SB2013E02

May. 1 9 9 8

Service Manual
Diesel Engine
3.3 Liter (DB33A)

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 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 train-
ing, 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 ÒSafetyÓ section of the Service or Technical Manual. Additional safety
precautions are listed in the ÒSafetyÓ 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 publica-
tion.

DAEWOO 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 DAEWOO is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubri-
cation, 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. DAEWOO dealers have the most current information avail-
able.

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 TO THE CUSTOMERS

This operation and maintenance manual is designed to serve as a reference for DHI's customers and distributors
who wish to gain basic product knowledge on DHI's DB33 Diesel engine.
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

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

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.

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 CONTENTS

1. GENERAL INFORMATIONS 1
1.1. General Repair Instructions 1.4. Major Parts Fixing Bolts
1.2. Engine Specifications 1.5. Engine Repair Kit
1.3. Torque Specifications 1.6. Repair

2. ENGINE ASSEMBLY 19
2.1. General Description 2.3. Inspection and Repair
2.2. Disassembly 2.4. Reassembly

3. LUBRICATING SYSTEM 61
3.1. General Description 3.3. Oil Filter
3.2. Oil Pump 3.4. Oil Cooler

4. COOLING SYSTEM 66
4.1. General Description 4.3. Thermostat
4.2. Water Pump

5. FUEL SYSTEM 70
5.1. General Description 5.3. Injection Nozzle
5.2. Fuel Filter

6. SPECIAL TOOL LIST 74

• WORLDWIDE NETWORK

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 1. GENERAL INFORMATION

1.1. General Repair Instructions

1. For safety, park the truck on even ground or work station and fix the wheels using wedges and hand brake
during operation.

2. Before performing service operations, disconnect the grounding cable from the battery to reduce the chance
of cable damage and burning due to short-circuiting.

3. Before performing service operations release the air pressure in the machine air line system for safety. To not
do so is extremely dangerous.

4. Use covers to prevent the components from damage or pollution.

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

6. The use of proper tools and special tools where specified is important for efficient and reliable service
operation.

7. Use genuine DAEWOO parts exclusively.

8. Used cotter pins, gaskets, O-rings, oil seals, lock washers and self-lock nuts should be discarded and new
ones should be prepared for installation as normal function of the parts can not be maintained if these parts
are reused.

9. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping
bolts and nuts separate is very important as they vary in hardness and design depending on the position of
installation.

10. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make
certain they are free from restrictions.

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

12. When necessary, use a sealant on gaskets to prevent leakage.

13. Carefully observe all specifications for bolts and nuts torques.

14. When a service operation is completed, make a final check to ensure that the service has been done
properly.

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 1.2. Engine Specifications

Engine Model
Items DB 33A

Engine type Water-cooled, 4 cycle in-line, overhead valve type

Combustion chamber type Direct injection type
Cylinder liner type Dry type, casting liner
Timing gear system Gear drive type
No. of piston ring Compression ring 2, oil ring 1
No. of cylinder-bore¡¿stroke (mm) 4-102¡¿100
Total piston displacement (cc) 3,268 (199 cu in)
Compression ratio 17.5 : 1
Engine dimension(length¡¿width¡¿height) (mm) 795¡¿701¡¿720 (31¡¿28¡¿28 in)
Engine weight(dry) (kg) 340 (750 lbs)
Fuel injection order 1-3-4-2
Fuel injection timing(B.T.D.C static) 13¡˘
Type of fuel used High-speed diesel fuel (SAE No.2)
Injection pump type VE (DOOWON)
Governor type Mechanical governing
Injection nozzle type Multi-hole type (6 hole) - VCO nozzle
Fuel injection pressure (Kg/cm )
2
220 (3,128 psi)
Compression pressure (kg/cm )
2
30 (at 200 RPM) (426 psi)
Low idle speed (R.P.M) 775-825
High idle speed (R.P.M) 2400-2500
Intake and exhaust valve clearance(at cold) (mm) 0.4
Open at 28 (B.T.D.C)
Intake valve
Close at 62 (A.B.D.C)
Open at 70 (B.B.D.C)
Exhaust valve
Close at 28 (A.T.D.C)
Lubrication method Pressurized circulation
Oil pump type Gear type
Oil filter type Full-flow type
Lubricating oil capacity (§⁄) 7.5 (Oil pan) (1.97 gal)
Oil cooler type Water cooled
Cooling method Pressurized circulation
Cooling water capacity(engine only) (§⁄) 7.5 (1.97 gal)
Thermostat type Wax pallet type (with jiggle valve)
Generator voltage-capacity(V-A) 12-61
Starter Voltage-output(V-KW) 12-2.5

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 1.3. Torque Specifications

¡ Standards bolts
The torque values given in the following table should be applied where a particular torque is not specified.

(Unit : kgƒUm)

Bolt
identification

Bolt
4T 7T 9T
diameter¡¿pitch
Low carbon steel High carbon steel Alloy steel

6¡¿1.0 0.4-0.8 0.5-1.0 -

8¡¿1.25 0.8-1.8 1.2-2.3 1.7-3.1

10¡¿1.25 2.1-3.5 2.8-4.7 3.8-6.4

¡ 10¡¿1.5 2.0-3.4 2.8-4.6 3.7-6.1

12¡¿1.25 5.0-7.5 6.2-9.3 7.7-11.6

¡ 12¡¿1.75 4.6-7.0 5.8-8.6 7.3-10.9

14¡¿1.5 7.8-11.7 9.5-14.2 11.6-17.4

¡ 14¡¿2.0 7.3-10.9 9.0-13.4 10.9-16.3

16¡¿1.5 10.6-16.0 13.8-20.8 16.3-24.5

¡ 16¡¿2.0 10.2-15.2 13.2-19.8 15.6-23.4

18¡¿1.5 15.4-23.0 19.9-29.9 23.4-35.2

20¡¿1.5 21.0-31.6 27.5-41.3 32.3-48.5

22¡¿1.5 25.6-42.2 37.0-55.5 43.3-64.9

24¡¿2.0 36.6-55.0 43.9-72.5 56.5-84.7

The ¡ indicates that the bolts are used for female-threaded parts that are made of soft materials such as casting, etc.

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 1.4. Major Parts Fixing Bolts

¡ Cylinder head and block

(unit : kgƒUm)

2.5
2.1
18.0 lb¡⁄ft
15.2 lb¡⁄ft

72.32 lb¡⁄ft
10.0
11.5

83.17 lb¡⁄ft

5.3

38.33 lb¡⁄ft

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 ¡ Intake and exhaust manifold

(unit : kgƒUm)

2.1

15.2 lb¡⁄ft

2.1

15.2 lb¡⁄ft

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 ¡ Cylinder block and others

(unit : kgƒUm)

13.7
99.1 lb¡⁄ft

2.1 Lubricate with engine oil

2.6
18.8 lb¡⁄ft 15.2 lb¡⁄ft

7.9
57.0 lb¡⁄ft

2.6
18.8 lb¡⁄ft

2.4
Lubricate with engine oil

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 ¡ Cylinder block and others

(unit : kgƒUm)

2.6
18.8 lb¡⁄ft

2.6
18.8 lb¡⁄ft

5.3
38.3 lb¡⁄ft
2.6
18.8 lb¡⁄ft
5.3
38.3 lb¡⁄ft

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 ¡ Crankshaft and camshaft

(unit : kgƒUm)

44.0

318 lb¡⁄ft

9.75¡ 0.25
70.5 ¡ 1.8 lb¡⁄ft
12¡ 0.25
86.8 ¡ 1.8 lb¡⁄ft

16.0
115.7 lb¡⁄ft

5.5
39.8 lb¡⁄ft

2.5
18.1 lb¡⁄ft

16.0
115.7 lb¡⁄ft

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 ¡ Thermostat and housing

(unit : kgƒUm)

2.1
10.5 lb¡⁄ft

5.3
25.1 lb¡⁄ft

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 1.5. Engine Repair Kit

Part No. 1¡›25 : Engine disassembly components

Part No. 1, 3, 21, 22, 25 : Engine top disassembly components

1. Gasket : Cylinder head 14. Gasket : Oil pan and body

2. Gasket : Cylinder head cover and bolt 15. Gasket : Oil filter
3. Gasket : Head cover 16. Gasket : Oil pump and pipe
4. Gasket : Relief valve 17. Gasket : Oil filter pipe
5. Gasket : Injection pump 18. Gasket : Oil jet pipe
6. Gasket : Tappet chamber and bolt 19. Gasket : Water pump
7. Gasket : Oil cooler 20. Gasket : Outlet pipe
8. Gasket : Oil pump cover 21. Gasket : Thermostat housing
9. Oil seal : Crankshaft(RR) 22. Gasket : Nozzle gasket
10. Gasket : Retainer 23. Oil seal : Crank gear case
11. Gasket : Case and cylinder block 24. Gasket : Exhaust manifold
12. Gasket : Cover and case 25. Gasket : Injection nozzle
13. Gasket : Oil pan drain plug

10

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 1.6. Repair

1.6.1. Cylinder Head Bolt

Tighten the cylinder head bolts in sequence as shown

in the figure.

11.5
Torque(kgƒUm)
( 83.2 lb¡⁄ft)

Front

1.6.2 Valve Clearance

Adjust the valve clearance in the following manner

using a feeler gauge.

Standard(in cold)

0.4
Intake and exhaust (mm)
(.016 in)

1. Bring the piston in either 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 to see if there is play in the No. 1 intake and

exhaust valve rocker arms. TDC
If the No. 1 cylinder intake and exhaust valve rocker
arms are depressed, the No. 4 piston is at TDC on the
compression stroke.

The same results can be obtained by using the TDC

line on flywheel and pointer.

TDC line Timing pointer

11

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 Adjust the clearances of valves marked with an
arrow

Rocker arm screw 2.5

lock nut torque (kgƒUm) (18.1 lb¡⁄ft)

After adjusting the valve clearances referring to the

drawing, turn the crankshaft one full turn in the
rotative direction and align the TDC mark with the
pointer, then adjust the remaining valve clearances.

1.6.3. Injection Timing

Inspection
Check the notched line on the crankshaft pulley and
timing pointer are aligned.

Setting Timing (BTDC)

Engine : 13¡B̆TDC
I/P : Plunger Lift 0.3mm
TDC
(.0118 in)

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.

Notched line

Arrow mark

Check the notched line on the injection pump is in

Arrow mark
alignment with the notched line on the timing gear
cover.

Check the alignment of the notched lines injection

pump and bracket.

Notched line
Notched line

12

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 Injection timing adjustment
1. Adjust fuel injection timing with crank pulley
notched line and timing pointer.

Adjust the timing pointer with the marking on the

pulley.
TDC

Disconnect the inj. pipes (4pieces) from I/P

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 lift.

3.Turn the timing flange to adjust the plunger lift to

0.3mm.

13

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 4. Install the No. 1 injection pipe and tighten to
specified torque.

3¡›3.5
Injection pipe nut torque (kgƒUm)
(21.7~25.3 lb¡⁄ft)
Do not overtighten the delivery valve holder. It will
distort the injection pump body shape and adversery
affect control rack operation.

1.6.4. Compression Pressure

Remove the glow plugs from all cylinders, then check

the compression pressure in each cylinder with a
compression gauge by engaging starter.
(kg/cm2, 200 rpm)

Standard Limit
22¡›23
30 (312~327 psi) Compression gauge adapter

Compression gauge adapter

1.6.5. Air Cleaner

Dry type air cleaner

¡ Observe the air cleaner service indicator
¡ Clean the air cleaner element and dust pan when the
Air cleaner
RED band in the service indicator looks in the visible service
position. indicator

Stop button

Cleaning primary filter element

¡ Direct air inside of the element and blow out dusts
from the pleats completely.
(Maximum air pressure does not excess 2.1kg /cm2)
¡ Always replace the secondary element.
Do not attempt to reuse it by cleaning.

14

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 Detergent
¡ Wash the element in warm water and nonsudsing
household detergent.
¡ Rinse the element with clean water
¡ Dry it thoroughly with natural air or electric fan.
Don't use a flame or compressed air for drying. It
damages the element.

Checking element
¡ Insert a light inside the clean and dry element and
examine it.
¡ Discard the element if tears, rips or damages are
found.
¡ Wrap and 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.

1.0
Measuring pressure (kg/cm2)
(14.2 psi)

Radiator cap

0.87
Pressure valve opening pressure (kg/cm2)
(12.4 psi)

0.05
Vaccum valve opening pressure (kg/cm2)
(.71 psi)

1.6.7. Lubricating System

Element
Oil filter replacement
¡ Before installing a new filter element apply a small
amount of clean engine oil to the element gasket.
¡ Install the new element. When the gasket contacts
the base, tighten it 3/4 of a turn more.
Do not overtighten.

15

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 1.6.8. Fuel System

Injection nozzle Correct Incorrect Incorrect

Check the spraying condition and injection starting
pressure.

220
Injection starting pressure (kg/cm2)
(3.128 psi)

Adjustment
Adjust the injection starting pressure with the
adjusting screw using a nozzle tester.

1.6.9. Fan Belt Fan pulley

(mm) Depress here

10
Specified belt deflection
(.393 in)

Generator pulley

Crank pulley

1.6.10. Glow Plug

Inspection(Resistance)

Silver color 4.5 §

Black color 1.6§

Check the continuity across the plug terminals and

body.

16

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 2. Engine Assembly

2.1. General Description

17

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 2.2. Disassembly

2.2.1. External Parts (A)

11
8

12

11
1 8

2
3
9
6
10

<Disassembly steps>
1. Breather hose 7. Oil pan
2. Exhaust manifold 8. Cylinder head cover
3. Oil guide tube and level gauge 9. Rubber hose
4. Starter 10. Water pump
5. Cooling fan belt 11. Thermostat housing assembly
6. Alternator

18

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 Important operations
¡ Exhaust manifold assembly(2)
Loosen the manifold fixing bolts in sequence of
figure's shown. 1 8 6 4

3 5 7 2

¡ Cylinder head cover(8)

Loosen the head cover bolts in sequence of figure's
shown

1 3 2

19

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 2.2.2. External Parts (B)

1
8

6 7
5

2
3

<Disassembly steps>
1. Fuel injection pipe 5. Oil pipe
2. Injection nozzle 6. Oil filter assembly
3. Glow plug 7. Injection pump
4. Intake manifold 8. Oil cooler assembly

20

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 Important operations
¡ Engine control cable.
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 the delivery valve holder to avoid dirt entry.

21

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 2.2.3. Internal Parts

¡ Major Components

<Disassembly steps>
1. Rocker arm shaft assembly 12. Crankshaft pulley
2. Push rod 13. Gear case cover
3. Cylinder head assembly 14. Idle gear
4. Cylinder head gasket 15. Camshaft assembly
5. Fly wheel 16. Timing gear case
6. Fly wheel housing 17. Crankshaft bearing cap and bearing
7. Rear oil seal assembly 18. Thrust bearing
8. Oil pump cover 19. Crankshaft assembly
9. Oil pump assembly 20. Crankshaft bearing
10. Piston and connecting-rod assembly 21. Tappet
11. Crankshaft front nut and washer

22

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 Important operations

¡ ‹ Rocker arm shaft assembly (1)

Loosen the rocker arm shaft assembly bolts a little
at a time in numerical sequence as shown in the
figure.

¡ ‹ Cylinderhead assembly (3)

Loosen the cylinder head bolts a little at a time in
the numerical sequence as shown in the figure.

Front

¡ ‹ Flywheel (5)
Loosen the flywheel bolts a little at a time in
numerical sequence as shown in the figure.

Apply engine oil

¡ ‹ Piston assembly (10)

Remove any carbon deposits from the upper part of
the cylinder bore using a scraper.
This will prevent damage to the piston and the
piston rings when they are removed from the
cylinder bore.

Position the piston to the top by turning the

crankshaft, remove the piston assembly from
cylinder using a wooden bar or hammer.

23

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 ¡ ‹ Crankshaft front nut and washer (11)
Wrench : 41 mm

Wrench

¡ ‹ Idle
gear (14)
Measure the following points before disassembly.

Idle gear end play. (mm)

Standard Limit

0.058¡›0.115 0.2
(.002~0.0045 in) (.0078 in)
Feeler gauge

Backlash (mm)

Standard Limit

0.10¡›0.17 0.3
(.0039~.0069 in) (.012 in)

Includes the crankshaft gear, camshaft gear and idle

gear.
Dial indicator

¡ ‹ Crankshaftbearing cap and bearing (17) Feeler gauge

Measure the crankshaft end play before
disassembly.

Crankshaft end play (mm)

Standard Limit

0.10¡›0.17 0.3
(.0039~.0067 in) (.012 in)
Crankshaft
Includes the crankshaft gear, camshaft gear and
idle gear.

Loosen the crankshaft bearing cap bolts in

numerical sequence as shown in the figure.

Apply engine oil

24

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 ¡ ‹ Thrust
bearing (18)
Remove the thrust bearing with steel wire.

Wire

¡ ‹ Tappet (21)
Mark the cylinder No
Remove the tappets and mark the cylinder number
each tappet.
(Be careful against the damages)

Exhaust Intake

2.2.4. General Components

¡‹ Rocker arm, Bracket and shaft assembly

<Disassembly steps>
1. Bracket 3. Spring
2. Rocker arm 4. Rocker arm shaft

25

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 ¡ Cylinder head assembly

<Disassembly steps>
1. Spring retainer and valve cotter 3. Valve
2. Spring and spring seat 4. Valve stem oil seal

Important operations

Mark the cylinder No. each component when it

disassembles.
¡ Valve spring
¡ Valve
¡ Valve seat

¡ Retainer and valve cotter (1)

Spring compressor

Valve spring compressor

26

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 ¡ Piston and connecting-rod assembly

<Disassembly steps>
1. Piston ring 3. Piston pin and connecting-rod
2. Snap ring 4. Piston

Important operations

Mark the cylinder No. each component when it

disassembles.
¡ Piston ring
¡ Piston
¡ Piston pin
¡ Connecting-rod

27

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 ¡ ‹Piston
ring (1)
Remove the piston rings

¡ ‹Snap
ring (2)
Remove the piston pin snap ring

¡ ‹ Piston pin and connecting-rod (3)

Pull out the 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 warpage

¡‹ Use a straight edge and a feeler guage to measure
the four sides and the two diagonals of the cylinder
head lower face.

28

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 Lower face warpage and height (mm)

Standard Limit
Warpage 0.05 or less 0.2
(.002 in) (.008 in)

Thickness 89.95¡›90.05 89.75

(reference) (3.54~3.55 in) (3.53 in)

2.3.2. Valve, Valve Guide and Valve Seat Insert

Valve contact width (mm)

Standard Limit

1.5 2.0
(.059 in) (.079 in)
Contact width

Valve depression (mm)

Standard Limit

1.0 2.5
(.039 in) (.098 in)

Depression

Valve seat angle

Valve seat angle

Valve seat insert replacement
Removal : Arc weld the entire inside circumference of Valve seat
the valve seat insert. insert
¡ ‹ Cooling the valve insert for a few minutes
and pull out with a screw driver. Cylinder head
Installation : Use a bench press to smoothly press the
valve seat insert.

Welding bead

29

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 Valve seat angle

Intake valve seat angle 45¡˘

Exhaust valve seat angle 45¡˘

45¡˘

Valve seat angle (mm)

Standard Limit
1.5 1.0
(.059 in) (.039 in)

Thickness

Valve stem outer diameter (mm)

Standard Standard

Intake valve 8.946¡›8.961 8.88

(.352~.353 in) (.350 in)

Exhaust valve 8.921~8.936 8.88

(.351~.352 in) (.350 in) ¥† ¥– ¥

Valve stem outer diameter (mm)

Standard Standard

Intake 0.04¡›0.07 0.2

(.002~.003 in) (.008 in)

0.06~0.09 0.25 Measuring

Exhaust point
(.002~.009 in) (.010 in)

Valve guide replacement

Remover, installer Remover, installer

30

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 2.3.3. Valve Spring

Valve Spring Free Length

Use a vernier caliper to measure the valve spring free
length.
If the measured value is less than the specified limit,
the valve spring must be replaced.

Standard Limit Remark

Exhaust and Intake 49.0 mm 47.0 mm for
Valve Spring Free
Length (1.93 in) (1.85 in) Industrial
Inner 52.4 mm 50.0 mm
Free for
(2.06 in) (1.97 in)
length Outer Automotive
53.6 mm 50.6 mm
(2.11 in) (1.99 in)

Valve Spring Inclenation

Use a surface plate and a square to measure the Inclination
valve spring inclination.
If the measured value exceeds the specified limit, the
valve spring must be replaced.

Standard Limit Remark

Valve spring less than Free
2.7 mm for length
Inclination 1.3 mm
(.051 in) (.106 in) Industrial
1.0 mm Square
Free Inner - for
(.039 in)
length Outer Automotive
- 1.0 mm
(.039 in)

Valve Spring Tension

Use a spring tester to measure the valve spring tension
if the measured value is less than the specified limit, the
valve spring must be replaced.

Standard Limit Remark

Valve Spring 14.5 kg 11.5 kg for
Tension at 40 mm
Set Length (32 lbs) (25.4 lbs) Industrial Spring tester
42mm 10.9 kg 9.9 kg
Inner for
(1.65 in) (24 lbs) (21.8 lbs)
44mm 23.0 kg 20.0 kg Automotive
Outer
(1.73 in) (50.7 lbs) (44.1 lbs)

2.3.4. Tappet

Inspect the tappets for excessive wear, damage and

any abnormalities.

Pitted Crack normal contact

Abnormal contact

31

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 Diameter (mm)

Standard Limit
27.97¡›27.98 0.2
(1.10 in) (1.09 in)

Micrometer

Clearance between the tappet and cylinder body

(mm) Dial indicator

Standard Limit
0.02¡›0.054 0.1
(.0008~.002 in) (.004 in)

2.3.5. Push Rod

Run-out

0.03
Limit (mm)
(.0012 in)

¡ ‹ Use
a feeler gauge to measure the push rod run-out
¡ ‹ Roll
the push rod along 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)

Standard Limit
18.98~19.00 18.85
(.747~.748 in) (.742 in)

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 Rocker arm bushing (mm)

Standard Limit
19.01~19.03 19.05
(.748¡›.749 in) (.75 in)

Clearance between rocker arm shaft and bushing

(mm)

Standard Limit

0.01¡›0.05 0.2
(.0004¡›.0020 in) (.0079 in)

2.3.7. Camshaft Assembly

Inspect all disassembled parts for wear, damage and

any abnormalities.

¡‹ Camshaft
¡‹ Cam gear
¡ ‹ Thrust plate

End play (mm) Camshaft gear

Standard Limit

0.050¡›0.114 0.2 Thrust plate

(.0020¡›.0045 in) (.0079 in)
Camshaft
Feeler gauge

Camshaft journal diameter (mm)

Standard Limit

55.94¡›55.97 55.60
(2.202~2.204 in) (2.189 in)

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 Run-out (mm)
56.00¡›56.03 Camshaft bearing
Standard
(2.205~2.206 in)

Clearance between camshaft journal and body

(mm)

Standard Limit

0.03¡›0.09 0.15
(.001~.004 in) (.006 in)

Camshaft bearing replacement

Remover, installer

Remover, installer

Align the camshaft oil holes with the cylinder body oil
ports.

The oil holes of No. 1 camshaft bearing(front side are

two otherwise is one.
Align the oil ports

Camshaft run-out (T.I.R) (mm)

0.1
Standard
(.004 in)
¡ ‹ Place the 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 backlash are found.

14.0
Gear bolt torque (kgƒUm) ¡ÿRefer to the standard
(101.3 lb¡⁄ft) backlash table at
"Major components disassembly"

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 Cam gear and thrust plate replacement
Camshaft gear
Disassembly : Gear puller
Install : Use a bench press and a hammer

16.0
Torque (kgƒUm)
(115.7 lb¡⁄ft)

Cam lobe height (mm)

Standard Limit

Cam lobe height (C) 47.7 46.5

(1.88 in) (1.83 in)
56.0 55.6
Cam journal diameter (A,B) (2.20 in) (2.19 in)
Use a micrometer to measure the cam lobe height and
journal diameter.
If the measured number is less than the specified limit,
the camshaft must be replaced.

2.3.8. Idle Gear and Idle Gear Shaft

Shaft outside diameter (mm)

Standard Limit

44.94¡›44.97 44.84
(1.76~1.77 in) (1.765 in)

use a micro.

Clearance between shaft and gear (mm)

Standard Limit

0.009¡›0.060 0.2
(.0004~.0023 in) (.008 in)

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 2.3.9. Cylinder Block and Liner

Cylinder bore measurement

Measuring point : Approx. 20mm bellow from upper
face(Maximum wear portion) (mm)

20mm
Standard Limit
105.00¡›105.04 105.10
For steel liner (4.13~4.14 in) (4.14 in)
105.99¡›106.01 106.10
For cast liner (4.17~4.179 in) (4.18 in)

Cylinder liner replacement

Angle
Disassembly : Removeer
Angle for steel liner only Remover

Installation
Installer
¡ ‹ Use a bench press to apply an initial seating force
of 500kg to the cylinder liner. Installer Bench press
¡ ‹ And then apply a final seating force of 2,500kg to
fully seat the cylinder liner.

0.001¡›0.019
Steel liner Tight fit (standard) (mm)
(.0004~.0007 in)
Cast liner 0.005¡›0.026
Loose fit (mm)
(.0002~.0010 in)

After installing the liner measure the cylinder liner

projection and inner diameter.
Square Liner projection
Liner projection
0.03¡›0.010
Standard (mm)
(.0011~.0004 in)

¡ ‹ Forthe cast liner, removal or installation is done

easily.

Feeler gauge

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 Cylinder liner inner diameter (mm)

Liner Grade Standard

102.021¡›102.040
A (4.016~4.017 in)
For steel liner
102.041¡›102.060

20mm
C
(4.017~4.018 in)
102.021¡›102.030
A
(4.016~4.017 in)
For cast liner
102.031¡›102.042
B
(4.017 in)

2.3.10. Piston, Piston Pin and Piston Ring

Piston outer diameter (mm)

Piston grade Standard

101.955¡›101.975
A (4.014~4.015 in)
For steel liner
101.975¡›101.994
C
(4.015~4.016 in)
101.953¡›101.967
A
(4.014~4.015 in)
For cast liner
101.963¡›101.977
B
(4.014~4.015 in)

Piston and liner bore clearance

Standard (mm) 0.055~ 0.075

Piston ring
Piston ring and ring groove clearance (mm)

Standard Limit
0.085¡›0.11 0.2
1st compression ring
(.003~.009 in) (.008 in)
0.035¡›0.055 0.15
2nd compression ring
(.001~.002 in) (.006 in)
Oil ring 0.03¡›0.07 0.15
(.001~.003 in) (.006 in)

Piston ring gap (mm)

Standard Limit
0.25¡›0.45 1.5
1st compression ring
(.010~.018 in) (.006 in)
0.2¡›0.4 1.5
2nd compression ring
(.008~.016 in) (.006 in)
Oil ring 0.2¡›0.4 1.5
(.008~.016 in) (.006 in)

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 Piston pin outside diameter (mm)

Standard Limit

35.000¡›35.005 34.95
(1.377~1.378 in) (1.376 in)

Piston pin and piston clearance (mm)

0.005
Limit (mm)
(.0002 in)

2.3.11. Connecting Rod and Bearing

Connecting rod aligmment (parallelism)

Alignment (per length of 100mm (3.94 in)) (mm)

Standard Limit

0.05 0.2
(.002 in) (.009 in)

Bushing inside diameter

35.017~35.025
Standard
(1.379 ~1.380 in)

Use a caliper calibrator and micrometer to measure

the piston pin and connecting rod small end bushing
clearance.
Piston pin and connecting rod small end bushing
(mm)

Standard Limit

0.01~0.03 0.05
(.0004~.0012 in) (.002 in)

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 Bushing replacement
Removal : Use a brass bar and a bench press Bench press

Installation : Use a brass bar and a bench press. The

connecting rod busing oil port must be
Brass bar
aligned with the connecting rod oil port.

After new bushing installation, ream the bushing

inside diameter with a pin hole grinder or a reamer to
fit the piston pin. Pin hole grinder

Reamer

Connecting rod bearing

Bearing spread

68.00¡›68.01
Standard (mm)
(2.677~2.678 in)

Bearing tension
1. Fit the connecting rod bearing lower half into the
connecting rod bearing cap.
2. Check the connecting rod bearing lower half
tension.
If the tension is insufficient, the bearing must be
replaced.
3. Reassemble the connecting rod and bearing cap.

2.3.12. Crankshaft and Bearing

¡‹ Crankshaft and bearing inspection

1. Inspect the crankshaft journal and pin surfaces for
excessive wear and damage.
2. Inspect the oil seal fitting surfaces of the crankshaft
front and rear ends for excessive wear and damage.
3. Replace or repair the crankshaft if any excessive
wear or damage is found.
4. Inspect the crankshaft oil ports for obstructions.
5. Use high pressure air to clean the oil ports if necessary.

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 Crankshaft pin outside diameter
¤ ¤Ø¤Œ
63.932¡›63.944
Standard (mm)
(2.517~2.517 in) ¤Ł ¤Ł

Use a micrometer to measure the crankshaft pin ¤Œ

¤ ¤Ø
outside diameter across points ¤ and ¤Łat the two
points ¤Øand ¤Œ.

Connecting rod bearing cap reassembly

12¡ 0.25 9.75¡ 0.25
Connecting rod bolt torque (kgƒUm)
(86.7 ¡ 1.81 lb¡⁄ft) (70.51 ¡ 1.81 lb¡⁄ft)
Bolt type A B

A: 11 Bolt head
B: TY
11T
or TY
12T
Inside diameter
- Apply engine oil to bearing surface.
- Measure the connecting rod inside diameter with an
inside dial indicator.
Connecting rod bearing 64§j
nominal diameter (mm) (2.52 in)

Crankshaft pin and bearing clearance (mm)

Standard Limit

0.03¡›0.07 0.10
(.001~.003 in) (.004 in) (mm)

Under size 0.25¡›0.50

Bearing specifications (.010~.020 in)

Crankshaft journal bearing

Tension
Fit the journal bearing into the journal bearing cap and
check the tension with the same method of connecting
rod cap bearing.

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 Crankshaft journal outside diameter
B I II
75.913¡›75.925
Standard (mm)
(2.989 in.)
B B
Use a micrometer to measure the crankshaft journal
outside diameter across points £ and £ at the two A
points ¥ and ¥–.

Journal bearing cap reassembly

24
Torque (kgƒUm)
(173.6 lb¡⁄ft)
Refer to
Inside diameter
"Major components disassembly"
-Apply engine oil to bearing surface. - Crankshaft bearing cap.
-Measure the journal bearing cap inside diameter with
an inside dial indicator.

Journal bearing 76§j

nominal diameter (mm) (2.992 in)

Crankshaft journal and bearing clearance (mm)

Standard Limit
0.065¡›0.116 0.15
Center bearing (.003~.006 in) (.006 in)
0.025~0.076 0.11
Other bearings (.004 in)
(.001~.003 in)

Under size 0.25~0.50

Bearing specifications (mm) (.010~.020 in)

Crankshaft run-out (mm)

Standard Limit

0.05 0.40
(.002 in) (.016 in)

1. Mount the crankshaft on a set of v-blocks.

2. Set a dial indicator to the center of the crankshaft journal
3. Gently turn the crankshaft in the normal direction of
engine rotation.
4. Read the dial indicator(TIR) as you turn the crankshaft.

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 Crankshaft gear
Inspect the crankshaft gear
- Before the gear disassembly, check the crank gear
backlash.
- If excessive wear of any damage is found through Refer to
the inspection, replace the crankshaft gear. "Major components disassembly"
- Gear backlash.

Crankshaft gear replacement

Removal : Remover Remover

Installation
Installer

Installer

Pilot bearing replacement

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

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 2.3.13. Flywheel and Housing(Rear Oil Seal)

¡ ‹Flywheel thickness (Friction face) (mm)

Standard Limit

33.4¡›33.6 32.5 Friction face

(1.315~1.323 in) (1.280 in) Crankshaft
assembly
face

Ring gear replacement

Removal : Use a brass bar and hammer
- Strike around the edges of the ring gear with a
hammer and brass bar to remove it.

Installation :
-Heat the ring gear evenly with a gas burner to invite
thermal expansion.
Do not allow the temperature of the ring gear to
exceed 200¡ (390¢ )
-Use a hammer to install the ring gear when it is
sufficiently heated.

Flywheel housing oil seal replacement

Installer
Removal : Use a pry bar and hammer.
Installation : Use a oil seal installer.

If the crankshaft contact area wears excessively,

move the contact area with a oil seal spacer. Install
new oil seal and discard the used one.
Oil seal

Spacer

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 2.3.14. Timing Gear Case Cover

Oil seal replacement

Installation : Installer Installer

2.4. Engine Reassembly

2.4.1. Minor Components

¡ ‹Piston and connecting-rod assembly

4
1
3

<Disassembly steps> 3. Snap ring

1. Piston 4. Piston ring
2. Piston pin 5. Connecting rod

Important operation
Piston heater

¡ ‹ Piston (1)
Use a piston heater to heat the piston approximately
60¡ (140¢ )

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 ¡ ‹ Piston pin and connecting-rod (2)
1. Install the connecting-rod to the piston with setting Piston head
the marks as illustrated.
Front mark
2. Install the piston pin into the piston and the
connecting-rod bushing
Cylinder numder
marked side

¡ ‹ Snap ring (3)

1. Use a pair of snap ring pliers to install the piston pin
snap ring.

2. Check that the piston moves smoothly on the piston

pin.

¡ ‹Piston ring (4)

Marked side
1. Use a piston ring installer to install the three piston FOR STEEL LINER
rings.
1st ring
- Install the piston rings in the following order: oil
ring ¤M2nd compression ring ¤M1st compression
2nd ring
ring.

¡ The marked side of the two compression rings

must be facing up. The undercut side of the 2nd Oil ring

compression ring will be facing down. As the oil

ring has no any facing mark, it may face in either
direction.

2. Lubricate the piston ring surfaces with engine oil. FOR CAST LINER

3. Check the piston ring rotate smoothly in the piston 1st ring

ring grooves.
2nd ring

4. Use Cr-coating piston ring for cast liner and normal

piston ring for steel liner.
Oil ring

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 ¡ ‹ Cylinder head assembly

<Disassembly steps>
1. Valve stem oil seal 3. Spring seat and spring
2. Valve 4. Spring retainer and cotter key

Important operation

¡ ‹ Valve stem oil seal (1)

Installer
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. Intake valve Exhaust valve

2. Install the valves to the intake and exhaust guides.

Install the valves to their original lapped valve
seats.
Big Small

(Valve face)

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 ¡ ‹ Spring seat and spring (3)
Install the valve springs with their painted end(the
close pitched end) facing down.

Painted portion

¡ ‹ Spring retainer and 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 with a rubber hammer.

Spring compressor

<Disassembly steps>
1. Bracket 3. Spring
2. Rocker arm 4. Rocker arm shaft

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 2.4.2. Internal Parts

¡ ‹ Major components

11

12

<Disassembly steps>
1. Tappet 13. Idle gear
2. Crankshaft bearing(upper) 14. Timing gear case cover
3. Crankshaft 15. Crankshaft pulley
4. Thrust bearing 16. Crankshaft front nut and washer
5. Crankshaft bearing cap and bearing(lower) 17. Flywheel housing
6. Timing gear case 18. Rear oil seal assembly
7. Camshaft assembly 19. Flywheel
8. Piston and connecting rod assembly 20. Cylinder head gasket
9. Oil pump assembly 21. Cylinder head assembly
10. Oil pump cover 22. Push rod
11. Oil cooler 23. Rocker arm shaft assembly
12. Injection pump assembly

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 Important operation
With oil hole Fit correctly
and groove

¡ ‹ Crankshaft bearing (upper) (2)

¡ ‹Crankshaft bearing (lower) (5)

Center lower half bearing has no oil groove and oil
hole while others all have oil groove and oil hole.

No oil groove and hole

(center lower)

¡ ‹Crank shaft (3)

Install the crankshaft so that the crank gear
assembled part is directed to the front of the engine.

Front

¡ ‹ Thrust bearing (4)

Install the thrust bearings with the oil groove side Oil groove side
facing the crankshaft contact face.

¡ ‹ Crankshaft bearing cap

Arrow mark(position No. punched)
- 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.

Front

Tighten the bearing cap bolts to the specified torque a Arrow mark
little at a time in the numerical order shown in the
figure.

24
Torque (kgƒUm)
(173.6 lb¡⁄ft)

Check that the crankshaft turns smoothly by manually

rotating it.

Lubricate with enging oil

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 ¡ ‹ Timing gear case (6)

2.6
Torque (kgƒUm)
(18.8 lb¡⁄ft)

¡ ‹ Camshaft (7)
Tighten the thrust plate bolts through the camshaft
gear hole.

¡ ‹Torque (kgƒUm)

Thrust plate bolt 2.1

(15.2 lb¡⁄ft)
16
Camshaft gear bolt (115.7 lb¡⁄ft)

Camshaft gear

¡ ‹Piston and connecting rod assembly (8)

2nd compression ring
Position the piston ring gaps as shown in the figure.

Oil ring Top ring

Position the piston front mark towards the front of the

engine. Use a hammer grip to push the piston in until
it makes contact with the crank pin. At the same time,
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 manifold.

¡ ‹ Connecting rod cap bolt

Bolt head 11 TY TY Cylinder No.

11T 12T

Torque (kgƒUm) 12¡ 0.25 9.75¡ 0.25

(86.8 ¡ 1.8 lb¡⁄ft) (70.5 ¡ 1.8 lb¡⁄ft)
-Lubricate the connecting-rod cap bolt threads and
setting faces with MoS grease.

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 ¡ ‹ Oil pump assembly(9)
Full up the oil pump with engine oil and install the
pump to the cylinder body.

Oil

Oil pump

¡ ‹ Oil pump mounting bolts

3.8
Torque (kgƒUm)
(27.5 lb¡⁄ft)

¡ ‹ Oil cooler(11)
Tighten the cooler bolts to the specified torque. Start
from the middle and work out to either side.

¡ ‹Injection pump assembly (12)

2.6
Torque (kgƒUm)
(18.8 lb¡⁄ft)

"ƒU" ; Injection pump fixing bolts

Check the punched line of the injection pump body is

Arrow mark
aligned to the pump bracket line.

Notched line
Notched line

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 ¡ ‹ Idle gear(13)
Use the thrust collar fixing bolt as a guide to install the
idler gear shaft.
The oil port must be facing the camshaft.

Set the timing marks (A,B,C) as shown in the figure. Injection pump gear
Idle gaer "B" mark
Idle gear bolt 2.6
Torque (kgƒUm) (18.8 lb¡⁄ft)

"C" mark Crankshaft

gear
"A" mark
Camshaft gear

¡ ‹ Crankshaft front nut (16)

Pulley
Wrench : 41 mm

2.6
Torque (kgƒUm)
(18.8 lb¡⁄ft)

Wrench

¡ ‹ Flywheel housing (17)

Fixing bolts torque 14kgƒUm (101.25 lb¡⁄ft)

¡ ‹ Flywheel (19)

16.0
Torque (kgƒUm)
(115.7 lb¡⁄ft)

Lubricate with engine oil

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 ¡ ‹ Cylinder head gasket (20)
Front top mark
The gasket "TOP" mark must be facing up and
"FRONT" mark is towards the front of the engine.

Front

¡ ‹ Cylinder head assembly (21)

Carefully place the cylinder head on the cylinder body.
Lubricate the head bolts and contact face of the
cylinder head.
Tighten the head bolts in the numerical order as
shown in the figure. Front

1st step 2nd step

7.0 11.5 ¡ Shorter head bolts are used
(50.6 lb¡⁄ft) (83.2 lb¡⁄ft) for injection pump side

¡ ‹ 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 in
the figure.

3.1
Torque (kgƒUm)
(22.4 lb¡⁄ft)

Adjust the valve clearance

Refer to MAINTENANCE for

the valve clearance adjustment
procedure.

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 2.4.3. External parts (A)

11
8

11
1 8

2
3
9
6
10

<Disassembly steps>
1. Breather hose 7. Oil pan
2. Exhaust manifold 8. Cylinder head cover
3. Oil guide tube and level gauge 9. Rubber hose
4. Starter 10. Water pump
5. Cooling fan belt 11. Thermostat housing assembly
6. Alternator

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 Important operation

¡ ‹ Oil pan (1)

- Apply liquid gasket to the cylinder block and oil pan.
- Install oil pan gasket and oil pan.

1.6
Bolt torque (kgƒUm)
(11.6 lb¡⁄ft)

¡ ‹ Cylinder head cover (2)

2.1
Bolt torque (kgƒUm)
(15.2 lb¡⁄ft)

Tighten the bolts as shown in the figure.

1 3 2

¡ ‹ Water pump assembly (3)

Apply liquid gasket
Apply liquid gasket(belco bond No. 4) to the water to the cylinder block side
pump gasket before installing the water pump.

¡ ‹Thermostat housing assembly (5)

5.3
Bolt torque (kgƒUm)
(38.3 lb¡⁄ft)

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 ¡ ‹ Cooling fan belt (13)
Adjust the cooling fan belt tension.

Refer to Maintenance for

the fan bolt tension adjustment

¡ ‹Starter motor (9)

8.6
Torque (kgƒUm)
(62.2 lb¡⁄ft)

¡ ‹Exhaust manifold (11)

Carefully install the gasket with the "TOP" mark side "TOP" mark
facing up.

Install either end of the distance tube in the spot

facing.
Distance tube

Tighten the exhaust manifold and gasket fixing bolts in

numerical order as shown in the figure.

2.6 1 8 6 4
Torque (kgƒUm)
(18.8 lb¡⁄ft)

3 5 7 2

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 2.4.4. Extermal Parts (B)

1
2

5
4 3

2
1

<Disassembly steps>
1. Oil filter and bracket 5. Injection nozzle
2. Oil pipe 6. Injection pipe
3. Intake manifold 7. Engine control lever
4. Glow plug

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 Important operation

¡ ‹Main oil filter and bracket (1) (kgƒUm)

5.3
'A' bolt torque
(38.3 lb¡⁄ft)

¡ ‹Intake manifold assembly (3)

Install the gasket with its protruding part facing up.
Protruding Part

¡ ‹ Glow plug (4)

5.3
Torque (kgƒUm)
(38.3 lb¡⁄ft)

¡ ‹ Injection nozzle (5)

Adjusting the opening pressure with adjust screw
using a nozzle tester.

Refer to maintenance for

the injection nozzle opening
pressure adjustment

Replace the nozzle gasket and dust cover with new

one. Dust cover
Tighten the injection pipe sleeve nut and flange nut.

2.6
Torque (kgƒUm)
(18.8 lb¡⁄ft)

Nozzle gasket

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 ¡ ‹ Fuel injection pipe (6)

3.0
Torque (kgƒUm)
(21.7 lb¡⁄ft)

Delivery valve holder must be tightened as specified

torque.
Excessive torque causes leakage at control rack and
pipe.

Delivery valve 4.0~4.5

Holder torque (kgƒUm) (28.9~32.5 lb¡⁄ft)

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 3. Lubricating System

3.1. General Description

O/P : Opening pressure
Full flow filter O/P warning
lamp Start
S/W Battery
By-pass Oil filter
valve warning lamp
O/P 1kg/cm2 By-pass Oil press S/W
valve
Cylinder body main oil gallery
Paper Oil
filter cooler
O/P 2kg/cm2 Crank Cam Timing
O/P 8kg/cm2 Injection
shaft shaft idle
brgs. pump
Oil relief brgs. gear
valve

Oil pump Oil Con. Cyl.

relief rod head
valve brgs. valve
system

Oil strainer

Oil pan

3.2. Oil Pump

Disassembly

3
6

<Disassembly steps>
1. Strainer 3. Cover and dowel 5. Drive shaft and gear
2. Suction pipe 4. Drive gear 6. Driven gear shaft

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 Inspection and repair
Make the necessary adjustments, repairs and part
replacements if excessive 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.

0.18
Limit (mm)
(.007 in)

Cover and driven gear clearance

0.12
Limit (mm)
(.005 in)

Drive gear shaft diameter (mm)

Standard Limit
15.9
16.0 (.626 in)

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 Reassembly
To Assemble, follow the disassembly procedures in
reverse order.

Important operation

¡ ‹Strainer (1)

1.0¡›1.8
Torque (kgƒUm)
(7.233~13.0 lb¡⁄ft)

3.3. Oil Filter

Disassembly

<Disassembly steps>
1. Oil filter ass'y 6. Bolt
2. Head-oil filter 7. Spring washer
3. Element-oil fiter 8. Plain washer
4. Relief valve ass'y 9. O-Ring
5. Gasket 10. Plug-screw

Inspection and repair

Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is found
through inspection.

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 Reassembly
To reassemble follow the disassembly procedures in
reverse order.

Important operation

¡ ‹ Relief Valve (1)

2.5
Torque (kgƒUm)
(18.1 lb¡⁄ft)

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 3.4. Oil Cooler

Disassembly

4
3
2

<Disassembly steps>
1. Element 3. Spring
2. Bolt 4. By-pass valve

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 procedures in
reverse order.

Important operation

¡ ‹ Element (1)

2.6
Torque (kgƒUm)
(18.8 lb¡⁄ft)

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 4. Cooling System

4.1. General Description

4.2. Water Pump

Disassembly

<Disassembly steps>
1. Cover 3. Center-Fan 5. Shaft bearing and spacer
2. Impeller 4. Snap ring 6. Seal unit, washer and seal

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 Important operation

¡ ‹Impeller (2)
Removal : Remover

¡ ‹Pulley center (3)

Remove the pulley center using a bench press and a Bench press
bar.

Pully center

¡ ‹ 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 and seal (6)

Remove the seal unit using a bench press and
suitable remover.

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 Inspection and repair
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is found
through inspection.

Bearing replacement

Removal ;

Use a bench press

Assembly
Use a bench press to install two bearings with a
marked side outward.

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 grease. Lubricate with multi purpose grease

Marked side outward

¡ ‹ Washer, seal and seal unit (6)

Apply a thin coat of liquid gasket(Belco bond No. 4) to
the seal unit outer periphery before installation.

Apply liquid gasket

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 ¡ ‹ Snap ring (4)
Install the snap ring using a snap ring plier.

¡ ‹ Pulley center (5)

Install the pulley center using a bench press.

¡ ‹ Impeller (2)
ƒUInstall the impeller to the shaft using a bench press. Bench press
ƒUUse a feeler gauge to measure the clearance
between the impeller and the pump body.
0.3¡›0.8
Standard (mm)
(.012~.031 lb¡⁄ft)

Feeler gauge

4.3. Thermostat

Inspection and repair

Make the necessary adjustments, pepairs and part
replacements if excessive wear or damage is found
through inspection.

Valve opening temperature

Agitating rod Thermometer
80¡›84
Standard (¡ )
(176¢ ~183¢ )

Valve lift(at testing temperature)

approx. 10 mm (at 95¡ )
Standard
(.393 in (at 203¢ ) ) Wood piece

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 5. Fuel System

5.1. General Description

Injection nozzle
Fuel
return

Injection pump

Fuel filter & water separator

Fuel tank

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 5.2. Fuel Filter

Inspection and repair

Make the necessary adjustments, repairs and part replacements if excessive wear or damage is found
through inspection.

Reassembly
To assemble, follow the disassembly procedures in reverse order.

5.3. Injection Nozzle

Disassembly

<Disassembly steps>
1. Plunger 4. Spacer 7. Adjust shim
2. Retaining nut 5. Spring seat 8. Nozzle holder body
3. Injection nozzle 6. Nozzle spring

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 Important operation

¡ ‹Injection nozzle (3)

Remove the nozzle assembly from the nozzle body.
Keep 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
through inspection.

Reassembly
To assemble, follow the disassembly procedures in
reverse order.

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 Important operation

¡ ‹Injection nozzle (3)

Align the nozzle dowel pin with the dowel hole in the
nozzle holder body.

¡ ‹Retaining nut (2)

6~8
Torque (kgƒUm)
( 43.4~57.9 lb¡⁄ft)

¡ ‹Adjust shim (7)

The injection nozzle injection starting pressure can be
adjusted after the adjusting shim is installed.

220
Injection starting pressure (kg/cm2)
( 3.128 psi)

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 6. Special Tool List

No. Figure Tool name

1. Cylinder head bolt wrench

2. Injection pump

3. Compression gauge adapter

4. Valve spring compressor

5. Valve guide remover and installer

Camshaft bearing remover and installer

6.

7. Cylinder remover

8. Cylinder liner remover angle

9. Cylinder liner installer

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 No. Figure Tool name

10. Crankshaft gear remover

11. Crankshaft gear installer

12. Crankshaft pilot bearing remover

13. Crankshaft rear oil seal installer

14. Crankshaft front oil seal installer

Valve stem oil seal installer

15.

16. Piston ring compressor

17. Water pump impeller remover

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