D34nap SCR
D34nap SCR
D34nap SCR
This Operation and Maintenance Manual provides information on engine management and maintenance techniques to
customers and technicians of Doosan Infracore's DL03-LEF00/LEF01/LEF02/LEF03/LEF04/
LEL00/LEL01/LEL02/LEL03/LEL04 electronically controlled industrial diesel engine.
To provide the best engine to our customers, the DL03-LEF00/LEF01/LEF02/LEF03/LEF04/
LEL00/LEL01/LEL02/LEL03/LEL04 electronically controlled industrial diesel engine is designed to satisfy all requirements
for low noise, economic fuel consumption, high speed and durability with the latest technology and quality.
Exact operation and proper maintenance are essential for operating engines for an extended time with optimum conditions and best performance. This Operation and Maintenance Manual provides detailed descriptions of specifications,
specified values, defect diagnosis, component diagrams, and drawings for easier and more precise understanding of
the product and for proper maintenance and troubleshooting.
With the help of the recommended operation methods and procedures, high-level maintenance techniques and safety
of workers can be ensured. Please read and understand this manual before working with our engines.
To ensure best performance and quality as well as to enhance maintenance techniques, Doosan Infracore is doing it's
best to continuously develop and invest. The design of our product may be changed without prior notice and Doosan
shall not be held liable for the failure of this manual to contain all the design changes made to improve the product.
We, Doosan Infracore, do our best to provide more convenient and safe maintenance techniques and to meet the
requirements of our customers.
If you have any questions or find any errors in this Operation and Maintenance Manual, please do not hesitate to
contact us.
Thank you for purchasing our engine and we hope this Operation and Maintenance Manual be helpful for you.
2014.06.
950106-014978
Doosan Infracore
* The contents included in the Operation and Maintenance Manual are property of Doosan Infracore. It is forbidden to
copy, print or distribute this manual without prior permission.
Table of contents
1. General introduction ............................................................................................................... 1
General information .................................................................................................................................. 3
Danger, warning, caution, and note ....................................................................................................... 4
Engine maintenance ................................................................................................................................. 7
1. General introduction
Danger, warning, caution, and note ..................................................................................3
General Information .................................................................................................................................... 3
1. General introduction
General information
General Information
This Operation and Maintenance Manual provides the
most efficient methods for engine maintenance as well as
quick, efficient methods to determine the cause of engine
faults to ensure that any actions taken by professionally
certified maintenance technicians are done in the most
efficient and efficient way possible. If maintenance is
performed by unskilled technicians, or maintenance
without the specified tools and facilities, serious bodily
injury or critical faults in engine performance may occur.
Regular inspection and maintenance are required to maintain long-term optimal engine conditions and best performance. In the event that a part must be replaced, only
genuine parts as defined by the parts the list (PARTS
BOOK) should be used. Doosan shall not be held liable
for any critical damage or faults which may be caused
by the use of unauthorized or remanufactured parts.
The maintenance methods stated in this Operation and
Maintenance Manual are the most efficient and safest
work procedures. Some work procedures require special
tools.
For questions about genuine parts and special tools,
please contact us.
This Operation and Maintenance Manual includes
'Danger,' 'Warning,' and 'Caution' in order to reduce
possible injuries and engine faults which may occur while
performing maintenance. If workers do not follow the
instructions, critical faults in engine performance and
operation or serious bodily injury may occurred. 'Danger,'
'Warning,' and 'Caution' instructions must be followed.
However, we inform you that it is not possible to describe
all possible and unexpected dangers which may arise
while performing engine maintenance.
1. General introduction
Danger, warning, caution, and note
General Information
causes of pollution.
WARNING
immediately.
DANGER
may occur.
WARNING
of workers or others.
CAUTION
engine is in operation.
General Instructions
tions.
DANGER
When accessories such as necklaces, rings,
watches, or gloves become stuck in rotating parts
while the engine is running, serious bodily injury
may occur.
1. General introduction
11. Before inspecting or replacing the electrical apparatus,
WARNING
bodily injuries.
engine oil.
the ECU.
General Repair
WARNING
engine.
hot, hot water will spurt out and may cause burns.
engine.
circuit.
3. Engine oil and coolant may damage paint and should
WARNING
repair.
coolant.
engine performance.
7. Replace parts such as cotter pins, gaskets, O-rings,
WARNING
these characteristics.
1. General introduction
12. Assemble bolts and nuts with the specified tightening
torque.
liable.
WARNING
Failure to observe the regulations of the relevant
authorities violates environmental pollution regulations and may be subject to legal penalties.
1. General introduction
Engine maintenance
Prevention of damage and abrasion
normal status.
9. Do not operate engine without coolant.
CAUTION
rization.
Use of genuine parts is recommended. Using unauthorized or remanufactured parts may cause critical damage
and faults to engine for which Doosan shall not be held
Prevention of Pollution
liable.
environmental pollution.
Manual.
CAUTION
Doosan.
3. Always keep surroundings of the engine clean.
nance manual.
rules:
WARNING
solvent.
hot, hot water will spurt out and may cause burns.
CAUTION
Immediately replenish engine oil when the engine oil
level is below the lower limit of the engine oil gauge.
1. General introduction
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.
10
Check the following before starting the engine for the first
lower limit of the oil level gauge. The upper and lower
2. Oil, air, or gas leaks may lower the oil pressure. Additionally, oil leaks may cause burning of bearings. As
CAUTION
During Operation
cause leaks.
the fluid clean while it is not in use. Use fuel, oil, and
the bearing part, the bearing metal and rotating shaft may
11
CAUTION
RPM.
period.
CAUTION
load.
by Doosan.
Check Points
engine.
gauge.
CAUTION
the oil level gauge, rotate the oil level gauge to 180
again to check.
12
Coolant Temperature
Operating an engine with insufficient coolant temperature
increases fuel consumption, abrasion of the cylinder liner,
shortening the engine's life span.
13
cation oil.
CAUTION
lamp.
from freezing.
engine.
the cooler.
Engine Oil
engine. To prevent this, replace the oil with engine oil for
air heater.
ON.
CAUTION
As the ECU heats the intake air for about 180
seconds after starting the engine, the white exhaust
gas is reduced quickly.
14
Intake Unit
If oil level of the wet air filter is below the specified level,
the oil level is higher, oil may flow into the case, and it
intake of air.
Exhaust Unit
ture, be careful not to mix the bolts and nuts with other
and inspections.
Lubrication system
inspected.
affect not only the engine itself, but also the engine
performance.
Air filter
Intercooler
Supercharger, silencer
Other parts
Air filter
Oil filter
Antifreeze
Other parts
15
16
17
18
DL03LEF00
DL03LEF01
DL03LEF02
DL03LEF03
Remarks
General Information
4-stroke series, water-cooled,
turbocharging and air cooling type
Engine types
Combustion chamber type
Direct injection
No liner
Number of cylinders
Cylinder bore
98 mm
Cylinder stroke
113 mm
Total displacement
3,409 cc
Compression ratio
17.0:1
Engine Dimension (L x W x H)
Engine weight
300 Kg
Direction of rotation
Counter-clockwise
Firing order
1 - 3 - 4 - 2
Cooling system
Cooling Type
Water-forced cooling
Capacity of coolant
4.7 L
Type
Water pump
Driving Type
Ribbed-Belt driven
Pump Speed
2,760 rpm
Drive Ratio
(Engine speed:Pump
speed)
1 : 1.2
Flow Rate
0.8 bar
Type
Cooling fan
Driving Type
Blow Type
Fan Bracket direct connection
Rotation Ratio
(Engine RPM: fan RPM)
1:1
19
DL03LEF00
Type
Thermostat
Coolant Temperature
Sensor
Water Temperature
Sensor
Radiator Cap
DL03LEF01
DL03LEF02
DL03LEF03
Valve-opening temperature
82 C
97 C
Lift
8 mm
Type
Resistance (at 20 C)
2.5k
0.148k
0.9 kg/cm2
Lubrication System
Lubricating type
Oil Pressure
1.0 kg/cm2
Oil Capacity
Oil Class
Total
Max.
12.6 L
Min.
6.0 L
35 / 35 / 35 / 35
Type
Gear type
Oil pump
Driving Type
Oil coolant type
Type
Oil filter
Allowable temperature
-40C ~ 140C
Flow
36 L/min
Lubrication indicator
Hydraulic indicator
Fuel System
Fuel injection pump type
Control type
E.C.U (DELPHI)
20
Remarks
DL03LEF00
DL03LEF02
DL03LEF03
Remarks
Injection nozzle
DL03LEF01
1,800 bar
Spin-on type
Intake/Exhaust System
Model
BorgWarner WGT
Driving Type
Lubricating type
2.22 kgfcm 2
At max. output
Air intake
133.6 g/s
At max. output
Turbine Speed
161 krpm
At max. output
194 krpm
750 C
Weight
4.3 kg
Intake valve
0.4 mm
When cold
Exhaust valve
0.45 mm
When cold
Open (BTDC)
16
Closed (ABDC)
54
Open (BBDC)
38
Closed (ATDC)
24
Valve gap
Intake valve
Exhaust valve
Intake
108.3 mm
Exhaust
110.3 mm
Valve length
Intake
6.97 0.007 mm
Exhaust
6.96 0.007 mm
Intake
7 ~ 7.015 mm
Exhaust
7 ~ 7.015 mm
43.4 ~ 43.6 mm
Exhaust
43.4 ~ 43.6 mm
Intake
2.14 mm
Exhaust
1.63 mm
21
DL03LEF00
DL03LEF01
DL03LEF02
Intake
44.5 ~ 45.0
Exhaust
44.5 ~ 45.0
DL03LEF03
Remarks
55.23 mm
2 and under (less than 1.8 mm)
0.05 mm
0.03 mm / 100 mm
0.05 mm / 100 mm
Intake
39.078 mm
Exhaust
38.716 mm
Camshaft height
Intake
44.95 ~ 44.966 mm
Exhaust
44.95 ~ 44.966 mm
0.065 ~ 0.106 mm
0.1 ~ 0.2 mm
97.99 ~ 98.01 mm
0.05 mm
0.03 mm / 100 mm
Electric apparatus
Engine control type
24 V, 5.0 kW
Pinion gear
11
12 V, 2.7 kW
11
Terminal voltage
23 V
11 V
No-load characteristics
Max. current
100 A
200 A
No-load characteristics
3,000 rpm
2,550 rpm
No-load characteristics
Starter
Min. speed
Others/Driving System
0.060 ~ 0.080 mm
2.415 ~ 2.445 mm
2.060 ~ 2.080 mm
3.020 ~ 3.040 mm
22
DL03LEF00
DL03LEF01
DL03LEF02
0.083 ~ 0.137 mm
0.070 ~ 0.110 mm
0.030 ~ 0.070 mm
0.20 ~ 0.40 mm
0.55 ~ 0.70 mm
0.2 ~ 0.4 mm
35.995 ~ 36,000 mm
36.008 ~ 36.014 mm
0.008 ~ 0.019 mm
36.025 ~ 36.038 mm
0.025 ~ 0.043 mm
66,000 ~ 66.015 mm
0.026 ~ 0.064 mm
0.15 ~ 0.3 mm
74.955 ~ 74.970 mm
62.955 ~ 62.970 mm
0.029 ~ 0.059 mm
0.1 ~ 0.31 mm
23
DL03LEF03
Remarks
Specifications
Item
DL03LEL00
DL03LEL01
DL03LEL02
DL03LEL03
DL03LEL04
Remarks
General Information
4-stroke series, water-cooled,
turbocharging and air cooling type
Engine types
Combustion chamber type
Direct injection
No liner
Number of cylinders
Cylinder bore
98 mm
Cylinder stroke
113 mm
Total displacement
3,409 cc
Compression ratio
17.0:1
Engine Dimension (L x W x H)
Engine weight
300 Kg
Direction of rotation
Counter-clockwise
Firing order
1 - 3 - 4 - 2
Cooling system
Cooling Type
Water-forced cooling
Capacity of coolant
4.7 L
Type
Water pump
Driving Type
Ribbed-Belt driven
Pump Speed
2,880 rpm
Drive Ratio
(Engine speed:Pump
speed)
1 : 1.2
Flow Rate
0.8 bar
Type
Cooling fan
Sucker Type
Driving Type
Hydraulic Drive
Rotation Ratio
(Engine RPM: fan RPM)
Variable
24
DL03LEL00
DL03LEL01
Type
Thermostat
Coolant Temperature
Sensor
Water Temperature
Sensor
DL03LEL02
DL03LEL03
DL03LEL04
Valve-opening temperature
82 C
97 C
Lift
8 mm
Type
Resistance (at 20 C)
2.5k
0.148k
0.97 kg/cm2
Lubrication System
Lubricating type
Oil Pressure
1.0 kg/cm2
Oil Capacity
Oil Class
Total
Max.
12.6 L
Min.
6.0 L
35 / 35 / 35 / 35
Type
Gear type
Oil pump
Driving Type
Oil coolant type
Type
Oil filter
Allowable temperature
-40C ~ 140C
Flow
36 L/min
Lubrication indicator
Hydraulic indicator
Fuel System
Fuel injection pump type
Control type
E.C.U (DELPHI)
25
Remarks
DL03LEL00
DL03LEL02
DL03LEL03
DL03LEL04
Remarks
Injection nozzle
DL03LEL01
1,800 bar
Spin-on type
Intake/Exhaust System
Model
BorgWarner WGT
Driving Type
Lubricating type
2.22 kgfcm2
At max. output
Air intake
133.6 g/s
At max. output
Turbine Speed
161 krpm
At max. output
194 krpm
750 C
Weight
4.3 kg
Intake valve
0.4 mm
When cold
Exhaust valve
0.45 mm
When cold
Open (BTDC)
16
Closed (ABDC)
54
Open (BBDC)
38
Closed (ATDC)
24
Valve gap
Intake valve
Exhaust valve
Intake
108.3 mm
Exhaust
110.3 mm
Valve length
Intake
6.97 0.007 mm
Exhaust
6.96 0.007 mm
Intake
7 ~ 7.015 mm
Exhaust
7 ~ 7.015 mm
43.4 ~ 43.6 mm
Exhaust
43.4 ~ 43.6 mm
Intake
2.14 mm
Exhaust
1.63 mm
26
DL03LEL00
DL03LEL01
DL03LEL02
DL03LEL03
Intake
44.5 ~ 45.0
Exhaust
44.5 ~ 45.0
DL03LEL04
55.23 mm
2 and under (less than 1.8 mm)
0.05 mm
0.03 mm / 100 mm
0.05 mm / 100 mm
Intake
39.078 mm
Exhaust
38.716 mm
Camshaft height
Intake
44.95 ~ 44.966 mm
Exhaust
44.95 ~ 44.966 mm
0.065 ~ 0.106 mm
0.1 ~ 0.2 mm
97.99 ~ 98.01 mm
0.05 mm
0.03 mm / 100 mm
Electric apparatus
Engine control type
Others/Driving System
Grade A: 97.920 ~ 97.930 mm
Grade B: 97.930 ~ 97.940 mm
0.060 ~ 0.080 mm
2.415 ~ 2.445 mm
2.060 ~ 2.080 mm
3.020 ~ 3.040 mm
0.083 ~ 0.137 mm
0.070 ~ 0.110 mm
0.030 ~ 0.070 mm
0.20 ~ 0.40 mm
0.55 ~ 0.70 mm
0.2 ~ 0.4 mm
27
Remarks
DL03LEL00
DL03LEL01
DL03LEL02
DL03LEL03
35.995 ~ 36,000 mm
36.008 ~ 36.014 mm
0.008 ~ 0.019 mm
36.025 ~ 36.038 mm
0.025 ~ 0.043 mm
66,000 ~ 66.015 mm
0.026 ~ 0.064 mm
0.15 ~ 0.3 mm
74.955 ~ 74.970 mm
62.955 ~ 62.970 mm
0.029 ~ 0.059 mm
0.1 ~ 0.31 mm
28
DL03LEL04
Remarks
Model
Performance
Product code
Output
(kW/rpm)
Torque
(Nm/rpm)
Idle at high
speed
(rpm)
DL03-LEF00
110/2,400
38.23/1,600
800 25
2,500 25
DL03-LEF01
100/2,300
34.96/1,600
800 25
2,500 25
DL03-LEF02
100/2,300
34.96/1,600
800 25
2,500 25
DL03-LEF03
75/2,300
33.65/1,400
800 25
2,500 25
D34NAP
29
12
1
11
2
10
9
4
5
8
6
7
13
14
26
15
25
24
16
23
20
22
17
18
19
21
EDL032143E
1. Turbocharger
8. Crankshaft pulley
2. Exhaust manifold
9. Generator bracket
3. EGR cooler
4. Starter
5. Water pump
12. Thermostat
13. Injector
7. Oil pan
21. Flywheel
30
11
12
1
10
9
2
8
4
6
5
20
19
21
18
13
17
14
16
15
EDL032144E
1.
8.
Idle pulley
15. Flywheel
2.
9.
Eye bolt
3.
Cylinder block
4.
Starter
18. Turbocharger
5.
Oil pan
6.
Crankshaft pulley
7.
Generator bracket
31
10
1
2
3
5
12
22
21
13
14
15
16
20
17
18
19
EDL032145E
1. Heat screen
7. Thermostat
2. Exhaust manifold
8. Turbocharger
3. EGR cooler
4. Starter
5. EGR Valve
(Injector-injection pump)
6. Water pump
32
19
18
17
1
2
16
15
4
5
14
6
7
13
8
12
11
10
20
23
21
22
EDL032146E
1. Idle pulley
7. Oil gauge
13. Injector
2. Generator bracket
8. Air heater
14. Turbocharger
3. Eye bolt
9. Intake manifold
15. Thermostat
4. Common Rail
10. Breather
23. Starter
6. Oil filter
33
12
1
11
2
10
9
4
5
8
6
7
13
14
26
25
15
24
16
23
20
22
18
17
21
19
EDL032143F
1. Turbocharger
8. Crankshaft pulley
2. Exhaust manifold
9. Generator bracket
3. EGR cooler
4. Starter
5. Water pump
12. Thermostat
13. Injector
7. Oil pan
21. Flywheel
34
12
11
10
9
2
7
3
8
14
4
6
5
20
21
19
13
18
17
16
15
EDL032144F
1.
8.
Idle pulley
15. Flywheel
2.
9.
Eye bolt
3.
Cylinder block
4.
Starter
18. Turbocharger
5.
Oil pan
6.
Crankshaft pulley
7.
Generator bracket
35
10
1
2
3
5
12
22
21
13
14
17
20
16
15
18
19
EDL032145F
1. Heat screen
7. Thermostat
2. Exhaust manifold
8. Turbocharger
3. EGR cooler
4. Starter
5. EGR Valve
(Injector-injection pump)
6. Water pump
36
19
18
1
2
17
3
16
15
5
14
8
13
7
9
12
10
11
23
20
21
22
EDL032146F
1. Idle pulley
7. Oil gauge
13. Injector
2. Generator bracket
8. Air heater
14. Turbocharger
3. Eye bolt
9. Intake manifold
15. Thermostat
4. Common Rail
10. Breather
23. Starter
6. Oil filter
37
1
2
7
4
5
9
22
10
21
20
11
12
19
13
14
15
18
16
17
EDL032143G
1. Thermostat
7. Crankshaft pulley
2. Turbocharger
3. EGR cooler
9. Injector
4. Water pump
6. Oil pan
38
4
15
14
13
12
10
11
EDL032144G
1.
6.
Air heater
2.
7.
Coolant hose
3.
Cylinder block
8.
13. Turbocharger
Oil filter
4.
Oil pan
9.
5.
Crankshaft pulley
39
7
1
21
11
20
12
13
14
15
19
16
10
17
18
EDL032145G
1. Heat screen
7. Turbocharger
2. Exhaust manifold
3. EGR cooler
4. EGR Valve
(Injector-injection pump)
5. Water pump
6. Thermostat
40
14
13
12
1
11
2
3
10
9
15
16
17
EDL032146G
1. Common Rail
6. Breather
11. Thermostat
7. Breather hose
3. Oil filter
8. Exhaust manifold
4. Air heater
9. Injector
5. Intake manifold
10. Turbocharger
41
EDL022165B
1. Name(6-digit)
2. Year(1-digit)
EDL032164F
DL03-LEF02/03
EDL032164G
DL03-LEL00/01/02/
03/04
EDL032213A
EDL032164E
42
B
EDL032214C
EDL032216B
connecting rod.
EDL022217A
A
EDL032215D
43
EDL032218C
Cyl. #1
Cyl. #2
Cyl. #3
Cyl. #4
EDL022219A
44
4. Regular inspection
General information ...........................................................................................................47
General Information .................................................................................................................................. 47
Routine Inspection .................................................................................................................................... 47
46
4. Regular inspection
General information
General Information
CAUTION
be maintained.
accidents in advance.
those parts.
Routine Inspection
performing an inspection.
engine.
engine.
DANGER
an engine or not.
Individuals who use a mechanical heart or artificial internal organ should not enter the area near
an engine while it is running. The high-voltage
current of the injectors or ECU may cause
abnormal operation of such equipment.
47
4. Regular inspection
Regular inspection table
General Conditions
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
Lubrication system
Lubricating device and oil leakage
Fuel system
Fuel line and connection unit
Fuel volume
Fuel filter
Fuel injection time
Injector
Compression pressure
Intake/Exhaust system
Air cleaner
Emission state
Cylinder head
Intake/Exhaust valve gap state
48
4. Regular inspection
Inspection interval (x 1,000 hours)
Check Points
Daily
0.5
1.0
1.5
2.0
2.5
Electric system
Battery charging state
49
3.0
3.5
4.0
4.5
5.0
4. Regular inspection
Cooling system
General Information
DANGER
freezing and anticorrosion of the coolant degrades. Maintain the condition of the coolant through daily inspections
For the water in the coolant, use clean tap water. Peri-
antifreeze.
CAUTION
the cooler.
Coolant standards
Coolant (C)
Antifreeze (%)
Above -10
85
15
-10
80
20
-15
73
27
-20
67
33
-25
60
40
-30
56
44
-40
50
50
DANGER
If the surge tank cap is opened to exchange or
replenish coolant while the engine is overheated, hot
water will spurt out and may cause serious burns.
If it is absolutely necessary to open the surge tank
cap while the engine is overheated, wrap the surge
Capacity of coolant
DL03-LEF00/LEF01/LEF02/
LEF03
4.7
DL03-LEL00/LEL01/LEL02/
LEL03/LEL04
4.7
50
4. Regular inspection
4. If there is insufficient coolant, replenish it.
Special Tools
Figure
Product Number/Name
60.99901-0038
Coolant test sheet
C)
B)
EDL0213002A
A)
follows.
table.
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.
TEST
2. Soak the test sheet in the coolant and take it out after
SERVICE
PRE CHARGE
CAUTION
EDL022154A
51
4. Regular inspection
2) The state of additives for anticorrosion is shown on
CAUTION
CAUTION
CAUTION
coolant as follows.
1. Remove the surge tank cap while the engine and radi-
CAUTION
3. After starting the engine let the coolant circulate sufficiently and check the coolant level. If there is insuffi-
are cold.
52
4. Regular inspection
5. Install the surge tank cap.
CAUTION
cooled.
the air from inside of the radiator and slowly fill the
CAUTION
Replacement of Coolant (Only
LEF00/LEF01/LEF02/LEF03)
DANGER
tions.
cooled sufficiently.
immediately.
CAUTION
times.
15. Replenish coolant to the upper limit of the supplemen-
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
drain coolant.
days.
CAUTION
cap.
Note) Slowly pour coolant in to let the air be discharged
days.
53
4. Regular inspection
11. Repeat the above mentioned processes from 1 to 8
WARNING
the air from inside of the radiator and slowly fill the
CAUTION
turers.
tions.
DANGER
by us.
immediately.
CAUTION
2 ~ 3 times.
17. Stop the engine and wait until the engine and the
1. Make sure that engine and radiator are cooled.
drain coolant.
CAUTION
7. Fill the surge tank inlet with water and install surge
tank cap.
Note) Slowly pour coolant in to let the air be discharged
from radiator and press the hose connected to it
to discharge the air inside.
8. Start the engine to let the cooling fan rotate 2 or 3
times. When the engine is warmed up, increase the
engine RPM two or three times.
9. Stop engine and wait until engine is cooled.
10. Remove the radiator drain plug and drain water.
54
4. Regular inspection
WARNING
Discard exchanged coolant according to the regulations set forth by the relevant authorities. Disposing
of exchanged coolant into the ground, sewers,
drains, rivers, or the sea will cause serious environmental pollution. Violation of regulations regarding
discard of engine oil without observing the handling
regulations, will be punished.
55
4. Regular inspection
Lubrication system
General Information
Engine oil lubricates, cools, seals, prevents corrosion, and
cleans engines, enhancing engine performance and
extending the engine's lifetime. If a vehicle is continuously
driven while engine oil is insufficient, the moving parts of
the engine may get stuck, causing engine faults.
Engine oil should be checked through the oil level gauge
and replenished if required. Oil level should be checked
while the engine is stopped. To check the oil level, turn
off the engine while it is running and wait for 5 ~10
minutes to allow the engine oil to flow back into the oil
pan. The engine oil level should indicate between the
upper limit and the lower limit of the oil level gauge.
Engine oil should be periodically replaced based on the
regular inspection table and the oil filter and the cartridge
should be replaced as the engine oil is replaced.
56
4. Regular inspection
Engine oil standards
Use the specified engine oil suitable for the environment
and conditions of the site where the engine will be used.
SAE 10 W-30
SAE 5 W-30
SAE 0W-30
Ambient
temperature
SAE 0W-40
SAE 5W-40
SAE 10W-40
SAE 15W-40
EDL0213001D
Please use the engine oil which satisfies the following recommended specifications.
Engine Model
Oil Class
DL03-LEF00/LEF01/LEF02/LEF03
API CJ-4
(ACEA-E9)
DL03-LEL00/LEL01/LEL02/LEL03/LEL04
API CJ-4
(ACEA-E9)
57
4. Regular inspection
Engine Oil Capacity
DL03-LEF02/03
Min.
DL03LEF00/LEF01/
LEF02/LEF03
12.6
6.0
13.6
DL03-LEL00/L
EL01/LEL02/L
EL03/LEL04
12.6
6.0
13.6
EDL032158D
DL03-LEL00/01/02/
03/04
DL03-LEF00/01
EDL032158E
2) The oil level gauge (A) is next to the oil filter at the
side of the engine.
3) Pull the hook of the oil level gauge (A) with your
fingers.
5. Clean the pointer of the oil level gauge with a clean
cloth.
CAUTION
EDL032158C
58
4. Regular inspection
6. Put the oil level gauge (A) back in.
7. Pull the oil level gauge out again to check level and
condition of the oil.
DL03-LEF00/01
A
B
EDL032158C
EDL022152A
DL03-LEF02/03
CAUTION
Be careful not to let foreign substances flow into the
EDL032158D
EDL032158E
1) Hold the hook of the oil level gauge (A) and put it
back in.
EDL032159C
2) If the oil level gauge does not fit in, turn the gauge
180 and then try again.
59
4. Regular inspection
3. Complete engine oil replenishment and cover the oil
cap.
DL03-LEF02/03
Special Tools
Figure
Product Number/Name
860104-03241
Wrench, Oil Filter
EDL032159D
DL03-LEL00/01/02/
03/04
Tightening Torque
Component
Tightening Torque
Drain plug
3.0 kgfm
Oil capacity
Engine oil capacity ( )
Engine Model
Min.
DL03-LEF00/L
EF01/LEF02/L
EF03
12.6
13.6
DL03-LEL00/L
EL01/LEL02/L
EL03/LEL04
12.6
13.6
EDL032159E
DANGER
time.
CAUTION
or solvent.
60
4. Regular inspection
WARNING
A
DL03-LEL00/01/02/
03/04
CAUTION
B
When exchange the New Oil filter, Please dispose of
EDL032160G
engine oil.
2) Remove the drain plug (B) and drain the engine oil.
DL03-LEF00/01
EDL032160E
DL03-LEF02/03
EDL032161C
DL03-LEF02/03
EDL032160F
EDL032161D
61
4. Regular inspection
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
B
EDL032160F
EDL032161E
1) Remove the oil filter (A), using the Wrench, Oil Filter.
CAUTION
DL03-LEL00/01/02/
03/04
EDL032160G
by hand.
of 3.0 kgfm.
DL03-LEF00/01
B
EDL032160E
62
4. Regular inspection
4) Check the level of engine oil with the oil level gauge.
CAUTION
Exceeding the upper limit of the oil level gauge may
cause engine faults. If you have exceeded the upper
limit of the oil gauge, drain it until the engine oil
level is indicated between the upper limit and the
lower limit of the oil level gauge.
63
4. Regular inspection
Fuel system
General Information
Fuel Ingredients
Standard
lation Point
CAUTION
Below360
Fuel filter
Fuel Standards
To maintain the optimum engine performance, refer to the
CAUTION
Fuel Ingredients
Specific Gravity
Standard
(C)
Above 40
(cSt)
1.9 ~ 5.5
(wtppm)
Below15
Sulfur Content
Cloud Point
(C)
Pour Point
(C)
Below-17.5
(C)
Below-16
Color (ASTM)
Below 2.5
(%)
Below0.15
(mg
KOH/g)
Below0.40
Below 1
(mass %)
Below0.01
(vol. %)
Below0.02
Above 45
64
4. Regular inspection
Replacement of Fuel Filter
EDL032813C
EDL032813A
CAUTION
in it.
to a new fuel filter.
4. Apply oil to the gasket.
EDL032813B
EDL032813D
65
4. Regular inspection
Air bleeding in the fuel circuit
EDL032813E
EDL032814A
EDL032813A
EDL032815A
(B).
66
4. Regular inspection
3. Bleed air out of the fuel delivery line.
A
B
EDL032815C
EDL032818A
filter.
CAUTION
Do not use tools to loosen the drain valve. Use of
tools may damage the drain valve.
2. Drain the fuel filter.
EDL032815B
A
A
H2O
EDL032818B
EDL032814B
67
4. Regular inspection
1) Discharge water from the fuel filter through the drain
valve (A) for about 10 seconds.
CAUTION
Drain the water from the fuel filter if the fuel filter
alarm lamp is turned on. Otherwise, moisture may
flow into the fuel unit, causing the engine to stop.
EDL032807G
CAUTION
Do not use tools to loosen the drain valve. Use of
tools may damage the drain valve.
68
4. Regular inspection
Intake/exhaust system
General Information
bars.
CAUTION
DANGER
faults.
minutes.
CAUTION
Never use steam spray, gasoline, alkali or hot
cleansing solution to cleansing the element.
EDL022155A
69
4. Regular inspection
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.
EDL022157A
CAUTION
Do not let dust get inside the air filter end.
1. Remove the fixed parts.
2. Remove the damaged or contaminated element.
3. Thoroughly cleanse the contact surface of the sealing
ring and the inside of the filter housing.
4. Assemble a new element.
5. Attach the fixed parts again.
70
4. Regular inspection
Cylinder block/head
Adjustment of Valve Gap
CYL. No
# 1
# 2
Rotation angle
# 4
E
360 Rotation
# 3
EDL032822A
CAUTION
3) Loosen the hex nut (C) and tighten the adjust screw
(D) to adjust the valve gap.
4) Check the valve gap between the caliper (A) and the
adjust screw cap (B) with the gap gauge.
5) The intake valve gap is 0.4 mm and the exhaust valve
gap is 0.45 mm.
Item
Specified Value
0.4 mm
0.45 mm
71
4. Regular inspection
Others/driving system
Belt tension
1. Inspection condition
1) Check the belt for crack, oil residue, deformation by
2) Tension measurement
Tension (kgf)
EDL022140A
20 - 27
27 - 36
34 - 45
41 - 57
48 - 66
59 - 73
3)
*S= C
(D - d)
2
D
C
B
C
EDL022142A
B
EDL022141A
72
.................................................................................................... 78
73
74
Item
Number
SI Unit
US Unit
Power
1.340483
kw
Hp
0.01
kPa
bar
7.500615
kPa
mmHg
20.88543
kPa
lb/ft2
14.2233
psi
kg/cm 2
1.3596
kw
PS
0.98635
ps
hp
0.00162
g/kwh
lb/psh
0.000947817
BTU
0.7375621
lbfft
0.0002777778
Wh
Luminous Flux
0.09290304
lm/m2
lm/ft2
Speed
0.6213712
km/h
mph
Temperature
Pressure
Number
SI Unit
US Unit
0.03937
mm
in
3.28084
ft
1.093613
yd
0.621371
km
mile
0.00155
mm 2
in2
0.1550
cm2
in2
10.76391
m2
ft2
1.19599
m2
yd2
2.204623
kg
lb
0.001
kg
t (ton)
0.061024
cc
in3
0.061024
ml
in3
0.061024
cm3
in3
61.023744
in3
0.264172
gal
2.204622
kgf
lbf
0.2248089
lbf
3.28084
m/s2
ft/s2
39.37008
m/s2
in/s2
7.233014
kgfm
lbfin
86.79619
kgfm
lbfin
0.7375621
Nm
lbfft
8.850748
Nm
lbfin
Fuel Consumption
Length
Energy
Area
Weight
Volume
Forcea
Acceleration
Torqueb
75
Main Parts
Nominal
(Diameter X Pitch)
Tensile
Strength
Rank
Tightening Torque
Remarks
M12x1.5x133
12.9T
M12x1.25x29
9.8T
M9x1.0x66
10.9T
M14x1.5
10.9T
26 kgfm 1 kgfm
Flywheel Bolt
M12x1.5
10.9T
M6x1.0
8.8T
M6x1.0
8.8T
M8x1.25
12.9T
4.35 kgfm
0.35
kgfm
M8x1.25
8.8T
2.2 kgfm
10%
Generator Bolt
M8x1.25
8.8T
2.2 kgfm
10%
M10x1.0
2.0 kgfm
10%
UNF 3/4-16
3.0 kgfm
10%
M8x1.25
2.2 kgfm
10%
M8x1.25
2.2 kgfm
10%
M8x1.0
1.5 kgfm
10%
M14x1.5
M8x1.25
2.2 kgfm
10%
Generator Nut
M8x1.25
2.2 kgfm
10%
M10x1.5
4.4 kgfm
10%
Union Nut
2.0 kgfm
10%
Union Nut
76
Nominal
(Diameter X Pitch)
Tensile
Strength
Rank
Union Nut
Union Nut
Main Parts
CAUTION
It is vary in torque according to the engine model
or parts.
77
Tightening Torque
Remarks
Nominal
Diameter
Pitch
(mm)
3.6
4.6
4.8
5.6
5.8
6.6
6.8
6.9
8.8
10.9
12.9
(4A)
(4D)
(4S)
(5D)
(5S)
(6D)
(6S)
(6G)
(8G)
(10K)
(12K)
54
64
90
106
24
32
30
40
36
46
0.15
0.16
0.25
0.22
0.31
0.28
0.43
0.48
0.5
0.75
0.9
M6
0.28
0.30
0.45
0.4
0.55
0.47
0.77
0.85
0.9
1.25
0.5
M7
0.43
0.46
0.7
0.63
0.83
0.78
1.2
1.3
1.4
1.95
2.35
M8
0.7
0.75
1.1
1.4
1.25
1.9
2.1
2.2
3.1
3.8
M8 X 1
0.73
0.8
1.2
1.1
1.5
1.34
2.1
2.3
2.4
3.35
4.1
M10
1.35
1.4
2.2
1.9
2.7
2.35
3.7
4.2
4.4
6.2
7.4
M10 X 1
1.5
1.6
2.5
2.1
3.1
2.8
4.3
4.9
8.4
M12
2.4
2.5
3.7
3.3
4.7
4.2
6.3
7.2
7.5
10.5
12.5
M12 X 1.5
2.55
2.7
3.5
4.6
6.8
7.7
11.2
13.4
M14
3.7
3.9
5.2
7.5
10
11.5
12
17
20
M14 X 1.5
4.1
4.3
6.6
5.7
8.3
7.5
11.1
12.5
13
18.5
22
M16
5.6
11.5
10.5
17.9
18.5
18
26
31
M16 X 1.5
6.2
6.5
9.7
8.6
12.5
11.3
17
19.5
20
28
33
M18
7.8
8.3
12.5
11
16
14.5
21
24.2
25
36
43
M18 X 1.5
9.1
9.5
14.5
12.5
18.5
16.7
24.5
27.5
28
41
49
M20
11.5
12
18
16
22
19
31.5
35
36
51
60
M20 X 1.5
12.8
13.5
20.5
18
25
22.5
35
39.5
41
58
68
M22
15.5
16
24.5
21
30
26
42
46
49
67
75
17
18.5
28
24
34
29
47
52
56
75
85
20.5
21.5
33
27
40
34
55
58
63
82
92
23
25
37
31
45
38
61
67
74
93
103
M22 X 1.5
M24
M24 X 1.5
Note) The standard torque values above are about 70% of the bolt elastic limit values.
Note) The tensile force has been calculated by multiplying the tensile strength with the screw cross-sectional area.
Note) A special screw should be tightened with 85% of the tightening torque of the standard value. For example, a
MoS2-coated screw should be tightened with 60% of the tightening torque of the standard value.
78
8.8T
10.9T
8.8T
Remarks
M6 X 1.0
1.25
1.5
M8 X 1.25
2.2
3.1
3.8
M8 X 1.0
2.4
3.35
4.1
M10 X 1.5
4.4
6.2
7.4
M10 X 1.0
8.4
M12 X 1.75
7.5
10.5
12.5
M12 X 1.5
11.2
13.4
M14 X 1.5
13
18.5
22
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
M8
M10
M12
M14
M16
M18
M22
M26
M30
M38
SM25C
1.6
2.5
3.5
4.5
5.5
9.0
13.0
18.0
30.0
SUM22La
0.8
1.8
3.0
4.0
5.5
6.5
11.0
16.0
20.0
35.0
STS304
0.8
1.8
3.0
4.0
5.5
6.5
11.0
16.0
20.0
35.0
79
Figure
Product Number/Name
Product Number/Name
TB1217H
587
Blue
LOCTITE 272
LOCTITE
LOCTITE
EF.120-208
Piston insertion tool
09-0666
LOCTITE BLUE 587
860104-02041
Valve Stem Seal Jig
EF. 120-262
Valve Spring
Compression Tool
860104-02047
Front Oil Seal
Disassembly Jig
T7621010E
Piston Ring Plier
860104-02048
Rear Oil Seal
Disassembly Jig
860104-02052
Wrench, Oil Filter
850306-00078
Oil seal disassembly jig
860104-01045
G2 Diagnostic Tool
80
DANGER
(Only LEL00/LEL01/LEL02/LEL03/LEL04)
CAUTION
parts as required.
while the engine is still hot, you may burn yourself with steam or hot coolant. Make sure that the
engine has fully cooled before opening the surge
tank cap.
of disassembly.
WARNING
1) Check if the engine and the radiator have been propDiscard coolant according to the regulations set
erly cooled.
2) Place a container in front of the coolant drain plug.
LEF00/LEF01/LEF02/LEF03).
LEL00/LEL01/LEL02/LEL03/LEL04)
CAUTION
plug again.
DANGER
(Only LEF00/LEF01/LEF02/LEF03)
DL03-LEF00/01
B
EDL032160E
81
DL03-LEF02/03
B
EDL032160F
DL03-LEL00/01/02/
03/04
EDL032810C
DL03-LEF02/03
B
EDL032160G
EDL032811B
2) Remove the drain plug (B) and drain the engine oil.
CAUTION
82
DL03-LEF00/01
A
A
EDL032558C
EDL032556C
DL03-LEF02/03
LEF00/LEF01/LEF02/LEF03).
EDL032556D
DL03-LEL00/01/02/
03/04
B
B
EDL032557A
EDL032556E
83
DL03-LEF00/01
C
B
EDL032055C
E
C
EDL032554B
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
EDL032555D
EDL032554C
1) Loosen the flange hex bolt (E) that fixes the boost
DL03-LEL00/01/02/
03/04
pressure sensor.
2) Remove the boost pressure sensor (D).
3) Loosen the flange hex bolts (B).
CAUTION
Replace the gasket with a new one; do not reuse it.
EDL032554D
84
B
C
B
EDL032552E
EDL032553B
DL03-LEF00/01
LEF00/LEF01)
DL03-LEF00/01
D
A
G
C
B
EDL032552C
DL03-LEF02/03
EDL032551D
1) Loosen the flange hex bolts (E, F) that fix idle pulley
bracket.
2) Remove the idle pulley bracket (A).
3) Loosen the flange hex bolt (D) that fixes the eye bolt
assembly.
4) Disassemble the eye bolt assembly (B).
5) Loosen the flange hex bolts (G) that hold the generator bracket.
6) Remove the generator bracket (C).
EDL032552D
85
DL03-LEF02/03
DL03-LEF02/03
C
B
A
D
F
E
EDL032050D
DL03-LEL00/01/02/
03/04
EDL032551E
1) Loosen the flange hex bolt (E) that holds the eye bolt
assembly.
F
DL03-LEF00/01
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
D
E
CAUTION
Replace the gasket with a new one; do not reuse it.
F
EDL032050C
86
CAUTION
disassembly.
removing the oil filter assembly, pay attention not
to contaminate adjacent parts, using a rag or
cloth and, after the replacement, wipe oil stains
off all affected areas.
19. Disconnect the fuel injection pipe.
B
EDL032549B
DL03-LEF02/03
EDL032548B
EDL032549C
DL03-LEL00/01/02/
03/04
CAUTION
Do not bend the fuel injection pipes by force.
20. Disconnect the fuel return hose.
B
EDL032549D
EDL032547C
87
23. Remove the knock sensors, and the oil pressure and
temperature sensor.
pumps.
2) Disconnect the fuel return hoses (A).
21. Remove the common rail.
D
EDL032544A
CAUTION
I
J
during disassembly.
D
22. Remove the intake manifold.
J
I
F
B
A
EDL032043C
D
C
CAUTION
EDL032045A
reuse them.
CAUTION
88
DL03-LEL00/01/02/
03/04
CAUTION
EDL032541C
C
1) Unscrew the flange hex bolts (B).
2) Remove the coolant pump pulley (A).
EDL032542C
(D).
3) Remove the spacer bolt (B).
4) Loosen the flange hex bolts (C).
5) Remove the thermostat(A).
26. Remove the coolant pump pulley.
EDL032540B
DL03-LEF00/01
02/03
EDL032541B
89
B
A
B
B
A
EDL032039D
EDL032535D
DL03-LEL00/01/02/
03/04
CAUTION
EDL032535E
CAUTION
C
EDL032537E
1) Loosen the hex bolts (B) that fix the EGR cooler
bracket.
2) Unscrew the flange hex bolts (C).
3) Disassemble the EGR cooler assembly (A).
4) With the clamp pressed, disconnect the hose (D).
90
B
C
A
EDL032536C
EDL032533C
screen (A).
LEF00/LEF01/LEF02/LEF03).
DL03-LEF00/01
02/03
B
EDL032534C
EDL032532B
CAUTION
Replace the exhaust manifold gasket with a new
one; do not reuse it.
91
CAUTION
A
B
disassembly.
removing the injectors.
37. Remove the cylinder head cover.
EDL032531B
EDL032529D
EDL032031C
A
EDL032529C
EDL032530A
92
CAUTION
A
EDL032528A
EDL032525A
CAUTION
Replace the cylinder head gasket with a new one;
EDL032027A
E
D
B
A
EDL032024A
EDL032526A
93
LEF00/LEF01/LEF02/LEF03).
B
B
EDL032021C
DL03-LEF02/03
EDL032523A
EDL032708C
CAUTION
EDL032022B
94
DL03-LEF00/01
02/03
A
B
EDL032520B
EDL032519C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
A
B
A
EDL032520D
EDL032520C
1) Detach the rear oil seal (A) from the flywheel housing,
CAUTION
B
EDL032518C
95
pipe.
CAUTION
E
Do not reuse connecting rod bolts; replace them
B
D
B
F
CAUTION
Be careful not to damage the piston and piston
rings.
4) Detach the lower connecting rod bearing (B) from the
connecting rod cap (D).
EDL032517B
2) Remove the oil suction pipe (A) and the O-ring (C).
CAUTION
CAUTION
sembly.
CAUTION
Be careful not to damage the O-rings during disas-
sembly.
D
E
EDL032015A
EDL032016B
96
small-end (C).
CAUTION
tion.
B
EDL032512B
CAUTION
Be careful not to damage the O-ring during disassembly.
A
55. Remove the front oil seal.
B
EDL032514B
EDL032511B
1) Detach the front oil seal (A) from the front oil seal
CAUTION
EDL032513C
97
CAUTION
Be careful not to damage the teeth of the timing
wheel.
B
EDL032510C
EDL032507A
CAUTION
EDL032509B
EDL032508C
98
A
C
B
EDL032506B
EDL032004A
CAUTION
There is a groove in the upper main bearing, but not
in the lower main bearing.
63. Detach the camshaft.
EDL032005B
CAUTION
There is a groove in the upper main bearing, but not
in the lower main bearing.
B
EDL032003A
99
EDL032002A
B
A
EDL032001A
100
CAUTION
and gaskets.
EDL032002A
should be avoided.
after reassembly.
assembly.
B
B
EDL032003A
CAUTION
Ensure that the camshaft journal and the inside of
the cylinder block bush are normal.
EDL032001A
cylinder block.
2.0 kgfm.
101
Specified Value
0.1 ~ 0.2 mm
CAUTION
Align the key groove of the cylinder block with the
key of the thrust washer.
Note) Main bearings are available in the following grades.
A
Inside diameter of
the cylinder block
main bearing
bore
C
B
EDL032004A
Grade B
Grade C
Grade A
YELLOW
BLUE
BLUE
Grade B
YELLOW
YELLOW
BLUE
Grade C
RED
RED
YELLOW
CAUTION
79.000 ~ 79.007 mm
Grade B
79.007 ~ 79.014 mm
Grade C
79.014 ~ 79.021 mm
Grade A
Specified Value
The grade of the main bearing bore inside diameter of the cylinder block is imprinted on the
cylinder block and that of the main journal diameter of the crankshaft on the crankshaft. For the
engraving positions, see the Engine Unique
Specified Value
Grade A
74.955 ~ 74.960 mm
Grade B
74.960 ~ 74.965 mm
Grade C
74.965 ~ 74.970 mm
Number of Chapter 3 (Performance and SpecificaNote) For the method to measure the crankshaft main
tions).
Units.
102
Specified Value
BLUE
1.995 ~ 2.000 mm
YELLOW
2.000 ~ 2.005 mm
RED
2.005 ~ 2.010 mm
A
EDL032005B
EDL032006B
CAUTION
CAUTION
A
2) Lubricant the assembly surface of the crankshaft and
the lower main bearings with sufficient engine oil.
EDL032007A
103
2nd Stage
90 Rotation
3rd Stage
CAUTION
Be careful not to damage the teeth of the timing
wheel.
90 Rotation
CAUTION
Make sure the main bearing cap bolts are tightened with the angle method.
CAUTION
EDL032009A
it rotates smoothly.
Specified Value
0.1 ~ 0.31 mm
B
EDL032010B
1) Place the front oil seal holder (B) with its assembly
surface facing down.
2) Insert the front oil seal (A) to the front oil seal
EDL032008C
1) Align the timing wheel (A) with the dowel pin and
attach it to the crankshaft surface.
104
3) Align and install the front oil seal holder (A) with
oil seal holder (B), pull out the front oil seal assembly
jig.
CAUTION
one.
2) Align the oil pump (A) with the pin and press it as
deeply into the cylinder block as possible.
Specified Value
0.066 ~ 0.247 mm
CAUTION
EDL032011B
CAUTION
Ensure that the front oil seal hold is facing the
right direction.
105
Specified Value
0.087 ~ 0.202 mm
Specified Value
0.087 ~ 0.213 mm
EDL032013B
CAUTION
The idle gear and the camshaft gear have 2 marks
imprinted on them.
2) Place the mark of the crankshaft gear between the
CAUTION
EDL032014B
2) Align and install the fuel injection pump (A) with stud
bolts.
CAUTION
Item
Specified Value
0.081 ~ 0.196 mm
upward.
5) Temporarily install the flange hex bolts (B), aligning
with the holes of the ilde gear shaft.
6) Tighten the flange hex bolts (B) to a tightening torque
of 4.4 kgfm.
7) The backlash between idle gear and crankshaft gear
is 0.087 ~ 0.202 mm.
106
CAUTION
EDL032015A
1) Note that the piston and the bumpy side (B) of the
CAUTION
CAUTION
them.
connecting rod should be facing the same direction, toward the front of the cylinder block.
2) Install the piston (A) to the connecting rod smallend
(C).
Note) Cylinder block and pistons are available in the
following grades.
E
Piston
Grade A
Grade B
Grade A
Grade B
A
B
EDL032016A
Specified Value
Grade A
97.990 ~ 98.000 mm
Grade B
98.000 ~ 98.010 mm
CAUTION
Specified Value
Grade A
97.920 ~ 97.930 mm
Grade B
97.930 ~ 97.940 mm
107
follows.
E
Thickness of Connecting Rod Bearing
Specified Value
YELLOW
1.497 ~ 1.502 mm
A
B
D
CAUTION
CAUTION
rings.
5) Install the connecting rod cap.
CAUTION
tion.
kfgm.
CAUTION
2nd Stage
90 Rotation
108
A
B
EDL032520C
EDL032518D
CAUTION
CAUTION
tion.
kgfm.
DL03-LEF00/01
02/03
D
EDL032020B
1) Install the rear oil seal (A) to the rear oil seal
EDL032519C
crankshaft (D).
109
C
B
EDL032022B
1) Align and install the crankshaft pulley (A) with the key.
2) Apply Loctite Ultra Blue 587 to the insdie of the flange
hex bolt (B).
3) Tighten the flange hex bolt (B) to a tightening torqueof
EDL032021C
26 kgfm.
4) Connect the crankshaft pulley (A) and (C).
DL03-LEF02/03
CAUTION
B
EDL032708C
45 Rotation
EDL032023A
CAUTION
Do no reuse the flange hex bolts when assembling
the flywheel.
110
CAUTION
C
B
2) Apply engine oil to the assembly surfaces of the valve
and the valve stem seals.
3) Install the valves (A).
CAUTION
EDL032025A
CAUTION
(Others/Driving Units).
holes graded C.
following grades.
CAUTION
Grade
Odd
Mark Number
111
Thickness
Average of step
height of the piston
top side
1ea
0.9T
0.24 ~ 0.33 mm
2ea
1.0T
0.33 ~ 0.43 mm
3ea
1.1T
0.43 ~ 0.52 mm
A
A
EDL032526A
EDL032027A
2nd Stage
90 Rotation
3rd Stage
90 Rotation
CAUTION
bolts.
112
B
A
EDL032529D
EDL032030A
CAUTION
EDL032529B
bility.
CAUTION
0.05 kgfm.
CAUTION
ones.
0.35kgfm.
113
B
A
A
EDL032031A
EDL032532B
EDL032031B
EDL032533C
CAUTION
114
DL03-LEF00/01
02/03
C
D
C
EDL032034C
EDL032535D
DL03-LEL00/01/02/
03/04
upward.
2) Install the exhaust manifold gasket (A).
CAUTION
D
3) Temporarily tighten the mounting bolts (B).
CAUTION
B
C
EDL032536C
kgfm.
3) Tighten the mounting bolts (C) to a tightening torque
of 2.2 kgfm.
115
CAUTION
A
CAUTION
EDL032537E
of 2.2 kgfm.
CAUTION
CAUTION
3) Tighten the mounting hex bolt (B) of the EGR cooler
B
A
B
A
E
D
EDL032039D
EDL032040B
116
kgfm.
4) With the clamps pressed, connect the hose running
EDL032542C
DL03-LEL00/01/02/
03/04
I
J
D
B
J
I
F
EDL032541C
kgfm.
EDL032043C
CAUTION
Replace the clamp with a new one after reuse of 3
times; do not reuse it any more.
117
43. Install the knock sensors, and the oil pressure and
temperature sensor.
CAUTION
gasket.
3) Connect the gasket (D) and the oil return pipe (E) to
the turbocharger.
CAUTION
Replace the gaskets with new ones; do not reuse
EDL032044A
them.
kgfm.
of 2.2 kgfm.
CAUTION
D
C
CAUTION
tion.
oil leaks.
assembly.
them.
ified torque.
118
CAUTION
B
right direction.
are properly engaged.
not reuse them. Otherwise, critical damage to the
engine performance may occur.
2) With the clamps pressed, connect the fuel return
hoses of common rail, injectors, and fuel injection
pumps.
EDL032046A
CAUTION
direction.
of 2.2 kgfm.
4) Tighten the nuts (B) of the fuel injection pipes to a
tightening torque of 3.0 kgfm.
5) Tighten the flange hex bolt (C).
CAUTION
EDL032547C
119
CAUTION
installed.
assembly.
2) Tighten the flange hex bolts to a tightening torque of
2.2 kgfm.
49. Install the intake stake.
DL03-LEF00/01
EDL032549B
B
DL03-LEF02/03
D
A
D
B
E
F
EDL032050C
DL03-LEF02/03
EDL032549C
DL03-LEL00/01/02/
03/04
D
D
E
F
EDL032050D
B
EDL032549D
120
DL03-LEL00/01/02/
03/04
DL03-LEF00/01
D
E
D
F
EDL032050E
EDL032551D
CAUTION
tion.
aligned.
them.
of 2.2 kgfm.
4) Install the EGR pipe gaskets (D).
6) Tighten the flange hex bolts (F) holding the EGR pipe
121
B
B
EDL032552C
DL03-LEF02/03
EDL032553B
B
1) Install the rear lifting hook (A).
2) Tighten the flange hex bolts (B) to a tightening torque
of 4.4 kgfm.
54. Install the front lifting hook.
DL03-LEF00/01
A
B
EDL032552D
DL03-LEL00/01/02/
03/04
B
C
EDL032554B
DL03-LEF02/03
A
B
B
EDL032552E
CAUTION
Replace clamps with new ones after reuse of 3
EDL032554C
122
DL03-LEF00/01
DL03-LEL00/01/02/
03/04
EDL032554D
EDL032808E
DL03-LEF02/03
E
C
D
A
EDL032808F
view - A
DL03-LEL00/01/02/
03/04
EDL032055C
E
C
DL03-LEL00/01/02/
03/04
B
EDL032808G
CAUTION
EDL032555D
123
CAUTION
DL03-LEF00/01
3) Press and install the oil level gauge guide tube (B) to
the cylinder block.
CAUTION
Install the oil level gauge guide tube in the way that
the handle of the oil level gauge faces the opposite
of the center of the engine.
B
4) Tighten the flange hex bolt (C) to a tightening torque
of 1.0 kgfm to fix the oil level gauge tube (B).
5) Install the oil level gauge (A).
EDL032556C
DL03-LEF02/03
B
EDL032556D
EDL032057A
1) Align and install the starter motor (A) with the stud
bolt.
2) Tighten the flange hex bolts (B) to a tightening torque
of 2.2 kgfm.
124
EDL032811B
EDL032058B
hose(A).
CAUTION
63. Assemble the air cooler and the cooling fan to the
engine.
CAUTION
DL03-LEF00/01
LEL00/LEL01/LEL02/LEL03/LEL04).
CAUTION
Use coolant recommended by Doosan.
EDL032810C
125
126
6. Cooling system
General information .........................................................................................................129
General Information ................................................................................................................................ 129
Specifications........................................................................................................................................... 130
Failure Diagnosis ................................................................................................................................... 132
Thermostat .......................................................................................................................136
General Information ................................................................................................................................ 136
Thermostat Disassembly......................................................................................................................... 136
Thermostat assembly.............................................................................................................................. 137
Check of thermostat ............................................................................................................................... 137
127
128
6. Cooling system
General information
General Information
coolant pump, and the heat absorbed into the oil cooler
1
2
EDL022059E
1. Radiator
4. Cylinder head
7.
EGR cooler
2. Water pump
5. Oil cooler
8.
thermostat
3. Cylinder Block
6. EGR Valve
9.
Bypass
129
6. Cooling system
Specifications
Specifications
Item
DL03LEF00
Cooling Type
Driving Type
Ribbed-Belt driven
Pump Speed
2,760 rpm
Drive Ratio
(Engine speed:Pump
speed)
1 : 1.2
Flow Rate
0.8 bar
Type
Driving Type
Blow Type
Fan Bracket direct connection
Rotation Ratio
(Engine RPM: fan RPM)
1:1
Type
Thermostat
Coolant Temperature
Sensor
Water Temperature
Sensor
Radiator Cap
DL03LEF03
4.7 L
Type
Cooling fan
DL03LEF02
Water-forced cooling
Capacity of coolant
Water pump
DL03LEF01
Valve-opening temperature
82 C
97 C
Lift
8 mm
Type
Resistance (at 20 C)
2.5k
0.148k
0.9 kg/cm2
130
Remarks
6. Cooling system
Specifications
Item
DL03LEL00
DL03LEL01
DL03LEL02
DL03LEL03
DL03LEL04
Cooling system
Cooling Type
Water-forced cooling
Capacity of coolant
4.7 L
Type
Water pump
Driving Type
Ribbed-Belt driven
Pump Speed
2,880 rpm
Drive Ratio
(Engine speed:Pump
speed)
1 : 1.2
Flow Rate
0.8 bar
Type
Cooling fan
Driving Type
Rotation Ratio
(Engine RPM: fan RPM)
Type
Thermostat
Coolant Temperature
Sensor
Water Temperature
Sensor
Valve-opening temperature
82 C
97 C
Lift
8 mm
Type
Resistance (at 20 C)
2.5k
0.148k
0.97 kg/cm2
131
Remarks
6. Cooling system
Failure Diagnosis
Phenomenon
Causes
Troubleshooting
Replace it
Contaminated radiator
Adjust or replace it
Replace it
Damaged impeller
Replace it
Replace it
Replace it
Replace it
Damaged radiator
Repair or replace it
Replace it
Repair or replace it
Repair or replace it
Replace it
Repair or replace it
Replace it
Adjust or replace it
Overheated engine
Overcooled engine
Leaking coolant
Noise
132
6. Cooling system
Water pump
General Information
WARNING
The water pump prevents the engine from being overheated by combustion heat during engine operation and
engine.
1. Drain coolant.
erly cooled.
2) Place a container in front of the coolant drain plug.
CAUTION
LEL00/LEL01/LEL02/LEL03/LEL04)
5) Unplug the coolant drain plug of the radiator and then
drain coolant.
DL03-LEF00/01
plug again.
DANGER
(Only LEF00/LEF01/LEF02/LEF03)
EDL032810C
DANGER
(Only LEL00/LEL01/LEL02/LEL03/LEL04)
EDL032811B
133
6. Cooling system
Note) For checking and measuring the belt tension, refer
EDL032540B
DL03-LEL00/01/02/
03/04
EDL032541C
EDL032040B
134
6. Cooling system
3. Install the coolant pump pulley.
DL03-LEF02/03
DL03-LEF00/01
02/03
A
A
B
EDL032811B
EDL032541B
DL03-LEL00/01/02/
03/04
LEF00/LEF01/LEF02/LEF03).
2) Open the surge tank cap and add coolant (Only
LEL00/LEL01/LEL02/LEL03/LEL04).
CAUTION
EDL032541C
EDL032810C
135
6. Cooling system
Thermostat
General Information
Thermostat Disassembly
CAUTION
mostat height.
CAUTION
EDL032812A
2
3
EDL032542C
1. Heat Exchanger
2. Bypass valve
3. water pump
4. Coolant pipe
136
6. Cooling system
Check of thermostat
Thermostat assembly
damaged or not.
2. Put the thermostat into water and heat the water
C
B
D
B
A
EDL032542C
of 2.2 kgfm.
4) With the clamps pressed, connect the rubber hose
A.
(D).
Thermometer
B.
Measuring point
mostat.
temperature controller.
Item
Specified Value
0.3 mm (at 82 C)
thermostat Open Tempera8.0 mm or larger (at 97
ture
C)
EDL032812A
137
6. Cooling system
Cooling fan
Fan mounting bracket disassembly
DL03-LEF00/01
DL03-LEF00/01
B
EDL032552C
EDL032810C
DL03-LEF02/03
DL03-LEF02/03
A
A
EDL032552D
EDL032811B
DL03-LEL00/01/02/
03/04
B
EDL032552E
138
6. Cooling system
3. Remove the V-belt pulley (Only
LEF00/LEF01/LEF02/LEF03) .
DL03-LEF00/01
02/03
DL03-LEF00/01
02/03
A
A
EDL032533C
EDL032532B
LEF00/LEF01/LEF02/LEF03).
of 2.2 kgfm.
2. Install the V-belt pulley (Only
DL03-LEF00/01
02/03
LEF00/LEF01/LEF02/LEF03).
DL03-LEF00/01
02/03
EDL032532B
EDL032533C
139
6. Cooling system
3. Connect the coolant pipe and hoses.
DL03-LEF00/01
B
EDL032552C
DL03-LEF02/03
EDL032810C
B
DL03-LEF02/03
A
A
EDL032552D
DL03-LEL00/01/02/
03/04
EDL032811B
B
EDL032552E
CAUTION
Replace clamps with new ones after reuse of 3
times; do not reuse them any more.
140
7. Lubrication system
Oil pump ..........................................................................................................................143
General Information ................................................................................................................................ 143
Failure Diagnosis .................................................................................................................................... 144
141
142
7. Lubrication system
General information
General Information
tion.
The oil pump delivers oil sucked from the oil pan with
14
13
13
13
12
12
11
11
10
11
10
12
11
10
11
10
13
10
5
4
2
EDL022202A
1.
Oil pump
6.
Bypass Valve
2.
Relief Valve
7.
3.
Bypass Valve
8.
Idle gear
4.
Oil cooler
9.
Piston
14. Turbocharger
5.
Oil filter
143
7. Lubrication system
Failure Diagnosis
Phenomenon
Causes
Troubleshooting
Bad oil
Replace it
Replace it
Replace it
Replace it
Replace it
Bad oil
Replace it
Replace it
Replace it
Repair or replace it
Repair or replace it
Worn bearings
Replace it
Gas leakage
Bad oil
Contaminated oil
144
7. Lubrication system
Oil pump
General Information
DL03-LEL00/01/02/
03/04
Engine oil is sucked from the oil pan by the gear type
DL03-LEF00/01
B
EDL032160G
CAUTION
B
EDL032160E
DL03-LEF02/03
B
EDL032160F
B
EDL032557A
145
7. Lubrication system
1) Loosen the flange nut (B).
DL03-LEF00/01
EDL032520B
DL03-LEL00/01/02/
03/04
EDL032021C
DL03-LEF02/03
A
EDL032520D
1) Detach the rear oil seal (A) from the flywheel housing,
using an oil seal disassembly jig.
EDL032708C
CAUTION
CAUTION
Replace the flywheel bolts with new ones; do not
reuse them.
146
7. Lubrication system
5. Remove the flywheel housing.
CAUTION
Be careful not to damage the O-ring during disassembly.
A
B
EDL032519C
DL03-LEL00/01/02/
03/04
EDL032012B
2) Align the oil pump (A) with the pin and press it as
EDL032520C
Item
Specified Value
0.066 ~ 0.247 mm
CAUTION
A
B
EDL032512B
147
7. Lubrication system
2. Install the flywheel housing.
D
A
B
B
EDL032519C
EDL032020B
1) Install the rear oil seal (A) to the rear oil seal
DL03-LEL00/01/02/
03/04
DL03-LEF00/01
EDL032520C
CAUTION
right direction.
LOCTITE onto the parts.
EDL032021C
148
7. Lubrication system
6. Feed engine oil.
1) Open the oil injection cap on the cylinder head cover
DL03-LEF02/03
CAUTION
Use genuine engine oil recommended by Doosan.
DL03-LEF00/01
2nd Stage
45 Rotation
CAUTION
B
Do no reuse the flange hex bolts when assembling
EDL032160E
the flywheel.
DL03-LEF02/03
EDL032160F
EDL032057A
1) Align and install the starter motor (A) with the stud
bolt.
2) Tighten the flange hex bolts (B) to a tightening torque
of 2.2 kgfm.
149
7. Lubrication system
3. Disconnect the oil suction pipe and the oil delivery
DL03-LEL00/01/02/
03/04
pipe.
E
A
B
D
B
C
F
B
EDL032160G
EDL032517B
2) Remove the drain plug (B) and drain the engine oil.
1) Unscrew the hex bolts (B).
2) Remove the oil suction pipe (A) and the O-ring (C).
CAUTION
CAUTION
sembly.
CAUTION
punished.
sembly.
E
A
B
D
A
B
F
EDL032518C
150
7. Lubrication system
1) Install the O-rings (F).
CAUTION
assembly.
CAUTION
CAUTION
EDL032518D
CAUTION
151
7. Lubrication system
Oil filter assembly
General Information
The oil cooler cools oil with coolant and the oil filter
2) Remove the drain plug (B) and drain the engine oil.
CAUTION
Discard all used oil according to the regulations set
forth by competent authorities. Disposing of used oil
to the land, sewers, drains, rivers, or the sea will
result in serious environmental pollution. Violation of
the regulations regarding discard of engine oil or
noncompliance with the handling regulations will be
punished.
2. Detach the oil level gauge.
B
DL03-LEF00/01
EDL032160E
DL03-LEF02/03
EDL032556C
B
DL03-LEF02/03
EDL032160F
DL03-LEL00/01/02/
03/04
EDL032556D
B
EDL032160G
152
7. Lubrication system
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
B
A
C
B
B
EDL032556E
EDL032552E
2) Loosen the flange hexagon bolt (C) that fixes the oil
3) Remove the oil level gauge guide tube (B) from the
cylinder block.
A
C
B
EDL032549B
DL03-LEF02/03
EDL032552C
DL03-LEF02/03
EDL032549C
EDL032552D
153
7. Lubrication system
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
B
EDL032549D
EDL032549C
DL03-LEL00/01/02/
03/04
CAUTION
EDL032549D
CAUTION
DL03-LEF00/01
installed.
assembly.
2) Tighten the flange hex bolts to a tightening torque of
2.2 kgfm.
B
EDL032549B
154
7. Lubrication system
2. Connect the coolant pipe and hoses.
DL03-LEF00/01
B
EDL032552C
DL03-LEF02/03
EDL032556C
B
DL03-LEF02/03
A
B
EDL032552D
DL03-LEL00/01/02/
03/04
EDL032556D
DL03-LEL00/01/02/
03/04
C
A
B
EDL032552E
(A).
CAUTION
155
7. Lubrication system
3) Press and install the oil level gauge guide tube (B) to
the cylinder block.
CAUTION
Install the oil level gauge guide tube in the way that
the handle of the oil level gauge faces the opposite
of the center of the engine.
4) Tighten the flange hex bolt (C) to a tightening torque
of 1.0 kgfm to fix the oil level gauge tube (B).
5) Install the oil level gauge (A).
4. Feed engine oil.
1) Open the oil injection cap on the cylinder head cover
top and add engine oil.
CAUTION
Use genuine engine oil recommended by Doosan.
156
7. Lubrication system
Oil pan
Disassembly of oil pan
DL03-LEF00/01
CAUTION
Discard all used oil according to the regulations set
forth by competent authorities. Disposing of used oil
to the land, sewers, drains, rivers, or the sea will
result in serious environmental pollution. Violation of
the regulations regarding discard of engine oil or
noncompliance with the handling regulations will be
punished.
2. Detach the oil level gauge.
B
EDL032160E
DL03-LEF00/01
DL03-LEF02/03
EDL032556C
B
EDL032160F
DL03-LEF02/03
DL03-LEL00/01/02/
03/04
EDL032556D
EDL032160G
157
7. Lubrication system
Assembly of oil pan
DL03-LEL00/01/02/
03/04
A
B
B
EDL032556E
2) Loosen the flange hexagon bolt (C) that fixes the oil
3) Remove the oil level gauge guide tube (B) from the
cylinder block.
CAUTION
EDL032518C
DL03-LEF00/01
EDL032556C
158
7. Lubrication system
DL03-LEF02/03
EDL032556D
DL03-LEL00/01/02/
03/04
EDL032556E
CAUTION
Install the oil level gauge guide tube in the way that
the handle of the oil level gauge faces the opposite
of the center of the engine.
4) Tighten the flange hex bolt (C) to a tightening torque
of 1.0 kgfm to fix the oil level gauge tube (B).
5) Install the oil level gauge (A).
3. Feed engine oil.
1) Open the oil injection cap on the cylinder head cover
top and add engine oil.
CAUTION
Use genuine engine oil recommended by Doosan.
159
7. Lubrication system
160
8. Fuel system
General information .........................................................................................................163
General information................................................................................................................................. 163
Injector .............................................................................................................................169
General Information ................................................................................................................................ 169
How to Operate an Injector ................................................................................................................... 169
Injector disassembly................................................................................................................................ 170
Injector assembly .................................................................................................................................... 173
Injector check .......................................................................................................................................... 178
161
162
8. Fuel system
General information
General information
ECU decides the fuel volume and the fuel injection timing
nozzles.
ECU.
The fuel tank should be anti-corrosive, and should have
no oil leaks at two times higher pressure than the operating pressure of the fuel low-pressure pump and have
internal pressure of no more than 0.3 bar.
12
13
10
11
3
12
9
14
EDL032166D
1. Fuel Tank
9. Injector
12. VENTURI
2. Fuel Filter
3. Pump Handle
4. Fuel Delivery Line
163
8. Fuel system
Fuel return hose
General Information
2) Loosen the flange hexagon bolt (C) that fixes the oil
level gauge guide tube.
3) Remove the oil level gauge guide tube (B) from the
cylinder block.
DL03-LEF00/01
02/03
E
C
B
B
EDL032556C
EDL032055C
DL03-LEF02/03
E
C
DL03-LEL00/01/02/
03/04
B
B
EDL032556D
EDL032555D
DL03-LEL00/01/02/
03/04
1) Loosen the flange hex bolt (E) that fixes the boost
pressure sensor.
2) Remove the boost pressure sensor (D).
CAUTION
Replace the gasket with a new one; do not reuse it.
EDL032556E
164
8. Fuel system
3. Remove the intake stake.
CAUTION
Replace the gasket with a new one; do not reuse it.
D
A
D
C
E
F
EDL032050C
DL03-LEF02/03
A
B
EDL032547C
DL03-LEL00/01/02/
03/04
D
D
E
EDL032547C
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).
3) Remove the EGR pipe gaskets (D).
4) Loosen the flange hex bolts (C) that fix the intake
stake.
5) Remove the intake stake (A).
165
8. Fuel system
1) Connect the fuel return hoses (A).
DL03-LEL00/01/02/
03/04
CAUTION
right direction.
are properly engaged.
EDL032050E
pumps.
CAUTION
A
F
EDL032050C
DL03-LEF02/03
of 2.2 kgfm.
6) Tighten the flange hex bolts (F) holding the EGR pipe
to a tightening torque of 2.2 kgfm.
D
D
E
F
EDL032050D
166
8. Fuel system
3. Install the air heater.
DL03-LEF02/03
DL03-LEF00/01
02/03
E
C
D
EDL032808F
EDL032055C
DL03-LEL00/01/02/
03/04
view - A
E
C
DL03-LEL00/01/02/
03/04
EDL032808G
EDL032555D
DL03-LEF00/01
air heater.
CAUTION
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
EDL032808E
167
8. Fuel system
5) Tighten the mounting bolt (E) of the boost pressure
3) Press and install the oil level gauge guide tube (B) to
the cylinder block.
CAUTION
DL03-LEF00/01
Install the oil level gauge guide tube in the way that
the handle of the oil level gauge faces the opposite
of the center of the engine.
EDL032556C
EDL032556D
DL03-LEL00/01/02/
03/04
EDL032556E
168
8. Fuel system
Injector
General Information
high-pressure pump.
return line.
hole.
into the fuel tank via the fuel return line. The
leakage fuel and the fuel gathered from the line, which
169
8. Fuel system
3. The injector is fully open. (injecting fuel)
EDL032556C
Injector disassembly
EDL032556D
DL03-LEL00/01/02/
03/04
A
B
EDL032556E
EDL032558C
2) Loosen the flange hexagon bolt (C) that fixes the oil
3) Remove the oil level gauge guide tube (B) from the
hose(A).
cylinder block.
170
8. Fuel system
3. Remove the air heater.
DL03-LEF00/01
B
D
D
A
D
B
E
F
EDL032055C
E
C
EDL032050C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
A
B
A
E
F
EDL032555D
EDL032050D
1) Loosen the flange hex bolt (E) that fixes the boost
DL03-LEL00/01/02/
03/04
pressure sensor.
2) Remove the boost pressure sensor (D).
CAUTION
F
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).
3) Remove the EGR pipe gaskets (D).
4) Loosen the flange hex bolts (C) that fix the intake
stake.
5) Remove the intake stake (A).
171
8. Fuel system
6) Remove the gasket (B).
CAUTION
Replace the gasket with a new one; do not reuse it.
A
5. Disconnect the fuel injection pipe.
A
B
EDL032546A
CAUTION
Take extra care not to damage the common rail
EDL032548B
during disassembly.
CAUTION
Do not bend the fuel injection pipes by force.
A
6. Disconnect the fuel return hose.
EDL032531B
EDL032547C
172
8. Fuel system
Injector assembly
1. Install the injector.
B
A
EDL032031C
CAUTION
A
damaged.
EDL032530A
CAUTION
CAUTION
disassembly.
0.35kgfm.
173
8. Fuel system
2. Install the right cylinder head cover.
B
B
EDL032031A
EDL032046A
CAUTION
CAUTION
EDL032547C
174
8. Fuel system
1) Connect the fuel return hoses (A).
CAUTION
right direction.
are properly engaged.
D
C
pumps.
EDL032050C
A
B
D
D
F
EDL032050D
EDL032548B
DL03-LEL00/01/02/
03/04
of 2.2 kgfm.
4) Tighten the nuts (B) of the fuel injection pipes to a
tightening torque of 3.0 kgfm.
CAUTION
E
F
right direction.
EDL032050E
175
8. Fuel system
1) Install gaskets (B) between the intake manifold and
the intake stake.
E
C
CAUTION
DL03-LEL00/01/02/
03/04
aligned.
them.
DL03-LEF00/01
DL03-LEF00/01
02/03
C
D
EDL032808E
DL03-LEF02/03
EDL032055C
EDL032808F
176
8. Fuel system
8. Install the oil level gauge.
DL03-LEL00/01/02/
03/04
view - A
DL03-LEF00/01
EDL032808G
EDL032556C
DL03-LEF02/03
CAUTION
it.
2) Install the air heater (A).
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
EDL032556D
DL03-LEL00/01/02/
03/04
A
3) Tighten the flange hex bolts (B) to a tightening torque
of 2.2 kgfm.
EDL032556E
177
8. Fuel system
3) Press and install the oil level gauge guide tube (B) to
CAUTION
Install the oil level gauge guide tube in the way that
the handle of the oil level gauge faces the opposite
EDL032167A
2) Insert the seal ring in the cylinder head (A) and attach
the injector (B).
3) Check the injector protrusion (C) based on the
cylinder head (A) surface with a dial gauge.
Note) Be careful not to allow foreign substances to flow
into the injector and the high-pressure connector
when detaching and checking the injector.
EDL032058B
CAUTION
Injector check
1. Check if there are any foreign substances and if the
end part of the injector is deformed.
178
Item
Specified Value
Injector protrusion
1.5 0.65 mm
8. Fuel system
Common rail
General information
The ECU decides the fuel volume and the fuel injection
12
13
10
11
3
12
9
14
EDL032166D
1. Fuel Tank
9. Injector
12. VENTURI
2. Fuel Filter
3. Pump Handle
4. Fuel Delivery Line
179
8. Fuel system
1. Electronic Control Unit (ECU)
engine.
pump.
characteristics curves.
common rail.
to the ECU.
RPM sensor.
3. Camshaft RPM sensor
1) The camshaft RPM sensor controls the intake and
exhaust valves of the engine. This rotates at half the
speed of the crankshaft, and determines if the position
of the camshaft is in the stage of pressure or in the
stage of exhaust when the piston moves to the top
dead point. This information cannot be determined by
the crankshaft RPM sensor. However, while the
engine is normally operating, the information given by
the crankshaft RPM sensor is enough to define the
engine state. It means that the ECU receives information about the engine from the crankshaft RPM sensor
if the camshaft RPM sensor cannot sense the engine
state while the vehicle is running.
180
8. Fuel system
EDL022065A-E
Injection pipe
follows.
low for the ignition delay time, i.e., the period from
181
8. Fuel system
Common rail disassembly
2. Common rail
6
8
DL03-LEF00/01
3
A
7
2
4
5
EDL032168B
EDL032556C
DL03-LEF02/03
3. Common Rail
4. Pressure sensor
5. Fuel injection pipe (Fuel injection pump-Common rail)
6. Fuel injection pipe (Common rail-Injector)
EDL032556D
DL03-LEL00/01/02/
03/04
2) Loosen the flange hexagon bolt (C) that fixes the oil
3) Remove the oil level gauge guide tube (B) from the
cylinder block.
182
8. Fuel system
2. Remove the air heater.
DL03-LEF00/01
B
D
D
A
D
B
E
F
EDL032055C
E
C
EDL032050C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
A
B
A
E
F
EDL032555D
EDL032050D
1) Loosen the flange hex bolt (E) that fixes the boost
DL03-LEL00/01/02/
03/04
pressure sensor.
2) Remove the boost pressure sensor (D).
CAUTION
F
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).
3) Remove the EGR pipe gaskets (D).
4) Loosen the flange hex bolts (C) that fix the intake
stake.
5) Remove the intake stake (A).
183
8. Fuel system
6) Remove the gasket (B).
CAUTION
Replace the gasket with a new one; do not reuse it.
A
4. Disconnect the fuel injection pipe.
A
B
EDL032546A
CAUTION
Take extra care not to damage the common rail
EDL032548B
during disassembly.
CAUTION
A
Do not bend the fuel injection pipes by force.
EDL032046A
CAUTION
EDL032547C
pumps.
184
8. Fuel system
2) Temporarily tighten the collared hex bolts (B) by hand.
of 2.2 kgfm.
CAUTION
EDL032547C
CAUTION
DL03-LEF00/01
right direction.
D
2) With the clamps pressed, connect the fuel return
pumps.
EDL032050C
DL03-LEF02/03
D
D
B
E
F
EDL032050D
EDL032548B
185
8. Fuel system
5. Install the air heater.
DL03-LEL00/01/02/
03/04
DL03-LEF00/01
02/03
C
D
D
A
D
E
C
B
F
EDL032050E
EDL032055C
E
C
CAUTION
DL03-LEL00/01/02/
03/04
aligned.
them.
DL03-LEF00/01
EDL032808E
186
8. Fuel system
5) Tighten the mounting bolt (E) of the boost pressure
DL03-LEF02/03
B
EDL032808F
DL03-LEL00/01/02/
03/04
view - A
EDL032556C
DL03-LEF02/03
EDL032808G
EDL032556D
CAUTION
DL03-LEL00/01/02/
03/04
it.
B
2) Install the air heater (A).
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
side, while DL03-LEF02/03, DL03-LEL00/01/02/03/04
has no rubber packing on its air heater side. Do not
mix the air heaters. Mixed use of air heaters may
EDL032556E
of 2.2 kgfm.
4) Install the boost pressure sensor (D).
187
8. Fuel system
3) Press and install the oil level gauge guide tube (B) to
the cylinder block.
CAUTION
Install the oil level gauge guide tube in the way that
the handle of the oil level gauge faces the opposite
of the center of the engine.
4) Tighten the flange hex bolt (C) to a tightening torque
of 1.0 kgfm to fix the oil level gauge tube (B).
5) Install the oil level gauge (A).
188
8. Fuel system
Fuel injection pump
General information
are use to detect the engine rev count for starting fuel
components.
3
5
EDL032169B
5. Drive shaft
189
8. Fuel system
1. Functions
Valve
Plunger
Fuel
Return
Common Rail
Valve Body
Valve Spring
EDL032069A-E
fuel from exiting the pumping chamber, which accordingly compresses the fuel more than the delivered
pressure.
DL03-LEF00/01
EDL032160E
190
8. Fuel system
2. Detach the oil level gauge.
DL03-LEF02/03
DL03-LEF00/01
B
EDL032160F
EDL032556C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
B
EDL032160G
EDL032556D
DL03-LEL00/01/02/
03/04
2) Remove the drain plug (B) and drain the engine oil.
3) Remove the oil cap A.
CAUTION
Discard all used oil according to the regulations set
forth by competent authorities. Disposing of used oil
to the land, sewers, drains, rivers, or the sea will
result in serious environmental pollution. Violation of
EDL032556E
punished.
2) Loosen the flange hexagon bolt (C) that fixes the oil
level gauge guide tube.
3) Remove the oil level gauge guide tube (B) from the
cylinder block.
4) Remove O-rings (D).
191
8. Fuel system
3. Remove the air heater.
DL03-LEF00/01
B
D
D
A
D
B
E
F
EDL032055C
E
C
EDL032050C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
A
B
A
E
F
EDL032555D
EDL032050D
1) Loosen the flange hex bolt (E) that fixes the boost
DL03-LEL00/01/02/
03/04
pressure sensor.
2) Remove the boost pressure sensor (D).
CAUTION
F
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).
3) Remove the EGR pipe gaskets (D).
4) Loosen the flange hex bolts (C) that fix the intake
stake.
5) Remove the intake stake (A).
192
8. Fuel system
6) Remove the gasket (B).
CAUTION
CAUTION
disassembly.
removing the oil filter assembly, pay attention not
DL03-LEF00/01
A
6. Disconnect the fuel injection pipe.
A
B
EDL032549B
DL03-LEF02/03
A
EDL032548B
CAUTION
Do not bend the fuel injection pipes by force.
EDL032549C
DL03-LEL00/01/02/
03/04
B
EDL032549D
EDL032547C
193
8. Fuel system
1) With the clamps pressed, disconnect the fuel return
EDL032547C
A
B
CAUTION
EDL032514B
pumps.
3. Connect the fuel injection pipes.
A
B
EDL032514B
1) Align the fuel injection pump (A) with the stud bolts
EDL032548B
194
8. Fuel system
4) Tighten the nuts (B) of the fuel injection pipes to a
tightening torque of 3.0 kgfm.
DL03-LEL00/01/02/
03/04
CAUTION
CAUTION
installed.
assembly.
B
EDL032549B
DL03-LEF02/03
D
D
A
E
B
F
EDL032050C
EDL032549C
195
8. Fuel system
6. Install the air heater.
DL03-LEF02/03
DL03-LEF00/01
02/03
E
A
C
B
D
A
D
E
C
B
F
EDL032050D
EDL032055C
DL03-LEL00/01/02/
03/04
E
C
DL03-LEL00/01/02/
03/04
D
B
D
E
F
EDL032050E
EDL032555D
DL03-LEF00/01
CAUTION
196
8. Fuel system
5) Tighten the mounting bolt (E) of the boost pressure
DL03-LEF02/03
B
EDL032808F
DL03-LEL00/01/02/
03/04
view - A
EDL032556C
DL03-LEF02/03
EDL032808G
EDL032556D
CAUTION
DL03-LEL00/01/02/
03/04
it.
B
2) Install the air heater (A).
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
side, while DL03-LEF02/03, DL03-LEL00/01/02/03/04
has no rubber packing on its air heater side. Do not
mix the air heaters. Mixed use of air heaters may
EDL032556E
of 2.2 kgfm.
4) Install the boost pressure sensor (D).
197
8. Fuel system
3) Press and install the oil level gauge guide tube (B) to
1) Align the fuel injection pump drive gear (B) with the
CAUTION
CAUTION
Install the oil level gauge guide tube in the way that
the handle of the oil level gauge faces the opposite
A
B
C
EDL032401A
A
B
C
EDL032401A
198
9. Intake/exhaust system
General information .........................................................................................................201
General Information ................................................................................................................................ 201
Turbocharger ...................................................................................................................202
General Information ................................................................................................................................ 202
Failure Diagnosis ................................................................................................................................... 204
How to Maintain Turbocharger .............................................................................................................. 207
Turbocharger disassembly...................................................................................................................... 208
Turbocharger assembly .......................................................................................................................... 209
Turbocharger Check ............................................................................................................................... 210
199
200
9. Intake/exhaust system
General information
General Information
device in it.
8
9
11
6
12
13
10
14
15
2
3
EDL032072C
1. Diesel Engine
6. Filter
12. Actuators
3. Temperature sensor
8. AdBlue tank
13. Sensors
4. SCR Catalyst
5. Temperature sensor
201
9. Intake/exhaust system
Turbocharger
General Information
Turbocharger increases the engine output by inhaling
high-density air to the cylinder by using the exhaust heat
energy of the engine.
3
4
2
9
1
5
6
EDL022073B
1.
Exhaust pipe
4.
Compressor housing
7.
Air inlet
2.
Turbine housing
5.
Compressor wheel
8.
Oil outlet
3.
6.
Intake pipe
9.
engine efficiency.
cylinder.
202
9. Intake/exhaust system
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:
203
9. Intake/exhaust system
Failure Diagnosis
Phenomenon
Noise or vibration
Causes
Troubleshooting
Repair or replace it
Repair or replace it
Burn
Repair or replace it
Loose joint
Check or repair it
Replace it
204
9. Intake/exhaust system
Phenomenon
Causes
Troubleshooting
Check or repair it
Replace or clean it
Repair or replace it
Check or repair it
Replace it
Replace it
Lowered output
Oil leakage
Oil leakage
205
9. Intake/exhaust system
Phenomenon
Oil consumption
Blue emissions
Causes
Troubleshooting
Replace it
Repair or replace it
Repair or replace it
Replace or clean it
Check or repair it
Check or repair it
Repair or replace it
Repair or replace it
Check or repair it
206
9. Intake/exhaust system
How to Maintain Turbocharger
1. Cautions for engine operation
1) Observe the followings when starting, operating, and
stopping an engine.
Item
Cautions
Reasons
If you replace oil, oil filter cartridge, or lubrication system parts or use an engine in cold
areas, or the engine has stopped for a long
When an engine has stopped or kept cold for
period, loosen the oil pipe joint at the inlet of
a long period, circulation of oil in the pipe
the turbocharger and run the starter motor
gets poor.
until oil flows out. After completing the work,
tighten the oil pipe joint again and start the
engine.
After starting an
engine
Stopping an Engine
related parts.
207
9. Intake/exhaust system
Note) It is not necessary to disconnect the clamp on
I
J
50,000 ~ 200,000 rpm. Therefore, lubrication of bearings may determine the turbocharger lifetime. Please
J
I
F
EDL032043C
delivery pipe.
washers (J).
CAUTION
reuse them.
hose (G).
4) Unscrew the flange hex bolts (C).
Turbocharger disassembly
CAUTION
Replace the gasket with a new one; do not reuse it.
EDL032558C
208
9. Intake/exhaust system
Turbocharger assembly
I
J
CAUTION
J
I
F
EDL032043C
CAUTION
ified torque.
CAUTION
3) Connect the gasket (D) and the oil return pipe (E) to
the turbocharger.
EDL032058B
CAUTION
them.
hose(A).
CAUTION
kgfm.
209
9. Intake/exhaust system
Turbocharger Check
precisely adjusted balance is broken, causing vibration. In addition, the bearings are overloaded, resulting
in bearing burn and abnormal wearing. Therefore, an
air filter should be carefully used and maintained
according to the instructed and specified ways. For a
dry type air filter, the intake resistance should be
small as possible.
2) Exhaust system: For the exhaust system, when
exhaust gas leaks from the exhaust pipe or turbocharger joint, supercharging efficiency is lowered. So
you need to pay attention to prevent gas leakage and
burn. Heat resistant nuts are used for parts which are
highly heated during operation, such as turbine seal,
and the nuts should not be mixed with other nuts. The
screw burn prevention paint should be applied to the
assembly nuts of the specified positions.
3) Lubrication system: For the lubrication system, be
careful with the oil quality and the replacement time
of the cartridge of the oil filter. Degradation of engine
oil has bad effect on the turbocharger, as well as the
engine body.
2. Regular Inspection and Repair: The state and contamination of a turbocharger should be checked regularly.
1) Cautions for attaching the turbocharger to the engine:
Please observe the following precautions as attaching
the turbocharger to the engine and handling it after
attaching. Especially, be careful not to let foreign
substances flow into the turbocharger.
210
9. Intake/exhaust system
Exhaust gas reduction
General information
The Doosan engine is equipped with the DOC (Diesel
Oxidation Catalyst) and SCR (Selective Catalytic Reduction) systems in order to comply with Tier 4 final (and
stage IV) emission control. This SCR system consists of
the dosing module, supply module, DCU (Dosing Control
Unit) and other components. The DEF (Diesel Exhaust
Fluid) is stored in the DEF tank. Once it is needed, it is
pressurized by the supply module and is delivered to the
dosing module under a certain level of pressure. The
dosing module is attached to the exhaust manifold to
spray DEF into the exhaust manifold in front of the SCR
system.
EK00298B
211
9. Intake/exhaust system
Aftertreatment muffler and catalyst
The aftertreatment muffler consists of the DOC muffler,
SCR muffler, mixer pipe and other pipes. The DOC
muffler contains DOC (Diesel Oxidation Catalyst) while
the SCR muffler contains SCR (Selective Catalytic Reduction).
TYPE-A
TYPE-B
EK00299B
1. DOC converter
3. SCR Muffler
2. Mixer
212
9. Intake/exhaust system
DNOx6.5 system
The DNOx6.5 system is used to reduce NOx in emissions
by spraying urea into the SCR catalyst. It consists of the
SM (Supply Module), which functions as a pump, DM
(Dosing Module) to spray urea, DCU to control the overall
system.
Coolant Out
Coolant In
Coolant In
Urea
Suction Line
Urea
Back Line
Urea Tank
Coolant Heat
DM
(Dosing Module)
Coolant Out
SM
(Supply Module)
electrical Heat
EK00300B
213
9. Intake/exhaust system
SM (Supply Module)
The supply module is used to pressurize DEF in the DEF
tank to a certain level and supply this pressurized DEF
to the dosing module.
6
Pin 8
Pin 2
Pin 6
Pin 12
PIN 1
Reserve
PIN 7
Reserve
PIN 2
PIN 8
PIN 3
PIN 9
PIN 4
PIN 10
PIN 5
PIN 11
Heater ubal
PIN 6
PIN 12
Heater GND
5
2
4
3
EK00303B
1. Connector
4. AdBlue outlet
2. AdBlue inlet
5. Filter cover
6. cover
7. Housing
214
9. Intake/exhaust system
DM (Dosing Module)
The dosing module is attached to the exhaust manifold
in front of the SCR system to receive DEF from the
supply module and spray it into the exhaust manifold.
3
4
EK00304A
1. Coolant outlet
4. Protective cap
2. Coolant inlet
5. Cooling adapter
7. AdBlue inlet
3. Head shield
6. Dosing valve
215
9. Intake/exhaust system
Urea filter replacement
1. Remove the filter cover.
EK00306C
EK00305C
EK00307B
EK00306B
EK00307C
216
9. Intake/exhaust system
4. Insert the end of the filter removing tool (2) until a
clicking sound is heard or engagement with the filter
is felt.
EK00309C
EK00310B
EK00308C
EK00311B
EK00309B
217
9. Intake/exhaust system
Check DNOx6.5 system failures
1. Dosing Module
Dosing Module fault is cause of the high temperature
exposure of Nozzle Tip injecting Urea, Electric
harness contact failure, Urea Hose Line break or poor
contacet, and more. Visual inspection of DM failure
are as follows.
2
3
EK00311C
order.
9. Tighten filter cover to (20Nm + 5Nm) using 27 inch
Wrench.
same Cabin.
caused by disconnected.
218
9. Intake/exhaust system
2. Supply Module
The Supply Module (SM) failure mode is associated
with Urea Line and Electric Connector damage and
poor connection. When replacing Urea main filter
regularly, Supply module failure can occur caused by
misassembly.
3
4
1
1
EK00344B
CAUTION
When replacing new filter, open the package on the
verge of replacement.
1) When connecting Urea Line, the failure caused by
Urea Line misassembly.
2) Electric connector misassembly or debris contamination inside of connector.
3) When replacing SM Filter, the damage caused by not
using the special tool.Also, it caused by filter remnants
inside SM filter.
4) When replacing filter, the Urea Cap damage is caused
by overtihgtneing and the filter detachment is caused
by not tightening.
219
9. Intake/exhaust system
3. UREA TANK
Urea Tank is keeping the urea solution. Assembly
connected line to correct location. When maintenance
of Urea Tank, be careful not to external impacts.
3
12
6
13
1
7
14
11
9
5
10
4
15
EK00302A
220
9. Intake/exhaust system
Urea Quality Characteristics
LIMITS
CHARACTERISTICS
UNIT
TEST METHODS
MIN.
MAX.
ISO 22241-2 Annex
Urea contenta
%(m/m)b
31.8
33.2
Bc
ISO 22241-2 Annex
Cc
kg/m3
1,087
1,093
1.3814
1.3843
Alkalinity as NH3
%(m/m)b
0.2
Biuret
%(m/m)b
0.3
Aldehydes
mg/kg
Insoluble matter
mg/kg
20
Phosphate (PO4)
mg/kg
0.5
Calcium
mg/kg
0.5
Iron
mg/kg
0.5
Copper
mg/kg
0.2
Zinc
mg/kg
0.2
Chromium
mg/kg
0.2
Nickel
mg/kg
0.2
Aluminium
mg/kg
0.5
Magnesium
mg/kg
0.5
Sodium
mg/kg
0.5
Potassium
mg/kg
0.5
Density at 20Cd
Refractive index at
20Ce
Identity
identical to reference
221
9. Intake/exhaust system
Note) The manufacturer of AUS 32 should aim at the target values defined in footnotes a, d and e.
Note) Should it be necessary to clarify the questions as to whether a given urea solution meets the requirement of the
specifications, the terms of ISO 4259 should be applied.
222
9. Intake/exhaust system
EGR (Exhaust Gas Recirculation) system
General Information
cools the gas, and then delivers the cooled gas to the
is reduced.
The EGR cooler is used to reduce NOx emission and
enhance engine combustion efficiency by reducing
temperature of high-temperature exhaust gas.
3
4
5
8
2
6
7
9
11
10
EDL022076B
1.
Intake
4.
Throttle valve
7.
Exhaust
10. DOC
2.
Compressor
5.
EGR cooler
8.
EGR Valve
11. Exhaust
3.
6.
Intake
9.
Turbine
223
9. Intake/exhaust system
1. Introduction to EGR
I
J
conditions.
2) The exhaust gas is piped from the exhaust manifold,
J
I
F
EGR rate.
3. EGR cooler summary
1) The EGR cooler is a heat exchanger which reduces
the high temperature of the circulated exhaust gas.
EDL032043C
delivery pipe.
washers (J).
Disassembly of EGR
CAUTION
CAUTION
Replace the gasket with a new one; do not reuse it.
EDL032558C
hose (A).
224
9. Intake/exhaust system
4. Disconnect the EGR pipe and hose.
B
A
D
B
A
E
D
EDL032039D
EDL032038C
CAUTION
CAUTION
Assembly of EGR
them.
A
B
EDL032038C
1) Install the EGR valve (A), the EGR cooler (B), and
the gasket (C).
EDL032537E
1) Loosen the hex bolts (B) that fix the EGR cooler
bracket.
2) Unscrew the flange hex bolts (C).
3) Disassemble the EGR cooler assembly (A).
4) With the clamp pressed, disconnect the hose (D).
225
9. Intake/exhaust system
2) Tighten the flange hex bolts (B:3ea) to a tightening
CAUTION
direction.
mounting it.
E
D
EDL032039D
CAUTION
B
them.
C
2) Connect the EGR pipes (A).
EDL032537E
CAUTION
of 2.2 kgfm.
CAUTION
CAUTION
226
9. Intake/exhaust system
5. Install the turbocharger.
I
J
CAUTION
H
J
I
F
EDL032043C
CAUTION
CAUTION
3) Connect the gasket (D) and the oil return pipe (E) to
the turbocharger.
EDL032058B
CAUTION
hose (A).
them.
CAUTION
227
9. Intake/exhaust system
Intake manifold
Disassembly of intake manifold
3) Remove the oil level gauge guide tube (B) from the
cylinder block.
C
D
B
EDL032556C
DL03-LEF02/03
EDL032055C
E
C
DL03-LEL00/01/02/
03/04
D
B
A
EDL032556D
DL03-LEL00/01/02/
03/04
EDL032555D
1) Loosen the flange hex bolt (E) that fixes the boost
pressure sensor.
2) Remove the boost pressure sensor (D).
3) Loosen the flange hex bolts (B).
CAUTION
Replace the gasket with a new one; do not reuse it.
EDL032556E
228
9. Intake/exhaust system
3. Remove the intake stake.
CAUTION
Replace the gasket with a new one; do not reuse it.
D
D
A
E
F
EDL032050C
DL03-LEF02/03
A
B
EDL032548B
D
E
CAUTION
D
D
E
F
EDL032050E
EDL032547C
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).
4) Loosen the flange hex bolts (C) that fix the intake
pumps.
stake.
229
9. Intake/exhaust system
Assembly of intake manifold
B
A
D
C
EDL032546A
EDL032045A
CAUTION
CAUTION
during disassembly.
B
2) Install the intake manifold (A).
D
C
B
EDL032045A
CAUTION
Replace the gasket with a new one; do not reuse it.
EDL032046A
230
9. Intake/exhaust system
1) Install the common rail (A) to the intake manifold.
CAUTION
direction.
during assembly.
common rail free from debris.
B
2) Temporarily tighten the collared hex bolts (B) by hand.
3) Tighten the collared hex bolts (B) to a tightening
torque of 2.2 kgfm.
3. Connect the fuel return hoses.
EDL032548B
of 2.2 kgfm.
4) Tighten the nuts (B) of the fuel injection pipes to a
tightening torque of 3.0 kgfm.
5) Tighten the flange hex bolt (C).
CAUTION
EDL032547C
CAUTION
right direction.
231
9. Intake/exhaust system
5. Install the intake stake.
CAUTION
EDL032050C
6) Tighten the flange hex bolts (F) holding the EGR pipe
to a tightening torque of 2.2 kgfm.
D
E
DL03-LEF00/01
02/03
C
F
D
EDL032050D
DL03-LEL00/01/02/
03/04
A
B
EDL032055C
D
E
F
EDL032050E
232
9. Intake/exhaust system
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
EDL032808E
EDL032808F
233
9. Intake/exhaust system
7. Install the oil level gauge.
3) Press and install the oil level gauge guide tube (B) to
the cylinder block.
DL03-LEF00/01
CAUTION
Install the oil level gauge guide tube in the way that
EDL032556C
DL03-LEF02/03
EDL032556D
DL03-LEL00/01/02/
03/04
EDL032556E
234
9. Intake/exhaust system
Exhaust manifold
Disassembly of exhaust manifold
CAUTION
B
B
A
I
J
D
D
EDL032039D
J
I
F
CAUTION
EDL032043C
washers (J).
CAUTION
235
9. Intake/exhaust system
5. Disassemble the EGR cooler assembly.
CAUTION
C
EDL032537E
1) Loosen the hex bolts (B) that fix the EGR cooler
bracket.
EDL032536C
screen (A).
8. Remove the exhaust manifold gasket.
D
C
A
EDL032535D
DL03-LEL00/01/02/
03/04
EDL032534C
D
E
CAUTION
Replace the exhaust manifold gasket with a new
EDL032535E
236
9. Intake/exhaust system
Assembly of exhaust manifold
DL03-LEF00/01
02/03
A
A
B
B
EDL032535D
EDL032034C
DL03-LEL00/01/02/
03/04
CAUTION
D
E
CAUTION
B
C
A
EDL032536C
sensor.
237
9. Intake/exhaust system
4. Assemble the EGR cooler assembly.
CAUTION
A
CAUTION
EDL032537E
of 2.2 kgfm.
CAUTION
CAUTION
3) Tighten the mounting hex bolt (B) of the EGR cooler
B
A
I
J
H
E
D
D
B
EDL032039D
J
I
F
EDL032043C
238
9. Intake/exhaust system
1) With the clamp pressed, connect the oil return hose
CAUTION
CAUTION
2) Align and install the gasket (B) with the stud bolts of
CAUTION
gasket.
them.
3) Connect the gasket (D) and the oil return pipe (E) to
ified torque.
the turbocharger.
8. Connect the breather hose.
CAUTION
Replace the gaskets with new ones; do not reuse
them.
4) Tighten the hex bolts (F) to a tightening torque of 1.0
kgfm.
5) Align and install the turbocharger (A) with the stud
bolts of the exhaust manifold.
6) Tighten the flange hex bolts (C) to a tightening torque
of 2.2 kgfm.
7) With the clamp pressed, connect the oil return hose
(G) to the return pipe (E).
8) Install the copper washers (J) and temporarily tighten
EDL032058B
CAUTION
239
9. Intake/exhaust system
Intake pipe
Air heater disassembly
DL03-LEF00/01
DL03-LEF00/01
02/03
E
C
D
C
A
B
B
EDL032809C
EDL032055C
E
C
DL03-LEF02/03
DL03-LEL00/01/02/
03/04
B
C
A
A
B
EDL032809D
EDL032555D
DL03-LEL00/01/02/
03/04
1) Loosen the flange hex bolt (E) that fixes the boost
view - A
pressure sensor.
2) Remove the boost pressure sensor (D).
3) Loosen the flange hex bolts (B).
4) Remove the air heater (A).
5) Remove the gasket (C).
CAUTION
C
Replace the gasket with a new one; do not reuse it.
A
B
EDL032809E
240
9. Intake/exhaust system
3) Remove the gasket (C).
DL03-LEL00/01/02/
03/04
CAUTION
view - A
DL03-LEF00/01
B
EDL032809E
1) Install a gasket (c) between the air heater and the air
suction pipe.
2) Install the air suction pipe (A) to the air heater.
CAUTION
DL03-LEF02/03
DL03-LEF00/01
02/03
C
D
C
A
B
EDL032809D
EDL032055C
241
9. Intake/exhaust system
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
EDL032808E
EDL032808F
242
9. Intake/exhaust system
Intake stake disassembly
DL03-LEF00/01
DL03-LEF00/01
02/03
C
D
D
A
D
C
E
B
F
EDL032050C
EDL032055C
E
C
DL03-LEF02/03
DL03-LEL00/01/02/
03/04
D
B
D
E
F
EDL032050D
EDL032555D
DL03-LEL00/01/02/
03/04
1) Loosen the flange hex bolt (E) that fixes the boost
pressure sensor.
CAUTION
F
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).
3) Remove the EGR pipe gaskets (D).
4) Loosen the flange hex bolts (C) that fix the intake
stake.
5) Remove the intake stake (A).
243
9. Intake/exhaust system
6) Remove the gasket (B).
CAUTION
CAUTION
DL03-LEF00/01
EDL032050C
E
A
DL03-LEF00/01
02/03
C
B
D
A
D
E
C
B
F
EDL032050D
EDL032055C
DL03-LEL00/01/02/
03/04
D
D
E
F
EDL032050E
244
9. Intake/exhaust system
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
EDL032808E
EDL032808F
245
9. Intake/exhaust system
246
Valve ................................................................................................................................253
Disassembly of Valve ............................................................................................................................. 253
Assembly of Valve.................................................................................................................................. 253
Measurement of Inside Diameter of Valve Guide ............................................................................... 253
Measurement of valve stem end........................................................................................................... 253
Measurement of valve step height........................................................................................................ 253
Measurement of gap between piston and valve.................................................................................. 254
Check of Valve Spring ........................................................................................................................... 254
Camshaft ..........................................................................................................................276
Disassembly of camshaft ....................................................................................................................... 276
Assembly of Camshaft ........................................................................................................................... 276
Measurement of Camshaft Journal Outside Diameter ......................................................................... 276
247
Breather ...........................................................................................................................281
Disconnection of breather hose............................................................................................................. 281
Connection of breather hose ................................................................................................................. 281
248
249
EDL032085A
corroded.
Item
Specified Value
79.0 ~ 79.021 mm
EDL032086A
EDL032084A
250
D
10 mm
70 mm
140 mm
EDL032089A
EDL032087A
bearing section.
45.025 mm.
Item
Specified Value
Item
Specified Value
97.990 ~ 98.010 mm
45.0 ~ 45.025 mm
EDL032088A
251
EDL032091A
Item
Specified Value
0.05 mm
0.03 mm / 100 mm
E
A
Item
Specified Value
0.05 mm / 100 mm
0.05 mm / 100 mm
252
Assembly of Valve
1. Mount the valve.
Note) Refer to Chapter (Procedure of Assembling an
Engine)
EDL022093A
Item
Specified Value
20.8 ~ 21.3 mm
20.8 ~ 21.3 mm
Specified Value
7.0 ~ 7.015 mm
D A
C B
D A
C B
253
Specified Value
1.69 ~ 2.52 mm
1.54 ~ 2.33 mm
1.2 mm.
Specified Value
0.6 ~ 0.9 mm
0.6 ~ 0.9 mm
EDL022096A
vernier calipers.
Item
Specified Value
55.23 mm
EDL022095A
piston.
5) Detach the cylinder head.
3. Measure the clearance between pistons and valves.
1) Measure the thickness of the lead with a vernier
caliper.
2) The clearance standard between piston and intake
valve is 1.69 ~ 2.52 mm.
EDL022097A
254
Specified Value
EDL022098B
255
DL03-LEL00/01/02/
03/04
E
C
D
B
A
EDL032555D
1) Loosen the flange hex bolt (E) that fixes the boost
EDL032558C
pressure sensor.
hose(A).
CAUTION
E
DL03-LEF00/01
02/03
D
DL03-LEF00/01
B
A
D
D
EDL032055C
F
EDL032050C
256
A
B
D
D
F
EDL032050D
EDL032548B
DL03-LEL00/01/02/
03/04
CAUTION
Do not bend the fuel injection pipes by force.
D
E
A
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).
3) Remove the EGR pipe gaskets (D).
4) Loosen the flange hex bolts (C) that fix the intake
stake.
5) Remove the intake stake (A).
6) Remove the gasket (B).
CAUTION
EDL032547C
257
B
A
EDL032031C
EDL032816B
CAUTION
Remove the heat screen bracket, using care not to
C
D
A
B
EDL032530A
EDL032531B
CAUTION
disassembly.
removing the injectors.
258
EDL032529D
EDL032028A
EDL032529C
EDL032528A
EDL032529B
259
CAUTION
CAUTION
ones.
0.35kgfm.
B
A
B
A
EDL032031A
EDL032030A
CAUTION
EDL032031B
cover (A).
bility.
260
CAUTION
CAUTION
right direction.
reassembly.
2) With the clamps pressed, connect the fuel return
hoses of common rail, injectors, and fuel injection
pumps.
7. Connect the fuel injection pipes.
A
B
A
EDL032817B
kgfm.
CAUTION
EDL032547C
261
CAUTION
EDL032050C
6) Tighten the flange hex bolts (F) holding the EGR pipe
to a tightening torque of 2.2 kgfm.
D
E
DL03-LEF00/01
02/03
C
F
D
EDL032050D
DL03-LEL00/01/02/
03/04
A
B
EDL032055C
D
E
F
EDL032050E
262
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
EDL032808E
EDL032808F
263
EDL032058B
EDL022101A
hose(A).
CAUTION
EDL032102A
EDL032100A
264
EDL032100A
EDL032103A
265
EDL022105A
Normal
Abnormal
(Embossment)
Abnormal
(Crack)
Abnormal
Abnormal
A
EDL0213006B
EDL032558C
hose(A).
Note) It is not necessary to disconnect the clamp on
quick connector side of hose.
266
DL03-LEF00/01
B
D
D
A
D
B
E
F
EDL032055C
E
C
EDL032050C
DL03-LEL00/01/02/
03/04
DL03-LEF02/03
A
B
A
E
F
EDL032555D
EDL032050D
1) Loosen the flange hex bolt (E) that fixes the boost
DL03-LEL00/01/02/
03/04
pressure sensor.
2) Remove the boost pressure sensor (D).
CAUTION
F
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).
3) Remove the EGR pipe gaskets (D).
4) Loosen the flange hex bolts (C) that fix the intake
stake.
5) Remove the intake stake (A).
267
CAUTION
Replace the gasket with a new one; do not reuse it.
4. Disconnect the fuel injection pipe.
B
A
EDL032816B
CAUTION
Remove the heat screen bracket, using care not to
EDL032548B
CAUTION
Do not bend the fuel injection pipes by force.
A
5. Disconnect the fuel return hose.
EDL032531B
EDL032547C
268
EDL032031C
EDL032529D
C
D
EDL032529C
EDL032530A
CAUTION
disassembly.
removing the injectors.
EDL032528A
269
EDL032027A
EDL032028A
hole.
EDL032529D
EDL032027A
EDL032529B
270
CAUTION
CAUTION
ones.
0.35kgfm.
B
A
B
A
EDL032031A
EDL032030A
CAUTION
EDL032031B
cover (A).
bility.
271
CAUTION
CAUTION
right direction.
reassembly.
2) With the clamps pressed, connect the fuel return
hoses of common rail, injectors, and fuel injection
pumps.
8. Connect the fuel injection pipes.
A
B
A
EDL032817A
kgfm.
CAUTION
EDL032547C
272
CAUTION
EDL032050C
6) Tighten the flange hex bolts (F) holding the EGR pipe
to a tightening torque of 2.2 kgfm.
D
E
DL03-LEF00/01
02/03
C
F
D
EDL032050D
DL03-LEL00/01/02/
03/04
A
B
EDL032055C
D
E
F
EDL032050E
273
E
C
DL03-LEL00/01/02/
03/04
DL03-LEL00/01/02/
03/04
view - A
EDL032555D
EDL032808G
DL03-LEF00/01
air heater.
CAUTION
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
EDL032808E
EDL032808F
274
EDL032058B
CAUTION
Gap gauge
EDL0213007A
Specified Value
0.5 mm
275
3) Align the cam gear (A) with the straight key groove
and fasten it with hot pressing.
CAUTION
C
2. Attach the camshaft.
Note) Refer to Chapter About the engine.
EDL032107A
CAUTION
Note that the heating temperature for the camshaft
gear should remain above at least 160C and must
not be over 200C.
Assembly of Camshaft
1. Install the cam gear.
EDL022108B
D
A
3) The standard measurement value of the outside diameter of the camshaft journal is within the range of
44.950 ~ 44.966 mm.
Item
Specified Value
Camshaft journal
44.950 ~ 44.966 mm
EDL032107A
2) Install the thrust washer (C) and the straight key (D)
scratched.
276
Measurement of Camshaft
1. Check the camshaft offset.
Gap gauge
EDL0213003A
Specified Value
Camshaft offset
0.1 ~ 0.2 mm
EDL022110A
277
A
EDL032708C
CAUTION
reuse them.
LEF00/LEF01/LEF02/LEF03).
DL03-LEF00/01
B
B
A
EDL032021C
EDL032520B
278
DL03-LEL00/01/02/
03/04
DL03-LEF00/01
02/03
A
EDL032520D
1) Detach the rear oil seal (A) from the flywheel housing,
CAUTION
EDL032519C
A
B
EDL032520C
CAUTION
DL03-LEL00/01/02/
03/04
right direction.
LOCTITE onto the parts.
minutes after applying LOCTITE to engine parts.
2) Attach the flywheel housing (A).
kgfm.
EDL032520C
279
D
A
B
B
D
EDL032708C
EDL032020B
1) Install the rear oil seal (A) to the rear oil seal
2) Install the rear oil seal assembly jig guide (B) to the
crankshaft (D).
3) Install the rear oil seal assembly jig holder (C) to the
1st Stage
2nd Stage
45 Rotation
jig holder until the real oil assembly jig holder reaches
the flywheel housing and press the rear oil seal (A).
3. Install the flywheel (Only LEF00/LEF01/LEF02/LEF03).
CAUTION
DL03-LEF00/01
the flywheel.
4. Install the starter motor.
EDL032021C
EDL032057A
1) Align and install the starter motor (A) with the stud
bolt.
2) Tighten the flange hex bolts (B) to a tightening torque
of 2.2 kgfm.
280
hose(A).
CAUTION
EDL032558C
EDL032058B
281
DL03-LEL00/01/02/
03/04
E
C
D
B
A
EDL032555D
1) Loosen the flange hex bolt (E) that fixes the boost
EDL032558C
pressure sensor.
hose(A).
CAUTION
E
DL03-LEF00/01
02/03
D
DL03-LEF00/01
B
A
D
D
EDL032055C
F
EDL032050C
282
A
B
D
D
F
EDL032050D
EDL032548B
DL03-LEL00/01/02/
03/04
CAUTION
Do not bend the fuel injection pipes by force.
D
E
A
EDL032050E
1) Loosen the flange hex bolts (F) that fix the EGR pipe.
2) Disconnect the EGR pipe (E).
3) Remove the EGR pipe gaskets (D).
4) Loosen the flange hex bolts (C) that fix the intake
stake.
5) Remove the intake stake (A).
6) Remove the gasket (B).
CAUTION
EDL032547C
283
B
A
EDL032031C
EDL032816B
CAUTION
Remove the heat screen bracket, using care not to
C
D
A
B
EDL032530A
EDL032531B
CAUTION
disassembly.
removing the injectors.
284
EDL032529B
EDL032529D
CAUTION
EDL032529C
EDL032030A
285
CAUTION
CAUTION
cover (A).
CAUTION
ones.
EDL032031A
B
A
EDL032817B
286
of 2.2 kgfm.
kgfm.
CAUTION
EDL032547C
CAUTION
DL03-LEF00/01
pumps.
EDL032050C
DL03-LEF02/03
A
B
B
D
E
F
EDL032548B
EDL032050D
287
DL03-LEF00/01
02/03
C
D
D
A
D
E
C
B
F
EDL032050E
EDL032055C
E
C
CAUTION
DL03-LEL00/01/02/
03/04
aligned.
them.
DL03-LEF00/01
EDL032808E
288
EDL032808F
DL03-LEL00/01/02/
03/04
view - A
EDL032058B
CAUTION
EDL032808G
CAUTION
CAUTION
DL03-LEF00/01 has a rubber packing on its air heater
side, while DL03-LEF02/03, DL03-LEL00/01/02/03/04
has no rubber packing on its air heater side. Do not
mix the air heaters. Mixed use of air heaters may
cause critical damage due to voltage difference.
3) Tighten the flange hex bolts (B) to a tightening torque
of 2.2 kgfm.
4) Install the boost pressure sensor (D).
289
A
EDL032708C
CAUTION
reuse them.
LEF00/LEF01/LEF02/LEF03).
DL03-LEF00/01
B
B
A
EDL032021C
EDL032520B
290
DL03-LEL00/01/02/
03/04
B
EDL032520D
1) Detach the rear oil seal (A) from the flywheel housing,
using an oil seal disassembly jig.
EDL032513C
CAUTION
3) Remove the idle gear (A), using its pulling tap (D).
B
EDL032519C
EDL032013B
DL03-LEL00/01/02/
03/04
CAUTION
The idle gear and the camshaft gear have 2 marks
imprinted on them.
A
B
EDL032520C
291
CAUTION
CAUTION
DL03-LEL00/01/02/
03/04
4) Install the idle gear shaft with its oil hole facing
upward.
5) Temporarily install the flange hex bolts (B), aligning
with the holes of the ilde gear shaft.
6) Tighten the flange hex bolts (B) to a tightening torque
of 4.4 kgfm.
7) The backlash between idle gear and crankshaft gear
is 0.087 ~ 0.202 mm.
Item
Backlash Between Idle
Gear and Crank Shaft
Gear
A
Specified Value
0.087 ~ 0.202 mm
EDL032520C
CAUTION
Specified Value
0.087 ~ 0.213 mm
right direction.
LOCTITE onto the parts.
minutes after applying LOCTITE to engine parts.
2) Attach the flywheel housing (A).
3) Tighten the hex bolts (B) to a tightening torque of 2.2
kgfm.
292
D
A
B
B
D
EDL032708C
EDL032020B
1) Install the rear oil seal (A) to the rear oil seal
2) Install the rear oil seal assembly jig guide (B) to the
crankshaft (D).
3) Install the rear oil seal assembly jig holder (C) to the
1st Stage
2nd Stage
45 Rotation
jig holder until the real oil assembly jig holder reaches
the flywheel housing and press the rear oil seal (A).
4. Install the flywheel (Only LEF00/LEF01/LEF02/LEF03).
CAUTION
DL03-LEF00/01
the flywheel.
5. Install the starter motor.
EDL032021C
EDL032057A
1) Align and install the starter motor (A) with the stud
bolt.
2) Tighten the flange hex bolts (B) to a tightening torque
of 2.2 kgfm.
293
2) The standard measurement value of the inside diameter of the idle gear is within the range of 64.0 ~
64.019 mm.
EDL032111A
Specified Value
59.921 ~ 59.940 mm
A
C
EDL032112A
294
Item
Specified Value
64.0 ~ 64.019 mm
A
DL03-LEF00/01
A
B
EDL032553B
EDL032554B
B
EDL032554C
DL03-LEL00/01/02/
03/04
EDL032553B
A
1) Install the rear lifting hook (A).
EDL032554D
295
A
B
EDL032554B
DL03-LEF02/03
A
B
EDL032554C
DL03-LEL00/01/02/
03/04
EDL032554D
296
D
A
EDL032022B
EDL032810C
EDL032811B
EDL032511B
1) Detach the front oil seal (A) from the front oil seal
holder (B), using an oil seal disassembly jig.
CAUTION
Do not reuse the oil seal; replace it with a new one.
297
4) When the front oil seal (A) is inserted into the front
oil seal holder (B), pull out the front oil seal assembly
jig.
CAUTION
C
EDL032510C
C
C
A
A
B
B
EDL032010B
EDL032010B
1) Place the front oil seal holder (B) with its assembly
1) Place the front oil seal holder (B) with its assembly
2) Insert the front oil seal (A) to the front oil seal
2) Insert the front oil seal (A) to the front oil seal
3) Align the front oil seal assembly jig (C) with the oil
3) Align the front oil seal assembly jig (C) with the oil
seal (A) to the front oil seal holder (B) and press the
seal (A) to the front oil seal holder (B) and press the
298
oil seal holder (B), pull out the front oil seal assembly
DL03-LEF00/01
jig.
B
CAUTION
EDL032810C
DL03-LEF02/03
B
EDL032811B
1) Align and install the crankshaft pulley (A) with the key.
CAUTION
299
300
Starter ..............................................................................................................................322
General information................................................................................................................................. 322
Wiring Diagram ....................................................................................................................................... 324
301
302
EDL032172B
303
F1
KL30
Pbatt
Protected Battery
201
Protected Battery
203
Protected Battery
205
245
219
A/C Request
258
211
Power Ground
202
Power Ground
204
Power Ground
206
177
KL87
F2
KL30
212
Key Switch
F3
KL30
01 2
AC Request
Normal Open
Vbatt
Starter Relay
F4
Battery
12V
Inlet Metering
Valve
5
EGR Valve
DC Motor
3
6
2
Boost Temperature
Sensor
186
194 Exhaust Gas Temperature Sensor 4
169 Exhaust Gas Temperature Sensor 4 Return
Waste Gate
PWR GND
SH-72544 C
140Mhz
(2.5MB internal
flash, 128kB
internal RAM
8kB emulated
EEPROM)
EGR, VREF3
164
116
172
166
192
193
167
228
235
233
VREF2, EG_DPS
VREFGND, EG_DPS
1
2
Exhaust Gas
Delta Pressure
Sensor
Pbatt
D
Air Mass Flow
and Air
Temperature
Sensor QL
Intake Throttle
IGN
Coolant
Temperature
Sensor
Fuel
Temperature
Sensor
Engine Block
Accelerometer #1
Engine Block
Accelerometer #2
1
2
1
1
2
1
2
VR Crank
Sensor
109
145
110
146
131
130
128
132
133
129
160
136
CPS_SHD
187
Pbatt
CAM Shaft
Sensor
CAM
159
147
HALL
Rail
Pressure
Sensor
C
A
B
138
135
119
Vbatt
KL15
KL30
A/C Relay
165
111
148
104
161
VREF2, INPRES
112
167
248
CAN_1 HI
247
CAN_1 LO
239
S_R_LIN
253
CAN_2 HI
254
CAN_2 LO
Vs
Sig
Rtn
VS
V
Vp
Rtn
Vt
P
t
Oil Pressure
and
Temperature
Sensor
B
A
Intake Manifold
Pressure Sensor
CAN_Vehicle HI
CAN_Vehicle LO
Un Terminated in ECU
CAN_Development HI
CAN_Development LO
231
Exhaust
Manifold
Pressure
Sensor
Terminated in ECU
C_ISOK
127
126
151
175
103
125
150
174
Cyl #1
Cyl #3
Cyl #4
Cyl #2
EDL032123A
304
Parking Brake
181
Diagnostic Request
195
196
152
PTO/Cruise - Engage
218
IGN
T87
Vbatt
PWR GND
Engine Brake
NC
217
246 Engine Speed Out. PWM 50mA MAX
134
153
222
VREF2, ACPRES
208
AC Pressure Sensor
220
227
137
VREF3 (5V)
114
Regen - Start
120
Switch Return
113
209
AC Pressure
Sensor
Option
V
P
Vehicle
Speed
Sensor
Regen
Switch
3 State
Switch
4 State
Switch
H 2O O
223
VREF3 (5V)
215
Cruise /
PTO
Switch
210
240
249
171
255
MIL Lamp
242
CE Lamp LSD
CE Lamp
241
Glow Lamp
238
DPF Regen
250
Warning
Auto Fan
FAN
LSD
237
257
Oil Pressure
Warning Lamp
EDL032123B
Wire
Size
Wire
Color
Wire
Type
103
0.75
AESSXF
104
0.75
106
0.75
109
ECU
PIN No
Sensor
PIN No
AESSXF
AESSXF
0.75
AESSXF
110
0.75
AESSXF
10
111
0.75
AESSXF
11
112
0.75
AESSXF
12
113
0.75
AESSXF
REGEN SWITCH-4STATE
SWITCH
13
116
0.75
AESSXF
16
119
0.75
AESSXF
19
120
0.75
AESSXF
REGEN SWITCH-RETURN
20
123
0.75
AESSXF
23
125
0.75
AESSXF
25
126
0.75
AESSXF
26
127
0.75
AESSXF
27
128
0.75
129
0.75
TUBE
_AMS12
130
0.75
131
0.75
132
Circuit Name
Remarks
28
SHIELD_130_131
(DRAIN)
29
SHIELD_132_133
(DRAIN)
AESSXF
_AMS11
30
SHIELD_130_131
AESSXF
_AMS11
31
SHIELD_130_131
0.75
AESSXF
_AMS12
32
SHIELD_132_133
133
0.75
33
SHIELD_132_133
134
0.75
AESSXF
34
135
0.75
AESSXF
35
306
Wire
Size
Wire
Color
Wire
Type
136
0.75
AESSXF
_AMS13
137
0.75
138
0.75
145
ECU
PIN No
Sensor
PIN No
36
AESSXF
37
AESSXF
38
0.75
AESSXF
45
146
0.75
AESSXF
46
147
0.75
AESSXF
47
148
0.75
AESSXF
48
150
0.75
AESSXF
50
151
0.75
AESSXF
51
152
0.75
AESSXF
52
153
0.75
AESSXF
53
10
159
0.75
AESSXF
59
160
0.75
AESSXF
_AMS13
60
161
0.75
AESSXF
VREF2, INPRES
61
164
0.75
AESSXF
EGR, VREF3
64
165
0.75
AESSXF
65
167
0.75
AESSXF
67
169
0.75
AESSXF
69
172
0.75
AESSXF
72
174
0.75
AESSXF
74
175
0.75
AESSXF
75
177
0.75
AESSXF
77
181
0.75
AESSXF
PARKING BRAKE
81
187
0.75
TUBE
_AMS13
87
192
0.75
AESSXF
92
193
0.75
AESSXF
93
Circuit Name
307
Remarks
SHIELD_136_160
SHIELD_136_160
SHIELD_136_160
(DRAIN)
Wire
Size
Wire
Color
Wire
Type
194
0.75
AESSXF
195
0.75
196
0.75
K87A
K87B
ECU
PIN No
Sensor
PIN No
94
AESSXF
DIAGNOSTIC REQUEST
95
AESSXF
96
0.75
AESSXF
INTER1_2M
0.75
AESSXF
INTER1_2M
Circuit Name
308
Remarks
Wire
Size
Wire
Color
Wire
Type
103
0.75
AESSXF
104
0.75
106
0.75
109
ECU
PIN No
Sensor
PIN No
AESSXF
AESSXF
0.75
AESSXF
110
0.75
AESSXF
10
111
0.75
AESSXF
11
112
0.75
AESSXF
12
116
0.75
AESSXF
16
119
0.75
AESSXF
19
120
0.75
AESSXF
REGEN SWITCH-RETURN
20
123
0.75
AESSXF
23
125
0.75
AESSXF
25
126
0.75
AESSXF
26
127
0.75
AESSXF
27
128
0.75
129
0.75
TUBE
_AMS12
130
0.75
131
0.75
132
Circuit Name
Remarks
28
SHIELD_130_131
(DRAIN)
29
SHIELD_132_133
(DRAIN)
AESSXF
_AMS11
30
SHIELD_130_131
AESSXF
_AMS11
31
SHIELD_130_131
0.75
AESSXF
_AMS12
32
SHIELD_132_133
133
0.75
33
SHIELD_132_133
135
0.75
AESSXF
35
136
0.75
AESSXF
_AMS13
36
SHIELD_136_160
137
0.75
AESSXF
37
309
Wire
Size
Wire
Color
Wire
Type
138
0.75
AESSXF
145
0.75
146
0.75
147
ECU
PIN No
Sensor
PIN No
38
AESSXF
45
AESSXF
46
0.75
AESSXF
47
148
0.75
AESSXF
48
150
0.75
AESSXF
50
151
0.75
AESSXF
51
159
0.75
AESSXF
59
160
0.75
AESSXF
_AMS13
60
161
0.75
AESSXF
VREF2, INPRES
61
164
0.75
AESSXF
EGR, VREF3
64
165
0.75
AESSXF
65
167
0.75
AESSXF
67
169
0.75
AESSXF
69
172
0.75
AESSXF
72
174
0.75
AESSXF
74
175
0.75
AESSXF
75
177
0.75
AESSXF
77
179
0.75
AESSXF
Circuit Name
79
Remarks
SHIELD_136_160
187
0.75
TUBE
_AMS13
87
192
0.75
AESSXF
92
193
0.75
AESSXF
93
194
0.75
AESSXF
94
K87
0.75
AESSXF
INTER1_4M
K87A
0.75
AESSXF
SPLICE(K87)
INTER1_4M
310
SHIELD_136_160
(DRAIN)
inhaled initially.
manifold.
No
ECU PIN
Description
228
235
120
Ground
137
Supply voltage(12V)
EDL022176B
No
ECU PIN
Description
161
Supply voltage(5V)
167
Ground
112
Pressure signal
No
ECU PIN
Description
169
Ground
194
Temperature signal
EDL022177A
311
No
ECU PIN
Description
123
Ground
106
Temperature signal
pump.
engine oil.
ECU#1
ECU#1
ECU#1
ECU#1
EDL022180A
EDL022178B
No
ECU PIN
Description
148
Ground
104
Temperature signal
165
Supply voltage(5V)
111
Pressure signal
No
ECU PIN
Description
110
Temperature signal
146
Ground
EDL022181A
No
ECU PIN
Description
135
Pressure signal
119
Ground
138
Supply voltage(5V)
EDL022179A
No
ECU PIN
Description
145
Ground
109
Temperature signal
312
Injector #3 (INJ)
126127
175151
EDL022182B
No
ECU PIN
126
127
EDL022184B
Description
No
ECU PIN
Description
175
151
Injector #2 (INJ)
Injector #4 (INJ)
174150
125103
EDL022183B
No
ECU PIN
174
150
EDL022185B
Description
No
ECU PIN
125
103
313
Description
No
ECU PIN
Description
160
CRS POS
187
Shield
each piston.
EDL022186B
No
ECU PIN
Description
136
CRS NEG
160
CRS POS
187A
Shield
EDL022187A
No
ECU PIN
Description
159
147
Ground
Supply voltage(12V)
of the piston.
EDL022186A
No
ECU PIN
136
Description
CRS NEG
314
No
ECU PIN
Description
133
Ground
132
Accelerometer signal
129
Shield (Screen)
EDL022188B
No
ECU PIN
Description
130
Ground
131
Accelerometer signal
128
Shield (Screen)
EDL022190A
Knock Sensor2(KNOCK2)
A sensor that is mounted on the cylinder block, sensing
No
ECU PIN
164
Supply voltage(5V)
193
H-Bridge NEG
172
Ground
116
192
H-Bridge NEG
Description
EDL022189B
315
EDL022191A
No
ECU PIN
177
Description
Supply voltage(12V)
PWM signal
EDL022221A
No
ECU PIN
Description
209
234
Ground
316
317
318
EDL022195A
1.
2.
319
Engine output
Engine
Injector output
ECU I/O
Vehicle output
Vehicle
Communication
Start switch
Failure Diagnosis Switch
EDL0213008A
320
1. Engine Start
Diagnosis Information Display Lamp: Provides information of fault state to drivers for safe driving.
5. Failure Diagnosis
1) When a fault occurs, the failure diagnosis information
display lamp on the gauge board is turned on.
2) With the failure diagnosis information display lamp,
drivers can see the fault code.
Note) It can be checked from the failure diagnosis information on the gauge board.
3) It can be diagnosed by connecting the diagnosis unit
to the check connector at the back of the driver's seat.
6. Driving record
1) Writes the information related driving to the ECU.
321
1
2
EDL032173C
322
DL03-LEF02/03
1
3
2
EDL032173D
2. Terminal S: M5 X 0.8P(Yellow)
S
M
S/W
EDL032174C
DL03-LEF02/03
S
M
S/W
EDL032174D
CAUTION
Before handling the electric system, the ground wire
of the battery ( - wire) must be disconnected. To
eliminate any possible short circuit, connect the
ground wire at the end after the work is completed.
324
2
(RPM)
BATT. ; 24 -C
(kg.m)
(kW)
(V)
3500
14
8.4
28
3000
12
7.2
24
2500
10
6.0
20
2000
4.8
16
1500
3.6
12
1000
2.4
500
1.2
(TEMP ; 20 C)
2
3
4
0
200
400
600
800
6 (A)
EDL032175C
2. Rev count
3. Torque
4. Output
5. Terminal voltage
6. Load current
325
DL03-LEF02/03
2
(RPM)
3000
3
(kg.m)
2500
2000
1500
1000
500
(kW)
BATT. ; 12 -E
(V)
12
10
(TEMP ; 20 C)
2
4
3
0
200
400
600
800
6 (A)
EDL032175D
2. Rev count
3. Torque
4. Output
5. Terminal voltage
6. Load current
326
B
EDL032557A
Assembly of Starter
1. Install the starter motor.
EDL032057A
1) Align and install the starter motor (A) with the stud
bolt.
2) Tighten the flange hex bolts (B) to a tightening torque
of 2.2 kgfm.
327
328
Crankshaft ........................................................................................................................332
Disassembly of Crankshaft..................................................................................................................... 332
Assembly of Crankshaft ......................................................................................................................... 332
Measurement of crankshaft main journal diameter.............................................................................. 332
Measurement of crankshaft bearing gap .............................................................................................. 332
Measurement of crankshaft warpage .................................................................................................... 333
Disassembly of timing wheel ................................................................................................................. 333
Assembly of timing wheel ...................................................................................................................... 335
Piston ...............................................................................................................................337
Disassembly of piston ............................................................................................................................ 337
Assembly of piston ................................................................................................................................. 337
Measurement of outside diameter of piston pin .................................................................................. 337
Measurement of Inside diameter of piston pin bore ........................................................................... 337
Measurement of gap of piston ring end............................................................................................... 338
Measurement of step height of piston top side................................................................................... 338
Flywheel ...........................................................................................................................341
Disassembly of flywheel ......................................................................................................................... 341
Assembly of flywheel.............................................................................................................................. 341
Others ..............................................................................................................................345
Engine timing .......................................................................................................................................... 345
Check of gear backlash ......................................................................................................................... 346
Check of gear axial offset ..................................................................................................................... 347
329
330
331
Engine)
Assembly of Crankshaft
1. Attach the crankshaft.
Note) Refer to Chapter (Procedure of Assembling an
Engine).
section.
journal.
disassemble it.
3) Check the width of the plastic gauges.
4) The outside diameter standard of crankshaft bearing
is 0.029 ~ 0.059 mm.
Item
Specified Value
0.029 ~ 0.059 mm
EDL032121A
Specified Value
74.955 ~ 74.970 mm
332
EDL032811B
on the V-block.
B
DL03-LEF00/01
EDL032022B
333
EDL032511B
EDL032509B
1) Detach the front oil seal (A) from the front oil seal
CAUTION
Do not reuse the oil seal; replace it with a new one.
4. Remove the front oil seal holder.
C
B
EDL032508C
CAUTION
EDL032510C
wheel.
334
A
B
A
EDL032010B
1) Place the front oil seal holder (B) with its assembly
EDL032008C
1) Align the timing wheel (A) with the dowel pin and
2) Insert the front oil seal (A) to the front oil seal
3) Align the front oil seal assembly jig (C) with the oil
seal (A) to the front oil seal holder (B) and press the
CAUTION
4) When the front oil seal (A) is inserted into the front
wheel.
oil seal holder (B), pull out the front oil seal assembly
jig.
CAUTION
2. Install the crank speed sensor.
EDL032009A
335
CAUTION
C
EDL032011B
DL03-LEF00/01
CAUTION
right direction.
3) Align and install the front oil seal holder (A) with
DL03-LEF02/03
B
EDL032811B
D
1) Install the V-belt (A).
EDL032022B
1) Align and install the crankshaft pulley (A) with the key.
336
D
C
A B
CD
EDL032130A
EDL022132A
1) Remove the 1st ring (D), the 2nd ring (C), and the
Assembly of piston
Specified Value
35.995 ~ 36.000 mm
D
C
A
AB
C D
EDL032130A
1) Install the 1st ring (D), the 2nd ring (C), and the oil
ring (B), using a piston ring plier.
CAUTION
EDL032133A
337
B, C, and D.
~ 36.014 mm.
Item
Specified Value
31.008 ~ 31.014 mm
A
R
F
B
EDL032135A
0.52 mm.
Item
Specified Value
0.24 ~ 0.52 mm
CAUTION
Item
Specified Value
0.25 ~ 0.40 mm
0.55 ~ 0.70 mm
0.20 ~ 0.40 mm
CAUTION
Use care not to damage the cylinder when
measuring the piston ring end clearance with the
clearance gauge.
338
Item
Specified Value
36.025 ~ 36.038 mm
Engine).
large-end.
EDL022199B
EDL022197B
B
C
A
A
D
B
E
C
EDL022200B
EDL022198B
Item
Specified Value
66.000 ~ 66.015 mm
339
CAUTION
Fasten the connecting rod bolt by hand until its head
reaches the bolt contact surfaces on both sides of
the connecting rod and tighten it securely to the
specified torque.
EDL032131A
Specified Value
0.026 ~ 0.066 mm
340
A
EDL032708C
CAUTION
reuse them.
LEF00/LEF01/LEF02/LEF03).
DL03-LEF00/01
Assembly of flywheel
1. Install the flywheel (Only LEF00/LEF01/LEF02/LEF03).
DL03-LEF00/01
A
B
EDL032021C
EDL032021C
341
DL03-LEF02/03
EDL032708C
2nd Stage
45 Rotation
CAUTION
Do no reuse the flange hex bolts when assembling
the flywheel.
2. Install the starter motor.
EDL032057A
1) Align and install the starter motor (A) with the stud
bolt.
2) Tighten the flange hex bolts (B) to a tightening torque
of 2.2 kgfm.
342
D
A
EDL032022B
EDL032810C
B
EDL032811B
EDL032022B
1) Align and install the crankshaft pulley (A) with the key.
2) Apply Loctite Ultra Blue 587 to the insdie of the flange
hex bolt (B).
3) Tighten the flange hex bolt (B) to a tightening torqueof
26 kgfm.
4) Connect the crankshaft pulley (A) and (C).
343
CAUTION
EDL032810C
DL03-LEF02/03
EDL032811B
344
6
5
EDL032136B
345
D
C
E
B
D
EDL032137B
EDL032138B
camshaft.
Note) The idle gear and the camshaft gear have 2 marks
imprinted on them.
Item
Specified Value
0.087 ~ 0.202 mm
0.066 ~ 0.247 mm
0.087 ~ 0.213 mm
0.081 ~ 0.196 mm
346
EDL032139A
Specified Value
0.10 ~ 0.31 mm
0.10 ~ 0.20 mm
0.10 ~ 0.20 mm
347
348