D34nap SCR

Forward
This Operation and Maintenance Manual provides information on engine management and maintenance techniques to
customers and technicians of Doosan Infracore's DL03-LEF00/LEF01/LEF02/LEF03/LEF04/
LEL00/LEL01/LEL02/LEL03/LEL04 electronically controlled industrial diesel engine.
To provide the best engine to our customers, the DL03-LEF00/LEF01/LEF02/LEF03/LEF04/
LEL00/LEL01/LEL02/LEL03/LEL04 electronically controlled industrial diesel engine is designed to satisfy all requirements
for low noise, economic fuel consumption, high speed and durability with the latest technology and quality.
Exact operation and proper maintenance are essential for operating engines for an extended time with optimum conditions and best performance. This Operation and Maintenance Manual provides detailed descriptions of specifications,
specified values, defect diagnosis, component diagrams, and drawings for easier and more precise understanding of
the product and for proper maintenance and troubleshooting.
With the help of the recommended operation methods and procedures, high-level maintenance techniques and safety
of workers can be ensured. Please read and understand this manual before working with our engines.
To ensure best performance and quality as well as to enhance maintenance techniques, Doosan Infracore is doing it's
best to continuously develop and invest. The design of our product may be changed without prior notice and Doosan
shall not be held liable for the failure of this manual to contain all the design changes made to improve the product.
We, Doosan Infracore, do our best to provide more convenient and safe maintenance techniques and to meet the
requirements of our customers.
If you have any questions or find any errors in this Operation and Maintenance Manual, please do not hesitate to
contact us.
Thank you for purchasing our engine and we hope this Operation and Maintenance Manual be helpful for you.
2014.06.
950106-014978
Doosan Infracore
* The contents included in the Operation and Maintenance Manual are property of Doosan Infracore. It is forbidden to
copy, print or distribute this manual without prior permission.
Table of contents
1. General introduction ............................................................................................................... 1
General information .................................................................................................................................. 3
Danger, warning, caution, and note ....................................................................................................... 4
Engine maintenance ................................................................................................................................. 7
2. Operation and maintenance ................................................................................................... 9

Starting and stopping of the engine .................................................................................................... 11
Break-in period of the engine ............................................................................................................... 12
Operation in winter ................................................................................................................................ 14
Inspection and repair of the engine ..................................................................................................... 15
3. Performance and specifications ..........................................................................................17

Engine specifications and performance ................................................................................................ 19
Outside drawing of the engine (DL03-LEF00/LEF01) ......................................................................... 30
Outside drawing of the engine (DL03-LEF02/LEF03) ......................................................................... 34
Outside drawing of the engine (DL03-LEL00/LEL01/LEL02/LEL03/LEL04) ....................................... 38
Engine identification number ................................................................................................................. 42
4. Regular inspection ................................................................................................................45

General information ................................................................................................................................ 47
Regular inspection table ........................................................................................................................ 48
Cooling system ....................................................................................................................................... 50
Lubrication system ................................................................................................................................. 56
Fuel system ............................................................................................................................................ 64
Intake/exhaust system ............................................................................................................................ 69
Cylinder block/head ................................................................................................................................ 71
Others/driving system ............................................................................................................................. 72
5. About the engine ...................................................................................................................73

Marking system of units ........................................................................................................................ 75
Tightening torque ................................................................................................................................... 76
Special tool ............................................................................................................................................. 80
Engine disassembly ............................................................................................................................... 82
Engine assembly .................................................................................................................................. 102
6. Cooling system .................................................................................................................... 127
General information .............................................................................................................................. 129

Water pump .......................................................................................................................................... 133
Thermostat ............................................................................................................................................ 136
Cooling fan ........................................................................................................................................... 138
7. Lubrication system ..............................................................................................................141

Oil pump ............................................................................................................................................... 145
Oil filter assembly ................................................................................................................................ 152
Oil pan .................................................................................................................................................. 157
8. Fuel system ..........................................................................................................................161

Fuel return hose .................................................................................................................................. 164
Injector .................................................................................................................................................. 169
Common rail ......................................................................................................................................... 179
Fuel injection pump ............................................................................................................................. 189
9. Intake/exhaust system ........................................................................................................199

Turbocharger ......................................................................................................................................... 202
Exhaust gas reduction ......................................................................................................................... 211
EGR (Exhaust Gas Recirculation) system ......................................................................................... 223
Intake manifold ..................................................................................................................................... 228
Exhaust manifold .................................................................................................................................. 235
Intake pipe ............................................................................................................................................ 240
10. Cylinder block/head .............................................................................................................247

Cylinder block ....................................................................................................................................... 250
Cylinder head ....................................................................................................................................... 252
Valve ..................................................................................................................................................... 253
Rocker arm ........................................................................................................................................... 256
Tappet and push rod ........................................................................................................................... 266
Camshaft ............................................................................................................................................... 276
Flywheel housing .................................................................................................................................. 278
Breather ................................................................................................................................................ 281
Cylinder head cover ............................................................................................................................. 282
Idle gear ............................................................................................................................................... 290
Lifting hook ........................................................................................................................................... 295

Oil seal ................................................................................................................................................. 297
11. Electric system ....................................................................................................................301

Circuit diagram ..................................................................................................................................... 303
Switches and sensors .......................................................................................................................... 311
Wire harness ........................................................................................................................................ 317
ECU (Electronic Control Unit) ............................................................................................................. 318
Starter ................................................................................................................................................... 322
12. Others/driving system .........................................................................................................329

Crankshaft ............................................................................................................................................. 332
Piston .................................................................................................................................................... 337
Connecting rod ..................................................................................................................................... 339
Flywheel ................................................................................................................................................ 341
Crankshaft pulley .................................................................................................................................. 343
Others ................................................................................................................................................... 345
1. General introduction
Danger, warning, caution, and note ..................................................................................3
General Information .................................................................................................................................... 3
Danger, warning, caution, and note ..................................................................................4

General Information .................................................................................................................................... 4
General Instructions .................................................................................................................................... 4
Cautions for Starting the Engine............................................................................................................... 4
Cautions for Inspection and Repair .......................................................................................................... 4
General Repair............................................................................................................................................ 5
Other Safety Instructions and Environmental Pollution............................................................................ 6
Use of Genuine Parts ................................................................................................................................ 6
Engine maintenance ...........................................................................................................7

Prevention of damage and abrasion ......................................................................................................... 7
Prevention of Pollution ............................................................................................................................... 7
Handling of Engine Oil............................................................................................................................... 7
General information
General Information
This Operation and Maintenance Manual provides the
most efficient methods for engine maintenance as well as
quick, efficient methods to determine the cause of engine
faults to ensure that any actions taken by professionally
certified maintenance technicians are done in the most
efficient and efficient way possible. If maintenance is
performed by unskilled technicians, or maintenance
without the specified tools and facilities, serious bodily
injury or critical faults in engine performance may occur.
Regular inspection and maintenance are required to maintain long-term optimal engine conditions and best performance. In the event that a part must be replaced, only
genuine parts as defined by the parts the list (PARTS
BOOK) should be used. Doosan shall not be held liable
for any critical damage or faults which may be caused
by the use of unauthorized or remanufactured parts.
The maintenance methods stated in this Operation and
Maintenance Manual are the most efficient and safest
work procedures. Some work procedures require special
tools.
For questions about genuine parts and special tools,
please contact us.
This Operation and Maintenance Manual includes
'Danger,' 'Warning,' and 'Caution' in order to reduce
possible injuries and engine faults which may occur while
performing maintenance. If workers do not follow the
instructions, critical faults in engine performance and
operation or serious bodily injury may occurred. 'Danger,'
'Warning,' and 'Caution' instructions must be followed.
However, we inform you that it is not possible to describe
all possible and unexpected dangers which may arise
while performing engine maintenance.
Danger, warning, caution, and note
General Information
2. We have divided the content of this manual into
This Operation & Maintenance manual divides mainte-
causes of bodily injury and damage to assets and
nance operations such as performing engine checks, trou-
causes of pollution.
bleshooting, or diagnosing faults into three categories,
WARNING
"Danger," "Warning," and "Caution." In addition, Note) is

used to provide additional descriptions and information
When a safety accident, such as skin contact with
required for maintenance technicians to successfully
corrosive acids or fuel, burns with hot oil, exposure
operate our engines. The recommended repair methods
of eyes to fuel or antifreeze, occurs while starting,
and 'Danger,' 'Warning,' and 'Caution' can enhance the
inspecting, or repairing an engine, see a doctor
degree of completion of engine maintenance and prevent
immediately.
bodily injury which may occur to workers. However, this

manual cannot predict all possible risks.
Cautions for Starting the Engine
DANGER
1. Before starting the engine, please read this manual

carefully and fully understand 'Danger,' 'Warning,' and
Workers must observe instructions, otherwise fatal
'Caution'. If you cannot fully understand it or have any
or serious injuries to workers and other persons
question, please contact us.
may occur.
2. For safety reasons, attach "Warning" signs around

engines in operation to keep people other than
workers from accessing the engines. Let engine oper-
WARNING
ators know that they are responsible for the safety of
Workers must follow this instruction as failing to do
the engine room.
so may result in the death or serious bodily harm
3. Only authorized people may start and operate
of workers or others.
engines. Unauthorized people should not be allowed

to handle engines.
4. Do not access running or rotating parts while the
CAUTION
engine is in operation.
Workers must observe this instruction since failing
5. Be careful not to touch or contact the engine during
to do so may cause critical faults which can have
operation since it becomes hot during operation.

6. Exhaust gas is poisonous. Fully ventilate before
impact on the engine performance and operation.
starting engine. If the space is airtight, ensure that it

is well ventilated.
Note) Indicates additional description, information, and

references for workers' easy understanding.
Cautions for Inspection and Repair

1. Inspection and repair of engine should be performed
General Instructions
only when the engine is stopped. Otherwise, burns or
1. In order to maintain the best long term performance
safety accidents may occur, so do not perform inspec-
and safety, please read and understand this manual
tion or repair while the engine is running.
and execute routine inspections and regular inspec-
2. If it is absolutely necessary to perform inspection or
tions.
repair on the operating engine, do not get close to

the rotating parts.
DANGER
When accessories such as necklaces, rings,
watches, or gloves become stuck in rotating parts
while the engine is running, serious bodily injury
may occur.
11. Before inspecting or replacing the electrical apparatus,
WARNING
disconnect the battery ground wire first. Connect the

battery ground wire after completing all required work
Do not exchange or disassemble a pipe or horse
for checking or replacing the electrical apparatus in
(from the engine fuel circuit, engine oil circuit,
order to prevent a short circuit.
coolant circuit, or compressed air circuit) while the
12. Before performing electric welding works, turn off
engine is running. The leaked liquid may cause
engine, block the power supply to the engine, and
bodily injuries.
remove the wire harness connector connected to the

engine control unit (ECU).
3. Use an engine oil drain container that is large enough
13. Do not give any electric or mechanical shocks or
to prevent the overflow of engine oil while draining
perform welding works on the electrical apparatus or
engine oil.
the ECU.
4. Open the engine coolant cap after fully cooling the

engine to exchange or replenish coolant.
General Repair
WARNING
1. Wait until the engine is properly cooled down before

starting work, since you may get burned by the heated
If the coolant cap is opened while the engine is still
engine.
hot, hot water will spurt out and may cause burns.
Before performing fuel line work, check the common
Open the engine coolant cap after fully cooling the
rail pressure and engine temperature by using the
engine.
failure diagnosis device.

2. Disconnect the battery ground wire from to prevent
5. Fuel is highly flammable. Smoking or use of fire
damage of wires and sensors caused by a short
around an engine may cause fire.
circuit.
3. Engine oil and coolant may damage paint and should
WARNING
be stored in a separate container and marked for safe

management.
Only refuel when the engine is stopped.
4. Store the disassembled parts in a specified space to

avoid damage or pollution.
6. Mark and separately manage the containers for storing
5. Use specified and special tools for efficient and safe
coolant from beverage containers for avoiding confu-
repair.
sion. See a doctor immediately in case of drinking
6. If parts need to be replaced, use only genuine parts
coolant.
for replacement. Using unauthorized or remanufac-
7. Follow the instructions provided by the battery manu-
tured parts may cause critical damage and faults in
facturer when checking or handling batteries.
engine performance.
7. Replace parts such as cotter pins, gaskets, O-rings,
WARNING
seal rings, oil seals, and washers with new ones

during repairs. Reuse of parts may be the cause of
Battery fluid is corrosive and dangerous because of
engine faults and engine may not operate properly.
its explosiveness and toxicity. Therefore, it should
8. Group and store disassembled parts in disassembling
only be handled by a skilled technician who special-
order. The strength, shape, and screw torque of bolts
izes in battery fluid.
and nuts are different according to their assembly

position. Please divide and store them accordingly to
8. Only certified professional technicians should repair
these characteristics.
and maintain engines.
9. Clean disassembled parts to remove foreign
9. Only appropriate tools should be used. If the jaws of
substances before inspecting or reassembling parts.
a wrench are worn out, the wrench might slip during
Use compressed air to clean the oil holes or holes.
use, causing safety accidents.
10. Thinly spread oil or grease on rotating parts or parts
10. Do not allow other persons to stay or pass under an
requiring lubrication, before assembling them.
engine when lifting the engine with a crane. Before
11. If required, use a specified adhesive to assemble
lifting the engine, ensure that there is no one around
gaskets to prevent water or oil from leaking.
the engine and reserve enough safety space.
12. Assemble bolts and nuts with the specified tightening
Use of genuine parts is recommended. Using unautho-
torque.
rized or remanufactured parts may cause critical damage
13. After completing repairs, conduct a final inspection
and faults to engine for which Doosan shall not be held
and perform a test operation to check if all works
liable.
have been successfully completed.
Other Safety Instructions and Environmental

Pollution
Observe the following instructions to protect workers from
danger and to prevent the environmental pollution while
performing engine repairs.
1. Good ventilation and low humidity should be maintained in the work space.
2. The workspace should be clean, in good order, and
no flammables are allowed in the workshop.
3. Smoking is strictly forbidden in the workshop.
4. Workers should wear working clothes, protective
goggles, and safety shoes.
5. Workers are not allowed to wear accessories such as
necklaces, rings, watches, and earrings.
6. Start the engine in a well-ventilated space and fully
ventilate the space before starting engine to prevent
carbon monoxide poisoning.
7. Wait until the engine is properly cooled down before
starting work, since you may get burned by the heated
engine.
8. Do NOT work on rotating or running parts once the
engine has been started.
9. Discard oil according to the regulations set forth by
the relevant authorities.
10. If engine oil or fuel leaks on the floor or is improperly
discharged, serious environmental pollution of sea,
river or underground water may occur.
11. Discard the undiluted anticorrosive agent, antifreeze,
filter elements, and cartridges as special wastes.
12. Discard coolant and special waste according to the
regulations of the appropriate authorities.
WARNING
Failure to observe the regulations of the relevant
authorities violates environmental pollution regulations and may be subject to legal penalties.
Use of Genuine Parts

An engine consists of many parts which are mechanically
harmonized. To prevent engine faults in advance and use
engines with best performance for a long period, maintenance and replacement of expendable parts should be
conducted regularly.
Engine maintenance
Prevention of damage and abrasion
8. If there are gauges for battery, oil pressure and
Using an engine for any purposes other than the
coolant and temperature, check if they indicate a
designed purpose may cause critical faults in engine
normal status.
9. Do not operate engine without coolant.
performance for which Doosan shall not be held liable.

For details concerning the usage and purpose of the
CAUTION
engine, please direct questions to our Sales Team. Do

not adjust, convert, or change the ECU without our autho-
Always use coolant mixed with antifreeze. If coolant
rization.
without antifreeze is used, the coolant may freeze
If a problem is found in an engine, figure out and solve
causing the coolant passage in the cylinder block to
the cause to prevent the critical faults in advance.
freeze and damaging the engine.
Use of genuine parts is recommended. Using unauthorized or remanufactured parts may cause critical damage
and faults to engine for which Doosan shall not be held
Prevention of Pollution
liable.
Consider the following to manage engine without causing
Consider the following while managing engines.
environmental pollution.
1. Use clean, specified, and qualified fuel only. Use fuel
1. Discharge oil and coolant using collection containers.
recommended in this Operation and Maintenance
2. Discard oil and coolant according to the regulations of
Manual.
the relevant authorities.

3. Be careful not to let discharged oil and cooling water
CAUTION
flow into the ground or the sewer. Otherwise, serious

pollution of the drinking water source may occur.
Using inappropriate or unspecified fuel may cause
4. Classify the oil, filters, and filter cartridges as environ-
critical damage and faults in engine performance.
mental pollution wastes and discards them according

to regulations.
2. Do not operate an engine without lubrication oil or
5. Classify the antifreeze, cooling water, and anticorro-
coolant. Use only the products (engine oil, cooling
sive agent as hazardous wastes and discards them
water, anticorrosive agent, and etc) recommended by
according to the regulations.
Doosan.
3. Always keep surroundings of the engine clean.
Handling of Engine Oil
4. Use fuel recommended in this Operation & Mainte-
Prolonged and repeated contact of skin with engine oil
nance manual.
may cause skin to dry out and contract, causing derma-
5. Conduct inspections and exchanges regularly
titis. Engine oil includes substances toxic to the human
according to the regular inspection table.
body. Handle engine oil by observing the following safety
6. If the engine is overheated, do not stop it immediately,
rules:
but operate it at idle status for five minutes or more
1. Do not expose skin to new engine oil for a long time.
to lower the engine temperature to the proper level.
2. Always wear working clothes and gloves.

3. If skin comes in contact with engine oil, immediately
WARNING
wipe it off with water, soap or hand cleaners.

4. Do not clean skin with gasoline, fuel, thinner, or
If the radiator cap is opened while the engine is still
solvent.
hot, hot water will spurt out and may cause burns.
5. Apply a skin protective cream after cleaning from oil.

7. Check the engine oil level on a flat surface. Do not
exceed the maximum on the oil level gauge.
CAUTION
Immediately replenish engine oil when the engine oil
level is below the lower limit of the engine oil gauge.
6. Do not put oil-stained gloves or cloth in ones pocket.
WARNING
Discard oil according to the regulations set forth by
the relevant authorities. Disposing of discharged oil
into the ground, sewers, drains, rivers, or the sea
will cause serious environmental pollution. Violation
of regulations regarding discard of engine oil without
observing the handling regulations, will be punished.
2. Operation and maintenance

Starting and stopping of the engine ...............................................................................11
Preparing for Start .................................................................................................................................... 11
Starting the Engine................................................................................................................................... 11
After Starting the Engine ......................................................................................................................... 11
During Operation....................................................................................................................................... 11
Stopping the Engine ................................................................................................................................. 11
Break-in period of the engine ..........................................................................................12

General Information .................................................................................................................................. 12
Break-in Period of a New Engine........................................................................................................... 12
Check Points ............................................................................................................................................. 12
Operation after Break-in ........................................................................................................................... 12
Inspection after Starting the Engine........................................................................................................ 12
Engine Oil Pressure ................................................................................................................................. 13
Coolant Temperature ................................................................................................................................ 13
Revolutions per Minute (rpm) .................................................................................................................. 13
Operation in winter ...........................................................................................................14

Cold Start .................................................................................................................................................. 14
Preventing Coolant from Freezing........................................................................................................... 14
Preventing Overcooling of the Engine .................................................................................................... 14
Engine Oil ................................................................................................................................................ 14
Inspection and repair of the engine ................................................................................15

Checking Engine Parts after Prolonged Operation ................................................................................ 15
Inspection and Repair of Supercharger .................................................................................................. 15
Intake Unit ................................................................................................................................................. 15
Exhaust Unit.............................................................................................................................................. 15
Lubrication system .................................................................................................................................... 15
10

Starting and stopping of the engine
Preparing for Start
After Starting the Engine
Check the following before starting the engine for the first
1. Do not rapidly raise the rpm while the engine and
time after purchase.
turbocharger do not rotate smoothly after starting the
1. Before starting an engine, check the levels of fuel,
engine. Otherwise, it may increase the load upon the
coolant, and oil and replenish those fluids if required.
engine and burning may occur at the positions that
2. Check if engine oil level is between the upper and
have not been sufficiently lubricated yet. To prevent
lower limit of the oil level gauge. The upper and lower
this, rotate the engine at idle after starting it to lubri-
limit of the oil level gauge indicate the maximum and
cate the turbocharger with oil.
minimum of the engine oil level.
2. Oil, air, or gas leaks may lower the oil pressure. Additionally, oil leaks may cause burning of bearings. As
CAUTION
such, if oil, air, or gas leaks occur, check the leaking

parts and solve the problem.
When replenishing engine oil, do not exceed the

maximum on the oil level gauge. Too much oil may
During Operation
cause damage to the engine.
1. Insufficient oil pressure may cause abnormal wear and

burning of bearings and excessive oil pressure may
3. Be careful not to mix foreign substances in fuel,
cause leaks.
engine oil, or coolant while adding the fluid, and keep
2. Continuing to operate the engine after noises or vibra-
the fluid clean while it is not in use. Use fuel, oil, and
tions coming from the engine may lead to serious
coolant recommended by Doosan. Otherwise, critical
engine damage. As such, if noises or vibrations come
damage to the engine may occur.
from the engine, slowly decrease the rpm to a stop

the engine and examine the cause.
Starting the Engine

Observe the following when starting the engine.
Stopping the Engine
1. For a cold start, start the engine after preheating it
Do not suddenly stop the engine after it was operated
sufficiently through the glow plug.
under high loads for a long period. If oil burns because
2. Starting the engine too quickly leads to engine rotation
of heat sent from the high-temperature turbine blade to
without lubricating the supercharger and other engine
the bearing part, the bearing metal and rotating shaft may
parts, causing abnormal wear to or burning of bear-
burn. As such, if the engine was operated under high
ings. Therefore, start the engine with the starter motor
loads for a long period, sufficiently rotate the engine at
to check raising of oil pressure (until the gradation of
idle before stopping it.
the oil pressure gauge mounted on the apparatus

moves or the pressure indicator lamp is turned on).
3. If the engine was not used or kept cold for a long
period of time, oil circulation will be poor. If you
replace oil, oil filter cartridge, or lubrication system
parts or use an engine in cold areas, or the engine
has been stopped for a long period, loosen the oil
pipe joint at inlet of the supercharger and run the
starter motor until oil flows out. After completing the
work, tighten the oil pipe joint again and start the
engine.
11

Break-in period of the engine
General Information
2. If the oil indicator lamp on the apparatus is turned on
Doosan engines are subjected to a final approval test to
or blinks, the oil pressure may be insufficient. In this
ensure the provision of high quality engines before being
case, check the oil level and replenish the oil if
shipped to ensure the best quality possible. However,
required. When replenishing engine oil, do not exceed
engines are not operated for a long period of time in this
the maximum on the oil level gauge. If the oil level
test. Therefore, new engines require a break-in period of
is normal, check other related parts such as the oil
during the initial 50 hours after delivery. By properly
pressure sensor, oil pump, or oil line.
breaking-in an engine, the highest levels of engine perfor-
CAUTION
mance can be maintained long-term.
The oil pressure may increase with high rpm and
Break-in Period of a New Engine
decrease with low rpm. In addition, the pressure of
If the engine's bearings are not properly broken in, they
cold oil may be higher at a specific rpm than of
may be easily damaged and the lifetime of the engine
warm oil. This phenomenon may occur when the
may be shortened by overloading or high-speeds. In order
engine is operating successfully.
to prevent this, please follow the guidelines below for the

initial 50 hours after delivery of new engine.
3. Check the coolant gauge on the apparatus and if the
1. Fully warm up the engine until the engine temperature
coolant circulates properly. If the coolant level in the
reaches normal operation condition, before starting
supplementary tank is too low, the coolant gauge may
operation of the engine.
be inaccurate. (may be disturbed).
2. Do not overload the engine or operate it at excessive
4. Exchange engine oil and oil filter after the break-in
RPM.
period.
3. Do not operate the engine with high speed at idle.

4. Do not rapidly start up or stop the engine.
CAUTION
5. Operate the engine with less than 70 % of the engine
If engine oil and oil filter need to be replaced, use
load.
only the genuine engine oil and parts recommended
6. Inspection, check, and repair of engines should be
by Doosan.
managed by officially-certified technicians at certified

service centers in compliance with corresponding
rules.
Operation after Break-in

Slowly preheat the engine when starting up during cold
Check Points
weather or in areas with cold climate. Do not rapidly raise
check the following during the break-in period of a new
the rpm while the engine has not been properly
engine.
preheated yet. The engine consumes additional oil until
1. Periodically check if the engine oil level is between
its piston ring is positioned properly and operates
the minimum and maximum limit of the oil level
successfully. Please check the engine oil level frequently
gauge.
during the initial 50 hour break-in period.
CAUTION
Inspection after Starting the Engine
If you cannot accurately check the oil level through
Check the pressure of the engine lubrication system by
the oil level gauge, rotate the oil level gauge to 180
using the engine oil pressure gauge mounted on the
degree, put it in the guide tube, and then pull it out
apparatus while the engine is in operation. If the oil pres-
again to check.
sure is low on oil pressure gauge, immediately stop the

engine. In addition, make sure that the recharge alarm
indicator lamp of the alternator is turned off while the
engine is operating.
12

1. Tightly connect the +/- terminals to prevent gaps
between them. The sheath of battery connection
cables should not be damaged or broken.
2. If the recharge alarm indicator lamp suddenly turns on
or blinks during engine operation and the engine
stops, fix the fault of the electric apparatus.
3. If color or odor of exhaust gas is unusual during operation, stop the engine, diagnose the cause and fix the
fault.
4. Check the engine status through the alarm indicator
lamp and gauges mounted on the apparatus during
operation.
Engine Oil Pressure

If the engine oil pressure is not consistent at idle or does
not reach the reference value while the engine is operating in high speed mode, immediately stop the engine
and check the oil level and leakage.
Coolant Temperature
Operating an engine with insufficient coolant temperature
increases fuel consumption, abrasion of the cylinder liner,
shortening the engine's life span.
Revolutions per Minute (rpm)

In the electronic control engine, the engine control unit
(ECU) prevents the engine from being operated at too
high rpm over the specifications to protect the engine.
The memory of ECU has various functions which cannot
be changed by operators, such as fuel flow control, ignition time delay, and blocking of fuel and ignition.
13

Operation in winter
Cold Start
Preventing Coolant from Freezing.
Periodically check for frozen coolant and viscosity of lubri-
When only water used as coolant without mixing with
cation oil.
antifreeze, corrosion in the engine, degradation of cooling

efficiency, and freezing of the engine in winter may occur.
CAUTION
If the engine is not operated for a long period during cold

weather or in areas with cold climate, fully discharge the
A preheater should be mounted on the engine to
coolant from the engine. Freezing of coolant leads to crit-
improve the cold start performance.
ical damage to the engine. Please use a mixture of
Start the engine after turning off the preheating
coolant with antifreeze at revised ratio when replacing or
lamp.
replenishing the coolant. The antifreeze prevents coolant
Do not operate the starter motor for over 10
from freezing.
seconds. If the engine does not start even though

it is fully preheated, wait for about 30 seconds,
Preventing Overcooling of the Engine
preheat the engine again, and then start the
When the engine is cooled below the normal operating
engine.
temperature, thermal efficiency is lowered and fuel

consumption as well as abrasion of the cylinder liner may
Perform the cold start in the following order.
increase. Therefore, the engine should be operated within
1. Turn the key switch to 'Preheat' and then the preheat
the normal operating temperature. If the engine has been
lamp will operate for about 20 seconds.
sufficiently operated, but the temperature of coolant
Note) Operate the preheater if coolant is below 10 C
remains below the normal operating temperature, check
during cold weather. If preheating is not necessary,
the water temperature controller or other parts related to
the preheat lamp will not switch on.
the cooler.
2. When the preheat lamp switches off, turn the key

switch to 'Start' to start the engine.
Engine Oil
Note) If the key is turned to 'Start', the air heater is
When the viscosity of engine oil increases due to its low
continuously heated to provide an easy start and
temperature during cold weather or in areas with cold
reduce white exhaust gas. If the coolant tempera-
climate, the rpm may not be stable after starting the
ture is above 10 C, it is not necessary to heat the
engine. To prevent this, replace the oil with engine oil for
air heater.
cold weather or areas with cold climate. When replacing
3. After starting the engine, the key switch changes to
engine oil, Use only engine oil recommended by Doosan.
ON.
CAUTION
As the ECU heats the intake air for about 180
seconds after starting the engine, the white exhaust
gas is reduced quickly.
14

Inspection and repair of the engine
Checking Engine Parts after Prolonged
Operation
Intake Unit
Wear, corrosion, or degradation of engine elements and
If oil level of the wet air filter is below the specified level,
assemblies may occur, causing lowered performance of
filtering performance is degraded. On the other hand, if
engine parts. To maintain high engine performance, check
the oil level is higher, oil may flow into the case, and it
the engine after prolonged operation to enhance the dura-
may become polluted. In regards to the dry air filter,
bility of the engine.
intake resistance should be small to ensure the smooth
Unexpected faults may occur in some weak engine parts
intake of air.
Be careful when handling the air filter in the intake unit.
after normal operation of the engine, when operation time

is prolonged. In this case, it is difficult to maintain high
Exhaust Unit
engine performance by simply repairing some parts. We
If exhaust emission is leaked from the part connecting
recommend the entire part be replaced or repaired in
the exhaust tube and the turbocharger, the supercharger
order to find out the causes more accurately and maintain
efficiency is lowered, causing degraded engine output
high engine performance.
and, if serious, burning of related parts. As parts related
To prevent engine failure in advance and use the engine
to exhaust and turbocharger are used at high tempera-
safely for a long period, perform periodic replacements
ture, be careful not to mix the bolts and nuts with other
and inspections.
parts when performing repair.
It is recommended to perform engine adjustments and

preventive inspections during spring after the engine was
Lubrication system
exposed to winter or cold weather. This allows economic,

long-term use of the engine without faults.
Inspection and replacement of the lubrication system
As the following parts affect the engine output and perfor-
should be performed according to the replacement
mance, these parts should be regularly checked and
schedule of oil and oil filter. Overheated engine oil can
inspected.
affect not only the engine itself, but also the engine
1. Parts affecting intake and exhaust
performance.
Air filter
Intercooler
Supercharger, silencer
EGR cooler and Calve
Other parts
2. Parts affecting lubrication and cooling
Air filter
Oil filter
Antifreeze
Other parts
Inspection and Repair of Supercharger

As performance of supercharger significantly affects the
engine performance, regular inspections and repairs
should be performed and inspection and maintenance
regulations should be observed.
15
16
3. Performance and specifications

Engine specifications and performance ...........................................................................19
Engine Specifications................................................................................................................................ 19
Engine output ............................................................................................................................................ 29
Outside drawing of the engine (DL03-LEF00/LEF01) ....................................................30

Isometric assembly drawings ................................................................................................................... 30
Assembly drawings (Front/Rear) .............................................................................................................. 31
Assembly drawings (Left/Right)................................................................................................................ 32
Assembly drawings (Top/Bottom) ............................................................................................................ 33
Outside drawing of the engine (DL03-LEF02/LEF03) ....................................................34

Outside drawing of the engine (DL03-LEL00/LEL01/LEL02/LEL03/LEL04) ..................38

Engine identification number ............................................................................................42

Engine number engraving ........................................................................................................................ 42
Cylinder block number engraving ............................................................................................................ 42
Engraving of piston bore level of cylinder block ................................................................................... 43
Engraving of main bearing bore level of cylinder block ....................................................................... 43
Crankshaft main journal engraving .......................................................................................................... 43
Connecting rod engraving ........................................................................................................................ 43
Piston engraving ....................................................................................................................................... 44
Cylinder head gasket engraving .............................................................................................................. 44
17
18

Engine specifications and performance
Engine Specifications
Specifications
Item
DL03LEF00
DL03LEF01
DL03LEF02
DL03LEF03
Remarks
General Information
4-stroke series, water-cooled,
turbocharging and air cooling type
Engine types
Combustion chamber type
Direct injection
Cylinder liner type
No liner
Timing gear unit
Gear drive type
Number of piston rings
Two compression rings and one oil ring
Number of cylinders
Cylinder bore
98 mm
Cylinder stroke
113 mm
Total displacement
3,409 cc
Compression ratio
17.0:1
Engine Dimension (L x W x H)
817 mm X 635.5 mm X 777 mm
Engine weight
300 Kg
Direction of rotation
Counter-clockwise
Firing order
1 - 3 - 4 - 2
Cooling system
Cooling Type
Water-forced cooling
Capacity of coolant
4.7 L
Type
Water pump
Centrifugal (impeller type)
Driving Type
Ribbed-Belt driven
Pump Speed
2,760 rpm
Drive Ratio
(Engine speed:Pump
speed)
1 : 1.2
Flow Rate
160 LPM or more
Pump back pressure
0.8 bar
Type
Cooling fan
Driving Type
Blow Type
Fan Bracket direct connection
Rotation Ratio
(Engine RPM: fan RPM)
1:1
19
View from flywheel

Specifications
Item
DL03LEF00
Type
Thermostat
Coolant Temperature
Sensor
Water Temperature
Sensor
Radiator Cap
DL03LEF01
DL03LEF02
DL03LEF03
Wax pellet type
Valve-opening temperature
82 C
Full valve-opening temperature
97 C
Lift
8 mm
Type
Thermo temperature sensor
Resistance (at 20 C)
2.5k
0.148k
Pressure for opening high

pressure valve
0.9 kg/cm2
Lubrication System
Lubricating type
Oil Pressure
Forced lubrication system

Idle (Idling revolution
count)
1.0 kg/cm2
Max. Load (rated RPM)

Oil Specifications
Oil Capacity
4.5 ~ 6.0 bar
Oil Class
API CJ-4 (ACEA-E9)
Total
13.6L (Including 1.0L in the engine)
Max.
12.6 L
Min.
6.0 L
Allowable tilt angle (oil pan) (front/rear/left/right)
35 / 35 / 35 / 35
Type
Gear type
Oil pump
Driving Type
Oil coolant type
CRANK GEAR driven

Water-cooled stack plate type
Type
Oil filter
Spin on Type Filter
Allowable temperature
-40C ~ 140C
Flow
36 L/min
Lubrication indicator
Oil pressure type
Opening pressure of the oil spray nozzle adjustment

valve
1.0 ~ 1.4 kg/cm 2
Hydraulic indicator
Oil Pressure Sensor
Fuel System
Fuel injection pump type
DELPHI DFP 4.4
Control type
E.C.U (DELPHI)
20
Remarks

Specifications
Item
DL03LEF00
Delivery pump type
DL03LEF02
DL03LEF03
Remarks
Gear type (with in DFP 4.4)

Type
Injection nozzle
DL03LEF01
Multi hole type
Opening pressure (Operating pressure)
1,800 bar
Fuel filter type
Spin-on type
Intake/Exhaust System
Model
BorgWarner WGT
Driving Type
EXHAUST PRESSURE FEED TYPE
Lubricating type
FORCED PRESSURE FEED TYPE
Compressor outlet air pressure

Turbocharger
2.22 kgfcm 2
At max. output
Air intake
133.6 g/s
At max. output
Turbine Speed
161 krpm
At max. output
Allowable max. RPM
194 krpm
From the turbine

inlet
Allowable max. exhaust

temperature
750 C
Weight
4.3 kg
Intake valve
0.4 mm
When cold
Exhaust valve
0.45 mm
When cold
Open (BTDC)
16
Closed (ABDC)
54
Open (BBDC)
38
Closed (ATDC)
24
Valve gap
Intake valve
Exhaust valve
Intake
108.3 mm
Exhaust
110.3 mm
Valve length
Intake
6.97 0.007 mm
Exhaust
6.96 0.007 mm
Stem outside diameter
Intake
7 ~ 7.015 mm
Exhaust
7 ~ 7.015 mm
Valve guide bore

Intake
43.4 ~ 43.6 mm
Exhaust
43.4 ~ 43.6 mm
Valve guide length
Valve sheet contact

width
Intake
2.14 mm
Exhaust
1.63 mm
21

Specifications
Item
DL03LEF00
DL03LEF01
DL03LEF02
Intake
44.5 ~ 45.0
Exhaust
44.5 ~ 45.0
DL03LEF03
Remarks
Valve sheet angle
Free length of valve spring
55.23 mm
2 and under (less than 1.8 mm)
Valve spring squareness

Cylinder block/head
Gasket Surface
0.05 mm
0.03 mm / 100 mm
Manifold mounting surface
0.05 mm / 100 mm
Cylinder head flatness
Intake
39.078 mm
Exhaust
38.716 mm
Camshaft height
Camshaft journal outside diameter
Intake
44.95 ~ 44.966 mm
Exhaust
44.95 ~ 44.966 mm
Camshaft bearing oil gap
0.065 ~ 0.106 mm
Camshaft end play
0.1 ~ 0.2 mm
Inside diameter of cylinder block piston bore
97.99 ~ 98.01 mm
Flatness of cylinder block gasket surface
0.05 mm
0.03 mm / 100 mm
Electric apparatus
Engine control type
Electronic Control Unit (ECU)
Engine stop unit
Fuel delivery shutdown by ECU

Output
24 V, 5.0 kW
Pinion gear
11
12 V, 2.7 kW
11
Terminal voltage
23 V
11 V
No-load characteristics
Max. current
100 A
200 A
3,000 rpm
2,550 rpm
Starter
Min. speed
Others/Driving System
Grade A: 97.920 ~ 97.930 mm

Grade B: 97.930 ~ 97.940 mm
Piston outside diameter

Gap between cylinder and piston
0.060 ~ 0.080 mm
Top ring groove
2.415 ~ 2.445 mm
Piston ring groove area 2nd ring groove
2.060 ~ 2.080 mm
Oil ring groove
3.020 ~ 3.040 mm
22

Specifications
Item
Piston ring side gap
Piston ring end gap
DL03LEF00
DL03LEF01
DL03LEF02
Top ring side gap
0.083 ~ 0.137 mm
2dn ring side gap
0.070 ~ 0.110 mm
Oil ring side gap
0.030 ~ 0.070 mm
Top ring end gap
0.20 ~ 0.40 mm
2nd ring end gap
0.55 ~ 0.70 mm
Oil ring end gap
0.2 ~ 0.4 mm
Piston pin outside diameter
35.995 ~ 36,000 mm
Piston pin hole bore
36.008 ~ 36.014 mm
Piston pin hole gap
0.008 ~ 0.019 mm
Connecting rod small-end bore
36.025 ~ 36.038 mm
Connecting rod small-end hole gap
0.025 ~ 0.043 mm
Connecting rod large-end bore
66,000 ~ 66.015 mm
Connecting rod bearing oil gap
0.026 ~ 0.064 mm
Connecting rod end play
0.15 ~ 0.3 mm
Crankshaft main journal outside diameter
74.955 ~ 74.970 mm
Crankshaft pin journal outside diameter
62.955 ~ 62.970 mm
Crankshaft main bearing oil gap
0.029 ~ 0.059 mm
Crankshaft end play
0.1 ~ 0.31 mm
23
DL03LEF03
Remarks
Specifications
Item
DL03LEL00
DL03LEL01
DL03LEL02
DL03LEL03
DL03LEL04
Remarks
General Information
4-stroke series, water-cooled,
turbocharging and air cooling type
Engine types
Combustion chamber type
Direct injection
Cylinder liner type
No liner
Timing gear unit
Gear drive type
Number of piston rings
Two compression rings and one oil ring
Number of cylinders
Cylinder bore
98 mm
Cylinder stroke
113 mm
Total displacement
3,409 cc
Compression ratio
17.0:1
Engine Dimension (L x W x H)
817 mm X 635.5 mm X 777 mm
Engine weight
300 Kg
Direction of rotation
Counter-clockwise
Firing order
1 - 3 - 4 - 2
Cooling system
Cooling Type
Capacity of coolant
4.7 L
Type
Water pump
Driving Type
Ribbed-Belt driven
Pump Speed
2,880 rpm
Drive Ratio
(Engine speed:Pump
speed)
1 : 1.2
Flow Rate
160 LPM or more
Pump back pressure
0.8 bar
Type
Cooling fan
Sucker Type
Driving Type
Hydraulic Drive
Rotation Ratio
Variable
24
View from flywheel

Specifications
Item
DL03LEL00
DL03LEL01
Type
Thermostat
Coolant Temperature
Sensor
Water Temperature
Sensor
Surge Tank Cap
DL03LEL02
DL03LEL03
DL03LEL04
Wax pellet type
82 C
97 C
Lift
8 mm
Type
2.5k
0.148k

pressure valve
0.97 kg/cm2
Lubrication System
Lubricating type
Oil Pressure
Forced lubrication system

Idle (Idling revolution
count)
1.0 kg/cm2
Max. Load (rated RPM)

Oil Specifications
Oil Capacity
4.5 ~ 6.0 bar
Oil Class
API CJ-4 (ACEA-E9)
Total
13.6L (Including 1.0L in the engine)
Max.
12.6 L
Min.
6.0 L
Allowable tilt angle (oil pan) (front/rear/left/right)
35 / 35 / 35 / 35
Type
Gear type
Oil pump
Driving Type
Oil coolant type
CRANK GEAR driven

Water-cooled stack plate type
Type
Oil filter
Spin on Type Filter
Allowable temperature
-40C ~ 140C
Flow
36 L/min
Lubrication indicator
Oil pressure type
Opening pressure of the oil spray nozzle adjustment valve
1.0 ~ 1.4 kg/cm2
Hydraulic indicator
Oil Pressure Sensor
Fuel System
Fuel injection pump type
DELPHI DFP 4.4
Control type
E.C.U (DELPHI)
25
Remarks

Specifications
Item
DL03LEL00
Delivery pump type
DL03LEL02
DL03LEL03
DL03LEL04
Remarks
Gear type (with in DFP 4.4)

Type
Injection nozzle
DL03LEL01
Multi hole type
Opening pressure (Operating pressure)
1,800 bar
Fuel filter type
Spin-on type
Intake/Exhaust System
Model
BorgWarner WGT
Driving Type
EXHAUST PRESSURE FEED TYPE
Lubricating type
FORCED PRESSURE FEED TYPE
Compressor outlet air

pressure
Turbocharger
2.22 kgfcm2
At max. output
Air intake
133.6 g/s
At max. output
Turbine Speed
161 krpm
At max. output
Allowable max. RPM
194 krpm
From the turbine

inlet
Allowable max. exhaust

temperature
750 C
Weight
4.3 kg
Intake valve
0.4 mm
When cold
Exhaust valve
0.45 mm
When cold
Open (BTDC)
16
Closed (ABDC)
54
Open (BBDC)
38
Closed (ATDC)
24
Valve gap
Intake valve
Exhaust valve
Intake
108.3 mm
Exhaust
110.3 mm
Valve length
Intake
6.97 0.007 mm
Exhaust
6.96 0.007 mm
Stem outside diameter
Intake
7 ~ 7.015 mm
Exhaust
7 ~ 7.015 mm
Valve guide bore

Intake
43.4 ~ 43.6 mm
Exhaust
43.4 ~ 43.6 mm
Valve guide length
Valve sheet contact

width
Intake
2.14 mm
Exhaust
1.63 mm
26

Specifications
Item
DL03LEL00
DL03LEL01
DL03LEL02
DL03LEL03
Intake
44.5 ~ 45.0
Exhaust
44.5 ~ 45.0
DL03LEL04
Valve sheet angle
Free length of valve spring
55.23 mm
2 and under (less than 1.8 mm)

Cylinder block/head
Gasket Surface
0.05 mm
0.03 mm / 100 mm
Manifold mounting surface
0.05 mm / 100 mm
Cylinder head flatness
Intake
39.078 mm
Exhaust
38.716 mm
Camshaft height
Camshaft journal outside diameter
Intake
44.95 ~ 44.966 mm
Exhaust
44.95 ~ 44.966 mm
Camshaft bearing oil gap
0.065 ~ 0.106 mm
Camshaft end play
0.1 ~ 0.2 mm
Inside diameter of cylinder block piston bore
97.99 ~ 98.01 mm
Flatness of cylinder block gasket surface
0.05 mm
0.03 mm / 100 mm
Electric apparatus
Engine control type
Electronic Control Unit (ECU)
Engine stop unit
Fuel delivery shutdown by ECU
Others/Driving System
Grade A: 97.920 ~ 97.930 mm
Grade B: 97.930 ~ 97.940 mm
Piston outside diameter

Gap between cylinder and piston
Piston ring groove

area
Piston ring side gap
Piston ring end gap
0.060 ~ 0.080 mm
Top ring groove
2.415 ~ 2.445 mm
2nd ring groove
2.060 ~ 2.080 mm
Oil ring groove
3.020 ~ 3.040 mm
Top ring side gap
0.083 ~ 0.137 mm
2dn ring side gap
0.070 ~ 0.110 mm
Oil ring side gap
0.030 ~ 0.070 mm
Top ring end gap
0.20 ~ 0.40 mm
2nd ring end gap
0.55 ~ 0.70 mm
Oil ring end gap
0.2 ~ 0.4 mm
27
Remarks

Specifications
Item
DL03LEL00
DL03LEL01
DL03LEL02
DL03LEL03
35.995 ~ 36,000 mm
Piston pin hole bore
36.008 ~ 36.014 mm
Piston pin hole gap
0.008 ~ 0.019 mm
Connecting rod small-end bore
36.025 ~ 36.038 mm
Connecting rod small-end hole gap
0.025 ~ 0.043 mm
66,000 ~ 66.015 mm
Connecting rod bearing oil gap
0.026 ~ 0.064 mm
Connecting rod end play
0.15 ~ 0.3 mm
Crankshaft main journal outside diameter
74.955 ~ 74.970 mm
Crankshaft pin journal outside diameter
62.955 ~ 62.970 mm
Crankshaft main bearing oil gap
0.029 ~ 0.059 mm
Crankshaft end play
0.1 ~ 0.31 mm
28
DL03LEL04
Remarks

Engine output
Engine
Model
Performance
Product code
Output
(kW/rpm)
Torque
(Nm/rpm)
Idle at low speed

(rpm)
Idle at high
speed
(rpm)
DL03-LEF00
110/2,400
38.23/1,600
800 25
2,500 25
DL03-LEF01
100/2,300
34.96/1,600
800 25
2,500 25
DL03-LEF02
100/2,300
34.96/1,600
800 25
2,500 25
DL03-LEF03
75/2,300
33.65/1,400
800 25
2,500 25
D34NAP
29

Outside drawing of the engine (DL03-LEF00/LEF01)
Isometric assembly drawings
12
1
11
2
10
9
4
5
8
6
7
13
14
26
15
25
24
16
23
20
22
17
18
19
21
EDL032143E
1. Turbocharger
8. Crankshaft pulley
15. Common Rail
22. Flywheel housing
2. Exhaust manifold
9. Generator bracket
16. Oil gauge
23. Cylinder head
3. EGR cooler
10. Eye bolt
17. Oil filter
24. Rear lifting hook
4. Starter
11. Front lifting hook
18. Fuel injection pump
25. Cylinder Head Cover
5. Water pump
12. Thermostat
19. Cylinder Block
26. Breather hose
6. Water pump Pulley
13. Injector
20. Intake manifold
7. Oil pan
14. Fuel injection pipe
21. Flywheel
30

Assembly drawings (Front/Rear)
11
12
1
10
9
2
8
4
6
5
20
19
21
18
13
17
14
16
15
EDL032144E
1.
Front lifting hook
8.
Idle pulley
15. Flywheel
2.
Water pump pulley
9.
Eye bolt
3.
Cylinder block
10. Air heater
4.
Starter
11. Coolant hose
18. Turbocharger
5.
Oil pan
12. V-belt pulley
6.
Crankshaft pulley
13. Oil gauge
20. Breather hose
7.
Generator bracket
14. Oil filter
17. Cylinder head
31

Assembly drawings (Left/Right)
10
1
2
3
5
12
22
21
13
14
15
16
20
17
18
19
EDL032145E
1. Heat screen
7. Thermostat
13. Intake manifold
18. Oil Pan
2. Exhaust manifold
8. Turbocharger
14. Fuel return hose
19. Discharge plug
3. EGR cooler
9. Oil delivery pipe
(Common rail-injection pump) 20. Fuel injection pump
4. Starter
10. Oil return pipe
15. Oil filter
5. EGR Valve
11. Oil gauge
16. Oil filter module
(Injector-injection pump)
6. Water pump
12. Common Rail
17. Oil cooler
22. Air heater
32

Assembly drawings (Top/Bottom)
19
18
17
1
2
16
15
4
5
14
6
7
13
8
12
11
10
20
23
21
22
EDL032146E
1. Idle pulley
7. Oil gauge
13. Injector
19. V-belt pulley
8. Air heater
14. Turbocharger
3. Eye bolt
9. Intake manifold
15. Thermostat
21. Discharge plug
4. Common Rail
10. Breather
16. Water pump
22. Oil Pan
11. Breather hose
17. Coolant pump pulley
23. Starter
6. Oil filter
12. Exhaust manifold
18. Coolant hose
33

Outside drawing of the engine (DL03-LEF02/LEF03)
12
1
11
2
10
9
4
5
8
6
7
13
14
26
25
15
24
16
23
20
22
18
17
21
19
EDL032143F
1. Turbocharger
15. Common Rail
2. Exhaust manifold
16. Oil gauge
23. Cylinder head
3. EGR cooler
10. Eye bolt
17. Oil filter
4. Starter
5. Water pump
12. Thermostat
19. Cylinder Block
26. Breather hose
13. Injector
20. Intake manifold
7. Oil pan
21. Flywheel
34

12
11
10
9
2
7
3
8
14
4
6
5
20
21
19
13
18
17
16
15
EDL032144F
1.
Front lifting hook
8.
Idle pulley
15. Flywheel
2.
Water pump pulley
9.
Eye bolt
3.
Cylinder block
10. Air heater
4.
Starter
11. Coolant hose
18. Turbocharger
5.
Oil pan
12. V-belt pulley
6.
Crankshaft pulley
13. Oil gauge
20. Breather hose
7.
Generator bracket
14. Oil filter
17. Cylinder head
35

10
1
2
3
5
12
22
21
13
14
17
20
16
15
18
19
EDL032145F
1. Heat screen
7. Thermostat
13. Intake manifold
18. Oil Pan
2. Exhaust manifold
8. Turbocharger
19. Discharge plug
3. EGR cooler
4. Starter
10. Oil return pipe
15. Oil filter
5. EGR Valve
11. Oil gauge
6. Water pump
12. Common Rail
17. Oil cooler
22. Air heater
36

19
18
1
2
17
3
16
15
5
14
8
13
7
9
12
10
11
23
20
21
22
EDL032146F
1. Idle pulley
7. Oil gauge
13. Injector
19. V-belt pulley
8. Air heater
14. Turbocharger
3. Eye bolt
9. Intake manifold
15. Thermostat
21. Discharge plug
4. Common Rail
10. Breather
16. Water pump
22. Oil Pan
11. Breather hose
23. Starter
6. Oil filter
12. Exhaust manifold
18. Coolant hose
37

Outside drawing of the engine (DL03-LEL00/LEL01/LEL02/LEL03/LEL04)
1
2
7
4
5
9
22
10
21
20
11
12
19
13
14
15
18
16
17
EDL032143G
1. Thermostat
13. Oil filter
19. Cylinder head
2. Turbocharger
14. Oil gauge
3. EGR cooler
9. Injector
4. Water pump
16. Cylinder Block
22. Breather hose
11. Common Rail
17. Discharge plug
6. Oil pan
12. Intake manifold
38

4
15
14
13
12
10
11
EDL032144G
1.
Front lifting hook
6.
Air heater
2.
Water pump pulley
7.
Coolant hose
12. Cylinder head
3.
Cylinder block
8.
Rear lifting hook
13. Turbocharger
Oil filter
4.
Oil pan
9.
5.
Crankshaft pulley
10. Oil gauge

15. Breather hose
39

7
1
21
11
20
12
13
14
15
19
16
10
17
18
EDL032145G
1. Heat screen
7. Turbocharger
18. Discharge plug
2. Exhaust manifold
3. EGR cooler
9. Oil return pipe
14. Oil filter
4. EGR Valve
10. Oil gauge
5. Water pump
11. Common Rail
16. Oil cooler
21. Air heater
6. Thermostat
12. Intake manifold
17. Oil Pan
40

14
13
12
1
11
2
3
10
9
15
16
17
EDL032146G
1. Common Rail
6. Breather
11. Thermostat
16. Discharge plug
7. Breather hose
12. Water pump
17. Oil Pan
3. Oil filter
8. Exhaust manifold
4. Air heater
9. Injector
14. V-belt pulley
5. Intake manifold
10. Turbocharger
41

Engine identification number
Engine number engraving
The engine code and manufacturing number are imprinted
on A in the figure. This number will be asked when
ordering parts or claiming on a warranty.
DL03-LEF00/01
EDL022165B
1. Name(6-digit)
3. Unit number (5-digit)
2. Year(1-digit)
4. Next to new main specifications(3-digit)
EDL032164F
Cylinder block number engraving
DL03-LEF02/03
The cylinder block serial number is imprinted on the part

marked in the figure (A).
EDL032164G
DL03-LEL00/01/02/
03/04
EDL032213A
EDL032164E
42

Engraving of piston bore level of cylinder
block
Crankshaft main journal engraving
The bore diameter grade of cylinder block pistons is
marked in the figure (A), and the crankshaft main journal
imprinted on the part marked in the figure (A). The piston
diameter grade is imprinted on the part marked in the
bore grade of the cylinder block is classified into A and
figure (B). The diameter grade of crankshaft main journals
B. This grade will be required when ordering pistons suit-
is classified into A, B, and C. This grade will be asked
able for your cylinder block piston bore diameter.
when ordering suitable main bearings.
The crankshaft serial number is imprinted on the part
B
EDL032214C
EDL032216B
Engraving of main bearing bore level of

cylinder block
Connecting rod engraving
The bore grade of the cylinder block main bearing is
marked as A in the drawing and classified by a letter
imprinted on the part marked in the figure (A). The bore
from A to F. These levels are necessary to order the
grade of cylinder block main bearings is classified into A,
connecting rod.
The connecting rod weight is engraved in the position
B, and C. This grade will be asked when ordering main

bearingssuitable for your cylinder block main bearing
bore.
EDL022217A
A
EDL032215D
43

Piston engraving
The piston grade is imprinted on the part marked in the
figure (A). The piston grade is classified into A and B.
This grade will be required when checking a suitable
piston grade.
EDL032218C
Cylinder head gasket engraving

The cylinder head gasket identification mark is engraved
in the position marked as (A) in the drawing, and the
class is engraved in the position marked as (B). It
belongs to class A if there is one hole of the identification
mark on the cylinder head gasket, to class B if there are
two holes ,and class C if there are three holes. These
engravings are necessary to order the suitable cylinder
head gasket.
Cyl. #1
Cyl. #2
Cyl. #3
Cyl. #4
EDL022219A
44
4. Regular inspection
General information ...........................................................................................................47
Routine Inspection .................................................................................................................................... 47
Regular inspection table ...................................................................................................48

General Conditions ................................................................................................................................... 48
Cooling system ..................................................................................................................50

Coolant standards ..................................................................................................................................... 50
Capacity of coolant................................................................................................................................... 50
Checking the Coolant (Only LEF00/LEF01/LEF02/LEF03) .................................................................... 50
Checking the Coolant (Only LEL00/LEL01/LEL02/LEL03/LEL04).......................................................... 50
Measurement of Coolant Concentration.................................................................................................. 51
Replenishment of Coolant (Only LEF00/LEF01/LEF02/LEF03) ............................................................. 52
Replenishment of Coolant (Only LEL00/LEL01/LEL02/LEL03/LEL04)................................................... 52
Replacement of Coolant (Only LEF00/LEF01/LEF02/LEF03) ................................................................ 53
Replacement of Coolant (Only LEL00/LEL01/LEL02/LEL03/LEL04) ..................................................... 54
Lubrication system ............................................................................................................56

Engine oil standards................................................................................................................................. 57
Engine Oil Capacity.................................................................................................................................. 58
Checking the Engine Oil .......................................................................................................................... 58
Replenishment of Engine Oil ................................................................................................................... 59
Replacement of Engine Oil...................................................................................................................... 60
Fuel system .......................................................................................................................64

Fuel Standards.......................................................................................................................................... 64
Fuel filter ................................................................................................................................................... 64
Replacement of Fuel Filter ...................................................................................................................... 65
Air bleeding in the fuel circuit ................................................................................................................. 66
Fuel Filter Draining ................................................................................................................................... 67
Intake/exhaust system ......................................................................................................69

Cleaning of Air Filter ................................................................................................................................ 69
Cleaning of the Air Filter Element .......................................................................................................... 69
Replacement of Air Filter Element .......................................................................................................... 70
Cylinder block/head ...........................................................................................................71

Adjustment of Valve Gap......................................................................................................................... 71
45
Others/driving system .......................................................................................................72

Belt tension ............................................................................................................................................... 72
46
General information
General Information
CAUTION
As time passes after purchasing an engine, each of the

engines parts age and initial engine performance cannot
be maintained.
Incorrect inspection methods may cause of

engine faults.
Regular inspection and replacement according to the
recommended regular inspection table allows you to
Cleaning an engine with liquids such as water or

wax may cause breakdown of electrical parts.
maintain an engine with the optimum conditions and best
performance for a long period and prevent unexpected
Be careful when handling batteries, cables, and

electrical wirings because current flows through
accidents in advance.
those parts.
Users are responsible for the proper operation and main-
Do not put heavy things or apply excessive force
Make sure that you connect the battery terminal
tenance of engines. Engines should be inspected and
or impact on the fuel-related units.
replaced by officially-certified technicians in a workspace

with the specified tools and facilities. Observe the
('+' and '-') to the right terminal. Connecting the
following instructions to perform inspections.
'+' and '-' terminals to the wrong terminal may
1. Perform inspections on a flat floor without a slope.
cause damage to the electrical unit parts and fire.
2. Excluding extreme circumstances, only perform

inspection while the engine is stopped.
Routine Inspection
3. Disconnect the '-' terminal of the battery before
Routine inspection is an inspection performed by an
performing an inspection.
engine operator before operating the engine. It should be
4. Perform inspection in a well ventilated space.
performed to protect operator's safety, as well as the
5. Use a wooden prop or lift when working under the
engine.
engine.
The following is a minimal check list.

1. Check whether the engine smoothly starts and the
DANGER
levels of fuel, oil, and coolant are within the normal

range.
Wait until the engine is sufficiently cooled before
2. Check if any discharged emissions are colored and if
starting inspection after operating the engine.
the exhaust contains toxic gas elements.
Otherwise, you may be burned.
3. Check whether abnormal noise occurs after starting
You may be poisoned by the emission when
an engine or not.
starting an engine in a closed space. Perform
4. Check whether oil or water is leaking.
inspection at the well-ventilate space.
Unless absolutely compelled, do not perform
Do not be close to fire when inspecting an
inspection under an engine.

engine. Fuel, oil, or batteries may generate gas,
causing fire.
If inspecting the engine while it is running, do

not wear accessories such as necklaces, rings,
watches or gloves. Such accessories may
become stuck in rotating parts while the engine
is running and may cause serious bodily injury.
Individuals who use a mechanical heart or artificial internal organ should not enter the area near
an engine while it is running. The high-voltage
current of the injectors or ECU may cause
abnormal operation of such equipment.
47
Regular inspection table
General Conditions
maintain the engine with optimum conditions and best
Regular inspection and replacement according to the
performance for a long period and prevent unexpected
recommended regular inspection table allows you to
accidents in advance.
( : Inspection and Adjustment, : Replacement)
Inspection interval (x 1,000 hours)
Check Points
Daily
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
Coolant system
State of connection between cooler
and coolant hose
Capacity and state of coolanta
Cooling fan belt tension
Replace every 1,200 hoursb
Lubrication system
Lubricating device and oil leakage
Capacity and condition of engine oilc
Engine oil filterc
Fuel system
Fuel line and connection unit
Fuel volume
Water draining from water separator
Fuel filter
Fuel injection time
Inspect and adjust if required
Injector
Compression pressure
Intake/Exhaust system
Air cleaner
Throttle body cleaning
Intake line and connection unit
Exhaust line and connection unit
Emission state
Clean and replace if required
Cylinder head
Intake/Exhaust valve gap state
48
Inspection interval (x 1,000 hours)
Check Points
Daily
0.5
1.0
1.5
2.0
2.5
Electric system
Battery charging state
Various electric units
a. Replenish coolant if required.

b. To maintain the concentration of anti-freeze, check coolant every 500 hours.
c. Replace it every 500 hours after the first 50 hours.
49
3.0
3.5
4.0
4.5
5.0
Cooling system
General Information
Checking the Coolant (Only

LEF00/LEF01/LEF02/LEF03)
The coolant plays an important role in the prevention of

overheating and freezing of the engine. However, if the
engine is used for a long period, the performance of anti-
DANGER
freezing and anticorrosion of the coolant degrades. Maintain the condition of the coolant through daily inspections
If the radiator cap is opened to exchange or
and periodic replacements.
replenish coolant while the engine is overheated, hot
The mixing ratio for the engine coolant is 40 % antifreeze.
water will spurt out and may cause serious burns.
For the water in the coolant, use clean tap water. Peri-
If it is absolutely necessary to open the radiator cap
odically check coolant to maintain the concentration of
while the engine is overheated, wrap the radiator cap
antifreeze.
with a cloth and slowly open the cap in two steps

until the steam pressure has been released from the
CAUTION
inside. After the steam pressure has been completely

released, remove the radiator cap.
The recommended mixing ratio allows coolant to

prevent corrosion of the engine efficiently and to
1. Check the position of the supplementary tank.
maintain the best engine performance for a long
2. Make sure that the engine and radiator are cooled.
period. Using contaminated water or unspecified
3. If the coolant level indicates between the upper limit
antifreeze or additives may cause critical faults in
and the lower limit on the supplementary tank, it
the cooler.
means that the coolant volume is normal.

4. If there is insufficient coolant, replenish it.
5. Open the radiator cap and check the condition of the
Coolant standards
coolant. If the coolant cap is contaminated or insuffi-
Amount of antifreeze during winter
cient, measure the coolant concentration. If the

coolant concentration is outside the specified range,
Ambient temperature (C)
Coolant (C)
Antifreeze (%)
Above -10
85
15
-10
80
20
-15
73
27
-20
67
33
-25
60
40
-30
56
44
-40
50
50
exchange the coolant.
Checking the Coolant (Only

LEL00/LEL01/LEL02/LEL03/LEL04)
DANGER
If the surge tank cap is opened to exchange or
replenish coolant while the engine is overheated, hot
water will spurt out and may cause serious burns.
If it is absolutely necessary to open the surge tank
cap while the engine is overheated, wrap the surge
Capacity of coolant
tank cap with a cloth and slowly open the cap in

two steps until the steam pressure has been
Engine Model and Product Code
Coolant capacity (l)
DL03-LEF00/LEF01/LEF02/
LEF03
4.7
DL03-LEL00/LEL01/LEL02/
LEL03/LEL04
4.7
released from the inside. After the steam pressure

has been completely released, remove the surge
tank cap.
1. Check the position of the supplementary tank.
2. Make sure that the engine and radiator are cooled.
and the lower limit on the supplementary tank, it
means that the coolant volume is normal.
50
4. If there is insufficient coolant, replenish it.
4. Check the color on test sheet.
5. Open the surge tank cap and check the condition of

the coolant. If the coolant cap is contaminated or
insufficient, measure the coolant concentration. If the
coolant concentration is outside the specified range,
exchange the coolant.
Measurement of Coolant Concentration
Special Tools
Figure
Product Number/Name
60.99901-0038
Coolant test sheet
C)
B)
EDL0213002A
1) Compare the color of part A on the test sheet to the
A)
color of GLYCOL / FREEZEPOINT (End pad) of the

standard color table.
2) Compare the color of the test sheet (B) to the color
The coolant concentration can be measured as
of MOLYBDATE (Middle pad) of the standard color
follows.
table.
1. If the engine coolant temperature is within a range of
3) Compare the color of the test sheet (C) to the color
10 ~ 55C, drain the coolant and fill half a plastic cup
of NITRITE of the standard color table.
with it.
5. Compare and confirm the parts with identical colors

on the test sheet and the standard color table.
CAUTION
When taking out a sample of coolant from the
supplementary tank, it is difficult to measure the
precise concentration. Always take out sample by
opening the drain plug of coolant.
TEST
2. Soak the test sheet in the coolant and take it out after
SERVICE
3 ~ 5 seconds. Shake the sheet to remove the

remaining coolant.
3. Wait for about 45 seconds until the test sheet
PRE CHARGE
changes its color.
CAUTION
EDL022154A
Measurement time should not exceed 75 seconds.
1) Compare the changed pink color part A of the test
The color changes as time passes.
sheet with the GLYOOL/FREEZEPOINT (End pad) of

the standard color table on top of the container and
confirm the concentration. The concentration indication
has to be within the color scope of 33~50%.
51
2) The state of additives for anticorrosion is shown on
6. Replenish coolant until its level is between the upper
the point where the color of MOLYBDATE (Middle
and lower limit of the supplementary tank.
pad) on the standard color table (which is identical
CAUTION
with the Middle (B) of the test sheet) is crossed with

the color of NITRITE on the standard color table
(which is identical with the (C) of the test sheet). It
If the radiator cap is opened while the engine is

hot, hot water will spurt out and may cause
should be maintained at the optimum range, in the
serious burns. Open the radiator cap after making
green section between 0.3 to 0.8.
sure that the engine has been fully cooled.
CAUTION
Mark and separately manage the containers for

storing coolant from beverage containers for
If the color on the test sheet does not match the
avoiding confusion. See a doctor immediately in
color of the standard color table, find a middle
case of drinking coolant.
color on the standard color table. For example, if

the color of (C) of the test sheet matches D and
Replenishment of Coolant (Only

F on the NITRITE of the standard color table,

select E.
If the coolant level of the surge tank is below the lower
To prevent corrosion inside of the engine cooling
limit, replenish the coolant as follows.
unit, drain the coolant and replace it with new
1. Remove the surge tank cap.
coolant once a year.

and lower limit of the surge tank.
Replenishment of Coolant (Only

3. Install the surge tank cap.
CAUTION
If the coolant level of the supplementary tank is below

the lower limit, replenish the coolant as follows.
Be careful not let foreign substances flow into the
1. Remove the supplementary tank cap.
engine when replenishing coolant.

and lower limit of the supplementary tank.
If there is not coolant in the surge tank, replenish the
3. Install the supplementary tank cap.
coolant as follows.
1. Remove the surge tank cap while the engine and radi-
CAUTION
ator are cold.
Be careful not let foreign substances flow into the
2. Replenish coolant up to the upper limit surge tank.
engine when replenishing coolant.
3. After starting the engine let the coolant circulate sufficiently and check the coolant level. If there is insuffi-
If there is not coolant in the supplementary tank,
cient coolant, replenish more.
replenish the coolant as follows.
1. Remove the radiator cap while the engine and radiator
and the lower limit on the surge tank, it means that
are cold.
the coolant volume is normal.
2. Replenish coolant up to the inlet of the radiator.

3. After starting the engine let the coolant circulate sufficiently and check the coolant level. If there is insufficient coolant, replenish more.
4. Install the supplementary tank cap.
5. Remove the supplementary tank cap.
52
5. Install the surge tank cap.
8. Start the engine to let the cooling fan rotate 2 or 3

times. When the engine is warmed up, increase the
CAUTION
engine RPM two or three times.

9. Stop engine and wait until engine is cooled.
If the surge tank cap is opened while the engine
10. Remove the radiator drain plug and drain water.
is hot, hot water will spurt out and may cause
11. Repeat the above mentioned processes from 1 to 8
serious burns. Open the surge tank cap after
until the drained water becomes clear.
making sure that the engine has been fully
12. Press the hose connected to the radiator to discharge
cooled.
the air from inside of the radiator and slowly fill the
radiator with the coolant at the specified mixing ratio
storing coolant from beverage containers for
to let the air be discharged from the radiator.
avoiding confusion. See a doctor immediately in
Note) Use recommended genuine antifreeze.
case of drinking coolant.
CAUTION
Replacement of Coolant (Only
Do not mix antifreezes from different manufacturers.
DANGER
tions.
Never open the radiator cap while the engine is
Do not add antirust which is not recommended

by us.
overheated. If the radiator cap is opened while
the engine is overheated, hot water will spurt out
As insufficient coolant concentration may cause

corrosion or freezing, on the other hand, an
and may cause serious burns. Open the radiator
excessive concentration may degrade the cooling
cap after ensuring that the engine has been
performance. Mix coolant with 40% antifreeze and
cooled sufficiently.
Do not mix the coolant with different concentra-
3~5% additives (DCA4) to prevent corrosion.

storing coolant from beverage containers to avoid
13. Operate the engine at idle after starting. When cooling
confusion. If coolant is ingested, see a doctor
fan is running and coolant is circulated, remove radi-
immediately.
ator cap and replenish coolant through the inlet.

14. Replenish coolant until the cooling fan rotates 3 ~ 5
CAUTION
times.
15. Replenish coolant to the upper limit of the supplemen-
Be careful not to get coolant on any belts or electric
tary tank and then install radiator cap.
apparatus when replacing the coolant.
16. Operate the engine at idle until the cooling fan rotates
2 ~ 3 times.
1. Make sure that engine and radiator are cooled.
17. Stop the engine and wait until the engine and the
2. Place a container in front of the coolant drain plug.
radiator are cooled.
3. Remove the radiator cap.
18. After checking the coolant level in the supplementary
4. Unplug the coolant drain plug of the radiator and then
tank, replenish coolant until the tank level stays
drain coolant.
between the upper and lower limit without changing.
5. After completing coolant drain, connect the coolant
Note) After replenishing coolant, check the coolant level
drain plug again.
of the supplementary tank for at least two or three
6. Drain the coolant from the coolant supplementary tank
days.
and cleanse the tank.

7. Fill the radiator inlet with water and install radiator
CAUTION
cap.
Note) Slowly pour coolant in to let the air be discharged
After replenishing coolant, check the coolant level of
from radiator and press the hose connected to it
the supplementary tank for at least two or three
to discharge the air inside.
days.
53
11. Repeat the above mentioned processes from 1 to 8
WARNING
until the drained water becomes clear.

12. Press the hose connected to the radiator to discharge
Discard exchanged coolant according to the regula-
the air from inside of the radiator and slowly fill the
tions set forth by the relevant authorities. Disposing
surge tank with the coolant at the specified mixing
of exchanged coolant into the ground, sewers,
ratio to let the air be discharged from the radiator.
drains, rivers, or the sea will cause serious environ-
Note) Use recommended genuine antifreeze.
mental pollution. Violation of regulations regarding

discard of engine oil without observing the handling
CAUTION
regulations, will be punished.
Replacement of Coolant (Only

Do not mix antifreezes from different manufac-
Do not mix the coolant with different concentra-
Do not add antirust which is not recommended
As insufficient coolant concentration may cause
turers.
tions.
DANGER
by us.
Never open the surge tank cap while the engine

is overheated. If the surge tank cap is opened
corrosion or freezing, on the other hand, an
while the engine is overheated, hot water will
excessive concentration may degrade the cooling
spurt out and may cause serious burns. Open the
performance. Mix coolant with 40% antifreeze and
surge tank cap after ensuring that the engine has
3~5% additives (DCA4) to prevent corrosion.
been cooled sufficiently.
13. Operate the engine at idle after starting. When cooling
storing coolant from beverage containers to avoid
fan is running and coolant is circulated, remove surge
confusion. If coolant is ingested, see a doctor
tank cap and replenish coolant through the inlet.
immediately.
14. Replenish coolant until the cooling fan rotates 3 ~ 5

times.
15. Replenish coolant to the upper limit of the surge tank
CAUTION
and then install surge tank cap.

16. Operate the engine at idle until the cooling fan rotates
2 ~ 3 times.
17. Stop the engine and wait until the engine and the
1. Make sure that engine and radiator are cooled.
radiator are cooled.
2. Place a container in front of the coolant drain plug.
18. After checking the coolant level in the surge tank,
3. Remove the surge tank cap.
replenish coolant until the tank level stays between
4. Unplug the coolant drain plug of the radiator and then
the upper and lower limit without changing.
drain coolant.
Note) After replenishing coolant, check the coolant level
5. After completing coolant drain, connect the coolant
of the surge tank for at least two or three days.
drain plug again.
CAUTION
6. Drain the coolant from surge tank and cleanse the

tank.
After replenishing coolant, check the coolant level of
7. Fill the surge tank inlet with water and install surge
the surge tank for at least two or three days.
tank cap.
Note) Slowly pour coolant in to let the air be discharged
from radiator and press the hose connected to it
to discharge the air inside.
8. Start the engine to let the cooling fan rotate 2 or 3
times. When the engine is warmed up, increase the
engine RPM two or three times.
9. Stop engine and wait until engine is cooled.
10. Remove the radiator drain plug and drain water.
54
WARNING
Discard exchanged coolant according to the regulations set forth by the relevant authorities. Disposing
of exchanged coolant into the ground, sewers,
drains, rivers, or the sea will cause serious environmental pollution. Violation of regulations regarding
discard of engine oil without observing the handling
regulations, will be punished.
55
Lubrication system
General Information
Engine oil lubricates, cools, seals, prevents corrosion, and
cleans engines, enhancing engine performance and
extending the engine's lifetime. If a vehicle is continuously
driven while engine oil is insufficient, the moving parts of
the engine may get stuck, causing engine faults.
Engine oil should be checked through the oil level gauge
and replenished if required. Oil level should be checked
while the engine is stopped. To check the oil level, turn
off the engine while it is running and wait for 5 ~10
minutes to allow the engine oil to flow back into the oil
pan. The engine oil level should indicate between the
upper limit and the lower limit of the oil level gauge.
Engine oil should be periodically replaced based on the
regular inspection table and the oil filter and the cartridge
should be replaced as the engine oil is replaced.
56
Engine oil standards
Use the specified engine oil suitable for the environment
and conditions of the site where the engine will be used.
Engine Oil Viscosity by temperature
SAE 10 W-30
SAE 5 W-30
SAE 0W-30
Ambient
temperature
SAE 0W-40
SAE 5W-40
SAE 10W-40
SAE 15W-40
EDL0213001D
Please use the engine oil which satisfies the following recommended specifications.
Engine Model
Oil Class
DL03-LEF00/LEF01/LEF02/LEF03
API CJ-4
(ACEA-E9)
DL03-LEL00/LEL01/LEL02/LEL03/LEL04
API CJ-4
(ACEA-E9)
Note) Use our genuine oil recommended by us.
57
Engine Oil Capacity
DL03-LEF02/03
Please replenish the engine oil based on the following

recommended oil injection amount.
Engine oil capacity ( )
Engine Model
Inside of the oil pan

Totala
Max.
Min.
DL03LEF00/LEF01/
LEF02/LEF03
12.6
6.0
13.6
DL03-LEL00/L
EL01/LEL02/L
EL03/LEL04
12.6
6.0
13.6
EDL032158D
a. Including 1.0 liter in the engine
DL03-LEL00/01/02/
03/04
Checking the Engine Oil

1. Move to the engine to the flat floor to maintain the
engine level.
2. Stop the engine after startup when the engine is
heated up to the normal temperature.
3. Stand by for 5-10 minutes.
4. Pull upward and out the oil level gauge (A).
DL03-LEF00/01
EDL032158E
1) Check the position of the oil level gauge (A).
2) The oil level gauge (A) is next to the oil filter at the
side of the engine.
3) Pull the hook of the oil level gauge (A) with your
fingers.
5. Clean the pointer of the oil level gauge with a clean
cloth.
CAUTION
EDL032158C
Cleaning the gauge with a contaminated cloth may

lead to debris flowing in the engine, resulting in
engine failure.
58
6. Put the oil level gauge (A) back in.
7. Pull the oil level gauge out again to check level and
condition of the oil.
DL03-LEF00/01
A
B
EDL032158C
EDL022152A
DL03-LEF02/03
1) Check if there are engine oil smears between upper

(A) and lower (B) limits of the oil level gauge.
2) If engine oil smears are below the lower limit (B) or
no smears between the limits, replenish engine oil.
3) Check the state of engine oil and if contaminated,
change the engine oil.
Replenishment of Engine Oil
CAUTION
Be careful not to let foreign substances flow into the
EDL032158D
engine when removing the oil cap.

DL03-LEL00/01/02/
03/04
1. Remove the oil cap (A) on the top of the engine.

DL03-LEF00/01
EDL032158E
1) Hold the hook of the oil level gauge (A) and put it
back in.
EDL032159C
2) If the oil level gauge does not fit in, turn the gauge
180 and then try again.
59
3. Complete engine oil replenishment and cover the oil
cap.
DL03-LEF02/03
Replacement of Engine Oil
Special Tools
Figure
Product Number/Name
860104-03241
Wrench, Oil Filter
EDL032159D
DL03-LEL00/01/02/
03/04
Tightening Torque
Component
Tightening Torque
Drain plug
3.0 kgfm
Oil capacity
Engine oil capacity ( )
Engine Model
Inside of the oil pan

Totala
Max.
Min.
DL03-LEF00/L
EF01/LEF02/L
EF03
12.6
13.6
DL03-LEL00/L
EL01/LEL02/L
EL03/LEL04
12.6
13.6
EDL032159E
2. Add our recommended genuine oil to replenish the oil

level.
1) Add our recommended genuine oil by dividing it into
a. Including 1.0 in the engine
several portions for replenishment.

2) Wait for about 1 ~ 2 minutes and then check the
DANGER
engine oil level.

3) Check whether the oil is smeared between the upper
limit and the lower limit of the oil level gauge.
dryness, leading to inflammation, upon contact
4) Repeat the above process until the engine oil level
with your skin repeatedly and for an extended
reaches the appropriate level.
time.
Avoid contact with discharged engine oil repeat-
When replenishing the engine oil, take care to
Wear protective clothing and gloves.
prevent debris from flowing into the engine.
If you are in contact with used engine oil, imme-
CAUTION
edly and for an extended time.
diately wash the affected part with water and
Exceeding the upper limit of the oil level gauge
soap, or hand cleaner.
may cause engine faults. If you have exceeded
Do not wipe your skin with gasoline, fuel, thinner
limit and the lower limit of the oil level gauge.
Wipe off oil and put on protective cream.
Do not use unspecified engine oil additives.
Do not put your gloves or towel contaminated
the upper limit of the oil gauge, drain it until the
or solvent.
engine oil level is indicated between the upper
Engine oil may result in skin contraction and
with oil into your pocket.
60
WARNING
A
Discard all used oil according to the regulations set
DL03-LEL00/01/02/
03/04
forth by competent authorities. Disposing of used oil

to the ground, sewers, drains, rivers, or the sea will
result in serious environmental pollution. Violation of
the regulations regarding discard of engine oil or
noncompliance without the the handling regulations
will be punished.
CAUTION
B
When exchange the New Oil filter, Please dispose of
EDL032160G
the Old Oil and filter.
1) Place a container under the engine to drain the

1. Drain engine oil.
engine oil.
2) Remove the drain plug (B) and drain the engine oil.
DL03-LEF00/01
3) Remove the oil cap A.

2. Replace the oil filter (A).
DL03-LEF00/01
EDL032160E
DL03-LEF02/03
EDL032161C
DL03-LEF02/03
EDL032160F
EDL032161D
61
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
B
EDL032160F
EDL032161E
1) Remove the oil filter (A), using the Wrench, Oil Filter.
CAUTION
DL03-LEL00/01/02/
03/04
As oil may flow out of the filter when removing the

oil filter assembly, take care not to contaminate adjacent parts. Use a rag or cloth and, after the replacement, wipe oil stains off the affected areas.
2) Cleanly wipe the surface on which the oil filter is
mounted.
3) Apply engine oil thin to the rubber packing of a new
oil filter (A).

4) Temporarily assemble the new oil filter by rotating it
EDL032160G
by hand.
1) Fasten the discharging plug (B) to a tightening torque
5) Use the wrench, oil filter to fasten the oil filter to a
of 3.0 kgfm.
tightening torque of 16 ~ 20 Nm.
2) Remove the oil level gauge.
3. Add the engine oil.
3) Feed the genuine oil that we recommend.

Note) Feed a half of the specified amount and wait for
DL03-LEF00/01
about 1 minute to feed the rest.

4) Install the oil filling cap (A).
5) Install the oil level gauge.
6) Move the engine oil discharging container at the
bottom of the engine.
4. Perform a final inspection when the work is complete.
1) Start the engine and check for oil leaks.
2) Stop the engine when the engine is heated up to the
normal temperature.
3) Stand by for 5-10 minutes.
B
EDL032160E
62
4) Check the level of engine oil with the oil level gauge.
CAUTION
Exceeding the upper limit of the oil level gauge may
cause engine faults. If you have exceeded the upper
limit of the oil gauge, drain it until the engine oil
level is indicated between the upper limit and the
lower limit of the oil level gauge.
63
Fuel system
General Information
Fuel Ingredients
Standard
Fuel quality is an important factors in satisfy standards

50 % DistilDistillation Test Tempera- lation Point
ture
90 % Distil-
for engine performance, engine lifetime, and emissions.

Doosan engines are designed to use diesel fuel available
in the area where the engines are sold.
lation Point
CAUTION
Below360
Note) High sulphur content in diesel fuel Doosan diesel

engines can be operated with fuels whose sulphur
Use clean, specified, and qualified fuel only.
content is max. 15wtppm.
Using irregular or unspecified fuel may cause

critical damage and faults to the engine.
Fuel filter
Inject fuel while the engine is stopped.
It is used to remove water and foreign materials from fuel

in order to send clean fuel to the fuel injection pump.
Fuel Standards
To maintain the optimum engine performance, refer to the
CAUTION
following recommended fuel table to select the appropriate fuel.
Ultra Low Sulfur Diesel
Make sure to check the fuel filter and drain water

from it periodically. Otherwise, water may enter
the engine fuel system, causing a serious
Fuel Ingredients
Specific Gravity
Standard
problem to the fuel injection pump, fuel injection

pipe, common rail, injector, etc. Also, it can dete-
(kg/lit) 0.820 ~ 0.845
riorate or damage the fuel filter.

Fire Point
Viscosity (40 C)
(C)
Above 40
(cSt)
1.9 ~ 5.5
(wtppm)
Below15
When draining water from the fuel filter, fuel may

be drained as well. Fuel is highly flammable.
Keep a lit cigarette or flame away from the engine
Sulfur Content
Cloud Point
(C)
Pour Point
(C)
Below-17.5
Low temperature filter

clogging point
(C)
Below-16
Color (ASTM)
during draining water from the filter.
fuel other than the specified one, more water can

be accumulated in the fuel filter.
Total acid value
may enter the fuel system, causing engine stall.
Below 2.5
Moisture and Precipitation

Cetane Index
A new fuel filter should be installed without fuel

in it. Never add fuel in the used fuel filter or fuel
(%)
Below0.15
(mg
KOH/g)
Below0.40
Back plate corrosion rate

(100 C, 3 hours)
Ash Content
If water is not drained from the fuel filter when

the fuel filter warning lamp is turned on, water
Residual carbon (10%)

Vapor/residual fraction
(wt)
Use the specified clean quality fuel only. If using
tank to a new fuel filter.
Below 1
(mass %)
Below0.01
(vol. %)
Below0.02
Above 45
64
Replacement of Fuel Filter
3. Replace the fuel filter.
1. Remove the WIFS (water in fuel sensor) connector.
EDL032813C
1) Prepare a new fuel filter.
EDL032813A
1) Arrange the engine filter to prevent any interference.
CAUTION
2) Remove the WIFS (water in fuel sensor) connector

from the fuel filter.
2. Remove the fuel filter.
Use the genuine fuel filters we recommend. Use

of irregular or recycled parts may lead to critical
failures in the engine.
A new fuel filter should be installed without fuel
Never add fuel in the used fuel filter or fuel tank
in it.
to a new fuel filter.
4. Apply oil to the gasket.
EDL032813B
1) Turn counterclockwise and loosen the fuel filter.
EDL032813D
1) Apply oil to the gasket of the fuel filter.
65
Air bleeding in the fuel circuit
5. Install the fuel filter.
1. Loosen the air discharge valve.
EDL032813E
1) Turn the fuel filter clockwise until its gasket reaches
EDL032814A
the cap of the fuel filter.
1) Turn counterclockwise and loosen the air discharge
2) Tighten the fuel filter to 3/4.
valve (A) on top of the fuel filter.
6. Connect the WIFS (water in fuel sensor) connector.
2. Loosen the pump handle.
EDL032813A
EDL032815A
1) Connect the WIFS (water in fuel sensor) connector to
1) Turn counterclockwise and loosen the pump handle
the fuel filter.
(B).
2) Keep the fuel filter and the surroundings clean and

out of foreign substances such as fuel.
7. Bleed air out of the fuel delivery line.
66
3. Bleed air out of the fuel delivery line.
1) Turn clockwise and fasten the air discharging valve

(A).
A
B
Fuel Filter Draining

1. Loosen the drain valve.
EDL032815C
1) Pump with the pump handle (B) until fuel is
discharged through the air discharge valve (A).

4. Fasten the pump handle.
EDL032818A
1) Loosen the drain valve (A) at the bottom of the fuel
filter.
CAUTION
Do not use tools to loosen the drain valve. Use of
tools may damage the drain valve.
2. Drain the fuel filter.
EDL032815B
1) Press and turn clockwise the pump handle (B) to

fasten it.
5. Fasten the air discharging valve.
A
A
H2O
EDL032818B
EDL032814B
67
1) Discharge water from the fuel filter through the drain
valve (A) for about 10 seconds.
CAUTION
Periodically check the fuel filter and drain the

water from it. Otherwise, moisture may flow into
the fuel unit of the engine, resulting in critical
faults in the fuel injection pump, the fuel injection
pipe, the common rail, and injectors. In addition,
the performance of the fuel filter may be
degraded or damaged.
Fuel may be drained when water is drained from

the fuel filter. Fuel is highly inflammable. Fire
may occur when you smoke or use fire near the
engine when draining water from the fuel filter.
Use clean, specified, and qualified fuel only.

Using irregular or unspecified fuel may result in
more water in the fuel filter.
Drain the water from the fuel filter if the fuel filter
alarm lamp is turned on. Otherwise, moisture may
flow into the fuel unit, causing the engine to stop.
3. Tighten the drain valve.
EDL032807G
1) Tighten the drain valve (A) at the bottom of the fuel

filter.
CAUTION
Do not use tools to loosen the drain valve. Use of
tools may damage the drain valve.
68
Intake/exhaust system
General Information
1) To clean, let sufficient compressed air reach the inside

bottom of the element at 90 direction with an air gun.
The air filter purifies dust and foreign substances included

in the air and supplies clean air into the engine. The air
2) Move air gun up and down the element to blow air
filter is directly related to engine lifetime, emissions, and
from inside to outside until no more dust is coming
engine output. Please periodically check, clean, and
out from the element.

3) Do not use compressed air pressure exceeding 5
replace the air filter.
bars.
CAUTION
DANGER
Do not operate the engine when the air filter is

separated from the engine.
Always wear protective goggles before starting work.
Use specified air filters only. Using unauthorized
Otherwise, dust or foreign substances from the
or remanufactured air filters may result in critical
element may get in your eyes and cause injuries.
faults.
Foreign substances in the engine may cause
2. Clean the element by washing it.
abrasion inside the engine.
Immediately exchange a damaged air filter with a

new one.
Be careful not to let foreign substances flow into

engine or damage the air filter-related electric
apparatus when replacing an air filter.
Be careful not let dust inside when assembling

the air filter.
Cleaning of Air Filter

1. Remove the air filter cover.
2. Remove the air filter element.
3. Remove the dust inside the air filter.
EDL022156A
1) Before washing the element, clean the element by
Cleaning of the Air Filter Element
using compressed air as described above.
Clean the air filter element by using the most suitable
2) Soak the element in the warm cleaning solvent for 10
method for your work environment among the three
minutes and then shake it back and forth for about 5
methods stated below.
minutes.
1. Use compressed air to clean the air filter element.
3) Rinse the element with clean water, drain the water,

and then dry it at room temperature. Fully dry the
element before reassembling it to the engine.
CAUTION
Never use steam spray, gasoline, alkali or hot
cleansing solution to cleansing the element.
EDL022155A
69
3. In an emergency, temporarily clean the element by
using the following method.
1) Tab the end plate of the element with the thumb to
clean it temporarily.
CAUTION
This method should only be used in an emergency when cleaning of element is necessary and
no compressed air or cleansing solution is available.
Under no circumstances should the surface of

the element be hit or beaten with a hard object
to shake the dust off.
EDL022157A
Note) Before reassembling the element, make sure that

the filter paper is not wrinkled, the state of rubber
sealing is good, and there is no deformed part in
the element.
Note) Under any circumstances, do not reuse damaged
elements. When in doubt, replace the element with
a new one.
Replacement of Air Filter Element
CAUTION
Do not let dust get inside the air filter end.
1. Remove the fixed parts.
2. Remove the damaged or contaminated element.
3. Thoroughly cleanse the contact surface of the sealing
ring and the inside of the filter housing.
4. Assemble a new element.
5. Attach the fixed parts again.
70
Cylinder block/head
Adjustment of Valve Gap
(I: Intake, E: Exhaust)
1. Adjust the valve gap.
CYL. No
# 1
# 2
Rotation angle
TDC (#1 CYL.)
# 4
E
360 Rotation
# 3
1) Check and adjust the following valve gaps when the

#1 cylinder is at the top dead point.
#1 cylinder: Intake and exhaust valve
#2 cylinder: Intake valve
#3 cylinder: Exhaust valve
2) Rotate a full 360 in order to make the #4 cylinder

be the top dead point.
3) Check and adjust the following valve gaps when the
#4 cylinder is at the top dead point.
EDL032822A
#2 cylinder: Exhaust valve
#3 cylinder: Intake valve
#4 cylinder: Intake and exhaust valve
3. Perform the final check after adjusting the gap.

D
1) Compare the height of the adjust screw of the intake
valve to that of the exhaust valve after adjusting the

gap by using the adjust screw.
2) If the difference is 2 pitches or more, check the
following.
Check the assembly state between the push rod and
Check the assembly state between the caliper and the
the valve tappet.

valve.
EDL032823A
CAUTION
1) Remove the left and right cylinder head cover.

2) Check the valve gap between the caliper (A) and the
Do not reuse the cylinder head RH cover gasket
adjust screw cap (B) with the gap gauge.
replace it with new one.
3) Loosen the hex nut (C) and tighten the adjust screw
(D) to adjust the valve gap.
4) Check the valve gap between the caliper (A) and the
adjust screw cap (B) with the gap gauge.
5) The intake valve gap is 0.4 mm and the exhaust valve
gap is 0.45 mm.
Item
Specified Value
Intake valve gap
0.4 mm
Exhaust valve gap
0.45 mm
2. Adjust the valve gap in the following order.
71
Others/driving system
Belt tension
1) Insert the belt to the protrusion (A) of the tension

measuring instrument.
The belt's tension should be checked daily and adjusted

as necessary.
Set the measuring instrument between the pulleys and
Press the pad (C) until unscrewing sound of the
set its contact end (B) to push the belt.
1. Inspection condition
1) Check the belt for crack, oil residue, deformation by
spring is heard. This force pushes the tension
heat and wear.
measuring instrument upwards.
2. Test with hands
If there is still tension left on the belt after removing

the pad (C), the measurement result is not accurate.
2) Tension measurement
Read the value where the top of the protrusion (A) of

the tension measuring instrument is aligned with the
scale.
Before reading the value, make sure that the needle

of the measuring instrument is returned back to the
original position.
4. The belt tension is as follows:

Number of belt folds (PK
type)
Tension (kgf)
EDL022140A
20 - 27
1) The tension of the belt can be inspected by checking
27 - 36
34 - 45
41 - 57
48 - 66
59 - 73
the amount of deflection of the belt when applying the

specified force (F) to it.
2) Adjust the belt so that the deflection (T) equals to
0.015 S (1.5 mm for 100 mm).
Note) T: deflection amount, S: distance
2
3)
*S= C
(D - d)
2
5. The belt consists of the following components:
Note) C : distance between shafts (mm), D: large pulley

diameter (mm), d: small pulley diameter (mm)
3. Tension measurement
D
C
B
C
EDL022142A
1) The belt consists of the cover layer (A), cord (B),

adhesive rubber (C) and belt reinforcement rubber (D).
B
EDL022141A
72
5. About the engine

Marking system of units ...................................................................................................75
Unit Conversion Methods ......................................................................................................................... 75
Tightening torque ..............................................................................................................76

Tightening Torque of Main Parts ............................................................................................................ 76
Tightening Torque of General Bolts
.................................................................................................... 78
Tightening torque of plug screw.............................................................................................................. 79

Hollow Screw (4-Hole) Tightening Torque .............................................................................................. 79
Special tool ........................................................................................................................80

Special Tools............................................................................................................................................. 80
Engine disassembly ..........................................................................................................81

Procedure of Disassembling an Engine.................................................................................................. 81
Engine assembly .............................................................................................................101

Procedure of Assembling Engine .......................................................................................................... 101
73
74
5. About the engine

Marking system of units
Unit Conversion Methods
Item
Number
SI Unit
US Unit
Power
1.340483
kw
Hp
0.01
kPa
bar
7.500615
kPa
mmHg
20.88543
kPa
lb/ft2
14.2233
psi
kg/cm 2
1.3596
kw
PS
0.98635
ps
hp
0.00162
g/kwh
lb/psh
0.000947817
BTU
0.7375621
lbfft
0.0002777778
Wh
Luminous Flux
0.09290304
lm/m2
lm/ft2
Speed
0.6213712
km/h
mph
Temperature
The following methods show how to convert SI units to

US units and vice versa.
1. To convert an SI unit to a US unit, multiply a SI unit
with the number in the following table.
Note) (SI Unit) X (Number) = (US Unit)
Pressure
Note) 1mm X 0.03937 = 0.03937 in

2. To convert a US unit to an SI unit, divide the US unit
by the number in the following table.
Note) (US Unit) (Number) = (SI Unit)
Electric Power
Note) 1 in 0.03937 = 25.4 mm

Item
Number
SI Unit
US Unit
0.03937
mm
in
3.28084
ft
1.093613
yd
0.621371
km
mile
0.00155
mm 2
in2
0.1550
cm2
in2
10.76391
m2
ft2
1.19599
m2
yd2
2.204623
kg
lb
0.001
kg
t (ton)
0.061024
cc
in3
0.061024
ml
in3
0.061024
cm3
in3
61.023744
in3
0.264172
gal
2.204622
kgf
lbf
0.2248089
lbf
3.28084
m/s2
ft/s2
39.37008
m/s2
in/s2
7.233014
kgfm
lbfin
86.79619
kgfm
lbfin
0.7375621
Nm
lbfft
8.850748
Nm
lbfin
Fuel Consumption
Length
Energy
Area
a. 9.806 x (kgf) = (N)

b. 9.806 x (kgfm) = (Nm)
c. {(9/5) x (C)+32} = (F)
{(F)-32} x (5/9) = (C)
Weight
Volume
Forcea
Acceleration
Torqueb
75
5. About the engine

Tightening torque
Tightening Torque of Main Parts
Main Parts
Nominal
(Diameter X Pitch)
Tensile
Strength
Rank
Tightening Torque
Remarks
Main Bearing Cap Bolt
M12x1.5x133
12.9T
1st: 5.5 kgfm 0.28 kgfm

2nd: 90 4
3rd: 90 4
Cylinder Head Bolt
M12x1.25x29
9.8T

2nd: 90 4
3rd: 90 4
M9x1.0x66
10.9T

2nd: 90 4
Crankshaft Pulley Bolt
M14x1.5
10.9T
26 kgfm 1 kgfm
Flywheel Bolt
M12x1.5
10.9T
1st: 7 kgfm 0.35 kgfm

2nd: 45 4
Cylinder Head Cover (Left, Right)
M6x1.0
8.8T
0.8 kgfm 0.05 kgfm
Cylinder Head Cover Bolt
M6x1.0
8.8T
0.8 kgfm 0.05 kgfm
Injector Mounting Bracket Bolt (socket)
M8x1.25
12.9T
4.35 kgfm
0.35
kgfm
Water Temperature Controller Mounting

Spacer Bolt
M8x1.25
8.8T
2.2 kgfm
10%
Generator Bolt
M8x1.25
8.8T
2.2 kgfm
10%
Turbocharger Oil Delivery Screw
M10x1.0
2.0 kgfm
10%
UNF 3/4-16
3.0 kgfm
10%
Turbocharger Mounting Nut
M8x1.25
2.2 kgfm
10%
Coolant Pump Mounting Nut
M8x1.25
2.2 kgfm
10%
Rocker Arm Adjusting Hexagon Nut
M8x1.0
1.5 kgfm
10%
High Pressure Pump Drive Gear Nut
M14x1.5
6.5 kgfm 0.5 kgfm
High Pressure Injection Pump Mounting Nut
M8x1.25
2.2 kgfm
10%
Generator Nut
M8x1.25
2.2 kgfm
10%
Starter Motor Nut
M10x1.5
4.4 kgfm
10%
Turbocharger Oil Delivery Pipe Nut
Union Nut
2.0 kgfm
10%
High Pressure Pipe Nut - High Pressure Pump
Union Nut
3.0 kgfm 0.2 kgfm
Connecting Rod Bolt
Oil Pan Drain Plug
76
5. About the engine
Nominal
(Diameter X Pitch)
Tensile
Strength
Rank
High Pressure Pipe Nut - Common

Rail
Union Nut
3.0 kgfm 0.2 kgfm
High Pressure Pipe Nut - Injector
Union Nut
3.0 kgfm 0.2 kgfm
Main Parts
Note) SM45C -> SCM435/440 2hole, Tightening Torque 2.0kgfm 10%
CAUTION
It is vary in torque according to the engine model
or parts.
77
Tightening Torque
Remarks
5. About the engine

Tightening Torque of General Bolts
Please refer to the following tightening torque for the bolts which are not listed in Tightening Torque of Main Parts.
1. Tightening Torque of General Bolts
Strength Classification
Nominal
Diameter
Pitch
(mm)
3.6
4.6
4.8
5.6
5.8
6.6
6.8
6.9
8.8
10.9
12.9
(4A)
(4D)
(4S)
(5D)
(5S)
(6D)
(6S)
(6G)
(8G)
(10K)
(12K)
54
64
90
106
Elastic Limit Value (kg/mm2)

20
24
32
30
40
36
46
Tightening Torque (kgm)

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
1.4
1.25
1.9
2.1
2.2
3.1
3.8
M8 X 1
0.73
0.8
1.2
1.1
1.5
1.34
2.1
2.3
2.4
3.35
4.1
M10
1.35
1.4
2.2
1.9
2.7
2.35
3.7
4.2
4.4
6.2
7.4
M10 X 1
1.5
1.6
2.5
2.1
3.1
2.8
4.3
4.9
8.4
M12
2.4
2.5
3.7
3.3
4.7
4.2
6.3
7.2
7.5
10.5
12.5
M12 X 1.5
2.55
2.7
3.5
4.6
6.8
7.7
11.2
13.4
M14
3.7
3.9
5.2
7.5
10
11.5
12
17
20
M14 X 1.5
4.1
4.3
6.6
5.7
8.3
7.5
11.1
12.5
13
18.5
22
M16
5.6
11.5
10.5
17.9
18.5
18
26
31
M16 X 1.5
6.2
6.5
9.7
8.6
12.5
11.3
17
19.5
20
28
33
M18
7.8
8.3
12.5
11
16
14.5
21
24.2
25
36
43
M18 X 1.5
9.1
9.5
14.5
12.5
18.5
16.7
24.5
27.5
28
41
49
M20
11.5
12
18
16
22
19
31.5
35
36
51
60
M20 X 1.5
12.8
13.5
20.5
18
25
22.5
35
39.5
41
58
68
M22
15.5
16
24.5
21
30
26
42
46
49
67
75
17
18.5
28
24
34
29
47
52
56
75
85
20.5
21.5
33
27
40
34
55
58
63
82
92
23
25
37
31
45
38
61
67
74
93
103
M22 X 1.5
M24
M24 X 1.5
Note) The standard torque values above are about 70% of the bolt elastic limit values.
Note) The tensile force has been calculated by multiplying the tensile strength with the screw cross-sectional area.
Note) A special screw should be tightened with 85% of the tightening torque of the standard value. For example, a
MoS2-coated screw should be tightened with 60% of the tightening torque of the standard value.
78
5. About the engine

2. Tightening Torque of Key General Bolts
Strength Classification
Nominal
Diameter X Pitch
(mm)
8.8T
10.9T
8.8T
Remarks
Tightening Torque (kgfm) 10 %
M6 X 1.0
1.25
1.5
M8 X 1.25
2.2
3.1
3.8
M8 X 1.0
2.4
3.35
4.1
M10 X 1.5
4.4
6.2
7.4
M10 X 1.0
8.4
M12 X 1.75
7.5
10.5
12.5
M12 X 1.5
11.2
13.4
M14 X 1.5
13
18.5
22
Tightening torque of plug screw

M10
M12
M14
M16
M18
M22
M24
M26
M30
5.0
5.0
8.0
8.0
10.0
10.0
12.0
12.0
15.0
Hollow Screw (4-Hole) Tightening Torque

Material
Classification
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
SUM22La
0.8
1.8
3.0
4.0
5.5
6.5
11.0
16.0
20.0
35.0
STS304
0.8
1.8
3.0
4.0
5.5
6.5
11.0
16.0
20.0
35.0
a. Applied to Doosan Engines
79
5. About the engine

Special tool
Special Tools
Figure
Figure
Product Number/Name
Product Number/Name
TB1217H
587
Blue
LOCTITE 272
LOCTITE
LOCTITE
EF.120-208
Piston insertion tool
09-0666
LOCTITE BLUE 587
860104-02041
Valve Stem Seal Jig
EF. 120-262
Valve Spring
Compression Tool
860104-02047
Front Oil Seal
Disassembly Jig
T7621010E
Piston Ring Plier
860104-02048
Rear Oil Seal
Disassembly Jig
860104-02052
Wrench, Oil Filter
850306-00078
Oil seal disassembly jig
860104-01045
G2 Diagnostic Tool
80
5. About the engine

Engine disassembly
Procedure of Disassembling an Engine
DANGER
(Only LEL00/LEL01/LEL02/LEL03/LEL04)
CAUTION
Before disassembly, prepare tools and genuine
is overheated. If you open the surge tank cap
parts as required.
Prepare a shelf for the storage of removed parts.
Perform repairs in a light and clean space.
Keep hands clean while performing repairs.
Keep parts removed from the engine in the order
while the engine is still hot, you may burn yourself with steam or hot coolant. Make sure that the
engine has fully cooled before opening the surge
tank cap.
of disassembly.
Do not open the surge tank cap while the engine
Keep the coolant container separately from

beverage containers to avoid confusion, marking
Do not allow parts removed from the engine to
on it. If you drink coolant, call your doctor or
touch each other or be mixed with other parts.
emergency medical personnel immediately.
Disassemble the engine in the following order.

1. Drain coolant.
WARNING
1) Check if the engine and the radiator have been propDiscard coolant according to the regulations set
erly cooled.
2) Place a container in front of the coolant drain plug.
forth by the relevant authorities. Disposing of
3) Remove the radiator cap (Only
discharged coolant into the ground, sewers, drains,
LEF00/LEF01/LEF02/LEF03).
rivers, or the sea will cause serious environmental

pollution. Violation of regulations when discarding
4) Remove the surge tank cap (Only
engine oil without observing the handling regula-
tions, will be punished.
5) Unplug the coolant drain plug of the radiator and then

drain coolant.
6) After draining the coolant, connect the coolant drain
CAUTION
plug again.
DANGER
(Only LEF00/LEF01/LEF02/LEF03)
2. Drain the engine oil.
Do not open the radiator cap while the engine is
overheated. If you open the radiator cap while the
DL03-LEF00/01
engine is still hot, you may burn yourself with

steam or hot coolant. Make sure that the engine
has fully cooled before opening the radiator cap.

B
EDL032160E
81
5. About the engine

5. Disconnect cables and harnesses running to the
engine sensors.
DL03-LEF02/03
6. Remove the V-belt (Only LEF00/LEF01/LEF02/LEF03).

DL03-LEF00/01
B
EDL032160F
DL03-LEL00/01/02/
03/04
EDL032810C
DL03-LEF02/03
B
EDL032160G

engine oil.
EDL032811B
1) Adjust eye bolts(B) to provide a clearance between
V-belt and bolts.
4) Remove the engine oil filter.
2) Remove the V-belt (A).
5) When engine oil discharging is complete, reassemble
Note) For checking and measuring the belt tension, refer
the engine oil filter and the drain plug.
to Belt Tension in (Others/Driving Units).

7. Remove the generator.
CAUTION
1) Loosen the mounting bolts and nuts of the generator.

2) Remove the generator.

to the land, sewers, drains, rivers, or the sea will
noncompliance with the handling regulations will be
punished.
3. Remove the air cooler and cooling fan from the
engine.
4. Remove the engine from the machine.
82
5. About the engine

10. Detach the oil level gauge.
8. Disconnect the breather hose.
DL03-LEF00/01
A
A
EDL032558C
EDL032556C
1) With the clamps on the quick connector and T/C side
DL03-LEF02/03
of the air inlet pipe pressed, disconnect the breather

hose(A).
Note) It is not necessary to disconnect the clamp on

quick connector side of hose.
9. Remove the starter motor (Only
EDL032556D
DL03-LEL00/01/02/
03/04
B
B
EDL032557A
1) Loosen the flange nut (B).

2) Detach the starter (A).
EDL032556E
1) Remove the oil level gauge (A).

2) Loosen the flange hexagon bolt (C) that fixes the oil
level gauge guide tube.
3) Remove the oil level gauge guide tube (B) from the
cylinder block.
4) Remove O-rings (D).
83
5. About the engine

11. Remove the air heater.
12. Remove the front lifting hook.

DL03-LEF00/01
02/03
DL03-LEF00/01
C
B
EDL032055C
E
C
EDL032554B
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
EDL032555D
EDL032554C
1) Loosen the flange hex bolt (E) that fixes the boost
DL03-LEL00/01/02/
03/04
pressure sensor.
2) Remove the boost pressure sensor (D).
3) Loosen the flange hex bolts (B).
4) Remove the air heater (A).

5) Remove the gasket (C).
CAUTION
Replace the gasket with a new one; do not reuse it.
EDL032554D
1) Unscrew the flange hex bolts (B).

2) Remove the front lifting hook (A).
84
5. About the engine

13. Remove the rear lifting hook.
DL03-LEL00/01/02/
03/04
B
C
B
EDL032552E
EDL032553B
1) With the clamps on both sides of the coolant hose
pressed, disconnect coolant hoses (B).
2) Remove the rear lifting hook (A).
2) Unscrew the flange hex bolts (C).
14. Disconnect the coolant pipe and hose.
3) Disconnect the coolant pump (A).

15. Disassemble the generator mounting stand. (DL03-
DL03-LEF00/01
LEF00/LEF01)
DL03-LEF00/01
D
A
G
C
B
EDL032552C
DL03-LEF02/03
EDL032551D
1) Loosen the flange hex bolts (E, F) that fix idle pulley
bracket.
2) Remove the idle pulley bracket (A).
3) Loosen the flange hex bolt (D) that fixes the eye bolt
assembly.
4) Disassemble the eye bolt assembly (B).
5) Loosen the flange hex bolts (G) that hold the generator bracket.
6) Remove the generator bracket (C).
EDL032552D
85
5. About the engine

16. Disassemble the generator bracket
(DL03-LEF02/LEF03)
DL03-LEF02/03
DL03-LEF02/03
C
B
A
D
F
E
EDL032050D
DL03-LEL00/01/02/
03/04
EDL032551E
1) Loosen the flange hex bolt (E) that holds the eye bolt
assembly.
2) Disassemble the eye bolt assembly (B).

3) Loosen the flange hex bolts (F) that fix the upper
generator bracket.
4) Remove the upper generator bracket (C).

5) Loosen the flange hex bolt (D, F, G) that fixes the
lower generator bracket.

6) Remove the lower generator bracket (A).
17. Remove the intake stake.
F
DL03-LEF00/01
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).

3) Remove the EGR pipe gaskets (D).
4) Loosen the flange hex bolts (C) that fix the intake
stake.
5) Remove the intake stake (A).

6) Remove the gasket (B).
D
E
CAUTION
F
EDL032050C
86
5. About the engine

18. Disassemble the oil filter assembly.
2) Disassemble the oil filter assembly (A).

DL03-LEF00/01
CAUTION
Be careful not to damage the O-rings during
Because oil may flow out of the filter when
disassembly.
removing the oil filter assembly, pay attention not
to contaminate adjacent parts, using a rag or
cloth and, after the replacement, wipe oil stains
off all affected areas.
19. Disconnect the fuel injection pipe.
B
EDL032549B
DL03-LEF02/03
EDL032548B
1) Loosen the flange hex bolt (B).

2) Loosen nuts on both sides of the fuel injection pipes
EDL032549C
and remove the fuel injection pipes (A).
DL03-LEL00/01/02/
03/04
CAUTION
Do not bend the fuel injection pipes by force.
20. Disconnect the fuel return hose.
B
EDL032549D
EDL032547C
87
5. About the engine

1) With the clamps pressed, disconnect the fuel return
23. Remove the knock sensors, and the oil pressure and
hoses of common rail, injectors, and fuel injection
temperature sensor.
pumps.
2) Disconnect the fuel return hoses (A).
21. Remove the common rail.
D
EDL032544A

2) Remove the knock sensors (A).
EDL032546A
3) Loosen the hex bolts (D).
4) Remove the oil pressure and temperature sensor (C).
2) Remove the common rail (A) from the intake manifold.
24. Remove the turbocharger.
CAUTION
I
J
Take extra care not to damage the common rail
during disassembly.
D
22. Remove the intake manifold.
J
I
F
B
A
EDL032043C
1) Loosen the hollow screws (I) on both sides of the oil

delivery pipe.
2) Remove the oil delivery pipe (H) and the copper
washers (J).
D
C
CAUTION
EDL032045A
1) Remove the intake temperature sensor (D).
Replace the copper washers with new ones; do not
2) Remove the flange hex bolts (C).
reuse them.
3) Remove the intake manifold (A).

4) Remove the intake manifold gasket (B).
3) With the clamps pressed, disconnect the oil return

hose (G).
CAUTION

5) Remove the turbocharger (A).
88
5. About the engine

7) Loosen the hex bolts (F).
8) Remove the oil return pipe (E) and the gasket (D).
DL03-LEL00/01/02/
03/04
CAUTION

25. Remove the thermostat.
EDL032541C
C
2) Remove the coolant pump pulley (A).
27. Remove the coolant pump.
EDL032542C
1) Remove the temperature sensor (E) of the water

temperature controller.
2) With the clamps pressed, disconnect the rubber hose
(D).
3) Remove the spacer bolt (B).
4) Loosen the flange hex bolts (C).
5) Remove the thermostat(A).
26. Remove the coolant pump pulley.
EDL032540B
DL03-LEF00/01
02/03
1) With the clamps pressed, disconnect the hose running

to the EGR cooler assembly.
2) Unscrew the hex bolts (B).
3) Remove the coolant pump (A).
EDL032541B
89
5. About the engine

28. Disconnect the EGR pipe and hose.
30. Remove the exhaust manifold.

DL03-LEF00/01
02/03
B
A
B
B
A
EDL032039D
EDL032535D
1) With the clamps on both sides of the hose pressed,
DL03-LEL00/01/02/
03/04
disconnect the hoses (D).

2) Loosen the flange hex bolts (C, E).
3) Disconnect the EGR pipes (A).

4) Remove the gaskets (B, F).
CAUTION
Take extra care not to mix gaskets.
Take care not to mix flange hex bolts. If flange
hex bolts are installed into the wrong parts, EGR
pipes can become dislocated or damaged.
Replace the gaskets with new ones; do not reuse

them.
EDL032535E
1) Loosen the camshaft speed sensor mounting bolt (E).

29. Disassemble the EGR cooler assembly.
2) Remove the camshaft speed sensor (D).

3) Remove the exhaust gas temperature sensor (C).
5) Remove the exhaust manifold (A).
CAUTION
Replace the exhaust manifold gasket with a new

one; do not reuse it.
C
EDL032537E
1) Loosen the hex bolts (B) that fix the EGR cooler
bracket.
3) Disassemble the EGR cooler assembly (A).
4) With the clamp pressed, disconnect the hose (D).
90
5. About the engine

31. Remove the heat screen.
33. Remove the V-belt pulley (Only

LEF00/LEF01/LEF02/LEF03) .
DL03-LEF00/01
02/03
B
C
A
EDL032536C
EDL032533C

2) Loosen the mounting bolts (C) and remove the heat
2) Remove the V-belt pulley (A).
screen (A).
34. Remove the fan mounting bracket (Only
32. Remove the exhaust manifold gasket.
DL03-LEF00/01
02/03
B
EDL032534C
EDL032532B
1) Loosen the mounting bolts (B).

2) Remove the exhaust manifold gasket (A).
2) Remove the fan mounting bracket (A).
CAUTION
91
5. About the engine

35. Remove the right cylinder head cover.
4) Remove the injector sealing washer (D).

Note) Remove the cylinder head cover and then the
injector sealing washer.
CAUTION
A
B
Be careful not to damage the injectors during
Be careful not to lose the washers while
disassembly.
removing the injectors.
37. Remove the cylinder head cover.
EDL032531B
EDL032529D
EDL032031C
1) Unscrew the flange hex bolts (B) from outside toward

inside and in the arrow direction.
2) Remove the right cylinder head cover (A).
36. Remove the injectors.
A
EDL032529C
2) Remove the cylinder head cover (A).
EDL032530A

2) Remove the injector mounting brackets (C).
3) Remove the injectors (A).
92
5. About the engine

38. Remove the rocker arm.
1) Unscrew the cylinder head bolts (A) from outside

toward the inside and in a counterclockwise direction.
CAUTION
Make sure the cylinder head bolts must be

unscrewed counterclockwise.
Do not reuse the cylinder head bolts.
Do not apply engine oil to the cylinder head

bolts.
41. Detach the cylinder head.
A
EDL032528A

2) Remove the rocker arm (A).
39. Remove the push rods.
EDL032525A
1) Detach the cylinder head (A).

2) Detach the cylinder head gasket (B).
CAUTION
Replace the cylinder head gasket with a new one;
EDL032027A
do not reuse it.
1) Remove the push rods (A) from the cylinder head

hole.
42. Remove the valve spring.
40. Remove the cylinder head bolts.
E
D
B
A
EDL032024A
EDL032526A
1) Remove the calipers (E).
93
5. About the engine

2) Remove the valve cotters (D).
45. Remove the flywheel (Only
3) Compress the valve spring (A) using valve spring
compression tools (C).

DL03-LEF00/01
4) Remove the valve spring retainers (B).

5) Remove the valve springs (A).
43. Remove the valve.
B
B
EDL032021C
DL03-LEF02/03
EDL032523A
1) Remove the valve springs (A).

2) Remove the valve stem seals (A).
44. Remove the crankshaft pulley
EDL032708C

2) Remove the flywheel (A).
CAUTION
Replace the flywheel bolts with new ones; do not

reuse them.
EDL032022B
1) Loosen the flange hex bolts (D).

2) Remove the crankshaft pulley (C).
3) Loosen the collared hex bolts (B).
4) Remove the crankshaft pulley (A).
94
5. About the engine

47. Remove the flywheel housing.
46. Remove the rear oil seal.

DL03-LEF00/01
02/03
DL03-LEF00/01
02/03
A
B
EDL032520B
EDL032519C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
A
B
A
EDL032520D
EDL032520C
1) Detach the rear oil seal (A) from the flywheel housing,
using an oil seal disassembly jig.
2) Remove the flywheel housing (A).

48. Remove the oil pan.
CAUTION
B
Do not reuse the oil seal; replace it with a new one.
EDL032518C

inside and counterclockwise.
2) Remove the oil pan (A).
95
5. About the engine

49. Disconnect the oil suction pipe and the oil delivery
1) Loosen the connecting rod bolts (E).
pipe.
CAUTION
E
Do not reuse connecting rod bolts; replace them
with new ones.
B
D
2) Remove the connecting rod cap (D).

3) Detach the connecting rod (C) from the cylinder block.
B
F
CAUTION
Be careful not to damage the piston and piston
rings.
4) Detach the lower connecting rod bearing (B) from the
connecting rod cap (D).
EDL032517B
5) Detach the upper connecting rod bearing (A) from the
connecting rod (C).
2) Remove the oil suction pipe (A) and the O-ring (C).
CAUTION
CAUTION
Be careful not to mix disconnected connecting rods,

Be careful not to damage the O-ring during disas-
connecting rod caps, and removed connecting rod
sembly.
bolts as they are set aside.
51. Remove the piston.
4) Remove the oil delivery pipe (D) and O-rings (F).
CAUTION
Be careful not to damage the O-rings during disas-
sembly.
50. Remove the connecting rod.
D
E
EDL032015A
1) Remove the snap rings (E) on both side of the piston.

2) Remove the piston pin (D).
EDL032016B
96
5. About the engine

3) Detach the piston (A) from the connecting rod
54. Remove the oil pump.
small-end (C).
CAUTION
Take care to keep the piston and the bumpy (B)

side of the connecting rod facing the same direc-
tion.
Take care not to mix connecting rods, pistons,

piston pins, and snap rings.
52. Remove the fuel injection pump.
B
EDL032512B
2) Remove the oil pump (A).
CAUTION
Be careful not to damage the O-ring during disassembly.
A
55. Remove the front oil seal.
B
EDL032514B

2) Remove the fuel injection pump (A).
53. Remove the idle gear.
EDL032511B
1) Detach the front oil seal (A) from the front oil seal
holder (B), using an oil seal disassembly jig.
CAUTION
EDL032513C

2) Remove the idle gear shaft (B).
3) Remove the idle gear (A), using its pulling tap (D).
97
5. About the engine

56. Remove the front oil seal holder.
1) Remove the key (B).

2) Remove the timing wheel (A).
CAUTION
Be careful not to damage the teeth of the timing
wheel.
59. Remove the main bearing cap bolts.
B
EDL032510C
2) Remove the front oil seal holder (A), using a driver

for the groove (C).
57. Remove the crank speed sensor.
EDL032507A

the inside and in a counterclockwise direction.
2) Unscrew the main bearing cap bolts (A) from outside
toward inward and counterclockwise.
CAUTION
When removing collared hex bolts and main

bearing cap bolts, do not unscrew them at a time
but little by little for several times.
EDL032509B
Remove the collared hex bolts and then the main
Replace the main bearing cap bolts with new
1) Unscrew the hex bolt (B).
bearing cap bolts.
2) Remove the crank speed sensor (A).

58. Remove the timing wheel.
ones; do not reuse them.
EDL032508C
98
5. About the engine

60. Remove the crank case.
62. Remove the crankshaft.
A
C
B
EDL032506B
EDL032004A
1) Detach the crank case (A) from the cylinder block.
1) Detach the crankshaft (A) from the cylinder block.
61. Remove the lower main bearing.
2) Detach the thrust bearings (C) from the cylinder block.

3) Detach the upper main bearings (B) from the cylinder
block.
CAUTION
There is a groove in the upper main bearing, but not
in the lower main bearing.
63. Detach the camshaft.
EDL032005B
1) Detach the lower main bearings (A) from the crank

case.
CAUTION
There is a groove in the upper main bearing, but not
in the lower main bearing.
B
EDL032003A

2) Remove the camshaft (A).
99
5. About the engine

64. Remove the valve tappets.
EDL032002A
1) Detach the valve tappets (A) from the cylinder block.

65. Remove the oil spray nozzles.
B
A
EDL032001A
1) Remove the relief valves (B).

2) Remove the oil spray nozzles (A).
100
5. About the engine

Engine assembly
Procedure of Assembling Engine
2. Attach the valve tappet.
CAUTION
Thoroughly clean all removed parts, particularly

those involving oil and coolant passage with
compressed air, and check if any part is exposed
to resistance.
Keep general tools and special tools for engine

assembly in order.
Prepare clean engine oil for each sliding part.
Prepare maintenance materials including sealant
Replace used gaskets, seal rings, and other
and gaskets.
EDL032002A
consumable parts with new ones.
1) Apply engine oil to the surfaces of the cylinder block
Each bolt should be tightened to the specified

tightening torque in the order of tightening;
and valve tappet assembly.
however, excessive tightening of the torque
2) Connect the valve tappets (A).
should be avoided.
3. Attach the camshaft.
Ensure that all engine parts function properly
Check if there is any bolt loosen after the first
Always keep your hands clean during assembly.
after reassembly.
assembly.
Assemble the engine in the following order.

1. Assemble the oil spray nozzles.
B
B
EDL032003A
1) Apply engine oil to the cam hole of the cylinder block.

2) Apply engine oil to the camshaft (A) journal.
CAUTION
Ensure that the camshaft journal and the inside of
the cylinder block bush are normal.
EDL032001A
3) Align the thrust washers of the camshaft and the
1) Assemble the oil spray nozzles (A), matching pins.
cylinder block.
2) Tighten the relief valves (B) to a tightening torque of
4) Temporarily fasten 1 hex bolt and then rotate the
2.0 kgfm.
camshaft gear to tighten the rest hex bolts.

5) Tighten the hex bolts (B) to a tightening torque of 2.2
kgfm.
6) The camshaft end play is 0.1 ~ 0.2 mm.
101
5. About the engine

4) Install 2 thrust washers (C) to the front and rear of
Item
Specified Value
Camshaft end play
0.1 ~ 0.2 mm
the 2nd crankshaft main journal diameter at the rear

of the engine.
4. Install the crankshaft.
CAUTION
Align the key groove of the cylinder block with the
key of the thrust washer.
Note) Main bearings are available in the following grades.
A
Inside diameter of
the cylinder block
main bearing
bore
C
B
EDL032004A
Crankshaft main journal diameter

Grade A
Grade B
Grade C
Grade A
YELLOW
BLUE
BLUE
Grade B
YELLOW
YELLOW
BLUE
Grade C
RED
RED
YELLOW
1) Install the upper main bearings (B) to the cylinder

block.
CAUTION
Remove foreign substances such as residues and

LOCTITE from the outside of the main bearings
79.000 ~ 79.007 mm
Grade B
79.007 ~ 79.014 mm
Grade C
79.014 ~ 79.021 mm
the cylinder block main bearing bore, refer to
Do not apply engine oil on the surface where the
Chapter Cylinder Block/Head.
cylinder block and the main bearings are assembled.
Grade A
Note) For the method to measure the inside diameter of
and oil seal assembly bore.
Specified Value
There is a groove in the upper main bearing, but

not in the lower main bearing.
Cylinder Block Inside

diameter of main bearing
bore
The grade of the main bearing bore inside diameter of the cylinder block is imprinted on the
cylinder block and that of the main journal diameter of the crankshaft on the crankshaft. For the
engraving positions, see the Engine Unique
Crankshaft Main Journal

Diameter
Specified Value
Grade A
74.955 ~ 74.960 mm
Grade B
74.960 ~ 74.965 mm
Grade C
74.965 ~ 74.970 mm
Number of Chapter 3 (Performance and SpecificaNote) For the method to measure the crankshaft main
tions).
Select the proper main bearing grade by checking
journal diameter, refer to Chapter Others/Driving
or measuring the grade of main bearing bore
Units.
inside diameter of the cylinder block and the

grade of main journal diameter of the crankshaft.
The main bearings are color-coded according

their thickness. Use upper and lower main bearings in the same color code.
2) Lubricant the assembly surfaces of the upper main

bearing and the crankshaft with sufficient engine oil.
3) Install the crankshaft (A).
102
Thickness of Main Bearing
Specified Value
BLUE
1.995 ~ 2.000 mm
YELLOW
2.000 ~ 2.005 mm
RED
2.005 ~ 2.010 mm
5. About the engine

5. Install the lower main bearing.
6. Install the crank case.
A
EDL032005B
EDL032006B
1) Install the lower main bearings (A) to the crank case.
1) Apply Loctite 5902 to the crank case assembly

surface (A), with a diameter of 3 0.5 mm for the
CAUTION
engine front (B) and a diameter of 6 0.5 mm for

the engine rear (C).
There is a groove in the upper main bearing, but
2) Install the crank case to the cylinder block.
not in the lower main bearing.
Do not apply engine oil on the surface where the
CAUTION
cylinder block and the main bearings are assembled.
Ensure that the cylinder block and the crank case
Attach parts within five minutes after applying
Do not start the engine or load pressure for 25
The grade of the main bearing bore inside diam-
are facing the right direction.
eter of the cylinder block is imprinted on the

cylinder block and that of the main journal diam-
LOCTITE onto the parts.
eter of the crankshaft on the crankshaft. For the

engraving positions, see the Engine Unique
minutes after applying LOCTITE to engine parts.
Number of Chapter 3 (Performance and Specifications).
7. Tighten the main bearing cap bolts.
Select the proper main bearing grade by checking

or measuring the grade of main bearing bore
inside diameter of the cylinder block and the

grade of main journal diameter of the crankshaft.
The main bearing are color-coded according their

thickness. Use upper and lower main bearings in
the same color code.
A
2) Lubricant the assembly surface of the crankshaft and
the lower main bearings with sufficient engine oil.
EDL032007A
1) Temporarily tighten the main bearing cap bolts (A)

from inside toward outside and clockwise.
2) Tighten the main bearing cap bolts (A) from inside
toward outside and clockwise, to a torque of 5.5 kgfm
+ 90 + 90 using the angle method.
103
5. About the engine

2) Install the key (B).
Main Bearing Cap Bolt Angle Method
1st Stage
Tightening Torque 5.5

kgfm
2nd Stage
90 Rotation
3rd Stage
CAUTION
Install the timing wheel with its non-toothed
wheel.
90 Rotation
surface facing 7 oclock at the front.
CAUTION
9. Install the crank speed sensor.
Make sure the main bearing cap bolts are tightened with the angle method.
Fasten the main bearing cap bolts and then

collared hex bolts.
Replace the main bearing cap bolts with new

ones; do not reuse them.
3) Temporarily fasten the collared hex bolts (B) in a

clockwise direction.
4) Tighten the collared hex bolts (B) clockwise to a tight-
ening torque of 2.2 kgfm.
CAUTION
EDL032009A
Tighten the main bearing cap bolts and collared hex
1) Install the crank speed sensor (A).
bolts, and turn the crankshaft 2-3 times to check if
2) Tighten the hex bolt (B).
it rotates smoothly.
10. Install the front oil seal.
5) The camshaft end play is 0.1 ~ 0.31 mm.

Item
Specified Value
Crankshaft End Play
0.1 ~ 0.31 mm
8. Install the timing wheel.
B
EDL032010B
1) Place the front oil seal holder (B) with its assembly
surface facing down.
2) Insert the front oil seal (A) to the front oil seal
assembly jig (C).

3) Align the front oil seal assembly jig (C) with the oil
seal (A) to the front oil seal holder (B) and press the
EDL032008C
front oil seals (A) by tapping with a rubber hammer.
1) Align the timing wheel (A) with the dowel pin and
attach it to the crankshaft surface.
104
5. About the engine

4) When the front oil seal (A) is inserted into the front
3) Align and install the front oil seal holder (A) with
oil seal holder (B), pull out the front oil seal assembly
dowel pins (C).
jig.
4) Tighten the flange hex bolts (B) to a tightening torque

of 2.2 kgfm.
CAUTION
12. Install the oil pump.
Care should be taken to the assembly surfaces
Care should be taken to the depth of the oil seal
Be careful not to damage the oil seal.
Attach the oil seal without applying lubrication,
so that the oil seal surface is facing outward.

assembly.
coolant, fuel, LOCTITE, or silicon.

LOCTITE from the oil seal assembly bore.
Do not reuse the oil seal; replace it with a new
one.
Be careful not to damage the oil seal when

attaching it.
EDL032012B
1) Align O-rings with the engine oil inlet and outlet.
11. Install the front oil seal holder.
2) Align the oil pump (A) with the pin and press it as
deeply into the cylinder block as possible.

kgfm.
4) The backlash between crankshaft gear and oil pump
gear is 0.066 ~ 0.247 mm.
Item
Backlash Between Crankshaft Gear and Oil Pump
Gear
Specified Value
0.066 ~ 0.247 mm
CAUTION
EDL032011B
1) Clean debris off the assembly surface of the front oil

seal holder with a dry cloth.
the assembly surface of the front oil seal holder.
CAUTION
Ensure that the front oil seal hold is facing the
right direction.

Make sure that the O-rings have been mounted.

assembly.
2) Apply Loctite 5902 in a diameter of 2.5 0.5 mm to

105
5. About the engine

13. Install the idle gear.
Item
Backlash Between Idle
Gear and Crank Shaft
Gear
Specified Value
0.087 ~ 0.202 mm
8) The backlash between idle gear and camshaft gear is

0.087 ~ 0.213 mm.
Item
Gear and Camshaft Gear
Specified Value
0.087 ~ 0.213 mm
14. Install the fuel injection pump.
EDL032013B
1) Align the imprinted marks of the idle gear and the

camshaft.
CAUTION
The idle gear and the camshaft gear have 2 marks
imprinted on them.
2) Place the mark of the crankshaft gear between the
two marks of the idle gear.
CAUTION
EDL032014B
1) If the gear mark is visible, place the idle gear mark
The idle gear has 4 marks imprinted on it.
With the key groove of the crankshaft gear at 12
between the marks of the fuel injection pump drive

gear. But if not visible, install the fuel injection pump
oclock, the crankshaft has one mark imprinted at
regardless of the position of gear mark.
the clockwise 4th tooth.
Note) The fuel injection pump drive gear has 2 marks

imprinted on it, while the idle gear has 1 mark.
3) Install the idle gear (A), aligning its marks.
2) Align and install the fuel injection pump (A) with stud
bolts.
CAUTION

of 2.2 kgmm.
Install the idle gear with it marks facing outward
4) The backlash between the fuel injection pump drive
from the engine.
gear and the idle gear is 0.081 ~ 0.196 mm.

4) Install the idle gear shaft with its oil hole facing
Item
Specified Value
Backlash Between Fuel

Injection Pump Drive Gear
and Idle Gear
0.081 ~ 0.196 mm
upward.
5) Temporarily install the flange hex bolts (B), aligning
with the holes of the ilde gear shaft.
of 4.4 kgfm.
7) The backlash between idle gear and crankshaft gear
is 0.087 ~ 0.202 mm.
106
5. About the engine

15. Install the piston.
Note) The piston grade is imprinted on the top surface of

the piston.
CAUTION
The grade of the inside diameter of the cylinder

block piston bore is imprinted on the cylinder
block and that of the piston on the top surface

of the piston. For the engraving positions, see
the Engine Unique Number of Chapter 3 (Performance and Specifications).
Ensure that the cylinder block piston bore inside

diameter and the piston are of the same grade.
3) Apply engine oil to the piston pin (D) before assembly.
EDL032015A
4) Install, to both sides of the piston, snap rings (E) with
1) Note that the piston and the bumpy side (B) of the
their openings facing 12 o'clock.
connecting rod should be facing the same direction.
CAUTION
CAUTION
Replace the snap rings with new ones; do not reuse
Ensure that the piston and the connecting rod are
them.
facing the right direction.
Note that the piston and the bumpy side of the

16. Install the connecting rod.
connecting rod should be facing the same direction, toward the front of the cylinder block.
2) Install the piston (A) to the connecting rod smallend
(C).
Note) Cylinder block and pistons are available in the
following grades.
E
Piston
Inside Diameter of Cylinder Block Piston Bore
Grade A
Grade B
Grade A
Grade B
A
B
EDL032016A
Inside Diameter of Cylinder

Block Piston Bore
Specified Value
1) Install the upper connecting rod bearing (A) to the
Grade A
97.990 ~ 98.000 mm
2) Install the lower connecting rod bearing (B) to the
Grade B
98.000 ~ 98.010 mm
connecting rod (C).

connecting rod cap (D).
Note) For the method of measuring the inside diameter
CAUTION
of cylinder block piston bores, see Chapter Cylinder

Block/Head.
Use both upper and lower connecting rod bear-
Do not apply engine oil to assembly surfaces of
ings of a yellow mark.

Piston
Specified Value
Grade A
97.920 ~ 97.930 mm
Grade B
97.930 ~ 97.940 mm
the connecting rods and the bearings.
107
5. About the engine

Note) The thickness of the connecting rod bearing is as
17. Install the oil suction pipe.
follows.
E
Thickness of Connecting Rod Bearing
Specified Value
YELLOW
1.497 ~ 1.502 mm
A
B
D
3) Lubricant the insides of the cylinder block bore and
the connecting rod bearing with sufficient engine oil.

4) Use a piston insertion tool to install the piston and
the connecting rod to the cylinder block.
CAUTION
Ensure that the piston and the bumpy side of the

connecting rod are facing the front of the engine.
EDL032517B
The front of the engine is the side where the

crankshaft pulley is positioned.
1) Install the O-rings (F).
Be careful not to damage the piston and piston
CAUTION
rings.
5) Install the connecting rod cap.
Check if the O-rings have been properly installed.

assembly.
CAUTION
Ensure that the connecting rod and the
2) Connect the oil delivery pipe (D).
connecting rod cap are facing the right direction.
3) Tighten the flange hex bolts (E).
Ensure that the connecting rod and the
4) Install the O-ring (C).
connecting rod cap have the same number
5) Connect the oil suction pipe (A).
imprinted on them and are facing the same direc-
tion.
kfgm.
CAUTION
6) Temporarily tighten the connecting rod bolts (E) by

hand.
7) Tighten the connecting rod bolts (E) to a torque of
3.0 kgfm + 90 using the angle method.

assembly.
Connecting Rod Bolt Angle Method

1st Stage

kgfm
2nd Stage
90 Rotation
108
5. About the engine

18. Install the oil pan.
DL03-LEL00/01/02/
03/04
A
B
EDL032520C
EDL032518D
1) Apply Loctite 5902 in a diameter of 3 0.5 mm to
the assembly surface of the flywheel housing.
the assembly surface of the oil pan.
CAUTION
CAUTION
Ensure that the flywheel housing is facing the

right direction.
tion.
Ensure that the oil pan is facing the right direc-

2) Attach the flywheel housing (A).
2) Attach the oil pan (A).
3) Temporarily tighten the flange hex bolts (B) from
kgfm.
inside toward outside and clockwise.
20. Install the rear oil seal.

insdie toward outside and clockwise, to a tightening
torque of 2.2 kgfm.
19. Install the flywheel housing.
DL03-LEF00/01
02/03
D
EDL032020B
1) Install the rear oil seal (A) to the rear oil seal
assembly jig guide (B).

2) Install the rear oil seal assembly jig guide (B) to the
EDL032519C
crankshaft (D).
109
5. About the engine

3) Install the rear oil seal assembly jig holder (C) to the
22. Install the crankshaft pulley.
rear oil seal assembly jig guide (B).

4) Tighten the bolt at the center of the oil seal insertion
jig holder until the real oil assembly jig holder reaches
the flywheel housing and press the rear oil seal (A).
21. Install the flywheel (Only LEF00/LEF01/LEF02/LEF03).

DL03-LEF00/01
C
B
EDL032022B
1) Align and install the crankshaft pulley (A) with the key.
2) Apply Loctite Ultra Blue 587 to the insdie of the flange
hex bolt (B).
3) Tighten the flange hex bolt (B) to a tightening torqueof
EDL032021C
26 kgfm.
4) Connect the crankshaft pulley (A) and (C).
DL03-LEF02/03
5) Tighten the collared hex bolts (D) to a tightening

torque of 2.2 kgfm.
CAUTION
B
Fix the crankshaft to allow the flange hex bolts

to be tightened with the specified torque.
23. Mount the valve.
EDL032708C
1) Install the flywheel (A).

2) Temporarily tighten the flange hex bolts (B).

of 7 kgfm + 45 using the angle method.
Flywheel Flange Hex Bolt Angle Method
1st Stage
2nd Stage

kgfm
45 Rotation
EDL032023A
CAUTION
Do no reuse the flange hex bolts when assembling
the flywheel.
110
5. About the engine

1) Align the valve stem seal jig (C) to the valve stem
25. Attach the cylinder head.
seal (B) and press the valve stem seals (B) by

tapping with a rubber hammer.
CAUTION
C
Do not give an excessive shock on the valve stem

seals; otherwise, they may be damaged.
B
2) Apply engine oil to the assembly surfaces of the valve
and the valve stem seals.
3) Install the valves (A).
CAUTION
EDL032025A
Be careful to use the right valve without
1) Align and install the cylinder head gasket with pins.
confusing the intake valve with the exhaust valve.
The intake valve has the larger valve head diam-
CAUTION
eter and the exhaust valve has the smaller one.
24. Install the valve springs.
Measure the height of the piston top side and

select the cylinder head gasket of a proper grade
for installation. For measure methods of the step
height of the piston top side, refer to Measure-
ment of the step height of the piston top side in
(Others/Driving Units).
Be careful to mind the direction of assembling

the cylinder head gasket.
Install the gasket with its grade mark (C) facing

upward.
Align the push rod hole, the cylinder head bolt

hole, and the cylinder head gasket hole and
attach the cylinder head.
Replace the cylinder head gasket with a new one;
A cylinder head gasket with 1 hole on its top side
do not reuse it.

EDL032024A
1) Install the valve springs (A).
is graded A, with 2 holes graded B, and with 3
2) Install the valve spring retainer (B).
holes graded C.
3) Compress the valve springs (A), using valve spring

compression tools (C).
Note) The cylinder head gaskets are available in the
4) Install the valve cotters (D).
following grades.
5) Install the calipers (E).

Cylinder Head Gasket Grade
CAUTION
Grade
Odd
Mark Number
After installing the valve cotters, check if they have

been correctly positioned with a plastic hammer.
111
Thickness
Average of step
height of the piston
top side
1ea
0.9T
0.24 ~ 0.33 mm
2ea
1.0T
0.33 ~ 0.43 mm
3ea
1.1T
0.43 ~ 0.52 mm
5. About the engine

26. Install the cylinder head bolts.
27. Install the push rods.
A
A
EDL032526A
EDL032027A
1) Temporarily tighten the cylinder head bolts (A) from
1) Apply engine oil on both ends of the push rods (A).
inside toward outside and clockwise, to a tightening
2) Install the push rods (A) in the cylinder head holes.
torque of 3.5 kgfm.
3) Tap the heads of the push rods 1 - 2 times with a

rubber hammer to be settled in the tappet holes.
2) Tighten the cylinder head bolts (A) from inside toward
28. Install the rocker arm.
outside and clockwise, to a tightening torque of 4.5

kgfm + 90 + 90 using the angle method.
Cylinder Head Bolt Angle Method
1st Stage
Tightening Torque 4.5 kgfm
2nd Stage
90 Rotation
3rd Stage
90 Rotation
CAUTION
The cylinder head bolts must be tightened from

the inside toward the outside and in a clockwise
direction.
EDL032028A
Do not reuse cylinder head bolts.
Do not apply engine oil to the cylinder head
1) Install the rocker arm (A).
bolts.

of 2.2 0.3 kgfm.
112
5. About the engine

29. Install the cylinder head cover.
30. Install the injector.
B
A
EDL032529D
EDL032030A
1) Align and install the injector sealing washer (D) to the

center of the injector hole and mount it.
2) Sufficiently apply engine oil on the cylinder head cover
surface where the injectors contact.
3) Attach the injectors (A).
CAUTION
Slowly turn and install the injector so that the

injector oil seal on the cylinder head cover is not
damaged.
Do not reuse the injector sealing washers. Reuse

of the injector sealing washers may cause critical
damage to the engine due to combustion insta-
EDL032529B
bility.
1) Align the rubber packing and the cylinder head cover

groove to install the cylinder head cover (A).
4) Install the injector mounting bracket (C).
2) Temporarily tighten the hex bolts (B) from inside
5) Temporarily tighten the hex bolt (B) to a tightening
toward outside and in the arrow direction.
torque of 0.3 kgfm.
3) Tighten the hex bolts (B) from inside to outside and

in the arrow direction, to a tightening torque of 0.8
CAUTION
0.05 kgfm.
When hex bolts are not smoothly tightened, do not
CAUTION
force to tighten the bolts. A forced tightening may

cause damage to the cylinder head.
Do not reuse the cylinder head cover rubber seal

and the injector oil seal; replace them with new
ones.
0.35kgfm.
When the oil seal replace, press in fully the oil

seal using the oil seal assembly jig.
113
5. About the engine

31. Install the right cylinder head cover.
32. Install the fan mounting bracket (Only

DL03-LEF00/01
02/03
B
A
A
EDL032031A
EDL032532B
1) Install the fan mounting bracket (A).

of 2.2 kgfm.
33. Install the V-belt pulley (Only
DL03-LEF00/01
02/03
EDL032031B
1) Align the rubber packing and the groove of the right

cylinder head cover to install the right cylinder head
cover (A).
inside toward outside and in the arrow direction.
3) Tighten the flange hex bolts (B) from inside toward
EDL032533C
outside and in the arrow direction, to a tightening
1) Install the V-belt pulley (A).
torque of 0.8 0.05 kgfm.

kgfm.
CAUTION

ones.
Remove foreign substances from the inside of the

quick connector and the RH cover nipple prior to
reassembly.
114
5. About the engine

36. Install the exhaust manifold.
34. Install the exhaust manifold gasket.
DL03-LEF00/01
02/03
C
D
C
EDL032034C
EDL032535D
1) Note that the mark of TOP(C) should be facing
DL03-LEL00/01/02/
03/04
upward.
2) Install the exhaust manifold gasket (A).
CAUTION
Ensure that the gasket is facing the right direction.
Replace the gasket with new one; do not reuse it.
D
3) Temporarily tighten the mounting bolts (B).
35. Install the heat screen.

EDL032535E
1) Install the exhaust manifold (A).
CAUTION
B
C
Be careful not to damage the gasket during
assembly of the exhaust manifold. If the gasket is

damaged, do not reuse it; replace it with a new one.
of 3.1 kgfm.
3) Tighten the exhaust gas temperature sensor (C) to a
tightening torque of 4.5 kgfm.
EDL032536C
1) Install the heat screen (A).
4) Install the camshaft speed sensor (D).
5) Tighten the mounting bolt (E) of the camshaft speed

sensor.
kgfm.
3) Tighten the mounting bolts (C) to a tightening torque
of 2.2 kgfm.
115
5. About the engine

37. Assemble the EGR cooler assembly.
1) Install the gaskets (B, F).
CAUTION
A
Pay attention not to mix gaskets.

them.
Pay attention to prevent gaskets from being

damaged, missing, or duplicated.
2) Connect the EGR pipes (A).

3) 3) Tighten the flange hex bolts (C) to a tightening
torque of 2.2 kgfm.
CAUTION
EDL032537E
1) Assemble the EGR cooler assembly (A).
Pay attention not to mix the flange hex bolts. If
2) Tighten the flange hex bolts (C) to a tightening torque
flange hex bolts are installed into the wrong parts,
of 2.2 kgfm.
EGR pipes can become dislocated or damaged.
CAUTION
4) Tighten the flange hex bolts (E) to a tightening torque

of 3.1 kgfm.
The EGR valve has to be handled with care, because

it is fragile to external impacts.
CAUTION
3) Tighten the mounting hex bolt (B) of the EGR cooler
bracket to a tightening torque of 2.2 kgfm.
4) With the clamp pressed, connect the hose (D).
38. Connect the EGR pipe and hose.

connect the hoses (D).
39. Install the coolant pump.
B
A
B
A
E
D
EDL032039D
EDL032040B
1) Install the coolant pump (A).

2) Temporarily tighten the hex bolts (B) to a tightening
torque of 1.0 kgfm.
116
5. About the engine

41. Install the thermostat.
kgfm.
4) With the clamps pressed, connect the hose running

40. Install the coolant pump pulley.
DL03-LEF00/01
02/03
EDL032542C
1) Install the thermostat (A).
2) Mount the spacer bolt (B) to a tightening torque of

2.2 kgfm.
EDL032541B

of 2.2 kgfm.
DL03-LEL00/01/02/
03/04
4) With the clamps pressed, connect the rubber hose

(D).
5) Install the temperature sensor (E) of the water

42. Install the turbocharger.
I
J
D
B
J
I
F
EDL032541C
1) Install the coolant pump pulley (A).

kgfm.
EDL032043C
1) With the clamp pressed, connect the oil return hose

(G) to the cylinder block.
CAUTION
Replace the clamp with a new one after reuse of 3
times; do not reuse it any more.
117
5. About the engine

2) Align and install the gasket (B) with the stud bolts of
43. Install the knock sensors, and the oil pressure and
the exhaust manifold.
temperature sensor.
CAUTION
Be careful to mind the direction of mounting the
gasket.

them.
3) Connect the gasket (D) and the oil return pipe (E) to
the turbocharger.
CAUTION
EDL032044A
them.
1) Tighten the hex bolts for the knock sensors (A).

2) Tighten the hex bolts for the oil pressure and
4) Tighten the hex bolts (F) to a tightening torque of 1.0
temperature sensor (B).
kgfm.
44. Install the intake manifold.
5) Align and install the turbocharger (A) with the stud

bolts of the exhaust manifold.
of 2.2 kgfm.

(G) to the return pipe (E).
8) Install the copper washers (J) and temporarily tighten
the hollow screws (I) to both sides of the banjo union.
9) Tighten the hollow screws (I) on both ends of the oil
delivery pipe to a tightening torque of 2.0 kgfm.
CAUTION
D
C
Replace oil delivery pipes and copper washers

EDL032045A
with new ones; do not reuse them.
When assembling the oil delivery pipe, ensure
1) Install the gasket (B).
that copper washers are installed as required.
CAUTION
Each side of the banjo union has 2 copper

washers installed, making a total of 4. Dislocation
or noninstallation of copper washers may cause
Ensure that the gasket is facing the right direc-
tion.
oil leaks.
When installing oil delivery pipes, first tighten the
assembly.
hollow screws on the cylinder block and then

those on the turbocharger.
them.
After temporary tightening, hold the oil delivery

pipe by hand and tighten the screws to the spec-
2) Install the intake manifold (A).
ified torque.

of 2.2 kgfm.
4) Fasten the intake temperature sensor (D) to a tightening torque of 3.0 kgfm.
118
5. About the engine

45. Install the common rail.
1) Connect the fuel return hoses (A).
CAUTION
B
Ensure that the fuel return hoses are facing the
Ensure that the injector and the fuel return hoses
Replace the fuel return hoses with new ones; do
right direction.
are properly engaged.
not reuse them. Otherwise, critical damage to the
engine performance may occur.
2) With the clamps pressed, connect the fuel return
pumps.
EDL032046A
47. Connect the fuel injection pipes.
1) Install the common rail (A) to the intake manifold.
CAUTION
Ensure that the common rail is facing the right
direction.

during assembly.
Take care to keep the fuel inlet/outlet holes of the

common rail free from debris.
2) Temporarily tighten the collared hex bolts (B) by hand.

3) Tighten the collared hex bolts (B) to a tightening
torque of 2.2 kgfm.
EDL032548B
46. Connect the fuel return hoses.
1) Loosen the collared hex bolts of the common rail.

2) Temporarily connect the fuel injection pipes (A).
3) Tighten the collared hex bolts to a tightening torque
of 2.2 kgfm.
4) Tighten the nuts (B) of the fuel injection pipes to a
5) Tighten the flange hex bolt (C).
CAUTION
Ensure that the fuel injection pipes are facing the

right direction.
EDL032547C
When tightening the nuts of the fuel injection

pipes, tighten those on one side first and then
the other side, making sure that the round part
of the pipe is engaged in the correct position.
Do not reuse the fuel injection pipes; replace

them with new ones. Otherwise, critical damage
to the engine performance may occur.
119
5. About the engine

48. Assemble the oil filter assembly.
1) Assemble the oil filter assembly (A).

DL03-LEF00/01
CAUTION
Check if the oil filter assembly has O-rings
installed.
assembly.
2) Tighten the flange hex bolts to a tightening torque of
2.2 kgfm.
49. Install the intake stake.
DL03-LEF00/01
EDL032549B
B
DL03-LEF02/03
D
A
D
B
E
F
EDL032050C
DL03-LEF02/03
EDL032549C
DL03-LEL00/01/02/
03/04
D
D
E
F
EDL032050D
B
EDL032549D
120
5. About the engine

50. Install the generator mounting stand
(DL03-LEF00/LEF01).
DL03-LEL00/01/02/
03/04
DL03-LEF00/01
D
E
D
F
EDL032050E
1) Install gaskets (B) between the intake manifold and
EDL032551D
the intake stake.

1) Install the generator bracket (C).
2) Tighten the flange hex bolts (G).
CAUTION
3) Assemble the eyebolt assembly (B).
Ensure that the gaskets are facing the right direc-
4) Tighten the flange hex bolts (D).
tion.
5) Install the idle pulley bracket (A).
Ensure that the center of the gasket holes are
6) Tighten the flange hex bolts (E, F).
aligned.
51. Install the generator bracket (DL03-LEF02/LEF03).

DL03-LEF02/03
them.

Clean debris off the inside of the intake stake.
2) Install the intake stake (A).

of 2.2 kgfm.
4) Install the EGR pipe gaskets (D).
5) Connect the EGR pipe (E).
6) Tighten the flange hex bolts (F) holding the EGR pipe
to a tightening torque of 2.2 kgfm.

EDL032551E
1) Install the lower generator bracket (A).

2) Tighten the flange hex bolt (D, F, G).
3) Install the upper generator bracket (C).
4) Tighten the flange hex bolts (F).
5) Assemble the eyebolt assembly (B).
121
5. About the engine

52. Connect the coolant pipe and hoses.

pressed, connect coolant hoses (B).
DL03-LEF00/01
53. Install the rear lifting hook.
B
B
EDL032552C
DL03-LEF02/03
EDL032553B
B
1) Install the rear lifting hook (A).
of 4.4 kgfm.
54. Install the front lifting hook.
DL03-LEF00/01
A
B
EDL032552D
DL03-LEL00/01/02/
03/04
B
C
EDL032554B
DL03-LEF02/03
A
B
B
EDL032552E
1) Tighten the flange hex bolts (C) of the coolant pipe

(A).
CAUTION
Replace clamps with new ones after reuse of 3
EDL032554C
times; do not reuse them any more.
122
5. About the engine
DL03-LEF00/01
DL03-LEL00/01/02/
03/04
EDL032554D
EDL032808E
1) Install the front lifting hook (A).
DL03-LEF02/03

of 4.4 kgfm.
55. Install the air heater.
DL03-LEF00/01
02/03
E
C
D
A
EDL032808F
view - A
DL03-LEL00/01/02/
03/04
EDL032055C
E
C
DL03-LEL00/01/02/
03/04
B
EDL032808G
1) Install the gasket between the intake stake and the

air heater.
CAUTION
EDL032555D
Clean debris off the gasket assembly surfaces.
Replace the gasket with a new one; do not reuse

it.
123
5. About the engine

2) Install the air heater (A).
DL03-LEL00/01/02/
03/04
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater

side, while DL03-LEF02/03, DL03-LEL00/01/02/03/04
has no rubber packing on its air heater side. Do not
mix the air heaters. Mixed use of air heaters may

cause critical damage due to voltage difference.
of 2.2 kgfm.
4) Install the boost pressure sensor (D).
5) Tighten the mounting bolt (E) of the boost pressure
EDL032556E
sensor to a tightening torque of 1 kgfm.
1) Replace the O-ring of the oil level gauge guide tube
56. Install the oil level gauge.
with a new one.

2) Lubricant the O-ring of the oil level gauge guide tube.
DL03-LEF00/01
3) Press and install the oil level gauge guide tube (B) to
the cylinder block.
CAUTION
Install the oil level gauge guide tube in the way that
the handle of the oil level gauge faces the opposite
of the center of the engine.
B
4) Tighten the flange hex bolt (C) to a tightening torque
of 1.0 kgfm to fix the oil level gauge tube (B).
5) Install the oil level gauge (A).
EDL032556C
57. Install the starter motor.
DL03-LEF02/03
B
EDL032556D
EDL032057A
1) Align and install the starter motor (A) with the stud
bolt.
of 2.2 kgfm.
124
5. About the engine

58. Connect the breather hose.
DL03-LEF02/03
EDL032811B
EDL032058B
1) Install the V-belt (A).
1) Connect the breather hose (A) to the hose clip (B).
2) Check visually if the V-belt has been properly settled
in the generator, the coolant pump pulley, and the
groove of the crankshaft pulley.
hose(A).
3) Adjust the tension using an eye bolt (B).

Note) For checking and measuring the belt tension, see
CAUTION
Belt Tension in Chapter Others/Driving Units.

61. Connect the cables and harness connected to each
sensor of the engine.
62. Install the engine on the machine.
Do not apply oil to hoses and clamps.
63. Assemble the air cooler and the cooling fan to the
engine.
59. Install the generator.
64. Feed engine oil.
1) Install the generator.
1) Open the oil injection cap on the cylinder head cover
2) Tighten the mounting bolts and nuts of the generator.
top and add engine oil.
60. Install the V-belt (Only LEF00/LEF01/LEF02/LEF03).
CAUTION
DL03-LEF00/01
Use genuine engine oil recommended by Doosan.

65. Feed coolant.
1) Open the radiator cap and add coolant (Only
2) Open the surge tank cap and add coolant (Only
LEL00/LEL01/LEL02/LEL03/LEL04).
CAUTION
Use coolant recommended by Doosan.
EDL032810C
125
5. About the engine
126
6. Cooling system
General information .........................................................................................................129
General Information ................................................................................................................................ 129
Specifications........................................................................................................................................... 130
Failure Diagnosis ................................................................................................................................... 132
Water pump .....................................................................................................................133

Water pump disassembly ....................................................................................................................... 133
Water pump Assembly ........................................................................................................................... 134
Thermostat .......................................................................................................................136
Thermostat Disassembly......................................................................................................................... 136
Thermostat assembly.............................................................................................................................. 137
Check of thermostat ............................................................................................................................... 137
Cooling fan ......................................................................................................................138

Fan mounting bracket disassembly ....................................................................................................... 138
Fan mounting bracket assembly............................................................................................................ 139
127
128
6. Cooling system
General information
General Information
The heat absorbed into the EGR cooler runs to the
This engine is water cooled. With the cooling unit, the
coolant pump, and the heat absorbed into the oil cooler
combustion heat of the cylinder block and head generated
and the cylinder head runs to the thermostat. If the
by engine fuel combustion and the heat of engine oil and
coolant temperature is lower than the valve-opening
EGR gas are absorbed into coolant by heat transfer, and
temperature of the thermostat, the coolant flows into the
then the coolant is cooled by a radiator and a cooling
coolant pump. If higher, it flows into the radiator. The
fan, enabling the engine to operate properly.
radiator cools the coolant by releasing the absorbed heat,
The cooling flow runs through to the coolant jacket of the
and recirculates the coolant to the coolant pump.
cylinder block by the coolant pump, and then diverges

into oil cooler, EGR cooler, and cylinder head.
1
2
EDL022059E
1. Radiator
4. Cylinder head
7.
EGR cooler
2. Water pump
5. Oil cooler
8.
thermostat
3. Cylinder Block
6. EGR Valve
9.
Bypass
129
6. Cooling system
Specifications
Specifications
Item
DL03LEF00
Cooling Type
Driving Type
Ribbed-Belt driven
Pump Speed
2,760 rpm
Drive Ratio
(Engine speed:Pump
speed)
1 : 1.2
Flow Rate
160 LPM or more
Pump back pressure
0.8 bar
Type
Driving Type
Blow Type
Fan Bracket direct connection
Rotation Ratio
1:1
Type
Thermostat
Coolant Temperature
Sensor
Water Temperature
Sensor
Radiator Cap
DL03LEF03
4.7 L
Type
Cooling fan
DL03LEF02
Capacity of coolant
Water pump
DL03LEF01
Wax pellet type
82 C
97 C
Lift
8 mm
Type
2.5k
0.148k

pressure valve
0.9 kg/cm2
130
Remarks
6. Cooling system
Specifications
Item
DL03LEL00
DL03LEL01
DL03LEL02
DL03LEL03
DL03LEL04
Cooling system
Cooling Type
Capacity of coolant
4.7 L
Type
Water pump
Driving Type
Ribbed-Belt driven
Pump Speed
2,880 rpm
Drive Ratio
(Engine speed:Pump
speed)
1 : 1.2
Flow Rate
160 LPM or more
Pump back pressure
0.8 bar
Type
Cooling fan
Driving Type
Sucker TypeHydraulic DriveVariable
Rotation Ratio
Type
Thermostat
Coolant Temperature
Sensor
Water Temperature
Sensor
Surge Tank Cap
Wax pellet type
82 C
97 C
Lift
8 mm
Type
2.5k
0.148k

pressure valve
0.97 kg/cm2
131
Remarks
6. Cooling system
Failure Diagnosis
Phenomenon
Causes
Troubleshooting
Not enough coolant
Replenish the coolant
Defective radiator cap
Replace it
Contaminated radiator
Clean the exterior of the radiator
Defective V-belt offset
Adjust or replace it
Contaminated or damaged V-belt
Replace it
Damaged impeller
Replace the water pump
Defective impeller fix
Replace the water pump
Bad water pump operation
Replace it
Bad thermostat operation
Replace it
Bad coolant flow
Clean the coolant path
Improper injection time
Check it with the failure diagnosis unit
Damaged cylinder head gasket
Replace it
Bad thermostat operation
Replace it
Too low ambient temperature
Heat the block
Damaged radiator
Repair or replace it
Loosened or damaged radiator connection
Repair or replace the connection
Defective radiator cap
Replace it
Badly mounted water pump
Bad or damaged water pump gasket
Replace the gasket
Badly mounted thermostat
Bad or damaged thermostat gasket
Replace the gasket
Damaged cylinder head gasket
Replace the gasket
Damaged cylinder head or block
Replace it
Bad water pump bearing
Replace the bearing
Bad or damaged cooling fan
Bad rotation of the cooling fan
Replace it
Defective V-belt offset
Adjust or replace it
Overheated engine
Overcooled engine
Leaking coolant
Noise
132
6. Cooling system
Water pump
General Information
WARNING
The water pump prevents the engine from being overheated by combustion heat during engine operation and
Discard coolant according to the regulations set
delivers coolant from the radiator to each part of the
forth by the relevant authorities. Disposing of
engine.
discharged coolant into the ground, sewers, drains,

rivers, or the sea will cause serious environmental
Water pump disassembly
pollution. Violation of regulations when discarding
1. Drain coolant.
engine oil without observing the handling regula-
1) Check if the engine and the radiator have been prop-
tions, will be punished.
erly cooled.
2) Place a container in front of the coolant drain plug.
CAUTION
3) Remove the radiator cap (Only

4) Remove the surge tank cap (Only
5) Unplug the coolant drain plug of the radiator and then
drain coolant.
DL03-LEF00/01
6) After draining the coolant, connect the coolant drain

B
plug again.
DANGER
(Only LEF00/LEF01/LEF02/LEF03)
Do not open the radiator cap while the engine is

A
overheated. If you open the radiator cap while the

engine is still hot, you may burn yourself with
steam or hot coolant. Make sure that the engine
has fully cooled before opening the radiator cap.

EDL032810C

DL03-LEF02/03
DANGER
(Only LEL00/LEL01/LEL02/LEL03/LEL04)
Do not open the surge tank cap while the engine

is overheated. If you open the surge tank cap
while the engine is still hot, you may burn yourself with steam or hot coolant. Make sure that the
engine has fully cooled before opening the surge
tank cap.
EDL032811B
V-belt and bolts.
133
6. Cooling system
5. Remove the coolant pump.

3. Remove the coolant pump pulley.
DL03-LEF00/01
02/03
EDL032540B
1) With the clamps pressed, disconnect the hose running

EDL032541B

DL03-LEL00/01/02/
03/04
3) Remove the coolant pump (A).
Water pump Assembly

1. Install the coolant pump.
EDL032541C

2) Remove the coolant pump pulley (A).
4. Disconnect the coolant hose running to the thermostat.

1) With the clamp pressed, disconnect the coolant hose
running to the thermostat and the coolant pump.
EDL032040B
1) Install the coolant pump (A).

2) Temporarily tighten the hex bolts (B) to a tightening
torque of 1.0 kgfm.
kgfm.
4) With the clamps pressed, connect the hose running
2. Connect the coolant hose running to the thermostat.
1) With the clamp pressed, connect the coolant hose
running from the thermostat and the coolant pump.
134
6. Cooling system
3. Install the coolant pump pulley.
DL03-LEF02/03
DL03-LEF00/01
02/03
A
A
B
EDL032811B
EDL032541B

DL03-LEL00/01/02/
03/04

5. Feed coolant.
1) Open the radiator cap and add coolant (Only
2) Open the surge tank cap and add coolant (Only
LEL00/LEL01/LEL02/LEL03/LEL04).
CAUTION
EDL032541C
1) Install the coolant pump pulley (A).
Use coolant recommended by Doosan.

kgfm.
DL03-LEF00/01
EDL032810C
135
6. Cooling system
Thermostat
General Information
Thermostat Disassembly
The thermostat maintains water temperature in the engine

consistently and prevents heat loss to improve heat effi-
CAUTION
ciency of the engine.

When the coolant temperature is below the normal
Detaching the thermostat itself may degrade cooling
temperature, the thermostat is closed and the coolant is
performance. Do not detach the thermostat itself.
bypassed and directly flows into the water pump. When

the coolant temperature reaches the normal temperature
1. Drain coolant until the coolant level is below the ther-
or is higher than the temperature, the thermostat is fully
mostat height.
open and the bypass circuit is closed. So the coolant
2. Disconnect the coolant hose.
flows into the radiator.
CAUTION
The wax pellet type thermostat shows slower

response to the change of cooling water than the
bellows type thermostat. This happens because
the heat capacity of the wax pellet type thermostat is larger than that of the bellows type thermostat. Therefore, to prevent a rapid increase in
the engine coolants temperature, you must first

operate the engine at idle until the engine is fully
warmed up. When the weather is very cold, do
not operate the engine in an overloaded condition
EDL032812A
or at a high speed after starting the engine.
1) Press the clamps (B) on both sides of the coolant
When draining water from the engine cooler or
hose running from the oil cooler to the thermostat.
injecting water to the engine cooler, work slowly
2) Disconnect the coolant hose (B).
to ensure that all air inside the cooler is expelled.
3. Remove the thermostat.
When a defect is found in the thermostat, replace

it with a new one.
2
3
EDL032542C
1) Remove the temperature sensor (E) of the water

EDL022060A
1. Heat Exchanger
2. Bypass valve
2) With the clamps pressed, disconnect the rubber hose

(D).
3. water pump
3) Remove the spacer bolt (B).
4. Coolant pipe
4) Loosen the flange hex bolts (C).
136
6. Cooling system
Check of thermostat
5) Remove the thermostat(A).
1. Check whether the wax pellet and the spring are
Thermostat assembly
damaged or not.
2. Put the thermostat into water and heat the water
1. Install the thermostat.
slowly to inspect thermostat operation.

3. If the thermostat starts open approximately 0.3 mm at
a water temperature of 82C and is fully open at more

than 8.0 mm at a water temperature of 97 C, the
thermostat is normal.
C
B
D
B
A
EDL032542C
1) Install the thermostat (A).

2) Mount the spacer bolt (B) to a tightening torque of
2.2 kgfm.
EDL022212A
of 2.2 kgfm.
4) With the clamps pressed, connect the rubber hose
A.
(D).
Thermometer
B.
Measuring point
4. Check if there are any foreign substances in the ther-
5) Install the temperature sensor (E) of the water
mostat.
Note) Clean the inside of the thermostat with an air gun.
2. Connect the coolant hose.
5. Check if there are any foreign substances or damaged

parts inside and outside of the hose.
Item
Specified Value
0.3 mm (at 82 C)
thermostat Open Tempera8.0 mm or larger (at 97
ture
C)
EDL032812A
1) Connect the coolant hose (A).

2) Fasten the clamps (B) on both sides of the coolant
hose running from the oil cooler to the thermostat.
3. Replenish the coolant.
137
6. Cooling system
Cooling fan
Fan mounting bracket disassembly
DL03-LEF00/01
DL03-LEF00/01
B
EDL032552C
EDL032810C
DL03-LEF02/03
DL03-LEF02/03
A
A
EDL032552D
EDL032811B
DL03-LEL00/01/02/
03/04
V-belt and bolts.


B
EDL032552E

138
6. Cooling system
3. Remove the V-belt pulley (Only
Fan mounting bracket assembly
LEF00/LEF01/LEF02/LEF03) .
1. Install the fan mounting bracket (Only

DL03-LEF00/01
02/03
DL03-LEF00/01
02/03
A
A
EDL032533C
EDL032532B
2) Remove the V-belt pulley (A).
1) Install the fan mounting bracket (A).
4. Remove the fan mounting bracket (Only
of 2.2 kgfm.
2. Install the V-belt pulley (Only
DL03-LEF00/01
02/03
DL03-LEF00/01
02/03
EDL032532B

2) Remove the fan mounting bracket (A).
EDL032533C
1) Install the V-belt pulley (A).

kgfm.
139
6. Cooling system

DL03-LEF00/01
DL03-LEF00/01
B
EDL032552C
DL03-LEF02/03
EDL032810C
B
DL03-LEF02/03
A
A
EDL032552D
DL03-LEL00/01/02/
03/04
EDL032811B


B
EDL032552E

(A).
CAUTION
140
7. Lubrication system
Oil pump ..........................................................................................................................143
Failure Diagnosis .................................................................................................................................... 144
Oil pump ..........................................................................................................................145

Oil pump disassembly ............................................................................................................................ 145
Oil pump assembly................................................................................................................................. 147
Check of oil pump.................................................................................................................................. 149
Disassembly of oil suction pipe............................................................................................................. 149
Assembly of oil suction pipe ................................................................................................................. 150
Oil filter assembly ...........................................................................................................152

Disassembly of oil filter module ............................................................................................................ 152
Assembly of oil filter module ................................................................................................................. 154
Check of oil Cooler ................................................................................................................................ 156
Oil pan .............................................................................................................................157

Disassembly of oil pan........................................................................................................................... 157
Assembly of oil pan ............................................................................................................................... 158
141
142
General information
General Information
From the cylinder block, oil is delivered to the crankshaft
This engine is a forced lubrication type of engine. Oil
bearings, camshaft bearings, and rocker arm for lubrica-
pressure is generated and delivered by rotating the gear
tion.
of the oil pump which is directly engaged with the crank-
In addition, the turbocharger is connected to the engine
shaft gear on the front of the cylinder block.
lubrication circuit. Around the cylinder block and the
The oil pump delivers oil sucked from the oil pan with
timing gear, lubricating oil is dispersed. Each cylinder has
the suction pipe to the main path of the cylinder block
an oil injection nozzle for cooling the bottom of the piston.
through the oil cooler and oil filter.
Engine oil is filtered through the oil filter and purified.
14
13
13
13
12
12
11
11
10
11
10
12
11
10
11
10
13
10
5
4
2
COOLED CLEAN OIL
COOLED DIRTY OIL

HOT DIRTY OIL
EDL022202A
1.
Oil pump
6.
Bypass Valve
11. Connecting rod bearing
2.
Relief Valve
7.
Piston cooling jet
12. Camshaft bearing
3.
Bypass Valve
8.
Idle gear
13. Rocker arm
4.
Oil cooler
9.
Piston
14. Turbocharger
5.
Oil filter
10. Crankshaft main bearing
143
Failure Diagnosis
Phenomenon
Causes
Troubleshooting
Bad oil
Replace oil with specified oil.
Oil leakage from the oil seal ring and

packing part
Replace it
Worn or damaged piston and piston ring
Replace it
Worn cylinder liner
Replace it
Burnt piston ring
Replace it
Worn valve guide oil seal, valve guide, or

valve stem
Replace it
Bad oil
Burnt oil pump relief valve
Replace it
Clogged oil pump strainer
Cleanse the strainer
Worn oil pump gear
Replace it
Cracked oil delivery pipe of the oil pump
Replace it
Defect oil pump
Oil pressure gauge fault
Worn bearings
Replace it
Clogged oil filter
Replace the oil filter with a new one
Gas leakage
Replace piston ring with a new one
Bad oil
Too much oil consumption
Low oil pressure
Contaminated oil
144
Oil pump
General Information
DL03-LEL00/01/02/
03/04
Engine oil is sucked from the oil pan by the gear type
oil pump and then all of the oil is forcibly delivered to

the oil cooler and filter for filtering. The filtered oil passes
through the main oil path of the cylinder block and lubricates bearing parts and the turbocharger of the engine
in order to maintain normal engine performance.
Oil pump disassembly

DL03-LEF00/01
B
EDL032160G

engine oil.
CAUTION
B
EDL032160E
DL03-LEF02/03

punished.
B
EDL032160F
B
EDL032557A
145

DL03-LEF00/01
02/03

DL03-LEF00/01
EDL032520B
DL03-LEL00/01/02/
03/04
EDL032021C
DL03-LEF02/03
A
EDL032520D
EDL032708C
CAUTION

CAUTION
reuse them.
146
2) Remove the oil pump (A).

DL03-LEF00/01
02/03
CAUTION
Be careful not to damage the O-ring during disassembly.
Oil pump assembly

1. Install the oil pump.
A
B
EDL032519C
DL03-LEL00/01/02/
03/04
EDL032012B
1) Align O-rings with the engine oil inlet and outlet.
2) Align the oil pump (A) with the pin and press it as
deeply into the cylinder block as possible.

kgfm.
EDL032520C
4) The backlash between crankshaft gear and oil pump
gear is 0.066 ~ 0.247 mm.

6. Remove the oil pump.
Item
Specified Value
Backlash Between Crankshaft Gear and Oil Pump

Gear
0.066 ~ 0.247 mm
CAUTION
A
Make sure that the O-rings have been mounted.

assembly.
B
EDL032512B
147

DL03-LEF00/01
02/03
D
A
B
B
EDL032519C
EDL032020B
DL03-LEL00/01/02/
03/04

crankshaft (D).
DL03-LEF00/01
EDL032520C

CAUTION
right direction.
EDL032021C

kgfm.
148
6. Feed engine oil.
DL03-LEF02/03
CAUTION
Check of oil pump

1. Check if the oil pump gear rotates smoothly with a
force of less than 3.0 kgfcm.
Disassembly of oil suction pipe

EDL032708C
DL03-LEF00/01

1st Stage

kgfm
2nd Stage
45 Rotation
CAUTION
B
EDL032160E
the flywheel.
DL03-LEF02/03
EDL032160F
EDL032057A
bolt.
of 2.2 kgfm.
149
3. Disconnect the oil suction pipe and the oil delivery
DL03-LEL00/01/02/
03/04
pipe.
E
A
B
D
B
C
F
B
EDL032160G

engine oil.
EDL032517B
2) Remove the oil suction pipe (A) and the O-ring (C).

CAUTION
Be careful not to damage the O-ring during disas-
CAUTION
sembly.

4) Remove the oil delivery pipe (D) and O-rings (F).
CAUTION

Be careful not to damage the O-rings during disas-
punished.
sembly.
Assembly of oil suction pipe

1. Install the oil suction pipe.
E
A
B
D
A
B
F
EDL032518C

EDL032517B
150
1) Install the O-rings (F).

CAUTION
torque of 2.2 kgfm.
3. Feed engine oil.

assembly.
CAUTION
2) Connect the oil delivery pipe (D).

4) Install the O-ring (C).
5) Connect the oil suction pipe (A).
kfgm.
CAUTION

assembly.
EDL032518D

CAUTION
Ensure that the oil pan is facing the right direction.

151
Oil filter assembly
General Information

engine oil.
The oil cooler cools oil with coolant and the oil filter
removes the foreign substances from the oil.

Disassembly of oil filter module

DL03-LEF00/01
CAUTION
punished.
B
DL03-LEF00/01
EDL032160E
DL03-LEF02/03
EDL032556C
B
DL03-LEF02/03
EDL032160F
DL03-LEL00/01/02/
03/04
EDL032556D
B
EDL032160G
152
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
B
A
C
B
B
EDL032556E
EDL032552E
cylinder block.

DL03-LEF00/01

DL03-LEF00/01
A
C
B
EDL032549B
DL03-LEF02/03
EDL032552C
DL03-LEF02/03
EDL032549C
EDL032552D
153
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
B
EDL032549D
EDL032549C

DL03-LEL00/01/02/
03/04
CAUTION

disassembly.

EDL032549D
Assembly of oil filter module

CAUTION
DL03-LEF00/01
installed.
assembly.
2.2 kgfm.
B
EDL032549B
154

DL03-LEF00/01
DL03-LEF00/01
B
EDL032552C
DL03-LEF02/03
EDL032556C
B
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A
B
EDL032552D
DL03-LEL00/01/02/
03/04
EDL032556D
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03/04
C
A
B
EDL032552E

EDL032556E
(A).
CAUTION
with a new one.


155
the cylinder block.
CAUTION
4. Feed engine oil.
CAUTION
Check of oil Cooler

1. Check if the coolant inlet of the oil cooler is damaged
and if coolant has leaked.
2. Check if the oil inlet and outlet of the oil cooler are
damaged and if oil has leaked.
3. Check if the exterior of the oil cooler is damaged and
leakage has occurs.
156
Oil pan
Disassembly of oil pan

DL03-LEF00/01
CAUTION
punished.
B
EDL032160E
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DL03-LEF02/03
EDL032556C
B
EDL032160F
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DL03-LEL00/01/02/
03/04
EDL032556D
EDL032160G

engine oil.
157
Assembly of oil pan
DL03-LEL00/01/02/
03/04
A
B
B
EDL032556E

EDL032518D
cylinder block.
CAUTION

Ensure that the oil pan is facing the right direction.




torque of 2.2 kgfm.
EDL032518C
DL03-LEF00/01

EDL032556C
158
DL03-LEF02/03
EDL032556D
DL03-LEL00/01/02/
03/04
EDL032556E

with a new one.
the cylinder block.
CAUTION
3. Feed engine oil.
CAUTION
159
160
8. Fuel system
General information................................................................................................................................. 163
Fuel return hose .............................................................................................................164

Disconnection of fuel return hose ......................................................................................................... 164
Connection of fuel return hose.............................................................................................................. 165
Check of fuel return hose...................................................................................................................... 168
Injector .............................................................................................................................169
How to Operate an Injector ................................................................................................................... 169
Injector disassembly................................................................................................................................ 170
Injector assembly .................................................................................................................................... 173
Injector check .......................................................................................................................................... 178
Common rail ....................................................................................................................179

Injection pipe ........................................................................................................................................... 182
Common rail disassembly ...................................................................................................................... 182
Common rail assembly........................................................................................................................... 185
Common Rail Check .............................................................................................................................. 188
Fuel injection pump ........................................................................................................189

Disassembly of fuel injection pump ..................................................................................................... 190
Assembly of fuel injection pump ........................................................................................................... 194
Disassembly of fuel injection pump drive gear.................................................................................... 198
Assembly of fuel injection pump drive gear......................................................................................... 198
161
162
8. Fuel system
General information
General information
Doosans common rail fuel injection system separates the
A diesel engine is a combustion engine that uses the
high-pressure apparatus from the fuel injection apparatus.
compression heat generated by compressing intake air in
Depending on the conditions of engine operation, the
the cylinder to burn the fuel injected by fuel injection
ECU decides the fuel volume and the fuel injection timing
nozzles.
and pressure for the optimum performance and injects the
High-pressure fuel generated by high-pressure pumps is
fuel into the cylinders.
stored in the common rail and the amount of fuel and
The common rail fuel injection system consists of the
injection timing is calculated by the electronic control unit
low-pressure stage for low-pressure fuel transfer, the
(ECU). The ECU injects fuel by operating the solenoid
high-pressure stage for highpressure fuel transfer, and the
valve for the injector installed in each cylinder.
ECU.
The fuel tank should be anti-corrosive, and should have
no oil leaks at two times higher pressure than the operating pressure of the fuel low-pressure pump and have
internal pressure of no more than 0.3 bar.
12
13
10
11
3
12
9
14
EDL032166D
1. Fuel Tank
5. Fuel Injection Pump
9. Injector
12. VENTURI
2. Fuel Filter
6. Fuel High Pressure Line

7. Common Rail
10. Fuel Pressure Limiting

Valve Return Line
13. 3-Way Connector
3. Pump Handle
4. Fuel Delivery Line
11. Injector Return Line
163
14. Fuel Injection Pump

Return Line
8. Fuel system
Fuel return hose
General Information
This hose is to transfer the fuel returned from the injector
to the high-pressure pipe back.
cylinder block.
Disconnection of fuel return hose

DL03-LEF00/01
DL03-LEF00/01
02/03
E
C
B
B
EDL032556C
EDL032055C
DL03-LEF02/03
E
C
DL03-LEL00/01/02/
03/04
B
B
EDL032556D
EDL032555D
DL03-LEL00/01/02/
03/04
pressure sensor.

CAUTION
EDL032556E
164
8. Fuel system

DL03-LEF00/01
CAUTION
D
A
D
C
E
F
EDL032050C
DL03-LEF02/03
A
B
EDL032547C

pumps.
Connection of fuel return hose

EDL032050D
DL03-LEL00/01/02/
03/04
D
D
E
EDL032547C
EDL032050E
stake.
165
8. Fuel system
DL03-LEL00/01/02/
03/04
CAUTION
right direction.
EDL032050E
pumps.
the intake stake.

DL03-LEF00/01
CAUTION
A
Ensure that the gaskets are facing the right direction.

aligned.

them.

F
EDL032050C

DL03-LEF02/03
of 2.2 kgfm.

D
D
E
F
EDL032050D
166
8. Fuel system
DL03-LEF02/03
DL03-LEF00/01
02/03
E
C
D
EDL032808F
EDL032055C
DL03-LEL00/01/02/
03/04
view - A
E
C
DL03-LEL00/01/02/
03/04
EDL032808G
EDL032555D
DL03-LEF00/01
air heater.
CAUTION

it.
CAUTION
EDL032808E

of 2.2 kgfm.
167
8. Fuel system
the cylinder block.

CAUTION
DL03-LEF00/01

Check of fuel return hose

1. Check if there is any foreign substance or damaged
part in the inside and the outside of the fuel line.
2. Check if oil is leaked from the joints.
EDL032556C
3. Check if the adaptor is damaged and oil is leaked.

DL03-LEF02/03
EDL032556D
DL03-LEL00/01/02/
03/04
EDL032556E

with a new one.
168
8. Fuel system
Injector
General Information
How to Operate an Injector
The injector uses the nozzle to inject fuel to the combus-
Injector operation is classified into four operation stages
tion chamber directly. To control the injection, the sole-
to operate the engine and create pressure in the
noid valve is used. Fuel is delivered as much as required
high-pressure pump.
from the open injector nozzle and the remaining fuel is
1. The injector is closed (high fuel pressure state)
returned to the fuel tank through the fuel return line. In
2. The injector is open (starting fuel injection).
addition, the fuel which has been used to lubricate the
3. The injector is fully open (injecting fuel).
high-pressure pump and returned from the fuel pressure
4. The injector is closed (ending fuel injection). These
adjustment valve is returned to the fuel tank through the
operation stages are decided by balancing the force
return line.
given to the injector components. If there is no pres-
The solenoid valve controls the fuel injection timing and
sure on the common rail or the engine is stopped, the
amount. The injector works instead of the nozzle and the
injector nozzle does not work.
nozzle holder mounted on the existing engine. Fuel is
1. The injector is closed (pause state)
delivered to the injector through the high-pressure
Under the pause state that no power is provided to
connector mounted on the cylinder head and then deliv-
the solenoid valve of the injector, the injector does not
ered to the valve control chamber through the delivery
operate. The surface where the discharge hole exists
hole.
is tightly closed with the valve ball by the force from
The valve control chamber is opened by the solenoid
a valve spring or magnet. High pressure in the
valve. It is connected to the fuel return line via the
common rail is kept by the fuel control valve and the
discharge hole. The hydraulic force which has been
same pressure is generated in the nozzle chamber of
increased by the valve control plunger with closed
the injector. The common rail fuel pressure, which is
discharge hole exceeds the pressure value of the nozzle
given to the end face of the valve control chamber of
needle. As a result, fuel delivery to the combustion
the injector, and the injector nozzle spring force are
chamber is blocked by the force given to the contact
larger than the force to open the nozzle. Therefore,
surface of the nozzle needle.
the injector is closed.
When the solenoid valve of the injector is pulled, the
2. The injector is open. (starting fuel injection)
discharge hole is opened. This lowers the pressure in the
When power is supplied while the injector solenoid
control chamber and the hydraulic power given to the
valve is closed, the fuel discharge hole is open by the
plunger. When hydraulic force is lower than the force
pulling force of the solenoid valve. Almost simulta-
given to the nozzle needle pressure, the nozzle needle
neous with that, the high current given to the solenoid
is opened. Finally, fuel is injected to the combustion
valve is reduced to the low current. This is because
chamber through the injection nozzle hole.
the air gap of the electromagnet circuit gets smaller.
The reason that the nozzle needle is controlled by
Fuel in the valve control chamber flows to the
hydraulic force is that the power required to open the
discharge valve hole on the upper side and then goes
needle quickly cannot be directly generated from the sole-
into the fuel tank via the fuel return line. The
noid valve. Fuel control amount required to open the
discharge hole completely breaks the pressure
nozzle needle is added to the fuel amount injected. The
balance and lowers the pressure in the valve control
used fuel is discharged to the fuel return line through the
chamber. As a result, the pressure in the valve control
hole of the valve control chamber.
chamber is lower than the nozzle chamber pressure
Fuel loss occurs on the nozzle needle, the valve plunger
which has been equal to the common rail pressure.
guide as well as the valve control chamber. The control
The lowered pressure of the valve control chamber
leakage fuel and the fuel gathered from the line, which
lowers the force from the control plunger. So the
connects the over flow valve, the high-pressure pump,
nozzle needle is open and fuel injection starts.
and the pressure control valve, is returned to the fuel tank

through the fuel return line.
169
8. Fuel system
3. The injector is fully open. (injecting fuel)
The valve control plunger is stopped at the upper

DL03-LEF00/01
position because fuel is full as fuel flows from the fuel

delivery hole. At this time, the injector nozzle is fully
open and fuel is injected to the combustion chamber
at the pressure equal to that of the common rail.

4. The injector is closed. (ending fuel injection)
As soon as the supply to the solenoid vale of the
injector is blocked, the valve spring applies force to
the armature downward and the valve ball closes the
discharge hole. The armature consists of two compo-
nents. The armature plate is guided by the driving

shoulder and pressed downward. However, in this
case, an overspring is used. It is a return spring that
prevents the force from being applied to the armature
EDL032556C
and the valve ball. As the discharge hole is closed,

DL03-LEF02/03
fuel is delivered from the delivery hole and generates

pressure in the control chamber. This fuel pressure is
equal to the pressure of the common rail and puts

pressure on the valve control plunger through the end
face of the valve control plunger. As a result, the force
of the spring is added to the pressure exceeding the

pressure of the nozzle chamber. Therefore, the nozzle
needle is closed. The speed of closing the nozzle
needle is decided by the flow that passes through the
delivery hole. As soon as the nozzle needle is positioned to the stop position, fuel injection is blocked.
Injector disassembly
EDL032556D
DL03-LEL00/01/02/
03/04
A
B
EDL032556E
EDL032558C
hose(A).
cylinder block.
170
8. Fuel system

DL03-LEF00/01
02/03
DL03-LEF00/01
B
D
D
A
D
B
E
F
EDL032055C
E
C
EDL032050C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
A
B
A
E
F
EDL032555D
EDL032050D
DL03-LEL00/01/02/
03/04
pressure sensor.

CAUTION
F
EDL032050E
stake.
171
8. Fuel system
CAUTION
A
A
B
EDL032546A
CAUTION
EDL032548B
during disassembly.

CAUTION
A
EDL032531B
EDL032547C

pumps.
172
8. Fuel system
Injector assembly
B
A
EDL032031C

EDL032030A

CAUTION
A

damaged.

damage to the engine due to combustion instability.
EDL032530A
torque of 0.3 kgfm.

CAUTION


CAUTION
disassembly.
0.35kgfm.

173
8. Fuel system
B
B
EDL032031A
EDL032046A
CAUTION

direction.

during assembly.


EDL032031B
torque of 2.2 kgfm.


cover (A).

CAUTION

ones.
EDL032547C

reassembly.
174
8. Fuel system

DL03-LEF00/01
CAUTION
right direction.

D
C

pumps.
EDL032050C

DL03-LEF02/03
A
B
D
D
F
EDL032050D
EDL032548B
DL03-LEL00/01/02/
03/04

of 2.2 kgfm.
CAUTION
E
F
right direction.
EDL032050E


175
8. Fuel system
the intake stake.
E
C
CAUTION
DL03-LEL00/01/02/
03/04
aligned.
them.


EDL032555D
DL03-LEF00/01

of 2.2 kgfm.
DL03-LEF00/01
02/03
C
D
EDL032808E
DL03-LEF02/03
EDL032055C
EDL032808F
176
8. Fuel system
DL03-LEL00/01/02/
03/04
view - A
DL03-LEF00/01
EDL032808G
EDL032556C

air heater.
DL03-LEF02/03
CAUTION
it.
CAUTION
EDL032556D

DL03-LEL00/01/02/
03/04

A
of 2.2 kgfm.

EDL032556E

with a new one.
177
8. Fuel system
2. Check the injector protrusion (C).
the cylinder block.
CAUTION


EDL032167A
1) Detach the cylinder head (A).

Note) Detach the cylinder head by referring to engine
disassembly order in Chapter About the engine.
2) Insert the seal ring in the cylinder head (A) and attach
the injector (B).
3) Check the injector protrusion (C) based on the
cylinder head (A) surface with a dial gauge.
Note) Be careful not to allow foreign substances to flow
into the injector and the high-pressure connector
when detaching and checking the injector.
EDL032058B

hose(A).
CAUTION

Injector check
1. Check if there are any foreign substances and if the
end part of the injector is deformed.
178
Item
Specified Value
Injector protrusion
1.5 0.65 mm
8. Fuel system
Common rail
General information
High-pressure fuel generated by the fuel highpressure
Doosans common rail fuel injection system separates the
pump is stored in the common rail, and when the driver
high-pressure apparatus from the fuel injection apparatus.
operates the vehicle, the optimum amount of fuel and fuel
The ECU decides the fuel volume and the fuel injection
injection timing are determined based on the data set in
timing and pressure for the optimum performance and
the Electronic Control Unit (ECU) depending on operating
injects the fuel into the cylinder.
speed and conditions, and then the injector solenoid valve

installed in each engine cylinder is activated to spray fuel
into the cylinder.
12
13
10
11
3
12
9
14
EDL032166D
1. Fuel Tank
9. Injector
12. VENTURI
2. Fuel Filter

7. Common Rail
10. Fuel Pressure Limiting

Valve Return Line
13. 3-Way Connector
3. Pump Handle
4. Fuel Delivery Line
11. Injector Return Line
Main components of the common rail fuel injection system

are as follows.
179

Return Line
8. Fuel system
1. Electronic Control Unit (ECU)
4. Accelerator pedal sensor
1) The Electronic Control Unit (ECU) receives the input
1) The accelerator pedal sensor delivers the data gener-
signals generated by the above input sensors based
ated when a driver depresses the accelerator pedal
on the drivers accelerator operation and works imme-
to the ECU. A voltage value is generated by the
diately according to the driving performance of the
adjustable resistance (potentiometer) of an accelerator
engine and the vehicle. In addition, based on the
pedal sensor, and the pedal position is calculated with
above information, the ECU generates open/close
programmed characteristics curves.
circuit - circulation circuit operations of the vehicle and
5. Fuel temperature sensor
engine.
1) This sensor measures the fuel temperature in the fuel
2) The engine speed is measured by the crankshaft RPM
pump.
sensor and the ignition order is determined by the
6. Boost pressure and temperature sensor
camshaft RPM sensor. Through electrical signals
1) The boost pressure and temperature sensor is
generated by the potentiometer of the accelerator
connected to the intake stake via the O-ring. It
pedal sensor, it shows how strong the driver has
measures the absolute pressure and temperature in
pressed the pedal. In addition, the ECU includes the
the intake stake.
turbocharger and the intake pressure sensor. The
2) The output signal is input to the ECU and the boost
intake pressure sensor measures the intake pressure.
pressure is calculated based on the ECUprogrammed
3) When it is very cold or the engine is cooled, the ECU
characteristics curves.
receives data from the thermo sensor and the air
7. Oil pressure and temperature sensor
temperature sensor to operate with the best conditions
1) The engine oil pressure and temperature sensor
for engine operation.
measures the temperature and pressure of engine oil
2. Crankshaft RPM sensor
and sends the data to the ECU.
1) Position of the piston in the combustion chamber is
8. Common rail pressure sensor
very important. Pistons of all engines are connected
1) It is installed at the end of the common rail,
to the crankshaft via the connecting rods. The crank-
measuring the instantaneous internal pressure of the
shaft RPM sensor installed in the flywheel housing
common rail.
provides information on the position of all pistons. The
9. Engine thermo sensor
rev-speed is defined as Revolutions per Minute (RPM)
1) The engine thermo sensor measures the temperature
of the crankshaft. The key input parameters are calcu-
of the engine coolant and sends the temperature data
lated by the ECU using signals from the crankshaft
to the ECU.
RPM sensor.
3. Camshaft RPM sensor
1) The camshaft RPM sensor controls the intake and
exhaust valves of the engine. This rotates at half the
speed of the crankshaft, and determines if the position
of the camshaft is in the stage of pressure or in the
stage of exhaust when the piston moves to the top
dead point. This information cannot be determined by
the crankshaft RPM sensor. However, while the
engine is normally operating, the information given by
the crankshaft RPM sensor is enough to define the
engine state. It means that the ECU receives information about the engine from the crankshaft RPM sensor
if the camshaft RPM sensor cannot sense the engine
state while the vehicle is running.
180
8. Fuel system
EDL022065A-E
The injection characteristics of the common rail are as
Injection pipe
follows.
1. Fuel high-pressure pipe
1. Compared to standard injection characteristics, the
1) The fuel high-pressure pipe delivers highpressure fuel
common rail requires the ideal fuel injection as
of 1,800 bar. Therefore, the fuel lines are made of
follows. The fuel injection volume and the injection
special materials that can stand the maximum pres-
pressure work independently from each other, satis-
sures and variations in pressure during fuel injection.
fying the conditions for all engines.
High-pressure pipes have an external diameter of
2. It should be possible to adjust the injection volume to
6.35 and a bore diameter of 3.0. In addition, the
low for the ignition delay time, i.e., the period from
length of the fuel high-pressure pipes between the
starting fuel injection to starting combustion at the
common rail and the injector should be identical and
early stage of fuel injection.
installed as short as possible.
3. The common rail, which is a modular system, has the

following components taking key roles in its injection
features.
1) Injector solenoid valve installed on the cylinder head
2) Common rail
3) Fuel high-pressure pump
4) Electronic Control Unit (ECU)
5) Crankshaft RPM sensor
181
8. Fuel system
Common rail disassembly
2. Common rail
6
8
DL03-LEF00/01
3
A
7
2
4
5
EDL032168B
EDL032556C

2. Injector
DL03-LEF02/03
3. Common Rail
4. Pressure sensor
5. Fuel injection pipe (Fuel injection pump-Common rail)
6. Fuel injection pipe (Common rail-Injector)
7. Fuel return hose (Common rail-Fuel injection pump)

8. Fuel return hose (Injector-Fuel injection pump)
Note) The front engine direction (F) is the coolant pump
direction and the rear engine direction (R) is the
flywheel direction.
1) After the injector has used fuel from the common rail
for fuel injection, the pressure in the common rail is
EDL032556D
actually kept consistently. The fuel pressure is

measured by the common rail pressure sensor and
DL03-LEL00/01/02/
03/04
kept at a desired value by the pressure control valve.

The fuel pressure is maintained to a maximum of
1,800 bar by the pressure control valve inside the

common rail.
2) The common rail stores the fuel pumped from the
high-pressure fuel pump at high pressure. Even after

the injector has used fuel from the common rail for
fuel injection, the pressure pulsation in the common
rail is maintained consistently because of the volume
of the common rail. The fuel pressure is measured by
the common rail pressure sensor and kept at a
desired value by the pressure control valve. The fuel
EDL032556E
pressure is maintained to a maximum of 1,800 bar by

the pressure control valve inside the common rail.
3) Doosans common rail fuel injection system separates
the high-pressure apparatus from the fuel injection
apparatus. The ECU decides the fuel volume and the
cylinder block.
fuel injection timing and pressure for the optimum
performance and injects the fuel into the cylinder.
182
8. Fuel system

DL03-LEF00/01
02/03
DL03-LEF00/01
B
D
D
A
D
B
E
F
EDL032055C
E
C
EDL032050C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
A
B
A
E
F
EDL032555D
EDL032050D
DL03-LEL00/01/02/
03/04
pressure sensor.

CAUTION
F
EDL032050E
stake.
183
8. Fuel system
CAUTION
A
A
B
EDL032546A
CAUTION
EDL032548B
during disassembly.

Common rail assembly

CAUTION
A
EDL032046A
CAUTION
EDL032547C

direction.
pumps.

during assembly.

184
8. Fuel system
of 2.2 kgfm.
torque of 2.2 kgfm.

CAUTION

right direction.


EDL032547C

CAUTION
DL03-LEF00/01
right direction.

D
pumps.
EDL032050C
DL03-LEF02/03
D
D
B
E
F
EDL032050D
EDL032548B

185
8. Fuel system
DL03-LEL00/01/02/
03/04
DL03-LEF00/01
02/03
C
D
D
A
D
E
C
B
F
EDL032050E
EDL032055C

the intake stake.
E
C
CAUTION
DL03-LEL00/01/02/
03/04
aligned.
them.


EDL032555D
DL03-LEF00/01

of 2.2 kgfm.
EDL032808E
186
8. Fuel system
DL03-LEF02/03

DL03-LEF00/01
B
EDL032808F
DL03-LEL00/01/02/
03/04
view - A
EDL032556C
DL03-LEF02/03
EDL032808G

air heater.
EDL032556D
CAUTION
DL03-LEL00/01/02/
03/04
it.
B
CAUTION
EDL032556E

with a new one.
of 2.2 kgfm.
187
8. Fuel system
the cylinder block.
CAUTION
Common Rail Check

1. Check if there is any damage on the exterior of the
common rail.
2. Check whether there is any damage of the pressure
sensor of the common rail.
3. Check if there is any damage of the fuel pressure
restrict valve.
188
8. Fuel system
Fuel injection pump
General information
Solenoid valve switching (open/close) is operated by high
The high-pressure fuel pump uses a radial piston pump
pressure and high current. Based on the values set in
to generate high pressure in fuel. Pressure is inde-
the ECU, the solenoid valve of the injector is sequentially
pendently generated as fuel is injected. The RPM of the
operated. The crankshaft sensor and the camshaft sensor
high-pressure fuel pump is directly connected to the
are use to detect the engine rev count for starting fuel
engine rotation speed regardless of the rotation ratio of
injection and adjusting the injection timing.
the transmission. Compared to standard injection
The fuel high-pressure pump pressurizes fuel to approx-
systems, the common rail injection system exhibits more
imately 1,800 bar, and this pressurized fuel is delivered
consistent fuel delivery volume.
to the tubular common rail through high-pressure lines.
The injector is connected to the common rail with the
The high-pressure fuel pump consists of the following
high-pressure pipe. It consists of a nozzle and a solenoid
components.
valve. When a key switch is operated, actuating power is

supplied to the solenoid valve by the ECU. When the key
switch is blocked, the solenoid valve ends injection.
3
5
EDL032169B
1. Fuel line inlet
4. Injector fuel return inlet and fuel line outlet
2. High pressure fuel line outlet
5. Drive shaft
3. High pressure fuel line return inlet
189
8. Fuel system
1. Functions
4. Fuel supply collection
1) The high-pressure fuel pump has two pressure phase
1) The fuel high pressure pump is designed to deliver a
processes: low-pressure phase and highpressure
lot of fuel. While the engine runs at idle or partial load,
phase. Under all operating conditions, it transfers
the fuel excessively delivered returns to the fuel tank
high-pressure fuel in a vehicle for the entire service
through the pressure adjustment valve.
lifetime. In addition, it delivers fuel required to respond
5. Fuel high-pressure pumping lock-off valve
to the rapidly-changing pressure in the common rail
1) When the fuel high pressure pumping lock-off valve is
or quick start of a vehicle. The high-pressure fuel
turned off, the amount of fuel feeding the common rail
pump continuously generates the system pressure
increases. With the lock-off valve turned off, the intake
necessary for the common rail.
valve is open and the fuel pumping solenoid valve is
2. Configuration of high-pressure fuel pump
pulled, and the pin attached to the electromagnet
1) Inside the fuel high-pressure pump, three pump
maintains the valve inlet open. Therefore, the fuel
pistons, installed with 120 degrees b etween each of
having flowed into this pumping valve cannot be
them, pressurize fuel in the circumferential direction.
compressed during transfer stroke. With the fuel
Compression strokes occur three times per rotation.
returning to the lowpressure passage, there is no
Therefore, consistent stress is kept in the pump
pressure created. The pumping lock-off valve, which
driving apparatus and low driving force is required.
operates with a small amount of power, is activated
The driving power of the common rail requires about
with short intervals between supply and shut-off of fuel
1/9 load consumed by typical pump systems.

3. Operation method
1) The fuel delivery pump delivers fuel from the fuel tank
to the high-pressure fuel pump through the fuel inlet
and the safety valve. Then the highpressure fuel pump
Valve
pumps and the transfers the fuel to the lubricating and
Plunger
cooling circuit of the high pressure pump through the

safety valve. The driving shaft, which has an eccentric
cam, moves the pump piston up and down according
Fuel
Return
Common Rail
to the cam shape.

2) When the transfer pressure of the fuel delivery pump
exceeds the open pressure of the safety valve, the
Valve Body
fuel is transferred to the intake stroke position of the

pumping chamber where the pump piston moves up
Valve Spring
EDL032069A-E
and down through the intake valve of the fuel high

pressure pump. When the pump piston exceeds the
Disassembly of fuel injection pump
bottom dead point, the valve inlet closes and prevents
fuel from exiting the pumping chamber, which accordingly compresses the fuel more than the delivered
pressure.
DL03-LEF00/01
3) Once the fuel pressure reaches the pressure of the

common rail, the outlet valve is opened. Then the
compressed fuel flows into the high pressure circuit.
The pump piston continuously transfers fuel until it
reaches the bottom dead point. After the bottom dead
point is reached, the outlet valve is closed. The fuel
in the pumping chamber is relaxed and then the pump
piston moves down again. When the pressure in the
pumping chamber is lower than the pressure of the
fuel delivery pump, the inlet valve is opened again
and the above procedure is started again.
EDL032160E
190
8. Fuel system
DL03-LEF02/03
DL03-LEF00/01
B
EDL032160F
EDL032556C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
B
EDL032160G
EDL032556D

engine oil.
DL03-LEL00/01/02/
03/04

CAUTION
EDL032556E

punished.
cylinder block.
191
8. Fuel system

DL03-LEF00/01
02/03
DL03-LEF00/01
B
D
D
A
D
B
E
F
EDL032055C
E
C
EDL032050C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
A
B
A
E
F
EDL032555D
EDL032050D
DL03-LEL00/01/02/
03/04
pressure sensor.

CAUTION
F
EDL032050E
stake.
192
8. Fuel system
CAUTION
CAUTION
disassembly.
DL03-LEF00/01

A
A
B
EDL032549B
DL03-LEF02/03
A
EDL032548B

CAUTION
EDL032549C
DL03-LEL00/01/02/
03/04
B
EDL032549D
EDL032547C
193
8. Fuel system

pumps.
8. Remove the fuel injection pump.
EDL032547C
A
B
CAUTION
EDL032514B

right direction.
2) Remove the fuel injection pump (A).

Assembly of fuel injection pump
1. Install the fuel injection pump.


pumps.
A
B
EDL032514B
1) Align the fuel injection pump (A) with the stud bolts
and fasten it.

2) Tighten the flange hex bolts (B:3ea) to a tightening
torque of 2.2 kgfm.
EDL032548B

of 2.2 kgfm.
194
8. Fuel system
DL03-LEL00/01/02/
03/04
CAUTION

right direction.


EDL032549D

CAUTION

DL03-LEF00/01
installed.
assembly.

2.2 kgfm.
DL03-LEF00/01
B
EDL032549B
DL03-LEF02/03
D
D
A
E
B
F
EDL032050C
EDL032549C
195
8. Fuel system
DL03-LEF02/03
DL03-LEF00/01
02/03
E
A
C
B
D
A
D
E
C
B
F
EDL032050D
EDL032055C
DL03-LEL00/01/02/
03/04
E
C
DL03-LEL00/01/02/
03/04
D
B
D
E
F
EDL032050E
EDL032555D
DL03-LEF00/01
the intake stake.
CAUTION

aligned.

them.


EDL032808E

of 2.2 kgfm.
196
8. Fuel system
DL03-LEF02/03

DL03-LEF00/01
B
EDL032808F
DL03-LEL00/01/02/
03/04
view - A
EDL032556C
DL03-LEF02/03
EDL032808G

air heater.
EDL032556D
CAUTION
DL03-LEL00/01/02/
03/04
it.
B
CAUTION
EDL032556E

with a new one.
of 2.2 kgfm.
197
8. Fuel system
1) Align the fuel injection pump drive gear (B) with the
the cylinder block.
pin of the fuel injection pump drive shaft (A) and

fasten it.
CAUTION
CAUTION
Ensure that the imprinted mark on the fuel injection
pump drive gear is facing outward from the engine.
2) Tighten the flange hex nuts (C) to a tightening torque

of 6.5 0.5 kgfm.

Disassembly of fuel injection pump drive

gear
1. Remove the drive gear of the fuel injection pump.
A
B
C
EDL032401A
1) Loosen the flange hex nuts (C).

2) Remove the fuel injection pump drive gear (B) from
the fuel injection pump drive shaft (A).
Assembly of fuel injection pump drive gear

1. Install the drive gear of the fuel injection pump.
A
B
C
EDL032401A
198
9. Intake/exhaust system
Turbocharger ...................................................................................................................202
Failure Diagnosis ................................................................................................................................... 204
How to Maintain Turbocharger .............................................................................................................. 207
Turbocharger disassembly...................................................................................................................... 208
Turbocharger assembly .......................................................................................................................... 209
Turbocharger Check ............................................................................................................................... 210
Exhaust gas reduction ....................................................................................................211

Aftertreatment muffler and catalyst........................................................................................................ 212
DNOx6.5 system ..................................................................................................................................... 213
SM (Supply Module)............................................................................................................................... 214
DM (Dosing Module) .............................................................................................................................. 215
Urea filter replacement ........................................................................................................................... 216
DNOx6.5 system components................................................................................................................ 218
Check DNOx6.5 system failures............................................................................................................ 218
Urea Quality Characteristics................................................................................................................... 221
EGR (Exhaust Gas Recirculation) system ....................................................................223

Disassembly of EGR ............................................................................................................................ 224
Assembly of EGR ................................................................................................................................. 225
Intake manifold ................................................................................................................228

Disassembly of intake manifold ............................................................................................................. 228
Assembly of intake manifold.................................................................................................................. 230
Exhaust manifold .............................................................................................................235

Disassembly of exhaust manifold .......................................................................................................... 235
Assembly of exhaust manifold ............................................................................................................... 237
Intake pipe .......................................................................................................................240

Air heater disassembly ........................................................................................................................... 240
Air heater assembly................................................................................................................................ 241
Intake stake disassembly ....................................................................................................................... 243
Intake stake assembly............................................................................................................................ 244
199
200
General information
General Information
1. The EGR system is a device that recirculates exhaust

gas to reduce NOx emissions.
Our new engine applies all applicable advanced technol-
2. The muffler has a diesel oxidation catalyst (DOC)
ogies to satisfy the tightened restrictions exhaust, while
device in it.
also improving fuel efficiency and reducing exhaust gas.
1) This DOC device reduces HC and CO emissions in
The exhaust reduction system features a diesel oxidation
exhaust gas with reduction catalysts.
catalyst (DOC) device to reduce soot particles and an
3. SCR is used to reduce NOx in emissions by spraying
exhaust gas recirculation (EGR) system and (SCR)
urea into the SCR catalyst.
system to reduce the nitrogen oxide (NOx) from the

engine exhaust gas.
8
9
11
6
12
13
10
14
15
2
3
EDL032072C
1. Diesel Engine
6. Filter
11. Dosing control unit
2. Dosing Module with Injector
7. AdBlue Supply module
12. Actuators
3. Temperature sensor
8. AdBlue tank
13. Sensors
4. SCR Catalyst
9. AdBlue Temperature sensor
14. Engine CAN
5. Temperature sensor
10. AdBlue level sensor
15. Diagnostic CAN
Note) SCR; Selective Catalytic Reduction
201
Turbocharger
General Information
Turbocharger increases the engine output by inhaling
high-density air to the cylinder by using the exhaust heat
energy of the engine.
3
4
2
9
1
5
6
EDL022073B
1.
Exhaust pipe
4.
Compressor housing
7.
Air inlet
2.
Turbine housing
5.
Compressor wheel
8.
Oil outlet
3.
Turbine wheel and shaft assembly
6.
Intake pipe
9.
Exhaust gas outlet
1. The engine output is determined by fuel amount and
4. Supercharger is to compress air and deliver the
engine efficiency.
compressed air to a cylinder of an engine and Turbo-
2. To combust the delivered fuel completely and convert
charger is a forced induction device that forces more
it to the useful work of the engine, enough air to
intake air, proportionately more fuel, into the combus-
completely combust the fuel should be delivered to the
tion chamber and supercharges the exhaust gas
cylinder.
energy into the atmosphere.
3. Actually, the engine output is determined by the

capacity of the cylinder. If air is compressed and delivered to the cylinder, the amount of air in the cylinder
is increased as much as compressed. Therefore, more
fuel can be combusted and the engine output can be
increased.
202
5. The key functions of a turbocharger are as follows.
1) Turbine: Kinetic energy of the exhaust gas from the
combustion chamber passes through the turbine
housing and is captured by the turbine blades, transferring the turning force to the turbine shaft. Turbine
refers to the device where this operation is generated.
A turbine has sealings and the heat screen to protect
bearings from harmful impact of exhaust gas.
2) Compressor: A compressor is connected to a shaft
where the turbine is connected, composing a rotor
assembly. It uses the turning energy from the turbine
shaft to inhale and compress air, and then transfers
the compressed air to the intake pipe. This is the
performance property of a compressor.
3) Bearing system:
Thrust bearing: Shaft force acts upon the turbine

wheel. The thrust bearing prevents a shaft from being
moved by the shaft force.
Journal bearing: Journal bearings are floating types.

They create a doubled-oil film on the exterior and interior of the bearing,
allowing the bearing to spin independently. The

doubled oil film works as a buffer reducing the sliding
speed on the surface of the bearing lower than the
shaft spinning speed, aiming dynamic stability.
4) Sealing of compressor shaft: A seal plate and seal

ring compose a dual structure to prevent the
compressed intake air and lubricating oil from leaking.
203
Failure Diagnosis
Phenomenon
Noise or vibration
Causes
Troubleshooting
Rotating part is contacted
Unbalanced rotation of a rotor
Burn
Loose joint
Check or repair it
Deformed or damaged intake unit hose
Replace it
Poor clamping state
Adjust and tighten the clamp
Contaminated or damaged air filter
Replace and check if the impeller of the turbocharger is damaged
Leakage of coolant from the turbocharger or oil

from the oil hose
Replace the hose and the gasket
Leakage of gas from the exhaust manifold
Replace the gasket or tighten the fixing nut
Poor turbo actuator operation
Replace the turbocharger
Leakage from the engine block and the exhaust

manifold
Check the engine
Contaminated blowby gas and abnormal oil

amount
Check the turbo impeller and the turbo intake

outlet
Large gap of the turbocharger wheel, causing

interference with the wall
Damaged turbocharger wheel
Damaged wheel and shaft of the turbocharger
Poor rotating force of the turbocharger wheel
204
Phenomenon
Causes
Troubleshooting
Leakage of gas from each part of the exhaust

system
Check or repair it
Clogged air filter element
Replace or clean it
Contaminated or damaged turbocharger
Leakage of air from the discharging part of the

compressor shaft
Check or repair it
Replace it
Poor clamping state

manifold
Check the engine

amount

outlet

Replace it
Poor clamping state

from the oil hose

manifold
Check the engine

amount

outlet

Lowered output
Oil leakage
Oil leakage
205
Phenomenon
Oil consumption
Black and white

emissions
Blue emissions
Too much fog
Too much exhaust

emissions
Causes
Troubleshooting
Poor clamping state

from the oil hose

manifold
Check the engine

amount

outlet

Replace it

from the oil hose

amount

outlet


manifold
Check the engine
Oil leakage to the turbine or compressor
Worn or damaged seal ring due to worn bearing
Clogged air filter element
Replace or clean it
Clogged air duct
Check or repair it
Air leakage from the intake system
Check or repair it
The turbocharger cannot rotate because of

burning
A turbine blade or compression wing contacts

with the other one or is damaged
Deformed or clogged exhaust system pipe
Check or repair it
206
How to Maintain Turbocharger
1. Cautions for engine operation
1) Observe the followings when starting, operating, and
stopping an engine.
Item
Cautions
Reasons
Check the oil amount

Therefore, start the engine with the starter
motor to check the rise of oil pressure (until
the gradation of the oil pressure gauge moves
or the pressure indicator lamp is turned on).
Starting an engine
Overhasty start of engine leads to engine

rotation without lubricating turbocharger and
other engine parts, causing abnormal wear or
burning of bearings.
If you replace oil, oil filter cartridge, or lubrication system parts or use an engine in cold
areas, or the engine has stopped for a long
When an engine has stopped or kept cold for
period, loosen the oil pipe joint at the inlet of
a long period, circulation of oil in the pipe
the turbocharger and run the starter motor
gets poor.
until oil flows out. After completing the work,
tighten the oil pipe joint again and start the
engine.
Operate the engine at idle for five minutes

from starting it.
When the engine is suddenly loaded while the

engine and the turbocharger have not been
smoothly rotated after starting the engine,
parts with insufficient oil may be burnt.
Check if oil, gas, or air is leaked from each

part. If so, take proper action.
Leakage of oil, gas, or air (especially oil)

reduces oil pressure and loss of oil cause
burning of bearings.
After starting an
engine
check the following.

Oil pressure
Too low oil pressure causes abnormal wearing

or burning of bearings. Too high oil pressure
causes oil leakage.
At idle: 1.5 ~ 3.0 kg/cm 2

During Operation
Stopping an Engine
Fully loaded: 3.0 ~ 5.5 kg/cm2

When abnormal noise or vibration occurs,
slowly reduce the rotate count until the engine
stops and then figure out the causes.
Operating an engine with noise or vibration

may cause irreversible damage of the engine.
Operate the engine at idle for five minutes

before stopping it.
Sudden engine stop after operating the engine

under high load allows the heat from the
red-heated turbine blade to be delivered to the
bearing system. Then oil burns and the bearing metal and rotation shaft are burnt.
2. Cautions for Maintenance
2) Please operate the engine for two minutes or more in
1) When the RPM is rapidly increased after starting the
order to lubricate the turbocharger fully after replacing
engine, the journal bearings in the crankshaft is
the engine oil or oil filter.
excessively rotated, the crankshaft is rotated at exces-
3) If an engine has been operated at high speed for a
sive speed before the journal bearing of the crankshaft
long period, fully operate the engine at idle and then
is lubricated fully. If the turbocharger rotates in this
stop the engine. Otherwise, the turbine wheel contin-
situation, bearings are not smoothly cooled and lubri-
uously runs without oil pressure in the turbocharger.
cated, causing bearing burn and damage of the
Therefore, no oil film is created on the center bearings
related parts.
and the journal bearings of the turbocharger, causing

bearing, wearing out and shortening of the turbocharger lifetime.
207
4) If an engine is not operated for a long period during
cold weather or in areas with cold climate, operate
the engine at idle after starting the engine until the

engine oil pressure is normal.
5) The turbocharger turbine spins at high speed of
I
J
50,000 ~ 200,000 rpm. Therefore, lubrication of bearings may determine the turbocharger lifetime. Please
use only recommended genuine engine oil and check
and replace the engine oil periodically.
6) Prolonged usage of contaminated air cleaner may
J
I
F
cause a critical damage of the turbocharger. Regularly

check and replace the air cleaner.
7) A turbocharger is a very complex and precise part.
Only certified and skilled technicians should work on

it.
8) If a turbocharger is operated without intake and
exhaust pipe, serious human injury may occur and
EDL032043C
critical faults of the engine performance may occur.
Please operate a turbocharger only when all of parts
delivery pipe.
are exactly mounted on the specified position.
9) Do not lift up a turbocharger by grabbing the actuator.
washers (J).
The actuator may be damaged because of the weight

of the turbocharger.
CAUTION
10) The weight of a turbocharger is about 4.0 kg or more.

To lift up a turbocharger for installing or removing it,
the worker should lower the center of gravity or press
reuse them.
his body close to the turbocharger. Otherwise, worker

may drop the turbocharger, causing damage of the
part and injury.
hose (G).
Turbocharger disassembly

CAUTION
EDL032558C

hose(A).
208
Turbocharger assembly

I
J
CAUTION

J
I
F


oil leaks.
EDL032043C


CAUTION
ified torque.


CAUTION

gasket.

them.
the turbocharger.
EDL032058B
CAUTION

them.
hose(A).
CAUTION
kgfm.


of 2.2 kgfm.
209
Turbocharger Check
Intake system: Check if there is any foreign substance
1. Routine Check and Repair: The turbocharger perfor-
within the intake system. Precisely attach the intake
mance is determined by maintenance state of the
system to the engine to prevent air leaks from the

joints of the intake system and the air filter.
engine. So you should regularly perform inspection
and check as specified.
substance in the exhaust system. The heat-resistant
1) Intake system: For the intake system, the air filter

should be carefully managed. For a wet type air filter,
bolts and nuts should be used. Do not use any of
if the oil amount is lower than the specified amount,
general nuts and bolts. Apply burn prevention paint to
filtering efficiency is lowered. On the contrary, if it is
the bolts and nuts. Precisely attach the exhaust
too high, the filter absorbs oil and contaminates the
system to the engine to prevent gas leaks from the
case. Especially, when the rotor is contaminated, the
exhaust system joints.
precisely adjusted balance is broken, causing vibration. In addition, the bearings are overloaded, resulting
in bearing burn and abnormal wearing. Therefore, an
air filter should be carefully used and maintained
according to the instructed and specified ways. For a
dry type air filter, the intake resistance should be
small as possible.
2) Exhaust system: For the exhaust system, when
exhaust gas leaks from the exhaust pipe or turbocharger joint, supercharging efficiency is lowered. So
you need to pay attention to prevent gas leakage and
burn. Heat resistant nuts are used for parts which are
highly heated during operation, such as turbine seal,
and the nuts should not be mixed with other nuts. The
screw burn prevention paint should be applied to the
assembly nuts of the specified positions.
3) Lubrication system: For the lubrication system, be
careful with the oil quality and the replacement time
of the cartridge of the oil filter. Degradation of engine
oil has bad effect on the turbocharger, as well as the
engine body.
2. Regular Inspection and Repair: The state and contamination of a turbocharger should be checked regularly.
1) Cautions for attaching the turbocharger to the engine:
Please observe the following precautions as attaching
the turbocharger to the engine and handling it after
attaching. Especially, be careful not to let foreign
substances flow into the turbocharger.
Exhaust system: Check if there is any foreign
Lubrication system: Before attaching the turbocharger

to the engine, inject new oil into the oil inlet and spin
the turbine shaft to lubricate journal bearings and
thrust bearings. Cleanse the pipes from starting from
the engine to the oil inlet and outlet and check if there
is any damage of the pipes or foreign substance in
the pipe. Precisely connect the oil pipes to prevent oil
leaks.
210
Exhaust gas reduction
General information
The Doosan engine is equipped with the DOC (Diesel
Oxidation Catalyst) and SCR (Selective Catalytic Reduction) systems in order to comply with Tier 4 final (and
stage IV) emission control. This SCR system consists of
the dosing module, supply module, DCU (Dosing Control
Unit) and other components. The DEF (Diesel Exhaust
Fluid) is stored in the DEF tank. Once it is needed, it is
pressurized by the supply module and is delivered to the
dosing module under a certain level of pressure. The
dosing module is attached to the exhaust manifold to
spray DEF into the exhaust manifold in front of the SCR
system.
EK00298B
211
Aftertreatment muffler and catalyst
The aftertreatment muffler consists of the DOC muffler,
SCR muffler, mixer pipe and other pipes. The DOC
muffler contains DOC (Diesel Oxidation Catalyst) while
the SCR muffler contains SCR (Selective Catalytic Reduction).
TYPE-A
TYPE-B
EK00299B
1. DOC converter
3. SCR Muffler
2. Mixer
212
DNOx6.5 system
The DNOx6.5 system is used to reduce NOx in emissions
by spraying urea into the SCR catalyst. It consists of the
SM (Supply Module), which functions as a pump, DM
(Dosing Module) to spray urea, DCU to control the overall
system.
Coolant Out
Coolant In
Coolant In
Urea
Suction Line
Urea Press Line
Urea
Back Line
Urea Tank
Coolant Heat
DM
(Dosing Module)
Coolant Out
SM
(Supply Module)
electrical Heat
EK00300B
213
SM (Supply Module)
The supply module is used to pressurize DEF in the DEF
tank to a certain level and supply this pressurized DEF
to the dosing module.
6
Pin 8
Pin 2
Pin 6
Pin 12
PIN 1
Reserve
PIN 7
Reserve
PIN 2
Pump motor control signal
PIN 8
Pressure sensor GND
PIN 3
Pump motor ubal
PIN 9
Pressure sensor signal
PIN 4
Pump motor GND
PIN 10
Pressure sensor ubal
PIN 5
Purging pump ubal
PIN 11
Heater ubal
PIN 6
Purging pump GND
PIN 12
Heater GND
5
2
4
3
EK00303B
1. Connector
4. AdBlue outlet
2. AdBlue inlet
5. Filter cover
3. AdBlue backflow outlet
6. cover
7. Housing
214
DM (Dosing Module)
The dosing module is attached to the exhaust manifold
in front of the SCR system to receive DEF from the
supply module and spray it into the exhaust manifold.
3
4
EK00304A
1. Coolant outlet
4. Protective cap
2. Coolant inlet
5. Cooling adapter
7. AdBlue inlet
3. Head shield
6. Dosing valve
215
Urea filter replacement
1. Remove the filter cover.
EK00306C
3. Insert the end of the filter removing tool 1 until a

EK00305B
clicking sound is heard or engagement with the filter

is felt.
EK00305C
2. Remove the equalizing element.
EK00307B
EK00306B
EK00307C
216
4. Insert the end of the filter removing tool (2) until a
clicking sound is heard or engagement with the filter
is felt.
EK00309C
6. Slide the filter removing tool (4).

EK00308B
EK00310B
7. Remove the filter by pulling the filter removing tool.
EK00308C
5. Slide the filter removing tool (3) until it touches at

edge of the filter removal tools (1&2).
EK00311B
EK00309B
217
Check DNOx6.5 system failures
1. Dosing Module
Dosing Module fault is cause of the high temperature
exposure of Nozzle Tip injecting Urea, Electric
harness contact failure, Urea Hose Line break or poor
contacet, and more. Visual inspection of DM failure
are as follows.
2
3
EK00311C
8. Assemble the new filter, new equalizing element in
order.
9. Tighten filter cover to (20Nm + 5Nm) using 27 inch
Wrench.
DNOx6.5 system components

EK00230A
1. DNOx6.5 system are each divided into a machine

equipped with the most suitable place, and each part
1) When replacing DM, DM and bolts is the leakage or
is protected from damage caused by external environ-
damage caused by under tightening bolts or over

tightening.
ment can be configured so.
2) Electric connector misassembly or debris contamina-
Note) Urea Tank and Supply Module is equipped with the
tion inside of connector.
same Cabin.
3) Urea leakage is caused by Urea Line misassembly.
2. Dosing Module (DM) is equipped by a mixer pipe
4) Coolant leakage is caused by coolant line misas-
between a DOC and SCR muffler. It is conneted with
sembly. The high temperature exposure of DM is
SM in the past Urea Line, the engine coolant Line
caused by disconnected.
and 2Pin connector for Urea dosing valve control.
5) The high temperature exposure of DM is caused by

gasket misassembly.
6) Urea leakage is caused by gasket reuse.
218
2. Supply Module
The Supply Module (SM) failure mode is associated
with Urea Line and Electric Connector damage and
poor connection. When replacing Urea main filter
regularly, Supply module failure can occur caused by
misassembly.
3
4
1
1
EK00344B
CAUTION
When replacing new filter, open the package on the
verge of replacement.
1) When connecting Urea Line, the failure caused by
Urea Line misassembly.
2) Electric connector misassembly or debris contamination inside of connector.
3) When replacing SM Filter, the damage caused by not
using the special tool.Also, it caused by filter remnants
inside SM filter.
4) When replacing filter, the Urea Cap damage is caused
by overtihgtneing and the filter detachment is caused
by not tightening.
219
3. UREA TANK
Urea Tank is keeping the urea solution. Assembly
connected line to correct location. When maintenance
of Urea Tank, be careful not to external impacts.
3
12
6
13
1
7
14
11
9
5
10
4
15
EK00302A
4. Muffler and other pipes

It is no necessary to replace, disassemble and move
mounted muffler and other pipes except by failure
caused by external impact. Tighten the each parts at
tightening torque not to leakage, when replacing,
disassembling and moving muffler and other pipes
caused by failure.
220
Urea Quality Characteristics
LIMITS
CHARACTERISTICS
UNIT
TEST METHODS
MIN.
MAX.
ISO 22241-2 Annex
Urea contenta
%(m/m)b
31.8
33.2
Bc
ISO 22241-2 Annex
Cc
kg/m3
1,087
1,093
ISO 3675 or ISO

12185
1.3814
1.3843
ISO 22241 2 Annex C
Alkalinity as NH3
%(m/m)b
0.2
ISO 22241 2 Annex D
Biuret
%(m/m)b
0.3
ISO 22241 2 Annex E
Aldehydes
mg/kg
ISO 22241 2 Annex F
Insoluble matter
mg/kg
20
ISO 22241 2 Annex

G
Phosphate (PO4)
mg/kg
0.5
ISO 22241 2 Annex H
Calcium
mg/kg
0.5
Iron
mg/kg
0.5
Copper
mg/kg
0.2
Zinc
mg/kg
0.2
Chromium
mg/kg
0.2
Nickel
mg/kg
0.2
Aluminium
mg/kg
0.5
Magnesium
mg/kg
0.5
Sodium
mg/kg
0.5
Potassium
mg/kg
0.5
Density at 20Cd
Refractive index at
20Ce
ISO 22241 2 Annex I
Identity
identical to reference
ISO 22241 2 Annex J
a. Target value 32.5%(m/m).

b. for the purposes of this International Standard. the term %(m/m) is used to represent the mass fraction of a
material.
c. Calculated without subtracting nitrogen from ammonia.
d. Target value 1,090 kg/m3
e. Target value 1.3829
Should it be necessary to add a tracer to AUS 32. it shall be ensured that the quality of AUS 32 specified in this
Table is not impaired and that the tracer does not damage the SCR system.
Note) In establishment of these limit values, the terms of ISO 4259 have been applied in fixing a maximum and minimum
value, a minimum difference of 4 x R (R is the Reproducibility of the test method) has been taken into account.
However, in case of urea content, the 4 x R rule has not been applied in order to keep the high quality.
Note) The values quoted regarding urea content, density and refractive index are true values (see ISO 4259 for definition of true values).
221
Note) The manufacturer of AUS 32 should aim at the target values defined in footnotes a, d and e.
Note) Should it be necessary to clarify the questions as to whether a given urea solution meets the requirement of the
specifications, the terms of ISO 4259 should be applied.
222
EGR (Exhaust Gas Recirculation) system
General Information
To reduce NOx emission from the engine, EGR circulates
Exhaust Gas Recirculation (EGR) System circulates some
the exhaust gas of which oxygen concentration is very
of the exhaust gas from the engine to the intake side,
little to the intake system. As a result, low temperature
cools the gas, and then delivers the cooled gas to the
combustion occurs in the engine and the NOx emission
engine for recombustion in order to reduce NOx emission.
is reduced.
The EGR cooler is used to reduce NOx emission and
enhance engine combustion efficiency by reducing
temperature of high-temperature exhaust gas.
3
4
5
8
2
6
7
9
11
10
EDL022076B
1.
Intake
4.
Throttle valve
7.
Exhaust
10. DOC
2.
Compressor
5.
EGR cooler
8.
EGR Valve
11. Exhaust
3.
Charge air cooler
6.
Intake
9.
Turbine
223
1. Introduction to EGR
1) EGR is a system that reduces NOx emission by recir-
culating some of exhaust gas according to the engine
I
J
conditions.
2) The exhaust gas is piped from the exhaust manifold,
mixed with the intake coming from the intercooler, and
then flows into the engine.
2. Key Characteristics of EGR
J
I
F
1) EGR cooler is used to reduce the temperature of

exhaust gas.
2) Motor-driven electric EGR valve is usedto adjust the
EGR rate.
3. EGR cooler summary
1) The EGR cooler is a heat exchanger which reduces
the high temperature of the circulated exhaust gas.
EDL032043C
2) With the EGR cooler, the EGR engine can reduce
NOx emission and enhance fuel efficiency.
delivery pipe.
4. Key Characteristics of EGR
1) General tube types are used.
washers (J).
Disassembly of EGR
CAUTION

reuse them.

hose (G).

CAUTION
EDL032558C
3. Move the clamp of the coolant hose.
1) Move the clamp that fixes the coolant hose between
hose (A).
the coolant pump and the EGR valve to the midsec-
tion of the coolant hose.
224
6. Remove the EGR valve.
B
A
D
B
A
E
D
EDL032039D
EDL032038C
1) Loosen the flange hex bolts (D:3ea).
2) Remove the EGR valve(A), the EGR cooler(B), and
the gasket (C).
CAUTION
CAUTION
Take care not to damage gaskets during

assembly.
Handle the EGR valve with extra care, because it

is susceptible to external impacts.

Assembly of EGR
1. Install the EGR valve.
them.
A
B
EDL032038C
1) Install the EGR valve (A), the EGR cooler (B), and
the gasket (C).
EDL032537E
bracket.
225
2) Tighten the flange hex bolts (B:3ea) to a tightening
torque of 1.0 kgfm.
CAUTION
Handle the EGR valve with extra care, because it
is susceptible to external impacts.
Ensure that the EGR cooler is facing the right
direction.
Take care not to damage the gasket while
mounting it.
E
D
EDL032039D
CAUTION
B
them.
C
EDL032537E
torque of 2.2 kgfm.
CAUTION
of 2.2 kgfm.
CAUTION



of 3.1 kgfm.

CAUTION

4. Fasten the coolant hose.
1) Tighten the clamp to fasten the coolant hose between
the coolant pump and the EGR valve.
226

I
J
CAUTION
H
J
I
F


oil leaks.

EDL032043C

pipe by hand and tighten the screws to the specified torque.
CAUTION

CAUTION

gasket.

them.
the turbocharger.
EDL032058B
CAUTION

hose (A).
them.
CAUTION

kgfm.


of 2.2 kgfm.
227
Intake manifold
Disassembly of intake manifold
cylinder block.

DL03-LEF00/01

DL03-LEF00/01
02/03
C
D
B
EDL032556C
DL03-LEF02/03
EDL032055C
E
C
DL03-LEL00/01/02/
03/04
D
B
A
EDL032556D
DL03-LEL00/01/02/
03/04
EDL032555D
pressure sensor.

CAUTION
EDL032556E

228

DL03-LEF00/01
CAUTION
D
D
A
E
F
EDL032050C
DL03-LEF02/03
A
B
EDL032548B

D
E
CAUTION

EDL032050D

DL03-LEL00/01/02/
03/04
D
D
E
F
EDL032050E
EDL032547C
pumps.
stake.
229
Assembly of intake manifold
1. Install the intake manifold.
B
A
D
C
EDL032546A
EDL032045A
1) Install the gasket (B).
CAUTION
CAUTION
during disassembly.
7. Remove the intake manifold.

assembly.

them.
B
2) Install the intake manifold (A).

of 2.2 kgfm.
4) Fasten the intake temperature sensor (D) to a tightening torque of 3.0 kgfm.
D
C
B
EDL032045A
1) Remove the intake temperature sensor (D).

2) Remove the flange hex bolts (C).
3) Remove the intake manifold (A).
4) Remove the intake manifold gasket (B).
CAUTION
EDL032046A
230
CAUTION
direction.
during assembly.
B
torque of 2.2 kgfm.
EDL032548B

of 2.2 kgfm.
CAUTION

right direction.
EDL032547C

CAUTION
right direction.

pumps.
231

the intake stake.
DL03-LEF00/01
CAUTION

aligned.

them.

EDL032050C

DL03-LEF02/03

of 2.2 kgfm.

D
E
DL03-LEF00/01
02/03
C
F
D
EDL032050D
DL03-LEL00/01/02/
03/04
A
B
EDL032055C
D
E
F
EDL032050E
232
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION

it.
CAUTION
EDL032808E

DL03-LEF02/03

of 2.2 kgfm.
EDL032808F
233
the cylinder block.
DL03-LEF00/01
CAUTION

EDL032556C
DL03-LEF02/03
EDL032556D
DL03-LEL00/01/02/
03/04
EDL032556E

with a new one.
234
Exhaust manifold
Disassembly of exhaust manifold

CAUTION
B

3. Move the clamp of the coolant hose.
1) Move the clamp that fixes the coolant hose between
the coolant pump and the EGR valve to the midsection of the coolant hose.
EDL032558C

hose(A).
B
A

I
J
D
D
EDL032039D
J
I
F


CAUTION
EDL032043C

delivery pipe.

washers (J).
CAUTION

them.

reuse them.
hose (G).
235
2) Remove the camshaft speed sensor (D).

3) Remove the exhaust gas temperature sensor (C).
5) Remove the exhaust manifold (A).
CAUTION

7. Remove the heat screen.
C
EDL032537E
bracket.

6. Remove the exhaust manifold.
DL03-LEF00/01
02/03
EDL032536C

2) Loosen the mounting bolts (C) and remove the heat
screen (A).
8. Remove the exhaust manifold gasket.
D
C
A
EDL032535D
DL03-LEL00/01/02/
03/04
EDL032534C
1) Loosen the mounting bolts (B).

2) Remove the exhaust manifold gasket (A).
D
E
CAUTION
EDL032535E
1) Loosen the camshaft speed sensor mounting bolt (E).
236
Assembly of exhaust manifold
3. Install the exhaust manifold.
1. Install the exhaust manifold gasket.
DL03-LEF00/01
02/03
A
A
B
B
EDL032535D
EDL032034C
DL03-LEL00/01/02/
03/04
1) Note that the mark of TOP(C) should be facing

upward.
2) Install the exhaust manifold gasket (A).
CAUTION
Replace the gasket with new one; do not reuse it.
D
E
3) Temporarily tighten the mounting bolts (B).

2. Install the heat screen.
EDL032535E
1) Install the exhaust manifold (A).
CAUTION
B

assembly of the exhaust manifold. If the gasket is
C
A
damaged, do not reuse it; replace it with a new one.

of 3.1 kgfm.
3) Tighten the exhaust gas temperature sensor (C) to a
4) Install the camshaft speed sensor (D).
EDL032536C
5) Tighten the mounting bolt (E) of the camshaft speed
1) Install the heat screen (A).
sensor.

kgfm.
3) Tighten the mounting bolts (C) to a tightening torque
of 2.2 kgfm.
237
CAUTION
A

them.


torque of 2.2 kgfm.
CAUTION
EDL032537E
of 2.2 kgfm.
CAUTION

of 3.1 kgfm.

CAUTION

6. Fasten the coolant hose.

1) Tighten the clamp to fasten the coolant hose between
the coolant pump and the EGR valve.
B
A
I
J
H
E
D
D
B
EDL032039D
J
I
F
EDL032043C
238
CAUTION
CAUTION


CAUTION

oil leaks.
gasket.

them.

ified torque.
the turbocharger.
CAUTION
them.
kgfm.
of 2.2 kgfm.
EDL032058B

hose(A).
CAUTION

239
Intake pipe
Air heater disassembly
2. Disconnect the air suction pipe.
DL03-LEF00/01
DL03-LEF00/01
02/03
E
C
D
C
A
B
B
EDL032809C
EDL032055C
E
C
DL03-LEF02/03
DL03-LEL00/01/02/
03/04
B
C
A
A
B
EDL032809D
EDL032555D
DL03-LEL00/01/02/
03/04
view - A
pressure sensor.
CAUTION
C
A
B
EDL032809E
1) Loosen the collared hex bolt (B).

2) Disconnect the air suction pipe (A) from the air heater.
240
DL03-LEL00/01/02/
03/04
CAUTION
view - A
The air heater has different models, depending on

whether of not it has a rubber packing (d). Do not
Air heater assembly

C
1. Install the air suction pipe.
DL03-LEF00/01
B
EDL032809E
1) Install a gasket (c) between the air heater and the air
suction pipe.
2) Install the air suction pipe (A) to the air heater.

torque of 2.2 kgfm.
CAUTION
The air heater has different models, depending on
whether of not it has a rubber packing (d). Do not

EDL032809C

DL03-LEF02/03
DL03-LEF00/01
02/03
C
D
C
A
B
EDL032809D
EDL032055C
241
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION

it.
CAUTION
EDL032808E

DL03-LEF02/03

of 2.2 kgfm.
EDL032808F
242
Intake stake disassembly
DL03-LEF00/01
DL03-LEF00/01
02/03
C
D
D
A
D
C
E
B
F
EDL032050C
EDL032055C
E
C
DL03-LEF02/03
DL03-LEL00/01/02/
03/04
D
B
D
E
F
EDL032050D
EDL032555D
DL03-LEL00/01/02/
03/04
pressure sensor.

CAUTION
F
EDL032050E
stake.
243

the intake stake.
CAUTION
CAUTION
Intake stake assembly

aligned.
DL03-LEF00/01

them.


of 2.2 kgfm.

EDL032050C

DL03-LEF02/03
E
A
DL03-LEF00/01
02/03
C
B
D
A
D
E
C
B
F
EDL032050D
EDL032055C
DL03-LEL00/01/02/
03/04
D
D
E
F
EDL032050E
244
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION

it.
CAUTION
EDL032808E

DL03-LEF02/03

of 2.2 kgfm.
EDL032808F
245
246
10. Cylinder block/head

Cylinder block ..................................................................................................................250

Disassembly of cylinder block ............................................................................................................... 250
Assembly of Cylinder Block ................................................................................................................... 250
Check of Cylinder Block ........................................................................................................................ 250
Measurement of Inside Diameter of Main Bearing Bore of Cylinder Block ...................................... 250
Measurement of inside diameter of piston bore of cylinder block..................................................... 250
Measurement of inside diameter of camshaft bearing of cylinder block ........................................... 251
Cylinder head ..................................................................................................................252

Disassembly of Cylinder Head .............................................................................................................. 252
Assembly of Cylinder Head ................................................................................................................... 252
Check of cylinder head .......................................................................................................................... 252
Valve ................................................................................................................................253
Disassembly of Valve ............................................................................................................................. 253
Assembly of Valve.................................................................................................................................. 253
Measurement of Inside Diameter of Valve Guide ............................................................................... 253
Measurement of valve stem end........................................................................................................... 253
Measurement of valve step height........................................................................................................ 253
Measurement of gap between piston and valve.................................................................................. 254
Check of Valve Spring ........................................................................................................................... 254
Rocker arm ......................................................................................................................256

Disassembly of rocker arm .................................................................................................................... 256
Assembly of rocker arm......................................................................................................................... 259
Check of rocker arm shaft..................................................................................................................... 264
Check of rocker arm .............................................................................................................................. 265
Tappet and push rod .....................................................................................................266

Disassembly of Valve Tappet ................................................................................................................ 266
Assembly of Valve Tappet..................................................................................................................... 266
Check of Valve Tappet ........................................................................................................................ 266
Disassembly of push rod ....................................................................................................................... 266
Assembly of Push Rod .......................................................................................................................... 270
Check of Warpage of Push Rod .......................................................................................................... 275
Camshaft ..........................................................................................................................276
Disassembly of camshaft ....................................................................................................................... 276
Assembly of Camshaft ........................................................................................................................... 276
Measurement of Camshaft Journal Outside Diameter ......................................................................... 276
247
Measurement of Camshaft ..................................................................................................................... 277
Flywheel housing ............................................................................................................278

Disassembly of flywheel housing........................................................................................................... 278
Assembly of flywheel housing ............................................................................................................... 279
Breather ...........................................................................................................................281
Disconnection of breather hose............................................................................................................. 281
Connection of breather hose ................................................................................................................. 281
Cylinder head cover .......................................................................................................282

Disassembly of cylinder head cover ..................................................................................................... 282
Assembly of cylinder head cover .......................................................................................................... 285
Idle gear ..........................................................................................................................290

Disassembly of idle gear ....................................................................................................................... 290
Assembly of idle gear ............................................................................................................................ 291
Measurement of outside diameter of idle gear shaft .......................................................................... 294
Measurement of inside diameter of idle gear ...................................................................................... 294
Lifting hook ......................................................................................................................295

Disassembly of lifting hook .................................................................................................................... 295
Assembly of lifting hook......................................................................................................................... 295
Oil seal ............................................................................................................................297

Front oil seal holder disassembly ......................................................................................................... 297
Front oil seal holder assembly .............................................................................................................. 298
248

General information
General Information
Doosan's diesel engine is an air-cooled electronic control
diesel engine that uses cooling fans, overhead valve, and
turbocharger.
The high-pressure fuel generated from the fuel high-pressure pump is stored in the common rail. When a driver
operates the vehicle, fuel injection timing and optimum
fuel amount are decided based on the data set in the
Electronic Control Unit (ECU) and the solenoid valve of
the injector installed in each engine cylinder is operated
to inject fuel into the cylinder.
The cylinder block is made out of cast iron alloy and an
anti-vibration and anti-noise crank case is mounted. In
addition, the cylinder block and the timing gear case are
designed as an integral structure to reduce the engine
length and improve tightness. The cylinder head is an
integral structure, too.
The forged crankshaft is an integral structure. The oil
seals of the crankshaft and the flywheel prevents oil from
permeating into the flywheel housing.
The connecting rod is forged and its big end part vertically separated. Like a piston, the connecting rod can be
disassembled through the upper side of the cylinder. The
alloy-type prefabricated bearing is used for the active part
of the crankshaft and the connecting rod.
249

Cylinder block
Disassembly of cylinder block
1. Detach the cylinder block.
Note) Refer to Chapter (Procedure of Disassembling an
Engine)
Assembly of Cylinder Block
1. Attach the cylinder block.

Note) Refer to Chapter (Procedure of Assembling an
Engine)
Check of Cylinder Block

1. Cleanse the cylinder block and check if there is any
cracked or damaged part with naked eye.
EDL032085A
2. Replace the cylinder block if it is seriously cracked or
1) Measure 10 points at front and rear of the cylinder
damaged. Repair tiny cracks if existing.
block main bearing (D).
3. Check if the oil path or coolant path is clogged or
2) Measure 3 points-A, B, C-of the cylinder block main
corroded.
bearing section. Measure points A, B, C 3.
4. Perform the hydrostatic test to check whether there is
3) The bore standard of cylinder block main bearings is
a crank or an air leakage.
79.0 ~ 79.021 mm.
5. Block the discharging outlets of the cooling water path

and the oil path of the cylinder block and put pressure
of 4 kg/cm 2 on the inlet. Then sink the cylinder block
Item
Specified Value
in the 70 C water for 1 minute and check if air leaks.
Cylinder Block Main Bearing Bore
79.0 ~ 79.021 mm
Measurement of Inside Diameter of Main

Bearing Bore of Cylinder Block
Measurement of inside diameter of piston

bore of cylinder block
1. Assemble the cylinder block and the crank case.
1. Set the gauge.
2. Set the gauge.
2. Remove any foreign substances from the piston bore

of the cylinder block.
3. Remove the foreign substances from the main bearing
3. Measure the piston bore of the cylinder block.
bore of the cylinder block.

4. Measure the inside diameter of the main bearing bore
EDL032086A
EDL032084A
250
D
10 mm
70 mm
140 mm
EDL032089A
EDL032087A
1) For 4 piston bores of the cylinder block, measure total
1) Measure 6 points of the cylinder block camshaft
12 points of the piston bores: top, middle and bottom.
bearing shell (D): front and rear for each of 3 shells.
2) Measure 2 points of A and B on the piston bore of
2) Measure 3 points-A, B, C-of the cylinder block main
the cylinder block.
bearing section.
3) The bore standard of cylinder block main bearings is
3) The bore standard of camshaft bearings is 5.0 ~
97.990 ~ 98.010 mm.
45.025 mm.
Item
Specified Value
Item
Specified Value
Cylinder Block Piston Bore
97.990 ~ 98.010 mm
Cylinder Block Bore of camshaft

bearing
45.0 ~ 45.025 mm
Measurement of inside diameter of camshaft

bearing of cylinder block
1. Set the gauge.
2. Remove any foreign substances from the camshaft
bearing shell of the cylinder block.
3. Measure the inside diameter of the camshaft bearing
EDL032088A
251

Cylinder head
Disassembly of Cylinder Head
4. Check flatness of the cylinder head.

Engine)
Assembly of Cylinder Head

1. Attach the cylinder head.
Engine)
Check of cylinder head

1. Remove carbon from the bottom surface of the
cylinder head.
Note) Be careful not to scratch the valve seat surface.
EDL032091A
2. For cracks or damage which cannot be checked with
1) Place the cylinder head on a flat surface with its
naked eye, perform the hydrostatic test or the
bottom facing upward.
magnetic particle testing.
2) Measure the flatness of the gasket surface of the
3. Check if the cylinder head is warped.
cylinder head, using a straight edge and a clearance

gauge.
3) The flatness standard of cylinder head gasket surfaces
is 0.05 mm, 0.03 mm / 100 mm.
Item
Specified Value
Flatness of cylinder head

gasket surface
0.05 mm
0.03 mm / 100 mm
E
A
4) Measure the flatness for assembly surfaces of the

intake manifold and the exhaust manifold, using a
straight edge and a clearance gauge.
5) The flatness standard for assembly surfaces of intake
and exhaust manifolds is 0.05 mm / 100 mm.
EDL032090A
1) Place the cylinder head on a flat surface with its

bottom facing upward.
2) Check 6 directions from A to F with a scale and a
clearance gauge.
Item
Specified Value
Flatness of exhaust manifold assembly surface
0.05 mm / 100 mm
Flatness of intake manifold

assembly surface
0.05 mm / 100 mm
5. Perform the hydrostatic test.

1) Close the coolant and oil outlets of the cylinder block,
put a pressure of about 4 kg/cm2 into the outlets, and
leave the cylinder block in the water for 70C to check
for leakage.
252

Valve
Disassembly of Valve
3. Measure the valve stem end (A).
1. Remove the valve.

Engine)
Assembly of Valve
1. Mount the valve.
Engine)
Measurement of Inside Diameter of Valve

Guide
1. Mount the valve guide to the cylinder head.
2. Set the meter.
EDL022093A
3. Measure the inside diameter of the valve guide.

1) Measure the intake valve stem ends.
2) The standard of intake valve stem ends is 20.8 ~ 21.3

mm.
3) Measure the intake valve stem ends.
4) The standard of intake valve stem ends is 20.8 ~ 21.3
mm.
Item
Specified Value
Intake valve stem end
20.8 ~ 21.3 mm
Exhaust valve stem end
20.8 ~ 21.3 mm
Measurement of valve step height

1. Measure the height of the contact surface of the
EDL022092A
intake and exhaust valve. If the measurement value
1) Measure total 6 points of the valve guide to the
is over the allowable limit, it means that the valve seat
vertical direction (B) and the horizontal direction (A):
is worn. Replace the valve seat.
top, middle, and bottom.
2. Measure the valve step height.
2) Measure 16ea valves; 8ea intake valves and 8ea

exhaust valves.
3) The standard measurement value of the valve guide
inside diameter is within the range of 7.0 ~ 7.015 mm.
Item
Specified Value
Valve guide inside diameter
7.0 ~ 7.015 mm
D A
C B
Measurement of valve stem end
D A
C B
1. Mount the valve to the cylinder head.

2. Perform the zero point adjustment of the meter.
EDL032094A
253

1) Put the valves in the valve seat of the cylinder head
Item
Specified Value
Clearance between pistons

and the intake valve
1.69 ~ 2.52 mm
Clearance between pistons

and the exhaust valve
1.54 ~ 2.33 mm
and measure how deep the valves have been put

from the bottom surface of the cylinder head.
2) Measure 4 points-A, B, C, D-of the valve.
3) The standard of intake valves is 0.6 ~ 0.9 mm, and
the valve should be replaced when it exceeds 0.6 ~
1.8 mm.
4) The standard of exhaust valves is 0.6 ~ 0.9 mm, and
Check of Valve Spring
the valve should be replaced when it exceeds 0.6 ~
1. Check visually the exterior of the valve spring.
1.2 mm.
1) Check visually if the valve spring has any external

Item
damage and replace it with a new one if required.
Specified Value
2. Check the free length of the valve spring.

Intake Valve Step Height
0.6 ~ 0.9 mm
Exhaust Valve Step Height
0.6 ~ 0.9 mm
Measurement of gap between piston and

valve
2. Prepare measurement of the gap between the piston
and the valve.
EDL022096A
1) Measure the free length of the valve spring with the
vernier calipers.
2) The free length of the valve spring is 55.23 mm.
Item
Specified Value
Valve spring free length
55.23 mm
3. Check the valve spring squareness.
EDL022095A
1) Prepare small pieces of lead of approx. 3mm thickness.
2) Place greased lead on 16 points: 4 points-A, B, C,

and D-on each top of 4 pistons.
3) Attach the cylinder head.
4) Rotate the crankshaft pulley in order to move the
piston.
5) Detach the cylinder head.
3. Measure the clearance between pistons and valves.
1) Measure the thickness of the lead with a vernier
caliper.
2) The clearance standard between piston and intake
valve is 1.69 ~ 2.52 mm.
EDL022097A
3) The clearance standard between piston and exhaust

valve is 1.54 ~ 2.33 mm.
254

A. Free length
B. Squareness
C. Right-angle square
1) Measure the squareness of the valve spring with the
surface plate and the right-angle square.
2) The squareness of the valve spring is 2 (less than
1.8 mm).
Item
Specified Value
2 (less than 1.8 mm)
4. Check the tension of the valve spring.
EDL022098B
1) Measure the tension of the valve spring with the

spring tester (A).
Note) If the measurement value is abnormal, replace the
valve spring with a new one.
255

Rocker arm
Disassembly of rocker arm
DL03-LEL00/01/02/
03/04
E
C
D
B
A
EDL032555D
EDL032558C
pressure sensor.
hose(A).

CAUTION
E
DL03-LEF00/01
02/03
D
DL03-LEF00/01
B
A
D
D
EDL032055C
F
EDL032050C
256

DL03-LEF02/03
A
B
D
D
F
EDL032050D
EDL032548B
DL03-LEL00/01/02/
03/04

CAUTION
D
E
A
EDL032050E
stake.
CAUTION
EDL032547C

pumps.
257

6. Remove the heat screen brackets.
B
A
EDL032031C
EDL032816B
1) Loosen the hex bolts (B).
2) Remove the heat screen bracket (A).

CAUTION
Remove the heat screen bracket, using care not to
damage the bracket and the cylinder head cover.

C
D
A
B
EDL032530A

EDL032531B
CAUTION
disassembly.
258

Assembly of rocker arm
EDL032529D
EDL032028A

of 2.2 0.3 kgfm.
EDL032529C

EDL032529D
EDL032528A
EDL032529B

259

torque of 0.3 kgfm.
CAUTION

0.05 kgfm.

CAUTION

ones.
0.35kgfm.

B
A
B
A
EDL032031A
EDL032030A

CAUTION

damaged.
EDL032031B
cover (A).
bility.

260

CAUTION
CAUTION
right direction.

ones.
reassembly.
5. Install the heat screen brackets.
pumps.
A
B
A
EDL032817B
1) Install the heat screen brackets (A).

EDL032548B
kgfm.

of 2.2 kgfm.

CAUTION

right direction.

EDL032547C

261


the intake stake.
DL03-LEF00/01
CAUTION

aligned.

them.

EDL032050C

DL03-LEF02/03

of 2.2 kgfm.

D
E
DL03-LEF00/01
02/03
C
F
D
EDL032050D
DL03-LEL00/01/02/
03/04
A
B
EDL032055C
D
E
F
EDL032050E
262
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION

it.
CAUTION
EDL032808E

DL03-LEF02/03

of 2.2 kgfm.
EDL032808F
263

2. Check warpage of the rocker arm shaft.
EDL032058B
EDL022101A
1) Put the rocker arm shaft on two V-blocks.
2) Install the dial gauge.
3) Check the degree of warpage of the rocker arm shaft
hose(A).
as rotating the rocker arm shaft.

Note) If the warpage is slight, correct it by pressing with
CAUTION
the press. If the warpage is out of the allowable

limit, replace it with a new one.
3. Check the outside diameter of the rocker arm shaft.
Check of rocker arm shaft

1. Remove the rocker arm shaft.
EDL032102A
1) Measure the outside diameter of the rocker arm shaft

on the position where the rocker arm is attached with
the outside diameter micrometer.
Note) If the outside diameter is out of the allowable limit,
replace it with a new one.
EDL032100A
1) Loosen and remove the fixing bolts from the rocker

arm bracket.
2) Remove the rocker arm bracket, the rocker arm shaft
spring, the rocker arm, and the rocker arm shaft in
the order as listed before.
264

Check of rocker arm
Note) Compare the measured value with the external

diameter of the rocker arm shaft, and if the clear-
ance exceeds the specified value, replace the more

worn-out one.
EDL032100A
1) Loosen and remove the fixing bolts from the rocker

arm bracket.
2) Remove the rocker arm bracket, the rocker arm shaft
spring, and the rocker arm in the order as listed
before.
2. Check the exterior of the rocker arm with the naked
eye.
1) Check whether the adjust screw cap assembly
surface, which moves as contacting to the valve stem,
is scratched, or the layer is worn with the naked eye.
Note) If the wear is slight, polish it with the oil-contained
whetstone or fine sandpaper. If the layer is seriously worn, replace the rocker arm with a new one.
Note) When polishing the rocker arm, use the sandpaper
dipped in oil
3. Measure the inside diameter of the rocker arm.
EDL032103A
1) Measure the rocker arm inside diameter with the

micrometer or the vernier calipers.
265

Tappet and push rod
Disassembly of Valve Tappet
3. Measure the outside diameter of the valve tappet.
1. Detach the valve tappet.

Engine)
Assembly of Valve Tappet

1. Attach the valve tappet.
Engine)
Check of Valve Tappet

1. Check the exterior of the valve tappet with naked eye.
EDL022105A
1) Measure the outside diameter of the valve tappet with

the outside diameter micrometer.
Note) If the diameter is out of the allowable limit, replace
Normal
Abnormal
(Embossment)
Abnormal
(Crack)
the valve tappet with a new one.
Disassembly of push rod

Abnormal
Abnormal
A
EDL0213006B
1) Check whether the valve tappet surface, which moves
as contacting to the camshaft, is cracked or scratched.

whetstone or fine sandpaper. If the crack or scratch
is serious, replace the valve tappet with a new one.
Note) For polishing the camshaft, use the sandpaper
dipped in oil.
2. Measure the gap of the valve tappet.
1) Measure the outside diameter of the valve tappet and
EDL032558C
the tappet hole diameter of the cylinder block.
Note) If the diameter is out of the allowable limit, replace
the valve tappet with a new one.
hose(A).
266


DL03-LEF00/01
02/03
DL03-LEF00/01
B
D
D
A
D
B
E
F
EDL032055C
E
C
EDL032050C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
A
B
A
E
F
EDL032555D
EDL032050D
DL03-LEL00/01/02/
03/04
pressure sensor.

CAUTION
F
EDL032050E
stake.
267

CAUTION
B
A
EDL032816B
CAUTION
EDL032548B

CAUTION
A
EDL032531B
EDL032547C

pumps.
268

EDL032031C
EDL032529D

C
D
EDL032529C

EDL032530A

CAUTION
disassembly.
EDL032528A

269

11. Remove the push rods.
EDL032027A
EDL032028A
1) Remove the push rods (A) from the cylinder head
hole.

of 2.2 0.3 kgfm.
Assembly of Push Rod
1. Install the push rods.
EDL032529D
EDL032027A
1) Apply engine oil on both ends of the push rods (A).

2) Install the push rods (A) in the cylinder head holes.
3) Tap the heads of the push rods 1 - 2 times with a
rubber hammer to be settled in the tappet holes.
EDL032529B

270

torque of 0.3 kgfm.
CAUTION

0.05 kgfm.

CAUTION

ones.
0.35kgfm.

B
A
B
A
EDL032031A
EDL032030A

CAUTION

damaged.
EDL032031B
cover (A).
bility.

271

CAUTION
CAUTION
right direction.

ones.
reassembly.
pumps.
A
B
A
EDL032817A

EDL032548B
kgfm.

of 2.2 kgfm.

CAUTION

right direction.

EDL032547C

272


the intake stake.
DL03-LEF00/01
CAUTION

aligned.

them.

EDL032050C

DL03-LEF02/03

of 2.2 kgfm.

D
E
DL03-LEF00/01
02/03
C
F
D
EDL032050D
DL03-LEL00/01/02/
03/04
A
B
EDL032055C
D
E
F
EDL032050E
273
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION

it.
CAUTION
EDL032808E

DL03-LEF02/03

of 2.2 kgfm.
EDL032808F
274

EDL032058B

hose(A).
CAUTION
Check of Warpage of Push Rod

1. Check warpage of the push rod.
Gap gauge
EDL0213007A
1) Put the push rod on the surface plate.

2) Measure the warped degree with the gap gauge as
rolling the push rod.
Item
Specified Value
Warpage of push rod
0.5 mm
275

Camshaft
Disassembly of camshaft
3) Align the cam gear (A) with the straight key groove
and fasten it with hot pressing.
1. Detach the camshaft.

Note) Refer to Chapter About the Engine
CAUTION
2. Remove the camshaft gear.
Note that the heating temperature for the

camshaft gear should remain above 160C and
must not be over 200C.
Ensure that the mark imprinted on the gear is

facing outward.
C
2. Attach the camshaft.
Note) Refer to Chapter About the engine.
Measurement of Camshaft Journal Outside

Diameter
1. Set the gauge.
2. Remove foreign substances from the camshaft.
EDL032107A
3. Measure the outside diameter of the camshaft journal.
1) Heat the camshaft gear (A) to 180C 10C.

2) Remove the camshaft gear (A), thrust washer (C), and
straight key (D) from the camshaft (B).
CAUTION
Note that the heating temperature for the camshaft
gear should remain above at least 160C and must
not be over 200C.
Assembly of Camshaft
1. Install the cam gear.
EDL022108B
1) For 3ea camshaft journals, measure total 6 points of
the outside diameters: front and rear.
D
A
2) Measure 2 points (vertical and horizontal) of the

outside diameters of the camshaft journals.
3) The standard measurement value of the outside diameter of the camshaft journal is within the range of
44.950 ~ 44.966 mm.
Item
Specified Value
Camshaft journal
44.950 ~ 44.966 mm
Note) If the outside diameter is out of the allowable limit,
EDL032107A
replace the camshaft with a new one.
1) Heat the cam gear (A) to 180C 10C.
Note) Check whether the camshaft surface is cracked or
2) Install the thrust washer (C) and the straight key (D)
scratched.
to the camshaft (B).
276

2) Check the degree of warpage of the camshaft with
the dial gauge.
whetstone or fine sandpaper. If the crack or scratch
Note) If the warpage is out of the allowable limit, replace
is serious, replace the camshaft with a new one.
the camshaft with a new one.
Note) For polishing the camshaft, use the sandpaper

dipped in oil.
Measurement of Camshaft
1. Check the camshaft offset.
Gap gauge
EDL0213003A
1) Move the camshaft gear to the opposite side of the

cylinder block.
2) Measure the gap between the thrust washer and the
camshaft gear with the gap gauge.
Item
Specified Value
Camshaft offset
0.1 ~ 0.2 mm
Note) Check if the gap is within the range of0.1 ~ 0.2

mm.
Note) If the offset is too large, replace the thrust washer
with a new one.
2. Measure warpage of the camshaft.
EDL022110A
1) Put the camshaft on two V-blocks.
277

Flywheel housing
Disassembly of flywheel housing
DL03-LEF02/03

A
EDL032708C

EDL032557A
CAUTION

reuse them.
DL03-LEF00/01

DL03-LEF00/01
02/03
B
B
A
EDL032021C
EDL032520B
278

DL03-LEL00/01/02/
03/04
Assembly of flywheel housing

DL03-LEF00/01
02/03
A
EDL032520D
CAUTION
EDL032519C

DL03-LEL00/01/02/
03/04

DL03-LEF00/01
02/03
A
B
EDL032520C

EDL032519C
CAUTION
DL03-LEL00/01/02/
03/04
right direction.
kgfm.
EDL032520C
279

DL03-LEF02/03
D
A
B
B
D
EDL032708C
EDL032020B
crankshaft (D).

1st Stage

kgfm
2nd Stage
45 Rotation
CAUTION
DL03-LEF00/01
the flywheel.
EDL032021C
EDL032057A
bolt.
of 2.2 kgfm.
280

Breather
Disconnection of breather hose

hose(A).
CAUTION

EDL032558C

hose(A).
Connection of breather hose

EDL032058B
281

Cylinder head cover
Disassembly of cylinder head cover
DL03-LEL00/01/02/
03/04
E
C
D
B
A
EDL032555D
EDL032558C
pressure sensor.
hose(A).

CAUTION
E
DL03-LEF00/01
02/03
D
DL03-LEF00/01
B
A
D
D
EDL032055C
F
EDL032050C
282

DL03-LEF02/03
A
B
D
D
F
EDL032050D
EDL032548B
DL03-LEL00/01/02/
03/04

CAUTION
D
E
A
EDL032050E
stake.
CAUTION
EDL032547C

pumps.
283

B
A
EDL032031C
EDL032816B

CAUTION

C
D
A
B
EDL032530A

EDL032531B
CAUTION
disassembly.
284

EDL032529B
EDL032529D

0.05 kgfm.
CAUTION

ones.
EDL032529C


Assembly of cylinder head cover

A
EDL032030A

EDL032529D
285

CAUTION

damaged.

damage to the engine due to combustion instability.

EDL032031B
torque of 0.3 kgfm.

CAUTION
cover (A).


0.35kgfm.
CAUTION

ones.

reassembly.
EDL032031A
B
A
EDL032817B
286

of 2.2 kgfm.
kgfm.

CAUTION

right direction.

EDL032547C
CAUTION
DL03-LEF00/01

right direction.



pumps.
EDL032050C
DL03-LEF02/03
A
B
B
D
E
F
EDL032548B
EDL032050D

287

DL03-LEL00/01/02/
03/04
DL03-LEF00/01
02/03
C
D
D
A
D
E
C
B
F
EDL032050E
EDL032055C

the intake stake.
E
C
CAUTION
DL03-LEL00/01/02/
03/04
aligned.
them.


EDL032555D
DL03-LEF00/01

of 2.2 kgfm.
EDL032808E
288

DL03-LEF02/03

EDL032808F
DL03-LEL00/01/02/
03/04
view - A
EDL032058B

hose(A).
CAUTION
EDL032808G

air heater.
CAUTION

it.
CAUTION
of 2.2 kgfm.
289

Idle gear
Disassembly of idle gear
DL03-LEF02/03

A
EDL032708C

EDL032557A
CAUTION

reuse them.
DL03-LEF00/01

DL03-LEF00/01
02/03
B
B
A
EDL032021C
EDL032520B
290

DL03-LEL00/01/02/
03/04
5. Remove the idle gear.
B
EDL032520D
EDL032513C
CAUTION
2) Remove the idle gear shaft (B).
3) Remove the idle gear (A), using its pulling tap (D).
Assembly of idle gear

1. Install the idle gear.
DL03-LEF00/01
02/03
B
EDL032519C
EDL032013B
DL03-LEL00/01/02/
03/04

camshaft.
CAUTION
The idle gear and the camshaft gear have 2 marks
imprinted on them.
A
B
EDL032520C
291


DL03-LEF00/01
02/03
CAUTION
The idle gear has 4 marks imprinted on it.
With the key groove of the crankshaft gear at 12

3) Install the idle gear (A), aligning its marks.
CAUTION
Install the idle gear with it marks facing outward

EDL032519C
from the engine.
DL03-LEL00/01/02/
03/04
4) Install the idle gear shaft with its oil hole facing
upward.
5) Temporarily install the flange hex bolts (B), aligning
with the holes of the ilde gear shaft.
of 4.4 kgfm.
7) The backlash between idle gear and crankshaft gear
is 0.087 ~ 0.202 mm.
Item
Gear and Crank Shaft
Gear
A
Specified Value
0.087 ~ 0.202 mm
EDL032520C
8) The backlash between idle gear and camshaft gear is
0.087 ~ 0.213 mm.

Item
Gear and Camshaft Gear
CAUTION
Specified Value
0.087 ~ 0.213 mm
right direction.
kgfm.
292

DL03-LEF02/03
D
A
B
B
D
EDL032708C
EDL032020B
crankshaft (D).

1st Stage

kgfm
2nd Stage
45 Rotation
CAUTION
DL03-LEF00/01
the flywheel.
EDL032021C
EDL032057A
bolt.
of 2.2 kgfm.
293

Measurement of outside diameter of idle
gear shaft
2) The standard measurement value of the inside diameter of the idle gear is within the range of 64.0 ~
64.019 mm.
1. Set the gauge.

2. Measure the outside diameter of the idle gear shaft.
EDL032111A
1) Measure total 4 points of the outside diameter of the

idle gear shaft: vertical (A), horizontal (B), front (C),
and rear (D).
2) The standard measurement value of the outside diameter of the idle gear shaft is within the range of 59.921
~ 59.940 mm.
Item
Specified Value
Outside diameter of the

idle gear shaft
59.921 ~ 59.940 mm
Measurement of inside diameter of idle gear

1. Set the gauge.
2. Measure the inside diameter of the idle gear.
A
C
EDL032112A
1) Measure total 4 points of the inside diameter of the

idle gear: vertical (A), horizontal (B), front (C), and
rear (D).
294
Item
Specified Value
Inside diameter of the idle

gear
64.0 ~ 64.019 mm

Lifting hook
Disassembly of lifting hook
2. Remove the rear lifting hook.
1. Remove the front lifting hook.
A
DL03-LEF00/01
A
B
EDL032553B
EDL032554B
2) Remove the rear lifting hook (A).

DL03-LEF02/03
Assembly of lifting hook

1. Install the rear lifting hook.
B
EDL032554C
DL03-LEL00/01/02/
03/04
EDL032553B
A
1) Install the rear lifting hook (A).

of 4.4 kgfm.
EDL032554D

2) Remove the front lifting hook (A).
295

2. Install the front lifting hook.
DL03-LEF00/01
A
B
EDL032554B
DL03-LEF02/03
A
B
EDL032554C
DL03-LEL00/01/02/
03/04
EDL032554D
1) Install the front lifting hook (A).

of 4.4 kgfm.
296

Oil seal
Front oil seal holder disassembly

DL03-LEF00/01
D
A
EDL032022B
EDL032810C

DL03-LEF02/03

EDL032811B

V-belt and bolts.
EDL032511B

CAUTION
297

jig.
CAUTION
C

assembly.

EDL032510C

one.
for the groove (C).

attaching it.
Front oil seal holder assembly
C
C
A
A
B
B
EDL032010B
EDL032010B
assembly jig (C).
assembly jig (C).
298

DL03-LEF00/01
jig.
B
CAUTION

assembly.

EDL032810C

one.
DL03-LEF02/03

attaching it.

A
B
EDL032811B


EDL032022B

hex bolt (B).
26 kgfm.
torque of 2.2 kgfm.
CAUTION

299
300
11. Electric system

Circuit diagram ................................................................................................................303
Engine Connector ................................................................................................................................... 304
Engine connector of engine control unit (ECU) (DL03-LEF00/LEF01/LEF02/LEF03) ....................... 306
Engine connector of engine control unit (ECU) (DL03-LEL00/LEL01/LEL02/LEL03/LEL04)............. 309
Switches and sensors ....................................................................................................311

Mass Air Flow Sensor (MAF)................................................................................................................ 311
Boost Temperature Sensor (BTS) ......................................................................................................... 311
Boost Pressure Sensor (BPS) ............................................................................................................... 311
Exhaust Gas Temperature Sensor (EGTS) .......................................................................................... 311
Oil Pressure and Temperature Sensor (OPTS) ................................................................................... 312
Water Temperature Sensor (WTS)........................................................................................................ 312
Fuel temperature sensor (FTS) ............................................................................................................. 312
Rail pressure sensor (RPS) ................................................................................................................... 312
Injector #1(INJ)........................................................................................................................................ 313
Injector #2 (INJ)...................................................................................................................................... 313
Injector #3 (INJ)...................................................................................................................................... 313
Injector #4 (INJ)...................................................................................................................................... 313
Crank Shaft Position Sensor (CRK)...................................................................................................... 314
Crank Shaft Position Sensor (CRK)...................................................................................................... 314
CAM Shaft Position Sensor (CAM)....................................................................................................... 314
Knock Sensor1(KNOCK1)....................................................................................................................... 315
Knock Sensor2(KNOCK2)....................................................................................................................... 315
Exhaust Gas Recirculation Valve Position Sensor (EGR) .................................................................. 315
Inlet Metering Valve (IMV) ..................................................................................................................... 316
Water In Fuel Sensor (WIFS) ............................................................................................................... 316
Wire harness ...................................................................................................................317

Disassembly of Wire Harness ............................................................................................................... 317
Assembly of Wire Harness .................................................................................................................... 317
ECU (Electronic Control Unit) ........................................................................................318

Electronic Control Unit (ECU) Connectors............................................................................................ 319
I/O of Electronic Control Unit (ECU) .................................................................................................... 320
Operational Conditions of Electronic Control Unit (ECU) .................................................................... 321
Starter ..............................................................................................................................322
Wiring Diagram ....................................................................................................................................... 324
301
Performance curve.................................................................................................................................. 325

Disassembly of Starter ........................................................................................................................... 327
Assembly of Starter ................................................................................................................................ 327
302
11. Electric system

Circuit diagram
General Information
1. Circuit diagrams allow you to check the circuit number
of the connector connected to the engine connector
of the engine control unit (ECU).
EDL032172B
2. The wire colors are as follows.

1) W: White
2) Y: Yellow
3) L: Blue
4) O: Orange
5) P: Purple
6) B: Black
7) RW: Red & White
3. The wire types are as follows.
1) AESSXF
2) TUBE_AMS11
3) TUBE_AMS12
4) AESSXF_AMS11
5) AESSXF_AMS12
6) AESSXG_AMS13
7) AEXF
4. ECU PIN No. is the pin number of the engine
connector.
5. Sensor PIN No. is the pin number of the sensor
connector.
303
11. Electric system

Engine Connector
Main Power
Relay
F1
KL30
Pbatt
Protected Battery
201
Protected Battery
203
Protected Battery
205
ECU Main Power Relay

Option
Start Button
Normal Open
Start Switch
245
Key Switch Input
219
A/C Request
258
Starter Relay HSD
211
Power Ground
202
Power Ground
204
Power Ground
206
Inlet Metering Valve, PWM
177
KL87
F2
KL30
224 VREF1 PPS1, (5V)

225 Accelerator Pedal Position Sensor 1
226 PPS1 Return
229 VREF2 PPS2, (5V)
213 Accelerator Pedal Position Sensor 2
212
Key Switch
F3
214 PPS2 Return

KL15
KL30
01 2
AC Request
Normal Open
216 Low Idle Switch

ECU
DCM 3.7
Vbatt
Starter Relay
F4
Battery
12V
Inlet Metering
Valve
105 Exhaust Gas Temperature Sensor 1

122 Exhaust Gas Temperature Sensor 1 Return
5
EGR Valve
DC Motor
3
6
2
Exhaust Gas Temperature

Sensor. Before DPF

Sensor. Before Turbine

Sensor. Before DOC
Boost Temperature
Sensor


Waste Gate
186
Waste Gate
PWR GND
SH-72544 C
140Mhz
(2.5MB internal
flash, 128kB
internal RAM
8kB emulated
EEPROM)
Pedal Position Sensor
EGR, VREF3
164
EGR Position Sensor Signal
116
EGR Sensor Return GND
172
166
EGR (H-Bridge Pos)
192
112 Exhaust Gas Delta Pressure Sensor
EGR (H-Bridge Neg)
193
167
Air Mass Flow Sensor, frequency signal
228
183 Intake Throttle (H-Bridge Neg)
Air Inlet Temperature, analogue signal
235
163 VREF 3, Intake Throttle Position Sensor
TMAF Sensor Return
233
VREF2, EG_DPS
VREFGND, EG_DPS
1
2
Exhaust Gas
Delta Pressure
Sensor
Pbatt
D
Air Mass Flow
and Air
Temperature
Sensor QL
184 Intake Throttle (H-Bridge Pos)

B
E
t
Intake Throttle
183 Intake Throttle Position Feedback (analogue)

183 Intake Throttle Position Sensor GND
IGN
Coolant
Temperature
Sensor
Fuel
Temperature
Sensor
Engine Block
Accelerometer #1
Engine Block
Accelerometer #2
1
2
1
1
2
1
2
VR Crank
Sensor
Coolant Temperature Sensor
109
Coolant Temperature Return
145
Fuel Temperature Sensor
110
Sensor Return GND
146
Engine Block Accelerometer #1
131
Engine Block Accelerometer Return
130
Engine Block Accelerometer Screen
128
Engine Block Accelerometer #2
132
Engine Block Accelerometer Return
133
Engine Block Accelerometer Screen
129
Crank Sensor Pos
160
Crank Sensor Neg
136
CPS_SHD
187
Pbatt
CAM Shaft
Sensor
CAM
CAM Shaft Position Sensor
159
CAM Shaft Position Sensor Return
147
HALL
Rail
Pressure
Sensor
C
A
B
VREF1 Rail Pressure Sensor
138
Rail Pressure Sensor
135
Rail Pressure Sensor Return
119
Vbatt
KL15
KL30
A/C Relay
251 A/C Relay
162 VREF2 EMP Sensor
117 Exhaust Manifold Pressure Sensor
121 EXHPRES Return GND
165
VREF3, Engine Oil Pressure
111
Engine Oil Pressure Sensor
148
Engine Oil Pressure & Temp Return GND
104
Engine Oil Temperature Sensor
161
VREF2, INPRES
112
Intake Manifold Pressure Sensor
167
INPRES Return GND
248
CAN_1 HI
247
CAN_1 LO
239
S_R_LIN
253
CAN_2 HI
254
CAN_2 LO
Vs
Sig
Rtn
VS
V
Vp
Rtn
Vt
P
t
Oil Pressure
and
Temperature
Sensor
B
A
Intake Manifold
Pressure Sensor
CAN_Vehicle HI
CAN_Vehicle LO
Un Terminated in ECU
CAN_Development HI
CAN_Development LO
231
Exhaust
Manifold
Pressure
Sensor
Terminated in ECU
C_ISOK
127
Fuel Injector HSDA
126
Fuel Injector LSD1A
151
Fuel Injector HSDB
175
Fuel Injector LSD1B
103
Fuel Injector HSDA
125
Fuel Injector LSD2A
150
Fuel Injector HSDB
174
Fuel Injector LSD2B
Cyl #1
Cyl #3
Cyl #4
Cyl #2
EDL032123A
304
Parking Brake
181
Diagnostic Request
195
Transmission Neutral Position Switch
196
Engine Stop Request
152
PTO/Cruise - Engage
218
IGN
T87
Vbatt
PWR GND
Engine Brake
236 Engine Brake Actuator

ECU
DCM 3.7
NC
Clutch top Switch
232 Brake Pedal Switch
Brake Pedal Switch, NC
230 Brake Lamp Switch
Brake Lamp Switch, NC

Brake
Lamp
217
246 Engine Speed Out. PWM 50mA MAX
Transmission Oil Temperature Switch
134
Ground Speed Control Switch
153
222
VREF2, ACPRES
208
AC Pressure Sensor
220
Shared Return GND
227
Vehicle Speed Sensor
137
VREF3 (5V)
114
Regen - Start
120
Switch Return
113
4 State switch Input
209
Water In Fuel Sensor
AC Pressure
Sensor
Option
V
P
Vehicle
Speed
Sensor
Regen
Switch
3 State
Switch
4 State
Switch
H 2O O
223
VREF3 (5V)
215
PTO/Cruise Control Input
Cruise /
PTO
Switch
210
Speed Sensor Vref
240
Fan Speed (Frequency Input)
249
Fan 1A LSD PWM
171
Fan Speed Return
255
MIL Lamp LSD
MIL Lamp
242
CE Lamp LSD
CE Lamp
241
Glow Lamp LSD
Glow Lamp
238
DPF Regen Lamp LSD
DPF Regen
250
Warning Lamp LSD
Warning
Auto Fan
FAN
LSD
237
REGEN Inhibit Lamp LSD
Regen Inhibit Lamp
257
Oil Pressure Warning Lamp LSD
Oil Pressure
Warning Lamp
EDL032123B
11. Electric system

Engine connector of engine control unit (ECU) (DL03-LEF00/LEF01/LEF02/LEF03)
Circuit
Number
Wire
Size
Wire
Color
Wire
Type
103
0.75
AESSXF
104
0.75
106
0.75
109
ECU
PIN No
Sensor
PIN No
FUEL INJECTOR HSDA
AESSXF
OIL TEMP SENSOR
AESSXF
EXHAUST GAS TEMP SENSOR

2
0.75
AESSXF
COOLANT TEMP SENSOR
110
0.75
AESSXF
FUEL TEMP SENSOR
10
111
0.75
AESSXF
OIL PRESSURE SENSOR
11
112
0.75
AESSXF
INTAKE MANIFOLD PRESSURE

SENSOR
12
113
0.75
AESSXF
REGEN SWITCH-4STATE
SWITCH
13
116
0.75
AESSXF
EGR POSITION SENSOR SIGNAL
16
119
0.75
AESSXF
RAIL PRESSURE SENSOR

RETURN
19
120
0.75
AESSXF
REGEN SWITCH-RETURN
20
123
0.75
AESSXF

2 RETURN
23
125
0.75
AESSXF
FUEL INJECTOR LSD2A
25
TWIST (103, 125)
126
0.75
AESSXF
FUEL INJECTOR LSD1A
26
TWIST (126, 127)
127
0.75
AESSXF
FUEL INJECTOR HSDA
27
TWIST (126, 127)
128
0.75
129
0.75
TUBE
_AMS12
130
0.75
131
0.75
132
Circuit Name
TUBE_AM ENGINE BLOCK ACCELEROMES11

TER #1 SCREEN
Remarks
TWIST (103, 125)
TWIST (119, 135,

138)
28
SHIELD_130_131
(DRAIN)
ENGINE BLOCK ACCELEROMETER #2 SCREEN
29
SHIELD_132_133
(DRAIN)
AESSXF
_AMS11
ENGINE BLOCK ACCELEROMETER #1 RETURN
30
SHIELD_130_131
AESSXF
_AMS11
ENGINE BLOCK ACCELEROMETER #1
31
SHIELD_130_131
0.75
AESSXF
_AMS12
32
SHIELD_132_133
133
0.75
AESSX- ENGINE BLOCK ACCELEROMEF_AMS12 TER #2 RETURN
33
SHIELD_132_133
134
0.75
AESSXF
TRANSMISSION OIL TEMP

SWITCH
34
135
0.75
AESSXF
RAIL PRESSURE SENSRO
35
306
TWIST (119, 135,

138)
11. Electric system

Circuit
Number
Wire
Size
Wire
Color
Wire
Type
136
0.75
AESSXF
_AMS13
137
0.75
138
0.75
145
ECU
PIN No
Sensor
PIN No
CRANK SENSOR NEG
36
AESSXF
VREF3(5V) REGEN SWITCH
37
AESSXF
VREF1 RAIL PRESSURE SENSOR
38
0.75
AESSXF
COOLANT TEMP SENSOR

RETURN
45
146
0.75
AESSXF
FUEL TEMP SENSOR RETURN

GND
46
147
0.75
AESSXF
CAM SHAFT POSITION SENSOR RETURN
47
148
0.75
AESSXF
OIL PRESSURE & TEMP

RETURN GND
48
150
0.75
AESSXF
FUEL INJECTOR HSDB
50
TWIST (150, 174)
151
0.75
AESSXF
FUEL INJECTOR HSDB
51
TWIST (151, 175)
152
0.75
AESSXF
E/G STOP REQUEST
52
153
0.75
AESSXF
TRANSMISSION OIL PRESS

SWITCH
53
10
159
0.75
AESSXF
CAM SHAFT POSITION SENSOR
59
160
0.75
AESSXF
_AMS13
CRANK SENSOR POS
60
161
0.75
AESSXF
VREF2, INPRES
61
164
0.75
AESSXF
EGR, VREF3
64
165
0.75
AESSXF
VREF3 OIL PRESSURE
65
167
0.75
AESSXF
INPRES RETURN GND
67
169
0.75
AESSXF
INTAKE AIR TEMP SENSOR

RETURN
69
172
0.75
AESSXF
EGR SENSOR RETURN GND
72
174
0.75
AESSXF
FUEL INJECTOR LSD2B
74
TWIST (150, 174)
175
0.75
AESSXF
FUEL INJECTOR LSD1B
75
TWIST (151, 175)
177
0.75
AESSXF
INLET METERING VALVE (PWM)
77
181
0.75
AESSXF
PARKING BRAKE
81
187
0.75
TUBE
_AMS13
CRANK SENSOR SHIELD
87
192
0.75
AESSXF
EGR (H-BRIDGE POS)
92
TWIST (192, 193)
193
0.75
AESSXF
EGR (H-BRIDGE NEG)
93
TWIST (192, 193)
Circuit Name
307
Remarks
SHIELD_136_160
TWIST (119, 135,

138)
SHIELD_136_160
SHIELD_136_160
(DRAIN)
11. Electric system

Circuit
Number
Wire
Size
Wire
Color
Wire
Type
194
0.75
AESSXF
195
0.75
196
0.75
K87A
K87B
ECU
PIN No
Sensor
PIN No

RETURN
94
AESSXF
DIAGNOSTIC REQUEST
95
AESSXF
T/M NEUTRAL POSITION

SWITCH
96
0.75
AESSXF
SENSOR 15A FUSE
INTER1_2M
0.75
AESSXF
SENSOR 15A FUSE
INTER1_2M
Circuit Name
308
Remarks
11. Electric system

Engine connector of engine control unit (ECU) (DL03-LEL00/LEL01/LEL02/LEL03/LEL04)
Circuit
Number
Wire
Size
Wire
Color
Wire
Type
103
0.75
AESSXF
104
0.75
106
0.75
109
ECU
PIN No
Sensor
PIN No
FUEL INJECTOR HSDA
AESSXF
OIL TEMP SENSOR
AESSXF

2
0.75
AESSXF
COOLANT TEMP SENSOR
110
0.75
AESSXF
FUEL TEMP SENSOR
10
111
0.75
AESSXF
OIL PRESSURE SENSOR
11
112
0.75
AESSXF
INTAKE MANIFOLD PRESSURE

SENSOR
12
116
0.75
AESSXF
EGR POSITION SENSOR SIGNAL
16
119
0.75
AESSXF
RAIL PRESSURE SENSOR

RETURN
19
120
0.75
AESSXF
REGEN SWITCH-RETURN
20
123
0.75
AESSXF

2 RETURN
23
125
0.75
AESSXF
FUEL INJECTOR LSD2A
25
TWIST (103, 125)
126
0.75
AESSXF
FUEL INJECTOR LSD1A
26
TWIST (126, 127)
127
0.75
AESSXF
FUEL INJECTOR HSDA
27
TWIST (126, 127)
128
0.75
129
0.75
TUBE
_AMS12
130
0.75
131
0.75
132
Circuit Name
TUBE_AM ENGINE BLOCK ACCELEROMES11

TER #1 SCREEN
Remarks
TWIST (103, 125)
TWIST (119, 135,

138)
28
SHIELD_130_131
(DRAIN)
ENGINE BLOCK ACCELEROMETER #2 SCREEN
29
SHIELD_132_133
(DRAIN)
AESSXF
_AMS11
ENGINE BLOCK ACCELEROMETER #1 RETURN
30
SHIELD_130_131
AESSXF
_AMS11
31
SHIELD_130_131
0.75
AESSXF
_AMS12
32
SHIELD_132_133
133
0.75
AESSX- ENGINE BLOCK ACCELEROMEF_AMS12 TER #2 RETURN
33
SHIELD_132_133
135
0.75
AESSXF
RAIL PRESSURE SENSRO
35
TWIST (119, 135,

138)
136
0.75
AESSXF
_AMS13
CRANK SENSOR NEG
36
SHIELD_136_160
137
0.75
AESSXF
VREF3(5V) REGEN SWITCH
37
309
11. Electric system

Circuit
Number
Wire
Size
Wire
Color
Wire
Type
138
0.75
AESSXF
145
0.75
146
0.75
147
ECU
PIN No
Sensor
PIN No
VREF1 RAIL PRESSURE SENSOR
38
AESSXF
COOLANT TEMP SENSOR

RETURN
45
AESSXF
FUEL TEMP SENSOR RETURN

GND
46
0.75
AESSXF
CAM SHAFT POSITION SENSOR RETURN
47
148
0.75
AESSXF
OIL PRESSURE & TEMP

RETURN GND
48
150
0.75
AESSXF
FUEL INJECTOR HSDB
50
TWIST (150, 174)
151
0.75
AESSXF
FUEL INJECTOR HSDB
51
TWIST (151, 175)
159
0.75
AESSXF
CAM SHAFT POSITION SENSOR
59
160
0.75
AESSXF
_AMS13
CRANK SENSOR POS
60
161
0.75
AESSXF
VREF2, INPRES
61
164
0.75
AESSXF
EGR, VREF3
64
165
0.75
AESSXF
VREF3 OIL PRESSURE
65
167
0.75
AESSXF
INPRES RETURN GND
67
169
0.75
AESSXF

RETURN
69
172
0.75
AESSXF
EGR SENSOR RETURN GND
72
174
0.75
AESSXF
FUEL INJECTOR LSD2B
74
TWIST (150, 174)
175
0.75
AESSXF
FUEL INJECTOR LSD1B
75
TWIST (151, 175)
177
0.75
AESSXF
INLET METERING VALVE (PWM)
77
179
0.75
AESSXF
Circuit Name
GLOW PLUG FEEDBACK
79
Remarks
TWIST (119, 135,

138)
SHIELD_136_160
187
0.75
TUBE
_AMS13
CRANK SENSOR SHIELD
87
192
0.75
AESSXF
EGR (H-BRIDGE POS)
92
TWIST (192, 193)
193
0.75
AESSXF
EGR (H-BRIDGE NEG)
93
TWIST (192, 193)
194
0.75
AESSXF

RETURN
94
K87
0.75
AESSXF
SENSOR 15A FUSE
INTER1_4M
K87A
0.75
AESSXF
SPLICE(K87)
INTER1_4M
310
SHIELD_136_160
(DRAIN)
11. Electric system

Switches and sensors
Mass Air Flow Sensor (MAF)
Boost Pressure Sensor (BPS)
A sensor that measures flow and temperature of air
A sensor that measures the pressure of air in the intake
inhaled initially.
manifold.
No
ECU PIN
Description
228
Intake air flow frequency signal
235
Intake temperature signal
120
Ground
137
Supply voltage(12V)
Boost Temperature Sensor (BTS)

A sensor that measures the temperature of air in the
intake manifold.
EDL022176B
No
ECU PIN
Description
161
Supply voltage(5V)
167
Ground
112
Pressure signal
Exhaust Gas Temperature Sensor (EGTS)

A sensor that measures the exhaust gas of the turbocharger.
EDL022175A
No
ECU PIN
Description
169
Ground
194
Temperature signal
EDL022177A
311
No
ECU PIN
Description
123
Ground
106
Temperature signal
11. Electric system

Oil Pressure and Temperature Sensor
(OPTS)
Fuel temperature sensor (FTS)
A sensor that measures the pressure and temperature of
pump.
A sensor that measures the fuel temperature in the fuel
engine oil.
ECU#1
ECU#1
ECU#1
ECU#1
148 104 165 111
EDL022180A
EDL022178B
No
ECU PIN
Description
148
Ground
104
Temperature signal
165
Supply voltage(5V)
111
Pressure signal
No
ECU PIN
Description
110
Temperature signal
146
Ground
Rail pressure sensor (RPS)

A sensor that is installed at the end of the common rail,
measuring the instantaneous internal pressure of the
common rail.
Water Temperature Sensor (WTS)

A sensor that senses the temperature of engine cooling
water.
EDL022181A
No
ECU PIN
Description
135
Pressure signal
119
Ground
138
Supply voltage(5V)
EDL022179A
No
ECU PIN
Description
145
Ground
109
Temperature signal
312
11. Electric system

Injector #1(INJ)
Injector #3 (INJ)
A part that injects fuel according to the injection signal
received from the ECU.
126127
175151
EDL022182B
No
ECU PIN
126
127
EDL022184B
Description
No
ECU PIN
Description
Low Side Drive
175
Low Side Drive
High Side Drive
151
High Side Drive
Injector #2 (INJ)
Injector #4 (INJ)
174150
125103
EDL022183B
No
ECU PIN
174
150
EDL022185B
Description
No
ECU PIN
Low Side Drive
125
Low Side Drive
High Side Drive
103
High Side Drive
313
Description
11. Electric system

Crank Shaft Position Sensor (CRK)
No
ECU PIN
Description
160
CRS POS
187
Shield
A sensor that senses the position of the crankshaft in

order to sense the engine rotation speed and the position
of the piston.
CAM Shaft Position Sensor (CAM)

A sensor that senses the position of the camshaft,
allowing it to check the position of each piston by using
the reference points with the same basis of the crank
shaft position sensor which cannot check the position of
each piston.
136 160 187A
EDL022186B
No
ECU PIN
Description
136
CRS NEG
160
CRS POS
187A
Shield
EDL022187A
Crank Shaft Position Sensor (CRK)

A sensor that senses the position of the crankshaft in
order to sense the engine rotation speed and the position
No
ECU PIN
Description
159
Position sensor signal
147
Ground
Supply voltage(12V)
of the piston.
EDL022186A
No
ECU PIN
136
Description
CRS NEG
314
11. Electric system

Knock Sensor1(KNOCK1)
A sensor that is mounted on the cylinder block, sensing
knocking of the engine. With the piezoelectric ceramic
element, when it senses vibration or pressure from the
No
ECU PIN
Description
133
Ground
132
Accelerometer signal
129
Shield (Screen)
external, it generates voltage higher than the reference

voltage and delivers the voltage to the ECU.
Exhaust Gas Recirculation Valve Position

Sensor (EGR)
A sensor used to reduce nitrogen oxide (NOx) from the
exhaust gas. It recirculates some of the exhaust gas from
the engine to the intake side. In this way, the combustion
temperature is reduced and the discharged NOx is
reduced.
130 131 128
EDL022188B
No
ECU PIN
Description
130
Ground
131
Accelerometer signal
128
Shield (Screen)
EDL022190A
Knock Sensor2(KNOCK2)
A sensor that is mounted on the cylinder block, sensing
No
ECU PIN
element, when it senses external vibrations or pressure,
164
Supply voltage(5V)
it generates voltage higher than the reference voltage and
193
H-Bridge NEG
172
Ground
116
Position sensor signal
192
H-Bridge NEG
knocking of the engine. With the piezoelectric ceramic
Description
delivers the voltage to the ECU.
133 132 129
EDL022189B
315
11. Electric system

Inlet Metering Valve (IMV)
A valve mounted on the high-pressure pump. It adjusts
the fuel volume pumped from the pump to the rail to
control the fuel pressure on the rail.
EDL022191A
No
ECU PIN
177
Description
Supply voltage(12V)
PWM signal
Water In Fuel Sensor (WIFS)

A sensor that senses the moisture in the filter and sends
the data to the ECU.
EDL022221A
No
ECU PIN
Description
209
Water sensing signal
234
Ground
316
11. Electric system

Wire harness
Disassembly of Wire Harness
1. Disconnect the connectors connected to each sensor.
2. Loosen the fixing bolts mounted on the wire harness
bracket.
3. Remove the wire harness.
Assembly of Wire Harness

1. Mount the wire harness.
2. Tighten the fixing bolts mounted on the wire harness
bracket.
3. Disconnect the connectors connected to each sensor.
317
11. Electric system

ECU (Electronic Control Unit)
General Information
The engine control unit (ECU) controls fuel delivery.
The ECU is connected to various sensors. Based on the
input values from the sensors, the ECU controls the
engine for optimum operation.
Before disconnecting connectors from the ECU, disconnect the ground wire (negative (-) wire) of the battery
cable. Do not dismantle the ECU.
318
11. Electric system

Electronic Control Unit (ECU) Connectors
The ECU connectors are classified into the connectors
connected to the vehicle and the connectors connected
to the engine.
EDL022195A
1.
Connectors connected to the engine
2.
319
Connectors connected to the vehicle
11. Electric system

I/O of Electronic Control Unit (ECU)
Engine output
Engine
Injector output
ECU I/O
Fuel high pressure pump

(fuel mitering unit)
Water Temperature Sensor

Fuel temperature sensor
Boost pressure / temperature Sensor
Oil pressure / temperature Sensor
Vehicle output
Crankshaft Rotation Detection Sensor
Preheater relay output
Camshaft Rotation Detection Sensor
Preheat indicator lamp
Rail pressure sensor
Failure diagnosis information display lamp

RPM and Vehicle Speed Display
Vehicle
Communication
Start switch
Failure Diagnosis Switch
Engine Diagnosis Communication

CAN Communication
EDL0213008A
320
11. Electric system

Operational Conditions of Electronic Control
Unit (ECU)
2) The information on fuel consumption, engine use time,
1. Engine Start
3) The information can be monitored with the ECU diag-
and ECU use time is written in the ECU.

nosis device.
1) Sets the reference temperature for determining

preheat to the lowest temperature among coolant
temperature, fuel temperature, intake air temperature,
and oil temperature.
2) Sets the reference temperature for determining fuel
volume by setting the engine cooling temperature.
3) Determines the appropriate fuel volume to start the
engine, delivers the fuel to the engine, and measures
the RPM signal by using the crankshaft rev-count
sensor.
2. Vehicle driving
1) Calculates the required data for driving a vehicle, such
as CAN data and the RPM transferred from the
vehicle control unit.
3. Driver-requested Adjustment of RPM
1) Controls the RPM based on request from the driver
and controls the engine based on the RPM requested
by the vehicle control unit.
4. Limp Home
1) A function that allows drivers to drive their vehicle to
the repair center safely with the minimum conditions
for driving the vehicle when a fault code occurs.
2) Limp Home function is applied under the following
conditions.
Accelerator pedal has failed: Regardless of pressing

the accelerator pedal, the vehicle is driven at a
consistent RPM.
Sensor has failed: When sensors have failed, the
Output is limited: According to the fault type, the fuel
vehicle is driven with the consistent alternative values.

volume delivered to the engine is limited. The limit is
classified into four levels. The fuel volume is limited
according to the severity of the fault.
Diagnosis Information Display Lamp: Provides information of fault state to drivers for safe driving.
5. Failure Diagnosis
1) When a fault occurs, the failure diagnosis information
display lamp on the gauge board is turned on.
2) With the failure diagnosis information display lamp,
drivers can see the fault code.
Note) It can be checked from the failure diagnosis information on the gauge board.
3) It can be diagnosed by connecting the diagnosis unit
to the check connector at the back of the driver's seat.
6. Driving record
1) Writes the information related driving to the ECU.
321
11. Electric system

Starter
General information
The starting motor is installed at the back of the flywheel
housing. When disassembling your engine, submerge the
starting motor pinion gear and the ring gear in fuel and
then clean them thoroughly with a brush, and grease the
gears to prevent rusting.
DL03-LEF00/01
1
2
EDL032173C
1. Terminal B : M10 X 1.5P
2. Terminal S/W : M5 X 0.8P
322
DL03-LEF02/03
1
3
2
EDL032173D
1. Terminal B : M10 X 1.5P
2. Terminal S: M5 X 0.8P(Yellow)
3. Terminal R : M5 X 0.8P (White)
11. Electric system

Wiring Diagram
DL03-LEF00/01
S
M
S/W
EDL032174C
DL03-LEF02/03
S
M
S/W
EDL032174D
Note) Ensure that the starting motor is protected from

humidity at all times.
CAUTION
Before handling the electric system, the ground wire
of the battery ( - wire) must be disconnected. To
eliminate any possible short circuit, connect the
ground wire at the end after the work is completed.
324
11. Electric system

Performance curve
DL03-LEF00/01
2
(RPM)
BATT. ; 24 -C
(kg.m)
(kW)
(V)
3500
14
8.4
28
3000
12
7.2
24
2500
10
6.0
20
2000
4.8
16
1500
3.6
12
1000
2.4
500
1.2
(TEMP ; 20 C)
2
3
4
0
200
400
600
800
1000 1200 1400
6 (A)
EDL032175C
1. Standard characteristic curve
2. Rev count
3. Torque
4. Output
5. Terminal voltage
6. Load current
325
11. Electric system
DL03-LEF02/03
2
(RPM)
3000
3
(kg.m)
2500
2000
1500
1000
500
(kW)
BATT. ; 12 -E
(V)
12
10
(TEMP ; 20 C)
2
4
3
0
200
400
600
800
1000 1200 1400
6 (A)
EDL032175D
1. Standard Characteristic Curve
2. Rev count
3. Torque
4. Output
5. Terminal voltage
6. Load current
326
11. Electric system

Disassembly of Starter
B
EDL032557A

Assembly of Starter
EDL032057A
bolt.
of 2.2 kgfm.
327
11. Electric system
328
12. Others/driving system

Crankshaft ........................................................................................................................332
Disassembly of Crankshaft..................................................................................................................... 332
Assembly of Crankshaft ......................................................................................................................... 332
Measurement of crankshaft main journal diameter.............................................................................. 332
Measurement of crankshaft bearing gap .............................................................................................. 332
Measurement of crankshaft warpage .................................................................................................... 333
Disassembly of timing wheel ................................................................................................................. 333
Assembly of timing wheel ...................................................................................................................... 335
Piston ...............................................................................................................................337
Disassembly of piston ............................................................................................................................ 337
Assembly of piston ................................................................................................................................. 337
Measurement of outside diameter of piston pin .................................................................................. 337
Measurement of Inside diameter of piston pin bore ........................................................................... 337
Measurement of gap of piston ring end............................................................................................... 338
Measurement of step height of piston top side................................................................................... 338
Connecting rod ................................................................................................................339

Disconnection of Connecting Rod ....................................................................................................... 339
Assembly of Connecting Rod ................................................................................................................ 339
Measurement of inside diameter of connecting rod small-end ........................................................... 339
Measurement of connecting rod large-end bore .................................................................................. 339
Measurement of gap of connecting rod big-end.................................................................................. 340
Flywheel ...........................................................................................................................341
Disassembly of flywheel ......................................................................................................................... 341
Assembly of flywheel.............................................................................................................................. 341
Crankshaft pulley ............................................................................................................343

Disassembly of crankshaft pulley .......................................................................................................... 343
Assembly of crankshaft pulley ............................................................................................................... 343
Others ..............................................................................................................................345
Engine timing .......................................................................................................................................... 345
Check of gear backlash ......................................................................................................................... 346
Check of gear axial offset ..................................................................................................................... 347
329
330

General information
General Information
1. The forged crankshaft is an integral structure. The
crankshaft and the rear oil seals prevent oil from
permeating into the flywheel housing.
2. The connecting rod is forged and its large end part
is vertically separated.
Therefore, like a piston, the connecting rod can be
disassembled through the upper side of the cylinder.
An alloy-type prefabricated bearing is used for the
active part of the crankshaft and the connecting rod.
3. The camshaft, oil pump, and high-pressure injection
pump are driven by gear connection in the timing gear
case.
331

Crankshaft
Disassembly of Crankshaft
Measurement of crankshaft bearing gap
1. Remove the crankshaft.
1. Install the crankshaft to the cylinder block.
2. Measure the clearance of the crankshaft bearing.
Engine)
Assembly of Crankshaft
1. Attach the crankshaft.
Engine).
Measurement of crankshaft main journal

diameter
1. Check visually the crankshaft journal and the crank
pin section for scratches or cracks.
2. Conduct a magnetic particle or penetrating inspection
to check for any cracks in the crankshaft and if any
EDL032122A
crack is found, replace the crankshaft.
1) Place plastic gauges in total 5 points throughout the
3. Set the gauge.
crankshaft having contact with the crankshaft bearing
4. Remove debris off the crankshaft.
section.
5. Measure the outside diameter of the crankshaft main
2) Fasten the crank case to the specified torque and
journal.
disassemble it.
3) Check the width of the plastic gauges.
4) The outside diameter standard of crankshaft bearing
is 0.029 ~ 0.059 mm.
Item
Specified Value
Crankshaft Bearing Gap
0.029 ~ 0.059 mm
3. Remove the plastic gauges.

1) Remove the plastic gauges.
2) Remove debris off the cylinder block and the crankshaft.
EDL032121A
1) Measure the outside diameter of the crankshaft journal

with an outside diameter micrometer.
2) Measure total 20 points of the crankshaft journal
section: 5 points at front and rear, and in the vertical
and horizontal directions.
3) The outside diameter standard of crankshaft journals
is 74.955 ~ 74.970 mm.
Item
Specified Value
Crankshaft journal diameter
74.955 ~ 74.970 mm
332

Measurement of crankshaft warpage
DL03-LEF02/03
1. Measure the flexure of the crankshaft.
EDL032811B
1) Adjust eye bolts (B) to provide a clearance between

EDL032196A
V-belt and bolts.
1) Put #1 and #5 sections of the crankshaft main journal
on the V-block.
2) Put the dial gauge on a surface plate and measure
the flexure of the crankshaft as rolling the crankshaft.
3) The flexure standards of crankshafts are 0.05 mm for

#2 and #4, and 0.05 mm for #3, based on the main
journal #1 and #5.
Disassembly of timing wheel

B
DL03-LEF00/01
EDL032022B

EDL032810C
333

5. Remove the crank speed sensor.
EDL032511B
EDL032509B
1) Unscrew the hex bolt (B).
2) Remove the crank speed sensor (A).

6. Remove the timing wheel.
CAUTION
C
B
EDL032508C
1) Remove the key (B).

2) Remove the timing wheel (A).
CAUTION
EDL032510C
wheel.
for the groove (C).
334

Assembly of timing wheel
1. Install the timing wheel.
A
B
A
EDL032010B
EDL032008C
1) Align the timing wheel (A) with the dowel pin and
attach it to the crankshaft surface.
assembly jig (C).
2) Install the key (B).
CAUTION
wheel.
Install the timing wheel with its non-toothed
jig.
surface facing 7 oclock at the front.
CAUTION
2. Install the crank speed sensor.

assembly.


one.

attaching it.
EDL032009A
1) Install the crank speed sensor (A).

2) Tighten the hex bolt (B).
335

4. Install the front oil seal holder.

hex bolt (B).

26 kgfm.
torque of 2.2 kgfm.
CAUTION
C

EDL032011B
1) Clean debris off the assembly surface of the front oil
DL03-LEF00/01
seal holder with a dry cloth.

the assembly surface of the front oil seal holder.
CAUTION
Ensure that the front oil seal hold is facing the

A
right direction.

EDL032810C
3) Align and install the front oil seal holder (A) with
DL03-LEF02/03
dowel pins (C).

of 2.2 kgfm.
A
B
EDL032811B
D

EDL032022B
336

Piston
Disassembly of piston
Measurement of outside diameter of piston

pin
1. Remove the piston.

Note) Refer to Chapter About the Engine.
2. Remove the piston ring.
1. Set the gauge.

2. Measure the outside diameter of the piston pin.
D
C
A B
CD
EDL032130A
EDL022132A
1) Remove the 1st ring (D), the 2nd ring (C), and the
1) Measure total 8 points of the piston pin outside diam-
oil ring (B), using a piston ring plier.
eter: A, B, C, and D, in the vertical (E) and horizontal

(F) directions.
Assembly of piston
2) Measure all 4 points of the piston pin.
1. Install the piston rings.
3) The outside diameter standard of piston pins is 35.995

~ 36.000 mm.
Item
Specified Value
35.995 ~ 36.000 mm
D
C
Measurement of Inside diameter of piston

pin bore
B
1. Set the gauge.

2. Measure the inside diameter of the piston pin bore.
A
AB
C D
EDL032130A
1) Install the 1st ring (D), the 2nd ring (C), and the oil
ring (B), using a piston ring plier.
CAUTION
Ensure that the mark Rs on the 1st and 2nd

rings are facing the topside of the piston.
Make the piston ring position dislocated to 120.
EDL032133A
2. Install the pistons.

337
vertical (F) and horizontal (E), in the directions of A,
Measurement of step height of piston top

side
B, C, and D.
1. Set the gauge as 0 with the top surface of the cylinder
1) Measure total 8 points of the piston pin bore diameter:
2) Measure all 4 points of the piston pin bore diameter.
block as a base point.
3) The bore diameter standard of piston pins is 36.008
2. Measure the height difference of the piston.
~ 36.014 mm.
Item
Specified Value
Piston pin of the piston Inside

diameter of bore
31.008 ~ 31.014 mm
A
R
F
B
Measurement of gap of piston ring end

1. Measure the clearance of the piston ring end.
EDL032135A
1) Set a piston at the top dead point.
2) Measure the height differences from the cylinder block

surfaces at 2 points of the piston topside: A and B.
3) Set the rest pistons at the top dead point by turns
and measure 2 points of each piston, a total of 8
points.
4) The height difference standard of pistons is 0.24 ~
EDL032134A
0.52 mm.
1) Insert the piston ring into the top of the cylinder,

perpendicularly to the wall.
2) Measure the clearance of the piston ring end with a
Item
Specified Value
Piston Height Difference
0.24 ~ 0.52 mm
clearance gauge (A).

3) Measure the gaps of the top ring, the 2nd ring, and
CAUTION
the oil ring.

4) The clearance standards of piston ring ends are 0.25
Take the average of 8 measured values of piston
~ 0.40 mm for top rings, 0.55 ~ 0.70 mm for 2nd
height differences to use the grade of cylinder
rings, and 0.20 ~ 0.40 mm for oil rings.
head gaskets. For the grade of cylinder head

gasket, see 19 Engine Assembly order, Engine
Item
Specified Value
Top ring clearance
0.25 ~ 0.40 mm
2nd ring clearance
0.55 ~ 0.70 mm
Oil ring clearance
0.20 ~ 0.40 mm
Assembly Order in Chapter About the engine.
The front engine direction (F) is the coolant pump

direction and the rear engine direction (R) is the
flywheel direction.
CAUTION
Use care not to damage the cylinder when
measuring the piston ring end clearance with the
clearance gauge.
338

Connecting rod
Disconnection of Connecting Rod
3) The inside diameter standard of connecting rod

small-ends is 36.025 ~ 36.038 mm.
1. Disconnect the connecting rod.

Item
Specified Value
Connecting rod small-end

bore
36.025 ~ 36.038 mm
Engine).
Assembly of Connecting Rod

1. Connect the connecting rods.
Measurement of connecting rod large-end

bore

Engine).
1. Set the meter.

2. Measure the inside diameter of the connecting rod
Measurement of inside diameter of

connecting rod small-end
large-end.
1. Set the gauge.

2. Measure the inside diameter of the connecting rod
small-end.
EDL022199B
EDL022197B
B
C
A
A
D
B
E
C
EDL022200B
1) Measure total 6 points of the connecting rod largeend:
front (D) and rear (E), in the direction of A, B and C.

2) Measure all 4 points of the connecting rod.
EDL022198B
3) The inside diameter standard of connecting rod
1) Measure total 4 points of the connecting rod
large-ends is 66.000 ~ 66.015 mm.
small-end: front (C) and rear (D), in the vertical (A)

and horizontal (B) directions.
Item
Specified Value
66.000 ~ 66.015 mm
2) Measure all 4 points of the connecting rod.
339
CAUTION
Fasten the connecting rod bolt by hand until its head
reaches the bolt contact surfaces on both sides of
the connecting rod and tighten it securely to the
specified torque.
Measurement of gap of connecting rod

big-end
1. Install the crankshaft to the cylinder block.
2. Measure the clearance of the connecting rod
large-end.
EDL032131A
1) Place plastic gauges in total 4 points throughout the

crankshaft having contact with the connecting rod.
2) Install the connecting rod.
3) Temporarily tight the connecting rod bolts (8ea) by
hand.
4) Tighten the connecting rod bolts (8ea) to a torque of
3.0 kgfm + 90, using the angle method.
5) Loosen the connecting rod bolts.
6) Remove the connecting rod cap.
7) Check the width of the plastic gauges.
8) The clearance standard of connecting rod largeends
is 0.026 ~ 0.066 mm.
Item
Specified Value
Gap of Connecting Rod Big-end
0.026 ~ 0.066 mm
3. Remove the plastic gauges.

1) Remove the plastic gauges.
2) Clean debris from the crankshaft and the connecting
rod large-end.
340

Flywheel
Disassembly of flywheel
DL03-LEF02/03

A
EDL032708C

EDL032557A
CAUTION

reuse them.
DL03-LEF00/01
Assembly of flywheel
DL03-LEF00/01
A
B
EDL032021C
EDL032021C
341
DL03-LEF02/03
EDL032708C

1st Stage

kgfm
2nd Stage
45 Rotation
CAUTION
the flywheel.
EDL032057A
bolt.
of 2.2 kgfm.
342

Crankshaft pulley
Disassembly of crankshaft pulley

DL03-LEF00/01
D
A
EDL032022B
EDL032810C

DL03-LEF02/03
Assembly of crankshaft pulley

B
EDL032811B
V-belt and bolts.


EDL032022B
hex bolt (B).
26 kgfm.
343

torque of 2.2 kgfm.
CAUTION


DL03-LEF00/01
EDL032810C
DL03-LEF02/03
EDL032811B

344

Others
Engine timing
The engine is driven by the connection of camshaft, oil
pump, high-pressure injection pump, idle gear and crankshaft gear
6
5
EDL032136B
1. Injection pump drive gear (number of teeth : 28ea)

2. Idle gear (large) (teeth : 81ea)
3. Idle gear (large) (teeth : 54ea)
4. Camshaft gear (teeth : 84ea)
5. Oil pump drive gear (teeth : 25ea)
6. Crankshaft gear (teeth : 42ea)
345

Adjustment of engine timing
Check of gear backlash
2. Align the imprinted marks on gears with each other.
2. Check the gear backlash.
D
C
E
B
D
EDL032137B
EDL032138B
1) Use a clearance gauge to check gear backlashes.
camshaft.
2) The backlash standard between crankshaft gear and
Note) The idle gear and the camshaft gear have 2 marks
idle gear (A) is 0.087 ~ 0.202 mm.
imprinted on them.
3) The backlash standard between crankshaft gear and
oil pump drive gear (B) is 0.066 ~ 0.247 mm.
4) The backlash standard between idle gear and
Note) The idle gear has 4 marks imprinted on it.
camshaft gear (C) is 0.087 ~ 0.213 mm.
Note) With the key groove of the crankshaft gear at 12
5) The backlash standard between idle gear and injection
pump drive gear (D) is 0.081 ~ 0.196 mm.

3) Position the idle gear in a way that its mark goes
between the marks of the fuel injection pump drive
gear.
Note) The fuel injection pump drive gear has 2 marks
imprinted on it, while the idle gear has 1 mark.
Item
Specified Value
Backlash between crankshaft

gear and idle gear
0.087 ~ 0.202 mm
Backlash between crankshaft

gear and oil pump drive gear
0.066 ~ 0.247 mm
Backlash between idle gear and

camshaft gear
0.087 ~ 0.213 mm
Backlash between idle gear and

injection pump drive gear
0.081 ~ 0.196 mm
Note) If you cannot identify the gear marks, install the

fuel injection pump regardless of the positions of
the gear marks.

346

Check of gear axial offset
Note) Refer to Chapter about the engine.
2. Check gear axial clearances.
EDL032139A
1) Install a dial gauge on the cylinder block.

2) Push the crankshaft gear into the cylinder block.
3) Set the dial gauge as 0 with the crankshaft gear
surface as a standard point.
4) Pull the crankshaft gear to read the dial gauge.
Note) The axial clearance of the crankshaft gears is 0.10
~ 0.31 mm.
5) Push the camshaft gear into the cylinder block.
6) Set the dial gauge as 0 with the camshaft gear
surface as a standard point.
7) Pull the camshaft gear to read the dial gauge.
Note) The axial clearance of the camshaft gears is 0.10
~ 0.20 mm.
8) Push the idle gear into the cylinder block.
9) Set the dial gauge as 0 with the idle gear surface as
a standard point.
10) Pull the idle gear to read the dial gauge.
Note) The axial clearance of the idle gears is 0.10 ~ 0.20
mm.
Item
Specified Value
Crankshaft gear axial clearance
0.10 ~ 0.31 mm
Camshaft gear axial clearance
0.10 ~ 0.20 mm
Idle gear axial clearance
0.10 ~ 0.20 mm

347
348

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Forward

2. Operation and maintenance ................................................................................................... 9

3. Performance and specifications ..........................................................................................17

4. Regular inspection ................................................................................................................45

5. About the engine ...................................................................................................................73

6. Cooling system .................................................................................................................... 127

General information .............................................................................................................................. 129

7. Lubrication system ..............................................................................................................141

8. Fuel system ..........................................................................................................................161

9. Intake/exhaust system ........................................................................................................199

10. Cylinder block/head .............................................................................................................247

Lifting hook ........................................................................................................................................... 295

11. Electric system ....................................................................................................................301

12. Others/driving system .........................................................................................................329

Danger, warning, caution, and note ..................................................................................4

Engine maintenance ...........................................................................................................7

2. We have divided the content of this manual into

This Operation & Maintenance manual divides mainte-

causes of bodily injury and damage to assets and

nance operations such as performing engine checks, trou-

bleshooting, or diagnosing faults into three categories,

"Danger," "Warning," and "Caution." In addition, Note) is

When a safety accident, such as skin contact with

required for maintenance technicians to successfully

corrosive acids or fuel, burns with hot oil, exposure

operate our engines. The recommended repair methods

of eyes to fuel or antifreeze, occurs while starting,

and 'Danger,' 'Warning,' and 'Caution' can enhance the

inspecting, or repairing an engine, see a doctor

degree of completion of engine maintenance and prevent

bodily injury which may occur to workers. However, this

Cautions for Starting the Engine

1. Before starting the engine, please read this manual

Workers must observe instructions, otherwise fatal

'Caution'. If you cannot fully understand it or have any

or serious injuries to workers and other persons

question, please contact us.

2. For safety reasons, attach "Warning" signs around

ators know that they are responsible for the safety of

Workers must follow this instruction as failing to do

the engine room.

so may result in the death or serious bodily harm

3. Only authorized people may start and operate

engines. Unauthorized people should not be allowed

Workers must observe this instruction since failing

5. Be careful not to touch or contact the engine during

to do so may cause critical faults which can have

operation since it becomes hot during operation.

impact on the engine performance and operation.

starting engine. If the space is airtight, ensure that it

Note) Indicates additional description, information, and

Cautions for Inspection and Repair

only when the engine is stopped. Otherwise, burns or

1. In order to maintain the best long term performance

safety accidents may occur, so do not perform inspec-

and safety, please read and understand this manual

tion or repair while the engine is running.

and execute routine inspections and regular inspec-

2. If it is absolutely necessary to perform inspection or

repair on the operating engine, do not get close to

disconnect the battery ground wire first. Connect the

Do not exchange or disassemble a pipe or horse

for checking or replacing the electrical apparatus in