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 1.2. Engine Specifications 1.3. Torque Specifications 1.4. Main Part Fixing Nuts And Bolts 1.5. Maintenance 1.6. Engine Repair Parts(Standard Engine) 1.7. Recommended Lubricants

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

2.1. External Parts Disassembly 2.2. Key Components Disassembly 2.3. Inspection and Repair 2.4. Reassembly

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

3.1. General Description 3.2. Oil Pump 3.3. Oil Cooler

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

4.1. General Description 4.2. Coolant pump 4.3. Thermostat

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

5.1. General Description 5.2. Fuel filter 5.3. Injection Nozzle

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

Engine Model Items Engine type Combustion chamber type Cylinder liner type Timing gear system Number of piston ring No. of cylinder-borestroke (mm) Total piston displacement (cc) Compression ratio Engine dimensions (lengthwidthheight)(mm) Engine weight (dry) (kg) Fuel injection order Fuel injection timing (B.T.D.C static) Type of fuel used Fuel filter type Injection pump type Governor type Injection nozzle type Fuel injection pressure (kg/cm2) Compression pressure (kg/cm )
2

DB 58

DB 58T

DB58TI

Water cooled, 4 cycle, vertical in-line, overhead valve Direct injection Dry type Gear drive type Compression ring 2, oil ring 1 6-102118 5,785 17.4 : 1

1122648775 455

1172671886 497 1-5-3-6-2-4

1172683928 505

18

13

13

High speed diesel fuel (SAE No. 2) Cartridge type Bosch in-line A type (for industrial) Bosch in-line AD type (for Automotive)

Mechanical governing (RLD, RSV type) Multi hole type 185 31 (at 200RPM) 850 0.4(at cold) 130/2800 38/1600 132ps/2200rpm 45kgm/1600rpm 162ps/2200rpm 60kgm/1600rpm 1100

Idle speed (RPM) Intake and exhaust valve clearance (mm) Max. power Max. torque Lubrication method Oil pump type Oil filter type Piston cooling method Lubrication oil capacity () Oil cooler type Cooling method Cooling water capacity () Water pump Thermostat type Battery(V) Alternator (V-A) Starter (V-KW)

Pressurized circulation Gear type Full flow, cartridge or center bolt type Oil zet cooling type 19 Water cooled Pressurized forced circulation 12 Belt driven impeller type Wax pellet type 24 24-60 24-4.5 20.5

-2-

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 : kgm)

Bolt identification

4
4T (Low carbon steel) 0.60.2 1.30.5 2.80.7 6.251.2 8.751.9 13.32.7 19.23.8 26.35.3 33.08.3 45.89.2 2.70.7 5.81.2 9.11.8 12.72.5

7
7T (High carbon steel) 0.750.2 1.750.5 3.750.9 7.751.5 11.852.3 17.303.5 24.905.0 34.406.9 46.259.2 58.2014.0 3.70.9 7.21.4 11.22.2 16.53.3

9
9T (Alloy steel)

Bolt diameter pitch (mm) M 61.0 M 81.25 M101.25 M121.25 M141.5 M161.5 M181.5 M201.5 M221.5 M242.0 *M101.5 *M121.5 *M142.0 *M162.0

2.00.7 5.01.3 9.651.9 14.502.9 20.404.1 29.305.9 40.408.1 54.1010.8 70.6014.1 4.91.2 9.11.8 13.62.2 19.53.9

Note : The marked (*) bolts which are made with the soft materials, e.g., cast-iron products shall be used for a female screw part.

-3-

1.4. Main Part Fixing Nuts And bolts

Cylinder Head and Cover (Unit : kgm)

2.10.5

11.505. (hexagon bolt) : (Torque Control Method) 4 Kg m + 90+60(0~30) (docoecagon bolt) : (Angle Control Method) 5.31

2.70.25 (19.51.8) preheating plug

5.31

EJM1001S

-4-

Cylinder Block (Unit : kgm)

5.31

2.60.5

2.60.5

2.60.5

24.11

2.10.5

EJM1002S

-5-

Oil Pan and Dipstick (Unit : kgm)

2.90.3

2.60.5

8.01.0

EJM1003S

-6-

Cam Shaft and Rocker Arm (Unit : kgm)

3.10.5

3.10.5

2.60.5

2.60.5

161.5 Engine oil application

5.51

EJM1004S

-7-

Crankshaft, Piston, and Flywheel (Unit : kgm)

A type : 120.25 B type : 9.250.25

Mark : ON BOLT HEAD or

B type

A type

605 22.32.2

EJM1005S

-8-

Thermostat and Thermostat Housing (Unit : kgm)

2.60.5

5.31

5.31

EJM1006S

-9-

Intake and Exhaust Manifold(DB58) (Unit : kgm)

2.60.5

2.90.3

EJM1007S

- 10 -

Intake and Exhaust Manifold(DB58T) (Unit : kgm)

5.31.0

2.60.5

EJM1008S

- 11 -

Intake and Exhaust Manifold(DB58TI) (Unit : kgm)

2.90.3

2.60.5

EJM1009S

- 12 -

Timing Gear Case and Flywheel Housing (Unit : kgm)

2.60.5

2.60.5

16.01.0 Outside

16.01.0

2.60.5 Inside

EJM1010S

- 13 -

Oil Cooler, Oil Filter and Oil Pump (Unit : kgm)

5.31.0

5.31.0

5.31.0

2.60.5

2.60.5

EJM1011S

- 14 -

Fuel System (DB58, DB58T) (Unit : kgm)

1.90.2

1.30.2

3.10.2

1.70.1

4.20.8

4.20.8

EJM1012S

- 15 -

Fuel System(DB58TI) (Unit : kgm)

1.90.2

1.30.2

3.10.2

1.70.2

4.20.8

EJM1013S

- 16 -

Turbo Charger and Related Parts (DB58T) (Unit : kgm)

2.60.5 3.80.7 5.31.0

3.10.5 3.80.7

EJM1014S

- 17 -

Turbo Charger and Related Parts (DB58TI) (Unit : kgm)

3.80.7 2.60.5 5.31.0

3.10.5

3.80.7

EJM1015S

- 18 -

1.5. Maintenance
1.5.1. Replacement of Oil Filter
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.
EJM1018I Drain Plug Cartridge

Set the Filter Wrench

<Upword type> 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.
EJM1019I

<Downword type>

1.5.2. Replacement of Fuel 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

- 19 -

<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.
EJM1021S

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.
EJM1022I
6 2 4 5 3 1

Center Bolt Type <Removal> 1) Loosen the drain plug to drain thd fuel from the fuel filter. 2) Loosen the center bolt to remove the filter body , the spring , the washer , the gas ket , and the filter element . 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.
EJM1020S

- 20 -

1.5.3. Injection Nozzle

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.

EJM1023S

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. DB58 Injection Starting Pressure 181 kg/cm2 DB58T 185 kg/cm2 DB58TI 185 kg/cm2
EIO3008S

EJM1024S

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.

EJM1025S

EJM1026S

- 21 -

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

EJM1027S

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)

EJM1028S

1.5.4. Feed of Pump Strainer

1) Release joint bolt A 2) Remove strainer with screwdriver, and wash strainer with light gasoline.

A
EJM1029S

Strainer

1.5.5. Separator of Leakage (Add if Necessary)

Check leakage separator on the surface. Release plug at the bottom part to be eliminated when indicate warning point on the surface. Elimination Plug Torque 1.20.3 kgm

EJM1030S

Warning surface Floating Elimination plug

EJM1031S

- 22 -

1.5.6. Air Bleeding

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.
EJM1032S

EJM1033I

1.5.7. Cooling System

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 and the alternator pulley . 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
EJM1034I About Depress here

10mm

1.5.8. Thermostat
Inspection Visualy inspect the thermostat. When inspect,if excessive wear or damage is discovered, replace thermostat.
Bar Thermo meter

measure the valve lift. Amount of Valve Lift Valve Opening Temperature 10.0 mm
EFM2055I

Wood Plate

80 ~ 84 - 23 -

1.5.9. Valve Clearance and Adjustment

CAUTION Tighten due to every means when tighten cylinder head bolts. No retighten bolt before adjust of valve

clearance.

EDM1003S

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.
EDM1003S EJM1035S

Intake and Exhaust Valve Clearance(cold)

0.40 mm
Front

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.

6B

When No.1 cylinder at TDC in compression stroke EJM1036S

Front

6B

Rocker Arm Screw Lock Nut Torque

2.60.5 kgm
EJM1037S

When #1 piston at TDC compression stroke.

- 24 -

1.5.10. Injection Timing

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 on the injection pump gear nut lock plate and the projection area mark 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 and .(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
EJM1038S EJM1035S

4
EJM1039I

3) #1 plunger of injection can be visually sured when disconnect injection pipe.

EJM1040I

- 25 -

4) Remove the delivery valve holder , the valve seat , valve spring the delivery valve 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. 6) Support fuel control lever at the wholly opened position.
EJM1041S

EJM1042S

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.

EJM1016I

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
EJM1044I

TDC

number.

- 26 -

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. Delivery Valve Delivery Valve Holder Torque 4.250.25 kgm
EJM1041S

Holder

Seat Spring

12) Assemblel the #1 cylinder injection pipe and tighten with the specified torque. Injection Pipe Nut Torque 3.10.2 kgm

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. 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 Relaxity of whole nuts

- 27 -

1.5.11. Compression Pressure Measurement

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.

EJM1046S

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.
EJM1047S

- 28 -

1.5.12. Inspection of Turbo charger

1) Check leakage at the connected part of suction.

EJM1048S

2) Check leakage at the connected part of Intake manifold.

EJM1049S

3) Check the leakage at tne connected part of exhaust duct.

4) Check relaxity of nuts.

trubocharger mounting

EJM1050S

5) Check the leakage at oil delivery pipe.

EJM1051S

6) Check the leakage at oil return pipe joints.

EJM1052P

- 29 -

1.6. Engine Repair Parts (Standard Engine)

EJM1053S

1. Cylinder head gasket 2. Cylinder head cover gasket 3. Inlet manifold gasket 4. Exhaust manifold gasket 5. Thermostat housing gasket 6. Thermostat gasket 7. Tappet chamber cover gasket 8. Tappet cover fixing bolt gasket 9. Crankshaft rear oil seal 10. Timing gear case oil seal 11. Valve guide oil seal 12. Oil pan gasket 13. Drain plug gasket 14. Oil filter cover gasket 15. Oil filter fixing bolt gasket 16. Oil cooler gasket

17. Gear case to cylinder block gasket 18. Cover to timing gear case gasket 19. Relief valve O-ring 20. Cylinder block side plug gasket 21. Water drain valve gasket 22. Oil pump hole cover gasket 23. Wate pump gasket 24. Oil pipe gasket 25. Oil pipe gasket 26. Fuel pipe joint bolt gasket 27. Leak off pipe joint bolt gasket 28. Injection nozzle gasket 29. Injection pump oil gasket 30. injection pump oil pipe gasket 31. Cylinder head cover nut gasket

- 30 -

2. ENGINE DISASSEMBLY AND ASSEMBLY

2.1. Engine External Parts
DB58

EJM2001I

- 31 -

DB58T

EJM2002I

- 32 -

DB58TI

EJM2003I

- 33 -

2.2. Disassembly
2.2.1. External Parts
DB58

3 11 5 2 4

8 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

- 34 -

DB58T

2 13 8 5 7 6 3 4 11

1 10

12
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

- 35 -

DB58TI

3 11 4

5 2 7 6

8 9

1 10 12
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

- 36 -

2.2.2. External Parts Disassambly Steps

DB58

6 1

2 5

EJM2007I

<Disassembly Steps> 1. Dipstick and guide tube 2. Starter motor 3. Fan belt 4. Generator 5. Fan plug 6. Cylinder Head cover

- 37 -

DB58T

10 2

11 7 1 9

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

- 38 -

DB58TI

12 6

11 5

13 2

10

EJM2009I

<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

- 39 -

2.2.3. Main Structured Parts

DB58/T/TI

: Repair Kit EJM2010S

<Diassembly Steps> 1. Rubber hose ; coolant by-pass 2. Rocker arm shaft assembly 3. Push rod 4. Cylinder head bolt 5. Cylinder head assembly 6. Cylinder head gasket 7. Coolant pump assembly 8. Tappet chamber cover 9. Oil pump driving pinion 10. Starting handle nut 11. Taper bushing 12. Crankshaft pulley and dust thrower 13. Timing gear cover 14. Oil thrower 15. Fly wheel

- 40 -

Engine Assembly
Importance Rocker Arm Shaft Orderly release rocker arm shaft fixed bolts.(as shown in figure)

EJM2013S

Cylinder Head Bolts Orderly release cylinder head bolts. (as shown in figure)

Front

EJM2014S

Crankshaft Pulley Nuts Wrench: 54 mm Adequately wrench when remove the crank shaft pulley nut.

Crank shaft pulley

Wrench EJM2015S

Taper Bushing Use the disassambleable tool when remove the crank shaft pulley bushing.

Taper bushing

Crankshaft pulley Taper bushing remover EJM2016I

Flywheel Orderly release the fly wheel. (as shown in figure)

3 5 2 4 1 6

EJM2017S

- 41 -

2.2.4. Major Structured Parts II

DB58

: Repair kit
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)

- 42 -

 Importance <Idler Gear> Prior to disassamble, measure as following. Standard Idler Gear End Play 0.058-0.115 mm Limit 0.2 mm
Feeler gauge

EJM2019S

Standard Timing Gears Backlash 0.10-0.17 mm

Limit 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.
Dial indicator EJM2020S

Cam Shaft Prior to disassamble, measure as following.

camshaft gear

Thrust plate

Standard Cam Gear End Play 0.050-0.114 mm

Limit 0.2 mm
Feeler gauge EJM2021S

Camshaft

Crankshaft Bearing Cap Prior to disassmble, measure the crankshaft end play at the thrust bearing.

Feeler gauge

Standard Crankshaft End Play 0.15-0.33 mm

Limit 0.4 mm

EJM2022S

Crankshaft

- 43 -

2.2.5. Rocker Arm, and Rocker Arm Shaft Disassembly Steps

EJM2023S

<Disassembly Steps> 1. Bracket 2. Rocker arm 3. Spring 4. Rocker arm shaft

- 44 -

2.2.6. Cylinder Head Disassembly Steps

DB58

EJM2024S

<Disassembly Steps> 1. Exhaust manifold and gasket 2. Intake manifold and gasket 3. Coolant outlet pipe 4. Thermostat 5. Thermostat housing and gasket 6. Sprint collar 7. Spring seat (upper) or *Valve rotator 8. Valve spring 9. Spring seat (lower) 10. Valve 11. Valve stem oil seal

Importance Split collar Use the valve spring compressor when remove split collar

Valve spring compressor EJM2027S

- 45 -

DB 58T

6 7 8 9 2 11

5
EJM2025S

10

DB 58TI 6 7 8 9 12 2 11

5
EJM2026S

10

- 46 -

2.2.7. Piston and Connecting Rod Disassembly Steps

1 4 2 3 2 2 3 4

1 2

<NA/T>

<TI>

EJM2028S

<Disassembly Steps> 1. Piston rings 2. Snap ring 3. Piston pin and connecting rod 4. Piston 5. Connceting rod bearing

- 47 -

Importance CAUTIONRemove the piled up

carbon at the upper of cylinder prevented bore to be of

Carbon deposits

damage

piston when remove.

EJM2029I

Piston Rings Remove the piston ring with using of piston ring disassambly tool.
Piston ring remover

EJM2030I

Snap Ring and Piston Pin 1) Use the snap ring pliers when remove the snap ring.

EJM2031S

2) Pull out piston pin as tapping of hammer and brass bar.

Piston pin

EJM2032S

- 48 -

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> Standard 0.05 mm Limit 0.2 mm Max. Grinding 0.3 mm
EJM2033I

<Height of Cylinder Head> Standard 89.95-90.05 mm Limit 89.65 mm

EJM2034S

CAUTIONYou must check of valve depression if ground

chylinder head.

EJM2035S

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.

EJM2036S

- 49 -

2.3.2. Valve Stem and Valve Guide Clearance

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 Standard Intake Side TIR Exhaust Side TIR Limit
EJM2037S

0.039-0.068 mm 0.064-0.093 mm

0.20 mm 0.25 mm

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.
EJM2038S

EJM2039S

Interval is 14.1 mm from the bottom of the cylinder head from the edge of valve guide top.

Remover and installer

EJM2040S

- 50 -

 Valve Depression 1) Install the valve to the cylinder head . 2) Measure valve depression by the using of depth gauge or calibrator from the bottom of cylinder head. Seat insert and valve must replace if the measured value was exceeded the specified limit. When replace of valve, the valve guide must be surely replaced. Standard Intake and Exhaust Valve Depression 1.0 mm Limit. 2.5 mm
EJM2041I

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 if the measured value was exceeded the specified limit.
EJM2042I

Standard Valve Contact Width 1.5 mm

Limit 2.0 mm

Replacement of Valve Seat Insert <Removal of Valve Seat Insert> 1) Arc weld entire inside circumference of the valve seat insert .(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). CAUTIONContact 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) CAUTIONDo not excessive press with tne bench press. It may be damaged the valve seat insert. - 51 EJM2044I EJM2043S

3 1

 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.

150 A 30

EJM2045I

Angle Location Intake Valve Seat Exhaust Valve Seat

Standard

45 45

CAUTIONUse 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.
EJM2047I B EJM2046S

EJM2048S

- 52 -

2.3.3. Valve Spring

Valve Spring Free Length Measure the valve spring with the vernier caliper. Replace the spring if measured the value escaped from the specified limit. Standard Exhaust and Intake Valve Spring Free Length 49.0 mm Limit 47.0 mm
EJM2049I

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. Standard Valve Spring Gradient 1.3 mm less Limit 2.7 mm
EJM2050I

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. Standard Valve Spring Tension at 40 mm Set Length 14.5 Limit 11.5
EJM2051S

- 53 -

2.3.4. Tappet
Check the valve tappets whether excessive wear and damage or not.

Pitting

Clack

Inferiority of contact

EJM2041I

Irregularity of contact

Measure the outside diameter of tappets with the micrometer. Standard Tappet Outside Diameter 27.97-27.98 Limit 27.92

EJM2052S

Measure the clearance between tappets and cylinder motion parts by the using of dial indicator Standard Tappet and Tappet Travelling Bore Clearance
EJM2053I

Limit 0.1 mm

0.020~0.054 mm

2.3.5. Push Rod

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) Limit Push Rod of Balanced Figure 0.3 mm
EJM2054I

- 54 -

2.3.6. Rocker Arm Correction

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.

EJM2055S

Rockder Arm Shaft and Rocker Arm Check the disassembled parts wehter damage or not.

EJM2056S

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. Standard Outside Diameter of Rocker Arm Shaft 18.98-19.00 mm Limit 18.85 mm
EJM2057S

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. Standard Inside Diameter of Rocker Arm Bushing 19.01-19.03 mm Limit 19.05 mm
EJM2058S

- 55 -

Standard Rocker Arm Bushing and Rocker Arm Shaft clearance 0.01-0.05 mm

Limit 0.2 mm

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.
EJM2059I

2.3.7. Idler Gear and Idler Gear Shaft

1) Replace the idler gear shaft if the measured value escaped from the specified limit. Standard Outside Diameter of Idler Gear Shaft 44.945-44.975 mm Limit 44.9 mm

EJM2060S

2) Measure the inside diameter of idler gear with the dial indicator. Standard Clearnance of Idler Gear and ldler Gear Shaft 0.025-0.085 mm Limit 0.2 mm

EJM2061I

2.3.8. Cam Shaft

1) Use the jig when install or overhaul cam shaft bearing at cylinder Block. 2) Measure clearance cam journal and cam shaft bearing. Standard Clearance of Cam Journal and Cam Bearing 0.030.09 mm Limit 0.15 mm
EJM2062S Jig

Cam bearing

EJM2063S

- 56 -

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

oil ports

EJM2064S

4) Measure the cam lobe with the micrometer. Replace the cam lobe if the measured value escaped from the specified limit. Standard Cam Lobe Height (C-D) Cam Journal Diameter 7.71 mm 56.0 mm Limit 7.21 mm 55.6 mm
EJM2065I
A C D B A B
I II I II

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. Limit
EJM2066S

Camshaft Run-Out (TIR)

0.12 mm

- 57 -

2.3.9. Cylinder Block and Liner

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. Standard Limit
EJM2067I

3 1

Diameter of Cylinder Liner Bore 102.021-102.060 mm 102.20 mm

CAUTIONInside 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)
EJM2068I

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). Limit Projection of cylinder Liner 0.03-0.10 mm
EJM2069S

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.

Remover

EJM2070S

- 58 -

3) Slowly turn the remover shaft handle counter clock-wise to pull the cylinder liner free. CAUTIONBe 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 liner 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.
EJM2071I

Measurement of Cylinder Body Inside Diameter 1) Measure from #1 measuring point toward WW, X-X, Y-Y, Z-Z. #1 Measuring Point: 115 mm 2) Average value for 4 measurements to be moderately determined the liner grade.
EJM2072I

EJM2073S

- 59 -

 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). 20.0 105.0 195.0
EJM2074S

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> Grade 1 2 Cylinder Bore 105.990-106.000 106.00-106.010 Outside Diameter 105.973-105.984 105.984-105.995

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).

EJM2075S

EJM2076S

- 60 -

 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 : 20mm Cylinder Liner Measuring Point : 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
EJM2077I
2 1

CAUTIONIt is most important to be correctly graded combination. It will be resulted a seizure if uncorrected. Always cylinder measure bore and the the

select piston grade.

- 61 -

2.3.10. Outside Diameter of Piston

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 Grade Limit
EJM2078I Steel Strut

A B

101.955-101.974 mm 101.975-101.994 mm

Cylinder Liner Bore and Piston Clearance : 0.053~0.077 mm CAUTIONThe cylinder liner piston kit clearances are preset.
EJM2079S

(3.228)

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 Standard Top Ring 2nd Ring Oil Ring 0.085-0.110 mm 0.030-0.055 mm 0.030-0.070 mm Limit 0.20 mm 0.15 mm 0.15 mm
EJM2080S

EJM2081S

- 62 -

 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 ; 10mm Cylinder Liner Measuring Point ; 130mm 3) Measure piston ring gap with a feeler gauge. Replace piston ring if the measured value escaped from the specified limit. Standard Top Ring Gap 2nd Ring Gap Oil Ring Gap 0.25-0.45 mm 0.20-0.40 mm 0.20-0.40 mm Limit 1. 50 mm 1. 50 mm 1. 50 mm
EJM2082S

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. Standard Piston Pin Outside Diameter Limit
EJM2083S

36.000-36.005 mm 35.95 mm

Piston Pin and Piston Clearance Measure diameter of tne pin hole with inside dial gauge. Standard

36.000-36.008 mm

EJM2084S

- 63 -

 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. Limit Clearance of Piston Pin and Piston Pin Hole 0.050 mm
EJM2085S

Measure it according to the below means if it is difficult for a inisde dial gauge to measure. 1) Heat piston about 60C with the heater. 2) Push piston with the thumb. Surely tightened to be inserted it.

EJM2086S

- 64 -

2.3.11. Connecting Rod

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) Standard Balancer 0.05 mm Limit 0.20 mm
EJM2087S

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. Standard Limit
EJM2088S

Clearance of Piston Pin & Bushing 0.010-0.030 mm 0.05 mm 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. CAUTIONAlign connecting rod bush oil port and connecting rod oil port. 3) Grinde the piston pin hole with grinder or adjustable pilot reamer. Standard Connecting Rod Bush Inside Diameter 35.017-35.025 mm
EJM2089S

EJM2090S

- 65 -

 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. A type Bolt Torque [Classification] A type : 11 TY 11T marked on bolt head TY 12T 120.25 B type 9.750.25
EJM2091S

B type :

or

4) Measure an inside of connecting rod bearing with an inside of dial gauge. Inside of connecting rod bearing 64 mm
EDM2044I

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 oil 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 - and -. 2) Measure from 2 point & 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.
EJM2093S

- 66 -

Classification Crankshaft Journal outside Diameter

Standard 79.905-79.925mm Standard

Crankshaft Pin outside Diameter

63. 924-63. 944 mm

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. Standard Crankshaft Journal and Main Bearing Clearance Limit

0.039-0.098 mm 0.11 mm

Standard Crank pin and Connecting Rod Bearing clearance 0.03-0.07 mm

Limit 0.10 mm

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. Main Bearing Cap Torque Main Bearing Diameter 24.11 kgm 80 mm
EJM2094S

Inside Diameter of Connecting Rod Bearing Measure the bearing inside diameter with the specified dial gauge after the tightened connecting rod bearing. A type Connecting Rod Cap Bolt Torpue Classification Connecting Rod Bearing Diameter 120.25 B type 9.750.25 TY 11T TY 12T

EDM2044I

11

64.0 mm

- 67 -

 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. Standard Crankshaft Run-Out 0.05 mm Limit 0.40 mm
EJM2095S

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.

EJM2091S

Grinding of Crankshaft Pay attention the below described in order to reuse the regrinded crank shaft. Undersize Bearing 0.25 mm 0.50 mm

System of Crankshaft Regrinding 1) Grind the crank shaft journal part and pin part. 2) Procedure "R" part of journl and pin min R3.50.2 more . Sucessively grinde when procedure 'R' part. 3) Procedure journal, pin and oil hole with R1, and finish it with soft cotton. Journal and Surface Illumination 0.4 or less
R Part EJM2096S less than 3.8

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.

- 68 -

 Grinding Limit of Crankshaft Classification Crank Jouranl Outside Diameter Crank pin Outside Diameter Limit 79.419 mm 63.424mm

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. Standard Main Bearing Clearance 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. Standard Connecting Rod Bearing 0.03-0.07 mm Limit 0.10 mm 0.039-0.098 mm Limit 0.11 mm

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.
EJM2097S Remover

<Installation> Utilize the tools for installation when it is installing crank shaft gear.

EJM2098S

Installer

- 69 -

2.3.13. Flywheel and Flywheel Housing (Rear Oil Seal)

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 200C. 2) Assemble ring gear to flywheel as tapping with a hammer when it is enough heating.
EJM2100S EJM2099S

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.

Installer

EJM2101S

2.3.14. Cover of Timing Gear Case 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.
Installer

EJM2102S

- 70 -

2.4. Reassembly
2.4.1. General Composed

3 2

<NA/T>

<TI>

EJM2103S

<Order of Assembly > 1. Piston 2. Piston pin and connecting rod 3. Snap ring 4. Piston ring 5. Connecting rod bearing

- 71 -

 Piston and Connecting Rod <Caution> Piston Heat piston approximately 60C. 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.

Heater of piston

EJM2104S

Piston head

Systematically indicate cylinder

EJM2105S

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.
EJM2105I Oil Marked side up EJM2031S

For steel liner

1st comp 2st comp

Connecting Rod Bearing 1) Assemble the connecting rod bearing to big end and cap. 2) Assemble the connecting rod and

For casting liner

chromium plating Top Ring 2st Ring

connecting rod bearing, and tighten cap bolt as the spesfied torque. 3) Spread the engine oil to bearing.
EJM2106I oil ring

- 72 -

 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

- 73 -

-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

- 74 -

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.

jig

EJM2109S

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.

EJM2110S

Spring of Intake and Exhaust Vavle Assemble the valve spring that it is the bottom painted parts.

Painted parts EJM2111I

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.
Compressed Spring EJM2112S

EJM2113S

- 75 -

 Intake Manifold and Gasket 1) Assembly the intake manifold that

Rear of Unchamfered corner

unchamfered corner is 'up' toward inside engine. 2) After assemble intake manifold, and systematically assemble the bolt with the specified torque.(see figure) Intake Manifold Bolt Torque 2. 60.5 kgm
Rear EJM2114S

EJM2115S

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) Exhaust Manifold Bolt Torque 2. 90.5 kgm
EJM2116I

TOP

EJM2117S

2) Assemble the spacer tube. (see figure)

Spacer tube

Spot face EJM2118S

- 76 -

 Assembly of Rocker Arm and Rocker Arm Shaft

EJM2119S

<Order of Assembly> 1. Rocker arm shaft 2. Spring 3. Rocker arm 4. Bracket

Caution

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

- 77 -

2.4.2. Inside parts

Main Components (I)

: Repair Kit EJM2120S

<Order of Assembly> 1. Oiling jet(DB58T/TI) 2. Crank shaft bearing 3. Crank shaft 4. Thrust bearing 5. Crankshaft bearing and crank shaft bearing cap 6. Timing gear case 7. Tappet 8. Camshaft * Prior to assemble cam shaft, firstly assemble the tappet without fail. 9. Idler gear shaft 10. Idler gear 11. Piston and ocnnecting rod 12. Oil pump and coupling 13. Flywheel housing 14. Oil pan 15. Oil cooler

- 78 -

 Oil Jet (DB58T) Assemble the oil jet nozzle not so as to be damaged it.

Oil Jet Torque

2.10.5 kgm

EJM2121S

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.

Oil port and oil home (uppter part)

Rightly set up

EJM2122S

No oil port and oil home, Center part.

Crank shaft Assemble the crank shaft gear so as to be front combined side. CAUTIONMake sure the part number because it may be Front
EJM2123S

difference upon engines.

Thrust washer Assemble thrust washer so as to be connected oil home in the bearing to crank shaft side.

EJM2124S

Oil home

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)

Arrow

Front

EJM2125S

- 79 -

Tightened Torque

24. 01 kgm

4) Check it whether it is smoothly rotated the crank shaft by hand or not.

EJM2126S

Spread of Engine Oil

Timing Gear Case Tighten timing gear case bolt with the specified torque. Tightened Torque 2.60.5 kgm

EJM2127S

Cam shaft Tighten thrust plate bolt so as to be fixed cam shaft gear port. Thrust Plate Bolt Torque 2.60.5 kgm 161.5 kgm
Cam shaft gear EJM2128S

Camshaft Gear Bolt Torque

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.

Oil port

EJM2129S

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. Torque 5.51 kgm

Injection Pump Gear

Mark "B" Idle gear

Mark "C" Mark "A" EJM2130S Crank shaft gear

Cam shaft gear

- 80 -

 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.
EJM2131S

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).

Piston ring compresser

EJM2132S

6) Agreely assemble the connecting rod bearing cap with the connecting rod cylinder number.
Cylinder Number

EJM2133S

Assemble the classified depend upon kind of bolt as following. Torque(kgm) Classified 11 (Bolt head) Treated surface oxidized steel 120.25 9.750.25 TY TY 11T , 12T phosphoric acid & basic film.
EJM2134S

Assembled Oil Pump Assemble the oil pump at the filled up oil at the pump.

- 81 -

Oil Pump Bolt Torque

5.31.0 kgm
Coupling

EJM2135S

Flywheel Housing Tighten bolt as it is specified torque after it is pasted sealant at the black face in the figure.

Touque

Outer Bolt Inner Bolt

2.60.5 kgm 16.11 kgm

EJM2136S Liquid gasket (for face of cylinder body only)

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. Torque 2.60.5 kgm

EJM2137S

Oil Cooler Orderly assemble the oil cooler bolt after set up the spreaded sealant at the oil cooler gasekt.

Torque

2.60.5 kgm

EJM2138S

- 82 -

 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 assy 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

- 83 -

- 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

- 84 -

Importance Flywheel 1) Apply engine oil on the flywheel bolt. 2) Orderly tighten the fly wheel bolt.(see figure)

Lubricate with enging oil

EJM2142S

Bolt Torque

22.32.2 kgm

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". Bolt Torque 2.60.5 kgm
EJM1029S

Injection pump gear

Idler gear

B mark

C mark A mark EJM2130S Crankshaft gear

Camshaft gear

Crank shaft pulley nut Tighten a nut with wrench.

pulley

Torque

60.05.0 kgm

Camshaft gear

EJM2144S

wrench

Tappet Chamber Cover Tighten a bolt spread sealant at the gasket.

Torque

2.60.5 kgm

EJM2145S

- 85 -

 Water Pump Prior to put on the gasket, spread a sealant.

Spreading Sealant

EJM2146S

Cylinder Head Gasket Be up mark "Top" and down mark "front".

Front, Mark TOP

Front

EJM2147S

Assembled Cylinder Head Orderly and repeatly tighten after it is spreaded engine oil at the cylinder head, as shown in figure. 1st step torque hexagon bolt dodecaon bolt 7.0 kgm 4.0 kgm 2nd step 11.5+0.5 90 +60 (0~30 )
EJM2148S Front

Limited value of dodecaon bolt Standard(mm) 115 102 Assembly Rocker Arm Shaft Orderly tighten the rocker arm bolt as shown in figure. Torque Adjust valve clearance Refer to section 1.5.9 3.10.5 kgm
EJM2149S

Limit(mm) 116.2 103.2

EJM2150S

- 86 -

2.4.3. External Parts(A)

DB58

6 1

2 5

EJM2170I

<Reassembly Steps> 1. Cylinder head cover 2. Fan pulley 3. Generater 4. Fan belt 5. Starter motor 6. Dipstick and guide tube

- 87 -

DB58T

10 2

11 7 1 9

EJM2171I

<Reassembly Steps> 1. Cylinder head cover 2. Breather 3. Fan pulley 4. Generate 5. Fan belt 6. Starter motor 7. Turbocharger 8. Turbocharger oil delivery pipe 9. Turbocharger oil return pipe 10. Dipstick and guide tube 11. Intake pipe

- 88 -

DB58TI

2 13

11

12

7 8

1 10

EJM2153I

<Reassembly Steps> 1. Cylinder head cove 2. Breather 3. Fan pulley 4. Generator 5. Fan belt 6. Starter motor 7. Inter cooler 8. Turbocharger 9. Turbocharge oil return pipe 10. Turbocharge oil delivery pipe 11. Dipstick and guide tube 12. Intake pipe 13. Coolant hose

- 89 -

 Cylinder Head Cover Orderly tighten the bolt as it is shown in figure. Bolt Torque 2.10.5 kgm

EJM2154S

Fan Belt Adjust the fan belt tension See the item "maintenance".

Starter Motor Tighten with the specified torque after assemble a starter motor to fly wheel housing.

Torque

8.4 kgm

EJM2155S

Turbocharger Mounting Flange Gasket Carefully posit the gasket with the edged side facing up.

EJM2156S

Turbocharger Tighten in the interim torborcharger nut. Completely tighen the nut after it is assemble oil pipe.

Torque

5.31 kgm

EJM2157S

- 90 -

 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.
Spacer Tube

EJM2158S

Oil drain pipe torque

3.80.7 kgm

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. Oil return pipe bolt torque 2.60.5 kgm

EJM2159S

- 91 -

2.4.4. External Parts (B)

DB58

9 1 7 10 8

11 4 2

EJM2160I

<Reassembly Steps> 1. Preheating plug 2. Oil filter 3. Fuel filter 4. Injection pump 5. Oil pipe (Oil filter to oil cooler) 6. Injection nozzle 7. Fuel pipe 8. Fuel pipe (Feed pump to fuel filter) 9. Fuel pipe (Fuel filter to injection pump) 10. Fuel return pipe 11. Cooling fan

- 92 -

DB58T

12 1 6 9 7 8 11 10 3

13 4

EJM2168I

<Reassembly Steps> 1. Preheating plug 2. Oil filter 3. Fuel filte 4. Injection pump 5. Oil pile: oil filter- oil cooler 6. Injection nozzle 7. Injection pipe 8. I/P boocom hose (T) 9. Fuel pipe; feed pump to filter 10. Fuel pipe: fuel filter to injection pump 11. Fuel retrun pipe 12. Intake pipe 13. Cooling fan

- 93 -

DB58TI

11 2 10

9 6 12 7 8

5 4

13 3 1

EJM2169I

<Reassembly Steps> 1. Oil filter 2. Fuel filter 3. Injection pump 4. Oil pile: oil filter- oil cooler 5. Injection piper 6. Inter cooler 7. Coolant outlet pipe in outlet pipe 8. Coolant inlet pipe in inter cooler 9. I/P boocom hose 10. Fuel pipe; feed pump to filter 11. Fuel pipe: fuel filter to injection pump 12. Fuel retrun pipe 13. Cooling fan

- 94 -

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. Torque 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. Torque 3.10.2 kgm
EJM2164S Dust cover

1.90.2 kgm

EJM2163S Nozzle gasket

Oil Filter Torque 4.3 ~ 6.3 kgm

EJM2165I

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. Torque 1.70.1 kgm

EJM2166S

Suction Pipe Torque 2.60.5 kgm

Adjustment of Injection Timing See 1.5. "maintenance".

EJM2167S

- 95 -

3. SYSTEM OF LUBRICATION
3.1. General Description

(1) (13) (2)

(6)

(14)

(15)

(16)

(5)

(7)

(17) (9)

(18)

(19)

(20)

(21)

(22)

(10)

(23)

(24)

(25)

(26)

(11)

(27) DB58T/TI
EJM3001I

(1) Oil filter (2) By-pass valve (Opening pressure 1kg/cm )

2

(16) Oil pressure switch (17) Crank shaft bearings (18) Cam-shaft bearings (19) Timing dile gear (20) Injection Pump
2

(5) Paper filter (6) By-pass valve (Opening pressure 2kg/cm ) (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

(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

- 96 -

3.2. Oil Pump

Disassembly

EJM3002S

<Order of disassembly> 1. Strainer 2. Suction pipe 3. Cover and dowel 4. Pinion 5. Drive shaft and gear 6. Pinion gear shaft

- 97 -

 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
EJM3004S EJM3003S

Clearance of oil Pump Driven Gear and oil pump body Limit 0.12 mm

EJM3005S

Reassembly Reassambly shall be inverted from the disassambled.

- 98 -

3.3. Oil Cooler

Disassembly

6 5 4 3

EJM3008S

<System of Disassembly> 1. Element (NA 3 plates. T/TI 4 plates) 2. Element gasket 3. By-pass vlave plug 4. O-ring ; plug 5. By-pass valve spring 6. By-pass valve

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

- 99 -

Reassembly
Reassembly shall be inverted inverted from the disassambled.

1 2 3 4

EJM3009S

<Reassembly order> 1. By-pass valve 2. By-pass valve spring 3. O-ring : plug 4. By-pass valve plug 5. Element gasket 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.

Torque

2.60.5 kgm

EJM3010S

- 100 -

4. COOLING SYSTEM
4.1. General Description
DB58T

Water pipe Thermostat

Reserve tank

R a d i a t o r Cylinder block

Cylinder head

Water pump EJM4001I

DB 58TI

Water pipe Thermostat Intercooler

Reserve tank

R a d i a t o r Cylinder block

Cylinder head

Water pump EJM4002I

- 101 -

4.2. Coolant Pump

Disassembly DB 58/T

3 7 4

6 5 1

EJM4003S

<Disassembly order> 1. Pulley 2. Cover 3. Gasket 4. Impeller 5. Pulley Flange 6. Snap ring 7. Seal 8. Impeller shaft

- 102 -

Disassembly DB 58TI

3 7 4

5 1

EJM4004S

<Disassembly order> 1. Pulley 2. Cover 3. Gasket 4. Impeller 5. Pulley Flange 6. Snap ring 7. Seal 8. Impeller shaft 9. Pipe

- 103 -

Importance Impeller Remove the impeller with the jig.

Remover

EJM4005S

Hub Remove the pulley center as it is moderately pressing with the bench press.
Hub Bench press

EJM4006S

Snap Ring Remove the snap ring with the snapping plier.

EJM4007S

Unit Bearing Remove the unit bearing as it is moderate with the bench and press.

EJM4008S

Seal Unit and Washer Seal Remove the seal unit as it is moderate with the bench and press.

EJM4009S

- 104 -

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

<Unit Bearing>

EJM4011I

- 105 -

Reassemblys DB58/T

6 2 5

3 4 8

EJM4013S

<Reassembly order> 1. Unit Bearing 2. Seal 3. Snap Ring 4. Pulley Fiange 5. Impeller 6. Gasket 7. Cover 8. Pulley

- 106 -

Reassembly DB58TI

6 2 5

3 4 8

EJM4014S

<Reassembly order> 1. Unit Bearing 2. Seal 3. Snap Ring 4. Pulley Flange 5. Impeller 6. Gasket 7. Cover 8. Pulley 9. Pipe

- 107 -

Importance Unit Bearing By untilizing bench press set up the unit bearing at the pump.

Spreading of multipurposable grease

Outside from sealed surface EJM4011I

Snap Ring Assemble the snap ring with the snap ring plier.

EJM4007S

Pulley Center Assemble pulley center with the bench press.

EJM4015S

Washer and Seal Unit Assemble it with the bench press after is is spreaded the sealant to pump body contacting surface.

Spreading of sealant EJM4016S

EJM4017S

- 108 -

 Impeller Assemble impeller to be in specified clearance between impeller and body with rock bench press. Standard 0.3 - 0.8 mm
Feeler gauge EJM4018S

Bench press

Pulley Tighten the pulley bolt As it is a specified torque. Torque 2.60.5 kgm

EJM4019S

4.3. Thermostat
Inspection and Repair Correct and replace if it is found the worn, defect or others when check it.
Thermometer Agitating rod

See item "maintenance"

Wood piece EFM2055I

- 109 -

5.2. Fuel Filter

Disassembly

2 7 6 7

1 : Element kit
EJM5003S

<Disassembly Steps> 1. Drain plug 2. Center bolt 3. Fuel fiter body 4. Body cover gasket Refer to Page 19 of the "Maintenance" for information on the cartridge type fuel filter. 5. Fuel filter element 6. Spiring seat 7. Spring

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.

- 111 -

 Reassembly Reassembly shall be inverted from the disassembled.

EJM5008S

<System Reassembly> 1. Nozzle holder body 2. Connector gasket 3. Injection pipe connector 4. Injectin nozzle 6. Nozzle holder push rod 7. Pushrod spring 8. Spring seat 9. Nozzle adjusting screw 10. Cap nut gasket 11. Nozzle holder cap nut

- 113 -

5.3. Injection Pump

5.3.1. Adjustment of Injection quantity.
CAUTIONInjection quantity shall be adjusted as it is seeing adjustment data of injection pump model as described "A".

101605-9100 0000000000000000000 Pump NO.- 000000000 S6A95C410RS2000

EJM5014I

LICENCE BOSCH

5.3.2 Calibration data

DB58 <Test conditions> Injection pump Injection nozzle Injection nozzle holder Nozzle opening pressure Injection pipe demensions 101605-9630 D.K.K.C.P.No. 105025-1380 D.K.K.C.P.No. 105160-4650 180 kg/cm2 INNER DIA. 1.6mmXOUTER DIA. 6 mm LENGTH 580 mm Transter pump pressure Testing diesel fuel ISO Operating temperature 1.6 kg/cm2 4 40~50C

<Governor Adjustment>

14
OR MORE

E 9.8
_ 0.1 +

9.4 9.1

C 0.3 + 0.1 A

6.4 6.3

0 EJM5015I

340

350

415

480

_ 20 970 1115 1175 850 +

- 115 -

 DB58TI <Test condition>

101605-9610 0000000000000000000 Pump NO.- 000000000 S6AD100B410R

EJM5021I

LICENCE BOSCH

Injection pump Injection nozzle Injection nozzle holder Nozzle opening pressure Injection pipe demensions

101605-9480 D.K.K.C.P.No. 105025-1390 D.K.K.C.P.No. 105160-4660 185 kg/cm2 INNER DIA. 1.8mmXOUTER DIA. 6 mm LENGTH 580 mm

Transter pump pressure Testing diesel fuel ISO Operating temperature

1.6 kg/cm2 4 40~50C

<Governor Adjustment>

RACK LIMIT
14
OR MORE

IDLING SUB SPRING SET BOOST COMPENSATOR STROKE 0.250.1mm

E

RACK POSITINON(mm)

GOVERNOR SPRING SET

C D A

9.7 R 2 (9.5)

EJM5017I

R2

2.3 6.7

230

450 + 20

550

+ 30 1000 + 20 1080

_ + 20

- 117 -

5.3.4. Governor Disassembly

4 236 6 7 1 132 10 9

183 170

181 130 150

101 19 21 20

103 102 100 10 118 117 140 44 174 47 35 237 173 52 182 47 331 138 137136 220 50 13 80 238 38 202 201203 141 332 211 207 205

82 48 49 39 51 83 255 82 190 198 192

195

EJM5019S

1. Governor housing 4. Plate 6. Adapter ; pump housing 7. Bolt 9. Spring eye 10. Bolt 13. Nut 19. Adaptor 20. Bolt 21. Gasket 35. Governor cover 38. Tension lever bolt 39. Nut 44. Speed lever stop bolt 46. Cap 47. Tension lever shaft plug 48. Full-load adjusting bolt 49. Nut 50. Lever stop bolt 51. Bolt 52. Bolt

80. Cover 82. Bolt 83. Bolt 100. Fly weight 101. Woodruf key 102. Spring washer 103. Nut 117. Sleeve 118. Shim 130. Governor spring 132. Starting spring 136. Nut 137. Gasket 138. Cap 140. Idling spring assembly 141. Nut 150. Speed setting lever 170. Guide leve assembly 173. Split pin 174. Floating leve link 181. Tension lever - 119 -

182. Tension lever shaft 183.Collar 190. Control-lever 192. Nut 195. Return spring 198. Spring washer 201. O-ring 202. Bush 203. Shim 205. Shaft lever 207. Support lever 211. Snap ring 220. Damper spring 236. Gasket 239. Gasket 240. Lead seal 241. Wire : lead seal 255. Bracket 331. Angleich spring assembly 332. Connection nut

6. EINGINE ELECTRICALS
6.1. Starter motor
Main data and specifications

Rated voltoge Rated output Rating Direction of rotation (viewed from the pinion side) Operating speed

24V 4.5KW/2.5KW 30 sec clockwise

More than 6500 rpm(No load) More than 1600 rpm(Load)

Construction

Center bracket Shift lever Thru bolt Front bracket Pinion clutch Pinion stopper

Magnetic switch

Yoke

Rear bracket Connect bar

Thru bolt

Dowel pipe

EJM6001S

- 120 -

6.2. Alternator
Specifications Type Rated voltage Rated output Max. allowable speed Polarity grounded Direction of rotation Weight 3 phase AC alternator 24V 45A/60A 8000 rpm Negative(-) Clockwise(viewde from pulley side) 6.1 kg (7.6 kg)

Generator

EJM6002S

<Disassembly steps> 1. Lock nut 2. Pulley 3. Fan 4. Front cover 5. Ball bearing 6. Thre bot 7. Roter assembly 8. Stator assembly 9. Rear side cover assembly 10. Diod assembly(+) 11. Diod assembly(-) 12. Brush holder assembly 13. Brush spring 14. Brush 15. Key 16. Bearing lock nut. 17. Washer 18. Bolt

- 121 -

7. TURBO CHARGER
General Description

RHB6A

EJM7001S

RHB7

EJM7002S

- 122 -

RHC7

EJM7003S

IHI turbor charger nameplate is furnished important imfomration for date manufactured and service. Nameplate shall be directly toward arrow.

EJM7004S

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.

HOLSET

Ass'y 3539678 Serial NO. H2064771 Customer 3539679 Moder HY35

EJM7005I

- 123 -

7.1. Inspection of Rotor Shaft

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). Limit Rotor Shaft Axial Play (TIR) 0.11 mm
EJM6006S

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. RHB6A Rotor Shaft Radial Play (TIR) Limit 0.19 mm
EJM6007S

RHC7, RHB7 Rotor Shaft Radial Play (TIR)

Limit 0.215 mm

3) Replace the shaft if the measured value is in excessive of specified limit.

- 124 -

8. CAUSE OF TROUBLE, DIAGNOSIS AND TROUBLESHOOTING

1) Starting Trouble

Statement Start Motor

Cause (1) Magenetic switch does not operate when turn starter swicth 1. Distribution inferiority, disconnection, connection inferiority, 2. starter switch connection inferiority 3.Coil disconnection of magenetic switch, strain 4. bend of flanger shaft 5. fixed humidity part of flanger. (2) Magnetic switch operate, but pinion does not clamp with ring gear. 1. Defect of amateur shaft bearing 2. Pinion & ring gear was excessive wore, changed. 3. Shortage of battery 4. Inferiority of Pinion moving 5. Flanger & connector shaft fixed (3) Pinion clamped with ring gear, but engine does not turn 1. Pinion clutch skip 2. Amateur field coil strain 3. Brush & communicator inferiority 4. Shortage of battery 5. Earth inferiority

Remedy Trouble of circuit Correction Replacement Replacement Correction or replacement Correction or replacement Correction or replacement Correction or replacement Charge or replacement Wash Correction or replacement Replacement Replacement Correction or replacement Charge or replacement correction Replenish Wash correction Replacement Correction or replacement Wash Replacement Replacement Removal air Correction or replacement correction correction Replacement Correction or replacement Correction or replacement

Fuel System Trouble

(1) Fuel does not feed from feed pump 1. No fuel 2. Clogged fuel tank strainer 3. Clogged fuel tank or air in fuel line 4. Defect of fuel feed pump valve 5. Feed pump piston & push rod fixed 6. Clogged fuel pump strainer (2) Fuel does not inject from injection pump 1. Clogged fuel filter element 2. Continually opened over flow valve of fuel filter 3. Air in fuel filter or injection pump 4. flanger, delivery valve fixed (3) Unfitness of fuel injector 1. Injection timing Inferiority 2. Unfitness of fuel timing 3. cam or cam shaft excessive wore (4) Injection nozzle does not operate 1. Needle valve fixed 2. Leakage between nozzle and needle valve 3. Unfitness of injection pressure

- 125 -

Statement
Insufficient of compression pressure

Cause
(1) Damage of cylinder head gasket, (2) Piston, piston ring or cylinder liner wore, (3) Piston ring Strain, (4) Unfitness of valve clearance, (5) Valve and seat connection inferiority, (6) Valve stem attachment (7) Wearing tension of valve spring or damage

Remedy
replacement replacement replacement adjustment adjustment replacement replacement

2) Abnormal of Operation

Statement
Abnormal of idle (2) Injection pipe relax (3) Injection nozzle defect

Cause
(1) Injection timing inferiority,

Remedy
adjustment adjustment correction or replacement correction correction or replacement correction or replacement

(4) Unequal fuel injection volume (5) Slow motion of control rack (6) Unsmooth of flanger operation

(7) Correctlnessless connection of Control pinion and control rack correction or replacement (8) Air suction of injection pump Abnorml drive at Low intermediate speed Unstopable at high speed drive (1) Governer idling spring bend (2) Governer spring tension weakness (1) Bend of linkage cable between accel pedal and injection pump (2) Bend of injection pump control removal correction or replacement correction or replacement correction correction

3) Shortage of Engine out put

Statement
Continuelly short of eingine out put (2) Valve closing inferiority

Cause
(1). Uncorrection of valve clearance

Remedy
correction correction or replacement replacement correction correction correction correction or replacement correction or replacement correction Maintain of air cleaner correction or replacement correction or replacement correction or replacement Engine overhaul adjustment correction or replacement

(3) Defect of cylinder head gasket (4) Piston ring wear and fix (5) Uncorrection of injection timing (6) Shortage of fuel valume (7) Unsuitable of nozzle injection presure or strain (8) Defect of fuel feed (9) Fuel pipe system clog (10) Shortage of suction valume (11) Throttle valve operation inferiority (12) Clutch skip (13) Brake inferiority Shortage of out put when accelerate (1) Shortage of compression pressure (2) Unsuitable of injection timing (3) Unfuction of injection pump timer

- 126 -

Statement

Cause
(4) Nozzle injection pressure or unsuitable of injection angle (5) Decline function feed pump (6) Shortage of suction valume (7) Throttle valve fix

Remedy
correction or replacement correction or replacement Maitenance of air cleaner correction or replacement Suppliment & check of leakage replacement correction or replacement replacement correction or replacement replacement replacement adjustment replacement

Overheat

(1) Shortage of coolant (2) Weakness of tension of radiator cap pressure valve spring (3) Radiator core system clog (4) Oil cooler system clog (5) Fan belt release, wear or damage (6) Thermostat operation inferiority (7) Water pump operation inferiority (8) Uncorrect of injection timing (9) Cylinder head gasket defect

4) Noise of Engine

Statement
Crank shaft bearing

Cause
(1) bigger of oil clearance due to bearing or crank shaft wear (2) Crank shaft side wear (3) Oil port system clog (4) Bearing strain

Remedy
grind crank shaft or replacement grind crank shaft or replacement Wash replacement & grind crank shaft replacement grind or replacement replacement grind or replacement crank shaft grind or replacement replacement replacement replacement replacement replacement throttle bearing replacement throttle collar replacement adjustment replacement replacement adjustment replacement replacement

Conn. rod & bearing

(1) Connecting rod bearing wear (2) Crank pin side wear (3) Connecting rod bend (4) Bearing seize

Piston, piston pin and pinston ring

(1) Piston & bigger of oil clearance due to piston ring wear (2) Piston or piston pin wear (3) Piston strain (4) Piston ring damage

Other

(1) crank shaft throttle bearing wear (2) cam shaft end pulley bigger (3) Idle gear end pulley bigger (4) Timing gear backlash being excessive (5) Uncorrect of valve clearance (6) valve strained into valve guide (7) Valve spring damage (8) valve seat insert defect (9) Tappet, cam excessive wear (10) rokcer arm & rocker am shaft excessiver wear

- 127 -

5) Fuel consumption excessive

Statement
Trouble of fuel system Other

Cause
(1) Uncorrect of injection timing (2) Fuel injection excessive valume (1) clutch skip (2) brake inferiority (3) unsuitable tire pressure (4) unsuitable of gear selection

Remedy
adjustment adjustment correction or replacement correction or replacement adjustment seelection gear due to load

6) Excessive oil consumption

Statement
Oil leakage (2) gasket inferiority

Cause
(1) release of every connected parts

Remedy
tighten replacement replacement replacement replacement replacement replacement replacement adjustment adjustment replacement wash

(3) cylinder head gasket defect Lack of oil (1) valve stem and oil seal inferiority (2) valve stem or valve guide excessive wear Plenfitul of oil (1) excessive clearance between piston and cylinder wall (2) piston ring and ring home excessive wear (3) piston ring damage, wear or fix (4) Uncorrect setting of piston ring gap (5) Uncorrect set up of piston ring (6) Oil controlling return home clog (7) air breather clog 7) Exhaust Escessive Smoke

Statement
Excessive white smoke

Cause
(1) Too late of injection timing (2) lack of compressor pressure

Remedy
adjustment mentioned "difficult of start"

(3) Mixed water in fuel (4) leakage of oil due to lose of fuel (5) Engine and excessive cooling drive (6) fuel injection excessive volume Ecessive black smoke (1) air cleaner element clog (2) completely unopended Intake shutter valve (3) Screwed intake house or to be flatted (4) lact of compression pressure (5) Too fast of injection timing (6) fuel injection excessive volume (7) Injection shape inferiority of nozzle (8) unsuitable of valve clearance

replacement fuel correction adjustment adjustment wash or replacement replacement or adjustment adjustment or replacement mentioned "engine out put lack adjustment adjustment or replacement adjdustment or repalcement adjustment

- 128 -