Doosan Common Rail Engines

DL06, DL08 & DV11

August, 2011
EMEA Training Team

Contents
1. Common rail system.
2. DL06 / DL08 / DV11 Common rail engines
3. E.C.Us
4. C.P Pumps
5. Common rail
6. Injectors
7. Sensors
8. Valve clearance adjusting & Maintenance

Common Rail System

Fuel injection is controlled by electrical

signal
- Fuel injection pressure is unlimited
(400 ~ 1600 bar)
- Fuel injection timing is unlimited
- Fuel injection frequency is unlimited
- Fuel injection volume is unlimited
The common rail system engine can solve the
above mechanical engine limitation problems.

Common rail system engine is able to satisfy the new emission regulations.

Common Rail System

High pressure supply pump :

Supplies fuel at high pressure.

ECU & Injector :

Determines fuel volume, Injection fuel timing,
fuel injection frequency by ECU signal

Common Rail System

1) High pressure supply pump

2) High pressure tube (=Injection pipe)
3) Common rail with pressure limiter valve and rail pressure sensor
4) CR Injector / High pressure connector
5) E.C.U
6) Sensors (Accel. Pedal, Temperature ,Pressure )
7) Harness (1.Engine 2.Injector 3.Vehicle )

Common Rail System

High Pressure supply

pump (CP3)

Rail Pressure Sensor

Pressure Pipe

Pressure Limiter Valve

CR Injector

ECU
Common Rail

Common Rail System

Pressure
limiter valve

High
pressure
pump
CP3

Rail pressure
sensor
Rail

Gear
pump

Flow limiter
Filter

Metering
unit ZME
Other actuators

Other sensors
Injector
Accelerator
pedal

Control unit

Tank

Prefilter

Engine
speed
(crank)
Engine
speed
(cam)

High pressure
Low pressure

Common Rail System

Temperature

Nox
(1)

PM (Smoke)
(2)

CRS Angle

(1)
(2)

Multiple injection and E.G.R.

Fuel atomization (High pressure fuel injection)

Common Rail System

Multiple Injection

Dispose noxious fumes

Noise Control

Pre/Pilot Injection

Main Injection

Post/After
Injection

Common Rail System

Valve Lift (mm)

IEGR - Internal Exhaust Gas Recirculation

Inputs exhaust gas to cylinder head during the exhaust stroke, by opening the intake
valve during the exhaust stroke.
1. Prevents excessive supply of oxygen to the cylinder during the suction stroke.
2. Reduces the combustion temperature in the cylinder.

Common Rail System

IEGR -Internal Exhaust Gas Recirculation
The EGR reduces combustion temperature.

- Combustion stroke
1) Pure air in cylinder only :
Combustion temperature in cylinder is too high with pure air
only.
2) Pure air + exhaust gas in cylinder :
The combustion temperature is lower than the combustion
temperature with pure air only, because of less oxygen in the
cylinder.
In order to increase exhaust gas 1C , It requires a lot of
calories. It means the exhaust gas consumes lots of energy to
increase 1C temperature.

Common Rail System

2. DL06 / DL08 / DV11

1. Purpose : Euro-III Emission Meet, Euro-IV/V Capable

2. Target Model :
DL06 (5.89 ltr) 95~175ps/1900rpm
DL08(7.6 ltr) 280~320ps/2200rpm,
DV11(11.0 ltr) 350~420ps/1800rpm,
3. Applied technique:
4-Valves Per Cylinder, Electronic Common Rail System,
Rear Gear Train, Internal E.G.R.

Common Rail System

Heavy Duty Engines for EURO-3 Emission Regulation
- Model

DL06 & DL08-EURO III

In-Line 6 , Turbo-Intercooled type

Bore x Stroke : 100 mm x 125mm (5.89 ltr)
108 mm x 139 mm (7.6 ltr )
Max. Power : 129 kW [ 175 PS] at 1900 rpm
235 kW [ 320 PS ] at 2200 rpm

4 Valves per
Cylinder
Electronic
Common-Rail
Fuel System
Low Pollution & Low
Consumption of Fuel,
Lub. oil

4-Valves
per
Cylinder
Common
Rail

High Output and

Durability

Common Rail System

Heavy Duty Engines for EURO-3 Emission Regulation
- Model

DV11-EURO III

Vee 6,

Turbo-Intercooled type

Bore x Stroke : 128 mm x 142 mm(11.0 Liter)

Max. Power : 309 kW [ 420 PS ] at 1800 rpm

4 Valves per
Cylinder
Electronic
Common-Rail
Fuel System
Low Pollution & Low
Consumption of Fuel,
Lub. oil
High Output and
Durability

4-Valves
per
Cylinder
Common
Rail

Compact and Light

Weight

Common Rail System

Wastegate
Turbocharger

Injector
Cyl. Head
Piston
Common rail
Con. Rod
Cyl. Block

High Pressure Pump

Cam Shaft
Starter

Crank Shaft
Combo Oil Filter

Oil Pan

Common Rail System

DL06 / DL08 / DV11

Common Rail System

DL08 Engine curve

Suffix

EUPEA (DX300)

Rated
power

200 ps/1900 rpm

Max torque

93 kg.m/1,300 rpm

Rate of fuel
consumptio
n

155 g/ps.h

Common Rail System

Engine serial number
DL08

DV11

DL08 4 00001 BA
DV11 4 00001 BA
Engine Model
Production year

Engine code (Engine suffix)

Serial number

Common Rail System

DL06 & DL08 Engine

No 1 cylinder is fan end

Common Rail System

DV11 Engine

No 1 Cylinder is next to the water pump

Common Rail System

Cylinder head
Hexagonally arranged
cylinder head bolts
Injector sleeve
Ex
Ex

4 valves & central injector port

In
In

Common Rail System

Intake/ Exhaust valve
Caliper adjust screw
Valve gap adjust screw
Caliper

Common Rail System

Intake / Exhaust Valve Calipers (DL06 Only)

Ball pin
Cap

Lubricating oil goes through the ball pin and

cap to the top contact face of the caliper.
Lubrication oil is sprayed on the top of the
Push rod and adjustment screw directly.

Intake/ Exhaust valve calipers are NOT the same

(Exhaust has larger pad area)
Direction of caliper installation is critical
(Oval hole nearest push rod)
The lubrication oil passage (1.0mm)

Common Rail System

Intake/ Exhaust valve (II)

Mark should be top position

Mark here

Valve spring
Intake valve

Exhaust valve

Common Rail System

Head gasket
One layer steel gasket
Fiber preforated gasket

Cylinder
liner

Cylinder
liner
Part No.
Cylinder block

Cylinder block

Current engine gasket

DL/DV Engine gasket

* Part number on gasket is top position when installing

Common Rail System

Tightening order for head bolts

Tightening torque : refer to the maintenance manual

Common Rail System

4 Valves & New combustion chamber shape
ELE
ELEControl
ControlCommon
CommonRail
Rail
44Valves
/
Cylinder
Valves / Cylinder
New
NewCombustion
CombustionSystem
System
Central
CentralVertical
VerticalInjector
Injector

High
Power

4-Valves

Low
Pollution

Common Rail
Injection system

Low Fuel
Consumption
Ratio

New Combustion System

Common Rail System

Fuel Injection

Current

New engine

Common Rail System

Cam shaft IEGR (Internal exhaust gas recirculation)

Intake
Intakecam
cam

IEGR lobe
Opens the intake valve a little, to put exhaust gas in to the intake manifold, while
the engine exhausts exhaust gas to outside.
- The exhaust gas causes lower temperature in cylinder during compression
stroke.

Common Rail System

Gear train (Timing gear)

Assembly of timing gear on engine

1.

Assemble cam shaft timing gear

2.

Assemble CRS shaft timing gear

3.

Assemble step idle gear on body

Align 0 mark with CRS timing gear
and idle gear
Align 1 mark with Cam timing gear
and idle gear
Gear backlash is 0.074~0.163
(Except oil pump gear backlash)

Common Rail System

Gear train

View to fly wheel direction

1.

Crank shaft gear

2/3

Idler gear

4.

Cam shaft gear

5.

Idler gears for Fuel high

pressure pump

6.

Fuel high pressure pump

7.

Oil pump

Common Rail System

Timing gear (DL08)
Timing mark

Cam
shaft

Idle
gear

C.R.S

Common Rail System

Timing gear (DV11)
Timing mark

Cam shaft

C.R.S

Common Rail System

DL06 engine oil circulation

Oil pan Oil pump Oil filter Oil cooler Main gallery Oil spray nozzle
Camshaft / rocker arm / turbo charger / timing gears Oil pan

Common Rail System

DL06 engine oil circulation

Oil Pan

Oil Pan

Oil pan Oil pump Oil cooler

Oil filter Main gallery Oil spray nozzle
Oil pan

Rocker arm shaft

Cam shaft
CRS
Oil pan
Gear train
Turbo charge

Common Rail System

DL06 Piston
1. Oil Spray Nozzle

The oil from engine main gallery is supplied

to the piston oil gallery for piston cooling.
2. Oil Hole

An oil passage connects oil from oil spray

nozzle to the inside of piston oil gallery

3. Oil Gallery
Oil hole for cooling piston and combustion
chamber.

4. Oil Drain Hole

Drained oil connects to piston pin on
connecting rod for lubrication

Common Rail System

DL06 coolant circulation
Cylinder Head

Thermostat

Water
pump

Radiator

Water pump Engine oil cooler Cylinder block Cylinder head Thermostat
Radiator Water pump

Common Rail System

DL06 coolant circulation

Water pump Engine oil cooler Cylinder block Cylinder head Thermostat
Radiator Water pump

Common Rail System

DL06 coolant circulation

Cylinder

Water
pump

Oil cooler

The coolant is distributed to engine cylinder block via the oil

cooler

Cooling water

Common Rail System

Oil lubrication (DL08)

Contaminated hot oil

Cleaned hot oil
Cleaned cool oil

Common Rail System

Cooling system (DL08)

Hot water
Cool water

Common Rail System

Oil lubrication (DV11)

Contaminated hot oil

Contaminated cool oil
Cleaned cool oil

Common Rail System

Cooling system (DV11)

Hot water
Cool water

Common Rail System

Fuel system (DL06 & DL08)
Common rail

Injector
Cylinder head

2nd fuel filter

Fuel pressure
pump
1st fuel filter
E.C.U

Fuel tank

Common Rail System

Fuel system (DV11)
Common rail
Fuel pressure
pump

2nd fuel filter

1st fuel filter

E.C.U

Fuel tank

Injector
Cylinder head

High pressure
connector

Common Rail System

Turbo Charger (Waste Gate Type)

Closed

Open

Reducing shaft power, avoiding excess air delivery and rotor over speed

Not Closed Crankcase Ventilation)

3. E.C.U

Common Rail System

DL06 : ECU
Injector connector Vehicle
Connector

Engine connector

Hardware : Bosch
EDC7UC31
Software : Special software
for Doosan
engine

Atmospheric
Pressure Sensor

Common Rail System

E.C.U
Vehicle
Connector

ATM Sensor
(Not use)

Engine connector

Injector connector

Common Rail System

E.C.U (Tightening order & torque)

6
2
Tightening torque : 1 0.2Kg.m

Common Rail System

DL06 : Engine connector harness

Common Rail System

DL08 & DV11 Engine connector harness

Common Rail System

DL06 : Injector connector harness

Common Rail System

DL08 & DV11 Injector connector harness

Common Rail System

ECU Control
1) Engine starting
* Sensing the coolant temp., fuel temp. and intake air temperature to
calculate
fuel quantity
* Sensing the engine RPM using crankshaft speed sensor on flywheel
housing
Calculate the optimalheating
fuel quantity for engine starting
2) *Preheating/After
* Sensing the coolant temp., fuel temp. and intake air temperature to
calculate
heating or not
- Heating function works below 10 degree C
* Preheating
- Key On position with warning lamp
- Heating time depends on coolant temperature
* After heating
- No warning lamp
- Heating time depends on coolant temperature
* Preheating (After heating) is not working if battery voltage is lower
than 12V.

Common Rail System

ECU Control
1) Engine Starting
Coolant Temp
Fuel Temp
Air Temp

Injector

ECU

Engine RPM

ECU decides optimal fuel quantity for engine starting

2) Preheating

Key on

Coolant Temp
Fuel Temp
Air Temp

ECU

Air heater
Warning lamp

ECU decides optimal preheating time

If battery voltage is lower than 12V, heating is not working

Common Rail System

ECU Control
3) After heating

Engine running signal

Coolant Temp

ECU

Fuel Temp

Air heater

Air Temp

ECU decides optimal preheating time

If battery voltage is lower than 12V, heating is not working

4) Limp home
LCD Panel
EPOS

X
X

ECU

1000 RPM

ECU Control (4/4)

5) Emergency stop

Emergency
engine stop signal

Engine running signal

ECU

Cut Fuel Injection

Common Rail System

Before doing electric welding on the machine ...
Very Important
If welding occurs on any vehicle (excavator or loading
shovel ..) while the harness connectors are connected on the
engine ECU, the ECU can be seriously damaged.
Please adhere to the following:
1. Disconnect the battery Earth cable ( - cable) from the
chassis.
2. Disconnect the wiring harness connectors from the engine
ECU (& also the e-Epos, Transmission Controller & Fan
controller as appropriate for the vehicle)
3. Once the welding is completed.
4. Re-connect the wire harness connectors on to the ECU (etc)
5. Re-connect the battery Earth cable ( - cable) on to the

4. CP pump

Common Rail System

Fuel system of DL06 & DL08

Common Rail System

Fuel schematic drawing (DL06 & DL08)

Back Pressure Valve

p back CRIN1: 0.3...1 bar erl.
p back CRIN2: 0...1 bar rel.

filter

injectors

burst pressure >15bar

DBV
rail
metering unit

over
pressure
valve
10.5...13 bar

bypass
valve
0.1 bar

p suction
0.5...1.0 bar abs

cooling
plate

handprimer

prefilter
<=100mm with
water separator

lubrication

KV
zero delivery drain

p back CP3 < 1.2 bar abs

KV: two step overflow valve
DBV: pressure limiter valve

: high pressure
: low pressure

Common Rail System

Fuel high pressure pump DL06 & DL08 (CP3.3 Pump)

Common Rail System

Fuel high pressure pump DL06 & DL08 (CP3.3 Pump)
60ml fuel here

When assembling the CP pump to the engine, 60ml of fuel must be put in the pump
before starting up the engine and pay attention to assembly of fuel hose connections

Common Rail System

Fuel high pressure pump DL06 & DL08 (CP3.3 Pump)

Fuel drain hole

Small amount of CP pump lubricating fuel can leak from fuel

drain hole in order to prevent the unwanted mixing of engine
oil and fuel.

Common Rail System

Fuel high pressure pump DL06 & DL08 (CP3.3 Pump)
T : Torque
(Nm)
Return
to fuel
tank
T = 252

From prefilter
T = 222

From fuel
filter
T = 252

To fuel filter
T = 222

Metering
Unit

T = 11010

For tightening
bolt M8
T = 305

To rail (high press.)

T = 20.52.5

When assembling a new CP pump on to the engine,

60ml clean fuel must be filled in pump for initial lubrication !!

Common Rail System

Fuel high pressure pump DL06 & DL08 (CP3.3 Pump)
Gear
Pump

High Pressure
Low Pressure

Metering
Unit

Fuel Lubricating System

Common Rail System

Gear pump (CP3.3 Pump)

Common Rail System

Fuel high pressure pump DV11 (CP3.4 Pump)

Common Rail System

Fuel high pressure pump DV11 (CP3.4 Pump)

Common Rail System

Fuel high pressure pump DV11 (CP3.4 Pump)

Fuel high pressure pump DV11 (CP3.4 Pump)

Gear pump

High Pressure
Low Pressure
Oil

Metering Unit

Oil Lubricating System

* First assemble, Input 40ml Engine Oil

Common Rail System

DV11 - Low & High pressure circuit CP3.4
p back CRIN1: 0,3...1 bar rel.
p back CRIN2: 0...1 bar rel.

filter
burst pressure >15bar

injectors
DBV
rail
metering unit

over
pressure
valve
10,5...13 bar

p suction
0,5...1,0 bar abs

handprimer

bypass
valve
0,15 bar

cooling
plate
prefilter
with water
separator

zero delivery
drain

p back CP3 < 1,2 bar abs

V: overflow valve
DBV: pressure limiter valve

: high pressure
: low pressure

Common Rail System

Gear pump

Common Rail System

Metering unit location

DL08

DV11

Common Rail System

CP Pump Part Number

Engine

Doosan Part No.

Spec.

Lubrication

DL06

65.10501-7005A

Euro3, Tier3

Fuel

DL08

65.10501-7001A

Euro3, Tier3

Fuel

DV11

65.10501-7002A

Euro3, Tier3

Engine Oil

Common Rail System

Metering unit

Coil resistance :
2.6 ~ 3.5

Open :
Below 8 Volt

Closed :
Above 8 Volt

Supply of fuel from the gear pump to the high pressure CP pump is controlled by the ECU

5. Common rail

Common Rail System

Common rail

Fuel Inlet from Supply pump

Fuel Outlets to Injectors

Rail Mounting Flange

Common rail

Common Rail System

Rail for DL06 / DL08 / DV11
DL06 & DL08 - 1 Rail

Pressure limiter valve

From CP3

3 4

1 2

To Tank

Left

To Tank

Rail pressure sensor

Right
From CP3

DV11 - 2 Rails

Common Rail System

Maintenance of common rail
Common rail maintenance
Fuel sealing by plastic deformation.
Do not re use common rail pipe when the pipe is disassembled.
(Fuel leakage can be a problem)
Keep clean common rail, high pressure pipe and fuel high pressure pump when
disassembled.

Common Rail System

Rail pressure sensor RDS3

Sensor Pin

DL08/DV11

DL06

Description

CN2-20

CN212

Ground

CN2-27

CN214

Pressure
Signal

If the rail pressure sensor fails, the E.C.U

makes
the CP pump
400~500
3
CN2-12
CN2- pressure
+ 5 V Supply
13
bar, for limp home function.

Location of the Rail Pressure Sensor

DL06

DL08

DV11

Common Rail System

Common rail pressure relief valve

Setting pressure : 1950 bar

The valve must be changed if the following conditions have been met:
- Over 5 hours working under limp home condition
- Over 50 times valve opening.
Fuel sealing is by plastic deformation with the common rail.
It can be re used, if the contact face is not damaged.

Common Rail System

Common rail pressure relief valve

If the Engine is working correctly this valve is never open.

If the valve does not open due to a mechanical problem under
high fuel system pressure in the common rail (Over 1750 bar for
a long time), the ECU will cut the fuel supply off, so stopping the
engine. (Fuel cut off by metering valve)

Common Rail System

Maintenance of rail pressure sensor
Common rail maintenance
Sensor sealing with common rail by plastic deformation.
Sensor can be re used if sensor sealing face is not damaged.
Keep sensor clean when disassembled from common rail.
If water separator condition is poor, water may enter the fuel system and cause
damage to the rail pressure sensor.
When disassembled from the common rail, dont allow the sensor connector to
become damaged (Most sensor problems are caused by use of incorrect tools)

6. Injector

Common Rail System

Injector Part Number

Engine

Doosan Part
No.

Remark

DL06

65.104017004A

Euro3, Tier3

DL08

65.104017001C

Euro3, Tier3

DV11

65.104017002C

Euro3, Tier3

Common Rail System

Injector

Common Rail System

Injector
Tightening torque
0.15 0.025 kgm

Fixing groove
Fuel return to tank

High pressure fuel

Injector coil resistance

DL06
: 0.22 ~
0.29
DL08 & DV11 : 0.31 ~
0.42

Common Rail System

Fuel Inlet
Magnet Nut
Terminal

Push Rod
High Pressure Bore

Nozzle Retaining Nut

Intermediate Pin

Control Chamber

Magnet Core

Nozzle

Injector Body

Armature

Fuel Drain

Before assembling injector & connector, the O-rings must be lubricated

Common Rail System

Spring
Coil

Ball

Armature
Control
Chamber

Ball Orifice

Supply Orifice

Common Rail System

Fuel injection

Common Rail System

Doosan Engine:
1 Pilot + 1 Main Injection

Common Rail System

Injector Part No.
Doosan Part No.

Bosch Part No.

Engine

Doosan Part
No.

Remark

DL06

65.104017004A

Euro3, Tier3

DL08

65.104017001C

Euro3, Tier3

DV11

65.104017002C

Euro3, Tier3

Common Rail System

Before assembling injector & connector, the O-rings must be lubricated.

Do not re-use the O-rings, when the injector and connector are disassembled the O- ring must b

Common Rail System

Maintenance injector
Maintenance of injector
HPC sealing with engine cylinder head is by plastic deformation
Dont re use the HPC, if the HPC is disassembled from the injector, the HPC must
be changed.
(Failure to change the HPC can cause fuel to leak between the injector and the HPC
contact point, resulting in a decrease in engine power)

Common Rail System

High pressure connector (HPC)

The HPC can only be assembled on the cylinder head in one position due to this pin.

The O-ring must be lubricated with clean engine oil, when assembling
the HPC to the cylinder head.

Common Rail System

High pressure connector (HPC)
Maintenance of HPC
You Must follow the correct injector assembly sequence and tightening torques.
You Must keep the injector holes and fuel return line clean when disassembled.
Before assembling the HPC on the cylinder head, you must lubricate the O rings.

Common Rail System

Remove caps only when necessary to allow assembly on the engine

(Keep all holes covered as long as possible)

7. Sensor

Common Rail System

Sensor Location (DL06)

1.

CRS sensor

2.

Common rail press.

sensor

3.

Common Rail press.

relief valve

4.

Fuel temp. sensor

5.

Metering units

6.

Oil press.& Temp.

sensor

Common Rail System

Sensor Location (DL06)
7.

Boost press. sensor

8.

Coolant temp. sensor

9.

Air heater

10. A/C compressor

11. Starter
12. Cam sensor

Common Rail System

Sensors
Coolant
Coolant Temperature
Temperature sensor
sensor

Fuel
Fuel Temperature
Temperature sensor
sensor

Boost
Boost press./Temperature
press./Temperature sensor
sensor

Engine
Engine oil
oil press./
press./ Temp.
Temp. sensor
sensor

CRS
CRS sensor
sensor

Cam
Cam sensor
sensor

ECU
ECU

Common Rail System

Coolant Temperature Sensor : DL06

Common Rail System

Coolant Temperature Sensor : DL08 &
DV11

DL08
DV11

Common Rail System

Fuel Temperature Sensor : DL06

Common Rail System

Coolant/Fuel Temperature Sensor

Sensor type : NTC Sensor

Sensor resistance
25 : 2.5 6 % .100 : 0.186 2 %

Common Rail System

Boost Pressure / Temperature Sensor : DL06

Common Rail System

Boost Pressure / Temperature Sensor : DL08 & DV11

DL08

DV11

Common Rail System

Boost Pressure & Temperature Sensor

Temperature sensor type : NTC sensor

Pressure sensor type : Piezo sensor

Common Rail System

Boost Pressure & Temperature Sensor

Temperature sensor resistance 25 : 2.5 6 %. 100 : 0.186 2 %

Pressure sensor normal range : 0.5 V ~4.5 V

Oil Pressure / Temperature Sensor location: DL06

Oil Pressure / Temperature Sensor location: DL08 &

DV11

DL08
DV11

Common Rail System

Engine Oil Pressure & Temperature Sensor

Temperature sensor resistance 25 : 2.5 6 %. 100 : 0.186 2 %

Pressure sensor normal range 0.5 V ~4.5 V

Common Rail System

Crankshaft Speed Sensor : DL06

Common Rail System

Crankshaft Speed Sensor : DL08 & DV11

DL08
DV11

Common Rail System

Camshaft Speed Sensor : DL06

Common Rail System

Camshaft Speed Sensor : DL08 & DV11

DL08

DV11

Common Rail System

C.R.S / Cam Sensor

Cam sensor

Sensor type : Magnetic pick up

Sensor resistance at 20 : 860 10 %
Air gap : 1.0mm (Fly wheel and Cam gear) - No need adjusting
gap.
CRS and Cam sensor are currently the same part No.
Keep off the pollution and rust on harness contact point.

Air gap

C.R.S/ Cam shaft speed sensor

*Sensor resistance : 20C : 860 10 %
*Air gap : 1.0mm 0.5 (Flywheel and Cam gear)
(No need to adjust gap)

Air gap

Cam gear
Flywheel

C.R.S/ Cam shaft speed sensor

* C.R.S Sensor :
1. Sensing engine R.P.M for display.
2. Sensing C.R.S Angle.
3. Sensing piston location.
4. Decision on injection timing.
* Cam Sensor :
1. Sensing OT point of No1 cylinder.
2. Sensing engine R.P.M

8. Valve clearance
adjustment & Maintenance

Common Rail System

DL06 & DL08 : Valve gap adjusting (1)

DL06 & DL08 : Valve gap adjusting (2)

Valve
Gap

Valve

Intake

Exhaust

Valve gap (X)

0.3mm

0.4mm

At cold
condition

Common Rail System

DL06 : Valve gap adjusting (3)
Method 1

Method 2
Valve-Overlapped
cylinder

Adjusting cylinder
(Intake/Exhaust valve)

- Engine rotation : Counter-clockwise (view from flywheel)

Common Rail System

DL08 Adjusting Valve Clearance (I)
Cylinder No

Adjust Cylinder
No 1 Cylinder T.D.C Point
(OT point 0)

EX

IN

EX

3
IN

EX

4
IN

EX

No 5 Cylinder T.D.C Point

(Turn flywheel 180)
No 6 Cylinder T.D.C Point
Turn flywheel 180
(Total 360)
No 2 Cylinder T.D.C Point
Turn flywheel 180
(Total 540)

5
IN

EX

6
IN

EX

IN

Engine turning : Count clock wise viewed from flywheel

Common Rail System

DL08 Adjusting Valve Clearance (II)

Overlap cylinder

Adjusting cylinder
(In/ Ex valve)

Valve

Intake

Exhaust

Valve gap

0.3mm

0.4mm

At cold condition

Common Rail System

DV 11 Valve Clearance (I)

Water pump

Common Rail System

DV 11 Valve Clearance (II)
Adjusting screw & nut

Measure valve gap here

Valve
Valve gap
(mm)

Intake

Exhaust
At cold
condition

0.4

0.5

Common Rail System

DV11 Adjusting valve clearances (I)
Cylinder No

Adjust Cylinder

EX

IN

EX

No 1 Cylinder T.D.C Point

(OT point 0)

3
IN

EX

4
IN

Turn flywheel 90
(Total rotation 450)

EX

IN

6
EX

Turn flywheel 90

No 5 Cylinder T.D.C Point

Turn flywheel 270
(Total rotation 360)

IN

5
IN

EX

Engine turning : Count clock wise viewed from flywheel

Common Rail System

Adjusting valve clearances (II)

Overlap cylinder

Adjusting cylinder
(In/ Ex valve)

Valve

Intake

Exhaust
At cold condition

Valve gap

0.4mm

0.5mm

End of Document

136