Daewoo D1146, D1146, D1146TI, DE08TIS, D1146TI Service Manual

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MAINTENANCE MANUAL

Diesel Engine

D1146 D1146TI

65.99897-8056 Feb. 2001

DE08TIS

PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

FOREWORD

This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries Ltd's (here after DAEWOO’s) customers and distributors who wish to gain basic product knowledge on DAEWOO's D1146, D1146TI and DE08TIS 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

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 and diesel fuel 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.

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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.

DAEWOO Heavy Industries & Machinery LTD.

Feb. 2001

Printed in Jan. 2001 PS-MMA0415-E1A

MAINTENANCE MANUAL

CONTENTS

1. GENERAL INFORMATION

1.1 General Repair Instructions 1

1.2. Engine Specific Character 2

1.3. Engine Specifications 4

1.4. Engine Assembly 8

2. MAJOR MAINTENANCE

2.1. Preventive Maintenance 13

2.2. Diagnosis and Remedy 22

2.3. Engine Inspection 32

3. MAINTENANCE

3.1. Engine Disassembly 33

3.2. Inspection and Measurement on Major Parts 48

3.3. Reassembly 69

3.4. Breaking in 96

D1146/D1146TI/DE08TIS

4. MAINTENANCE OF MAJOR COMPONENTS

4.1. Cooling System 98

4.2. Lubrication System 102

4.3. Fuel Injection Pump 106

4.4. Turbocharger 122

5. Special Tool List 132

● Appendix 134

● WORLDWIDE NETWORK

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1. GENERAL INFORMATION

1.1. 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 DAEWOO 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 separate 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 a sealer on gaskets to prevent leakage.

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

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

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.2. Engine Specific Character

1.2.1. Toroidal combustion mode (D1146)

The D1146 engine is operated in the toroidal combustion mode that was developed by this company with AVL Co. Australia. The feature of this mode in the fundamental structure is that there are combustion chambers in the centers of piston heads and swirling passages in the cylinder heads. This swirling passages when intake stroke generates the strong swirling motion in the combustion chambers by giving the intake air a big moment, and when compression stroke, the special piston’s shapes causing very complicated and distorted flows by means of eddy current and squashed flows will make the air and fuel mix more smoothly. Also, when explosion stroke, a considerable output increase came to be expected with the accomplishment of nearly perfect combustion by the more smooth mixing of air and fuel which was injected through multi-nozzles in the combustion chamber. This engine by means of Toroidal Combustion Mode has the specific character such as quiet and stable revolutional motion, multi-purpose application, economical fuel and oil consumption, etc.

1.2.2. OMEGA combustion bowl (D1146TI, DE08TIS)

The OMEGA combustion bowl is a unit designed to perform high efficiency, low emission combustion. As the rim around the combustion bowl port of the upper of the piston has been machined in a smaller size than the interior of the combustion bowl, strong swirl is produced in the combustion bowl and strong squish flow makes the fuel be mixed more sufficiently with air. Due to the application of OMEGA combustion system and optimal utilization of intake and

M1041A

exhaust port configuration within the cylinder head, the D1146TI, DE08TIS diesel engines discharge very low level of hazardous exhaust gases such as smoke, nitrogen oxide, hydrocarbon, or carbon monoxide and thus ensure high performance and low fuel consumption.

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

1.2.3. Oil gallery cooling type piston (DE08TIS)

Oil gallery cooling is used for the piston of DE08TIS diesel engine. When thermal loading is high, piston cooling by means of an oil gallery in the crown is normally necessary to prevent crown cracking and ring sticking. The design of the gallery, the design and location of the oil spray nozzle and the quantity of oil flowing in the gallery are critical in order to achieve the desired temperature reduction. The cross section shape of the gallery should be designed to achieve sufficient oil movement to maximize cooling efficiency.

M1255

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MAINTENANCE MANUAL

1.3. Engine Specifications

1.3.1. Specification

Engine Model Items

Engine type

Combustion chamber type Direct injection type Cylinder liner type Replaceable dry liner Timing gear system Gear driven type No. of piston ring Compression ring 2, oil ring 1 No. of cylinder-bore x stroke (mm) Total piston displacement (cc) 8,071 Compression ratio 17.5 : 1 16.8 : 1 18.5 : 1 Engine dimension (length x width x height) (mm) 1,253x811.5x934.5 1,253x812.5x1,009 1,253x812.5x1,009 Engine weight (kg) 730 745 745 Rotating direction (viewed from flywheel) Counter clockwise Fuel injection order 1 – 5 – 3 – 6 – 2 – 4 Fuel injection timing (B.T.D.C static) Injection pump type Zexel in-line “AD” type Zexel in-line “P” type

Governor type

Injection nozzle type Multi-hole type (5 hole) Fuel injection pressure (kg/cm2) 210 214 160/220

Compression pressure (kg/cm2) 28 (at 200 rpm) Intake and exhaust valve clearance (at cold) (mm) 0.3

Intake valve

Exhaust valve

Lubrication method Full forced pressure feed type Oil pump type Gear type driven by crankshaft Oil filter type Paper element type Cartridge type Lubricating oil capacity (max./min.) (lit) 15.5/12 or 20/17 Oil cooler type Water cooled Water pump Centrifugal type driven by belt Cooling Method Fresh water forced circulation Cooling water capacity (engine only) (lit) 14

Thermostat type Air compressor type & capacity (cc) Belt driven type, 220 or 300

Alternator voltage – capacity (V – A) 24 – 45 or 24-150 Starting Motor voltage – output (V - kW) 24 – 4.5 Air heater capacity (V – A) 22 – 95 (2.1kW) Battery capacity (V - AH) 24 - 150

Open at Close at Open at Close at

D1146 D1146TI DE08TIS

4 cycle in-line,

Water-cooled type

Naturally aspirated

6 – 111 × 139

15° 9° 3°

Mechanical governor

type(RLD)

16° (B.T.D.C) 36° (A.B.D.C) 46° (B.B.D.C) 14° (A.T.D.C)

Wax pallet type

(79 ∼ 94 °C or 83 ∼ 95 °C )

4 cycle in-line,

Water-cooled type

Turbo charged & intercooled

Mechanical

governor

type(RLD-J)

Multi-hole type

(7 hole)

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1.3.2. Engine power

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Engine model Performance

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Production tolerance : ±5%

Model Suffix

EACBA EACBB EACBE

D1146

EACBH

EACBI

EACBK

EAPBA 9 205/2,200 75/1,400 600-650

D1146TI

EAPCA 9 215/2,300 82/1,400 600-650

Injection

timing

(BTDC°)

15 182/2,500 57.5/1,600 600-650 2750

Power

(PS/rpm)

Torque

(kg.m/rpm)

Low idle

(rpm)

High idle

(rpm)

2370

2,470

2250

2,350

Remark

EURO-I

ECPBA ECPCA

DE08TIS

ECPBB ECPCB

3 225/2,300 82/1,200 600-650 2,530

3 240/2,300 90/1,200 600-650 2,530

* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349).

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EURO-II

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1.3.3. Performance curve (DE08TIS – 225PS)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Performance ISO 1585(SAE J1349)

Output (max.) 165 kW (225PS) / 2,300 rpm Torque (min) 804 N.m (82 kg.m) / 1,200 rpm Fuel consumption (min) 192 g/kW.h (141 g / PS.h)

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1.3.4. Performance curve (DE08TIS – 240PS)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Performance ISO 1585(SAE J1349)

Output (max.) 176 kW (240PS) / 2,300 rpm Torque (max.) 882 N.m (90 kg.m) / 1,200 rpm Fuel consumption (min.) 192 g/kW.h (141 g / PS.h)

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1.4. Engine Assembly

1.4.1. Engine sectional view (longitudinal)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

8 9

11 12

14 15

16 17

24 25 26

1 Water pump 2 Piston 3 Air compressor 4 Intake valve 5 Exhaust valve 6 Breather

7 Cylinder head cover 8 Exhaust valve spring 9 Cylinder head 10 Intake valve spring 11 Cylinder block 12 Push rod 13 Flywheel housing 14 Ring gear 15 Tappet 16 Cam shaft 17 Fly wheel 18 Oil seal (Rear) 19 Oil seal (Front) 20 Crank shaft pulley 21 Crank gear 22 Vibration damper 23 Oil pump 24 Oil suction pipe 25 Oil pan 26 Crank shaft

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1.4.2. Engine sectional view (cross)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

13 14

6 7

8 9

1 Fuel injection pipe 9 Turbo charger 2 Fuel filter 10 Fuel injection pump 3 Fuel injection nozzle 11 Timing gear case 4 Intake manifold 12 Oil filler cap 5 Air heater 13 Connecting rod 6 Rocker arm 14 Oil spray nozzle 7 Rocker arm bracket 15 Oil filter 8 Exhaust manifold 16 Oil cooler

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1.4.3. Engine Assembly Views

(1) D1146 (bus)

3 4 5 6 7

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

17 18

1 Flywheel housing 8 Oil filler cap 16 Water pump 2 Intake manifold 9 Oil level gauge 17 Exhaust manifold 3 Breather 10 Oil pan 18 Cylinder head cover 4 Air pipe 11 Oil drain plug 19 Crank shaft pulley

(Air cleaner to intake manifold)

12 Oil filter 20 Vibration damper 5 Fuel filter 13 Fuel injection pump 21 Oil cooler 6 Power steering pump 14 Air compressor pulley 22 Starter 7 Air compressor 15 Thermostat 23 Cooling water pipe

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MAINTENANCE MANUAL

(2) DE08TIS (Truck)

34 5

9 10

678

11 12

20 21

15 16

29 30

23 24 25

26 27

Magnetic pick-up sensor

12 Cooling fan 21 Exhaust elbow 2 Flywheel housing 13 Cooling fan guide 22 Crank shaft pulley 3 Intake manifold 14 Air compressor pulley 23 Vibration damper 4 Fuel filter 15 Thermostat 24 Mounting bracket 5 Air pipe 16 Water pump 25 Oil cooler

(Intercooler to intake manifold)

17 Alternator 26 Starter relay 6 Fuel injection pipe 18 Air pipe 27 Starter 7 Air compressor

(Turbocharger to intercooler)

28 Breather 8 Air con. compressor 19 Air pipe 29 Water delivery pipe 9 Oil pan

(Air cleaner to turbocharger)

30 Air heater relay 10 Fuel injection pump 20 Turbocharger 31 Cooling water pipe 11 Oil filter

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(3) DE08TIS (Bus)

192

3 4 5 6 7

12 13 14

18 19 20

28 29

1 Intake manifold 10 Oil level gauge 20 Water pump 2 breather 11 Flywheel housing 21 Exhaust manifold 3 Air pipe 12 Drain plug 22 Belt

(Intercooler to intake manifold)

13 Oil pan 23 Mounting bracket 4 Fuel injection pipe 14 Oil filter 24 Oil cooler 5 Air pipe 15 Fuel injection pump 25 Turbocharger

(Turbocharger to intercooler)

6 Fuel filter 17 Idle gear pulley 27

16 Vibration damper 26 Starter

Cooling water pipe

7 Power steering pump 18 Air compressor pulley 28 Fly wheel 8 Air compressor 19 Thermostat 29 Pilot bearing 9 Oil filler cap

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

2. Major Maintenance

2.1. Preventive Maintenance

The preventive maintenance means that the operator performs the servicing of engine to obtain long life and best performance from DAEWOO diesel engine.

2.1.1. Cooling Water

z Regarding the cooling water that is to be used for engine, the soft water not the hard

water must be used.

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 D1146, D1146TI and DE08TIS (diesel engine of D1146 series) 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 or DAEWOO

60.99901-0038)

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.

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.

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MAINTENANCE MANUAL

(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) locates in the range of 0.3 to 0.8 at the color list of label on the test paper storage bottle.

(7) 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.

z Amount of Anti-freeze in winter

Ambient

Temperature (°C)

Over -10

-10

-15

-20

-25

-30

-40

Cooling water (%) Anti-freeze (%)

85 80 73 67 60 56 50

15 20 27 33 40 44 50

2.1.2. Fan belt

deteriorated.

z Check the fan belt for belt tension.

If belt tension is lower than the specified limit, adjust the tension by relocating the alternator. (specified deflection: 10 ∼ 15 mm when pressed down with thumb)

z Use a fan belt of specified dimensions, and replace if damaged, frayed, or

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2.1.3. Engine oil

z Check oil level with the oil level gauge and replenish if necessary.

z Check the oil level with the engine cooled. If the engine is warm, allow time for 5

∼ 10 minutes for oil drain into the crankcase before checking oil level. The oil level must be between Max and Min. lines on the gauge.

z Engine oil should be changed at the specified intervals.

Oil filter cartridge should be changed simultaneously.

- First oil change : 1,000km(50 hr) operating First oil change

(city bus, dump truck)

(express bus, cargo truck)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

After 1,000km (50hr)

operation D1146/TI every 10,000km Short-distance operation vehicle DE08TIS every 20,000km D1146/TI every 15,000km Long-distance operation vehicles DE08TIS every 30,000km

z The following oils are also recommended

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

2.1.4. Oil filter

z Check for oil pressure and oil leaks, and

repair or replace the oil filter if necessary.

z Change the oil filter cartridge simultaneously

at every replacement of engine oil.

Engine

model

D1146 D1146TI

DE08TIS

Recommend oil

Remark

SAE No. API No.

SAE 15W40 above CD or CE

SAE15W40 SAE10W40

ACEA-E2 or ACEA-E3

(API CH-4)

Oil filter head

Oil filter (Cartridge)

G1081

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2.1.5. Fuel filter

z Drain water in cartridge with loosening

the

cock under filter manually (6) from time to

time.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

2.1.6. Air cleaner.

z In case that elements are deformed,

damaged or if the air cleaner has a crack,

replace it.

z By the definite interval, the elements must be

cleaned and replaced.

2.1.7. Intercooler

G1019

The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is occurred. So you always check whether the intake air systems like air filter element are worn or polluted.

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Air fl

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

󰼿

Air/air intercooler with radiator (combined radiator)

ow by cooling fan

Hot air by turbo charger compressor

Cooled air to intake manifold (max. 50°C)

󰼿

2.1.8. Valve clearance adjust procedure

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.

Model

D1146 D1146TI DE08TIS

Intake Valve Exhaust Valve

0.3 mm 0.3 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.

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MAINTENANCE MANUAL

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.

z No. 1 cylinder is located at the side where

flywheel was installed.

Flywheel

Intake Valve Exhaust Valve Cylinder No. Cooling Fan

2.1.9. Cylinder compression pressure

z Stop the engine after warming up,

and

take out nozzle holder assembly.

G1048

G1067

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MAINTENANCE MANUAL

z Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there.

Standard value 28kg/cm

over Limit value 24kg/cm2 Difference between each cylinder

Within ± 10 %

♦ Condition : Water temperature 20°C,

Engine rotation 200rpm (10 rotations)

G1068

2.1.10. 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 D1146 D1146TI DE08TIS

Opening pressure

z Check the atomizing state and replace it if abnormal.

2.1.11. Fuel injection pump

z Check the housing crack, damage etc. and replace it if abnormal.

210 kg/cm

214 kg/cm

1st : 160 kg/cm

2nd : 220 kg/cm

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z Check if the idle operation and speed regulating lever's sealing is removed.

z The adjustment and testing of fuel injection pump should necessarily be done at

the test bench.

2.1.12. 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.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

2.1.13. Air removal of fuel system

The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve.

In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump, after loosening the air removing screws of cartridge filter respectively, remove the air by operating the manual pump of fuel supply pump until bubble will disappear.

2.1.14. Fuel supply pump

Every time of engine oil replacement, the fuel strainer installed at the fuel supply pump should be removed and cleaned.

2.1.15. Turbocharger

The turbocharger needs not arty special equipment. Every time of engine replacement, a leakage or clogging of oil pipes should be

inspected. Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic inspection should be applied on the compressed air and exhaust gas

Printed in Jan. 2001 PS-MMA0415-E1A

pipes, For leaking air will bring the overheat engine, an immediate repair must be done. During the operation that is surrounded by the dust and oil mixed air, frequent cleaning must be done on the impellers. Tear down the impeller casing (attention: be careful not to bend) and must clean with non-acid solvent solution. If necessary, use plastic scraper If impeller is severely polluted, dip the impeller into solution and may be better to clean it with stiff brush. Then one thing to beware is to dip only impeller part and so do not support by impeller but bearing housing.

2.1.16. Starting motor

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

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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

Printed in Jan. 2001 PS-MMA0415-E1A

2.2. Diagnosis and Remedy

z The following description summarizes the probable cause of and remedy for

generall failure by item.

z Immediate countermeasures should be taken before a failure is inflamed if any

symptom is detected.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Operating state

1. Overload

2. Radiator core clogged

3. Continuous over-run

Check fresh Radiator tank cap

Inspect Radiator

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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MAINTENANCE MANUAL

Causes according to operating conditions

1. Overload

2. Freqent use of low geae position at high speed

3. Freqent use of high geae position at low speed

4. Clutch slip

5. Too low tire inflation pressure

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Cause according to use conditions

1. Excessive oil infusing

2. continuous operation in low speed

or extremely cold state

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D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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Condition Causes Remedies

1) Starting difficult

(1) Compression pressure lack z Valve's poor shut, stem

2) Idle operation abnormal

3) Engine output insufficient

(1) Continuous output

insufficient

(2) Output insufficient

when in acceleration

4) Overheating

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Repair or replace

distortion

z Valve spring damage Replace valve spring z Cylinder head gasket's leak Replace gasket z Wear of piston, piston ring

or liner

z Injection timing incorrect Adjust z Air mixing at injection pump Remove air

z Valve clearance incorrect Adjust z Valve tightness poor Repair

z Cylinder head gasket's leak Replace gasket z Wear, stick, damage of

piston ring

z Injection timing incorrect Adjust z Fuel injection amount

insufficient

z Nozzle injection pressure

improper or stuck

z Supply pump's function

lowered

z Fuel pipe system clogged Repair z Air suction amount

insufficient

z Turbocharger poor Repair or replace z Compression pressure

insufficient

z Injection timing incorrect Adjust z Fuel injection amount

insufficient

z Injection pump timer's

function insufficient

z Nozzle infection pressure,

infection angle improper

z Supply pump's function

lowered z Air intake amount insufficient

z Engine oil insufficient or

poor

z Cooling water insufficient Replenish or replace z Fan belt loosened, worn,

damaged z Cooling water pump's

function lowered z Water temp. regulator's

operation poor

z Valve clearance incorrect Adjust z Exhaust system's resistance

increased

Adjust

Replace piston ring

Adjust injection pump Adjust or replace Repair or replace

Clean or replace air cleaner

Disassemble engine

Adjust injection pump Repair or replace Repair, replace Repair or replace Clean or

replace air cleaner Replenish or replace

Adjust or replace Repair or replace Replace

Clean or replace

Printed in Jan. 2001 PS-MMA0415-E1A

5) Engine noisy

(1) Crankshaft

(2) Con.-rod and

Con.-rod bearing

(3) Piston, piston pin &

Piston ring

(4) Others

6) Fuel Consumption Excessive

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Condition Causes Remedies

For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the cause of noises accurately. z As the wear of bearing or

crankshaft progress, the oil

clearances increase.

z Lopsided wear of crankshaft Grind or replace z Oil supply insufficient due to

oil passage clogging

z Stuck bearing Replace bearing & z Lopsided wear of con rod

bearing

z Lopsided wear of crank pi n Grind crankshaft z Connecting rod distortion Repair or replace z Stuck bearing Replace &

z Oil supply insufficiency as

clogging at oil passage

progresses z Piston clearance increase

as the wear of piston and

piston ring progresses

z Wear of piston or piston pin Replace z Piston stuck Replace piston z Piston insertion poor Replace piston z Piston ring damaged Replace piston z Wear of crankshaft, thrust

bearing z Camshaft end play

increased

z Idle gear end play increased Replace thrust washer z Timing gear backlash

excessive

z Valve clearance excessive Adjust valve clearance z Abnormal wear of tappet,

cam z Supercharger inner part

damaged

z Injection timing incorrect Adjust

z Fuel injection amount

excessive

Replace bearing & grind crankshaft

Clean oil passage

Grind Replace bearing

grind crankshaft Clean oil passage

Replace piston & piston ring

Replace thrust bearing Replace thrust plate

Repair or replace

Replace tappet, cam Repair or replace

Adjust injection pump

Printed in Jan. 2001 PS-MMA0415-E1A

7) Oil Consumption Excessive

(1) Oil level elevated z Clearance between cylinder

(2) Oil level lowered z Looseness of valve stem &

(3) Oil leak z Looseness of connection

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Condition Causes Remedies

Replace

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 z Oil ring's oil return hole

clogged z Oil ring's contact poor Replace piston ring

guide

z Wear of valve stem seal Replace seal z Cylinder head gasket’ s leak Replace gasket

parts

z Various parts' packing poor Replace packing z Oil seal poor Replace oil seal

Replace piston, piston ring Replace piston ring

Correct position Replace piston Replace piston ring

Replace in set

Replace gasket, repair

Printed in Jan. 2001 PS-MMA0415-E1A

2.3. Engine Inspection

2.3.1. Stopping engine

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

2.3.2. General engine inspection cycle

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

О󰼿:󰼿Check󰼿&󰼿adjust󰼿󰼿󰼿●󰼿:󰼿Replace󰼿

Cooling

System

Lubrication

System

Intake &

Exhaust

System

Fuel

System

Inspection time(km)

Inspection

Check for leakage(hoses, clamp) Check the water level Check the V-belt tension

Change the coolant water Check for leakage

Check the oil level gauge Change the lubricating oil

eplace the oil filter cartridge

Check the leakage for intercoole (hoses, clamp)

Clean and change

he air cleaner element

rain the water in separator

Clean the fuel strainer of fuel feed pump

Check the fuel line leakage Check fuel Injection timing

eplace the fuel filter cartridge

Check the injection nozzles

Daily

1,000 10,000 15,000 20,000 40,000

О О О

О О

●

1st

●

1st

О О

(О)

●

Remark

When

necessary

When

necessary

When

necessary

When

necessary

Engine

Adjust

Check the exhaust gas state Check the battery charging

Check the compression pressure

djust Intake/Exhaust

alve clearance

О О

*󰼿(О)󰼿The󰼿engine󰼿oil󰼿change󰼿interval󰼿is󰼿determine󰼿by󰼿engine󰼿use󰼿and󰼿oil󰼿grade.󰼿 󰼿

2.3.3. 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 illl performances, it may rather bring early engine failure.

Printed in Jan. 2001 PS-MMA0415-E1A

3. MAINTENANCE

3.1. Engine Disassembly

3.1.1. Heed at disassembly

z Before disassembly, the part shelf should be prepared for various tools and repair parts.

z When assembling, clean empty hand should be used and clean environment

maintained.

z In case of storing the disassembled parts, each part should not touch each other. z In case of disassembly, the parts should be laid in order.

3.1.2. Oil level gauge

z Pull out the oil level gauge.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

3.1.3. Cooling water

z Remove the radiator cap. Open the drain

valve at the radiator lower part to drain the coolant as the right figure.

CAUTION: When removing radiator filler cap while

the engine is still hot, cover the cap with a rag, then turn it slowly to release the internal steam pressure. This will prevent a person from scalding with hot steam spouted out from the filler port.

Drain valve

P1024a

z Remove the drain plug from the cylinder

block and drain out the cooling water into a container.

Drain plug

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.4. Engine oil

z Remove the oil drain plug of oil pan and

pour the engine oil into the prepared vessel.

3.1.5. Cooling fan

z Remove the flange fixing bolts, then take off

the flange and cooling fan.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Drain plug

3.1.6. Belt

z Loosen the tension adjusting bolts of the

alternator and the idle pulley, and take off the belts.

3.1.7. Thermostat

G1086

z Loosen the rubber hose connected to the

cooling water pipe and remove the thermostat.

z Remove the rubber hose of the by-pass

line.

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.8. Starter

z Unscrew the starter fixing nuts and

remove the starter being careful not to damage its gears.

3.1.9. Fuel filter

z Remove the hollow screws of filter and

tear down fuel supply and discharge

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

rubber hose.

z Remove fuel filter fixing bolts and

disassemble the fuel filter. (If the fuel filter is of cartridge type, disassemble the cartridge element only.)

3.1.10. Breather

z Loosen the clamp screw to remove the

rubber hose.

3.1.11. Intercooler (D1146TI, DE08TIS)

z Tear down the various hoses and air pipes

from the inter cooler.

z Remove the intercooler fixing bolts and

tear it down.

P068

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.12. Alternator

z Remove the alternator fixing bolts and

take off the alternator.

3.1.13. Oil cooler

z Loosen the cooling water pump and the

rubber hose clamps of connected pipes,

and disassemble it.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Remove the oil cooler fixing bolts and

take off the oil cooler.

3.1.14. Oil filter

z Remo ve the oil filter fixing bolts and take

off the oil filter.

3.1.15. Power steering pump

z Remove the oil hose between power

steering oil pump and control unit of the vehicle.

z Unscrew the power steering oil pump fixing

bolts and remove the power steering pump.

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.16. Air compressor

z Remove the oil pipe between cylinder

block and air compressor.

z Unscrew the air compressor fixing bolts

and take off the air compressor.

3.1.17. Idle pulley

z Unscrew the idle pulley fixing

bolts and take off the idle pulley

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

3.1.18. Water pump

z Unclamp the rubber hose connected to

the oil cooler.

z Unscrew the water pump fixing bolts from

the cylinder block and take off the water pump.

3.1.19. Cylinder head cover

z Remove the head cover fixing bolts and

lift the cylinder head cover.

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.20. Fuel injection nozzle

z Unscrew the fuel injection pipe between

the injection pump and nozzle and take

off the pipe.

z Install a special jig on the nozzle holder, and then pull out the nozzle as striking

the hammer of the jig backwardly.

Take care not to damage the nozzle at disassembly.

z Take out the seal ring from the nozzle

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

hole of the cylinder head and discard it.

3.1.21. Turbo charger (D1146TI, DE08TIS)

z Remove the oil supply pipe and oil return

pipe between the turbo charger and the

cylinder block.

z Unclamp the rubber hose connected the

intercooler and air cleaner.

z Unscrew the turbo charger fixing nuts and

take off the turbo charger from the

exahust manifold.

3.1.22. Exhaust manifold

z Unscrew the exhaust manifold fixing nuts

and remove the heat shield from the

exhaust manifold.

z Then disassemble the exhaust manifold

and gasket.

z Scrap the used gasket.

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.23. Intake manifold

z Unscrew the intake manifold fixing bolts

and remove the intake manfold from the

cylinder head.

z Disassemble the intake manifold gasket

and discard it.

3.1.24. Cooling water pipe

z Unscrew the cooling water pipe fixing

bolts and remove the cooling water pipe

from the cylinder head.

z Remove the cooling water pipe gasket

Air heater

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Intake manifold

and finish the surface with a scraper.

CAUTION :

Be sure that piece of the gasket do not come into the cooling water passage.

3.1.25. Rocker arm

z Remove the rocker arm bracket fixing

bolts in reverse order (zigzag method) of

assembling and disassemble the rocker

arm.

z Take out the push rod upwards. z Disassembly of rocker arm assembly

- Remove the snap ring fron the both ends of rocker arm shaft by means of a plier.

G1088

- Remove the washer, rocker arm, bracket and spring from the rocker arm shaf in sequence.

- Press out the rocker arm bush.

Printed in Jan. 2001 PS-MMA0415-E1A

G1056

CAUTION : When reassembling the bush, cool the bush in dry ice and press the bush while aligning the bush with the oil hole of the rocker arm.

3.1.26. Cylinder head

z Remove the cylinder head bolts in the

reverse order of tightening but remove it step by step.

First step : Loosen 1 ～2 threads

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Second step : Remove by loosening fully.

However, remove the total bolts simultaneously by the step of 1 and 2.

z Lay the removed bolts orderly not to

damage the threads at all and store.

CAUTION : Prevent a collision between the bolt thread each other.

z Take out the cylinder head gasket and

scrap it.

z Remove the foreign residues from the

cylinder head surface and block surface.

CAUTION : Try not to make any damage on the

G1089

contact surfaces.

z Disassembly of cylinder head

G1102

- Place the cylinder head on a individual shelf.

- As pressing the valve spring with a special tool, remove the cotter pin, valve spring.

- Take out the intake and exhaust valves.

Compress the spring

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

- For removal of the valve seat, apply arc welding work to two points of valve seat insert, and pull out the valve seat insert with inner extractor.

3.1.27. Oil pan

z Unscrew the oil pan fixing bolts and

remove the oil pan.

z Remove the oil pan gasket and discard it.

3.1.28. Vibration damper

z Unscrew the vibration damper fixing

bolts in reverse sequence of installing sequence and remove the vibration damper assembly.

M1072

3.1.29. Timing gear case cover

z Disassemble the oil seal using an oil seal removing jig.

z Remove the cover fixing bolts and

disassemble the cover from the timing gear case.

G1090

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.30. Oil pump

z Unscrew the bracket fixing bolts of the oil

suction pipe.

z Unscrew the pipe fixing bolts of oil pump

and disassemble the suction and supply oil pipe.

z Unscrew the oil pump fixing bolts, and

disassemble the oil pump.

3.1.31. Piston and connecting rod

z Remove the connecting rod cap bolts in

the reverse order of assembling but do

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

same as the cylinder head bolt removal.

z Disassemble the upper/lower of

connecting rod caps by tapping lightly with urethane hammer, and remove the bearing.

z By pushing the connecting rod with

wooden bar from the direction of oil pan toward cylinder head, disassemble the piston assembly.

z The disassembled piston assembly

should be handled to prevent bumping each other, and stored as the cylinder's order.

z In order for connecting rod cap not to be

swapped, temporarily assemble to the corresponding connecting rod.

(1) Remove the snap rings by means of a plier.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(2) Heat the piston with a electric heater,

then take out the piston pin from the piston as tapping it with a round wooden bar.

(3) Remove the piston ring with a plier.

(4) Clean the piston thoroughly.

3.1.32. Cylinder liner

z Disassemble the cylinder liner with a

special tool or hand but be careful not to generate any damage at cylinder block.

3.1.33. Cam shaft gear and idle gear

z Unscrew the camshaft gear fixing bolts

and remove the camshaft gear.

Printed in Jan. 2001 PS-MMA0415-E1A

z Unscrew two bolts fxing the idle gear,

then remove the idle gear and its pin.

3.1.34. Fuel injection pump

z Disassembly the oil hose for lubrication. z Remove the bolts and nuts of injection

pump flange.

z Unscrew the injection pump fixing bolts

and remove the injection pump by lifting

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

it up.

z Remove the bracket fixing bolts of

injection pump, and disassemble by pulling the injection pump backward.

3.1.35. Water chamber cover

z Unscrew the fixing bolts and remove the

water chamber cover.

z Remove the remnant gasket thoroughly.

3.1.36. Fly wheel

z Remove the flywheel fixing bolts and

disassemble it.

z The bolt removal is done by the reverse

order of assembling and by the steps.

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.37. Fly wheel housing

z Remove the flywheel housing fixing bolts

and disassemble the flywheel housing.

z Disassemble the oil seal of flywheel

housing.

3.1.38. Injection pump drive gear

z Unscrew the drive gear housing fixing

bolts and remove the drive gear assembly.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Oil seal

3.1.39. Timing gear case

z Remove the timing gear case

assembling bolts.

z By tapping lightly with a urethane

hammer the right and left back of timing gear case's connecting part, disassemble the timing gear case.

3.1.40. Bearing cap

z Remove the bearing cap assembling

G1097

bolts by the step in the reverse order of assembling, and disassemble the bearing cap. (Remove by the same way as the cylinder head bolts' removal.)

z Disassembled bearing caps are kept laid

in order.

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.41. Crankshaft

z Assemble the bolts on the both side of

crankshaft temporarily.

z Connect the rope to the bolts and lift the

crankshaft by means of crane being careful not to give any damage on it.

z In order for the disassembled crankshaft

to be prevented from bends or damage, put it on the special lathe and store.

z Disassemble the metal bearings in turn

and store them.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

NOTES : Do not mingle with the metal bearings and bearing caps randomly. To prevent mixing, temporarily assemble the metal bearings to the corresponding bearing caps in turn.

3.1.42. Camshaft and tappet

z In order for camshaft not to be damaged,

disassemble turning it.

z In order for the disassembled camshaft to

be prevented from bends or damage, put it on the special lathe and store.

z Pull out the tappet. z As required, pull out the camshaft bush

from the cylinder block by a press. z Check for damage, scratch, wearing state and if abnormal, tear down.

Printed in Jan. 2001 PS-MMA0415-E1A

3.1.43. Oil spray nozzle (D1146TI, DE08TIS only)

z Remove the valve screws of oil spray

nozzle and disassemble it.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Printed in Jan. 2001 PS-MMA0415-E1A

3.2. Inspection and Measurement on Major Parts

3.2.1. Cylinder block

z Clean the cylinder block thoroughly, and check for any crack or damage. z If there is any crack or severe damage, replace it and if there is minor one, correct

it.

z Check for any clogging or corrosion in the oil passage and water passage.

z Carry out a leakage test for any crack or air leaking. (Hydraulic test) z Plug each cylinder block's water and oil discharge ports, and apply the air

pressure of about 4kg/cm

check if there is any leakage. (Water temperature : 70°C)

3.2.2. Cylinder head

to intake port and soak it in water for about 1 minute to

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(1) Cylinder head assembly & disassembly

1) Disassemble the cylinder assembly, and put it on the shelf for assembly or clean lathe.

CAUTION : Prevent any damage to gasket's contact surface of the cylinder head.

2) Disassemble the cotter pin, spring,

spring seat pushing valve spring by a

special tool.

3) Pull out the intake and exhaust valves.

4) The disassembled parts are kept laid in turn.

5) Disassemble the valve stem seal.

G1102

Compress the spring

6) By means of the special tool, punch,

pull out a valve guide.

Printed in Jan. 2001 PS-MMA0415-E1A

(2) Inspection of cylinder head

1) Check for the cylinder head. z Remove carbon from the cylinder head lower surface, and then should be

careful not to scratch the surface.

z Check any crack or damage that can not found by naked eyes through the

hydraulic or magnetic particle test.

2) Distortion of lower surface

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z As shown in figure, measure the

M1067

cylinder head's distortion at 6 directions

with horizontal ruler and clearance gauge.

z If the measured value is beyond the

limit value, correct it by means of the fine grinding paper or grinding machine.

z If it is beyond the max. allowable value,

replace the cylinder head

Lower face warpage and height

Warpage 0.2 mm or less 0.3 mm

Thickness : t

(reference)

Standard Limit

109.9 ∼ 110.1 mm

108.4 mm

G1093

3) Flatness

Check the flatness of the installing surface of cylinder head's intake and exhaust manifolds with horizontal ruler and clearance gauge.

Standard Limit

0.05 mm 0.2 mm

4) The hydraulic test

The hydraulic test of cylinder head is same as the cylinder block test.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(3) Inspection of valve and valve guide

1) Valve After cleaning valve with fuel, check it.

z Valve stem outer diameter Measure the valve stem outer diameter

at 3 positions (top, middle, and bottom), and check for any wear and if beyond the limit value, replace the valve.

Description

Dimension

Intake valve stem φ8.950 ∼ φ8.970 mm Exhaust valve stem φ8.935 ∼ φ8.955 mm

Standard Limit

φ8.93 mm φ8.91 mm

z Valve seat contacting faces Check the valve seat contact surface

for any crack and wear, and if necessary, correct with grinding paper, and if excessive, replace it.

z Valve head thickness Measure the thickness of valve head

and if beyond the limit value, replace the valve

Description

Dimension

Intake valve Exhaust valve

Standard Limit

2.7 mm 1 mm or less

2.2 mm 1 mm or less

2) Valve guide z Insert a valve into cylinder head and

measure the clearance between valve guide and valve by valve movement. If the clearance is

Measuring Poin

excessive, measure the valve and replace the excessively worn valve

M1076

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

or valve guide.

Valve stem end play

Intake valve

Exhaust valve

Standard Limit

0.04 ∼ 0.07 mm

0.06 ∼ 0.09 mm

0.2 mm

0.25 mm

z Assemble the valve at cylinder head's valve guide and see if it is centered with the valve seat using a special tool.

3) Valve seat

z Contacting face amount As for the valve seat's wear, measure

the width of the contact surface with intake valve seat and exhaust valve seat. If beyond the limit value, replace the valve seat.

z Assemble the valve at the valve seat

of the cylinder head, and check the amount of depression of the valve from the lower portion of the cylinder head using a dial gauge.

Valve depression

Intake & Exhaust

Standard Limit

0 ∼ 0.3 mm

0.55 mm

If the amount of depression is beyond the specified limit, replace the valve seat.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z For the disassembling of valve seat,

by welding the welding bead to a valve seat rotating tool or valve seat, pull it out with a special tool.

M1072

z For the assembling of a new valve seat, by putting it among the dry ices

of an ice box previously for about 2 hours for the cold shrinkage, and press it in the cylinder head by a special tool. (bench press)

z Apply valve lapping compound to the

valve head seating face on the valve seat and lap the valve seat by turning it until it is seated in position, then wipe out the lapping compound.

4) Valve spring z Visual check

Check the appearance of valve spring and if necessary replace the

spring.

z 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.

(mm)

Spring free Length Standard

Intake valve

Exhaust

valve

Inner

Outer

64 mm

D1146/TI : 60

DE08TIS : 73.8

D1146/TI : 71

DE08TIS : 77.7

Printed in Jan. 2001 PS-MMA0415-E1A

M1078

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Valve spring inclination

Use a surface plate and a square to

M1079

measure the valve spring inclination.

If the measured value exceeds the specified limit, the valve spring must be replaced.

(unit : mm) Standard Limit

Valve Spring

Inclination

Less than 1.8 mm 2.7 mm

z Valve spring tension

Use a spring tester to measure the

M1080

valve spring tension if the measured

value is less than the specified limit, the valve spring must be replaced.

Intake

valve

Exhaust

valve

Set Length

Valve Spring

Tension at 41mm

Set Length

Inner 38 mm

Outer 41 mm

Spring

force

70 kg ± 3%

D1 146/TI : 28.6 kg DE08TIS

: 38 kg

D1 146/TI

: 66 kg

DE08TIS

: 75kg

Limit

± 6 % ± 2kg ± 5 % ± 4kg

5) Assembling cylinder head

z Clean the cylinder head thoroughly.

z Replace the valve stem seal with

new one, and by means of a special

tool, press the stem seal into the valve guide of cylinder head.

z Coat engine oil to valve stem and

valve guide and assemble the valve. However, be careful for the damage of valve stem seal.

Printed in Jan. 2001 PS-MMA0415-E1A

z Install the lower seat of valve spring

to the valve guide of cylinder head.

z After putting inner, outer springs,

install the spring upper seat on it. z Assemble the valve by inserting the valve cotter pressing the valve

spring with a special tool.

z After installing the valve, check

whether the valve is correctly

installed or not tapping it lightly with

urethane hammer.

3.2.3. Rocker arm assembly

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(1) Disassembly

1) Disassemble the snap rings that are located at both ends of rocker arm shaft by a plier.

2) Disassemble in the order of washer, rocker arm bracket, rocker arm spring, rocker arm.

G1056

(2) Inspection of rocker arm assembly

1) Rocker arm shaft

z Rocker arm shaft run-out Place the rocker arm shaft on two V

blocks and inspect the shaft for bend using a dial gauge. If the amount of this run-out is small, press the shaft with a bench press to correct the run-out Replace the shaft if the measured value exceeds the limit.

Limit

0.2 mm

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Rocker arm shaft diameter With an outside micrometer, measure

the rocker arm shaft diameter at the point where the rocker arms have been installed. Replace the rocker arm if the amount of wear is beyond the specified limit.

Standard Limit

φ23.978 ∼ φ23.959 mm φ23.75 mm

2) Rocker arm

z Visual check Visually check the face of the

rocker arm in contact with the valve stem end for scores and step wear. If the wear is small, correct it with an oil stone or grinding paper of fine grain size. Rocker arm with a considerable amount of step wear should be replaced.

z Rocker arm bushing diameter Measure the inside diameter of the

rocker arm bushing with an inside micrometer or vernier calipers, and compare the measured values with the rocker arm shaft diameter. If the clearance exceeds the limit, replace

M1087

either bushing or shaft, whichever worn more.

Standard Limit

0.020 ∼ 0.093 mm

0.3 mm or less

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

3) Tappet and push rod

z Clearance Measure the clearance of the

tappet and tappet holes of the cylinder block. If the value is beyond the specified limit, replace tappets.

Standard Limit

0.035 ∼ 0.077 mm

0.15 mm

z Visual check of tappet Visually check the face of the

tappets in contact with the cam for pitting, scores or cracks, and replace if severely damaged. If the amount of cracks or pitting is small, correct with an oil stone or grinding paper.

z Outside diameter of tappet With an outside micrometer,

measure the tappet outside diameter If the measured value is beyond the limit, replace tappets.

Standard

φ19.944 ∼ φ19.965 mm

z Push rod run-out

Limit 0.3 mm or less 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.

feeler gauge

M1084

Printed in Jan. 2001 PS-MMA0415-E1A

)

4) Reassembling rocker arm assembly

Reassembling can be done in the reverse order of disassembling and following things should be heeded

z Check the oil supply hole of rocker arm shaft for any clog and clean

thoroughly.

z Be careful not to occur any swap of position and reverse assembly.

3.2.4. Camshaft (1) Camshaft end play

z Push the thrust plate toward the cam

gear.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z With a feeler gauge, measure

the clearance between the thrust plate and camshaft journal.

z If the end play is excessive, replace

the thrust plate.

Feeler gauge

Standard Limit

0.28 ∼ 0.43 mm

0.6 mm

(2) Cam

z Cam lobe height

Intake 49.15 mm 48.85 mm

Cam lobe height

(C)

Cam journal diameter (A,B

Exhaust

Standard Limit

D1146/TI : 49.32mm

49.00 mm

DE08TIS : 49.35mm

φ57.86 ∼ φ57.88 mm φ57.52 mm

M1095

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 replaced.

z Cam surface

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Inspect the cam face for scratch or damage. Slight step wear or damage on the cam face may be corrected with oil stone or oiled grinding paper. But, replace if severely damaged.

(3) Cam shaft

z Clearance

between camshaft journal and camshaft bush

- With an outside micrometer, measure the camshaft journal diameter.

- Measure the inside diameter of the camshaft bushing on the cylinder block using a cylinder bore indicator, and compare the measured value with the camshaft outside diameter to determine the clearance.

M1090

Standard Limit

0.12 ∼ 0.17 mm

0.24 mm

Replace the bushing if the measured value is beyond the specified limit.

z Run-out Support the camshaft on two V

blocks and check for run-out using a dial indicator. Correct or replace the cam shaft if the amount of run-out is beyond the value indicating need for servicing.

Standard Limit

Printed in Jan. 2001 PS-MMA0415-E1A

3.2.5. Crankshaft (1) Inspection of crankshaft

1) Defect check

z By naked eyes, check for any

scratch or damage on the crankshaft journal and crank pin.

z By means of magnetic particle test

and color check, check the crankshaft for any crack and if found, replace it.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

0.05 mm 0.2 mm

2) Wear measuring

z With an outside micrometer measure

the diameter of the crankshaft journals and pins in the directions as shown, and compare the measured values to determine the amount of wear.

z If the amount of wear is beyond the

limit, have the crankshaft ground and install undersize bearings. However, if the amount of wear is within the limit, you can correct the wear using an oil stone or oiled grinding paper of fine grain size. (Be sure to use grinding paper which has been immersed in oil.)

Journal diameter

Pin diameter

Standard

φ83.966 ∼ φ83.988 mm φ83.000 mm φ70.971 ∼ φ70.990 mm φ70.000 mm

Limit

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z In case that pin's wear is more than

the limit value, grind the crankshaft journal and crank pin, and use the

undersized bearings. Be sure to use grinding paper which has been immersed in oil.

 Standard  0.25 (Inside diameter is 0.25 mm

lesser than the standard size.)

 0.50 (Inside diameter is 0.50 mm

lesser than the standard size.)

"R" part's specified value

① Crank pin's "R" : 4.5 ② Crank Journal "R" : 4

2.0−

 0.75 (Inside diameter is 0.75 mm

lesser than the standard size.)

 1.00 (Inside diameter is 1.00 mm

lesser than the standard size.) Undersize bearings are available in 4 different sizes as indicated above, and the crankshaft can be reused through the regrinding as described above.

CAUTION : In case of regrinding, the grinding the "R" part of bearing end should

be correctly done and keep in mind to remove any jaws or coarse surface absolutely.

3) Crankshaft run-out

z Support the crankshaft on V blocks.

z Turn the crankshaft with a dial

indicator placed on the surface plate

and take the amount of crankshaft run-out.

Standard Limit

0.05 mm 0.1 mm

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(2) Crankshaft bearing and connecting rod

1) Visual check

Visually check the crankshaft bearing and connecting rod bearing for scores,

uneven wear or damage.

2) Oil clearance between crankshaft and bearing (Method 1 : dial gauge)

z Main bearing clearance

Install the main bearing in the cylinder block, tighten the bearing cap to specified torque, then measure the inside diameter.

Torque

30 kg.m

M1116

Compare the two values obtained through measurement of main bearing inside diameter with the outside diameters of crankshaft journals to determine the oil clearance.

Standard Limit

0.052 ∼ 0.122 mm

0.25 mm

z Connecting rod bearing clearance

Install the connecting rod bearing in the connecting rod bearing cap, tighten the connecting rod cap bolts to the specified torque, then measure the inside diameter.

Torque

18 kg.m

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Compare the two values obtained through measurement of connecting rod bearing inside diameter with the outside diameters of crankshaft pins to determine the oil clearance.

Standard Limit

0.034 ∼ 0.098 mm

0.25 mm

z If the clearance deviates from the specified range, have the crankshaft

journals and pins ground and install undersize bearings.

3) Oil clearance between crankshaft and bearing (Method 2 : plastic gauge)

z Assemble the crankshaft on the cylinder block and put plastic gauge on the journal and pin of crankshaft and then after assembling bearing

cap, tighten the bolts at the specific torque. Again after disassembling the bearing cap by removing the bolts, take out the flatted plastic gauge and measure the width of plastic gauge by means of plastic gauge measuring scale. This is the oil clearance.

z The oil clearance too can be

measured in the same manner

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

4) Bearing spread and crush

z Inspection

Check to see that the bearing requires a considerable amount of

finger pressure at reassembly operation.

M1112

Spread

z Crankshaft bearing crush

Install the bearing and cap in the cylinder block, retighten the bolts to

specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and cylinder block using a feeler gauge.

Standard

0.19 ∼ 0.22 mm

z Connecting rod bearing crush

Install the bearing and cap in the connecting rod big end, retighten

the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and connecting rod big end using a feeler gauge.

Standard

0.3 ∼ 0.5 mm

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

5) Crank shaft end play

z Assemble the crankshaft to the

cylinder block. z With a dial gauge, measure crankshaft end play.

Standard Limit

0.15 ∼ 0.325 mm

3.2.6. Piston assembly (1) Disassemby of piston assembly

Disassemble piston according to the disassembly process.

(2) Piston inspection

1) Visual check

Visually check the pistons for cracks, scuff or wear, paying particular attention

to the ring groove.

2) Clearance between the piston and cylinder liner

z With an outside micrometer, measure the piston outside diameter

at a point 13mm away from the lower end of piston skirt in a direction at a

0.5 mm

Position of measuring

outside diameter

right angle to the piston pin hole.

Standard

φ110.883 ∼ φ110.897 mm

G1095

13 mm

z Using a cylinder bore gauge, measure cylinder liner inside

diameter at 3 points (cylinder top ring contacting face, middle, and oil ring contacting face on BDC) in a direction at an angle of 45°. Take the mean value with the largest and smallest values excepted.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Standard Limit

φ111 ∼ φ111.022 mm φ111.122 mm

z The clearance is computed by

subtracting the piston outside diameter from the cylinder liner inside diameter. Replace either piston or cylinder liner, whichever damaged more, if the clearance is beyond the specified limit.

Clearance between piston and liner

Standard

0.103 ∼ 0.139 mm

(3) Piston rings

1) Visual check

Replace the piston rings with new ones if detected worn or broken when the

engine is overhauled.

2) Piston ring gap

z Insert the piston ring into the upper

portion of the cylinder liner bore so that it is held at a right angle to the

cylinder liner wall. z Measure the piston ring gap with a feeler gauge.

Top ring 2nd ring Oil ring

Standard Limit

0.40 ∼ 0.60 mm

0.30 ∼ 0.50 mm

1.5 mm

feeler gauge

z Replace piston rings with new ones if

M1104

the gap is beyond the limit

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

3) Piston ring side clearance

z Fit the compression ring and oil ring in

the piston ring groove.

feeler gauge

z With a feeler gauge, measure side clearance of each ring, and replace

either the ring or piston if the measured value is beyond the specified limit.

Top ring 2nd ring Oil ring

Standard Limit

- -

0.07 ∼ 0.102 mm

0.05 ∼ 0.085 mm

0.15 mm

G1071

4) Piston ring tension

With a tension tester, measure piston ring tension. Replace the piston ring if

the measured value is beyond the limit.

Top ring 2nd ring Oil ring

Standard

2.58 ∼ 3.88 kg

1.81 ∼ 2.71 kg

3.57 ∼ 5.03 kg

(4) Piston pin inspection

1) Wear

Measure the amount of wear on the

M1105

piston pin at the points as shown. The

measured values are beyond the limit (0.08 mm or greater), replace the pin.

Standard Limit

φ41.994 ∼ φ 42.000 mm φ 41.94 mm

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

2) Clearance Measure the clearance between the piston pin and connecting rod bushing,

and replace either of them, whichever damaged more, if the measured value is beyond the limit.

M1106

Standard Limit

0.003 ∼ 0.015 mm

0.08 mm

3) Condition check Check the engaged condition of the piston and piston pin. If it is possible to

force the pin into the piston heated with piston heater, the piston is normal. When replacing the piston, be sure to replace the piston pin together.

(5) Connecting rod inspection

1) Distorsion

Check the connecting rod for distortion. As shown in the figure below, install the

connecting rod to the connecting rod tester, and check for distortion using a feeler gauge. If the connecting rod is found distorted, never re-use it but replace with a new one.

2) Holes alignment (parallelism)

Measure the alignment of the connecting rod piston pin bushing holes

with connecting rod big end holes. At this time also, use both connecting rod tester and feeler gauge.

feeler gauge

Standard Limit

0.05 mm 0.1 mm or less

M1107

Printed in Jan. 2001 PS-MMA0415-E1A

g.m

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

3) Wear

z Assemble the connecting rod to the crankshaft and measure connecting

rod big end side clearance using a feeler gauge.

z Assemble the connecting rod to the

piston and measure connecting rod small end side clearance.

z If the measured values are beyond

the limit, replace the connecting rod.

Limit

0.5 mm

3.2.7. Fuel injection nozzle projection (DE08TIS)

z Insert a seal ring on the cylinder head

and assemble the injection nozzle

z Measure the clearance between the

cylinder head bottom and nozzle tip. If the measured values are beyond the limit, replace the seal ring.

Standard

(Thickness of seal ring)

(Projection of nozzle)

3.5±0.1 mm

2.43~2.80 mm

Torque

Fuel injection nozzle

Cylinder hea

Printed in Jan. 2001 PS-MMA0415-E1A

3.3. Reassembly

3.3.1. General precautions

z Clean all the disassembled parts, particularly oil and water ports, using

compressed air, then check that they are free from restrictions.

z Arrange the general and special tools in order for engine assembly operation. z To wet each sliding part, prepare the clean engine oil. z Prepare service materials such as sealant, gaskets, etc. z Discard used gaskets, seal rings, and consumable parts, and replace with new

ones.

z Apply only the specified torque for bolts in the specified tightening order and

avoid over-tightening.

z Be sure to check that all the engine parts operate smoothly after being

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

reassembled.

z Check the bolts for looseness after reassembly. z After completing the engine reassembly operation, check if there is missing parts

or shortage of parts.

z Keep your hands clean during the working.

3.3.2. Cylinder block

Cover the floor of the workshop with wood plate or thick paper to prevent damage to the cylinder head and place the cylinder block with the head fitting surface facing downward.

3.3.3. Oil spray nozzle (D1146TI, DE08TIS)

Tighten and assemble the oil spray nozzle flange with fixing bolts using the spray

nozzle jig.

Torque

7 kg.m

Printed in Jan. 2001 PS-MMA0415-E1A

3.3.4. Tappet and cam shaft

z Undercool a new bush with dry ice

for

about 2 hours and press it into position in the

cylinder block using a bench press. After the pressing operation, measure the inside diameter of the cam bush to check if it is not deformed.

z Apply engine oil to the entire face

of the

tappets and slide them into the tappet holes on

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

the cylinder block.

z Wet the cam bush inside diameter

and

camshaft with oil, and carefully assemble them

while turning the camshaft.

CAUTION : Be careful not to generate a damage to camshaft and bush.

z Check to see that the camshaft rotates

smoothly.

Printed in Jan. 2001 PS-MMA0415-E1A

3.3.5. Crankshaft

z Install the main bearing (refer to assemble sequence : right figure) machined with two holes in the cylinder block so that the key is aligned with the

key groove, then apply oil to the bearing surface.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Heat the crankshaft gear for at least 10

minutes to 120°C, then apply sealant (Loctite # 641) to the inside wall of the heated crankshaft gear evenly before inserting it to the end of crankshaft.

G1051

z Semi-tighten a bolt at both sides of the crankshaft, apply engine oil to journals

and pins, then assemble the crankshaft with the cylinder block by tightening the fixing bolts.

CAUTION : Coat engine oil to the pin and journal of

crankshaft.

z Install the oiled thrust washers

with the

oil groove facing outward.

Printed in Jan. 2001 PS-MMA0415-E1A

z Install the bearing and thrust

washers to

the bearing cap and apply oil to the bearing

and thrust washers.

z Install the bearing cap by matching the

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

cylinder block No. with the bearing cap

No.

z Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque.

Torque 30 kg.m

z After semi-tightening both bolts

evenly,

tighten them diagonally to the specified torque

using a torque wrench as follows.

<Tightening Order> (1) First stage : Coat the cap bolts with engine oil (2) Second stage : Temporary bolt screwing about 1 ～2 threads (3) Third stage : With impact wrench, tighten up to about 15 kg.m (4) Fourth stage : With torque wrench, tighten up to about 25 kg.m (5) Fifth stage : By means of torque wrench, tighten finally in the specified

Printed in Jan. 2001 PS-MMA0415-E1A

torque. (30 kg.m).

z Tighten the bearing cap in the

sequence of 4–3–5–2–6–1-7. z Check to see that the assembled crankshaft turns smoothly with hand.

3.3.6. Flywheel housing

z Temporarily install the guide bar on the

cylinder block.

z Apply gasket to the cylinder block.

z Using the dowel pin and guide bar, install

the flywheel housing and tighten the

fixing bolts in a diagonal sequence to specified torque. (Zigzag method)

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Oil seal

Torque 8 kg.m

CAUTION : When the bolts are tightened, remove the guide bar.

z The flywheel housing is assembled after

the new oil seal was pressed (Coat

engine oil over the outside of oil seal)

before in the housing by a press.

z If any peripheral scar was generated

due to oil seal at the oil seal contact

surface of crankshaft, after inserting

about 1 mm shim or thereabout in front

of oil seal (Direction toward crankshaft.),

measure and adjust.

3.3.7. Oil seal (Rear side)

z Apply lubricating oil to the outside of the oil seal and flywheel housing inside diameter and fit them over the crank

Printed in Jan. 2001 PS-MMA0415-E1A

Oil Seal Fitting Jig

G1052

shaft, then assemble the oil seal using an oil seal fitting jig.

3.3.8. Flywheel

z Installation of flywheel ring gear

With a gas burner, heat the ring gear evenly until heat expansion takes place, then install it using a hammer.

CAUTION : Do not allow the temperature of the ring

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

gear to exceed 200 °C (390 °F).

M1122

z By means of mandrel, assemble pilot

bearing to the flywheel.

z By means of mandrel, press in the wear

ring at the backward face.

wear ring

ring gear

G1031

z Install a guide bar into a bolt hole on

the crank shaft, and lift the flywheel to align the dowel pin with the pin hole on the flywheel for temporary assembly operation.

z Coat the adhesive (#271 Loctite) over the

assembling bolts and install bolts in the

remaining holes. After that take out the

guide bar, then install a bolt in the hole

where the guide bar had been inserted.

z According to the order of tightening tighten the fixing bolts using a torque wrench in a diagonal sequence to

Printed in Jan. 2001 PS-MMA0415-E1A

specified torque.

Torque 18 kg.m

3.3.9. Magnetic pick-up sensor

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Move the lock nut to hexagonal side of

sensor completely.

z Rotate (Clockwise) the pick-up sensor on

fly wheel housing, until the end of it reach on fly wheel ring gear.

z Then rotate (Counter clockwise) the

pick-up sensor for 270° (gap 1.0 mm)

and fix lock nut.

z Tolerance limit is 27°. (gap ± 0.1 mm)

3.3.10. Water chamber cover

z Coat the adhesive over the water

chamber cover (Particular around bolt

Lock nut

Flywheel

housin

Tolerance

limit

holes) and after attaching the gasket, assemble it to the cylinder block using the bolts for assembling.

z As for tightening of bolts, after primarily

tightening the bolts located at the both ends of cover (4ea at both sides) and middle bolts (Upper, lower 2ea) , tighten the rest.

3.3.11. Cylinder liner

z Stand the cylinder block so that the

flywheel faces downward.

z Thoroughly clean the liner flange

fitting

surface and bore inside with

Printed in Jan. 2001 PS-MMA0415-E1A

compressed air to prevent the entry of foreign substances.

z After the cleaning operation, make the

cylinder liner dried up and push it into the cylinder block by hand.

z Wet the liner inside diameter with

engine oil.

3.3.12. Piston and connecting rod

z Use a piston heater to heat the piston approximately 100 °C (212 °F) for 5

minutes.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Align the piston pin hole with the oiled

connecting rod small end and press the piston pin (by lightly tapping with a rubber hammer) to assemble the connecting rod with the piston.

z Nothing the direction of the

piston,

make the longer side(machined with

key groove on the bearing) of the connecting rod big end.

M1127

Valve seating

z On the piston head surface, the longer

side connecting rod big end is in opposite

direction from the valve seating surface as well as in the same direction with the narrow margin of the combustion chamber.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Install the snap rings and check to see that it is securely assembled.

z Install the piston ring in the piston using piston ring pliers.

Piston

Top ring

Second rin

Oil rin

z Identify the mark "Y" or "TOP" on the ring end to prevent the top and bottom

of the piston ring from being interchanged and make the marked portion face upward. (The surface marked as “Y” is upper surface.)

z Adjust the angle among individual piston ring gaps to 90° and fit a piston

G1055

2nd ring gap

45°

Top ring gap

assembling jig onto the piston, Use care not to match the ring gaps with the pin

direction. z Install the bearing by aligning it with the connecting rod key groove and apply oil

Piston pin

Piston

90°

Oil ring gap

to the bearing and piston.

z Position the valve seating surface

toward the tappet hole and insert the piston with hand.

Tappet hole

Valve seating

CAUTION :

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Use care not to damage the cylinder liner and piston, and slightly lift and insert the piston into the cylinder so that the ring may not be damaged by the fillet of the liner.

z Install the bearing in the connecting rod cap and apply oil.

CAUTION : Make sure that the manufacture serial

numbers impressed on the

connecting rod cap and connecting

rod big end are identical, and install

the connecting rod cap by aligning it

with dowel pin.

z Wet the fixing bolts with engine oil, semi-tighten them with hand, tighten

them to the specified torque using a

torque wrench as follows.

(1) First stage : Coat engine oil over bolts.

(2) Second stage : Temporary bolt screwing about 1～2 threads

(3) Third stage : With torque wrench, tighten up to about 10 kg.m

(4) Fourth stage : With torque wrench, tighten up to about 15 kg.m

Serial no.

(5) Fifth stage

: By means of torque wrench, tighten finally in the specified

torque. (18 kg.m).

Torque 18 kg.m

z When the connecting rod bearing cap bolts are tightened, check the

connecting rod end play to the right and left with hand. If no end play is found,,

Printed in Jan. 2001 PS-MMA0415-E1A

remove and reinstall or replace the connecting rod bearing cap.

3.3.13. Timing gear case

z Mount a new gasket using dowel pin on the cylinder block.

z Put the time gear case to the cylinder

block by aligning the dowel pin hole of timing gear case with its pin, and then assemble it by tapping lightly with an urethane hammer to the right and left

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(Particularly around dowel pin).

z Tighten the bolts for assembling to the

specified torque. However, in case of tightening the bolts, tighten primarily the bolts of both end parts and then do the rest.

3.3.14. Timing gear and idle gear pin z Install the oil pump idle gear onto the

No.7 bearing cap. z Install a thrust washer over the camshaft and assemble the cam gear by aligning

it with camshaft dowel pin. Tighten the cam gear assembling bolts to the specified torque. (Zigzag method)

Idle gear pin

Torque 2.2 kg.m

z With the oil port on the idle gear pin

Idle gear pin

facing the cylinder block, install the idle

gear pin.

Printed in Jan. 2001 PS-MMA0415-E1A

Oil hole

G1053a

z Idler gear pin with oil hole is assembled toward cylinder block.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Install the idle gear by coinciding the

Mark “2”

marks impressed on the crank gear, cam

gear, fuel injection pump drive gear, and

idle gear. z Install a thrust washer on the idle gear and tighten to specified torque.

G1054

Mark “o”

Mark “1”

Torque 3.1 kg.m

z Check and adjust the amount of backlash between gears using a feeler gauge.

Measuring position

(between)

cam gear & idle gear

crank gear & idle gear

injection pump & idle gear

Backlash Limit

0.16 ∼ 0.28 mm

0.35 mm

3.3.15. Injection pump flange z After assembling the fuel injection pump

gear to the idle gear, tighten the assembling bolts of the injection pump flange.

z Mount gasket by aligning the bolt holes

with the pin holes on the bearing housing.

z Turning the flywheel, adjust the pointer

to the position of the engraved scale.

z After adjusting the injection timing of fuel

injection pump drive gear, tighten the

G1097

Printed in Jan. 2001 PS-MMA0415-E1A

fixing bolts in the direction of fuel injection pump.

3.3.16. Fuel injection pump z Install the injection pump bracket in the

cylinder block. z After measuring the amount of run-out with an alignment setting jig, disassemble the bracket, adjust the shims, then reassemble it.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Run-out

0.2 mm or less

z Mount the top/bottom adjusting shims in the bracket and then mount the fuel

injection pump.

z Tighten the fixing bolts in a diagonal sequence to specified torque.

Torque

4.4 kg.m

z Bring the piston of #1 cylinder to the

compression TDC (OT) by turning the

crankshaft. Again, turn 60° in the

reverse direction of engine rotation.

z Disassemble the fuel injection pipe that

connect the fuel injection pump and #1

injection nozzle.

z Disassemble the fuel injection pump

delivery valve holder, and after

removing the valve and valve spring,

again assemble the valve holder and

then, on it assemble the pipe of "U"

shape on it.

Timing check hole

Injection timing

notch mark

(Fly wheel)

Printed in Jan. 2001 PS-MMA0415-E1A

Flywheel ring gear

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Operating the priming pump of supply

pump, turn the crankshaft slowly in the

direction of engine rotation until the fuel

will drop at the rate of a drop for 6 ～ 8

sec.

z Confirm then whether the indication

point at the flywheel housing inspection

hole and the engraved specified

injection angle are coincided or not,

and if the injection timing is not correct,

adjust as follows.

(1) As above adjusting method,

Please coincide the indication point(↓) at the flywheel housing's inspection hole with the flywheel's inspection angle.

Model Timing angle D1146 D1146TI DE08TIS

BTDC 15°

BTDC 9° BTDC 3°

(2) Loosen the drive gear fixing bolt

of injection pump a bit.

(3) After turning slowly the coupling of

injection pump until the fuel will drop from #1 plunger at the rate of a drop for 6～8 sec., tighten the driving gear fixing bolt of fuel pump.

z After the adjustment of injection timing,

disassemble the "U" shape pipe, the delivery valve and the valve spring.

Printed in Jan. 2001 PS-MMA0415-E1A

Notch

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Turn the coupling until the notch mark of the indicator plate attached to the fuel

injection pump is aligned with the notch mark of the coupling.

z Tighten the coupling fixing bolts and nuts to specified torque.

Torque

6.0 ∼ 6.5 kg.m

z Install the oil delivery pipe and return

pipe.

3.3.17. Oil pump and oil pipe

z Install a dowel pin in the No.7 bearing cap, then assemble the oil pump by

tapping lightly with urethane hammer.

z Tighten the assembling bolts with

specified torque.

Torque

z Assemble the oil suction pipe with the

delivery pipe to oil pump by the bolts.

3.3.18. Timing gear case cover

z Install dowel pin on the timing gear

4.4 kg.m

case.

z Mount a gasket by aligning the fixing

bolt holes with those on the gasket.

z Align the dowel pin with the cover pin

hole, then install the cover with light tap.

z Tighten the fixing bolts beginning with

Printed in Jan. 2001 PS-MMA0415-E1A

the oil pan fitting face.

CAUTION : In the assembling, be careful not to be damaged by the crankshaft.

3.3.19. Front oil seal

z Apply lubricating oil to the outside of the oil seal and the oil seal hole of the

timing gear case cover.

z Put the new oil seal on the oil seal

hole of timing gear case cover aligning

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

the center of them, then assemble the oil seal using an oil seal fitting jig.

3.3.20. Water pump

z Mount a new gasket. z Install the water pump on the cylinder

block and tighten the assembling bolts

with specified torque.

Torque

z Connect water pipes and by-pass pipe

to the water pump.

z Connect a water pipe to the expansion

tank.

3.3.21. Vibration damper

Oil seal fitting jig

2.2 kg.m

z Insert the vibration damper to the crankshaft, and assemble by

tightening the assembling bolts at the specified tightening torque according to bolt tightening order. (refer to right figure.)

M1047

Torque

13 kg.m

Printed in Jan. 2001 PS-MMA0415-E1A

3.3.22. Oil pan

z Remove the gaskets thoroughly that

project at the timing gear case, case cover of cylinder block, and the contacting part of flywheel housing by means of a scraper.

CAUTION :

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

Be careful for the gasket pieces not fall

into the engine during the work.

z Coat the silicone at the gasket part that

was removed (Contacting part), and attach the new oil pan gasket.

z Assemble the oil pan by

tightening the oil pan assembling bolts, and when tightening bolts, primarily tighten the bolts (4ea) at the both ends, and then tighten the rest bolts to specified torque.

Torque

2.2 kg.m

CAUTION : Align the bolt holes with gasket holes to prevent damage to the gasket and tighten.

3.3.23. Oil filter

z Install the oil filter onto the cylinder block,

and tighten the fixing bolts.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Apply engine oil to the oil filter cartridge o-ring and assemble the cartridge using a

filter wrench.

3.3.24. Oil cooler

z Install the gasket on the cylinder block. z Assemble the oil cooler by tightening the

assembling bolts.

z Connect the cooling water pipe with the

cooling water pump and tighten a hose clamp.

Torque

2.2 kg.m

3.3.25. Starter

z Assemble the starter in position on the

flywheel housing.

Torque

3.3.26. Intake and exhaust valves

z Identify the marks of "IN" and "EX" impressed on the valve head before

assembling the valve with the valve head.

8.0 kg.m

z With a valve stem seal fitting jig, assemble the valve stem seal on the

Printed in Jan. 2001 PS-MMA0415-E1A

G1101

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

valve guide.

z After installing valve springs and spring retainer, press the retainer with a jig, then

install the cotter pin.

z Tap the valve stem lightly with a rubber hammer to check that the valve is

assembled correctly.

3.3.27. Cylinder head

z Blow the bolt holes of cylinder block with

a compressed air and remove the foreign matter.

z Clean the head gasket contact

surface

thoroughly.

CAUTION :

G1102

Compress the spring

However, be careful for the foreign material not to enter into the

combustion chamber.

z Assemble the new head gasket by aligning the holes with dowel pins of

cylinder block with “TOP” mark facing upward.

TOP

G1103

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Check the inside of combustion chamber for foreign substances, and

carefully mount the cylinder head assembly in the block by aligning the dowel pin with the dowel pin hole.

CAUTION :

Be careful not to damage the cylinder head gasket. If the dowel pin is not in alignment, lift the cylinder head again and then remount it.

CAUTION :

After tightening the cylinder head bolts,

even at disassembling, the cylinder

head gasket should be changed a new

one.

z Coat the cylinder head bolts with

engine oil, and tighten in proper

sequence to the specified torque

G1089

Front side

Rear side

according to bolt tightening order. (refer to the figure).

Type 1 Type 2

Specification

Torque

12.9T

M14×1.5×146

24.5 kg.m

6 kg.m +180°+150°

10.9T

M14×1.5×146

(Angle torque)

z However, before tightening bolts, the

side parallel degree between cylinder heads should be adjusted.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

(1) First stage : Coat the bolts with engine oil. (2) Second stage : Tighten 1 ～2 threads with hands. (3) Third stage : Tighten at about 6 kg.m with a wrench. (4) Fourth stage : Tighten at rotating angle method 180° with a wrench. (5) Fifth stage

: Finally, tighten at rotating angle method 150° with a torque

However, all bolts are tightened

simultaneously by above steps. z Coat the push rod with engine oil and insert it into the push rod hole.

3.3.28. Rocker arm assembly

z Apply lubricating oil to the rocker arm bush and shaft, and assemble the intermediate bracket with the rocker arm (rocker arm assembly) on the

cylinder block using fixing bolts. In

tightening the bolts, it must be done at

the specified value using zigzag

method.

wrench .

G1088

M10x1.5 4.4 kg.m

Torque

M12x1.5 8.0 kg.m

z Semi-install valve clearance adjusting

bolts onto the rocker arm.

z Install the spring, rocker arm, bracket,

rocker arm, spring, washer, and snap ring in the described sequence.

z Install the rocker arm and bracket in the same direction.

G1056

z Adjust the valve clearance as

following guide.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

 By turning the crankshaft, when the

intake and exhaust of #6 cylinder (the fifth cylinder from the flywheel) overlap, that is, when #1 cylinder’s piston come at the compression top dead center (OT), adjust the valve clearances by . mark indicated.

 After having turned the crankshaft by

360° and Intake & exhaust valves of #1 cylinder overlap, that is, when #6 cylinder is in the state of compression TDC (OT), the clearance indicated by mark is adjusted.

Flywheel

Intake Valve Exhaust Valve Cylinder No.

Cooling Fan

G1048

 To adjust the clearance, 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

(to measure the clearance of the valve and rocker arm contacting part) and adjust the clearance with adjusting screw respectively and then tighten with the lock nut.

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

 As for the valve clearance, adjust it

when in cold.

Model

D1146 D1146TI DE08TIS

Intake Valve Exhaust Valve

0.3 mm 0.3 mm

CAUTION : (1) Crankshaft revolution is done by hands without using a starting motor.

(2) Turn it to the direction of engine

rotation, but do not use the installing bolts at the turn.

(3) The cylinder no. and the order of intake

and exhaust can be determined from the crank shaft pulley.

z Adjust valve clearance with a feeler gauge and tighten the fixing nuts to specified torque.

Torque

3.3.29. Intake manifold

z Put in the new gasket between the

cylinder head and manifold, and

5.0 kg.m

Air heater

Valve clearance adjust

M1013

Intake manifold

assemble the intake manifold by tightening the assembling bolts.

3.3.30. Exhaust manifold

Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Install the exhaust manifold gasket over

the stud bolts by aligning the gasket with the exhaust port on the cylinder head so that the face and back of the gasket can be positioned correctly.

z Semi-assemble the exhaust manifold

and install the heat resisting plate.

z Assemble them by tightening the

assembling bolts. The tightening order of bolts is from the middle to left and right alternately.

CAUTION : For upper and lower bolts differ in the length, so use the correct bolts.

3.3.31. Turbocharger (D1146TI, DE08TIS)

z Fit a new gasket over the stud bolts of

the exhaust manifold before tightening those turbocharger fixing nuts.

z Install the oil supply pipe and return

pipe.

z Tighten the clamps of rubber hose that

is connected air pipe to the intercooler.

3.3.32. Cooling water pipe

z Attach a new gasket on the cylinder

head.

z Install the cooling water pipe and

tightening the fixing bolt on it.

Printed in Jan. 2001 PS-MMA0415-E1A

3.3.33 Idle pulley

z Assemble the air compressor

mounting bracket on the timing gear case.

z Install the idle pulley on the air

compressor mounting bracket and tightening the fixing bolt.

3.3.34 Air compressor & power steering pump

z Couple the power steering oil pump

to the air compressor with the driving dog engaged.

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Insert the O-ring coated with grease into

the oil outlet of the air compressor.

z Place the air compressor on the

mounting bracket carefully and tighten the fixing bolts to the specified torque.

(Carefully damage the O-ring)

z Assemble the oil feed pipe.

3.3.35. Alternator

z Install the alternator mounting bracket

and supporter to the cylinder block, then tighten the fixing bolts.

z Install the alternator with fixing bolts to

the mounting bracket.

3.3.36. Fuel filter

z Assemble the fuel filter with the intake

manifold.

z Assemble the fuel feed hose

according

Printed in Jan. 2001 PS-MMA0415-E1A

to the direction of an arrow impressed on the fuel filter head so that fuel can be fed in the sequence of

FUEL FEED PUMP → FUEL FILTER → FUEL INJECTION PUMP.

3.3.37. Injection nozzle

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

z Install a new seal ring in the nozzle hole of the cylinder head.

z As aligning the ball of nozzle with a

groove in the nozzle hole, Insert the

nozzle into the cylinder head and tighten the nozzle.

Torque

7.0 kg.m

3.3.38. Fuel injection pipe

z Semi-assemble a nut at both ends of the fuel injection pipe and tighten them up

one by one to specified torque.

G1104

Torque

3.0 kg.m

z Assemble the fuel return pipe on the

nozzle holder.

z Connect the injection pump lubricating

oil pipe with a hollow screw.

CAUTION : Be sure not to damage the connection part due to over-tightening the hollow

Printed in Jan. 2001 PS-MMA0415-E1A

screw.

3.3.39. Cylinder head cover

z Attach a new gasket on the cylinder head cover.

z Assemble the cylinder head cover to the

cylinder head by tightening the cap bolts for fixing the cylinder head cover.

Torque 1.2 kg.m

z Assemble the breather and breather

hose.

z Fit the oil filler cap on the cylinder head

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

cover.

3.3.40. Cooling fan

z Install the flange to the water pump

pulley, then assemble the cooling fan to the pulley by tightening the fixing bolts.

Torque

3.3.41. Belt

z Install the V-belt on the crank pulley,

alternator pulley and water pump pulley.

z Adjust the V-belt tension using the

4.4 kg.m

G1086

10-15mm

Press here

tension adjusting support.

3.3.42. Oil level gauge

z Apply sealant (Locktite #262) to the

Water pump

pulley

G1105

Alternator pulley

Crank pulley

Printed in Jan. 2001 PS-MMA0415-E1A

V-belt

bottom side of the guide tube.

z Then assemble the guide tube and oil

level gauge on the oil pan.

3.3.43. Others

z Assemble by connecting the other oil and

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

fuel hoses.

Printed in Jan. 2001 PS-MMA0415-E1A

Daewoo D1146, D1146, D1146TI, DE08TIS, D1146TI Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual