Daewoo D50S-2 Service Manual
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Daewoo D50S-2 Service Manual

Diesel engine 5.8 liter (db58)
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Service Manual
Diesel Engine
5.8 Liter (DB58)
D50S-2, D60S-2, D70S-2
SB2148E00
O c t. 1 9 9 8

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  • Page 1 SB2148E00 O c t. 1 9 9 8 Service Manual Diesel Engine 5.8 Liter (DB58) D50S-2, D60S-2, D70S-2...
  • Page 2 If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
  • Page 3 TO THE CUSTOMERS This operation and maintenance manual is designed to serve as a reference for DHI's customers and distributors who wish to gain basic product knowledge on DHI's DB58 Diesel engine. To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential.

  • Page 4: Table Of Contents

    CONTENTS 1. GENERAL INFORMATION ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ ¥ 1 1.1.

  • Page 5: General Information

    6. The use of proper tools and special tools where specified is important for efficient and reliable service operation. 7. Use genuine DAEWOO parts exclusively. 8. Used cotter pins, gaskets, O-rings, oil seals, lock washers and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.

  • Page 6: Engine Specifications

    1.2. Engine Specifications Engine Model DB 58 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 7: Torque Specifications

    1.3. Torque Specifications Standards bolts The torque values given in the following table should be applied where a particular torque is not specified. (Unit : kg ¥ m) Bolt identification Bolt diameter pitch Low carbon steel High carbon steel Alloy steel 0.4-0.8 0.5-1.0 1.25...
  • Page 8 1.4. Major Parts Fixing Bolts Cylinder Head and Block (Unit : kg ¥ m) 11.5 05. (hexagon bolt) : (Torque Control Method) 4 Kg m + 90û+60û(0~30û) (docoecagon bolt) : (Angle Control Method) 0.25 (19.5 1.8) preheating plug 5.3 L 1 EJM1001S - 4 -...
  • Page 9 ¥ Intake and Exhaust Manifold(DB58) (Unit : kg ¥ m) EJM1007S - 5 -...
  • Page 10 ¥ Cylinder Block (Unit : kg ¥ m) 5.3 L 1 2.6 L 0.5 2.6 L 0.5 2.6 L 0.5 2.1 L 0.5 24.1 L 1 EJM1002S - 6 -...
  • Page 11 ¥ Oil Pan and Dipstick (Unit : kg ¥ m) 2.9 L 0.3 2.6 L 0.5 8.0 L 1.0 EJM1003S - 7 -...
  • Page 12 ¥ Cam Shaft and Rocker Arm (Unit : kg ¥ m) 3.1 L 0.5 3.1 L 0.5 2.6 L 0.5 2.6 L 0.5 16 L 1.5 Engine oil application 5.5 L 1 EJM1004S - 8 -...
  • Page 13 ¥ Crankshaft, Piston, and Flywheel (Unit : kg ¥ m) A type : 12 L 0.25 B type : 9.25 L 0.25 Mark : ON BOLT HEAD B type A type 60 L 5 22.3 L 2.2 EJM1005S - 9 -...
  • Page 14 ¥ Thermostat and Thermostat Housing (Unit : kg ¥ m) 2.6 L 0.5 5.3 L 1 5.3 L 1 EJM1006S - 10 -...
  • Page 15 ¥ Timing Gear Case and Flywheel Housing (Unit : kg ¥ m) 2.6 L 0.5 2.6 L 0.5 16.0 L 1.0 Outside 16.0 L 1.0 EJM1010S - 11 -...
  • Page 16 ¥ Oil Cooler, Oil Filter and Oil Pump (Unit : kg ¥ m) 5.3 L 1.0 5.3 L 1.0 5.3 L 1.0 2.6 L 0.5 2.6 L 0.5 EJM1011S - 12 -...
  • Page 17 ¥ Fuel System (Unit : kg ¥ m) 1.9 L 0.2 1.3 L 0.2 3.1 L 0.2 4.2 L 0.8 EJM1013S - 13 -...
  • Page 18 1.5. Maintenance 1.5.1. Replacement of Oil Filter ¥ Removal <Remover and Installer> 1) Remove filter as turning it counterclock wise. 2) Do not reuse the used filter. ¥ Assembly 1) Wipe the oil filter mounting face with a clean rag to install a new filter.
  • Page 19 1.5.3. Water separator 1) Drain plug should be loosened to remove water in fuel filter if necessary. 2) When assembling plug, make to surely keep the forque to be 1.2 L 0.3 kg ¥ m 1.5.4. Injection Nozzle • Disassembly Procedure 1) Fix the injection nozzle with a vise.
  • Page 20 Carefully keep away from skin and keep off from tester because pressure of nozzle tester is very high when inject. EJM1025S EJM1026S Injection Condition Check (Operating the Nozzle Tester) 1) Tighten cap nut (1) 2) Check injection nozzle opening pressure 3) Check the injection nozzle sparay condition EJM1027S Prior to injecting the fuel completely, compress 4~6...
  • Page 21 1.5.5. Feed Pump Strainer 1) Release joint bolt A 2) Remove strainer with screwdriver, and wash strainer with light gasoline if necessary. EJM1029S Strainer 1.5.6. Air Bleeding EJM1030S 1) Release the feed pump cap (1) on the Injection pump. 2) Release an air bleed nut (2) on the Injection pump. 3) Operate feed pump as visually seeing until completely remove an air.
  • Page 22 1.5.7. Cooling System ¥ Cooling Fan Belt Adjustment Depress 1) Check cooling fan belt for cracking and damage. here 2) Check the drive belt deflection by applying a force of 10kg midway between the water pump pulley (2) and the alternator pulley (3). About 3) Adjust the belt tension by loosening the alternator 10mm...
  • Page 23 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 and exhaust valve rocker arms.
  • Page 24 1.5.10. Injection Timing Carefully keep away dust or foreign articles not to be entered into injection pump when adjusting injection timing. ¥ 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.
  • Page 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 delivery holder (1) and tighten specified torque. Do not assemble valve spring, valve seat and delivery valve.
  • Page 26 9) Remove delivery valve holder from #1 plunger. 10) Assemble the delivery valve intenal parts at the Holder devilvery valve holder. 11) Assemble the delivery valve holder assembly to #1 plunger and tighten with the specified torque. Seat 4.25 L 0.25 kg ¥ m Delivery Valve Holder Torque Spring Delivery Valve...
  • Page 27 1.6. Engine Repair Parts 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 28: Engine Disassembly And Assembly

    2. Engine Disassembly and Assembly 2.1. Engine External Parts EJM2001I - 24 -...

  • Page 29: Disassembly

    2.2. Disassembly 2.2.1. External Parts EJM2004I <Disassembly Steps> 1. Cooling fan 5. Injection pump 2. Fuel retrun pipe 6. Oil pipe (Oil filter to oil cooler) 3. Injection pipe 7. Oil filter 4. Injection nozzle - 25 -...
  • Page 30 2.2.2. External Parts Disassembly Steps EJM2007I <Disassembly Steps> 1. Dipstick and guide tube 4. Generator 2. Starter motor 5. Fan pulley 3. Fan belt 6. Cylinder Head cover - 26 -...
  • Page 31 2.2.3. Major Structured Parts I : 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 32 ¥ 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 Use 54mm wrench when removing the crank shaft pulley pulley nut.
  • Page 33 2.2.4. Major Structured Parts II : Repair kit EJM2018S <Diassembly Steps> 1. Oil Cooler 9. Timing gear case 2. Oil Pan 10. Idle gear shaft 3. Oil Pump and Coupling 11. Crank shaft bearing cap 4. Fly wheel housing 12. Crank shaft bearing (lower part) 5.
  • Page 34 Idler Gear Prior to disassembly, measure as following. Standard Limit Idle 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 The backlash of crank shaft gear & cam shaft gear is equal to idle gear backlash.
  • Page 35 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 - 31 -...
  • Page 36 2.2.6. Cylinder Head Disassembly Steps 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 37 2.2.7. Piston and Connecting Rod Disassembly Steps EJM2028S <Disassembly Steps> 1. Piston rings 4. Piston 2. Snap ring 5. Connceting rod bearing 3. Piston pin and connecting rod - 33 -...
  • Page 38 Remove the piled up carbon at the upper of cylinder bore to prevent damage of piston when removing it. Carbon deposits EJM2029I ¥ Piston Rings Remove the piston ring with piston ring remover. Piston ring remover EJM2030I ¥ Snap Ring and Piston Pin 1) Use the snap ring pliers when removing the snap ring.
  • Page 39 2.3. Inspection and Repair Adjust and repair if necessary, and replace the excessively worn or damaged parts which were found at inspction. 2.3.1. Cylinder Head ¥ Lower face flatness 1) Use a straight edge and a feeler guage to measure the four sides and the two diagonals of the cylinder head lower face.
  • Page 40 2.3.2. Valve Stem and Valve Guide Clearance ¥ Measuring Method-1 1) Install of dial gauge needle with valve stem assembled as figure. Set up calibrator to "O". 2) Shake well valve head. Record total dial indicator reading. Valve and guide set must be replaced if measured value was exceeded the specified limit.
  • Page 41 ¥ Valve Depression 1) Install the valve (1) to the cylinder head (2). 2) Measure valve depression with a depth gauge or calibrator from the bottom of cylinder head. Seat insert and valve must be replaced if the measured value exceeds the specified limit. When replacing valve, the valve guide must be surely replaced.
  • Page 42 ¥ Correction of Valve Seat Insert 1) Remove the carbon deposits from the valve seat 60û insert surface. 2) Remove the rough areas with a valve cutter (15û, 30û or 75û) Do not cut the valve seat insert too much. EJM2045I Contacting Angle(B)
  • Page 43 2.3.3. Valve Spring • Valve Spring Free Length Measure the valve spring with the vernier caliper. Replace the spring if the measured value is out of the specified limit. Standard Limit Exhaust and Intake Valve 49.0 mm 47.0 mm EJM2049I Spring Free Length •...
  • Page 44 2.3.4. Tappet Check the valve tappets whether excessive wear and damage or not. Inferiority of Pitting Clack contact Irregularity of EJM2041I contact Measure the outside diameter of tappets with a micrometer. Standard Limit Tappet Outside Diameter 27.97-27.98mm 27.92mm EJM2052S Measure the clearance between tappets and cylinder hole with a dial indicator Standard Limit...
  • Page 45 2.3.6. Rocker Arm Correction Check the valve stem contact part of roker arm. Grind contact surface with an abrasive if it is irregularly contacted. Replace the rocker arm if it is extremely damaged. EJM2055S ¥ Rockder Arm Shaft and Rocker Arm Check the disassembled parts whether damaged or not.
  • Page 46 Standard Limit Clearance Between Rocker Arm 0.01-0.05 mm 0.2 mm Bushing and Shaft 3) Check the rocker arm shaft oil port whether alien substance is in it or not. Clean the rocker arm shaft oil port with an air if necessary.
  • Page 47 3) Align 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 shaft if the measured value is out of the specified limit. Standard Limit Cam Lobe Height (C-D) 7.71 mm 7.21 mm...
  • Page 48 ¥ 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 of liner projection to other clylinder must be less than 0.03mm.
  • Page 49 ¥ Measurement of Cylinder Liner Outside Diameter 1) Measure the liner outside diameter from (1), (2) & (3) measuring point toward X-X, Y-Y. Location of the Measuring point. (1) 20.0 (2) 105.0 (3) 195.0 2) Average value for 6 measurements should be used to moderately determine the liner grade.
  • Page 50 2.3.10. Piston ¥ Selection of Piston Grade Correctly selected pistion grade to operate engine efficiently. Meassure the bore after assembling the cylinder liner. Determine piston grade after assembling liner. EJM2077I • Measurement of Cylinder Liner Bore 1) To be measured at 2 points. Cylinder Liner Bore Measuring Point (1) : 20mm Cylinder Liner Bore Measuring Point (2) : 105mm 2) Measure cylinder liner bore from (1), (2) &...
  • Page 51 ¥ 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 is out of the specified limit. EJM2080S ¥...
  • Page 52 ¥ Piston Pin Measure the pin outside diameter with micrometer. Replace the pin if the measured value is out of the specified limit. Standard Limit Piston Pin Outside Diameter 36.000-36.005 mm 35.95 mm EJM2083S ¥ Piston Pin Hole Measure diameter of the pin hole with inside dial gauge.
  • Page 53 2.3.11. Connecting Rod ¥ Connecting Rod Alignment Measure the alignment between big end and small end with connecting rod balancer. Replace the connecting rod if the measured value is out of the specified limit. Connecting Rod alignment ( at 100 mm distance) Standard Limit EJM2087S...
  • Page 54 ¥ 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 the tension is lack. 3) Tighten the connecting rod bearing cap to the specified bolt torque. A type B type 12 L 0.25...
  • Page 55 ¥ Crankshaft Main Bearing Inside Diameter 1) Tighten to the specified torque after assembling cap for the arrow of the bearing cap to be toward front of engine. 2) Measure main bearing diameter with a inside dial gauge. 24.1 L 1 kg ¥ m Main Bearing Cap Torque Main Bearing Diameter 80 mm...
  • Page 56 ¥ 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. Read the dial indicator (TIR) as you turn the crankshaft. Replace the crank shaft if the crank shaft measured value is out of the specified limit.
  • Page 57 ¥ Grinding Limit of Crankshaft Classification Limit Crank Jouranl Outside Diameter 79.405 mm Crank pin Outside Diameter 63.424mm Use the undersize bearing (0.25, 0.5 mm) when the main bearing clearance was in excess of limit. Regrind the crank shaft in comply with below standard if undersize bearing is used.
  • Page 58 2.3.13. Flywheel and Flywheel Housing (Rear Oil Seal) ¥ Inspection of Ring Gear Replace the ring gear when wear of damage is found. If the ring gear tooth are broken or excessively worn, the ring gear must be replaced. ¥ Disassembly of Ring Gear Disassemble the ring gear with a hammer and a chisel.
  • Page 59 2.4. Reassembly 2.4.1. General Parts EJM2103S <Order of Assembly > 1. Piston 4. Piston ring 2. Piston pin and connecting rod 5. Connecting rod bearing 3. Snap ring - 55 -...
  • Page 60 ¥ Piston and Connecting Rod Heater of piston Heat piston approximately 60ûC. 1) Assemble the piston and connecting rod with the pin. EJM2104S ¥ Piston Pin Snap Ring Piston head 1) Assemble the piston pin and piston ring with snap ring plier.
  • Page 61 ¥ Assembly parts of Cylinder Head 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. Intake and exhaust valve sping 10.
  • Page 62 ¥ Valve Stem Oil Seal 1) Spread the engine oil to oil seal and the assembled part. 2) Assemble the valve stem oil seal. EJM2109S ¥ Intake and Exhaust Valves 1) Put the cylinder head on plate. 2) Spread the engine oil to valve stem. 3) Assemble valves in guicle.
  • Page 63 ¥ Intake Manifold and Gasket Unchamfered corner 1) Assemble the intake manifold of which unchamfered corner is toward up and rear of engine. 2) After assembling intake manifold, and assemble the bolt to the specified torque in order. (see figure) 2.
  • Page 64 ¥ Assembly of Rocker Arm and Rocker Arm Shaft EJM2119S <Order of Assembly> 1. Rocker arm shaft 3. Rocker arm 2. Spring 4. Bracket ¥ Rocker Arm Shaft Assemble the rocker arm shaft of which oil hole is toward up. - 60 -...
  • Page 65 2.4.2. Inside parts ¥ Main Components (I) : Repair Kit EJM2120S <Order of Assembly> 1. Crank shaft bearing 8. Idler gear shaft 2. Crank shaft 9. Idler gear 3. Thrust bearing 10. Piston and ocnnecting rod 4. Crankshaft bearing and crank shaft bearing cap 11.
  • Page 66 Caution Oil port and oil groove Correctly set up ¥ for upper bearing Crank shaft Bearing (Upper Half) All upper bearing have oil port and groove. ¥ Crank shaft Bearing(Lower Half) No oil port and oil groove for lower bearing EJM2122S ¥...
  • Page 67 24. 0 L 1 kg ¥ m Tightened Torque 4) Check it whether the crank shaft is smoothly rotated by hand or not. Spread of Engine Oil EJM2126S ¥ Timing Gear Case Tighten timing gear case bolt to the specified torque. 2.6 L 0.5 kg ¥...
  • Page 68 ¥ Piston and Connecting Rod 1) Fix the position of piston ring (see figure) 2) Spread engine oil to piston, pinston ring, connecting rod bearing. 3) Piston front mark should be directed to front of engine. EJM2131S 4) Use the piston ring compressor when assembling Piston ring compresser pistion.
  • Page 69 5.3 L 1.0 kg ¥ m Oil Pump mounting Bolt Torque Coupling Bolt EJM2135S ¥ Flywheel Housing Tighten bolt to specified torque after liquid gusket is applied on the gasket. 16.1 L 1 kg ¥ m Bolt Torque EJM2172S ¥ Oil Pan 1) Install an oil fan after putting on oil fan gasket and liquid gasket between cyliner block and oil fan.
  • Page 70 ¥ Major Component Reassembly Parts (II) : 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.
  • Page 71 ¥ Flywheel 1) Apply engine oil on the flywheel bolt. 2) Orderly tighten the fly wheel bolt.(see figure) 22.3 L 2.2 kg ¥ m Bolt Torque Lubricate with enging oil EJM2142S ¥ Injection Pump Tighten the injection pump bolts to a specified torgue for "C"...
  • Page 72 ¥ Water Pump Spread liquid gasket Prior to putting the gasket, spread a liquid gasket. EJM2146S ¥ Cylinder Head Gasket Front, TOP Make sure mark "Top" is up and mark "Front" is down. Front EJM2147S ¥ Assembled Cylinder Head Orderly and repeatedly tighten bolts with engine oil at the cylinder head, as shown in figure.
  • Page 73 2.4.3. External Parts(A) EJM2170I <Reassembly Steps> 1. Cylinder head cover 4. Fan belt 2. Fan pulley 5. Starter motor 3. Generater 6. Dipstick and guide tube - 69 -...
  • Page 74 ¥ Cylinder Head Cover Orderly tighten the bolt as it is shown in figure. 2.1 L 0.5 kg ¥ m Bolt Torque EJM2172I ¥ Fan Belt Adjust the fan belt tension See the 1.5.7. colling fan belt. ¥ Starter Motor Tighten bolts to the specified torque after assembling a starter motor to fly wheel housing.
  • Page 75 2.4.4. External Parts (B) EJM2004I <Reassembly Steps> 1. Oil filter 5. Injection nozzle 2. Oil pipe (Oil filter to oil cooler) 6. Fuel return pipe 3. Injection pump 7. Cooling fan 4. Injection pipe - 71 -...
  • Page 76 ¥ Injection Nozzle Ajdust the injection opening pressure with an Dust cover adjustment screw. Use a new gasket and dust cover when assembling the nozzle. 1.9 L 0.2 kg ¥ m Torque Nozzle gasket EJM2163S ¥ Fuel Injection Pipe Surely tighten the delivery valve holder to a specified torque.

  • Page 77: System Of Lubrication

    3. System of Lubrication 3.1. General Description (13) (14) (15) (16) (17) (18) (19) (20) (10) (12) (21) (22) (23) (11) (24) EJM3001I (1) Full flow filter (13) Oil pressure and oil filter warning lamp (2) By-pass valve (14) Starter switch (3) Valve opening pressure 1kg/cm (15) Battery (4) Valve opening pressure 8kg/cm...

  • Page 78: Oil Pump

    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 - 74 -...
  • Page 79 • Inspection and repair Visually Inspect the disassembled parts whether there are excessive wear or damage. Use a feeler gauge to measure the clearance between the oil pump cover (oil pump case) inside surface and the driven gear. If the clearance exceeds the specified limit, the drive gear and/or the oil pump cover must be replaced.
  • Page 80 3.3. Oil Cooler ¥ Disassembly EJM3008S <System of Disassembly> 1. Element. 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 it if there are worn or defect parts. - 76 -...
  • Page 81 ¥ Reassembly Reassembly is reverse order of disassembly. 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. ¥ Oil cooler element tigthening bolts Tighten the bolts with the specified torque after assembling an oil cooler element.

  • Page 82: Cooling System

    4. Cooling System 4.1. General Description Water pipe Thermostat Cylinder head Radiator Reserve tank Cylinder block Water pump EJM4001I - 78 -...

  • Page 83: Coolant Pump

    4.2. Coolant Pump ¥ Disassembly EJM4003S <Disassembly order> 1. Pulley 5. Pulley Flange 2. Cover 6. Snap ring 3. Gasket 7. Seal 4. Impeller 8. Impeller shaft - 79 -...
  • Page 84 Remover ¥ Impeller Remove the impeller with a jig. EJM4005S ¥ Remove the bearing by pressing with a bench press. Bench press EJM4006S ¥ Snap Ring Remove the snap ring with a snap ring plier. EJM4007S ¥ Seal Unit and Washer Seal Remove the seal unit with a hammer.
  • Page 85 ¥ Reassembly EJM4013S <Reassembly order> 1. Unit Bearing 5. Impeller 2. Seal 6. Gasket 3. Snap Ring 7. Cover 4. Pulley Fiange 8. Pulley - 81 -...
  • Page 86 ¥ Unit Bearing Spreading of multipurposable grease With bench press, set up the unit bearing at the pump. Outside from sealed surface EJM4011I ¥ Snap Ring Assemble the snap ring with a snap ring plier. EJM4007S ¥ Pulley Center Assemble pulley center with a bench press. EJM4015S ¥...
  • Page 87 5. Fuel System 5.1. General Description Injection nozzle Fuel filter Injection pump Fuel tank EJM5001I - 83 -...
  • Page 88 5.2. Fuel Filter ¥ Disassembly EJM5020S <Disassembly> 1. Cover 4. Cartriage 2. Seal ring 5. Bolt assÕy 3. Plug screw Refer to section 1.5.2., 1.5.3. 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.
  • Page 89 5.3. Injection Nozzle ¥ Disassembly EJM5003S <Disassembly> 1. Nozzle holder cap nut. 7. Retaining nut. 2. Cap nut gasket. 8. Injection nozzle. 3. Nozzle adjusting screw. 9. Injection pipe connector. 4. Spring seat. 10. Connector gasket. 5. Push rod spring. 11.
  • Page 90 Inspection and Repair Correct and replace it if there are worn or defect parts. ¥ Push Rod Spring Check wear, damage and corrosion, etc. EJM5005S ¥ Nozzle Holder Push Rod 1. Check the nozzle holder push rod curvature. 2. Check whether connected surface with needle valve is damaged or not.
  • Page 91 ¥ Reassembly Reassembly is reverse order of disassembly. EJM5008S <Reassembly order> 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 5. Retaining nut 11.
  • Page 92 Nozzle Connector Torque 5.5±0.5 kg ¥ m EJM5009S ¥ Injection Nozzle Clean injection nozzle Assemble nozzle to be correctly fixed to dowel pin on nozzle hold body. EJM5010S ¥ Retaining Nut Torque 7±1 kg ¥ m EJM5011S ¥ Adjustment of Screw Adjust with the adjustment screw.

  • Page 93: Injection Pump

    5.4. Injection Pump 5.4.1. Adjustment of Injection quantity. 101605-9630 Injection quantity shonld be adjusted, 0000000000(Serial NO) seeing adjustment data of injection pump model as Pump NO. 101062-8120 described below. NP-PE S6A95C410RS2000 LICENCE BOSCH EJM5014I 5.3.2. Calibration data <Test conditions> Injection pump 101605-9630 Injection nozzle D.P.I.C.
  • Page 94 5.4.2. Injection Pump Disassembly 133a 131a 130a 132a 104a 112a 115a 118a 117a 92a 93a 91a 101a 154 152 91 93 92 122 121 18 23 20 21 196 195 194 192 191 EJM5018S 1. Pump Housing 56. Shim 117a. Pipe connectin bolt 2.
  • Page 95 5.4.3. 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 96 6. 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 97 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 98 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 99 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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