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
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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
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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

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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

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MAINTENANCE MANUAL
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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

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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).

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MAINTENANCE MANUAL
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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)