D24NAP

Table of contents
1. General Introduction...............................................................................................................1-3
General Information................................................................................................................................ 1-3
Danger, Warning, Caution, and Comment ............................................................................................. 1-4
Engine Management .............................................................................................................................. 1-7
2. Operation and Management...................................................................................................2-3

Starting and Stopping an Engine............................................................................................................ 2-3
Break-in Period of an Engine ................................................................................................................. 2-4
Operation in Winter ................................................................................................................................ 2-6
Inspecting and Repairing an Engine ...................................................................................................... 2-7
3. Performance and Specifications ...........................................................................................3-3

Engine Specifications and Performance................................................................................................. 3-3
Outside Drawing of the Engine (DL02-LEE00, DL02-LEE01, DL02-MDE00, DL02-MDE01) .............. 3-14
Outside Drawing of the Engine (DL02-LEL00, DE02 LEL01, DL02-LEL02, DL02-LEL03, DL02-LEL05,
DE02-MDL00, DL02-MDL01, DL02-MDL02, DL02-MDL03, DL02-MDL05)......................................... 3-18
Outside Drawing of the Engine (DL02-LEL04, DL02-MDL04).............................................................. 3-22
Outside Drawing of the Engine (DL02-LEU00, DL02-MDU00) ............................................................ 3-26
Engine Identification Number ............................................................................................................... 3-30
4. Regular Inspection..................................................................................................................4-3
General Information................................................................................................................................ 4-3
Regular Inspection Table ....................................................................................................................... 4-4
Engine Oil ............................................................................................................................................... 4-5
Coolant ................................................................................................................................................... 4-9
Fuel ...................................................................................................................................................... 4-13
Air Filter ................................................................................................................................................ 4-14
6. About the engine.....................................................................................................................6-3

Marking System of Units......................................................................................................................... 6-3
Tightening Torque .................................................................................................................................. 6-4
Engine Disassembly ............................................................................................................................... 6-7
Engine Assembly.................................................................................................................................. 6-21
7. Cooling System.......................................................................................................................7-3
General Information............................................................................................................................... 7-3
water Pump ........................................................................................................................................... 7-7
Thermostat ............................................................................................................................................ 7-9
8. Lubrication System................................................................................................................ 8-3

Oil Pump................................................................................................................................................ 8-7
Oil Filter Assembly................................................................................................................................ 8-13
9. Fuel System............................................................................................................................ 9-3

Fuel return hose .................................................................................................................................... 9-5
Injector................................................................................................................................................... 9-6
Common Rail........................................................................................................................................ 9-12
Fuel injection pump .............................................................................................................................. 9-17
10. Intake/Exhaust System.......................................................................................................10-3

General Information.............................................................................................................................. 10-3
Specifications ....................................................................................................................................... 10-4
Intake manifold ..................................................................................................................................... 10-6
Turbocharger ...................................................................................................................................... 10-10
Exhaust Gas Recirculation (EGR) System ......................................................................................... 10-23
11. Cylinder block/head ............................................................................................................11-3

Cylinder Block ...................................................................................................................................... 11-5
Timing Gear Case ................................................................................................................................ 11-7
Breather................................................................................................................................................ 11-9
Cylinder Head..................................................................................................................................... 11-10
Cylinder Head Cover .......................................................................................................................... 11-11
Oil Pan................................................................................................................................................ 11-17
Valve .................................................................................................................................................. 11-19
Rocker Arm ........................................................................................................................................ 11-22
Valve Tappet and Push Rod .............................................................................................................. 11-31
Camshaft ............................................................................................................................................ 11-42
Idle Gear............................................................................................................................................. 11-43
Lifting Hook ........................................................................................................................................ 11-47
12. Electric System ...................................................................................................................12-3
Electric Parts ........................................................................................................................................ 12-3
Circuit Diagram..................................................................................................................................... 12-4
Air Heater ............................................................................................................................................. 12-8
Switches and Sensors ........................................................................................................................ 12-11
Wire harness ...................................................................................................................................... 12-17
Electronic Control Unit (ECU)............................................................................................................. 12-18
13. Others/Driving System .......................................................................................................13-3

Crankshaft ............................................................................................................................................ 13-6
Connecting Rod.................................................................................................................................... 13-9
Piston ................................................................................................................................................. 13-12
Crankshaft Pulley ............................................................................................................................... 13-14
Others................................................................................................................................................. 13-15
1. General Introduction
General Information....................................... 1-3

General Information ..........................................1-3
Danger, Warning, Caution, and Note ............ 1-4

General Instructions ..........................................1-4
Cautions for Starting the Engine .......................1-4
Cautions for Inspection and Repair ...................1-4
General Repair ..................................................1-5
Other Safety Instructions
and Environmental Pollution .............................1-6
Use of Genuine Parts ........................................1-6
Engine Management ..................................... 1-7

Prevention of damage and abrasion .................1-7
Prevention of Pollution ......................................1-7
Handling of Engine Oil ......................................1-8
1 - 1
1 - 2
General Preface
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 to describe
all possible and unexpected dangers which may arise
while performing engine maintenance.
1 - 3
Danger, Warning, Caution, and Note
General Information
WARNING
This Operation & Maintenance manual divides
When a safety accident, such as skin contact with
maintenance operations such as performing engine
corrosive acids or fuel, burns with hot oil,
checks, troubleshooting, or diagnosing faults into three
exposure of eyes to fuel or antifreeze, occurs
categories, "Danger," "Warning," and "Caution." In while starting, inspecting, or repairing an engine,
addition, Note) is used to provide additional see a doctor immediately.
descriptions and information required for maintenance
technicians to successfully operate our engines. The
recommended repair methods and 'Danger,' 'Warning,'
Cautions for Starting the Engine
and 'Caution' can enhance the degree of completion of
engine maintenance and prevent bodily injury which 1. Before starting the engine, please read this manual
may occur to workers. However, this manual cannot carefully and fully understand 'Danger,' 'Warning,'
predict all possible risks. and 'Caution'. If you cannot fully understand it or
have any question, please contact us.
DANGER 2. For safety reasons, attach "Warning" signs around
Workers must observe instructions, otherwise engines in operation to keep people other than
fatal or serious injuries to workers and other workers from accessing the engines. Let engine
persons may occur.
operators know that they are responsible for the
safety of the engine room.
WARNING 3. Only authorized people may start and operate
Workers must follow this instruction as failing to engines. Unauthorized people should not be
do so may result in the death or serious bodily allowed to handle engines.
harm of workers or others. 4. Do not access running or rotating parts while the
engine is in operation.
CAUTION 5. Be careful not to touch or contact the engine
during operation since it becomes hot during
Workers must observe this instruction since
failing to do so may cause critical faults which can operation.
have impact on the engine performance and 6. Exhaust gas is poisonous. Fully ventilate before
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
General Instructions 1. Inspection and repair of engine should be

performed only when the engine is stopped.
1. In order to maintain the best long term
Otherwise, burns or safety accidents may occur,
performance and safety, please read and
so do not perform inspection or repair while the
understand this manual and execute routine
engine is running.
inspections and regular inspections.
2. If it is absolutely necessary to perform inspection
2. We have divided the content of this manual into
or repair on the operating engine, do not get close
causes of bodily injury and damage to assets and
to the rotating parts.
causes of pollution.
1 - 4
9. Only appropriate tools should be used. If the jaws

DANGER of a wrench are worn out, the wrench might slip
When accessories such as necklaces, rings, during use, causing safety accidents.
watches, or gloves become stuck in rotating parts
10. Do not allow other persons to stay or pass under
while the engine is running, serious bodily injury
may occur. an engine when lifting the engine with a crane.
Before lifting the engine, ensure that there is no
one around the engine and reserve enough safety
WARNING space.
Do not exchange or disassemble a pipe or horse 11. Before inspecting or replacing the electrical
(from the engine fuel circuit, engine oil circuit, apparatus, disconnect the battery ground wire
coolant circuit, or compressed air circuit) while
first. Connect the battery ground wire after
the engine is running. The leaked liquid may
cause bodily injuries. completing all required work for checking or
replacing the electrical apparatus in order to
3. Use an engine oil drain container that is large prevent a short circuit.
enough to prevent the overflow of engine oil while 12. Before performing electric welding works, turn off
draining engine oil. engine, block the power supply to the engine, and
4. Open the engine coolant cap after fully cooling the remove the wire harness connector connected to
engine to exchange or replenish coolant. the engine control unit (ECU).
13. Do not give any electric or mechanical shocks or
WARNING
perform welding works on the electrical apparatus
If the coolant cap is opened while the engine is or the ECU.
still hot, hot water will spurt out and may cause
burns. Open the engine coolant cap after fully
cooling the engine. General Repair
1. Wait until the engine is properly cooled down
5. Fuel is highly flammable. Smoking or use of fire
before starting work, since you may get burned by
around an engine may cause fire.
the heated engine.
Before performing fuel line work, check the
WARNING
common rail pressure and engine temperature by
Only refuel when the engine is stopped.
using the failure diagnosis device.
2. Disconnect the battery ground wire from to
6. Mark and separately manage the containers for
prevent damage of wires and sensors caused by a
storing coolant from beverage containers for
short circuit.
avoiding confusion. See a doctor immediately in
case of drinking coolant. 3. Engine oil and coolant may damage paint and
should be stored in a separate container and
7. Follow the instructions provided by the battery
marked for safe management.
manufacturer when checking or handling
batteries. 4. Store the disassembled parts in a specified space
to avoid damage or pollution.
WARNING 5. Use specified and special tools for efficient and

safe repair.
Battery fluid is corrosive and dangerous because
of its explosiveness and toxicity. Therefore, it 6. If parts need to be replaced, use only genuine
should only be handled by a skilled technician parts for replacement. Using unauthorized or
who specializes in battery fluid.
remanufactured parts may cause critical damage
and faults in engine performance.
8. Only certified professional technicians should
7. Replace parts such as cotter pins, gaskets, O-
repair and maintain engines.
rings, seal rings, oil seals, and washers with new
1 - 5
ones during repairs. Reuse of parts may be the 8. Do NOT work on rotating or running parts once the
cause of engine faults and engine may not operate engine has been started.
properly. 9. Discard oil according to the regulations set forth by
8. Group and store disassembled parts in the relevant authorities.
disassembling order. The strength, shape, and 10. If engine oil or fuel leaks on the floor or is
screw torque of bolts and nuts are different improperly discharged, serious environmental
according to their assembly position. Please divide pollution of sea, river or underground water may
and store them accordingly to these occur.
characteristics. 11. Discard the undiluted anticorrosive agent,
9. Clean disassembled parts to remove foreign antifreeze, filter elements, and cartridges as
substances before inspecting or reassembling special wastes.
parts. Use compressed air to clean the oil holes or 12. Discard coolant and special waste according to
holes. the regulations of the appropriate authorities.
10. Thinly spread oil or grease on rotating parts or
parts requiring lubrication, before assembling WARNING
them.
Failure to observe the regulations of the relevant
11. If required, use a specified adhesive to assemble authorities violates environmental pollution
gaskets to prevent water or oil from leaking. regulations and may be subject to legal penalties.
12. Assemble bolts and nuts with the specified

tightening torque.
Use of Genuine Parts
13. After completing repairs, conduct a final inspection
and perform a test operation to check if all works An engine consists of many parts which are
have been successfully completed. mechanically harmonized. To prevent engine faults in

advance and use engines with best performance for a
long period, maintenance and replacement of
Other Safety Instructions and Environmental expendable parts should be conducted regularly.
Pollution Use of genuine parts is recommended. Using
unauthorized or remanufactured parts may cause
Observe the following instructions to protect workers
critical damage and faults to engine for which Doosan
from danger and to prevent the environmental pollution
shall not be held liable.
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.
1 - 6
Engine Management
Prevention of damage and abrasion 7. Check the engine oil level on a flat surface. Do not
Using an engine for any purposes other than the exceed the maximum on the oil level gauge.
designed purpose may cause critical faults in engine
performance for which Doosan shall not be held liable. CAUTION
For details concerning the usage and purpose of the Immediately replenish engine oil when the engine
engine, please direct questions to our Sales Team. Do oil level is below the lower limit of the engine oil
not adjust, convert, or change the ECU without our gauge.
authorization.
If a problem is found in an engine, figure out and solve 8. If there are gauges for battery, oil pressure and
the cause to prevent the critical faults in advance. coolant and temperature, check if they indicate a
Use of genuine parts is recommended. Using normal status.
unauthorized or remanufactured parts may cause 9. Do not operate engine without coolant.
critical damage and faults to engine for which Doosan
shall not be held liable. CAUTION
Consider the following while managing engines.
Always use coolant mixed with antifreeze. If
coolant without antifreeze is used, the coolant
1. Use clean, specified, and qualified fuel only. Use may freeze causing the coolant passage in the
fuel recommended in this Operation and cylinder block to freeze and damaging the engine.
Maintenance Manual.
CAUTION Prevention of Pollution

Using inappropriate or unspecified fuel may Consider the following to manage engine without
cause critical damage and faults in engine causing environmental pollution.
performance.
1. Discharge oil and coolant using collection

2. Do not operate an engine without lubrication oil or
containers.
coolant. Use only the products (engine oil, cooling
2. Discard oil and coolant according to the
water, anticorrosive agent, and etc) recommended
regulations of the relevant authorities.
by Doosan.
3. Be careful not to let discharged oil and cooling
3. Always keep surroundings of the engine clean.
water flow into the ground or the sewer.
4. Use fuel recommended in this Operation &
Otherwise, serious pollution of the drinking water
Maintenance manual.
source may occur.
5. Conduct inspections and exchanges regularly
4. Classify the oil, filters, and filter cartridges as
according to the regular inspection table.
environmental pollution wastes and discards them
6. If the engine is overheated, do not stop it according to regulations.
immediately, but operate it at idle status for five
5. Classify the antifreeze, cooling water, and
minutes or more to lower the engine temperature
anticorrosive agent as hazardous wastes and
to the proper level.
discards them according to the regulations.
WARNING
If the radiator cap is opened while the engine is
still hot, hot water will spurt out and may cause
burns.
1 - 7
Handling of Engine Oil

Prolonged and repeated contact of skin with engine oil
may cause skin to dry out and contract, causing
dermatitis. Engine oil includes substances toxic to the
human body. Handle engine oil by observing the
following safety rules:
1. Do not expose skin to new engine oil for a long

time.
2. Always wear working clothes and gloves.
3. If skin comes in contact with engine oil,
immediately wipe it off with water, soap or hand
cleaners.
4. Do not clean skin with gasoline, fuel, thinner, or
solvent.
5. Apply a skin protective cream after cleaning from
oil.
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.
1 - 8
2. Operation and Management
Starting and Stopping of the Engine.............. 2-3

Preparing for Start.............................................2-3
Starting the Engine............................................2-3
After Starting the Engine ...................................2-3
During Operation...............................................2-3
Stopping the Engine ..........................................2-3
Break-in Period of the Engine ....................... 2-4

Break-in Period of a New Engine ......................2-4
Check Points .....................................................2-4
Operation after Break-in ....................................2-4
Inspection after Starting the Engine ..................2-5
Engine Oil Pressure ..........................................2-5
Coolant Temperature ........................................2-5
Revolutions per Minute (rpm) ............................2-5
Operation in Winter ....................................... 2-6

Cold Start ..........................................................2-6
Preventing Coolant from Freezing ....................2-6
Preventing Overcooling of the Engine...............2-6
Engine Oil..........................................................2-6
Inspection and Repair of the Engine ............. 2-7

Checking Engine Parts
after Prolonged Operation .................................2-7
Inspection and Repair of Supercharger ............2-7
Intake Unit .........................................................2-7
Exhaust Unit......................................................2-7
Lubrication Unit .................................................2-7
2 - 1
2 - 2
Operation and Management
Starting and Stopping of the Engine
starter motor until oil flows out. After completing

Preparing for Start
the work, tighten the oil pipe joint again and start
Check the following before starting the engine for the
the engine.
first time after purchase.
1. Before starting an engine, check the levels of fuel, After Starting the Engine
coolant, and oil and replenish those fluids if 1. Do not rapidly raise the rpm while the engine and
required. turbocharger do not rotate smoothly after starting
2. Check if engine oil level is between the upper and the engine. Otherwise, it may increase the load
lower limit of the oil level gauge. The upper and upon the engine and burning may occur at the
lower limit of the oil level gauge indicate the positions that have not been sufficiently lubricated
maximum and minimum of the engine oil level. yet. To prevent this, rotate the engine at idle after
starting it to lubricate the turbocharger with oil.
CAUTION 2. Oil, air, or gas leaks may lower the oil pressure.
Additionally, oil leaks may cause burning of
When replenishing engine oil, do not exceed the
maximum on the oil level gauge. Too much oil bearings. As such, if oil, air, or gas leaks occur,
may cause damage to the engine. check the leaking parts and solve the problem.
3. Be careful not to mix foreign substances in fuel,

During Operation
engine oil, or coolant while adding the fluid, and
keep the fluid clean while it is not in use. Use fuel, 1. Insufficient oil pressure may cause abnormal wear
oil, and coolant recommended by Doosan. and burning of bearings and excessive oil
Otherwise, critical damage to the engine may pressure may cause leaks.
occur. 2. Continuing to operate the engine after noises or
vibrations coming from the engine may lead to
Starting the Engine serious engine damage. As such, if noises or

vibrations come from the engine, slowly decrease
Observe the following when starting the engine.
the rpm to a stop the engine and examine the
cause.
1. For a cold start, start the engine after preheating it
sufficiently through the glow plug.
2. Starting the engine too quickly leads to engine Stopping the Engine
rotation without lubricating the supercharger and Do not suddenly stop the engine after it was operated
other engine parts, causing abnormal wear to or under high loads for a long period. If oil burns because
burning of bearings. Therefore, start the engine of heat sent from the high-temperature turbine blade to
the bearing part, the bearing metal and rotating shaft
with the starter motor to check raising of oil
may burn. As such, if the engine was operated under
pressure (until the gradation of the oil pressure
high loads for a long period, sufficiently rotate the
gauge mounted on the apparatus moves or the
engine at idle before stopping it.
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
2 - 3
Break-in Period of the Engine
General Information 2. If the oil indicator lamp on the apparatus is turned

on or blinks, the oil pressure may be insufficient. In
Doosan engines are subjected to a final approval test
this case, check the oil level and replenish the oil if
to ensure the provision of high quality engines before
being shipped to ensure the best quality possible. required. When replenishing engine oil, do not
However, engines are not operated for a long period of exceed the maximum on the oil level gauge. If the
time in this test. Therefore, new engines require a oil level is normal, check other related parts such
break-in period of during the initial 50 hours after as the oil pressure sensor, oil pump, or oil line.
delivery. By properly breaking-in an engine, the
highest levels of engine performance can be CAUTION
maintained long-term.
The oil pressure may increase with high rpm and
decrease with low rpm. In addition, the pressure
Break-in Period of a New Engine of cold oil may be higher at a specific rpm than of
warm oil. This phenomenon may occur when the
If the engine's bearings are not properly broken in, engine is operating successfully.
they may be easily damaged and the lifetime of the
engine may be shortened by overloading or high- 3. Check the coolant gauge on the apparatus and if
speeds. In order to prevent this, please follow the the coolant circulates properly. If the coolant level
guidelines below for the initial 50 hours after delivery of in the supplementary tank is too low, the coolant
new engine.
gauge may be inaccurate. (may be disturbed).
1. Fully warm up the engine until the engine
4. Exchange engine oil and oil filter after the break-in
temperature reaches normal operation condition,
period.
before starting operation of the engine.
2. Do not overload the engine or operate it at CAUTION
excessive RPM.
If engine oil and oil filter need to be replaced, use
3. Do not operate the engine with high speed at idle. only the genuine engine oil and parts
4. Do not rapidly start up or stop the engine. recommended by Doosan.
5. Operate the engine with less than 70 % of the

engine load.
Operation after Break-in
6. Inspection, check, and repair of engines should be
managed by officially-certified technicians at Slowly preheat the engine when starting up during cold
certified service centers in compliance with weather or in areas with cold climate. Do not rapidly
raise the rpm while the engine has not been properly
corresponding rules.
preheated yet. The engine consumes additional oil
until its piston ring is positioned properly and operates
Check Points successfully. Please check the engine oil level
check the following during the break-in period of a new frequently during the initial 50 hour break-in period.
engine.
1. Periodically check if the engine oil level is between

the minimum and maximum limit of the oil level
gauge.
CAUTION
If you cannot accurately check the oil level
through the oil level gauge, rotate the oil level
gauge to 180 degree, put it in the guide tube, and
then pull it out again to check.
2 - 4
Inspection after Starting the Engine

Check the pressure of the engine lubrication system
by using the engine oil pressure gauge mounted on
the apparatus while the engine is in operation. If the oil
pressure 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.
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.
2 - 5
Operation in Winter
Cold Start Preventing Overcooling of the Engine

Periodically check for frozen coolant and viscosity of When the engine is cooled below the normal operating
lubrication oil. temperature, thermal efficiency is lowered and fuel
consumption as well as abrasion of the cylinder liner
CAUTION may increase. Therefore, the engine should be
• A preheater should be mounted on the engine operated within the normal operating temperature. If
to improve the cold start performance. the engine has been sufficiently operated, but the
• Do not operate the starter motor for over 10 temperature of coolant remains below the normal
seconds. If the engine does not start even operating temperature, check the water temperature
though it is fully preheated, wait for about 30 controller or other parts related to the cooler.
seconds, preheat the engine again, and then
start the engine.
Engine Oil
Perform the cold start in the following order.
When the viscosity of engine oil increases due to its
1. Turn the key switch to 'Preheat' and then the low temperature during cold weather or in areas with
preheat lamp will operate for about 20 seconds. cold climate, the rpm may not be stable after starting
Note) Operate the preheater if coolant is below 10 °C the engine. To prevent this, replace the oil with engine
during cold weather. If preheating is not oil for cold weather or areas with cold climate. When
necessary, the preheat lamp will not switch on. replacing engine oil, Use only engine oil recommended
by Doosan.
2. When the preheat lamp switches off, turn the key
switch to 'Start' to start the engine.
Note) If the key is turned to 'Start', the air heater is

continuously heated to provide an easy start
and reduce white exhaust gas. If the coolant
temperature is above 10°C , it is not necessary
to heat the air heater.
3. After starting the engine, the key switch changes

to ON.
CAUTION
As the ECU heats the intake air for about 180
seconds after starting the engine, the white
exhaust gas is reduced quickly.
Preventing Coolant from Freezing.

When only water used as coolant without mixing with
antifreeze, corrosion in the engine, degradation of
cooling efficiency, and freezing of the engine in winter
may occur. If the engine is not operated for a long
period during cold weather or in areas with cold
climate, fully discharge the coolant from the engine.
Freezing of coolant leads to critical damage to the
engine. Please use a mixture of coolant with antifreeze
at revised ratio when replacing or replenishing the
coolant. The antifreeze prevents coolant from freezing.
2 - 6
Inspection and Repair of the Engine
Checking Engine Parts after Prolonged Intake Unit

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

operation time is prolonged. In this case, it is difficult to Exhaust Unit
maintain high engine performance by simply repairing
If exhaust emission is leaked from the part connecting
some parts. We recommend the entire part be
the exhaust tube and the turbocharger, the
replaced or repaired in order to find out the causes
supercharger efficiency is lowered, causing degraded
more accurately and maintain high engine
engine output and, if serious, burning of related parts.
performance.
As parts related to exhaust and turbocharger are used
To prevent engine failure in advance and use the
at high temperature, be careful not to mix the bolts and
engine safely for a long period, perform periodic
nuts with other parts when performing repair.
replacements and inspections.
It is recommended to perform engine adjustments and
preventive inspections during spring after the engine Lubrication Unit
was exposed to winter or cold weather. This allows Inspection and exchange of oil and oil filter should be
economic, long-term use of the engine without faults. performed while considering their exchange cycle.
As the following parts affect the engine output and Overheated engine oil significantly affects the engine
performance, these parts should be regularly checked performance as well as the engine performance, as
and inspected. well as the engine itself.
1. Parts affecting intake and exhaust

• Air filter
• Intercooler
• Supercharger, silencer
• EGR cooler and Calve
• DPF muffler
• 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.
2 - 7
2 - 8
3. Performance and Specifications
Engine Specifications and Performance .........3-3

Engine Specifications........................................3-3
Engine output .................................................3-13
Outside Drawing of the Engine (DL02-LEE00,

DL02-LEE01, DL02-MDE00, DL02-MDE01) .....3-14
Isometric assembly drawings...........................3-14
Assembly drawings (Front/Rear) .....................3-15
Assembly drawings (Left/Right) .......................3-16
Assembly drawings (Top/Bottom) ....................3-17
Outside Drawing of the Engine (DL02-LEL00,

DE02 LEL01, DL02-LEL02, DL02-LEL03,
DL02-LEL05, DE02-MDL00, DL02-MDL01,
DL02-MDL02, DL02-MDL03, DL02-MDL05) ....3-18
Outside Drawing of the Engine

(DL02-LEL04, DL02-MDL04)........................3-22
Outside Drawing of the Engine

(DL02-LEU00, DL02-MDU00) ......................3-26
Engine Identification Number .......................3-30

Engine number engraving ...............................3-30
Cylinder block number engraving ....................3-30
Engraving of piston bore level
of cylinder block ..............................................3-30
Engraving of main bearing bore level
of cylinder block ..............................................3-31
Crankshaft main journal engraving ..................3-31
Piston engraving .............................................3-31
Cylinder head gasket engraving ......................3-32
3 - 1
3 - 2
Performance and Specifications
Engine Specifications and Performance
Engine Specifications
D24NAP
Item DL02- DL02- DL02- DL02- DL02- DL02- DL02- DL02- DL02- DL02-
LEE00 LEE01 LEL00 LEL01 LEL02 LEL03 LEL04 LEL05 LEU00 MDE00
General Information
Engine types 4-Stroke series, water-cooled, Turbocharger and air cooling type
Combustion chamber type Direct injection
Cylinder liner type No liner
Timing gear unit Gear drive
Number of piston rings Two compression rings and one oil ring
Number of cylinders 4
Cylinder bore 90 mm
Cylinder stroke 94 mm
Total displacement 2,392 cc
Compression ratio 17.0:1
616.9mm X
Engine Dimension 616.9mm X 507.2mm
616.9mm X 507.2mm X 748.2mm 515.1mm X
(L x W x H) X 673.1mm
673.1mm
Engine weight 200 Kg
Direction of rotation Counter-clockwise
Firing order 1-3-4-2
Cooling system
Cooling Type Water-forced cooling
Capacity of coolant 3.7 L
Type Centrifugal (impeller type)
Driving Type Ribbed-Belt driven
Pump Speed 3,120 rpm
Water pump Flow rate 1 : 1.2
Supply Above 133 LPM
Pump back
0.66 bar
pressure
Type -
Directly
Directly
Driving connected
connected to -
Type to water
Cooling fan water pump pump
Rotation Ratio
(Engine RPM: 1:1.2
fan RPM)
3 - 3
D24NAP
Type Wax pellet type
Valve-
opening 82 °C
temperature
Thermostat
Full valve-
opening 97 °C
temperature
Lift 8 mm
Coolant
Temperature Type Thermo temperature sensor
Sensor
Resistance
Water 2.5 ㏀
(at 20 °C)
Temperatur
e Sensor Resistance
0.148 ㏀
(at 110 °C)
Pressure for
Radiator opening high
0.9 kg/cm2
Cap pressure
valve
Lubrication System
Lubricating type Forced lubrication system
Idle (Idling
revolution Above 1.5 kg/cm2
Oil Pressure count)
Max. Load
4.0 kg/cm2 ~ 5.5 kg/cm2
(rated RPM)
Oil Oil Class API CJ-4 (ACEA-E9)
Specificatio
ns SAE SAE 10W30
Total 9.2L (Including 0.6L in the engine)

Oil Capacity Max. 8.6 L
Min. 4.5 L
Allowable tilt angle (oil pan)
35° / 35° / 35° / 35°
(front/rear/left/right)
Type Gear type
Oil pump Driving
CRANK GEAR driven
Type
Oil coolant type Water-cooled stack plate type
Type Spin on Type Filter
Allowable
Oil filter -40°C ~ 140°C
temperature
Flow 36 L/min
Lubrication indicator Oil pressure type
Opening pressure of the
oil spray nozzle 1.0 ~ 1.4 kg/cm2
adjustment valve
Hydraulic indicator Oil Pressure Sensor
Fuel System
3 - 4
D24NAP
Fuel injection pump type DELPHI DFP 4.4
Control type E.C.U (DELPHI)
Delivery pump type Gear type (with in DFP 4.4)
Type Multi hole type
Injection Opening
nozzle pressure
1,800 bar
(Operating
pressure)
Intake/Exhaust System
Model Honeywell WGT
Driving
EXHAUST PRESSURE FEED TYPE
Type
Lubricating
FORCED PRESSURE FEED TYPE
type
Compressor
outlet air 2.24 kgf•cm2
Turbocharger
pressure
Allowable
270 krpm
max. RPM
Allowable
max. exhaust 750 °C
temperature
Weight 3.4 kg
Intake valve 0.4 mm
Valve gap
Exhaust valve 0.45 mm
Open
19°
(BTDC)
Intake valve
Closed
45°
(ABDC)
Open
29°
Exhaust (BBDC)
valve Closed
23°
(ATDC)
Intake 104.53 mm
Valve length
Exhaust 106.33 mm
Stem Intake 6.97 ± 0.007 mm
outside
diameter Exhaust 6.96 ± 0.007 mm
Valve guide Intake 7 ~ 7.015 mm

bore Exhaust 7 ~ 7.015 mm
Valve guide Intake 43.4 ~ 43.6 mm

length Exhaust 43.4 ~ 43.6 mm
Valve sheet Intake 1.91 mm

contact width Exhaust 1.89 mm
3 - 5
D24NAP
Valve sheet Intake 44.5° ~ 45.0°

angle Exhaust 44.5° ~ 45.0°
Free length of valve spring 53.8 mm
Valve spring squareness Below2° (below 1.8 mm)
Cylinder block/head
Gasket
0.05 mm
Cylinder Surface
head Manifold
flatness mounting 0.05 mm / 100 mm
surface
Camshaft Intake 39.496 mm

height Exhaust 38.555 mm
Camshaft Intake 44.95 ~ 44.966 mm
journal
outside Exhaust 44.95 ~ 44.966 mm
diameter
Camshaft bearing oil gap 0.034 ~ 0.075 mm
Camshaft end play 0.1 ~ 0.2 mm
Inside diameter of cylinder
89.99 ~ 90.01 mm
block piston bore
Flatness of cylinder block
0.05 mm
gasket surface
Electric apparatus
Engine control type Electronic Control Unit (ECU)
Engine stop unit Cut off fuel supply through ECU
Preheating system Glow Plug (12V X 4EA)
Others/Driving System
Piston outside diameter Grade A: 89.920 ~ 89.930 mm
Gap between cylinder and
0.060 ~ 0.080 mm
piston
Top ring
1.915 ~ 1.945 mm
groove
Piston ring 2nd ring
2.060 ~ 2.080 mm
groove area groove
Oil ring
3.020 ~ 3.040 mm
groove
Top ring
0.083 ~ 0.133 mm
side gap
Piston ring 2dn ring
0.070 ~ 0.110 mm
side gap side gap
Oil ring
0.030 ~ 0.070 mm
side gap
3 - 6
D24NAP
Top ring
0.20 ~ 0.30 mm
end gap
0.55 ~ 0.70 mm
end gap end gap
Oil ring
0.2 ~ 0.4 mm
end gap
Piston pin outside
30.995 ~ 31,000 mm
diameter
Piston pin hole bore 31.008 ~ 31.014 mm
Piston pin hole gap 0.008 ~ 0.019 mm
Connecting rod
31.025 ~ 31.038 mm
small-end bore
Connecting rod
0.025 ~ 0.043 mm
small-end hole gap
Connecting rod
57,000 ~ 57.015 mm
large-end bore
Connecting rod bearing
0.026 ~ 0.064 mm
oil gap
Connecting rod end play 0.15 ~ 0.3 mm
Crankshaft main journal
57.955 ~ 57.970 mm
outside diameter
Crankshaft pin journal
53.955 ~ 53.970 mm
outside diameter
Crankshaft main bearing
0.029 ~ 0.059 mm
oil gap
Crankshaft end play 0.1 ~ 0.31 mm
3 - 7
D24NAP
Item DL02- DL02- DL02- DL02- DL02- DL02- DL02- DL02-
Remark
MDE01 MDL00 MDL01 MDL02 MDL03 MDL04 MDL05 MDU00
General Information
Engine types 4-Stroke series, water-cooled, Turbocharger and air cooling type
Combustion chamber type Direct injection
Cylinder liner type No liner
Timing gear unit Gear drive
Number of piston rings Two compression rings and one oil ring
Number of cylinders 4
Cylinder bore 90 mm
Cylinder stroke 94 mm
Total displacement 2,392 cc
Compression ratio 17.0:1
Engine Dimension
616.9mm X 515.1mm X 673.1mm
(L x W x H)
View
Engine weight 200 Kg from
flywheel
View
Direction of rotation Counter-clockwise from
flywheel
Firing order 1-3-4-2
Cooling system
Pump back
0.66 bar
pressure
Type -
Directly
Driving
connected -
Type
Cooling fan to water pump
Rotation Ratio
(Engine RPM: 1:1.2
fan RPM)
Valve-
opening 82 °C
temperature
Thermostat
Full valve-
opening 97 °C
temperature
Lift 8 mm
3 - 8
D24NAP
Remark
Coolant
Sensor
Resistance
Water 2.5 ㏀
(at 20 °C)
Temperature
Sensor Resistance
0.148 ㏀
(at 110 °C)
Pressure for
0.9 kg/cm2
Cap pressure
valve
Lubrication System
Idle (Idling
Oil Pressure count)
Max. Load
4.0 kg/cm2 ~ 5.5 kg/cm2
(rated RPM)

Specifications SAE SAE 10W30
Min. 4.5 L
35° / 35° / 35° / 35°
Type Gear type
Oil pump Driving
CRANK GEAR driven
Type
Allowable
temperature
Flow 36 L/min
adjustment valve
Fuel System
Injection Opening
nozzle pressure
1,800 bar
(Operating
pressure)
3 - 9
D24NAP
Remark
Model Honeywell WGT
Driving
Type
Lubricating
type
Compressor
At max.
output
pressure
Turbocharger
From
Allowable the
270 krpm
max. RPM turbine
inlet
Allowable
temperature
Weight 3.4 kg
Intake valve 0.4 mm
Valve gap
Open
19°
(BTDC)
Intake valve
Closed
45°
(ABDC)
Open
29°
Exhaust (BBDC)
valve Closed
23°
(ATDC)
Intake 104.53 mm
Valve length
Exhaust 106.33 mm
outside
Valve guide Intake 7~7.015 mm

bore Exhaust 7~7.015 mm



Valve spring squareness Below 2° (below 1.8 mm)
Cylinder block/head
3 - 10
D24NAP
Remark
Gasket
0.05 mm
Cylinder Surface
head Manifold
surface

Camshaft
Intake 44.95 ~ 44.966 mm
journal
outside
Exhaust 44.95 ~ 44.966 mm
diameter
89.99 ~ 90.01 mm
block piston bore
0.05 mm
gasket surface
Electric apparatus
Engine control type Electronic Control Unit (ECU)
Engine stop unit Cut off fuel supply through ECU
Preheating system Glow Plug (12V X 4EA)
Others/Driving System
0.060 ~ 0.080 mm
piston
Top ring
1.915 ~ 1.945 mm
groove
2.060 ~ 2.080 mm
groove area groove
Oil ring
3.020 ~ 3.040 mm
groove
Top ring
0.083 ~ 0.133 mm
side gap
0.070 ~ 0.110 mm
side gap side gap
Oil ring
0.030 ~ 0.070 mm
side gap
Top ring
0.20 ~ 0.30 mm
end gap
0.55 ~ 0.70 mm
end gap end gap
Oil ring
0.2 ~ 0.4 mm
end gap
Piston pin outside
30.995 ~ 31,000 mm
diameter
3 - 11
D24NAP
Remark
Connecting rod
31.025 ~ 31.038 mm
small-end bore
Connecting rod
0.025 ~ 0.043 mm
small-end hole gap
Connecting rod
57,000 ~ 57.015 mm
large-end bore
0.026 ~ 0.064 mm
oil gap
57.955 ~ 57.970 mm
outside diameter
53.955 ~ 53.970 mm
outside diameter
0.029 ~ 0.059 mm
oil gap
3 - 12
Engine output
Engine Performance
Idle at low Idle at high
Output Torque
Model Product code speed speed
(PS/rpm) (kgf m/rpm)
(rpm) (rpm)
DL02-LEE00 49/2,200 20.9/1,600 1,220 ± 50 2,400 ± 50
DL02-LEE01 42/2,200 15.3/1,600 1,220 ± 50 2,400 ± 50
DL02-LEL00 74/2,600 28.6/1,800 1,150 ± 50 2,800 ± 50
DL02-LEL01 66/2,600 25/1,800 1,150 ± 50 2,800 ± 50
DL02-LEL02 61/2,600 22.9/1,800 1,150 ± 50 2,800 ± 50
DL02-LEL03 49/2,600 17.8/1,800 1,150 ± 50 2,800 ± 50
DL02-LEL04 61/2,600 22.9/1,800 1,150 ± 50 2,800 ± 50
DL02-LEL05 74/2,600 28.6/1,800 1,150 ± 50 2,800 ± 50
DL02-LEU00 61/2,600 22.9/1,800 1,220 ± 50 2,800 ± 50
D24NAP
DL02-MDE00 49/2,200 20.9/1,600 1,220 ± 50 2,400 ± 50
DL02-MDE01 42/2,200 15.3/1,600 1,220 ± 50 2,400 ± 50
DL02-MDL00 74/2,600 28.6/1,800 1,150 ± 50 2,800 ± 50
DL02-MDL01 66/2,600 25/1,800 1,150 ± 50 2,800 ± 50
DL02-MDL02 61/2,600 22.9/1,800 1,150 ± 50 2,800 ± 50
DL02-MDL03 49/2,600 17.8/1,800 1,150 ± 50 2,800 ± 50
DL02-MDL04 61/2,600 22.9/1,800 1,150 ± 50 2,800 ± 50
DL02-MDL05 74/2,600 28.6/1,800 1,150 ± 50 2,800 ± 50
DL02-MDU00 61/2,600 22.9/1,800 1,220 ± 50 2,800 ± 50
3 - 13
Outside Drawing of the Engine (DL02-LEE00, DL02-LEE01, DL02-MDE00, DL02-MDE01)
Isometric assembly drawings
11
10
1
9
2
8 3
7 4
5
6
12
22
13
21
14
20
19 15
18
16
17
EDL022262A
1. Turbocharger 8. Coolant pump pulley 15. Fuel injection pump 22. Breather
2. Exhaust manifold 9. Coolant pump 16. Oil filter
3. EGR cooler 10. Alternator mountng 17. Drain cock
4. Thermostat 11. Front lifting hook 18. Cylinder block
5. Oil Pan 12. Injector 19. Intake manifold
6. Crankshaft Pulley 13. Fuel Injection pipe 20. Rear lifting hook
7. Timing gear case 14. Common rail 21. Cylinder head cover
3 - 14
Assembly drawings (Front/Rear)
8
1
7
5
2
17
16
15
9
14 10
11
13
12
EDL022263A
1. Coolant pump pulley 8. Intake stake 15. Rear lifting hook

2. Timing gear case 9. Oil filter 16. Cylinder head cover
3. Crankshaft pulley 10. Oil level gauge 17. Breather hose
4. Oil pan 11. Oil cooler
5. Coolant hose 12. Fuel injection pump
6. Alternator mountin 13. Cylinder block
7. Front lifting hook 14. Cylinder head
3 - 15
Assembly drawings (Left/Right)
10 1
2
4
3
9
4
8
6
7
11
23
12
4
13
22 14
15
21
16
20
17
18
19
EDL022264A
1. Heat screen 8. Coolant rubber hose 15. Coolant pump 22. Oil filter
2. Turbocharger 9. Thermostat 16. Crankshaft pulley 23. Intake stake
3. Oil suplly pipe 10. Exhaust manifold 17. Oil level gauge
4. EGR connection pipe 11. Fuel Injection pipe 18. Fuel injection pump
5. EGR cooler 12. Common rail 19. Drain cock
6. Oil return pipe 13. Intake manifold 20. Oil cooler
7. EGR Valve 14. Coolant pump pulley 21. Coolant hose
3 - 16
Assembly drawings (Top/Bottom)
2
11
10 3
4
9
5
8
7
7
1
12
13
15
14
EDL022265A
1. Oil cap 7. EGR connection pipe 13. Drain cock

2. Fuel Injection pipe 8. Breather hose 14. Fuel injection pump
3. Common rail 9. Turbocharger 15. Oil pan
4. Oil level gauge 10. Injector
5. Oil filter 11. Thermostat
6. Intake stake 12. Oil cooler
3 - 17
Outside Drawing of the Engine (DL02-LEL00, DE02 LEL01, DL02-LEL02, DL02-LEL03,

DL02-LEL05, DE02-MDL00, DL02-MDL01, DL02-MDL02, DL02-MDL03, DL02-MDL05)
11
10
1
9
2
8 3
7 4
5
6
12
22
13
21
14
20
19 15
18
16
17
EDL022266A
3 - 18
8
1
7
5
2
17
16
15
9
14 10
11
13
12
EDL022267A

3 - 19
10 1
2
4
3
9
4
8
6
7
11
23
12
4
13
22 14
15
21
16
20
17
18
19
EDL022268A
3 - 20
2
11
10 3
4
9
5
8
7
7
1
12
13
15
14
EDL022269A

3 - 21
Outside Drawing of the Engine (DL02-LEL04, DL02-MDL04)
11
10
1
9
2
8 3
7 4
5
6
12
22
13
21
14
20
19 15
18
16
17
EDL022270A
3 - 22
8
1
7
5
2
17
16
15
9
14 10
11
13
12
EDL022271A

3 - 23
10 1
2
4
3
9
4
8
6
7
11
23
12
4
13
22 14
15
21
16
20
17
18
19
EDL022272A
3 - 24
2
11
10 3
4
9
5
8
7
7
1
12
13
15
14
EDL022273A

3 - 25
Outside Drawing of the Engine (DL02-LEU00, DL02-MDU00)
11
1
10
9
2
8 3
7 4
5
6
12
22 13
21
14
20
19
15
18
16
17
EDL022274A
3 - 26
8
1
7
5
2
17
16
15
9
14 10
11
13
12
EDL022275A

3 - 27
10 1
2
4
3
9
4
8
6
7
11
23
12
4
13
22 14
15
21
16
20
17
18
19
EDL022276A
3 - 28
2
11
10 3
4
9
5
8
7
7
1
12
13
15
14
EDL022277A

3 - 29
Engine Identification Number
Engine number engraving Cylinder block number engraving

The engine code and manufacturing number are The cylinder block serial number is engraved in the
engraved in the position marked with A in the drawing. position marked as A in the drawing.
These numbers are necessary to request quality
assurance or to order parts.
A
EDL022213A
EDL022278A
Engraving of piston bore level of cylinder

block
The piston bore level of the cylinder block is engraved
in the position marked as A in the drawing. The piston
bore level of the cylinder block is classified as A or B.
1 2 These levels are necessary to order the suitable piston
for the piston bore of the cylinder block.
3 4 A
EDL022165B
Product name
1. 3. Serial Number (5 digits)
(6 digits)
After new representative
2. Year (1 digit) 4.
specification (3 digits)
EDL022214A
3 - 30
Engraving of main bearing bore level of Connecting rod engraving

cylinder block
The connecting rod weight is engraved in the position
The main bearing bore level of the cylinder block is
marked as A in the drawing and classified by a letter from
engraved in the position marked as A in the drawing.
A to F. These levels are necessary to order the
The main bearing bore level of the cylinder block is
connecting rod.
classified as A, B, or C. These levels are necessary to
order the suitable main bearing for the main bearing
bore of cylinder block.
A
EDL022217A
EDL022215A
Piston engraving
The piston class is engraved on the position marked
Crankshaft main journal engraving as A in the drawing. The piston class is classified into
A and B. These levels are necessary to check the
The crankshaft serial number is engraved at the
suitable piston class.
position (A) in the drawing and the crankshaft main
journal diameter class is engraved at the position (B) in
the drawing. The crankshaft main journal diameter
class is classified into A, B, and C. These levels are
necessary to order the suitable main bearing.
A
EDL022218B
EDL022216A
3 - 31
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.
A B
Cyl. #1 Cyl. #2 Cyl. #3 Cyl. #4
EDL022219A
3 - 32
4. Regular Inspection

Routine Inspection ............................................4-3
Regular Inspection Table .............................. 4-4

General Conditions ...........................................4-4
Engine oil....................................................... 4-5

Engine oil standards..........................................4-5
Engine Oil Capacity...........................................4-6
Checking the Engine Oil....................................4-6
Replenishment of Engine Oil.............................4-7
Replacement of Engine Oil ...............................4-7
Coolant .......................................................... 4-9

Coolant standards .............................................4-9
Capacity of coolant............................................4-9
Checking the Coolant ........................................4-9
Measurement of Coolant Concentration ...........4-9
Replenishment of Coolant ...............................4-11
Replacement of Coolant..................................4-11
Fuel ............................................................. 4-13

General Information ........................................4-13
Fuel Standards................................................4-13
Air filter ........................................................ 4-14

Cleaning of Air Filter........................................4-14
Cleaning of the Air Filter Element ...................4-14
Replacement of Air Filter Element ..................4-15
4 - 1
4 - 2
Regular Inspection
General Information
CAUTION
General Information • Incorrect inspection methods may cause of
engine faults.
As time passes after purchasing an engine, each of
• Cleaning an engine with liquids such as water
the engines parts age and initial engine performance
or wax may cause breakdown of electrical
cannot be maintained.
parts.
Regular inspection and replacement according to the
• Be careful when handling batteries, cables,
recommended regular inspection table allows you to
and electrical wirings because current flows
maintain an engine with the optimum conditions and
through those parts.
best performance for a long period and prevent
• Do not put heavy things or apply excessive
unexpected accidents in advance.
force or impact on the fuel-related units.
Users are responsible for the proper operation and
• Make sure that you connect the battery
maintenance of engines. Engines should be inspected
terminal ('+' and '-') to the right terminal.
and replaced by officially-certified technicians in a
Connecting the '+' and '-' terminals to the
workspace with the specified tools and facilities.
wrong terminal may cause damage to the
Observe the following instructions to perform
electrical unit parts and fire.
inspections.
1. Perform inspections on a flat floor without a slope.
2. Excluding extreme circumstances, only perform
Routine Inspection
inspection while the engine is stopped.
Routine inspection is an inspection performed by an
3. Disconnect the '-' terminal of the battery before
engine operator before operating the engine. It should
performing an inspection. be performed to protect operator's safety, as well as
4. Perform inspection in a well ventilated space. the engine.
The following is a minimal check list.
5. Use a wooden prop or lift when working under the
1. Check whether the engine smoothly starts and the
engine.
levels of fuel, oil, and coolant are within the normal
DANGER range.
• Wait until the engine is sufficiently cooled 2. Check if any discharged emissions are colored
before starting inspection after operating the and if the exhaust contains toxic gas elements.
engine. Otherwise, you may be burned.
3. Check whether abnormal noise occurs after
• You may be poisoned by the emission when
starting an engine in a closed space. Perform starting an engine or not.
inspection at the well-ventilate space. 4. Check whether oil or water is leaking.
• Unless absolutely compelled, do not perform
inspection under an engine.
• Do not be close to fire when inspecting an
engine. Fuel, oil, or batteries may generate
gas, causing fire.
• If inspecting the engine while it is running, do
not wear accessories such as necklaces,
rings, watches or gloves. Such accessories
may become stuck in rotating parts while the
engine is running and may cause serious
bodily injury.
• Individuals who use a mechanical heart or
artificial internal organ should not enter the
area near an engine while it is running. The
high-voltage current of the injectors or ECU
may cause abnormal operation of such
equipment.
4 - 3
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 coolant Note 1) ○ Replace every 1,200 hours Note 2)
Cooling fan belt tension ○
Lubrication system
Lubricating device and oil leakage ○
Capacity and condition of engine
○ ● ● ● ● ● ● ● ● ● ●
oil
Engine oil filter ○ ● ● ● ● ● ● ● ● ● ●
Fuel system
Fuel line and connection unit ○
Fuel volume ○
Water draining from water separator ○
Fuel injection time Inspect and adjust if required
Injector Inspect and adjust if required
Compression pressure Inspect and adjust if required
Intake/Exhaust system
Air cleaner ○ Clean and replace if required
Throttle body cleaning ○
Intake line and connection unit ○
Exhaust line and connection unit ○
Emission state ○
Cylinder head
Intake/Exhaust valve gap state ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Electric system
Battery charging state ○
Various electric units ○
Note 1) Replenish coolant if required.

Note 2) Check coolant every 500 hours to maintain the concentration of antifreeze and additives.
4 - 4
Engine oil the oil pan. The engine oil level should indicate
between the upper limit and the lower limit of the oil
General Information level gauge.
Engine oil should be periodically replaced based on
Engine oil lubricates, cools, seals, prevents corrosion, the regular inspection table and the oil filter and the
and cleans engines, enhancing engine performance cartridge should be replaced as the engine oil is
and extending the engine's lifetime. If a vehicle is replaced.
continuously driven while engine oil is insufficient, the
moving parts of the engine may get stuck, causing
engine faults. Engine oil standards
Engine oil should be checked through the oil level
Use the specified engine oil suitable for the
gauge and replenished if required. Oil level should be
environment and conditions of the site where the
checked while the engine is stopped. To check the oil
engine will be used.
level, turn off the engine while it is running and wait for
5 ~10 minutes to allow the engine oil to flow back into
Engine Oil Viscosity by temperature
Ambient
temperature
EDL0213001A
Please use the engine oil which satisfies the following recommended specifications.
Engine Model SAE Classification Oil Class
API CJ-4
D24NAP SAE 10W30
(ACEA-E9)
Note) Use our genuine oil recommended by us.
4 - 5
Engine Oil Capacity 6. Insert the oil level gauge (A) again.
Please replenish the engine oil based on the following
recommended oil injection amount.
Engine oil capacity ( ℓ )

Engine
Inside of the oil pan A
Model Total Note)
Max. Min.
D24NAP 8.6 4.5 9.2
Note) Including 0.6 liter in the engine
Checking the Engine Oil

1. Move the engine to a flat surface to maintain the
engine level. EDL022279A
2. Start the engine and then stop it when it reaches 1) Insert the oil level gauge (A) again by using the
the normal temperature.
ring.
3. Wait for 5 ~ 10 minutes. 2) If the dipstick doesn't slide in, rotate it 180°ý and
4. Pull the oil level gauge (A) upward to pick it out. try again.
7. Pull the oil level dipstick (A) upward to pull it out.
A
B
EDL022279A
1) Check the position of the oil level gauge (A).

EDL022152A
2) It is mounted beside the oil filter at the side of the
engine. 1) Check if the oil is smeared between the upper limit
3) Pull the ring of the oil level gauge (A) to pick it out. (A) and the lower limit (B) of the oil level gauge.
2) If engine oil is smeared below the lower limit (B) or
5. Clean the indication line of the oil level gauge with not smeared on the gauge at all, replenish engine
clean cloth. oil.
3) Check condition of engine oil. If it is polluted,
CAUTION
replace it with new oil.
Cleaning the indication line of the oil level gauge
with dirty cloth allows the foreign substances to
get into the engine, causing engine faults.
4 - 6
Replenishment of Engine Oil Replacement of Engine Oil

• Special Tools
CAUTION
Figure Product Number/Name
Be careful not to let foreign substances flow into
the engine when removing the oil cap.
1. Remove the oil cap(A). 65.98801-0001

Filter wrench
• Tightening Torque
A
Component Tightening Torque
Drain plug 3 kgf•m
• Oil capacity
Engine oil capacity ( ℓ )

Engine
Inside of the oil pan
EDL022280A Model Total Note)
Max. Min.
D24NAP 8.6 4.5 9.2

2. Add our recommended genuine oil to replenish the
oil level.
1) Add our recommended genuine oil by dividing it
Note) Including 0.6 ℓ in the engine
into several portions for replenishment.
2) Wait for about 1 ~ 2 minutes and then check the DANGER
engine oil level.
• Prolonged and repeated contact of skin with
3) Check whether the oil is smeared between the engine oil may lead to shrinking, dryness of
upper limit and the lower limit of the oil level skin and even cause dermatitis.
gauge. • Do not expose skin with exchanged engine oil
for a long period.
4) Repeat the above process until the engine oil level
• Always wear work clothes and gloves.
reaches the appropriate level. • When skin is stained with engine oil,
immediately wash it with water, soap or hand
CAUTION cleaners.
• Do not clean skin with gasoline, fuel, thinner,
• Be careful not to let foreign substances flow
or solvent.
into the engine when replenishing engine oil.
• Apply a skin protective cream after cleaning
• Exceeding the upper limit of the oil level gauge
from oil.
may cause engine faults. If you have exceeded
• Do not put oil-stained gloves or cloth in pockets.
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
WARNING
gauge.
• Do not use unspecified engine oil additives. Discard exchanged 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
3. Complete engine oil replenishment and cover the serious environmental pollution. Violation of
oil cap. regulations regarding discard of engine oil
without observing the handling regulations, will
be punished.
4 - 7
1. Drain engine oil. 4) Temporarily assemble the new oil filter by rotating
it by hand.
A B 5) Assemble the oil filter with the filter wrench
(65.98801-0001) at a torque of 16 ~ 20 N•m.
3. Add the engine oil.
A B
A
EDL022281A
1) Place a container under the engine to drain the

engine oil.
2) Remove the drain plug B and drain the engine oil.
A
3) Remove the oil cap A.
EDL022281A
2. Remove the oil cap A. 1) Connect the drain plug B at a torque of 3.0 kgf•m.
2) Disassemble the oil level gauge.
3) Inject genuine oil recommended by Doosan.
Note) Inject 1/2 of specified oil and then wait for about
1 minute. Then inject the other 1/2 of oil.
4) Assemble the oil cap A.
5) Assemble the oil level gauge.
A 6) Remove the engine oil drain container from under
the engine.
4. After this, perform the final inspection.

B 1) Check if engine oil leaks after starting the engine.
2) Start the engine and then stop it when it reaches a
EDL022282A normal temperature.
3) Wait for 5 ~ 10 minutes.
1) Disassemble oil filter A with the filter wrench
4) Check the engine oil level with the oil level gauge.
(65.98801-0001).
CAUTION
CAUTION
Adding oil which exceeds the upper limit of the oil
Oil in the filter may run down while detaching the
level gauge may cause engine faults. If you have
oil filter. Be careful not to contaminate the other
injected engine oil far over the upper limit of the
parts by using a cloth when detaching the filter.
oil level gauge, drain it until the engine oil level
After replacing the oil filter, wipe clean any other
indicates somewhere between the upper and
parts which the oil has touched.
lower limit of the oil level gauge.
2) Cleanly wipe the surface on which the oil filter is

mounted.
3) Thinly spread engine oil over the rubber packing B
of the new oil filter A.
4 - 8
Coolant
General Information Checking the Coolant

The coolant plays an important role in the prevention
of overheating and freezing of the engine. However, if DANGER
the engine is used for a long period, the performance
If the radiator cap is opened to exchange or
of antifreezing and anticorrosion of the coolant
replenish coolant while the engine is overheated,
degrades. Maintain the condition of the coolant hot water will spurt out and may cause serious
through daily inspections and periodic replacements. burns. If it is absolutely necessary to open the
The mixing ratio for the engine coolant is 40 % radiator cap while the engine is overheated, wrap
antifreeze and 3~5 % additives (DCA4) to prevent the radiator cap with a cloth and slowly open the
corrosion. For the water in the coolant, use clean tap cap in two steps until the steam pressure has been
water. Periodically check coolant to maintain the released from the inside. After the steam pressure
concentration of antifreeze and additives. has been completely released, remove the radiator
cap.
CAUTION
1. Check the position of the supplementary tank.
The recommended mixing ratio allows coolant to
prevent corrosion of the engine efficiently and to 2. Make sure that the engine and radiator are cooled.
maintain the best engine performance for a long
period. Using contaminated water or unspecified 3. If the coolant level indicates between the upper
antifreeze or additives may cause critical faults in limit and the lower limit on the supplementary tank,
the cooler. it 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
Coolant standards
the coolant. If the coolant cap is contaminated or
• Amount of antifreeze during winter insufficient, measure the coolant concentration. If
Ambient the coolant concentration is outside the specified
temperature Coolant (°C) Antifreeze (%)
range, exchange the coolant.
(°C)
Above -10 85 15
Measurement of Coolant Concentration
-10 80 20
• Special Tools
-15 73 27
-20 67 33
-25 60 40
60.99901-0038
-30 56 44 CC2602M
(Fleet guard number)
-40 50 50 C) B) A)
Coolant test sheet
Capacity of coolant
The coolant concentration can be measured as
Engine Model and follows.
Coolant capacity (l)
Product Code 1. If the engine coolant temperature is within a range
D24NAP 3.7 of 10 ~ 55°C, drain the coolant and fill half a plastic
cup with it.
CAUTION
When taking out a sample of coolant from the
supplementary tank, it is difficult to measure the
precise concentration. Always take out sample by
opening the drain plug of coolant.
4 - 9
2. Soak the test sheet in the coolant and take it out

after 3 ~ 5 seconds. Shake the sheet to remove
the remaining coolant.
3. Wait for about 45 seconds until the test sheet
changes its color. TEST
CAUTION SERVICE
Measurement time should not exceed 75 seconds.

The color changes as time passes.
PRE CHARGE
4. Check the color on test sheet.
EDL022154A
1) Compare the changed pink color part A of the test

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%.
2) The state of additives for anticorrosion is shown
on the point where the color of MOLYBDATE
(Middle pad) on the standard color table (which is
identical with the Middle (B) of the test sheet) is
EDL0213002A crossed with the color of NITRITE on the standard
1) Compare the color of part A on the test sheet to color table (which is identical with the (C) of the
the color of GLYCOL / FREEZEPOINT (End pad) test sheet). It should be maintained at the optimum
of the standard color table. range, in the green section between 0.3 to 0.8.
2) Compare the color of the test sheet (B) to the color 3) If the measurement result is below 0.3, replenish
of MOLYBDATE (Middle pad) of the standard anticorrosion additives (DCA4). If it is above 0.8
color table. or, drain a little coolant and then inject clean tap
3) Compare the color of the test sheet (C) to the color water to adjust the concentration.
of NITRITE of the standard color table.
CAUTION
5. Compare and confirm the parts with identical • If the color on the test sheet does not match
the color of the standard color table, find a
colors on the test sheet and the standard color
middle color on the standard color table. For
table. example, if the color of (C) of the test sheet
matches D and F on the NITRITE of the
standard color table, select E.
• To prevent corrosion inside of the engine
cooling unit, drain the coolant and replace it
with new coolant once a year.
4 - 10
Replenishment of Coolant Replacement of Coolant

If the coolant level of the supplementary tank is below
the lower limit, replenish the coolant as follows. DANGER
1. Remove the supplementary tank cap. • Never open the radiator cap while the engine is
2. Replenish coolant until its level is between the overheated. If the radiator cap is opened while
the engine is overheated, hot water will spurt
upper and lower limit of the supplementary tank.
out and may cause serious burns. Open the
3. Install the supplementary tank cap. radiator cap after ensuring that the engine has
been cooled sufficiently.
CAUTION • Mark and separately manage the containers
for storing coolant from beverage containers
Be careful not let foreign substances flow into the
to avoid confusion. If coolant is ingested, see
engine when replenishing coolant.
a doctor immediately.
If there is not coolant in the supplementary tank,

CAUTION
replenish the coolant as follows.
1. Remove the radiator cap while the engine and Be careful not to get coolant on any belts or
electric apparatus when replacing the coolant.
radiator are cold.
2. Replenish coolant up to the inlet of the radiator. 1. Make sure that engine and radiator are cooled.
3. After starting the engine let the coolant circulate 2. Place a container in front of the coolant drain plug.
sufficiently and check the coolant level. If there is
3. Remove the radiator cap.
insufficient coolant, replenish more.
4. Unplug the coolant drain plug of the radiator and
4. Install the supplementary tank cap. then drain coolant.
5. Remove the supplementary tank cap. 5. After completing coolant drain, connect the
6. Replenish coolant until its level is between the coolant drain plug again.
upper and lower limit of the supplementary tank.
6. Drain the coolant from the coolant supplementary
tank and cleanse the tank.
CAUTION
7. Fill the radiator inlet with water and install radiator
• If the radiator cap is opened while the engine
is hot, hot water will spurt out and may cause cap.
serious burns. Open the radiator cap after Note) Slowly pour coolant in to let the air be discharged
making sure that the engine has been fully from radiator and press the hose connected to it
cooled. to discharge the air inside.
• Mark and separately manage the containers
8. Start the engine to let the cooling fan rotate 2 or 3
for avoiding confusion. See a doctor times. When the engine is warmed up, increase
immediately in case of drinking coolant. 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.
11. Repeat the above mentioned processes from 1 to
8 until the drained water becomes clear.
12. Press the hose connected to the radiator to
discharge the air from inside of the radiator and
slowly fill the radiator with the coolant at the
specified mixing ratio to let the air be discharged
from the radiator.
Note) Use recommended genuine antifreeze.
4 - 11
CAUTION
• Do not mix antifreezes from different
manufacturers.
• Do not mix the coolant with different
concentrations.
• Do not add antirust which is not recommended
by us.
• As insufficient coolant concentration may
cause corrosion or freezing, on the other
hand, an excessive concentration may
degrade the cooling performance. Mix coolant
with 40% antifreeze and 3~5% additives
(DCA4) to prevent corrosion.
13. Operate the engine at idle after starting. When

cooling fan is running and coolant is circulated,
remove radiator cap and replenish coolant through
the inlet.
14. Replenish coolant until the cooling fan rotates 3 ~
5 times.
15. Replenish coolant to the upper limit of the
supplementary tank and then install radiator 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
radiator are cooled.
18. After checking the coolant level in the
supplementary tank, replenish coolant until the
tank level stays between the upper and lower limit
without changing.
Note) After replenishing coolant, check the coolant level

of the supplementary tank for at least two or
three days.
CAUTION
After replenishing coolant, check the coolant level
of the supplementary tank for at least two or three
days.
WARNING
Discard exchanged coolant according to the
regulations set forth by the relevant authorities.
Disposing of exchanged coolant into the ground,
serious environmental pollution. Violation of
regulations regarding discard of engine oil
without observing the handling regulations, will
be punished.
4 - 12
Fuel
General Information
Fuel quality is an important factors in satisfy standards
for engine performance, engine lifetime, and
emissions. Doosan engines are designed to use diesel
fuel available in the area where the engines are sold.
CAUTION
• Use clean, specified, and qualified fuel only.
Using irregular or unspecified fuel may cause
critical damage and faults to the engine.
• Inject fuel while the engine is stopped.
Fuel Standards
To maintain the optimum engine performance, refer to
the following recommended fuel table to select the
appropriate fuel.
• Ultra Low Sulfur Diesel

Fuel Ingredients Standard
Specific Gravity (kg/lit) 0.820 ~ 0.845
Fire Point (°C) Above 40
Viscosity (40 °C) (cSt) 1.9 ~ 5.5
Sulfur Content (wtppm) Below15
Cloud Point (°C) -
Pour Point (°C) Below-17.5
Low temperature filter
(°C) Below-16
clogging point
Color (ASTM) Below 2.5
Residual carbon (10%)
(%) Below0.15
Vapor/residual fraction (wt)
Total acid value (mg KOH/g) Below0.40
Back plate corrosion rate
Below 1
(100 °C, 3 hours)
Ash Content (mass %) Below0.01
Moisture and
(vol. %) Below0.02
Precipitation
Cetane Index Above 45
50 %
Distillation -
Distillation Point
Test Temperature 90 %
Distillation Below360
Point
Note) The fuel product level has been prepared based

on SK Ultra Low Sulfur Diesel.
4 - 13
Air filter
General Information 1) To clean, let sufficient compressed air reach the

The air filter purifies dust and foreign substances inside bottom of the element at 90° direction with
included in the air and supplies clean air into the an air gun.
engine. The air filter is directly related to engine
2) Move air gun up and down the element to blow air
lifetime, emissions, and engine output. Please
periodically check, clean, and replace the air filter. from inside to outside until no more dust is coming
out from the element.
CAUTION 3) Do not use compressed air pressure exceeding 5
• Do not operate the engine when the air filter is bars.
separated from the engine.
• Use specified air filters only. Using DANGER
unauthorized or remanufactured air filters may
result in critical faults. Always wear protective goggles before starting
• Foreign substances in the engine may cause work. Otherwise, dust or foreign substances from
the element may get in your eyes and cause
abrasion inside the engine.
injuries.
• 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 2. Clean the element by washing it.
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.
Cleaning of the Air Filter Element

Clean the air filter element by using the most suitable
EDL022156A
method for your work environment among the three
methods stated below. 1) Before washing the element, clean the element by
1. Use compressed air to clean the air filter element. using compressed air as described above.
2) Soak the element in the warm cleaning solvent for
10 minutes and then shake it back and forth for
about 5 minutes.
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
4 - 14
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.
4 - 15
4 - 16
6. About the engine
Marking system of Units ................................ 6-3

Unit Conversion Methods .................................6-3
Tightening Torque ......................................... 6-4

Tightening Torque of Main Parts .......................6-4
Tightening Torque of General Bolts ..................6-5
Tightening torque of plug screw ........................6-6
Hollow Screw (4-Hole) Tightening Torque ........6-6
Engine Disassembly...................................... 6-7

Special Tools.....................................................6-7
Procedure of Disassembling an Engine ............6-7
Engine Assembly......................................... 6-21

Special Tools...................................................6-21
Procedure of Assembling Engine ....................6-22
6 - 1
6 - 2
6. About the engine
About the engine
Marking system of Units Item Number SI Unit US Unit

7.500615 kPa mmHg
Unit Conversion Methods Pressure 20.88543 kPa lb/ft2
The following methods show how to convert SI units to 14.2233 psi kg/cm2
US units and vice versa. 1.3596 kw PS
Electric
1. To convert an SI unit to a US unit, multiply a SI Power 0.98635 ps hp
unit with the number in the following table.
Fuel
Note) (SI Unit) X (Number) = (US Unit) Consum 0.00162 g/kwh lb/psh
ption
Note) 1mm X 0.03937 = 0.03937 in
0.000947817 J BTU
Energy
0.7375621 J lbfïft
2. To convert a US unit to an SI unit, divide the US
0.0002777778 J Wh
unit by the number in the following table.
Luminou
0.09290304 lm/m2 lm/ft2
Note) (US Unit) ÷ (Number) = (SI Unit) s Flux
Note) 1 in ÷ 0.03937 = 25.4 mm Speed 0.6213712 km/h mph

Tempera Note 3) °C °F
Item Number SI Unit US Unit ture
0.03937 mm in
Note 1) 9.806 x (kgïf) = (N)
3.28084 m ft
Length Note 2) 9.806 x (kgfïm) = (N•m)
1.093613 m yd
Note 3) {(9/5) x (°C)+32} = (°F)
0.621371 km mile {(°F)-32} x (5/9) = (°C)
0.00155 mm2 in2
0.1550 cm2 in2
Area
10.76391 m2 ft2
1.19599 m2 yd2
2.204623 kg lb
Weight
0.001 kg t (ton)
0.061024 cc in3
0.061024 ml in3
Volume 0.061024 cm3 in3
61.023744 L in3
0.264172 L gal
Force 2.204622 kgf lbf

Note 1)
0.2248089 N lbf
Accelera 3.28084 m/s2 ft/s2

tion 39.37008 m/s2 in/s2
7.233014 kgf•m lbf•in
Torque 86.79619 kgf•m lbf•in

Note 2)
0.7375621 N•m lbf•ft
8.850748 N•m lbf•in
Power 1.340483 kw Hp
Pressure 0.01 kPa bar
6 - 3
6. About the engine
Tightening Torque
Tightening Torque of Main Parts
Tensile
Nominal
Main Parts Strength Tightening Torque Remarks
(Diameter X Pitch)
Rank
1st: 5.5 kgf•m ± 0.28 kgf•m
Main Bearing Cap Bolt M12x1.5x118 10.9T 2nd: 90° ± 4°
3rd: 90° ± 4°
1st: 4.0 kgf•m ± 0.2 kgf•m
2nd: 90° ± 4°
Cylinder Head Bolt M11x1.25x130 10.9T
3rd: 90° ± 4°
4th: 90° ± 4°
1st: 2.0 kgf•m ± 0.1 kgf•m
Connecting Rod Bolt M8x1.0x56 10.9T
2nd: 90° ± 4°
Crankshaft Pulley Bolt M14x1.5 10.9T 26 kgf•m ± 1 kgf•m
Cylinder Head Cover (Left, Right) M6x1.0 8.8T 0.8 kgf•m ± 0.05 kgf•m
Cylinder Head Cover Bolt M6x1.0 8.8T 0.8 kgf•m ± 0.05 kgf•m
± 0.35
Injector Fixing Bracket Bolt (Socket) M8x1.25 12.9T 4.35 kgf•m
kgf•m
Thermostat Mounting Space Bolt M8x1.25 8.8T 2.2 kgf•m ± 10%
Pressure Sensor Adaptor Bolt M6x1.0 8.8T 0.7 kgf•m ~ 1.0 kgf•m
Turbocharger Hollow Screw (M10) M10x1.0 - 1.8 kgf•m ~ 2.0 kgf•m
Oil Pan Drain Plug UNF 3/4-16 - 3.0 kgf•m ± 10%
Glow Plug Body M8x1 - 0.9 kgf•m ~ 1.2 kgf•m
Glow Plug Terminal M4x0.7 - 0.25 kgf•m ~ 0.3 kgf•m
Turbocharger Mounting Nut M8x1.25 - 2.2 kgf•m ± 10%
water pump Mounting Nut M8x1.25 - 2.2 kgf•m ± 10%
Rocker Arm Adjust Hex Nut M8x1.0 - 1.5 kgf•m ± 10%
High Pressure Pump Drive Gear Nut M14x1.5 - 6.5 kgf•m ± 0.5 kgf•m
High Pressure Pump Mounting Nut M8x1.25 - 2.2 kgf•m ± 10%
Turbocharger Oil Delivery Pipe Nut Union Nut - 2.0 kgf•m ± 10%
High Pressure Pipe Nut - High
Union Nut - 3.0 kgf•m ± 0.2 kgf•m
Pressure Pump
High Pressure Pipe Nut - Common Rail Union Nut - 3.0 kgf•m ± 0.2 kgf•m
High Pressure Pipe Nut - Injector Union Nut - 3.0 kgf•m ± 0.2 kgf•m
High Pressure Pump Fuel Hose
M12x1.75 8.8T 5.5 kgf•m
Bracket Bolt
6 - 4
6. 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
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Nominal
Diameter × (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
Pitch Elastic Limit Value (kg/mm2)
(mm)
20 24 32 30 40 36 46 54 64 90 106
Tightening Torque (kg•m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.5 0.75 0.9
M6 0.28 0.30 0.45 0.4 0.55 0.47 0.77 0.85 0.9 1.25 0.5
M7 0.43 0.46 0.7 0.63 0.83 0.78 1.2 1.3 1.4 1.95 2.35
M8 0.7 0.75 1.1 1 1.4 1.25 1.9 2.1 2.2 3.1 3.8
M8 X 1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.35 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10 X 1 1.5 1.6 2.5 2.1 3.1 2.8 4.3 4.9 5 7 8.4
M12 2.4 2.5 3.7 3.3 4.7 4.2 6.3 7.2 7.5 10.5 12.5
M12 X 1.5 2.55 2.7 4 3.5 5 4.6 6.8 7.7 8 11.2 13.4
M14 3.7 3.9 6 5.2 7.5 7 10 11.5 12 17 20
M14 X 1.5 4.1 4.3 6.6 5.7 8.3 7.5 11.1 12.5 13 18.5 22
M16 5.6 6 9 8 11.5 10.5 17.9 18.5 18 26 31
M16 X 1.5 6.2 6.5 9.7 8.6 12.5 11.3 17 19.5 20 28 33
M18 7.8 8.3 12.5 11 16 14.5 21 24.2 25 36 43
M18 X 1.5 9.1 9.5 14.5 12.5 18.5 16.7 24.5 27.5 28 41 49
M20 11.5 12 18 16 22 19 31.5 35 36 51 60
M20 X 1.5 12.8 13.5 20.5 18 25 22.5 35 39.5 41 58 68
M22 15.5 16 24.5 21 30 26 42 46 49 67 75
M22 X 1.5 17 18.5 28 24 34 29 47 52 56 75 85
M24 20.5 21.5 33 27 40 34 55 58 63 82 92
M24 X 1.5 23 25 37 31 45 38 61 67 74 93 103
Note) The standard torque values above are about Note) A special screw should be tightened with 85%
70% of the bolt elastic limit values. of the tightening torque of the standard value.
For example, a MoS2-coated screw should be
Note) The tensile force has been calculated by multiplying
tightened with 60% of the tightening torque of
the tensile strength with the screw cross-
the standard value.
sectional area.
6 - 5
6. About the engine
2. Tightening Torque of Key General Bolts
Strength Classification
Nominal
Diameter X Pitch 8.8T 10.9T 8.8T Remarks
(mm)
Tightening Torque (kgf•m) ± 10 %
M6 X 1 1 1.25 1.5
M8 X 1.25 2.2 3.1 3.8
M8 X 1 2.4 3.35 4.1
M10 X 1.5 4.4 6.2 7.4
M10 X 1.0 5 7 8.4
M12 X 1.75 7.5 10.5 12.5
M12 X 1.5 8 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
Classificatio M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
n
SM25C - 1.6 2.5 3.5 4.5 5.5 9.0 13.0 18.0 30.0
SUM22L Note) 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
Note) Applied to Doosan Engines
6 - 6
6. About the engine
Engine Disassembly
Special Tools 3) Remove the radiator cap.

4) Remove the coolant drain plug of the radiator and
then drain coolant.
5) After completing coolant drain, reconnect the
coolant drain plug.
860104-00462
Valve Spring
Compression Tool
DANGER
• If the radiator cap is opened while the engine
is hot, hot water will spurt out and may cause
serious burns. Open the radiator cap after
making sure that the engine has been fully
cooled.
T7621010E • Mark and separately manage the containers
Piston Ring Plier for storing coolant from beverage containers
to avoid confusion. See a doctor immediately
in case of drinking coolant.
WARNING
65.98801-0001 Discard coolant according to the regulations set forth by
Filter wrench the relevant authorities. Disposing of discharged
coolant into the ground, sewers, drains, rivers, or the
sea will cause serious environmental pollution. Violation
of regulations when discarding engine oil without
observing the handling regulations, will be punished.
850306-00078
CAUTION
Oil seal disassembly jig
Be careful not to get coolant on any belts or electric
apparatus when replacing the coolant.
2. Drain the engine oil.

Procedure of Disassembling an Engine
A B
CAUTION
• Prepare tools and genuine parts necessary
before disassembling engine.
• 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 of disassembly.
• Do not allow parts removed from the engine to
touch each other or be mixed with other parts.
A
Disassemble the engine in the following order.
EDL022281A
1. Drain coolant. 1) Place a container under the engine to drain the
1) Check if the engine and radiator are cooled. engine oil.
2) Place a container in front of the coolant drain plug. 2) Remove the oil cap (A).
6 - 7
6. About the engine
3) Remove the drain plug (B) and drain the engine 8. Disconnect the oil level gauge (A).
oil.
WARNING
Discard oil according to the regulations set forth by A
the relevant authorities. Disposing of discharged oil
into the ground, sewers, drains, rivers, or the sea
will cause serious environmental pollution.
Violation of regulations when discarding engine oil
without observing the handling regulations, will be B
C
punished.
3. Detach the air cooler and cooling fan from engine.
EDL022231A
4. Detach the engine from the machine.
1) Remove the oil level gauge (A).
5. Disconnect the cables and harness connected to 2) Loosen the flange hex bolt (C).
each sensor of the engine. 3) Disconnect the oil level gauge gauide tube (B).
CAUTION
6. Remove the V-belt.
Do not reuse fuel injection pipes; replace them
with new ones. If fuel injection pipes are reused it
7. Disconnect the breather hose (A).
may allow foreign substances into the fuel pipes
or cause oil leaks from bolt clamping and cause a
critical fault in engine performance.
B 9. Disconnect the intake stake (A).
EDL022230A
B
1) Remove the hose clamps. C
CAUTION
Do not reuse the clamps but replace with new ones. EDL022232A
2) Disconnect the breather hose (A).

3) Remove 3 hose clips (B) to the cylinder head
cover.
6 - 8
6. About the engine
11. Remove the common rail(A) and the injection

pipes(B) and (C).
A A
E
2 3
EDL022232B C
D
1) Loosen the fixing bolt.
2) Remove the boost pressure sensor( D). EDL022234A
3) Loosen 4 collared hex bolts (B). 1) Loosen the fixing bolt (E).
4) Remove the intake stake (A) and gasket (C) from 2) Loosen the nuts of the fuel injection pipe (C),
the intake manifold. which are connected to the common rain and the
fuel injection pump.
3) Loosen the nuts of the fuel injection pipe (B),
10. Disconnect the EGR connection pipe (A).
which are connected to the common rail and the
C injector.
1 B
CAUTION
A
A
4) Loosen 2 collared hex bolts (D) of the common rail.
5) Remove the common rail (A) from the intake manifold.
2 12. Remove the oil filter assembly.
EDL022233A
1) Loosen 4 flange hex bolts (B). I

2) Disconnect the EGR Connection pipe (A) and the
H
gasket (C).
F G
EDL022235A
6 - 9
6. About the engine
1) Remove the boost temperature sensor (E).

A 2) Loosen 8 flange hex bolts (C) and 2 flange hex
bolts (D).
3) Remove the intake manifold (A) and the gasket (B).
C 14. Remove 2 knock sensors (A) and the oil pressure

and temperature sensor (B).
B D E
EDL022236A
1) Remove the hose clamps.

C
2) Disconnect the coolant hose (E) from the water
pump.
B
3) Remove the oil filter (I) with the filter wrench. D
CAUTION
Oil in the filter may run down while removing the EDL022238A
1) Loosen 2 bolts (D).
parts by using a cloth when removing the filter.
After replacing the oil filter, wipe clean any other 2) Remove the oil pressure and temperature sensor
parts which the oil has touched. (B) from the cylinder block.
3) Loosen 2 bolts (C).
4) Loosen 3 flange hex bolts (F) and 2 flange hex
4) Remove 2 knock sensors (A) from the cylinder block.
bolts (G).
5) Remove the oil filter assembly and 3 O-rings from
15. Remove the turbocharger (A).
the cylinder block.
6) Disconnect the coolant hose (E). L
7) Loosen 4 flange hex bolts (D). K
8) Remove the oil cooler (B) and 3 O-rings from the
oil filter head (A). J
I
A
13. Remove the intake manifold (A).
B A
H
E K
L
EDL022239A
C E
EDL022237A
6 - 10
6. About the engine
3) Loosen 2 flange hex bolts (D) and 2 flange hex

F bolts (E).
4) Loosen 4 flange hex bolts (C).
Type-1 5) Disconnect 2 EGR connection pipes (A) and 4
Type-2
A gaskets.
F
G C
DANGER
F
Type-3
D Exhaust gas make engine parts extremely hot.
B Only remove the parts when they have fully cooled
F to prevent burns.
Type-4 17. Remove the EGR valve (A) and EGR cooler (B).
E
EDL022240A
1) Loosen 2 hollow screws (L) from the oil delivery

pipe (J).
2) Disconnect the oil delivery pipe (J).
3) Remove 4 sealing washers (K).
4) Remove the hose clamps. E
5) Disconnect the rubber hose (E).

6) Loosen 4 flange hex nuts (I). H
F
7) Remove the gasket (H) and the turbocharger from
the exhaust manifold. G
8) Disconnect the suction hose (G) and the air inlet
pipe (F) after removing the hose clamps.
9) Remove the hose clamps and disconnect the EDL022242A
rubber hose (E).

10) Loosen 2 flange hex bolts (D).
B
11) Disconnect the gasket (C) and the oil return pipe
(B) from the turbocharger (A).
C
16. Disconnect pipes (A) and hoses (B).
E D
A
A
C
D EDL022243A
1) Loosen 2 collared hex bolts (G) and 1 hex bolt (H).

F
2) Remove the EGR Assembly from the cylinder
block.
3) Loosen the bolt (F).
B
4) Remove the cam shaft position sensor (E) from
EDL022241A
the cylinder block.
1) Remove the exhaust gas temperature sensor (F). 5) Remove the EGR coolder (B) and the gasket (D)
2) Remove the clamps and disconnect 3 hoses (B). from the EGR valve (A).
6 - 11
6. About the engine
19. Remove the heat screen (A).

DANGER
Exhaust gas make engine parts extremely hot.
Only remove the parts when they have fully cooled A
to prevent burns.
C
18. Remove the thermostat (A).
A
B
F
B EDL022246A
E
1) Loosen 2 hex bolts (B) and 3 hex bolts (C).
C 2) Remove the heat screen (A).
D 20. Remove the exhaust manifold (A).
EDL022245A
C
A
2
D
F B
B
E
C
EDL022247A
D
1) Loosen 8 flange hex bolts (B).
2) Remove the exhaust manifold (A) and the gasket
EDL022244A
(C).
1) Remove the hose clamps (E).
2) Disconnect the rubber hose (F). DANGER
3) Loosen 1 flange hex nut and 1 space bolt (C). Exhaust gas make engine parts extremely hot.
4) Loosen 3 flange hex bolts (B). Only remove the parts when they have fully cooled
to prevent burns.
5) Remove the thermostat (A) from the cylinder
head.
6 - 12
6. About the engine
21. Disconnect the glow plug (A). 23. Remove the water pump pulley (A).
D
C
B
B
EDL022248A EDL022250A
1) Loosen 4 hex nuts (D) and remove 4 washers (C). 1) Loosen 4 hex bolts (B).
2) Remove the electric connector (B). 2) Remove the water pump pulley (A).
3) Disconnect 4 glow plugs (A) from the cylinder
head. 24. Remove the water pump (A).
22. Disconnect the fuel return hose (A).
A
A
C
B
EDL022251A
1) Loosen 4 hex bolts (B) and 2 flange hex nuts (C).

EDL022249A
2) Remove the water pump (A) and the gasket (D).
1) Loosen the flange hex bolts (B).
2) Remove the hose clips.
3) Disconnect the fuel return hose (A).
6 - 13
6. About the engine
25. Remove the rear lifting hook (A). 27. Remove the right cylinder head cover (A).
B A
EDL022252A EDL022026A
1) Loosen 3 flange hex bolts (B). 1) Loosen 10 flange hex bolts (B).
2) Remove the rear lifting hook (A). 2) Remove the right cylinder head cover (A).
26. Remove the front lifting hook (A). 28. Remove the left cylinder head cover (A).
A
A B
EDL022253A EDL022254A
1) Loosen 2 flange hex bolts (B). 1) Loosen 13 flange hex bolts (B).
2) Remove the front lifting hook (A). 2) Remove the left cylinder head cover (A).
6 - 14
6. About the engine
29. Remove the injectors (A). 2) Loosen 12 hex bolts (B).

3) Remove the cylinder head cover (A).
31. Remove the rocker arm (A).
C
A
A
B
D
EDL022255A
1) Loosen 4 hex bolts (B).

EDL022029A
2) Remove 4 injector fixtures (C).
3) Remove 4 injectors (A). 1) Loosen 10 flange hex bolts (B).
Note) Remove the cylinder head cover and remove 2) Remove the rocker arm (A).
the injector seal ring washers (D).
32. Remove the push rods (A).

CAUTION
• Do not reuse the head cover rubber seal and
the injector oil seal but replace with new ones.
• Be careful not to damage the injector oil seal A
of the cylinder head cover.
• Remove it by turning the injector slowly from
left to right.
• Do not reuse the injector seal ring washers.
Reuse of the injector seal ring washers may
cause critical damage to the engine due to
unstable combustion.
30. Remove the cylinder head cover (A).
EDL022030A
C
1) Remove the push rods (A).
EDL022257A
1) Remove the oil injection cap (C).
6 - 15
6. About the engine
33. Detach the cylinder head (A). 35. Remove the valves (A).
D
B
C
B
A
C A
EDL022031A EDL022033A
1) Loosen 18 cylinder head bolts (B). 1) Remove the valves (A) from the cylinder head (B).
2) Detach the cylinder head (A). 2) Remove the valve stem seals (C).
3) Remove the cylinder head gasket (C). 3) Remove the spacer seal rings (D).
CAUTION 36. Remove the crankshaft pulley (A).

Do not reuse the cylinder head gasket but replace
with new one.
34. Remove the valve spring (D).
A A
B
C
B
EDL022258A
1) Loosen the flange hex bolt (B).

2) Remove the crankshaft pulley (A).
CAUTION
EDL022032A
Be careful not to damage the oil seal.
1) Remove the calipers (A).
2) Compress the valve with the valve spring
compression tool (860104-00462).
3) Remove the valve cotters (B).
4) Remove the valve spring retainers (C).
5) Remove the valve springs (D).
6 - 16
6. About the engine
37. Remove the oil pan (A). 39. Remove the connecting rods (A).
D
C
B
E
B
C
EDL022259A EDL022037A
1) Remove the drain plug (C). 1) Loosen 8 connecting rod bolts (C).
2) Remove the O-ring (D). 2) Uncap the connecting rod caps (B).
3) Loosen 26 flange hex bolts (B). 3) Remove the connecting rods (A).
4) Remove the oil pan (A).
CAUTION
38. Disconnect the oil suction pipe (A) and oil delivery
pipe (B). Be careful not to mix disconnected connecting rods,
connecting rod caps, and removed connecting rod
E bolts as they are set aside.
B
D 4) Remove the top connecting rod bearings (D) and
F the bottom connecting rod bearings (E).
C
F 40. Remove the piston (A).
F
A
D
E
F
C A
B
EDL022036A
G
1) Loosen 2 hex bolts (C).
2) Remove the oil suction pipe (A) and 1 O-ring (F).
3) Loosen 1 hex bolt (D) and 2 hex bolts (E).
4) Disconnect the oil delivery pipe (B) and 2 O-rings (F).
EDL022038A
1) Remove 2 snap rings from the both ends of the

piston.
2) Remove the piston pin (B).
3) Remove the piston (A) from the connecting rod (G).
4) Remove the 1st ring (D), the 2nd ring (E), and the
oil ring (F) with the piston ring plier (T7621010E).
6 - 17
6. About the engine
41. Remove the timing gear case (A). 43. Remove the fuel injection pump (A).
E
D
C B
EDL022261B EDL022043A
1) Loosen the fixing bolt (E) and remove the crank

speed sensor (D).
3) Remove the timing gear case (A). G
4) Remove the front oil seal (C) with the oil seal
F
disassembly jig.
E
CAUTION D
C
Do not reuse the oil seal; replace them with new
ones.
42. Remove the timing wheel (A).
B EDL022043B
1) Loosen 3 flange hex nuts (B).

2) Remove the fuel injection pump (A).
3) Loosen the flange hex nut (C).
4) Remove the injection pump drive gear (D).
5) Remove the collar (F).
6) Remove the O- ring (E) from the collar (F).
A 7) Remove the O- ring (D).
CAUTION
Do not reuse the O-ring; replace with a new one.
EDL022040B Reuse of the O-ring may cause critical damage to
engine performance to occur.
1) Remove the parallel key (B).
2) Remove the timing wheel (A).
6 - 18
6. About the engine
44. Remove the idle gear (A). 46. Remove the crank case (A).
A
E
C
EDL022044B EDL022046B

2) Remove the idle gear shaft (C).
3) Remove the idle gear(A) with remove tap (D).
B
45. Remove the oil pump (A).

C
C D
EDL022051A
1) Remove the rear oil seal (E) with oil seal

disassembly jig (850306-00078).
B CAUTION
EDL022045B Do not reuse the oil seal; replace it with a new one.

2) Loosen 16 collared hex bolts (B).
2) Remove the oil pump (C) and 2 O-rings (F).
3) Loosen 10 main bearing cap bolts (C).
4) Remove the crank case (A).
5) Loosen 5 bottom main bearings (D) from the crank
case (A).
6 - 19
6. About the engine
47. Remove the crankshaft (A). 49. Remove the valve tappets (A).
A
A
EDL022047B EDL022049A
1) Remove 2 thrust washers (B). 1) Remove 8 valve tappets (A) from the cylinder
2) Remove the crankshaft (A). block.
3) Remove the top main bearings (C) from the
cylinder block. 50. Disconnect the oil spray nozzles (A).
48. Remove the camshaft (A).
EDL022050B
B
1) Remove 4 relief valves (B).
EDL022048A
2) Remove 4 oil spray nozzles (A).
2) Remove the camshaft (A).
6 - 20
6. About the engine
Engine Assembly
Special Tools
860104-02047
Front Oil Seal
LOCTITE
LOCTITE 272 Disassembly Jig
860104-02048
Rear Oil Seal
LOCTITE 500212-00016 Disassembly Jig
5902 LOCTITE 5902
860104-02793
T7621010E G2 Diagnostic Tool
Piston Ring Plier - UVIM(CAN
Communication)
- 14pin OBD Connector
- USB Cable
- 6pin OBD Connector
EF.120-208
Piston insertion tool
LOCTITE
09-0666
Blue
587
LOCTITE BLUE 587
860104-02041
Valve Stem Seal Jig
860104-00462
Valve spring compression
tool
6 - 21
6. About the engine
Procedure of Assembling Engine 2. Connect the valve tappets (A).
CAUTION
A
• Cleanse all disassembled and disconnected
parts. Especially, clean the oil and coolant
path with compressed air and check if there is
any resistance.
• Arrange general tools and special tools for
engine assembly.
• Prepare clean engine oil to be applied on each
sliding component.
• Prepare repair materials such as sealant and
gaskets.
• Replace used gaskets, seal rings, and
expendable parts with new ones.
• Each bolt should be tightened with the
specified tightening torque in the order of
tightening; however, excessive tightening EDL022049A
torque should be avoided.
• Ensure that all engine parts are successfully 1) Apply engine oil on the surface where the cylinder
operating after reassembly. block and the valve tappets (A) are assembled.
• Check if any bolts are loose after the first 2) Connect 8 valve tappets (A).
assembly.
• Always keep hands clean during assembly.
3. Attach the camshaft (A).
Assemble the engine in the following order.
1. Attach the oil spray nozzles (A).
EDL022048A
1) Apply engine oil in the cam hole of the cylinder block.

2) Apply engine oil on the camshaft (A) journal.
EDL022050B
Note) Ensure that the camshaft journal and the inside
1) Attach 4 oil spray nozzles (A) to the corresponding of the cylinder block bush are normal.
pins. 3) Align the thrust washer with the cylinder block part.
2) Mount 4 relief valves (B) at a tightening torque of 4) Tighten 2 hex bolts (B) at a tightening torque of 2.2
2.0 kgf•m. kgf•m.
Note) Temporarily mount one hex bolt manually and then
rotate the camshaft gear to tighten the other
hex bolt.
5) The camshaft end play is 0.1 ~ 0.2 mm.
Item Specified Value
Camshaft end play 0.1 to 0.2 mm
6 - 22
6. About the engine
4. Attach the crankshaft (A). Note) The class of the main bearing is as follows.
Inside diameter Crankshaft main journal

of the cylinder diameter
A block main
bearing bore Class A Class B Class C
B
Class A YELLOW BLUE BLUE
Class B YELLOW YELLOW BLUE
Class C RED RED YELLOW

C
Inside diameter of the
cylinder block main Specified Value
bearing bore
Class A 62.000 ~ 62.007 mm

EDL022047B Class B 62.007 ~ 62.014 mm
1) Mount 5 top main bearings (C) to the cylinder block. Class C 62.014 ~ 62.021 mm
CAUTION Note) For the method to measure the inside diameter

of the cylinder block main bearing bore, refer to
• Bearings with a groove are the top main Chapter 11 Cylinder Block/Head.
bearings on the cylinder block side and
bearings without a groove are the bottom main Crankshaft main
Specified Value
bearings on the crank case side. journal diameter
• Remove foreign substances such as residues
Class A 57.955 ~ 57.960 mm
and LOCTITE from the inside of the main
bearings and the oil seal assembly bore. Class B 57.960 ~ 57.965 mm
• Do not apply engine oil on the surface where
Class C 57.965 ~ 57.970 mm
the cylinder block and the main bearings are
assembled.
Note) For the method to measure the crankshaft main
• The class of the main bearing bore inside
journal diameter, refer to Chapter 13 Others/
diameter of the cylinder block is engraved on
Driving Units.
the cylinder block and the class of main
journal diameter of the crankshaft is engraved
Thickness of Main
on the crankshaft. For the engraving Specified Value
Bearing
positions, see the Engine Unique Number of
Chapter 3 (Performance and Specifications). BLUE 1.995 ~ 2.000 mm
• Select the proper main bearing class by
YELLOW 2.000 ~ 2.005 mm
checking or measuring the class of main
bearing bore inside diameter of the cylinder RED 2.005 ~ 2.010 mm
block and the class of the main journal
diameter of the crankshaft.
• The top main bearing class should be same as
the bottom main bearing class.
2) Sufficiently apply engine oil on the surface where

the top main bearings (C) and the crankshaft (A)
are assembled.
3) Attach the crankshaft (A).
4) Mount 2 thrust washers (B).
CAUTION
Align the key groove of the cylinder block with the
key of thrust washer.
6 - 23
6. About the engine
5. Assemble the crank case (A).

J
L M G
F I
K EDL022224A
EDL022225A 1) Mount 5 bottom main bearings (D) to the crank case.
CAUTION
• Bearings with a groove are the top main
bearings on the cylinder block side and
bearings without a groove are the bottom main
bearings on the crank case side.
• Do not apply engine oil on the surface where
the cylinder block and the main bearings are
assembled.
• The class of main bearing bore inside diameter
of the cylinder block is engraved on the
cylinder block and the class of main journal
diameter of the crankshaft is engraved on the
crankshaft. For the engraving positions, see
the Engine Unique Number of Chapter 3
(Performance and Specifications).
EDL022046C
• Select the proper main bearing class by
checking or measuring the class of main
25
bearing bore inside diameter of the cylinder
22
block and the class of main journal diameter of
21 26
17 18
13
14
16
12
15
11
7
the crankshaft.
20
24
19
3 • The top main bearing class should be same
B 23
2
with the bottom main bearing class.
6
8 F
4
10
1
5 2) Sufficiently apply engine oil on the surface where
C 9
the bottom main bearings (D) and the crankshaft
A are assembled.
3) Apply LOCTITE 5902 on the crank case assembly
R surface (K). Apply it on the rear part of the engine (L)
with the diameter ø 6 ± 0.5 mm and on the front part
of the engine (M) with the diameter ø 3 ± 0.5 mm.
4) Assemble the crank case (A).
EDL022051C
CAUTION
• Be careful to attach the cylinder block and the
crank case in the right direction.
• Attach parts within five minutes after applying
LOCTITE onto the parts.
• Do not start the engine or load pressure within 25
minutes of applying LOCTITE onto the parts.
6 - 24
6. About the engine
5) Temporarily mount 10 main bearing cap bolts (C)

in order from (1) - (10).
CAUTION
6) Tighten 10 main bearing cap bolts (C) at a • Be careful in noting the direction of the oil seal
assembly and ensuring that the oil seal
tightening torque of 5.5 kgf•m(±5%) + 90°(±4°) +
surface faces the outside of the engine.
90°( ± 4°) by using the angle method. • Be careful of the depth of the oil seal when
attaching it.
.
CAUTION • Be careful not to damage the oil seal.
• Attach the oil seal without applying
• Tighten the main bearing cap bolts with the lubrication, coolant, fuel, LOCTITE, or silicon.
angle method.
• Tighten the main bearing cap bolts in order
and LOCTITE from the oil seal assembly bore.
from (1) - (10). The front engine direction (F) is
the water pump direction and the rear engine • Do not reuse the oil seal; replace it with a new
direction (R) is the flywheel direction. one.
• Attach the crank case by tightening the main • Be careful not to damage the oil seal when
bearing cap bolts and then the collared hex attaching it.
bolts.
7) Temporarily tighten 16 collared hex bolts in order 6. Attach the oil pump (A).
from (11) - (26).
8) Tighten 16 collared hex bolts (B) at a tightening
torque of 2.2 kgf•m.
CAUTION A
• Tighten collared hex bolts in order from (11) -

(26). The front engine direction (F) is the water C
pump direction and the rear engine direction
(R) is the flywheel direction.
• Rotate the crankshaft 2 or 3 times to check for
defects.
9) The crankshaft end play is 0.1 ~ 0.31 mm.

B
EDL022045B
1) Align 2 O-rings (C) to the engine oil inlet and
10) Mount the rear oil seal assembly jig (860104- outlet.
02048) to the real oil seal (E) of guide (H). 2) Align the oil pump (A) with the pin and press it to
11) Mount the rear oil seal assembly jig (860104- the cylinder block as much as possible.
02048) guide (H) to the crankshaft (G). 3) Tighten 4 hex bolts (B) at a tightening torque of 2.2 kgf•m.
12) Mount the rear oil seal assembly jig (860104- 4) The backlash between the crankshaft gear and
02048) holder (I) to the guide (H). the oil pump gear is 0.006 ~ 0.259 mm.
13) Turn the bolt on the center of the rear oil seal
assembly jig (I) until the rear oil seal assembly jig
(860104-02048) holder (I) contacts with the Backlash between the
crankshaft gear 0.06 ~ 0.259 mm
cylinder block surface (F) and the crank case and the oil pump gear
surface (J) and press in the rear oil seal (E).
CAUTION
• Make sure that the O-rings have been
mounted.
• Be careful not to damage the O-rings while
mounting them.
6 - 25
6. About the engine
7. Attach the idle gear (A). Note) You can see one crankshaft gear engraving and
two idle gear engravings.
CAUTION
D Make sure that the crankshaft gear engraving is
positioned between two idle gear engravings.
5) Align the flange hex holes of the cylinder block to

C
those of the idle gear shaft.
6) Attach the idle gear shaft (C).
A
CAUTION
B Make the oil hole of the idle gear shaft (C) face the
top surface of the cylinder block.
EDL022044A
7) Tighten 3 flange hex bolts (B) at a tightening
8) Backlash of the idle gear and the crankshaft gear
is 0.087 ~ 0.200 mm.
D E
Backlash between the

idle gear and 0.087 ~ 0.200 mm
the crankshaft gear
F 9) The backlash between the idle gear and the

camshaft gear is 0.087 ~ 0.211 mm.
G Item Specified Value

EDL022052A idle gear and the 0.087 ~ 0.211 mm
camshaft gear
1) Apply engine oil to the inside of the idle gear bush
in the idle gear (A).
2) Attach the idle gear (A). 8. Attach the fuel injection pump (A).
CAUTION
Make sure that you are attaching the idle gear so
that its engraving faces the outside of the cylinder
block. G
F
3) Position the idle gear engraving (D) between the
E
camshaft gear engravings (E).
D
Note) You can see two camshaft gear engravings and C
one idle gear engraving.
CAUTION
Make sure that the idle gear engraving is positioned
between the two camshaft gear engravings. EDL022043B
4) Position the crankshaft gear engraving mark (G)

between the idle gear engravings (F).
6 - 26
6. About the engine
CAUTION
• Ensure that the idle gear engraving is
positioned between the two injection pump
drive gear engravings.
• Align the injection pump drive gear engravings,
the idle gear engraving, and the pin of the fuel
injection pump shaft before attaching them.
A 8) The backlash between the fuel injection pump and

the idle gear is 0.087 ~ 0.2 mm.

B
fuel injection pump and 0.087 ~ 0.2 mm
EDL022043A the idle gear
9) Tighten 3 flange hex nuts (B) at a tightening

9. Attach the timing wheel (A).

H I
EDL022053A
A
1) Mount the O- ring (D).
2) Mount the O- ring (E) to the collar (F).
3) Mount the collar (F).
EDL022040B
4) Be careful to mount the injection pump drive gear
(D) with attention to the pin direction. 1) Align the timing wheel (A) to the pin and attach it
to the crankshaft gear surface.
CAUTION 2) Connect the paralle key (B).
• Ensure that you are attaching the injection
pump drive gear so that its engraving faces CAUTION
the outside of the cylinder block.
• Ensure that the pin direction is the opposite Be careful not to damage the teeth of the timing
direction of the idle gear. wheel.
5) Tighten the flange hex nuts (C) at a tightening

torque of 6.5 ± 0.5 kgf•m.
6) Attach the fuel injection pump (A).
Note) To replace stud bolts, apply LOCTITE 272 to
the stud bolts and then press in those bolts.
7) Position the idle gear engraving (I) between the
injection pump drive gear engravings (H).
Note) You can see two injection pump drive gear
engravings and one idle gear engraving.
6 - 27
6. About the engine
10. Attach the timing gear case (A) the timing gear case (A) and beat it with a rubber
hammer.
4) when the front oil seal (B) is inserted to the timing
gear case (A), pull off the front oil seal assembly
jig (860104-02047).
CAUTION
B
• Be careful in noting the direction of the oil seal
A surface fasces the outside of the engine.
• Be careful of the depth of the oil seal when
attaching it.
• Be careful not to damage the oil seal.
lubrication. coolant, fuel, LOCTITE, or silicon.
EDL022227B • Remove foreign substances such as residues
• Do not reuse the oil seal; replace it with a new
one.
• Be careful not to damage the oil seal when
attaching it.
5) Remove the foreign substances on the timing gear

case assembly surface (C) and clean it with a dry
cloth.
6) Apply LOCTITE 5902 to the timing gear case
assembly surface (C) with the diameter of ø 2.5
C ± 0.5mm.
CAUTION
EDL022226B • Be careful that the timing gear case has been
attached in the right direction.
• Attach parts within five minutes of applying
• Do not start the engine or load pressure for 25
minutes after applying LOCTITE onto the parts
7) Align the timing gear case (A) with the pin and
D attach it.
8) Tighten 16 hex bolts (D) at a tightening torque of
2.2kgf•m.
9) Mount the crank speed sensor (E) and then
tighten the fixing bolt (F).
F
E
A
EDL022261A
1) Make the assembly surface of the timing gear

case (A) face the ground.
2) Mount the front oil seal (B) to the front oil seal
assembly jig (860104-02047).
3) Align the front oil seal assembly jig (860104-
02047) where the front oil seal (B) is mounted to
6 - 28
6. About the engine
11. Attach the piston (A).

CAUTION
D • Be careful to mind the direction when
E attaching the piston and the connecting rod.
F • Place the product number on the top surface
of the piston, the larger side of the valve
contact. and the bumpy side of the piston to
C make them face the front of the cylinder block.
A
• Make the bumpy side of the connecting rod
B face the front of the cylinder block.
• Make the direction of the bumpy side of the
piston the same as that of the bumpy side of
G
the connecting rod.
• The class of the inside diameter of the cylinder
block piston bore is engraved on the cylinder
block and the piston class is engraved on the top
surface of the piston. For the engraving positions,
see the Engine Unique Number of Chapter 3
EDL022038A
(Performance and Specifications).
• Check or measure the class of the inside diameter
of the cylinder block piston bore and the cylinder
block piston to select a suitable piston class.
• Be careful in noting the direction of the piston
and the connecting rod when attaching them.
• Make the direction of the bumpy side (H) of the
piston the same as that of the bumpy side (I) of
the connecting rod.
H I • If the gap between the piston ring and the
small end of the connecting rod is out of the
range of 0.025 - 0.043, replace the more worn
of the two.
Note) The classes of the cylinder block and the piston

are as follows.
EDL022054A Inside Diameter of Cylinder Piston

Block Piston Bore Class A Class B
1) Mount the 1st ring (D), the 2nd ring (E), and the oil
ring (F) with the piston ring plier (T7621010E). Class A O -
Class B - O
CAUTION
• Ensure that the ‘R’ mark of the piston ring Inside Diameter of Cylinder
Specified Value
faces the top surface of the piston. Block Piston Bore
• Make the piston ring position dislocated to 120
degrees. Class A 89.990 ~ 90.000 mm
Class B 90.000 ~ 90.010 mm
2) Apply engine oil on the piston pin (C).
3) Align the pin hole of the connecting rod small-end Note) For the method to measure the inside diameter
of the cylinder block piston bore, refer to
with that of the piston (A).
Chapter 11 (Cylinder Block/Head).
Piston Specified Value

Class A 89.920 ~ 89.930 mm
Class B 89.930 ~ 89.940 mm
Note) The piston class is engraved on the top surface

of the piston.
4) Attach the piston pin (C).
6 - 29
6. About the engine
2) Sufficiently apply engine oil on the inside of the

CAUTION cylinder block bore and the connecting rod
• Check the attached piston and piston ring. If bearings.
the piston should be replaced, replace the 3) Mount the piston and the connecting rods (A) to
piston pin along with the piston.
the cylinder block with the piston insertion tool
• The gap between the piston pin bore and the
piston pin should be within the range from (EF.120-208).
0.008 mm to 0.019 mm.
CAUTION
5) Mount 2 snap rings (B) on the both ends of the piston. • Be careful to mind the direction when
attaching the piston and the connecting rod.
CAUTION • Make the bumpy side of the connecting rod
• Do not reuse snap rings. face the front of the cylinder block.
• Assemble snap rings with the opening of the • The front engine direction is the water pump
snap rings facing 12 o’clock. direction and the rear engine direction is the
flywheel direction.
12. Mount the connecting rods (A). • Be careful not to damage the piston and the
piston rings.
A 4) Attach the connecting rod caps (B).
CAUTION
• Be careful to mind the direction when
attaching the connecting rods and the
D
connecting rod caps.
• Ensure that the number engraved on the
connecting rods is same with that engraved on
the connecting rod caps and the assembly
direction is same.
E
B
C 5) Temporarily tighten 8 connecting rod bolts (C) by
hand.
EDL022037A
1) Mount the top connecting rod bearings (D) and the CAUTION
bottom connecting rod bearings (E). Do not reuse connecting rod bolts; replace them
with new ones.
CAUTION
6) Tighten 8 connecting rod bolts (C) at a tightening
• Regardless of the tolerance of the connecting
rod or the crankshaft, select the top connecting torque 2.0 kgf•m + 90° by using the angle method.
rod bearings and the bottom connecting rod
bearings with the yellow-marked class.
• Do not use the top connecting rod bearings and CAUTION
the bottom connecting rod bearings with the blue-
or red-marked class when repairing the engine. After attaching the connecting rods, rotate the
• Do not apply engine oil to the assembly part of crankshaft 2 or 3 times to check whether there is
the connecting rods and the bearings. any interference.
• You can see the oil gap by comparing the
connecting rod bearing bore with the
crankshaft pin outside diameter.
Note) The class of the connecting rod bearing is as

follows.
Thickness of
Specified Value
connecting rod bearing
YELLOW 1.498 ~ 1.502 mm
6 - 30
6. About the engine
13. Connect the oil suction pipe (A) and the oil
delivery pipe (B).
E
B A
D
F
C
F
F
A
D
C
B
EDL022259A
EDL022036A
26 F
14 25
1) Connect the oil delivery pipe (B) and 2 O-rings (F). 10 24
2) Tighten 1 hex bolt (D) at a tightening torque of 2.2 6 23
2 22
± 0.3 kgf•m. 3
7
3) Tighten 2 hex bolts (E) at a tightening torque of 1.0 11 21
15
± 0.3 kgf•m. 13
9
4) Connect the oil suction pipe (A) and 1 O-ring (F). 5
1
5) Tighten 2 hex bolts (C) at a tightening torque of 16 4
17 8
2.2 ± 0.3 kgf•m. 18
12
R 19
20
CAUTION
EDL022055A
• Ensure that the O-rings of the inlet and the
outlet have been mounted. 1) Apply LOCTITE 5902 to the oil pan assembly
surface (E) with the diameter of ø 3 ± 0.5 mm.
mounting them.
CAUTION
14. Attach the oil pan (A). • Be careful that the oil pan has been attached in
the right direction.
E • Attach parts within five minutes after applying
minutes after applying LOCTITE onto the parts.
2) Attach the oil pan (A).

CAUTION
Tighten flange hex bolts in the order from (1) - (26).
The front engine direction (F) is the water pump
direction and the rear engine direction (R) is the
flywheel direction.
EDL022260A
4) Mount the O - ring (D).
5) Connect the drain plug (C) at a tightening torque
of 3 kgf•m.
6 - 31
6. About the engine
15. Attach the crankshaft pulley (A).

CAUTION
Do not give an excessive shock on the valve stem
seals; otherwise, they may be damaged.
2) Apply engine oil on the surface where the valves

(A) and the valve stem seals (C) are assembled.
A 3) Attach the valves (A).
CAUTION
B • Be careful to use the right valve without
confusing the intake valve with the exhaust
valve.
• The intake valve has the larger valve head
diameter and the exhaust valve has the
EDL022258A smaller one.
1) Align the crankshaft pulley (A) to the pin and

attach it.
17. Attach the valve springs (D).
2) Apply LOCTITE Blue 587 to the inside of the
flange hex bolts (B). A
3) Tighten flange hex bolts (B) at a tightening torque B
of 26 kgf•m.
C
CAUTION
• Be careful not to damage the oil seal. D
• Fix the crankshaft to allow the flange hex bolts
to be tightened with the specified torque.
16. Attach the valves (A).
D
EDL022032A
4) Attach the valve springs (D).

C 5) Mount the valve spring retainers (C).
B
6) Compress the valve with the valve spring
compression tool (860104-00462).
7) Mount the valve cotters (B).
A 8) Mount the calipers (A).
CAUTION
Check if the valve cotters have been positioned
EDL022033A correctly with the plastic hammer after completing
attaching them.
1) Align the valve stem seal jig (860104-02041) to
the valve stem seal (C) and beat it with a rubber
hammer to press it in.
6 - 32
6. About the engine
18. Attach the cylinder head (A).

CAUTION
• Measure the step height of the piston top side
B and select the cylinder head gasket with the
suitable class. For methods to measure the
F step height of the piston top side, refer to
Measurement of the step height of the piston
A top side in Chapter 13 (Others/Driving Units).
• Be careful to mind the direction when
assembling the cylinder head gasket.
• Attach the cylinder head so that its
C identification mark and class mark face
upward.
D • Align the push rod hole, the cylinder head bolt
R
hole, and the cylinder head gasket hole and
attach the cylinder head.
• Do not reuse the cylinder head gasket but
replace with new one.
EDL022031B
• Class A has one hole of the identification mark
on the cylinder head gasket, Class B has two
17 F holes, and Class C has three holes.
13
9 18
5 Note) The class of the cylinder head gasket is as
14 follows.
1 10
4
6
8 2 Cylinder head gasket Average of step height
12
3 class of the piston top side
16 7
11 Class A
15
Gasket 0.11 ~ 0.20 mm
0.77mm
thickness
Class B
Gasket 0.20 ~ 0.30 mm
R 0.87mm
thickness
EDL022056A
Class C
Gasket 0.30 ~ 0.39mm
0.97mm
thickness
Note) For method to measure the step height of the

1 2
3 piston top side, refer to Measurement of the
step height of the piston top side in Chapter 13
(Others/Driving Units).
F Cyl. #1 Cyl. #2 Cyl. #3 Cyl. #4 R 2) Attach the cylinder head (A).

3) Temporarily tighten 18 cylinder head bolts (B) in
the order from (1) - (18).
4) Tighten 18 cylinder head bolts (B) at a tightening
4
torque 4.0 kgf•m + 90°+ 90°+ 90° with the angle
method.
.
EDL022056C CAUTION
• Tighten cylinder head bolts in order from (1) -
1. Identification mark of the 3. Intake manifold (18).
cylinder head gasket side
Exhaust • The front engine direction (F) is the water
2. Cylinder head gasket class 4.
manifold side pump direction and the rear engine direction
1) Align the cylinder head gasket (C) with the pin (D) • Do not reuse cylinder head bolts.
and mount it. • Do not apply engine oil to the cylinder head bolts.
6 - 33
6. About the engine
19. Connect the push rods (A). 21. Attach the cylinder head cover (A).
EDL022030A EDL022257A
1) Apply engine oil on both ends of the push rods (A).

2) Connect the push rods (A) in the cylinder head
holes.
7 3 2 6
3) Hit the head of the push rods with a rubber 12
hammer lightly once or twice to get them
positioned in the tappet holes.
8 11
CAUTION
After connecting the push rods, rotate them to
check the connection state. 9
4 1 5 10
20. Attach the rocker arm (A).

EDL022256A
1) Attach the cylinder head cover (A).

2) Temporarily tighten 12 hex bolts (B) in the order of
(1) ~ (12).
A
3) Tighten 12 hex bolts (B) at a tightening torque of
B 8 ± 0.05 kgf•m.
CAUTION
• Be careful not to allow the seal ring of the
cylinder head cover to get out to the outside.
• Tighten the hex bolts of the cylinder head
cover in the order from (1) ~ (12). The front
engine direction (F) is the water pump
EDL022029A direction and the rear engine direction (R) is
the flywheel direction.
1) Attach the rocker arm (A).
2) Tighten 10 flange hex bolts (B) at a tightening 4) Mount the oil injection cap (C).
6 - 34
6. About the engine
22. Attach the injectiors (A). 23. Attach the left cylinder head cover (A).
A
B B
C
A
EDL022255A EDL022254A
1) Align the injector seal ring washer (D) with the 1) Mount the left cylinder head cover (A).
center of the injector hole and mount it. 2) Tighten 13 flange hex bolts(B) at a tightening
2) Sufficiently apply engine oil on the cylinder head torque of 0.8 ± 0.05 kgf•m.
cover surface where the injectors contact.
3) Attach 4 injectors (A). 24. Attach the right cylinder head cover (A).
CAUTION
• Attach injectors by slowly turning them to A
B
prevent damage to the cylinder head cover
surface which contacts the injectors.
Otherwise, critical damage to the engine may
occur because of unstable combustion.
C
4) Mount 4 injector fixtures (C).
5) Temporarily tighten 4 hex bolts (B).
CAUTION EDL022026B
Do not tighten the hex bolts by force when it is
difficult to tighten them temporarily. Forced
tightening may cause damage to the cylinder head. 10
6 F
6) Tighten 4 hex bolts (B) at a tightening torque of 9
2
4.35 ± 0.35 kgf•m. 5
3
7 1
4
8
R
EDL022058A
6 - 35
6. About the engine
1) Align the right cylinder head cover (A) with the 27. Attach the water pump (A).
assembly pin hole (D) and attach it.
2) Temporarily tighten 10 flange hex bolts (B) in the
order of (1) - (10).
torque of 0.8 ± 0.05 kgf•m. A
25. Mount the rear lifting hook (A).

B
A
C
EDL022251A
1) Align the gasket (D) with 2 stud bolts and mount it.
2) Align the water pump (A) with 2 stud bolts and
B
attach it.

3) Tighten 4 hex bolts (B) and 2 flange hex nuts (C)
EDL022253A
at a tightening torque of 2.2 kgf•m.
1) Mount the front lifting hook (A).
CAUTION
torque of 4.4 kgf•m. • Do not allow the gasket to protrude from or be
to one side of the water pump.
• Be careful not to damage the gasket while
26. Mount the rear lifting hook (A). mounting it.
A 28. Attach the water pump pulley (A).
B A
EDL022252A
1) Mount the rear lifting hook (A).

EDL022250A
1) Attach the water pump pulley (A).
2.2 kgf•m.
6 - 36
6. About the engine
29. Connect the fuel return hose (A). 3) Mount 4 washers (C).
4) Tighten 4 hex nuts (D) at a tightening torque of
2.5~3 N•m.
A
31. Attach the exhaust manifold (A).
C
A
EDL022249A B
1) Press the fuel return hose (A) into the end of the
nipple and connect it.
CAUTION EDL022247A
• Be careful to note the direction when 1) Mount the gasket (C) so that the TOP mark (D)
connecting the fuel return hose. faces the top surface and the front of the engine.
• The injector should be fully connected with the 2) Attach the exhaust manifold (A).
hose.
CAUTION
2) Mount the hose clips.
• Be careful to note the direction in which the
CAUTION gasket is mounted. Mount the gasket so that
the TOP mark faces the front of the engine.
Fix the handle of hose clip to face the front of the • Be careful not to damage the gasket while
engine. mounting it.
3) Tighten the flange hex bolts (B). 3) Tighten 8 flange hex bolts (B) at a tightening
30. Connect the glow plug (A).
32. Attach the heat screen (A).
D
C
C
B
EDL022248A
1) Tightening 4 glow plugs (A) to the cylinder head at EDL022246A
a tightening torque of 9~12 N•m. 1) Temporarily tighten 2 hex bolts (B) to the exhaust
2) Attach the electric connector (B). manifold side.
6 - 37
6. About the engine
2) Mount the heat screen (A). 34. Attach the EGR valve (A) and EGR cooler (B).
3) Tighten 3 hex bolts (C).
4) Tighten 2 hex bolts (B).
B
33. Mount the thermostat (A).

C
1
A
D
A
F
B
E
C EDL022243A
EDL022245A
2
E
A H
F
F G
B
E
C EDL022242A
D 1) Mount the EGR cooler (B) and the gasket (D) to

the EGR valve (A).
EDL022244A CAUTION
1) Mount the thermostat (A) to the cylinder head. • The EGR valve has to be handled with care,
2) Tighten 3 flange hex bolts (B) at a tightening because it is sensitive to external impact.
• Be careful to note the direction when
mounting the EGR cooler.
3) Tighten 1 space bolt (C) and 1 flange hex nut (D) • Be careful not to damage the gasket while
at a tightening torque of 2.2 kgf•m. mounting it.
4) Connect the rubber hose (F).
5) Mount the hose clamps (E). 2) Tighten 3 flange hex bolts (C) at a tightening
CAUTION 3) Mount the cam shaft position sensor (E) to the
• After mounting the hose clamps, make the cylinder block.

protrusion face the cylinder head side to 4) Tighten the bolt (F).
prevent interference between the protrusion 5) Mount the EGR Assembly to the cylinder block.
and the water pump pulley.
6) Tighten 2 collared hex bolts (G) and 1 hex bolt (H)
• Do not use the hose clamps more than twice;
replace them with new ones. at a tightening torque of 2.2 kgf•m.
6 - 38
6. About the engine
35. Connect pipes (A) and hoses (B). 36. Assemble the turbocharger (A).
F
E
Type-1
A Type-2
C A
F
G C
D F
Type-3
D
F B
F
B Type-4
E
EDL022241A EDL022240A
1) Connect 2 EGR connection pipes (A) and 4

gaskets. L
K
CAUTION
J
Be careful not to damage the gasket while mounting I
it. A
2) Tighten 4 flange hex bolts (C) at a tightening

3) Tighten 2 flange hex bolts (D) and 2 flange hex
bolts (E) at a tightening torque of 2.2 kgf•m H
4) Connect 3 hoses (B). E K
L
CAUTION EDL022239A
• Be careful to note the direction when 1) Connect the gasket (C) and the oil return pipe (B)
connecting the hose. to the turbocharger (A).
• press in the hose in as deeply as possible.
2) Tighten 2 flange hex bolts (D) at a tightening
5) Attach the clamps. torque of 1.0 kgf•m.

3) Connect the rubber hose (E).
CAUTION 4) Mount the hose clamps.
Do not reuse the clamps but replace with new ones.

CAUTION
6) Mount the exhaust gas temperature sensor (F) at • Be careful to note the direction when
a tightening torque of 4.5 ± 0.5 kgf•m. connecting the hose.
• Do not reuse the hose clamps but replace
them with new ones.
5) Connect the suction hose (G) and the air inlet pipe
(F).
6) Mount the hose clamps at a tightening torque of
0.5 kgf•m.
7) Mount the gasket (H) and the turbocharger to the
exhaust manifold.
6 - 39
6. About the engine
38. Attach the intake manifold (A).

CAUTION
B A
mounting the gasket. D
mounting it.
8) Tighten 4 flange hex nuts (I) at a tightening torque

of 2.2kgf•m.
10) Mount the hose clamps.
C E
CAUTION
connecting the hose.
EDL022237A
them with new ones.
1) Mount the intake manifold (A) and the gasket (B).
11) Mount 4 sealing washers.
12) Connect the oil delivery pipe (J). CAUTION
13) Tightening 2 hollow screws (L) at a tightening
torque of 2.2 kgf•m to connect the oil delivery pipe mounting the gasket.
(J). • Be careful not to damage the gasket while
mounting it.
CAUTION
2) Tighten 8 flange hex bolts (C) and 2 flange hex
• Do not reuse the oil delivery pipe.
• Tighten the fixing bolt at the cylinder block bolts (D) at a tightening torque of 2.2 kgf•m.
side first, and then tighten the other at the 3) Mount the boost temperature sensor (E) at a
turbocharger side. tightening torque of 3.0 kgf•m.
39. Attach the oil filter assembly.

37. Mount 2 knock sensors (A) and the oil Pressure
and temperature sensor (B).
A
A
B
D B E
D
EDL022236A
EDL022238A
1) Mount 2 knock sensors (A) to the cylinder block.

2) Tighten 2 bolts (C).
3) Mount the oil pressure and temperature sensor (B)
to the cylinder block.
4) Tighten 2 bolts (D).
6 - 40
6. About the engine
40. Attach the common rail (A) and the injection pipes
(B) and (C).
I
E
E
A
F G
C
EDL022235A D
1) Mount the oil cooler (B) and 3 O-rings (C) to the oil
EDL022234A
filter head (A).
2) Tighten 4 flange hex bolts (D). 1) Attach the common rail (A) to the intake manifold.
3) Connect the coolant hose (E)
CAUTION
4) Mount the oil filter assembly and 3 O-rings (H) to
the cylinder block. • Be careful to note the direction when attaching
the common rail.
• Be careful not to damage the common rail
CAUTION while attaching it.
mounted. 2) Temporarily tighten 2 collared hex bolts (D) by
• Be careful not to damage the O-rings while hand.
mounting them.
3) Temporarily connect the fuel injection pipe (B), (C)
5) Tighten 3 flange hex bolts (F) and 2 flange hex by hand.
bolts (G) at a tightening torque of 2.2 kgf•m.
CAUTION
6) Wipe the surface on which the oil filter (I) is
mounted clean. • Do not bend the fuel injection pipes by force.
7) Temporarily mount the oil filter (I) by turning it by connecting the fuel injection pipes.
hand. • Assemble the nut on one side of the fuel
8) Mount the oil filter wrench at a tightening torque of injection pipe first, and then the nut on the
other side to connect the round part of the
16~20 N•m. pipe to the correspondent part correctly.
9) Connect the coolant hose (E) to the water pump. • Do not reuse fuel injection pipes; replace them
with new ones. Reusing fuel injection pipes
may allow foreign substances into the fuel
pipes or oil leaks from the bolt clamping to
occur, causing a critical fault in engine
performance.
4) Tighten 2 collared hex bolts (D) of the common rail

5) Tighten the nuts of the fuel injection pipe (B),
injector, at a tightening torque of 3.0 kgf•m.
6) Tighten the nuts of the fuel injection pipe (C), which
are connected to the common rail and the fuel
injection pump, at a tightening torque of 3.0 kgf•m.
7) Tighten the fixing bolt (E).
6 - 41
6. About the engine
41. Connect the EGR connection pipe (A).
C
1 B
A A
2 3
2 EDL022232B
EDL022233A 1) Mount the intake stake (A) and gasket (C) to the
1) Connect the EGR connection pipe (A) and the intake manifold.
gasket (C).
CAUTION
CAUTION • Be careful to note the direction when
mounting the gasket.
connecting the EGR connection pipe.
mounting it.
mounting it.
2) Tighten 4 flange hex bolts (B) at a tightening torque of 2.2 kgf•m.
torque of 2.2 kgf•m. 3) Mount the boost pressure sensor (D) and then
tighten the fixing bolt.
42. Connect the intake stake (A).

43. Mount the oil level gauge (A).
D A
B B
C
C
EDL022232A
EDL022231A
1) Insert the oil level gauge guide tube (B) in the

cylinder block.
2) Tighen the flange hex bolt (C) at a tightening
3) Mount the oil level gauge (A).
6 - 42
6. About the engine
50. Inject coolant.

CAUTION
1) Open the radiator cap and add coolant.
Make the handle of the oil level gauge face the
reverse direction from the center of the engine. WARNING
Use coolant recommended.
44. Connect the breather hose (A).
EDL022230A
1) Mount 3 hose clips (B) to the cylinder head cover.

2) Connect the breather hose (A).
CAUTION
45. Attach the V-belt.
46. Connect the cables and harness connected to

each sensor or the engine.
47. Attach the engine to the machine.
48. Assemble the air cooler and the cooling fan on the
engine.
49. Inject the engine oil.

1) Open the oil injection cap.
2) Inject engine oil.
WARNING
Use genuine engine oil recommended.
6 - 43
7. Cooling System

Specifications ....................................................7-4
Failure Diagnosis ..............................................7-6
water pump.................................................... 7-7

water pump Disassembly ..................................7-7
water pump Assembly .......................................7-8
Thermostat .................................................... 7-9

thermostat Disassembly ....................................7-9
Check of thermostat ........................................7-10
thermostat Assembly.......................................7-10
7 - 1
7 - 2
7. Cooling System
Cooling System
General Information
General Information Coolant which absorbed the oil and combustion heat
flows into the thermostat through the coolant pipe. If
This engine is water-cooled. It uses coolant to cool the
the coolant temperature is lower than the valve-
engine by absorbing heat from the combustion
opening temperature of the thermostat, the coolant
chamber and the engine oil and then releases the
flows into the water pump. If higher, it flows into the
heat, allowing for normal engine operation.
radiator. The radiator releases the heat absorbed from
In this cooling unit system, coolant provided by the
the coolant and sends the coolant to the water pump
water pump flows into the oil cooler through the
again.
coolant pipe to absorb oil heat and passes through the
coolant jacket of the cylinder block and the
cooling path of the cylinder head to absorb the
combustion heat.
7 6
8 4
1
2 3
EDL022059C
1. Radiator 4. Cylinder head 7. EGR cooler

2. water pump 5. Oil cooler 8. thermostat
3. Cylinder Block 6. EGR Valve 9. Bypass
7 - 3
7. Cooling System
Specifications
D24NAP
Pump back
0.66 bar
pressure
Type -
Directly
Directly
Driving connected
connected to -
Type to water
Cooling fan water pump pump
Rotation Ratio
(Engine RPM: 1:1.2
fan RPM)
Valve-
opening 82 °C
temperature
Thermostat
Full valve-
opening 97 °C
temperature
Lift 8 mm
Coolant
Sensor
Resistance
Water 2.5 ㏀
(at 20 °C)
Temperatur
e Sensor Resistance
0.148 ㏀
(at 110 °C)
Pressure for
0.9 kg/cm2
Cap pressure
valve
7 - 4
7. Cooling System
D24NAP
Remark
Pump back
0.66 bar
pressure
Type -
Directly
Driving
connected -
Type
Cooling fan to water pump
Rotation Ratio
(Engine RPM: 1:1.2
fan RPM)
Valve-
opening 82 °C
temperature
Thermostat
Full valve-
opening 97 °C
temperature
Lift 8 mm
Coolant
Sensor
Resistance
Water 2.5 ㏀
(at 20 °C)
Temperature
Sensor Resistance
0.148 ㏀
(at 110 °C)
Pressure for
0.9 kg/cm2
Cap pressure
valve
7 - 5
7. Cooling System
Failure Diagnosis
Phenomenon Causes Troubleshooting
Not enough coolant Replenish the coolant
Defective radiator cap Replace it
Contaminated radiator Clean the exterior of the radiator
Defective V-belt offset Adjust or replace it
Contaminated or damaged V-belt Replace it
Damaged impeller Replace the water pump

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

Overcooled engine
Too low ambient temperature Heat the block
Damaged radiator Repair or replace it
Loosened or damaged radiator

Repair or replace the connection
connection
Defective radiator cap Replace it
Badly mounted water pump Repair or replace it

Leaking coolant
Bad or damaged water pump gasket Replace the gasket
Badly mounted thermostat Repair or replace it
Bad or damaged thermostat gasket Replace the gasket
Damaged cylinder head gasket Replace the gasket
Damaged cylinder head or block Replace it
Bad water pump bearing Replace the bearing
Bad or damaged cooling fan Repair or replace it

Noise
Bad rotation of the cooling fan Replace it
Defective V-belt offset Adjust or replace it
7 - 6
7. Cooling System
water pump
General Information 2. Remove the V-belt.

The water pump prevents the engine from being
overheated by combustion heat during engine 3. Remove the water pump pulley (A).
operation and delivers coolant from the radiator to
each part of the engine.
water pump Disassembly A
1. Drain coolant.
B
1) Check if the engine and radiator are cooled.
2) Place a container in front of the coolant drain plug.
3) Remove the radiator cap.
4) Remove the coolant drain plug of the radiator and
then drain coolant.
5) After completing coolant drain, connect the
coolant drain plug again.
EDL022250A
DANGER
• Do not open the radiator cap while the engine 2) Remove the water pump pulley (A).
is overheated. If the radiator cap is opened
while the engine is heated, hot water will spurt
out and may cause serious burns. Open the 4. Remove the water pump (A).
radiator cap after making sure that the engine
has been fully cooled.
• Mark and separately manage the containers
for avoiding confusion. See a doctor
immediately in case of drinking coolant. A
WARNING
B
Discard exchanged coolant according to the
regulations set forth by the relevant authorities. D
Disposing of exchanged coolant into the ground,
serious environmental pollution. Violation of C
regulations regarding discard of engine oil
EDL022251A
without observing the handling regulations will be
punished. 1) Loosen 4 hex bolts(B) and 2 flange hex nuts (C).
2) Remove the water pump(A) and the gasket (D).
CAUTION
Be careful not to allow coolant to touch any belts
or electric apparatus when replacing the coolant.
7 - 7
7. Cooling System
water pump Assembly 4. Add coolant.

1. Attach the water pump( A). 1) Open the radiator cap and add coolant.
WARNING
Use coolant recommended by Doosan.
EDL022251A
1) Align the gasket (D) with 2 stud bolts and mount it.
2) Align the water pump (A) with 2 stud bolts and
attach it.
3) Tighten 4 hex bolts (B) and 2 flange hex nuts (C)
CAUTION
• Do not allow the gasket to protrude from or be
to one side of the water pump.
mounting it.
2. Attach the water pump pulley (A).
EDL022250A
1) Attach the water pump pulley (A).

2.2 kgf•m.
7 - 8
7. Cooling System
Thermostat
General Information thermostat Disassembly

The thermostat maintains water temperature in the
engine consistently and prevents heat loss to improve CAUTION
heat efficiency of the engine.
Detaching the thermostat itself may degrade
When the coolant temperature is below the normal cooling performance. Do not detach the
temperature, the thermostat is closed and the coolant thermostat itself.
is bypassed and directly flows into the water pump.
When the coolant temperature reaches the normal 1. Drain coolant until the coolant level is below the
temperature or is higher than the temperature, the
thermostat height.
thermostat is fully open and the bypass circuit is
closed. So the coolant flows into the radiator.
2. Remove the thermostat (A).
CAUTION
1
• The wax pellet type thermostat shows slower
response to the change of cooling water than
the bellows type thermostat. This happens A
because the heat capacity of the wax pellet
type thermostat is larger than that of the
bellows type thermostat. Therefore, to prevent F
B
a rapid increase in the engine coolant’s
E
temperature, you must first operate the engine
at idle until the engine is fully warmed up.
C
When the weather is very cold, do not operate
the engine in an overloaded condition or at a D
high speed after starting the engine.
• When draining water from the engine cooler or
injecting water to the engine cooler, work
EDL022245A
slowly to ensure that all air inside the cooler is
expelled.
• When a defect is found in the thermostat, 2
replace it with a new one.
1
F
B
E
4 2
EDL022244A
3
1) Remove the hose clamps (E).
2) Disconnect the rubber hose (F).
EDL022060A 3) Loosen 1 flange hex nut and 1 space bolt (C).
1. Heat Exchanger 3. water pump
5) Remove the thermostat (A) from the cylinder
2. Bypass valve 4. Coolant pipe
head.
7 - 9
7. Cooling System
Check of thermostat thermostat Assembly

1. Check whether the wax pellet and the spring are 1. Mount the thermostat (A).
damaged or not.
1
2. Put the thermostat into water and heat the water
slowly to inspect thermostat operation.
A
3. If the thermostat starts open approximately 0.3
mm at a water temperature of 82°C and is fully
open at more than 8.0 mm at a water temperature F
B
of 97 °C, the thermostat is normal.
E
C
B
D
A EDL022245A
F
EDL022212A B
E
A. Thermometer B. Measuring point
C
4. Check if there are any foreign substances in the D

thermostat.
Note) Clean the inside of the thermostat with an air EDL022244A

gun.
1) Mount the thermostat (A) to the cylinder head.
5. Check if there are any foreign substances or
damaged parts inside and outside of the hose.
3) Tighten 1 space bolt (C) and 1 flange hex nut (D)
Item Specified Value at a tightening torque of 2.2 kgf•m.
thermostat 0.3 mm (at 82 °C) 4) Connect the rubber hose (F).
Open Temperature 8.0 mm or larger (at 97 °C) 5) Mount the hose clamps (E).
CAUTION
• After mounting the hose clamps, make the
protrusion face the cylinder head side to
prevent interference between the protrusion
and the water pump pulley.
• Do not use the hose clamps more than twice;
replace them with new ones.
2. Replenish the coolant.
7 - 10
8. Lubrication System

Specifications ....................................................8-4
Failure Diagnosis ..............................................8-6
Oil pump ........................................................ 8-7

Oil Pump Disassembly ......................................8-7
Check of Oil Pump ............................................8-8
Oil Pump Assembly ...........................................8-8
Disassembly of Oil Suction Pipe
and Oil Delivery Pipe.......................................8-10
Assembly of Oil Suction Pipe
and Oil Delivery Pipe.......................................8-11
Oil Filter Assembly ...................................... 8-13

Disassembly of Oil Filter Assembly .................8-13
Check of Oil Cooler .........................................8-14
Assembly of Oil Filter Assembly......................8-14
8 - 1
8 - 2
Lubrication System
General Information From the cylinder block, oil is delivered to the

crankshaft bearings, camshaft bearings, and rocker
General Information arm for lubrication.
This engine is a forced lubrication type of engine. Oil In addition, the turbocharger is connected to the
pressure is generated and delivered by rotating the engine lubrication circuit. Around the cylinder block
gear of the oil pump which is directly engaged with the and the timing gear, lubricating oil is dispersed. Each
crankshaft gear on the front of the cylinder block. cylinder has an oil injection nozzle for cooling the
The oil pump delivers oil sucked from the oil pan with bottom of the piston. Engine oil is filtered through the
the suction pipe to the main path of the cylinder block oil filter and purified.
through the oil cooler and oil filter.
14
13 13 13 13
12 12 12
11 11 11 11 11
10 10 10 10 10
9 9 9 9
7 7 7 7
8
6 5
4
COOLED CLEAN OIL
2
1 COOLED DIRTY OIL
3 HOT DIRTY OIL
EDL022202A
Connecting rod
1. Oil pump 6. Bypass Valve 11.
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
8 - 3
Specifications
D24NAP
Idle (Idling
Oil Pressure count)
Max. Load
4.0 kg/cm2 ~ 5.5 kg/cm2
(rated RPM)
Specificatio
ns SAE SAE 10W30

Min. 4.5 L
35° / 35° / 35° / 35°
Type Gear type
Oil pump Driving
CRANK GEAR driven
Type
Allowable
temperature
Flow 36 L/min
adjustment valve
8 - 4
D24NAP
Remark
Idle (Idling
count)
Oil Pressure
Max. Load
4.0 kg/cm2 ~ 5.5 kg/cm2
(rated RPM)

Specifications SAE SAE 10W30
Min. 4.5 L
35° / 35° / 35° / 35°
Type Gear type
Oil pump Driving
CRANK GEAR driven
Type
Allowable
temperature
Flow 36 L/min
adjustment valve
8 - 5
Failure Diagnosis

Bad oil Replace oil with specified oil.
Oil leakage from the oil seal ring and
Replace it
packing part
Worn or damaged piston and piston ring Replace it
Too much oil consumption
Worn cylinder liner Replace it
Burnt piston ring Replace it
Worn valve guide oil seal, valve guide,
Replace it
or valve stem
Burnt oil pump relief valve Replace it
Clogged oil pump strainer Cleanse the strainer
Worn oil pump gear Replace it
Low oil pressure
Cracked oil delivery pipe of the oil pump Replace it
Defect oil pump Repair or replace it
Oil pressure gauge fault Repair or replace it
Worn bearings Replace it
Clogged oil filter Replace the oil filter with a new one
Contaminated oil Gas leakage Replace piston ring with a new one
8 - 6
Oil pump
General Information 2. Remove the V-belt.
Engine oil is sucked from the oil pan by the gear type
oil pump and then all of the oil is forcibly delivered to 3. Remove the crankshaft pulley (A).
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 A
A B
B
EDL022258A

CAUTION
A
EDL022281A
4. Remove the timing gear case (A).
engine oil.
2) Remove the oil cap (A). A
3) Remove the drain plug (B) and drain the engine
oil.
B
WARNING
Discard oil according to the regulations set forth
rivers, or the sea will cause serious environmental E
pollution. Violation of regulations when D
C
discarding engine oil without observing the
EDL022261B

speed sensor (D).
3) Remove the timing gear case (A).
disassembly jig.
8 - 7
Check of Oil Pump

CAUTION
1. With the gap gauge (60.99901-0027), check if the
Do not reuse the oil seal; replace them with new
oil pump gear backlash is within the range of 0.06
ones.
~ 0.259 mm.
2. Make sure that the oil pump gear spins smoothly
5. Remove the timing wheel (A). when spinning it with the torque of 3.0 kgf•cm.

B
Oil pump gear backlash 0.06 ~ 0.259 mm
Oil Pump Assembly

1. Attach the oil pump (A).
EDL022040B
C
1) Remove the parallel key (B).
6. Remove the oil pump (A).

B
EDL022045B
A 1) Align 2 O-rings (C) to the engine oil inlet and

outlet.
C 2) Align the oil pump (A) with the pin and press it to
the cylinder block as much as possible.
3) Tighten 4 hex bolts (B) at a tightening torque of 2.2
kgf•m.
4) The backlash between the crankshaft gear and
the oil pump gear is 0.006 ~ 0.259 mm.
B
EDL022045B
1) Loosen 4 hex bolts (B). crankshaft gear 0.06 ~ 0.259 mm
and the oil pump gear
2) Remove the oil pump (C) and 2 O-rings (F).
CAUTION
mounted.
mounting them.
8 - 8
C
A
EDL022226B
EDL022040B
1) Align the timing wheel (A) to the pin and attach it

2) Connect the paralle key (B).
CAUTION D
Be careful not to damage the teeth of the timing

wheel.
F
3. Attach the timing gear case (A) E
A
EDL022261A

case(A) face the ground.
2) Mount the front oil seal(B) to the front oil seal
B assembly jig (860104-02047).
A 02047) where the front oil seal(B) is mounted to
the timing gear case (A) and beat it with a rubber
hammer.
gear case(A), pull off the front oil seal assembly jig
EDL022227B
(860104-02047).
8 - 9

CAUTION attach it.
• Be careful in noting the direction of the oil seal 2) Apply LOCTITE Blue 587 to the inside of the
assembly and ensuring that the oil seal flange hex bolts (B).
surface fasces the outside of the engine.
3) Tighten flange hex bolts (B) at a tightening torque
attaching it. of 26 kgf•m.
• Attach the oil seal without applying CAUTION
one.
• Be careful not to damage the oil seal when 5. Attach the V-belt.
attaching it.
5) Remove the foreign substances on the timing gear 1) Open the oil injection cap.
cloth.
6) Apply LOCTITE 5902 to the timing gear case assembly WARNING
surface (C) with the diameter of ø 2.5 ± 0.5 mm.
CAUTION
• Be careful that the timing gear case has been
attached in the right direction. Disassembly of Oil Suction Pipe and Oil
Delivery Pipe
• Do not start the engine or load pressure for 25 1. Drain the engine oil.
A B
attach it.
2.2 kgf•m.
A
EDL022281A

A engine oil.
2) Remove the oil cap (A).
3) Remove the drain plug (B) and drain the engine oil.
B
EDL022258A
8 - 10
Assembly of Oil Suction Pipe and Oil Delivery

WARNING Pipe
Discard oil according to the regulations set forth 1. Connect the oil suction pipe (A) and the oil deliv-
ery pipe (B).
rivers, or the sea will cause serious environmental
pollution. Violation of regulations when
E
discarding engine oil without observing the B
D
F
C
F
F
2. Remove the oil pan (A). A
EDL022036A
1) Connect the oil delivery pipe (B) and 2 O-rings (F).

D 2) Tighten 1 hex bolt (D) at a tightening torque of 2.2
C
B ± 0.3 kgf•m.
3) Tighten 2 hex bolts (E) at a tightening torque of 1.0
± 0.3 kgf•m.
EDL022259A 4) Connect the oil suction pipe (A) and 1 O-ring (F).
5) Tighten 2 hex bolts (C) at a tightening torque of
1) Remove the drain plug (C).
2.2 ± 0.3 kgf•m.
2) Remove the O-ring (D).
3) Loosen 26 flange hex bolts (B). CAUTION
• Ensure that the O-rings of the inlet and the
3. Disconnect the oil suction pipe (A) and oil delivery outlet have been mounted.
pipe (B). • Be careful not to damage the O-rings while
mounting them.
E
B
D
F
C
F
F
A
EDL022036A
1) Loosen 2 hex bolts (C).

2) Remove the oil suction pipe (A) and 1 O-ring (F).
3) Loosen 1 hex bolt (D) and 2 hex bolts (E).
4) Disconnect the oil delivery pipe (B) and 2 O-rings (F).
8 - 11
2. Attach the oil pan (A).

CAUTION
E • Be careful that the oil pan has been attached in
the right direction.
• Attach parts within five minutes after applying

CAUTION
EDL022260A direction and the rear engine direction (R) is the
flywheel direction.
4) Mount the O - ring (D).

of 3 kgf•m.
A 3. Inject the engine oil.
WARNING
D
C Use genuine engine oil recommended.
B
EDL022259A
26 F
14 25
10 24
6 23
2 22
3
7
11 21
15
13
9
5
1
16 4
17 8
18
12
R 19
20
EDL022055A
1) Apply LOCTITE 5902 to the oil pan assembly

surface (E) with the diameter of ø 3 ± 0.5 mm.
8 - 12
Oil Filter Assembly

General Information
2) Loosen the flange hex bolt (C).
The oil cooler cools oil with coolant and the oil filter
3) Disconnect the oil level gauge auide tube (B).
removes the foreign substances from the oil.
CAUTION
Disassembly of Oil Filter Assembly
1. Drain the engine oil. with new ones. If fuel injection pipes are reused it
A B
3. Remove the oil filter assembly.
A
EDL022281A

engine oil. E
F G
EDL022235A
WARNING
Discard oil according to the regulations set forth by
the relevant authorities. Disposing of discharged oil A
into the ground, sewers, drains, rivers, or the sea will
cause serious environmental pollution. Violation of
regulations when discarding engine oil without
observing the handling regulations, will be punished.
C
2. Disconnect the oil level gauge (A).
A
B D E
EDL022236A
C
B 2) Disconnect the coolant hose (E) from the water
pump.
3) Remove the oil filter (I) with the filter wrench.
EDL022231A
8 - 13
CAUTION
Oil in the filter may run down while removing the I
parts by using a cloth when removing the filter. H
4) Loosen 3 flange hex bolts(F) and 2 flange hex

bolts (G).
5) Remove the oil filter assembly and 3 O-rings from
the cylinder block. E
6) Disconnect the coolant hose (E).
F G
EDL022235A
8) Remove the oil cooler (B) and 3 O-rings from the
oil filter head (A). 1) Mount the oil cooler (B) and 3 O-rings (C) to the oil
filter head (A).
2) Tighten 4 flange hex bolts (D).
Check of Oil Cooler
1. Check if the coolant inlet of the oil cooler is dam- 4) Mount the oil filter assembly and 3 O-rings (H) to
aged and if coolant has leaked. the cylinder block.
2. Check if the oil inlet and outlet of the oil cooler are
damaged and if oil has leaked. CAUTION
3. Check if the exterior of the oil cooler is damaged • Make sure that the O-rings have been
mounted.
and leakage has occurs. • Be careful not to damage the O-rings while
mounting them.
Assembly of Oil Filter Assembly 5) Tighten 3 flange hex bolts (F) and 2 flange nex
1. Attach the oil filter assembly. bolts (G) at a tightening torque of 2.2 kgf•m.
6) Wipe the surface on which the oil filter(I) is
A mounted clean.
7) Temporarily mount the oil filter (I) by turning it by
hand.
8) Mount the oil filter wrench at a tightening torque of
C 16~20 N•m.
9) Connect the coolant hose (E) to the water pump.
B D E
EDL022236A
8 - 14
2. Mount the oil level gauge(A).
B
C
EDL022231A

cylinder block.
3) Mount the oil level gauge (A).
CAUTION
reverse direction from the center of the engine.

WARNING
8 - 15
9. Fuel System
General Information...................................... 9-3

Specifications ....................................................9-4
Fuel return hose ............................................ 9-5

Disconnection of fuel return hose......................9-5
Check of fuel return hose ..................................9-5
Connection of fuel return hose ..........................9-5
Injector........................................................... 9-6
How to Operate an Injector ...............................9-6
Injector Disassembly .........................................9-7
Injector Check ...................................................9-9
Injector Assembly ..............................................9-9
Common Rail............................................... 9-12

Injection Pipe...................................................9-14
Common Rail Disassembly .............................9-15
Common Rail Check .......................................9-15
Common rail assembly....................................9-16
Fuel injection pump ..................................... 9-17

Disassembly of Fuel Injection Pump ...............9-18
Assembly of Fuel Injection Pump ....................9-19
9 - 1
9 - 2
9. Fuel System
Fuel System
General Information
General Information operation, the ECU decides fuel amount, fuel injection
A diesel engine is combusted by the compression heat timing, and pressure for optimum performance and
generated by compressing air inhaled into the cylinder injects fuel in the cylinder.
and the fuel injected by the fuel injection nozzle.
The common rail fuel injection system consists of the
The high-pressured fuel generated by the high- low-pressure level for low-pressure fuel transfer, the
pressure pump is stored in the common rail. The high-pressure level for high-pressure fuel transfer, and
timing and amount of fuel injection is calculated by the the ECU.
Electronic Control Unit (ECU). The ECU injects fuel by
operating the solenoid valve for the injector installed in The fuel tank should be anti-corrosive. No fuel should
each cylinder. be leaked from the fuel tank under the doubled
Doosan's common rail fuel injection system separates operating pressure of the fuel low-pressure pump. The
the high-pressure apparatus from the fuel injection pressure in the tank should not exceed 0.3 bar.
apparatus. Depending on the conditions of engine
6
3
4 8
9
5
2
11
10
EDL022166B
1. Fuel Tank 5. Fuel injection pump 9. Injector

2. Fuel Filter 6. Common Rail 10. Fuel return hose
3. Fuel hose 7. Fuel injection pipe 11. Return fuel hose of fuel injection pipe
4. VENTURI 8. Injector Fuel Return Hose
9 - 3
9. Fuel System
Specifications
D24NAP
Injection Opening
nozzle pressure
1,800 bar
(Operating
pressure)
D24NAP
Remark
Injection Opening
nozzle pressure
1,800 bar
(Operating
pressure)
9 - 4
9. Fuel System
Fuel return hose
General Information Connection of fuel return hose

This hose is to transfer the fuel returned from the 1. Connect the fuel return hose (A).
injector to the high-pressure pipe back.
A
Disconnection of fuel return hose
EDL022249A
B nipple and connect it.
CAUTION
EDL022249A
1) Loosen the flange hex bolts (B). connecting the fuel return hose.
2) Remove the hose clips. • The injector should be fully connected with the
hose.

Check of fuel return hose
CAUTION
1. Check if there is any foreign substance or
Fix the hanlde of hose clip to face the front of the
damaged part in the inside and the outside of the
engine.
fuel line.
2. Check if oil is leaked from the joints. 3) Tighten the flange hex bolts (B).
3. Check if the adaptor is damaged and oil is leaked.
9 - 5
9. Fuel System
Injector
General Information
How to Operate an Injector
The injector uses the nozzle to inject fuel to the
Injector operation is classified into four operation
combustion chamber directly. To control the injection,
stages to operate the engine and create pressure in
the solenoid valve is used. Fuel is delivered as much
the high-pressure pump.
as required from the open injector nozzle and the
remaining fuel is returned to the fuel tank through the 1. The injector is closed (high fuel pressure state)
fuel return line. In addition, the fuel which has been 2. The injector is open (starting fuel injection).
used to lubricate the high-pressure pump and returned 3. The injector is fully open (injecting fuel).
from the fuel pressure adjustment valve is returned to 4. The injector is closed (ending fuel injection).
the fuel tank through the return line. These operation stages are decided by balancing
the force given to the injector components. If there
The solenoid valve controls the fuel injection timing is no pressure on the common rail or the engine is
and amount. The injector works instead of the nozzle stopped, the injector nozzle does not work.
and the nozzle holder mounted on the existing engine.
Fuel is delivered to the injector through the high- 1. The injector is closed (pause state)
pressure connector mounted on the cylinder head and Under the pause state that no power is provided to the
then delivered to the valve control chamber through solenoid valve of the injector, the injector does not
the delivery hole. operate. The surface where the discharge hole exists
is tightly closed with the valve ball by the force from a
The valve control chamber is opened by the solenoid valve spring or magnet. High pressure in the common
valve. It is connected to the fuel return line via the rail is kept by the fuel control valve and the same
discharge hole. The hydraulic force which has been pressure is generated in the nozzle chamber of the
increased by the valve control plunger with closed injector. The common rail fuel pressure, which is given
discharge hole exceeds the pressure value of the to the end face of the valve control chamber of the
nozzle needle. As a result, fuel delivery to the injector, and the injector nozzle spring force are larger
combustion chamber is blocked by the force given to than the force to open the nozzle. Therefore, the
the contact surface of the nozzle needle. injector is closed.
2. The injector is open. (starting fuel injection)

When the solenoid valve of the injector is pulled, the When power is supplied while the injector solenoid
discharge hole is opened. This lowers the pressure in valve is closed, the fuel discharge hole is open by the
the control chamber and the hydraulic power given to pulling force of the solenoid valve. Almost
the plunger. When hydraulic force is lower than the simultaneous with that, the high current given to the
force given to the nozzle needle pressure, the nozzle solenoid valve is reduced to the low current. This is
needle is opened. Finally, fuel is injected to the because the air gap of the electromagnet circuit gets
combustion chamber through the injection nozzle hole. smaller. Fuel in the valve control chamber flows to the
The reason that the nozzle needle is controlled by discharge valve hole on the upper side and then goes
hydraulic force is that the power required to open the into the fuel tank via the fuel return line. The discharge
hole completely breaks the pressure balance and
needle quickly cannot be directly generated from the
lowers the pressure in the valve control chamber. As a
solenoid valve. Fuel control amount required to open
result, the pressure in the valve control chamber is
the nozzle needle is added to the fuel amount injected.
lower than the nozzle chamber pressure which has
The used fuel is discharged to the fuel return line
been equal to the common rail
through the hole of the valve control chamber.
pressure. The lowered pressure of the valve control

Fuel loss occurs on the nozzle needle, the valve
chamber lowers the force from the control plunger. So
plunger guide as well as the valve control chamber.
the nozzle needle is open and fuel injection starts.
The control leakage fuel and the fuel gathered from the
line, which connects the over flow valve, the high-
3. The injector is fully open. (injecting fuel)
pressure pump, and the pressure control valve, is
The valve control plunger is stopped at the upper
returned to the fuel tank through the fuel return line.
position because fuel is full as fuel flows from the fuel
9 - 6
9. Fuel System
delivery hole. At this time, the injector nozzle is fully 2. Remove the common rail (A) and the injection
open and fuel is injected to the combustion chamber at pipes (B) and (C).
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 B
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
components. The armature plate is guided by the
driving shoulder and pressed downward. However, in E
this case, an overspring is used. It is a return spring
that prevents the force from being applied to the A
armature and the valve ball. As the discharge hole is
C
closed, fuel is delivered from the delivery hole and D
generates pressure in the control chamber. This fuel
pressure is equal to the pressure of the common rail EDL022234A
and puts pressure on the valve control plunger through
1) Loosen the fixing bolt (E).
the end face of the valve control plunger. As a result,
2) Loosen the nuts of the fuel injection pipe (C),
the force of the spring is added to the pressure
which are connected to the common rain and the
exceeding the pressure of the nozzle chamber.
Therefore, the nozzle needle is closed. The speed of
3) Loosen the nuts of the fuel injecton pipe (B), which
closing the nozzle needle is decided by the flow that
are connected to the common rail and the injector.
passes through the delivery hole. As soon as the
nozzle needle is positioned to the stop position, fuel CAUTION
injection is blocked.
Injector Disassembly may allow foreign substances into the fuel pipes
1. Disconnect the breather hose (A). critical fault in engine performance.

A
3. Disconnect the glow plug (A).
B
D
C
A
EDL022230A
CAUTION
Do not reuse the clamps but replace with new ones. EDL022248A
2) Disconnect the breather hose (A). 1) Loosen 4 hex nuts (D) and remove 4 washers (C).
3) Remove 3 hose clips (B) to the cylinder head cover. 2) Remove the electric connector (B).
3) Disconnect 4 glow plugs (A) from the cylinder head.
9 - 7
9. Fuel System
4. Disconnect the fuel return hose (A). 6. Remove the left cylinder head cover (A).
A
B
EDL022249A EDL022254A
1) Loosen the flange hex bolts (B). 1) Loosen 13 flange hex bolts (B).
2) Remove the hose clips. 2) Remove the left cylinder head cover (A).
7. Remove the injectors (A).
5. Remove the right cylinder head cover (A).
C
A A
B
EDL022255A
EDL022026A 1) Loosen 4 hex bolts (B).

1) Loosen 10 flange hex bolts (B). 2) Remove 4 injector fixtures (C).
2) Remove the right cylinder head cover (A). 3) Remove 4 injectors (A).
Note) Remove the cylinder head cover and remove
CAUTION
• Remove the injectors (A).
• Be careful not to damage the injector oil seal
left to right.
9 - 8
9. Fuel System
Injector Check Injector Assembly

1. Check if there are any foreign substances and if 1. Attach the injectiors (A).
the end part of the injector is transformed.
2. Check the injector protrusion (C).
C
A
B
A
D
EDL022255A
1) Align the injector seal ring washer (D) with the

EDL022167A center of the injector hole and mount it.
1) Detach the cylinder head (A). 2) Sufficiently apply engine oil on the cylinder head
Note) Detach the cylinder head by referring to engine cover surface where the injectors contact.
disassembly order in Chapter 6. 3) Attach 4 injectors (A).
2) Insert the seal ring in the cylinder head (A) and
attach the injector (B). CAUTION
3) Check the injector protrusion (C) based on the • Do not reuse the head cover rubber seal and
cylinder head (A) surface with a dial gauge. the injector oil seal but replace with new ones.
Note) Be careful not to allow foreign substances to • Attach injectors by slowly turning them to
flow into the injector and the high-pressure prevent damage to the cylinder head cover
connector when detaching and checking the surface which contacts the injectors.
injector. • Do not reuse the injector seal ring washers.
Item Specified Value occur because of unstable combustion.
Injector protrusion 1.5 ± 0.65 mm
CAUTION
tightening may cause damage to the cylinder head.

4.35 ± 0.35 kgf•m.
9 - 9
9. Fuel System
2. Attach the left cylinder head cover (A). 1) Align the right cylinder head cover (A) with the
A order of (1) - (10).

B 3) Tighten 10 flange hex bolts (B) at a tightening
torque of 0.8 ± 0.05 kgf•m.Connect the fuel
return hose (A).
4. Connect the fuel return hose (A).
EDL022254A
1) Mount the left cylinder head cover (A).

2) Tighten 13 flange hex bolts(B) at a tightening
3. Attach the right cylinder head cover (A). B
EDL022249A
B A
CAUTION
connecting the fuel return hose.
• The injector should be fully connected with the
C
hose.
EDL022026B
CAUTION
Fix the handle of hose clip to face the front of the
10 engine.
6 F
9 3) Tighten the flange hex bolts (B).

2
3 5
7 1
4
8
R
EDL022058A
9 - 10
9. Fuel System

CAUTION
D • Do not bend the fuel injection pipes by force.
C
connecting the fuel injection pipes.
• Assemble the nut on one side of the fuel
injection pipe first, and then the nut on the
B pipe to the correspondent part correctly.
• Do not reuse fuel injection pipes; replace them
A
performance.

EDL022248A
1) Tightening 4 glow plugs (A) to the cylinder head at 5) Tighten the nuts of the fuel injection pipe (B),
a tightening torque of 9~12 N•m. which are connected to the common rail and the
2) Attach the electric connector (B). injector, at a tightening torque of 3.0 kgf•m.
3) Mount 4 washers (C). 6) Tighten the nuts of the fuel injection pipe (C), which
4) Tighten 4 hex nuts (D) at a tightening torque of are connected to the common rail and the fuel
2.5~3 N•m.
(B) and (C).
B
A
C
D
EDL022234A
EDL022230A
1) Attach the common rail (A) to the intake manifold.
CAUTION 2) Connect the breather hose (A).
• Be careful to note the direction when attaching 3) Mount the hose clamps.
the common rail.
• Be careful not to damage the common rail CAUTION
while attaching it.
2) Temporarily tighten 2 collared hex bolts (D) by
hand.
by hand.
9 - 11
9. Fuel System
Common Rail
General Information The high-pressure fuel generated from the fuel high-
pressure pump is stored in the common rail. When a
Doosan's common rail fuel injection system separates
driver operates the vehicle, fuel injection timing and
the high-pressure apparatus from the fuel injection
optimum fuel amount are decided based on the data
apparatus. The ECU decides the fuel amount and the
set in the Electronic Control Unit (ECU) and the
fuel injection timing and pressure for the optimum
solenoid valve of the injector installed in each engine
performance and injects fuel in the cylinder.
cylinder is operated to inject fuel into the cylinder.
6
3
4 8
9
5
2
11
10
EDL022166B
1. Fuel Tank 5. Fuel injection pump 9. Injector

2. Fuel Filter 6. Common Rail 10. Fuel return hose
3. Fuel hose 7. Fuel injection pipe 11. Return fuel hose of fuel injection pipe
4. VENTURI 8. Injector Fuel Return Hose
Main components of the common rail fuel injection 2) The engine speed is measured by the crankshaft
system are as follows. RPM sensor and the ignition order is determined
1. Electronic Control Unit (ECU) by the camshaft RPM sensor. Through electrical
1) The Electronic Control Unit (ECU) receives the signals generated by the potentiometer of the
input signals generated by the above input accelerator pedal sensor, shows how strong the
sensors based on the driver's accelerator driver has pressed the pedal. In addition, the ECU
operation and works immediately according to the
includes the turbocharger and the intake pressure
driving performance of the engine and the vehicle.
sensor. The intake pressure sensor measures the
In addition, based on the above information, the
ECU generates open/close circuit - circulation intake pressure.
circuit operations of the vehicle and engine.
9 - 12
9. Fuel System
3) When it is very cold or the engine is cooled, the 1) The accelerator pedal sensor sends the data
ECU receives data from the coolant temperature generated when a driver presses the accelerator
sensor and the air temperature sensor to operate pedal to the ECU. The voltage value is generated
with the best conditions for engine operation. by the potentiometer in the accelerator pedal
sensor. The pedal position is calculated with the
2. Crankshaft RPM sensor programmed characteristics curves.
1) Position of the piston in the combustion chamber
is very important. Pistons of all engines are 5. Fuel temperature sensor
connected to the crankshaft via the connecting 1) This sensor measures the fuel temperature in the
rods. The crankshaft RPM sensor installed in the fuel pump.
flywheel housing provides information on the
position of all pistons. The rev-speed is defined as 6. Boost pressure and temperature sensor
Revolutions per Minute (RPM) of the crankshaft. 1) The boost pressure and temperature sensor is
The key input parameters are calculated by the connected to the intake stake via the O-ring. It
ECU by using the signals received from the measures the absolute pressure and temperature
crankshaft RPM sensor. in the intake stake.
2) The output signal is input to the ECU and the
3. Camshaft RPM sensor boost pressure is calculated based on the ECU-
1) The camshaft RPM sensor controls the intake and programmed characteristics curves.
exhaust valve of the engine. It revolves at the half
of the crankshaft speed and determines whether 7. Oil pressure and temperature sensor
the camshaft position is at the compression stage 1) The engine oil pressure and temperature sensor
or the exhaust stage when the piston is moving senses the temperature and pressure of engine oil
toward the top dead point. This information cannot and sends the data to the ECU.
be determined by the crankshaft RPM sensor.
However, while the engine is normally operating, 8. Common rail pressure sensor
the information given by the crankshaft RPM 1) It is installed at the end of the common rail,
sensor is enough to define the engine state. It measuring the instantaneous internal pressure of
means that the ECU receives information of the the common rail.
engine from the crankshaft RPM sensor if the
camshaft RPM sensor cannot sense the engine
9. Engine coolant temperature sensor
state while the vehicle is running.
1) The engine coolant temperature sensor perceives
the temperature of the engine coolant sends the
4. Accelerator pedal sensor data to the ECU.
Fuel Injection from the Injection Pump Common rail fuel injection
Main injection pressure Max injection pressure Main injection pressure Common rail pressure
Fuel delivery start
Fuel injection start Fuel injection

Injection pressure
Injection pressure
Time Time
EDL0213004A
The injection characteristics of the common rail are as follows.
9 - 13
9. Fuel System
1. Comparing to the existing injection characteristics, Fuel injection Fuel injection pipe for
A. F.
the common rail requires the ideal fuel injection as pump injector #1
follows. The fuel injection amount and the injection Fuel injection pipe for
B Injector G.
pressure work independently from each other, injector #2
satisfying conditions for all engines. Fuel injection pipe for

C Common Rail H.
injector #3
2. It should be available to adjust the injection
Fuel injection pipe for
amount to low for the ignition delay time, i.e., the D. Pressure sensor I.
injector #4
period from starting fuel injection to starting Fuel supply
E. J. Fuel return hose
combustion at the early stage of fuel injection. Fuel injection pipe
3. The common rail system is a modulized system.
Note) The front engine direction (F) is the water pump
Generally, the following components take key direction and the rear engine direction (R) is the
roles of the injection characteristics. flywheel direction.
1) Injector solenoid valve installed on the cylinder head
2) Common rail 1) After the injector has used fuel from the common
3) Fuel high-pressure pump rail for fuel injection, the pressure in the common
4) Electronic Control Unit (ECU) rail is actually kept consistently. The fuel pressure
5) Crankshaft RPM sensor is measured by the common rail pressure sensor

and kept as a desired value by the pressure
adjustment valve. The pressure control valve
Injection Pipe controls the fuel pressure up to 1,800 bar in the
1. Fuel high-pressure pipe common rail.

2) The common rail stores the fuel pumped from the
1) The fuel high-pressure pipe transfers high-
high-pressure fuel pump at the high pressure.
pressured fuel of 1,800 bar. Therefore, special
After the injector has used fuel from the common
materials are used for fuel line to stand the
rail for fuel injection, the pressure pulsation in the
maximum pressure of the system and the high-
common rail is actually kept consistently because
pressure changes which are generated while fuel
of the volume of the common rail. The fuel
is injected. The high-pressure pipe uses both the pressure is measured by the common rail
external diameter of ø 6.35 and the bore of ø 3.0. pressure sensor and kept as a desired value by
In addition, the length of the fuel high-pressure pipes the pressure adjustment valve. The pressure
between the common rail and the injector should be control valve controls the fuel pressure up to 1,800
identical and installed as short as possible. bar in the common rail.
3) Doosan's common rail fuel injection system
separates the high-pressure apparatus from the
2. Common rail
fuel injection apparatus. The ECU decides the fuel
amount and the fuel injection timing and pressure
F F for the optimum performance and injects fuel in
the cylinder.
G
H D J
I 3. Common rail pressure sensor
1) Fuel flows from the common rail into the common
rail pressure sensor through the path. The end of
B
E the pressure sensor is sealed with diaphragm. The
C
pressurized fuel reaches the diaphragm of the
sensor through the hole. The sensor which
R A converts the fuel pressure to the electrical signal is
connected to this diaphragm and the signal
EDL022168A amplifies the measurement signal. The signal is
sent to the ECU and input in the evaluation circuit.
9 - 14
9. Fuel System
4) Remove the intake stake (A) and gasket (C) from

the intake manifold.
Connector
2. Remove the common rail (A) and the injection
pipes (B) and (C).
Detection circuit
diaphragm
High pressure fuel line B
Thread
EDL0213005A E
A
Common Rail Disassembly C
D
1. Disconnect the intake stake (A).
EDL022234A

1
D fuel injection pump.
3) Loosen the nuts of the fuel injection pipe (B),
A which are connected to the common rail and the
injector.
B
CAUTION
C
EDL022232A

A A
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.
2 3 3. Check if there is any damage of the fuel pressure

restrict valve.
EDL022232B

2) Remove the boost pressure sensor (D).
9 - 15
9. Fuel System
Common rail assembly 6) Tighten the nuts of the fuel injection pipe (C), which
(B) and (C).

B
E D
A A
C
D B
C
EDL022234A
EDL022232A
CAUTION
• Be careful to note the direction when attaching
the common rail.
while attaching it. A A

hand.
by hand.
CAUTION
2 3
• Do not bend the fuel injection pipes by force.
• Assemble the nut on one side of the fuel EDL022232B
other side to connect the round part of the 1) Mount the intake stake (A) and gasket (C) to the
pipe to the correspondent part correctly. intake manifold.
with new ones. Reusing fuel injection pipes CAUTION
pipes or oil leaks from the bolt clamping to • Be careful to note the direction when
occur, causing a critical fault in engine mounting the gasket.
performance. • Be careful not to damage the gasket while
mounting it.
at a tightening torque of 2.2 kgf•m. 2) Tighten 4 collared hex bolts (B) at a tightening
5) Tighten the nuts of the fuel injection pipe (B), torque of 2.2 kgf•m.
which are connected to the common rail and the 3) Mount the boost pressure sensor (D) and then
injector, at a tightening torque of 3.0 kgf•m. tighten the fixing bolt.
9 - 16
9. Fuel System
Fuel injection pump
General Information Solenoid valve switching (open/close) is operated by

Fuel high-pressure pump uses a radial piston pump to high pressure and high current. Based on the values
generate high pressure in fuel. Pressure is set in the ECU, the solenoid valve of the injector is
independently generated as fuel is injected. The RPM sequentially operated. The crankshaft sensor and the
of the fuel high-pressure pump is directly connected to camshaft sensor use to detect the engine rev count for
the engine rotation speed regardless of the rotation starting fuel injection and adjusting the injection timing.
ratio of the transmission. Comparing to the existing
injection system, the common rail injection system The fuel high pressure pump pressurizes fuel at the
shows the consistent fuel delivery amount. pressure of 1,800 bar and the pressurized fuel is
delivered to the common rail through the high-pressure
The injector is connected to the common rail with the line.
high-pressure pipe. It consists of a nozzle and a
solenoid valve. When a key switch is operated, The fuel high-pressure pump consists of the following
actuating power is supplied to the solenoid valve by components.
the ECU. When the key switch is blocked, the solenoid
valve ends injection.
2 1
5 4
EDL022169A
1. High pressure fuel line outlet 3. Low pressure fuel line inlet 5. Drive shaft
2. High pressure fuel line return inlet 4. Low pressure fuel line outlet
9 - 17
9. Fuel System
1. Functions 4. Fuel supply collection

1) The fuel high pressure pump has two pressure 1) The fuel high pressure pump is designed to deliver
phase processes: low-pressure phase and high- a lot of fuel. While the engine runs at idle or partial
pressure phase. Under all operating conditions, it load, the fuel excessively delivered returns to the
transfers high-pressure fuel in a vehicle for the entire fuel tank through the pressure adjustment valve.
service lifetime. In addition, it delivers fuel required
to respond to the rapidly-changing pressure in the
Disassembly of Fuel Injection Pump
common rail or quick start of a vehicle. The fuel high
pressure pump continuously generates the system 1. Remove the fuel injection pump (A).
pressure necessary for the common rail.
2. Configuration of fuel high pressure pump

1) Inside of the fuel high pressure pump, there are three
pump pistons and the pistons are installed with 120,
compressing fuel to the circumferential direction.
Compression strokes occur three times per rotation.
Therefore, consistent stress is kept in the pump
driving apparatus and low driving force is required. A
Pump driving force of the common rail requires about
1/9 of that of the existing pump system.
B
3. Operation method
1) The fuel delivery pump delivers fuel from the fuel EDL022043A
tank to the fuel high pressure pump through the
fuel inlet and the safety valve. Then the fuel high
pressure pump pumps and the transfers the fuel to
the lubricating and cooling circuit of the high
pressure pump through the safety valve. The G
driving shaft, which has the eccentric cam, moves
F
the pump piston up and down according to the
cam shape. E
2) When the transfer pressure of the fuel delivery D
pump exceeds the open pressure of the safety C
valve, the fuel is transferred to the intake stroke
position of the pumping chamber where the pump
piston moves up and down through the intake
valve of the fuel high pressure pump. When the
pump piston exceeds the bottom dead point, the
EDL022043B
valve inlet is closed and fuel cannot be transferred
from the pumping chamber. So the fuel is 1) Loosen 3 flange hex nuts (B).
compressed over the delivered pressure. 2) Remove the fuel injection pump (A).
3) As soon as the fuel pressure reaches the common 3) Loosen the flange hex nut (C).
rail pressure, the outlet valve is opened. Then the 4) Remove the injection pump drive gear (D).
compressed fuel flows into the high pressure
5) Remove the collar (F).
circuit. The pump piston continuously transfers
6) Remove the O- ring (E) from the collar (F).
fuel until it reaches the bottom dead point. After
7) Remove the O- ring (D).
the bottom dead point is reached, the outlet valve
is closed. The fuel in the pumping chamber is
CAUTION
relaxed and then the pump piston moves down
again. When the pressure in the pumping Do not reuse the O-ring; replace with a new one.
chamber is lower than the pressure of the fuel Reuse of the O-ring may cause critical damage to
engine performance to occur.
delivery pump, the inlet valve is opened again and
the above procedure is started again.
9 - 18
9. Fuel System
Assembly of Fuel Injection Pump

1. Attach the fuel injection pump (A).
G
F
E
D
C
EDL022043B
EDL022043A

2) Mount the O- ring (E) to the collar (F).
3) Mount the collar (F).
4) Be careful to mount the injection pump drive gear
(D) with attention to the pin direction.
CAUTION
• Ensure that you are attaching the injection
pump drive gear so that its engraving faces
the outside of the cylinder block.
• Ensure that the pin direction is the opposite
direction of the idle gear.
5) Tighten the flange hex nuts (C) at a tightening

6) Attach the fuel injection pump (A).
7) Tighten 3 flange hex nuts (B) at a tightening
9 - 19
10. Intake/Exhaust System
General Information .....................................10-3

General Information.........................................10-3
Specifications ...............................................10-4
Intake manifold.............................................10-6
Disassembly of Intake Manifold.......................10-6
Assembly of Intake Manifold ...........................10-7
Turbocharger..............................................10-10
General Information.......................................10-10
Failure Diagnosis...........................................10-12
How to Maintain Turbocharger ......................10-15
Turbocharger Disassembly ...........................10-16
Turbocharger Check......................................10-17
Turbocharger Assembly ................................10-18
Disassembly of Exhaust Manifold .................10-19
Assembly of Exhaust Manifold ......................10-21
Exhaust Gas Recirculation (EGR) System.10-23

General Information.......................................10-23
Disassembly of EGR .....................................10-24
Assembly of EGR ..........................................10-24
Diesel Oxidation Catalyst (DOC)...................10-26
10 - 1
10 - 2
General Information
General Information 1. The EGR is a system that recirculates exhaust

Doosan's new engine is designed with Doosan's latest fumes to reduce the Nox.
technology to satisfy the tightened exhaust 2. In the muffler, the Diesel Oxidation Catalyst
restrictions, improve fuel efficiency, and reduce (DOC) is included.
exhaust fumes.
The Exhaust Gas Reduction is designed with the Diesel 1) The DOC Catalyst reduces HC and CO included in
Oxidation Catalyst (DOC) to reduce the exhaust soot and exhaust gas.
the Exhaust Gas Recirculation System (EGR) to reduce
nitrogen oxide (NOx) of the engine exhaust emission.
4
2
3
1
12
11
9
10
O
6
7
8 N
EDL022072C
1. Fuel Tank 5. Fuel Return 9. Engine CAN Communication

2. Injection Pump 6. Exhaust Pipe (from the engine) 10. Diagnosis CAN Communication
3. Fuel Filter 7. Engine Exhaust Gas 11. Sensor
4. Fuel Inlet 8. DOC 12. ECU
10 - 3
Specifications
D24NAP
Model Honeywell WGT
Driving Type EXHAUST PRESSURE FEED TYPE
Lubricating
type
Compressor
Turbocharger pressure
Allowable
270 krpm
max. RPM
Allowable
temperature
Weight 3.4 kg
Intake valve 0.4 mm
Valve gap
Open
19°
(BTDC)
Intake valve
Closed
45°
(ABDC)
Open
29°
Exhaust (BBDC)
valve Closed
23°
(ATDC)
Intake 104.53 mm
Valve length
Exhaust 106.33 mm
outside
Valve guide Intake 7 ~ 7.015 mm

bore Exhaust 7 ~ 7.015 mm



Valve spring squareness Below2° (below 1.8 mm)
10 - 4
D24NAP
Remark
Model Honeywell WGT
Driving
Type
Lubricating
type
Compressor At max.
Turbocharger pressure output
Allowable From the

270 krpm turbine inlet
max. RPM
Allowable
temperature
Weight 3.4 kg
Intake valve 0.4 mm
Valve gap
Open
19°
(BTDC)
Intake valve
Closed
45°
(ABDC)
Open
29°
Exhaust (BBDC)
valve Closed
23°
(ATDC)
Intake 104.53 mm
Valve length
Exhaust 106.33 mm
Stem outside Intake 6.97 ± 0.007 mm

Valve guide Intake 7~7.015 mm

bore Exhaust 7~7.015 mm



Valve spring squareness Below 2° (below 1.8 mm)
10 - 5
Intake manifold 2. Disconnect the EGR connection pipe (A).
Disassembly of Intake Manifold C

1 B
D A
B 2
C
EDL022233A
1) Loosen 4 flange hex bolts(B).

2) Disconnect the EGR Connection pipe(A) and the
EDL022232A gasket(C).

pipes(B) and (C).
A A
2 3 E
A
EDL022232B
C
D
2) Remove the boost pressure sensor( D).
EDL022234A
4) Remove the intake stake (A) and gasket (C) from 1) Loosen the fixing bolt (E).
the intake manifold. 2) Loosen the nuts of the fuel injection pipe (C),
CAUTION

5) Remove the common rai l (A) from the intake manifold.
10 - 6
4. Remove the oil filter assembly. 5. Remove the intake manifold (A).
B A
D
I
C E
E
F G
EDL022235A EDL022237A
1) Remove the boost temperature sensor (E).

A 2) Loosen 8 flange hex bolts (C) and 2 flange hex
bolts (D).
3) Remove the intake manifold (A) and the gasket (B).
C Assembly of Intake Manifold

1. Attach the intake manifold (A).
B A
B D E
EDL022236A

2) Disconnect the coolant hose (E) from the water
pump.
C E
3) Remove the oil filter (I) with the filter wrench.
CAUTION
Oil in the filter may run down while removing the
EDL022237A
parts by using a cloth when removing the filter. 1) Mount the intake manifold (A) and the gasket (B).
CAUTION
4) Loosen 3 flange hex bolts(F) and 2 flange hex • Be careful to note the direction when
bolts (G).
5) Remove the oil filter assembly and 3 O-rings from mounting it.
the cylinder block.
6) Disconnect the coolant hose (E). 2) Tighten 8 flange hex bolts (C) and 2 flange hex
7) Loosen 4 flange hex bolts (D). bolts (D) at a tightening torque of 2.2 kgf•m.
8) Remove the oil cooler (B) and 3 O-rings from the 3) Mount the boost temperature sensor(E) at a
oil filter head (A). tightening torque of 3.0 kgf•m.
10 - 7
2. Attach the oil filter assembly. 8) Mount the oil filter wrench at a tightening torque of
16~20 N•m.
A 9) Connect the coolant hose (E) to the water pump.


C (B) and (C).
B D E
EDL022236A
E
A
I C
D
H
EDL022234A
CAUTION
E the common rail.
F G while attacing it.
EDL022235A
1) Mount the oil cooler (B) and 3 O-rings (C) to the oil hand.
filter head (A). 3) Temporarily connect the fuel injection pipe (B), (C)
2) Tighten 4 flange hex bolts (D). by hand.
4) Mount the oil filter assembly and 3 O-rings (H) to CAUTION
the cylinder block. • Do not bend the fuel injection pipes by force.
CAUTION connecting the fuel injection pipes.
• Make sure that the O-rings have been injection pipe first, and then the nut on the
mounted. other side to connect the round part of the
• Be careful not to damage the O-rings while pipe to the correspondent part correctly.
mounting them. • Do not reuse fuel injection pipes; replace them
5) Tighten 3 flange hex bolts (F) and 2 flange nex may allow foreign substances into the fuel
bolts (G) at a tightening torque of 2.2 kgf•m.
occur, causing a crirical fault in engine
6) Wipe the surface on which the oil filter(I) is performance.
mounted clean.
7) Temporarily mount the oil filter (I) by turning it by 4) Tighten 2 collared hex bolts (D) of the common rail
hand. at a tightening torque of 2.2 kgf•m.
10 - 8
5) Tighten the nuts of the fuel injection pipe (B),

A A
4. Connect the EGR connection pipe(A).
C
1 B
2 3
A EDL022232B
1) Mount the intake stake (A) and gasket (C) to the

intake manifold.
A
CAUTION
2 • Be careful not to damage the gasket while
mounting it.
EDL022233A
1) Connect the EGR connection pipe (A) and the
gasket (C).
3) Mount the boost pressure sensor (D) and then
CAUTION tighten the fixing bolt.

mounting it.
2) Tighten 4 flange nex bolts (B) at a tightening

B
C
EDL022232A
10 - 9
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.
4
2
9 7
1
5
8
EDL022073B
1. Exhaust pipe 4. Compressor housing 7. Air inlet

2. Turbine housing 5. Compressor wheel 8. Oil outlet
Exhaust gas
3. Turbine wheel and shaft assembly 6. Intake pipe 9.
outlet
1. The engine output is determined by fuel amount much as compressed. Therefore, more fuel can be
and engine efficiency. combusted and the engine output can be
2. To combust the delivered fuel completely and increased.
convert it to the useful work of the engine, enough 4. Supercharger is to compress air and deliver the
air to completely combust the fuel should be compressed air to a cylinder of an engine and
delivered to the cylinder. Turbocharger is a forced induction device that
3. Actually, the engine output is determined by the forces more intake air, proportionately more fuel,
capacity of the cylinder. If air is compressed and into the combustion chamber and supercharges
delivered to the cylinder, the exhaust gas energy into the atmosphere.
the amount of air in the cylinder is increased as
10 - 10
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.
10 - 11
Failure Diagnosis
Rotating part is contacted Repair or replace it
Unbalanced rotation of a rotor Repair or replace it
Burn Repair or replace it
Loose joint Check or repair it
Deformed or damaged intake unit hose Replace it
Poor clamping state Adjust and tighten the clamp
Contaminated or damaged air filter Replace and check if the impeller of the
turbocharger is damaged
Leakage of coolant from the turbocharger or Replace the hose and the gasket
oil from the oil hose
Leakage of gas from the exhaust manifold Replace the gasket or tighten the fixing nut
Noise or vibration
Poor turbo actuator operation Replace the turbocharger
Leakage from the engine block and the Check the engine
exhaust manifold
Contaminated blowby gas and abnormal oil Check the turbo impeller and the turbo intake
amount outlet
Large gap of the turbocharger wheel, causing Check if there is any sand or metallic foreign
interference with the wall substance
Damaged turbocharger wheel Check if there is any sand or metallic foreign

substance
Damaged wheel and shaft of the Check if there is any sand or metallic foreign
turbocharger substance
Poor rotating force of the turbocharger wheel Check if there is any sand or metallic foreign
substance
Leakage of gas from each part of the exhaust Check or repair it

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

the compressor shaft
Contaminated or damaged air filter Replace and check if the impeller of the
Lowered output Poor turbo actuator operation Replace the turbocharger
Leakage from the engine block and the Check the engine
exhaust manifold
amount outlet
Damaged turbocharger wheel Check if there is any sand or metallic foreign

substance
Damaged wheel and shaft of the turbocharger Check if there is any sand or metallic foreign
substance
Poor rotating force of the turbocharger wheel Check if there is any sand or metallic foreign
substance
10 - 12
Replace and check if the impeller of the

Contaminated or damaged air filter
Oil leakage turbocharger is damaged
Leakage of coolant from the turbocharger or

Replace the hose and the gasket
Leakage from the engine block and the

Check the engine
exhaust manifold
amount outlet
Oil leakage
Check if there is any sand or metallic foreign
Damaged turbocharger wheel
substance

Poor rotating force of the turbocharger wheel
substance


Check the engine
exhaust manifold
amount outlet
Oil consumption Large gap of the turbocharger wheel, causing Check if there is any sand or metallic foreign

substance

substance
10 - 13
Replace and check if the impeller of the

Contaminated or damaged air filter

Black and white amount outlet
emissions

substance

substance

Blue emissions Check the engine
exhaust manifold
Oil leakage to the turbine or compressor Repair or replace it

Too much fog Worn or damaged seal ring due to worn
Repair or replace it
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

Too much
exhaust The turbocharger cannot rotate because of
emissions 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
10 - 14
How to Maintain Turbocharger

1. Cautions for engine operation
1) Observe the followings when starting, operating,
and stopping an engine.
Item Cautions Reasons
1) Check the oil amount
2) Therefore, start the engine with the 1) Overhasty start of engine leads to
starter motor to check the rise of oil engine rotation without lubricating
pressure (until the gradation of the oil turbocharger and other engine parts,
pressure gauge moves or the pressure causing abnormal wear or burning of
indicator lamp is turned on). bearings.
2) If you replace oil, oil filter cartridge, or 1) When an engine has stopped or kept
Starting an engine
lubrication system parts or use an cold for a long period, circulation of oil
engine in cold areas, or the engine has in the pipe gets poor.
stopped for a long period, loosen the oil
pipe joint at the inlet of the turbocharger
and run the starter motor until oil flows
out. After completing the work, tighten
the oil pipe joint again and start the
engine.
1) Operate the engine at idle for five 1) When the engine is suddenly loaded
minutes from starting it. while the engine and the turbocharger
have not been smoothly rotated after
After starting an starting the engine, parts with
engine insufficient oil may be burnt.
2) Check if oil, gas, or air is leaked from 1) Leakage of oil, gas, or air (especially
each part. If so, take proper action. oil) reduces oil pressure and loss of oil
cause burning of bearings.
check the following.
1) Oil pressure 1) Too low oil pressure causes abnormal

At idle: 1.5 ~ 3.0 kg/cm2 wearing or burning of bearings. Too
Fully loaded: 3.0 ~ 5.5 kg/cm2 high oil pressure causes oil leakage.
During Operation
2) When abnormal noise or vibration 1) Operating an engine with noise or
occurs, slowly reduce the rotate count vibration may cause irreversible
until the engine stops and then figure damage of the engine.
out the causes.
1) Operate the engine at idle for five 1) Sudden engine stop after operating the
minutes before stopping it. engine under high load allows the heat
from the red-heated turbine blade to be
Stopping an Engine
delivered to the bearing system. Then
oil burns and the bearing metal and
rotation shaft are burnt.
2. Cautions for Maintenance cooled and lubricated, causing bearing burn and
1) When the RPM is rapidly increased after starting damage of the related parts.
the engine, the journal bearings in the crankshaft 2) Please operate the engine for two minutes or more
is excessively rotated, the crankshaft is rotated at in order to lubricate the turbocharger fully after
excessive speed before the journal bearing of the replacing the engine oil or oil filter.
crankshaft is lubricated fully. If the turbocharger 3) If an engine has been operated at high speed for a
rotates in this situation, bearings are not smoothly long period, fully operate the engine at idle and
then stop the engine. Otherwise, the turbine wheel
10 - 15
continuously runs without oil pressure in the Turbocharger Disassembly

turbocharger. Therefore, no oil film is created on
the center bearings and the journal bearings of the
turbocharger, causing bearing, wearing out and
shortening of the turbocharger lifetime.
4) If an engine is not operated for a long period A
during cold weather or in areas with cold climate,
B
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
50,000 ~ 200,000 rpm. Therefore, lubrication of
bearings may determine the turbocharger lifetime.
Please use only recommended genuine engine oil
and check and replace the engine oil periodically.
6) Prolonged usage of contaminated air cleaner may
cause a critical damage of the turbocharger. EDL022230A
Regularly check and replace the air cleaner. 1) Remove the hose clamps.
7) A turbocharger is a very complex and precise part.
Only certified and skilled technicians should work CAUTION
on it. Do not reuse the clamps but replace with new ones.
8) If a turbocharger is operated without intake and
exhaust pipe, serious human injury may occur and 2) Disconnect the breather hose (A).
critical faults of the engine performance may 3) Remove 3 hose clips (B) to the cylinder head cover.
occur. Please operate a turbocharger only when
all of parts are exactly mounted on the specified 2. Remove the turbocharger (A).
position.
9) Do not lift up a turbocharger by grabbing the L
actuator. The actuator may be damaged because K
of the weight of the turbocharger.
J
10) The weight of a turbocharger is about 4.0 kg or
I
more. To lift up a turbocharger for installing or A
removing it, the worker should lower the center of
gravity or press his body close to the turbocharger.
Otherwise, worker may drop the turbocharger,
causing damage of the part and injury.
H
E K
L
EDL022239A
10 - 16
Turbocharger Check
F
1. Routine Check and Repair: The turbocharger per-
formance is determined by maintenance state of
Type-1
Type-2 the engine. So you should regularly perform
A
F inspection and check as specified.
G C 1) Intake system: For the intake system, the air filter
F should be carefully managed. For a wet type air
Type-3
D filter, if the oil amount is lower than the specified
B
amount, filtering efficiency is lowered. On the
F contrary, if it is too high, the filter absorbs oil and
contaminates the case. Especially, when the rotor
is contaminated, the precisely adjusted balance is
Type-4 broken, causing vibration. In addition, the bearings
E
EDL022240A are overloaded, resulting in bearing burn and
abnormal wearing. Therefore, an air filter should
be carefully used and maintained according to the
pipe (J).
instructed and specified ways. For a dry type air
2) Disconnect the oil delivery pipe (J). filter, the intake resistance should be small as
3) Remove 4 sealing washers (K). possible.
4) Remove the hose clamps 2) Exhaust system: For the exhaust system, when
5) Disconnect the rubber hose (E). exhaust gas leaks from the exhaust pipe or
6) Loosen 4 flange hex nuts (I). turbocharger joint, supercharging efficiency is
lowered. So you need to pay attention to prevent
7) Remove the gasket (H) and the turbocharger from
gas leakage and burn. Heat resistant nuts are
the exhaust manifold.
used for parts which are highly heated during
8) Disconnect the suction hose (G) and the air inlet operation, such as turbine seal, and the nuts
pipe (F) after removing the hose clapms. should not be mixed with other nuts. The screw
9) Remove the hose clamps and disconnect the burn prevention paint should be applied to the
rubber hose (E). assembly nuts of the specified positions.
3) Lubrication system: For the lubrication system, be
careful with the oil quality and the replacement
11) Disconnect the gasket (C) and the oil return
time of the cartridge of the oil filter. Degradation of
pipe(B) from the turbocharger (A). 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) How to check the rotating state of a rotor
assembly: You can check the rotating state of a
rotor assembly by checking the abnormal sound
which occurs while the solid of rotation is rotating.
If you use a sound rod, contact the neb of the
sound rod to the turbocharger housing and slowly
raise the RPM. If high-pitched sound continues, it
means that the state is abnormal. In this case, the
bearing or the rotor assembly may be abnormal.
So you need to replace or repair the turbocharger.
2) How to detach and check the turbocharger:
Detach the turbocharger from the engine and
clean or check it. At this time, seal the oil inlet and
outlet with sealing tape.
10 - 17
3) Cautions for attaching the turbocharger to the

engine: Please observe the following precautions L
K
as attaching the turbocharger to the engine and
handling it after attaching. Especially, be careful
J
not to let foreign substances flow into the I
turbocharger. A
• 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.
H
Cleanse the pipes from starting from the engine to
the oil inlet and outlet and check if there is any E K
L
damage of the pipes or foreign substance in the
EDL022239A
pipe.
Precisely connect the oil pipes to prevent oil leaks. 1) Connect the gasket (C) and the oil return pipe (B)
• Intake system:
to the turbocharger (A).
Check if there is any foreign substance within the
intake system. 2) Tighten 2 flange hex bolts (D) at a tightening
Precisely attach the intake system to the engine to torque of 1.0 kgf•m.
prevent air leaks from the joints of the intake 3) Connect the rubber hose (E).
system and the air filter.
• Exhaust system:
Check if there is any foreign substance in the
exhaust system. CAUTION
The heat-resistant bolts and nuts should be used. • Be careful to note the direction when
Do not use any of general nuts and bolts. Apply connecting the hose.
burn prevention paint to the bolts and nuts. • Do not reuse the hose clamps but replace
Precisely attach the exhaust system to the engine them with new ones.
to prevent gas leaks from the exhaust system
joints. 5) Connect the suction hose (G) and the air inlet pipe
(F).
Turbocharger Assembly 6) Mount the hose clamps at a tightening torque of

0.5 kgf•m.
1. Assemble the turbocharger (A).
7) Mount the gasket (H) and the turbocharger to the
exhaust manifold.
F
CAUTION
Type-1
Type-2 • Be careful to note the direction when
A
F mounting the gasket.
C • Be careful not to damage the gasket while
G
mounting it.
F
Type-3
D 8) Tighten 4 flange hex nuts (I) at a tightening torque
B
of 2.2kgf•m.
F
Type-4
E
EDL022240A CAUTION
them with new ones.
10 - 18
11) Mount 4 sealing washers (K). Disassembly of Exhaust Manifold

12) Connect the oil delivery pipe (J).
torque of 2.2 kgf•m to connect the oil delivery pipe
(J).
A
CAUTION
B
• Tighten the fixing bolt at the cylinder block
side first, and then tighten the other at the
turbocharger side.
EDL022230A
A
B
CAUTION

3) Remove 3 hose clips (B) to the cylinder head
cover.
2. Remove the turbocharger (A).

EDL022230A
1) Mount 3 hose clips (B) to the cylinder head cover. L

K
J
I
CAUTION
A
H
E K
L
EDL022239A
10 - 19

F bolts (E).
Type-1 5) Disconnect 2 EGR connection pipes (A) and 4
Type-2
A gaskets.
F
G C
DANGER
F
Type-3 Exhaust gas make engine parts extremely hot.
D
B Only remove the parts when they have fully cooled
F to prevent burns.
Type-4 4. Remove the exhaust manifold (A).

E
EDL022240A

pipe (J). C
A
2) Disconnect the oil delivery pipe (J).
3) Remove 4 sealing washers (K). D
4) Remove the hose clamps
5) Disconnect the rubber hose (E).
6) Loosen 4 flange hex nuts (I).
7) Remove the gasket (H) and the turbocharger from B
the exhaust manifold.
8) Disconnect the suction hose (G) and the air inlet
pipe (F) after removing the hose clapms.
9) Remove the hose clamps and disconnect the EDL022247A
rubber hose (E).
2) Remove the exhaust manifold(A) and the gasket (C).
11) Disconnect the gasket (C) and the oil return
pipe(B) from the turbocharger (A). DANGER
Exhaust gas make engine parts extremely hot.
3. Disconnect pipes (A) and hoses (B). Only remove the parts when they have fully cooled
to prevent burns.
A
C
B
EDL022241A
1) Remove the exhaust gas temperature sensor (F).

2) Remove the clamps and disconnect 3 hoses (B).
10 - 20
Assembly of Exhaust Manifold Becareful not to damage the gasket while mounting
1. Attach the exhaust manifold (A). it.

C 3) Tighten 2 flange hex bolts (D) and 2 flange hex
A
bolts (E) at a tightening torque of 2.2 kgf•m
D 4) Connect 3 hoses (B).
CAUTION
B
5) Attach the clamps.
EDL022247A CAUTION
1) Mount the gasket (C) so that the TOP mark( D) Do not reuse the clamps but replace with new ones.
faces the top surface and the front of the engine.
6) Mount the exhaust gas temperature sensor (F) at
2) Attach the exhaust manifold (A).
a tightening torque of 4.5 ± 0.5 kgf•m.
CAUTION
• Be careful to note the direction in which the 3. Assemble the turbocharger(A).
gasket is mounted. Mount the gasket so that
the TOP mark faces the front of the engine. F
mounting it.
Type-1
Type-2
3) Tighten 8 flange hex bolts (B) at a tightening A
F
torque of 3.1 kgf•m. G C
F
Type-3
2. Connect pipes(A) and hoses (B). D
B
F
E
A Type-4
E
C EDL022240A
B
EDL022241A

gaskets.
CAUTION
10 - 21
12) Connect the oil delivery pipe (J).

L
K
torque of 2.2 kgf•m to connect the oil delivery pipe
J (J).
I
A CAUTION
• Tighten the fixing bolt at the cylinder block
side first, and then tighten the other at the
turbocharger side.
H
E K
L
EDL022239A
1) Connect the gasket (C) and the oil return pipe (B) A
to the turbocharger (A).
B
2) Tighten 2 flange hex bolts (D) at a tightening
CAUTION
EDL022230A
them with new ones.
5) Connect the suction hose( G) and the air inlet pipe 2) Connect the breather hose (A).
(F).
6) Mount the hose clamps at a tightening torque of
0.5 kgf•m. CAUTION
7) Mount the gasket (H) and the turbocharger to the Do not reuse the clamps but replace with new ones.
exhaust manifold.
CAUTION
mounting it.
8) Tighten 4 flange hex nuts(I) at a tightening torque

of 2.2kgf•m.
9) Connect the rubber hose(E).
CAUTION
them with new ones.
11) Mount 4 sealing washers (K).
10 - 22
Exhaust Gas Recirculation (EGR) System

To reduce Nox emission from the engine,
General Information
EGR circulates the exhaust gas of which oxygen
Exhaust Gas Recirculation (EGR) System circulates concentration is very little to the intake system. As a
some of the exhaust gas from the engine to the intake result, low temperature combustion occurs in the
side, cools the gas, and then delivers the cooled gas to engine and the NOx emission is reduced.
the engine for recombustion in order to reduce Nox
The EGR cooler is used to reduce NOx emission and
emission.
enhance engine combustion efficiency by reducing
temperature of high-temperature exhaust gas.
8
2
6 7
9
11
10
EDL022073B
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
1. Introduction to EGR 2) Motor-driven electric EGR valve is usedto adjust

the EGR rate.
1) EGR is a system that reduces Nox emission by
recirculating some of exhaust gas according to the 3. EGR cooler summary
engine conditions. 1) The EGR cooler is a heat exchanger which
2) The exhaust gas is piped from the exhaust reduces the high temperature of the circulated
manifold, mixed with the intake coming from the exhaust gas.
intercooler, and then flows into the engine. 2) With the EGR cooler, the EGR engine can reduce
2. Key Characteristics of EGR Nox emission and enhance fuel efficiency.

1) EGR cooler is used to reduce the temperature of 4. Key Characteristics of EGR
exhaust gas. 1) General tube types are used.
10 - 23
Disassembly of EGR
1. Disconnect pipes (A) and hoses (B). B
E C
A
C
D
A
D
EDL022243A
B 1) Loosen 2 collared hex bolts (G) and 1 hex bolt (H).

EDL022241A 2) Remove the EGR Assembly from the cylinder
block.
1) Remove the exhaust gas temperature sensor (F).
3) Loosen the bolt (F).
1) Remove the clamps and disconnect 3 hoses (B).
4) Remove the cam shaft position sensor (E) from
the cylinder block.
bolts (E).
5) Remove the EGR coolder (B) and the gasket (D)
from the EGR valve (A).
1) Disconnect 2 EGR connection pipes (A) and 4
gaskets. DANGER
DANGER Exhaust gas make engine parts extremely hot.
Only remove the parts when they have fully cooled
Exhaust gas make engine parts extremely hot. to prevent burns.
Only remove the parts when they have fully cooled
to prevent burns.
Assembly of EGR
2. Remove the EGR valve (A) and EGR cooler (B). 1. Attach the EGR valve (A) and EGR cooler (B).
H
D
F A
EDL022242A EDL022243A
10 - 24

gaskets.
CAUTION
Becareful not to damage the gasket while mounting
E it.

H
F
3) Tighten 2 flange hex bolts (D) and 2 flange hex
G bolts (E) at a tightening torque of 2.2 kgf•m
4) Connect 3 hoses (B).
EDL022242A CAUTION
1) Mount the EGR cooler(B) and the gasket(D) to the • Be careful to note the direction when
EGR valve(A). connecting the hose.
CAUTION
5) Attach the clamps.
• The EGR valve has to be handled with care,
because it is sensitive to external impact. CAUTION
mounting the EGR cooler. Do not reuse the clamps but replace with new ones.
mounting it. 6) Mount the exhaust gas temperature sensor (F) at
a tightening torque of 4.5 ± 0.5 kgf•m.
3) Mount the cam shaft position sensor (E) to the
cylinder block.
4) Tighten the bolt (F).
5) Mount the EGR Assembly to the cylinder block.
6) Tighten 2 collared hex bolts (G) and 1 hex bolt (H)
2. Connect pipes(A) and hoses (B).
A
C
B
EDL022241A
10 - 25
Diesel Oxidation Catalyst (DOC)

DOC oxidizes HC(hydrocarbon) and CO(carbon
monoxide) and reduces them from exhaust gas.
1 2
3 4
EDL022283A
10 - 26
11. Cylinder block/head
General Information..................................... 11-3

Specifications ..................................................11-4
Cylinder Block ............................................. 11-5

Disassembly of cylinder block .........................11-5
Check of Cylinder Block ..................................11-5
Measurement of Inside Diameter
of Main Bearing Bore of Cylinder Block ..........11-5
of Piston Bore of Cylinder Block......................11-5
of Camshaft Bearing of Cylinder Block ...........11-6
Assembly of Cylinder Block.............................11-6
Timing gear case......................................... 11-7

Detaching timing gear case.............................11-7
Assembly of Timing Gear Case ......................11-7
Breather....................................................... 11-9
Disconnection of Breather Hose .....................11-9
Connection of Breather Hose ..........................11-9
Cylinder head ............................................ 11-10

Disassembly of Cylinder Head ......................11-10
Check of Cylinder Head ................................11-10
Assembly of Cylinder Head ...........................11-10
Cylinder Head Cover ...................................... 11-11

Disassembly of Cylinder Head Cover ...........11-11
Assembly of Cylinder Head Cover ................11-13
Oil Pan....................................................... 11-17

Disassembly of Oil Pan .................................11-17
Assembly of Oil Pan ......................................11-17
Disassembly of Engine Oil Level Gauge
and Guide Tube ............................................11-18
Assembly of Engine Oil Level Gauge
and Guide Tube ............................................11-18
Valve ......................................................... 11-19

Disassembly of Valve ....................................11-19
of Valve Guide...............................................11-19
Measurement of Valve Stem End .................11-19
Measurement of Valve Step Height ..............11-20
Measurement of Gap between Piston
11 - 1
and Valve ......................................................11-20
Check of Valve Spring...................................11-21
Assembly of Valve.........................................11-21
Rocker Arm ............................................... 11-22

Disassembly of Rocker Arm ..........................11-22
Adjustment of Valve Gap ..............................11-25
Check of Rocker Arm Shaft...........................11-25
Check of Rocker Arm ....................................11-26
Assembly of Rocker Arm...............................11-27
Valve Tappet and Push Rod ..................... 11-31

Disassembly of Valve Tappet........................11-31
Check of Valve Tappet..................................11-31
Assembly of Valve Tappet ............................11-31
Disassembly of Push Rod .............................11-31
Check of Warpage of Push Rod....................11-35
Assembly of Push Rod ..................................11-35
Camshaft ................................................... 11-40

Disassembly of Camshaft .............................11-40
Measurement of Camshaft Journal
Outside Diameter ..........................................11-40
Measurement of Camshaft ............................11-41
Assembly of Camshaft ..................................11-41
Idle gear .................................................... 11-42

Disassembly of Idle Gear ..............................11-42
Measurement of Outside Diameter
of Idle Gear Shaft ..........................................11-43
of Idle Gear .........................................................11-43
Assembly of Idle Gear ...................................11-44
Lifting Hook ............................................... 11-47

Assembly of Lifting Hook...............................11-47
Assembly of Lifting Hook...............................11-47
11 - 2
Cylinder block/head
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.
11 - 3
Specifications
D24NAP
Gasket
0.05 mm
Cylinder Surface
head Manifold
surface

journal
diameter
89.99 ~ 90.01 mm
block piston bore
0.05 mm
gasket surface
D24NAP
Remark
Gasket
0.05 mm
Cylinder Surface
head Manifold
surface

journal
diameter
89.99 ~ 90.01 mm
block piston bore
0.05 mm
gasket surface
11 - 4
Cylinder Block
Disassembly of cylinder block

1. Detach the cylinder block.
Note)Refer to Chapter 6 (Procedure of Disassembling
C B
an Engine)
A
Check of Cylinder Block

1. Cleanse the cylinder block and check if there is
any cracked or damaged part with naked eye.
D
2. Replace the cylinder block if it is seriously cracked
or damaged. Repair tiny cracks if existing.
3. Check if the oil path or coolant path is clogged or EDL022205A
corroded.
4. Perform the hydrostatic test to check whether 1) For 5ea main bearings (D) of the cylinder block,
measure 10 points of the bearings: front and rear.
there is a crank or an air leakage.
2) Measure three (A, B, and C) points of the main
5. Block the discharging outlets of the cooling water bearing part of the cylinder block.
path and the oil path of the cylinder block and put 3) The standard measurement value of the inside
diameter of the main bearing bore of the cylinder
pressure of 4 kg/cm2 on the inlet. Then sink the
block is within the range of 62.0 ~ 62.021 mm.
cylinder block in the 70 °C water for 1 minute and
check if air leaks. Specified
Item
Value
Cylinder Block 62.0 ~
Measurement of Inside Diameter of Main Inside diameter of main bearing bore 62.021 mm
Bearing Bore of Cylinder Block

1. Assemble the cylinder block and the crank case.
Measurement of Inside Diameter of Piston
2. Set the gauge. Bore of Cylinder Block
3. Remove the foreign substances from the main 1. Set the gauge.
bearing bore of the cylinder block. 2. Remove the foreign substances from the piston
4. Measure the inside diameter of the main bearing bore of the cylinder block.
bore of the cylinder block. 3. Measure the inside diameter of the piston bore of
the cylinder block.
EDL022204A
EDL022206A
11 - 5
10 mm B
70 mm
140 mm
A A
C B
EDL022207A EDL022089B
1) For 4ea piston bores of the cylinder block, 1) For 3ea of the cylinder block, measure total 6
measure total 12 points of the piston bores: top, points of the camshaft bores: front and rear.
middle, and bottom. 2) Measure 3 points (A, B, and C) of camshaft
2) Measure 2 points of A and B on the piston bore of bearing shells of the cylinder block.
the cylinder block.
3) The standard measurement value of the inside
diameter of the camshaft bearing of the cylinder
diameter of the piston bore of the cylinder block is
block is within the range of 45.0 ~ 45.025 mm.
within the range of 89.990 ~ 90.010 mm.
Camshaft bearing inside diameter 45.025 mm
Piston bore inside diameter 90.010 mm
Assembly of Cylinder Block

Measurement of Inside Diameter of Camshaft
Bearing of Cylinder Block 1. Attach the cylinder block.
Note)Refer to Chapter 6 (Procedure of Assembling an
1. Set the gauge.
Engine)
2. Remove the foreign substances from the camshaft
bearing shell of the cylinder block.
3. Measure the inside diameter of the camshaft
bearing of the cylinder block.
EDL022088A
11 - 6
Timing gear case
Detaching timing gear case CAUTION

1. Remove the V-belt.
Do not reuse the oil seal; replace them with new ones.
2. Remove the crankshaft pulley (A).
Assembly of Timing Gear Case

1. Attach the timing gear case(A).
B B
EDL022258A

EDL022227B
CAUTION
B C
EDL022226B
E
D
C
EDL022261B

speed sensor (D).
disassembly jig.
11 - 7
CAUTION
D LOCTITE onto the parts.
attach it.
F
E
A 2.2kgf•m.
EDL022261A tighten the fixing bolt(F).
case(A) face the ground. 2. Attach the crankshaft pulley (A).
assembly jig (860104-02047).
02047) where the front oil seal(B) is mounted to
the timing gear case(A) and beat it with a rubber
hammer.
A
(860104-02047). B
CAUTION
EDL022258A
• Be careful of the depth of the oil seal when 1) Align the crankshaft pulley (A) to the pin and
attaching it.
attach it.
• Attach the oil seal without applying 2) Apply LOCTITE Blue 587 to the inside of the
lubrication. coolant, fuel, LOCTITE, or silicon. flange hex bolts (B).
• Remove foreign substances such as residues 3) Tighten flange hex bolts (B) at a tightening torque
of 26 kgf•m.
one.
CAUTION
attaching it. • Be careful not to damage the oil seal.
5) Remove the foreign substances on the timing gear to be tightened with the specified torque.
cloth.
6) Apply LOCTITE 5902 to the timing gear case 3. Attach the V-belt.
± 0.5mm.
11 - 8
Breather
Disconnection of Breather Hose

EDL022230A
CAUTION

3) Remove 3 hose clips (B) to the cylinder head cover.
Connection of Breather Hose

EDL022230A

CAUTION
11 - 9
Cylinder head
Disassembly of Cylinder Head 4. Check flatness of the cylinder head.
1. Detach the cylinder head.

an 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.
2. For cracks or damage which cannot be checked

with naked eye, perform the hydrostatic test or the
EDL022091A
magnetic particle testing.
3. Check if the cylinder head is warped.

1) Measure flatness of the intake assembly surface
and the exhaust assembly surface of the cylinder
F head with the scale and the gap gauge.
D B
C 5. Perform the hydrostatic test.

E 1) Block the discharging outlets of the cooling water
path and the oil path of the cylinder head and put
A
pressure of 4 kg/cm2 on the inlet. Then sink the
cylinder head in the 70 °C water for 1 minute and
check if air leaks.
Assembly of Cylinder Head

EDL022090A
1. Attach the cylinder head.
1) Check 6 directions from A to F with the scale and
the gap gauge. Engine)
11 - 10
Cylinder Head Cover
Disassembly of Cylinder Head Cover

A A
2 3
EDL022232B

2) Remove the boost pressure sensor( D).
EDL022230A
CAUTION
pipes(B) and (C).

2. Disconnect the intake stake (A). B
1
E
D
A
A
C
D
B
C EDL022234A

EDL022232A which are connected to the common rain and the
11 - 11

CAUTION
critical fault in engine performance. B A

5) Remove the common rai l (A) from the intake manifold.
A
EDL022026A
C
2) Remove the right cylinder head cover (A).
7. Remove the left cylinder head cover (A).
B
A
B
EDL022246A
1) Loosen 2 hex bolts(B) and 3 hex bolts (C).

2) Remove the heat screen (A).
EDL022254A

2) Remove the left cylinder head cover (A).
EDL022249A

2) Remove the hose clips.
11 - 12
8. Remove the injectors (A). Assembly of Cylinder Head Cover

1. Attach the cylinder head cover (A).
C
B
C
A
A
D
B
EDL022255A
1) Loosen 4 hex bolts (B). EDL022257A

2) Remove 4 injector fixtures (C).
3) Remove 4 injectors (A).
the injector seal ring washers (D). 7 2 6
3
12
CAUTION
8 11
left to right. 9
4 1 5 10
EDL022256A

9. Remove the cylinder head cover (A). 2) Temporarily tighten 12 hex bolts (B) in the order of
(1) ~ (12).
C 3) Tighten 12 hex bolts (B) at a tightening torque of
8 ± 0.05 kgf•m.
CAUTION
A
B
engine direction (F) is the water pump
direction and the rear engine direction (R) is
4) Mount the oil injection cap (C).

EDL022257A

11 - 13
2. Attach the injectiors (A). 3. Attach the left cylinder head cover (A).
A
B B
C
A
EDL022255A EDL022254A
1) Align the injector seal ring washer (D) with the 1) Mount the left cylinder head cover (A).
center of the injector hole and mount it. 2) Tighten 13 flange hex bolts(B) at a tightening
2) Sufficiently apply engine oil on the cylinder head torque of 0.8 ± 0.05 kgf•m.
3) Attach 4 injectors (A). 4. Attach the right cylinder head cover (A).
CAUTION
• Attach injectors by slowly turning them to A
B
occur because of unstable combustion.
C
CAUTION EDL022026B
6 F
2 9
4.35 ± 0.35 kgf•m. 5
3
7 1
4
8
R
EDL022058A
11 - 14
1) Align the right cylinder head cover (A) with the 6. Attach the heat screen (A).
order of (1) - (10). A

C
5. Connect the fuel return hose (A).
EDL022246A
1) Temporarily tighten 2 hex bolts (B) to the exhaust

manifold side.
2) Mount the heat screen (A).
3) Tighten 3 hex bolts (C).
B
EDL022249A
1) Press the fuel return hose (A) into the end of the (B) and (C).
CAUTION
B
• The injector should be fully connected with the
hose.
2) Mount the hose clips. E
CAUTION A
Fix the hanlde of hose clip to face the front of the C

D
engine.
EDL022234A
3) Tighten the flange hex bolts (B).
CAUTION
the common rail.
while attacing it.

hand.
by hand.
11 - 15
CAUTION
• Be careful to note the direction when A A
pipe to the correspondent part correctly.
pipes or oil leaks from the bolt clamping to 2 3
occur, causing a crirical fault in engine
performance.
EDL022232B
at a tightening torque of 2.2 kgf•m. 1) Mount the intake stake(A) and gasket(C) to the
5) Tighten the nuts of the fuel injection pipe (B), intake manifold.
injector, at a tightening torque of 3.0 kgf•m. CAUTION
6) Tighten the nuts of the fuel injection pipe (C), which • Be careful to note the direction when
are connected to the common rail and the fuel mounting the gasket.
injection pump, at a tightening torque of 3.0 kgf•m. mounting it.
8. Connect the intake stake(A). torque of 2.2 kgf•m.

1 9. Connect the breather hose (A).

D
A
A
B B
C
EDL022232A
EDL022230A

CAUTION
11 - 16
Oil Pan
Disassembly of Oil Pan
A B Assembly of Oil Pan

1. Attach the oil pan (A).
A
EDL022281A

engine oil.
EDL022260A
WARNING
Discard oil according to the regulations set forth by
the relevant authorities. Disposing of discharged oil A
into the ground, sewers, drains, rivers, or the sea
will cause serious environmental pollution.
Violation of regulations when discarding engine oil
without observing the handling regulations, will be
punished.
D
C
B
2. Remove the oil pan (A).
EDL022259A
26 F
A 14 25
10 24
6 23
2 22
3
7
11 21
D 15
13
C 9
B
5
1
16 4
17 8
18
EDL022259A 12
R 19
20
1) Remove the drain plug (C).
EDL022055A
2) Remove the O-ring (D).
11 - 17
1) Apply LOCTITE 5902 to the oil pan assembly 2) Loosen the flange hex bolt (C).
surface (E) with the diameter of ø 3 ± 0.5 mm. 3) Disconnect the oil level gauge auide tube (B).
CAUTION CAUTION
• Be careful that the oil pan has been attached in Do not reuse fuel injection pipes; replace them
the right direction. with new ones. If fuel injection pipes are reused it
• Attach parts within five minutes after applying may allow foreign substances into the fuel pipes
LOCTITE onto the parts. or cause oil leaks from bolt clamping and cause a
• Do not start the engine or load pressure for 25 critical fault in engine performance.

3) Tighten 26 flange hex bolts (B) at a tightening Assembly of Engine Oil Level Gauge and
torque of 2.2 kgf•m. Guide Tube
CAUTION 1. Mount the oil level gauge(A).
direction and the rear engine direction (R) is the
flywheel direction.
A
of 3 kgf•m.
B
C
WARNING EDL022231A
cylinder block.
Disassembly of Engine Oil Level Gauge and
Guide Tube 3) Mount the oil level gauge (A).
1. Disconnect the oil level gauge (A).
CAUTION
reverse direction from the center of the engine.
B
C
EDL022231A
11 - 18
Valve
Disassembly of Valve Measurement of Valve Stem End

1. Remove the valve. 1. Mount the valve to the cylinder head.
Note)Refer to Chapter 6 (Procedure of Disassembling 2. Perform the zero point adjustment of the meter.
an Engine) 3. Measure the valve stem end (A).
Measurement of Inside Diameter of Valve

Guide
A
1. Mount the valve guide to the cylinder head.
2. Set the meter.
3. Measure the inside diameter of the valve guide.
EDL022093A
B A
1) Measure 8ea intake valve stem ends.
2) The standard measurement value of the intake
valve stem end is within the range of 17.0 ~ 17.5
mm.
3) Measure 8ea exhaust valve stem ends.
4) The standard measurement value of the exhaust
EDL022092A
valve stem end is within the range of 17.1 ~ 17.6
1) Measure total 6 points of the valve guide to the mm.
vertical direction (B) and the horizontal direction
(A): top, middle, and bottom.
Intake valve stem end 17.0 ~ 17.5 mm
2) Measure 16ea valves; 8ea intake valves and 8ea
exhaust valves. Exhaust valve stem end 17.1 ~ 17.6 mm
3) The standard measurement value of the valve
guide inside diameter is within the range of 7.0 ~
7.015 mm.
Valve guide inside

7.0 ~ 7.015 mm
diameter
11 - 19
Measurement of Valve Step Height Measurement of Gap between Piston and

1. Measure the height of the contact surface of the Valve
intake and exhaust valve. If the measurement 1. Detach the cylinder head.
value is over the allowable limit, it means that the
2. Prepare measurement of the gap between the
valve seat is worn. Replace the valve seat.
piston and the valve.
2. Measure the valve step height.
A
D
B
C
D A
D A
C B
C B
EDL022095A
EDL022094A
1) Prepare the lead with thickness of 3mm.
1) Put the valves in the valve seat of the cylinder 2) Position the greased lead on total 16 points (A, B,
head and measure how deep the valves have C, and D) on the top of each piston.
been put from the cylinder head bottom surface 3) Attach the cylinder head.
with the dial gauge. 4) Rotate the crankshaft pulley in order to move the
2) Measure 4 points (A, B, C, and D) of the valve. piston.
3) The standard measurement value of the intake 5) Detach the cylinder head.
valve is within the range of 0.6 ~ 0.9 mm.
4) The standard measurement value of the exhaust 3. Measure the gap between the piston and the
valve is within the range of 0.9 ~ 1.2 mm. valve.
Item Specified Value 1) Measure thickness of the lead with the vernier
calipers.
Intake Valve Step Height 0.6 ~ 1.8 mm
2) The standard value of gap between the piston and
Exhaust Valve Step
0.9 ~ 1.5 mm the intake valve is within the range of 1.12 ~ 2.29
Height
mm.
3) The standard value of gap between the piston and
the exhaust valve is within the range of 1.44 ~
2.58 mm.
Gap between the piston

1.12 ~ 2.29 mm
and the intake valve
Gap between the piston

1.44 ~ 2.58 mm
and the exhaust valve
11 - 20
Check of Valve Spring 4. Check the tension of the valve spring.

1. Check the exterior of the valve spring with naked
eye.
1) Check if the exterior of the valve spring is
damaged with naked eye. Replace it with a new
one if required.
2. Check the free length 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.
EDL022096A Assembly of Valve

1) Measure the free length of the valve spring with 1. Mount the valve.
the vernier calipers. Note)Refer to Chapter 6 (Procedure of Assembling an
Note)If the length is too small, replace the valve spring Engine)
with a new one.
3. Check the valve spring squareness.
B
A
EDL022097A
Right-angle
A. Free length B. Squareness C
square
1) Measure the squareness of the valve spring with

the surface plate and the right-angle square.
Note)If the measurement value is abnormal, replace

the valve spring with a new one.
11 - 21
Rocker Arm
Disassembly of Rocker Arm

A A
2 3
EDL022232B

EDL022230A
CAUTION
3. Disconnect the EGR connection pipe (A).
2) Disconnect the breather hose (A). C
1 B

A
1 A
A
2
B EDL022233A
C
gasket (C).
EDL022232A
11 - 22
4. Remove the common rail (A) and the injection 6. Disconnect the fuel return hose (A).
pipes (B) and (C).
A
A B
C
D
EDL022249A
EDL022234A
1) Loosen the fixing bolt (E). 2) Remove the hose clips.
2) Loosen the nuts of the fuel injection pipe (C), 3) Disconnect the fuel return hose (A).
CAUTION
with new ones. If fuel injection pipes are reused it B A

EDL022026A
A
2) Remove the right cylinder head cover (A).
C
EDL022246A
1) Loosen 2 hex bolts (B) and 3 hex bolts (C).

2) Remove the heat screen (A).
11 - 23
8. Remove the left cylinder head cove r (A). 10. Remove the cylinder head cover (A).
A
B
EDL022254A EDL022257A
1) Loosen 13 flange hex bolts (B). 1) Remove the oil injection cap (C).
2) Remove the left cylinder head cover (A). 2) Loosen 12 hex bolts (B).
9. Remove the injectors (A).
11. Remove the rocker arm (A).
C
A
A
EDL022255A
1) Loosen 4 hex bolts (B). EDL022029A
2) Remove 4 injector fixtures (C). 1) Loosen 10 flange hex bolts (B).

3) Remove 4 injectors (A). 2) Remove the rocker arm (A).
CAUTION
left to right.
11 - 24
Adjustment of Valve Gap 2. Adjust the valve gap in the following order.
1. Adjust the valve gap. CYL. No #1 #2 #3 #4
Rotation Inta Exh Inta Exh Inta Exh Inta Exh
angle ke aust ke aust ke aust ke aust
B TDC (#1
CYL.) ● ● ● ●
A 360°
Rotation ● ● ● ●
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

EDL032822A be the top dead point.
3) Check and adjust the following valve gaps when
the #4 cylinder is at the top dead point.
• #2 cylinder: Exhaust valve
• #3 cylinder: Intake valve
• #4 cylinder: Intake and exhaust valve
D
C 3. Perform the final check after adjusting the gap.
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 the valve tappet.
• Check the assembly state between the caliper and
EDL032823A the valve.
1) Remove the left and right cylinder head cover.
2) Check the valve gap between the caliper (A) and Check of Rocker Arm Shaft
the adjust screw cap (B) with the gap gauge. 1. Remove the rocker arm shaft.
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.
Intake valve gap 0.4 mm
Exhaust valve gap 0.45 mm
EDL022100B
1) Loosen and remove the fixing bolts from the

rocker arm bracket.
11 - 25
2) Remove the rocker arm bracket, the rocker arm Check of Rocker Arm
shaft spring, the rocker arm, and the rocker arm
1. Remove the rocker arm.
shaft in the order as listed before.
2. Check warpage of the rocker arm shaft.
EDL022100B
1) Loosen and remove the fixing bolts from the
EDL022101A rocker arm bracket.

2) Remove the rocker arm bracket, the rocker arm
1) Put the rocker arm shaft on two V-blocks.
shaft spring, and the rocker arm in the order as
2) Install the dial gauge.
listed before.
3) Check the degree of warpage of the rocker arm
shaft as rotating the rocker arm shaft. 2. Check the exterior of the rocker arm with the
naked eye.
Note)If the warpage is slight, correct it by pressing with
the press. If the warpage is out of the allowable 1) Check whether the adjust screw cap assembly
limit, replace it with a new one. surface, which moves as contacting to the valve stem,
is scratched, or the layer is worn with the naked eye.
3. Check the outside diameter of the rocker arm Note)If the wear is slight, polish it with the oil-contained
shaft. whetstone or fine sandpaper. If the layer is
seriously worn, replace the rocker arm with a
new one.
Note)For polishing the rocker arm, use the sandpaper
dipped in oil
3. Measure the inside diameter of the rocker arm.
EDL022102B
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.
EDL022103A
11 - 26
1) Measure the rocker arm inside diameter with the

micrometer or the vernier calipers.
Note)Compare the measurement value with the

7 3 2 6
outside diameter of the rocker arm shaft. If the 12
gap is larger than the specified value, replace the
one of which wear is more serious.
8 11
Assembly of Rocker Arm
9 10
4 1 5
EDL022256A
A
B 2) Temporarily tighten 12 hex bolts (B) in the order of
(1) ~ (12).
8 ± 0.05 kgf•m.
CAUTION
EDL022029A cylinder head cover to get out to the outside.
1) Attach the rocker arm (A). cover in the order from (1) ~ (12). The front
2) Tighten 10 flange hex bolts (B) at a tightening engine direction (F) is the water pump
torque of 2.2 ± 0.3 kgf•m. direction and the rear engine direction (R) is
C
3. Attach the injectiors (A).
B
A
C
B A
EDL022257A
EDL022255A

center of the injector hole and mount it.
2) Sufficiently apply engine oil on the cylinder head
11 - 27
3) Attach 4 injectors (A).
CAUTION
the injector oil seal but replace with new ones. B A
• Attach injectors by slowly turning them to
occur because of unstable combustion. C

EDL022026B
CAUTION
10
F
2 9
3 5
4.35 ± 0.35 kgf•m. 7 1
4
4. Attach the left cylinder head cover (A). 8
R
A
B
EDL022058A
1) Align the right cylinder head cover (A) with the

order of (1) - (10).
EDL022254A

5. Attach the right cylinder head cover (A).
11 - 28
6. Connect the fuel return hose (A). 3) Tighten 3 hex bolts (C).
A
(B) and (C).
B
E
EDL022249A A
1) Press the fuel return hose (A) into the end of the C
D
EDL022234A
CAUTION
• The injector should be fully connected with the CAUTION
hose. • Be careful to note the direction when attaching
the common rail.
2) Mount the hose clips. • Be careful not to damage the common rail
while attaching it.
CAUTION
Fix the hanlde of hose clip to face the front of the
hand.
engine.
3) Tighten the flange hex bolts (B). by hand.
7. Attach the heat screen (A). CAUTION

A connecting the fuel injection pipes.
C other side to connect the round part of the
performance.
B
EDL022246A 5) Tighten the nuts of the fuel injection pipe (B),
1) Temporarily tighten 2 hex bolts (B) to the exhaust which are connected to the common rail and the
manifold side. injector, at a tightening torque of 3.0 kgf•m.
11 - 29

A A
C
1 B
2 3
A
EDL022232B
A
intake manifold.
CAUTION
2
EDL022233A mounting the gasket.
1) Connect the EGR connection pipe (A) and the mounting it.
gasket (C).
CAUTION torque of 2.2 kgf•m.
• Be careful to note the direction when 3) Mount the boost pressure sensor (D) and then
connecting the EGR connection pipe. tighten the fixing bolt.
mounting it.
10. Connect the intake stake (A). A
B
C
EDL022230A

EDL022232A 3) Mount the hose clamps.
11 - 30
Valve Tappet and Push Rod
Disassembly of Valve Tappet 3. Measure the outside diameter of the valve tappet.
1. Detach the valve tappet.

an 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

Embossment Crack Normal with the outside diameter micrometer.
Note)If the diameter is out of the allowable limit,
replace the valve tappet with a new one.
Abnormal Assembly of Valve Tappet

1. Attach the valve tappet.
EDL0213006A
1) Check whether the valve tappet surface, which Engine)
moves as contacting to the camshaft, is cracked or
scratched.
Disassembly of Push Rod
Note)If the wear is slight, polish it with the oil-contained
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
A
dipped in oil.
B
2. Measure the gap of the valve tappet.
1) Measure the outside diameter of the valve tappet
and 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.
EDL022230A
CAUTION
11 - 31
2) Disconnect the breather hose (A). 3. Disconnect the EGR connection pipe (A).
C
1 B
A
1
D A
B 2
C
EDL022233A

EDL022232A
gasket (C).
4. Remove the common rail (A) and the injection

pipes (B) and (C).
A A
2 3
E
A
EDL022232B
C
1) Loosen the fixing bolt. D
3) Loosen 4 collared hex bolts (B). EDL022234A
4) Remove the intake stake (A) and gasket (C) from 1) Loosen the fixing bolt (E).
the intake manifold. 2) Loosen the nuts of the fuel injection pipe (C),
CAUTION

11 - 32
5. Remove the heat screen (A). 7. Remove the right cylinder head cover (A).
C A
B
EDL022246A EDL022026A
1) Loosen 2 hex bolts (B) and 3 hex bolts (C). 1) Loosen 10 flange hex bolts (B).
2) Remove the heat screen (A). 2) Remove the right cylinder head cover (A).

8. Remove the left cylinder head cover (A).
A
A
B
EDL022249A
EDL022254A
2) Remove the hose clips. 3) Loosen 13 flange hex bolts (B).
3) Disconnect the fuel return hose (A). 4) Remove the left cylinder head cover (A).
11 - 33
9. Remove the injectors (A). 11. Remove the rocker arm (A).
B
A
C
A
B
EDL022255A EDL022029A
1) Loosen 4 hex bolts (B). 1) Loosen 10 flange hex bolts (B).

2) Remove 4 injector fixtures (C). 2) Remove the rocker arm (A).
3) Remove 4 injectors (A).
Note) Remove the cylinder head cover and remove 12. Remove the push rods (A).
CAUTION
A
left to right.
10. Remove the cylinder head cover (A).

EDL022030A
C 1) Remove the push rods (A).
EDL022257A

11 - 34
Check of Warpage of Push Rod

CAUTION
1. Check warpage of the push rod.
After connecting the push rods, rotate them to
check the connection state.
B
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 EDL022029A
Warpage of push rod 0.5 mm 1) Attach the rocker arm (A).

Assembly of Push Rod
1. Connect the push rods (A).
EDL022257A
EDL022030A
1) Apply engine oil on both ends of the push rods (A).

2) Connect the push rods (A) in the cylinder head
holes.
3) Hit the head of the push rods with a rubber
hammer lightly once or twice to get them
positioned in the tappet holes.
11 - 35
3) Attach 4 injectors (A).
CAUTION
7 3 2 6 • Do not reuse the head cover rubber seal and
12
• Attach injectors by slowly turning them to
8 11 surface which contacts the injectors.
9 occur because of unstable combustion.
4 1 5 10
EDL022256A
CAUTION
2) Temporarily tighten 12 hex bolts (B) in the order of
(1) ~ (12). tightening may cause damage to the cylinder head.
8 ± 0.05 kgf•m.
4.35 ± 0.35 kgf•m.
CAUTION
• Be careful not to allow the seal ring of the 5. Attach the left cylinder head cover (A).
engine direction (F) is the water pump A
B
direction and the rear engine direction (R) is
4. Attach the injectiors (A).
B
EDL022254A
C
A
D
EDL022255A

center of the injector hole and mount it.
2) Sufficiently apply engine oil on the cylinder head
11 - 36
6. Attach the right cylinder head cover (A). 7. Connect the fuel return hose (A).
B A
C
B
EDL022026B EDL022249A
10 nipple and connect it.
6 F
CAUTION
2 9
3 5
7 1 • The injector should be fully connected with the
4 hose.
8
R
CAUTION
Fix the handle of hose clip to face the front of the
engine.
EDL022058A
1) Align the right cylinder head cover (A) with the 3) Tighten the flange hex bolts (B).
2) Temporarily tighten 10 flange hex bolts (B) in the 8. Attach the heat screen (A).
order of (1) - (10).
A
EDL022246A
1) Temporarily tighten 2 hex bolts (B) to the exhaust

manifold side.
11 - 37
3) Tighten 3 hex bolts (C). 6) Tighten the nuts of the fuel injection pipe (C), which
4) Tighten 2 hex bolts (B). are connected to the common rail and the fuel
9. Attach the common rail (A) and the injection pipes 7) Tighten the fixing bolt (E).
(B) and (C).
C
1 B
B
E
A
A
C
D
EDL022234A 2
1) Attach the common rail (A) to the intake manifold. EDL022233A
1) Connect the EGR connection pipe (A) and the

CAUTION
gasket (C).
the common rail. CAUTION
while attacing it. • Be careful to note the direction when
2) Temporarily tighten 2 collared hex bolts (D) by • Be careful not to damage the gasket while
mounting it.
hand.
3) Temporarily connect the fuel injection pipe (B), (C) 2) Tighten 4 flange hex bolts (B) at a tightening
by hand. torque of 2.2 kgf•m.
CAUTION
injection pipe first, and then the nut on the 1
pipe to the correspondent part correctly. D
with new ones. Reusing fuel injection pipes A
occur, causing a critical fault in engine B
performance. C

5) Tighten the nuts of the fuel injection pipe (B), EDL022232A
11 - 38
A A
2 3
EDL022232B

intake manifold.
CAUTION
mounting it.

EDL022230A

CAUTION
11 - 39
Camshaft
Disassembly of Camshaft 3. Measure the outside diameter of the camshaft

journal.
1. Detach the camshaft.
an Engine)
2. Remove the camshaft gear (A).
A B
EDL022108B
1) For 3ea camshaft journals, measure total 6 points

C of the outside diameters: front and rear.
2) Measure 2 points (vertical and horizontal) of the
outside diameters of the camshaft journals.
EDL022107A
3) The standard measurement value of the outside
1) Heat the camshaft gear (A) at 180 °C ± 10 °C. diameter of the camshaft journal is within the
2) Remove the camshaft gear (A) and the thrust range of 44.950 ~ 44.966 mm.
washer (C) from the camshaft (B).
CAUTION Camshaft journal 44.950 ~ 44.966 mm
• NEVER let the camshaft gear heat to a
temperature exceeding 200 °C. Note)If the outside diameter is out of the allowable
limit, replace the camshaft with a new one.
Note)Check whether the camshaft surface is cracked
or scratched.
Measurement of Camshaft Journal Outside
Note)If the wear is slight, polish it with the oil-contained
Diameter whetstone or fine sandpaper. If the crack or
scratch is serious, replace the camshaft with a
1. Set the gauge.
new one.
2. Remove foreign substances from the camshaft.
Note)For polishing the camshaft, use the sandpaper
dipped in oil.
11 - 40
Measurement of Camshaft Assembly of Camshaft

1. Check the camshaft offset. 1. Mount the cam gear (A).
A B
Gap gauge
C
EDL0213003A EDL022107A
1) Move the camshaft gear to the opposite side of the 1) Mount the thrust washer (C) on the camshaft (B).
cylinder block. 2) Mount the woodruff key (D), heat the cam gear (A)
2) Measure the gap between the thrust washer and at the temperature of 180 °C ± 10 °C, and then
the camshaft gear with the gap gauge. press in the camshaft into the cam gear.

CAUTION
Camshaft offset 0.1 ~ 0.2 mm
• NEVER let the cam gear heat to a temperature
exceeding 200 °C.
Note)Check if the gap is within the range of0.1 ~ 0.2 • The gear engraving should face outward.
mm.
Note)If the offset is too large, replace the thrust washer
with a new one. 2. Attach the camshaft.
2. Measure warpage of the camshaft. Engine)
EDL022110A
1) Put the camshaft on two V-blocks.

2) Check the degree of warpage of the camshaft with
the dial gauge.
Note)If the warpage is out of the allowable limit,

replace the camshaft with a new one.
11 - 41
Idle gear
Disassembly of Idle Gear CAUTION

1. Remove the V-belt. Do not reuse the oil seal; replace them with new
ones.
B
A
EDL022258A
EDL022040B
2) Remove the crankshaft pulley (A). 1) Remove the parallel key (B).
CAUTION
Be careful not to damage the oil seal. 5. Remove the idle gear (A).

D
A
C
B
A
E EDL022044B
D
C
2) Remove the idle gear shaft (C).
EDL022261B
3) Remove the idle gear (A) with remove tap (D).
speed sensor (D).
disassembly jig.
11 - 42
Measurement of Outside Diameter of Idle Measurement of Inside Diameter of Idle Gear

Gear Shaft 1. Set the gauge.
1. Set the gauge.
2. Measure the inside diameter of the idle gear.
2. Measure the outside diameter of the idle gear
shaft.
A
C
C
A D
B
B D
EDL022112A
1) Measure total 4 points of the inside diameter of the

EDL022111A idle gear: vertical (A), horizontal (B), front (C), and
1) Measure total 4 points of the outside diameter of rear (D).
the idle gear shaft: vertical (A), horizontal (B), front 2) The standard measurement value of the inside
(C), and rear (D). diameter of the idle gear is within the range of 64.0
2) The standard measurement value of the outside ~ 64.019 mm.
diameter of the idle gear shaft is within the range Item Specified Value
of 59.921 ~ 59.940 mm.
Inside diameter of the
64.0 ~ 64.019 mm
Item Specified Value idle gear
Outside diameter of the

59.921 ~ 59.940 mm
idle gear shaft
11 - 43
Assembly of Idle Gear 4) Position the crankshaft gear engraving mark (G)
between the idle gear engravings (F).
1. Attach the idle gear (A).
Note) You can see one crankshaft gear engraving and
two idle gear engravings.
CAUTION
D
Make sure that the crankshaft gear engraving is
positioned between two idle gear engravings.
C
5) Align the flange hex holes of the cylinder block to
those of the idle gear shaft.
A 6) Attach the idle gear shaft (C).
B CAUTION
Make the oil hole of the idle gear shaft (C) face the
EDL022044B top surface of the cylinder block.

8) Backlash of the idle gear and the crankshaft gear
D E
is 0.087 ~ 0.200 mm.

the crankshaft gear
F
9) The backlash between the idle gear and the

camshaft gear is 0.087 ~ 0.211 mm.
G
EDL022052A
1) Apply engine oil to the inside of the idle gear bush idle gear and the 0.087 ~ 0.211 mm
camshaft gear
in the idle gear (A).
2) Attach the idle gear (A).

CAUTION
Make sure that you are attaching the idle gear so B
that its engraving faces the outside of the cylinder
block.
3) Position the idle gear engraving (D) between the

camshaft gear engravings (E).
Note) You can see two camshaft gear engravings and

one idle gear engraving.
A
CAUTION
Make sure that the idle gear engraving is positioned
between the two camshaft gear engravings.
EDL022040B
11 - 44

2) Connect the paralle key (B).
CAUTION
D
wheel.
3. Attach the timing gear case (A)

F
E
A
EDL022261A

case (A) face the ground.
B
2) Mount the front oil seal (B) to the front oil seal
assembly jig (860104-02047).
A 3) Align the front oil seal assembly jig (860104-
02047) where the front oil seal (B) is mounted to
the timing gear case (A) and beat it with a rubber
hammer.
EDL022227B
gear case (A), pull off the front oil seal assembly
jig (860104-02047).
CAUTION
attaching it.
C lubrication. coolant, fuel, LOCTITE, or silicon.
EDL022226B one.
attaching it.

cloth.
± 0.5mm.
11 - 45
CAUTION
attach it.
2.2kgf•m.
EDL022258A

attach it.
flange hex bolts (B).
3) Tighten flange hex bolts (B) at a tightening torque
of 26 kgf•m.
CAUTION
11 - 46
Lifting Hook
Assembly of Lifting Hook Assembly of Lifting Hook

1. Remove the rear lifting hook (A). 1. Mount the front lifting hook (A).
A
A
EDL022252A EDL022253A
1) Loosen 3 flange hex bolts (B). 1) Mount the front lifting hook (A).
2) Remove the rear lifting hook (A). 2) Tighten 2 flange hex bolts(B) at a tightening torque
of 4.4 kgf•m.
2. Remove the front lifting hook (A).
2. Mount the rear lifting hook (A).
A A
B
B
EDL022253A
EDL022252A
2) Remove the front lifting hook (A). 1) Mount the rear lifting hook (A).
2) Tighten 3 flange hex bolts(B) at a tightening torque
of 2.2 kgf•m.
11 - 47
12. Electric System
Electric Part .................................................................12-3

Electric Parts.....................................................................12-3
Circuit Diagram ............................................................12-4

General Information ..........................................................12-4
Engine Connector .............................................................12-5
Engine Connector of Engine Control Unit (ECU)..............12-6
Air Heater.....................................................................12-8
Disconnection of Glow Plug..............................................12-8
Connection of Glow Plug ..................................................12-9
Switches and Sensors ............................................... 12-11

Mass Air Flow Sensor (MAF)..........................................12-11
Boost Temperature Sensor (BTS) ..................................12-11
Boost Pressure Sensor (BPS) ........................................12-11
Exhaust Gas Temperature Sensor (EGTS) ....................12-11
Oil Pressure and Temperature Sensor (OPTS)..............12-12
Water Temperature Sensor (WTS).................................12-12
Fuel temperature sensor (FTS) ......................................12-12
Rail pressure sensor (RPS) ............................................12-12
Injector #1(INJ) ...............................................................12-13
Injector #2 (INJ) ..............................................................12-13
Injector #3 (INJ) ..............................................................12-13
Injector #4 (INJ) ..............................................................12-13
Crank Shaft Position Sensor (CRK)................................12-14
CAM Shaft Position Sensor (CAM).................................12-14
Knock Sensor1(KNOCK1) ..............................................12-14
Knock Sensor2(KNOCK2) ..............................................12-15
Exhaust Gas Recirculation Valve Position Sensor (EGR) ......12-15
Inlet Metering Valve (IMV) ..............................................12-15
Water In Fuel Sensor (WIFS) .........................................12-16
Wire harness.............................................................. 12-17

Disassembly of Wire Harness.........................................12-17
Assembly of Wire Harness .............................................12-17
Electronic Control Unit (ECU) .................................... 12-18

General Information ........................................................12-18
Electronic Control Unit (ECU) Connectors......................12-18
I/O of Electronic Control Unit (ECU) ...............................12-19
Operational Conditions of Electronic Control Unit (ECU) .......12-19
12 - 1
12 - 2
12. Electric System
Electric System
Electric Parts
Electric Parts
11
1
5
6
7
4 10
2
8
9
3
12
16
15
14
13
EDL022171B
1. EGTS : Exhaust Gas Temperature Sensor 6. BTS : Boost Temperature Sensor 11. BPS : Boost Pressure Sensor
2. CAM : CAM Shaft Position Sensor 7. FTS : Fuel temperature sensor 12. RPS: Rail pressure sensor
3. CRK : Crank Shaft Position Sensor 8. IMV : Inlet Metering Valve 13. INJ : Injector #4
EGR : Exhaust Gas Recirculation OPTS : Oil Pressure and 14. INJ : Injector #3
4. 9.
Valve Position Sensor Temperature Sensor 15. INJ : Injector #2
5. WTS : Water Temperature Sensor 10. KNOCK : Knock Sensor 16. INJ : Injector #1
12 - 3
12. 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).
EDL022172B
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.
12 - 4
12. Electric System
Engine Connector
EDL022123D
12 - 5
12. Electric System
Engine Connector of Engine Control Unit (ECU)
Cir-
cuit Wire Wire Wire ECU Sensor
Circuit Name Remarks
Num- Size Color Type PIN No PIN No
ber
103 0.75 W AESSXF FUEL INJECTOR HSDA 3 2 TWIST (103, 125)
104 0.75 Y AESSXF Oil Pressure Sensor 4 2
EXHAUST GAS TEMP
106 0.75 L AESSXF 6 2
SENSOR 2
109 0.75 O AESSXF COOLANT TEMP SENSOR 9 2
110 0.75 L AESSXF FUEL TEMP SENSOR 10 1
111 0.75 W: AESSXF OIL PRESSURE SENSOR 11 4
INTAKE MANIFOLD
112 0.75 L AESSXF 12 3
PRESSURE SENSOR
EGR POSITION SENSOR
116 0.75 O AESSXF 16 5
SIGNAL
RAIL PRESSURE SENSOR TWIST (119, 135,
119 0.75 B AESSXF 19 2
RETURN 138)
AIR MASS FLOW SENSOR
120 0.75 B AESSXF 20 3
RETURN
EXHAUST GAS TEMP
123 0.75 B AESSXF 23 1
SENSOR 2 RETURN
125 0.75 B AESSXF FUEL INJECTOR LSD2A 25 1 TWIST (103, 125)
126 0.75 B AESSXF FUEL INJECTOR LSD1A 26 1 TWIST (126, 127)
127 0.75 W AESSXF FUEL INJECTOR HSDA 27 2 TWIST (126, 127)
ENGINE BLOCK
TUBE_A SHIELD_130_131
128 0.75 B ACCELEROMETER #1 28
MS11 (DRAIN)
SCREEN
ENGINE BLOCK
TUBE SHIELD_132_133
129 0.75 B ACCELEROMETER #2 29
_AMS12 (DRAIN)
SCREEN
ENGINE BLOCK
AESSXF
130 0.75 P ACCELEROMETER #1 30 1 SHIELD_130_131
_AMS11
RETURN
AESSXF ENGINE BLOCK
131 0.75 O 31 2 SHIELD_130_131
_AMS11 ACCELEROMETER #1
AESSXF ENGINE BLOCK
132 0.75 L 32 2 SHIELD_132_133
_AMS12 ACCELEROMETER #2
ENGINE BLOCK
AESSXF
133 0.75 P ACCELEROMETER #2 33 1 SHIELD_132_133
_AMS12
RETURN
TWIST (119, 135,
135 0.75 O: AESSXF RAIL PRESSURE SENSOR 35 1
138)
AESSXF
136 0.75 P CRANK SENSOR NEG 36 1 SHIELD_136_160
_AMS13
VREF3(5V) AIR MASS FLOW
137 0.75 W AESSXF 37 1
SENSOR
VREF1 RAIL PRESSURE TWIST (119, 135,
138 0.75 P AESSXF 38 3
SENSOR 138)
COOLANT TEMP SENSOR
145 0.75 B AESSXF 45 1
RETURN
FUEL TEMP SENSOR
146 0.75 P AESSXF 46 2
RETURN GND
12 - 6
12. Electric System
Cir-
cuit Wire Wire Wire ECU Sensor
Circuit Name Remarks
Num- Size Color Type PIN No PIN No
ber
CAM SHAFT POSITION
147 0.75 B AESSXF 47 3
SENSOR RETURN
OIL PRESSURE & TEMP
148 0.75 L AESSXF 48 1
RETURN GND
150 0.75 W AESSXF FUEL INJECTOR HSDB 50 2 TWIST (150, 174)
151 0.75 W AESSXF FUEL INJECTOR HSDB 51 2 TWIST (151, 175)
CAM SHAFT POSITION
159 0.75 Y AESSXF 59 2
SENSOR
AESSXF
160 0.75 O CRANK SENSOR POS 60 2 SHIELD_136_160
_AMS13
161 0.75 O AESSXF VREF2, INPRES 61 1
164 0.75 W AESSXF EGR, VREF3 64 1
165 0.75 O AESSXF VREF3 OIL PRESSURE 65 3
167 0.75 W AESSXF INPRES RETURN GND 67 2
INTAKE AIR TEMP SENSOR
169 0.75 B AESSXF 69 1
RETURN
172 0.75 P AESSXF EGR SENSOR RETURN GND 72 3
174 0.75 B AESSXF FUEL INJECTOR LSD2B 74 1 TWIST (150, 174)
175 0.75 B AESSXF FUEL INJECTOR LSD1B 75 1 TWIST (151, 175)
INLET METERING VALVE
177 0.75 B AESSXF 77 2
(PWM)
179 0.75 P AESSXF GLOW PLUG FEEDBACK 79 4
TUBE SHIELD_136_160
187 0.75 B CRANK SENSOR SHIELD 87
_AMS13 (DRAIN)
192 0.75 W AESSXF EGR (H-BRIDGE POS) 92 6 TWIST (192, 193)
193 0.75 B AESSXF EGR (H-BRIDGE NEG) 93 2 TWIST (192, 193)
INTAKE AIR TEMP SENSOR
194 0.75 P AESSXF 94 2
RETURN
8500 5 RW AEXF GLOW PLUG POWER LINE 1 1 INTER2_1M
K87A 0.75 W AESSXF SENSOR 15A FUSE 2 3 INTER1_2M
K87B 0.75 O AESSXF SENSOR 15A FUSE 1 1 INTER1_2M
K87C 0.75 O AESSXF SPLICE (KL87) S07 1 K87
12 - 7
12. Electric System
Air Heater 2. Remove the common rail(A) and the injection

pipes(B) and (C).
Disconnection of Glow Plug
D
E
A
A
B C
D
C
EDL022234A

EDL022232A

A A
CAUTION
2 3 may allow foreign substances into the fuel pipes
EDL022232B
4) Loosen 2 collared hex bolts (D) of the common
1) Loosen the fixing bolt. rail.
2) Remove the boost pressure sensor( D). 5) Remove the common rai l (A) from the intake
3) Loosen 4 collared hex bolts (B). manifold.
12 - 8
12. Electric System
3. Disconnect the glow plug (A). 2. Attach the common rail (A) and the injection pipes
(B) and (C).
D
C
A
E
C
D
EDL022248A
EDL022234A
1) Loosen 4 hex nuts (D) and remove 4 washers (C).
2) Remove the electric connector (B). 1) Attach the common rail (A) to the intake manifold.
3) Disconnect 4 glow plugs (A) from the cylinder
head. CAUTION
the common rail.
Connection of Glow Plug • Be careful not to damage the common rail
while attacing it.

D
C hand.
by hand.
CAUTION
B
A • Be careful to note the direction when
EDL022248A with new ones. Reusing fuel injection pipes
1) Tightening 4 glow plugs (A) to the cylinder head at pipes or oil leaks from the bolt clamping to
a tightening torque of 9~12 N•m. occur, causing a crirical fault in engine
performance.
2) Attach the electric connector (B).
3) Mount 4 washers (C). 4) Tighten 2 collared hex bolts (D) of the common rail
4) Tighten 4 hex nuts (D) at a tightening torque of at a tightening torque of 2.2 kgf•m.
2.5~3 N•m. 5) Tighten the nuts of the fuel injection pipe (B),
12 - 9
12. Electric System
3. Connect the intake stake(A).
B
C
EDL022232A
A A
2 3
EDL022232B
1) Mount the intake stake(A) and gasket(C) to the

intake manifold.
CAUTION
mounting it.

12 - 10
12. 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
inhaled initially. intake manifold.
No ECU PIN Description
1 228 Intake air flow frequency signal
2 235 Intake temperature signal
3 120 Ground
4 137 Supply voltage(12V)
Boost Temperature Sensor (BTS)

A sensor that measures the temperature of air in the
intake manifold.
EDL022176B

2 167 Ground
3 112 Pressure signal
Exhaust Gas Temperature Sensor (EGTS)

A sensor that measures the exhaust gas of the
turbocharger.
EDL022175A
1 169 Ground
2 194 Temperature signal
EDL022177A
1 123 Ground
12 - 11
12. Electric System
Oil Pressure and Temperature Sensor (OPTS) Fuel temperature sensor (FTS)
A sensor that measures the pressure and temperature A sensor that measures the fuel temperature in the
of engine oil. fuel pump.
EDL022178A EDL022180A
No ECU PIN Description No ECU PIN Description
1 148 Ground 1 110 Temperature signal
2 104 Temperature signal 2 146 Ground

Rail pressure sensor (RPS)
A sensor that is installed at the end of the common rail,
measuring the instantaneous internal pressure of the
Water Temperature Sensor (WTS)
common rail.
A sensor that senses the temperature of engine
cooling water.
EDL022181A
EDL022179A

2 119 Ground
1 145 Ground
12 - 12
12. Electric System
Injector #1(INJ) Injector #3 (INJ)

A part that injects fuel according to the injection signal A part that injects fuel according to the injection signal
received from the ECU. received from the ECU.
EDL022182A EDL022184A
1 126 Low Side Drive 1 175 Low Side Drive
2 127 High Side Drive 2 151 High Side Drive
Injector #2 (INJ) Injector #4 (INJ)

A part that injects fuel according to the injection signal A part that injects fuel according to the injection signal
received from the ECU. received from the ECU.
EDL022183A EDL022185A
1 174 Low Side Drive 1 125 Low Side Drive
2 150 High Side Drive 2 103 High Side Drive
12 - 13
12. Electric System
Crank Shaft Position Sensor (CRK)

A sensor that senses the position of the crankshaft in
1 - Supply voltage(12V)
order to sense the engine rotation speed and the
position of the piston. 2 159 Position sensor signal
3 147 Ground
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 external, it generates voltage higher than the
reference voltage and delivers the voltage to the ECU.
EDL022186A
1 136 CRS NEG
2 160 CRS POS 130 131 128

- 187 Shield
CAM Shaft Position Sensor (CAM)

EDL022188B
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
1 130 Ground
shaft position sensor which cannot check the position
of each piston. 2 131 Accelerometer signal
3 128 Shield (Screen)
EDL022187A
12 - 14
12. Electric System
Knock Sensor2(KNOCK2)
A sensor that is mounted on the cylinder block,
sensing knocking of the engine. With the piezoelectric
ceramic element, when it senses external vibrations or 2 193 H-Bridge NEG
pressure, it generates voltage higher than the 3 172 Ground

reference voltage and delivers the voltage to the ECU. 5 116 Position sensor signal
6 192 H-Bridge NEG
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.
133 132 129
EDL022189B
1 133 Ground
2 132 Accelerometer signal
3 129 Shield (Screen)
EDL022191A
Exhaust Gas Recirculation Valve Position
Sensor (EGR)
1 - Supply voltage(12V)
A sensor used to reduce nitrogen oxide (NOx) from the
2 177 PWM signal
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.
EDL022190A
12 - 15
12. Electric System
Water In Fuel Sensor (WIFS)

A sensor that senses the moisture in the filter and
sends the data to the ECU.
EDL022221A
1 209 Water sensing signal
2 234 Ground
12 - 16
12. 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.
12 - 17
12. Electric System
Electronic Control Unit (ECU)
General Information Electronic Control Unit (ECU) Connectors

The engine control unit (ECU) controls fuel delivery. The ECU connectors are classified into the connectors
The ECU is connected to various sensors. Based on connected to the vehicle and the connectors
the input values from the sensors, the ECU controls connected to the engine.
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.
1 2
EDL022195A
1. Connectors connected to the engine 2. Connectors connected to the vehicle
12 - 18
12. 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
3. Driver-requested Adjustment of RPM

Operational Conditions of Electronic Control
1) Controls the RPM based on request from the
Unit (ECU) driver and controls the engine based on the RPM
1. Engine Start requested by the vehicle control unit.
1) Sets the reference temperature for determining
preheat to the lowest temperature among coolant
temperature, fuel temperature, intake air 4. Limp Home
temperature, and oil temperature. 1) A function that allows drivers to drive their vehicle
2) Sets the reference temperature for determining to the repair center safely with the minimum
fuel volume by setting the engine cooling conditions for driving the vehicle when a fault code
temperature. occurs.
3) Determines the appropriate fuel volume to start 2) Limp Home function is applied under the following
the engine, delivers the fuel to the engine, and conditions.
measures the RPM signal by using the crankshaft
rev-count sensor. • Accelerator pedal has failed: Regardless of
pressing the accelerator pedal, the vehicle is
driven at a consistent RPM.
2. Vehicle driving • Sensor has failed: When sensors have failed, the
1) Calculates the required data for driving a vehicle, vehicle is driven with the consistent alternative
such as CAN data and the RPM transferred from values.
the vehicle control unit. • Output is limited: According to the fault type, the
fuel 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.
12 - 19
12. Electric System
• 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.
2) The information on fuel consumption, engine use
time, and ECU use time is written in the ECU.
3) The information can be monitored with the ECU
diagnosis device.
12 - 20
13. Others/Driving System
General Information ..................................... 13-3

General Information........................................ 13-3
Crankshaft ................................................... 13-6

Disassembly of Timing Wheel ........................ 13-6
Assembly of Timing Wheel ............................. 13-6
Disassembly of Crankshaft............................. 13-8
Measurement of Crankshaft
Main Journal Diameter ................................... 13-8
Measurement of Crankshaft Bearing Gap ...... 13-8
Measurement of Crankshaft Warpage ........... 13-9
Assembly of Crankshaft ................................. 13-9
Connecting Rod ......................................... 13-10

Disconnection of Connecting Rod ................ 13-10
of Connecting Rod Small-end ...................... 13-10
Measurement of Connecting rod
large-end bore .............................................. 13-10
Measurement of Gap
of Connecting Rod Big-end .......................... 13-11
Assembly of Connecting Rod ....................... 13-11
Piston......................................................... 13-12
Disassembly of Piston .................................. 13-12
Measurement of Outside Diameter
of Piston Pin ................................................. 13-12
of Piston Pin Bore......................................... 13-12
Measurement of Gap of Piston Ring End ..... 13-12
Measurement of Step Height
of Piston Top Side ........................................ 13-13
Assembly of Piston ....................................... 13-13
Crankshaft Pulley....................................... 13-14

Disassembly of Crankshaft Pulley ................ 13-14
Assembly of Crankshaft Pulley..................... 13-14
Others ........................................................ 13-15

Engine Timing .............................................. 13-15
Adjustment of Engine Timing ....................... 13-16
Check of Gear Backlash............................... 13-16
Check of Gear Axial Offset ........................... 13-17
13 - 1
13 - 2
Others/Driving System Therefore, like a piston, the connecting rod can be

disassembled through the upper side of the
cylinder.
General Information
An alloy-type prefabricated bearing is used for the
active part of the crankshaft and the connecting
General Information
rod.
1. The forged crankshaft is an integral structure. The 3. The camshaft, oil pump, and high-pressure
crankshaft and the rear oil seals prevent oil from injection pump are driven by gear connection in
permeating into the flywheel housing. the timing gear case.
2. The connecting rod is forged and its large end part
is vertically separated.
Specifications
D24NAP
0.060 ~ 0.080 mm
piston
Top ring
1.915 ~ 1.945 mm
groove
2.060 ~ 2.080 mm
groove area groove
Oil ring
3.020 ~ 3.040 mm
groove
Top ring
0.083 ~ 0.133 mm
side gap
0.070 ~ 0.110 mm
side gap side gap
Oil ring
0.030 ~ 0.070 mm
side gap
Top ring
0.20 ~ 0.30 mm
end gap
0.55 ~ 0.70 mm
end gap end gap
Oil ring
0.2 ~ 0.4 mm
end gap
Piston pin outside
30.995 ~ 31,000 mm
diameter
Connecting rod
31.025 ~ 31.038 mm
small-end bore
Connecting rod
0.025 ~ 0.043 mm
small-end hole gap
Connecting rod
57,000 ~ 57.015 mm
large-end bore
0.026 ~ 0.064 mm
oil gap
13 - 3
D24NAP
57.955 ~ 57.970 mm
outside diameter
53.955 ~ 53.970 mm
outside diameter
0.029 ~ 0.059 mm
oil gap
D24NAP
Remark
0.060 ~ 0.080 mm
piston
Top ring
1.915 ~ 1.945 mm
groove
2.060 ~ 2.080 mm
groove area groove
Oil ring
3.020 ~ 3.040 mm
groove
Top ring
0.083 ~ 0.133 mm
side gap
0.070 ~ 0.110 mm
side gap side gap
Oil ring
0.030 ~ 0.070 mm
side gap
Top ring
0.20 ~ 0.30 mm
end gap
0.55 ~ 0.70 mm
end gap end gap
Oil ring
0.2 ~ 0.4 mm
end gap
Piston pin outside
30.995 ~ 31,000 mm
diameter
Connecting rod
31.025 ~ 31.038 mm
small-end bore
Connecting rod
0.025 ~ 0.043 mm
small-end hole gap
Connecting rod
57,000 ~ 57.015 mm
large-end bore
0.026 ~ 0.064 mm
oil gap
13 - 4
D24NAP
Remark
57.955 ~ 57.970 mm
outside diameter
53.955 ~ 53.970 mm
outside diameter
0.029 ~ 0.059 mm
oil gap
13 - 5
Crankshaft
Disassembly of Timing Wheel CAUTION

1. Remove the V-belt. Do not reuse the oil seal; replace them with new
ones.
B
A
EDL022258A
EDL022040B
2) Remove the crankshaft pulley (A). 1) Remove the parallel key (B).
CAUTION
Be careful not to damage the oil seal. Assembly of Timing Wheel

A
E
D
C
EDL022040B
EDL022261B
speed sensor (D).
2) Loosen 16 hex bolts (B). 2) Connect the paralle key (B).

CAUTION
disassembly jig.
wheel.
13 - 6
2. Attach the timing gear case(A) the timing gear case(A) and beat it with a rubber
hammer.
(860104-02047).
CAUTION
B
A surface fasces the outside of the engine.
attaching it.
EDL022227B • Remove foreign substances such as residues
one.
attaching it.

case assembly surface(C) and clean it with a dry
cloth.
assembly surface(C) with the diameter of ø 2.5 ±
C 0.5mm.
CAUTION
EDL022226B • Be careful that the timing gear case has been
D attach it.
2.2kgf•m.
tighten the fixing bolt(F).
F
E
A
EDL022261A

case(A) face the ground.
assembly jig (860104-02047).
02047) where the front oil seal(B) is mounted to
13 - 7
3. Attach the crankshaft pulley (A). 5. Measure the diameter of the crankshaft main
journal
EDL022258A
EDL022121C
attach it. 1) Measure the diameter of the crankshaft journal
2) Apply LOCTITE Blue 587 to the inside of the with the outside diameter micrometer.
flange hex bolts (B). 2) Measure total 20 points of the inside diameter of
3) Tighten flange hex bolts (B) at a tightening torque the idle gear: 5 points of vertical (A), horizontal
of 26 kgf•m. (B), front (C), and rear (D).
3) The standard measurement value of the diameter
CAUTION of the crankshaft journal is within the range of
• Be careful not to damage the oil seal. 57.955 ~ 57.970 mm.
to be tightened with the specified torque. Item Specified Value
Crankshaft journal
57.955 ~ 57.970 mm
diameter
Disassembly of Crankshaft Measurement of Crankshaft Bearing Gap
1. Remove the crankshaft. 1. Mount the crankshaft to the cylinder block.
Note)Refer to Chapter 6 (Procedure of Disassembling 2. Measure the gap of the crankshaft bearing.
an Engine)
Measurement of Crankshaft Main Journal

Diameter
1. Check whether there is any cracked or scratched
part on the journal and pins of the crankshaft with
the naked eye.
2. Perform the magnetic particle testing or the liquid
penetrant testing to check the cracks on the
crankshaft. If cracks are found, replace the
crankshaft with a new one.
3. Set the gauge. EDL022122A
4. Remove foreign substances from the crankshaft.
13 - 8
1) Put the plastic gauges on 5 points on the crankshaft

which contact with the crankshaft bearing part.
2) Assemble the crank case at the specified torque
and then disassemble it.
3) Check the width of the plastic gauges.
4) The standard measurement value of the gap of the
crankshaft bearing is within the range of 0.029 ~
0.059 mm.
Crankshaft Bearing Gap 0.029 ~ 0.059 mm
3. Remove the plastic gauges.

5) Remove the plastic gauges.
6) Remove any foreign substances from the cylinder
block and the crankshaft.
Measurement of Crankshaft Warpage

1. Measure the crankshaft warpage.
EDL022196A
1) Put the #1 and #5 main journal of the crankshaft

on the V- block.
2) Put the dial gauge on the surface plate and
measure the warpage of the crankshaft as
spinning the crankshaft.
3) The standard measurement value of the warpage
of the crankshaft is 0.02 mm for #2 and #4 and
0.03 mm for #3 based on #1 and #5 main journal.
Assembly of Crankshaft
1. Attach the crankshaft.
Engine).
13 - 9
Connecting Rod
Disconnection of Connecting Rod Measurement of Connecting rod large-end bore

1. Disconnect the connecting rod. 1. Set the meter.

2. Measure the inside diameter of the large-end of
an Engine). the connecting rod.
Measurement of Inside Diameter of

Connecting Rod Small-end
1. Set the gauge.
2. Measure the inside diameter of the small end of
the connecting rod.
EDL022199B
C
EDL022197B
D
A
E
B
EDL022200B

C
connecting rod big-end: A, B, C, front (D), and rear (E).
2) Measure all of 4 connecting rods.
D 3) The standard measurement value of the inside
diameter of the connecting rod big-end is within
EDL022198B
the range of 57.0 ~ 57.015 mm.
connecting rod small-end: vertical (A), horizontal
(B), front (C), and rear (D). Connecting rod large-end bore 57.0 ~ 57.015 mm
2) Measure all of 4 connecting rods.
diameter of the connecting rod small-end is within CAUTION
the range of 31.025 ~ 31.038 mm. Connect the connecting rods manually until the
head of the connecting rod bolt contacts the bolt
Item Specified Value bearing surfaces on both sides, and then tighten
Connecting rod small-end bore 31.025 ~ 31.038 mm them at the specified torque.
13 - 10
Measurement of Gap of Connecting Rod Big-end

1. Mount the crankshaft to the cylinder block.
2. Measure the gap of the connecting rod big-end.
EDL022131A
1) Put the plastic gauges on 4 points on the

crankshaft that contacts with the connecting rods.
2) Connect the connecting rods.
3) Temporarily connect the connecting rods
manually.
4) Tighten the connecting rod bolts at a tightening
torque of 2 kgf m + 90 with 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 standard measurement value of the gap of the
connecting rod big-end is within the range of 0.026
~ 0.064 mm.
Gap of Connecting Rod Big-end 0.026 ~ 0.064 mm
3. Remove the plastic gauges.

9) Remove the plastic gauges.
10) Remove any foreign substances from the
crankshaft and the connecting rod big-end.
Assembly of Connecting Rod

1. Connect the connecting rods.
Engine).
13 - 11
Piston
Disassembly of Piston Measurement of Inside Diameter of Piston Pin

Bore
1. Detach the piston.
1. Set the gauge.
2. Measure the inside diameter of the piston pin
an Engine) .
bore.
Measurement of Outside Diameter of Piston Pin AB C D

1. Set the gauge.
2. Measure the outside diameter of the piston pin.
F
EDL022133A
A B CD
piston pin bore: A, B, C, D, vertical (E), and
horizontal (F).
2) Measure all of 4 piston pin bores.
EDL022132A 3) The standard measurement value of the inside
diameter of the piston pin bore is within the range
1) Measure total 8 points of the outside diameter of
of 31.008 ~ 31.014 mm.
the piston pin: A, B, C, D, vertical (E), and
horizontal (F). Item Specified Value
2) Measure all of 4 piston pins. Piston pin of the piston

31.008 ~ 31.014 mm
Inside diameter of bore
3) The standard measurement value of the outside
diameter of the piston pin is within the range of
30.995 ~ 31 mm.
Measurement of Gap of Piston Ring End
1. Measure the gap of the piston ring end.
Piston pin outside diameter 30.995 ~ 31 mm
EDL022134A
13 - 12
1) Insert the piston ring to the cylinder top at a right 4) The standard measurement value of the step
angle with the wall. height of the piston top side is within the range of
2) Measure the piston ring end gap with the gap 0.11 ~ 0.39 mm.
gauge (A).
3) Measure the gaps of the top ring, the 2nd ring, and
Step height of piston top side 0.11 ~ 0.39 mm
the oil ring.
4) The standard measurement values of the gap of
the piston ring end is within the range of 0.20 ~
0.35 mm for the top ring, 0.55 ~ 0.70 mm for the CAUTION
2nd ring, and 0.20 ~ 0.40 mm for the oil ring. • Select the cylinder head gasket class based on
the average of step heights of the piston top
Item Specified Value side by measuring average value of step
heights at 8 points. For the cylinder gasket
Gap of top ring 0.20 ~ 0.35 mm
class, refer to #19 of Procedure of Assembling
Gap of 2nd ring 0.55 ~ 0.70 mm an Engine of General Information in Chapter 6.
• The front engine direction (F) is the water
Gap of oil ring 0.20 ~ 0.40 mm pump direction and the rear engine direction
CAUTION
Be careful not to damage the cylinder with the gap
Assembly of Piston
gauge when measuring the gap of the piston ring
end. 1. Attach the piston.
Engine).
Measurement of Step Height of Piston Top Side
1. Perform the zero point adjustment of the meter
based on the top surface of the cylinder block.
2. Measure the step height of the piston top side.
A
F R
B
EDL022135A
1) Adjust the piston to position on the top dead point.

2) Measure the step height on A and B on the piston
top side based on the cylinder block surface.
3) Adjust the other pistons to position on the top
dead point and measure 8 points.
13 - 13
Crankshaft Pulley 3) Tighten flange hex bolts (B) at a tightening torque

of 26 kgf•m.
Disassembly of Crankshaft Pulley
CAUTION
EDL022258A

CAUTION
Assembly of Crankshaft Pulley

EDL022258A

attach it.
flange hex bolts (B).
13 - 14
Others
Engine Timing
The camshaft, oil pump, and high-pressure injection
pump are driven by gear connection.
2 3
4
5
EDL022136A
1. Injection pump drive gear (gear: 30)

2. Idle gear (gear: 65)
3. Camshaft gear (gear: 60)
4. Oil pump drive gear (gear: 25)
5. Crankshaft gear (gear: 30)
13 - 15
Adjustment of Engine Timing Check of Gear Backlash

1. Remove the timing gear case. 1. Remove the timing gear case.
2. Align the engravings of gears. 2. Check the gear backlash.
B C
I H
A
D
C
J K
F
D B
G
E
EDL022137A EDL022138A
1) Position the crankshaft gear engraving mark (E) 1) Check the gear backlash with the gap gauge.
between the idle gear engravings (B). 2) The standard backlash between the idle gear (A)
Note)You can see one crankshaft gear engraving (G) and the crankshaft gear is 0.087 ~ 0.2 mm.
and two idle gear engravings (F). 3) The standard backlash between the oil pump drive
Note)Position the idle gear engraving (B) between the gear and the crankshaft gear (B) is 0.06 ~ 0.259 mm.
camshaft gear engravings (C). 4) The standard backlash between the idle gear and
Note)You can see one idle gear engraving (I) and two the camshaft gear (C) is 0.067 ~ 0.211 mm.
camshaft gear engravings (H). 5) The standard backlash between the idle gear and
Note)Position the idle gear engraving (B) between the the injection pump drive gear (D) is 0.087 ~ 0.2
injection pump drive gear engravings (A). mm.
Note)You can see one idle gear engraving (K) and two
injection pump drive gear engravings (J).
3. Mount the timing gear case. and the idle gear

and oil pump drive gear

and the camshaft gear

and injection pump drive gear
3. Mount the timing gear case.
13 - 16
Check of Gear Axial Offset

1. Remove the timing gear case. The axial offset
0.100 ~ 0.300 mm
of the idle gear
2. Check the gear axial offset. The axial offset
0.1 ~ 0.2 mm
of the idle gear
The axial offset
0.1 ~ 0.2 mm
of the idle gear
3. Mount the timing gear case.
EDL022139A
1) Mount the dial gauge on the cylinder block.

2) Press the crankshaft gear (A) into the cylinder
block direction.
3) Perform the zero point adjustment of the dial
gauge based on the crankshaft gear (A).
4) Pull the crankshaft gear (A) and check the
measured value of the dial gauge.
Note)The axial offset of the crankshaft gear is 0.100 ~

0.300 mm.
5) Press the camshaft gear (B) into the cylinder block

direction.
gauge based on the camshaft gear (B).
7) Pull the camshaft gear (B) and check the
measured value of the dial gauge.
Note)The axial offset of the camshaft gear is 0.1 ~ 0.2

mm.
8) Press the idle gear (C) into the cylinder block

direction.
gauge based on the idle gear (C).
10) Pull the idle gear (C) and manually measured
value of the dial gauge.
Note)The axial offset of the idle gear is 0.1 ~ 0.2 mm.
13 - 17

D24NAP

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D24NAP

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D24NAP

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Table of contents

2. Operation and Management...................................................................................................2-3

3. Performance and Specifications ...........................................................................................3-3

6. About the engine.....................................................................................................................6-3

8. Lubrication System................................................................................................................ 8-3

9. Fuel System............................................................................................................................ 9-3

10. Intake/Exhaust System.......................................................................................................10-3

11. Cylinder block/head ............................................................................................................11-3

13. Others/Driving System .......................................................................................................13-3

General Information....................................... 1-3

Danger, Warning, Caution, and Note ............ 1-4

Engine Management ..................................... 1-7

Danger, Warning, Caution, and Note

Cautions for Inspection and Repair

General Instructions 1. Inspection and repair of engine should be

9. Only appropriate tools should be used. If the jaws

WARNING 5. Use specified and special tools for efficient and

12. Assemble bolts and nuts with the specified

have been successfully completed. mechanically harmonized. To prevent engine faults in

1. Good ventilation and low humidity should be

CAUTION Prevention of Pollution

1. Discharge oil and coolant using collection

Handling of Engine Oil

1. Do not expose skin to new engine oil for a long

Starting and Stopping of the Engine.............. 2-3

Break-in Period of the Engine ....................... 2-4

Operation in Winter ....................................... 2-6

Inspection and Repair of the Engine ............. 2-7

Operation and Management

Starting and Stopping of the Engine

starter motor until oil flows out. After completing

3. Be careful not to mix foreign substances in fuel,

Starting the Engine serious engine damage. As such, if noises or

Break-in Period of the Engine

General Information 2. If the oil indicator lamp on the apparatus is turned

5. Operate the engine with less than 70 % of the

1. Periodically check if the engine oil level is between

Inspection after Starting the Engine

1. Tightly connect the +/- terminals to prevent gaps

Engine Oil Pressure

Revolutions per Minute (rpm)

Cold Start Preventing Overcooling of the Engine

Note) If the key is turned to 'Start', the air heater is

3. After starting the engine, the key switch changes

Preventing Coolant from Freezing.

Inspection and Repair of the Engine

Checking Engine Parts after Prolonged Intake Unit

parts after normal operation of the engine, when

1. Parts affecting intake and exhaust

Inspection and Repair of Supercharger

Engine Specifications and Performance .........3-3

Outside Drawing of the Engine (DL02-LEE00,

Outside Drawing of the Engine (DL02-LEL00,

Outside Drawing of the Engine

Outside Drawing of the Engine

Engine Identification Number .......................3-30

Performance and Specifications

Engine Specifications and Performance

Total 9.2L (Including 0.6L in the engine)