The document provides instructions for removing the cylinder head from a DX140LC-5 excavator engine. It outlines 8 steps: 1) draining coolant, 2) disconnecting hoses and sensors, 3) disconnecting wiring harness assemblies from sensors, 4) removing a bypass tube, 5) removing cable straps securing wiring, 6) disconnecting plastic tubes, and 7) capping disconnected tubes. The summary provides an overview of the key steps and tasks involved in the cylinder head removal process.

1. Original InstructionsCopyright DOOSAN 2015
Serial Number 1001 and Up
Shop Manual
DX140LC-5 Excavator
950106-01141E
February 2015
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

2. Table of Contents
Page I
1Table of Contents
1 Safety 1 Track Excavator Maintenance Safety
2 Specifications 1 Specifications
3 General Maintenance 1 General Maintenance Instructions
2 Standard Torques
4 Engine 1 Engine
2 Engine Coolant Heater (Option)
5 Upper Structure 1 Cabin
2 Counterweight
3 Hydraulic Oil Tank
4 Fuel Tank
5 Main Pump
6 Drive Coupling (Main Pump)
7 Main Control Valve
8 Swing Device
9 Joystick Valve (Work Lever)
10 Dozer Joystick Valve
11 Travel Control Valve (with Damper)
12 Solenoid Valve
13 EPPR Valve (One or Two-way)
14 Accumulator
15 Gear Pump (Rotating)
16 One Spool Valve (Rotating)

3. Table of Contents
Page II
6 Lower Structure and Chassis 1 Swing Bearing
2 Center Joint
3 Center Joint (Dozer)
4 Travel Device
5 Track Assembly
6 Dozer System
7 Front 1 Boom and Arm
2 Bucket
3 Cylinders
8 Hydraulic System 1 Hydraulic System
2 Hydraulic System Testing and Adjustment
3 Hydraulic System Troubleshooting
9 Electrical System 1 Electrical System
10 Options 1 One Way
2 Two-way
3 Rotating
4 Quick Coupler
5 Two Pump
11 Schematic 1 Hydraulic Schematic/Electrical Schematic

4. Track Excavator Maintenance Safety
1-1-1
DX140LC-5
Track Excavator
Maintenance
Safety
Edition 1

5. Track Excavator Maintenance Safety
1-1-5
DX140LC-5
SAFETY INSTRUCTIONS
SAFETY MESSAGES
Replace with Safety Messages Section on pages III and IV in
the Doosan Operation & Maintenance Manual.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.

6. DX140LC-5Track Excavator Maintenance Safety
1-1-6
GENERAL
Safe Operation is Operator's
Responsibility
Only trained and authorized personnel should operate and
maintain the machine.
Follow all safety rules, regulations and instructions when
operating or performing maintenance on machine.
• Do not operate machine if you are under the influence of
drugs or alcohol. An operator who is taking prescription
drugs must get medical advice to determine if he or she
can safely operate a machine.
• When working with other personnel on a work site, be sure
that all personnel know nature of work and understand all
hand signals that are to be used.
• Be sure that all guards and shields are installed in their
proper location. Have guards and shields repaired or
replaced immediately if damaged.
• Be sure that you understand the use and maintenance of
all safety features such as safety lever and seat belt. Use
them properly.
• Never remove, modify or disable any safety features.
Always keep them in good operating condition.
• Always check for and know the location of underground
and overhead utility lines before excavating.
• Failure to use and maintain safety features according to
instructions in this manual, Safety Manual and Shop
Manual can result in death or serious injury.
Know Your Machine
Know how to operate your machine. Know the purpose of all
controls, gauges, signals, indicators and monitor displays. Know
the rated load capacity, speed range, braking and steering
characteristics, turning radius and operating clearances. Keep in
mind that rain, snow, ice, loose gravel, soft ground, slopes etc.,
can change operating capabilities of your machine.

7. Track Excavator Maintenance Safety
1-1-7
DX140LC-5
Proper Work Tools and Attachments
Only use work tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When installing and
using optional attachments, read instruction manual for
attachment, and general information related to attachments in this
manual. Because DOOSAN cannot anticipate, identify or test all
attachments that owners may want to install on their machines,
contact DOOSAN for written authorization and approval of
attachments, and their compatibility with optional kits.
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or combination of work
equipment, there is a potential that work equipment could
interfere with the cabin or other parts of machine. Before using
unfamiliar work equipment, check if there is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary hydraulic kits
for attachments installation. If you are in doubt about
compatibility of a particular attachment with a machine, consult
your DOOSAN distributor.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure
to do so can result in death or serious injury.
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.
FG018457
Figure 1

8. Engine
4-1-1
DX140LC-5
Engine
Edition 1

9. Engine
4-1-21
DX140LC-5
BASIC ENGINE
Cylinder Block
Overview
The cast iron cylinder block for the four cylinder engine has four
cylinders which are arranged in-line.
The cylinder block is made of cast iron. The cylinder block
provides support for the full length of the cylinder bores. The
cylinder bores are machined into the block.
The cylinders are honed to a specially controlled finish in order
to ensure long life and low oil consumption.
The cylinder block has five main bearings which support the
crankshaft. Thrust washers are installed on both sides of
number 3 main bearing in order to control the end play of the
crankshaft. The thrust washers can only be installed one way.
Passages supply the lubrication for the crankshaft bearings.
These passages are machined into the cylinder block.
Cooling passages are cast into the cylinder block in order to
allow the circulation of coolant.
The cylinder block has a bush that is installed for the front
camshaft journal. The other camshaft journals run directly in the
cylinder block. The engine has a cooling jet that is installed in
the cylinder block for each cylinder. The piston cooling jet sprays
lubricating oil onto the inner surface of the piston in order to cool
the piston.
A Multi-Layered Steel (MLS) cylinder head gasket is used
between the engine block and the cylinder head in order to seal
combustion gases, water, and oil.
EX1500801
Figure 16

10. DX140LC-5Engine
4-1-22
Parts List
1-10
1-11
1-5
27
1-18
1-17
1-16
1-20
26
28
1-15
25
1-3
1-2
1-4
41
42
EX1500803
1-1
1-13
1-14
1-12
1-7
29
1-8
24
30
1-21
1-9
1-19
1-6
1
40
Figure 17

11. Engine
4-1-23
DX140LC-5
Cylinder Head
Overview
The engine has a cast iron cylinder head (5). The inlet manifold
is integral within the cylinder head. There are two inlet valves
and two exhaust valves for each cylinder. Each pair of valves (6)
are connected by a valve bridge that is controlled by a pushrod
valve system. The ports for the inlet valves are on the left side of
the cylinder head. The ports for the exhaust valves are on the
right side of the cylinder head. The valve stems move in valve
guides that are pressed into the cylinder head. There is a
renewable stem seal (4) that fits over the top of the valve guide.
The valve seats are replaceable.
Reference
Number
Description
1 Cylinder Block Assembly
1-1 Cylinder Block
1-2 Bearing Cap
1-3 Bearing Cap
1-4 Bearing Cap
1-5 Thimble
1-6 Screw
1-7 Bushing, Camshaft
1-8 Plug
1-9 Plug
1-10 Plug
1-11 Plug
1-12 Plug
1-13 Plug
1-14 Plug
1-15 Plug
1-16 Plug
1-17 Plug
1-18 Plug
1-19 Plug
1-20 Plug
1-21 Dowel
24 Plug
25 Seal, O-ring
26 Plug
27 Seal, O-ring
28 Seal; REOS Housing
29 Bolt; Metric
30 Dowel
40 Plug
41 Stud
42 Nut
Reference
Number
Description
EX1500802
1
2
3
4
5
6
Figure 18
Reference
Number
Description
1 Valve Keepers
2 Valve Spring Retainer
3 Valve Spring

12. DX140LC-5Engine
4-1-24
Parts List
4
5
13
12
16
6
3
10
8
9
7
15
14
11
2
26
28
25
27
29
20
21
22-1
22-222
30
30
TIMING GEAR CASE
A
EX1501046
Figure 19

13. Engine
4-1-25
DX140LC-5
Reference
Number
Description
A Cylinder Head Sub Assembly
2 Cylinder Head
3 Guide, Valve
4 Plug
5 Plug
6 Plug
7 Plug
8 Plug
9 Plug
10 Gasket; Cylinder Head
11 Bolt; Cylinder Head
12 Plug
13 Seal, O-ring
14 Plug
15 Seal, O-ring
16 Plug
20 Bar, Bus
21 Plug; Glow
22 Harness; Wiring
22-1 Harness
22-2 Tie, Cable
25 Tie, Cable
26 Nut
27 Insulator
28 Screw
29 Cap
30 Plug
Reference
Number
Description

14. DX140LC-5Engine
4-1-26
Cylinder Head - Specification
Lubricate the threads and the underside of the head bolts with
clean engine oil.
1. Tighten the bolts in the sequence that is shown in Figure
20 to the following torque.
• Torque: 50 N.m (5 kg.m, 36.9 ft lb)
2. Tighten the bolts again to the following torque.
• Torque: 100 N.m (10 kg.m, 73.8 ft lb)
3. Tighten the head bolts to the additional amount:
225 degrees
4. Minimum thickness of cylinder head.
• Thickness: 150.8 mm (5.93700 inch)
NOTE: The maximum distortion of the bottom face of
the cylinder head is given in table.
(D) Valve guide height from the top of the valve guide to
the valve spring seat.
– 10.85 ~ 11.15 mm (0.42716 ~ 0.43898 inch)
(E) Outside diameter of the valve guides
– 11.029 ~ 11.040 mm (0.43421 ~ 0.43464 inch)
(F) Length of the valve guides
– 43.75 ~ 44.25 mm (1.72244 ~ 1.74212 inch)
(G) Internal diameter of the valve guides
– 7.007 ~ 7.020 mm (0.27587 ~ 0.27638 inch)
(H) Valve depths Inlet
– 0.905 ~ 1.163 mm (0.0356 ~ 0.0458 inch)
The service limit for the depth of the inlet valve
– 1.41 mm (0.0555 inch)
Exhaust
– 0.876 ~ 1.131 mm (0.0345 ~ 0.0445 inch)
The service limit for the exhaust valve depth
– 1.38 mm (0.0543 inch)
2
EX1500804
2
1 5 9 8 4
6 10 7 3
Figure 20
EX1500805
A A A A A
C
B
B
B
C
Figure 21
Dimension
Maximum Permissible
Distortion
Width (A) 0.08 mm (0.0032 inch)
Length (B) 0.08 mm (0.0032 inch)
Diagonal Line (C) 0.08 mm (0.0032 inch)
EX1500806
H
G
F
E
D
Figure 22

15. Engine
4-1-27
DX140LC-5
(J) Diameter of the parent bore in the cylinder head
– 11.000 ~ 11.022 mm (0.43307 ~ 0.43394 inch)
(K) Seat angle
– Inlet: 119.25 degrees
– Exhaust: 89.25 degrees
(L) Seat surface finish: Ra 0.8 microns
(M) Concentricity of valve seat to valve guide parent bore
Maximum Total Indicated Reading (TIR)
– 0.08 mm (0.00315 inch)
J
EX1500807
K
Figure 23
EX1500808
L
M
Figure 24

16. DX140LC-5Engine
4-1-28
Cylinder Head - Remove
1. Drain the coolant from the cooling system into a suitable
container for storage or for disposal.
2. Disconnect the upper radiator hose from water
temperature regulator housing (1) on the cylinder head.
3. Remove crankcase breather. Refer to "Crankcase
Breather - Remove".
IMPORTANT
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
IMPORTANT
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component containing
fluids.
Dispose of all fluids according to local regulations and
mandates.
1
EX1500809
Figure 25
EX1500810
Figure 26

17. Engine
4-1-29
DX140LC-5
4. Follow Step 3.A. through Step 3.B. in order to disconnect
harness assembly (7) from boost pressure sensor (5).
A. Slide the locking tab into unlocked position (4).
B. Disconnect harness assembly (7) from boost
pressure sensor (5).
5. Follow Step 4.A. through Step 4.B. in order to disconnect
harness assembly (6) from inlet air temperature sensor (3).
A. Slide the locking tab into unlocked position (2).
B. Disconnect harness assembly (6) from inlet air
temperature sensor (3).
6. Follow Step 14.A. through Step 14.C. in order to
disconnect harness assembly (26) from coolant
temperature sensor (25).
A. Slide locking tab (27) into the unlocked position.
B. Disconnect harness assembly (26) from coolant
temperature sensor (25).
C. Cut cable strap (28) and remove harness assembly
(26) from bypass tube (30). The harness assembly
must be positioned away from the cylinder head in
order to avoid causing an obstruction during the
removal of the cylinder head.
Remove bolts (29). Remove bypass tube (30) from the
cylinder head. Remove O-ring seal (31) and O-ring seal
(32) from bypass tube (30).
7. Remove all cable straps that secure harness assembly to
the cylinder head. The harness assembly must be
positioned away from the cylinder head in order to avoid
causing an obstruction during the removal of the cylinder
head.
8. Disconnect plastic tube assembly (8) and plastic tube
assembly (11) from tube assembly (15). Use a suitable tool
in order to plug the plastic tube assemblies and to cap the
tube assembly.
EX1500814
4
5
7
3
2
6
Figure 27
28
25 26
29
27
30
31
30
32
EX1500811
Figure 28
EX1500815
Figure 29

18. DX140LC-5Engine
4-1-30
9. Disconnect hose assembly (13) from connection on tube
assembly (15). Remove O-ring seal (14) (not shown).
Use a suitable tool in order to plug the hose assembly and
to cap the tube assembly.
10. Use a suitable tool in position (X) in order to hold tube
assembly (15) as nut (12) is loosened.
Remove bolt (16) from tube assembly (15).
11. Remove tube assembly (15) from the bracket and the
cylinder head. Use a suitable tool in order to plug the
cylinder head and to cap the tube assembly.
12. Remove O-ring seal (17) from tube assembly (15).
13. Remove clean emission module and exhaust back
pressure valve.
Refer to "Clean Emissions Module - Remove" and
"Exhaust Back Pressure Valve - Remove".
14. Remove turbocharger. Refer to " Turbocharger - Remove".
15. Remove Exhaust Cooler (NRS). Refer to "Exhaust Cooler
(NRS) - Remove".
16. Remove exhaust manifold. Refer to "Exhaust Manifold -
Remove".
17. Remove NRS induction mixer. Refer to "Inlet Air Control -
Remove".
18. Remove valve mechanism cover. Refer to "Valve
Mechanism Cover - Remove".
19. Gradually loosen bolts (33) in the reverse numerical order
to the tightening sequence. Refer to the Figure 31.
NOTE: Follow the correct sequence in order to help
prevent distortion of the cylinder head.
20. Remove bolts (33) from cylinder head (34).
21. Attach a suitable lifting device to cylinder head (34).
Support the weight of the cylinder head. The weight of the
cylinder head is approximately 66 kg (146 lb).
NOTE: A spreader bar must be used in order to
distribute the weight of the cylinder head during
the lifting operation.
8 9 10
11
X
12
13 14 15 16 17
EX1500816Figure 30
EX1500812
33
34
Figure 31

19. Engine
4-1-31
DX140LC-5
22. Use the suitable lifting device to lift cylinder head (34)
carefully off the cylinder block.
NOTE: Do not use a lever to separate the cylinder head
from the cylinder block. Take care not to
damage the machined surfaces of the cylinder
head during the removal procedure.
23. Remove cylinder head gasket (36).
24. Note the position of dowels (35) in the cylinder block.
25. If necessary, remove water temperature regulator from the
cylinder head. Refer to "Water Temperature Regulator -
Remove" or the correct procedure.
EX1500813
2 6 10 7 3
1 5 9 8 4
Figure 32
35
36 EX1500817
Figure 33
IMPORTANT
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.

20. DX140LC-5Engine
4-1-32
Cylinder Head - Install
1. Thoroughly clean the gasket surfaces of the cylinder head
and the cylinder block. Do not damage the gasket surfaces
of the cylinder head of the cylinder block.
Ensure that no debris enters the cylinder bores, the coolant
passages, or the lubricant passages.
2. Inspect the gasket surface of the cylinder head for
distortion. Refer to "Cylinder Head - Specification" for more
information. If the gasket surface of the cylinder head is
distorted beyond maximum permitted limits, replace the
cylinder head.
3. Inspect dowels (35) for damage. If necessary, replace the
dowels in the cylinder block.
4. Install a suitable tool to the cylinder block.
5. Align cylinder head gasket (36) with dowels (35).
Install cylinder head gasket (36) onto the cylinder block.
6. Use a suitable lifting device to lift cylinder head.
The weight of the cylinder head is approximately 66 kg
(146 lb).
NOTE: A spreader bar must be used in order to
distribute the weight of the cylinder head during
the lifting operation.
7. Use a suitable tool to align the cylinder head with the
cylinder block. Install the cylinder head to the cylinder
block.
NOTE: Ensure that the cylinder head is correctly
positioned on dowels (35).
8. Remove a tool.
IMPORTANT
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
IMPORTANT
Ensure that the wiring harness assembly is correctly routed
and the cable straps are not over tightened.
Over tightening of the cable straps will damage the wiring
harness convoluting.
A A
EX1500818
35
36
Figure 34

21. Engine
4-1-33
DX140LC-5
9. Clean bolts (33). Follow Step 9.A. for the procedure to
inspect the bolts.
A. Use a straight edge to check the threads of the bolts.
Refer to Figure 35. Replace any bolts that show
visual reduction in the diameter of the thread over
Length (Y).
10. Lubricate the threads and the shoulder of bolts (33) with
clean engine oil.
11. Install bolts (33) to cylinder head (34).
12. Tighten the bolts to a torque of 50 N.m (5 kg.m, 37 ft lb) in
the numerical sequence. Refer to Figure 36.
13. Tighten the bolts to a torque of 100 N.m (10 kg.m, 74 ft lb)
in the numerical sequence. Refer to Figure 36.
EX1500819
33
Y
Figure 35
EX1500812
33
34
Figure 36
EX1500821
2 6 710 3
225
1 5 9 8 4
Figure 37

22. DX140LC-5Engine
4-1-34
Cylinder Head - Inspect
1. Remove cylinder head from the engine.
2. Remove water temperature regulator housing.
3. Inspect the cylinder head for signs of gas or coolant
leakage.
4. Remove valve springs and valves.
5. Clean the bottom face of the cylinder head thoroughly.
Clean the coolant passages and the lubricating oil
passages. Make sure that the contact surfaces of the
cylinder head and the cylinder block are clean, smooth,
and flat.
6. Inspect the bottom face of the cylinder head for pitting,
corrosion, and cracks. Inspect the area around the valve
seat inserts and the holes for the fuel injection nozzles
carefully.
7. Test the cylinder head for leaks at a pressure of 2 bar
(29 psi).
8. Measure the cylinder head for flatness. Use a straight edge
and a feeler gauge to check the cylinder head for flatness.
Resurfacing the Cylinder Head
The bottom face of cylinder head can be resurfaced if any of the
following conditions exist:
• The bottom face of the cylinder head is not flat within the
specifications.
• The bottom face of the cylinder head is damaged by pitting,
corrosion, or wear.
NOTE: The thickness of the cylinder head must not be
less than 150.8 mm (5.93 inch) after the
cylinder head has been machined.
NOTE: The dimension of the valve seats to the flame
face must be corrected after resurfacing the
cylinder head. Refer to "Cylinder Head-
Specification" for the correct dimensions for the
valve seats.
EX1500820
A A A A A
C
B
B
B
C
Figure 38 Flatness of the Cylinder Head
Reference
Number
Description
A Side to Side
B End to End
C Diagonal

23. Engine
4-1-35
DX140LC-5
Valve Mechanism Cover
Overview
10 6 2 4 8
11
7315
9
EX1500822
Figure 39

24. DX140LC-5Engine
4-1-36
Parts List
7
6
9
2
8
10
3-1
3
A
EX1501081Figure 40
Reference
Number
Description
A Cover Assembly, Cylinder Head
2 Cover; Cylinder Head
3 Cap, Oil Filter
3-1 Seal, O-ring
6 Cap
7 Seal, O-ring
8 Screw
9 Seal
10 Screw
Reference
Number
Description

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26. Engine
4-1-37
DX140LC-5
Valve Mechanism Cover - Specification
When the valve springs (1) are replaced the valve springs must
be replaced in pairs.
1. Valve face angle (2, Figure 42)
• Inlet: 30 degrees
• Exhaust: 45 degrees
2. Valve stem diameter (3, Figure 42)
• Inlet: 6.970 ~ 6.985 mm (0.2744 ~ 0.2750 inch)
• Exhaust: 6.945 ~ 6.960 mm (0.2734 ~ 0.2740 inch)
Clearance
• Maximum clearance of the inlet valve stem: 0.05 mm (0.0020 inch)
• The service limit for the inlet valve stem: 0.08 mm (0.0031 inch)
Clearance
• Maximum clearance of the exhaust valve stem: 0.075 mm (0.00295 inch)
• The service limit for the exhaust valve stem: 0.10 mm (0.00394 inch)
3. Length of valve (4, Figure 42)
• Inlet valve: 109.82 ~ 110.27 mm (4.32361 ~ 4.34133 inch)
• Exhaust valve: 109.853 ~ 110.303 mm (4.32491 ~ 4.34263 inch)
4. Valve head (5, Figure 42)
• Diameter of inlet valve head: 35 mm (1.3780 inch)
• Diameter of exhaust valve head: 33 mm (1.2992 inch)
1
EX1500823Figure 41
2
5
3
4
EX1500824
Figure 42
Inlet Valve
The Load for the Spring The Length of the Spring
209 ~ 231 N (47 ~ 52 lb) 31.5 mm (1.2402 inch)
389.5 ~ 430.5 N (87.5 ~ 97 lb) 22.2 mm (0.87401 inch)
Exhaust Valve
The Load for the Spring The Length of the Spring
285 ~ 315 N
(64.07085 ~ 70.81515 lb)
31.5 mm (1.2402 inch)
408.5 ~ 451.5 N
(91.83488 ~ 101.50172 lb)
22.3 mm (0.87795 inch)

27. DX140LC-5Engine
4-1-38
Valve Mechanism Cover - Remove
1. Remove bolts (1) and bolts (4) from bracket (2) and
bracket (3). Position brackets and harness assembly away
from valve mechanism cover (7).
2. Disconnect the plastic tube assembly (5) from the valve
mechanism cover for the crankcase breather. Refer to
"Crankcase Breather - Remove" for the correct procedure.
3. Remove bolts (6) from valve mechanism cover (7).
4. Remove valve mechanism cover (7) from the cylinder
head.
NOTE: Remove valve mechanism cover vertically in
order to avoid damage to the electronic unit
injectors.
5. Remove gasket (8) from valve mechanism cover (7).
Valve Mechanism Cover - Install
1. Thoroughly clean all gasket surfaces of valve mechanism
cover (7). Clean the gasket surfaces of the cylinder head.
2. Inspect gasket (8) for damage. If necessary, install a new
gasket (8) to valve mechanism cover (7).
NOTE: Ensure that the gasket is fully seated into the
groove of the valve mechanism cover.
5
EX1500825
43
76
21
Figure 43
EX1500826
7
8
Figure 44
EX1500826
7
8
Figure 45

28. Engine
4-1-39
DX140LC-5
3. Ensure that harness assemblies (10) are not in contact
with rocker arms (11) or cylinder head (9).
NOTE: Install the valve mechanism cover vertically in
order to avoid damage to the electronic unit
injectors.
4. Position valve mechanism cover (7) onto cylinder head (9).
Ensure that harness assemblies (10) are not trapped
during the assembly procedure.
5. Install bolts (6).
6. Tighten the bolts in the numerical sequence that is shown in
Figure 48. Tighten the bolts to a torque of 22 N.m (2.2 kg.m,
16.2 ft lb).
7. Position brackets and harness assembly onto the valve
mechanism cover. Install bolts (1) and bolts (4) to bracket
(2) and bracket (3).
8. Tighten bolts (1) and bolts (4) 9 N.m (0.9 kg.m, 6.6 ft lb).
9. Connect the plastic tube assembly to the valve mechanism
cover for the crankcase breather.
Refer to "Crankcase Breather - Install" for the correct
procedure.
EX1500827
9
10
11
Figure 46
5
EX1500825
43
76
21
Figure 47
EX1500829
5
9
10 6 2 4
11
8
1 3 7
Figure 48