6599892-

PREFACE

This operation and maintenance manual for DB58/T/TI, diesel engine, is explained to correctly and

systematically maintain in order to accurately operate and guarantee for the life span of motors.

This manual, not only thorough overhaul drawing of numerical value for service, maintenance items

and various torques but also disassembly parts, installation, overhaul, inspection and repair,

principle of reassembly, is quickly and usefully understand of the service procedure to be repaired

parts, and evolved services is as follows.

Removal Adjustment

Installation Liquid gasket application

Disassembly Cleaning

Reassembly Pay close attention-Important

Alignment(Marks) Tighten to specified torque

Directional Indication Use special tools of manufacturer's

Inspection Lubricate with oil

Measurement Lubricate with grease

This manual is eligible a training aids to the trainees, and further information, please feel free to call

Service Center of Engine Parts, DaeWoo, at any time.

TABLE OF CONTENTS

1. GENERAL .................................................................................................................................. 1

1.1. General Repair Instructions 1.5. Maintenance

1.2. Engine Specifications 1.6. Engine Repair Parts(Standard Engine)

1.3. Torque Specifications 1.7. Recommended Lubricants

1.4. Main Part Fixing Nuts And Bolts

2. ENGINE ASSEMBLY AND DISASSEMBLY ............................................................................31

2.1. External Parts Disassembly 2.3. Inspection and Repair

2.2. Key Components Disassembly 2.4. Reassembly

3. SYSTEM OF LUBRICATION ....................................................................................................96

3.1. General Description 3.3. Oil Cooler

3.2. Oil Pump

4. COOLING SYSTEM ................................................................................................................101

4.1. General Description 4.3. Thermostat

4.2. Coolant pump

5. FUEL SYSTEM .......................................................................................................................110

5.1. General Description 5.3. Injection Nozzle

5.2. Fuel filter

6. ENGINE ELECTRICALS ........................................................................................................120

6.1. Starter Motor 6.2. Alternator

7. TURBO CHARGER ................................................................................................................122

8. CAUSE OF TROUBLE, DIAGNOSIS AND TROUBLESHOOTING........................................125

• WORLDWIDE NETWORK

1. General

1.1. General Repair Instructions

1) Equipment shall be safely parked on the ground, and propped front and rear wheel when work.

2) Prior to maintain, disconnect the grounding cable from the battery to be prevented the

damaged cable and burning due to short-circuiting.

3) Shield body and sheet with the coverlet in order to prevent of damage and getting stained.

4) All the persons handling brake oil and anti-freezing solution shall be carefully treated to be

undamaged the painting parts.

5) When maintain the specially designated parts, the appropriated tools or special tools shall be of

importance used to maintain the life span.

6) Changeable parts shall be rightly used the genuine parts of DAEWOO.

7) When the used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts do reuse,

you may need to maintain again, so that why you use the brand new products.

8) Orderly place the disassembled parts in groups to be smoothly reassembled after maintained.

9) Prior to inspect reassemble, you must clean the parts, and also clean the perforated oil ring

with the compressed pneumatic in order to prevent of inflow an alien substance.

10) Prior to assemble, lubricate the oil or grease to the rotating and sliding faces of parts.

11) Adhere to the gaskets to prevent of leakage if necessary.

12) Getting tightened the bolts and nuts torque shall be comply with a rule.

13) Finally check to make sure when the maintenance has been done.

14) The system of an aerial parts for a safety shall be removed the compressed pneumatic without

fail when disassemble in a working.

- 1 -

1.2. Engine Specifications

- 2 -

Engine ModelItems

DB 58 DB 58T DB58TI

Engine type Water cooled, 4 cycle, vertical in-line, overhead valve

Combustion chamber type Direct injection

Cylinder liner type Dry type

Timing gear system Gear drive type

Number of piston ring Compression ring 2, oil ring 1

No. of cylinder-bore×stroke (mm) 6-102×118

Total piston displacement (cc) 5,785

Compression ratio 17.4 : 1

Engine dimensions (length×width×height)(mm) 1122×648×775 1172×671×886 1172×683×928

Engine weight (dry) (kg) 455 497 505

Fuel injection order 1-5-3-6-2-4

Fuel injection timing (B.T.D.C static) 18� 13� 13�

Type of fuel used High speed diesel fuel (SAE No. 2)

Fuel filter type Cartridge type

Injection pump type Bosch in-line A type (for industrial) Bosch in-line AD type (for Automotive)

Governor type Mechanical governing (RLD, RSV type)

Injection nozzle type Multi hole type

Fuel injection pressure (kg/cm2) 185

Compression pressure (kg/cm2) 31 (at 200RPM)

Idle speed (RPM) 850 1100

Intake and exhaust valve clearance (mm) 0.4(at cold)

Max. power 130/2800 132ps/2200rpm 162ps/2200rpm

Max. torque 38/1600 45kg•m/1600rpm 60kg•m/1600rpm

Lubrication method Pressurized circulation

Oil pump type Gear type

Oil filter type Full flow, cartridge or center bolt type

Piston cooling method Oil zet cooling type

Lubrication oil capacity (ℓ) 19 20.5

Oil cooler type Water cooled

Cooling method Pressurized forced circulation

Cooling water capacity (ℓ) 12

Water pump Belt driven impeller type

Thermostat type Wax pellet type

Battery(V) 24

Alternator (V-A) 24-60

Starter (V-KW) 24-4.5

- 3 -

Bolt identification

Bolt 4T 7T 9T

diameter × pitch (mm) (Low carbon steel) (High carbon steel) (Alloy steel)

M 6×1.0 0.6±0.2 0.75±0.2

M 8×1.25 1.3±0.5 1.75±0.5 2.0±0.7

M10×1.25 2.8±0.7 3.75±0.9 5.0±1.3

M12×1.25 6.25±1.2 7.75±1.5 9.65±1.9

M14×1.5 8.75±1.9 11.85±2.3 14.50±2.9

M16×1.5 13.3±2.7 17.30±3.5 20.40±4.1

M18×1.5 19.2±3.8 24.90±5.0 29.30±5.9

M20×1.5 26.3±5.3 34.40±6.9 40.40±8.1

M22×1.5 33.0±8.3 46.25±9.2 54.10±10.8

M24×2.0 45.8±9.2 58.20±14.0 70.60±14.1

*M10×1.5 2.7±0.7 3.7±0.9 4.9±1.2

*M12×1.5 5.8±1.2 7.2±1.4 9.1±1.8

*M14×2.0 9.1±1.8 11.2±2.2 13.6±2.2

*M16×2.0 12.7±2.5 16.5±3.3 19.5±3.9

Note : The marked (*) bolts which are made with the soft materials, e.g., cast-iron products

shall be used for a female screw part.

4 7 9

1.3. Torque Specifications

��Standard Bolts

The below described torque value shall be applied for the general torque which are not

specially specified in this table.

(Unit : kg∙m)

1.4. Main Part Fixing Nuts And bolts

��Cylinder Head and Cover

(Unit : kg∙m)

- 4 -

2.7±0.25

(19.5±1.8)

5.3±1

2.1±0.5

5.3±1

11.5±05. (hexagon bolt) : (Torque Control Method)

4 Kg m + 90˚+60˚(0~30˚)

(docoecagon bolt) : (Angle Control Method)

EJM1001S

preheating plug

�Cylinder Block

(Unit : kg∙m)

- 5 -

5.3±1

2.6±0.5

2.6±0.5

2.6±0.5

2.1±0.524.1±1

EJM1002S

�Oil Pan and Dipstick

(Unit : kg∙m)

- 6 -

2.6±0.5

8.0±1.0

2.9±0.3

EJM1003S

�Cam Shaft and Rocker Arm

(Unit : kg∙m)

- 7 -

16±1.5

Engine oil application

5.5±1

2.6±0.5

2.6±0.5

3.1±0.5

3.1±0.5

EJM1004S

�Crankshaft, Piston, and Flywheel

(Unit : kg∙m)

- 8 -

22.3±2.2

60±5

A type : 12±0.25

B type : 9.25±0.25

B type or

A type

EJM1005S

Mark : ON BOLT HEAD

�Thermostat and Thermostat Housing

(Unit : kg∙m)

- 9 -

EJM1006S

5.3±1

5.3±1

2.6±0.5

�Intake and Exhaust Manifold(DB58)

(Unit : kg∙m)

- 10 -

2.9±0.3

2.6±0.5

EJM1007S

�Intake and Exhaust Manifold(DB58T)

(Unit : kg∙m)

- 11 -

5.3±1.0

2.6±0.5

EJM1008S

�Intake and Exhaust Manifold(DB58TI)

(Unit : kg∙m)

- 12 -

EJM1009S

2.9±0.3

2.6±0.5

�Timing Gear Case and Flywheel Housing

(Unit : kg∙m)

- 13 -

EJM1010S

16.0±1.0

16.0±1.0

Outside

2.6±0.5

2.6±0.5

2.6±0.5

Inside

�Oil Cooler, Oil Filter and Oil Pump

(Unit : kg∙m)

- 14 -

2.6±0.5

2.6±0.5

5.3±1.0

EJM1011S

5.3±1.0

5.3±1.0

�Fuel System (DB58, DB58T)

(Unit : kg∙m)

- 15 -

EJM1012S

1.9±0.2

1.3±0.2

3.1±0.21.7±0.1

4.2±0.8

4.2±0.8

�Fuel System(DB58TI)

(Unit : kg∙m)

- 16 -

EJM1013S

1.9±0.2

1.3±0.2

3.1±0.21.7±0.2

4.2±0.8

�Turbo Charger and Related Parts (DB58T)

(Unit : kg∙m)

- 17 -

EJM1014S

3.8±0.7

5.3±1.0

3.1±0.5

3.8±0.7

2.6±0.5

�Turbo Charger and Related Parts (DB58TI)

(Unit : kg∙m)

- 18 -

EJM1015S

3.8±0.7

5.3±1.0

3.1±0.5

3.8±0.7

2.6±0.5

- 19 -

��Removal

<Remover and Installer : Filter Wrench>

1) After release the drain plug, and remove the

oil if upper system.

2) Draw out filter as turning it counterclock

wise.

3) Do not reuse the drew out filter.

��Assembly

1) Wipe the oil filter mounting face with a clean

rag to install the new filter.

2) Lightly oil at the O-ring part.

3) Turn in the new oil filter until the sealing face

is fitted against the O-ring.

4) Additionally tighten 3/4 of a turn with a

wrench.

5) Check the engine oil level and replenish to

the specified level if necessary.

6) Check the leakage at the replaced filter as

operating the engine.

EJM1018I

EJM1019I

Set the FilterWrench

Cartridge

Drain Plug

<Upword type>

<Downword type>

1.5. Maintenance

1.5.1. Replacement of Oil Filter

Cartridge (Spin-On) Type

<Removal>

1) Turn in the filter toward counterclock wise

with a wrench or manual, and discard it.

2) Wipe the oil filter mounting face with a clean

rag to install the new filter.

EJM1021S

1.5.2. Replacement of Fuel Filter

- 20 -

<Assembly>

1) Lightly oil at the O-ring part.

2) Inject fuel to the new fileter to be easily

discharged an air.

3) Additionally tighten 2/3 of a turn with a

wrench until O-ring contact against the

block.

��Means Replacement of Filter.

1) Release the plug (1) a fixed height.

2) Separate cartirage (2) from head (3) with the

tools.

3) Fill up clean fuel to the new cartirage.

4) Replace the rubber packing (4) which is

centered at the head.

5) Smear clean fuel to the rubber packing (5)

which is a cartirage.

6) Turn cartirage until packing is getting to

head.

7) Farther make a round 1/3~1/2 with manual

when packing get to head.

8) Remove an air in the filter with a feed pump

which is in the injection pump.

9) When flow out a foamless fuel without

interruption, then tighten plug and check a

leakage as setting start.

��Center Bolt Type

<Removal>

1) Loosen the drain plug ① to drain thd fuel

from the fuel filter.

2) Loosen the center bolt ② to remove the filter

body ⑤, the spring ⑥, the washer ⑦, the

gas ket ⑧, and the filter element ⑨.

3) Discard the used element.

<Installation>

1) Wash the filter body and the other parts

immersing them into clean diesel oil.

2) Reassemble the parts in reverse oreder. Use

the new element.

3) Check that the gaskets are properly seated.

This will prevent fuel leakage.

EJM1021S

1

5

2

3

4

6

EJM1022I

EJM1020S

- 21 -

• Inspection procedure

1) Fix the injection nozzle in a vise.

2) Release nozzle holder cap with a wrench.

3) Disassemble the injection nozzle holder from

a vise.

��Adjusting Procedure

Check of Injection Starting Pressure

1) Assemble nozzle holder at nozzle tester.

2) Release adjustment screw (1), As shown in

fig.

3) Check injection pressure and injection

statement.

4) Adjust injection nozzle starting pressure if

necessary.

Adjust injection nozzle starting pressure as

set starting a handle of nozzle tester.

��CAUTION��The marked (*) can be

changed according to the

loaded vehicles.

Feel free contact to this

firm when you have a

quantion in this manual.

��CAUTION��Carefully keep away from

skin and keep off from

tester because pressure of

nozzle tester is very high

when inject.

EJM1023S

EIO3008S

EJM1024S

EJM1025S

EJM1026S

1.5.3. Injection Nozzle

DB58 DB58T DB58TI

Injection Starting Pressure 181 kg/cm2 185 kg/cm2 185 kg/cm2

①

①

①

- 22 -

Check of Injection Condition(Operating the

Nozzle Tester)

1) Tighten cap nut (1)

2) Check injection nozzle starting pressure

3) Check the injection nozzle condition

Prior to inject the fuel completely, compress

4~6 times to be finally injected.

See figure for check of injection test condition.

1) Good

2) Inferiority (orifice)

3) Inferiority ((dripping)

1) Release joint bolt A

2) Remove strainer with screwdriver, and wash

strainer with light gasoline.

Check leakage separator on the surface.

Release plug at the bottom part to be

eliminated when indicate warning point on the

surface.

EJM1027S

EJM1028S

EJM1029S

EJM1030S

EJM1031S

1.5.4. Feed of Pump Strainer

Strainer

1.5.5. Separator of Leakage (Add if Necessary)

Elimination Plug Torque 1.2±0.3 kg∙m

Warningsurface

Floating

E l i m i n a t i o nplug

A

- 23 -

1) Release the feed pump cap (1) at the

Injection pump.

2) Release an air bleed nut (2) at the Injection

pump.

3) Operate feed pump as visually seeing until

completely remove an air.

3) Tighten eye bolt.

4) Make sure to check leakage of Injection

pump ＆ filter after operating feed pump

many times.

��Cooling Fan Belt

Adjustment

1) Check cooling fan drive belt for cracking and

damage.

2) Check the drive belt tension by exerting a

force of 10kg midway between the water

pump pulley ② and the alternator pulley ③.

3) Adjust the belt tension by loosening the

alternator mounting bolt and the alternator

adjusting bolt and pivoting the alternator.

Be sure to retighten the bolts after adjusting

the belt tension.

Cooling Fan Drive Belt Deflection 8.0 ~ 12.0 mm

��Inspection

Visualy inspect the thermostat.

When inspect,if excessive wear or damage is

discovered, replace thermostat.

��measure the valve lift.

EJM1032S

EJM1033I

EJM1034I

EFM2055I

1.5.6. Air Bleeding

1.5.7. Cooling System

Amount of Valve Lift 10.0 mm

Valve Opening Temperature 80 ~ 84 ℃

1.5.8. Thermostat

①

②

②

①

③

Depresshere

About10mm

Thermometer

WoodPlate

Bar

- 24 -

��CAUTION��Tighten due to every means

when tighten cylinder head

bolts. No retighten bolt

before adjust of valve

clearance.

1) Bring the piston in either the #1 cylinder or

the #6 cylinder to Top dead Center

on the compression stroke by turning the

crankshaft until the TDC notchecd line on

the crankshaft pulley is aligned with the

timing pointer.

Check to see if there is play in the #1 intake

an exhaust valve rocker arms.

If #1 cylinder intake and exhaust valve

rocker arms are shifted, the #1 piston is at

TDC on the compression stroke.

If the #1 cylinder intake and exhaust valve

rocker arms are fixed, the #6 piston is at

TDC on the compression stroke.

2) Adjust valve clearances when #1 or #6

piston is TDC on compression stroke.

3) Release adjusted screw. See figure.

4) Insert a 0.4mm filter gauge which is between

rocker arm and valve stem end.

5) Turn the valve clearance adjusting screw

until slight drag can be felt on the feeler

gauge.

6) Tighten lock nut.

7) Rotate crankshaft 360�to be realigned

crankshaft pulley TDC notched line with

timing pointer.

8) Adjust valve clearances as shown in figure.

EDM1003S

EJM1035S

EDM1003S

EJM1036S

EJM1037S

1.5.9. Valve Clearance and Adjustment

Intake and Exhaust Valve Clearance(cold) 0.40 mm

Rocker Arm Screw Lock Nut Torque 2.6±0.5 kg∙m

Front

When No.1 cylinder at TDC incompression stroke

6B

Front

When #1 piston at TDCcompression stroke.

6B

- 25 -

��CAUTION��Carefully keep away to be not

entried dust or alien

substance into injection pump

when adjust injecting timing.

��Check and Adjust of flange Mounted

Pump Injection Timing.

Flange mounted injection pump injection

timing checking and adjustment.

��Checking Procedure

1) Align the crankshaft pulley TDC mark with

the pointer.

Remove the inspection hole cover at the

front of the injection pump on the timing gear

case cover.

Check the alignment between the pointer ④

on the injection pump gear nut lock plate

and the projection area mark ③ on the

injection pump gear case.

If it is in misalignment, recheck with turning

the crankshaft pulley one more turn to repeat

the aforegoing procedure to mark sure to be

aligned.

Check the alignment of the notched lines ①

and ②.(These notched lines were aligned at

the plant to set injection pump body and

mounting flange.)

Make sure the position of next crank angle

of in jection starting.

2) Turn the crankshaft pulley counterclockwise

about 30�crankangle.

3) #1 plunger of injection can be visually sured

when disconnect injection pipe.

EJM1035S

EJM1038S

3

4

EJM1039I

EJM1040I

1.5.10. Injection Timing

- 26 -

6) Support fuel control lever at the wholly

opened position.

7) Continuely feed fuel with pumping priming

pump as slowly turning crankshaft clockwise.

Immediately stop to feed fuel when fuel stop

from #1 devilvery valve holder.

This crankangle position is the injection

starting of the engine.

8) Make sure that crankshaft pulley and point is

specifically injection starting angle line.

Blow out remained fuel from delivery valve

holder, and no feeded fuel from priming

pump.

��CAUTION��Applied engine for injection

timing are different, and

feel free contact to Branch,

Engingineering Technical

Service Center or Engine

Quality Service Team to

DAEWOO Heavy Ind., Ltd.,

and inform us serial

number.

EJM1042S

EJM1016I

TDC

EJM1044I

4) Remove the delivery valve holder ①, the

valve seat ②, valve spring ③ the delivery

valve ④ from the #1 plunger.

5) Assemble the devlivery holder (1) and

tighten specified torque.

Do not assemble delivery valve, valve

spring, valve seat and delivery valve.

These parts will be Reassembled later. EJM1041S

α�

- 27 -

��Adjusting Procedure

1) Align to crank pulley with specified mark and

pointer.

2) Practice 1) of 1.5.10, page 25.

3) Release fixed nuts to 4 injection pump.

4) When rapid injection timing,

rotate injection pump toward right side.

When reduce the injection timing,

rotate injection pump toward left side.

�Note�When mark slip 1mm, injection

timing differ about 2˚.

5) As operating of fuel feed pump, rotate

injection pump at the same time, and then

stop injection pump and fuel feed when stop

fuel from #1 delivery holder.

6) Fix fixed nut of 4 injection pump.

7) Tighten installed inside parts with specified

torque after remove #1 delivery valve holder.

8) Tighten installed injection pipe with specified

torque.

EJM1045S

9) Remove delivery valve holder from #1

plunger.

10) Assemble the delivery valve intenal parts at

the devilvery valve holder.

11) Assemble the delivery valve holder

assembly to #1 plunger and tighten with the

specified torque.

12) Assemblel the #1 cylinder injection pipe

and tighten with the specified torque.

��CAUTION��Tighten with the specified

torque.

Injection pump which was

manufactured aluminum,

so that why too much

tightening will be damaged

body and related parts.

EJM1041SDelivery Valve Holder Torque 4.25±0.25 kg∙m

Injection Pipe Nut Torque 3.1±0.2 kg∙m

① Holder

② Seat

③ Spring

④ Delivery Valve

Relaxity ofwhole nuts

- 28 -

1) Warm-up egine to be 75˚ C coolant

temperature.

2) Remove the preheating plug and injection

pipe.

3) Assemble the compressed gauge at the nuts

of preheating plug and injection pipe.

4) Read the calibration of compressed gauge

as rotating engine with start motor.

Standard Limit

31.0 kg/cm2(at 200 rpm) 26.0 kg/cm2(at 200 rpm)

5) Practice other cylinder as same sequence.

Every compression pressure shall be alike.

Inequality of compression is 2.0 kg/cm2 and

more, check related parts and replace it.

EJM1046S

EJM1047S

1.5.11. Compression Pressure Measurement

- 29 -

1) Check leakage at the connected part of

suction.

2) Check leakage at the connected part of

Intake manifold.

3) Check the leakage at tne connected part of

exhaust duct.

4) Check relaxity of trubocharger mounting

nuts.

5) Check the leakage at oil delivery pipe.

6) Check the leakage at oil return pipe joints.

EJM1048S

EJM1049S

EJM1050S

EJM1051S

EJM1052P

1.5.12. Inspection of Turbo charger

1.6. Engine Repair Parts (Standard Engine)

- 30 -

1. Cylinder head gasket 17. Gear case to cylinder block gasket

2. Cylinder head cover gasket 18. Cover to timing gear case gasket

3. Inlet manifold gasket 19. Relief valve O-ring

4. Exhaust manifold gasket 20. Cylinder block side plug gasket

5. Thermostat housing gasket 21. Water drain valve gasket

6. Thermostat gasket 22. Oil pump hole cover gasket

7. Tappet chamber cover gasket 23. Wate pump gasket

8. Tappet cover fixing bolt gasket 24. Oil pipe gasket

9. Crankshaft rear oil seal 25. Oil pipe gasket

10. Timing gear case oil seal 26. Fuel pipe joint bolt gasket

11. Valve guide oil seal 27. Leak off pipe joint bolt gasket

12. Oil pan gasket 28. Injection nozzle gasket

13. Drain plug gasket 29. Injection pump oil gasket

14. Oil filter cover gasket 30. injection pump oil pipe gasket

15. Oil filter fixing bolt gasket 31. Cylinder head cover nut gasket

16. Oil cooler gasket

EJM1053S

2. ENGINE DISASSEMBLY AND ASSEMBLY

2.1. Engine External Parts

�DB58

- 31 -

EJM2001I

�DB58T

- 32 -

EJM2002I

�DB58TI

- 33 -

EJM2003I

2.2. Disassembly

2.2.1. External Parts

�DB58

- 34 -

81

9

4

325

11

6

7

10

EJM2004I

<Disassembly Steps>

1. Cooling fan

2. Fuel retrun pipe

3. Fuel pipe: fuel filter to injection pump

4. Fuel pipe; feed pump to filter

5. Injection pipe

6. Injection nozzle

7. Oil pipe: oil filter- oil cooler

8. Injection pump

9. Fuel filter

10. Oil filter

11. Preheating plug

�DB58T

- 35 -

13 7 62

34 11

5

1

1012

9

8

EJM2005I

<Disassembly Steps>

1. Cooling fan

2. Intake pipe

3. Fuel retrun pipe

4. Fuel pipe: fuel filter to injection pump

5. Fuel pipe; feed pump to filter

6. I/P boocom hose (T)

7. Injection pipe

8. Injection nozzle

9. Oil pile: oil filter- oil cooler

10. Injection pump

11. Fuel filter

12. Oil filter

13. Preheating plug

�DB58TI

- 36 -

4

113 5

8

9

1210

1

6

7

2

EJM2006I

<Disassembly Steps>

1. Cooling fan

2. Fuel retrun pipe

3. Fuel pipe: fuel filter to injection pump

4. Fuel pipe; feed pump to filter

5. I/P boocom hose

6. Coolant inlet pipe in inter cooler

7. Coolant outlet pipe in outlet pipe

8. Injection pipe

9. Oil pile: oil filter- oil cooler

10. Injection pump

11. Fuel filter

12. Oil filter

2.2.2. External Parts Disassambly Steps

�DB58

- 37 -

61

5

4

2

3

EJM2007I

<Disassembly Steps>

1. Dipstick and guide tube

2. Starter motor

3. Fan belt

4. Generator

5. Fan plug

6. Cylinder Head cover

- 38 -

2

10

7 11

1

9

685

3

4

EJM2008I

<Disassembly Steps>

1. Dipstick and guide tube

2. Turbocharger oil return pipe

3. Turbocharger oil delivery pipe

4. Intake pipe

5. Turborcharger

6. Starter motor

7. Fan belt

8. Generator

9. Fan pulley

10. Breather

11. Cylinder head cover

�DB58T

- 39 -

612 1

114

513

2

738

10

9

EJM2009I

�DB58TI

<Disassembly Steps>

1. Dipstick and guide tube

2. Turbocharger oil return pipe

3. Turbocharger oil delivery pipe

4. Intake pipe

5. Turborcharger

6. Coolant pipe

7. Starter motor

8. Fan belt

9. Generator

10. Fan plug

11. Intercooler

12. Breather

13. Cylinder head cover

2.2.3. Main Structured Parts

�DB58/T/TI

- 40 -

EJM2010S

<Diassembly Steps>

1. Rubber hose ; coolant by-pass 9. Oil pump driving pinion

2. Rocker arm shaft assembly 10. Starting handle nut

3. Push rod 11. Taper bushing

4. Cylinder head bolt 12. Crankshaft pulley and dust thrower

5. Cylinder head assembly 13. Timing gear cover

6. Cylinder head gasket 14. Oil thrower

7. Coolant pump assembly 15. Fly wheel

8. Tappet chamber cover

★ : Repair Kit

- 41 -

Engine Assembly

Importance

��Rocker Arm Shaft

Orderly release rocker arm shaft fixed bolts.(as

shown in figure)

��Cylinder Head Bolts

Orderly release cylinder head bolts. (as shown

in figure)

��Crankshaft Pulley Nuts

Wrench: 54 mm

Adequately wrench when remove the crank

shaft pulley nut.

��Taper Bushing

Use the disassambleable tool when remove the

crank shaft pulley bushing.

��Flywheel

Orderly release the fly wheel. (as shown in

figure)

EJM2013S

EJM2014S

EJM2015S

EJM2016I

3 1

2

5 6

4

EJM2017S

Front

Crank shaftpulley

Wrench

Taperbushing

Crankshaft

Taper bushing remover

pulley

- 42 -

EJM2018S

<Diassembly Steps>

1. Oil Cooler

2. Oil Fan

3. Oil Pump and Coupling

4. Oil Fan

5. Fly wheel housing

6. Idler gear

7. Cam shaft

8. Tappet

9. Timing gear case

10. Idler gear shaft

11. Crank shaft bearing cap

12. Crank shaft bearing (lawer part)

13. Thrust bearing

14. Crank shaft

15. Crank shaft bearing (upper part)

16. Oiling jet (DB58T/TI)

2.2.4. Major Structured Parts II

�DB58

: Repair kit

- 43 -

��Importance

<Idler Gear>

Prior to disassamble, measure as following.

Standard Limit

Idler Gear End Play 0.058-0.115 mm 0.2 mm

Standard Limit

Timing Gears Backlash 0.10-0.17 mm 0.3 mm

Crank shaft gear & cam shaft gear equal to

idler gear and back lash.

Includes the crankshaft gear, the camshaft

gear, and the idler gear.

��Cam Shaft

Prior to disassamble, measure as following.

��Crankshaft Bearing Cap

Prior to disassmble, measure the crankshaft

end play at the thrust bearing.

EJM2019S

EJM2020S

EJM2021S

EJM2022S

Standard Limit

Cam Gear End Play 0.050-0.114 mm 0.2 mm

Standard Limit

Crankshaft End Play 0.15-0.33 mm 0.4 mm

Feeler gauge

Dial indicator

Feelergauge

Feeler gauge

Crankshaft

camshaftgear

Thrust plate

Camshaft

- 44 -

2.2.5. Rocker Arm, and Rocker Arm Shaft Disassembly Steps

EJM2023S

<Disassembly Steps>

1. Bracket 3. Spring

2. Rocker arm 4. Rocker arm shaft

- 45 -

2.2.6. Cylinder Head Disassembly Steps

�DB58

Importance

��Split collar

Use the valve spring compressor when remove

split collar

EJM2027S

EJM2024S

<Disassembly Steps>

1. Exhaust manifold and gasket 7. Spring seat (upper) or *Valve rotator

2. Intake manifold and gasket 8. Valve spring

3. Coolant outlet pipe 9. Spring seat (lower)

4. Thermostat 10. Valve

5. Thermostat housing and gasket 11. Valve stem oil seal

6. Sprint collar

Valve spring compressor

- 46 -

�DB 58T

EJM2025S

�DB 58TI

EJM2026S

7

8

9 2 11

3

4

5 101

6

7

8

9 2 11

12

3

4

5 101

6

- 47 -

2.2.7. Piston and Connecting Rod Disassembly Steps

EJM2028S

<Disassembly Steps>

1. Piston rings 4. Piston

2. Snap ring 5. Connceting rod bearing

3. Piston pin and connecting rod

<NA/T> <TI>

1

2

4

3

2

3

5

4

3

2

1

2

3

5

- 48 -

Importance

��CAUTION��Remove the piled up

carbon at the upper of

cylinder bore to be

prevented damage of

piston when remove.

��Piston Rings

Remove the piston ring with using of piston ring

disassambly tool.

��Snap Ring and Piston Pin

1) Use the snap ring pliers when remove the

snap ring.

2) Pull out piston pin as tapping of hammer and

brass bar.

EJM2029I

EJM2030I

EJM2031S

EJM2032S

Carbondeposits

Piston pin

Pistonringremover

- 49 -

2.3. Inspection and Repair

Adjust and repair if necessary, and replace

excessive wore or damaged parts which was

found when inspect.

2.3.1. Cylinder Head

��Plane Figure of Cylinder Head

1) Compose a plane figure by plane measure

from both side angles of cylinder head to

direction of diagonal.

2) You must be grinding when plane figure is

more than normal, however, replace the

cylinder head if escape from the grinding

scope.

<Plane figure of Cylinder Head>

<Height of Cylinder Head>

��CAUTION��You must check of valve

depression if ground

chylinder head.

��Test of Hydraulic Pressure for Water

Jacket

Sound pressure of water Jacket by the water

gauge to be maintain 5Kg/cm2 for 3 minutes.

Generally check for the coolant leakage.

EJM2033I

EJM2034S

EJM2035S

EJM2036S

Standard Limit Max. Grinding

0.05 mm 0.2 mm 0.3 mm

Standard Limit

89.95-90.05 mm 89.65 mm

- 50 -

��Measuring Method-1

1) After install of dial gauge needle as of

insterting valve stem, and set up calibrator to

"O". (as shown in figure)

2) Shake well valve head.

Record total dial indicator reading

to be valve stem and guide value.(TIR)

Valve and guide set must replace if

measured value was exceeded the specified

limit.

Inequality of outside valve stem diameter

and inside guide diameter is valve stem

clearance.

��Valve Stem Clearance

��Measuring Method-II

1) Measure valve stem outside diameter.

2) Measure valve guide inside diagram by

using of caliper calibrator or telescoping

gauge.

Inequality of outside valve stem diameter

and inside guide diameter is valve stem

clearance.

��Replacement of Valve Guide

<Removal of Valve Guide>

Pull out the valve guide by tne using of hammer

and valve guide remover from bottom of

cylinder head.

Interval is 14.1 mm from the bottom of the

cylinder head from the edge of valve guide top.

EJM2037S

EJM2038S

EJM2039S

EJM2040S

Standard Limit

Intake Side TIR 0.039-0.068 mm 0.20 mm

Exhaust Side TIR 0.064-0.093 mm 0.25 mm

2.3.2. Valve Stem and Valve Guide Clearance

Remover andinstaller

- 51 -

1

2

��Valve Depression

1) Install the valve ① to the cylinder head ②.

2) Measure valve depression by the using of

depth gauge or calibrator from the bottom of

cylinder head.

Seat insert and valve must replace i f the

measured value was exceeded the specified limit.

When replace of valve, the valve guide must

be surely replaced.

��Width of Valve Contact

1) Inspect the valve contact faces for the

roughness and unevenness.

Smoothly Make valve contact surfaces.

2) Measure width of valve contact.

Seat valve seat insert must replace i f the

measured value was exceeded the specified limit.

��Replacement of Valve Seat Insert

<Removal of Valve Seat Insert>

1) Arc weld entire inside circumference of the

valve seat insert ②.(See figure)

2) Cool valve seat insert for a few minutes

to be easily pulled out the valve insert.

3) Pull out the valve seat insert by the using of

screw driver.

4) Carefully remove the carbon and other alien

substance from the cylinder head insert bore.

<Installation of Valve Seat>

1) Carefully place Jig (1).

��CAUTION��Contact smoothed face of

valve seat insert.

2) Assemble valve insert as of slowly pressing

againt the jig with the bench press.

(To need press 25000 Kg more)

��CAUTION��Do not excessive press

with tne bench press.

It may be damaged the

valve seat insert.

EJM2041I

EJM2042I

EJM2043S

1

3

2

EJM2044I

Standard Limit.

Intake and Exhaust Valve Depression 1.0 mm 2.5 mm

Standard Limit

Valve Contact Width 1.5 mm 2.0 mm

- 52 -

150

30A

��Correction of Valve Seat Insert

1) Remove the carbon deposits from the valve

seat insert surface.

2) Remove the rough areas by the using of

valve cutter (15˚, 30˚ or 75˚)

Do not cut the valve insert too much.

��CAUTION��Use mediated handle of

valve cutter.

Do not move the handle

which is inside of valve

guide.

3) Spread compound on the surface of valve

insert .

4) Insert valve into valve guide.

5) Grinde the valve and valve seat with the

lapping cup.

6) Check contact surface of valve whether

good or not.

7) Check the contact condition of valve insert.

EJM2045I

EJM2046S

B

EJM2047I

EJM2048S

Angle Location Standard

Intake Valve Seat 45�

Exhaust Valve Seat 45�

- 53 -

• Valve Spring Free Length

Measure the valve spring with the vernier

caliper.

Replace the spring if measured the value

escaped from the specified limit.

• Gradient of Valve Spring

Measure the valve spring gradient by the using

of square.

Replace the valve spring if the measured value

is excessive from the specified limit.

•Tension of Valve Spring

Measure the valve tension by the using of

tension measure.

Replace the valve spring if the measured value

is excessive from the specified limit.

EJM2049I

EJM2050I

EJM2051S

2.3.3. Valve Spring

Standard Limit

Exhaust and Intake Valve49.0 mm 47.0 mm

Spring Free Length

Standard Limit

Valve Spring Gradient 1.3 mm less 2.7 mm

Standard Limit

Valve Spring Tension 14.5 ㎏ 11.5 ㎏

at 40 mm Set Length

- 54 -

Check the valve tappets whether excessive

wear and damage or not.

Measure the outside diameter of tappets with

the micrometer.

Measure the clearance between tappets and

cylinder motion parts by the using of dial

indicator

Measure the plane figure of push rod with the

feeler gauge.

Measure it as of slowly rolling push rod on the

flat of a hand. (See figure)

EJM2041I

EJM2052S

EJM2053I

EJM2054I

Standard Limit

Tappet Outside Diameter 27.97-27.98 27.92

Standard Limit

Tappet and Tappet Travelling0.020~0.054 mm 0.1 mm

Bore Clearance

Limit

Push Rod of Balanced Figure 0.3 mm

2.3.5. Push Rod

Pitting Clack Inferiorityof contact

Irregularity ofcontact

2.3.4. Tappet

- 55 -

Check of the valve stem contact part of roker

arm

Grind contact surface with an abradant if it is

irregualitly contacted.

Replace the rocker arm if it is extremely

damaged contact surface.

��Rockder Arm Shaft and Rocker Arm

Check the disassembled parts wehter damage

or not.

��Outside Diameter of Rocker Arm Shaft

Measure the outside diameter of rocker arm

with the micrometer.

Replace shaft if measured value escaped from

the specified limit.

Clearance of Rocker Arm Shaft and Rccker

Arm

1) Measure tne inside diameter of rocker arm

bushing with tne vernier caliper.

2) Measure the outside diameter of rocker arm.

Replace the rocker arm or rocker arm shaft if

measured value escaped from the specified

limit.

EJM2055S

EJM2056S

EJM2057S

EJM2058S

Standard Limit

Outside Diameter of Rocker Arm Shaft 18.98-19.00 mm 18.85 mm

Standard Limit

Inside Diameter of Rocker Arm Bushing 19.01-19.03 mm 19.05 mm

2.3.6. Rocker Arm Correction

- 56 -

3) Check the rocker arm oil port whether alien

substance is in it or not.

Clean the rocker arm oil port with an air if

necessary.

1) Replace the idler gear shaft if the measured

value escaped from the specified limit.

2) Measure the inside diameter of idler gear

with the dial indicator.

1) Use the jig when install or overhaul cam

shaft bearing at cylinder Block.

2) Measure clearance cam journal and cam

shaft bearing.

EJM2059I

EJM2060S

EJM2061I

EJM2062S

EJM2063S

Standard Limit

Rocker Arm Bushing and 0.01-0.05 mm 0.2 mmRocker Arm Shaft clearance

Standard Limit

Outside Diameter of 44.945-44.975 mm 44.9 mmIdler Gear Shaft

Standard Limit

Clearnance of Idler Gear 0.025-0.085 mm 0.2 mmand ldler Gear Shaft

Standard Limit

Clearance of Cam Journal 0.03–0.09 mm 0.15 mmand Cam Bearing

2.3.7. Idler Gear and Idler Gear Shaft

2.3.8. Cam Shaft

Jig

Cam bearing

- 57 -

3) Agree with oil port of the cam shaft and the

cylinder oil port.

4) Measure the cam lobe with the micrometer.

Replace the cam lobe if the measured value

escaped from the specified limit.

5) Set up the cam shaft at the measured jig.

Measure the run out of cam shaft with the

dial indicator.

Record the measured value (TIR)

Replace the cam shaft if the measured value

escaped from the specified limit.

EJM2064S

C

A

A

B B

D

I II I II

EJM2065I

EJM2066S

Standard Limit

Cam Lobe Height (C-D) 7.71 mm 7.21 mm

Cam Journal Diameter 56.0 mm 55.6 mm

Limit

Camshaft Run-Out (TIR) 0.12 mm

oil ports

- 58 -

3

1

Measurement of the Cylinder Liner Bore

Measure the bore from which is measured

location

(1) to direction of the crank shaft (3) and

counter direction (2).

Measured location: from the top of liner to

bottom 20 mm.

(Max. ware part)

Replace the cylinder liner if the measured

value escaped from specified limit.

��CAUTION��Inside of dry type cyliner

liner was electroplated with

chromium.

No honing and boring.

Scarred or damaged inside liner must replace it.

The casted liner is specially procedured honing without the plating

with chromium inside, so that why ring, plated with chromium ring

(Top ring and oil ring) must be used it.(importance)

�Inspection of the Cylinder Liner Projection

1) Set up the straight measure (1) at the top

part of liner.

2) Measure liner projection with the feeler gauge (2).

Inequality liner projection to other clylinder

must be less than 0.3mm.

Replacement of the Cylinder Liner

<Removal of Cylinder Liner>

1) Set up remover of the cylidner liner to cyliner

liner.

2) Check whether surely set up remover of the

cylinder liner at bottom of cylinder liner or

not.

EJM2067I

1

EJM2068I

EJM2069S

EJM2070S

2.3.9. Cylinder Block and Liner

Standard Limit

Diameter of Cylinder Liner Bore 102.021-102.060 mm 102.20 mm

Limit

Projection of cylinder Liner 0.03-0.10 mm

Remover

- 59 -

3) Slowly turn the remover shaft handle counter

clock-wise to pull the cylinder liner free.

��CAUTION��Be advised to be not

damaged the cylinder

block when remove the

cylinder liner.

Take care to be not damage the cylinder body

upper face when remove the cylinder liner.

��Measurement of Cylinder Bore

<Grade Selection of Cylinder Liner >

Select a grade as of seeing outside diameter of

the cylinder l iner and inside of block

combination.

Determine a grade of the cyliner liner after the

measured inside diameter of the cylinder block.

Unapproprated a grade of the cylinder

liner(Liner is less than cylinder block) do not

promote efficiency of cooling to be damaged

engine.

Too big cyliner liner will be difficulted to be

assembled.

��Measurement of Cylinder Body Inside

Diameter

1) Measure from #1 measuring point toward W-

W, X-X, Y-Y, Z-Z.

#1 Measuring Point: 115 mm

2) Average value for 4 measurements to be

moderately determined the liner grade.

EJM2071I

1

EJM2072I

EJM2073S

- 60 -

��Measurement of Cylinder Liner Outside

Diameter Measurement

1) Measure the liner outside diameter from (1),

(2) & (3) measuring point toward X-X, Y-Y.

Location of the Measurement(mm).

① 20.0

② 105.0

③ 195.0

2) Average value for 6 measurements to be

moderately determine the liner grade.

Combination of the cylinder bore and the

cylinder liner outside.

<Cylinder bore and cylinder liner outside diameter>

��Assembley of the Cylinder Liner

1) Cleanly wash both of the cylinder liner inside

& outside and block inside.

2) Cleanly wash both of liner and bore surface

with the light gasoline and the kerosene.

3) Cleanly wash tracks with the rag which was

printed when washing.

4) Insert the liner (1) to cyliner block (2).

EJM2074S

EJM2075S

EJM2076S

Grade Cylinder Bore Outside Diameter

1 105.990-106.000 105.973-105.984

2 106.00-106.010 105.984-105.995

- 61 -

2 1

��Selection of Piston Grade

See the piston diameter and the cylinder liner

combination about "pistion grade".

Correctly selected the pistion grade does

operate efficiency of engine to be protected

cylinder liner and piston.

Meassure the bore after assemble the cylinder

liner.

Determine piston grade after assemble liner.

• Measurement of Cylinder Liner Bore

1) To be measured 2 points.

Cylinder Liner Measuring Point ① : 20mm

Cylinder Liner Measuring Point ② : 105mm

2) Measure cylinder liner from (1), (2) & (3)

measuring point toward X-X, Y-Y, W-W, Z-Z.

3) Average value for 8 measurements.

Limit of Cylinder Liner Bore

102.021-102.060 mm

��CAUTION��It is most important to be

correctly graded combination.

It will be resulted a seizure

if uncorrected.

Always measure the

cylinder bore and the

select piston grade.

EJM2077I

- 62 -

1) Piston outside diameter vary depending on

the piston type to be used.

2) Measure the piston outside diameter. (see

figure 1 & 2).

3) Piston Grade

Cylinder Liner Bore and Piston Clearance :

0.053~0.077 mm

��CAUTION��The cylinder liner piston kit

clearances are preset.

However, the clylinder liner

installation procedure may

result in slight decreases

in the cylinder liner bore

clearances.

Correctly combinate after

measure the cylinder liner

bore clearance.

Piston And Piston Ring

��Piston Ring and Piston Ring Groove

Clearance

Measure the piston ring and the piston ring

groove clearance with a feeler gauge.

Measure it around of the piston.

Replace the piston ring if the measured value

escaped from the specified limit.

��Piston Ring and Piston Groove Clearance

EJM2078I

EJM2079S

EJM2080S

EJM2081S

2.3.10. Outside Diameter of Piston

Grade Limit

A 101.955-101.974 mm

B 101.975-101.994 mm

SteelStrut

Standard Limit

Top Ring 0.085-0.110 mm 0.20 mm

2nd Ring 0.030-0.055 mm 0.15 mm

Oil Ring 0.030-0.070 mm 0.15 mm

(3.228＂)

- 63 -

��Piston Ring Gap

1) Horizontally assemble the piston ring into

cylinder liner.(original place).

2) Push inverted the piston ring to be reached (1) & (2)

The cylinder liner diameter is the smallest at

these two points.

Perfectly horizontalize to set up without a

slant.

Cylinder Liner Measuring Point ① ; 10mm

Cylinder Liner Measuring Point ② ; 130mm

3) Measure piston ring gap with a feeler gauge.

Replace piston ring if the measured value

escaped from the specified limit.

��Piston Pin

<Piston Pin Outside >

Measure the various placed pin outside with

micrometer.

Replace the pin if the measured value escaped

from the specified limit.

��Piston Pin and Piston Clearance

Measure diameter of tne pin hole with inside

dial gauge.

EJM2082S

EJM2083S

EJM2084S

Standard Limit

Top Ring Gap 0.25-0.45 mm 1. 50 mm

2nd Ring Gap 0.20-0.40 mm 1. 50 mm

Oil Ring Gap 0.20-0.40 mm 1. 50 mm

Standard Limit

Piston Pin Outside Diameter 36.000-36.005 mm 35.95 mm

Standard

36.000-36.008 mm

- 64 -

��Piston Pin and Clearance of Piston Pin

Hole

Measure the pin and clearance of the pistion as

of measuring of pin hole diameter and pin

outside.

Measure it according to the below means if it is

difficult for a inisde dial gauge to measure.

1) Heat piston about 60˚C with the heater.

2) Push piston with the thumb.

Surely tightened to be inserted it.

EJM2085S

EJM2086S

Limit

Clearance of Piston Pin and Piston Pin Hole 0.050 mm

- 65 -

��Connecting Rod Alignment

Measure the changed between big end and

small end from the calibration of connecting rod

balancer.

Replace the connecting rod if the measured

value escaped from the specified limit.

Connecting Rod Balancer ( Standard 100 mm)

��Piston Pin and Small End Bushing

clearance

Measure an inside of small end pushing and

outside of pin with the caliper gauge and

micrometer.

Replace a connecting rod bush or piston pin if

the measured value escaped from the specified

limit.

1) Fix connecting rod to vice.

2) Pull out connecting rod bush as of the using

brass rod with the Press or hammer.

��Assemble of Connecting Rod Bush

Use special jig when assemble connecting rod

bush.

��CAUTION��Align connecting rod bush

oil port and connecting rod

oil port.

3) Grinde the piston pin hole with grinder or

adjustable pilot reamer.

EJM2087S

EJM2088S

EJM2089S

EJM2090S

2.3.11. Connecting Rod

Standard Limit

Balancer 0.05 mm 0.20 mm

Standard Limit

Clearance of Piston Pin & Bushing 0.010-0.030 mm 0.05 mm

Standard

Connecting Rod Bush Inside Diameter 35.017-35.025 mm

[Classification]

∙A type :

∙B type : or

- 66 -

��Check of Connecting Rod Bearing

1) Assemble the bearing to connecting rod cap.

2) Check the tension of connecting rod bearing.

Replace the bearing if it is lack of tension.

3) Tighten the connecting rod bearing cap with

the specified bolt torque.

4) Measure an inside of connecting rod bearing

with an inside of dial gauge.

2.3.12. Crankshaft

��Crank shaft and Bearing Inspection

Check of Crank shaft and bearing

1) Check the crank shaft journal surface pin

part whethere excessive wore and damaged

or not.

2). Check assembled front & rear end of oil

seal part for oi l seal assembled part

whethere exesive wore and damaged or

not.

3) Replace or repair the crank shaft when crank

shaft found excessive wore or damaged.

4) Check the obstruction of crank shaft oil port.

5) Blow hard high pressured air into oil port if

necessary.

��Crank shaft Journal and Crank pin

Outside Diameter

1) Measure the crank shaft journal outside

diameter with the micrometer torward ①-①

and ②-②.

2) Measure from 2 point ③ & ④ when measure

crank shaft journal outside diameter.

3) Repeatedly practice item 1 & 2.

Grind if the pin and journal measured value

escaped from the specified limit.

EJM2091S

EDM2044I

EJM2093S

A type B type

Bolt Torque 12±0.25 9.75±0.25

11

TY11T

TY12T

marked on bolt head

Inside of connecting rod bearing 64 mm

- 67 -

4) Determine the bearing clearance after the

measured crank shaft journal outside (or

outside pin) and inside bearing.

Grinde the crank shaft or replace bearing if

the crank shaft journal and bearing

clearance escaped from the specified limit.

��Crankshaft Journal Bearing Inside

Diameter

1) Tighten with the specified torque after

assemble cap to be forward inside arrow of

the bearing cap.

2) Measure main bearing diameter with the

inside dial gauge.

��Inside Diameter of Connecting Rod

Bearing

Measure the bearing inside diameter with the

specif ied dial gauge after the t ightened

connecting rod bearing.

EJM2094S

EDM2044I

Standard Limit

Crankshaft Journal and0.039-0.098 mm 0.11 mm

Main Bearing Clearance

Standard Limit

Crank pin and Connecting0.03-0.07 mm 0.10 mm

Rod Bearing clearance

Main Bearing Cap Torque 24.1±1 kg∙m

Main Bearing Diameter 80 mm

A type B type

Connecting Rod Cap12±0.25 9.75±0.25

Bolt Torpue

Classification ,

Connecting Rod 64.0 mm

Bearing Diameter

11TY11T

TY12T

Classification Standard

Crankshaft Journal outside Diameter 79.905-79.925mm

Standard

Crankshaft Pin outside Diameter 63. 924-63. 944 mm

- 68 -

��Crankshaft Run-Out

1) Mount the crankshaft on a set of V-blocks.

2) Set up the dial indicator to the center of

crankshaft journal.

3) Slowly rotate the crank shaft toward egine.

Read the dial indicator (TIR) as you turn the

crankshaft.

Replace the crank shaft if the crank shaft

measured value escaped from the specified

limit.

Check the repaired crank shaft after repaired,

and replace it if found cracked it.

��Main Bearing and Connecting Rod

Bearing Tension

Check to be maintained enough tension, and

set up its regular position with the finger

pressure.

��Grinding of Crankshaft

Pay attention the below described in order to

reuse the regrinded crank shaft.

��System of Crankshaft Regrinding

1) Grind the crank shaft journal part and pin

part.

2) Procedure "R" part of journl and pin min

R3.5±0.2 more .

Sucessively grinde when procedure 'R' part.

3) Procedure journal, pin and oil hole with R1,

and finish it with soft cotton.

4) Measure the clearance of journal and pin.

See page 68 about clearance of journal and

pin measurement.

5) Measure the crank shaft run-out.

EJM2095S

EJM2091S

EJM2096S

Standard Limit

Crankshaft Run-Out 0.05 mm 0.40 mm

Undersize Bearing 0.25 mm 0.50 mm

Journal and Surface Illumination 0.4μor less

R Part

less than 3

.8

- 69 -

��Grinding Limit of Crankshaft

Utilize the undersize bearing (0.25, 0.5 mm)

when the main bearing clearance was in

excess of limit.

Regrinde the crank shaft in comply with below

standard when it is used undersize bearing.

Use the undersize bearing (0.25, 0.5mm) when

the connecting rod bearing clearance was in

excess of limit.

Regrinde the crank shaft when it is used

undersize bearing.

��Crank Shaft Gear

<Overhaul>

Disassemble the crank shaft gear as the using

tool of crank shaft remover.

Visually inspect the crankshaft gear.

Replace the crankshaft gear if excessive wear

or damage is discovered.

<Inspection>

Replace the brand new parts when it is visually

found over wore or defect.

<Installation>

Utilize the tools for installation when it is

installing crank shaft gear.

EJM2097S

EJM2098S

Classification Limit

Crank Jouranl Outside Diameter 79.419 mm

Crank pin Outside Diameter 63.424mm

Standard Limit

Main Bearing0.039-0.098 mm 0.11 mm

Clearance

Standard Limit

0.03-0.07 mm 0.10 mm

Remover

Installer

Connecting

Rod Bearing

- 70 -

��Inspection of Ring Gear

Rightly replace the ring gear when it is found

over wore and damaged it

If the ring gear teeth are broken or excessively

worn the ring gear must be replaced.

<Replacement of Ring Gear>

<Disassembly of Ring Gear>

Disassemble the ring gear as tapping edge it

with a hammer and chisel.

Strike around the edges of the ring gear with a

hammer and chisel tore move it.

��Assemble of Ring Gear

1) Does thermal expansion as the heating ring

gear.

Pay attention that temperature of ring gear is

not high 200˚C.

2) Assemble ring gear to flywheel as tapping

with a hammer when it is enough heating.

��Oil Seal

<Disassemble>

Disassemble oil seal as it is using overhaul

tool.

<Assemble>

Assemble the oil seal to fly wheel housing as it

is an using oil seal assemble jig.

��Remove and Assemble of Front Oil Seal

<Disassembly>

Remove the oil seal as it is the using jig and

hammer.

<Assemble>

Assemble the oil seal as it is using assemble jig.

EJM2099S

EJM2100S

EJM2101S

EJM2102S

2.3.13. Flywheel and Flywheel Housing (Rear Oil

Seal)

2.3.14. Cover of Timing Gear Case

Installer

Installer

2.4. Reassembly

2.4.1. General Composed

- 71 -

EJM2103S

<Order of Assembly >

1. Piston 4. Piston ring

2. Piston pin and connecting rod 5. Connecting rod bearing

3. Snap ring

2

3

<NA/T> <TI>

- 72 -

��Piston and Connecting Rod

<Caution>

��Piston

Heat piston approximately 60˚C.

1) Agreely assemble the pistion and connecting

rod as it is seeing figure.

2) Assemble the piston and connecting rod with

the pin.

��Piston Pin Snap Ring

1) Assemble the pistion and piston ring as it is

the using snap ring flyer.

2) Check it whethere the piston and piston pin

is smoothly operated or not.

��Piston Ring

1) Assemble the piston ring as it is an using

piston ring assembly jig.

Systematically assembly piston ring as

follows:

(1) Oil ring

(2) 2nd compressed ring

(3) 1st compressed ring

Rightly assembly the indicated surface that

1st and 2nd compressed ring will be 'up'

Oil ring may be assembled any way because

it is not indicated.

2) Spread engine oil to surface of piston ring.

3) Check it whether piston ring is smoothly

rotating at the inside of piston ring home or

not.

��Connecting Rod Bearing

1) Assemble the connecting rod bearing to big

end and cap.

2) Assemble the connecting rod and

connecting rod bearing, and tighten cap bolt

as the spesfied torque.

3) Spread the engine oil to bearing.

EJM2104S

EJM2105S

EJM2031S

EJM2105I

EJM2106I

Heater of piston

Piston head

Systematical lyindicate cylinder

∙For casting liner chromium plating

∙For steel liner

Marked side up

1st comp

Top Ring

2st Ring

2st comp

Oil

oil ring

- 73 -

��Assembly parts of Cylinder Head

-DB 58/T

EJM2107S ★ : Repair Kit

<Order of Assembly>

1. Valve stem oil seal

2. Intake and exhaust valves

3. Spring seat(Lower)

4. Intake and exhaust value sping

5. Spring seat(Upper)

6. Split collar

7. Thermostat housing and gasket

8. Thermostat

9. Coolant outlet pipe

10. Intake manifold and gasket

11. Exhaust manifold and gasket

- 74 -

-DB 58TI

EJM2108S ★ : Repair Kit

<Order of Assembly>

1. Valve stem oil seal

2. Intake and exhaust valves

3. Spring seat(Lower)

4. Intake and exhaust value sping

5. Spring seat(Upper)

6. Split collar

7. Thermostat housing and gasket

8. Thermostat

9. Coolant outlet pipe

10. Intake manifold and gasket

11. Exhaust manifold and gasket

12. Intercooler

- 75 -

Warning

��Valve Stem Oil Seal

1) Spread the engine oil to oil seal and the

assembled part.

2) Assemble the valve stem oil seal as it is the

using jig.

��Intake and Exhaust Valves

1) Put up the cylinder head on plate.

2) Spread the engine oil to valve stem.

3) Assemble guide position when it is an

overhauling valve.

��Spring of Intake and Exhaust Vavle

Assemble the valve spring that it is the bottom

painted parts.

��Spring Seat Split Pin

1) Assemble the split pin with the spring

compressed jig as it is a pressing spring.

2) After assemble split pin, completely

assemble split pin as it is tapping with the

rubber hammer.

EJM2109S

EJM2110S

EJM2111I

EJM2112S

EJM2113S

jig

Painted parts

Compressed Spring

- 76 -

��Intake Manifold and Gasket

1) Assembly the intake manifold that

unchamfered corner is 'up' toward inside

engine.

2) After assemble intake manifold, and

systematically assemble the bolt with the

specified torque.(see figure)

��Exhaust Manifold and Gasket

1) Assemble the exhaust manifold and gasket

that it is seeing "TOP" at the front side.

2) After assemble the exhaust manifold, and

systematically assemble blots with the

specified torque.(see figure)

2) Assemble the spacer tube. (see figure)

EJM2114S

EJM2115S

TOP

EJM2116I

EJM2117S

EJM2118S

Intake Manifold Bolt Torque 2. 6±0.5 kg∙m

Exhaust Manifold Bolt Torque 2. 9±0.5 kg∙m

Rear of Unchamfered corner

Rear

Spacer tube

Spot face

- 77 -

��Assembly of Rocker Arm and Rocker Arm Shaft

Caution

��Rocker Arm Shaft

Assemble the rocker arm shaft to rightly be "upper" above the oil hole.

EJM2119S

<Order of Assembly>

1. Rocker arm shaft 3. Rocker arm

2. Spring 4. Bracket

- 78 -

2.4.2. Inside parts

��Main Components (I)

EJM2120S

<Order of Assembly>

1. Oiling jet(DB58T/TI) 9. Idler gear shaft

2. Crank shaft bearing 10. Idler gear

3. Crank shaft 11. Piston and ocnnecting rod

4. Thrust bearing 12. Oil pump and coupling

5. Crankshaft bearing and crank shaft bearing cap 13. Flywheel housing

6. Timing gear case 14. Oil pan

7. Tappet 15. Oil cooler

8. Camshaft

* Prior to assemble cam shaft, firstly assemble the tappet without fail.

★ : Repair Kit

- 79 -

��Oil Jet (DB58T)

Assemble the oil jet nozzle not so as to be

damaged it.

Caution

��Crank shaft Bearing (Upper Half)

��Crank shaft Bearing(Lower Half)

There are not oil port at centering of lower half

bearing, therefore

there are oil port and home at the other

bearing.

��Crank shaft

Assemble the crank shaft gear so as to be front

combined side.

��CAUTION��Make sure the part number

because it may be

difference upon engines.

��Thrust washer

Assemble thrust washer so as to be connected

oil home in the bearing to crank shaft side.

��Crank shaft Bearing Cap

1) Spread the engine oil at the bearing cap bolt.

2) Assemble the bearing cap at the crank shaft.

Rightly direct arrow to inside engine.

3) Systematically tighten bearing cap bolt as it

is a specified torque. (see figure)

EJM2121S

EJM2122S

EJM2123S

EJM2124S

EJM2125S

Oil Jet Torque 2.1±0.5 kg∙m

Oil port and oilhome (uppter part)

Rightly set up

No oil port and oilhome,Center part.

�Front

Front

Arrow

Oil home

- 80 -

4) Check it whether it is smoothly rotated the

crank shaft by hand or not.

��Timing Gear Case

Tighten timing gear case bolt with the specified

torque.

��Cam shaft

Tighten thrust plate bolt so as to be fixed cam

shaft gear port.

��Idler Gear Shaft

Assemble an idler gear shaft as it is utilizing

thrust collar fixing bolt so as to be rightly

directed oil port toward cam shaft side.

��Idler Gear

1) Assembly of idler gear.

Assemble the gear so as to be agreely every

timing mark of ABC.

Assembly thrust collar that the chamfered

side will be front side.

EJM2126S

EJM2127S

EJM2128S

EJM2129S

EJM2130S

Tightened Torque 24. 0±1 kg∙m

Tightened Torque 2.6±0.5 kg∙m

Thrust Plate Bolt Torque 2.6±0.5 kg∙m

Camshaft Gear Bolt Torque 16±1.5 kg∙m

Torque 5.5±1 kg∙m

Spread of Engine Oil

Cam shaft gear

Oil port

Injection Pump GearIdle gear

Mark "B"

Mark "C"

Mark "A"

Crank shaft gear

Camshaftgear

- 81 -

��Piston and Connecting Rod

Settle a clearance of piston ring. (see figure)

1) Fix a clearance of piston ring (see figure)

2) Spread the engine oil to piston, pinston ring,

connecting rod bearing.

3) Front piston mark to be directed in front of

engine.

4) Utilize the piston ring compresser when

assemble pistion.

5) Pull in pistion until connect crank pin by a

handle of hammer.

Rotate the crank shaft so as to be reached

bottom dead center (BDC).

6) Agreely assemble the connecting rod

bearing cap with the connecting rod cylinder

number.

Assemble the classified depend upon kind of

bolt as following.

��Assembled Oil Pump

Assemble the oil pump at the filled up oil at the

pump.

EJM2131S

EJM2132S

EJM2133S

EJM2134S

Piston ring compresser

CylinderNumber

Torque(kg∙m) 12±0.25 9.75±0.25

Classified

,(Bolt head)

Treated surface oxidized steel phosphoric acid & basic film.

11TY11T

TY12T

- 82 -

��Flywheel Housing

Tighten bolt as it is specified torque after it is

pasted sealant at the black face in the figure.

��Oil Pan

1) Install an oil fan after put on oil fan gasket at

the spreaded sealant at the inveral between

cyliner block and oil fan.

��Oil Cooler

Orderly assemble the oil cooler bolt after set up

the spreaded sealant at the oil cooler gasekt.

EJM2135S

EJM2136S

EJM2137S

EJM2138S

Oil Pump Bolt Torque 5.3±1.0 kg∙m

Torque 2.6±0.5 kg∙m

Torque 2.6±0.5 kg∙m

Outer Bolt 2.6±0.5 kg∙m

Inner Bolt 16.1±1 kg∙m

Coupling

Liquid gasket(for face of cylinderbody only)

Touque

- 83 -

�� Major Component Reassembly Parts (II)

- DB58/T

EJM2139S★ : Repair Kit

<Reassembly Steps>

1. Rubber hose

2. Push rod

3. Rocker arm and rocker arm shaft

4. Cylinder head bolt

5. Cylinder head ass’y

6. Cylinder head gasket

7. Water pump

8. Tappet chamber cover

9. Oil pump driving pinion

10. Crankshaft pulley nut

11. Taper bushing

12. Crankshaft pulley and dust thrower

13. Timing gear cover

14. Oil thrower

15. Flywheel

- 84 -

- DB58TI

EJM2141S★ : Repair Kit

<Reassembly Steps>

1. Rubber hose

2. Push rod

3. Rocker arm and rocker arm shaft

4. Cylinder head bolt

5. Cylinder head

6. Cylinder head gasket

7. Water pump

8. Tappet chamber cover

9. Oil pump driving pinion

10. Crankshaft pulley nut

11. Taper bushing

12. Crankshaft pulley and dust thrower

13. Timing gear cover

14. Oil thrower

15. Flywheel

- 85 -

Importance

��Flywheel

1) Apply engine oil on the flywheel bolt.

2) Orderly tighten the fly wheel bolt.(see figure)

��Injection Pump

Tighten the injection pump bolt as it is a

specified torgue after assemble the injection

pump that it was agreed idler gear angle "C"

carving seal and injection pump driving gear

angle "C".

��Crank shaft pulley nut

Tighten a nut with wrench.

EJM2142S

EJM1029S

EJM2130S

EJM2144S

EJM2145S

Bolt Torque 22.3±2.2 kg∙m

Bolt Torque 2.6±0.5 kg∙m

Torque 60.0±5.0 kg∙m

��Tappet Chamber Cover

Tighten a bolt spread sealant at the gasket.

Torque 2.6±0.5 kg∙m

Injection pumpgear Idler gear

�B�mark

�C�markCamshaftgear�A�mark

Crankshaft gear

Camshaftgear

Lubricate with enging oil

pulley

wrench

- 86 -

��Water Pump

Prior to put on the gasket, spread a sealant.

��Cylinder Head Gasket

Be up mark "Top" and down mark "front".

��Assembled Cylinder Head

Orderly and repeatly tighten after it is spreaded

engine oil at the cylinder head, as shown in

figure.

��Assembly Rocker Arm Shaft

Orderly tighten the rocker arm bolt as shown in

figure.

Adjust valve clearance

Refer to section 1.5.9

EJM2146S

EJM2147S

EJM2148S

EJM2149S

EJM2150S

Standard(mm) Limit(mm)

115 116.2

102 103.2

1st step 2nd step

hexagon bolt 7.0 kg∙m 11.5+0.5

dodecaon bolt 4.0 kg∙m 90�+60�(0~30�)

torque

Torque 3.1±0.5 kg∙m

Spreading Sealant

Front, Mark TOP

Front

Front

��Limited value of dodecaon bolt

- 87 -

2.4.3. External Parts(A)

• DB58

61

5

4

2

3

EJM2170I

<Reassembly Steps>

1. Cylinder head cover

2. Fan pulley

3. Generater

4. Fan belt

5. Starter motor

6. Dipstick and guide tube

- 88 -

�DB58T

2

10

7 11

1

9

685

3

4

EJM2171I

<Reassembly Steps>

1. Cylinder head cover 7. Turbocharger

2. Breather 8. Turbocharger oil delivery pipe

3. Fan pulley 9. Turbocharger oil return pipe

4. Generate 10. Dipstick and guide tube

5. Fan belt 11. Intake pipe

6. Starter motor

- 89 -

�DB58TI

132 11

712

81

10

695

3

4

EJM2153I

<Reassembly Steps>

1. Cylinder head cove 8. Turbocharger

2. Breather 9. Turbocharge oil return pipe

3. Fan pulley 10. Turbocharge oil delivery pipe

4. Generator 11. Dipstick and guide tube

5. Fan belt 12. Intake pipe

6. Starter motor 13. Coolant hose

7. Inter cooler

- 90 -

��Cylinder Head Cover

Orderly tighten the bolt as it is shown in figure.

��Fan Belt

Adjust the fan belt tension

See the item "maintenance".

��Starter Motor

Tighten with the specif ied torque after

assemble a starter motor to fly wheel housing.

��Turbocharger Mounting Flange Gasket

Carefully posit the gasket with the edged side

facing up.

��Turbocharger

Tighten in the interim torborcharger nut.

Completely tighen the nut after it is assemble

oil pipe.

EJM2154S

EJM2155S

EJM2156S

EJM2157S

Bolt Torque 2.1±0.5 kg∙m

Torque 8.4 kg∙m

Torque 5.3±1 kg∙m

- 91 -

��Oil Drain Pipe

1) Disassemble the exhaust manifold spacer

which it is just bottom of the torbo charger

part so as to be easily set up oil drain pipe.

2) Tighten the flange nut as it is the specified

torque after it is assemble oil return pipe.

3) Tighten it as it is specified torque after

reinstalled the exhaust manifold spacer tube.

(See page 71)

��Oil Feed Pipe

1) Pre-lubricate turbo charger with CD grade oil

through the oil port shown by the arrow in

the illustration.

2) Tighten flange bolt as it is a specified torque

after it is assemble oil delivey pipe.

EJM2158S

EJM2159S

Oil drain pipe torque 3.8±0.7 kg∙m

Oil return pipe bolt torque 2.6±0.5 kg∙m

SpacerTube

- 92 -

2.4.4. External Parts (B)

�DB58

411

3

8

9107

1

6

5

2

EJM2160I

<Reassembly Steps>

1. Preheating plug 7. Fuel pipe

2. Oil filter 8. Fuel pipe (Feed pump to fuel filter)

3. Fuel filter 9. Fuel pipe (Fuel filter to injection pump)

4. Injection pump 10. Fuel return pipe

5. Oil pipe (Oil filter to oil cooler) 11. Cooling fan

6. Injection nozzle

- 93 -

�DB58T

1 7 812

1110 3

9

13

42

5

6

EJM2168I

<Reassembly Steps>

1. Preheating plug 8. I/P boocom hose (T)

2. Oil filter 9. Fuel pipe; feed pump to filter

3. Fuel filte 10. Fuel pipe: fuel filter to injection pump

4. Injection pump 11. Fuel retrun pipe

5. Oil pile: oil filter- oil cooler 12. Intake pipe

6. Injection nozzle 13. Cooling fan

7. Injection pipe

- 94 -

�DB58TI

10

211 9

5

4

13

13

8

7

612

EJM2169I

<Reassembly Steps>

1. Oil filter 8. Coolant inlet pipe in inter cooler

2. Fuel filter 9. I/P boocom hose

3. Injection pump 10. Fuel pipe; feed pump to filter

4. Oil pile: oil filter- oil cooler 11. Fuel pipe: fuel filter to injection pump

5. Injection piper 12. Fuel retrun pipe

6. Inter cooler 13. Cooling fan

7. Coolant outlet pipe in outlet pipe

- 95 -

Importance

��Injection Nozzle

Ajdust the injection opening pressure with an

adjustment screw which is utilizing the nozzle

tester.

Utilize a new gasket and dust cover when it is

assemble the nozzle.

��Fuel Injection Pipe

Surely tighten the delivery valve holder as it is

a specified torque.

It will be reason to leakage from the control

rack and pipe if it is in excessive tightening.

��Oil Filter

��Fuel Pipe

Tighten the joint bolt as it is a specified torgue

when it is setting up fuel pipe not so as it is a

changed to combine check bolt or valve joint.

Install the intake pipe and tighten the intake

pipe flange bolts to the specified torque.

��Suction Pipe

EJM2163S

EJM2164S

EJM2165I

EJM2166S

EJM2167S

Torque 1.9±0.2 kg∙m

Torque 3.1±0.2 kg∙m

Torque 4.3 ~ 6.3 kg∙m

Torque 1.7±0.1 kg∙m

��Adjustment of Injection Timing

See 1.5. "maintenance".

Torque 2.6±0.5 kg∙m

Dust cover

Nozzle gasket

3. SYSTEM OF LUBRICATION

3.1. General Description

- 96 -

EJM3001I

(27)

(25)(24)(23) (26)

DB58T/TI

(19) (20) (21) (22)(18)(17)

(11)

(10)

(9)

(15)(14)

(16)

(13)

(7)(5)

(6)

(2)

(1)

(1) Oil filter

(2) By-pass valve

(Opening pressure 1kg/cm2)

(5) Paper filter

(6) By-pass valve

(Opening pressure 2kg/cm2)

(7) Oil cooler

(9) Oil relief(Opening pressure 7kg/cm2)

(10) Oil pump

(11) Oil strainer

(13) Oil pressure and oil filter warning lamp

(14) Starter switch

(15) Battery

(16) Oil pressure switch

(17) Crank shaft bearings

(18) Cam-shaft bearings

(19) Timing dile gear

(20) Injection Pump

(21) Turbo charger

(22) Oiling jet(Opening pressure 2.2kg/cm2)

(23) Oil relief valve

(Opening pressure 4.5kg/cm2)

(24) Conn. rod bearings

(25) Cyl. head valve system

(26) Piston

(27) Oil pan

- 97 -

3.2. Oil Pump

�Disassembly

EJM3002S

<Order of disassembly>

1. Strainer 4. Pinion

2. Suction pipe 5. Drive shaft and gear

3. Cover and dowel 6. Pinion gear shaft

4

6

6

3

2

1

- 98 -

• Inspection and repair

Visually Inspect the disassembled parts for the

excessive wear and damage.

Correct or replace if it is found the worn and

defect when check it.

Check the disassembled parts for the damaged

parts of defect.

Use a feeler gauge to measure the clearance

between the oil pump cover (oil pump case)

inside surface and the driven gear.

If the clearance exceeds the specified limit, the

drive gear and/or the oil pump cover must be

replaced.

Clearance between oil pump drive gear and

inside of cover.

Limit of Oil Pump Cover and Oil Pump Drive Gear Clearance 0.18 mm

Clearance of oil Pump Driven Gear and oil

pump body

Reassembly

Reassambly shall be inverted from the

disassambled.

EJM3003S

EJM3004S

EJM3005S

Limit 0.12 mm

- 99 -

3.3. Oil Cooler

��Disassembly

EJM3008S

<System of Disassembly>

1. Element (NA 3 plates. T/TI 4 plates) 4. O-ring ; plug

2. Element gasket 5. By-pass valve spring

3. By-pass vlave plug 6. By-pass valve

Inspection and Repair

Correct and replace if it is found the worn, defect or others when check it.

1

6

5

4

3

2

- 100 -

EJM3009S

EJM3010S

<Reassembly order>

1. By-pass valve 4. By-pass valve plug

2. By-pass valve spring 5. Element gasket

3. O-ring : plug 6. Element(DB58 3plates. T/Ti 4plales)

��Dil cooler element tigthening bolts

Tighten the bolts with the specified torque after

assemble an oil cooler element.

��Reassembly

Reassembly shall be inverted inverted from the disassambled.

Torque 2.6±0.5 kg∙m

6

1

2

3

4

5

4. COOLING SYSTEM

4.1. General Description

�DB58T

- 101 -

EJM4001I

�DB 58TI

EJM4002I

RadiatorReserve tank

Water pump

Cylinder block

Cylinder head

Thermostat

Water pipe

RadiatorReserve tank

Water pump

Cylinder block

Cylinder head

Thermostat Intercooler

Water pipe

- 102 -

4.2. Coolant Pump

Disassembly

�DB 58/T

EJM4003S

<Disassembly order>

1. Pulley 5. Pulley Flange

2. Cover 6. Snap ring

3. Gasket 7. Seal

4. Impeller 8. Impeller shaft

6

5

7

8

4

3 2

1

- 103 -

Disassembly

�DB 58TI

EJM4004S

<Disassembly order>

1. Pulley 6. Snap ring

2. Cover 7. Seal

3. Gasket 8. Impeller shaft

4. Impeller 9. Pipe

5. Pulley Flange

7 4

3 2

5

89

1

- 104 -

Importance

��Impeller

Remove the impeller with the jig.

��Hub

Remove the pulley center as it is moderately

pressing with the bench press.

��Snap Ring

Remove the snap ring with the snapping plier.

��Unit Bearing

Remove the unit bearing as it is moderate with

the bench and press.

��Seal Unit and Washer Seal

Remove the seal unit as it is moderate with the

bench and press.

EJM4005S

EJM4006S

EJM4007S

EJM4008S

EJM4009S

Remover

Bench press

Hub

- 105 -

��Inspection And Repair

Correct and replace if it is found the worn,

defect or others when check it.

<Unit Bearing>

EJM4011I

- 106 -

Reassemblys

• DB58/T

EJM4013S

<Reassembly order>

1. Unit Bearing 5. Impeller

2. Seal 6. Gasket

3. Snap Ring 7. Cover

4. Pulley Fiange 8. Pulley

7

76

52

1

8

3

4

- 107 -

Reassembly

• DB58TI

EJM4014S

<Reassembly order>

1. Unit Bearing 6. Gasket

2. Seal 7. Cover

3. Snap Ring 8. Pulley

4. Pulley Flange 9. Pipe

5. Impeller

19

7

2

3

4

8

5

6

- 108 -

Importance

��Unit Bearing

By until izing bench press set up the unit

bearing at the pump.

��Snap Ring

Assemble the snap ring with the snap ring plier.

��Pulley Center

Assemble pulley center with the bench press.

��Washer and Seal Unit

Assemble it with the bench press after is is

spreaded the sealant to pump body contacting

surface.

EJM4011I

EJM4007S

EJM4015S

EJM4016S

EJM4017S

Spreading of multipurposable grease

Outside from sealed surface

Spreading ofsealant

- 109 -

��Impeller

Assemble impeller to be in specified clearance

between impeller and body with rock bench

press.

��Pulley

Tighten the pulley bolt As it is a specified

torque.

4.3. Thermostat

��Inspection and Repair

Correct and replace if it is found the worn,

defect or others when check it.

See item "maintenance"

EJM4018S

EJM4019S

EFM2055I

Standard 0.3 - 0.8 mm

Torque 2.6±0.5 kg•m

Bench press

Feeler gauge

Agitating rod

Thermometer

Woodpiece

- 111 -

5.2. Fuel Filter

��Disassembly

EJM5003S

<Disassembly Steps>

1. Drain plug 5. Fuel filter element

2. Center bolt 6. Spiring seat

3. Fuel fiter body 7. Spring

4. Body cover gasket

Refer to Page 19 of the "Maintenance" for information on the cartridge type fuel

filter.

Inspection and repair

Make the necessary adjustments, rapairs, and part replacements if excessive wear or

damage is discovered during inspection.

Reassembly

To reassembly the fuel filter, follow the disassembly procedure in the reverse order.

3

2

1

7

★

★

★ 5

6

7

4

★ : Element kit

- 113 -

��Reassembly

Reassembly shall be inverted from the disassembled.

EJM5008S

<System Reassembly>

1. Nozzle holder body 7. Pushrod spring

2. Connector gasket 8. Spring seat

3. Injection pipe connector 9. Nozzle adjusting screw

4. Injectin nozzle 10. Cap nut gasket

6. Nozzle holder push rod 11. Nozzle holder cap nut

5.3. Injection Pump

5.3.1. Adjustment of Injection quantity.

��CAUTION��Injection quantity shall be adjusted as

it is seeing adjustment data of

injection pump model as described

"A".

5.3.2 Calibration data

�DB58

<Test conditions>

- 115 -

101605-91000000000000000000000Pump NO.- 000000000

S6A95C410RS2000LICENCE BOSCH

EJM5014I

Injection pump 101605-9630

Injection nozzle D.K.K.C.P.No. 105025-1380

Injection nozzle holder D.K.K.C.P.No. 105160-4650

Nozzle opening pressure 180 kg/cm2

Injection pipe demensions INNER DIA. 1.6mmXOUTER DIA. 6 mm -

LENGTH 580 mm

Transter pump pressure 1.6 kg/cm2

Testing diesel fuel ISO 4

Operating temperature 40~50°C

<Governor Adjustment>

0

B

E

C

A

340480

415350 850 970 11751115

9.8

9.19.4

6.3

6.4

+_ 0.1

0.3

+_0.

1

+_ 20

14OR MORE

EJM5015I

- 117 -

�� DB58TI

<Test condition>

Injection pump 101605-9480

Injection nozzle D.K.K.C.P.No. 105025-1390

Injection nozzle holder D.K.K.C.P.No. 105160-4660

Nozzle opening pressure 185 kg/cm2

Injection pipe demensions INNER DIA. 1.8mmXOUTER DIA. 6 mm -

LENGTH 580 mm

Transter pump pressure 1.6 kg/cm2

Testing diesel fuel ISO 4

Operating temperature 40~50°C

<Governor Adjustment>

0

B

E

D

C A

230 550 1000 1080

9.7(9.5)

2.36.7

450 +_

_

20

+++

_ 203020

2

14OR MORE

R

2R

EJM5017I

RACK LIMIT

IDLING SUB SPRING SET

BOOST COMPENSATOR STROKE 0.25±0.1mm

GOVERNOR SPRING SET

RACK P

OSIT

INO

N(m

m)

101605-96100000000000000000000Pump NO.- 000000000

S6AD100B410RLICENCE BOSCH

EJM5021I

- 119 -

5.3.4. Governor Disassembly

EJM5019S

1. Governor housing 80. Cover 182. Tension lever shaft

4. Plate 82. Bolt 183.Collar

6. Adapter ; pump housing 83. Bolt 190. Control-lever

7. Bolt 100. Fly weight 192. Nut

9. Spring eye 101. Woodruf key 195. Return spring

10. Bolt 102. Spring washer 198. Spring washer

13. Nut 103. Nut 201. O-ring

19. Adaptor 117. Sleeve 202. Bush

20. Bolt 118. Shim 203. Shim

21. Gasket 130. Governor spring 205. Shaft lever

35. Governor cover 132. Starting spring 207. Support lever

38. Tension lever bolt 136. Nut 211. Snap ring

39. Nut 137. Gasket 220. Damper spring

44. Speed lever stop bolt 138. Cap 236. Gasket

46. Cap 140. Idling spring assembly 239. Gasket

47. Tension lever shaft plug 141. Nut 240. Lead seal

48. Full-load adjusting bolt 150. Speed setting lever 241. Wire : lead seal

49. Nut 170. Guide leve assembly 255. Bracket

50. Lever stop bolt 173. Split pin 331. Angleich spring assembly

51. Bolt 174. Floating leve link 332. Connection nut

52. Bolt 181. Tension lever

136 220

202

18247

201203

190 198 192

195

5148

82255

49 39

52

35

44 174

173

141 332

211 207 205

117

103 102 100 10

192120

140

331

38137138

47 237

83

82

80 23850 13

118

181 130 150

183 170132

101

10 9

7 1

4 236 6

6. EINGINE ELECTRICALS

6.1. Starter motor

��Main data and specifications

- 120 -

EJM6001S

Center bracket Magnetic switch

Rear bracket

Connect bar

Thru bolt

Dowel pipe

Yoke

Shift lever

Pinion clutch

Pinion stopper

Thru bolt

Front bracket

Rated voltoge 24V

Rated output 4.5KW/2.5KW

Rating 30 sec

Direction of rotation clockwise

(viewed from the pinion side)

Operating speed More than 6500 rpm(No load)

More than 1600 rpm(Load)

��Construction

- 121 -

6.2. Alternator

��Specifications

EJM6002S

Type 3 phase AC alternator

Rated voltage 24V

Rated output 45A/60A

Max. allowable speed 8000 rpm

Polarity grounded Negative(-)

Direction of rotation Clockwise(viewde from pulley side)

Weight 6.1 kg (7.6 kg)

��Generator

<Disassembly steps>

1. Lock nut 7. Roter assembly 13. Brush spring

2. Pulley 8. Stator assembly 14. Brush

3. Fan 9. Rear side cover assembly 15. Key

4. Front cover 10. Diod assembly(+) 16. Bearing lock nut.

5. Ball bearing 11. Diod assembly(-) 17. Washer

6. Thre bot 12. Brush holder assembly 18. Bolt

7. TURBO CHARGER

��General Description

- 122 -

EJM7001S

EJM7002S

RHB6A

RHB7

- 123 -

IHI turbor charger nameplate is furnished

important imfomration for date manufactured

and service.

Nameplate shall be directly toward arrow.

The below described statement is recorded on

turbor charger nameplate.

(1) Size number of torbor charger, month and

year manufactured,

(2) Date manufactured & serial number,

(3) Part number.

EJM7003S

EJM7004S

Ass'y 3539678

Serial NO. H2064771

Customer 3539679

Moder HY35

HOLSET

EJM7005I

RHC7

- 124 -

��Rotor Shaft Axial Play Measurement

1) Assemble dial indicator at the turbine

housing as the shown in figure.

2) Use dial indicator to measure the rotor shaft

axial play with the moving shaft push and

pull. Read the total indicator reading(TIR).

3) Replace the shaft if the measured value is in

excessive of specified limt.

��Rotor Shaft Radial Play Measurement

1) Turn over the turbo charger with the turbine

exhaust inlet flange facing up.

2) Install a dial indicator to measure the rotor

shaft radial play.

Use the dial indicator to measure the play.

Read the TIR.

3) Replace the shaft if the measured value is in

excessive of specified limit.

EJM6006S

EJM6007S

7.1. Inspection of Rotor Shaft

Limit

Rotor Shaft Axial Play (TIR) 0.11 mm

RHB6A Limit

Rotor Shaft Radial Play (TIR) 0.19 mm

RHC7, RHB7 Limit

Rotor Shaft Radial Play (TIR) 0.215 mm

8. CAUSE OF TROUBLE, DIAGNOSIS AND TROUBLESHOOTING

1) Starting Trouble

- 125 -

Statement Cause Remedy

Start Motor (1) Magenetic switch does not operate when turn starter swicth Trouble of circuit

1. Distribution inferiority, disconnection, connection inferiority, Correction

2. starter switch connection inferiority Replacement

3.Coil disconnection of magenetic switch, strain Replacement

4. bend of flanger shaft Correction or replacement

5. fixed humidity part of flanger. Correction or replacement

(2) Magnetic switch operate, but pinion does not clamp with ring gear.

1. Defect of amateur shaft bearing Correction or replacement

2. Pinion & ring gear was excessive wore, changed. Correction or replacement

3. Shortage of battery Charge or replacement

4. Inferiority of Pinion moving Wash

5. Flanger & connector shaft fixed Correction or replacement

(3) Pinion clamped with ring gear, but engine does not turn

1. Pinion clutch skip Replacement

2. Amateur field coil strain Replacement

3. Brush & communicator inferiority Correction or replacement

4. Shortage of battery Charge or replacement

5. Earth inferiority correction

Fuel System (1) Fuel does not feed from feed pump

Trouble 1. No fuel Replenish

2. Clogged fuel tank strainer Wash

3. Clogged fuel tank or air in fuel line correction

4. Defect of fuel feed pump valve Replacement

5. Feed pump piston & push rod fixed Correction or replacement

6. Clogged fuel pump strainer Wash

(2) Fuel does not inject from injection pump

1. Clogged fuel filter element Replacement

2. Continually opened over flow valve of fuel filter Replacement

3. Air in fuel filter or injection pump Removal air

4. flanger, delivery valve fixed Correction or replacement

(3) Unfitness of fuel injector

1. Injection timing Inferiority correction

2. Unfitness of fuel timing correction

3. cam or cam shaft excessive wore Replacement

(4) Injection nozzle does not operate

1. Needle valve fixed Correction or replacement

2. Leakage between nozzle and needle valve Correction or replacement

3. Unfitness of injection pressure

- 126 -

Statement Cause Remedy

Insufficient of compression pressure (1) Damage of cylinder head gasket, replacement

(2) Piston, piston ring or cylinder liner wore, replacement

(3) Piston ring Strain, replacement

(4) Unfitness of valve clearance, adjustment

(5) Valve and seat connection inferiority, adjustment

(6) Valve stem attachment replacement

(7) Wearing tension of valve spring or damage replacement

2) Abnormal of Operation

Statement Cause Remedy

Abnormal of idle (1) Injection timing inferiority, adjustment

(2) Injection pipe relax adjustment

(3) Injection nozzle defect correction or replacement

(4) Unequal fuel injection volume correction

(5) Slow motion of control rack correction or replacement

(6) Unsmooth of flanger operation correction or replacement

(7) Correctlnessless connection of Control pinion and control rack correction or replacement

(8) Air suction of injection pump removal

Abnorml drive at Low (1) Governer idling spring bend correction or replacement

intermediate speed (2) Governer spring tension weakness correction or replacement

Unstopable at high (1) Bend of linkage cable between accel pedal and injection pump correction

speed drive (2) Bend of injection pump control correction

3) Shortage of Engine out put

Statement Cause Remedy

Continuelly short (1). Uncorrection of valve clearance correction

of eingine out put (2) Valve closing inferiority correction or replacement

(3) Defect of cylinder head gasket replacement

(4) Piston ring wear and fix correction

(5) Uncorrection of injection timing correction

(6) Shortage of fuel valume correction

(7) Unsuitable of nozzle injection presure or strain correction or replacement

(8) Defect of fuel feed correction or replacement

(9) Fuel pipe system clog correction

(10) Shortage of suction valume Maintain of air cleaner

(11) Throttle valve operation inferiority correction or replacement

(12) Clutch skip correction or replacement

(13) Brake inferiority correction or replacement

Shortage of out put (1) Shortage of compression pressure Engine overhaul

when accelerate (2) Unsuitable of injection timing adjustment

(3) Unfuction of injection pump timer correction or replacement

- 127 -

Statement Cause Remedy

(4) Nozzle injection pressure or unsuitable of injection angle correction or replacement

(5) Decline function feed pump correction or replacement

(6) Shortage of suction valume Maitenance of air cleaner

(7) Throttle valve fix correction or replacement

Overheat (1) Shortage of coolant Suppliment & check of leakage

(2) Weakness of tension of radiator cap pressure valve spring replacement

(3) Radiator core system clog correction or replacement

(4) Oil cooler system clog replacement

(5) Fan belt release, wear or damage correction or replacement

(6) Thermostat operation inferiority replacement

(7) Water pump operation inferiority replacement

(8) Uncorrect of injection timing adjustment

(9) Cylinder head gasket defect replacement

4) Noise of Engine

Statement Cause Remedy

Crank shaft (1) bigger of oil clearance due to bearing or crank shaft wear grind crank shaftbearing or replacement

(2) Crank shaft side wear grind crank shaftor replacement

(3) Oil port system clog Wash

(4) Bearing strain replacement & grind crank shaft

Conn. rod & (1) Connecting rod bearing wear replacement

bearing (2) Crank pin side wear grind or replacement

(3) Connecting rod bend replacement

(4) Bearing seize grind or replacement

Piston, piston pin (1) Piston & bigger of oil clearance due to piston ring wear crank shaft grind or replacement

and pinston ring (2) Piston or piston pin wear replacement

(3) Piston strain replacement

(4) Piston ring damage replacement

Other (1) crank shaft throttle bearing wear replacement

(2) cam shaft end pulley bigger replacementthrottle bearing

(3) Idle gear end pulley bigger replacement throttle collar

(4) Timing gear backlash being excessive replacement

(5) Uncorrect of valve clearance adjustment

(6) valve strained into valve guide replacement

(7) Valve spring damage replacement

(8) valve seat insert defect adjustment

(9) Tappet, cam excessive wear replacement

(10) rokcer arm & rocker am shaft excessiver wear replacement

- 128 -

5) Fuel consumption excessive

Statement Cause Remedy

Trouble of (1) Uncorrect of injection timing adjustment

fuel system (2) Fuel injection excessive valume adjustment

Other (1) clutch skip correction or replacement

(2) brake inferiority correction or replacement

(3) unsuitable tire pressure adjustment

(4) unsuitable of gear selection seelection gear due to load

6) Excessive oil consumption

Statement Cause Remedy

Oil leakage (1) release of every connected parts tighten

(2) gasket inferiority replacement

(3) cylinder head gasket defect replacement

Lack of oil (1) valve stem and oil seal inferiority replacement

(2) valve stem or valve guide excessive wear replacement

Plenfitul of oil (1) excessive clearance between piston and cylinder wall replacement

(2) piston ring and ring home excessive wear replacement

(3) piston ring damage, wear or fix replacement

(4) Uncorrect setting of piston ring gap adjustment

(5) Uncorrect set up of piston ring adjustment

(6) Oil controlling return home clog replacement

(7) air breather clog wash

7) Exhaust Escessive Smoke

Statement Cause Remedy

Excessive white (1) Too late of injection timing adjustment

smoke (2) lack of compressor pressure mentioned

"difficult of start"

(3) Mixed water in fuel replacement fuel

(4) leakage of oil due to lose of fuel correction

(5) Engine and excessive cooling drive adjustment

(6) fuel injection excessive volume adjustment

Ecessive black (1) air cleaner element clog wash or replacement

smoke (2) completely unopended Intake shutter valve replacement or adjustment

(3) Screwed intake house or to be flatted adjustment or replacement

(4) lact of compression pressure mentioned "engine out put lack

(5) Too fast of injection timing adjustment

(6) fuel injection excessive volume adjustment or replacement

(7) Injection shape inferiority of nozzle adjdustment or repalcement

(8) unsuitable of valve clearance adjustment