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Doosan DM02VB Engine

The Doosan Hyundai DM02VB is an in-line, 4-cylinder, 4-cycle industrial diesel engine designed to succeed or act as a Generation 2 replacement for the widely used Bobcat D24 engine platform. It is engineered primarily for compact industrial machinery, including skid steer loaders, compact track loaders, mini excavators, and telehandlers. Utilizing a robust cast-iron cylinder block and an integrated overhead valve assembly, this turbocharged and air-to-air aftercooled engine balances heavy-duty performance with a compact footprint. The DM02VB complies with stringent Tier 4 Final and Stage V emission standards by incorporating an Electronic Control Unit (ECU), high-pressure common-rail fuel injection, and an Exhaust Gas Recirculation (EGR) valve working alongside subsequent aftertreatment systems (DOC and DPF).

The valve system is of the Overhead Valve (OHV) design, driven by a camshaft layout. It features a total of 16 valves, distributed as 2 intake valves and 2 exhaust valves per cylinder. Valve clearance management is facilitated through an integrated Hydraulic Valve Lash Adjuster (HLA) mechanism, making the valve train entirely maintenance-free under normal operating conditions. Bore diameter: 90 mm. Stroke length: 94 mm. Total engine displacement: 2.4 liters. Compression ratio: 17.0:1.

Fuel delivery is governed by a high-pressure Bosch Common-Rail System. Fuel is drawn from the machine supply tank by a mechanical transfer feed pump before entering the high-pressure Bosch injection pump. Pressurized fuel is delivered to the combustion chambers through electronically modulated multi-hole type injection nozzles (injectors). The entire injection sequence, timing advance, and fuel mass delivery are monitored and continuously updated by the engine ECU to ensure strict frequency regulation and a steady-state performance profile. The primary filtration stage utilizes a full-flow, heavy-duty cartridge-type fuel filter often paired with an auxiliary inline fuel heater for cold-weather operations.

Lubrication operates via a fully forced pressure feed system managed by a reliable internal circuit. Pressure is generated through a gear-type oil pump driven directly by the crankshaft. The oil filtering loop includes a full-flow, replaceable cartridge-type filter canister alongside an integrated oil cooler assembly. Engine thermal regulation relies on a closed-loop freshwater forced circulation system. Coolant circulation is powered by a centrifugal-type water pump driven by an auxiliary belt connected to the crankshaft pulley. Temperature control is strictly maintained via an inline thermostat. The cooling system is pressurized, utilizing a pressure cap with a designated opening configuration of 0.9 bar, supporting a maximum standby/prime water operating threshold of 110C.

General Technical Data

Engine Specifications

Engine Model ............... Doosan DM02VB
Engine Type ............... Vertical 4-cycle inline 4-cylinder common rail liquid-cooled diesel
Number of Cylinders ............... 4
Cylinder Arrangement ............... In-line industrial design
Engine Bore, in (mm) ............... 3.543 (90.0)
Engine Stroke, in (mm) ............... 3.701 (94.0)
Displacement, cu.in (L) ............... 145.96 (2.392)
Rated Engine Power, hp (kW) ............... 74.3 (55.4) at 2600 rpm
Lower Output Rating, hp (kW) ............... 55.0 (41.0) at 2600 rpm
Industrial Output Rating, hp (kW) ............... 49.0 (36.6) at 2600 rpm
Rated Engine Speed, rpm ............... 2600
Governor Engine Speed, rpm ............... 2800
Peak Torque at 1600 rpm, lb-ft (Nm) ............... 236.0 (320.0)
Peak Torque at 1800 rpm, lb-ft (Nm) ............... 185.8 (252.0)
Low Idle Speed, rpm ............... 800-900
High Idle Speed, rpm ............... 2750-2850
Aspiration Type ............... Turbocharged and air-to-air aftercooled
Combustion System ............... Common rail direct injection
Compression Ratio ............... 17.0:1
Firing Order ............... 1-3-4-2
Cylinder Block Material ............... High-strength heavy duty cast iron block
Cylinder Head Material ............... Monolithic single-piece cast iron alloy head
Valves Per Cylinder ............... 2 intake and 2 exhaust valves per single cylinder
Total Valves ............... 16 overhead valves configuration
Camshaft Drive ............... Rigid gear-driven system assembly
Direction of Crankshaft Rotation ............... Counterclockwise flywheel face
Crankcase Ventilation System ............... Closed-loop breather circuit ventilation
Lubrication System ............... Forced full-pressure lubrication circuit
Oil Pump Type ............... High-efficiency gear-driven internal pump mechanism
Oil Filter Type ............... Full-flow spin-on cartridge filtration type
Cooling System ............... Pressurized liquid-cooled fresh water forced circulation
Water Pump Type ............... Centrifugal high-flow pulley belt-driven assembly
Cooling Fan Rotation ............... Suction or blower application dependent style
Air Intake Filtration ............... Dry heavy duty dual-element paper cleaner
Engine Controller Mechanism ............... Full electronic control unit module system
Exhaust Emissions Control ............... DOC and DPF
Emissions Certification ............... EPA Tier 4 Final and EU Stage V compliant
Starting System ............... High-torque electric starter motor
Electrical System, V ............... 12
Alternator Charging, A ............... 110 or 140

Fuel System

Fuel Injection Pump Manufacturer ............... Bosch high-pressure system
Fuel Injection Pump Model ............... CP4.1 common rail single plunger
Fuel Injector Assemblies Brand ............... Delphi high-precision common rail series
Fuel Injector Actuation Concept ............... Solenoid controlled electronic command module
Maximum Common Rail Pressure, psi (bar) ............... 29007 (2000)
Normal Operating Rail Pressure, psi (bar) ............... 4351-26106 (300-1800)
Fuel Feed Pump Type ............... Mechanical gear-driven low-pressure lift pump
Fuel Transfer Supply Pump Pressure, psi (bar) ............... 58.0-87.0 (4.0-6.0)
Fuel Filter Water Separator Type ............... Spin-on element water sensor component
Maximum Fuel Supply Temp at Pump Inlet, F (C) ............... 140 (60)
Minimum Required Fuel Tank Return Line Diameter, in (mm) ............... 0.315 (8.0)
Fuel Injection Timing Architecture ............... Electronic map regulated via ECU parameters
Fuel System Diagnostic Fault Strategy ............... Automated torque reduction and speed deration
Recommended Fuel Grade ............... Ultra-low sulfur diesel standard containing less than 15 ppm sulfur
Fuel Injection Line Wall Thickness, in (mm) ............... 0.078 (2.0)

Dimensions and Weight

Overall Length Without Aftertreatment, in (mm) ............... 29.2 (7400)
Overall Length With Aftertreatment System, in (mm) ............... 32.6 (830)
Overall Width Standard Profile, in (mm) ............... 22.6 (575)
Overall Height Without Aftertreatment, in (mm) ............... 27.8 (705)
Overall Height Including Aftertreatment Package, in (mm) ............... 28.4 (720)
Overall Length Including Complete Powerpack Assembly, in (mm) ............... 43.3 (1100)
Overall Width Including Complete Powerpack Assembly, in (mm) ............... 24.8 (630)
Overall Height Including Complete Powerpack Assembly, in (mm) ............... 37.7 (960)
Dry Weight Bare Block configuration, lbs (kg) ............... 515 (233)
Total Wet Weight Full Fluid Configuration, lbs (kg) ............... 547 (248)
Complete Powerpack Assembly Shipping Weight, lbs (kg) ............... 750 (340)

Maintenance Data

Service Information

Oil Pressure at Low Idle, psi (bar) ............... 14.5 (1.0)
Oil Pressure at Rated Speed, psi (bar) ............... 43.5-65.2 (3.0-4.5)
Cylinder Compression Pressure, Minimum, psi (bar) ............... 406 (28)
Turbocharger Boost Pressure (Rated Speed), psi (bar) ............... 18.8 (1.3)
Maximum Oil Temperature Limit, F (C) ............... 248 (120)
Cooling Thermostat Full Opening Temperature, F (C) ............... 203 (95)
Cooling Thermostat Initial Opening Start Point, F (C) ............... 180 (82)
Cooling Pressure Cap Rating, psi (bar) ............... 12.7 (0.88)
Drive Belt Deflection Under 22 lbs Force, in (mm) ............... 0.39-0.47 (10.0-12.0)
Intake Valve Clearance, Cold, in (mm) ............... 0.0098 (0.25)
Exhaust Valve Clearance, Cold, in (mm) ............... 0.0137 (0.35)

Engine Oil and Coolant

Engine Oil Type .................. SAE 5W-30, SAE 10W-30, or 15W-40
API Service Classifications ......................... CJ-4 or CK-4
Engine Oil Capacity, Maximum Level, gal (L) ............... 2.27 (8.6)
Engine Oil Capacity, Minimum Level, gal (L) ............... 1.45 (5.5)
Total Engine Oil Capacity Including Filter, gal (L) ............... 2.43 (9.2)
Coolant Capacity, Water Jackets Only, gal (L) ............... 1.05 (4.0)
Cooling Capacity Including Radiator, gal (L) ............... 2.90 (11.0)

Service Intervals

Change oil and filter ............... Every 500 hours
Inspect air cleaner ............... Every 250 hours
Replace air cleaner ............... Every 1000 hours
Replace fuel filter ............... Every 500 hours
Valve clearance adjustment ............... Every 1500 hours
Fuel system inspection ............... Every 1000 hours
Change coolant ............... Every 2000 hours
Compression test ............... Every 1000 hours
Clean radiator core ............... Every 250 hours
Inspect belt tension ............... Every 250 hours

Service Specifications

Cylinder Bore Inner Diameter, in (mm) ............... 3.5433-3.5441 (90.000-90.022)
Cylinder Bore Maximum Wear Limit, in (mm) ............... 3.5472 (90.100)
Cylinder Bore Out of Roundness, in (mm) ............... 0.0005 (0.015)
Cylinder Block Top Surface Flatness, in (mm) ............... 0.0019 (0.050)
Cylinder Head Bottom Surface Distortion Flatness, in (mm) ............... 0.0019 (0.050)
Crankshaft Axial End Play, in (mm) ............... 0.0039-0.0098 (0.10-0.25)
Main Bearing Bore Inside Diameter, in (mm) ............... 2.9527-2.9535 (75.000-75.020)
Crankshaft Main Journal Diameter, in (mm) ............... 2.7551-2.7559 (69.980-70.000)
Crankpin Journal Diameter, in (mm) ............... 2.1645-2.1653 (54.980-55.000)
Crankshaft Main Bearing Clearance, in (mm) ............... 0.0015-0.0033 (0.040-0.085)
Connecting Rod Bearing Clearance, in (mm) ............... 0.0013-0.0031 (0.035-0.080)
Connecting Rod Small End Bushing I.D, in (mm) ............... 1.1818-1.1824 (30.020-30.035)
Connecting Rod Big End Bore I.D, in (mm) ............... 2.2834-2.2842 (58.000-58.020)
Connecting Rod Side Play, in (mm) ............... 0.0039-0.0098 (0.100-0.250)
Piston Skirt Outer Diameter, in (mm) ............... 3.5401-3.5409 (89.920-89.940)
Piston to Cylinder Wall Clearance, in (mm) ............... 0.0023-0.0039 (0.060-0.102)
Piston Pin Bore Inside Diameter, in (mm) ............... 1.1812-1.1816 (30.003-30.012)
Piston Pin Outside Diameter, in (mm) ............... 1.1807-1.1811 (29.991-30.000)
Piston Pin to Piston Bushing Clearance, in (mm) ............... 0.0001-0.0008 (0.003-0.021)
Top Ring Groove Width, in (mm) ............... 0.0807-0.0815 (2.050-2.070)
Second Ring Groove Width, in (mm) ............... 0.0602-0.0610 (1.530-1.550)
Oil Ring Groove Width, in (mm) ............... 0.1189-0.1197 (3.020-3.040)
Top Ring Side Clearance, in (mm) ............... 0.0023-0.0037 (0.060-0.095)
Second Ring Side Clearance, in (mm) ............... 0.0015-0.0029 (0.040-0.075)
Oil Ring Side Clearance, in (mm) ............... 0.0009-0.0025 (0.025-0.065)
Top Ring End Gap, in (mm) ............... 0.0078-0.0137 (0.200-0.350)
Second Ring End Gap, in (mm) ............... 0.0137-0.0216 (0.350-0.550)
Oil Ring End Gap, in (mm) ............... 0.0098-0.0196 (0.250-0.500)
Intake Valve Stem Outside Diameter, in (mm) ............... 0.2740-0.2748 (6.960-6.980)
Exhaust Valve Stem Outside Diameter, in (mm) ............... 0.2732-0.2740 (6.940-6.960)
Intake Valve Guide Inside Diameter, in (mm) ............... 0.2755-0.2763 (7.000-7.020)
Exhaust Valve Guide Inside Diameter, in (mm) ............... 0.2755-0.2763 (7.000-7.020)
Intake Valve Stem to Guide Clearance, in (mm) ............... 0.0007-0.0023 (0.020-0.060)
Exhaust Valve Stem to Guide Clearance, in (mm) ............... 0.0015-0.0031 (0.040-0.080)
Intake Valve Seat Width, in (mm) ............... 0.0472-0.0590 (1.200-1.500)
Exhaust Valve Seat Width, in (mm) ............... 0.0551-0.0669 (1.400-1.700)
Intake Valve Sink Depth, in (mm) ............... 0.0275-0.0393 (0.700-1.000)
Exhaust Valve Sink Depth, in (mm) ............... 0.0275-0.0393 (0.700-1.000)
Valve Spring Free Length Standard, in (mm) ............... 1.8897 (48.000)
Camshaft Journal Outer Diameter (Front), in (mm) ............... 1.9673-1.9681 (49.970-49.990)
Camshaft Journal Outer Diameter (Middle), in (mm) ............... 1.9476-1.9484 (49.470-49.490)
Camshaft Journal Outer Diameter (Rear), in (mm) ............... 1.9279-1.9287 (48.970-48.990)
Camshaft Bushing Inner Diameter (Front), in (mm) ............... 1.9696-1.9708 (50.030-50.060)
Camshaft Bushing Inner Diameter (Middle), in (mm) ............... 1.9500-1.9511 (49.530-49.560)
Camshaft Bushing Inner Diameter (Rear), in (mm) ............... 1.9303-1.9314 (49.030-49.060)
Camshaft Journal Oil Clearance, in (mm) ............... 0.0015-0.0035 (0.040-0.090)
Intake Cam Lobe Height, in (mm) ............... 1.5551-1.5590 (39.500-39.600)
Exhaust Cam Lobe Height, in (mm) ............... 1.5748-1.5787 (40.000-40.100)
Camshaft Axial End Play, in (mm) ............... 0.0027-0.0078 (0.07-0.20)
Rocker Arm Shaft Outside Diameter, in (mm) ............... 0.7862-0.7870 (19.970-19.990)
Rocker Arm Bushing Inside Diameter, in (mm) ............... 0.7874-0.7885 (20.000-20.030)
Rocker Arm Bushing to Shaft Clearance, in (mm) ............... 0.0003-0.0023 (0.010-0.060)
Crankshaft Gear to Idler Gear Backlash, in (mm) ............... 0.0027-0.0059 (0.070-0.150)
Idler Gear to Camshaft Gear Backlash, in (mm) ............... 0.0027-0.0059 (0.070-0.150)
Idler Gear to Fuel Injection Pump Gear Backlash, in (mm) ............... 0.0027-0.0059 (0.070-0.150)

Tightening Torques

Cylinder Head Bolts (1-Stage), lb-ft (Nm) ............... 33.1 (45.0)
Cylinder Head Bolts (2-Stage), lb-ft (Nm) ............... 66.3 (90.0)
Cylinder Head Bolts (3-Stage), lb-ft (Nm) ............... 88.5 (120.0)
Main Bearing Cap Bolts (1-Stage), lb-ft (Nm) ............... 36.8 (50.0)
Main Bearing Cap Bolts (2-Stage), lb-ft (Nm) ............... 73.7 (100.0)
Connecting Rod Bearing Cap (1-Stage), lb-ft (Nm) ............... 22.1 (30.0)
Connecting Rod Bearing Cap (2-Stage), lb-ft (Nm) ............... 44.2 (60.0)
Flywheel Assembly Mounting Bolts, lb-ft (Nm) ............... 62.6 (85.0)
Flywheel Housing Assembly Fixing Outer Bolts, lb-ft (Nm) ............... 36.8 (50.0)
Crankshaft Pulley Vibration Damper Central Nut, lb-ft (Nm) ............... 191.7 (260.0)
Camshaft Thrust Retaining Plate Locating Bolts, lb-ft (Nm) ............... 18.4 (25.0)
Camshaft Drive Gear Center Mounting Bolt, lb-ft (Nm) ............... 66.3 (90.0)
Idler Gear Shaft Support Center Stub Bolt, lb-ft (Nm) ............... 36.8 (50.0)
Rocker Shaft Assembly Mounting Support Bolts, lb-ft (Nm) ............... 25.8 (35.0)
Rocker Clearance Adjusting Screw Locking Nuts, lb-ft (Nm) ............... 18.4 (25.0)
Valve Mechanism Protective Top Cover Fasteners, lb-ft (Nm) ............... 8.8 (12.0)
High Pressure Fuel Injection Pump Hub Mounting Bolts, lb-ft (Nm) ............... 18.4 (25.0)
High Pressure Fuel Injection Pump Driven Gear Nut, lb-ft (Nm) ............... 47.9 (65.0)
Fuel Injection Common Rail Fuel Supply Mounting Bolts, lb-ft (Nm) ............... 18.4 (25.0)
High Pressure Fuel Line Injection Pipe Couplings, lb-ft (Nm) ............... 22.1 (30.0)
Fuel Injector Assembly Hold Down Clamp Bolts, lb-ft (Nm) ............... 22.1 (30.0)
Oil Pan Perimeter Bolts, lb-ft (Nm) ............... 18.4 (25.0)
Oil Pan Main Fluid Drainage Plug, lb-ft (Nm) ............... 33.1 (45.0)
Oil Pressure Relief Valve Assembly Body Plug, lb-ft (Nm) ............... 29.5 (40.0)
Oil Filter Assembly Base Mounting Fasteners, lb-ft (Nm) ............... 25.8 (35.0)
Exhaust Manifold Heat Duct Casting Mount Nut, lb-ft (Nm) ............... 25.8 (35.0)
Intake Manifold Induction Assembly Fixing Bolts, lb-ft (Nm) ............... 18.4 (25.0)
Turbocharger Gas Charger Assembly Inward Exhaust Nuts, lb-ft (Nm) ............... 33.1 (45.0)
Exhaust Gas Recirculation Cooling Module Frame Fasteners, lb-ft (Nm) ............... 18.4 (25.0)
Cooling Water Pump Assembly Shell Housing Bolts, lb-ft (Nm) ............... 18.4 (25.0)
Cooling Loop Fluid Thermostat Cover Distribution Pipe Bolts, lb-ft (Nm) ............... 18.4 (25.0)
Alternator Pivot Base Swing Adjustment Support Bolt, lb-ft (Nm) ............... 33.1 (45.0)
Starter Motor Mounting Fixing Flange Bolts, lb-ft (Nm) ............... 47.9 (65.0)
Oil Pressure Monitoring Sensor Sending Unit, lb-ft (Nm) ............... 14.7 (20.0)
Coolant Temperature Thermal Switch Sensor, lb-ft (Nm) ............... 22.1 (30.0)
Crankshaft Positioning Sensor Bracket Small Bolt, lb-ft (Nm) ............... 7.3 (10.0)
Camshaft Phase Timing Positioning Sensor Bolt, lb-ft (Nm) ............... 7.3 (10.0)
Glow Plug Preheater Units, lb-ft (Nm) ............... 11.0 (15.0)
Lifting Attachment Brackets Bolts, lb-ft (Nm) ............... 36.8 (50.0)
Timing Gear Case Outer Cover Fasteners, lb-ft (Nm) ............... 18.4 (25.0)
Piston Cooling Oil Jet Nozzle Screws, lb-ft (Nm) ............... 8.8 (12.0)

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• Doosan Engines Specs
  
• Doosan D18 Specs
  
• Doosan D24 Specs
  
• Doosan DL02 Specs
  
• Doosan DL03 Specs
  
• Doosan DM02P Specs
  

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