DV15 (T) (Ti) (Tis)

FOREWORD
This manual has been prepared for Diesel Engine Maintenance of DV15, DV15T and DV15TIS
produced by Daewoo Heavy Industries ltd.
These economical and high-performance Diesel Engines, characterized by 8 cylinders, 4 strokes,

V-shape and Direct injection type, have been designed and manufactured for the use of overland
transport and industrial purpose. They meet all the requirements such as quiet operation, fuel
economy, high speed durability and so on (especially, DV15TIS model is an environment friendly
one fulfilling the EURO2 emission regulation)
Nonetheless, to ensure the best performance and long life expectancy of an Engine, it is
indispensable to operate it properly and to carry out periodic check-ups as instructed in the manual.
We strongly urge you to read this manual from cover to cover thoroughtly and acquaint yourself
fully with all the information contained in the manual. For more information or inquires on the
maintemance, please contact the nearest after sales service line.
AS all the information, illustrations and specification in this manual are based on the latest product
information available at the moment of publication approval, the right is reserved to make changes
at any time without previous notice with a view to enhancing the Engine performance or
maintenance.
1999. 2
“Duplicating or copying of the manual are not allowed without permission as required by Daewoo
Heavy Industries ltd.”
CONTENTS
¥ Exterior View .................................................................................................................1

¥ Open-up view(Front elevation) ....................................................................................4
¥ Sectional view ...............................................................................................................5
¥ Lubricating system .......................................................................................................6
¥ Fuel System ...................................................................................................................7
¥ Cooling System .............................................................................................................7
¥ Engine timing gear diagram.........................................................................................8
Section 1. Major maintenance ........................................................................................9

1. Specifications 3. Troubleshooting for the engine
2. Preventive maintenance
Section 2. Maintenance .................................................................................................28

1. Engine overhaul 3. Engine reassembly
2. Inspection and correction of 4. Breaking-in engine
major component parts
Section 3. Turbocharger ...............................................................................................61

1. Specifications and construction 5. Walk-around check and maintenance
2. General information 6. Periodical servicing
3. Functions 7. Diagnostics and troubleshooting
4. How to handle the engine
Section 4. Fuel injection pump.....................................................................................68

1. DV 15(RQ) 5. DV15T(RQV)
2. DV15T(RQ) 6. DV15TI(RQ)
3. DV15T(RQV) 7. DV15TIS(RQ)
4. DV15T(RQV) 8. DV15TIS(RQ)
¥ Supplement
- Tightening torque ratings
- Maintenance specifications
- Special tool list
¥ WORLDWIDE NETWORK
¥ Exterior view
1. DV15
EPM0001I
-1-
2. DV15T
EPM0002I
-2-
3. DV15TI, DV15TIS
EPM0003I
-3-
¥ Open-up view(front elevation)
6 11 7 9 13
8
3 5
12
4
1
10 14
15
EPM0005I
1. Cylinder block 6. Push rod 11. Breather pipe

2. Cylinder head 7. Injection pump 12. Exhaust manifold
3. Cylinder head cover 8. Nozzle 13. Intake manifold
4. Cylinder liner 9. Injection pipe 14. Starter
5. Rocker arm 10. Oil cooler 15. Connecting rod
-4-
¥ Sectional view
9 10 13 4 24 26 22
19
20
11
21
15 25
6
5
3
8 2
7 1
23
12 18 17 16 14
EPM0006I
1. Flywheel housing 10. Combustion chamber 19. Water pump

2. Flywheel 11. Piston pin 20. Thermostat
3. Oil seal 12. Oil injection nozzle 21. Cooling fan
4. Tappet 13. Valve 22. Turbocharger
5. Crank shaft 14. Oil pump 23. Generator
6. Cam shaft 15. Oil filter 24. Pre-heating plug
7. Vibration damper 16. Pressure relief valve 25. Power steering oil pump
8. Crankshaft pulley 17. Oil pan 26. Air compressor
9. Piston 18. Oil suction pipe
-5-
¥ Lubricating system
1 Filter housing
2 Fixing bolt
4 3 2 1
3 Cu-washer
4 4 Filter element
5 Spring
6 Packing
7 Bypass line
8 Regulator valve Normal oil circulation
9 Bypass valve Oil circulation with bypass valve open
9
7 8
1 Oil suction pipe
2 Oil pump
3 Pressure relief valve
4 Oil cooler
5 Oil filter
13 6 Bypass valve
7 Main oil gallery
7 12 8 Oil line to crankshaft
13
9 9 Main bearing lubrication
11
4 10 Conn. rod bearing lubrication
10 11 Piston pin lubrication
12 Camshaft bearing lubrication
13 Rocker arm and ball screw lubrication
2 14 Spray jet for piston cooling and cam lubrication
3 1 15 Injection pump lubrication
16 Oil path for compressor lubrication
15
16
12 10
8
1
2
EPM0007I
-6-
¥ Fuel system
4 5 7 6 8 2
1
10
EPM0008I
1. Fuel tank 7. Injector

2. Strainer 8. Fuel pressure relief valve
3. Fuel filter 9. Fuel return pipe
5. Air bleeding screw 10. Fuel feed pump
6. Injection pump
¥ Cooling system
Thermostat Coolant pipe
Cylinder head
Radiator
Oil cooler
Water pump Coolant pipe
-7-
¥ Engine timing gear diagram
6
5
4
7
2
3
EPM0008I
1. Crankshaft gear 5. Air compressor drive gear

2. Oil pump drive gear 6. PTO drive gear
3. Oil pump gear 7. Injection pump drive gear
4. Camshaft drive gear 8. Injection pump gear
-8-
Section 1. Major maintenance
1. Specifications
Series DV15 DV15T DV15TI DV15TIS
Type V-type 90° four stroke diesel engine
Combustion chamber 'M' combustion system Toroidal combustion system OMEGA

system Combustion system
Combustion Direct injection
Cylinder bore x stroke 128x142-8 128x142-10

- No. of cylinders
Total displacement 14,618 cc 18,273 cc
Compression ratio 16.9:1 16.5:1 17.4:1
Maximum power(PS) 305/2,300 rpm 370/2,300 rpm 420ps/2,100 rpm 420ps/2,100 rpm
Maximum torque ratings 105/1,400 rpm 145/1,300 rpm 170kg.m/1,200 rpm 170kg.m/1,200 rpm
Injection timing BTDC 10° BTDC 7° BTDC 11°L1° BTDC 5.5°L0.5°
Firing order 1-5-7-2-6-3-4-8
Injection pump type Flanged serial type in-line injection pump
Governor RQ or RQV
Timer Automatic, centrifugal type
Injection nozzle Multiholes
Feed pump Plunger type(FR/K)
Valve open/closing time
Intake opening 12° 15°
Intake closing 48° 35°
61° 71.5°
Exhaust opening
11° 15.5°
Exhaust closing
Gear type
Oil pump
Water-cooled type
Oil cooler type fuel
Felt-filter type
Filter
Oil capacity 21 24
Water capacity 19M (for engine block) 21M (for engine block)
Thermostat Wax-pallet type
Starter voltage-output 24V - 6.6kw
-9-
1.1. Engine performance curve
1.1.1. DV15
Conditions Standard value

Atmospheric pressure Standard(760mmHg)
Break-in operation time 30 hours
Cooling fan
Alternator
Air cleaner New one
Silencer Not mounted
110
Torque(kg.m)
100
90
300
270
Output(ps)
240
210
180
Fuel consumption(g/ps.h)
150
120 175
170
165
160
1 000 1200 1400 1600 1800 2000 2200 2400
Revolution(rpm)
Performance KS-R0071
Power(max.) 305 ps/ 2,300 rpm
Maximum torque 105 kg.m/ 1,400 rpm
Fuel consumption rating(min) 162 g/ps.h
EAIM1001
- 10 -
1.1.2. DV15T

Cooling fan ø700, clutch
Alternator 24V B 45A(no load)
Air cleaner New one
380 150
140
Torque(kg.m)
360 130
120
340 110
320
Output(ps)
300
280
260
Fuel consumption(g/ps.h)
240
190
220 180
170
200 160
150
1 80
1 000 1200 1400 1600 1800 2000 2200 2400
Revolution(rpm)
EAIM1002I
- 11 -
1.1.3. DV15TI/TIS

Cooling fan ø711, clutch
Alternator 24V B 45A(no load)
Air cleaner New one
180
420 170
160
Torque(kg.m)
400 150
140
380
360
Output(ps)
340
320
300
280 Fuel consumption(g/ps.h)

180
260 170
160
240 150
140
220
200
1 000 1200 1400 1600 1800 2000 2100
Revolution(rpm)
EPM1004I
- 12 -
2. Preventive maintenance
The preventive maintenance means that the operator performs the servicing of the engine
mounted on the vehicle from time to time to obtain a long life and the best performance of your
Daewoo diesel engine.
2.1. Cooling water
1) Check the coolant level of the radiator by removing the radiator filler cap, and add coolant if
necessary.
2) Check the pressure valve opening pressure using a radiator cap tester. Replace the radiator
filler cap assembly if the valve fails to meet the specified limit.
3) When injecting antifreeze solution, first drain out the old coolant from the cylinder block and
radiator and then clean them with cleaning solution.
4) Be sure to mix soft water with antifreeze solution .
5) A proportion of antifreeze is represented as the ratio of antifreeze in volume, and antifreeze
must be added according to each ambient temperature as described below.
Antifreeze solution(%) Freezing point(°C)

20 -10
27 -15
33 -20
40 -25
44 -30
50 -40
* If you add antifreeze in excess of 50% in volume, the engine may be overheated. Avoid this.
* As the individual freezing points corresponding to the above proportions of antifreeze are
subject to change slightly according to the kind of antifreeze, you must follow the
specifications provided by the antifreeze manufacturer.
6) As the ratio of antifreeze in the mixture decreases each time new coolant is added to make
up for the loss in old coolant resulting from engine operation, check the mix ratio with every
replenishment of coolant, and top up as necessary.
7) To prevent corrosion or air bubbles in the coolant path, be sure to add a specific additive, i.e.
corrosion inhibitor, to the coolant.
I Type : DCA65L (Inhibitor)
I Mix ratio : 1.5M of inhibitor to 50M of coolant

(Namely, add corrosion inhibitor amounting to 3% of coolant capacity.)
8) Add antifreeze of at least 15% in volume to prevent possible engine corrosion in hot weather.
2.2. Fan belt
1) Use a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated.
2) Check the fan belt for belt tension. If belt tension is lower than the specified one, adjust the
tension by relocating the alternator and idle pulley.
(Specified deflection : 10~15mm/when pressed down with thumb)
- 13 -
2.3. Engine oil
1) Check oil level using the oil level gauge and replenish if necessary.
2) Check the oil level with the vehicle stationary on a level ground, engine cooled. The oil level
must be between MAX and MIN lines on the gauge.
3) Engine oil should be changed at the specified intervals. Oil in the oil filter also should be
changed simultaneously.
I Oil change intervals

Vehicle type Intervals
Initial 1,000 km
Long-distance,
high speed 15,000 km
operation operation
vehicles
Short-distance 10,000 km
operation Every
vehicles operation
Heavy vehicles 8,000 km operation
* Engine oil should be changed at least twice a year.
I Suggested engine oils

Engine
SAE No. API No.
Model
DV15, DV15T CD grade

15W40
DV15TI or above
DV15TIS 15W40 CG grade

or above
2.4. Oil filter
1) Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary.
2) Change the oil filter element simultaneously at every replacement of engine oil.
2.5. Fuel filter
1) Drain water in cartridge with loosen the cock under filter from time to time.
2) The fuel filter should be replaced at every 20,000km.
- 14 -
2.6. Air cleaner
1) Replace any deformed or broken element or cracked air cleaner.

2) Clean or replace the element at regular intervals.
2.7. Valve clearance
1) At end of first 500km(10 hours) operation,

2) Every second time engine oil is changed,
3) When the engine is overhauled or the cylinder head is removed,
4) When unusual sound is heard from the valve system, or
5) When the fuel system has no trouble, but the engine fails to normally function
6) Valve clearance should be adjusted in the following cases: Valve clearance(with engine
cooled) should be 0.25mm for intake and 0.35mm for exhaust.
2.8. Compression pressure
1) Stop the engine after warming it up, then remove the nozzle assemblies.
2) Install a special tool(gauge adapter) in nozzle holder hole and connect the compression
pressure gauge to the adapter.
3) Cut off fuel circulation, rotate the starter, then measure compression pressure of each cylinder.
Standard 28 kg/cm2 or above

Limit 24 kg/cm2 or less
Allowance among cylinders L10 % or less
* Testing conditions : At water temperature of 20C and speed of 200 rpm (10 turns)
2.9. Injection nozzle
1) Install a nozzle to a nozzle tester.

2) Check injection pressure, and adjust the
nozzle using shims if the pressure does not
meet the specified limit.
(Every additional number of 0.1mm shim will
increase the pressure by 10kg/cm2)
Normal
DV15, DV15T, DV15TI DV15TIS

200 kg/cm
+8 2
250+8 kg/cm2
3) Check nozzle spray patterns and replace if

damaged.
Abnormal Abnormal
EPM1006I
- 15 -
2.10. Fuel injection pump
1) Check the fuel injection pump housing for cracks or breaks and replace if damaged.
2) Check and see if the lead seal for idling control and speed control levers have not been
removed.
3) Be sure to adjust or test the fuel injection pump on a test bench.
2.11. Battery
1) Check the battery for damage or leaking of battery fluid(electrolyte) through cracks on the
battery. Replace the battery if damaged.
2) Check battery fluid level and add distilled water if necessary.
3) Measure the specific gravity of the electrolyte in the battery. Recharge the battery if the
hydrometer readings are lower than the specified limit(1.12~1.28).
2.12. Bleeding the fuel system
The suction chamber of the injection pump is continuously bled through the relief valve
during operation. If the suction chamber has run out of fuel, e.g. when a new pump is
installed, it can be bled by loosening the bleed screws and actuating the manual primer on
the fuel feed pump until air bubbles are not visible.
2.13. Fuel feed pump
The strainer installed onto the fuel feed pump should be removed and cleaned with every
engine oil change.
2.14. Turbocharger (For DV15T/TI/TIS engine only)
No special operations are needed for maintenance of this turbocharger. At each engine oil
change, the oil pipes should be checked for leaks or restrictions. The air cleaner should be
carefully serviced to prevent the entry of foreign substances such as nuts or dirt. The charge
air and exhaust gas piping should be inspected periodically. Leakages should be remedied
immediately as they can lead to overheating of the engine. During operation in your work
area having high dust content, it is necessary to clean the impeller from time to time. The
impeller casing should be removed (CAUTION : DO NOT SKEW) and cleaned with a non-
aggressive solution; where necessary with the aid of a plastic scraper. If the impeller has
been heavily fouled, it is advisable to soak the impeller in a container with solvent and clean
it with a stiff brush. At this time, use exceptional care so that only the impeller is immersed
and the turboch arger is supported on the bearing hous ing, not on the impeller.
2.15. Starter
During engine overhauling operation, the starter pinion and ring gear should be immersed in
diesel oil and thoroughly cleaned with a brush and then re-greased. Also, when washing the
vehicle, check wiring conditions with care so that moisture cannot penetrate.
- 16 -
2.16. Pre-heating system
To ease engine starting, the Diesel

engine is equipped with a pre heating
system as an auxiliary device, which heat
intake air in the combustion chamber and
therein the air temperature at
ACC ON
compression stroke becomes high
Fuse
enough to ensure easy Engine starting. (1) (7) IG
OFF B ST (8) (4) L"
Besides, the adoption of pre-heating Relay
(2) (5) (6)
system also decrease the emission level. E
AH1 Temp Ramp

CAUTION: This Engine has a pre heating
sensor
system available in severe AH2
DC24V
cold air.
EPM1005I
IKEY SWITCH
Wait until the pre heat lamp is turned off, and then turn the key to the start position.
-. It takes about 20 seconds for the lamp to be off and after heating lasts for maximal 5
mimutes.
-. In case pre heating is not necessary, the lamp is on for just 0.3 second and after heating
function is not activated.
2.17. Check point after starting
After engine starting, keep state of engine operating by idle RPM till reach normal operating
temperature of engine. Especially turbo charged engine, DV15T, DV15TI, DV15TIS have to
operate with idle RPM for 5 min.
CAUTION: In case turbo charged engine, do not rapidly RPM up on engine starting or do not
stop engine on high RPM, and it may be seized because of not yet supply engine
oil on shaft of turbocharger.
- 17 -
3. Trouble shooting for the engine
1. Engine won’t start
Starter does not turn Starter motor turns but engine

does not turn over
Check battery fluid and specific gravity Engine Fuel
Normal Too low Check air cleaner Check fuel level
Replenish or recharge Normal Fouled Normal No fuel
Check cable connections Replace or clean element Replenish
Normal Replenish or recharge Check compression pressure Check fuel injection
Check starter s/w Normal Too low Normal No fuel injection injection
Normal Replenish or recharge Retighten or replace Air bleeding and re-start
Check starter relay Check other parts Check injection timing
Normal Replace Check valve clearance Normal Adjust
Check magnetic s/w Normal Adjust Check injection nozzle(injection

pressure, injection condition, etc.)
Normal Replenish or recharge Check cylinder head gasket

Normal Repair or replace
Disassemble and check starter Normal Replace
Disassemble and check

Overhaul the engine injection pump
(valve assembly, cylinder
liner, piston, etc.)
Check fuel feed pump for function
Normal Check feed pump valve and strainer Air in the fuel
Disassemble and check injection pump Normal Clean or replace Retighten the joint and/or replace gasket
Check fuel filter Air bleeding
Dirty element and/or overflow valve faulty Continuous entry of air in fuel system
Replace Disassemble and check feed pump
- 18 -
2. Engine overheating
Cooling system Fuel system Operating conditions

1. Overload
2. Clogged radiator core
3. Continued overrunning
Check coolant level Check fuel quality
Normal Too low Bad
Check fan belt for tension, wear, or breaks Clean or replace with the specified fuel
Check radiator cap Replenish Check water pump
Normal Replace External Internal
Check thermostat Retighten or repair Overhaul engine
Normal Replace
Excessive fuel rate

Check radiator
Check injection nozzles

Normal Damaged
Normal Abnormal
Repair or replace
Repair or replace
Clean cooling water path
Adjust or repair injection pump
Check water pump
Overhaul the engine
- 19 -
3. Lack of power
Engine Chassis
Fuel system Others Check for clutch slip
Check fuel line for air Check air cleaner Adjust or replace clutch
Check fuel feed pump Normal Clean or replace
Normal Clean or replace check Check engine control rod, link and
cable
fuel filter element and overflow valve

Normal Adjust
Normal Replace
Check valve clearance
Check injection piping

Normal Adjust

Check cylinder head gasket for break
Check injection nozzle(injection

pressure, nozzle spray patterns, etc.) Normal Replace
Normal Adjust or replace Overhaul engine(valve assembly)
Check injection timing
Normal Adjust
Overhaul engine or injection pump Check turbocharger <For DV15T only>
Overhaul injection pump or engine
- 20 -
4. Low oil pressure
Check if oil pressure gauge

indicates exactly
Check oil level
Normal Too low
Check cooling water temperature Refill with recommanded oil
Normal Too high
Check oil quality Refer to ‘Engine overheating’
Normal
Check oil pressure relief valve Water, fuel, etc. mixed in oil Inadequate
Normal Adjust or replace Overhaul engine or injection pump Replace with suggested lub. oil
Overhaul the engine
- 21 -
5. Excessive fuel consumption
Causes according to operating

conditions
1. Overload
2. Frequent use of low
gear position at high speed
3. Frequent use of high gear
position at low speed
4. Clutch slip
5. Too low tire pressure
Check fuel leakage
Normal Oil leakage
Check injection nozzle (injection Retighten or replace

pressure, injection condition, etc.)
Adjust or replace
Normal
Check compression pressure
Normal Adjust
Disassemble injection pump
Normal Check valve clearance
Check head gasket Repair or replace

Cylinder liner
Piston ring
Piston
Normal Replace
Overhaul engine(valve assembly,

piston, cylinder liner, etc.)
- 22 -
6. Excessive oil consumption
Caused by incorrect use

1. Too high lub. oil level
2. Continuous driving at low speed or
with excessive cold engine
Check oil leakage Check air cleaner
Clean or replace
Normal Oil leak
Check oil quality External Internal
Replace with suggested lub. oil Retighten or replace Check compression pressure
Overhaul cylinder Normal

head(valve stem
seal)
Overhaul cylinder
head(valve stem seal)
7. Engine knocks(excessive)
Check fuel and oil burning(Check

carbon deposit from exhaust gas)
Not located Located
Check compression pressure Overhaul engine
Normal Too low
Check injection timing Check valve clearance, cyl.

head gasket crush
Normal Adjust
Normal Replace or adjust

Check fuel quality
Overhaul engine
Use recommended fuel
- 23 -
7. Battery discharge
Battery Harness, switch Alternator
Check battery fluid level Check wiring connections Check fan belt for
for short, etc deflection
Repair or replace A
Normal
Replenish Damaged battery case Battery discharged Battery overcharged
Replace Recharge Check alternator and

voltage regulator
Normal Abnormal
Check charging condition Adjust or replace
Discharged
Disassemble alternator
and regulator
- 24 -
Complaint Cause Correction
1) Difficulty in engine
starting
(1) Lack of com 1 Valves holding open, Repair or replace
pression pressure skewed valve stem
2 Valve springs damaged Repair
3 Leaky cylinder head gasket Repair
4 Worn pistons, piston ring, or liner Repair
2) Rough engine idling

1 Wrong injection timing Adjust
2 Air in injection pump Air bleeding
3) Lack of engine power

(1) Engine continues to 1 Valve clearance incorrect Adjust
lack power 2 Valve poorly seated Repair
3 Leaky cylinder head gasket Replace gasket
4 Piston rings worn, sticking, or damaged Replace piston rings
5 Injection timing incorrect Adjust
6 Volume of fuel delivery insufficient Adjust injection pump
7 Nozzle injection pressure incorrect Adjust or replace nozzles
or nozzles seized
8 Feed pump faulty Repair or replace
9 Restrictions in fuel pipes Repair
10 Volume of intake air insufficient Clean or replace air cleaner
11 Defective turbochargerRepair or replace
(applicable only to DV15T/TI/TIS engine)
(2) Engine lacks power on 1 Compression pressure insufficient Overhaul engine

acceleration 2 Injection timing incorrect Adjust
3 Volume of fuel delivery insufficient Adjust injection pump
4 Injection pump timer out of function Repair or replace
5 Nozzle injection pressure Repair or replace
or spray angle incorrect
6 Feed pump faulty Repair or replace
7 Volume of intake air insufficient Clean or replace air cleaner
4) Engine overheating
1 Lack of engine oil or poor oil Replenish or replace
2 Lack of coolant Replenish or replace
3 Fan belts slipping, worn or damaged Adjust or replace
4 Water pump faulty Repair or replace
5 Thermostat inoperative Replace
6 Valve clearance incorrect Adjust
7 Back pressure in exhaust line Clean or replace
- 25 -
5) Engine noises
It is important to correctly locate the
causes of noise since generally
noises may originate from various
engine components such as rotating
parts, sliding parts, etc.
(1) Crankshaft 1 Oil clearance excessive due to Replace bearings
worn bearings or crankshaft Grind crankshaft
2 Crankshaft worn out-of-round Grind or replace crankshaft
3 Restrictions in oil ports and Clean oil path
resultant lack of oil supply
4 Bearings seized up Replace bearings and grind
crankshaft
(2) Conn. rod and conn. 1 Connecting rod worn out-of-round Replace bearings
rod bearings 2 Crank pin worn out-of-round Grind crankshaft
3 Conn. rod skewed Repair or replace
4 Bearings seized up Replace bearings and grind
crankshaft
5 Restrictions in oil ports and Clean oil path
resultant lack of oil supply
(3) Pistons, piston pins, 1 Piston clearance excessive due to Replace pistons
and piston rings worn piston and piston rings and piston rings
2 Piston or piston pin worn Replace pistons
and piston rings
3 Piston seized up Replace pistons
4 Piston poorly seated Replace pistons
5 Piston rings damaged Replace piston rings
(4) Others 1 Crankshaft thrust bearing worn Replace thrust bearings

2 Camshaft end play excessive Replace thrust plate
3 Idle gear end play excessive Replace thrust washers
4 Timing gear backlash excessive Adjust or replace
5 Valve clearance excessive Adjust valve clearance
6 Tappets and cams worn Replace tappets
and camshaft
7 Turbocharger defective internally Repair or replace
(applicable only to DV15T/TI/TIS engine)
6) Excessive fuel 1 Injection timing incorrect Adjust
consumption 2 Volume of fuel injection excessive Adjust injection pump
3 Tire under-inflated Adjust
4 Gear selection inadequate Select gears correctly
(frequent use of low gears) according to load
- 26 -
7) Excessive oil
consumption
(1) Oil leaking into 1 Clearance between cylinder liner Replace

combustion chamber and piston excessive
2 Piston rings and ring grooves Replace pistons
worn excessively and piston rings
3 Piston rings broken, worn, or sticking Replace piston rings
4 Piston rings gaps set incorrectly Correct
5 Piston skirt portion broken, worn Replace pistons
excessively
6 Oil return holes in oil Replace piston rings
control ring restricted
7 Oil ring seated incorrectly Replace piston rings
(2) Oil leaking past cylinder 1 Valve stems and valve Replace in complete set
head guide worn excessively
2 Valve stem seals worn Replace seals
3 Leaky cylinder head gasket Replace gasket
(3) Oil leaks 1 Applicable parts loosened Replace or repair gasket

2 packings worn Replace packings
3 Oil seals worn Replace oil seals
- 27 -
Section 2. Maintenance
I Before disassembly, provide parts racks for storage of various tools and disassembled parts.
I Perform disassembly and reassembly operations with clean bare hands and keep clean your
surroundings.
I After disassembly, prevent disassembled parts from being interchanged or colliding with each
other.
I Arrange the disassembled parts in the disassembly sequence.

1. Engine overhaul
1.1. Oil level gauge
Take out the oil level gauge.
1.2. Engine oil

Remove the drain cock from the oil pan and drain out the engine oil into a container.
1.3. Cooling water

Remove the drain plug from the cylinder block and drain out the cooling water into a container.
1.4. Cooling fan(assembly)
1) Remove fan fixing bolts, then take off

cooling fan and fan coupling.
EPM2001I
<Fig. 1> Disassembling cooling fan
1.5. V-belt
1) Loosen the tension adjusting bolt installed

on the alternator and take off the V-belt.
EPM2002I
<Fig. 2> Disassembling V-belt
- 28 -
1.6. Alternator
1) Remove the tension adjusting bolt, guide

piece bolt, and alternator fixing bolt, then
disassemble the alternator.
EPM2003I
<Fig. 3> Disassembling alternator

1.7. Vibration damper
1) Reverse the assembly sequence to the

crank pulley fixing bolts and take off the
pulley and vibration damper assembly.
2) Unscrew the vibration damper fixing bolts
and disassemble the damper and pulley.
EFM2004I
<Fig. 4> Disassembling vibration dampe

1.8. Oil filter
1) Loosen the filter housing fixing bolts then

the spring will force the filter housing to
move upward a little.
EPM2004I
<Fig. 5> Disassembly of oil filter
2) Allow an interval of 2~3 minutes until the

engine oil by-passes to the oil pan, then
take off the filter.
EPM2005I
<Fig. 6> By-pass holes of filter head
- 29 -
2) Unscrew the oil filter head fixing bolts and
take off the oil filter head.
EPM2006I
<Fig. 7> Disassembling oil filter
1.9. Water pump
1) Release the pipe clamps on the rubber

joint from water pump.
2) Remove cooling water outlet pipe, and
take off thermostats.
3) Unscrew the water pump fixing bolts and
take off the water pump from the engine
block.
EFM2007I
<Fig. 8> Disassembling water pump
1.10. Starter
1) Unscrew the starter fixing nuts and

remove the starter.
EFM2008I
<Fig. 9> Disassembling starter

1.11. Fuel filter
1) Remove fuel hoses.

2) Unscrew the filter fixing bolts and take
off the fuel filter assembly.
1.12. Injection pipe
1) Remove the high pressure injectien

pipes connecting nozzle holders to fuel
injection pump.
EPM2007I
2) Remove the fuel pipes and hoses from
<Fig. 10> Disassembling fuel filter
the fuel injection pump.
- 30 -
1.13. Oil cooler
1) Remove drain plug from the oil cooler

cover and drain out the cooling water.
EPM2008I
<Fig. 11> Draining cooling water
2) Remove the oil cooler assembly fixing

bolts and take off the oil cooler
assembly.
EPM2009I
<Fig. 12> Disassembling oil cooler assembly
3) Clamp the oil cooler assembly to the

vise, remove the cooler insert fixing
bolts, then disassemble the cooler insert.
EPM2010I
<Fig. 13> Disassembling oil cooler insert
1.14. Turbocharger
(For DV15T/TI/TIS engine only)
1) Release the clamp fixing the hose

connected to the intake stake and take
off the intake stake.
2) Remove the inlet and outlet lub. oil pipes
by unscrewing the pipe clamping
screws.
3) Unscrew the turbocharger fixing nuts.
4) Remove the turbocharger using care so EPM2011S
that the connecting pipes of the intake <Fig. 14> Disassembling turbocharger
flange and O-ring may not be damaged.
- 31 -
1.15. Exhaust manifold
1) Unscrew the exhaust manifold fixing

bolts and remove the exhaust manifold
from the cylinder head.
EPM2012I
<Fig. 15> Disassembling exhaust manifold
1.16. Intake manifold
1) Unscrew the intake manifold fixing bolts

and remove the intake manifold from the
cylinder head.
EPM2013I
<Fig. 16> Disassembling intake manifold
1.17. Air compressor
1) Remove the oil, water, air pipes and

hoses between cylinder block and air
compressor.
2) Remove the power steering oil pump.
3) Unscrew the cylinder head bolts and
remove the compressor head.
4) Unscrew the side compressor head bolts
EPM2014I
and remove the compressor head.
<Fig. 17> Disassembling cylinder head of air
(Double type air compressor) compressor head
5) Remove the side cover. (Single type air

compressor)
6) Remove the flywheel housing cover.
7) Unscrew the liner fixing bolts and take
off the air compressor liner assembly
over the piston.
EFM2018I
<Fig. 18> Disassembling flywheel housing cover
- 32 -
8) Remove the side cylinder liner fixing
bolts using a special tool('T'-shaped
socket spanner) and put aside the
cylinder liner assembly.
(Double type air compressor)
9) Unscrew the connecting rod bearing cap
fixing bolts and take them off together
with the cylinder liner assembly.
10) Unscrew the fixing nuts on the
compressor driving gear using a special EPM2015I
spanner and disassemble the driving
<Fig. 19> Disassembling of cylinder liner
gear.
assembly of air compressor
11) Disassemble the flange on the front side
of the flywheel housing.
12) Disassemble the crank shaft.
13) Disassemble the bearing flange on rear
side.
1.18. Injection pump
1) Disassemble lub. oil and fuel pipes and

hoses.
2) Remove the joint bolts and nuts on the
injection pump and remove the injection
pump. EFM2019I
<Fig. 20> Disassembling injection pump
1.19. Cylinder head cover
1) Loosen the cylinder head cover fixing

bolts and take off the cylinder head
cover.
EFM2020I
1.20. Nozzle holder <Fig. 21> Disassembling cylinder head cover
1) Unscrew nozzle holder fixing nut by

using a special tool and remove the
nozzle holder assembly.
EFM2021I
<Fig. 22> Disassembling nozzle holder

assembly
- 33 -
1.21. Rocker arm
1) Remove rocker arm bracket fixing bolts

and take out the rocker arm assembly.
2) Take out push rods upwards.
EFM2022I
<Fig. 23> Disassembling rocker arm
1.22. Cylinder head
1) Reverse the installation sequence to

loosen the cylinder head fixing bolts,
then remove the cylinder head
completely for disassembly operation.
2) Take off the cylinder head gasket and
discard it.
3) Remove any gasket debris remaining on
EFM2023I
the surfaces of cylinder head and
<Fig. 24> Disassembling cylinder head
cylinder block.
CAUTION: Do not damage the contacting
face of the cylinder head gasket.
1.23. Oil pan
1) Unscrew the oil pan fixing bolts and

remove the oil pan.
2) Remove the oil pan gasket and discard
it.
EFM2024I
<Fig. 25> Disassembling oil pan
1.24. Oil pump
1) Unscrew oil suction pipe bracket fixing

bolts and remove the oil suction pipe.
2) Unscrew oil relief valve fixing bolts and
remove the relief valve.
3) Unscrew oil pump mounting bolts and
take off the oil pump assembly.
EFM2025I
<Fig. 26> Disassembling oil pump
- 34 -
1.25. Piston
1) Remove the bolts clamping the connecting

rod bearing cap in reverse sequence of
installation order. Do this operation in the
same manner as for removal of the
cylinder head bolts.
2) Take off connecting rod bearing caps by
slightly tapping with urethane hammer.
3) Push out the piston assembly toward the
cylinder head side using a wooden EFM2026I
hammer.
<Fig. 27> Disassembling connecting rod
4) The disassembled pistons may not be
interchanged with each other or collide
with other parts.
5) Arrange and keep the pistons in the
cylinder installation sequence.
(To prevent connecting rod caps from
being interchanged, it is advisable to
temporarily assemble each cap with its
mating conn. rod.)
1.26. Front oil seal holder
1) Remove oil seal holder fixing bolts and

take off oil seal holder.
2) Remove oil seal and gasket from the oil
seal holder, and then discard them.
EFM2027I
1.27. Flywheel <Fig. 28> Disassembling front oil seal holder
1) Remove the flywheel fixing bolts by

loosening them in reverse sequence of
the installation order.
2) Take off the flywheel from the crank
shaft.
3) Remove the flywheel ring gear.
I burner(up
Heat the ring gear evenly with a gas
to 200C) to invite volumetric
expansion.
I by
Remove the ring gear from the flywheel
tapping around the side face of the
EFM2028I
<Fig. 29> Disassembling flywheel

gear with a brass bar.
I Do not damage the flywheel.
- 35 -
1.28. Flywheel housing
1) Remove the flywheel housing fixing bolt,

then remove the flywheel housing by
tapping it lightly with a copper or plastic
hammer.
2) Remove the oil seal from the flywheel
housing.
1.29. Crank shaft
1) Remove the bearing cap side bolts.

2) Remove main bearing cap bolts by
loosening them in sequence
commencing with the outer ones, then
remove the bearing caps together with
the bearing.
3) Arrange and keep the bearing caps in
the installation order.
4) Tighten bolts temporarily on both sides EFM2029I
of the crank shaft and carefully lift out the
<Fig. 25> Disassembling of crank shaft
crank shaft with a rope.
5) Take bearing shells out of the cylinder
block and mark them.
1.30. Cam shaft & tappet
1) Remove the cam shaft by carefully

sliding it out toward the front of the
engine.
I damage
Do not force the cam shaft as
can occur to cam shaft
bearings.
2) Take the tappets out of the cylinder
block.
1.31. Oil spray nozzle
1) Unscrew the fixing bolts and remove the

oil spray nozzle.
1.32. Cylinder liner
1) Remove the cylinder liner using a

special tool(liner extractor).
EFM2030I
<Fig. 31> Disassembling cylinder liner
- 36 -
2. Inspection and correction of major component parts
2.1. Cleaning and checking cylinder block
1) Clean the cylinder block thoroughly and make a visual inspection for cracks or damage.
2) Check oil and water flow liners for restriction or corrosion.
3) Make a hydraulic test if necessary and check for any leaks from oil and water passages.
Stop up each outlet port of water/oil passages in the cylinder block, apply air pressure of about
5kg/cm2 against the inlet ports, then immerse the cylinder block in water for about 1 minute to
check any leaks. (Water temperature: 70C)
4) Check the camshaft bush of the cylinder block for damage and alignment with oil supply port,
and replace as necessary.
2.2. Checking cylinder liner
1) Insert the cylinder liner into the block,

then measure the bore of the cylinder liner
at 3 positions of top ring contact area,
center area, and oil ring contact area
when the piston reaches bottom dead
center at an angle of 45C respectively.
Take the mean value with the largest and
EFM2032I
smallest values discarded.
<Fig. 32> Measuring liner inside diameter
2) If the measured value is close to or
beyond the specified limit, replace the
cylinder liner.
Liner inside Standard Limit

diameter (mm) 127.990~128.010 0.15
2.3. Cylinder head
2.3.1. Disassembly of cylinder head assembly
1) Use care not to damage the cylinder EFM2033I

head gasket contacting face. <Fig. 33> Removing valve cotter pin
2) Use a special tool(valve spring
compressor) to compress the valve
springs and remove the valve cotter pin.
3) Then disassemble the valve spring
seats, valve springs, and washers.
4) Remove the valve stem seal.
5) Take out the intake and exhaust valves.
6) Turn the head over and place the special
tool on the upper side of valve guide and
EFM2034I
drive out the valve guide by hammering.
<Fig. 34> Removing valve guide
- 37 -
2.3.2. Inspection and correction of cylinder head
1) Make a visual inspection to the cylinder head for cracks or damage.

2) Carefully remove carbon and gasket debris from the lower face of the cylinder head to prevent
scratching of the valve seat faces.
3) Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight using
a hydraulic tester or a magnetic flaw detector.
(Hydraulic test method is the same as that for cylinder block.)
4) Check the lower face of the cylinder head for distortion using a a feeler gauge.
2.3.3. Inspection and correction of valve

and valve guide
1) Inspecting the valve

(1) Clean the valves with clean diesel
oil, then measure the valve stem
outer diameter at 3 positions(top,
middle, and bottom). If the amount of
wear is beyond the limit of 0.15mm,
replace the valve.
Valve stem outer Intake valve Exhaust valve Stem end

diameter (mm) 11.969~11.980 11.945~11.955
(2) Check the valve seat contacting

faces for scratch or wear, and correct EFM2036I
the faces with an oil stone or valve
<Fig. 35> Measuring valve stem
refacer as necessary. Replace if
severely damaged.
(3) Measure the thickness of the valve

head and replace the valve if the
amount of wear is beyond the
specified limit.
Valve Standard (mm) Limit (mm)

H
Intake 2.6~3.0 1.6
Exhaust 1.9~2.3 1.3
2) Inspection and correction of valve guide

EFM2037I
(1) Install the valve into the valve guide
<Fig. 36> Inspecting valve head
and measure the clearance between
them. Compare the measured valve
inside diameter with the valve stem
diameter to determine the amount of
wear.
(2) If the amount of wear is beyond
0.15mm, replace the valve guide.
- 38 -
(3) After replacing the valve guide, check if it is centered with the valve seat insert. Be sure to
reface any faulty valve seat insert. (Reface simultaneously with guide reamer refacing.)
3) Inspection and correction of valve seat

(1) Check the valve seat for wear or 0
10
20
90 30
damage, and replace if necessary. 80

40
70
50
(2) Install the valve into the cylinder

60
head and check the amount of

depression of the valve from the
cylinder head fitting surface using a
dial gauge.
If the amount of depression is EFM2038I
beyond the specified limit, replace <Fig. 37> Measuring depression of valve head
the valve seat insert.
Depression of intake and exhaust valves 0.65~0.95mm
(3) For removal of the valve seat, apply arc welding work to two points of valve seat insert,
and pull out valve seat insert with inner extractor.
(4) Undercool a new valve seat with dry ice for about 1 hour and press the valve seat insert
into position in the cylinder head using a special tool(bench press).
(5) Apply valve lapping compound to the seating face of the valve and lap the valve seat by
turning it until it is seated in position, then wipe out the lapping compound.
4) Inspection and correction of valve spring
(1) Visually check the valve springs for
damage, and replace if necessary.
(2) Measure free length and spring
tension with a valve spring tester.
(3) Measure the spring inclination with a
square.
(4) Replace the valve spring if the
measured value is beyond the limit. EFM2039I
<Figure 3-4> Measuring spring tension and

inclination
<DV15/T/TI> (Unit : mm) <DV15TIS> (Unit : mm)
Free length 72.43 Free length 68.3
Inner When compressed Inner When compressed
spring with load of 46.3 spring with load of 46.3
15~17kg 44.5~49.5kg
Free length 68.17 Free length 61.9
Outer When compressed with Outer When compressed with
spring 46.8 spring 46.8
load of 37~41kg load of 26.5~30kg
5) Reassembly of cylinder head
(1) Clean the cylinder head assembly.
(2) Apply engine oil to valve stem and valve guide before reassembling the valve.
(3) Insert a new valve stem seal into valve guide using a special tool.
(Do not damage the valve stem seal.)
(4) Place valve spring washers over the valve guide.
(5) Install the outer and inner springs and mount the valve spring seat on them.
Note : Install the valve spring seat with 'TOP'(painted in yellow) side up.
- 39 -
(6) Using a special tool(valve spring
compressor), compress the valve
springs and slide in valve cotters.
(7) Check the valves and springs to
ensure they are properly seated by
tapping slightly with a urethane
hammer.
EFM2033I
<Fig. 39> Reassembling valves and valve
springs
2.4. Rocker arm shaft assembly
2.4.1. Disassembly of rocker arm shaft assembly
1) Remove the snap rings from both sides of rocker arm shaft using pliers.
2) Remove the washers, rocker arm bracket and then spring from the rocker arm shaft.
3) Press out the rocker arm bush using a press.
2.4.2. Inspection and correction of rocker arm shaft assembly
1) Measurement of rocker arm bracket(shaft-integrated type).

(1) With an outside micrometer, measure the rocker arm shaft diameter at the point where
the rocker arms have been installed. Replace the rocker arm bracket if the amount of
wear is beyond the specified limit.
2) Inspection of rocker arm
(1) Visually check the face of the rocker arms in contact with the valve stem end for scores
and step wear. If necessary, correct with an oil stone. Rocker arm with a considerable
amount of step wear should be replaced.
(2) Measure the inside diameter of the rocker arm bushing with an inside micrometer and
compare the measured values with the rocker arm shaft diameter to determine the
clearance. If the amount of clearance is beyond the specified limit, replace either the
rocker arm shaft or the bushings.
2.4.3. Reassembly of rocker arm shaft assembly
1) To reassemble, reverse the disassembly procedure.

Clean the oil path passing through the rocker arm and rocker arm bracket, and check to see
that they are free from restrictions.
- 40 -
2.4.4. Inspection of tappet and push rod
1) Measure the diameter of the tappets with

an outside micrometer. If the amount of
wear is beyond the specified limit,
(1)Pitting (2)Crank (3)Normal
replace the tappets.
2) Visually check the face of the tappets in
contact with the cam for pitting, scores or
cracks, and replace if excessively (4)Abnormal
EFM2041I
damaged. If the amount of cracks or
<Fig. 40> Inspecting tappet face
pitting is small, correct with an oil stone
or grinding paper.
3) Roll each push rod on a surface plate

and check for distortion using a feeler
gauge.
Replace the push rod if the amount of
distortion is beyond the value indicating
need for servicing(allowance of
distortion: 0.3mm or less).
EFM2042I
<Fig. 41> Inspecting for push rod distortion

2.5. Cam shaft
2.5.1. Measurement of camshaft axial play
1) Slide completely the camshaft in the

direction of flywheel housing.
2) Place a dial gauge onto the camshaft
gear.
EFM2016S
<Fig. 42> Measuring camshaft axial play
3) With a screwdriver, move the camshaft

gear and measure the camshaft axial
play. (0.2~0.9mm)
4) If the axial play is excessive, it can be
adjusted with a thrust washer of
difference thickness.
EPM2017S
<Fig. 43> Measuring camshaft axial play
- 41 -
2.5.2. Inspection and correction of
camshaft
1) Visually check the journals and cam face

for wear or damage, and replace if
necessary.
Slight step wear or damage on the cam
face may be corrected with oil stone.
2) Measure the cam height with a
EFM2045I
micrometer and replace the camshaft if
<Fig. 44> Measuring cam height
the measured value is beyond the
specified limit.
3) With an outside micrometer, measure
the camshaft journal diameter.
4) Measure the inside diameter of the
camshaft bushing of the cylinder block
using a cylinder bore indicator, and
compare the measured value with the
camshaft outside diameter to determine
the clearance. Replace the bushing if the
measured is beyond the specified limit.
5) Support the cam shaft on V-blocks at its EFM2046I
both ends and check for run-out using a <Fig. 45> Measuring cam shaft run-out
dial indicator. Adjust or replace the cam
shaft if the amount of run-out is beyond
the value indicating need for servicing.
2.6. Crank shaft
2.6.1. Inspection and correction of crank

shaft
1) Visually check the crank shaft for scores or

cracks using a magnetic flaw detector. Have 12 A
the crank shaft ground if the amount of wear
12
is beyond the limit, and install undersize B B
bearings.
B B
2) With magnetic powder and color check, 12
check for cracks. Replace the crankshaft 12

which has cracks.
3) With an outside micrometer, measure the A
EPM2047S
diameter of the crank shaft journals and pins
<Fig. 46> Measuring crank shaft outer diameter
in 2 directions A and B at the front and rear
portions 1 and 2, and compare measured
values to determine the amount of wear.
- 42 -
4) If the amount of wear is beyond the limit,
have the crank shaft ground and install
undersize bearings. "R"
I different
Undersize bearings are available in 4
sizes as follows:
(1) Standards "R"
i) 0.25(Inside diameter is lesser than the
standard value by 0.25mm.)
ii) 0.50(Inside diameter is lesser than the
"R" "R" "R"
iii) 0.75(Inside diameter is lesser than the

standard value by 0.75mm.) EFM2048I
iv) 1.00(Inside diameter is lesser than the <Fig. 47> The shape of crankshaft 'R'
The crankshaft can be reground to the above sizes.
- Standard values of 'R'

1 Crankshaft pin: 4.0-0.5
2 Crankshaft journal: 4.0-0.5
Note: When reworking the crank shaft to undersize, the fillet section 'R' should be finished
correctly. Avoid sharp corners or insufficient fillet.
5) Measurement of crankshaft run-out

(1) Support the crankshaft on V-blocks.
(2) Turn the crankshaft slowly in one direction with the probe of a dial indicator resting on the
No. 3 journal and take the highest reading of the indicator.
(same method as that for measuring the camshaft run-out)
2.6.2. Inspection and correction of crankshaft bearing and connecting rod bearing
1) Visually check the contacting surface of crankshaft bearing and connecting rod bearing for
scoring, uneven wear or damage, and replace if damaged.
2) Check oil clearance between crankshaft and bearing.
(1) Measurement of oil clearance with a
cylinder bore indicator A 10 Section A-B
1 Install the main bearing in the cylinder 10
block and tighten the bolts to specified
2 8
torque, then measure the inside 1 3
8
diameter with a cylinder bore indicator.
2 Install the bearing in the connecting
rod big end and tighten the connecting
B ab
rod cap bolts to the specified torque, EFM2049I
then measure the inside diameter with <Fig. 48> Measuring connecting rod bearing
a cylinder bore indicator. inside diameter
- 43 -
3 Compare the two values obtained through measurement of bearing inside diameter with
the outside diameters of crankshaft journals and pins to determine the clearance.
4 If the clearance deviates from the specified range, have the crankshaft journals and pins
ground and install appropriate undersize bearings.
(2) Measurement of bearing clearance with a plastigauge
1 Install the crankshaft over the bearing, position a Plastigauge (PG-1) over the crankshaft
journal and pin to cover the full width of the bearings, then tighten the bearing cap to
specified torque. Re-disassemble the bearing cap, remove the flattened plastigauge to take
the plastigauge width. This is the oil clearance.
2 Oil clearance of the connecting rod can be taken in the same manner.
3) Measurement of crankshaft end play

(1) Assemble the crankshaft to the
cylinder block.
(2) Install a dial gauge, then move the
crankshaft in the axial direction to
measure the end play.
(0.190mm~0.322mm)
EPM2018S
2.7. Piston assembly
<Fig. 49> Measuring crankshaft end play
2.7.1. Disassembly of piston assembly
1) Remove the piston pin and snap rings

using a special tool(snap ring pliers).
2) Take out the piston pin from the piston
using a round brass bar.
3) Remove the piston rings using a piston
ring expander.
4) Thoroughly clean the piston.
2.7.2. Inspection and correction of pistons EFM2051I
<Fig. 50> Disassembling piston rings

1) Visually check the pistons for cracks,
scratch or wear, paying particular
attention to the ring grooves.
2) With an outside micrometer, measure
the piston diameter at a point 71.5mm
away from the end of piston skirt in a
direction at a right angle to the piston pin
hole.
3) Compare the value of piston diameter
with cylinder bore diameter to determine
EFM2052I
the clearance.
<Fig. 51> Measuring piston outside diameter
Replace pistons or cylinder liners, if the
clearance is beyond the specified range.
- 44 -
2.7.3. Inspection of piston rings
1) Replace the piston rings with new ones if

found to have been worn or broken when
the engine is overhauled.
2) Measurement of piston ring gap
(1) Insert the piston ring into the cylinder
liner bore so that it is held at a right
angle to the cylinder liner wall. EFM2053I
(2) Measure the piston ring gap with a
<Fig. 52> Measuring piston ring gap
feeler gauge.
(3) Replace piston rings with new ones if
the gap is beyond the limit.
I Piston ring gap

Location Standard(mm) Limit(mm) I Piston ring side clearance
Top ring 0.35~0.55 1.5 Location Standard(mm) Limit(mm)
2nd ring 0.40~0.60 1.5 Top ring 0.10~0.150 0.3
0.35~0.55 1.5 2nd ring 0.50~0.82 0.15
Oil ring
*0.40~0.70 1.5 Oil ring 0.030~0.062 0.15
*DV15TIS
3) Measurement of piston ring side clearance
(1) Place the piston rings over the piston.
(2) With a feeler gauge, measure side clearance of each ring, and replace either rings or piston
if the measured value is beyond the specified limit.
2.7.4. Inspection of piston pin
1) With an outside micrometer, measure the diameter of the piston pin at several points. Replace
the piston pin if the measured value is beyond the limit. (0.005mm)
2) Measure the clearance between the piston pin and conn. rod bushing, and replace either the
connecting rod or the piston pin, whichever having greater wear, if the clearance is beyond the
limit (0.011mm).
2.7.5. Inspection of connecting rod
1) Check the connecting rod for distortion between the small end and large end using a
connecting rod aligner.
2) If the value is beyond the limit of bend(0.02mm) or twist(0.005mm), replace the connecting rod.
2.7.6. Reassembly of the piston and connecting rod assembly

1) Heat the piston to about 120~150C for about 5 minutes with a piston heater. Align the piston
pin hole with the pin hole of connecting rod small end, apply engine oil to the pin, then insert
the piston pin into the piston.
Note: Note the direction of the connecting rod.
2) Secure the piston pin snap ring in the groove with snap ring pliers.
3) Install the piston rings in the piston ring grooves identifying the 'TOP' mark, then check to see
that each ring moves freely within the ring groove.
4) Keep the piston and connecting rod assembly in the order of cylinder No.
- 45 -
2.7.7. Inspection of thermostat
Temperature
1) Check the wax pallet and spring for damage. Bar
2) Submerge the thermostat in a container of
water and heat the water slowly, then the
valve will start to open at water temperature
of 83C and completely open at 94C
3) Measure the valve opening temperature Plate
and wide opening temperature, and check
EFM2055I
to see if the valve lift is 8mm or more.
Replace the valve if found defective. <Fig. 54> Inspection of thermostat
2.7.8. Inspection of injection nozzle
1) Clamp the nozzle and nozzle holder

assembly in vice and disassemble the 1 1.Nozzle holder body
nozzle holder. 2. Cap nut
2
2) Remove the nozzle nuts and take out the 33 3. Adjusting shim
internal parts. 4.Compression spring
4
5. Spindle
5
6. Spacer
66
77 7. Nozzle nut
88 8. Nozzle
EFM2054I
<Fig. 53> Cross section of nozzle assembly
3) Check the disassembled parts for damage.

4) For reassembly, reverse the disassembly
sequence.
5) After completing reassembly operation,
assemble a nozzle with a nozzle tester.
6) Operate the hand lever to check injection
pressure and spray patterns.
EFM2056I
<Fig. 55> Inspection of injection nozzle
7) If the measured injection pressure deviates

from the standard value, adjust the pressure
by increasing or decreasing the adjusting
shims.
Normal
8) Replace the nozzle assembly if spray
pattern is abnormal.
Abnormal Abnormal EFM1006I
- 46 -
3. Engine reassembly
3.1. Preparation and precautions before or after reassembling the engine
1) Wash clean all the disassembled parts, particularly oil and water ports, using compressed air,
then check that they are free from restrictions.
2) Arrange the general and special tools in order for engine assembly operation.
3) Prepare clean engine oil to wet each sliding part.
4) Prepare service materials such as bond and so forth.
5) Use THREE BOND when fitting a gasket on the engine, while SILICONE for the cooling water
system.
6) Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
7) Apply only the specified torque for bolts in the specified tightening order and avoid over-
tightening.
8) Be sure to check that all the engine parts operate smoothly after being reassembled.
9) Check the bolts for looseness after preliminary reassembly.
10) After completing the engine reassembly operation, check if there is omission or shortage of
some parts.
11) Keep your hands clean during the working.
3.2. Cylinder liner
1) Replace O-rings with new ones and install

the upper rings into the cylinder liner and
the lower rings into the cylinder block
respectively.
2) Apply O-ring fitting face with lubricating oil.
3) Push the cylinder liner into the cylinder
block and press it with care against
possible damage to the O-rings.
4) Make a hydraulic test after installing the EFM2058I
cylinder liner to check for water leaks. <Fig. 56> Installing cylinder liner
(Test pressure is 5kg/cm .) 2
3.3. Oil spray nozzle
1) Install the oil spray nozzle flange with a

hollow screw.
2) Tighten and assemble the oil spray nozzle
assembly with fixing bolts.
EFM2059I
<Fig. 57> Installing oil spray nozzle
- 47 -
3.4. Tappet
Apply engine oil to the tappets, then install them into the tappet holes on the cylinder block.
3.5. Crankshaft
1) Heat wear ring at temperature of

150~200C in the heating furnace. And
then, fit it to the crankshaft front journal
using an assembling jig.
2) Install the main bearing in the cylinder
block and wet them with engine oil. At
this time, use care so that the bearing
with oil feed hole is fit to the cylinder
block, while the bearing without oil feed
hole is fit to the bearing cap. Do not
EFM2060I
interchange these bearings.
<Fig. 58> Installing maim bearing
3) Temporarily tighten a bolt into each of the
bolt holes at both sides of the crankshaft,
fit a rope to the bolts, lift them using a
crane or chain block, then bring them
down on the cylinder block carefully.
4) Wet the crankshaft journals and pins IDV15, DV15T, DV15TI, DV15TIS
with engine oil, assemble another main 5 3 1 2 4
bearing with a bearing cap. Ensure the
numbers of the bearing caps are not
interchanged before installing them in
the cylinder block.
EPM2020I
5) Be sure to wet the bearing cap bolt taps
and bolt seating faces with engine oil <Fig. 59> Bearing cap bolt tightening
sequence
and tighten to the specified
torque(30kg.m) and by rotating
angle(90+10˚) method. The tightening
sequence is as follows:
(1) 1st stage: Wet the bolts with engine

oil.
(2) 2nd stage: Tighten 1~2 threads by
hand.
(3) 3rd stage: Tighten to about 15kg.m
using a wrench.
(4) 4th stage: Tighten to about 25kg.m
using a torque wrench.
(5) 5th stage: Tighten to about 30kg.m
using a torque wrench.
(6) 6th stage: Tighten to 90+10˚ by the
rotating angle method. The tightening
EFM2062I
operation should be performed in
stages as described above. <Fig. 60> Tightening bearing cap bolts
6) Check by hand that the crankshaft is turned smoothly.

7) Install the crankshaft gear over the crankshaft and paint in white on the tooth of gear mark '1'
to make it easy to identify it.
- 48 -
3.6. Cam shaft
1) Apply engine oil to cam bush and

camshaft on the cylinder block.
2) Carefully insert the cam bush and
camshaft into cam hole on the cylinder
block.
3) At assembly, make sure that the gear
1
marks of crankshaft and camshaft are 1 1
aligned.
Camshaft gear
EFM2063I
<Fig. 61> Aligning crankshaft and camshaft

gear positions
3.7. Flywheel housing
1) Assemble the following parts in the

flywheel housing before installing the
flywheel housing onto the cylinder block:
(1) Assemble the air compressor
crankshaft with the drive gear.
(Gear fixing bolt torque: 36kg.m )
EPM2021I
<Fig. 62> Installing air compressor

crankshaft and gear
(2) Apply loctite to the fixing bolts and

assemble the thrust washer to the
specified torque(4kg.m ).
EFM2065I
<Fig. 63> Installing thrust washer
(3) Apply lubricating oil to the outside of

the oil seal(P.T.F.E. oil seal) and fit it to
the flywheel housing using a mandrel
guide so that it may not be inclined or
damaged.
- 49 -
2) Apply gasket on the flywheel housing fitting face of the cylinder block. (Apply grease to the
cylinder block surface so as to prevent the gasket from falling out.
3) Temporarily fit two flywheel housing fixing guide bolts on the cylinder block.
4) Install the flywheel housing over the dowel pins and temporarily tighten the fixing bolts 2~4
threads to the specified torque(7.5kg.m ) in the specified tightening sequence(diagonally).
(Do not damage the oil seal.)
3.8. Flywheel
1) When assembling ring gear with the

flywheel, heat it to a max. temperature of
4 7
230C and press on up to a complete stop.
9 5
2) With a mandrel, install the pilot bearing in
the flywheel. 2 1
3) With a mandrel, strike wear ring onto the 6 10
rear side of the flywheel. 8 3
4) Temporarily tighten two flywheel fixing
EFM2066I
guide bolts on the crankshaft.
5) Place the flywheel over the dowel pin, then <Fig. 64> Flywheel bolt tightening sequence
temporarily tighten the fixing bolts

2~3 threads to the specified torque
(26kg.m ) in the specified sequence (diagonally).
3.9. Tacho Sensor
1) Move the lock nut to hexagon side of

sensor completely. Rock nut Ring gear
2) Rotate(cw) the tacho sensor on fly
wheel housing, untill the end of it reach
on fly wheel ring gear.
3) Rotate(ccw) the tacho sensor for 270˚
and fix lock nut.
M16x1.5
4) Toleration limits is 27˚(Ref. Fig)
EPM2030I
3.10. Oil cooler <Fig. 65> Installing oil cooler assembly
1) Apply gasket to the oil cooler fitting

surface on the oil cooler housing.
2) Fix the oil cooler with fixing bolts.
3) Apply gasket to the oil cooler assembly
fitting surface on the cylinder block.
4) Tighten oil cooler assembly fixing bolts
in diagonal directions.
EPM2022I
<Fig. 66> Installing oil cooler assembly
- 50 -
3.11. Air compressor
1) Assemble the piston assembly into air

compressor cylinder liner before installing
it to the flywheel housing. (Same method
as that of piston reassembly)
2) Fit a gasket to the air compressor fitting
surface of the flywheel housing.
3) Assemble the connecting rod of the air
compressor liner assembly with the air
compressor crankshaft and tighten it to EPM2023I
the specified torque(3.5kg.m). <Fig. 67> Installing air compressor piston

assembly
.
4) Tighten the liner fixing bolts to the specified torque(4kg m ).
5) Tighten the side air compressor liner fixing bolts using a special tool('T'-shape socket spacer).
6) Mount a gasket on the liner.
7) Tighten air compressor head fixing bolts to the specified torque(3kg.m ).
3.12. Starter
1) Assemble stud bolts into tapped holes on the flywheel housing.

2) Install the starter into the flywheel housing hole and tighten fixing nuts.
3.13. Piston
120˚
1) Arrange the piston assembly in cylinder
numerical order and install the conn. rod 2nd ring cap Top ring cap
bearings tapped in the connecting rod Piston pin

and cap respectively. Ensure that a 120˚ 120˚
conn. rod is assembled with its mating
cap. Piston
Oil ring cap
EFM2069I
<Fig. 68> Piston ring gap position
4) Push the piston into the cylinder by hand or a wooden bar.

(Do not damage the piston and rings.)
5) Push further in the piston and turn the crankshaft about 180° to fit the bearing cap in the
connecting rod.
6) Apply engine oil to the connecting rod bolt taps and seating surface and tighten them 2~3
threads to specified torque (10kg.m +90+10).
I Bolt tightening sequence

(1) 1st stage : Apply engine oil to bolts.
(2) 2nd stage : Tighten 2~3 threads by hand.
(3) 3rd stage : Tighten to about 7kg.m with a wrench.
(4) 4th stage : Tighten to 10kg.m with a torque wrench.
(5) 5th stage : Tighten to 90+10 by the rotating angle method.
- 51 -
The tightening operation should be performed in stages as described above.
* Limit for re-used bolt and length from bolt
contacting face to bolt end
Standard (mm) Limit (mm)
67.5 -0.3
69
7) Check with hand the connecting rod

bearing cap for horizontal movement.
8) Turn the crankshaft in the above-stated
manner to assemble all the other conn.
rod assemblies with each corresponding
cylinder.
EFM2070I
<Fig. 69> Installing connecting rod bearing caps
3.14. Injection pump
1) Fit a greased O-ring in the oil passage

under the fuel injection pump assembly.
(Do not allow the O-ring to slip off.)
2) Fit a rubber gasket in position before
installing the fuel injection pump drive
gear.
3) Temporarily tighten drive gear fixing
bolts with the injection pump pointer
aligned with the drive gear pointer. EFM2071I
<Fig. 70> Adjusting injection timing
4) Turn the fly wheel until the No. 6 cylinder is at T.D.C (Valves of these cylinder must overlap)
5) Turn back the flywheel to approx. 30°(to remove gear backlash), then again turn it in the
direction of rotation to exactly adjust the injection angle.
6) After completing the preparations for fuel injection pump reassembly as above, mount the
injection pump and tighten injection pump fixing bolts in diagonal directions.
7) After reassembling the injection pump, make sure to check if the pump pointer is aligned with
drive gear pump. If aligned, completely tighten the semi-tightened drive gear fixing bolts.
However, if not aligned, loosen the semi-tightened pump fixing bolts and re-adjust the pointer
positions by turning the camshaft, then tighten the fixing bolts.
- 52 -
3.15. Flywheel housing cover
1) Assemble the rubber packing over the

flywheel housing cover.
2) Mount the flywheel housing cover and
tighten fixing bolts in diagonal directions.
EFM2072I
<Fig. 71> Installing flywheel housing cover
3.16. Front oil seal holder
1) Put new oil seal correctly on the oil seal

holder hole and press it in with a
mandrel.
(Be careful not to damage the oil seal.)
2) Assemble a gasket to oil seal holder.
3) Install the oil seal holder with the cylinder
block dowel pin aligned with the oil seal
pin hole, and then slightly tap the seal
holder with a urethane hammer. EFM2073I
Note: Avoid applying engine oil or any <Fig. 72> Installing front oil seal holder
other lubricating oil to the oil seal. Install it
in a dried condition.
4) Tighten fixing bolts in diagonal directions.
3.17. Oil pump
1) Place the oil pump assembly on the

cylinder block.
2) Fit an oil relief valve gasket in position
and then put the oil relief valve assembly
on it.
3) Tighten oil pump fixing bolts.
4) Re-place gasket in position on the oil
suction pipe, and then tighten oil suction
pipe fixing bolts.
EFM2074I
5) Assemble and fix the oil pipe bracket to
<Fig. 73> Installing oil pump assembly
the cylinder block.
- 53 -
3.18. Oil pan
1) Cut away cleanly protruded gaskets of

the flywheel housing and oil seal holder
under the cylinder block using a cutter.
Be careful not to allow gasket debris to
enter the engine compartment.
2) Fit an oil pan gasket on the cylinder
block.
3) Install the oil pan and tighten fixing bolts.
Be careful not to squeeze out the oil pan EFM2072I
gasket. <Fig. 74> Installing oil pan
4) Assemble the guide tube and then fit an
oil level gauge.
3.19. Cylinder head
1) Clean the head bolt holes on the cylinder

block with compressed air.
2) Thoroughly clean the gasket fitting face
of the cylinder block.
3) Check for foreign substances in the
combustion chamber and remove
completely, if any.
4) Install new head gasket on the cylinder
block by aligning the holes with dowels.
5) Carefully mount the cylinder head EFM2076I
assembly on the block by aligning it with <Fig. 75> Installing cylinder head
dowel pin. (Be careful not to damage the
head gasket.)
6) Coat the head bolts with engine oil, then
tighten them in proper sequence to the 1
specified torque. Before tightening the
head bolts, parallel the cylinder heads
with a long, straight rule. 6 3
I(1)Bolt tightening sequence

1st stage: Apply engine oil to the bolts.
(2) 2nd stage: Temporarily tighten 1~2
threads by hand.
(3) 3rd stage: Tighten to about 8kg.m with
a wrench. 4 5
(4) 4th stage: Tighten to 15kg.m with a
torque wrench. 2
(5) 5th stage: Tighten to 90° by the rotating EFM2077I
angle method. <Fig. 76>
(6) 6th stage: Tighten to further 90°.
- 54 -
I Limit for re-used bolt and length from bolt contact face to bolt end
Bolt No. Length (mm) Limit (mm)
3,6 168 171
2,4,5. 144 147
1 109 112
(7) When working, install wooden cover so that foreign substances may not enter the cylinder
head suction path.
3.20. Nozzle
1) Insert a new seal ring into the nozzle hole of

cylinder head and install the nozzle
assembly fixing bolts. Apply Never-Seiz(anti-
seizure coating material) to nozzle holder
surface before installation.
3.21. Rocker arm
1) Install the push rods coated with engine

EFM2090I
oil into the push rod holes.
<Fig. 77> Installing nozzle holder assembly
2) Install the rocker arm assembly on the
cylinder head and tighten fixing bolts to
specified torque(6.5kg.m).
3) Adjust valve clearance in the following
sequence:
(1) Turn the engine until the valve of No. 1
cylinder is overlapped.
(2) Adjust the valve clearances marked
with [ ] in the following tables.
(3) Make one turn of the crankshaft so that
No. 7 cylinder(for 10-cylinder equipped EFM2091I
engine) or No. 6 cylinder(for 8-cylinder <Fig. 78> Installing rocker arm assembly
equipped engine) is overlapped.
(4) Adjust the valve clearances marked
with [ o ] in the following tables.
I For DV15, DV15T, DV15TI, DV15TIS (equipped with 8 cylinders)

Cylinder No. 1 2 3 4 5 6 7 8
Volar Ex In Ex In Ex In Ex In Ex In Ex In Ex In Ex In
No. 6 overlap o o o o o o o
No. 1 overlap
Firing order: 1-5-7-2-6-3-4-8
- 55 -
3.22. Cylinder head cover
1) Replace the cylinder head cover gaskets with new ones and install them onto the cover fitting
position.
2) Assemble the cylinder head cover by tighten fixing bolts.
3) Install oil filler cap.
4) Install the oil breather pipe assembly in position and fix with clamping bolts.
3.23. Vibration damper
1) Assemble the vibration damper with the

crank pulley with fixing bolts.
2) Install the crankshaft pulley assembly on
the crankshaft, then tighten the bolts in
diagonal sequence to 21kg.m.
EFM2092I
3.24. Oil filter <Fig. 79> Installing vibration damper
1) Assemble the tachodrive assembly

before installing the oil filter assembly.
2) Insert greased O-rings into the oil port of
the oil filter head. (Prevent the O-ring
from slipping out.)
EFM2093I
<Fig. 80> Installing oil filter assembly
3) Install the filter head on the cylinder block

and tighten bolts in a diagonal sequence.
4) Install the oil filter element in the oil filter
assembly.
EFM2094I
<Fig. 81> Installing oil filter element
- 56 -
5) Install new O-rings (packings) in the oil
filter housing. (Filter element, Cu-
washer, and packing are supplied
together as A/S parts.)
6) Assemble the oil filter housing with the
filter head (Be careful not to damage the
O-ring.)
7) Place Cu-washer over filter housing
fixing bolt and tighten the bolt.
EFM2095I
3.25. Water pump <Fig. 82> Installing vibration damper
1) Fit a new gasket on the water pump(to

cylinder block side).
2) Tighten water pump assembly fixing
bolts in diagonal sequence.
3) Install two(2) thermostats in the water
pump.
4) Install O-rings on the thermostats and
assemble water outlet pipe by tightening
fixing bolts. .
EFM2028I
3.26. Intake manifold <Fig. 83> Installing oil filter assembly
1) Fit new gaskets on the cylinder head.

2) Tighten the manifold fixing bolts.
3) Install a gasket on inlet flange and
tighten fixing bolts.
4) Assemble both sides of the intake
manifold in the same manner as
described in 3.24.
5) Fit gaskets on equalizing pipe which
connects both sides of the intake
manifold, and tighten equalizing pipe EFM2082I
fixing bolts. <Fig. 84> Installing oil filter element
3.27. Exhaust manifold
1) Insert an exhaust gas seal ring in

between a pair of exhaust manifolds to
join them.
2) Fit new gaskets on the exhaust manifold.
3) Tighten the exhaust manifold fixing bolts.
4) Fit a gasket on the exhaust elbow which
is connected to the exhaust manifold,
and tighten it with fixing nuts.
5) Assemble both sides of the exhaust
EPM2026I
manifold in the same manner as
<Fig. 85> Installing oil filter element
described in 3.24.
- 57 -
3.28. Turbocharger
(For DV15T/TI/TIS engine only)
1) Fit a new gasket on the exhaust elbow

and tighten turbocharger fixing bolts.
2) Connect the intermediate pipe and pre-
oiled O-ring between the inlet flange and
the turbocharger.
3) Fit a gasket on the oil feed pump and
tighten fixing bolts. EPM2011S
4) Fit a gasket on the oil return pipe and
<Fig. 86> Installing turbocharger
tighten fixing bolts.
5) Assemble both sides of the manifold in
the same manner as described in 3.24.
3.29. Intake stake
1) Connect rubber hose between intake

stake and turbocharger and tighten
clamps.
3.30. Injection pipes
1) Connect the fuel injection pipes between

the injection pump and the nozzle and
tighten clamping nuts.
2) Fix the fuel return pipe by tightening
hollow screws.
EFM2087I
<Fig. 87> Reassembling fuel injection pipe
3.31. Fuel filter
1) Install the fuel filter assembly on intake stake and tighten fixing bolts.
2) When replacing the fuel filter element, loosen the fixing bolts from filter head and replace
O-rings with new ones.
3.32. Power steering oil pump
1) Connect the power steering oil pump to the air compressor and push them inward.
Be careful not to damage power steering pump O-ring. Ensure that the driving dog is cross-
assembled with the air compressor coupling.
2) Tighten fixing bolts.
- 58 -
3.33. Hoses and pipes
1) Assemble the pre-heater plug to intake

stake, install the magnetic valve on the
intake manifold with fixing bolts, then
connect the fuel pipes between the pre-
heater plug and magnetic valve.
2) Connect fuel strainer to fuel feed pump,
and assemble the fuel hose therewith.
3) Connect fuel delivery and return hoses.
4) Connect lub. oil delivery pipes and
hoses to air compressor.
3.34. Alternator
1) Assemble the alternator mounting

bracket with fixing bolt to the lower side
of cylinder block.
2) Assemble the alternator support (V-belt
tension adjusting bolt) with fixing bolt to
oil pan.
3) Assemble the alternator with bracket and
support.
4) Install V-belt over water pump pulley, EPM2028I
crankshaft, and alternator pulley. <Fig. 88> Installing alternator and V-belt
5) Adjust the V-belt tension by adjusting the
alternator support(V-belt tension adjusting
bolt).
(The belt deflection should be within the
range of 10~15mm.)
3.35. Cooling fan
1) Assemble cooling fan to fan coupling

with fixing bolts.
2) Install the cooling fan assembly to the
crankshaft pulley fitting surface with
fixing bolts and tighten to the specified
torque.
EPM2029I
<Fig. 89> Installing cooling fan assembly
- 59 -
4. Breaking-in engine
I Preparations for breaking-in

1) Fill new engine oil through the oil filler cap.
2) Check engine oil level using the oil level gauge. (on a level ground)
3) Connect water hose.
4) Inject cooling water.
5) Connect the fuel hose.
6) Bleed the fuel system. (Loosen the bleeding screws on the fuel filter and operate the fuel feed
pump by hand.)
I Implementing breaking-in operation

1) Locate causes of any complaints in assembly condition or defects in engine performance
through the breaking-in operation and take proper measures accordingly.
I Breaking in the new engine mounted on the vehicle

1) Run the engine at 1,200~1,600 rpm for 2.5 hours and then at 1,600~2,100 rpm for further 2
hours.
2) Adjust valve clearance.
3) Check the oil level and replenish if necessary.
4) Start the engine and raise the temperature of cooling water gradually to 80C~95C.
5) Slowly increase the engine speed up to 2,300 rpm. And then, run the engine at approximately
90% of the maximum speed.
6) Keep checking the oil pressure all the while running the engine.
7) Make sure to check for leaks of oil, fuel, or cooling water from the engine.
8) Drive the vehicle steadily on a good road applying 50% of vehicle load capacity for
approximately 2 hours.
9) Replace the lubricating oil with the specified one after completing the breaking-in.
10) Replace the filter element of the oil filter.
- 60 -
Section 3. Turbocharger (For DV15T engine only)
1. Specifications and construction
1.1. Main data and Specifications
Model Allied signal TB4122
Air pressure at compressor outlet Approx. 1,270kg/cm2 Gauge
At maximum output Air suction volume Approx. 13.5m3/min
Speed of turbine revolution Approx. 100,000 rpm
Maximum allowable speed 130,000 rpm
Maximum allowable temperature of exhaust 700C(instantaneous temp.: 760C)
gas at turbine inlet External oil supply
Lubricating system
Weight 12kg
1.2. Construction
Exhaust
Turbine wheel gas outlet
Compressor
Engine
Exhau
cylinder st gas
Exhaust gas inlet discha
Compressed air rge
discharge Engine
exhaust Ambient air inlet Turbine
Ambient air gas flow
Compressor wheel Compressed
EFM3002I air flow EFM3003I
<Operating principle>
1 D 1. Impeller housing
2
3
2. Turbine housing
3. Bearing housing
5
4. Impeller
A B 5. Turbine
A. Air inlet
B. Gas outlet
4 C. Gas inlet
E
D. Oil supply
E. Oil return
C
EAO5008I
- 61 -
22
23
24
15
7
6
3
14 8 4
19
18
16
2
17 13
21
5
1
9
10
27, 30, 31 11
EFM3001I
1 Turbine shaft assembly 15 Seal plate

2 Thrust bush 16 Thrust bearing
3 Oil thrower 17 Journal bearing
4 Lock nut 18 Screw
5 Seal ring 19 Screw
6 Seal ring 21 Heat protector
7 Seal ring 22 Compressor housing
8 Compressor wheel 23 Clamp
9 Turbine housing 24 Bolt
10 Bolt 27 Liquid gasket
11 Clamp 30 Loctite
13 Bearing housing 31 Liquid anti-seizure
14 Retaining ring coating material
- 62 -
2. General information
Engine output depends on fuel delivery volume and engine efficiency.

To completely burn the fed fuel to convert into effective power, the cylinders should be supplied
with a sufficient volume of air enough to burn the fuel completely.
For this reason, the engine output is determined substantially by the size of cylinder. Accordingly,
the feeding of compressed air to the cylinder with a given capacity will increase the air volume
within the cylinder and can burn much more fuel, resulting in increase in engine output.
As stated above, compressing ambient air to supply into the cylinders of the engine is called
"Supercharging"; while turbocharging employs exhaust gas energy to charge compressed air into
the cylinders.
3. Functions
3.1. Turbine
Exhaust gas discharged from the combustion chamber flows into the turbine housing and
distributes its own energy to the turbine blades to give rotating force to the turbine shaft.
This is the main function of the turbine. The turbine is equipped with seal rings and heat
protector so that exhaust gas may not adversely affect the bearings.
3.2. Compressor
The compressor, which is connected to the turbine over the one and same shaft to form a rotary
assembly, takes in and compresses ambient air with rotating force created by the turbine. Then,
the compressed air is distributed to the intake pipe.
3.3. Bearings
1) Thrust bearing
The turbine wheel creates thrust force, which prevents the deviation of the shaft from its
position.
2) Journal bearing
The journal bearing is of a floating type. Unlike the fixed-type bearing, it forms a dual oil film
on its both inner and outer circumferences and thus can independently rotate. Accordingly,
as the dual oil film functions as a damper, the sliding speed of the bearing surface becomes
lower than the rotating speed of the rotary shaft, resulting in assurance of stability in its
movement.
3.4. Sealing-compressor shaft
The bearing-compressor shaft is of a dual structure type consisting of seal plate and seal ring,
so that intake air compressed in the compressor or lubricating oil may not leak out.
- 63 -
4. How to handle the engine
4.1. Precautions for operation of the engine
Be sure to follow the following instructions when starting, running, or stopping the engine:
Operation Caution Reason

When starting 1) Check oil level. 2) If you abruptly start the engine,
the engine 2) Crank the engine with the starter individual parts of the engine as
and check the rise of hydraulic well as the turbocharger will turn
pressure (until the needle of the over with no oil fed. The lack of
pressure gauge moves or pressure lubricating oil as in this situation
indicator lamp is actuated), then causes premature wear or seizure
start the engine. to the bearing.
3) If stopping the vehicle for extended
3) When replacing oil, oil filter periods or in cold place, the fluidity
element, or parts for lubricating of the oil within the piping will
system, or when stopping the become worse.
engine for an extended period of
time(one week or longer), or when
attempting to operate the engine in
cold place, release the oil piping
connections installed at the
turbocharger inlet port and run the
starter until the oil flows out. After
completing the engine operation,
make sure to re-tighten the piping
connections before re-starting.
Immediately 1) Idle the engine for 5 minutes after 1) Applying load abruptly
starting the engine. If applying load abruptly with the
after starting
engine and turbocharger not
rotating smoothly immediately after
starting off, seizure will occur at
such positions that fail to take up
sufficient amount of oil.
2) Check individual parts for leaks of 2) Oil leak, gas leak, or air leak
oil, gas, and air. causes hydraulic pressure to
decrease, and resultant lack of oil
causes the bearing to seize up.
During operation Check the following points: 1) If the hydraulic pressure is too low,
1) Hydraulic pressure the bearing can be worn out or
At idling : 0.9~3.0 bar seized up. On the contrary, if the
At full load : 3.0~6.5 bar hydraulic pressure is too high, oil
2) When unusual sound or vibration is can leak out.
heard or felt, reduce rpm gradually 2) If continuing to operate the engine
to stop the engine and locate the with unusual sound or vibration
cause. heard or felt, the engine may break
down irreparably.
When stopping 1) When attempting to stop the 1) If stopping the engine suddenly
the engine engine, idle for 5 minutes before after operating on high load, heat
stopping. will be transferred to the bearing
portion from the red-heated turbine
blades and burns the oil, causing
seizure to the bearing metal and
rotary shaft.
- 64 -
5. Walk-around check and maintenance
As the conditions of the turbocharger depends mainly on how well the engine has been
maintained, it is essential to accurately follow the maintenance instructions for the engine.
5.1. Air intake system
Exercise exceptional care for the air cleaner among all the component parts of the air intake
system. For a wet-type air cleaner, if the oil surface is lower than the specified limit, the air
cleaner's purifying effect is low; if too high, the air cleaner sucks in the oil and fouls the filter case.
Especially, if the rotor is contaminated, the sophisticatedly- adjusted balance will be lost. As a
result, vibration is generated and great load is imposed on the bearing, which brings about
seizure and abnormal wear to the bearing. Therefore, it is very important to use high-quality air
cleaner all the time. For a dry-type air cleaner, it is necessary to clean it properly according to
the readings of dust indicator to reduce suction resistance as much as possible.
5.2. Air exhaust system
Pay particular attention to gas leak and seizure for the air exhaust system. If exhaust gas leaks
from the exhaust manifold and turbocharger fittings, charging effect will be reduced. It is
important to note the joints of individual components. Since such components as the turbine
housing that is red-heated during operation are equipped with heat-resisting steel nuts, never
interchange them with ordinary steel nuts. Also be sure to apply anti-seizure coating material to
fixing nuts for the specified positions.
5.3. Fuel system
If you adjust, without using a pump tester, the full load stopper(which regulates the maximum
injection volume of the fuel injection pump) and the maximum speed stopper(which regulates the
maximum speed), the turbocharger may overrun and be damaged. In addition, if the nozzle
spray pattern is bad or injection timing is incorrect, the temperature of exhaust gas will rise and
adversely affect the turbocharger. In this case, be sure to adjust the injection nozzle.
5.4. Lubricating system
For the lubricating system, be sure to check the oil quality and to follow the oil filter element
change intervals. The deterioration of the oil fed to the turbocharger affects adversely the engine
body as well as the turbocharger. Make sure to use the suggested engine oil.
(15W40,CD grade or above)
- 65 -
6. Periodical servicing
It is essential to regularly check the turbocharger assembly for conditions and contamination.
6.1. Rotating condition of the rotor and checking tips
When checking the rotor for rotating condition, be sure to locate unusual sound heard during
rotation. When using a sound detecting bar, install its tip against the turbocharger housing and
increase engine revolution slowly. If a high-pitched sound is heard every 2~3 seconds, it
indicates that the floating bearing and rotor assembly may be out of order. Then, repair or
replace the turbocharger.
6.2. Measuring rotor clearance
Inspect the axial clearance and radial clearance as follows with the turbocharger disassembled
from the engine. When disassembling the turbocharger, make sure that the oil inlet and outlet
should be sealed with tape or similar.
1) Rotor axial clearance

• Wear limit : 0.20mm
Turbine housing
Magnetic stand
Move turbine
shaft in axial
direction
Move turbine
shaft in axial
direction
Dial indicator
Wear limit: 0.20mm

EFM3004I
< Measuring axial clearance >
2) Rotor radial clearance

• Wear limit : 0.65mm
Dial indicator
Magnetic stand
Oil outlet
Move turbine shaft

at both right and
left sides
Oil inlet simultaneously in
EFM3005I radial direction
< Measuring axial clearance >

3) If the axial and radial clearances are beyond the specified limit, replace or repair the turbocharger.
- 66 -
6.3. Cleaning and checking tips
Be sure to dismantle the turbocharger from the engine before cleaning. Also, make sure to seal
the oil inlet and outlet with tape or similar.
6.4. Precautions for turbocharger reassembly
Be sure to follow the these precautions when installing the turbocharger on the engine or after
completing the installation. In particular, exercise exceptional care to prevent foreign substances
from entering the inside of turbocharger.
1) Lubricating system
(1) Apply new engine oil into the oil intake port before installing the oil suction pipe onto the
engine, and turn the turbine shaft with hand to thoroughly lubricate the journals and
bearings.
(2) Clean the pipes from the engine to oil intake port and oil return pipes, and check them for
damage or foreign substances.
(3) Securely tighten individual joints on the oil pipes to prevent oil leaks.
2) Air intake system
(1) Check the air intake system for foreign substances.
(2) Use bolts and nuts made of heat-resisting steel. When assembling these fixing bolts and
nuts, do not interchange them with ordinary steel ones. Apply anti-seizure coating material
to them.
(3) Securely tighten individual joints on the exhaust pipes to prevent gas leaks.
7. Diagnostics and troubleshooting
Complaints Possible causes Corrections

1. Excessive 1) Air cleaner element severely fouled Replace or clean
smoke 2) Air inlet port restricted Check and repair
3) Air leak from joints on exhaust manifold Check and repair
4) Turbocharger has seized up Disassemble and
and fails to turn ove repair or replace
5) Turbine or compressor wheel Disassemble and
touching housing or broken repair or replace
6) Exhaust line deformed or restricted Check and repair
2. Excessive 1) Oil leaks into turbine and compressor Disassemble and repair
white moke or replace
2) Seal rings excessively worn or broken Disassemble and repair or
due to excessive wear of bearing replace
3. Low engine 1) Gas leaks from individual Check and repair
output parts of exhaust system
2) Air cleaner element clogged Replace or clean
3) Turbocharger fouled or broken Disassemble and
repair or replace
4) Air leaks from delivery port on compressor Check and repair
4. Unusual sound 1) Rotor rubbing Disassemble and repair or replace
or vibration 2) Imbalanced rotation of rotor Disassemble and repair or replace
3) Seizure Disassemble and repair or replace
4) Looseness on individual joints Check and repair
- 67 -
Section 4. Fuel Injection Pump
1. DV15(RQ)
1) Main data and specifications. ( ) : BOSCH Part No.
Part No. : 65.11102-7360(0 401 848 829)
Pump Body : PE8P110A320LS3865(0 411 818 728)
Governor : RQ 250/1150PA1250(0 421 801 796)
Fuel Feed Pump : FP/KG24P215(0 440 080 101)
Timer : CAM ASS’Y
Plunger : ø11mm(2 418 455 071)
Delivery valve : ø8mm, R/V=80mm3(2 418 552 075)
Overflow Valve : (1 417 413 047)
Pre-stroke : 4.0L0.05mm at 10.50L1.50mm
Rotating Direction : C.C.W. at driving gear side
Injection Order : 8-7-2-6-3-5-4-1
Injection Timing : BTDC 10°L1°
*1 bar=1.0332 kg/cm2
2) Calibration data *1 mmHg=1.33mbar
Adjusting Rack position Pump speed Injection volume Variation LDA Pressure Ref.
point (mm) (rpm) (mm3/1,000st) rate (mm3/1000st) (m bar) point
V1 11.8L0.05 1,150 126 L1 Max. Output Point
V2 11.8L0.1 650 127 L3 Max. Torque Point
VS 500
LQ 8.1L0.3 250 25 L3 Low speed Idle Point
A3 0.5L0.5 1,350 High speed Idle Point
*Low idle speed should be adjusted at engine condition
Contents Specifications Engine application
Nozzle holder assembly 1 688 901 101 65.10101-7074
4 B 0.34 ; DLLA136S1034
Nozzle -
(0 433 271 487)
Nozzle holder - 0 430 233 028 ; KDAL80S56
Adjusting Opening pressure 208.5 L 1.5 bar 200 + 8 bar

conditions
2.0 - 6.0 B 600mm Inner Dia -Outer Dia B Length
Injection pipe
(1 680 750 008) 2.0 - 6.0 B 650mm(65.10302-6042/3)
Fuel inlet Pressure 1.5 L 0.1 bar
Fuel inlet temperature 40L2C
Oil spec. ISO 4113/SAE J 967d
Overflow Valve 1 417 413 047
- 68 -
3) Performance curve of governor
14
12 V2 V1
10
Rack Position(mm)
LQ
8
A3
0
250 650 1150 1350
Pump Speed(rpm)
EPM4001I
- 69 -
2. DV15T(RQ)
1) Main data and specifications ( ) BOSCH Part No.
Part No. : 65.11102-7358(0 401 648 974)
Pump Body : PE8P120A320LS7915(0 412 628 929)
PE8P120A320LS7875(0 412 628 881)
Governor : RQ 300/1150PA1374(0 421 801 833)
RQ 250/1150PA1122(0 421 801 704)
Timer : CAM ASS’Y
Plunger : ø12mm(2 418 455 501)
*1 bar=1.0332 kg/cm2
Adjusting Rack position Pump speed Injection volume Variation Basic Ref.
point (mm) (rpm) (mm3/1,000st) rate (%) point point
V1 14.35L0.05 1,150 220.5 L1 1500 Max. Output Point

V2 14.35L0.05 650 238.0 L3 1500
VS 9.0L0.2 500 137.0 L1 0
LQ 5.8L0.2 300 18.0 L3 0 Low speed Idle Point
A3 0.5L0.5 1,350 0 High speed Idle Point
3) LDA Adjust Data
Adjusting Rack position Pump speed Injection volume Variation Basic Ref.
point (mm) (rpm) (mm3/1,000st) rate (%) point point
P1 14.35L0.05 500 1500

P2 9.0L0.2 500 0
P3 10.0L0.05 500 250
P 4 12.3L0.2 500 650

Nozzle holder assembly 1 688 901 105 65.10101-7068(0 432 231 669)
5 B ø0.32 ; DLLA136S1289
Nozzle -
(0 433 271 627)
Adjusting
Opening pressure 208.5 L 1.5 bar 200 + 8 bar
conditions
Fuel inlet pressuer
(1 680 750 089) 2.0 - 6.0 B 650mm(65.10302-6042/3)
Fuel inlet delivery Pipe 1.5 L 0.1 bar
Fuel temperature 40L2C
- 70 -
V2 V1
14
12
10
Rack Position(mm)
VS
LQ
6
A3
0
300 500 650 1150 1350
Pump Speed(rpm)
16.0
P1
14.0
Rack Position(mm)
13.0
12.0 P4
11.0
10.0 P3
P2
9.0
8.0
0 250 650 1500
Pump Speed(rpm)
EPM4002I
- 71 -
3. DV15T(RQV)
1) Main data and specifications ( ) : BOSCH Part No.
Part No. : 65.11102-7290(0 401 648 702)
Pump Body : PE8P120A320LS7915(0 412 628 929)
Governor : RQV 250/1150PA1346(0 421 814 193)
Timer : CAM ASS’Y
Plunger : ø12mm(2 418 455 501)
*1 bar=1.0332 kg/cm2
2) Calibration data
*1 mmHg=1.33mbar

V2 13.8L0.05 650 244.0 L3 1500
VS 8.1L0.2 500 123.0 L1 0

3) LDA Adjust Data
P1 13.8L0.05 500 1500

P2 8.1L0.2 500 0
P3 12.1L0.05 500 735
P4 10.0L0.2 500 350

5 B 0.32 ; DLLA136S1289
Nozzle -
(0 433 271 627)
Adjusting
conditions
Injection pipe 3.0 - 8.0 B 600mm Inner Dia -Outer Dia B Length
(1 680 750 089) 2.0 - 6.0 B 650mm(65.10302-6042/3)
Fuel inlet delivery Pipe 1.5 L 0.1 bar
Oil spec. ISO 4113/SAE J 967
- 72 -
14 V2 V1
12
10
Rack Position(mm)
VS
6
LQ
A3
0
250 500 650 1150 1400
Pump Speed(rpm)
16.0
14.0 P1
Rack Position(mm)
13.0
12.0 P4
11.0
10.0 P3
P2
9.0
8.0
0 350 735 1500
Pump Speed(rpm)
EPM4003I
- 73 -
4. DV15T(RQV)
Part No. : 65.11102-7364(0 402 648 796)
Pump Body : PE8P120A320LS7875(0 412 628 881)
Governor : RQV 250/1150PA1240(0 421 814 160)
Timer : CAM ASS’Y
Plunger : ø12mm(2 418 455 501)
*1 bar=1.0332 kg/cm2
2) Calibration data
*1 mmHg=1.33mbar
Adjusting Rack position Pump speed Injection volume Variation LDA pressure Ref.

V2 12.7L0.05 650 218.0 L3 1500
VS 8.4L0.2 500 135.0 L1 0

3) LDA Adjust Data
P1 12.7L0.05 500 1500

P2 8.4L0.2 500 0
P3 11.7L0.05 500 725
P4 9.5L0.2 500 315
<None> Contents Specifications Engine application

5 B ø0.32 ; DLLA136S1289
Nozzle -
(0 433 271 627)
Nozzle holder - KDAL80S53(0 430 233 025)
Adjusting
conditions
3.0 - 8.0 B 600mm 2.0 - 6.0 B 650mm(65.10302-604213)
Injection pipe
(1 680 750 089) (65.10302-6042/3)
Fuel inlet pressure 1.5 L 0.1 bar
- 74 -
14
V2 V1
12
Rack Position(mm)
10
VS
6
LQ
A3
0
250 500 650 1150 1350
Pump Speed(rpm)
15.0
14.0
P1
Rack Position(mm)
13.0
12.0
P4
11.0
10.0
P3
9.0
P2
8.0
0 350 735 1500
Pump Speed(rpm)
EPM4006I
- 75 -
5. DV15T(RQV)
Part No. : 65.11102-7366(0 401 848 830)
Pump Body : PE8P110A320LS3865(0 411 818 728)
Governor : RQV 250/1000PA1286(0 421 814 175)
Timer : CAM ASS’Y
Plunger : ø11mm(2 418 455 071)
*1 bar=1.0332 kg/cm2
V1 13.0L0.05 1,000 142.0 L1 Max. Output Point
V2 13.0L0.10 650 145.0 L3
VS
LQ 8.2L0.3 250 25.0 L3 Low speed Idle Point

3) LDA Adjust Data

5 B ø0.32 ; DLLA136S1289
Nozzle -
(0 433 271 627)
Adjusting Nozzle holder - KDAL80S53(0 430 233 025)
conditions Opening pressure 208.5 L 1.5 bar 200 + 8 bar
2.0 - 6.0 B 600mm 2.0 - 6.0 B 650mm
Injection pipe
(1 680 750 008) (65.10302-6042/3)
- 76 -
14
V2 V1
12
10
Rack Position(mm)
LQ
8
A3
0
250 650 1000 1300
Pump Speed(rpm)
EPM4007I
- 77 -
6. DV15TI(RQ)
Part No. : 65.11102-7368(0 401 848 832)
Pump Body : PE8P120A320LS3868(0 411 828 730)
Governor : RQ 300/1050PA1345(0 421 801 823)
Timer : CAM ASS’Y
Plunger : ø12mm(2 418 455 501)
*1 bar=1.0332 kg/cm2
2) Calibration data
*1 mmHg=1.33mbar

V2 11.3L0.10 650 204.0 L3 1000
VS 8.3L0.20 500 94.5 L1.0 0

3) LDA Adjust Data
P1 11.3L0.05 500 1000

P2 8.30L0.20 500 0
P3 9.05L0.05 500 280
P4 10.55L0.15 500 580

4 B ø0.39 ; DLLA131S1035
Nozzle -
(0 433 271 486)
Adjusting Nozzle holder - KDAL80S53(0 430 233 025)
conditions Opening pressure 208.5 L 1.5 bar 200 + 8 bar
Injection pipe
(1 680 750 089) 2.0 - 6.0 B 650mm(65.10302-6042/3)
- 78 -
12
V2 V1
10
VS
Rack Position(mm)
LQ
6
A3
0
300 500 650 1050 1300
Pump Speed(rpm)
11.5 P1
11.0
P4
10.5
Rack Position(mm)
10.0
9.5
P3
9.0
8.5 P2
8.0
0 280 580 1000
Pump Speed(rpm)
EPM4004I
- 79 -
7. DV15TIS(RQ)
Part No. : 65.11101-7662(0 402 648 708)
Pump Body : PE8P120A320LS7927(0 411 628 934)
Governor : RQ 300/1050PA1389(0 421 801 836)
Timer : CAM ASS’Y
Plunger : ø12mm(2 418 455 155)
Rotating Direction : C.W. at driving gear side
Injection Timing : BTDC 5.5°L0.5°
*1 bar=1.0332 kg/cm2
V1 13.7L0.10 1,050 249 L1 1800
V2 13.7L0.10 600 263.0 L4 1800
VS 8.50L0.20 500 128.0 L1 0
LQ 6.0L0.20 300 18.0 L3 0
A3 0.5L0.5 1,300 0

3) LDA Adjust Data
P0 12.65L0 500 800
P1 13.7L1.35 500 1800
P2 8.5L0.2 500 0
P3 9.6L0.05 500 300
P4 11.7L0.2 500 600
P5 13.0L0.05 500 1200
P6 13.6L0.1 500 1400

5 B 0.32 ; P-TYPE
Nozzle -
(0 433 171 569)
Nozzle holder - 250 bar(0 430 133 944)
Adjusting
conditions
3.0 - 8.0 B 600mm 1.8 - 6.0 B 650mm
Injection pipe
(1 680 750 089) (65.10301-7011/7012)
- 80 -
14 V2 V1
12
10
VS
Rack Position(mm)
6
LQ
A3
0
300 500 600 1050 1300
Pump Speed(rpm)
15.0
14.0 P1
P6
13.0
Rack Position(mm)
P5
P0
12.0
P4
11.0
10.0
P3
9.0
P2
8.0
0 300 600 800 1200 1400 1900
Pump Speed(rpm)
EPM4008I
- 81 -
7. DV15TIS(RQ)
Part No. : 65.11101(0 401 648 707)
Pump Body : PE8P120A320LS7915(0 412 628 929)
Governor : RQ 300/1150PA1371(0 421 801 829)
Timer : CAM ASS’Y
Plunger : ø12mm(2 418 455 501)
*1 bar=1.0332 kg/cm2
V1 14.35L0.05 1,150 220.5 L1.0 1500

V2 14.35L0.10 650 240.0 L3.0 1500
VS 8.15L0.20 500 109.0 L1.0 0
LQ 5.80L0.20 300 18.0 L3.0 0
A3 0.5L0.50 1,400 - - 0

3) LDA Adjust Data
P0 12.60L0.10 500 600
P1 14.35L0.05 500 1500
P2 8.15L0.20 500 0
P3 9.10L0.05 500 250
P4 11.80L0.20 500 500
P5 12.90L0.05 500 725
P6 13.90L0.20 500 900

5 B 0.32 ; P-TYPE
Nozzle -
(0 433 271 627)
Nozzle holder - 200+8 bar(0 430 233 025)
Adjusting
Opening pressure 208.5 L 1.5 bar 208.5 L 1.5 bar
conditions
3.0 - 8.0 B 600mm 2.0 - 6.0 B 650mm
Injection pipe
(1 680 750 089) (65.10301-6042/3)
- 82 -
V2 V1
14
12
10
Rack Position(mm)
VS
8
6 LQ
A3
0
300 500 650 1150 1400
Pump Speed(rpm)
15.0
P1
14.0
P6
13.0
Rack Position(mm)
P5
12.0 P4 P0
11.0
10.0
9.0 P3
P2
8.0
0 250 600 900 1500
500 725
Pump Speed(rpm)
EPM4009I
- 83 -
SUPPLEMENT
•Tightening torque ratings
Group Descriptions Thread Strength Tightening torque kg.m
Main bearingcap block M18B2 12.9 Initial 30+ angle torque 90°
Bearing cap(side) block M12B1.5 10.9 8
Oil spray nozzle block M14B1.5 7
01 Flywheel hsg. cover flywheel hsg. M8 12.9 4
Flywheel hsg. cover block M10 12.9 7.5
M12B1.5 10.9 10
Flywheel hsg. cover hsg.and block M8 10.9 2.5
Radiator bracket block M14 10.9 17
Counter weight crank shaft M16B1.5 10.9 Initial 10+ angle torque 90°
Hub hub M16B1.5 10.9 21
Vibration damper crank shaft M10 10.9 6

02
Flywheel crank shaft M16B1.5 12.9 26
Fan damper crank shaft M8 8.8 2.2
Conn. rod cap conn. rod M16B1.5 10.9 Initial 10+ angle torque 90°
Cylinder head block M15B2 12.9 8/15+angle torque 90°/90°
03 Cylinder head cover cylinder head M8 8.8 2.2
Injection nozzle holder block M28 CK60 7L0.5
Timer camshaft M10 10.9 9
Timer camshaft drive gear M10 9

04
Rocker arm cylinder haed M10 10.9 6.5
Lock nut adjusting screw M12B1 8.8 5
Oil pump cover oil pump M8 8.8 2.2
Oil pump block M8 8.8 2.2
Oil cooler oil filter head M8 8.8 2.2

05
Oil filter oil filter head M12 10.9 5
Oil pan block M8 8.8 2.2
Oil pan plug oil pan M26B1.5 8
Exhaust manifold cylinder head M10 4

08
Intake manifold cylinder head M8 8.8 2.2
block M10 10.9 6.5
Injection pump M8 10.9 2.5

11
Injection pump block M10 8.8 4.5
Fuel filter M12B1.5 8.8 8
- 87 -
Group Descriptions Thread Strength Tightening torque kg.m
Starter motor flywheel hsg. M12B1.5 8 8

26
Alternator bracket block M14 8.8 12
Oil pressure monitor block M18B1.5 8

27
Thermocouple block M14B1.5 2
P.T.O. gear P.T.O. shaft M33B1.5 30
Flange P.T.O. shaft M24B1.5 30
Hub oil pump M12B1.5 5

38
Oil pump housing M10 10.9 5
Bearing flange bearing housing M8 8.8 2.5
Oil atomizer block M18B1.5 8
Air comp. drive gear air comp. shaft M18B1.5 10.9 36
Conn. rod cap conn. rod M8 10.9 3.5
Cylinder liner housing M8 10.9 4

54
Cylinder liner cylinder liner M8 10.9 3
Rotary pump air comp. flange M10 10.9 6.1
Mounting flange ball bearing hub M8 12.9 5
Plug screw M12B1.5 5
All Plug screw M22B1.5 10
Plug screw AM10B1 5
Plug screw AM14B1.5 8
- 88 -
•Maintenance specifications
Group DV15, DV15T, DV15TI, DV15TIS Remarks
Bore for liners press fit(upper) 145.800~145.840 ø145.8 H7

standard 145.800~145.840 ø145.8 H7
oversize 0.5 146.300~146.340 ø146.3 H7
oversize 1.0 146.800~146.840 ø146.8 H7
Bore for liners press fit(lower)
Block
standard 144.500~144.540 ø144.5 H7

oversize 0.5 145.000~145.040 ø145.0 H7
oversize 1.0 145.500~145.54 ø145.5 H7
Bore for liner collar press fit
standard 153.900~154.150 ø153.9 H11

oversize 0.5/1.0 154.400~154.650 ø154.4 H11
Depth of liner collar seat 9.97~9.99
Outer dia. of liner(upper)
standard 145.761~145.786 ø145.8 g6

oversize 0.5 146.261~146.286 ø146.3 g6
oversize 1.0 146.761~146.786 ø146.8 g6
Outer dia. of liner(lower)
standard 144.432~144.457 ø144.5 f6

oversize 0.5 144.932~144.957 ø145.0 f6
oversize 1.0 145.432~145.457 ø145.5 f6
Cylinder lIner
Outer dia. of liner collar
standard 153.692~153.757 ø153.8 f8

oversize 0.5/1.0 154.192~154.257 ø154.3 f8
Liner collar height 10.03~10.05
Clearance for liner collar 0.143~0.458
Clearance for liner fitter(upper) 0.014~0.079
Clearance for liner fitter (lower) 0.043~0.108
Liner inner dia. 127.990~128.010 ø128L0.01

Roundness for liner(upper) 0.01 168mm from top
Roundness for liner(lower) 0.015 85mm from bottom
Liner protrusion 0.040~0.080 Measuring at 4 points
Piston outer diameter 127.739~127.757 71.5mm measuring from bottom(long part)

Piston
Inner dia. of piston pin hole 46.003~46.009
Clearance of piston ring 0~4
- 89 -
Piston protrusion over block upper face 0~0.4
Max. permissible weight per eng. unit 50g

Piston
Width of 1st ring groove 3.5
Width of 2nd ring groove 3.040~3.060
Width of oil ring groove 4.020~4.040
Height of 1st ring(thickness) 3.5
Height of 2nd ring(thickness) 2.978~2,990
Height of oil ring(thickness) 3.97~3.99

Piston ring
1st ring end clearance -
2nd ring axial clearance 0.050~0.082
Oil ring axial clearance 0.030~0.062
1st ring end clearance 0.35~0.55
2nd ring end clearance 0.40~0.60
Oil ring end clearance 0.35~0.55 DV15TIS:0.40~0.70

Piston
Outer dia. of piston 45.994~46.000

ring
Piston pin radial clearance 0.055~0.071
Conn. rod width at small end 38.070~39.000
Conn. rod width at big end 35.341~35.380 ø35.5 C8
Conn. rod cap 32.800~33.100 ø32.8+0.3
Conn. rod axial clearance 0.240~0.392
Conn. rod small end axial clearance 0.064~0.126
Conn. rod bushing clearance 0.055~0.071

Connecting rod
Conn. rod inner dia. at small end 50.600~50.630 ø50.6 H7
Conn. rod bushing inner dia. 40.055~46.065
Clearance 0.04~0.10
Conn. rod inner dia at big end 94.4~94.6 ø94.5L0.1
Conn. rod. bearing spread(MIBA) 0.5~1.4
Max. permissible weight of conn. rod per engine unit 50g
Straightness for outer dia. at big end 0.035 From conn. rod side face
Roundness for outer dia. at big end 0.01
Flatness for inner dia. at big end 0.005
Parallelism between big end & small end bores 0.02
- 90 -
Piston protrusion over block upper face 111.000~111.022 ø111 H6
Main bearing bore in case 0.05
Max. center deviation(run-out)
Main bearing journal dia. 103.98~104.00
standard N 103.88~103.90
standard N1(0.10) 103.73~103.75
undersize 0.25 103.48~103.50
undersize 0.50 103.23~103.25
undersize 0.75 102.98~103.00
undersize 1.00
Thrust bearing journal length
standard N 38.000~38.062 ø38 H9
oversize 1.2 38.500~38.562
oversize 3.4 39.000~39.062
Conn. rod bearing journal dia.
standard N 89.98~90.00
Crank shaft
standard N1(0.1mm) 89.88~89.00
undersize 0.25mm 89.73~89.75
undersize 0.50mm 89.48~89.50
undersize 0.75mm 89.23~89.25
undersize 1.00mm 88.98~89.00
Roundness of main bearing journal 0.01
Flatness of main bearing journal 0.005
Max. permissible run-out of center 0.06 No. 1, 5 supported
Journal nominal dia. for front face 99.985~100.020 ø100 J7
Wear ring inside diameter 99.942~99.907 ø100 S7
Clearance overlap 0.050~0.020
Thrust bearing shell width
standard size-standard width 37.74~37.81
oversize 0.25~0.50mm(AA) 38.24~38.31
oversize 0.75~1.00mm(AA) 38.74~38.81
Crank shaft axial end play 0.190~0.322
Main bearing shell wall thickness
Standard(AA) 3.454~3.467
Standard I 0.10mm (AA) 3.504~3.517
- 91 -
Oversize 0.25mm(AA) 3.579~3.592
Oversize 0.50mm(AA) 3.704~3.717

Crank shaft
Oversize 0.75mm(AA) 3.829~3.842
Oversize 1.00mm(AA) 3.954~3.967
Main bearing oil clearance(AA) 0.066~0.132
Main bearing spread(AA) 0.278~1.200
Thrust bearing spread(AA) 0.078~0.500
Outer dia. of ring gear fitted 432.490~432.645
Inner dia. of ring gear 432.000~432.155

Flywheel
Overlap 0.335~0.645
Temperature for installing in C 200~230
Max. permissible lateral run-out 0.5
Race take-up 114.980~115.015
Thickness of head gasket(after bolt tightened) 1.163~1.297
Height of cylinder head(standard) 113.9~114.0
Height of cylinder head(undersize) 112.9~113.0
Roughness of cyl. head fitting face 8~16µ
Valve depression -0.65~-0.95
Intake valve stem dia. 11.969~11.980
Exhaust valve stem dia. 11.945~11.955
Valve guide bore 12.000~12.018 ø12 H7

Cylinder Head & Valve
Valve axial end play(IN) 0.020~0.049
Valve axial end play(EX) 0.045~0.074
Valve seat angle(IN) 30°
Valve seat angle(EX) 45°
Valve head dia.(IN) 57.85~58.15
Valve head dia.(EX) 50.9~51.1
"H" width of valve head(IN) 2.6~3.0 2.8L0.2
"H" width of valve head(EX) 1.9~2.3 2.1L0.2
Head(N) dia. of valve seat fitted(IN)
standard 61.00~61.03 ø61 H7
tandard(l) 61.20~61.23
Head(N) dia. of valve seat fitted(EX)
standard 53.00~53.03 ø53 H7
standard(l) 53.20~53.23
- 92 -
Head(N) depth of valve seat fitted
standard 12.5~12.6
standard(l) 12.7~12.8
Outer dia. of valve seat(IN)N 61.10~61.11
Outer dia. of valve seat(IN)Nl 61.30~61.31
Outer dia. of valve seat(EX)N 53.10~53.11
Outer dia. of valve seat(EX)Nl 53.30~53.31 ø18 H7

Block
Valve guide inner dia. N 18.000~18.018 ø18.25 H7
Valve guide inner dia. Nl 18.250~18.271 ø18 S7
Overlap N 18.028~18.046 ø18.25 S7
Overlap Nl 18.285~18.306
0.010~0.046
0.014~0.056
Valve seat clearance 0.04 Valve guide
Valve stroke 14.1
Valve guide protrusion 17.1~17.5 Valve Spring Set
Free length of inner spring 72.43

Valve Spring
Spring load of inner spring 15~17kg at 46.3mm
Spring load of inner spring 27~32kg at 32.3mm
Free length of outer spring 68.17
Spring load of outer spring 37~41kg at 46.8mm
Spring load of outer spring 66.5~76.5kg at 32.8mm
Rocker arm bush dia. 25.005~25.035 When assembled
Rocker arm bearing journal dia. 24.967~24.990
Bearing clearance 0.015~0.068
Push rod end play 0.3
Inner dia. of valve tappet fitted N 20.000~20.021 ø20 H7
Inner dia. of valve tappet fitted Nl 20.250~20.271 ø20.25 H7

Timing
Push rod outer dia. N 19.944~19.965
Push rod outer dia. Nl 20.194~20.215
Tappet clearance 0.035~0.077
Block inner dia. for bush fitted 70.077~70.061
Camshaft diameter 69.910~69.940 ø70 e7
Oil clearance for camshaft bearing 0.060~0.120
Camshaft axial end play 0.20~0.90
- 93 -
Back lash(crank gear-cam gear) 0.118~0.242

Timing
Back lash(drive gear-injection pump gear) 0.102~0.338
Intake valve clearance 0.25 at the cold engine
Exhaust valve clearance 0.35 at the cold engine
Oil pressure at idle speed 0.9~3.0bar
Oil pressure at rated speed 3.0~6.5bar
Oil temperature in C 100C
Momentary permissible temperature 100

Lubricating system
Opening pressure of oil filter bypass valve 1.8~2.4bar
Opening pressure of ol pump regulating valve 8.5~10bar
Opening pressure of oil spray nozzle 1.6~1.9bar
Closing pressure of oil spray nozzle 1.3~1.6bar
Tip dia. of oil spray nozzle 1.75~1.85
Back lash(crank gear-oil pump gear) 0.10~0.45
Oil pump housing depth/gear width 43~43.039/42.91~42.95 43H8/43e8
Oil pump housing axial end play 0.050~0.128

Cooling system
Water pump shaft dia. 21.930~21.950
Bearing clearance 0.050~0.091
Impeller clearance(impeller body) 1.0~1.5
Thermostat operating temperature 83C
Maker Allied signal
Max. vacuum pressure in manifold 0.05bar

Turbocharger
Min. pressure at rated speed 2.00bar
Min. pressure at idle speed 0.70bar
Min. dia. of oil filter mesh 0.015
Axial end play 0.20
Radial end play 0.65
Good Above 28 bar

Compressed
Pressure
Usable 25~28 bar
Repairing Below 24 bar
Max. difference in pressure 4bar
Opening pressure of 1/P overflow valve 1~1.5bar

Fuel system
Injection pump type BOSCH
Governor type RQ or RQV
Injection nozzle maker BOSCH
- 94 -
Injection nozzle holder maker BOSCH
Injection nozzle tip dia. DV15:0.34B4 holes

Fuel system
DV15T/DV15TIS:0.32B5 holes
DV15TI:0.39B4 holes
Nozzle tip projection DV15:1.1~2.0
on cylinder head DV15T/TI/TIS:0.9~1.8
Cylinder bore B 90.000~90.010
C 90.010~90.020
D 90.020~90.030
Piston outer dia. B 89.910~89.920
C 89.920~89.930
D 89.930~89.940
Piston ring groove 1st, 2nd 2.51~2.53
3rd, 4th 4.02~4.04

Air compressor
Piston pin bore 20.003~20.008
Piston pin dia. 19.994~20.000
Conn. rod bush bore at small end 20.020~20.033
Conn. rod bearing shell width 2.004~2.010 When assembled ø20 f6
Conn. rod bearing journal dia. 31.957~31.975
Main bearing journal dia. 29.959~29.980
Main bearing inner dia. 32.020~30.041 ø30f7
Piston protrusion -0.75~0.2 When assembled
Piston clearance 0.080~0.100
Conn. rod bearing oil clearance 0.027~0.073
Back lash(A/C drive gear-cam gear) 0.097~0.353
- 95 -
•Special tool list
No. Part Name Part No.
1 Test connection for compression 80.99607-0002
2 Pin spanner for injector holder(4-groove) 80.99603-0049
2a Pin spanner for injector holder(3-groove) 80.99603-0038
3 Cylinder liner mandrel 80.99617-0018
4 Cylinder liner extractor 80.99602-0019
4a Support 80.99623-0003
4b Extractor plate(ø128)
5 Dial gauge holder A5.00026-1141
6 Cylinder liner installer 80.99617-0091
6a Hook 83.09144-6094
7 Guide mandrel for flywheel 80.99617-0020
8 Mandrel to drive race onto flywheel 80.99617-0017
9 Mandrel on front crank seal 80.99601-0076
10 Mandrel on front crank shaft race 80.99617-0016
11 Torque angle tester 80.99605-0010
12 Engine turner with intermediate flange(with flange) 80.99626-0004
12a Ratchet for engine turner 80.99267-0001
13 Piston ring compressor 83.09144-6038
14 Piston ring sleeve(ø128) 83.99913-0008
15 Piston ring pliers 83.09144-6090
16 Open end spanner for injection line couplings(17, 19) 80.06013-0500
17 Special spanner for cylinder head bolt 80.99603-0095
18 Valve adjusting spanner 83.09195-0002
19 Valve gauge 0.25/0.35mm 80.09160-7000
20 Valve assembly lever 80.99606-0031
21 Guide sleeve for valve stem seals 80.99616-0004
22 Press in sleeve for valve stem seals 80.99604-0005
23 Mandrel to press in valve guide 80.99617-0013
24 Press rings for valve guide 80.99616-0003
25 V-belt tension inspector 81.66814-6001
26 Extractor for water pump pulley(new type) 80.99601-0037
27 Inertia extractor for fuel injection 80.99602-0011
28 Spanner for injection line couplings 80.99603-0025
32 Holding device for fuel injector holder 80.99606-0008
- 96 -
No. Part Name Part No.
33 Socket spanner for fuel injector holder nuts 80.99603-0024
34 Holder for air compressor crank shaft 80.99606-0007
35 Special spanner for air compressor drive gear nut 80.99603-0007
36 Mandrel to press in air comp. crank shaft bearings 80.99617-0015
37 Piston ring compressor for air comp. 80.99625-0001
37a Socket spanner for air comp. (double air comp.)
The following tools are excepted from the text of this repair guide
38 Overflow tube for injection pump adjustment 80.99629-0002
39 Spanner for oil pressure gauge 80.99603-0044
40 M15 x 2 tap set for cylinder head bolt 80.40001-0001
41 Threading die for above 80.43001-0001
- 97 -
•Special tool list
- 98 -
- 99 -

DV15 (T) (Ti) (Tis)

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DV15 (T) (Ti) (Tis)

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FOREWORD

These economical and high-performance Diesel Engines, characterized by 8 cylinders, 4 strokes,

¥ Exterior View .................................................................................................................1

Section 1. Major maintenance ........................................................................................9

Section 2. Maintenance .................................................................................................28

Section 3. Turbocharger ...............................................................................................61

Section 4. Fuel injection pump.....................................................................................68

1. Cylinder block 6. Push rod 11. Breather pipe

1. Flywheel housing 10. Combustion chamber 19. Water pump

1. Fuel tank 7. Injector

Thermostat Coolant pipe

Water pump Coolant pipe

1. Crankshaft gear 5. Air compressor drive gear

Series DV15 DV15T DV15TI DV15TIS

Type V-type 90° four stroke diesel engine

Combustion chamber 'M' combustion system Toroidal combustion system OMEGA

Combustion Direct injection

Cylinder bore x stroke 128x142-8 128x142-10

Compression ratio 16.9:1 16.5:1 17.4:1

Injection timing BTDC 10° BTDC 7° BTDC 11°L1° BTDC 5.5°L0.5°

Firing order 1-5-7-2-6-3-4-8

Injection pump type Flanged serial type in-line injection pump

Timer Automatic, centrifugal type

Injection nozzle Multiholes

Feed pump Plunger type(FR/K)

Valve open/closing time

Intake opening 12° 15°

Intake closing 48° 35°

Thermostat Wax-pallet type

Starter voltage-output 24V - 6.6kw

Conditions Standard value

1 000 1200 1400 1600 1800 2000 2200 2400

Conditions Standard value

Conditions Standard value

280 Fuel consumption(g/ps.h)

2.1. Cooling water

Antifreeze solution(%) Freezing point(°C)

I Type : DCA65L (Inhibitor)

I Mix ratio : 1.5M of inhibitor to 50M of coolant

2.2. Fan belt

I Oil change intervals

Heavy vehicles 8,000 km operation

* Engine oil should be changed at least twice a year.

I Suggested engine oils

DV15, DV15T CD grade

DV15TIS 15W40 CG grade

2.4. Oil filter

2.5. Fuel filter

1) Replace any deformed or broken element or cracked air cleaner.

2.7. Valve clearance

1) At end of first 500km(10 hours) operation,

2.8. Compression pressure

Standard 28 kg/cm2 or above

2.9. Injection nozzle

1) Install a nozzle to a nozzle tester.

DV15, DV15T, DV15TI DV15TIS

3) Check nozzle spray patterns and replace if

2.12. Bleeding the fuel system

2.13. Fuel feed pump

2.14. Turbocharger (For DV15T/TI/TIS engine only)

To ease engine starting, the Diesel

AH1 Temp Ramp

2.17. Check point after starting