
tion of such equipment.
33
Regular Inspection Table
General Condition The maintenance schedule may be different by driving

Periodic inspection and replacement are absolutely neces- conditions of the engine.
sary to ensure the optimum state of the engine during its
service life and prevent any unexpected engine failure.
(o : Check and Adjust, : Replace)
Initial Interval (Hr)

Inspection item Daily Remarks
50 500 1,000 1,500 2,000 2,500 3,000
Coolant System
Check for Water Leakage
o
(Hose and Clamp)
Check Coolant Level o
Check Belt Tension o
Check Coolant o o o o o o
Change Coolant Change every 1,200 hours
Lubrication System
Check for Oil Leakage o
Check Oil Level Gauge o
Change Lubricantab       
Replace Oil Filter Cartridgeab       
Fuel System
Drain Water from Water/Oil Separator o
Check Fuel Line for Leakage o
Check Fuel Injection Timing As Necessary
Replace Fuel Filter Cartridge      

Check Injector As Necessary
Whichever Occurs
Urea Filter Replace every 4,500 hours or 3 years
First
Engine Adjustment
Check Emission Condition o
Check Battery Charging Level o
Check Compression Pressure
Adjust Intake/Exhaust Valve Clearance o o o o o o As Necessary
a) The change intervals for oil and cartridge may differ by their operating conditions.
b) Change it after initial 50 hours and then every 500 hours.
34
Cooling System
General Information Checking the Coolant

The coolant plays an important role in the prevention of over-
heating and freezing of the engine. However, if the engine is DANGER
used for a long period, the performance of antifreezing and
If the radiator cap is opened to exchange or replenish
anticorrosion of the coolant degrades. Maintain the condition
coolant while the engine is overheated, hot water will
of the coolant through daily inspections and periodic replace-
spurt out and may cause serious burns. If it is absolutely
ments.
necessary to open the radiator cap while the engine is
The mixing ratio for the engine coolant is 50% antifreeze. For
overheated, wrap the radiator cap with a cloth and
the water in the coolant, use clean tap water. Periodically
slowly open the cap in two steps until the steam pres-
check coolant to maintain the concentration of antifreeze.
sure has been released from the inside. After the steam
pressure has been completely released, remove the
CAUTION radiator cap.
The recommended mixing ratio allows coolant to
prevent corrosion of the engine efficiently and to main- 1. Check the position of the surge tank.
tain the best engine performance for a long period. 2. Make sure that the engine and radiator are cooled.
Using contaminated water or unspecified antifreeze may 3. If the coolant level indicates between the upper limit and
cause critical faults in the cooler. the lower limit on the surge tank, it means that the coolant
volume is normal.
4. If there is insufficient coolant, replenish it.
Coolant Standards 5. Open the surge tank cap and check the condition of the
• Amount of antifreeze during winter coolant. If the coolant cap is contaminated or insufficient,
measure the coolant concentration. If the coolant
Ambient
Coolant (°C) Antifreeze (%) concentration is outside the specified range, exchange
Temperature (°C)
the coolant.
Above -10 85 15
-10 80 20
Measurement of Coolant Concentration
-15 73 27
• Special Tools
-20 67 33
-25 60 40 Figure Product Number/Name
-30 56 44
-40 50 50
60.99901-0038
Coolant Level
Coolant Test Sheet
C) B) A)
Coolant Capacity
Engine Model and Product Code
(L)
DL08-LEE00/LEE01/LEL00/LEL01/ The coolant concentration can be measured as follows.

13.3
MEE00/MEE01/MEL00/MEL01
1. If the engine coolant temperature is within a range of 10
~ 55°C, drain the coolant and fill half a plastic cup with it.
CAUTION
When taking out a sample of coolant from the supple-
mentary tank, it is difficult to measure the precise
concentration. Always take out sample by opening the
drain plug of coolant.
35
2. Soak the test sheet in the coolant and take it out after 3 ~ 1) Compare the changed pink color part A of the test sheet
5 seconds. Shake the sheet to remove the remaining with the GLYOOL/FREEZEPOINT (End pad) of the stan-
coolant. dard color table on top of the container and confirm the
3. Wait for about 45 seconds until the test sheet changes its concentration. The concentration indication has to be
color. within the color scope of 33 ~ 50%.
2) The state of additives for anticorrosion is shown on the
CAUTION point where the color of MOLYBDATE (Middle pad) on
the standard color table (which is identical with the Middle
Measurement time should not exceed 75 seconds. (B) of the test sheet) is crossed with the color of NITRITE
The color changes as time passes. on the standard color table (which is identical with the (C)
of the test sheet). It should be maintained at the optimum
4. Check the color on test sheet. range, in the green section between 0.3 to 0.8.
CAUTION
• If the color on the test sheet does not match the color
of the standard color table, find a middle color on the
standard color table. For example, if the color of (C)
of the test sheet matches D and F on the NITRITE of
the standard color table, select E.
• To prevent corrosion inside of the engine cooling
unit, drain the coolant and replace it with new coolant
once a year.
Replenishment of Coolant
EDL0213002A
If the coolant level of the supplementary tank is below the
1) Compare the color of part A on the test sheet to the color lower limit, replenish the coolant as follows.
of GLYCOL / FREEZEPOINT (End pad) of the standard 1. Remove the supplementary tank cap.
color table. 2. Replenish coolant until its level is between the upper and
2) Compare the color of the test sheet (B) to the color of lower limit of the supplementary tank.
MOLYBDATE (Middle pad) of the standard color table. 3. Install the supplementary tank cap.
3) Compare the color of the test sheet (C) to the color of
NITRITE of the standard color table. CAUTION
5. Compare and confirm the parts with identical colors on
the test sheet and the standard color table. Be careful not let foreign substances flow into the
engine when replenishing coolant.
If there is not coolant in the surge tank, replenish the

coolant as follows.
1. Remove the surge tank cap while the engine and radiator
TEST
are cold.
2. Replenish coolant up to the inlet of the radiator.
SERVICE
3. After starting the engine let the coolant circulate suffi-
ciently and check the coolant level. If there is insufficient
coolant, replenish more.
PRE CHARGE
4. Install the supplementary tank cap.
5. Remove the supplementary tank cap.
EDL022154A
36
6. Replenish coolant until its level is between the upper and 11. Repeat the above mentioned processes from 1 to 8 until
lower limit of the supplementary tank. the drained water becomes clear.
12. Press the hose connected to the radiator to discharge the
CAUTION air from inside of the radiator and slowly fill the radiator
with the coolant at the specified mixing ratio to let the air
• If the radiator cap is opened while the engine is hot, be discharged from the radiator.
hot water will spurt out and may cause serious Note) Use recommended genuine antifreeze.
burns. Open the radiator cap after making sure that
the engine has been fully cooled.
• Mark and separately manage the containers for
CAUTION
storing coolant from beverage containers for • Do not mix antifreezes from different manufacturers.
avoiding confusion. See a doctor immediately in • Do not mix the coolant with different concentrations.
case of drinking coolant. • Do not add antirust which is not recommended by us.
• As insufficient coolant concentration may cause
corrosion or freezing, on the other hand, an exces-
Replacement of Coolant
sive concentration may degrade the cooling perfor-
mance. Mix coolant with 40% antifreeze and 3~5%
DANGER additives (DCA4) to prevent corrosion.
• Never open the radiator cap while the engine is over-

13. Operate the engine at idle after starting. When cooling
heated. If the radiator cap is opened while the engine
fan is running and coolant is circulated, remove radiator
is overheated, hot water will spurt out and may cause
cap and replenish coolant through the inlet.
serious burns. Open the radiator cap after ensuring
14. Replenish coolant until the cooling fan rotates 3 ~ 5
that the engine has been cooled sufficiently.
times.
• Mark and separately manage the containers for storing
15. Replenish coolant to the upper limit of the supplementary
coolant from beverage containers to avoid confusion. If
tank and then install radiator cap.
coolant is ingested, see a doctor immediately.
16. Operate the engine at idle until the cooling fan rotates 2
~ 3 times.
CAUTION 17. Stop the engine and wait until the engine and the radiator
are cooled.
Be careful not to get coolant on any belts or electric 18. After checking the coolant level in the supplementary
apparatus when replacing the coolant. tank, replenish coolant until the tank level stays between
the upper and lower limit without changing.
1. Make sure that engine and radiator are cooled. Note) After replenishing coolant, check the coolant level of
2. Place a container in front of the coolant drain plug. the supplementary tank for at least two or three days.
3. Remove the radiator cap.
4. Unplug the coolant drain plug of the radiator and then
drain coolant.
CAUTION
5. After completing coolant drain, connect the coolant drain After replenishing coolant, check the coolant level of the
plug again. supplementary tank for at least two or three days.
6. Drain the coolant from the coolant supplementary tank
and cleanse the tank.
7. Fill the radiator inlet with water and install radiator cap. WARNING
Note) Slowly pour coolant in to let the air be discharged from Discard exchanged coolant according to the regulations
radiator and press the hose connected to it to set forth by the relevant authorities. Disposing of
discharge the air inside. exchanged coolant into the ground, sewers, drains,
8. Start the engine to let the cooling fan rotate 2 or 3 times. rivers, or the sea will cause serious environmental pollu-
When the engine is warmed up, increase the engine tion. Violation of regulations regarding discard of engine
RPM two or three times. oil without observing the handling regulations, will be
9. Stop engine and wait until engine is cooled. punished.
10. Remove the radiator drain plug and drain water.
37
Cleaning Cooling Circuit Lubrication System

If the internal cooling circuit is contaminated by corrosion or
foreign materials, the cooling effect can be deteriorated. General Information
Restriction in the cooling circuit can damage the mechanical Engine oil lubricates, cools, seals, prevents corrosion, and
seal of the water pump. The cooling circuit can be negatively cleans engines, enhancing engine performance and
affected by use of improper anti-freeze or anti-corrosion extending the engine's lifetime. If a vehicle is continuously
agent or no use of them. If the water pump leaks or the driven while engine oil is insufficient, the moving parts of the
coolant is severely contaminated (cloudy. Its contamination engine may get stuck, causing engine faults. Engine oil
level can be identified by its discoloration: brown, gray and should be checked through the oil level gauge and replen-
black) within a short period of time of engine use, clean the ished if required. Oil level should be checked while the
cooling system as follows before removing the water pump: engine is stopped. To check the oil level, turn off the engine
1. Drain coolant. while it is running and wait for 5 ~ 10 minutes to allow the
2. To clean the cooling circuit quickly, remove the water engine oil to flow back into the oil pan. The engine oil level
temperature controller. should indicate between the upper limit and the lower limit of
3. Replenish the cooling circuit with water mixed with 1.5% the oil level gauge. Engine oil should be periodically replaced
of cleaning agent (Henkel P3T5175). based on the regular inspection table and the oil filter and the
4. Apply load to the engine. When the coolant temperature cartridge should be replaced as the engine oil is replaced.
rises to 60°C, run the engine for approx. 15 minutes.
5. Drain the cleaning agent.
6. Repeat the step 3 to step 4.
7. Add hot water into the cooling circuit.
8. While idling the engine for approx. 30 minutes, check the
drain plug and coolant line for leakage. If coolant is insuf-
ficient, add more.
CAUTION
Clean the cooling circuit with a cleaning agent regularly.
38
Engine Oil Specifications

Use only specified engine oil according to the environment
and condition of the area.
Engine Oil Viscosity by temperature
SAE 10 W-30
SAE 5 W-30
SAE 0W-30
Ambient
temperature
SAE 0W-40
SAE 5W-40
SAE 10W-40
SAE 15W-40
EDL0213001D
Make sure to use proper engine oil according to the following recommendation.
Engine Model SAE Classification Oil Grade
DL08P SAE 10W40 API CJ-4 or more or ACEA-E9 or more
Note) Make sure to use the recommended genuine oil.
39
Engine Oil Capacity 2) If the oil level is below the lower limit (B) or engine oil is
Add a proper amount of engine oil to the engine according to not on the dipstick at all, add engine oil.
the following recommended capacity:
CAUTION
Engine Oil Capacity (L)
Engine Model Do not add engine oil over the upper limit mark on the
and Oil Pan
a dipstick. If the engine oil level is over the upper limit, the
Product Code Total
Max. Min. engine can be damaged.
DL08-LEE00/LEE01/
39 26 42
MEE00/MEE01 3) Check the viscosity and condition of engine oil. When
DL08-LEL00/LEL01/ necessary, change it.
32 27 35
MEL00/MEL01
a. Including 2.0 liters in engine Adding Engine Oil
Checking Engine Oil CAUTION

1. Move the vehicle onto level ground to maintain the
engine horizontally. When working on the vehicle with the oil filler cap
2. Start the engine. When the engine temperature increases removed, never let foreign materials enter the engine.
to a normal operating temperature, stop the engine.

1. Remove the oil filler cap from the top of the engine.
3. Wait for 5 ~ 10 minutes.
2. Replenish the engine with the recommended genuine
4. Pull out the dipstick.
engine oil.
5. Clean the level indicating section of the dipstick with a
1) Add the recommended genuine oil into the engine little by
clean cloth.
little in several steps.
2) Wait for approx. 1 to 2 minutes before checking the
CAUTION engine oil.
If wiping the dipstick with a dirty cloth, foreign materials 3) Check if the oil level is between the upper limit and lower
may enter the engine, causing engine failure. limit on the dipstick.
4) Repeat the above steps until the engine oil level
6. Fit the dipstick back into the engine. becomes proper.
7. Pull out the dipstick to check the oil level and oil condition.
CAUTION
• When adding engine oil, make sure no foreign mate-
rial enter the engine.
• If adding engine oil over the upper limit, it can lead to
engine failure. If the engine oil level is over the upper
limit, drain engine oil until the level is between the
upper and lower limit marks on the dipstick.
A
• Never mix engine oil with any unspecified additive.
B
3. After adding engine oil, fit the oil filler cap.
EDL022152A
1) Check if the oil level is between the upper limit (A) and
lower limit (B) on the dipstick.
Changing Engine Oil 1) Place a container under the engine to collect drained
1. Drain engine oil. engine oil.
40
2) Remove the drain plug to drain engine oil. 2) Add engine oil while checking the oil level through the oil
3) Remove the oil filler cap. filler hole.
2. Replace the oil filter.
CAUTION
Never let any foreign material enter the system while
adding oil.
3) Confirm that the needle on the oil level gauge is on the

Oil cooler upper limit indication.
4. Perform the final inspection after performing the specified
steps.
Oil filter 1) Idle the engine for a few minutes to let oil circulate in the
engine lubrication circuit.
2) Stop the engine and wait for 10 minutes.
3) Check the oil level and add more oil as necessary.
EA5OM006-E
1) Remove the oil filter using its service wrench. CAUTION

2) Wipe the head and cartridge contact area of the oil filter If adding engine oil over the upper limit, it can lead to
clean. engine failure. If the engine oil level is over the upper
3) Seat the cartridge of the oil filter properly. limit, drain engine oil until the level is between the upper
4) Apply a small amount of oil to the O-ring section of the and lower limit marks on the dipstick.
cartridge.
5) Fit a new oil filter loosely by screwing it with a hand.
6) Remove the oil filter using its service wrench.
CAUTION
• When replacing the cartridge of the oil filter, make
sure to use the specified genuine one.
• The oil filter should be installed to the engine without
oil in it. Never fill the new oil filter with oil drained
from the used oil filter.
3. Add engine oil.
EJ5OM007
1) Install the drain plug.
41
Fuel System Note) High sulphur content in diesel fuel Doosan diesel
engines can be operated with fuels whose sulphur
General Information content is max. 15 wtppm.
Fuel quality is an important factors in satisfy standards for
engine performance, engine lifetime, and emissions. Doosan Fuel Filter
engines are designed to use diesel fuel available in the area It is used to remove water and foreign materials from fuel
where the engines are sold.
in order to send clean fuel to the fuel injection pump.
CAUTION CAUTION
• Use clean, specified, and qualified fuel only. Using
• Make sure to check the fuel filter and drain water
irregular or unspecified fuel may causecritical
from it periodically. Otherwise, water may enter the
damage and faults to the engine.
engine fuel system, causing a serious problem to the
• Inject fuel while the engine is stopped.
fuel injection pump, fuel injection pipe, common rail,
injector, etc. Also, it can deteriorate or damage the
Fuel Standards fuel filter.
To maintain the optimum engine performance, refer to the • When draining water from the fuel filter, fuel may be
following recommended fuel table to select the appropriate drained as well. Fuel is highly flammable. Keep a lit
fuel. cigarette or flame away from the engine during
• Ultra Low Sulfur Diesel draining water from the filter.
• Use the specified clean quality fuel only. If using fuel
Fuel Ingredients Standard other than the specified one, more water can be
accumulated in the fuel filter.
Specific Gravity (kg/lit) 0.820 ~ 0.845
• If water is not drained from the fuel filter when the
Fire Point (°C) Above 40
fuel filter warning lamp is turned on, water may enter
Viscosity (40°C) (cSt) 1.9 ~ 5.5 the fuel system, causing engine stall.
Sulfur Content (wtppm) Below 15 • A new fuel filter should be installed without fuel in it.
Never add fuel in the used fuel filter or fuel tank to a
Cloud Point (°C) -
new fuel filter.
Pour Point (°C) Below -17.5
Low Temperature Filter (°C)

Below -16 Air Bleeding in the Fuel Circuit
Clogging Point
To bleed the fuel line, loosen the fuel feed pipe between the
Color (ASTM) Below 2.5
secondary fuel filter and high-pressure fuel pump slightly and
Residual Carbon (10%) (%) operate the priming pump of the primary fuel filter manually
Below 0.15
Vapor/Residual Fraction (wt)
until air bubbles are not visible any more.
(mg
Total Acid Value Below 0.40
KOH/g)
Back Plate Corrosion Rate
Below 1
(100°C, 3 hours)
Ash Content (mass %) Below 0.01
Moisture and Precipitation (vol. %) Below 0.02
Cetane Index Above 45
50 % Distillation
-
Distillation Test Point
Temperature 90 % Distillation
Below 360
Point
42
General Information 2) The canister can be removed by undoing its two clamps (B).
The air filter is used to remove dust and foreign materials 3) Remove the cover (C) and empty the canister.
from the air in order to supply clean air into the engine. 4) Install the cover and canister correctly with care.
The air filter should be checked, cleaned and replaced regu- 5) There is a groove around the cover for its correct align-
larly since it directly affects the engine service life, emissions ment with the protrusion of the dust canister.
and engine power. 6) Check the "TOP" mark on the air filter cylinder so that the
filter is installed horizontally.
DANGER
Cleaning of the Air Filter Element
• Never run the engine with the air filter removed.
Clean the air filter element by using the most suitable method
• Use the specified air filter only. If using a fake or recy-
for your work environment among the three methods stated
cled one, a serious problem may occur to the system.
below.
• If foreign materials are led into the engine, they can
1. Use compressed air to clean the air filter element.
wear the interior of the engine.
• When replacing the air filter, be careful not to
damage any electric part and let foreign materials
enter the engine.
• If the air filter is damaged, replace it with a new one
immediately.
• When installing the air filter, make sure that no dust
is entered the system.
• If the element of the air filter is deformed, damaged or
cracked, replace it with a new one.
• Clean and replace the element periodically.
Cleaning of Air Filter

1. Clean the air filter. EDL022155A
1) To clean, let sufficient compressed air reach the inside

B C A bottom of the element at 90° direction with an air gun.
2) Move air gun up and down the element to blow air from
inside to outside until no more dust is coming out from the
element.
3) Do not use compressed air pressure exceeding 5 bars.
CAUTION
Always wear protective goggles before starting work.
Otherwise, dust or foreign substances from the element
may get in your eyes and cause injuries.
EK00021A
1) Clean the canister (A) regularly.
CAUTION
Never let the canister filled with dust more than its half.
43
2. Clean the element by washing it.
EDL022157A
EDL022156A
Note) Before reassembling the element, make sure that the
1) Before washing the element, clean the element by using
filter paper is not wrinkled, the state of rubber sealing
compressed air as described above.
is good, and there is no deformed part in the element.
2) Soak the element in the warm cleaning solvent for 10
Note) Under any circumstances, do not reuse damaged
minutes and then shake it back and forth for about 5
elements. When in doubt, replace the element with a
minutes.
new one.
3) Rinse the element with clean water, drain the water, and
then dry it at room temperature. Fully dry the element
Replacement of the Air Filter Element
before reassembling it to the engine.
1. Replace the air filter element.
CAUTION
Never use steam spray, gasoline, alkali or hot cleansing
solution to cleansing the element.
3. In an emergency, temporarily clean the element by using

the following method.
1) Tab the end plate of the element with the thumb to clean
it temporarily.
CAUTION
• This method should only be used in an emergency
when cleaning of element is necessary and no
EK00025A
compressed air or cleansing solution is available.
• Under no circumstances should the surface of the 1) Unscrew the hex. nut and remove the dirty element.
element be hit or beaten with a hard object to shake Clean it or replace it with a new one.
the dust off. 2) Wipe the inside of the filter housing and seal ring contact
area of the element with a wet cloth cleanly.
CAUTION
Make sure that no dust is entered the air filter through its
tip.
44
Turbocharger
1. The turbocharger is a maintenance-free part.
2. When changing engine oil, make sure to check the oil
pipe for leakage and restriction as well.
3. The air filter should be carefully maintained so that no
foreign material is led into it. Compressed air and exhaust
pipe of the turbocharger should be inspected periodically.
If air leak occurs, it should be repaired immediately as it
can result in overheating of the engine.
4. When running the engine in a work space mixed with dust
or oil, the impeller needs to be cleaned frequently.
Remove the impeller casing and clean it only with
non-acid solvent solution. If necessary, use a plastic
scraper. If the impeller is severely contaminated, soak it
in solvent and use a bristle brush to clean it thoroughly.
In this cleaning process, soak the impeller only and
support the turbocharger with the bearing housing, not
with the impeller.
CAUTION
Be careful not to bend it.
45
Cylinder Block/Head
Valve Clearance
Adjust the valve clearance under the following conditions:
• When disassembling the engine or cylinder head,
• When loud noise is heard from the valve connection,
• When the fuel injection system is intact but the engine
operates abnormally.
Valve Clearance Adjustment Procedure
Cooling fan Exhaust valve Intake valve Cylinder no. Flywheel
1 2 3 4 5 6
Valve clearance adjusting position
EK4OM014-E
46
Valve adjusting bolt
Valve Rocker arm

Rocker arm adjusting
Valve adjusting
nut
Calliper adjusting Adjusting screw
screw screw
A Valve adjusting
B
Push rod nut
Calliper Calliper Push rod
Intake valve spring Exhaust valve spring
(inside & outside) (inside & outside)
Intake valve Exhaust valve
Valve seat
Valve seat
Intake valve adjusting Exhaust valve adjusting
EJ9OM089-E
[Method 1] [Method 2]
1. Turn the crankshaft to set the piston of the cylinder No. 1 1. Turn the crankshaft to set the valves of the cylinder No. 6
to the TDC on the compression stroke. overlapped.
Note) The cylinder No. 1 can be identified by the cooling fan. Note) When the cylinder No. 1 is at the TDC on the compres-
Note) When the cylinder No. 1 is at the TDC on the compression stroke, valve overlap is occurred at the cylinder
sion stroke, valve overlap is occurred at the cylinder No. 6.
No. 6. Note) The cylinder No. 1 can be identified by the cooling fan.
2. Unscrew the rocker arm mounting nut at the cylinder No. 1. 2. Adjust the valve clearance marked with '' in the table.
3. Adjust the cylinder clearance with its adjusting nut. Then, 3. Rotate the engine for 1 turn (360°) in the engine rotating
tighten the mounting nut. direction to set the valves for the cylinder No. 1 over-
lapped.
Intake Valve Exhaust Valve Note) When the cylinder No. 6 is at the TDC on the compres-
Engine Model
(mm) (mm)
sion stroke, valve overlap is occurred at the cylinder
DL08-LEE00/LEE01/ No. 1.
LEL00/LEL01/MEE00/ 0.3 0.4 4. Adjust the valve clearance marked with 'o' in the table.
MEE01/MEL00/MEL01
5. Check the valve clearance again, and adjust it as neces-
sary.
4. Turn the crankshaft to adjust the valve clearance for each
(E: Exhaust valve, I: Intake vale)
cylinder at the TDC on the compression stroke.
5. According to the cylinder in the valve overlap period, Cylinder No. 1 2 3 4 5 6
adjust the valve clearance for the corresponding cylinder
Valve E I E I E I E I E I E I
at the TDC on the compression stroke as follows:
No. 1 TDC      
Cylinder No. in Valve Overlap Period Turn 360° o o o o o o
1 5 3 6 2 4
6 2 4 1 5 4
Cylinder No. for Valve Adjustment
47
Electric System
Battery
1) Check the battery for electrolyte leakage from its crack. If
the battery is in a poor condition, replace it.
2) Check the electrolyte amount. If it is insufficient, add
distilled water to the battery.
3) Measure the specific gravity of the electrolyte.
If the measurement is below the specification (1.12 ~
1.28), replenish the battery.
Viewing the Liquid level liquid level upper limit lsotator

gravity meter indicating line liquid level lower limit
1,100
1,200
1,300 UPPER LEVEL
LOWER LEVEL
EFM1007I-E
48
Others/Driving System
Belt Tension 1) Insert the belt to the protrusion (A) of the tension
The belt's tension should be checked daily and adjusted as measuring instrument.
necessary. • Set the measuring instrument between the pulleys and
1. Inspection condition set its contact end (B) to push the belt.
1) Check the belt for crack, oil residue, deformation by heat • Press the pad (C) until unscrewing sound of the spring is
and wear. heard. This force pushes the tension measuring instru-
2. Test with hands ment upwards.
• If there is still tension left on the belt after removing the
pad (C), the measurement result is not accurate.
2) Tension measurement
• Read the value where the top of the protrusion (A) of the
tension measuring instrument is aligned with the scale.
• Before reading the value, make sure that the needle of
the measuring instrument is returned back to the original
position.
4. The belt tension is as follows:
Number of Belt Folds

Tension (kgf)
(PK Type)
EDL022140A
3 20 ~ 27
1) The tension of the belt can be inspected by checking the
4 27 ~ 36
amount of deflection of the belt when applying the speci-
fied force (F) to it. 5 34 ~ 45
2) Adjust the belt so that the deflection (T) equals to 6 41 ~ 57
0.015 × S (1.5 mm for 100 mm).
7 48 ~ 66
Note) T: deflection amount, S: distance
8 59 ~ 73
2
2 (D - d)
*S= C 2
3) 5. The belt consists of the following components:
Note) C : distance between shafts (mm), D: large pulley
diameter (mm), d: small pulley diameter (mm)
3. Tension measurement
D
C
C B
EDL022142A
B 1) The belt consists of the cover layer (A), cord (B), adhe-
sive rubber (C) and belt reinforcement rubber (D).
EDL022141A
49
50
5. About the Engine
Marking System of Units .........................................................................................................53

Unit Conversion Methods................................................................................................................................ 53
Tightening Torque ...................................................................................................................54
Tightening Torque of Major Parts ................................................................................................................... 54
Tightening Torque for General Bolts ............................................................................................................... 55
Tightening Torque of Plug Screw.................................................................................................................... 56
Hollow Screw (4-Hole) Tightening Torque ...................................................................................................... 56
Special Tool ............................................................................................................................57
Special Service Tools ..................................................................................................................................... 57
Engine Disassembly ...............................................................................................................59
Engine Disassembly Procedure ...................................................................................................................... 59
Engine Assembly ....................................................................................................................72
Engine Assembly Sequence ........................................................................................................................... 72
51
52
5. About the Engine
Marking System of Units
Unit Conversion Methods Item Number SI Unit US Unit

The following methods show how to convert SI units to US
0.01 kPa bar
units and vice versa.
1. To convert an SI unit to a US unit, multiply a SI unit with 7.500615 kPa mmHg
Pressure
the number in the following table. 20.88543 kPa lb/ft2
Note) (SI Unit) X (Number) = (US Unit)
14.2233 psi kg/cm2
Note) 1mm X 0.03937 = 0.03937 in
2. To convert a US unit to an SI unit, divide the US unit by 1.3596 kw PS
Electric Power
the number in the following table. 0.98635 ps hp
Note) (US Unit) ÷ (Number) = (SI Unit) Fuel Con-
Note) 1 in ÷ 0.03937 = 25.4 mm 0.00162 g/kwh lb/psh
sumption
0.000947817 J BTU
Item Number SI Unit US Unit
Energy 0.7375621 J lbfïft
0.03937 mm in
0.0002777778 J Wh
3.28084 m ft
Length Luminous Flux 0.09290304
1.093613 m yd lm/m2 lm/ft2
0.621371 km mile Speed 0.6213712 km/h mph
Temperature c °C °F
0.00155 mm2 in2
0.1550 cm2 in2 a. 9.806 x (kgïf) = (N)

Area b. 9.806 x (kgfïm) = (N.m)
10.76391 m2 ft2 c. {(9/5) x (°C)+32} = (°F)
{(°F)-32} x (5/9) = (°C)
1.19599 m2 yd2
2.204623 kg lb
Weight
0.001 kg t (ton)
0.061024 cc in3
0.061024 ml in3
Volume 0.061024 cm3 in3
61.023744 L in3
0.264172 L gal
2.204622 kgf lbf

Forcea
0.2248089 N lbf
3.28084 m/s2 ft/s2

Acceleration
39.37008 m/s2 in/s2
7.233014 kgf.m lbf.in
86.79619 kgf.m lbf.in

Torqueb
0.7375621 N.m lbf.ft
8.850748 N.m lbf.in
Power 1.340483 kw Hp
53
5. About the Engine
Tightening Torque
Tightening Torque of Major Parts
Size
Major Parts Tightening Torques
(Diameter x Pitch)
Cylinder Block Bearing Cap Bolt M16 x 2.0 30 ±2 kgf.m
Oil Spray Nozzle M10 x 1.25 2.1 +0.5 kgf.m
Flywheel Housing Mounting Bolt M12 x 1.5 11.2 +1.0 kgf.m
Crank Pulley Mounting Bolt M14 x 1.5 20 +0.2 kgf.m
Shock Absorber M10 x 1.5 6.2 +0.5 kgf.m
Flywheel Mounting Bolt M14 x 1.5 20 +2.0 kgf.m
Connecting Rod Cap Bolt M12 x 1.5 9.75 +0.25 kgf.m
Cylinder Head Bolt M13 x 1.5 5 kgf.m +90° +90° +90°
Cylinder Head Cover Bolt M8 2.2 +0.5 kgf.m
Injector Cable Mounting Nut M4 0.15 +0.01 kgf.m
Rocker Arm Bracket Mounting Bolt M8 x 1.25 3.7 +0.5 kgf.m
Rocker Arm Adjusting Nut M10 x 1.0 5.0 +0.5 kgf.m
Oil Pump Cover M8 2.2 +0.5 kgf.m
Oil Pump Mounting Bolt M10 x 1.5 4.4 +0.5 kgf.m
Oil Cooler Mounting Bolt M8 2.2 +0.5 kgf.m
Oil Pan Mounting Bolt M8 2.2 +0.5 kgf.m
Oil Drain Plug M30 x 1.5 10 +1.0 kgf.m
Exhaust Manifold Mounting Bolt M8 5.0 +0.5 kgf.m
Intake Manifold Mounting Bolt M10 x 1.5 4.4 +0.5 kgf.m
Start Motor M12 x 1.5 8.0 +1.0 kgf.m
Alternator Bracket Mounting Bolt M12 x 1.5 7.7 +0.5 kgf.m
Coolant Temperature Sensor M12 x 1.5 2.2 kgf.m (Max. 2.5 kgf.m)
Engine Mounting Bracket M10 x 1.5 6.2 +0.5 kgf.m
Fuel High-pressure Pump Gear Nut (CP Pump) M18 x 1.5 11 ±0.5 kgf.m
Fuel Injector Mounting Bracket Bolt M8 3.1 kgf.m
Fuel High-pressure Pump Mounting Bolt
M8 4.4 +0.5 kgf.m
(Cylinder Block)
Fuel High-pressure Connector Nut M22 x 1.5 5 +0.5 kgf.m
Common Rail Mounting Bolt M8 2.2 +0.5 kgf.m
Fuel High-pressure Pipe - High-pressure
M14 x 1.5 2.8 +0.5 kgf.m
Fuel Connector
Fuel High-pressure Pipe - Common Rail M14 x 1.5 2.5 +0.5 kgf.m
Fuel High-pressure Pipe - Fuel
M14 x 1.5 2.1 +0.5 kgf.m
High-pressure Pump
Fuel Filter Mounting Bolt M10 4.4 +0.5 kgf.m
54
5. About the Engine
Tightening Torque for General Bolts

Keep the following torque values for bolts not specified in the Tightening Torque for Major Parts table.
1. Tightening Torque for General Bolts
Hardness
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Nominal
Diameter × (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
Pitch Elastic Limit (kg/mm2)
(mm)
20 24 32 30 40 36 46 54 64 90 106
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
M8 x 1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.35 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10 x 1 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
M12 x 1.5 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
M14 x 1.5 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
M16 x 1.5 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
M18 x 1.5 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
M20 x 1.5 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
M22 x 1.5 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
M24 x 1.5 23 25 37 31 45 38 61 67 74 93 103
Note) The standard torque values specified above are based on 70% of a bolt's elastic limit.
Note) The tensile force is calculated by multiplying the tensile strength by the cross-sectional area of a screw.
Note) A special screw should be tightened to about 85% of the standard torque. For example, a screw coated with MoS2 should
be tightened to about 60% of the standard torque.
55
5. About the Engine
Tightening Torque of 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
Hollow Screw (4-Hole) Tightening Torque
Material
M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
Classification
SM25C - 1.6 2.5 3.5 4.5 5.5 9.0 13.0 18.0 30.0
SUM22La 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
a. Applied to Doosan Engines
56
5. About the Engine
Special Tool
Special Service Tools Figure Part Number / Part Name
Figure Part Number / Part Name
EF.121-181
Camshaft Hole Cover
EF.121-299 Punch
Oil Seal Installation Jig
(Front)
EF.121-252
Step Idle Gear Pin
EF.121-300 Installation Jig
Oil Seal Installation Jig
(Rear)
60.99901-0027
Feeler Gauge
EF.123-065
Valve Spring Compressor
EF.121-260
EF.123-365A Wear Ring Punch (Rear)
Cylinder Liner Disassembly
Tool
65.98801-0001
EF.121-250 Filter Wrench
Piston Inserting Tool
(Only for DL08 Engine)
T7610001E
EF.120-208
Snap Ring Pliers
Piston Inserting Tool
(for All Engine Models)
EF.121-253 EF.121-259
Valve Stem Seal Inserting Crankshaft Gear Inserting
Tool Jig
(for All Engine Models)
57
5. About the Engine
Figure Part Number / Part Name
T7621010E
Piston Ring Pliers
860104-01045
Diagnostic Device
860104-01046
UVIM (CAN Module)
(for Diagnostic Device)
860104-01047
14-pin Connector
860104-01048
USB
58
5. About the Engine
Engine Disassembly
Engine Disassembly Procedure 7) After draining coolant, install the drain plug.
DANGER
CAUTION
• Never open the radiator cap while the engine is hot.
• Prepare the necessary tools and genuine parts If opening the radiator cap while the engine is still
before engine disassembly. hot, hot coolant may spurt, resulting in a severe
• Prepare a shelf to keep removed parts. burn. Open the radiator cap after confirming that the
• Keep the working area well lighted and clean. engine is sufficiently cooled down.
• Keep your hands clean at all times during service. • Put a label on the coolant container not to get mixed
• Keep parts removed from the engine in the removal with other containers. If you swallow coolant, seek
order. professional medical help immediately.
• Make sure that removed parts are not mixed and do
not touch each other.
WARNING
Disassemble the engine according to the following proce-
dure: Used coolant should be discarded according to the local
1. Drain coolant. regulations. Never discard used engine oil to the
ground, ditch, sewer, river, sea, etc. Such action can
pollute the environment. Discarding used engine oil
Radiator
cap improperly can result in punishment due to violation of
the corresponding regulation.
Radiator
CAUTION
When changing coolant, make sure that it is not left on
any belt or electric part.
2. Separate the dipstick.

1) Pull out the dipstick.
Drain valve 3. Drain engine oil.
FG000494-E
1) Check that the engine and radiator is sufficiently cooled

down.
2) Place a container in front of the coolant drain plug.
3) Remove the radiator cap.
4) Open the drain valve on the bottom of the radiator to drain
coolant.
5) Remove the coolant drain plugs from the cylinder block
and oil cooler.
6) Drain coolant into the prepared container.
Drain valve
EJ5OM008-E
1) Place a container under the engine to collect drained engine

oil.
2) Remove the drain plug from the oil pan and drain engine
oil into the prepared container.
59
5. About the Engine
3) Remove the oil filler cap.

4) Remove the engine oil filter.
5) After draining engine oil, install the engine oil filter and
drain plug.
WARNING
Used oil should be discarded according to the local
regulations. Never discard used engine oil to the
ground, ditch, sewer, river, sea, etc. Such action can
pollute the environment. Discarding used engine oil
improperly can result in punishment due to violation of
the corresponding regulation.
EJ9OM028
4. Remove the belt.
1) Unscrew the mounting bolt to remove the alternator.
2) Unscrew the idle puller mounting bolt to remove the A/C
compressor.
8. Remove the breather.
Water Pump
Belt
Crank Pulley
Air compressor
EK1OM017-E
1) Unscrew the tension adjusting bolts and mounting bolts

of the A/C compressor, air compressor and alternator.
2) Remove the belt. EJ5OM009
5. Remove the engine from the machine.
1) Unscrew the mounting clamp screw to disconnect the
6. Disconnect the cables and harnesses of the engine from
rubber hose.
each sensor.
2) Remove the breather valve assembly.
7. Remove the alternator and A/C compressor.
EJ9OM027
60
5. About the Engine
9. Disconnect the air pipe and remove the air heater. 11. Separate the intake manifold.
Intake manifold
EJ5OM010 EK1OM005-E
1) Unscrew the mounting bolt to disconnect the air pipe and 1) Unscrew the intake manifold mounting bolts to remove
remove the air heater. the intake manifold from the cylinder block.
2) Remove the gasket and clean the gasket mounting
CAUTION surface thoroughly with a scraper.
12. Remove the common rail and high-pressure pipe.
Never let foreign materials enter the turbocharger.
10. Remove the fuel filter.
EK1OM006
1) Disconnect the high-pressure pipe between the fuel

EJ5OM011 high-pressure connector and common rail.
2) Unscrew the common rail mounting bolts to remove the
1) Unscrew the hollow screw from the fuel filter and discon-
common rail.
nect the fuel hose.
2) Unscrew the fuel filter mounting bolt to remove the fuel
filter. CAUTION
• Seal the common rail thoroughly after removing it to
prevent foreign materials from entering it.
• Once the fuel high-pressure pipe is disconnected, it
cannot be reused.
61
5. About the Engine
13. Remove the fuel high-pressure pump.
EJ9OM020
EK1OM018
1) Unscrew the EGR valve mounting bolts to remove the
1) Unscrew the fuel high-pressure pump mounting bolts to
EGR valve and exhaust manifold.
remove the fuel high-pressure pump.
2) Unscrew the mounting bolts to remove the exhaust pipe
from the EGR cooler.
CAUTION 3) Disconnect the coolant pipe from the EGR valve.
Seal the fuel high pressure pump to prevent from mixing

foreign material into inside of the fuel. CAUTION
Seal the EGR valve and exhaust pipe thoroughly after
14. Remove the EGR valve. removing them to prevent foreign materials from
entering them.
EJ9OM019
62
5. About the Engine
15. Remove the EGR cooler. 16. Remove the HC (Hydro-Carbon) injector.
EJ9OM021 EK1OM007
EJ9OM022 EK1OM008
1) Unscrew the EGR cooler and bracket connecting bolt to 1) Disconnect the HC injector pipe.
separate the EGR cooler. 2) Disconnect the cooling hose from the HC injector.
2) Disconnect the pipe and hose from the EGR cooler. 3) Unscrew the HC injector mounting bolts to remove it from
the exhaust pipe.
CAUTION
Seal the EGR cooler thoroughly after removing it to
CAUTION
prevent foreign materials from entering it. Seal the HC injector, pipe and hose thoroughly after
removing them to prevent foreign materials from
entering them.
63
5. About the Engine
17. Remove HC dosing metering unit. 19. Remove the exhaust manifold.
Exhaust manifold
EK1OM024 EJ9OM034
1) Unscrew the mounting bolt of the HC dosing metering 1) Unscrew the exhaust manifold mounting bolts to remove
unit to remove it from the bracket. the exhaust manifold.
CAUTION CAUTION
Seal the HC dosing metering unit thoroughly after Do not reuse the removed gasket.
removing it to prevent foreign materials from entering it.
20. Disconnect the coolant pipe and thermostat.
18. Remove the turbocharger.
cylinder head Thermostat
Cooling water
pump
EJ9OM040-E
EJ9OM029
1) Unscrew the coolant pipe mounting bolt to disconnect the
1) Disconnect the intake stake from the turbocharger.
coolant pipe from the thermostat housing.
2) Disconnect the coolant hose from the turbocharger.
2) Remove the coolant thermostat and O-ring.
3) Disconnect the oil feed pipe and oil drain pipe between
3) Clean the gasket mounting surface of the coolant pipe
the cylinder block and turbocharger.
with a scraper thoroughly.
4) Unscrew the turbocharger mounting bolts to separate the
turbocharger from the exhaust manifold.
CAUTION
Make sure that the gasket residual does not enter the
coolant passage.
64
5. About the Engine
21. Remove the coolant pump. 22. Remove the start motor.
EJ9OM031 EJ9OM094
1) Unscrew the start motor mounting nut and remove the

start motor with care. Be careful not to damage its gear.
23. Remove the oil filter.
Oil cooler
Oil filter
EJ9OM032
1) Unscrew the bracket mounting bolts for the coolant pump

and oil cooler.
EA5OM006-E
2) Unscrew the bolt (1 ea) for the oil cooler.
1) Remove the oil filter cartridge using a special service tool.
3) Unscrew the coolant pump mounting bolts to remove the
24. Remove the vibration damper.
coolant pump.
4) Remove the O-ring for the coolant pump.
CAUTION
Do not reuse the O-ring.
EJ9OM047
65
5. About the Engine
1) Unscrew the mounting bolts of the vibration damper and 27. Remove the push rod.
crank pulley in the reverse order to remove the vibration
damper assembly.
25. Remove the cylinder head cover.
EJ9OM038
1) Remove the push rod.

28. Remove the fuel injector.
EJ9OM036
1) Unscrew the cylinder head cover mounting bolts to

remove the cylinder head cover.
Injector
2) Unscrew the intermediate cover mounting bolts to
remove the intermediate cover. Fuel high pressure
connector
26. Remove the rocker arm.
Fixing bracket
EG9OM173-E
1) Unscrew the fuel high-pressure connector mounting bolts

to disconnect the fuel high-pressure connector.
2) Remove the harness from the injector.
3) Unscrew the injector mounting bracket bolts to remove
the injector.
EJ9OM037
1) Unscrew the rocker arm bracket mounting bolts in the

CAUTION
reverse order to remove the rocker arm assembly.
Be careful not to damage the nozzle during removing the
injector.
66
5. About the Engine
4) Remove the seal ring from the nozzle hole from the 30. Remove the valve and valve stem seal.
cylinder head.
CAUTION
To remove the injector, unscrew the fuel high-pressure
connector mounting nut to disconnect the fuel
high-pressure connector completely. Then, unscrew the
caliper mounting bolt to remove the injector.
29. Remove the cylinder head.
Valve spring compression jig

Head bolt
EG9OM078-E
Torque wrench
EE1OM052-E
1) Unscrew the cylinder head bolts in the reverse order of

tightening to remove the cylinder head.
• Step 1: Unscrew the bolt for 1 to 2 threads.
EJ9OM042
• Step 2: Unscrew the bolt completely to remove it.
2) Remove the cylinder head bolts in these two steps. 1) Press the valve spring and retainer with the valve spring
3) Keep the removed bolts in order with care, being careful compressor to remove the valve cotter.
not to damage their threads. 2) Remove the valve spring and retainer.
3) Remove the calipers.
CAUTION 4) Use a general service tool to remove the valve stem seal.
Make sure that the bolts are not hit by each other.
CAUTION
4) Remove the cylinder head gasket. Do not reuse the valve stem seal.
5) Remove foreign materials from the surface of the cylinder
head and block. 5) Remove valve.
6) Unscrew the mounting bolt of the lifting hook from the
CAUTION cylinder block to remove the lifting hook.
Be careful not to damage the mating surface.
6) Unscrew the mounting bolt of the lifting hook from the

cylinder head to remove the lifting hook.
67
5. About the Engine
31. Remove the oil cooler. 1) Remove the oil seal using a oil seal removing tool.
2) Unscrew the gear case cover mounting bolt to remove
the oil seal cover.
Oil cooler 34. Remove the oil pump and disconnect the pipe.
EK1OM050
1) Unscrew the oil cooler mounting bolts to remove the oil

cooler.
32. Remove the oil pan. EE1OM086
1) Unscrew the oil suction pipe mounting bolt to remove the

bracket.
2) Unscrew the oil pump pipe mounting bolts to disconnect
the suction pipe and feed pipe.
3) Unscrew the oil pump mounting bolts to remove the oil
pump.
35. Remove the flywheel.
Oil pan
Gasket
EK1OM051-E
1) Unscrew the oil pan mounting bolts to remove the oil pan.
2) Remove the oil pan gasket.
33. Remove the front oil seal and cover.
EJ5OM013
Oil seal 1) Unscrew the flywheel mounting bolts and install the guide
Oil seal cover bolt to remove the flywheel.
2) Unscrew the bolts in the reverse order of their tightening
Gasket
to remove the flywheel.
EK1OM052-E
68
5. About the Engine
36. Flywheel housing. 38. Remove the timing gear case.
EJ5OM014 EJ9OM049
1) Unscrew the flywheel housing mounting bolts to remove 1) Unscrew the timing gear case mounting bolts.
the flywheel housing. 2) Tap the left and right sides on the back of the contact
2) Remove the flywheel housing oil seal. surface of the timing gear case with a urethane hammer
37. Remove the cam gear and idle gear. gently to remove the timing gear case.
39. Remove the piston and connecting rod.
EK4OM062
1) Unscrew the camshaft gear mounting bolts to remove the EFM2026I
camshaft gear. 1) Unscrew the connecting rod cap bolts in the reverse
2) Unscrew the idle gear mounting bolts to remove the idle order of their tightening.
gear. Note) Unscrew these bolts in two steps as the cylinder head
bolts.
2) Tap the top and bottom of the connecting rod cap with a
urethane hammer lightly to remove the bearing cap and
bearing.
3) Push the connecting rod from the oil pan side toward the
cylinder head with a wooden stick to separate the piston
assembly.
4) Keep the removed pistons in the corresponding cylinder
order and make sure that they are not hit by each other.
5) Install the connecting rod caps to their corresponding
connecting rods loosely. Be careful not to mix them.
69
5. About the Engine
40. Remove the piston. 41. Remove the bearing cap.

1) Remove the snap ring of the piston pin using pliers.
EK4OM064
EA3M2029
1) Unscrew the bearing cap mounting bolts in the reverse
order of their tightening to remove the bearing cap.
2) Tap the piston pin with a wooden stick gently to remove
Note) Unscrew these bolts with the same method for the
the piston.
cylinder head bolts.
2) Keep the bearing caps in order.
42. Remove the crankshaft.
EAMD088I
3) Remove the piston ring using piston ring pliers.

EI4OM090
1) Fit the bolts to both sides of the crankshaft temporarily.

2) Connect a rope to the bolts and lift the crankshaft with a
crane. Be careful not to damage the crankshaft.
3) Store the removed crankshaft on a safe special shelf so
that it is not deformed or damaged.
4) Remove and store the main bearings in order.
CAUTION
• Make sure that the main bearing and bearing caps
are not mixed.
• Fit the main bearings to their bearing caps temporarily
EH4OM048 to prevent mixing.
4) Remove carbon from the piston completely and clean it.
70
5. About the Engine
43. Remove the oil spray nozzle. 45. Remove the cylinder liner.
EK4OM065 EJ9OM052
1) Unscrew the oil spray nozzle valve mounting screw to 1) Be careful not to damage the cylinder block when
remove the oil spray nozzle. removing the cylinder liner.
44. Remove the camshaft and tappet. 2) Remove the cylinder liner with its removing tool and
hands.
EK4OM066
1) To prevent damage of the camshaft, pull it out while

turning it.
2) Store the removed camshaft on a safe special shelf so
that it is not deformed or damaged.
3) Remove the tappet.
CAUTION
Check for damage, scratch and wear. If any abnormal
condition is found, replace it.
71
5. About the Engine
Engine Assembly
Engine Assembly Sequence 4) Apply engine oil to the inside of the cylinder liner.
3. Install the oil spray nozzle.
CAUTION
• Clean all the removed parts thoroughly. Especially,
clean the oil and coolant passages with compressed
air thoroughly to eliminate any restriction.
• Organize general tools and special service tools for
engine assembly.
• Prepare clean engine oil to apply onto moving parts.
• Prepare service parts, such as sealant and gasket.
• Replace any used gasket, seal ring and consu ables
with new ones.
• Each bolt should to tightened to the specified torque
according to the tightening order. Never over-tighten
it.
EK4OM065
• After installing the engine components, check their
proper operation. 1) Align the oil spray nozzle with the groove of the cylinder
• After primary assembly, check if any bolt is loose. block using the oil spray nozzle installing jig.
• Keep your hands clean at all times during work. 2) Install the relief valve.
3) Tighten the mounting bolt to 4.5 kgf.m.
Assemble the engine according to the following procedure: 4. Install the crankshaft.
1. Install the cylinder block. 1) Make sure to align the holes of the main bearing with the
1) Place a wooden block or thick paper on the ground of the machined oil holes (2 ea) on the cylinder block during
working area to prevent damage of the cylinder head installation.
mounting surface. Then, set the head mounting surface
toward the ground.
2. Install the cylinder liner.
7 5 3 1 2 4 6
EH6OM062
EE1OM061
1) Stand the cylinder block with its flywheel side facing the
ground.
2) Clean the flange mounting surface and inside of the liner
with compressed air thoroughly.
3) After cleaning the cylinder liner, dry it completely and
insert it into the cylinder block with hands.
72
5. About the Engine
5) Apply engine oil to the pin and journal of the crankshaft.

6) After oil application, install the thrust washer with its oil
groove facing the outside.
Key groove
Oil port and passage
EA0M4083-E
2) Apply clean engine oil to the bearing surface.

3) Heat the wear ring at 150°C for 10 minutes with a heater
and install this front wear ring using an assembly jig. EAMD076S
7) Install the bearing and thrust washer to the bearing cap.
EE1OM076
4) Fit the bolts to both sides of the crankshaft temporarily. EAMD077I

8) Apply oil to the bearing and thrust washer.
Then, place the crankshaft on the cylinder block using the
9) Install the bearing caps correctly by matching their
mounting bolts.
numbers with the cylinder block numbers.
EI4OM090
73
5. About the Engine
10) Tighten the bearing cap bolts to the specified tightening 5. Install the tappet and camshaft.
torque in the specified order.
Tightening order
1 2 3 4 5 6 7
Bearing cap
EAMD072S
EH8OM018-E 1) Cool a new bushing in dry ice for approx. 2 hours.
2) Press the new bushing into the cam bushing position of
the cylinder block using a bench press.
3) After pressing it in, measure the inside diameter of the
cam bushing to check for its deformation.
4) Apply engine oil to the face of the tappet and insert the
tappet into its hole of the cylinder block.
5) Apply engine oil to the camshaft hole and camshaft
journal sections of the cylinder block.
6) Insert the camshaft into its hole of the cylinder block.
6. Install the timing gear case.
EH8OM017
11) Tighten both bolts evenly to set the bearing cap tight.
12) Tighten the bolt according the following steps with a
torque wrench:
• Step 1: Tighten the bolt to 5 kgf.m until it is tightly set
against the surface.
• Step 2: Tighten it to 15 kgf.m with a torque wrench.
• Step 4: Tighten it to 30 kgf.m with a torque wrench for the
final time.
13) Tighten the bearing caps in the following order: EJ9OM049
4-3-5-2-6-1-7. 1) Install the gasket to the cylinder block using a reference

14) Rotate the installed crankshaft for 2 to 3 turns to check its pin.
free motion. 2) Align the pin hole of the timing gear case with the refer-
ence pin.
3) Install the timing gear case to the cylinder block.
4) Set it tightly against the cylinder block by tapping its left
and right with a urethane hammer.
5) Tighten the relief valve to 2.6 kgf.m.
74
5. About the Engine
6) Tighten the timing gear case mounting bolts to 4.4 kgf.m. 2) Install the cam gear, aligning it with the pin hole of the
camshaft.
CAUTION 3) Tighten the camshaft thrust washer to 1.0 kgf.m.
4) Tighten the camshaft gear mounting bolt to 3.1 kgf.m.
When tightening the bolts, tighten the bolts on both
ends first and tighten the remaining bolts.
CAUTION
7. Install the fuel high-pressure pump. When installing the gears, install the camshaft gear, idle
gear, fuel high-pressure pump idle gear and fuel
high-pressure pump in this order.
5) Install the idle gear while aligning the marks on the crank-
shaft gear, camshaft gear and idle gear.
Fuel high pressure

pump gear
High pressure
pump idle gear
Fuel high pressure

pump idle gear
Idle gear(A, B)
EE1OM078-E Camshaft gear
1) Install the fuel high pressure idle gear and air compressor
Oil pump gear
idle gear onto the timing gear case. Crankshaft gear
2) In case of the disassembly of all sorts of the gear, check
the position of the bolts, and assemble it to the correct
position. EK4OM076-E
• Gear mark
M8(10.9T) 3.1 kg.m
Torque M8(10.9T) 3.1 kg.m Crankshaft Gear -

''0'' and ''0''
Idle Gear (A)
M10(10.9T) 6.0 kg.m
Camshaft Gear -
''2'' and ''1''
Idle Gear (B)
8. Install the gear system.
6) Tighten the step idle gear to 6.2 kgf.m.

7) Tighten the fuel high-pressure pump idle gear to 6.2 kgf.m.
Thrust washer
8) Use a feeler gauge to check the backlash and end play of
the gear.
• Backlash
Camshaft gear
Measuring Position Standard (mm)
Camshaft Gear and Idle

0.054 ~ 0.14
Gear
Idle gear Fuel High-pressure Pump

0.054 ~ 0.14
Gear and Idle Gear
Crankshaft Gear and Oil

0.073 ~ 0.178
Pump Drive Gear
EE1OM079-E
1) Install the thrust washer to the camshaft.
75
5. About the Engine
9. Install the flywheel housing. 11. Install the flywheel.

1) Heat the ring gear with a gas burner evenly to expand it.
Gasket Then, install it with a hammer.
Fixing bolt
Oil seal
EJ5OM015-E
1) Install a guide bar to the cylinder block temporarily.

2) Install the gasket to the cylinder block. EA0M4029
3) Use a dowel pin and guide bar to install the flywheel
housing.
CAUTION
4) Tighten the mounting bolts to 11.2 kgf.m in the specified
order. • Make sure that the temperature of the ring gear does
5) Remove the guide bar. not exceed 200°C.
6) Apply a thin film of engine oil to the outer surface of the • When installing the wear ring, heat it to 150°C with a
oil seal and fit this seal into the flywheel housing. heater, and apply LOCTITE #262 to it, and use an
10. Install the rear oil seal. assembly jig to install it.
2) The front of the wear ring can be identified by the

mounting surface on the outer skirt.
Oil seal jig
EA8M3003-E
1) Align the oil seal with the crankshaft.

2) Install the oil seal using its jig.
EJ5OM016
3) Fit a guide bar into the crankshaft bolt hole.

4) Align the flywheel with the reference pin to install it
temporarily.
5) Apply adhesive (LOCTITE #587) to the mounting bolt.
6) Fit the bolts that have no guide pin in their holes. Then,
remove the guide pin and fit the remaining bolt.
76
5. About the Engine
2) When installing the piston and connecting rod, the weight

controlling section at the small end of the connecting rod
and the oil gallery inlet (big hole side) of the piston should
face the opposite direction.
3) Apply oil to the pin hole of the piston and align this hole
with the small end of the connecting rod. Then, tap the
piston pin with a rubber hammer gently to install the
connecting rod and piston.
EJ5OM017
7) Tighten the bolts (M14 x 1.5) to 15 kgf.m in the specified

order.
1
EAMD088I
8 6
4) The openings of the snap rings should be set in the oppo-
3 4 site direction (upwards and downwards).
5 7
2
EE1OM081
12. Install the piston and connecting rod.

1) Heat the piston to approx. 100°C with a heater for 5
minutes. CAUTION :
Direction of snap ring is assembling
to be positioned the opposite side
Piston heater
EE2OM072-E
5) Install the snap ring. Check its mounting condition.
EA3M2058-E
77
5. About the Engine
6) Use piston ring pliers to install the piston ring to the

piston.
2nd ring Oil ring
Top ring
2nd ring
Oil ring Piston
Piston
Top ring
EE1OM083-E
9) Install the connecting rod bearing while aligning it with the

EE1OM082-E key groove. Then, apply oil to the bearing and piston.
7) Make sure to install the piston ring in the correct direction. 10) Fit the piston so that the oil gallery inlet of the piston is in
The mark "Y" or "TOP" on the ring connection should face the same direction with the spray nozzle.
up. 11) Use a piston inserting tool to insert it into the cylinder
liner. Be careful not to damage the ring by the tip of the
liner.
CAUTION
Make sure that the cylinder liner and piston are not
damaged.
View from crankshaft pulley

"Y" or "TOP"
EAMD090I-E
8) Adjust each piston ring connection angle to 120° and fit a

piston inserting jig into the piston.
CAUTION Piston oil gallery

Spray nozzle
The connection of the piston ring should not be in the
same direction with the pin.
EE1OM085-E
12) Fit the bearing to the connecting rod cap and apply oil on
it.
78
5. About the Engine
13) Check that the manufacturing serial numbers stamped on 17) Shake the bearing cap with a hand. If it does not move,
the connecting rod cap and connecting rod big end are loosen and tighten it again.
the same.
Install the opening part of

the snap ring on the opposite
side of upper/lower side
Same number marking position
EK4OM001-E EAMD094I
14) Install the connecting rod cap while aligning it with the 13. Install the oil pump and oil pipe.
reference pin.
15) Apply oil to the mounting bolt and install the bolt loosely.
16) Tighten the bolts to the specified tightening torque in the
specified order using a torque wrench.
• First stage: Coat engine oil over bolts.
• Second stage: For the assembly of the connecting rod
bolt, assemble with your hand until the head of the bolt
contacts both sides of the bolt surface of the connecting
rod, and then use the Torque wrench to tighten the bolt.
• Third stage: With torque wrench, tighten up to about
10 kg.m.
• Fourth stage: With torque wrench, tighten up to about
15 kg.m.
• Fifth stage: With torque wrench, tighten finally up to
18 kg.m.
EE1OM086
1) Install the reference pin to the bearing cap No. 7.

2) Tap the oil pump with a urethane hammer gently to install
it.
3) Fit the washer and tighten the mounting bolt (M8) to
2.2kgf.m.
4) Connect the oil feed pipe to the oil pump with the bolt.
79
5. About the Engine
14. Install the front oil seal. 4) Tighten the bolts (4 ea) on both ends of the oil pan first
and tighten the remaining bolts.
5) Tighten the oil pan mounting bolt to 3.1 kgf.m.
Oil seal
Oil seal cover CAUTION

Gasket Align the bolt holes with the gasket holes before tight-
ening the bolts.
6) Tighten the drain plug to 10 kgf.m.

16. Install the crankshaft pulley and vibration damper.
EJ9OM048-E
1) Apply engine oil to the inside of the oil seal before

installing the oil seal to the cover.
2) Align a new oil seal with the center of the hole on the oil
seal cover.
3) Use an installing jig to install the oil seal.
4) Tighten it to 2.2 kgf.m.
15. Install the oil pan.
EJ9OM047
1
8 6
3 4
5 7
2
Oil pan
Gasket
EJ9OM046-E Bolt tightening order
1) Remove any protruded gasket on the timing gear case, EE1OM155-E

cover, cylinder block and flywheel housing contact
1) Install the vibration damper to the crankshaft pulley.
surface with a scraper thoroughly.
2) Tighten the bolts in the correct order.
3) Tighten the vibration damper to 6.2 kgf.m.
CAUTION 4) Tighten the crankshaft pulley to 20 kgf.m.
Make sure any gasket does not enter the engine during
work.
2) Apply silicon on the surfaces where the used gasket was

removed. Then, attach a new oil pan gasket.
3) Install the oil pan.
80
5. About the Engine
17. Install the intake and exhaust valves. 3) Align the new gasket bolt hole with the reference pin on
1) Before installing the valve to the cylinder head, check the the cylinder block.
marks "I" and E" on the valve head surface. 4) When installing the gasket, its mark on the right should
be upwards.
CAUTION
Replace the gasket with a new one.
Valve marking position
Intake valve Exhaust valve
EE1OM156-E
Model number mark
2) Use a valve stem seal installing jig to install the valve
stem seal to the valve guide. Manufactured date
3) Install the valve cotter by pressing the retainer with a
valve spring compressing tool after installing the valve
spring and retainer. EK4OM002-E
5) Check if there is any foreign material in the combustion

chamber.
6) Install the cylinder head by aligning it with the retaining
pin.
CAUTION
• Be careful not to damage the gasket.
• If the pin hole cannot be aligned, lift the head and
then try to seat it again.
Valve spring compression jig 7) Install the cylinder head bolt.
EG9OM078-E
Head bolt
4) Tap the valve stem with a rubber hammer gently to check
if the valve is corrected installed.
18. Install the cylinder head. Torque wrench
1) Blow compressed air through the bolt hole of the cylinder
head to remove any foreign materials.
2) Clean the gasket mating surface of the cylinder head
thoroughly.
CAUTION
Ensure that no foreign material enters the combustion
chamber. EE1OM052-E
81
5. About the Engine
8) Tighten the cylinder head bolts to the specified tightening 20. Install the injector.
torque in the specified order.
Injector type Bolts
Fixing bracket
21 25
26
13 17
O-ring
5 9 18 22
4 1 14 Seal ring
10
12 8 2 6
20 16 7 3
24 15 11
19
23
EK4OM055-E
EE1OM087
• Step 1: Tighten it for 1 to 2 threads with a hand, and then CAUTION

tighten it to 4 kgf.m temporarily.
• Clean all parts thoroughly and make sure that no
foreign material enters any part.
• Step 3: Tighten it for 90° with a torque wrench.
• Especially, the fuel line between the common rail and
• Step 4: Tighten it for 90° with a torque wrench.
injector is not equipped with a filtering function.
• Step 5: Tighten it for 90° with a torque wrench for the final
Therefore, this section should be kept clean with care.
time.
• Clean the drilling of the head for the fuel high-pres-
sure connector and the hole for the injector thor-
CAUTION oughly to remove any foreign materials from them.
All the bolts should be tightened according to the above • If the injector is removed, the fuel high-pressure
steps. connector should be replaced with a new one.
• If fuel collected in the fuel return line enters the
combustion chamber during injector disassembly
19. Install the push rod.
process, remove fuel by sucking it out with a hand
pump or by cranking the engine with fuel flow
blocked.
1) Install the injector correctly according to the following

steps:
Injector
High pressure connector

1 , 2
3 5
EK4OM054 Coat the engine oil on O-ring

(Be careful not to allow the engine
1) Apply engine oil to the push rod.

oil to go into the hole for high
pressure connector)
2) Insert the push rod into the push rod hole of the cylinder
Lubricant positions
- O-ring
- Hold down shoulder
head. - Thread of fixing nut
EG9OM130-E
82
5. About the Engine
2) Fit the O-ring to the injector and apply engine oil to the 9) Align the fuel high-pressure connector through the hole
outer circumference surface. on the side of the head, and push in the fuel high-pres-
sure connector enough.
CAUTION 10) Tighten the mounting nut (M22 x 15) of the fuel high-pres-
sure connector for 2 ~ 3 threads with a hand.
Make sure that oil or foreign material is not on the fuel 11) Tighten the injector mounting bracket bolt to 0.3 kgf.m
high-pressure connector hole on the side of the injector. with a torque wrench.
12) Tighten the injector mounting bracket bolt to 1.5
3) Align the seal ring with the injector hole on the cylinder +0.5 kgf.m using a torque wrench.
head. Then, insert the injector gently. 13) Tighten the injector mounting bracket mounting bolt (4) to
4) Align the injector mounting bolt with the thread of the 3.1 ~ 3.5 kgf.m
head. Then, tighten the bolt for 2 ~ 3 threads with a hand.
5) Set the injectors to the mounting positions of the injector
mounting brackets (1 & 2) with the mounting bolts. Then, Final tighten the fixing bolt of injector
with specified torque
tighten them temporarily.
Install the injector with pre-tightening

4
torque and then loosen the fixing bolt.
Assemble the seal ring for

1 , 2 the contacted surface it.
Final step : final assemble injector with

specified torque
EG9OM132_1E
14) Tighten the fuel high-pressure connector mounting nut

1st step : Installing injector & pre-tightening (5) to 5 ~ 5.5 kgf.m.
EG9OM131_1E
6) After tightening the injectors temporarily, unscrew the Final tighten the fixing nut of
bolts of the mounting brackets enough to move the injec- high pressure connector with
specified torque
tors freely without load.
7) Set the fuel high-pressure connector (3) with its balls set
vertically.
5
Mount the high pressure

connector and then
assemble the fixing nut
with pre-tightening
Final step : final assemble high pressure

connector with specified torque
3
EG9OM132_2E
2nd step : Installing high pressure connector

& temporarily assembling
EG9OM131_2E
8) Ensure that it is aligned with the groove in the hole on the

side of the head on the intake manifold side.
83
5. About the Engine
21. Install the rocker arm. 22. Install the intermediate cover.
1) For rocker arm assembly, install the spring, rocker arm,
bracket, rocker arm, spring, washer and snap ring in
order.
CAUTION
Install the rocker arm and bracket in the same direction.
EK4OM022
1) Install a new gasket to the intermediate cover.

23. Install the cylinder head cover.
Cylinder head cover

EK4OM021
2) Apply oil to the rocker arm bushing and shaft.

3) Use the mounting bolts to install the rocker arm and
bracket onto the cylinder head.
4) Tighten the bolts to 6.2 kgf.m diagonally.
5) Install the valve clearance adjusting screw to the rocker
arm temporarily.
EJ9OM103-E
1) Install a new rubber gasket to the cylinder head cover.

2) Install the cylinder head cover to the cylinder head.
4) Install the oil filler cap to the cylinder head cover.
EK4OM053
6) Adjust the valve clearance.
84
5. About the Engine
24. Install the oil cooler. 26. Install the coolant pump.
1) Install the coolant pump cover and coolant pump gasket.
2) Install the coolant pump to the cylinder block.
Oil Cooler
coolant pump
EJ9OM044-E
1) Install the oil cooler and gasket to the cylinder block.

EJ9OM033-E
CAUTION
Make sure to install the gasket in the correct direction.
2) Tighten the bolt to 2.2 kgf.m.

25. Install the oil filter.
Oil cooler
EK4OM049

Oil filter 4) Install the idle pulley bracket.
27. Install the start motor.
EA5OM006-E
1) Install the oil filter cartridge using a special service tool.
CAUTION
The oil filter should be installed to the engine without oil
in it. Never fill the new oil filter with oil drained from the
used oil filter.
EJ9OM094
85
5. About the Engine
1) Install the start motor to the stud bolt of the flywheel 1) Install a new gasket between the cylinder head and
housing. intake manifold.
2) Tighten the mounting nut to 8.0 kgf.m. 2) Tighten the mounting bolt to 4.4 kgf.m.
28. Install the common rail and high-pressure pipe. 30. Install the exhaust manifold.
1) Install the exhaust manifold gasket to the stud bolt of the
cylinder head.
Projection face
EK1OM006
1) Install the common rail to the cylinder block.

2) Connect the fuel feed pipe between the common rail and FG001341-E
fuel high-pressure connector.
2) Align the gas outlet of the cylinder head with the gasket
3) Tighten the fuel high-pressure pipe on the common rail
hole.
side to 3.0 kgf.m.
3) Install the exhaust manifold.
4) Tighten the fuel high-pressure pipe on the fuel high-pres-
sure connector side to 3.0 kgf.m.
Exhaust manifold
5) Tighten the common rail fuel high-pressure pipe from the
fuel high-pressure pump to 3.0 kgf.m.
6) Tighten the common rail mounting bolt to 2.2 kgf.m.
CAUTION
• Never reuse the fuel high-pressure pipe.
• Tighten the fuel high-pressure pipe to the specified
torque for a cylinder by cylinder.
29. Install the intake manifold.
EJ9OM034-E
Intake manifold 4) Tighten the mounting bolt to 8.0 kgf.m.
EK1OM005-E
86
5. About the Engine
31. Install the turbocharger. 33. Install the HC (Hydro-Carbon) injector.
EJ9OM029 EK1OM007
1) Install a new gasket to the stud bolt of the exhaust mani-

fold.
2) Install the turbocharger.
3) Connect the oil feed pipe and drain pipe.
4) Tighten the clamp for the rubber hose to connect the air
pipe and turbocharger.
32. Install the coolant pipe and thermostat.
cylinder head Thermostat EK1OM008
1) Install the HC injector to the exhaust pipe with its

mounting bolts.
2) Install the cooling hose to the HC injector.
3) Connect the HC injection pipe.
34. Install HC dosing metering unit.
Cooling water
pump
EJ9OM040-E
1) Install the gasket to the cylinder head.

2) Install the housing to the thermostat.
3) Install the O-ring to the thermostat.
4) Connect the coolant pipe.
5) Tighten the bolt to 2.2 kgf.m.
EK4OM106
87
5. About the Engine
1) Install the HC dosing metering unit to the bracket with the 36. Install the EGR valve.
mounting bolts.
2) Install the cover for the HC dosing metering unit with the
mounting bolts.
3) Connect the HC dosing pipe.
35. Install the EGR cooler.
EJ9OM019
EJ9OM021
EJ9OM020
1) Install the exhaust pipe to the EGR cooler with the gasket
and secure it with the mounting bolt.
2) Install the EGR valve to the exhaust pipe with the gasket
and secure it with the mounting bolt.
EJ9OM022
1) Install the EGR cooler mounting bracket to the cylinder

CAUTION
head with the mounting bolts.
2) Install the EGR cooler to the bracket with the mounting Do not reuse the gasket.
bolts.
3) Connect the pipe and hose to the EGR cooler.
CAUTION
Do not reuse the gasket.
88
5. About the Engine
37. Install the ECU (Electrical Control Unit).
EJ9OM081
EK4OM023 1) Fuel needs to flow through the following components in
1) Fix the ECU mounting plate. this order: fuel feed pump, fuel filter, fuel high-pressure
2) Install the ECU. pump and common rail. Connect the fuel feed pipe
38. Install the crankshaft speed sensor and camshaft speed correctly according to the arrow direction mark on the
sensor. head of the fuel filter to ensure correct fuel flow.
2) Tighten the fuel pipe to 3.0 kgf.m.
3) Tighten the fuel temperature sensor to 2.2 kgf.m.
4) Tighten the mounting bracket to 4.4 kgf.m.
Crankshaft speed sensor

CAUTION
Adjusting shim
A new fuel filter should be installed without fuel in it.
Never add fuel in the used fuel filter or fuel tank to a new
fuel filter.
40. Install the alternator and belt.
EJ5OM019-E
1) Measure the clearance between the mounting section of Water Pump

the crankshaft speed sensor and flywheel. Use shims to
adjust this clearance to 1.0 mm.
2) Tighten the crankshaft speed sensor to 1.0 kgf.m.
Belt
3) Measure the clearance between the mounting section of
the camshaft speed sensor and timing gear. Use shims
Crank Pulley
to adjust this clearance to 1.0 mm.
4) Tighten the camshaft speed sensor to 1.0 kgf.m.
Air compressor
39. Install the fuel filter.
EK1OM017-E
1) Install the alternator and A/C bracket. Then, secure them

with the mounting bolts.
2) Install the alternator, A/C compressor and idle pulley.
3) Tighten the alternator mounting bolt to 8.0 kgf.m.
4) Tighten the alternator support mounting bolt to 4.4 kgf.m.
89
5. About the Engine
5) Install the belt and adjust its tension with its adjusting 45. Add engine oil.
bolt. 1) Open the oil filler cap on top of the cylinder head cover
41. Connect the air pipe and install the air heater. and add engine oil to it.
CAUTION
Make sure to use the recommended genuine oil.
46. Add coolant.

1) Open the radiator cap and add coolant.
CAUTION
Make sure to use the recommended coolant.
EK4OM044
1) Install the air pipe, air heater and throttle valve.

CAUTION
Never let foreign materials enter the turbocharger.
42. Fit the dipstick.
EK4OM082
1) Apply adhesive (LOCTITE #262) to the guide tube.

2) Install the guide tube and dipstick to the oil pan.
43. Connect the cables and harnesses of the engine to each
sensor.
44. Mount the engine to the machine.
90
6. Cooling System

Failure Diagnosis ....................................................................................................................94
Thermostat ..............................................................................................................................95
Cautions for Replacement and Handling of Thermostat ................................................................................. 95
Thermostat Inspection .................................................................................................................................... 95
91
92
6. Cooling System
General Information
General Information After this coolant absorbs oil heat and combustion heat, it is
This engine is a water-cooled type. Combustion heat from led to the thermostat through the coolant pipe. If the coolant
the combustion chamber and heat from engine oil are temperature is below the valve opening temperature of the
absorbed by coolant and dissipating them to the outside air thermostat, the coolant flows into the coolant pump. If the
to ensure optimum engine operation. temperature is over the opening temperature, it flows into the
In the cooling system, coolant supplied from the coolant radiator. In the radiator, it releases heat and returns back to
pump is sent to the oil cooler through the coolant pipe to the coolant pump in a low temperature condition again.
absorb heat from oil before it passes through the coolant
jacket of the cylinder block and through the cooling passage
of the cylinder head to absorb combustion heat.
Turbo charger actuator
Thermostat Cylinder head

Radiator
EGR
Cylinder block EGR valve
cooler
HC dosing
Water pump Oil cooler
injector
EK1OM072
93
6. Cooling System
Failure Diagnosis
Phenomenon Causes Troubleshooting
Not enough coolant Replenish the coolant
Defective radiator cap Replace it
Contaminated radiator Clean the exterior of the radiator
Defective V-belt offset Adjust or replace it
Contaminated or damaged V-belt Replace it
Damaged impeller Replace the water pump

Overheated Engine
Defective impeller fix Replace the water pump
Bad water pump operation Replace it
Bad thermostat operation Replace it
Bad coolant flow Clean the coolant path
Improper injection time Check it with the failure diagnosis unit
Damaged cylinder head gasket Replace it
Bad thermostat operation Replace it

Overcooled Engine
Too low ambient temperature Heat the block
Damaged radiator Repair or replace it
Loosened or damaged radiator connection Repair or replace the connection
Defective radiator cap Replace it
Badly mounted water pump Repair or replace it
Leaking Coolant Bad or damaged water pump gasket Replace the gasket
Badly mounted thermostat Repair or replace it
Bad or damaged thermostat gasket Replace the gasket
Damaged cylinder head gasket Replace the gasket
Damaged cylinder head or block Replace it
Bad water pump bearing Replace the bearing
Bad or damaged cooling fan Repair or replace it

Noise
Bad rotation of the cooling fan Replace it
Defective V-belt offset Adjust or replace it
94
6. Cooling System
Thermostat
General Information Cautions for Replacement and Handling of

The thermostat maintains water temperature in the engine Thermostat
consistently and prevents heat loss to improve heat effi- 1. Cautions for handling
ciency of the engine. A wax pellet type thermostat features relatively slow
When the coolant temperature is below the normal tempera- response for change in coolant temperature compared to
ture, the thermostat is closed and the coolant is bypassed a bellows type. This is because the wax pellet type has
and directly flows into the water pump. When the coolant larger thermal capacity. Therefore, it needs to idle the
temperature reaches the normal temperature or is higher engine sufficiently before running it in order to prevent
than the temperature, the thermostat is fully open and the surge of engine coolant temperature. In cold weather,
never overload the engine or speed drive.
bypass circuit is closed. So the coolant flows into the radiator.
2. When adding or draining coolant to/from the engine
cooling system, do it slowly to let air in the system
CAUTION escape.
• The wax pellet type thermostat shows slower 3. Thermostat replacement
response to the change of cooling water than the If any defect is found on the thermostat, replace it with a
bellows type thermostat. This happens because the new one.
heat capacity of the wax pellet type thermostat is
larger than that of the bellows type thermostat. Thermostat Inspection
Therefore, to prevent a rapid increase in the engine 1. Check if the wax pellet and spring are damaged.
coolant’s temperature, you must first operate the 2. Put the thermostat into water and heat the water gradually
engine at idle until the engine is fully warmed up. to check for operation of the thermostat. If the thermostat
When the weather is very cold, do not operate the starts to open at 83°C (water temperature) and it is fully
engine in an overloaded condition or at a high speed open at 95°C, it is normal.
after starting the engine.
• When draining water from the engine cooler or
injecting water to the engine cooler, work slowly to
ensure that all air inside the cooler is expelled.
• When a defect is found in the thermostat, replace it Ruler
Thermometer
with a new one.
Wood plate
1
EFM2055IE
3. Check if there is any foreign material in the thermostat.

4 Note) Clean the inside of the thermostat using a air gun.
2
4. Check the hose for internal or external damage or foreign
3
materials.
EDL022060A
1. Heat Exchanger 3. Water Pump

2. Bypass Valve 4. Coolant Pipe
95
6. Cooling System
96
7. Lubrication System

Failure Diagnosis .......................................................................................................................................... 100
Oil Pump ...............................................................................................................................101
General Information ...................................................................................................................................... 101
Oil Pump Disassembly and Assembly .......................................................................................................... 101
Oil pump inspection ...................................................................................................................................... 101
97
98
General Information
General Information Also, as the turbocharger is connected to the engine lubrica-

This engine is a forced lubrication type. Oil pressure is gener- tion circuit, it receives oil for engine brake operation.
ated and supplied by rotation of the oil pump gear which is Lubricant is sprayed around the cylinder block and timing
engaged with the crankshaft gear on the back of the cylinder gear. Each cylinder is equipped with its own oil spray nozzle
block. to cool down the internal section of the piston.
The oil pump receives oil from the oil pan through the suction Engine oil is filtered by the oil filter.
pipe to send it to the main passage of the cylinder block
through the oil filter and oil cooler. Then, it is distributed to the
crankshaft bearing, camshaft bearing and rocker arm for
lubrication.
Turbo charger
Oil spray nozzle

Rocker arm shaft
(for piston cooling)
Oil cooler
Air compressor
Oil filter
(bypass valve 2.1 bar)
Camshaft bush
Oil pressure adjustment valve

(5bar)
Oil pump Oil pump relief valve

(10bar)
EK1OM015-E
99
Failure Diagnosis
Bad oil Replace oil with specified oil.
Oil leakage from the oil seal ring and packing

Replace it
part
Worn or damaged piston and piston ring Replace it

Too much Oil Consumption
Worn cylinder liner Replace it
Burnt piston ring Replace it
Worn valve guide oil seal, valve guide, or

Replace it
valve stem
Burnt oil pump relief valve Replace it
Clogged oil pump strainer Cleanse the strainer
Worn oil pump gear Replace it

Low Oil Pressure
Cracked oil delivery pipe of the oil pump Replace it
Defect oil pump Repair or replace it
Oil pressure gauge fault Repair or replace it
Worn bearings Replace it
Clogged oil filter Replace the oil filter with a new one
Contaminated Oil Gas leakage Replace piston ring with a new one
100
Oil Pump
General Information Oil pump inspection

Engine oil is sucked from the oil pan by the gear type oil 1. Use a steel ruler and feeler gauge to measure the axial
pump and then all of the oil is forcibly delivered to the oil play of the oil pump gear. If the measurement is over the
cooler and filter for filtering. The filtered oil passes through allowable limit, replace it.
the main oil path of the cylinder block and lubricates bearing
parts and the turbocharger of the engine in order to maintain
normal engine performance.
Oil Pump Disassembly and Assembly

[Disassembly]
1. Remove the oil pump drive gear.
1) Loosen the screw to remove the oil relief valve. Steel plate
2) Unfold the lock washer of the oil pump drive gear to
remove the mounting nut and washer.
Feeler gauge
3) Remove the drive gear.
2. Unscrew the mounting nut of the oil pump cover to
remove the oil pump cover.
EQM4008I-E
Allowable Limit 0.055 ~ 0.105 mm
2. Use a feeler gauge to measure the backlash between the

drive gear and driven gear of the oil pump. If the
measurement is over the allowable limit, replace it.
Cover fixing bolt

EE1OM142-E
Note) The oil pump cover is fixed

3. To the body with 2 retaining pins.
4. Remove the drive gear and driven gear.
[Assembly]
1. Assemble in the reverse order of disassembly.
EQM4009I
Standard 0.312 ~ 0.476 mm
Allowable Limit 0.64 mm
101
3. Measurement of clearance between drive shaft and

bushing
1) Measure the outside diameter of the drive shaft and drive
shaft. If any measurement is below the allowable limit,
replace the corresponding part.
Standard ø 16.93 ~ ø 16.95 mm

2) Measure the inside diameter of the pump body bushing

and the outside diameter of the shaft. Compare this
measurement with the standard oil clearance value to
determine the necessity of replacement.
Oil Clearance 0.075 ~ 0.127 mm
102
8. Fuel System
General Information ..............................................................................................................105

Fuel High-pressure System Components ..................................................................................................... 106
Injector ..................................................................................................................................106
How to Operate an Injector ........................................................................................................................... 107
Injector Protrusion ......................................................................................................................................... 108
Common Rail ........................................................................................................................109
Fuel Injection Pump ..............................................................................................................111
Fuel Feed Pump ...................................................................................................................113
103
104
8. Fuel System
General Information
General Information As the high-pressure pump produces high-pressure fuel, this

This diesel engine compresses air delivered into its cylinders fuel is kept by the common rail. When a driver operates the
and sprays fuel with its injection nozzles to burn fuel with vehicle, the optimum fuel injection timing and injection
compression heat. amount are determined by the ECU (Electronic Control Unit)
When the high-pressure pump produces high-pressure fuel, based on the preset data, vehicle speed and driving condi-
this fuel is kept by the common rail and its injection timing tion. Then the ECU operates the solenoid valves of the injec-
and injection amount are calculated by the ECU (Electronic tors on each cylinder to inject a proper amount of fuel into the
Control Unit). The ECU (Electronic Control Unit) operates the cylinders.
solenoid valves of the injectors on each cylinder to inject fuel. The fuel tank should be made of non-corrosive material, and
This common rail fuel injection system has the high-pressure the fuel low-pressure pump should not leak at twice the ope
producing part and the fuel injection part separated. rating pressure. Also, the pressure in the tank should not
The ECU determines the fuel injection amount, injection exceed 0.3 bars.
timing and injection pressure according to the operating
condition of the engine before injecting fuel into the cylinders
in order to ensure optimum engine performance.
Injector
Common rail
Cylinder head
Secondary fuel filter
High pressure fuel pump

(CP 3.3 NH fuel pump)
Primary fuel filter

Electronic Control Unit
(ECU)
Fuel tank
EK1OM013-E
105
8. Fuel System
Fuel High-pressure System Components Injector

The common rail fuel injection system consist of the
low-pressure stage for low-pressure fuel delivery, high-pres- General Information
sure stage for high-pressure fuel delivery, and electronic The injector uses the nozzle to inject fuel to the combustion
control unit. chamber directly. To control the injection, the solenoid valve
1. Fuel high-pressure pump is used. Fuel is delivered as much as required from the open
The fuel high-pressure pump pressurizes fuel up to injector nozzle and the remaining fuel is returned to the fuel
approx. 1,800 bars and sends this pressurized fuel to the tank through the fuel return line. In addition, the fuel which
common rail (pipe shape) through the high-pressure line. has been used to lubricate the high-pressure pump and
2. Common rail returned from the fuel pressure adjustment valve is returned
Even after the injector uses fuel from the common rail to to the fuel tank through the return line.
inject fuel, the fuel pressure in the common rail is still The solenoid valve controls the fuel injection timing and
maintained at a constant level. The common rail pressure amount. The injector works instead of the nozzle and the
sensor detects the fuel pressure while the pressure nozzle holder mounted on the existing engine. Fuel is deliv-
control valve maintains the fuel pressure at the desired ered to the injector through the high-pressure connector
level. The fuel pressure in the common rail is controlled mounted on the cylinder head and then delivered to the valve
to max. 1,800 bars by the pressure control valve. control chamber through the delivery hole.
3. Injector The valve control chamber is opened by the solenoid valve.
As the solenoid valve is operated, fuel flows to the It is connected to the fuel return line via the discharge hole.
injector nozzle which then sprays fuel directly into the The hydraulic force which has been increased by the valve
combustion chamber. control plunger with closed discharge hole exceeds the pres-
When the injector nozzle opens and sprays the sure value of the nozzle needle. As a result, fuel delivery to
commanded amount of fuel, the excess fuel is returned to the combustion chamber is blocked by the force given to the
the tank through the return line. Also, fuel returned from contact surface of the nozzle needle.
the fuel pressure control valve and low-pressure stage When the solenoid valve of the injector is pulled, the
and fuel used to lubricate the high-pressure pump are discharge hole is opened. This lowers the pressure in the
returned back to the fuel tank through the return line as control chamber and the hydraulic power given to the
well. plunger. When hydraulic force is lower than the force given
4. Fuel high-pressure pipe to the nozzle needle pressure, the nozzle needle is opened.
The fuel high-pressure pipe carries high-pressure fuel at Finally, fuel is injected to the combustion chamber through
1,800 bars. Therefore, this pipe is made of special mate- the injection nozzle hole.
rial to be able to withstand the maximum pressure of the The reason that the nozzle needle is controlled by hydraulic
system and fluctuation of high pressure occurred during force is that the power required to open the needle quickly
fuel injection. The high-pressure pipe has 8.0 mm of cannot be directly generated from the solenoid valve.
outside diameter and 3.5 mm of inside diameter. Also, Fuel control amount required to open the nozzle needle is
the fuel high-pressure pipes installed between the added to the fuel amount injected. The used fuel is
common rail and injectors should be in the same length discharged to the fuel return line through the hole of the valve
and they are installed as short as possible. control chamber.
Fuel loss occurs on the nozzle needle, the valve plunger
guide as well as the valve control chamber. The control
leakage fuel and the fuel gathered from the line, which
connects the over flow valve, the high-pressure pump, and
the pressure control valve, is returned to the fuel tank
through the fuel return line.
106
8. Fuel System
How to Operate an Injector 8. The injector is closed. (ending fuel injection)

Injector operation is classified into four operation stages to As soon as the supply to the solenoid vale of the injector
operate the engine and create pressure in the high-pressure is blocked, the valve spring applies force to the armature
pump. downward and the valve ball closes the discharge hole.
1. The injector is closed (high fuel pressure state) The armature consists of two components.
2. The injector is open (starting fuel injection). The armature plate is guided by the driving shoulder and
3. The injector is fully open (injecting fuel). pressed downward.
4. The injector is closed (ending fuel injection). However, in this case, an overspring is used. It is a return
These operation stages are decided by balancing the spring that prevents the force from being applied to the
force given to the injector components. If there is no pres- armature and the valve ball. As the discharge hole is
sure on the common rail or the engine is stopped, the closed, fuel is delivered from the delivery hole and gener-
injector nozzle does not work. ates pressure in the control chamber.
5. The injector is closed (pause state) This fuel pressure is equal to the pressure of the common
Under the pause state that no power is provided to the rail and puts pressure on the valve control plunger
solenoid valve of the injector, the injector does not through the end face of the valve control plunger.
operate. The surface where the discharge hole exists is As a result, the force of the spring is added to the pres-
tightly closed with the valve ball by the force from a valve sure exceeding the pressure of the nozzle chamber.
spring or magnet. High pressure in the common rail is Therefore, the nozzle needle is closed. The speed of
kept by the fuel control valve and the same pressure is closing the nozzle needle is decided by the flow that
generated in the nozzle chamber of the injector. The passes through the delivery hole. As soon as the nozzle
common rail fuel pressure, which is given to the end face needle is positioned to the stop position, fuel injection is
of the valve control chamber of the injector, and the blocked.
injector nozzle spring force are larger than the force to
open the nozzle. Therefore, the injector is closed.
6. The injector is open. (starting fuel injection)
When power is supplied while the injector solenoid valve
is closed, the fuel discharge hole is open by the pulling
force of the solenoid valve. Almost simultaneous with
that, the high current given to the solenoid valve is
reduced to the low current. This is because the air gap of
the electromagnet circuit gets smaller.
Fuel in the valve control chamber flows to the discharge
valve hole on the upper side and then goes into the fuel
tank via the fuel return line. The discharge hole
completely breaks the pressure balance and lowers the
pressure in the valve control chamber. As a result, the
pressure in the valve control chamber is lower than the
nozzle chamber pressure which has been equal to the
common rail pressure. The lowered pressure of the valve
control chamber lowers the force from the control
plunger. So the nozzle needle is open and fuel injection
starts.
7. The injector is fully open. (injecting fuel)
The valve control plunger is stopped at the upper position
because fuel is full as fuel flows from the fuel delivery
hole. At this time, the injector nozzle is fully open and fuel
is injected to the combustion chamber at the pressure
equal to that of the common rail.
107
8. Fuel System
Injector Protrusion
1. Insert the seal ring to the cylinder cylinder head, and
install the injector.
Note) Refer to the engine assembly instruction for installa-
tion steps.
2. Measure the protrusion of the injector from the cylinder
head, and adjust it as necessary.
A (Seal Ring Thickness) 2.0 mm
B (Injector Protrusion) 3.0 mm
Cylinder head Injector
A
B
EE1OM075-E
108
8. Fuel System
Common Rail
General Information Even after the injector uses fuel from the common rail to
This common rail fuel injection system has the high-pressure inject fuel, the pressure pulse in the common rail is still main-
producing part and the fuel injection part separated. tained by the volume of the rail to keep the fuel pressure at a
The ECU determines the fuel injection amount, injection constant level.
timing and injection pressure according to the operating The common rail pressure sensor detects the fuel pressure
condition of the engine before injecting fuel into the cylinders while the pressure control valve maintains the fuel pressure
in order to ensure optimum engine performance. at the desired level. The fuel pressure in the common rail is
The common rail stores fuel under high pressure delivered controlled to max. 1,800 bars by the pressure control valve.
from the high-pressure fuel pump.
High fuel pressure connector
High pressure pipe

Common rail
Common rail pressure

sensor
Fuel high pressure pump
EK4OM007-E
The common rail fuel injection system consists of the • As a driver depresses the accelerator pedal, the ECU
following main components: (Electronic Control Unit) receives information from
1. ECU (Electronic Control Unit) various sensors mentioned above to operate the engine
2. Crankshaft Speed Sensor and vehicle according to the operating condition instantly.
3. Camshaft Speed Sensor Also, the ECU operates the open/closed circuits and
4. Accelerator Pedal Sensor circulation circuit of the vehicle and engine based on
5. Fuel Temperature Sensor such information.
6. Boost Pressure and Temperature Sensor, Oil Pressure
and Temperature sensor
7. Common Rail Pressure Sensor
8. Coolant Temperature Sensor
109
8. Fuel System
• The crankshaft speed sensor detects the engine speed • When the engine temperature is low in cold weather, the
while information from the camshaft speed sensor is ECU receives information from the coolant temperature
used to determine the ignition order. The potentiometer sensor and air temperature sensor to operate the engine
of the accelerator pedal sensor produces an electric ideally based on the current operating condition.
signal to inform the ECU of how deep the pedal is
depressed. Also, the turbocharger and intake pressure
sensor are installed, and the intake pressure sensor is
used to measure the intake air pressure.
Fuel Injection from the Injection Pump Common rail fuel injection
Main injection pressure Max injection pressure Main injection pressure Common rail pressure
Fuel delivery start
Fuel injection start Fuel injection

Injection pressure
Injection pressure
Time T i me
EDL0213004A
The common rail features the injection characteristics as 3. The common rail system is a modular type and has the
follows: following major components for is injection characteris-
1. Compared to the conventional system's injection charac- tics:
teristics, the common rail manages the fuel injection 1) Injector Solenoid Valve (Installed to Cylinder Head)
amount and injection pressure separately to satisfy with 2) Common rail
any engine condition in order to ensure optimum fuel 3) Fuel High-pressure Pump
injection. 4) ECU (Electronic Control Unit)
2. In the initial fuel injection period, i.e. the ignition delay 5) Crankshaft Speed Sensor
from the beginning of fuel injection until the beginning of
combustion, the fuel injection amount should be adjusted
to a low level.
110
8. Fuel System
Fuel Injection Pump
General Information It consists of the nozzle and solenoid valve which is ener-
The fuel high-pressure pump uses a radial shaped piston gized by the ECU when the ignition switch is operated. When
pump to produce high pressure. Pressure is independently the ignition switch is blocked, the solenoid valve ends the
generated during the fuel injection process. The speed of the injection operation. As the switching (opening/closing) oper-
fuel high-pressure pump is directly connected to the engine ation of the injector's solenoid valve is performed by high
RPM, regardless of the transmission's speed ratio. voltage and current, the injectors' solenoid valves are oper-
Compared to the conventional injection system, the common ated in sequence according to the preset value in the ECU.
rail injection system delivers a certain amount of fuel The crankshaft speed sensor and camshaft speed sensor
constantly. are used to detect the engine speed in order to adjust the fuel
The injector is connected to the common rail with the injection timing and the beginning of fuel injection correctly.
high-pressure pipe.
Fuel high pressure valve Fill fuel at 60 ml

before reassemble Fuel
Pump piston
Gear pump outlet
Eccentric cam
Fuel
inlet
Driving shaft Metering unit
Lubrication of driving shaft by fuel

Fuel high pressure line
Fuel low pressure line
EE1OM096-E
1. Function 2. Structure fuel high-pressure pump

1) The fuel high-pressure pump has both low pressure 1) The fuel high-pressure pump has three pump pistons
stage and high pressure stage. It carries high pressure set 120° apart from each other in it to compress fuel in the
fuel under any operating circumstance during the service circumferential direction. As every rotation creates three
life of the vehicle. Also, it supplies a proper amount of fuel compression strokes, the pump drive system's stress is
to the common rail to handle any harsh condition, such as maintained steadily and it needs low driving force. The
abrupt vehicle start or rapid change of pressure in the common rail needs low pump driving force which is only
common rail. The fuel high-pressure pump produces the approx. 1/9 of force required for the conventional pump
system pressure required in the common rail constantly. system.
111
8. Fuel System
3. Operation 5. Fuel high-pressure pumping cut-off valve

1) The fuel feed pump supplies fuel to the high-pressure 1) When the switch of the fuel high-pressure pumping
pump through the fuel inlet and safety valve. Then, this cut-off valve is turned off, the fuel amount delivered to the
fuel is transferred to the high-pressure pump's lubrication common rail is increased. When the switch is turned off,
and cooling circuits through the safety valve. The drive the fuel pumping solenoid valve is pulled, so the pin
shaft is equipped with the eccentric cam to move the attached to an electric magnet keeps the valve open.
pump's piston up and down according to the shape of the Therefore, fuel led into the pumping valve cannot be
cam. compressed during the delivery stroke. As this fuel is
2) If the fuel pressure delivered from the fuel feed pump returned to the low-pressure passage, no pressure is
exceeds the fully open pressure of the safety valve, fuel produced. Since the pumping cut-off valve is operated
moves the pump piston downwards through the intake only with a small amount of force, it is possible to switch
valve of the fuel high-pressure valve to the intake stroke between the delivery phase and cut-off phase at short
position of the pumping chamber. When the pump piston intervals.
passes the B.D.C., the valve is closed. Then, as fuel
cannot escape the pumping chamber, it is compressed
further over the delivered pressure.
3) As soon as the fuel pressure reaches the common rail
pressure, it opens the exhaust valve. Then, this
compressed fuel enters the high-pressure circuit. The
pump piston continues to carry fuel until it reaches the
T.D.C. Then, as soon as the pressure drops, the exhaust
valve is closed. Then, fuel left in the pumping chamber is
depressurized and the pump piston moves downwards
again. When the pressure in the pumping chamber drops
below the pressure of the fuel feed pump, the intake
valve opens and the above steps are repeated.
4. Fuel return
EJ5OM020
1) The fuel high-pressure pump is designed to supply a
large amount of fuel. While the engine is running at an
idle speed or with partial load, excess fuel is returned to
the tank through the pressure control valve.
112
8. Fuel System
Fuel Feed Pump
General Information
The fuel feed pump is located behind the fuel high-pressure
pump and it is a gear driven type. The fuel feed pump draws
fuel from the fuel tank to supply the required amount of fuel
continuously toward the high-pressure pump.
Fuel delivery pump

1. Fuel inlet
2. Driving gear
3. Fuel outlet
1 3
EE1OM095-E
113
8. Fuel System
114
9. Intake/Exhaust System

Turbocharger ........................................................................................................................117
Structure ....................................................................................................................................................... 118
Failure Diagnosis .......................................................................................................................................... 119
How to Maintain Turbocharger...................................................................................................................... 122
Inspection Items During Disassembly/Assembly of Turbocharger................................................................ 124
Turbocharger Inspection ............................................................................................................................... 125
Exhaust Gas Reduction ........................................................................................................127
Aftertreatment Muffler and Catalyst .............................................................................................................. 128
DNox2.2 System ........................................................................................................................................... 129
Urea Tank ..................................................................................................................................................... 130
SM (Supply Module) ..................................................................................................................................... 131
DM (Dosing Module) ..................................................................................................................................... 132
Urea Filter Replacement ............................................................................................................................... 133
DNOx2.2 System Components ..................................................................................................................... 135
Check DNOx2.2 System Failures ................................................................................................................. 135
Urea Quality Characteristics ......................................................................................................................... 137
EGR (Exhaust Gas Reduction) System ................................................................................138
EGR Disassembly and Assembly ................................................................................................................. 140
EGR cooler disassembly and assembly ....................................................................................................... 140
Intake Pipe ............................................................................................................................141
Major Air Heater Specifications..................................................................................................................... 141
115
116
General Information
General Information
This engine is a state-of-the-art engine made of advanced
technologies available to comply with strict emission control,
enhance fuel consumption and reduce emissions.
Turbocharger
General Information
The turbocharger uses heat energy of exhaust gas in the
engine to draw in high density air into the cylinders to
increase the engine power.
Turbine wheel and

shaft assembly
Oil inlet
Compressor housing
Turbine housing
Exhaust gas discharge
Exhaust pipe
Fresh air inlet
Compressor wheel
Oil outlet
Intake manifold
EA0M8001-E
1. Power of the engine is determined by the amount of fuel 4. Supercharging is a process to compress and supply air
supply and the engine's efficiency. into the engine's cylinders. The turbocharger is a device
2. A sufficient amount of air should be supplied to the cylin- to supply extra air for combustion with energy of exhaust
ders to burn fuel completely and convert this energy to gas in the combustion chamber which is usually released
effective work. and disappeared into the air.
3. Power of the engine is actually determined by the size of
the cylinders. The larger the cylinders are, the more the
air is delivered to burn more fuel, resulting in increase of
engine power.
117
5. The turbocharger has the following major functions: 3) Bearings:

1) Turbine: As exhaust gas discharged from the combustion • Thrust bearing: The turbine wheel is applied with axial
chamber passes through the turbine housing, its energy force. This axial force keeps the shaft from moving.
is transferred to the turbine blades to deliver the rotating • Journal bearing: This bearing is a floating type and has
force to the turbine shaft. These series of motions are double oil film on its inside and outside so that it can
occurred in a component called turbine. rotate independently. As its double oil film acts as a
The turbine is equipped with the seal ring and heat shield cushion, the sliding speed on the bearing surface
to prevent exhaust gas from affecting its bearing. becomes lower than the rotating speed of the shaft,
2) Compressor: As it is connected to the same shaft with the ensuring dynamic stability.
turbine, it rotates together to receive rotating force from 4) Seal ring of compressor shaft: The shaft is equipped with
the turbine shaft in order to receive, compress and send the seal plate and seal ring in a dual structure to prevent
air to the intake manifold. This is the basic principle of a leakage of compressed intake air and lubricant.
compressor.
Structure
1 D
2
3
A B
4
E
EAO5008I
1. Impeller Casing A. Intake Air Inlet

2. Turbine Casing B. Gas Outlet
3. Bearing Casing C. Gas Inlet
4. Impeller D. Oil Supply
5. Turbine E. Oil Discharge
118
Failure Diagnosis

Rotating part is contacted Repair or replace it
Unbalanced rotation of a rotor Repair or replace it
Burn Repair or replace it
Loose joint Check or repair it
Deformed or damaged intake unit hose Replace it
Poor clamping state Adjust and tighten the clamp
Replace and check if the impeller of the
Contaminated or damaged air filter
turbocharger is damaged
Leakage of coolant from the turbocharger or oil from the
Replace the hose and the gasket
oil hose
Leakage of gas from the exhaust manifold Replace the gasket or tighten the fixing nut
Noise or Vibration
Poor turbo actuator operation Replace the turbocharger
Leakage from the engine block and the exhaust manifold Check the engine
Check the turbo impeller and the turbo intake
Contaminated blowby gas and abnormal oil amount
outlet
Large gap of the turbocharger wheel, causing interfer- Check if there is any sand or metallic foreign
ence with the wall substance
Check if there is any sand or metallic foreign
Damaged turbocharger wheel
substance
Damaged wheel and shaft of the turbocharger
substance
Poor rotating force of the turbocharger wheel
substance
Leakage of gas from each part of the exhaust system Check or repair it
Clogged air filter element Replace or clean it
Contaminated or damaged turbocharger Repair or replace it
Leakage of air from the discharging part of the compres-
Check or repair it
sor shaft
Replace and check if the impeller of the tur-
bocharger is damaged
Lowered Output
outlet
substance
substance
substance
119

Oil Leakage bocharger is damaged
oil hose
outlet
Oil Leakage Check if there is any sand or metallic foreign
substance
substance
substance
oil hose
outlet
Oil Consumption Large gap of the turbocharger wheel, causing interfer- Check if there is any sand or metallic foreign
substance
substance
substance
120

bocharger is damaged
oil hose
Black and White outlet
Emissions Large gap of the turbocharger wheel, causing interfer- Check if there is any sand or metallic foreign
substance
substance
substance
Blue Emissions Leakage from the engine block and the exhaust manifold Check the engine
Oil leakage to the turbine or compressor Repair or replace it
Too Much Fog
Worn or damaged seal ring due to worn bearing Repair or replace it
Clogged air filter element Replace or clean it
Clogged air duct Check or repair it
Air leakage from the intake system Check or repair it
Too Much Exhaust
Emissions The turbocharger cannot rotate because of burning Repair or replace it
A turbine blade or compression wing contacts with the
Repair or replace it
other one or is damaged
Deformed or clogged exhaust system pipe Check or repair it
121
How to Maintain Turbocharger

1. Cautions for engine operation
1) Observe the followings when starting, operating, and
stopping an engine.
Item Cautions Reasons

Check the oil amount
Therefore, start the engine with the starter motor Overhasty start of engine leads to engine rotation
to check the rise of oil pressure (until the grada- without lubricating turbocharger and other engine
tion of the oil pressure gauge moves or the pres- parts, causing abnormal wear or burning of bear-
sure indicator lamp is turned on). ings.
Starting an Engine If you replace oil, oil filter cartridge, or lubrication

system parts or use an engine in cold areas, or
the engine has stopped for a long period, loosen
When an engine has stopped or kept cold for a
the oil pipe joint at the inlet of the turbocharger
long period, circulation of oil in the pipe gets poor.
and run the starter motor until oil flows out. After
completing the work, tighten the oil pipe joint
again and start the engine.
When the engine is suddenly loaded while the
Operate the engine at idle for five minutes from engine and the turbocharger have not been
starting it. smoothly rotated after starting the engine, parts
After Starting an Engine with insufficient oil may be burnt.
Leakage of oil, gas, or air (especially oil) reduces
Check if oil, gas, or air is leaked from each part. If
oil pressure and loss of oil cause burning of bear-
so, take proper action.
ings.
Check the following.
Oil pressure Too low oil pressure causes abnormal wearing or
At idle: 1.5 ~ 3.0 kg/cm2 burning of bearings. Too high oil pressure causes
During Operation Fully loaded: 3.0 ~ 5.5 kg/cm2 oil leakage.
When abnormal noise or vibration occurs, slowly
Operating an engine with noise or vibration may
reduce the rotate count until the engine stops and
cause irreversible damage of the engine.
then figure out the causes.
Sudden engine stop after operating the engine
under high load allows the heat from the
Operate the engine at idle for five minutes before
Stopping an Engine red-heated turbine blade to be delivered to the
stopping it.
bearing system. Then oil burns and the bearing
metal and rotation shaft are burnt.
2. Cautions for Maintenance 3) If an engine has been operated at high speed for a long
1) When the RPM is rapidly increased after starting the period, fully operate the engine at idle and then stop the
engine, the journal bearings in the crankshaft is exces- engine. Otherwise, the turbine wheel continuously runs
sively rotated, the crankshaft is rotated at excessive without oil pressure in the turbocharger.
speed before the journal bearing of the crankshaft is Therefore, no oil film is created on the center bearings
lubricated fully. If the turbocharger rotates in this situa- and the journal bearings of the turbocharger, causing
tion, bearings are not smoothly cooled and lubricated, bearing, wearing out and shortening of the turbocharger
causing bearing burn and damage of the related parts. lifetime.
2) Please operate the engine for two minutes or more in
order to lubricate the turbocharger fully after replacing the
engine oil or oil filter.
122
4) If an engine is not operated for a long period during cold

weather or in areas with cold climate, operate the engine
at idle after starting the engine until the engine oil pres-
sure is normal.
5) The turbocharger turbine spins at high speed of 50,000 ~
200,000 rpm. Therefore, lubrication of bearings may
determine the turbocharger lifetime. Please use only
recommended genuine engine oil and check and replace
the engine oil periodically.
6) Prolonged usage of contaminated air cleaner may cause
a critical damage of the turbocharger. Regularly check
and replace the air cleaner.
7) A turbocharger is a very complex and precise part.
Only certified and skilled technicians should work on it.
8) If a turbocharger is operated without intake and exhaust
pipe, serious human injury may occur and critical faults of
the engine performance may occur.
Please operate a turbocharger only when all of parts are
exactly mounted on the specified position.
9) Do not lift up a turbocharger by grabbing the actuator.
The actuator may be damaged because of the weight of
the turbocharger.
10) The weight of a turbocharger is about 4.0 kg or more. To
lift up a turbocharger for installing or removing it, the
worker should lower the center of gravity or press his
body close to the turbocharger. Otherwise, worker may
drop the turbocharger, causing damage of the part and
injury.
123
Inspection Items During Disassembly/Assembly of Turbocharger
Possible Problem
Oil
No. Inspection Items Oil White/ Action
Power Con- Blue
Noise Leak- Black
Drop sump- Smoke
age Smoke
tion
Before removal
1 Is the intake hose torn or deformed? o o o o Replace hose
2 Is the clamp tightened firmly? o o o o Tighten bolt/nut correctly
Replace air filter and check
3 Is the air filter intact? o o o o turbocharger
impeller for damage
4 Does turbocharger or oil hose leak? o o o o Replace hose and gasket
Is gas leaked from exhaust manifold
5 o Replace nut and gasket
gasket?
Do solenoid valve and EGR system Replace solenoid and
6 o o o
intact? EGR valve
Does the turbocharger actuator oper-
7 o o o o Replace turbocharger
ate correctly?
During removal
Is there a sign of leak between the
1 o o o o o Check engine
engine block and exhaust manifold?
Check turbocharger impel-
Is the amount of oil and foreign mate-
2 o o o o o ler and turbocharger intake
rial led with blow-by gas normal?
air outlet
Is there a sign of interference of the
Check for foreign materials
3 wheel with the wall due to excessive o o o o o
(sand, metallic object)
play of the wheel?
Check for foreign materials
4 Is the wheel damaged? o o o o o
(sand, metallic object)
After removal
Is the wheel damaged or is the shaft Check for foreign materials
1 o o o o o
broken? (sand, metallic object)
2 Does the wheel rotate properly? o o o o o
124
Turbocharger Inspection • Axial play of rotating part

1. Daily inspection and service
It is important to handle the engine and maintain its C
optimum condition according to the instructions as the B
performance of the turbocharger is highly affected by the
maintenance condition of the engine.
1) Intake system
In the intake system, the air filter should be maintained D
with care. For a wet type air filter, if the oil level is below the
A
specified level, its filtering performance is deteriorated. On
the other hand, if the oil level is too high, it sucks in oil and
contaminates the case. Especially, if the rotor is contami-
nated, the precisely adjusted balance is destroyed and the
E
bearing is applied with large force, resulting in vibration, F
seizure and abnormal wear. Therefore, the air filter should EDL022074B
be well-maintained and handled with care. A dry air filter
should feature low possible intake air restriction. A. Dial Gauge D. Move the turbine shaft in
2) Exhaust system the axial direction.
If exhaust gas is leaked from the exhaust pipe or turbo- B. Magnet Vice E. Service Standard
charger connection in the exhaust system, the turbo- (0.038 ~ 0.093 mm)
charger's performance is deteriorated. Extra care is C. Turbine Compartment F. Wear Limit (0.24 mm)
needed to prevent a gas leak and seizure. A heat • Circumferential play of rotating part
resisting steel nut is used for parts, which can become
hot during driving, such as the turbine housing. Make
sure not to mix it with a general nut, and apply screw's
anti-seize compound to the specified mounting nut.
3) Lubrication system B
C
In the lubrication system, the oil quality and the cartridge A
replacement interval of the oil filter should be monitored
with care. Degraded engine oil can affect not only the
engine body, but also the turbocharger negatively. D
2. Periodic inspection and service
F
Check the turbocharger for its condition and contamina- E
G
tion periodically.
1) How to check rotating condition of rotating part When
checking the rotating condition of a rotating part, check
EDL022075B
for abnormal noise. When using a sound bar, touch the
turbocharger housing with its tip and rev up the engine Move the turbine shaft to
slowly. If a high pitch note is continuously heard, it is A. Oil Outlet D. the left and right in the
abnormal. If abnormal condition is found, it is possible circumferential direction.
that the bearing or rotating part is defective. In this case, Standard circumferential
B. Dial Gauge E.
replace or repair the turbocharger. play (0.326 - 0.496 mm)
2) How to check play of rotating part Standard Wear
C. Magnet Vice F.
Separate the turbocharger from the engine and check the (0.50 mm)
axial play and circumferential play of the rotating part. • If the axial or circumferential play is over the wear limit,
When separating the turbocharger, make sure to seal the replace or remove and repair the turbocharger.
oil inlet and outlet with plastic tape. 3) Tips for turbocharger disassembly and inspection
Remove the turbocharger from the engine to clean or
check it. Make sure to seal the oil inlet and outlet with
plastic tape after its removal.
125
4) Cautions for turbocharger installation When or after

installing the turbocharger to the engine, make sure keep
the followings: Make sure that no foreign material enters
the turbocharger.
• Lubrication system
- Before installation to the engine, add new oil through
the oil filler hole and turn the turbine shaft with a hand
to lubricate the journal bearing and thrust bearing.
- Clean the pipes between the engine and oil inlet and
between the pipe and oil outlet thoroughly and check
them for damage and foreign materials.
- Tighten each connection of the oil pipes firmly to
prevent an oil leak.
• Intake system
- Check if there is no foreign material in the intake
system.
- Install each connection of the intake system and air
filter firmly to prevent an air leak.
• Exhaust system
- Check if there is no foreign material in the exhaust
system.
- Make sure to use only heat resisting bolts and nuts. Be
careful not to mix them with general bolts and nuts
during assembly. Apply anti-seize compound to the
bolt and nut before installing them.
- Tighten each connection of the exhaust system firmly
to prevent any gas leak.
126
Exhaust Gas Reduction
General Information The DEF (Diesel Exhaust Fluid) is stored in the DEF tank.
The Doosan engine is equipped with the DOC (Diesel Oxida- Once it is needed, it is pressurized by the supply module and
tion Catalyst) and SCR (Selective Catalytic Reduction) is delivered to the dosing module under a certain level of
systems in order to comply with Tier 4 final (and stage IV) pressure. The dosing module is attached to the exhaust
emission control. This SCR system consists of the dosing manifold to spray DEF into the exhaust manifold in front of
module, supply module, ECU (Engine Control Unit) and the SCR system.
other components.
EK00298B
127
Aftertreatment Muffler and Catalyst

The aftertreatment muffler consists of the DOC muffler, SCR
muffler, mixer pipe and other pipes. The DOC muffler
contains DOC (Diesel Oxidation Catalyst) while the SCR
muffler contains SCR (Selective Catalytic Reduction).
EJ5OM021
1. DOC Converter 3. SCR Muffler

2. Mixer
128
DNox2.2 System
The DNox2.2 system is used to reduce NOx in emissions by
spraying urea into the SCR catalyst. It consists of the SM
(Supply Module), which functions as a pump, DM (Dosing
Module) to spray urea, DCU to control the overall system,
urea tank to store urea and urea/cooling water line.
Coolant Out
Coolant In
Coolant In
Urea Urea Press Line

Suction Line
Urea
Back Line
Urea Tank
Coolant Out
Coolant Heat
SM
(Supply Module)
electrical Heat
EK00300A
129
Urea Tank
The urea tank is used to store urea liquid. Connect lines to
the specified positions. Also, be careful not to apply impact
to the urea tank during its service.
3
12
13 6
1
7
14
11 8
2
9
5 10
4
15
EK00302A
1. +24V (Pin No. 1) 6. Coolant Outlet 11. Urea Tank Cap

2. Ground (Pin No. 2) 7. Urea Outlet 12. Inlet
3. Can High (pin No. 3) 8. Urea Inlet 13. Backflow
4. Can Low (pin No. 4) 9. Coolant Inlet 14. Outlet
5. Coolant Inlet 10. Level Indicator 15. Drain Plug
130
SM (Supply Module)
The supply module is used to pressurize DEF in the DEF
tank to a certain level and supply this pressurized DEF to the
dosing module.
Pin 8 Pin 2
7 Pin 12 Pin 6
5 4
EK00303A
1. Connector 5. Cover Plate

2. AdBlue Inlet 6. Detail Marking
3. AdBlue Backflow Outlet 7. Filter Cover
4. AdBlue Outlet
131
DM (Dosing Module)
The dosing module is attached to the exhaust manifold in
front of the SCR system to receive DEF from the supply
module and spray it into the exhaust manifold.
1 2
7 4
EK00304A
1. Coolant Outlet 5. Cooling Adapter

2. Coolant Inlet 6. Dosing Valve
3. Head Shield 7. AdBlue Inlet
4. Protective Cap
132
Urea Filter Replacement 4. Set the color of the mark on the end of the filter removing
1. Remove the filter cover. tool in the same direction with the filter color section.
EK00305A EK00308A
2. Remove the equalizing element. 5. Insert the end of the filter removing tool until a clicking
sound is heard or engagement with the filter is felt.
EK00306A
EK00309A
3. Check the color (gray/green) in the filter.
6. Pull the filter removing tool to remove the filter.
EK00307A
EK00310A
133
7. The surface should be kept clean. It can be cleaned with 9. Install a new equalizing element.
water only.
EK00313A
EK00311A 10. Tighten the filter cover to 20 +5 Nm.
8. Apply oil to the O-ring and install a new filter.
EK00314A
EK00312A
CAUTION
CAUTION Check that the filter surface is clean. It can be cleaned
Use Mobil Velocite No. 6 oil from Bosch. with water only.
134
DNOx2.2 System Components 1) When replacing DM, DM and bolts is the leakage or
1. NOx2.2 system are each divided into a machine damage caused by under tightening bolts or over tight-
equipped with the most suitable place, and each part is ening.
protected from damage caused by external environment 2) Electric connector misassembly or debris contamination
can be configured so. inside of connector.
Note) Urea Tank and Supply Module is equipped with the 3) Urea leakage is caused by Urea Line misassembly.
same Cabin. 4) Coolant leakage is caused by coolant line misassembly.
The high temperature exposure of DM is caused by
disconnected.
5) The high temperature exposure of DM is caused by
gasket misassembly.
6) Urea leakage is caused by gasket reuse.
2. Supply Module
The Supply Module (SM) failure mode is associated with
Urea Line and Electric Connector damage and poor
connection. When replacing Urea main filter regularly,
Supply module failure can occur caused by disassembly.
3 2
EK00343A
4
2. Dosing Module (DM) is equipped by a mixer pipe
between a DOC and SCR muffler. It is conneted with SM
in the past Urea Line, the engine coolant Line and 2Pin
connector for Urea dosing valve control.
1
Check DNOx2.2 System Failures
1
1. Dosing Module
1
Dosing Moduel fault is cause of the high temperature
exposure of Nozzle Tip injecting Urea, Electric harness EK00344A
contact failure, Urea Hose Line break or poor contacet,
and more. Visual inspection of DM failure are as follows.
CAUTION
When replacing new filter, open the package on the
1 2
verge of replacement.
3
1) When connecting Urea Line, the failure caused by Urea
Line misassembly.
2) Electric connector misassembly or debris contamination
5
inside of connector.
4 3) When replacing SM Filter, the damage caused by not
using the special tool.Also, it caused by filter remnants
inside SM filter.
4) When replacing filter, the Urea Cap damage is caused by
overtihgtneing and the filter detachment is caused by not
tightening.
EK00230A
135
3. Urea Tank
Urea Tank is keeping the urea solution. Assembly
connected line to correct location. When maintenance of
Urea Tank, be careful not to external impacts.
3
12
13 6
1
7
14
11 8
2
9
5 10
4
15
EK00302A
1) Urea inlet hose and backflow hose are incompatible, Do 5) Make sure that the connection condition of Urea Line
not use them together. Be careful to damage the Heater (2-PIN). Not running a heater in winter season
connector, assemble the connector. there is a danger of frost.
4. Muffler and other pipes
CAUTION It is no necessary to replace, disassemble and move
mounted muffler and other pipes except by failure caused
Urea inlet hose is marked red color, backflow hose is by external impact. Tighten the each parts at tightening
marked yellow color. torque not to leakage, when replacing, disassembling
and moving muffler and other pipes caused by failure.
2) Make sure that Urea Tank fixing Bracket Mount is tight-
ened. If it is not tightened, it could occur the damage
caused by vibration.
3) Make sure that the connection condition of Tank
temperature and level sensor connector. Be careful to
damage connector and be contaminated debris.
4) Assembly coolant line to correct location. If it is not tight-
ened, it could leak coolant.
136
Urea Quality Characteristics
Limits
Characteristics Unit Test Methods
Min. Max.
ISO 22241-2 Annex Bc
Urea Contenta %(m/m)b 31.8 33.2
ISO 22241-2 Annex Cc
Density at 20°Cd kg/m3 1,087 1,093 ISO 3675 or ISO 12185
Refractive Index at 20°Ce - 1.3814 1.3843 ISO 22241 2 Annex C

Alkalinity as NH3 %(m/m)b - 0.2 ISO 22241 2 Annex D
Biuret %(m/m)b - 0.3 ISO 22241 2 Annex E
Aldehydes mg/kg - 5 ISO 22241 2 Annex F
Insoluble Matter mg/kg - 20 ISO 22241 2 Annex G
Phosphate (PO4) mg/kg - 0.5 ISO 22241 2 Annex H
Calcium mg/kg - 0.5
Iron mg/kg - 0.5
Copper mg/kg - 0.2
Zinc mg/kg - 0.2
Chromium mg/kg - 0.2
ISO 22241 2 Annex I
Nickel mg/kg - 0.2
Aluminium mg/kg - 0.5
Magnesium mg/kg - 0.5
Sodium mg/kg - 0.5
Potassium mg/kg - 0.5
Identity - identical to reference ISO 22241 2 Annex J
a. Target value 32.5%(m/m).

b. for the purposes of this International Standard. the term “%(m/m)” is used to represent the mass fraction of a material.
c. Calculated without subtracting nitrogen from ammonia.
d. Target value 1,090 kg/m3
e. Target value 1.3829
Should it be necessary to add a tracer to AUS 32. it shall be ensured that the quality of AUS 32 specified in this Table is not
impaired and that the tracer does not damage the SCR system.
Note) In establishment of these limit values, the terms of ISO 4259 have been applied in fixing a maximum and minimum value,
a minimum difference of 4 x R (R is the Reproducibility of the test method) has been taken into account.
However, in case of urea content, the 4 x R rule has not been applied in order to keep the high quality.
Note) The values quoted regarding urea content, density and refractive index are “true values” (see ISO 4259 for definition of
true values).
Note) The manufacturer of AUS 32 should aim at the target values defined in footnotes a, d and e.
Note) Should it be necessary to clarify the questions as to whether a given urea solution meets the requirement of the specifi-
cations, the terms of ISO 4259 should be applied.
137
EGR (Exhaust Gas Reduction) System
General Information As a result, a reduced amount of NOx is produced.

The EGR (Exhaust Gas Recirculation) system recirculates a This system is equipped with the EGR cooler to reduce the
portion of exhaust gas back to the intake system to cool it temperature of hot exhaust gas in order to reduce the
down and supply it to the engine for re-combustion in order amount of NOx and enhance engine combustion efficiency.
to reduce NOx emission. To reduce NOx and other emis-
sions from the engine, it circulates exhaust gas containing
almost no oxygen toward the intake system to decrease the
density of oxygen supplied to the engine and induce
combustion at a low temperature.
EK4OM089-E
[EGR] 2) To control the EGR rate, it is equipped with the electric

1. Overview EGR valve which uses a motor.
1) It is a device to recirculate a port of exhaust back to the
engine according to the engine condition to reduce the
amount of NOx production.
2) Exhaust gas is taken from the end of the exhaust mani-
fold before it joins intake air, which is passed through the
intercooler, and flows back to the engine.
2. Major characteristics
1) It is equipped with the EGR cooler to decrease the
temperature of exhaust gas.
138
<EGR>
EK4OM088
[EGR Cooler]
1. Overview of EGR cooler
1) It is a heat exchanger to reduce the temperature of recir-
culated exhaust gas with coolant.
2) The EGR cooler not only reduces the quantity of NOx, but
also enhances combustion efficiency.
2. Major characteristics of EGR
1) It is a typical tube type.
139
EGR Disassembly and Assembly

[Disassembly]
1. Remove the EGR valve and disconnect the elbow pipe.
Note) Perform the process with the heat shield and bellows
pipe removed.
CAUTION
As the EGR system is hot by exhaust gas, it should be
disassembled after it is sufficiently cooled down.
1) Remove the nut from the stud bolt.

2) The cooling pipe should be disconnected to remove the
EGR valve.
2. Remove the EGR bracket.
Note) Components available for removal after removal of
exhaust manifold
[Assembly]
CAUTION
Any used gasket should be replaced with a new one.
EGR cooler disassembly and assembly

[Disassembly]
1. As the EGR system becomes hot by exhaust gas while
the engine is running, it should be disassembled after it is
sufficiently cooled down.
1) Disconnect the coolant inlet/outlet pipes and hoses.
2) Remove the gas pipe outlet and hose.
3) Remove the heat shield.
4) Disconnect the bellows pipe.
5) Remove the EGR cooler mounting bolts.
6) Remove the EGR cooler from the EGR bracket.
[Assembly]
CAUTION
Any used gasket should be replaced with a new one.
140
Intake Pipe
Major Air Heater Specifications
Rating DC 22 V (95 A ±10%)

Capacity 2.1 kW
FLOW
AIR FLOW
24V
+
Pay attention to the assembly directions
EJ9OM086-E
141
142
10. Cylinder Block/Head

Cylinder Block .......................................................................................................................145
Check of Cylinder Block ................................................................................................................................ 145
Cylinder Head .......................................................................................................................146
Cylinder Head Disassembly .......................................................................................................................... 146
Cylinder Head Assembly............................................................................................................................... 146
Cylinder Head Inspection .............................................................................................................................. 147
Valve .....................................................................................................................................148
Valve Inspection............................................................................................................................................ 148
Valve Guide Inspection ................................................................................................................................. 148
Valve Seat Inspection ................................................................................................................................... 149
Valve Spring Inspection ................................................................................................................................ 149
Rocker Arm ...........................................................................................................................151
Rocker Arm Removal .................................................................................................................................... 151
Rocker Arm Installation ................................................................................................................................. 151
Rocker Arm Inspection.................................................................................................................................. 151
Rocker Arm Shaft Inspection ........................................................................................................................ 151
Tappet and Push Rod ...........................................................................................................152
Valve Tappet Inspection ............................................................................................................................... 152
Push Rod Deflection Inspection .................................................................................................................... 153
Camshaft ...............................................................................................................................153
Camshaft Play............................................................................................................................................... 153
Camshaft Inspection ..................................................................................................................................... 153
143
144
General Information Cylinder Block
General Information Check of Cylinder Block

Doosan's diesel engine is an air-cooled electronic control 1. Cleanse the cylinder block and check if there is any
diesel engine that uses cooling fans, overhead valve, and cracked or damaged part with naked eye.
turbocharger. 2. Replace the cylinder block if it is seriously cracked or
The high-pressure fuel generated from the fuel high-pres- damaged. Repair tiny cracks if existing.
sure pump is stored in the common rail. When a driver oper- 3. Check if the oil path or coolant path is clogged or
ates the vehicle, fuel injection timing and optimum fuel corroded.
amount are decided based on the data set in the Electronic 4. Perform the hydrostatic test to check whether there is a
Control Unit (ECU) and the solenoid valve of the injector crank or an air leakage.
installed in each engine cylinder is operated to inject fuel into 5. Block the discharging outlets of the cooling water path
the cylinder. and the oil path of the cylinder block and put pressure of
The cylinder block is made out of cast iron alloy and an 4 kg/cm2 on the inlet. Then sink the cylinder block in the
anti-vibration and anti-noise crank case is mounted. In addi- 70°C water for 1 minute and check if air leaks.
tion, the cylinder block and the timing gear case are designed
as an integral structure to reduce the engine length and
improve tightness. The cylinder head is an integral structure,
too.
The forged crankshaft is an integral structure. The oil seals
of the crankshaft and the flywheel prevents oil from perme-
ating into the flywheel housing.
The connecting rod is forged and its big end part vertically
separated. Like a piston, the connecting rod can be disas-
sembled through the upper side of the cylinder. The
alloy-type prefabricated bearing is used for the active part of
the crankshaft and the connecting rod.
145
Cylinder Head
Cylinder Head Disassembly

1. After disassembling the cylinder head, keep it on a shelf
in an organized way for later assembly. Valve guide
2. Be careful not to damage the contact surface of the
cylinder head gasket.
3. Remove the valve cotter, spring and spring seat using a
valve spring compression tool.
Valve seat
EE1OM069-E
5. Install the valve spring seat to the valve guide on the

cylinder head.
6. Install the inner and outer valve springs and place the
spring seat on the top.
EJ9OM080 Painted portion

4. Pull out the intake and exhaust valves. (Assemble spring
to the upper side)
5. Keep the removed parts in order.
6. Remove the valve stem seal.
Cylinder Head Assembly

1. Clean the cylinder head thoroughly.
2. Replace the valve stem seal with a new one.
3. Use a special service tool to install the stem seal to the
valve guide of the cylinder head.
4. Apply engine oil to the valve stem and valve guide, and
install the valve. EE1OM070-E
7. While pressing the valve spring with the valve spring

CAUTION compression tool, insert the valve cotter to install the
valve.
Be careful not to damage the valve stem seal. 8. After installing the valve, tap the valve gently with a
urethane hammer to check if it is firmly installed.
146
Cylinder Head Inspection 3. Flatness

1. Cylinder head inspection 1) Use a straightedge and feeler gauge to measure the flat-
ness of the intake/exhaust manifold mounting surface of
1) Remove carbon from the bottom of the cylinder head.
the cylinder head.
CAUTION
Be careful not to scratch the valve seat surface.
2) Visually check if the cylinder head is damaged.

3) A minute scratch or damage that cannot be found with
the naked eyes can be found through the hydraulic pres-
sure test or magnetic particle test.
2. Bottom distortion
1) Use a straightedge and feeler gauge to measure the
distortion of the cylinder head in 6 directions.
C
(t) B D EH6OM029
E
F Standard Allowable Limit
0.15 mm 0.3 mm
4. Flatness
A
1) The hydraulic pressure test for the cylinder head is same
to the test for the cylinder block.
EH6OM028
2) If any measured value is over the allowable service limit,

correct it with a fine sandpaper or grinder.
3) If it is over the allowable limit, replace the cylinder head.
• Distortion and height of cylinder head
Allowable
Standard
Limit
Cylinder Head 0.08 mm or
0.15 mm
Bottom Flatness below
Head Height: t 104.9 ~ 105.1 mm 104.4 mm
147
Valve
General Information 3. Valve head thickness

The overhead valve is operated through the cast iron tappet,
push rod and rocker arm from the camshaft.
Valve Inspection
Wash the valve with clean engine oil and inspect it as follows:
1. Valve stem O.D.
Valve stem EE1OM066
1) Measure the thickness of the valve head.

2) If the measurement is below the allowable limit, replace
the valve.
Standard Allowable Limit
Intake Valve (A) 3.3 - 3.7 mm 2.8 mm or below
DV2213117A_E Exhaust Valve (A) 3.3 - 3.7 mm 2.8 mm or below
1) Measure the outside diameter of the valve stem at three
location (upper, middle and lower points).
Valve Guide Inspection
2) If the wear amount is over the allowable limit, replace the
1. Install the valve to the cylinder head.
valve.
2. Measure the clearance between the valve guide and
Allowable
Standard valve with motion of the valve.
Limit
Intake Valve Stem Ø6.963 - Ø6.977 mm Ø6.93 mm
Exhaust Valve Stem Ø6.950 - Ø6.964 mm Ø6.91 mm
2. Valve seat contact surface

1) Check if the valve seat contact surface is scratched or
damaged.
2) If necessary, correct the surface with sandpaper. If
Measure
damage is severe, replace the seat. location
DV2213119A_E
3. If the clearance is excessive, measure the size of the

valve and replace either the valve or valve guide which is
worn more.
148
• Valve stem play • Valve step portion
Standard Allowable limit Standard Allowable limit

Intake Valve 0.023 ~ 0.052 mm 0.1 mm Intake Valve (A) 0.35 ~ 0.65 mm 0.85 mm
Exhaust Valve 0.036 ~ 0.065 mm 0.15 mm Exhaust Valve (A) 0.35 ~ 0.65 mm 0.85 mm
4. Install the valve to the cylinder head valve guide. • Valve stem play
5. Use a special service tool to check if its center is aligned
Intake Valve (B) Exhaust Valve (B)
with the valve seat.
60° 0.023 ~ 0.052 mm
Valve Seat Inspection 5) If the amount of valve insertion is over the allowable limit,
replace the valve seat.
1. Contact area on contact surface
6) When removing the valve seat, arc weld two positions of
the valve seat and use a special service tool to pull out
the valve seat.
Note) When replacing the valve seat, it should be bored.
Valve sheet
Cylinder head
EE1OM067
Weld bead
DV2213122A_E
Valve 7) When installing the valve seat, put it in dry ice for approx.
two hours to cool it down.
8) Use a bench press to press the valve seat into the
Valve seat
cylinder head.
9) Apply abrasive to the valve head contact surface of the
valve seat.
A
10) Rotate the valve to grind the valve seat until the valve is
seated. Then, remove the abrasive thoroughly.
B
Valve Spring Inspection
EE1OM068-E
1. Visually check the outside of the valve spring.
1) To check the wear level of the valve seat, measure the 1) Visually check if the valve spring is damaged. Replace it
height of the contact surface from the intake/exhaust if necessary.
valves.
2) If the measurement is over the allowable limit, replace the
seat.
3) Install the valve to the valve seat of the cylinder head.
4) Use a dial gauge to measure the amount of insertion of
the value from the bottom of the cylinder head.
149
2. Check the free length of the valve spring. 4. Check the tension of the valve spring.
EA3M2033 EDL022098B
1) Use vernier calipers to measure the free length of the 1) Use a spring tester (A) to measure the tension of the
valve spring. valve spring.
2) If the measurement is below the standard value, replace 2) If the measurement is below the allowable limit, replace
the valve spring. the valve spring.
Free Length of Spring Standard

Setting Spring Allowable
Item
Intake Valve 53.5 Length Tension Limit
Exhaust Valve 53.5 Intake/Exhaust 39.4 mm 28.8 kg ±2 kg
3. Check the squareness of the valve spring. Valves 29.67 mm 50 kg ±2 kg
B
A
EDL022097A
A. Free Length B. Squareness C. Straightedge
1) Use a surface plate and straightedge to measure the

squareness of the valve spring.
valve spring.
Allowable
Standard
Limit
Valve Spring Squareness 1.4 mm or below 2.0 mm
150
Rocker Arm
Rocker Arm Removal 2. Rocker arm bushing I.D.

1. Use pliers to remove the snap rings from both ends of the
rocker arm shaft.
2. Remove the washer, rocker arm bracket, rocker arm
spring and rocker arm in order.
EE1OM073
1) Use a micrometer or vernier calipers to measure the

inside diameter of the rocker arm bushing.
2) Compare the measurement with the outside diameter of
EE1OM071 the rocker arm shaft. If the clearance is over the allow-
able limit, replace either the bushing or shaft which is
worn more.
Rocker Arm Installation
1. Install the rocker arm in the reverse order of its removal. Standard Allowable Limit
Ø24.991 ~ Ø25.012 mm Ø25.04 mm
CAUTION
• Check if there is any foreign material in the oil feed
Clearance
hole of the rocker arm shaft. Wash it cleanly. 0.14 mm or
Between Rocker 0.031 ~ 0.073 mm
• Make sure to install the rocker arm in the correct below
Arm and Shaft
position in the correct order.
Rocker Arm Shaft Inspection
1. Deflection of rocker arm shaft
Rocker Arm Inspection
1. Visual inspection
1) Visually check the surface of the adjusting screw cap
assembly which moves in contact with the valve stem.
Check if the surface is scratched or has worn layers.
2) If the wear level is small, grind the surface with an oily
whetstone or fine sandpaper. If the surface has severely
worn layers, replace the rocker arm.
EDM2037I
1) Place the rocker arm shaft on two V-blocks and use a dial
gauge to measure the deflection of the shaft.
151
2) If its deflection is minute, use a press to straighten it. Tappet and Push Rod
If its deflection is over the allowable limit, replace it.
Valve Tappet Inspection
1. Tappet clearance
2. Rocker arm shaft O.D. 1) Measure the outside diameter of the tappet and the
1) Use a O.D. micrometer to measure the outside diameter inside diameter of the tappet hole of the cylinder block.
of the rocker arm shaft at the location where the rocker 2) If the measurement is over the allowable limit, replace the
arm was installed. tappet.
2) Loosen nuts on both sides of the fuel injection pipes and
remove the fuel injection pipes (A). Standard Allowable Limit
0.028 ~ 0.069 mm 0.13 mm
2. Visual inspection of tappet
Ø24.939 ~ Ø24.960 mm Ø24.90 mm
normal abnormal abnormal

(irregularity) (crack)
abnormal abnormal
DV2213128A_E
1) Visually check the surface of the tappet which moves in

contact with the camshaft. Check if the surface is
cracked, scratched or damaged.
2) If such damage is minute, grind the surface with an oily
whetstone or fine sandpaper. If its surface has severely
damaged, replace it.
3. Tappet O.D.
EDM2061I
152
1) Use a O.D. micrometer to measure the outside diameter Camshaft

of the tappet.
2) If the measurement is over the allowable limit, replace the Camshaft Play
tappet. 1. Move the camshaft gear to the opposite side of the
cylinder block.
Standard Ø27.962 ~ Ø27.982 mm
2. Use a feeler gauge to measure the clearance between
the thrust plate and camshaft gear.
Push Rod Deflection Inspection
1. Place the push rod on the surface plate.
2. Measure its deflection with a feeler gauge while rolling it.
Feeler gauge
EA0M4067-E
Feeler gauge
3. If the play is excessive, replace the thrust plate.
DV2213129A_E
3. If the measurement is over the allowable limit, replace it. 0.280 ~ 0.430 mm 0.5 mm
Allowable Limit 0.25 mm or below Camshaft Inspection

1. Measure the height of the cam lobe.
Push Rod Length 344 mm
C
B B
D A
EH6OM030
1) Use a micrometer to measure the cam lobe height and

journal diameter.
2) If the measurement is below the allowable limit, replace
the camshaft.
153
4. Camshaft deflection
Allowable
Standard
Limit
Cam Lobe Intake 46.025 mm 45.73 mm

Height (C) Exhaust 47.782 mm 47.48 mm
Cam Journal Ø55.92 ~
Ø57.65 mm
Diameter (A & B) Ø55.95 mm
2. Check the cam surface.

1) Check if the cam surface is scratched or damaged.
2) Minutely worn layers or small damage can be corrected
with an oily whetstone or fine oily sandpaper. If damage
is severe, replace it.
3. Clearance between camshaft and bearing
EH6OM032
1) Place the camshaft on two V-blocks.

2) Use a dial gauge to check the deflection of the camshaft.
Correct it as necessary.
Camshaft bearing 3) If its deflection is excessive and cannot be corrected,
replace it.

0.05 mm 0.15 mm
EH6OM031-E
1) Use an O.D. micrometer to measure the outside diameter

of the camshaft bearing section.
2) Use a cylinder I.D. gauge to measure the inside diameter
of the camshaft bearing, and compare the measurement
result with the outside diameter of the camshaft to calcu-
late the clearance.
camshaft bearing.

0.03 - 0.09 mm 0.18 mm
154
11. Electric System
Circuit Diagram .....................................................................................................................157

Engine Connector ......................................................................................................................................... 158
ECU (Engine Control Unit) Engine Connector .............................................................................................. 160
Switches and Sensors ..........................................................................................................164
ECU (Electronic Control Unit) ....................................................................................................................... 164
Boost Pressure and Temperature Sensor .................................................................................................... 166
Engine Oil Pressure and Temperature Sensor ............................................................................................. 166
Engine Coolant Temperature Sensor ........................................................................................................... 166
Common Rail Pressure Sensor .................................................................................................................... 167
Crankshaft Speed Sensor ............................................................................................................................. 167
Camshaft Speed Sensor ............................................................................................................................... 167
Pressure Limiter Valve .................................................................................................................................. 168
Accelerator Pedal Sensor ............................................................................................................................. 168
ECU (Electronic Control Unit) ...............................................................................................169
ECU (Engine Control Unit) Connector .......................................................................................................... 169
ECU (Engine Control Unit) Input/Output ....................................................................................................... 170
Operational Conditions of Electronic Control Unit (ECU).............................................................................. 171
Starter ...................................................................................................................................172
Circuit Diagram ............................................................................................................................................. 173
155
156
11. Electric System
Circuit Diagram
General Information
1. It is possible to identify the circuit number for the
connector and engine wire harness information.
EK00337A
2. The wiring colors can be identified as follows:

1) B : Black
2) Brn : Brown
3) G : Green
4) Gra : Gray
5) L : Blue
6) O : Orange
7) P : Purple
8) RW : Red & White
9) W : White
10) Y : Yellow
3. The ECU pin No. means each pin number of an engine
connector.
4. The sensor pin No. means each pin number of a sensor
connector.
157
11. Electric System
Engine Connector
EJ5OM022
158
11. Electric System
EJ5OM023
159
11. Electric System
ECU (Engine Control Unit) Engine Connector
Wiring Label Abbrev. Circuit Name

1.46 B_D_CANH0 Controller Area Network 0 (High)
1.47 B_D_CANL0 Controller Area Network 0 (Low)
1.70 B_D_ISOK ISO-K interface
1.10 G_C_GND Ground shield
1.03 G_G_BAT1 Battery minus 1
2.30 G_R_AMS Air-mass sensor ground (Hot-film)
2.90 G_R_AN05 Ground analog input 5
1.80 G_R_APP1 Accelerator pedal position sensor 1 ground
1.51 G_R_DIA Error memory read switch ground
1.65 G_R_FSS Fan speed sensor ground
2.06 G_R_OPS Oil pressure sensor ground
2.60 G_R_RAILPS Rail pressure sensor ground
2.40 G_R_TVA Throttle plate actuator (valve) feedback ground
1.54 G_R_VSS Vehicle speed sensor ground
1.79 I_A_APP1 Accelerator pedal position sensor 1 signal
2.86 I_A_BPS Boost pressure sensor signal
2.37 I_A_BTS Boost temperature sensor signal
2.39 I_A_CTS Coolant temperature sensor signal
1.16 I_A_EXTS1 Exhaust gas temperature sensor 1 signal
2.12 I_A_FTS Fuel temperature sensor signal
1.56 I_A_HCIPSDN HCI pressure sensor downstream
1.30 I_A_HCIPSUP HCI pressure sensor upstream
1.42 I_A_HCITS HCI temperature sensor signal
2.38 I_A_IATS Intake air temperature sensor signal
2.35 I_A_OPS Oil pressure sensor input signal
2.13 I_A_OTS Oil temperature sensor signal
1.55 I_A_PFDP Particle filter, differential pressure sensor signal
2.36 I_A_RAILPS Rail pressure sensor signal
160
11. Electric System

1.41 I_A_TL Torque limitation signal
2.15 I_A_TVA Throttle plate actuator (valve) feedback signal
2.54 I_F_AMS Air-mass sensor signal (Hot-film)
2.67 I_F_CASNEG Segment (camshaft) speed sensor signal minus
2.68 I_F_CASPOS Segment (camshaft) speed sensor signal plus
2.65 I_F_CRSNEG Crankshaft speed sensor signal minus
2.66 I_F_CRSPOS Crankshaft speed sensor signal plus
1.64 I_F_FSS Fan speed sensor signal
2.94 I_F_TWSNEG Turbo wheel speed sensor signal minus
2.93 I_F_TWSPOS Turbo wheel speed sensor signal plus
1.53 I_F_VSS Vehicle speed sensor input signal
1.38 I_S_ACSW A/C request switch
1.82 I_S_BRKMN Brake main switch signal
1.12 I_S_BRKRED Redundant brake switch signal
1.14 I_S_CRCNEG Cruise control activator "Set/decelerate"
1.36 I_S_CRCOFF Cruise control activator "Off"
1.81 I_S_CRCPOS Cruise control activator "Set/accelerate"
1.35 I_S_CRCRES Cruise control activator "Resume"
1.37 I_S_DIA Error memory read signal
1.59 I_S_DPF1 DPF regeneration switch
1.58 I_S_DPF2 DPF regeneration inhibit switch
1.15 I_S_EBR Engine brake switch signal
1.60 I_S_LIS Low idle position switch input signal
1.11 I_S_STP Engine stop switch signal
1.69 I_S_T15 Terminal 15 (switched BAT+)
1.63 I_S_T50 Start switch term. 50 input signal
2.43 O_F_CAS Segment (camshaft) speed sensor output signal
2.44 O_F_CRS Crankshaft sensor output signal
1.34 O_F_ENGN Engine speed output signal
2.49 O_P_SVH11 Injector 1 "high" Bank 1
2.73 O_P_SVL11 Injector 1 "low" Bank 1
1.06 O_S_CSLP Cold start lamp
1.77 O_S_DIA Diagnostic lamp
2.70 O_S_EBR1 Engine brake 1 power output
1.94 O_S_EBR2 Engine brake 2 power output
1.61 O_S_FHRLY Fuel filter heating relay
1.83 O_S_IMPH Intake manifold preheating (Grid heater)
161
11. Electric System

1.44 O_S_MIL Malfunction indication lamp (MIL)
2.95 O_S_RH05 High side source driver 5
1.21 O_S_RH06 High side source driver 6
1.19 O_S_STRTH Starter relay high
1.88 O_S_STRTL Starter relay low
2.29 O_T_DCNEG1 DC-motor control 1, high bridge, negative
2.05 O_T_DCPOS1 DC-motor control 1, high bridge, positive
1.87 O_T_FAN1 Motor fan relay 1
1.24 O_T_HCIMEU HCI metering valve
2.83 O_T_MEU Fuel metering unit
1.22 O_T_RH02 High side source driver 2
1.20 O_T_RH03 High side source driver 3
1.45 O_T_SOFFL HCI Shut off "low"
2.58 O_V_MEU Fuel metering unit supply (BAT+)
1.50 O_V_RH11 Battery plus output 11 (high side driver)
2.84 O_V_VDD12 12 V supply
2.07 V_V_5VSS1A 5V sensor supply 1A
1.91 V_V_5VSS1C 5V sensor supply 1C
2.31 V_V_5VSS1F 5V sensor supply 1F
1.66 V_V_5VSS2D 5V sensor supply 2D
2.11 V_V_5VSS3B 5V sensor supply 3B
2.34 V_V_5VSS3C 5V sensor supply 3C
1.73 V_V_BAT1 Battery plus 1
1.02 O_S_SMH Supply module heater
1.04 O_S_PHH Reduction agent auxiliary relay 3 (pressure hose heater)
1.07 I_A_PRAS Reduction agent pressure sensor signal
1.08 I_A_TRATS Reduction agent tank temperature sensor signal
1.09 I_A_CATTSPOST1 CATTSPOST1 Post-catalyst temperature sensor signal 1 (downstream)
1.13 I_S_OCS Engine oil combination sensor input signal
1.23 O_T_RAMVH Reduction agent metering valve (high-side)
1.29 G_G_RL11 Ground for low side power stage 11
1.31 I_A_RALS Reduction agent level sensor signal
1.32 I_A_CATTSPRE1 Catalyst temperature sensor 1 signal (upstream)
1.44 O_S_MIL Malfunction indication lamp (MIL)
1.48 O_S_SHH Reduction agent auxiliary relay 1 (suction hose heater)
1.62 O_S_RATH Reduction agent tank heating
162
11. Electric System

1.68 O_V_5VPRAS Reduction agent pressure sensor supply
1.72 O_S_BHH Back flow hose heater
1.76 G_G_RL14 Ground for low side power stage 14
1.84 B_T_RAPMP Reduction agent pump motor
1.85 O_T_RARV Reduction agent reverting valve
1.86 O_S_RL01 Low side source driver 1
1.89 G_G_RAPMP Ground for reduction agent pump motor
1.93 O_S_MRHH Reduction agent electro-mechanical relay
1.96 O_T_RAMVL Reduction agent metering valve (low-side)
2.09 O_V_5VSS2F 5 V sensor supply 2F
2.14 I_A_CAT Combust air humidity temperature sensor signal
2.16 I_A_CAH Combust air humidity sensor signal
2.33 V_V_5VCAH Combust air humidity sensor supply
2.41 N_X_NU Not used, function not classified (function is not applied)
2.42 G_R_CAH Combust air humidity sensor ground
2.61 I_A_WFS Water in fuel sensor signal
2.85 I_A_ATS Ambient temperature sensor signal
289 G_R_WFS Water in fuel sensor ground
163
11. Electric System
Switches and Sensors
ECU (Electronic Control Unit)
Shape Symbol Pin No. Circuit Name
Fuel Metering Unit 2.58 Fuel metering unit (O_V_MEU)
1 2
FMU
2.58 2.83
2.83 Fuel metering unit (O_T_MEU)
2.06 Oil pressure/temperature sensor GND (G_R_OPS)

Oil Press Temp Sensor
2.13 Oil temperature sensor SIG (I_A_OTS)

OPTS
2.06 2.13 2.31 2.35 2.31 Oil pressure/temperature sensor voltage (O_V_5VSS1F)
2.35 Oil pressure sensor SIG (I_A_OPS)
Rail Press Sensor

2.60 Rail pressure sensor GND (G_R_RAILPS)
1 3
RPS 2.36 Rail pressure sensor SIG (I_A_RAILPS)
2.60 2.36 2.11
2.11 Rail pressure sensor voltage (O_V_5VSS3B)
2.90 Boost pressure/temperature sensor GND (G_R_BPS)

Boost Press Temp Sensor
2.37 Boost temperature sensor SIG (I_A_BTS)

BPTS
2.90 2.37 2.07 2.86 2.07 Boost pressure/temperature sensor voltage (O_V_5VSS1A)
2.86 Boost pressure sensor SIG (I_A_BPS)
Coolant Temp Sensor 2.39 Coolant temperature sensor SIG (I_A_CTS)
1 2
CTS
2.39 2.59
Fuel temperature/coolant temperature sensor GND
2.59
(G_R_AN18)
Crank Shaft Speed Sensor

2.66 Crankshaft speed sensor POS (I_F_CRSPOS)
2.65 Crankshaft speed sensor NEG (I_F_CRSNEG)

CRS
2.66 2.65 2.69
Crankshaft/camshaft speed sensor protective GND

2.69
(G_C_GND)
Cam Shaft Speed Sensor

2.68 Camshaft speed sensor POS (I_F_CASPOS)
2.67 Camshaft speed sensor NEG (I_F_CASNEG)

CAM
2.68 2.67 2.69
Crankshaft/camshaft speed sensor protective GND

2.69
(G_C_GND)
Vbat 24 V battery voltage

EGR Valve
GND Body GND

4 1
EGR
2.17 2.18 GND Vbat
2.18 CAN 2 LOW (B_D_CAN2L)
2.17 CAN 2 HIGH (B_D_CAN2H)
164
11. Electric System
Shape Symbol Pin No. Circuit Name
2.49 Cylinder 1, injector 1 HIGH (O_P_SVH11)
2.73 Cylinder 1, injector 1 LOW (O_P_SVL11)
Injector Connector

INJ
Fuel Temp Sensor 2.12 Fuel temperature sensor SIG (I_A_FTS)
1 2
FTS
Fuel temperature/coolant temperature sensor GND
2.12 2.59
2.59
(G_R_AN18)
Inter Connector
2.85 Ambient temperature sensor signal (I_A_ATS)
for Vehicle
2.89 Ambient temperature sensor GND (G_R_WFS)
Interconnector
Vbat 24 V Battery voltage
GND Body GND
Resistance
2.17 CAN 2 HIGH (B_D_CANH2)
2.17
2
2.18
Resistance
2.09 HFM sensor PWR (V_V5VCAH)

HFM Sensor
2.38 HFM sensor temperature SIG (I_A_IATS)

HFM Sensor
2.54 HFM sensor (I_A_IATS)
2.30 HFM sensor GND (G_R_AMS)
2.17 CAN 2 HIGH (B_D_CANH2)

VTG Connector
VTG
Vbat 24 V Battery voltage
GND Body GND
165
11. Electric System
Boost Pressure and Temperature Sensor

1. The boost pressure and temperature sensor is connected
to the intake manifold with the O-ring to measure the
absolute pressure and temperature in the intake mani-
fold.
2. Its output signal is sent to the ECU which then calculates
the boost pressure based on the programmed character-
istic curve.
Engine Oil Pressure and Temperature Sensor

The engine oil pressure and temperature sensor detects the
pressure and temperature of engine oil and sends these
information to the ECU (Electronic Control Unit)
Engine Coolant Temperature Sensor

The engine coolant temperature sensor detects the tempera-
ture of engine coolant and sends this information to the ECU
(Electronic Control Unit).
166
11. Electric System
Common Rail Pressure Sensor

Fuel passes through the passage in the common rail before A sensor to convert a fuel pressure value into an electric
it heads to the common rail pressure sensor. signal is connected to this diaphragm. This sensor produces
The tip of this pressure sensor is sealed with the diaphragm. a signal by amplifying the detected value before it delivers
After fuel is pressurized, it reaches the diaphragm of the the signal to the ECU (Electronic Control Unit) and evalua-
sensor through the hole. tion circuit.
Electric connections
Evaluation circuit
Diaphragm
High pressure
connection
Mounting thread
EE1OM099-E
Crankshaft Speed Sensor Camshaft Speed Sensor

The position of the pistons in the combustion chamber has a The camshaft speed sensor is used to control the intake and
major role in the fuel injection process. exhaust valves of the engine.
All pistons in the engine are connected to the crankshaft by This rotates at half speed of the crankshaft. When the piston
the connecting rod. is moving toward T.D.C., it determines whether the camshaft
The flywheel housing is equipped with the crankshaft speed position is in the compression stage or in the exhaust stage.
sensor to supply information for the position of all pistons. This information cannot be detected by the crankshaft speed
This speed sensor detects the rotation per minute of the sensor.
crankshaft, and this information is used by the ECU (Elec- On the other hand, during normal operation, information
tronic Control Unit) for calculation as an important factor. supplied by the crankshaft speed sensor is enough to tell the
condition of the engine.
In other words, if the camshaft speed sensor cannot detect
the camshaft position while the engine is running, the ECU
(Electronic Control Unit) receives engine condition informa-
tion from the crankshaft speed sensor.
167
11. Electric System
Pressure Limiter Valve 2. As soon as the pressure exceeds the operating pressure
1. The pressure limiter valve is connected to the end of the limit, load is applied to the spring of the valve to keep the
common rail, and its body houses a conical plunger valve fuel pressure at a normal level. After fuel passes through
in it. This valve is normally closed by force of the spring the valve, it is returned to the fuel tank through the return
at a normal operating pressure (1,800 bars) to keep the pipe.
pressure in the common rain.
Valve Plunger
Fuel
return
Common rail
Valve body Valve spring
EE1OM100-E
Accelerator Pedal Sensor

When a driver depresses the accelerator pedal, the acceler-
ator pedal sensor senses this and delivers this information to
the ECU (Electronic Control Unit).
As the voltage value is produced by the potentiometer in the
accelerator pedal sensor, this is used to calculate the posi-
tion of the pedal based on the programmed characteristic
curve.
168
11. Electric System
ECU (Electronic Control Unit)
ECU (Engine Control Unit) Connector

There are two ECU (Engine Control Unit) connectors: one for
connection to the vehicle and one for connection to the
engine.
1 2
Vehicle side connector Engine side connector
EJ9OM058-E
169
11. Electric System
ECU (Engine Control Unit) Input/Output
Engine output
Engine
Injector output
Input and output of ECU Fuel high pressure pump
- fuel metering unit
Coolant temperature sensor
Fuel temperature sensor
Boost pressure and
temperature sensor
Vehicle output
Oil pressure and
temperature sensor Preheating relay output
Crankshaft speed sensor Preheating display lamp
Camshaft speed sensor Diagnostic information
Common rail pressure sensor output lamp
Engine speed and vehicle speed
display
Vehicle
Starter switch Communication

Diagnostic switch
Engine diagnostic communication
CAN communication
EK1OM067
170
11. Electric System
Operational Conditions of Electronic Control 6. Driving record

Unit (ECU) 1) Writes the information related driving to the ECU.
1. Engine start 2) The information on fuel consumption, engine use time,
1) Sets the reference temperature for determining preheat and ECU use time is written in the ECU.
to the lowest temperature among coolant temperature, 3) The information can be monitored with the ECU diag-
fuel temperature, intake air temperature, and oil tempera- nosis device.
ture.
2) Sets the reference temperature for determining fuel
volume by setting the engine cooling temperature.
3) Determines the appropriate fuel volume to start the
engine, delivers the fuel to the engine, and measures the
RPM signal by using the crankshaft rev-count sensor.
2. Vehicle driving
1) Calculates the required data for driving a vehicle, such as
CAN data and the RPM transferred from the vehicle
control unit.
3. Driver-requested Adjustment of RPM
1) Controls the RPM based on request from the driver and
controls the engine based on the RPM requested by the
vehicle control unit.
4. Limp home
1) A function that allows drivers to drive their vehicle to the
repair center safely with the minimum conditions for
driving the vehicle when a fault code occurs.
2) Limp Home function is applied under the following condi-
tions.
• Accelerator pedal has failed: Regardless of pressing the
accelerator pedal, the vehicle is driven at a consistent
RPM.
• Sensor has failed: When sensors have failed, the vehicle
is driven with the consistent alternative values.
• Output is limited: According to the fault type, the fuel
volume delivered to the engine is limited. The limit is clas-
sified into four levels. The fuel volume is limited according
to the severity of the fault.
• Diagnosis Information Display Lamp: Provides informa-
tion of fault state to drivers for safe driving.
5. Failure diagnosis
1) When a fault occurs, the failure diagnosis information
display lamp on the gauge board is turned on.
2) With the failure diagnosis information display lamp,
drivers can see the fault code.
Note) It can be checked from the failure diagnosis informa-
tion on the gauge board.
3) It can be diagnosed by connecting the diagnosis unit to
the check connector at the back of the driver's seat.
171
11. Electric System
Starter
General Information
The start motor is installed behind the flywheel housing.
When disassembling the engine, soak the start motor's
pinion gear and ring gear into fuel and clean them with a
brush thoroughly. Then, apply grease to them prevent their
corrosion.
24V X 6.0kW
EK4OM010
CAUTION
The start motor should always be protected from mois-
ture and humid condition.
172
11. Electric System
Circuit Diagram
Circuit diagram
Battery Terminal
Solenoid Motor
Magnetic Switch
Solenoid Terminal
Switch Terminal
Ground Terminal
EJ9OM010-E
CAUTION
Before working on any electric system, make sure to
disconnect the negative battery cable in advance.
Connect the ground cable last after work to avoid a short
circuit during work.
173
11. Electric System
174
12. Others/Driving System

Crankshaft .............................................................................................................................177
Crankshaft Inspection ................................................................................................................................... 177
Crankshaft Bearing and Connecting Rod Inspection .................................................................................... 178
Piston ....................................................................................................................................181
Piston Disassembly....................................................................................................................................... 181
Piston Assembly ........................................................................................................................................... 181
Piston Inspection........................................................................................................................................... 181
Piston Ring Inspection .................................................................................................................................. 181
Piston and Piston Pin Inspection .................................................................................................................. 182
Connecting Rod ....................................................................................................................183
Connecting Rod Inspection ........................................................................................................................... 183
Assembly of Connecting Rod........................................................................................................................ 183
Others ...................................................................................................................................184
Engine Timing ............................................................................................................................................... 184
175
176
General Information Crankshaft
General Information Crankshaft Inspection

1. This engine cools the pistons through the oil gallery. 1. Inspection for defect
To obtain optimum cooling efficiency from the gallery, the 1) Visually check the crankshaft journal and crank pin for a
nozzle shape, nozzle position and oil flow play important scratch or crack.
roles. The piston gallery is designed to facilitate oil flow 2) Perform the magnetic particle test or dye penetrant test
efficiency in order to obtain superior cooling efficiency. (color check) to check the crankshaft for a crack. If the
2. The crankshaft is a single unit. The crankshaft and rear crankshaft is cracked, replace it.
oil seal prevent oil from getting into the flywheel housing. 2. Wear measurement
3. The connecting rod is a single unit as well. As its big end 1) Use a O.D. micrometer to measure the journal and pin of
can be separated horizontally, it can be removed through the crankshaft in the specified direction as illustrated to
the top of the cylinder with the piston. An alloy bearing check its wear amount.
assembly is used on the operating part of the crankshaft
and connecting rod.
4. The camshaft, oil pump and fuel high-pressure pump are
driven by the gear connection in the flywheel housing.
5. The overhead valve is operated through the valve tappet,
push rod and rocker arm from the camshaft.
EH6OM026
B B
B B
EH6OM033
2) If the wear amount is over the allowable limit, grind the

crankshaft to install an undersized bearing.
3) However, if the wear amount is within the allowable limit,
correct it with an oily whetstone or fine oily sandpaper.
177
Note) Use a sandpaper soaked in oil. 3. Crankshaft deflection

Allowable 1) Place the crankshaft on two V-blocks.
Standard
Limit 2) Place a dial gauge on the surface plate. While turning the
Ø83.966 ~ crankshaft, measure the deflection of the crankshaft.
Journal O.D. Ø82.966 mm
Ø83.988 mm
Ø70.971 ~
Pin O.D. Ø69.971 mm 0.06 mm 0.1 mm or below
Ø70.990 mm
4) If the pin wear amount is over the allowable limit, grind

the crank journal and crank pin and use an undersized
bearing.
Note) Use a sandpaper soaked in oil to grind the crankshaft.
5) There are four types of undersized bearings. The crank-
shaft can be reused by grinding it according to the under-
sized bearing to be used.
• Standard
• 0.25 (I.D.: 0.25 mm smaller than standard)
6) Standard for section "R"
EH6OM035
• Crank pin section "R": 4.50-0.2
• Crank journal section "R": 4.00-0.2 Crankshaft Bearing and Connecting Rod
Inspection
CAUTION 1. Visual inspection
1) Visually check the crankshaft bearing and connecting rod
When grinding the crankshaft, the section "R" at the end bearing for a scratch, abnormal wear or damage.
of the bearing should be precisely ground. 2. Oil clearance between crankshaft and bearing (method 1:
There should be no step or rough surface. using dial gauge):
1) Main bearing clearance
a) Install the main bearing to the cylinder block, tighten the
bearing cap to the specified torque, and measure the
"R" inside diameter.
Torque 30 kgf.m
"R"
Normal Abnormal Abnormal
EH6OM034
EH6OM036
178
b) Compare the inside diameter of the main bearing with the

outside diameter of the crankshaft journal to calculate the
oil clearance.
Main Bearing Oil Clearance

0.052 ~ 0.122 mm 0.15 mm
2) Connecting rod bearing clearance
a) Install the connecting rod bearing to the connecting rod
bearing cap, tighten the bolt to the specified torque, and
measure the inside diameter.
Torque 18 kgf.m
EH6OM038
c) If the clearance is over the allowable limit, grind the

CAUTION crankshaft journal and pin sections to install an under-
When tightening the connecting rod bolt, tighten it with sized bearing.
a hand until its head touches the bolt seat of the 3. Oil clearance between crankshaft and bearing (method 2:
connecting rod. Then, tighten it finally with a torque using plastigauge.):
wrench. 1) Install the crankshaft onto the cylinder block.

2) Place a plastigauge onto the journal and pin sections of
the crankshaft.
3) Install the bearing cap and tighten the bolt to the specified
torque.
4) Unscrew the bolt to remove the bearing cap.
A 5) Measure the thickness of the flat section of the plasti-
gauge with a plastigauge measuring ruler.
B
6) This is the oil clearance.
4. Bearing spread and crush
1) Inspection
a) When installing the bearing, check if a large crush is felt.
1
2
EH6OM037
b) Compare the two values obtained from measurement of

the inside diameter of the connecting rod bearing with the
outside diameter of the crankshaft pin to calculate the oil
clearance.

0.034 ~ 0.098 mm 0.15 mm
EH6OM039
179
OA OB
Spread = O A - O B
EDM2047I-E EA6M064I
2) Bearing cap crush 4) Axial play of crankshaft

a) Install the bearing and cap to the cylinder block. a) Install the crankshaft onto the cylinder block.
b) Tighten the bolt to the specified tightening torque. b) Use a dial gauge to measure the axial play of the crank-
c) Unscrew one bolt completely and use a feeler gauge to shaft.
measure the clearance between the bearing cap and
cylinder block. Standard Allowable Limit
0.15 ~ 0.289 mm 0.5 mm
EH6OM041
EH6OM040
3) Connecting rod bearing crush

a) Install the bearing and cap to the big end of the
connecting rod.
b) Tighten the bolt to the specified tightening torque.
c) Unscrew one bolt completely and use a feeler gauge to
measure the clearance between the bearing cap and
connecting rod big end.
180
Piston
Piston Disassembly 3) Perform the measurement at 3 locations of the cylinder

1. Disassemble the piston according to the specified disas- liner: the top ring contact section, middle section, and oil
sembly steps. ring contact section around the B.D.C. in the 45° direc-
tion.
4) Calculate the average value from the measurement
Piston Assembly
results and exclude the maximum and minimum values.
1. Assemble the piston according to the specified assembly
5) The clearance can be calculated by subtracting the
steps.
outside diameter of the piston from the inside diameter of
the cylinder liner.
Piston Inspection
6) this value is over the allowable limit, replace either the
1. Visual inspection piston or cylinder liner which is worn more.
1) Visually inspect the piston for a crack, scratch and wear.
2) Especially, check if the ring groove is worn. Clearance between piston and liner
2. Clearance between piston and cylinder liner Standard 0.233 ~ 0.296 mm
1) Use an O.D. micrometer to measure the outside diameter
of the piston at the position 12 mm down from the bottom Piston Ring Inspection
of the piston in the orthogonal direction of the piston pin 1. Visual inspection
hole. 1) If any worn or damaged piston ring is found during disas-
sembling the engine, replace it with a new one.
2. Piston ring gap
1) Insert the piston into the top of the cylinder at a right angle
to the cylinder liner wall.
2) Use a feeler gauge to measure the piston ring gap.
12 mm Standard Allowable Limit

Ring No. 1. 0.30 ~ 0.50 mm 1.5 mm
Ring No. 2 1.20 ~ 1.35 mm 1.5 mm
Oil ring 0.30 ~ 0.50 mm 1.5 mm
EH6OM042
2) Use a cylinder I.D. gauge to measure the inside diameter

of the cylinder liner.
Feeler gauge
EH6OM044-E
3) If the piston ring gap is over the allowable limit, replace

the piston ring with a new one.
EH6OM043
181
3. Piston ring side clearance 3. Measure the clearance between the piston pin and
1) Install the compression ring and oil ring to the piston's connecting rod bushing.
ring groove.
2) Use a feeler gauge to measure the side clearance of the
ring.

Ring No. 1. - -
Ring No. 2 0.07 ~ 0.105 mm 0.15 mm
Oil ring 0.05 ~ 0.09mm 0.15 mm
ring or piston.
4. Piston ring tension
1) Use a tension gauge to measure the tension of the piston
ring.
2) If the measurement is over the allowable limit, replace the EH6OM067
piston ring. 4. If the measurement is over the allowable limit, replace
either one of them which is worn more.
Standard
Ring No. 1 1.82 ~ 2.72 kg Standard Allowable Limit
Ring No. 2 1.61 ~ 2.41 kg 0.008 mm 0.08 mm
Oil ring 4.40 ~ 5.96 kg 1) Measure the height differences from the cylinder block
surfaces at 2 points of the piston topside: A and B.
Piston and Piston Pin Inspection 5. Check the mounting status of the piston and piston pin.
1. Measure the wear amount of the piston pin.
CAUTION
If the piston needs to be replaced, replace the piston pin
as well.
EA0M4031
2. If the measurement is over the allowable limit, replace the

pin.
Standard Value for Piston Pin Allowable Limit

EH8OM008
Ø43.994 ~ Ø40.000 mm Ø43.94 mm
182
Connecting Rod
Connecting Rod Inspection Assembly of Connecting Rod

1. Distortion 2) Connect the connecting rods.
1) Check the distortion of the connecting rod. Note) Refer to Chapter (Procedure of Assembling an
2) Fit the connecting rod to its measuring device and use a Engine).
feeler gauge to check its distortion.
0.02 mm 0.1 mm or below
3. Wear
1) Install the connecting rod to the crankshaft.
2) Use a feeler gauge to measure the side clearance at the
big end of the connecting rod.
3) Install the connecting rod to the piston.
Feeler gauge 4) Measure the side clearance at the small end of the
connecting rod.
connecting rod.

0.170 ~ 0.248 mm 0.50 mm
EA0M4034-E
3) If the connecting rod is distorted, do not reuse it, but

replace it with a new one.
2. Hole parallelization
1) Measure the parallelization of the small end bushing hole
and big end bearing hole of the connecting rod.
Note) Use the connecting rod measuring device and feeler
gauge for this measurement.
183
Others
Engine Timing
High pressure pump idle gear

(18 Z)
Camshaft driving gear

(56 Z)
High pressure pump

driving gear
(33 Z)
Idle gear
(A gear Z=44)
(B gear Z=25)

(44 Z)
(33 Z)
EK4OM009-E
184

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950106-01727

DL08P Tier4 Final

1. General Introduction .................................................................................................................1

2. Operation and Maintenance .....................................................................................................7

3. Performance and Specifications ............................................................................................15

4. Regular Inspection ..................................................................................................................31

5. About the Engine .....................................................................................................................51

6. Cooling System .......................................................................................................................91

8. Fuel System ...........................................................................................................................103

9. Intake/Exhaust System .........................................................................................................115

10. Cylinder Block/Head .............................................................................................................143

11. Electric System ......................................................................................................................155

12. Others/Driving System ..........................................................................................................175

General Information ..................................................................................................................3

General Information Danger, Warning, Caution and Note

General Information General Information

The maintenance methods stated in this Operation and occur.

Maintenance Manual are the most efficient and safest work

Note) Indicates additional description, information, and

Engine Maintenance 9. Do not operate engine without coolant.

Prevention of damage and abrasion CAUTION

8. If there are gauges for battery, oil pressure and coolant

Starting and Stopping of the Engine .........................................................................................9

Starting and Stopping of the Engine

Preparing for Start After Starting the Engine

Inspection after Starting the Engine Operation in Winter

be damaged or broken. improve the cold start performance.

4. Check the engine status through the alarm indicator lamp

Revolutions per Minute (rpm)

Preventing Overcooling of the Engine Inspection and Repair of the Engine

Inspection and Repair of Supercharger

Engine Specifications and Performance .................................................................................17

Engine Specifications and Performance

4-stroke, Inline, Water-cooled,

Combustion Chamber Type Direct Injection

Cylinder Liner Type Dry Liner

Timing Gear System Gear Driven Type

Cylinder Bore 108 mm

Cylinder Stroke 139 mm

Total Displacement 7,640 cc

Compression Ratio 17.4 : 1

Compression Pressure 28 bar at 200 rpm

Engine Dimension (L x W x H) 1,324 x 958 x 1,249 mm

Engine Weight 855 kg 840 kg 855 kg 840 kg

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

Cooling Type Water-forced Cooling

Coolant Pump Type Centrifugal (Impeller Type)

Type Wax Pellet Type

Coolant Temperature Indicator Coolant Temperature Sensor Mounted

Lubricating Type Forced Lubrication System

Idle above 1.5 bar

Oil Grade API CJ-4

Oil Capacity Max. 39 L 32 L 39 L 32 L

Allowable Oil Pan Inclination

Oil Pump Type Gear Type

Oil Coolant Type Water-cooled Layered Plate

Oil Strainer Type Full Flow (Cartridge)

Oil Separator Type Impact (CCV)

Hydraulic Pressure Indicator Oil Pressure Sensor