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Engine - DB58, DB58T & Db58ti PDF
Engine - DB58, DB58T & Db58ti PDF
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.
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
Disassembly Cleaning
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
• 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)
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
2.1±0.5
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
5.5±1
EJM1004S
-7-
�Crankshaft, Piston, and Flywheel
(Unit : kg∙m)
A type : 12±0.25
B type : 9.25±0.25
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
� 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.
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
<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
EJM1024S
� CAUTION�
�The marked (*) can be
changed according to the
loaded vehicles. ①
� 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
1) Good
2) Inferiority (orifice)
3) Inferiority ((dripping)
EJM1028S
EJM1029S
Strainer
Elimination
plug
EJM1031S
- 22 -
1.5.6. Air Bleeding
EJM1033I
1.5.8. Thermostat
� Inspection
Thermo
Visualy inspect the thermostat. meter
Bar
When inspect,if excessive wear or damage is
discovered, replace thermostat.
- 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
- 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.
� 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
EJM1039I
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
EJM1042S
EJM1016I
� 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
� 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
EJM1046S
Standard Limit
- 28 -
1.5.12. Inspection of Turbo charger
EJM1048S
EJM1049S
EJM1050S
EJM1051S
EJM1052P
- 29 -
1.6. Engine Repair Parts (Standard Engine)
EJM1053S
- 30 -
2. ENGINE DISASSEMBLY AND ASSEMBLY
2.1. Engine External Parts
�DB58
EJM2001I
- 31 -
�DB58T
EJM2002I
- 32 -
�DB58TI
EJM2003I
- 33 -
2.2. Disassembly
�DB58
3
5 2 4
11
1
8
10
EJM2004I
<Disassembly Steps>
- 34 -
�DB58T
2
7 6 3
13
4 11
10
12
EJM2005I
<Disassembly Steps>
- 35 -
�DB58TI
3 5
11
2
4 7
1
10
12
EJM2006I
<Disassembly Steps>
- 36 -
2.2.2. External Parts Disassambly Steps
�DB58
6
1
2
5
EJM2007I
<Disassembly Steps>
- 37 -
�DB58T
10 11
2 7
1
5 8
6
EJM2008I
<Disassembly Steps>
- 38 -
�DB58TI
4 11
12 1
6
5
13
10
8 3
7
EJM2009I
<Disassembly Steps>
- 39 -
2.2.3. Main Structured Parts
�DB58/T/TI
★ : Repair Kit
EJM2010S
<Diassembly Steps>
- 40 -
Engine Assembly
Importance
� Rocker Arm Shaft
Orderly release rocker arm shaft fixed bolts.(as
shown in figure)
EJM2013S
Front
EJM2014S
Wrench
EJM2015S
Crankshaft
pulley
� 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>
- 42 -
� Importance
<Idler Gear>
Prior to disassamble, measure as following.
Standard Limit
Feeler gauge
EJM2019S
Standard Limit
Thrust plate
Standard Limit
Camshaft
Cam Gear End Play 0.050-0.114 mm 0.2 mm Feeler
gauge
EJM2021S
Standard Limit
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>
Importance
� Split collar
Use the valve spring compressor when remove
split collar
- 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>
- 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
EJM2031S
EJM2032S
- 48 -
2.3. Inspection and Repair
Standard Limit
89.95-90.05 mm 89.65 mm
EJM2034S
� CAUTION�
�You must check of valve
depression if ground
chylinder head.
EJM2035S
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.
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
EJM2039S
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.
EJM2042I
Standard Limit
� CAUTION�
�Contact smoothed face of
1
valve seat insert.
- 51 -
� Correction of Valve Seat Insert 150
1) Remove the carbon deposits from the valve A
seat insert surface. 30
EJM2045I
� CAUTION�
�Use mediated handle of
valve cutter.
Do not move the handle EJM2046S
EJM2048S
- 52 -
2.3.3. Valve Spring
Standard Limit
EJM2049I
Exhaust and Intake Valve
49.0 mm 47.0 mm
Spring Free Length
Standard Limit
Standard Limit
- 53 -
2.3.4. Tappet
Irregularity of
EJM2041I contact
Standard Limit
EJM2052S
Standard Limit
EJM2053I
Limit
- 54 -
2.3.6. Rocker Arm Correction
EJM2055S
EJM2056S
Standard Limit
Standard Limit
- 55 -
Standard Limit
Standard Limit
EJM2060S
Standard Limit
EJM2061I
Cam bearing
EJM2063S
- 56 -
3) Agree with oil port of the cam shaft and the
cylinder oil port.
oil ports
EJM2064S
Standard Limit
EJM2065I D A
Limit
EJM2066S
Camshaft Run-Out (TIR) 0.12 mm
- 57 -
2.3.9. Cylinder Block and Liner
Standard Limit
� 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)
Limit
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.
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
1 105.990-106.000 105.973-105.984
2 106.00-106.010 105.984-105.995
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.
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
Standard Limit
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
� 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
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
EJM2086S
- 64 -
2.3.11. Connecting Rod
Standard Limit
� CAUTION�
�Align connecting rod bush
oil port and connecting rod
oil port.
Standard
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
2.3.12. Crankshaft
- 66 -
Classification Standard
Standard
Standard Limit
Standard Limit
EJM2094S
Main Bearing Cap Torque 24.1±1 kg∙m
A type B type
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
EJM2091S
� Grinding of Crankshaft
Pay attention the below described in order to
reuse the regrinded crank shaft.
- 68 -
� Grinding Limit of Crankshaft
Classification Limit
Standard Limit
Main Bearing
0.039-0.098 mm 0.11 mm
Clearance
Standard Limit
Connecting
0.03-0.07 mm 0.10 mm
Rod Bearing
<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)
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
EJM2102S
- 70 -
2.4. Reassembly
<NA/T> <TI>
EJM2103S
- 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
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
EJM2106I
- 72 -
� Assembly parts of Cylinder Head
-DB 58/T
<Order of Assembly>
- 73 -
-DB 58TI
★ :Repair Kit
EJM2108S
<Order of Assembly>
- 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
EJM2110S
Painted parts
EJM2111I
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)
EJM2115S
EJM2117S
Spot face
EJM2118S
- 76 -
� Assembly of Rocker Arm and Rocker Arm Shaft
EJM2119S
<Order of Assembly>
Caution
- 77 -
2.4.2. Inside parts
★ : Repair Kit
EJM2120S
<Order of Assembly>
* 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.
EJM2121S
� 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
EJM2125S
- 79 -
Tightened Torque 24. 0±1 kg∙m
EJM2127S
� Cam shaft
Tighten thrust plate bolt so as to be fixed cam
shaft gear port.
EJM2129S
- 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
EJM2132S
Cylinder
Number
EJM2133S
Classified
TY TY
11
11T , 12T
(Bolt head)
- 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.
� 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.
EJM2137S
� Oil Cooler
Orderly assemble the oil cooler bolt after set up
the spreaded sealant at the oil cooler gasekt.
EJM2138S
- 82 -
� Major Component Reassembly Parts (II)
- DB58/T
★ : Repair Kit
EJM2139S
<Reassembly Steps>
- 83 -
- DB58TI
★ : Repair Kit
EJM2141S
<Reassembly Steps>
- 84 -
Importance
� Flywheel
1) Apply engine oil on the flywheel bolt.
2) Orderly tighten the fly wheel bolt.(see figure)
� Injection Pump
Tighten the injection pump bolt as it is a
specified torgue after assemble the injection
pump that it was agreed idler gear angle "C"
carving seal and injection pump driving gear
angle "C".
Injection pump �B
�mark
gear Idler gear
�C
�mark
Camshaft
�A
�mark gear
Crankshaft gear
EJM2130S
EJM2144S wrench
EJM2145S
- 85 -
� Water Pump
Spreading Sealant
Prior to put on the gasket, spread a sealant.
EJM2146S
Front
EJM2147S
Standard(mm) Limit(mm)
115 116.2
102 103.2
EJM2150S
- 86 -
2.4.3. External Parts(A)
• DB58
6
1
2
5
EJM2170I
<Reassembly Steps>
- 87 -
�DB58T
10 11
2 7
1
5 8
6
EJM2171I
<Reassembly Steps>
- 88 -
�DB58TI
7
2 11 12
13
8
1
10
5 9
6
EJM2153I
<Reassembly Steps>
- 89 -
� Cylinder Head Cover
Orderly tighten the bolt as it is shown in figure.
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.
EJM2155S
EJM2156S
� Turbocharger
Tighten in the interim torborcharger nut.
Completely tighen the nut after it is assemble
oil pipe.
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
- 91 -
2.4.4. External Parts (B)
�DB58
9
7 10
1 8
11
4
EJM2160I
<Reassembly Steps>
- 92 -
�DB58T
12
7 8 11
1
10 3
13
4
2
EJM2168I
<Reassembly Steps>
- 93 -
�DB58TI
11 9
2 6
12
10 7
13
3
1
EJM2169I
<Reassembly Steps>
- 94 -
Importance
� Injection Nozzle Dust cover
EJM2164S
� Oil Filter
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.
� Suction Pipe
EJM2167S
- 95 -
3. SYSTEM OF LUBRICATION
3.1. General Description
(1)
(13) (14) (15)
(2)
(6) (16)
(7)
(5)
(10) (26)
(23) (24) (25)
(11)
(27)
DB58T/TI
EJM3001I
- 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
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>
- 99 -
�Reassembly
Reassembly shall be inverted inverted from the disassambled.
1
2
3
EJM3009S
<Reassembly order>
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>
- 102 -
Disassembly
�DB 58TI
9 8
3 2
7 4
EJM4004S
<Disassembly order>
- 103 -
Importance
� Impeller
Remover
Remove the impeller with the jig.
EJM4005S
� Hub
Remove the pulley center as it is moderately Bench press
EJM4006S
� Snap Ring
Remove the snap ring with the snapping plier.
EJM4007S
� Unit Bearing
Remove the unit bearing as it is moderate with
the bench and press.
EJM4008S
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>
- 106 -
Reassembly
• DB58TI
9 1
6 7
2 5
EJM4014S
<Reassembly order>
- 107 -
Importance
Spreading of multipurposable grease
� Unit Bearing
By untilizing bench press set up the unit
bearing at the pump.
� Snap Ring
Assemble the snap ring with the snap ring plier.
EJM4007S
� Pulley Center
Assemble pulley center with the bench press.
EJM4015S
Spreading of
sealant
EJM4016S
EJM4017S
- 108 -
� Impeller
Bench press
Assemble impeller to be in specified clearance
between impeller and body with rock bench
press.
Feeler gauge
EJM4018S
� Pulley
Tighten the pulley bolt As it is a specified
torque.
EJM4019S
4.3. Thermostat
Agitating rod
Wood
piece
EFM2055I
- 109 -
5.2. Fuel Filter
� Disassembly
3 ★ 4
★ 5
7 6
7
★
1
★ : Element kit
EJM5003S
<Disassembly Steps>
Reassembly
To reassembly the fuel filter, follow the disassembly procedure in the reverse order.
- 111 -
� Reassembly
EJM5008S
<System Reassembly>
- 113 -
5.3. Injection Pump
� 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
�DB58
<Test conditions>
LENGTH 580 mm
<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
- 115 -
� DB58TI
<Test condition>
101605-9610
0000000000000000000
Pump NO.- 000000000
S6AD100B410R
LICENCE BOSCH
EJM5021I
LENGTH 580 mm
<Governor Adjustment>
RACK LIMIT
14
OR MORE
IDLING SUB SPRING SET
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
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
- 119 -
6. EINGINE ELECTRICALS
6.1. Starter motor
Rating 30 sec
� Construction
Shift lever
Thru bolt
Dowel pipe
EJM6001S
- 120 -
6.2. Alternator
� Specifications
� Generator
EJM6002S
<Disassembly steps>
- 121 -
7. TURBO CHARGER
� General Description
RHB6A
EJM7001S
RHB7
EJM7002S
- 122 -
RHC7
EJM7003S
EJM7004S
Moder HY35
EJM7005I
- 123 -
7.1. Inspection of Rotor Shaft
� Rotor Shaft Axial Play Measurement
1) Assemble dial indicator at the turbine
housing as the shown in figure.
2) Use dial indicator to measure the rotor shaft
axial play with the moving shaft push and
pull. Read the total indicator reading(TIR).
Limit
EJM6006S
Rotor Shaft Axial Play (TIR) 0.11 mm
EJM6007S
RHB6A Limit
- 124 -
8. CAUSE OF TROUBLE, DIAGNOSIS AND TROUBLESHOOTING
1) Starting Trouble
- 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
- 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
- 127 -
5) Fuel consumption excessive
- 128 -