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

65.99897-8056 Feb. 2001

MAINTENANCE MANUAL

Diesel Engine

D1146

D1146TI

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;

zTake old oil to an old oil disposal point only.

zEnsure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.

zTreat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.

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MAINTENANCE MANUAL

zThe 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

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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
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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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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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	M1041A
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
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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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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1.3. Engine Specifications

1.3.1. Specification

	Engine Model		D1146		D1146TI			DE08TIS
Items
Engine type			4 cycle in-line,			4 cycle		in-line,
			Water-cooled type			Water-cooled type
			Naturally aspirated		Turbo charged & intercooled
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)			6 – 111 × 139
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)			15°		9°			3°
Injection pump type			Zexel in-line “AD” type					Zexel in-line “P” type
Governor type			Mechanical governor					Mechanical
								governor
			type(RLD)
								type(RLD-J)
Injection nozzle type			Multi-hole type (5 hole)					Multi-hole type
								(7 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	Open at				16° (B.T.D.C)
	Close at				36° (A.B.D.C)
Exhaust valve	Open at				46° (B.B.D.C)
	Close at				14° (A.T.D.C)
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					Wax pallet type
			(79 94 °C or 83 95 °C )
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
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1.3.2. Engine power

Production tolerance : ±5%

	Engine model				Performance
			Injection	Power	Torque	Low idle	High idle
	Model	Suffix	timing					Remark
				(PS/rpm)	(kg.m/rpm)	(rpm)	(rpm)
			(BTDC°)
		EACBA
		EACBB
	D1146	EACBE	15	182/2,500	57.5/1,600	600-650	2750
		EACBH
		EACBI
		EACBK
							2370
		EAPBA	9	205/2,200	75/1,400	600-650	-
							2,470
	D1146TI							EURO-I
							2250
		EAPCA	9	215/2,300	82/1,400	600-650	-
							2,350
		ECPBA	3	225/2,300	82/1,200	600-650	2,530
		ECPCA
	DE08TIS							EURO-II
		ECPBB	3	240/2,300	90/1,200	600-650	2,530
		ECPCB

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

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1.3.3. Performance curve (DE08TIS – 225PS)

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)

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)

	4	5
				6
3				7
				8
2				9
1				10
				11
				12
				13
				14
19				15
				16
				17
20				18
21
22	23	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)

5

4

3

2

1

10

11

12

13

14

15

6

7

8

9

16

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)

2

3

4

5

6

7

14

15

16

8 1

9

10

11

12

13

17

18

23

19

20

21

22

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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(2) DE08TIS (Truck)

3

4

5

6

7

8

14

15

16

2

1

9	10	11		12	13
18			19	20	21	28	29	30
17								31

	22	23	24	25		26	27
1	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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(3) DE08TIS (Bus)

1

2

3

4

5

6

7

8

18

19

20

9 17

10

11 12 13 14 15 16

21	27

22

23

24

25

26

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)	16	Vibration damper	26	Starter
6	Fuel filter	17	Idle gear pulley	27	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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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

zRegarding the cooling water that is to be used for engine, the soft water not the hard water must be used.

zThe engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust prevention (DCA4) 3 5 %.

zThe 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.

zSince D1146, D1146TI and DE08TIS (diesel engine of D1146 series) cylinder liner is dry type, particularly the cooling water control should be applied thoroughly.

zThe 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)

zHow 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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(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.

zAmount of Anti-freeze in winter

	Ambient	Cooling water (%)	Anti-freeze (%)
	Temperature (°C)
	Over -10	85	15
	-10	80	20
	-15	73	27
	-20	67	33
	-25	60	40
	-30	56	44
	-40	50	50

2.1.2. Fan belt

zUse a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated.

zCheck 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)

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2.1.3. Engine oil

zCheck 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 510 minutes for oil drain into the crankcase before checking oil level. The oil level must be between Max and Min. lines on the gauge.

zEngine 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	After 1,000km (50hr)
		operation
Short-distance operation vehicle	D1146/TI		every 10,000km
(city bus, dump truck)	DE08TIS		every 20,000km
Long-distance operation vehicles	D1146/TI		every 15,000km
(express bus, cargo truck)	DE08TIS		every 30,000km

z The following oils are also recommended

	Engine	Recommend oil		Remark
	model	SAE No.	API No.
	D1146	SAE 15W40	above CD or CE
	D1146TI
	DE08TIS	SAE15W40	ACEA-E2 or ACEA-E3
		SAE10W40	(API CH-4)

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

2.1.4.Oil filter

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

zChange the oil filter cartridge simultaneously at every replacement of engine oil.

Oil filter head

Oil filter (Cartridge)

G1081

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2.1.5. Fuel filter

zDrain water in cartridge with loosening the

cock under filter manually (6) from time to time.

G1019

2.1.6. Air cleaner.

zIn case that elements are deformed, damaged or if the air cleaner has a crack, replace it.

zBy the definite interval, the elements must be cleaned and replaced.

2.1.7. Intercooler

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/air intercooler with radiator (combined radiator)

Air flow by cooling fan

Hot air by turbo charger compressor

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

2.1.8. Valve clearance adjust procedure

	zAfter	letting the #1 cylinder's piston
	come at
the compression top dead center by turning
	the crankshaft, adjust the valve clearances.
	zLoosen 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	Intake Valve		Exhaust Valve
	D1146
	D1146TI	0.3 mm		0.3 mm
	DE08TIS
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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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

G1048

2.1.9. Cylinder compression pressure

zStop the engine after warming up, and

take out nozzle holder assembly.

G1067

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

	Standard value	28kg/cm2 over
	Limit value	24kg/cm2
	Difference	Within ± 10 %
	between each cylinder
♦ Condition : Water temperature 20°C,
				G1068
	Engine rotation 200rpm (10 rotations)

2.1.10. Injection nozzle

z Install a nozzle on the nozzle tester.

zIf the inspected injection pressure is less than the specified value, adjust using the adjusting shims.

Engine Model	D1146		D1146TI		DE08TIS
Opening pressure	210 kg/cm	2	214 kg/cm	2	1st : 160 kg/cm2
					2nd : 220 kg/cm2

zCheck the atomizing state and replace it if abnormal.

2.1.11.Fuel injection pump

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

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zCheck 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

zInspect for any leakage of electrolytic solution owing to battery crack, and replace

the battery in case of poor condition.

zInspect for amount of electrolytic solution, and replenish if insufficient.

zMeasure the gravity of electrolytic solution, if less than specified value (1.12 1.28), replenish.

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

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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.

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

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Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

2.2. Diagnosis and Remedy

zThe following description summarizes the probable cause of and remedy for generall failure by item.

zImmediate countermeasures should be taken before a failure is inflamed if any symptom is detected.

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Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS MAINTENANCE MANUAL

Check fresh Radiator tank cap

Operating state

1.Overload

2.Radiator core clogged

3.Continuous over-run

Inspect

Radiator

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Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

MAINTENANCE MANUAL

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Printed in Jan. 2001 PS-MMA0415-E1A

D1146/D1146TI/DE08TIS

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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Printed in Jan. 2001 PS-MMA0415-E1A