Daewoo D1146 User manual

PS-MMA0415-E1A
MAINTENANCE MANUAL
Diesel Engine
D1146
D1146TI
DE08TIS
65.99897-8056
Feb. 2001

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Printed in Jan. 2001 PS-MMA0415-E1A
FOREWORD
This maintenance manual is designed to serve as a reference for DAEWOO Heavy
Industries Ltd's (here after DAEWOO’s) customers and distributors who wish to gain basic
product knowledge on DAEWOO's D1146, D1146TI and DE08TIS Diesel engine.
This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct
injection type) has been so designed and manufactured to be used for the overland transport
or industrial purpose. That meets all the requirements such as low noise, fuel economy, high
engine speed, and durability.
To maintain the engine in optimum condition and retain maximum performance for a long
time, CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.
Removal Adjustment
Installation Cleaning
Disassembly Pay close attention-Important
Reassembly Tighten to specified torque
Align the marks Use special tools of manufacturer's
Directional Indication Lubricate with oil
Inspection Lubricate with grease
Measurement
During engine maintenance, please observe following instructions to prevent environmental
damage;
zTake old oil to an old oil disposal point only.
zEnsure without fail that oil and diesel fuel will not get into the sea or rivers and
canals or the ground.
zTreat undiluted anti-corrosion agents, antifreeze agents, filter element and
cartridges as special waste.

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Printed in Jan. 2001 PS-MMA0415-E1A
zThe regulations of the relevant local authorities are to be observed for the
disposal of spent coolants and special waste.
If you have any question or recommendation in connection with this manual, please do not
hesitate to contact our head office, dealers or authorized service shops near by your location
for any services.
For the last, the content of this maintenance instruction may be changed without notice for
some quality improvement. Thank you.
DAEWOO Heavy Industries & Machinery LTD.
Feb. 2001

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
Printed in Jan. 2001 PS-MMA0415-E1A
CONTENTS
1. GENERAL INFORMATION
1.1 General Repair Instructions 1
1.2. Engine Specific Character 2
1.3. Engine Specifications 4
1.4. Engine Assembly 8
2. MAJOR MAINTENANCE
2.1. Preventive Maintenance 13
2.2. Diagnosis and Remedy 22
2.3. Engine Inspection 32
3. MAINTENANCE
3.1. Engine Disassembly 33
3.2. Inspection and Measurement on Major Parts 48
3.3. Reassembly 69
3.4. Breaking in 96
4. MAINTENANCE OF MAJOR COMPONENTS
4.1. Cooling System 98
4.2. Lubrication System 102
4.3. Fuel Injection Pump 106
4.4. Turbocharger 122
5. Special Tool List 132
●Appendix 134
●WORLDWIDE NETWORK

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
1
Printed in Jan. 2001 PS-MMA0415-E1A
1. GENERAL INFORMATION
1.1. General Repair Instructions
1. Before performing service operation, disconnect the grounding cable from the battery
for reducing the chance of cable damage and burning due to short-circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they
cause paint damage.
4. The use of proper tools and special tools where specified is important to efficient and
reliable service operation.
5. Use genuine DAEWOO parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should
be discarded and new ones should be prepared for installation as normal function of
the parts can not be maintained if these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts
neatly in groups. Keeping fixing bolts and nut separate is very important as they vary
in hardness and design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using
compressed air to make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for bolts and nuts torques.
12. When service operation is completed, make a final check to be sure service has
been done property.

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
2
Printed in Jan. 2001 PS-MMA0415-E1A
1.2. Engine Specific Character
1.2.1. Toroidal combustion mode (D1146)
The D1146 engine is operated in the toroidal combustion mode that was developed by
this company with AVL Co. Australia.
The feature of this mode in the fundamental structure is that there are combustion
chambers in the centers of piston heads and swirling passages in the cylinder heads.
This swirling passages when intake stroke generates the strong swirling motion in the
combustion chambers by giving the intake air a big moment, and when compression
stroke, the special piston’s shapes causing very complicated and distorted flows by
means of eddy current and squashed flows will make the air and fuel mix more
smoothly.
Also, when explosion stroke, a considerable output increase came to be expected with
the accomplishment of nearly perfect combustion by the more smooth mixing of air and
fuel which was injected through multi-nozzles in the combustion chamber.
This engine by means of Toroidal Combustion Mode has the specific character such as
quiet and stable revolutional motion, multi-purpose application, economical fuel and oil
consumption, etc.
1.2.2. OMEGA combustion bowl (D1146TI, DE08TIS)
The OMEGA combustion bowl is a unit designed
to perform high efficiency, low emission
combustion. As the rim around the combustion
bowl port of the upper of the piston has been
machined in a smaller size than the interior of the
combustion bowl, strong swirl is produced in the
combustion bowl and strong squish flow makes
the fuel be mixed more sufficiently with air.
Due to the application of OMEGA combustion
system and optimal utilization of intake and
exhaust port configuration within the cylinder
head, the D1146TI, DE08TIS diesel engines
discharge very low level of hazardous exhaust
gases such as smoke, nitrogen oxide,
hydrocarbon, or carbon monoxide and thus
ensure high performance and low fuel
consumption.
M1041A

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
3
Printed in Jan. 2001 PS-MMA0415-E1A
1.2.3. Oil gallery cooling type piston (DE08TIS)
Oil gallery cooling is used for the piston of DE08TIS diesel engine.
When thermal loading is high, piston cooling by means of an oil gallery in the crown is
normally necessary to prevent crown cracking and ring sticking. The design of the
gallery, the design and location of the oil spray nozzle and the quantity of oil flowing in
the gallery are critical in order to achieve the desired temperature reduction.
The cross section shape of the gallery should be designed to achieve sufficient oil
movement to maximize cooling efficiency.
M1255

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
4
Printed in Jan. 2001 PS-MMA0415-E1A
1.3. Engine Specifications
1.3.1. Specification
EngineModel
Items D1146 D1146TI DE08TIS
Engine type 4 cycle in-line,
Water-cooled type
Naturally aspirated
4 cycle in-line,
Water-cooled type
Turbo charged & intercooled
Combustion chamber type Direct injection type
Cylinder liner type Replaceable dry liner
Timing gear system Gear driven type
No. of piston ring Compression ring 2, oil ring 1
No. of cylinder-bore x stroke (mm) 6 – 111 ×139
Total piston displacement (cc) 8,071
Compression ratio 17.5 : 1 16.8 : 1 18.5 : 1
Engine dimension (length x width x height) (mm) 1,253x811.5x934.5 1,253x812.5x1,009 1,253x812.5x1,009
Engine weight (kg) 730 745 745
Rotating direction (viewed from flywheel) Counter clockwise
Fuel injection order 1 – 5 – 3 – 6 – 2 – 4
Fuel injection timing (B.T.D.C static) 15°9°3°
Injection pump type Zexel in-line “AD” type Zexel in-line “P” type
Governor type Mechanical governor
type(RLD)
Mechanical
governor
type(RLD-J)
Injection nozzle type Multi-hole type (5 hole) Multi-hole type
(7 hole)
Fuelinjectionpressure (kg/cm
2) 210 214 160/220
Compressionpressure (kg/cm
2) 28 (at 200 rpm)
Intake and exhaust valve clearance (at cold) (mm) 0.3
Open at 16°(B.T.D.C)
Intake valve Close at 36°(A.B.D.C)
Open at 46°(B.B.D.C)
Exhaust valve Close at 14°(A.T.D.C)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Paper element type Cartridge type
Lubricating oil capacity (max./min.) (lit) 15.5/12 or 20/17
Oil cooler type Water cooled
Water pump Centrifugal type driven by belt
Cooling Method Fresh water forced circulation
Cooling water capacity (engine only) (lit) 14
Thermostat type Wax pallet type
(79 ∼94 °C or 83 ∼95 °C )
Air compressor type & capacity (cc) Belt driven type, 220 or 300
Alternator voltage – capacity (V – A) 24 – 45 or 24-150
Starting Motor voltage – output (V - kW) 24 – 4.5
Air heater capacity (V – A) 22 – 95 (2.1kW)
Battery capacity (V - AH) 24 - 150

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
5
Printed in Jan. 2001 PS-MMA0415-E1A
1.3.2. Engine power
Production tolerance : ±5%
Engine model Performance
Model Suffix
Injection
timing
(BTDC°)
Power
(PS/rpm) Torque (kg.m/rpm) Low idle (rpm) High idle (rpm) Remark
D1146
EACBA
EACBB
EACBE
EACBH
EACBI
EACBK
15 182/2,500 57.5/1,600 600-650 2750
EAPBA 9 205/2,200 75/1,400 600-650
2370
-
2,470
D1146TI
EAPCA 9 215/2,300 82/1,400 600-650
2250
-
2,350
EURO-I
ECPBA
ECPCA 3 225/2,300 82/1,200 600-650 2,530
DE08TIS
ECPBB
ECPCB 3 240/2,300 90/1,200 600-650 2,530
EURO-II
* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349).

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
6
Printed in Jan. 2001 PS-MMA0415-E1A
1.3.3. Performance curve (DE08TIS – 225PS)
Performance ISO 1585(SAE J1349)
Output (max.) 165 kW (225PS) / 2,300 rpm
Torque (min) 804 N.m (82 kg.m) / 1,200 rpm
Fuel consumption (min) 192 g/kW.h (141 g / PS.h)

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
7
Printed in Jan. 2001 PS-MMA0415-E1A
1.3.4. Performance curve (DE08TIS – 240PS)
Performance ISO 1585(SAE J1349)
Output (max.) 176 kW (240PS) / 2,300 rpm
Torque (max.) 882 N.m (90 kg.m) / 1,200 rpm
Fuel consumption (min.) 192 g/kW.h (141 g / PS.h)

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
8
Printed in Jan. 2001 PS-MMA0415-E1A
1.4. Engine Assembly
1.4.1. Engine sectional view (longitudinal)
1 Water pump 2 Piston 3 Air compressor
4 Intake valve 5 Exhaust valve 6 Breather
7 Cylinder head cover 8 Exhaust valve spring 9 Cylinder head
10 Intake valve spring 11 Cylinder block 12 Push rod
13 Flywheel housing 14 Ring gear 15 Tappet
16 Cam shaft 17 Fly wheel 18 Oil seal (Rear)
19 Oil seal (Front) 20 Crank shaft pulley 21 Crank gear
22 Vibration damper 23 Oil pump 24 Oil suction pipe
25 Oil pan 26 Crank shaft
9
1
2
3
4 5
6
7
8
10
11
12
13
14
19
20
21
22 23
15
16
17
18
24 25 26

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
9
Printed in Jan. 2001 PS-MMA0415-E1A
1.4.2. Engine sectional view (cross)
1 Fuel injection pipe 9 Turbo charger
2 Fuel filter 10 Fuel injection pump
3 Fuel injection nozzle 11 Timing gear case
4 Intake manifold 12 Oil filler cap
5 Air heater 13 Connecting rod
6 Rocker arm 14 Oil spray nozzle
7 Rocker arm bracket 15 Oil filter
8 Exhaust manifold 16 Oil cooler
10
1
2
3
4
5 6
7
8
11
12
13
14
15
16
9

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
10
Printed in Jan. 2001 PS-MMA0415-E1A
1.4.3. Engine Assembly Views
(1) D1146 (bus)
1 Flywheel housing 8 Oil filler cap 16 Water pump
2 Intake manifold 9 Oil level gauge 17 Exhaust manifold
3 Breather 10 Oil pan 18 Cylinder head cover
4 Air pipe 11 Oil drain plug 19 Crank shaft pulley
(Air cleaner to intake manifold) 12 Oil filter 20 Vibration damper
5 Fuel filter 13 Fuel injection pump 21 Oil cooler
6 Power steering pump 14 Air compressor pulley 22 Starter
7 Air compressor 15 Thermostat 23 Cooling water pipe
1
23 4 5 6 7
8
9
10 11 12 13
14 15
17 18
19 20 21 22
23
16

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
11
Printed in Jan. 2001 PS-MMA0415-E1A
(2) DE08TIS (Truck)
1 Magnetic pick-up sensor 12 Cooling fan 21 Exhaust elbow
2 Flywheel housing 13 Cooling fan guide 22 Crank shaft pulley
3 Intake manifold 14 Air compressor pulley 23 Vibration damper
4 Fuel filter 15 Thermostat 24 Mounting bracket
5 Air pipe 16 Water pump 25 Oil cooler
(Intercooler to intake manifold) 17 Alternator 26 Starter relay
6 Fuel injection pipe 18 Air pipe 27 Starter
7 Air compressor (Turbocharger to intercooler) 28 Breather
8 Air con. compressor 19 Air pipe 29 Water delivery pipe
9 Oil pan (Air cleaner to turbocharger) 30 Air heater relay
10 Fuel injection pump 20 Turbocharger 31 Cooling water pipe
11 Oil filter
1
2
34 5 678
9 10 11 12 13
14 15 16
17
18 19 20 21
22 23 24 25 26 27
28 29 30
31

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
12
Printed in Jan. 2001 PS-MMA0415-E1A
(3) DE08TIS (Bus)
1 Intake manifold 10 Oil level gauge 20 Water pump
2 breather 11 Flywheel housing 21 Exhaust manifold
3 Air pipe 12 Drain plug 22 Belt
(Intercooler to intake manifold) 13 Oil pan 23 Mounting bracket
4 Fuel injection pipe 14 Oil filter 24 Oil cooler
5 Air pipe 15 Fuel injection pump 25 Turbocharger
(Turbocharger to intercooler) 16 Vibration damper 26 Starter
6 Fuel filter 17 Idle gear pulley 27 Cooling water pipe
7 Power steering pump 18 Air compressor pulley 28 Fly wheel
8 Air compressor 19 Thermostat 29 Pilot bearing
9 Oil filler cap
8
1
9
2 3 4 5 6 7
10
11 12 13 14 15 16
17
18 19 20
21
22 23 24 25 26
27
28 29

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
13
Printed in Jan. 2001 PS-MMA0415-E1A
2. Major Maintenance
2.1. Preventive Maintenance
The preventive maintenance means that the operator performs the servicing of engine
to obtain long life and best performance from DAEWOO diesel engine.
2.1.1. Cooling Water
zRegarding the cooling water that is to be used for engine, the soft water not the hard
water must be used.
zThe engine cooling water can be used diluting it with antifreezing solution 40% and
the additive for rust prevention (DCA4) 3 ～5 %.
zThe density of above solution and additive must be inspected every 500 hours to
maintain it properly.
NOTE :
The proper density control of antifreezing solution and rust preventing
additive will be able to prevent the rusting effectively and maintain the stable
quality of engine. For the improper control might give the fatal damage to the
cooling water pump and cylinder liners, detail care is needed.
zSince D1146, D1146TI and DE08TIS (diesel engine of D1146 series) cylinder liner is
dry type, particularly the cooling water control should be applied thoroughly.
zThe density of antifreezing solution and additive for rust prevention is able to be
confirmed by the cooling water test kit. (Fleetguard CC2602M or DAEWOO
60.99901-0038)
zHow to use the cooling water test kit
(1) When the cooling water temp. of engine is in the range of 10 ～55 °C,
loosen the plug for cooling water discharge and fill the plastic cup about a half.
NOTE :
In taking the cooling water sample, if the water in auxiliary tank were taken, it
is hard to measure the accurate density. Take the cooling water sample
necessarily loosening the cooling water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after taking the paper
out through water agitation, shake off the water.

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
14
Printed in Jan. 2001 PS-MMA0415-E1A
(3) Wait for about 45 sec. till the color change of test paper.
NOTE :
However, it should not elapse longer than 75 sec, and if it did, the hue would
change.
(4) Make the numerical value by comparing the test paper which hue has
changed with the color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color
indication of test paper storage bottle, confirm the density. (Then, the density
indication must be in the hue range of 33% to 50%).
(6) The brown at the middle of test paper and the lower pink color indication
represent the additive state for rust prevention, and the proper range is that
the meeting numerical value of brown (vertical) and pink color (horizontal)
locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and
in case of more than 0.8, pour out the cooling water about 50% and then
readjust the density after refilling with clean fresh water.
zAmount of Anti-freeze in winter
Ambient
Temperature (°C) Cooling water (%) Anti-freeze (%)
Over -10
-10
-15
-20
-25
-30
-40
85
80
73
67
60
56
50
15
20
27
33
40
44
50
2.1.2. Fan belt
zUse a fan belt of specified dimensions, and replace if damaged, frayed, or
deteriorated.
zCheck the fan belt for belt tension.
If belt tension is lower than the specified limit, adjust the tension by relocating the
alternator. (specified deflection: 10 ∼15 mm when pressed down with thumb)

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
15
Printed in Jan. 2001 PS-MMA0415-E1A
2.1.3. Engine oil
zCheck oil level with the oil level gauge and replenish if necessary.
zCheck the oil level with the engine cooled. If the engine is warm, allow time for 5
∼10 minutes for oil drain into the crankcase before checking oil level. The oil level
must be between Max and Min. lines on the gauge.
zEngine oil should be changed at the specified intervals.
Oil filter cartridge should be changed simultaneously.
- First oil change : 1,000km(50 hr) operating
First oil change After 1,000km (50hr)
operation
D1146/TI every 10,000kmShort-distance operation vehicle
(city bus, dump truck) DE08TIS every 20,000km
D1146/TI every 15,000kmLong-distance operation vehicles
(express bus, cargo truck) DE08TIS every 30,000km
zThe following oils are also recommended
Recommend oil
Engine
model SAE No. API No. Remark
D1146
D1146TI SAE 15W40 above CD or CE
DE08TIS SAE15W40
SAE10W40 ACEA-E2 or ACEA-E3 (API CH-4)
* If long oil change intervals are to be used, ACEA-E3 oil must be used.
2.1.4. Oil filter
zCheck for oil pressure and oil leaks, and
repair or replace the oil filter if necessary.
zChange the oil filter cartridge simultaneously
at every replacement of engine oil.
G1081
Oil filter head
Oil filter
(Cartridge)

D1146/D1146TI/DE08TIS
MAINTENANCE MANUAL
16
Printed in Jan. 2001 PS-MMA0415-E1A
2.1.5. Fuel filter
zDrain water in cartridge with loosening
the
cock under filter manually (6) from time to
time.
2.1.6. Air cleaner.
zIn case that elements are deformed,
damaged or if the air cleaner has a crack,
replace it.
zBy the definite interval, the elements must be
cleaned and replaced.
2.1.7. Intercooler
The intercooler is air to air type and has a large
cooling fan capacity. The intercooler life and
performance depends on the intake air
condition greatly. Fouled air pollutes and clogs
the air fins of intercooler. As a result of this, the
engine output is decreased and engine
malfunction is occurred. So you always check
whether the intake air systems like air filter
element are worn or polluted.
G1019