Doosan A2300 - In Chassis Overhaul

A Series Diesel Engine Base Engine Components 189
In-Chassis Overhaul
The remaining procedures in this manual are
organized for an in-chassis overhaul. An in-chassis
overhaul includes:
z Inspecting the turbocharger
z Replacing piston rings
z Replacing connecting rod bearings
z Replacing crankshaft main bearings
z Grinding valves
z Testing injectors
This manual gives the procedures to replace the
piston rings, rod bearing, main bearings and grinding
the valves. The procedure to test the injectors and
rebuild the turbocharger are given in the Shop
Manual, Bulletin Number 3810206. Refer to pages 5-
3 through 5-9 for inspecting the turbocharger.
Segments of the procedures can also be used to
replace individual components when required.
The condition of the cylinder block and crankshaft is
the limiting criteria for in-chassis overhaul. If there is
reason to believe that either is severely damaged, the
engine should be removed for major overhaul.
Prior to deciding on an in-chassis overhaul, inspect
the air intake for evidence of ingestion of particles
that could have severely damaged the cylinder walls,
Check the oil and oil filter to be sure the lube system
is not thoroughly contaminated with metal. Also check
for rust in the coolant which can indicate build up in
the passages in the cylinder block and require the
block to be removed for cleaning. Also consider the
condition of other components, particularly those that
are more difficult to replace in-chassis; e.g. the
camshaft rear sea, etc. The combination of in-chassis
overhaul and time to repair those components may
exceed the time required to remove the engine and
perform an out of chassis overhaul.
The in-chassis overhaul procedures include
prescribed checks of the hardware to determine if
continued in-chassis work is practical. If the
conditional limits are not met, the engine should be
removed for completion of the overhaul.