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