Академический Документы
Профессиональный Документы
Культура Документы
99897-8056
Feb. 2001
MAINTENANCE MANUAL
Diesel Engine
D1146
D1146TI
DE08TIS
PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
FOREWORD
This maintenance manual is designed to serve as a reference for DAEWOO Heavy
Industries Ltd's (here after DAEWOOs) customers and distributors who wish to gain basic
product knowledge on DAEWOO's D1146, D1146TI and DE08TIS Diesel engine.
This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct
injection type) has been so designed and manufactured to be used for the overland transport
or industrial purpose. That meets all the requirements such as low noise, fuel economy, high
engine speed, and durability.
To maintain the engine in optimum condition and retain maximum performance for a long
time, CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.
Removal
Adjustment
Installation
Cleaning
Disassembly
Reassembly
Directional Indication
Inspection
Measurement
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
z The regulations of the relevant local authorities are to be observed for the
disposal of spent coolants and special waste.
If you have any question or recommendation in connection with this manual, please do not
hesitate to contact our head office, dealers or authorized service shops near by your location
for any services.
For the last, the content of this maintenance instruction may be changed without notice for
some quality improvement. Thank you.
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
CONTENTS
1. GENERAL INFORMATION
1.1 General Repair Instructions
1.2. Engine Specific Character
1.3. Engine Specifications
1.4. Engine Assembly
1
2
4
8
2. MAJOR MAINTENANCE
2.1. Preventive Maintenance
2.2. Diagnosis and Remedy
2.3. Engine Inspection
13
22
32
3. MAINTENANCE
3.1. Engine Disassembly
3.2. Inspection and Measurement on Major Parts
3.3. Reassembly
3.4. Breaking in
33
48
69
96
98
102
106
122
132
Appendix
134
WORLDWIDE NETWORK
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
1. GENERAL INFORMATION
1.1. General Repair Instructions
1. Before performing service operation, disconnect the grounding cable from the battery
for reducing the chance of cable damage and burning due to short-circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they
cause paint damage.
4. The use of proper tools and special tools where specified is important to efficient and
reliable service operation.
5. Use genuine DAEWOO parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should
be discarded and new ones should be prepared for installation as normal function of
the parts can not be maintained if these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts
neatly in groups. Keeping fixing bolts and nut separate is very important as they vary
in hardness and design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using
compressed air to make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for bolts and nuts torques.
12. When service operation is completed, make a final check to be sure service has
been done property.
1
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
perform
high
efficiency,
low
M1041A
emission
such
as
smoke,
nitrogen
oxide,
high
performance
and
low
fuel
consumption.
2
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
M1255
3
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
D1146
Items
D1146TI
4 cycle in-line,
Water-cooled type
Naturally aspirated
Engine type
Combustion chamber type
4 cycle in-line,
Water-cooled type
Turbo charged & intercooled
Direct injection type
(mm)
(cc)
6 111 139
8,071
Compression ratio
Engine dimension (length x width x height)
Engine weight
(mm)
17.5 : 1
16.8 : 1
18.5 : 1
1,253x811.5x934.5
1,253x812.5x1,009
1,253x812.5x1,009
730
745
745
(kg)
Counter clockwise
153624
15
(kg/cm )
210
Compression pressure
(kg/cm )
214
160/220
Exhaust valve
Mechanical governor
type(RLD)
Governor type
Intake valve
DE08TIS
0.3
Open at
16 (B.T.D.C)
Close at
36 (A.B.D.C)
Open at
46 (B.B.D.C)
Close at
14 (A.T.D.C)
Lubrication method
Cartridge type
15.5/12 or 20/17
Water cooled
Water pump
Cooling Method
(lit)
14
Wax pallet type
(79 94 C or 83 95 C )
Thermostat type
Air compressor type & capacity
Alternator voltage capacity
Starting Motor voltage output
Air heater capacity
Battery capacity
(cc)
(V A)
24 45 or 24-150
(V - kW)
24 4.5
(V A)
22 95 (2.1kW)
(V - AH)
24 - 150
4
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Suffix
Performance
Injection
timing
(BTDC)
Power
(PS/rpm)
Torque
(kg.m/rpm)
Low idle
(rpm)
High idle
(rpm)
15
182/2,500
57.5/1,600
600-650
2750
Remark
EACBA
EACBB
D1146
EACBE
EACBH
EACBI
EACBK
2370
EAPBA
205/2,200
75/1,400
600-650
2,470
D1146TI
EURO-I
2250
EAPCA
215/2,300
82/1,400
600-650
2,350
ECPBA
ECPCA
225/2,300
82/1,200
600-650
2,530
DE08TIS
EURO-II
ECPBB
ECPCB
240/2,300
90/1,200
600-650
2,530
* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349).
5
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Performance
Output
(max.)
Torque
(min)
Fuel consumption
(min)
6
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Performance
Output
(max.)
Torque
(max.)
Fuel consumption
(min.)
7
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
6
3
7
8
9
2
10
11
12
13
14
15
16
17
19
18
20
21
22
1
4
7
10
13
16
19
22
25
23
Water pump
Intake valve
Cylinder head cover
Intake valve spring
Flywheel housing
Cam shaft
Oil seal (Front)
Vibration damper
Oil pan
24
2
5
8
11
14
17
20
23
26
25
Piston
Exhaust valve
Exhaust valve spring
Cylinder block
Ring gear
Fly wheel
Crank shaft pulley
Oil pump
Crank shaft
26
3
6
9
12
15
18
21
24
Air compressor
Breather
Cylinder head
Push rod
Tappet
Oil seal (Rear)
Crank gear
Oil suction pipe
8
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
6
7
2
1
10
11
12
13
16
14
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Turbo charger
Fuel injection pump
Timing gear case
Oil filler cap
Connecting rod
Oil spray nozzle
Oil filter
Oil cooler
9
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
14
15
16
11
10
12
17
19
20
13
22
21
1
2
3
4
Flywheel housing
Intake manifold
Breather
Air pipe
5
6
7
Fuel filter
Power steering pump
Air compressor
23
18
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Water pump
Exhaust manifold
Cylinder head cover
Crank shaft pulley
Vibration damper
Oil cooler
Starter
Cooling water pipe
10
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
14
15
16
2
1
10
11
12 13
18
19
20
21
28
22 23
24
Flywheel housing
Intake manifold
Fuel filter
Air pipe
(Intercooler to intake manifold)
6
7
8
9
10
11
30
31
17
1
2
3
4
5
29
25
26
12
13
14
15
16
17
18
27
Cooling fan
Cooling fan guide
Air compressor pulley
Thermostat
Water pump
Alternator
Air pipe
(Turbocharger to intercooler)
19
Air pipe
(Air cleaner to turbocharger)
20
Turbocharger
21
22
23
24
25
26
27
28
29
30
31
Exhaust elbow
Crank shaft pulley
Vibration damper
Mounting bracket
Oil cooler
Starter relay
Starter
Breather
Water delivery pipe
Air heater relay
Cooling water pipe
11
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
18
19 20
17
10
16
12 13 14 15
11
27
21
22 23
1
2
3
Intake manifold
breather
Air pipe
4
5
6
7
8
9
Fuel filter
Power steering pump
Air compressor
Oil filler cap
24
(Turbocharger to intercooler)
25
26
10
11
12
13
14
15
16
17
18
19
28
29
20
21
22
23
24
25
26
27
28
29
Water pump
Exhaust manifold
Belt
Mounting bracket
Oil cooler
Turbocharger
Starter
Cooling water pipe
Fly wheel
Pilot bearing
12
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
2. Major Maintenance
2.1. Preventive Maintenance
The preventive maintenance means that the operator performs the servicing of engine
to obtain long life and best performance from DAEWOO diesel engine.
2.1.1. Cooling Water
z Regarding the cooling water that is to be used for engine, the soft water not the hard
water must be used.
z The engine cooling water can be used diluting it with antifreezing solution 40% and
the additive for rust prevention (DCA4) 3 5 %.
z The density of above solution and additive must be inspected every 500 hours to
maintain it properly.
NOTE :
The proper density control of antifreezing solution and rust preventing
additive will be able to prevent the rusting effectively and maintain the stable
quality of engine. For the improper control might give the fatal damage to the
cooling water pump and cylinder liners, detail care is needed.
z Since D1146, D1146TI and DE08TIS (diesel engine of D1146 series) cylinder liner is
dry type, particularly the cooling water control should be applied thoroughly.
z The density of antifreezing solution and additive for rust prevention is able to be
confirmed by the cooling water test kit. (Fleetguard CC2602M or DAEWOO
60.99901-0038)
z How to use the cooling water test kit
(1) When the cooling water temp. of engine is in the range of 10 55 C,
loosen the plug for cooling water discharge and fill the plastic cup about a half.
NOTE :
In taking the cooling water sample, if the water in auxiliary tank were taken, it
is hard to measure the accurate density. Take the cooling water sample
necessarily loosening the cooling water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after taking the paper
out through water agitation, shake off the water.
13
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
(3) Wait for about 45 sec. till the color change of test paper.
NOTE :
However, it should not elapse longer than 75 sec, and if it did, the hue would
change.
(4) Make the numerical value by comparing the test paper which hue has
changed with the color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color
indication of test paper storage bottle, confirm the density. (Then, the density
indication must be in the hue range of 33% to 50%).
(6) The brown at the middle of test paper and the lower pink color indication
represent the additive state for rust prevention, and the proper range is that
the meeting numerical value of brown (vertical) and pink color (horizontal)
locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and
in case of more than 0.8, pour out the cooling water about 50% and then
readjust the density after refilling with clean fresh water.
z Amount of Anti-freeze in winter
Ambient
Cooling water (%)
Temperature (C)
Over -10
85
-10
80
-15
73
-20
67
-25
60
-30
56
-40
50
Anti-freeze (%)
15
20
27
33
40
44
50
14
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Engine
model
D1146
D1146TI
Recommend oil
Remark
SAE No.
API No.
SAE 15W40
above CD or CE
Oil filter
(Cartridge)
G1081
15
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
G1019
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
output
is
decreased
and
engine
16
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Air/air intercooler
with radiator
(combined radiator)
Model
Intake Valve
Exhaust Valve
D1146
D1146TI
DE08TIS
0.3 mm
0.3 mm
adjust
corresponding to
the
valve
clearance
of lower figure.
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
adjust
the
corresponding to
5) After
reinsuring
valve
clearances
of lower figure.
the
valve
clearances,
retighten if necessary.
z
Flywheel
Intake Valve
Exhaust Valve
Cylinder No.
Cooling Fan
G1048
G1067
18
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
z
z
If the inspected injection pressure is less than the specified value, adjust using
the adjusting shims.
Engine Model
Opening pressure
D1146
D1146TI
DE08TIS
210 kg/cm2
214 kg/cm2
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
z Check if the idle operation and speed regulating lever's sealing is removed.
z The adjustment and testing of fuel injection pump should necessarily be done at
the test bench.
2.1.12. Battery
z Inspect for any leakage of electrolytic solution owing to battery crack, and
replace
the battery in case of poor condition.
z Inspect for amount of electrolytic solution, and replenish if insufficient.
z Measure the gravity of electrolytic solution, if less than specified value (1.12
1.28), replenish.
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
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.
21
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
The following description summarizes the probable cause of and remedy for
generall failure by item.
22
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Operating state
1. Overload
2. Radiator core clogged
3. Continuous over-run
Check fresh
Radiator tank cap
Inspect
Radiator
23
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
24
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
25
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Overload
Freqent use of low geae position at high speed
Freqent use of high geae position at low speed
Clutch slip
Too low tire inflation pressure
26
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
27
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
28
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Condition
1) Starting difficult
(1) Compression pressure lack
Causes
z
z
z
z
z
z
Remedies
Repair or replace
Replace valve spring
Replace gasket
Adjust
Adjust
Remove air
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Adjust
Repair
Replace gasket
Replace piston ring
Adjust
Adjust injection pump
Adjust or replace
Repair or replace
Repair
Clean or replace air
cleaner
Repair or replace
Disassemble engine
Adjust
Adjust injection pump
Repair or replace
Repair, replace
Repair or replace
Clean or
replace air cleaner
4) Overheating
z
z
z
z
z
z
z
Replenish or replace
Replenish or replace
Adjust or replace
Repair or replace
Replace
Adjust
Clean or replace
29
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Condition
5) Engine noisy
(1) Crankshaft
Causes
For noises arise compositely
such as rotating parts, lapping
parts etc., there is necessity to
search the cause of noises
accurately.
z As the wear of bearing or
crankshaft progress, the oil
clearances increase.
z Lopsided wear of crankshaft
z Oil supply insufficient due to
oil passage clogging
z Stuck bearing
z
z
z
z
z
(4) Others
z
z
z
z
z
z
z
z
z
z
z
z
6) Fuel Consumption
Excessive
Remedies
z
z
30
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Condition
7) Oil Consumption
Excessive
(1) Oil level elevated
Causes
z
z
z
z
z
z
z
z
z
z
z
z
z
Remedies
Replace
Replace piston,
piston ring
Replace piston ring
Correct position
Replace piston
Replace piston ring
Replace piston ring
Replace in set
Replace seal
Replace gasket
Replace gasket, repair
Replace packing
Replace oil seal
31
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
: Replace
Inspection time(km)
Inspection
Daily
Remark
1,000
Cooling
System
10,000
15,000
20,000
1st
1st
Lubrication
Change the lubricating oil
System
Replace the oil filter cartridge
Check the leakage for intercooler
Fuel
System
40,000
()
()
When
necessary
When
necessary
Engine
Adjust
When
necessary
When
necessary
* () The engine oil change interval is determine by engine use and oil grade.
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3. MAINTENANCE
3.1. Engine Disassembly
3.1.1. Heed at disassembly
z Before disassembly, the part shelf should be prepared for various tools and repair
parts.
z When assembling, clean empty hand should be used and clean environment
maintained.
z In case of storing the disassembled parts, each part should not touch each other.
z In case of disassembly, the parts should be laid in order.
3.1.2. Oil level gauge
z Pull out the oil level gauge.
3.1.3. Cooling water
z Remove the radiator cap. Open the drain
valve at the radiator lower part to drain the
coolant as the right figure.
CAUTION:
When removing radiator filler cap while
the engine is still hot, cover the cap with a rag,
then turn it slowly to release the internal
Drain valve
P1024a
Drain plug
33
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Drain plug
G1086
3.1.6. Belt
z Loosen the tension adjusting bolts of the
alternator and the idle pulley, and take off
the belts.
3.1.7. Thermostat
z Loosen the rubber hose connected to the
cooling water pipe and remove the
thermostat.
z Remove the rubber hose of the by-pass
line.
34
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3.1.8. Starter
z Unscrew the starter fixing nuts and
remove the starter being careful not to
damage its gears.
3.1.10. Breather
z Loosen the clamp screw to remove the
rubber hose.
P068
35
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3.1.12. Alternator
z Remove the alternator fixing bolts and
take off the alternator.
36
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
37
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
38
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Intake manifold
cylinder head.
z Disassemble the intake manifold gasket
and discard it.
G1088
G1056
39
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
CAUTION :
When reassembling the bush, cool the
bush in dry ice and press the bush
while aligning the bush with the oil
hole of the rocker arm.
3.1.26. Cylinder head
z Remove the cylinder head bolts in the
reverse order of tightening but remove it
step by step.
First step : Loosen 1 2 threads
Second step : Remove by loosening fully.
However,
remove
the
total
bolts
G1089
G1102
40
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
M1072
G1090
41
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
the
upper/lower
of
disassembled
piston
assembly
42
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
43
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
44
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Oil seal
and
remove
the
drive
gear
assembly.
G1097
the
timing
gear
case
assembling bolts.
z By tapping lightly with a urethane
hammer the right and left back of timing
gear
case's
connecting
part,
and
disassemble
the
45
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3.1.41. Crankshaft
z Assemble the bolts on the both side of
crankshaft temporarily.
z Connect the rope to the bolts and lift the
crankshaft by means of crane being
careful not to give any damage on it.
z In order for the disassembled crankshaft
to be prevented from bends or damage,
put it on the special lathe and store.
z Disassemble the metal bearings in turn
and store them.
NOTES :
Do not mingle with the metal bearings
and bearing caps randomly. To prevent
mixing, temporarily assemble the metal
bearings to the corresponding bearing
caps in turn.
46
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
47
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
If there is any crack or severe damage, replace it and if there is minor one, correct
it.
z Check for any clogging or corrosion in the oil passage and water passage.
z Carry out a leakage test for any crack or air leaking. (Hydraulic test)
z Plug each cylinder block's water and oil discharge ports, and apply the air
pressure of about 4kg/cm2 to intake port and soak it in water for about 1 minute to
check if there is any leakage. (Water temperature : 70C)
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,
G1102
48
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
M1067
Limit
Warpage
0.2 mm or less
0.3 mm
Thickness : t
(reference)
109.9 110.1 mm
108.4 mm
G1093
3) Flatness
Check the flatness of the installing
surface of cylinder head's intake and
exhaust manifolds with horizontal ruler
and clearance gauge.
Standard
Limit
0.05 mm
0.2 mm
49
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Limit
8.93 mm
8.91 mm
correct
with
grinding
Standard
Intake valve
Exhaust valve
2.7 mm
2.2 mm
Limit
1 mm or less
1 mm or less
2) Valve guide
z Insert a valve into cylinder head and
measure
the
clearance
between
If
the
clearance
is
Measuring
Point
50
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
or valve guide.
Valve stem end play
Intake valve
Standard
Limit
0.04 0.07 mm
0.2 mm
Valve depression
Intake &
Exhaust
Standard
Limit
0 0.3 mm
0.55 mm
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
M1072
Standard
Intake valve
64 mm
Exhaust
valve
Inner
Outer
D1146/TI : 60
DE08TIS : 73.8
D1146/TI : 71
DE08TIS : 77.7
52
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
M1079
Standard
Limit
Valve Spring
Inclination
2.7 mm
M1080
Intake
valve
Exhaust
valve
Set Length
Spring
force
Limit
Valve Spring
Tension at 41mm
Set Length
70 kg
3%
Inner
Outer
38 mm
41 mm
D1146/TI
: 28.6 kg
DE08TIS
: 38 kg
D1146/TI
: 66 kg
DE08TIS
: 75kg
6%
2kg
5%
4kg
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
cotter
pressing
the
valve
the
valve
is
correctly
G1056
0.2 mm
54
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Limit
23.978 23.959 mm
23.75 mm
2) Rocker arm
z Visual check
Visually check the face of the
rocker arm in contact with the valve
stem end for scores and step wear.
If the wear is small, correct it with
an oil stone or grinding paper of
fine grain size. Rocker arm with a
considerable amount of step wear
should be replaced.
z Rocker arm bushing diameter
Measure the inside diameter of the
rocker arm bushing with an inside
micrometer or vernier calipers, and
compare the measured values with
the rocker arm shaft diameter. If the
clearance exceeds the limit, replace
M1087
Limit
0.020 0.093 mm
0.3 mm or less
55
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
the
clearance
of
the
Limit
0.035 0.077 mm
0.15 mm
scores
or
cracks,
and
an
outside
micrometer,
19.944 19.965 mm
0.3 mm or less
feeler gauge
M1084
56
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Limit
0.28 0.43 mm
0.6 mm
(2) Cam
z Cam lobe height
Intake
Cam lobe height
(C)
Standard
Limit
49.15 mm
48.85 mm
M1095
D1146/TI : 49.32mm
Exhaust
49.00 mm
DE08TIS : 49.35mm
57.52 mm
lobe
height
and
journal
diameter.
If the measured number is less than
the specified limit, the camshaft
must replaced.
z Cam surface
57
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
With
an
outside
micrometer,
value
outside
with
the
diameter
to
M1090
Limit
0.12 0.17 mm
0.24 mm
Replace
the
bushing
if
the
indicating
need
for
servicing.
Standard
Limit
58
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
0.05 mm
0.2 mm
3.2.5. Crankshaft
(1) Inspection of crankshaft
1) Defect check
z By naked eyes, check for any
scratch
or
damage
on
the
color
check,
check
the
2) Wear measuring
z With an outside micrometer measure
the diameter of the crankshaft journals
and pins in the directions as shown,
and compare the measured values to
determine the amount of wear.
Limit
Journal diameter
83.966 83.988 mm
83.000 mm
Pin diameter
70.971 70.990 mm
70.000 mm
59
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Limit
0.05 mm
0.1 mm
60
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
to
specified
torque,
then
Torque
M1116
measurement
of
main
diameters
journals
to
of
crankshaft
determine
the
oil
clearance.
<Main bearing oil clearance>
Standard
Limit
0.052 0.122 mm
0.25 mm
the
specified
torque,
then
18 kg.m
61
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Limit
0.034 0.098 mm
0.25 mm
62
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
pressure
at
reassembly
operation.
M1112
Spread
0.19 0.22 mm
bolts
to
specified
torque,
measure
the
clearance
0.3 0.5 mm
63
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Limit
0.15 0.325 mm
0.5 mm
piston
according
to
the
disassembly process.
(2) Piston inspection
1) Visual check
Visually check the pistons for cracks,
scuff or wear, paying particular attention
to the ring groove.
2) Clearance between the piston and cylinder liner
z With an outside micrometer,
measure the piston outside diameter
end of piston skirt in a direction at a
Position of measuring
outside diameter
13 mm
110.883 110.897 mm
G1095
cylinder
liner
inside
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Standard
Limit
111 111.022 mm
111.122 mm
z The
clearance
subtracting
is
the
computed
piston
by
outside
0.103 0.139 mm
Top ring
2nd ring
Oil ring
Standard
0.40 0.60 mm
0.40 0.60 mm
0.30 0.50 mm
Limit
1.5 mm
1.5 mm
1.5 mm
M1104
65
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
G1071
Standard
Top ring
2nd ring
Oil ring
0.07 0.102 mm
0.05 0.085 mm
Limit
0.15 mm
0.15 mm
Top ring
2nd ring
Oil ring
Standard
2.58 3.88 kg
1.81 2.71 kg
3.57 5.03 kg
M1105
Limit
41.994 42.000 mm
41.94 mm
66
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
2) Clearance
Measure the clearance between the
piston pin and connecting rod bushing,
and replace either of them, whichever
damaged more, if the measured value is
beyond the limit.
M1106
Standard
Limit
0.003 0.015 mm
0.08 mm
3) Condition check
Check the engaged condition of the
piston and piston pin. If it is possible to
force the pin into the piston heated with
piston heater, the piston is normal. When
replacing the piston, be sure to replace
the piston pin together.
(5) Connecting rod inspection
1) Distorsion
Check the connecting rod for distortion.
As shown in the figure below, install the
connecting rod to the connecting rod
tester, and check for distortion using a
feeler gauge. If the connecting rod is
found distorted, never re-use it but
replace with a new one.
2) Holes alignment (parallelism)
Measure
the
alignment
of
the
Limit
0.05 mm
0.1 mm or less
M1107
67
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3) Wear
z Assemble the connecting rod to the
crankshaft and measure connecting
rod big end side clearance using a
feeler gauge.
z Assemble the connecting rod to the
piston and measure connecting rod
small end side clearance.
z If the measured values are beyond
the limit, replace the connecting rod.
Limit
0.5 mm
Torque
7kg.m
Cylinder head
Standard
A
(Thickness of seal ring)
B
(Projection of nozzle)
3.50.1
mm
2.43~2.80
mm
68
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3.3. Reassembly
3.3.1. General precautions
z Clean all the disassembled parts, particularly oil and water ports, using
compressed air, then check that they are free from restrictions.
z Arrange the general and special tools in order for engine assembly operation.
z To wet each sliding part, prepare the clean engine oil.
z Prepare service materials such as sealant, gaskets, etc.
z Discard used gaskets, seal rings, and consumable parts, and replace with new
ones.
z Apply only the specified torque for bolts in the specified tightening order and
avoid over-tightening.
z Be sure to check that all the engine parts operate smoothly after being
reassembled.
z Check the bolts for looseness after reassembly.
z After completing the engine reassembly operation, check if there is missing parts
or shortage of parts.
z Keep your hands clean during the working.
3.3.2. Cylinder block
Cover the floor of the workshop with wood
plate or thick paper to prevent damage to
the cylinder head and place the cylinder
block with the head fitting surface facing
downward.
3.3.3. Oil spray nozzle (D1146TI, DE08TIS)
Tighten and assemble the oil spray nozzle
flange with fixing bolts using the spray
nozzle jig.
Torque
7 kg.m
69
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
70
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3.3.5. Crankshaft
z Install the main bearing (refer to
assemble sequence : right figure)
machined with two holes in the cylinder
block so that the key is aligned with the
key groove, then apply oil to the bearing
surface.
71
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
z Install
the
bearing
and
thrust
washers to
the bearing cap and apply oil to the bearing
and thrust washers.
30 kg.m
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
8 kg.m
CAUTION :
When the bolts are tightened, remove
the guide bar.
z The flywheel housing is assembled after
the new oil seal was pressed (Coat
engine oil over the outside of oil seal)
before in the housing by a press.
z If any peripheral scar was generated
due to oil seal at the oil seal contact
surface of crankshaft, after inserting
about 1 mm shim or thereabout in front
of oil seal (Direction toward crankshaft.),
measure and adjust.
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
shaft, then assemble the oil seal using an oil seal fitting jig.
3.3.8. Flywheel
z Installation of flywheel ring gear
With a gas burner, heat the ring gear
evenly until heat expansion takes place,
then install it using a hammer.
CAUTION :
Do not allow the temperature of the ring
gear to exceed 200 C (390 F).
M1122
wear ring
ring gear
G1031
in
diagonal
sequence
to
74
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
specified torque.
Torque
18 kg.m
Lock nut
sensor completely.
z Rotate (Clockwise) the pick-up sensor on
fly wheel housing, until the end of it reach
on fly wheel ring gear.
z Then rotate (Counter clockwise) the
pick-up sensor for 270 (gap 1.0 mm)
and fix lock nut.
z Tolerance limit is 27. (gap 0.1 mm)
Flywheel
housing
Tolerance
limit
and
bore
inside
with
75
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
M1127
hammer)
to
assemble
the
Valve seating
longer
side connecting rod big end is in opposite
direction
from
the
valve
seating
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Top ring
Second ring
Oil ring
the
piston
ring
from
being
G1055
45
45
90
Piston pin
Piston
the
valve
seating
surface
Valve seating
CAUTION :
77
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
impressed
on
Serial no.
the
Torque
18 kg.m
are
tightened,
check
the
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
2.2 kg.m
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Mark 2
Mark 1
G1054
Torque
Mark o
3.1 kg.m
Backlash
Limit
0.16 0.28 mm
0.35 mm
0.16 0.28 mm
0.35 mm
0.35 mm
housing.
z Turning the flywheel, adjust the pointer
to the position of the engraved scale.
z After adjusting the injection timing of fuel
injection pump drive gear, tighten the
80
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
0.2 mm or less
4.4 kg.m
valve
holder,
and
after
Timing
check hole
Injection timing
notch mark
(Fly wheel)
Flywheel
ring gear
81
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
and
the
engraved
specified
As
above
adjusting
method,
hole
with
the
Timing angle
D1146
BTDC 15
D1146TI
BTDC 9
DE08TIS
BTDC 3
82
Printed in Jan. 2001 PS-MMA0415-E1A
Notch
mark
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Torque
the
assembling
bolts
with
specified torque.
Torque
4.4 kg.m
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
2.2 kg.m
and
assemble
by
M1047
Torque
13 kg.m
84
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
of
cylinder
block,
and
the
Assemble
the
oil
pan
by
2.2 kg.m
CAUTION :
Align the bolt holes with gasket holes
to prevent damage to the gasket and
tighten.
3.3.23. Oil filter
z Install the oil filter onto the cylinder block,
and tighten the fixing bolts.
85
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Torque
2.2 kg.m
3.3.25. Starter
z Assemble the starter in position on the
flywheel housing.
Torque
8.0 kg.m
G1101
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
valve guide.
G1102
G1103
87
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
CAUTION :
Be careful not to damage the cylinder
head gasket. If the dowel pin is not in
alignment, lift the cylinder head again
and then remount it.
CAUTION :
After tightening the cylinder head bolts,
even at disassembling, the cylinder
head gasket should be changed a new
one.
z Coat the cylinder head bolts with
engine
oil,
sequence
and
to
tighten
the
in
proper
specified
torque
Front side
Rear side
Type 2
TY
Specification
M141.5146
Torque
TY
12.9T
24.5 kg.m
10.9T
M141.5146
6 kg.m +180+150
(Angle torque)
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
However,
all
bolts
are
tightened
specified
value
using
zigzag
G1088
method.
Torque
M10x1.5
4.4 kg.m
M12x1.5
8.0 kg.m
89
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Flywheel
Intake Valve
Exhaust Valve
Cylinder No.
Cooling Fan
G1048
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Model
Intake Valve
Exhaust Valve
D1146
D1146TI
DE08TIS
0.3 mm
0.3 mm
CAUTION :
(1) Crankshaft revolution is done by hands
without using a starting motor.
(2) Turn it to the direction of engine
rotation, but do not use the installing
bolts at the turn.
(3) The cylinder no. and the order of intake
and exhaust can be determined from
the crank shaft pulley.
specified torque.
5.0 kg.m
Torque
M1013
head
the
and
intake
manifold,
and
manifold
Air heater
Intake manifold
by
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
them
by
tightening
the
92
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
the
air
compressor
on
the
3.3.35. Alternator
z Install the alternator mounting bracket
and supporter to the cylinder block, then
tighten the fixing bolts.
z Install the alternator with fixing bolts to
the mounting bracket.
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
to
the
direction
of
an
arrow
G1104
7.0 kg.m
3.0 kg.m
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
screw.
3.3.39. Cylinder head cover
z Attach a new gasket on the cylinder
head cover.
z Assemble the cylinder head cover to the
cylinder head by tightening the cap bolts
for fixing the cylinder head cover.
Torque
1.2 kg.m
4.4 kg.m
G1086
3.3.41. Belt
z Install the V-belt on the crank pulley,
alternator pulley and water pump
10-15mm
Press here
pulley.
z Adjust the V-belt tension using the
tension adjusting support.
Water pump
pulley
Alternator
pulley
G1105
Crank pulley
V-belt
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3.3.43. Others
96
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3.4. Breaking in
97
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
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 the oil pick-up
screen 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.
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.
Min line
(lit)
Total
(lit)
API No.
12
12
17
17.5
17.5
22
Truck
15.5
15.5
20
Bus
15.5
12
17.5
20
17
22
Model
D1146
D1146TI
Recommend oil
Bus
Truck
DE08TIS
Truck
ACEA-E2 or ACEA-E3
(API CH-4)
* If long oil change intervals are to be used, ACEA-E3 oil must be used.
98
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
4.1.2. Specification
Item
1. Water pump
2. Thermostat
Specification
Type
Pump speed
Delivery capacity
Operation pressure
Allowable back pressure
Operating temperature
Valve lift
Operating temperature
3. Cooling fan and belt
Fan diameter Number of blades
Fan belt tension
Centrifugal type
2,000 rpm
2,700 rpm
about 190 liter/min
about 280 liter/min
0.5 bar
0.8 bar
bellow 0.5 bar
79C
83C
8 mm or more
8 mm or more
(at 94C)
(at 94C)
79 94C
83 95C
Truck : 700mm 8
15mm deflection by thumb
98
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
4.1.3. Thermostat
z General descriptions and main data
The thermostat maintains a constant
temperature of coolant and improves
thermal efficiency of the engine by
preventing heat loss.
Namely,
when
the
temperature
of
Specifications
In moderate climates
In tropical climates
Bus
Truck
Wax-pallet type
Wax-pallet type
79 C
83 C
71 C
94 C
95 C
85 C
Bus : 8mm or more
10mm or
8mm or more
Truck : 10 mm or more
more
CAUTION :
There
are
kinds
of
thermostats
Thermometer
Ruler
99
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
100
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Possible causes
z
z
z
z
z
z
z
z
z
z
2. Engine overcooling
z
z
3. Lack of coolant
z
z
z
z
z
z
z
4. Cooling system
noisy
z
z
z
z
Lack of coolant
Radiator cap pressure
valve spring weakened
Fan belt loosened or
broken
Fan belt fouled with oil
Thermostat inoperative
Water pump defective
Restrictions in water
passages
due
to
deposit of scales
Injection
timing
incorrect
Restriction in radiator
core
Gases
leaking
into
water jacket due to
broken cylinder head
gasket
Thermostat inoperative
Ambient
temperature
too low
Radiator leaky
Radiator hoses loosely
connected or damaged
Radiator cap valve
spring weakened
Water pump leaky
Heater hoses loosely
connected or broken
Cylinder head gasket
leaky
Cylinder
head
or
cylinder block cracked
Water pump bearing
defective
Fan loosely fitted or
bent
Fan out of balance
Fan belt defective
Corrections
z
z
Replenish coolant
Replace cap
z
z
z
z
Adjust
injection
timing
correctly
Clean exterior of radiator
z
z
Replace
gasket
z
z
Replace thermostat
Install radiator curtain
z
z
z
Correct or replace
Retighten clamps or replace
hoses
Replace cap
z
z
Repair or replace
Tighten or replace hoses
Replace
cylinder
head
gasket
Replace cylinder head or
block
Replace bearing
z
z
Replace fan
Replace fan belt
cylinder
head
101
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Specifications
Item
Forced pressure
circulation
Lubricating system
Specifications
Full flow
Bypass valve
Connecting rod
bearing
Relief valve
Bypass valve
Oil cooler
Air compressor
Crankshaft
bearing
Cylinder head
Turbocharger
Idle gear
bush
Piston spray nozzle
Camshaft
bearing
Oil filter
Relief valve
Oil pan
102
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
steel
rule
and
feeler
gauge,
0.025 0.089 mm
Feeler gauge
0.50 0.64 mm
103
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
16.95 16.968 mm
0.032 0.077 mm
z Reassembly
(1) For reassembly, reverse the disassembly sequence.
104
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Possible causes
z
Poor oil
z
z
Gases leaking
z
z
z
z
z
z
z
3. Oil deteriorates
quickly
Corrections
z
and/or
Replace pistons
piston rings
Replace
z
z
Clean strainer
Replace
Replace
Correct or replace
Correct or replace
Replace
and/or
105
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
1.
1a
2.
3.
4.
5.
6.
Fuel filter
Water separater
Air bleeding screw (for fuel filter)
Injection nozzle
Overflow tube
Fuel pipe (filter injection pump)
Overflow valve
7.
8.
9.
10.
11.
12.
13.
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
1) D1146
(1) Injection pump assy
Injection pump
: KP-PE6AD95B412RS2 (101060-6100)
Governor
: KP-EP/RLD250-1400AIFFL (105931-5901)
Timer
: KP-EP/SA900-1250B4DR (105644-0520)
: KP-FP/KE-ADS (105210-5280)
Coupling
: 105662-1290
Micro switch
: 153169-3320
: 131153-1720
Delivery valve
: 131160-3620
: 65.10301-6036A
:153624
: BTDC 15
105780-8140
ISO4113
65.10102-6026
65.10101-7050
65.10301-6036A
Rack
Pump
Check
position speed
point
(mm)
(rpm)
9.7
300
8.51.5
11.8
700
79.51
11.9
1250
(84.02.0)
11.55
500
(65.02.0)
100
(115.015)
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)
Start spring
k=0.7 kgf/mm
Idle spring(inner)
retraction pressure
k=0.05 kgf/mm
59mm3/st , t=0.99
opening pressure
20.8 kgf/cm2
Spring
k=1.63 kgf/mm
k=0.005 kgf/mm
Plunger
Feed pump
105210-5280
Delivery
valve
107
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
108
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
2) D1146TI
(1) Injection pump assy
Injection pump
: KP-PE6AD100B412RS2 (101060-6541)
Governor
: KP-EP/RLD250-1400A1FXL (105932-3550)
Timer
: KP-EP/SA700-1100630DR (105644-0570)
: KP-FP/KE-ADS (105210-5280)
Coupling
: 105662-1490
Micro switch
: 153169-3320
: 131150-3120
Delivery valve
: 131160-8620
: 65.10301-7007
:1 5 3 6 2 4
: BTDC 9
10101-7293
ISO4113
65.10102-6042
65.10101-7293
65.10301-7007
1.8 x 6 - 550mm
Governor weight
Governor spring
Start spring
740 g
k=1.0+0.6 kgf/mm
k=0.005 kgf/mm
10 Right hand
Plunger
20+50lead
Lever ratio(min/max) 1 : 1.15 / 1 : 3.9
Rack Pump
Check
position speed
point
(mm) (rpm)
9.7
300
8.51.5
11.9
700
98.51.6
12.3
1100
(106.52.0)
11.7
500
(822.0)
10.5
500
(58.72.0)
P1
10.5
500
250
P2
11.7
500
100
Idle spring
Boost spring
Delivery
Valve
retraction pressure
k=0.7+0.05 kgf/mm
k=0.54 kgf/mm
51mm3/st , t=0.15
opening pressure
20.8 kgf/cm2
spring
k=1.63kgf/mm
109
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
a) Governor adjustment
110
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3) DE08TIS (225PS)
(1) Injection pump assy
Injection pump
Governor
: NP-EP/RLD300-1100P5JXR (105923-4810)
Timer
: 105681-2670
Coupling
: 105663-0470
: 134153 -2420
Delivery valve
: 134180 - 0420
: 65.10301-6049 , 65.10301-6052
:153624
: BTDC 3
65.10101-7087
65.10301-6076
65.10301-6077
Injection pipe(IDxOD - L)
Governor weight
Governor spring(outer)
Idle spring (outer)
Start spring
Boost srping
Plunger
850 g
k=9.8 N/mm
k=4.9 N/mm
k=0.049 N/mm
k=23.5 N/mm
12 Right hand
35lead
Rack Pump
position speed
(mm) (rpm)
R1(12.9)
1100
1312
R1-1.5
600
(122)
R2(R1-1.5)
500
(126)
(140)
R2-1.0
500
(100)
50
8.5
300
14.51.5
R1
100
(160)
1 : 1.1
k=5.88 N/mm
k=0.49 N/mm
0 mm3 , (8mm)
0.87 MPa
k=12.7 N/mm
111
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
112
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3) DE08TIS (240PS)
(1) Injection pump assy
Injection pump
Governor
: NP-EP/RLD300-1100P5JXR (105923-4810)
Timer
: 105681-2670
Coupling
: 105663-0470
: 134153 -2420
Delivery valve
: 134180 - 0420
: 65.10301-6049 , 65.10301-6052
:153624
: BTDC 3
65.10101-7087
65.10301-6076
65.10301-6077
Injection pipe(IDxOD - L)
Governor weight
Governor spring(outer)
Idle spring (outer)
Start spring
Boost srping
Plunger
850 g
k=9.8 N/mm
k=4.9 N/mm
k=0.049 N/mm
k=23.5 N/mm
12 Right hand
35lead
Rack Pump
position speed
(mm) (rpm)
R1(12.9)
1100
1312
R1-1.5
600
(122)
R2(R1-1.5)
500
(126)
(140)
R2-1.0
500
(100)
50
8.5
300
14.51.5
R1
100
(160)
1 : 1.1
k=5.88 N/mm
k=0.49 N/mm
0 mm3 , (8mm)
0.87 MPa
k=12.7 N/mm
113
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
114
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
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.
115
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
M1232
2) disassembly
M1232
z Clamp the feed pump with a vise and disassemble the hollow screw (30, 32),
strainer (31) and seal ring (35, 36).
z Take off the priming pump (25), plug (16), both seal rings (18), spring (15),
and check valve (14).
z Take off the plug (7), seal ring (8), spring (6), and piston (5) on the piston side.
z Pull out the snap ring (20) holding the tappet (10).
z Disassemble the snap ring, then take off the tappet (10) and push rod (1).
3) Inspection
z If the check valve is damaged or scored on its seat face, replace it with a new
one.
z Inspect the piston and tappet for damage.
z 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.
116
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
4) Reassembly
Reassembly operation is performed in reverse order of disassembly. All the gaskets
must be replaced with new ones at reassembly.
5) Testing
(1) Suction capacity test
Connect one end of a hose to the inlet
side of the feed pump and immerse the
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
and check to see if fuel is drawn in and
delivered for 40 seconds or so.
117
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
2) Construction
1. Nozzle holder
2. Union nut
3. Shim
4. Spring
5. Guide bush
6. Intermediate washer
7. Cap nut
7. Nozzle ass`y
3) Disassembly
z
4) Inspection
z
118
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
5) Reassembly
z
After removing carbon deposit, submerge the nozzle in diesel oil and clean it.
6) Adjustment
z After reassembly, install the nozzle
on a tester.
z With the adjusting screw loosened,
operate the nozzle 2 3 times to
bleed it.
z Operate the nozzle tester lever at
the specified rate.
z Adjust the injection pressure to the
standard
pressure
by
spring
tension shims.
z After
adjusting
the
injection
Normal
Abnormal
Abnormal
7) Testing
With the nozzle assembled to a nozzle
tester and specified pressure applied,
check the nozzle for fuel leakage.
Engine Model
Opening pressure
D1146
210 kg/cm2
D1146TI
214 kg/cm2
DE08TIS
1st : 160 kg/cm2
2nd : 220 kg/cm2
119
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
4) Injection nozzles
inoperative
4. Engine knocking
Possible causes
Fuel pipes clogged or air into
pipe fine
Feed pump valve defective
Feed pump piston or Push rod
sticking
Fuel filter element restricted
Air in fuel filter or injection
pump
Plunger and/or delivery valve
sticking or defective
Injection pump not properly
installed on pump bracket
Injection pump tappet
incorrectly adjusted
Cams on cam shaft worn
excessively
Needle valves sticking
Fuel leaking past clearance
between nozzle and needle
valve
injection pressure incorrect
Pipe from feed pump to
injection pump clogged or filter
clogged
Air in fuel
Feed pump delivery insufficient
Fuel delivery insufficient due to
clogging of fuel tank air
breather
Plunger worn excessively
Injection timing incorrect
Delivery valves defective
Nozzle leaks excessively
Nozzle not working normally
Injection timing too fast
Nozzle injection pressure too
high
Nozzles not working normally
Injection timing incorrect
Nozzle injection pressure too
low
Nozzle spring broken
Nozzles not working normally
Plungers worn excessively
Delivery valves seat defective
Supply of fuel excessively
Corrections
Correct
Replace
Disassemble, correct
Clean
Bleed
Disassemble, correct
Check, correct
Check, correct
Replace
Correct or replace
Correct or replace
Adjust
Clean
Bleed
Disassemble, correct
Replace breather
Replace
Adjust
Replace
Correct or replace
Disassemble, correct
Adjust
Adjust
Disassemble, correct
Adjust
Adjust
Replace
Replace
Adjust
Replace
Check feed pump
120
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Complaints
6. Engine output unstable
Possible causes
Corrections
Check feed pump
Bleed
Replace fuel
Disassemble, correct
Disassemble, correct
Disassemble, correct
Adjust
Disassemble, correct
Disassemble, correct
Disassemble, correct
Disassemble, correct
Disassemble, correct
Disassemble, correct
121
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Specification
Turbocharger Model
Air pressure
at compressor outlet
Air suction volume
Speed of turbine revolution
Maximum allowable speed
Max. allowable temperature of exhaust gas
at turbine inlet
Lubricating system
Weight
at maximum
output
D1146TI
DE08TIS
240PS
225PS
Allied Signal
466721-12
HOLSET
WH1E-8284AX/H14EC8
1.26 kg/cm2
1.33 kg/cm2
1.40 kg/cm2
16.8 m3/min
102,800 rpm
126,150 rpm
18.0 m3/min
18.4 m3/min
98,200 rpm
99,840 rpm
127,660 rpm
750 C
720 C
2) Construction
1. Impeller casing
2. Turbine casing
3. Bearing casing
4. Impeller
5. Turbine
A. Air inlet
B. Gas outlet
C. Gas inlet
D. Oil supply
E. Oil return
122
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3) Construction
4
5
6
7
8
11
12
13
16
22
31
Bearing housing
Turbine housing
Turbine wheel ass`y
Compressor wheel
Compressor housing
Journal bearing
Thrust bearing
32
33
34
36
38
43
46
Piston ring seal(turbine) 57
Piston ring seal
61
Retainer ring
64
Oil stopper
O-ring
Oil baffle
Inlet baffle
Thrust collar
Heat protector cover
Oil seal plate
Gasket
Hex bolt
Lock nut
Snap ring
67
74
75
77
80
81
82
83
88
91
Hex bolt
Actuator ass`y
Hose clamp
Actuator clip
Cover plate
Hose
Elbow
Hex nut
Clamp plate
Retaining ring
123
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3) Operating principle
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.
124
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
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.
125
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Immediately
after starting
During operation
When stopping
the engine
Precautions
Reasons
126
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Recommend oil
SAE No.
API No.
Sulfated ash
content
SAE 15W40
above CD or CE
Engine
model
D1146
D1146TI
128
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
(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
z 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 .
z 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.
z Assemble each joint on oil pipes securely to prevent oil leaks.
129
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Possible causes
Corrections
Replace or clean
Disassemble/repair
or replace
Disassemble/repair
or replace
Disassemble/repair
or replace
Disassemble/repair
or replace
Replace or clean
4. Unusual sound or
vibration
Disassemble/repair
or replace
Check and correct
Disassemble/repair
or replace
Disassemble/repair
or replace
Disassemble/repair
or replace
Check and correct
130
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Part No.
Figure
Tool Name
Remark
EF.123-014
1
D1146/TI
Injection pump setting assy
EF.123-015
DE08TIS
EF.123-127
CR : made USA
(up to 2000. Apr.)
EF.123-043
CR : made USA
(up to 2000. Apr.)
EF.123-184
EF.123-052
EF.123-048
EU.2-0530
EU.123-086
EF.123-179
EU.2-0131
132
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
No.
Part No.
Figure
Tool Name
10
EF.123.-065
11
EU.2-0647
D1146/TI
DE08TIS
EF.123-064
12
Remark
Piston sleeve
EF.120-208
All engine
13
60.99901-0027
Feeler gauge
14
T7610001E
15
T7621010E
133
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Appendix
z Tightening torque for major parts
Major Parts
Screw
Strength
(Diameter x pitch)
(grade)
Tightening
Torque
Remarks
M14 x 1.5
10.9T
2nd : 180
3rd : 150
(Angle method)
1st : 10 kg.m
M14 x 1.5
12.9T
2nd : 15 kg.m
3rd : 18 kg.m
1st : 15 kg.m
M16 x 1.5
12.9T
2nd : 25 kg.m
3rd : 30 kg.m
M12 x 1.5
10.9T
9.0 kg.m
M14 x 1.5
10.9T
8.0 kg.m
M14 x 1.5
10.9T
21.5 kg.m
M12 x 1.5
10.9T
13.4 kg.m
M14 x 1.5
7.0 kg.m
Strength
(Diameter x pitch)
M28 x 1.5
(grade)
-
M10
8.8T
4.4 kg.m
M24 x 1.5
8.8T
25.0 kg.m
M14 x 1.5
8.8T
3.0 kg.m
Major Parts
Injection nozzle nut
Injecton pump bracket bolt
Injection pump coupling bolt
Tightening
Torque
Remarks
134
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3.6
4.6
4.8
5.6
5.8
6.6
6.8
(4A)
(4D)
(4S)
(5D)
(5S)
(6D)
(6S)
6.9
8.8
10.9
12.9
(6G) (8G)
(10K)
(12K)
64
90
108
0.5
0.9
1.4
2.2
2.4
4.4
5
7.5
8
12
13
18
20
25
28
36
41
49
56
63
74
0.75
1.25
1.95
3.1
3.35
6.2
7
10.5
11.2
17
18.5
26
28
36
41
51
58
67
75
82
93
0.9
0.5
2.35
3.8
4.1
7.4
8.4
12.5
13.4
20
22
31
33
43
49
60
68
75
85
92
103
24
32
30
40
36
48
54
0.15
0.28
0.43
0.7
0.73
1.35
1.5
2.4
2.55
3.7
4.1
5.6
6.2
7.8
9.1
11.5
12.8
15.5
17
20.5
23
0.16
0.30
0.46
0.75
0.8
1.4
1.6
2.5
2.7
3.9
4.3
6
6.5
8.3
9.5
12
13.5
16
18.5
21.5
25
0.25
0.45
0.7
1.1
1.2
2.2
2.5
3.7
4
6
6.6
9
9.7
12.5
14.5
18
20.5
24.5
28
33
37
0.22
0.4
0.63
1
1.1
1.9
2.1
3.3
3.5
5.2
5.7
8
8.6
11
12.5
16
18
21
24
27
31
0.31
0.55
0.83
1.4
1.5
2.7
3.1
4.7
5
7.5
8.3
11.5
12.5
16
18.5
22
25
30
34
40
45
0.28
0.47
0.78
1.25
1.34
2.35
2.8
4.2
4.6
7
7.5
10.5
11.3
14.5
16.7
19
22.5
26
29
34
38
0.43
0.77
1.2
1.9
2.1
3.7
4.3
6.3
6.8
10
11.1
17.9
17
21
24.5
31.5
35
42
47
55
61
0.48
0.85
1.3
2.1
2.3
4.2
4.9
7.2
7.7
11.5
12.5
18.5
19.5
24.2
27.5
35
39.5
46
52
58
67
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.
z
SM25C
SUM22L
STS304
M8
0.8
0.8
M10
1.6
1.8
1.8
M12
2.5
3.0
3.0
M14
3.5
4.0
4.0
M16
4.5
5.5
5.5
M18
5.5
6.5
6.5
M22
9.0
11.0
11.0
M26
13.0
16.0
16.0
M30
18.0
20.0
20.0
M38
30.0
35.0
35.0
135
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Group
Part
Inspection Item
Inside
diameter
of
cylinder liner for wear
Engine
body
Cylinder Amount
of
liner
block & projection
liner
The flatness of upper
surface of cylinder block
Hydraulic test for 1
minute (kg/cm2)
Valve seat Intake
Exhaust
Cylinder depression
head & Cylinder head height
valve
Hydraulic test for 1
minute (kg/cm2)
Stand value
for assembly
Limit
for use
111~111.022 111.122
Correction
Remark
Replace liner
Need amount of
projection without
fail
Correct with a
surface grinder
0.03~0.08
0.05
0~0.3
0~0.3
109.9 ~110.1
0.55
0.55
108.4
Replace if leaky
Measure unworn
portion beneath the
rim of the upper side
Projection difference
between
adjacent
liners : 0.15
Referenced length :
200mm
Replace if leaky
Replace valve seat
110.801~110.959
Replace liner
Clearance between
piston and liner
Piston
Width
of
piston ring
grooves
0.041~0.221
0.3
Top ring
2nd ring
3.06~3.08
Oil ring
4.04~4.06
Major
moving
parts
Piston
ring
Piston ring
side
clearance
Top ring
2nd ring
Oil ring
0~0.12
Must exist
15 g
96 g
0.40~0.60
0.40~0.60
0.30~0.50
1.5
1.5
1.5
0.07~0.102
0.05~0.085
0.15
0.15
41.994 ~ 42
41.94
0.003~0.015
0.08
Replace piston
Standard gauge inside
diameter : 108
Replace ring
Replace ring or
piston
Cross
120
Install
136
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Group
Part
Inspection Item
Stand value
for assembly
Limit
for use
0.01
Outside diameter of
83.966~83.988
journal
Outside diameter of pin 70.971~70.990
Ellipticity of journal
0.008
and pin
Concentricity of journal
0.01
and pin
Taper of journal and pin
0.02
Clearance between
0.052~0.122
crankshaft and bearing
Crank
shaft
Timing
gear
0.03
0.03
0.25
Replace bearings
Replace
thrust bearing
Run-out of crankshaft
0.06
0.1
Balance of crankshaft
(g.cm)
Torque value journal
bearing cap bolt
(kg.m)
60
60 or less
30
0.08~0.110
0.170 ~ 0.248
0.50
0.034 ~ 0.098
0.25
Replace bearing
0.050~0.081
0.12
0.04~0.07
0.50
30 g
18
57.86~57.88
57.52
0.12~0.17
0.24
0.28~0.43
0.6
Run-out of camshaft
0.05
0.2
0.025~0.091
0.15
0.043~0.167
0.3
0.16~0.28
0.35
Correct or replace
gear
Measure In horizontal
and vertical directions
(against axial direction)
0.025
0.5
Connecting
bearing
rod
Remark
0.15~0.325
Cam
shaft
70
Correct
with a grinder
Major
moving
parts
83
Correction
Adjust by a press
if bended
Check dynamic
balance
Measure
after
installing the bearing
and releasing one bolt
Replace con-rod
Clean out
objects on
surface
foreign
joining
137
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Group
Part
Stand value
for assembly
Limit
for use
8.950~8.970
8.93
8.935~8.955
8.91
Intake
0.030~0.065
0.15
Exhaust
0.045~0.080
0.15
2.7
2.2
Max. 1
2.0
2.0
Inspection Item
Diameter of intake valve
stem
Diameter of
exhaust valve stem
Clearance
between valve
stem
and
valve
guide
Thickness
Intake
of valve head Exhaust
Clearance
Intake
between
valve guide
and
valve Exhaust
spring seat
Clearance between valve
guide and cyl. head
installing hole
Concentricity between
valve stem and valve
head
Free length (mm)
Valve
Intake
valve
spring
Tension force
(when pressed
to 41mm)kg
Squareness
(along
free
length direction)
Inner
Exhaust
valve
spring
Outer
Valve
clearance
(at cold)
When
replacing
valve, replace valve
guide alike
Replace
valve or valve guide
Replace
more
one
worn
Replace valve
Approx. 64
67~73
66.5
1.5
D1146/TI : 71
DE08TIS : 77.7
Tension
force(when D1146/TI:62.7~69.3
pressed toDE08TIS : 71~79
41mm)kg
Squreness
(along free
1.5
length
direction)
Replace
valve spring
Exhaust
0.3
Clearance between
rocker arm shaft &
0.040~0.113
rocker arm bush
Diameter of rocker arm
23.939~23.96
shaft for wear
Run-out of push rod
-
Replace
valve spring
0.3
Replace
valve spring
Intake
Replace
Valve & valve guide
0.05
Tension
force(when D1146/TI:26.9~30.3
pressed toDE08TIS : 36~40
38mm)kg
Squreness
(along free
1.5
length
direction)
Free length
Remark
-0.039~-0.010
(Press fit)
Valve
system
Correction
0.2
Adjust
Grind or replace if
severely pitted on
tip of rocker arm
and stem
Replace bush
or shaft
23.75
Replace
0.3
Replace
138
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Group
Valve
system
Part
Tappet
Inspection Item
Clearance between
tappet & tappet hole of
0.035~0.077
cyl. block
Diameter of tappet
19.944~19.965
Tappet face in contact
with cam
Oil
pressure
Oil
tempera
ture
Lubricating
system
Oil
pump
Valve
opening
pressure
Oil
filter
Stand value
for assembly
Limit
for use
0.15
-
Oil pressure
4.8 or less
(at normal speed)
kg/cm2
Oil pressure
0.8~1.4
(idling) kg/cm2
Max. permissible
oil temperature C
Permissible
oil temperature
in short time C
Axial play
0.055~0.105
of oil pump gear
Clearance between gear
shaft & oil pump cover
0.032~0.077
hole
Clearance between drive
0.040~0.094
gear shaft and cover
hole
Diameter of gear shaft
16.950~16.968
Diameter of driving gear
28.000~28.033
bush
Between crank
gear & idle
0.15~0.25
gear
Backlash Between oil
pump drive
0.15~0.25
gear &
idle gear
Oil pressure control
4.0 ~ 4.8
valve (kg/cm2 )
By-pass valve for filter
1.8 ~ 2.3
element (kg/cm2 )
By-pass valve for full oil
4.0 ~ 4.8
filter (kg/cm2 )
Relief valve for oil
8.5 ~ 11.5
pump (kg/cm2 )
Spray nozzle control
1.5 ~ 1.8
valve (kg/cm2 )
Damage of oil filter
cartridge
3.5
0.6
Correction
Remark
Replace tappet
Replace tappet
Replace
if severely worn or
deformed
Check oil leakage
and clearance
between each part
Use recommended
oil
105
Must not exceed this
value
120
-
Replace gear
or cover
Replace bush
or cover
Replace gear shaft
17e7
Replace bush
28e7
0.8
Adjust back-lash
0.8
Replace valve
Replace valve
-
Clean or replace
139
Printed in Jan. 2001 PS-MMA0415-E1A
D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Group
Part
Inspection Item
Stand value
for assembly
Limit
For use
Correct or replace
1.0
Submerge in water
and replace if air
bubbles found
0.5
20
280
0.35
Cooling
system
Water
pump
Cooling
water
temp
Thermostat
Clearance between
impeller & housing
Perpendicularity
of
pulley
Fan belt depression(with
thumb) mm
Operating temperature
(permissible temp.) C
Permissible temperature
in a short time C
Thermostat
opening temp. C
Fuel
system Injection pressure of injection
nozzle (kg/cm2)
Operating pressure of overflow
valve (kg/cm2)
Projection height of nozzle from
the cyl. head surface(mm)
Running-in the engine
Inspection
at
completion Cylinder
pressure
Check the
passage
water
Approx. 15
79~95
105
79
Replace
94
Replace if defective
Stroke : min. 8mm
Repair or replace
Replace cartridge
Adjust by shim
1.0~1.5
Replace valve
2.53
Refer to supplement
running-in
Compression pressure of
cylinder (kg/cm2)
Compression pressure
difference of each cylinder
24 ~ 28
24 or
more
D1146 : 210
D1146TI : 214
DE08TIS: 1st 160
2nd 220
10% or less
against average
Remark
Replace if impeller
&
housing
are
damaged
Adjust by a bench
press
Adjust
Must not exceed this
value
Type II
Piping
&
others
0.3
Correction
Correct
Correct
at 200rpm or more
(20C)
140
Printed in Jan. 2001 PS-MMA0415-E1A
z WORLDWIDE NETWORK