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DB58, DB58T &

DB58TI DIESEL
ENGINE
Shop Manual
65.99892-8026A

Daewoo reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine’s package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.

65.99892-8026A Shop Manual


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

Engine Model
DB 58 DB 58T DB58TI
Items
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/cm ) 2
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

-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 : kg∙m)

Bolt identification
4 7 9
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.

-3-
1.4. Main Part Fixing Nuts And bolts

� Cylinder Head and Cover


(Unit : kg∙m)

2.1±0.5

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


4 Kg m + 90˚+60˚(0~30˚) 5.3±1
(docoecagon bolt) : (Angle Control Method)

2.7±0.25

(19.5±1.8)

preheating plug

5.3±1

EJM1001S

-4-
�Cylinder Block

(Unit : kg∙m)

5.3±1

2.6±0.5

2.6±0.5

2.6±0.5

24.1±1 2.1±0.5

EJM1002S

-5-
�Oil Pan and Dipstick

(Unit : kg∙m)

2.9±0.3

2.6±0.5

8.0±1.0

EJM1003S

-6-
�Cam Shaft and Rocker Arm

(Unit : kg∙m)

3.1±0.5

3.1±0.5

2.6±0.5

2.6±0.5

16±1.5

Engine oil application

5.5±1

EJM1004S

-7-
�Crankshaft, Piston, and Flywheel

(Unit : kg∙m)

A type : 12±0.25
B type : 9.25±0.25

Mark : ON BOLT HEAD

B type or

A type

60±5
22.3±2.2

EJM1005S

-8-
�Thermostat and Thermostat Housing

(Unit : kg∙m)

2.6±0.5

5.3±1

5.3±1

EJM1006S

-9-
�Intake and Exhaust Manifold(DB58)

(Unit : kg∙m)

2.6±0.5

2.9±0.3

EJM1007S

- 10 -
�Intake and Exhaust Manifold(DB58T)

(Unit : kg∙m)

5.3±1.0

2.6±0.5

EJM1008S

- 11 -
�Intake and Exhaust Manifold(DB58TI)

(Unit : kg∙m)

2.9±0.3

2.6±0.5

EJM1009S

- 12 -
�Timing Gear Case and Flywheel Housing

(Unit : kg∙m)

2.6±0.5

2.6±0.5
16.0±1.0

Outside

16.0±1.0

2.6±0.5

Inside

EJM1010S

- 13 -
�Oil Cooler, Oil Filter and Oil Pump

(Unit : kg∙m)

5.3±1.0

5.3±1.0

5.3±1.0

2.6±0.5

2.6±0.5

EJM1011S

- 14 -
�Fuel System (DB58, DB58T)

(Unit : kg∙m)

1.9±0.2

1.3±0.2

1.7±0.1
3.1±0.2

4.2±0.8

4.2±0.8

EJM1012S

- 15 -
�Fuel System(DB58TI)

(Unit : kg∙m)

1.9±0.2

1.3±0.2

1.7±0.2
3.1±0.2

4.2±0.8

EJM1013S

- 16 -
�Turbo Charger and Related Parts (DB58T)

(Unit : kg∙m)

2.6±0.5

3.8±0.7

5.3±1.0

3.1±0.5

3.8±0.7

EJM1014S

- 17 -
�Turbo Charger and Related Parts (DB58TI)

(Unit : kg∙m)

3.8±0.7

2.6±0.5

5.3±1.0

3.1±0.5

3.8±0.7

EJM1015S

- 18 -
1.5. Maintenance

1.5.1. Replacement of Oil Filter

� Removal
Set the Filter
<Remover and Installer : Filter Wrench> Wrench
1) After release the drain plug, and remove the
Cartridge
oil if upper system.
2) Draw out filter as turning it counterclock
wise.
3) Do not reuse the drew out filter. Drain Plug

EJM1018I
<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
EJM1019I
the specified level if necessary. <Downword type>
6) Check the leakage at the replaced filter as
operating the engine.

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.
1
2) Separate cartirage (2) from head (3) with the
tools. 3

3) Fill up clean fuel to the new cartirage.


5
4) Replace the rubber packing (4) which is 4

centered at the head.


2
5) Smear clean fuel to the rubber packing (5)
which is a cartirage.
6) Turn cartirage until packing is getting to
head.
6
7) Farther make a round 1/3~1/2 with manual
when packing get to head. EJM1022I

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. 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 EIO3008S
necessary.
Adjust injection nozzle starting pressure as
set starting a handle of nozzle tester. ①

DB58 DB58T DB58TI

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

EJM1024S

� CAUTION�
�The marked (*) can be
changed according to the
loaded vehicles. ①

Feel free contact to this


firm when you have a
quantion in this manual.

� CAUTION�
�Carefully keep away from
EJM1025S
skin and keep off from
tester because pressure of
nozzle tester is very high ①
when inject.

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.

EJM1029S

Strainer

1.5.5. Separator of Leakage (Add if Necessary) EJM1030S

Check leakage separator on the surface.


Release plug at the bottom part to be
eliminated when indicate warning point on the
surface. Warning
surface
Elimination Plug Torque 1.2±0.3 kg∙m
Floating

Elimination
plug
EJM1031S

- 22 -
1.5.6. Air Bleeding

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


Injection pump. ②
2) Release an air bleed nut (2) at the Injection
pump.
3) Operate feed pump as visually seeing until
completely remove an air. ①

3) Tighten eye bolt.


4) Make sure to check leakage of Injection EJM1032S
pump & filter after operating feed pump
many times.

EJM1033I

1.5.7. Cooling System

� Cooling Fan Belt Depress


Adjustment here

1) Check cooling fan drive belt for cracking and
damage.
About
2) Check the drive belt tension by exerting a ③ 10mm
force of 10kg midway between the water
pump pulley ② and the alternator pulley ③.
3) Adjust the belt tension by loosening the EJM1034I ①
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

1.5.8. Thermostat

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

� measure the valve lift.


Wood
Plate
Amount of Valve Lift 10.0 mm
EFM2055I

Valve Opening Temperature 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. EJM1035S
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
Intake and Exhaust Valve Clearance(cold) 0.40 mm

3) Release adjusted screw. See figure. 6B


Front
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.
When No.1 cylinder at TDC in
6) Tighten lock nut. compression stroke
EJM1036S
7) Rotate crankshaft 360�to be realigned
crankshaft pulley TDC notched line with
6B
timing pointer. Front
8) Adjust valve clearances as shown in figure.

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


When #1 piston at TDC
compression stroke.
EJM1037S

- 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 ④
on the injection pump gear nut lock plate
EJM1035S
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 EJM1038S
mounting flange.)
Make sure the position of next crank angle
of in jection starting. 3

2) Turn the crankshaft pulley counterclockwise


about 30�crankangle.

EJM1039I

3) #1 plunger of injection can be visually sured


when disconnect injection pipe.

EJM1040I
- 25 -
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

6) Support fuel control lever at the wholly


opened position.

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 TDC

specifically injection starting angle line.


Blow out remained fuel from delivery valve
holder, and no feeded fuel from priming
pump. α

� CAUTION�
�Applied engine for injection
timing are different, and
feel free contact to Branch, EJM1044I

Engingineering Technical
Service Center or Engine
Quality Service Team to
DAEWOO Heavy Ind., Ltd.,
and inform us serial
number.

- 26 -
9) Remove delivery valve holder from #1
plunger.
① Holder
10) Assemble the delivery valve intenal parts at
the devilvery valve holder.
② Seat
11) Assemble the delivery valve holder
assembly to #1 plunger and tighten with the ③ Spring
specified torque.
④ Delivery Valve
EJM1041S
Delivery Valve Holder Torque 4.25±0.25 kg∙m

12) Assemblel the #1 cylinder injection pipe


and tighten with the specified torque.

Injection Pipe Nut Torque 3.1±0.2 kg∙m

� 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.
Relaxity of
�Note�When mark slip 1mm, injection
whole nuts
timing differ about 2˚.
EJM1045S
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.

- 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. EJM1047S
Inequality of compression is 2.0 kg/cm2 and
more, check related parts and replace it.

- 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 trubocharger mounting


nuts.

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 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

- 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
5 2 4
11

1
8

10

EJM2004I

<Disassembly Steps>

1. Cooling fan 6. Injection nozzle


2. Fuel retrun pipe 7. Oil pipe: oil filter- oil cooler
3. Fuel pipe: fuel filter to injection pump 8. Injection pump
4. Fuel pipe; feed pump to filter 9. Fuel filter
5. Injection pipe 10. Oil filter
11. Preheating plug

- 34 -
�DB58T

2
7 6 3
13
4 11

10
12
EJM2005I

<Disassembly Steps>

1. Cooling fan 8. Injection nozzle


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

- 35 -
�DB58TI

3 5
11
2
4 7

1
10
12

EJM2006I

<Disassembly Steps>

1. Cooling fan 8. Injection pipe


2. Fuel retrun pipe 9. Oil pile: oil filter- oil cooler
3. Fuel pipe: fuel filter to injection pump 10. Injection pump
4. Fuel pipe; feed pump to filter 11. Fuel filter
5. I/P boocom hose 12. Oil filter
6. Coolant inlet pipe in inter cooler
7. Coolant outlet pipe in outlet pipe

- 36 -
2.2.2. External Parts Disassambly Steps

�DB58

6
1

2
5

EJM2007I

<Disassembly Steps>

1. Dipstick and guide tube 4. Generator


2. Starter motor 5. Fan plug
3. Fan belt 6. Cylinder Head cover

- 37 -
�DB58T

10 11
2 7
1

5 8
6

EJM2008I

<Disassembly Steps>

1. Dipstick and guide tube 7. Fan belt


2. Turbocharger oil return pipe 8. Generator
3. Turbocharger oil delivery pipe 9. Fan pulley
4. Intake pipe 10. Breather
5. Turborcharger 11. Cylinder head cover
6. Starter motor

- 38 -
�DB58TI

4 11
12 1
6
5
13

10

8 3
7

EJM2009I

<Disassembly Steps>

1. Dipstick and guide tube 8. Fan belt


2. Turbocharger oil return pipe 9. Generator
3. Turbocharger oil delivery pipe 10. Fan plug
4. Intake pipe 11. Intercooler
5. Turborcharger 12. Breather
6. Coolant pipe 13. Cylinder head cover
7. Starter motor

- 39 -
2.2.3. Main Structured Parts

�DB58/T/TI

★ : Repair Kit
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

- 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 Crank shaft


Wrench: 54 mm pulley

Adequately wrench when remove the crank


shaft pulley nut.

Wrench
EJM2015S

� Taper Bushing Taper


Use the disassambleable tool when remove the bushing

crank shaft pulley bushing.

Crankshaft

pulley

Taper bushing remover


EJM2016I

� Flywheel
Orderly release the fly wheel. (as shown in
figure)
3 1
5 6
2 4

EJM2017S

- 41 -
2.2.4. Major Structured Parts II

�DB58

: Repair kit

EJM2018S

<Diassembly Steps>

1. Oil Cooler 9. Timing gear case


2. Oil Fan 10. Idler gear shaft
3. Oil Pump and Coupling 11. Crank shaft bearing cap
4. Oil Fan 12. Crank shaft bearing (lawer part)
5. Fly wheel housing 13. Thrust bearing
6. Idler gear 14. Crank shaft
7. Cam shaft 15. Crank shaft bearing (upper part)
8. Tappet 16. Oiling jet (DB58T/TI)

- 42 -
� Importance
<Idler Gear>
Prior to disassamble, measure as following.

Standard Limit

Idler Gear End Play 0.058-0.115 mm 0.2 mm

Feeler gauge
EJM2019S

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.
Dial indicator
EJM2020S

� Cam Shaft camshaft


gear
Prior to disassamble, measure as following.

Thrust plate

Standard Limit
Camshaft
Cam Gear End Play 0.050-0.114 mm 0.2 mm Feeler
gauge

EJM2021S

� Crankshaft Bearing Cap Feeler gauge


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

Standard Limit

Crankshaft End Play 0.15-0.33 mm 0.4 mm

EJM2022S Crankshaft

- 43 -
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

- 44 -
2.2.6. Cylinder Head Disassembly Steps

�DB58

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

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 1
10
EJM2025S

�DB 58TI

6
7

8
9 2 11

12

5 1
10
EJM2026S

- 46 -
2.2.7. Piston and Connecting Rod Disassembly Steps

1 1
4 4

2 2

3 3

2 2

3 3

5 5

<NA/T> <TI>

EJM2028S

<Disassembly Steps>

1. Piston rings 4. Piston


2. Snap ring 5. Connceting rod bearing
3. Piston pin and connecting rod

- 47 -
Importance
� CAUTION�
�Remove the piled up
carbon at the upper of
cylinder bore to be
Carbon
prevented damage of deposits
piston when remove.

EJM2029I

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


brass bar.

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. EJM2033I

<Plane figure of Cylinder Head>

Standard Limit Max. Grinding


0.05 mm 0.2 mm 0.3 mm

<Height of Cylinder Head>

Standard Limit
89.95-90.05 mm 89.65 mm
EJM2034S

� CAUTION�
�You 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 EJM2037S
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 Limit
Intake Side TIR 0.039-0.068 mm 0.20 mm
Exhaust Side TIR 0.064-0.093 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. EJM2038S

� 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.

EJM2039S

Interval is 14.1 mm from the bottom of the


Remover and
cylinder head from the edge of valve guide top. installer

EJM2040S
- 50 -
� Valve Depression
1) Install the valve ① to the cylinder head ②. 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 if the 1
measured value was exceeded the specified limit.
When replace of valve, the valve guide must EJM2041I
be surely replaced.

Standard Limit.

Intake and Exhaust Valve Depression 1.0 mm 2.5 mm

� 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 Limit

Valve Contact Width 1.5 mm 2.0 mm

� 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. EJM2043S
4) Carefully remove the carbon and other alien
substance from the cylinder head insert bore.

<Installation of Valve Seat>


1) Carefully place Jig (1). 3

� CAUTION�
�Contact smoothed face of
1
valve seat insert.

2) Assemble valve insert as of slowly pressing 2


againt the jig with the bench press.
(To need press 25000 Kg more)
� CAUTION�
�Do not excessive press EJM2044I
with tne bench press.
It may be damaged the
valve seat insert.

- 51 -
� Correction of Valve Seat Insert 150
1) Remove the carbon deposits from the valve A
seat insert surface. 30

2) Remove the rough areas by the using of


valve cutter (15˚, 30˚ or 75˚)
Do not cut the valve insert too much.

EJM2045I

Angle Location Standard

Intake Valve Seat 45�


Exhaust Valve Seat 45�

� CAUTION�
�Use mediated handle of
valve cutter.
Do not move the handle EJM2046S

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 B

good or not. EJM2047I

7) Check the contact condition of valve insert.

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 Limit
EJM2049I
Exhaust and Intake Valve
49.0 mm 47.0 mm
Spring Free Length

• 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 Limit

Valve Spring Gradient 1.3 mm less 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 Limit

Valve Spring Tension


14.5 ㎏ 11.5 ㎏ EJM2051S
at 40 mm Set Length

- 53 -
2.3.4. Tappet

Check the valve tappets whether excessive


wear and damage or not.

Pitting Clack Inferiority


of contact

Irregularity of
EJM2041I contact

Measure the outside diameter of tappets with


the micrometer.

Standard Limit

Tappet Outside Diameter 27.97-27.98 27.92

EJM2052S

Measure the clearance between tappets and


cylinder motion parts by the using of dial
indicator

Standard Limit

Tappet and Tappet Travelling


0.020~0.054 mm 0.1 mm
Bore Clearance

EJM2053I

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 Limit

Outside Diameter of Rocker Arm Shaft 18.98-19.00 mm 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. EJM2058S

Standard Limit

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

- 55 -
Standard Limit

Rocker Arm Bushing and


0.01-0.05 mm 0.2 mm
Rocker Arm Shaft clearance

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 Limit

Outside Diameter of 44.945-44.975 mm 44.9 mm


Idler Gear Shaft

EJM2060S

2) Measure the inside diameter of idler gear


with the dial indicator.

Standard Limit

Clearnance of Idler Gear 0.025-0.085 mm 0.2 mm


and ldler Gear Shaft

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 Limit Jig

Clearance of Cam Journal 0.03–0.09 mm 0.15 mm EJM2062S


and Cam Bearing

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 Limit

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


I II I II
A
Cam Journal Diameter 56.0 mm 55.6 mm C B B

EJM2065I D A

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 3


Measure the bore from which is measured
1
location
(1) to direction of the crank shaft (3) and
counter direction (2).
Measured location: from the top of liner to
bottom 20 mm. EJM2067I

(Max. ware part)


Replace the cylinder liner if the measured
value escaped from specified limit. 1

Standard Limit

Diameter of Cylinder Liner Bore 102.021-102.060 mm 102.20 mm

� CAUTION�
�Inside of dry type cyliner
liner was electroplated with EJM2068I

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).

Limit

Projection of cylinder Liner 0.03-0.10 mm

Inequality liner projection to other clylinder EJM2069S

must be less than 0.3mm.

Replacement of the Cylinder Liner


<Removal of Cylinder Liner>
Remover
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.

EJM2070S

- 58 -
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 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 EJM2071I
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- 1
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.

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).
① 20.0
② 105.0
③ 195.0 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 Cylinder Bore Outside Diameter

1 105.990-106.000 105.973-105.984

2 106.00-106.010 105.984-105.995

� 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
1
2
cylinder liner and piston.
Meassure the bore after assemble the cylinder
liner. EJM2077I
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.

- 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 Steel
Strut
Grade Limit EJM2078I
A 101.955-101.974 mm
B 101.975-101.994 mm

Cylinder Liner Bore and Piston Clearance :


0.053~0.077 mm
� CAUTION�
�The cylinder liner piston kit (3.228")
EJM2079S
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. EJM2080S

� Piston Ring and Piston Groove Clearance

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

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. EJM2082S
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.

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

� 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 Limit
EJM2083S
Piston Pin Outside Diameter 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 60˚C 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) EJM2087S

Standard Limit

Balancer 0.05 mm 0.20 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. EJM2088S
Standard Limit

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.

� CAUTION�
�Align connecting rod bush
oil port and connecting rod
oil port.

3) Grinde the piston pin hole with grinder or


EJM2089S
adjustable pilot reamer.

Standard

Connecting Rod Bush Inside Diameter 35.017-35.025 mm

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 B type
EJM2091S
Bolt Torque 12±0.25 9.75±0.25

[Classification]
∙A type : 11 marked on bolt head

TY TY
∙B type : or
11T 12T

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 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. EJM2093S
Grind if the pin and journal measured value
escaped from the specified limit.

- 66 -
Classification Standard

Crankshaft Journal outside Diameter 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 Limit

Crankshaft Journal and


0.039-0.098 mm 0.11 mm
Main Bearing Clearance

Standard Limit

Crank pin and Connecting


0.03-0.07 mm 0.10 mm
Rod Bearing clearance

� 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.

EJM2094S
Main Bearing Cap Torque 24.1±1 kg∙m

Main Bearing Diameter 80 mm

� Inside Diameter of Connecting Rod


Bearing
Measure the bearing inside diameter with the
specified dial gauge after the tightened
connecting rod bearing.

A type B type

Connecting Rod Cap


12±0.25 9.75±0.25 EDM2044I
Bolt Torpue

TY TY
Classification 11
, 11T 12T

Connecting Rod
64.0 mm
Bearing Diameter

- 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 EJM2095S
measured value escaped from the specified
limit.

Standard Limit

Crankshaft Run-Out 0.05 mm 0.40 mm

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


less than 3.8

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,
R Part
and finish it with soft cotton. EJM2096S

Journal and Surface Illumination 0.4μor less

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 Limit

Crank Jouranl Outside Diameter 79.419 mm

Crank pin Outside Diameter 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 Limit

Main Bearing
0.039-0.098 mm 0.11 mm
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 Limit

Connecting
0.03-0.07 mm 0.10 mm
Rod Bearing

� Crank Shaft Gear


<Overhaul> Remover

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> EJM2097S
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.

Installer
EJM2098S

- 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 EJM2099S
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.

EJM2100S

� Oil Seal
Installer
<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.

EJM2101S

2.3.14. Cover of Timing Gear Case

� Remove and Assemble of Front Oil Seal


Installer
<Disassembly>
Remove the oil seal as it is the using jig and
hammer.
<Assemble>
Assemble the oil seal as it is using assemble jig.

EJM2102S

- 70 -
2.4. Reassembly

2.4.1. General Composed

<NA/T> <TI>

EJM2103S

<Order of Assembly >

1. Piston 4. Piston ring


2. Piston pin and connecting rod 5. Connecting rod bearing
3. Snap ring

- 71 -
� Piston and Connecting Rod
Heater of piston
<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. EJM2104S

� Piston Pin Snap Ring


Piston head
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.
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 EJM2031S
Rightly assembly the indicated surface that
1st and 2nd compressed ring will be 'up' Marked side up
Oil ring may be assembled any way because ∙For steel liner
1st comp
it is not indicated.
2) Spread engine oil to surface of piston ring. 2st comp

3) Check it whether piston ring is smoothly


rotating at the inside of piston ring home or
Oil
not.
EJM2105I

� Connecting Rod Bearing chromium plating


∙For casting liner
1) Assemble the connecting rod bearing to big
end and cap. Top Ring

2) Assemble the connecting rod and 2st Ring


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

EJM2106I

- 72 -
� Assembly parts of Cylinder Head
-DB 58/T

EJM2107S ★ :Repair Kit

<Order of Assembly>

1. Valve stem oil seal 7. Thermostat housing and gasket


2. Intake and exhaust valves 8. Thermostat
3. Spring seat(Lower) 9. Coolant outlet pipe
4. Intake and exhaust value sping 10. Intake manifold and gasket
5. Spring seat(Upper) 11. Exhaust manifold and gasket
6. Split collar

- 73 -
-DB 58TI

★ :Repair Kit
EJM2108S

<Order of Assembly>

1. Valve stem oil seal 7. Thermostat housing and gasket


2. Intake and exhaust valves 8. Thermostat
3. Spring seat(Lower) 9. Coolant outlet pipe
4. Intake and exhaust value sping 10. Intake manifold and gasket
5. Spring seat(Upper) 11. Exhaust manifold and gasket
6. Split collar 12. Intercooler

- 74 -
Warning jig
� 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.

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
Rear of Unchamfered corner
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
Rear
specified torque.(see figure)

Intake Manifold Bolt Torque 2. 6±0.5 kg∙m 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
TOP
systematically assemble blots with the
specified torque.(see figure)

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


EJM2116I

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 3. Rocker arm


2. Spring 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) 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.

- 78 -
� Oil Jet (DB58T)
Assemble the oil jet nozzle not so as to be
damaged it.

Oil Jet Torque 2.1±0.5 kg∙m

EJM2121S

Caution Oil port and oil


Rightly set up
home (uppter part)
� 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. No oil port and oil
home,
EJM2122S Center part.

� 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.
�Front

EJM2123S

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

Oil home
EJM2124S

� Crank shaft Bearing Cap Arrow


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) Front

EJM2125S

- 79 -
Tightened Torque 24. 0±1 kg∙m

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 2.6±0.5 kg∙m

EJM2127S

� Cam shaft
Tighten thrust plate bolt so as to be fixed cam
shaft gear port.

Thrust Plate Bolt Torque 2.6±0.5 kg∙m

Camshaft Gear Bolt Torque 16±1.5 kg∙m


Cam shaft gear
EJM2128S

� Idler Gear Shaft Oil port

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.

EJM2129S

� Idler Gear Injection Pump Gear Mark "B"


Idle 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. Mark "C" Cam
shaft
Mark "A" gear
Torque 5.5±1 kg∙m
Crank shaft gear
EJM2130S

- 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 Piston ring compresser


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).

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(kg∙m) 12±0.25 9.75±0.25

Classified
TY TY
11
11T , 12T
(Bolt head)

Treated surface oxidized steel 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 5.3±1.0 kg∙m
Coupling

EJM2135S

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

Outer Bolt 2.6±0.5 kg∙m


Touque Liquid gasket
Inner Bolt 16.1±1 kg∙m (for face of cylinder
body only)
EJM2136S

� 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 2.6±0.5 kg∙m

EJM2137S

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

Torque 2.6±0.5 kg∙m

EJM2138S

- 82 -
� Major Component Reassembly Parts (II)
- DB58/T

★ : Repair Kit
EJM2139S

<Reassembly Steps>

1. Rubber hose 9. Oil pump driving pinion


2. Push rod 10. Crankshaft pulley nut
3. Rocker arm and rocker arm shaft 11. Taper bushing
4. Cylinder head bolt 12. Crankshaft pulley and dust thrower
5. Cylinder head ass’y 13. Timing gear cover
6. Cylinder head gasket 14. Oil thrower
7. Water pump 15. Flywheel
8. Tappet chamber cover

- 83 -
- DB58TI

★ : Repair Kit
EJM2141S

<Reassembly Steps>

1. Rubber hose 9. Oil pump driving pinion


2. Push rod 10. Crankshaft pulley nut
3. Rocker arm and rocker arm shaft 11. Taper bushing
4. Cylinder head bolt 12. Crankshaft pulley and dust thrower
5. Cylinder head 13. Timing gear cover
6. Cylinder head gasket 14. Oil thrower
7. Water pump 15. Flywheel
8. Tappet chamber cover

- 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 22.3±2.2 kg∙m

� 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 2.6±0.5 kg∙m


EJM1029S

Injection pump �B
�mark
gear Idler gear

�C
�mark
Camshaft
�A
�mark gear
Crankshaft gear
EJM2130S

� Crank shaft pulley nut pulley


Tighten a nut with wrench.

Torque 60.0±5.0 kg∙m


Camshaft
gear

EJM2144S wrench

� Tappet Chamber Cover


Tighten a bolt spread sealant at the gasket.

Torque 2.6±0.5 kg∙m

EJM2145S
- 85 -
� Water Pump
Spreading Sealant
Prior to put on the gasket, spread a sealant.

EJM2146S

� Cylinder Head Gasket Front, Mark TOP


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

Front

EJM2147S

� Assembled Cylinder Head


Orderly and repeatly tighten after it is spreaded
engine oil at the cylinder head, as shown in
figure. Front

1st step 2nd step


torque hexagon bolt 7.0 kg∙m 11.5+0.5
dodecaon bolt 4.0 kg∙m 90�
+60�
(0~30�
)
EJM2148S

� Limited value of dodecaon bolt

Standard(mm) Limit(mm)
115 116.2
102 103.2

� Assembly Rocker Arm Shaft


Orderly tighten the rocker arm bolt as shown in
figure.

Torque 3.1±0.5 kg∙m


EJM2149S
Adjust valve clearance
Refer to section 1.5.9

EJM2150S
- 86 -
2.4.3. External Parts(A)

• DB58

6
1

2
5

EJM2170I

<Reassembly Steps>

1. Cylinder head cover 4. Fan belt


2. Fan pulley 5. Starter motor
3. Generater 6. Dipstick and guide tube

- 87 -
�DB58T

10 11
2 7
1

5 8
6

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

- 88 -
�DB58TI

7
2 11 12
13
8
1

10

5 9
6

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

- 89 -
� Cylinder Head Cover
Orderly tighten the bolt as it is shown in figure.

Bolt Torque 2.1±0.5 kg∙m

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 kg∙m

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 5.3±1 kg∙m

EJM2157S

- 90 -
� Oil Drain Pipe
1) Disassemble the exhaust manifold spacer
which it is just bottom of the torbo charger
Spacer
part so as to be easily set up oil drain pipe. Tube
2) Tighten the flange nut as it is the specified
torque after it is assemble oil return pipe.

EJM2158S
Oil drain pipe torque 3.8±0.7 kg∙m

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 2.6±0.5 kg∙m


EJM2159S

- 91 -
2.4.4. External Parts (B)

�DB58

9
7 10
1 8

11
4

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

- 92 -
�DB58T

12
7 8 11
1
10 3

13

4
2

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

- 93 -
�DB58TI

11 9
2 6
12
10 7

13
3
1

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

- 94 -
Importance
� Injection Nozzle Dust cover

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 1.9±0.2 kg∙m EJM2163S Nozzle gasket

� 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 3.1±0.2 kg∙m

EJM2164S

� Oil Filter

Torque 4.3 ~ 6.3 kg∙m

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 1.7±0.1 kg∙m


EJM2166S

� Suction Pipe

Torque 2.6±0.5 kg∙m

� Adjustment of Injection Timing


See 1.5. "maintenance".

EJM2167S

- 95 -
3. SYSTEM OF LUBRICATION
3.1. General Description

(1)
(13) (14) (15)
(2)

(6) (16)

(7)
(5)

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


(9)

(10) (26)
(23) (24) (25)

(11)

(27)

DB58T/TI
EJM3001I

(1) Oil filter (16) Oil pressure switch


(2) By-pass valve (17) Crank shaft bearings
(Opening pressure 1kg/cm ) 2
(18) Cam-shaft bearings
(5) Paper filter (19) Timing dile gear
(6) By-pass valve (20) Injection Pump
(Opening pressure 2kg/cm ) 2
(21) Turbo charger
(7) Oil cooler (22) Oiling jet(Opening pressure 2.2kg/cm2)
(9) Oil relief(Opening pressure 7kg/cm2) (23) Oil relief valve
(10) Oil pump (Opening pressure 4.5kg/cm2)
(11) Oil strainer (24) Conn. rod bearings
(13) Oil pressure and oil filter warning lamp (25) Cyl. head valve system
(14) Starter switch (26) Piston
(15) Battery (27) Oil pan

- 96 -
3.2. Oil Pump

�Disassembly

3
6

EJM3002S

<Order of disassembly>

1. Strainer 4. Pinion
2. Suction pipe 5. Drive shaft and gear
3. Cover and dowel 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 EJM3003S
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

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

5
4

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.

- 99 -
�Reassembly
Reassembly shall be inverted inverted from the disassambled.

1
2
3

EJM3009S

<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.

Torque 2.6±0.5 kg∙m

EJM3010S

- 100 -
4. COOLING SYSTEM
4.1. General Description

�DB58T

Water pipe

Thermostat

R Cylinder head
a
d
i
a
t
o
Reserve tank r

Cylinder block

Water pump

EJM4001I

�DB 58TI

Water pipe
Thermostat Intercooler

R Cylinder head
a
d
i
a
t
o
Reserve tank r

Cylinder block

Water pump

EJM4002I

- 101 -
4.2. Coolant Pump

Disassembly
�DB 58/T

3 2
7 4

EJM4003S

<Disassembly order>

1. Pulley 5. Pulley Flange


2. Cover 6. Snap ring
3. Gasket 7. Seal
4. Impeller 8. Impeller shaft

- 102 -
Disassembly
�DB 58TI

9 8

3 2
7 4

EJM4004S

<Disassembly order>

1. Pulley 6. Snap ring


2. Cover 7. Seal
3. Gasket 8. Impeller shaft
4. Impeller 9. Pipe
5. Pulley Flange

- 103 -
Importance
� Impeller
Remover
Remove the impeller with the jig.

EJM4005S

� Hub
Remove the pulley center as it is moderately Bench press

pressing with the bench press.


Hub

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 7
2 5

EJM4013S

<Reassembly order>

1. Unit Bearing 5. Impeller


2. Seal 6. Gasket
3. Snap Ring 7. Cover
4. Pulley Fiange 8. Pulley

- 106 -
Reassembly
• DB58TI

9 1

6 7
2 5

EJM4014S

<Reassembly order>

1. Unit Bearing 6. Gasket


2. Seal 7. Cover
3. Snap Ring 8. Pulley
4. Pulley Flange 9. Pipe
5. Impeller

- 107 -
Importance
Spreading of multipurposable grease
� Unit Bearing
By untilizing bench press set up the unit
bearing at the pump.

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
Bench press
Assemble impeller to be in specified clearance
between impeller and body with rock bench
press.

Standard 0.3 - 0.8 mm

Feeler gauge
EJM4018S

� Pulley
Tighten the pulley bolt As it is a specified
torque.

Torque 2.6±0.5 kg•m

EJM4019S

4.3. Thermostat

� Inspection and Repair


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

See item "maintenance" Thermometer

Agitating rod

Wood
piece

EFM2055I

- 109 -
5.2. Fuel Filter

� Disassembly

3 ★ 4

★ 5

7 6
7

1

★ : Element kit
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.

- 111 -
� 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

- 113 -
5.3. Injection Pump

5.3.1. Adjustment of Injection quantity.

� CAUTION�
�Injection quantity shall be adjusted as
101605-9100
it is seeing adjustment data of 0000000000000000000
injection pump model as described Pump NO.- 000000000
"A". S6A95C410RS2000
LICENCE BOSCH
EJM5014I

5.3.2 Calibration data

�DB58
<Test conditions>

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>

14
OR MORE

E
_ 0.1
+
9.8
9.4 C
9.1
A
0.3 + 0.1
_

6.4
B
6.3

0 340 415 850 +_ 20 970 1115 1175


350 480
EJM5015I

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� DB58TI
<Test condition>

101605-9610
0000000000000000000
Pump NO.- 000000000
S6AD100B410R
LICENCE BOSCH
EJM5021I

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>

RACK LIMIT
14
OR MORE
IDLING SUB SPRING SET

BOOST COMPENSATOR STROKE 0.25±0.1mm


RACK POSITINON(mm)

E
GOVERNOR SPRING SET
9.7 C A
R 2 (9.5)

EJM5017I _
R2 2.3
6.7 B

0 + 30 _
230 _
550 1000 + 20 1080 + 20
450 + 20

- 117 -
5.3.4. Governor Disassembly

4 236 6

7 1

132 10 9
183 170

181 130 150 101

19
21
103 102 100 10 20
118 117
140
44 174

47 35 237
173
52 211 207 205
182 47
141 332
331
220
138 137136
38
50 13 202 201203
80 238

82
48 49 39 51
190 198 192

83 255 82
195
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

- 119 -
6. EINGINE ELECTRICALS
6.1. Starter motor

� Main data and specifications

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

Center bracket Magnetic switch

Shift lever

Thru bolt Rear bracket


Yoke
Front bracket Connect bar
Pinion clutch
Pinion stopper

Thru bolt

Dowel pipe

EJM6001S

- 120 -
6.2. Alternator

� Specifications

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

EJM6002S

<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

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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
HOLSET Ass'y 3539678

year manufactured, Serial NO. H2064771


(2) Date manufactured & serial number,
Customer 3539679
(3) Part number.

Moder HY35
EJM7005I

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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
EJM6006S
Rotor Shaft Axial Play (TIR) 0.11 mm

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.

EJM6007S
RHB6A Limit

Rotor Shaft Radial Play (TIR) 0.19 mm

RHC7, RHB7 Limit

Rotor Shaft Radial Play (TIR) 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 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

- 125 -
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

- 126 -
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 shaft
bearing or replacement
(2) Crank shaft side wear grind crank shaft
or 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 replacement
throttle 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

- 127 -
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

- 128 -