Service Manual: Diesel Engine

SB2012E02
Service Manual
Diesel Engine
DC24(2.4 Liter)
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.
Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read and
understood the operation, Iubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.
In this manual, the following symbols are used to indicate the type of service operations to be performed.
Removal Adjustment
Installation Cleaning
Disassembly Pay close attention-Important
Reassembly Tighten to specified torque
Align the marks Use special tools
Directional Indication Lubricate with oil
Inspection Lubricate with grease
Measurement
If you have any question or recommendation in connection with this manual, please do not hesitate to contact our
head office, dealers or authorized service shops.
Vehicle Systems -1- Specifications

Index
1. General Informations ...........................................................................................................................................5

1.1. General Repair Instructions 1.2. Engine Model and Serial Number
1.3. Engine Specifications 1.4. Engine Assembly
2. Preventive Maintemance ...................................................................................................................................11

2.1. Preventive Maintenance 2.2. Torque Specifications
3. Major Maintenance.............................................................................................................................................16
3.1. Major Parts Fixing Bolts 3.2. Engine Repair Kit
3.3. Repair
4. Engine Disassembly and Reassembly ............................................................................................................26

4.1. External Parts 4.2. Internal Parts
4.3. Inspection and Repair 4.4. Reassembly
5. Lubricating System............................................................................................................................................59
5.1. General description 5.2. OIl Pump
5.3. Oil Filter 5.4. Oil Cooler
6. Cooling System ..................................................................................................................................................64

6.1. General Description 6.2. Water Pump
6.3. Thermostat
7. Fuel System ........................................................................................................................................................68

7.1. General Description 7.2. Injection Nozzle
7.3. Injection Pump Calibration
8. Intake and Exhaust System ..............................................................................................................................74

8.1. Intake Manifold 8.2. Exhaust Manifold
9. Special Tool List.................................................................................................................................................75
Appendix
- Engine Assembly (ELFFO)
DC24 (2.4 Liter) -3- General Informations

1. General Informations
1.1. General Repair Instructions

1. For safty, park the truck on even ground or work station and fix the wheels using wedges or hand brake during
operation
2. Before performing service operation, disconnect the grounding cable form the battery for reduce the chance of
cable damage and burning due to short-circuliting.
3. Before performing service operation release the air pressure in the machine air line machine air line system for
safty. To not do so in extremely dangerous.
4. Use covers for prevention the components from damage or pollution.
5. Brake oil and anti-freeze solution must be handled with reasonable to efficient and reliable service operation.
6. The use of proper tools and special tools where specificed is important to efficient and reliable service operation.
7. Use genuine DOOSAN parts necessarily.
8. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones
should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.
9. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing
bolts and nut separate is very improtant as they vary in hardness and design depending on position of installation.
10. Clean the parts before inspection or reassembly. Also clean oil ports, etc. usig compressed air to make certain
they are free form restrictions.
11. Lubricate rotation and sliding faces of parts with oil or grease before installation.
12. When necessary, use a sealer on gaskets to prevent leakage.
13. Carefully observe all specifications for bolts and nuts torques.
14. When service operation is completed, make a final check to be sure service has been done propery.
1.2. Engine Model and Serial Number
The engine model and serial number is located on the engine as

illustrated. These numbers are required when requesting Serial number
warranty and ordering parts. They are also referred to as engine
model and serial number because of their location.
Engine serial No. (example 1 : DC24)
DC24 O 00001 FO
Suffix (ELFFO)
Serial No.
Production Year(2000)
Engine Model

1.3. Engine Specifications
1.3.1. Specification
Engine Model DC24

Items ELFFO / N / L / E ELFFA / D / I / J
Engine type 4 cycle in-line, Water-cooled type
Naturally aspirated
Combustion chamber type Swirl chamber
Cylinder liner type Replaceable dry liner
Timing gear system Gear driven type
No. of piston ring Compression ring 2, oil ring 1
No. of cylinder-bore x stroke (mm) 4 - 86 x 102
Total piston displacement (cc) 2,369
Compression ratio 20 : 1
Engine dimension (length x width x height) (mm) 702 x 559 x 677
Engine weight (kg) 245
Rotating direction (viewed from flywheel) Counter clockwise
Fuel injection order 1-3-4-2
Fuel injection timing (B.T.D.C static) 13˚
Injection pump type VE type Zexel in-line “A” type
Governor type Mechanical governor Mechanical governor
type(RSV)
Injection nozzle type Throttle type
2
Fuel injection pressure (kg/cm ) 120
2
Compression pressure (kg/cm ) 28 (at 200 rpm)
Intake and exhaust valve clearance (at cold) (mm) 0.45
Intake valve Open at 11˚ (B.T.D.C)
Close at 40˚ (A.B.D.C)
Exhaust valve Open at 51˚ (B.B.D.C)
Close at 9˚ (A.T.D.C)
Lubrication method Full forced pressure feed type
Oil pump type Rotor type driven by camshaft
Oil filter type Full-flow, cartridge type
Lubricating oil capacity (oil pan) (lit) 6.5
Oil cooler type Water cooled
Water pump Centrifugal type driven by belt
Cooling Method Fresh water forced circulation
Cooling water capacity (engine only) (lit) 5.2
Thermostat type Wax pallet type (76.5 ~ 90 C˚)
Alternator voltage - capacity (V - A) 12 - 50
Starting Motor voltage - output (V - kW) 12 - 2.2

1.3.2. Engine Power
Production tolerance : ±5%
Engine Model Performance

Model Suffix Power Torque Low idle High idle
(PS/rpm) (kg.m/rpm) (rpm) (rpm)
DC24 Base 56/3,000 15/2,000 - -
ELFFA 44/2,300 14.5/2,000 850-900 2,600-2,650
ELFFD 49~53/2,900 12.7~14.2/2,200 600-750 3,170-3,250
ELFFE 44~48/2,400 14.5/2,000 775-825 2,600-2,700
ELFFI 44/2,300 14.5/2,000 850-950 2,600-2,650
ELFFJ 49/2,650 14.5/2,000 600-700 2,920 L 50
ELFFL 46.2/2,400 14.5/2,000 775-825 2,650-2,700
ELFFN 45/2,400 14.5/2,000 775-825 2,650-2,700
ELFFO 44/2,250 14.5/1,800 775-825 2,500-2,600
* Note : All data are based on operation without cooling fan at KS-R1004

1.3.3. Engine Performance
1) Engine suffix : ELFFO
Performance KS-R1004
Power (max.) 44 PS/2,250 rpm
Maximum torque 14.5 kg.m/1,800 rpm
Fuel consumption rating (min.) 200 g/PS.h

2) Engine suffix : ELFFN
Performance KS-R1004
Power (max.) 45 PS / 2,400 rpm
Maximum torque 14.5 kg.m / 2,000 rpm
Fuel consumption rating (min.) 200 g / PS.h

1.4. Engine Assembly
4 5 6 7 8 21
3 20
2
1
12 11 10
13 14 15 16 17
22 23 24
18 19
1. Fly wheel. 13. Alternator.

2. Rear plate. 14. Exhaust manifold.
3. Oil filter. 15. Oil level gauge.
4. Nozzle holder ass’y. 16. Intake manifold.
5. Fuel injection pipe. 17. Lifting hook.
6. Oil filler cap. 18. Power take off.
7. Water outlet 19. Starter.
8. Cooling fan. 20. Water pump ass’y.
9. Crank shaft pulley. 21. Intake stake.
10. Injection pump. 22. Breather hose.
11. Oil pan. 23. Cylinder head cover.
12. Oil pressure switch. 24. Pre heater plug.
DC24 (2.4 Liter) - 10 - General Informations

2. Preventive Maintenance
2.1. Preventive Maintenance

The preventive maintenance means that the operator performs the servicing of engine to obtain long life
and best performance from DOOSAN diesel engine.
2.1.1. Cooling Water

Regarding the cooling water that is to be used for engine, the soft water not the hard water must be
used.
The engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust
prevention (DCA4) 3 ~ 5%.
The density of above solution and additive must be inspected every 500 hours to maintain it properly.
NOTE : The proper density control of antifreezing solution and rust preventing additive will be
able to prevent the rusting effectively and maintain the stable quality of engine.
Since DC24 diesel engine cylinder liner is dry type, particularly the cooling water control should be
applied thoroughly.
The density of antifreezing solution and additive for rust prevention is able to be confirmed by the
cooling water test kit. (Fleetguard CC260M or DOOSAN 60.99901-0038)
How to use the cooling water test kit
(1) When the cooling water temp of engine is in the range of 10 ~ 55 ˚C, loosen the plug for cooling
water discharge and fill the plastic cup about a half.
NOTE : In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to
measure the accurate density. Take the cooling water sample necessarily loosening the cooling
water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after taking the paper out through water
agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.
NOTE : However, it should not elapse longer than 75 sec, and if it did, the hue would change.
(4) Make the numerical value by comparing the test paper which hue has changed with the color list of
label on storage bottle.
(5) By comparing thehue changed into yellowish green or so with the green color indication of test paper
storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to
50%).
(6) The brown at the middle of test paper and the lower pink color indication represent the additive state
for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and
pink color (horizontal) locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storqge bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more than
0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh
water.

Amount of Anti-freze in winter
Ambient
Cooling water (%) Anti-freeze (%)
Temperature (°C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
2.1.2. Fan Belt

Use a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated.
Check the fan belt for belt tension.
If belt tension is lower than the specified limit, adjust the tension by relocating the alternator. (specified
deflection : 10 ~ 15 mm when pressed down with thumb)
2.1.3. Engine Oil

Check oil leel with the oil level gauge and replenish if necessary.
Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ~ 10 minutes for oil
drain into the crankcase before checking oil level. The oil level must be between Max and Min. lines
on the gauge.
Engine oil should be changed at the specified intervals. Oil in the oil filter should be changed
simultaneously.
Engine oil change interval : at least 2 times/year
First oil change After the first

1,000km (50hr) Every 3,000km (250hr)
Suggested engine oil
Engine Recommend engine oil

model SAE No. API No. Remark
SAE 15W40 API CD grade or CE grade above -
DC24 SAE 15W40 ACEA-E2 or ACEA-E3 Bellow 0.05% sulfur
SAE 10W40 (APICH-4)

2.1.4. Oil Filter
Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary.
Change the oil filter cartridge simultaneously at every replacement of engine oil.
2.1.5. Fuel Filter

The fuel filter should be replaced at every 18,000km (1,200hr)
2.1.6. Air cleaner

In case that elements are deformed, damaged or if the air cleaner has a crack, replace it.
By the definite interval, the elements must be cleaned and replaced.
2.1.7. Valve Clearance Adjust Procedure

After the first 1,000km(50 hr) operation.
When doing engine overhaul or dismantling Cylinder Head off the block.
When Abnormal sound from the valve train is noticed.
When Poor operation condition continues inspite of faultless fuel system.
Valve clearance(with engine cooled) : 0.45 mm for both intake and exhaust.
2.1.8. Cylinder Compression Pressure

Stop the engine after warming up, and take out nozzle holder assembly.
Install the special tool (compression gauge adapter) at the nozzle holder hold, and connect the
compression pressure gauge thers.
Standard valure 28 kg/cm2 over

Limit value 24 kg/cm2
Difference
between each cylinder Within ± 10 %
• Testing conditions : coolant temperature 20°C, Engine rpm 200rpm (10 turns)
2.1.9. Injection Nozzle

Install a nozzle on the nozzle tester
If the inspected injection pressure is less than the specified value, adjust using the adjusting shims.
Engine Model DC24

Opening pressure 120 kg/cm2
Check the atomizing state and replace it if abnormal.

2.1.10. Fuel Injection Pump
Check the housing crack, damage etc. and replace it if abnormal.
Check if the idle operation and speed regulating lever’s sealing is removed.
The adjustment and testing of fuel injection pump should necessarily be done at the test bench.
2.1.11. Battery
Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case
of poor condition.
Inspect for amount of electrolytic solution, and replenish if insufficient.
Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish.
2.1.12. Air removal of Fuel System

The suction room of fuel injection pump has the function of air removal continuously during the operation
through a relief valve.
In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump,
after loosening the air removing screws of cartridge filter respectively, remove the air by operating the
manual pump of fuel supply pump until bubble will disappear.
2.1.13. Fuel Supply Pump

Every time of engine oil replacement, the fuel strainer installed at the fuel supply pump should be
removed and cleaned.
2.1.14. Starting Motor

In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and coat them
with grease.
Also, In case of washing engine (room) and so forth, inspect the wiring state being careful for water not
to get in.

2.2. Torque Specifications
Standards bolts
The torque values given in the following table should be applied where a particular torque is not specified.
Bolt identification
4T 7T 9T
Bolt diameter x pitch Low carbon steel High carbon steel Alloy steel
6 x 1.0 0.4 - 0.8 0.5 - 1.0 -

8 x 1.25 0.8 - 1.8 1.2 - 22 1.7 - 3.1
10 x 1.25 2.1 - 3.5 2.8 - 4.7 3.8 - 6.4
10 x 1.5 2.0 - 3.5 2.8 - 4.7 3.8 - 6.4
12 x 1.25 5.0 - 7.5 6.2 - 9.3 7.7 - 11.6
12 x 1.75 4.6 - 7.0 5.8 - 8.6 7.3 - 10.9
14 x 1.5 7.8 - 11.7 9.5 - 14.2 11.6 - 17.4
14 x 2.0 7.3 - 10.9 9.0 - 13.4 10.9 - 16.3
16 x 1.5 10.6 - 16.0 13.8 - 20.8 16.3 - 24.5
16 x 20 10.2 - 15.2 13.2 - 19.8 15.6 - 23.4
18 x 1.5 15.4 - 23.0 19.9 - 29.9 23.4 - 35.2
20 x 1.5 21.0 - 31.6 27.5 - 41.3 43.3 - 64.9
22 x 1.5 25.6 - 42.2 37.0 - 55.5 43.3 - 64.9
24 x 2.0 36.6 - 55.0 43.9 - 72.5 56.5 - 84.7
The indicates that the bolts used for female-threaded parts that are made of soft materiails such casting, etc.

3. Major Maintenance
3.1. Major Parts Fixing Bolts
3.1.1. Cylinder Head and Block

(kg.m)

3.1.2. Crankshaft and Camshaft
(kg.m)

3.1.3. Injection Pump and Other (kg.m)
3.1.4. In-line Injection Pump Type (kg.m)
3.1.5. VE Injection Pump Type (kg.m)

3.2. Engine Repair Kit
1. Gasket : Cylinder head. 14. Gasket : Gear case.

2. Gasket : Cylinder head cover. 15. Gasket : Water pump to cylinder block.
3. Gasket : Intake and exhaust manifold. 16. Gasket : Outlet pipe.
4. Gasket : Joint bolt 17. Gasket : Housing cylinder head.
5. Seal : Crankshaft(Rear). 18. Seal Ring
6. Gasket : Front plate. 19. Gasket : Oil filter to block.
7. Gasket : Drain plug. 20. Seal Ring.
8. Gasket : Oil pan. 22. Seal Ring.
9. Gasket : Oil pan to bearing cap 23. Seal Ring.
10. Gasket : Tappet chamber cover. 25. Gasket : Bracket to front plate
12. Gasket : Gear case. 27. Gasket : Head cover bolt.
13. Oil Seal. 28. Repair Kit : Top overhaul kit

3.3. Repair
3.3.1. Cylinder Head Bolt
Tighten the cylinder head bolts in sequence as shown
in the figure.
Torque(kg•m) 8.0 L 0.5
3.3.2. Valve Clearance

Adjust the valve clearance in the following manner
using a feeler gauge.
Standard (in cold)
Intake and exhaust (mm) 0.45

Feeler gauge
EA0O4014
1. Bring the piston in either the No.1 cylinder or the

No.4 cylinder to top dead center on the compression
stroke by turning the crankshaft until the TDC
notched line on the crankshaft pulley is aligned the
timing pointer.
2. Check to see if there is play in the No.1 intake and

exhaust valve rocker arms. If the No.1 cylinder intake T 13° 18°
and exhaust valve rocker arms are deprssed, the D
No.4 piston is at TDC on the compression stroke. C
EA0O4011
Adjust the clearances of valves marked with an arrow.
Rocker arm screw

lock nut torque (kg•m) 2.5
<------ Front side Rear side ------

>

After adjusting the valve clearances referring to the
figure, turn the crankshaft one full turn in the rotative
direction and align the TDC mark with the pointer, then
adjust the remaining valve clearances.
<------ Front side Rear side ------

>
3.3.3. Injection Timing

1) In-Line Injection Pump
Timing 13° ± 1°
T 13° 18°
D
C
EA0O4011
Check the notched line on the injection pump is in

alignment with the notched line on the injection pump
bracket.
2) VE Injection Pump
Turn the crank pulley until No. 1 piston is placed in
the “TDC” position of notch marks on the crank
pulley, and then turn again the crank pulley
clockwise until showing the notch mark of the right
figure corresponding to the injection timing is
aligned with the pointer ( ) on the crank pulley. T 13° 18°
D
C
DC24
EA0O4011
Fuel injection timing
(B.T.D.C static) 13°
Check the alignment of the notched lines injection

pump and timing flange
Loosen 2 fixing bolts of the injection pump.
Turn the injection pump until the notch mark of the
injection pump attached to the fuel injection pump
flange is aligned with the notch mark of the flange.
Tighten the fixing bolts to specified torque.
Torque (kg•m) 3.5 ~ 4.5

3.3.4. Compression Pressure
Remove the glow plugs from all cylinders, then check
the comprssion pressure in each cylinder with a
compression gauge by engaging starter.
(kg/cm2, 200rpm)
Standard Limit
28 22.0 - 23.0
EA0O4015
3.3.5. Fuel System

Injection nozzle
Check the spraying condition and injection starting
pressure
Injection starting pressure (kg/cm2) 120
EA0M3002
Adjustment
Adjust the injection starting pressure with the adjusting
screw using a nozzle tester
EA0M3003
Air Bleeding of the Fuel System Bleeder screw
1) In-Line Injection Pump

Bleed the system by manually operating the priming
pump with the fuel filter outlet joint bolt and injection
pump bleeder screw loosened.
Priming pump
EA0O4010
2) VE Injection Pump
After the cleaning of the fuel filter or after the engine
stop by the lack of fuel, the bleeding of the fuel
system must be executed by all means.
Bleed the system by manually operating the priming
pump with fuel injection pipe nut and filter bleeder
screw loosened.
• Press the priming pump cap repetitively until the
fuel without bubbles comes out from the bleeding
screw
• After the whole air is pulled out, close the screw of
the fuel filter and fuel injection pipe nut.

Feed pump strainer
Remove the strainer using a screw driver. Wash the
Strainer
stainer in clean diesel fuel.
EA0O4008
Fuel filter replacement

Remover and installer(filter wench)
EA3M1031
Apply diesel fuel to o-ring. Turn in filter until sealing face

is brought into contact with the o-ring. Further tighten
2/3 of a turn.
EA0M3005
Fuel sedimentor (if eguipped)
Removal steps
Disconnect water separator sensor wiring at the
connector.
Remove the filter using filter wrench.
EA3M1031
Installation steps
Install the water separator sensor in the new filter. Apply
diesel fuel to o-ring.

Fill the filter sufficiently with diesel fuel before installing it
in the housing. Apply diesel fuel to o-ring. Turn in filter
until sealing face is brought into contact with the o-ring.
Further tighten 2/3 of a turn.
3.3.6. Lubricating System

Cartridge
Main oil filter replacement (Oil filter)
Remove the filter cartridge using filter wrench Oil filter head
EA0M3006
3.3.7. Fan Belt Depress here
Fan pulley
Adjust belt tension by moving generator pulley. about 10mm
Specified belt deflection(mm) 10

Generator pulley
Crank pulley EA0M3009
3.3.8. Pre-Heating System

Q.O.S System IND.
"ON" Lamp Relay
Q.O.S System makes the pre-heating time short and Acc 1
easy start. 3 4
"OFF" ST Glow
Stater plug
S/W 2 9
Batt 5
DC 12V Thermo O/N
60°C
EA0M3010
Thermo Switch
Operating temperature
Operating temperature 15°C
EA0M3011

Glow Plug
Check the continuity across the plug terminals and
body.
EA0M3012

4. Engine Disassembly and Reassembly
4.1. External Parts
DC24 (2.4 Liter) 26 Engine Assembly

4.2. Internal Parts (Timing gear train)
4.2.1. Major Components
4
5
EA0M4003
EA0M4003
<Disassembly steps>
1. Pulley. 3. Injection pump gear.
2. Timing gear case cover. 4. Idle gear.
Important Operations
Injection pump assembly

Inspect the following items before timing gear removal.
Backlash (Crankshaft gear, camshaft gear, injection
pump gear)
Standard Limit
0.10-0.17 mm 0.3 mm EA0M4004
Idle gear end play
Standard Limit
0.07 mm 0.2 mm
EA0M4004

4.2.2. Cylinder head
<Disassembly steps>
1. Spring seat and valve cotter
2. Valve spring
3. Valve
Important Operation
Spring seat and valve cotter (1)
: Valve spring compressor

4.2.3. Piston and Connecting Rod Assembly
EA0M4008
<Disassembly steps>
1. Piston ring 4. Piston
2. Snap ring 5. Connecting-rod
3. Piston pin

Important Operation
Piston ring
: Remover
EA0M4009
Piston pin Piston Pin

Remove the piston pin snap ring using a snap ring plier.
Drive out the piston pin using a brass rod at normal
temperature.
4.2.4. Rocker Arm and Shaft Assembly
<Disassembly steps>
1. Rocker arm (A) 4. Rocker arm shaft bracket
2. Rocker arm shaft bracket 5. Rocker arm shaft
3. Rocker arm (B)

4.3. Inspection and Repair
Make necessary corrction or parts replacement if wear, if wear, damage or any other abnormal conditions
are found through inspection.
4.3.1 Cylinder Body and Liner

Cylinder body warpage
Standard Limit
Overall length 0.05 mm 0.2 mm
Thickness (H) 247.97-248.03 mm 247.7 mm
EA0M4012
Grade datermination
Take an average of 3 values obtained by measuring the
diameters shown in the right.
90
Measunng point : Approx. 90 mm from the upper face.
The mark on the upper face should be neglected in
case of Engine overhaul.
Cylinder block (steel liner)

(mm) EA0M4013
Grade tolerance Projection

Standard
1 2 3 4 Straight edge
Ø88.010 Ø88.020 Ø88.030 Ø88.040

Cylinder
Ø88 ~ ~ ~ ~
bore dia
Ø88.001 Ø88.011 Ø88.021 Ø88.031
Ø88.020 Ø88.030 Ø88.040 Ø88.050

Liner
Ø88 ~ ~ ~ ~
outer dia
Ø88.011 Ø88.021 Ø88.031 Ø88.041
Feeler gage
EA0M4014
Cylinder block (cast liner) (mm)
Grade tolerance
Standard
1 2
Ø90.010 Ø90.020
Cylinder
Ø90 ~ ~
bore dia
Ø90.001 Ø90.011
Ø89.984 Ø89.995
Liner
Ø90 ~ ~
outer dia
Ø89.995 Ø90.006
Amount of projection (mm)
Standard
Steel liner -0.015~0.115 mm
Cast liner 0.008~0.070 mm

Cylinder liner replacement
: Remover
: Liner grip
Installer Bench press

Wipe clean the cylinder liner and cylinder body to
Installer
remove oil, then install the cylinder liner into cylinder
bore using a bench press. The use of dry ice to cool the
cylinder liner will invite contraction, facilitating smooth
installation of the cylinder liner.
Tightness 0 - 0.02 mm
EA0M4016
4.3.2. Crankshaft and Bearing

A
Crankshaft journal and pin diameter
B
Standard
Journal Ø 69.92 - Ø 69.932 mm A
Pins Ø 52.918 - Ø 52.930 mm
Undersize bearings are available in 4 different sizes

which include 0.25, 0.5, 0.75 and 1.0 mm undersizes. EA0M4017
Crankshaft diameter when using undersize

bearing
Journal Pin
U/S 0.25 Ø 69.67-Ø 69.68 mm Ø 52.67-Ø 52.68 mm
U/S 0.50 Ø 69.42-Ø 69.43 mm Ø 52.42-Ø 52.43 mm
U/S 0.75 Ø 69.17-Ø 69.18 mm Ø 52.17-Ø 52.18 mm
U/S 1.00 Ø 68.92-Ø 68.93 mm Ø 51.92-Ø 51.93 mm

Uneven wear Fillet section
Fillet section
Standard Limit
Journal 0.001 mm 0.05 mm
Pin 0.001 mm 0.05 mm
Wear
Curvature of the fillet section on the crankshaft journals

and pins should be finished as shown bellow. Wear
EA0M4018
Standard
Journal R3.3 - R3.7 mm
Pin R3.3 - R3.7 mm
When regrinding the crank shaft, the fillet section

should be correctly finished. Avoid stepped portion or
rough surface on it.
Clearance between crankshaft journal and bearing
Standard Limit
Clearance 0.018-0.065 mm 0.12 mm
Crankshaft bearing cap bolt
Torque(kg•m) 18.5
Clearance between crank pin and connecting-rod

bearing
Standard Limit
0.029-0.082 mm 0.12 mm
Crankshaft bearing cap bolt
Torque(kg•m) 8-9 EA0M4020
Bearing clearance Measurement

Measure the clearance using plastic gauge.
EA0M4021

Bearing spread
Limit
Crankshaft bearing 74.5 mm
Connecting-rod bearing 56.5 mm
EA0M4022
Run-out
Standard Limit
0.03 mm 0.06
EA0M4023
Crankshaft gear replacement

Removal Remover
: Remover
EA0M4024
Installation
: Installer
Installer EA0M4025
Pilot bearing replacement

: Remover
EA0M4026

4.3.3. Flywheel
Inspect the following parts for wear, damage or other
abnormal conditions.
EA0M4027
Ring gear replacement

Remove the ring gear from the flywheel by tapping
around the side face of the gear with a brass bar.
EA0M4028
Heat the ring gear evenly with a gas burner(Max.

temperature 200°C) to invite volumetric expansion.
Install the ring gear on the flywheel when it is sufficently
heated.
EA0M4029
4.3.4. Maintenance of cylinder block,

cylinder liner and piston
To maintain the engine in optimum condition and retain
maximum performance for a long time, the cylinder
Marking
block, cylinder liner and piston which have the same
grade marking number (the same size tolerance)
should be assembled. The marking number (the part’s
grade) and marking position is as follows.
Cylinder block
a) Marking number ; 1 or 2
(Size grade for of cylinder bore diameter)
b) Marking position ; Middle of the cylinder block side surface.
Piston grade of Cylinder block grade
cylinder No.4

Cylinder liner
a) Marking number ; 1A, 1B, 2A or 2B
1A
Can used the piston A grade
Can used the cylinder block 1 grade
b) Marking position ; Cylinder liner lower surface
Pistion
a) Marking number ; A or B Marking EA4M2021
(Size grade for piston outer diameter)
b) Marking position ; Center of the piston upper surface
Assembly process of cylinder block, cylinder liner

and piston
(1) Check the marking number (1 or 2) of cylinder block.
(Middle of side surface)
(2) Then assemble the liner whose first digit of the
marking (1A, 1B, 2A, 2B) is just the same with it on
the cylinder block.
(3) Assemble the piston whose marking is just same
with the second digit (A or B) of the assembled
cylinder liner’s marking.
4.3.5. Piston
Piston clearance
Piston outside diameter

Take measurement in direction at a right angle to the
piston pin hole.
Grading position ; 14mm.
The piston grade should be selected by referring to
the following table, so that specified piston clearance
can be obtained. EA0M4030
Piston grade for steel liner
Piston grade Standard

A Ø 85.970 mm ~ Ø 85.985 mm
B Ø 85.980 mm ~ Ø 85.996 mm
C Ø 85.990 mm ~ Ø 86.006 mm
D Ø 86.000 mm ~ Ø 86.016 mm
Piston grade for cast liner
Piston grade Standard

A Ø 85.970mm ~ Ø 85.985mm
B Ø 85.980mm ~ Ø 85.996mm

Cylinder inside diameter
(mm)
Grade A B
Cylinder Ø86.020 Ø86.031
inside Cast liner ~ Ø86.031 ~ Ø86.042
diameter
Steel liner Ø86.020~Ø86.060
Piston clearance 0.035~0.062
Piston pin outside diameter
Standard Limit
Ø26.995-Ø27.0 mm Ø26.96 mm
Fitting interference between piston pin and piston
Standard 0.004 - 0.015mm

EA0M4031
Clearance between piston ring and ring groove
Standard Limit
1st compression ring 0.085 - 0.115mm 0.2mm
2nd compression ring 0.05 - 0.085mm 0.15mm
Oil ring 0.03 - 0.065mm 0.15mm
EA0M4032
Piston ring gap
Standard Limit
1st compression ring 0.20 - 0.40mm 1.5mm Feeler Gouge
2nd compression ring 0.20 - 0.40mm 1.5mm
Oil ring 0.10 - 0.30mm 1.5mm
EA0M4033
4.3.6. Connecting Rod

Connecting-rod
Distortion and parallelism
Standard Limit
Distortion 0.05 mm 0.20 mm
Parallelism 0.05 mm 0.15 mm
EA0M4034

Bushing
Clearance between bushing and piston pin
Standard Limit
0.008 - 0.02mm 0.05mm
EA0M4035
Bushing Replacement
Removal
: Remover
Installation
: Installer
The inner face of the bushing must be finished with a

reamer after installation of the bushing.
Inside diameter 27.008 - 27.015 mm
EA0M4036
4.3.7. Cylinder Head

H
Cylinder head warpage
Standard Limit
Overall length 0.05 mm 0.2 mm
Thickness (H) 91.95-92.05mm 91.75 mm
EA0M4038
Depression of hot plug

Check the amount of depression of swirl chambers on
No.1 through No.4 cylinder using a feeler gauge, with a
straight edge held against the swirl chamber face.
Limit 0.02 mm
EA0M4039

Swirl chamber Replacement
Remove the hot plug in the following manner ; Insert a
suitable round bar sizing 3 to 5mm in diameter into
nozzle holer fitting hole to touch the swirl chamber, then
drive out the swirl chamber using a hammer.
EA0M4040
Heat shield replacement

Remove the heat shield using a brass bar and a
hammer.
EA0M4041
Installation of new swirl chamber

Install lock ball into groove in swirl chamber. Drive the
swirl chamber into cylinder head by aligning lock ball in
swirl chamber with groove in cylinder head.
EA0M4042
Press the swirl chamber into position by applying 4,500

to 5,000 kg pressure using a bench press with a piece
of metal fitted against the swirl chamber face for
protection. After installation, grind the face of swirl
chamber flush with the face of the cylinder head.
EA0M4043
Installation of new heat shield

Install the heat shield with the flanged side up on the
cylinder head by tapping on the flange lightly with a
brass bar.
EA0M4044

4.3.8. Valve and Valve Seat Insert
Valve stem diameter
Standard Limit
Intake valves Ø7.946 - Ø7.961mm Ø7.88mm
Exhaust valve Ø7.921 - Ø7.936mm Ø7.85mm II III
I
EA0M4045
Depression
Standard Limit
Intake valves 0.65mm 2.5 mm
Exhaust valve 0.65mm 2.5 mm Depression
EAOM4046
Contact width
Standard Limit
1.06mm 3.6 mm
Contact width
EAOM4047
Valve seating angle
Valve seating angle 45°
B
EA0M4048
EA0M4048
Valve thickness
Standard Limit
Intake valve 1.3 mm 1.0 mm
Exhaust valve 1.3 mm 1.0 mm
Thickness
EA0M4049

Valve seat replacement Valve seat
Arc-weld excess metal around inner face of the valve
seat and allow to cool off a few minutes, then pull out the
valve seat with vibration hammer
Cylinder
head
Welding
bead
Press a new valve seat insert into the bore using a

bench press. After installation of the valve seat insert,
grind finish the seating face with a seat grinder carefully
noting the seating angle, contact width and depression.
Lap the valve and seat as te final step.
EA0M4051
4.3.9. Valve Guide

Clearance between valve stem and valve guide
Standard Limit
Intake valve 0.039 - 0.071 mm 0.20 mm
Eahaust valve 0.064 - 0.096 mm 0.25 mm
EA0M4052
Valve guide replacement

Removal
: Remover
EA0M4053
Installation ; Valve guide installer.

Apply engine oil to the outer circumference of the valve
guide.
Set the installer to the valve guide, then the guide into
position from the upper face of the cylinder head a
hammer.
EA0M4054

Height of valve guide upper end Intake 12.5 ± 0.2mm
from cylinder head upper face Exhaust 12.5 ± 0.2mm
Discard used oil seals and install new ones.
4.3.10. Valve Spring

Inclination
Free lenght and inclination
Standard Limit
Free Square
lnner 47.9mm 46.5mm
Free length Length
Outer 47.3mm 45.8mm
lnner - 1.0mm
Inclination
Outer - 1.0mm EA0M4055
EA0M40
Free lenght and inclination
Set length Standard Limit

Ineer 37.0 mm 5.55 - 6.25 kg 5.02 kg
Outer 39 mm 19.65 - 22.15 kg 18.1 kg
EA0M4056
4.3.11. Rocker Arm and Rocker Arm

Assembly
Run-out
Limit 0.4 mm
EA0M4057
Rocker arm shaft diameter
Standard Limit
Ø18.98 - Ø19.00 mm Ø18.85 mm
EA0M4058

Rocker arm
Clearance between rocker arm shaft and rocker arm
Standard Limit
0.020 - 0.070 mm 0.2 mm
If the amount of wear is beyond the limit, replace

either the shaft or rocker arms depending on the
condition of wear.
EA0M4059
It is necessary to drill an oil port in the new rocker arm

bushing as it is not provided with the oil port.
EA0M4060
4.3.12. Camshaft Assembly
EA0M4061
Camshaft diameter and height of cam lobe
Standard Limit
Journal diameter Ø47.945 - Ø47.975mm Ø47.6mm
Height of cam lobe 40.568mm 40.2mm
I II I II
A
C B B
D A EA0M4062
Clearance between camshaft and bearing

Camshaft bearing
Standard Limit
0.05 mm 0.12 mm
EA0M4063
EA M

Cam bearing replacement
Removal : remover and installer
Remover and installer

EA0M4064
Installation : remover and installer

The oil port in the cylinder body must be aligned with
that in the camshaft bearing.
Align oil port
Run-out
Standard Limit
0.05 mm 0.1 mm
EA0M4066
End play
Standard Limit
0.05-0.11mm 0.2 mm
EA0M4067
Camshaft gear replacement

Removal : remover
EA0M4068

Installation
Drive the gear to the shaft, aligning the key groove on
the gear with the key on the shaft.
EA0M4069
Tappet
Inspect tappet for wear, damage or other abnormal
condition.
Pitting Crack Normal contact
Irregular contact EA0M4070
Diameter
Standard Limit
Ø12.977-Ø12.990mm Ø12.95 mm
Clearance between tappet and cylinder body
Standard Limit
0.03 mm 0.1 mm
EA0M4072
EA M
4.3.13. Push Rod
Run-out
Limit 0.4 mm

4.3.14. Idle Gear and Shaft
Idle gear shaft
Standard Limit
Ø44.945 - Ø44.975mm Ø44.845 mm
EA0M4074
Clearance between shaft and idle gear
Standard Limit
0.025-0.085mm 0.2 mm
EA0M4075
Timing gear case cover oil seal replacement

Removal
: Remover
EA0M4076
Installation
: Installer
EA0M4077

4.4. Reassembly
4.4.1. Minor Components
Cylinder Head
EA0M4078
<Reassembly steps>
1. Valve 3. Retainer and valve cotter
2. Valve spring
Important operations
Valve spring (2)

Install the valve spring with the painted end down.
Painted portion
EA0M4079
Retainer and valve cotter (3)

: Compressor

Rocker arm and shaft assembly
3 21 4 5 6 7 8 9 10 11 12 13 14 15 16
EA0M4080
<Ressembly steps> 11. Spring

1. Rocker arm shaft 12. Rocker arm (C)
2. Waving washer 13. Rocker arm shaft bracket
3. Snap ring 14. Rocker arm (D)
4. Rocker arm (A) 15. Spring
5. Rocker arm shaft bracket 16. Rokcer arm (C)
6. Rocker arm (D) 17. Rocker arm shaft bracket
7. Spring 18. Rocker arm (B)
8. Rocker arm (C) 19. Waving washer
9. Rocker arm shaft bracket 20. Snap ring
10. Rocker arm (D)
Rocker arm (A) (4) Rocker arm(B) Rocker arm(D)

Rocker arm (C) (8, 12, 16)
Difference between rocker arm (A) and (C)
EA0M4081
E A0 M 4 0
Rocker arm (B) (18)
Rocker arm (D) (6, 10, 14)
Difference between rocker arm (B) and (D)
Rocker arm(C) Rocker arm(A)
EA0M4081

Piston and connecting-rod assembly
<Reassembly steps>
1. Piston and connecting-rod 3. Snap ring
2. Piston pin 4. Piston ring
Piston and connecting-rod

Install the piston on the connecting-rod, so that
combustion chamber on piston head is on the same
side with the cylinder number mark side (side with
bearing stopper) of the connecting-rod big-end.
DOOSAN mark on the connecting-rod should be on the
same side of the front mark on the piston head.
Piston pin
Install the piston pin after heating the piston to about
100°C

Snap ring
Install the snap ring into the piston using snap ring
pliers, then check to make certain the snap ring is fitted
properly into the groove.
Snap ring
Piston ring 2nd Ring

Use piston ring installer. Install the 1st and 2nd
compression rings with manufacturer’s mark turned up.
Oil ring can be installed on the piston with either side up.
Piston ring gaps should be positioned as shown in the 3 1
figure. 5
2 4
6
Use Cr-coating piston ring for cast liner and

nominal piston ring for steel liner.
120 E
EA0M4090
Fit correctly
With oil hole
Crankshaft and bearing and groove
Journal diameter Ø70 mm
Install the crankshaft after applying engine oil to the

face of the bearing in contact with the crankshaft.
EA0M4083
The bearings should be installed correctly in their

respecive position. Install the thrust bearing with the oil
grooved side turned outward.
Block
Cap side
EA0M4106
Installation of bearing cap arch gaskets.

Install the arch gasket on the No.1 and No.5 bearing
caps.
No. 5
Amount of projection of gasket 0 - 0.05 mm Arch gasket 0-0.05
No. 1
0-0.05
EA0M4084

Apply a coat of silicon gasket evenly to the joining
faces of the No.5 bearing cap and cylinder block. The
No.1 and No.5 bearing caps should be installed flush
with the face of the cylinder Block.
No. 5 bearing cap
EA0M4085
EA M
Install front and rear side thrust bearings with the oil
groove turned to the timing gear and flywheel,
respectively.
EA0M4086
Tighten crankshaft bearing cap bolts in numerical order.
Torque (kg-m) 18.5
Bolt lenght 89 mm
Apply engine oil EA0M4087
Rear oil seal

Apply engine oil to the lipped portion of the rear oil Cylincer block
Oil seal
seal, then install it in position using installer. Crankshaft
Installer
Engine oil Hammer
EA0M4088
Flywheel
Tighten the bolts in the numerical order as the
illustration
3 1
5 6
Torque (kg-m) 12.0 2 4
EA0M4089

Piston and connecting-rod 2nd Ring
Lightly oil the piston rings fitted to the piston, then
position piston ring gaps as illustrated in the drawing.
1st Ring Oil Ring
120 EA0M4090
Piston ring compressor

Install the piston and connecting-rod with mark turned
to the front of engine.
Use the piston sleeve.
EA0M4091
Install the connecting-rod bearing caps by matching

numbers.
Torque (kg-m) 8.0 - 9.0
Matching
number
EA0M4092
Oil jet pipe

Tighten the oil jet pipe fixing bolts in the order.
EA0M4093
Inspect the gap between oil Jet pipe and piston.
Oil jet
pipe
EA0M4094

Crank case
Apply liquid gasket to the arch gasket fitting face of the Rubber gasket
No.1 and No.5 bearing caps. Liquid gasket
Liquid gasket
applying
applying
portion
portion
45
45
Crankshaft
EA0M4095
4.4.2. Internal Parts (Timing gear train)

Major components : Gear drive type
EA0M4096
<Reassmbly steps>
1. Idle gear assembly 3. Timing gear case cover
2. Injection pump gear 4. Crank shaft pulley

Idle gear (1)

Install the idel gear, so that the oil port in the idle gear Oil port
shaft is turned to the crankshaft gear side and bolt holes
are aligned.
Align the marks on the camshaft gear, idle gear and

crankshaft gear.
EA0M4098
Injection pump gear (2)

Install the injection pump gear together with injection
pump by aligining the mark with that on the camshaft.
EA0M4099
Timing gear case cover (3)

Check to make sure the o-ring is fitted properly into ring
groove in the timing gear case cover.
EA0M4107
Crank shaft pulley (4)

Bolt
Torque (kg-m) 19.0
EA0M4100

Adjustment of injection timing
1) In-Line Injection pump

Bring the piston in No.1 cylinder to the injection timing
before T.D.C on compression stroke so that T.D.C line
on the pulley is aligned with the point.
Timing 13° ± 1° T 13° 18°

D
C
EA0M4011
EA0O4
Bring the mark on the injection pump housing with the
mark on the injection pump backet.
2) VE Injection pump
Turn the crank pulley until No. 1 piston is placed in the
“TDC” position of notch marks on the crank pulley, and
then turn again the crank pulley clockwise until
showing the notch mark of the right figure
corresponding to the injection timing is aligned with
the pointer ( ) on the crank pulley.
T 13° 18°
DC24 D
C
Fuel injection timing EA0O4011
(B.T.D.C static) 13°
Check the alignment of the notched lines injection

pump and timing flange
Loosen 2 fixing bolts of the injection pump.
Turn the injection pump until the notch mark of the
injection pump attached to the fuel injection pump
flange is aligned with the notch mark of the flange.
Tighten the fixing bolts to specified torque.
Torque (kg.m) 3.5 ± 4.5

4.4.3. Internal Components
<Reassembly steps>
1. Cylinder head gasket 3. Rocker arm shaft assembly
2. Cylinder head 4. Water pump

Cylinder head gasket (1)

Install head gasket on the cylinder block with “TOP”
mark side up.
"TOP" 0048
"TOP" mark EA0M4102
Cylinder head (2)

Tighten cylinder head bolts in numerical sequence.
1st step 2nd step

New bolt 6.5 kg.m 8.0 kg.m
Reused bolt 6.5 kg.m 10.0 ± 0.5 kg.m
Rocker arm shaft assembly (3)

Tighten rocker arm shaft bolts in numerical sequence.
Rocker arm bracket torque 1.3 - 2.3 kg.m

4.4.4. External Components
Important operations Depress here
Fan pulley
Fan belt (6) about 10mm
Specified belt deflection
Fan belt 10 mm Generator pulley
Crank pulley EA0M3009

5. Lubricating System
5.1. General Description
Oil filter assembly

Relief valve
War ning
lamp
Batter y
Oil filter Cylinder block main oil galler y
Regulation
valve
Crankshaft Camshaft
Timing gear
bear ing bear ing
Piston
Oil jet
Cylinder
Connecting-
head valve
rod bear ing
mechanism
Piston
Oil pump
EA0M5001
5.2. Oil Pump

Disassembly
Rotor type
1 3
E A 0 M 50 0 2
<Disassembly steps>
1. Oil pipe 3. Pump cover
2. Strainer 4. Vane
DC24 (2.4 Liter) 59 Lubricating System

Inspection and repair
Make necessary correction or parts replacement if wear,

damage or any other abnormal conditions are found
through inspection.
Clearance between vane and body
Standard Limit
0.02 - 0.07 mm 0.15 mm
Clearance between rotor and vane
Standard Limit
0.02 - 0.13 mm 0.15 mm
Clearance between vane and pump body
Standard 0.2 - 0.27 mm
Clearance between rotor shaft and pump body
Standard Limit
0.04 mm 0.2 mm
Pinion replacement
Removal
File off caulked end of the pinion stopper, then drive out
the pin toward opposite side.
Installation
Install a new stopper pin and caulked end of the pin after
installation.
EA0M5006

Rotor replacement
Removal
Drive out the pin from one side.
EA0M5008
Installation
When the pin is installed, check to make sure the end of
the pin is not projected from the end of rotor.
EA0M5009
Reassembly
To assemble, follow the disassemble procedure in
reverse order.

5.3. Oil Filter
Without oil cooler type
3
5
1
EA0M5010
<Disassembly steps>
1. Drain plug 4. Oil filter cartridge
2. Plug screw 5. Relief valve ass’y
3. Plug screw 6. Oil filter housing

Make necessary correction or parts replacement if damage or any other abnormal conditions are found
through inspection.
Reassembly
To assemble, follow the disassembly procedure in reverse order.

5.4. Oil Cooler
5.4.1. Oil Jet Pipe and Oil Pressure Regulating Valve
Make necessary correction or parts replacement if
wear, damage or any other abmormal conditions are
found through inspection.
Oil jet pipe

Inspect for wear or any other abmormal conditions.
EA0M5015
Inspect the regulating valve moving smoothly when it is

pressed using a screw driver.
EA0M5016

6. Cooling System
Thermostat
Cylinder head
By-pass
Car heater
Radiator
Cylinder block
Water pump
EA0M6001
6.2. Water Pump

Disassembly
<Disassembly steps>
1. Cover 4. Impeller and mechanial seal
2. Set screw 5. Unit bearing
3. Hub

Important operation
Hub (3)
EA0M6003
Impeller and Mechanical seal

Heat the pump body in hot water (80-90°C). (For
aluminum body only.)
EA0M6004
Remove impeller using a bench press and a suitable

bar.
EA0M6005

through inspection.
Check the bearing for abmormal noise, binding and

other abnormal conditions.
EA0M6006
2.4 Liter (DC24) 65 Cooling System

Reassembly
<Reassembly steps>
1. Unit bearing 4. Cover
2. Set screw 5. Hub
3. Impeller and Mechanical seal
Unit bearing (1)

Press the unit bearing into place by aligning set screw
hole in bearing with that in the pump body, then secure
the unit bearing in position with the screws.
Set screw hole
EA0M6008
Impeller and Mechanial seal (3)

Apply thin coat of liquid gasket (Belco bond No.4) to the
outer periphery of Mechanial seal before installing the
Mechanial seal.
Apply liquid
gasket here
EA0M6009

Install the impeller in position using bench press, so that
the specified clearance is provided between the impeller
and pump body.
Clearance 0.3 - 0.6 mm
EA0M6010
After installation, check that rear face of the impeller is

indented from the face of the pump body.
Depth 1.0 mm
EA0M6011
Fan center (5)

Distance between fan fitting face and rear face of the
rear cover
Distance 110.7 - 111.3 mm
EA0M6012
6.3. Thermostat Thermometer
Inspection and repair Rule

damage or any other abmormal conditions are found
through inspection.
Valve opening Valve lift at testing Wood piece

Temperature Temperature
82 °C 8 mm(at 95°C) EA0M6013
EA0M6013

7. Fuel System

1) In-Line Injection pump
Nozzle holder
Fuel filter
Fuel tank Injection pump
EA0M7001
2) VE Injection pump

With the VE type injection pump, the number of the plungers has no relationship to the number of
engine cylinders, and there is only one plunger.
This single plunger reciprocates while rotating, and fuel oil is injected into each cylinder through the
injection pipes in accordance with the engine`s firing order.
2.4 Liter (DC24) 69 Fuel System

7.2. Injection Nozzle
Disassembly
7 3
2
6
<Disassembly steps>
1. Cap nut 6. Nozzle nut
2. Nut 7. Nozzle
3. Adjusting screw 8. Nozzle holder screw
4. Nozzle spring 9. Connector
5. Push rod
Nozzle (7)
After removal of nozzle assembly from the nozzle
body, keep them separate to maintain proper needle
valve to body combinations.
Reassembly
To reassemble, follow the disassembly procedure in
reverse order.
Refer to “FUEL SYSTEM” in general information for
injection of spraying condition and injection starting
pressure adjustment.

7.3. Injection Pump Calibration
7.3.1. VE Injection pump (ELFFO/FFN/FFL/FFE)
(1) Injection pump 65.11101 - 7329 (104780 - 9340 ZEXEL) - ELFFO
65.11101 - 7665 (104780 - 7120 ZEXEL) - ELFFN / L / E
(2) Nozzle & holder ass’y ALTERNATIVE
Nozzle & holder ass’y : 65.10101 - 7075A (DOOWON)
Nozzle ass`y 65.10102 - 6012 (105000 - 1740)
Nozzle & holder ass’y 65.10101 - 7076A (LUCAS)
Nozzle ass`y 65.10102 - 6030 (9135-173)
(3) Injection pipe: 65.10301 - 6301
(4) Injection order: 1-3-4-2
(5) Injection timing: BTDC 13 ± 1°
(A) Test condition for Nozzle 105000-2010 Opening pressure: 150 kg/cm2
injection pump Holder Ass’y 105780-2080 -
Injection pipe(IDxOD-L) - Ø2.0 x Ø6.0-840 mm
Test oil ISO4113 Temperature: 40 ± 5 °C
(B) Engine stan 65.10101-7075A
Nozzle (Ø1.0)
dard parts (DOOWON)
Nozzle & holder Ass’y
65.10101-7076A
(LUCAS) Opening pressure: 120 kg/cm2
Injection pipe(ID x L) 65.10301-6301 Ø2.0 x 500 mm

INJECTION SYSTEM
Plunger diameter Ø10 Plunger spring k=7.25 kg/mm
Delivery valve spring k=0.48 kg/mm Damping valve spring k=0.182 kg/mm
TIMER SYSTEM
Timer advance ELFFO 4.4°/600 ~ 1,125 rpm Timer spring ELFFO k=2,05 kg/mm
characteristic ELFFN/L/E 4.4°/600 ~ 1,200 rpm ELFFN/L/E k=1.9 kg/mm
Advance angle/Piston stroke 1°/0.82
GOVERNOR SYSTEM
Governor ELFFO k=0.104 kg/mm Idle spring constant I ELFFO k=0.03 kg/mm
spring ELFFN/L/E k=0.122 kg/mm Idle spring constant II ELFFN/L/E k=0.23 kg/mm
FUEL CUT MAGNET VALVE
Rated voltage 12 V Power consumption 16 W
Starting voltage bellow 6.5 V Holding voltage above 2.5V
Opening voltage 0.5 V
CONTROL LEVER REACTION FORCE
at Idle above 0.3kg at Full load bellow 3.0kg
2.4 Liter (DC24) 71 Fuel System

6) Injection pump calibration (DC24 : ELFFO)
(1) Governor adjustment
Pump speed Average quantity Max. various Adjust

(rpm) (mm3/stroke) between cylinder Remark
(mm3/stroke)
500 (41.0 ± 2.0)
Full load 900 41.0 ± 1.0 3.0 Full load
1125 (41.0 ± 1.0)
Governing 1285 9.0 ± 3.0 Governing
Idling 425 7.5 ± 2.0 2.0 Idling
Start (idling) 100 (60.0 ± 20)
(2) Timer and pump adjustment
Pump speed Pressure of pump

Timer stroke
(rpm) camber Adjust Remark
(mm)
(kg/cm2)
700 (3.4 ± 0.3) (0.6 ± 0.4) Check point
900 4.0 ± 0.2 1.8 ± 0.4 Adjust of pump and timer
1125 (4.7 ± 0.3) 3.4 ± 0.4 Check point
7) Injection pump calibration (DC24 : ELFFN / L / E)
(1) Governor adjustment
Max. various
Pump speed Average quantity Adjust
between cylinder Remark
(rpm) (mm3/stroke) Adjust
(mm3/stroke)
500 (34.5 ± 2.0)
Full load 900 35.5 ± 1.0 3.0 Full load
1200 (36.0 ± 1.0)
Governing 1320 8.5 ± 3.0 Governing
Idling 425 7.5 ± 2.0 2.0 Idling
Start (idling) 100 (60.0 ± 20)
(2) Timer and pump adjustment
Pump speed Pressure of pump

Timer stroke
(rpm) camber Adjust Remark
(mm)
(kg/cm2)
700 (3.2 ± 0.3) (0.4 ± 0.4) Check point
900 3.8 ± 0.2 1.3 ± 0.4 Adjust of pump and timer
1200 (4.6 ± 0.3) 3.4 ± 0.4 Check point

7.3.2. In-line Injection pump (ELFFA / FFD / FFI / FFJ)
1) Injection pump ass’y 65.11101 - 7289 (101441 - 9830 ZEXEL)
- Fuel injection pump 101044 - 9160 (NP - PES4A65C312LS2000)
- Governor 105419 - 2610 (NP - EP/RSV200 - 1600A021A301)
- Timer 105621 - 0370 (NP - EP/SCD500 - 1750A6LN106)
- Feed pump 105200 - 6450 (NP - FP/KS - A)
2) Nozzle & holder ass’y : ALTERNATIVE
Nozzle & holder ass’y : 65.10101 - 7075A (DOOWON)
Nozzle ass`y 65.10102 - 6012 (105000 - 1740)
Nozzle & holder ass’y 65.10101 - 7076A (LUCAS)
Nozzle ass’y 65.10102 - 6030 (9135 - 173)
3) Injection pipe: 65.10301 - 6172
4) Injection order: 1-3-4-2
5) Injection timing: BTDC 13 ± 1°
(A) Test condition for Nozzle 105780-0000 Opening pressure: 175 kg/cm2
injection pump Nozzle & holder Ass’y 105780-8140 -
Injection pipe(IDxOD-L) - Ø6.0 x Ø2.0 - 600 mm
Test oil ISO4113 Temperature: 40 ± 5 °C
(B) Engine standard 65.10101-7075A
Nozzle (Ø1.0)
parts Nozzle & holder Ass’y (DOOWON)
65.10101-7076A
Opening pressure: 120 kg/cm2
(LUCAS)
Injection pipe(ID x L) 65.10301-6172 Ø2.0 x 334 mm
Rack diagram and setting valve at each point
Check Rack Pump Injection Q`ty on RIG
Point position speed (mm3 / 1,000st) Press.
(mm) (rpm) (A) Test condition (B) Engine (mmHg)
18+30 for inj. pump standard parts
RACK CAP:APPROX15.0
A 12.5 750 37 ± 1.6 - -
A
12.2 B B 12.0 1200 38.5 ± 1.0 - -
12.0
0.5 +0.1
11.2
C 8.2 350 8 ± 1.1 - -
8.2 C
6.9
0 350 (1000) 1325 +10
1:00 1200+90
-10
(1160)

8. Intake and Exhaust System
8.1. Intake Manifold
Intake manifold
Check intake manifold head side for flatness.
Limit 0.4 mm
EA0M8006
Reassemble
To reassemble, follow the disassembly procedure in
reverse.
8.2. Exhaust Manifold

through inspection.
Limit 0.4 mm
Check manifold head side for flatness

9. Special Tool List
No. Part No. Figure Tool Name
1 EF.122-254 Oil seal insert ass’y (Front)
2 EF.122-256 Oil seal insert ass’y (Rear)
3 EF.122-252 Pilot bearing puller
4 EF.122-250 Pilot bearing punch
5 EF.122-249 Valve spring press
6 EF.122-264 Crank gear punch
7 EF.122-177 Valve stem seal punch
8 EU.2-0525 Cylinder pressure tester adapter
9 EF.122-266 Piston sleeve

No. Part No. Figure Tool Name
10 EF.122-260 Cylinder liner insert
11 EF.122-258 Cylinder liner puller
12 EU.2-0131 Valve clearance adjust ass’y
13 60.99901-0027 Feeler gauge
14 T7610001E Snap ring plier
15 T7621010E Piston ring plier

Appendix
- Engine Assembly(ELFFO)

Service Manual: Diesel Engine

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SB2012E02

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools

Directional Indication Lubricate with oil

Inspection Lubricate with grease

Vehicle Systems -1- Specifications

1. General Informations ...........................................................................................................................................5

2. Preventive Maintemance ...................................................................................................................................11

4. Engine Disassembly and Reassembly ............................................................................................................26

6. Cooling System ..................................................................................................................................................64

7. Fuel System ........................................................................................................................................................68

8. Intake and Exhaust System ..............................................................................................................................74

9. Special Tool List.................................................................................................................................................75

DC24 (2.4 Liter) -3- General Informations

1.1. General Repair Instructions

4. Use covers for prevention the components from damage or pollution.

7. Use genuine DOOSAN parts necessarily.

12. When necessary, use a sealer on gaskets to prevent leakage.

1.2. Engine Model and Serial Number

The engine model and serial number is located on the engine as

Engine serial No. (example 1 : DC24)

DC24 (2.4 Liter) -5- General Informations

Engine Model DC24

DC24 (2.4 Liter) -6- General Informations

Production tolerance : ±5%

Engine Model Performance

DC24 (2.4 Liter) -7- General Informations

DC24 (2.4 Liter) -8- General Informations

DC24 (2.4 Liter) -9- General Informations

1. Fly wheel. 13. Alternator.

DC24 (2.4 Liter) - 10 - General Informations

2.1. Preventive Maintenance

2.1.1. Cooling Water

DC24 (2.4 Liter) - 11 - General Informations

2.1.2. Fan Belt

2.1.3. Engine Oil

First oil change After the first

Suggested engine oil

Engine Recommend engine oil

DC24 (2.4 Liter) - 12 - General Informations

2.1.5. Fuel Filter

2.1.6. Air cleaner

2.1.7. Valve Clearance Adjust Procedure

2.1.8. Cylinder Compression Pressure

Standard valure 28 kg/cm2 over

2.1.9. Injection Nozzle

Engine Model DC24

Check the atomizing state and replace it if abnormal.

DC24 (2.4 Liter) - 13 - General Informations

2.1.12. Air removal of Fuel System

2.1.13. Fuel Supply Pump

2.1.14. Starting Motor

DC24 (2.4 Liter) - 14 - General Informations

6 x 1.0 0.4 - 0.8 0.5 - 1.0 -

DC24 (2.4 Liter) - 15 - General Informations

3.1. Major Parts Fixing Bolts

3.1.1. Cylinder Head and Block

DC24 (2.4 Liter) - 16 - General Informations

DC24 (2.4 Liter) - 17 - General Informations

3.1.4. In-line Injection Pump Type (kg.m)

3.1.5. VE Injection Pump Type (kg.m)