65.

99897- 8111

Operation &
Maintenance Manual

DIESEL ENGINE for INDUSTRIAL

DV11

PS-MMI0608-E1
 DV11
Operation and Maintenance

FOREWORD
This maintenance manual is designed to serve as a reference for DOOSAN Infracore (here
after DOOSAN’s) customers and distributors who wish to gain basic product knowledge on
DOOSAN's DV11 Diesel engine.
This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct
injection type) has been so designed and manufactured to be used for industrial purpose.
That meets all the requirements such as low noise, fuel economy, high engine speed, and
durability.
To maintain the engine in optimum condition and retain maximum performance for a long
time, CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.

Removal Adjustment

Installation Cleaning

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufacturer's

Directional indication Lubricate with oil

Inspection Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental

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

Jan. 2006

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Operation and Maintenance

CONTENTS

1. Safety regulations & engine specifications

1.1. Safety regulations 1
1.2. Engine specifications 6
1.3. Engine power 7
1.4. Performance curve 8
1.5. Engine assembly 11

2. Technical information
2.1. Engine model and serial number 14
2.2. Diagnostic tool (SCAN-200) 14
2.3. Engine characteristic 15
2.4. Diagnosis and remedy 35
2.5. Engine inspection 45

3. Disassembly and reassembly of major components

3.1. Engine disassembly 47
3.2. Measurement and inspection on major parts 60
3.3. Engine reassembly 81
3.4. Fuel injection system 102
3.5. Electrical system 116
3.6. Engine diagnostic 125
3.7. Operating condition of the ECU 130

4. Commissioning and operation

4.1. Preparations 132
4.2. Operation of a new engine (Break-in) 132
4.3. Inspections after Starting 134
4.4. Operation in winter time 136
4.5. Tuning the engine 138
4.6. Maintenance and care 139
4.7. Cooling system 140
4.8. Adjustment of valve clearance 143
4.9. Tightening the cylinder head bolts 145

5. Maintenance of major components

5.1. Cooling system 147
5.2. Lubrication system 151
5.3. Turbo charger 154
5.4. Belt 163

6. Special tool list 165

● Appendix 168
● Worldwide network

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Operation and Maintenance

1. Safety Regulations & Specifications

1.1. Safety Regulations

1.1.1. General notes
z Day-to-day use of power engines and the service products necessary for running
them presents no problems if the persons occupied with their operation,
maintenance and care are given suitable training and think as they work.
z This summary is a compilation of the most important regulations, These are
broken down into main sections which contain the information necessary for
preventing injury to persons, damage to property and pollution. In addition to
these regulations those dictated by the type of engine and its site are to be
observed also.

IMPORTANT:
If despite all precautions, an accident occurs, in particular through contact
with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being
splashed in the eyes etc, consult a doctor immediately.

1.1.2. To prevent accidents with injury to persons

(1) Engine starting and operation
z Before putting the engine into operation for the first time, read the operating
instructions carefully and familiarize yourself with the “critical” points. If you
are unsure, ask your DOOSAN representative or service man.
z For reason of safety we recommend you attach a notice to the door of the
engine room prohibiting the access of unauthorized persons and that you
draw the attention of the operating personal to the fact that they are
responsible for the safety of person who enter the engine room.
z The engine must be started and operated only by authorized personnel.
z Ensure that the engine cannot be started by unauthorized person.
z When the engine is running, do not get too close to the rotating parts.
z Do not touch the engine with bare hands when it is warm from operation risk
of bums.
z Exhaust gases are toxic. If it is necessary to run an engine in an enclosed
area, remove the exhaust gases from the area with an exhaust pipe
extension.

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(2) Maintenance and care

z Always carry out maintenance work when the engine is switched off. If the
engine has to be maintained while it is running, e.g. changing the elements of
change-over filters, remember that there is a risk of scalding. Do not get too
close to rotating parts.
z Change the oil when the engine is warm from operation.

CAUTION:
There is a rise of burns and scalding. Do not touch oil drain plug or oil filters
with bare hands.

z Take into account the amount of oil in the sump. Use a vessel of sufficient
size to ensure that the oil will not overflow.
z If change or refill the cooling water, disassemble the drain plug when the
engine has cooled down. Heated cooling water has the risk of scalding and
safety accidents.
z Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit
and any additional hydraulic oil circuit) during the operation. The fluids which
flow out can cause injury.
z Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank
must be filled only when the engine is switched off.
z Keep service products (anti-freeze) only in containers which can not be
confused with drinks containers.
z Comply with the manufacturer's instructions when handling batteries.

CAUTION:
Accumulator acid is toxic and caustic. Battery gases are explosive.
Therefore it should be done by an expert of the handling professionally.

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

z Checking, setting and repair work must be carried out by authorized
personnel only.
z Use only tools which are in satisfactory condition. Slip caused by the worn
open-end wrench could lead to injury.

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z When the engine is hanging on a crane, no-one must be allowed to stand or

pass under it. Keep lifting gear in good condition.
z When do electric weld, stop the engine, power off, then remove the wire
harness’ connector which is connected to the ECU.
z Do not weld the electric control unit (ECU) absolutely, and do not damage on
it by electrical or mechanical shock.
z When working on the electrical system disconnect the battery earth cable
first. Connect it up again last in prevent short circuits.

1.1.3. To prevent damage to engine and premature wear

(1) Never demand more of the engine than it was designed to yield for its intended
purpose.
Detailed information on this can be found in the sales literature. Engine control
unit must not be adjusted without prior written permission of DOOSAN.
(2) If faults occur, find the cause immediately and have it eliminated in order to
prevent more serious of damage.
(3) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility
for damage resulting from the installation of other parts which are supposedly
"just as good”.
(4) In addition to the above, note the following points.
z Never let the engine run when dry, i.e. without lube oil or coolant.
z Pay attention to cleanliness. The Diesel fuel must be free of water.
z Use only DOOSAN approved service products (engine oil, anti-freeze and
anticorrosion agent)
z Refer to the subjects of recommendation of the fuel.
z Have the engine maintained at the specified intervals.
z Do not switch off the engine immediately when it is warm, but let it run without
load for about 5 minutes so that temperature equalization can take place.
z Never put cold coolant into an overheated engine.
z Do not add so much engine oil that the oil level rises above the max. marking
on the dipstick. Do not exceed the maximum permissible tilt of the engine.
z Always ensure that the testing and monitoring equipment (for battery charge,
oil pressure, coolant temperature) function satisfactorily.

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z Do not let the raw water pump run dry. If there is a risk of frost, drain the
pump when the engine is switched off.

1.1.4. To prevent pollution

(1) Engine oil, filter elements, fuel filters
z Take old oil only to an oil collection point.
z Take strict precautions to ensure that oil does not get into the drains or into
the ground. The drinking water supply could be contaminated.
z Filter elements are classed as dangerous waste and must be treated as such.

(2) Coolant
z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
z When disposing of spent coolant comply with the regulations of the relevant
local authorities.

1.1.5. Notes on safety in handling used engine oil

Prolonged or repeated contact between the skin and any kind of engine oil
decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil
also contains dangerous substances which have caused skin cancer in animal
experiments. If the basic rules of hygiene and health and safety at work are
observed, health risks are not to the expected as a result of handling used engine oil
.
< Health precautions >
z Avoid prolonged or repeated skin contact with used engine oil.
z Protect your skin by means of suitable agents (creams etc.) or wear protective
gloves.
z Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
z After washing apply a fatty skin cream to the skin.
z Change oil-soaked clothing and shoes.
z Do not put oily rags into your pockets.

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CAUTION:
Ensure that used engine oil is disposed of properly.
- Engine oil can endanger the water supply.

For this reason do not let engine oil get into the ground, waterways, the drains or the
sewers. Violations are punishable. Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local
authorities.

1.1.6. General repair instructions

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

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1.2. Engine Specifications

Engine model
Items DV11

Water-cooled, 4 cycle V-type 90°, Turbo charged &

Engine type
intercooled
Combustion chamber type Direct injection type
Cylinder liner type Wet type
Timing gear system Gear driven type
No. of piston ring 2 compression ring, 1 oil ring
No. of cylinder-bore x stroke (mm) 6 – 128 × 142
Total piston displacement (cc) 10,964
Compression ratio 17.0 : 1
Engine dimension
1,060 x 1,039 x 1,345
(length x width x height) (mm)
Engine weight (kg) 882
Rotating direction (from flywheel) Counter clockwise
Firing order 1–4–2–5–3-6
Fuel high pressure pump type Bosch CP3.4 fuel high pressure pump type
Engine control type Electric control type(ECU)
Injector type Multi-hole(8 x φ0.197 Bosch DLLA146)
Fuel injection pressure (kg/cm2) 250bar (operating pressure 1,600bar)
Intake valve 0.4
Valve clearance
Exhaust valve 0.5
Open at 24° (B.T.D.C)
Intake valve
Close at 30° (A.B.D.C)
Open at 52.5° (B.B.D.C)
Exhaust valve
Close at 14.5° (A.T.D.C)
Fuel filter type Full-flow (cartridge)
Oil pressure at idle speed 1.0 ~ 3.0
(kg/cm2) at rated speed 3.0 ~ 5.5
Using lubrication oil ACEA-E5 (API CI-4 class)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Full-flow (cartridge)
Lubricating oil capacity (max./min.) (lit) 41 / 27
Oil cooler type Water cooled
Oil pressure indicator Oil pressure sensor
Water pump Belt driven centrifugal type
Cooling method Pressurized circulation
Cooling water capacity(engine only) (lit) 14.3
Type Wax pallet type (71 ∼ 85 °C)
Open at (°C) 71 °C
Thermostat
Open wide at (°C) 85 °C
Valve lift (mm) 8

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Engine model
DV11
Items
Water temperature indicator Water temperature sensor mounted
Turbo charger Exhaust gas driven type (waste gate)
Engine stop system Fuel feeding shut-off by ECU
Alternator (voltage – capacity) (V - A) 24 - 50
Starting motor(voltage – output) (V-kW) 24 – 7.0
Air heater capacity (V – A) 24V – 2.64 kW
Battery capacity (V - AH) 20 - 150

1.3. Engine Power

tolerance : ±5%

Engine model Performance

Remark
Power Torque Low idle High idle
Model Suffix
(PS / rpm) (kg.m / rpm) (rpm) (rpm)

EUJEA 333 / 1,800 157 / 1,300 750 1,900 Tier-2

EUJEB 333 / 1,800 157 / 1,300 750 1,900 Tier-3

DV11
EUJEC 297 / 1,800 140 / 1,300 750 1,900 Tier-2

EUJED 297 / 1,800 140 / 1,300 750 1,900 Tier-3

* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349)

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1.4. Engine Performance Curve

1.4.1. Performance curve (333PS)

Torque (kg.m)
Output (PS)

Fuel consumption (g/ps.h)

Revolution (rpm)

Performance ISO 1585 (SAE J1349)

Output (max.) 245 kW (333PS) / 1,800 rpm

Torque (max) 1,540 N.m (157 kg.m) / 1,300 rpm

Fuel consumption (min.) 211g/kW.h (155 g / PS.h)

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1.4.2. Performance curve (297PS)

Torque (kg.m)
Output (PS)

Fuel consumption (g/ps.h)

Revolution (rpm)

Performance ISO 1585 (SAE J1349)

Output (max.) 218 kW (297PS) / 1,800 rpm

Torque (max) 1,373 N.m (140 kg.m) / 1,200 rpm

Fuel consumption (min.) 199 g/kW.h (146 g / PS.h)

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1.4.3. Performance curve (297PS : Tier-3)

Torque (kg.m)
Output (PS)

Fuel consumption (g/ps.h)

Revolution (rpm)

Performance ISO 1585 (SAE J1349)

Output (max.) 218 kW (297PS) / 1,800 rpm

Torque (max) 1,373 N.m (140 kg.m) / 1,200 rpm

Fuel consumption (min.) 218 g/kW.h (160 g / PS.h)

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1.5. Engine Assembly

1.5.1. Engine sectional view (longitudinal)

3 4 5 6

7 8 9 10 11 12

1 Vibration damper 7 Drain plug

2 Thermostat 8 Oil suction pipe
3 Exhaust valve 9 Crank shaft
4 Push rod 10 Oil pump
5 Tappet 11 Fly wheel
6 Cam shaft 12 Flywheel housing

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1.5.2. Engine sectional view (cross)

4 5

7
3
8

1 Oil cooler 5 Common rail

2 Cylinder liner 6 Injector
3 Cylinder head 7 Oil spray nozzle
4 Fuel high pressure pump 8 Connecting rod

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1.5.3. Engine assembly

6
8

9
4

3 10

15

11
16
6
12
17
111
13
18

14 19

20

21

1 Electric control unit (ECU) 8 Lifting hook 15 Fuel filter

2 Air con. compressor 9 Air pipe 16 Alternator
3 Water pump (Intercooler to intake manifold) 17 Intake manifold
4 Water outlet 10 Starting motor 18 Breather
5 Idle pulley 11 Oil filler cap 19 Water inlet
6 Air pipe 12 Air heater 20 Mounting bracket
( turbocharger to intercooler) 13 Cylinder head cover 21 Oil filter
7 Turbocharger 14 Flywheel housing

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2. Technical Information
2.1. Engine Model and Serial Number
z The engine model and serial

number is located on the engine as

illustrated.
Engine number
z These numbers are required when (located the
cylinder block)
requesting warranty and ordering

parts. They are also referred to as

engine model and serial number

because of their location.

z Engine serial No. (example 1 : DV11)

DV11 5 00001 EA

Engine model suffix (EUJEA)

Serial no.
Production year (2005)
Engine model

z Engine serial No. (example 2 : DV11)

DV11 5 00001 EB

Engine model suffix (EUJEB)

Serial no.
Production year (2005)
Engine model

2.2. Diagnostic tool (SCAN-200)

The SCAN-200 is a powerful tool to
support the service personal
diagnosing and repairing of electric
system for vehicle with installed DV11
engine.

< SCAN-200 tool>

z High resolution digital type display.
z Soft touch key-board.

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z Diagnosis trouble code or sensor

Diagnostic tool
data operation via help.
z Large memory expansion ROM
pack data storage area for flight
recorded data.

NOTE:
Inspect the electrical parts problem
with SCAN-200 and refer diagnostic
manual.

2.3. Engine Character

z DOOSAN ‘s DV11 diesel engine apply the over head valve and the turbocharger,
is the electric control engine of the air cooling type by the cooling fan.
z The fuel is stored under pressure in the high-pressure accumulator (the "Common
Rail") ready for injection. The injected fuel quantity is defined by the driver, and
the start of injection and injection pressure are calculated by the ECU on the
basis of the stored map. The ECU then triggers the solenoid valve sensor that the
injector (injection unit) at each engine cylinder injects accordingly.
z Oil gallery cooling is used for the
piston of the engine. The design of
the gallery, the design and location
of the oil spray nozzle and the
quantity of oil flowing in the gallery
are critical in order to achieve the
desired temperature reduction. The
cross section shape of the gallery
should be designed to achieve
sufficient oil movement to
maximize cooling efficiency.

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2.3.1. Cylinder block

z The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is
extended to a level below the crankshaft center line. The engine has replaceable
wet cylinder liners and individual cylinder heads.

2.3.2. Piston/ Connecting rod/ Crank assembly

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

2.3.3. Electric control unit : ECU

z This electric control unit is used to
control the engine feed fuel.
z ECU is connected with various
sensors, control the engine to keep
the optimum condition on the basis
of input values from this sensors.

CAUTION:
Do not connect or disconnect the
ECU to/from the wiring harness
without first removing the negative
(-) battery cable from the battery. Do
not perform remove the inner parts
of ECU.

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2.3.4. Common rail system

z Pressure generation and fuel injection are completely decoupled from each
other in the "Common Rail" fuel injection system. The injection pressure is
generated independent of engine speed and injected fuel quantity stored in the
ECU.

No. 3 injector

No. 2 injector

No. 1 injector

Pressure limiter
valve

No. 6 injector

No. 5 injector

No. 4 injector

Common rail
pressure sensor

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2.3.5. Engine timing

z Camshaft, oil pump and fuel high pressure pump are driven by a gear train
arranged at the inside of flywheel housing.

High pressure pump

gear (Z=24)

High pressure pump drive gear

(Z=80)

Cam shaft gear

(Z=86)

Crank shaft gear

(Z=43)

Oil pump drive gear

(Z=44)

Viewed from crankshaft pulley

2.3.6. Valves
z The overhead valves are actuated via tungsten carbide tappets, push rods and
rocker arms from the camshaft.

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2.3.7. Lubrication system

z The engine is equipped with force-feed lubrication. The pressure is produced by a
gear pump whose drive gear is in direct mesh with the crankshaft gear at the
flywheel end.
z The oil pump draws the oil from the oil sump and delivers it through the oil cooler
and oil filter to the main distributor gallery and from there to the main bearings,
big-end bearings and camshaft bearings as well as to the small-end bearings and
the rocker arms. The turbocharger is also connected to the engine lubricating
system. The cylinder walls and timing gears are splash-lubricated.
z Each cylinder has an oil jet provided for cooling the underside of the pistons. The
lube oil is cleaned in a full-flow oil filter.

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2.3.8. Engine oil

z Check oil level with the oil level gauge and replenish if necessary.
z Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ∼
10 minutes for oil drain into the crankcase before checking oil level. The oil level
must be between Max. and Min. lines on the gauge.
z Engine oil should be changed at the specified intervals. Oil filter cartridge should
be changed simultaneously.

- First oil change : After 50Hr operating

First oil change After 50Hr operating

Oil change interval Every 500Hr

z The following oils are also recommended.

Engine oil SAE No. API No.

ACEA-E5
DV11 SAE 10W40
(API CI-4)

z Engine oil capacity

Engine oil capacity

Oil pan inside
Total
Engine model Max. Min.
(lit)
(lit) (lit)

DV11 41 27 44

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Engine oil viscosity – ambient temperature

Ambient
temperature

2.3.9. Oil filter

z Check for oil pressure and oil leaks,
and repair or replace the oil filter if
necessary.
z Change the oil filter cartridge
simultaneously at every
replacement of engine oil.

2.3.10. Poly belt

z Use a fan belt of genuine part, and
replace if damaged, frayed, or
deteriorated.
z Check the fan belt for belt tension,
inspect suitability for specified
dimensions.

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- Adjust the tension of poly belt

when pressed down with
specified force (F kg):

T = 0.015 x S
(Deflection : 1.5 mm per 100 mm)

2.3.11. Air cleaner

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

2.3.12. Pre fuel filter

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

2.3.13. Fuel filter

z The filter cartridge should be
replaced at every 500Hr.

Fuel filter &

cartridge

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2.3.14. Fuel requirements

z DOOSAN diesel engines was designed to use Number 2-D diesel fuel or

equivalent that meets specification ASTM D (Grade Low Sulfur). For maximum fuel

economy, Number 2-D fuel whenever possible. When temperatures are below -7

°C, use Number 1-D fuel. If Number 1-D fuel is not available, the mixture of one
kerosene to two gallons of Number 2-D fuel can be used. Once kerosene has

been added, the engine should be run for several minutes to mix the fuel.

2.3.15. How to select fuel oil

z Fuel quality is an important factor in obtaining satisfactory engine performance,

long engine life, and acceptable exhaust emission levels. DOOSAN engines are

designed to operate on most diesel fuels marketed today. In general, fuels

meeting the properties of ASTM Designation D975 (grades 1-D and 2-D : Grade

Low Sulfur) have provided satisfactory performance.

z The ASTM 975 specification, however, does not in itself adequately define the

fuel characteristics needed for assurance of fuel quality.

z The properties listed in the fuel oil selection chart below have provided optimum

engine performance. Grade 2-D fuel is normally available for generator service.

Grade 1-D fuel should not be used in pleasure craft engines, except in an

emergency.

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z Fuel oil selection chart

Fuel classification Unit DIN EN 590

Cetane number - ≥ 51

Cetane index - ≥ 46

Density @ 15°C kg/m3 820 ~ 845

Poly aromatic hydrocarbon % (m/m) ≤ 11

Sulfur content mg/kg ≤ 50

Flash point °C ≥ 55

Ash content % (m/m) ≤ 0.01

Water content mg/kg ≤ 200

Particulate matter content mg/kg ≤ 24

Copper corrosion 50°C, 3h grade 1

Oxidation stability g/m3 ≤ 25

Lubricity (wsd 1.4 @ 60°C) g/m3 ≤ 460

Viscosity (40°C) mm2/s 2.0 ~ 4.5

Distillation (95%) °C ≤ 360

Note:

The cloud point should be 6°C below the lowest expected fuel temperature to
prevent clogging of fuel fitters by crystals

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2.3.16. Fuel injection system

z The fuel is stored under pressure in the common rail ready for injection. The
injected fuel quantity is defined by the driver, and the start of injection and
injection pressure are calculated by the ECU on the basis of the stored maps. The
ECU then triggers the solenoid valves so that the injector (injection unit) at each
engine cylinder injects accordingly.

Common rail

Fuel high
pressure pump
Fuel filter (CP 3.4 fuel pump)

Pre fuel filter

Injector

Cylinder
ECU head
Fuel cooler

Fuel high pressure

connector

Fuel tank

2.3.17. Bleeding the fuel system

z Loosen the fuel delivery pipe
connected to the fuel high
pressure pump from the
secondary fuel filter, operate
manually the priming pump until
bubble is not found, and bleed the
system.

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2.3.18. Injector & high pressure connector

z Be careful to mix the foreign matter
High pressure fuel
into the injector and inside of the connector nut
Injector harness
connector
connector for connecting the high O-ring
Injector
pressure at disassembly and check.
z O-ring and cupper washer should
Seal ring
be changed with new one at
reassembly.
z Assemble after coat the oil on the
O-ring.
z Assemble after check serial number
at replacement.
z Have to assemble according to assembly order refer to the chapter of the
disassembly and reassembly.

2.3.19. Inter cooler

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

Air / air intercooler

with radiator
(combined radiator)

Air flow by cooling fan

Hot air by turbo charger

compressor

Cooled air to intake

manifold (max. 50°C)

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2.3.20. Turbo charger

z The turbocharger needs not any
specific maintenance.
z Every time of engine replacement, a
leakage or clogging of oil pipes
should be inspected.
z Air cleaner should be maintained
carefully for nut or foreign material
not to get in. Periodic inspection
should be applied on the
compressed air and exhaust gas
pipes, For leaking air will bring the
overheat engine, an immediate
repair must be done.
z During the operation that is surrounded by the dust and oil mixed air, frequent
cleaning must be done on the impellers. Tear down the impeller casing (attention:
be careful not to bend) and must clean with non-acid solvent solution. If necessary,
use plastic scraper If impeller is severely polluted, dip the impeller into solution
and may be better to clean it with stiff brush
Then one thing to beware is to dip only impeller part and so do not support by
impeller but bearing housing.

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2.3.21. Cooling system

The engine has a liquid-cooling system. The fresh water pump is a maintenance-free
by belt from the crankshaft pulley.

z Check the coolant level of the expansion tank by removing the expansion tank
filler cap, and add coolant if necessary
z When injecting antifreeze solution, first drain out the old coolant from the cylinder
block and radiator, and then clean them with cleaning solution.
z Be sure to mix soft water with antifreeze solution.

Cylinder head Cylinder head

Cylinder No

Oil cooler

Cylinder block
Thermostat
Water pump

Radiator

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2.3.22. Coolant pressure cap

z Check the pressure valve opening
pressure using an expansion tank
Radiator cap
cap tester. Radiator cap

z Replace the filler cap assembly if Surge tank cap

the measured valve does not reach
Radiator
the specified limit.

NOTE :
Because it is dangerous to open
the pressure cap quickly when
coolant is hot, after lowering the
inside pressure of the tank by slow-
opening at first open it fully.
Drain valve

2.3.23. Cooling water

z Regarding the cooling water that is to be used for engine, the soft water not the
hard water must be used.
z The engine cooling water can be used diluting it with anti-freezing solution 40%
and the additive for rust prevention (DCA4) 3 ∼ 5 %.
z The density of above solution and additive must be inspected every 500 hours to
maintain it properly.

NOTE:
The proper density control of anti-freezing solution and rust preventing
additive will be able to prevent the rusting effectively and maintain the stable
quality of engine.
For the improper control might give the fatal damage to the cooling water
pump and cylinder liners, detail care is needed.

z Since DV11 engine cylinder liner is wet type, particularly the cooling water control
should be applied thoroughly.

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z The density of anti-freezing solution and additive for rust prevention is able to be
confirmed by the cooling water test kit.
(Fleetguard CC2602M or DOOSAN 60.99901-0038)

z How to use the cooling water test kit

(1) When the cooling water temp. of engine is in the range of 10 ~ 55°C, loosen
the plug for cooling water discharge and fill the plastic cup about a half.

NOTE:
In taking the cooling water sample, if the water in auxiliary tank were taken, it
is hard to measure the accurate density. Take the cooling water sample
necessarily loosening the cooling water discharge plug.

(2) At the state of a test paper soaked in the sampled water, after 3 - 5 seconds
past, take the paper out through water agitation, and shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.

NOTE:
However, it should not elapse longer than 75 sec, and if it did, the hue would
change.

(4) Make the numerical value by comparing the test paper which hue has
changed with the color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color
indication of test paper storage bottle, confirm the density. (Then, the density
indication must be in the hue range of 33% to 50%).
(6) The brown at the middle of test paper and the lower pink color indication
represent the additive state for rust prevention, and the proper range is that
the meeting numerical value of brown (vertical) and pink color (horizontal)
locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and
in case of more than 0.8, pour out the cooling water about 50% and then
readjust the density after refilling with clean fresh water.

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z Amount of Anti-freeze in winter

Ambient
Cooling water (%) Anti-freeze (%)
Temperature (°C)
Over –10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50

2.3.24. Valve clearance adjust procedure

z After letting the #1 cylinder's piston come at the compression top dead center by
turning the crankshaft, adjust the valve clearances.
z Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge
of specified value between a rocker arm and a valve stem and adjust the
clearance with adjusting screw respectively and then tighten with the lock nut.
z As for the valve clearance, adjust it when in cold, as follows.

Engine model Intake valve (A) Exhaust valve (A)

DV11 0.4 mm 0.5 mm

Rocker arm Valve adjusting bolt

Caliper adjusting bolt

Valve adjusting nut

A

Caliper Push rod

Intake valve
spring

Valve

Valve seat

Intake & exhaust valve adjusting

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< Adjust the valve clearance as following order >

1) Rotating the engine, let #6 cylinder overlap.
2) In time that #1 cylinder become the state of top dead center, adjust the valve
clearance corresponding to ” ◎ “ of following lists.
3) Rotating the crankshaft by 90° rotation, adjust the valve clearance
corresponding to " ⊙ ".
4) Rotating the crankshaft by 1 rotation (360° rotation), let #1 cylinder overlap.
5) In time that #5 cylinder become the state of top dead center, adjust the valve
clearance corresponding to ” ● “ of following lists.
6) Rotating the crankshaft by 450° rotation, adjust the valve clearance
corresponding to " ○ ".
7) After rechecking the valve clearance, readjust if necessary.

z No. 1 cylinder is located at the side where cooling water pump was installed.

Fly wheel Cylinder No Exhaust valve Intake valve Cooling fan

Valve adjusting position Intake valve Exhaust valve

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z Adjusting of valves (Type 1)

Cylinder No 1 2 3 4 5 6

Valve adjusting Exhaust Intake Exhaust Intake Exhaust Intake Intake Exhaust Intake Exhaust Intake Exhaust

#1 cylinder top dead center

◎ ◎ ◎ ◎ ◎
(#5 cylinder valve overlap)

Crankshaft 90° rotation ⊙

360° rotation
#5 cylinder top dead center
(#1 cylinder valve overlap)
● ● ● ● ●
Crank shaft 450° rotation ○

z Adjusting of valves (Type 2)

Adjusting of the valve overlapping on each cylinder is done as follow.
When each cylinder is valve overlap
1 4 2 5 3 6
(Firing cylinder no. order)

Valve adjusting cylinder No. 5 3 6 1 4 2

2.3.25. Battery
z Inspect for any leakage of electrolytic solution owing to battery crack, and replace
the battery in case of poor condition.
z Inspect for amount of electrolytic solution, and replenish if insufficient.
z Measure the gravity of electrolytic solution, if less than specified value (1.12 ∼
1.28), replenish.

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2.3.26. Starting motor

z The sliding-gear starter motor is flanged to the rear of the flywheel housing on the
left-hand side. As parts of every engine overhaul, the starter pinion and ring gear
should be cleaned with a brush dipped in fuel and then a coat of grease should
be applied again.

24V x 7.0kW

Always protect starter motor against moisture.

Circuit diagram Battery terminal

Assistance
switch

Key switch

Battery Starter

IMPORTANT:
Always disconnect the battery earth cable before starting work on the
electrical system. Connect up the earth cable last as there is otherwise a risk
of short-circuit.

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2.4. Diagnosis and Remedy

z The following description summarizes the probable cause of and remedy for
general failure by item.
z Inspect the electrical parts problem with SCAN-200 and refer diagnostic manual.
z Immediate countermeasures should be taken before a failure is inflamed if any symptom
is detected.

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Inspect cylinder head gasket

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Condition Causes Remedies

1) Starting difficult
(1) Starting motor trouble z Refer to diagnostics
(2) Fuel system trouble z Refer to diagnostics
(3) Compression pressure lack z Valve's poor shut, stem Repair or replace
distortion
z Valve spring damage Replace valve spring
z Cylinder head gasket's leak Replace gasket
z Wear of piston, piston ring Adjust
or liner
2) Idle operation abnormal z Injection timing incorrect Check by SCAN-200
z Air mixing at high pressure Remove air
pump
3) Engine output insufficient
(1) Continuous output z Valve clearance incorrect Adjust
insufficient z Valve tightness poor Repair
z Cylinder head gasket's leak Replace gasket
z Wear, stick, damage of Replace piston ring
piston ring
z Injection timing incorrect Check
z Fuel injection amount Check injector
insufficient
z Injector injection pressure Adjust or replace
improper or stuck
z Supply pump's function Repair or replace
lowered
z Fuel pipe system clogged Repair
z Air suction amount Clean or replace air
insufficient cleaner
z Turbocharger poor Repair or replace
(2) Output insufficient z Compression pressure Disassemble engine
when in acceleration insufficient
z Injection timing incorrect Check
z Fuel injection amount Check
insufficient
z Injector infection pressure, Repair, replace
infection angle improper
z Supply pump's function Repair or replace
lowered
z Air intake amount Clean or
insufficient replace air cleaner
4) Overheating z Engine oil insufficient or Replenish or replace
poor
z Cooling water insufficient Replenish or replace
z Fan belt loosened, worn, Adjust or replace
damaged
z Cooling water pump's Repair or replace
function lowered
z Water temperature Replace
regulator's operation poor
z Valve clearance incorrect Adjust
z Exhaust system's resistance Clean or replace
increased

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Condition Causes Remedies

5) Engine noisy For noises arise compositely
such as rotating parts, lapping
parts etc., there is necessity to
search the cause of noises
accurately.
(1) Crankshaft z As the wear of bearing or Replace bearing &
crankshaft progress, the oil grind crankshaft
clearances increase.
z Lopsided wear of crankshaft Grind or replace
z Oil supply insufficient due to Clean oil passage
oil passage clogging
z Stuck bearing Replace bearing &
grind
(2) Connecting-rod and z Lopsided wear of con rod Replace bearing
connecting-rod bearing bearing
z Lopsided wear of crank pin Grind crankshaft
z Connecting rod distortion Repair or replace
z Stuck bearing Replace &
grind crankshaft
z Oil supply insufficiency as Clean oil passage
clogging at oil passage
progresses
(3) Piston, piston pin & z Piston clearance increase Replace piston &
piston ring as the wear of piston and piston ring
piston ring progresses
z Wear of piston or piston pin Replace
z Piston stuck Replace piston
z Piston insertion poor Replace piston
z Piston ring damaged Replace piston
(4) Others z Wear of crankshaft, thrust Replace thrust bearing
bearing
z Camshaft end play Replace thrust plate
increased
z Idle gear end play increased Replace thrust washer
z Timing gear backlash Repair or replace
excessive
z Valve clearance excessive Adjust valve clearance
z Abnormal wear of tappet, Replace tappet, cam
cam
z Turbocharger inner part Repair or replace
damaged
6) Fuel consumption z Injection timing incorrect Check
excessive z Fuel injection amount Adjust
excessive
z Tire air pressure incorrect
Use of low speed gear is
too frequent

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Condition Causes Remedies

7) Oil Consumption
Excessive
(1) Oil level elevated z Clearance between cylinder Replace
liner & piston
z Wear of piston ring, ring Replace piston,
groove piston ring
z Piston ring's damage, stick, Replace piston ring
wear
z Piston ring opening's Correct position
disposition improper
z Piston skirt part damaged or Replace piston
abnormal wear
z Oil ring's oil return hole Replace piston ring
clogged
z Oil ring's contact poor Replace piston ring
(2) Oil level lowered z Looseness of valve stem & Replace in set
guide
z Wear of valve stem seal Replace seal
z Cylinder head gasket’s leak Replace gasket
(3) Oil leak z Looseness of connection Replace gasket, repair
parts
z Various parts' packing poor Replace packing
z Oil seal poor Replace oil seal

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2.5. Engine Inspection

2.5.1. Stopping engine

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

2.5.2. General engine inspection cycle

О : Check & adjust ● : Replace
Inspection time (Hr) Remark
Inspection Daily
50 250 500
Check for leakage
О
(hoses, clamp)
Cooling Check the water level О
system Check the V-belt tension О
Change the coolant water ●(1,200Hr)
Check for leakage О
Check the oil level gauge О
LubricationChange the lubricating oil ● (●)
system 1st

Replace the oil filter cartridge ● (●)

1st
Check the leakage
Intake & for intercooler (hoses, clamp) О
Exhaust
Clean and change
System the air cleaner element О

Drain the water in separator О

Clean the fuel strainer
О
of fuel feed pump
Check the fuel line leakage О
Fuel Check fuel injection timing
When
system necessary
Replace the fuel filter cartridge ●
When
Check the injector nozzles necessary

Check the exhaust gas state О

Check the battery charging О
Engine Check the compression When
adjust pressure necessary
Adjust intake / exhaust When
О necessary
valve clearance

* (●) The engine oil change interval is determined by engine use and oil grade.

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2.5.3. Use of original parts for repair and replacement

For engine is being mechanically harmonized with many parts, only when the
original parts that the manufacture recommends to use is used, the engine trouble
would be preventively maintained and capable to keep up the maximum
performances.
For the analogous parts not the original parts are poor in qualities and gives ill
performances, it may rather bring early engine failure.

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3. Disassembly and Reassembly of Major Components

3.1. Engine Disassembly

3.1.1. General precautions

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

3.1.2. Cooling water

z Remove the radiator cap. Open the

drain valve at the radiator lower Radiator cap

Radiator cap
part to drain the coolant as the
Surge tank cap
right figure.
Radiator

CAUTION:

When removing surge tank cap or

radiator filler cap while the

engine is still hot, cover the cap

with a rag, then turn it slowly to

release the internal steam

Drain valve
pressure. This will prevent a

person from scalding with hot

steam spouted out from the filler

port.

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z Remove the cooling water drain

plug from the cylinder block and oil

cooler, various pipes, etc. and let

the cooling water discharge into

Cooling
the prepared vessel. water drain

3.1.3. Oil level gauge

z Take out the oil level gauge from
the guide tube.

3.1.4. Engine oil

z Remove an oil drain plug from the
oil pan, and let engine oil discharge
into the prepared vessel

Drain plug

3.1.5. Inter cooler

z Tear down the various hoses and
air pipes from the inter cooler.
z Remove the intercooler fixing bolts Hot air by
turbocharger
and tear it down. compressor

Cooling air to
Air flow by intake manifold
cooling fan

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3.1.6. Belt
z Loosen the belt tension adjusting
bolts, and remove the belt.
Tension
adjusting bolt

Tension
adjusting bolt

3.1.7. Air pipe & air heater

z Remove fixing bolts, then take off
the air pipe and air heater.
z Be careful about the mixing of
foreign material into interior of the
turbocharger.

3.1.8. Oil filter

z Loosen the filter housing fixing
bolts then the spring will force the
filter housing to move upward a
little.
z Do not use again the cartridge
removed after use.
z Unscrew the oil filter head fixing
bolts and take off the oil filter head.

3.1.9. Alternator
z Remove the supporting guide
piece for installing the alternator
and the bracket bolts.
z Disassemble the alternator.

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3.1.10. Turbocharger
z Loosen the hose clamp for
connecting the intake stake and
tear down the air pipe.
z Unscrew the turbo charger
lubrication supplying bolt and tear
down oil pipe
z Unscrew the turbo charger fixing
nuts and take off the turbo charger
from the exhaust manifold.

3.1.11. Fuel filter

z Disassemble the fuel hose for the
fuel supply and suction.
z Remove the fuel filter fixing bolts
and disassemble the fuel filter.

NOTE:
Seal the fuel filter to prevent from
mixing foreign material into inside
of the fuel filter after disassembling.

3.1.12. Exhaust manifold

z Remove the exhaust manifold
fixing bolts and tear down the
manifold from the cylinder head.

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3.1.13. Intake manifold

z Remove the manifold fixing bolts
and tear down the manifold from
the cylinder head.

3.1.14. Common rail and high pressure pipe

z Remove the high pressure pipe
between fuel high pressure
connecter and common rail.
z Remove the common rail fixing
bolts and take off the common rail.

NOTE:
Seal the pipe to prevent from
mixing foreign material into inside
of the pipe after disassembling.

3.1.15. Fuel high pressure pump

z Remove the connecting pipe of the
fuel high pressure pump.
z Remove the fuel high pressure
pump fixing bolts and take off the
fuel high pressure pump by pushing
to backward.

NOTE:
Seal the fuel high pressure pump to
prevent from mixing foreign
material into inside of the fuel high
pressure pump after disassembling.

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3.1.16. Water pump

z Loosen the various hose clamps Thermostat
for the connections. Water pump
z Remove the cooling water
discharging pipe and disassemble
the thermostat.
z Remove the cooling water pump
fixing bolts and disassemble the
cooling water pump.

3.1.17. Starting motor

z Remove the starting motor fixing
nuts and disassemble the starting
motor.

3.1.18. Fuel pump housing cover

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

3.1.19. Oil cooler

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

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z Remove the oil cooler fixing bolts

and take off the oil cooler.

Drain plug

3.1.20. Vibration damper

z Remove the fixing bolts for
crankshaft pulley in reverse order
Dust protect cover
of assembling and disassemble the
crankshaft pulley and vibration
damper.

Crank shaft pulley &

damper

3.1.21. Electric control unit

z Remove the electric control unit
fixing bolts, then take off the
electric control unit and bracket.

Rubber cushion

Bracket

Electric control unit

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3.1.22. Cylinder head cover

z Remove cylinder head cover fixing
bolts and take off the cylinder head
cover.

3.1.23. Rocker arm

z Remove the rocker arm bracket
fixing bolts and take out the rocker
arm.
z Pull out the push rod.

3.1.24. Injector
z Remove the fuel high pressure
Injector
connecter fixing nuts and take off
Injector bush
the fuel high pressure connecter.
Fuel high pressure connecter
z Remove the harness connected to
injector, then remove injector fixing
Caliper
bracket bolts and take off the
injector. Fixing nut
z Be careful about damage of the
nozzle when take off the injector.
z Take out the sealing from the
nozzle hole of the cylinder head
and scrap it.

CAUTION:
1) When disassemble the injector, after the fuel high pressure connecter is
separated perfectly by removing the fuel high pressure connecter fixing
nuts, then remove injector caliper fixing bolts and take off the injector.

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2) Seal the injector and the fuel high pressure connecter to prevent from
mixing foreign material into inside of the injector and the fuel high pressure
connecter after disassembling.

3.1.25. Cylinder head

z Loosen the cylinder head fixing
Cylinder head bolt
bolts in the reverse order of
assembling, and remove them all Disassembly order no.

and then take the cylinder head out.

z Remove the cylinder head gasket
and scrap it.
z Eliminate the residue from the
cylinder head face and cylinder
block face.

CAUTION:
Be careful not to damage the
cylinder head face where its
gasket contacts.

3.1.26. Oil pan

z Remove the oil pan fixing bolts and
separate the oil pan.
z Remove the oil pan gasket and
scrap it.

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3.1.27. Oil pump

z Remove the oil suction pipe fixing
bolts and tear them down.
z Remove the oil pump fixing bolts
and separate it.

3.1.28. Piston
z Remove the connecting rod cap
bolts in the reverse order of
assembling.
z Tapping the upper and lower of
connecting rod caps lightly with an
urethane hammer, separate them
and take the bearings out.
z By pushing the piston assembly
with a wooden bar toward the
cylinder head's direction remove
the piston.

CAUTION:
Be careful for the removed
pistons not to collide each other
or with the other parts.
At the storage of pistons,
maintain them in the order of
cylinders. (In order for
connecting rod caps not to mix
one another, temporarily
assemble them to the
corresponding connecting rods.)

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3.1.29. Front oil seal cover

z Remove the oil seal holder fixing
bolts and tear down.
z Remove the oil seal holder fixing
bolts and tear down.

Oil seal cover

Oil seal

3.1.30. Fly wheel

z Remove the flywheel fixing bolts in
the order of disassembling and
remove the flywheel.

z Remove the flywheel ring gear.

z Heat the ring gear evenly with a gas
burner (up to 200 °C) to invite
volumetric expansion.
z Tapping around the edges of the
ring gear with a hammer and brass
bar to remove it.

CAUTION:
Do not damage the flywheel.

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3.1.31. Flywheel housing

z Remove the flywheel housing fixing
bolts and take them out.
z Remove the oil seal from the
flywheel housing.
Thrust
washer
Oil seal

3.1.32. Crank shaft

z Remove the fixing bolts from
bearing caps.
z Remove the main bearing cap
fixing bolts in the reverse order of
assembling.
z Maintain the removed bearing caps
in the order of cylinders.
z Temporarily install the bolts at the
both side of crankshaft, and lift the
crankshaft with a rope.

NOTES:
Do not mingle with the metal
bearings and bearing caps
randomly. To prevent mixing,
temporarily assemble the metal
bearings to the corresponding
bearing caps in turn.

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3.1.33. Cam shaft & tappet

z Pull out the tappets from the cylinder
block.
z Remove the camshaft being
careful not to damage the
camshaft and its bearings.

3.1.34. Oil spray nozzle

z Remove the oil injection nozzle
fixing bolts and tear down the oil
injection nozzles.

3.1.35. Cylinder liner

z By means of a special tool
(Extractor), pull out the liner from
the cylinder block.

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3.2. Measurement and Inspection of Major Parts

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

3.2.2. Cylinder liner measurement

z Assemble the cylinder liner at the
cylinder block and measure inner
diameters at upper, middle, lower 3
levels by 45° interval and calculate
the average values after
eliminating the max. and min.
values.
z If the measured values are very
close to the limit value or beyond,
replace it.
Liner inner Standard Limit
diameter φ127.990 ∼ φ128.010 mm 0.15 mm

3.2.3. Cylinder head

1) Cylinder head disassembly
z Be careful for the cylinder head
gasket contacting surface of
cylinder head not to be damaged.
z Remove the cotter pin pressing the
valve spring by means of a special
tool.
z Take out the valve stem seal. Valve spring
compression tool

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z Pull out the intake and exhaust valves.

2) Inspection and measurement of cylinder head

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

b) Distortion of lower surface

z As shown in figure, measure the
z cylinder head's distortion at 6
directions with horizontal ruler
and clearance gauge
z If the measured value is beyond
the limit value, correct it by
means of the fine grinding paper
or grinding machine.
z If it is beyond the max. allowable
value, replace the cylinder head.

< Lower face warpage and thickness>

Standard Limit

Warpage 0.08 mm or less 0.1 mm

Thickness : t
116.9 ∼ 117.1 mm 116.4 mm
(reference)

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3) Inspection and measurement of valve and valve guide

a) Valve
z After cleaning the valves with
clean diesel oil, measure the
valve stem's outside diameter
at upper, middle, and lower to Valve stem
determine the wears and if
there is minor damage, correct
it and when the wears is more
than max allowable limit value,
replace the valves.

<Valve stem outer diameter>

Standard Limit
Intake φ7.963 ∼ φ7.977 mm φ7.94 mm
Exhaust φ7.950 ∼ φ7.964 mm φ7.93 mm

z Inspect the scratch and wear

of valve stem seal contacting
face, and if necessary correct
with the grinding paper but if
severe replace it.
z If valve head thickness (H)
becomes less than 1.6mm for
intake and 1.3mm for exhaust,
replace the valve.

<Valve head thickness>

Standard Limit
Intake (A) 3.0 ~ 3.4 mm 2.5 mm
Exhaust (B) 3.3 ~ 3.7 mm 2.8 mm

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b) Valve guide
z Insert the valve into valve guide
and measure the clearance
between valve and valve guide
Measuring
by the shaking degree of valve. 측정위치
point

z If the clearance is bigger,

measure the valve and then
replace the more worn valve
guide.

<Valve stem end play>

Standard Limit

Intake 0.023 ∼ 0.052 mm 0.10 mm

Exhaust 0.036 ∼ 0.065 mm 0.15 mm

z Assemble the valve at cylinder

head valve guide and see if it is
centered with the valve seat
using a special tool.

c) Valve seat
z Inspect the damage and wear of
valve seat and if necessary
replace it.
z Assemble the valves at the
cylinder head and using the
measuring instrument from the
lower face, measure the
projection amount of valve. If
the measured value is more
than the use limit, replace the
valve seat.

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< Valve seat thickness >

Standard Limit

Intake (A) 0.38 ∼ 0.42 mm 0.7 mm

Valve
Exhaust (A) 0.38 ∼ 0.42 mm 0.8 mm

Valve seat
< Valve seat angle >
Intake (B) Exhaust (B)
O O
60 45

z The disassembly of valve seat

Valve seat
can be pulled out by means of a
special tool with the arc welding
done at two points of valve seat
Cylinder head
rotating tool or valve seat.
z Regarding the valve seat
assembling, shrink the valve Welding bead

seat by putting it in the dry ices

for about 1 hour or so, and then
press it into the cylinder head
by means of a special tool.
z It is necessary to work boring
of inner diameter of it when
replace the valve seat.
z After coating the grinding
powder paste on valve head
contacting face of valve seat,
and after executing a sufficient
lapping operation with the
rotating and grinding motion of
valve, wipe off the grinding
agent thoroughly.

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d) Valve spring
z Inspect the outlook of valve
spring and if necessary replace
it.
z By means of spring tester,
measure the tension and free
length.

Free length Standard

Intake Inside 62.5 mm

Inside 62.0 mm
Exhaust
Outside 62.5 mm

z Measure the perpendicularity of valve spring.

z In case that the measured value exceeds the limit value, replace it.

< Valve spring tension >

Spring
Set length Limit
force
44 mm 39.4 kg ±2 kg
Intake Inner
31.6 mm 65.8 kg ±2.5 kg

41 mm 20.5 kg ±1.5 kg
Inner
28.6 mm 32.6 kg ±2 kg
Exhaust
44 mm 39.4 kg ±2 kg
Spring tester
Outer
31.6 mm 65.8 kg ±2.5 kg

z Valve spring inclination

Use a surface plate and a square
to measure the valve spring
inclination.
If the measured value exceeds the
specified limit, the valve spring
must be replaced.

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Standard Limit

Valve spring
Less than 1.6 2.0 mm
inclination

4) Cylinder head assembling

z Clean the cylinder head thoroughly.
z Coat the valve stems and valve
guides with engine oil and
assemble the valves.
z Replace the valve stem seals
with new ones and insert the
stem seals to the valve guides of
cylinder head with a special tool.
(Be careful for the valve stem
seals not to be damaged.)
z Install the valve spring washer to
Painted portion
valve guide. (Assemble spring
z After putting on the inside, to the upper side)

outside spring, install the valve

spring seat on them.

NOTES:
Install the valve spring seat with
“TOP” (painted in red) side up.

z Pressing the spring down with a

special tool, assemble by
inserting the valve cotter.
z After the valve is assembled,
inspect the valve tapping it lightly
with an urethane hammer if
accurate assembling was done. Valve spring
compression tool

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3.2.4. Rocker arm ass`y

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

2) Inspection and measurement

z Measure the outer diameter of
rocker arm bracket with outside
micrometer at the position that
the rocker arm is installed, and
Measuring
in case that it exceeds the limit point
value, replace.

< Rocker arm Specification >

Standard Limit

Bush inner diameter φ24.991 ∼ φ25.012 mm φ25.04 mm

Shaft outer diameter φ24.739 ∼ φ24.960 mm φ24.90 mm

Clearance 0.031 ∼ 0.073 mm 0.14 mm

a) Rocker arm
z Inspect the rocker arm
surface that contacts with the
valve stem for any scratch, Caliper adjusting bolt

step wear and correct the Caution:

Fix the nut after adjust
minor degree of wear with an the valve depression
with in 0.05mm with the
oil stone or the fine grinding adjusting bolt

paper and replace if they are

severe.

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b) Tappet & push rod

z By means of outside
micrometer, measure the
clearance of the tappet and
tappet holes of the cylinder
block. If the value is beyond the
specified limit, replace tappets.

Standard φ19.944 ∼ φ19.965 mm

<Clearance of block and tappet>

Standard Limit

0.035 ∼ 0.077 mm 0.13 mm

z By inspecting the tappet

surface that contacts with the
camshaft's cam for any crack
and scratch etc., and if the
degree is small, correct them
with an oil stone or the grinding
paper but if severe replace
them.
z Place the push rod on the
surface plate and rolling it,
Inspect the curving degree with
a clearance gauge and if
abnormal, replace it.

< Run-out >

Limit 0.3 mm or less

3) Rocker arm reassembling

z Inspect the oil passages of rocker arm and rocker arm bracket for any
clogs and reassemble them in the reverse order of disassembling after
thorough cleaning.

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3.2.5. Cam shaft

1) Axial end play
z Push the camshaft toward the
crankshaft pulley side.
z Place a dial gauge onto the
camshaft gear.
z Measure the camshaft's axial
end play, moving the camshaft
gear by means of a driver.

Standard 0.10 ∼ 0.55 mm

z If excessive end play, assemble it by means of other thrust washer.

2) Inspection and measurement of camshaft

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

z Cam lobe height and cam journal diameter

Use a micrometer to measure
the cam lobe height and journal
diameter.
If the measured number is less
than the specified limit, the
camshaft must be replaced.

Standard Limit

Intake 55.06 mm 54.76 mm

Cam lobe
height (C)
Exhaust 56.57 mm 56.27 mm

Cam journal diameter φ69.91 ∼ φ69.94 mm φ69.64mm

(A,B)

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z Camshaft bearing diameter

Measure the camshaft bush
inside diameter with a cylinder
gauge.

< Cam bearing inside diameter>

Standard Limit

Thrust bush φ70.07 ∼ φ70.09 mm -

Cam bush inside
φ70.00 ∼ φ70.03 mm φ70.06 mm
diameter

z Clearance between camshaft journal and bush

Calculate the clearance by complying measured value of the camshaft
bearing inside diameter and journal bearing outside diameter. Replace the
camshaft bearing if the calculated value is beyond the specified limit.

<Clearance >
Standard limit

0.060 ∼ 0.120 mm 0.18 mm

z Camshaft bearing replacement

Use with the special tool for
replacement of bearing.

Disassembly
& assembly
tool

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z Camshaft run-out
With placing the camshaft on
the 2ea of V-blocks, and inspect
the run-out of the camshaft,
adjust or replace the severe one.

< Camshaft run-out >

Standard Limit

0.05 mm 0.1 mm

3.2.6. Crank shaft

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

a) Journal and pin diameter

z With outside micrometer,
measure the outside diameter of
crank journal and crank pin at
the direction and position of the
figure shown and take the wear.
z In case that the lopsided wear is
more than the limit value, grind
to the undersize, and use the
undersized bearing.
z If the amount of wear is within
the limit, you can correct the
wear using an oil stone or oiled
grinding paper of fine grain size.
(be sure to use grinding
paper which has been
immersed in oil)

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<Journal and pin outside diameter>

Standard
Journal
φ103.98∼ φ104.00 mm
diameter
Pin diameter φ89.98 ∼ φ90.00 mm

z In case that pin's wear is more than the limit value, grind the crankshaft
journal and crank pin, and use the undersized bearings.
z Be sure to use grinding paper which has been immersed in oil.

< Kinds of bearings for undersize>

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

NOTE:
There are 4 kinds as above, and the crankshaft also can be used by
regrinding as above.

NOTE:
In case of crankshaft regrinding, the
"R” part at the end of bearing must
accurately be ground without fail
and should avoid any processed jaw
or coarse surface.

<"R” part standard value> Normal Abnormal Abnormal

① Crank pin 'R' : 3.0 −0.05

② Crank journal 'R' : 4.0− 0.05

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b) Run out of crankshaft

z Place the crankshaft on the V-
block.
z Turn the crankshaft with a dial
Indicator on the surface plate
and measure the run out of
crankshaft, replace or correct
the camshaft bearing if the
measured value is beyond the
limit.

< Run out of crankshaft >

Standard Limit

0.04 mm 0.2 mm

2) Crankshaft bearing and connecting rod bearing

Inspect the crankshaft bearing and connecting rod bearing for any damages such
as lopsided wear, scratch etc. and if abnormal, replace it.

a) Oil clearance of crankshaft and bearing

z Assemble the main bearing at
the cylinder block and after
tightening the bearing cap at the
specified torque, measure the
inside diameter of bearing

O
Torque 30 kg.m + 90

Journal bearing
φ103.98 ∼ φ104.00 mm
nominal diameter

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z Assemble the bearing at the

Section A-B
bigger end of connecting rod
(bigger end) tightening the
bearing cap at the specified
torque, measure the inside
diameter.

O
Torque 10 kg.m + 90

Connecting rod
bearing φ89.98 ∼ φ90.00 mm
nominal diameter

b) Bearing oil clearance

z Compare the two values obtained through measurement of bearing inside
diameter (journal bearing, connecting rod bearing) with the outside diameter of
journal and pin of crankshaft to determine the 0il clearance

Standard Limit
Journal
0.066 ∼ 0.132 mm 0.166 mm
bearing
Connecting
0.054 ∼ 0.116 mm 0.154 mm
rod bearing

z In case that this clearance value exceeds the limit value, grind the crankshaft
journal and pin and then use the undersized bearing.

c) Journal and connecting bearing inspection

z Check to see that the bearing
requires a considerable amount
of finger pressure at reassembly
operation.

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z The spread of journal bearing

and connecting rod bearing
should be measured with
special tool as a figure, but
measure it under condition of
assembling as below for Spread = φA - φB

convenience of working in the

field.

z Journal bearing
Install the bearing and cap in
the cylinder block, retighten the
bolts to specified torque,
unscrew out one bolt completely,
then measure the clearance
between the bearing cap and
cylinder block using a feeler
gauge.

<Cylinder block and bearing clearance>

Standard 0.3 ∼ 1.2 mm

z Connecting rod bearing crush

Install the bearing and cap in
the connecting rod big end,
retighten the bolts to specified
torque, unscrew out one bolt
completely, then measure the
clearance between the bearing
cap and connecting rod big end
using a feeler gauge.

< Connecting rod bearing clearance >

Standard 0.5 ∼ 1.4 mm

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d) Crank shaft end play

z Assemble the crankshaft to the
cylinder block with a dial gauge,
measure crankshaft end play.

< Crank shaft end play >

Standard Limit

0.190 ∼ 0.322 mm 0.452 mm

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

z With a pair of pliers, remove the

piston rings.
z Clean the piston thoroughly.

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2) Check and measurement

z With naked eyes, inspect the
piston for any wear, crack and
scratch and particularly inspect
carefully at the ring grooves for
any wear.
z With the outside micrometer,
measure the piston's outside
diameter the measuring position is
71.5mm from the piston lower end,
and the direction of measurement
must be perpendicular to the 56.8mm

piston pin direction.

Standard φ127.739 ∼ φ127.757 mm

a) Cylinder bore diameter

z Measure cylinder liner inside
diameter at 3 points (cylinder
top ring contacting face, middle,
and oil ring contacting face on
BDC) in a direction at an angle
of 45°. Take the mean value
with the largest and smallest
values excepted.

Standard φ127.990 ∼ φ128.010 mm

b) Piston and cylinder clearance

z The clearance is computed by subtracting the piston outside diameter from
the cylinder liner inside diameter. Replace either piston or cylinder liner,
whichever damaged more, if the clearance is beyond the specified limit.

Standard 0.233 ∼ 0.271 mm

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c) Piston ring and ring groove

z In case of piston ring's wear,
damage or engine overhaul,
replace piston rings.

d) Piston ring cut part clearance

z Measure the piston ring cut part.
z Insert the piston ring at the
cylinder liner's upper part
perpendicularly. Feeler gauge

z With a feeler gauge, measure

the gap clearance of piston ring.
z If the measured value exceeds
the limit value, replace it

Standard Limit
Top ring 0.35 ∼ 0.55 mm 1.5 mm
2nd ring 0.80 ∼ 0.95 mm 1.5 mm
Oil ring 0.40 ∼ 0.70 mm 1.5 mm

e) Piston side clearance

z Assemble the piston ring at the
piston.
z Measure the each ring's side
clearance and if the measured
value exceeds the limit value,
replace rings or piston.

Standard Limit
Top ring 0.105 ∼ 0.155 mm 0.20 mm
2nd ring 0.050 ∼ 0.085 mm 0.15 mm
Oil ring 0.030 ∼ 0.070 mm 0.15 mm

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f) Piston pin
z Measure the amount of wear on
the piston pin at the points as
shown. The measured values
are beyond the limit replace the
pin.

Standard Limit

φ 45.994 ∼ φ 46.0 mm φ 44.983 mm or less

g) Piston pin and connecting rod bush clearance

z Inspect the clearance between
the piston pin and the
connecting rod bush, if it is
more than the use limit value,
replace either one that is more
severe.

Limit 0.055 ~ 0.071 mm

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

0.02 mm 0.1 mm

z Assemble the connecting rod to

the crankshaft and measure
connecting rod big end side
clearance using a feeler gauge.

Standard Limit

0.175 mm ~ 0.321mm 0.5

z Assemble the connecting rod to

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

3.2.8. Injector projection

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

Standard

A
1.9 ~ 2.1 mm
(Thickness of seal ring)

B
2.6 mm
(Projection of injector)

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3.3. Engine Reassembly

3.3.1. Preparation and precaution before and after engine reassembly

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

3.3.2. Cylinder liner

z Replace O-ring with new one
without fail and at the upper side,
insert to the cylinder liner, but at the
lower side, to the cylinder block. O-ring
for cylinder liner
z Coat the joint parts where O-ring
O-ring for cylinder block
contacts with oil. (Black color upper side,
Green color lower side)
z After slipping the cylinder liner
smoothly into the cylinder block,
press it in being careful for O-ring
not to damage.
z After completion of assembling the
cylinder liner, confirm no leaks with
4 kg/cm2 hydraulic test.

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3.3.3. Oil spray nozzle

z Tighten the oil injection nozzle
flange with hollow screws.
z Assemble the oil injection nozzle
with the fixing bolts.

Hollow screw 7 kg.m

Torque
Fixing bolt 1.2 kg.m

3.3.4. Crank shaft

z Put the wear ring into the heater to
heat it up to 150 ∼ 200 °C level,
push it over the crankshaft by
means of a jig.

Wear ring

z Assemble the main bearing to the

cylinder block and coat it with
engine oil. Then assemble the
bearing that has a hole to the
cylinder block side and one that
has no hole to the bearing cap and
be careful not to change.
z Assemble temporarily one bolt
each at both bolt holes of
crankshaft and by connecting the
wire to the bolts, lift it with crane or
chain block and put down on the
cylinder block carefully.

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z Coat the crankshaft journal and pin

parts with engine oil, and after
fitting the main bearing into the
bearing cap and assemble it to the
cylinder block making sure of the
number in order not to change the
bearing cap.

z Coat the bearing cap bolt and its

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

< Bearing cap bolt’s tightening order >

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

z Inspect if the crankshaft's rotation

is smooth.
z Assemble the crankshaft gear on
the crankshaft and coat a white
paint mark on "1" part in order to
find easily.

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3.3.5. Tappet
z Coat the tappet wholly clean oil and
push in the tappet hole of the
cylinder block.

3.3.6..Cam shaft
z Coat the cam bush of cylinder Camshaft gear

block and camshaft with engine oil.

z Assemble the cam bush and
camshaft for them not to be
Crankshaft gear
damaged.
z Assemble the crankshaft gear and
the camshaft gear making sure that
the gear marks on both gears are
aligned together.

3.3.7. Flywheel housing

z Apply loctite to the fixing bolt and
assemble the thrust washer.

Thrust washer
4 kg.m
fixing bolt
Thrust
washer
Oil seal

z Coat the oil seal (P.T.F.E.) with

lubricating oil and assemble the oil
seal carefully for it not to deviate
or be damaged by means of
special tool. (Mandrel for
assembling.)

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z Attach the gasket on the surface of

cylinder block where the flywheel
housing is to be installed. (In order
to prevent the gasket slip down,
coat a grease on the cylinder block
surface.
z Temporarily assemble 2ea of guide
bolts for installing the flywheel
housing to the cylinder block.
z After fitting the flywheel housing
holes to the guide pins and engage
temporarily 2 ∼ 3 threads of fixing
bolts, and according to the
tightening order (zigzag method)
tighten them in the specified torque.

M10 7.5 kg.m

Torque
M12 11.2 kg.m

3.3.8.. Fly wheel

z Installation of flywheel ring gear
with a gas burner, heat the ring
gear evenly until heat expansion
takes place, then install it using a
hammer.
z Do not allow the temperature of the
ring gear to exceed 200°C (392°F).
z By means of mandrel, press in the
wear ring at the backward face.
(Apply mounting face with #262
loctite.)

Wear ring Ring gear

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z Install two guide bolts for installing

the flywheel to the crankshaft.
z After letting the guide pin insert
through the flywheel holes and
engaging the fixing bolts by 2∼3
threads temporarily, tighten them to
the specified torque according to
tightening order. (Zigzag order)

Torque 26 kg.m

1
8 6
3 4

5 7
2

3.3.9. Front oil seal holder

z After placing the oil seal in the oil
seal holder hole properly, press it in
with a special tool. (Be careful for
oil seal not be damaged.)
z Attach a gasket at the oil seal
holder.
z Align the dowel pin with the oil seal
holder dowel hole and assemble
them by tapping lightly the dowel
pin part with an urethane hammer
when in assembling, take care not
to hurt the oil seal by the crankshaft.

NOTE:
Without coating the oil seal with oil
or lubricant, assemble it in the dry
state.
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z Apply lubricating oil to the inside of

oil seal and tighten the fixing bolts
in the zigzag method.

Torque 2.2 kg.m

3.3.10. Piston
z Line up the piston assembly in the
order of cylinders and fit the 2nd ring
Oil ring

bearings to the connecting rods

and bearing caps. However, take
care not to swap between the
Piston pin
connecting rods and bearing caps.
View of piston top
z Coat the pistons and connecting Top ring

rod bearings sufficiently with clean

engine oil.
z By means of a special tool, insert
the piston rings and adjust the
angles between the ring gaps at
120°.
z Identify the mark "Y" or "TOP" on
the ring end to prevent the top and “Y” or “TOP”
bottom of the piston ring from
being interchanged and make the
marked portion face upward.
(The surface marked as “Y” or
“TOP” is upper surface.)
z Push in the piston with hands or
wooden bar into cylinder. (Be
careful for piston and rings not be Top ring

damaged. 2nd ring

z Pushing the piston down, rotate the
Oil ring
crankshaft about 180° and fit the
bearing cap to the connecting rod.

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z Coat the tap parts of connecting

rod bolts and their seats with
engine oil, and after engaging 2∼
3 threads of bolts primarily rind
then tighten them to the specified
torque. (10 kg.m + 90°+10°)
CAUTION:
Direction of snap ring is
assembling to be positioned the
opposite side

<Connecting rod bolt tightening order>

(1) First step : Coat the bolts with engine oil.
(2) Second step: Engage 2∼3 threads by hands.
(3) Third step : Tighten to about 7kg.m with wrench.
(4) Fourth step : By means of torque wrench tighten to 10 kg.m.
(5) Fifth step : Finally assemble by means of rotation angle method 90°+10°.
However, according to above tightening order, tighten them step by step

< Standard length of bolt and use limit>

From head seat to bolt tip Oil supply hole

Standard length Use limit

-0.3
67.5 mm 69 mm

View from crank Connecting rod

shaft pulley bolt

z By moving the connecting rod

bearing cap by hands, make sure if
there is any play in left and right.
z With the same method as above,
assemble in each cylinder rotating
the crankshaft.

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3.3.11. Oil pump

z Put the oil pump at the place to be
installed on the cylinder block.
z Attach a gasket at the surface of
oil pump where the pressure
regulating valve is to installed and
place the regulating valve on a
gasket.
z Assemble the oil pump and
pressure regulating valve by
tightening the fixing bolts.

Oil pump back lash 0.1 ~ 0.45 mm

z Attach a gasket at the surface of

the oil pump where the oil suction
pipe is to be installed, and install
the oil suction pipe by tightening the
fixing bolts.
z Assemble the pipe bracket on the
cylinder block side with bolts.

Torque 2.2 kg.m

3.3.12 Vibration damper

z Install the vibration damper on the
crankshaft pulley.
Dust protect cover
z Install the crankshaft pulley
assembly on the crankshaft, then
tighten the bolts with apply engine
oil. Crank shaft pulley
& damper

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Vibration damper
6 kg.m
and pulley
Torque
Crankshaft pulley 21 kg.m

Bolt tightening order

3.3.13. Oil pan

z Clean thoroughly the gasket that is
projecting at the junction parts of
front oil seal holder and flywheel
housing of cylinder block's lower
face with a scraper.
z In the process of gasket removal,
be careful for the gasket pieces not
to get into the engine inside.
z Apply silicon to each joint and
attach a gasket to the cylinder
block.
z Install the oil pan and tighten the
fixing bolts. Then takes care not to
squeeze out the gasket.

Torque 2.2 kg.m

3.3.14. Intake & exhaust valve

z Identify the marks of "I" and "E"
impressed on the valve head
before assembling the valve with
the valve head. Valve marking position

z With a valve stem seal fitting jig,

assemble the valve stem seal on
the valve guide.
Intake valve Exhaust valve

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3.3.15. Cylinder head

z Blow the cylinder head bolt holes Cylinder head bolt

with compressed air to remove the Assembly order no.

foreign material cleanly.

z Wipe off cleanly the junction part of
cylinder block's head gasket.
z After confirming whether there is
foreign material or not necessarily,
if there is, remove it.
z Assemble a gasket fitting with the
fixing pin of cylinder block.
z Position the cylinder head
assembly on the cylinder block
aligning with its dowel pin. (Take
care not to damage the head
gasket.)
z Coat the cylinder head bolts with Part no.
mark position
engine oil and tighten them to the
specified torque according to step
by step.

< Cylinder head bolts tightening order>

1) First step : Coat bolts with engine oil.
2) Second step : Tighten temporarily 1 ∼ 2 threads by hands.
3) Third step : Tighten to about 8 kg.m with a wrench.
4) Forth step : Tighten to 15kg.m with a torque wrench.
5) Fifth step : Rotate 90° by rotation angle method.
6) Sixth step : Rotate 90° by rotation angle method.
7) Seventh step : Finally tighten additionally rotating 60°.

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< Standard length of bolt and use limit >

(From head seat to bolt tip)
Standard length Limit

176 mm 178.5 mm

Note:
Take care for the foreign material
not to get into the cylinder head
suction passages.

3.3.16. Injector
z The injector should be assembled
Injector
correctly by the following order.
Fuel high
z Put the O-ring into the injector and Injector bush
pressure
connector
coat the circumference face of it
with engine oil.
Injector fixing
z The sealing set to injector hole of bracket
cylinder head, then the injector Fixing nut
insert. (The side groove face of
injector set to the fuel high pressure
connector.)
z The injector set to injector fixing
bracket with the fixing bolt, then
assemble temporarily it.

Fuel high pressure

Injector fixing bracket
Temporarily connector fixing nut
torque
0.3 kg.m 0.25 kg.m

z Assemble the injector fixing bracket

bolt with specified torque, and
assemble the fuel high pressure
connector fixing nut.

Injector fixing bracket bolt 3.5 kg.m

Torque Fuel high pressure connector
5 ~ 5.5 kg.m
fixing nut

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3.3.17. Rocker arm

z Coat the push rod with engine oil
and put it into the push rod hole. Fixing bolt

z Position the rocker arm assembly

on the cylinder head and tighten
the fixing bolts to the specified
tightening torque.

Torque 6.2 kg.m

z Adjust the valve clearance as

reference of major maintenance
part.

3.3.18. Fuel high pressure pump housing cover

z Coat with the liquid gasket on the Serial no. mark position
(Fuel high pressure
surface of the cylinder block for pump housing cover)

mounting of the fuel high pressure

Serial no. mark position
pump housing cover. (Cylinder block)

z Assemble the fuel high pressure

pump housing cover after check
the serial number of the cylinder
block and the pump housing cover.
z Tighten the fixing bolts of the fuel
high pressure pump housing cover
by the specified tightening torque.

Torque 7.5 kg.m

NOTES:
Do not mingle with the pump
housing cover and cylinder block
randomly.

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3.3.19. Fuel high pressure pump

z Assemble the gear of the fuel high
pressure pump by using specified
tool.

Gear nut torque 11±0.5 kg.m

Driving gear

Fuel high
pressure pump

z Install the fuel high pressure pump

on the backside of the fly wheel
housing.
z Assemble the stud bolt after apply
the loctite.
z Assemble the fuel high pressure
pump fixing bolts with specified
torque.

Torque 4.4 kg.m

3.3.20. Intake manifold

z Attach a new gasket to the cylinder
head side.
z Assemble the intake manifold by
tightening the fixing bolts.
z Assemble both sides by the above
method.
z Attach a gasket to the equalizing
pipe that connects the intake
manifolds of both sides and
assemble both manifolds by
tightening the fixing bolts.

Torque 2.2 kg.m

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3.3.21. Common rail & high pressure pipe

z Assemble the common rail on the
cylinder block.
z Install the fuel high pressure pipe
between the common rail and the
fuel high pressure connector, then
tighten the cylinder by cylinder with
specified torque.

Side of common rail 3.0 kg.m

Fuel high
pressure Side of fuel high pressure connector 3.0 kg.m
Torque pipe
Common rail from fuel high pressure pump 3.0 kg.m

Common rail fixing bolt 2.2 kg.m

3.3.22. Cylinder head cover

z Attach a new gasket on the surface
of cylinder head where the cover is
to be installed.
z Assemble the cylinder head cover
by tightening the fixing bolts.

Middle cover 3.6 kg.m

Torque
Cylinder head
2.2 kg.m
cover

z Insert the oil filler cap.

Oil filler cap

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3.2.23. Exhaust manifold

z Attach a new gasket to the exhaust
manifold.
z Fix the pipe that is connected
exhaust manifold by tightening the
fixing bolts.
z Assemble both sides in the same
method as above.

Torque 8.0 kg.m

3.3.24. Electric control unit

z Install the electric control unit fixing
bracket on the oil pan, and then
assemble the electric control unit.

8 1

Bracket fixing bolt 4 5

4.5 kg.m
Torque 6
3
Electric control 2
10±2 N.m
unit fixing bolt 7

z Assemble the electric control unit

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

Electric control unit

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3.3.25. Crankshaft speed sensor

z Measure the clearance of the
Crankshaft speed sensor
assembling part of the sensor and Adjust shim
fly wheel, then assemble it with the
adjust shim.

Clearance 1. 0 ±0.1mm

Torque 1.0 kg.m

3.3.26. Camshaft speed sensor

z Measure the clearance of the Camshaft
speed sensor
assembling part of the sensor and
timing gear, then assemble it with
the adjust shim.

Clearance 1. 0 ±0.1mm

Torque 1.0 kg.m

3.3.27. Oil cooler

z Attach a gasket on the surface in
the oil cooler housing where the oil
cooler is installed.
z Tighten the oil cooler with fixing
bolts.
z Install the oil cooler assembly by
tightening the fixing bolts in the
zigzag order.

Torque 4.4 kg.m

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3.3.28. Starter
z Install stud bolts at the bolt holes
on the flywheel housing for
installing the starter.
z Insert the starter into the flywheel
housing and tighten the fixing nuts.

Torque 8.0 kg.m

3.3.29. Oil filter

z Install the filter head on the oil pan
and tighten bolts in a diagonal
sequence.
z Apply engine oil to the oil filter
cartridge O-ring and assemble the
cartridge using a filter wrench.

3.3.30. Water pump

z Attach a gasket at the cooling water

pump. (at cylinder block side.) Water pump
z Assemble the cooling water pump
by tightening the fixing bolts.
(Zigzag method.)

Torque 4.4 kg.m

3.3.31. Thermostat
z Put the thermostat into the water Thermostat

pump with gasket. Water pump

z Put the O-ring into the thermostat,

then assemble cooling water pipe
by tightening the fixing bolt.

Torque 2.2 kg.m

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2.3.32. Turbo charger

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

Turbocharger fixing nut

4.4 kg.m
torque

3.3.33. Intake stake and air heater

z Connect the intake stake to the
intake manifold.
z Assemble the air heater according
the direction of an arrow impressed
on the air heater and assemble the
pipe by tightening the bolts.

Torque 2.2 kg.m

z Install the air pipe, then connect

Intake stake
the rubber hose into the
Air heater
turbocharger and assemble with
clamping.

Air pipe

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3.3.34. Fuel filter

z Assemble the fuel filter on the
support bracket.
z Assemble the fuel filter after fill the
fuel into inside of the cartridge
when replace the new fuel filter.

Torque 2.2 kg.m

3.3.35. Alternator and belt

z Install the alternator bracket, idle
pulley and adjusting bolt to lifting
hook.
z Install the alternator, and then
tighten the fixing bolts.

z Put the belt into the crankshaft

pulley, alternator pulley, water
Tension
pump and air con. pulley for adjusting bolt

connecting.
z Adjust the belt tension of the
adjusting bolts.
Tension
adjusting bolt

z Poly belt will be properly tensioned

if the deflection force “F” is applied
midway between the belt’s tangent
points with the pulley.

(T) = 0.015 x S
(about 1.5mm per 100mm)
(T : Deflection, S : span)

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3.3.36. Oil level gauge

z Apply sealant (Loctite #262) to the
bottom side of the guide tube.
z Then assemble the guide tube and
oil level gauge on the oil pan.

3.3.37. Others
z Assemble by connecting the other
sensor, harness, oil and fuel line.

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3.4. Fuel injection System

3.4.1. Common rail fuel-injection system

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

Common rail

Fuel high
pressure pump
Fuel filter (CP 3.4 fuel pump)

Pre fuel filter

Injector

Cylinder
ECU head
Fuel cooler

Fuel high pressure

connector

Fuel tank

z The fuel is stored under pressure in the common rail ready for injection. The
injected fuel quantity is defined by the driver, and the start of injection and
injection pressure are calculated by the ECU on the basis of the stored map. The
ECU then triggers the solenoid valves that the injector at each engine cylinder
injects accordingly.

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3.4.2. Major components of the common rail system

1) Electric control unit(ECU)
2) Crankshaft speed sensor
3) Camshaft speed sensor
4) Accelerator pedal sensor
5) Fuel temperature sensor
6) Boost pressure and temperature sensor
7) Common rail pressure sensor
8) Coolant temperature sensor
9) oil pressure and temperature sensor

z Using the input signals from the above sensors, the ECU registers the driver's
requirements(accelerator pedal setting) and defines the instantaneous operating
performance of the engine and the vehicle as a whole. On the basis of this
information, it can then intervene with open and closed-loop controlling action at
the vehicle and particularly at the engine.
z The engine speed is measured by the crankshaft speed sensor, and the camshaft
speed sensor determines the firing sequence (phase length). The electrical signal
generated across a potentiometer in the accelerator pedal module informs the
ECU about how far the driver has depressed the pedal, the engine is equipped
with a turbocharger and boost pressure control, the boost pressure sensor also
measures boost pressure.
z At low outside temperatures and with the engine cold, the ECU applies the data
from the coolant temperature and air temperature sensors to adapt the set point
values for start of the particular operating conditions.

3.4.3. Injection characteristics with common rail

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

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Fuel injection of injection pump Common rail fuel injection

Pm : Main injection pressure Pm : Main injection pressure
Ps : Max. injection pressure Ps : Max. injection pressure

Ps
Start of delivery
Start of injection Fuel injection
Injection pressure P

Injection pressure P
Pm PR
(Pm)

Time t Time t

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

3.4.4. Fuel high pressure pump

z A radial-piston pump is used as the high pressure pump for pressure generation.
Pressure is generated independently of the injection process. The speed of the
high pressure pump is coupled directly to the engine speed with a non-variable
transmission ratio. In comparison with conventional injection systems, the fact
that delivery is practically uniform.
z The injectors are connected to the common rail by high pressure pipe, comprise a
nozzle, and a solenoid valve which is energized by the ECU to switch it on (start
of injection), When the solenoid valve is switched off injection ceases.

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z The required high-speed solenoid switching is achieved by using high voltages

and currents. This means that the solenoid valve triggering stage in the ECU must
be designed accordingly. The start of injection is controlled by the angle-time
control system of the EDC(Electronic Diesel Control).This uses a sensor on the
crankshaft to register engine speed, and a sensor on the camshaft for phase
detection(working cycle).

3.4.5. Fuel system

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

3.4.6. Fuel tank

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

3.4.7. Fuel delivery pump

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

Fuel delivery pump

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

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3.4.8. Fuel filter

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

3.4.9. High pressure fuel delivery

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

3.4.10. High pressure system components

z Fuel high pressure pump
The high-pressure pump pressurizes the fuel to a system pressure of up to
1,600bar. This pressurized fuel then passes through a high-pressure line and into
the tubular high pressure fuel accumulator (common rail).
z Common rail
Even after an injector has taken fuel from the common rail in order to inject it, the
fuel pressure inside the rail remains practically constant. Fuel pressure is
measured by the rail pressure sensor and maintained at the desired level by the
pressure control valve. It is the job of the pressure limiter valve to limit the fuel
pressure in the rail to maximum 1,600 bar.
z Injector
The nozzles of these injectors open when the solenoid valve is triggered and
permit the flow of fuel. They inject the fuel directly into the engine's combustion
chamber, The excess fuel which was needed for opening the injector nozzles
flows back to the tank through a collector line. The return fuel from the pressure
control valve and from the low pressure stage is also led into this collector line
together with the fuel used to lubricate the high pressure pump.

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z Fuel high pressure pipe

These fuel high pressure pipes carry the high pressure fuel of up to 1600bar.
They must therefore be able to permanently withstand the maximum system
pressure and, during the pauses in injection, the sometimes high frequency
pressure fluctuations which occur. They are therefore manufactured from the high
pressure pipe. They have an outside diameter of 8.0 mm and an internal diameter
of 3.0 mm. The fuel high pressure pipe lines between the common rail and the
injectors must all be of the same length, should be kept as short as possible.

3.4.11. Construction of the fuel high pressure pump

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

Fuel high pressure valve

Gear pump Fuel Fill fuel at 40ml
Pump piston inlet before operating
Fuel Metering unit
inlet Fuel
outlet
Eccentric
cam

Driving shaft Fuel outlet

Fuel high pressure line

Lubrication of driving shaft by
Fuel low pressure line lubricating engine oil
Engine oil

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2) Construction of the fuel high pressure pump

The fuel is compressed with three radially arranged pump pistons which are at an
angle of 120° to each other. Since three delivery strokes take place for every
revolution, only low peak drive torques are generated so that the stress on the
pump drive remains uniform. The driving torque of the common rail is only about
1/9 of torques to drive existing pump system.

3) Method of operation
The fuel supply pump fuel from the tank to the high pressure pump through the
fuel inlet and the safety valve. It forces the fuel through the safety valve into the
high pressure pump. The driveshaft with its eccentric cams moves the piston of
the pump up and down in accordance with the shape of the cam.
As soon as the delivery pressure exceeds the safety valve's opening pressure
(0.5 ~ 0.5 bar), the fuel supply pump can force fuel through the high pressure
pump's inlet valve into the pumping-element chamber whose pump piston is
moving downwards(suction stroke). The inlet valve closes when the pump piston
passes through the bottom dead center (BDC) and, since it is impossible for the
fuel in the pumping-element chamber to escape, it can now be compressed
beyond the delivery pressure. The increasing pressure opens the outlet valve as
soon as the rail pressure is reached, and the compressed fuel enters the high
pressure circuit. The pump piston continues to deliver fuel until it reaches TDC,
after which the pressure collapses so that the outlet valve closes. The fuel
remaining in the pumping-element chamber relaxes and the pump piston moves
downwards again. As soon as the pressure in the pumping-element chamber
drops below the presupply pump pressure, the inlet valve opens and the pumping
process starts again.

4) Fuel delivery rate

Since the high-pressure pump is designed for large delivery quantities, excess
high-pressure fuel is delivered during idle and part load operation. This excess
fuel is returned to the tank via the pressure control valve.

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5) Fuel metering shut off valve

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

6) Common rail
The common rail stores the fuel at high pressure. At the same time, the pressure
oscillations which are generated due to the high pressure pump delivery and the
injection of fuel are damped by the rail volume. After the injector use the fuel from
the common rail for fuel injection, the pressure oscillation of the common rail is
maintained constantly by the common rail volume. The fuel pressure is calculated
by the pressure sensor of the common rail, is maintained with required value by
the pressure control valve. The fuel pressure is controlled at max. 1,600 bar in the
common rail.

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No. 3 cylinder injector

No. 2 cylinder injector

No. 1 cylinder injector

Fuel high pressure

connector

Pressure control valve

No. 6 cylinder injector

No. 5 cylinder injector

No. 4 cylinder injector

Pressure sensor of
the common rail

7) Common rail pressure sensor

The fuel flows to the rail pressure sensor through an opening in the common rail,
the end of which is sealed off by the sensor diaphragm. Pressurized fuel reaches
the sensor's diaphragm through a blind hole. The sensor element for converting
the pressure to an electric signal is mounted on this diaphragm. The signal
generated by the sensor is inputted to an evaluation circuit which amplifies the
measuring signal and sends it to the ECU.

Electric connections

Evaluation circuit

Diaphragm

High pressure
connection
Mounting thread

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3.4.12. Pressure limiter valve

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

Valve Plunger

Fuel
return
Common
rail

Valve body Valve spring

3.4.13. Injector
z The start of injection and the injected fuel quantity are adjusted by the solenoid
valve of the injector. These injectors supersede the nozzle and nozzle holder of
the existing engine. The fuel is fed from the high pressure connector, to the
nozzle through the passage, and to the control chamber through the feed orifice.
z The control chamber is connected to the fuel return via a bleed orifice which is
opened by the solenoid valve. With the bleed orifice closed, the hydraulic force
applied to the valve control plunger exceeds that at the nozzle needle pressure
shoulder. As a result, the needle is forced into its seat and seals off the high
pressure passage from the combustion chamber.
z When the injector's solenoid valve is triggered, the bleed orifice is opened. This
leads to a drop in control-chamber pressure and, as a result, the hydraulic
pressure on the plunger also drops. As soon as the hydraulic force drops below
the force on the nozzle-needle pressure shoulder, the nozzle needle opens and
fuel is injected through the spray holes into the combustion chamber.

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Nozzle & needle

z This indirect control of the nozzle needle using a hydraulic force-amplification

system is applied because the forces which are necessary for opening the needle
very quickly cannot be directly generated by the solenoid valve. The so-called
control quantity needed for opening the nozzle needle is in addition to the fuel
quantity which is actually injected, and it is led back to the fuel-return line via the
control chamber's orifices. In addition to the control quantity, fuel is also lost at the
nozzle-needle and valve plunger guides. These control and leak-off fuel quantities
are returned to the fuel tank via the fuel return and the collector line to which
overflow valve, high pressure pump, and pressure control valve are also
connected.

1) Method of operation
The injector's operation can be subdivided into four operating states with the
engine running and the high pressure pump generating pressure.
- Injector closed (with high pressure applied)
- Injector opens (start of injection)
- Injector opened fully, and
- Injector closes (end of injection)
These operating states result from the distribution of the forces applied to the
injector's components. With the engine at standstill and no pressure in the rail, the
nozzle spring closes the injector.

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2) Injector closed (at rest status)

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

3) Injector opens (start of injection)

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

4) Injector closes (end of injection)

As soon as the solenoid valve is no longer triggered, the valve spring forces the
armature downwards and the ball closes the bleed orifice. The armature is a 2-
piece design. Here, although the armature plate is guided by a driver shoulder in
its downward movement, it can "over spring" with the return spring so that it

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exerts no downwards-acting forces on the armature and the ball.

The closing of the bleed orifice leads to pressure buildup in the control chamber
via the input from the feed orifice. This pressure is the same as that in the rail and
exerts an increased force on the control plunger through its end face. This force,
together with that of the spring, now exceeds the force exerted by the chamber
volume and the nozzle needle closes.
The nozzle needle's closing speed is determined by the flow through the feed
orifice. Injection ceases as soon as the nozzle needle comes up against its
bottom stop again.

3.4.14. Crank shaft speed sensor

z The piston position in the
Fixing Bolt
combustion chamber is decisive in
defining the start of injection. All Crank Shaft
Sensor
the engine's pistons are connected
to the crankshaft by connecting
Shim
rods. A sensor on the crankshaft
can therefore provide information
on the position of all the pistons.
The rotational speed defines the number of crankshaft rotations per minute. This
important input variable is calculated in the ECU using the signal from the
inductive crankshaft speed sensor.

3.4.15. Cam shaft speed sensor

z The camshaft controls the engine's
Fixing Bolt
intake and exhaust valves. It turns
at half the speed of the crankshaft. Crank Shaft
Sensor
When a piston travels in the
direction of TDC, the camshaft
Shim
position determines whether it is in
the compression phase with
subsequent ignition, or in the
exhaust phase. This information cannot be generated from the crankshaft position
during the starting phase. During normal engine operation on the other hand, the
information generated by the crankshaft sensor suffices to define the engine
status. In other words, this means that if the camshaft sensor should fail while the
vehicle is being driven, the ECU still receives information on the engine status

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from the crankshaft sensor.

3.4.16. Accelerator pedal sensor

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

3.4.17. Boost pressure & temperature sensor

z The boost pressure & temperature
Fixing bolt
sensor are connected to the intake Boost pressure &
temperature
manifold by the O-ring and sensor

measures the intake manifold's

absolute pressure and temperature. Shim
z The output signal is inputted to the
ECU where, with the help of a
programmed characteristic curve, it
is used for calculating the boost
pressure.

3.4.18. Engine oil pressure & temperature sensor

z The engine oil pressure and oil Fixing bolt

temperature sensor measure in the

engine lube oil and measuring data Engine oil
pressure &
is inputted into ECU. temperature
sensor

3.4.19. Engine coolant temperature sensor

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

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3.5. Electrical System

3.5.1. Electrical parts

2
5

11

10

8
6

1 Coolant temperature sensor 7 Air con. compressor

2 Alternator 8 Engine oil pressure & temperature sensor
3 Fuel temperature sensor 9 Boost pressure & temperature sensor
4 Camshaft speed sensor 10 Starter
5 Air heater 11 Crankshaft speed sensor
6 Electric control unit (ECU)

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3.5.2. Harness of electrical control unit

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3.5.3. Connector of electrical control unit (ECU)

Vehicle side connector Engine side connector

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3.5.4. Electrical Control Unit

Signal
Pin no. Part name
BOSCH DOOSAN
1.01 V_V_BAT+1 V_V_BAT+1 Battery plus (+24V)
1.03 G_G_BAT-1 G_G_BAT-1 Battery minus (-24V)
1.04 G_G_RH01 G_G_RH01 Ground (-24V)
1.07 V_V_BAT+2 V_V_BAT+2 Battery minus (+24V)
1.08 O_V_RL O_V_RL ECU Battery voltage (+24V)
1.09 G_G_BAT-2 G_G_BAT-2 Battery minus (-24V)
1.12 V_V_BAT+3 V_V_BAT+3 Battery plus (+24V)
1.13 V_V_BAT+4 V_V_BAT+4 Battery plus (+24V)
1.14 G_G_BAT-3 G_G_BAT-3 Battery minus (-24V)
1.15 G_G_BAT-4 G_G_BAT-4 Battery minus (-24V)
1.16 O_S_CSHRLY O_S_RH01 Air heater relay
1.19 G_R_DIG G_R_DIG Digital ground
1.27 I_S_DIA I_S_DIG15 Diagnostic operation switch
ECU Battery voltage (+24V)
1.28 O_V_DIA O_V_RL06
for diagnostic lamp operation
1.29 O_S_CSLP O_S_RL02 Cold starting lamp
1.31 B_D_ISOK B_D_ISOK ISO K-line
1.33 G_C_CAN2 G_C_CAN2 ECU network 2 , shield
1.34 B_D_CANL2 B_D_CANL2 ECU network 2 , low
1.35 B_D_CANH2 B_D_CANH2 ECU network 2 , high
1.39 I_S_T15 I_S_T15 Key switch (Terminal 15)
1.45 I_S_STP I_S_DIG21 Engine stop switch signal
1.51 G_C_CAN1 G_C_CAN1 ECU network 1, shield
1.52 B_D_CANL1 B_D_CANL1 ECU network 1, low
1.53 B_D_CANH1 B_D_CANH1 ECU network 1, high
1.64 O_S_DIA O_S_RL06 Diagnostic lamp
Power ground output
2.02 O_G_BPA O_G_RHS03
for boost pressure actuator
2.04 O_T_BPA O_T_RHS03 Boost pressure actuator
2.05 O_G_MEU O_G_RHS01 Fuel metering unit (low side)
2.07 O_T_MEU O_T_RHS01 Fuel metering unit (high side)
2.09 V_V_5VOPS V_V_5VSS3B Oil pressure sensor supply (5V)
2.10 V_V_5VBPS V_V_5VSS1A Boost pressure sensor supply (5V)
Common rail pressure sensor supply
2.12 V_V_5VRAILPS V_V_5VSS2A
(5V)
2.16 O_V_RHS03 O_V_RHS03 ECU battery plus output (+24V)
2.17 G_R_FTS G_R_PAS01 Fuel temperature sensor ground
2.18 G_R_CTS G_R_PAS02 Coolant temperature sensor ground
2.19 G_R_OPS G_R_ACT06 Oil pressure sensor ground
2.20 G_R_RAILPS G_R_ACT01 Common rail pressure sensor ground
2.21 G_R_BPS G_R_ACT02 Boost pressure sensor ground
2.23 I_F_CAS I_F_DF02 Camshaft speed sensor signal
2.24 G_R_CRS G_R_DF01 Crankshaft speed sensor ground
2.25 I_F_CRS I_F_DF01 Crankshaft speed sensor signal
2.27 I_A_RAILPS I_A_ACT01 Common rail pressure sensor signal
2.28 I_A_BPS I_A_ACT02 Boost pressure sensor signal
2.29 I_A_BTS I_A_PAS03 Boost air temperature sensor signal

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Signal
Pin no. Part name
BOSCH DOOSAN
2.30 G_R_CAS G_R_DF02 Camshaft speed sensor ground
2.33 I_A_OPS I_A_ACT06 Oil pressure sensor signal
2.34 I_A_FTS I_A_PAS01 Fuel temperature sensor signal
2.35 I_A_OTS I_A_PAS05 Oil temperature sensor signal
2.36 I_A_CTS I_A_PAS02 Coolant temperature sensor signal
3.03 O_P_SVH13 O_P_SVH13 #3 cylinder injector power supply
3.04 O_P_SVH12 O_P_SVH12 #2 cylinder injector power supply
3.05 O_P_SVH23 O_P_SVH23 #6 cylinder injector power supply
3.06 O_P_SV13 O_P_SV13 #3 cylinder injector power return
3.07 nc G_R_GND01
3.08 nc G_R_GND02
3.09 O_P_SVH11 O_P_SVH11 #1 cylinder injector power supply
3.10 O_P_SVH22 O_P_SVH22 #5 cylinder injector power supply
3.11 O_P_SVH21 O_P_SVH21 #4 cylinder injector power supply
3.12 O_P_SV12 O_P_SV12 #2 cylinder injector power return
3.13 O_P_SV11 O_P_SV11 #1 cylinder injector power return
3.14 O_P_SV23 O_P_SV23 #6 cylinder injector power return
3.15 O_P_SV22 O_P_SV22 #5 cylinder injector power return
3.16 O_P_SV21 O_P_SV21 #4 cylinder injector power return
nc = not connected

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3.5.5. Engine harness

Water Oil
temperature pressure
sensor sensor Boost Common Cam shaft
(CTS) (OPTS) pressure rail pressure speed
sensor sensor sensor
(BPTS) (RPS) (CAS)

Engine ECU Crank shaft Fuel Fuel metering

speed temperature unit
sensor sensor (MEU)
(CRS) (FTS)

Part Pin position Wire

Signal Circuit name
name ECU no. Connecting pin no. color

2.25 ECU no. 25 Crankshaft sensor 1 White Speed sensor signal

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

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3.5.6. Harness of injector (Engine harness - 2)

Injector
cylinder
#1 Injector
cylinder
Injector #4
cylinder
#2

Injector
cylinder
Injector #5
cylinder
#3

Injector
cylinder
#6

Injector cylinder # 3 Injector cylinder

# 5, # 6
Injector cylinder Injector cylinder # 4
# 1, # 2

Engine ECU

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1) Harness of injector (outside)

Cylinder # 3 Cylinder
# 5, # 6
Cylinder Cylinder # 4
# 1, # 2

Engine ECU

Side of ECU Side of injector Wire

Circuit name
Connector no. Pin no. Connector no. Pin no. color

3.09 3 White High side of injector 1

3.13 P_02 4 White Low side of injector 1
936254-1
3.04 (AMP) 1 White High side of injector 2
3.12 2 White Low side of injector 2
3.03 P_03 1 White High side of injector 3
P_01 936254-1
3.06 (AMP) 2 White Low side of injector 3
Y462 U03 027
(1 928 404 202) 3.11 P_05 1 White High side of injector 4
(BOSCH) 936254-1
3.16 (AMP) 2 White Low side of injector 4

3.10 1 White High side of injector 5

3.15 P_04 2 White Low side of injector 5

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

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2) Harness of injector - A (inside)

Side of ECU harness Side of engine brake Wire

Circuit name
Connector no. Pin no. Connector no. Pin no. color
High side of
1 1 White
P_01 injector
Low side of
2 Y462 U00 226(Bosch) 2 White
99013-00201 injector
or
(AMP) High side of
3 45360.212.179(GHW) 3 White
65.26810-5006 injector
(DOOSAN) Low side of
4 4 White
injector

3) Harness of injector – B (inside)

Side of ECU harness Side of engine brake Wire

Circuit name
Connector No Pin No Connector No Pin No color
High side of
P_01 1 Y462 U00 226(Bosch) 1 White
injector
or
99013-00501 Low side of
2 45360.212.179(GHW) 2 White
(AMP) injector
65.26810-5009 3 - - -
None
(DOOSAN) 4 - - -

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3.6. Engine Diagnostic

3.6.1. Method of confirmation for the fault code
The method of performing the DV11 engine diagnostic is using the SCAN-200.
DOOSAN recommend the using the SCAN-200, because it can be worked speedy
and correctly.

3.6.2. Method by SCAN-200

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

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3.6.3. Engine fault code and occurring condition

1) Trouble code of vehicle parts
Fault
Contents of trouble Condition of occurring
code

V201 Gauge panel communication error Connector harness is abnormal

V202 ECU communication error Connector harness is abnormal

V210 Pump proportion valve Current below and/or above normal

V212 Flow control proportion valve Current below and/or above normal

V213 Relief pressure up solenoid valve Current below and/or above normal

V214 High speed solenoid valve Current below and/or above normal

V215 Swing priority solenoid valve Current below and/or above normal

V217 Starter relay Current below and/or above normal

V220 Front pump pressure sensor Voltage above and/or below normal

V221 Rear pump pressure sensor Voltage above and/or below normal

V222 Hydraulic oil temperature sensor Voltage above and/or below normal

V225 Fuel level sensor Voltage above and/or below normal

V226 Alternator potential Voltage above and/or below normal

V227 Dial Voltage above and/or below normal

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2) Trouble code of engine parts

Fault
Contents of trouble Grade Condition of occurring
code
Relation to coolant temperature * Sensor / harness is abnormal
E011 C
sensor is abnormal * Coolant temperature is too high
Relation to fuel temperature sensor * Sensor / harness is abnormal
E012 C
is abnormal * Fuel temperature is too high
* Sensor / harness is abnormal
Relation to boost temperature
E013 C * Intake temperature is excessive after intercooler
sensor is abnormal
* Engine / turbocharger / intercooler is abnormal
* Sensor / harness is abnormal
Relation to boost pressure sensor is
E014 C * Intake pressure is excessive after intercooler
abnormal
* Engine / turbocharger / intercooler is abnormal
Relation to oil temperature sensor is * Sensor / harness is abnormal
E017 N
abnormal * Oil temperature is too high
Relation to oil pressure sensor is * Sensor / harness is abnormal
E018 C
abnormal * Oil pressure is too abnormal(leakage etc.)
E021 Battery voltage is abnormal C * Battery / alternator / ECU is abnormal
Relation to fuel pressure sensor is
E022 B * Sensor / harness is abnormal
abnormal
Common rail pressure is excessive
E032 B * Common rail pressure is abnormal
fluctuation
E037 CAN signal is abnormal N * Connector harness is abnormal
Warning which engine speed is
E038 C * Engine-over-speed
excessive
* ECU inner main relay is abnormal
E039 ECU inner relay is abnormal B
* Power supplying is abnormal
Abnormality by abnormal stopping of
E041 B * Abnormal engine stopping
engine
Relation to crank shaft speed sensor * Sensor / harness is abnormal
E042 C
is abnormal * Sensor gap is abnormal
Relation to cam shaft speed sensor * Sensor / harness is abnormal
E043 C
is abnormal * Sensor gap is abnormal
* Motivation of cam shaft / crankshaft speed sensor
E044 Engine speed sensor is abnormal C
signal is abnormal
Dater storage of EEPROM in ECU is * Error is occurred during storing important data of
E045 C
abnormal operating in ECU to EEPROM when engine stop.
Initialization is not good after power
E046 C ECU initialization is abnormal
supply to ECU
Pressure limit value is opened compulsory when rail
Pressure limit valve of common rail
E047 B pressure is occurred at excessive pressure more
is opened by excessive rail pressure
than rail pressure or high pressure pump
Battery voltage is abnormal : ECU, battery and
E048 Power supplying source is abnormal N
alternator is abnormal
Supplying voltage of injector (#1,5,3)
E049 B
is abnormal * Injector cable / connector is abnormal or ECU is
Supplying voltage of injector (#6,2,4) trouble
E051 B
is abnormal
Relation to connecting of injector #1
E058 B
harness is abnormal
Relation to connecting of injector #5
E059 B
harness is abnormal
Relation to connecting of injector #3
E061 B
harness is abnormal
* Injector cable / connector is abnormal
Relation to connecting of injector #6
E062 B
harness is abnormal
Relation to connecting of injector #2
E063 B
harness is abnormal
Relation to connecting of injector #4
E064 B
harness is abnormal

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Fault
Contents of trouble Grade Condition of occurring
code
Relation to air heater lamp is Lamp / harness is abnormal
E066 N
abnormal
Air heater operation relay is
E072 C Air heater relay / harness is abnormal
abnormal
Relation to high pressure pump Fuel metering unit of high pressure pump / harness
E083 C
control is abnormal is abnormal
Starting procedure is abnormal, ECU is abnormal,
E091 Abnormal starting B
power supplying is abnormal
E092 Ignition of #1 cylinder is not good C

E093 Ignition of #5 cylinder is not good C

E094 Ignition of #3 cylinder is not good C *Injector is abnormal, compression pressure is a

drop, camshaft / crankshaft speed sensor signal is
E095 Ignition of #6 cylinder is not good C abnormal

E096 Ignition of #2 cylinder is not good C

E097 Ignition of #4 cylinder is not good C

Ignition of several cylinder is not
E098 C
good
Opening time of injector is excessive from standard
E099 Injector is opened too long C
values

Engine speed is abnormal Error is occurred when calculate engine speed using
E101 C
(Additional function) crankshaft / camshaft speed sensor

* Check of the grade’s operation

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

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3.6.4. Input and output of the ECU

Input Output
Engine
Engine
Engine output
Input and output of ECU
• Injector output
• Fuel high pressure pump
• Coolant temperature sensor
- Fuel metering unit
• Fuel temperature sensor
• Boost pressure and
temperature sensor
• Oil pressure and
temperature sensor
• Crankshaft speed sensor
• Camshaft speed sensor
• Common rail pressure sensor Vehicle output

• Preheating relay output

Electric • Preheating display lamp
control • Diagnostic information
unit output lamp
Vehicle
Vehicle
(ECU) • Engine speed and vehicle speed
• Starter switch display

Communication

• Engine diagnostic communication

• CAN communication

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3.7. Operating condition of the ECU

3.7.1. Engine starting

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

3.7.2. Vehicle running

z Essential dater for the running of the vehicle.
- Engine speed
- Vehicle speed

3.7.3. Engine idle adjusting

z Adjusting of engine’s idle speed by the necessity of the driver.

z Preparing condition for the adjusting of the idle speed

- Vehicle speed : stop
- Coolant temperature : more than limit
- Engine speed : less than limited scope of the speed

3.7.4. Limp home function

z The limp home is a function which the vehicle can be operated to the
maintenance shop with minimum condition for traveling on the condition of
taking safety when the defect code is occurred.

z Application condition
- Accelerator pedal is trouble : The vehicle is operated by constant engine
speed no relation to depressing of the accelerator pedal.
- Sensor is trouble : The vehicle is operated with constant transfer value when
the trouble of all kinds sensors is occurred.
- Fuel quantity is limited : The fuel quantity supplied into the engine is limited
according to kind of the defect. (is applied by division into 4 stages)
- Diagnostic information output lamp : The safety driving is leaded to the
driver by proposal of information about status of occurred faults.

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3.7.5. Diagnostic
z Diagnostic information output lamp (CEL: Check engine lamp) is operated when
the trouble is occurred.

z Method of confirmation of the fault code by using the CEL

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

z Diagnostic by the SCAN-200

- Diagnostic is executed by the connection SCAN-200 to the connector in the
relay box.

3.7.6. Vehicle operating record

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

z The contents recorded in the electric control unit

- Fuel quantity according to the division : total, idle state.
- Fuel consumption rate.
- operating mileage.
- Engine operating time, ECU using time.

z The monitoring is possible by using diagnostic tool.

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4. Commissioning and Operation

4.1. Preparations
At the time of initial commissioning of a new or overhauled engine make sure to have
observed the "Technical information for the installation DOOSAN engines”.

z Oil filler neck on cylinder head cover

Before daily starting of the engine, check the fuel, coolant and oil level, replenish
if necessary.
z The oil level must be between Max. and Min. lines on the gauge. The notches in
the oil level gauge indicate the highest and lowest permissible oil levels.

IMPORTANT:
Do not fill above the top of the mark by over lifting. Over lifting will result in
damage to the engine.

z Cleanliness
Ensure outmost cleanliness when handling fuels, lubricants and coolants, be
careful about mixing of the foreign matter during the supplement.
In case that DOOSAN recommended the fuel and lubrication oil and coolant do
not used, DOOSAN do not guarantee the field claim.

4.2. Breaking-In
z DOOSAN engine for the vehicle is operated during a short time for the engine last
Approving test, therefore operator must execute the process of proper breaking in
the engine during the first 500 Hr then The maximum performance of the engine
have the maximum performance , and the life of the engine can be
prolonged.

4.2.1. Operation of a new engine (Break-in)

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

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Up to the first 500 Hr

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

4.2.2. Check points for break-in

During the break-in (the initial running of the engine) period, be particularly observant

as follows:

z Check engine oil level frequently. Maintain oil level in the safe range, between

the "min." and “max." marks on dipstick.

NOTE:
If you have a problem getting a good oil level reading on the oil level gauge,
rotate the oil level gauge 180° and re-insert for check.

z Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up

screen is not covered with oil. Check oil level gauge. Add oil to the oil pan, if

required. Do not overfill. If level is correct and the status still exists, see your

DEALER for possible switch or oil pump and line malfunction.

Note:
Oil pressure will rise as RPM increases, and fall as RPM decreases. In
addition, cold oil will generally show higher oil pressure for any specific RPM
than hot oil. Both of these conditions reflect normal engine operation.

z Watch the engine water temperature gauge and be sure there is proper water

circulation. The water temperature gauge needle will fluctuate if water level in

expansion tank is too low.

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z At the end of the break-in period, remove break-in oil and replace the oil filter.

z Fill oil pan with recommended engine oil. Refer to following table
SAE no. Oil grade
ACEA-E5
10W40
（API CI-4）

z Engine oil capacity

Engine oil capacity

Oil pan inside
Total
Engine model Max. Min.
(lit)
(lit) (lit)

DV11 41 27 44

4.2.3. Operating after break-In

When starting a cold engine, always allow the engine to warm up gradually. Never

run the engine at full throttle until the engine is thoroughly warmed up. Be sure to

check the oil level frequently during the first 500Hr of operation, since the oil

consumption will be high until the piston rings are properly seated.

4.3. Inspections after Starting

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

not normal.

z Confirm the following things through warning lamps and gauge panel.

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4.3.1. Pressure of lubricating oil

The normal pressure comes up to 1.0 ~ 3 kg/cm2 at idling and 3 ~ 5 kg/cm2 (3.0 ~

4.9 bar) at maximum speed. If the pressure fluctuates at idling or does not reach up

to the expected level at high speed, shut down the engine immediately and check

the oil level and the oil line leakage.

4.3.2. Temperature of cooling water

The cooling water temperature should be 85°C in normal operating conditions.

Abnormally high cooling water temperature could cause the overheating of engine

and the sticking of cylinder components. And excessively low cooling water

temperature increases the fuel consumption, accelerates the wears of cylinder liners

and shortens the engine life-time.

4.3.3. Over-speed control

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

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4.4. Operation in winter time

Pay special attention to the freezing of cooling water and the viscosity of lubricating

oil.

4.4.1. Operation in winter time

CAUTION :
1. Preheating devices are attached to the engine for improving the starting
abilities at extremely low temperature.
2. Do not actuate the starter for longer than 10 seconds. If starting fails
regardless of the preheating, start the preheating again after 30 seconds.

Operation 1 : Turn the key switch to the HEAT position, then the pilot lamp lights

up for about 20 seconds When the pilot lamp is extinguished, do

operation 2

Behavior - When the coolant temperature is below 10°C in cold weather, you’d
better operate the pre-heating system (Air heater).

- If the pre-heating is not necessary, the pre-heating system is not

operated with the pilot lamp.

Operation 2 : After checking the pilot lamp, turn the key switch to the START

position to crank the engine, at once.

Behavior - When the key switch is placed in the START position, air heater is

continuously heated to facilitate starting operation and to reduce

white smoke automatically.

- If the coolant temperature is above 10°C, air eater needs not be

heated.

Operation 3 : After the engine is cranked, convert the key switch to the ON position.

Behavior - As the engine is cranked, air heater is heated for 180 seconds (3

minute after-heating) to reduce and to element quickly white smoke.

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* Air heater major specification

Rated voltage DC22V (120A ±10%)

Rated current 2.64 kW

Battery cable
(form relay)

Caution air flow of

assembly direction

Earth cable

4.4.2. Prevention against freezing of cooling water

z When not using anti-freeze, cause the diffusion of corrosion in inner part of the

engine, cause drop the cooling efficiency, cause being frozen to burst in winter,

therefore the whole cooling water should be completely discharged after engine

running.

z The freezing of cooling water is the reason of fatal damage on the engine, always

use by mixing the anti-freeze. (anti-freeze quantity filled : 40-50% of the cooling

water) the anti-freeze is used to prevent cooling water from freeze.

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4.4.3. Prevention against excessive cooling

z Drop of thermal efficiency caused by excessive cooling increases fuel

consumption, therefore prevent the engine from excessive cooling. If the

temperature of coolant does not reach to normal condition (78 ~ 85°C) after
continuous operation, examine the thermostat or the other cooling lines.

4.4.4. Lubricating oil

As cold weather leads to the rise of oil viscosity, engine speed becomes unstable

after starting. Therefore the lubricating oil for winter should be used to prevent this

unstability. Refer to lubricating system section.

4.5. Engine components check after long time running

z The purpose of an engine tune-up is to restore power and performance that's

been lost through wear, corrosion or deterioration of one or more parts or

components.

z In the normal operation of an engine, these changes can take place gradually at a

number of points, so that it's seldom advisable to attempt an improvement in

performance by correction of one or two items only. Thorough procedure of

analysis and correction, it is desirable to change or correct of all items affecting

power and performance.

z In case that the engine is perform in advance the prevention against trouble,

the engine can be run safely during a long time as that time , there can be used

more reliably.

z Economical, trouble-free operation can better be ensured if a complete tune-up is

performed once every years, preferably in the spring.

z Below components that affect power and performance to be checked are:.

- Components affecting intake & exhaust

Air cleaner, inter-cooler, turbo charger, silencer, etc

- Components affecting lubrication & cooling

Air & oil filter, anti- freeze, etc

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4.6. Maintenance and Care

4.6.1. Periodical Inspection and Maintenance
In order to insure maximum, trouble-free engine performance at all times, regular
inspection, adjustment and maintenance are vital.
z Daily inspections in bellow figure should be checked every day.

z The maintenance should be executed thoroughly at regular intervals.

(refer to appendix “General engine inspection cycle”.)

4.6.2. Exchanging of lubrication oil

Engine oil and the oil filter are important factors affecting engine life. They affect

ease of starting, fuel economy, combustion chamber deposits and engine wear.

At the end of the break-in period, change the oil sump oil and replace the oil filter

cartridge.

4.6.3. Oil level gauge

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

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

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4.6.4. Oil exchange procedure

While the oil is still hot, exchange oil
as follows.
z Take out the oil level gauge.
z Remove the drain plug from oil pan,
then drain out the engine oil into a
container.
z Refill with new engine oil at the oil
Drain plug
filler neck on the head cover and

the lubricating oil in accordance Rubber gasket

with the oil capacity of the engine

Oil filter cap

through oil filler.

Cylinder head
z Be careful about the mixing of dust intermediate
cover

or contaminator during the

supplement of oil. Then confirm

that oil level gauge indicates the

vicinity of its maximum level.

z For a few minutes, operate the engine at idling in order to circulate oil through

lubrication system.

z Thereafter shut down the engine. After waiting for about 10 minutes measure the

quantity of oil and refill the additional oil if necessary.

4.7. Cooling System

z The coolant must be changed at intervals of 1,200 hour operation or six months

whichever comes first. If the coolant is being fouled greatly, it will lead an engine

overheat or coolant blow off from the expansion tank.

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4.7.1. Coolant draining

z Remove the pressure cap.

z Open the drain valve at the radiator

lower part to drain the coolant as

the right figure.

z Loosen the coolant drain plug of

the cylinder block.

Drain valve

Cooling
water drain

CAUTION:

When removing the pressure filler cap while the engine is still hot, cover the

cap with a rag, then turn it slowly to release the internal steam pressure. This

will prevent a person from scalding with hot steam spouted out from the filler

port.

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4.7.2. Cleaning of the cooling inside system circuit

When the cooling system circuits are fouled with water scales or sludge particles, the

cooling efficiency will be lowered. When the cooling system circuits are clogged, the

water pump mechanical seal is damaged.

The poor condition of the cooling system is normally due to use of unsuitable or no

anti-freezing agents and corrosion inhibitor or defect.

If twice in a short time (within 6 months) the water pump of an engine develops

leases or the coolant is heavily contaminated (dull, brown, mechanically

contaminated, gray or black sings of a leakage on the water pump casing) clean the

cooling system prior to removing that water pump as follows.

a) Drain coolant.
b) Remove thermostats, so that the whole cooling system is immediately flown
through when cleaned.
c) Fill the cooling system with a mixture of potable water and 1.5% by volume of
cleaner. (Henkel P3T5175)
d) Warm up engine under load. After a temperature of 60°C is reached, run engine
for a further 15 minutes.
e) Drain cleaning fluid.
f) Repeat steps c) and d).
g) Fill cooling system with hot water.
h) Run engine at idle for 30 minutes. At the same time continuously replenish the
water leaking from the bore in drain plug by adding fresh water.

CAUTION:

Periodically clean the circuit interior with a cleaner.

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4.8. Adjustment of valve clearance

4.8.1. General information
The valve clearances are to be adjusted at the times of the following situations.
z When the engine is overhauled and the cylinder heads are disassembled.
z When severe noise comes from valve train.
z When the engine is not normally operated, even though there is no trouble in the
fuel system.

4.8.2. Valve clearance adjust procedure

z After letting the #1 cylinder's piston come at the compression top dead center by
turning the crankshaft, adjust the valve clearances.
z Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge
of specified value between a rocker arm and a valve stem and adjust the
clearance with adjusting screw respectively and then tighten with the lock nut.
z As for the valve clearance, adjust it when in cold, as follows.

Engine model Intake valve (A) Exhaust valve (A)

DV11 0.4 mm 0.5 mm

Rocker arm Valve adjusting bolt

Caliper adjusting bolt

Valve adjusting nut

A

Caliper Push rod

Intake valve
spring

Valve

Valve seat

Intake & exhaust valve adjusting

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< Adjust the valve clearance as following order. >

1) Rotating the engine, let #6 cylinder overlap.
2) In time that #1 cylinder become the state of top dead center, adjust the valve
clearance corresponding to ” ◎ “ of following lists.
3) Rotating the crankshaft by 90° rotation, adjust the valve clearance
corresponding to " ⊙ ".
4) Rotating the crankshaft by 1 rotation (360° rotation), let #1 cylinder overlap.
5) In time that #5 cylinder become the state of top dead center, adjust the valve
clearance corresponding to ” ● “ of following lists.
6) Rotating the crankshaft by 450° rotation, adjust the valve clearance
corresponding to " ○ ".
7) After rechecking the valve clearance, readjust if necessary.

z No. 1 Cylinder is located at the side where cooling water pump was installed.

Fly wheel Cylinder No Exhaust valve Intake valve Cooling fan

Valve adjusting position Intake valve Exhaust valve

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z Adjusting of valves (Type 1)

Cylinder No 1 2 3 4 5 6

Valve adjusting Exhaust Intake Exhaust Intake Exhaust Intake Intake Exhaust Intake Exhaust Intake Exhaust

#1 cylinder top dead center

◎ ◎ ◎ ◎ ◎
(#5 cylinder valve overlap)

Crankshaft 90° revolution ⊙

360° revolution
#5 cylinder top dead center
(#1 cylinder valve overlap)
● ● ● ● ●
Crank shaft
450° revolution ○

z Adjusting of valves (Type 2)

Adjusting of the valve overlapping on each cylinder is done as follow.
When each cylinder is valve overlap
1 4 2 5 3 6
(Explosion cylinder No. order)

Valve adjusting cylinder No. 5 3 6 1 4 2

4.9. Tightening the cylinder head bolts

z Coat the engine oil on the cylinder
head bolts, assemble with specified
torque according to the order of the
assembling.

< Cylinder head bolts >

Spec

M16×2.0×176
1st : 8kg.m
2nd : 180°
Torque
2rd : 150°
(Angle torque)

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< Cylinder head bolt’s Tightening Order >

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

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5. Maintenance of Major Components

5.1. Cooling System
5.1.1. General descriptions and main data
z This engine is water-cooling type. Heat from the combustion chamber and engine
oil heat are cooled down by coolant and radiated to the outside, resulting in the
normal operation of the engine.
z Looking into the cooling system, the water pumped up by the water pump
circulates around the oil cooler through the water pipe to absorb the oil heat, and
then flows through the water jacket of the cylinder block and water passage of the
cylinder head to absorb the heat of the combustion chamber.

Cylinder block Cylinder head

Cylinder no.

Oil cooler

Cylinder block
Thermostat
Water pump

Radiator

z The water absorbing the oil heat and combustion chamber heat goes on to the
thermostat through the water pipe, and circulates to the water pump if water
temperature is lower than the valve opening temperature on the thermostat, while
circulating to the radiator at water temperature higher than the valve opening
temperature. At the radiator, the heat absorbed in the coolant is radiated to cool
down and the coolant recirculates to the water pump.

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5.1.2. Specification

Item Specification
Type Centrifugal type
Pumping speed 3,500 rpm
1. Water pump
Delivery about 452 liter/min or more
Pumping back pressure Bellow 1.8 bar
Operating temperature 71°C type
8mm or more
2. Thermostat Valve lift
(at 85°C)
Operating temperature 71 ∼ 85°C

5.1.3. Thermostat
z General descriptions and main data
The thermostat maintains a
constant temperature of coolant (71
∼ 85 °C) and improves thermal
efficiency of the engine by
preventing heat loss.
Namely, when the temperature of
coolant is low, the thermostat valve
is closed to make the coolant
bypass to directly enter the water pump; when the coolant temperature rises to
open wide the thermostat valve, the bypass circuit is closed and the water
passage to the radiator is opened so that the coolant is forced to flow into the
radiator.

z Inspecting
(1) Check the wax pallet and
spring for damage.
(2) Put the thermostat in a
container of water, then heat
the water slowly and check
temperature with a
thermometer. If the valve lift is
0.1 mm (starting to open) at
temperature of 71°C and 8 mm or more (opening wide) at temperature of
85°C, the thermostat is normal.

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z Replacing thermostat and precautions for handling

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

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5.1.4 Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Engine overheating z Lack of coolant z Replenish coolant
z Radiator cap pressure z Replace cap
valve spring weakened
z Fan belt loosened or z Adjust or replace fan belt
broken
z Fan belt fouled with oil z Replace fan belt
z Thermostat inoperative z Replace thermostat
z Water pump defective z Repair or replace
z Restrictions in water z Clean radiator and water
passages due to deposit passages
of scales
z Injection timing incorrect z Check injection timing by
SCAN-200
z Restriction in radiator core z Clean exterior of radiator
z Gases leaking into water z Replace cylinder head gasket
jacket due to broken
cylinder head gasket
2. Engine overcooling z Thermostat inoperative z Replace thermostat
z Ambient temperature too z Install radiator curtain
low
3. Lack of coolant z Radiator leaky z Correct or replace
z Radiator hoses loosely z Retighten clamps or replace
connected or damaged hoses
z Radiator cap valve spring z Replace cap
weakened
z Water pump leaky z Repair or replace
z Heater hoses loosely z Tighten or replace hoses
connected or broken
z Cylinder head gasket z Replace cylinder head gasket
leaky
z Cylinder head or cylinder z Replace cylinder head block
block cracked
4. Cooling system z Water pump bearing z Replace bearing
noisy defective
z Fan loosely fitted or bent z Retighten or replace fan
z Fan out of balance z Replace fan
z Fan belt defective z Replace fan belt

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5.2. Lubrication system

5.2.1. General descriptions and main data
z General descriptions
All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated
through the oil cooler and oil filter, and this filtrated oil is forced through the main
oil gallery in the cylinder block from where it is distributed to lubricate the various
sliding parts in order to ensure normal engine performance.

z Specifications
Item Specifications Item Specifications
Forced pressure
Lubricating system Oil filter type Full flow
circulation
Oil pump type Gear type Bypass for cartridge
Relief valve opening pressure 10 -1.5 kg/cm2 Valve opening pressure 1.8∼2.4 kg/cm2
Oil cooler bypass Bypass for entire oil filter
Opening pressure 5 +1 kg/cm2 Valve opening pressure 4.3∼4.7 kg/cm2
Adjusting valve for spray nozzle
Opening pressure 1.5∼1.8 kg/cm2

5.2.2. Oil pump

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

2) Remove the oil pump cover

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

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z Inspection and correction

(1) With steel rule and feeler
gauge, measure the axial end
play of the oil pump gear.
Replace if the measured value
is beyond the limit. Steel plate

Feeler gauge
End play limit 0.055 ∼ 0.105 mm

(2) With a feeler gauge, measure

the amount of backlash
between the oil pump drive
gear and driven gear. Replace
if the measured value is
beyond the limit.

Backlash limit 0.50 ∼ 0.64 mm

(3) Measuring clearance between drive shaft and bushing

a. Measure the outside diameters of the drive shaft and driven shaft, and
replace if the measured values are less than the limit.

Standard φ16.95∼φ16.968 mm

Limit φ16.95mm

b. Measure the inside diameter of the pump body bushing to determine the
clearance between the bushing and shaft, and compare the measured
value with the standard value to determine whether to replace or no.

Clearance 0.075 ∼ 0.127 mm

z Reassembly
(1) For reassembly, reverse the disassembly sequence.

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5.2.3. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Oil consumption z Poor oil z Use suggested oil
excessive z Oil seal or packing leaky z Replace
z Pistons or piston rings z Replace pistons and/or
worn piston rings
z Cylinder liner worn z Replace cylinder liner
z Piston rings sticking z Replace pistons and/or
piston rings
z Valve guide oil seals or z Replace
valve guides, or valve
stem worn
Oil pressure too low z Poor oil z Use suggested oil
z Relief valve sticking z Replace
z Restrictions in oil pump z Clean strainer
strainer
z Oil pump gear worn z Replace
z Oil pump feed pipe z Replace
cracked
z Oil pump defective z Correct or replace
z Oil pressure gauge z Correct or replace
defective
z Various bearings worn z Replace
2. Oil deteriorates z Restriction in oil filter z Replace filter element
quickly z Gases leaking z Replace piston rings and
cylinder liner

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5.3. Turbo Charger

5.3.1. Specification and construction
1) Main data and specification
Specification DV11
Model Honeywell 753834-1/2
At Air pressure at compressor outlet Approx. 1.9 kgr/cm2
maximum Air suction of turbine revolution Approx. 23 m3/min
output Speed of turbine revolution Approx. 95,000 rpm
Maximum allowable speed 118,900 rpm
Maximum allowable temperature of exhaust gas
750°C
at turbine inlet
Lubricating system External oil supply
Weight 18 kg

2) Operating principle

3) Construction

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4) Components of turbocharger
z Make sure that servicing should be performed at the professional maintenance
shop as authorized by Honeywell Company.

1 Hose 12 Piston ring 23 Hex nut

2 Hose clamp 13 Thrust collar 24 Hex bolt
3 Connector 14 Thrust bearing 25 Turbine housing
4 Compressor housing 15 Journal bearing 26 Actuator bracket
5 Clamp, compressor 16 Center housing 27 Hex bolt
6 Hex bolt 17 Bearing spacer 28 Rod
7 Compressor wheel 18 Journal bearing 29 Retaining ring
8 O - ring 19 Shroud wheel 30 Crank ass’y
9 Hex bolt 20 Piston ring 31 Arm valve ass’y
10 Back plate 21 Turbine wheel ass’y 32 Actuator
11 Seal ring 22 V - clamp 33 Hose clamp

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5.3.2. . General information

The engine output depends upon the supplied fuel quantity and the engine efficiency.
In order to transform into the effective work of engine by burning the supplied fuel
fully, the sufficient air to burn the fuel should be supplied to the cylinder. Therefore,
the engine output is essentially determined by the size of the cylinder, and for if the
air is supplied to the given volume of cylinder with the air being compressed, the air
quantity in the cylinder will Increase as much to result in that it may burn more fuel.
the output will also be able to increase, Supplying the air by compressing like this
into the engine cylinder is called as super charging, and super charging by means of
exhaust gas energy that discharges to the atmosphere is called as the turbo
charging.

5.3.3. Function
1) Turbine
The exhaust gas that is discharged from combustion chamber passes through
turbine housing conveying an energy to turbine wings to give the rotating power,
This is called as the turbine and in order not to influence a bad effect at bearing
part, there are the seal ring and heat protector.

2) Compressor
It is connected to the same shaft with the turbine to make a revolving assembly,
and receive the revolving force of turbine, and sends air to the suction manifold
by suctioning and compressing it. This is called as the compressor.

3) Bearing
(1) Thrust bearing
Thrust bearing force is applied to the turbine wheel and an arrangement is
made for the shaft not to shift.
(2) Journal bearing
Journal bearing (floating bearing) is adopted and it forms the double oil films at
the inner and outer surfaces in comparison to the general stationary type so
that the bearing may be able to rotate independently and consequently the
double layers of films act as the damper to make the slipping speed on the
bearing surface less than the rotating speed of shaft so that the dynamic
stability may be obtained.

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4) Sealing at compressor shaft

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

5.3.4. How to handle the engine

1) Precautions for operation of the engine
Operation following items must be observed at the starting, operation and stop of
engine.

Operation Caution Reason

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

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Operation Caution Reason

Following items must be confirmed.
1) Oil pressure 1) If the pressure is too low,
At idling : 1.0 ~ 3.0 kg/cm2 abnormal wear or stuck may be
At full load : 3.0 ~ 5.5 kg/cm2 caused. Or if too high, the oil leak
During may be generated.
operation 2) When abnormal noises and 2) If the engine operation were
vibration are generated, slow continued with abnormal noises
down the revolution and must and vibration, it causes the
stop it to investigate the causes. engine trouble that can not be
repaired or some other troubles.
1) At stopping the engine, perform 1) After heavy load operation, if the
the idling operation for 5min. and engine were stopped suddenly,
then stop it. the heat would be conducted to
At stop bearing parts from red hot turbine
wings that would result in burning
the oil to cause the stuck bearing
metal and revolving shaft.

5.3.5. Routine inspection and maintenance

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

1) Air intake system

System the intake air system, care must be taken to the air cleaner. In case of oil
passing type air cleaner, if the oil level is lower than the specified value, the
cleaning efficiency get worse, if higher, the sucked oil pollutes a case.
Particularly, for if the rotor were polluted, the balance adjusted precisely would
be deviated to cause a vibration that may cause the stuck or abnormal wear by
loading large force to the bearing, the perfect air cleaner must always be used.
In case of dry type filter, according to the indication of a dust indicator, cleaning
must be done to make the intake air resistance as small as possible.

2) Exhaust system
In exhaust system, a care must be taken to the gas leak and the stuck
prevention if exhaust gas leaks from the exhaust pipe and turbocharger etc., for
the super charging effect will be lowered, the installed states of various parts
must be paid with careful attention. Since the parts that reach to high
temperature during operation such as the turbine room use the anti- heat nuts, a
care must be paid not to mix with the general nuts and at the same time, bolt
stuck preventing paint should be coated on the nut for the designated places.

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3) Lubricating system
In the lubricating system, a care must be paid to the oil quality and oil element
replacement cycle. For the oil deterioration of turbocharger equipped engine,
needless to speak of engine assembly itself, influences badly to the turbocharger
too. Suggested engine oils for the turbocharger-mounted engine are as follows:

Recommended oil
Engine model
SAE no. API no.
ACEA-E5
DV11 SAE 10W40
(API CI-4)

5.3.6. Periodical servicing

Make it a rule to check the turbocharger assembly for condition and contamination
periodically.

1) Guide for checking the rotor for rotating condition

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

2) Guide for checking rotor end play

Disassemble the turbocharger from the engine, then check the rotor axial play
and radial play. When disassembling the turbocharger, be sure to plug the oil
inlet and outlet ports with taps, etc.

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(1) Rotor axial direction end play

Turbine wheel
Magnitic vise chamber

Move the turbine

shaft in axial
Dial direction
gauge

Standard : 0.117~0.20mm
Limit of wear : 0.24mm

(2) Rotor radial direction end play

Dial Magnetic vise

gauge
Move the turbine
Oil outlet
shaft in both
direction
simultaneously

Radial play
Standard : 0.075~0.11mm
Limit of wear : 0.12mm
Oil inlet

(3) If the measured axial and radial end plays are beyond the limit of wear, replace
or repair the turbocharger.

3) Guide for disassembling/cleaning and checking the turbocharger

First, disassemble the turbocharger from the engine and clean/check it with the oil
inlet and outlet plugged with tape and so on.

4) Precautions for reassembling the turbocharger onto the engine

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

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(1) Lubricating system

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

(2) Air intake system

z Check the inside of the intake system for foreign matters.
z Assemble each joint on the intake duct and air cleaner securely to prevent
air leaks.

(3) Exhaust system

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

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5.3.7. Diagnostics and troubleshooting

Complaints Possible causes Corrections

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

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5.4. Belt
The tension of the belts should be checked after every 2,000 hours of operation.

(1) Change the belts if necessary

If in the case of a multiple belt drive, wear or differing tensions are found, always
replace the complete set of belts.
(2) Checking condition
Check belts for cracks, oil, overheating and wear
(3) Testing by hand
z Poly belt
Poly belt will be properly
tensioned if the deflection force
“F” is applied mid-way between
the belt’s tangent points with the
pulley.

(T) = 0.015 x S (about 1.5mm per 100mm).

T = 0.015 x *S (mm)
(T : Deflection, S : Span)

* (D − d )2
S= C − 2
(mm)
2

C : Distance of pulleys (mm)

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

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(4) Measuring tension

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

② Reading of tension
z Read of the tensioning force
of the belt at the point where
the top surface of the indicator
arm (1) intersects with the
scale.
z Before taking readings make
ensure that the indicator arm
remains in its position.

z Poly belt tension

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

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6. Special Tool List

No Part no. Figure Tool name Remark

Fuel high pressure pump gear

1 EF.120-232
assembly

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

3 EF.120-029 Oil seal insert assembly (Rear)

4 EF.120-238 Valve spring compression

5 EF.123-365 Cylinder liner puller

6 EF.120-208 Piston insert All engine

7 EF.120-246 Valve stem seal punch

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No Part no. Figure Tool name Remark

Wearing assembly
8 E1.05508-0185
(Crankshaft pulley)

9 E1.05508-0025 Wearing assembly (Fly wheel)

10 E1.76-035-00D Cam shaft assembly

11 60.99901-0027 Feeler gauge

12 65.98801-0001 Filter wrench

13 T7610001E Snap ring plier

14 T7621010E Piston ring plier

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No Part name Figure Tool name Remark

15 EF.123-322 SCAN-200 Diagnostic unit Memory card

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Appendix
z Tightening torque for major parts
Screw Strength
Major parts Tightening torque
(Diameter x pitch) (Grade)
Cylinder block bearing cap
- Main bolt M18 x 2.0 12.9T Initial 30 kg-m + angle torque 90°
- Side bolt M12 x 1.5 10.9T 8 kg-m
Oil spray nozzle
- Valve M14 x 1.5 - 7 kg-m
- Fixing bolt M6 8.8T 1.2 kg-m
Flywheel housing M12 x 1.5 10.9T 11.2 kg-m
M10 x 1.5 12.9T 7.5 kg-m
Balance weight M16 x 1.5 10.9T Initial 10 kg-m + angle torque 90°
Crank pulley M16 x 1.5 10.9T 21 kg-m
Vibration damper M10 10.9T 6 kg-m
Flywheel M16 x 1.5 12.9T 26 kg-m
Connecting rod cap M16 x 1.5 10.9T Initial 10 kg-m + angle torque 90°
Cylinder head M16 x 2.0 10.9T 6kg.m + 15kg.m + 90°+ 90° + 60°
Cylinder head cover M8 8.8T 2.2 kg-m
Rocker arm bracket M10 x 1.5 10.9T 6.2 kg-m
Lock nut (adjusting screw) M10 x 1.0 8.8T 4.4 kg-m
Oil pump cover M8 8.8T 2.2 kg-m
Oil pump mounting M8 8.8T 2.2 kg-m
Oil cooler M12 10.9T 5 kg-m
Oil pan M8 8.8T 2.2 kg-m
Oil pan drain plug M26 x 1.5 - 8.2 kg-m
Exhaust manifold M10 x 1.5 10.9T 8.0 kg-m
Intake manifold M8 8.8T 2.2 kg-m
Starting motor M12 x 1.5 8.8T 8 kg-m
Alternator bracket M14 x 1.5 8.8T 12 kg-m
Coolant temperature sensor M12 x 1.5 - 2.2 kg-m (max. 2.5 kg-m)

z Tightening torque for fuel injection system

Screw Strength
Major parts Tightening torque
(Diameter x pitch) (Grade)
Fuel high pressure pump drive gear M18 x 1.5 - 11 kg.m ±0.5 kg.m
Fuel high pressure pump cap M10 x 1.5 10.9T 7.5 kg.m
Fuel injector M8 10.9T 3.5 kg.m
Fuel high pressure pump (cylinder block) M10 x 1.5 10.9T 4.4 kg.m
Fuel high pressure connector M22 x 1.5 - 5 ~ 5.5 kg.m
Common rail M8 - 2.2 kg.m
Fuel high pressure pipe - Connector M14 x 1.5 - 3.0 kg.m
Fuel high pressure pipe - Common rail M14 x 1.5 - 3.0 kg.m
Fuel high pressure pipe - Pump M14 x 1.5 - 2.0 kg.m
Fuel return hollow screw M8 x 1.0 - 0.8 kg.m
Fuel filter M10 x 1.5 8.8T 4.4 kg.m
Injector cable M4 - 0.15 kg.m

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z Standard bolt tightening torque table

Refer to the following table for bolts other then described above
Degree of strength
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Diameter (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
x
2
pitch (mm) Limit value for elasticity (kg/mm )
20 24 32 30 40 36 48 54 64 90 108
Tightening torque (kg.m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.5 0.75 0.9
M6 0.28 0.30 0.45 0.4 0.55 0.47 0.77 0.85 0.9 1.25 0.5
M7 0.43 0.46 0.7 0.63 0.83 0.78 1.2 1.3 1.4 1.95 2.35
M8 0.7 0.75 1.1 1 1.4 1.25 1.9 2.1 2.2 3.1 3.8
M8x1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.35 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10x1 1.5 1.6 2.5 2.1 3.1 2.8 4.3 4.9 5 7 8.4
M12 2.4 2.5 3.7 3.3 4.7 4.2 6.3 7.2 7.5 10.5 12.5
M12x1.5 2.55 2.7 4 3.5 5 4.6 6.8 7.7 8 11.2 13.4
M14 3.7 3.9 6 5.2 7.5 7 10 11.5 12 17 20
M14x1.5 4.1 4.3 6.6 5.7 8.3 7.5 11.1 12.5 13 18.5 22
M16 5.6 6 9 8 11.5 10.5 17.9 18.5 18 26 31
M16x1.5 6.2 6.5 9.7 8.6 12.5 11.3 17 19.5 20 28 33
M18 7.8 8.3 12.5 11 16 14.5 21 24.2 25 36 43
M18x1.5 9.1 9.5 14.5 12.5 18.5 16.7 24.5 27.5 28 41 49
M20 11.5 12 18 16 22 19 31.5 35 36 51 60
M20x1.5 12.8 13.5 20.5 18 25 22.5 35 39.5 41 58 68
M22 15.5 16 24.5 21 30 26 42 46 49 67 75
M22x1.5 17 18.5 28 24 34 29 47 52 56 75 85
M24 20.5 21.5 33 27 40 34 55 58 63 82 92
M24x1.5 23 25 37 31 45 38 61 67 74 93 103

Others:
1. The above torque rating have been determined to 70% or so of the limit value for
bolt elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the
standard value.

z Tightening torque for plug screw

M10 M12 M14 M16 M18 M22 M24 M26 M30
5.0 5.0 8.0 8.0 10.0 10.0 12.0 12.0 15.0

z Tightening torque for hollow screw(4-hole)

M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
SM25C - 1.6 2.5 3.5 4.5 5.5 9.0 13.0 18.0 30.0
*SUM22L 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
STS304 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
* : Adopted in DOOSAN engine

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z Maintenance specification table

(unit : mm)
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use
Measure unworn
Inside diameter of portion beneath
φ127.990~φ128.010 φ128.122 Replace liner
cylinder liner the rim of the
upper side
Liner’s roundness & From top up to
0.005 -
columness (upper) 168mm
Cylinder
Liner’s roundness & From bottom up to
block & 0.008 -
columness (lower) 85mm
liner
Amount of liner Measure at upper
0.04 ~ 0.08 -
projection side of cylinder block
The flatness of upper Correct with a Referenced
0.03 -
surface of cylinder block surface grinder length : 150mm
Cylinder Hydraulic test for 1 Replace if Temperature
4 -
block minute (kg/cm2) leaky 70°C
Intake -0.39 ~ -0.41 0.55 Depression of valve
Valve seat Replace valve
from lower face
depression Exhaust -0.39 ~ -0.41 0.55 seat
of cylinder head
Replace
Cylinder head height 116.9 ~ 117.1 116.4
cylinder head
Cylinder
The flatness of lower
head & 0.08 0.1
surface of cylinder head
valve
Thick of cylinder head
gasket(at assembly 1.215 ~ 1.285 -
status)
Hydraulic test for 1 Replace if
4 - Temperature 70°C
minute (kg/cm2) leaky
Major Measure at 56.8 mm
moving Outer diameter of piston φ127.739~φ127.757 - Replace liner away from piston
parts head(long diameter)
Clearance between Replace one
0.233 ~ 0.271 0.35
piston and liner worn more
Inner diameter of
φ46.010~φ46.016 - Standard diameter
piston pin
Top ring 3.5 - Replace piston
Width of Measure
if groove width
Piston piston ring 2nd ring 3.040~3.060 - at 125mm
is beyond
grooves of top ring groove
Oil ring 4.020~4.040 - specified value
Measure unworn
Piston projection from
portion beneath
cylinder block upper 0 ~ 0.12 - Must exist
the rim of
surface
the upper side
Permissible weight
Replace
difference of each 50g 50g↓
piston
piston
Piston Top ring 3.34~3.36 -
Width of
ring 2nd ring 2.975~2.990 - Replace ring
piston ring
Oil ring 3.97~3.99 -
Piston ring Top ring 0.35~0.55 1.5 Replace ring Standard gauge
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Stand value Limit

Group Part Inspection item Correction Remark
for assembly for use
gap 2nd ring 0.80 ~ 0.95 1.5 inside
Oil ring 0.40 ~ 0.70 1.5 diameter : φ128

Piston ring Top ring 0.105~0.155 0.20 Limit for use is if

Replace ring
side 2nd ring 0.050~0.082 0.15 for standard
or piston
clearance Oil ring 0.030~0.070 0.15 clearance
Cross Install
Direction of ring gap - -
by 120°
Outer diameter of Replace
φ45.994~φ46.000 φ45.94
Piston piston pin piston pin
pin Clearance between Replace one
0.010~0.021 0.08
piston pin and its bush worn more

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(unit: mm)
Stand value Limit
Group Part Inspection item Correction Remark
for assembly for use
Major Measure in
Radial run-out of journal Correct
- 0.01 horizontal and
moving and pin with a grinder
vertical directions
parts
Outside diameter of Use under sized
φ103.98~φ104.00 φ102.98
journal bearings
Outside diameter of pin φ89.980~φ90.000 φ88.980 respectively
(0.25, 0.5, 0.75,
Width of thrust journal 38.000~38.062 37.000 1.0)
Ellipticity of journal
0.01 0.025
and pin
Taper of journal and pin 0.02 0.03
Adjust by Measure at journal
Run-out of crankshaft 0.04↓ 0.2↓
a press # 1, 4 supported
Clearance between Replace Measure at crown
0.066~0.132 0.166
crankshaft and bearing bearings part not parting line
Crank
Replace
shaft End play of crankshaft 0.190~0.322 0.5
thrust bearing
Balance of crankshaft Check dynamic
60 ↓ 60 or less Measure at 400 rpm
(g.cm) balance
Clean out foreign
Torque value journal Coat the bolt
30kg.m + 90o - objects on joining
bearing cap bolt with engine oil
surface.
Main 0.3~1.2 - Measure after
Crush height
tightening metal cap
of Journal
Thrust 0.3~1.2 - and releasing one
bearing cap
bolt
Out diameter of wear ring 5 minutes or more
φ104.86~φ105.00 -
after assembled at 220°C
Replace
Oil seal for wear
- - oil seal
(crank shaft rear)
if oil leaking
Connecting Width of Small end 38.070~39.000 -
rod connecting Big end 32.291~32.33 -
rod Cap 30.5 ~ 30.8 -
Inner diameter
φ46.055~φ46.065 -
of small end
Outer diameter of
φ95.000~φ95.022 -
big end
End play of Big end 0.175 ~ 0.321 0.50
Replace
connecting
Small end 1.5 - Connecting rod
rod
Clearance between
Replace
connecting rod bearing 0.054 ~ 0.116 0.154
bearing
and crank pin
Clearance between
small end bush & 0.055~0.071 0.12
piston pin
Measure after
Crush height of
installing the bearing
connecting rod 0.3 ~ 0.5 -
and releasing one
bearing cap
bolt
Perpendicularity of big
0.05 0.08
end inner diameter
Replace
Roundness of big end
0.005 0.01 connecting
inner diameter
rod
Parallelness of small
0.02 0.1
end side and big end
Allowable weight
50g ↓ -
difference per con-rods

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Stand value Limit

Group Part Inspection item Correction Remark
for assembly for use
Torque value of Clean out foreign
Coat the bolt
connecting rod bearing 10kg.m + 90o - objects on joining
with engine oil
cap bolt (kg.m) surface
Inner
diameter
φ70.07~φ70.09 -
Diameter(bea of thrust
ring) of cam bush
shaft side of Inner
cylinder block diameter
φ70.00~φ70.03 φ70.06
of cam
bush
Cam Diameter of cam shaft
shaft φ69.910~φ69.940 φ69.64
journal
Clearance between
Replace cam
cam shaft and cam 0.060~0.120 0.18
bush
bush
Replace thrust
End play of camshaft 0.10~0.55 0.6
washer
Correct or
Run-out of camshaft 0.05 0.1 replace the
cam shaft
Clearance between idle
gear shaft bush and 0.025~0.066 0.15
Timing idle gear shaft
gear
End play of idle gear Correct or
0.107~0.183 0.3
shaft replace gear
Ring gear assembly Heating
φ432.490~φ432.645 -
part’s outer diameter temperature at
Ring gear ring gear
φ432.000~φ432.155 -
inner diameter assembly
Fly Overlap 0.335~0645 - (200~230oC)
wheel
Allowable shaking
0.5 -
amount after assembly
Outer diameter after
φ119.860~φ120.000 -
assembly wear ring
Valve Valve Outer diameter of
φ7.963~φ7.977 φ7.94
system and intake valve stem
valve Outer diameter of
guide φ7.950~φ7.964 φ7.93
exhaust valve stem
Clearance
between Intake 0.023~0.052 0.1
valve stem When replacing
and valve Replace valve guide & seat,
Exhaust 0.036~0.065 0.15
guide valve work simultaneously
Degree of Intake 30˚ - by special tools
valve seat Exhaust 45˚ -
Diameter of Intake φ42.9~φ43.1 -
valve head Exhaust φ39.9~φ40.1 -
Thickness of Intake 3.0~3.4
2.5 or less
valve head Exhaust 3.3~3.7
Projection
Intake 14.8~15.2 - To upper side of
amount of
Use with valve guide from
valve guide
assembly jig spring seat side of
and valve Exhaust 14.8~15.2 - cylinder head
spring seat

173 Appendix
Printed in Dec. 2005 PS-MMI0608-E1A
 DV11
Operation and Maintenance

Stand value Limit

Group Part Inspection item Correction Remark
for assembly for use
Valve seat
assembly Intake φ43.50~φ43.75
part’s inner -
diameter of Exhaust φ41.50~φ41.75
cylinder head
Diameter of Intake φ43.554~φ43.570
-
valve seat Exhaust φ41.554~φ41.570
Valve seat assembly
part’s depth of 11.9~12.1 -
cylinder head
When replacing
Inner diameter of valve guide & seat,
φ8.000~φ8.015 -
valve guide work simultaneously
by special tools
Valve guide assembly
part’s inner diameter of φ14.000~φ14.018 -
cylinder head
Diameter of valve guide φ14.028~φ14.039 -
Apply oil over
Clearance between
valve guide and
valve guide and cylinder 0.01~0.039 -
press it into
head installing hole
the hole
Concentricity between
Replace Without spring
valve seat and 0.05 -
valve spring seat
valve guide
Free length 62.5 -
Tension 44mm 37.4~41.4 37
Intake force
31.6mm 63.3~68.3 63 Replace
valve (kg)
valve spring
spring Squareness
2.0 or
(along free 1.6mm
less
length direction)
Free length 62.0 -
Tension 41mm 19~22 18.5
force
28.6mm 30.6~34.6 30 Replace
(kg) Inside spring
valve spring
Squareness
2.0 or
(along free 1.6mm
Exhaust length direction) less
valve Free length 62.5 -
spring
Tension 44mm 37.4~41.4 37
force
Replace
(kg) 31.6mm 63.3~68.3 63 Outside spring
valve spring
Squareness
2.0 or
(along free 1.6mm
less
length direction)
Rocker Valve Intake 0.4 -
arm clearance Adjust
& (at cold) Exhaust 0.5 -
push rod Grind or
replace if
Joining surface of valve
severely pitted
stem and rocker arm - -
on tip of
bush
rocker arm
and stem
Inner diameter of
φ24.991~φ25.012 φ25.04
rocker arm bush
Diameter of
φ24.939~φ24.960 φ24.90
rocker arm shaft

174 Appendix
Printed in Dec. 2005 PS-MMI0608-E1A
 DV11
Operation and Maintenance

Stand value Limit

Group Part Inspection item Correction Remark
for assembly for use
Clearance between
Replace bush
rocker arm shaft & 0.031~0.073 0.14
or shaft
rocker arm bush
Replace or
Run-out of push rod 0.3 0.5
correct
Tappet assembly part’s
inner diameter of φ20.000~φ20.021 -
cylinder head
Replace
Diameter of tappet φ19.944~φ19.965 -
tappet
Tappet Clearance between
Replace
tappet & tappet hole of 0.035~0.077 0.13
tappet
cylinder block
Replace
Tappet face in contact
- - if severely worn
with cam
or deformed
Check oil
leakage
Lubricating Oil pressure (kg/cm2)
3.0~5.5 - and clearance
system (at rated speed)
between each
part
Use
Oil pressure (kg/cm2) 0.8 or
1.0~3.0 recommended
(at idle speed) more
oil
Oil temperature (°C) 110 or less -
Engine Must not exceed
Permissible
oil this value
oil temperature Max. 120 -
in short time (°C)
By-pass valve for filter
1.8 ~ 2.4 -
element (kg/cm2 )
Operating
1.6 ~1.9
pressure
Oil spray Closing
1.3 ~1.6 Replace valve
nozzle pressure
Nozzle
φ2
diameter
Delivery volume lit/min Replace
- Pump speed : 2,440rpm 175 or more -
gear or cover
- Oil temperature : 50°C
Gear assembly part’s
depth of oil pump 43.000~43.039 -
housing
Width of oil pump gear 42.910~42.950 -
Clearance of oil pump
0.050~0.128 -
at axial direction
Oil pump pressure
8.5 ~ 10 - Replace valve
control valve (kg/cm2 )
Oil
pump Oil pressure control
2 1.9 ~ 2.1 - Replace valve
valve (kg/cm )
Clearance between
drive gear shaft and 0.032~0.077 -
cover hole Replace bush
Clearance between or cover
drive gear shaft and 0.040~0.094 -
cover hole
Replace
Diameter of gear shaft φ16.950~φ16.968 -
gear shaft
Diameter of Replace
φ28.000~φ28.033 -
driving gear bush bush or cover
175 Appendix
Printed in Dec. 2005 PS-MMI0608-E1A
 DV11
Operation and Maintenance

Stand value Limit

Group Part Inspection item Correction Remark
for assembly for use
Damage of oil filter Clean or
- -
element replace
By-pass valve pressure
Oil filter 1.8 ~ 2.4
(kg/cm2 )
Oil filter control valve
4.3 ~ 4.7
pressure (kg/cm2 )
Radiator & water pump
Correct or
for corrosion, damage & - -
replace
improper connecting
Submerge in
Test for leakage
water and
by air pressure 1.0 -
replace if air
(kg/cm2 )
Radiator bubbles found
Pressure valve for
opening pressure 0.5 -
(kg/cm2 )
Negative pressure valve
for opening pressure 20 -
(mmHg)
Delivery volume lit/min Check
- Pump speed : 3,500rpm
452 or more - the water
- Water temp. : 25°C
- Pressure : 1.8 kg/cm
2 passage
Diameter Pulley side φ25.048~φ25.061 -
of water
Cooling pump Impeller side φ16.045~φ16.056 -
system Water shaft
pump Clearance of bearing 0.050~0.091
Replace if
Clearance between impeller &
0.5 ~ 0.9 -
impeller & housing housing are
damaged
Refer
Fan belt depression - Adjust
to adjust table
Operating
79 ~ 95 -
Cooling temperature (°C) Must not
water Permissible exceed this
temperature temperature - 105 value
in a short time (°C)
Opening
71 - Replace
temperature (°C)
Thermostat Replace if
Full opening defective
85 -
temperature (°C) Stroke : min.
8mm
Fuel Fuel high pressure pump
system maker (CP pump)
Bosch -
Common rail maker
Fuel injector maker
Fuel pipe, injection pipe
& injector for
Fuel - - Replace
damage, cracks,
piping &
improper O-ring
others
Damage of fuel filter Replace
- -
cartridge cartridge
Injection pressure of
2 1,600 -
injector (kg/cm )
Operating pressure of overflow
10.5 ~13 - Replace valve
valve (kg/cm2)
Diameter of injector nozzle 8 - φ0.197

176 Appendix
Printed in Dec. 2005 PS-MMI0608-E1A
 DV11
Operation and Maintenance

Stand value Limit

Group Part Inspection item Correction Remark
for assembly for use
Projection height of nozzle from the Replace
2.4 ~ 2.9 -
cylinder head surface(mm) sealing
Between crank gear
0.10 ~ 0.45 0.3
& oil pump drive gear
Gear Between crank gear
Drive 0.118 ~ 0.242 0.3 Adjust
back & cam shaft gear
system back lash
lash Between drive gear &
fuel pump gear 0.050 ~ 0.178 0.45
(CP pump)

177 Appendix
Printed in Dec. 2005 PS-MMI0608-E1A
 1. Engine assembly

178