65.99897-8059 Diesel Engine DV15 DV15T. abn DV15TIS PS MMAU200 E14pyisrrmitis FOREWORD This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries & Machinery Ltd's (here after DAEWOO's) customers and distributors who wish to gain basic product knowledge on DAEWOO's DV series diese! engines (DV15, DV15T, DVI5TI and DV15TIS) These economical and high-performance diesel engines (8 cylinders, 4 strokes, V-type. direct injection type) have been so designed and manufactured to be used for overland transport and industral purpose. That meets all the requirements such as low noise, fue! economy, high engine speed, and durability. (especially, DV1STIS model is an environment friendly one fulfiling the EURO-II emission regulation) To maintain the engine in optmum 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. [es] Removal fel Installation ie Disassembly EA Reassombly Align the marks. [=] Directional Indica Inspection Adjustment Cleaning Pay close attention-Important Tighten to specified torque Use special tools of manufacturer's Lubricate with cil Lubricate with grease DM E> By A Measurement During engine maintenance, please observe following instructions to prevent environmental damage: © Take old oi lo an old cil 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 wasle. © The regulations of the relevant local authorities are to b of spent coolants and special waste. observed for the disposal Sd Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis F 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. For the last, the content of this maintenance instruction may be changed without notice for some quality improvement and please feel free to contact to our agents near by your location for any services. Thank you. DAEWOO Heavy Industries & Machinery LTD. Dec. 2001 Printed i Avg. 2001 PS-MMAUIOMELACONTENTS 1. GENERAL INFORMATION 1.1, General Repair Instruction 1.2. Engine Characteristics 1.3. Engine Specifications 1.4 Engine General Views 2. MAINTENANCE 2.1, Preventive Maintenance 2.2, Diagnosis and Remedy 2.3, Engine Inspection 3. Disassembly and Reassembly of Major Components 3.1. Engine Disassembly 3.2, Measurement and Inspection of Mejor Parts, 3.3. Engine Reassombly 3.4, Saarting and Trial Operation 4. MAINTENANCE OF MAJOR COMPONENTS 4.1. Cooling System 4.2. Lubricating System 4.3. Specilication and Construction 4.4, Fuel Injection Pump §. SPECIAL TOOL LIST 6. APPENDIX 6.1. Tightening torque for major parts 6.2, Standard bolt tightening torque table 6.3, Engine assembly tolerance © WORLDWIDE NETWORK 38 49 66 84 86 90 92 00 129 130 431 132 pyissrrnuis MAINTENANCE MANUAL Printed i Au 2001 PS-MMAO?00-E1pyisrrmitis 1. GENERAL INFORMATION 1.1. General Repair Instructions Before performing service operation, disconnect the grounding cable from the battery for reducing the chance of cable damage and burning due to short-circuiting, Use covers for preventing the components from damage or pollution Engine oil and anti 7e solution must be handled with reasonable care as they cause paint damage. The use of proper tools and special tools where specified is important to efficient and reliable service operation. Use genuine DAEWOO parts ne Used cotter pins, gaskets, O-rings, oil seals, lock wasner and self-lock nuts should sarily be discarded and new ones should be pr ‘or installation as normal function of the parts can not be maintained if these parts are reused. To facilitate proper and smooth roassomble operation, keop 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 . Clean the parts before inspection or reassembly. Also clean oil ports, ete. using compressed air to make certain they are free from restrictions Lubricate rotating and sliding faces of parts with oil or grease before installation When nei sary, use a sealer on gaskets to prevent leakage: Carefully observe all specifications for bolts and nuts torques. When service operation is completed, make a final check to be sure service has been done property. GENERAL INFORMATION _! Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 1.2. Engine characteristics 1 1. OMEGA combustion bow! 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 swid 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 DV1STIS diesel engines discharge very low level of hazardous exhaust gases such as smoke, nitrogen oxide, hydrocarbon, or carbon monoxide and thus ensure high performance and low fuel consumption GENERAL INFORMATION Printed i Aug. 2001 PS-MMAUTOMEIApyissrrnuis MAINTENANCE MANUAL. 1.3.1. Specification vows! ee DV15 DV15T. DV1STI DV15TIS “ TSE Soe Waa Sealy vonene naan septa] Tenochagea_| "Wee caged a nerenoes Corton chante yoo rect nation pe Cylinder liner type Wet type Teg restr Gear drven type 1 of og 2 eomoression ring, 1 ailing Ne ofofinerboreXatoke rm 8-128 x 142 Tota ait dpaconon a) 14.618 Compression ato waa wei | esa [an Teo cima high ‘nen 1.9771 982x1 206.5 |. 77K%,082x1 206 5] 1 975x1 62x 206.5] Eoin oat to) 80 980 7,020 7,020 Fuethaton ode [STR RE Pat tng BOE wo mee Ta 36 Tasco Np Oe Bosch imine Piyoe Govererpe BQ or ROV type Tiectn mloe Tuiinosanan [wie 09h) [valcroot cose [wa 030) Fuel injection pressure traiom’) 20048 200+8 200+8 250+8 Compression pressure tagiom®) 28 (at 200 rpm) asta SRT 0257 0.85 ima vane ‘Open at 12° (B.T.D.C) 15° (B.1.0.0) Close at 48° (A.B.D.C) 35° (A.B.D.C} exnaust valve ‘Open at 81° (B.B.D.C) 715° (B.B.D.C) Close at 11° (A.T.D.C) 15.5° (A.T.D.C) oaton nated Pressurized creation Olena ype Gear type Olier ype Tullow, paper element iype(double) Cabiearg ocapecy ecinn) Bus :24/ 80 Truck: 24/18 Sie pe Water cooled Tat pp Belt criven centrifugal Woe ing Maio Pressurized orculaton Cong wal apy (re ay) 19 Thermostat ype ‘Wax palllet type (79 ~ 94 °C) Air compressor type & capacity _(oc/rev) Gear driven type : 300 Power eng in Tb) Bus 16/100, Tuk 1072S Arar voage—coasiy =A Bus 106-150, Truck :24— 45, 000780 ring Moo volage =o V=KA Bus :26=6.6, Truck 24~7.0 fret capscy =a 22= 96 (1.05 KW) Balerycaecty (Wma 200 Wy DAEWOO GENERAL INFORMATION > Printed i Au 2001 PS-MMAO?00-E1pyisrrmitis 1.3.2, Engine power Production tolerance : 5% Engine Model Perteance femark ina vigh Mocet | sutnx | timing | Power | Torque Lowidle (ato pt ‘gm fpr) (pr (pm) DVIS ECLBA 10 305/2,300 | 105/1,400 | 550- 2530 " _ 2600 EOVKA 220 7 | s40/2.900 | 192/1,900 | $75.28 eovxe 2000 EovBA coves steno | syezae | 252 Eevee | 7 | agss2a00 | 198/1,200 | S525 2520, ECVCr EURO-| EOVCA coves DVI5T Ecvce / sto. 2500 7 |.370/2,900 | 145/1,300 | 57825 | “Eq 9 | 300/2,000 | 125/'1,800 | e50+25 2250-50 | TIER- 230 ovisti | Ecsce | 11 | 4za/2.100 170/1,200 ~ EURO! ECJcC 2360 EDJBA 2320 EDJXA| 5.5 | 390/2,100 | 160/1,200 | s7s+25 = EDJXC 2379 Dvtstis | EDJGA EURO. EDJcB 2320 epucc| 85 | 420/2,100 | 170/1,200 ~ EDJCF 2370 EDJCG * Note : All data are based on operation without cooling ‘an at ISO 1585(SAE J1349). Ally Daewoo __ GENERAL INFORMATION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 1.3.3, Performance curve 4) DV15 Performance ISO 1585 (SAE J1349) Output (max.) | 224 kW (305PS) / 2,300 rpm Torque (max) | 1,029 N.m (105 kg.m) / 1,400 rpm Fuel consumption (min.) | 220 g/kW.h (162 g/ PS.h) GENERAL INFORMATION > Printed i Avg. 2001 PS-MMAUIOMELApyisrrrttis 2) DVIST Performance DIN 6270B DIN 6270A 238 KW (324PS) | 228 KW (311PS) Output (max.) 12,300 rpm / 2,300 rpm Torque (max) 1,255 N.m (128 kg.m) / 7,400 rpm Fuel consumption (min.) 211 g/kWz.h (155 g / PS.h) ly paewoo GENERAL INFORMATION Prine in Aug. 2001 PS-MMAOTOOELA,3) DVIST pyisrrmitis ISO 1585 (SAE J1349) Performance Output (max.) | 272 kW (370PS) / 2.300 rpm Torque (max) | 1,422 N.m (145 kg.m) / 1,300 rpm Fuel consumption (min.) | 211 g/kWh (155 g/PS.h) GENERAL INFORMATION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 4) DV1STI t Performance ISO 1585 (SAE J1349) Output (max.) | 309 kW (420PS) / 2,100 rpm Torque (max) | 1,667 N.m (170 kg.m) / 1,200 rpm Fuel consumption (min.) | 211 g/kW.h (155 g / PS.h) GENERAL INFORMATION Printed i Avg. 2001 PS-MMAUIOMELA Alp DOEWOO,pyisrrmitis 5) DV1STIS - 420PS Performance ISO 1585 (SAE J1349) Output (max.) | 309 kW (420PS) / 2.100 rpm Torque (max) | 41,667 N.m (170 kg.m) / 1,200 rpm Fuel consumption (min.) | 211 g/kW.h (155 g/ PS.h) GENERAL INFORMATION _° Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 1.4. Engine General Views 1.4.1. Engine Sectional View (longitudinal) 15 6 17 181920 1 Oilseal(front) 11 Aircompressor 2 Vibration damper 12 Pilot bearing 3 Water oump 13° Oil seal (rear) 4 Thermostat 14 Fly wheel 5 Piston pin 15. Crank shaft 8 Piston 16 Drain plug 7 Exhaust valve 17 Oil suction pipe @ Valve cotter 18 Relief valve(Oil ump) 9 Valve guide 19 Cam shaft 10 Power steering pump 20. Flywheel housing 10 GENERAL INFORMATION Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 1.4.2. Eni gine Sectional View (cross) B Is 16 7 1 Cylinder block 10 Fuel injection pipe 2 Oilcooler 17 Intake manifold 3 Cylinder liner 12 Fuel injection nozzle 4 Cylinder head 13 Combustion chamber 5 Rocker arm 14 Exhaust manifold 6 Push rod 15 Balance weight 7 Breather 16 Oil pump 8 Priming pump 17 Oil spray nozzle 9 Fuel injection pump ily DAEWDO | GENERAL INFORMATION _ |! Printed i Avg. 2001 PS-MMAUIOMELA1.4.3, Engine Assembly Views (1) DV15 (Bus) pyisrrmitis 21 1 Flywheel housing 9 Ollfiller cap 2 Lifthook 10 Drain plug 3 Air compressor 11 Oilcooler 19. Crank shaft pulley 4 Breather 12 Oilpan 20. Oillovel gauge 5 Fuel filter 13 Vibration damper 21 Starter 6 Exhaust manifold 14° Idle pulley 22. Air pipe(Air cleaner to (Water pump) intake manifold) 7 Water outlet 15 Water pump. 23 Power steering pump 8 Mounting bracket 16 Idle pulley(Alternator) 24 Pick-up sensor GENERAL INFORMATION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis (2) DV15T (Truck) 2 2B 1 Flywheel housing 10 Mounting bracket. 19 Fan guide 2 Exhaust elbow 11 Alternator 20. Oilfilter 3 Fuel filtor 12 Water pump 21 Air heater relay 4 Airpipe(loair tank) 13 Water outlet 22 Mounting bracket 5 Airvent pipe 14 Oil pressure unit 23° Starter 6 Ollfiller cap 15 Idle pulley(Aircon.) 24 Lifting hook 7 Oilcooler 16 Aircon. bracket 25. Air pipe (Air cleaner to Turbocharger) 8 Ollfiller pipe 17 Fan clutch 26 Power steering pump 9 Drain plug 18 Cooling fan 27. Pick-up sensor B Ally Daewoo __ GENERAL INFORMATION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis (3) DV15T (Bus) 2 3 18 ” 9 1 Flywheel housing 9 Oilcooler 417. Crank shaft pulley 2 Turbo charger 10 Ollpan 48 Oillevel gauge 3. Breather 11 Vibration damper 19 Starter 4 Exhaust manifold 12° Idle pulley 20 Air pipe (Air cleaner to (Water pump) turbocharger) 5 Water outlet 13. Water pump 21 Power steering pump 6 Mounting bracket 14 Idle pulley(Alternator) 22 Pick-up sensor 7. Oilfiller cap 15 Alternator 8 Drain plug 16 Gilfiter 1 Ally Daewoo __ GENERAL INFORMATION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis (4) DV15TI (Truck) 1 Flywheel housing 42. Drain plug 23 Fan guide 2 Exhaust elbow 13 Mounting bracket 24 Oil filter 3 Fuel filter 14 Altemator 25. Mounting bracket 4 Air pipe(to air tank) 15. Water pump 26 Air pipe (Turbocharger to intercooler) 5 Air vont pipe 18 Water outlet 27 Starter 6 Oilfiller cap 47 Control lever 28 PTO (Power take olf) 7 Exhaust manifold 48 Oil pressure unit 29 Lifting hack 8 Airheater relay 19 Idle pulley (Aircon) 30. Air pipe (Air cleaner to turbocharger) 9 Airpipe 20 Aircon. bracket 31. Power steering pump (riatebaler_ to intake wanitold) 40. Oilcooler 21 Fan clutch 32 Pick-up sensor 11 Oilfiller pipe 22 Cooling fan 33 1s Ally Daewoo __ GENERAL INFORMATION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis (5) DV15TIS (Bus) 1 Flywheel housing 9 Turbo charger 10 3 Aircompressor 11 4 Breather pipe 2 5 Exhaust manifold 13 6 Water outlet “ 7 Oilfiller cap. 1s 8 Olleooler 6 Drain plug Oil pan Water pump pulley Water pump Air pipe Utereooler to intake manifold) Alternator Oil filter Mounting bracket 17 Oil level gauge 18 Starter 19 Airpipe wer fo turbo charger) » (lurbacharger to inter cooler) 21 Power steering pump 22 Pick-up sensor 23 Fly whee! GENERAL INFORMATION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis (6) DV15TIS (Truck) 2 ae 4 Sethe 2s 1. Flywheel housing 12. Oilfiller pipe 23 Fan guide 2 Exhaust elbow 13. Drain plug 24 Cooling fan 2 Fuel filter 44 Mounting bracket 25. Fan clutch 4 Air pipe(to air tank) 15 Alternator 26 Mounting bracket 5 Airvont pipe 16 Water pump 27 Air pipe (Turbo charger to Intercooler) 6 Ollfiller cap 17 Water outlet 28 Starter 7 Exhaust manitold 18 Control lever 29 Power take off (PTO) 8 Starter relay 19. Oil pressure unit 20 Lilting hook 9 Airheater relay 20° Idle pulley (Aircon) 31 Air pipe (ir eleaner to turbocharger) 10 Airpipe 21 Alreon. bracket 32 Power steering pump (inarcencer te intake manifold) 11 Ollcooler 22° ollfilter 33. Pick-up sensor Ally Daewoo __ GENERAL INFORMATION Printed i Avg. 2001 PS-MMAUIOMELApyissrrnuis 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. 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 diluti 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 contro! 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 DV15, DV15T, DV1STI, DVISTIS (Engine of D28 base engine) cylinder liner is wet type, particularly the cooling water control should be applied thoroughly. © 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 60.9990" -0038) © How to use the cooling water tost 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 agilation, shake off the water. (3) Wait for about 45 sec. till the color change of test paper. MAJOR MAINTENANCE Printed i Au 2001 PS-MMAO?00-E1 Alp DAEWOO,pyisrrmitis NOTE: However, it should not elapse longer than 75 sec, and i it did, the hue would change. (4) Make the numerical value dy comparing the test paper which hue has changed with the cola’ list of label on storage bottle. een color (5) By comparing the nue changed into yellowish green or so with the g indication of test paper storage bott'e, 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 velue of brown (vertical) and pink color (horizontal) locates in the range of 0.3 to 0.8 at the color ist of label on the test paper storage bottle. (7) In case of less than 0.3, rep! enish 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 . (2 (9%) Temperature (°C) Cooling water (%) Anti-freeze (%) ‘Over 10) 85 5 -10 80 “15 73 20 67 “25 60 30 56 -40 50 2.1.2. Fan belt @ Use a fan belt specified wy dimensions, and replace if damaged, Presshere frayed, or deteriorated Crank aha © Check the fan belt for bell tension. “ue If belt tension is lower than the | Mis Pune atey specified limil, adjust the tension by relocating the alternator and idle pulley. (specified deflection: 10~ 15 | insu? mm when pressed down with thumb) pulley Air con. pulley MAJOR MAINTENANCE |? Sd Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis Aerator mis —\ (Crank shaft 7 si LU Bae pulley | ye Sy } @P _ 2.1.3. Engine oil © Check oil level with the cil level gauge and replenish if necessary. Ee © 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 0 level must be between Max and Min, lines on the gauge © Engine oil should be changed at the specified intervals. Oil in the oil filter should be changed simultancously, First oil change After 1,000km (S0hr) operation every 10,000km Short-distance operation vehicle | DVISTT ML) hours) (city bus, dump truck, construction |_______EP’ Pewrs)_ equipments) DVI5TIS every 20,000km Long-distance operation vehicles | PV15/V/Tl__ every 15,000km {express bus, cargo truck) DV15TIS every 30,000km © The following o's are a'so recommended Recommend oil Engine model SAE No. API No. DvisT/T SAE 18W40 above CD or CE SAE1SWa0 ACEA-E2 or ACEA-E3 ovisTis SAE10W40 (API.CH-4) * If long cil change intervals are to be used, ACEA-E3 oil must be used. 20 iy DAEWOO MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis © Engine Oil capacity Engine oil capacity in Oil pan Total Vehicle [— Max. Min. «iy (lit) (lit) DvIs Bus 24 20 27 DvisT Truck 21 19 24 DvisTl Industrial 24 18 24 Bus 24 20 27 DVISTIS Truck 21 19 24 2.1.4. Fuel filter © Drain water in cartridge with loosening ; the cock under ‘ilter manually (6) from time to time 3 q 5 2 6 ena 2.1.5. Air cleaner. @lIn 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, Aly DAEWOO MAJOR MAINTENANCE 7! Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 2.1.6. Intercooler (DVISTI, DVISTIS) The intercooler is air to air type and has a large cooling fan capacity. The intercooler life and performance deoends on the intake air condition greatly. Fouled air pollutes and clogs the air fins of intercooler. As a resull 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. 2.1.7. Valve clearance adjust procedure Atter letting the #1 cylinder’s oiston come at the compression top dead center by turning the crankshaf, 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 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 Dvis | DVIST . DvisT 0.25 mm 0.35 mm DVI5TIS 2 ip paewoo MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis © Adjusting sequence of valve clearance (Type 1) 1) Rotate the crankshaft to overlap the intake and the exnaust valves of #6. then enter. #1 cylinder become the compression state of top dead 2) Therefore adjust the valve clearance corresponding ‘o “[2) 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) Thereatter adjust she valve clearances corresponding to “ —) ” of lower figure 5) Alter reinsuring the valve clearances, retighten if necessary. © No. 1 Cylinder is located at the side where cooling water pump was installed, Fly wheel Cylinder No. / atthe #6 cylinder overlap Cooling fan 2: atthe tl eylinder overlap Exhaust valve Intake valve © Adjusting sequence of valve clearance (Type 2) Type 1 is the conventional and simple method, but if you have some problem to adjust your engine, please try type 2 sequence. This is a precision method, but it takes more time, 4,8 Cylinder Engine (DVIS/DVIST/TUTIS) Valve overlapping on cylinder (intake & Exhaust valve) ‘Adjusting valves on cylinder (intake & Exhaust valve) eye i4 fe ts [7 [2 1/5 7/2 6/3 ]ale MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIA Alp DOEWOO,pyisrrmitis 2.1.8. Cylinder compression pressure EH bd © Stop the engine after warming up, and take out nozzle holder assembly. © Install the special tool (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there. ‘Standard value DWkglem" over Lirait value [2akg/em Difference ‘thin & 10% betwicen each cylinder Within +10 + Condition : Water temperature 20°C, Engine rotation 200rpm (10 rotation) 2.1.9. Injection nozzle © Install a nozzle on the nozzle tester. © | the inspected injection pressure is less than the specified value, adjust using the adjusting shims. Engine model | DV15 DVIST DvisTI DVISTIS Injection nozzle | 20018 20918 jem? | 25048 ke/em? pressure kgicm* kgicm* 200+8 kg 25048 ke © Check the atomizing state and replace it if abnormal. Alp DOEWOO, MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyissrrnuis MAINTENANCE MANUAL. 2.1.10. 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. 11. 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), roplenish 2.1.12. Air removal of fuel system The suction room of ‘vel injection pump has the function of air removal continuously during the operation through a relief valve. In case thal 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. 13. Fuel supply pump Every time of engine oil replacement, the fuel strainer installed at the fuel supply pump should be removed and cleaned. MAJOR MAINTENANCE Printed i Au 2001 PS-MMAO?00-E1 Alp DAEWOO,pyisrrmitis 2.1.14, Turbocharger The turbocharger needs not acy special equipment. Every time of engine replacement, a leakage or clogging of oil pipes should be ing ted. 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. Teer down the impeller casing (attention: be careful not to bend) and must clean with non-acid solvent solution. If sary, 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 suppor: by impeller but bes ing housing, 2.1.15, Starting motor Al In case of engine maintenance, clean pinion and ring gear thoroughly putting in the {uol, and coat them with grease. Also, In case of washing car and so forth, inspect the wiring state being careful for not to got MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyissrrrutis. TENANCE MANUAL. 2.2. Diagnosis and Remedy © The following description summarizes the probable cause of and remedy for general failure by item. © Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected. 1. Engine Starting Impossible a Stating mete operation poor ‘Stating ter evowion | I 1 Inapecton a batary eociorbie naire Ful loud amour osuty r Ipc Toepact mun oF bt [Nema] [tee low] tropes ok rare iepet " facusomont Nowa ] | Polasd Nowra Nowe Recharging aia Repace oF epneh ineporion ol feos seco clean clement irspect al waesont a then | [wt now L_wingeeten rosston possula a oral cnet] (eter Canto No ‘porston ate inapedion of arin ooh ol Seren nape " ins of Torna [Beoer L- ‘noeten gma | Repco ates || ines repent ering lay hace fae | sens [Rema] [Resco _ seston ! Nepal | (Aaa nora [specter oimapenieenibh] | — 1 —_— cai mer ‘check cinder roca i apa rend geass [+ Papiee || | ste ee) Forma Res Raplace Rapa —_ (Derma) Noma on see Engine daaasambly ineaion aap ‘one sorb. in, Sassen enor nr st) - —— ——___Linapeer pay eum operation | 1 1 (Renal) Inspaet spp pump end stainer ‘mice Tul I _ T I ‘ryectonpurs | Caan? Normat Festi] | Hetghien sanacion Sonn”) [Epes] ° Tee) Etepcrno Inepeet fin ar ‘Arromoval 1 I enert plied ay Contnuous a ming rerio vale pooe ( cerovou oe ming | —— uly pug Replace sesso 0h MAJOR MAINTENANCE Printed i Au 2001 PS-MMAO?00-E1pyisrrmitis 2, Engine Overheated cating sate +. ovesoad Sees Feel ener Bement hwo cot — ipa it aiziy [Fast mene ssp co Teer a I Poor (Swine fenccr. wear |] Fema oor Check inaction nowzia rasnago 1 ep Tape aaa = votes Chascaah oS tnt nccap|—|_PEE® alas | I T I Normal Fotighten | | Engine ses Replace | Normal | | abner [emtereeast] | nepne rae | acl “a ‘Mecton | | Fepace I pump pet air . ere seer Paes Feplace I Normal (Cheok eocling Repair wanroure ae lo 7 Sterposme {| [Nema pee omg app Engine sienonoy Paps wnat | [ apse I overea 28 ly DAEWOO. MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 3, Output insufficient Engine Crassis E I Fuel sysom Obes (heck for eich ip I I “Check or airmbing Tnopoct ar eaner Adit or replace cuch] wn tuo I T I [Normal] [Gisan-Ralpaoa | Inspect fuel supply cum I I r Inepect engine contol inspect ar eakags [Nornal][ Cisan-Replace tink, cable, et, Inspect : 1 of ar piping ioe Inspect fue filer and (Norra) [adjust over ow valve t Nomar |. [ Retonten: - t check valve clearance Replace Normal] [Restac] ; r z Normal] [Achust Inspect alr eakage ‘nispeet injection pine I ot Intercooler T T Inspect cylinder head [Roca] Repair-Roplace gasket forcamage i I ‘nspeet jection noza Normal] [Peace (jection pressure, T atomizing state) Engine t i (valve sasemoty) Norma Ais Replace I (Check injection tring I I [wormal][ Adjustment [| r?! ‘Disassemble engine or (Check turbocharger ejection pure I T [Normal] | Repair Replace Disassombie injection pump or angie Aly DAEWOO MAJOR MAINTENANCE 7? Printed i Aug. 2001 PS-MMAUTOMEIA30 pyisrrmitis ‘Ghecic of pressure gauge insictes wrongly TT Inspect ol quaity (Normal Nonna Toa iow ~t ir (Ghai cooing (Use recomended ail tomparature [tresersh To Nowa 7) ‘Water 8 ie mixed ral _——t Disossombi ergins| [normal] | erignen- cr irestion pump pace —— Dsessemble Alp DOEWOO. MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 5. Fuel Consumption Excessive ‘Causes aocording to Use Conditions 4. Overond 2 Frequent use of ger postion at highspeed Frequent use of igh gear poston stow spoed 4.ciuch sip Inspect uel eakago 5 Toolow to intaion proseue Nowa I Inapedt jection razzie Ci lonkage (ejection possi, ‘aj Replace stoning wate te) eee ame a rece Normal [_Newal_] Chicinecton ting ae I Normal I inapoct compressed ‘Check valve Fre ee =e ‘earance Piston ring, piston Norra I Disassemble injection pump Aduct i Normal L_ fem | Trepect ad gash place T Normal Dssassemoe engine vata ascery,ton, eyincor nee et) aI ly DAEWOO, MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 6. Oil Consumptton Excassive Replace wth poate ol ‘Cause according to use conditions 1. Excessive of ntusing 2. Contiwous operation in low speed crextemay cod slate oS a Engiow disassembly (Wecral (piston, eylnder ren os creat tae ten seat Irapec combo offs & carton rei f exhat oa) [iene Contr lL —[— rsoec compressed Diassembie assure (a sore | I won | Nomal I Checcave clerance ana ‘nspea ein ovine head geet erin ne TL — rome] [am] [aera] [Sep c t Achust ‘Ghee qty ‘isaeerble eure [Deweieana 2 Aly DAEWOO. MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 8. Battery Discharge Baty | Wing Sich Serer T 1 I heck occ asec one hes fan bot ta roar shore anclecee Sonoon &cenage conmectors Lemos evar Reaiace em] eiewroine | [ eateryroan | | aatiryeat | I ater nr vate carnage deauge | [cheno stad t I Inspeot alerator opie Popace votaoy oss oe ‘rma (anormal — T Creat targersemoa] [Aout f Fosase occa 1 Dearne sonora otage ruler 3 lg DAEWDO | MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis Condi nm Causes Remedies 1) Starting difficult () Starting motor troubie © Refer to diagnostes (2) Fuel system trouble © Refer to diagnostes (3) Compression pressure lack | @ Valve's poor shul, stem Repair or replace distortion © Valve spring damage Replace valve spring © Cylinder head gasket's leak Replace gasket © Wear of piston, piston rng Adjust orliner 2) Idle operation abnormal | @ Injection timing incorrect Adjust @ Air mixing at injection pump __ Remove air 3) Engine output insufficient (1) Continuous output © Valve clearance incorrect Adjust insuiticent © Valve tightness poor Repair © Cylinder head gaske''s leak Replace gasket © Wear, slick, damage of Replace piston ring piston ting © Injection timing incorrect. Adjust © Fuel injection amount Adjust injection sump insutticent © Nozzle injection pressure Adjust or replace improper or stuck © Supply pump's function Repair or replace lowered © Fuel pipe system clogged | Repair © Air suction amount Clean or replace air insufficient cleaner © Turbocharger 900r Repair 0° reolace (2) Output insufficient © Compression pressure Disassemble engine when in acceleration insufficient © Injection timing incorrect Adjust © Fuel injection amount Adjust injection cump insutficent © Injection pump timers Repair or replace function insufficient © Nozzle infection pressure, Hepair, replace infection angle improper © Supply pump’s function Repair or replace lowered © Airintake amount Clean or insufficient replace air cleaner 4) Overheating © Engine oil insufficient or Replenish or -eplace poor © Cooling water insuficient -Reolenish or replace © Fan belt loosened, worn, Adjust or replace damaged © Cooling water pump's Repair o” replace function lowered © Water temp. regulators Replace operation poor © Valve clearance incorrect Adjust © Exhaust system's resistance Clean or replace at Aly DAEWOO MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis Condi Causes Remedies 5) Engine noisy For noises arse compositely such as rotaling parts, lapping parts etc., there is necessity to search the cause accurately (1) Crankshaft © As the wear of bearng or | Realace bearing & crankshaft progress, the oil grind crarkshatt clearances increase. © Lopsided wear of crankshat Grind or replace © 0) suppyy insufficient due to | Clean oil passage ol passage clogging © Stuck bearing Replace bearing & Grind (2) Gon.-rod and © lopsided wear of con rod Replace bearing Con.-rod bearing bearing © Lopsided wear of crank pin Grind crankshaft © Connecting rod distortion Repair or reolace © Stuck bearing Replace & grind crankshaft © 0} supoly insufficiency as Clean oll pascage clogging at oll passage progresses (3) Piston, piston pin & ® Pision clearance increase Aeolace pision & Piston ring ‘as the wear of piston and | piston ring piston ring progresses © Wear of ciston or piston pin | Replace © Piston stuck Replace piston © Piston insertion poor Replace piston @ Piston ring damaged |_Beplace piston (4) Others © Wear of crankshatt, thrust" Reolace thrust bearing bearng © Camshat end ~— play Replace thrust plate increasea © Idic gear ond play increased | Reolace thrust washer @ Timng gear backlash Repair o- replace © Valve clearance excessive Adjust valve clearance © Abnormal wear ci tappet, Replace tappet, cam © Turbocharger inner part Repair 0” replace damaged 6) Fuel Consumption ® Injection timing incorrect Adjust Excessive © Fuel injection amount Adjust injection cump 35 Aly DAEWOO MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis Condition Causes Remedies 7) Oil Consumption Excessive | (1) Olllevel elevated © Clearance between cylinder | Replace liner & piston ‘© Wear of piston ring, rng Replace piston, groove piston ring © Piston ring's damage, stick, Replace piston ring © Piston ring openings Correct position disposition improper © Piston skirt part damaged or Replace piston abnormal wear © 0} rings oil return hole Replace piston ring clogged © Oi ring’s contact poor Replace piston ring (2) Oil eve! lowered © Looseness of valve stem & Aeplace in set guide © Wear of valve stem seal Replace seal @ Cylinder head gasker's leak _ Replace gasket (3) Oil leak ® Looseness of conneclon | Replace gaskel, repair parts © Various parts’ packing poor Aeplace packing © Oi'sea! poor Replace oil seal 36 Aly DAEWOO MAJOR MAINTENANCE Printed i Aug. 2001 PS-MMAUTOMEIApyissrrnuis MAINTENANCE MANUAL. 2.3. Engine Inspection 2.3.1. Stopping engine Ater checking the engine for any unusual condition at the idling speed, then tum the key switch to stop the engine. 2.3.2. General engine inspection cycle 0: Check Bacust ¢ : Replace Taspection inet) Inspection Daiy err 1.000 | 1000 | 45.000 | 23.000 | 4.000 Sick or eakagetioss chm) | 0 Coating PASH ewer vel o seen rss he-W eran @ feck fr eakige o Shek he ol evel sae ° Lubrication = change the Ibricting oil . ‘System » e Ist er erlace the i er earidge . © eck he Tak Forno hoses. clamp) ° System [peat camer ceneat ° Prin the warn sepa 3 Team Ge Tac pf fuel feed pump. ° ug Pike a o 1 Senet, sk el ren ding = pave he us ter earcidse : eck he injection noses ce feck heewamwsete [0 gine FSET i nin 3 — duct heck the compression pesare ia i Take a se clams ewe *(e) The engine oi] charge interval 1s deternine by engine use and OT grade 2.3.3. Use of original parts for repair and replacement For engine is being mechanically harmonized with many parts, only when the orig inal parts that the manufacture recommends to use is used, the engine trouble would be preventively mai ned and capable to keep up the maximum performances, For the analogous parts not the original parts are poor in qualities and gives ill performances, it may rather bring early engine failure Allg DAEWOO MAJOR MAINTENANCE _*? Printed i Au 2001 PS-MMAO?00-E1pyisrrmitis 3. 3.1. Engine Disassembly 3.1.1. General precautions disassembled parts jisassembly and Reassembly of Major Components Maintenance operation should be carried out in 2 bright and clean olace. Before disassembly, provide parts racks for storage of various tools and © Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to them 3.1.2. Cooling water A 38 @ 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 steam pressure will prevent a person from scalding with hot steam spouted out from the filler port. © Remove the cooling water drain plug from the cylinder block and oil cooler, various pipes, etc. and let the cooling water discharge into the prepared vessel y } S > Drain valve NI ENGINE DISASSEMBLY Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 3.1.3. Oil level gauge © Take out the oil level gauge Engine oil @ Remove an cil drain plug from the oi pan, and let engine oil discharge into the prepared vessel 3.1.5, Co ling fan hi | @ Remove fan fixing bolts, then take off the cooling fan epuzont 3.1.6. V-belt, © Loosen the V-belt tension adjusting bolts, and remove the V-belt, J 3.1.7. Alternator © Remove the supporting guide piece for instaling the alternator and the bra bolts. © Disassemble the alternator. Al Daewoo _ ENGINE DISASSEMBLY __*? Printed i Avg. 2001 PS-MMAUIOMELA3.1.8. Vibration damper @ Remove the fixing bolts for crankshaft pullay in reverse order of assembling and disassemble the crankshaft pulley and vibration damper. 3.1.9. Oil filter Loosen the filter housing fixing bolts then the spring will tor the filter housing to move upward a little. Allow an interval of 2 ~ 3 minutes until the engine oll by-p: take off the filter. 5 to the oil pan, then © Do not use again the cartridge removed atter use. © Unscrew the oil filter head fixing bolts and lake off the oil filter head 40 pyisrrmitis iy Daewoo _ ENGINE DISASSEMBLY Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3.1.10. Cooling water pump © Loosen the various hose clamps for the connections. © Remove the cooling water discharging pipe and disassemble the thermosiat. @ Remove the cooling water pump fixing bolts / and disassemble the cooling water pump. a 3.1.11. Starting motor © Remove the starting motor fixing nuts and disassemble the starting motor. 2.1.12. Fuel filter © Disassemble the fuel hose for the fuel supply and suction. : © Remove the fual fiker fixing and disassernole the filter. 3.1.13. Fuel filter © Disassemble the fuel hose for the fuel supply and suction © Rom and e the fuel filter fixing disassernole the fuel filter. \ 3.1.14, Fuel injection pipe © Disassemble various fuel pipe and hose. © Disassemble the fuel injection pipe from the nozzle holder and fuel injection pump, ip Daewoo ENGINE DISASSEMBLY 1! Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3.1.15. Oil cooler © Remove the drain plug from the oil cooler T cover and drain out the cooling water. © Remove the oll cooler cover fixing bolts and disassemble the oll cooler. © Clamp the oil cooler assembly to the vise, remove the oil cooler insert fixing bolts then disassemble the cooler insert. 3.1.16. Turbocharger © Loosen the hose clamp for connecting the intake stake and tear down the air intake stake. © Loosen the fixing bolls for connecting the air intake manifold © Remove the hollow screws of pipes for turbocharger lubrication and its discharge. and lear the pipos down. © Remove the turbocharger fixing nuts. Remove the turbocharger using care so that the connecting pipes of the intake flange and O-ring may not be damaged a Ally Daewoo _ ENGINE DISASSEMBLY Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3.1.17. Intercooler (DV15TI, DV1STIS) © Tear down the various hoses and air pipes from the inter cooler. © Remove the intercooler fixing bolts and | tear it down, 3.1.18, Exhaust manifold @ Remove the exhaust manifold fixing jl boits and tear down the manifold from the cylinder head RY | 3.1.19. Intake manifold © Remove the manifold fixing bolts and tear down the manifold from the cylinder head 3.1.20. Air compressor © Remove the oll, water, air pipes and hoses belween cylinder block and air compressor. © Remove the power steering oil pump. © Unscrew the cylinder head bolts and remove the compressor head. Al Daewoo ENGINE DISASSEMBLY _** Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis © Remove the side cover. © Remove the flywhs s| housing side cover. © Unscrew the liner fixing bolts and take off the air compressor liner over the piston. © Unscrew the connecting rod bearing cap fixing bolts and take them off together with the cylinder liner. Kor © Unscrew the fixing nuts on the spanner and disassemble the driving gear. © Disassemble the flange on the front side of the flywnee! housing, Disassemble the crank shalt. Disassemble the bearing flange on rear side. 3.1.21. Fuel Injection pump © Remove the oil pipes for lubrication and the fuel hoses. © Remove the fixing bolts of fuel injection pump and take out the fuel Injection pump. 3.1.22. Cylinder head cover ® Remove cylinder head cover fixing Dots and take off the cylinder head cover. 3.1.23. Nozzle holder © Unscrew nozzle holder fixing nut by using @ a special tool and remove the nozzle holder, # iy Dazwoo _ ENGINE DISASSEMBLY Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3.1.24. Rocker arm @ Remove the rocker arm bracket fixing bolts and take out the rocker arm © Pull out the push rod. oy \ is 3.1.25. Cylinder head © Loosen the cylinder head fixing bolts in the reverse order of assembling, and remove them all and then take the cylinder head out © Remove the cylinder head gasket and © Fliminate the residue from the cylinder head face and cylinder block face. CAUTION: Be careful not to damage the cylinder head face where its gasket contacts. 3.1.26. Oil pan @ Remove the oil pan fixing bolts and separate the oil pan. @ Remove the oil pan gasket and scrap it. 3.1.27. Oil pump © Remove the oil suction pipe fixing bolls and tear them down © Remove the oil relief valve fixing bolts and take them out. © Remove the oil pump fixing bolts and separate it Al Daewoo ENGINE DISASSEMBLY _* Printed i Avg. 2001 PS-MMAUIOMELA3.1.28. Piston @ Remove the connecting rod cap bolts in the reverse order of assembling and follow the similar method as in the cylinder nead bolt removal © Tapping the upper and lower connecting rod caps lightly with an urethane hammer, separate them and take the bearings out. © By pushing the piston assembly with a [=] wooden bar toward the cylinder head's direction remove the piston. NOTES: Be careful for the removed pistons not to. collide each other or with the other parts. At the storage of pistons, maintain them in the order of cylinders. (In order for connecting rod caps not to mix one another, temporarily assemble them to the cortesponding connecting rods.) 3.1.29. Front oil seal holder © Remove the oil seal holder fixing bolts and tear down, Fu Remove the oil seal and gasket from the oil seal holder and scrap them 3.1.30. Flywheel © Remove the flywheel fixing bolts in the 1 of disass or and remove the flywheel 46 pyisrrmitis ENGINE DISASSEMBLY Alp DOEWOO, Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis © Remove the flywheel ring gear. ~ Heat the ring gear evenly with a gas burner (uo to 200 °C) to invite volumetric expansion - Tapping around the edges of the ring | || ii ‘ar wth a hammer and brass bar to remove it. CAUTION: A Do not damage the flywheel. 3.1.31. Flywheel housing © Remove the flywheel housing fixing bolts and take them out. © Remove the oil seal from the flywheel housing 3.1.32. Crankshaft © Remove the bolts from bearing caps. : © Remove the main bearing cap fixing bolts \. in the order of assembling (Remove them in the same way of the cylinder head bolts.) p rr © Maintain the removed bearing caps in the order of cylinders. Its at the both © Tomporarily install the side of crankshaft, and lift the shaft with a rope, 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. Aly paewoo ENGINE DISASSEMBLY __“” 101 PS-MMAUHO-EIA, Print in Avg. 2pyisrrmitis 3.1.33. Camshaft and tappet © Pull out the tappets from the xylinder block. ® Remove the camshaft being careful not to damage the camshaft and its bearings 3.1.34. Oil spray nozzle © Remove the oil inj jon nozzle fixing bolts and tear down the oil injection nozzles. roo) ge a 3.1.35. Cylinder liner a © By means of a special tool (Extractor), m pull out the liner from the cylinder block. R as Ally Daewoo _ ENGINE DISASSEMBLY Printed i Avg. 2001 PS-MMAUIOMELApyisrrmuti MAINTENANCE MANU 3.2. Measurement and Inspection of Major Parts 3.2.1. Cleaning and inspection of cylinder block © Clean the cylinder block and inspect it for any crack or a damage. BE © Inspect the oil passage and water passage for any clog and erosion. © By performing the hydra ‘est, inspect for any leaks. With plugging the water and oil passages of cylinder block, put in the air of 5 kg/cm* pressure in the Inlet port of cylinder block and then soak the cylinder block in the water for about 1 minute to check for any leaks. (water temperature: 70 °C) © Inspect the cylinder block's camshaft bush to any damage and the alignment of oil supply holes and if abnormal, replace it 3.2.2. Cylinder liner measurement a © Assemble the cylinder liner at the cylinder block and measure inner meters at upper, middle, lower 3 levels by 45° interval and calculate the average values after eliminating the max. and min. values, @ If the measured values are very close to the limit value or beyond, replace it. Liner inner Standard Limit diameter [9177.990~ 0128.010 mm 0.15 mm 3.2.3. Cylinder head (1) Cylinder head disassembly © Be careful fo che oylinder head gasket contacting surface of cylinder head not to be damaged. @ Remove the cotter pin pressing the valve @ spring by means of a special tool ly Ba=woo MEASUREMENT & INSPECTION Printed i Au 2001 PS-MMAO?00-E1pyisrrmitis Take out the valve stem seal Pull out the intake and exhaust valves. Remo the valve quides from the combustion room side of cylinder head | by means of a special tool 2) Inspection and measurement of cylinder head a) Damage check Inspect the cylinder head for any crack or damage. or head lower Eliminate the carbon residue and gasket piece from the cylind ‘ace thoroughly. Then be careful for the valve seat not to be damaged The cracks or damages that are difficut to search may be inspected by a aydraulic test or a magnetic powder test, (Hydraulic test is same as for cylinder block.) b) Distortion Measure the flatness degree (any distortion) of cylinder head. Ev on beyond the limit value of maintenance. a it may be correct d by grinding. (iF € more than limit value of use, replace it) Standard Limit Warpage (0.05 mm or les 02 mm ly Daewoo MEASUREMENT & INSPECTION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3) Inspection and measurement of valve and valve quide a) Valve @ After cleaning the valves with clean diesel ol, measure the valve stem’s outside diameter at upper, middle, and lower to determine the wears and when the wear limit is more than 0.15mm, replace the vaives. Valve Standard Limit Intake | 411.959 ~ 11.980 mm| 412.130 me Exhaust © Inspect the scratch and wear of valve face, and stem seal necessary correct with the grinding paper but if severe replace it. © |F valve head thickness (H) becomes less than 1.6mm for intake and 1.3mm pO for exhaust, replace the valve Valve [Standard Limit Intake 30 a 6mm Exhaust] | 9=2 ¥mm Sm b) Valve guide @ Insert the valve into valve guide and measure the clearance between valve and valve guide by the shaking degree of valve. If the clearance is bigger, measure the valve and then replace the more worn valve guide. ly Daewoo MEASUREMENT & INSPECTION Printed n sl 101 PS-MMAUIOMELApyisrrmitis © If the valve guide has already been replaced, measure the center with vaive seat if it deviates or not and if abnormal it must be corrected. (Simultaneously be processed when in guide reamer process.) Valve Standard Limit Intake | 0.020~0.019 mm | 020mm Exhaust | 0.045 ~0.074 mm | 025mm ¢) Valve seat thickness and angle © Inspect the damage and wear of valve seat and it necessary replac © Assemble the valves at the cylinder head and using the measuring instrument @, measure the projection amount of valve. If the measured from the lower value is more than the use limit, replace the valve seat. ao ‘Standard Limit a — 0.65 ~ 0.95 mm 2.5mm bet ~ Intake valve 30° Exhaust valve 45° ea © The disassembly of valve seat can be pulled out by means of a special too! with the arc welding done at two points { of valve seat rotating tool or vaive seat. ly Daewoo MEASUREMENT & INSPECTION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis FA © Regarding the valve seat assembling, shrink the valve seat by putting t in the dry ices for about 1 hour or so, and then press it into the cylinder head by means of a special too! | © After coating the grinding powder paste on valve head contacting face of valve seat, and a‘ter executing a sufficient laoping operation with the rotating and grinding motion of valve, wipe off the © grinding agent thoroughly. 4) Valve spring © Inspect the outlook of valve spring and if necessary replace it. © By means of spring tester, measure the tension and free length @ Measure the perpendicularity of valve — = spring VOTE? @ In case that the measured value N exceeds the limit value, replace it. By Tate Free lenth By 2Gnn Inside [ When onpeset wi TOTO] spring Petiks | Varma Whar compressed wilhTead ot 5s vis 445 ~49.5 kg | Dvistis pve | e617 mm Free length DVISTIS 61.9 mm Ouiside | Whee compressed oil ATT | yy cernr) Spring ike ‘asmn Wher apencd win 26.5 ~ Ike DyisTis e) Cylinder head assembling © Clean the cylinder head thorough'y. © Coat the valve stems and valve guides with engine oil and assemble the valves. © Replace the vaive stem seals with new ones and insert the stem seals to the valve guides of cylinder head with a special tool. (Be careful for the valve stem seals not to be damaged.) © Install the valve soring washer to valve guide. A Me @ After putting on the inside, outside spring, install the valve spring seat on them ly Daewoo MEASUREMENT & INSPECTION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis Painted portion [=| © Install the valve spring seat with “TOP” (painted in red) side up. a © Pressing the spring down with a special oe tool, assemble by inserting the valve 3 cotter. A @ Aiter the valve is assembled. inspect @ the valve tapping it lightly with an Se urethane hammer if accurate 2 assembling was done. 3.2.4, Rocker arm 1) Rocker arm disassembling ea © Remove the snap rings in both ends of rocker arm with a pair of pliers. © Tear down washer, rocker arm. ® Disassemble the rocker arm bush by means of a prass. - 2) Inspection and measurement a) Rocker arm bracket (Single unit type with a shaft) © Measure the outer diameter of rocker arm bracket wilh oulside micrometer at the position that the rocker arm is K and in case thal il exceeds the rn limit value, replace = x ly Baewoo MEASUREMENT & INSPECTION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis Standard Limit Bush inner Diameter 925005 ~ 925085 mm] 2505S 1m 24.990 | Shaft outer Diameter 62.95 Clearance ors~on6 mn | 025mm b) Rocker arm © Inspect the rocker arm surface that contacts with the valve stem for any scratch, step wear and correct the minor degree of wear with an cil stone or the fine grinding paper and replace if they are severe. ¢) Tappet and push rod © By means of outside micrometer, measure the outer diameter of tappet and replace the severe ones. Standard Limit ‘Tappet clearance [0035 ~ 0.077 mm | 0.25 me © By inspecting the tappet surface that contacts with the camshatt's cam for any crack and scratch etc., and if the degree is small, correct them with an oil stone or the grinding paper but if severe replace them. © Place the push rod on the surface plate and rolling it, Inspect the curving degree with a clearance gauge and if abnormal replace it. ui 3 mm or le: d) Rocker arm reassembling iy pa=woo MEASUREMENT & INSPECTION _** Te Ang 2001 PSMMADTOO-EIAFl © Inspect the oil passages of rocker arm and rocker arm bracket for any clogs and reassemble them in the reverse order of disassembling after thorough cleaning. 3.2.5. Camshaft 1) Axial end play pyisrrnvtt MAINTENANCE MANU © Push the camshaft toward the pulley side. © Place a dial gauge onto the camshaft gear. @ Measure the camshatt’s axial end play, moving the camshaft gear by means of a driver. Limit 0.2~ 0.9mm © If excessive end play, assemble it by means of other thrust washer. 2) Inspection and measurement 56 © With inspecting the cam surface for any damage with naked eyes and correct any minor scratch by means of an oil stone grinding and if severe, replace it a) Cam lobe height © Use a micrometer to measure the cam lobe height and journal diameter. It the measured number is less than the specified limit, the camshaft must replaced. ly Baewoo MEASUREMENT & INSPECTION Pinte i Au. 2001 PS-MMAO700-E1pyissrrnuis MAINTENANCE MANUAL [standard | Limit Cam lobe heght (Gi [47.7 mm Cam journal diameter (A,0)fo56.0 mm 965.6 mm b) Cam journal iameter © By means of outside micrometer, measure the camshall journal. Standard | 069.91 ~ 968.94mm c) Cam bearing diameter @ Measure the camshaft bush inside diameter with a cylinder gauge and by comparing the inside and outside diameters, replace if abnormal. Standard | 670.077 670.061 mm i Clearance between camshatt journal and body Standard Limit 0.060~0.120mm | 0.18mm e) Camshatt bearing replacement a © Remover, installer 1) — iy pa=woo MEASUREMENT & INSPECTION _*) Pinte i Au. 2001 PS-MMAO700-E1) Camshaft run-out © With placing the camshaft on the 2ea of \V-blocks, and inspect the run-out of the camshatt, adjust or replace the severe one. Standard Ot mm 2.2.6. Crankshaft 1) Inspection and measurement © Inspect for any scratch or damage with naked eyes, and grind to the undersize according to the damaged degree and use the undersized bearing, © Inspect for any crack by means of magnetic powder and color check. and replace the cracked ones. a) Journal and pin diameter © With outside micrometer, measure the outside diameter of crank journal and crank pin at the direction and position of the figure shown and take the weer. Standard [9103.98 ~ 104.00 mm Standard | 989.98 ~ )90.00 mm pyisrrmitis © In case that the lopsided wear is more than the limit value, grind to the undersize, and use the undersized bearing. ly Daewoo MEASUREMENT & INSPECTION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis (@) Standard (b) 0.25 (Inside diameter 0.25mm less than standard) (c) 0.50 (Inside diameter 0.50mm less than standard) (d) 0.75 (Inside diameter 0.75mm less than standard) (€) 1.00 (Inside diameter 1.00mm less than standard) © There are 4 kinds as above, and the crankshaft a'so can be used by regrinding as above. <"R” part standard value> (a) Crank pin "RY part: 4.0.2 () Crank journal "RY part: 4.0 4 NOTE: A In case of crankshaft regrinding, the "R” part at the end of bearing must accurately be ground without fail and should avoid any processed jaw or coarse surface. b) Run out of crankshaft @ Place the crankshaft on the V-block ® Place the dial gauge on the surface plate and measure the run out of crankshaft rotating the crankshatt. Standard Limit 0.06 mm 0.4mm ij pacwoo MEASUREMENT & INSPECTION © Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 2) Inspection on crankshaft bearing and connecting rod bearing © Inspect the crankshaft bearing and connecting rod bearing for any damages such as lopsided wear, scratch etc. and if abnormal, replace it © Inspect the oil clearance between the crankshait and bearing a) How to utilize the cylinder gauge el © Assemble the main bearing at the cylinder block and after tightening the bearing cap at the specified torque, measure the inside diameter. Journal bearing ominal dameter 0104 mm Bearing cap Bat ace _[!ntial 30 kg.m + angle 90 Assemble the bearing at the bigger end of connecting rod, and after tightening the bearing cap at the fo / specified torque, measure the inside |) (* diameter Connecting rod bbearng journal diameter 980 mm ¥ Connecting rod Dat tonsa _{Inial 104g. m + angle 90 © Crankshatt pin and bearing clearance In case that this clearance value exceeds the limit value, grind the crankshatt joumal enc in and then use the undersized bearing Standard Limit 0.066 ~ 0.132 mm | 0.166 mm ad iy Daewoo MEASUREMENT & INSPECTION Printed i Avg. 2001 PS-MMAUIOMELAb) How to utilize plastic gauge © Install the crankshaft in the cylinder block and place the plastic gauge on the cranksna‘t journal and pin at axial direction and then after tightening the bearing cap at the specified torque and again after tearing apart the bearing cap, measure the flatten plastic gauge thickness by pick it up. This is the oil clearance, © With the same points, the oil clearance of connecting rod also can be measured ) End play © Assemble the crankshaft in the cylinder block ® Install the dial gauge, and measure the ond play of crankshaft by pushing the crankshaft to axial direction. ‘Standard 0.190 ~ 0.322 mm Limit 0.452 mm 2.2.7. Piston 1) Piston disassembling © Pull out the snap ring for piston pin and ] with a pair of snap ring pliers © With a round bar, remove the piston pin pyisrrmitis iy Baewoo MEASUREMENT & INSPECTION _‘! Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis © With a pair of pliers, remove the piston ‘ings. © Clean the piston thoroughly. 2) Piston © With naked eyes, inspect the piston for any wear, crack and scratch and . particularly insp: carefully at the ring grooves for any wear. © With the outside micrometer, measure the piston’s outside diameter the ' measuring position is 74.5mm from the piston lower end, and the direction of measurement must be perpendicular to the piston pin direction Standard | 9127.739 ~ 9127.757 mm © By comparing the measured value of piston outside diameter with the cylinder liner inside diameter, the bigger clearance is replaced. 3) Piston ring and ring groove a) Inspection © Incase of piston ring’s wear, damage or engine overhaul, replace piston rings. b) Gap clearance Measure the piston ring cut part. © Insert the piston ring at the cylinder { rer's upper part perpendicularly \( Feces om © With a feeler gauge, measure Ar clearance of piston ring he @ ‘If the measured value exceeds the limit —_ value, replace it. @ iy Daewoo MEASUREMENT & INSPECTION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis ¢) Piston ring gap Division Suandand Tint Top ring 0.35 ~ 0.55 mm 1S orm [2nd ring | 0.40~0.60mm_|_15mm_| ¢) Piston side clearance. © Assemble the piston ring at the piston. © Measure the each ring's side clearance and if the measured value exceeds the limit value, repla e rings or piston, kL d) Piston side clearance Division | Specified value [Limit value) Top ring) 0.95 ~ 0.55 mmm) 15 sam Dna ring [0.050 ~ 0.082 mm |_1-5 mm Oil ring 0.030 ~ 0.062 mmm 4) Piston pin a) Outside diameter © With the outside micrometer, measure the piston pin's outside diameter and if the value is same as the use limit value or less, replace it. . Standard Limit 945.994 ~ 46.000 mm] 945.983 mm or less b) Piston pin and connecting rod bush clearance © Inspect the clearance betw nthe piston pin and the connecting sod bush, | if it is more than the use limit value, replace either one that is more severe. Limit 003 ~ 0.015 mm| ly Ba=woo MEASUREMENT & INSPECTION“ Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 5) Connecting rod © Inspect and measure the bigger end the smaller end / bearing hole and bearing hole with respect to the parallelness and if abnormal, replace 4 / the rod Standard Lime 0.02 mm 0.2 mm 6) Piston reassembling © Alter healing the piston at the piston heater for about 5 min (120 ~ 150 °C), by aligning the piston pin hole with the Ee] pin hole of connecting rod's smaller end, insert the oil coated piston pin. NOTE: Confirm the direction of connecting rod and assemble. With the snap ring plier, insert the piston pin snap ring. With confirming the upper side indication of piston ring, after assembling the ring in the piston ring groove, inspect if the movement of ring is smooth. © Keep in order of the assembled piston as the cylinder No. turn: 7) Water temperature inspection © Inspect the wax case and soring for any damage. © With putting the water temperature +a Bo oT | gauge into water and heating the water at the indirect method, when the water mp reaches to 83 °C, the valve begin to open and fully open when it reaches 95°C, ® Measure the valve opening temperature and the valve full opening o ly Baewoo MEASUREMENT & INSPECTION Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis temperature and inspect if the valve lift 8 more than 8mm and if abnormal, replace it 8) Injection nozzle Fe] © Set the nozzle assembly between the mH vise holder and disassemble it. j @ Remove the nozzle ruts and | 1 Nocti hose disassemble the inner parts. 6 Spee 7 Nazala mot 6 News © Inspect the disassembled parts if there s any damage, replace it © Assembling can be done in the reverse 8 order of disassembling. tt © After assembling the nozzle, set it in % the injection pressure measuring tester. © By manipulating the tester handle, spec’ the injection oressure and atomizing state Engine model Dv1sTI DVIsTIS Injection nozzle zoos gem? | 250189 © Incase of low or high injection pressure, adjust by adding or reducing the spring tension adjusting shims. - + © Incase that atomizing state is not good, | \~ ; t should be replaced, wuG, Gey iy paewoo MEASUREMENT & INSPECTION“ Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3.3. Engine Reassembly 3.3.1. Preparation and precaution before and after engine reassembly © Clean all the parts thoroughly and also clean thoroughly by blowing into each Fl passage of oil and cooling water. Disposition the various special and general tools for assembling in order. In order to coat the lapping parts with engine oll, prepare the clean engine ol Prepare the sub-material such as an adhesive ete. Use three bond as an adhesive in the engine oil system and use silicone in the cool yystem. © Scrap the used gasket and seal ring, consumable parts etc. and replace with new ones. © Tighten the various bolts in the specified tightening torque, and also according to the tightening order bur the excessive torque must be avoide © Inspect if the movement of engine is smooth a‘ter assembling © After comple sion of assembling, whether various bolts are loose or not should necessarily be insured. © Make sure that ther of assembling, © Work only with clean hands is any missing parts or insufficient parts after full completion 3.3.2. Cylinder liner © Replace O-ring wth new one without ‘ail and at the upper side, insert to the cylinder liner, but at the lower side, to the cylinder € ( block = © Coat the joint parts where O-ring contacts © After slipping the cylinder liner smoothly into the cylinder block, press it in being careful for O-ring not to damage. Mller completion of assembling the cylinder liner, confirm no leaks with 4 kg/cm? hydraulic test. 66 Ally Daewoo ENGINE REASSEMBLY Printed i Aug. 2001 PS-MMAUTOMEIA3.3.3. Oi . I spray nozzle Tighten the oil injection nozzle flange with hollow screws. © Assemble the oil injection nozzle with the PAY” iecpoots Torque 1.2 kgm 3.3.4. Tappet © Coat th holly clean oi! and push fe in the tappet hole of the cylinder block. 3.3.5. Crankshaft 4 © Put the wear ring into the heater to heat it up to 150 ~ 200 °C level, push it over the crankshatt by means of a jig. © Assemble the main bearing to the cylinder block and coat it with engine oil. Then assemble the bearing that has a hole to the cylinder block side and one that has no hole to the bearing cap and be careful not to change. © Assemble temporarily one bolt each at both bolt holes and by connecting the wire to the bol, lift it with crane or chain block and put down on the cylinder block carefully. pyisrrmitis Beat ENGINE REASSEMBLY © Printed i Avg. 2001 PS-MMAUIOMELA4 fe} a pyisrrmuti MAINTENANCE MANU © Coat the crankshaft journal and pin parts with engine oil, and after fitting the main bearing into the bearing cap and assemble it to the cylinder block making sure of the number in order not to change the bearing cap © Coat the bearing cap bolt and its bolt seat part with engine oil necessarily and according to the tightening order, tighten them with 30 kg.m and with rotating angle method (90° +10") and tightening order is as follows. (1) First step: Coat the bolts with engine oil. (2) Second step: Screw down 1 ~2 threads (3) Third step: Tighten with about 15 kg.m by wrench. (4) Fourth step: Tighten with about 25kg.m by torque wrench. (5) Fifth step: Tighten with 30kg.m by torque wrench. (6) Sixth step: Tighten with final rotating angle method 90° +10°. However, according to above tightening order, tighten step by step. © Inspect if the crankshaft's rotation is smooth. © Assemble the crankshatt gear on the crankshaft and coat a white paint mark on “ id easily. part in order t 3.3.6. Camshatt | © Coat the cam bush of cylinder block and ( camshaft with engine oil. ‘ceaibaiant ser © Assemble the cam bush and camsha't for them not to be damaged. ed © Assemble the crankshaft gear and the al camshaft gear making sure that the gear marks on both gears are aligned together. All Daewoo ENGINE REASSEMBLY Pinte i Au. 2001 PS-MMAO700-E1pyisrrmitis 3.3.7. Flywheel housing ay ay the the the Assemble following parts in flywheel rousing before installing flywheel housing onto the cylinder block. Assemble the air compressor crankshaft with the drive gear. Torque 36 kg.m Apply loctite to the and assemble the thrust washer. fixing bolt Torque 4 kg. Coat the oil seal (P-T.F.E.) with lubricating oil and assemble the oil seal carefully for it not to deviate or be damaged by means of special tool. (Mandrel for assembling) Attach the gasket on the surface of cylinder block where the ywheel housing is to be installed. (In order to prevent the gasket slip down, coal a grease on the cylinder block surface.) Temporarily assemble 2ea of guide bolls for installing the Fywheel housing to the k. Aiter fitting the flywheel housing holes 0 cylinder bio the guide pins and engage temporarily 2 ~ 3 threads of fixing bolls, and according to the tightening order (zigzag method) tighten them in the specified torque Torque 7.5 kgm rs XS ye wheel ic ENGINE REASSEMBLY. Printed i Avg. 2001 PS-MMAUIOMELApyisrrmuti MAINTENANCE MANU 3.3.8. Tacho sensor © Move the lock nut to hexagonal side of sensor completely. © Rotate (CW) the tacho sensor an flywheel housing, until the end of it reach on flywheel ring gear. Rotate (CCW) the tacho sensor for 270” (gap 1.0 mm) and fix lock nut. © Tolerance limit is 27°. (gap + 0.1 mm) 3.3.9. 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 hammor. © Do not allow the temperature of the ring gear to exceed 200 °C (390 “F). © By means of mandrel, assemble pilot bearing to the ‘lywheo! By means of mandrel, press in the wear ring at the backward face. © Install two guide bolls for installing the flywheel to the crankshak. ay © Alter letting the guide pin insert through the ‘flywheel holes and engaging the fixing bolls by 2~3 threads temporatily, tighten them to the specified torque 70 Pinte i Au. 2001 PS-MMAO700-E1according to lightening order. (Zigzag order) Torque 26 kg.m 3.3.10. Oil cooler © Attach a gasket on the surface in the oil cooler housing where the oil cooler is installed, © Tighten the oil er with fixing bolts. © Install the ol/ cooler assembly by lightening the fixing bolls in the zigzag order. 3.3.11. Air compressor © Assemble the piston assembly into air compressor cylinder liner before installing it to the flywheel housing. (Same method as that of piston reassembly) © Fit a gasket to the air comaressor fitting surface of the flywheel housing el Assemble the connecting rod of the air compressor liner assembly with the air compressor crankshaft and tighten it to the specified torque. Torque 3.5 kg.m al Tighten the liner fixing bolts to the specified torque, Torque 4 kgm al Tighten the air compressor head fixing bolts to the specified torque. Torque 4 kg.m pyisrrmitis ENGINE REASSEMBLY__7! Printed i Avg. 2001 PS-MMAUIOMELApyissrrnuis MAINTENANCE MANUAL 3.3.12. Starting motor © Install stud bolts at the bolt holes on the flywheel housing for installi © Insert the starter into the flywheel housing al and tighten the fixing nuts 08 he starter. Torque 8 kgm \ 3.3.13. Piston © Line up the piston assembly in the order of cylinders and fil the bearings to the = connecting rods and bearing caps. ‘ However, take care not to swap between 4 the connecting rods and bearing caps. A i © Coat the pistons and connecting rod | bearings sufficiently with clean engine oil. © By means of a special tool, insert the piston rings and adjust the angles between the ring gaps at 120° @ Push in the piston with hands or wooden bar into cylinder. (Be careful for piston and & rings not be damaged.) ® Pushing the piston down, rotate the crankshaft about 180" and fit the beering cap to the connecting rod Coat the tap parts of connecting rod bolts and their seats with engine oil, and after engaging 2-3 threads of bolts primarily rind then tighten them to the specified torque. (10 kg.m ~ 90°""") (1) First step: Coat the bolts with engine oil. (2) Second step: Engage 2~3 threads by hands. (3) Third step: Tighten to about 7kg.m with wrench. (4) Fourth step: By means of torque wrench tighten to 10 kg.m. 2 Ay Daewoo __ENGINE REASSEMBLY Pinte i Au. 2001 PS-MMAO700-E1pyisrrmitis (5) Fifth step: Finally assemble by means of rotation angle method 90°+10°. 1g to above tightening order, tighten them step by step. However, accor * Standard length of bolt and use [i from head seat ‘o bolt tip Standard length Use limit 67.5% mm 69 mm © By moving the connecting rod bearing cap by hands, make sure if there is any play in H left and right. © With the same method as above, assemble in each cylinder rotating the crankshaft. 3.3.14. Fuel injection pump Bl © Coat the O-ring with grease and insert it at the lower part of fuel injection pump. (Be careful for O-ring not to be removed) © Prior to installing the fuel pump drive gear, fit the rubber gasket. © Tighten temporarily the fuel injection pump drive gear with aligning the pointer on drive gear with injection pump pointer. Rotate the ‘lywheel so as to let No. 6 cylinder for come to top dead center (TDC), that is, the above cylinder's valves may be overlapped. © Ro! te the flywheel to the opposite direction about 30° {in order to remove 2 backlash) and then rotate in normal direction to set the injection angle. © After completing the prearation for injection pump assembling, install the ‘uel injection pump and tighten the bolts in the zigzag method After assembling the fuel injection pump, 7 ly paewoo ENGINE REASSEMBLY Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis find out if the fuel pump pointer and drive gear's pointer are aligned, and if aligned, tighten the fixing bolts that were temporarily tightened. However, if not aligned, loosen the fixing bolts and turn the fuel pump camshait so as to align the pointers and tighten the fixing Do'ts. Torque 3.1 kgm 3.3.15. Flywheel housing cover © Altach a gasket to the flywheel housing cover. © Install the flywheel housing cover and tighten the fixing bolts by the zigzag method. 3.3.16. Front oil seal holder © After placing the cil seal in the oil seal @ holder hole properly, press it in with a special t00), (Be careful fer oil seal not be damaged.) © Attach a gasket at the oil seal holder. © Align the dowel pin with the oil seal holder dowel hole and assemble them by tapping lightly the dowel pin part with an urethane hammer When in assembling, take care not to hurt the oil seal by the crankshaft. NOTI Without coating the oll scal with ofl or lubricant, assemble if In the dry state, © Tighton tho fixing bolts in the zigzag method. um 5 J : esha Oil seal holder #8 ON tine “xc vvankshaft | ENGINE REASSEMBLY. Allg DREWOO, Printed i Avg. 2001 PS-MMAUIOMELAbv! yEeTUTIs 3.3.17. Oil pump © Put the oil pump at the place to be installed on the cylinder block © Attach 2 gasket at the surface of oil pump |— where the pressure regulating valve is to installed and place the regulating valve on a gasket, 7 © Assemble the oil pump by tightening the fixing bolts. © Attach a gasket at the surface of the oil pump where the oil suction pipe is to be installed, and install the oil suction pipe by tightening the fixing bolts. © Assemble the pipe bracket on the cylinder block side with bolts. 3.3.18. Oil pan Clean thoroughly the gasket that is projecting at the junction parts of front oi! | j— seal holder and flywheel housing of cylinder block's lower face with a scraper. © In the process of gasket removal, be careful for the gasket pieces not to get into the engine inside. \ © Apply silicon to each joint and attach a gasket to the cylinder block © Install the oil pan and tighten the fixing bolts. Then take: ‘are not to squeeze out the gasket Torque 3.1 kgm © Install the guide tube and insert the oil level gauge. All Daewoo ENGINE REASSEMBLY 5 Printed i Avg. 2001 PS-MMAUIOMELA3.3.19. Fy’ Wipe off cleanly the junction part of © Ater confirming whether there is foreign © Assemble a gasket ‘iting with the fixing © Position the cylinder head assembly on the a 16 pyissrrnuis MAINTENANCE MANUAL Cylinder head © Blow the cylinder head bol holes with J compressed air to remove the foreign material cleanly. cylinder block's head gasket. material or not necessarily, if there is, remove it, pin of cylinder block cylinder block aligning with its dowel pin. (Take care not to damage the head gasket.) Coat the cylinder head bolts ith engine oil and tighten them to the specified torque according to step by step. However, prior 9 the bolts, with a long steel 6 rule, the paralloiness between the cylinder heads must be adjusted. 1) First step: Coat bolts with engine oil 2) Second step: Tighten temporarily 1 ~ 2 threads by hands. 3) Third step: Tighten to about 8 kg. m with a wrench. 4) Forth step: Tighten to 15kg.m with a torque wrench. 5) Fifth step: Rotate 90° by rotation angle method. 6) Sixth step: Finally tighten additionally rotating 90°. * Standard length of bolt and use limit: Standard length “Lon | _ Permissible Bolt No. maximum repair | | =f} -—>y——— oa length (mm) ap ul) 3,6 168 7 2,4,5 144 147 1 108 12 All Daewoo ENGINE REASSEMBLY Pinte i Au. 2001 PS-MMAO700-E1pyisrrmitis © Take care for the foreign material not to get into the cylinder head suction passages. 3.3.20. Fuel injection nozzle © Put a new seal ring in the nozzle hole of cylinder head and after inserting the nozzle assembly into it, tighten to g assemble However, coat the nozzle outer me part with the stuck preventing agents and At assemble it Oo \ \ Torque 7 kg.m 3.3.21. Rocker arm © Coat the push rod with engine oil and put | it into the push rod hole. = Al © Position the rocker arm assembly on the \ cylinder head and tighten the fixing bolts }/ to the specified tightening torque. Torque 1) Valve clearance adjust procedure After letting the #1 cylinder’s oiston come at the compression top dead center by lurning the erankshral Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge adjust the valve clearances. of specified value between a rocker arm and @ 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 Dvi5 DvisT 2 . bvistl 0.25 mm 0.35 mm DvisTIS All Daewoo ENGINE REASSEMBLY 7 Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 2) Adjusting sequence of valve clearance (Type 1) 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 *[Z2)_" 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 cooling water pump was installed. Fly wheel Cylinder No. Intake valve Exhaust valve S : at the #6 cylinder overlap Exhaust valve Intake valve HS catthe #1 eytinder overlap 3) Adjusting sequence of valve clearance (Type 2) Type 1 is the conventional and simple method, but if you have some problem to adjust your engine, please try type 2 sequence. This is a precision method, but it takes more time. #, 8 Cylinder engine (DV 15/DVIST/TITIS) Valve overlapping on cylinder (Intake & Exhaust valve) 1} s 7/2 6/3 | 4 | 8 Adjusting valves on cylinder (intake & Exhaust valve) eye it fe ts]? |? All Daewoo ENGINE REASSEMBLY Printed i Avg. 2001 PS-MMAUIOMELA3.3.22. Cylinder head cover 3.3.23. Vibration damper . ay 3.3.24. Oil filter Attach a new gasket on the surface of cylinder head where the caver is to be pyisrrmitis installed, Assemble the cylinder head cover by tightening the fixing bots. Insert the oil filler cap. After inserting the oil bleeder pipe, assemble by tightening clamp. Assemble the vibration damper tightening firstly by the crankshaft pulley and the fixing bolts. Insert the crankshaft pulley assembly to the crankshaft and tighten the fixing bolts in the method of zigzag to the specified torque. Torque 21 kgm Insert greased O-rings into the oil port of the cil filter head.(Prevent the O-ring from slipping out.) 7 Install the filter head on the cylinder block and tighten bolts in a diagonal sequence. Install the oil filter element in the oil filter [ assembly. Install new O-tings(packings) in the oil) filter housing. (Filter element, Cu-washer, | and packing are supplied together as A/S | ( parts) | ly DAEWOO, ENGINE REASSEMBLY. Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis © Assemble the oil filter housing with the filter head (Be careful not to damage the O-ring.) © Place Cu-washer over filter housing fixing bolt and tighten the bolt 3.3.25. Cooling water pump © Attach a gasket at the cooling water pump. (at cylinder block side) © Assemble the cooling water pump by tightening the fixing bolts. (zigzag method) © Insert the thermostat of cooling water purnp. © Insert the O-ring to the thermostat and assemble the cooling water pipes by tightening the fixing bolts. 3.3.26. Intake manifold @ Attach 2 new gasket te the cylinder head side. ; © Assemble the intake manifold ty| ° YO ~P@ gol Lightening the fixing bolts | © Attach 2 gasket to the inlet flange and assemble by tightening the fixing bolts. ® Assemble both sides by the above method. ® Altach a gasket to the equalizing pipe thal connecls the intake manifolds of both sides and assemble both manifolds by tightening the fixing bolts. 80 All Daewoo ENGINE REASSEMBLY Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3.3.27. Exhaust manifold © Connect the exhaust manifold that is [7S consists of two sets after inserting the exhaust gas ring between them. © Attach a new gasket to the exhaust | | L 3] manifold, / © Attach a gasket to the exhaust elbow that oe ay : ok Is connected to the exhaust manifold, and assemble the elbow by tighten the nuts for connection. © Assemble both sides in the same method as above. 3.3.28, Turbocharger © Attach a gasket to the exhaust elbow and assemble the turbocharger with fixing bolts. © Install the connecting pipes and an O-ring | between the inlet flange and turbocharger Then, it is assembled with the O-ring that was coated with engine oil © Attach 2 gasket on the oil supply pipe and assemble the pipe with the fixing bolts. © Attack a gasket on the oil discharge pipe and assemble the pipe by tightening the bolts. © Atthe sa me method as above, both sides are assembled. 3.3.29. Intake stake and air hearter © Assemble the air hearter according to the From air cleaner Intake stake direction of an arrow impressed on the air % heater and assemble the pipe by 7 hams tightening the bolts Ait heater Intake manifold ENGINE REASSEMBLY__*! Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3.3.30. Fuel jection pipe © Connect the fuel injection pipes between the fuel injection pump and the nozzle holder ang tighten clamping nuts © Fix the fuel return pipe by tightening hollow screw. 3.3.31. Fuel filter © Assemble the fuel filter to the intake stake by tightening bolts, 5 Fuel inlet i=] © Assemble the fuel feed hose according ssed Fuel © — to the direction of an arrow impr outlet Fuel filter on the fuel filler head so that fuel can head be fed in the sequence of FUEL FEED reat PUMP — FUEL FILTER - FUEL cartridge INJECTION PUMP. 3.3.32. Power steering oil pump © Connect the power steering oil pump to | power steering pump the air compressor and push them (Gor leh) inward. hosing, © Be caroful not to damage power steering 9 r pump O-ring, Ensure that the driving dog is cross-assembled with the air compressor coupling. 9 Powersigering pump Driving dog (O5tit) “ © Tighten fixing bolts 3.3.33. Hoses and pipes © Connect ‘uel strainer to fuel feed pump and assemble the fuel hoses therewith. © Connect fuel delivery and return hoses © Connect lubrication oll delivery pipes and hoses to air compressor. All Daewoo ENGINE REASSEMBLY Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3.3.34. Alternator f° Assemble the altemator mounting bracket with fixing bolt to the lower side of cylinder block Assemble the alternator support(V-belt tension adjusting bolt) with fixing bolt to oil pan Assemble the alternator with bracket and support. Install V-belt over water pump pulley, crankshaft and alternator pulley. Adjust the V-belt tension by adjusting bolt) (The beit deflection should be within the range 10~15mm} 3.3.35. Cooing fan Assemble cooling fan to fan coupling with fixing botts, Install the cooling an assembly to the crankshaft pulley fitting surface with fixing bolts and tighten to the specified torque. Alp DOEWOO, ENGINE REASSEMBLY _** Printed i Avg. 2001 PS-MMAUIOMELApyissrrnuis MAINTENANCE MANUAL 3.4. Starting and Trial Operation 3. Operation of a new engine (Breaking-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 Therelore the following things must be obeyed by all means. Up to the first 1,000km(50 hours) A 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% ol its maximum speed. Maintenance and inspection must be accomplished thoroughly. a 3.4.2. Check points for break-in During the breakin (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 oil level gauge. NOTE: It you have a problem getting a good oil level reading on oil 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 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 malt jon. 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 All Daewoo ENGINE REASSEMBLY Printed i Au 2001 PS-MMAO?00-E1pyisrrmuti MAINTENANCE MANU oil. Both of these conditions reflect normal engine operation. ©) Watch the engine water temperature gauge and be sure there is proper water circulation. The water temperature gauge needle will ‘luctuate 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 cartridge. Fill oil pan with recommended engine oil. Refer to following table. © Engine Oil capacity Engine oll capacity in Oil pan Engine Vehicle Max. Min. Total Model (ity it) i) vis Bus 24 20 27 DvisT Truck 21 19 24 vist! Industrial 18 24 24 Bus 24 20 27 PvisTIS | Truck 21 19 24 * If long oil change intervals are to be used, ACEA-E3 oil must be used. ly DAEWOO, ENGINE REASSEMBLY__** Pinte i Au. 2001 PS-MMAO700-E1pyisrrmitis 4. MAINTENANCE OF MAJOR COMPONENTS .1. Cooling System 1, General information This engine is water-cooling type. Heat from the combustion chamber and engine o heat are cooled down by coolant and radiated to the outside, resulting in the normal operation of the engine Looking into the cooling system, the water pumped up by the waler pump circulates around the oil cooler through the water pipe to absorb the oil heat, and then flows through the water jacket of the cylinder block and water passage of the cylinder head to absorb the heat of the combustion chamber. The water absorbing the oil heat and combustion chamber heat goes on to the thermostat through the water pipe, and circulates to the water pump if, water temperature is lower than the valve opening temperature on the thermostat, while circulating to the radiator at water temperature higher than the valve opening temperature. At the radiator, the heat absorbed in the coolant is radiated to coo! down and the coolant recirculates to the water pump. > "pe 4 4 ve= | |< > 4 y Wr a vs ay a " veo) vey voy Wea, es Yoo = yvoyy a y © Specification Item Specification 7 Water puma Centrifugal type Type Delivery About 350 liter/min Pumping speed 2,100 rpm Pumping back pressure 760 mmHg 2. Thermosiat Operating temperature 83 ~ 95°C 3. Cooling fan and belt Fan ciameter — Number of blades 700mm —9 Fan belt tension 15mm / deilection by thumb 86 iy BaEWoo MAINTENANCE OF MAJOR COMPONENTS Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 4.1.2. Thermostat © General descrip data ns and m: The thermostat maintains a constant “7 Yesraditor | temperature of coolant (90 ~ 95 °C) and improves thermal efficiency of the engine by preventing heat loss Namely, when the temperature of roa vane coolant is low, the thermostat valve is closed to make the coolant bypass to directly enter the water pump; when the coolant temperature rises to open wide the thermostat valve, the bypass circuit is closed and the water passage to the radiator is opened so that the coolant is forced to flow into the radiator. ‘Specifications be Inmoderate mates —_| i, yopical climates [Type] Wagar ype | Waxcpallet ype Open at. 79°C 83°C eC Open wide at 94°C 95°C 85°C Valve lift 8 mm or more 8 mm or more NOTE: There are 2 kinds of thermostats according to surrounding and operating conditions. One is named by 71 °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 cf Thermometer water, then heat the water slowly and C check temperature with 2 thermometer. Hf the valve lift is 0.1 mm (starting to open} at temperature of 83 °C and 8 Wood plate mm or more (opening wide) at i temperature of 95 °C, the thermostat is normal MAINTENANCE OF MAJOR COMPONENTS 87 Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 88 © Replacing thermostat and precautions for handling (+) 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 joid a to the large heat capacity of the wax pellet type thermostat. Therefore, to sharp tise 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 engine starting (2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently from the entire cooling system (3) Replacing thermostat It the thermostat is detected defective, retrace with a new one. MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 4.1.3. Diagnostics and troublesho: ‘Complaints Possible causes Corrections 7. Engine overheating | © Lack of coolant Radialor cap pressure valve spring weakened Fan belt oosened or broker Fan bell fouled with oll ‘Thermostat inoperative Water pump defective Restrictions in water passages due to deposil of scales Injection uiming incorrect Restriction in radiator core Gases leaking into water jacket due to broken cylinder head Replenish coolant Replace cap Adjust or replace fan bolt Replace fan belt Replace thermostat Repair or replace Clean radiator and water passages Adjust inject correctly Clean exterior of radiator timing Replace cylinder head gasket gasket 2. Engine overcoaing Thermostal noperalive Replace thermostal © Ambient temperature | @ Install radiator curtain oo low 3. Lack of coolant © Radiator leaky Correct or replace © Radiator hoses loosely | @ Retighten clamps or replace connected or damaged. hoses © Radiator cap valve|@ Replace cap spring weakened © Water pump leaky Reparr or replace © Hester hoses loosely | @ Tighten or replace hoses connected or broken © Cylinder head gasket|® Replace cylinder nead leaky gasket © Cylinder head or] @ Replace cylinder head blo: cylinder block cracked 4. Gooling system © Water pump bearing | ® Replace bearing noisy defective © Fan loosely fitled or| @ Retighten or replace far bent © Fan out of balance Replace tan © Fan belt defective Replace tan belt 89 iy BaEWoo MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 4.2. Lubricating System 4.2.1, General descriptions and main data General descriptions All the engine cil pumped up from the oil pan by the gear type oil pump is filtrated through the oil cooler and oil filter, and this fitrated oil is forced through the main o 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 tem ‘Specifications Item ‘Specifications Lubricating system Forced presse | Oi titer type Full flow Oil pursp type Gear type _ | Bypass for filter elernent Relief valve opening pressure 85-10 kglem? | Valve opening pressre | 2.1403 kgfem? Adjusting valve for spray nozzle Bypass for entire oil filter Opening pressure 1.6~1.9ksiem*| Valve opening pressure | 4.5+0.2 kgfem? © Diagram of lubricating system - ‘ 1 5 8 ’ ' ' tem - 4 oo ' 1 ot “1 1 ' ' Porro ' ' rorom 90 lp paewoo MAINTENANCE OF MAJOR COMPONENTS Printed i Aug. 2001 PS-MMAUTOMEIApyissrrnuis MAINTENANCE MANUAL. 4.2.2. Oilfilter ‘The oil filter mounted in this engine is of element type, so it is necessary to replace with anew one at the specified intervals. Oil filter head il filter element 4.2.3. Diagnostics and troubleshooting ‘Complaints Possible causes Corrections: 1. Oilconsumption | ® Poor oll © Use suggested oil excessive © Oil seal or packing|® Replace leaky © Fistons or piston rings |@ Replace oistons andlor worn pston rings. © Cylinder finer worn © Replace cylinder Iner © Fistonrings sticking | ® Replace istons andlor pston rings © Valve guide oil seals or| ® Replace valve guides. or valve stem worn 2. Gil pressure too low | ® Poor oil © Use suggested 0! © Relief valve sticking | @ Replace © Restrictions in oll pump | @ Clean strainer strainer Oilpump gear worn | @ Replace Oil pump feed pive|@ Replace cracked © Oil pump defective © Correct or replace © Oil pressure gauge | ® Correct or replace detective © Various bearings worn_| @ Replace 3. Gil deteriorates © Resticlion in ailfiter | @ Replace filler elament quickly © Gases leaking © Replace piston rings and cylinder liner 1 Qj BaEWoo MAINTENANCE OF MAJOR COMPONENTS Pinte i Au. 2001 PS-MMAO700-E1pyisrrmitis 4,3, Specification and Construction 4.3.1, Main data and specification Model DVvisT DvisTI DVISTIS: Air pressure at compressor Allied Signal TO4E | Allied Signal TOAE | Alied Signal TOaE a fi sucton of maximum a 4 am? rox. 20 mifmin | Approx.29 m*imin rox 33 mPtmin butput | tine Approx 20 rh Approx.28 Approx 3a Speed oF turbine | po orox. rom | Approx. tpm| Aporox. 115.000 -pr epee ‘Aporox. 90.000 rpm | Approx. 108,000 rpn | Aporox. 115.000 Maximum allowable speed 712,000 pn 120.258 rpm 10.4856 rpm Maximum allowable temperature of exhaust gas 750°C 750°C 750°C at turbine inlet Tusrieating system External oi'supply | Exemalot supply | Exlemalai supply ‘We ght 12 kg 14kg 14g 4.3.2, Operating principle oe ey fa eatal =a] w1) (pe ent oo MCs U exhaust ga: an ) Compressed Engne t bd a Piitecca 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 ig BAEWOO MAINTENANCE OF MAJOR COMPONENTS Printed i Aug. 2001 PS-MMAUTOMEIA4.3.3. Construction Make sure that servici pyisrrmitis 9 should be performed at the professional maintenance shop as authorized by Allied signal Company. eFma0011 4 | Turbine shat 15 | Seal plate 2 | Thrust bush 16 | Thrust bearing 3. | Oil shut off 17 | Journal bearing 4 | Fixing nut 18 | Screw 5 | Seal ring 19 | Screw 6 | Seal ring 21 | Heat dissipator 7 | Seal ring 22 | Compressor housing 8 | Compressor wing whee! | 23 | Clamp 9 | Turbine housing 24 | Bolt 10 | Bolt 27 | Liquid gasket 11 | Clamp 30 | Loctite 13. | Bearing housing 31 | Liquid ant’-purn agents 14_ | Retainer ring ip BAEWoO MAINTENANCE OF MAJOR COMPONENTS ** Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 4.3.4, General information The engine output depends upon the supplied fuel quantity and the engine efficiency. In order to transform into the effective work of engine by burning the supplied fuel fully the sufficient air to burn the fuel should be supplied to the cylinder. Therefore, the er }@ output is essentially determined by the size of the cylinder, and for if the air is supplied to the given volume of cylinder with the air being compressed, the air quantity in the cylinder will Increase as much to result in that it may burn more fuel. the output will also be able to increase, Supplying the air by compressing like *his into the engine cylinder is called as super charging, and super charg 1g by means of exhaust gas energy that discharges to the atmosphere is called as the turbo charging 433.5. Funetion 1) Turbine The exhaust gas th: 8 discharged from combustion chamber passes through turbine housing conveying an energy to turbine wings to give the rotating power, This is called as the turbine and in order not to influence a bad effect at bearing part, there are the seal ring and heat dissipator. 2) Compressor It is connected to the same shaft with the turbine to make 2 revolving « sembly, and receive the revolving force of turbine, and sends air to the suction manifold by suctioning and compressing it. This is called as the compressor. 3) Bearing © Thrust bearing force ‘s applied to the turbine wheel and an arrangement is made for the shafl not to shill © Journal bearing (‘loating bearing) is adopted and it forms the double oil films at the inner and outer surfaces in comparison to the general stationary type so that the bearing may be able to rotate independently and consequently the double layers on the of films act as the damper to make the slipping spe faring surface less than the rotating speed of shaft so that the dynamic stability may be obtained. 4) Sealing at compressor shaft In order for the compressed intake air and lubricating oi nol to leak, a seal plate and a seal ring are made to the double structures. 94 ly BaEWoo MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELA4.3.6. How to handle the en, 1) Precautions tor operation of the engine Operation following items must be observed at the startin pyisrrmitis operation and stop of engine. Operation | Caution Reason Atstarting | 7) Inspect oil quantity 2) After confirming that oil | 2) If engine is started quickly, of pressure rises dy starting] course beginning with every engine with starter (until the pointer of oil pressure gauge moves or pressure indicating lamp operates), the starting must be done. In case that oil, oil filter and lubricating system's part are replaced or engine was stalled for long time (more than a week), and in case of operation under cold weather, | loosen the oil pipe connecting parts of turbocharger inlet, and operate the starting motor until oil comes out the connecting parts. Care must be paid that alter the confirming above, retighten the pipe connecting parts without fail. and proceed with the normal staring 3) 3) parts of engine, for it revolves without cil that is to reach to the turbocharger, the bearing's abnormal wear or stuck may be caused. In case that engine stalled for long time and of cold weather, the fluidity of oil may be worse. Immediately | 1) After starting Perform idling operation for about 5 min, immediately atter engine starting must no 2) Various inspections insure that there are leakage of oil, gas and air. ) 2) Sudden load at time soon after engine starting and at the state when turbocharger did not yet reach to smooth revolution, if abrupt load is applied to engine, some parts were oil cid still not reach may cause a burn to be stuck IF there are the leakage of oi gas, air, particularly oil, for the oil pressure lowers, it causes a burn of bearing to be stuck MAINTENANCE OF MAJOR COMPONENTS > Printed i Avg. 2001 PS-MMAUIOMELApyissrrnuis MAINTENANCE MANUAL. Operation Caution Reason During Following items must be confirmed. operation | 1 ) Oil pressure at 1) If the pressure is too low, ing: 8 ~ 300 KPa (09 ~ 3.0 ba) abnormal wear or stuck may full wad 301~630kPAG~6Stee) | be caused. Or if Loo high, the oil leak may be generated 2) When abnormal noises and 2) If the engine operation were vibration are generated, slow] continued with abnormal down the revolution and must} _ noises and vibration, it causes stop it to investigate the| the engine trouble that can not causes. be repaired or some other troubles. At stop 1) At stopping the engine, | 1) Atter heavy load operation, iF perform the idling operation for| the engine were stopped 5min. and then stop i. suddenly, the heat would be conducted to bearing parts from red hol turbine wings that would result in buming the oil to cause the stuck bearing metal and revolving shatt 4.3.7. Routine inspection and maintenance Since the slate of turbocharger depends largely on the slate of engine maintenance, to perform the speci up keep thoroughly is needed. 1) Air intake system System in the intake air system, care must be taken to the air cleaner. In case of oil passing type air cleaner, ifthe oil level is lower than the specified value, the cleaning efficiency get worse, if higher, the sucked cil pollutes a case. Particularly, for if the rotor were polluted, the balance adjusted precisely would be deviated to cause a vibration that may cause the stuck or abnormal wear by loading large force to the bearing, the perfect air cleaner must always be used. In case of dry type filter, according to the indication of a dust indicator, cleaning must be done to make the intake air resistance as small as possible 2) Exhaust system In exhaust system, a care must be taken to the gas leak and the stuck prevention If exhaust gas leaks from the exhaust pipe and turbocharger ete., for the super charging effect will be lowered, the installed states of various parts must be paid with careful attention. Since the parts that reach to igh temperature during operation such as the turbine room use the anti- heat nuts, a care must be paid not to mix with the general 96 Ay Daewoo MAINTENANCE OF MAJOR COMPONENTS Pinte i Au. 2001 PS-MMAO700-E1pyissrrnuis MAINTENANCE MANUAL. nuts and at the same time, bol: stuck preventing paint should be coated on the nut for the designated places 3) Fuel system If the full load stopper that restricts the maximum fuel injection quantity of fuel injection is the maximum speed are adjusted pump and the maximum speed stopper that restr without the pump tester, the turbocharger may overrun to be damaged. Also, if the atomizing state of fuel injection nozzle becomes worse or the injection timing gets wrong, for the raised temperature of exhaust gas will influence badly to the turbocharger, the nozzle testing must be done. 4) Lubricating system In the lubricating system, a care must be paid to the oil quality and oil element roplacement cycle. For the oil deterioration of turbocharger equipped engine, needless the turbocharger too, the to speak of engine assembly itself, influences badly « specified engine oil (15W40, CF class) should used. 4.3. 8. Periodical servicing The turbocharger assembly must be inspected periodically 1) Rotating condition of the rotor and checking tips Inspection on the revolving state of rotor is performed according to abnormal noises. In case of using an acoustic bar, touch the turbocharger housing with a tip of bar and raise the engine revolution slowly, Then, in case that high sound is heard by every 2 ~ 3.sec. continuously, for there should be the possibilily 10 be abnormal metal and rotor, replace or repair the turbocharger. 2) Measuring rotor clearance Disassemble the turbocharger from the engine and should inspect the end plays in axial and circumference direction. In case of disassembling the turbocharger, the oil inlot and outlet should necessarily be sealed with a tape, ig BAEWoo MAINTENANCE OF MAJOR COMPONENTS *7 Pinte i Au. 2001 PS-MMAO700-E1pyisrrmitis a) Rotor axial direction end play © Wear limit : 0.20mm L. Woee ina 0.20mm b) Rotor's circumference direction end play. © Wear limit : 0.65mm iat gauge Magnetic c) In case that the end plays to axial and circumference directions, replace or repair the turbocharger. 3) Overhaul and cleaning points Be sure to dismantle the turbocharger from the engine before cleaning. Also, make sure to seal the oil inlet and outlet with tape or similar. 4) Precautions for turbocharger reassembly When in assembling the turbocharger or the handling atter assembling should work observing the [ollowing precautions necessarily. Particularly, precise care should be taken for foreign material not to get into the turbocharger. a) Lubricating system © Prior to assembling il inlo the engine, fill new cil into ol! Inlet and turning turbine shaft with hand, lubricate journal and thrust bearing, © Clean the pipe and oil cullet pipe between engine and cil inlet, and confirm if there is any oipe damage or foreign material. 8 ig BAEWOO MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis © In order for oil not to leak from various connections, assemble securely. b) Air intake system © Confirm if there is any foreign material inside the air intake system © Assemble securely the air intake duct and air cleaner so that the connections from them may not leak an air. c) Exhaust system © Confirm if there is any foreign material in the exhaust system © Bolts and nuts must be made of anti-heat steel and in assembling, care should be taken not use the general nuts and coat the bolts and nuts with the anti-stuck agents at the same time, © Assemble securely for gas not to leak from various connecting parts of exhaust pipes 4.3.9. Trouble cause diagnosis and remedy Condition Remedies if. Exhaust gas rT Replace or clean excessive 2) Ar Inlet por clogged Inspect or repair 3) Arr leaks rom airintaxe syste. | Inspect or repair 4) Turbocharger impossible to rotate | Overhaul and repair or replace due to stuck 5) Turbine wing's contact (Overhaul and vepair or replace 6) Piping de‘ermation or clogging ot | Inspect and repair exhaust system Whiesmoke 1} Or caks. Info turbine and | Gvorhauand ropa or oplacs ow 2) Seal rng abnormal wear ar | Overhaul and repairor replace Suipaowsred Ty Gas bak Wom varbus pars OT Hapee ara oper 2)Ar carers slomeris dogged —|Replace ar lean 3) Turbochargers poluien ar] Overhaul and reparorTepace damage | 4) Air leaks from discharge part of | Inspect ard repair compressor side 4. Abnormal noises | 1) Revo\virg parts’ contact | Overhaul and repair or replace or vibrations 2) Revolving mpalance of rotor ‘Overhaul and repair or replace 9) Stuck. | Overhaul and repair or replace 4) Var ous connections loose Inspect ard repair ig BAEWoO MAINTENANCE OF MAJOR COMPONENTS °° Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 4.4, Fuel Injection Pump 4.4.1. 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. 6 ae FUEL, FUEL RETURI RETURN 7. Fueltank 6. Air bleeding plug 2. Fuel strainer 7. Fuel filter 3. Hand priming pump 8. Fuel injection nozzle 4. Fuel injection pump 9. Over low valve 5. Fuel supply line 10. Fuel return pipe 4.4.2. Injection pump 100 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 Comaany. For adjustment of fuel injection volume, refer to the ‘Specifications of fuel injection pump’ described on the following pages. MAINTENANCE OF MAJOR COMPONENTS Printed i Aug. 2001 PS-MMAUTOMEIA1) DV15(RQ) engine (1) Injection pump Model Governor Plunger & barrel Delivery valve Overflow valve Feed pump - Prestroke Rotating direction (2) Nozzle holder assembly : pyisrrmitis 65.11102-7380 (0 401 848 829 BOSCH) PE8P110A3201 $3865 (0 411 818 728) FQ 250/1150PA1250 (0 421 801 796) 65.11125-0016 (2 418 455 071) 65.11119-6016 (2 478 552 075) 65.12505-5004 (1 417 413 047) 65.12101-7025 (0 440 008 101) 4.0 10.05mm at 10.5 +1.5mm Counter clockwise (viewed from driving gear) '5.10101-7074 (0 432 231 666) (3) Nozzle £65.10102-0118 (0 433 271 487) (4) Injection pipe 10302-6110A , 65.10301-6111A (5) Injection order: :1-5-7-2-6-3-4-8 (6) Injection timing Nozzle & Holder Ass’y 1688901 105 | Opening pressure : 208.5 11.5 bar (A) Test condition For injection pump BTDC 10° T Injection pipe(IDxOD-L) 493.0 x 68.0 600 mm Test oil ISO4LL3 Temperature :40.15°C Nozzle & holder Ass'y | 65.10101-7074 20048 helen (B) Engine standard parts. | Nozzle 65.10102-0118 Multi hole (4 x 60.34) ) 85 10302-61104, Injection pipe(DxOD-1)| Po iQsor erst a 2 x 6 = 650mm Rack diagrasn and setting valve at each point van Thksiion Q'y on RIG Check] Rack | Pam (om"/ 1,000 st) Pressure poten | Preven! sPe64 Yr: conn (B) Eine (bar) fori pump | standard par ‘ vi | ins | 14150] 126 “ v2 | us | 60 | i273 vs 500 LQ] 38. 250 2533 ” AR 05 | 1.350 - - - MAINTENANCE OF MAJOR COMPONENTS 20! Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 2) DV1ST(RQ : 365PS ECVBAVBIC) engine (1) Injection pump 65.11101-7322 (0 402 648 974 BOSCH) (use 2nd stage LDA spring at 65.11102-7358) Model : PEBP120A3201 $7915 (0 412 628 929) Governor FQ 300/1150PA1374 (0 421 801 833) Plunger & barrel: 65.11125-0075 (2 418 455 501) Delivery valve :65.11108-6015 (2 418 552 149) Overflow valve 65.12505-5004 (1 417 413 047) Feed pumo 65.12101-7016 (0 440 008 099) Coupling 12416 434 074 (2) Nozzle holder assembly Rotating direction: Counter clockwise (viewed from driving gear) 65.10101-7084A (9135 — 278 LUCAS) (B) Engine standard parts (3) Nozzle 2 65.10102-0008 (9135 ~ 261 LUCAS) (4) Injection pipe 10301-6060A , 65.10301-6061A (5) Injection order: :1-5-7-2-6-3-4-8 (6) Injection timing BTDC 7° wh [Nozzle & Holder Assy [1688901 1 ing press yestion pomp | Test ei Is04113 Temperature dO 15°C Nozzle M holder Ay | OS I0101-70RIA 20048 kaler Nozzle 65:10102-0008 [Muli hole (5 x 0.313) 65.10301-6060 Injection pipe(DxOD-1) | be Osyr coe 12 x 65.35 - 650mm Rack diagram and setting valve at each point Tiscion Q on RIG Coe] Rack | ame ‘ome Pressure point | Postion] seed ae condion (B)Engins | (mbar) forinj pum | standard pare vi [1425 [1.150 [20541 1500 ve [435 [50 [239 1500 vs [83 | so | 121 : o ig [ss [wo | ies 0 Ax | 05 [1.350 = = o TO UDA adjust datas (ist stage LDA sping O46, K=TE Nin, L=2T Tan) (2a stage LDA spring : 2424 618 062, k-10 Nina, L=19.1za Adjusting pai Rack position (pm) Pump speed (pn) Pressure (ba) PO 1.65 40.1 500 wo PI 14.25.1008 500 7.500 P2 83.102 50 a PS 3020.05 300 330 Pa 300 150 Ps 500 725 P6 13.15 102 300 300 102 MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 7) Performan uurve of governor 14.25 vs 83 PI 14.25 13s P6 12.05 (Ps 1.65 —— 7 «Po 11.08 Pa 90 /P3 83 2 250 450, 600.725 900 1500 DA Pressure (mbar) iy BaEwoo MAINTENANCE OF MAJOR COMPONENTS (0° Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 3) DV1ST(RQ : 370PS ECVCA/B) engine (1) Injection pump 65.11101-7323 (0 402 648 974 BOSCH) (use 2nd stage LDA spring at 65.11102-7358) = Model : PEBP120A3201 $7915 (0 412 628 929) - Governor FQ 300/1150PA1374 (0 421 801 833) - Plunger & barrel: 65.11125-0075 (2 418 455 501) - Delivery valve :65.11108-6015 (2 418 552 149) - Overllow valve 65.12505-5004 (1 417 413 047) - Feed oump 65.12101-7016 (0 440 008 099) = Coupling 12416 434 074 - Rotating direction: Counter clockwise (viewed from driving gear) (2) Nozzle holder assembly : 65.10101-7084A (9135 — 278 LUCAS) (3) Nozzle 1 65.10102-0008 (9135 — 261 LUCAS) (4) Injection pipe 65.10301-6060A , 65.10301-6061A (5) Injection order: :1-5-7-2-6-3-4-8 (6) Injection timing BTDC 7° wk [Nozzle & Holder Ass'y | _1 6889011 yeston pump [Test oil 1s04113 Temperature 40.15°C Nowie W holder Ay | O5:10101-70848 20048 Kaler Nozzle 65.10102-0008 | Multi nole (5 x 0.313) (B) Engine standard parts 65.10301-60604 Injection pipeIDxOD-1) | Oe Osyr coe 296.35 - 650mm Rack diagram and setting valve at each point Rack |] Pump eetom 100 | Pressure poston] sel FaTercondson (B) nine] “(mbar vip sama par Vi pas [is 1500 va [rias [650 : 7500 vs 8.5 [500 : 0 To | 38 | 300 : 0 as [os [1.00 0 (CUDA atu daa Ist sge UDA sing 2404 ON {and singe LDA sring 2424 618 08? ‘Ajualng pak Rack positon pm) Purp speed (pm) | Pasune aba) i Patol 500 cao PL 1435 4005 500 73500 P2 E1542 500 v Ps 310-1008 500 330 Ba TR102 500 4a 5 12.9 4005 500 75 Pe 139402 500 300 104 ly PAEWOO MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 7) Performance curve of governor yags_ | \ ‘ vs \to = 58 os 7 Le PL las 139 Ps 129 ps 126 Po 18 4 on bs sas m 250 500 60d 725 900 1500 LDA Pressure (mbar) LA Pressure mbar) 05 ay Baewoo MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 4) DVIST(RQ : 370PS ECVCCIFIG/H) engine (1) Injection pump 65.11101-7358 (0 402 648 974 BOSCH) Model : PEBP120A320L87915 (0 412 628 929) Governor RQ 300/1150PA1374 (0 421 801 833) Plunger & barrel: 65.1125-0075 (2 418 455 501) Delivery valve 165,11108-6015 (2 418 552 149) Overllow valve 65.12505-5004 (7 417 413 047) Feed puma 65.12101-7016 (0 440 008 099) Coupling 22.416 434074 Rotating dir tion: Counter clockwise (viewed from driving ger) (2) Nozzle holder assembly : 65.10101-7068 (0 432 231 669 BOSCH) (3) Nozzle 10.433 271 627 (4) Injection pipe 2 65.10301-6060A , 65.10301-8081A (5) Injection order: 5-7-2-6-3-4-8 (6) Injection timing BTDC 7” MI Novzle & Helder Ass'y_| 1 588901 105 [Opening pressure : 2085115 har (A) Testconttion | [injection pipeIDxOD-1)| 1 689750089] 9.0. 48.0 600 mim jection pume [Test oil ISO ‘Temperature :40 45°C Nozzle Zholder Assy | —65.10101-7068 20048 Klemm (8) Raine standard pans L222 0.493271 627_[ Mali ole 80303) Injection pipeADxOD-L)| PO OOAIOOAT ha x 5.35 - 650mm Rack diagrasm and setting valve al each point Trjecnog OW on RIG cect] R2ek | Pome com 100) Presure riot | Peton! Peel Tr conditn (1) Fain (mbar) crim, pump | standscd pars vi [as | nis | 22051 - 7500 2 | 143s | 60 | 23833 1.500 vs | 90 17 o TQ [60 | 300 BS 0 as | os_| 1350 : : © (C) LDA adjust data Adjusting point Rack position (rpm) Pump speed (cpm) Pressure (mbar) Pr 14.35 40.05 300 7.500 Pz 90102 500 © PS 700-4008 500 20 PA 12.3402 500 650 MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 7) Performance curve of governor v2 vi 1435 |————— Ns | : Vs 500650 14.35 — EW bs 4 3 100 z p23 a0 oO 250 650 1500 LDA Pressure (mbar) _ iy BaEwoo MAINTENANCE OF MAJOR COMPONENTS ‘07 — Prine Ang 2001 PS-MMAUTOOELApyisrrmitis 4) DV15T(RQV-300PS) industrial engine (1) Injection pump - Model - Governor - Plunger & barrel - Delivery valve - Overtlow valve - Feed sumo = Coupling - Rotating direction 65.11102-7386 (0 401 848 830 BOSCH) : PE8P120A3201 $3865 (0 411 818 728) RQV 250/1000PA1286 (0 421 814 175) 165,11125-0016 (2 418 455 071) 2 65.11108-6016 (2 418 552 075) 65.12505-5004 (1 417 413 047) 65.12101-7025 (0 440 008 101) 12 416 434 068 : Counter clockwise (viewed from driving gear) (2) Nozzle holder assembly : 65.10101-7084A (9135 — 278 LUCAS) (3) Nozzle (4) Injection pipe (5) Injection order: (6) Injection timing 1 65.10102-0008 (9135 — 261 LUCAS) 6110A , 65.10302-6111A :1-5-7-2-6-3-4-8 BTDC 9° 40302 (A) Test condition For injection pump (BRP ine standard parts Nozzle & Holder Ass’y T i 1688901 105 | Opening pressure : 208.5 +1.5 bar Injection pipe(IDxOD-L) 493.0 x 68.0 600 mm Test oil ISO4LL3 Temperature :40.15°C Nozzle & holder Ass'y | 65.10101-7084. 20048 kyver Nozzle 65.10102.0008 Multi hole (5 x 40.313) ) 85 10801-6110, 65.10301-61 1A X06 650mm Injection pipe(IDxOD-L) 108 Rack diagrasn and setting valve at each point van Thksiion Q'y on RIG Check] Rack | Pam (om"/ 1,000 st) Pressure poten | Preven! sPe64 Yr: conn (B) Eine (bar) fori pump | standard par vi} 1s | 1000) 42 v2 | 3 [60 | wases wl. | : - - tq | 82 | 20 20:3 - MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 4) DVIST(RQV ECVXA) engine (1) Injection pump 65.11102-7364 (0 402 648 796 BOSCH) - Medel : PEBP120A320L87875 (0 412 628 881) = Governor RAV 250/1150PA1240 (0 421 814 160) - Plunger & barrel: 65.1125-0075 (2 418 455 501) - Delivery valve 165,11108-6075 (2 418 552 149) - Overtlow valve 65.12505-5004 (7 417 413 047) - Feed pump 65.12101-7016 (0 440 008 099) - Coupling 22.416 434074 - Rotating direction: Counter clockwise (viewed from driving gear) (2) Nozzle holder assembly : 65.10101-7084A (9135 — 278 LUCAS) (3) Nozzle 5.10102-0008 (9135 ~ 261 LUCAS) (4) Injection pipe 1 65.10301-8060A , 65.10301-8061A (5) Injection order: :1-5-7-2-6-3-4-8 (6) Injection timing BTDC 7° Nozele & Holder Ass'y | 1588901 105. Opening pressure: 208.5 1. bar A) Test condition " ‘ ‘ Injection pipe(DxOD-L.) 3.0.x $8.0 600 mm forinjection pump | ction pied | aor Test oil | tsoans Temperature 40 15°C Nozele & holder Ass’y | 65.10101-7084A. 20018 kg/ern (B) Engine standard parts. | Nozzle 65.10102.0008 Multi hole (5 x 0.313) 7 65.10301-6060A 65,10301-6061A. Injection pipe(DxOD-1.) P24 §6.39 - 650e Rack diagram and setting valve at each point chek] Rack] Pare om 600 Pressure point | itor) eel FA Tesi condition (1) Engine (mbar) crinj pomp | — standard pars vi [ia7 [aise [200 - 1.500 v2 [27 | 60 | 2s 1.500 vs | sa [300 | 135= : 0 1Q | 55 250 2043 o ‘Az 0s [1350 - @ (C)LDA adjust data ‘Adjusting point Rack posifon pm) Purnp speed pan) Pressure (war) Pr 1271005 300) 1.300) P2 4102 300) ¢ PS 170.08 500 7 Pa 95402 500) 315 MAINTENANCE OF MAJOR COMPONENTS £0? Printed i Avg. 2001 PS-MMAUIOMELA7) Performance curve of governor pyisrrmitis 127 84 55 Os 250 500650 1501350 Specctpm 5 PL 127; 117 P3 é 5 9.5 é p24 8.41 | 0 3S ns 1500 LDA Pressure (mbar) ~ ho ly PAEWOO MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELA4) DV1ST(RQV ECVCD/E/ECVXC) engine 65.11102-7290 (0 401 648 702 BOSCH) (1) Injection pump - Model - Governor - Plunger & barrel - Delivery valve - Overllow valve - Feed sumo = Coupling - Rotating direction (2) Nozzle holder assembly : (3) Nozzle (4) Injection pipe (5) Injection order: (6) Injection timing : PEBP120A3201.$7915 (0 412 628 RQV 250/11 50PA1346 (0 421 814 165.11125-0075 (2 418 455 501) £65.11108-6015 (2 418 552 149) 65.12505-5004 (1 417 413 047) 65.12101-7016 (0 440 008 099) 12416 434 074 : Counter clockwise (viewed from di 5.10101-7068 (0 432 231 669) 10.433 271 627 :1-5-7-2-6-3-4-8 pyisrrmitis 929) 193) riving gear) 10301-80604 , 65.10301-8061A, (A) Test condition For injection pump (BRP ine standard parts Nozzle & Holder Ass’y BTDC 7° T Injection pipe(IDxOD-L) Test oil Nozzle & holder Ass'y Nozzle ) 65 10301-6060 Injection pipe(IDxOD-L) 1.688 901 105 1.680 750 089 Open ISO4LL3 65.10101-7068 0.433.271 627 65,10301-60614, Multi hole (5 x 40.313) ing pressure : 208.5 +1.5 bar 493.0 x 68.0 600 mm Temperature :40.15°C 20048 kg/en 12 65.35 - 650mm (C)LDA adfust data Rack diagrasn and setting valve at each point Tijocion Qy on RIG point | Peston] seed Te concon (B) Engine | (mbar) forinj puma | standard pare vi [iss [1150 | 222 - 1.500 ve [ose | 6s0_| ares 7.500 81 | soo | 1232 : ° so | 250) 063 o os [100 = = o Adjusting paint Rack position (rpm) Pump specd (rpm) Prewsure (mbar) PI 13.8 +005 500) 1,500 P2 81402 500) 0 PS 111005 500) 135 Pa 10.0402 500 350 MAINTENANCE OF MAJOR COMPONENTS !!! Pi i in Aug. 2001 PS-MMAUTO-EIA,7) Performance curve of governor pyisrrmitis bs ve vi 4 Vs 81 56 | Aa 05} Lt 250 500 650 nso 1400 138) a 124 23 é z p4 0 350735 1500 LDA Pressure (mbar) — 12 ay paewoo MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELA5) DV1STI(RQ) engine (1) Injection pump Model Governor :PEBP120A32 RQ 30/1050 :O12mm (241 265,11108-607 - Plunger & barrel Delivery valve Overtlow valve Feed puma Prestroke 23.5 10.05mm Rotating dir tion (2) Nozzle holder assembly (3) Nozzle (4) Injection pipe (5) Injection order: a BTDC 11° 5-7-2 (6) Injection timing pyisrrmitis 65.11102-7368 (0 401 848 832 BOSCH) OLS3868 (0 411 828 730) PA1345 (0.421 801 823) 8 455 082) 5 (2.418 552 149) 1.417 413 047 FP/KG24P215 (0 440 008 101) at 20.5 £0.5mm : Counter clockwise (viewed from driving gear) 165.10101-7266 (0 432 231 657) 10.433 271 486 1 65.10301-8060A , 65.10301-8061A 63-48 Nozzle & Holder Ass'y | 1688901105 | Opening pressure : 208.5 11.5 bar (A) Teg godin Injection pipeDsOD-0 | 1680 750089 93.0. $8.0 600 mm for injection pump Test oil | Isoanis ‘Temperature :40 15°C Nozele & holder Ass’y 65.10101-7266 20018 kygvern (B) Engine standard parts. | Nozzle Injection pipe(IDxOD-L) Rack diagram and setting valve at each point 0433 271 486 65.10302.6042 65.10301-6043 Multi hole (4 x 60.39) P25 $6 650m (CULDA aadgust data (LDA spring : 2424 619 095, k=3 chek] Rack] Pare om 600 Pressure point | itor) eel FA Tesi condition (1) Engine (mbar) crinj pomp | standacd pars vi [ira [1050 [191 mui | 1.000 v2 [13 [650 3 182147 | 1.000 vs [83] 300 > lus 12 o Lg | 63 | 30 24 o ‘Az [05 [1300 ° 8.35N/onm , L=25.9mnm) Adjusting paint Rack position (mpm) Pump specd (rpm) Prewsure (mbar) Pl 1.3 =0.05 500) 1,000 P2 BOSH 500) 0 PS 905.4005 500) eT} Pa 10.55 40.2 500 580 1B lg Baewoo MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 7) Performance curve of governor a va vi A gsl Vs _ La \ \ \ os Aa 0 x 500 850 105¢ 1300 Pump Speedirom) 113 fl ~ 10.58 : 9.05} —* 803 {22 0 280 «580~=SS«1000 LDA Pressure (mbar) Oe it ig BaEWoo MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 6) DV15TIS(RQ-390PS) engine (1) Injection pump 65.11101-7662 (0 402 648 708 BOSCH) - Medel : PEBP120A320L87927 (0 412 628 934) = Governor RQ 300/1050PA7389 (0 421 801 836) - Plunger &barrel : 212mm (2 418 455 155) - Delivery valve 1: 88mm (2 418 552 157) - Overtlow valve 65.12505-5004 (7 417 413 047) - Feed pump 65.12101-7016 (0 440 008 099) - Coupling 12.416 434 105 - Rotating direction: Counter clockwise (viewed from driving gear) (2) Nozzle holder assembly : 65.10101-7299 (0 432 131 682) (3) Nozzle 5.10102-0190 (0 433 171 569) (4) Injection pipe 2 65.10301-7011A,, 65.10301-7012A (5) Injection order :1-5-7-2-6-3-4.8 (6) Injection timing BTDC 5.5° MI Novzle & Helder Ass'y_| 1 588901 105 [Opening pressure : 2085 115 har (A) Testconttion | Tinjetion pipeDxOD-1)| 1 680.750089 | 43.0. §8.0- 1000 mm jection pume [Test oil ISO ‘Temperature :40 45°C Nozzle &helderAss'y | _65:10101-7299 25048 kg/em| 1B) Fngine standard parts Nozzle 65.10102-0190 | Muli hole (5x 00 iy irgine se 65. 10801-TO1TA Injection pipedDxOD-1), PX TPT UA) 61.85 46.35- 650mm Rack diagrasm and setting valve al each point Injection Q'ty on RIG ceca sk | Pome tm 03) Presse Print | POM) eel FT condition (B) Enaine (mbar) 12.52 [1,050 [207.31 2,000 1252 | 600 | 27st - 2,000 86 [500 | ia/sst ° rod | oo | 633 o 0 | 1.250 ° 2,000 (C) LDA adjust data Adjusting point Rack position (pm) Pamp spexd pm Pressure (mbar) Po 12.0.40.05 500 800 PL 1252.41.35 500 L.ouo P2 86102 500 o PS 9.5 =0005 500 333) Pe 145 40.2 500 600 PS 120.4005 500 1.200 PG 12.52 10.1 500 L347 MAINTENANCE OF MAJOR COMPONENTS !!5 Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 7) Performance curve of governor v2 vl 1252 vs 86 La \ 782 \ a3 300500600 : 1050 1250 Pump Speed (rpm) —__ Po PL 1282 Po 2 bs Pa 11.45) 98 P3 86 PR 333600 soo 120013471600 Pump Speed (rpm) 16 MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 7) DV1STIS(RQ-420PS) engine (1) Injection pump 65.11101-7662 (0 402 648 708 BOSCH) - Medel : PEBP120A320L87927 (0 412 628 934) = Governor RQ 300/1050PA7389 (0 421 801 836) - Plunger &barrel : 212mm (2 418 455 155) - Delivery valve 1: 88mm (2 418 552 157) - Overtlow valve 65.12505-5004 (7 417 413 047) - Feed pump 65.12101-7016 (0 440 008 099) - Coupling 12.416 434 105 - Rotating direction: Counter clockwise (viewed from driving gear) (2) Nozzle holder assembly : 65.10101-7299 (0 432 131 682) 5.10102-0190 (0 433 171 569) (3) Nozzle (4) Injection pipe 1 65.10301-7011A , 65.10301-7012A (5) Injection order: :1-5-7-2-6-3-4-8 (6) Injection timing BTDC 5.5° Nozzle & Helder Ass'y | 1688901105 | Opening pressure : 208.5 11.5 bar aie teion punp | !8ieetion pipetDxOD-1)] 1.680 750089 | 43.0 480-600 mm Test ot tso4113 “Temperate 0 15°C Novie holder As'y | 65:10103.7299 25048 kaler (8) Engine standard pants | Nowe 65.10102.0190 | Mult ole (5x 90.32) 65.10301-7011A, 65,10301-7012 Injection pipe(DxOD-1.) O18 x 46.39 - 650mm Rack diagram and setting valve at each point chek] Rack] Pare om 600 Pressure point | itor) eel FA Tesi condition (1) Engine (mbar) crinj pomp | standard pars vi [37 [oso [2492 : 1800 v2 [i37_[ 600 [2634 1300 85 | s00 | 128 - ° 6.0 | 300 133 : 0 05 [1.300 : 5 © (C)LDA adjust data Adjusting pain K position (rpm) Damp speed pm Pressure fbr) m0 12.65 10.05 500) 800 Pr 13,7402 500 1800 Pr 8.5 £0.05 500 ° PS 9.6 102. 500 300) Pa 1720.05 500 600 bs 13.0 40.05 500 1200 PG 13.6 10.05 500 1400 MAINTENANCE OF MAJOR COMPONENTS !!7 Printed i Avg. 2001 PS-MMAUIOMELA7) Performan pyisrrmitis uurve of governor v2 v1 137 vs 85 1Q 60 \ 0s a3 300-500 600 1050 1250 Pump Speed (rpm) ———_, PL 137 13.6 Ps . Po of 6 bs E Pa z x = 96 P3 2 85 P2 300 600 s09 1200 1400 1800 LDA PRESSURE (mbar) us MAINTENANCE OF MAJOR COMPONENTS Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 8) DVISTIS(RQV-390PS) engine (1) Injection pump 65.11101-7358 (0 402 648 718 BOSCH) - Medel : PEBP120A320L87927 (0 412 628 934) = Governor RQV 300...1050PA1456 (0 421 814 234) - Plunger &barrel : 212mm (2 418 455 155) - Delivery valve 1: 88mm (2 418 552 157) - Overtlow valve 65.12505-5004 (7 417 413 047) - Feed pump 65.12101-7016 (0 440 008 099) - Coupling 12.416 434 105 = Rotating dir tion: Counter clockwise (viewed from driving ger) (2) Nozzle holder assembly : 65.10101-7299 (0 432 131 682) (3) Nozzle 5.10102-0190 (0 433 171 569) (4) Injection pipe 1 65.10301-7011A , 65.10301-7012A (5) Injection order: :1-5-7-2-6-3-4-8 (6) Injection timing BTDC 5.5° Nozele & Holder Ass'y | 1588901 105. Opening pressure: 208.5 1. bar (A) Test condition ‘ Injection pipe(ID Fuel leaking past clearance between nozzle and needle Disassemble, correct Clean Bleed Disassemble, correct Check, correct Check, correct Replace Correct oF replace Correct or replace @ injection pressure incorrect __| Adjust 2. Engine starts but stalls Pipe trom feed purap Clean immediately injection pump clogged or ‘ltr clogged Avrin uel Bleed Feed pump delivery insufficient © Fuel delivery insufficient due to clogging of fuel tank sir breather Disassemble, correct Replace breather 3. Engine lacks power Plunger worn excessively Injection unin incorrect Delivery valves defective Nozzle leaks excessively )_Nozrle not working normally Replace Adjust Replace Correct or replace Disassemble, correct @. Engine knocking Injection timing too fast Noz7le injection pressure 100 hi Nozzles not working normally | Disassemble, correct, Agjust Adjust 5. Engine knocks seriously | ( Injection timing incocrect Adjust Producing excessive ® Nozzle injection pressure too Adjust exhaust smoke tow Nozele spring broken Replace Novrles ot working normally | Replace Plungers wom excessively Adjust © Delivery valves seat defective | Replace Supply of fuelexcessively | Check feed pump Wy DAEWOO MAINTENANCE OF MAJOR COMPONENTS !2° Pinte i Au. 2001 PS-MMAO700-E1pyissrrnuis MAINTENANCE MANUAL. Complaints Possible causes Corrections 6 Engine output unstable | @ supply of fuel insutficient ‘Check feed pump Airin fuel Bleed ‘Water in fuel Replace fuel Operation of plungers unsmooth | Disassemble, correct ‘Movernent of control cack Disassemble, correct sluggish ) Nozzles defective Disassemble, correct Injection starting pressure of | Adjust each barrel incorrect Automatic timer detective Disassemble, correct 7. Engine does notreach | @ Nozzles not working normally | Disassemble, correct maximum speed Governor defective Disassemble, correct @. 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 130 ig Daewoo MAINTENANCE OF MAJOR COMPONENTS Pinte i Au. 2001 PS-MMAO700-E1pyisrrmitis 5. SPECIAL TOOL LIST No.) Part No. Figure Tool Name Remark 1 | EF.120-030 Front oil seal insert assembly 2 | EF 120-029 S Rear oil seal insert assembly 3 | EF.123-065, f sf a Valve cotter extractor 4 | EF 120-183, Ge : Valve stem oil seal installer 5 | E.00308-c084 2 Nozzle holder £4 6 | FU2.0832 7 | 60.99907-9036 Nozzle plug socket 8 | EF.120-189 S Injection pump alignment — DvisiTiTI EF. 120-031 c Dvistis. 9 — Piston sleeve EF 120-208 Allengine 29 iy DAEWOO SPECIAL TOOL LIST Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis No.| Part No. Figure Tool Name Remark ea 40 | £u.2.0131 Valve clearance adjust ass'y 11 | 60.99901-0027 LF Feeler gauge 12 | T7610001€ Snap ring plior 13 | T7621010E Piston ring plier Alp DOEWOO. SPECIAL TOOL LIST Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis 6. APPENDIX 6.1. Tightening torque for major parts ‘Screw Strength (Diameter x piten) | (Grace) Major parts Tightening torque Cylinder bieck bearing cap = main bott Miax2 12.9T | initial 30 kg-m + angle torque 90 - side bolt Mi2x1.5 | 10.97 8 kgm Oil spray nozzle M14x15 : 7 kgem Fiywhee! housing Mi2x1.5 | 10.97 10 kgm tightening bolt M0 12.97 7.5 kgm ~ cover bolt Ma 8.aT 2.2 kgm Balance weight Mi6x7.5 | 10.97 | Initial 10 kg-m + angle torque 90 Crank pulley Mi6x+.5 | 10.9T. 21 gm Vibration damper M0 10.9T &kg-m Fiywhee! Mi6x15 | 1297 26 kgm Fan clutch Ma 8.8T 2.2 kgm Connecting rod cap M16x1.5 | 10.91 | intial 10 kg-m + angle torque 90° Cylinder nead Mi5 x2 12.97 | ekg + 18 4gin rangle torque 90°= 90 Cylinder head cover Ma 8.8T 2.2 kgm Fuel injection nozzle holder | M28 cK6o 710.5 kg-m Fuel injection pipe |M14xt.5 | = | 25 kgm Cam shaft timer M10 10.97 kgm Rocker arm bracket mio 10.97 6.5 kgm Lock nut (adjusting screw) | M12 x + 8.81 Skg-m Oil pump cover ma 8.8T 2.2 kgm Oil pump Ma 8.8T 2.2 kgm Oil cooler M2 10.91 5 kg-m Gil pan Ma 8.8T 2.2 kgm Oil pan drain plug M26 x15 : 3 kgm Exhaust manifold M0 10.8T 5.0 kgm Intake manifold Ma 8.8T 2.2 kg-m Fuel injection pumpieynt= sin) | M10 10.9T 6.5 kgm Fuel filter M12x1.5 8.8T 3 kgm Staring motor Mi2x15 al 8 kg-m Alternator bracket Mia. 8.8T 42kgm Oil pressure unit Mi0x15 2 kgm Thermo sensor M14x1.5 : 2 kgm P.1.0 gear shaft M33 x15 - 30 kg-m ~ flange M24 x15 30 kg-m coupling Mi2x15 - Skgm Aircompressor drive gear [Mi8x15 | 10.87 Skg-m = connecting rod cap | MB 10.97 28kgn cylinder liner Ma 10.97 kgm Aly DAEWOO APPENDIX 3 Printed i Aug. 2001 PS-MMAUTOMEIApyisrrmitis 6.2. Standard bolt tightening torque table Refer to the following table for holts other then described above Degree of strength ac |4s]es 5s sele6 6s|6o| es to9 | 1s Diameter | (aa) | 4D)[ 48) (6D) | (65) | (60) | (65) | (2a) | 120) | (104) | (r2Ky eae) Limit value for elasticity (kg/mm?) 20 | 24 | e230 40 | 36 | 48 | 54 | 64 a0 | 108 Tightening torque (kg.m) vs 0.75 [0.16 [025] 022 031 [028] ous [oae[ 5 | 075 | 08 6 028 [0.30}0.45_ 04 055/047 /0.77[085| 09 1.25] 08 M7 043 [0.46 | 0.7 0.63 083/078) 12 | 1.3 | 14 195 | 235 Ve o7 jo7{11) + 14 [125/19] 21] 22) 31 | 38 ext ors [oe ]t2 i145 [131/21 [23 [24335] at M10 135 | 14 [2219 27 [235/37] 42 [44 62 | 74 Mioxt 15 | 16]25 21 /31)28|)43|)49| 5 7 | 84 Mi2 2a [25)37 33 47/42) 63 [72/75 105| 125 Viexts [265 [27/4 35) 5 | 46) 68l77| 8 11.2 | 134 via a7 [se [6 52.78 | 7) 10 (18/12 17 | 20 Mints [41 [43 [66 576375 1.7 /125| 13 165 | 22 Mi6 56 | 6 | 9 | 8 [11.5] 105/179|1e5| 18 | 26 | 31 MiextS | 62/68 |o7) 86) 125/113) 17 |1e5| 20 28 | 33 Mie 78 [83 [125/11 | 16 [145] 21 [2s2[ 25) 36 | 43 Migxi5 | 9.1 | 9.5 [14.51 12.51 18.5 | 167/245 |27.5| 28 41 | 49 Mz0 118 | 12 1622 | 19 31.5] 35 | 36 60 Maoxt5 | 12.8 | 13.5 je 25 [22.5| 35 [395/41 sa | 68 M22 15.5 | 16 [245 21 30 | 26 42 | 46 | 49 67 | 75 M2oxt8 | 17 |18.5| 2824 3¢ | 29) 47 | 82 | 56 75 | 85 Mad 20.5 [21.5| 332740 | 34 | 55 | 58 | 63 62 | 92 Medxts | 23 | 25 [97 31 45 | 98 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. 3.9 special screws should be lightened lo 85% or so ol the standard value. For example, a screw coated with MoS: should be tightened to 60% or so of the slandard value. @ Tightening torque for hollow screw(4-hole) Material [ Mé | MiO | Miz | Mia | M16 | Mie | M22 | M26 | M30 | M38 ‘SM25C 16 | 25 7 35 | 45 | 55 | 90 | 139 180 | 300 *suvaal | 08 | 18 | 30 40 | 55 | 65 | 1.0 169 200 | 350 stss04 | 08 | 18 | 30 40 | 55 | 65 | 11.0 | 16.0 | 200 | 35.0 %& : Adooled in DAEWOO engine APPENDIX Printed i Avg. 2001 PS-MMAUIOMELA Alp DOEWOO,pyisrrmitis 6.2. Engine assembly tolerance (Unit : mm) lems DV series Remarks Cylinder | lside dia. of Tner forced in oint part usper par) | 9145.800~p145.840 | 0145.87 block Inside dia. of Iner forced in jeint part (lewer part) Inside dia. of liner color forced in p Liner colores surface depth 0144,500~p144.540 | 9144.57 §152.900-184.150 | 9153.9 11 9.97-9.98 Gylinder | Ouiside dia of inar forced in joint parupper) | 0145.741~-p146.786 | 9145.8 g6 iner Outside dia. of liner forced in joint part(lower) | g144.a32-praa.as7 | 9144.5 6 Outside dia. of liner color par: ()159.65-p153.75 1508 Liner collar height 10.03 10.05 Liner forced in joint part (upser} 0.014~0.079 Liner torced in joint part lower) 0.043-0.108 Liner collar part clearance 0.150-0.500 Inside dia. of liner 6127,990~p128.010 | 4128 40.01 Liner’s roundness & columiness (uppe") oot from top up to 68mm Liner’s roundness & columness (lower) 0 of from bottom up to 8smm Liners projection 104 ~ 0.08 | measure a4 pl Piston ‘Outside diameter of piston 127. 799-12 7.787 | TRIE Sea Inside diameter of piston pin o46.003~26.009 |" rors om Max. allowable weight per engire 509 st ring groove wicth 25 2nd ring groove width 3.040 ~ 3.960 ii ring home width 4.020 ~ 4.940 Piston string height (thickness) 25 ring 2nd ring height (thickness) 2978-2980 ii ing height (thickness) 3.97-3.99 tating axial direction clearance - 2nd ring axial direction clearance 9,050~0.082 Oi ring axial direction clearance 0.030~0.070 {st ring end part clearance 0.35-0.55 2nd ring end part clearance 0.40-0.60 Oil ring end part clearance 0.40~0.70 Piston pa | Piston ain's outside diameter 48.994 = }46,000 Clearance between piston pin & pin hole 9,003~0.015 Aly DAEWOO APPENDIX 8 Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis tems DV series Remarks Connecting | Con red small end part widin 38.070-39.000 rod Con rad large end oart width 85.241 -35.380 35.5 08 Con rod cap 82.800~33.100 32.8108 Con rad axial direction clearance 0.240~0.382 Con rod small end par axial directon clearance 0.064-0.126 Con rod bush ol clearance 0.055-0.071 Con rod small enc inside diamezer (wh tush) | 946.055~p46.085 Con rod small enc inside diameter (wio tush) | §59.600~ps0.630 | 450.6 H7 Con rad bush’s diameter $50,670-450.700 Tightaness 0.04~0.10 Con rad large end part's inside diameter )98.000~95.022 g98HE Con rad bearirg spread (MIBA) ose Con rad max. weight tolerance per engine 509 Pergendicularty of large en inside diameter o.0as relerence to Large end parts inside roundness & columness 00: can ro¢ side tace Large end par'’s inside straightness 0.008 Parallolness of email end insice with large ond 0.02 Crank Bearing housing diameter ITT 000-4111 022 ot? shalt Maximum shaking 0.05 Main bearing journal diameter Standard 6103.98-4104.00 Undersize 0.10 103,88 103.90 Undersize 0.25 103.7341 Undersize 0.50 $103.48-)103.50 Undersize 0.75 9103.23-9103.25 Undersize 1.00 102.98-4108.00 Thrust bearing journal width standard 38,000~38.062 38 H9 Undersize 1,2 38,500~38.562 Undersize 3,4 93,000-39.062 Con rad bearing journal dameter Standard 489.98~)30.00 Undersize 0.19 $89.88~$89.00 Undersize 0.25, 489.73~)89.75, Undersize 0.59 89.48~p89.50 Undersize 0.75 )89.25~)89.25 Undersize 1.00 $89.98-489.00 IM APPENDIX Alp DOEWOO, Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis (Unit : mm} tems DV series Remarks Grark Man bearing journals roundness Dar shatt Main pearing journal's paralleiness 0.008 Medium main bearing journal's shake 0.06 no 1, no 5 support Wear ring press in part's journal diameter 99.985~9100.020 $1007 Wear ring's inside ciameter $99.9907-jo9,002 | 1007 Overlap: 0.043~9.113 Thrust bearing width Standard 37.74-37.8 Oversize 38.24~38.3 Oversize 38.74~38.81 Crarkshat's axial direction's clearance 0.190-0.322 thickness Standard 3.460-3.472 Oversize 0.10 3.810~3.522 Oversize 0.25 3.585-2.597 Oversize 0.50 3.710~3.722 Oversize 0.75 3.835~3.847 Oversize 1.00 3.960~3.972 0,066~0.132 oa~12 Thrust bearing’s soread 03~12 Flywheel | Ring Gear assembly pars Outside diameter | 6432.490~ 432.645 Ring gear irside diameter (000~$432.155 Overap 0.335~0.645 Heat fitting ternp. (°C) 200-230 Allowable shaking ammount aller assembly os Outside diameter afler reassembly used ring | 9114.980~p115.91 Gylinder | Head gasket tiseness (aller (ghiening Bos) 1.205 = 1.296 head Gylinder head height 13.9~ 114.0 &valve | Cylindor head seal surtace roughness max. 16} Valve projecting amount = 0.65 ~- 9.95 Exhaust valve Stem diameter 11.945 511.955 Radius direction clearance 0.045 ~ 0.073 Seat angle 45 iy DAEWOO APPENDIX 3s Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis (Unit : mm) tems DV series Remarks Head diameter eevee H’ thickness of valve head 1.92.3 Valve seat part diameter of head (983,00~953.03 Outside diameter of valve seat 0988.10-453.11 Cylinder | Intake valve head Stem diameter 11.969-611.980 & valve Radius direction clearance 0.020~-0.049 Seat angle 30° Head diameter $57.85~p58.15, H’ thickness of valve head 2.6~3.0 Valve seat part diameter of head )81.00~p61.03 961 H7 Outside dia. of valve seat 961.10-461.11 Depth of head's valve seat assembly part 125-126 Valve guide insice diameter o12.000-y12. 018 e247 Valve guide's inside diameter of head $18.000-)18,018 o1gH? Valve guide's outside diameter 18.028-418.086 018.25 87 Valve guide assembly locking piece 0.010-0.046 Valve seat's shaking 0.04 relerence to valve guide Valve Valve lift 144 spring Projecting amount of valve guide 17.1~17.5 | Above vahe spring Free length of inside spring DV15/T/TI : 72.43 DVISTIS : 68.3 Spring ‘cad of inside spring DV1S/T/TI 15~17kg | at 46.3mm DV1STIS44.5-49.5 Free length of outside spring DVIS/T/T 68.17 DvisTIS:61.9 Spring (oad of outside spring DVISMT/TTS7~41K9 | at 46.8mm. DV15TIS:26.5-30 Alp DOEWOO, APPENDIX Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis tems DV series Remarks Timing Rocker arm bust’s inside diameter 2E.005-F25.005 | when Rocker arm bearing journal's ciameter $24.967~424.990 Bearing’s clearance 9.015~0.068 Push rod's shaking 93 Valve tapoel ass'y part's inside dia. of block | ©20.000-420.021 920 H7 Push rod's outside diameter 19.944~)19,965 Tappet clearance 9.035~0.077 Bush assembly's inside diameter of block $70,077 20.081 Camshatt diameter 69.910~)59.940 70 e7 Camshaft bearing oll gap 0.060~0.120 Camshaft axial direction play 0.20~0.90 Backlash (crank gear-camshatt gear) o.tte-o.242 Backlash (driving gear — injection pump gear) 0.102~0.938 Intake vaive clearance 0.28 Exhaust valve clearance 0.38 Engine Oil pressure atiding 08-30 bar lubricating | Oil pressure at rated speed operation 3.0-6.5 bar system Oil temperature less than 110°C Instantaneous allowable temperature max. 100°C Bypass valve opening pressure 1.8-2.4 bar Pressure regulaing valve of ol pump 8.5-10bar Spray nozzle Operating pressure 1.6-1.9 bar Crossing pressure 1.3-1.6 bar Tip diameter b2 Backlash (orankshall gear-ol pump ctive gear) o.10-0.88 il pump housing's depth'gear width 42.000~23.039 age 42.910~42.950 43.68 1 pump housing axial play 0.050-0.128 Engine Cooling water pump shall diameter 21.930-)21.950 cooling Bearing gap 0.050~0.08 system Impeller clearance (impeller ~ body) 10-15 Thermostat Operating temperature [°S) 71°0, 79°C or 79°C Tnspacton | Good above 28 kgicm on Possible to use 25-28 kgiem! compressed | Need up keap boliow 24 kgiom? pressure | Alonable max pressue difeonce botwoor eying 4 kglem APPENDIX a Alp DOEWOO, Printed i Avg. 2001 PS-MMAUIOMELApyisrrmitis lems DV series Remarks Fuel system ] Overiow valve’s oparatng pressure ofirjecion pune | 1.2 1.8 kgiem Maker of fue! injection pump Bosch Governor type RO or ROV Injection nozzle’s manufacture Bos Injection nozzle tio diameter DV"5 : 00.34x4noles DVIST: 00 32x5holes DVISTI: 20.38x4holes Dy1aTIS : @o.325holes Nozzle tip projection on cylinder head 0.9-1.8 Air Cylinder bore. B grade 90,000~090.010 compressor C grade 990,010~290.020 D grade 990,020~190.030 Piston outer diameter 3 grade 989.910~089.920 Cograde 89.920~289.930 D grade 89.930~289.940 Piston ring groove = tstand 2nd 251-253 = 3rd and ath ring 4.02~4.04 Piston pin bore 0.003~220.008 Piston oin diameter 919.994~220.000 Connecting rod bush bore at small end 920.020~020.033 Connecting rod bearing shell width 2,004~2,010 | Whunsssombios ann Connecting rod bearing journal diameter 931.97-031.875 629,959~029.980 232.020~~030.041 23087 Piston pro‘rusion -0.75~0.2 wien assembled Piston clearance 9.080~0.100 Connecting rod bearing ail clearance 0.027~0.073 Back lash(air comp. drive gear-cam shat: gear) 0.097-0.953 38 APPENDIX ly DAEWOO, Printed i Avg. 2001 PS-MMAUIOMELA@ WORLDWIDE NETWORK Overseas Subsidiaries: ese ntarational (Amacca) Comp. nto nn ww ‘Acwee herons! Stel Corps temo wr v erweo imemaons! 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