Daewoo D1146-T-TI Engine Shop Manual Daewoo D1146-T-TI Engine Shop Manual

FOREWORD

This is the Diesel Engine Maintenance manual of D1146, D1146T, D1146TI Diesel Engines produced by Daewoo Heavy Industries Co.

D1146, D1146T, D1146TI Diesel Engines (In-line, 6 cylinders, 4 stroke, direct injection type) have been so designed and manufactured to be used for the overland transport or industrial purpose. They meet all the requirements such as quiet operation, fuel economy, excellent durability at high speed running condition and so on, and accordingly are more economical and outstanding engines with high efficiency than any others. For the contents for maintenance explained in detail by means of illustrations and graphs, we wish all the relevant person will consult with this manual in needs, securing it sufficiently.

All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice, and if you have any questions on its contents or maintenance, please feel free to contact with our service line.

CONTENTS

1. General Information

...............................................................................................................

1.1. Engine Characteristics 1.3. Engine Performance Curve

1.2. Main Data and Specifications 1.4. Exterior View of Engine

2. Major Maintenance

................................................................................................................ 9

2.1. Preventive Maintenance 2.2. Diagnostics and Troubleshooting for the Engine

3. Disassembly and Reassembly of Major Components

...................................................... 23

3.1. Disassembly 3.3. Reassembly

3.2. Measurement and Inspection 3.4. Breaking-In

4. Maintenance of Major Components

.................................................................................... 72

4.1. Cooling System 4.3. Fuel System

4.2. Lubricating System 4.4. Preheating System

4.5. Turbo Charger

5. Maintenance Specifications

................................................................................................ 96

5.1. Torque Values 5.2. Maintenance Specification Table

WORLDWIDE NETWORK

1. General Information

1.1. Engine Characteristics

Toroidal combustion system developed by Daewoo Heavy Industries Co.

The main design features of this system are the combustion chamber arranged in the center of the piston and the swirling passage in the cylinder head.

Due to the swirling passage, the air entering the cylinder through the helical port designed specially during intake stroke is imparted a strong rotary motion in the combustion chamber and the complicated turbulence motion created by the swirl produced during compression stroke and strong squish flow makes the fuel be mixed more sufficiently with air.

During the power stroke, the fuel injected from a multi-orifice nozzle is mixed sufficiently with air for complete combustion, so that the improvement of performance is achieved.

Engine with the Toroidal combustion system are characterized by their quiet running, high flexibility and very low specific fuel and oil consumption.

- 1 -

ENM1001S

<Fig.1> Toroidal Combustion System

Engine Model D1146 D1146T D1146TI

Type In-line, 6 Cylinders,

4 Stroke, Vertical Type

Intake Air Handling Natural Aspirated Turbo Charged

Turbo Charged & Inter Cooled

Combustion Chamber

Toroidal Combustion Chamber Fuel Injection Direct Injection Type Bore BStroke- No. of Cyl. 111mm

139mm - 6 Total Displacement 8,071 cc Compression Ratio 17.6 : 1 17.2 : 1 16.7 : 1 Maximum Output 182PS / 2,500 rpm 238PS / 2,300 rpm 205PS / 2,200 rpm Maximum Torque 57.5 kg.m/1,600 rpm 80 kg.m/1,400 rpm 75 kg.m/1,400 rpm Injection Timing 15° BTDC 11° BTDC 9° BTDC Firing Order 1 - 5 - 3 - 6 - 2 - 4 Injection Pump Type

NP-PE 6AD95 B412 RS2

NP-PE 6P120/721RS3000 KP-PE 6AD100 B412 RS2

Governor Type

NP-EP/RFD200/1650AF9CHL

NP-EP/RFD200/1650PF9CZR

KP-EP/RLD250-1400A1FXL

Timer Type

NP-EP/SP700-1250 B4R NP-EP/SP950-1150Z4R

KP-EP/SA700-1100B3DR Injection Nozzle Type DLLA150S312 DLLA150S1064 LUCAS DPN5227 Feed Pump Type NP-FP/KE ADS NP-FP/K-P KP-FP/KE ADS

BTDC 16° ABDC 36°

BBDC 46°

ATDC 14°

Oil Pump Gear Type

Oil Cooler Water - Cooled Fuel Filter Double Element Type Cartridge Type Oil Capacity 15.5 M(In Oil Pan ) Coolant Capacity 11

Thermostat Wax-Pallet Alternator : V - I

24V-25A (For Industrial Use)

Starter : V - kW 24V-45kW

1.2. Main Data and Specifications

- 2 -

Valve open/

Intake Valve Open At

Intake Valve Close At

Exhaust Valve Open At

Exhaust Valve Close At

1.3. Engine Performance Curve

1.3.1. D1146

- 3 -

Performance

KS-R0071

Creteria

Output(Max.) 182ps/2,500rpm

Torque(Max.) 57.5kg.m/1,600rpm

Fuel Cousumption Ratio(Min.)

163g/ps.h

Revolution(rpm)

Torque

Output

Fuel Cousumption

ENM1002I

<Fig.2>

- 4 -

1.3.2. D1146T

200

160

120

150

120

1000 1400 1800 2200

210

220

230

170

160 150

g/kW h

N m

kg m 700 650

600

70 65 60

g/ps h

Performance

KS-R1004

Creteria

Output(Max.) 190ps/2,200rpm

Torque(Max.) 71kg.m/1,400rpm

Fuel Cousumption Ratio(Min.)

152g/ps.h

Revolution(rpm)

Torque

Output

Fuel Cousumption

ENM1003I

<Fig.3>

- 5 -

1.3.3. D1146TI

g/kW h

g/ps h

Performance

KS-R0071

Creteria

Output(Max.) 205ps/2,200rpm

Torque(Max.) 75kg.m/1,400rpm

Fuel Cousumption Ratio(Min.)

143g/ps.h

Revolution(rpm)

Torque

Output

Fuel Cousumption

ENM1004I

<Fig.4>

- 6 -

1.4. Exterior View of Engine

1.4.1. D1146

2723

912

HNM1005I

<Fig.5>

1. Cylinder Block

2. Flywheel Housing

3. Breather

4. Oil Filler Pipe

5. Vibration Damper

6. Flywheel

7. V-Pulley

8. Cylinder Head

9. Oil Filter

10. Oil Cooler

11. Oil Pan

12. Oil Dipstick

13. Water Pipe

14. Water Pump

15. Exhaust Manifold

16. Intake Manifold

17. Intake Stake

18. Injection Pump

19. Injection Pump Bracket

20. Fuel Filter

21. Starter

22. Air Compressor

23. Mounting Bracket

24. P/S Pump

25. Thermostat

- 7 -

1.4.2. D1146T

420

12 10

ENM1006I

<Fig.6>

1. Fuel Filter

2. Intake-Manifold

3. Fuel Pipe

4. Oil Filler Cap

5.Water Pump

6. Cooling Fan

7. V-Belt

8. Vibration Damper

9. Timing Gear Case Cover

10. Oil Pan

11. Oil Dipstick

12. Oil Filter

13. Flywheel Housing

14. Fuel Injection Pump

15. Fuel Hose

16. Exhaust Manifold

17. Cylinder Head Cover

18. Cylinder Head

19. Breather Pipe

20. Turbo Charger

21. Starter

22. Cylinder Block

23. Oil Cooler

24. Cooling Water Pipe

25. Air Heater

26. Alternator

- 8 -

1.4.3. D1146TI(Inter Cooler Saparate Type)

ENM1007I

<Fig.7>

1. Cylinder Block

2. Flywheel Housing

3. Breather

4. Oil Filler Pipe

5. Vibration Damper

6. Flywheel

7. V-Pulley

8. Cylinder Head

9. Oil Filter

10. Oil Cooler

11. Oil Pan

12. Oil Dipstick

13. Water Pipe

14. Water Pump

15. Exhaust Manifold

16. Intake Manifold

17. Intake Stake

18. Turbocharger

19. Air Pipe (T/C-A/P)

20. Air Pipe (A/P-I/C)

21. Injection Pump

22. Injection Pump Bracket

23. Fuel Filter

24. Starter

25. Air Heater

26. Air Compressor

27. Mounting Bracket

28. P/S Pump

29. Thermostat

2. Major Maintenance

2.1. Preventive Maintenance

2.1.1. Coolant

1) Check the coolant level of the radiator by removing the radiator filler cap, and add coolant if necessary.

2) Check the pressure valve opening pressure using a radiator cap tester. Replace the radiator filler cap assembly if the measured value does not reach the specified limit (0.5 kg/cm

3) When injecting antifreeze solution, first drain out the old coolant from the cylinder block and radiator, and then clean them with cleaning solution.

4) Be sure to mix soft water with antifreeze solution .

5) A proportion of antifreeze is represented as the ratio of antifreeze in volume, and antifreeze must be added according to each ambient temperature as described below:

6 If you add antifreeze in excess of 50% in volume, the engine may be overheated. Avoid this. 6 As the individual freezing points corresponding to the above proportions of antifreeze are

subject to change slightly according to the kind of antifreeze, you must follow the specifications provided by the antifreeze manufacturer.

6) As the ratio of antifreeze in the mixture decreases each time new coolant is added to make up for the loss in old coolant resulting from engine operation, check the mix ratio with every replenishment of coolant, and top up as necessary.

7) To prevent corrosion or air bubbles in the coolant path, be sure to add a specific additive, i.e. corrosion inhibitor, to the coolant.

• Type : INHIBITOR (DCA4, DCA65L

...

)

• Mix ratio : 1.5M of inhibitor to 50M of coolant

(Namely, add corrosion inhibitor amounting to 3% of water capacity.)

8) Add antifreeze of at least 5% in volume to prevent possible engine corrosion in hot weather.

Antifreeze Solution(%) Freezing Point(C) 85 15 -10 or above 80 20 -10 73 27 -15 67 33 -20 60 40 -25 56 44 -30 50 50 -40

- 9 -

Cooling

Water(%)

2.1.2. Fan Belt

1) Use a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated.

2) Check the fan belt for belt tension. If belt tension is lower than the specified limit, adjust the tension by relocating the alternator and idle pulley. (Specified deflection: 10~15mm when pressed down with thumb)

2.1.3. Engine Oil

1) Check oil level using the oil dip stick and replenish if necessary.

2) Check the oil level with the vehicle stationary on a level ground, engine cooled. The oil level must be between MAX and MIN lines on the stick.

3) Engine oil should be changed at the specified intervals. Oil in the oil filter also should be changed simultaneously.

• Engine Oil Change Interval : At Least 2 Times / Year

• Suggested Engines Oils

2.1.4. Oil Filter

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

2) Change the oil filter element simultaneously at every replacement of engine oil.

2.1.5. Fuel Filter (Cartridge Type)

1) Drain water in cartridge with losen the cock under filter from time to time.

2) The fuel filter should be replaced at every 20,000km

2.1.6. Fuel Filter (Element Type)

1) The secondary stage fuel filter (fine filter) should be replaced at the same time when replacing Engine oil because that filter cannot be cleaned.

2) The primary stage fuel filter (felt element) should be cleaned up using diesel oil and compressed air at every 5,000km.

3) Be sure to replace the felt element after its 3rd cleaning.

SAE NO. API NO

15W40 CD grade or above

First Oil Change 500 ~ 1,000km (50 hours)

High speed, long distance running vehicle

every 15,000 km Inner city, short distance running vehicle every 10,000 km Heavy duty vehicle

every 8,000 km (2

50 hours)

- 10 -

2.1.7. Air Cleaner

1) Replace any deformed or broken element or cracked air cleaner.

2) Clean or replace the element at regular intervals.

2.1.8. Valve Clearance

1) Turn the crank shaft so that the piston in No. 1 cylinder reaches the TDC on compression stroke, then adjust the valve clearance.

2) After releasing the lock nut for the rocker arm adjusting screw, insert a feeler gauge of specified thickness into the clearance between the rocker arm and valve stem, and adjust the clearance with the adjusting screw. Fully tighten the lock nut when a correct adjustment is obtained.

3) Carry out the same adjusting operation according to the firing order(1-5-3-6-2-4) (Valve clearance(with engine cooled): 0.30mm for both intake and exhaust)

2.1.9. Cylinder Compression Pressure

1) Stop the engine after warming it up, then remove the nozzle holder assembly.

2) Install a special tool(gauge adapter) in nozzle holder hole and mount the compression gauge in position of the nozzle holder.

3) Cut off fuel circulation, rotate the starter, then measure compression pressure in each cylinder.

6 Testing conditions: Coolant temperature, 20C Engine rpm, 200 rpm (10 turns)

2.1.10. Injection Nozzle

1) Assemble a nozzle to a nozzle tester.

2) Check injection pressure, and adjust the nozzle using the adjusting shim if the pressure does not meet the specified limit.

3) Check nozzle spray patterns and replace if damaged.

Standard 28 kg/cm2Over

Limit 24 kg/cm2or less

Difference between each cylinder L10% or less

- 11 -

2.1.11. Fuel Injection Pump

1) Check the fuel injection pump housing for cracks or breaks, and replace if damaged.

2) Check and see if the lead seal for idling control and speed control levers have not been removed.

2.1.12. Battery

1) Check the battery for damage or leaking of battery fluid(electrolyte) from cracks on the battery. Replace the battery if damaged.

2) Check battery fluid level and add distilled water if necessary.

3) Measure the specific gravity of the electrolyte in the battery. Recharge the battery if the hydrometer readings are lower than the specified limit(1.12~1.28)

- 12 -

2.2. Diagnostics and Troubleshooting for the Engine

- 13 -

1. Engine Won’t Start

Starter does not turn Starter turns but engine does not start

Check battery fluid and specific gravity Engine Fuel

Too low Check air cleaner Check fuel level

Replenish or recharge

Check cable connections

Check starter s/w

Check starter relay

Check magnetic s/w

Disassemble and check starter motor

Disassemble and check injection pump

Normal

Fouled

Replace or clean element

Check compression pressure

Check other parts

Check cylinder head gasket

Overhaul the engine

(valve assembly, cylinder

liner, piston, etc.)

Check fuel feed pump for function

Check feed pump valve and strainer Air in the fuel

Retighten the joint and/or replace gasket

Air bleeding

Continuous entry of air in fuel system

Disassemble and check feed pump

Dirty element and/or overflow valve faulty

Check fuel filter

Replace

Normal

Too low

Retighten or replace

Check valve clearance

Normal

No fuel

Replenish

Check fuel injection

Normal

AdjustNormal

Repair or replaceNormal

No fuel injection

Air bleeding and re-start

Check injection timing

Check injection nozzle(injection pressure, injection condition, etc.)

Disassemble and check injection pump

Normal

AdjustNormal

ReplaceNormal

Clean or replaceNormal

Normal

Retighten or replaceNormal

Repair or

replaceNormal

ReplaceNormal

Repair or

replaceNormal

Overhaul the engine

- 14 -

2. Engine Overheating

Cooling system Fuel system

Check coolant level Check fuel quality

Operating conditions

1. Overload

2. Clogged radiator core

3. Continued overrunning

Too lowNormal Bad

Repair or replaceNormal

ReplaceNormal

Damaged

Repair or replace

Normal

Check fan belt for tension, wear, or breaks Clean or replace with the specified fuel

Check radiator cap Replenish

Check thermostat

Check radiator

Repair or replaceNormal

Check water pump

InternalExternal

Overhaul engineRetighten or repair

Clean coolant path

- 15 -

3. Lack of Power

Engine Chassis

Check for clutch slip

Adjust or replace clutch

Fuel system Others

Check fuel line for air Check air cleaner

Check engine control rod, link and

cable

Check fuel feed pump

Check fuel filter element and overflow valve

Check injection piping

Check injection nozzle(injection

pressure, nozzle spray patterns, etc.)

Normal Clean or replace

Normal

Check valve clearance

Check cylinder head gasket for break

Overhaul engine(valve assembly)

Adjust

Normal Adjust

Normal Replace

Normal Repair or replace

Normal Adjust or replace

Normal Adjust

Check injection timing

Overhaul engine or injection pump

- 16 -

4. Low Oil Pressure

Normal

Normal Too high

Normal

Normal Adjust or replace

Check if oil pressure gauge

indicates exactly

Check cooling water temperature

Too low

Refill with recommended oil

Check oil quality Refer to ‘Engine overheating’

Check oil pressure relief valve Water, fuel, etc. mixed in oil

Overhaul engine or injection pump

Inadequate

Replace with recommended lub. oil

Overhaul the engine

Check oil level

- 17 -

5. High Fuel Consumption

Normal

Normal Adjust or replace

Normal

Check injection timing

Check compression pressure

Disassemble injection pump

Check head gasket

Overhaul engine

(valve assembly, piston,

cylinder liner, etc.)

Check injection nozzle (injection

pressure, spray patterns, etc.)

Causes according to operating conditions

1. Overload

2. Frequent use of low gear shift at high speed

3. Frequent use of high gear shift at low speed

4. Clutch slip

5. Too low tire inflation pressure

Oil leakage

Retighten or replace

Check fuel leakage

Adjust

Check valve clearance

Repair or replace

Cylinder liner

Piston ring

Piston

Adjust

Replace

Oil leak

External Internal

Normal

Disassemble cylinder

head(valve stem seal, valve)

Check compression pressureRetighten or replace

Overhaul engine

(piston, cyl. liner)

- 18 -

6. Excessive Oil Consumption

Normal

Check oil quality

Replace with suggested lub. oil

Causes according to operating conditions

1. Too high lub. oil level

2. Continuous driving at low speed or with excessive cold engine

Check oil leakage Check air cleaner

Clean or replace

- 19 -

7. Engine Knocks(Excessive)

Identified

Overhaul engine

Check compression pressure

Check injection timing

Check fuel quality

Use recommended fuel

Normal Too low

Check valve clearance, cyl.

head gasket for damage

Normal Adjust

Normal

Replace or adjust

Overhaul engine

Check fuel and oil burning(Check carbon deposit from exhaust gas)

Unidentified

8. Dead or weak battery

Alternator

Check fan belt for

deflection, damage, etc.

Check battery fluid level

Harness, switch

Check wiring connections

short, open, etc.

Repair or replace

Battery

Normal

Replenish Replace Recharge

Check battery fluid specs.

Damaged battery case

Normal

Check charging condition

Discharged

Disassemble alternator

and regulator

Abnormal

Adjust or replace

Battery discharged Battery overcharged

Check alternator and

voltage regulator

Complaint Cause Correction

- 20 -

1) Difficulty in engine starting

(1) Trouble in starter (2) Trouble in fuel system (3) Lack of compression

pressure

2) Rough engine idling

3) Lack of engine power

(1) Engine continues to

lack power

(2) Engine lacks power on

acceleration

4) Engine overheating

(See <page 103>) (See <Section 4.3 Fuel system>)

Valves holding open, skewed valve

stem Valve springs damaged Leaky cylinder head gasket Worn pistons, piston ring, or liner

Wrong injection timing Air in injection pump

Valve clearance incorrect Valve poorly seated Leaky cylinder head gasket Piston rings worn, sticking, or

damaged

Injection timing incorrect Volume of fuel delivery insufficient Nozzle injection pressure incorrect or nozzles seized Feed pump faulty Restrictions in fuel pipes Volume of intake air insufficient

Compression pressure insufficient Injection timing incorrect Volume of fuel delivery insufficient Injection pump timer faulty Nozzle injection pressure or spray

angle incorrect

Feed pump faulty Volume of intake air insufficient

Lack of engine oil or poor oil Lack of coolant Fan belts slipping, worn or damaged Water pump faulty Thermostat inoperative Valve clearance incorrect Back pressure in exhaust line

212

Check valve and valve seat, then repair or replace Replace valve springs Replace gasket Replace

Adjust Air bleeding

Adjust Repair Replace gasket Replace piston rings

Adjust Adjust injection pump Adjust or replace nozzles

Repair or replace Repair Clean or replace air cleaner

Overhaul engine Adjust Adjust injection pump Repair or replace Repair or replace

Repair or replace Clean or replace air cleaner

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

- 21 -

Complaint Cause Correction

5) Engine noises

(1) Crankshaft

(2) Conn. rod and conn.

rod bearings

(3) Pistons, piston pins,

and piston rings

(4) Others

6) Excessive fuel consumption

It is important to correctly locate the causes of noise since generally noises may originate from various engine components such as rotating parts, sliding parts, etc.

Oil clearance excessive due to worn bearings or crankshaft Crankshaft worn out-of-round Restrictions in oil ports and resultant lack of oil supply Bearings seized up

Conn. rod bearings worn out-ofround Crank pin worn out-of-round Conn. rod skewed Bearings seized up

Restrictions in oil ports and resultant lack of oil supply

Piston clearance excessive due to

worn piston and piston rings

Piston or piston pin worn

Piston seized up Piston poorly seated Piston rings damaged

Crankshaft and/or thrust bearing worn Camshaft end play excessive Idle gear end play excessive Timing gear backlash excessive Valve clearance excessive Tappets and cams worn

Injection timing incorrect Volume of fuel injection excessive Tire under-inflated Gear selection inadequate(frequent use of low gears)

Replace bearings and grind crankshaft Grind or replace crankshaft Clean oil path Replace bearings and grind crankshaft

Replace bearings

Grind crankshaft Repair or replace Replace bearings and grind crankshaft Clean oil path

Replace pistons and piston rings Replace pistons and piston rings Replace pistons Replace pistons Replace piston rings

Replace thrust bearings

Replace thrust plate Replace thrust washers Adjust or replace Adjust valve clearance Replace tappets and camshaft

Adjust Adjust injection pump Adjust Select gears correctly according to load

- 22 -

Complaint Cause Correction

7) High oil consumption

(1) Oil leaking into

combustion chamber

(2) Oil leaking past cylinder

head

(3) Oil leaks

Clearance between cylinder liner and piston excessive Piston rings and ring grooves worn excessively Piston rings broken, worn, or sticking Piston rings gaps set incorrectly Piston skirt portion broken, worn excessively Oil return holes in oil control ring restricted Oil ring seated incorrectly Breather piping restricted

Valve stems and valve guide loose excessively Valve stem seals worn Leaky cylinder head gasket

Applicable parts loosened Applicable packings worn Oil seals worn

Replace

Replace pistons and piston rings Replace piston rings Correct Replace pistons

Replace piston rings

Replace piston rings Clean or replace

Replace as complete set

Replace seals Replace gasket

Replace or repair gasket Replace packings Replace oil seals

3. Disassembly and Reassembly of Major Components

3.1. Disassembly

3.1.1. General Precautions

1) Prior to disassembly, provide parts shelf for storage of various tools and disassembled parts.

2) Perform disassembly and reassembly works with clean bare hands and keep clean your surroundings.

3) After disassembly, prevent disassembled parts from being interchanged or colliding with each other.

4) Keep the disassembled parts in the disassembled sequence.

3.1.2. Oil Dipstick

1) Take out the oil Dipstick from the guide tube.

3.1.3. Cooling Water

1) Remove the drain plug in the cylinder block and drain out the cooling water into a prepared container.

3.1.4. Engine Oil

1) Remove the drain cock in the oil pan and drain out the engine oil into a prepared container.

2) Also, drain the oil filter by removing the drain plug.

- 23 -

3.1.5. Cooling Fan

1) Remove the flange fixing bolts, then take off the flange and cooling fan.

ENM3001I

<Fig.1> Cooling Fan Disassembling

- 24 -

<Fig.3> Thermostat Disassembling

<Fig.4> Starter Disassembling

<Fig.5> Fuel Filter (Cartridge Type)

<Fig.2> V-Belt Removal

3.1.6. V-Belt

1) Loosen the tension adjusting bolts of the alternator and the idle pulley, and take off the V-belts.

ENMD003I

3.1.7. Thermostat

1) Loosen the rubber hose connected to the cooling. Water pipe, and remove the thermostat.

2) Remove the rubber hose of the by-pass line.

ENM3002S

3.1.8. Starter

1) Unscrew the starter fixing nuts and remove the starter as taking care not to damage it.

EAMD017I

3.1.9. Fuel Filter

1) Unscrew the hollow screw, then remove the fuel inlet and outlet hoses.

2) Unscrew the filter fixing bolts and remove the fuel filter.

(if the fuel filter is of cartridge type,

disassemble the cartridge element only)

ENM3003P

- 25 -

<Fig. 8> Alternator Disassembling

<Fig.9> Oil Cooler

<Fig. 6> Breather Pipe (On The Cylinder Head Cover)

3.1.10. Breather Pipe

1) Unscrew the hose clamp with a screw driver and remove the breather pipe. (There are two types of breather pipes according to their mounting locations. that is, on the oil cooler and on the cylinder head cover)

ENM3004I

<Fig. 7> Breather Pipe (Top View)

ENM3005P

3.1.11. Alternator

1) Remove the alternator fixing bolts and take off the alternator.

ENM3006S

3.1.12. Oil Cooler

1) Loosen the rubber hose clamps of both sides of the oil cooler.

2) Unscrew the nuts and take off the oil cooler.

ENM3007I

Breather Pipe

- 26 -

<Fig.11> Air Compressor Disassembling

<Fig.12> Idle Pulley Disassembling

<Fig.10> Oil Filter Disassembling

3.1.13. Oil Filter

1) Remove the oil drain cock from the oil filter and drain out the Engine oil into a container.

2) Unscrew the oil filter fixing bolt and take off the oil filter.

ENM3008S

3.1.14. Air Compressor and Idle Pulley

1) Remove the oil pipe between cylinder block and air compressor.

2) Unscrew the air compressor fixing bolts and take off the air compressor.

ENM3009S

3) Unscrew the idle pulley fixing bolts and take off the idle pulley.

4) Unscrew the air compressor fixing bolts and remove the bracket.

5) Unscrew the power steering pump fixing bolts and remove the power steering pump.

ENM3010S

<Fig. 14> Cylinder Head Cover Removing

<Fig. 15> Injection Pipe Removal

<Fig.16> Injection Nozzle Removal

<Fig.13> Water Pump Disassembling

ENM3011S

3.1.16. Cylinder Head Cover

1) Unscrew the cylinder head cover fixing bolts and take off the cylinder head cover.

EDM2012P

3.1.17. Injection Nozzle

1) Unscrew the injection pipe between the injection pump and injection nozzle and take off the pipe.

ENM3013S

2) 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)

3) Take out the seal ring from the nozzle hole of the cylinder head and discard it.

EFM1004I

- 27 -

3.1.15. Water Pump

1) Remove the cooling fan fixing bolt and take off the fan and flange.

2) Unclamp the rubber hose connected to the oil cooler.

3) Unscrew the V-belt fixing nuts.

4) Unscrew the water pump fixing bolt from the cylinder block and take off the water pump.

<Fig.18> Inter Cooler

<Fig.19> Exhaust Manifold Disassembling

<Fig.20> Intake Manifold

<Fig.17> Turbo Charger

3.1.18. Turbo Charger <For D1146T and D1146TI>

1) Remove the oil feed pipe and the oil return pipe between the turbo charger and the cylinder block.

2) Unclamp the rubber hose connected to the intake manifold.

3) Unscrew the turbo charger fixing bolts and take off the turbo charger from the exhaust manifold.

ENM3014S

3.1.19. Inter Cooler <For D1146TI Only>

1) Unscrew the air heater fixing bolt, then loosen the air heater (4) from the air pipe (3) which is connected to the turbo charger (2) on the other side.

2) Unclamp the water outlet pipe (5) and water inlet pipe (6)

3) Unscrew the bolt tightened to both the intake manifold(7) and inter cooler(1).

EMN3015P

3.1.20. Exhaust Manifold

1) Unscrew the exhaust manifold fixing bolts and remove the exhaust manifold from the cylinder head.

2) Remove the exhaust manifold gasket and discard it.

ENM3016S

3.1.21. Intake Manifold

1) Unscrew the intake manifold fixing bolts and remove the intake manifold from the cylinder head.

2) Remove the intake manifold gasket and discard it.

ENM3017S

- 28 -

<Fig.21> Rocker Arm Disassembling

<Fig.22> Rocker Arm Disassembled

3.1.22. Cooling Water Pipe

1) Unscrew the cooling water pipe fixing bolts and remove the cooling water pipe from the cylinder head.

2) Remove the cooling water pipe gasket and finish the surface with a scraper. (Be sure that pieces of the gasket do not come into the water passage)

3.1.23. Rocker Arm Shaft Assembly

1) Remove the rocker arm bracket fixing bolts in reverse sequence of assembling sequence and take out the rocker arm shaft assembly.

2) Take out the push rod upwards.

EFM2091I

3) Optional Disassembly

(1) Remove the snap rings from the both

ends of rocker arm shaft by means of a piler.

(2) Remove the washer, rocker arm,

bracket and spring from the rocker arm shaft in sequence.

(3) Press out the rocker arm bush.

(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)

EQM3079I

- 29 -

<Fig.24> Valve Spring Disassembling

<Fig. 23> Cylinder Head Bolt Removal

3.1.24. Cylinder Head Assembly

1) Remove the cylinder head bolts by loosening them in sequence in two steps.

(1) 1st step : Loosen all the bolts evenly

by 1 ~ 2 threads.

(2) 2nd step : Loosen all the bolts

completely.

EFM2076I

2) Keep the removed bolts in place to avoid damage.

3) Hoist the cylinder head carefully and put it sidewards.

4) Remove the gasket and discard it.

5) Be sure that gasket residue does not remain on the surfaces of the cylinder head and cylinder block. (besides, the gasket joining surfaces should be free from any scar)

6) Optional Disassembly

(1) Place the cylinder head assembly on

a individual shelf.

(2) As pressing the valve spring with a

special tool, remove the cotter pin, valve spring.

EDM2029S

EJM2112S

- 30 -

<Fig. 25> Valve Guide Disassembling

<Fig.26> Oil Pan Disassembling

<Fig.27> Vibration Damper Disassembling

(3) Take out the intake and exhaust

valves.

(4) For removal of valve seat, apply

welding bead to the valve seat, and pull out the valve seat with a special tool.

(5) The disassembled parts are to be

kept laid in turn.

(6) Remove the valve stem seals.

(7) By means of a special tool, punch,

pull out the valve guide.

EDM2030P

3.1.25. Oil Pan

1) Unscrew the oil pan fixing bolts and remove the oil pan.

2) Remove the oil pan gasket and discard it.

EDM2021P

3.1.26. Vibration Damper

1) Unscrew the vibration damper fixing bolts in reverse sequence of installing sequence and remove the vibration damper assembly.

ENM3021S

- 31 -

<Fig.28> Oil Pipe Disassembling

<Fig.29> Of Connecting-rod Cap Disassembling

3.1.27. Timing Gear Case Cover

1) Unscrew the timing gear case fixing bolts.

2) To disassemble the timing gear case cover, Near the locations of dowel pin, insert a sharp scraper into the crevice between timing gear case and its cover. and tap the scraper lightly from right and left directions in an alternate manner.

(Be sure no damage or crack takes place)

3.1.28. Oil Pump

1) Unscrew the bracket fixing bolts of the oil suction pipe.

2) Unscrew the bolts fixing the oil suction pipe and remove the oil suction pipe.

EDM2023P

3.1.29. Piston

1) Unscrew the bolts clamping the connectingrod bearing cap on reverse sequence of assembling sequence while taking the same steps as disassembling way of cylinder head bolts.

EDM2024P

- 32 -

<Fig.30> Snap Ring Removal

<Fig.31> Piston Pin Removal

<Fig.32> Piston Ring Removal

2) As tapping the upper and lower portions of the bearing cap with a urethane hammer, remove

the bearing cap and take off the bearing inside.

3) Disassemble the piston assembly by pushing the connecting-rod with a wooden bar toward

cylinder head side from oil pan side.

4) Prevent disassembled piston assembly from being interchanged or colliding with each other.

5) Semi-Assemble the bearing caps to their respective connecting-rod to avoid their interchange.

6) Optional Disassembly of Piston

(1) Remove the snap rings by means of

a plier.

EAMD038S

(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) Wash clean the piston thoroughly.

EAMD039S

- 33 -

EDM2057I

<Fig.34> Camshaft Gear Disassembling

<Fig.35> Idle Gear Disassembling

<Fig.33> Liner Extracting

3.1.30. Cylinder Liner

1) Pull out the cylinder liner by means of a special tool or by hands carefully so as not to damage the cylinder bore.

EAMD087I

3.1.31. Cam Shaft Gear and Idle Gear

1) Unscrew the fixing bolts and remove the cam shaft gear.

EDM2025P

2) Unscrew two bolts fixing the idle gear, then remove the idle gear and its pin.

ENM3024S

- 34 -

<Fig.36> Injection Pipe Removal

3.1.31. Fuel Injection Pump

1) Remove the oil hose for lubrication.

2) Unscrew the injection pipe fixing bolts and remove the injection pipe.

EDM2027P

- 35 -

<Fig.37> Coupling Disassembling

<Fig.38> Bracket Disassembling

3) Remove the bolts and nuts which connect the coupling flange. To the injection pump.

4) Unscrew the injection pump fixing bolts and remove the injection pump by lifting it up.

ENM3025S

5) Unscrew the bracket fixing bolts and remove the bracket while tapping it lightly with a urethane hammer.

ENM3026I

- 36 -

<Fig.39> Flywheel Disassembling

3.1.32. Flywheel

1) Remove the fixing bolts by loosening them in diagonal sequence.

2) Remove the flywheel.

ENM3027P

3.1.33 Flywheel Housing

1) Remove the fixing bolts of the flywheel housing, then remove the flywheel housing by tapping it lightly with a copper or urethane hammer.

2) Remove the rear oil seal.

3.1.34. Injection Pump Drive Gear

1) Unscrew the bolts fixing the drive gear and remove the gear.

2) Unscrew the bolts fixing the drive gear housing and remove the drive gear assembly.

3.1.35. Timing Gear Case

1) Unscrew the bolts fixing the timing gear case.

2) With a urethane hammer, remove the timing gear case as tapping the rear side of the case lightly from right and left directions in an alternate manner.

3.1.36. Main Bearing Cap

1) Remove the bearing cap bolts by loosening them in sequence beginning with the outer ones. and take out the main bearing caps. (Be sure to take the same steps as disassembling way of cylinder head bolts)

2) Keep the disassembled main bearing cap sequencely according to their designated No.

3.1.37. Crank Shaft

1) Tighten bolts temporarily on the both sides of the crank shaft.

2) Carefully hoist the crank shaft with a wire rope.

3) Keep the removed crank shaft on a individual shelf so as to avoid its bending and damage.

4) Take the metal bearings out of the cylinder block and keep them according to their designated No.

3.1.38. Cam Shaft and Tappet

1) Remove the cam shaft as carefully turning it out to the engine front.

2) Keep the removed crank shaft on a individual shelf so as to avoid its bending and damage.

3) Take the tappets out of the cylinder block.

4) Press out the cam shaft bush from the cylinder block if necessary ( Disassemble further if it is damaged, scratched or worn away)

- 37 -

<Fig.40> Oil Spray Nozzle

3.1.39. Oil Spray Nozzle

(For D1146T & D1146TI)

1) Unscrew the bolts and remove the oil spray nozzle.

EAMD048S

3.2. Measurement and Inspection

3.2.1. Cylinder Block

1) Clean the cylinder block and visually check it for cracks or any damage.

2) Replace if cracked or severely damaged, and correct if lightly damaged.

3) Check oil and water flow lines for restriction or corrosion.

4) Make a hydraulic test to check for any cracks or air leak. (Hydraulic test) Close each outlet port of water and oil passage in the cylinder block, apply air pressure of approx. 4 kg/cm

into the inlet port, the immerse the cylinder block in water for about 1 minute to check any leak (water temperature : 70

3.2.2. Cylinder Head Assembly

1) Cylinder Head (1) Inspect the cylinder head for cracks or damage. (2) Carefully remove the carbon residue from the lower surface of the cylinder head by means

of nonmetallic material to prevent any scratches of the valve seat face.

(3) In case very fine crack or damage may be suspected which is invisible, Make a test with a

hydraulic tester or a magnetic flaw detector.

- 38 -

2) Distortion of Bottom Face (1) Measure the amount of distortion by

means of a straight edge and a feeler gauge in 6 directions as illustrated.

(2) If the measured value exceeds the

standard for use (0.2mm), resurface the head with grinding paper of fine grain size to correct such defect.

(3) If the measured value exceeds the

limit for use (0.3mm), replace the cylinder head.

3) Measure the flatness of the joining surfaces to the intake and exhaust manifolds by means of

a straight edge and a feeler gauge.

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

C D

EQM3047I

<Fig.41> Measuring Cylinder Head for Distortion

- 39 -

<Fig.43> Valve Head Thickness Measurement

<Fig.42> Valve Stem Measurement

5) Valve (1) clean the valves with clean diesel oil, (2) Measure the diameter of valve stem

at 3 locations (top, middle and bottom) if the amount of wear exceeds the limit for use (0.02mm), replace the valve and valve guide.

END OF STEM

EFM2036I

(4) Measure the thickness of the valve

head, and replace the valve head if the thickness is less than 1mm.

(3) Inspect the valve seat faces for

scratch or wear, and refinish the faces with grinding paper as necessary, replace the valve seat if severely damaged.

EQM3048I

Valve stem wear standard Limit

Intake valve stem (mm)

l8.950~8.970 l8.93

Exhaust valve stem (mm)

l8.935~8.955 l8.91

- 40 -

<Fig.44> Valve Projection Measurement

<Fig.45> Spring’s Free Length Measurement

6) Valve Guide (1) Insert the valve stem into the valve guide and measure the clearance between themselves

by valve movement. if the clearance is too excessive, measure the outer diameter of valve stem and inner diameter of the valve guide, determining to replace either of the two, which ever is worn more.

(2) Assemble the valve into the valve guide installed in the cylinder head, and see if it is being

well centered with the valve seat by means of a special tool.

(2) Install the valve onto the valve seat of

the cylinder head, and measure the amount of valve projection from the head face. if the measured value exceeds the limit for use, replace the valve seat.

7) Valve Seat (1) Measure the width of mating faces

between the valve seats and intake/exhaust valves for valve seat wear, and replace the valve seat if measured value exceeds the limit for use.

EDM2032P

8) Valve Spring (1) Visually inspect the appearance of

the valve spring, and replace it if necessary.

(2) With a venier calipers,measure the

free length of the spring.

EDM2033I

- 41 -

<Fig.47> Rocker Arm Run-Out Measurement

<Fig.46> Spring’s Tension & Straightness

Measurement

(3) With a spring tester, measure the

tension force of the spring.

(4) Measure the straightness of the

spring with an L square.

1mm or Less

Free Length

Square

EFM2039I

(5) Compare the measured value with

the limit for use, determining to repair or replace the valve spring.

3.2.3. Rocker Arm Shaft Assembly

1) Run Out of the Rocker Arm Shaft (1) Place the rocker arm shaft on two V-

blocks and Measure its shaft for bending with a dial indicator. If the amount of run-out is under the limit for use, correct the bending with a press. If the amount of run-out is beyond the limit for use, replace the rocker arm shaft.

EDM2037I

(2) With an outside micrometer, measure the diameter of rocker arm shaft at the position

where it was assembled. if the measured value deviates the limit, replace the rocker arm shaft.

<Fig.48> Tappet Dia. Measurement

<Fig.49> Tappet Surface Inspection

3) Inspection of Tappet and Push Rod (1) With an outer diameter, measure the

diameter of the tappets. if the amount of wear exceeds the limit for use, replace the tappet.

A (A) (B) (C)

EDM2058I

(2) Visually inspect the face of the

tappets in contact with the cam for pitting, scores or crack. then correct them with oil stone or fine grinding paper if necessary.Replace the tappet if severely damaged.

(1) Pitting (2) Crack (3) Normal

(4) Abnormal

EFM2041I

- 42 -

2) Inspection of Rocker Arm (1) Visually inspect the rocker arm face in contact with valve stem ends for scores and stepped

wear. then correct them with oil stone or fine grinding paper if necessary.

(2) With an inner diameter or vernier calipers, measure the inner diameter of the rocker arm

bush and compare the measured value with rocker arm shaft diameter, determining the clearance. if the clearance is exceeds the limit for use, replace either rocker arm shaft or bush.

(3) While laying the push rod down the

surfasce plate for measurement, check the push rod for bend by means of clearance gauge and if abnormal, replace the push rod with a new one.

EFM2042I

<Fig.50 > Push Rod Inspection for Bend

<Fig.52 > Cam Height Measurement

<Fig.53> Cam Bush Inner Dia. Measurement

<Fig.51> Cam Shaft End-Play Measurement

3.2.4. Cam Shaft

1) Measuring End Play (1) Push the thrust washer toward the

cam shaft gear side.

(2) With a feeler gauge, measure the

clearance between the thrust washer and cam shaft journal

(3) if the end-play exceeds the limit for

use, replace the thrust washer.

EDM2038S

2) Inspection of Cam Profile (1) Measure the height of the cam and

replace it if the cam nose is severely worn out.

(2) Inspect the cam face for scratch or

damage. minor wear on the cam face may be corrected with oil stone or oiled grinding paper, however, replace the cam shaft if severely damaged.

EDN2045I

3) Clearance Between Cam Shaft and Cam

Shaft Bush

(1) With an outer diameter, measure the

diameter of the cam shaft journal.

(2) With a cylinder gauge, measure the

inside diameter of cam shaft bush in the cylinder block,

(3) Compare the two measured value,

determining the clearance between them. If the clearance exceeds the limit for use, replace the cam shaft bush.

EDM2039S

- 43 -

4) Run-Out of Cam Shaft Place the cam shaft on two V-blocks and measure its run-out, and correct or replace the cam shaft if the run-out exceeds the limit for use.

<Fig.54 > Cam Shaft Run-Out Measurement

EFM0546I

3.2.5. Crank Shaft

1) Inspection of Crank Shaft for Scratch or Crack (1) visually check the crank shaft journal and pin for wear or damage. (2) Check the crank shaft for any crack by means of magnetic powder or red check, and

replace the crankshaft if cracked.

2) Measurement of crank shaft for wear (1) With an outside micrometer, measure the

diameter of the crank shaft journals and pins in the directions and at the location as illustrated.

(2) If the amount of wear exceeds the

limit for use, grind the crankshaft and install undersized bearings.

3) Undersized Bearings Available (1) STD

(Standard bearing)

(2) 0.25

(inner diameter is smaller than STD by 0.25mm)

(3) 0.50

(inner diameter is smaller than STD by 0.50mm)

(4) 0.75

(inner diameter is smaller than STD by 0.75mm)

(5) 1.00

(inner diameter is smaller than STD by 1.00mm) 4 different undersized bearings are available as indicated above , and the crank shaft also can be reused through the regrinding like above.

EDM2041S

B B

EFM2047S

- 44 -

<Fig.55> Crankshaft’s Dia. Measurement

<Fig.56> “R” Formation of Crank Shaft

<Fig. 57> Crank Shaft Run-Out Measurement

<Fig.58> Main Bearing Inner Dia. Measurement

Note : When regrinding the crank shaft, the

fillet “R” should be correctly finished. Avoid stepped portion or rough surface on it.

" R "

Right Wrong Wrong

" R " " R "

EFM2048I

3) Run-Out of Crank Shaft (1) Place the crank shaft with its No.1

and No.7 journals on two V-blocks respectively.

(2) Measure the run-out of crank shaft as

turning the crank shaft slowly in one direction with the probe of a dial indicator on a crank shaft journal.

EAMD056S

5) Measurement of Oil Clearance (1) Install the main bearing onto the

cylinder block and tighten the bearing cap to the specified torque and measure its inner diameter.

4) Inspection of Crank Shaft Bearing and Connectingrod Bearing

(1) Visually inspect the surfaces of crank

shaft bearing and connectingrod bearing for scores, scratch or uneven wear.

EAMD058S

- 45 -

Standard Value for “R” Portion

Crankshaft pin “R” (mm) 4.5 Crankshaft journal “R” (mm) 4.0

<Fig.59> Connecting Rod Bearing Inner Dia.

Measurement

(2) Insert the bearing into the big-end of

connectingrod and tighten the cap bolt to the specified torque, and measure its inside diameter.

(3) Compare two values through (1) and

(2) with two inner diameter of crank shaft journal and pin respectively, determining the two clearances for oil passage.

(4) If the calculated clearances exceed

the limit for use, grind the crank shaft and adopt undersized bearing.

EAMD060I

- 46 -

<Fig. 60> Piston Dia. Measurement

<Fig.61> Liner’s Inner Dia. Measurement

3.2.6. Piston

1) Visually check the piston for cracks, scuff and wear.

2) Clearance Between Piston and Liner

(1) With an outside micrometer, measure

the piston diameter at the location 13mm away from its bottom end and at the right angle against the piston pin direction.

ENM3030S

(2) With a cylinder bore gage, measure

the inside diameter of cylinder liner at 3 locations, that is, top ring joining portion, middle portion and oil ring joining portion of BDC in every 45°£ direction respectively. Among the obtained values, rule out the largest and smallest and take an average of the rest.

(3) The difference between inner diameter of cylinder liner and outer diameter of piston is

defined as clearance. If the clearance deviates the limit for use, replace either the piston or liner whichever is worn more.

EQM3052I

- 47 -

- 48 -

<Fig.62> Piston Ring Gap

3) Visual Inspection of Piston Ring

(1) Replace the piston ring with a new one when found be worn or broken, or in case of

overhauling work.

EFM2053I

4) Piston Ring Gap

(1) Insert the piston ring into the upper

portion of cylinder liner so that the ring is secured at the right angle to the cylinder liner wall.

(2) With a filler gauge, measure the gap

of piston ring.

(3) If the measured gap exceeds the limit for use, replace the piston with a new one.

5) Side Clearance of Piston Ring

(1) Assemble the compression rings (1st / 2nd rings) and oil ring into the piston ring grooves. (2) With a feeler gauge, measure the side clearance of each ring. if the measured value

exceeds the limit, replace either the ring or the piston whichever is worn more.

Standard (mm) Limit (mm)

1st ring 0.40 ~0.65 1.5

2nd ring 0.40 ~ 0.65 1.5

Oil ring 0.30 ~ 0.60 1.5

Item

Dimension

Standard (mm) Limit (mm)

1st ring - -

2nd ring 0.07 ~0.102 0.15

Oil ring 0.05 ~ 0.085 0.15

Item

Dimension

6) Tension of Piston Ring

Measure the tension of piston ring with a tension tester, if the measured value exceeds the limit, replace the piston ring with a new one.

<Fig.64> Piston Pin Outer Dia. Measurement locations

<Fig.63> piston Pin Outer Dia. Measurement

7) Piston Pin

(1) Measure the diameter of piston pin at

several portions illustrated in Fig.64 Replace the piston pin if the measured value exceeds the limit for use.

EDM2057I

A (A) (B) (C)

EDM2058I

(2) With a cylinder bore gauge, measure the inner diameter of the bush in the connecting rod,

and compare the measured value with piston pin diameter, determining the clearance. if the clearance exceeds the limit for use, replace either the piston pin or its bush whichever is worn more.

(3) Inspect the fitting condition of piston pin with piston.

The piston pin fitting interference may be regarded as normal when it is fitted into the piston with fingered pressure after heating the piston to a certain temperature. When replacing the piston, it’s necessary to replace the piston pin alike.

- 49 -

<Fig. 65> Connecting Rod Distortion Measurement

3.2.7. Connecting Rod

1) Distortion;

Install the connecting rod on a individual tester and measure its distortion with a feeler gauge. If the connecting rod is twisted or bent, a new connecting rod should be substituted for. No attempt would be allowed to straighten the connecting rod.

EJM2087I

2) Alignment;

Check the alignment between the piston pin bush hole and bearing hole in big-end portion. A individual aligner and a filler gauge are also necessary to do this.

3) Side Clearance;

(1) Assemble the connecting rod to the crank shaft and measure the side clearance of its big-

end.

(2) Assemble the connecting rod to the cam shaft and measure the side clearance of its small-

end.

(3) If the above measured values exceed the limit for use (0.5mm), Replace the connecting

rod.

- 50 -

3.3. Reassembly

3.3.1. Precautions Before and After Engine Reassembly

1) Clean up disassembled parts, particularly oil ports and water passages of each part applying compressed air, then check that they are all free from any restrictions.

2) Arrange all the general and special tools sequencely.

3) prepare clean engine oil for spreading on every sliding parts.

4) Prepare side materials such as an adhesive.

5) Discard used gaskets and seal rings and replace them with new ones at reassembly.

6) Check to see if the motions of moving parts are smooth after reassembly.

7) Check to see if the tightness of every fastenings is achieved after reassembly.

3.3.2. Oil Spray Nozzle <For D1146T & D1146TI>

1) Place the oil spray nozzle in position onto the cylinder block and tighten its fixing bolts. Make sure that the oil spray nozzle be stall at assembly with a special jig.

- 51 -

3.3.3. Cam Shaft and Tappet

1) When replacing the cam shaft bush, undercool a new bush in dry ice for about 2 hours and press it into the cylinder block.

2) After pressing the cam shaft bush into the block, measure the inner diameter of the bush. if any discrepancy is found, replace the bush again.

3) Apply engine oil over the tappet holes and tappets, then install the tappets in cylinder block.

4) Apply engine oil over the cams and journals of the cam shaft and the inside of cam shaft bush as well, then install the cam shaft in position into the cylinder block while turning the cam shaft. (When installing the cam shaft, exercise care not to scratch the cam shaft and the bush)

EDM2059S

<Fig.66> Tappet Assembling

EDM2060I

<Fig.67> Cam Shaft Assembling

5) When the cam shaft has been installed, turn the cam shaft to see if the cam shaft turns smoothly.

<Fig. 69> Bearing Cap Assembling

<Fig. 70> Bearing Cap Tightening

<Fig.68> Metal Bearing Assembling Sequence

6421357

EFM2061I

3) Tighten bolts temporarily on the both sides of the crank shaft, then carefully hoist the crank shaft, installing it onto the cylinder block as keeping its balance. (Apply engine oil over the pin and journal of the crankshaft)

4) Assemble the bearing and thrust washer to the bearing cap.

5) Place the pre-assembled bearing cap to

the cylinder block as identifying their assembly No. (Apply engine oil over the bearing)

6) coat the cap bolt with engine oil, then tighten the cap bolt to the specified torque of 30kg.m in the following manner;

(1) 1st step : coat the cap bolt with engine oil. (2) 2nd step : Tighten the bolt in 1 ~ 2

threads.

(3) 3rd step : Tighten the bolt to the torque of

approx. 15kg.m with a wrench.

(4) 4th step : Tighten the bolt to the torque of

approx. 25kg.m with a wrench.

(5) 5th step : Finally, tighten the bolts to the

specified torque of 30kg.m with a torque wrench in sequence of bearing cap number, 4 3 5 2 6 1 7

EFM2070I

EFM2071I

- 52 -

3.3.4. Crank Shaft

1) Press the locating ring into the cylinder block.

2) Place the metal bearing onto the cylinder block and lubricate it with engine oil.

7) As a final check, Turn the crank shaft to check that the crankshaft turns smoothly with hands.

- 53 -

<Fig.71> Rear Oil Seal Press In

<Fig. 72> Flywheel Assembling

<Fig. 73> Flywheel Bolt Tightening Sequence

3.3.5 Flywheel Housing

1) Temporarily install guide bars to the cylinder block and attach the gasket on the cylinder block.

2) Hoist the flywheel housing and attach it to the cylinder block as sliding the housing holes along outside of the guide bars.

3) Assemble the flywheel housing fixing bolts and tighten them in diagonal sequence to the specified torque.

(Remove the guide bars when bolts fixing)

4) With a oil seal fitting jig, Press a new rear oil seal lubricated with engine oil in the flywheel housing. If the crankshaft is skid marked with old oil seal, shift new oil seal location by inserting a shim which has about 1mm thickness. Be sure to avoid damage of oil seal when assembling.

EAMD080I

3.3.6. Flywheel

1) Temporarily install guide bars to crankshaft bollt holes, then hoist the flywheel and attach it to the crankshaft as sliding flywheel with its holes along the guide bars.

EDM2072P

2) Coat the flywheel fixing bolts with adhesive (#271 Loctite) and tighten them in numerical sequence to the specified torque of 21.5kg

m, while taking the same steps as those of bearing cap bolts tightening procedure mentioned in section 3.3.4.

(Remove the guide bars when bolts

fixing)

EDM2073I

<Fig.78> Timing Gear Train

<Fig. 79> Gear Mark and Idle Gear Assembling

<Fig.77> Cam Gear Assembling

3) Install the camshaft thrust washer on the timing gear case, then install the cam gear by tapping it lightly with a urethane hammer.

4) Tighten the fixing bolts in diagonal sequence to the specified torque.

EQM3066I

5) Install the idle gear, so that the marks on the idle gear are exactly met with marks on the camshaft gear and crankshaft gear respectively.

Fuel injection pump drive gear

Idle gear

Cam gear

Crank gear

EDM2075I

6) Install the thrust washer on the idle gear and tighten the fixing bolts to the specified torque.

7) When assembling the timing gear in position, check the amount of backlash between gears by means of a thickness gauge. If the amount of backlash exceeds the specified value, correct or replace the defective gear.

ENM3032S

- 54 -

Measuring Position Backlash (mm) Between Cam gear & Idle gear 0.16 ~0.28 Between Crank gear & Idle gear 0.16 ~ 0.28 Between Injection pump drive gear & Idle gear

0.16 ~ 0.28

<Fig.81> Injection Pump Marking

<Fig.82> Cylinder Liner Assembling

<Fig. 80> Injection Pump Assembling

3.3.7. Injection Pump

1) Install the injection pump mounting bracket with a shim between the bracket and cylinder block and tighten the bolts.

If the thickness of the original shim is not correct, determine which new shim is to be used.

There are 4 types of shim for adjusting the horizontal alignment such as

0.1mm, 0.15mm, 0.2mm and 0.5mm in thickness and there are also 3 types of shim for adjusting the vertical alignment such as 0.1mm, 0.2mm and 0.3mm in thickness.

2) Mount the injection pump on the bracket, then tighten the bolts to the specified torque.

EQM3087I

EQM3090I

3) Assemble the coupling as checking the alignment between injection pump shaft and drive gear shaft. If the alignment is not achieved, do disassembling and replace the shim with correct one and reassemble the mounting bracket and the injection pump.

4) Rotate the flywheel in direction of rotation until the mark on the vibration damper exactly meets the pointer.

5) Align the pointer on the injection pump with the line on timer, and couple the injection pump to the coupling drive shaft by tightening fixing bolts and nuts.

3.3.8. Cylinder Liner

1) Completely clean the cylinder liners and blow off the dust and water by compressed air.

2) Insert the cylinder liner into the cylinder block and push the cylinder liner with hands. (Be careful that no foreign objects get in the bottom side of liner flange when assembling)

3) Coat engine oil inside the liner.

EDM2078P

- 55 -

<Fig.84> Piston Hanging

<Fig.85> Angles Between Piston Ring Gaps

<Fig.83> Piston Arrangement Before Assembling

3.3.9. Piston

1) Array the pistons sequencely according to their designated No. and insert the bearing onto the piston.

2) Coat engine oil over the pistons.

EDM2079P

3) Insert the special tool for piston assembling to the piston and hang the piston in the cylinder block.

EDM2080I

4) The gap of each piston ring should be positioned so that it is 120° opposite that of the preceding ring. Make sure that rings are installed with “Y” mark turned up and piston ring gap is away from pin direction.

Top ring gap

Piston pin

Oil ring gap 2nd ring gap

Piston

120

EFM2069I

- 56 -

<Fig.87> Connecting Rod Bearing Cap Tightening

<Fig.88> Connecting Rod End Play Inpection

<Fig.86> Connecting Rod Bearing Cap Assembling

5) Push the piston into the cylinder block until the connecting rod bearing is brought into contact with the crankshaft pin, taking care not to scratch the piston or cylinder liner wall.

6) Install the bearing cap on the connecting rod and Coat engine oil over it.

7) Turn the crankshaft until connecting rod big end rides on the crankshaft pin, and assemble the connecting rod bearing cap with a urethane hammer.

EAMD093S

8) Coat engine oil over the connecting rod bearing cap bolts and tighten them to the specified torque in a following manner;

(1)

1st step

: Lubricate the cap bolt with

engine oil.

(2) 2nd step : Tighten the bolt in 1 ~ 2

threads.

(3) 3rd step : Tighten the bolt to the torque

of approx. 10kg.m with a wrench.

(4) 4th step : Tighten the bolt to the torque

of approx. 15kg.m with a wrench.

(5) 5th step : Finally, tighten the bolts to

the specified torque of 18kg.m with a torque wrench.

However, tighten both sides of bolts simultaneously as above steps.

EDM2024P

9) 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, remove and reinstall or replace the connecting rod bearing cap.

EAMD094I

- 57 -

<Fig.90> Oil Pipe Assembling

<Fig.91> Water Pump Assembling

<Fig.89> Oil Pump Assembling

3.3.10 Oil Pump

1) Install the oil pump assembly in position on #7 bearing cap, as tapping lightly with a urethane hammer.

EDM2083P

2) Install the nut with lock washer and tighten the bolts to the specified torque.

3) Bend the lock washer toward the bolt to prevent its release.

4) Connect the oil suction pipe and supply pipe to the oil pump.

EDM2084P

3.3.11. Water Pump

1) Attach a new gasket on the water pump, then place the water pump to the cylinder block.

2) Tighten the fixing bolts to the specified torque.

ENM3011S

- 58 -

<Fig.93> Timing Gear Case Cover Assembling

<Fig.94> Vibration Damper Assembling

<Fig.95> Virbration Damper Bolt Tightening Sequence

<Fig.92> Oil Seal Press In

3.3.12. Timing Gear Case Cover

1) Coat engine oil over the bore of the timing gear case cover, where the front oil seal is to be installed.

2) Assemble a new front oil seal by means of a oil seal fitting jig and press it into the bore carefully. Be sure to avoid damage of the front oil seal when assembling.

EAMD086I

3) Attach new gasket on the timing gear case cover, and assemble the case as tapping the locating pin side lightly with a urethane hammer.

EAMD085S

3.3.13. Vibration Damper

1) Install the vibration damper on the crankshaft, then tighten the bolts in numerical sequence as shown in the right to the specified torque.

EDM2088P

4 3

6 7

8 5

EDM2089I

- 59 -

<Fig. 97> Oil Filter Assembling

<Fig. 98> Oil Cooler Assembling

<Fig.96> Oil Pan Assembling

3.3.14 Oil Pan

1) Remove gasket residue on the joining surface of timing gear case, timing gear case cover, flywheel housing in cylinder block by means of a scraper. Be sure that gasket residue do not enter inside the engine.

2) Coat the silicone on the joining surfaces and place a new oil pan gasket.

3) Assemble the oil pan, and tighten primarily the bolts located at both the ends of the cover (4EA at both sides) and middle bolts (upper, lower 2EA), then tighten the rest.

ENM3033I

ENM3008S

3.3.15. Oil Filter

1) Install the oil filter with a new gasket on the cylinder block and tighten the bolts in diagonal sequence to the specified torque so as to prevent oil leakage.

ENM3007I

3.3.16. Oil Cooler

1) Coat the grease on the oil hole of oil cooler housing insert O-ring in it.

2) Assemble the oil cooler on the cylinder block and tighten the nuts.

- 60 -

<Fig.100> Starter Assembling

<Fig.101> Stem Seal Press In

<Fig. 99> Rubber Hose Clamping

3) Connecting the cooling water pipe between oil cooler and water pump, and tighten the hose clamp securely.

ENM3002S

3.3.17. Starter

1) Insert the starter inside the flywheel housing then tighten the fixing nuts.

EAMD121I

3.3.18. Cylinder Head Assembly

1) Cylinder head assembling;

(1) Clean the cylinder head thoroughly. (2) Replace the valve stem seal with a

new one, and by means of a special tool press the stem seal into the valve guide of cylinder head.

EJM2040S

- 61 -

(3) Coat engine oil over valve stem and valve guide and assemble the valve.

However, be careful for the damage of valve stem seal. (4) Install the lower seat of valve spring to the valve guide of cylinder head. (5) After putting inner, outer spring, install the retainer on it. (6) Assemble the valve by inserting the valve cotter pin, while pressing the retainer with a

special tool. (7) After installinng the valve, check whether the valve is correctly installed or not, tapping it

lightly with a urethane hammer.

<Fig.103> Cylinder Head Assembling

<Fig.102> Cylinder Head Gasket Assembling

2) Clean up the cylinder head bolt holes with compressed air.

3) Wipe out the gasket joining surface of cylinder block. Be sure that gasket residue do not enter inside the engine.

4) Attach a new gasket on the cylinder block as aligning its locating pins.

EDM2095P

5) Install the cylinder head on the cylinder block as aligning it with locating pins of cylinder block. If the cylinder head does not engage with locating pins well, Lift up the cylinder head again and retry to settle the cylinder head on the cylinder block. (Be careful not to damage the cylinder head gasket during this attempt)

EDM2096P

6) When having to disassemble the cylinder head even after tightening the cylinder head bolts, cylinder head gasket should be replaced with a new one.

- 62 -

<Fig. 105> Rocker Arm Assembling

<Fig. 104> Cylinder Head Bolt Tightening Sequence

7) Clean the cylinder head bolts and dip them in engine oil, then install the bolts on the cylinder head to the specified torque of 24.5kg.mm in a following manner;

(1) 1st step : Coat the cylinder head

bolts with engine oil.

(2) 2rd step : Tighten the bolt in 1 ~ 2

threads.

(3) 3rd step : Tighten the bolt to the

torque of approx. 15kg

with a wrench.

(4) 4th step : Tighten the bolt to the

torque of approx. 20kg

with a wrench.

(5) 5th step : Finally, tighten the bolts to

the specified torque of

24.5kg.m with a torque wrench. However, tighten all the bolts simultaneously as above steps.

EDM2096P

3.3.19. Rocker Arm

1) Insert the push rod coated with engine oil into the cylinder head.

2) Place the rocker arm assembly on the cylinder head and tighten the fixing bolts to the specified torque in diagonal sequence.

EFM2091I

- 63 -

<Fig. 106> Vlave Clearance Adjustment

3) Adjust the valve clearance in the following manner;

EDM1003S

I : Intake valve E : Exhaust valve

- 64 -

12 34 5 6

I E I E I E I E I E I E #1 TDC #6 TDC

CYLINDER

NUMBER

(1) Turn the crankshaft until intake/exhaust valves of #6 cylinder (1st cylinder from water pump)

are overlapped (that is, #1 piston is at TDC position). Adjust the valve clearance marked with in the table.

(2) Conversely, Turn the crankshaft until intake/exhaust valves of #1 cylinder are overlapped

(that is, #6 piston is at TDC position), Adjust the valve clearance marked with in the table.

(3) In performing the valve clearance adjustment operation, Insert the feeler gauge of 0.3mm

thickness into the clearance between the valve stem and rocker arm, then adjust the clearance with the adjust screw. Fully tighten the rock nut when a correct adjustment is achieved.

<Cautions> (1) Turing the crankshaft is to be done by hands not by the starter. (2) Turn the crankshaft in the direction of engine rotation, but do not use the fixing bolts at the

turn.

(3) The cylinder No. and the sequence of intake and exhaust can be nominated from the

flywheel housing.

<Fig. 108> Intercooler Assembling

<Fig.109> Air Heater Assembling

<Fig. 107> Intake Manifold Assembling

3.3.20. Intake Manifold

1) Install the manifold gasket on the cylinder head by aligning its openings with the intake port in the cylinder head.

2) Install the intake manifold on the cylinder head by means of bolts and tighten them to the specified torque.

ENM3017S

3.3.21. Inter Cooler < For D1146TI only>

1) Remove gasket residue on the joining surface of inter cooler by means of a scraper.

2) Coat the surface with silicon adhesive (spec: TB1107) using a brush.

3) Insert a new gasket (5) between intake manifold(4) and intercooler(3), then tighten the fixing bolts to the specified torque of 2.2kg.m

Notice : For overland use, the inter

cooler is mounted on the vehicle side.

ENM3035P

ENM3036P

3.3.22. Air Heater

1) The air heater(2) is ,in the direction of arrow mark on it, assembled to the inter cooler(3).

2) Attach the gaskets on both sides of air heater and tighten the fixing bolts respectively.

- 65 -

<Fig.111> Turbo Charger Assembling

<Fig.112> Cooling Water Pipe Assembling

<Fig.110> Exhaust Manifold Assembling

3.3.23. Exhaust Manifold

1) Check the seal ring on the jointing face of the exhaust manifold and replace it if found to be defective.

2) Attach a new gasket on the cylinder head, and temporarily place the exhaust manifold on the cylinder head and tighten the fixing bolts securely.

ENM3037S

3.3.24. Turbo Charger (For D1146T, D1146TI)

1) Install the turbo charger(D) with a new gasket to the exhaust manifold(C). then tighten the nuts in diagonal sequence to the specified torque.

2) Align the air inlet portion of the turbo charger with the intake manifold (A), and connect the rubber hose to intake manifold.

3) Assemble the oil feed pipe(E) and oil return pipe (F).

ENM3038P

ENM3002S

3.3.25. Cooling Water Pipe

1) Attach a new gasket on the cylinder head.

2) Install the cooling water pipe as tightening the fixing bolts of it

- 66 -

<Fig.114> Air Compressor Assembling

<Fig.115> Alternator Assembling

<Fig.113> Idle Pulley Assembling

3.3.26. Idle Pulley

1) Install the air compressor mounting bracket to the timing gear case.

2) Assemble the idle pulley to the air compressor mounting bracket.

ENM3039S

3.3.27. Air Compressor

1) Couple the power steering oil pump to the air compressor with the driving dog engaged.

2) Insert the O-ring coated with grease into the oil outlet of the air compressor.

3) Place the air compressor on the mounting bracket carefully and tighten the fixing bolts to the specified torque.

(Exercise care not to damage the O-ring)

4) Assemble the oil feed pipe.

ENM3009S

3.3.28 Alternator

1) Install the mounting bracket and supporter to cylinder block, then tighten the fixing bolts.

2) Install the alternator to the mounting bracket and to supporter, then tighten the fixing bolts.

ENM3006S

- 67 -

<Fig.117> Fuel Filter Assembled

<Fig.118> Fuel Filter (Cartridge Type)

<Fig.116> Breather Pipe Assembled

3.3.29. Breather Pipe

1) Assemble the breather pipe and tighten its hose clamp.

ENM3005P

3.3.30. Fuel Filter

1) Install the fuel filter to the intake manifold and tighten the bolts to the specified torque.

ENM3003P

2) Connect the fuel inlet hose and outlet hose to the fuel filter respectively by tightening hollow screws. Be sure not to damage the connection part due to over-tightening the hollow screw.

3) Fuel filter (cartridge type)

(1) Remove the used cartridge(2) from the

head(3). (Fuel should be drained into a container so as not to stain the ground

and the engine) (2) Fill a new cartridge with fresh diesel fuel. (3) Lubricate the surface of rubber packing

(5) of the cartridge. (3) Clean the joining face of the head, and

spin the cartridge until the surface of its

packing comes into contact with the

head face. (4) From this position, additionally, tighten

the cartridge by 1/2 turn.

EPM2027I

5) Loosen the air bleeding screw on the head of the fuel filter and feed fuel by manually operating the priming pump of the feed pump until the air bubbles completely expel in the fuel flowing from the filter.

6) Tighten the plug screw, and spin engine over with key and check for any fuel leakage.

- 68 -

Breather Pipe

<Fig.120> Fuel Injection Assembling

<Fig.121> Cylinder Head Cover Assembling

<Fig.119> Nozzle Assembling

3.3.31. Injection Nozzle

1) Install a new seal ring in the nozzle hole of cylinder head,

2) As aligning the ball of nozzle with a groove in the nozzle hole, Insert the nozzle into the cylinder and tighten the nozzle.

ENM3013S

3) Connect the fuel injection pipe to the fuel injection pump and to the nozzle, and tighten them with nuts.

4) Assemble the fuel return hose to the nozzle.

5) Connect the injection pump lubricating oil hose with a hollow screw. Be sure not to damage the connection part due to over-tightening the hollow screw.

ENM3041P

3.3.32. Cylinder Head Cover

1) Attach a new gasket on the cylinder head cover.

2) Assemble the cylinder head cover to the cylinder head by tightening the cap bolts for fixing the cylinder head cover.

3) Fit the oil filler cap on the cylinder head cover.

ENM3012S

- 69 -

<Fig.124> Cooling Fan Assembling

<Fig.125> V-Belt Assembling

<Fig.122> Thermostat Assembling

3.3.33. Thermostat

1) Connect the thermostat housing to the cooling water pipe with rubber hose engaged, then tighten the hose clamps.

2) Connect the thermostat housing to the water pump with rubber hose engaged, then tighten the hose clamps.

ENM3002S

3.3.34. Cooling Fan

1) Install the flange to the water pump pulley, then assemble the cooling fan to the pulley by tightening the fixing bolts .

ENM3042I

3.3.35. V-Belt

1) Check the V-belt for fraying or damage and replace it with a new one if necessary.

2) Wind one V-belt around the alternator pulley, water pump pulley and crankshaft pulley, and then adjust the V-belt tension by shifting the tension adjusting bolt of the alternator.

3) Wind the other V-belt around the idle pulley, crankshaft pulley and air compressor pulley, then adjust the Vbelt tension by shifting the tension adjusting bolt of the idle pulley.

3.3.36. Oil Dipstick

1) Insert the oil dipstick into the guide tube.

ENM3043I

- 70 -

3.3.37. Miscellaneous Items

1) Connect all the rest pipes and hoses for lubrication and fuel system.

- 71 -

3.3.38. Injection Timing Adjustment

1) Turn the crankshaft until #6 cylinder is overlapped.

2) Open the rubber cap of the inspection hole located in the flywheel housing, and adjust the injection timing by rotating the crankshaft.

3) Loosen the flange bolt in the injection pump, and align the timing mark on the injection pump timer with the pointer on the inspection of the flywheel housing.

4) Reassemble the flange bolts and the rubber cap.

3.4 Breaking-In

3.4.1. Preparations Prior to Breaking-In

1) Fill fresh engine oil through the oil filler cap.

2) Check the oil level with the oil dipstick. the oil level should be about 10mm above the MAX. line.

3) Connect the cooling water hose and replenish cooling water.

4) Further on, connect the fuel hose to the fuel tank, and bleed the fuel system (refer to section 3.3.34.)

3.4.2. Execution of Breaking-In

1) Attach the engine to the test bench.

2) Execute the breaking-in according to breaking-in regulations.

3) Any problem in assembly or performance of engine could be detected and corrected by breaking-in test.

4) After breaking-in, readjust the valve clearance.

- 72 -

4.1.2. Specification

Cooling Water Pipe

Cylinder Head

Cylinder Block

Water Pump

Thermostart

Oil Cooler

R a d

EQM4001I

<Fig.1> Cooling Circuit Diagram

Item

1. Water Pump Type Delivery (M/min.) pump Back Pressure

2. Thermostat Opening Temperature Valve Lift Operating Temperature

3. Cooling Fan and Belt Fan Dia.

No. of Blades

Fan Belt Tension

Specification

Centrifugal Approx.190 (At Pump Speed of 2000 rpm)

0.5 bar

79c 8mm or More (At 94c) 79 ~ 94c

528 B6 15mm / Deflection by Thumb

4. Maintenance of Major Components

4.1. Cooling System

4.1.1. General Description

This Engine is of Water-cooled type. Heat generated from combustion chamber and Engine oil is cooled down by coolant, and radiated to the outside, which enables the normal operation of the Engine. When it comes to cooling system, the coolant pumped up by the water pump goes through the oil cooler along the cooling water pipe to absorb the oil heat, flowing through the water jacket of the cylinder block and water passages of the cylinder head to absorb the heat of the combustion chamber. then the coolant moves on to the thermostat through the cooling water pipe, where the coolant returns to the water pump if the coolant temperature is lower than the valve opening temperature of the thermostat, otherwise further circulating to the radiator, where the heat of the coolant is radiated and the cooled coolant again returns to the water pump, completing 1 cycle of cooling system.

<Fig.3> Water Pump Cover Removal

<Fig.4> Water Pump Hub Removal

<Fig.5> Unit Bearing Removal

<Fig. 2> Water Pump Pulley Removal

ENM4001I

ENM4002I

ENM4003I

ENM4004I

- 73 -

4.1.3. Water Pump

1) Disassembly (1) Unscrew the nuts of the pulley, then

remove the pulley.

(2) Loosen the bolts and disassemble

the water pump cover.

(3) Remove the hub by means of a

suitable extractor or press, then remove the snap ring with a plier. (the hub is securely fitted on the shaft of the unit bearing)

(4) Press out the unit bearing from the

housing.

<Fig. 7> Mechanical Seal

<Fig.6> Mechanical Seal Removal

(5) Take out the mechanical seal from

the housing.

(6) Wash clean disassembled parts.

ENM4005I

EJM4016S

2) Inspection (1) Inspect the bearing for wear and scores. turn the bearing with hand to see if

it rotates smoothly without noise.

(2) Replace the bearing with a new one if the radial movement of the shaft exceeds the limit

for use (0.2mm)

(3) Inspect the impeller and shaft for wear, corrosion, bending, and damage.

Pay a special attention to the surface of impeller and seal unit fitting face for wear and corrosion.

3) Reassembly (1) Coat the selant over the periphery of

the mechanical seal and press it onto the housing.

- 74 -

<Fig.9> Snap Ring Inserting

<Fig.10> Impeller

<Fig.11> Impeller Press In

<Fig. 8> Unit Bearing Assembling

(2) Coat the multipurposable grease

over the periphery of unit bearing body and press it into the housing.

(3) Insert the snap ring into the housing

to secure the unit bearing.

(4) Press the impeller into the shaft of

the unit bearing.

ENM4010I

EJM4007S

ENM4008I

ENM4009I

- 75 -

<Fig.13> Water Pump Cover Assembling

<Fig.14> Pulley Perpendicularity Measurement

<Fig.12> Clearance Measurement

(5) Press the hub into the other part of

the shaft of the unit bearing.

(6) Measure the clearance between the

impeller and the housing with a feeler gauge the clearance can be adjusted by a bench press or by a puller when the clearance exceeds the limit for use. (0.35mm)

(7) Coat adhesive on the either side of a

new gasket, and assemble the water pump cover to the housing with the gasket engaged.

(8) Press the pulley into the shaft of the

unit bearing and measure its perpendicularity around the shaft axis. The measured value can be adjusted by a bench press or by a puller when the value exceeds the limit for use. (0.3mm)

ENM4011P

ENM4012I

ENM4013I

- 76 -

<Fig. 15> Thermostat

EAMC002I

<Fig. 16> Thermostat Inspection

EFMC2055I

- 77 -

3) Precautions and Replacement (1) Precautions for handling the thermostat;

The wax-pallet type thermostat does not respond as quickly as bellows type ones do. That is mainly due to its higher heat capacity. Therefore, to avoid a stiff uprise of coolant temperature, it is necessary to have the Engine under idling sufficiently before running it, do not run the Engine at overload or overspeed right after starting-up.

(2) When draining out or replenishing coolant, do it slowly so that the air is bled sufficiently from

the entire cooling system.

(3) Replacement of thermostat;

If the thermostat is found defective, replace it with a new one. It is preferable to replace the thermostat every 50,000~70,000 km run as it varies according to the running condition.

Item Specification

Type Wax-Pallet

Open At (c) 79 (71)

Full Open At (c) 94 (85)

Valve Lift 8mm or More

4.1.4. Thermostat

1) General description and specification The thermostat is designed to maintain a constant temperature of coolant (79 ~ 94c) and enhance the thermal efficiency of the Engine by deterring heat loss. In other words, when the coolant temperature is low, the thermostat is closed to make the coolant bypass to the water pump directly. when the coolant temperature rises to open wide the thermostat valve, the bypass circuit is closed and the water passage to the radiator opens instead so that the coolant is forced to flow into the radiator.

There are 2 kinds of thermostats according to surrounding and operating conditions. One is named by 71c type and the other is 74c.

2) Inspection (1)

Inspect the Wax-pallet and spring for damage.

(2) Check valve lift and valve opening

temperature by submerging the thermostat in the water and increasing the water temperature gradually. Check if the valve lift is 0.1mm at 79c (starting to open) and 8mm at 94c (full open)

Temperature

Bar

Plate

- 78 -

4.1.5. Diagnostics and Troubleshooting

Complaints Possible causes Corrections

1. Engine (1) Lack of coolant (1) Replenish coolant overheating (2) Radiator cap pressure valve spring (2) Replace cap

weakened (3) Fan belt loosened or broken (3) Adjust or replace fan belt (4) Fan belt fouled with oil (4) Replace fan belt (5) Thermostat inoperative (5) Replace thermostat (6) Water pump defective (6) Repair or replace (7) Restrictions in water passages due (7) Clean radiator and water

to deposit of scales passages (8) Injection timing incorrect (8) Adjust injection timing correctly (9) Restriction in radiator core (9) Clean exterior of radiator (10) Gases leaking into water jacket (10) Replace cylinder head gasket

due to broken cylinder head gasket

2. Engine (1) Thermostat inoperative (1) Replace thermostat overcooling (2) Ambient temperature too low (2) Install radiator curtain

3. Lack of (1) Radiator leaky (1) Correct or replace

coolant (2) Radiator hoses loosely connected (2) Retighten clamps or replace hoses

or damaged (3) Radiator cap valve spring weakened (3) Replace cap (4) Water pump leaky (4) Repair or replace (5) Heater hoses loosely connected or (5) Tighten or replace hoses

broken (6) Cylinder head gasket leaky (6) Replace cylinder head gasket (7) Cylinder head or cylinder block (7) Replace cylinder head block

cracked

4. Cooling (1) Water pump bearing defective (1) Replace bearing system (2) Fan loosely fitted or bent (2) Retighten or replace fan noisy (3) Fan out of balance (3) Replace fan

(4) Fan belt defective (4) Replace fan belt

- 79 -

4.2. Lubrication System

4.2.1. General Description

Engine oil pumped up from the oil pan by the gear type oil pump is filtrated through the oil cooler and oil filter, and the filtrated oil is forced to go through the main oil gallery in the cylinder block, from where it is distributed evenly to lubricated the various sliding parts, fuel injection pump, and air compressor in sequence to keep the Engine in normal condition.

4.2.2. Specification and Diagram

Item Specifications Item Specifications

Lubricating System Forced Pressure Oil Filter Type Full-Flow

Circulation

Oil Pump Type Gear Type Bypass for Filter Element

Relief Valve Opening Pressure 10

L1.5 Valve Opening Pressure(kg/cm

) 1.8~2.3

(kg/cm

)

Bypass for Oil Cooler Bypass for Entire Oil Filter

Opening Pressure (kg/cm

) 5+1 Valve Opening Pressure(kg/cm

) 4.0~4.8

Adjusting Valve for Spray Nozzle

Opening Pressure (kg/cm

) 1.5~1.8

1. Oil Pipe (Injection Pump)

2. Oil Pipe (Timing~Idle gear)

3. Oil Pipe (Connecting-Rod Bearing)

4. Oil Pipe

5. Oil Cooler

6. Oil Pump

7. Oil Suction Pipe

8. Oil Filter

9. Strainer

10. Oil Pipe (Air Compressor)

11.

Oil Pipe (Rocker Arm Shaft)

12. Main Oil Gallery

13. Oil Pressure Unit

14.

Oil Pipe (Cam Shaft Bearing)

15. Oil Spray Nozzle (Piston)

16.

Oil Pipe (Crank Shaft Bearing)

17. Oil Pipe (Turbo Charger)

ENM4014S

<Fig.1> Lubrication System

<Fig.3> Pump Cover Disassembling

<Fig.4> End Play Measurement

<Fig.5> Gear Back Lash Measurement

<Fig.2> Drive Gear Disassembling

EAMC004I

EAMC005I

EAMC006I

EAMC007I

- 80 -

4.2.2. Oil Pump

1) Disassembly (1) Unscrew the screw and disassemble

the oil relief valve

(2) Unfold the lock washer and remove

the nut.

(3) Disassemble the oil pump drive gear.

(4) Remove the oil pump cover fixing

nuts and disassemble the oil pump cover. The oil pump cover is secured to the pump housing with two dowel pins.

(5) Remove the pump gears.

2) Measurement and Inspection (1) With a steel rule and a feeler gauge,

measure the axial end play of the oil pump gear. Replace if the measured value exceeds the limit for use.

(2) With the feeler gauge, measure the

back-lash between the driving gear and driven gear in the oil pump housing. Replace if the measured value exceeds the limit for use.

Limit (mm) 0.025 ~ 0.089

Limit (mm) 0.50 ~ 0.64

- 81 -

ENM4015S

<Fig.6> Oil filter

(3) Measure the diameters of driving shaft and driven shaft, and replace if the measured values

are under the limit for use (l16.95mm)

(4) Measure the inner diameter of the pump housing bush to determine the clearance between

the bush and shaft, and compare the measured value with the standard value (0.032 ~

0.077mm) to determine if they are to be replaced or not.

3) Reassembly (1) To reassemble, follow the disassembly procedures in the reverse sequence.

1. Packing

2. Spring

3. Packing

4. Drain Plug

5. Seating Plate

6. Filter Housing

7. Filter Element

8. Center Bolt

9. Packing

10. O-Ring

11. Filter Head

12. Plug Screw

13. Oil Outlet

14. Over Flow Valve

15. Oil Inlet

16. Seating Plate

17. Oil Drain Gallery

18. Valve Seat

19. By-Pass Valve

4.2.3. Oil filter

1) construction

2) Disassembly (1) Drain out the oil by removing the drain plug (2) Remove the oil filter assembly from the Engine (3) Loosen the center bolt and take out the filter element (4) Remove the by-pass valve from the filter head.

3) Inspection (1)

Visually Inspect the filter housing and head for cracks or damage and replace as necessary. (2) Visually check its spring for damage. (Opening pressure of over flow valve for paper filter element : 1.8 ~ 2.3 kg/cm

)

(3) Visually Inspect the full flow by-pass valve

(Opening pressure of by-pass valve : 5.3 ~ 6.3 kg/cm

)

4) Reassembly (1) To reassemble, follow the disassembly procedures in the reverse sequence.

- 82 -

4.2.4. Diagnostics and Troubleshooting

Complaints Possible causes Corrections

Excessive (1) Wrong oil in use (1)

Drain and refill with recommended oil

Oil Consumption (2) Leakage from oil seal or packing (2) Repair or replace

(3)

Piston ring and piston ring groove worn

(3) Replace piston ring or piston (4) Cylinder liner worn (4) Replace Cylinder liner (5) Piston ring sticking (5) Replace pistons and/or piston rings (6) Valve guide oil seal, valve guide, (6) Replace valve guide oil seal,

or valve stem worn valve guide, or valve stem worn

Low (1) Wrong oil in use (1)

Drain and refill with recommended oil

Oil Pressure (2) Relief valve sticking (2) Replace

(3) Strainer clogged (3) Clean strainer (4) Pump gear worn (4) Replace (5) Oil pump defective (5) Repair or Replace (6) Oil pressure gauge defective (6) Repair or Replace (7)

Crankshaft or connecting rod bearings worn

(7) Replace bearings

Quick (1) Clogged oil filter (1) Replace filter element Oil Contamination

(2) Gas leakage (2) Replace piston rings and

cylinder liners

(3) Wrong oil in use (3)

Drain and refill with recommended oil

4.3. Fuel System

4.3.1. General Description

The fuel system is composed of the fuel tank, injection pump, injection nozzle, fuel filter and the certain connecting fuel lines such as pipes and hoses.

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1a1

EAMC009I

<Fig. 1> Fuel System

1. Primary Fuel Filter (Felt Type) 6. Over Flow Valve 1a. Secondary Fuel Filter (Paper Type) 7. Injection Pipe 1b.

Cartridge Fuel Filter

(Equals Both 1 and 1a)

8. Fuel Hose (Feed Pump Filter)

2. Air Bleeding Screw 9. Fuel Tank 2a. Water Drain Screw 10. Fuel Return Line

3. Injection Nozzle 11. Suction Pipe

4. Over Flow Hose 12. Feed Pump

5. Fuel Hose (Filter Injection Pump) 13. Injection Pump

4.3.2. Fuel Injection nozzle

1) General Description The fuel injection nozzle assembly is so designed that pressurized fuel from the injection pump is injected into the combustion chamber with a certain pressure and angle for the normal operation of the Engine.

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EFM1006I

<Fig.2> Nozzle Spray Condition

EFM2054I

<Fig.3> Section View of Injection Nozzle Assembly

2) Construction

1. Nozzle Holder

2. Union Nut

3. Shim

4. Coil Spring

5. Guide Bush

6. Intermediate Washer

7. Nozzle

3) Disassembly

(1) Clamp the nozzle assembly and remove the nozzle holder. (2) Remove the nozzle nut and components inside.

4) Inspection

(1) Visually Inspect the disassembled components for damage.

5) Reassembly

(1) To reassemble, follow the disassembly procedures in the reverse sequence.

6) Nozzle Spray Test

(1) After reassembly, install the nozzle

on a tester.

(2) Operate the hand lever 2 or 3 times

to see if the nozzle is properly set in position.

(3) When the injection pressure deviates

from the specified range. adjust the spring tension by means of the shim. Besides, spray pattern should be uniform and free of spattering.

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EFM2056I

<Fig.4> Nozzle Spray Test

Contents Specification Engine application

Nozzle holder ass’y 65.10101-7050

Nozzle

Nozzle holder

Opening pressure 175 kg/cm

Injection pipe l6.0 B l2.0-600 mm

Fuel dilivery pressure

Fuel temperature 40L5c

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4.3.3. Injection Pump

1) D1146

(1) Main Data and Specification

Part No. : 65.11101-7259(101603-9980) Model : PE6P type Governor : KP-EP/RLD250-1400A1FFL(105931-5901) Timer : KP-EP/SA900-1250B4DR(105644-0520) Plunger : Delivery valve : Feed pump : KP-EP/KE-ADS(105210-5280) Prestrock : Rotation direction

: C.W at driving gear side Injection older : 1-5-3-6-2-4 Injection timing : BTDC 15 L1°

(2) Calibration Data

Adjusting

point

Adjusting point Rack position

Pump speed(rpm)

Injection volume Variation rate

Pressure

(mm3/1,000st) (%) H 9.7 300 8.5 L1.5 A 11.8 700 79.5 L1 B 11.9 1250 84.0 L2 C 11.5 500 65.0 L2

I - 100 115.0 L15

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11.9

11.8

11.55

12.8

7.4

9.7

4.8

10.1

±0.19

100 300 500 700 95 1250 1310 1385

-2.22

±1.10

(3) Adjusting Governor

Rack position(mm)

Pump speed (rpm)

HAM4017I

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2) D1146TI (1) Main Data and Specification

Part No. : 65.11101-7298(101608-9531) Model : PE6P type Governor : KP-RLD2501400A1FXL(105932-2490) Timer : KP-EP/SA700-1100B3DR(105644-0570) Plunger : l=10mm, 20+50 LEAD Delivery valve : Feed pump : KP-EP/KE-ADS(105210-5280) Prestrock : 4.6mm Rotation direction

: C.W at driving gear side Injection older : 1-5-3-6-2-4 Injection timing : BTDC 9 L1°

(2) Calibration Data

Adjusting point Rack position

Pump speed(rpm)

Injection volume Variation rate

Pressure

(mm3/1,000st) (%) H 9.7 300 8.5 L1.5 A 11.9 700 98.5 L1.6 B 12.3 1100 106.5 L2 C 11.7 500 82.0 L2 D 10.5 100 58.7 L2

Adjusting point Rack position

Pump speed(rpm)

Injection volume Variation rate

Pressure

(mm3/1,000st) (%)

10.5 500 - - 100

11.7 500 - - 250

(3) LDA Calibration data

Contents Specification Engine application

Nozzle holder ass’y 65.10101-7293

Nozzle 65.10102-6032

Nozzle holder

Opening pressure 175 kg/cm

214+8 kg/cm

Injection pipe l6.0 B l2.0 -600 mm

Fuel dilivery pressure

Fuel temperature 40L5c

Adjusting

point

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(4) Adjusting Governor

(5) B-COM Calibration

12 .3

300 500 700 1000

Rack position(mm)

Pump speed (rpm)

HNM4018I

11.7

100

250

11.5

11.0

10.5

Rack position(mm)

Boost pressure (mmHg)

HNM4019I

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4.3.4. Diagnostics and Troubleshooting

Complaints Possible Causes Corrections

1. Engine won’t start (1) Fuel pipes clogged or air into pipe line Correct

1) Fuel not being pumped (2) Feed pump valve defective Replace out from feed pump (3) Feed pump piston or push rod sticking Disassemble, correct

2) Fuel not being injected (1) Fuel filter element restricted Clean from injection pump (2) Air in fuel filter or injection pump Bleed

(3) Plunger and/or delivery valve sticking Disassemble, correct

or defective

3) Fuel injection timing (1) Injection pump not properly installed Check, correct incorrect on pump bracket

(2) Injection pump tappet incorrectly Check, correct

adjusted

(3) Cams on cam shaft worn excessively Replace

4) Injection nozzles (1) Needle valves sticking Correct or replace inoperative (2) Fuel leaking past clearance between Correct or replace

nozzle and needle valve

(3) Injection pressure incorrect Adjust

2. Engine starts but (1) Pipe from feed pump to injection pump Clean stalls immediately clogged or filter clogged

(2) Air in fuel Bleed (3) Feed pump delivery insufficient Disassemble, correct (4) Fuel delivery insufficient due to clogging Replace breather

of fuel tank air breather

3. Engine lacks power (1) Plunger worn excessively Replace

(2) Injection timing incorrect Adjust (3) Delivery valves defective Replace (4) Nozzle leaks excessively Correct or replace (5) Nozzle not working normally Disassemble, correct

4. Engine knocking (1) Injection timing too fast Adjust

(2) Nozzle injection pressure too high Adjust (3) Nozzles not working normally Disassemble, correct

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Complaints Possible Causes Corrections

5. Engine knocks (1) Injection timing incorrect Adjust seriously producing (2) Nozzle injection pressure too low Adjust excessive exhaust (3) Nozzle spring broken Replace smoke (4) Nozzle not working normally Replace

(5) Plungers worn excessively Adjust (6) Delively valves seat defective Replace (7) Supply of fuel excessively Check feed pump

6. Engine output (1) Supply of fuel insufficient Check feed pump unstable (2) Air in fuel Bleed

(3) Water in fuel Replace fuel (4) Operation of plungers unsmooth Disassemble, correct (5) Movement of control rack sluggish Disassemble, correct (6) Nozzles defective Disassemble, correct (7) Injection starting pressure of each barrel Adjust

incorrect Disassemble, correct

(8) Automatic timer defective Disassemble, correct

7. Engine does not reach (1) Nozzles not working normally Disassemble, correct maximum speed (2) Governor defective Disassemble, correct

8. Engine idling unstable (1) Movement of control rod sluggish Disassemble, correct

(2) Operation of plungers unsmooth Disassemble, correct (3) Control pinions not engaged with control

rod correctly

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4.4. Preheating system

4.4.1. General Description and Construction

When temperature of intake air is low or Engine is cold, temperature of compressed air is not sufficiently high, making it difficult for the Engine to start up. As a auxiliary device of the Engine, Preheating system is introduced to ease Engine starting, which preheats intake air.

4.4.2. Key Switch

1) Step 1 : After Turning the key switch from “OFF” to “ON” position, check to see whether the preheating lamp is on or off. If the lamp is on, wait until it turns off. (Mechanism) : The heater is automatically preheated if temperature of Engine is low, and the lamp turns off about 20 seconds after its on. When temperature of Engine is sufficiently high, the heater is not being preheated.

2) Step 2 : Turn the key switch from “ON” to “START” position on condition that the preheating lamp be off. (Mechanism) : The heater is still heated for about 30 seconds even after Engine start, which function is for perfect fuel combustion.

1 4

ENM4020I

<Fig.1> Circuit Diagram of Preheating System

“ON”

Temp Switch 15c

“OFF”

Battery DC 24V

Indicator Lamp

Air Heater

Relay

Timer

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4.5. Turbo Charge

4.5.1. General Descriptions

The engine output is determined by the fuel delivery volume and engine efficiency. To burn the supplied fuel completely to change it into effective power for the engine, the volume of air enough to burn the fuel completely should be supplied into the cylinders.

Therefore, the engine output is determined substantially by the cylinder capacity, and the greater volume of compressed air is charged into the cylinders of given capacity, the greater engine output can be obtained as a greater volume of air charged into the cylinders burns so much more fuel.

As explained, the compressing of air to supply into the cylinders is called "Supercharging" and the making use of the energy of exhaust gas discharged from the combustion chamber to charge the compressed air into the cylinders is called "Turbocharging".

4.5.2. Functions

1) Turbine

Exhaust gas discharged from the combustion chamber distributes its own energy to the turbine blades while passing the inside of the turbine housing, with the result that the turbine shaft can get rotating force. This is the working principle of 'turbine', which is mounted with seal rings and heat protector to prevent exhaust gas from affecting the bearings adversely.

2) Compressor

The compressor, which is connected to the turbine over the one and same shaft to form a rotating body, takes in and compresses ambient air with rotating force transmitted from the turbine shaft. Then, the compressed air is delivered to the intake pipe. This is the working principle of the compressor.

3) Bearings

(1) Thrust Bearing

The turbine wheel creates thrust force. Therefore, exercise care so that the shaft is not deviated from its original position due to this thrust.

(2) Journal Bearing

This journal bearing of floating type forms a dual oil film on both the inside and outside of the bearing so that the bearing can rotate independently. As the dual oil film plays a role as a damper, the sliding speed of the bearing surface becomes lower than the rotating speed of the shaft, resulting in assurance of stability in its movement.

4) Sealing-Compressor Shaft

The compressor is of a dual construction type composed of seal plate and seal ring to prevent the leak of compressed air or lubricating oil.

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Item Specifications

Type 1300VQ32NF BRL 557A

Air pressure (at compressor outlet) Approx. 1,23kg/cm

gauge

Air suction volumetric speed Approx. 13.6m

/min

Turbine revolution Approx. 110,000 rpm Maximum speed (allowable) 120,000 rpm Maximum

temperature of exhaust gas at turbine inlet (allowable)

750c Lubrication system External oil supply Weight 10 kg

4.5.3. Specification

At maximum

output

4.5.4. Working Mechanism

Turbine Wheel

Exhaust Gas Outlet

Exhaust Gas Inlet

Compressed Air Outlet

Compressor Wheel

Air-Inlet

EAO5008I

EFM3002I

1. Compressor Housing

2. Turbine Housing

3. Bearing Housing

4. Compressor

5. Turbine A. Air Inlet B. Exhaust Gas Outlet C.Exhaust Gas Inlet D.Oil Inlet E. Oil Outlet

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4.5.5. Construction

23, 24, 25

EAM3002I

1 2 3 4 5 6 7 8

9 10 11 12 13

Part Shaft & Turbine Wheel Ass’y Thrust Bush Oil Thrower Lock Nut Seal Ring; Turbine Side Seal Ring; Large Seal Ring; Small Compressor Wheel Turbine Housing Bolt Clamp Bearing Housing Retaining Ring

No 14 15 16 17 18 19 20 21 22 23 24 25

Part Seal Plate Thrust Bearing Journal Bearing Screw Screw Heat Protector Compressor Housing Clamp Bolt Liquid Gasket Loctite Anti-seize Sealing Liquid

5. Maintenance Specifications

5.1. Torque Values

5.1.1. Major Part Torque Values

5.1.2. Injection Pump System

1) Injection pump delivery valve holder : 2.5 ~ 3kg

2) Nozzle holder fixing cap nut : 7kg

3) Nozzle fixing cap nut : 6~8kg

4) High pressure injection pipe fixing cap nut : Max. 2.9 ~ 3.2kg

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Part Dia.BPitch(mm) Grade Torque Value Remarks

Cylinder Head Bolt M14B1.5 12.9X 24.5 Conn. Rod Bearing Cap Bolt M14B1.5 12.9X 18 Crankshaft Main Bearing Cap Bolt

M16B1.5 12.9X 30 Balance Weight Fixing Bolt M12B1.5 10.9X 10 Flywheel Fixing Bolt M14B1.5 10.9X 21.5 Crankshaft Gear Fixing Bolt M12B1.5 10.9X 13

Daewoo D1146-T-TI Engine Shop Manual Daewoo D1146-T-TI Engine Shop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual