FOREWORD

This maintenance manual is designed to serve as a reference for DOOSAN Infracore Co., Ltd. (here
after DOOSAN’s) customers and distributors who wish to gain basic product knowledge on
DOOSAN’s D1146, D1146TI and DE08TIS Diesel engine.
This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct injection type)
has been so designed and manufactured to be used for the overland transport or industrial purpose.
That meets all the requirements such as low noise, fuel economy, high engine speed, and durability.
To maintain the engine in optimum condition and retain maximum performance for a long time,
CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be performed.

Removal Adjustment

Installation Cleaning

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufatur’s

Directional Indication Lubricate with oil

Inspection Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental damage ;

• Take old oil to an old oil disposal point only.

• Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
• Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special
waste.

• The regulations of the relevant local authorities are to be observed for the disposal of spent
coolants and special waste.

If you have any question or recommendation in connection with this manual, please do not hesitate
to contact our head office, dealers or authorized service shops near by your location for any services.

For the last, the content of this maintenance instruction may be changed without notice for some
quality improvement. Thank you.

DOOSAN Infracore Co., Ltd.

Mar. 2001
 CONTENTS

1. GENERAL INFORMATION ................................................................................................... 1

1.1. General Repair Instructions 1.3. Engine Specifications

1.2. Engine Specific Character 1.4. Engine Assembly

2. MAJOR MAINTENANCE ..................................................................................................... 13

2.1. Preventive Maintenance 2.3. Engine Inspection

2.2. Diagnosis and Remedy

3. MAINTENANCE .................................................................................................................... 30

3.1. Engine Disassembly 3.3. Engine Reassembly

3.2. Inspection and Measurement 3.4. Breaking In
on Major Parts

4. MAINTENANCE OF MAJOR COMPONENTS ................................................................ 90

4.1. Cooling System 4.3. Fuel Injection Pump

4.2. Lubrication System 4.4. Turbocharger

5. SPECIAL TOOL LIST ........................................................................................................ 123

¥ APPENDIX

¥ WORLDWIDE NETWORK
1. GENERAL INFORMATION

1.1. General Repair Instructions

1. Before performing service operation, disconnect the grounding cable from the battery for
reducing the chance of cable damage and burning due to short-circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint
damage.
4. The use of proper tools and special tools where specified is important to efficient and reliable
service operation.
5. Use genuine DOOSAN parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded
and new ones should be prepared for installation as normal function of the parts can not be
maintained if these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in
groups. Keeping fixing bolts and nut separate is very important as they vary in hardness and
design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air
to make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for bolts and nuts torques.
12. When service operation is completed, make a final check to be sure service has been done
property.

-1- GENERAL INFORMATION

1.2. Engine Specific Character

1.2.1. Toroidal combustion mode (D1146)

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

1.2.2. OMEGA combustion bowl (D1146TI, DE08TIS)

The OMEGA combustion bowl is a unit
designed to perform high efficiency, low
emission combustion. As the rim around
the combustion bowl port of the upper of
the piston has been machined in a
smaller size than the interior of the
combustion bowl, strong swirl is
produced in the combustion bowl and
strong squish flow makes the fuel be
mixed more sufficiently with air.
Due to the application of OMEGA
combustion system and optimal
utilization of intake and exhaust port
configuration within the cylinder head,
the D1146TI, DE08TIS diesel engines
discharge very low level of hazardous
exhaust gases such as smoke, nitrogen
oxide, hydrocarbon, or carbon monoxide EA8M1001

and thus ensure high performance and

low fuel consumption.

GENERAL INFORMATION -2-

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

-3- GENERAL INFORMATION

1.3. Engine Specifications

1.3.1. Specification

Engine Model
D1146 D1146TI DE08TIS
Items

4 cycle in-line, 4 cycle in-line,

Engine type Water-cooled type Water-cooled type
Naturally aspirated Turbo charged & intercooled

Combustion chamber type Direct injection type

Cylinder liner type Replaceable dry liner
Timing gear system Gear driven type
No. of piston ring Compression ring 2, oil ring 1
No. of cylinder-bore B stroke (mm) 6 - 111 B 139
Total piston displacement (cc) 8,071
Compression ratio 17.5 : 1 16.8 : 1 18.5 : 1
Engine dimension (length B width B height) (mm) 1,253 B 811.5 B 934.5 1,253 B 812.5 B 1,009 1,253 B 812.5 B 1,009
Engine weight (kg) 730 745 745
Rotating direction (viewed from flywheel) Counter clockwise
Fuel injection order 1-5-3-6-2-4
Fuel injection timing (B.T.D.C static) 15° 9° 3°
Injection pump type Zexel in-line “AD” type Zexel in-line “P” type
Mechanical governor Mechanical governor
Governor type type (RLD) type (RLD-J)
Multi-hole type
Injection nozzle type Multi-hole type (RLD)
(7 hole)
Fuel injection pressure (kg/cm2) 210 214 184 / 286
Compression pressure (kg/cm )2
28 (at 200 rpm)
Intake and exhaust valve clearance (at cold) (mm) 0.3
Open at 16° (B.T.D.C)
Intake valve
Close at 36° (A.B.D.C)
Open at 46° (B.B.D.C)
Exhaust valve
Close at 14° (A.T.D.C)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Paper element type Cartridge type
Lubricating oil capacity (max. / min.) (lit) 15.5 / 12 or 17 / 14
Oil cooler type Water cooled
Water pump Centrifugal type driven by belt
Cooling Method Fresh water forced circulation
Cooling water capacity (engine only) (lit) 14
Thermostat type Wax pallet type (79 ~ 94°C or 83 ~ 95°C)
Air compressor type & capacity (cc) Belt driven type, 220 or 300
Alternator voltage - capacity (V - A) 24 - 45 or 24 - 150
Starting Motor voltage - output (V - kW) 24 - 4.5
Air heater capacity (V - A) 22 - 95 (2.1 kW)
Battery capacity (V - AH) 24 - 150

GENERAL INFORMATION -4-

1.3.2. Engine power

Production tolerance : L5%

Engine model Condition

Injection
Model Suffix timing Power Torque Low idle High idle Remark
(BTDC°) (Ps / rpm) (kg.m / rpm) (rpm) (rpm)

EACBA

EACBB

EACBE
D1146 15 182 / 2,500 57.5 / 1,600 600 - 650 2750
EACBH

EACBI

EACBK

2,370

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

D1146TI EURO-I
2,470

EAPCA 9 215 / 2,300 82 / 1,200 600 - 650 2,530

ECPBA
3 225 / 2,300 82 / 1,200 600 - 650 2,530
ECPCA
D1146TI EURO-II
ECPBB
3 240 / 2,300 90 / 1,200 600 - 650 2,530
ECPCB

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

-5- GENERAL INFORMATION

1.3.3. Performance curve (DE08TIS - 225PS)

TORQUE (kg . m)
80
75
70

220

200
POWER OUTPUT (PS)

180

160

140

FUEL CONSUMPTION (g/ps . h)

120

100 160
150
140

1000 1200 1400 1600 1800 2000 2200 2400

REVOLUTION (rpm)

EB5O1001

Performance ISO 1585 (SAE J1349)

Output (max.) 165 kW (225PS) / 2,300 rpm

Torque (max.) 804 N.m (82 kg.m) / 1,200 rpm

Fuel consumption (min.) 192 g/kW.h (141 g / PS.h)

GENERAL INFORMATION -6-

1.3.4. Performance curve (DE08TIS - 240PS)

TORQUE (kg . m)
90
80
70
240

220

200
POWER OUTPUT (PS)

180

160

FUEL CONSUMPTION (g/ps . h)

140

120
160
150
140

1000 1200 1400 1600 1800 2000 2200 2400

REVOLUTION (rpm)

EB5O1002

Performance ISO 1585 (SAE J1349)

Output (max.) 176 kW (240PS) / 2,300 rpm

Torque (max.) 882 N.m (90 kg.m) / 1,200 rpm

Fuel consumption (min.) 192 g/kW.h (141 g / PS.h)

-7- GENERAL INFORMATION

1.4. Engine Assembly

1.4.1. Engine sectional view (longitudinal)

4 5
6
3 7
8
9
2
1 10
11
12
c13
14
19 15
16
17

18
20
21

22 23 24 25 26

EB5O1004

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

GENERAL INFORMATION -8-

1.4.2. Engine sectional view (cross)

5 6
7
4
8
3
9
2
1

10
11
12
13 16
14
15

EB5O1005

1. Fuel injection pipe 9. Turbo charger

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

-9- GENERAL INFORMATION

1.4.3. Engine assembly views

(1) D1146 (Bus)

2 3 4 5 6 7 14 15 16

1
8

10 11 12 13

17 18 23

22
19 20 21
EB5O1003

1. Flywheel housing 8. Oil filler cap 16. Water pump

2. Intake manifold 9. Oil level gauge 17. Exhaust manifold
3. Breather 10. Oil pan 18. Cylinder head cover
4. Air pipe 11. Oil drain plug 19. Crank shaft pulley
(Air cleaner to intake manifold) 12. Oil filter 20. Vibration damper
5. Fuel filter 13. Fuel injection pump 21. Oil cooler
6. Power steering pump 14. Air compressor pulley 22. Starter
7. Air compressor 15. Thermostat 23. Cooling water pipe

GENERAL INFORMATION - 10 -
(2) DE08TIS (Truck)

3 4 5 6 7 8 14 15 16

2
1

9 10 11 12 13

18 19 20 21 28 29 30

17 31

22 23 24 25 26 27
EB5O1006

1. Magnetic pick-up sensor 12. Cooling fan 22. Crank shaft pulley
2. Flywheel housing 13. Cooling fan guide 23. Vibration damper
3. Intake manifold 14. Air compressor pulley 24. Mounting bracket
4. Fuel filter 15. Thermostat 25. Oil cooler
5. Air pipe 16. Water pump 26. Starter relay
(Intercooler to intake manifold) 17. Alternator 27. Starter
6. Fuel injection pipe 18. Air pipe 28. Breather
7. Air compressor (Turbocharger to intercooler) 29. Water delivery pipe
8. Air con. compressor 19. Air pipe 30. Air heater relay
9. Oil pan (Air cleaner to turbocharger) 31. Cooling water pipe
10. Fuel injection pump 20. Turbocharger
11. Oil filter 21. Exhaust elbow

- 11 - GENERAL INFORMATION
(3) DE08TIS (Bus)

1 2 3 4 5 6 7 8 18 19 20

9 17
10

11 12 13 14 15 16
27
21

22 23 24 25 26 28 29

EB5O1007

1. Intake manifold 10. Oil level gauge 21. Exhaust manifold

2. breather 11. Flywheel housing 22. Belt
3. Air pipe 12. Drain plug 23. Mounting bracket
(Intercooler to intake manifold) 13. Oil pan 24. Oil cooler
4. Fuel injection pipe 14. Oil filter 25. Turbocharger
5. Air pipe 15. Fuel injection pump 26. Starter
(Turbocharger to intercooler) 16. Vibration damper 27. Cooling water pipe
6. Fuel filter 17. Idle gear pulley 28. Fly wheel
7. Power steering pump 18. Air compressor pulley 29. Pilot bearing
8. Air compressor 19. Thermostat
9. Oil filler cap 20. Water pump

GENERAL INFORMATION - 12 -
2. MAJOR MAINTENANCE

2.1. Preventive Maintenance

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

2.1.1. Cooling Water

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

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

• The density of above solution and additive must be inspected every 500 hours to maintain it
properly.

Note :
The proper density control of antifreezing solution and rust preventing additive will
be able to prevent the rusting effectively and maintain the stable quality of engine.
For the improper control might give the fatal damage to the cooling water pump and
cylinder liners, detail care is needed.

• Since D1146, D1146TI and DE08TIS (diesel engine of D1146 series) cylinder liner is dry type,
particularly the cooling water control should be applied thoroughly.by the cooling water test kit.
(Fleetguard CC2602M or DOOSAN 60.99901-0038)

• The density of antifreezing solution and additive for rust prevention is able to be confirmed by
the cooling water test kit. (Fleetguard CC2602M or DOOSAN 60.99901-0038)

• How to use the cooling water test kit

(1) When the cooling water temp. of engine is in the range of 10 ~ 55 °C, loosen the plug for
cooling water discharge and fill the plastic cup about a half.

Note :
In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard
to measure the accurate density. Take the cooling water sample necessarily
loosening the cooling water discharge plug.

(2) A t the state of a test paper soaked in the sampled water, after taking the paper out through
water agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.

Note :
However, it should not elapse longer than 75 sec, and if it did, the hue would change.

(4) Make the numerical value by comparing the test paper which hue has changed with the
color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color indication of
test paper storage bottle, confirm the density. (Then, the density indication must be in the
hue range of 33% to 50%).

- 13 - MAJOR MAINTENANCE
 (6) The brown at the middle of test paper and the lower pink color indication represent the
additive state for rust prevention, and the proper range is that the meeting numerical value
of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color
list of label on the test paper storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of
more than 0.8, pour out the cooling water about 50% and then readjust the density after
refilling with clean fresh water.

• Amount of Anti-freeze in winter

Ambient
Cooling water (%) Anti-freeze (%)
Temperature (˚C)
Over -10 85 15

-10 80 20

-15 73 27

-20 67 33

-25 60 40

-30 56 44

-40 50 50

2.1.2. Fan belt

• Use a fan belt of specified dimensions, and replace if damaged, frayed, or deteriorated.
• Check the fan belt for belt tension.
If belt tension is lower than the specified limit, adjust the tension by relocating the alternator.
(specified deflection: 10 ~ 15 mm when pressed down with thumb)

2.1.3. Engine oil

• Check oil level with the oil level gauge and replenish if necessary.
• Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ~ 10
minutes for oil drain into the crankcase before checking oil level. The oil level must be
between Max and Min. lines on the gauge.

• Engine oil should be changed at the specified intervals.

Oil filter cartridge should be changed simultaneously.
- First oil change : 1,000km(50 hr) operating

First oil change After 1,000 km (50hr) operation

Short-distance operation vehicles D1146/TI every 10,000km

(city bus, dump truck) DE08TIS every 20,000km

Long-distance operation vehicles D1146/TI every 15,000km

(express bus, cargo truck) DE08TIS every 30,000km

MAJOR MAINTENANCE - 14 -
 • The following oils are also recommended.
Recommend oil
Engine model
SAE No. API No.

D1146, D1146TI SAE 15W40 above CD or CE

SAE15W40 ACEA-E2 or ACEA-E3

DE08TIS
SAE10W40 (API CH-4)

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

2.1.4. Oil filter

• Check for oil pressure and oil leaks,

and repair or replace the oil filter if Oil filter head
necessary.

• Change the oil filter cartridge

simultaneously at every replacement
of engine oil.
Oil filter
(Cartridge)

EA9O2005

2.1.5. Fuel filter

• Drain water in cartridge with loosening

the cock under filter manually (6) from 1
time to time.
3

4 5
2

6
EA2O4009

2.1.6. Air cleaner

• In case that elements are deformed,

damaged or if the air cleaner has a
crack, replace it.

• By the definite interval, the elements

must be cleaned and replaced.

EFM1002I

- 15 - MAJOR MAINTENANCE
2.1.7. Intercooler

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

Air/air intercooler
with radiator
(combined radiator)

Air flow by cooling fan

Hot air by turbo charger

compressor

Cooled air to intake

manifold (max. 50 C)

EA5O4003

2.1.8. Valve clearance adjust procedure

• After letting the #1 cylinder’s piston come at the compression top dead center by turning the
crankshaft, adjust the valve clearances.

• Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified
value between a rocker arm and a valve stem and adjust the clearance with adjusting screw
respectively and then tighten with the lock nut.

• As for the valve clearance, adjust it when in cold, as follows.

Model Intake Valve Exhaust Valve
D1146
D1146TI 0.3 mm 0.3 mm
DE08TIS

MAJOR MAINTENANCE - 16 -
 1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then #1 cylinder
become the compression state of top dead center.
2) Therefore adjust the valve clearance corresponding to “ “ of lower figure.
At this time there are no force on the push rods of #1 cylinder.
3) Rotating the crankshaft by one revolution, #6 cylinder become the compression state of
top dead center.
4) Thereafter adjust the valve clearances corresponding to “ “ of lower figure.
5) After reinsuring the valve clearances, retighten if necessary.

• No. 1 cylinder is located at the side where flywheel was installed.

Flywheel Intake valve Exhaust valve Cylinder no. Cooling fan

1 2 3 4 5 6

EA9O5005

2.1.9. Cylinder compression pressure

• Stop the engine after warming up, and

take out nozzle holder assembly.

EFM1004I

- 17 - MAJOR MAINTENANCE
 • Install the special tool (compression
gauge adapter) at the nozzle holder
hole, and connect the compression
pressure gauge there.

Standard value 28kg/cm2 over

Limit value 24kg/cm2
Difference
Within L 10 %
between each cylinder
EFM1005I

* Condition : Water temperature 20°C,

Engine rotation 200rpm (10
rotations)

2.1.10. Injection nozzle

Normal Abnormal Abnormal

EFM1006I

• Install a nozzle on the nozzle tester.

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

Engine Model D1146 D1146TI DE08TIS

1st : 160 kg/cm2

Opening pressure 210 kg/cm2 214 kg/cm2
2nd : 220 kg/cm2

• Check the atomizing state and replace it if abnormal.

2.1.11. Fuel injection pump

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

• Check if the idle operation and speed regulating lever’s sealing is removed.
• The adjustment and testing of fuel injection pump should necessarily be done at the test
bench.

2.1.12. Battery

• Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery
in case of poor condition.

• Inspect for amount of electrolytic solution, and replenish if insufficient.

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

MAJOR MAINTENANCE - 18 -
 Viewing Liquid level Liquid level upper limit Isolator
the gravity indicating line Liquid level lower limit
meter
1,100
1,200
1,300 UPPER LEVEL
LOWER LEVEL

EA7M2001

2.1.13. Air removal of fuel system

The suction room of fuel injection pump has the function of air removal continuously during
the operation through a relief valve.
In case that the suction room lacks fuel at all, for instance, in case of new installation of
injection pump, after loosening the air removing screws of cartridge filter respectively,
remove the air by operating the manual pump of fuel supply pump until bubble will disappear.

2.1.14. Fuel supply pump

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

2.1.15. Turbocharger
The turbocharger needs not arty special equipment.
Every time of engine replacement, a leakage or clogging of oil pipes should be inspected. Air
cleaner should be maintained carefully for nut or foreign material not to get in. Periodic
inspection should be applied on the compressed air and exhaust gas pipes, For leaking air
will bring the overheat engine, an immediate repair must be done.
During the operation that is surrounded by the dust and oil mixed air, frequent cleaning must
be done on the impellers. Tear down the impeller casing (attention: be careful not to bend)
and must clean with non-acid solvent solution. If necessary, use plastic scraper If impeller is
severely polluted, dip the impeller into solution and may be better to clean it with stiff brush.
Then one thing to beware is to dip only impeller part and so do not support by impeller but
bearing housing.

2.1.16. Starting motor

In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and
coat them with grease.
Also, In case of washing engine (room) and so forth, inspect the wiring state being careful
for water not to get in.

- 19 - MAJOR MAINTENANCE
2.2. Diagnosis and Remedy

• The following description summarizes the probable cause of and remedy for generall failure by item.
• Immediate countermeasures should be taken before a failure is inflamed if any symptom is
detected.

1. Engine Starting Impossible

Starting motor operation poor Starting motor revolution

Inspection of battery electorlytic Engine Fuel

Iiquid amount & gravity
Inspect air cleaner Inspect amount of fuel
Normal Too low

Adjustment Normal Polluted Normal None

Recharging
Replace or Replenish
Inspection of loose electric clean element
Inspect fuel
wring & short injection No injection
Check compression
pressure
Retighten Normal
Normal
Replace Too low
Continuous
Normal operation after
Inspection of starting switch Repair
Replace air removal
Inspect
Repair Inspect of
Normal injection
Replace other parts
timing
Inspection of starting relay Check valve Adjust
clearance Normal
Normal Replace
Inspect injection
Normal Adjust
nozzle (injection
Inspection of magentic switch
Check cylinder pressure, injection
Replace state etc.)
Repair head gasket
Normal
Replace Repair
Normal Normal
Replace
Starting motor
disassembly Engine disassembly Injection pump
(valve assembly piston disassembly
cylinder liner etc.)

Inspect supply pump operation

Normal Inspect supply pump valve strainer Air mixture in fuel

Injection pump Clean Retighten connection

Normal
dasassembly Replace parts. Replace gasket

Inspect fuel filter Air removal

Element polluted Continuous air mixing

Overflow valve poor
Supply pump
Replace disassembly

MAJOR MAINTENANCE - 20 -
 2. Engine Overheated

Operating state

1. Overload
2. Radiator core clogged
Cooling unit Fuel unit 3. Continuous over-run

Check coolant
Inspect fuel quality Fuel excessive supply

Normal Too low

Poor

Check fan belt Clean and replace

Repair Check injection nozzle
tension wear with specified fuel
Replace
or damage etc.

Replenish Inspect cooling

Normal water leakage

Check fresh
Replace
radiator tank cap External Internal

Normal Retighten Engine

Normal Abnormal
Replace disassembly

Check thermostat Replace

Adjust
repair Repair
Normal injection Replace
pump
Repair
Inspect radiator Damage
Replace

Check cooling Repair

Normal
water pump Replace

Clean cooling
Normal
water passage

Engine
disassembly

- 21 - MAJOR MAINTENANCE
 3. Output Insufficient

Engine Installation improper

Fuel unit Check for coupling

Others
alignemnt
Check for air mixing
Inspect air cleaner Adjust or replace
in fuel
coupling
Inspect fuel supply pump Normal Clean Relpace

Inspect air leakage

Normal Clean Replace Inspect engine control
of air piping line
rod, link, cable, etc.

Inspect fuel filter over folw valve

Retighten
Normal Adjust Normal
Replace
Normal Replace
Check valve clearance
Inspect air leakage
Inspect injection pipe
Adjust of Intercooler
Normal
Normal Repair Replace
Inspect cylinder head
Inspect injection nozzle gasket for damage
injection pressure,
atomizing state Normal Replace

Normal Adjust Replace Engine disassembly

(valve assembly)
Check injection timing

Normal Adjustment

Disassemble engine or Check turbocharger

injection pump

Normal Repair
Replace

Disassemble injection
pump or engine

MAJOR MAINTENANCE - 22 -
 4. Oil pressure lowered

Check if oil pressure

gauge indicates wrongly

Check oil amount

Too low
Normal

Use recommended oil

Check cooling
(replenish)
temperature
Too high
Normal

Refer to engine overheat

Inspect oil quality

Normal

Check oil relief Water & fuel mixed Improper

valve in oil

Replace with
Retighten Disassemble engine
Normal recommended oil
Replace or injection pump

Disassemble
engine

- 23 - MAJOR MAINTENANCE
 5. Fuel Consumption Excessive

Causes according to Use 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
Inspect fuel leakage 5. Too low tire inflation pressure

Normal

Oil leakage
Inspect injection nozzle
(injection pressure Adjust Replace
atomizing state etc.)
Retighten Replace

Normal

Check injection timing Adjust

Normal

Repair Replace
Inspect compressed Check valve
cylinder liner,
pressure clearance
piston ring, piston

Normal

Disassemble
Adjust
injection pump

Normal

Inspect head gasket Replace

Normal

Disassemble engine
(valve assembly, piston,
cylinder liner etc.)

MAJOR MAINTENANCE - 24 -
 6. Oil Consumption Excessive

Cause according to use conditions

1. Excessive oil infusing
2. Continuous operation in low or
extremely cold state

Inspect oil leakage

Inspect air cleaner

Normal Oil leakage Clean Replace

Check oil quality External Internal

Replace with Retighten Check compressed

specified oil Replace pressure

Engine disassembly Normal

(piston cylinder liner)

Disassemble
cylinderhead
(valve stem seal)

7. Engine Knocking

Inspect combustion of fuel & oil

(carbon residue exhaust gas)

Unconfirmed Confirm

Inspect compressed Disassemble

pressure engine
Too low
Normal
Check valve clearance and
Inspect injection cylinder head gasket for damage
pump

Normal Adjust Normal Replace

Adjust
Check fuel quality Disassemble
engine

Use specified fuel

- 25 - MAJOR MAINTENANCE
 8. Battery Discharge

Battery Wiring, Switch Generator

Check electrolytic Inspect cut wire Check fan belt

liquid amount shorts and loose tension & damage
connections

Repair Replace

Normal

Electrolytic Battery room Battery self Battery over

liquid's damage discharge charging
standard
Inspect generator
Replenish Replace Charging Voltage regulator

Normal Abnormal

Check charged stated Adjust

Replace

Discharging

Disassemble
generator Voltage
regulator

MAJOR MAINTENANCE - 26 -
 Condition Causes Remedies

1) Starting difficult • Valve’s poor shut, stem distortion Repair or replace

(1) Compression pressure • Valve spring damage Replace valve spring

lack • Cylinder head gasket’s leak Replace gasket

• Wear of piston, piston ring or liner Adjust

2) Idle operation abnormal • Injection timing incorrect Adjust

• Air mixing at injection pump Remove air

3) Engine output insufficient • Valve clearance incorrect Adjust

(1) Continuous output • Valve tightness poor Repair

insufficient • Cylinder head gasket’s leak Replace gasket

• Wear, stick, damage of piston ring Replace piston ring

• Injection timing incorrect Adjust

• Fuel injection amount insufficient Adjust injection pump

• Nozzle injection pressure Adjust or replace

improper or stuck

• Supply pump’s function lowered Repair or replace

• Fuel pipe system clogged Repair

• Air suction amount insufficient Clean or replace air cleaner

• Turbocharger poor Repair or replace

(2) Output insufficient when • Compression pressure insufficient Disassemble engine

in acceleration • Injection timing incorrect Adjust

• Fuel injection amount insufficient Adjust injection pump

• Injection pump timer’s function Repair or replace

insufficient

• Nozzle injection pressure, Repair, replace

injection angle improper

• Supply pump’s function lowered Repair or replace

• Air intake amount insufficient Clean or

replace air cleaner

4) Overheating • Engine oil insufficient or poor Replenish or replace

• Cooling water insufficient Replenish or replace

• Fan belt loosened, worn, damaged Adjust or replace

• Cooling water pump’s function Repair or replace

lowered

• Water temp. regulator’s operation Replace

poor

• Valve clearance incorrect Adjust

• Exhaust system’s resistance Clean or replace

increased

- 27 - MAJOR MAINTENANCE
 Condition Causes Remedies
5) Engine noisy For noises arise compositely such
as rotating parts, lapping parts etc.,
there is necessity to search the
cause of noises accurately.
(1) Crankshaft • As the wear of bearing or crankshaft Replace bearing &
progress, the oil clearances increase. grind crankshaft
• Lopsided wear of crankshaft Grind or replace
• Oil supply insufficient due to oil Clean oil passage
passage clogging
• Stuck bearing Replace bearing & Grind

(2) Con rod and • Lopsided wear of con rod bearing Replace bearing
Con rod bearing • Lopsided wear of crank pin Grind crankshaft
• Connecting rod distortion Repair or replace
• Stuck bearing Replace & grind crankshaft
• Oil supply insufficiency as clogging Clean oil passage
at oil passage progresses
(3) Piston, piston pin & • Piston clearance increase as the Replace piston & piston ring
piston ring wear of piston and piston ring
progresses
• Wear of piston or piston pin Replace
• Piston stuck Replace piston
• Piston insertion poor Replace piston
• Piston ring damaged Replace piston

(4) Others • Wear of crankshaft, thrust bearing Replace thrust bearing

• Camshaft end play increased Replace thrust plate
• Idle gear end play increased Replace thrust washer
• Timing gear backlash excessive Repair or replace
• Valve clearance excessive Adjust valve clearance
• Abnormal wear of tappet, cam Replace tappet, cam
• Turbocharger inner part damaged Repair or replace

6) Fuel Consumption • Injection timing incorrect Adjust

Excessive • Fuel injection amount excessive Adjust injection pump

7) Oil Consumption Excessive

(1) Oil level elevated • Clearance between cylinder liner & piston Replace

• Wear of piston ring, ring groove Replace piston, piston ring

• Piston ring’s damage, stick, wear Replace piston ring
• Piston ring opening’s disposition improper Correct position
• Piston skirt part damaged or Replace piston
abnormal wear
• ring’s oil return hole clogged
Oil Replace piston ring
• Oil ring’s contact poor Replace piston ring

(2) Oil level lowered • Looseness of valve stem & guide Replace in set
• Wear of valve stem seal Replace seal
• Cylinder head gasket’s leak Replace gasket

(3) Oil leak • Looseness of connection parts Replace gasket, repair

• Various parts’ packing poor Replace packing
• Oil seal poor Replace oil seal

MAJOR MAINTENANCE - 28 -
2.3. Engine Inspection

2.3.1. Stopping engine

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

2.3.2. General engine inspection cycle

: Check & adjust : Replace

Inspection time (km)

Inspection Daily Remark
1,000 10,000 15,000 20,000 40,000
Check for leakage(hoses, clamp)
Cooling Check the water level
System Check the belt tension
Change the coolant water
Check for leakage
Check the oil level gauge
Lubrication
Change the lubricating oil ( )
System 1st

Replace the oil filter cartridge ( )

1st
Check the leakage for intercooler
Intake & (hoses, clamp)
Exhaust
Clean and change
System the air cleaner element
Drain the water in separator
Clean the fuel strainer
of fuel feed pump
Check the fuel line leakage
Fuel
System When
Check the fuel line timing necessary
Replace the fuel filter cartridge
When
Check the injection nozzles necessary
Check the exhaust gas state
Check the battery charging
Engine When
Check the compression pressure
Adjust necessary

Adjust Intake/Exhaust When

valve clearance necessary

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

2.3.3. Use of original parts for repair and replacement

For engine is being mechanically harmonized with many parts, only when the original parts
that the manufacture recommends to use is used, the engine trouble would be preventively
maintained and capable to keep up the maximum performances.
For the analogous parts not the original parts are poor in qualities and gives illl performances,
it may rather bring early engine failure.

- 29 - MAJOR MAINTENANCE
3. MAINTENANCE

3.1. Engine Disassembly

3.1.1. Heed at disassembly

• Before disassembly, the part shelf should be prepared for various tools and repair parts.
• When assembling, clean empty hand should be used and clean environment maintained.
• In case of storing the disassembled parts, each part should not touch each other.
• In case of disassembly, the parts should be laid in order.
3.1.2. Oil level gauge
• Pull out the oil level gauge.
3.1.3. Cooling water
• Remove the radiator cap. Open the drain plug at the radiator lower part to drain the coolant
as the right figure.

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

Drain Valve
EA5O4002

• Remove the drain plug from the

cylinder block and drain out the
cooling water into a container.

Drain plug
EB5M3001

ENGINE DISASSEMBLY - 30 -
3.1.4. Engine oil
• Remove the oil drain plug of oil pan
and pour the engine oil into the
prepared vessel.

Drain플러그
드레인 plug
EB5M3002

3.1.5. Cooling fan

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

EA9M3001

3.1.6. Belt
• Loosen the tension adjusting bolts of
the alternator and the idle pulley, and
take off the belts.

EB5M3003

3.1.7. Thermostat
• Loosen the rubber hose connected to
the cooling water pipe and remove the
thermostat.

• Remove the rubber hose of the by-

pass line.

ENM3002S

- 31 - ENGINE DISASSEMBLY
3.1.8. Starter
• Unscrew the starter fixing nuts and
remove the starter being careful not to
damage its gears.

EB5M3006

3.1.9. Fuel filter

• Remove the hollow screws of filter and
tear down fuel supply and discharge
rubber hose.

• Remove fuel filter fixing bolts and

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

EB5M3007

3.1.10. Breather
• Loosen the clamp screw to remove
the rubber hose.

3.1.11. Intercooler (D1146TI, DE08TIS)

• Tear down the various hoses and air
pipes from the inter cooler.

• Remove the intercooler fixing bolts

and tear it down.

EB6M2001

ENGINE DISASSEMBLY - 32 -
3.1.12. Alternator
• Remove the alternator assembling
bolts and disassemble the alternator.

EA9M3004

3.1.13. Oil cooler

• Loosen the cooling water pump and
the rubber hose clamps of connected
pipes, and disassemble it.

• Remove the oil cooler fixing bolts and

take off the oil cooler.

EB5M3008

3.1.14. Oil filter

• Remove the oil filter assembling
bolts and disassemble the oil filter
assembly.

EA9M3006

3.1.15. Power steering pump

• Remove the oil hose between power
steering oil pump and control unit of
the vehicle.

• Unscrew the power steering oil pump

fixing bolts and remove the power
steering pump.

EB0M3009

- 33 - ENGINE DISASSEMBLY
3.1.16. Air compressor
• Remove the oil pipe between cylinder
block and air compressor.

• Unscrew the air compressor fixing

bolts and take off the air compressor.

EB5M3030

3.1.17. Idle pulley

• Unscrew the idle pulley fixing bolts
and take off the idle pulley

EB5M3028

3.1.18. Water pump

• Unclamp the rubber hose connected
to the oil cooler.

• Unscrew the water pump fixing bolts

from the cylinder block and take off
the water pump.

EB5M3011

3.1.19. Cylinder head cover

• Remove the head cover fixing bolts
and lift the cylinder head cover.

EB5M3012

ENGINE DISASSEMBLY - 34 -
3.1.20. Fuel injection nozzle
• Unscrew the fuel injection pipe
between the injection pump and
nozzle and take off the pipe.

• Install a special jig on the nozzle

holder, and then pull out the nozzle as
striking the hammer of the jig
backwardly.

Caution :
Take care not to damage the nozzle
at disassembly.

• Take out the seal ring from the nozzle hole of the cylinder head and discard it.
3.1.21. Turbo charger (D1146TI, DE08TIS)
• Remove the oil supply pipe and oil
return pipe between the turbo charger
and the cylinder block.

• Unclamp the rubber hose connected

the intercooler and air cleaner.

• Unscrew the turbo charger fixing nuts

and take off the turbo charger from the
exahust manifold.

EB5M3013

3.1.22. Exhaust manifold

• Unscrew the exhaust manifold fixing
nuts and remove the heat shield from
the exhaust manifold.

• Then disassemble the exhaust

manifold and gasket.

• Scrap the used gasket.

EB5M3014

- 35 - ENGINE DISASSEMBLY
3.1.23. Intake manifold
• Unscrew the intake manifold fixing
bolts and remove the intake manfold Air heater Intake manifold
from the cylinder head.

• Disassemble the intake manifold

gasket and discard it.

EB5M3015

3.1.24. Cooling water pipe

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

• Remove the cooling water pipe gasket

and finish the surface with a scraper.

Caution :
Be sure that piece of the gasket do
not come into the cooling water EB5M3016
passage.

3.1.25. Rocker arm

• Remove the rocker arm bracket fixing
bolts in reverse order (zigzag method)
of assembling and disassemble the
rocker arm.

• Take out the push rod upwards.

• Disassembly of rocker arm assembly
- Remove the snap ring fron the both
ends of rocker arm shaft by means
of a plier. EA9M3011
- Remove the washer, rocker arm,
bracket and spring from the rocker
arm shaf in sequence.
- Press out the rocker arm bush.

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

EA8M3008

ENGINE DISASSEMBLY - 36 -
3.1.26. Cylinder head
• Remove the cylinder head bolts in the
reverse order of tightening but remove
it step by step.
First step : Loosen 1 ~ 2 threads
Second step : Remove by loosening
fully.
However, remove the total bolts
simultaneously by the step of 1 and 2.

• Lay the removed bolts orderly not to EAMD102I

damage the threads at all and store.

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

• Take out the cylinder head gasket and scrap it.

• Remove the foreign residues from the cylinder head surface and block surface.

Caution :
Try not to make any damage on the contact surfaces.

• Disassembly of cylinder head

- Place the cylinder head on a
individual shelf.
- As pressing the valve spring with a
special tool, remove the cotter pin,
valve spring.
- Take out the intake and exhaust
Compress
valves. the spring

EA0M4007

- For removal of the valve seat, apply

arc welding work to two points of
Valve seat
valve seat insert, and pull out the insert
valve seat insert with inner extractor.

Cylinder head

Welding bead
EA3M2032

- 37 - ENGINE DISASSEMBLY
3.1.27. Oil pan
• Unscrew the oil pan fixing bolts and
remove the oil pan.

• Remove the oil pan gasket and

discard it.

EAMD034I

3.1.28. Vibration damper

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

3.1.29. Timing gear case cover

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

• Remove the cover fixing bolts and

disassemble the cover from the timing
gear case.

EAMD025I

3.1.30. Oil pump

• Unscrew the bracket fixing bolts of the
oil suction pipe.

• Unscrew the pipe fixing bolts of oil

pump and disassemble the suction
and supply oil pipe.

• Unscrew the oil pump fixing bolts, and

disassemble the oil pump.

EB5M3017

ENGINE DISASSEMBLY - 38 -
3.1.31. Piston and connecting rod
• Remove the connecting rod cap bolts
in the reverse order of assembling but
do same as the cylinder head bolt
removal.

• Disassemble the upper/lower of

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

• By pushing the connecting rod with EFM2026I

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

• The disassembled piston assembly should be handled to prevent bumping each other, and
stored as the cylinder’s order.

• In order for connecting rod cap not to be swapped, temporarily assemble to the
corresponding connecting rod.

<Disassembly of piston>
(1) Remove the snap rings by means of
a plier.

(2) Heat the piston with a electric heater,

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

EAMD088I

- 39 - ENGINE DISASSEMBLY
 (3) Remove the piston ring with a plier.

(4) Clean the piston thoroughly.

3.1.32. Cylinder liner

• Diassemble the cylinder liner with a
special tool or hand but be careful not
to generate any damage at cylinder
block.

EAMD087I

3.1.33. Cam shaft gear and idle gear

• Unscrew the camshaft gear fixing

bolts and remove the camshaft gear.

ENGINE DISASSEMBLY - 40 -
 • Unscrew two bolts fxing the idle gear,
then remove the idle gear and its pin.

3.1.34. Fuel injection pump

• Disassembly the oil hose for
lubrication.

• Remove the bolts and nuts of injection

pump flange.

• Unscrew the injection pump fixing

bolts and remove the injection pump
by lifting it up.

EAMD021I

• Remove the bracket fixing bolts of

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

EAMD022I

3.1.35. Water chamber cover

• Unscrew the fixing bolts and remove the water chamber cover.
• Remove the remnant gasket thoroughly.

- 41 - ENGINE DISASSEMBLY
3.1.36. Fly wheel
• Remove the flywheel fixing bolts and
disassemble it.

• The bolt removal is done by the

reverse order of assembling and by
the steps.

EDM2072I

3.1.37. Fly wheel housing

• Remove the flywheel housing fixing
bolts and disassemble the flywheel
housing.

• Disassemble the oil seal of flywheel

housing.

Oil seal
EB5M3004

3.1.38. Injection pump drive gear

• Unscrew the drive gear housing fixing
bolts and remove the drive gear
assembly.

EA9M3021

3.1.39. Timing gear case

• Remove the timing gear case
assembling bolts.

• By tapping lightly with a urethane

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

EAMD046I

ENGINE DISASSEMBLY - 42 -
3.1.40. Bearing cap
• Remove the bearing cap assembling
bolts by the step in the reverse order
of assembling, and disassemble the
bearing cap. (Remove by the same
way as the cylinder head bolts’
removal.)

• Disassembled bearing caps are kept

laid in order.

3.1.41. Crankshaft
• Assemble the bolts on the both side of crankshaft temporarily.
• Connect the rope to the bolts and lift the crankshaft by means of crane being careful not to
give any damage on it.

• In order for the disassembled crankshaft to be prevented from bends or damage, put it on
the special lathe and store.

• Disassemble the metal bearings in turn and store them.

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

3.1.42. Camshaft and tappet

• In order for camshaft not to be
damaged, disassemble turning it.

• In order for the disassembled

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

• Pull out the tappet.

• As required, pull out the camshaft
bush from the cylinder block by a
press.

• Check for damage, scratch, wearing

state and if abnormal, tear down.

- 43 - ENGINE DISASSEMBLY
3.1.43. Oil spray nozzle (D1146TI, DE08TIS only)
• Remove the valve screws of oil spray
nozzle and disassemble it.

ENGINE DISASSEMBLY - 44 -
3.2. Inspection and Measurement on Major Parts

3.2.1. Cylinder block

• Clean the cylinder block thoroughly, and check for any crack or damage.
• If there is any crack or severe damage, replace it and if there is minor one, correct it.
• Check for any clogging or corrosion in the oil passage and water passage.
• Carry out a leakage test for any crack or air leaking. (Hydraulic test)
• Plug each cylinder block’s water and oil discharge ports, and apply the air pressure of about
4kg/cm2 to intake port and soak it in water for about 1 minute to check if there is any
leakage. (Water temperature : 70˚C)

3.2.2. Cylinder head

1) Cylinder head assembly & disassembly
(1) Disassemble the cylinder assembly, and put it on the shelf for assembly or clean lathe.

Caution :
Prevent any damage to gasket’s contact surface of the cylinder head.

(2) Disassemble the cotter pin, spring,

spring seat pushing valve spring by
a special tool.

(3) Pull out the intake and exhaust

valves. Compressor
(4) The disassembled parts are kept the spring

laid in turn.
(5) Disassemble the valve stem seal. EA0M4007

(6) By means of the special tool, punch,

pull out a valve guide.

EB5M3018

- 45 - INSPECTION & MEASUREMENT

2) Inspection of cylinder head
(1) Check for the cylinder head.

• Remove carbon from the cylinder head lower surface, and then should be careful not to
scratch the surface.

• Check any crack or damage that can not found by naked eyes through the hydraulic or
magnetic particle test.

(2) Distortion of lower surface

• As shown in figure, measure the

(t)
cylinder head’s distortion at 6
directions with horizontal ruler and
B
clearance gauge. A

• If the measured value is beyond the D

C
limit value, correct it by means of the
fine grinding paper or grinding
E
machine.
F
• If it is beyond the max. allowable EA3M2031
value, replace the cylinder head

<Lower face warpage and height>

Standard Limit

Warpage 0.2 mm or less 0.3 mm

Thickness : t
109.9 ~ 110.1 mm 108.4 mm
(reference)

(3) Flatness EA9M3020

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

Standard Limit
0.05 mm 0.2 mm

(4) The hydraulic test

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

INSPECTION & MEASUREMENT - 46 -

3) Inspection of valve and valve guide
(1) Valve
After cleaning valve with fuel, check it.

• Valve stem outer diameter

Measure the valve stem outer
diameter at 3 positions (top, middle,
and bottom), and check for any wear
and if beyond the limit value, replace
the valve.
End of stem
Dimension
Standard Limit
Description

Intake
N8.950 ~ N8.970 mm N8.93 mm EFM2036I
valve stem

Exhaust
N8.935 ~ N8.955 mm N8.91 mm
valve stem

• Valve seat contacting faces

Check the valve seat contact surface for any crack and wear, and if necessary, correct
with grinding paper, and if excessive, replace it.

• Valve head thickness

Measure the thickness of valve head
and if beyond the limit value, replace
the valve.

Dimension
Standard Limit
Description
Intake valve 2.7 mm 1 mm or less
Exhaust valve 2.2 mm 1 mm or less

EFM2037I

(2) Valve guide

• Insert a valve into cylinder head and

measure the clearance between
valve guide and valve by valve
movement. If the clearance is
excessive, measure the valve and
replace the excessively worn valve or Measuring
position
valve guide.

EA0M4052

- 47 - INSPECTION & MEASUREMENT

 <Valve stem end play>

Dimension
Standard Limit
Description

Intake valve 0.04 ~ 0.07 mm 0.2 mm

Exhaust valve 0.06 ~ 0.09 mm 0.25 mm

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

3) Valve seat

• Contacting face amount

As for the valve seat’s wear, measure the width of the contact surface with intake valve seat
and exhaust valve seat. If beyond the
limit value, replace the valve seat.

• Assemble the valve at the valve seat

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

<Valve depression>

Standard Limit
Intake &
Exhaust 0 ~ 0.3 mm 0.55 mm

If the amount of depression is beyond

the specified limit, replace the valve
seat.

EA0M4046

INSPECTION & MEASUREMENT - 48 -

 • For the disassembling of valve seat,
by welding the welding bead to a valve
Valve seat
seat rotating tool or valve seat, pull it insert
out with a special tool.

Cylinder head

Welding bead
EA3M2032

• For the assembling of a new valve seat, by putting it among the dry ices of an ice box
previously for about 2 hours for the cold shrinkage, and press it in the cylinder head by a
special tool. (bench press)

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

4) Valve spring

• Visual check
Check the appearance of valve spring and if necessary replace the spring.

• Valve spring free length

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

Spring free Length Standard

Intake valve 64
D1146/TI 60 EA3M2033
Inner
Exhaust DE08TIS 73.8
valve D1146/TI 71
Outer
DE08TIS 77.7

• Valve spring inclination

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

(mm)

Standard Limit
Valve Spring Square
Less than 1.8 2.7
Inclination
EJM2050I

- 49 - INSPECTION & MEASUREMENT

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

Spring
Set Length Limit
force
Spring tester
Valve Spring
Intake
valve Tension at 41mm 70 kg L 3kg
Set Length
EA0M4056
D1146/TI
L 6%
: 28.6 kg
Inner 38 mm
DE08TIS
L 2kg
: 38 kg
Exhaust
valve D1146/TI
L 5%
: 66 kg
Outer 41 mm
DE08TIS
L 4kg
: 75 kg

5) Assembling cylinder head

• Clean the cylinder head thoroughly.

• Replace the valve stem seal with new

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

• Coat engine oil to valve stem and

valve guide and assemble the valve.
However, be careful for the damage EB5M3019

of valve stem seal.

• Install the lower seat of valve spring to

the valve guide of cylinder head.

• After putting inner, outer springs, install the spring upper seat on it.
• Assemble the valve by inserting the valve cotter pressing the valve spring with a special
tool.

• After installing the valve, check whether the valve is correctly installed or not tapping it
lightly with urethane hammer.

INSPECTION & MEASUREMENT - 50 -

3.2.3. Rocker arm assembly
1) Disassembly
(1) Disassemble the snap rings that are
located at both ends of rocker arm
shaft by a plier.
(2) Disassemble in the order of washer,
rocker arm bracket, rocker arm
spring, rocker arm.

EA8M3008

2) Inspection of rocker arm assembly

(1) Rocker arm shaft

• Rocker arm shaft run-out

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

Limit 0.2 mm EDM2037I

• Rocker arm shaft diameter

With an outside micrometer,
measure the rocker arm shaft
diameter at the point where the
rocker arms have been installed.
Replace the rocker arm if the
amount of wear is beyond the
specified limit.

Standard Limit
N23.978 ~ N23.959 mm N23.75 mm EA9M3014

(2) Rocker arm

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

- 51 - INSPECTION & MEASUREMENT

 • Rocker arm bushing diameter
Measure the inside diameter of the
rocker arm bushing with an inside
micrometer or vernier calipers, and
compare the measured values with
the rocker arm shaft diameter. If the
clearance exceeds the limit, replace
either bushing or shaft, whichever
worn more.

Standard Limit EA0M4059

0.020 ~ 0.093 mm 0.3 mm or less

(3) Tappet and push rod

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

Standard Limit
0.035 ~ 0.077 mm 0.15 mm

• Visual check of tappet

Visually check the face of the
tappets in contact with the cam for
pitting, scores or cracks, and replace
if severely damaged. If the amount
of cracks or pitting is small, correct (1) Unevenness (2) Crack (3) Normal

with an oil stone or grinding paper.

(4) Abnormal
EA0M4070

• Outside diameter of tappet

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

Standard N19.944 ~ N19.965 mm

EDM2061I

INSPECTION & MEASUREMENT - 52 -

 • Push rod run-out
Limit 0.3 mm or less

Use a feeler gauge to measure the

push rod run-out.
Roll the push rod along a smooth flat
surface as shown in the figure.

Feeler gauge
EA0M4073

(4) Reassembling rocker arm assembly

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

• Check the oil supply hole of rocker arm shaft for any clog and clean thoroughly.
• Be careful not to occur any swap of position and reverse assembly.
3.2.4. Camshaft
1) Camshaft end play

• Push the thrust plate toward the cam

gear

• With a feeler gauge, measure the

clearance between the thrust plate
and camshaft journal.

• If the end play is excessive, replace

the thrust plate.

Standard Limit
0.28~ 0.43 mm 0.6 mm Feeler gauge

EA0M4067

2) Cam

• Cam lobe height

unit : mm
Standard Limit

Cam lobe Intake 49.15 48.85

height (C) D1146/TI : 49.32
Exhaust 49.00
DE08TIS :49.35

Cam journal
N57.86 ~N57.88 N57.52
diameter (A,B) I II
I II
A
C B B

D A

EA0M4062

- 53 - INSPECTION & MEASUREMENT

 Use a micrometer to measure the cam lobe height and journal diameter.
If the measured number is less than the specified limit, the camshaft must replaced.

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

3) Cam shaft

• Clearance
between camshaft journal and camshaft bush
- With an outside micrometer,
measure the camshaft journal
diameter.
- Measure the inside diameter of the
camshaft bushing on the cylinder Camshaft bearing
block using a cylinder bore indicator,
and compare the measured value
with the camshaft outside diameter
to determine the clearance.
<Clearance>

Standard Limit EA0M4063

0.12~ 0.17 mm 0.24 mm

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

• Run-out
Support the camshaft on two V blocks
and check for run-out using a dial
indicator. Correct or replace the cam
shaft if the amount of run-out is
beyond the value indicating need for
servicing.

Standard Limit
0.05 mm 0.2 mm
EA0M4066

INSPECTION & MEASUREMENT - 54 -

3.2.5. Crankshaft
1) Inspection of crankshaft
(1) Defect check

• By naked eyes, check for any scratch or damage on the crankshaft journal and crank pin.
• By means of magnetic particle test and color check, check the crankshaft for any crack and
if found, replace it.

(2) Wear measuring

• With an outside micrometer measure

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

• If the amount of wear is beyond the

limit, have the crankshaft ground and A
install undersize bearings. However, if
the amount of wear is within the limit, B B

you can correct the wear using an oil B B

stone or oiled grinding paper of fine
grain size. (Be sure to use grinding
paper which has been immersed in
A
oil.)
EFM2047I

Standard Limit

Journal diameter N 83.966 ~ N 83.988 N 83.000 mm

Pin diameter N 70.971 ~ N 70.990 N 70.000 mm

• In case that pin’s wear is more than

the limit value, grind the crankshaft "R"
journal and crank pin, and use the
undersized bearings.
"R"

CAUTION :
Be sure to use grinding paper which "R" "R" "R"
has been immersed in oil.
Normal Poor Poor EFM2048I

- 55 - INSPECTION & MEASUREMENT

 <Undersize bearings available>

• Standard
• 0.25 (Inside diameter is 0.25 mm lesser than the standard size.)
• 0.50 (Inside diameter is 0.50 mm lesser than the standard size.)
• 0.75 (Inside diameter is 0.75 mm lesser than the standard size.)
• 1.00 (Inside diameter is 1.00 mm lesser than the standard size.)
Undersize bearings are available in 4 different sizes as indicated above, and the crankshaft
can be reused through the regrinding as described above.

* “R” part’s specified value

0
1 Crank Pin’s “R” : 4.5 -0.2

0
2 Crank journal “R” : 4 -0.2

Caution :
In case of regrinding, the grinding the “R” part of bearing end should be correctly
done and keep in mind to remove any jaws or coarse surface absolutely.

(3) Crankshaft run-out

• Support the crankshaft on V blocks.

• Turn the crankshaft with a dial
indicator placed on the surface plate
and take the amount of crankshaft
run-out.

Standard Limit
0.05 mm 0.1 mm

EJM2095S

2) Crankshaft bearing and connecting rod

(1) Visual check
Visually check the crankshaft bearing and
connecting rod bearing for scores, uneven
wear or damage.

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

• Main bearing clearance

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

Torque 30 kg•m

Compare the two values obtained

through measurement of main bearing
inside diameter with the outside

INSPECTION & MEASUREMENT - 56 -

 diameters of crankshaft journals to determine the oil clearance.

<Main bearing oil clearance>

Standard Limit
0.052 ~ 0.122 mm 0.25 mm

• Connecting rod bearing clearance

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

Torque 18 kg•m

Compare the two values obtained

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

Standard Limit
0.034 ~ 0.098 mm 0.25 mm

• If the clearance deviates from the

specified range, have the crankshaft
journals and pins ground and install
undersize bearings. EAMD060I

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

• Assemble the crankshaft on the cylinder block and put plastic gauge on the journal and pin
of crankshaft and then after assembling bearing cap, tighten the bolts at the specific torque.
Again after disassembling the bearing cap by removing the bolts, take out the flatted plastic
gauge and measure the width of plastic gauge by means of plastic gauge measuring scale.
This is the oil clearance.

• The oil clearance too can be measured in the same manner

- 57 - INSPECTION & MEASUREMENT

(4) Bearing spread and crush

• Inspection
Check to see that the bearing
requires a considerable amount of
finger pressure at reassembly
operation.

OA OB

Spread = O A - O B

EDM2047I

• Crankshaft bearing crush

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

Standard 0.19 ~ 0.22 mm

EAMD063I

• Connecting rod bearing crush

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

Standard 0.3 ~ 0.5 mm

EAMD064I

INSPECTION & MEASUREMENT - 58 -

 (5) Crank shaft end play

• Assemble the crankshaft to the

cylinder block.

• With a dial gauge, measure

crankshaft end play.

Standard Limit
0.15 ~ 0.325 mm 0.5 mm

3.2.6. Piston assembly

1) Disassemby of piston assembly
Disassemble piston according to the disassembly process.

2) Piston inspection
(1) Visual check
Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring
groove.

(2) Clearance between the piston

and cylinder liner

• With an outside micrometer,

measure the piston outside
diameter at a point 13mm away
from the lower end of piston skirt in
a direction at a right angle to the
piston pin hole.

Standard N110.833 ~ N110.897 mm

• Using a cylinder bore gauge, measure

cylinder liner inside diameter at 3
points (cylinder top ring contacting 2
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.

Standard Limit EAMD067I

N111 ~ N111.022 mm N111.122 mm

- 59 - INSPECTION & MEASUREMENT

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

<Clearance between piston and liner>

Standard 0.103~ 0.139 mm

3) Piston rings
(1) Visual check
Replace the piston rings with new ones if detected worn or broken when the engine is
overhauled.

(2) Piston ring gap

• 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.

• Measure the piston ring gap with a

feeler gauge.

Standard Limit
Top ring 0.40 ~ 0.60 mm 1.5 mm
2nd ring 0.40 ~ 0.60 mm 1.5 mm
Oil ring 0.30 ~ 0.50 mm 1.5 mm

• Replace piston rings with new ones if

the gap is beyond the limit

(3) Piston ring side clearance

• Fit the compression ring and oil ring in

the piston ring groove.
Feeler gauge
• 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.

Standard Limit
EA0M4032
Top ring - -
2nd ring 0.07 ~ 0.102 mm 0.15 mm
Oil ring 0.05 ~ 0.085 mm 0.15 mm

INSPECTION & MEASUREMENT - 60 -

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

Standard
Top ring 2.58 ~ 3.88 kg
2nd ring 1.81 ~ 2.71 kg
Oil ring 3.57 ~ 5.03 kg

4) Piston pin inspection

(1) Wear
Measure the amount of wear on the
piston pin at the points as shown. The
measured values are beyond the limit
(0.08 mm or greater), replace the pin.

Standard Limit
N41.994 ~ N42.000 mm N41.94 mm

EA0M4031

(2) Clearance
Measure the clearance between the
piston pin and connecting rod bushing,
and replace either of them, whichever
damaged more, if the measured value
is beyond the limit.

Standard Limit
0.003 ~ 0.015 mm 0.08 mm

EA3M2047

(3) Condition check

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

5) Connecting rod inspection

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

- 61 - INSPECTION & MEASUREMENT

 (2) Holes alignment (parallelism)
Measure the alignment of the
connecting rod piston pin bushing holes
with connecting rod big end holes. At
this time also, use both connecting rod
tester and feeler gauge.
Feeler gauge

Standard Limit
0.05 mm 0.1 mm or less

EA0M4034

(3) Wear

• Assemble the connecting rod to the crankshaft and measure connecting rod big end side
clearance using a feeler gauge.

• Assemble the connecting rod to the piston and measure connecting rod small end side
clearance.

• If the measured values are beyond the limit, replace the connecting rod.
Limit 0.5 mm

3.2.7. Fuel injection nozzle projection (DE08TIS)

• Insert a seal ring on the cylinder head
and assemble the injection nozzle Fuel injection nozzle

• Measure the clearance between the Cylinder head

cylinder head bottom and nozzle tip. If

the measured values are beyond the
limit, replace the seal ring.

Standard A

A
3.5 L 0.1 mm B
EB6M3001
(Thickness of seal ring)

B
2.43 ~ 2.80 mm
(Projection of nozzle)

INSPECTION & MEASUREMENT - 62 -

3.3. Engine Reassembly

3.3.1. General precautions

• Clean all the disassembled parts, particularly oil and water ports, using compressed air,
then check that they are free from restrictions.

• Arrange the general and special tools in order for engine assembly operation.
• To wet each sliding part, prepare the clean engine oil.
• Prepare service materials such as sealant, gaskets, etc.
• Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
• Apply only the specified torque for bolts in the specified tightening order and avoid over-
tightening.

• Be sure to check that all the engine parts operate smoothly after being reassembled.
• Check the bolts for looseness after reassembly.
• After completing the engine reassembly operation, check if there is missing parts or
shortage of parts.

• Keep your hands clean during the working.

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

3.3.3. Oil spray nozzle (D1146TI, DE08TIS)

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

Torque 7 kg•m

EDM3053I

3.3.4. Tappet and cam shaft

• 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.

- 63 - ENGINE REASSEMBLY
 • Apply engine oil to the entire face of
the tappets and slide them into the
tappet holes on the cylinder block.

• Wet the cam bush inside diameter

and camshaft with oil, and carefully
assemble them while turning the
camshaft.

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

EDM2060I
• Check to see that the camshaft
rotates smoothly.

3.3.5. Crankshaft
• Install the main bearing (refer to
assemble sequence : right figure)
machined with two holes in the 7 5 3 1 2 4 6
cylinder block so that the key is
aligned with the key groove, then
apply oil to the bearing surface.

EFM2061I

Key groove
Oil port and passage

EA0M4083

ENGINE REASSEMBLY - 64 -
• Heat the crankshaft gear for at least
10 minutes to 120°C, then apply
sealant (Loctite # 641) to the inside
wall of the heated crankshaft gear
evenly before inserting it to the end of
crankshaft.

EA8M3014

• Semi-tighten a bolt at both sides of

the crankshaft, apply engine oil to
journals and pins, then assemble the
crankshaft with the cylinder block by
tightening the fixing bolts.

Caution :
Coat engine oil to the pin and
journal of crankshaft.

• Install the oiled thrust washers with

the oil groove facing outward.

• Install the bearing and thrust washers

to the bearing cap and apply oil to the
bearing and thrust washers.

EAMD077I

- 65 - ENGINE REASSEMBLY
 • Install the bearing cap by matching
the cylinder block No. with the bearing
cap No.

7 6 5 4 3 2 1

EQM3058I

• Apply oil to the entire part of the

bearing cap bolts, then tighten in
tightening sequence to specified
torque.

Torque 30 kg•m

• After semi-tightening both bolts

evenly, tighten them diagonally to the EQM3059I

specified torque using a torque

wrench as follows.

<Tightening order>
(1) First stage : Coat the cap bolts with engine oil
(2) Second stage : Temporary bolt screwing about 1 ~ 2 threads
(3) Third stage : With impact wrench, tighten up to about 15 kg.m
(4) Fourth stage : With torque wrench, tighten up to about 25 kg.m
(5) Fifth stage : By means of torque wrench, tighten finally in the specified
torque. (30 kg.m).

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

• Check to see that the assembled crankshaft turns smoothly with hand.

3.3.6. Flywheel housing

• Temporarily install the guide bar on
the cylinder block.

• Apply gasket to the cylinder block.

• Using the dowel pin and guide bar,
install the flywheel housing and
tighten the fixing bolts in a diagonal
sequence to specified torque. (Zigzag
method)
Oil seal
Torque 8 kg•m EB5M3004

ENGINE REASSEMBLY - 66 -
 Caution :
When the bolts are tightened, remove the guide bar.

• The flywheel housing is assembled after the new oil seal was pressed (Coat engine oil over
the outside of oil seal) before in the housing by a press.

• If any peripheral scar was generated due to oil seal at the oil seal contact surface of
crankshaft, after inserting about 1 mm shim or thereabout in front of oil seal (Direction
toward crankshaft.), measure and adjust.

3.3.7. Oil seal (Rear side)

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

3.3.8. Flywheel
• Installation of flywheel ring gear
With a gas burner, heat the ring gear
evenly until heat expansion takes
place, then install it using a hammer.

Caution :
Do not allow the temperature of the
ring gear to exceed 200 °C (390 °F).

EA0M4029
• By means of mandrel, assemble pilot
bearing to the flywheel.

• By means of mandrel, press in the

wear ring at the backward face.

Wear ring Ring gear

EA6M2004

- 67 - ENGINE REASSEMBLY
 • 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.

• Coat the adhesive (#271 Loctite) over

the assembling bolts and install bolts
in the remaining holes. After that take
out the guide bar, then install a bolt in EDM2072I

the hole where the guide bar had been

inserted.

• According to the order of tightening

tighten the fixing bolts using a torque
wrench in a diagonal sequence to 1

specified torque. 5 3

Torque 18 kg•m
4 6

EDM2073I

3.3.9. Magnetic pick-up sensor

• Move the lock nut to hexagonal side
of sensor completely. Lock nut Ring gear
• Rotate (Clockwise) the pick-up sensor
on fly wheel housing, until the end of
it reach on fly wheel ring gear.

• Then rotate (Counter clockwise) the

pick-up sensor for 270° (gap 1.0 mm)
and fix lock nut. M16 x 1.5

• Tolerance limit is 27°. (gap L 0.1 mm) EPM2030I

Flywheel
Housing

Tolerance
limit
27
27

27
0

EPM2031I

ENGINE REASSEMBLY - 68 -
3.3.10. Water chamber cover
• Coat the adhesive over the water chamber cover (Particular around bolt holes) and after
attaching the gasket, assemble it to the cylinder block using the bolts for assembling.

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

3.3.11. Cylinder liner

• Stand the cylinder block so that the
flywheel faces downward.

• Thoroughly clean the liner flange

fitting surface and bore inside with
compressed air to prevent the entry of
foreign substances.

• After the cleaning operation, make the

cylinder liner dried up and push it into
the cylinder block by hand. EAMD087I
• Wet the liner inside diameter with
engine oil.

3.3.12. Piston and connecting rod

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

• Align the piston pin hole with the oiled

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

EAMD088I

- 69 - ENGINE REASSEMBLY
 • Nothing the direction of the piston,
make the longer side(machined with
key groove on the bearing) of the Valve seating
connecting rod big end.

• On the piston head surface, the

longer side connecting rod big end is

106
in opposite direction from the valve
seating surface as well as in the same
direction with the narrow margin of the EAMD089I
combustion chamber.

• Install the snap rings and check to see

that it is securely assembled. Piston

• Install the piston ring in the piston Top ring

using piston ring pliers.

Second ring

Oil ring

EB6M3002

• Identify the mark “Y” or “TOP” on the

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

Marked with the name of piston ring

manulacturing company
EAMD090I

• Adjust the angle among individual

O O

piston ring gaps to 90° and fit a piston 45 45

2nd ring gap Top ring gap
assembling jig onto the piston, Use
care not to match the ring gaps with
the pin direction.
O
90
• Install the bearing by aligning it with
the connecting rod key groove and Piston pin
apply oil to the bearing and piston.
Oil ring gap
Piston
EA8M3006

ENGINE REASSEMBLY - 70 -
• Position the valve seating surface
toward the tappet hole and insert the
piston with hand.
Tappet hole

Caution : Valve seatig

Use care not to damage the cylinder

liner and piston, and slightly lift and
insert the piston into the cylinder so
EAMD092I
that the ring may not be damaged
by the fillet of the liner.

• Install the bearing in the connecting

rod cap and apply oil.

Caution :
Make sure that the manufacture
serial numbers impressed on the
connecting rod cap and connecting
rod big end are identical, and install
the connecting rod cap by aligning
it with dowel pin.

• Wet the fixing bolts with engine oil, semi-tighten them with hand, tighten them to the
specified torque using a torque wrench as follows.

<Tightening order>
(1) First stage : Coat engine oil over bolts.
(2) Second stage : Temporary bolt screwing about 1 ~ 2 threads
(3) Third stage : With torque wrench, tighten up to about 10 kg.m
(4) Fourth stage : With torque wrench, tighten up to about 15 kg.m
(5) Fifth stage : By means of torque wrench, tighten finally in the specified torque.
(18 kg.m).

Torque 18 kg•m

- 71 - ENGINE REASSEMBLY
 • When the connecting rod bearing cap
bolts are tightened, check the
connecting rod end play to the right
and left with hand. If no end play is
found,, remove and reinstall or
replace the connecting rod bearing
cap.

EAMD094I

3.3.13. Timing gear case

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

• Put the time gear case to the cylinder

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

• Tighten the bolts for assembling to the EAMD082I

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

3.3.14. Timing gear and idle gear pin

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

• Install a thrust washer over the

camshaft and assemble the cam gear
by aligning it with camshaft dowel pin.
Idle gear pin
Tighten the cam gear assembling
bolts to the specified torque. (Zigzag
method)

Torque 2.2 kg•m

EAMD083I

ENGINE REASSEMBLY - 72 -
 • With the oil port on the idle gear pin
facing the cylinder block, install the Idle gear pin

idle gear pin.

• Idler gear pin with oil hole is

assembled toward cylinder block.
Oil hole

EA8M3004

• Install the idle gear by coinciding the

marks impressed on the crank gear, Mark "2"
cam gear, fuel injection pump drive
Fuel injection Camshaft gear
gear, and idle gear. 1
pump drive gear 22 1
1

• Install a thrust washer on the idle gear

2 1
2 1
2
Idle gear
and tighten to specified torque.
Mark "1"
Torque 3.1 kg•m Crank
Mark "0" shaft
gear
EA9M3015
• Check and adjust the amount of
backlash between gears using a
feeler gauge.

Measuring position
(between) Backlash Limit

cam gear & idle gear 0.16 ~ 0.28 mm 0.35 mm

crank gear & idle gear 0.16 ~ 0.28 mm 0.35 mm
injection pump & idle gear 0.16 ~ 0.28 mm 0.35 mm

3.3.15. Injection pump flange

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

• Mount gasket by aligning the bolt

holes with the pin holes on the
bearing housing.

• Turning the flywheel, adjust the

pointer to the position of the engraved EA9M3021
scale.

• After adjusting the injection timing of

fuel injection pump drive gear, tighten the fixing bolts in the direction of fuel injection pump.

- 73 - ENGINE REASSEMBLY
3.3.16. Fuel injection pump
• Install the injection pump bracket in
the cylinder block.

• After measuring the amount of run-out

with an alignment setting jig,
disassemble the bracket, adjust the
shims, then reassemble it.

Run - out 0.2 mm or less

• Mount the top/bottom adjusting shims

in the bracket and then mount the fuel EAMD107I
injection pump.

• Tighten the fixing bolts in a diagonal

sequence to specified torque.

Torque 4.4 kg•m

<Injection Timing Adjustment>

• Bring the piston of #1 cylinder to the

compression TDC (OT) by turning the
crankshaft. Again, turn 60° in the
reverse direction of engine rotation.

• Disassemble the fuel injection pipe

that connect the fuel injection pump
and #1 injection nozzle.

• Disassemble the fuel injection pump

delivery valve holder, and after
removing the valve and valve spring,
again assemble the valve holder and
then, on it assemble the pipe of “U”
Timing
shape on it. check hole
• Operating the priming pump of supply
pump, turn the crankshaft slowly in Flywheel
ring gear
the direction of engine rotation until Injection timing
notch mark
the fuel will drop at the rate of a drop (Flywheel)
for 6 ~ 8 sec.

• Confirm then whether the indication

point at the flywheel housing
inspection hole and the engraved
EB5O6006
specified injection angle are coincided
or not, and if the injection timing is not
correct, adjust as follows.

ENGINE REASSEMBLY - 74 -
(1) As above adjusting method, Please coincide the indication point( ) at the flywheel housing’s
inspection hole with the flywheel’s inspection angle.

<Fuel injection timing>

Model Timing angle

D1146 BTDC 15˚
D1146TI BTDC 9˚
DE08TIS BTDC 3˚

(2) Loosen the drive gear fixing bolt of injection

pump a bit.
(3) After turning slowly the coupling of injection
pump until the fuel will drop from #1 plunger
at the rate of a drop for 6 ~ 8 sec., tighten
the driving gear fixing bolt of fuel pump.

EB5M3006

• After the adjustment of injection

timing, disassemble the “U” shape
pipe, the delivery valve and the valve
spring.

• Turn the coupling until the notch mark

of the indicator plate attached to the
fuel injection pump is aligned with the Notch
notch mark of the coupling. mark

EB5O5003

• Tighten the coupling fixing bolts and

nuts to specified torque.

Torque 6.0 ~ 6.5 kg•m

• Install the oil delivery pipe and return

pipe.

EAMD021I

- 75 - ENGINE REASSEMBLY
3.3.17. Oil pump and oil pipe
• Install a dowel pin in the No.7 bearing
cap, then assemble the oil pump by
tapping lightly with urethane hammer.

• Tighten the assembling bolts with

specified torque.

Torque 4.4 kg•m

• Assemble the oil suction pipe with the EB5M3017

delivery pipe to oil pump by the bolts.

3.3.18. Timing gear case cover

• Install dowel pin on the timing gear
case.

• Mount a gasket by aligning the fixing

bolt holes with those on the gasket.

• Align the dowel pin with the cover pin

hole, then install the cover with light
tap.

• Tighten the fixing bolts beginning with

the oil pan fitting face. EB5M3022

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

3.3.19. Front oil seal

• Apply lubricating oil to the outside of
the oil seal and the oil seal hole of the
timing gear case cover.

• Put the new oil seal on the oil seal

hole of timing gear case cover
aligning the center of them, then
assemble the oil seal using an oil seal
fitting jig. Oil seal fitting jig

EAMD086I

ENGINE REASSEMBLY - 76 -
3.3.20. Water pump
• Mount a new gasket.
• Install the water pump on the cylinder
block and tighten the assembling
bolts with specified torque.

Torque 2.2 kg•m

• Connect water pipes and by-pass

pipe to the water pump. EB5M3011

• Connect a water pipe to the

expansion tank.

3.3.21. Vibration damper

• Insert the vibration damper to the
crankshaft, and assemble by
tightening the assembling bolts at the
specified tightening torque according
to bolt tightening order. (refer to right
figure.)

Torque 13 kg•m

1
6 7

4 3

8 5
2

EDM2089I

3.3.22. Oil pan

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

Caution :
Be careful for the gasket pieces not fall into the engine during the work.

• Coat the silicone at the gasket part that was removed (Contacting part), and attach the new
oil pan gasket.

- 77 - ENGINE REASSEMBLY
 • Assemble the oil pan by tightening the
oil pan assembling bolts, and when
tightening bolts, primarily tighten the
bolts (4ea) at the both ends, and then
tighten the rest bolts to specified
torque.

Torque 2.2 kg•m

Caution : EAMD034I

Align the bolt holes with gasket holes

to prevent damage to the gasket and tighten.

3.3.23. Oil filter

• Install the oil filter onto the cylinder
block, and tighten the fixing bolts.

Torque 2.2 kg•m

• Apply engine oil to the oil filter

cartridge o-ring and assemble the
cartridge using a filter wrench.

EA9M3006

3.3.24. Oil cooler

• Install the gasket on the cylinder
block.

• Assemble the oil cooler by tightening

the assembling bolts.

• Connect the cooling water pipe with

the cooling water pump and tighten a
hose clamp.

EB5M3008

3.3.25. Starter
• Assemble the starter in position on
the flywheel housing.

Torque 8.0 kg•m

EB5M3006

ENGINE REASSEMBLY - 78 -
3.3.26. Intake and exhaust valves
• Identify the marks of “IN” and “EX” impressed on the valve head before assembling the
valve with the valve head.

• With a valve stem seal fitting jig,

assemble the valve stem seal on the
valve guide.

• After installing valve springs and

spring retainer, press the retainer with
a jig, then install the cotter pin.

• Tap the valve stem lightly with a

rubber hammer to check that the
valve is assembled correctly.
Compressor
the spring

EA0M4007

3.3.27. Cylinder head

• Blow the bolt holes of cylinder block with a compressed air and remove the foreign matter.
• Clean the head gasket contact surface thoroughly.

Caution :
However, be careful for the foreign material not to enter into the combustion chamber.

• Assemble the new head gasket by

aligning the holes with dowel pins of
cylinder block with “TOP” mark facing
upward.
TOP

EB1M3025

- 79 - ENGINE REASSEMBLY
 • Check the inside of combustion
chamber for foreign substances, and
carefully mount the cylinder head
assembly in the block by aligning the
dowel pin with the dowel pin hole.

Caution :
Be careful not to damage the
cylinder head gasket. If the dowel EA9M3022
pin is not in alignment, lift the
cylinder head again and then
remount it.

Caution :
After tightening the cylinder head bolts, even at disassembling, the cylinder head
gasket should be changed a new one.

• Coat the cylinder head bolts with

engine oil, and tighten in proper
sequence to the specified torque
according to bolt tightening order 5 3 2 7 5 3 2 7 5 3 2 7

(refer to the figure).

8 1 4 6 8 1 4 6 8 1 4 6

<Cylinder head bolts>

Type 1 Type 2
EDM2097I
TY TY
Specification 12.9T 10.9T

M14B1.5B146 M14B1.5B150
6 kg•m +180°+150°
Torque 24.5 kg•m
(Angle torque)

• However, before tightening bolts, the side parallel degree between cylinder heads should
be adjusted.

<Tightening order of bolts by steps>

(1) First stage : Coat the bolts with engine oil.
(2) Second stage : Tighten 1 ~ 2 threads with hands.
(3) Third stage : Tighten at about 6 kg.m with a wrench.
(4) Fourth stage : Tighten at rotating angle method 180° with a wrench.
(5) Fifth stage : Finally, tighten at rotating angle method 150° with a torque wrench .

However, all bolts are tightened simultaneously by above steps.

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

ENGINE REASSEMBLY - 80 -
3.3.28. Rocker arm assembly
• Apply lubricating oil to the rocker arm
bush and shaft, and assemble the
intermediate bracket with the rockerarm
(rocker arm assembly) on the cylinder
block using fixing bolts. In tightening the
bolts, it must be done at the specified
value using zigzag method.

M10 B1.5 4.4 kg.m

Torque EB1M3026
M12 B1.5 8.0 kg.m

• Semi-install valve clearance adjusting

bolts onto the rocker arm.

• Install the spring, rocker arm, bracket,

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

• Install the rocker arm and bracket in

the same direction.

EA8M3008
• Adjust the valve clearance as
following guide.

<Guide for valve clearance adjustment>

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

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

Flywheel Intake valve Exhaust valve Cylinder no. Cooling fan

1 2 3 4 5 6

EA9O5005

- 81 - ENGINE REASSEMBLY
 • To adjust the clearance, loosen the locknuts of rocker arm adjusting screws and push the
feeler gauge of specified value between a rocker arm and a valve stem (to measure the
clearance of the valve and rocker arm contacting part) and adjust the clearance with
adjusting screw respectively and then tighten with the lock nut.

• As for the valve clearance, adjust it when in cold.

Model Intake valve Exhaust valve

D1146
D1146TI 0.3 mm 0.3 mm
DE08TIS

Caution :
(1) Crankshaft revolution is done by hands without using a starting motor.
(2) Turn it to the direction of engine rotation, but do not use the installing bolts at
the turn.
(3) The cylinder no. and the order of intake and exhaust can be determined from the
crank shaft pulley.

• Adjust valve clearance with a feeler

gauge and tighten the fixing nuts to Valve clearance adjust
specified torque.

Torque 5.0 kg•m

EA8M3007

3.3.29. Intake manifold

• Put in the new gasket between the
cylinder head and manifold, and
Air heater Intake manifold
assemble the intake manifold by
tightening the assembling bolts.

EB5M3015

ENGINE REASSEMBLY - 82 -
3.3.30. Exhaust manifold
• 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.

• Semi-assemble the exhaust manifold

and install the heat resisting plate.

• Assemble them by tightening the EB5M3014

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

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

3.3.31. Turbocharger (D1146TI, DE08TIS)

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

• Install the oil supply pipe and return

pipe.

• Tighten the clamps of rubber hose

that is connected air pipe to the
intercooler. EB5M3013

3.3.32. Cooling water pipe

• Attach a new gasket on the cylinder
head.

• Install the cooling water pipe and

tightening the fixing bolt on it.

EB5M3016

- 83 - ENGINE REASSEMBLY
3.3.33. Idle pulley
• Assemble the air compressor
mounting bracket on the timing gear
case.

• Install the idle pulley on the air

compressor mounting bracket and
tightening the fixing bolt.

EB5M3016

3.3.34. Air compressor & power steering pump

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

• Insert the O-ring coated with grease

into the oil outlet of the air
compressor.

• Place the air compressor on the

mounting bracket carefully and
tighten the fixing bolts to the specified EB5M3030
torque.
(Carefully damage the O-ring)

• Assemble the oil feed pipe.

3.3.35. Alternator
• Install the alternator mounting bracket
and supporter to the cylinder block,
then tighten the fixing bolts.

• Install the alternator with fixing bolts

to the mounting bracket.

EA9M3004

ENGINE REASSEMBLY - 84 -
3.3.36. Fuel filter
• Assemble the fuel filter with the intake
manifold.

• Assemble the fuel feed hose

according to the direction of an arrow
impressed on the fuel filter head so
that fuel can be fed in the sequence of
FUEL FEED PUMP FUEL FILTER
FUEL INJECTION PUMP.

EB5M3007

3.3.37. Injection nozzle

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

• As aligning the ball of nozzle with a

groove in the nozzle hole, Insert the
nozzle into the cylinder head and
tighten the nozzle.

Torque 7.0 kg•m

3.3.38. Fuel injection pipe

• Semi-assemble a nut at both ends of
the fuel injection pipe and tighten
them up one by one to specified
torque.

Torque 3.0 kg•m

• Assemble the fuel return pipe on the

nozzle holder.

• Connect the injection pump

lubricating oil pipe with a hollow
screw.

Caution :
Be sure not to damage the connection part due to over-tightening the hollow screw.

- 85 - ENGINE REASSEMBLY
3.3.39. Cylinder head cover
• Attach a new gasket on the cylinder
head cover.

• Assemble the cylinder head cover to

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

Torque 1.2 kg•m

EB5M3002

• Assemble the breather and breather

hose.

• Fit the oil filler cap on the cylinder

head cover.

3.3.40. Cooling fan

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

Torque 4.4 kg•m

EA9M3001

3.3.41. Belt
• Install the V-belt on the crank pulley, Press here
alternator pulley and water pump 10~15mm
pulley.

• Adjust the V-belt tension using the

tension adjusting support. Water pump
pulley
Alternator
pulley

Crank pulley
V-belt EA9O2006

ENGINE REASSEMBLY - 86 -
 • Poly belt will be properly tensioned if
the deflection force “F” is applied
midway between the belt’s tangent
points with the pulley. S(SPAN)
T = 0.015 X S (about 1.5 mm per 100
T D
mm) d
F

EB5O6001

3.3.42. Oil level gauge

• Apply sealant (Locktite #262) to the
bottom side of the guide tube.

• Then assemble the guide tube and oil

level gauge on the oil pan.

EQM3005I

3.3.43. Others
• Assemble by connecting the other oil and fuel hoses.

- 87 - ENGINE REASSEMBLY
3.4. BREAKING IN

3.4.1. Preparations for breaking-in

• Fill of new engine oil through the oil filler cap.
• When measuring the oil level with the oil level gauge with the engine mounted, the oil level
must indicate about 10mm above the max. line.

• Connect water hoses and fill up cooling water.

• Connect the fuel hoses to the fuel tank and to top(radiator or surge tank).
Check the air bleeding of the fuel system.

• Connect the electrical systems such as starter, air heater, etc. with power source.
3.4.2. Operation of a new engine (Break-In)
Because the sliding surfaces of a new engine are not lapped enough, the oil film can be
destroyed easily by overload or overspeed and the engine life-time may be shortened.
Therefore the following things must be obeyed by all means.
Up to the first 1,000km(50 hours)

• Engine should be run at fast idling until the temperature of the engine becomes normal
operating condition.

• Overload or continuous high speed operation should be avoided.

• High speed operation with no load should be prevented.
• Abrupt start and stop of the engine should be avoided.
• Engine speed must be under 70% of its maximum speed.
• Maintenance and inspection must be accomplished thoroughly.
3.4.3. Check points for break-in
During the break-in (the initial running of the engine) period, be particularly observant as
follows :
a) Check engine oil level frequently. Maintain oil level in the safe range, between the “min.”
and “max.” marks on dipstick.

Note :
If you have a problem getting a good oil level reading on dipstick, rotate the level
gauge 180° and re-insert for check.

b) Watch the oil pressure warning lamp. If the lamp blinks, it may be oil pick-up scrreen is not
covered with oil. Check oil level gauge. Add oil to the oil pan, if required. Do not overfill. If
level is correct and the status still exists, see your DEALER for possible switch or oil pump
and line malfunction.

Note :
Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition, cold
oil will generally show higher oil pressure for any specific RPM than hot oil. Both of
these conditions reflect normal engine operation.

BREAKING IN - 88 -
c) Watch the engine water temperature gauge and be sure there is proper water circulation. The
water temperature gauge needle will fluctuate if water level in expansion tank is too low.
At the end of the break-in period, remove break-in oil and replace the oil filter. Fill oil pan with
recommended engine oil. Refer to following table.

<Recommended Engine oil and capacity>

Engine oil capacity Recommend oil

Model Max. line (lit) Min line (lit) Total (lit) API No.

D1146 Bus 15.5 12 19

API CD grade
Truck 15.5 12 19 or
D1146TI above CE grade
Truck 17 14 21

Bus 15.5 12 19 ACEA-E2

or
DE08TIS
ACEA-E3
Truck 17 14 21 (API CH-4)

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

- 89 - BREAKING IN
4. MAINTENANCE OF MAJOR COMPONENTS

4.1. Cooling System

4.1.1. General information

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.
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.

Thermostat
Thermostart Cooling water pipe

R
a Cylinder head
Radiator

d
i
a
t
o Cylinder block
r

Oil cooler Water pump

EQM4001I

4.1.2. Specification

Item Specifications
Type Centrifugal type
Pump speed 2,000 rpm 2,700 rpm
1. Water pump Delivery capacity about 190 liter/min about 280 liter/min
Operation pressure 0.5 bar 0.8 bar
Allowable back pressure bellow 0.5 bar
Operating temperature 79°C 83°C
2. Thermostat Valve lift 8mm or more (at 94°C) 8mm or more (at 94°C)
Operating temperature 79 ~ 94°C 83 ~ 95°C
3. Cooling fan and belt
Fan diameter - Number of blades Truck : N700mm - 8
Fan belt tension 15mm deflection by thumb

MAINTENANCE OF MAJOR COMPONENTS - 90 -

4.1.3. Thermostat
• General descriptions and main data
The thermostat maintains a constant
To radiator
temperature of coolant and improves
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 Bypass
From cooling valve
directly enter the water pump; when To bypass
water pump tube
the coolant temperature rises to open
EAMC002I
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.

Specifications
Item In moderate climates
In tropical climates
Bus Truck
Type Wax-pallet type Wax-pallet type
Open at 79 °C 83 °C 71 °C
Open wide at 94°C 95°C 85°C

10 mm or Bus : 8 mm or more
Valve lift 8 mm or more
more Truck : 10 mm or more

Caution :
There are 3 kinds of thermostats according to surrounding and operating conditions.
One is named by 71 °C , 79°C type and the other is 83 °C.

• Inspecting
(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 Ruler
Thermometer
a thermometer. If the valve lift is
0.1 mm (starting to open) at
temperature of 83 °C and 10 mm Wood plate
or more (full open) at temperature
of 95 °C, the thermostat is normal.

EFM2055I

- 91 - MAINTENANCE OF MAJOR COMPONENTS

• 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.

MAINTENANCE OF MAJOR COMPONENTS - 92 -

4.1.4. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Engine overheating • Lack of coolant • Replenish coolant

• Radiator cap pressure valve • Replace cap

spring weakened

• Fan belt loosened or broken • Adjust or replace fan belt

• Fan belt fouled with oil • Replace fan belt

• Thermostat inoperative • Replace thermostat

• Water pump defective • Repair or replace

• Restrictions in water passages • Clean radiator and water

due to deposit of scales passages

• Injection timing incorrect • Adjust injection timing

correctly

• Restriction in radiator core • Clean exterior of radiator

• Gases leaking into water jacket • Replace cylinder head gasket

due to broken cylinder head

gasket

2. Engine overcooling • Thermostat inoperative • Replace thermostat

• Ambient temperature too low • Install radiator curtain

3. Lack of coolant • Radiator leaky • Correct or replace

• Radiator hoses loosely • Retighten clamps or replace

connected or damaged hoses

• Radiator cap valve spring • Replace cap

weakened

• Water pump leaky • Repair or replace

• Heater hoses loosely • Tighten or replace hoses

connected or broken

• Cylinder head gasket leaky • Replace cylinder head gasket

• Cylinder head or cylinder block • Replace cylinder head block

cracked

4. Cooling system noisy • Water pump bearing defective • Replace bearing

• Fan loosely fitted or bent • Retighten or replace fan

• Fan out of balance • Replace fan

• Fan belt defective • Replace fan belt

- 93 - MAINTENANCE OF MAJOR COMPONENTS

4.2. Lubricating System

4.2.1. General descriptions and specifications

• 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, and fuel injection pump
in order to ensure normal engine performance.

• Specifications
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 kg/cm 2
Valve opening pressure 1.8 ~ 2.3 kg/cm2
Bypass for oil cooler Bypass for entire oil filter
Opening pressure 5+1 kg/cm 2
Valve opening pressure 4.0 ~ 4.8 kg/cm2
Adjusting valve for spray nozzle
Opening pressure 1.5 ~ 1.8 kg/cm2

• Diagram of lubricating system

Main oil gallery

Relief valve
1.3 bar Relief valve
4.6 bar
Oil filter

Camshaft head Idle gear bush

Bypass valve : 2.0 bar
Piston spray nozzle

Fuel injection pump

Air compressor
Turbocharger

Camshaft head

Crankshaft bearing

Rocker arm shaft

Oil cooler

Connecting rod
Bypass valve : 6.0 bar

bearing
Rocker arm bush

Relief valve
10 bar

Oil pan

EB5M4001

MAINTENANCE OF MAJOR COMPONENTS - 94 -

4.2.2. Oil pump
• Disassembly
(1) Disassembly of oil pump drive gear
a. Unscrew the screw and
disassemble the oil relief valve.
b. Unfold the washer for the oil pump
drive gear fixing nut and remove the
nut.
c. Disassemble the drive gear.

EQM4006I

(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
driven gear.

EQM4007I

• 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.

End play limit 0.025 ~ 0.089 mm

Steel plate

Feeler gauge

EQM4008I

(2) With a feeler gauge, measure the

amount of backlash between the oil
pump drive gear and driven gear.
Replace if the measured value is
beyond the limit.

Backlash limit 0.50 ~ 0.64 mm

EQM4009I

- 95 - MAINTENANCE OF MAJOR COMPONENTS

 (3) Measuring clearance between drive shaft and bushing
a. Measure the outside diameters of the drive shaft and driven shaft, and replace if the
measured values are less than the limit (N16.95mm)

Standard N16.95 ~ N16.968 mm

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 ~ 0.077 mm

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

4.2.3. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Oil consumption • Poor oil • Use suggested oil

excessive • Oil seal or packing leaky • Replace

• Pistons or piston rings worn • Replace pistons and/or

piston rings

• Cylinder liner worn • Replace cylinder liner

• Piston rings sticking • Replace pistons and/or

piston rings

• Valve guide oil seals or valve • Replace

guides, or valve stem worn

2. Oil pressure too low • Poor oil • Use suggested oil

• Relief valve sticking • Replace

• Restrictions in oil pump strainer • Clean strainer

• Oil pump gear worn • Replace

• Oil pump feed pipe cracked • Replace

• Oil pump defective • Correct or replace

• Oil pressure gauge defective • Correct or replace

• Various bearings worn • Replace

3. Oil deteriorates quickly • Restriction in oil filter • Replace filter element

• Gases leaking • Replace piston rings and

cylinder liner

• Wrong oil used • Use suggested oil

MAINTENANCE OF MAJOR COMPONENTS - 96 -

4.3. Fuel Injection Pump

4.3.1. General information of fuel system

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.

2 1. Fuel filter
5
1a. Water separater
2. Air bleeding screw (for fuel filter)
1
4 3. Injection nozzle
3 7 4. Overflow tube
5. Fuel pipe (filter injection pump)
1a
6 6. Overflow valve
7. Fuel injection pipe
8. Fuel pipe (manual pump filter)
8 9. Fuel tank
12 10. Fuel return pipe

10 11. Suction pipe

12. Feed pump
9 11
13. Injection pump

EA8O3004

4.3.2. Injection pump

The components relating 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.

- 97 - MAINTENANCE OF MAJOR COMPONENTS

1) D1146
(1) Injection pump ass’y : 65.11101-7259A (101603-9981 ZEXEL)
- Injection pump : KP-PE6AD95B412RS2 (101060-6100)
- Governor : KP-EP/RLD250-1400AIFFL (105931-5901)
- Timer : KP-EP/SA900-1250B4DR (105644-0520)
- Fuel feed pump : KP-FP/KE-ADS (105210-5280)
- Coupling : 105662-1290
- Micro switch : 153169-3320
- Plunger & barrel : 131153-1720
- Delivery valve : 131160-3620
(2) Nozzle holder assembly : 65.10101-7050 (9134-153C LUCAS)
(3) Nozzle : 65.10102-6026 (9135-143 LUCAS)
(4) Injection pipe : 65.10301-6036A
(5) Firing order :1-5-3-6-2-4
(6) Injection timing : BTDC 15˚

Nozzle & holder ass’y 105780-8140 Opening pressure : 175 bar

(A) Test condition
Injection pipe (ID x OD - L) - N 2.0 x N 6.0 – 600 mm
for injection pump
Test oil ISO4113 Temperature : 40 L 5C

65.10102-6026 Nozzle (5 x N 0.29)

Nozzle & holder Ass’y
(B) Engine standard parts 65.10101-7050 214 kg/cm2

Injection pipe (ID x OD - L) 65.10301-6036A N 1.8 x N 6 – 550 mm

Rack diagram and setting valve at each point

Injection Q`ty on RIG

Rack Pump
Power Check (mm3 / 1,000st) Press.
position speed
point (A) Test condition (B) Engine (mmHg)
(mm) (rpm)
for inj. Pump standard parts

H ≠ 9.7 300 8.5 L 1.5 - -

A 11.8 700 79.5 L 1 - -

B 11.9 1250 (84.0 L 2.0) - -

C 11.55 500 (65.0 L 2.0) - -

I - 100 (115.0 L 15) - -

Boost pressure : zero boost

Governor weight 740 g Lever ratio (min/max) 1 : 1.15 / 1 : 3.9

Governor spring (outer) k = 1.8 kgf/mm Governor spring (inner) k=0.6 kgf/mm

Idle spring (outer) k = 0.7 kgf/mm Idle spring (inner) k=0.05 kgf/mm

Start spring k = 0.005 kgf/mm retraction pressure 59mm3/st , t=0.99

Delivery
Plunger N9.5 Left hand 20 + 45 lead opening pressure 20.8 kgf/cm2
Valve
Feed pump 105210-5280 spring k=1.63 kgf/mm

MAINTENANCE OF MAJOR COMPONENTS - 98 -

(7) Governor adjustment (D1146)

16

I A B
12 C

H
Rack position (mm)

0
400 700 800 1200 1600

Injection pump speed (rpm)

EA9M4002

- 99 - MAINTENANCE OF MAJOR COMPONENTS

2) D1146TI
(1) Injection pump ass’y : 65.11101-7298 (101701-9630 ZEXEL)
- Injection pump : KP-PE6AD100B412RS2 (101060-6541)
- Governor : KP-EP/RLD250-1400A1FXL (105932-3550)
- Timer : KP-EP/SA700-1100630DR (105644-0570)
- Fuel feed pump : KP-FP/KE-ADS (105210-5280)
- Coupling : 105662-1490
- Micro switch : 153169-3320
- Plunger & barrel : 131150-3120
- Delivery valve : 131160-8620
(2) Nozzle holder assembly : 65.10101-7293 (9134-153C LUCAS)
(3) Nozzle : 65.10102-6042 (9135-283 LUCAS)
(4) Injection pipe : 65.10301-7007
(5) Firing order :1-5-3-6-2-4
(6) Injection timing : BTDC 9˚

Nozzle & holder ass’y 10101-7293 Opening pressure : 175 bar

(A) Test condition
Injection pipe (ID x OD - L) - N 2.0 x N 6.0 – 650 mm
for injection pump
Test oil ISO4113 Temperature : 40 L 5C

65.10102-6042 Nozzle (5 x N 0.32)

Nozzle & holder Ass’y
(B) Engine standard parts 65.10101-7293 214 kg/cm2

Injection pipe (ID x OD - L) 65.10301-7007 N 1.8 x N 6 – 550 mm

Rack diagram and setting valve at each point

Injection Q`ty on RIG

Rack Pump
Power Check (mm3 / 1,000st) Press.
position speed
point (A) Test condition (B) Engine (mmHg)
(mm) (rpm)
for inj. Pump standard parts

H ≠ 9.7 300 8.5 L 1.5 - -

A 11.9 700 98.5 L 1.6 - -

B 12.3 1100 (106.5 L 2.0) - -

C 11.7 500 (82 L 2.0) - -

D 10.5 500 (58.7 L 2.0) - -

P1 10.5 500 - - 250

P2 11.7 500 - - 100

Governor weight 740 g Idle spring k=0.7 + 0.05 kgf/mm

Governor spring k = 1.0 + 0.6 kgf/mm Boost spring k=0.54 kgf/mm

Start spring k = 0.005 kgf/mm retraction pressure 51mm3/st , t=0.15

Delivery
Plunger N10 Right hand 20 + 50 lead opening pressure 20.8 kgf/cm2
Valve
Lever ratio (min/max) 1 : 1.15 / 1 : 3.9 spring k=1.63 kgf/mm

MAINTENANCE OF MAJOR COMPONENTS - 100 -

(7) Governor adjustment (D1146TI)
a) Governor adjustment

B
C A
12

10 D
H
Rack position (mm)

0
300 500 700 1100

Injection pump speed (rpm)

EA9M4003

b) Boost compensator adjustment

12.0

P2

11.5
Rack position (mm)

11.0

P1
10.5

10.0
100 250

Boost pressure (mmHg)

EA9M4004

- 101 - MAINTENANCE OF MAJOR COMPONENTS

3) DE08TIS (225PS)
(1) Injection pump ass’y : 65.11101-7331 (106671-9960 ZEXEL)
- Injection pump : NP-PE6P120/721RS3S (106067-6280 ZEXEL)
- Governor : NP-EP/RLD300-1100P5JXR (105923-4810)
- Timer : 105681-2670
- Coupling : 105663-0470
- Plunger & barrel : 134153 -2420
- Delivery valve : 134180 - 0420
(2) Nozzle holder assembly : 65.10101-7087 (Y430 K02 049 BOSCH)
(3) Nozzle : 65.10102-6057 (0 433 171 694 BOSCH)
(4) Injection pipe : 65.10301-6049 , 65.10301-6052
(5) Firing order :1-5-3-6-2-4
(6) Injection timing : BTDC 3˚

Nozzle & holder ass’y Y430 k02 049 BOSCH Opening pressure : 214L8 bar
(A) Test condition
Injection pipe (ID x OD - L) - N 2.2 x N 6.35 – 650 mm
for injection pump
Test oil ISO4113 Temperature : 40 L 5C

65.10102-6057 Nozzle (5 x N 0.32)

Nozzle & holder Ass’y Opening pressure

65.10101-7087 1st : 184 kg/cm2
(B) Engine standard parts
2nd : 286 kg/cm2
65.10301-6076
Injection pipe (ID x OD - L) N 2.2 x N 6.35 – 650 mm
65.10301-6077

Rack diagram and setting valve at each point

Injection Q`ty on RIG

Rack Pump
Power Check (mm3 / 1,000st) Press.
position speed
point (A) Test condition (B) Engine (mmHg)
(mm) (rpm)
for inj. Pump standard parts

A R1(12.9) 1100 131 L 2 - -

B R1-1.5 600 (122) - -

C R2(R1-1.5) 500 (126) - (140)

D R2-1.0 500 (100) - 50

H ≠ 8.5 300 14.5 L 1.5 - -

I ≠ R1 100 (160) - -

Governor weight 850 g Lever ratio (min.) 1 : 1.1

Governor spring (outer) k = 9.8 N/mm Governor spring (inner) k = 5.88 N/mm

Idle spring (outer) k = 4.9 N/mm Idle spring (inner) k = 0.49 N/mm

Start spring k = 0.049 N/mm retraction pressure 0mm3, (N8mm)

Delivery
Boost spring k = 23.5 N/mm opening pressure 0.87 MPa
Valve
Plunger N12 Right hand 35 lead spring k=12.7 N/mm

MAINTENANCE OF MAJOR COMPONENTS - 102 -

(7) Governor adjustment (DE08TIS-225PS)

I
A

C B

D
Rack position (mm)

Injection pump speed (rpm)

EA9M4005

- 103 - MAINTENANCE OF MAJOR COMPONENTS

4) DE08TIS (240PS)
(1) Injection pump ass’y : 65.11101-7331 (106671-9960 ZEXEL)
- Injection pump : NP-PE6P120/721RS3S (106067-6280 ZEXEL)
- Governor : NP-EP/RLD300-1100P5JXR (105923-4810)
- Timer : 105681-2670
- Coupling : 105663-0470
- Plunger & barrel : 134153 -2420
- Delivery valve : 134180 - 0420
(2) Nozzle holder assembly : 65.10101-7087 (Y430 K02 049 BOSCH)
(3) Nozzle : 65.10102-6057 (0 433 171 694 BOSCH)
(4) Injection pipe : 65.10301-6049 , 65.10301-6052
(5) Firing order :1-5-3-6-2-4
(6) Injection timing : BTDC 3˚

Nozzle & holder ass’y Y430 k02 049 BOSCH Opening pressure : 214L8 bar
(A) Test condition
Injection pipe (ID x OD - L) - N 2.2 x N 6.35 – 650 mm
for injection pump
Test oil ISO4113 Temperature : 40 L 5C

65.10102-6057 Nozzle (5 x N 0.34)

Nozzle & holder Ass’y Opening pressure

65.10101-7087 1st : 184 kg/cm2
(B) Engine standard parts
2nd : 286 kg/cm2
65.10301-6076
Injection pipe (ID x OD - L) N 2.2 x N 6.35 – 650 mm
65.10301-6077

Rack diagram and setting valve at each point

Injection Q`ty on RIG

Rack Pump
Power Check (mm3 / 1,000st) Press.
position speed
point (A) Test condition (B) Engine (mmHg)
(mm) (rpm)
for inj. Pump standard parts

A R1(12.9) 1100 131 L 2 - -

B R1-1.5 600 (122) - -

C R2(R1-1.5) 500 (126) - (140)

D R2-1.0 500 (100) - 50

H ≠ 8.5 300 14.5 L 1.5 - -

I ≠ R1 100 (160) - -

Governor weight 850 g Lever ratio (min.) 1 : 1.1

Governor spring (outer) k = 9.8 N/mm Governor spring (inner) k = 5.88 N/mm

Idle spring (outer) k = 4.9 N/mm Idle spring (inner) k = 0.49 N/mm

Start spring k = 0.049 N/mm retraction pressure 0mm3, (N8mm)

Delivery
Boost spring k = 23.5 N/mm opening pressure 0.87 MPa
Valve
Plunger N12 Right hand 35 lead spring k=12.7 N/mm

MAINTENANCE OF MAJOR COMPONENTS - 104 -

(7) Governor adjustment (DE08TIS-240PS)

I
A

C B

D
Rack position (mm)

Injection pump speed (rpm)

EA9M4006

- 105 - MAINTENANCE OF MAJOR COMPONENTS

4.3.4. Fuel feed pump
1) General descriptions and construction
The P-type injection pump is mounted with K-ADS or KP type feed pump. These pumps
have the same basic construction and operation, and the general descriptions of the KP
type pump are given below:
The figures show its construction (right figure) and operation (below figure). The piston in
the fuel feed pump is driven by the push rod and tappet via the camshaft of injection pump
and performs reciprocating operation to control the suction and delivery of fuel. When the
cam reaches the Bottom Dead Center as shown in the figure, the fuel is drawn in through
the check valve on the inlet side.
The fuel pressurized as the cam rotates on flows through the check valve on the outlet side
as shown in (B). If the feeding pressure increases abnormally, the spring is compressed,
resulting in interrupting further delivery of fuel as shown in (C).

Priming pump

Check valve

Check valve

Outlet
Inlet
side
side

Tappet
Piston

Cam shaft

EQM4019I

MAINTENANCE OF MAJOR COMPONENTS - 106 -

 (A) (B) (C)
Inlet side Outlet side Interruption
EQM4020I

This feed pump is mounted with a priming pump designed to permit manual feeding of fuel from the
fuel tank with the injection pump mounted in the engine. During the manual feeding operation, air
must be bled from the fuel lines.
When using the priming pump, fix it securely to prevent the possible entry of moisture or other foreign
substances in the inside of feed pump.

In addition, a strainer is fitted into joint bolt on

the inlet side of the fuel feed pump to filtrate any
foreign substances possibly mixed in fuel.

Strainer

EB1M4003

- 107 - MAINTENANCE OF MAJOR COMPONENTS

2) disassembly

• Clamp the feed pump with a vise and disassemble the hollow screw (30, 32), strainer (31) and
seal ring (35, 36).

• Take off the priming pump (25), plug (16), both seal rings (18), spring (15), and check valve (14).
• Take off the plug (7), seal ring (8), spring (6), and piston (5) on the piston side.
• Pull out the snap ring (20) holding the tappet (10).
• Disassemble the snap ring, then take off the tappet (10) and push rod (1).
3) Inspection

• If the check valve is damaged or scored on its seat face, replace it with a new one.
• Inspect the piston and tappet for damage.
• Replace the push rod if excessively worn, and replace together with the pump housing if
required. The inspection for wear should be performed in the same procedure as for suction
pressure test described below.

4) Reassembly
Reassembly operation is performed in reverse order of disassembly. All the gaskets must be
replaced with new ones at reassembly.

MAINTENANCE OF MAJOR COMPONENTS - 108 -

5) Testing
(1) Suction capacity test
Connect one end of a hose to the inlet Outlet hose
side of the feed pump and immerse the
Feed pump
other end of it into the fuel tank as
illustrated.
Hold the feed pump in position about 1 m
above the level of fuel in the fuel tank.
Operate the tappet at the rate of 100 rpm Inlet hose

and check to see if fuel is drawn in and

delivered for 40 seconds or so.

Fuel tank

EQM4022I

(2) Delivery test

Make a test with the feed pump mounted
on a pump tester as illustrated. Operate
the pump at the rate of 1,000 rpm and
check to see if the pump delivery is more
than 405 cc/15 seconds.

EAMC016I

(3) Sealing test

Plug up the delivery port on the feed
Compressed Mass cylinder
pump and apply compressed air of 2
air 2kg / cm2
kg/cm2 into the inlet side.
Submerge the feed pump in a container
of diesel fuel and check for air leak.

Feed pump

EQM4023I

- 109 - MAINTENANCE OF MAJOR COMPONENTS

4.3.5. Injection nozzle
1) General descriptions
Pressurized fuel delivered from the fuel injection pump is sprayed into the combustion
chamber past the injection nozzle at proper spray pressure and spray angle, then burnt
completely to achieve effective engine performance.

(1) At valve closed (2) At valve opened

EQM4024I

2) Construction

1. Nozzle holder
2. Union nut
3. Shim
1 4. Spring
2 5. Guide bush
3 6. Intermediate washer
4 7. Cap nut

5 8. Nozzle ass’y
6
7
8
EFM2054I

3) Disassembly

• Clamp the nozzle assembly and remove the nozzle holder.

• Remove the nozzle nut and components inside.
4) Inspection

• Visually inspect the disassembled components for damage.

5) Reassembly

• After removing carbon deposit, submerge the nozzle in diesel oil and clean it.
• Replace all the seal rings with new ones.
• Assemble the parts and tighten them to specified torque.
MAINTENANCE OF MAJOR COMPONENTS - 110 -
6) Adjustment

• After reassembly, install the nozzle on a

tester.

• With the adjusting screw loosened,

operate the nozzle 2 ~ 3 times to bleed it.

• Operate the nozzle tester lever at the

specified rate.

• Adjust the injection pressure to the

standard pressure by spring tension
shims.
EFM2056I
• After adjusting the injection pressure,
tighten the cap nut to specified torque.

• Re-check the injection pressure and see if

the spray pattern is normal. Spray pattern
should be uniform and free of spattering.

Normal Abnormal Abnormal

EFM2057I

7) Testing
With the nozzle assembled to a nozzle tester
and specified pressure applied, check the
nozzle for fuel leakage.

EAMC022I

Engine Model D1146 D1146TI DE08TIS

1st : 184 kg/cm2

Opening pressure 210 kg/cm2 214 kg/cm2
2nd : 286 kg/cm2

- 111 - MAINTENANCE OF MAJOR COMPONENTS

4.3.6. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Engine won’t start • Fuel pipes clogged or air into Correct

1) Fuel not being pumped pipe line
out from feed pump • Feed pump valve defective Replace

• Feed pump piston or Push rod Disassemble, correct

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

• Plunger and/or delivery valve Disassemble, correct

sticking or defective
3) Fuel injection timing • Injection pump not properly Check, correct
Incorrect installed on pump bracket

• Injection pump tappet Check, correct

incorrectly adjusted

• Cams on cam shaft worn Replace

excessively
4) Injection nozzles • Needle valves sticking Correct or replace
inoperative • Fuel leaking past clearance Correct or replace
between nozzle and needle
valve

• injection pressure incorrect Adjust

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

• Air in fuel Bleed

• Feed pump delivery insufficient Disassemble, correct

• Fuel delivery insufficient due to Replace breather

clogging of fuel tank air breather
3. Engine lacks power • Plunger worn excessively Replace

• Injection timing incorrect Adjust

• Delivery valves defective Replace

• Nozzle leaks excessively Correct or replace

• Nozzle not working normally Disassemble, correct

4. Engine knocking • Injection timing too fast Adjust

• Nozzle injection pressure too Adjust

high

• Nozzles not working normally Disassemble, correct

5. Engine knocks seriously • Injection timing incorrect Adjust

producing excessive • Nozzle injection pressure too low Adjust
exhaust smoke • Nozzle spring broken Replace

• Nozzles not working normally Replace

• Plungers worn excessively Adjust

• Delivery valves seat defective Replace

• Supply of fuel excessively Check feed pump

MAINTENANCE OF MAJOR COMPONENTS - 112 -

 Complaints Possible causes Corrections

6. Engine output unstable • supply of fuel insufficient Check feed pump

• Air in fuel Bleed

• Water in fuel Replace fuel

• Operation of plungers unsmooth Disassemble, correct

• Movement of control rack Disassemble, correct

sluggish

• Nozzles defective Disassemble, correct

• Injection starting pressure of Adjust

each barrel incorrect

• Automatic timer defective Disassemble, correct

7. Engine does not reach • Nozzles not working normally Disassemble, correct

maximum speed • Governor defective Disassemble, correct

8. Engine idling unstable • Movement of control rod Disassemble, correct

sluggish • Operation of plungers unsmooth Disassemble, correct

• Control pinions not engaged Disassemble, correct

with control rod correctly

- 113 - MAINTENANCE OF MAJOR COMPONENTS

4.4. Turbocharger (D1146TI, DE08TIS)

4.4.1. Main data and specifications

1) Main data and specifications

DE08TIS
Specification D1146TI
225PS 240PS

ALLIED SIGNAL HOLSET

Turbocharger model
466721-12 WH1E-8284AX/H14EC8

Air pressure at compressor outlet 1.26 kg/cm2 1.33 kg/cm2 1.40 kg/cm2
At maximum
Air suction volume 16.8 m3/min 18.0 m3/min 18.4 m3/min
output
Speed of turbine revolution 102,800 rpm 98,200 rpm 99,840 rpm
Maximum allowable speed 126,150 rpm 127,660 rpm

Max. allowable temperature of exhaust gas at

turbine inlet 750 ˚C 720 ˚C

Lubricating system External oil supply External oil supply

Weight 9.5 kg 14.4 kg

2) Construction

1 D 2
3

A B

4 E

C EA05008I

1. Impeller casing A. Air inlet

2. Turbine casing B. Gas outlet
3. Bearing casing C. Gas inlet
4. Impeller D. Oil supply
5. Turbine E. Oil return

MAINTENANCE OF MAJOR COMPONENTS - 114 -

3) Construction

43 32 16
7 66
91
8 61 *
61 * 31 33

13

4 64

34 82 38
22 67
80
64 11 46

77

11
36
12 57
83
75

88 74
81

EB5M4003

4 Bearing housing 32 O-ring 67 Hex bolt

5 Turbine housing 33 Oil baffle 74 Actuator ass`y
6 Turbine wheel ass`y 34 Inlet baffle 75 Hose clamp
7 Compressor wheel 36 Thrust collar 77 Actuator clip
8 Compressor housing 38 Heat protector cover 80 Cover plate
11 Journal bearing 43 Oil seal plate 81 Hose
12 Thrust bearing 46 Gasket 82 Elbow
13 Piston ring seal(turbine) 57 Hex bolt 83 Hex nut
16 Piston ring seal 61 Lock nut 88 Clamp plate
22 Retainer ring 64 Snap ring 91 Retaining ring
31 Oil stopper

- 115 - MAINTENANCE OF MAJOR COMPONENTS

 3) Operating principle

Compressor housing

Compressor wheel

The turbocharger is a system designed to make use of the engine exhaust gas energy to
charge high-density air into the cylinders, thereby to increase the engine output.

4.4.2. General descriptions

The engine output is determined by the fuel delivery volume and engine efficiency.
To burn the supplied fuel completely to change into effective power for the engine, the volume
of air enough to burn the fuel completely should be supplied into the cylinders.
Therefore, the engine output is determined substantially by the cylinder capacity, and a greater
volume of compressed air is charged into cylinders of given capacity, the greater engine output
can be obtained as a greater volume of air charged into the cylinders burns so much more fuel.
As explained, the compressing of air to supply into the cylinders is called “Supercharging” and
the making use of the energy of exhaust gas discharged from the combustion chamber to
charge the compressed air into the cylinders is called “Turbocharging”.

MAINTENANCE OF MAJOR COMPONENTS - 116 -

4.4.3. Functions

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

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

3) Bearings
(1) Thrust bearing
The turbine wheel creates thrust force. Therefore, exercise care so that the shaft is not
deviated from its the original position due to this thrust.
(2) Journal bearing
This journal bearing of floating type forms a dual oil film on both the inside and outside of
the bearing so that the bearing can rotate independently. As the dual oil film plays a role as
a damper, the sliding speed of the bearing surface becomes lower than the rotating speed
of the shaft, resulting in assurance of stability in its movement.

4) Sealing-Compressor shaft
The compressor is of a dual construction type composed of seal plate and seal ring to prevent
the leak of compressed air or lubricating oil.

- 117 - MAINTENANCE OF MAJOR COMPONENTS

4.4.4. Precautions for operation
1) Precautions for operation of engine
The following precautions should be observed when starting, operating, or stopping the
engine:

Operations Precautions Reasons

When starting 1) Check oil level

the engine 2) Crank the engine with starter to 2) Abrupt starting of the engine
check the increase in oil causes the engine to rotate with oil
pressure(until the needle of not being distributed not only to
pressure gauge starts to move or each part but also to the
pressure indicator lamp is turbocharger, resulting in abnormal
actuated) before starting the wear or seizure on the bearing due
engine. to insufficient supply of oil.
3) When having replaced oil, oil filter 3) In the case of the engine stopped
element, or lubricating parts, or for extended time or in a cold
when having stopped the engine place, oil fluidity within the pipes
for extended period of time, or in a can be deteriorated
cold place, loosen the oil pipe
connections and operate the
starter motor until oil is discharged.
After completing the operation, be
sure to retighten the oil pipe
connections portion before starting
the engine.

Immediately 1) Run the engine at idle for 5 1) Applying load abruptly If load is
after starting minutes after starting off. abruptly applied with the engine
and turbocharger rotating
unsmoothly, such parts that a
sufficient amount of oil has not
reached can be seized up.
2) Check each part for leakage of oil, 2) Leakage of oil, gas, and air
gas, and air, and take proper (especially, oil leak) causes drop in
measure. oil pressure and loss of oil results
in seizure of the bearing.

During operation Check the followings: 1) Excessively low oil pressure

1) Oil pressure At idle: 0.8 kg/cm2 or causes unusual wear or seizure of
more At full load: 3.0 ~ 4.8 kg/cm2 the bearing. Too high pressure
causes oil leakage.
2) If unusual sound or vibration is 2) The engine is operated continuously
heard or felt, reduce engine with unusual sound or vibration not
revolutions slowly and locate the corrected, it can be damaged
cause. beyond repair.
When stopping 1) Run the engine at idle for 5 1) If the engine is put to a stop after
the engine minutes before stopping. being operated at high load, heat
from the red-hot turbine blades is
transmitted to the bearing portion
and burns oil to cause seizure of
the bearing metal and rotating
shaft.

MAINTENANCE OF MAJOR COMPONENTS - 118 -

4.4.5. Walk-around check and servicing
As the condition of turbocharger depends greatly on how well the engine is serviced, it is very
important to maintain the engine in accordance with the specified maintenance procedure.

1) Intake system
Pay particular attention to the air cleaner when servicing the intake system.
In the case of wet-type air cleaner, if the level of oil surface is lower than specified, cleaning
effect is poor; if too high, the cleaner draws in oil to foul the case.
Especially, if the rotor is fouled, the sophisticatedly-tuned balance is broken to create
vibration and to cause seizure and unusual wear to the bearing.
Therefore, it is very important to use a good quality air cleaner all the time.
In the case of dry-type air cleaner, it is essential to clean it to reduce intake resistance as
much as possible.

2) Exhaust system
Pay particular attention to prevent gas leaks and seizure when servicing the exhaust system
because leakage of exhaust gas from discharge pipes, turbocharger fixing portions, etc.
lowers charging effect.
As such components as turbine chamber that becomes red-hot during operation use heat
resisting steel nuts, do not interchange these nuts with ordinary steel nuts. In addition, apply
anti-seizure coating to fixing nuts on the portions as designated.

3) Fuel system
If the full load stopper regulating the maximum injection volume and the maximum speed
stopper regulating the maximum speed in the fuel injection pump are adjusted without using
a pump tester, the turbocharger rotates at excessively rapid speed and may suffer damage.
Besides of it, if spray pattern from the fuel injection nozzles is bad or the injection timing is
incorrect, temperature of exhaust gas rises up to affect the turbocharger adversely. To avoid
such trouble, be sure to make a nozzle test.

4) Lubricating system
Pay particular attention to oil quality and oil filter change intervals when servicing the
lubricating system. Deteriorated engine oil affects adversely not only the engine but torso the
turbocharger. Suggested engine oils for the turbocharger-mounted engine are as follows :

Recommend oil
Engine model
SAE No. API No.

D1146
SAE15W40 above CD or CE
D1146TI

ACEA-E2 or ACEA-E3
DE08TIS SAE15W40
(API CH-4)

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

- 119 - MAINTENANCE OF MAJOR COMPONENTS

4.4.6. Periodical checking and servicing
Make it a rule to check the turbocharger assembly for condition and contamination periodically.

1) Guide for checking the rotor for rotating condition

The inspection of the rotor assembly for rotating condition should be performed by the
degree of unusual sound. If a sound detecting bar is used, install its tip on the turbocharger
housing and increase the engine revolutions slowly. If a high-pitch sound is heard
continuously, it means that the rotor assembly is not normal. In this case, as the metal
bearing and rotor are likely to be in abnormal conditions, the turbocharger should be
replaced or repaired.

2) Guide for checking rotor end play

Disassemble the turbocharger from the engine, then check the rotor axial play and radial play.
When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports with taps,
etc.

(1) Rotor axial play

Turbine wheel room
Magnet vise

Move the turbine

shaft to axial
direction
Dial gauge

Standard : 0.117~0.20mm
Limit of wear : 0.24mm EA8M4003

(2) Rotor radial play

Dial gauge
Magnetic vise

Oil outlet

Radial play Move the turbine shaft

Standard : 0.075~0.11mm in both directions
Limit of wear : 0.12mm simultaneously

Oil inlet

EA8M4004

MAINTENANCE OF MAJOR COMPONENTS - 120 -

 (3) If the measured axial and radial plays are beyond the limit of wear, replace or repair the
turbocharger.

3) Guide for disassembling/cleaning and checking the turbocharger

First, disassemble the turbocharger from the engine and clean/check it with the oil inlet and outlet
plugged with tape and so on.

4) Precautions for reassembling the turbocharger onto the engine

For reassembly of the turbocharger or handling it after reassembly operation, be sure to observe
the following precautions :
Especially, exercise extreme care to prevent foreign matters from entering the inside of the
turbocharger.

(1) Lubricating system

• Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port and
lubricate the journal and thrust bearings by rotating them with hand.

• Clean not only the pipes installed between the engine and oil inlet port but also the oil outlet
pipe and check them for damage or foreign matters.

• Assemble each joint on oil pipes securely to prevent oil leaks.

(2) Intake system

• Check the inside of the intake system for foreign matters.

• Assemble each joint on the intake duct and air cleaner securely to prevent air leaks.
(3) Exhaust system

• Check the inside of the exhaust system for foreign matters.

• Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordinary
steel bolts and nuts when performing reassembly operation.
Apply anti-seizure coating to the bolts and nuts.

• Assemble each joint on the exhaust pipes securely to prevent gas leaks.

- 121 - MAINTENANCE OF MAJOR COMPONENTS

4.4.7. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Excessive black smoke 1) Air cleaner element clogged Replace or clean

2) Restrictions in air duct Check and correct

3) Leakage at intake manifold Check and correct

4) Turbocharger seized up and not rotating Disassemble/repair

or replace

5) Turbine blades and compressor blades Disassemble/repair

coming in contact with each other or damaged or replace

6) Exhaust piping deformed or clogged Check and correct

2. Excessive white smoke 1) Oil leak into turbine and compressor Disassemble/repair

or replace

2) Worn or damaged seal ring due to excessive Disassemble/repair

wear of bearing or replace

3. Low engine output 1) Gas leak at each part of exhaust system Check and correct

2) Air cleaner element restricted Replace or clean

3) Turbocharger fouled or damaged Disassemble/repair

or replace

4) Leakage at discharge port on compressor side Check and correct

4. Unusual sound or 1) Rotor assembly coming in contact Disassemble/repair

vibration or replace

2) Unbalanced rotation of rotor Disassemble/repair

or replace

3) Seized up Disassemble/repair

or replace

4) Each joint loosened Check and correct

MAINTENANCE OF MAJOR COMPONENTS - 122 -

5. SPECIAL TOOL LIST

No. Part No. Figure Tool Name Remark

EF.123-014 D1146/TI

1 Injection pump setting ass’y

EF.123-015 DE08TIS

CR : made USA
EF.123-127
(up to 2000. Apr.)
2 Oil seal insert ass’y (Front)
NOK : made Japan
EF.123-173
(From 2000. may.)

CR : made USA
EF.123-043
(up to 2000. Apr.)
3 Oil seal insert ass’y (Rear)
NOK : made Japan
EF.123-184
(From 2000. may.)

4 EF.123-052 Oil seal puller ass’y (Front)

5 EF.123-048 Oil seal puller ass’y (Rear)

6 EU.2-0530 Cylinder pressure tester adapter

7 EU.123-086 Cylinder liner puller ass’y

8 EF.123-179 Valve stem seal punch

9 EU.2-0131 Valve clearance adjust ass’y

EB1M70

- 123 - SPECIAL TOOL LIST

 No. Part No. Figure Tool Name Remark

10 EF.123.-065 Valve spring press

11 EU.2-0647 Crankshaft gear punch

D1146/TI
EF.123-064
DE08TIS
12 Piston sleeve

EF.120-208 All engine

13 60.99901-0027 Feeler gauge

14 T7610001E Snap ring plier

15 T7621010E Piston ring plier

SPECIAL TOOL LIST - 124 -

APPENDIX

• Tightening torque for major parts

Screw Strength
Major Parts Tightening Torque Remarks
(Diameter x pitch) (grade)

1st : 6.0 kg•m

2nd : 180°
Cylinder head bolt M14 B 1.5 10.9T
3rd : 150°
(Angle method)

1st : 10 kg•m
Connecting rod bearing cap bolt M14 B 1.5 12.9T 2nd : 15 kg•m
3rd : 18 kg•m

1st : 15 kg•m
Crankshaft main bearing cap bolt M16 B 1.5 12.9T 2nd : 25 kg•m
3rd : 30 kg•m

Balance weight fixing bolt M12 B 1.5 10.9T 9.0 kg•m

Flywheel housing fixing bolt M14 B 1.5 10.9T 8.0 kg•m

Flywheel fixing bolt M14 B 1.5 10.9T 21.5 kg•m

Crankshaft pulley fixing bolt M12 B 1.5 10.9T 13.4 kg•m

Oil spray nozzle M14 B 1.5 - 7.0 kg•m

• Tightening torque for fuel injection pump system

Screw Strength
Major Parts Tightening Torque Remarks
(Diameter x pitch) (grade)

Injection nozzle nut M28 B 1.5 - 7.0 L 0.5 kg•m

Injection pump bracket bolt M10 8.8T 4.4 kg•m

Injection pump coupling bolt - - 6.0 ~ 6.5 kg•m

Injection pump driving gear nut M24 B 1.5 8.8T 25.0 kg•m

Injection pipe nut M14 B 1.5 8.8T 3.0 kg•m

Injection pump delivery valve holder - - 11.0 ~ 12.0 kg•m

- 125 - APPENDIX
• Standard bolt tightening torque table
Refer to the following table for bolts other then described above

Degree of strength
Diameter 3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
B (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
pitch Limit value for elasticity (kg/mm2)
(mm) 20 24 32 30 40 36 48 54 64 90 108
Tightening torque (kg•m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.5 0.75 0.9
M6 0.28 0.30 0.45 0.4 0.55 0.47 0.77 0.85 0.9 1.25 0.5
M7 0.43 0.46 0.7 0.63 0.83 0.78 1.2 1.3 1.4 1.95 2.35
M8 0.7 0.75 1.1 1 1.4 1.25 1.9 2.1 2.2 3.1 3.8
M8 B 1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.35 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10 B 1 1.5 1.6 2.5 2.1 3.1 2.8 4.3 4.9 5 7 8.4
M12 2.4 2.5 3.7 3.3 4.7 4.2 6.3 7.2 7.5 10.5 12.5
M12 B 1.5 2.55 2.7 4 3.5 5 4.6 6.8 7.7 8 11.2 13.4
M14 3.7 3.9 6 5.2 7.5 7 10 11.5 12 17 20
M14 B 1.5 4.1 4.3 6.6 5.7 8.3 7.5 11.1 12.5 13 18.5 22
M16 5.6 6 9 8 11.5 10.5 17.9 18.5 18 26 31
M16 B 1.5 6.2 6.5 9.7 8.6 12.5 11.3 17 19.5 20 28 33
M18 7.8 8.3 12.5 11 16 14.5 21 24.2 25 36 43
M18 B 1.5 9.1 9.5 14.5 12.5 18.5 16.7 24.5 27.5 28 41 49
M20 11.5 12 18 16 22 19 31.5 35 36 51 60
M20 B 1.5 12.8 13.5 20.5 18 25 22.5 35 39.5 41 58 68
M22 15.5 16 24.5 21 30 26 42 46 49 67 75
M22 B 1.5 17 18.5 28 24 34 29 47 52 56 75 85
M24 20.5 21.5 33 27 40 34 55 58 63 82 92
M24 B 1.5 23 25 37 31 45 38 61 67 74 93 103

Others : 1. The above torque rating have been determined to 70% or so of the limit value for bolt
elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the standard
value.

• Tightening torque for hollow screw (4-hole)

Material M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
SM25C - 1.6 2.5 3.5 4.5 5.5 9.0 13.0 18.0 30.0
*SUM22L 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
STS304 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0

* : Adopted in DOOSAN engine

APPENDIX - 126 -
• Maintenance specification table (unit : mm)
Stand value Limit
Group Part Inspection Item Correction Remark
for assembly for use

Measure unworn
Inside diameter of N111 ~
N111.122 Replace liner portion beneath the
Cylinder liner for wear N111.022
rim of the upper side

Need amount of Projection difference

Amount of liner
Cylinder 0.03 ~ 0.08 - projection without between adjacent
projection
block & fail liners : 0.15 vl
liner The flatness of upper Correct with a Referenced length :
0.05 -
Engine surface of cylinder block surface grinder 200mm

body Hydraulic test for 1

4 Replace if leaky
minute (kg/cm2)

Valve seat Intake 0~0.3 0.55 Replace valve

Cylinder depression Exhaust 0~0.3 0.55 seat

head & Cylinder head height 109.9 ~ 110.1 108.4 Replace cyl. head

valve Hydraulic test for 1

4 - Replace if leaky Water temp. 70˚C
minute (kg/cm2)

Measure at 13mm
N110.883~
Outer dia. piston Replace liner away from lower
N110.897
surface of piston

Clearance between Replace one worn

0.103~0.139 0.3
piston and liner more

Width of Top ring - Replace piston if

Piston piston ring 2nd ring 3.06~3.08 groove width is beyond
grooves Oil ring 4.04~4.06 specified value

Piston projection from Measure unworn

cylinder block upper 0~0.12 Must exist portion beneath the
surface rim of the upper side

Permissible weight
±15 g 96 g vl Replace piston
Major difference of each piston

moving Top ring 0.40~0.60 1.5 Standard gauge

Piston ring
parts 2nd ring 0.40~0.60 1.5 Replace ring inside diameter :
gap
Oil ring 0.30~0.50 1.5 N108
Piston Piston ring Top ring - -
Replace ring or Limit for use if for
ring side 2nd ring 0.07~0.102 0.15
piston standard clearance
clearance Oil ring 0.05~0.085 0.15

Cross Install by
Direction of ring gap - -
120˚

Outer diameter of piston

N41.994 ~ N42 41.94 Replace piston pin
Piston pin

pin Clearance between Replace one worn

0.003 ~ 0.015 0.08
piston pin and its bush more

- 127 - APPENDIX
 (unit : mm)
Stand value Limit
Group Part Inspection Item Correction Remark
for assembly for use
Radial run-out of journal Correct Measure In horizontal
- 0.01 installing the bearing
and pin with a grinder and releasing one bolt
Outside diameter of N83.966 ~ Use under sized
journal N83.988 N83
bearings
N70.971~ respectively(0.25,
Outside diameter of pin N70.990 N70 0.5, 0.75, 1.0)
Ellipticity of journal
and pin 0.008 0.025
Concentricity of journal
and pin 0.01 0.03
Taper of journal and pin 0.02 0.03
Clearance between Replace bearing Measure at crown
Crank crankshaft and bearing 0.052~0.122 0.25 part not parting line
shaft Replace
End play of crankshaft 0.15~0.325 0.5 thrust bearing
Measure at No.4
Run-out of crankshaft 0.06 0.1 vl Adjust by a press bearing (No. 1 & 7
if bended bearing supported)
Balance of 60 or Check dynamic Measure
crankshaft(g•cm) 60 vl less balance at 400 rpm
Torque valve journal Clean out foreign
bearing cap bolt 30 Coat the bolt with objects on joining
(kg•m) engine oil surface
Measure after
Crush height of journal 0.08~0.110 - tightening metal cap
bearing and releasing one stud
Oil seal for wear (crank Replace oil seal
Major shaft rear) - - if oil leaking
moving End play of con-rod 0.170 ~ 0.248 0.50 Replace con-rod
parts Clearance between con-
rod bearing and crank 0.034 ~ 0.098 0.25 Replace bearing
pin
Clearance between
small end bush & 0.050~0.081 0.12
piston pin
Connec- Measure after
ting rod Crush height of con-rod 0.04~0.07 - installing the bearing
bearing and releasing one bolt
Side clearance of big-
end and small-end - 0.50 Replace con-rod
Allowable weight
difference per con-rods 30 g vl -
Torque valve of Clean out foreign
con-rod bearing cap bolt 18 - Coat the bolt with objects on joining
(kg•m) engine oil surface
Diameter of cam shaft
journal N57.86~N57.88 N57.52
Clearance between cam
Cam shaft and cam bush 0.12~0.17 0.24 Replace cam bush
shaft Replace thrust
End play of camshaft 0.28~0.43 0.6 washer
Correct or replace
Run-out of camshaft 0.05 0.2 the cam shaft

APPENDIX - 128 -
 (unit : mm)
Stand value Limit
Group Part Inspection Item Correction Remark
for assembly for use
Clearance between idle
shaft bush and idle shaft 0.025~0.091 0.15
Major End play of idle gear Replace thrust
0.043~0.167 0.3
moving Timing shaft collar
gear
parts Back-lash between
gears(cam, idle, crank 0.16~0.28 0.35 Correct or replace
and injection) gear
Diameter of intake valve
stem N8.950~N8.970 N8.93 Replace valve & When replacing
valve, replace
Diameter of valve guide
exhaust valve stem N8.935~N8.955 N8.91 valve guide alike
Clearance
Intake 0.030~0.065 0.15
between valve Replace valve or Replace one worn
stem and valve guide more
valve guide Exhaust 0.045~0.080 0.15
Thickness Intake 2.7
Max. 1 Replace valve
of valve head Exhaust 2.2
Clearance
Intake 2.0 -
between valve
guide and valve
spring seat Exhaust 2.0 -
Clearance between valve Spread oil over
guide and cyl. head -0.039~-0.010 valve guide and
installing hole (Press fit) press it into the hole
Concentricity between
valve stem and valve 0.05 Without spring seat
head
Free length(mm) Approx.64 -
Valve
Valve Tension force
system Intake (when pressed 67~73 66.5 Replace
valve to 41mm)kg valve spring
spring Squareness
(along free 1.5°
length direction)
Free length D1146/TI : 60
(mm) DE08TIS : 73.8
Tension
I force(when D1146/TI : 26.9~30.3 Replace
n -
pressed to DE08TIS : 36~40 valve spring
n 38mm)kg
e
r Squreness
(along free 1.5°
Exhaust length
valve direction)
spring D1146/TI : 71
Free length
DE08TIS : 77.7
Tension
O force(when D1146/TI : 62.7~69.3 Replace
u -
pressed to DE08TIS : 71~79 valve spring
t
e 41mm)kg
r Squreness
(along free
1.5° -
length
direction)

- 129 - APPENDIX
 (unit : mm)
Stand value Limit
Group Part Inspection Item Correction Remark
for assembly for use
Valve Intake 0.3 -
clearance Adjust
(at cold) Exhaust 0.3 -
Grind or replace if
Joining surface of valve severely pitted on
stem and rocker arm - -
tip of rocker arm
bush and stem
Clearance between
Replace bush
rocker arm shaft & 0.040~0.113 0.2
or shaft
rocker arm bush
Valve Diameter of rocker arm
system shaft for wear N23.939 ~ N23.96 N23.75 Replace
Tappet
Run-out of push rod - 0.3 Replace
Clearance between
tappet & tappet hole 0.035 ~ 0.077 0.15 Replace tappet
of cyl.bolck
Diameter of tappet N19.944 ~ N19.965 - Replace tappet
Tappet face in contact Replace
- - if severely worn or
with cam
deformed
Check oil leakage
Oil pressure (at
4.8 or less 3.5 and clearance
Oil normal speed)kg/cm2
between each part
pressure
Oil pressure Use recommended
0.8~1.4 0.6
(idling)kg/cm2 oil
Max. permissible
- 105
Oil oil temperature (˚C) Must not exceed this
tempera Permissible valve
ture oil temperature - 120
in short time (˚C)
Axial play
0.055 ~ 0.105 -
Lubricating of oil pump gear Replace gear
system Clearance between or cover
gear shaft & oil pump 0.032 ~ 0.077 -
cover hole
Clearance between
Replace bush
drive gear shaft and 0.040 ~ 0.094 -
or cover
Oil cover hole
pump Diameter of gear shaft N16.950 ~ N16.968 Replace gear shaft N17e7
Diameter of driving gear
N28.000 ~ N28.033 Replace bush N28e7
bush
Between crank
gear & idle 0.15 ~ 0.25 0.8
gear
Backlash Adjust back-lash
Between oil
pump drive 0.15 ~ 0.25 0.8
gear & idle gear

APPENDIX - 130 -
 (unit : mm)
Stand value Limit
Group Part Inspection Item Correction Remark
for assembly for use
Oil pressure control
4.0 ~ 4.8 -
valve (kg/cm2)
By-pass valve for filter
1.8 ~ 2.3 - Replace valve
element (kg/cm2)
Valve By-pass valve for full oil
Lubricating 4.0 ~ 4.8 -
opening filter (kg/cm2)
system
pressure Relief valve for oil
8.5 ~ 11.5 -
pump (kg/cm2)
Replace valve
Spray nozzle control
1.5 ~ 1.8 -
valve (kg/cm2)
Oil Damage of oil filter
- - Clean or replace
filter cartridge
Radiator & water pump
for corrosion, damage & - - Correct or replace
improper connecting
Submerge in water
Test for leakage
1.0 - and replace if air
(air pressure) (kg/cm2)
bubbles found
Radiator Pressure valve for
opening pressure 0.5 -
(kg/cm2)
Negative pressure valve
for opening pressure 20 -
(mmHg)
Delivery volume l/min
- Engine speed 2,700rpm
Check the water
Cooling - Water temp.80 ˚C 280 - For any restrictions
passage
system - Back pressure : 0.8
kg/cm2
Water Clearance between Replace if impeller
0.35 -
pump impeller & housing & housing are damaged
Perpendicularity of Adjust by a bench
0.3
pulley press
Fan belt depression(with
Approx. 15 Adjust
thumb) mm
Operating temperature
Cooling 79 ~ 95 -
(permissible temp.) ˚C Must not exceed this
water
Permissible temperature valve
temp - 105
in a short time. ˚C
Thermostat
Type-II
opening temp. ˚C 79 - Replace
- Opening temp. : 83˚C
Thermostat (under atmospheric pressure)
- Full opening temp. :
Replace if defective
Full opening temp. ˚C 94 - 95˚C
Stroke min. 8mm

- 131 - APPENDIX
 (unit : mm)
Stand value Limit
Group Part Inspection Item Correction Remark
for assembly for use
Fuel pipe, injection pipe
& nozzle holder for
Piping - - Repair or replace
damage, cracks,
&
improper packing, etc.
others
Fuel filter cartridge for
- - Replace cartridge
Fuel damage or dimple
system Injection pressure of injection D1146 : 210
D1146TI : 214 - Adjust by shim
nozzle (kg/cm2) DE08TIS : 1st 184
2nd 286
Operating pressure of overflow
1.0 ~ 1.5 - Replace valve
valve (kg/cm2)
Projection height of nozzle from
2.53 - Replace seal ring
the cyl. head surface(mm)
Refer to supplement
Running-in the engine - -
“running-in”
Inspection Compression pressure of 24 or
24 ~ 28 Correct
at Cylinder cylinder (kg/cm2) more
at 200rpm or more
completion pressure Compression pressure
L10% or less more(20 ˚C)
difference of each Correct
against average
cylinder

APPENDIX - 132 -