DE12, DE12T DE12TI DE12TIS DIESEL ENGINE ‘Shop Manual 165.99897-8057 Daewoo reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment ‘This documentation may include attachments and optional equipment that is not available in your ‘machine's package. Please call your distributor for addtional items that you may requir. llustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item {65.99897-8057 Shop Manual ‘Copyright 2001 Daewoo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 tq gain basic product knowledge on DAEWOO's DE series diesel engines (DE12, DE12T, DE12TI and DE12TIS), ‘These economical and high-performance diesel engines (6 cylinders, 4 strokes, in-line, direct injection type) have been so designed and manufactured to be used for overland transport 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 per- formed, Removal Adjustment | Installation Cleaning Disassembly Pay close attention-Important Reassembly =| El EA a fel a Tighten to specified torque Use special tools of manufacturer's Directional Indication Lubricate with oi Inspection Lubricate with grease ea} Ka] Of || Measurement During engine maintenance, please observe following instructions to prevent environmental damage: Take old oil to an old oll disposal point only. * Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground, Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste. ‘* The regulations of the relevant local authorities are to be observed for the disposal of spent coolants, and special waste. Hf 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. June, 2001CONTENTS 1. GENERAL INFORMATION 1.1. General Repair Instructions 1.2. Engine Characteristics 1.8. Engine Specification 1.4. Engine Assembly ssn . 2. MAJOR MAINTENANCE 2.1. Preventive Maintenance 2.2. Diagnosis and Remedy 2.8. Engine Inspection 3. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS, 3.1, Disassembly .. . 3.2, Inspection and Measurement 3.3, Reassembly 8.4. Breaking-In 4. MAINTENANCE OF MAJOR COMPONENTS 4.1. Cooling System 4.2. Lubricating System oo 4.8, Electrical System (DF12TIS) 4.4. Fuel Injection Pump, 5. SPECIAL TOOL LIST @ APPENDIX earns 22 32 39 a7 ee 85, 87 92 96 118 1581. GENERAL INFORMATION 1.1. General Repair Instructions 1 9. 10. " 12, 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-freeze 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 necessarily Used cotter pins, gaskets, O-rings, oll seals, lock washer and salt-lock nuts should be discarded and new ones should be prepared for installation as normal funetion of the parts ‘can not be maintained if these parts are reused, 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, 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 oll or grease before installation, ‘When necessary, use a sealer on gaskets to prevent leakage. Caretully 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, a GENERAL INFORMATION1.2. Engine Characteristics 1.2.1, OMEGA combustion bow! The OMEGA combustion bowl Is a r unit designed to perform high ctficiency, low emission combustion AAs the fim around the combustion bowl port of the upper of the piston has been machined in a smaller size than the interior of the combustion bow, strong swirl is produced in the combustion bow! and strong squish flow makes the fuel be mixed more sufficiently with air. Due to the application of OMEGA combustion system and optimal | | re oreo aries ae | ee GENERAL INFORMATION1.3. Engine Specification 1.3.1. Specification a a rr Spec. — Engine type ‘cycle imtine, | # cycle mine, 4 cycle in-line, vinecsoestos | Wranichge | Waterco pe vay eas | “toca | Turbo charged & nooo CoaGaTeH SRA We Direct rieeton ype Gyinder ner pe Replaceable ry ter Timing gear system Gear arven ype No.of piston rng Canipression tna 2, AT No.of eynder bor x Sake (a) 6120x485 Total piston displacement (60) 1.051 Compression aio wat [eat | ee | ea Engr emerson eng xan engi (rm [P17 795%) 1SH7 BIT] sap 3a x 1,181 Erie wei wl a 08 0 Fotaing drecion Wiewed Ton hyve) Courter cocise Fost inetion order 1-5-0-6-8-4 Fuel injection timing (B.T.D.C static) 12" o ry cee ineston pump pe Washarieal | Mechanical | Wacharical | Cote Sowemer ype REDCTALD! AFDC | _RFDD | ALOI Injection nozzle type ‘Muti-tole(S-40.29) | Mult-hole (5-40.31) | Mult-hole(5-40.33) | Mult-hoie(S-#0 23) | Fuel injection pressure BGT] aon zo | TH T60 | Tet: 60 ona: 220_ | ana 220 ‘Compression pressure tkgiom) 28 (at 200m) Tike re ec a ne 03 = __Open at 18° (B.T.D.C) 18° (B.T.D.C) ee [Close at (34° (A.B.D.C) 32° (AB.D.C) ‘Open at ___ 46° (88.0.6) 70 (BB.D.C) Exhaust valve Close at iF (ATO) 30° (AT.D.C) Lubrication method Full forced pressure Teed type —] Oil pump type ‘Gear type driven by crankshaft Oilfilter type ze Cartridge type Lubricating oll capacity(max.min) (iter) | __ T7i4 (cooler ype Water coated Water pump Cenifugal type driven by gear Cooling method Fresh water forced cieulalion iC (iter) 19 Thermostat type ——- Wax pallet type (83 ~ 95 "C) ‘ir compressor type & capacity (ecirow) | Gear driven type, Truck: 250 , Bus 1318 Power steoring pump (ban) Bus: 16/100, Tuck: 187125 Altemator voltage - capacity (V-A) ‘Truck : 24 - 45 , Bus : 24 - 150 = ‘Starting motor voltage - output (V - KW) 24-60 Air heater capacity Battery capacity 23-95 (2.1 KW) 24 - 200 GENERAL INFORMATION1.3.2. Engine power Production tolerance : =5% Ehaine oder Pertommence vroaat | sume | MEE” | power | torque | tow ite | ignite | Remark (eTDC *) (PS / rpm)| (kg.m/rpm)) (rpm) (rpm) exces cease | 12 | z28/22001 915/140) 600-050 | 2420450 — escor cere | eoaas | 10 2307/2200) 61/1400 | eooeso | 2420450 eecoK eecat cece 35650 BEG80 |, |zz0/2a00|@18/1.400| soso | 2szosso eeacn | 12 |e Teams wi87 100] SooEsO | BHaOASO DE12T EBHBA 8 300/ 2,200| 110/ 1,300 | 600-650 | 242050 epee EBIBB 9 "900 72,100| 120/1,260| 600-650 | 2.020250 Zero | "> [2807200] 167 1.260] 00-880 | 2.0650 DEI2TI T EBIBD 9 310/2,100| 125/1,260| 600-650 | 2,820%50 | EURO! EBICA Fobv | 12 | 00/2100) 19571200) ooeso | 2.020880 tne cic ECICB 1 340/2.100) 45 / 1,260 ecico verans | eco 355700 coores | 2580-2400| EURO Scie | F202 00 a8 aR sews [151072 00) 267.280 Seo [ a |ss07 200] 15.380 ECIBE 1 360 /2,100| 145 / 1,260 * Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349), GENERAL INFORMATION .1.3.3. Performance curve 1) DET2TIS - 360PS POWER OUTPUT (PS) = 140 ie 370 10 3 g 340 5 310 ; 280 250 220 . 190 z = 160 1600 3 NE 10 «6 | 3 40g I 2 70001200 1400. 1600 1800 20002000 REVOLUTION (rpm) __ 8601001 | Performance 180 1585 (SAE J1349) ‘Output (max. | 265 KW (S60PS) / 2,100 rpm Torque (max) | 1,421 Nim (145 kg.m) /1,260 rpm Fuel consumption (min) | 186 g/kW.h (143 g/ PS.h) GENERAL INFORMATION2) DEt2TIS - 340PS 2) x6 z 3] 20 g 2 x on|— = 1000 1200 71400 7600 1800 20002100 REVOLUTION (rom) 160 160 140 130 120 180 170 150 140 Performance ISO 1585 (SAE J1349) Output (max) | 250 kW (240PS) / 2,100 rpm. Torque (max.) 4,421 Nim (145 kg.m) / 1,260 rpm Fuel consumption (min) 186 gikW.n (143 g/ PS.n) TORQUE (kgm) FUEL CONSUMPTION (a/ps-h) EB=01002 GENERAL INFORMATION3) DE12TIS - 200PS 15 t ss | é % 8 220 fe 3 & z e| 280 2 E 5 Ke. 3 & E] 20 g 200 = 7 3 160 & 3 2B 5 2 8 10 3 “6 2 Too 1200 1400 ~—«1600=«1800=« 2000 2200 REVOLUTION (rpm) epe01008 Performance 150 1585 (SAE J1949) ‘Output (max) | 223 KW (290PS) /2,100 rpm Torque (enax) | 9427 Nim (116 Kg.m) / 1,260 rpm Fuel consumption (min) | 186 gkWh (143 9/ PS.M) "7 ‘GENERAL INFORMATION1.4, Engine Assembly 1.4.1. Engine sectional view (longitudinal) 1 ‘ | \ 1 \ \ I Yi 1 oY a 7 1% 19 1. Costing water pump 8 Piston pin 18. 0l1pan 2. Fuel iter 9. Piston 16. Connecting rod 3. Vane 10. Chamber 17. Cam shatt 4. Valve spring 11. Crank shaft pulley 18. Flywheel housing 5.oilfiler 12, Vibration damper 19. Flywheel 6. Tappet 13. 011 pump 7, Push rod 14, Crank shaft ‘GENERAL INFORMATION1.4.2. Engine sectional view (cross) 7 8 9 10 6 / 7 = 12 a 13 3. © 2 io 1 | 14 coneore! | 1. Oil fiter 8. Rocker arm 2. Gylinder block 9. Cylinder head cover 2, Fuel injection pump 410. Cylinder head 4, Alternator 411. Exhaust manitold 5. Oil cooler 42. Piston ring 6, Cooling water outlet 13. Turbocharger 7. Fuel injection nozzle 414. Oil suction pipe GENERAL INFORMATION1.4.3. Engine assembly views 1) DE12 (Bus) Fly wheel Flywheel housing il pressure unit Lifting hook Oil cooler Intake manifold Air heater Cooling warning switch ‘Thermostat Ol filer cap ‘GENERAL INFORMATION 11, Oil level gauge 12 13, 14, 15. 16. 7 18. 19. 20 Pilot bearing . Oil fier Oil drain plug Ollpan Fuel injection pump Mounting bracket Power steering pump Alternator Fuel filter “07 ie 2 22. 23. 24, 25. 28. 27. 28. 29. 30. conor | Air pipe Cooling water pump Air compressor Exhaust manifold Crank shatt pulley Vibration damper Mounting bracket Starting motor Fuel injection nozzle Cooling water pips2) DE12TI (Bus) 45 6 7 8 2 \\.\ AO \ a 2 ’ 10 | a ; : n | = le ir k 7 \ \ \ L\\ a 2m mw % 4. Fly whee! 12. Pict bearing 28. Air pipe 2. Fiywhee! housing 13. oi titer (ir dearer to tubocharge) 8. Of preseure unt 14. Ol drain pug 24. Turbocharger 4: Liting nook 15. Oi pan 25, Exaust manifold 5. Oil cooler 16. Fue! injection pune 26. Crank shat pulley 6. Intake manifold 17, Mounting bracket 27. Vibration damper 7. Airheater 18. Power steering pump 28. Mounting bracket 48. Alternator 28. Staring motor (Turbocharger to inercolen 20. Air pipe @. Thermostat 20. Fue iter (riereootr itake manok 10.01ttereap 21. Cooling water pump 31. Cooling water pipe 11. Olllvel gauge 22. Air compressor 32, Fuel injecton nozzle 17 GENERAL INFORMATION3) DE12TIS (Truck) \ 15 16 17 |. Flywheel housing Oil cooler Breather hose Fuel filter Intake manifold Air heater Air pipe (Intercooler to intake manifold) 8. Thermostat, 9. Air-con, Compressor 10. Fan guide 11. Cooling fan 42, Oil fiter 13. Oil pan 14. Oil level gauge GENERAL INFORMATION 16. 16. 7. 18. 19. 20. at 22, 23, 2a, 25. 28. 27. Fuel injection pump, Engine mounting bracket Power steering pump Alternator Lifting hook(Front) Cooling water pump Ol hose (Power steering pump) Fan guide bracket lll drain plug Fan clutch Air pipe (Turbocharger to intercooler) Air compressor Air pipe (Air cleaner to turbocharger) —E7 28. 29. at 22, aa, 34, 36, a7. 38. 99. 40. aMB009" Turbocharger Exhaust elbow Cooling delivery pipe Engine mounting bracket Ladder frame Starting motor Fly wheel Pilot bearing Exhaust manitold Cylinder head cover Fuel injection nozzle Cooling water pipe ll pressure unit4) DE12TIS (Bus) 1 10 " ie \ is es te Wie 2B mM B EaMe0d8! 1. Fly wheel 23. Alr pipe 2. Flywheel housing 13, Oil fiter (Air cleaner to turbocharger) 8. Oil pressure unit 14, Oil drain plug 24. Turbocharger 4. Lifting hook 15. Oil pan 25. Exhaust manifold 5. Oil cooler 16. Fuel injection pump 26. Crank shaft pulley 6. Intake manifold 17, Mounting bracket 27. Vibration damper 7. Air heater 18. Power steering pump 28. Mounting bracket 8. Alr pipe 19, Alternator 29. Starting motor (Turbocharger ta intercooler) 30. Air pipe 9. Thermostat 20. Fuel fier {intercooler to intake: maniole 10. Oil filler cap 21, Cooling water pump 31, Cooling water pipe 11. Oil level gauge 22. Air compressor 32, Fuel injection nozzle 48 - GENERAL INFORMATION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 @ Regarding the cooling water that is to be used for engine, the soft water not the hard water must be used.he use of proper tools and special tools where specified is important to efficient and reliable service operation. @ The engine cooling water can be used diluting it with antitreezing solution 40% and the additive for rust prevention (DCAd) 3 ~ 5 %. @ The density of above solution and additive must be inspected every 500 hours to maintain it properly. NOTE: ‘The proper density control of antifreezing solution and rust preventing additive will be able to prevent the rusting effectively and maintain the stable quality of engine. For the improper control might give the fatal damage to the cooling water pump and cylinder liners, detail care is needed. @ Since DE12/T/71 and DE12TIS (diesel engine of DE12 series) cylinder liner Is dry type, particularly the cooling water control should be applied theroughly. @ The density of antifreezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit. (Fleetguard CC2602M) @ How to use the cooling water test kit (1) When the cooling water temp. of engine is in the range of 10 ~ 55 °C, loosen the plug for cooling water discharge and fll the plastic cup about a halt A tris me ootna weer sample the water in aun tank war tania mromurs he soca aot Take the ootng weer eure moore osrang he (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. (8) Wait for about 45 sec. tll the color change of test paper. NOTE: However, it should not elapse longer than 75 sec, and if it did, the hue would change. MAJOR MAINTENANCE, 14(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 oF 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 83% to 50%). (©) 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 refiling with clean fresh water. @ Amount of Anti feeze in winter Ambient Cooling water (2%) nti-freeze (% ‘Temperature (°C) ° o = = Over -10 85 15 “10 80 20 16 73 27 -20 67 33 25 60 40 -30 56 44 -40 | 50 50 2.1.2. Fan belt © Use a fan belt of specified dimensions, and replace it damaged, frayed, or deteriorated. © Check the fan belt for belt tension. Press here Atecrator If belt tension is lower than the pulley specified limit, adjust the tension by relocating the alternator. (specified deflection: 10 ~ 15 mm when pressed. down with thurn) (Crank pulley Vibett EBa0s011 15> MAJOR MAINTENANCEEngine Oil @ Check oil level with the oll level gauge and replenish if necessary. @ check the oil level with the engine cooled. If the engine is warm, allow time for § ~ 10 minutes for oil drain into the crankcase before checking cil level. The oil 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 simultaneously. First oll change ‘After 1,000km (50h) operation ‘Short-distance operation vehicle Dever | _every 10,000km (city bus, dump truck) DE12TIS ‘every 20,000km Long-distance operation vehicles | DET2//TI every 15,000km (express bus, cargo truck) DEIZTIS ‘every 30,000km @ The following olls are also recommended Recommend Engine mode! ‘SAE No. ‘API NO. DEtanm ‘SAE 15040 ‘above GD or CE SAETSWa0 (ACEA-E2 or ACEA-ES ee SAE10W40 (API.CH-4) * if long oil change intervals are to be used, ACEA-ES oil must be used. @ Engine Oil capacity Engine oil capacity in Olt pan Engine Total Max. Min. model ity it) ain DEI2 Bus 7 14 24 DEV2T ee Truck 7 14 an Bus De12Ts 7 14 2 Truck MAJOR MAINTENANCE, ~16-2.1.4, Ol filter © Check for oil pressure and oll leaks, and repair or replace the oll filter if necessary. @ change the oil filter cartridge simultaneously at every replacement of engine oil 2.1.5. Fuel filter @ Drain water in cartridge with loosening the cock under filter manually (8) from time to time. 2.1.6. Air cleaner @in case that elements are deformed, damaged or if the air cleaner has crack, replace it © By the definite interval, the elements must be cleaned and replaced, il fiter (Cartridge) EaMao101 eFuvo0a1 <7 MAJOR MAINTENANCE2.1.7. Intercooler ‘The intercooler is air to air type and has a large cooling fan capacity. The Intercooler life and performance depends on the intake air condition greatly. Fouled air pollutes and clogs the air fing 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. Aira intercooler with radiator (combined raciator) | <5 Airtow by cooting fan | Mes Hot air by tuo charger compressor " of lower figure. [At this time there are no foree on the push rods of #1 cylinder, MAJOR MAINTENANCE 18 -8) Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top dead center. 4) Thereafter adjust the valve clearances corresponding to * mai " of lower figure, 5) After reinsuring the valve clearances, retighton if necessary. @ No. 1 Cylinder is located at the side where flywheel was installed, Fywheal” ate Vane” Extause Veo GynderNa.Goalng Fan \ / / | EAgO6001 2.1.9. Cylinder compression pressure @ Stop the engine after warming up, and take out nozzle holder assembly. @ install the special too! (compression gauge adapter) at the nozzle holder hole, and connect the compression pressure gauge there. Standard value Bakgiemover Limit value Bakgiome Ditterence between each cylinder Within + 10 9% @ Concition : Water temperature 20°C, Engine rotation 200rpm (10 rotations) 3 MAJOR MAINTENANCE2.4.10. Inject ae ‘Abnormal EFW3006 Normal @ install a nozzle on the nozzle tester. @ ithe inspected injection pressure is less than the specified value, adjust using the adjusting shims. Engine model DEI2 Detar DEIN DEW2TIS Injection nozzte Jat: TeOkgiem™ | tat: 160KgIom* 220kg/e mm Pressure lem | 220K@/Cm | ong: 220kg/em* | 2nd : 220kg/om* @ Check the atomizing state and replace It if abnormal 2.1.11. Fuel Injection nozzle @ Check the housing crack, damage etc. and replace it if abnormal. @ Check if the idle operation and speed regulating lever’s sealing is removed, @ The adjustment and testing of fuel injection pump should necessarily be done at the test bench, 2.1.12. Battery @ Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case of poor condition. @ inspect for amount of electrolytic solution, and replenish if insufficient. @ Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish, uewing tigated tra a | 2 gravity Indteating tine Wei level lower I o | 1.100 i I. ‘200 i ; “Geren = || eFro0r! MAJOR MAINTENANOE, ~20-2.1.13. Air removal of fuel system ‘The suction room of fuel injection pump has the function of air removal continuously during the operation through a relief valve. In case that the suction room lacks fuel at all, for instance, in case of new installation of injection pump, after loosening the air removing screws of cartridge filter respectively, remove the air by operating the manual pump of fuel supply pump until bubble will disappear. 2.1.14. Fuel supply pump Every time of engine oil replacement, the fuel strainer installed at the fuel supply pump should be removed and cleaned. 2.1.15. Turbocharger ‘The turbocharger needs not arty special equipment. Every time of engine replacement, a leakage or clogging of oil pipes should be inspected. Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic inspection should be applied on the compressed air and exhaust gas pipes, For leaking air will bring the overheat engine, an immediate repair must be done. During the operation that is surrounded by the dust and oil mixed air, frequent cleaning must bbe done on the impellers. Tear down the impeller casing (attention: be careful not to bend) and must clean with non-acid solvent solution. If necessary, use plastic scraper If impeller is severely polluted, dip the impeller into solution and may be better to clean it with stiff brush.Then one thing to beware is to dip only impeller part and so do not support by impeller but bearing housing. 2.41.16. Starting motor In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and. coat them with grease. Aso, In case of washing car and so forth, inspect the witing state being careful for not to get. T2T- MAJOR MAINTENANCE2.2. Diagnosis and Remedy @ The following description summarizes the probable cause of and remedy for general failure by item, © DEIZTIS inspect the electrical parts problem with SCAN 200 and refer diagnostic manual. @ Immediate countermeasures should be taken before a fallure is inflamed it any symptom is detected. 1. Engine Starting Impossible ‘Stating mator operation poor Staring meter evolulon = t Inspectonafbaterycectoryic] [Engine [ Fuel tgud amount & gravy ; inspect aircosner Inspect amount of fue = ce eect a e pes anoint jusirent Normal | [” Polttes Nermal_] [None Fecnarsing Replace oF Replenish Trepoaton clean element a : ving 8s Crone injection _|[ No nection L T Forma) [Retoren | pressure Normal eee ae ews Terral t operation str inspection 6 staring sich Fepair ‘i ai s : Replace Tripeet air removal a [Pema spect ineaton Replace 2 part Liming 1 i inspection of staring relay ‘heck vale = ‘Aust See | clearance Nonna (eral) [ Replace r z I Nena] [Aauet iepet econ inspection of ragente svi heck ender preseut, injection : Replace | | | stato te) faa [Pemee head gasket formal! | Replace r Repair : —_ Normal Normal = ‘Staring motor I Sarna et ae Te (rave assembty piston disassomby extn ner ete) inspect evply pump operation T L Neva Inspect supply pump valve stainer Armia in fuel T (a 1 t Trectonpume] [Gear > aa Fatghion someon dasassemby | | Repiace pars. Replace gasket [inspect fue! fiter ‘rroroval I Element polluted [ Continuous ait mixing |_Overtiow valve poor cada ae ‘Supply pump Replace disassembly MAJOR MAINTENANCE, 22 -2. Engine Overheated Operating state 1. Overload 2. Raciator core logged ‘Cooling unit Fuel unit 3, Continuous over-run aoa (Check coolant I Inspect fuel quality Fuel excessive supply c 1 (ema Teoiow Poor J (Check tan bet Clean and replace ‘Check injection nozzle tension wear with specified fuel or damage et| 1 Replenish Inspect cooling ial water leakage I i Check resh ropace raat anion] —|_P* [Ewa] Lio sesees | aeeee I I Tonal Retighten- | | Engine lee | eee Normal | | Abnormal Replace 7 Adjust a Repair Normal injeoton | | Replace pump Inspectrasator|—[ Damage Replce a a ee [ check cooing Repair- | water pump Replace Clean cooking water passage owt) Engine cisassemdly a TWAJOR MAINTENANCE3. Output insufficient Se Engine instalation improper ———— . Fuel anit Others ‘Check for counting : = aignernt Cheek for ai mixing insped air dleaner aaa in fel I L covplng Normal] [Crean-Repace Inspect fuel supply pump: x - —— Inspect engine conch] >= [Normal] Ciean-Replace 10d, link, cable, ete, Inspect alr leakage r I of air piping line pect rover ow va re on T T Nomar) | Retonen. Replace [Normal Replace} ‘Check valve clearance | L I r Inspedt econ pipe Normal] [Aajst Inspect air akage I I I of intercooler ermal] [Repair Replace Inspect eyinder head I gaskat for damage Inspect injection nozzle, I i injection pressure, ermal] [Replace atomizing sate i I Engine disassembly Normai]| Adjust-Replace (valve assembly) = Cheek injection tring Normal]| _Aejustment Disassemble engine or Check trbooharger injection pump as oe Normal] [ Repai Replace Dieassombi nicton pump or engine MAJOR MAINTENANCE, 244. Oil pressure lowered ‘Check oil amount ‘Check it ol pressure T ‘Check coating | temperature Normal Inspect oll quality Normal Reler to engine overheat ‘Too low T Use recommended oil (replenish) Check oi reset ‘Normal Disassemble engine Retghten: piace Water & fuel mixed ino Disassemble engine or injection pump 25 wore] Replace with recommended oil MAJOR MAINTENANCEFuel Consumption Excessive Causes according to Use Conditions 1. Overload 2. Frequent use of low gear postion athigh speed 3, Frequent use of high gear pesition atlow speed Inspect tue leakage 4. Clutch stip 6.00 low tie inflaton pressure Normal a {Injection pressure atomizing state etc) Inspect injection nozzie | Oilleakage L ‘Normal ‘Adjust Replace Check injection timing Adjust Normal Ingpect compressed (Check valve | Retighten-Replace Repair-Replace cylinder ine, pressure Glearance . ‘Normal Disassemble Injection pump Normal Adjust Ingpect head gasket Replace jects eee Normal Disassemble engine (alve assembiy. piston, oylinder liner etc) TIAJOR MAINTENANCE, 726- piston ring piston6. Oil Consumption Excessive Cause according to use conditions 1. Excessive oil intusing 2, Continuous operation in low speed oF extremely cold state Inspect oll leakage oo ino cr Normal [ootteakae lean - Replace I Check ot quality Exermat] [7 ntemal as Replace with Retignten-| [Check compressed spectied ot Replace | | pressure Engine dsassembiy] Normal {Pton,oyineer ine) I Disassemble cinder head (vale stom sea) 7. Engine Knocking ee Inspect combustion of fuel & oil (carbon resisue of exhaust gas) Uncontfimed Contin lL ee Inspect compressed Disassemble I Too iow Normal = T ‘Check valve clearance and Inspect injection | evlindernead gasket for damage pump | Lowe | =a ween] [Tage] [tomar] [Ree eee ee eles crete [ Besser crane Use specified fue! a7 MAJOR MAINTENANOE8. Battery Discharge [ =i Wg, Sh Sonwater or Tope ae Sekine ‘liquid amount a tansion & damage v_ ome : | secon | [ona = 1 Sam) [eamyaen] [Emo] [eee mee) | Sima" | [semwme | | eors Sa — woeen] [Lemme] [wow] [este Check charged stated Adjust - eo I ae "Disassemble imi MAJOR MAINTENANCE,‘Condition Causes Remedies 1) Starting aifficult (1) Starting motor trouble (2) Fuel system trouble (8) Compression pressure lack © Refer to diagnostics © Refer to diagnostics © Valve's poor shut, stem distortion © Valve spring damage ‘© Cylinder head gasket's leak Repair or replace Replace valve spring Replace gasket, ‘© Wear of piston, piston ring or liner | Adjust 2) Idle operation abnormal @ Injection timing incorrect Adjust © Air mixing at injection pump Remove alr 3) Engine output insufficient (1) Continuous output © Valve clearance incorrect Adjust Insuffictont ‘© Valve tightness poor Repair (2) Output insutficient when in acceleration © Cylinder head gasket's leak '© Wear, stick, damage of piston ring © Injection timing incorrect ‘© Fue! injection amount insufficient © Nozzle injection pressure improper or stuck © Supply pump’s function lowered ‘© Fuel pipe system cloggea @ Air suction amount insutficient © Turbocharger poor © Compression pressure insufticient © Injection timing incorrect © Fuel injection amount insufficient @ Injection pump timer's function insufficient @ Nozzle injection pressure, Injection angle improper ‘© Supply pump’s function lowered @ Air intake amount insutficient Repair or replace | Replace gasket Replace piston ring Adjust ‘Adjust injection pump Adjust or replace Repair or replace Repair Clean or replace air cleaner| Disassemble engine Adjust Adjust injection pump Repair or replace Repair, replace Repair or replace Clean oF replace air cleaner| 4) Overheating © Engine oil insufficient or poor ‘© Cooling water insufficient (© Fan belt loosened, wor, damaged © Cooling water pump’s function lowered @ Water temp. regulator's oparation poor @ Valve clearance incorrect © Exhaust system's resistance increased Replenish or replace Replenish or replace Adjust or replace Repair or replace Replace Adjust Clean or replace Ta87 MAJOR MAINTENANCECondition Causes Remedies: 5) Engine noisy (1) Crankshaft (2) Con-rod and, Con-rod bearing (8) Piston, piston pin & piston ting (4) Others, For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the ises accurately. '@ As the wear of bearing or crankshaft progress, the oll clearances increase| © Lopsided wear of crankshaft © Oil supply insufficient due to oil passage clogging © Stuck bearing '® Lopsided wear of con rod bearing ‘® Lopsided wear of crank pin ‘© Connecting rod distortion © Stuck bearing © Oil supply insufficiency as clogging at oil passage progresses '@ Piston clearance increase as the wear of piston and piston ring progresses © Wear of piston or piston pin Piston stuck @ Piston insertion poor @ Piston ring damaged ‘@ Wear of crankshaft, thrust bearing ‘® Camshatt end play increased ‘@ Idle gear end play increased ‘© Timing gear backlash excessive © Valve clearance excessive ‘© Abnormal wear of tappet, cam © Turbocharger inner part damaged Replace bearing & grind crankshaft Grind or replace Clean oll passage Replace bearing & Grind Replace bearing Grind crankshaft Repair or replace Replace & grind crankshatt| Clean oll passage Replace piston & piston ring Replace Replace piston Replace piston Replace piston Replace thrust bearing Replace thrust plato Replace thrust washer Repair or replace Adjust valve clearance Replace tappet, cam Repair or replace 6) Fuel Consumption Excessive '@ Injection timing incorrect ‘@ Fuso! injection amount excessive Adjust Adjust injection pump WAJOR MAINTENANCE, 7307Condition Causes Remedies 7) Oil Consumption Excessive (1) Oil level elevated (2) Oil level lowered (@) Oil leak © Clearance between cylinder liner & piston © Wear of piston ring, ring groove @ Piston ring’s damage, stick, wear © Fiston ring opening’scisposition imprope © Piston skirt part damaged or abnormal wear @ Oil ring’s oil return hole clogged '® Looseness of valve stem & guide ‘© Wear of valve stem seal © Cylinder head gasket’s leak Replace Replace piston, piston ring Replace piston ring Correct position Replace piston Replace piston ring Replace in set Replace seal Replace gasket ‘@ Looseness of connection paris © Various parts’ packing poor © Oil seal poor Replace gasket, repair Replace packing Replace oil seal Tats MAJOR MAINTENANOE2.3. Engine Inspection 2.3.1. Stopping engine ‘After checking the engine for any unusual condition at the idling speed, then turn the key switch to stop the engine. 2.3.2. General engine inspection cycle O: Check & adjust @ : Replace inspection time (km) Inspection Dau iemark| " af 1,000 |10,000 | 15,000 | 20,000 |40,000) [Gheck for eakagomnoses, campy] —O 2 Cooling [Check the water level 3 a ‘System [Check the V-belt tension o Ghange the coolant water e Check for leakage o (Check the oll level gauge o Lubrication e SSyotem Change the lubricating ol = Replace the oil filer cartridge i. Check the leakage for inereooler Intake & (hoses, clamp) ° exhaust oe jean and change System the air cleaner element ° ‘Drain the water in separator o (Clean tho fuel strainer lof fuel feed pump ° rues [Sheek the fuetiine eakage _|_O System | Check the fuel line timing — Replace the fuel liter oariage © (Check the injection nozzles ai, Check the exhaust gas sate | O (Shock the battery charging | _O. Engine When ‘neck the compression pressure raha [oheek he comeression pe = ‘Adjust Intake/Exhaust Wren valve clearance ceaeary + (@) The engine oil change interval is determine by engine use and oil grade. 2.3.3. Use of original parts for repair and replacement For engine is being mechanically harmonized with many parts, only when the original parts that the manufacture recommends to use Is used, the engine trouble would be preventively maintained and capable to keep up the maximum performances. For the analogous parts not the original parts are poor in qualities and gives ill performances, It may rather bring early engine failure MAJOR MAINTENANCE 323. DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS. 3.1. Disassembly 3.1.1. General precautions @ Maintenance operation should be carried out in a bright and clean place. @ Before disassembly, provide parts racks for storage of various tools and disassembled parts. @ Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to them. 3.1.2. Cooling water @ Remove the radiator cap. Open the drain plug at the radiator lower part to drain the coolant as the right figure. CAUTION : When removing radiator filler cap while the engine is still hot, cover the cap with a rag, then turn it slowly to release the internal steam pressure ‘This will prevent a person from scalding with hot steam spouted out from the filler port. @ Remove the drain plug from the cylinder block and drain out the cooling water into a container. LH) Jeseosor0 ENGINE DISASSEMBLYEngine oil @ Take out the oll level gauge, @ Remove the oil drain plug of oil pan and drain out the engine oil into a prepared container. @ Reassembie the drain plug with the ol pan ater draining out the engine oil OMa00%1 |. Engine Control Unit : ECU (DE12TIS) @ Remove the wiring harness and the engine control unit. (ECM) EaMso2ol | | Engine harness Water temp. Pre stroke ECU connector Rack Air beater Ne sensor relay 3.1.5. Cooling fan @ Remove the flange fixing bolts, then take off the flange and cooling fan. _EaMs00A | ENGINE DISASSEMBLY 734-3.1.6. V-Belt @ Loosen the tension adjusting nuts on - the alternator, and take off the alternator belts, Ai con, ‘compressor Alternator 3.1.7. Alr con. compressor @ Remove the air con. compressor fixing bolts and disassemble the air con. compressor, @ Remove the tension adjusting bolt and bracket 3.1.8. Oil level gauge guide tube @ Loosen the flange nut installed on the ladder frame to remove the guide tube. _ omc | 35 ENGINE DISASSEMBLY3.1.9. Fuel filter @ Remove fuel hoses connected to the fuel injection pump, take off the bracket fixing bolts, then disassemble the fue! filter. 10. Breather @ Loosen the clamp screw to remove the rubber hose. 3.1.11. Intercooler @ Tear down the various hoses and air pipes from the inter cooler @ Remove the intercooler fixing bolts and tear it down. 3.1.12. Fuel injection pipe @unscrow the hollow screws to disassemble the fuel retum pipe. @ Remove the nuts installed on the fuel Injection pump and nozzles, then disassemble the injection pipe. ENGINE DISASSEMBLY ~36-3.1.13. Air heater @ Remove the electrical wiring for the air heater. @ Disassemble the intake pipes by loosening the nuts installed thereon, @ Disassemble the air heater and gasket. 3.1.14, Intake mai Ic @ Remove the air hose connected to the fue! injection pump. @ Loosen the intake manifold fixing bolts, then disassemble the intake manifold 3.1.15. Turbo charger @Release the clamp screw of the rubber hose connected to the intake manifold, and take off the intake pipes both simultaneously. @ unscrew the exhaust pipe bracket {fixing bolts, release the nuts installed on the turbocharger, then disassemble the exnaust pipe. @Remove the turbocharger after removing the oil supply pipe and return pipe and releasing the fixing nuts. 3.1.16. Exhaust manifold @ Release the exhaust manifold fixing bolts, disassemble the exhaust ‘manifold, then remove the heat shield and gasket, NOTE: Make sure to release the nuts one after another because the exhaust manifold will be removed if you unscrew two nuts simultaneously, "a7 ENGINE DISASSEMBLY9.1.17. Thermostat @ Remove the by-pass pipe connected to the water pump, unscrew the thermostat fixing bolts, then disassemble the thermostat housing. @ Disassemble the thermostat housing and remove the thermostat. @ Disassemble the water pipe by unscrewing the bolts and nuts installed on the cylinder head 3.1.18. Starter @ Unscrew the starter fixing bolts, then disassemble the starter. 3.1.19. Cooling water pump @ Remove the water pipe connected to the expansion tank. @ Remove the water pipe and hoses connected to the water pump. @ Unscrew the water pump fixing bolts and remove the water pump. 3.1.20. Air compressor @ Remove the oil hoses, water pipe, air pipe connected to the air compressor. @ Remove the air compressor fixing bolts, then disassemble the air ‘compressor from the timing gear case. ENGINE DISASSEMBLY 38-3.1.21. Fuel injection pump @Remove the oil supply pipe and return pipe connected to the fuel Injection pump, @ Unscrew the bolts connecting the ‘coupling and drive shaft, loosen the Injection pump attaching bolts, then disassemble the injection pump, NOTE: Place the No.1 cylinder in ‘OT’ in exact Position to disassemble the injection pump. @ Release the pump fixing bracket bolts to disassemble the bracket from the cylinder block. a moet pe mewea Ionia a @Using @ filter remover wrench, OY ere ne tine conage @ Remove the pipe connected to the oil cooler. @ Loosen the cil filter fixing bolts and disassemble the oil fiter head from the cylinder block. 3.1.23. Idle pulley @ Remove the bolts and disassemble the fan drive pulley. os ENGINE DISASSEMBLY3.1.24. Power steering pump @ Remove the oil hoses, @ Unscrew the hex bolts and remove the steering pump. 3.1.25. Vibration damper @ Unscrew the pulley fixing bolts and disassemble the pulley-vibration damper assembly. © Unscrow the vibration damper fixing bolts and disassemble the damper from the pulley 3.1.26. TI ing gear case cover @ Disassemble the oil seal using an oil @ Remove the cover fixing bolts and disassemble the cover from the timing gear case 3.1.27. Idle gear @ Unscrew the idle gear fixing bolts and disassemble the thrust washer and Idle gear. @ Disassemble the idle gear pin using a rubber hammer to prevent damage to them. ENGINE DISASSEMBLY ~40-3.1.28. Fuel injection pump drive @ Remove the dowel pin for the steering pump. @ Unscrew the injection pump drive shaft bearing housing fixing bolts and remove the injection pump drive assembly in which the shaft, gear, bearings, and housing are put together. 3.1.29. Cylinder head cover @ Unscrew the cover fixing bolts and disassemble the cover. @ Koop the bolts in an assembly state so that the gaskets and washers may not be lost, and keep the cover gasket as assembled with the cover. 3.1.30. Rocker arm @ Unscrew the rocker arm bracket bolts and remove the rocker arm assembly. @ Take off the snap rings to remove the washers and rocker arm, then unscrew the bracket fixing bolts to take off the bracket and springs. @ Take out the push rods, 3.1.31. Injection nozzle and tube @ Remove the nozzle fixing nuts and extract the nozzles. @ Remove the nozzle tube using nozzie tube removing jig. NOTE : Do not disassemble the nozzle tube It coolant or gas, ete. does not come out during engine operation. T4T- EAMOOz8! EAMOO901 ENGINE DISASSEMBLY3.1.92. Cylinder head @ Unscrew the cylinder head fixing boris and take off the cylinder head. © Remove the cylinder head gasket. 3.1.83. Valve and stem seal © Compress the valve spring retainer cotter pins, @ Disassemble the valve springs and retainers. @ Take off the valves. @ Remove and discard the valve stem ‘seal using a general tool as it should not be re-used. EAows007 3.1.84. Oil cooler @ Remove the water pipe connected to the water pump. @ Remove the oll pipe connected to the cylinder block and oil filter. @ Unscrew the oil cooler cover fixing bolts and disassemble the oll cooler assembly from the cylinder block, @ Unscrew the oll cooler fixing bolts and remove the cil cooler from the oil cooler cover. 3.1.35. Oil pan @ Stand the engine with the flywheel housing facing the bottom. @ Release the oil pan fixing bolts, remove the stiffeners then. disassemble the oil pan, ENGINE DISASSEMBLY3.1.36, Oil pump and pipe @ Unscrew the oll suction pipe bracket bolts, releasing the pipe fixing bolts, g then disassemble the oil suction pipe ® assembly. @ Disassemble the oil pipe 1 from the oil pump to the cylinder block. @ Unscrew the oll pump fixing borts and disassemble the oil pump. ding oil EAMDOSS! 3.1.37. Ladder frame @ Disassemble the ladder trame. 3.1.38. Relief valve @ Disassemble the relief vaive. 3.1.99. Piston and connecting rod @disassembie the pistons by two cylinders while turning the crankshaft, @ Unscrew the connecting rod fixing bolts and take off the pistons and Hl connecting rods in the direction of i piston { | ie ie ve eaMoosni ~43- ENGINE DISASSEMBLY@ Remove the piston pin snap rings, take off the piston pin, then disconnect the connecting rod from. the piston. @ Disassemble the piston rings using ON reir decom pars ancy mh grecoqpre ina Ne 3.1.40. Cylinder liner @ Disassemble the cylinder liner using a liner puller. EAMDOAO! 3.1.41. Fly wheel @ Position the engine so that the head installing surface of the cylinder block. faces down. @ Unscrew the flywheel fixing bolts and fit a dowel pin. @ install flywheel disassembling botts in the bolt holes machined on the flywheel, and disassemble the flywheel. ENGINE DISASSEMBLY3.1.42. Oil seal @ Take off the rear oil seal using an cil Qe @ 1 only the inside guise ring is removed, use a special tool to take off the outside seal 3.1.43. Flywheel housing @ Loosen the housing fixing bolts and disassemble the flywheel housing. 3.1.44. Cam shaft and tappet @ Remove the cam shatt gear. @ Take off the cam shaft gear and thrust washer, @ Take out the cam shaft care not to damage the cam shaft, @ Siide out the tappets by hand 3.1.48. Crankshaft gear and oil pump idle gear es a ENGINE DISASSEMBLY3.1.46. Timing gear case @ unscrew the case fixing bolts and disassemble the timing gear case. 3.1.47. Crank shaft @ Remove the main bearing cap fixing bolts in the opposite direction of a assembling, ie @ Maintain the removed bearing caps in the order of cylinders. @ Temporarily install the bolts at the both side of crankshaft, and lift the ‘shaft with a rope. 2] ‘EANNDONTS| NOTE - Do not mingle with the metal bearings and bearing caps randomly. To prevent mixing, temporarily assemble the metal bearings to the corresponding bearing caps in turn. 3.1.48. Oll spray nozzle @ Unscrew the fixing bolt and remove the oil spray nozzles. ENGINE DISASSEMBLY ~46-3. Inspection and Measurement 3.2.1. Cylinder block 1) Clean the eylinder block thoroughly and make a visual inspection for cracks or damage. 2) Replace if cracked or severely damaged, and correct if slightly damaged. 98) Check oil and water flow lines for restriction or corrosion, 4) Make a hydraulic test to check for any cracks or air leaks. Hydraulic test ‘Stop up each outlet port of water/oll passages in the cylinder block, apply air pressure of about ‘4kg/emn? against the inlet ports, then immerse the cylinder block in water for about 1 minute to check any leaks. (Water temperature: 70 °C) 3.2.2. Cylinder head 1) Inspection © Carefully remove carbon from the lower lace of the cylinder head using nonmetallic material to prevent scratching of the valve seat faces. @ Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight using a hydraulic tester or a magne! 2) Distortion at the lower face @ Measure the amount of distortion using a straight edge and a tecler gauge at six positions (A ~ F) as shown in the right figure. @ it the measured value exceeds the standard value, retrace the head with grinding paper of fine grain size to correct such defect. @ it the measured value exceeds the maximum allowable limit, replace the cylinder head, Low face warpage and height ‘Standard | Limit Warpage | 0.2mm orless | 0.3 mm Thickness : = 115.0 mm/113.9 mm (ieleenoe) fea econ Enomeon9 a INSPECTION & MEASUREMENT3) flatness @ Measure flatness of the intake/exhaust manifolds fitting surfaces on the cylinder head using a straight edge and a feeler gauge. ‘Standard Limit (0.05 mm 2mm 4) Hydraulic test @ Hydraulic test method for the cylinder head is same as that for cylinder block. 3.2.3. Valve and valve guide 4) Valve Clean the valves with clean diesel oll, then inspect them as follows Valve stem outer diameter Measure the valve stem outer diameter at 3 positions. (top, middle, ‘and bottom) If the amount of wear is beyond the limit, replace the valve. = Valve stem Standard | Limit fl \ \ = val ee, | 10980 ~F10870 mn $10.87 mm = T T D a I — > eruosel ateust, | oss #0085 nn $10.84 mm @ Valve seat contacting faces Check the valve seat contacting faces for scratches or wear, and correct the faces with grinding paper as necessary. Replace it severely damaged. @ Valve head thickness iz Measure the valve head thickness, land replace the valve if the measured value Is beyond the limit. Standard | Limit esenptio® intake vave | 1Smm_|1mmor less Ehavstvaie | 15mm _[0@mmorless INSPECTION & MEASUREMENT2) Valve guide @ install the vaive into the valve guide and measure the clearance between them by valve movement. It the clearance is excessive, measure the valve and replace either the valve or the valve guide, whichever worn more. Valve stem end play Measuring Point Li nomaos2 ‘Standard Limit intake valve | 0.04 ~ 0.07 mm 02 mm Exhaust valve | 0.06 ~ 0.08 mm 0.25 mim @ install the vaive into the cylinder head valve guide, then check and see if i the valve seat using a special tool 8) Valve seat is centered with © Contacting face amount Measure the contacting face between the intake valve seat and exhaust valve seat for valve seat wear, and replace if the measured value ‘exceeds the specified limit, @ Install the vaive into the vaive seat on the cylinder head, and check the amount of depression of the valve from the lower portion of the cylinder head using a dial gauge. Valve depression Vavle I i Vavie seat | ‘Standard Limit intake & | 9- 0.03mm Exhaust 0.55 mm Hf the amount of depression is beyond the specified limit, replace the valve seat. “a7 INSPECTION & MEASUREMENT@ Undercool a new valve seat with dry Jce for about 2 hours and press the valve seat insert into position in the cylinder head using a special tool (bench press). @ Apply valve lapping compound to the Vavle seat ingert Cylinder head Welding bead eaayzose valve head seating face on the valve seat and lap the valve seat by turning it until itis seated in position, then wipe out the lapping compound. 4) Valve spring @ Visual check @ Functional check -Measure free length and spring tension with a valve spring tester, (Reter to appendix) = Measure the spring inclination with a square. = Compare the measured value with the standard value to determine whether to replace or repair. T ‘Standard] Limit Valve | DEI2/T/TI | 1.0 mm spring 12.0 mm inclination | DE12TIS_ | 1.7 mm INSPECTION & MEASUREMENT 30 Visually check the exterior of the valve springs for damage, and replace if necessary. — samo Froe length3.2.4. Rocker arm shaft assembly 1) Rocker arm shaft @ Rocker arm shatt run-out Place the rocker arm shaft on two V blocks and inspect the shatt for bend using a dial gauge. @ 1 the amount of this run-out is small, press the shaft with a bench press to ‘correct the run-out. Replace the shatt it the measured value exceeds the limit. Limit 0.2 mm @ Rocker arm shaft diameter With an outside micrometer, measure the rocker arm shaft diameter at the point where the rocker arms have been installed. | Replace the rocker arm if the amount of wear is beyond the specified limit. ‘Standard ¥23,078 ~ 923.059 mm Limit 23.75 mm 2) Rocker arm @ Visual check OO) eDMz0s71 Visually check the face of the rocker arm in contact with the valve stem end for scores and step wear. If the wear is small, correct it with an oll stone or grinding paper of fine grain size. Rocker arm with a considerable amount of step wear should be replaced. © Diameter bushing Measure the inside diameter of the of the rocker arm ial rocker arm bushing with an inside micrometer or verier calipers, and compare the measured values with the rocker arm shaft diameter. If the clearance exceeds the limit, replace either bushing or shatt, whichever worn more. Standard 0.020 ~ 0.093 mm O2 mm EAOMAO5S 37 INSPECTION & MEASUREMENT5) Tappet and push ro @ Clearance fe Measure the clearance of the tappet and tappet holes of the cylinder block. if the value is beyond the specified limit, replace tappets. ig @ Visual check of tappet Visually check the face of the tappets —— ‘cracks or pitting Is small, correct with J SrUeevernes. 2) Crk () Normal stone or grinding paper. (ui) Le @ Outside diameter Abnormal eA0MAo70 With an outside micrometer, measure | the tappet outside diameter If the measured value is beyond the limit, | replace tappets. Standard | Limit Tappet reer ce] 0.085 ~ 0.07 mm | 0.15 mm ‘Tappet diameter [19.984 - 419.965 mm EDW206 A @ Push rod run-out Limit (0.3 mm or less, Use a feeler gauge to measure the push rod run-out. Roll the push rod along a smooth flat surface as shown in the figure. EAOMAO7S fecler gauge INSPECTION & MEASUREMENT 323.2.5. Cam shaft 1)cam © cam lobe height Use a micrometer to measure the cam lobe height and journal diameter. If the measured value is less than the specified limit, the camshatt must replaced, unit: mm Standard [Limit am obe| ie | 50.05 A508] |” height (C)| intake [50.06 ~#59.88 fam journal jamete (48) 459.86 ~#59.88| $59.52 @ cam surtace Inspect the cam face for scratch or damage, @ Sight step wear or damage on the cam face may be corrected with oll stone or olled grinding paper. But, replace if severely damaged. 2) Cam shaft @Clearance between camshaft journal and camshaft bush -With an outside micrometer, measure the camshaft journal diameter. - Measure the inside diameter of the ‘camshaft bushing on the cylinder block using a cylinder bore indicator, and compare the measured value with the camshaft outside diameter to determine the clearance. ‘Standard Limit EAoNa06s 0.050 ~0.128mm_ | 02mm Replace the bushing if the measured value is beyond the specified limit INSPECTION & MEASUREMENT@ Run-out ‘Support the camshatt on two V blocks | land check for run-out using @ dial Incater Corect or replace the cam | shaft if the amount of run-out is | beyond the value indicating need for servicing, ‘Standard Limit | (0.05 mm o2 mm 3) Cam shaft end play FE goa @ wih a fecler gauge, measure the clearance between the thrust plate and camshaft gear. | @ If the ond play is excessive, replace the thrust plate. Feeler gauge cee | Tis bar mm | Bs = Aouo67 3.2.6. Cam shaft 41) Defect check @ Visually check the crankshaft journal and crank pins for scores or cracks. @ Using a magnetic particle test and color check, Inspect the crankshaft for cracks, and replace the crankshaft which has cracks. 2) Wear @ with an outside micrometer measure the diameter of the crankshaft journals and pins in the directions as shown, and compare the measured values to determine the amount of INSPECTION & MEASUREMENT Ba@11 the amount of wear is beyond the limit, have the crankshaft grind and install undersize bearings. However, If the amount of wear is within the limit, you can correct the wear using an oll stone or olled grinding paper of fine grain size. (Be sure to use grinding paper which has been immersed in | oil) EF M20471 ‘Standard Limit Journal diameter | 95.966 #05.088 | #04.966 mm [Pin diameter 702.966 - fe2 588 | F87.066 mm * Undersize bearings availablo © Standard © 0.26 (Inside diameter is 0.25 mm lesser than the standard size.) © 0.50 (Inside diameter is 0.50 mm lesser than the standard size.) © 0,75 (Inside diameter is 0.75 myn lesser than the standard size.) © 1.00 (Inside diameter is 1.00 mm lesser than the standard size.) Undersize bearings are available in 4 different sizes as indicated above, and the crankshatt can be reground to the above sizes. wore ee Standard Limit 0.072 ~ 0.142 mm | __0.25mm © Connecting rod bearing clearance Install the connecting rod bearing in the connecting rod bearing cap, tighten the connecting rod cap bolts | to the specified torque, then measure the inside diameter. Teraue wien 4 ‘Standard | 983.02 - 983.082 mm | ‘Compare the two values obtained through measurement of connecting fod bearing inside diameter with the outside diameters of crankshaft pins to determine the oil clearance. | see) EAuuDoe0! INSPECTION & MEASUREMENT@ If the clearance deviates from the journals and pins grind and install undersize bearings, 8) Bearing spread and crush @ inspection Check to see that the bearing requires a considerable amount of finger pressure at reassembly ‘operation, Epwzo4a7t © Crankshatt bearing crush Install the bearing and cap in the cylinder block, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and cylinder block using a teeler gauge. Standard_| 0.17 —0.13mm @ connecting rod bearing crush Install the bearing and cap in the connecting rod big end, retighten the bolts to specitied torque, unscrew out ‘one bolt completely, then measure the clearance between the bearing cap and connecting rod big end using a feeler gauge. Standard _| 0.086 ~ 0.116 mm EaMooest 737 INSPECTION & MEASUREMENT4) Crank shaft end play @Assomble the crankshaft to the oylinder block. @with a dial gauge, measure crankshaft end play. ‘Standard Limit 0.15 ~ 0.025 mm | 05mm 3.2.8. Piston 1) Visual check eB © Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring groove, 2) Clearance between the piston and cylinder liner @ with an outside micrometer, measure the piston outside diameter at a point 18mm away from the lower end of Position of measuring piston skirt in @ direction at a right ais dae angle to the piston pin hole. ‘Standard [#122679 ~ #122877 mm 18mm) ia EAMO065! @ Using a cylinder bore gauge, measure cylinder liner inside diameter at 3 points (cylinder top ring contacting face, middie, and oll ring contacting face on BDC) in a direction at an angle of 45° Take the mean value ¥ h the ‘Standard Limit #128 ~ $123.023 mm [123.223 mm largest and smallost values oxcopted | | eawoven @ The clearance is computed by subtracting the piston outside diameter from the cylinder liner Inside diameter. Replace either piston or cylinder liner, whichever damaged more, if the clearance is beyond the specified limit, Clearance between piston and liner Standard | 0.113 ~ 0.162 mm INSPECTION & MEASUREMENT 7583.2.9. Piston rings 1) Visual check Replace the piston rings with new ones if detected worn or broken when the engine is overhauled, 2) Piston ring gap @ Insert the piston ring into the upper portion of the cylinder liner bore so that it is held at a right angle to the cylinder liner wall. @ Measure the piston ring gap with a Feeler gauge feeler gauge. ‘Standard [Limit 030-048 mm | FS 2nd ring (0.35 — 050 mm |S mm — [pEarmil 030-050mm) | "S "evans | 040- 070mm enomaoss ou 15mm @ Replace piston rings with new ones if the gap is beyond the limit 3) Piston ring side clearance @ Fit the compression ring and oll ring in the piston ring groove. @ With a fesler gauge, measure side clearance of each ring, and replace either the ring or piston if the measured value is beyond the specified limit, ‘Standard | Limit Top rng 7 [2néring | 0.07 ~ 0.102 mm | 0.15 mm 2nd ring | 0.05 - 0.085 mm | 0.15 mm 4) Piston ring tension @ with a tension tester, measure piston ring tension @ Replace the piston ring if the measured value is beyond the limit. Standard Top mma | 227-3469 Bnding [20-309 On ing | 4.08 5.57 Kg INSPECTION & MEASUREMENT3.2.10. Piston pin 4) Wear @ Measure the amount of wear on the piston pin at the points as shown. @ it the measured values are beyond the limit (0.005 mm or greater), replace the pin. ‘Standard Limit $44,995 ~ #450 mm_| $44,900 mM or ess 2) Clearance @ Measure the clearance between the piston pin and connecting rod bushing, and replace either of them, | whichever damaged more, it the measured value is beyond the limit. 5 } Limit 0.011 mm | y/ | | 3) Condition check [Ee xaMa047 © Check the engaged condition of the piston and piston pin. If itis possible to force the pin into the piston heated with piston heater, the piston is normal ‘When replacing the piston, be sure to replace the piston pin together. 3.2.11. Connecting rod 4) Distorsion @ Check the connecting rod for distortion. @ As shown in the figure below, install the connecting rod to the connecting rod tester, and check for distortion using a feeler gauge. @ It tne connecting rod is found distorted, never re-use it but replace with a new one. 2) Holes alignment (parallelism) @Measure the alignment of the connecting rod small bushing hole with connecting rod big end hole. @ At this time also, use both connecting rod tester and feeler gauge. ‘Standard Limit 005mm | 0.1 mm orless INSPECTION & MEASUREMENT3) Wear @ Assemble the connecting rod to the crankshaft and measure connecting rod big end side clearance using a feeler gauge. @ Assemble the connecting rod to the piston and measure connecting rod small end side clearance. @ I the measured values are beyond the limit, replace the connecting rod, Limit 0.5 mm @ insert a seal ring and injection nozzle I ‘on the cylinder head. Fuel injection nozzle @ Measure the clearance between the eyfinder head bottom and nozzle tp. the measured values are beyord tne | limit, replace the sea ng. Cylinder head Standard | DEV] DEIZTIS: a Tacks of sealing] 27 am Nozzle tube (rojo nomi [84~28 mi] 24 ~ 25 me EaMeoi01 Ter INSPECTION & MEASUREMENT3.3. Reassembly 3.3.4. 3.3.2. 3.3.3. General precautions @ wash clean all the disassembled parts, particularly oll and water ports, using compressed air, then check that they are free from restrictions. @ Arrange the general and special tools in order for engine assembly operation. @ To wet each sliding part, prepare the clean engine oi © Prepare service materials such as sealant, gaskets, etc. @ Discard used gaskets, seal rings, and consumable parts, and replace with new ones. @ Apply only the specified torque for bolts in the specified tightening order and avoid over- tightening. @ Be sure to check that all the engine parts operate smoothly after being reassembled @ Check the bolts for looseness after preliminary reassembly. @ Atter completing the engine reassembly operation, check if there is missing parts or shortage of parts. @ Keep your hands clean during the wor Cylinder block King. @ Cover the floor of the workshop with wood plate or thick paper to prevent damage to the cylinder head and place the cylinder block with the head fitting surface facing downward, Oil spray nozzle @ Tighten and assemble the cil spray nozzle flange with fixing bolts using the spray nozzle jig. 3.3.4. Tappet and cam shaft @ Undercoo! a new bush with dry ice for about 2 hours and press it into position in the cylinder block using a bench press. After the pressing operation, measure the inside diameter of the cam bush to check if it Is not deformed, o| °\ ron DM20581 ENGINE REASSEMBLY TaEt@ Apply engine oil to the entire face of the tappets and slide them into the tappet holes on the cylinder block. @Check to see that the camshaft rotates smoothly. 3.3.5. Crankshaft @ install the main bearing machined | that the key is aligned with the kéy groove, then apply oll to the bearing surface. @ Heat the crankshaft gear for at least 10 minutes to 120°C, then apply sealant (Loctite # 641) to the inside wall of the heated crankshaft gear ‘evenly betore inserting it to the end of crankshatt. ease | TST ENGINE REASSEMBLYjournals and pins, then assemble the tomerng he ng bt @ Install the oiled thrust washers with the oil groove facing outward. @ Install the bearing and thrust washers to the bearing cap and apply oil to the bearing and thrust washers. @ Install the bearing cap by matching the cylinder block No. with the bearing cap No. ENGINE REASSEMBLY eae@ Apply ol to the entire part of the bearing cap bolts, then tighten in Al tightening sequence to specified torque. Torque 80 kgm @ After semitightening both bolts evenly, tighten them diagonally to about 15kg:m for the first stage and 25 kgm for the second stage respectively, then tighten them completely to the specified torque using a torque wrench. @ Tighten the bearing cap in the sequence of 4-3-5-2-6-1-7. @ Check to see that the assembled crankshaft turns smoothly. 3.3.6. Flywheel housing @ Temporarily install the guide bar on the cylinder block. @ Apply gasket to the cylinder block. @Using the dowel pin and guide bar, tighten the fixing bolts in a diagonal ‘sequence to specified torque. Torque 42 kgm 3.3.7. Rear oll seal @ Apply lubricating oil to the outside of 765 - ENGINE REASSEMBLY3.3.8. Flywheel @ Install a guide bar into a bolt hole on tan ut re gue ba hon ta (© Tighten the fixing bolts using a torque wrench in a diagonal sequence to specifies torque. Torque | 18kgm 3.3.9, Magnetic pick-up sensor @ Move the lock nut to hexagonal side of sensor completely. @ Rotate (Cicokwise) the pick-up sensor on flywheel housing, until the end of it reach on tly wheel ring gear. @ Then rotate (Counter clockwise) the pick-up sensor for 270° (gap 1.0 mm) land fix lock nut @ Tolerance limit is 27° (gap ++ 0.1 mm) ing gear 33 M615 20901 Tolerance lt i Pwo | ENGINE REASSEMBLY 66 -3.3.10. Timing gear case @ Mount gasket using dowel pin on the cylinder block. @ Install the timing gear case by aligning the dowel pin with the dowel pin hole on the ming gear case. 3.3.11. Timing gear @ install the oll pump idle gear onto the No.7 bearing cap. @ install a thrust washer over the camshaft and assemble the cam gear by aligning it with camshaft key groove. Torque 38 kgm End play Limit 0.13- 027mm | 030mm @ With the oil port on the idle gear pin facing the cylinder block, install the late gear pin, Install the idle gear by coinciding the Torque 7.4 kgm @ Check and adjust the amount of backlash between gears using a feeler gauge. Backlash | 0.15 ~0.25 mm Ter HIN. ©\_ tale gear pin (pune ave pour ENGINE REASSEMBLY3.3.12. Fuel injection pump drive gear @ Mount gasket by aligning the bolt holes with the pin holes on the bearing housing. @ Tighten the fixing bolts in the direction of fuel injection pump. 3.3.13. ing gear case cover @ install dowel pin on the timing gear case. @ Mount a gasket by aligning the fixing bolt noles with those on the gasket, @ Align the dowel pin with the cover pin hole, then install the cover with light tap. @ Tighten the fixing bolts beginning with the oil pan fitting face. 3.3.14, Front oil seal Srrtna, nen ase ofS 3.3.15. Cylinder liner @ Stand the cylinder block so that the flywheel faces downward. Thoroughly clean the liner flange fitting surface and bore inside with compressed air to prevent the entry of foreign substances. @ Aiter the cleaning operation, make the cylinder liner dried up and push it into the cylinder block by hand. @ Wet the liner inside diameter with engine oil ENGINE REASSEMBLY TE- Oil seal fiting fig EAWDOB6:3.3.16, Piston and connec 1g rod approximately 100 °C (212 "F) for § minutes. IQ @ Use a piston heater to heat the piston @ Align the piston pin hole with the oiled connecting rod small end and press the piston pin (by lightly tapping with a rubber hammer) to assemble the connecting rod with the piston. @ Noting the direction of the piston, [eel ree ne lng a rac wr key groove on the bearing) of the connecting rod big end and the marc of “Wp impressed on the inside of the piston face each other in opposite directions. On the piston head surface, the longer side of connecting rod big end is in opposite direction from the valve seating surface as well as in the same direction with the narrow margin of combustion chamber. @ Install the snap rings and check to see that it is securely assembled @ install the piston ring in the piston using piston ring pliers, To AMO ENGINE REASSEMBLYee eo @ Position the valve seating surface toward the tappet hole and insert the piston with hand, Use care not to damage the cylinder liner and piston, and slightly lift and insert the piston into the cylinder so that the ring may not be damaged by the fillet of the liner. @ Install the bearing in the connecting rod cap and apply oil. @ Make sure that the manufacture serial numbers impressed on the connecting rod cap and connecting rod big end are Identical, and install the connecting rod cap by aligning it with dowel pin. @ Wet the fixing bolts with oil, semi tighten them with hand, tighten them to 15 kgm for 1st stage and 22 kg.m for 2nd stage respectively, and finally to specified torque, Torque | 28kgm ENGINE REASSEMBLY Marked with the name of piston ring ‘manufacturing company | A6M3006@ Move the bearing cap with hand, and release and reassemble it if no movement is detected, 3.3.17. Relief valve @ Assombie the relief valve. 9.9.18. Ladder frame © Cut out the gasket protruding from the joints of the timing gear case, case cover and flywheel housing. © Apply silicon to each joint and attach gasket to the cylinder block. @ Tighten fixing bolts at both ends, intermediate bolts and remaining bolts in the described order. 3.3.19. Oil pump and oil pipe @ Install a dowel pin in the No.7 bearing cap, then assemble the oll pump with specified torque. Torque | 4.4 kgm @ Assemble the oil suction pipe with the delivery pipe, then install the bracket ‘on the bearing cap. ENGINE REASSEMBLY3.3.20. Oil pan @ Mount gasket and put the oil pan thereon © Place stiffeners and tighten bots. © Align the bolt holes with gasket holes to prevent damage to the gasket and tighten to specified torque. Torque 2.2 kgm 3.3.21. Intake and exhaust valves @Icentity the marks of “IN” and “EX” impressed on the valve head before assembling the valve with the valve head. © Using the valve stem seal fiting jig assemble the valve stem seal with the valve guide @ Aiter installing valve springs and spring retainer, press the retainer with 2 ig, then install cotter pin @ Tap the valve stom lightly with a rubber hammer to check that the valve is assembled correctly. ENGINE REASSEMBLY Compress the spring 723.3.22. Nozzle tube | © Apply sealant (LOCTITE # 620) to the ele peta ieee © Apply engine oll to an expander and install it onto the special tool (guider) © Tighten the bolts until the expander is. forced out of the cylinder head bottom. @ After mounting the nozzle tube, make a hydraulic test to check for water leaks, Test pressure 2 kglom* 3.3.23. Rocker arm assembly © Apply lubricating oil to the rocker arm bush and shaft, and assemble the I intermediate bracket with the rocker arm using fixing bolts. Torque | 44kgm © Semi-install valve clearance adjusting bolts onto the rocker arm. EAWDI001 773 ENGINE REASSEMBLY@ Install the spring, rocker arm, bracket, rocker arm, spring, washer, and snap fing in the described sequence. @ Install the rocker arm and bracket in the same direction. .24, Cylinder head @ Install the injection nozzle fixing stud bolts and water pipe fixing stud bolts. @Clean the head bolt holes on the cylinder block with compressed air to remove foreign substances and thoroughly clean the gasket fitting face of the cylinder block. el @ Install head gasket, with “TOP” mark facing upward, on the cylinder block by aligning the holes with dowels. yinde [Ashes core pe] Seri tel yoo ead | gasket | Pibeercsor Black [Auster eaor- ea Use bt @ Check the inside of combustion ‘chamber for foreign substances, and EaMDr01! | carefully mount the cylinder head —* OO assembly in the block by aligning the dowel pin with the dowel pin hole, Be careful not to damage the head gasket. If the dowel pin is not in alignment, lit the cylinder head again and then remount it, ENGINE REASSEMBLY 74al © Coat the head bolts with engine oll, [ then tighten them in proper sequence to the specified torque. Tee Type? we caer] Tee asx sts | 4X1 8410 lavas] Tighten aegm ramen | sestam |: t Fred 150 iheigm 2 00 Fashed 30 © Coat the push rod with engine oil and isert it into the push rod hole. Ele the valve clearance as following guide. O®OO®@ EAwD1091 © ater letting the #1 cylinder’s piston come at the compression top dead center by tuming the crankshatt, adjust the valve clearances. @ Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge of specified value between a rocker arm and a valve stem and adjust the clearance with adjusting screw respectively and then tighten with the lock nut. EL As or he vate cloarance, acs! it when In col, a fotow Mode! | Intake Valve | Exhaust Valve DE2 peWT 0.3mm 0.3mm Det2Tt peteris | - By cranking the engine, let #6 cylinder’s valves overlap, - In time, adjust the valve clearance corresponding to “ => of lower figure. ~ Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top. dead center. - Adjust the valve clearance corresponding to “mi * of lower figure. - After reinsuring the valve clearances, retighten if necessary. = ~75- ENGINE REASSEMBLY