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

ECU CR Injector
Common Rail
Common Rail System

Pressure Rail pressure

High limiter valve sensor
pressure
Rail
pump
CP3
Gear Flow limiter
pump Filter

Metering
unit ZME

Other actuators Other sensors

Injector

Accelerator
pedal
Control unit
Engine
speed
(crank)

Tank Engine
Prefilter High pressure
speed
(cam) Low pressure
 Common Rail System

Temperature

Nox

(1)

PM (Smoke)
(2)

CRS Angle

(1) Multiple injection and E.G.R.

(2) Fuel atomization (High pressure fuel injection)
Common Rail System

Multiple Injection

Dispose noxious fumes

Main Injection
Noise Control

Post/After
Pre/Pilot Injection Injection
Common Rail System

IEGR - Internal Exhaust Gas Recirculation

Valve Lift (mm)

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
4-Valves Consumption of Fuel,
per Lub. oil
Cylinder
High Output and
Common
Rail 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

4-Valves High Output and

per
Cylinder
Durability

Common Compact and Light

Rail Weight
Common Rail System

Wastegate
Turbocharger

Injector

Cyl. Head

Piston
Common rail
Con. Rod High Pressure Pump
Cyl. Block 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 200 ps/1900 rpm
power
Max torque 93 kg.m/1,300 rpm
Rate of fuel
consumptio 155 g/ps.h
n
Common Rail System

Engine serial number

DL08 DV11

DL08 4 00001 BA
DV11 4 00001 BA
Engine Model Engine code (Engine suffix)
Production year 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
In
Ex
In

4 valves & central injector port

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
Cylinder liner
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
CommonRailRail
44Valves / Cylinder
Valves / Cylinder
New
NewCombustion
CombustionSystem
System
Central
CentralVertical
VerticalInjector
Injector

High
4-Valves Power

Low Fuel
Low Consumption
Pollution Ratio
Common Rail
Injection system
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

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

View to fly wheel direction

Common Rail System

Timing gear (DL08)

Timing mark

Cam Idle
shaft 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 Rocker arm shaft

Cam shaft
CRS
Oil filter Main gallery Oil spray nozzle Oil pan
Oil pan
Gear train
Turbo charge
Common Rail System

DL06 Piston
1. Oil Spray Nozzle

4 The oil from engine main gallery is supplied

to the piston oil gallery for piston cooling.

2. Oil Hole
3 An oil passage connects oil from oil spray
nozzle to the inside of piston oil gallery

2
3. Oil Gallery
Oil hole for cooling piston and combustion
chamber.

1
4. Oil Drain Hole
Drained oil connects to piston pin on
connecting rod for lubrication
Common Rail System

DL06 coolant circulation

Cylinder Head

Thermostat

Radiator
Water
pump

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

Cooling water
Oil cooler

The coolant is distributed to engine cylinder block via the oil

cooler
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) Injector

Common rail Cylinder head

2nd fuel filter

Fuel pressure
pump

1st fuel filter

E.C.U

Fuel tank
Common Rail System

Fuel system (DV11)

Common rail

2nd fuel filter Fuel pressure

pump

1st fuel filter

Injector
E.C.U Cylinder head

High pressure
connector
Fuel tank
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
Hardware : Bosch
Injector connector Vehicle EDC7UC31
Software : Special software
Connector for Doosan
engine

Engine connector Atmospheric

Pressure Sensor
Common Rail System

E.C.U

Vehicle
Connector Engine connector

ATM Sensor
(Not use) Injector connector
 Common Rail System

E.C.U (Tightening order & torque) 1

8 5

4 3

7
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

2) *Preheating/After
Calculate the optimalheating
fuel quantity for engine starting

* 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
ECU Injector
Air Temp
Engine RPM

ECU decides optimal fuel quantity for engine starting

2) Preheating
Key on

Coolant Temp
Fuel Temp ECU Air heater

Air Temp 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
Air heater
Fuel Temp ECU
Air Temp

ECU decides optimal preheating time

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

4) Limp home

LCD Panel X
ECU 1000 RPM
EPOS X
ECU Control (4/4)

5) Emergency stop
Engine running signal

Emergency
engine stop 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
burst pressure >15bar injectors

DBV
rail
metering unit

over
pressure bypass
valve valve
10.5...13 bar 0.1 bar lubrication

p suction KV
0.5...1.0 bar abs cooling
plate zero delivery drain
prefilter
<=100mm with
hand-
water separator p back CP3 < 1.2 bar abs
primer
KV: two step overflow valve : high pressure
DBV: pressure limiter valve : 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)

From fuel
T : Torque From pre- filter
(Nm) filter T = 252
Return T = 222
to fuel
To fuel filter
tank
T = 222
T = 252

Metering
Unit

For tightening To rail (high press.)

T = 11010 bolt M8 T = 20.52.5
T = 305

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 Metering
Unit

High Pressure Fuel Lubricating System

Low Pressure
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
Metering Unit

High Pressure
Low Pressure Oil Lubricating System
Oil
* 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 bypass
valve valve
10,5...13 bar 0,15 bar
V

p suction
0,5...1,0 bar abs
zero delivery
cooling
drain
plate
hand-
primer prefilter
with water p back CP3 < 1,2 bar abs
separator
V: overflow valve : high pressure
DBV: pressure limiter valve : 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 : Closed :
Below 8 Volt 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

6
5
3 4
1 2 To Tank
Left
4
6 5
To Tank

2 1
3
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

1 CN2-20 CN2- Ground
12
2 CN2-27 CN2- Pressure
14 Signal
If the rail pressure sensor fails, the E.C.U
3 makes the CP pump
CN2-12 CN2- pressure 400~500
+ 5 V Supply
bar, for limp home function. 13
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

Doosan Part
Engine Remark
No.
65.10401-
DL06 Euro3, Tier3
7004A
65.10401-
DL08 Euro3, Tier3
7001C
65.10401-
DV11 Euro3, Tier3
7002C
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 Push Rod Nozzle

Terminal High Pressure Bore Nozzle Retaining Nut

Control Chamber Intermediate Pin

Magnet Core

Armature Injector Body

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.

Doosan Part
Engine Remark
No.
65.10401-
DL06 Euro3, Tier3
7004A
65.10401-
DL08 Euro3, Tier3
7001C
65.10401-
DV11 Euro3, Tier3
7002C
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 ECU
ECU

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

CRS
CRS sensor
sensor

Cam
Cam sensor
sensor
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

Air gap
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.
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

At cold
Valve gap (X) 0.3mm 0.4mm condition
Common Rail System
DL06 : Valve gap adjusting (3)
Method 1

Method 2
Valve-Overlapped
1 5 3 6 2 4
cylinder
Adjusting cylinder
6 2 4 1 5 3
(Intake/Exhaust valve)

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

Common Rail System

DL08 Adjusting Valve Clearance (I)

Cylinder No 1 2 3 4 5 6

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

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)
Engine turning : Count clock wise viewed from flywheel
Common Rail System

DL08 Adjusting Valve Clearance (II)

Overlap cylinder 1 5 3 6 2 4

Adjusting cylinder
6 2 4 1 5 3
(In/ Ex valve)

Valve Intake Exhaust

At cold condition
Valve gap 0.3mm 0.4mm
 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 Intake Exhaust

At cold
condition
Valve gap
0.4 0.5
(mm)
Common Rail System
DV11 Adjusting valve clearances (I)

Cylinder No 1 2 3 4 5 6

Adjust Cylinder EX IN EX IN EX IN IN EX IN EX IN EX

No 1 Cylinder T.D.C Point

(OT point 0)

Turn flywheel 90

No 5 Cylinder T.D.C Point

Turn flywheel 270
(Total rotation 360)

Turn flywheel 90
(Total rotation 450)

Engine turning : Count clock wise viewed from flywheel

Common Rail System

Adjusting valve clearances (II)

Overlap cylinder 1 4 2 5 3 6

Adjusting cylinder
5 3 6 1 4 2
(In/ Ex valve)

Valve Intake Exhaust

At cold condition
Valve gap 0.4mm 0.5mm
End of Document

136