doosan D35S-5, D40S-5, D45S-5, D50C-5, D55C-5 D50S-5 Service Manual

Service Manual

SB4118E01
May. 2007

Diesel Engine 5.8 Liter (DB58S)

D35S-5, D40S-5, D45S-5, D50C-5, D55C-5
D50S-5, D60S-5, D70S-5, D80S-5, D90S-5
D50S-5, D60S-5, D70S-5

(2 speed)

(3 speed)

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this
publication and on the product labels are identified by the following symbol.

WARNING

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 on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN 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.

The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.

FOREWORD

This maintenance manual is designed to serve as a reference for DOOSAN Infracore Ltd's (here after DOOSAN’s)
customers and distributors who wish to gain basic product knowledge on DOOSAN's DB58S Diesel engine.

This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct injection type) has been
so designed and manufactured to be used for the overland transport or industrial purpose. That meets all the
requirements such as low noise, fuel economy, high engine speed, and durability.

To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT
OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be performed.

Removal Adjustment

Installation Cleaning 15

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufacturer's

Directional Indication Lubricate with oil

Inspection Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental damage;

z Take old oil to an old oil disposal point only.
z Ensure without fail that oil will not get into the sea or rivers and canals or the ground.
z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.
z The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and

special waste.

If you have any question or recommendation in connection with this manual, please do not hesitate to contact our
head office, dealers or authorized service shops near by your location for any services.

For the last, the content of this maintenance instruction may be changed without notice for some quality
improvement. Thank you.

1. GENERAL INFORMATION

1.1. Engine specifications..................................1

1.2. Performance curve.....................................2

1.2.1. Performance curve (ECRFA),

D50/60/70/80/90S-5 (3 speed) .... 2

1.2.2. Performance curve (ECRFD),

D35/40/45S-5, D50/55C-5 ..........3

1.2.3. Performance curve (ECRFE),

D50/60/70S-5 (2 speed).............. 4

1.3. Engine assembly........................................5

1.3.1. Engine assembly view (ECRFA),

D50/60/70/80/90S-5 (3 speed) .... 5

1.3.2. Engine assembly view (ECRFD),

D35/40/45S-5, D50/55C-5 ..........6

1.3.3. Engine assembly views (ECRFE),

D50/60/70S-5 (2 speed).............. 7

1.4. Safety regulations.......................................8

1.4.1. General notes ............................. 8

1.4.2. Regulations designed to prevent

accidents .................................... 8

1.4.3. Regulations designed to prevent
damage to engine and premature

wear........................................... 9

1.4.4. Regulations designed to prevent

pollution.................................... 10

1.4.5. General repair instructions ........ 11

2. TECHNICAL INFORMATION

2.1. Engine model and serial number..............12

2.2. Engine type ..............................................13

2.2.1. Cylinder block ........................... 13

2.2.2. Piston con-rod / crankshaft........ 13

2.3. Engine timing............................................13

2.4. Valves.......................................................14

2.5. Lubrication system ...................................14

2.5.1. Recommend of lubricating oil .... 15

2.5.2. Oil cooler .................................. 16

2.5.3. Oil filter..................................... 16

2.6. Air cleaner ................................................17

2.7. Fuel system..............................................17

2.7.1. Injection pump .......................... 18

2.7.2. Fuel filter................................... 18

2.7.3. Fuel requirements ..................... 18

2.7.4. How to select fuel oil................. 19

CONTENTS

2.8. Cooling system ........................................ 20

2.8.1. Anti-freeze.................................21

2.8.2. Cooling water............................21

2.9. V-belt tension check and adjust............... 23

2.10. Valve clearance and adjustment............ 24

2.11. Cylinder compression pressure ............. 25

2.12. Injection nozzle...................................... 26

2.13. Battery ................................................... 26

2.14. Starting motor ........................................ 26

2.15. Diagnosis and remedy........................... 27

2.16. Engine inspection .................................. 36

2.16.1. Stopping engine ......................36

2.16.2. General engine inspection cycle36

2.17. Use of original parts for repair and

replacement.................................................... 37

3. Maintenance

3.1. Engine Disassembly ................................ 38

3.1.1. Major part fixing nuts and bolts ..38

3.1.2. Main structure parts (1) .............49

3.1.3. Main structure parts (2) .............51

3.1.4. Rocker arm disassembly...........53

3.1.5. Cylinder head disassembly........54

3.1.6. Piston and connecting rod

disassembly.............................. 55

3.2. Engine Inspection .................................... 57

3.2.1. Cylinder block............................57

3.2.2. Cylinder head ............................57

3.2.3. Valve stem and valve guide

clearance..................................58

3.2.4. Valve spring .............................. 62

3.2.5. Tappet ......................................63

3.2.6. Push rod ...................................63

3.2.7. Rocker arm correction...............64

3.2.8. Idler gear and shaft ...................65

3.2.9. Camshaft ..................................65

3.2.10. Cylinder liner ...........................67

3.2.11. Cylinder block..........................68

3.2.12. Piston......................................71

3.2.13. Maintenance of cylinder block,

cylinder liner and piston ...........74

3.2.14. Connecting rod........................75

3.2.15. Crankshaft...............................77

3.2.16. Flywheel and flywheel housing 81

3.3. Engine Reassembly .................................82

3.3.1. Piston and connecting rod assembly

................................................. 82

3.3.2. Cylinder head assembly parts ... 84

3.3.3. Rocker arm and shaft assembly 87

3.3.4. Main components ..................... 88

3.3.5. Major component assembly ...... 94

3.3.6. External parts ........................... 98

4. Commissioning and Operation

4.1. Preparation.............................................103

4.1.1. Starting................................... 103

4.2. Starting and operation ............................104

4.2.1. Operation of a new engine (Break-

In)........................................... 104

4.2.2. Check points for break-in ........ 104

4.3. Inspections after starting ........................106

4.4. Operation in winter time .........................106

4.4.1. Prevention against the freeze of

cooling water .......................... 106

4.4.2. Prevention against excessive

cooling.................................... 106

4.4.3. Lubricating oil ......................... 107

4.4.4. Starting of engine in winter...... 107

4.4.5. Tuning the engine ................... 107

4.5. Maintenance and care............................108

4.5.1. Periodical inspection and

maintenance........................... 108

4.5.2. Exchanging of lubrication oil.... 108

4.5.3. Oil level................................... 108

4.5.4. Oil exchange procedure .......... 108

4.5.5. Replacement of oil filter cartridge109

4.6. Cooling system.......................................110

4.6.1. Coolant draining...................... 110

4.6.2. Cleaning of the cooling inside

system circuit.......................... 111

4.7. Valve clearance and adjustment ............111

4.8. Injection timing .......................................113

4.9. Tightening the cylinder head bolts..........116

4.10. Fuel injection pump ..............................116

4.11. Feed pump strainer ..............................117

4.12. Separator (Add if necessary)................117

4.13. Air bleeding ..........................................117

4.14. Belts .....................................................118

5. Maintenance of Major Components

5.1. Lubrication system................................. 121

5.1.1. Oil pump .................................121

5.1.2. Oil cooler.................................123

5.2. Cooling system ...................................... 124

5.2.1. Water pump ............................124

5.2.2. Thermostat.............................. 128

5.3. Fuel system ........................................... 129

5.3.1. Fuel filter.................................129

5.3.2. Injection nozzle ....................... 130

5.3.3. Injection Pump Calibration.......134

5.3.4. Precautions for operation......... 137

5.3.5. Walk-around check and servicing

...............................................138

5.3.6. Diagnostics and troubleshooting139

6. Special Tool List ......................... 140

• Appendix ...............................................142

1. GENERAL INFORMATION

1.1. Engine specifications

Engine Model
Items

Engine type 4 cycle in-line Naturally aspirated

Combustion chamber type Direct injection type

Cylinder liner type Dry type

Timing gear system Gear driven type

No. of piston ring 2 Compression 1 ring, oil ring
No. of cylinder-bore x stroke (mm) 6 – 102 × 118

Total piston displacement (cc) 5,785

Compression ratio 17.5 : 1 18.5 : 1

Engine dimension
(length X width X height)
(mm)

Engine weight (kg) 450

Rotating direction (from fly wheel) counter clockwise

Fuel injection order 1 – 5 - 3 – 6 - 2 – 4

Fuel injection timing (B.T.D.C static) 15°

Injection pump type Bosch in-line A type

Governor type Mechanical governor RSV type

Injection nozzle type Multi-hole type (5 hole)

Fuel injection pressure (kg/cm²) 220

Compression pressure (kg/cm²) 28 (at 200 rpm)

Intake & exhaust valve clearance (mm)
(at cold)

Intake valve

Exhaust valve

Lubrication method Pressurized circulation

Oil pump type Gear type

Oil filter type Full-flow, cartridge type

Lubricating oil capacity (oil pan) (lit) 20.5(19)

Oil cooler type Water cooled

Water pump Belt driven impeller type

Cooling Method Pressurized circulation

Cooling water capacity(engine only) (lit) 12

Thermostat type Wax pallet type (82 ∼95°C)

Cooling fan 10- Ø 520.7 blower 7 – Ø 457 blower 10- Ø 520.7 blower

Starting Motor
(voltage – output) (V - kW)

Open at 17° B.T.D.C

Close at 51° A.B.D.C

Open at 60° B.B.D.C

Close at 18° A.T.D.C

DB58S ECRFA

D50/60/70/80/90S-5

(3 speed)

DB58S ECRFD

D35/40/45S-5,

D50/55C-5

1,173 x 666 x 793

0.4

24 – 4.5

DB58S ECRFE

D50/60/70S-5

(2 speed)

General information - 1 -

1. 2. Performance curve

1. 2.1. Performance curve (ECRFA), D50/60/70/80/90S-5 (3 speed)

General information - 2 -

1. 2.2. Performance curve (ECRFD), D35/40/45S-5, D50/55C-5

General information - 3 -

1. 2.3. Performance curve (ECRFE), D50/60/70S-5 (2 speed)

General information - 4 -

1.3. Engine assembly

1.3.1. Engine assembly view (ECRFA), D50/60/70/80/90S-5 (3 speed)

10

4

5

2

3

1

14

15

24

1 Oil filter 11 C.C.V 21 Push rod chamber cover
2 Lifting hook 12 Crank shaft pulley 22 Flywheel housing
3 Oil cooler 13 Vibration damper 23 Fly wheel
4 Intake manifold 14 Oil drain plug 24 Oil pan

5 Priming pump 15 water pump 25 Starter

6 Fuel injection pump 16 Alternator 26 Cylinder head cover

7 Fuel injection pipe 17 Oil level gauge 27 Fuel injection nozzle
8 Water outlet 18 Exhaust manifold 28 Fuel filter

9 Cooling fan 19 Water pump pulley
10 Oil filler cap 20 Thermostat housing

6

11

17 26

18

12

22

28

8

19

9

13

7

21

23

25

20

16

27

General information - 5 -

1.3.2. Engine assembly view (ECRFD), D35/40/45S-5, D50/55C-5

10

2

4

5

6

9

28

8

3

19

1

14

15

11

17 26

7

13

21

12

22

24

18

1 Oil filter 11 C.C.V 21 Push rod chamber cover
2 Lifting hook 12 Crank shaft pulley 22 Flywheel housing
3 Oil cooler 13 Vibration damper 23 Fly wheel
4 Intake manifold 14 Oil drain plug 24 Oil pan

5 Priming pump 15 water pump 25 Starter

6 Fuel injection pump 16 Alternator 26 Cylinder head cover

7 Fuel injection pipe 17 Oil level gauge 27 Fuel injection nozzle
8 Water outlet 18 Exhaust manifold 28 Fuel filter

9 Cooling fan 19 Water pump pulley
10 Oil filler cap 20 Thermostat housing

25

23

20

16

27

General information - 6 -

1.3.3. Engine assembly views (ECRFE), D50/60/70S-5 (2 speed)

10

4

5

6

9

28

8

2

3

19

15

1

14

11

17

7

26

13

21

12

22

24

18

25

23

1 Oil filter 11 C.C.V 21 Push rod chamber cover
2 Lifting hook 12 Crank shaft pulley 22 Flywheel housing
3 Oil cooler 13 Vibration damper 23 Fly wheel
4 Intake manifold 14 Oil drain plug 24 Oil pan

5 Priming pump 15 water pump 25 Starter

6 Fuel injection pump 16 Alternator 26 Cylinder head cover

7 Fuel injection pipe 17 Oil level gauge 27 Fuel injection nozzle
8 Water outlet 18 Exhaust manifold 28 Fuel filter

9 Cooling fan 19 Water pump pulley
10 Oil filler cap 20 Thermostat housing

20

16

27

General information - 7 -

1.4. Safety regulations

1.4.1. General notes

Day-to-day use of power engines and the service products necessary for running them presents no
problems if the persons occupied with their operation, maintenance and care are given suitable training
and think as they work.

This summary is a compilation of the most important regulations. These are broken down into main
sections which contain the information necessary for preventing injury to persons, damage to property and
pollution. In addition to these regulations those dictated by the type of engine and its site are to be
observed also.

IMPORTANT.
If, despite all precautions, an accident occurs, in particular through contact with caustic acids, fuel

penetrating the skin, scalding from oil, antifreeze being splashed in the eyes etc., consult a doctor
immediately.

1.4.2. Regulations designed to prevent accidents

a) During commissioning, starting and operation

Before putting the engine into operation for the first time, read the operating instructions carefully and
familiarize yourself with the "critical" points. If you are unsure, ask your DOOSAN representative.

z For reasons of safety we recommend you attach a notice to the door of the engine room prohibiting

the access of unauthorized persons and that you draw the attention of the operating personal to
the fact that they are responsible for the safety of persons who enter the engine room.

z The engine must be started and operated only by authorized personnel. Ensure that the engine

cannot be started by unauthorized persons.

z When the engine is running, do not get too close to the rotating parts. Wear close-fitting clothing.
z Do not touch the engine with bare hands when it is warm from operation risk of burns.
z Exhaust gases are toxic. Comply with the installation instructions for the installation of DOOSAN

diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate
ventilation and air extraction.

z Keep vicinity of engine, ladders and stairways free of oil and grease.

Accidents caused by slipping can have serious consequences.

b) During maintenance and care

z Always carry out maintenance work when the engine is switched off. If the engine has to be

maintained while it is running, e.g. changing the elements of change-over filters, remember that
there is a risk of scalding. Do not get too close to rotating parts.

z Change the oil when the engine is warm from operation.

CAUTION
There is a risk of burns and scalding. Do not touch oil drain valve or oil filters with bare hands.

Safety regulations - 8 -

z Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the

oil will not overflow.

z Open the coolant circuit only when the engine has cooled down. If opening while the engine is still

warm is unavoidable, comply with the instructions In the chapter entitled "Cooling".

z Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional

hydraulic oil circuit) during the operation. The fluid which flow out can cause injury.

z Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled only

when the engine is switched off.

z Keep service products (anti-freeze) only in containers which can not be confused with drinks

containers.

z Comply with the manufacturer's instructions when handling batteries.

CAUTION

Accumulator acid is toxic and caustic. Battery gases are explosive.

c) When carrying out checking, setting and repair work

z Checking, setting and repair work must be carried out by authorized personnel only.
z Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench could

lead to Injury.

z When the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep

lifting gear in good condition.

z When checking injectors, do not put your hands under the jet of fuel.
z Do not inhale at atomized fuel.
z When working on the electrical system disconnect the battery earth cable first. Connect it up again

last in prevent short circuits.

1.4.3. Regulations designed to prevent damage to engine and premature wear

(1) Never demand more of the engine than it was designed to yield for its intended purpose.

Detailed information on this can be found in the sales literature. The injection pump must not be
adjusted without prior written permission of DOOSAN.

(2) If faults occur, find the cause immediately and have it eliminate in order to prevent more serious of

damage.

(3) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility for damage resulting

from the installation of other parts which are supposedly "just as good".

(4) In addition to the above, note the following points.

z Never let the engine run when dry, i.e. without lube oil or coolant. Use only DOOSAN-approved

service products. (engine oil, anti-freeze and anticorrosion agent)

z Pay attention to cleanliness. The Diesel fuel must be free of water. See "Maintenance and care".
z Have the engine maintained at the specified intervals.
z Do not switch off the engine immediately when it is warm, but let it run without load for about 5

minutes so that temperature equalization can take place.

z Never put cold coolant into an overheated engine. See "Maintenance and care".

Safety regulations - 9 -

z Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Do

not exceed the maximum permissible tilt of the engine. Serious damage to the engine may result if
these instructions are not adhered to.

z Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, and

coolant temperature) function satisfactorily.

z Comply with instructions for operation of the alternator. See "Commissioning and operation".
z Do not let the water pump run dry. If there is a risk of frost, drain the water when the engine

switched off.

1.4.4. Regulations designed to prevent pollution

a) Engine oil, filter element, fuel filter

z Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not get into

the drains or into the ground.

z The drinking water supply may be contaminated.
z Oil and fuel filter elements are classed as dangerous waste and must be treated as such.

b) Coolant

z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
z When disposing of spent coolant comply with the regulations of the relevant local authorities.

1.4.5. Notes on safety in handling used engine oil

Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous
substances which have caused skin cancer in animal experiments. If the basic rules of hygiene and health
and safety at work are observed, health risks are not to the expected as a result of handling used engine oil.

<Health precautions>

z Avoid prolonged or repeated skin contact with used engine oil.
z Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
z Clean skin which has been in contact with engine oil.
z Wash thoroughly with soap and water, A nailbrush is an effective aid.
z Certain products make it easier to clean your hands.
z Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
z After washing apply a fatty skin cream to the skin.
z Change oil-soaked clothing and shoes.
z Do not put oily rags into your pockets.

Ensure that used engine oil is disposed of properly.

- Engine oil can endanger the water supply -

For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations
are punishable. Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local authorities.

Safety regulations - 10 -

1.4.5. General repair instructions

1. Before performing service operation, disconnect the grounding cable from the battery for reducing the

chance of cable damage and burning due to short-circuiting.

2. Use covers for preventing the components from damage or pollution.

3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage.

4. The use of proper tools and special tools where specified is important to efficient and reliable service

operation.

5. Use genuine DOOSAN parts necessarily.

6. Used cotter pins, gaskets, O-rings, oil seals, lock washer 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.

7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in groups.

Keeping fixing bolts and nut separately is very important as they vary in hardness and design depending
on position of installation.

8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make

certain they are free from restrictions.

9. Lubricate rotating and sliding faces of parts with oil or grease before installation.

10. When necessary, use sealer on gaskets to prevent leakage.

11. Carefully observe all torque specifications for bolts and nuts.

12. When service operation is completed, make a final check to be sure service has been done properly.

Safety regulations - 11 -

2. TECHNICAL INFORMATION

2.1. Engine model and serial number

The engine model and serial number is located on the
engine as illustrated. These numbers are required
when requesting warranty and ordering parts. They

are also referred to as engine model and serial
number because of their location.

Engine serial No. (example : DB58)
DB58S 3 00001 FA

Engine suffix (ECRFA)
Serial no.
Production year (2003)
Engine model

ENGINE SERIAL NO.

EC90M011

Technical information - 12 -

2.2. Engine type

The Engines DB58S are in-line vertical, water-cooled, 6-cylinder four stroke diesel engines with direct
injection. DB58S is natural aspiration.

2.2.1. Cylinder block

The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is extended to a level
below the crankshaft center line. The engine has replaceable dry cylinder liners and common cylinder
heads with struck-in valve seat rings and replaceable valve guides,

2.2.2. Piston con-rod / crankshaft

The forged crankshaft is a integrate type (Counterweight is integrated with crank shaft body). Radial oil
seal on crankshaft and flywheel are provided to seal the flywheel housing inside penetrations.
The con-rods (connecting rods) are die-forged and can be removed through the top of the cylinders
together with the pistons. Crankshaft and connecting rods run in steel-backed lead bronze ready-to fit type
bearings.

2.3. Engine timing

Camshaft, oil pump, PTO (power take off) pump and injection pump are driven by a gear train arranged at
the front end.

Injection pump gear

(Z = 50)

Idle gear

(Z = 51)

Camshaft gear

(Z = 50)

Oil pump drive gear

(Z = 12)

P.T.O Drive gear

(Z=24)

Crankshaft gear

(Z = 25)

Oil pump gear

(Z = 9)

P.T.O gear (Option)

(Z = 25)

EC90M013

Technical information - 13 -

2.4. Valves

The overhead valves are actuated via chilled cast iron tappets, push rods and rocker arms from the
camshaft.

2.5. Lubrication system

The engine is equipped with force-feed lubrication.
The pressure is produced by a gear pump whose drive gear is in direct mesh with the camshaft gear at the
middle of cylinder block.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the main
distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as
to the small-end bearings and the rocker arms.
The injection pump are also connected to the engine lubricating system.
The cylinder block walls and timing gears are splash-lubricated.
The lube oil is cleaned in a full-flow oil filter.

EC90M014

Technical information - 14 -

2.5.1. Recommend of lubricating oil

Initial factory fill is high quality break-in oil for API Service. During the break-in period (50 hours),
frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated.
The oil level should be maintained in the safe range between the Min. and Max. marks on the dipstick. The
safe range between the marks represents approximately 3 liters. To obtain the best engine performance
and engine life, grade of engine oil is recommended. Engine oils are specified by API Service, letter
designations and SAE viscosity numbers. If the specified motor oil is not available, use a reputable brand
of engine oil labeled for API Service CH-4 and SAE viscosity 30 or 15W40. Refer to oil identification
symbol on the container.

z Engine oil should be changed at the specified intervals.

Oil filter cartridge should be changed simultaneously.

- First oil change : 50 hr operating

- After 50hr operation ; 250

z The following oils are also recommended

Engine oil capacity Recommend oil

Max.

(liter)

Oil pan

(liter)

Min.

Total

(liter)

SAE No. API No.

SAE10W40
SAE15W40

ACEA-E2 or ACEA-E3

(API CH-4)

Engine model

DB58S 19 14 20.5

Technical information - 15 -

* If long oil change intervals are to be used, ACEA-E3 oil must be used.

2.5.2. Oil cooler

An oil cooler is provided between the oil filter and the cylinder block. This cooler is a flat tube type with
turbulence inserts and operated by the coolant.

2.5.3. Oil filter

• Check for oil pressure and oil leaks, and
repair or replace the oil filter if necessary.

• Change the oil filter cartridge
simultaneously at every replacement of
engine oil.

EA4M1008

Technical information - 16 -

EDM3001I

<ECRFD>

Cartridge,
Oil filter

<ECRFA, ECRFE>

Head, oil filter

2.6. Air cleaner

In case that elements are deformed, damaged
or if the air cleaner has a crack, replace it.
By the definite interval, the elements must be
cleaned and replaced.

2.7. Fuel system

The fuel is delivered by the fuel feed pump via the fuel filter to the injection pump and from there to the
injection nozzles.

EC9OM015

EFM1002I

EC9OM065

Technical information - 17 -

The fuel is sprayed into the cylinders through nozzles fitted in screw-fit injection nozzle holders in the
cylinder heads.
Excessively delivered fuel and leak fuel from the nozzle flow through the return pipe back to the tank.
A strainer is arranged ahead of the fuel feed pump.

2.7.1. Injection pump

The in-line injection pump is driven via gears
from the crankshaft. It is connected to the
force feed lubricating system of the engine
and consequently maintenance-free. The
governor flange-mounted on the pump casing
is a variable range governor designed to
keep the speed set of varying load.

2.7.2. Fuel filter

This fuel filter has two functions not only oil
filtering but
also water separating
Before entering the suction chamber of the
injection pump, the fuel is cleaned in a
strainer of fuel feed pump and a fuel filter.
Drain water in filter with loosening the drain
plug under filter manually from time to time.
The fuel filter element should be replaced at
every 200 hours.

Air bleeding plug

Seal ring

Head, fuel filter

Cartridge, fuel filter

Water drain plug

2.7.3. Fuel requirements

DOOSAN diesel engines was designed to use Number 2-D diesel fuel or equivalent that meets
specification DIN 51601-DK. For maximum fuel economy, Number 2-D fuel whenever possible. When
temperatures are below -7 °C (20 °F), use Number 1-D fuel. If Number 1-D fuel is not available, the
mixture of one kerosene to two gallons of Number 2-D fuel can be used. Once kerosene has been added,
the engine should be run for several minutes to mix the fuel.

EC9OM016

EC9OM017

Technical information - 18 -

2.7.4. How to select fuel oil

Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and
acceptable exhaust emission levels. DOOSAN engines are designed to operate on most diesel fuels
marketed today. In general, fuels meeting the properties of ASTM Designation D975 (grades 1-D and 2-D)
have provided satisfactory performance.
The ASTM 975 specification, however, does not in itself adequately define the fuel characteristics needed
for assurance of fuel quality.
The properties listed in the fuel oil selection chart below have provided optimum engine performance.
Grade 2-D fuel is normally available for generator service. Grade 1-D fuel should not be used in pleasure
craft engines, except in an emergency.

Fuel Oil Selection Chart

General Fuel

Classification

Gravity, °API #) D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855

ASTM

Test

No. 1

ASTM 1-D

No. 2

ASTM 2-D

DIN 51601

Flash Point

Min. °F (°C)

Viscosity, Kinematic

CST 100 °F (40 °C )

Cloud Point °F #) D 2500 See Note 1) See Note 1) See Note 1)

Sulfur Content

wt%, Max.

Carbon Residue

on 10%, wt%, Max.

Accelerated Stability
Total Insolubles

mg/100 ml, Max. #)

Ash, wt%, Max. D 482 0.01 0.01

Cetane Number, Min. +) D 613 45 45 > 45

Distillation
Temperature, ℉(℃)

IMP, Typican #)
10% Typical #)
50% Typical #)
90% +)
End Point #)

D 93 100 (38) 125 (52) 131 (55)

D 445 1.3 ~ 2.4 1.9 ~ 4.1 1.8 ~ 10

D 129 0.5 0.5 0.15

D 524 0.15 0.35 0.1

D 2274 1.5 1.5

D 86

350(177)
385(196)

45(218)

500 (260) Max.

550(288) Max.

625(329) Max.
675(357) Max.

375(191)
430(221)
510(256)

680(360)

Water & Sediment

%, Max.

#) Not specified In ASTM D 975
+) Differs from ASTM D 975

NOTE

1) The cloud point should be 6 °C (10 °F) below the lowest expected fuel temperature to prevent clogging
of fuel fitters by crystals.

D 1796 0.05 0.05 0.05

Technical information - 19 -

2.8. Cooling system

The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by V-belt from the
crankshaft pulley.
Depending on the agreed extent of delivery and the design of the engine, the coolant circuit can be
equipped with temperature monitors which, in the event of loss of coolant, shut the engine down.

z Check the coolant level of the expansion tank by removing the expansion tank filler cap, and add coolant

if necessary.

z When injecting antifreeze solution, first drain out the old coolant from the cylinder block and radiator, and

then clean them with cleaning solution.

z Be sure to mix soft water with antifreeze solution.

Technical information - 20 -

2.8.1. Anti-freeze

The anti-freeze, 50% of the whole coolant, is always to be used to prevent the cooling system from the
corrosion. And in winter the amount of anti-freeze shown in the following table should be used in
accordance with the ambient temperature.

Temperature (°C)

Ambient

Cooling water (%) Anti-freeze (%)

Over -10

-10

-15

-20

-25

-30

-40

85
80
73
67
60
56
50

15
20
27
33
40
44
50

As the individual freezing points corresponding to the proportions of antifreeze in the table are subject to
change slightly according to the kind of antifreeze, you must follow the specifications provided by the
antifreeze manufacturer.
As the ratio of antifreeze in the mixture decrease each time new coolant is added to make up for the loss
coolant resulting from engine operation, Check the mix ratio with every replenishment of coolant, and top
up as necessary.

2.8.2. Cooling water

z Regarding the engine cooling water, the hard water must be used (Do not use the soft water).
z The engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust

prevention (DCA4) 3 ∼ 5 %.

z The density of above solution and additive must be inspected every 500 hours to maintain it properly.

NOTE
The proper density control of antifreezing solution and rust preventing additive will be able to

prevent the rusting effectively and maintain the stable quality of engine.
For the improper control might give the fatal damage to the cooling water pump and cylinder liners,
detail care is needed.

z Since DB58 cylinder liner is dry type, particularly the cooling water control should be applied thoroughly.
z The density of antifreezing solution and additive for rust prevention is able to be confirmed by the

cooling water test kit. (Fleetguard CC2602M)

z How to use the cooling water test kit

(1) When the cooling water temp. of engine is in the range of 10 ∼ 55 °C, loosen the plug for cooling

water discharge and fill the plastic cup about a half.

Technical information - 21 -

NOTE:

In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure
the accurate density. Take the cooling water sample necessarily loosening the cooling water
discharge plug.

(2) At the state of a test paper soaked in the sampled water, after taking the paper out through water

agitation, shake off the water.

(3) Wait for about 45 sec. till the color change of test paper.

NOTE:

However, it should not elapse longer than 75 sec, and if it did, the hue would change.

(4) Make the numerical value by comparing the test paper which hue has changed with the color list of

label on storage bottle.

(5) By comparing the hue changed into yellowish green or so with the green color indication of test paper

storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to
50%).

(6) The brown at the middle of test paper and the lower pink color indication represent the additive state

for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and
pink color (horizontal) (7) locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storage bottle.

(8) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more than

0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh
water.

Technical information - 22 -

2.9. V-belt tension check and adjust

z V-Belt

By the finger-pressure the belt is pressed by
10mm ∼ 15mm between the fan pulley and
the alternator pulley in normal condition. For
the adjustment of the tension, loosen the
adjusting bolts which support the alternator,
adjust the tension and tighten the bolts
again.

z Poly belt

Poly belt will be properly tensioned if the
deflection force “F” is applied midway
between the belt`s tangent points with the
pulley.

T = 0.015 x S (about 1.5mm per 100mm)

EA9O2006

EB5O6003

Technical information - 23 -

2.10. Valve clearance and

adjustment

NOTE:
The cylinder head bolts were previously
tightened with the torque wrench.

Therefore it is not necessary to retighten
the cylinder head bolts before adjusting
the valve clearance.

Rocker arm screw

lock nut torque

z After letting the #1 cylinder's piston come

at the compression top dead center by
turning the crankshaft, adjust the valve
clearances.

z Loosen the lock nuts of rocker arm

adjusting screws and push the feeler
gauge of specified value between a rocker
arm and a valve stem and adjust the
clearance with adjusting screw
respectively and then tighten with the lock
nut.

z As for the valve clearance, adjust it when

in cold, as follows.

2.6 ±0.5kg.m

EAOO4014

EJM1035S

Model Intake Valve Exhaust Valve

DB58S 0.4 mm 0.4 mm

1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then #1 cylinder become the
compression state of top dead center.

2) Therefore adjust the valve clearance corresponding to “ ” of lower figure. At this time there are
no force on the push rods of #1 cylinder.

3) Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top dead center.

4) Thereafter adjust the valve clearances corresponding to “ ” of lower figure.

5) After reinsuring the valve clearances, retighten if necessary.

Technical information - 24 -

• No. 1 cylinder is located at the side where flywheel was installed.

Cooling fan Cylinder no.

2.11. Cylinder compression
pressure

z Stop the engine after warming up, and

take out preheating plug and injection pipe.

z Install the special tool (compression gauge

adapter) at the preheating plug hole, and
connect the compression pressure gauge
there.

z Check the compression pressure at gauge

several times until highest compression
reading is reached.

Standard value 28kg/cm² over

Limit value 24kg/cm²

Difference
between each
cylinder

z Condition : Water temperature 75°C.

Within ± 10 %

Exhaust valve Intake valve Fly wheel

EC9OM020

EJM1046S

EJM1047I

Technical information - 25 -

2.12. Injection nozzle

z Install a nozzle on the nozzle tester.
z If the inspected injection pressure is less than the specified value, adjust using the adjusting shims.

Engine model Injection nozzle pressure

DB58S 220 kg/cm²

z Check the atomizing state and replace it if abnormal.

2.13. Battery

z Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case of

poor condition.

z Inspect for amount of electrolytic solution, and replenish if insufficient.
z Measure the gravity of electrolytic solution, if less than specified value (1.12 ∼ 1.28), replenish.

2.14. Starting motor

z In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and coat them

with grease.
Also, in case of washing engine room and so forth, inspect the wiring state being careful for water not to
get in.

EFM1006I

EFM1007I

Technical information - 26 -

2.15. Diagnosis and remedy

r

z The following description summarizes the probable cause of and remedy for general failure by item.
z Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected.

1. Engine Starting Impossible

Starting motor does not turn

Inspection of battery electrolytic
Iiquid amount & gravity

Normal Too Iow

Adjustment,
Recharging

Inspection of Ioose electric
Wiring & short

Normal

Inspection of starter switch

Inspection of starter relay

Normal Replace

Inspection of starter switch

Normal

Starting motor
disassembly

Retighten.
Replace

Retighten.
Replace

Retighten.
Replace

Starting motor turns but
engine does not revolution

Engine

Inspect air cleaner

Normal Polluted

Replace or
Clean element

Check compression
pressure

Normal Too low

Repai
Replace

Inspect of
other parts

Check valve
clearance

Normal

Check
clinder
head gasket

Normal

Adjust

Replace

Fule

Inspect amount of fule

Normal No fule

Replenish

Inspect fule injection

Normal No fule injection

Inspect
injection
timing

Normal

Inspect injust
nozzle (injection
pressure, injection
state ect.)

Normal

Disassemble and
Inspect injection pump

Air bleeding
and re-start

Adiust

Repair
Replace

Engine disassembly
(valve assembly, piston,
cylinder liner ect.

Inspect fule feed pump for function

Normal

Disassemble and
Inspect injection pump

Inspect feed pump valne and

Normal

Inspect fule filter

Dirty element ald/or
overflow valve faulty

Replace

Clean
Replace

Air mixture in fule

Retighten connection
Parts. Replace gasket

Air bleeding

Continuous entry of air
In fuel system

Disassemble and
Check fuel feed pump

Technical information - 27 -

2. Engine Overheated

Operating state

1. Overload

2. Radiator core clogged

Cooling system

Fule system

3. Continuous over-run

Check coolant level

Normal Too low

Check fan belt
tension, wear
or damage etc.

Normal

Repair.

Replenish

Replace

Check fresh
radiator tank cap

Normal Repair

Check thermostat

Normal Repair

Inspect radiator Damage

Inspect fule quality

Poor

Clean and replace
with specified fule

Inspect cooling
water leakage

Extemal

Repair
Replace

Intemal

Engine
disassembly

Fuel excessive supply

Check injection nozzle

Normal Abnormal

Adjust or
repair

Repair

Replace
Injection
pump

Normal

Check cooling
water passage

Repair.
Replace

Check cooling
water pump

Normal

Repair.
Replace

Engine
disassembly

Technical information - 28 -

3. Output insufficient

Engine Chassis

Check for clutch silp

Check for air maxing
In fule

Inspect fule supply pump

Normal

Clean.
Replace

Inspect fule filter
and over flow valve

Normal Replace

Inspect injection pipes

Normal

Repair
Replace

Inspect injection nozzle
(injection pressure,
atomizing state ect.)

Normal

Adjust.
Replace

Others Fule system

Inspect air cleaner

Normal

Clean.
Replace

Inspect engine control
rod, link, cable, ect

Normal

Repair
Replace

Check valve clearance

Normal Adjust

Inspect cylinser head
gasket for damage

Normal

Replace

Engine disassembly
(valve assembly)

Adjust or replace clutch

Inspect air leakage
of air piping line

Normal

Retighten.
Replace

Inspect air leakage
of intercooler

Check injection timing

Normal Adjust.

Disassemble engine
or injection pump

Check turbocharger

Normal

Repair
Replace

Disassemble injection
pump or engine

Technical information - 29 -

4. Oil Pressure Iowered

Check oil amount

Check if pressure
gauge indicates wrongly

Normal

Check cooling
temperature

Normal

Inspect oil quality

Normal

Check oil
relief valve

Normal

Refer to engine overheat

Reyighten.
Replace

Too high

Disassemble engine
or injection pump

Water and fule
mixed in oil

To Iow

Use recommened oil
(replenish)

Improper

Replace with
recommended oil

Disassemble
engine

Technical information - 30 -

5. Fule Consumption Excessive

Cause according to use conditions

1. Overlow

2. Frequent use of low gear position

3. Frequent use of high gear position

Inspect fule Ieakage

at low speed

4. Clutch slip

5. Too low tire inflation pressure

Normal Fule leakage

Inspect injection nozzle
(injection pressure
atomizing state, ect.)

Normal

Adjust
Replace

Inspect injection timing

Normal

Adjust

Inspect compressed
pressure

Normal

Adjust

Disassemble
injection pump

Check valve
clearance

Retighten
Replace

Pepair, Replace
(cylinder liner,
piston ring, piston)

Normal

Adjust

Inspect head gasket

Normal

Replace

Disassemble engine
(valve assembly, pistion,
cylinder er, ect.)

Technical information - 31 -

6. Oil Consumption Excessive

Cause according to use conditions

1. Excessive oil infusing

2. Continuous operation in low speed
or extremely cold state

Inspect oil leakage

Normal Oil leakage

Check oil quality

Extermal Internal

Replace with
specified oil

Retighten.
Replace

7. Engine Knocking

Inspection combustion of fule & oil
(carbon residue of exhaust gas)

Check compressed
pressure

Engine disassembly
(piston, cylinder liner)

Inspect air cleaner

Clean Replace

Normal

Disassemble
cylinder head
(valve stem seal)

Unconfirmed Confirm

Inspect compressed
pressure

Normal Too Low

Inspect injection
timing

Normal Adjust

Check fule quality

Check valve clearance and
cylinder head gasket crush

Normal

Disassemble
engine

Use specified fule

Technical information - 32 -

Disassemble
engine

Replace
Adjust

8. Battery Discharge

Battery Wiring, Switch Altemator

Check electrolytic
liquid amount

Normal

Electrolytic
liquid’s standard

Replenish

Inspect cut wire
shorts and loose
connections, etc.

Repair. Replace

Damaged
battery case

Replace Charging

Normal Abnormal

Check charged stated

Battery self
dischage

Check fan belt
tension & damage

Battery over
charging

Inspect altemator
and voltage regulator

Adjust
Replace

Discharging

Disassemble altemator
and voltage regulator

Technical information - 33 -

Condition Causes Remedies

1) Starting difficult
(1) Compression pressure

2) Idle operation abnormal

3) Engine output insufficient
(1) Continuous output

z Valve's poor shut, stem distortion
z Valve spring damage
z Cylinder head gasket's leak
z Wear of piston, piston ring or liner

z Injection timing incorrect
z Air mixing at injection pump

z Valve clearance incorrect

Insufficient

(2) Output insufficient

z Valve tightness poor
z Cylinder head gasket's leak
z Wear, stick, damage of piston ring
z Injection timing incorrect
z Fuel injection amount insufficient
z Nozzle injection pressure improper or stuck
z Supply pump's function lowered
z Fuel pipe system clogged
z Air suction amount insufficient
z Turbocharger poor

z Compression pressure insufficient

when in acceleration

4) Overheating

z Injection timing incorrect
z Fuel injection amount insufficient
z Injection pump timer's function insufficient
z Nozzle injection pressure, injection angle

improper

z Supply pump's function lowered
z Air intake amount insufficient

z Engine oil insufficient or poor
z Cooling water insufficient
z Fan belt loosened, worn, damaged
z Cooling water pump's function lowered
z Water temperature regulator's operation poor
z Valve clearance incorrect
z Exhaust system's resistance increased

Repair or replace
Replace valve spring
Replace gasket
Adjust

Adjust
Remove air

Adjust

Repair
Replace gasket
Replace piston ring
Adjust
Adjust injection pump
Adjust or replace
Repair or replace
Repair
Clean or replace air cleaner
Repair or replace

Disassemble engine

Adjust
Adjust injection pump
Repair or replace
Repair, replace

Repair or replace
Clean or replace air cleaner

Replenish or replace
Replenish or replace
Adjust or replace
Repair or replace
Replace
Adjust
Clean or replace

Technical information - 34 -

Condition Causes Remedies

5) Engine noisy For noises arise compositely such as

rotating parts, lapping parts etc., there is
necessity to search the cause of noises
accurately.

(1) Crankshaft

z As the wear of bearing or crankshaft

progress, the oil clearances increase.

z Lopsided wear of crankshaft
z Oil supply insufficient due to oil passage

clogging

(2) Connecting rod and

z Stuck bearing

z Lopsided wear of connecting rod bearing

Connecting rod bearing

z Lopsided wear of crank pin
z Connecting rod distortion
z Stuck bearing
z Oil supply insufficiency as clogging at oil

passage progresses
(3) Piston, piston pin &
piston ring

(4) Others

6) Fuel Consumption excessive

7) Oil consumption excessive

z Piston clearance increase as the wear of

piston and piston ring progresses

z Wear of piston or piston pin
z Piston stuck
z Piston insertion poor
z Piston ring damaged

z Wear of crankshaft, thrust bearing
z Camshaft end play increased
z Idle gear end play increased
z Timing gear backlash excessive
z Valve clearance excessive
z Abnormal wear of tappet, cam

z Injection timing incorrect
z Fuel injection amount excessive

excessive

(1) Oil level elevated

z Clearance between cylinder liner &

piston

z Wear of piston ring, ring groove
z Piston ring's damage, stick, wear
z Piston ring opening's disposition

improper

z Piston skirt part damaged or abnormal

wear

(2) Oil level lowered

(3) Oil leak

z Oil ring's oil return hole clogged
z Oil ring's contact poor

z Looseness of valve stem & guide
z Wear of valve stem seal
z Cylinder head gasket’s leak

z Looseness of connection parts
z Various parts' packing poor
z Oil seal poor

Replace bearing & grind
crankshaft

Grind or replace
Clean oil passage

Replace bearing & grind

Replace bearing

Grind crankshaft
Repair or replace
Replace & grind crankshaft
Clean oil passage

Replace piston &
piston ring

Replace
Replace piston
Replace piston
Replace piston

Replace thrust bearing
Replace thrust plate
Replace thrust washer
Repair or replace
Adjust valve clearance
Replace tappet, cam

Adjust
Adjust injection pump

Replace

Replace piston, piston ring
Replace piston ring
Correct position

Replace piston

Replace piston ring
Replace piston ring

Replace in set
Replace seal
Replace gasket

Replace gasket, repair
Replace packing
Replace oil seal

Technical information - 35 -

2.16. Engine inspection

2.16.1. Stopping engine

After checking the engine for any unusual condition at the idling speed, then turn the key switch to the stop
the engine.

2.16.2. General engine inspection cycle

In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment
and maintenance are vital.

z Daily inspections in below figure should be checked every day.
z The following maintenance details should be executed thoroughly at regular internals.

Inspection Daily

Check for leakage(hoses,
clamp)

Cooling
System

Lubrication

System

Intake & Exhaust

System

Fuel

System

Engine

Adjust

Check the water level O
Change the coolant water ●

Adjust the V-belt tension O

Clean the radiator O
Check for leakage O
Check the oil level gauge O

Change the lubricating oil

Replace the oil filter
cartridge

Check the leakage for
intercooler (hoses, clamp)
Clean and change
the air cleaner element
Check the leakage fuel
line
Clean the fuel strainer
of fuel feed pump
Remove sediment from
fuel tank
Drain the water in
separator
Replace the fuel filter
element

Check fuel injection timing O

Check the injection
nozzles
Check the state of
exhaust gas
Check the battery
charging
Check the compression
pressure
Adjust Intake/Exhaust
valve clearance

O : Check & adjust ● : Replace

Every
50hrs

O

●

1st

O

O

O

O

O

●

O

O

O

O

●

1st

O

1st

Every

200hrs

O

clean

Every

500hrs

●

●

Every

600hrs

●

Every

1200hrs

Remark

Every

2,000hrs

When

necessary

When

necessary

When

necessary

When

necessary

Technical information - 36 -

2.17. Use of original parts for repair and replacement

For engine is being mechanically harmonized with many parts, only when the original parts that the
manufacture recommends to use is used, the engine trouble would be preventively maintained and
capable to keep up the maximum performances.
For the analogous parts not the original parts are poor in qualities and gives ill performance, it may rather
bring early engine failure.

Technical information - 37 -

3. Maintenance

3.1. Engine Disassembly

3.1.1. Major part fixing nuts and bolts

1) Cylinder head cover

(Unit : kg.m)

Engine disassembly - 38 -

EJM1001S

2) Cylinder block

(Unit : kg.m)

EJM1002S

Engine disassembly - 39 -

3) Oil pan and level gauge

(Unit : kg.m)

Engine disassembly - 40 -

EJM1003S

4) Camshaft and rocker arm

(Unit : kg.m)

EJM1004S

Engine disassembly - 41 -

5) Crankshaft, piston and flywheel

(Unit : kg.m)

Engine disassembly - 42 -

EJM1005S

6) Thermostat and housing

(Unit : kg.m)

EJM1006S

Engine disassembly - 43 -

7) Intake and exhaust manifold

(Unit : kg.m)

Engine disassembly - 44 -

EJM1009S

8) Timing gear case and flywheel housing

(Unit : kg.m)

EFM1010S

Engine disassembly - 45 -

9) Oil cooler, oil filter and oil pump

(Unit : kg.m)

Engine disassembly - 46 -

EFM1011S

10) Fuel system

(Unit : kg.m)

EFM1012S

Engine disassembly - 47 -

11) Engine repair parts

1

6

11

16

1. Cover to timing gear case gasket 12. Oil filter cover gasket

2. Gear case to cylinder block gasket 13. Oil cooler gasket

17

12

2

3

5

4

8

9

10

7

18

13

14

20

19

21

15

22

EC9OM064

3. Timing gear case oil seal 14. Intake manifold gasket

4. Flywheel housing gasket 15. Oil pan gasket

5. Crank shaft rear oil seal 16. Turbocharger gasket

6. Cylinder head gasket 17. Turbocharger outlet gasket

7. Cylinder head cover gasket 18. Water pump gasket

8. Valve guide oil seal 19. Water pump housing gasket

9. Tappet chamber cover gasket 20. Exhaust manifold gasket

10. Air heater gasket 21. Thermostat gasket

11. Thermostat housing gasket 22. Oil pump hole cover gasket

Engine disassembly - 48 -

3.1.2. Main structure parts (1)

1. Rubber hose (Coolant by-pass) 9. Oil pump driving pinion

▲ 2. Rocker arm shaft assembly 10. Nut

3. Push rod ▲ 11. Crankshaft pulley and dust cover

4. Cylinder head bolt ▲ 12. Taper bushing

▲ 5. Cylinder head assembly 13. Timing gear cover

6. Cylinder head gasket 14. Oil thrower

7. Coolant pump assembly ▲ 15. Fly wheel

8. Tappet chamber cover

2) Rocker arm shaft

Loosen the rocker arm shaft fixing bolts a
little in numerical sequence as specified.

EJM2010S

EJM2013S

Engine disassembly - 49 -

5) Cylinder head

Loosen the cylinder head bolts a little in the
numerical order shown in the figure.

11) Crankshaft pulley

Use an appropriate wrench (54 mm) to
remove the crankshaft pulley nut.

12) Taper bushing

Use the taper bushing remover to remove
the crankshaft end taper bushing.

15) Flywheel

Loosen the flywheel bolts a little in the
numerical order as specified.

EJM2014S

EJM2015S

EDM1010I

Engine disassembly - 50 -

EJM2017S

3.1.3. Main structure parts (2)

1. Oil cooler 9. Timing gear case

2. Oil pan 10. Idler gear shaft

3. Oil pump and coupling ▲ 11. Crank shaft bearing cap

4. Flywheel housing 12. Crank shaft bearing (lower part)

5. Piston and connecting rod 13. Thrust bearing

▲ 6. Idler gear 14. Crank shaft
▲ 7. Cam shaft 15. Crank shaft bearing (upper part)

8. Tappet

EJM2018S

Engine disassembly - 51 -

6) Idler gear

Measure the following points before
disassembly.

<Idler gear end play>

Standard Limit

0.058 ∼ 0.115 mm 0.2 mm

<Timing gear back lash>

Standard Limit

0.10 ∼ 0.17 mm 0.3 mm

Includes the crankshaft gear, the camshaft
gear and the idler gear

7) Camshaft

Measure the following points before
disassembly.

<Cam Gear End Play>

Standard Limit

EJM2022S

EJM2019S

0.050 ∼ 0.114 mm 0.2 mm

11) Crankshaft bearing cap

Measure the crankshaft endplay at the thrust
bearing (center main bearing) before
disassembly.

<Crankshaft End Play>

Standard Limit

0.15 ∼ 0.33 mm 0.4 mm

Engine disassembly - 52 -

EJM2020S

EJM2021S

3.1.4. Rocker arm disassembly

1. Bracket 3. Spring

EJM2023S

2. Rocker arm

4. Rocker arm shaft

Engine disassembly - 53 -

3.1.5. Cylinder head disassembly

1. Exhaust manifold and gasket 7. Spring seat (upper)

2. Intake manifold and gasket 8. Valve spring

3. Coolant outlet pipe 9. Spring seat (lower)

4.Thmostat 10.Valve

5. Thermostat housing and gasket 11. Valve stem oil seal

▲ 6. Valve cotter

EJM2024S

Engine disassembly - 54 -

Importance

6) Valve cotter

Use the valve spring compressor to remove
the valve cotter.

3.1.6. Piston and connecting rod disassembly

▲ 1. Piston rings

▲ 2. Snap ring 5. Connecting rod bearing
▲ 3. Piston pin and connecting rod

EJM2027S

EJM2028I

4. Piston

Engine disassembly - 55 -

IMPORTANT:

Remove any carbon deposits from the
upper part of the cylinder bore.
This will prevent damage to the piston and

the piston rings when they are removed
from the cylinder bore.

1) Piston rings

Use a piston ring remover to remove the piston
rings.
Do not attempt to use other tools. Stretching
piston ring will result in reduced piston ring
tension.

2) Snap ring

Use a pair of snap ring pliers to remove the
snap ring.

3) Piston pin

Tap the piston pin out with a hammer and
brass bar.

EDM1011I

EJM2030I

EJM2031S

Engine disassembly - 56 -

EJM2032S

3.2. Engine Inspection

3.2.1. Cylinder block

z Clean the cylinder block thoroughly and make a visual inspection for cracks or damage.
z Replace if cracked or severely damaged, and correct if slightly damaged.
z Check oil and water flow lines for restriction or corrosion.
z Make a hydraulic test to check for any cracks or air leaks.

(Hydraulic test) :

Stop up each outlet port of water/oil passages in the cylinder block, apply air pressure of about
5kg/cm2 against the inlet ports, then immerse the cylinder block in water for about 3 minute to check
any leaks. (Water temperature : 70 °C)

3.2.2. Cylinder head

1) Inspection

z Carefully remove carbon from the lower lace of the cylinder head using nonmetallic material to

prevent scratching of the valve seat faces.

z Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight using a

hydraulic tester or a magnetic flaw detector.

2) Distortion at the lower face

z Measure the amount of distortion using a

straight edge and a feeler gauge at six
positions (A ∼ F) as shown in the right
figure.

z If the measured value exceeds the

standard value, retrace the head with
grinding paper of fine grain size to correct
such defect.

z If the measured value exceeds the

maximum allowable limit, replace the
cylinder head.

<Lower face warpage and height>

Standard Limit

EA3M2031

Warpage

Thickness : t

0.2 mm or
less

89.95 ∼ 90.05
mm

0.3 mm

89.65 mm

EJM2034S

Engine inspection - 57 -

3) Flatness

Measure flatness of the intake/exhaust
manifolds fitting surfaces on the cylinder
head using a straight edge and a feeler
gauge.

Standard Limit

0.05 mm 0.2 mm

4) Hydraulic test

Hydraulic test method for the cylinder head
is same as that for cylinder block.

3.2.3. Valve stem and valve guide
clearance

1) Measuring method - I

z After install dial gauge needle on the

inserted valve stem, set up calibrator to
“0”. (as shown in figure)

z Move valve head from side to side.
z Record total dial indicator reading.
z This valve is the clearance between the

valve stem and valve guide.

z Valve and guide set must be replaced if

measured value exceed the specified
limit

<Valve stem clearance (T.I.R)>

EJM2036S

EJM2037S

Standard Limit

Intake side

Exhaust side

0.039 ∼

0.071mm

0.064 ∼

0.096mm

0.20mm

0.25mm

Engine inspection - 58 -

2) Measuring method – II

z Measure valve stem outside diameter.
z Measure valve guide inside diameter by

using of caliper calibrator of telescoping
gauge.

z The difference between the valve stem

outside diameter and the valve guide
inside diameter is the valve stem
clearance.

3) Valve guide replacement

z Removal of valve guide
z Pull out the valve guide, by using

hammer and valve guide remover, from
bottom of cylinder head.

z Install of valve guide

z The height from the bottom of the

cylinder head to the edge of valve guide
top should be 14.1mm.

4) Valve depression

z Install the valve① to the cylinder head②.
z Measure valve depression by using the

depth gauge or calibrator from the bottom
of cylinder head.

z Seat insert and valve must be replaced if

the measured value exceed the specified
limit.

z If the valve is replaced, the valve guide

must be also replaced.

EJM2038S

EJM2039S

EJM2040S

EJM2041I

Engine inspection - 59 -

Standard Limit

Intake and exhaust
valve depression

1.0 mm 2.5mm

5) Valve contact width

z Inspect the valve contact faces for the

roughness and unevenness.

z Make valve contact surfaces smooth.
z Measure the width of valve contact.

Standard

Valve contact width, Intake 2.4mm

Valve contact width, Exhaust 1.6mm

6) Valve seat replacement

z Arc weld entire inside circumference① of

the valve seat②. (see figure)

z Cool valve seat for a few minutes. This

will make removal of the valve seat
easier.

z Pull out the valve seat by using the inner

extractor.

z Carefully remove the carbon and other

foreign material from the cylinder head
insert bore.

7) Valve seat installation

z Carefully place Jig①.

CAUTION:

The smooth face of jig must contact the
valve seat.

z Assemble valve insert by slowly pressing

it against the jig with the bench press.
(The amount of needed pressure is more
than 2,500kg.)

IMPORTANT:
Do not press the valve seat excessively with the bench press.
It may damage the valve seat.

EJM2042I

EJM2043S

EJM2044I

Engine inspection - 60 -

8) Valve seat correction

z Remove the carbon deposits from the

valve seat surface.

z Remove the rough areas by using valve

cutter. (30°, 90° or 150°)
Do not cut the valve seat too much.

Angle Location Standard

Intake valve seat 90°

Exhaust valve seat

IMPORTANT:
Use an adjustable valve cutter pilot.
Do not allow the cutter pilot to wobble

inside the valve guide.

z Spread compound on the surface of

valve seat.

z Insert valve into valve guide.
z Lap the valve and valve seat with the

lapping tool.

z Check that valve contact width is correct.

z Check that the entire surface of valve

seat is in contact with the valve.

90°

EJM2046S

EJM2047I

EJM2048S

Engine inspection - 61 -

3.2.4. Valve spring

1) Valve spring free length

z Measure the valve spring with the vernier

caliper.

z Replace the spring if the measured value

is less than the specified limit.

Standard Limit

Exhaust and intake
valve spring free
length

2) Valve spring inclination

z Measure the valve spring inclination by

the using of square.

z Replace the valve spring if the measured

value exceed the specified limit.

Standard Limit

Valve spring

Inclination

3) Valve spring tension

z Measure the valve tension by using

spring tester.

z Replace the valve spring if the measured

value exceed the specified limit.

Standard Limit

Valve spring tension
at 44mm set length

53.65 mm
52 mm

2.5 mm 3.5 mm

22.5 kg 20.0 kg

EJM2049I

EJM2050I

EA0M4056

Engine inspection - 62 -

3.2.5. Tappet

z Check the valve tappets for excessive

wear, damage or abnormalities.

z Measure the outside diameter of tappet

with the micrometer.

Standard Limit

Tappet
outside
diameter

z Measure the clearance between tappets

and cylinder motion parts by the using
dial indicator.

Standard Limit

Tappet and tappet
bore clearance

3.2.6. Push rod

z Measure the run out of push rod with the

feeler gauge.

z Roll the push rod along a smooth flat

surface as shown in the figure.

Limit

∅27.96 ∼

∅27.98mm

0.020 ∼

0.054mm

EA0M4070

∅27.92

mm

EJM2052S

0.1mm

EJM2053S

Push rod of run-out 0.2mm

EA0M4073

Engine inspection - 63 -

3.2.7. Rocker arm correction

z Check the valve stem contact part of

rocker arm.

z Grind contact surface with an oil stone if it

is irregularly contacted.

z Replace the rocker arm if it is extremely

damaged.

1) Rocker arm and shaft

z Check the disassembled parts for wear,

damage and abnormalities.

2) Rocker arm shaft outside diameter

z Measure the outside diameter of rocker

arm with the micrometer.

z Replace shaft if measured value exceed

the specified limit.

Standard Limit

diameter of
rocker arm
shaft

∅18.98-∅19.00

mm

3) Rocker arm and shaft clearance

z Measure the inside diameter of rocker

arm bushing with the vernier caliper.

the out side diameter of rocker arm
shaft.

z Replace the rocker arm or rocker arm

shaft if measured value exceed the
specified limit.

Standard Limit

Diameter of rocker
Arm bushing

∅19.02 ∼

∅19.05mm

Engine inspection - 64 -

∅18.85

mm

∅19.07

mm

EJM2055S

EC9OM054

EJM2057S

EJM2058S

Standard

Rocker arm
bushing and
rocker arm shaft

0.02 ∼ 0.07
mm

clearance

z Check the rocker arm oil port whether

alien substance is in it or not.

z Clean the rocker arm oil port with

compressed air if necessary.

3.2.8. Idler gear and shaft

z Replace the idler gear shaft if the

measured value exceeds the specified
limit.

Standard Limit

Diameter of
idler gear
shaft

∅44.945 ∼

∅44.975 mm

z Measure the inside diameter of idler gear

with the dial indicator,

Standard Limit

Clearance of idle
gear and shaft

0.045 ∼

0.105 mm

3.2.9. Camshaft

z Use the jig to install or overhaul camshaft

bearing in cylinder block.

z Measure the clearance between the cam

journal and the camshaft bearing.

Limit

0.2 mm

EJM2059I

∅44.9

mm

EJM2060S

0.2 mm

EJM2061I

EJM2062S

Engine inspection - 65 -

Standard

Clearance of
cam journal and
cam bearing

0.03 ∼ 0.09
mm

z Align the camshaft bearing oil port with the

mating oil port (machined on the cylinder
block).

z Measure the cam lobe with the micrometer.

Replace the camshaft if the measured
values exceed the specified limit.

Standard Limit

Cam lobe height
(C-D), In

Cam lobe height
(C-D), Ex

Cam journal
diameter

7.44 mm

7.71 mm

∅56.0 mm

z Set up the camshaft on a measuring stand.
z Measure the run out of camshaft with the

dial indicator.
Record the measured value (T.I.R)
Replace the camshaft if the measured value
exceeds the specified limit.

Limit

Limit

0.15
mm

6.94
mm

7.21
mm

∅55.6

mm

EJM2063S

EJM2064S

EA0M4062

Camshaft run-out 0.12 mm

Engine inspection - 66 -

EJM2066I

3.2.10. Cylinder liner

1) Cylinder liner bore measurement

z Measure the bore at measuring position

① in line with the crankshaft③ and
across the crankshaft②.

z Measured position: 20 mm from the top

of liner. (max. wear portion)

z Replace the cylinder liner if the measured

value exceeds specified limit.

Standard Limit

Diameter of
cylinder liner
bore

CAUTION:
The casting liner is specially honed without

the chrome plating inside, so that chrome
plated ring (top ring and oil ring) must be
used.

2) Cylinder liner inspection

z Set up the straight square along the top

edge of cylinder liner.

z Measure liner projection with the feeler

gauge.

Standard

Cylinder
liner
projection

z The difference in the liner projection

height between any two adjacent
cylinders must NOT exceed 0.3mm

∅102.017∼

∅102.046 mm

Cast liner

Steel liner

∅102.20

mm

0.02 ∼ 0.07
mm

0.015 ∼

0.115mm

EJM2067I

EJM2068I

EJM2069S

Engine inspection - 67 -

3) Cylinder liner replacement

z Set the cylinder liner remover to the

cylinder liner.

z Check that cylinder liner remover shaft

ankle is firmly gripping the cylinder liner
bottom edge.

z Slowly turn the remover shaft handle

counter-clockwise to pull the cylinder liner
free.

IMPORTANT:
Take care not to damage the cylinder body
upper face when remove the cylinder liner.

3.2.11. Cylinder block

1) Grade selection of cylinder liner

z Select a grade from the outside diameter

of the cylinder liner and inside diameter
of block combination.

z Determine a grade of the cylinder liner

after measuring the inside diameter of the
cylinder block.

z Loose fitting cylinder liners (the liner is

too small for the cylinder bore) will
adversely affect engine cooling efficiency
and may lead to serious engine damage.
Cylinder liners which are too large for the
cylinder bore will be difficult to install.

2) Cylinder block bore measurement

z Measure at measuring point① across

the positions W- W, X-X, Y-Y and Z-Z.

Measuring pointL diameter : 115 mm

z Calculate average value of four

measurements to determine the correct
cylinder liner grade.

EDM3004S

EA3M2043

EJM2072I

Engine inspection - 68 -

Grade
marking

Cylinder block bore diameter

1 ∅105.090 ∼ ∅106.000 mm

2 ∅106.000 ∼ ∅106.010 mm

3) Cylinder liner outside diameter

z Measure the liner outside diameter at ①,

② and ③measuring point across X-X,
Y-Y.

Measuring Points :

① 20.0 mm
② 105.0 mm
③ 185.0 mm

z Calculate the average value of 6

measurements to determine the correct
cylinder liner grade.

z Combination of the cylinder bore and the

cylinder liner outside diameter.

Cylinder liner fitting clearance 0.001 ∼ 0.019mm 0.005 ∼ 0.026mm

<Cylinder bore and liner outside diameter>

(A) Steel cylinder liner

Grade Cylinder bore Cylinder liner outside diameter

1 ∅105.001 ∼ ∅105.010mm ∅105.011 ∼ ∅105.020mm

2 ∅105.011 ∼ ∅105.020mm ∅105.021 ∼ ∅105.030mm

3 ∅105.021 ∼ ∅105.030mm ∅105.031 ∼ ∅105.040mm

(B) Cast iron cylinder liner

∅102.020 ∼ ∅102.031mm ∅102.017 ∼ ∅102.035mm 1 ∅D

(Inner diameter)

(Outer diameter)

∅102.031 ∼ ∅102.042mm ∅102.028 ∼ ∅102.046mm 2

∅105.973 ∼ ∅105.984mm ∅105.970 ∼ ∅105.988mm A ∅E

∅105.984 ∼ ∅105.995mm ∅105.981 ∼ ∅105.999mm B

Steel liner

(tightness)

Cylinder liner diameter

② position ①, ③ position

EJM2073S

EJM2074S

Cast iron liner

(clearance)

Grade marking

Engine inspection - 69 -

Part no of
cylinder
liner grade

65.01201­0068

65.01201­0069

65.01201­0070

65.01201­0071

4) Cylinder liner assembly

z Carefully wipe away any foreign material

from the cylinder liner inside and outside
surfaces and the cylinder bore.

z Cleanly wash cylinder liner and bore

surfaces with new kerosene or diesel oil.

z Use a clean rag to remove all traces of

kerosene or diesel oil from cylinder liner
and bore surfaces.

z Insert the cylinder liner into cylinder block

from the top of the cylinder block.

z Set the cylinder liner installer to the top of

the cylinder liner.

z Position the cylinder body so that the

installer center is directly beneath the
bench press shaft center.

z Check that the cylinder liner is set

perpendicular to the cylinder.

z Use the bench press to apply an initial

seating force of 500kg to the cylinder
liner.

z Use the bench press to apply a final

seating force of 2,500kg to fully seat the
cylinder liner.

z After installing the cylinder liner, measure

the cylinder liner projection.

5) Piston grade selection

z ”Piston grade” refers to the piston diameter and the cylinder liner bore combination.
z Selection of the proper piston grade will ensure efficient engine operation, free from cylinder liner and

piston problems.

z Measure the cylinder liner bore after installing the cylinder liner.
z Determine the appropriate piston grade after measuring cylinder liner bore.

Cylinder liner

diameter

Outer Inner

1 A 1A

1 A 1B

2 B 2A

2 B 2B

Marking

EJM2074S

EJM2074S

EJM2074S

Engine inspection - 70 -

6) Cylinder liner bore measurement

z Loacte the two measuring points.

Cylinder liner measuring point

- ① : 20mm

- ② : 105mm

z Measure cylinder liner bore at measuring

points ① and ② in four different
directions (X-X, Y-Y, W-W and Z-Z).

z Calculate the average value of the 8

measurements.

Cylinder liner bore

Standard

∅102.020 ∼

∅102.042 mm

CAUTION:

It is most important to use correct piston­liner combination. Incorrect combination
will result in piston seizure.

Always measure the cylinder bore and
select the appropriate piston grade.

3.2.12. Piston

1) Piston outside diameter

z Piston outside diameter vary depending

on the piston type to be used.

z Measure the piston outside diameter ②

(see figure).

<Piston grade>

Grade Limit

A

B ∅101.963 ∼ ∅101.977 mm

∅101.953 ∼ ∅101.967 mm

EJM2077I

EJM2073S

EJM2078I

Engine inspection - 71 -

<Cylinder liner bore and piston>

Clearance 0.053 ~ 0.077 mm

CAUTION:
The cylinder liner-piston kit clearances are
preset. However, the cylinder liner

installation procedure may result in slight
decreases in the cylinder liner bore
clearances.

Always measure the cylinder liner bore
clearance after installation to be sure that it
is correct.

2) Piston ring and piston groove clearance

z Measure the piston ring and the piston

ring groove clearance with a feeler gauge.

z Measure it at several points around the

piston.

z Replace the piston ring If the measured

value exceeds the specified limit.

<Piston ring and piston groove clearance>

Standard Limit

Top ring 0.070 ∼ 0.120 mm 0.20

EJM2079S

EJM2080S

3) Piston ring gap

z Insert the piston ring horizontally (in the

z Push the piston ring with an inverted

2nd ring 0.050 ∼ 0.085 mm 0.15

Oil ring 0.030 ∼ 0.070 mm 0.15

position it will assume if it were installed
to the piston) into the cylinder liner.

piston into the cylinder liner until it
reaches measuring point ① or ②.
The cylinder liner diameter is the smallest
at these two points.
Do not allow the piston ring to slant to
one side or the other. It must be perfectly
horizontal.

Cylinder liner measuring point

- ① : 10mm

- ② : 130mm

EJM2082S

Engine inspection - 72 -

z Measure piston ring gap with a feeler gauge.
z The piston ring must be replaced if the measured value exceeds the specified limit.

Standard Limit

Top ring gap 0.25-0.45 mm 1.50 mm

2nd ring gap 0.40-0.60 mm 1.50 mm

Oil ring gap 0.20-0.40 mm 1.50 mm

4) Piston pin

z Measure piston pin outside diameter with

micrometer at several points.

z Replace the piston pin if the measured

value exceeds the specified limit.

Standard Limit

Piston pin
outside
diameter

Ø35.000 ∼

Ø35.005mm

5) Piston pin hole

z Measure diameter of the piston pin hole

with inside dial gauge.

Standard

Piston pin and piston
clearance

6) Piston pin and piston pin hole clearance

z Determine the clearance between the

piston pin and the piston pin hole by
calculating the difference between the
piston pin hole diameter and the piston
pin outside diameter.

Limit

Piston pin and piston
pin hole clearance

0.005 ∼ 0.018 mm

∅34.95 mm

EJM2083S

Ø35.010 ∼

Ø35.018 mm

EJM2084S

EJM2085S

Engine inspection - 73 -

z If an inside dial indicator is not available,

use the following procedure to check the
piston pin fit.
(1) Heat piston to approximately 60°C

with the piston heater.

(2) Push strongly against the piston pin

with your thumb. The piston pin fitting
should feel tight.

3.2.13. Maintenance of cylinder block, cylinder liner and piston

To maintain the engine in optimum condition and retain maximum performance for a long time, the cylinder
block, cylinder liner and piston which have the same grade marking number (the same size tolerance)
should be assembled. The marking number (the part’s grade) and marking position is as follows.

z Cylinder block

a) Marking number ; 1 or 2

(Size grade for of cylinder bore

diameter)

b) Marking position ; Top of the cylinder

block side surface

z Cylinder liner

a) Marking number; 1A, 1B, 2A or 2B

1A

b) Marking position ; Cylinder liner
lower surface

z Piston

a) Marking number ; A or B

(Size grade for piston outer diameter)

b) Marking position ; Center of the piston upper surface

Can used the piston A grade

Can used the cylinder block 1

EJM2086S

ENGINE SERIAL NO.

EC9OM021

EJM2172I

Engine inspection - 74 -

z Assembly process of cylinder block, cylinder liner and piston

(1) Check the marking number (1 or 2) of cylinder block. (Top of side surface)
(2) Then assemble the liner whose first digit of the marking (1A, 1B, 2A, 2B) is just the same with it on

the cylinder block.

(3) Assemble the piston whose marking is just same with the second digit (A or B) of the assembled

cylinder liner’s marking.

3.2.14. Connecting rod

1) Connecting rod alignment

z Measure the parallelism between the

connecting rod big end hole and small
end hole with a connecting rod aligner.

z Replace the connecting rod if the

measured value exceeds the specified
limit.

Standard Limit

Connecting
rod
parallelism

2) Piston pin and bush clearance

z Measure an inside of connecting rod

bushing and outside of piston pin with the
caliper gauge and micrometer.

z Replace a connecting rod bush or piston

pin if the measured value exceeds the
specified.

Standard Limit

Piston pin and
bushing
clearance

3) Connecting rod bush replacement

z Connecting rod bush removal

1) Clamp the connecting rod in a vise.

2) Pull out connecting rod bush by using
a brass bar with a bench press or a
hammer.

z Connecting rod bush assembly

(1) Use special jig to assemble the

connecting rod bush.

IMPORTANT:

Align the connecting rod bush oil hole with
the connecting rod oil hole.

0.05mm or less 0.20 mm

0.012 ∼

0.030mm

EJM2087S

0.05 mm

EJM2088S

EJM2089S

Engine inspection - 75 -

(2) Use a piston pin hole grinder① fitted

with a reamer② or an adjustable pilot
reamer to ream the piston pin hole.

Standard

Connecting rod bush
inside diameter

4) Connecting rod bearing Inspection

z Fit the connecting bearing lower half into

the connecting rod bearing cap.

z Check the tension of the connecting rod

bearing lower half.

z If the tension is insufficient, the bearing

must be replaced.

z Tighten the connecting rod and the

bearing cap to the specified torque.

A type B type

Connecting
rod bolt
torque

12 0±

0.25kg.m

A type :

B type : or

TY

11

TY

12

z Measure the inside diameter of the

connecting rod bearing with an inside dial
gauge.

Standard

Connecting rod
bearing diameter

Ø35.017 ∼

Ø35.030 mm

EJM2090S

EJM2091S

9.75±

0.25kg.m

Ø63.974 ∼

Ø64.005 mm

Engine inspection - 76 -

EJM2044I

3.2.15. Crankshaft

1) Crankshaft and bearing inspection

z Check the crankshaft journal surfaces and pin surfaces for excessive wear and damage.
z Check oil seal fitting surfaces of the crankshaft front and rear ends for excessive wear and damage.
z Replace or repair the crankshaft if any excessive wear or damage is discovered.
z Check the crankshaft oil ports for obstructions.
z Clean oil port with high pressure air if necessary.

2) Crankshaft journal and pin diameter

z Measure the crankshaft journal outside

diameter with the micrometer across ①­① and ②-②.

z Measure crankshaft journal outside

diameter at two points ③ and ④ by
using the micrometer.

z Repeat step 1 and 2 to measure the

crankshaft outside diameter.

z The crankshaft must be reground if the

measured value of the crank pin outside
diameter and/or crankshaft journal
diameter exceeds the specified limit.

Standard

Crankshaft
journal outside
diameter

Standard

Crankshaft pin
outside diameter

z Measure the crankshaft journal outside diameter (and/or crankshaft pin outside diameter) and bearing

inside diameter to determine the bearing clearance.

3) Crankshaft journal and bearing clearance

z If the bearing clearance exceeds the specified limit, the crankshaft must be reground and/or the

bearing must be replaced.

Standard Limit

Main bearing
clearance

Ø79.905 ∼ Ø79.925mm

Ø63.924 ∼ Ø63.944 mm

0.025 ∼

0.090 mm

EJM2093S

0.11 mm

Engine inspection - 77 -

Standard Limit

Rod bearing
clearance

0.03 ∼ 0.073 mm 0.10 mm

4) Crankshaft bearing diameter

z Install the main bearing cap with bearings

to the cylinder block with the specified
torque and facing the arrow mark on the
bearing cap toward front. Place them in
order of punched cylinder numbers.

z Measure the main bearing diameter with

an inside dial gauge.

Main bearing cap torque 24.1±1kg.m

Main bearing diameter Ø80 mm

5) Crankshaft run-out

z Mount the crankshaft on a set of V-blocks.
z Set the dial gauge to the center of the

crankshaft journal.

z Gently rotate the crankshaft in the normal

direction of engine rotation.

z Read the dial indicator (TIR) as you turn

the crankshaft.

z The crankshaft must be replaced if the

measured value exceeds the specified
limit.

Standard Limit

Crankshaft run-out 0.05 mm 0.40 mm

z If the repaired crankshaft generated a crack, replace it.

EA0M4019

EAMD056S

Engine inspection - 78 -

6) Main bearing and con-rod bearing

tension

z Check to see if the bearing has enough

tension, and set bearing into its regular
position with the finger pressure.

7) Crankshaft regrinding

z Pay close attention to the following steps in order to ensure the reground-crankshaft reliability.

Undersize bearing
Availability

0.25 mm 0.50 mm

<Crankshaft regrinding procedure>

(1) Grind the crankshaft journal part and

pin part.

(2) Fillet the crankshaft journal and crank

pin radius to a minimum of R3.5±0.2.
There must be no stepping around the
fillet area.

(3) Finish the crankshaft journal, crank

pin and oil hole corners to a smooth
surface having a chamfer radius of
1mm.

Crankshaft Journal and
crank pin roughness

0.4μ or less

(4) Measure the clearance between crankshaft journal and crank pin.
(5) Measure the crankshaft run-out.

8) Crankshaft grinding limit

Classification Limit

Crank journal outside
Diameter

Crank pin outside
Diameter

∅79.419 mm

∅63.424mm

z Undersize bearings (0.25 and 0.5 mm) are available to compensate for excessive clearance between

the crankshaft journal bearing and the crankshaft. Regrinding of the crankshaft to fit the undersize
bearings is require

EAMD056S

EAMD056S

Engine inspection - 79 -

Standard Limit

Main bearing
clearance

Standard Limit

Connecting
rod bearing

9) Crankshaft gear replacement

z Visually inspect the crankshaft gear.

z Replace the crankshaft gear as following

steps if excessive wear or damage is
discovered.

(1) Disassemble the crankshaft gear by

using the crankshaft remover.

(2) Replace new part.
(3) Heat the crankshaft gear for at least

10 minutes to 120oC

(4) Use the crankshaft gear installer to

install the crankshaft gear.

0.039 ∼

0.098 mm

0.03 ∼

0.073 mm

0.11 mm

0.10 mm

EJM2097S

Engine inspection - 80 -

EJM2098S

3.2.16. Flywheel and flywheel housing

1) Ring gear inspection

z Inspect the ring gear.
z If the ring gear teeth are broken or

excessively worn the ring gear must be
replaced.

2) Ring gear replacement

z Strike around the edges of the ring gear

with a hammer and chisel to remove it.

3) Ring gear installation

z Heat the ring gear evenly with a gas

burner to invite thermal expansion.
Pay attention that temperature of ring

gear is not exceeded 200°C.

z Use a hammer to install the ring gear

when it is sufficiently heated.

4) Oil seal replacement (rear)

z Use a pry bar to remove the flywheel

housing oil seal.

z Assemble the oil seal to flywheel housing

by using the oil seal assemble jig.

5) Oil seal replacement (front)

z Use an adapter and a hammer to remove

the crankshaft front end oil seal.

z Assemble the oil seal to flywheel housing

by using the oil seal assemble jig.

EJM2099S

EJM2100S

EJM2101S

EJM2102S

Engine inspection - 81 -

3.3. Engine Reassembly

3.3.1. Piston and connecting rod assembly

▲ 1. Piston

▲ 2. Piston Pin and connecting rod ▲ 5. Connecting rod

▲ 3. Snap ring 6. Connecting rod bolt

1) Piston

z Use a piston heater to heat piston to

approximately 60°C.

EJM2103I

▲ 4. Piston ring

EJM2104S

Engine reassembly - 82 -

2) Connecting rod

z Install the piston and connecting rod with

setting the marks as illustrated.

z Assemble the piston pin into the piston

and connecting rod bushing.

3) Snap ring

z Assemble the snap rings by using snap

ring flyer.

z Check that the piston moves smoothly on

the piston pin.

4) Piston ring

z Assemble the piston ring by using piston

ring assembly jig.

z Systematically assemble piston rings as

follows:
(1) Oil ring
(2) 2nd compression ring
(3) 1st compression ring
Rightly assemble the 1st and 2nd
compression rings that the marked side
must be facing ”up”.
Oil ring may be assembled any way
because it is not indicated.

z Lubricate the surface of piston ring with engine oil.
z Check it whether piston rings are smoothly rotating in the piston ring grooves.

5) Connecting rod bearing

z Assemble the connecting rod bearing to the big end and the cap.
z Lubricate the bearing with engine oil.
z Assemble the connecting rod and connecting rod bearing, and tighten cap bolt as the specified torque.

EJM2105S

EJM2031S

EJM2106I

Engine reassembly - 83 -

3.3.2. Cylinder head assembly parts

▲ 1. Valve stem oil seal

▲ 2. Intake and exhaust valve 8. Thermostat

3. Spring seat (lower) 9. Cooling water outlet

▲ 4. Intake and exhaust valve spring ▲ 10. Intake manifold and gasket)

▲ 5. Spring seat (upper)
▲ 6. Valve cotter

1) Valve stem oil seal

z Lubricate the oil seals and valve stem

sealing area with engine oil.

z Assemble the valve stem oil seal by

using oil seal installer.

EJM2107S

7. Thermostat housing and gasket

▲ 11. Exhaust manifold and gasket

Engine reassembly - 84 -

EJM2106I

2) Intake and exhaust valves

z Place the cylinder head on a flat wooden

surface.

z Lubricate valve stem with the engine oil.
z Assemble the valves to the intake or

exhaust valve guides.

4) Intake and exhaust valve springs

z Assemble the valve spring with their

painted end facing top.

5) Spring seat

6) Valve cotter

z Use a spring compressor to push the

valve spring into position.

z Install the spring seat split collar.

z Set the spring seat split collar by tapping

lightly around the head of the collar with a
rubber hammer.

EJM2110S

EJM211I

EJM2112S

EJM2113S

Engine reassembly - 85 -

10) Intake manifold and gasket

z Assembly the intake manifold gasket.

The intake manifold gasket must be
installed with its unchamfered corner
facing “up” and to the front of the engine.

z Assemble the intake manifold.
z Tighten the intake manifold bolts to the

specified torque a little at a time in the
numerical order. (see figure)

Intake manifold bolt torque 2.2 kg.m

11) Exhaust manifold and gasket

z Install the exhaust manifold gasket.
z The “TOP” mark must be facing up.

z Install the exhaust manifold
z Tighten the exhaust manifold bolts to the

specified torque a little at a time in the
numerical order. (see figure)

Exhaust manifold bolt
torque

EJM2114S

EJM2115S

EJM2116I

2.2 kg.m

EJM2117S

Engine reassembly - 86 -

3.3.3. Rocker arm and shaft assembly

▲1. Rocker arm shaft 2. Spring

3. Rocker arm

1) Rocker arm shaft

z The rocker arm shaft must be installed with the oil holes facing up.

EJM2119S

4. Bracket

Engine reassembly - 87 -

3.3.4. Main components

▲2. Crankshaft bearing (lower) ▲ 9. Idler gear shaft
▲3. Crank shaft ▲10. Idler gear
▲4. Thrust washer ▲11. Piston and connection rod
▲5. Crank shaft bearing (upper) and cap ▲12. Oil pump and coupling
▲6. Timing gear case ▲13. Flywheel housing

7. Tappet ▲14. Oil pan
▲8. Camshaft ▲15. Oil cooler

* The tappet must be installed before the camshaft installation.

EJM2120S

Engine reassembly - 88 -

2) Crankshaft bearing (lower)

z There is no oil hole and oil groove on the

lower bearing. But opposite upper
bearing has oil hole and oil groove.

3) Crankshaft

z Assemble the crankshaft gear in front

side.

CAUTION:
Make sure the part number of crankshaft
because its counterweight size may be

different depending upon engines.

4) Thrust washer

z Assemble thrust washer with the oil

groove side facing the crankshaft sliding
face.

5) Crankshaft bearing cap

z Lubricate the bearing cap bolts with

engine oil.

z Assemble the bearing caps to the

crankshaft.
The arrow mark must be pointing to the
front of the engine.

EJM2122S

EJM2123S

EJM2124S

EJM2125S

Engine reassembly - 89 -

z Tighten the bearing cap bolts to the

specified torque a little at a time in the
numerical order. (see figure)

Crankshaft bearing
cap bolt torque

z Check that the crankshaft turns smoothly

by manually rotating it.

6) Timing gear case

z Tighten timing gear case bolt to the

specified torque.

Timing gear case bolt torque 2.2 kg.m

z Apply silicon to the indicated area. (see

figure)

8) Camshaft

z Tighten thrust plate bolt through the

camshaft gear hole.

24.0±1kg.m

EJM2126S

EJM2127S

Thrust plate bolt torque 2.2 kg.m

Camshaft gear bolt torque 13 kg.m

9) Idler gear shaft

z Assemble an idler gear shaft by using the

z The oil hole must be facing the camshaft.

z Lubricate the idle gear shaft with engine

EJM2128S

thrust collar fixing bolt as a guide.

oil.

EJM2129S

Engine reassembly - 90 -

10) Idler gear

z Assemble the idle gear.

Set the timing marks “A”, ”B”, and ”C” as
shown in the figure.

z Tighten the idle gear bolts seating the

thrust collar to the specified torque.

z The thrust collar must be installed with

the chamfered side facing the front of the
engine.

Idle gear bolt torque 4.4 kg m

11) Piston and connecting rod

z Set the piston ring gaps as shown in the

figure.

z Lubricate the piston, the piston ring and

the connecting rod bearings with engine
oil.

z Position the piston front mark towards the

front of the engine.

z Use the piston ring compressor to

compress the piston rings.

z Push the piston in until it makes contact

with the crank pin by using a hammer
grip.
At the same time, rotate the crankshaft
until the crank pin reaches its highest
point.

z Set the bearing cap cylinder number

marks and the connecting rod cylinder
number marks.

z Lubricate the connecting rod cap bolt

threads and setting face with MoS2
grease.

z Tighten the connecting rod cap bolts to

the specified torque.
Refer to the following table.

EJM2130S

EJM2131S

EJM2132S

EJM2133S

Engine reassembly - 91 -

Torque

12±

0.25kg.m

9.75±

0.25kg.m

Bolt head

12) Oil pump assembled

z Lubricate the oil pump with the specified

engine oil.

z Install the oil pump with the coupling.
z Tighten the oil pump bolts to the specified

torque.

Oil pump bolt torque 5.0 kg.m

13) Flywheel housing

z Apply silicon to the shaded area. (see

figure)

z Install the flywheel housing.
z Tighten the flywheel housing bolts to the

specified torque.

M14 x 1.5 13 kg.m

TY
11

TY

12

EJM2134S

EJM2135S

M14 x 1.5 18 kg.m

14) Oil pan

z Apply liquid gasket to the area indicated

by the arrows in the figure.

z Install the gasket and oil pan.
z Tighten the oil pan bolts to the specified

torque.

Oil pan bolt torque 2.2 kg m

Engine reassembly - 92 -

EJM2136S

EJM2137S