Doosan D35S-5 Service Manual

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Service Manual

D439E Diesel Engine

D35S-5, D40S-5, D40SC-5, D45SC-5

D45S-5, D50C-5, D55C-5, D50SC-5, D55SC-5

D60S-5, D70S-5

D80S-5, D90S-5

SB4323E00

Nov. 2008

Table of Contents

Other manuals for Doosan D35S-5

Disassembly/Assembly62 pages

Operation & Maintenance Manual350 pages

Questions and Answers:

M
Melissa GoldenAug 2, 2025
Why is there excessive black smoke coming from my Doosan D35S-5 Engine?
- S
  Savannah SmithAug 2, 2025
  Excessive black smoke from your Doosan Engine may be due to several reasons. The air cleaner element might be clogged, so try replacing or cleaning it. There could be restrictions in the air duct, which you should check and correct. Another potential cause is leakage at the intake manifold, so inspect and fix that as well. The turbocharger could be seized up and not rotating, or the turbine and compressor blades might be damaged or in contact with each other, requiring disassembly, repair, or replacement. Finally, the exhaust piping could be deformed or clogged; check and correct it.
N
Nicole MillsAug 10, 2025
What to do if my Doosan D35S-5 has low output?
- R
  Robert WeeksAug 10, 2025
  If your Doosan Engine has low output, start by checking for gas leaks in the exhaust system and correct them. Also, the air cleaner element may be restricted, so replace or clean it. The turbocharger could be fouled or damaged, requiring disassembly, repair, or replacement. Lastly, check for leakage at the discharge port on the compressor side and correct it.
J
jordanmichaelAug 17, 2025
How to fix unusual sound or vibration in my Doosan D35S-5 Engine?
- J
  James BlevinsAug 17, 2025
  If your Doosan Engine is making unusual sounds or vibrating, the rotor assembly might be coming into contact, or the rotor rotation may be unbalanced, either of which would require disassembly, repair, or replacement. Also, the engine could be seized up, which would also require disassembly, repair, or replacement. Check if each joint loosened and correct.
A
Andrea PetersAug 25, 2025
What causes excessive white smoke from a Doosan D35S-5?
- J
  Jordan NelsonAug 26, 2025
  Excessive white smoke from a Doosan Engine can be caused by an oil leak into the turbine and compressor, which requires disassembly, repair, or replacement. It may also be due to a worn or damaged seal ring because of excessive bearing wear, also requiring disassembly, repair, or replacement.

Doosan D35S-5 Specifications

General

Engine Type	Diesel
Number of Cylinders	4
Cooling System	Water-cooled
Bore x Stroke	98 mm x 110 mm
Fuel System	Direct injection
Displacement	3.3 L
Aspiration	Natural

Summary

1. General Information

How to Read Disassembly and Reassembly Drawings

Guidance on interpreting disassembly and reassembly diagrams and part numbering conventions.

Definition of Terminologies

Explanation of standard terms and abbreviations used in the manual, like NV, RL, SL, BD, T.

Unit of Measurement

Specifies that SI units are used, with metric notation presented in parentheses.

Note, Warning, and Caution Symbols

Defines the meaning of NOTE, CAUTION, and WARNING symbols used throughout the manual.

General Precautions for Servicing

Covers vehicle protection, tool preparation, removal, disassembly, inspection, and general safety.

2. Engine Mechanical System (D439E)

General Information

Covers engine description, specifications, tightening torque, special tools, diagnosis, and adjustments.

Timing System

Details on the timing gear assembly, including components, removal, inspection, and installation.

Cylinder Head Assembly

Covers cylinder head components, removal, disassembly, inspection, replacement, reassembly, and installation.

Crankcase Assembly

Details on the crankcase and flywheel, including components, removal, inspection, and installation.

3. Engine Electrical System (D439E)

Specifications

Provides specifications for Starting System, Charging System, and Preheating System.

Service Standards

Lists service standards for starter motor and alternator components.

Tightening Torque

Specifies tightening torque values for various electrical system components.

Troubleshooting

Provides solutions for common problems with the alternator, starter, and pre-heating systems.

4. Fuel System

General Specifications

Details specifications for sensors, actuator, supply pump, and fuel filter.

Tightening Torque

Lists tightening torque values for fuel system components.

Troubleshooting

Covers common fuel system issues like poor injection, engine stall, and lack of power.

Engine Control System - Electronic

Explains the diesel control system, ECU, sensors, and diagnostic procedures.

Fuel Delivery System Components

Details components like fuel filter, injectors, common rail, and injection pump.

5. Service Tool

Introduction and Safety

Provides an overview of the G-scan tool, its components, and safety precautions for use.

Hardware Specifications

Details the technical specifications of the G-scan hardware, including interface and power.

Vehicle Communication Function

Covers vehicle selection, fault code searching, DTC analysis, data analysis, and actuation tests.

ECU Upgrade and Management

Explains how to perform ECU upgrades and manage vehicle software.

PC Utility Installation and Usage

Guides on installing, running, and updating the G-scan PC utility software.

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