P3D32N007 e PDF
P3D32N007 e PDF
P3D32N007 e PDF
FOREWORD
In particular
- Use of unsuitable fuels and oils may compromise the
engine's regular operation, reducing its performance, re
liability and working life.
- Exclusive use of FPT Original Parts is a necessary condi
tion to maintain the engine in its original integrity.
- Any tampering, modifications, or use of non-original
parts may jeopardize the safety of service personnel and
boat users.
To obtain spare parts, you must indicate:
- Commercial code, serial number and the indications
shown on the engine tag;
- The number of the spare part. This can be found in the
spare part catalog.
The information provided below refers to engine
characteristics current at the date of publication.
FPT reserves the right to make modifications at any time and
without advance notice, to meet technical or commercial
requirements or to comply with local legal and regulatory
requirements.
SECTION CONTENTS
Section Page
1. OVERVIEW 5
2. TECHNICAL DATA 53
3. ELECTRICAL EQUIPMENT 59
4. DIAGNOSTICS 73
5. MAINTENANCE 89
6. SERVICING OPERATIONS
ON INSTALLED ENGINE 95
7. TOOLS 115
8. OVERHAUL 123
UPDATING
3 Maintenance 91 12.2013
Revi - 12.2013
1.6 N67 ENT M57 APRIL 2013
APRIL 2013 OVERVIEW N67 ENT M57 1.7
SECTION 1
OVERVIEW
Page
IDENTIFYING DATA 9
COMMERCIAL CODE 10
ENGINE ARCHITECTURE 14
Crankcase 14
Crankshaft 15
Connecting Rods 15
Pistons 16
Cylinder head 18
Turbocompressor 21
Thermostatic valve 24
Water pump 24
SEA-WATER OPEN
COOLING LOOP 25
Sea-water pump 26
Page Page
Crankshaft sensor 47
Camshaft sensor 48
IDENTIFYING DATA
Figure 1
187778
1. Commercial code/version - 2. Homologation number - 3. Production serial number - 4. Maximum output at rated speed -
5. Drowing number - 6. Engine family - 7. Maritime classification register - 8. Commercial code -
9. Setting code - 10. Production year
Figure 2
187779
The identification data of the engine are stamped on a nameplate situated on the expansion tank.
1.10 N67 ENT M57 OVERVIEW APRIL 2013
COMMERCIAL CODE
The purpose of the commercial code is to make the characteristics of the product easier to understand, categorizing the engines
according to their family, origins and intended application. The commercial code, therefore, cannot be used for the technical pur
pose of recognizing the engine's components, which is served by the ENGINE S/N.
N 67 E N T M 57 . 1 0
VERSION
VERSION:
TURBOCHARGED:
1 = COOLED
2 = NOT COOLED
APPLICATION: M = MARINE
The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to characterize
its application and power output level. It is stamped on a side of crank-case, close to oil filter.
F 4 K E 0 6 8 6 A * A 0 0 1
VARIANTS TO
BASIC ENGINE
A = EMISSION FOR
MARINE APPLICATION
POWER RANGE:
A = MAXIMUM POWER 560 HP
NO. OF CYLINDERS
ENGINE
DESIGN ITERATION
Figure 3
187780
1. Electric starter motor - 2. Engine coolant discharge cap - 3. Tube bundle engine coolant/sea-water heat exchanger -
4. Sacrificial anode - 5. Oil/sea water heat exchanger - 6. Exhaust gas and sea-water discharge pipeline -
7. Rocker arm cover - 8. Lifting eyebolts - 9. Cap for engine coolant outlet to sanitary water heating system -
10. High water temperature sensor plug - 11. Water temperature sensor plug - 12. Oil refill cap -
13. Coolant refill cap - 14. Engine coolant tank - 15. Thermostatic valve - 16. Auxiliary belt automatic tensioner -
17. Alternator - 18. Cap for engine coolant discharge and recirculation from sanitary water heating system -
19. Cooled exhaust manifold - 20. Oil temperature sensor - 21. Sea water drain plug - 22. Oil filter
APRIL 2013 OVERVIEW N67 ENT M57 1.13
Figure 4
187781
1. Manual lubricating oil extraction pump - 2. Throttle potentiometer - 3. Common rail distributor -
4. Oil dipstick - 5. Cooledturbocompressor - 6. Clogged air filter indicator - 7. Oil vapor separator -
8. Combustion air filter - 9. Sea-water junction pipe from after-cooler to engine coolant/sea-water heat exchanger -
10. Fuel filter - 11. Common rail high pressure injection pump - 12. Sea-water pump - 13. Sacrificial anode -
14. Combustion air/sea-water heat exchanger - 15. Grid Heater - 16. Grid Heater control box
1.14 N67 ENT M57 OVERVIEW APRIL 2013
ENGINE ARCHITECTURE
NEF engines are the highest expression of design and engin combustion conditions, metering and injection, optimized
eering efficiency that FPT makes available on the market place. instant by instant, enable to obtain a new balance between
They are highly innovative engines designed to be able to high performance and consumption reduction. NEF engines
comply now with the regulations on fumes and acoustic can be fitted with a mechanical pump or a total electronic
emissions that will be enforced in the near future. controlled Common Rail fuel supply system.
Designed with innovative techniques and manufactured with Every technical solution has been accurately devised so as to
advanced working processes, they are the result of hundreds assure qualitative product perfection. The configuration of
of years of design and engineering tradition as well as of an
the engine itself has been designed in such a way as to facili
important international cooperation.
The excellent performance of NEF engines originates from tate access to each individual part thus reducing maintenance
induction and exhaust ducts of new design where, by time.
improving the gas exchange phases, the intaken air turbo Cylinder head fitted with four valves per cylinder, rear timing
lence is improved, thus enabling the complete exploitation of control, new design connecting rods and aluminum-nickel
the new injection system capacity. pistons are components of an engine fitted with 40% less
The new criteria chosen in defining the parameters setting the elements than an engine of equivalent performance.
Crankcase
Figure 5
1. Reconditionable integral cylinder barrels - 2. Water pump seat - 3. Camshaft bushing seat - 4. Oil pump seat -
5. Main bearings - 6. Crankcase backing plate - 7. Seat for oil filter housing - 8. Product model number location.
Moreover, within the cast iron crankcase, coolant circulation in. The backing plate (6) applied to the lower par t makes the
grooves, ducts for lubrication loops for the various machine crankcase tougher and improves resistance to stress.
par ts and the seat for push rod bushings have been grooved
APRIL 2013 OVERVIEW N67 ENT M57 1.15
Crankshaft
Figure 6
1. Timing system driving gear - 2. Flywheel connecting hub - 3. Oil pump driving gear.
Figure 8 Figure 9
Figure 10
The pistons integrate the high swirl combustion chamber; the
annular chambers inside the junk ring enable an effective heat
elimination obtained by circulating the lubrication oil deliv
ered by the spray nozzles mounted on the crankcase. On the
piston skirt the are three seats for the retaining rings; the first
one of these is obtained by a special trapezoidal section cast
iron insert.
The piston rings have different functions and different
geometry.
- The 1st piston ring has a trapezoidal section and ceramic
chrome plating;
- The 2nd piston ring has a a torsional conical rectangular
seal;
- The 3rd piston ring has a double oil scraper with internal
spring.
Figure 11
189016
1. Spindle - 2. Rocker - 3. Adjuster screw - 4. Rod - 5. Bridge - 6. Cotters - 7. Cup - 8. Spring - 9. Tappet - 10. Camshaft -
11. Holes for camshaft sensor.
Cylinder head
Figure 12
The cylinder head is monolithic and is made in cast iron; it Are coupled to the cylinder head:
houses slots for the following:
- Exhaust manifold;
- Valves, with seats and elements inserted;
- Induction manifold
- Thermostatic valve;
On the top part of the head the chassis is secured, to which
- Electro-injectors; the connectors of the wiring harness for the control of elec
tro-injectors, are fastened.
- Fuel delivery filling pipes conections to the electroinjec
tors.
Inside the cylinder head the duct for the recovery of the fuel
not used by electro-injectors has been fitted.
APRIL 2013 OVERVIEW N67 ENT M57 1.19
Figure 13 Figure 14
Figure 15
187783
1. Exhaust terminal (riser) - 2. Turbocompressor - 3. Air filter - 4. Sea water pump - 5. Heat exchanger air/sea-water -
6. Intake manifold - 7. Exhaust manifold - 8. Oil/sea water heat exchanger - 9. Coolant/sea water heat exchanger
Before reaching the cylinders, supercharging feeding air (3), The turbocompressor casing (2) and exhaust manifold (7)
intaken through the filter, runs through the heat/sea-water are cooled down by engine coolant.
exchanger (5), thus reducing its temperature, in order to The exhaust gas flows into the exhaust terminal (1) where
favour a higher engine volumetric efficiency. it is mixed with sea water for expulsion.
The pressure and air temperature sensor located on the
induction manifold (6), provides the ECU of the EDC system
with the information enabling a fuel metering adequate to the
density of the intaken comburent air and an optimum treat
ment of the injection advance.
APRIL 2013 OVERVIEW N67 ENT M57 1.21
Figure 16 Figure 18
134384 187784
1. Coolant inlet.
The engine is turbosupercharged by a fixed geometry turbine
with no waste-gate control.
The turbine is cooled by the circulation of coolant coming
from the exhaust manifold.
The turbine-compressor shaft turns on bushings lubricated
by the pressurized lubricant oil, which derives directly from
the oil filter housing.
1.22 N67 ENT M57 OVERVIEW APRIL 2013
Figure 19
187785
1. Coolant pump - 2. Thermostatic valve - 3. Coolant/sea-water heat exchanger - 4. Oil/engine coolant heat exchanger -
5. Turbocompressor - 6. Exhaust manifold - 7. Air filter - 8. Sea water pump - 9. Air/sea water heat exchanger
The centrifugal pump (1), set in rotation by the driving shaft fold after having cooled the volute of the turbocharger (5).
through the poly-V belt, draws the coolant and delivers it to The liquid is made to return to the pump until it reaches the
the cylinder block to come into contact with the cylinders' setting temperature of the valve; once this temperature has
heat exchange areas and afterwards to the cylinder head from been reached it is deviated proportionally to the temperature
which a portion of the coolant exits and goes through the reached, towards the coolant/sea-water heat exchanger (3).
thermostatic valve (2) and another portion goes through the A part of it goes back to the pump, another reaches the heat
exhaust manifold (6) cavity to reduce its temperature as pre exchanger where it heats the sea-water up to re-enter then
scribed by regulations concerning maritime equipment; this into the inlet of the pump.
portion of fluid then flows into the water pump intake mani
APRIL 2013 OVERVIEW N67 ENT M57 1.23
187786
1. Sea-water/coolant exchanger - 2. Oil/sea water heat exchanger - 3. Turbocompressor - 4. Sea water pump - 5. Air/sea
water heat exchanger - 6. Thermostatic valve - 7. Expansion tank - 8. Exhaust manifold - 9. Water pump manifold inlet
1.24 N67 ENT M57 OVERVIEW APRIL 2013
Figure 21 Figure 23
Figure 22
The water pump has its own seat within the crankcase and
is set into rotation by the poli-V belt.
Figure 24
187787
Sea-water
1. Turbocharger - 2. Outlet (riser) - 3. Sea-water pump - 4. Oil/sea water heat exchanger - 5. Exhaust manifold -
6. Sea-water/oil gear exchanger (optional) - 7. Sea-water/coolant exchanger - 8. Outlet (riser)
Sea-water drawn from under the bottom of the boat is the water/fresh water (7) heat exchanger removing the heat
means by which the engine heat that has not been trans yielded by the engine and conveyed by the coolant; tempera
formed into mechanical work is eliminated. ture control is carried out by the thermostatic valve.
Sea water is conveyed into the oil/sea water heat exchanger
The water, intaken by the pump (3) set into rotation by the
(5) from the sea water/fresh water heat exchanger (7) thus
cranckshaft by means of a toothed wheel transmission, is
cooling the engine oil.
directly sent to the supercharging heat exchanger (after
cooler) (4), where the water temperature is reduced to The water, before being let into the sea drainage duct,
improve engine volumetric efficiency and thus its perform touches and cools down the riser - the exhaust gas outlet -
ance; the water from the after-cooler, reaches the sea- leaving the boat with the latter.
1.26 N67 ENT M57 OVERVIEW APRIL 2013
Figure 25
Figure 26
1. Inlet - 2. Outlet.
The sea-water pump, with a neoprene rotor, is geared up
by crankshaft.
134386
Figure 27
187788
1. Oil sump - 2. Crankshaft - 3. Oil pump - 4. Oil filter bracket - 5. Oil filter -
6. Oil/sea water heat exchanger - 7. Oil filler cap - 8. Oil delivery to turbocompressor -
9. Oil return from turbocompressor - 10. Timing camshaft
Lubrication of the engine machine parts is oil forced circula A duct is specifically assigned to supply the nozzles that
tion obtained by a gear pump (3) located in the crankcase. deliver the coolant to the pistons, the other one is assigned
The pump is set into rotation by the crankshaft (2) by means to the lubrication of the machine internal parts: bench bear
of a toothed wheel and an intermediate gear. ings, connecting rods and timing, push rods and rockers; the
The oil that is pressurized by the pump, is sent to the filter lubrication of spindles and toothed wheels to actuate ancil
(5) and afterwards to the engine ducts after having gone lary machine parts is obtained by dedicated ducts.
through the oil/engine water heat exchanger (6). The flows afterwards converge by gravity into the oil sump
(1). The oil lubricating the turbocharger rotor shaft is directly
drawn from the oil filter housing (4), and is delivered through
an external pipe to the cylinder block joined to the housing
with an appropriate fitting.
1.28 N67 ENT M57 OVERVIEW APRIL 2013
Figure 28 Figure 30
187795
FUEL LINE
Figure 31
High pressure
1. Fuel filter - 2. Common rail - 3. Electro-injector - 4. Electro-injector return loop pressurization valve -
5. Rail overpressure valve - 6. High and low pressure pump - 7. Priming pump - 8. Settling pre-filter.
1. High pressure radial pump - 2. Fuel temperature sensor - 3. Fuel filter - 4. Electro-injector - 5. Pressure sensor -
6. Common rail - 7. Common rail overpressure valve - 8. Electro-injector return loop pressurization valve, 1.3 to 2 bar -
9. Fuel tank - 10. Recirculation manifold - 11. Manual priming pump - 12. Pre-filter - 13. Low pressure pump recirculation
valve - 14. High and low pressure pump - 15. Low pressure mechanical feed pump - 16. Low pressure pump by-pass valve -
17. Fuel filter support - 18. Low pressure limiter valve - 19. Pressure regulating electrical valve.
The heart of the system is made up of the solenoid valve pulses, modulates the fuel flow going into the radial pump and
control (19) and by the high pressure radial pump (1). Low as a consequence the flow and the value of the high pressure
pressure fuel supply takes place by means of a gear pump at the outlet of the pump and supplied to the rail (6). The rail
(15). While the engine rotates, the pump draws fuel from the has both the function of storing pressure, timing fuel to the
tank (9) through the pre-filter (12) and sends it through the electro-injectors (4) and of supporting and connecting both
main filter (3) to the limiting valve (18) that sets up the pres to the overpressure valve (7) and the sensor of the internal
sure at 5 bar, recirculating the excess delivery to the inlet of pressure (5). The rail internal pressure sensor (5), enables the
the supply pump (15). The fuel at constant pressure supplies EDC central unit to measure its value and to control in loop
the internal duct for the lubrication of the radial pump (1) and the control solenoid valve in order to always obtain the high
the inlet of the control solenoid valve. The electrovalve pressure value required by the injection mapping, while the
actuated by the EDC central unit by means of a fast sequence overpressure valve, in the event of an anomaly on the control
of
APRIL 2013 OVERVIEW N67 ENT M57 1.31
Pump assembly
Figure 35
1. Connector fuel outlet to rail - 2. High pressure pump - 3. Pressure control solenoid - 4. Fuel inlet connector from filter -
5. Fuel outlet connector to recirculation manifold - 6. Fuel inlet from tank - 7. Fuel outlet connector from low pressure
pump to filter - 8. Low pressure pump.
A. Fuel inlet from tank - B. Fuel outlet to filter - 1. Recirculation valve - 2. By-pass valve.
The gear wheel pump is assembled on the rear part of the It is set into rotation by the high pressure pump shaft. Under
high pressure pump. It transfers the fuel from the tank to the normal operation conditions, the fuel flow inside the mech
high pressure pump. anical pump is illustrated in Figure 36.
Figure 37
A. Fuel inlet from tank - B. Fuel outlet to filter - 1. Recirculation valve - 2. By-pass valve.
In the case of overpressure at the outlet, Figure 37, the recir (2), recirculating the fuel in excess inside the pump and
culation valve comes into action. keeping a pressure rating equal to that of the setting of the
The existing pressure, overcoming the spring valve elastic valve.
strength (1), connects the outlet with the inlet through a duct
APRIL 2013 OVERVIEW N67 ENT M57 1.35
Figure 38
A. Fuel inlet from tank - B. Fuel oulet to filter - 1. Recirculation valve - 2. By-pass valve.
Figure 39 Figure 40
134379
1. Coil - 2. Nucleus - 3. Preloading spring - 4. Spear valve - 5. High pressure pump feed - 6. Fuel inlet (from filter) -
7. Fuel backflow from the high pressure pump - 8. Cylinder for exhaust duct opening - 9. Fuel discharge -
10. Fuel delivery to rail.
134380
1. Coil - 2. Nucleus - 3. Preloading spring - 4. Spear valve - 5. High pressure pump feed - 6. Fuel inlet (from filter) -
7. Fuel backflow form the high pressure pump - 8. Cylinder for exhaust duct opening - 9. Fuel discharge - 10. Fuel delivery.
When the engine is in the condition of minimum rpm, the The control solenoid is in maximum choking as the common
EDC Central Unit controls the solenoid by a PWM (Pulse rail has to be kept at relatively low pressure (from 350 to 400
Width Modulation) timely signal to energize the coil and bar). The cylinder (8) of the low pressure limiter valve, which
cause the shifting of the nucleus (2). controls the opening of the exhaust duct, is in the maximum
The nucleus, while shifting, moves the spear valve (4) into the opening position in order to allow the fuel in excess to back
minimum opening position allowing the minimum flow of fuel flow to the exhaust (9).
to the high pressure pump.
APRIL 2013 OVERVIEW N67 ENT M57 1.39
High pressure pump During the induction stroke, the pumping, driven by the cam
located on the pump shaft, is fed through the pumping feeding
Figure 43 duct. The amount of fuel to send to the pumping is set by the
D-D section pressure control solenoid according to the PWM control
received by the electronic Central Unit. During the com
pression stage of the pumping, the fuel reaches such a pres
sure to open the delivery valve to common rail and supply it
through the outlet.
Figure 45
C-C section
Figure 44
B-B section
1, 3, 6. Pumping feed ducts - 2. Pump lubrication ducts -
4. Pumping feed main duct - 5. Pressure control solenoid -
7. Control exhaust duct - 8. Low pressure limiter valve -
9. Fuel feed duct from filter - 10. Fuel outlet.
In the section of Figure 45 the low pressure fuel paths inside
the pump are represented. The pumping feed main duct (4),
pumping feed ducts (1, 3, 6), ducts used for pump lubrication
(2), the pressure control valve (5), the low pressure limiter
valve (8) and the fuel exhaust (10), are outlined. The pump
shaft is lubricated by the fuel through the delivery and back
flow (2) ducts. The control valve enables to define the fuel
amount by which feeding pumpings; the excess fuel backflow
through duct (9).
The lower pressure limiter valve in addition to operate as
manifold of the high pressure pump fuel drainage, also keeps
pressure constant at the regulator inlet.
1.40 N67 ENT M57 OVERVIEW APRIL 2013
Figure 46
A-A section
108609
1. Common Rail - 2. Fuel inlet from the high pressure pump - 3. Overpressure valve - 4. Pressure sensor
The internal volume of the rail is sized in such a way as to Fitted on one end of the rail, it protects the system compo
allow a fast pressurization during transient states and at the nents in case of malfunction of the rail pressure sensor or of
same time to level pressure surging caused by the openings the pump pressure control causes and excessive pressure
and the closures of the injectors and by the cyclic operation increase in the high pressure system.
of the high pressure pump. This function is facilitated by the It is of a mechanical type and it has a double operating
gauge hole located after the high pressure pump. At the ends threshold: 1750 bar and 800 bar.
of the rail the internal pressure sensor and overpressure valve In case 1750 bar is reached, in the high pressure system the
are located. Every piping connected to the rail undergo valve comes into action initially as a normal one stage to let
pressure above 1600 bar, and for this reason the piping dis the fuel backflow and thus consequently reducing pressure
assembled have to be replaced. In the case of maintenance to safety values and afterwards mechanically controls the
actions on the high pressure line, special care is to be given pressure in the rail up to about 800. The two stage valve can
to avoid the introduction of dirt. be recognized by the acronym F775 inside the encoding.
This valve allows to operate the engine for prolonged times
under limited performance and avoids the excessive over
heating of the fuel preserving the system components.
Electro-injectors
Figure 49
1. Pressure rod - 2. Metering rod - 3. Nozzle - 4. Coil - 5. Pilot Valve - 6. Ball valve - 7. Control area - 8. Pressure chamber -
9. Control volume - 10. Feed/control duct - 11. Control fuel outlet - 12. Electric connection - 13. Spring.
Figure 50
1. Pressure rod - 2. Metering rod - 3. Nozzle - 4. Coil - 5. Pilot Valve - 6. Ball valve - 7. Control area - 8. Pressure chamber -
9. Control volume - 10. Feed control duct - 11. Control fuel outlet - 12. Electric connection - 13. Spring.
The fuel that is in the control volume, backflows towards the The injection ceases by disenergizing the coil. The ball valve
reflux duct causing a pressure decrease in the control volume goes back into idle posifigure tion, to recreate an equilibrium
itself. At the same time, the fuel pressure in the pressurized of forces such as to make the metering rod go back to the
chamber causes the rise of the metering rod and conse close position and stop the injection.
quently the injection of the fuel into the cylinder.
1.44 N67 ENT M57 OVERVIEW APRIL 2013
The ratio between the pilot system time and the amount of Pressurization valve of the electro-injector
fuel delivered is a non linear characteristic and with a narrow backflow
limit of tolerance typical of every family of electro-injectors;
it is the basis of the injection data stored in the ECU. Figure 51
The use of certified injectors is mandatory for the best effi
ciency of the engine performance and the accuracy required
by the common rail system management. They must have
the characteristics prescribed, i.e. analogue to those used to
make up the mapping of the injection timing. Injectors do not
need calibration and, due to the high accuracy degree of their
components and the complexity of their assembly, replace
ment of any spare part is not allowed.
Figure 52
187791
1. Coolant temperature sensor - 2. Electro-injector - 3. Fuel pressure sensor on rail - 4. Combustion air
pressure/temperature sensor - 5. Timing sensor - 6. Pressure control solenoid valve - 7. Fuel filter with temperature
sensor and electric heater - 8. ECU EDC - 9. Throttle control position sensor - 10. Crankshaft sensor -
11. Oil temperature-pressure sensor.
1.46 N67 ENT M57 OVERVIEW APRIL 2013
Figure 53 Figure 54
08_053_C
08_024_C
Figure 55 Figure 56
Figure 57 Figure 58
Figure 59 Figure 60
A. Solenoid connector.
The amount of fuel that feeds the high pressure pump is It provides the primary indication for the reckoning of the fuel
metered by the solenoid valve connected to the low pres amount to be injected.
sure system. The solenoid is normally open and controlled It is operated by the linkage of the controls on bridge or
by an ECU EDC PWM signal to obtain a high pressure value assisted, produces in output a potentiometric variation of the
ranging between 250 and 1600 bar. The choice to use a nor voltage which supplies it, in relation to the position where the
mally open valve enables to maintain a good engine func throttle lever is set.
tionality even in the case of an interruption of the control A simultaneous safety indication is provided by the internal
circuit. switch to confirm the acceleration position: minimum - out
of minimum.
The component has a resistance of about 2.8 . Such an indication in addition to the self-adative strategies of
the potentiometric signal, is used in the case of anomalies to
manage limp-home strategies, that enables to get back to
Throttle lever position harbour notwithstanding the potentiometer being faulty.
Figure 62
APRIL 2013 OVERVIEW N67 ENT M57 1.51
SYSTEM FUNCTIONS
Cut off
It consists of non injecting fuel during the engine deceleration
phase. The function is operating until the idle speed is
reached below which it would be impossible to restore
engine thermic operation.
Derating
It can be considered as a recovery programme. It does not
produce a storage of an anomaly record. It is caused by the
recognition of fuel high temperature, coolant, or comburent
air. Derating consists of reducing the torque delivered by the
engine to preserve it from operation inefficiency. It takes
place when overcoming preset thresholds, in a way propor
tional and gradual to the amount of the overcoming of para
meter; it does not entail fault signalling on the instrument
panel.
Recovery
It is a special way of control and management characterised
by the adoption of a number of strategies which enable the
system to operate even in the case selfdiagnosis has recog
nized the presence of anomalies. In the majority of cases
seafaring can be continued regularly or with reduced per
formance.
Adopting a recovery strategy entails the storing of an
anomaly code and the corresponding limitation of the maxi
mum power rating delivered by the engine.
The power rating limitation due to recovery strategy is active
up to the stopping of the engine even if the anomaly detected
is not there anymore. The blink code light on the instrument
and control panel will turn on only for the most serious
events.
After run
The stage following after every engine stop. It is characterised
by the delay in deenergizing the main supply solenoid con
tained inside the ECU EDC. During this phase the central unit
is still powered for some seconds, during which the data that
have characterised the optimized management of the engine
up to that moment, are transferred from the main volatile
memory to the EEPROM non volatile memory; these data
will then be available for the next starting.
These data can be summarised into:
- Management modes (idle speed, torque delivery balance,
smoke limit...);
- Threshold setting min/max of signal recognition;
- Fault memory.
At every start up it is important to have available the data that
optimize the management and the engine behaviour in terms
of TORQUE AND POWER DELIVERY. It is therefore man
datory to use engine stopping strategies (e.g. battery discon
nection) not different from those prescribed by the manu
facturer (key in OFF position) or which may prevent the
correct execution of the after run function.
1.54 N67 ENT M57 OVERVIEW APRIL 2013
APRIL 2013 TECHNICAL DATA N67 ENT M57 2.55
SECTION 2
TECHNICAL DATA
Page
SPECIFICATIONS 57
General specifications 57
Supercharge 57
Lubrication 57
Fuel Supply 58
Injection System 58
Cooling 58
Electrical system 59
Weights 59
Dimensions 59
2.56 N67 ENT M57 TECHNICAL DATA APRIL 2013
APRIL 2013 TECHNICAL DATA N67 ENT M57 2.57
SPECIFICATIONS
General specifications
Cycle 4-Stroke Diesel
Charge Supercharged and intercooled
Injection Direct
Number of cylinders 6 in line
Bore mm 104
Stroke mm 132
Total displacement cm3 6700
Compression ratio 14.1 : 1
Direction of rotation, brake side counterclockwise
Minimum idling rpm rpm 600 25
Maximum engine rpm, no load rpm 3150 25
Supercharge
Lubrication
Fuel Supply
Fuel oil compliant with standard EN 590*
Injection System
Type Common rail
Cooling
Closed coolant loop with sea-water 50% mixture of water/Paraflu 11 or equiv.
heat exchanger Compliant with SAE J 1034 specification
Total coolant quantity liters 24.5
Expansion tank standard
Forced circulation centrifugal pump
Flow rate at maximum rpm liters/h -
Temperature regulation with thermostatic valve
initial opening C 65
maximum opening C 78
Sea-water line forced circulation
Water pump volumetric self-priming
with neoprene impeller
Sea-water pump height above sea level m 2
Max. pump capacity liters/h 14000
CAUTION
Low temperature diesel
EN 590 specifications distinguish different classes of diesel fuel, identifying the characteristics of those best suited to low tem
peratures. It is entirely up to the Oil companies to comply with these regulations, which foresee that fuels suited to the climactic
and geographic conditions of the various Countries be distributed.
APRIL 2013 TECHNICAL DATA N67 ENT M57 2.59
Electrical system
Nominal voltage V dc 12
Self-regulated alternator:
Voltage V dc 14
Maximum current intensity A 90
Electrical starter motor:
Nominal voltage V dc 12
Absorbed electrical power W 3000
Recommended battery capacity Ah 120
Current discharge at - 18 C (SAE J 537) A 900
Weights
Without liquids and without marine gear kg 650
Dimensions
Figure 1
187792
SECTION 3
ELECTRICAL EQUIPMENT
Page
OVERALL 63
ALTERNATOR 66
ELECTRO-INJECTORS CONNECTORS 72
OVERALL
Figure 1
187796
1. Engine wiring - 2. Connector JC for main panel wiring - 3. Connector J4 - 4. Connector J3 - 5. Connector JH -
6. Connector J2 - 7. Connector J1 - 8. Power relay for electric starter motor and alternator. - 9. Electric power system
wiring - 10. Single comprehensive module (Electronic Unit EDC, Relay box, Converter module) - 11. Power supply
connector JAL - 12. Connector JQA set for connection to the main analog instrument panel - 13. Connector JE -
14. Instrument panel wiring connector JQ - 15. Engine wiring interface connector JA -
16. Engine wiring interface connector JX - 17. Connector JD for CAN BUS electronic handwheels -
18. Connector JINV for inverter and external accelerator control- 19. Sedimentation tank prefilter -
20. Water in fuel presence sensor - 21. Wiring to be carried out by site
The electric equipment of the system carries out the main Wiring harness for power supply has to be manufactured by
connections by means of the wiring provided with the engine, the shipyard following the indications contained in the N67
to which the power supply, the electronic components ENT M57 Installation Directive document.
assembled on the engine, the electronic central unit of the
injection system, the relay box, and the instrument and
CAUTION
control panel are connected.
The product overall is apt for the needs of an adequate Never use the wiring of the engine equipment to supply any
installation and complies with electromagnetic compatibility other electrical appliance for the boat.
limits legislation on electric installations (EMC). Wiring
cannot be modified in any way and any possibility of using its
wiring lines for different components is absolutely excluded. Information related to analogue and digital instrument and
control panel and the related sensors are present in the N67
ENT M57 Installation Directive document.
3.64 N67 ENT M57 ELECTRICAL EQUIPMENT APRIL 2013
Figure 2
187844
A. Fuel temperature sensor for EDC - B. Drive shaft sensor - C. Camshaft sensor - F. Engine coolant temperature sensor
for EDC - H. Combustion air pressure/temperature sensor for EDC - K. Air filter clogging sensor (for alarm) -
E1. Electro-injectors cylinders 1 and 2 connector - E2. Electro-injectors cylinders 3 and 4 connector - E3. Electro-injectors
cylinders 5 and 6 connector (*) - GG. Alternator - GH. Thermal starter relay (grid heater) - IN. Electro-injectors -
MM. Starter motor - PA. Accelerator potentiometer position sensor - PF. Heating element on fuel filter -
PR. Rail pressure sensor - VE. Engine oil pressure/temperature sensor for EDC - ZH. High pressure fuel pump sensor
APRIL 2013 ELECTRICAL EQUIPMENT N67 ENT M57 3.65
09_061_N 187845
1. Equipment power supply - 2. Batteries - 1. GH control relay - 2. Cable between relay contact
3. Electric starter motor - 4. Alternator - 5. Grid heater and GH positive - 3. Grid Heater - 4. Connection
connector with engine wiring
The connection of the +B terminal of the alternator to the
positive+30 terminal of the electric startermotormust be
achieved with a conductor having a cross section of at least
40 mm2. The connection of the positive +30 terminal of the
electric starter motor to the positive pole of the battery,
achieved with a conductor having a cross section of at least
95 mm2, allows to obtain, as shown in the figure, the simulta
neous connection of the alternator to the battery.
The connection between the engine ground and the nega Grid Heater circuit (GH)
tive pole of the battery must be achieved according to the
guidelines provided in the Engine electrical ground paragraph. Figure 5
The connection (*) between alternator terminal B- and ter
minal 31 of the starter motor must be made only in the case
of an isolated terminal system and the cross-section must be
equal to 40 mm2.
The connection (**) for the thermal starter relay is the
responsibility of the customer and the cross-section must be
equal to at least 16 mm2.
CAUTION
If magneto-thermal protecting breakers are inserted, they
must not be used to stop the engine and in any case they
must be activated only a few seconds after shut-down.
187848
ALTERNATOR
Figure 6
Ambient temp. 80 C
Specifications
Nominal voltage 14 V
Nominal current max 90 A
Rpm max 12000 min -1
Current max at
1800 rpm 50 A
Polarity Negative ground
Rotation Clockwise
viewed from pulley
Belt Poli-V
Poles 12
Alternator speed (rpm x 1000)
Weight 5.7 kg 187881
CHARACTERISTIC CURVES
APRIL 2013 ELECTRICAL EQUIPMENT N67 ENT M57 3.67
Figure 8
Starter
control
Engine electrical
ground connection
point
Figure 9
CHARACTERISTIC CURVES
3.68 N67 ENT M57 ELECTRICAL EQUIPMENT APRIL 2013
Figure 11
08_024_C
Pin Function
1 Injector cylinder 5
2 Injector cylinder 6
3 Injector cylinder 4
4 Injector cylinder 1
5 Injector cylinder 3
6 Injector cylinder 2
7 -
8 -
9 Pressure regulator
10 Pressure regulator
11 Injector cylinder 2
12 Injector cylinder 3
13 Injector cylinder 1
14 Injector cylinder 4
15 Injector cylinder 6
16 Injector cylinder 5
3.70 N67 ENT M57 ELECTRICAL EQUIPMENT APRIL 2013
ELECTRO-INJECTORS CONNECTORS
Figure 14
Figure 15
Figure 16
187843
SECTION 4
DIAGNOSTICS
Page
FOREWORD 77
PT - BOX 78
FOREWORD
A successful troubleshooting is carried out with the com Every time there is a breakdown claim and this breakdown
petence acquired by years of experience and attending is actually detected, it is necessary to proceed inquiring the
training courses. electronic unit in one of the ways indicated and then pro
ceed with the diagnostic research making trials and tests in
When the user complains for bad efficiency or working
order to have a picture of the working conditions and identify
anomaly, his indications must be kept into proper consider
the root causes of the anomaly.
ation using them to acquire any useful information to focus
the intervention. In case the electronic device is not providing any indication,
it will be necessary to proceed relying on the experience,
Using FPT processing instruments, it is also possible to es
adopting traditional diagnosis procedures.
tablish a bi-directional connection with the central unit, by
which not only to decoding the failure codes but also input
an enquiry relying on memory files, in order to achieve any
further necessary information to identify the origin of the CAUTION
anomaly.
Any kind of operation on the electronic center unit must
be executed by qualified personnel, duly authorized by FPT.
PT - BOX
PT - BOX is a test tool to be connected to a Personal Computer.
Figure 1
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator -
5. Serial port indicator - 6. Error indicator - 7. CAN line indicator -
8. Line K indicator for automatic management
NO Engine does not start Batteries - Low charge - Recharge (disconnecting system wir
- Faulty terminal connections ing)
- Clean, check, tighten terminals or re
place them
NO Engine does not start Electrical starter motor - Malfunction - Check
- Faulty terminal connections - Clean, check, tighten terminals
NO Engine does not start Relay to control power - Malfunction - Check supply wiring
supply to terminal 50 of - Check main relay, replace
the electric starter motor
(contained in the relay
box)
NO Engine does not start Fuel feed pump - Priming incorrect (air leaking inside) - Check seal on intake branch
- Check pressure
DIAGNOSTICS
NO Engine does not start Fuel circuit - Incorrect filling (air in fuel circuit) - Check seal
- Bleed circuit
NO Engine does not start Fuel filter and pre-filter - Filter and pre-filter clogged - Check reservoir
- Replace
NO Engine does not start Electrical grid heater (if - Malfunction - Check the electric connections of
present), at temperatures - Faulty terminal connections engine ground and positive +30
lower than 0 C.
- Check efficiency of the relevant
contactor
- Check the efficiency in active diagnosis
- Replace
N67 ENT M57
4.79
GUIDE TO SYMPTOM DIAGNOSIS 4.80
NO Engine overheats Coolant level - Below MIN level - Check for leaks
- Top up correct level
NO Engine overheats Coolant pump drive belt - Loose tension - Check tension
- Wear - Replace
- Verify liquid spillage on the belt
NO Engine overheats Coolant pump - Malfunction - Check belt tension
- Replace
NO Engine overheats Thermostatic valve - Locked, closed or only partially open - Check coolant liquid
- Replace
NO Engine overheats Coolant-sea water heat - Clogged - Clean or replace
exchanger
NO Engine overheats Air filter - Clogged - Check filter clogged indicator
- Replace filter
NO Engine overheats Cylinder head gasket - Compression leaking from cylinder head gasket - Check water circuit pressure
- Replace head gasket
DIAGNOSTICS
APRIL 2013
GUIDE TO SYMPTOM DIAGNOSIS
APRIL 2013
NO The engine emits greywhite Water in cylinders - Leakages from cylinder gasket - Check level and pressurization of water
smoke - Leakages from injector sleeves circuit
- Water in intake system - Check pressurisation of cooling circuit
- Water in fuel - Check efficiency of exchangers
- Check efficiency of presence sensor
detecting water in diesel oil
NO The engine emits blue Oil in cylinders - Excessive oil consumption - Check lubrication oil consumption
smoke - Oil leaking in turbocompressor - Overhaul
- Oil leaking from valve guides
NO Engine stops Fuel reservoir - Fuel reservoir empty - Proceed with refuelling
- Adjust fuel suction head or inclination
of the tank
NO Engine stops Net filter - Filter clogged - Clean or replace
Prefilter - Check efficiency of the clogging sensor
DIAGNOSTICS
Fuel filter
NO Engine stops Fuel circuit - See item Poor performance - See item Poor performance
APRIL 2013
APRIL 2013 DIAGNOSTICS N67 ENT M57 4.83
Legend:
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
Vehicle 1 (Sensors/Plausibility checks)
111 x x x x Fault path 1 for vehicle Speed sensing
211 x x x x Fault path 2 for vehicle Speed sensing(CAN)
311 x x x Fault path 3 for veh. Speed (max.pulse width)
112 x Accelerator Pedal 1
212 x x x Accelerator Pedal 2
113 x Accelerator Pedal and brake not plausible
114 x x x Multiple State Switch
116 x x Main clutch signal
117 x x Brake signal
118 x Engine brake preselection switch status
119 x No terminal 15 signals detected
11A x Terminal 50 always pressed
11B x High resolution wheel speed CAN message
21B x Vehicle dynamics control unit CAN message
11C x Water in fuel
21D x x x x Catalyst ageing limit exceeded
31D x x x x DCU state monitoring
11E x NH3Slip
21E x x x x Catalyst efficiency lower than first Nox prediction threshold level
31E x x x x Catalyst efficiency lower than first Nox prediction threshold level
41E x x x x Catalyst presence monitoring
11F x x x x Plausibility check of catalyst system
21F x x x x Boost pressure actuator current monitoring
31F x x x x Too high efficiency of catalyst system
Vehicle 2 (Lamps/relays/actuators)
121 x x x x Adjustable speed limit lamp
122 x x x x Power stage fault status for MIL
123 x x x x Power stage for system lamp
124 x x x x Cold start lamp
224 x x x x Coolant temperature lamp
Main relay defect (for High press pump P340/for engine brake
125 x x
decompr.valve P342)
225 x Interrupted afterrun
4.84 N67 ENT M57 DIAGNOSTICS APRIL 2013
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
126 x x Battery voltage fault
127 x x Eng.brake decompr.valve
128 x Main relay SCBatt (Lambda H./Grid H./Batt.switch)
228 x Main relay SCGND (Lambda H./Grid H./Batt.switch)
129 x x Main relay 3 (A/C compr./fuel filter heater)
12A x x Main relay 4 (Exhaust valve eng.brake flap)
22A x x x x Particulate filter lamp
12B x x x Power stage air heater 1 actuator
12C x x x Power stage air heater 2 actuator
12D x x Air heater test switch on (voltage<low thresh.)
22D x x Air heater test switch off (voltage>high thresh.)
12E x Grid heater always switched on
12F x x Air condition power stage CAN message
Engine 1 (Temperature and Pressure Sensors)
131 x x x x Coolant temperature sensor
132 x Coolant temperature sensor dynamic test
232 x Coolant temperature sensor absolute test
332 x x Engine temperature check
133 x x x Boost Temp. Signal
134 x x x x Boost pressure sensor
135 x x Fuel Temp. Signal
136 x x Rail pressure sensor CP3
236 x x x Rail pressure sensor offset monitoring
137 x x x Rail pressure relief valve
138 x x x x Oil Pressure Sensor
238 x Oil Pressure too low
338 x x x x Oil Pressure sensor lamp
13A x x x x Oil Temp. Sensor
23A x Oil Temperature above normal
13C x x x Atmospheric Temperature Sensor (Humidtiy?)
13D x x x Fuel pressure sensor
23D x x Fuel pressure sensor dynamic plausibility test
Engine 2 (Speed sensing/actuators)
141 x x Crankshaft sensor failure
142 x Running with camshaft sensor only
143 x x Camshaft sensor failure
144 x x Offset between camshaft and cranksh.
145 x x x x Power stage Fan actuator
146 x x Power stage Fan 2 actuator
147 x x Fan speed sensor signal
148 x x x x Air condition power stage
149 x x x x Fuel filter heating output
APRIL 2013 DIAGNOSTICS N67 ENT M57 4.85
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
14A x Engine Compartment Start Button is stuck
24A x Engine Compartment Stop Button is stuck
14D x Engine overspeed protection
14E x x x x TurboCompound monitoring
Fuel metering CR Systems
151 x Rail pressure max.positive deviation exceeded
251 x Rail pressure positive deviation 2nd part
152 x Rail pr.max.pos.deviation exceeded conc.set flow of fuel
Maximum negative rail pressure deviation with metering unit on
153 x
lower limit is exceeded
154 x Minimum rail pressure exceeded
155 x Maximum rail pressure exceeded
156 x Rail pressure drop rate is higher than expected
157 x Setpoint of metering unit in overrun mode not plausible
Setpoint of fuel volume flow through metering unit is lower than
158 x
calculated limit
159 x x Metering unit PWM-powerstage
259 x Short circuit to battery of metering unit output
359 x Short circuit to ground of metering unit output
15A x x Metering unit AD-Channel
15B x High pressure test(deactivates rail pr.Monitor.)
15F x First collection fault path for potentially long term fault path
25F x Second collection fault path for potentially long term fault path
35F x Third collection fault path for potentially long term fault path
45F x Forth collection fault path for potentially long term fault path
55F x Fifth collection fault path for potentially long term fault path
Injectors 1
161 x x x x Cylinder1 - Short circuit Low/High
162 x x x x Cylinder2 - Short circuit Low/High
163 x x x x Cylinder3 - Short circuit Low/High
164 x x x x Cylinder4 - Short circuit Low/High
165 x x x x Cylinder5 - Short circuit Low/High
166 x x x x Cylinder6 - Short circuit Low/High
167 x x x x Cylinder1 - Open load
168 x x x x Cylinder2 - Open load
169 x x x x Cylinder3 - Open load
16A x x x x Cylinder4 - Open load
16B x x x x Cylinder5 - Open load
16C x x x x Cylinder6 - Open load
4.86 N67 ENT M57 DIAGNOSTICS APRIL 2013
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
16D x Fault path to disable rail monitor. while compr.test active
16E x x x x The minimum number of injections was not reached --> stop the engine
16F x x x x Additive valve actuator
Injectors 2
171 x x x x Bank 1 specific errors - Short circuit / not classifyable
172 x x x x Bank 1 specific warnings - Open load
173 x x x x Bank 2 specific errors - Short circuit / not classifyable
174 x x x x Bank 2 specific warnings - Open load
175 x Misfire Cylinder 1
275 x x leakage or misfiring in cylinder 1
176 x Misfire Cylinder 2
276 x x leakage or misfiring in cylinder 2
177 x Misfire Cylinder 3
277 x x leakage or misfiring in cylinder 3
178 x Misfire Cylinder 4
278 x x leakage or misfiring in cylinder 4
179 x Misfire Cylinder 5
279 x x leakage or misfiring in cylinder 5
17A x Misfire Cylinder 6
27A x x leakage or misfiring in cylinder 6
17B x Misfire in multiple cylinders
17C x x x x Chip-specific errors-->stop engine
27C x x x x Chip-specific errors-->stop engine
17D x Common fault in combustion monitoring
17E x x x x Fault path of injection limitation
Air inlet system / EGR
181 x x Induction exhaust differential pressure
184 x Messages SRA2EDC
187 x AirCtl permanent positive governor deviaton
287 x AirCtl permanent positive governor deviaton
188 x AirCtl permanent negative governor deviaton
288 x AirCtl permanent negative governor deviaton
189 x Short circuit to Batt. for EGR power stage
289 x Short circuit to ground for EGR power stage
389 x x No load/excessive temp. for EGR power stage
18A x x x Power stage for EGR Bypass valve actuator
28A x x x Intercooler Bypass Valve Powerstage
18B x SC to BATT for throttle valve actuator powerst.
28B x SC to GND for throttle valve actuator powerst.
38B x x No load and excess temp. for TVA powerst.
18F x x x x Monitoring of Lambdasensor 1 Heater powerstage
Boost system and turbine speed
790 x Monitoring of the controller
APRIL 2013 DIAGNOSTICS N67 ENT M57 4.87
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
191 x x x Boost pressure actuator current AD-channel
192 x Short circuit to Battery for BPA powerstage
292 x Short circuit to Ground for BPA powerstage
392 x x No load/excessive temp.for BPA power stage
193 x x x x Turbine speed
293 x x x x Actual turbo speed evaluation for interface
194 x Multi signal defects in EPCtl
195 x x x P2 pressure errors in EPCtl
196 x P3 pressure errors in EPCtl
197 x x x Turbine speed errors in EPCtl
198 x Multi signal defects in PCR
199 x x x P2 pressure errors in PCR
19A x x Turbine speed errors in PCR
19B x High turbine speed and high air pressure
19C x x P3 pressure errors in PCR
19D x Indicates torque limitation due to performance limiter
29D x Torque limitation due to NTC
39D x Performance limit active due to either stage
49D x Indicates torque limitation due to particulate filter
59D x Indicates torque limitation due to SCR
19E x Indicates torque limitation due to smoke limitation
29E x Indicates torque limitation due to turbo compound
39E x Indicates torque limitation due to turbo charger protection
49E x Indicates the torque limitation due to engine protection
59E x Indicates torque limitation due to noise control
69E x Indicates torque limitation due to Fuel quantity Limitation
19F x Multi signal defects in EGSys_NOxEstIv
Exhaust system (Aftertreatment)
1A1 x x x Lambda linear signal of Nox Sensor
2A1 x x x Lambda binary signal of Nox Sensor
1A2 x x x x Nox signal of Nox Sensor
2A2 x x x x NOx Sensor drift test
3A2 x x x x Nox Sensor plausibility test
1A3 x x x Heater of Nox Sensor
1A4 x Message Nox Sensor timeout
1A5 x Message DM1DCU timeout
1A6 x Message SCR1 timeout
2A6 x Message SCR2 timeout
1A7 x x x x Urea level error path
2A7 x SCR2 message: low urea level
3A7 x Not plausible CAN value of urea sensing
4A7 x Timeout for urea sensor
4.88 N67 ENT M57 DIAGNOSTICS APRIL 2013
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
1A8 Error / Protection request on urea valve via SCR1
1AA x Not plausible CAN value of urea status
2AA x x x x Urea conductivity error path
3AA x x x x Urea concentration error path
1AB x x Exhaust gas temperature sensor before turbine
2AB x Exhaust Gas Pipe pressure sensor
1AC x x x x Heater used in EGR Mass Flow rate
2AC x CAN message EngGsFlowRt
1AD x x x x Recirculated Engine Exhaust Gas Temp. sensor
1AE x x Air humidity sensor
1AF x DM1DCU SPN1 message
2AF x DM1DCU SPN2 message
3AF x DM1DCU SPN3 message
4AF x DM1DCU SPN4 message
5AF x DM1DCU SPN5 message
Interfaces 1 (CAN-Bus)
1B1 x Busoff in CAN A
1B2 x Busoff in CAN B
1B3 x Busoff in CAN C
1B4 x Timeout for BC2EDC1
2B4 x Timeout for BC2EDC2
1B5 x Timeout for VM2EDC
1B6 x Timeout of CAN message WSI
1B7 x Timeout in CAN send messages
1B8 x Physical unplausibility of TSC-demand
1B9 x MIL visualization for BC2EDC1
1BA x Message Dashboard Display timeout
1BB x Message ERC1DR timeout
1BC x Message RxAMCONlv timeout
1BD x Timeout error of RxCCVS message
1BE x Physical plausibility DCS
1BF x CAN message RxEngTemp2
Interfaces 2 (CAN messages timeout)
1C1 x Timeout of CAN message EBC1
1C2 x Timeout of CAN message ETC1
1C3 x Timeout of CAN message TCO1
2C2 x Timeout of CAN message ETC2
1C4 x Timeout of CAN message TSC1-AE active
2C4 x Timeout of CAN message TSC1-AR active
3C4 x Timeout of CAN message TSC1-AE passive
4C4 x Timeout of CAN message TSC1-AR passive
1C5 x Timeout of CAN message TSC1-DE active
2C5 x Timeout of CAN message TSC1-DR active
APRIL 2013 DIAGNOSTICS N67 ENT M57 4.89
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
3C5 x Timeout of CAN message TSC1-DE passive
4C5 x Timeout of CAN message TSC1-DR passive
1C6 x Timeout of CAN message TSC1-PE active
2C6 x Timeout of CAN message TSC1-PE passive
1C7 x Timeout of CAN message TSC1-TE active
2C7 x Timeout of CAN message TSC1-TR active
3C7 x Timeout of CAN message TSC1-TE passive
4C7 x Timeout of CAN message TSC1-TR passive
1C8 x Timeout of CAN message TSC1-VE active
2C8 x Timeout of CAN message TSC1-VR active
3C8 x Timeout of CAN message TSC1-VE passive
4C8 x Timeout of CAN message TSC1-VR passive
1C9 x Timeout of CAN message TF
2C9 x Timeout for message TimeDate
3C9 x Timeout for message HRVD (high resol.vehicle distance)
ECU 1 (internal checks)
1D1 x Communication error of CJ940
1D2 x x x Error state of EEPROM
1D3 x Recovery which is locked
2D3 x Recovery which is suppressed
2D4 x Recovery which is visible
1D4 x Communic.supervision Watchdog/Contr.-Flag
1D5 x x x Redundant shutoff paths during initial.
1D6 x Deviation between TPU and system time
1D7 x x Dataset variant coding
1D8 x Supervision of SPI-handler Flag
1D9 x x x x Error status ADC monitoring
Fault FMTC_trq2qBas_MAP containes non strictly monotonous q
1DA x
curves
ECU 2 (Powerst./Immobil./Overrun/Sensor supply)
Short circuit to Batt or Ground, no load, excess.temp. for high side
1E1 x x
power stage
Short circuit to Batt or Ground, no load, excess.temp. for low side
2E1 x x x
power stage
1E2 x Error state of Immobilizer (no fuel release)
1E3 x Energising time exceeds limit of overrun monitor.
1E4 x Plausibility error in engine speed check
1E5 x x 12V sensor supply voltage
1E6 x x Sensor supply voltage 1
1E7 x x Sensor supply voltage 2
1E8 x x Sensor supply voltage 3
1E9 x Supply voltage CJ940 upper limit
1EA x Supply voltage CJ940 lower limit
4.90 N67 ENT M57 DIAGNOSTICS APRIL 2013
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
1EB x x x Atmospheric Pressure Sensor
1EC x Runuptest is set to disable misfire detection during runup test
1ED x Fault path for Runup test
1EF x Mass of soot in oil beyond prescribed limit
Particulate trap
7F0 x Too long time spent in transition mode RgnNrm
1F1 x x Part.filter differential pressure sensor
1F2 x x Flow resistance monitoring
2F2 x Part.filter differential press.sensor not plaus.
1F3 x x x Differential pressure signal
2F3 x Dynamics of differential press.signal not plaus.
3F3 x Hose line defect so signal not plausible
4F3 x Pressure sensor blocked so signal not plaus.
1F4 x Pressure sensor frozen so signal not plausible
1F5 x Differential pressure above limit
1F6 x x Exhaust gas temp.sensor bef. oxidation catalyst
2F6 x Monitor.temp. upstream of Oxid.Catalyst
Temp.difference upstream from Oxidation catalyst of bank1 and 2
3F6 x
exceeded threshold
4F6 x Monitor.temperature upstream of Turbo charger
1F7 x x Part.filter pre temperature sensor
2F7 x Monitor.temp. upstream of Particul.filtre
Temp.difference upstream from Particulate filtre of bank1 and 2
3F7 x
exceeded threshold
1F8 x x x First exhaust gas temperature monitoring
2F8 x General temperature not plausible
3F8 x x x Second exhaust gas temperature monitoring
1F9 x Too high regeneration demand
1FA x Number of locked regenerations
2FA x Permanent regeneration
3FA x Regeneration demand number 2
4FA x Regeneration demand number 3
1FB x Error path of oxidation catalyst not present
1FC x Defect ratio between threshold limits
1FD x x Temperature of Outer control loop
2FD x x Temperature of Inner control loop
1FE x Mass of fuel in oil beyond warning limit
1FF x Mass of fuel in oil beyond action limit
2FF x Error check of critical time for oil dilution
APRIL 2013 MAINTENANCE N67 ENT M57 5.91
SECTION 5
MAINTENANCE
Page
PERIODICITY OF CHECKS
AND MAINTENANCE OPERATIONS 93
Checks Periodicity
Every 150 300 500 600 1200 3000 Years
start hours hours hours hours hours hours (3)
Check oil level in engine J
Check oil level in marine gear J
Check engine coolant level J
Check exhaust pipe/s for damage J
Drain water from the fuel pre-filter (1) J
Check/top up electrolyte level in batteries J
and clean terminals
Periodic maintenance operations Periodicity
Every 150 300 500 600 1200 3000 Years
start hours hours hours hours hours hours (3)
Clean air filter/s (2) J 1 Year
Check corrosion of zinc anodes (4) J 1 Year
Check state of oil vapour filter J 1 Year
Drain/suck condensation from fuel tank/s (1) J 1 Year
Change engine oil (5) J 1 Year
Change oil filter/s (5)(7) J 1 Year
Change fuel filter/s (1)(7) J 1 Year
Change fuel pre-filter (1) J 1 Year
Change oil in the marine gear Consult the manufacturer's data
Inspect sea chest J 1 Year
Check tension and state of belt J
Change coolant J 2 Years
Change air filter 2 Years
Change oil vapour filter/s (5) 2 Years
Extraordinary maintenance operations (8) Periodicity
Every 150 300 500 600 1200 3000 Check
start hours hours hours hours hours hours (3)
Check wear in sea water pump rotor J 1 Year
Replace belt J 3 Years
Clean heat exchangers (6) J 1 Year
Visual inspection of turbocharger (5) J 1 Year
Adjust play in valves-rocker arms J
Revi - 12.2012
5.94 N67 ENT M57 MAINTENANCE APRIL 2013
(1) Maximum period when using good quality fuel , (EN 590
standard); this is reduced if the fuel is contaminated and
alarms are triggered due to blockage of the filters and pres
ence of water in the pre-filter.
When blockage of the filter is indicated, it must be replaced.
If the water in pre-filter indicator does not go out after
drainage, the prefilter must be replaced.
(2) The frequency with which operations are carried out will de
pend on the working conditions and efficiency/wear of the
product. If the engine is not used for long periods of time,
check it before you start it.
(3) These operations must be performed in the time intervals
indicated even if the specified operating hours are not
reached.
(4) The anode must be replaced if corrosion has exceeded 50%
of the volume of zinc.
(5) Replace lubricants according to the frequency indicated in
the REFUELLING table.
(6) Sea water/combustion air heat exchanger: clean both the air
and water sections; engine coolant/sea water heat ex
changer: clean the sea water section; sea water/marine gear
oil heat exchanger: clean the sea water section.
(7) Only use filters with the following characteristics:
- filtration level < 10 m
- filtering efficiency > 200.
(8) Instructions provided in Section 8.
APRIL 2013 MAINTENANCE N67 ENT M57 5.95
SECTION 6
SERVICING OPERATIONS
ON INSTALLED ENGINE
Page
FOREWORD 99
Removal 101
Fitting 102
Handling 116
6.98 N67 ENT M57 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2013
APRIL 2013 SERVICING OPERATIONS ON INSTALLED ENGINE N67 ENT M57 6.99
FOREWORD
Many of the procedures for carrying out the instructions that
follow depend on the con.tion of the housing on the vessel
and on the configuration of the installation components.
Prescriptions and cautions for use, handling and technical
assistance are provided in Section 9.
Technicians and maintenance personnel are reminded of the
need to comply with safety rules.
The checks necessary at the completion of an installation
or re-embarkation are described in the N67 ENT M57 In
stallation Directive document.
Spare parts will be supplied only if the following data are
provided:
- Engine technical code and serial number;
- Part number as per spare parts catalog.
The information provided below refers to engine character
istics that were current as of the publishing data. The manu
facturer reserves the right to make changes at any time and
without advance notice, to comply with technical or com
mercial requirements or to adapt to legal requirements in
different Countries.
The manufacturer shall not be liable for any errors and
omissions.
The FPT Technical Assistance Network is always at the Cus
tomer's side with its competence and professionalism.
6.100 N67 ENT M57 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2013
CAUTION
- Do not disconnect electrical connections without
removing power from the circuits first;
- Do not proceed with operating simulations with
unsuitable tools and instruments;
- Do not force measuring probes or mechanical tools
into the electrical connections;
- Do not proceed with arc welding without first
disconnecting electronic system units.
APRIL 2013 SERVICING OPERATIONS ON INSTALLED ENGINE N67 ENT M57 6.101
CAUTION
When unlocking the fitting fastening the pipe to the hy
draulic accumulator, it is necessary to prevent the flow li
miters from turning, by using a special wrench.
Figure 1
Loosen tappet adjustment fastening nuts (1) and unscrew the
adjusters.
Remove the screws (2), remove the rocker assembly (3),
consisting of: bracket (6), rockers (4), shafts (5) and remove
jumpers (7) from valves.
Figure 3
Fitting Figure 6
Figure 4
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on the injector (1).
Figure 5
Fit a new sealing ring (3) lubricated with petroleum jelly on
the fuel manifold (2) and fit it into the cylinder head seat so
that the positioning ball (5) fits the relevant housing (4).
CAUTION
Disassembled fuel manifolds (2) must not be used again.
Replace them with new ones.
CAUTION
During this operation (Figure 6), the injector (1) is to be
moved so that the manifold (2) is properly inserted into the
Fit injectors (1) on the cylinder head seats, directed so that fuel inlet hole.
the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
CAUTION Figure 7
Use tool 99342101 to fit the injector into its seat.
Figure 8 Figure 9
CAUTION
In case piping removal is necessary DO NOT REUSE IT
AND ALWAYS REPLACE IT WITH NEW PIPING.
6.104 N67 ENT M57 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2013
Figure 10
CAUTION
Never attempt to vent the high pressure system, as this is
useless and extremely dangerous.
APRIL 2013 SERVICING OPERATIONS ON INSTALLED ENGINE N67 ENT M57 6.105
Figure 11 CAUTION
In order to adjust faster the operating clearance for rocker
arms - valves, proceed as follows:
Rotate the drive shaft, balance cylinder 1 valves and adjust the
valves marked by the J symbol as shown in the table:
Cylinder n. 1 2 3 4 5 6
intake - - J - J J
Cylinder n. 1 2 3 4 5 6
intake J J - J - -
exhaust J - J - J -
6.106 N67 ENT M57 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2013
134387
134388
1. Cover - 2. Spacer - 3. Tube bundle - 4. Sealing rings - 5. Plug - 6. Tube bundle fixing screw -
7. Zinc sacrificial anode.
Figure 14
187844
A. Fuel temperature sensor for EDC - B. Crankshaft sensor - C. Camshaft position sensor - F. Engine coolant temperature
sensor for EDC - H. Pressure/comburent air temperature sensor for EDC - K. Clogged air filter sensor (for alarm) -
E1. Cylinder electro-injector connector 1 and 2 - E2. Cylinder electro-injector connector 3 and 4 - E3. Cylinder
electro-injector connector 5 and 6 (*) - GG. Alternator - GH. Thermal starter relay (grid heater) - IN. Electro-injector -
MM. Starter motor - PA. Accelerator potentiometer position sensor - PF. Heating element on fuel filter - PR. Rail pressure
sensor - VE. Engine oil pressure/temperature sensor for EDC - ZH. High pressure fuel pump sensor.
APRIL 2013 SERVICING OPERATIONS ON INSTALLED ENGINE N67 ENT M57 6.109
Figure 15 Figure 17
187814
187812
Remove the pipes of the degassing valves of the cooling cir Remove the oil filter.
cuit, situated on the cylinder head.
CAUTION
The oil filter contains approx. 1 kg of engine oil.
Position a suitable container to collect the oil.
Avoid the engine oil coming into contact with the skin: in
case of contact, wash thoroughly with water.
Figure 16
Engine oil is highly polluting: it must be disposed of accord
ing to applicable laws.
187813
Remove the lubricant oil feed pipes that join the oil/sea water
heat exchanger to the oil filter housing.
CAUTION
Lubricate the seal with engine oil during the assembly stage.
Tighten the oil filter to a torque of 20 2 Nm.
6.110 N67 ENT M57 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2013
Figure 18 Figure 20
187818 187820
Remove the oil pump together with the threaded bush and Remove the sea water feed pipe that joins the engine
gaskets. coolant/sea water heat exchanger to the oil/sea water heat
exchanger.
Figure 19 Figure 21
187819 187821
Remove the sea water feed pipes that join the oil/sea water Remove the sea water feed pipes that join the air/sea water
heat exchanger to the exhaust riser. heat exchanger to the engine coolant/sea water heat ex
changer.
APRIL 2013 SERVICING OPERATIONS ON INSTALLED ENGINE N67 ENT M57 6.111
Figure 22 Figure 24
187823 187815
Remove the oil/sea water heat exchanger. Remove the coolant feed pipe that joins the engine to the
engine coolant/sea water heat exchanger.
Figure 23 Figure 25
187824 187822
Remove the fixing brackets of the oil/sea water heat ex Remove the engine coolant/sea water heat exchanger to
changer - exhaust manifold. gether with relevant fastening plate.
6.112 N67 ENT M57 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2013
Figure 26 Figure 28
187825 187827
Remove the exhaust riser from the turbocharger. Remove the lubricant oil feed pipes that join the turbochar
ger to the crankcase.
Figure 27 Figure 29
187826 187828
Remove the lubricant oil feed pipe that joins the turbochar Remove the turbocharging air feed pipes that join the tur
ger to the oil filter housing. bocharger to the air/sea water heat exchanger.
APRIL 2013 SERVICING OPERATIONS ON INSTALLED ENGINE N67 ENT M57 6.113
Figure 30 Figure 32
187829 187816
Remove the oil vapour feed pipe that joins the oil vapour fil Remove the engine coolant feed pipes that join the tur
ter assembly to the engine intake. bocharger to the water pump intake manifold.
Figure 31 Figure 33
187830 187831
Remove the air filter with relevant adapter. Disconnect the turbocharger from the exhaust manifold and
remove it.
CAUTION
During assembly it is necessary to observe the installation
direction of the gasket interposed between the two parts,
indicated by the definition TURBO SIDE present on the
same.
6.114 N67 ENT M57 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2013
Figure 34 Figure 35
187817
187832
Remove the guard, expansion tank with relevant pipe, and Remove the exhaust manifold in order to complete engine
control belt by operating on the spring tensioner. Then re preparation for overhauling operations.
move the assembly composed of the water pump intake
manifold, alternator and alternator support.
CAUTION Figure 36
In the event of re-fitting the previously removed belt during
assembly, first carefully examine the belt to check for any
incisions or clear signs of wear and tear.
187833
Remove the sea water feed pipe that joins the sea water
pump to the air/sea water heat exchanger.
APRIL 2013 SERVICING OPERATIONS ON INSTALLED ENGINE N67 ENT M57 6.115
Figure 37 Figure 39
187834 187841
Remove the sea water pump. Remove the lubricant oil feed pipes that join the manual oil
extraction pump to the oil sump.
CAUTION
Be careful of the diesel pipes situated on the filter. Remove
them if necessary.
Figure 38 Figure 40
187835 187842
Remove the air/sea water heat exchanger together with the Remove the manual lubricant oil extraction pump, the ac
relevant fixing bracket after having removed the screws of the celerator potentiometer and the grid heater control box to
manifold and grid heater. gether with the relevant fixing brackets.
6.116 N67 ENT M57 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2013
Handling
The engine must be handled by experienced personnel, using
the prescribed tool or a rocker arm that keeps the lifting lines
parallel and with adequate equipment in terms of capacity
and size. The two eyebolts provided for lifting the engine
alone must always be used simultaneously.
APRIL 2013 TOOLS N67 ENT M57 7.117
SECTION 7
TOOLS
Page
TOOLS 119
7.118 N67 ENT M57 TOOLS APRIL 2013
APRIL 2013 TOOLS N67 ENT M57 7.119
TOOLS
TOOL NO. DESCRIPTION
99327230 PT - Plus
99327281 PT - Box
TOOLS
TOOL NO. DESCRIPTION
99341015 Press
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
99360605 Band for fitting piston into cylinder barrel (60 125 mm)
TOOLS
TOOL NO. DESCRIPTION
99370415 Gauge base for different measurements (to be used with 99395603)
99395216 Pair of gauges with and square head for angle tightening
7.124 N67 ENT M57 TOOLS APRIL 2013
TOOLS
TOOL NO. DESCRIPTION
SECTION 8
OVERHAUL
Page
Foreword 135
Bushes 146
Tappets 148
Page
Bushes 157
VALVES 161
Interference
Strained assembly
Thickness
Clearance
Intake
Exhaust
Operation
Compression ratio
Preload
Oversized
Higher than ...
Maximum, peak
Undersized
Less than ...
Minimum
Selection
Classes
Oversizing
8.128 N67 ENT M57 OVERHAUL APRIL 2013
GENERAL SPECIFICATIONS
Engine 6 Cylinders
Bore mm 104
Stroke mm 132
Timing
start before T.D.C. A 18.5
end after B.D.C. B 29.5
Checking timing
{
mm 0.25 0.05
X
mm 0.50 0.05
Fuel feed
Injection High pressure common rail
Type: Bosch EDC7 ECU
CLEARANCE DATA
Engine 6 Cylinders
> 0.4
Spare pistons
1 type:
X Size X 61
Outside diameter 1 103.730 to 103.748
2 Pin housing 2 38.010 to 38.016
X
Piston protrusion X 0.28 to 0.52
Engine 6 Cylinders
1 Small end
bush housing 1 38.019 to 39.033
Big end
2 bearing housing 2 72.987 to 73.013
4 Small end bush diameter
Engine 6 Cylinders
Main bearings
3 n 1-7 3 87.982 to 88.008
n 2-3-4-5-6 3 87.977 to 88.013
Shoulder
journal X1 37.475 to 37.545
X1
Shoulder
main bearing X2 25.98 to 26.48
X2
Shoulder
half-rings X3 37.28 to 37.38
Engine 6 Cylinders
4 Valves:
4 6.970 to 6.999
60 0.25
4 6.970 to 6.999
45 0.25
1 34.837 to 34.863
1 1 34.837 to 34.863
2 34.917 to 34.931
45
X 0.59 to 1.11
0.054 to 0.094
Between valve
seat and head
0.054 to 0.094
Valve seats -
APRIL 2013 OVERHAUL N67 ENT M57 8.133
Engine 6 Cylinders
Camshaft bush
housings n 1 59.222 to 59.248
Camshaft housings
n 2-3-4-5-6-7 54.089 to 54.139
2
Camshaft
journals:
17 53.995 54.045
1 3
Bush inside
diameter 54.083 to 54.147
H H 6.045
H 7.582
8.134 N67 ENT M57 OVERHAUL APRIL 2013
Engine 6 Cylinders
Tappet cap
outside diameter:
2 15.924 to 15.954
3 15.960 to 15.975
Between tappets and housings 0.025 to 0.070
Tappets -
ENGINE OVERHAUL -
ENGINE DISASSEMBLY AT THE BENCH
Figure 2
Foreword
Part of the operations illustrated within this section can be
partially executed while the engine is assembled on the boat,
depending on the room available for access to the engine and
on the equipment application as well.
CAUTION
All operations of engine disassembly operations as well as
overhaul operations must be executed by qualified en
gineers provided with the specific tooling and equipment
required.
Figure 3 Figure 4
- Disconnect the connectors (2, 6 and 10) from wiring - Assemble the 99361037 second bracket by means of the
harness; screw-threaded ports (1);
- Remove low pressure fuel pipes (3, 7, 8 and 9); - Lift the engine using the 99360595 rocker arm and put
it on the 99322205 turning stand;
- With the 99360076 tool remove the fuel filter (11) from
bearing (1); - Drain the oil through the cap on the side of the sump.
- Disconnect the high pressure fuel pipe (4) from rail and
from high pressure pump (5), and remove it from engine
block loosening the fixing clamps.
CAUTION CAUTION
Because of the high pressure in the pipelines connecting the Avoid contact of engine oil with the skin: in case of skin
high pressure pump to the rail, and this one to the electro- contamination rinse in running water.
injectors, it is absolutely forbidden to: Engine oil is highly pollutant: provide for disposal in com
pliance with the law and regulations in force.
- Disconnect the pipelines when the engine is running;
- Re-use the disassembled pipelines.
APRIL 2013 OVERHAUL N67 ENT M57 8.137
Figure 5 Figure 6
108543
187836
- Disconnect from the rail (2): the fuel pipe (7) according - Disconnect the pipeline (2) from the fuel recover pres
to procedures described in figure 3. Disconnect fuel sure-limiter (2), working on the connections as
pipes (5) from rail (2) and injector manifolds (6). described in Figure 3;
- Unscrew the nut and loosen the clamp tightening the oil
vapour pipe (6);
CAUTION - Remove the pipe (5);
- Loosen the screws (3) and disassemble the blow-by filter
When releasing pipe (6) connections (4) to rail (2), use the (4);
proper wrench to avoid rotation of flow limiters (3).
- Remove on the nuts and tappet cover.
Figure 7
- Remove the screws (1) and disconnect the rail (2).
CAUTION
Disassembled fuel manifolds (4) must not be used again,
replace with new ones during reassembly.
8.138 N67 ENT M57 OVERHAUL APRIL 2013
Figure 8 Figure 10
Figure 11
Figure 9
Figure 12
187837
Remove injector fastening screws. Use tool 99342101 (1) to - Remove the screws (2) and dismantle the oil filter hous
remove injectors (2) from the cylinder head. ing (3).
- Recover the gasket (4).
APRIL 2013 OVERHAUL N67 ENT M57 8.139
Figure 13 Figure 15
Figure 14 Figure 16
116241
- Fit tool 99360339 (2) to the flywheel housing (1) to stop - Remove the screws (1) and disconnect the water pump
flywheel (3) rotation; (2);
- Loosen the screws (4). - Remove the screw (3) and the roller (4);
- Remove the screw (5) and disconnect the engine speed
sensor (6).
8.140 N67 ENT M57 OVERHAUL APRIL 2013
Figure 17 Figure 19
Figure 18 Figure 20
116242
- Loosen the screws (1) and remove the front cover (2).
- Using the specially provided tie rod (3) for the tool CAUTION
99363204 and the lever (4), extract the external holding
ring (2) from the front cover (1). Take note of the screw (1) assembly position, since the
screws have different length.
APRIL 2013 OVERHAUL N67 ENT M57 8.141
Figure 21 Figure 23
Figure 24
- Screw out the opposite screws (1) from the ports where
the withdrawal pins are to be introduced (see following
picture);
- Loosen remaining flywheel fixing screws (3) to the
engine drive shaft (4);
- Remove the flywheel cover box fixing ring using the tool
- Remove the flywheel block tool 99360351 (2). 99340056 (3) to operate on the back tang (5) of the
engine drive shaft;
- Through the tool guide ports, drill the internal holding
ring using 3.5 mm drill for a 5mm depth;
- Fix the tool 99340056 (3) to the ring (1) tightening the
6 screws specially provided (4);
- Proceed with drawing the ring (1) tightening the screw
(2);
- Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), extract the external holding
ring of the flywheel cover box.
8.142 N67 ENT M57 OVERHAUL APRIL 2013
Figure 25 Figure 27
- Loosen the screws (2) and remove the flywheel cover - Loosen the screws (1) and disassemble the gear from the
box (1). camshaft (2).
CAUTION
Take note of the screw (1) assembly position, since the
screws have different length.
Figure 26 Figure 28
187838
- Turn engine over; - Loosen the screws (2) and disassemble the timing gear
box (1).
- Loosen the screws (3) and disassemble the oil suction
rose pipe (4);
- Loosen the screws (1) and remove the stiffening plate CAUTION
(2).
Take note of the screw (2) assembly position, since the
screws have different length.
APRIL 2013 OVERHAUL N67 ENT M57 8.143
CYLINDER UNIT
Figure 29 Figure 31
- Remove the screws (1) fastening the connecting rod - The last main bearing cap but one (1) and the relevant
caps (2) and remove them; support are fitted with shoulder half-bearing (2).
- Remove the pistons including the connecting rods from
the top of the engine block.
CAUTION CAUTION
Keep the half-bearings into their housings since in case of Take note of lower and upper half-bearing assembling
use they must be fitted in the same position found at re positions since in case of reuse they must be fitted in the
moval. same position found at removal.
Figure 30 Figure 32
- Remove the screws (1) and the main bearing caps (2). - Use tool 99360500 (1) and hoist to remove the crank
shaft (2) from the block.
8.144 N67 ENT M57 OVERHAUL APRIL 2013
Figure 33 Figure 35
- Remove the main half-bearings (1); - Withdraw carefully the camshaft (1) from the engine
block.
- Remove the screws (2) and remove the oil nozzles (3).
Figure 34 Figure 36
- Remove the screws (1) and disconnect camshaft (3) - Remove the tappets (1) from the engine block.
retaining -plate (2).
CAUTION
Take note of plate (2) assembling position.
APRIL 2013 OVERHAUL N67 ENT M57 8.145
Checks and measurements Should ovalisation, taper or wear be found, bore and grind
the cylinder barrels. Cylinder barrel regrinding must be per
Figure 37 formed according to the spare piston diameter oversized by
0.5 mm and to the specified assembling clearance.
Figure 39
CAUTION
Should the ring gauge be not available, use a micrometer for
zero-setting.
CAUTION
Figure 38 In case of regrinding, all barrels must have the same over
size (0.5 mm).
TIMING SYSTEM
Figure 40
Figure 41
Camshaft bush (2) shall be pressed into its housing.
Internal surface must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft bush (2) and
intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
axes.
Figure 43
Secc. A-A
107268
To replace bush (1), remove and refit them using the beater - Lubricate the tappets (1) and fit them into the relevant
99360362 (2) and the handgrip 99370006 (3). housings on the engine block.
CAUTION Figure 47
When refitting the bushes (1), direct them to make the lu
bricating holes (2) coincide with the holes on the block
housings.
Tappets
Figure 45
OUTPUT SHAFT
Figure 48 Measuring journals and crankpins
Figure 51
- Set camshaft (3) retaining plate (1) with the slot facing
the top of the engine block and the marking facing the
operator, then tighten the screws (2) to the prescribed Grind journals and crankpins if seizing, scoring or excessive
torque. ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
Figure 49
CAUTION
It is recommended to insert the found values in the proper
table.
See Figure 52.
CAUTION
Journals and crankpins must always be ground to the same
undersize class.
Journals and crankpins undersize must be marked on the
- Check camshaft end float (1). It must be 0.23 0.13 mm.
side of the crank arm no. 1.
For undersized crankpins: letter M;
For undersized journals: letter B;
For undersized crankpins and journals: letters MB.
Figure 50
- Fit nozzles (2) and tighten the fastening screws (1) to the
prescribed torque.
8.150 N67 ENT M57 OVERHAUL APRIL 2013
Figure 52
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
* Rated value.
Figure 53
Figure 54
Figure 56
128169
CAUTION
Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the lubri
cating hole and fit them into their housings.
The last main half bearing but one (1) is fitted with shoulder
half rings.
APRIL 2013 OVERHAUL N67 ENT M57 8.153
Figure 61
Tighten the pre-lubricated screws (1) in the following three This check is performed by setting a magnetic-base dial gauge
successive stages: (2) on the crankshaft (3) as shown in the figure, standard
- 1st stage, with torque wrench to 50 5 Nm; value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings of
- 2nd stage, with torque wrench to 80 5 Nm. the second rear support but one (1) and repeat the clearance
check between crankshaft pins and main half bearings.
Figure 60
Figure 62
- 3rd stage, with tool 99395216 (1) set as shown in the fig
ure, tighten the screws (2) with 90 angle.
CAUTION
Pistons are supplied from parts with 0.5 mm oversize.
8.154 N67 ENT M57 OVERHAUL APRIL 2013
Figure 63 Figure 64
126311
126312
- Remove split rings (2) from piston using pliers 99360183
(1). - Piston pin split rings (2) are removed using a scriber (1).
Figure 65
Figure 67 Figure 69
- Lubricate the pin (1) and its seat on piston hubs with en 128140
gine oil; the pin have to be fitted into the piston with a
slight finger pressure and must not fall down because of
its own weight. - Check the clearance between the sealing rings (3) of the
2nd and 3rd slot and the relevant housings on the piston
(2), using a feeler gauge (1).
8.156 N67 ENT M57 OVERHAUL APRIL 2013
Figure 71
CAUTION
The surface of connecting rod and rod cap are knurled to
ensure better coupling.
therefore, it is recommended not to smooth the knurls.
Figure 73 Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
CONNECTING ROD BODY Removal and refitting will be performed using the proper
1234 W
beater.
When refitting take care to make coincide the oil holes set
Connecting Weight on the bush with those set on the connecting rod small end.
rod No. Grind the bush to obtain the specified diameter.
0001 V
W
9999 X
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the cyl
inder barrel and the numbers (5) marked on the connecting
rod (5) are read as shown in the figure.
8.158 N67 ENT M57 OVERHAUL APRIL 2013
Figure 76 Figure 78
126311
Use pliers 99360183 (1) to fit the split rings (2) on the piston.
Split rings must be fitted with the marking TOP facing up
wards and their openings displaced with each other by 120.
Figure 80 Figure 82
- Lubricate the screws (1) with engine oil and then tighten
them to the prescribed torque using the torque wrench
DIAGRAM FOR CONNECTING ROD-PISTON (2).
ASSEMBLY FITTING INTO BARREL
- Split ring openings must be displaced with each other by
120;
- Connecting rod-piston assemblies must have the same Figure 83
weight;
- The arrow marked on the piston crown must be facing
the front side of the engine block or the slot obtained on
the piston skirt must be corresponding to the oil nozzle
position.
Figure 81
128170
CYLINDER HEAD
Figure 84 Removing the valves
Figure 86
CAUTION CAUTION
Before the final fitting of the connecting rod cap fastening Should cylinder head valves be not replaced, number them
screws, check that their diameter measured at the centre before removing in order to refit them in the same position.
of the thread length is not < 0.1 mm than the diameter
measured at approx. 10 mm from screw end. A = intake side - S = Exhaust side
Figure 90
CAUTION
Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
The rated thickness A for the cylinder head is 105 0.25 mm,
Checking cylinder head wet seal max. metal removal cannot exceed thickness B by 0.13 mm.
Figure 89
CAUTION
After grinding, check valve sinking. Regrind the valve seats,
if required, to obtain the specified value.
VALVES
Figure 91
CAUTION
Before refitting, smear the plug surfaces with water-repel
lent sealant.
Removing carbon deposits, checking and Checking clearance between valve stem and
grinding valves valve guide and valve centering
Figure 92 Figure 94
Intake Exhaust
Figure 96
Exhaust Intake
Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80 - 100C and using the proper
them with the spare ones. punch, fit the new valve seats, previously cooled, into the
In this case, machine the seats on the cylinder head (as indi cylinder head.
cated above) to insert the spare valve seats. Use tool 99305018 to regrind the valve seats according to
the values shown in Figure 97.
Figure 97
Exhaust Intake
Figure 99 CAUTION
Sealing rings (2) for intake valves are yellow.
Sealing rings (3) for exhaust valves are green.
Figure 101
INSTALLATION OF COMPONENTS
Figure 103
Figure 102
- Tighten the screws (1) fixing the gear (2) to the camshaft
- With a penmarker, mark the tooth (1) of the driving gear (3) and lock them to the prescribed torque.
assembled to the engine drive shaft (2) with () timing
notch. Figure 107
CAUTION
Screw down two pins to make operation of engine drive
shaft rotation easier.
Figure 105
CAUTION
It is necessary and essential to clean the surface to be sealed
in order to achieve excellent tight seal.
- Orient engine drive shaft (4) and camshaft (2), taking Apply sealing LOCTITE 5205 on the box in order to form
care that during assembly of the driving gear (1) to the a kerbstone of a few mm. diameter.
camshaft, the notches marked on the gears (1 and 3) are It must be uniform (no lumps), with no air blisters, thinner
to match. or irregular zones.
Any imperfection must be corrected as soon as possible.
Avoid using material in excess to seal the joint.
Too much sealing material would spill on both sides of the
joint and obstruct lubricant passages.
After having completed seal application, the joints must be
assembled within 10-20 minutes.
APRIL 2013 OVERHAUL N67 ENT M57 8.167
CAUTION
Before every assembly, always check that threads of holes
and screws have no evidence of tear and wear nor dirt.
Tighten the screws (1) fixing the engine flywheel (4) to the
engine shaft. Put tool 99360339 (2) on the flywheel cover - Assemble oil pump (1);
box (1) to block engine flywheel rotation.
- Tighten fixing screws (2) and lock them to the prescribed
torque.
APRIL 2013 OVERHAUL N67 ENT M57 8.169
- Apply to the water pump (1) a new fixing ring (2). 106550
Figure 119
Figure 117
106549
- Remove the fixing ring (2) from the front cover (1), accu
rately clean the contact surface and apply sealing Loctite
5205 on it.
8.170 N67 ENT M57 OVERHAUL APRIL 2013
187838
- Assemble oil sump (1). Tighten the screws (2) and lock
them to the prescribed torque.
- Assemble plate (4), suction rose (2) and tighten the fixing
screws (3 and 1) locking them on the prescribed torque. - Assemble the connection bracket of the engine mounts.
Figure 123
CAUTION
The pictures illustrating the sump and the rose pipe may not
correspond to the ones of your model.
However the procedures described are applicable anyway.
Accurately clean the contact surface. - Assemble the pulley (1) and the damping flywheel (2) to
Apply sealing Loctite 5999 on it, on areas around couplings the driving shaft;
between engine block and front cover, engine block and rear
- Tighten the fixing screws (3) and clamp them to the
gearbox.
torque 68 7 Nm.
After sealing application, mount the sump within 10-20 min
utes.
APRIL 2013 OVERHAUL N67 ENT M57 8.171
- Fit a new sealing ring on the speed sensor (3) (if fitted); - Mount the high pressure pump (5) including the feed
pump (6) and tighten the nuts (3) to the prescribed
- Fit the speed sensor (3) on the front cover (1) and
torque;
tighten the screw (2) to the prescribed torque (if fitted).
- Fit the support (4) with a new sealing ring, the timing
sensor (2) with a new sealing ring and tighten the
relevant fastening nut (1) to the prescribed torque.
Figure 125
187839
CAUTION
Before every assembly, always check that threads of holes
and screws have no evidence of tear and wear nor dirt.
8.172 N67 ENT M57 OVERHAUL APRIL 2013
CAUTION
Before every assembly, always check that threads of holes
and screws have no evidence of tear and wear nor dirt.
Figure 128
Figure 130
Figure 131
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).
Figure 132
Use tool 99342101 (1) to fit the injector (2) into its seat.
Screw injector fastening screws without tightening them.
Figure 134
Figure 135
ROCKER ASSEMBLY COMPONENTS:
1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
Figure 137
122587
Figure 139
Connect new fuel pipes (1) to rail (3) and injector manifolds
Figure 142 (2).
Figure 144
108567
108569
Fit the rail (2) and tighten the screws (1) to the specified
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut to the specified torque.
CAUTION
Pipe (7) connections must be tightened to 20 Nm torque,
CAUTION using the proper wrench (5) and the torque wrench
Because of the high pressure in the pipelines connecting the 99389829 (4).
high pressure pump to the rail, and this one to the electro- Connections (6) must be tightened while holding the flow
injectors, it is absolutely forbidden to: limiting valve hexagon (1) with the proper wrench.
- Disconnect the pipelines when the engine is running;
- Re-use the disassembled pipelines.
Connect the fuel pipe (3) to the rail (2).
APRIL 2013 OVERHAUL N67 ENT M57 8.177
Check electrical cable (5) conditions, if damaged replace Connect the electrical cables (1) to the injectors (3) and use
them by cutting the support clamps (2) and removing the the torque wrench 99389834 (4) to tighten the fastening
screws (4) that secure it to connections (3). nuts (2) to the prescribed torque.
Fit a new gasket (1) on the support (2).
Figure 148
Figure 146
Figure 149
Fit the wiring support (2) and tighten the screws (1) to the
prescribed torque.
CAUTION
Before every assembly, always check that threads of holes
and screws have no evidence of tear and wear nor dirt.
187836
Insert the blow-by filter (4) and tighten the screws (3).
Connect the pipeline (6) and fix the oil vapour recover pipe
(5) using the clamp; lock up the nut fixing it to the upper edge.
Connect the pipeline (2) to the pressure limiter (1).
8.178 N67 ENT M57 OVERHAUL APRIL 2013
Engine completion
Figure 150
TIGHTENING TORQUES
Marine parts tightening torques
Part Torque
Nm Kgm
M10 Nut turboblowers fixing on exhaust manifold 43 6 4.3 0.6
M10 Lock nut fixing turboblowers on exhaust manifold 26 10 2.6 0.1
M8 x 115 Screw for air / air or water / water exchanger 18 2 1.8 0.2
M8 x 120 Screw for air / water heat exchanger 18 2 1.8 0.2
Nuts for fastening rear engine support prongs 95,5 19,5 9.55 1.95
Screws for fastening front engine support prongs 111 22 11.1 2.2
M6 x 20 Screw for cooled riser stub pipe 81 0.8 0.1
M10 Screw anchoring the alternator 43 6 4.3 0.6
M10 x 140 Screw fixing the pump water inlet pipe and support bracket 43 6 4.3 0.6
M10 x 80 Screw fixing pump water inlet pipe and support bracket 43 6 4.3 0.6
M10 Nut fixing the electric engine starter 43 6 4.3 0.6
M12 x 30 Screw fixing the sea-water pump 85 8 8.5 0.8
M10 x 120 Screw for lower anchoring of the exhaust manifold 53 6 5.3 0.6
M10 Screw for lower anchoring of the exhaust manifold 53 5 5.3 0.5
8.180 N67 ENT M57 OVERHAUL APRIL 2013
Alternator
M10 Screw, bracket fixing on water feed pipefitting 43 6 4.3 0.6
M10 Screw, alternator locking 43 6 4.3 0.6
Starter
M10 Nuts starter fixing screw 43 6 4.3 0.6
A
1 2 3 4 5 6
7 8 9 10 11 12
A - Engine front
187882
APRIL 2013 SAFETY REGULATIONS N67 ENT M57 9.183
SECTION 9
SAFETY REGULATIONS
Page
SAFETY REGULATIONS
Standard safety regulations - Do not carry out any intervention you have not been
Pay particular attention to some precautions that must be given all necessary instructions for;
followed by all means in any working place and whose non- - Do not use any tool or equipment for any operation dif
observance will make any other measures useless or not ferent from the ones they have been designed and pro
sufficient to ensure safety to the personnel in charge of vided for. Serious injury may occur;
maintenance.
- In case of test or calibration operations requiring the
- Be informed and also inform personnel of the laws in engine to be in operation, ensure that the area is suffi
force regulating safety, by making informative docu ciently ventilated or use specific aspirators to eliminate
mentation available for consultation; exhaust gas. Danger: poisoning and death.
- Keep working areas as clean as possible, and ensure
adequate ventilation; During maintenance
- Ensure that working areas are provided with emergency - Never open the filler cap of the cooling circuit when the
kits. These must be clearly visible and always fitted with engine is hot. Operating pressure would provoke hot
adequate sanitary equipment; liquid to pour out with serious danger and risk of scalding.
Wait until the temperature decreases below 50 C;
- Provide for adequate fire extinguishing means, properly
indicated and always easy to reach. Their efficiency must - Never top up an overheated engine with cooler and use
be checked on a regular basis and the personnel must be only appropriate liquids;
trained on intervention methods and priorities; - Always operate with the engine turned off: in case par
- Provide specific exit points to evacuate the areas in case ticular circumstances require maintenance intervention
of emergency, giving adequate indications of emergency on the running engine, be aware of all risks involved in
escape paths; such operation;
- Smoking in working areas subject to fire danger must be - Be equipped with adequate and safe containers for drain
strictly prohibited; ing engine liquids and exhaust oil;
- Provide warnings by means of adequate boards signaling - Keep the engine clean from oil, diesel fuel, and/or chemi
danger, prohibitions, and indications to ensure easy cal solvents stains;
understanding of the instructions even in case of emerg - The use of solvents or detergents during maintenance
ency. may generate toxic vapors. Always keep working areas
ventilated. Whenever necessary wear a safety mask;
Accident prevention
- When working close to engines and equipment in - Do not leave rags impregnated with flammable sub
motion, do not wear unsuitable clothes, with loose ends, stances close to the engine;
nor jewels such as rings and chains; - Upon engine start after maintenance, undertake proper
- Wear safety gloves and goggles when performing the fol preventive action to stop air suction in case of over
lowing operations: speed;
- Filling inhibitors or antifreeze; - Do not use fast screwdriver tools;
- Topping or replacing lubrication oil;
- Using compressed air or liquids under pressure (pres - Never disconnect batteries when the engine is running;
sure allowed: 2 bar). - Disconnect batteries before any intervention on the
- Wear a safety helmet when working close to hanging electrical system;
loads or equipment operating at head height level; - Disconnect batteries from the system to charge them
- Always wear safety shoes and clothes that adhere to the with the battery charger;
body, better if provided with elastics at the ends; - After every intervention, verify that the battery clips'
- Use protection cream for your hands; polarity is correct and that the clips are tight and safe
from accidental short circuit and oxidation;
- Change wet clothes as soon as possible;
- Do not disconnect or connect electrical connections
- In presence of current tension exceeding 48-60 V verify while the power is connected.
the efficiency of earth and mass electrical connections.
Ensure that hands and feet are dry and carry out working
operations using isolating foot-boards. Do not carry out
working operations you are not trained for;
- Do not smoke nor have exposed flames close to bat
teries and flammable material;
- Put rags smeared with oil, diesel fuel, or solvents in fire
proof containers;
9.186 N67 ENT M57 SAFETY REGULATIONS APRIL 2013