Manual Doosan V158ti Doosan 2002 Español Parte 2

FOREWORD
This manual is designed to serve as a reference for the operation & Maintenance of V158TI / V180TI
/ V222TI Marine engines and AD158TI / 180TI / 222TI marine generator engine united in one book.
The former is explained for operation and the latter is described for maintenance like parts disassembly,
maintenance & inspection and re-assembly etc in order to available understanding the maintenance
procedure more easily.
To maintain the engine in optimum condition and retain maximum performance for a long time,
CORRECT OPERATION and PROPER MAINTENANCE is 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
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 manual instruction may be changed without notice for some quality
improvement. Thank you.
May. 2002.
Doosan Infracore Co., Ltd.
CONTENTS
1. SPECIFICATION............................................................................................................. 1
1.1. Engine Specification 1.3. Engine Performance Curve
1.2. Engine Aspects 1.4. Engine Model & Serial Number
2. SAFETY REGULATIONS ............................................................................................. 11

2.1. General Notes 2.4. Regulations Designed to Prevent Pollution
2.2. Regulations Designed to Prevent Accidents 2.5. Notes on Safety in Handling Used Engine Oil
2.3. Regulations Designed to Prevent Damage
3. COMMISSIONING AND OPERATION.......................................................................... 15

3.1. Inspections before Operation 3.5. DAEWOO Dealer Service -50 Hour Check
3.2. Starting 3.6. Operation in Winter
3.3. Engine Break-in 3.7. Tuning the Engine
3.4. Inspection after Starting
4. GENERAL INFORMATION........................................................................................... 24
4.1. General Repair Instructions 4.6. Fuel System
4.2. Periodical Inspection & Maintenance 4.7. Electric System
4.3. Cooling System 4.8. When the Engine is not Used Long Time
4.4. Lubrication System 4.9. When the Engine is Sunk
4.5. Intake & Exhaust System
5. MAIN ACCESSORY PARTS......................................................................................... 45

5.1. Reduction Gear 5.3. Propeller Selection
5.2. Power Take Off (FPTO) 5.4. Electric System
6. DISASSEMBLY & ASSEMBLY OF MAJOR COMPONENTS...................................... 58

6.1. Disassembly 6.3. Engine Re-assembly
6.2. Inspection 6.4. Break-in after Maintenance
7. MAIN PARTS MAINTENANCE................................................................................... 104

7.1. Lubricating System 7.3. Fuel System
7.2. Cooling System 7.4. Turbo-charger
8. TROUBLE SHOOTING ............................................................................................... 166
9. SPECIAL TOOL LIST ................................................................................................. 172
¥ APPENDIX
1. SPECIFICATION
1.1. Engine Specification
1.1.1. V158TI
Marine Engine Specification

V158TI
Model Units
V158TIE V158TIH V158TIM V158TIL
4 cycle, V type, direct- injection, water cooled

Engine type
with wet turbo charger & inter-cooler
Rating output (B.H.P) PS(kW)/rpm 420(309)/1,800 480(353)/1,800 540(397)/2,10 680(500)/2,300

Displacement cc 14,618
Cylinder number - bore(N) x stroke mm 8 - N128 x 142
Valve clearance at cold In / Ex mm 0.25 / 0.35
Low idling rpm rpm 725 ± 25
No load max. rpm rpm below 2070 below 2070 Below 2415 below 2645
Mean effective pressure kg/cm 2
14.47 16.42 15.84 18.21
Mean piston speed m/sec. 8.52 8.52 9.94 10.89
Compression ratio 16.5 : 1 15 : 1
Firing order 1-5-7-2-6-3-4-8
Max. firing pressure of cylinder kg/cm2 130 130 128 150
Compression pressure at 200 rpm kg/cm 2
28 (Initial Condition)
Governor type of injection pump Mechanical variable speed (R.Q.V)
g/PS.h 155 155 163 185
Fuel consumptio n
liter/h 90 90 106 152
Injection timing (B.T.D.C) deg 26û ± 1û 24û ± 1û 24û ± 1û 24û ± 1û
Fuel inj. nozzle opening pressure kg/cm2 286
Starting system Electric Starting by starter motor
Starter motor capacity V - kW 24 - 6.6
Alternator capacityV - A 24 - 50
Battery V - Ah 24 - 200
Cooling system Indirect sea water cooling with heat exchanger
Cooling water capacity Max. / Min. lit. 89 / 78
Fresh water pump type Centrifugal type, driven by v-belt pulley
Sea water pump type Bronze impeller type driven by v-belt pulley
Lubricating oil pan capacity lit. Max : 31, Min : 25 (Engine total : 35)
(Engine) pressure kg/cm2 Full : 3.5, Idle : 1.2
crankshaft Counter clockwise viewed from stern side
Direction of revolution
propeller Clockwise viewed from stern side
Engine size without M/G mm 1337x1222x1074 1,337 x 1,222 x 1,074

(L x W x H) with M. gear mm 1777x1222x1115 1,872 x 1,222 x 1,111
without M/G kg 1,300 1,300
Engine dry weight
with M. gear kg 1,590 1,710
-1-
1.1.2. V180TI

V180TI
Model Units
V180TIH V180TIM V180TIL

Engine type
Rating output (B.H.P) PS(kW)/rpm 600(441)/1,800 650(478)/2,100 820(603)/2,300

No load max. rpm rpm Below 2,070 Below 2,415 below 2,645
16.42 15.25 18.56
Mean piston speed m/sec. 8.52 9.94 10.89
Compression ratio 15 : 1
Firing order 1 - 6 - 5 - 10 - 2 - 7 - 3 - 8 - 4 - 9
Max. firing pressure of cylinder kg/cm 2
130 128 150
28 (Initial Condition)
g/PS.h 153 156 185
Fuel consumption
liter/h 111 122 183
Injection timing (B.T.D.C) deg 24û ± 1û 24û ± 1û 24û ± 1û
Fuel inj. nozzle opening pressure kg/cm 2
286
Alternator capacity V-A 24 - 50
Cooling water capacity Max. / Min. lit. 92 / 81
Engine size without M/G mm 1,495 x 1,222 x 1,169

(L x W x H) with M. gear mm 2,016 x 1,222 x 1,192
without M/G kg 1,550
Engine dry weight
with M. gear kg 2,065
-2-
1.1.3. V222TI

V222TI
Model Units
V222TIH V222TIM V222TIL

Engine type
Rating output (B.H.P) PS(kW)/rpm 720(530)/1,800 800(588)/2,100 1,000(736)/2,300

No load max. rpm rpm Below 2070 Below 2415 Below 2645
16.42 15.64 17.85
Mean piston speed m/sec. 8.52 9.94 10.89
Firing order 1 - 12 - 5 - 8 - 3 - 10 - 6 - 7 - 2 - 11 - 4 - 9
Max. firing pressure of cylinder kg/cm 2
130 126 150
28 (Initial condition)
g/PS.h 152 160 190
Fuel consumption
liter/h 132 154 229
Injection timing (B.T.D.C) deg 22û ± 1û 22û ± 1û 22û ± 1û
Fuel inj. nozzle opening pressure kg/cm 2
286
Alternator capacity V-A 24 - 50
Cooling water capacity Max. / Min. lit. 98/ 87
Engine size without M/G mm 1,653 x 1,222 x 1,199

(L x W x H) with M. gear mm 2,263 x 1,222 x 1,250
without M/G kg 1,750
Engine dry weight
with M. gear kg 2,460
-3-
1.1.4. AD158TI / AD180TI / AD222TI
Model DV Series
Units
Spec. AD158TI AD180TI AD222TI
4 cycle, V-type, direct-injection, water cooled

Engine type
with wet-turbo charger & inter-cooler
410(302)/1,500 485(357)/1,500 606(446)/ 1,500

50 Hz
PS(kw) (AD158TIIF) (AD180TIF) (AD222TIF)
Rating output (B.H.P)
/ rpm 480(353)/1,800 600(441)/1,800 720(530)/ 1,800
60 Hz
(AD158TIS) (AD180TIS) (AD222TIS)
Displacement cc 14,618 18,273 21,927

Cyl. No - bore(N) x stroke mm 8 - N128 x 142 10 - N128 x 142 12 - N128 x 142
Valve clearance at cold mm 0.3 / 0.3
Mechanical governor : 1,575 (52.5 Hz) / 1,890 (63 Hz)
No load max. rpm (50 Hz / 60 Hz) rpm
Electric governor : 1,500 (50 Hz) / 1,800 (60 Hz)
Mean effective press. (Initial) kg/cm2 16.83 / 16.42 15.93 / 16.42 16.58 / 16.42
Mean piston speed (50 Hz / 60 Hz) m/sec. 7.10 / 8.52
Max. firing press. of cylinder kg/cm 2
130 130 130
Com. Press. (at 200 rpm) kg/cm2 28 (Initial condition)
Governor type of inj. pump Electric Governor
g/PS.h 148 / 153 152 / 153 151 / 150
Fuel consumption
liter/h 73 / 88 89 / 111 110 / 130
Injection timing (B.T.D.C) deg. 24 ± 1û 22 ± 1û
Inj. nozzle opening press. kg/cm2 224
Starter motor capacity V-kW 24V - 6.0
Alternator capacity V-A 24V - 50
Battery V-Ah 24V - 200
Cooling system Indirect cooling by sea water with heat exchanger
Cooling water capacity lit Max. : 89, Min. : 78 Max. : 92, Min. : 81 Max. : 98, Min. : 87
Fresh water pump type Centrifugal type, driven by V-belt
Sea water pump type Rubber impeller type driven by gear
Max . : 31, Min . : 25 Max . : 35, Min . : 28 Max . : 40, Min . : 33
Lub. Oil Pan capacity lit
(Engine total : 35) (Engine total : 38) (Engine total : 43)
(Engine)
Pressure kg/cm2 Full : 3.5, Idle : 1.2
Revolution of Crankshaft Counter clockwise viewed from stern side
Engine size (L x W x H) mm 1,037 x 1,222 x 1,074 1,195 x 1,222 x 1,169 1,353 x 1,222 x 1,199
Engine dry weightkg 1,295 1,545 1,735
-4-
1.2. Engine Aspects
1.2.1. Engine Sectional View (Longitudinal Ñ

> V222TI)
2 3 4
5
9
8 6
7
EB2M1001
1. Cylinder head 4. Tappet 7. Oil pump

2. Cylinder head cover 5. Camshaft 8. Crankshaft
3. Push rod 6. Flywheel 9. Thermostat
-5-
1.2.2. Engine Sectional View (Cross Ñ> V222TI)
1 2 3 4 1
14 5
6 6
9 7
13
8
12
9
10
7 11
EB2M1002
1. Intake manifold 6. Exhaust manifold 11. Oil cooler

2. Breather assembly 7. Piston 12. Oil level gauge
3. Injection pump 8. Connecting rod 13. Oil filter
4. Injection pipe 9. Cylinder liner 14. Push rod
5. Oil filler cap 10. Cylinder block
-6-
1.2.3. Engine Assembly (V222TI)
16 9 7 3 14
15 4
2
8 12
1 6 10 5 11
EB2M1003
1. Crank pulley 7. Fresh water filler cap 13. Exhaust manifold

2. Fuel filter 8. Sea water pump 14. Turbocharger (wet)
3. Intercooler 9. Heat exchange assÕy 15. Sea water inlet pipe
4. Oil drain pump 10. Starter 16. Sea water outlet pipe
5. Flywheel housing 11. Marine gear assÕy
6. Oil pan 12. Exhaust manifold
-7-
1.3. Engine Performance Curve
1.3.1. V158TIE
500
400
500
d
400 oa
ll L
Fu
n ge
300 Ra
n
(PS) a tio (PS)
er
200 Op
Propulsion Curve
100
Full Consumption
(g/PS.h)
170
160
150
1000 1500 2000
Engine Speed (rpm)

EB2O1004
EB2O1004
1.3.2. V158TI
(Heavy Duty) (Medium Duty) (Light Duty)
500 500 500
400 400 400

d
500 500 d 500 oa
d oa ll L
L oa ll L Fu
ull Fu
Output (PS)
Output (PS)
Output (PS)
400 F 400 400
e
e
ng
ng
Ra
e
Ra
ng
on
Ra
on
300 300 300
ati
ati
on
er
(PS) (PS) (PS)
er
ati
Op
Op
er
200 200 200

Op
Propulsion Curve Propulsion Curve Propulsion Curve

100 100 100
Full Consumption Full Consumption Full Consumption

(g/PS.h)
(g/PS.h)
(g/PS.h)
170 170 170
160 160 160
150 150 150
1000 1500 2000 1000 1500 2000 1000 1500 2000
Engine Speed (rpm) Engine Speed (rpm) Engine Speed (rpm)

EB2O1001
EB2O1001
1.3.3. V180TI
1000 1000 1000

d
oa
900 900 900

ll L
Fu
800 800 800

d
nge
oa
Output (PS)
Output (PS)
Output (PS)
700 700 L 700

ull
Ra
d
oa F
tion
L
nge
600 ull 600 600

era
F
Ra
nge
Op
(PS) (PS) (PS)

tion
Ra
500 500 500

era
tion
Op
era
400 400 400

Op
Propulsion Curve Propulsion Curve Propulsion Curve

300 300 300
Full Consumption
(g/PS.h)
(g/PS.h)
(g/PS.h)
Full Consumption 170 Full Consumption 170 170

160 160 160
150 150 150
1000 1500 2000 1000 1500 2000 1000 1500 2000
Engine Speed (rpm) Engine Speed (rpm) Engine Speed (rpm) EB2O1002
EB2O1002
-8-
1.3.4. V222TI
800 800 800
d
oa
700 700 700
ll L
Fu
d
600 600 oa 600
oa
d ll L
ll L Fu
Fu
Output (PS)
Output (PS)
Output (PS)
500 500 500
ge
n
ge
Ra
e
an
ng
tion
400 400 400
nR
Ra
era
tio
on
era
ati
Op
er
Op
300 300 300
Op
(PS) Propulsion Curve (PS) Propulsion Curve (PS) Propulsion Curve
200 200 200
100 100 100

Full Consumption Full Consumption Full Consumption
(g/PS.h)
(g/PS.h)
(g/PS.h)
170 170 170
160 160 160
150 150 150
1000 1500 2000 1000 1500 2000 1000 1500 2000
Engine Speed (rpm) Engine Speed (rpm) Engine Speed (rpm) EB2O1003
EB2O1003
-9-
1.4. Engine Model & Serial Number
The engine serial number is inscribed on

the engine as illustrated. This number is
required when requesting warranty and
ordering parts. It is also referred to as
engine model and serial number because
of their location.
Note : The engine model name

Name Plate
(V222TI) is described in the
EB2O3001
name plate on the cylinder
block.
¥ Engine serial No. (Example : V222TI)

EBYKM200001
Serial No.
Production Year (2002)
Engine Model Suffix
- 10 -
2. SAFETY REGULATIONS
2.1. General Notes
Day-to-day use of power engines and the service products necessary for running them presents
no problems if the persons occupied with their operation, maintenance and care are given suit-
able training and think as they work.
This summary is a compilation of the most important regulations. These are broken down into
main sections which contain the information necessary for preventing injury to persons, dam-
age to property and pollution. In addition to these regulations those dictated by the type of
engine and its site are to be observed also.
IMPORTANT.
If, despite all precautions, an accident occurs, in particular through contact with caustic
acids, fuel penetrating the skin, scalding from oil, antifreeze being splashed in the eyes
etc, consult a doctor immediately.
2.2. Regulations Designed to Prevent Accidents with Injury to Persons

2.2.1. During commissioning, starting and operation
Before putting the engine into operation for the first time, read the operating instructions care-
fully and familiarize yourself with the ÒcriticalÓ points, If you are unsure, ask your DAEWOO
representative.
¥ For reasons of safety we recommend you attach a notice to the door of the engine room
prohibiting the access of unauthorized persons and that you draw the attention of the oper-
ating personal to the fact that they are responsible for the safety of persons who enter the
engine room.
¥ The engine must be started and operated only by authorized personnel. Ensure that the
engine cannot be started by unauthorized persons.
¥ When the engine is running, do not get too close to the rotating parts. Wear close-fitting
clothing.
¥ Do not touch the engine with bare hands when it is warm from operation risk of burns.
¥ Exhaust gases are toxic. Comply with the installation instructions for the installation of DAE-
WOO marine diesel engines which are to be operated in enclosed spaces. Ensure that there
is adequate ventilation and air extraction.
¥ Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
- 11 -
2.2.2. During maintenance and care
¥ Always carry out maintenance work when the engine is switched off. If the engine has to be
maintained while it is running, e.g. changing the elements of change-over filters, remember
that there is a risk of scalding. Do not get too close to rotating parts.
¥ Change the oil when the engine is warm from operation.

CAUTION :
There is a risk of burns and scalding. Do not touch oil drain plug or oil filter with bare
hands.
¥ Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that
the oil will not overflow.
¥ Open the coolant circuit only when the engine has cooled down. If opening while the engine
is still warm unavoidable, comply with the instructions in the chapter entitled Ò4.3. Cooling
SystemÓ.
¥ Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any addi-
tional hydraulic oil circuit) during the operation. The fluid which flow out can cause injury.
¥ Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled
only when the engine is switched off.
¥ When using compressed air, e.g. for cleaning the heat exchanger, wear goggles.
¥ Keep service products (anti-freeze) only in containers which can not be confused with drinks
containers.
¥ Comply with the manufacturerÕs instructions when handling batteries.

CAUTION :
Accumulator acid is toxic and caustic. Battery gases are explosive.
2.2.3. When carrying out checking, setting and repair work
¥ Checking, setting and repair work must be carried out by authorized personnel only.
¥ Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench
could lead to Injury.
¥ When the engine is hanging on a crane, no-one must be allowed to stand or pass under it.
Keep lifting gear in good condition.
¥ When checking injectors, do not put your hands under the jet of fuel.
Do not inhale at atomized fuel.
¥ When working on the electrical system disconnect the battery earth cable first.
After repair engine parts , connect it up again last in prevent short circuits.
- 12 -
2.3. Regulations Designed to Prevent Damage to Engine and Premature Wear
(1) Never demand more of the engine than it was designed to yield for its intended purpose.
Detailed information on this can be found in the sales literature. The injection pump must not
be adjusted without prior written permission of DAEWOO.
(2) If faults occur, find the cause immediately and have it eliminate in order to prevent more seri-
ous of damage.
(3) Use only genuine DAEWOO spare parts. DAEWOO will accept no responsibility for damage
resulting from the installation of other parts which are supposedly Òjust as goodÓ.
(4) In addition to the above, note the following points.
¥ Never let the engine run when dry, i.e. without lube oil, fuel or coolant. Use only DAEWOO-
approved service products. (engine oil, anti-freeze and anticorrosion agent)
¥ Pay attention to cleanliness. The diesel fuel must be free of water. See Ò4.6. Fuel SystemÓ.
¥ Have the engine maintained at the specified intervals.
¥ Do not switch off the engine immediately when it is warm, but let it run without load for
about 5 minutes so that temperature equalization can take place.
¥ Never put cold coolant into an overheated engine.

¥ Do not add so much engine oil that the oil level rises above the max. marking on the dip-
stick. Do not exceed the maximum permissible tilt of the engine. Serious damage to the
engine may result if these instructions are not adhered to.
¥ Always ensure that the testing and monitoring equipment (for battery charge, oil pressure,
and coolant temperature) function satisfactorily.
¥ Do not let the sea water pump run dry. If there is a risk of frost, drain the water when the
engine switched off.
- 13 -
2.4. Regulations Designed to Prevent Pollution
2.4.1. Engine oil, filter element, fuel filter
¥ Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not
get into the drains or into the ground and sea.
¥ The drinking water supply may be contaminated.

¥ Oil and fuel filter cartridges are classed as dangerous waste and must be treated as such.
2.4.2. Coolant
¥ Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.

¥ When disposing of spent coolant comply with the regulations of the relevant local authori-
ties.
2.5. Notes on Safety in Handling Used Engine Oil
Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains
dangerous substances which have caused skin cancer in animal experiments. If the basic rules
of hygiene and health and safety at work are observed, health risks are not to the expected as
a result of handling used engine oil.
Health precautions
¥ Avoid prolonged or repeated skin contact with used engine oil.

¥ Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
¥ Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water. A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, diesel fuel, gas oil, thinners or solvents as washing agents.
¥ After washing apply a fatty skin cream to the skin.

¥ Change oil-soaked clothing and shoes.
¥ Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly.
- Engine oil can endanger the water supply -
For this reason do not let engine oil get into the ground, waterways, the drains or the sewers.
Violations are punishable. Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local authori-
ties.
- 14 -
3. COMMISSIONING AND OPERATION
3.1. Inspections before Operation
3.1.1. Lubricating oil
a).The notches in dipstick must indicate

the oil level between max. and min.
permissible.
b) The measurement of the oil level
must be done on a even water line
and in 10 minutes after engine oper-
ating.
c) Examining the viscosity and the cont-
amination of the oil smeared at the EB4O4001
EA4O4001
dipstick, replace the engine oil if nec-
essary.
3.1.2. Cooling water
Checking the level of the cooling water in tank.
Caution
If the installation angle of the engine exceeds 6 degrees, please remark the
maximum and minimum level of the oil dipstick by engraving on the lube oil
capacity of the engine. ( Refer to 4.4. ÒLubrication SystemÓ)
Check the opening pressure of the pres-

sure valve using cap tester. Replace the
filler cap assembly if the measured valve
Pressure Cap
does not reach the specified limit.
(Opening pressure of valve : 0.9 kg/cm2)
NOTE :
Because it is dangerous to open Expansion Tank
the pressure cap quickly when
EB2O3006
coolant is hot, after covering the
cap with a cloth and then lower
the inside pressure of the tank by
opening slowly at first, open it up.
- 15 -
3.1.3. Sea water pump
Impeller of the sea water pump is a

bronze type, therefore you should install
the sea water strainer as right figure in
order not to suck in any hard pieces and
sharp scales.
Install the sea water strainer in adequate
size for the engine between kingston
valve and sea water pump.
EB2O3007
EB2O3007
¥ Over-tightened belt or over loaded
gear will reduce the bearing life of the
sea water pump.
¥ If sea water is not sucked in sea water pump at starting, restart the engine after filling water
in the sea water pump housing and inlet hose.
¥ Make sure that all valves / cocks in the sea water line are opened before run.
¥ If there is a risk of freezing weather, drain the water by loosening bolts of end cover.
¥ Temperature range : 5 ûC (41 ûF) ~ 60 ûC (140 ûF)
3.1.4. Intake & Exhaust Line
Make sure that intake & exhaust piping lines are properly designed and air filter element is
fouled and worn severely. If so, correct and clean or replace it.
3.1.5. Fuel Line
Check the fuel line leaking on opening the valve.

The contamination of fuel may cause the nozzle clogging or the sticking of the injection pump
components. Therefore, cleanness of fuel system should be maintained at any time.
3.1.6. Bottom of the engine room
(1) Always keep the bottom clean.

Check the bilge for excessive water accumulation. Always keep the bilge clean and dry.
Never allow the water depth in the bilge to exceed the bottom of the engine.
If water accumulation is unavoidable, you have to install a bilge pump with an automatic
control switch.
CAUTION :
The water level in the boatÕs bilge will increase when the boat is operated at a high incli-
nation before rated speed is reached. Excessive water in the bilge can cause engine
damage like corrosion , malfunction of engine parts.
- 16 -
3.1.7. Gauge Panel
Check the all gauges of the panel whether the function is in normal or not.
Before operation your engine familiarize yourself with the instruments supplied with
your boat.
1) V158TIE
4 6 3 2 1 11
WATER TEMP. ENGINE SPEED ENG. OIL PRESS.
CHARGE WATER TEMP ENG. OIL PRSS OVER SPEED
7 8 9 10
ENGINE STOP START SWITCH
EA7O4001
1. Key Switch 5. Engine Stop Button 9. Oil Press. Warning Lamp

2. Engine Oil Pressure Gauge 6. Hour Meter 10. Over Speed Warning Lamp
3. Tacho-Meter 7. Battery Warning Lamp 11. Fuse
4. Water Temp. Gauge 8. Water Temp. Warning Lamp
2) V158TI / V180TI / V222TI
13 4 3 2 12
16
17 18
15
14 11 6 7, 8, 9, 10 5 1 16
EB2O4001
EB2O4001
1. Key Switch 7. Battery Warning Lamp 13. Battery Charge Meter

2. Engine Oil Pressure Gauge 8. Water Temp. Warning Lamp 14. Lamp Dimmer
3. Tachometer 9. Oil Press. Warning Lamp 15. Gauge Panel
4. Water Temp. Gauge 10. Over Speed Warning 16. Bolt
5. Engine Stop Button 11. Warning Lamp Stop Button 17. Connector
6. Hour Meter 12. Clutch Oil Press. Gauge
- 17 -
3.1.8. Engine Stop & warning devices
V158TI/V180TI/V222TI gauge panel is equipped with an audible alarm to alert the operator to
the following.
1) Engine Stop Device (Stop Solenoid)

Engine stop solenoid is operated with a warning lamp and buzzer sound at the same time
as follows.
¥ When the engine oil pressure is less than 0.5 kg/cm . 2
¥ When the engine over speed becomes more than 120% of the engine rated speed but,
marine generator engine becomes more than 115%.
2) Engine Warning Lamps

Engine warning lamp is turned on with buzzer sound at the same time.
¥ When the engine oil pressure is less than 1 bar (1st stage) and 0.5 bar (2nd stage).
¥ When the engine water temperature is more than 93ûC.
¥ When the battery is not charged.
If a warning lamp of the gauge panel on engine operation is turned on, you will find as
follows.
The alarm horn will sound when the ignition is turned on and continue to sound until the key
switch is shifted into ÒOFFÓ position or minimum oil pressure is obtained. This provides a func-
tional test of warning system.
If the engine oil pressure becomes to less than 0.5 kg/cm2, the alarm horn will sound
and the engine is stopped by stop solenoid at the same time automatically. Proceed as
follows :
First, quickly observe the oil pressure gauge for the engine low pressure such as nee-
dle oscillation indicating low oil. If oil temperature gauge indicates below 0.5kg/cm2, put
the control lever back to the idle speed position IMMEDIATELY and shift the reduction
gear control lever into the NETURAL position. Do not restart engine until the cause for
the alarm has been found and corrected. Refer to ÒPerformance LossÓ in 8. Trouble
Shooting Chart. Check the oil lines or switch and sensor malfunction. If the cause for
the alarm cannot be found, contact your DAEWOO dealer.
- 18 -
3.2. Starting
3.2.1. Operation 1
After checking the warning lamps of the gauge panel and the NEUTRAL position of reduction
gear control lever, turn the key switch to the START position to crank the engine, at once.
Behavior - When the key switch is placed in the START position.
3.2.2. Operation 2
After the engine is cranked, convert the key switch to the ACC position quickly.
Behavior - As the engine is cranked, donÕt fix the key switch too long (over 4 seconds) in the
ÒSTARTÓ position. If you do, the starter may be malfunction.
If you fail the engine starting at first, restart the engine after waiting for 30 seconds
at least to prevent the circuit malfunction of the starter.
3.3. Engine Brek-in
During the first 20 hours of operation, you must follow the Engine Break-In procedure to ensure
maximum performance and long engine life.
Note:
Failure to follow the Engine Break-in procedure may result in serious engine damage.
3.3.1. New Engine Break-In 20 hours
All DAEWOO marine engines have been run for a short period of time as a final test at the fac-
tory. You must follow the Engine Break-In procedure during the first 20 hours of operation to
ensure maximum performance and longest engine life.
Note:
To ensure proper lubrication during the break-in period, do not remove factory break-in
oil until 20 hours break-in is completed.
3.3.2. Initial two hours of break-in
For the first five to ten minutes of operation, operate engine at a fast idle (below 1,300 rpm).
During the remaining first two hours of operation, accelerate to bring boat onto plane quickly
and bring throttle back to maintain a planing attitude. During this period, vary the engine speed
frequently by accelerating to approximately three-fourths throttle (1500~1600rpm) for two to
three minutes, then back to minimum planing speed(700~800rpm).
After the engine has reached operating temperature, momentarily reduce engine speed, then
increase engine speed, to assist the break-in of rings and bearings. Maintain planing boat atti-
tude to avoid excessive engine load.
Note:
Do not run engine at any constant rpm for prolonged periods of time for this initial two
hours of break-in.
- 19 -
3.3.3. Next 8 Hours
During the next 8 hours, continue to operate at approximately three-fourths throttle or less
(minimum planing speed). Occasionally reduce throttle to idle speed for a cooling period.
During this 8 hours of operation it is permissible to operate at full throttle for periods of less
than two minutes only 2 times.
Note:
Do not run engine at a constant rpm for prolonged periods of time during the break-in
period.
3.3.4. Final 10 hours
During the final 10 hours of break-in, it is permissible to operate at full throttle for five to ten
minutes at a time. After warming engine to operating temperature, momentarily reduce then
increase engine speed. Continue to operate at approximately three-fourths throttle.
Occasionally reduce engine speed to idle to provide cooling periods.
Note:
Do not run engine at a constant rpm for prolonged periods of time during the break-in
period.
During the break-in period, be particularly observe as follows :
¥ Check engine oil level frequently. Maintain oil level in the safe range, between the Òmin.Ó and
Òmax.Ó marks on dipstick.
¥ Watch the oil pressure warning lamp. If the lamp blinks whenever the boat attitude (i.e. turn-
ing, climbing on plane, etc.) is changed, it may be the oil pick-up screen is not covered with
oil. Check oil dipstick. Add oil to the oil pan, if required. Do not overfill.
Note:
Oil pressure will rise as RPM increases, and fall as the engine RPM decreases. In
addition, cold oil will generally show higher oil pressure for any specific RPM than hot
oil. Both of these conditions reflect normal engine operation.
¥ Watch the engine water temperature gauge and be sure there is proper water circulation.
The water temperature gauge needle may fluctuate if water level in expansion tank is too
low.
Note:
Failure to follow the break-in procedure will avoid the engine warranty.
When the engine operation become to reach 50 hours in total including the break-in period
20 hours, replace the engine oil and oil filter to new ones. Fill oil pan with recommended
engine oil. Refer to Ò4.4. Lubricating SystemÓ.
Note:
When engine is overheated, do not stop the engine immediately.
Lower the engine load and run the engine and its cooling systems continuously.
- 20 -
3.3.5. Operating after break-in 20 hours
When starting a cold engine, always allow the engine to warm up gradually. Never run the
engine at full throttle until the engine is thoroughly warmed up.
And youÕd better run the engine at three-fourths throttle (about 1600 rpm) before initial 50
hours as possible. Be sure to check the oil level frequently during the first 50 hours of opera-
tion since the oil consumption will be high until the piston rings are properly seated.
3.4. Inspections after Starting
During operation the oil pressure in the engine lubrication system must be monitored. If the mon-
itoring devices register a drop in the lube oil pressure, switch off the engine immediately.
And the charge warning lamp of the alternator should go out when the engine is running.
¥ Do not disconnect the battery or pole terminals or the cables!

¥ If, during operation, the battery charge lamp suddenly lights up, stop the engine immediately
and remedy the fault in the electrical system!
¥ Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal.
¥ Confirm the following things through warning lamps and gauge panel.
3.4.1. Pressure of lubricating oil
The normal pressure comes up to 1 bar at idling and 3 ~ 5 bar at rated speed. If the pressure
fluctuates at idling or does not reach up to the expected level at high speed, shut down the
engine immediately and check the oil level and the oil line leakage.
3.4.2. Temperature of cooling water
The cooling water temperature should be 71 ~ 85 ûC in normal operating conditions.

Abnormally high cooling water temperature could cause the overheating of engine and the
sticking of cylinder components. And excessively low cooling water temperature increases the
fuel consumption, accelerates the wears of cylinder liners and shortens the engine life-time.
- 21 -
3.5. Check after Initial 50 Hours Operation.
To insure your continued boating enjoyment, you should check as follows :
¥ Change engine oil and oil filter cartridge.

¥ Change fuel filter cartridge.
¥ Check coolant level.
¥ Check the tension of all drive belts.
¥ Check all engine mounts screws for tightness.
¥ Check for any deficiencies, malfunctions, signs of abuse, etc. Correction of any problems at
this time will prevent the worsening of a minor problem and help ensure a trouble free boating
season.
Note:
This is an opportune time to discuss with your dealer any questions about your boat and
stern drive unit which may have arisen after the first 50 hours of operation and establish
a routine preventive maintenance schedule.
3.6. Operation in Winter
Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.
3.6.1. Prevention against the freeze of cooling water
When not using anti-freeze, completely discharge the whole cooling water after engine run-
ning. The freeze of cooling water causes the fatal damages of the engine. Because the anti-
freeze is used to prevent cooling water from freeze and corrosion, it is always to be filled with
the anti-freeze 35 ~ 40% of the whole coolant .
3.6.2. Prevention against excessive cooling
Drop of thermal efficiency caused by excessive cooling increases fuel consumption. Therefore
should prevent the engine from excessive cooling. If the temperature of coolant does not reach
to normal condition (71 ~ 85ûC) after continuous operation, examine the thermostat or the
other cooling lines.
3.6.3. Lubricating oil
As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after start-
ing. Therefore the lubricating oil for winter(SAE 15W40 or 10W30) should be used to prevent
this unstableness. Refer to Ò4.4. Lubricating SystemÓ.
- 22 -
3.7. Tuning the Engine
The purpose of an engine tune-up is to restore power and performance thatÕs been lost through
wear, corrosion or deterioration of one or more parts or components. In the normal operation of
an engine, these changes can take place gradually at a number of points, so that itÕs seldom
advisable to attempt an improvement in performance by correction of one or two items only.
Time will be saved and more lasting results will be obtained by following define and thorough
procedure of analysis and correction of all items affecting power and performance.
Economical, trouble-free operation can better be ensured if a complete tune-up is performed
once every year, preferably in the spring. Components that affect power and performance to be
checked are:
¥ Components affecting fuel injection ;

Nozzle, delivery valve, fuel filter, fuel water separator, etc.
¥ Components affecting intake & exhaust ;

Air filter, inter-cooler, turbo-charger, silencer, good ventilation of engine room etc.
¥ Components affecting lubrication & cooling ;

Air & oil filter, anti- freeze, heat exchanger, rubber impeller, sea water filter, kingston valve,
misalignment of propeller, stableness of bed frame, bent propeller blade etc.
- 23 -
4. GENERAL INFORMATION
4.1. 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 to prevent the disassembled parts and components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with care. They can cause damage for
painted parts.
4. The use of proper tools or specified special tools is important to perform the efficient and
reliable maintenance operation.
5. Use genuine DAEWOO parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be dis-
carded. New ones should be used for re-assembled parts. If these are reused, normal per-
formance can not be maintained.
7. To facilitate reassembling, keep disassembled parts neatly in groups. Fixing bolts and nuts
for reassembled parts should be reused at the original position. They are varied in hardness
or length because they are designed depending on their application.
8. Clean the disassembled parts prior to inspection or re-assembly. By using compressed air,
make oil ports and etc. of them free from any foreign material.
9. Lubricate the surface of rotating and sliding parts with oil or grease before installation.
10. If necessary, use sealant onto gaskets to prevent leakage.
11. Carefully obey all specified torque to tighten bolts and nuts
12. When maintenance is completed, make a final check to be sure it has been done properly.
- 24 -
4.2. Periodical Inspection & Maintenance
In order to insure maximum, trouble-free engine performance at all times, regular inspection,
adjustment and maintenance are vital before occurring any problems.
¥ Daily inspections in below figure should be checked every day.

¥ The following maintenance details should be executed thoroughly at regular internals.
Every Every Every Every Every Every
Inspection Daily
50hrs 100hrs 250hrs 500hrs 600hrs 1,000hrs
Coolant level check and refill
Contamination of the coolant check
1 Year change
and the quantity of the anti-freeze
Cooling Heat-exchanger and
1,200 hr
System water cooling line cleaning
V-belt check and adjustment 2,000 hrs change
Thermostat check 2 years
Impeller of sea water pump check 2,000 hr change
Oil level check
Lubrication oil exchange 1st
Oil filter cartridge replacement 1st
Lubrication Marine gear oil exchange 1st
System Cylinder compression pressure
check
Rotor for bypass filter

change
In./ Ex. valve clearance

adjustment
Intake & Air filter element cleaning &
Exhaust change clean change
System Inter-cooler cleaning
Turbocharger cleaning 2,000 hrs
Exhaust gas check
Priming pump strainer cleaning
Fuel tank check & cleaning
Fuel Water separator cleaning
System Fuel filter exchange 1st
Fuel Injection timing check 1 year
Fuel Injection nozzle check 1 year
Warning lamps check
Electrical
Battery charging check
System
Wiring harness check
- 25 -
4.3. Cooling System
4.3.1. Coolant level check and refill
¥ Replenish the deficient coolant in the expansion tank every day before running. The coolant
must be changed at intervals of 1,200 hours operation or six months whichever comes first.
If the coolant is being fouled greatly, it will lead engine overheat or coolant blow off from the
expansion tank.
¥ The clean fresh water should be used for engine coolant.

¥ Additional agent (35 ~ 40% anti-freeze and 3 ~ 5% anti-corrosion agent) should be mixed
with fresh water for engine coolant to prevent the cooling system problem like freezing, cor-
rosion and etc.
Caution
Suitable mixture of anti-freeze and anti-corrosion agent can protect the engine corro-
sion from deteriorating and raises a boiling point, but by using unsuitable mixture
engine components like water pump impeller and water jacket of cylinder block may be
occurred a malfunction by any bad corrosion damage or cavitation.
(1) Coolant replenishment

Let the plug in the highest level of the water lines or the upper plug of wet tur-
bocharger open, and fill the coolant about three forth of the expansion tank slowly
until the air bubbles in water do not come out through the plug hole. Then reassem-
ble the plug.
After filling the coolant, run the engine at the idle rpm for around 5 minutes and you
will find out the engine coolant level becomes lower than before cause of escaping the
air bubbles in water. Then stop the engine and replenish additional coolant properly.
(2) Coolant change
¥ Open the pressure cap of expansion to remove the air pressure.

CAUTION
When remove the pressure of the filler cap while the engine is still hot, cover
the cap with a cloth, then turn it counter-clockwise slowly to release internal
steam pressure. This will prevent a person from scalding by hot steam spout-
ed out from the filler cap.
¥ V-type engines have 5 places of drain plug as follows

1) Lower part of right exhaust elbow
2) Front part of the left exhaust manifold cover
3) Lower part of the heat exchanger outlet pipe
4) Lower part of oil cooler
5) Cylinder block part of starter upper side.
¥ After water draining, re-assemble the drain plugs and then replenish the coolant
as same as Ò(1) Coolant replenishmentÓ.
- 26 -
4.3.2. Contamination check of coolant and quantity of anti-freeze
¥ We recommend the engine coolant for DAEWOO marine engines should be mixture of fresh
water and additional agent (35 ~ 40% anti-freeze and 3 ~ 5% anti-corrosion agent).
Check the quantity of anti-freeze every 600 hours. From time to time, refill the anti-freeze as
much as required.
You can check the quantity of anti-freeze and anti-corrosion agent by using a FLEETGUARD
test kit simply as follow. (Fleetguard CC2602M : DHI No. ; 60.99901-0038)
1) Contamination check
¥ How to use test kit (Striped pad)

(1) Collect half of a coolant sample cup from a drain plug at the lower side of the water
pump inlet pipe or cylinder block. Coolant must be between 10 ûC and 55 ûC when
tested. Room temperature is preferred.
Do not collect the coolant from the expansion tank or overflow system.
The collected sample is less contaminated, so it can not be substituted for the
quality of whole coolant.
(2) Shake the bottle filled with sample coolant to mix well and take out one strip from bot-
tle of the test kit. Then dip the strip into coolant sample for 3 ~ 5 seconds, take it out
and shake it briskly to remove excess liquid.
Do not touch the pads on the end of the strip. Discard the kit if unused
strips have turned brown for the nitrite test pad.
(3) Wait for 45 seconds until color of the dipping stripe pad is turned into any colors and
then compare and record the results compared with the color figure as following order.
Caution
All three pad readings must be completed no later than 75 seconds after dip-
ping strip. Do not touch the stripe with fingers.
¥ How to judge the strip

Striped
c) b) a)
a) Compare FREEZEPOINT (end pad) to chart and record result.

b) Next compare MOLYDATE (middle pad) to chart and record result.
c) Finally compare NITRITE test to chart and record result.
- 27 -
(1) Compare the end pad Òa)Ó color
of the strip with color blocks of a % GLYCOL / FREEZEPOINT ( ) (End Pad)
25% 33% 40% 50% 60%
row at the upper part of the
standard color chart (below of
-12 -15 -18 -21 -23 -29 -34 -43 -51
the letter ÒGLYCOL/FREEZE
SCA Units per Litre
POINTÓ). Same color in the
block of the row means the con- Row 6
0.0 0.4 0.7 0.9 1.0 1.1 1.3 1.5
TEST
tent of anti-freeze in the 0.0 0.4 0.6 0.7 0.9 0.9 1.1 1.3
Row 5
coolant. (Normal range is
0.0 0.4 0.5 0.5 0.6 0.7 1.0 1.2
between 33% and 50%.) Row 4
SERVICE
(2) Compare the middle pad Òb)Ó 0.0 0.3 0.4 0.4 0.6 0.7 0.9 1.1
Row 3
color of the strip with the color 0.0 0.2 0.3 0.4 0.5 0.6 0.8 1.0
Row 2
that the column block color of
0.0 0.2 0.2 0.2 0.4 0.5 0.7 0.9
MOLYDATE at the left side of Row 1
PRE CHARGE
the table intersects the row 0.0 0.1 0.2 0.2 0.3 0.4 0.6 0.9
Row 0
(MIDDLE PAD)
MOLYBDATE
block color of NITRITE at the
A B C D E F G H
bottom (pad Òc)Ó color of the
NITRITE
strip) on the table ÒSCA Units EA7O5013
per LitreÓ.
(Normal range of ÒSCA Units
per LitreÓ is between 0.3 and 0.8 : Ògreen color areaÓ)
During the comparison, if uncertain about color match, pick the lower num-
bered block. (example: if the color of NITRITE pad is between standard color
ÒDÓ and ÒFÓ, then use column E.)
(3) If the value of ÒSCA Units per LitreÓ is less than 0.3, refill the DCA4 liquid (anti-corro-
sion agent) a little, But larger than 0.8, Drain some amount of engine coolant and
replenish the fresh water instead. The content of the anti-freeze and anti-corrosion
agent can be regulated by this way.
Every year coolant must be replaced. It is essential the coolant should be mix-
ture of fresh water, proper anti-freeze and anti-corrosion agent.
4.3.3. Anti-freeze
The anti-freeze, 35 ~ 40% of the whole coolant, is always to be used to prevent the cooling
system from the corrosion. And in winter the amount of anti-freeze shown in the following table
should be used in accordance with the ambient temperature.
As the individual freezing points corresponding to the proportions of antifreeze in the table are
subject to change slightly according to the kind of antifreeze, you must follow the specifications
provided by the antifreeze manufacturer.
- 28 -
Ambient
Fresh Water (%) Anti-freeze (%)
Temperature (ûC)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
Any coolant loss due to engine operation must be replenished. But adding fresh water for
coolant tends to lower the content of anti-freeze. Always replenish the coolant with a mixture
of antifreeze and water, and keep the proper content of antifreeze (35 ~ 40%).
4.3.4. Heat exchanger and cooling line cleaning
(1) Heat exchanger cleaning

If the heat exchanger tubes are
clogged by many small pieces or pol-
luted by corrosion, the sea water
quantity will be reduced gradually
also as a result of it engine overheat-
ing may be occurred.
a) Remove the heat exchanger both

left and right side covers.
b) Remove the clogged small pieces EB25002I
and clean the heat-exchanger

tubes.
When the heat-exchanger tubes do cleaning, clean outside and inner side of tubes with
a small wire brush and pressurized water.
(2) Fresh water line cleaning

If the cooling circuits are fouled with water scales or sludge particles, the cooling efficien-
cy will be dropped down.
The poor condition of the cooling system is normally due to use of unsuitable anti-freezing
agents so periodically clean the circuit interior with a cleaner
Cooling system cleaning interval : Every 1,200 hours
- 29 -
4.3.5. Check and Adjust of V-belt Tension
(1) V - belt condition

Check the belt for cracks, oil, overheating and wear.
(2) V - belt Tension

By the finger-pressure the belt is
pressed by 10~15mm between the Water pump pulley
mm
water pump pulley and the alternator
10
pulley in normal condition. For the Sea water
pump pulley
adjustment of the tension, loosen the
10mm
adjusting bolts which support the
alternator, adjust the tension and Idle pulley
tighten the bolts again. Alt. pulley
Crank pulley
EB2O3005
(3) Change the V-belt
Change the belt if necessary after
every 2,000 hours of operation.
If, in the case of a multiple belt drive, wear or differing tensions are found, always replace
the complete set of the belts.
Note :
Always apply to DAEWOO genuine parts every replacement.
4.3.6. Thermostat
The thermostat maintains a constant

To heat exchanger
temperature of coolant (71 ~ 85 ûC) and
improves thermal efficiency of the
engine by preventing heat loss.
Namely, when the temperature of
coolant is lower than 85 ûC , the thermo-
stat valve is closed to make the coolant
Bypass valve
From cooling
bypass to directly enter the water pump. water pump To bypass
tube
When the coolant temperature rises to
EAMC002I
open wide the thermostat valve, the
bypass circuit is closed and the water
passage to the heat exchanger is opened so that the coolant is forced to flow into the heat
exchanger.
Item Specifications
Type Wax-pallet type
Open at 71 ûC
Open wide at 85 ûC
Valve lift 8 mm or more
- 30 -
¥ Inspecting
(1) Check the wax pallet and spring for
damage.
(2) Put the thermostat in a container of Bar
Thermometer
water, then heat the water slowly
and check temperature with a ther-
mometer. If the valve lift is 0.1 mm
Wood plate
(starting to open) at temperature of
71 ûC and 8 mm or more (opening
wide) at temperature of 85 ûC, the
EFM2055I
thermostat is normal.
¥ Replacing thermostat and precautions for handling

(1) Precautions for handling
The wax pallet type thermostat does not react as quickly as bellows type one to a varia-
tion of temperature of coolant. Such relatively slow reaction is mainly due to the large
heat capacity of the wax pellet type thermostat. Therefore, to avoid a sharp rise of coolant
temperature, it is essential to idle the engine sufficiently before running it. In cold weath-
er, do not run the engine at overload or overspeed it immediately after starting off.
(2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently from
the entire cooling system.
(3) Replacing thermostat
¥ If the thermostat is detected defective, replace with a new one.

¥ Change the thermostat every 2 years.
As the sea water pump is a bronze impeller type driven by V-belt, should install the sea water
strainer between sea water pump and kingston valve to prevent malfunction of impeller due to
clogging by any matters sucked.
Every the engine starts you should always check whether the kingston valve on the bottom of
the boat is opened. If sea water does not flowed out through outlet pipe of the boat outside, fill
coolant in the sea water pump inlet pipe and hose after loosening clamp.
- 31 -
4.4. Lubrication System
4.4.1. Oil level
¥ The notches in dipstick must indicate

the oil level between high and low per-
missible when the vessel is in the
water that is at normal trim.
¥ The oil level should be checked at the

horizontal position of the boat after
waiting about 10 minutes since then MAX
the engine has been shut down. MIN
¥ Examining the viscosity and the cont- EA6O5001
amination of the oil smeared at the
dipstick replace the engine oil if nec-
essary.
CAUTION :
Do not add so much engine oil
that the oil level rises above the
maximum marking on the dip-
stick. Over filling will result in
damage to the engine like a
excessive blow-by gas.
EB0O7002
¥ How to re-mark the oil dipstick

Since the inclination angle of marine
engine may differ greatly among ves-
sels, the high and low oil levels on the
dipstick should be also changed for
over 6 degree of the engine inclina-
tion.
Dipstick should be re-marked by
engraving on the lube oil capacity of
each engine. Be sure to check and EB0O7003
mark the oil levels between High and
Low when the vessel is commission-
ing at first. Please note that stamping or notching will weaken the dipstick and the tip of the
dipstick may break off in the oil pan.
The capacity of lube oil can be referred before Ò1.1. Engine SpecificationÓ
- 32 -
4.4.2. Exchanging of lubrication oil
Engine oil and the oil filter is important factors affecting engine life. They affect ease of starting,
fuel economy, combustion chamber deposits and engine wear. Change the engine oil at 50 hours
of operation at first and next exchange will be performed every 250 hours. At the end of the break-
in period (50 hours), change the sump oil and replace the oil filter cartridge to new one.
(1) Oil drainage
¥ While the oil is still hot, discharge

the sump oil or marine gear sump
oil by motion oil drain pump lever
manually as figure.
EB2M3001
¥ Refill new engine oil to the filler

neck on the head cover in accor-
dance with the oil capacity of the
engine. Be careful about the mix-
ing of dust or contaminator during
the supplement of oil. Then con-
firm whether the oil level gauge
indicates the vicinity of its maxi-
mum level.
EB2M5001
¥ For a few minutes, operate the
engine at idling in order to circulate
oil through lubrication system.
¥ Thereafter shut down the engine. After waiting for about 10 minutes measure the quan-
tity of oil and refill the additional oil if necessary.
Recommend of lubricating oil

Initial factory fill is high quality break-in oil for API Service CH-4 grade. During the
break-in period, frequently check the oil level. Somewhat higher oil consumption is
normal until piston rings are seated. The oil level should be maintained in the safe
range between the Min. and Max. mark on the dipstick. To obtain the best engine
performance and engine life, Engine oil is specified by API service, lettered desig-
nations and SAE viscosity numbers. If the specified engine oil is not available, use
a reputable brand of engine oil labeled for API Service CH-4 and SAE viscosity
15W40. Refer to oil identification symbol on the container.
- 33 -
Engine oil viscosity ambient temperature
SAE 20, 20W SAE 40, 50
Single SAE 10W SAE 30

temp
Ambient -30 C -15 C -0 C 15 C 25 C 30 C

temp (-20 F) (-0 F) (-32 F) (60 F) (80 F) (90 F)
SAE 10W - 30
Multi
grade SAE 15W - 40
SAE 10W - 40, 20W - 40, 20W - 50
SAE 5W - 20
EA4M1008
4.4.3. Replacement of oil filter cartridge
At the same time of oil exchanges, replace the oil filter cartridges.
¥ Drain engine oil by loosening the drain plug on the filter head.
CAUTION :
DonÕt forget tightening the drain plug after having drained engine oil.
¥ Loosen the oil filter by turning it

counter-clockwise with a filter wrench.
¥ With a rag wipe, clean the fitting face

of the filter body and the oil filter body
so that new oil filter cartridge can be
seated properly.
NOTE
It is strongly advisable to use
EFM2010I
DAEWOO genuine oil filter car-
tridge for replacement.
¥ Lightly oil the O-ring and turn the oil filter until sealing face is fitted against the O-ring. Turn
3/4 ~1 turns further with the filter wrench.
During continuous operation the selector lever that both filter halves are in oper-
ation. Observe positions of selector level.
- 34 -
Right-hand filter cut out Continuous operation Left-hand filter cut out
(both filter halves in operation)
EBO4019I
CAUTION :
Do not leave selector lever in any intermediate position because this would be liable to
interfere with oil supply.
4.4.4. Oil centrifugal filter
¥ Oil centrifugal filter is an auxiliary filter 3

which has a special structure able to 2
separate some impurity from oil cen- 4
trifugal by means of oil pressure, and 5
that can be used semi-perpetually by
maintaining without a necessity of
replacement.
¥ The oil centrifugal filter should be

6
maintained at every time of oil
replacement.
1 EBO4020I
4.4.5. Marine gear oil change
Always apply to API Service SAE #30 for reduction gear oil. Change the reduction gear oil at
100 hours of operation at first and next exchange will be performed every 600 hours.
4.4.6. Cylinder compression pressure
¥ Stop the engine after warming

up, and take out nozzle holder
assembly.
¥ Install the special tool (com-

pression gauge adapter) at the
nozzle holder hole, and con-
nect the compression pressure
gauge there.
EB4O403I
Standard value 24 ~ 28kg/cm2
Limit value 24kg/cm2 or less
Difference between
each cylinder Within ± 10 %
* Condition : Cooling water temperature 20ûC, Engine rotation 200rpm.(about 10 revolutions)
- 35 -
4.5. Intake & Exhaust System
4.5.1. Cleaning & change of the air filter element
The engine life and performance

depends on the intake air condition
greatly.
A fouled air filter element result a
decreased intake air amount leading the
engine output decrease and finally may
cause an engine malfunction.
Further, a damaged air filer element
results wear on the cylinder component
or the valve mechanism etc. leading
increased engine oil consumption and
decreased engine output, finally leads to
shorten the engine life.
The air filter element should clean peri-
odically as follow.
EA7O5006
Cleaning of the air filter element : Every 100 hours

Exchange of the air filter element : Every 400 hours
Replace the air cleaner if deformed, broken or cracked.
(1) Air filter element cleaning
¥ Wash the polluted element in warm water non-sudsy household detergent.

¥ Rinse the element with clean water.
¥ Dry it thoroughly with natural air or electric fan.
DonÕt use a flame or compressed air for dry.
It makes damages to the element.
(2) Checking element
¥ Confirm inside of the element clean and dry.

¥ Replace the new element if tears, rips or damages are found.
- 36 -
4.5.2. Inter-cooler
Inter cooler depends on the intake air

condition greatly. The fouled air pollutes
and clogs the air fins of the inter cooler.
As a result of this, the engine output is
decreased and the engine malfunction
may be occurred. Therefore always
check weather the intake air systems like
air filter element are worn or polluted.
The inter-cooler has to be removed from EB203004
the engine for cleaning.
< Inter cooler Cleaning >
In order to maintain the heat transfer efficiency of the inter-cooler, it is necessary to clean it at
regular intervals. For this purpose, dismantle the inter-cooler. In almost all cases, it will suffice
to clean the individual parts in a hot alkaline solution, e.g. a 3 to 5% P3-FD solution.
If hard and firmly adhering scale deposits continue to exist, a second treatment should be
made with a descaling agent which will not corrode the cooler core. Use new gaskets when
reassembling the inter-cooler.
Be sure to clean the sealing surfaces carefully before installing the gaskets.
Observe the specified pressure when making the hydraulic test.
water side 400 kPa (4 bar)

Test gauge pressure
charge air side 300 kPa (3 bar)
Observe the specified pressure when making the hydraulic test.
Cleaning of inter cooler : Every 1,000 hours.
4.5.3. Turbo-charger cleaning
¥ Turbo-charger should clean every 2,000 hours. The only points to be observed are the oil
pipes which should be checked at every oil change for leakage and restrictions and should
check the condition of turbo-charger like oil leaks, unusual turbo sounds periodically.
¥ Air cleaner element should be checked and cleaned periodically to prevent foreign matters
from entering the inside of the engine.
¥ Should check and measure the pressure of intake air and exhaust gas periodically. If there
is an air leakage, should repair the problem at once to prevent from occurring the engine
power loss and over heating.
¥ In case of operating in highly dust or oil-laden atmospheres, cleaning of the air compressor
impeller may be necessary from time to time. To this end, remove compressor casing
(Caution : Do not skew it!) and clean in a non-acid solvent, if necessary use a plastic
scraper.
- 37 -
If the air compressor should be badly fouled, it is recommended that the wheel be allowed to
soak in a vessel with solvent and to clean it then with a stiff non-steel brush. In doing so, take
care to see that only the compressor wheel is immersed and that the turbocharger is support-
ed on the bearing casing and not on the wheel.
4.5.4. Exhaust gas checking
Exhaust gas depends on much or less of it shows whether combustion condition of the engine
is good or not. If exhaust gas is any abnormal condition like excessive smoke, white smoke,
black smoke, the engine should be serviced maintenance from specialist.
4.6. Fuel system
As fuel injection pumps and injection nozzles consist of very complicated and precise components,
the contamination of fuel causes the clogging of the nozzle or the sticking of the components of
injection pump. Therefore, the cleanness of the fuel system should be maintained all the time.
If the engine is equipped with a fuel water separator, drain off any water that has accumulated.
Water in fuel can seriously affect engine performance and may cause engine damage.
4.6.1. Priming pump strainer cleaning
Clean the priming pump strainer every

100 hours operation. The strainer is
incorporated in the priming pump inlet
side joint bolt. Clean the strainer with the
compressed air and rinse it in the fuel oil.
Strainer
EA7O5009
EA7O5009
4.6.2. Fuel tank cleaning & checking
Fill the tank with recommended fuel. Keeping tanks full reduces water condensation and helps
keep fuel cool, which is important to engine performance. Make sure fuel supply valves (if
used) are opened. In marine environment, the most likely fuel contaminants are water and
microbial growth (black ÒslimeÓ). Generally, this type of contamination is the result of poor fuel
handling practices.
Black ÒslimeÓ requires water in the fuel to form and grow, so the best prevention is to keep
water content to a minimum in storage tanks.
If diesel fuel which contains moisture is used, injection system and cylinder liners, pistons will
be damaged. Drain moisture and accumulated sediment from drainage device of storage tank
regularly. You should change the element of the water separator or fuel filter cartridge several
times until fuel of the suction line is cleaned.
- 38 -
NOTICE :
A galvanized steel tank should never be used for fuel storage, because fuel oil reacts chemi-
cally with the zinc coating to form powdery flakes which can quickly clog the fuel filters and
damage the fuel pump and injection nozzles.
¥ How to select fuel oil

Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and
acceptable exhaust emission levels. DAEWOO engines are designed to operate on most diesel
fuels marketed today. In general, fuels meeting the properties of ASTM designation D975 (grades
1-D and 2-D) have provided satisfactory performance.
The ASTM 975 specification, however, does not in itself adequately define the fuel characteristics
needed for assurance of fuel quality.
The properties listed in the fuel oil selection chart below have provided optimum engine perfor-
mance. Grade 2-D fuel is normally available for marine service. Grade 1-D fuel should not be used
in pleasure craft engines, except in an emergency.
- 39 -
Fuel Oil Selection Chart
General Fuel ASTM No. 1 No. 2

DIN 51601
Classification Test ASTM 1-D ASTM 2-D
Gravity, (API #) D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855
Flash Point
D 93 100 (38) 125 (52) 131 (55)
Min. ûF (ûC)
Viscosity, Kinematic
D 445 1.3 ~ 2.4 1.9 ~ 4.1 1.8 ~ 10
CST 100 ûF (40 ûC)
Cloud Point ûF #)
D 2500 See Note 1) See Note 1) See Note 1)
Sulfur Content
D 129 0.5 0.5 0.15
wt%, Max.
Carbon Residue
D 524 0.15 0.35 0.1
on 10%, wt%, Max.
Accelerated Stability
Total Insolubles D 2274 1.5 1.5

mg/100 ml, Max. #)
Ash, wt%, Max. D 482 0.01 0.01
Cetane Number, Min. +)

D 613 45 45 > 45
Distillation D 86
Temperature, ûF(ûC)
IMP, Typical #)
350(177) 375(191)
10% Typical #)
385(196) 430(221)
50% Typical #)
45(218) 510(256) 680(360)
90% +)
500 (260) Max. 625(329) Max.
End Point #)
550(288) Max. 675(357) Max.
Water & Sediment

D 1796 0.05 0.05 0.05
%, Max.
#)
Not specified In ASTM D 975
+)
Differs from ASTM D 975
Note : 1. The cloud point should be 6ûC (10ûF) below the lowest expected fuel temperature to prevent
clogging of fuel fitters by crystals.
- 40 -
4.6.3. Water separator
DAEWOO recommends the fuel water Bleed Screw

separator to install between fuel tank
and fuel injection pump strongly. out C D out
Condensation formed in a partially filled Stage 5
tank promotes the growth of microbial
Stage 4
organisms that can clog fuel filters and in A B in
restrict fuel flow and cause the engine Stage 1
power decrease before. Stage 3
Water in the fuel will decrease the lubri- Stage 2
cation in the pump and possibly cause a
failure of the pump. Injection nozzles are
also lubricated by fuel and can also fail Drain Valve
(push in and
as a result of water in the fuel. Therefore, turn yellow knob)
it is necessary to remove any water from
the fuel before it reaches the fuel pump
by using a fuel water separator.
Fuel water separators that are available from DAEWOO are recommended. If another fuel
water separator is to be used, it must be sized for the engineÕs fuel supply flow rate.
4.6.4. Fuel filter exchanging
a) Loosen the fuel filter by turning it

counter-clockwise with the filter
wrench.
¥ Discard the used filter a designated

place. Lever
b) Wipe the filter fitting face clean.
c) Apply a light coat of engine oil to the O-
ring and supply fuel to the new filters.
d) Turn the new filter until the filter O- EB2M2001
ring is fitted against the sealing face.
e) And then turn the filter cartridge about
3/4 ~1 turn more with hands or filter wrench.
Right-hand filter cut out Continuous operation Left-hand filter cut out
(both filter halves in operation)
EBO4019I
Caution : Do not leave selector lever in any intermediate position because this would be liable
to interfere with oil supply.
- 41 -
Bleeding of the fuel system
Whenever fuel filter is changed or the engine is stopped cause of the fuel lack, the air
of fuel line must be removed as follows.
Bleed the fuel by manually operating the priming pump with fuel filter outlet joint bolt
and injection pump bleeder screw loosened.
¥ Press the feed pump cap

repetitively until the fuel without
bubbles comes out from the
bleeding plug screw.
¥ After the whole air is pulled out, Strainer

close the plug screws of the fil-
ter and the pump.
¥ Confirm the resistance of fuel

delivery by repetition pressing EB1M4003
of the feed pump cap, Pressure
and turn the priming pump cap
simultaneously to close it.
4.6.5. Checking the fuel injection timing (by authorized specialist personnel )
Check the fuel injection timing every year. Refer to details Ò6.3.15. Injection pump & injec-
tion timingÒ.
Caution
¥ Check the fuel injection pump housing for cracks or breaks, and replace if damaged.
¥ Check whether the lead seal for idling control and speed control levers have been
removed or not.
¥ No alterations must be made to the injection pump. If the lead seal is damaged the
warranty on the engine will become null and void.
¥ We strongly recommend that any faults developing in the injection pump should be
taken care of by authorized specialist personnel.
4.6.6. Injection Nozzle Maintenance (by authorized specialist personnel)
Check the fuel injection nozzle every year or increasing the smoke excessively.
Refer to details Ò7.3.3. Fuel injection nozzleÓ.
- 42 -
4.7. Electric System
4.7.1. Warning lamp check
Check the lamps of the gauge panel carefully whether the lamp is switch on or not while the
engine is running. If the oil warning lamp is switched on below 0.5 bar of the oil pressure and
the water temp warning lamp is switched off over 95 ûC of water temperature, their function is
normal.
4.7.2. Battery charging check
Always check whether battery capacity is sufficient or not before sailing far away from harbor.
4.7.3. Engine wiring check
Check the engine wiring is loosened, shorted or worn every 600 hours.
4.8. Valve Clearance
The valve clearances are to be adjusted at the times of the following situations.
¥ After initial 50 hours operation.

¥ When the engine is overhauled and the cylinder heads are disassembled.
¥ When severe noise comes from valve train.
¥ When the engine is not normally operated, even though there is no trouble in the fuel system.
The valve clearance of the cold engine are as follows ;
- Intake valves : 0.25 mm
- Exhaust valves : 0.35 mm
4.8.1. When the engine is not used long time
In case of the engine is not used long time, preserve the engine from corrosion, faulty matters
in order to run the engine operation easy and keep it long maintenance.
Especially the main external and internal components of the engine are likely to corrode as fol-
lows.
¥ Drain the coolant of the engine completely and refill the new flesh water in the engine and
run it until the water line is cleaned quite.
After draining the coolant refill the anti-freeze 35~40% with the fresh water again.
¥ Run the engine until engine coolant is up to normal temperature 71~85 ûC and then stop the
engine.
¥ Change the oil and oil filter cartridge new one after running the engine for 10~15 minutes in
order to drain the faulty matters in the oil pan as clearly as possible.
¥ Close the valve or cock of the fuel tank and clean the fuel filter and water separator..
¥ Run the engine about 5 minutes in order to circulate the new fuel through the all lines fully.
¥ Clean the air filter element and If worn severely change it new one.
- 43 -
¥ Drain the reduction gear oil completely and clean the strainer inserted in the inner side of it
and then refill the specified oil (SAE #30) up to the maximum level of the oil dipsticks.
¥ Run the engine on idle rpm for 5 minutes and then shift the control lever of the reduction
gear Neutral to Forward, Neutral to Reverse position in turn to circulate the oil around the
all lines of it.
¥ Put the engine throttle lever on idle position then reduction gear and FPTO lever on switch
off position (Neutral & OFF).
¥ Drain the engine coolant completely and remove the drain plugs.
¥ Close the kingston valve of the sea water line tightly, Specially likely to freeze, drain the
water of the heat exchanger, inter cooler, reduction gear oil cooler and keep the plugs
opened. At last donÕt forget to detach the sea water pump impeller and preserve it a dark
place.
¥ First of all detach the battery wire (-) and then the other wires and clean the wires. If the bat-
tery is refilled with the distilled water, refill it but DAEWOO batteries need not.
And apply the grease on the surface of the wire terminals to protect corrosion.
¥ Loosen the V-belt to prevent its tension and push the paper sheet in the pulley homes under
the V-belts.
¥ Run the engine on idle rpm or some more for 10 minutes once 10 days at least to lubricate
all lubrication system and charge the batteries of the engine.
¥ The engine not used for a long time should check the condition of it regularly. Specially apply
the grease on the engine parts likely to corrode.
4.9. When the Engine is Sunk
If the engine is sunk to water, remove the moisture of all engine parts as soon as possible and
ask your DAEWOO dealer for service of the engine at once.
Repair man disassembles all parts of the engine and remove the salty moisture of each disas-
sembled component then apply oil to the parts at once.
At last check whether the components of the engine is dried and eroded away or damaged
especially components of the fuel system. This action must be finished quickly without delay
time or maybe results engine fatal damage from salty corrosion. Be sure to install the auto bilge
pump in the bottom of the boat to keep the water level below the flywheel housing and to pre-
vent overflowing with water.
- 44 -
5. MAIN ACCESSORY PARTS
5.1. Reduction Gear
Refer to Òreduction gear manualÓ provided with engine separately for detail operation and main-
tenance of reduction & maintenance.
5.1.1. Construction and operation
The reduction gear is used for high-speed engine and consists of 4 major components such
as input shaft, gear shaft, output shaft, and housing.
The clutch for forward and reverse movements is composed of a hydraulic wet-type and multi-
plate type, and the construction and power line is as follows ;
1
2
3
4
5
11
6
7
8
9
10
EFM6006I
<Power line>
Neutral : 1-2-5-4-8
Forward : 1-2-5-3-7-10
Reverse : 1-2-5-4-8-9-6-7-10
1 Rubber block 6. Reverse pinion

2. Spider 7. Output shaft
3. Forward pinion 8. Reverse drive gear
4. Reverse drive gear 9. Gear shaft
5. Input shaft 10. Propeller shaft
- 45 -
The hydraulic-type clutch is composed of forward main body, reverse main body, output shaft,
and selector valve.
The selector valve assembly installed on the external part is a device designed to control for-
ward, neutral, and reverse movements and also it can be remote-controlled. The oil pumped
up at the pump supplies hydraulic pressure for the clutch assembly, lubricating portions on
gear and bearings, and cooling system. But when assembling this hydraulic type clutch, use
care so that it is aligned with the engine correctly.
5.1.2. Operation
1) Before operation
¥ Check the tightening bolts and nuts on the components as a whole for looseness.
¥ Check the oil level with the oil level gauge.
(Run the engine at idle for a few minutes, then stop it before checking the oil level.)
¥ Place the control lever in the neutral position before starting the engine.
2) Starting
¥ Run the engine at idle for about 10 minutes.

¥ Check for oil leaks, unusual sound, temperature, etc. while idling the engine.
¥ While checking the clutch pressure, increase the engine rpm.
3) Driving and stopping
¥ Check to see that the specified pressure is obtained when engaging the clutch.
The pressure may drop slightly at low engine rpm, but it does not affect the operation of
the engine.
¥ When attempting to change gears for forward or reverse movement, first put the engine
rpm to idle.
¥ The temperature of oil at operation must be 60 ~ 90 ûC.

¥ When attempting to stop the engine, be sure to place the control lever in the neutral position.
4) Emergency bolt
The emergency bolt is designed to couple the clutch mechanically when the clutch indicates
abnormal condition or slip at clutch coupling operation. The reverse clutch pack has no
emergency bolt. When using the emergency bolt, first loosen the tightening bolts to remove
the control block, tighten the 8mm wrench bolt on the forward disc pack using a 6mm L-
shaped wrench, then reassemble the control block in the reverse order. Be sure to use this
emergency bolt literally in case of emergency.
Snap Steel plate

ring Sintered plate
Emergency
bolt
Back Piston
plate
EA7O6011
- 46 -
5.2. Front Power Take Off
Refer to Service and Operation manual of AP Power Take Off company for detail operation and
maintenance.
5.2.1. PTO Description and operation
Below figure shows a section view of a typical multiple-plate PTO.

A driveshaft(1) is carried in a cast iron housing(2). The tapered roller bearing(4) locates in the
flywheel(5) (various types of bearing can be specified) to support the input end of the drive-
shaft. The body(6) is pressed on the driveshaft and retained by a key(28). External(male)
splines on the body are mated to internal splines on the pressure plate(7). With double and
triple plate PTO there are intermediate pressure plates(8) which also slide on the body.
Between the body and pressure plates are the friction facings(9) which (as shown on the lower
figure) are molded with gear teeth along the outside diameter. The gear teeth on the facings
engage with gear teeth on the drive ring(10) which is in turn bolted to the engine flywheel.
Power flow is from the engine flywheel to the drive ring, through the drive ring gear teeth to
the friction facings. With the PTO engaged, the facings are clamped between the pressure
plates and transmit power through the splines on the pressure plates to the body. Finally,
power is transmitted to the driveshaft through the key(28).
EB4O5001
- 47 -
Release levers(11) carried on the pressure plate are connected to a release sleeve(12) by
control links(13). The PTO is engaged by moving the lever(14) in the direction of the engine.
The lever is attached to a cross-shaft(15) in the PTO housing and a release bearing yoke(16).
As the lever moves toward the engine, the bearing yoke rotates with the cross shaft and
moves the release bearing(17) and sleeve(12) to contact with the adjusting ring assembly(18).
As pressure is applied to the adjusting ring, the control links force the release levers against
the pressure plate. When sufficient pressure has been applied through the lever, the release
levers and control links snap Òover-centerÓ thus locking the pressure plates and friction facings
together in the engaged position.
Regular adjustment is required to maintain the over-center load as frictionfaces

wear during service.(see adjustment procedure).
5.2.2. How to use PTO
(1) PTO engagement procedure
Start the engine and run until sufficiently Òwarmed upÓ to maintain normal engine idle
speed. With the engine running at, or slightly above, idle speed but not in excess of
1,200 rpm, push handle firmly and quickly, without stalling the engine, until the handle
snaps into engaged position.
Do not slip the PTO excessively during engagement. Engagement of the PTO
at engine speeds above 1,200 rpm and/or excessive slipping of the PTO during
engagement or operation can cause clutch failure and will void the clutch warranty.
(2) Checking engagement load
Check PTO adjustment as follow :
¥ Using a torque wrench and 1-1/4Ó (32 mm) socket on the hex fitting on the PTO operat-
ing handle, check torque on cross shaft required to engage PTO.
Note :
If the PTO handle does not have a hex fitting, use special service tool on the cross
shaft spline. (Refer to the ÒService & Operation Manual of AP POWER TAKE OFFÓ)
¥ Readjust PTO with adjusting ring if necessary. (Refer to Ò5.9.3. PTO engagement pro-
cedureÓ.)
<Engagement load at end of Standard PperatingLever 63.5 cm (25Ó)>
Over-Center Load at end of Lever Equivalent Torque at Cross Shaft

PTO Size
lbs. Kg lb.ft. Nm
10Ó & 11.5Ó 75 ~ 90 34 ~ 41 156 ~ 187 211 ~ 254
14Ó 80 ~ 100 36 ~ 45 167 ~ 208 226 ~ 282
- 48 -
DAEWOO engines only apply to 11.5Ó PTO size.
Do not adjust the PTO too tightly. Loads above the maximum quoted can cause PTO com-
ponent failure.
¥ Re-adjust PTO with adjusting ring if necessary.(Refer to PTO adjustment 5.2.2.)

¥ Recheck cross shaft torque.
¥ Repeat adjustment until correct torque is achieved at cross shaft.
Note : After installation and during Òwear inÓ frequent adjustment may be necessary to
maintain correct overcenter loads. Failure to do this adjustment will result in exces-
sive wear and/or burn out which in not warrantable.
Do not adjust the PTO too tightly. Loads above the maximum quoted can cause PTO com-
ponent failure.
(3) PTO adjustment
¥ Do not attempt to adjust PTO with the engine running.

<Removing PTO from engine> <Shaft bearing adjustment>
LOCKING SCREW
LOCKING PLATE
SHAFT BEARING
KEY RETAINER RING
DRIVE SHAFT
PULLER CREASE NIPPLE HOUSING

HOLES (IF FITTED) BEARINGS
(1 on each side CROSS
of housing flange) SHAFT
¥ To adjust the PTO remove the inspection cover and release either the adjuster lock or socket
head screw in the red adjuster ring from the splines in the clutch body. Once the lock or socket
screws are disengaged turn the adjuster ring by hand, or by tapping it with a soft metal drift and
a hammer until the approriate over center load or cross shaft torque is obtained.
(See table bow or inspection cover).
- 49 -
<Adjusting rings>
DRIVE SCREW PLATE

DRIVE SCREW ADJUSTING
SPRING
LOCK RING
WASHER
SPRING
SCREW
ROLL STOP
LOCK (PIN)
PIN
ADJUSTING
LOCK
PLATE ADJUSTING LOCK

RING SPRING
EB2O5002
¥ Relocate lock or socket screw, turning adjuster ring clockwise if required, to ensure engagement
of the screw or lock in the nearest spline space. The socket screw should be tightened with a
torque of 10-13 Ibs.ft.(14~18Nm)
¥ Remove all foreign objects (tools etc.) from the PTO housing and replace the inspection cover.
(4) Facing Check
¥ If facings are worn, heat affected, or contaminated with lubricant they must be replaced. Severe
discoloration of facings often indicates the PTO has been operating in a slipping condition, pos-
sibly due to faulty adjustment.
¥ In cases of severe lubricant contamination, the source of the lubrication must be found and rec-
tified. Examine the teeth for wear or cracks, replace as required.
¥ New PTO assemblies and those serviced with new friction facings will requier frequent adjust-
ment until the facings are fully bedded in.
Do not use the PTO friction factions on over slip and over wear.
It may be resulted in any early failure.
- 50 -
(5) Lubrication point
¥ The release bearing is lubricated through a grease nipple on the PTO housing which is con-
nected to the bearing by a flexible hose. The driveshaft output bearings are lubricated through
a grease nipple located on the PTO housing just above the bearings. Internal drillings in the
housing carry the grease to the bearings.
¥ Do not over grease. Excess lubrication at any of the points can result in contamination of the
friction facings which will cause immediate PTO failure.
4 PIVOT PINS
1 RELEASE
BEARING
M119
5 PILOT BEARING
(GREASABLE TYPE)
3 CROSS SHAFT
(2 Fittings) 2 MAIN BEARING 4 YOKE ENDS
EB2O5001
Note : Refer to the ÒService & Operation Manual of AP POWER TAKE OFFÓ attached
with AP Co. clutch itself for all detail contents.
- 51 -
5.2.3. Exploded View of Typical 11-1/2Ó ~ 14Ó Twin Clutch
EB4O5002
- 52 -
5.2.4. Front Power Take-Off (F.P.T.O)
1) For medium power
For front power take-off in line with

Flexible coupling V-pulley
crankshaft, it is a standard procedure
Driveshaft
to support driveshaft and V-pulley by
two pillow blocks by using flexile cou- Engine
pling for connection to engine.

When the front PTO is installed, be
sure to take deflection reading. Radial
run-out should be no more than 0.02
mm. Crank pulley Pillow blocks
EA4O7001
Be sure to limit the front PTO output
within the maximum allowable horse-
power as specified for each model in figure below. (Torque represents when there is no pro-
peller load)
Model Load(kW) rpm Model Load(kW) rpm

V158TIE 162 1,500 V180TI 220 1,500
V158TI 176 1,500 V222TI 265 1,500
2) For small power
The right figure is applicable to the

Crank pulley
drive arrangement in which the dis-
V-pulley, PTO
tance between the end face of the
MAX. 170mm
engine pulley and the centerline
Engine (6.7 in)dia
through pulley groove is not greater
than 60mm. The distance is indicated
as ÒLÓ in right figure.
L EA4O7002
Model L mm Belt driven side load(kW) rpm
V158TIE 91
V158TI 95
60 1,500
V180TI 115
V222TI 125
- 53 -
5.3. Propeller Selection
Your dealer has chosen a propeller
OUTPUT
POWER
designed to deliver top performance and 100% C D
90%
economy under most conditions. To obtain
80%
the maximum percentage of available 70%
A
horsepower (A), the engine RPM at Full 60%
50%
Throttle should be in the specified Full B
40%
Throttle Operating Rage (B). 30%
Refer to Specifications in Performance

Curve. EA4O7003 RPM
If the engineÕs full throttle RPM on normal

load is below the specified on the low side of the range, use a propeller with less pitch to
increase the RPM.
Should the engineÕs full throttle RPM want to exceed the specified range(B), the engine RPM is
limited by the governor. Use a propeller of higher pitch to stop the limiting by the governor.
Note : Engine damage can result from incorrect propeller selection which :
¥ (C) Prevents engine RPM from attaining the specified ÒFull Throttle Operating RangeÓ.
Engine is laboring, install lower pitch propeller.
¥ (D) Allows engine RPM above the specified. ÒFull Throttle Operating RangeÓ. Engine
RPM is livited by the governor, install a higher pitch propeller.
- 54 -
5.4. Electric System
5.4.1. Alternator
Terminal R Terminal L
Terminal P Terminal B
Terminal E
EFM5001I
The alternator is fitted with integral sili-

P
con rectifiers. A transistorized regulator
B
mounted on the alternator controls the
L
alternator voltage evenly. The alternator
I.C
should be operated with the regulator R
Regulator
and battery connected in circuit to avoid F
the damage of the rectifier and regulator.

Body
The alternator is maintenance free, but it
must be protected against dust and Circuit EA7O3008
above all against moisture therefore it
must be mounted a cover for protector
properly.
(1) In case of abnormal charging
¥ Voltage measurement between terminal and alternator body during operation.

<Voltage during operation> <Voltage during stop>
Measuring point Voltage Measuring point Voltage
Terminal B - Body About DC28V~29V Terminal B - Body about DC24V
Terminal L - Body About DC28V~29V Terminal L - Body about DC2V
Terminal R - Body about DC28V~29V Terminal R - Body about DC24V
6 For the confirmation of wiring state, measurement of voltage should be carried out only
at each terminal during engine stop.
- 55 -
(2) Inspection points on the voltage regulator
<Resistance value between voltage regulatorÕs terminals>
Resistance Value Resistance Value

Terminal Terminal
A)
(KA A)
(KA
+ - + -
L E about 2
R E about 53 E R °
F E about 50
L B about 50
H L about 50 L R °
R B About 168 B R °
5.4.2. Precautions in use
¥ Pay attention to dropping the battery voltage capacity when they are left for long time even
without use.
¥ As starting may not be done well sometime in cold winter season, do not try it to be contin-
uous immediately but try to start again after waiting about 30 seconds.
¥ Prior to operating the gauge panel, make sure the polarity of battery once again (In majori-
ty of polarities, red side is Ò+Ó and black one is Ò-Ó)
¥ On disassembling the gauge panel may be accompanied a risk of electrical shock, always
work after pulling off the connector at rear side of it without fail.
¥ If the silver paper etc is used for connecting the cut-off fuse, because the excessive current
might flow into the parts to damage, when fuse is cut off, after resolving the problem locat-
ing the cause, replace it with new fuse.
¥ Since battery has a danger of explosion by a heat, it must not be placed at the spot where
generates a lot of heat.
¥ When engine is in stop, pull out the key always. Thus, a hazard of fire or wound due to
wrong operation may not happen.
¥ In case of scrapping the batteries, observe the followings.

NOTE : Do not throw it in the fire to scrap.
It should not be thrown away into the places where are liable to cause the envi-
ronmental pollution such as stream, river and mountain. Pack them as far as
possible and dispose it as rubbish that is unable to use again.
¥ DAEWOO will not be responsible to the problems that might be raised by the disassembling
and structural change of this product without consultation.
- 56 -
5.4.3. Starter motor
The starter motor is installed on the fly-

Circuit diagram
50 30
wheel housing.
When the starting key switch is turned
on, the starter motor pinion flies out and
engages the ring gear of the flywheel.
Then the main contact is closed, current
flows, and the engine is started. M
After the engine starts, the pinion auto-
matically returns to its initial position 31 EB2M6002
when the starting key switch is released.
Once the engine starts, the starting key
switch should be released immediately.
Otherwise, the starter motor may be
damaged or burned out.
In case of repairing the engine, dip the
pinion of the starter and ring gear into
the fuel and remove the corrosion with
brush.
After that apply the grease on them to
protect the corrosion.
Whenever you clean the starter, always
pay attention not to occur the electric
short due to entering the water etc.
Starter motor always should be prevented from humid.
Precaution
Before working the electric system of the engine be sure to detach the battery
wire (-) to prevent from electric short.
- 57 -
6. DISASSEMBLY AND ASSEMBLY OF MAJOR COMPONENTS
6.1. Disassembly
6.1.1. General precautions
¥ Maintenance operation should be carried out in a bright and clean place.

¥ Before disassembly, provide racks for arrangement of various tools and disassembled parts.
¥ Arrange the disassembled parts in the disassembly sequence and use care to prevent any
damage to them.
6.1.2. Cooling water
¥ Open the pressure cap of heat exchanger tank to remove the air pressure.
¥ Loosen the drain plugs as follows and then drain out the cooling water into a container.
1) Below the right wet turbocharger elbow
2) Below the left exhaust manifold cover
3) Below the heat exchanger inlet pipe.
4) Below the oil cooler housing
5) Cylinder block face upper the starter.
6.1.3. Engine oil
Remove the oil after opening the oil

drain cock of engine or reduction gear
side, and let engine oil discharge into
the prepared vessel.
EB2M3001
¥ Remove sea water pipes connected

to the inlet and outlet pipes.
¥ Remove the sea water pumps.
EFM2001I
- 58 -
6.1.5. V-belt.
Loosen the belt tension adjusting bolts,

and remove the V-belt.
EFM2002I
6.1.6. Alternator
Remove the supporting guide piece for

installing the alternator and the bracket
bolts.
Disassemble the alternator.
EFM2003I
6.1.7. Vibration damper
Remove the fixing bolts for crankshaft

pulley in reverse order of assembly and
disassemble the crankshaft pulley and
vibration damper.
EFM2004I
6.1.8. Oil filter assembly
This filter is change-over type, that is the

servicing procedure is for the filter side
requiring to be shut off while the engine
is running.
During continuous operation, the selec-
tor lever should be placed in a position
where both filter halves are in operation.
¥ Disassemble the oil filter cartridge

EFM2010I
using a filter wrench.
- 59 -
¥ Do not use again the cartridge
removed after use.
¥ Remove the oil filter head fixing bolts

and disassemble the filter head.
EFM2006I
6.1.9. Cooling water pump
¥ Loosen the various hose clamps for

the connections.
¥ Remove the cooling water discharg-

ing pipe and disassemble the thermo-
stat.
¥ Loosen the water pump fixing bolts

and detach the cooling water pump.
EFM2007I
6.1.10. Starting motor
Loosen the starting motor fixing nuts

and dismantle the starting motor.
EFM2008I
6.1.11. Fuel filter
This filter is change-over type, that is

the servicing procedure is for the filter
side requiring to be shut off while the
engine is running.
During continuous operation, the selec-
tor lever should be placed in a position
where both filter halves are in opera-
tion.
EB2M2001
- 60 -
¥ Disassemble the rubber hoses of the
fuel supply and discharge.
¥ Remove the fuel filter fixing bolts and

disassemble the filter.
6.1.12. Injection pipe
¥ Disassemble the injection pipe from

the nozzle holder and fuel injection
pump.
¥ Disassemble various fuel pipe and

hose.
EB2M3003
6.1.13. Oil cooler assembly
¥ By removing the plug screw of cool-

ing water discharge port, the cooling
water is discharged.
¥ By removing the cooler housing fix-

ing bolts and detach the oil cooler
housing from the cylinder block.
EFM2012I
¥ Remove the oil cooler cover fixing

bolts and disassemble the oil cooler.
EFM2012I
- 61 -
6.1.14. Turbocharger
¥ Loosen the hose clamp for connect-

ing the intake stake and tear down
the air intake stake.
¥ Loosen the clamp for connecting the

air intake manifold.
¥ Remove the hollow screw of the

turbocharger inlet & outlet pipe for
lubricating, and tear the pipes down.
¥ Loosen the turbocharger fixing nuts EB2M3004

and detach the turbocharger from
the exhaust manifold elbow.
6.1.15. Inter-cooler
¥ Tear down the various hoses and

pipes from the inter cooler.
¥ Remove the inter-cooler fixing bolts

and detach it.
EFM2014I
6.1.16. Exhaust manifold
¥ Loosen the exhaust manifold fixing

bolts and dismantle the manifold
from the cylinder head.
EFM2015I
- 62 -
6.1.17. Intake manifold
¥ Remove the manifold fixing bolts and

detach the intake manifold from the
cylinder head.
EFM2016I
6.1.18 Heat exchanger
¥ Remove the hoses and the pipes.

¥ Remove the cover bolts
¥ Remove the 4 fixing bolts from the
lower plate.
¥ Pull out the heat exchanger tube

bundle.
¥ Clean the tubes.

EFM2017I
6.1.19. Flywheel housing cover
¥ Detach the side cover.

¥ Disassemble the flywheel housing
cover.
EFM2018I
6.1.20. Fuel injection pump
¥ Remove the oil hoses for lubrication

and the fuel hoses.
¥ Loosen the fixing bolts of fuel injec-

tion pump and detach the fuel
Injection pump.
- 63 -
6.1.21. Cylinder head cover
Remove the fixing bolts and tear the

cylinder head cover down.
EFM2020I
6.1.22. Nozzle holder
¥ By means of a special tool, loosen the

nozzle holder assembly and take it
out.
EFM2021I
6.1.23. Rocker arm
¥ Remove the rocker arm bracket fix-

ing bolts and take the rocker arm
assembly out.
¥ Pull out the push rod.
EFM2022I
6.1.24. Cylinder head
¥ Loosen the cylinder head fixing bolts

in the reverse order of assembling,
and remove them all and then take
the cylinder head out.
¥ Remove the cylinder head gasket

and scrap it.
¥ Eliminate the residue from the cylin-

der head face and cylinder block
face. EFM2023I
- 64 -
Notes :
Be careful not to damage the cylinder head face where its gasket contacts.
6.1.25. Oil pan
¥ Remove the fixing bolts and detach

the oil pan.
¥ Remove the oil pan gasket and

scrap it.
EFM2024I
6.1.26. Oil pump
¥ Remove the oil suction pipe fixing

bolts and tear them down.
¥ Remove the oil relief valve fixing

bolts and take them out.
¥ Remove the oil pump fixing bolts and

detach the oil pump.
EFM2025I
6.1.27. Piston
¥ Remove the connecting rod cap

bolts in the reverse order of assem-
bling and follow the similar method
as in the cylinder head bolt removal.
¥ Tapping the upper and lower con-

necting rod caps lightly with a non-
steel hammer, detach them and take
the bearings out.
¥ By pushing the piston assembly with EFM2026I

a wooden bar toward the cylinder
headÕs direction, remove the piston.
Notes :
Be careful of the removed pistons not to collide each other or with the other
parts.
At the storage of pistons, maintain them in the order of cylinder number. (In
order for connecting rod caps not to mix one another, temporarily assemble
them to the corresponding connecting rods.)
- 65 -
6.1.28. Front oil seal holder
¥ Remove the oil seal holder fixing

bolts and tear it down.
¥ Remove the oil seal and gasket from

the oil seal holder and scrap them.
EFM2027I
6.1.29. Flywheel
¥ Remove the flywheel fixing bolts in

the order of disassembling and
detach the flywheel.
EFM2028I
¥ Remove the flywheel ring gear.

- Heat the ring gear evenly with a
gas burner (up to 200 ûC) to invite
volumetric expansion.
- Tapping around the edges of the
ring gear with a hammer and brass
bar to remove it.
Caution :
EA0M4028
Do not damage the flywheel.
6.1.30. Flywheel housing
¥ Loosen the housing fixing bolts and

detach the flywheel housing.
¥ Remove the oil seal from the fly-

wheel housing.
EA6M2010
- 66 -
6.1.31. Crankshaft
¥ Loosen the bolts from bearing caps.

¥ Dissemble the main bearing cap fix-
ing bolts in order of assembling.
¥ Remove them in the same way of the

cylinder head bolts.
¥ Maintain the removed bearing caps

in the order of cylinder number.
¥ Temporarily install the bolts at the

both side of crankshaft, and lift the EFM2029I
shaft with a rope.
Notes :
Do not mingle with the metal bearings and bearing caps randomly. To prevent mixing,
temporarily assemble the metal bearings to the corresponding bearing caps in turn.
6.1.32. Camshaft and tappet
¥ Pull out the tappets from the cylinder block.

¥ Remove the camshaft being careful not to damage the camshaft and its bearings.
6.1.33. Oil spray nozzle
¥ Remove the spray nozzle fixing bolts

and tear down the oil spray nozzles.
6.1.34. Cylinder liner
¥ By means of a special tool (Extractor),

pull out the liner from the cylinder
block.
EFM2030I
- 67 -
6.2. Inspection
6.2.1. Cylinder block
1) Clean the cylinder block thoroughly and check a visual inspection for cracks or damage.
2) Replace if cracked or severely damaged, and correct if slightly damaged.
3) Check the oil and water passing lines for restriction or corrosion.
4) Inspect the cylinder blockÕs camshaft bush to any damage and the alignment of oil supply
holes and if abnormal or severe wears, replace it.
5) Make a hydraulic test to check for any cracks or air leaks.
Hydraulic test :
Stop up each outlet port of water and oil passages in the cylinder block, apply air pressure of
about 5 kg/cm2 against the inlet ports, then immerse the cylinder block in water for about 1
minute to check any leaks. (Water temperature: 70 ûC)
6.2.2. Cylinder liner measurement
¥ Assemble the cylinder liner at the

cylinder block and measure inner
diameter at upper, middle, lower that
is, 3 steps by 45û interval and calculate
the average values after eliminating
the maximum and minimum values.
¥ If the measured values are very close

to the limit value or beyond, replace it.
EFM2032I
Liner Standard Limit
inner dia. N127.990 ~ N128.010 mm N128.16 mm
6.2.3. Cylinder head
¥ Carefully remove carbon from the lower face of the cylinder head using nonmetallic materi-
al 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 magnetic flaw detector.
- 68 -
(1) Cylinder head disassembly
Notes :
Be careful for the cylinder head gasket
contact face of the cylinder head not to
be damaged.
¥ Remove the cotter pin pressing the

valve spring by means of a special
tool. Valve spring
compressor
EA0M4007
¥ Take out the valve stem seal.

¥ Pull out the intake and exhaust valves.
¥ Remove the valve guides from the
combustion room side of cylinder head
by means of a special tool.
EFM2034I
(2) Inspection and measurement of cylinder head
Inspection of cracks and damage
¥ Eliminate the carbon residue and gasket piece from the cylinder head lower face thorough-
ly. Then be careful for the valve seat not to be damaged.
¥ For cracks or damages to search difficult may be inspected by a hydraulic test or a magnetic
powder test. (Hydraulic test is same as for cylinder block.)
Distortion of cylinder head bottom face
1) Distortion at the lower face
¥ Measure the amount of distortion

(t)
using a straight edge and a feeler
gauge at six positions as shown in the
B
right figure. A
¥ If the measured value exceeds the

D
C
standard value, retrace the head with
grinding paper of fine grain size to cor-
E
rect such defects.
F
EA3M2031
- 69 -
maximum allowable limit, replace the
cylinder head.
<Lower face warp and height>
Standard Limit
Warp 0.05 mm or less 0.2 mm
Thickness : t
113.9 ~ 114.0 mm 112.9 mm
(reference) EA6M2002
(3) Inspection and measurement of valve & valve guide
a) Valve
¥ After cleaning the valves with clean

diesel oil, measure the valve stemÕs
outside diameter at upper, middle, and
lower to determine the wears and
when the wear limit is more than the
Stem tip
limit, replace the valves.
Valve Standard Limit
Intake N11.969 ~ N11.980 mm N12.130 mm

EFM2036I
Exhaust N11.945 ~ N11.955 mm N12.105 mm
¥ Inspect the scratch and wear of valve

stem seal contacting face, and if nec-
essary correct with the grinding paper
but if severe replace it.
¥ If valve head thickness (H) becomes

less than 1.6mm for intake and 1.3mm
for exhaust, replace the valve.

Intake 2.6 ~ 3.0 mm 1.6 mm
H
Exhaust 1.9 ~ 2.3 mm 1.3 mm
EFM2037I
- 70 -
b) Valve guide
¥ Insert the valve into valve guide and

measure the clearance between valve
and valve guide by the shaking degree
of valve. If the clearance is bigger,
measure the valve and then replace
Measuring
the more worn valve guide. Point
¥ If the valve guide has already been

replaced, measure the center with
EA0M4052
valve seat if it deviates or not and if
abnormal it must be corrected.
(Simultaneously be processed when in guide reamer process.)
Intake 0.020 ~ 0.049 mm 0.20 mm

Exhaust 0.045 ~ 0.074 mm 0.25 mm
¥ After inserting the valves in the valve guide of the cylinder head using a special tool, mea-
sure whether the concentric circles between the valve guide and seat is aligned.
c) Valve seat
¥ Inspect the damage and wear of valve seat and if necessary replace.
¥ Valve seat thickness and angle
Assemble the valves at the cylinder
head and using the measuring instru- 10
0 20
ment from the lower face, measure the 90 30
80
40
projection amount of valve. If the mea-

70
50
60
sured value is more than the use limit,

replace the valve seat.
<Valve seat projection>
Standard Limit EFM2038I
0.65 ~ 0.95 mm 2.5 mm
<Valve seat angle>
Intake Valve 30û
Exhaust Valve 45û
O
EA0M4048
- 71 -
¥ The disassembly of valve seat can be
pulled out by means of a special tool
Valve seat
with the arc welding done at two points Insert
of valve seat rotating tool or valve
seat.
Cylinder head
Wdlding bead EA3M2032
¥ Regarding the valve seat assembling,

shrink the valve seat by putting it in the dry ices for about 1 hour or so, and then press it into
the cylinder head by means of a special tool.
¥ After coating the grinding powder paste on valve head contacting face of valve seat, and
after executing a sufficient lapping operation with the rotating and grinding motion of valve,
wipe off the grinding agent thoroughly.
d) Valve spring
¥ Inspect the outlook of valve spring and

if necessary replace it. 1.0mm or less
¥ By means of spring tester, measure
the tension and free length.
Free length
¥ Measure the perpendicularity of valve
spring.
¥ In case that the measured value

exceeds the limit value, replace it.
EFM2039I
<Tension test and Free length >
Free length 65.5 mm

Inner
When given a regular load
Spring 46.3 mm
(15 ~ 17 kg)
Free length 64 mm
Outer
When given a regular load
Spring 46.3 mm
(37 ~ 41 kg)
e) Assembling cylinder head
¥ Clean the cylinder head thoroughly.

¥ Coat the valve stems and valve guides with engine oil and assemble the valves.
¥ Replace the valve stem seals with new ones and insert the stem seals to the valve guides
of cylinder head using a special tool.
(Be careful for the valve stem seals not to be damaged.)
¥ Install the valve spring washer to valve guide.

¥ After putting on the inside, outside spring, install the valve spring seat on them.
- 72 -
NOTE :
Install the valve spring seat with ÒTOPÓ side (painted in yellow) up.
¥ Pressing the spring down using a spe-

cial tool, assemble by inserting the
valve cotter.
¥ After the valve is assembled, inspect

the valve tapping it lightly with a ure-
thane hammer if accurate assembly
was done.
EFM2040I
6.2.4. Rocker arm
(1) Rocker arm disassembling
¥ Remove the snap rings in both

ends of rocker arm with a pair
of pliers.
¥ Tear down washer, rocker arm.

¥ Disassemble the rocker arm
bush by means of a press.
EFM2091I
(4) Inspection and measurement
a) Rocker arm bracket

(Single unit type with a shaft)
Measure the outer diameter of
rocker arm bracket with out-
side micrometer at the position
that the rocker arm is installed,
and in case that it exceeds the
limit value, replace.
Diameter
Items Standard Limit
Bush Inner Dia. N25.005 ~ N25.035 mm N25.055 mm

EA6M2003
Shaft outer Dia. N24.967 ~ N24.990 mm N24.837 mm
Clearance 0.015 ~ 0.068 mm 0.25 mm
b) Rocker arm
Inspect the rocker arm surface that contacts with the valve stem for any scratch,
step wear and correct the minor degree of wear with an oil stone or the fine grind-
ing paper and replace if they are severe.
- 73 -
c) Tappet and push rod
¥ By means of outside micrometer,

measure the outer diameter of
tappet and replace the severe
(1) Unevenness (2) Crack (3) Normal
ones.

Tappet clearance 0.035 ~ 0.077 mm 0.25 mm
(4) Abnormal
EA0M4070
¥ By inspecting the tappet sur-

face that contacts with the
camshaftÕs cam for any crack
and scratch etc., and if the
degree is small, correct them
with an oil stone or the grinding
paper but if severe replace
them.
Feeler gauge
EA0M4073
¥ Place the push rod on the sur-
face plate and rolling it, Inspect
the curving degree with a clearance gauge and if abnormal, replace it.
<Run-out>
Limit 0.3 mm or less
d) Rocker arm reassembling

Inspect the oil passages of rocker arm and rocker arm bracket for any clogs and
reassemble them in the reverse order of disassembling after thorough cleaning.
6.2.5. Camshaft
(1) Axial end play
¥ Push the camshaft toward the

pulley side.
¥ Place a dial gauge onto the

camshaft gear.
- 74 -
¥ Measure the camshaftÕs axial end
play, moving the camshaft gear by
means of a driver.
Limit 0.2 ~ 0.9 mm
¥ If excessive end play, assemble it by

means of other thrust washer.
¥ Visual check
With inspecting the cam surface for any damage with naked eyes and correct any minor
scratches by means of an oil stone grinding and if severe, replace it.
¥ Cam lobe height

Use a micrometer to measure the cam
lobe height and journal diameter.
If the measured number is less than
the specified limit, the camshaft must
replaced.

I II
Cam lobe Intake 56.37 mm 55.17 mm A I II
C B B
height (C) Exhaust 56.43 mm 55.11 mm
D A EA0M4062
Cam journal N69.91~
-
diameter (A,B) 69.94 mm
¥ Cam bearing diameter

Measure the camshaft bush inside
diameter using a cylinder gauge and Camshaft bearing
after comparing the inside and outside
diameters, replace if abnormal.
Standard Limit
N70.077 ~ N70.061 mm N69.897 mm
EA0M4063
¥ Clearance between camshaft journal

and body
Standard Limit
0.060 ~ 0.120 mm 0.18 mm
- 75 -
Camshaft bearing replacement
Remover, installer
Camshaft run-out
With placing the camshaft on two
V-blocks, and inspect the run-out
of the camshaft, adjust or replace
the severe one.
Limit 0.1 mm
EA0M4066
6.2.6. Crankshaft
¥ Inspect for any scratch or damage with naked eyes, and grind to the undersize
according to the damaged degree and use the undersized bearing.
¥ Inspect for any crack by means of magnetic powder and color check, and replace the
cracked ones.
Journal and pin diameter

With outside micrometer, mea-
sure the outside diameter of A ¥ ¥–
crank journal and crank pin at the
direction and position of the fig- B B
ure shown and take the wear.
A
<Crankshaft journal outside diameter>
Standard N103.98 ~ N104.00 mm
EA3M2050
- 76 -
<Crankshaft pin outside diameter>
1 3 4
Standard N89.98 ~ N90.00 mm
2 2
¥ In case that the lopsided wear is more than
3 4
the limit value, grind to the undersize, and 1
use the undersized bearing.
<kinds of bearings for undersize>

(a) Standard EA0M4017
(b) 0.25 (Inside dia. 0.25mm less than standard)

(c) 0.50 (Inside dia. 0.50mm less than standard)
(d) 0.75 (Inside dia. 0.75mm less than standard)
(e) 1.00 (Inside dia. 1.00mm less than standard)
There are 4 kinds of rounds as right figure, and

the crankshaft also can be used by regrinding "R"
as above.
<ÒR partÓ standard value> "R"

0
(a) Crank pin ÒR partÓ : 4.0 -0.5
0
(b) Crank journal ÒR partÓ : 4.0-0.5
"R" "R" "R"
NOTE :
In case of crankshaft regrinding, the ÒR EFM2048I
partÓ at the end of bearing must accu-
rately be ground without fail and should
avoid any processed jaw or coarse surface.
Run out of crankshaft

(a) Place the crankshaft on the V-block.
(b) Place the dial gauge on the surface
plate and measure the run out of
crankshaft rotating the crankshaft.
Standard Limit
0.06 mm 0.4 mm
(2) Inspection on crankshaft bearing and

connecting rod bearing
Inspection
¥ Inspect the crankshaft bearing and connecting rod bearing for any damages such as lopsided
wear, scratch etc. and if abnormal, replace it.
¥ Inspect the oil clearance between the crankshaft and bearing.

- 77 -
a) How to utilize the cylinder gauge
1 Assemble the main bearing at the

cylinder block and after tightening the
bearing cap at the specified torque,
measure the inside diameter.
Journal bearing
N103.98 ~104.00 mm
nominal diameter
Bearing cap
Initial 30 kg.m + angle 90û
Bolt torque
2 Assemble the bearing at the bigger

end of connecting rod, and after tight- Section
A 10 A-B
ening the bearing cap at the specified
10
torque, measure the inside diameter.
2 8
1 3
8
Connecting rod
N89.98~90.00 mm
bearing journal diameter
B
Connecting rod EFM2049I
Initial 10 kg.m + angle 90û
Bolt torque
3 Crankshaft pin and bearing clearance In case that this clearance value exceeds the limit
value, grind the crankshaft journal and pin and then use the undersized bearing.
Standard Limit
0.066 ~ 0.132 mm 0.166 mm
b) How to utilize plastic gauge
1 Install the crankshaft in the cylinder block and place the plastic gauge on the crankshaft journal
and pin at axial direction and then after tightening the bearing cap at the specified torque and
again after tearing apart the bearing cap, measure the flatten plastic gauge thickness by pick it
up. This is the oil clearance.
2 With the same points, the oil clearance of connecting rod also can be measured.
- 78 -
End play
¥ Assemble the crankshaft in the

cylinder block.
¥ Install the dial gauge, and

measure the end play of crank-
shaft by pushing the crankshaft
to axial direction.
Standard Limit EFM2050I

0.190 ~ 0.322 mm 0.452 mm
6.2.7. Piston
(1) Piston disassembling
¥ Pull out the snap ring for piston

pin and with a pair of snap ring
pliers.
¥ With a round bar, the piston

pin.
¥ With a pair of pliers, remove

the piston rings.
¥ Clean the piston thoroughly.
EFM2051I
(2) Inspection & Measurement of the piston
¥ With naked eyes, inspect the piston for any wear, crack and scratch and particularly
inspect carefully at the ring grooves for any wear.
- 79 -
¥ With the outside micrometer, measure
the pistonÕs outside diameter the mea-
suring position is 71.5mm from the
piston lower end, and the direction of
measurement must be perpendicular to
the piston pin direction.
Standard N127.739 ~ N127.757 mm
¥ By comparing the measured value of

the piston outside diameter with the
cylinder liner inside diameter, the
bigger clearance is replaced.
¥ Measurement of Cylinder bore

Assemble the cylinder liner at the cylin-
der block and measure inner diameter
at upper, middle, lower that is, 3 steps 2
by 45û interval and calculate the
average values after eliminating the
maximum and minimum values.
Standard N127.990 ~ N128.010 mm
EAMD067I
¥ Measure the clearance between the
cylinder liner bore and the piston outer
diameter, if it is more than the use limit
value, replace either one that is more
severe.
Standard 0.233 ~ 0.271 mm
(3) Piston ring & ring groove
Inspection
In case of piston ringÕs wear, damage or engine overhaul, replace piston rings.
Gap clearance
Measure the piston ring cut part.
¥ Insert the piston ring at the cylinder

linerÕs upper part perpendicularly.
¥ With a feeler gauge, measure the gap

clearance of piston ring.

limit value, replace it.
- 80 -
<Piston ring gap>
Division Standard Limit
Top ring 0.35 ~ 0.55 mm 1.5 mm
2nd ring 0.40 ~ 0.60 mm 1.5 mm
Oil ring 0.35 ~ 0.55 mm 1.5 mm
Piston ring groove clearance.
¥ Assemble the piston ring at the piston.

¥ Measure the each ringÕs groove clear- Feeler
gauge
ance and if the measured value
exceeds the limit value, replace rings
or piston.
<Piston side clearance>
Division Specified value Limit value
Top ring 0.35 ~ 0.55 mm 0.3 mm EA0M4032
2nd ring 0.050 ~ 0.082 mm 0.15 mm
Oil ring 0.030 ~ 0.062 mm 0.15 mm
(4) Piston pin
Outside diameter
With the outside micrometer, measure
the piston pinÕs outside diameter and if
the value is same as the use limit value
or less, replace it.
Standard Limit
N44.994 ~ N46.000 mm N44.979 mm or less
EA0M4031
Piston pin & connecting rod bush

clearance
Inspect the clearance between the pis-
ton pin and the connecting rod bush, if it
is more than the use limit value, replace
either one that is more severe.
Limit 0.003 ~ 0.015 mm
EA3M2047
- 81 -
(5) Connecting rod
Distortion and parallel

Install the measurement tester as figure.
Measure the distortion of the bigger and
smaller end bearing holes after that do
as regard parallel of both holes and if
abnormal, replace the connecting rod.
Standard Limit
0.02 mm 0.2 mm
EA0M4034
Amounts of wear
¥ After assembling the connecting rod in

the crankshaft measure the clearance between connecting rod bigger hole and crank pin
diameter using filler gauge.
¥ Assemble the connecting rod in the piston and then measure the clearance of these parts.
¥ If it is more than the use limit value, replace the connecting rod.
Standard Limit
0.02 mm 0.2 mm
(6) Piston reassembling
¥ After heating the piston at the piston

heater for about 5 min (120 ~ 150 ûC),
by aligning the piston pin hole with the
pin hole of connecting rodÕs smaller
end, insert the oil coated piston pin.
NOTE :
Confirm the direction of connecting
rod and assemble.
¥ With the snap ring plier, insert the snap

rings of the piston pin.
¥ With confirming the upper side indication of piston ring, after assembling the ring in the pis-
ton ring groove, inspect if the movement of ring is smooth.
¥ Arrange the assembled piston in order as the cylinder number.
- 82 -
6.2.8. Injection nozzle
¥ Set the nozzle assembly

between the vise holder and
disassemble it.
¥ Remove the nozzle nuts and 1 Nozzle holder body

disassemble the inner parts.
2 Cap nut
¥ Inspect the disassembled 3 Adjusting shim
parts if there is any damage, Compression spring
4
replace it.
5 Spindle
¥ Assembling can be done in the
6 Spacer
reverse order of disassem- 7 Nozzle nut
bling.
8 Nozzle
¥ After assembling the nozzle,
EFM2054I
set it in the injection pressure
measuring tester.
¥ By manipulating the tester

handle, inspect the injection
pressure and atomizing state.
<Operating pressure>
New nozzle holder 300 + 8 kg/cm2
Used nozzle holder 285 + 8 kg/cm2
EFM2056I
¥ In case of low or high injection

pressure, adjust by adding or
reducing the spring tension
adjusting shims.
¥ In case that atomizing state is

not good, it should be
replaced.
Normal Abnormal Abnormal
EFM2057I
- 83 -
6.3. Engine Re-assembly
6.3.1. General Preparation
¥ Clean all the disassembled parts, particularly oil 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 oil.
¥ 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-tight-
ening.
¥ Be sure to check that all the engine parts operate smoothly after being reassembled.
¥ Check the bolts for looseness after preliminary re-assembly.
¥ After completing the engine re-assembly operation, check if there is missing parts or short-
age of parts.
¥ Keep your hands clean during the working.

6.3.2. Cylinder block
Cover the floor of the workshop with wood plate or thick paper to prevent damage to the cylin-
der head and place the head face of the cylinder block towards downward.
6.3.3. Cylinder liner
¥ Replace the used O-rings with new

ones and insert the O-ring in the cylin-
der liner upper side, but the other one
in the cylinder block lower side sepa-
rately.
O-ring
¥ Coat the joint parts where O-ring con- for cylinder liner
tacts with oil. O-ring
for cylinder block
¥ After slipping the cylinder liner
smoothly into the cylinder block, press EA6M2008
it in being careful for O-ring not to
damage.
¥ After completion of assembling the cylinder liner, confirm no leaks with 4 kg/cm 2
hydraulic
test.
- 84 -
6.3.4. Oil spray nozzle
¥ Assemble the oil spray nozzle.

¥ Tighten the fixing bolts.
6.3.5. Tappet
Coat the tappet wholly with clean oil and

push in the tappet hole of the cylinder
block.
6.3.6. Crankshaft
¥ Put the wear ring into the heater to

heat it up to 150 ~ 200 ûC level, push
it over the crankshaft by means of a
jig.
Wear ring
EA6M2009
¥ Assemble the main bearing to the

cylinder block and coat it with engine
oil. Then assemble the bearing that
has a hole to the cylinder block side
and one that has no hole to the bear-
ing cap and be careful not to change.
EFM2060I
- 85 -
Assemble temporarily one bolt each at
both boltÕ holes and by connecting the
wire to the bolts, lift it with crane or
chain block and put down on the cylin-
der block carefully.
7 5 3 1 2 4 6
¥ Coat the crankshaft journal and pin

parts with clean engine oil, and after
fitting the main bearing into the bear-
EFM2061
ing cap and assemble it to the cylinder
block making sure of the number in
order not to change the bearing cap.
¥ Coat the bearing cap bolt and its bolt

seat part with engine oil necessarily and according to the tightening order, tighten them with
30 kg.m and with rotating angle method (90û ) and tightening order is as follows.
+10û
<Bearing cap boltÕs tightening order>

(1) First step : Coat the bolts with
engine oil.
(2) Second step : Screw down 1 ~ 2
threads.
(3) Third step : Tighten with about 15
kg.m by wrench.
(4) Fourth step : Tighten with about
25kg.m by torque wrench.
(5) Fifth step: Tighten with 30kg.m by EFM2062I
torque wrench.
(6) Sixth step: Tighten with final rotat-
ing angle method 90¡ +10¡
.
However, according to above tightening order, tighten step by step.
¥ Inspect if the crankshaftÕs rotation is smooth.

¥ Assemble the crankshaft gear on the crankshaft and coat a white paint mark on Ò1Ó part in
order to find easily.
6.3.7. Camshaft
¥ Coat the cam bush of cylinder block

and camshaft with engine oil.
¥ Assemble the cam bush and camshaft

for them not to be damaged.
¥ Assemble the crankshaft gear and the

camshaft gear making sure that the
1
gear marks on both gears are aligned 1 1
together as right figure.
EFM2063I
- 86 -
6.3.8. Flywheel housing
¥ Coat the thrust washer fixing bolt with

an adhesive and tighten it with speci-
fied torque.
Torque 4 kg.m
EFM2065I
¥ Coat the oil seal with lubricating oil

and assemble it carefully not to be
deviated or damaged by means of
special tool. (Mandrel for assembling).
¥ Attach the gasket on the surface of

cylinder block where the flywheel
housing is to be installed. (In order to
prevent the gasket slip down, coat a
grease on the cylinder block surface.) EA6M2010
¥ Temporarily assemble 2ea of guide

bolts for installing the flywheel housing
to the cylinder block.
¥ After fitting the flywheel housing holes to the guide pins and engage temporarily 2 ~ 3
threads of fixing bolts, and according to the tightening order (zigzag method) tighten them in
the specified torque.
Torque 7.5 kg.m
6.3.9. Tacho sensor
¥ Loosen the lock nut to hexagonal

side of sensor. Rock nut Ring gear
¥ Rotate (CW) the tacho-sensor on fly
wheel housing, until the end of it reach
on fly wheel ring gear as figure.
¥ Rotate (CCW) the tacho-sensor for

270¡ (gap: about 1.0 mm) and fix the
M16 x 1.5
lock nut.
¥ Tolerance limit is 27¡ (gap L 0.1 mm) EPM2030I
- 87 -

Manual Doosan V158ti Doosan 2002 Español Parte 2

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FOREWORD

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

2. SAFETY REGULATIONS ............................................................................................. 11

3. COMMISSIONING AND OPERATION.......................................................................... 15

5. MAIN ACCESSORY PARTS......................................................................................... 45

6. DISASSEMBLY & ASSEMBLY OF MAJOR COMPONENTS...................................... 58

7. MAIN PARTS MAINTENANCE................................................................................... 104

8. TROUBLE SHOOTING ............................................................................................... 166

9. SPECIAL TOOL LIST ................................................................................................. 172

Marine Engine Specification

4 cycle, V type, direct- injection, water cooled

Rating output (B.H.P) PS(kW)/rpm 420(309)/1,800 480(353)/1,800 540(397)/2,10 680(500)/2,300

Engine size without M/G mm 1337x1222x1074 1,337 x 1,222 x 1,074

Marine Engine Specification

4 cycle, V type, direct- injection, water cooled

Rating output (B.H.P) PS(kW)/rpm 600(441)/1,800 650(478)/2,100 820(603)/2,300

Engine size without M/G mm 1,495 x 1,222 x 1,169

Marine Engine Specification

4 cycle, V type, direct- injection, water cooled

Rating output (B.H.P) PS(kW)/rpm 720(530)/1,800 800(588)/2,100 1,000(736)/2,300

Engine size without M/G mm 1,653 x 1,222 x 1,199

4 cycle, V-type, direct-injection, water cooled

410(302)/1,500 485(357)/1,500 606(446)/ 1,500

Displacement cc 14,618 18,273 21,927

1.2.1. Engine Sectional View (Longitudinal Ñ

1. Cylinder head 4. Tappet 7. Oil pump

1. Intake manifold 6. Exhaust manifold 11. Oil cooler

1. Crank pulley 7. Fresh water filler cap 13. Exhaust manifold

Engine Speed (rpm)

(Heavy Duty) (Medium Duty) (Light Duty)

500 500 500

400 400 400

400 F 400 400

300 300 300

200 200 200

Propulsion Curve Propulsion Curve Propulsion Curve

Full Consumption Full Consumption Full Consumption

Engine Speed (rpm) Engine Speed (rpm) Engine Speed (rpm)

(Heavy Duty) (Medium Duty) (Light Duty)

1000 1000 1000

900 900 900

800 800 800

700 700 L 700

600 ull 600 600

(PS) (PS) (PS)

500 500 500

400 400 400

Propulsion Curve Propulsion Curve Propulsion Curve

Full Consumption 170 Full Consumption 170 170

(Heavy Duty) (Medium Duty) (Light Duty)

800 800 800

(PS) Propulsion Curve (PS) Propulsion Curve (PS) Propulsion Curve

200 200 200

100 100 100