NEF ENGINE
N45 MNA M10
N67 MNA M15
TECHNICAL AND REPAIR
MANUAL
T E C H N O L O G I C A L
E X C E L L E N C E
MARCH 2006 EDITION
1.2
N45 MNA M10
N67 MNA M15
MARCH 2006
FOREWORD
We strongly recommend that you carefully read the indications contained in this document: compliance with them
protects the engine against irregular operation and assures
its reliability, safeguarding sea-going and maintenance personnel against accident hazards.
The indications contained in this document pertain to the
N45 MNA M10.00, N45 MNA M10.01, N67 MNA M15.00,
N67 MNA M15.01 marine engine and complement the
IVECO MOTORS publication of “Marine Diesel Engines
Installation Handbook” that the reader should refer to for
anything that is not explained herein.
Technical engineers and fitters are required to comply with
safety regulations on work. They have to implement and
adopt the device required for individual personal safeguard
while carrying out maintenance or checks.
Safety rules are reported in Section 9 of this publication.
Regulations on handling engine are reported at the end of
Section 6 of this publication.
In order to start the engine, strictly follow the procedure
stated at the end of Section 5 of this publication.
To get the best possible performance out of the engine, it
is mandatory to conform with its intended mission profile.
The engine must not be used for purposes other than those
stated by the manufacturer.
IVECO MOTORS is available beforehand to examine
requirements for special installations, if any.
In particular
o Use of unsuitable fuels and oils may compromise the
engine’s regular operation, reducing its performance,
reliability and working life;
o Exclusive use of IVECO Original Parts is a necessary
condition to maintain the engine in its original integrity;
o 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 indications shown
on the engine tag;
Part number of the spare as per spare part catalog.
The information provided below refer to engine characteristics that are current as of the publication date.
IVECO MOTORS 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.
We refuse all liability
for any errors and omissions.
The reader is reminded that the IVECO MOTORS Technical
Assistance Network is always at the Customer’s side with its
competence and professionalism.
Publication IVECO MOTORS edited by:
IVECO PowerTrain
Advertising & Promotion
Pregnana Milanese (MI)
www.ivecomotors.com
Printed P3D32N003 E - March 2006 Edition
N45 MNA M10
N67 MNA M15
MARCH 2006
1.3
SECTION CONTENTS
Section
Page
1.
OVERVIEW
5
2.
TECHNICAL DATA
31
3.
ELECTRICAL EQUIPMENT
37
4.
DIAGNOSTICS
69
5.
MAINTENANCE
79
6.
SERVICING OPERATIONS
ON INSTALLED ENGINE
85
7.
TOOLS
97
8.
OVERHAUL
105
9.
SAFETY REGULATIONS
167
Indications for consultation
The different versions of the motors are generally hown
using the same pictures and descriptions, however important
differences are shown separately.
Sections 1-2-3 are intended for sales personnel, to provide
them with exact knowledge of the product’s characteristics and enable them to meet the Customer’s demands
with precision.
The remaining sections are meant for personnel in charge of
carrying out ordinary and extraordinary maintenance; with
an attentive consultation of the chapter devoted to diagnosing, they will also be able to provide an effective technical
assistance service.
1.4
N45 MNA M10
N67 MNA M15
MARCH 2006
MARCH 2006
N45 MNA M10
N67 MNA M15
OVERVIEW
1.5
SECTION 1
OVERVIEW
Page
IDENTIFYING DATA
7
COMMERCIAL CODE
8
PRODUCT MODEL NUMBER
9
ENGINE PARTS AND COMPONENTS
10
ENGINE ARCHITECTURE
12
Crankcase
12
Crankshaft
13
Connecting Rods
13
Pistons
14
Timing system driving gear
14
Cylinder head
16
Valves and valve seats
17
Ancillary machine parts drive
17
COMBUSTION AIR INTAKE AND EXHAUST SYSTEM 18
Comburent air filter
19
COOLING FRESH WATER CLOSED-LOOP
20
Exhaust manifold cooling
21
Thermostatic valve
22
Water pump
22
Additional expansion tank
22
SEA-WATER OPEN COOLING LOOP
23
Sea-water pump
24
Sea-water / coolant heat exchanger
24
ENGINE OIL LUBRICATION LOOP
25
Gear pump
26
Filter bracket
26
Oil vapour recirculation
26
(continues on next page)
1.6
N45 MNA M10
N67 MNA M15
OVERVIEW
Page
FUEL LINE
27
Fuel supply system scheme
28
Fuel pre-filter
29
Fuel filter
29
MARCH 2006
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
1.7
IDENTIFYING DATA
Figure 1
04_404_N
The engine identification data are stenciled on a tag positioned aside the coolant tank.
Figure 2
S. p. A.
Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY
ENGINE TYPE
ENGINE FAMILY
ENGINE DWG
POWER (KW)
AND SPEED (RPM)
POWER SET CODE
ENGINE S/N
YEAR OF BUILD
HOMOLOGATION
N�
COMMERC. TYPE / VERSION
06_016_N
The last two figures of the commercial code refer to the
engine model (detail A or B in figure n. 2).
Until the beginning of the year 2006 the engines produced
had the code N45 MNA M10.00 or N67 MNA M15.00
(detail A in figure n. 2).
During the year 2006 relevant modifications have been made
to the electric system and to the fuel supply circuit and a new
N67 MNA M15
�
.00
.XX
.01
�
model identified with the code N45 MNA M10.01 or N67
MNA M15.01 was created (detail B in figure 2).
This document concerns both the models. The relating
contents are developed in different chapters which can
be identified thanks to the presence in each title of the
extension M10.00/M15.00 or M10.01/M15.01.
N45 MNA M10
N67 MNA M15
1.8
OVERVIEW
MARCH 2006
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
purpose of recognizing the engine’s components, which is served by the “ENGINE S/N”.
N
67
M
N
A
M
15
.
0
0
VERSION
MAXIMUM PERFORMANCE LEVEL ACHIEVABLE
15 = 150 CV
APPLICATION: M = MARINE
AIR INTAKE: A = NATURAL
BASE: N = NON STRUCTURAL
FUEL SUPPLY: M = MECHANICAL INJECTION PUMP
DISPLACEMENT: 67 = 6700 cc NOMINAL
ENGINE FAMILY IDENTIFIER: N = NEF
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
1.9
PRODUCT MODEL NUMBER
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
G
E
0
6
0
6
A
*
E
6
0
0
VARIANTS TO
BASIC ENGINE
E = EMISSION FOR
MARINE APPLICATION
POWER RANGE:
A = MAXIMUM POWER 150 CV
INTENDED USE (6 = MARINE)
FUEL + INJECTION (0 = DIESEL, NA)
NO. OF CYLINDERS
NO. OF STROKES AND CYLINDER DISPOSITION (0 = 4 STROKES, VERTICAL)
ENGINE
DESIGN ITERATION
ENGINE FAMILY IDENTIFIER
N45 MNA M10
N67 MNA M15
1.10
OVERVIEW
MARCH 2006
ENGINE PARTS AND COMPONENTS
Figure 3
7
8
9
10
11
6
12
5
13
4
3
2
04_400_N
1
17
16
15
14
1. Tube bundle engine coolant / sea-water heat exchanger - 2. Engine coolant discharge cap - 3. Electric starter motor 4. Location of sacrificial anode - 5. Cooled exhaust manifold - 6. Exhaust gas and sea-water discharge pipeline - 7. Lifting eyebolt 8. Rocker arm covers - 9. Oil refill cap - 10. Location of thermostatic valve - 11. Cap for engine coolant outlet to sanitary water
heating system - 12. Coolant refill cap - 13. Engine coolant tank - 14. Auxiliary belt automatic tensioner - 15. Alternator 16. Cap for engine coolant discharge and recirculation from sanitary water heating system - 17. Oil filter.
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
1.11
Figure 4
10
11
16
12
13
14
9
8
7
15
6
5
06_606_N
4
3
2
1
1. Manual lubricating oil extraction pump - 2. Sea-water inlet - 3. Sea-water pump - 4. Throttle lever lever on injection pump 5. Rubber holder junction for fuel outflow to the tank - 6. Wiring connectors N45 MNA M10.00 and N67 MNA M15.00 7. Low pressure mechanical feed pump - 8. Fuel intake fitting - 9. Fuel filter - 10. Combustion air filter - 11. Lifting eyebolt 12. Oil vapours vent - 13. Oil dipstick - 14. Lifting eyebolt - 15. Sea-water junction pipe from after-cooler to engine coolant/sea-water
heat exchanger (Oil gearbox heat exchanger, on request) - 16. Connector for instrument panel connection wire harness
N45 MNA M10.01 and N67 MNA M15.01.
N45 MNA M10
N67 MNA M15
1.12
OVERVIEW
MARCH 2006
ENGINE ARCHITECTURE
NEF engines are the highest expression of design and engineering efficiency that IVECO MOTORS makes available on
the market place.They are highly innovative engines designed
to be able to comply now with the regulations on fumes and
acoustic emissions that will be enforced in the near future.
Designed with innovative techniques and manufactured with
advanced working processes, they are the result of hundreds
of years of design and engineering tradition as well as of an
important international cooperation.
The excellent performance of NEF engines originates
from induction and exhaust ducts of new design where, by
improving the gas exchange phases, the intaken air turbolence is improved, thus enabling the complete exploitation
of the new injection system capacity.
The new criteria chosen in defining the parameters setting
the combustion conditions, metering and injection, enable
to obtain new balance between high performance and
consumption reduction. NEF engines can be fitted with a
mechanical pump or a total electronic controlled “Common
Rail” fuel supply system.
Every technical solution has been accurately devised so as
to assure qualitative product perfection. The configuration
of the engine itself has been designed in such a way as to
facilitate access to each individual part thus reducing maintenance time.
Cylinder head fitted with two valves per cylinder, rear timing
control, new design connecting rods and aluminum-nickel
pistons are components of an engine fitted with 40% less
elements than an engine of equivalent performance.
Crankcase
Figure 5
8
1
2
7
3
4
5
6
04_011_N
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. Oil cooler (water/oil) seat - 8. Product model number location.
Moreover, within the cast iron crankcase, coolant circulation grooves, ducts for lubrication loops for the various
machine parts and the seat for push rod bushings have
been grooved in. The backing plate (6) applied to the
lower part makes the crankcase tougher and improves
resistance to stress.
MARCH 2006
N45 MNA M10
N67 MNA M15
OVERVIEW
1.13
Crankshaft
Figure 6
3
1
2
04_012_N
1. Timing system driving gear - 2. Flywheel connecting hub - 3. Oil pump driving gear.
The crankshaft is made in steel hardened by induction and
rests on seven mountings; inside the hollow shaft are the
ducts for the lubrication oil circulation.
On the front tang, the oil pump driving gear, the phonic
wheel, the flywheel connecting hub and the driving pulley of
the ancillary components are keyed on.
On the rear tang the camshaft driving gear and the coupling
flange to the engine flywheel are keyed on.
The bench half bearings are in cast babbitt lining steel and
the 6th is fitted with a shoulder ring to contain the end play
of the driving shaft.
Details 1 and 2 in the figure, assembled by negative allowance on the rear tang, are not replaceable. The front and
rear retaining rings are of the slide type with radial seal
and require special fixtures to be assembled and disassembled.
Connecting Rods
Figure 7
04_013_N
They are made in steel, manufactured by pressing, with small
end oblique edged and cap separation obtained by fracture
splitting technique.
The connecting rod half bearings are cast babbitt lining
steel.
Every connecting rod is marked on the body and on the
cap by a number that identifies their coupling and the cylinder into which it is to be assembled; moreover, a letter is
impressed on the body stating its weight class.
In case a replacement were necessary, only one type of
connecting rod is available as spare part of an intermediate
class weight that can be used to replace any other. Therefore,
connecting rods that are still efficient, do not need to be
replaced even if they are of a different class weight.
1.14
N45 MNA M10
N67 MNA M15
OVERVIEW
Pistons
MARCH 2006
Timing system driving gear
Figure 8
Figure 9
1
04_015_N
04_014_N
The timing system driving gear machine is a push rods and
rockers type, with a camshaft (1) that is located in the crankcase and set into rotation directly by the crankshaft.
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
delivered 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.
1
3
04_317_N
2
1. Positioning reference - 2. Crankshaft - 3. Camshaft.
The figure illustrates the position that the toothed wheel has
to have to set the correct timing strokes.
MARCH 2006
N45 MNA M10
N67 MNA M15
OVERVIEW
1.15
Figure 11
1
2
5
3
6
7
4
8
9
04_316_N
1. Rocker - 2. Rocker support - 3. Adjuster screw - 4. Rod - 5. Cotters - 6. Cup - 7. Spring - 8. Tappet - 9. Camshaft.
The timing camshaft rests on seven mountings; the mounting
points at front and rear end, are fitted with cast babbitt lining
steel bushings, assembled by negative allowance.
The timing camshaft is set into rotation by the crankshaft
with direct coupling to a straight toothed wheel.
N45 MNA M10
N67 MNA M15
1.16
OVERVIEW
MARCH 2006
Cylinder head
Figure 12
7
8
9
6
5
04_318_N
1
2
3
4
1. Engine coolant outlet to sea-water heat exchanger - 2. Lifting eyebolt - 3. Thermostat valve - 4. Cylinder head 5. Combustion air inlet - 6. Exhaust valve - 7. Induction valve - 8. Exhaust gas outlet - 9. Injector.
The cylinder head is monolithic and is made in cast iron; it
houses the slots for the following parts:
-
Valves, with seats and elements inserted;
-
Thermostatic valve;
-
Injectors.
To the cylinder head are coupled:
-
Exhaust manifold;
-
Induction manifold.
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
Valves and valve seats
1.17
Ancillary machine parts drive
Figure 13
Figure 14
04_327_N
3
2
4
5
1
3
2
1. Induction valve - 2. Exhaust valve - 3. Inserted elements.
Valves seat, obtained in the cylinder head, have elements
inserted with 45° taper ratio for the exhaust valve and 60°
taper ratio for the induction valves.
1
6
04_400_N
1. Crankshaft - 2. Engine coolant pump pulley - 3. Stationary
guide pulley - 4. Alternator pulley - 5. Tightener spring 6. Stationary guide pulley.
Motion to ancillary machine parts is transmitted by a Poly-V
belt put under tension by a gauged spring (5).
Stationary guide pulley (3) is located between the alternator pulley and the engine coolant pump pulley in order to
provide an adequate contact surface on the latter.
N45 MNA M10
N67 MNA M15
1.18
OVERVIEW
MARCH 2006
COMBUSTION AIR INTAKE AND EXHAUST SYSTEM
Figure 15
1
4
2
3
04_410_N
Engine coolant
Air inlet
Exhaust gas
Sea-water
1. Air filter - 2. Exit of the exhaust from the induction - 3. Pipe for exit of sea water from the heat exchanger with motor
refrigerating liquid - 4. Exhaust terminal (riser).
The supply air, which is drawn in through the filter, arrives at
the cylinders through the induction.
The exhaust gas flows into the exhaust terminal and, where
applicable (riser), mixed with sea-water to be expelled.
OVERVIEW
MARCH 2006
Comburent air filter
Figure 16
3
2
1
3
04_411_N
1. Filtering element - 2. Cover - 3. Nuts.
The air is sucked in by the motor through the filter (I) which
is made of a synthetic material (Bulpren). To clean it, it is
necessary to unscrew the nuts (3), remove the cover (2),
remove from its location the filtering element and clean it
with compressed air.
N45 MNA M10
N67 MNA M15
1.19
1.20
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
COOLING FRESH WATER CLOSED-LOOP
Figure 19
5
6
2
4
3
1
04_412_N
Hot engine coolant
Cold engine coolant
Sea-water
1. Coolant pump - 2. Thermostatic valve - 3. Pump intake flow - 4. Oil / coolant heat exchanger - 5. Coolant / sea-water heat
exchanger - 6. To exhaust manifold cooling - 7. Turbocompressor.
The centrifugal pump (1) set into rotation by the crankshaft
by means of the poli-V belt, intakes the coolant and sends it
to the crankcase to touch the areas of the thermic exchange
of the cylinders and afterwards to the engine head put of
which it comes through the thermostatic valve (2).
The liquid is made to return to the pump until it reaches the
setting temperature of the valve; once this temperature has
been reached it is deviated proportionally to the temperature
reached, towards the coolant / sea-water heat exchanger (5).
A part of it goes back to the pump, another reaches the heat
exchanger where it heats the sea-water up to re-enter then
into the inlet of the pump. The coolant, before going through
the crankcase, cools down the engine oil that goes through
its own heat exchanger (4). Some of this oil comes out from
the rear branchpipe goes through the exhaust manifold cavity, in order to reduce its temperature as it is prescribed by
nautical regulations; this part of the liquid flows then into the
branch pipe intake of the centrifugal pump.
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
1.21
Exhaust manifold cooling
Figure 20
3
4
5
2
6
7
1
8
04_413_N
Engine coolant going through exhaust manifold
Hot engine coolant going through coolant exchanger
Sea-water
1. Sea-water/coolant exchanger - 2. Pipe for the entrance of the refrigerating liquid into the exhaust induction - 3. Exhaust manifold 4. Degassing piping - 5. Thermostatic valve water / water exchanger connector - 6. Plug with pressure valve 7. Thermostatic valve - 8. Water pump manifold inlet.
1.22
N45 MNA M10
N67 MNA M15
OVERVIEW
Thermostatic valve
MARCH 2006
Water pump
Figure 21
Figure 23
3
1
04_331_N
2
Low temperature operation
When the temperature of the coolant is lower than the set
values, the coolant coming from inside the engine (1) recirculate directly towards the centrifugal pump (2).
Figure 22
04_030_N
3
1
The water pump has its own seat within the crankcase and
is set into rotation by the poli-V belt.
Additional expansion tank
04_332_N
2
High temperature operation
When the temperature of the coolant is above the set
values, the thermostatic valve partially or totally shuts in the
recirculation towards the pump and opens the path towards
the coolant / sea-water heat exchange (3).
In some cases an additional tank may be fitted with the purpose of increasing the available expansion volume; the connection to the main tank will be made through a pipe fitted
on the hose holder of the union pipe “overflow”. The plug of
this tank has to be equipped with a pressure relief valve to
enable liquid downflow while the engine is cooling.
This second tank, usually made in transparent material and
not pressurized, can be installed in order to have a better
access to check its level, that anyway has to be periodically
checked also in the main tank.
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
1.23
SEA-WATER OPEN COOLING LOOP
Figure 24
1
2
3
4
5
6
04_414_N
Engine coolant
Sea-water
1. Sea-water / coolant exchanger - 2. Outlet (riser) - 3. Sea-water outlet piping from exchanger 4. Sea-water / oil gear exchanger (optional) - 5. Sea-water pump - 6. Sea-water inlet.
Sea-water drawn from under the bottom of the boat is the
means by which the engine heat that has not been transformed into mechanical work is eliminated.
The water is sucked in by the pump which is rotated by the
shaft thorough a cogwheel gear, it then goes through the oil
inverter heat exchanger – if present – and it reaches the
“seawater / fresh water” heat exchanger, where it removes
the heat produced by the motor and transmitted by the
cooling liquid. The temperature is controlled through a
thermostatic valve.
The water, before being let into the sea drainage duct,
touches and cools down the “riser” - the exhaust gas outlet
- leaving the boat with the latter.
N45 MNA M10
N67 MNA M15
1.24
OVERVIEW
Sea-water pump
MARCH 2006
Sea-water / coolant heat exchanger
Figure 25
Figure 26
2
3
1
2
04_427_N
1
1. Inlet - 2. Outlet..
The sea-water pump, with a neoprene rotor, is geared up
by crankshaft.
5
1
3
2
04_035_N
4
1. Sea-water inlet - 2. Sea-water outlet - 3. Engine coolant inlet 4. Engine coolant outlet - 5. Sacrificial anode.
The engine coolant, coming from thermostatic valve, goes
into the exchanger (3) and touches the tube bundle that is
run through the sea-water flow coming from the supercharging air heat exchanger (1); the cooled down engine coolant,
goes through the manifold leading to the induction of the
centrifugal pump (4).
The sea-water coming out of the exchanger (2) is sent to
the outlet.
OVERVIEW
MARCH 2006
N45 MNA M10
N67 MNA M15
1.25
ENGINE OIL LUBRICATION LOOP
Figure 27
7
6
5
4
8
3
2
1
04_330_N
Oil delivery
Return to sump
1. Oil sump - 2. Crankshaft - 3. Oil pump - 4. Oil filter bracket with engine coolant / oil heat exchanger - 5. Oil filter 6. Oil filler cap - 7. Oil vapours vent - 8. Timing camshaft.
Lubrication of the engine machine parts is oil forced circulation obtained by a gear pump located in the crankcase. The
pump is set into rotation by the crankshaft by means of a
toothed wheel and an intermediate gear.
The oil pressurized by the pump, is sent to a filter and then
to the engine ducts after going through the heat exchanger
located on the flange coupling onto the crankcase also integrating the oil filter bracket; the exchanger is inserted on a
seat in the engine crankcase and is touched by the engine
coolant.
A duct is specifically assigned to supply the nozzles that
deliver the coolant to the pistons, the other one is assigned
to the lubrication of the machine internal parts: bench bear-
ings, connecting rods and timing, push rods and rockers; the
lubrication of spindles and toothed wheels to actuate ancillary machine parts is obtained by dedicated ducts.
The flows afterwards converge by gravity into the oil sump.
The oil fumes exit from the vent and reach the engine
intake.
1.26
N45 MNA M10
N67 MNA M15
OVERVIEW
Gear pump
MARCH 2006
Oil vapour recirculation
Figure 28
Figure 30
04_417_N
1
2
1
2
04_037_N
1. Gear oil pump - 2. Crankshaft with driving gear oil pump.
1. Condensate oil to the sump - 2. Flow limiter valve 3. Residual vapours to engine intake - 4. Oil vapour filter unit 5. Centrifugal separator.
Filter bracket
Figure 29
Oil vapours
7
The oil vapours which generate inside the engine, flow out
from the vent located on the 4th and 5th cylinder rocker arm
lid, going through the centrifugal gas separator, where some
of them condensate and return to the oil sump through the
dedicated ducts.
The part which is not condensated is sent to the engine
intake by a gauged hole after the air filter.
6
5
4
3
2
1
Inlet air
04_416_N
1. Heat exchanger with engine coolant - 2. Oil delivery
to internal engine machine parts - 3. Flow recirculated by
pressure regulator valve. - 4. Delivery to nozzles piston
cooling - 5. Flow inlet from the pump. - 6. Flange coupling
onto crankcase - 7. Oil filter.
Seats for the pressure and the by-pass valve are fitted on
the support. The ducts fitted inside enable to divert the
oil inside the engine crankcase to the different lubrication
functions. The filter, single cartridge, is two-stage with 5 µm
parallel filtering.
OVERVIEW
MARCH 2006
N45 MNA M10
N67 MNA M15
1.27
FUEL LINE
Figure 31
4
3
2
5
1
04_405_N
1. Settling prefilter - 2. Low pressure mechanical feed pump - 3. Fuel filter - 4. Injector - 5. Injection pump.
Injection system is made up of mechanical rotary pump.
Main components are set on board of the engine except
the prefilter.
1.28
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
Fuel supply system scheme
Figure 32
2
1
8
3
4
7
5
6
04_308_N
1. Fuel filter - 2. Engine stop solenoid valve - 3. Low pressure mechanical feed pump - 4. Injection pump - 5. Injector 6. Fuel tank - 7. Manual priming pump - 8. Pre-filter.
During engine rotation, the low pressure pump (3) draws
fuel from the tank (6) through the prefilter (8), the main
filter (1) and the solenoid valve (2) to supply the injection
pump (4).
The injection pump supply injectors (5) with adequate timing
and pressure parameters to obtain the performance and, at
the same time, complying with anti-pollution regulations.
Fuel not injected by the pump flows with the injectors leakage to recirculate to the tank.
Manual priming pump (7) allows to fill up the fuel system.
The solenoid valve (2) cut off the fuel to the injection pump
inlet to obtain the engine stop.
The standard set-up includes a normally open solenoid valve;
it requires electric supply to stop the engine (excitation
engine stop).
On request, it is possible to insert a normally closed solenoid
valve, viceversa requesting electric supply to keep the engine
running (non-excitation engine stop).
Fuel pre-filter
1.29
Fuel filter
Figure 33
1
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
Figure 34
5
2
2
3
1
3
04_322_N
4
1. Inlet pipe from prefilter - 2. Injection pump supply pipe 3. Screw cap to drain water.
04_041_N
1. Fastener bracket - 2. System bleeding screw 3. Cartridge - 4. Sensor for detecting the presence
of water in the fuel - 5. Manual priming pump.
In the fuel circuit, it is placed before the fuel filter to protect it.
Holds impurity larger than 300 µm and assures an high separation from water which may be present in fuel.
On request can be equipped with the sensor for detecting
the presence of water in fuel (4).
-
Filtering rating: 300 µm;
Operating max pressure: 3 bar;
Operating temperature: from -40 to +70 °C.
In the lower part there is a screw cap (3) to drain the water
which may be present in fuel.
1.30
N45 MNA M10
N67 MNA M15
OVERVIEW
MARCH 2006
MARCH 2006
TECHNICAL DATA
N45 MNA M10
N67 MNA M15
2.31
SECTION 2
TECHNICAL DATA
Page
GENERAL SPECIFICATIONS
Dimensions
33
35
2.32
N45 MNA M10
N67 MNA M15
TECHNICAL DATA
MARCH 2006
N45 MNA M10
N67 MNA M15
TECHNICAL DATA
MARCH 2006
2.33
GENERAL SPECIFICATIONS
N45 MNA M10
Cycle
N67 MNA M15
4 Stroke Diesel
Air supply
naturally aspirated
Injection
direct
Number of cylinders
4 in line
6 in line
Bore
mm
104
Stroke
mm
132
Total displacement
cm3
4485
6725
17,5 ± 0,8 : 1
Compression ratio
Direction of rotation, brake side
rpm
counterclockwise
Minimum idling rpm
rpm
650 ± 25
Maximum engine rpm, no load
rpm
3100 ± 25
Allowed engine inclination angles
Maximum longitudinal in continuous operation (static + dynamic)
degrees/360
+20
Maximum transverse in continuous operation (static + dynamic)
degrees/360
±22°30'
Longitudinal for oil level check with standard dipstick
degrees/360
0 to +6
Lubrication
Oil
type
Oil compliant with specifications
SAE 15 W40/E 3
ACEA E3/API CF4/MIL L2104E/F
Total oil capacity on first filling
liters (kg)
11,5 (10,5)
16,5 (15)
Total oil capacity with sump at minimum level
liters (kg)
7 (6,3)
8 (7,3)
Total oil capacity with sump at top level
liters (kg)
9 (8,2)
13 (11,8)
Oil pressure, warm engine, minimum idling rpm
bar
≥ 0,7
Oil pressure, warm engine, maximum rpm
bar
≥ 3,8
Maximum allowed temperature
°C
120
Oil dipstick valid for static inclination
degrees/360
0 to +6
Fuel Supply
Fuel oil compliant with standard
EN 590
Low pressure transfer pump
inside injection pump
Flow rate at maximum rpm
liters/h
-
Fuel return flow rate to tank
liters/h
-
Filtering:
µm
µm
pre-filter
filter
300
4
Injection System
Type
mechanical rotary pump
2.34
N45 MNA M10
N67 MNA M15
TECHNICAL DATA
MARCH 2006
N45 MNA M10
N67 MNA M15
Low Temperature Starting
Allowed, without external aids, down to
°C
-10
Cooling
Cooling fresh water closed loop
Total coolant quantity
liters
50% mixture of water/antifreeze
Compliant with SAE J 1034 specification
21
22,5
Expansion tank
standard
Forced circulation
centrifugal pump
Flow rate at maximum rpm
Temperature regulation
initial opening
maximum opening
liters/h
°C
°C
with thermostatic valve
72° ± 2
82° ± 2
Sea-water line
forced circulation
Water pump
self-priming
with neoprene impeller
Sea-water pump height above sea level
m
Max. pump capacity
liters/h
≤2
1200
Exhaust gas expulsion
Optional
mixed with sea water
Electrical system
Nominal voltage
Self-regulated alternator:
Voltage
Maximum current intensity
Electrical starter motor:
Nominal voltage
Absorbed electrical power
Recommended battery capacity
Current discharge at -18 °C (SAE J 537)
V dc
12
V dc
A
14
90
V dc
W
Ah
12
4000
≥ 180
A
≥ 800
Drive train coupling
Flywheel diameter
mm (inches)
- (11,5)
Flywheel case
type
SAE 3
Weights
Without liquids and without marine gear
kg
-
605
N45 MNA M10
N67 MNA M15
TECHNICAL DATA
MARCH 2006
2.35
Dimensions
N45 MNA M10
Figure 1
342 (13.46)
358 (14.09)
355 (13.97)
355 (13.97)
257 (10.12)
30 (1.18)
799 (31.45)
915(36.02)
588.5 (.)
60 (2.36)
390 (15.35)
390 (15.35)
04_428_N
Measurements in: millimeters (inches).
N67 MNA M15
Figure 2
1139 (44.84)
355.5 (13.99)
909.5 (35.80)
30 (1.18)
343.5 (13.52) 361.5 (14.23)
828.5 (32.61)
60 (2.36)
355 (13.97)
390 (15.35)
Measurements in: millimeters (inches).
355 (13.97)
390 (15.35)
04_403_N
2.36
N45 MNA M10
N67 MNA M15
TECHNICAL DATA
MARCH 2006
MARCH 2006
ELECTRICAL EQUIPMENT
N45 MNA M10
N67 MNA M15
3.37
SECTION 3
ELECTRICAL EQUIPMENT
Page
FOREWORD
39
ALTERNATOR
40
ELECTRICAL STARTER MOTOR
41
EQUIPOTENTIAL CONNECTIONS
TO ENGINE GROUND
42
N45 MNA M10.00 - N67 MNA M15.00
43
M10.00/M15.00 OVERALL
45
M10.00/M15.00 SYNOPTIC
46
M10.00/M15.00 WIRE HARNESS
47
M10.00/M15.00 LOCATION OF ELECTRICAL
COMPONENTS IN THE ENGINE
48
M10.00/M15.00 ELECTRICAL COMPONENTS
49
M10.00/M15.00 POWER SUPPLY LINE
49
M10.00/M15.00 RELAY BOX
50
Internal components position
50
M10.00/M15.00 ELECTRICAL DIAGRAMS
52
Wiring diagram key
52
Electrical equipment component code
53
Main analog instrument panel
54
Secondary analog instrument panel
55
Supplementary services battery recharge
56
N45 MNA M10.01 - N67 MNA M15.01
57
M10.01/M15.01 OVERALL
59
M10.01/M15.01 SYNOPTIC
60
M10.01/M15.01 WIRE HARNESS
61
M10.01/M15.01 LOCATION OF ELECTRICAL
COMPONENTS IN THE ENGINE
62
M10.01/M15.01 ELECTRICAL COMPONENTS
63
M10.01/M15.01 POWER SUPPLY LINE
63
(continues on next page)
3.38
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
Page
M10.01/M15.01 ELECTRICAL DIAGRAMS
64
Electrical equipment component code
65
Main analog instrument panel
66
Secondary analog instrument panel
67
Supplementary services battery recharge
68
MARCH 2006
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
3.39
FOREWORD
Figure 1
04_404_N
The engine identification data are stenciled on a tag positioned aside the coolant tank.
Figure 2
S. p. A.
Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY
ENGINE TYPE
ENGINE FAMILY
ENGINE DWG
POWER (KW)
AND SPEED (RPM)
POWER SET CODE
ENGINE S/N
YEAR OF BUILD
HOMOLOGATION
N�
COMMERC. TYPE / VERSION
06_016_N
The last two figures of the commercial code refer to the
engine model (detail A or B in figure n. 2).
Until the beginning of the year 2006 the engines produced
had the code N45 MNA M10.00 or N67 MNA M15.00
(detail A in figure n. 2).
During the year 2006 relevant modifications have been made
to the electric system and to the fuel supply circuit and a new
N67 MNA M15
�
.00
.XX
.01
�
model identified with the code N45 MNA M10.01 or N67
MNA M15.01 was created (detail B in figure 2).
This document concerns both the models. The relating
contents are developed in different chapters which can
be identified thanks to the presence in each title of the
extension M10.00/M15.00 or M10.01/M15.01.
3.40
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
ALTERNATOR
Figure 3
+B
D+
04_223_N
“Bosch” Model 14 V - 90 A
+B. (12 V)
D+. (Lamp)
Figure 4
Power supply output terminal
Power supply voltage of recharge/alarm indicator light located on the panel.
100
Tightening torque for wire terminal nut B+ from 12 to 15
Nm.
80
Ambient temp. 25 °C
90
Specifications
Nominal voltage
14 V
Nominal current max
90 A
Rpm max
6000 rpm
Current max at 1800 rpm
50 A
Polarity
Negative ground
Rotation
Clockwise
viewed from pulley
Belt
Poli-V
Poles
12
Weight
5.7 kg
Output current (A)
70
Ambient temp. 90 °C
60
50
40
30
20
10
0
04_224_N
0
1
2
3
4
5
6
Alternator speed (rpm x 1000)
CHARACTERISTIC CURVES
7
8
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
3.41
ELECTRICAL STARTER MOTOR
Figure 5
+B
+50
Starter
control
04_225_N
Engine electrical ground
connection point
“Bosch” Model - Specifications
Nominal power
4.3 kW
Nominal voltage
12 V
Polarity
Negative ground
Engagement circuit
Positive command
Rotation
Clockwise
viewed from pinion end
Operating voltage
13 V max (20 °C)
Water resistance
Water spray test
based on JIS D0203 SI
Figure 6
RPM kW
Nm
V
2600
65
130
13
2400
60
120
12
2200
55
110
11
2000
50
100
10
1800
45
90
9
1600
40
80
8
1400
35
70
7
1200
30
60
6
1000
25
50
5
800
20
40
4
600
15
30
3
400
10
20
2
200
5
10
1
0
0
0
0
V
kW
RPM
Nm
04_226_N
200
400
600
800
1000
1200
CHARACTERISTIC CURVES
1400
1600
I (A)
3.42
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
EQUIPOTENTIAL CONNECTIONS TO ENGINE GROUND
Figure 7
04_420_N
2
1
To prevent electrochemical corrosion phenomena, some
elements included in the cooling circuits were electrically
grounded with copper braids with eyelet terminations.
Elements connected to the engine ground with metallic
braid conductors:
1.
Junction of the fresh water outlet pipe from the water/
water heat exchanger;
2.
Fresh water supply pipe to water/water exchanger.
CAUTION
To enhance connection efficiency, the screw threads
and the surfaces in contact with the electrical terminals
must be clean and not oxidized, so thoroughly inspect
and remove any impurities before each reinstallation
procedure.
MARCH 2006
ELECTRICAL EQUIPMENT
N45 MNA M10
N67 MNA M15
N45 MNA M10.00
N67 MNA M15.00
MODEL PRODUCED UNTIL THE BEGINNING OF THE YEAR 2006
3.43
3.44
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
3.45
M10.00/M15.00 OVERALL
Figure 8
2
3
1
11
10
4
9
8
7
6
5
04_407_N
1. Indicator and control panel - 2. Provided wire harness - 3. Relay box - 4. JF Connection - 5. Power supply and interface wire
harness - 6. JA and JB connectors - 7. Wiring harness to be manufactured by the shipyard - 8. Sensor for the presence of water in
fuel - 9. Sedimenting pre-filter - 10. M Connector - 11. Power line for electric starter motor and alternator.
The electric equipment of the system carries out the main
connections by means of the wiring provided with the
engine, to which the power supply, the electronic components assembled on the engine, the electronic central unit
of the injection system, relay box and the instrument and
control panel are connected.
The entire product is apt for the needs of an adequate installation and complies with electromagnetic compatibility 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.
Wiring harness for power supply has to be manufactured
by the shipyard following the indications contained in the
“N45 MNA M10 - N67 MNA M15 Installation Directive”
document.
CAUTION
Never use the wiring of the engine equipment to supply
any other electrical appliance for the boat.
Information related to analogue and digital instrument and
control panel and the related sensors are present in the
“N45 MNA M10 - N67 MNA M15 Installation Directive”
document.
3.46
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
M10.00/M15.00 SYNOPTIC
Figure 9
INDICATION AND
ALARM SENSORS
ENGINE STOP
SOLENOID VALVE
EMERGENCY STOP
BUTTON (OPT)
ENGINE SPEED ADDITIONAL SENSORS (OPT)
ALTERNATOR
ELECTRIC
STARTER MOTOR
N45 MNA M10.00
N67 MNA M15.00
JB
JA
JF
BATTERY
RELAY
BOX
04_408_N
04_315_N
1
2
3
4
1. Connector for instrument panel connection wire harness - 2. Engine wire harness - 3. Interface wire harness - 4. Power line.
The wire harnesses provided with the engine include the connectors for all optional components which may ordered and their
connections to the JB connector for the indicator and control panel.
04_309_N
Engine wire harness
MM
GG
A
I
JA
B
W
T
JB
W
M
V
O
V
EC
K
C
K
ELECTRICAL EQUIPMENT
Figure 10
Interface wire harness
A. Drive shaft sensor (on request) - B. Drive shaft sensor (on request) - C. Emergency shut-down push-button (on request, installer’s responsibility) - I. High coolant temperature
sensor (for alarm) - K. Air filter clogging sensor (for alarm) - M. Sensor for detecting the presence of water in the fuel pre-filter (for alarm) - O. Exhaust gas temperature sensor
(on request) - T. Coolant temperature sensor (for gauge) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - EC. Injection pump connector I1. KSB Refrigerating liquid temperature sensor - J1. Engine stop solenoid valve - KSB. Cold injection advance adjustment device - GG. Connector for alternator J1. Alternator excitation - W. Signal for revolution counter - JB. Instrument panel connection wire harness - JF. Relay box - MM. Electric starter motor.
JF
– BATT
+ BATT
T
MARCH 2006
N45 MNA M10
N67 MNA M15
3.47
M10.00/M15.00 WIRE HARNESS
3.48
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
M10.00/M15.00 LOCATION OF ELECTRICAL COMPONENTS IN THE ENGINE
Figure 11
W
GG
I
EC
MM
I1
J1
KSB
J1
B
M
JA-JB
T
W
V
A
04_418_N
A. Drive shaft sensor (on request) - B. Drive shaft sensor (on request) - I. High coolant temperature sensor (for alarm) - K. Air filter
clogging sensor (for alarm) - M. Sensor for detecting the presence of water in the fuel pre-filter (for alarm) - T. Coolant temperature
sensor (for gauge) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - EC. Injection pump connector -
I1. KSB Refrigerating liquid temperature sensor - J1. Engine stop solenoid valve - KSB. Cold injection advance adjustment
device - GG. Connector for alternator - J1. Alternator excitation - W. Signal for revolution counter - JA. Interface connection
wire harness - JB. Instrument panel connection wire harness - MM. Electric starter motor.
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
M10.00/M15.00 ELECTRICAL COMPONENTS
KSB Refrigerating liquid temperature sensor
3.49
M10.00/M15.00 POWER SUPPLY LINE
Figure 13
4
Figure 12
2
30
50
+B
W
D+
04_313_N
M
Thermometrical switch which manages the activation of the
cold injection advance adjustment device.
Operating voltage
from 6 V to 24 V
04_302_N
Condition at ambient temperature normally closed
Closing temperature
≥ 63 ± 3 °C
Opening temperature
≤ 53 ± 3 °C
Maximum current
15A (inductive)
Poles
isolated
1
3
1.Alternator - 2. Electric starter motor - 3. Battery 4. Engine wire harness.
The power supply line, to be implemented by the shipyard,
comprises:
o A. A connection between the negative pole of the battery and engine ground with a conductor having a cross
section of at least 70 mm2;
KSB solenoid valve
Operating voltage
12 V
Resistance value
7 ± 1,4 Ω
Operating voltage
24 V
Resistance value
28 ± 5,6 Ω
o B. A connection between the positive pole of the battery
and the terminal “30” of the electrical starter motor, with
a conductor having a cross section of at least 70 mm2;
o C. A connection between the +B terminal of the alternator to the positive +30 terminal of the electric starter
motor, to complete the recharge circuit, is reached with
a conductor having a cross section of at least 10 mm2..
The connection of the electric equipment of the engine to
the battery has to be carried out by the two-eyed terminals,
+B and -B present on the wiring harness.
CAUTION
Engine stop solenoid valve
Operating voltage
12 V
Resistance value
5±1Ω
Operating voltage
24 V
Resistance value
20 ± 4 Ω
In presence of equipments with excitation engine stop, if
magneto-thermal protecting breakers or battery-switch
are installed on system electrical supply lines, eventual
interruption of electrical supply will not allow to stop the
engine.
N45 MNA M10
N67 MNA M15
3.50
ELECTRICAL EQUIPMENT
MARCH 2006
M10.00/M15.00 RELAY BOX
Figure 14
Figure 16
1
04_310_N
1. JF connection.
It is the main point of interconnection and carries out many
interfacing functions among the various components of the
system.
Inside the box, are present the power management relays of
some components and two fuses that protect the electrical
lines against short circuits or excessive current absorption.
Connect it to wiring using the 16 pole JF connector.
This is to be installed and anchored in such a way as to
dampen the vibrations and stresses occurring when underway, and will be accessible during servicing operations and
when underway.
1
3
6
13
16
5
9
10
2
4
7
8
12
15
11
14
04_324_N
Internal components position
JF CONNECTOR
(view of the wire harness terminal, coupling side)
Figure 15
R1
FS3
R3
FS2
R2
RS
JF
04_325_N
R1. Power supply to terminal 50 of the electric starter motor R2. Emergency engine shut-down provision - R3.-Key switch
electric discharge - FS 2. Fuse on solenoid valve supply line for
engine stop - FS 3. Fuse on main supply line - RS. Alternator
pre-excitation resistor - JF.-Interface connector wire harness.
MARCH 2006
ELECTRICAL EQUIPMENT
N45 MNA M10
N67 MNA M15
3.51
N45 MNA M10
N67 MNA M15
3.52
ELECTRICAL EQUIPMENT
MARCH 2006
M10.00/M15.00 ELECTRICAL DIAGRAMS
Wiring diagram key
General conditions for the preparation and interpretation of wiring diagrams
o Key switch open;
o Engine not running;
o Liquids at efficient levels and pressures.
Figure 17
Connection
JC: connector
8: terminal
Component
terminal
Fuse code
Component
code
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connections
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MARCH 2006
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
3.53
Electrical equipment component code
A
drive shaft sensor (on request)
AC
battery
AQ
engine shut-off push-button on main panel
AS
engine shut-off push-button on secondary panel
B
drive shaft sensor (on request)
C
emergency shut-down push-button
(optional, installer’s responsibility)
CA
key switch
CS
engine start push-button on secondary panel
EDC
EDC malfunction
EC
injection pump connector
SAC
presence of water in fuel pre-filter
GG
connector for alternator
SATA
coolant high temperature
I
high coolant temperature sensor (for alarm)
SBLA
low coolant level
I1
KSB refrigerating liquid temperature sensor
SBPO
low oil pressure
J1
engine stop solenoid valve
SCP
pre-post heating
J1
alternator excitation
SIFA
clogged air filter
K
air filter clogging sensor (for alarm)
SIFB
clogged oil vapor filter
KSB
cold injection advance adjustment device
SIFC
clogged fuel filter
L
instrument panel light switch
SIFO
clogged oil filter
M
sensor for detecting the presence of water in
the fuel pre-filter (for alarm)
SP
pre-lubrication
SS
alternator fault
MM
electric starter motor
SSV
engine overspeed
MS
IVECO MOTORS indications and alarms module
O
exhaust gas temperature sensor (on request)
Gauges
P1
sound alarm inhibition push-button
CG
revolution-counter
QP
main analog instrument panel
MO
engine oil pressure
QS
secondary analog instrument panel
TA
engine temperature
SA
buzzer
V
voltmeter
T
coolant temperature sensor (for gauge)
V
oil pressure sensor (for gauge)
W
low oil pressure sensor (for alarm)
W
signal for revolution counter
JE
ON MAIN ANALOG INSTRUMENT PANEL
set for connection to the secondary analog
instrument panel
JF
JH
relay box
ON SECONDARY ANALOG INSTRUMENT PANEL
set for connection to the main analog
instrument panel
Indicator lights
Relays contained in the relay box
R1
power supply to terminal 50 of the electric
starter motor
R2
emergency engine shut-down provision
Connectors
R3
key switch electric discharge
JA
Fuses contained in the relay box
JB
JC
JD
connection between engine wiring and interface
wire harness
ON ENGINE WIRE HARNESS
set for connection to the main analog
instrument panel
ON MAIN ANALOG INSTRUMENT PANEL
set for connection to the engine wire harness
IVECO MOTORS indications and alarms module
FS 2
on solenoid valve supply line for engine stop
FS 3
on main supply line
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N45 MNA M10
N67 MNA M15
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3.54
ELECTRICAL EQUIPMENT
MARCH 2006
M10.00/M15.00
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�
MARCH 2006
N45 MNA M10
N67 MNA M15
3.55
M10.00/M15.00
*
–
+
Two-engines
installation
AC2
–
IE1
M
30
10
50
JA
11
10
J1
GG2
B+
B+
GG
J1
50
MM
30
M
87
85
30
86
70
6
6
–
BAT
70
70
10
AC1
MM
RL
10
BAT +
6
+
11 JA
BAT –
70
–
AC2
+
–
+
*
AC1
+ BAT
– BAT
M
30
50
MM
GG1
J1
B+
11
Key:
- AC1: Main Battery
- AC2: Battery for auxiliary services
- IE1: Engine 1 electrical system
- IE2: Engine 2 electrical system
- RL: Relay 50A max.
- * : Electrical power supply for services
6
Single engine
installation
10
10
70
+ BAT
JA
IE2
Supplementary services battery recharge
6
70
N45 MNA M10
N67 MNA M15
6
10
3.56
ELECTRICAL EQUIPMENT
MARCH 2006
M10.00/M15.00
MARCH 2006
ELECTRICAL EQUIPMENT
N45 MNA M10.01
N67 MNA M15.01
MODEL PRODUCED FROM THE YEAR 2006
N45 MNA M10
N67 MNA M15
3.57
3.58
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
3.59
M10.01/M15.01 OVERALL
Figure 18
1
2
3
4
4
06_009_N
1. Indicator and control panel - 2. Provided wire harness - 3. JB Connection - 4. Power line for electric starter motor and alternator.
The electric equipment of the system carries out the main
connections by means of the wiring provided with the
engine, to which the power supply, the electronic components assembled on the engine, the electronic central unit
of the injection system, relay box and the instrument and
control panel are connected.
The entire product is apt for the needs of an adequate installation and complies with electromagnetic compatibility 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.
Wiring harness for power supply has to be manufactured
by the shipyard following the indications contained in the
“N45 MNA M10 - N67 MNA M15 Installation Directive”
document.
CAUTION
Never use the wiring of the engine equipment to supply
any other electrical appliance for the boat.
Information related to analogue and digital instrument and
control panel and the related sensors are present in the
“N45 MNA M10 - N67 MNA M15 Installation Directive”
document.
3.60
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
M10.01/M15.01 SYNOPTIC
Figure 19
INDICATIONS AND ALARMS
SENSORS
ENGINE STOP
SOLENOID VALVE
EMERGENCY STOP
BUTTON (OPT)
ALTERNATOR
ELECTRIC STARTER
MOTOR
N45 MNA M10.01
N67 MNA M15.01
��
RL1
1
2
BATTERY
3
06_011_N
1. Connector for instrument panel connection wire harness - 2. Engine wire harness - 3. Power line.
The wire harnesses provided with the engine include the
connectors for all optional components which may ordered
and their connections to the JB connector for the indicator
and control panel.
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Figure 20
module connector - J16F. Engine rotation over speed control module (on request) - RL1. Starter relay motor - MM. Electric starter motor.
ELECTRICAL EQUIPMENT
I. High coolant temperature sensor (for alarm) - K. Air filter clogging sensor (for alarm) - T. Coolant temperature sensor (for gauge) - V. Oil pressure sensor (for gauge) - W. Low
oil pressure sensor (for alarm) - W. Signal for revolution counter - EC. Injection pump connector - I1. KSB Refrigerating liquid temperature sensor - J1. Engine stop solenoid valve
- KSB. Cold injection advance adjustment device - GG. Connector for alternator - JB. Instrument panel connection wire harness - J1. Alternator excitation - JSV. Over speed
06_012_N
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MARCH 2006
N45 MNA M10
N67 MNA M15
3.61
M10.01/M15.01 WIRE HARNESS
3.62
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
M10.01/M15.01 LOCATION OF ELECTRICAL COMPONENTS IN THE ENGINE
Figure 21
W
GG
I
EC
MM
I1
J1
KSB
J1
B
M
JA-JB
T
W
V
A
04_418_N
I. High coolant temperature sensor (for alarm) - K. Air filter clogging sensor (for alarm) - T. Coolant temperature sensor (for gauge)
- V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - EC. Injection pump connector -
I1. KSB Refrigerating liquid temperature sensor - J1. Engine stop solenoid valve - KSB. Cold injection advance adjustment
device - GG. Connector for alternator - J1. Alternator excitation - W. Signal for revolution counter - JB. Instrument panel
connection wire harness - MM. Electric starter motor - JSV. Over speed module connector - RL1. Starter relay motor.
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
MARCH 2006
M10.01/M15.01 ELECTRICAL COMPONENTS
KSB Refrigerating liquid temperature sensor
3.63
M10.01/M15.01 POWER SUPPLY LINE
Figure 23
4
Figure 22
5
6
Equipment
power supply
30
04_313_N
+B
W
D+
M
Thermometrical switch which manages the activation of the
cold injection advance adjustment device.
Operating voltage
50
from 6 V to 24 V
06_004_N
Condition at ambient temperature normally closed
3
Closing temperature
≥ 63 ± 3 °C
Opening temperature
≤ 53 ± 3 °C
Maximum current
15A (inductive)
Poles
isolated
KSB solenoid valve
Operating voltage
12 V
Resistance value
7 ± 1,4 Ω
Operating voltage
24 V
Resistance value
28 ± 5,6 Ω
Engine stop solenoid valve
Operating voltage
12 V
Resistance value
5±1Ω
Operating voltage
24 V
Resistance value
20 ± 4 Ω
2
1
1.Alternator - 2. Electric starter motor - 3. Battery 4. Engine wire harness - 5. This conductor is present on the
engine wiring - 6. This conductor must be parallel connected
to the existing one.
The connection of the +B terminal of the alternator to the
positive +30 terminal of the electric starter motor must be
achieved with a conductor having a cross section of at least
20 mm2. On the engine wiring there is a 6 mm2 section
conductor: a 16 mm2 section or – or higher – conductor
must be connected to it. 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 70 mm2, allows to obtain, as shown in the figure,
the simultaneous connection of the alternator to the battery.
On the same +30 terminal of the start-up electric engine
it is necessary to connect the eye battery lead connection
marked with “+ BAT (MM)”. The connection between the
engine ground and the negative pole of the battery must be
achieved according to the guidelines provided in the Engine
electrical ground paragraph.
CAUTION
Do not use any magneto-thermal activation protection
items to stop engine. Using off-the-shelf equipment, you
stop the engine energizing the proper solenoid valve. In
lack of power supply you could not stop the engine.
N45 MNA M10
N67 MNA M15
3.64
ELECTRICAL EQUIPMENT
MARCH 2006
M10.01/M15.01 ELECTRICAL DIAGRAMS
Wiring diagram key
General conditions for the preparation and interpretation of wiring diagrams:
o Key switch open
o Engine not running
o Liquids at efficient levels and pressures
Figure 24
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16: terminal
Component
terminal
Fuse code
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Minimum cable cross
section in mm2
Quadro princ N 100-150 AFAM
Component code
or connector code
Cable colour
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MARCH 2006
N45 MNA M10
N67 MNA M15
ELECTRICAL EQUIPMENT
3.65
Electrical equipment component code
AC
battery
Lampes de signalisation
AQ
engine shut-off push-button on main panel
SAC
AS
engine shut-off push-button on secondary panel
CA
key switch
SATA
Presence of an alarm on the personalized board
(if the IVECO MOTORS alarm and signalling
module is not present)
coolant high temperature
CS
engine start push-button on secondary panel
SBLA
low coolant level
D
6 diodes block
SBPO
low oil pressure
D1
Protection diode (on the main board)
SCP
pre-post heating
GG
alternator
SIFA
clogged air filter
I
high coolant temperature sensor (for alarm)
SS
alternator fault
I1
KSB refrigerating liquid temperature sensor
SSV
runaway engine
J1
engine stop solenoid valve
J1
alternator excitation
Gauges
CG
revolution-counter
K
air filter clogging sensor (for alarm)
MO
engine oil pressure
KSB
cold injection advance adjustment device
TA
engine temperature
MA
alarms management module
V
voltmeter
MM
QP
electric starter motor
main analog instrument panel
QS
secondary analog instrument panel
SA
buzzer
T
coolant temperature sensor (for gauge)
V
oil pressure sensor (for gauge)
W
low oil pressure sensor (for alarm)
J16F
Engine rotation over speed control module
(on request)
Connecteurs
JA
IVECO MOTORS indications and alarms
module
JB ON ENGINE WIRE HARNESS
set for connection to the main analog
instrument panel
JC ON MAIN ANALOG INSTRUMENT PANEL
set for connection to the engine wire harness
JSV
Over speed module connector
MF ON SECONDARY ANALOG INSTRUMENT PANEL
pre-set clamp for connection to the main
analog instrument panel
MP
ON MAIN ANALOG INSTRUMENT PANEL
pre-set clamp for connection to the
secondar y analog instrument panel
Relays
RL1
RL
power supply to terminal 50 of the electric
starter motor
For engine stop from alarm module
Fusibles
FS
on “15” supply line
Board electric cables colour index
K
orange
A
sky blue
B
white
L
blue
G
yellow
H
grey
M
brown
N
black
S
pink
R
red
V
green
Z
purple
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N45 MNA M10
N67 MNA M15
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3.66
MARCH 2006
M10.01/M15.01
Quadro princ N 100-150 AFAM
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MARCH 2006
N45 MNA M10
N67 MNA M15
3.67
M10.01/M15.01
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Two-engines
installation
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Key:
- AC1: Main Battery
- AC2: Battery for auxiliary services
- IE1: Engine 1 electrical system
- IE2: Engine 2 electrical system
- RL: Relay 50A max.
- *: Electrical power supply for services
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installation
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N67 MNA M15
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3.68
ELECTRICAL EQUIPMENT
MARCH 2006
Supplementary services battery recharge
M10.01/M15.01
MARCH 2006
N45 MNA M10
N67 MNA M15
DIAGNOSTICS
4.69
SECTION 4
DIAGNOSTICS
Page
FOREWORD
71
MAJOR DIAGNOSTIC ACTIONS
72
Checking pressure in fuel supply line
72
Checking component resistance value
72
Checking line insulation
72
REFERENCE VALUES
73
For non hardwired sensors
73
For inductive sensors
73
GUIDE TO SYMPTOM DIAGNOSING
74
4.70
N45 MNA M10
N67 MNA M15
DIAGNOSTICS
MARCH 2006
MARCH 2006
DIAGNOSTICS
FOREWORD
A proper diagnosis is reached through the competence
acquired with years of experience and attending training
courses.
When the user complains of poor performance or operating anomalies, due consideration must be given to his/her
indications, in order to derive useful information that will
orient our actions.
After ascertaining the existence of the anomaly, we recommend starting troubleshooting operations with tests and
measurements, to obtain a picture of the overall operating
conditions and identify the real fault causes.
If adopted diagnostic modes provide no indications, proceed
to check ratings and technical data provided in the “N45
MNA M10 - N67 MNA M15 Installation Directive” document.
We have provided, in the following pages, a TROUBLESHOOTING GUIDE organized by symptoms, describing the
possible anomalies not recognized by the electronic unit,
frequently mechanical or hydraulic in nature.
For operation and maintenance instructions, see the indications provided in Section 5.
N45 MNA M10
N67 MNA M15
4.71
N45 MNA M10
N67 MNA M15
4.72
DIAGNOSTICS
MARCH 2006
MAJOR DIAGNOSTIC ACTIONS
Checking pressure in fuel supply line
Figure 1
Checking component resistance value
Figure 2
A
04_086_N
Ensure that the system is not powered.
The measurement must be taken on each individual component, isolated from its wiring or connected only to the instrument, set as ohmmeter on the appropriate end of scale value
(see REFERENCE VALUE table in the pages that follow). At
the end, restore the correct connection.
B
Checking line insulation
Figure 3
04_405_N
Gauges will be interposed in A and B by “T” unions. Measurements have to be carried out at various engine speeds from
minimum to maximum at intervals of 200 RPM.
Acceptable limit ratings
Point
Minimum
Maximum
A
- 20 kPa
0 kPa
B
0 kPa
10 kPa
04_087_N
Figure 4
04_088_N
Ensure that the system is not powered. The measurement
must be taken on each individual conductor, isolated from
all the components to which it is normally connected.The
measurement must be taken with the instrument set as
ohmmeter on end of scale value ≥ 200 KΩ, and it must be
N45 MNA M10
N67 MNA M15
DIAGNOSTICS
MARCH 2006
4.73
REFERENCE VALUES
For non hardwired sensors
Component
Test conditions
Minimum
Ω value
Maximum
Ω value
Coolant temperature sensor
90 °C
51.2
± 4.3
Lubrication oil pressure sensor
0 bar
2 bar
4 bar
6 bar
maximum
10
52
88
124
-
+3/-5
±4
±4
±5
184
Drive shaft sensor
20 °C
800
1000
Camshaft sensor
20 °C
800
1000
Engine stop solenoid valve (12V)
20 °C
4
6
Engine stop solenoid valve (24V)
20 °C
16
24
KSB solenoid valve (12V)
20 °C
5,6
8,4
KSB solenoid valve (24V)
20 °C
22,4
33,6
CAUTION
Measurements refer only to the reference component.
Measurements closest to reality are taken including the relevant wiring.
Always check the continuity of the SHIELD conductor from the sensor to the electronic unit and the latter’s good insulation from the other signal conductors.
For inductive sensors
Sensors wired with shielded wires
Component
Test conditions
Value
Drive shaft sensor
Engine running
650 rpm
> 0.8 Vac
Camshaft sensor
Engine running
650 rpm
> 0.8 Vac
Figure 5
1
1, 2. Sensor terminals 3. Shield electrically
insulated from sensor.
2
3
04_063_N
Part
Battery
Electrical starter motor
Injection pump
"15" control from key switch
Fuel feed pump
Fuel circuit
Fuel circuit
Fuel filter and pre-filter
Symptom
Engine does not start
Engine does not start
Engine does not start
Engine does not start
Engine does not start
Engine does not start
Engine does not start
Engine does not start
GUIDE TO SYMPTOM DIAGNOSING
- Clogged
- Presence of water
- Incorrect filling (air in fuel circuit)
- Bleed
- Check tank
- Replace
- Drain water from fuel filter and prefilter. Clean fuel
tank and piping. Remove and clean injection pump.
Restore fuel loop, fill the tank and vent the air.
- Check seal and air with a clear tube, arranged as an
inverted U, inserted before the inlet junction.
- Check seal or air intake on induction side
- Check wiring, key switch and relay R1 contained in
relay box
- Check, restore correct timing
- Injection pump overhaul
- Check efficiency
- Check connections to positive (+ 30) and engine
ground
- Recharge (disconnecting battery from system wiring)
- Clean, check insulation, tighten terminals
Recommended tests or action
N45 MNA M10
N67 MNA M15
- Incorrect priming
- Malfunction
- Faulty terminal connections
- Incorrect timing
- Wear or defective
- Malfunction
- Faulty terminal connections
- Low charge
- Faulty terminal connections
Possible cause
4.74
DIAGNOSTICS
MARCH 2006
Part
Coolant level
Water pump drive belt
Water pump
Thermostatic valve
Coolant / sea-water heat
exchanger
Air filter
Cylinder head gaskets
Injection pump
Symptom
Engine frequently overheats
Engine frequently overheats
Engine frequently overheats
Engine frequently overheats
Engine frequently overheats
Engine frequently overheats
Engine frequently overheats
Engine frequently overheats
GUIDE TO SYMPTOM DIAGNOSING
- Incorrect timing
- Incorrect calibration
- Compression leaking from cylinder head gaskets
- Clogged
- Clogged
- Locked, closed or only partially open
- Malfunction
- Poor tension
- Wear
- Below MIN level
Possible cause
- Check, restore correct timing
- Injection pump calibration/overhaul
- Check cooling water circuit pressure
- Replace head gaskets
- Clean or replace
- Clean or replace
- Replace
- Check for impurities in coolant
- Replace
- Check belt tension
- Check for liquid leakage on drive belt
- Check tension
- Replace
- Check for liquid leakage on drive belt
- Check for leaks
- Top up correct level
Recommended tests or action
MARCH 2006
DIAGNOSTICS
N45 MNA M10
N67 MNA M15
4.75
- Clogged
- Wear
- Incorrect timing
- Excessive or nil clearance
- Incorrect timing
- Incorrect calibration
- Malfunction
Injectors
Engine air feed
Gas exhaust system
Camshaft
Engine valves
Injection pump
Automatic injection advance
device
Poor performance
Poor performance
Poor performance
Poor performance
Poor performance
Poor performance
- Air filter clogged
- Malfunction
- Locked, closed
- Locked, open
Tank net filter clogged
Fuel prefilter clogged
Fuel filter clogged
Air in fuel circuit
Heavy fuel leakage
Poor performance
-
Fuel circuit
Poor performance
Possible cause
Part
Symptom
GUIDE TO SYMPTOM DIAGNOSING
- Injection pump calibration/overhaul
- Check, restore correct timing
- Injection pump overhaul
- Check, restore correct clearance
- Check
- Replace
- Check, restore correct timing
N45 MNA M10
N67 MNA M15
- Check exhaust back-pressure
- Clean or replace filter
- Loosening the connector on the pipe connecting the
injector, it excludes the injection, enabling to locate
the cylinder where the anomaly is present. Proceed
with caution in order to avoid dangerous fuel sprays
and dispersions in the environment.
- Clean or replace clogged filters
- Check intake seals
- Check the integrity of the fuel gear pump
Recommended tests or action
4.76
DIAGNOSTICS
MARCH 2006
Tie rods between command
lever and regulation lever on
injection pump
Cylinders, pistons
Water in cylinders
Oil in cylinders
Poor performance
Poor performance
The engine emits grey-white
smoke
The engine
smoke
Fuel tank
Net filter
Prefilter
Fuel filter
Fuel circuit
Engine stop solenoid valve
power supply only (on versions with de-energizing
engine stop)
Engine stops
Engine stops
Engine stops
Engine stops
blue
Speed regulator on injection
pump
Poor performance
emits
Part
Symptom
GUIDE TO SYMPTOM DIAGNOSING
Connections
Wiring
Key switch
Relay R1
Check coolant level
Check fresh water circuit pressurization
Check heat exchanger
Check efficiency of sensor to detect the presence of
water in fuel
- Check +B and –B electrical connections
- Check wiring, key switch and relay R1
- See “Poor performance”
- Replace
- Check efficiency of fuel filter clogging sensor
- Refill and bleed fuel circuit
- Modify float or tank tilt
- Check lubrication oil consumption
- Overhaul
-
- Engine overhaul
- Check, adjust the tie-rods so that command lever can
be moved to the full delivery position.
- Injection pump calibration/overhaul
Recommended tests or action
DIAGNOSTICS
-
- See “Poor performance”
- Clogged
- Not enough fuel in tank
- Float in incorrect position
- Oil leaking in turbocompressor
- Oil leaking from valve guides
- Leakages from cylinder gasket
- Water in intake system from air / sea-water
heat exchanger
- Water in fuel
- Excessive wear
- Incorrectly adjusted
- Malfunction
Possible cause
MARCH 2006
N45 MNA M10
N67 MNA M15
4.77
4.78
N45 MNA M10
N67 MNA M15
DIAGNOSTICS
MARCH 2006
MARCH 2006
MAINTENANCE
N45 MNA M10
N67 MNA M15
5.79
SECTION 5
MAINTENANCE
Page
PERIODICITY OF CHECKS
AND MAINTENANCE OPERATIONS
81
PREPARING THE ENGINE
FOR LONG IDLE PERIODS
83
ENGINE’S FIRST START / RESTORING
NORMAL OPERATING CONDITIONS
83
5.80
N45 MNA M10
N67 MNA M15
MAINTENANCE
MARCH 2006
N45 MNA M10
N67 MNA M15
MAINTENANCE
MARCH 2006
5.81
PERIODICITY OF CHECKS AND MAINTENANCE OPERATIONS
Execution of the operations indicated below requires competence and compliance with the safety regulations enforced in each
Country.
Checks can be performed by the user of the vessel and/or by the workshop personnel.
Periodic maintenance operations must be performed by qualified personnel and require the use of tools, work instruments, and
suitable protection means.
Extraordinary maintenance operations is to be performed by IVECO MOTORS authorized workshop personnel with adequate
training and sufficient technical information.
Checks
Periodicity
Every
start
Check engine lubricating oil level
n
Check engine coolant level
n
Check oil level in the gearbox
n
Inspect exhaust duct(s)
n
Drain water from fuel pre-filter(s)
(1)
150
hours
600
hours
900
hours
1200 Annual
hours
(2)
n
Check battery terminal tightening and cleanliness
Check electrolyte level in batteries
300
hours
(1)
Check condition of oil vapor filter
n
n
n
n
n
Periodic maintenance operations
Periodicity
Every
start
Clean air filter(s)
150
hours
(1)
Check belt tension and conditions
Check zinc anode corrosion condition
(4)
Restore battery electrolyte level
Drain/draw water and condensations from tank(s)
(1)
300
hours
600
hours
900
hours
1200
hours
Annual
(2)
n
n
n
n
n
n
n
n
n
n
Replace engine lubricating oil (after first 50 hours)
n
n
Replace fuel pre-filter(s)
(1) (3)
Max
n
Replace fuel filter(s)
(1) (3)
Max
n
Replace oil filter(s) (after first 50 hours)
n
n
Replace gearbox(es) oil (see data provided by the manufacturer)
n
n
Inspect sea-water intake
(1)
Check wear of sea-water pump impeller
Adjust valve-rocker arm clearance
Inspect damper in drive shaft front pulley
n
n
Periodicity
Every
start
Replace water pump and alternator drive belt
n
every 3000 hours
Extraordinary maintenance operations (5)
Clean heat exchangers
n
(6)
150
hours
300
hours
600
hours
900
hours
1200
hours
n
Every 3
years (7)
n
n
n
n
5.82
N45 MNA M10
N67 MNA M15
MAINTENANCE
(1) The periodicity of these operations may vary depending on
engine use and environmental conditions of operation.
(2) These operations must be carried out annually even if the
specified number of operating hours is not reached.
(3) Maximum time interval for high quality fuel; it may be
reduced depending on their contamination. The filter is
provided with clogging sensor; if a clogging indication is
provided, replace the filter. The pre-filter is provided with
a water presence detector; if the presence of water is
detected, drain the water from the appropriate drain and if
the light stays lighted, replace the filter.
(4) If zinc corrosion exceeds 50% of its volume, replace it.
(5) Instructions provided in Section 8.
(6) Engine coolant/sea-water exchanger: clean the sea-water
side - Gearbox oil/sea-water heat exchanger (if-provided):
clean sea-water side.
(7) These operations must be performed every three years
even if the specified operating hours are not reached.
MARCH 2006
MARCH 2006
N45 MNA M10
N67 MNA M15
MAINTENANCE
PREPARING THE ENGINE
FOR LONG IDLE PERIODS
To prevent oxidation to the internal parts of the engine
and to some components of the injection system, if idle
periods exceeding two months are expected, the engine
needs to be prepared with six-months periodicity, proceeding as follows:
5.83
ENGINE’S FIRST START / RESTORING
NORMAL OPERATING CONDITIONS
1.
Drain the residual protective oil type 30/M from the
sump;
2.
Pour lubricating oil into the engine, as provided by the
specifications and in the quantities set out in the Table of
Refills;
1.
Drain the lubricating oil from the sump, after heating the
engine;
3.
2.
Pour 30/M type protective oil (alternatively, oil conforming with MIL 2160B Type 2 specifications) into the engine
to the “minimum” level marked on the dipstick.
Start the engine and let it run for about 5 minutes;
Drain the CFB protective liquid from the fuel line, completing the operations set out in item 3 of “PREPARING
THE ENGINE FOR LONG IDLE PERIODS”;
4.
Remove the caps and/or the seals from the engine’s
intake, exhaust, aeration and vent ports, restoring normal operating conditions. Connect the turbocompressor
intake to the air filter;
5.
Attach the fuel lines to the vessel’s fuel tank, completing
the operations set out in item 4 of “PREPARING THE
ENGINE FOR LONG IDLE PERIODS”.
During the filling operations, attach the fuel tank return
pipe to a collecting container to prevent residues of CFB
protective liquid from flowing into the vessel’s fuel tank;
6.
Verifiy the quantity of cooling liquid and refill as provided
by the specifications;
7.
Start the engine and keep it running until idling speed
has completely stabilized;
8.
Shut the engine down;
9.
Remove the tags with the inscription “ENGINE WITHOUT OIL” from the engine and from the panel.
3.
4.
5.
Drain the fuel from the injection line and from the filter,
taking care to avoid letting the fuel come in contact with
the auxiliaries belt;
Connect the fuel line to a tank containing CFB protective liquid (ISO 4113) and assist the inflow of the liquid
by pressurizing the line and turning the engine over for
about 2 minutes, after excluding the operation of the
injection system. The required operation may be carried
out by directly polarizing the terminal 50 of the electric
starter motor with positive voltage 12 V, using a conductor prepared for the occasion;
Nebulize 30/M type protective oil at the rate of about
10 g per liter of displacement:
N45 MNA M10 = 45g
N67 MNA M15 = 70g
into the engine intake, while the engine is turning over
as described above;
6.
Close with suitable stoppers or seal with adhesive tape
all engine intake, exhaust, aeration and venting ports;
7.
Drain the residual 30/M type protective oil from the
sump; it may be re-used for 2 more engine preparation operations;
8.
Apply tags with the inscription “ENGINE WITHOUT
OIL” on the engine and onboard panel;
9.
Drain the coolant, if it has not been mixed with antifreeze and corrosion inhibiting agents, affixing tags to
indicate that the operation has been carried out.
If external parts of the engine are to be protected, spray
protective liquid OVER 19 AR onto unpainted metal parts,
such as flywheel, pulleys and others; avoid spraying belts, connector cables and electrical equipment.
5.84
N45 MNA M10
N67 MNA M15
MAINTENANCE
MARCH 2006
MARCH 2006
SERVICING OPERATIONS ON INSTALLED ENGINE
N45 MNA M10
N67 MNA M15
6.85
SECTION 6
SERVICING OPERATIONS
ON INSTALLED ENGINE
Page
FOREWORD
87
PRESCRIPTIONS FOR WORK
88
ON THE INJECTION SYSTEM
88
VENTING THE AIR FROM THE FUEL FEED LOOP
88
VALVES CLEARANCE ADJUSTMENT
89
CLEANING THE ENGINE COOLANT / SEA-WATER
HEAT EXCHANGER
90
ADJUSTING INJECTION PUMP TIMING
91
Injection pump timing data
92
VERIFY INJECTION PUMP TIMING
92
CALIBRATING THE INJECTION PUMP
92
MARINE PARTS DECOUPLING
93
INSTRUCTIONS FOR DISEMBARKING THE ENGINE 95
Handling
95
6.86
N45 MNA M10
N67 MNA M15
SERVICING OPERATIONS ON INSTALLED ENGINE
MARCH 2006
MARCH 2006
SERVICING OPERATIONS ON INSTALLED ENGINE
FOREWORD
Many of the procedures for carrying out the instructions
that follow depend on the configuration of the housing on
the vessel and on the disposition 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 “N45 MNA M10 - N67
MNA M15 Installation 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 refer to engine characteristics which were current as of the publishing date.
The manufacturer reserves the right to make changes at any
time and without advance notice, to comply with technical
or commercial requirements or to adapt to legal requirements in different Countries.
The manufacturer shall not be liable for any errors and
omissions.
The IVECO MOTORS Technical Assistance Network is
always at the Customer’s side with its competence and
professionalism.
N45 MNA M10
N67 MNA M15
6.87
6.88
N45 MNA M10
N67 MNA M15
SERVICING OPERATIONS ON INSTALLED ENGINE
PRESCRIPTIONS FOR WORK
ON THE INJECTION SYSTEM
The successful outcome of repair work is assured by the
operator’s experience and ability and by compliance with the
following instructions.
o Keep parts and components clean, making sure that
during handling and assembly (starting with the simple
replacement of filter and pre-filter) no sludge or foreign
matter is allowed to enter the lines, with particular
attention to the fuel supply line in the segment downstream of the filter;
MARCH 2006
VENTING THE AIR FROM THE FUEL FEED LOOP
Figure 1
3
2
o Maintain the proper polarization of all electrical connections;
o Tighten the threaded connections to the prescribed
torque;
o Make sure that the flywheel and camshaft sensors are
positioned so they abut, ensuring they are as close to
perpendicular (with respect to the bearing surface) as
possible.
1
CAUTION
o Do not disconnect electrical connections without
removing power from the circuits first;
o Do not proceed with operating simulations with
unsuitable tools and instruments;
o Do not force measuring probes or mechanical tools
into the electrical connections;
o Do not proceed with arc welding without first disconnecting electronic system units.
To proceed with the overhaul of the engine or its parts, you
must disconnect the electrical connections of the system’s
components and of the sensors providing indications
on the control panel.
To proceed as indicated, we provide below the procedure to
avoid the risk to damage the electrical components.
o Set the key switch to the STOP position and shut the
engine down;
o Wait 10 sec. and disconnect the battery terminals;
o Disconnect the connectors releasing the restrain system,
than split the parts avoiding sudden motions;
o Remove, if necessary, the entire wiring harness from the
engine.
04_041_N
1. Fuel prefilter - 2. System bleeding screw 3. Manual priming pump.
To exhaust air from fuel system, operate the pre-filter (1)
manual pump (3) or use a specific electric pump.
Loosen the vent fitting (2) on the pre-filter and operate
the pump until only fuel without air flows out. Tighten the
vent fitting and continue pumping during the initial startup phases.
Make sure that the fuel that flows out of the fitting is not
dispersed in the environment.
CAUTION
Never attempt to vent the high pressure system, as this is
useless and extremely dangerous.
N45 MNA M10
N67 MNA M15
SERVICING OPERATIONS ON INSTALLED ENGINE
MARCH 2006
6.89
VALVES CLEARANCE ADJUSTMENT
N45 MNA M10
Rotate the drive shaft, balance cylinder 1 valves and adjust
the valves marked by the n symbol as shown in the table:
Figure 2
2
1
3
Cylinder n.
1
2
3
4
intake
-
-
n
-
exhaust
-
n
-
n
Rotate the drive shaft, balance cylinder 4 valves and adjust
the valves marked by the n symbol as shown in the table:
04_335_N
Adjust clearance between rockers and valves using setscrew
wrench (1), box wrench (3) and feeler gauge (2).
Working clearance shall be as follows:
-
Intake valves 0.25 ± 0.05 mm;
Exhaust valves 0.50 ± 0.05 mm.
CAUTION
In order to adjust faster the operating clearance for rocker
arms - valves, proceed as follows:
Cylinder n.
1
2
3
4
intake
n
n
-
n
exhaust
n
-
n
-
N67 MNA M15
Rotate the drive shaft, balance cylinder 1 valves and adjust
the valves marked by the n symbol as shown in the table:
Cylinder n.
1
2
3
4
5
6
intake
-
-
n
-
n
n
exhaust
-
n
-
n
-
n
Rotate the drive shaft, balance cylinder 6 valves and adjust
the valves marked by the n symbol as shown in the table:
Cylinder n.
1
2
3
4
5
6
intake
n
n
-
n
-
-
exhaust
n
-
n
-
n
-
6.90
N45 MNA M10
N67 MNA M15
SERVICING OPERATIONS ON INSTALLED ENGINE
MARCH 2006
CLEANING THE ENGINE COOLANT / SEA-WATER HEAT EXCHANGER
Figure 3
1
2
1
3
5
4
04_271_N
4
1. Cover - 2. Spacer - 3. Tube bundle - 4. Sealing rings - 5. Zinc sacrificial anode.
In order to guarantee a perfect operation of the heat
exchanger, regularly clean the tube bundle. If the surfaces of
the heat exchanger come into contact with salted water, they
may be subjected to biological fouling and to hydrocarbon
deposit which may be present in harbors’ waters.
o Remove the tube bundle (3) from the exchanger body
and immerse it for a few minutes in a solution prepared
with water and a degreasing scale-remover detergent,
observing the detergent manufacturer’s directions for
use. The cleansing solution should not damage copper,
brass, aluminum and tin;
o Complete tube cleaning by rinsing thoroughly with fresh
water, until detergent residues are entirely removed;
o Reassemble the tube bundle (3) by correctly positioning
spacer (2), sealing rings (4), and covers (1);
o Check the zinc anode corrosion level (5); replace the
anode if corrosion exceeds 50% of the volume.
MARCH 2006
N45 MNA M10
N67 MNA M15
SERVICING OPERATIONS ON INSTALLED ENGINE
6.91
ADJUSTING INJECTION PUMP TIMING
It requires to ensure the exact pumper position of injection
pump compared to an exact angular position of crankshaft.
Figure 5
04_419_N
Figure 4
88141
1
2
1
2
3
6
4
5
o Remove the screw (3) and screw the tool 99395100
(2), inclusive of centesimal dial gauge (1), ensuring that
the shaft is making contact with the pumper;
Bring the cylinder 1 piston to T.D.C., compression end, proceeding as follows:
o Rotate crankshaft in a position where both intake and
exhaust valves are closed;
o Swap the cylinder 1 injector with tool 99395097 (1)
inclusive of centesimal dial gauge, and preload the dial
gauge;
o Rotate the crankshaft in the opposite direction to
normal rotation, until reaching the lesser value on the
dial gauge;
o Carefully rotate the crankshaft in the normal direction
of rotation, until reaching the maximum value on the
dial gauge (corresponding to cylinder 1 piston T.D.C.
position);
o Verify that both intake and exhaust valves are closed,
then set the dial gauge to zero.
o Preload the dial gauge by 3 mm;
o Rotate the crankshaft in the opposite direction to normal rotation, until the pumper reaches its own B.D.C., as
shown by the dial gauge;
o Set the dial gauge to zero;
o Rotate the crankshaft of about 30° in the opposite
direction to normal rotation;
o Carefully rotate the crankshaft in the normal direction
of rotation, until reading the 0.00 mm value on the dial
gauge (1) of tool 99395097 (Fig. 4), corresponding to
cylinder 1 piston T.D.C. position;
o Partially loosen the lateral screw (5) locking the pump
shaft, without removing the slip washer;
o Loosen the pump fixing nuts (4) without remove them,
so as to allow the pump body rotation;
o Carefully rotate the pump body until reading the prescribed pumper stroke value on the dial gauge (1) of
tool 99395100 (Fig. 6) (see following table);
o Tighten the pump fixing nuts (4) and the lateral screw
(5) to prescribed torque values; proceed with timing
verification.
6.92
N45 MNA M10
N67 MNA M15
SERVICING OPERATIONS ON INSTALLED ENGINE
MARCH 2006
Injection pump timing data
With reference to the engine code and that applied to the injection pump (point 6 of Figure 5).
Engine
N45 MNA M10 (74 kW)
Injection pump
Pumper stroke
with cylinder 1 piston at T.D.C.
Bosch VE4/12F 1400 L 1057
1,8 ± 0,05 mm
N45 MNA M10 (66,5 kW)
Bosch VE4/12F 1400 L 1057A
1,9 ± 0,05 mm
PRELIMINARY
N45 MNA M10 (63 kW)
Bosch VE4/12F 1400 L 1057B
1,9 ± 0,05 mm
PRELIMINARY
N67 MNA M15 (110 kW)
Bosch VE6/12F 1400 L 1055
1,8 ± 0,05 mm
N67 MNA M15 (99,5 kW)
Bosch VE6/12F 1400 L 1055A
1,8 ± 0,05 mm
PRELIMINARY
N67 MNA M15 (92 kW)
Bosch VE6/12F 1400 L 1055B
1,8 ± 0,05 mm
PRELIMINARY
VERIFY INJECTION PUMP TIMING
CALIBRATING THE INJECTION PUMP
Arrange in advance the tools on the engine, as shown in
procedures described in Figures 5 and 6.
The BOSCH servicing network must carry out the revision
and calibration operations.
o Carefully rotate the crankshaft in the normal direction
of rotation, until reading the 0.00 mm value on the dial
gauge (1) of tool 99395097 (Fig. 5), corresponding to
cylinder 1 piston T.D.C. position;
The paper containing the data for calibrating the pump on
the bench is identified by the code applied to the body of
the injection pump (point 6 of Figure 6) and is available from
the BOSCH servicing network.
o Read the pumper stroke value on the dial gauge (1) of
tool 99395100 (Fig. 6);
Otherwise contact the IVECO MOTORS Technical Service
Centre.
o If the measured value is not within the prescribed tolerance, follow operations described in chapter “ADJUSTING INJECTION PUMP TIMING” in the previous page.
MARCH 2006
SERVICING OPERATIONS ON INSTALLED ENGINE
N45 MNA M10
N67 MNA M15
6.93
MARINE PARTS DECOUPLING
Some periodical maintenance and overhaul interventions
require full access to engine parts and removal of marine
parts. The following sequence is suggested to simplify the
necessary operations.
Figure 8
Figure 6
04_273_N
Remove the support and the oil filter from their housing
located on engine base.
Decouple the air filter exhaust riser.
Figure 9
04_423_N
Remove cooling circuit exhaust pipes, located on engine
head.
Figure 7
04_279_N
Remove the tube bundle heat exchanger and the circulating
pump outlet/inlet coolant pipe after having loosened the
threaded collar of the coolant outlet pipe.
Figure 10
04_280_N
04_424_N
04_337_N
Remove coolant inlet pipe which joints the engine to the
water / water heat exchanger.
The alternator and the belt tensioner are simultaneously
anchored to the exchanger support. Remove them if necessary.
6.94
N45 MNA M10
N67 MNA M15
SERVICING OPERATIONS ON INSTALLED ENGINE
Figure 11
04_425_N
Remove the exhaust manifold to complete engine preparation for overhauling.
Figure 12
04_426_N
Marine parts include the open cooling circuit sea-water
pump which may be removed from its housing if necessary.
MARCH 2006
MARCH 2006
SERVICING OPERATIONS ON INSTALLED ENGINE
INSTRUCTIONS FOR DISEMBARKING THE ENGINE
The following is a description of the recommended sequence
of the operations to be completed before extracting the
engine from the vessel.
o After the key switch has been in the OFF position for at
least 10 seconds, disconnect the battery terminals and
disconnect the connectors from the relay box;
o Disconnect from the engine the power wiring harness
terminals (battery positive and negative);
o Loosen and remove the fuel pipelines and the pipes of
the gearbox heat exchanger, if provided;
o Loosen and remove the sea-water inlet pipes, engine
exhaust pipes, and, if separate, the sea-water loop discharge;
o Remove the pipeline from the additional engine coolant
expansion tank (if provided);
o Loosen and remove engine anchor bolts;
o Uncouple the gearbox;
o Observe the following instructions when hooking the
engine.
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.
N45 MNA M10
N67 MNA M15
6.95
6.96
N45 MNA M10
N67 MNA M15
SERVICING OPERATIONS ON INSTALLED ENGINE
MARCH 2006
MARCH 2006
N45 MNA M10
N67 MNA M15
TOOLS
7.97
SECTION 7
TOOLS
Page
TOOLS
99
7.98
N45 MNA M10
N67 MNA M15
TOOLS
MARCH 2006
MARCH 2006
TOOLS
TOOLS
Tool No.
Definition
99305019
Kit for valve seat regrinding
99305047
Spring load tester
99322205
Revolving stand for overhauling units
(700 daN/m capacity, 120 daN/m torque)
99340035
Injection pump gear extractor
99340055
Tool to remove output shaft front gasket
99340056
Tool to remove output shaft rear gasket
N45 MNA M10
N67 MNA M15
7.99
7.100
N45 MNA M10
N67 MNA M15
TOOLS
TOOLS
Tool No.
Definition
99340205
Tool to remove injectors
99346252
Tool for fitting output shaft rear gasket
99346253
Tool for fitting output shaft rear gasket
99360076
Tool to remove oil filter (engine)
99360183
Pliers for removing/refitting piston rings (65 - 110 mm)
99360268
Tool for removing/refitting engine valves
MARCH 2006
MARCH 2006
TOOLS
N45 MNA M10
N67 MNA M15
TOOLS
Tool No.
Definition
99360330
Flywheel crank handle
99360339
Tool for stopping the engine flywheel
99360344
Adapter, cylinder compression test
(use with 99395682)
99360351
Tool for flywheel holding
99360362
Beater for removing/refitting camshaft bushes
(to be used with 993700069)
99360500
Tool for lifting the output shaft
7.101
7.102
N45 MNA M10
N67 MNA M15
TOOLS
MARCH 2006
TOOLS
Tool No.
Definition
99360595
Lifting rig for engine removal/refitting
99360605
Band for fitting piston into cylinder barrel (60 - 125 mm)
99361037
Brackets for fastening engine to revolving stand 99322205
99363204
Tool to remove gaskets
99365195
Comparator holder tool for injection pump timing
(to be used with 99395604)
99367121
Manual pump for pressure and de-pressure measuring
MARCH 2006
TOOLS
N45 MNA M10
N67 MNA M15
7.103
TOOLS
Tool No.
Definition
99370006
Interchangeable willow handgrip
99370415
Gauge base for different measurements
(to be used with 99395603)
99395097
Tool to check top dead centre (use with 99395604)
99395100
Dial gauge holder for rotary injection pump timing
(use with 99395603)
99395216
Pair of gauges with 1/2” and 3/4” square head for angle tightening
99395220
All-purpose goniometer/Inclinometer
7.104
N45 MNA M10
N67 MNA M15
TOOLS
TOOLS
Tool No.
Definition
99395363
Complete bush testing square
99395603
Dial gauge (0 to 5 mm)
99395604
Dial gauge (0 v 10 mm)
99395682
Diesel fuel engine cylinder compression control device
MARCH 2006
MARCH 2006
N45 MNA M10
N67 MNA M15
OVERHAUL
8.105
SECTION 8
OVERHAUL
Page
Graph and symbols
107
GENERAL SPECIFICATIONS
108
CLEARANCE DATA
109
ENGINE OVERHAUL - ENGINE
REMOVAL AT THE BENCH
115
Preface
115
Engine setting operations
for the assembly on-turning stand
115
Components removal
116
CYLINDER UNIT
122
Checks and measurements
124
Checking head supporting
surface on cylinder unit
124
TIMING SYSTEM
125
Checking cam lift and pin alignment
125
Bushes
125
Bush replacement
127
Tappets
127
Fitting tappets - camshaft
127
Measuring journals and crankpins
128
OUTPUT SHAFT
128
Measuring journals and crankpins (4 cylinders)
129
Measuring journals and crankpins (6 cylinders)
131
Replacing oil pump control gear
133
Fitting main bearings
133
Finding journal clearance
133
Checking crankshaft shoulder clearance
134
(continues on next page)
8.106
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Page
Page
CONNECTING ROD - PISTON ASSEMBLY
135
Adjusting injection pump phase
162
Measuring piston diameter
136
Completion of the engine
162
Piston pins
136
Conditions for proper pin-piston coupling
136
Split rings
136
Connecting rods
137
Bushes
138
Checking connecting rods
138
Checking torsion
138
Checking bending
139
Fitting connecting rod-piston
assembly - Connecting rod-piston coupling
139
Fitting split rings
140
Fitting connecting rod-piston
assembly into-cylinder barrels
140
Finding crankpin clearance
141
Checking piston protrusion
142
CYLINDER HEAD
143
Removing the valves
143
Checking cylinder head wet seal
144
Checking cylinder head supporting surface
144
VALVES
145
Removing carbon deposits,
checking and-grinding valves
145
Checking clearance between valve
stem and-valve guide and valve centering
145
Valve guide
146
Regrinding - Replacing the valve seats
146
Valve springs
147
FITTING CYLINDER HEAD
147
INSTALLATION OF COMPONENTS
148
Refitting the cylinder head
156
Adjusting valve clearance
159
TIGHTENING TORQUES
163
OVERHAUL
MARCH 2006
Graph and symbols
Surface for machining
Machine finish
Interference
Strained assembly
Thickness
Clearance
Intake
Exhaust
Operation
Compression ratio
Preload
Oversized
Higher than …
Maximum, peak
Undersized
Less than …
Minimum
Selection
Classes
Oversizing
Replacement
Original spare parts
N45 MNA M10
N67 MNA M15
8.107
8.108
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
GENERAL SPECIFICATIONS
Type
N45 MNA M10
Cycle
N67 MNA M15
Four-stroke diesel engine
Air feeding
Naturally aspirated
Injection
Direct
Number of cylinders
4
6
Bore
mm
104
Stroke
mm
132
Total displacement
cm3
4485
6728
Timing
start before T.D.C.
end after B.D.C.
A
B
15°
35°
start before B.D.C.
end after T.D.C.
D
C
69°
21°
Checking timing
X
Checking operation
X
{
{
mm
-
mm
-
mm
0.25 ± 0.05
mm
0.50 ± 0.05
Fuel feed
Injection
Type:
rotary Bosch
VE 4/12 F 1400 L 1057
Nozzle type Injectors
Injection sequence
VE 6/12 F 1400 L 1055
DSLA 145 P
1-3-4-2
1-5-3-6-2-4
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.109
CLEARANCE DATA
Type
N45 MNA M10
Cylinder unit and crankshaft components
Cylinder barrels
Spare pistons
type:
Size
Outside diameter
Pin housing
mm
Ø1
104.000 to 104.024
X
Ø1
Ø2
55.9
103.730 to 103.748
38.010 to 38.016
Piston - cylinder barrels
Piston diameter
Piston protrusion
Piston pin
Piston pin - pin housing
N67 MNA M15
0.252 to 0.294
Ø1
X
Ø3
0.4; 0.8
0.28 to 0.52
37.994 to 38.000
0.010 to 0.022
8.110
N45 MNA M10
N67 MNA M15
OVERHAUL
Type
MARCH 2006
N45 MNA M10
N67 MNA M15
mm
Cylinder unit and crankshaft components
Split ring slots
X1
X2
X3
2.705 to 2.735
2.440 to 2.460
4.030 to 4.050
Split rings
S1
S2
S3
2.560 to 2.605
2.350 to 2.380
3.970 to 3.990
1
2
3
0.100 to 0.175
0.060 to 0.110
0.040 to 0.080
Split rings - slots
Split rings
Split ring end opening
in cylinder barrel:
0.4; 0.8
X1
X2
X3
0.30 to 0.40
0.60 to 0.80
0.30 to 0.55
Small end bush
housing
Ø1
40.987 to 41.013
Big end bearing
housing
Ø2
72.987 to 73.013
Small end bush
diameter
Outside
Inside
Ø4
Ø3
40.987 to 41.013
38.019 to 38.033
Spare big end half
bearings
S
1.955 to 1.968
Small end bush - housing
0.266 to 0.566
Piston pin - bush
0.019 to 0.039
Big end half bearings
0.250 to 0.500
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Type
N45 MNA M10
N67 MNA M15
mm
Cylinder unit and crankshaft components
Size
X
-
Max. tolerance
on connecting rod
axis alignment
=
-
Journals
Crankpins
Main half bearings
Big end half bearings
Main bearings
n° 1-7
n° 2-3-4-5-6
Ø1
Ø2
82.99 to 83.01
68.987 to 69.013
S1
S2
2.456 to 2.464
1.955 to 1.968
Ø3
Ø3
87.982 to 88.008
87.977 to 88.013
Half bearings - Journals
n° 1-7
n° 2-3-4-5-6
Half bearings Crankpins
0.064 to 0.095
0.059 to 0.100
0.033 to 0.041
Main half bearings
Big end half bearings
+ 0.250 ; + 0.500
Shoulder journal
X1
Shoulder
main bearing
X2
31.730 to 32.280
Shoulder
half-rings
X3
37.28 to 37.38
Output shaft shoulder
8.111
37,350 to 37,650
37,475 to 37,545
0.095 to 0.270
8.112
N45 MNA M10
N67 MNA M15
OVERHAUL
Type
MARCH 2006
N45 MNA M10
N67 MNA M15
mm
Cylinder head - timing system
Valve guide seats
on cylinder head
Ø1
8.019 to 8.039
Ø4
α
7.943 to 7.963
60°
Ø4
α
7.943 to 7.963
45°
Valves:
Valve stem and guide
0.056 to 0.096
Housing on head
for valve seat:
Ø1
46.987 to 47.013
Ø1
43.637 to 43.663
Valve seat outside diameter;
valve seat angle
on cylinder head:
Sinking
Between valve seat
and head
Ø2
α
47.063 to 47.089
60°
Ø2
α
43.713 to 43.739
45°
X
0.356 to 1.102
X
0.104 to 0.840
0.050 to 0.102
0.050 to 0.102
Valve seats
-
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Type
N45 MNA M10
N67 MNA M15
mm
Cylinder head - timing system
Valve spring height:
free spring
under a load equal to:
329 N
641 N
Injector protrusion
H
63.50
H1
H2
49.02
38.20
X
non regolabile
Camshaft bush
housings n° 1-7
59.222 to 59.248
Camshaft housings
n° 2-3-4-5-6
54.089 to 54.139
Camshaft journals:
1‘7
Ø
53.995 to 54.045
Camshaft bush
outside diameter:
Ø
59.222 to 59.248
Bush
inside diameter
Ø
54.083 to 54.147
Bushes and housings on block
Bushes and journals
8.113
0.038 to 0.162
Cam lift:
H
11.02
H
10.74
8.114
N45 MNA M10
N67 MNA M15
OVERHAUL
Type
MARCH 2006
N45 MNA M10
Cylinder head - timing system
N67 MNA M15
mm
Tappet cap housing
on block
Tappet cap
outside diameter:
Ø1
-
Ø2
Ø3
15.929 to 15.959
15.965 to 15.980
Between tappets and housings
-
Tappets
-
Rocker shaft
Ø1
18.963 to 18.975
Rockers
Ø2
19.000 to 19.026
Between rockers and shaft
0.025 to 0.063
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.115
ENGINE OVERHAUL - ENGINE REMOVAL AT THE BENCH
Preface
Figure 2
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 engineers provided with the specific tooling and equipment
required.
Operations described below refer to the engine without the
components for its marine adaptation (see Section 6).
The following operations are relating to the 4 cylinder engine
but are similar and applicable for the 6 cylinder.
1
76147
o Assemble the bracket bearing 99361037 using the four
screw threaded ports (1).
On the left hand side:
Engine setting operations for the assembly
on-turning stand
o Remove the hose between sea water pump and heat
exchanger;
o Remove the oil dipstick together with guide pipe (2);
(loosen the guide pipe disassembling from the block);
properly pipe the screw-threaded port to avoid inlet of
foreign matters.
Figure 1
Figure 3
2
1
76146
1
On the right hand side:
o Disassemble the starter; properly hold the starter (1)
and loosen the fixing screws (2);
76145
o Disassemble oil filter.
CAUTION
The oil filter contains inside approx. 1 kg of engine oil. Provide tank with enough capacity to contain the liquid.
Avoid contact of engine oil with the skin: in case of skin
contamination rinse in running water.
Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.
o Assemble the second bracket 99361037 throughout the
screw-threaded ports (1);
o Lift the engine using the rocker arm 99360595 and put
it on the turning stand 99322205;
o Drain the oil through the cap underneath the plug.
CAUTION
Avoid contact of engine oil with the skin: in case of skin
contamination rinse in running water.
Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.
N45 MNA M10
N67 MNA M15
8.116
OVERHAUL
Components removal
MARCH 2006
Figure 6
Figure 4
3
1
2
1
3
90510 B
04_339_N
o Place a container under the fuel filter and screw out the
condense drain faucet underneath said filter. Carry out
complete drainage of the fuel contained therein;
o Screw out completely the faucet and, using equipment
99360076 disassemble oil filters (1);
o Disconnect fuel pipelines (2 and 3) respectively from
prefilter to filter bearing and from this last one to the
feed pump;
2
4
o Disconnect the supply pipe unit from the injectors (1);
o Remove fuel exhaust pipe (2) from the injectors by
removing screw (4) and seal (3).
Figure 7
o Remove the fuel filter bearing from the bracket fixed to
the engine head.
1
Figure 5
1
76148
o Loosen the screws (1) holding the fixing brackets of
such pipelines.
Pipe the pipeline ends.
2
88142
o Disconnect the LDA pipe (1) from the head and from
the feed pump;
o Cap the ends of the pipelines as well as the feed pump
and the engine head;
o Disassemble the pipes (2) that constitute the fuel recovery and supply between the pump and the injectors.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 8
8.117
Figure 10
1
76149
2
1
04_340_N
o Remove tappet caps: Loosen the fixing screws (1) and
lift the caps (2); remove the gaskets.
CAUTION
On the tappet cap there is a blow-by valve for the lubrication oil vapours.
All the gaskets shall always be replaced during assembly.
o Disassemble rocker arm bearings; loosen the two fixing
screws (1) and remove the complete rocker armbearing;
withdraw tappet rods;
o Repeat the operation for all the remaining rocker arm
bearings.
Figure 11
Figure 9
1
2
1
04_285_N
2
84082
o Remove injectors (2) with tool 99340205 (1) and take
out the cylinder head.
o Workon the drive belt tensor (1) and extract the belt
(2) from the belt pulleys, from the water pump ones and
from the belt rebound pulleys;
o Disassemble the belt tensor;
o Unloose the screw fixing the alternator to the upper
bracket.
8.118
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 12
Figure 15
1
1
2
4
5
2
3
3
75685
76152
o Disassemble thermostat unit; loosen the three fixing
screws (1) and disassemble the thermostat unit (2)
together with the bracket (3); remove the gasket (4) and
the thermostat (5);
o In order to facilitate head overhauling operations at the
test bench keep bracket (3) assembled on it by fixing it
with the thermostat unit screws.
o Disassemble cylinder head; loosen the screws (1) and
(2) fixing the cylinder head (3);
o Hook the brackets with metal ropes and, throughout a
hoist withdraw cylinder head from the block.
Figure 16
Figure 13
2
2
1
1
3
4
75686
o Properly hold the alternator (1) separating it from its
bearing by loosening the screw (2); remove screw nut
and washer.
o Apply the suitable tool (2) on the flywheel covering box
(1) in order to lock flywheel (3) rotation. (use the starting motor fixing nuts and studs);
o Loosen the flywheel fixing screws (4) to engine drive
shaft.
Figure 14
2
75692
Figure 17
3
74175
1
1
2
3
04_273_N
o Loosen the screws (1) and disassemble the oil filter/heat
exchanger bearing (2), interlayer plate (6) and relating
gaskets;
o Disassemble injection pump (see specific procedure).
o Unloose the screws (3) and disassemble the damping
flywheel (2) and the pulley (1);
o The tool for flywheel holding can help removal of damping flywheel (2) mounted on the pulley (1).
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
CAUTION
8.119
Figure 20
In some versions, the phonic wheel mounted on pulley (1)
may be not present and pulley (1) can be different from the
pulley shown in Figure 17.
Figure 18
1
2
3
4
5
6
70148
o Remove the screws (1) and disconnect the water pump
(2);
o Remove the screw (3) and the roller (4);
o Remove the screw (5) and disconnect the engine speed
sensor (6).
Figure 19
04_205_N
o Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external holding ring (2) from the front cover (1).
Figure 21
1
04_204_N
2
70149
1
o Loosen the screws (1) and remove the front cover (2).
CAUTION
Take note of the screw (1) assembly position, since the
screws have different length.
o Remove the engine drive shaft fixing ring from the front
cover. Use the tool 99340055 (4) to operate on the
front tang (2) of the engine drive shaft. Throughout the
tool guide ports, drill the internal holding ring (1) using
Ø 3.5 mm drill for a 5 mm depth;
o Fix the tool to the ring tightening the 6 screws specially
provided. Proceed withdrawing the ring (1) tightening
the screw (3).
8.120
N45 MNA M10
N67 MNA M15
OVERHAUL
Figure 22
MARCH 2006
Figure 25
1
2
75811
o Loosen the screws (1) and remove oil pump (2).
Figure 23
04_207_N
1
2
o Remove the flywheel cover box fixing ring using the tool
99340056 (3) to operate on the back tang (5) of the
engine drive shaft;
o Throughout the tool guide ports, drill the internal holding ring using Ø 3.5 mm drill for a 5mm depth;
4
o Fix the tool 99340056 (3) to the ring (1) tightening the
6 screws specially provided (4);
3
75691
o Screw out the opposite screws (1) fromthe portswhere the
withdrawal pins shall be introduced (see following picture);
o Loosen remaining flywheel fixing screws (3) to the
engine drive shaft (4);
o Remove the flywheel block tool (2).
o Proceed with drawing the ring (1) tightening the screw
(2);
o Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external holding ring of the flywheel cover box.
Figure 26
Figure 24
4
1
1
2
2
3
70153
75690
o Screw down two medium length screws in the ports (4)
to sling the flywheel with a hoist;
o Throughout two guide pins (2) previously screwed up
into the engine drive shaft ports (3) control the engine
flywheel withdrawal by means of a hoist.
o Loosen the screws (2) and remove the flywheel cover
box (1).
CAUTION
Take note of the screw (1) assembly position, since the
screws have different length.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 27
8.121
Figure 29
04_374_N
1
1
2
2
3
3
o Turn the engine upside-down;
o Assemble oil pan (1), apply the plate over it (2). Tighten
the screws (2) and lock them to the prescribed couple.
1
2
CAUTION
The shape and dimensions of the sump and of the rose
pipe may vary according to the engine application.
The relating illustrations provide general guidelines of the
operation to be performed.
The procedures described are applicable anyway.
3
90505
Figure 28
o Loosen the screws (1) and disassemble the gear from
the camshaft (2).
3
Figure 30
1
1
2
1
2
4
88074
70157
o Loosen the screws (1) and disassemble the oil suction
rose pipe (3);
o Loosen the screws (2) and remove the stiffening plate (4).
o Loosen the screws (2) and disassemble the timing gearbox (1).
CAUTION
Take note of the screw (2) assembly position, since the
screws have different length.
8.122
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
CYLINDER UNIT
Figure 31
Figure 33
1
1
2
2
70158
Remove the screws (1) fastening the connecting rod caps (2)
and remove them.
Withdraw the pistons including the connecting rods from
the top of the engine block.
70160
The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).
CAUTION
CAUTION
Keep the half-bearings into their housings since, in case
of use, they shall be fitted in the same position found at
removal.
Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same
position found at removal.
Figure 34
Figure 32
1
1
2
2
70161
70159
Remove the screws (1) and the main bearing caps (2).
Use tool 99360500 (1) and hoist to remove the crankshaft
(2) from the block.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 35
8.123
Figure 37
1
2
1
3
70164
70162
Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).
Withdraw carefully the camshaft (1) from the engine block.
Figure 38
Figure 36
1
1
3
2
70163
Remove the screws (1) and disconnect camshaft (3) retaining -plate (2).
CAUTION
Take note of plate (2) assembling position.
70165
Withdraw the tappets (1) from the engine block.
8.124
N45 MNA M10
N67 MNA M15
OVERHAUL
Checks and measurements
Should ovalisation, taper or wear be found, bore and grind
the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by
0.5 mm and to the specified assembling clearance.
Figure 39
Figure 41
1
1
MARCH 2006
2
2
70166
Once engine is disassembled, clean accurately the cylinderblock assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Check operating plug conditions and replace them in case of
uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free from seizing, scores, ovalisation, taper or excessive wear.
Inspection of cylinder barrel bore to check ovalisation, taper
and wear shall be performed using the bore dial gauge
99395687 (1) fitted with the dial gauge previously set to
zero on the ring gauge (2) of the cylinder barrel diameter.
CAUTION
Should the ring gauge be not available, use a micrometer
for zero-setting.
70168
CAUTION
Figure 40
In case of regrinding, all barrels shall have the same oversize (0.5 mm).
Check main bearing housings as follows:
o Fit the main bearings caps on the supports without
bearings;
o Tighten the fastening screws to the specified torque;
o Use the proper internal gauge to check whether the
housing diameter is falling within the specified value.
Replace if higher value is found.
70167
Measurements shall be performed on each cylinder, at three
different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of
the engine (A), and the other perpendicular (B). Maximum
wear is usually found on plane (B) in correspondence with
the first measurement.
Checking head supporting surface
on cylinder unit
After checking for possible deformation zones, perform the
smoothing of supporting surface using a grinder.
Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug (1) conditions, replace
them in case of uncertain seal or if rusted.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.125
TIMING SYSTEM
N45 MNA M10
Figure 42
04_429_N
MAIN DATA ABOUT CAMSHAFT PINS (4 cylinders)
N67 MNA M15
Figure 43
04_347_N
MAIN DATA ABOUT CAMSHAFT PINS (6 cylinders)
Camshaft pin and cam surfaces shall be absolutely smooth; if
they show any traces of seizing or scoring replace the camshaft and the bushes.
Checking cam lift and pin alignment
Bushes
Set the camshaft on the tailstock and using a centesimal dial
gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the
camshaft.
Check cam lift; found values shall be: 6.045 mm for exhaust
cams and 7.582 mm for intake cams, in case of different values replace the camshaft.
Figure 45
1
Figure 44
1
3
2
2
70172
70171
Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.
Camshaft bushes (2) shall be pressed into their housings.
Internal surfaces must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft front and rear
bush (2) and intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
axes.
8.126
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 46
Section A-A
*
04_430_N
CAMSHAFT BUSH AND HOUSING MAIN DATA
*
Value to be obtained after driving the bushes.
Figure 47
Section A-A
70513
CAMSHAFT BUSH AND HOUSING MAIN DATA
*
Value to be obtained after driving the bushes.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Bush replacement
8.127
Fitting tappets - camshaft
Figure 48
Figure 50
1
2
2
1
3
70176
70174
To replace front and rear bushes (1), remove and refit
them using the beater 99360362 (2) and the handgrip
99370006 (3).
Lubricate the tappets (1) and fit them into the relevant housings on the engine block.
Figure 51
CAUTION
When refitting the bushes (1), direct them to make the
lubricating holes (2) coincide with the holes on the block
housings.
Tappets
1
Figure 49
84053
70164
Lubricate the camshaft bushes and fit the camshaft (1) taking
care not to damage the bushes or the housings.
MAIN DATA CONCERNING THE TAPPETS AND
THE-RELEVANT HOUSINGS ON THE ENGINE BLOCK
8.128
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
OUTPUT SHAFT
Measuring journals and crankpins
Figure 52
Figure 55
70182
1
3
1
2
2
70238
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 specified torque.
Figure 53
Grind journals and crankpins if seizing, scoring or excessive
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.
CAUTION
It is recommended to insert the found values in the proper
table.
See Figure 54.
1
Undersize classes are : 0.250 - 0.500 mm.
CAUTION
70179
Check camshaft end float (1).
It shall be 0.23 ± 0.13 mm.
Figure 54
1
2
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Journals and crankpins shall always be ground to the same
undersize class.
Journals and crankpins undersize shall be marked on the
side of the crank arm No. 1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.129
Measuring journals and crankpins (4 cylinders)
Figure 56
82.99
83.01
68.98
69.01
04_431_N
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*
Rated value.
Figure 57
04_432_N
MAIN OUTPUT SHAFT TOLERANCES
* Measured on a radius greater than 45.5 mm.
**
0.500
between adjacent main journals.
N45 MNA M10
N67 MNA M15
8.130
OVERHAUL
MARCH 2006
Figure 58
MAIN BEARING ON TIMING
SYSTEM CONTROL SIDE
INTERMEDIATE
MAIN BEARINGS
FIRST MAIN
BEARING
ON-FRONT SIDE
70237
Tolerances
Tolerance characteristic
Shape
Roundness
Graphic symbol
Cilindricity
Parallelism
Direction
Verticality
Straightness
Position
Concentricity or coaxiality
Circular oscillation
Oscillation
Total oscillation
Taper
Levels of importance for product characteristics
Critical
Important
Secondary
Graphic symbol
OVERHAUL
MARCH 2006
N45 MNA M10
N67 MNA M15
8.131
Measuring journals and crankpins (6 cylinders)
Figure 59
70514
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*
Rated value.
Figure 60
70577
MAIN OUTPUT SHAFT TOLERANCES
* Measured on a radius greater than 45.5 mm.
**
0.500
between adjacent main journals.
N45 MNA M10
N67 MNA M15
8.132
OVERHAUL
MARCH 2006
Figure 61
MAIN BEARING ON TIMING
SYSTEM CONTROL SIDE
INTERMEDIATE
MAIN BEARINGS
FIRST MAIN
BEARING
ON-FRONT SIDE
70237
Tolerances
Tolerance characteristic
Shape
Roundness
Graphic symbol
Cilindricity
Parallelism
Direction
Verticality
Straightness
Position
Concentricity or coaxiality
Circular oscillation
Oscillation
Total oscillation
Taper
Levels of importance for product characteristics
Critical
Important
Secondary
Graphic symbol
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Replacing oil pump control gear
8.133
Finding journal clearance
Figure 64
Figure 62
1
2
1
2
70184
70161
3
Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3).
When fitting the new gear, heat it to 180 °C for 10 minutes
in an oven and then key it to the crankshaft.
Refit the crankshaft (2).
Check the backlash between crankshaft main journals and
the relevant bearings as follows:
Figure 65
Fitting main bearings
1
Figure 63
2
3
1
4
70186
o Clean accurately the parts and remove any trace of oil;
o Position a piece of calibrated wire (3) on the crankshaft
pins (4) so that it is parallel to the longitudinal axis;
70185
CAUTION
Refit the main bearings that have not been replaced, in the
same position found at removal.
Main bearings (1) are supplied spare with 0.250 - 0.500 mm
undersize on the internal diameter.
CAUTION
Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
o Fit caps (1), including the half bearings (2) on the relevant supports.
8.134
N45 MNA M10
N67 MNA M15
OVERHAUL
Figure 66
MARCH 2006
Figure 68
1
1
2
70187
70189
Tighten the pre-lubricated screws (1) in the following three
successive stages:
o Remove caps from supports.
o 1st stage, with torque wrench to 50 ± 6 Nm;
The backlash between the main bearings and the pins is
found by comparing the width of the calibrated wire (2)
at the narrowest point with the scale on the envelope (1)
containing the calibrated wire.
The numbers on the scale indicate the backlash in mm.
Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is
obtained, lubricate the main bearings and fit the supports by
tightening the fastening screws as previously described.
o 2nd stage, with torque wrench to 80 ± 6 Nm.
Figure 67
2
Checking crankshaft shoulder clearance
1
Figure 69
70188
o 3rd stage, with tool 99395216 (1) set as shown in the
figure, tighten the screws (2) with 90° ± 5° angle.
1
70190
2
3
This check is performed by setting a magnetic-base dial
gauge (2) on the crankshaft (3) as shown in the figure, standard value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between crankshaft pins and main half bearings.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.135
CONNECTING ROD - PISTON ASSEMBLY
Figure 70
Figure 71
3
4
1
1
2
2
5
1
8
7
6
3
70191
CONNECTING ROD - PISTON ASSEMBLY COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush.
32613
Remove split rings (1) from piston (2) using pliers
99360183 (3).
CAUTION
Pistons are supplied from parts with 0.5 mm oversize.
Figure 72
1
2
3
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
Figure 73
87760
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS
8.136
N45 MNA M10
N67 MNA M15
OVERHAUL
Measuring piston diameter
MARCH 2006
Piston pins
Figure 74
Figure 76
1
1
2
2
32615
o Using a micrometer (2), measure the diameter of the
piston (1) to determine the assembly clearance.
18857
o To measure the piston pin (1) diameter use the micrometer (2).
Conditions for proper pin-piston coupling
Figure 77
CAUTION
The diameter shall be measured at 12 mm from the piston
skirt.
1
Figure 75
1
70192
32619
o Lubricate the pin (1) and its seat on piston hubs with
engine oil; the pin shall be fitted into the piston with a
slight finger pressure and shall not be withdrawn by gravity.
o The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown
in the figure.
Split rings
Figure 78
1
2
16552
o Use a micrometer (1) to check split ring (2) thickness.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 79
8.137
Figure 81
1
1
2
2
3
3
70194
32620
o 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).
o Use feeler gauge (1) to measure the clearance between
the ends of the split rings (2) fitted into the cylinder barrel (3).
Connecting rods
Figure 80
Figure 82
1
3
2
41104
DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT
AND THE TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance
(X) between ring and slot: found value shall be the specified
one.
87762
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN
AND HALF BEARINGS
*
Value for inside diameter to be obtained after driving in
connecting rod small end and grinding.
** Value not measurable in released condition.
CAUTION
The surface of connecting rod and rod cap are knurled to
ensure better coupling.
Therefore, it is recommended not to smooth the knurls.
N45 MNA M10
N67 MNA M15
8.138
OVERHAUL
MARCH 2006
Checking connecting rods
Figure 84
‘
CONNECTING
ROD BODY
1234
W
Connecting Weight
rod No.
0001
V
W
9999
X
1
2
5
3
70196
4
61696
‘
‘
CONNECTING ROD CAP
1234
A
123
Connecting rod No.
Year
Day
0001
A 1998
001
B 1999
9999
C 2000
366
D 2001
CAUTION
Check that the axis of the connecting rods (1) are parallel
using tool 99395363 (5) as follows:
o Fit the connecting rod (1) on tool 99395363 (5) spindle
and lock it with screw (4);
Every connecting rod is marked as follows:
o Set the spindle (3) on V-blocks by resting the connecting
rod (1) on the stop bar (2).
o On body and cap with a number showing their coupling and the corresponding cylinder.
In case of replacement it is therefore necessary to
mark the new connecting rod with the same numbers
of the replaced one;
Checking torsion
o On body with a letter showing the weight of the connecting rod assembled at production:
- S V, 1820 to 1860 (yellow marking);
- S W, 1861 to 1900 (green marking);
- S X, 1901 to 1940 (blue marking).
Spare connecting rods are of the W class with green
marking (see position of * in Fig. 78).
Material removal is not allowed.
Figure 85
1
2
3
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.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
4
5
61694
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Check connecting rod (5) torsion by comparing two points
(A and B) of pin (3) on the horizontal plane of the connecting rod axis.
Position the dial gauge (2) support (1) to obtain a preload
of approx. 0.5 mm on the pin (3) in point A and then set the
dial gauge (2) to zero. Move the spindle (4) with the connecting rod (5) and compare any deviation on the opposite
side (B) of the pin (3): the difference between A and B shall
not exceed 0.08 mm.
Fitting connecting rod-piston assembly Connecting rod-piston coupling
Figure 87
1
2
Checking bending
3
Figure 86
2
C
8.139
4
1
D
3
5
4
70198
The piston crown is marked as follows:
1. Part number and design modification number;
2. Arrow showing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
block;
3. Marking showing 1st slot insert testing;
4. Manufacturing date.
Figure 88
1
2
61695
Check connecting rod (5) bending by comparing two points
C and D of the pin (3) on the vertical plane of the connecting rod axis.
Position the vertical support (1) of the dial gauge (2) to rest
the latter on pin (3), point C.
Move the connecting rod forwards and backwards to find pin
top position, then in this condition reset the dial gauge (2).
Move the spindle with the connecting rod (5) and repeat
the check of the top point on the opposite side D of the pin
(3). The difference between point C and point D shall not
exceed 0.08 mm.
3
4
5
70199
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting
rod (5) are read as shown in the figure.
Figure 89
1
2
72705
Insert split rings (2) for locking pin (1).
8.140
N45 MNA M10
N67 MNA M15
OVERHAUL
Fitting split rings
MARCH 2006
Fitting connecting rod-piston assembly
into-cylinder barrels
Figure 90
Figure 92
1
2
1
3
2
70201
32613
Use pliers 99360183 (3) to fit the split rings (1) on the
piston (2).
Split rings shall be fitted with the marking “TOP” facing
upwards and their openings shall be displaced with each
other by 120°.
CAUTION
Split rings are supplied spare with the following sizes:
o Standard, yellow marking;
o 0.5 mm oversize, yellow/green marking.
Lubricate accurately the pistons, including the split rings and
the cylinder barrel inside.
Use band 99360605 (2) to fit the connecting rod-piston
assembly (1) into the cylinder barrels and check the following:
o
The number of each connecting rod shall correspond to
the cap coupling number.
Figure 93
Figure 91
1
1
70202
DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY
FITTING INTO BARREL
70200
Fit half bearings (1) on connecting rod and cap.
CAUTION
Refit the main bearings that have not been replaced, in the
same position found at removal.
Do not try to adapt the half bearings.
o Split ring openings shall be displaced with each other
by 120°;
o Connecting rod-piston assemblies shall have the same
weight;
o The arrow marked on the piston crown shall be facing
the front side of the engine block or the slot obtained
on the piston skirt shall be corresponding to the oil
nozzle position.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Finding crankpin clearance
8.141
Figure 96
2
Figure 94
70205
1
2
1
3
4
70203
To measure the clearance proceed as follows:
o Apply tool 99395216 (1) to the socket wrench and
tighten screws (2) of 60°.
o Clean the parts accurately and remove any trace of oil;
o Set a piece of calibrated wire (2) on the output shaft
pins (1);
Figure 97
2
o Fit the connecting rod caps (3) with the relevant half
bearings (4).
Figure 95
2
1
70206
1
70204
o Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the torque wrench (2).
o Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on
the wire envelope (2).
8.142
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Checking piston protrusion
Figure 98
70207
Figure 99
1
3
70208
2
1
2
If a different clearance value is found, replace the half bearings and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.
CAUTION
Before the final fitting of the connecting rod cap fastening
screws, check that their diameter measured at the centre
of the thread length is not < 0.1 mm than the diameter
measured at approx. 10 mm from screw end.
Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.250 to 0.275 mm.
Once connecting rod-piston assemblies refitting is over, use
dial gauge 39395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block.
Protrusion shall be 0.28 to 0.52 mm.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.143
CYLINDER HEAD
Removing the valves
Figure 102
Figure 100
2
1
2
1
75750
Intake (1) and exhaust (2) valves have heads with different
diameter.
Remove sealing rings (1 and 2) from the valve guide.
CAUTION
Should cylinder head valves be not replaced, number them
before removing in order to refit them in the same position.
Figure 101
2
1
3
4
6
75751
75752
5
Valve removal shall be performed using tool 99360268 (1)
and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove the
cap (3) and the springs (4) and the protective cap (5).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves (6).
CAUTION
Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
N45 MNA M10
N67 MNA M15
8.144
OVERHAUL
Checking cylinder head wet seal
MARCH 2006
Figure 104
Figure 103
1
75756
75753
This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90 °C and
2 to 3 bar pressure.
Replace the cup plugs (1) if leaks are found, use the proper
beater for their removal/refitting.
CAUTION
Before refitting, smear the plug surfaces with water-repellent sealant.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.
The rated thickness A for the cylinder head is 95 ± 0.25
mm, max. metal removal shall not exceed thickness B by
0.13 mm.
CAUTION
After grinding, check valve sinking. Regrind the valve seats,
if required, to obtain the specified value.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.145
VALVES
Figure 105
Exhaust valve
Figure 107
Intake valve
1
2
18882
04_348_N
Check the valve stem (1) using a micrometer (2), it shall be
7.943 to 7.963.
Checking clearance between valve stem
and-valve guide and valve centering
INTAKE AND EXHAUST VALVE MAIN DATA
Figure 108
Removing carbon deposits, checking
and-grinding valves
1
Figure 106
2
75757
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.056 ± 0.096 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
18625
Remove carbon deposits from valves using the proper metal
brush.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, using tool 99305018 and
removing as less material as possible.
8.146
N45 MNA M10
N67 MNA M15
OVERHAUL
Valve guide
MARCH 2006
Regrinding - Replacing the valve seats
Figure 109
Figure 110
04_349_N
1
2
75754
Intake
Exhaust
Use a bore dial gauge to measure the inside diameter of
the valve guides, the read value shall comply with the value
shown in the figure.
Check the valve seats (2). If slight scoring or burnout is found,
regrind seats using tool 99305014 (1) according to the angle
values shown in Figure 111.
Figure 111
Intake
Exhaust
75755
VALVE SEAT MAIN DATA
Should valve seats be not reset just by regrinding, replace
them with the spare ones. Use tool 99305019 (Figure 110)
to remove as much material as possible from the valve seats
(take care not to damage the cylinder head) until they can be
extracted from the cylinder head using a punch.
Heat the cylinder head to 80-100 °C and using the proper
beater, fit the new valve seats, previously cooled, into the
cylinder head.
Use tool 99305019 to regrind the valve seats according to
the values shown in Figure 111.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.147
FITTING CYLINDER HEAD
Figure 112
Figure 114
1
3
2
1
3
75758
1
After regrinding, check that valve (3) sinking value is the
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1).
2
75759
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
Valve springs
Figure 113
CAUTION
50676
Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
Figure 115
2
1
4
MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS
6
Before refitting use tool 99305047 to check spring flexibility.
Compare load and elastic deformation data with those of
the new springs shown in the following table.
Height
Under a load of
H (free)
63.50
N
H1
49.02
329
H2
38.20
641
3
75751
5
Position on the cylinder head: the protective cap (5), the
spring (4), the upper cap (3); use tool 99360268 (1) to
compress the spring (4) and lock the parts to the valve (5)
by the cotters (2).
N45 MNA M10
N67 MNA M15
8.148
OVERHAUL
MARCH 2006
INSTALLATION OF COMPONENTS
Figure 116
Figure 117
1
9
10
6
4
1
DIAGRAM SHOWING SEALING LOCTITE 5205
APPLICATION WITHIN GEARBOX AREAS
1
7
o Accurately clean the timing gearbox (1) and the engine
block.
5
75711
DIAGRAM SHOWING SCREW TIGHTENING
TO FIX REAR GEARBOX
CAUTION
It is necessary and essential to clean the surface to be
sealed in order to achieve excellent tight seal.
Apply sealing Loctite 5205 on the box in order to form a
kerbstone of a few mm. diameter.
It must be uniform (no lumps), with no air blisters, thinner
or irregular zones.
Any eventual imperfection shall be correct as soon as possible.
Avoid using material in excess to seal the joint.
Too much sealing material would drop out on both sides
of the joint and obstruct lubricant passages.
After having completed seal application, the joints must be
immediately assembled (10-20 minutes time).
3
2
75712
8
o Reassemble to box (1) to the engine block;
o Tighten the fixing screws in the same position as found
out during disassembly and fix the screws to the locking
torques listed here below, following the order as shown
in the picture.
-
Screws M12 65 to 89 Nm;
Screws M8 20 to 28 Nm;
Screws M10 42 to 52 Nm.
CAUTION
Before every assembly, always check that threads of holes
and screws have no evidence of tear and wear nor dirt.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.149
o Orient engine drive shaft (3) and camshaft (4) taking
care that in phase of assembly of the driving gear (2) to
the camshaft, the notches marked on the gears (1 and
2) shall match.
Figure 118
Figure 120
1
2
1
70211
2
o With a penmarker, mark the tooth (1) of the driving
gear assembled to the engine drive shaft (2) with (·)
timing notch.
CAUTION
Screw down two pins to facilitate operation of engine drive
shaft rotation.
3
90507
o Position comparator (1) on timing system gear (2) and
check that the clearance between gears (2) and (3) is
within 0.076 to 0.280 mm range.
Figure 121
Figure 119
1
4
1
2
2
3
3
1
4
1
2
2
3
90508
3
90506
o Tighten the screws (1) fixing the gear (2) to the camshaft (3) and lock them to the prescribed torque.
N45 MNA M10
N67 MNA M15
8.150
OVERHAUL
MARCH 2006
o Reassemble the box (1) to the engine block, tighten the
fixing screws in the same position as found out during
disassembly and fix the screws to the locking torques
listed here below, following the order as shown in the
picture.
Figure 122
-
Screws M12 75 to 95 Nm;
Screws M10 44 to 53 Nm.
CAUTION
Before every assembly, always check that threads of holes
and screws have no evidence of tear and wear nor dirt.
1
75708
Figure 124
DIAGRAM SHOWING SEALING LOCTITE 5205
APPLICATION
CAUTION
It is necessary and essential to clean the surface to be
sealed in order to achieve excellent tight seal.
Apply sealing Loctite 5205 on the box in order to form a
kerbstone of a few mm. Diameter.
It must be uniform (no lumps), with no air blisters, thinner
or irregular zones.
Any eventual imperfection shall be correct as soon as possible.
Avoid using material in excess to seal the joint.
Too much sealing material would drop out on both sides
of the joint and obstruct lubricant passages.
After having completed seal application, the joints must be
immediately assembled (10-20 minutes time).
04_208_N
o Apply to engine drive shaft rear tang (6), the detail (5)
of the tool 99346252, fix it tightening the screws (4) and
key the new holding ring on it (3).
Figure 123
o Place detail (1) on detail (5), tighten the screw nut (2)
until complete assembly of the fixing ring (3) into the
flywheel cover box (7).
1
75709
DIAGRAM SHOWING SCREW TIGHTENING
TO FIX FLYWHEEL COVER BOX.
Figure 125
1
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.151
Figure 127
2
2
1
3
75696
Check the conditions of the rim tooth (2). Whether tooth
break or excessive wear is detected, disassemble the rim
from the engine flywheel using a common willow and
replace with a new one, previously heated to 150 °C
degrees for 15-20 seconds; bevelling must be made towards
engine flywheel direction.
4
75692
o Tighten the screws (4) fixing the engine flywheel (3)
to the engine shaft. Use tool 99360339 (2) to operate
on the flywheel cover box (1) to block engine flywheel
rotation.
Figure 128
Figure 126
4
1
2
1
2
3
75695
75690
o Screw down two hooks or trail rings in the flywheel (1)
threaded ports (4) for handling;
o Using a hoist, handle the flywheel to place it in its housing inside the flywheel cover box;
o Screw down to pins (2) having appropriate length, in the
shaft ports (3) and using them as guide, assemble the
engine flywheel (1) properly placing it inside the flywheel
cover box.
Tighten the engine flywheel (1) fixing screws (2) in two
phases:
o 1st phase; tightening by means of dynamometric wrench
to torque 30 ± 4 Nm;
o 2nd phase, 60° ± 5° angle dwell.
CAUTION
Angle dwell shall always be performed using 99395216
tool.
Before every assembly, always check that threads of holes
and screws have no evidence of tear and wear nor dirt.
N45 MNA M10
N67 MNA M15
8.152
OVERHAUL
Figure 129
MARCH 2006
Figure 132
1
2
1
2
70223
70220
o Remove the fixing ring (2) from the front cover (1),
accurately clean the plug surface.
o Assemble oil pump (1);
o Tighten fixing screws (2) and lock them to the prescribed torque.
Figure 133
75710
Figure 130
2
1
70221
o Apply to the water pump (1) a new fixing ring (2).
Figure 131
o Accurately clean the contact surface of engine block
and apply sealing Loctite 5205 on it in order to form a
uniform and continuous kerbstone with no lumps.
1
2
76112
o Assemble the water pump (1);
o Tighten the screws (2) and lock them to the prescribed
torque.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 134
8.153
Figure 136
3
1
2
1
1
2
4
75812
o Assemble the front cover (2) to the block and tighten
the screws (1) fixing them to the prescribed torque.
Figure 135
88074
o Assemble plate (4), suction rose (3) and tighten the
fixing screws (2 and 1) locking them on the prescribed
torque.
Figure 137
1
1
2
3
2
3
1
2
7
4
5
6
04_422_N
00902T
o Apply on engine drive shaft front tang (6) the detail (4)
of the tool 99346252, fix it with the screws (5) and key
the new holding ring on it (7);
o Provide for newgasket replacement (1) of the oil
sump (2).
o Place the detail (2) on the detail (4), screw-up the
threaded nut until carrying out the complete assembly
of the holding ring (7) to the front cover.
CAUTION
The pictures illustrating the sump and of the rose pipe may
not correspond to the ones of your model.
However the procedures described are applicable anyway.
8.154
N45 MNA M10
N67 MNA M15
OVERHAUL
Figure 138
MARCH 2006
Figure 140
04_374_N
2
1
1
2
3
3
70230
o Fit a new sealing ring on the speed sensor (3) (if fitted);
o Assemble oil sump (1) , apply the plate over it (3).
Tighten the screws (2) and lock them to the prescribed
torque.
o Fit the speed sensor (3) on the front cover (1) and
tighten the screw (2) to the specified torque (if fitted).
Figure 141
CAUTION
Before every assembly, always check that threads of holes
and screws have no evidence of tear and wear nor dirt.
1
2
3
Figure 139
4
74175
1
5
2
04_345_N
3
o Assemble the pulley (1) and the dumping flywheel (2) to
the driving shaft;
o Tighten the fixing screws (3) and clamp them to the
torque 68 ± 7 Nm.
o Assemble the following elements to the block: new
gasket (1), heat exchanger (2), new gasket (3), oil filter
bearing (4);
o Tighten the screws (5) and lock them 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.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
8.155
Figure 144
Figure 142
2
04_344_N
1
3
2
1
75686
o Connect the alternator (1) to the support;
o Tighten without locking the screw (2).
4
Figure 145
o Lubricate the fixing ring (2) using engine oil and place it
on the oil filter (3);
o Manually start the oil filter (3) on the bearing union (1)
until counter-boring, further screw down the oil filter
(3) by 3/4 turn;
o Place a new fixing ring on the block housing (4).
1
2
Figure 143
3
74178
1
3
2
o Refit the automatic belt tensioner (2);
o Tighten the screw (3) to the specified torque;
4
o Turn the automatic belt tensioner (2) to fit the belt (1)
on pulleys and guide rollers.
CAUTION
70234
o Assemble the alternator bearing (1) ensuring that the
pins (3 and 4) are against the engine block;
o Tighten the screws (2) and lock them 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.
In case the previously removed belt is assembled again,
examine it carefully to check possible cuts or yielding
marks.
8.156
N45 MNA M10
N67 MNA M15
OVERHAUL
Refitting the cylinder head
MARCH 2006
Figure 147
Figure 146
1
87759
88775
Check cleanness of cylinder head and engine block coupling
surface.
Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking “N. of
component” (1) facing the head.
The arrow shows the point where the gasket thickness is
given.
There are two types of head seals, for the thickness (1.25mm
Type A and 1.15 mm Type B); take the following measures:
o For each piston detect, as indicated on Figure 142, at a
distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper
plane then calculate the average:
Scil1 =
S1 + S2
2
For 4 cylinder versions
Repeat the operation for pistons 2, 3 and 4 and calculate
the average value:
S=
Scil1 + Scil2 + Scil3 + Scil4
4
For 6 cylinder versions
Repeat the operation for pistons 2, 3, 4, 5 and 6 and
calculate the average value:
S=
Scil1 + Scil2 + Scil3 + Scil4 + Scil5 + Scil6
6
If S is > 0.40 mm use seal type A.
If S is < 0.40 mm use seal type B.
CAUTION
Before re-utilising the fixing screws for the cylinder head, verify there is no evidence of wear or
deformation and in that case replace them.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 148
8.157
Figure 150
1
1
2
2
3
3
04_433_N
76152
o Place the head (3) over the block and insert screws (1)
and (2).
o Place the head (3) over the block and insert screws (1)
and (2).
CAUTION
CAUTION
If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on
the engine block.
If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on
the engine block.
Figure 149
Figure 151
10
4
13
1
7
9
5
2
3
8
6
12
11
18
14
20
10
4
13
17
1
7
9
5
2
3
11
8
6
15
14
12
19
16
04_434_N
76214
o Lubricate cylinder head bolts and install to head;
o Lubricate cylinder head bolts and install to head;
o Bolts must be torqued using stitching pattern starting with the centre bolts and moving out. Bolts to be
torqued in stages: all bolts torqued to snug torque,
then 90 degrees rotation for all bolts. Then a further 90
degrees for the M12 x 140 and M12 x 180.
o Bolts must be torqued using stitching pattern starting with the centre bolts and moving out. Bolts to be
torqued in stages: all bolts torqued to snug torque,
then 90 degrees rotation for all bolts. Then a further 90
degrees for the M12 x 140 and M12 x 180.
-
-
M12 x 70
M12 x 140
M12 x 180
50 Nm + 90 degrees;
40 Nm + 180 degrees;
70 Nm + 180 degrees.
M12 x 70
M12 x 140
M12 x 180
50 Nm + 90 degrees;
40 Nm + 180 degrees;
70 Nm + 180 degrees.
8.158
N45 MNA M10
N67 MNA M15
OVERHAUL
Figure 152
MARCH 2006
Figure 154
1
1
4
2
3
3
2
1
75705
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring - 2. Spacer - 3. Rocker arms - 4. Support.
75702
ROCKER ARM ADJUSTMENT SCREW
If unscrewed, check adjustment quota.
Tighten the screw-threaded nut (1) to the 0.4-0.6 Nm torque.
Figure 155
o Carry out the assembly of the rocker arms after previous check of the components.
Figure 153
32655
Before executing assembly, check the Rocker Arm driving
rods: these shall not be deformed; the spherical ends in
contact with the Rocker Arm adjustment screw and with
the tappet (arrows) shall not present evidence of seizure or
wear: in case of detection proceed replacing them.
The rods driving the suction and exhaust valves are identical
and therefore interchangeable.
75704
SHAFT AND ROCKER ARM BASIC DATA
Check the coupling surfaces of bearing and shaft: no evidence of excessive wear shall be detected or damages.
Replace if necessary.
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 156
8.159
Figure 158
75707
75703
o Insert the tappet driving rods and the Rocker Arm unit.
Before using the fixing screws again, measure them twice as
indicated in the picture, checking D1 and D2 diameters:
-
If D1 - D2 < 0.1 mm the screw can be utilised again;
If D1 - D2 > 0.1 mm the screw must be replaced.
1
o Assemble injectors after having replaced the sealing
gasket (1).
Figure 157
1
CAUTION
During assembly of injectors, verify that the injector sphere
is correctly positioned on the head housing.
04_340_N
o Tighten the screws (1) to the prescribed torque.
Adjusting valve clearance
(see Section 6).
8.160
N45 MNA M10
N67 MNA M15
OVERHAUL
Figure 159
MARCH 2006
Figure 161
76149
2
1
4
5
2
1
3
75685
o Assemble thermostat unit (2) including thermostat (5)
and gasket (4);
o Assemble cylinder covers (2) with the respective gaskets;
o Fit the seal nods and tighten the screws (1) fixing them
to the prescribed torque.
CAUTION
Always replace the gaskets using new ones.
Check the threads of the fixing screws: there shall be no
evidence of wear or dirt deposit.
Seal nods shall have no visible deformation. In such case
provide for replacement with new nods.
o Tighten the screws to the prescribed torque.
CAUTION
The screws (1) have been have been utilised to fix the
bracket (3).
Disassemble the bracket (3) and reassemble components
from 1 to 5 as shown in the picture.
The gasket (4) must be new.
Figure 162
Figure 160
1
6
2
3
76206
1
o Assemble exhaust manifold (1) providing new gaskets
(2).
CAUTION
The illustration of exhaust manifold may be not matching
your model. Anyhow, described procedure is applicable.
2
5
6
4
04_400_N
o Mount Poly-V belt (4) engine shaft pulley (5), guide pulleys (6), water pump (3) and alternator (1); stretch the
belt by operating on automatic belt tensioner (2).
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Figure 163
8.161
Figure 165
1
1
1
76208
76148
o Also assemble the brackets (1) fixing the fuel pipelines
to the injectors: use the same screws (2) fixing the manifold plate as shown in the picture;
o Fix the pipes to the injectors throughout the brackets
previously assembled.
o Also assemble feed pump (see specific procedure).
Figure 166
CAUTION
1
Pump mounting requires specific procedure contained in
this section.
Figure 164
88146
o Assemble the injection pump pipe (1).
1
04_421_N
o Assemble the injection pump supply pipes (1);
o Screw down the locking nuts fixing the pipes to the
injection pump;
o Tighten the screws fixing the fuel recovery manifold to
the injection pump;
o Tighten the locking nuts on the injectors and tighten the
screws to fasten the fuel recovery manifold.
N45 MNA M10
N67 MNA M15
8.162
OVERHAUL
Adjusting injection pump phase
MARCH 2006
Completion of the engine
(see Section 6)
Figure 168
Figure 167
3
2
1
2
1
76146
90510 B
o Assemble the fuel filter bearing (4) to the bracket fixed
to the engine head;
o Connect the fuel pipelines (2 and 3) respectively from
priming pump to filter bearing and from this last one to
feed pump;
o Using 99360076 equipment assemble fuel filter (1).
o Reassemble the starter;
o Properly hold the starter (1) and tighten the fixing
screws (2) to the prescribed torque;
o Assemble oil filter;
o Assemble oil level rod together with guide pipe;
o Proceed to install marine parts;
o Fill the engine with oil and coolant liquid quantity required.
CAUTION
The filter shall be priory filled with fuel to facilitate feed
system bleed operations.
To complete engine assembly it is necessary to remove it
from the turning stand.
o Using rocker arm 99360595 hold the engine and loosen
the screws fixing the brackets to the turning stand
99322205;
o Disassemble the brackets from the engine after having
properly put it on a wooden bearing.
MARCH 2006
N45 MNA M10
N67 MNA M15
OVERHAUL
TIGHTENING TORQUES
Marine parts tightening torques
Part
Nm
Torque
kgm
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
M12 x 30 Screw for front engine support legs
69 ± 7
6.9 ± 0.7
M12 x 30 Screw for back engine support legs
66 ± 7
6.6 ± 0.7
8±1
0.8 ± 0.1
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
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 x 150 Screw for lower anchoring of the exhaust manifold
53 ± 6
5.3 ± 0.6
M6 x 20 Screw for cooled Riser stub pipe
8.163
8.164
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
Engine parts tightening torques
Part
Nm
Cooling Nozzles (M8x1.25x10)
Torque
kgm
15 ± 3
1.5 ± 0.3
5.0 ± 0.6
8.0 ± 0.6
Main bearing cap
1st stage
2nd stage
3rd stage
50 ± 6
80 ± 6
Rear gear housing assembly
(M8x1.25x40)
(M8x1.25x25)
(M10x1.5)
24 ± 4
24 ± 4
49 ± 5
2.4 ± 0.4
2.4 ± 0.4
4.9 ± 0.5
Oil pump (M8x1.25x30)
1st stage
2nd stage
8±1
24 ± 4
0.8 ± 0.1
2.4 ± 0.4
Front cover assembly
(M8x1.25x45)
(M8x1.25x30)
24 ± 4
24 ± 4
2.4 ± 0.4
2.4 ± 0.4
1st stage
2nd stage
3rd stage
30 ± 3
60 ± 5
3.0 ± 0.3
6.0 ± 0.5
Connecting rod bolts (M11x1.25)
Ladder frame assembly (M10x1.25x25)
90° ± 5°
60° ± 5°
43 ± 5
4.3 ± 0.5
6±1
11 ± 2
0.6 ± 0.1
1.1 ± 0.2
24 ± 4
2.4 ± 0.4
24 ± 4
60 ± 9
2.4 ± 0.4
6.0 ± 0.9
5±1
0.5 ± 0.1
M8 screw
M6 screw
M6 nut
24 ± 4
10 ± 1
10 ± 1
2.4 ± 0.4
1.0 ± 0.1
1.0 ± 0.1
M10x1.5 flange head nuts pre-torque
1st stage
2nd stage
10 -15
50 -55
1.0 -1.5
5.0 -5.5
Fuel pump gear (drive gear nut)
snug torque
final torque
15 -20
85 -90
1.5 -2.0
8.5 -9.0
Inspection cover on the gearbox
30 -35
3.0 -3.5
Rocker assys (M8)
24 ± 4
2.4 ± 0.4
50 + 90°
40 + 180°
70 + 180°
5.0 + 90°
4.0 + 180°
7.0 + 180°
Assy rocker covers (M8x1.25x25)
24 ± 4
2.4 ± 0.4
Intake manifold (M8x1.25)
24 ± 4
2.4 ± 0.4
Assy air intake connection (M8x1.25)
24 ± 4
2.4 ± 0.4
Oil bypass valve into lube filter head (nut M22x1.5x10)
80 ± 8
8.0 ± 0.8
Plug (M12x1.5x12)
10 ± 1
1.0 ± 0.1
Water pump (M8x1.25x25)
24 ± 4
2.4 ± 0.4
24 ± 4
24 ± 4
2.4 ± 0.4
2.4 ± 0.4
77 ± 12
7.7 ± 1.2
Oil rifle plugs
(M10x1)
(M14x1.5)
Assemble oil suction tube (M8x1.25x20)
Oil sump assembly
(M8x1.25x25)
(M18x1.50)
Set timing pin (Torx screw M5 T25)
Fuel pump assembly
Cylinder head bolts
Water inlet connection
Rear lifting bracket (M12x1.75x30)
(M12x70)
(M12x140)
(M12x180)
(M8x1.25x35)
(M8x1.25x70)
MARCH 2006
N45 MNA M10
N67 MNA M15
OVERHAUL
Engine parts tightening torques (cont)
Part
Nm
Crankshaft pulley (M12x1.75x10.9)
Flywheel housing
Flywheel housing on crankshaft (M12x1.25)
110 ± 5
(M12x120)
(M12x80)
(M10x80)
(M10x40)
1st stage
2nd stage
Torque
kgm
11.0 ± 0.5
85 ± 10
85 ± 10
49 ± 5
49 ± 5
30 ± 4
8.5
8.5
4.9
4.9
60° ± 5°
±
±
±
±
1.0
1.0
0.5
0.5
3.0 ± 0.4
Aspiration pump gear cover (M8x1.25x16)
24 ± 4
2.4 ± 0.4
Fuel injectors
60 ± 5
6.0 ± 0.5
Oil feed to oil filter head
24 ± 4
2.4 ± 0.4
Alternator to alternator support (M8x1.25x30)
24 ± 4
2.4 ± 0.4
Alternator to water inlet conn. assy (M8x1.25x30)
24 ± 4
2.4 ± 0.4
Lower alternator mounting (M10x1.25x25)
24 ± 4
2.4 ± 0.4
Alternator upper pivot to support (M10)
49 ± 5
4.9 ± 0.5
Alternator mounting hardware (M12x1.75x120)
43 ± 6
4.3 ± 0.6
Alternator wiring (M6x1.0 nut)
10 ± 2
1.0 ± 0.2
Starter motor to gear case (M10)
49 ± 5
4.9 ± 0.5
Screw M8 for fastening cylinder barrel lubricating nozzles
15 ± 3
1.5 ± 0.3
50 ± 6
80 ± 6
5 ± 0.6
8 ± 0.6
Screw M12 for fastening output shaft caps
1st stage
2nd stage
3rd stage
90° ± 5°
Screw M8 for fastening camshaft longitudinal retaining plate
24 ± 4
2.4 ± 0.4
Screw M8 for fastening camshaft gear
36 ± 4
3.6 ± 0.4
Screw M11 for fastening connecting rod caps
1st stage
2nd stage
60 ± 5
60° ± 5°
6 ± 0.5
8.165
8.166
N45 MNA M10
N67 MNA M15
OVERHAUL
MARCH 2006
MARCH 2006
SAFETY REGULATIONS
N45 MNA M10
N67 MNA M15
9.167
SECTION 9
SAFETY REGULATIONS
Page
SAFETY REGULATIONS
169
Standard safety regulations
169
Accident prevention
169
During maintenance
169
Respecting the Environment
170
9.168
N45 MNA M10
N67 MNA M15
SAFETY REGULATIONS
MARCH 2006
MARCH 2006
SAFETY REGULATIONS
N45 MNA M10
N67 MNA M15
9.169
SAFETY REGULATIONS
Standard safety regulations
Pay particular attention to some precautions that must
be followed by all means in any working place and whose
non-observance will make any other measures useless or
not sufficient to ensure safety to the personnel in charge
of maintenance.
o Be informed and inform the personnel as well of the
laws in force regulating safety, by providing information
documentation available for consultation;
o Keep working areas as clean as possible, and ensure
adequate ventilation;
o Ensure that working areas are provided with emergency
kits, that must be clearly visible and always fitted with
adequate sanitary equipment;
o Provide for adequate fire extinguishing means, properly
indicated and always easy to reach. Their efficiency must
be checked on a regular basis and the personnel must
be trained on intervention methods and priorities;
o Provide specific exit points to evacuate the areas in case
of emergency, giving adequate indications of the emergency escape paths;
o Smoking in working areas subject to fire danger must be
strictly prohibited;
o Put rags smeared with oil, diesel fuel, or solvents in fireproof containers;
o Do not carry out any intervention you have not been
given all necessary instructions for;
o Do not use any tool or equipment for any operation
different from the ones they have been designed and
provided for. Serious injury may occur;
o In case of test or calibration operations requiring the
engine to be in operation, ensure that the area is sufficiently ventilated or use specific aspirators to eliminate
exhaust gas. Danger: poisoning and death.
During maintenance
o Never open the filler cap of the cooling circuit when the
engine is hot. Operating pressure would provoke hot
liquid to pour out with serious danger and risk of scalding.
Wait until the temperature decreases below 50 °C;
o Never top up an overheated engine with cooler and use
only appropriate liquids;
o Always operate when the engine is turned off: in case
particular circumstances require maintenance intervention on the running engine, be aware of all risks involved
in such operation;
o Provide warnings by means of adequate boards signaling danger, prohibitions, and indications to ensure
easy understanding of the instructions even in case of
emergency.
o Be equipped with adequate and safe containers for
draining engine liquids and exhaust oil;
Accident prevention
o The use of solvents or detergents during maintenance
may generate toxic vapors. Always keep working areas
ventilated. Whenever necessary wear a safety mask;
o When working close to engines and equipment in
motion, do not wear unsuitable clothes, with loose ends,
nor jewels such as rings and chains;
o Wear safety gloves and goggles when performing the
following operations:
- filling inhibitors or antifreeze;
- topping or replacing lubrication oil;
- using compressed air or liquids under pressure (pressure allowed: ≤ 2 bar).
o Wear a safety helmet when working close to hanging
loads or equipment operating at head height level;
o Keep the engine clean from oil, diesel fuel, and/or chemical solvents stains;
o Do not leave rags impregnated with flammable substances close to the engine;
o Upon engine start after maintenance, undertake proper
preventing actions to stop air suction in case of overspeed;
o Do not use fast screwdriver tools;
o Never disconnect batteries when the engine is running;
o Disconnect batteries before any intervention on the
electrical system;
o Always wear safety shoes and clothes adhering to the
body, better if provided with elastics at the ends;
o Disconnect batteries from the system to charge them
with the battery charger;
o Use protection cream for your hands;
o After every intervention, verify that the battery clips
polarity is correct and that the clips are tight and safe
from accidental short circuit and oxidation;
o Change wet clothes as soon as possible;
o In presence of current tension exceeding 48-60 V verify
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;
o Do not smoke nor light up flames close to batteries and
any fuel;
o Do not disconnect and connect electrical connections in
presence of electrical supply;
9.170
N45 MNA M10
N67 MNA M15
SAFETY REGULATIONS
o Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) check for liquid or air under
pressure. Take all necessary precautions by bleeding and
draining residual pressure or closing separation valves.
Always wear adequate safety masks or goggles. Nonobservance of these instructions may cause serious
injuries and poisoning;
o Avoid incorrect or over-torque tightening. Danger:
incorrect tightening may seriously damage the engine
components, affecting its duration;
o Avoid priming from fuel tanks made of copper alloys
and/or with ducts without filters;
o Do not modify cable wires: their length must not be
changed;
o Do not connect any other equipment to the engine
electrical equipment unless specifically approved by
IVECO MOTORS;
o Do not modify the fuel or hydraulic systems without
having received specific approval from IVECO MOTORS.
Any unauthorized modifications will compromise the
warranty assistance and furthermore may affect the
engine correct working and duration.
For engines equipped with an electronic control unit:
o Do not carry out any electric arc welding without having
removed the electronic control unit first;
o Remove the electronic control unit in case of any interventions requiring heating over 80 °C;
o Do not paint the components and the electronic
connections;
o Do not vary or alter any data filed in the electronic
control unit. Any manipulation or alteration of electronic
components will totally compromise the engine warranty assistance and furthermore may affect the engine
correct working and duration.
MARCH 2006
Respecting the Environment
o Respecting the Environment is of primary importance:
all necessary precautions to ensure the personnel’s
safety and health are to be adopted;
o Be informed and inform the personnel as well of laws
in force regulating use and exhaust of liquids and engine
exhaust oil. Provide for adequate board indications and
organize specific training courses to ensure that the
personnel is fully aware of such law instructions and of
basic preventive safety measures;
o Collect exhaust oils in adequate containers with air-tight
sealing ensuring that storage is made in specific, properly
identified, areas that will be ventilated, far from heat
sources, and not exposed to fire danger;
o Handle batteries with care, storing them in ventilated
environment and in anti-acid containers. Warning: battery exhalations represent serious danger of intoxication
and environment contamination.
IVECO S.p.A.
PowerTrain
Viale Dell’Industria, 15/17
20010 Pregnana Milanese - MI - (Italy)
Tel. +39 02 93.51.01 - Fax +39 02 93.59.00.29
www.ivecomotors.com
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