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Crankshaft gear replacement

Removal : Remover

Installation

Installer

Remover

Installer

Crankshaft gear

Inspect the crankshaft gear
- Before the gear disassembly, check the crank gear

backlash.

- If excessive wear of any damage is found through

the inspection, replace the crankshaft gear.

Refer to
"Major components disassembly"
- Gear backlash.

Pilot bearing replacement

Removal : remover
Installation : Use a brass bar and hammer.

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Содержание DB33A

Страница 1: ...Service Manual Diesel Engine 3 3 Liter DB33A SB2013E02 May 1998...

Страница 2: ...lowing symbol Improper 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: ...ssential In this manual the following symbols are used to indicate the type of service operations to be performed Removal Installation Disassembly Reassembly Align the marks Directional Indication Ins...

Страница 4: ...1 General Description 5 3 Injection Nozzle 5 2 Fuel Filter 6 SPECIAL TOOL LIST 74 WORLDWIDE NETWORK CONTENTS 1 GENERAL INFORMATIONS 1 1 1 General Repair Instructions 1 4 Major Parts Fixing Bolts 1 2 E...

Страница 5: ...n 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 fun...

Страница 6: ...on pump type VE DOOWON Governor type Mechanical governing Injection nozzle type Multi hole type 6 hole VCO nozzle Fuel injection pressure Kg cm2 220 3 128 psi Compression pressure kg cm2 30 at 200 RPM...

Страница 7: ...16 2 0 18 1 5 20 1 5 22 1 5 24 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 2 8 4 6 6 2 9 3...

Страница 8: ...4 1 4 Major Parts Fixing Bolts Cylinder head and block unit kg U m 15 2 lb ft 2 1 10 0 11 5 2 5 5 3 72 32 lb ft 83 17 lb ft 18 0 lb ft 38 33 lb ft...

Страница 9: ...5 Intake and exhaust manifold unit kg U m 15 2 lb ft 2 1 2 1 15 2 lb ft...

Страница 10: ...6 Cylinder block and others unit kg U m 2 1 2 6 7 9 2 6 2 4 13 7 Lubricate with engine oil Lubricate with engine oil 99 1 lb ft 15 2 lb ft 18 8 lb ft 18 8 lb ft 57 0 lb ft...

Страница 11: ...7 Cylinder block and others unit kg U m 2 6 2 6 2 6 5 3 5 3 38 3 lb ft 38 3 lb ft 18 8 lb ft 18 8 lb ft 18 8 lb ft...

Страница 12: ...8 Crankshaft and camshaft unit kg U m 44 0 5 5 2 5 16 0 16 0 12 0 25 9 75 0 25 318 lb ft 39 8 lb ft 18 1 lb ft 115 7 lb ft 115 7 lb ft 70 5 1 8 lb ft 86 8 1 8 lb ft...

Страница 13: ...9 Thermostat and housing unit kg U m 2 1 5 3 25 1 lb ft 10 5 lb ft...

Страница 14: ...t 7 Gasket Oil cooler 8 Gasket Oil pump cover 9 Oil seal Crankshaft RR 10 Gasket Retainer 11 Gasket Case and cylinder block 12 Gasket Cover and case 13 Gasket Oil pan drain plug 14 Gasket Oil pan and...

Страница 15: ...the No 1 cylinder or the No 4 cylinder to top dead center on the compression stroke by turning the crankshaft until the TDC notched line on the crankshaft pulley is aligned the timing pointer 2 Check...

Страница 16: ...pointer are aligned Remove the inspection hole cover at the front of gear case cover Check the alignment between the notched line on the camshaft gear and the arrow mark of gear case cover Setting Ti...

Страница 17: ...er Adjust the timing pointer with the marking on the pulley 2 Remove 2 fixing bolts of timing flange and injection pump Remove bolt located at the center Insert the dial gauge to check the plunger lif...

Страница 18: ...sure in each cylinder with a compression gauge by engaging starter kg cm2 200 rpm Compression gauge adapter Standard 30 Limit 22 23 312 327 psi 1 6 5 Air Cleaner Dry type air cleaner Observe the air c...

Страница 19: ...store good elements in a clean dry place 1 6 6 Radiator Install the radiator cap tester and pressurize the radiator Inspect the cooling system if there any leak Measuring pressure kg cm2 1 0 14 2 psi...

Страница 20: ...the adjusting screw using a nozzle tester Incorrect Incorrect Correct 1 6 9 Fan Belt mm Fan pulley Depress here Generator pulley Crank pulley 1 6 10 Glow Plug Inspection Resistance Check the continuit...

Страница 21: ...17 2 Engine Assembly 2 1 General Description...

Страница 22: ...embly steps 1 Breather hose 2 Exhaust manifold 3 Oil guide tube and level gauge 4 Starter 5 Cooling fan belt 6 Alternator 7 Oil pan 8 Cylinder head cover 9 Rubber hose 10 Water pump 11 Thermostat hous...

Страница 23: ...4 2 7 5 3 1 3 2 Important operations Exhaust manifold assembly 2 Loosen the manifold fixing bolts in sequence of figure s shown Cylinder head cover 8 Loosen the head cover bolts in sequence of figure...

Страница 24: ...2 2 2 External Parts B Disassembly steps 1 Fuel injection pipe 2 Injection nozzle 3 Glow plug 4 Intake manifold 5 Oil pipe 6 Oil filter assembly 7 Injection pump 8 Oil cooler assembly 7 8 6 5 2 6 3 8...

Страница 25: ...Disassemble the engine control cable Injection nozzle 2 Avoid damaging the nozzle tips or other parts during disassembly Injection pump assembly 7 When disassembving the injection pump cap or tape th...

Страница 26: ...Fly wheel housing 7 Rear oil seal assembly 8 Oil pump cover 9 Oil pump assembly 10 Piston and connecting rod assembly 11 Crankshaft front nut and washer 12 Crankshaft pulley 13 Gear case cover 14 Idl...

Страница 27: ...the figure Flywheel 5 Loosen the flywheel bolts a little at a time in numerical sequence as shown in the figure Piston assembly 10 Remove any carbon deposits from the upper part of the cylinder bore...

Страница 28: ...rd 0 10 0 17 0039 0069 in Limit 0 3 012 in Backlash mm Includes the crankshaft gear camshaft gear and idle gear Crankshaft bearing cap and bearing 17 Measure the crankshaft end play before disassembly...

Страница 29: ...t 21 Remove the tappets and mark the cylinder number each tappet Be careful against the damages Wire Intake Exhaust Mark the cylinder No 2 2 4 General Components Rocker arm Bracket and shaft assembly...

Страница 30: ...ring compressor Disassembly steps 1 Spring retainer and valve cotter 2 Spring and spring seat 3 Valve 4 Valve stem oil seal Important operations Mark the cylinder No each component when it disassemble...

Страница 31: ...g rod assembly Important operations Mark the cylinder No each component when it disassembles Disassembly steps 1 Piston ring 2 Snap ring 3 Piston pin and connecting rod 4 Piston Piston ring Piston Pis...

Страница 32: ...e piston pin with brass bar 2 3 Inspection and Repair Make the necessary adjustments repairs and replacements if excessive wear or damage is discovered during inspection 2 3 1 Cylinder Head Lower face...

Страница 33: ...n mm Valve seat angle Valve seat angle Valve seat insert replacement Removal Arc weld the entire inside circumference of the valve seat insert Cooling the valve insert for a few minutes and pull out w...

Страница 34: ...ter mm Valve guide replacement Remover installer 45 Thickness Measuring point Remover installer Standard 1 5 059 in Limit 1 0 039 in Intake valve Exhaust valve Standard 8 946 8 961 352 353 in 8 921 8...

Страница 35: ...tandard less than 1 3 mm 051 in Limit 2 7 mm 106 in 1 0 mm 039 in 1 0 mm 039 in Inner Outer Remark for Industrial for Automotive Valve Spring Tension at 40 mm Set Length 42mm 1 65 in 44mm 1 73 in Rema...

Страница 36: ...a smooth flat surface as shown in the figure 2 3 6 Rocker Arm Shaft Assembly Inspect all disassembled parts for wear damage and any abnormalities Rocker arm shaft mm Micrometer Dial indicator Standar...

Страница 37: ...any abnormalities End play mm Camshaft journal diameter mm Camshaft Cam gear Thrust plate Camshaft gear Thrust plate Camshaft Feeler gauge Standard 19 01 19 03 748 749 in Limit 19 05 75 in Standard 0...

Страница 38: ...camshaft on a measuring stand Use a dial indicator to measure the camshaft run out Note the total indicator reading T I R Camshaft bearing Replace the camshaft gear if any damages or excessive backlas...

Страница 39: ...han the specified limit the camshaft must be replaced Camshaft gear Cam lobe height C Cam journal diameter A B 2 3 8 Idle Gear and Idle Gear Shaft Shaft outside diameter mm use a micro Clearance betwe...

Страница 40: ...f 2 500kg to fully seat the cylinder liner After installing the liner measure the cylinder liner projection and inner diameter Liner projection For the cast liner removal or installation is done easil...

Страница 41: ...015 in 101 963 101 977 4 014 4 015 in 20mm 2 3 10 Piston Piston Pin and Piston Ring Piston outer diameter mm Piston and liner bore clearance Standard mm 0 055 0 075 Piston ring Piston ring and ring gr...

Страница 42: ...arallelism Alignment per length of 100mm 3 94 in mm Bushing inside diameter Use a caliper calibrator and micrometer to measure the piston pin and connecting rod small end bushing clearance Piston pin...

Страница 43: ...cting rod bearing lower half tension If the tension is insufficient the bearing must be replaced 3 Reassemble the connecting rod and bearing cap Reamer Pin hole grinder 2 3 12 Crankshaft and Bearing C...

Страница 44: ...ure the connecting rod inside diameter with an inside dial indicator Crankshaft journal bearing Tension Fit the journal bearing into the journal bearing cap and check the tension with the same method...

Страница 45: ...25 2 989 in Torque kg U m 24 173 6 lb ft Journal bearing 76 j nominal diameter mm 2 992 in Crankshaft journal and bearing clearance mm Crankshaft run out mm 1 Mount the crankshaft on a set of v blocks...

Страница 46: ...ect the crankshaft gear Before the gear disassembly check the crank gear backlash If excessive wear of any damage is found through the inspection replace the crankshaft gear Refer to Major components...

Страница 47: ...e a hammer to install the ring gear when it is sufficiently heated Flywheel housing oil seal replacement Removal Use a pry bar and hammer Installation Use a oil seal installer 2 3 13 Flywheel and Hous...

Страница 48: ...ller 2 4 Engine Reassembly 2 4 1 Minor Components Piston and connecting rod assembly Disassembly steps 1 Piston 2 Piston pin 3 Snap ring 4 Piston ring 5 Connecting rod 1 2 3 4 3 5 Important operation...

Страница 49: ...t the piston moves smoothly on the piston pin Piston ring 4 1 Use a piston ring installer to install the three piston rings Install the piston rings in the following order oil ring M2nd compression ri...

Страница 50: ...e stem oil seal 1 Installer Lubricate the oil seals and valve guides and install the oil seals with an installer Intake and exhaust valves 2 1 Lubricate valve stems with engine oil 2 Install the valve...

Страница 51: ...d cotter key 4 Installer Spring compressor Use a spring compressor to push the valve spring into position Install the cotter key Set the cotter key by tapping lightly around the head of the collar wit...

Страница 52: ...ase 7 Camshaft assembly 8 Piston and connecting rod assembly 9 Oil pump assembly 10 Oil pump cover 11 Oil cooler 12 Injection pump assembly 13 Idle gear 14 Timing gear case cover 15 Crankshaft pulley...

Страница 53: ...rankshaft contact face Crankshaft bearing cap Lubricate the bearing cap bolts with engine oil Install the bearing caps to the crankshaft The arrow mark must be pointing to the front of the engine Tigh...

Страница 54: ...me rotate the crankshaft until the crank pin reaches its highest point Set the bearing cap cylinder number marks and the connecting rod cylinder number marks The marks must be facing the exhaust manif...

Страница 55: ...en the cooler bolts to the specified torque Start from the middle and work out to either side Injection pump assembly 12 Check the punched line of the injection pump body is aligned to the pump bracke...

Страница 56: ...as shown in the figure Crankshaft front nut 16 Wrench 41 mm Flywheel housing 17 Fixing bolts torque 14kg U m 101 25 lb ft Flywheel 19 Crankshaft gear Camshaft gear A mark C mark B mark Idle gaer Inje...

Страница 57: ...n the head bolts in the numerical order as shown in the figure Rocker arm shaft assembly 23 Tighten the rocker arm bracket bolts to the specified torque a little at a time in the numerical order shown...

Страница 58: ...eps 1 Breather hose 2 Exhaust manifold 3 Oil guide tube and level gauge 4 Starter 5 Cooling fan belt 6 Alternator 7 Oil pan 8 Cylinder head cover 9 Rubber hose 10 Water pump 11 Thermostat housing asse...

Страница 59: ...over 2 Tighten the bolts as shown in the figure Water pump assembly 3 Apply liquid gasket belco bond No 4 to the water pump gasket before installing the water pump Thermostat housing assembly 5 Apply...

Страница 60: ...gasket with the TOP mark side facing up Install either end of the distance tube in the spot facing Tighten the exhaust manifold and gasket fixing bolts in numerical order as shown in the figure Refer...

Страница 61: ...57 2 4 4 Extermal Parts B 6 7 1 3 2 5 4 2 1 3 6 Disassembly steps 1 Oil filter and bracket 2 Oil pipe 3 Intake manifold 4 Glow plug 5 Injection nozzle 6 Injection pipe 7 Engine control lever...

Страница 62: ...sting the opening pressure with adjust screw using a nozzle tester Replace the nozzle gasket and dust cover with new one Tighten the injection pipe sleeve nut and flange nut Protruding Part Refer to m...

Страница 63: ...on pipe 6 Delivery valve holder must be tightened as specified torque Excessive torque causes leakage at control rack and pipe Torque kg U m 3 0 21 7 lb ft Delivery valve 4 0 4 5 Holder torque kg U m...

Страница 64: ...and gear 6 Driven gear shaft 4 6 3 2 5 1 Full flow filter By pass valve O P 1kg cm2 Paper filter O P 8kg cm2 Oil relief valve Oil pump Oil pan Oil strainer By pass valve Oil cooler O P 2kg cm2 O P war...

Страница 65: ...wear or damage is found through inspection Visually inspect the disassembled parts for excessive wear and damage Oil pump cover and oil pump drive gear clearance Cover and driven gear clearance Drive...

Страница 66: ...ssembly steps 1 Oil filter ass y 2 Head oil filter 3 Element oil fiter 4 Relief valve ass y 5 Gasket 6 Bolt 7 Spring washer 8 Plain washer 9 O Ring 10 Plug screw Inspection and repair Make the necessa...

Страница 67: ...63 Reassembly To reassemble follow the disassembly procedures in reverse order Important operation Relief Valve 1 Torque kg U m 2 5 18 1 lb ft...

Страница 68: ...lve Inspection and repair Make the necessary adjustments repairs and part replacements if excessive wear or damage is found through inspection Reassembly To reassemble follow the disassembly procedure...

Страница 69: ...65 4 Cooling System 4 1 General Description 4 2 Water Pump Disassembly Disassembly steps 1 Cover 2 Impeller 3 Center Fan 4 Snap ring 5 Shaft bearing and spacer 6 Seal unit washer and seal...

Страница 70: ...g a bench press and a bar Snap ring 4 Remove the snap ring using a snap ring plier Shaft bearing and spacer 5 Remove the shaft and bearings using a bench press and suitable remover Seal unit Washer an...

Страница 71: ...earings with a marked side outward Reassembly To assemble follow the disassembly procedures in reverse order Important operation Shaft bearing and spacer 5 Lubricate the bearing with multi purpose gre...

Страница 72: ...clearance between the impeller and the pump body 4 3 Thermostat Inspection and repair Make the necessary adjustments pepairs and part replacements if excessive wear or damage is found through inspect...

Страница 73: ...69 5 Fuel System 5 1 General Description Injection nozzle Injection pump Fuel filter water separator Fuel tank Fuel return...

Страница 74: ...if excessive wear or damage is found through inspection Reassembly To assemble follow the disassembly procedures in reverse order Disassembly steps 1 Plunger 2 Retaining nut 3 Injection nozzle 4 Spac...

Страница 75: ...ep the parts separately to maintain the proper needle valve to body combination Inspection and repair Make the necessary adjustments repairs and part replacements if excessive wear or damage is found...

Страница 76: ...pin with the dowel hole in the nozzle holder body Retaining nut 2 Adjust shim 7 The injection nozzle injection starting pressure can be adjusted after the adjusting shim is installed Torque kg U m 6 8...

Страница 77: ...name Cylinder head bolt wrench Injection pump Compression gauge adapter Valve spring compressor Valve guide remover and installer Camshaft bearing remover and installer Cylinder remover Cylinder line...

Страница 78: ...rankshaft gear remover Crankshaft gear installer Crankshaft pilot bearing remover Crankshaft rear oil seal installer Crankshaft front oil seal installer Valve stem oil seal installer Piston ring compr...

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