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Daewoo DB58 Shop Manual

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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

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  • Page 1 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.
  • Page 2 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...

  • Page 3: Table Of Contents

    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.

  • Page 4: General

    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.

  • Page 5: Engine Specifications

    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.

  • Page 6: Torque Specifications

    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 Bolt diameter × pitch (mm) (Low carbon steel) (High carbon steel) (Alloy steel) M 6×1.0...

  • Page 7: Main Part Fixing Nuts And Bolts

    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) 5.3±1 4 Kg m + 90˚+60˚(0~30˚) (docoecagon bolt) : (Angle Control Method) 2.7±0.25 (19.5±1.8) preheating plug 5.3±1 EJM1001S - 4 -...
  • Page 8 �Cylinder Block (Unit : kg∙m) 5.3±1 2.6±0.5 2.6±0.5 2.6±0.5 2.1±0.5 24.1±1 EJM1002S - 5 -...
  • Page 9 �Oil Pan and Dipstick (Unit : kg∙m) 2.9±0.3 2.6±0.5 8.0±1.0 EJM1003S - 6 -...
  • Page 10 �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 -...
  • Page 11 �Crankshaft, Piston, and Flywheel (Unit : kg∙m) A type : 12±0.25 B type : 9.25±0.25 Mark : ON BOLT HEAD B type A type 60±5 22.3±2.2 EJM1005S - 8 -...
  • Page 12 Thermostat and Thermostat Housing � (Unit : kg∙m) 2.6±0.5 5.3±1 5.3±1 EJM1006S - 9 -...
  • Page 13 Intake and Exhaust Manifold(DB58) � (Unit : kg∙m) 2.6±0.5 2.9±0.3 EJM1007S - 10 -...
  • Page 14 Intake and Exhaust Manifold(DB58T) � (Unit : kg∙m) 5.3±1.0 2.6±0.5 EJM1008S - 11 -...
  • Page 15 Intake and Exhaust Manifold(DB58TI) � (Unit : kg∙m) 2.9±0.3 2.6±0.5 EJM1009S - 12 -...
  • Page 16 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 -...
  • Page 17 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 -...
  • Page 18 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 -...
  • Page 19 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 -...
  • Page 20 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 -...
  • Page 21 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 -...
  • Page 22 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.
  • Page 23 <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.
  • Page 24 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/cm 185 kg/cm 185 kg/cm EJM1024S �...
  • Page 25 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)
  • Page 26 1.5.6. Air Bleeding 1) Release the feed pump cap (1) at the ② Injection pump. 2) Release an air bleed nut (2) at the Injection pump. 3) Operate feed pump as visually seeing until ① completely remove an air. 3) Tighten eye bolt. 4) Make sure to check leakage of Injection EJM1032S pump ＆...
  • Page 27 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...
  • Page 28 1.5.10. Injection Timing � � CAUTION� � Carefully keep away to be not entried dust 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.
  • Page 29 α � pump. � � CAUTION� � Applied engine for injection timing are different, and EJM1044I feel free contact to Branch, Engingineering Technical Service Center or Engine Quality Service Team to DAEWOO Heavy Ind., Ltd., inform serial number. - 26 -...
  • Page 30 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 ③ assembly to #1 plunger and tighten with the Spring specified torque.
  • Page 31 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.
  • Page 32 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.
  • Page 33 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.

  • Page 34: Engine Assembly And Disassembly

    2. ENGINE DISASSEMBLY AND ASSEMBLY 2.1. Engine External Parts �DB58 EJM2001I - 31 -...
  • Page 35 �DB58T EJM2002I - 32 -...
  • Page 36 �DB58TI EJM2003I - 33 -...

  • Page 37: External Parts Disassembly

    2.2. Disassembly 2.2.1. External Parts �DB58 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.
  • Page 38 �DB58T 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.
  • Page 39 �DB58TI 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.
  • Page 40 2.2.2. External Parts Disassambly Steps �DB58 EJM2007I <Disassembly Steps> 1. Dipstick and guide tube 4. Generator 2. Starter motor 5. Fan plug 3. Fan belt 6. Cylinder Head cover - 37 -...
  • Page 41 �DB58T 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 -...
  • Page 42 �DB58TI 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.
  • Page 43 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.
  • Page 44 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 pulley Wrench: 54 mm...
  • Page 45 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.
  • Page 46 � � 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.
  • Page 47 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 -...
  • Page 48 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.
  • Page 49 �DB 58T EJM2025S �DB 58TI EJM2026S - 46 -...
  • Page 50 2.2.7. Piston and Connecting Rod Disassembly Steps <TI> <NA/T> EJM2028S <Disassembly Steps> 1. Piston rings 4. Piston 2. Snap ring 5. Connceting rod bearing 3. Piston pin and connecting rod - 47 -...
  • Page 51 Importance � � CAUTION� � Remove piled carbon at the upper of cylinder bore Carbon prevented damage deposits piston when remove. EJM2029I � � Piston Rings Remove the piston ring with using of piston ring Piston disassambly tool. ring remover EJM2030I �...

  • Page 52: Inspection And Repair

    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.
  • Page 53 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...
  • Page 54 � � Valve Depression 1) Install the valve ① to the cylinder head ②. 2) Measure valve depression by the using of depth gauge or calibrator from the bottom of cylinder head. Seat insert and valve must replace if the measured value was exceeded the specified limit.
  • Page 55 � � 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. EJM2045I Angle Location Standard...
  • Page 56 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 •...
  • Page 57 2.3.4. Tappet Check the valve tappets whether excessive wear and damage or not. Inferiority Pitting Clack of contact Irregularity of contact EJM2041I 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...
  • Page 58 2.3.6. Rocker Arm Correction Check of the valve stem contact part of roker 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.
  • Page 59 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.
  • Page 60 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...
  • Page 61 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 EJM2067I bottom 20 mm.
  • Page 62 3) Slowly turn the remover shaft handle counter clock-wise to pull the cylinder liner free. � � CAUTION� � Be advised to be not damaged cylinder block when remove the cylinder liner. Take care to be not damage the cylinder body upper face when remove the cylinder liner.
  • Page 63 � � 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.
  • Page 64 � � 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.
  • Page 65 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 101.955-101.974 mm 101.975-101.994 mm Cylinder Liner Bore and Piston Clearance : 0.053~0.077 mm (3.228＂)
  • Page 66 � � 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.
  • Page 67 � � 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.
  • Page 68 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. EJM2087S Connecting Rod Balancer ( Standard 100 mm) Standard Limit Balancer...
  • Page 69 � � 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.
  • Page 70 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.
  • Page 71 � � 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.
  • Page 72 � � 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.
  • Page 73 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>...

  • Page 74: Reassembly

    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 -...
  • Page 75 � � 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 �...
  • Page 76 � � Assembly parts of Cylinder Head -DB 58/T ★ : Repair Kit EJM2107S <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.
  • Page 77 -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.
  • Page 78 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. EJM2109S � � Intake and Exhaust Valves 1) Put up the cylinder head on plate. 2) Spread the engine oil to valve stem.
  • Page 79 � � Intake Manifold and Gasket Rear of Unchamfered corner 1) Assembly 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.
  • Page 80 � � 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 -...
  • Page 81 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.
  • Page 82 � � 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) �...
  • Page 83 Tightened Torque 24. 0±1 kg∙m 4) Check it whether it is smoothly rotated the crank shaft by hand or not. Spread of Engine Oil EJM2126S � � Timing Gear Case Tighten timing gear case bolt with the specified torque. Tightened Torque 2.6±0.5 kg∙m EJM2127S �...
  • Page 84 � � 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.
  • Page 85 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)
  • Page 86 � � 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.
  • Page 87 - 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.
  • Page 88 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"...
  • Page 89 � � 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 Front figure.
  • Page 90 2.4.3. External Parts(A) • DB58 EJM2170I <Reassembly Steps> 1. Cylinder head cover 4. Fan belt 2. Fan pulley 5. Starter motor 3. Generater 6. Dipstick and guide tube - 87 -...
  • Page 91 �DB58T 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 -...
  • Page 92 �DB58TI 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.
  • Page 93 � � 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.
  • Page 94 � � 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.
  • Page 95 2.4.4. External Parts (B) �DB58 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.
  • Page 96 �DB58T 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.
  • Page 97 �DB58TI 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.
  • Page 98 Importance Dust cover � � 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. Nozzle gasket EJM2163S Torque 1.9±0.2 kg∙m �...

  • Page 99: System Of Lubrication

    3. SYSTEM OF LUBRICATION 3.1. General Description (14) (13) (15) (16) (18) (19) (22) (17) (20) (21) (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 (18) Cam-shaft bearings (5) Paper filter...
  • Page 100 3.2. Oil Pump � Disassembly EJM3002S <Order of disassembly> 1. Strainer 4. Pinion 2. Suction pipe 5. Drive shaft and gear 3. Cover and dowel 6. Pinion gear shaft - 97 -...
  • Page 101 • 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.

  • Page 102: Oil Cooler

    3.3. Oil Cooler � � Disassembly EJM3008S <System of Disassembly> 1. Element (NA 3 plates. T/TI 4 plates) 4. O-ring ; plug 2. Element gasket 5. By-pass valve spring 3. By-pass vlave plug 6. By-pass valve Inspection and Repair Correct and replace if it is found the worn, defect or others when check it. - 99 -...
  • Page 103 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.

  • Page 104: Cooling System

    4. COOLING SYSTEM 4.1. General Description �DB58T Water pipe Thermostat Cylinder head Reserve tank Cylinder block Water pump EJM4001I �DB 58TI Water pipe Thermostat Intercooler Cylinder head Reserve tank Cylinder block Water pump EJM4002I - 101 -...

  • Page 105: Coolant Pump

    4.2. Coolant Pump Disassembly �DB 58/T EJM4003S <Disassembly order> 1. Pulley 5. Pulley Flange 2. Cover 6. Snap ring 3. Gasket 7. Seal 4. Impeller 8. Impeller shaft - 102 -...
  • Page 106 Disassembly �DB 58TI EJM4004S <Disassembly order> 1. Pulley 6. Snap ring 2. Cover 7. Seal 3. Gasket 8. Impeller shaft 4. Impeller 9. Pipe 5. Pulley Flange - 103 -...
  • Page 107 Importance � � Impeller Remover Remove the impeller with the jig. EJM4005S � � Hub Bench press Remove the pulley center as it is moderately pressing with the bench press. EJM4006S � � Snap Ring Remove the snap ring with the snapping plier. EJM4007S �...
  • Page 108 � � Inspection And Repair Correct and replace if it is found the worn, defect or others when check it. <Unit Bearing> EJM4011I - 105 -...
  • Page 109 Reassemblys • DB58/T EJM4013S <Reassembly order> 1. Unit Bearing 5. Impeller 2. Seal 6. Gasket 3. Snap Ring 7. Cover 4. Pulley Fiange 8. Pulley - 106 -...
  • Page 110 Reassembly • DB58TI EJM4014S <Reassembly order> 1. Unit Bearing 6. Gasket 2. Seal 7. Cover 3. Snap Ring 8. Pulley 4. Pulley Flange 9. Pipe 5. Impeller - 107 -...
  • Page 111 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 �...
  • Page 112 � � 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.
  • Page 113 5.2. Fuel Filter � � Disassembly ★ ★ ★ ★ : 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.
  • Page 114 � � 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.

  • Page 115: Injection Nozzle

    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...
  • Page 116 � � 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/cm Injection pipe demensions INNER DIA. 1.8mmXOUTER DIA. 6 mm - LENGTH 580 mm Transter pump pressure 1.6 kg/cm...
  • Page 117 5.3.4. Governor Disassembly 4 236 6 10 9 183 170 181 130 150 103 102 100 10 44 174 211 207 205 182 47 141 332 136 220 50 13 201203 80 238 49 39 190 198 192 EJM5019S 1. Governor housing 80.

  • Page 118: Engine Electricals

    6. EINGINE ELECTRICALS 6.1. Starter motor � � Main data and specifications Rated voltoge 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) �...

  • Page 119: Alternator

    6.2. Alternator � � Specifications Type 3 phase AC alternator Rated voltage 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.

  • Page 120: Turbo Charger

    7. TURBO CHARGER � � General Description RHB6A EJM7001S RHB7 EJM7002S - 122 -...
  • Page 121 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. HOLSET Ass'y 3539678 (1) Size number of torbor charger, month and Serial NO.
  • Page 122 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.

  • Page 123: Cause Of Trouble, Diagnosis And Troubleshooting

    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...
  • Page 124 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...
  • Page 125 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 &...
  • Page 126 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...

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