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CONTENTS

1. GENERAL INFORMATION

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1.1. General Repair Instructions

1.4. Major Part Fixing Bolts

1.2. Engine Specifications

1.5. Maintenance

1.3. Torque Specifications

1.6. Engine Repair Parts

2. ENGINE DISASSEMBLY AND ASSEMBLY

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2.1. Engine External Parts

2.3. Inspection and Repair

2.2. Disassembly

2.4. Reassembly

3. SYSTEM OF LUBRICATION

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3.1. General Description

3.3. Oil Cooler

3.2. Oil Pump

4. COOLING SYSTEM

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4.1. General Description

4.2. Coolant pump

5. FUEL SYSTEM

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5.1. General Description

5.3. Injection Nozzle

5.2. Fuel filter

5.4. Injection Pump

6. CAUSE OF TROUBLE, DIAGNOSIS AND TROUBLESHOOTING

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Содержание D50S-2

Страница 1: ...Service Manual Diesel Engine 5 8 Liter DB58 D50S 2 D60S 2 D70S 2 SB2148E00 Oct 1998...

Страница 2: ...lowing symbol IImproper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair...

Страница 3: ...his manual the following symbols are used to indicate the type of service operations to be performed Removal Adjustment Installation Liquid gasket application Disassembly Cleaning Reassembly Pay close...

Страница 4: ...ASSEMBLY AND ASSEMBLY 24 2 1 Engine External Parts 2 3 Inspection and Repair 2 2 Disassembly 2 4 Reassembly 3 SYSTEM OF LUBRICATION 73 3 1 General Description 3 3 Oil Cooler 3 2 Oil Pump 4 COOLING SYS...

Страница 5: ...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 funct...

Страница 6: ...Fuel filter type Cartridge type Injection pump type Bosch in line A type Governor type Mechanical governing RSV type Injection nozzle type Multi hole type Fuel injection pressure Kg cm2 220 Compressi...

Страница 7: ...1 5 816 b 2 0 18 b 1 5 20 b 1 5 22 b 1 5 24 b 2 0 0 4 0 8 0 8 1 8 2 1 3 5 2 0 3 4 5 0 7 5 4 6 7 0 7 8 11 7 7 3 10 9 10 6 16 0 10 2 15 2 15 4 23 0 21 0 31 6 25 6 42 2 36 6 55 0 0 5 1 0 1 2 2 3 2 8 4 7...

Страница 8: ...ixing Bolts Cylinder Head and Block Unit kg m 4 2 7L 0 25 19 5 L 1 8 5 3 L 1 2 1 L 0 5 5 3 L 1 11 5L05 hexagon bolt Torque Control Method 4 Kg m 90 60 0 30 docoecagon bolt Angle Control Method EJM1001...

Страница 9: ...Intake and Exhaust Manifold DB58 Unit kg m 5 2 9 L 0 3 2 6 L 0 5 EJM1007S...

Страница 10: ...6 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...

Страница 11: ...Oil Pan and Dipstick Unit kg m 7 2 6 L 0 5 8 0 L 1 0 2 9 L 0 3 EJM1003S...

Страница 12: ...Cam Shaft and Rocker Arm Unit kg m 8 16 L 1 5 Engine oil application 5 5 L 1 2 6 L 0 5 2 6 L 0 5 3 1 L 0 5 3 1 L 0 5 EJM1004S...

Страница 13: ...Crankshaft Piston and Flywheel Unit kg m 9 22 3 L 2 2 60 L 5 A type 12 L 0 25 B type 9 25 L 0 25 B type or A type EJM1005S Mark ON BOLT HEAD...

Страница 14: ...Thermostat and Thermostat Housing Unit kg m 10 EJM1006S 5 3 L 1 5 3 L 1 2 6 L 0 5...

Страница 15: ...Timing Gear Case and Flywheel Housing Unit kg m 11 EJM1010S 16 0 L 1 0 16 0 L 1 0 Outside 2 6 L 0 5 2 6 L 0 5...

Страница 16: ...Oil Cooler Oil Filter and Oil Pump Unit kg m 12 2 6 L 0 5 2 6 L 0 5 5 3 L 1 0 EJM1011S 5 3 L 1 0 5 3 L 1 0...

Страница 17: ...Fuel System Unit kg m 13 EJM1013S 1 9 L 0 2 1 3 L 0 2 3 1 L 0 2 4 2 L 0 8...

Страница 18: ...filter Assembly 1 Wipe the oil filter mounting face with a clean rag to install a new filter 2 Lightly oil the O ring part 3 Turn the new oil filter until the sealing face is fitted against the O ring...

Страница 19: ...Release nozzle holder cap with a wrench 3 Disassemble the injection nozzle holder from a vise Adjusting Procedure Injection Opening Pressure Check 1 Assemble nozzle holder at nozzle tester 2 Release...

Страница 20: ...zzle sparay condition Prior to injecting the fuel completely compress 4 6 times and finally inject See figure for injection condition 1 Good 2 Inferiority orifice 3 Inferiority dripping EJM1027S EJM10...

Страница 21: ...rainer Strainer A 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 4 Tighten...

Страница 22: ...oosening the alternator mounting bolt and the alternator adjusting bolt and pivoting the alternator Be sure to retighten the bolts after adjusting the belt tension Cooling Fan Belt Deflection 8 0 12 0...

Страница 23: ...TDC on the compression stroke 2 Adjust valve clearances when 1 or 6 piston is TDC on compression stroke 3 Release adjusted screw See figure 4 Insert a 0 4mm feeler gauge between rocker arm and valve s...

Страница 24: ...t lock plate 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 foregoing procedure to align...

Страница 25: ...starting of the engine 8 Make sure that crankshaft pulley and point is specifically on injection starting angle line Blow out remained fuel from delivery valve holder EJM1042S EJM1054I TDC EJM1044I 4...

Страница 26: ...dure 1 Release injection pump mounting nuts 2 To advance injection timing rotate injection pump for injection pump notch line to be toward below To retard the injection timing rotate injection pump in...

Страница 27: ...pump hole cover gasket 7 Tappet chamber cover gasket 23 Wate pump gasket 8 Tappet cover fixing bolt gasket 24 Oil pipe gasket 9 Crankshaft rear oil seal 25 Oil pipe gasket 10 Timing gear case oil seal...

Страница 28: ...2 Engine Disassembly and Assembly 2 1 Engine External Parts 24 EJM2001I...

Страница 29: ...2 2 1 External Parts 25 3 1 6 7 5 4 2 EJM2004I Disassembly Steps 1 Cooling fan 2 Fuel retrun pipe 3 Injection pipe 4 Injection nozzle 5 Injection pump 6 Oil pipe Oil filter to oil cooler 7 Oil filter...

Страница 30: ...2 2 2 External Parts Disassembly Steps 26 6 1 5 4 2 3 EJM2007I Disassembly Steps 1 Dipstick and guide tube 2 Starter motor 3 Fan belt 4 Generator 5 Fan pulley 6 Cylinder Head cover...

Страница 31: ...ing pinion 2 Rocker arm shaft assembly 10 Starting handle nut 3 Push rod 11 Taper bushing 4 Cylinder head bolt 12 Crankshaft pulley and dust thrower 5 Cylinder head assembly 13 Timing gear cover 6 Cyl...

Страница 32: ...se 54mm wrench when removing the crank shaft pulley nut Taper Bushing Use the taper bushing remover as shown in figure tool when removing the crank shaft pulley bushing Flywheel Orderly release the fl...

Страница 33: ...4 Fly wheel housing 5 Piston Ass y 6 Idle gear 7 Cam shaft 8 Tappet 9 Timing gear case 10 Idle gear shaft 11 Crank shaft bearing cap 12 Crank shaft bearing lower part 13 Thrust bearing 14 Crank shaft...

Страница 34: ...ual to idle gear backlash Cam Shaft Prior to disassembly measure as following Crankshaft Bearing Cap Prior to disassembly measure the crankshaft end play at the thrust bearing EJM2019S EJM2020S EJM202...

Страница 35: ...31 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...

Страница 36: ...EJM2027S 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 Thermosta...

Страница 37: ...33 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...

Страница 38: ...removing it Piston Rings Remove the piston ring with piston ring remover Snap Ring and Piston Pin 1 Use the snap ring pliers when removing the snap ring 2 Pull out piston pin as tapping with hammer an...

Страница 39: ...der head lower face 2 You must grind when flatness is more than normal however replace the cylinder head if the grinding scope is out of specification Flatness of Cylinder Head Height of Cylinder Head...

Страница 40: ...side diameter 2 Measure valve guide inside diameter with a caliper calibrator or telescoping gauge The gap of outside valve stem diameter and inside guide diameter is valve stem clearance Replacement...

Страница 41: ...t must be replaced if the measured value exceeds the specified limit Replacement of Valve Seat Insert Removal of Valve Seat Insert 1 Arc weld entire inside circumference of the valve seat insert 2 See...

Страница 42: ...alve seat insert too much 3 Spread compound on the surface of valve seat insert 4 Grind the valve and valve seat with the lapping cup 5 Insert valve into valve guide 6 Check contact surface of valve w...

Страница 43: ...measured value is excessive from the specified limit Tension of Valve Spring Measure the valve tension with a tension measure Replace the valve spring if the measured value is out of the specified li...

Страница 44: ...e flatness of push rod with a feeler gauge Measure it by slowly rolling push rod on the flat desk by hand See figure EJM2041I EJM2052S EJM2053I EJM2054I Standard Limit Tappet Outside Diameter 27 97 27...

Страница 45: ...rometer Replace shaft if the measured value is out of the specified limit Clearance of Rocker Arm Shaft and Rccker Arm 1 Measure the inside diameter of rocker arm bushing with tne vernier caliper 2 Me...

Страница 46: ...2062S EJM2063S Standard Limit Outside Diameter of 44 945 44 975 mm 44 9 mm Idle Gear Shaft Standard Limit Clearnance between Idler 0 025 0 085 mm 0 2 mm Gear and ldler Gear Shaft Standard Limit Cleara...

Страница 47: ...Diameter 56 0 mm 55 6 mm Limit Camshaft Run Out TIR 0 12 mm oil ports 3 1 Measurement of the Cylinder Liner Bore Measure the bore from measuring location 1 to direction of the crank shaft 3 and counte...

Страница 48: ...tely determine the liner grade 1 EJM2072I EJM2073S 44 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 ga...

Страница 49: ...nd the cylinder liner outside Cylinder bore and cylinder liner outside diameter Assembley of the Cylinder Liner 1 Cleanly wash both of the cylinder liner inside outside and block inside 2 Cleanly wash...

Страница 50: ...mit A 101 955 101 974 mm B 101 975 101 994 mm Steel Strut 46 2 1 Selection of Piston Grade Correctly selected pistion grade to operate engine efficiently Meassure the bore after assembling the cylinde...

Страница 51: ...0 0 070 mm 0 15 mm Piston Ring Gap 1 Horizontally assemble the piston ring into cylinder liner original place 2 Push inverted piston ring to be reached 1 2 The cylinder liner diameter is the smallest...

Страница 52: ...it Clearance between Piston Pin and Piston Pin Hole 0 050 mm Piston Pin Hole Measure diameter of the pin hole with inside dial gauge EJM2084S Standard 36 000 36 008 mm Piston Pin Measure the pin outsi...

Страница 53: ...easured value is out of the specified limit Disassembly of Connecting Rod Bush 1 Fix connecting rod with a vice 2 Pull out connecting rod bush with brass rod and the Press or hammer Assemble of Connec...

Страница 54: ...excessive wear or damage or not 2 Check assembled front rear end oil seal part whether there are excessive wear or damage or not 3 Replace or repair the crank shaft if excessive wear or damage is on c...

Страница 55: ...p Torque 24 1 L 1 kg m Main Bearing Diameter 80 mm A type B type Connecting Rod Cap 12 L 0 25 9 75 L 0 25 Bolt Torpue Classification Connecting Rod 64 0 mm Bearing Diameter 11 TY 11T TY 12T Clearance...

Страница 56: ...earing to be maintained tension enough and set up its regular position with the finger pressure Crankshaft Grinding Pay attention the below described in order to reuse the regrinded crank shaft Proced...

Страница 57: ...dersize bearing is used Crank Shaft Gear 1 Disassemble the crank shaft gear with a crank shaft remover Visually inspect the crankshaft gear Replace the crankshaft gear if excessive wear or damage is d...

Страница 58: ...y attention that temperature of ring gear is not higher than 200 C 2 Assemble ring gear to flywheel as tapping with a hammer when it is heated enough Rear Oil Seal Disassemble oil seal from fly wheel...

Страница 59: ...2 4 Reassembly 2 4 1 General Parts 55 EJM2103S Order of Assembly 1 Piston 4 Piston ring 2 Piston pin and connecting rod 5 Connecting rod bearing 3 Snap ring...

Страница 60: ...st compressed ring Make sure the direction of 1st and 2nd compressed ring as shown in figure 2 Spread engine oil to surface of piston ring 3 Check it whether piston ring is smoothly rotating at the in...

Страница 61: ...Assembly 1 Valve stem oil seal 2 Intake and exhaust valves 3 Spring seat Lower 4 Intake and exhaust valve sping 5 Spring seat Upper 6 Key 7 Thermostat housing and gasket 8 Thermostat 9 Coolant outlet...

Страница 62: ...gine oil to valve stem 3 Assemble valves in guicle Spring of Intake and Exhaust Vavle Assemble the valve spring of which painted direction is toward bottom Spring Seat Split Pin 1 Assemble the split p...

Страница 63: ...specified torque in order see figure Exhaust Manifold and Gasket 1 Assemble the exhaust manifold and gasket of which TOP mark is shown 2 After assembling the exhaust manifold assemble blots to the sp...

Страница 64: ...0 Assembly of Rocker Arm and Rocker Arm Shaft Rocker Arm Shaft Assemble the rocker arm shaft of which oil hole is toward up EJM2119S Order of Assembly 1 Rocker arm shaft 3 Rocker arm 2 Spring 4 Bracke...

Страница 65: ...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 Oil pump and coupling 5 Timing gear case 1...

Страница 66: ...oove side is toward crank shaft side Crank shaft Bearing Cap 1 Spread the engine oil at the bearing cap bolt 2 Assemble the bearing cap at the crank shaft Make sure the direction of arrow is toward fr...

Страница 67: ...haft to be toward cam shaft Idle Gear Assemble the gear so as to be aligned with every timing mark of A B C Assemble thrust washer of which the chamfered side is toward front side EJM2126S EJM2127S EJ...

Страница 68: ...embling pistion 5 Push piston in position until con rod touch the crank pin 6 Assemble the connecting rod bearing cap to the connecting rod idenfifying cylinder NO Torque the bolt to below spec Oil Pu...

Страница 69: ...an gasket and liquid gasket between cyliner block and oil fan Oil Cooler Assemble the oil cooler bolt in order figure after putting liquid gasket and the oil cooler gasekt on the block EJM2135S EJM217...

Страница 70: ...sh rod 3 Rocker arm and rocker arm shaft 4 Cylinder head bolt 5 Cylinder head ass y 6 Cylinder head gasket 7 Water pump 8 Tappet chamber cover 9 Oil pump driving pinion 10 Crankshaft pulley nut 11 Tap...

Страница 71: ...aligned each other Crank shaft pulley nut Tighten a nut with wrench EJM2142S EJM1029S EJM2130S EJM2144S EJM2145S Bolt Torque 22 3 L2 2 kg m Bolt Torque 2 6 L 0 5 kg m Torque 60 0 L 5 0 kg m Tappet Cha...

Страница 72: ...eatedly tighten bolts with engine oil at the cylinder head as shown in figure Assembly Rocker Arm Shaft Orderly tighten the rocker arm bolt as shown in figure Adjust valve clearance Refer to section 1...

Страница 73: ...69 2 4 3 External Parts A 6 1 5 4 2 3 EJM2170I Reassembly Steps 1 Cylinder head cover 2 Fan pulley 3 Generater 4 Fan belt 5 Starter motor 6 Dipstick and guide tube...

Страница 74: ...is shown in figure 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 EJM217...

Страница 75: ...4 External Parts B 3 1 6 7 5 4 2 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 4 6 5...

Страница 76: ...eason for leakage from the control rack and pipe if it is in excessive tightening Oil Filter Fuel Pipe Make sure not to use different joint bolt when assembling it Torque joint bolts to specified torq...

Страница 77: ...kg cm2 5 Paper filter 6 By pass valve 7 Oil cooler 8 Valve opening pressure 2kg cm 2 9 Oil relief 10 Oil pump 11 Oil strainer 12 Valve opening pressure 4 5kg cm 2 13 Oil pressure and oil filter warnin...

Страница 78: ...74 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 4 6 6 3 2 1...

Страница 79: ...d 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 is as follows Limit o...

Страница 80: ...bly 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 o...

Страница 81: ...ug 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 Reassembly Rea...

Страница 82: ...4 Cooling System 4 1 General Description 78 EJM4001I Radiator Reserve tank Water pump Cylinder block Cylinder head Thermostat Water pipe...

Страница 83: ...79 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 6 5 7 8 4 3 2 1...

Страница 84: ...JM4011I 80 Impeller Remove the impeller with a jig Hub Remove the bearing by pressing with a bench press Snap Ring Remove the snap ring with a snap ring plier Seal Unit and Washer Seal Remove the seal...

Страница 85: ...81 Reassembly EJM4013S Reassembly order 1 Unit Bearing 5 Impeller 2 Seal 6 Gasket 3 Snap Ring 7 Cover 4 Pulley Fiange 8 Pulley 7 7 6 5 2 1 8 3 4...

Страница 86: ...ng plier Pulley Center Assemble pulley center with a bench press Washer and Seal Unit Assemble it with a bench press after putting liguid gasket to the pump body contacting surface EJM4011I EJM4007S E...

Страница 87: ...5 Fuel System 5 1 General Description 83 Injection pump Fuel filter Fuel tank Injection nozzle EJM5001I...

Страница 88: ...ew 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 disc...

Страница 89: ...etaining 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 Nozzle holder body 6 Nozzle holder push rod...

Страница 90: ...on etc Nozzle Holder Push Rod 1 Check the nozzle holder push rod curvature 2 Check whether connected surface with needle valve is damaged or not Injection Nozzle Check the needle valve valve seat nozz...

Страница 91: ...bly 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...

Страница 92: ...dowel pin on nozzle hold body Retaining Nut Adjustment of Screw Adjust with the adjustment screw Nozzle Holder Cap Nut EJM5009S EJM5010S EJM5011S EJM5012S EJM5013S Nozzle Connector Torque 5 5 0 5 kg...

Страница 93: ...410RS2000 LICENCE BOSCH EJM5014I Injection pump 101605 9630 Injection nozzle D P I C No 105025 138A Injection nozzle holder D P I C No 105160 465A Nozzle opening pressure 220 kg cm 2 Injection pipe de...

Страница 94: ...3a Gasket 23 O ring 90 Camshaft 145 Screw Plug 30 Plunger 91 91a Taper roller bearing 146 Gasket 36 Delivery valve 92 92a Camshaft ring 152 Pipe connection bolt 37 Delivery valve spring 93 93a Shim 15...

Страница 95: ...on lever bolt 136 Nut 211 Snap ring 39 Nut 137 Gasket 220 Damper spring 44 Speed lever stop bolt 138 Cap 236 Gasket 46 Cap 140 Idling spring assembly 239 Gasket 47 Tension lever shaft plug 141 Nut 240...

Страница 96: ...h skip Replacement 2 Amateur field coil strain Replacement 3 Brush communicator inferiority Correction or replacement 4 Shortage of battery Charge or replacement 5 Earth inferiority correction Fuel Sy...

Страница 97: ...termediate speed 2 Governer spring tension weakness correction or replacement Unstopable at high 1 Bend of linkage cable between accel pedal and injection pump correction speed drive 2 Bend of injecti...

Страница 98: ...nd crank shaft bearing or replacement 2 Crank shaft side wear grind crank shaft or replacement 3 Oil port system clog Wash 4 Bearing strain replacement grind crank shaft Conn rod 1 Connecting rod bear...

Страница 99: ...t 4 Uncorrect setting of piston ring gap adjustment 5 Uncorrect set up of piston ring adjustment 6 Oil controlling return home clog replacement 7 air breather clog wash 7 Exhaust Escessive Smoke State...

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