Daewoo DE12, De12, DE12T, DE12TI, DE12TIS Service Manual

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DE12, DE12T &

DE12TI & DE12TIS

DIESEL ENGINE

Shop Manual

65.99892-8030B

Daewoo reserves the righ t to improve our products in a continuing proc ess to provide the best possible product to the mar ket place. These improvements can be implem ented at any time with no obligation t o change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment.

This documentation may include attachments and optional equipment that is not available in your machine’s package. Please call your distributor for additional items that you may require.

Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item.

65.99892-8030B Shop Manual

FOREWORD

This manual has been prepared to help you use and maintain the DE series diesel engines (DE12, DE12T, DE12TI and DE12TIS) safely and correctly.

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

Nonetheless, to obtain the best performance and long life of an engine, it is essential to operate it appropriately and to carry out periodic checks as instructed in this manual. You are requested to thoroughly read this manual from cover to cover and to acquaint yourself with all the information contained in this manual.

All information, illustration and specifications continued in this literature 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.

Please contact Daewoo dealer for the answers to any questions you may have about DE series engine's features, operation or manuals.

CONTENTS

1. General information

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

1.1. Engine characteristics 1.4. Engine performance curve

1.2. Main data and specifications 1.5. Exterior view of engine

1.3. Engine specification(’98 type)

2. Major maintenance

.............................................................................................................. 22

2.1. Preventive maintenance 2.2. Diagnostics and troubleshooting for the engine

3. Disassembly and reassembly of major components

....................................................... 37

3.1. Disassembly 3.3. Reassembly

3.2. Inspection 3.4. Breaking-in

4. Maintenance of major components

.................................................................................... 79

4.1. Cooling system 4.3. Fuel system

4.2. Lubricating system 4.4. Turbocharger

5. Scan pole diagnosis for DE12TIS

..................................................................................... 142

5.1. Wire harness connection 5.4. Sensor data

5.2. System & Vehicle selection 5.5. Actuator test

5.3. Self-diagnosis(current) 5.6. Flight record

6. Maintenance specifications

............................................................................................... 154

6.1. Tightening torque 6.2. Maintenance specification table

WORLDWIDE NETWORK

1. General information

1.1. Engine characteristics

1.1.1. OMEGA combustion bowl

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

Due to the application of OMEGA combustion system and optimal ultilization of intake and exhaust port configuration within the cylinder head, the DE12 series engines discharge a very low level of hazardous exhaust gases such as smoke, nitrogen oxide, hydrocarbon, or carbon monoxide and thus ensure high performance and low fuel consumption.

- 1 -

EA2M1001

<Figure. 1-1> OMEGA combustion bowl

1.1.2. Wastegated turbocharging system

1) What is the wastegated turbocharging system? Turbocharger is a system designed to pressurize the intake air to increase engine output and decrease fuel consumption by using the energy of exhaust gas discharged from the engine. However, the turbocharger has a weak point at low engine speed, its performance may drop, thus performance at low speed is relatively low. The WASTEGATED TURBOCHARGING SYSTEM is an up-to-date turbocharging system remedying such a defect, and the working principle is as follows: A small-sized high performance turbine is used to improve engine performance at low speeds. As high charging efficiency can be obtained even If a small amount of exhaust gas is present at low speed. On the other hand, if higher charging pressure is produced than what is present at high speed, fuel consumption increases. To correct this, part of exhaust gas is forced to be discharged into the exhaust manifold through the waste gate, not through the turbine. The waste gate is controlled by the ACTUATOR mounted in the turbocharger, and if the pressure in the turbocharger becomes higher than what is required for the engine, the waste gate is forced to open.

2) DE12T, DE12TI and DE12TIS engines are featured by the application of turbochager so that the torque in low speeds can be increased by 30% or more, not only to create high performance, just from the time of starting off the vehicle but also to greatly reduce fuel consumption.

- 2 -

Compressed air outlet por

Intake air

Turbine

Turbine port

Exhaust gas outlet port

Waste gate

Compressor

Actuator

EQM1003I

<Figure 1-3> Turbochager

1.2. Main data and specifications

Engine Model DE12 DE12T DE12TI DE12TIS

Type In-line, 4-stroke, vertical type

Combustion chamber type

OMEGA Combustion bowl

Fuel injection Direct injection type

BoreB stroke-No. of cylinders

123mm B 155 - 6

Total displacement 11,051cc

Compression ratio 17.1:1 17.1:1 16.5:1 16.8

Maximum power(PS) 225 ps/2,200 rpm 300 ps/2,200 rpm 340 ps/2,100 rpm

Maximum torque 81.5 kg.m/1,400 rpm 110 kg.m/1,300 rpm 135 kg.m/1,260 rpm

Injection timing 12° BTDC 9° BTDC 12° BTDC 1.0° BTDC

Firing order 1-5-3-6-2-4

Injection pump type S3000 S3000 S3S HD-TICS

Governor type RFD-C/RLD RFD-C RFD-D RLD-J

Timer type SP SP SPG Electronically control

Nozzle type

Multi-hole type(5-N0.29) Multi-hole type(5-N0.31) Multi-hole type(5-N0.33) Multi-hole type(5-N0.29)

Feed pump type K-P K-P K-PS

Valve Timing

Intake valve open at BTDC 18° BTDC 18°

Intake valve close at ABDC 34° ABDC 32°

Exhaust valve open at BBDC 46° BBDC 70°

Exhaust valve close at ATDC 14° ATDC 30°

Oil pump type Gear type

Oil cooler type Water-cooler

Fuel filter type Full flow type

Oil capacity 20M(Oil pan 17M)

Coolant capacity 19M

Thermostat type Wax-pallet

Starter : Voltage-output 24V-6.0Kw

Alternator : Voltage-capacity

24V-45A

- 3 -

1.3. Engine specification(’98 type)

- 4 -

Item DE12-228 DE12TI-280 DE12TI-310 DE12TIS

Manufacturer DHI Mounting location Under Seat Starting type SELF Engine type Diesel 4 Cycle

Turbocharged & Intercooled Cylinder(No. arrangement) In-line, vertical Combustion chamber type Direct injection Valve position OHV Diameter x stroke 123x155 Compression ratio 17.1 16.1 16.8 Comp. pressure(kg/cm2-rpm) 28-200 Average efficient comp.(kg/cm2) 9.27 13.08 14.21 Max. horse power(ps/rpm) 228/2,200 280/2,100 310/2,100 340/2,100 Max. torque(kg•m/rpm) 80/1,400 115/1,260 125/1,260 140/1,260 Firing order 1-5-3-6-2-4 Engine dimension(LxWxH) 1,317x747x1,015 1,317x847x1,064 Dry weight(kg) 872 909 910 Cycle 4 Piston Material AL

Comp. ring 2 Oil ring 1 Open BTDC 18° BTDC 18° Close ABDC 34° ABDC 32° Open BBDC 46° BBDC 70° Close ATDC 14° ATDC 30° Intake 0.3

Exhaust 0.3 Engine speed at no load 550~600 Lubricating Type

Forced pressure type Oil pump type Gear Oil filter type Strainer Oil capacity(M)20 Oil cooler type Water cooled

Intake

Exhaust

No. of piston ring

Valve clearance (cold engine)

Lubricatring

system

In. & Ex. Valve timing

- 5 -

Item DE12-228 DE12TI-280 DE12TI-310 DE12TIS

Turbocharger type -

Exhaust gas driven

Intercooler type - Air cooled

Cooling type

Forced water circulation Coolant capacity 19(engine only) Water pump type Centrifugal Thermostat type Wax pellet

Fuel pump type Plunger Fuel filter type Full flow Fuel injection type Mechanical

Electronic control Type Inline Timing BTDC 8° BTDC 12° BTDC 1.0° Plunger Dia. 12 Cam lift(mm) 11 12 14 Nozzle mounting Flange Nozzle type Multi hole

Orifice

No 5 Dia.(mm) 0.29 0.33 0.29

Inj. pressure(kg/cm2) 220 130/220 163/224

Voltage(V) 24V

Type Electric Voltage(V) - Amp(A) 22-120 Output(V-A) ---Regulator ---Type Reduction Output(kW) 24V-6.0kW Type

Air compression

Cooling

system

Engine

Fuel

system

Electric system

Inj.

pump

system

Inj.

nozzle

Preheat

-ing

system

Alternator

Starter

Ignition

1.4. Engine performance curve

1.4.1. DE12

- 6 -

220

200

180

160

140

120

100

1000 1200 1400 1600 1800 2000 2200 2400

85 80 75

170

160

165

Performance criteria ISO 1585(SAE J1349)

Output(Max.) 235 ps/2,200 rpm Torque(Max.) 81.5 kg.m/1,400 rpm Fuel consumption ratio(min.) 160 g/ps.h

EQM1004I

Revolution(rpm)

Output(ps)

Torque(kg

m)Fuel consumption(g/ps

- 7 -

1.4.2. DE12(’98 type)

220

200

180

160

140

120

100

1000 1200 1400 1600 1800 2000 2200 2400

80 75

165 160

155

Performance ISO 1585(SAE J1349)

Output(Max.) 228 ps/2,200 rpm Torque(Max.) 80 kg.m/1,400 rpm Fuel consumption ratio(min.) 155 g/ps.h

EQM1005I

Revolution(rpm)

Output(ps)

Torque(kg

m)Fuel consumption(g/ps

- 8 -

1.4.3. DE12T

155

160

165

170

90 80

100

110

1 000

1200

1400 1600 1800

2000

2200 2400

120

150

180

210

240

270

300

Performance ISO 1585(SAE J1349)

Output(Max.) 300 ps/2,200 rpm Torque(Max.) 110 kg.m/1,300 rpm Fuel consumption ratio(min.) 155 g/ps.h

EQM1006I

Revolution(rpm)

Output(ps)

Torque(kg

Fuel consumption(g/ps

- 9 -

1.4.4. DE12TI

150

155

160

125 120

130

135

1 000

1200

1400 1600 1800

2000

2200 2400

160

190

220

250

280

310

340

Performance ISO 1585(SAE J1349)

Output(Max.) 340 ps/2,100 rpm Torque(Max.) 135 kg.m/1,260 rpm Fuel consumption ratio(min.) 147 g/ps.h

EQM1007I

Revolution(rpm)

Output(ps)

Torque(kg

Fuel consumption(g/ps

- 10 -

1.4.5. DE12TI(280 ps : ’98 type)

300

220

180

1000 1200 1600 1800 2000 2200 2400

145

150

155

115 105

1400

140

260

Performance ISO 1585(SAE J1349)

Output(Max.) 280 ps/2,100 rpm Torque(Max.) 115 kg.m/1,260 rpm Fuel consumption ratio(min.) 145 g/ps.h

EQM1008I

Revolution(rpm)

Output(ps)

Torque(kg

Fuel consumption(g/ps

- 11 -

1.4.6. DE12TI(310 ps : ’98 type)

320

125 115 105

155 150 145

280

240

200

160

1000 1200 1400 1600 1800 2000 2200 2400

Performance ISO 1585(SAE J1349)

Output(Max.) 310 ps/2,100 rpm Torque(Max.) 125 kg.m/1,260 rpm Fuel consumption ratio(min.) 145 g/ps.h

EQM1009I

Revolution(rpm)

Output(ps)

Torque(kg

Fuel consumption(g/ps

- 12 -

1.4.7. DE12TIS

400

300

100

200

ps kW

350

300

250

200

150

1200 120

1400

N.m

g/kW.h g/ps.h

ISO 1585

kg.m

140

1000

200 190

210

160

150

140

220

100

1000

EA2M1002

2000 22001800160014001200

Revolution(rpm)

Power output(ps)

Fuel consumption(g/ps

Torque(kg

Performance ISO 1585(SAE J1349)

Output(Max.) 340 ps/2,100 rpm Torque(Max.) 140 kg.m/1,260 rpm Fuel consumption ratio(min.) 143 g/ps.h

1.5. Exterior view of engine

1.5.1. DE12- for Bus

- 13 -

17 19 18 13

67920

14 5 1 226 23

25 16 15 3 8

21 12 11 27

2410

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. Cooling water pipe

14. Water pump

15. Exhaust manifold

16. Heat shield

17. Intake manifold

18. Intake stake

19. Injection pipe

20. Injection pump

21. Injection pump bracket

22. Fuel filter

23. Starter

24. Air heater

25. Air compressor

26. Mounting bracket

27. Power steering pump

EQM1010I

- 14 -

1.5.2. DE12- for Truck

610

2251285

EA2M1003

30 17938

22 294121321

272319 142620

1. Cylinder block

2. Flywheel housing

3. Breather

4. Oil filler pipe

5. Vibration damper

6. Flywheel

7. Idle pulley

8. Cylinder head

9. Cylinder head cover

10. Oil filter

11. Oil cooler

12. Oil pan

13. Oil dipstick

14. Cooling water pipe

15. Water pump

16. Cooling fan

17. Exhaust manifold

18. Intake manifold

19. Intake stake

20. Injection pipe

21. Injection pump

22. Injection pump bracket

23. Fuel filter

24. Alternator

25. Starter

26. Air heater

27. Air-conditioning compressor

28. Engine mounting bracket

29. Power steering pump

30. Air compressor

- 15 -

1.5.3. DE12T- for Bus

10 2016 18 13

621

111222 2897

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. Cooling water pipe

14. Water pump

15. Exhaust manifold

16. Intake manifold

17. Heat shield

18. Intake stake

19. Turbocharger

20. Injection pipe

21. Injection pump

22. Injection pump bracket

23. Fuel filter

24. Starter

25. Air heater

26. Air compressor

27. Mounting bracket

28. Power steering pump

EQM1011I

- 16 -

1.5.4. DE12TI(340 ps)- for Bus

10 16 22 17 27 21

67923

25 28 20 18

14 30 2651 2

19 1538

24 12 3111

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. Cooling 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. Air pipe, A/P-I/C

22. Injection pipe

23. Injection pump

24. Injection pump bracket

25. Fuel filter

26. Starter

27. Air heater

28. Air compressor

29. Alternator

30. Mounting bracket

28. Power steering pump

EQM1012I

- 17 -

1.5.5. DE12TI(280 ps : ’98 type)- for Bus

9722

24 27 19 18

14 29 2551 2

1538

12 11 30236

17 1321 26 2016

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. Cooling 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 pipe

22. Injection pump

23. Injection pump bracket

24. Fuel filter

25. Starter

26. Air heater

27. Air compressor

28. Alternator

29. Mounting bracket

30. Power steering pump

EQM1013I

- 18 -

1.5.6. DE12TI(310 ps : ’98 type)- for Bus

10 16 22 17 27 21

67923

25 28 20 18

14 30 2651 2

19 1538

24 12 3111

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. Cooling 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. Air pipe, A/P-I/C

22. Injection pipe

23. Injection pump

24. Injection pump bracket

25. Fuel filter

26. Starter

27. Air heater

28. Air compressor

29. Alternator

30. Mounting bracket

31. Power steering pump

EQM1014I

- 19 -

1.5.7. DE12TI - for Truck

EA2M1004

11 14 28 3119 24 30 20

15 23 34 22 17 1893 8

2134

5 32 1 29 621

3312252610

1. Cylinder block

2. Flywheel housing

3. Breather

4. Oil filler pipe

5. Vibration damper

6. Flywheel

7. Idle pulley

8. Cylinder head

9. Cylinder head cover

10. Oil filter

11. Oil cooler

12. Oil pan

13. Oil dipstick

14. Cooling water pipe

15. Water pump

16. Cooling fan

17. Exhaust manifold

18. Heat screen

19. Intake manifold

20. Intake stake

21. Turbocharger

22. Air pipe, A/C-T/C

23. Air pipe, T/C-I/C

24. Injection pipe

25. Injection pump

26. Injection pump bracket

27. Fuel filter

28. Alternator

29. Starter

30. Air heater

31. Air-conditioning compressor

32. Engine mounting bracket

33. Power steering pump

34. Air compressor

- 20 -

1.5.8. DE12TIS - for Bus

EA2M1005

71 233 31205

1735 22 21 16938

10 2912 12 341325

24 32 19 1426 23 3027 28

1. Cylinder block

2. Flywheel housing

3. Breather

4. Oil filler pipe

5. Vibration damper

6. Flywheel

7. Crank shaft pulley

8. Cylinder head

9. Cylinder head cover

10. Oil filter

11. Oil cooler

12. Oil pan

13. Oil dipstick

14. Cooling water pipe

15. Water pump

16. Exhaust manifold

17. Heat screen

18. Intake manifold

19. Intake stake

20. Turbocharger

21. Air pipe, A/C-T/C

22. Air pipe, T/C-A/P

23. Air pipe, A/P-I/C

24. Injection pipe

25. Injection pump

26. Pick-up sensor

27. Prestroke actuator sensor

28. Rack sensor

29. Injection pump bracket

30. Fuel filter

31. Starter

32. Air heater

33. Engine mounting bracket

34. Power steering pump

35. Air compressor

- 21 -

1.5.9. DE12TIS - for Truck

20 26 27 28 34332419 14

2410

56135 3221

923 37 22 17 18 3 8

29 25 13 12 36

EA2M1006

1. Cylinder block

2. Flywheel housing

3. Breather

4. Oil filler pipe

5. Vibration damper

6. Flywheel

7. Idle pulley

8. Cylinder head

9. Cylinder head cover

10. Oil filter

11. Oil cooler

12. Oil pan

13. Oil dipstick

14. Cooling water pipe

15. Water pump

16. Cooling fan

17. Exhaust manifold

18. Heat screen

19. Intake manifold

20. Intake stake

21. Turbocharger

22. Air pipe, A/C-T/C

23. Air pipe, T/C-I/C

24. Injection pipe

25. Injection pump

26. Pick-up sensor

27. Prestroke actuator sensor

28. Rack sensor

29. Injection pump bracket

30. Fuel filter

31. Alternator

32. Starter

33. Air heater

34. Air-conditioning compressor

35. Engine mounting bracket

36. Power steering pump

37. Air compressor

2. Major maintenance

2.1. Preventive maintenance

2.1.1. Cooling water

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.

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) When the ratio of antifreeze in the mixture decreases new coolant should be 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 : DAC65L

• 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.

If you add antifreeze in excess of 50% in volume, the engine may be overheated. Avoid this. 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.

Antifreeze solution(%) Freezing point(C)

20 -10 27 -15 33 -20 40 -25 44 -30 50 -40

- 22 -

CAUTION

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 air conditioner. (Specified deflection: 10~15mm when pressed down with thumb)

2.1.3. Engine oil

1) Check oil level using the oil dipstick 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. (First oil change : 1,000km running)

• 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

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. Air cleaner

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

2) Clean or replace the element at regular intervals

Engine Model SAE NO. API NO DE12, DE12T,DE12TI 15W40 CD grade or above DE12TIS 15W40 CG grade

- 23 -

2.1.7. 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)

2.1.8. Cylinder compression pressure

1) Stop the engine after warming 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 speed, 200 rpm (10 turns)

2.1.9. 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

- 24 -

Normal Abnormal Abnormal

<Figure 2-1> Nozzle spray patterns

EFM1006I

2.1.10. 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.

2.1.11. 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)

- 25 -

2.2. Diagnostics and trouble shooting for the engine

2.2.1. Diagnostics

- 26 -

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

Replenish or recharge

Normal

Replenish or recharge

Normal

ReplaceNormal

Replenish or recharge

Normal

Overhaul the engine

- 27 -

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

Abnormal

Repair or replace

Normal

Check injection nozzles

Excessive fuel rate

Adjust or repair injection pump

- 28 -

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 pres-

sure, 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

- 29 -

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 recommanded 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 suggested lub. oil

Overhaul the engine

Check oil level

- 30 -

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 position at high speed

3. Frequent use of high gear position 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

Clean or replace

Oil leak

External Internal

Normal

Disassemble cylinder

head(valve stem seal)

Check compression pressureRetighten or replace

Overhaul engine

(piston, cyl. liner)

- 31 -

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

- 32 -

7. Engine knocks(excessive)

Identified

Overhaul engineCheck compression pressure

Check injection timing

Check fuel quality

Use suggested 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)

Not identified

- 33 -

8. Dead or weak battery

Alternator

Check fan belt for

deflection, damage, etc.

Check battery fluid level

Harness, switch

Check wiring connections

for short, 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

- 34 -

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 <2.2.1>) (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

2.2.2. Trouble shooting

- 35 -

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

- 36 -

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) Maintenance operation should be carried out in a bright and clean place.

2) Before disassembly, provide parts racks for storage of various tools and disassembled parts.

3) Arrange the disassembled parts in the disassembly sequence and take care to prevent any damage to them.

3.1.2. Engine oil

1) Take out the oil dipstick.

2) Remove the drain plug from the oil pan and drain out the engine oil into a container.

3) Reassemble the drain plug with the oil pan after draining out the engine oil.

- 37 -

EQM3001I

3.1.3. Cooling water

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

EQM3002I

3.1.4. Fan belt

1) Remove the fan guide and bracket.

2) Loosen the tension adjusting nuts installed on the alternator and air-conditioning compressor, and take off the fan belt.

EQM3003I

3.1.5. Cooling fan

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

- 38 -

EQM3004I

3.1.6. Oil level gauge guide tube

1) Loosen the flange nut installed on the ladder frame to remove the guide tube.

EQM3005I

3.1.7. Alternator

1) Loosen the alternator fixing bolts to disassemble the alternator, then remove the tension adjusting bolt and bracket.

EQM3006I

3.1.8. Air-conditioning compressor

1) Remove the compressor fixing bolts and disassemble the A/C compressor.

2) Disassemble the A/C compressor tension adjusting bolt and alternator fixing bracket.

3) Disassemble the A/C compressor fixing bracket.

EQM3007I

3.1.9. Fuel filter

1) Remove fuel hoses connected to the fuel injection pump, take off the bracket fixing bolts, then disassemble the fuel filter.

3.1.10. Breather

1) Loosen the clamp screw to remove the rubber hose.

- 39 -

EQM3008I

3.1.11. Injection pipe

1) Unscrew the hollow screws to disassemble the fuel return pipe.

2) Remove the nuts installed on the fuel injection pump and nozzles, then disassemble the injection pipe.

EQM3009I

3.1.12. Air heater

1) Remove the electrical wiring for the air heater.

2) Disassemble the intake pipes by loosening the nuts installed thereon.

3) Disassemble the air heater and gasket.

EQM3010I

3.1.13. Intake manifold

1) Remove the air hose connected to the fuel injection pump.

2) Loosen the intake manifold fixing bolts, then disassemble the intake manifold.

EQM3011I

3.1.14. Turbocharger (for DE12T / DE12TI / DE12TIS only)

1) Release the clamp screw of the rubber hose connected to the intake manifold, and take off the intake pipes both simultaneously.

2) Unscrew the exhaust pipe bracket fixing bolts, release the nuts installed on the turbocharger, then disassemble the exhaust pipe.

3) Remove the turbocharger after removing the oil supply pipe and return pipe and releasing the fixing nuts.

3.1.15. Exhaust manifold

1) Release the exhaust manifold fixing bolts, disassemble the exhaust manifold, then remove the heat shield and gasket.

Note : Make sure to release the nuts one

after another because the exhaust manifold will be removed if you unscrew the two nuts simultaneously.

3.1.16. Starter

1) Unscrew the starter fixing bolts, then disassemble the starter.

- 40 -

EQM3012S

EQM3013S

EQM3014I

EQM3015I

3.1.17. Thermostat

1) Remove the by-pass pipe connected to the water pump, unscrew the thermostat fixing bolts, then dissemble the thermostat assembly.

2) Disassemble the thermostat housing and remove the thermostat.

3) Disassemble the water pipe by unscrewing the bolts and nuts installed on the cylinder head.

3.1.18. Fuel injection pump

1) Remove the oil supply pipe and return pipe connected to the fuel injection pump.

2) Unscrew the bolts connecting the coupling and drive shaft, loosen the injection pump attaching bolts, then disassemble the injection pump.

Note : Place the No.1 cylinder in the

exact 'OT' position to disassemble the injection pump.

3) Release the pump fixing bracket bolts to disassemble the bracket from the cylinder block.

Note : Do not interchange the shims as

they must be installed in their original positions at reassembly.

3.1.19. Oil filter

1) Using a filter remover, remove the filter element.

2) Remove the pipe connected to the oil cooler.

3) Loosen the oil filter fixing bolts and disassemble the oil filter head from the cylinder block.

3.1.20. Idle pulley

1) Remove the bolts and disassemble the idle pulley.

- 41 -

EQM3017I

EQM3016I

EQM3018S

EQM3019S

3.1.21. Power steering pump

1) Remove the oil hoses.

2) Unscrew the hex bolts and remove the steering pump.

- 42 -

EQM3020S

3.1.22. Water pump

1) Remove the water pipe connected to the expansion tank

2) Remove the water pipe and hoses connected to the water pump.

3) Unscrew the water pump fixing bolts and remove the water pump.

EQM3021S

3.1.23. Air compressor

1) Remove the oil hose, water pipe, air pipe connected to the air compressor, remove the air cooler fixing bolts, then disassemble the air compressor from the timing gear case.

EQM3022S

3.1.24. Vibration damper

1) Unscrew the pulley fixing bolts and disassemble the pulley-vibration damper assembly.

2) Unscrew the vibration damper fixing bolts and disassemble the damper from the pulley.

EQM3023S

3.1.25. Timing gear case cover

1) Disassemble the oil seal using an oil seal removing jig.

2) Remove the cover fixing bolts and disassemble the cover from the timing gear case.

- 43 -

EQM3024I

3.1.26. Idle gear

1) Unscrew the idle gear fixing bolts and disassemble the thrust washer and idle gear.

2) Disassemble the idle gear pin using a rubber hammer to prevent damage to them.

EQM3025S

3.1.27. Fuel injection pump drive assembly

1) Remove the dowel pin for the steering pump.

2) Unscrew the injection pump drive shaft bearing housing fixing bolts and remove the injection pump drive assembly in which the shaft, gear, bearings, and housing are put together.

EQM3026I

3.1.28. Cylinder head cover

1) Unscrew the cover fixing bolts and disassemble the cover.

2) Keep the bolts in an assembly state so that the packings and washers may not be lost, and keep the cover packing as assembled with the cover.

EQM3027I

3.1.29. Rocker arm assembly

1) Unscrew the rocker arm bracket bolts and remove the rocker arm assembly.

2) Take off the snap rings to remove the washers and rocker arm, then unscrew the bracket fixing bolts to take off the bracket and springs.

3) Take out the push rods.

- 44 -

EQM3028I

3.1.30. Injection nozzle

1) Remove the nozzle fixing nuts and extract the nozzles.

2) Remove the nozzle tube using nozzle tube removing jig.

Do not perform disassembly operation unless coolant, gas, etc. leak out.

EQM3029I

3.1.31. Cylinder head

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

2) Remove the cylinder head gasket.

EQM3030I

3.1.32. Valve and valve stem seal

1) Compress the valve spring retainer using a jig and take off the valve cotter pin.

2) Disassemble the valve springs and retainer.

3) Take off the valve.

4) Remove and discard the valve stem seal using a general tool as it should not be re-used.

EJM3027S

Compress the spring

3.1.33. Oil cooler

1) Remove the water pipe connected to the water pump.

2) Unscrew the oil cooler cover fixing bolts and disassemble the oil cooler assembly from the cylinder block.

3) Unscrew the oil cooler fixing bolts and remove the oil cooler from the oil cooler cover.

3.1.34. Oil pan

1) Stand the engine with the flywheel housing facing toward the bottom.

2) Release the oil pan fixing bolts, remove the stiffeners, then disassemble the oil pan.

- 45 -

EQM3031I

EQM3032I

3.1.35. Oil pump and oil pipe

1) Unscrew the oil inlet pipe bracket bolts, releasing the pipe fixing bolts, then disassemble the oil suction pipe assembly.

2) Disassemble the oil pipe feeding oil from the oil pump to the cylinder block.

3) Unscrew the oil pump fixing bolts and disassemble the oil pump.

EQM3033I

3.1.36. Ladder frame

1) Disassemble the ladder frame.

EQM3034I

3.1.37. Piston and connection rod

1) Disassemble the pistons by two hands while turning the crankshaft.

2) Unscrew the conn. rod fixing bolts and take off the pistons and conn. rods in the direction of piston.

- 46 -

EQM3035I

3) Remove the piston pin snap rings, take off the piston pin, then disconnect the conn. rod from the piston.

EQM3036S

4) Disassemble the piston rings using ring pliers.

5) Take care not to interchange the disassembled parts and keep them in the sequence of cylinder No.

EQM3037S

3.1.38. Cylinder liner

1) Take off the cylinder liner.

EQM3038I

Piston ring jig

3.1.39. Flywheel

1) Position the engine so that the head installing surface of the cylinder block faces down.

2) Unscrew the flywheel fixing bolts and fit a dowel pin.

3) Install flywheel disassembling bolts in the bolt holes machined on the flywheel, and disassemble the flywheel.

3.1.40. Oil seal

1) Take off the rear oil seal using an oil seal disassembling jig.

2) If only the inside guide ring is removed, use a general tool to take off the outside seal.

- 47 -

EQM3039I

EQM3040I

3.1.41. Flywheel housing

1) Loosen the housing fixing bolts and disassemble the flywheel housing.

EQM3041I

3.1.42. Cam shaft and tappet

1) Remove the cam shaft gear.

2) Take off the cam shaft gear thrust washer.

3) Take out the cam shaft carefully not to damage the cam shaft.

4) Slide out the tappets by hand.

EQM3042I

3.1.43. Crankshaft gear and oil pump idle gear

1) Loosen the socket head bolts and take out the oil pump idle gear.

2) Use a puller to remove the crankshaft gear.

- 48 -

EQM3043S

3.1.44. Timing gear case

1) Unscrew the case fixing bolts and disassemble the timing gear case.

EQM3044I

3.1.45. Crankshaft

1) Unscrew the main bearing cap fixing bolts and remove the bearing cap.

2) Take off the crankshaft.

3) Take off the main bearing.

EQM3045S

3.1.46. Oil spray nozzle

1) Remove the oil spray nozzles.

EQM3046S

Puller

3.2. Inspection

3.2.1. Cylinder block

1) Clean the cylinder block thoroughly and make a visual inspection for cracks or damage.

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

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

4) Make a hydraulic test to check for any cracks or air leaks. (Hydraulic test) : Stop up each outlet port of water/oil passages in the cylinder block, apply air pressure of about 4kg/cm

against the inlet ports, then immerse the cylinder block in water for about 1

minute to check any leaks. (Water temperature: 70

3.2.2. Cylinder head

1) Check the cylinder head for cracks or damage. (1) Carefully remove carbon from the lower face of the cylinder head using nonmetallic mate-

rial to prevent scratching of the valve seat faces.

(2) Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight

using a hydraulic tester or a magnetic flaw detector.

2) Check the lower face of the cylinder head for distortion. (1) Measure the amount of distortion

using a straight edge and a feeler gauge at six positions as shown in the figure right.

(2) If the measured value exceeds the

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

(3) If the measured value exceeds the

maximum allowable limit(0.3mm), replace the cylinder head.

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

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

- 49 -

C D

EQM3047I

<Figure 3-1> Measuring cylinder head

distortion

3.2.3. Valve and valve guide

1) Inspecting the valve

Clean the valves with clean diesel oil, then inspect them as follows: (1) Measure the valve stem outer diam-

eter at 3 positions(top, middle, and bottom). If the amount of wear is beyond the limit(0.18mm), replace the valve.

(2) Check the valve seat contacting

faces for scratches or wear, and correct the faces with grinding paper as necessary. Replace if severely damaged.

(3) Measure the valve head thickness,

and replace the valve if the measured value is 1mm or less(a).

Dimensions

Standard Limit

Descriptions Intake valve

N10.950~10.970 10.87

stem (mm) Exhaust valve

N10.935~10.955 10.84

stem (mm)

2) Inspection and measurement of valve guide (1) Install the valve into the valve guide and measure the clearance between them by valve

movement. If the clearance is excessive, measure the valve and replace either the valve or the valve guide, whichever worn more.

(2) Install the valve into the cylinder head valve guide, then check and see if it is centered with

the valve seat using a special tool.

- 50 -

END OF STEM

EFM2036I

<Figure 3-2> Measuring valve stem

EQM3048I

<Fig. 3-3> Measuring thickness of valve head

3) Inspection and correction of valve seat (1) Measure the contacting face

between the intake valve seat and exhaust valve seat for valve seat wear, and replace if the measured value exceeds the specified limit.

(2) Install the valve into the valve seat on

the cylinder head, and check the amount of depression of the valve from the lower portion of the cylinder head using a dial gauge. If the amount of depression is beyond the specified limit, replace the valve seat.

(3) For removal of the valve seat, apply arc welding work to two points of valve seat insert,

and pull out valve seat insert with inner extractor.

(4) Undercool a new valve seat with dry ice for about 2 hours and press the valve seat insert

into position in the cylinder head using a special tool(bench press).

(5) Apply valve lapping compound to the valve head seating face on the valve seat and lap

the valve seat by turning it until it is seated in position, then wipe out the lapping compound.

- 51 -

EQM3049I

4) Inspection and correction of valve spring (1) Visually check the exterior of the

valve springs for damage, and replace if necessary.

(2) Measure free length and spring ten-

sion with a valve spring tester.

(3) Measure the spring inclination with a

square.

(4) Compare the measured value with

the standard value to determine whether to replace or repair.

1mm or less

Free length

Square

EFM2039I

<Figure 3-4> Measuring spring tension and

inclination

-0.3~0

3.2.4. Rocker arm shaft assembly

1) Measurement of rocker arm shaft

(1) Place the rocker arm shaft on two V-

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

(2) With an outside micrometer, measure the rocker arm shaft diameter at the point where

the rocker arms have been installed. Replace the rocker arm if the amount of wear is beyond the specified limit.

2) Inspection of rocker arm (1) Visually check the face of the rocker arm in contact with the valve stem end for scores

and step wear. If the wear is small, correct it with an oil stone or grinding paper of fine grain size. Rocker arm with a considerable amount of step wear should be replaced.

(2) Measure the inside diameter of the rocker arm bushing with an inside micrometer or

vernier calipers, and compare the measured values with the rocker arm shaft diameter. If the clearance exceeds the limit, replace either bushing or shaft, whichever worn more.

- 52 -

EDM2037I

<Figure 3-5> Measuring run-out of rocker arm

shaft

3) Inspection of tappet and push rod (1) Measure the outer diameter of the

tappets with an outside micrometer. If the amount of wear is beyond the specified limit, replace tappets.

(2) Visually check the face of the tappets

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

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

(4) Abnormal

EFM2041I

<Figure 3-6> Inspecting tappet face

(3) Support the push rod on two V-

blocks and check for bend using a feeler gauge.

EDM2037I

<Figure 3-7> Measuring push rod run-out

3.2.5. Cam shaft

1) Inspection of cam (1) Measure the cam height with a

micrometer and replace the camshaft if the measured value is beyond the specified limit.

(2) Inspect the cam face for scratch or

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

- 53 -

EDM2045I

<Figure 3-8> Measuring cam height

2) Inspection of cam shaft (1) With an outside micrometer, mea-

sure the camshaft journal diameter.

(2) Measure the inside diameter of the

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

(3) Replace the bushing if the measured

value is beyond the specified limit.

(4) Support the cam shaft on two V-

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

EAOM4063

<Figure 3-9> Measuring inside diameter of

cam shaft bushing on cylinder block

EFM2046I

<Figure 3-10> Measuring cam shaft run-out

3) Cam shaft end play (1) Push the thrust plate toward the cam

gear.

(2) With a feeler gauge, measure the

clearance between the thrust plate and cam shaft journal.

(3) If the end play is excessive, replace

the thrust plate.

EAOM4067

<Figure 3-11> Measuring cam shaft axial play

Cam bushing

3.2.6. Crank shaft

1) Inspection for scores or cracks (1) Visually check the crank shaft journal and crank pins for scores or cracks. (2) Using a magnetic power and color check, inspect the crank shaft for cracks, and replace

the crank shaft which has cracks.

2) Checking crank shaft for wear (1) With an outside micrometer, measure the diameter of the crank shaft journals and pins in

the directions as shown, and compare the measured values to determine the amount of wear.

(2) If the amount of wear is beyond the limit, have the crank shaft ground and install under-

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

•Undersize bearings available

(1) Standard (2) 0.25 (Inside diameter is 0.25mm

lesser than the standard size.)

(3) 0.50 (Inside diameter is 0.50mm

lesser than the standard size.)

(4) 0.75 (Inside diameter is 0.75mm

lesser than the standard size.)

(5) 1.00 (Inside diameter is 1.00mm

lesser than the standard size.)

Undersize bearings are available in 4 different sizes as indicated above, and the crankshaft can be reground to the above sizes.

- 54 -

B B

EFM2047I

<Figure 3-12> Measuring crank shaft outer

diameter

Note : When regrinding the crank

shaft as described above, the fillet section 'R' should be finished correctly. Avoid sharp corners or insufficient fillet.

Standard values of 'R'

Crankshaft pin 'R' : 4.5 Crankshaft journal 'R' : 4

" R "

Right Wrong Wrong

" R " " R "

EFM2048I

<Figure 3-13> The shape of crankshaft 'R'

1 2

“R”

3) Measurement of crankshaft run-out (1) Support the crankshaft on V-blocks. (2) Turn the crankshaft with a dial indi-

cator placed on the surface plate and take the amount of crank shaft runout.

- 55 -

EDM2040S

<Figure 3-14> Measuring crank shaft run-out

EDM2041S

<Figure 3-15> Measuring crank shaft outer

diameter

3.2.7. Crank shaft bearing and connecting rod bearing

1) Visually check the crank shaft bearing and connecting rod bearing for scores, uneven wear or damage.

2) Check oil clearance between crankshaft and bearing. (1) Install the main bearing in the cylin-

der block, tighten the bearing cap to specified torque, then measure the inside diameter.

(2) Install the connecting rod bearing in

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

EDM2042S

EQM3050S

<Figure 3-16> Measuring main bearing inside

diameter

(3) Compare the two values obtained

through measurement of bearing inside diameter with the outside diameters of crankshaft journals and pins to determine the oil clearance.

(4) If the clearance deviates from the

specified range, have the crankshaft journals and pins ground and install undersize bearings.

- 56 -

EDM2044I

<Figure 3-17> Measuring conn. rod bearing

inside diameter

3) Inspection of bearing spread and crush (1) Check to see that the bearing

requires a considerable amount of finger pressure at reassembly operation.

(2) With a bearing crush aligner, mea-

sure bearing crush.

•Standard bearing crush

Crank shaft bearing crush(mm)

0.15~0.25

Conn. rod bearing crush(mm)

0.3~0.5

EDM2046S

<Figure 3-18> Checking bearing tension

<Figure 3-19> Bearing and cylinder block

O A

Spread = O A - O B

O B

EDM2047I

EDM2048I

<Figure 3-20> Measuring main bearing crush

(3) Conn. rod bearing crush can be

checked as follows: Install the bearing and cap in the conn. rod big end, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and conn. rod big end using a feeler gauge.

- 57 -

EDM2049I

<Figure 3-21> Conn. rod bearing crush

4) Measurement of crank shaft end play (1) Assemble the crankshaft to the cylin-

der block.

(2) With a dial gauge, measure crank

shaft end play.

EPM2018S

<Figure 3-22> Measuring crankshaft end play

3.2.8. Piston

1) Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring groove.

2) Measurement of the clearance between the piston and cylinder liner. (1) With an outside micrometer, mea-

sure the piston outside diameter at a point 18mm away from the lower end of piston skirt in a direction at a right angle to the piston pin hole.

EQM3051S

<Figure 3-23> Measuring piston outside

diameter

<Figure 3-24> Measuring cylinder liner inside

diameter

(2) Using a cylinder bore gauge, mea-

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

EQM3052I

Position of measuring

outside diameter

(3) The clearance is computed by sub-

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

3.2.9. Piston rings

1) Replace the piston rings with new ones if detected worn or broken when the engine is overhauled.

2) Measure piston ring gap. (1) Insert the piston ring into the upper

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

(2) Measure the piston ring gap with a

feeler gauge.

(3) Replace piston rings with new ones if

the gap is beyond the limit.

3) Measure piston ring side clearance. (1) Fit the compression ring and oil ring

in the piston ring groove.

(2) With a feeler gauge, measure side

clearance of each ring, and replace either the ring or piston if the measured value is beyond the specified limit.

Dimensions

Standard(mm) Limit(mm)

Descriptions

Top ring 0.40~0.65 1.5 2nd ring 0.40~0.65 1.5

Oil ring 0.30~0.60 1.5

Liner Standard Limit

Cylinder line

inside diameter l123

+0.005

123.225

(mm)

-0.015

- 58 -

EFM2053I

<Figure 3-25> Measuring piston ring gap

4) With a tension tester, measure piston ring tension. Replace the piston ring if the measured value is beyond the limit.

3.2.10. Piston pin

1) Measure the amount of wear on the piston pin (1) Measure the amount of wear on the

piston pin at the points as shown. The measured values are beyond the limit(0.005mm or greater), replace the pin.

(2) Measure the clearance between the

piston pin and conn. rod bushing, and replace either of them, which ever damaged more, if the measured value is beyond the limit(0.011mm).

2) Check the engaged condition of the piston and piston pin. If it is possible to force the pin into the piston heated with piston heater, the piston is normal. When replacing the piston, be sure to replace the piston pin together.

Dimensions

Standard(mm) Limit(mm)

Descriptions

Top ring 2nd ring 0.07~0.102 0.15

Oil ring 0.05~0.085 0.15

- 59 -

A (A) (B) (C)

EDM2058I

<Figure 3-26> Measuring piston pin

3.2.11. Connecting rod

1) Check the connecting rod for distortion. As shown in the figure right, install the conn. rod to the conn. rod tester, and check for distortion using a feeler gauge. If the conn. rod is found distorted, never re-use it and replace it with a new one.

2) Measure the alignment of the conn. rod piston ring bushing holes with conn. rod big end holes. At this time also, use both conn. rod tester and feeler gauge.

3) Inspection of the amount of wear on the conn. rod big end and small end

(1) Assemble the conn. rod to the crank

shaft and measure conn. rod big end side clearance using a feeler gauge.

(2) Assemble the conn. rod to the piston

and measure conn. rod small end side clearance.

(3) If the measured values are beyond

the limit(0.5mm), replace the connecting rod.

- 60 -

EJM2087I

<Figure 3-27> Measuring alignment of

conn. rod

3.2.12. Tappet

1) Check the tappets for cracks, scores, or damage.

2) With an outside micrometer, measure the tappet outside diameter. If the measured value is beyond the limit, replace tappets.

EDM2061I

<Figure 3-28> Measuring tappet outside

diameter

3.3.3. Oil spray nozzle

1) Tighten and assemble the oil spray nozzle flange with fixing bolts.

- 61 -

EQM3053I

3.3.4. Tappet and cam shaft

1) Undercool a new bush with dry ice for about 2 hours and press it into position in the cylinder block using a bench press. After the pressing operation, measure the inside diameter of the cam bush to check if it is not deformed.

2) Apply engine oil to the entire face of the tappets and slide them into the tappet holes on the cylinder block.

EDM2059S

3.3. Reassembly

3.3.1. General precautions

1) Wash clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions.

2) Arrange the general and special tools for engine assembly operation.

3) To wet each sliding part, prepare clean engine oil.

4) Prepare service materials such as sealant, etc.

5) Discard used gaskets, seal rings, and consumable parts, and replace with new ones.

6) Apply only the specified torque for bolts in the specified tightening order and avoid over-tightening.

7) Be sure to check that all the engine parts operate smoothly after being reassembled.

8) Check the bolts for looseness after preliminary reassembly.

9) After completing the engine reassembly operation, check if there is missing parts or shortage of parts.

10) Keep your hands clean during the working

3.3.2. Cylinder block

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

3) Wet the cam bush inside diameter and cam shaft with oil, and carefully assemble them while turning the cam shaft.

4) Check to see that the cam shaft rotates smoothly.

- 62 -

EDM2060I

3.3.5. Crank shaft

1) Install the main bearing machined with two holes in the cylinder block so that the key is aligned with the key groove, then apply oil to the bearing surface.

2) Apply sealant in the inside wall of the crank shaft gear evenly before placing over the shaft

3) Semi-tighten a bolt at both sides of the crank shaft, apply engine oil to journals and pins, then assemble the crank shaft with the cylinder block by tightening the fixing bolts.

4) Install the oiled thrust washers with the oil groove facing outward.

EQM3054S

EQM3055S

EQM3056S

Oil port and passage

Key groove

5) Install the bearing and thrust washers to the bearing cap and apply oil to the bearing and thrust washers.

- 63 -

EQM3057I

6) Install the bearing cap by matching the cylinder block No. with the bearing cap No.

7) Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque(30kg

•

m).

8) After semi-tightening both bolts evenly, tighten them diagonally to about 15kg

•

for the first stage and 25kg

•

m for the second stage respectively, then tighten them completely to the specified torque using a torque wrench.

9) Tighten the bearing cap in the sequence of 4-3-5-2-6-1-7.

10) Check to see that the assembled crank shaft turns smoothly.

EQM3058I

EQM3059I

3.3.6. Flywheel housing

1) Temporarily install the guide bar on the cylinder block.

2) Apply gasket to the cylinder block.

3) Using the dowel pin and guide bar, install the flywheel housing and tighten the fixing bolts in a diagonal sequence to specified torque(12kg°m)

EQM3060I

3.3.7. Rear oil seal

1) Apply lubricating oil to the outside of the oil seal and flywheel inside diameter and fit them over the crank shaft, then assemble the oil seal using an oil seal fitting jig.

- 64 -

EQM3061I

3.3.8. Flywheel

1) Install a guide bar into a bolt hole on the crank shaft, and lift the flywheel to align the dowel pin with the pin hole on the flywheel for temporary assembly operation.

2) Install bolts in the remaining holes with no guide bar installed, take out the guide bar, then install a bolt in the hole where the guide bar had been inserted.

3) Tighten the fixing bolts using a torque wrench in a diagonal sequence to specified torque(18kg•m).

EQM3062I

4 8

1 5

EQM3063I

3.3.9. Timing gear case

1) Mount gasket using dowel pin.

2) Install the timing gear case by aligning the dowel pin with the dowel pin hole on the timing gear case.

EQM3064I

3.3.10. Fuel injection pump drive gear assembly

1) Mount gasket by aligning the bolt holes with the pin holes on the bearing housing.

2) Tighten up the fixing bolts in the direction of fuel injection pump.

- 65 -

EQM3065I

3.3.11. Timing gear

1) Install the oil pump idle gear onto the No. 7 bearing cap.

2) Install a thrust washer over the cam shaft and assemble the cam gear by aligning it with cam shaft key groove.

3) With the oil port on the idle gear pin facing the cylinder head, install the idle gear pin.

4) Install the idle gear by coinciding the marks impressioned on the crank gear, cam gear, fuel injection pump drive gear, and idle gear.

5) Install a thrust washer on the idle gear and tighten to specified torque (6.2kg

•

m).

6) Check and adjust the amount of backlash between gears using a feeler gauge. (backlash : 0.1~0.2)

EQM3066I

Fuel injection pump drive gear

Idle gear

Cam gear

Crank gear

EDM2075I

3.3.12. Timing gear case cover

1) Install dowel pin on the timing gear case.

2) Mount a gasket by aligning the fixing bolt holes with those on the gasket.

3) Align the dowel pin with the cover pin hole, then install the cover with a light tap.

4) Tighten the fixing bolts beginning with the oil pan fitting face.

EQM3067S

3.3.13. Front oil seal

1) Apply lubricating oil to the outside of the oil seal and timing gear case inside diameter and fit them over the crank shaft, then assemble the oil seal using an oil seal fitting jig.

- 66 -

EQM3068I

3.3.14. Cylinder liner

1) Stand the cylinder block so that the flywheel faces downward.

2) Thoroughly clean the liner flange fitting surface and bore inside with compressed air to prevent the entry of foreign substances.

3) After the cleaning operation, make the cylinder liner dried up and push it into the cylinder block by hand.

4) Wet the liner inside diameter with engine oil.

EQM3069I

3.3.15. Piston and connecting rod

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

2) Noting the direction of the piston, make the longer side(machined with key groove on the bearing) of the conn. rod big end and the mark of ' ' impressioned on the inside of the piston face each other in opposite directions. On the piston head surface, the longer side of conn. rod big end is in opposite direction from the valve seating surface as well as in the same direction with the narrow margin of combustion chamber.

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

EDM2057I

106

EQM3070I

4) Install the piston ring in the piston using piston ring pliers.

5) Identify the mark "Y" or "TOP" on the ring end to prevent the top and bottom of the piston ring from being interchanged and make the marked portion face upward.

- 67 -

EQM3071I

6) Adjust the angle among individual piston ring gaps to 120° and fit a piston assembling jig onto the piston. Use care not to match the ring gaps with the pin direction.

7) Install the bearing by aligning it with the conn. rod key groove and apply oil to the bearing and piston.

Top ring gear

Piston pin

Oil ring gear 2nd ring gear

Piston

120

EFM2069I

8) Position the valve seating surface toward the tappet hole and insert the piston with hand. Take care not to damage the cylinder liner and piston, and slightly lift and insert the piston into the cylinder so that the ring may not be damaged by the fillet of the liner.

EDM2080I

9) Install the bearing in the conn. rod cap and apply oil.

10) Make sure that the manufacture numbers impressioned on the conn. rod cap and conn. rod big end are identical, and install the conn. rod cap by aligning it with dowel pin.

11) Wet the fixing bolts with oil, semi-tighten them with hand, tighten them to 15kg

•

for 1st stage and 22kg

•

m for 2nd stage respectively, and finally to specified torque(28kg•m).

EQM3072S

Marked with the name of piston ring manufacturing company

12) Move the bearing cap with hand, and release and reassemble it if no movement is detected.

- 68 -

EQM3073I

3.3.16. Ladder frame

1) Cut out the gasket protruding from the joints of the timing gear case, case cover, and flywheel housing.

2) Apply silicon to each joint and attach gasket to the cylinder block.

3) Tighten fixing bolts at both ends, intermediate bolts, and remaining bolts in the described order.

EQM3074I

3.3.17. Oil pump and oil pipe

1) Install a dowel pin in the No.7 bearing cap, mount gasket, then assemble the oil pump.

2) Install the fixing bolts and bend the fixing washers to prevent looseness of bolts.

3) Assemble the oil suction pipe with the delivery pipe, then install the bracket on the ladder frame.

EQM3075I

3.3.18. Oil pan

1) Mount gasket and put the oil pan thereon.

2) Place stiffeners and tighten bolts.

3) Align the bolt holes with gasket holes to prevent damage to the gasket and tighten to specified torque(2.2kg

•

m).

EQM3076I

3.3.19. Intake and exhaust valves

1) Identify the marks of "IN" and "EX" impressioned on the valve head before assembling the valve with the valve head.

2) With a valve stem seal fitting jig, assemble the valve stem seal with the valve guide.

- 69 -

EJM2040S

3) After installing valve springs and spring retainer, press the retainer with a jig, then install cotter pin.

4) Tap the valve stem lightly with a rubber hammer to check that the valve is assembled correctly.

EJM2027S

3.3.20. Nozzle tube

1) Apply sealant (LOCTITE 620) to the nozzle tube and place the O-ring over the cylinder head fitting face on the nozzle tube, then install the nozzle tube in the cylinder head.

2) Install a nozzle tube pressing tool into the cylinder head, then tighten the nozzle fixing nuts.

3) Apply engine oil to an expander and install it onto the special tool.

4) Tighten the bolts until the expander is forced out of the cylinder head bottom.

5) After mounting the nozzle tube, make a hydraulic test to check for water leaks. (Test pressure: 2kg/cm

)

EQM3077I

EQM3078I

Jig

Compress the spring

3.3.21. Rocker arm assembly

1) Apply lubricating oil to the rocker arm bush and shaft, and assemble the intermediate bracket with the rocker arm using fixing bolts.

2) Semi-install valve clearance adjusting bolts onto the rocker arm.

3) Install the washer, rocker arm, spring, rocker arm, washer, bracket, spring, washer, and snap ring in the described sequence.

4) Install the rocker arm and bracket in the same direction.

- 70 -

EQM3079I

3.3.22. Cylinder head

1) Install the injection nozzle fixing stud bolts and water pipe fixing stud bolts.

2) Clean the head bolt holes on the cylinder block with compressed air to remove foreign substances and thoroughly clean the gasket fitting face of the cylinder block.

3) Install head gasket, with 'TOP' mark facing upward, on the cylinder block by aligning the holes with dowels.

4) Check the inside of combustion chamber for foreign substances, and carefully mount the cylinder head assembly in the block by aligning the dowel pin with the dowel pin hole. Be careful not to damage the head gasket. If the dowel pin is not in alignment, lift the cylinder head again and then re-mount it.

5) Coat the head bolts with engine oil, then tighten them in proper sequence to the specified torque(24.5kg

•

m).

TOP

EQM3080I

EQM3081I

6) Coat the push rod with engine oil and insert it into the push rod hole.

7) Mount the rocker arm assembly on the cylinder head and tighten the rocker arm bracket fixing bolts to specified torque(4.4kg•m).

8) Adjust the valve clearance.

•

Guide for valve clearance adjustment

- Place No. 1 piston in the "OT" position

and adjust valve clearance at six positions as shown in th right-hand figure. At this time, the intake and exhaust valves of No. 6 cylinder are in an overlapped state.

- Turn the crank 360 degrees to bring the

No. 6 piston in the "OT" position, then adjust the remaining valve clearance.

- Determine the sequence of the cylinders

and intake/exhaust valves beginning with the flywheel housing size.

- Intake valve clearance : 0.3mm

- Exhaust valve clearance : 0.3mm

9) Adjust valve clearance with a feeler gauge and tighten the fixing nuts to specified torque(4.4kg

•

m).

- 71 -

EQM3082I

654321

EA2O2001

EDM1003S

EQM3083I

<Tightening sequence of cylinder head fixing

bolts>

ENGINE TOP VIEW

•

Cylinder No.

123456

IN EX IN EX IN EX IN EX IN EX IN EX

No. 1 TDC No. 6 TDC

Adjusting valve

3.3.23. Injection nozzle

1) Install the dust seal with its round portion facing downward.

2) Mount a seal ring(0.5mm) on the seal ring seating surface of the nozzle tube and assemble it with the stud bolt with the nozzle pipe installing direction facing outward.

3) Be sure to follow the specified torque (1.0kg•m).

Flywheel housing side

Cooling fan side

3.3.24. Water pipe and thermostat

1) Install the water pipe onto the cylinder head.

2) Install the thermostat in the housing.

3) With socket head bolts, install the thermostat housing onto the water pipe.

- 72 -

EQM3084I

3.3.25. Oil cooler

1) Install the oil cooler onto the oil cooler cover. Carefully apply the gasket to prevent oil leakage.

2) Do not damage the gasket and install the cover onto the cylinder block.

3) Connect a connection pipe between the water pump and oil cooler.

EQM3018S

3.3.26. Oil filter

1) With the hollow screw, assemble the oil pipe connected between the oil cooler and cylinder block.

2) Install a connection pipe between the oil cooler and oil filter.

3) Install the oil cooler connecting pipe.

4) Install packing and assemble the oil filter using a filter assembling wrench.

EQM3018S

3.3.27. Injection pump

1) Install the fuel injection pump bracket in the cylinder block.

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

3) Mount the top/bottom adjusting shims in the bracket and then mount the fuel injection pump.

EQM3087I

4) Tighten the fixing bolts in a diagonal sequence to specified torque (4.4kg

•

m).

5) Turn the flywaheel until No. 1 piston is placed in the "OT" position, and then turn again the flywheel clockwise until, of notch marks on the flywheel, the notch mark under the figure corresponding to the injection timing is aligned with the pointer( ) on the flywheel housing.

6) Turn the timer until the notch mark of the indicator plate attached to the fuel injection pump is aligned with the notch mark of the timer.

- 73 -

EQM3088I

EQM3089S

7) Tighten the coupling fixing bolts and nuts to specified torque(6.0kg•m).

8) Tighten the drive shaft connecting flange fixing bolts to specified torque(7.5~8.5kg•m).

9) Install the oil delivery pipe and return pipe.

10) At the same time, install the oil delivery pipe which feeds oil to the air compressor.

EQM3090I

3.3.28. Power steering pump

1) Mount gasket, align the dowel pin with the pin hole, then assemble the power steering pump by using hammer not to damage the gears .

EQM3091S

Injection timing notch mark

Flywheel

Flywheel ring gear

3.3.29. Vibration damper and pulley

1) Install the vibration damper on the crank shaft pulley.

2) Install the crank shaft pulley assembly on the crank shaft, then tighten the bolts and thrust washers. (bolt tightening torque : 13.4kg

•

- 74 -

EQM3092S

3.3.30. Idle pulley

1) Install the idle pulley onto the timing gear case cover.

EQM3093S

3.3.31. Air compressor

1) Mount gasket and assemble the air compressor assembly with care to prevent damage.

2) Using hollow screw, assemble the oil delivery pipe with the adaptor.

3) Install water hoses to the water pump.

4) Connect the air hoses and pipes to the air compressor.

EQM3094S

3.3.32. Water pump

1) Mount a new gasket.

2) Install the water pump drive pinion over the air compressor spline.

3) Connect water pipes, by-pass pipe, and air compressor cooling water hoses to the water pump.

4) Connect a water pipe to the expansion tank.

EQM3095I

3.3.33. Exhaust manifold

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

2) Semi-assemble the exhaust manifold and install the heat resisting plate.

3) First, install the nuts and then place an additional nut on each of them to prevent looseness.

3.3.34. Turbocharger

1) Fit a new gasket over the stud bolts of the exhaust manifold before tightening those turbocharger fixing bolts.

2) Install the oil supply pipe and return pipe.

3) Fit a gasket on the exhaust side of the turbocharger to assemble the exhaust elbow, then install the bracket onto the cylinder block.

4) Semi-assemble the bracket to the intake pipe, connect a rubber hose between the turbocharger and intake pipe using rubber hose, then assemble the bracket completely.

- 75 -

EQM3096I

EQM3097I

EQM3098I

3.3.35. Starter

1) Assemble the starter in position on the flywheel housing.

EQM3099I

3.3.36. Intake manifold

1) Fit a gasket on the intake manifold before assembling the intake manifold.

2) Mount the air heater gasket on the intake manifold, then assemble the air heater with the intake manifold.

3) Connect the air hose to the boost compensator mounted on the fuel injection pump.

- 76 -

EQM3100I

3.3.37. Injection pipe

1) Semi-assemble a nut at both ends of the fuel high pressure pipe and tighten them up one by one to specified torque.

2) Tighten hollow screws to assemble the fuel return pipe.

3) Assemble the fuel return hose with the fuel injection pump.

EQM3101I

3.3.38. Fuel filter

1) Assemble the fuel filter at bracket.

2) Assemble the fuel hose.

EQM3102I

3.3.39. Cylinder head cover

1) Assemble the cover packing with the cover, install the cover on the head, then tighten the fixing bolts in sequence to specified torque (1.5kg

•

m).

2) Assemble the breather hose with PCV valve.

EQM3103I

3.3.40. Air-conditioning compressor

1) Install the A/C compressor mounting bracket on the timing gear case.

2) Install the alternator mounting bracket on the timing gear case, then install A/C compressor fixing bolts.

3) Tighten the fixing bolts.

- 77 -

EQM3104I

3.3.41. Alternator

1) Install the alternator mounting bracket with a fixing bolt onto the cylinder head.

2) Install the alternator in position.

EQM3105S

3.3.42. Cooling fan

1) Install the cooling fan and flange onto the fan coupling.

2) Install the flange onto the crank pulley.

EQM3106I

3.3.43. V-belt

1) Install the V-belt on the crank pulley, idle pulley and alternator pulley.

2) Adjust the V-belt tension using the A/C compressor tension adjusting bolt.

3) Install another V-belt on the idle pulley and alternator pulley.

4) Adjust the V-belt tension using the alternator tension adjusting bolt.

EQM3107I

3.3.44. Fan guide

1) Install the three fan guide brackets.

2) Install the fan guide to the bracket.

3.3.45. Oil level gauge

1) Assemble the oil level gauge to the ladder frame.

3.4. Breaking-in

3.4.1. Preparations for breaking-in

1) Fill 20M of new engine oil through the oil filler cap. When measuring the oil level with the oil dip stick with the engine mounted, the oil level must indicate about 10mm above the MAX line.

2) Connect water hose and fill up cooling water.

3) Connect the fuel hose to the fuel tank and to top(radiator or surge tank). check the air bleeding of the fuel system.

4) Connect the electrical systems such as starter, air heater, etc. with power source.

3.4.2. Breaking-in

1) Idle the engine for about 30 minutes.

2) Run the engine at 1,200~1,600 rpm for about 2 hours.

3) Run the engine at the maximum speed for about 10 minutes when the temperature of cooling water reaches 80°~95°.

4) Keep checking the oil pressure while running the engine.

5) Make sure to check for leaks of oil, fuel, or cooling water and pay particular attention to exhaust gases and unusual sound.

3.4.3. Diagnostics after the breaking-in

1) Readjust the valve clearance with the engine cooled down.

2) Recheck the oil level and replenish as required.

- 78 -

EQM3108S

4. Maintenance of major components

4.1. Cooling system

4.1.1. General descriptions and main data

This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are cooled down by coolant and radiated to the outside, resulting in the normal operation of the engine. Looking into the cooling system, the water pumped up by the water pump circulates around the oil cooler through the water pipe to absorb the oil heat, and then flows through the water jacket of the cylinder block and water passage of the cylinder head to absorb the heat of the combustion chamber. The water absorbing the oil heat and combustion chamber heat goes on to the thermostat through the water pipe, and circulates to the water pump if water temperature is lower than the valve opening temperature on the thermostat, while circulating to the radiator at water temperature higher than the valve opening temperature. At the radiator, the heat absorbed in the coolant is radiated to cool down and the coolant recirculates to the water pump.

- 79 -

Water pipe

Cylinder head

Cylinder block

Oil cooler

Thermostart

Water pump

Air compressor

a d

EQM4001I

<Figure 4-1> Diagram of cooling system

Item Specifications

1. Water pump Centrifugal type Type Delivery(

M/min) About 350 Pumping speed 2,100 rpm Pump back pressure 760mmHg

2. Thermostat Operating temperature(C) 83~95

3. Cooling fan and belt Fan diameter B Number of blades 700 B 8 Fan belt tension 15mm/deflection by thumb

•

Specifications

4.1.2. Water pump

1) Loosen the bolt (14) to disassemble the housing cover (13).

2) Heat the impeller (5) slightly, then remove it using a puller.

3) Remove the mechanical seal.

4) Remove the shaft and bearing assembly from the housing.

5) With a press, remove the spline shaft and bearing.

6) Reverse the disassembly sequence for reassembly operation.

7) Replace the oil seal (6) with a new one at reassembly.

8) To reassemble the impeller, maintain a constant gap(0.3~0.6mm) between the impeller and pump housing using a feeler gauge.

- 80 -

- 81 -

4 6

13 12

18.5

Thickness 0.3 ~ 0.6

Par latex coating

2(Bead)

1. Water pump housing

2. Pipe

3. Shaft

4. Mechanical seal

5. Impeller

6. Oil seal

7. Ball bearing

8. Spacer

9. Ang. contact ball

10. Stop ring

11. Spline shaft

13. Cover, water pump housing

14. Bolt ass’y

15. Pipe for surge tank

EQM4003I

4.1.3. Thermostat

1) General descriptions and main data The thermostat maintains a constant temperature of coolant(90 ~95c) and improve thermal efficiency of the engine by preventing heat loss. Namely, when the temperature of coolant is low, the thermostat valve is closed to make the coolant bypass to directly enter the water pump; when the coolant temperature rises to open wide the thermostat valve, the bypass circuit is closed and the water passage to the radiator is opened so that the coolant is forced to flow into the radiator.

Item Specifications

Type Wax-pallet type

Open at(C)83

Open wide at(C)95

Valve lift mm 8 or more

- 82 -

EQM4004I

<Figure 4-3> Thermostat

Thermometer

Wood plate

Bar

EFM2055I

<Figure 4-4> Checking thermostat

2) Inspection (1) Check the wax pallet and spring for damage. (2) Put the thermostat in a container of water, then heat the water slowly and check temperature with

a thermometer. If the valve lift is 0.1mm(starting to open) at temperature of 83C and 8mm or more(opening wide) at temperature of 95C, the thermostat is normal.

3) Replacing thermostat and precautions for handling (1) Precautions for handling

The wax pallet type thermostat does not react as quickly as bellows type one to a variation of temperature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax pellet type thermostat. Therefore, to avoid a sharp rise of coolant temperature, it is essential to idle the engine sufficiently before running it. In cold weather, do not run the engine at overload or overspeed it immediately after starting off.

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

the entire cooling system.

(3) Replacing thermostat

If the thermostat is detected defective, replace with a new one.

From cooling water pump

To bypass tube

To radiator

Bypass valve

4.1.4. 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

- 83 -

4.2. Lubricating system

4.2.1. General descriptions and main data

1) General descriptions All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the cylinder block from where it is distributed to lubricate the various sliding parts, fuel injection pump, and air compressor in order to ensure normal engine performance.

2) Specifications

3) Diagram of lubricating system

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 10L1.5 Valve opening pressure(kg/cm

) 1.8~2.3

(kg/cm

) Bypass for entire oil filter

Bypass for oil cooler Valve opening pressure(kg/cm

) 4.0~4.8

Opening pressure (kg/cm

) 5+1

Adjusting valve for spray nozzle

Opening pressure (kg/cm

) 1.5~1.8

- 84 -

5bar

4.4bar

1.3bar

2bar

10bar

<Figure 4-5> Diagram of lubricating system

Conn. rod bearing

Main bearing

Main oil gallery

Valve

Oil cooler Oil filter Oil pump

Oil spray nozzle

Rocker arm

Air compressor Water pump

bearing Fuel injection

pump Turbocharger

EQM4005I

4.2.2. Oil pump

1) Disassembly (1) Disassembly of oil pump drive gear

a. Unscrew the screw and disassem-

ble the oil relief valve.

b. Loosen the washer for the oil

pump drive gear fixing nut and remove the nut.

c. Disassemble the drive gear.

(2) Remove the oil pump cover fixing

nuts and disassemble the oil pump cover. The oil pump cover is fixed with the two dowel pins.

(3) Disassemble the drive gear and dri-

ven gear.

- 85 -

EQM4006I

<Figure 4-6> Disassembling drive gear

EQM4007I

<Figure 4-7> Disassembling pump cover

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

measure the axial end play of the oil pump gear. Replace if the measured value is beyond the limit.

EQM4008I

<Figure 4-8> Measuring end play

(2) With a feeler gauge, measure the

amount of back lash between the oil pump drive gear and driven gear. Replace if the measured value is beyond the limit(0.50~0.64mm).

EQM4009I

<Figure 4-9> Measuring gear back lash

Limit (mm) 0.025~0.089

(3) Measuring clearance between drive shaft and bushing

a. Measure the outside diameter of the drive shaft and driven shaft, and replace if the mea-

sured values are less than the limit (N16.95mm).

b. Measure the inside diameter of the pump body bushing to determine the clearance

between the bushing and shaft, and compare the measured value with the standard value to determine whether to replace or not. (Clearance : 0.032~0.077mm)

3) Reassembly (1) For reassembly, reverse the disassembly sequence.

4.2.3. Oil filter

The oil filter mounted in this engine is of cartridge type, so it is necessary to replace it with a new one at the specified intervals.

- 86 -

Oil filter (Cartridge)

Oil filter head

EQM4010I

<Figure 4-10> Oil filter

4.2.4. Diagnostics for oil

- 87 -

Complaints Possible causes Corrections Oil consumption (1) Poor oil (1) Use suggested oil excessive (2) Oil seal or packing leaky (2) Replace cap

(3) Pistons or piston rings worn (3) Replace pistons and/or piston rings (4) Cylinder liner worn (4) Replace cylinder liner (5) Piston rings sticking (5) Replace pistons and/or piston rings (6) Valve guide oil seals or valve (6) Replace

guides, or valve stem worn Oil pressure (1) Poor oil (1) Use suggested oil too low (2) Relief valve sticking (2) Replace

(3) Restrictions in oil pump strainer (3) Clean strainer (4) Oil pump gear worn (4) Replace (5) Oil pump feed pipe cracked (5) Replace (6) Oil pump defective (6) Correct or replace (7) Oil pressure gauge defective (7) Correct or replace

(8) Various bearings worn (8)Replace Oil deteriorates (1) Restriction in oil filter (1) Replace filter element quickly (2) Gases leaking (2) Replace piston rings and

cylinder liner

(3) Wrong oil used (3) Use suggested oil

4.3. Fuel system

4.3.1. General descriptions

The fuel system consists of the fuel tank, injection pump, injection nozzle, fuel filter, and fuel lines such as pipes and hoses necessary to connect those components.

- 88 -

1. Fuel filter ass’y 1a. Fuel water drain plug 1b. Air bleeding plug (for fuel filter)

2. Fuel pipe connector

3. Injection nozzle

4. Overflow tube

5. Fuel pipe (filter - injection pump)

6. Overflow valve

7. Delivery pipe

8. Fuel pipe (manual pump - filter)

9. Fuel tank

10. Fuel return pipe

11. Suction pipe

12. Feed pump

13. Injection pump

EQM4011I

4.3.2. Injection pump

The components related to the injection pump should be serviced at regular intervals as the plunger and delivery valve may be worn after a given length of time for use and cause the deterioration of the engine. Make sure that servicing should be performed at the professional maintenance shop as authorized by Bosch or Zexel Company. For adjustment of fuel injection volume, refer to the 'Specifications of fuel injection pump' described on the following pages.

<Figure 4-11> Diagram of fuel system

1) DE12 (1) DE12(A)

(a) Main data and specifications

Part No. : 65.11101-7260(106671-9170) Model : PE6P type Governor : RFD+C type Timer : SD type, range of operation: 5.5°/600-1100 rpm Plunger : 65.11125-0010 Delivery valve : 65.11108-6009 Fuel feed pump : 65.12101-7013 Pre-stroke : 4.7L0.05mm Rotating direction : C.W. at driving gear side Injection order : 1-5-3-6-2-4 Injection timing : BTDC 12°

(b) Calibration data

- 89 -

Adjusting

Rack position Pump speed Injection volume

Variation Basic Fixing Ref.

point (mm) (rpm) (mm3/1,000st) rate (%) point point

A 9.4 700 123L2 L20 B 9.4 1,100 117L3 L3 C 8.9 500 110L2 L3 D 5.2 250 14.5L1.5 L15 E - 100 100 or more -

Contents Specifications Engine application

Nozzle holder assembly 105780-8140 65.10101-7070

Nozzle 105780-0000 65.10102-6032

Nozzle holder 105780-2080

Opening pressure 175 kg/cm

220 kg/cm

Injection pipe N8 B N3 - 600mm N6 B N2 - 650mm

Fuel delivery pressure 1.6 kg/cm

Fuel temperature 35~45 C

Adjusting

conditions

- 90 -

9.4

8.9

8.4

6.7

5.2

3.9

1170

1150

+20

680

+20

500

±15

390

-10

1205

±5

380

250

RACK LIMIT CR=9.5

Rack position (mm)

Injection pump speed (rpm)

or more

±0.05

EQM4012I

- 91 -

(2) DE12(B)

(a) Main data and specifications

Part No. : 65.11101 - 7296 Model : PE6P type Governor : RLD+J type Timer : SD type, range of operation: 6°/600-950 rpm Plunger : 65.11125-0021 Delivery valve : 65.11108-6019 Fuel feed pump : 65.12101-7027 Pre-stroke : 4.7L0.05mm Rotating direction : C.W. at driving gear side Injection order : 1-5-3-6-2-4 Injection timing : BTDC 8°

(b) Calibration data

Adjusting

Rack position Pump speed Injection volume

Variation Basic Fixing Ref.

point (mm) (rpm) (mm3/1,000st) rate (%) point point

A 12° 700 99 L20 B 12.3 1,100 95L3 C 11.3 500 81 D 8.5 250 14.5 L15

E - 100 95L3-

Contents Specifications Engine application

Nozzle holder assembly 105780-8140 65.10101-7070

Nozzle 105780-0000 65.10102-6032

Nozzle holder 105780-2080

Opening pressure 175 kg/cm

220 kg/cm

Injection pipe N8 B N3 - 600mm N6 B N2 - 650mm

Fuel delivery pressure 1.6 kg/cm

Fuel temperature 35~45 C

Adjusting

conditions

- 92 -

RACK LIMIT

12.1

12.0

11.3

8.5

10.5 or more

8.1

- 0.1

0.1

6.5

250

290

380 500 700 1100

(1120)

1210

12.3

Rack position (mm)

Injection pump speed (rpm)

Damper spring set

EQM4013I

- 93 -

2) DE12T

(1) DE12T(A)

(a) Main data and specifications

Part No. : 65.1101-7261(106671-9170) Model : PE6P type Governor : RFD+C type Timer : SD type, range of operation: 3°/700-1100 rpm Plunger : 65.11125-0010 Delivery valve : Fuel feed pump : 65.12101-7013 Pre-stroke : 4.2L0.05mm Rotating direction : C.W. at driving gear side Injection order : 1-5-3-6-2-4 Injection timing : BTDC 9°

(b) Calibration data

Adjusting

Rack position Pump speed Injection volume

Variation Basic Fixing Ref.

point (mm) (rpm) (mm3/1,000st) rate (%) point point

A 10.9 700 161.5L2 L20 B 10.9 1,100 152L3 L3 C - 500 (97) D 5.2 250 14.5L1.5 L15 E - 100 165L5-

Contents Specifications Engine application

Nozzle holder assembly 105780-8140 65.10101-7071

Nozzle 105780-0000 65.10102-6033

Nozzle holder 105780-2080

Opening pressure 175 kg/cm

220 kg/cm

Injection pipe N8 B N3 - 600mm N6 B N2.2 - 650mm

Fuel delivery pressure 1.6 kg/cm

Fuel temperature 35~45 C

Adjusting

conditions

- 94 -

9.4

8.9

8.4

6.7

5.2

3.9

1170

1150

+20

680

+20

500

±15

390

-10

1205

±5

380

250

RACK LIMIT CR=9.5

I0.05

EQM4014I

Rack position(mm)

Pump speed(rpm)

Rack limit CR=9.5

10.05

or more

- 95 -

3) DE12TI

(1) DE12TI-280

(a) Main data and specifications

Part No. : 65.11101 - 7296 Model : PE6P type Governor : RFD+D type Timer : SPG type, range of operation: 3°/700-1100 rpm Plunger : 65.11125-0010 Delivery valve : 65.11108-6009 Fuel feed pump : 65.12101-7013 Pre-stroke : 4.2L0.05mm Rotating direction : C.W. at driving gear side Injection order : 1-5-3-6-2-4 Injection timing : BTDC 12°

(b) Calibration data

Adjusting

Rack position Pump speed Injection volume

Variation Basic Fixing Ref.

point (mm) (rpm) (mm3/1,000st) rate (%) point point

A 8.2 1,050 135L2 L20 B 5.1 250 16L1.5 L15 C - 100 90 or More D 8.7 500 150L3-

E 7.1 500 (115)L3-

Contents Specifications Engine application

Nozzle holder assembly 105780-8140 65.10101-7072

Nozzle 105780-0000 65.10102-6034

Nozzle holder 105780-2080

Opening pressure 175 kg/cm

1st : 160 kg/cm2, 2nd : 220 kg/cm

Injection pipe N8 B N3 - 600mm N6 B N2 - 650mm

Fuel delivery pressure 1.6 kg/cm

Fuel temperature 35~45 C

Adjusting

conditions

- 96 -

8.7

7.1

8.2=R1

R2+1.5

4.0=R4

5.1=R2

(R2-3.6)

±0.5

(250)

±25

450

±15

720

±15

1100

±10

0.5

±0.1

(850)

(1185)

250

BOOST COMPENSATOR STROKE:1.6

±0.1

Rack position (mm)

Injection pump speed (rpm)

or more

EQM4016I

- 97 -

(2) DE12TI-310

(a) Main data and specifications

Part No. : 65.11101 - 7297 Model : PE6P type Governor : RFD+D type Timer : SPG type, range of operation: 3°/700-1100 rpm Plunger : 65.11125-0010 Delivery valve : 65.11108-6009 Fuel feed pump : 65.12101-7013 Pre-stroke : 4.2L0.05mm Rotating direction : C.W. at driving gear side Injection order : 1-5-3-6-2-4 Injection timing : BTDC 12°

(b) Calibration data

Adjusting

Rack position Pump speed Injection volume

Variation Basic Fixing Ref.

point (mm) (rpm) (mm3/1,000st) rate (%) point point

A 9.2 1,050 154L2 L20 B 5.1 250 16L1.5 L15 C - 100 100 D 9.7 500 170L3-

E 7.1 500 115L3-

Contents Specifications Engine application

Nozzle holder assembly 105780-8140 65.10101-7072

Nozzle 105780-0000 65.10102-6034

Nozzle holder 105780-2080

Opening pressure 175 kg/cm

1st : 160 kg/cm2, 2nd : 220 kg/cm

Injection pipe N8 B N3 - 600mm N6 B N2 - 650mm

Fuel delivery pressure 1.6 kg/cm

Fuel temperature 35~45 C

Adjusting

conditions

Daewoo DE12, De12, DE12T, DE12TI, DE12TIS Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual