Technical FTP

C87 ENT M62.
10
C87 ENT M65.10
C87 ENT M62.11
C87 ENT M65.11
TECHNICAL AND
REPAIR MANUAL
MAY 2012 EDITION
We strongly recommend that you carefully read the
indications contained in this document: compliance with
these indications protects the engine from irregular
operation, assures reliability, safeguards sea-going and
protects maintenance personnel from accident hazards.
The indications contained in this document pertain to the
C87 ENT M62.10 - C87 ENT M64.10 marine engines and
complement the FPT Marine Diesel Engines Installation
Handbook. You should refer to this for anything that is not
explained herein.
Technical engineers and fitters must comply with work safety
regulations. They must implement and adopt the methods
foreseen for personal safety while carrying out maintenance
or checks.
There is a reminder of the regulations for engine handling at
the end of Section 6 of the present publication.
To start the engine, you must adhere to the procedure stated
at the end of Section 5 of the present publication.
To get best engine performance you must conform with its
intended mission profile.The engine must not be used for
purposes other than those stated by the manufacturer.
FPT is available for a prior examination of any requirements
regarding special installations, should this be necessary.
In particular
- Use of unsuitable fuels and oils may compromise the
engine's regular operation, reducing its performance,
reliability and working life.
- Exclusive use of FPT Original Parts is a necessary
condition to maintain the engine in its original integrity.
- Any tampering, modifications, or use of non-original
parts may jeopardize the safety of service personnel and
boat users.
To obtain spare parts, you must indicate:
- Commercial code, serial number and the indications
shown on the engine tag;
- The number of the spare part. This can be found in the
spare part catalog.
The information provided below refers to engine
characteristics current at the date of publication.
FPT reserves the right to make modifications at any time and
without advance notice, to meet technical or commercial
requirements or to comply with local legal and regulatory
requirements.
We refuse all liability
for any errors and omissions.
The reader is reminded that the FPT Technical Assistance
Network is always at the Customer's side with its
competence and professionalism.
Publication edited by:
FPT - Fiat Powertrain Technologies
www.fptpowertrain.com
Printed P3D32C005 E - 3
th
Ed. 05.12
MAY 2012 1.2
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
FOREWORD
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 1.3
SECTION CONTENTS
Section Page
1. OVERVIEW 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. TECHNICAL DATA 43 . . . . . . . . . . . . . . . . . . . .
3. ELECTRICAL EQUIPMENT 51 . . . . . . . . . . . . . .
4. DIAGNOSTICS 71 . . . . . . . . . . . . . . . . . . . . . . . .
5. MAINTENANCE 87 . . . . . . . . . . . . . . . . . . . . . . .
6. SERVICING OPERATIONS
ON INSTALLED ENGINE 93 . . . . . . . . . . . . . . .
7. TOOLS 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. OVERHAUL 119 . . . . . . . . . . . . . . . . . . . . . . . . . .
9. SAFETY REGULATIONS 195 . . . . . . . . . . . . . . . .
MAY 2012 1.4
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 OVERVIEW 1.5
SECTION 1
Overview
Page
VIEWS OF ENGINE 7 . . . . . . . . . . . . . . . . . . . . . . . .
M62.10 / M65.10 Engines 7 . . . . . . . . . . . . . . . . .
M62.10 / M65.10 Engines 10 . . . . . . . . . . . . . . . . .
IDENTIFICATION DATA 13 . . . . . . . . . . . . . . . . . . . .
COMMERCIAL CODE 14 . . . . . . . . . . . . . . . . . . . . . .
PRODUCT MODEL NUMBER 15 . . . . . . . . . . . . . . . .
COMBUSTION AIR INTAKE AND EXHAUST
SYSTEM 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Comburent air filter 17 . . . . . . . . . . . . . . . . . . . . .
Turbocompressor 17 . . . . . . . . . . . . . . . . . . . . . . .
Air/sea-water heat exchanger 17 . . . . . . . . . . . . . .
COOLING FRESH WATER CLOSED LOOP 18 . . . .
Tube bundle water/water heat exchanger 19 . . . .
M62.10 / M65.10 Engines 19 . . . . . . . . . . . . . . . . .
M62.11 / M65.11 Engines 19 . . . . . . . . . . . . . . . . .
Bypass junction for thermostatic valve 20 . . . . . . .
SEA WATER OPEN COOLING LOOP 21 . . . . . . . . .
M62.10 / M65.10 Engines 21 . . . . . . . . . . . . . . . . .
M62.11 / M65.11 Engines 22 . . . . . . . . . . . . . . . . .
Sea water pump 23 . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL - LUBRICATION LOOP 24 . . . . . . . . . .
Oil fume recycle (Blow-by) 25 . . . . . . . . . . . . . . . .
SUPPLY 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SUPPLY DIAGRAM 27 . . . . . . . . . . . . . . . . . . . .
MAY 2012 1.6
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
Page Page
Pump assembly 28 . . . . . . . . . . . . . . . . . . . . . . . . .
Low pressure feed pump 29 . . . . . . . . . . . . . . . . .
Pressure control solenoid valve 31 . . . . . . . . . . . .
Low pressure limiter valve 31 . . . . . . . . . . . . . . . .
High pressure pump 32 . . . . . . . . . . . . . . . . . . . . .
Operation 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAIL (PRESSURE ACCUMULATOR) 34 . . . . . . . . . . .
Electroinjector 34 . . . . . . . . . . . . . . . . . . . . . . . . . .
EDC 7 UC31 Electronic Central Unit 35 . . . . . . . .
Air pressure/temperature sensor 35 . . . . . . . . . . .
Atmospheric pressure sensor 35 . . . . . . . . . . . . . .
Oil pressure/temperature sensor 36 . . . . . . . . . . .
Crankshaft sensor 36 . . . . . . . . . . . . . . . . . . . . . . .
Camshaft sensor 37 . . . . . . . . . . . . . . . . . . . . . . . .
Coolant temperature sensor 37 . . . . . . . . . . . . . . .
Fuel temperature sensor 38 . . . . . . . . . . . . . . . . . .
Throttle lever position 38 . . . . . . . . . . . . . . . . . . .
Fuel pressure sensor on rail 38 . . . . . . . . . . . . . . .
SYSTEM FUNCTIONS 39 . . . . . . . . . . . . . . . . . . . . . .
Run up 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metering and fuel injection 39 . . . . . . . . . . . . . . . .
Injection advance management 39 . . . . . . . . . . . . .
Pre-injection 40 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection pressure modulation 40 . . . . . . . . . . . . . .
Idling adjusting 40 . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-diagnosis 40 . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDC indicator light 40 . . . . . . . . . . . . . . . . . . . . . .
Fuel heating 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linearization of the acceleration gradient 40 . . . . .
Balance of the cylinder torque delivery 40 . . . . . . .
Rotation speed control 40 . . . . . . . . . . . . . . . . . . .
Top speed limitation 40 . . . . . . . . . . . . . . . . . . . . .
Cut off 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Derating 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recovery 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After run 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
174584
177445
VIEWS OF ENGINE
M62.10 / M65.10 Engines
LEFT-HAND SIDE VIEW
RIGHT-HAND SIDE VIEW
Figure 1
Figure 2
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
.
174585
174582
FRONT VIEW
REAR VIEW
Figure 3
Figure 4
MAY 2012 1.8
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
174581
TOP VIEW
Figure 5
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
174584
174583
M62.11 / M65.11 Engines
LEFT-HAND SIDE VIEW
RIGHT-HAND SIDE VIEW
Figure 6
Figure 7
MAY 2012 1.10
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
174585
174582
FRONT VIEW
REAR VIEW
Figure 8
Figure 9
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
174581
TOP VIEW
Figure 10
MAY 2012 1.12
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
Figure 11
143677
The engine identification data are stenciled on a tag positioned over the engine coolant tank
1. Trade name/version - 2. Homologation - 3. Production serial number- 4. Maximum rated power - 5. Family of engines -
6. Trade name - 7. Design number- 8. Programming code - 9. Year of production - 10. Homologation number.
174575
Figure 12
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
IDENTIFICATION DATA
The purpose of the commercial code is to make it easier to understand the characteristics of the product, categorizing the engines
according to their family, origins and intended application. The commercial code, therefore, cannot be used for technical purposes
and to identify the engine's components, this is the purpose of the ENGINE S/N.
VERSION:
TURBOCOMPRESSOR:
1 = COOLED
2 = NOT COOLED
APPLICATION: M = MARINE
ENGINE FAMILY IDENTIFIER: C = CURSOR
DISPLACEMENT: 8.710 c.c.
FUEL SUPPLY: E = ELECTRONIC INJECTION
BLOCK: N = NON STRUCTURAL
AIR INTAKE: T = INTERCOOLED SUPERCHARGED
VERSION
MAXIMUM PERFORMANCE LEVEL ACHIEVABLE
62 = 620 CV
65 = 650 CV
C 87
E N T M
62
. 1 0
65 1
MAY 2012 1.14
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
COMMERCIAL CODE
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 the side of the crank-case.
ACTUAL POWER OUTPUT
VARIANTS TO
BASIC ENGINE
F 2 C H 8 A 0
0 6 A
*
6 0 1
POWER RANGE
INTENDED USE (6 = MARINE)
FUEL +INJECTION (8 = DIESEL, TCA, DIRECT INJECTION)
NO. OF CYLINDERS
NO. OF STROKES AND CYLINDER DISPOSITION (0 = 4 STROKES, VERTICAL)
ENGINE
DESIGN ITERATION
ENGINE FAMILY IDENTIFIER
J
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
PRODUCT MODEL NUMBER
Description and Operation
Air, drawn in and compressed by the turbocompressors,
flows through the heat exchanger together with sea water.
The latter, by reducing temperature, allows an increase in the
engine's volumetric efficiency.
The air density at the inlet of the intake manifold is measured
by two sensors, for pressure and temperature, allowing the
ECU of the EDC system to calculate fuel dosage relative to
the actual quantity of air available for combustion.
Lubricating oil vapors (blow-by) not condensed in the
separator, are sent to the engine intake by a gauged hole
downstream of the air filters.
Exhaust gas expelled by the engine flows through the cooled
exhaust manifold to reach the turbocompressors rotors.
Exhaust manifold and turbocompressor body are cooled by
the fresh water loop. Exhaust gases flow into the exhaust
terminal and, when provided, they are mixed with the sea
water it carries for overboard discharge.
Figure 13
143694
Intake Exhaust Sea water
MAY 2012 1.16
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
COMBUSTION AIR INTAKE AND EXHAUST SYSTEM
1. Filter clogging sensor.
1. Sea-water outlet - 2. Sacrificial anode (Zinc) -
3. Sea-water inlet - 4. comburent air inlet -
5. Comburent air outlet
The flow of water coming from the sea-water pump goes
through the tube bundle (3) and, by going through it, absorbs
some of the heat of the overheated air of the
turbosupercharge, passing through the exchanger coming
from the turbocompressor (4).
The outlet water (1) is conveyed towards the fresh
water/sea-water heat exchanger, while the
turbosupercharged air, cooled down, reaches the induction
manifold (5) and from there reaches the cylinders.
Comburent air filter Air/sea-water heat exchanger
Figure 14
Turbocompressor
Figure 15
1. Coolant inlet.
The engine is turbosupercharged by a fixed geometry turbine
with no waste-gate control.
The turbine is cooled by the coolant circulation from the
crankcase.
The compressor-turbine spindle rotates on brass bearings
lubricated by pressure lubrication, directly from the oil filter.
Figure 16
134384
143670
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Description and operation
The centrifuge pump, rotated by the drive shaft with a poly-V
belt, draws in the coolant coming from the fresh water/sea
water heat exchanger or from the exhaust manifold cooling
loop and sends it into the block, where it comes in contact
with the lubricating oil heat exchanger. It then touches the
heat exchange areas of the cylinders and subsequently those
of the engine head, from which it exits flowing through the
junction fitting that contains the temperature sensors for the
instrument panel and the injection system. This junction has
the purpose of bypassing the coolant from the engine head
to the exhaust manifold and fromthe exhaust manifold tothe
thermostat - which routes it according to the temperature
either to the water/water heat exchanger or to the
recirculation pump.
Fromthe bypass fitting the liquid is then injected into the heat
exchange chamber of the exhaust manifold - through which
it flows going to touch the body of the waste gate, of a
portion the exhaust and of the turbo compressor. When it
returns into the bypass junction it comes in contact with the
wax actuator of the thermostatic valve. This will throttle
flows according to temperature.
Part of the liquid will enter the tank and flowthrough thetube
bundle heat exchanger, releasing heat to sea water, while the
rest will go directly to the pump, to be recirculated.
Figure 17
High temperature liquid
Low temperature liquid
Low temperature liquid
Sea water
143697
MAY 2012 1.18
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
COOLING FRESH WATER CLOSED LOOP
M62.11 / M65.11 Engines
Tube bundle water/water heat exchanger
M62.10 / M65.10 Engines
Figure 18
Figure 19
174577
143671
1. Sea water outlet to overboard discharge - 2. Sea water inlet from after cooler - 3. Coolant inlet from thermostatic valve -
4. Coolant outlet to pump.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Bypass junction for thermostatic valve
Figure 20
05_066_C
1. Bypass flow to engine - 2. Outflow from engine - 3. Outflow from exhaust manifold - 4. Inflow to exhaust manifold -
5. Flow to sea water heat exchanger - 6. Temperature sensor.
MAY 2012 1.20
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
Figure 21
Sea water
143698
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
SEA WATER OPEN COOLING LOOP
M62.10 / M65.10 Engines
Sea water, drawn fromunder the keel and necessarily filtered,
is drawn by the pump and sent to the supercharger air heat
exchanger and from there to the water/water heat
exchanger of the closed cooling loop; only after this will it
flow through the heat exchanger for the gearbox oil, if one
is provided.
The configuration of the discharge lines depends on the
choice of a dry chimney exhaust, or a mixed one. The
outlet pipe will carry the water directly to the overboard
discharge or, if the water/exhaust gas mixer solution is
adopted, a conduit will connect the outlet of the last heat
exchanger with the mixer inflow junction pipe.
Figure 22
Sea water
174578
MAY 2012 1.22
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
M62.11 / M65.11 Engines
1. Pump impeller seat - 2. Driving gear shaft -
3. Sea water intake - 4. Sea water delivery.
The sea water pump, centrifugal type, is rotated by the gears
keyed to the rear of the flywheel.
Sea water pump
Figure 23
139550
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
The gear pump, rotated by the gears at the rear of the
flywheel sends the lubricating oil directly to the heat
exchanger which, incorporated in the block and lapped by
the coolant, reduces temperature to maintain optimal
lubricating capability.
The thermostatic valve that regulates oil flowis located at the
inlet of the heat exchanger, opening the bypass pipe if
temperature falls below calibration temperature.
From the output of the heat exchanger, the oil is sent to the
filter assembly and from this back to the engine block to
lubricate all anti-friction elements.
The blow-by vapor condenser, provided with filter and safety
valve, is located on the upper part of the timing mechanism
lid. The vapors, after returning to the liquid state, will flow
from the vapor condensor into the sump. The engine is
provided with the pre-lubrication systemon request. This can
inject enough oil into the engine's ducts to guarantee a totally
safe start.
The operation of the electrical pre-lubrication pump (on
request), is automatically controlled by the ECU electronic
unit.
This system, with the aid of the flow-switching solenoid valve,
also permits the oil sump to be emptied and filled.
Detailed descriptions of this operation are provided in
Section 3.
Figure 24
143695
Delivery oil
Sump return oil
MAY 2012 1.24
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
ENGINE OIL - LUBRICATION LOOP
114248
Oil fume recycle (Blow-by)
Part of gas produced by combustion during engine operation leaks through piston elastic ring openings into sump, mixing with
oil fumes in sump.
This mixture, conveyed upward, is partially separated from oil by a device located in timing cover upper part and introduced in
air intake circuit.
The device mainly consists of a rotary filter secured on propeller shaft and by a front cover housing normally closed valves
controlling mixture flow.
Gas with oil contents greater than 10 g/h
Gas with oil contents approx. 0,2 g/h
Condensed oil returning to oil sump
Figure 25
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
SUPPLY
The Common Rail supply system is equipped with a special pump that maintains fuel at constant high pressure regardless
from phase and cylinder under injection and accumulated in an common duct shared by all electric injectors.
Therefore, fuel at injection pressure, calculated by ECU, is always available at electric injection inlet.
When the solenoid valve of an injector is energized by ECU, in related cylinder the injection of fuel taken directly from the
rail takes place.
High pressure
Low pressure
Figure 26
149570
MAY 2012 1.26
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
127140
1. High-pressure pump - 2. Fuel filter - 3.Tank - 4. Fuel pre-filter - 5.ECU - 6. Electric injectors - 7.Common Rail -
8. Pressure sensor
FUEL SUPPLY DIAGRAM
High pressure
Low pressure
After high-pressure pipeline installation, during the following 20 hours of work, frequently check engine oil level.
( IT MUST NOT INCREASE ).
ATTENTION
Figure 27
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
The high pressure pump is made up of three radial pumping
elements driven by a tappet set into rotation by a gear of the
timing shaft. In the rear part the feed mechanical pump, driven
by the radial pump, is fitted.
The pressure control solenoid valve is located on its side.
The positioning of the pump does not require timing as the
injections management is entirely electronically controlled.
Pump assembly
Figure 28
1. Connector fuel outlet to rail - 2. High pressure pump - 3. Pressure control solenoid - 4. Fuel inlet connector from filter -
5. Fuel outlet connector to recirculation manifold - 6. Fuel inlet from tank - 7. Fuel outlet connector from low pressure
pump to filter - 8. Low pressure pump.
MAY 2012 1.28
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
Low pressure feed pump
Figure 29
A. Fuel inlet from tank - B. Fuel outlet to filter - 1. Recirculation valve - 2. By-pass valve.
The gear wheel pump is assembled on the rear part of the
high pressure pump. It transfers the fuel from the tank to the
high pressure pump.
It is set into rotation by the high pressure pump shaft. Under
normal operation conditions, the fuel flow inside the
mechanical pump is illustrated in Figure 29.
Figure 30
A. Fuel inlet from tank - B. Fuel outlet to filter - 1. Recirculation valve - 2. By-pass valve.
In the case of overpressure at the outlet, Figure 30, the recir
culation valve comes into action.
The existing pressure, overcoming the spring valve elastic
strength (1), connects the outlet with the inlet through a duct
(2), recirculating the fuel in excess inside the pump and
keeping a pressure rating equal to that of the setting of the
valve.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 31
A. Fuel inlet from tank - B. Fuel oulet to filter - 1. Recirculation valve - 2. By-pass valve.
Figure 31 represents the section of the pump during the stage
of filling up the line, as an example by means of the manual
pump located on the pre-filter. With the engine not in
rotation, due to the pressure in the inlet, the by-pass valve (2)
opens up enabling the fuel to flow towards the filter.
MAY 2012 1.30
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
Figure 32 Figure 33
Pressure control solenoid valve
1. Electric connector - 2. Fuel outlet - 3. Fuel inlet.
Positioned at the inlet of the high pressure pump, it enables
to control the quantity of fuel feeding the pump according
to the controls received by the electronic Central Unit. In the
absence of control signal, the valve is normally open,
therefore the high pressure pump is in maximum delivery
condition.
The Central Unit sends a PWM control signal to the
controller, in order to choke in a greater or lesser way the
inlet section of the fuel to the high pressure pump.
This component cannot be replaced individually and
therefore must not be disassembled.
Low pressure limiter valve
Assembled in parallel to the pressure control solenoid valve,
has the function of keeping the inlet pressure constant to the
value of 5 bar, that is a necessary condition for a correct
operation of the control system.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 34
High pressure pump
1. Outlet for delivery to rail - 2. Delivery valve to rail -
3. Pumping - 4. Pump shaft - 5. Pumping feed duct -
6. Pressure control feed duct - 7. Pressure control
solenoid - 8. Fuel inlet from filter.
Figure 35
During the induction stroke, the pumping, driven by the cam
located on the pump shaft, is fed through the pumping feeding
duct. The amount of fuel to send to the pumping is set by the
pressure control solenoid according to the PWM control
received by the electronic Central Unit. During the
compression stage of the pumping, the fuel reaches such a
pressure to open the delivery valve to common rail and
supply it through the outlet.
Figure 36
1, 3, 6. Pumping feed ducts - 2. Pump lubrication ducts -
4. Pumping feed main duct - 5. Pressure control solenoid -
7. Control exhaust duct - 8. Low pressure limiter valve -
9. Fuel feed duct from filter - 10. Fuel outlet.
In the section of Figure 36 the low pressure fuel paths inside
the pump are represented. The pumping feed main duct (4),
pumping feed ducts (1, 3, 6), ducts used for pump lubrication
(2), the pressure control valve (5), the low pressure limiter
valve (8) and the fuel exhaust (10), are outlined. The pump
shaft is lubricated by the fuel through the delivery and
backflow (2) ducts. The control valve enables to define the
fuel amount by which feeding pumpings; the excess fuel
backflow through duct (9).
The lower pressure limiter valve in addition to operate as
manifold of the high pressure pump fuel drainage, also keeps
pressure constant at the regulator inlet.
D-D section
B-B section
C-C section
MAY 2012 1.32
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
Figure 37
1, 2. Fuel outlet ducts - 3. Fuel outlet from the pump with
connector for high pressure piping for common rail
In the section of Figure 39 the fuel flowthrough the pumping
outlet ducts is represented.
A-A section
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
144833
Operation
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on
the pumping elements (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing
in the rail.
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure
circuit.
The pumping element compresses the fuel till the top dead
center (delivery stroke) is reached. Afterwards, the pressure
decreases till the exhaust valve is closed.
The pumping element piston goes back towards the bottom
dead center and the remaining fuel is decompressed.
When the pumping element chamber pressure becomes less
than the supply pressure, the intake valve is again opened and
the cycle is repeated.
The delivery valves must always be free in their movements,
free from impurities and oxidation.
The rail delivery pressure is modulated by the electronic
control unit, through the pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.
1. Rail - 2. Fuel return - 3.Pipelines to injectors - 4. Fuel
supply to high pressure pump - 5. Pressure sensor -
6. Overpressure valve
The rail volume is of reduced sizes to allow a quick
pressurisation at startup, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise use of plenum
chambers caused by injectors openings and closings and by
the high-pressure pump operation. This function is further
enabled by a calibrated hole being set downstream of the
high-pressure pump.
A fuel pressure sensor (5) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
value is checked and, if necessary, corrected.
Electroinjector
RAIL (PRESSURE ACCUMULATOR)
114255
Figure 38
Figure 39
1. Fuel return hole - 2. Fuel supply
MAY 2012 1.34
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
Figure 40 Figure 41
EDC 7 UC31 Electronic Central Unit
A. Connector for components assembled on engine -
A1. Electro-injector connector - B. Connector for
connections on the boat side.
The Electronic Central Unit (or ECU) is the component
operating the entire injection system. The process begins
with the start up of the main program and the run-up
procedure that enables to recall into the RAM those data
which, having characterized the engine management until the
previous stop, were stored into the non-volatile memory
E
2
PROM by the after-run procedure. After the run-up, the
test of the blink code light signalling EDC anomalies and the
procedures which lead to the start of the engine, follow;
during such procedures the presence and consistency of the
sensors electric signals are checked. The start of the
computer application routine of time and injection advance,
is preceded by the analogue-digital conversion of the data
coming from the sensors. At the end of the processing, the
final data still in digital format are transferred to the various
final and power stages, which will control (with the proper
ways) the electro-injectors and the system actuators.
Air pressure/temperature sensor
It integrates a temperature sensor and a pressure one.
Positioned at the entrance of the intake manifold, it produces
a signal that is proportional to the absolute pressure value of
the intaken and supercharged air. This information, together
with the temperature, enables to adequate time and advance
to the density of the comburent air, in order to reach the
maximum thermodynamic efficiency avoiding harmful
emissions and smoke. The pressure sensor is a solid state type
with an amplifier electronic circuit adjusted for thermic drift,
while the comburent air temperature sensor is a resistor with
negative temperature coefficient.
The pressure sensor is powered by a 5 V voltage and the
output voltage is proportional to the pressure detected.
The temperature sensor has a resistance of about 2.5 k at
20 C temperature.
Atmospheric pressure sensor
Located inside the ECU, it produces a useful datum to
adequate injection procedures to the different positive
displacement of the engine caused by the changes of the
environmental pressure conditions.
08_053_C
08_024_C
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 42 Figure 43
Oil pressure/temperature sensor
The body of the sensor is similar to that of the air
pressure/temperature sensor and the functions carried out
are analogous. It is assembled onto the engine oil filter
support, to measure the engine oil temperature andpressure.
The signal detected is sent to the ECUEDCthat manages the
lowpressure indicator light. In this appliance, pressure and oil
temperature values are not shown by instruments but the
data are used by the ECU to carry out the monitoring
functions. In order to control the oil pressure gauge on the
instrument panel, a specific sensor is used.
The pressure sensor is powered by a 5 V voltage and the
output voltage is proportional to the pressure detected. The
temperature sensor has a resistance of about 2.5 kat 20C
temperature.
Crankshaft sensor
It is a variable reluctance inductive type, which generates
periodical alternate signals due to flow variation in the
magnetic circuit produced inside the cranckshaft by the
presence of a permanent magnet. It faces the pulley keyed on
the crankshaft to detect the passage of 58 tooths for every
revolution. The number of 58 tooths has been derived by a
constant pitch of 6 which would lead to a total of 60 tooths,
2 of which have been eliminated to generate an asimmetry of
the signal that the ECU EDC uses as crankshaft positioning
reference.
The signal of this sensor is processed in the ECU to assess:
- Engine rotation speed;
- Engine crankshaft acceleration;
- Angular position of the engine in respect to the TDC(top
dead center) of the pair of pistons.
It originates the information of the engine RPM on the
instrument and control panel.
The interruption of the signal of this sensor during engine
operation is provided by a recovery of ECU actuated using
the signal of the camshaft sensor, thus enabling the engine to
carry on operating. The solenoid is connected to terminals 1
and 2 and has a resistance of about 900 . Terminal 3 is
connected to the electric shielding and is insulated from the
sensor.
05_086_C
MAY 2012 1.36
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
Figure 44 Figure 45
Camshaft sensor
It is an inductive type like the previous one, and generates a
signal at the passage of 6 + 1 slots located on the toothed
wheel set into rotation by the camshaft.
Six reliefs equidistant among themselves provide the signal of
the following one another of the strokes in the 6 cylinders;
the seventh relief provides the synchronism signal enabling
to recognize the typical injection sequence: 1 - 4 - 2 - 6 - 3
- 5.
The interruption of this signal during the operation of the
engine is overcomed by having stored in ECU the injection
sequence; if it is occurred before the starting it requires that
a specific stroke recognition strategy is actuated.
The solenoid is connected to terminal 1 and 2 and has a
resistance of about 900 . Terminal 3 is connected toelectric
shielding and is insulated from sensor.
Coolant temperature sensor
It is a resistor with negative temperature coefficient and is
positioned on the cylinder head at a short distance from the
thermostatic valve. It provides the indication of the metering
and the advance during the various engine strokes:
- Cold starting;
- Putting in a steady state;
- Steady state;
- Overtemperature.
The recognition of the overtemperature condition leads ECU
to activate derating strategies in order to reduce heat intake
and protect engine efficiency.
The sensor has a resistance of about 2.5 k at the
temperature of 20 C.
05_086_C
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 46
Figure 47
Figure 48
Fuel temperature sensor
1. Fuel temperature sensor
It is identical to the coolant temperature sensor and it is
positioned on the fuel filter bracket.
It provides a useful datum to recognize the fuel density that
feeds the electro-injectors in order to adequate the injection
time to the real quantity to be injected. The derating
strategies, used when the fuel critical temperature is
overcome, are due to the sensitive reduction of its lubricating
action caused by the temperature increase. Sometimes these
strategies become evident by the limitation of the maximum
performance of the engine.
The ECU activates the relay for the filter heating element
with a fuel temperature 0 C and heats up + 5 C.
Temperature sensor has a resistance of about 2.5 , at 20C.
Fuel pressure sensor on rail
Fitted to one end of the rail, it measures the pressure of the
existing fuel in order to determine the injection pressure.
The injection pressure value is used to control the injection
pressure and to determine the duration of the electrical
injection command
It is powered at 5 V.
Throttle lever position
It provides the primary indication for the reckoning of the fuel
amount to be injected.
It is operated by the linkage of the controls on bridge or
assisted, produces in output a potentiometric variation of the
voltage which supplies it, in relation to the position where the
throttle lever is set.
A simultaneous safety indication is provided by the internal
switch to confirm the acceleration position: minimum - out
of minimum.
Such an indication in addition to the self-adative strategies of
the potentiometric signal, is used in the case of anomalies to
manage limp-home strategies, that enables to get back to
harbour notwithstanding the potentiometer being faulty.
114620
Ref Description
1
2
3
Earth
Pressure
Power supply
MAY 2012 1.38
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
SYSTEM FUNCTIONS
By means of the computer electronic management it is
possible to actuate in fast sequence both primary functions
such as metering computation and injection advance and
secondary ones, only necessary in special conditions.
Metering and advance, actuated three times per every
crankshaft revolution, are selectively calculated cylinder by
cylinder at every injection, while secondary functions as the
acceleration management or heating element on fuel filter
activation are controlled only when necessary.
Moreover the electronic unit is programmed to carry out
continuous checks on presence and consistency of the
signals originated from the system sensors, to timely notify
the onset of faults or actuate the exclusion of a datum
whenever its content is in contrast with the logic sequence
of the events occurred up to that moment.
Run up
Immediately after having electrically powered up the system
(key is in the ONposition), the central unit before setting on
the cranking motor, transfers into the main working memory
data which have characterised the best engine operation
during the previous operation period; they represent the
progressive engine ageing and they progressively evolve with
usage.
By using this function, engine management is always
optimized even fromthe first operation stages, indipendently
from the usage conditions of the engine.
The data transferred after the run-up are those stored after
the last engine stop during the after run function.
Starting
It is the management stage of the engine functions
characterised by the adotpion of useful strategies to a fast
reaching of the endothermic engine functions.
Among the restrained signals the most evident is the
recognition of the throttle position that does not require to
be operated until the starting procedure is concluded.
Metering and fuel injection
It is carried out by the span of time of the injectors electric
control fed by the pressurized fuel in the common rail
distributor.
Fuel pressure in the common rail distributor is made to
change according to the performance goals required fromthe
engine.
The primary datum of the amount of fuel to be injected is
calculated according to the information of:
- Throttle position;
- Engine number of RPM.
This datum is further adjusted according to the data of:
- Comburent air pressure and temperature;
- Fuel temperature;
- Engine coolant temperature.
It may be modified by linearization for acceleration gradient,
the minimum RPM, to avoid overspeed or to control limit
condition of engine operation.
The span of time of the electro-injector control which sets
the real quantity injected is, moreover, related to the fuel
pressure datum detected on the common rail distributor and
the battery voltage.
Only in case of anomalies which entail serious damages for
the engine, injection time zeroing is reached.
Injection advance management
It is obtained by changing in the span of time of one revolution
of the crankshaft the instant of the electric control beginning
of the electro-injectors.
The values actuated may vary from one injection to the next
and in the same way as for the metering varied among the
cylinders.
The parameters affecting the injection advance are:
- Throttle position;
- Engine RPM;
- Comburent air temperature and pressure;
- Fuel temperature;
- Coolant temperature.
The values are determined experimentally in order to obtain
the best performance and at the same time complying with
containment goals on acoustic and fumes emissions.
A further dynamic adjustment during the acceleration phase
gives the engine a greater static torque.
The information to check the actuated value obtained in
loop is provided by the electro-injector solenoid
impedance change.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Pre-injection
This term indicates the delivery of a limited amount of fuel
that is obtained in the short interval of opening and closing
of the spray-nozzle metering rod, before the main injection.
Pre-injection is programmed in the ECU and it is possible up
to 2,000 RPM. Its purpose is to limit the pressure increase
gradient within the combustion chamber to reduce its peaks
and contain typical noise of the direct injection engines.
The amount of fuel injected is an integral part of the main
metered injection.
Injection pressure modulation
The best and more reliable torque and power delivery,
complying with fumes and acoustic emission containment, is
made possible by having a high pressure fuel delivery and by
using injectors having a high atomization. In order to conform
fuel metering with the high dynamics required by the engine
control, apart from managining the injection time, managing
the pressure of the fuel injected is also necessary.
This goal is obtained in loop by using the datum supplied by
the pressure sensor located on the common rail distributor.
Idling adjusting
This function enables to obtain a constant and repeatable
RPM notwithstanding the changing of the operational
environmental conditions. The adjustment is obtained by
managing metering and the injection beginning instant
according to the processing of the information produced by
the sensors.
If battery voltage is below efficiency rating, ECU increases
rotation to improve alternator recharging.
Self-diagnosis
It is the constant check of the presence of the electrical
signals sent by the sensors or delivered to actuators. In the
case of anomalies being detected, it enables the electronic
unit to process data according to a recovery programme.
The central unit not only checks the efficiency of the sensors,
actuators and wiring connected to them, but also checks a
consistency evaluation of the signals and the information
deducted from them.
It is possible to recognise an inconsistency and not use an
invalidated datum replacing it with that one predefined by
means of comparison with pre-programmed limit
parameters or by assessing their increasing or decreasing
gradient. The recovery procedure is integrated by the
storing of the codes identifying the errors detected. These
codes can be decoded by using diagnostic computerized
appliances or by means of a blinking light named blink code.
EDC indicator light
It is located on the instrument and control panel, is directly
controlled by the EDC system from the central unit. It is
normally off, it will come on for an instant immediately after
having supplied the system by means of an efficiency test.
If lit, the EDCindicator shows a likely anomaly of the injection
system or an irregular engine operation or of one of its
machine parts.
Fuel heating
It assures a correct density of the fuel even at low
temperatures, improving atomization in order to obtain a
better gradient smoke and emissions.
The heating element is activated on the filter according to the
temperature detected.
Linearization of the acceleration gradient
The exhaust and acoustic noxious emissions containment has
been obtained by implementing strategies especially to
control the injection required for accelerations. Management
of the fuel metering and advance, during transient states, has
been obtained by devising experimental progression modes
stored in the central unit.
Balance of the cylinder torque delivery
It contributes to reduce vibrations and equilibrates its
operation.
It is obtained by controlling delivery and injection advance
cylinder by cylinder; in such a way it is possible to adequate
crankshaft angular acceleration produced by each
combustion to equal ratings.
Cylinders balance can be carried out only at idle speed, due
to software structure complexity, but data thus gathered with
a wise adaptation, can be used for higher speed too.
Rotation speed control
It represents the electronic equivalent of the speed controls
of the traditional injection pumps.
Like the latter it has the following adjustment characteristics:
- Minum and maximum;
- Every speed.
Top speed limitation
It preserves the efficiency of the engine operation by not
allowing overspeed even if accidental.
Limitation strategies are actuated in the following ways:
- When the first threshold is overcome, fuel delivery
reduces progressively;
- When the expected top speed has been reached, fuel
delivery is zeroed.
MAY 2012 1.40
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
Cut off
It consists of non injecting fuel during the engine deceleration
phase. The function is operating until the idle speed is
reached below which it would be impossible to restore
engine thermic operation.
Derating
It can be considered as a recovery programme. It does not
produce a storage of an anomaly record. It is caused by the
recognition of fuel high temperature, coolant, or comburent
air. Derating consists of reducing the torque delivered by the
engine to preserve it from operation inefficiency. It takes
place when overcoming preset thresholds, in a way
proportional and gradual to the amount of the overcoming
of parameter; it does not entail fault signalling on the
instrument panel.
Recovery
It is a special way of control and management characterised
by the adoption of a number of strategies which enable the
system to operate even in the case selfdiagnosis has
recognized the presence of anomalies. In the majority of
cases seafaring can be continued regularly or with reduced
performance.
Adopting a recovery strategy entails the storing of an
anomaly code and the corresponding limitation of the
maximum power rating delivered by the engine.
The power rating limitation due to recovery strategy is active
up to the stopping of the engine even if the anomaly detected
is not there anymore. The blink code light on the instrument
and control panel will turn on only for the most serious
events.
After run
The stage following after every engine stop. It is characterised
by the delay in deenergizing the main supply solenoid
contained inside the ECUEDC. During this phase the central
unit is still powered for some seconds, during which the data
that have characterised the optimized management of the
engine up to that moment, are transferred from the main
volatile memory to the EEPROMnon volatile memory; these
data will then be available for the next starting.
These data can be summarised into:
- Management modes (idle speed, torque delivery balance,
smoke limit...);
- Threshold setting min/max of signal recognition;
- Fault memory.
At every start up it is important to have available the data that
optimize the management and the engine behaviour in terms
of TORQUE AND POWER DELIVERY. It is therefore
mandatory to use engine stopping strategies (e.g. battery
disconnection) not different from those prescribed by the
manufacturer (key in OFF position) or which may prevent
the correct execution of the after run function.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 1.42
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERVIEW
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 TECHNICAL DATA 2.43
SECTION 2
Technical data
Page
SPECIFICATIONS C87 ENT M62.10 / M62.11 47 . . . .
SPECIFICATIONS C87 ENT M65.10 / M65.11 48 . . . .
MAY 2012 2.44
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TECHNICAL DATA
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Injection system
Type HPCR
System Bosch EDC7 UC31
Maximum injection pressure bar 1600
Low temperature starting
Allowed, without external aids, down to C -15
With electrical heating of intake air (optional), down to C -25
With additional external heater, down to C -30
Cooling
Closed coolant loop with
sea water heat exchanger
50% mixture of water/Paraflu 11 or
equiv. Compliant with SAE J 1034
specification
Total coolant quantity liters 38
Engine-only capacity liters 16
Expansion tank standard
Forced circulation centrifugal pump
Flow rate at maximum rpm (Freshwater) l/h 22440
Temperature regulation
Initial opening C
with thermostatic valve
68 78
Sea water line forced circulation
Sea water pump centrifugal self-priming
Max. pump capacity (Sea water) l/h 20000
Exhaust gas expulsion
Optional stack
Optional riser
Electrical system
Nominal voltage Vcc 24
Self-regulated alternator:
Voltage
Maximum current intensity
Vcc
A
28
90
Electrical starter motor:
Nominal voltage
Absorbed electrical power
V
W
24
4500
Recommended batteries capacity Ah 120
Current discharge at - 18 C (SAE J 537) A 900
Dimensions
Figure 1
Sizes in mm
143679
MAY 2012 2.46
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TECHNICAL DATA
Drive train coupling
Flywheel diameter mm (inches) 355 (14)
Flywheel case type SAE 1
Weights
Without liquids and without gearbox kg 940
ATTENTION
Low temperature diesel
EN 590 specifications distinguish different classes of diesel fuel, identifying the characteristics of those best suited to low
temperatures. It is entirely up to the Oil companies to comply with these regulations, which foresee that fuels suited to the
climactic and geographic conditions of the various Countries be distributed.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
SPECIFICATIONS C87 ENT M62.10 / M62.11
Cycle
Charge
Injection
4-Stroke Diesel
Supercharged and intercooled
Direct
Number of cylinders 6 in line
Bore mm 117
Stroke mm 135
Total displacement cm
3
8710
Compression ratio 16 to 1
Maximum power kW 456
Speedat maximum power rpm 2530
Direction of rotation, flywheel side counterclockwise
Minimum idling rpm rpm 600
Maximum engine rpm, no load rpm 2700
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 +10
Supercharge
Turbocompressor with water-cooled body HOLSET HX 55WM
Maximum pressure bar 2.2
Lubrication
Oil type ACEA E7/E4 (URANIA LD5)
Oil compliant with specifications SAE 15W-40
Total oil capacity on first filling liters (kg) 28.5 (25.5)
Total oil capacity with sump at minimum level liters (kg) 15.5 (14)
Total oil capacity with sump at top level liters (kg) 24 (21.5)
Oil pressure, warm engine, minimum idling rpm bar 2
Oil pressure, warm engine, maximum rpm bar 5.0
Maximum allowed temperature C 105
Oil dipstick valid for static inclination degrees/360 0 to + 10
Fuel supply
Fuel oil compliant with standard EN 590*
Low pressure transfer pump gear pump
Flow rate at maximum rpm kg/h 104.8
Fuel return flow rate to tank kg/h -
Filtering: pre filter m 36.5
Filtering: filter m 5
ATTENTION
Low temperature diesel
EN 590 specifications distinguish different classes of diesel fuel, identifying the characteristics of those best suited to low
temperatures. It is entirely up to the Oil companies to comply with these regulations, which foresee that fuels suited to the
climactic and geographic conditions of the various Countries be distributed.
MAY 2012 2.48
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TECHNICAL DATA
SPECIFICATIONS C87 ENT M65.10 / M65.11
Cycle
Charge
Injection
4-Stroke Diesel
Supercharged and intercooled
Direct
Number of cylinders 6 in line
Bore mm 117
Stroke mm 135
Total displacement cm
3
8710
Compression ratio 16 to 1
Maximum power kW 478
Speedat maximum power rpm 2530
Direction of rotation, flywheel side counterclockwise
Minimum idling rpm rpm 600
Maximum engine rpm, no load rpm 2700
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 +10
Supercharge
Turbocompressor with water-cooled body HOLSET HX 55WM
Maximum pressure bar 2.2
Lubrication
Oil type ACEA E7/E4 (URANIA LD5)
Oil compliant with specifications SAE 15W-40
Total oil capacity on first filling liters (kg) 28.5 (25.5)
Total oil capacity with sump at minimum level liters (kg) 15.5 (14)
Total oil capacity with sump at top level liters (kg) 24 (21.5)
Oil pressure, warm engine, minimum idling rpm bar 2
Oil pressure, warm engine, maximum rpm bar 5.0
Maximum allowed temperature C 105
Oil dipstick valid for static inclination degrees/360 0 to + 10
Fuel supply
Fuel oil compliant with standard EN 590*
Low pressure transfer pump gear pump
Flow rate at maximum rpm kg/h 104.8
Fuel return flow rate to tank kg/h -
Filtering: pre filter m 36.5
Filtering: filter m 5
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Injection system
Type HPCR
System Bosch EDC7 UC31
Maximum injection pressure bar 1600
Low temperature starting
Allowed, without external aids, down to C -
With electrical heating of intake air (optional), down to C -25
With additional external heater, down to C -30
Cooling
Closed coolant loop with
sea water heat exchanger
50% mixture of water/Paraflu 11 or
equiv. Compliant with SAE J 1034
specification
Total coolant quantity liters 38
Engine-only capacity liters 16
Expansion tank standard
Forced circulation centrifugal pump
Flow rate at maximum rpm l/h 42300
Temperature regulation Initial opening
C
with thermostatic valve
68 78
Sea water line forced circulation
Sea water pump centrifugal self-priming
Max. pump capacity l/h -
Exhaust gas expulsion
Optional stack
Optional riser
Electrical system
Nominal voltage Vcc 24
Self-regulated alternator:
Voltage
Maximum current intensity
Vcc
A
28
90
Electrical starter motor:
Nominal voltage
Absorbed electrical power
V
W
24
4500
Recommended batteries capacity Ah 120
Current discharge at - 18 C (SAE J 537) A 900
Dimensions
Figure 1
Sizes in mm
143679
MAY 2012 2.50
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TECHNICAL DATA
Drive train coupling
Flywheel diameter mm (inches) 355 (14)
Flywheel case type SAE 1
Weights
Without liquids and without gearbox kg 970
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 ELECTRICAL EQUIPMENT 3.51
SECTION 3
Electrical equipment
Page
ELECTRICAL EQUIPMENT 53 . . . . . . . . . . . . . . . . . . .
PARTS AND COMPONENTS ENGINE 58 . . . . . . . . .
M62.10 / M65.10 Engines 58 . . . . . . . . . . . . . . . . .
M62.11 / M65.11 Engines 59 . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM 61 . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mitsubishi 90A 62 . . . . . . . . . . . . . . . . . . . . . . . . .
Specification 62 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL STARTER ENGINE 63 . . . . . . . . . . . . . .
Nippondenso model 63 . . . . . . . . . . . . . . . . . . .
Specification 63 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTIONS OF THE CENTRAL
ELECTRONIC UNITCONVERTER
MODULE 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification of terminal function 64 . . . . . . . . . . .
EQUIPOTENTIAL CONNECTIONS TO
ENGINE GROUND 68 . . . . . . . . . . . . . . . . . . . . .
M62.10 / M65.10 Engines 68 . . . . . . . . . . . . . . . . .
M62.11 / M65.110 Engines 69 . . . . . . . . . . . . . . . .
MAY 2012 3.52
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ELECTRICAL EQUIPMENT
Figure 1
10_032_C
1. Eelectronic Unit - 2. Mm Connector - 3. Wiring harness to be manufactured by the yard - 4.M Sensor for the presence of
water in the fuel - 5. Sedimenting pre-filter - 6. Power line for electric starter motor and alternator - 7. Relay box -
8. JECCM and JECCF connectors - 9. Analog to digital converter module -10. JG connector - 11. JSV connector - 12. JQA
connector set for connection to the main analog instrument panel - 13. Connector JE - 14. Connector JH - 15. Connector
JQ - 16. Connector J3 - 17. Connector J4 - 18. Connector - 19. Connector J2. - 20. Extension cables available in 3,5,7,10
and15
The electrical equipment of the engine comprises a series of
components provided separately from the engine to enable
an easy and diversified installation, according to the Yard's
design choices. The need to make accessible, at sea or
underway, the controls to the electrical components and to
the connector for diagnostics contained in the relay box may
be met through different installation arrangements.
Together with the coupling of all the wiring connectors it is
necessary to carry out the connection wiring (3) for the
water in fuel sensor (4), the power network and the
connection of the accumulator with the engine wiring, in
order to complete the installation In order to activate the
function which stops the engine in case of excitation, it is
necessary to connect the JECCMand JECCF connectors with
each other.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 2
143680
1. Electroinjector - 2. Wires passage - 3. Coolant temperature sensor - 4. Oil pressure/temperature sensor -
5. Combustion air pressure/temperature sensor - 6. EDC connector A1 - 7. EDC connector A -
8. Fuel temperature sensor - 9. Camshaft sensor - 10. Crankshaft sensor - 11. Rail pressure sensor -
12. Pressure regulating electrical valve.
Engine cable
MAY 2012 3.54
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 3
10_034_C
EDCA. EDC connector A - C. Camshaft sensor - B. Crankshaft sensor - VS. Oil pressure/temperature sensor -
HP. Combustion air pressure/temperature sensor - ZH. Fuel high-pressure pump sensor - A. Fuel temperature sensor -
F. Coolant temperature sensor - PR. Rail pressure sensor - 1. Electroinjector - EDCA1. EDC connector A1
Engine cable wiring diagram
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 4
143681
Wiring layout engine
A
.
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.
MAY 2012 3.56
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 5
10_035_C
Wiring layout engine
J
B
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/
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C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 6
177444
1. Air filter - 2. Common rail high pressure injection pump - 3. Air/sea-water heat exchanger - 4. Air pressure/temperature
sensor - 5. Chimney exhaust gas (pot.) - 6. Engine coolant-sea water heat exchanger - 7. Oilfilter - 8. Coolant temperature
sensor - 9. Thermostatic valve - 10. Alternator - 11. Inverter oil heat exchanger - 12. Electrical starter motor - 13. Sea water
pump - 14. Fuel Filter.
MAY 2012 3.58
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
PARTS AND COMPONENTS ENGINE
M62.10 / M65.10 Engines
Figure 7
174587
1. Air filter - 2. Common rail high pressure injection pump - 3. Air/sea-water heat exchanger - 4. Air pressure/temperature
sensor - 5. Chimney exhaust gas (pot.) - 6. Engine coolant-sea water heat exchanger - 7. Oil filter clogging - 8. Coolant
temperature sensor - 9. Thermostatic valve - 10. Alternator - 11. Inverter oil heat exchanger - 12. Electrical starter motor -
13. Sea water pump - 14. Fuel Filter.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
M62.11 / M65.11 Engines
Figure 8
10_030_C
1. Connector JB - 2. Coolant expansion tank - 3. Coolant refill cap - 4. Coolant low level sensor - 5. Lifting U-bolt - 7. Oil
refill cap - 8. Clogged fuel filter sensor - 9. Clogged air filter sensor - 10. Cooled turbo-charger - 11. Exhaust gas and sea
water discharge - 12. Camshaft sensor - 13. Accelerator potentiometer position sensor - 14. Oil dipstick - 15. Cooled
exhaust manifold - 16. Oil sump emptying pump.
MAY 2012 3.60
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
1. Equipment power supply - 2. Batteries -
3. Electric starter motor - 4. Alternator - 5. Grid heater
The connection of the +B terminal of the alternator to the
positive+30 terminal of the electric startermotormust be
achieved with a conductor having a cross section of at least
40 mm
2
. The connection of the positive +30 terminal of the
electric starter motor to the positive pole of the battery,
achieved with a conductor having a cross section of at least
95 mm
2
, allows to obtain, as shown in the figure, the
simultaneous connection of the alternator to the battery.
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.
The connection (*) between alternator terminal B- and
terminal 31 of the starter motor must be made only in the
case of an isolated terminal system and the cross-section
must be equal to 40 mm
2
.
The connection (**) for the thermal starter relay is the
responsibility of the customer and the cross-section must be
equal to at least 16 mm
2
.
ATTENTION
If magneto-thermal protecting breakers are inserted, they
must not be used to stop the engine and in any case they
must be activated only a few seconds after shut-down.
Figure 9
09_061_N
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ELECTRICAL SYSTEM
MAY 2012 3.62
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ALTERNATOR
Nominal voltage 28.3 0.5V (20C)
Nominal current 90 A
Rpm for min power ~ 1800 rpm
Rpm for max power ~ 5000 rpm
Polarity negative ground
Rotation clockwise viewed from
pulley
Belt poly V
Belt tension 730 N
Weight 7.0 kg
Figure 10
Mitsubishi 90A
+B. (24 V) Power supply output terminal
S. (Sense) Reference voltage of battery charge status
(connected to +B terminal or to be
connected to the positive pole of the battery
in case of remote installation of the battery);
IG. (Ignition) Regulator enabling signal (connected to
voltage +, driven by key switch);
L. (Lamp) Power supply voltage of recharge/alarm
indicator light located on the panel.
05_093_C
Alternator speed (rpm x 1000)
CHARACTERISTIC CURVES
Figure 11
O
u
t
p
u
t
c
u
r
r
e
n
t
(
A
)
Specification
81797
Ambient temp. 25 C
Ambient temp. 90 C
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ELECTRICAL STARTER ENGINE
Nominal power 5.5 kW
Nominal voltage 24V
Polarity negative ground
Engagement circuit positive command
Rotation clockwise viewed from
pinion end
Weight ~ 10.5 kg
Operating voltage 26V MAX (20 C)
Water resistance spray test based on JIS
D0203 SI
Condition (20 C) Voltage (V) Current (A) Speed (rpm) Torque (Nm)
No load 23 120 3800 -
Load 16 690 900 49
Stall 6 1260 0 73.5
Figure 12
Figure 13
81799
+50 Starter control
Engine
electrical
ground
connection
point
81800 Current (A)
CHARACTERISTIC CURVES
Nippondenso model
Specification
MAY 2012 3.64
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
CONNECTIONS OF THE CENTRAL ELECTRONIC UNITCONVERTER MODULE
Pin Function
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 Timing sensor
10 Timing sensor
11 -
12 Negative for rail temperature and pressure sensor
13 Positive for rail temperature and pressure sensor
14 Signal from rail temperature and pressure sensor
15 Coolant temperature sensor
16 -
A. 36 poles connector - A1. 16 poles connector -
B. 89 poles connector.
The connection of the central electronic unit, the ECU, to
the components of the EDC system is achieved by means of
three connectors so as to subdivide the wiring harnesses,
thereby favoring a quicker identification of the lines during
testing operations.
The different connectors are polarized and provided with
levers to favor the connection and disconnection operations
and assure proper coupling.
They are dedicated to the following functions:
- Connector A for engine mounted components;
- Connector A1 for electro-injector connection;
- Connector B for boat side connections.
Identification of terminal function
EDC A Connector
Figure 14
Figure 15
08_024_C
EDC A1 Connector
Figure 16
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Pin Function
17 -
18 Signal from fuel temperature sensor
19 Engine rpm sensor
20 -
21 -
22 -
23 Engine rpm sensor
24 Negative for engine oil pressure and temperature
sensor
25 Negative for air temperature and pressure sensor
26 Coolant temperature sensor
27 Signal from engine oil pressure sensor
28 Signal from engine oil temperature sensor
29 -
30 -
31 -
32 Positive for engine oil pressure and temperature
sensor
33 Positive for air temperature and pressure sensor
34 Signal from air pressure sensor
35 Negative for fuel temperature sensor
36 Signal from air temperature sensor
Pin Function
1 Injector cylinder 5
7 -
8 -
9 Pressure regulator
10 Pressure regulator
EDC B Connector
Figure 17
MAY 2012 3.66
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Pin Function
1 -
2 Supply
3 Supply
4 -
5 Ground
6 Ground
7 -
8 Supply
9 Supply
10 Ground
11 Ground
12 Positive for grid heater relay
13 Positive for fuel filter heating relay
14 -
15 -
16 -
17 Starting relay negative voltage
18 -
Pin Function
19 -
20 -
21 Neutral switch input
22 -
23 -
24 -
25 -
26 -
27 -
28 -
29 Digital round
30 -
31 -
32 Signal for start engine from box relay
33 -
34 Line CAN - L
35 Line CAN - H
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Pin Function
36 Negative voltage for fuel filter heater switch
37 Starting relay positive voltage
38 -
39 -
40 Positive voltage +15 under lock
41 -
42
Negative voltage from sensor detecting water in the
pre-filter
43 -
44 -
45 -
46 -
47 Signal for stop engine from box relay
48
Negative voltage from accelerator pedal idling
switch
49 -
50 -
51 -
52 -
53 -
54 -
55 -
56 -
57 -
58 -
59 -
60 -
61 -
62 -
Pin Function
63 -
64 -
65 -
66 Neutral switch input
67 -
68 -
69 -
70 -
71 -
72 -
73 -
74 -
75 Negative for grid on heater
76 -
77 Supply voltage for accelerator potentiometer
78 Negative for accelerator potentiometer
79 Signal from accelerator potentiometer
80 -
81 -
82 -
83 -
84 -
85 Signal for start engine from box relay
86 -
87 -
88 -
89 ISO K interface
1, 2, 3, 4. Copper braids
Figure 18
To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean and
not oxidized. Thoroughly inspect and remove any impurities before each reinstallation procedure.
ATTENTION
To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean
and not oxidized. Thoroughly inspect and remove any impurities before each reinstallation procedure.
147000
MAY 2012 3.68
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
EQUIPOTENTIAL CONNECTIONS TO ENGINE GROUND
M62.10 / M65.10 Engines
1, 2, 3, 4. Copper braids
Figure 19
To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean and
not oxidized. Thoroughly inspect and remove any impurities before each reinstallation procedure.
ATTENTION
To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean
and not oxidized. Thoroughly inspect and remove any impurities before each reinstallation procedure.
174588
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
M62.11 / M65.110 Engines
MAY 2012 3.70
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 DIAGNOSTICS 4.71
SECTION 4
Diagnostics
Page
FOREWORD 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PT - BOX 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GUIDE TO SYMPTOM DIAGNOSIS 75 . . . . . . . . . . .
FAULTS CODE - EDC 7 UC31 79 . . . . . . . . . . . . . . .
MAY 2012 4.72
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DIAGNOSTICS
Every time there is a breakdown claim and this breakdown
is actually detected, it is necessary to proceed inquiring the
electronic unit in one of the ways indicated and then
proceed with the diagnostic research making trials and tests
in order to have a picture of the working conditions and
identify the root causes of the anomaly.
In case the electronic device is not providing any indication,
it will be necessary to proceed relying on the experience,
adopting traditional diagnosis procedures.
A successful troubleshooting is carried out with the
competence acquired by years of experience and attending
training courses.
When the user complains for bad efficiency or working
anomaly, his indications must be kept into proper
consideration using them to acquire any useful information
to focus the intervention.
Using FPT processing instruments, it is also possible to
establish a bi-directional connection with the central unit, by
which not only to decoding the failure codes but also input
an enquiry relying on memory files, in order to achieve any
further necessary information to identify the origin of the
anomaly.
Any kind of operation on the electronic center unit must
be executed by qualified personnel, duly authorized by FPT.
Any unauthorized tamper will involve decay of after-sales
service in warranty.
ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
FOREWORD
Figure 1
PT - BOX
PT - BOX is a test tool to be connected to a Personal Computer.
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator -
5. Serial port indicator - 6. Error indicator - 7. CAN line indicator -
8. Line K indicator for automatic management
With the PT-BOX you can perform:
- Basic testing: central unit ID reading, failure memory reading, parameter reading, failure memory clearing and Flight
Recorder memory reading;
- Active testing: main component testing (actuators, contactors, etc..);
- Flight Recorder reading;
- ECU acknowledgement of replaced electronic components;
- 2
nd
level and PTO programming;
- Parameter acquisition during operation tests.
120995
MAY 2012 4.74
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DIAGNOSTICS
C
8
7
E
N
T
M
6
2
.
1
0
/
C
8
7
E
N
T
M
6
5
.
1
0
C
8
7
E
N
T
M
6
2
.
1
1
/
C
8
7
E
N
T
M
6
5
.
1
1
M
A
Y
2
0
1
2
D
I
A
G
N
O
S
T
I
C
S
4
.
7
5
GUIDE TO SYMPTOM DIAGNOSIS
Blink
Code
Symptom Part Possible cause Recommended tests or action
NO Engine does not start Batteries - Low charge
- Faulty terminal connections
- Recharge (disconnecting system
wiring)
- Clean, check, tighten terminals or
replace them
NO Engine does not start Electrical starter motor - Malfunction
- Check
- Clean, check, tighten terminals
NO Engine does not start Relay to control power
supply to terminal 50 of
the electric starter motor
(contained in the relay
box)
- Malfunction - Check supply wiring
- Check main relay, replace
NO Engine does not start Fuel feed pump - Priming incorrect (air leaking inside) - Check seal on intake branch
- Check pressure
NO Engine does not start Fuel circuit - Incorrect filling (air in fuel circuit) - Check seal
- Bleed circuit
NO Engine does not start Fuel filter and pre-filter - Filter and pre-filter clogged - Check reservoir
- Replace
NO Engine does not start Electrical grid heater (if
present), at temperatures
lower than 0 C.
- Malfunction
- Check supply and earth connection
- Carry out active diagnosis
M
A
Y
2
0
1
2
4
.
7
6
C
8
7
E
N
T
M
6
2
.
1
0
/
C
8
7
E
N
T
M
6
5
.
1
0
C
8
7
E
N
T
M
6
2
.
1
1
/
C
8
7
E
N
T
M
6
5
.
1
1
D
I
A
G
N
O
S
T
I
C
S
Blink
Code
NO Engine overheats Coolant level - Below MIN level - Check for leaks
- Top up correct level
NO Engine overheats Coolant pump drive belt - Loose tension
- Wear
- Check tension
- Replace
- Verify liquid spillage on the belt
NO Engine overheats Coolant pump - Malfunction - Check belt tension
- Replace
NO Engine overheats Thermostatic valve - Locked, closed or only partially open - Check coolant liquid
- Replace
NO Engine overheats Coolant-sea water heat
exchanger
- Clogged - Clean or replace
NO Engine overheats Air filter - Clogged - Check filter clogged indicator
- Replace filter
NO Engine overheats Cylinder head gasket - Compression leaking fromcylinder head gasket - Check water circuit pressure
- Replace head gasket
C
8
7
E
N
T
M
6
2
.
1
0
/
C
8
7
E
N
T
M
6
5
.
1
0
C
8
7
E
N
T
M
6
2
.
1
1
/
C
8
7
E
N
T
M
6
5
.
1
1
M
A
Y
2
0
1
2
D
I
A
G
N
O
S
T
I
C
S
4
.
7
7
Blink
Code
NO Poor performance Fuel circuit - Reservoir net filter clogged
- Fuel prefilter clogged
- Fuel filter clogged
- Air in fuel circuit
- Fuel pressure too low
- Heavy fuel leakage
- Replace clogged filters
- Check intake seals
- Check pressure relief valve on the fuel
gear pump
- Check the integrity of the fuel gear pump
NO Poor performance Injectors - Malfunction
- Fuel leaking from seal rings
- Check for fuel presence in engine
- Call FPT and follow their instructions to
replace the injectors
NO Poor performance Air filter - Clogged - Check filter clogged indicator
- Replace filter
NO Poor performance Gas exhaust system - Leaks from exhaust manifold - Check and remove cause of leak
NO Poor performance Turbocompressor - Blades inefficient
- Bearings inefficient
- Check parts and lubrication circuit
- Replace
NO Poor performance Control cams - Wear
- Incorrect timing
- Check, replace
- Check, restore
NO Poor performance Valves - Excessive or no clearance - Check, restore correct clearance
NO Poor performance Intake air pressure sensor - Output signal too low (below to the pressure
value)
- Using a multimeter on the component,
check the output voltage and refer to a
manometer
NO Poor performance - Intake air temperature
sensor
- Water temperature
sensor
- Fuel temperature sensor
- Output signal too high - Using a multimeter on the component,
check the resistance and refer to a
thermometer
M
A
Y
2
0
1
2
4
.
7
8
C
8
7
E
N
T
M
6
2
.
1
0
/
C
8
7
E
N
T
M
6
5
.
1
0
C
8
7
E
N
T
M
6
2
.
1
1
/
C
8
7
E
N
T
M
6
5
.
1
1
D
I
A
G
N
O
S
T
I
C
S
Blink
Code
NO The engine emits greywhite
smoke
Water in cylinders - Leakages from cylinder gasket
- Leakages from injector sleeves
- Water in intake system
- Water in fuel
- Check level and pressurization of water
circuit
- Check fuel tank, clean as required
- Check water in fuel sensor
The engine emits blue
smoke
Oil in cylinders - Excessive oil consumption
- Oil leaking in turbocompressor
- Oil leaking from valve guides
- Check lubrication oil consumption
- Overhaul
NO Engine stops Fuel reservoir - Fuel reservoir empty - Refill and bleed fuel circuit
NO Engine stops Net filter
Prefilter
Fuel filter
- Filter clogged - Clean, replace
NO Engine stops Fuel circuit - See item Poor performance - See item Poor performance
FAULTS CODE - EDC 7 UC31
Legend:
MAX = 3 Electronic control unit has read value OVER range
MIN = 4 Electronic control unit has read value UNDER range
SIG = 2 Electronic control unit has read a FAILURE of signal
NPL = 12 Electronic control unit has read of UNPLAUSIBILITY of signal
The fault codes depend on the application, therefore some may never be displayed during diagnosis.
ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DMx
SPN
DMx
FMI
Failure description
HEX
values
MAX
= 3
MIN
= 4
SIG
= 2
NPL
= 12
Vehicle 1 (Sensors/Plausibility checks)
111 x x x x Fault path 1 for vehicle Speed sensing
211 x x x x Fault path 2 for vehicle Speed sensing(CAN)
311 x x x Fault path 3 for veh. Speed (max.pulse width)
112 x Accelerator Pedal 1
212 x x x Accelerator Pedal 2
113 x Accelerator Pedal and brake not plausible
114 x x x Multiple State Switch
116 x x Main clutch signal
117 x x Brake signal
118 x Engine brake preselection switch status
119 x No terminal 15 signals detected
11A x Terminal 50 always pressed
11B x High resolution wheel speed CAN message
21B x Vehicle dynamics control unit CAN message
11C x Water in fuel
21D x x x x Catalyst ageing limit exceeded
31D x x x x DCU state monitoring
11E x NH3Slip
21E x x x x Catalyst efficiency lower than first Nox prediction threshold level
31E x x x x Catalyst efficiency lower than first Nox prediction threshold level
41E x x x x Catalyst presence monitoring
11F x x x x Plausibility check of catalyst system
21F x x x x Boost pressure actuator current monitoring
31F x x x x Too high efficiency of catalyst system
Vehicle 2 (Lamps/relays/actuators)
121 x x x x Adjustable speed limit lamp
122 x x x x Power stage fault status for MIL
123 x x x x Power stage for system lamp
124 x x x x Cold start lamp
224 x x x x Coolant temperature lamp
125 x x
Main relay defect (for High press pump P340/for engine brake
decompr.valve P342)
MAY 2012 4.80
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DIAGNOSTICS
DMx
SPN
DMx
FMI
Failure description
HEX
values
MAX
= 3
MIN
= 4
SIG
= 2
NPL
= 12
225 x Interrupted afterrun
126 x x Battery voltage fault
127 x x Eng.brake decompr.valve
128 x Main relay SCBatt (Lambda H./Grid H./Batt.switch)
228 x Main relay SCGND (Lambda H./Grid H./Batt.switch)
129 x x Main relay 3 (A/C compr./fuel filter heater)
12A x x Main relay 4 (Exhaust valve eng.brake flap)
22A x x x x Particulate filter lamp
12B x x x Power stage air heater 1 actuator
12C x x x Power stage air heater 2 actuator
12D x x Air heater test switch on (voltage<low thresh.)
22D x x Air heater test switch off (voltage>high thresh.)
12E x Grid heater always switched on
12F x x Air condition power stage CAN message
Engine 1 (Temperature and Pressure Sensors)
131 x x x x Coolant temperature sensor
132 x Coolant temperature sensor dynamic test
232 x Coolant temperature sensor absolute test
332 x x Engine temperature check
133 x x x Boost Temp. Signal
134 x x x x Boost pressure sensor
135 x x Fuel Temp. Signal
136 x x Rail pressure sensor CP3
236 x x x Rail pressure sensor offset monitoring
137 x x x Rail pressure relief valve
138 x x x x Oil Pressure Sensor
238 x Oil Pressure too low
338 x x x x Oil Pressure sensor lamp
13A x x x x Oil Temp. Sensor
23A x Oil Temperature above normal
13C x x x Atmospheric Temperature Sensor (Humidtiy?)
13D x x x Fuel pressure sensor
23D x x Fuel pressure sensor dynamic plausibility test
Engine 2 (Speed sensing/actuators)
141 x x Crankshaft sensor failure
142 x Running with camshaft sensor only
143 x x Camshaft sensor failure
144 x x Offset between camshaft and cranksh.
145 x x x x Power stage Fan actuator
146 x x Power stage Fan 2 actuator
147 x x Fan speed sensor signal
148 x x x x Air condition power stage
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DMx
SPN
DMx
FMI
Failure description
HEX
values
MAX
= 3
MIN
= 4
SIG
= 2
NPL
= 12
149 x x x x Fuel filter heating output
14A x Engine Compartment Start Button is stuck
24A x Engine Compartment Stop Button is stuck
14D x Engine overspeed protection
14E x x x x TurboCompound monitoring
Fuel metering CR Systems
151 x Rail pressure max.positive deviation exceeded
251 x Rail pressure positive deviation 2nd part
152 x Rail pr.max.pos.deviation exceeded conc.set flow of fuel
153 x
Maximum negative rail pressure deviation with metering unit on
lower limit is exceeded
154 x Minimum rail pressure exceeded
155 x Maximum rail pressure exceeded
156 x Rail pressure drop rate is higher than expected
157 x Setpoint of metering unit in overrun mode not plausible
158 x
Setpoint of fuel volume flow through metering unit is lower than
calculated limit
159 x x Metering unit PWM-powerstage
259 x Short circuit to battery of metering unit output
359 x Short circuit to ground of metering unit output
15A x x Metering unit AD-Channel
15B x High pressure test(deactivates rail pr.Monitor.)
15F x First collection fault path for potentially long term fault path
25F x Second collection fault path for potentially long term fault path
35F x Third collection fault path for potentially long term fault path
45F x Forth collection fault path for potentially long term fault path
55F x Fifth collection fault path for potentially long term fault path
Injectors 1
161 x x x x Cylinder1 - Short circuit Low/High
167 x x x x Cylinder1 - Open load
16A x x x x Cylinder4 - Open load
16B x x x x Cylinder5 - Open load
MAY 2012 4.82
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DIAGNOSTICS
DMx
SPN
DMx
FMI
Failure description
HEX
values
MAX
= 3
MIN
= 4
SIG
= 2
NPL
= 12
16C x x x x Cylinder6 - Open load
16D x Fault path to disable rail monitor. while compr.test active
16E x x x x The minimumnumber of injections was not reached -->stop theengine
16F x x x x Additive valve actuator
Injectors 2
171 x x x x Bank 1 specific errors - Short circuit / not classifyable
172 x x x x Bank 1 specific warnings - Open load
173 x x x x Bank 2 specific errors - Short circuit / not classifyable
174 x x x x Bank 2 specific warnings - Open load
175 x Misfire Cylinder 1
275 x x leakage or misfiring in cylinder 1
17A x Misfire Cylinder 6
27A x x leakage or misfiring in cylinder 6
17B x Misfire in multiple cylinders
17C x x x x Chip-specific errors-->stop engine
27C x x x x Chip-specific errors-->stop engine
17D x Common fault in combustion monitoring
17E x x x x Fault path of injection limitation
Air inlet system / EGR
181 x x Induction exhaust differential pressure
184 x Messages SRA2EDC
187 x AirCtl permanent positive governor deviaton
287 x AirCtl permanent positive governor deviaton
188 x AirCtl permanent negative governor deviaton
288 x AirCtl permanent negative governor deviaton
189 x Short circuit to Batt. for EGR power stage
289 x Short circuit to ground for EGR power stage
389 x x No load/excessive temp. for EGR power stage
18A x x x Power stage for EGR Bypass valve actuator
28A x x x Intercooler Bypass Valve Powerstage
18B x SC to BATT for throttle valve actuator powerst.
28B x SC to GND for throttle valve actuator powerst.
38B x x No load and excess temp. for TVA powerst.
18F x x x x Monitoring of Lambdasensor 1 Heater powerstage
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DMx
SPN
DMx
FMI
Failure description
HEX
values
MAX
= 3
MIN
= 4
SIG
= 2
NPL
= 12
Boost system and turbine speed
790 x Monitoring of the controller
191 x x x Boost pressure actuator current AD-channel
192 x Short circuit to Battery for BPA powerstage
292 x Short circuit to Ground for BPA powerstage
392 x x No load/excessive temp.for BPA power stage
193 x x x x Turbine speed
293 x x x x Actual turbo speed evaluation for interface
194 x Multi signal defects in EPCtl
195 x x x P2 pressure errors in EPCtl
196 x P3 pressure errors in EPCtl
197 x x x Turbine speed errors in EPCtl
198 x Multi signal defects in PCR
199 x x x P2 pressure errors in PCR
19A x x Turbine speed errors in PCR
19B x High turbine speed and high air pressure
19C x x P3 pressure errors in PCR
19D x Indicates torque limitation due to performance limiter
29D x Torque limitation due to NTC
39D x Performance limit active due to either stage
49D x Indicates torque limitation due to particulate filter
59D x Indicates torque limitation due to SCR
19E x Indicates torque limitation due to smoke limitation
29E x Indicates torque limitation due to turbo compound
39E x Indicates torque limitation due to turbo charger protection
49E x Indicates the torque limitation due to engine protection
59E x Indicates torque limitation due to noise control
69E x Indicates torque limitation due to Fuel quantity Limitation
19F x Multi signal defects in EGSys_NOxEstIv
Exhaust system (Aftertreatment)
1A1 x x x Lambda linear signal of Nox Sensor
2A1 x x x Lambda binary signal of Nox Sensor
1A2 x x x x Nox signal of Nox Sensor
2A2 x x x x NOx Sensor drift test
3A2 x x x x Nox Sensor plausibility test
1A3 x x x Heater of Nox Sensor
1A4 x Message Nox Sensor timeout
1A5 x Message DM1DCU timeout
1A6 x Message SCR1 timeout
2A6 x Message SCR2 timeout
1A7 x x x x Urea level error path
2A7 x SCR2 message: low urea level
MAY 2012 4.84
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DIAGNOSTICS
DMx
SPN
DMx
FMI
Failure description
HEX
values
MAX
= 3
MIN
= 4
SIG
= 2
NPL
= 12
3A7 x Not plausible CAN value of urea sensing
4A7 x Timeout for urea sensor
1A8 Error / Protection request on urea valve via SCR1
1AA x Not plausible CAN value of urea status
2AA x x x x Urea conductivity error path
3AA x x x x Urea concentration error path
1AB x x Exhaust gas temperature sensor before turbine
2AB x Exhaust Gas Pipe pressure sensor
1AC x x x x Heater used in EGR Mass Flow rate
2AC x CAN message EngGsFlowRt
1AD x x x x Recirculated Engine Exhaust Gas Temp. sensor
1AE x x Air humidity sensor
1AF x DM1DCU SPN1 message
Interfaces 1 (CAN-Bus)
1B1 x Busoff in CAN A
1B2 x Busoff in CAN B
1B3 x Busoff in CAN C
1B4 x Timeout for BC2EDC1
2B4 x Timeout for BC2EDC2
1B5 x Timeout for VM2EDC
1B6 x Timeout of CAN message WSI
1B7 x Timeout in CAN send messages
1B8 x Physical unplausibility of TSC-demand
1B9 x MIL visualization for BC2EDC1
1BA x Message Dashboard Display timeout
1BB x Message ERC1DR timeout
1BC x Message RxAMCONlv timeout
1BD x Timeout error of RxCCVS message
1BE x Physical plausibility DCS
1BF x CAN message RxEngTemp2
Interfaces 2 (CAN messages timeout)
1C1 x Timeout of CAN message EBC1
1C2 x Timeout of CAN message ETC1
1C3 x Timeout of CAN message TCO1
2C2 x Timeout of CAN message ETC2
1C4 x Timeout of CAN message TSC1-AE active
2C4 x Timeout of CAN message TSC1-AR active
3C4 x Timeout of CAN message TSC1-AE passive
4C4 x Timeout of CAN message TSC1-AR passive
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DMx
SPN
DMx
FMI
Failure description
HEX
values
MAX
= 3
MIN
= 4
SIG
= 2
NPL
= 12
1C5 x Timeout of CAN message TSC1-DE active
2C5 x Timeout of CAN message TSC1-DR active
3C5 x Timeout of CAN message TSC1-DE passive
4C5 x Timeout of CAN message TSC1-DR passive
1C6 x Timeout of CAN message TSC1-PE active
2C6 x Timeout of CAN message TSC1-PE passive
1C7 x Timeout of CAN message TSC1-TE active
2C7 x Timeout of CAN message TSC1-TR active
3C7 x Timeout of CAN message TSC1-TE passive
4C7 x Timeout of CAN message TSC1-TR passive
1C8 x Timeout of CAN message TSC1-VE active
2C8 x Timeout of CAN message TSC1-VR active
3C8 x Timeout of CAN message TSC1-VE passive
4C8 x Timeout of CAN message TSC1-VR passive
1C9 x Timeout of CAN message TF
2C9 x Timeout for message TimeDate
3C9 x Timeout for message HRVD (high resol.vehicle distance)
ECU 1 (internal checks)
1D1 x Communication error of CJ940
1D2 x x x Error state of EEPROM
1D3 x Recovery which is locked
2D3 x Recovery which is suppressed
2D4 x Recovery which is visible
1D4 x Communic.supervision Watchdog/Contr.-Flag
1D5 x x x Redundant shutoff paths during initial.
1D6 x Deviation between TPU and system time
1D7 x x Dataset variant coding
1D8 x Supervision of SPI-handler Flag
1D9 x x x x Error status ADC monitoring
1DA x
Fault FMTC_trq2qBas_MAP containes non strictly monotonous q
curves
ECU 2 (Powerst./Immobil./Overrun/Sensor supply)
1E1 x x
Short circuit to Batt or Ground, no load, excess.temp. for high side
power stage
2E1 x x x
Short circuit to Batt or Ground, no load, excess.temp. for low side
power stage
1E2 x Error state of Immobilizer (no fuel release)
1E3 x Energising time exceeds limit of overrun monitor.
1E4 x Plausibility error in engine speed check
1E5 x x 12V sensor supply voltage
1E6 x x Sensor supply voltage 1
MAY 2012 4.86
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
DIAGNOSTICS
DMx
SPN
DMx
FMI
Failure description
HEX
values
MAX
= 3
MIN
= 4
SIG
= 2
NPL
= 12
1E9 x Supply voltage CJ940 upper limit
1EA x Supply voltage CJ940 lower limit
1EB x x x Atmospheric Pressure Sensor
1EC x Runuptest is set to disable misfire detection during runup test
1ED x Fault path for Runup test
1EF x Mass of soot in oil beyond prescribed limit
Particulate trap
7F0 x Too long time spent in transition mode RgnNrm
1F1 x x Part.filter differential pressure sensor
1F2 x x Flow resistance monitoring
2F2 x Part.filter differential press.sensor not plaus.
1F3 x x x Differential pressure signal
2F3 x Dynamics of differential press.signal not plaus.
3F3 x Hose line defect so signal not plausible
4F3 x Pressure sensor blocked so signal not plaus.
1F4 x Pressure sensor frozen so signal not plausible
1F5 x Differential pressure above limit
1F6 x x Exhaust gas temp.sensor bef. oxidation catalyst
2F6 x Monitor.temp. upstream of Oxid.Catalyst
3F6 x
Temp.difference upstream from Oxidation catalyst of bank1 and 2
exceeded threshold
4F6 x Monitor.temperature upstream of Turbo charger
1F7 x x Part.filter pre temperature sensor
2F7 x Monitor.temp. upstream of Particul.filtre
3F7 x
Temp.difference upstream from Particulate filtre of bank1 and 2
exceeded threshold
1F8 x x x First exhaust gas temperature monitoring
2F8 x General temperature not plausible
3F8 x x x Second exhaust gas temperature monitoring
1F9 x Too high regeneration demand
1FA x Number of locked regenerations
2FA x Permanent regeneration
3FA x Regeneration demand number 2
4FA x Regeneration demand number 3
1FB x Error path of oxidation catalyst not present
1FC x Defect ratio between threshold limits
1FD x x Temperature of Outer control loop
2FD x x Temperature of Inner control loop
1FE x Mass of fuel in oil beyond warning limit
1FF x Mass of fuel in oil beyond action limit
2FF x Error check of critical time for oil dilution
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 MAINTENANCE 5.87
SECTION 5
Maintenance
Page
PERIODICITY OF CHECKS AND MAINTENANCE
OPERATIONS 89 . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARING THE ENGINE
FOR LONG IDLE PERIODS 91 . . . . . . . . . . . . . . .
ENGINE'S FIRST START/RESTORING NORMAL
OPERATING CONDITIONS 91 . . . . . . . . . . . . . .
MAY 2012 5.88
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAINTENANCE
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
PERIODICITY OF CHECKS AND MAINTENANCE OPERATIONS
Checks Periodicity
Check engine lubricating oil level Daily
Check engine coolant level Daily
Check oil level in the gearbox Daily
Inspect exhaust duct(s) Daily
Drain water from fuel pre-filter(s) (1) 150 hours
Check battery terminal tightening and cleanliness Half-yearly
Check electrolyte level in batteries (1) Half-yearly
Check condition of oil vapor filter with clogging indicator (with the engine
running)
300 hours
Periodic maintenance operations Periodicity
Clean air filter(s) (1) 300 hours
Check belt tension and conditions 300 hours
Check zinc anode corrosion condition (4) yearly
Restore battery electrolyte level Half-yearly
Drain/draw water and condensations from tank(s) (1) 300 hours
Replace engine lubricating oil (2) 300 / 600 hours
Replace oil vapor filter (8) 600 hours
Replace fuel pre-filter(s) (1) (3) 600 hours (Max)
Replace fuel filter(s) (1) (3) 600 hours (Max)
Replace oil filter(s) (2) 300 / 600 hours
Replace gearbox(es) oil (see data provided by the manufacturer)
Check seal of one-way valve in pre-lubrication system (as required) 600 hours
Clean turbocompressor 900 hours or 2 years
Inspect sea water intake (1) yearly
Check wear of sea water pump impeller 900 hours
Adjust valve-rocker arm clearance 1200 hours
Extraordinary maintenance operations (5) Periodicity
Clean heat exchangers (6) 1200 hours or 2 years
Check pre-post heating system operating condition (as required) 1200 hours or 3 years
Replace water pump and alternator drive belt 1200 hours or 3 years
Execution of the operations indicated below requires competence and compliance with the safety regulations enforced in
various Countries.
Checks can be performed by the user of the vessel and/or by 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 must be performed by FPT authorized workshop personnel with adequate training and
sufficient technical information.
(1) The periodicity of these operations may vary depending on
engine use and environmental conditions of operation.
(2) These operations must be conducted annually even if the
specified number of operating hours is not reached.
(3) Maximum time interval for high quality fuel; This may be
reduced depending on contamination. The filter is provided
with a clogging sensor; if a clogging indication occurs, 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 6.
(6) Combustion air/sea water exchanger: clean air side and
water side. Engine coolant/sea water exchanger: clean the
sea water side. Gearbox oil/sea water 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.
(8) On every engine oil replacement.
MAY 2012 5.90
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAINTENANCE
To prevent oxidation of the internal parts of the engine and
of 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:
1. Drain the lubricating oil from the sump, after heating the
engine;
2. Pour 30/M 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;
3. Drain the fuel from the injection line, from the filter and
fromthe ducts in the cylinder heads. To do so, loosen the
drain cap in the front part of the cylinder head and the
fuel inlet junction with the cylinder head, taking care to
prevent the fuel from coming in contact with the
auxiliaries belt;
4. 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 24 V, using a
conductor prepared for the occasion;
5. Nebulize 30/M protective oil at the rate of about 87 g
(10 g per liter of displacement) into the two
turbocompressors 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 protective oil from the sump; it
may be re-used for 2 more engine preparation perations;
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.
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;
3. 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. In order to enable the sea water pump priming it is
necessary to input water into the forcing circuit.
Remove the sacrifical anode (1 of Figure 1), introduce 1.5
litres of water into the hole; reassemble the anode and
tighten it as required.
WARNING
If the engine is activated after a long time, it is necessary
to repeat the operations mentioned in item 7.
8. Start the engine and keep it running until idling speed has
completely stabilized;
9. Shut the engine down and delete the errors which may
have been stored in the injection systemECU during the
operation stabilization phases. For reset operation, see
Blink code paragraph in Section 4;
10. Remove the tags with the inscription ENGINE
WITHOUT OIL from the engine and from the panel.
Figure 1
147001
(Demonstrative)
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
PREPARING THE ENGINE ENGINE'S FIRST START/RESTORING
FOR LONG IDLE PERIODS NORMAL OPERATING CONDITIONS
MAY 2012 5.92
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAINTENANCE
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012
SERVICING OPERATIONS
ON INSTALLED ENGINE
6.93
SECTION 6
Servicing operations on installed engine
Page
FOREWORD 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESCRIPTIONS FOR WORK ON THE INJECTION
SYSTEM AND ITS COMPONENTS 96 . . . . . . . .
REPLACING BELT 97 . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE ELECTRO-INJECTORS 97 . . . . . . .
Removal 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake and exhaust rocker arm clearance
adjustment 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine lubricant replacement 98 . . . . . . . . . . . . . .
Air filter/s replacement 99 . . . . . . . . . . . . . . . . . . .
Fuel filter/s replacement 99 . . . . . . . . . . . . . . . . . .
Oil filter replacement (demonstrative) 99 . . . . . . .
Filter support with exclusion levers
(demonstrative) 100 . . . . . . . . . . . . . . . . . . . . . . . .
MARINISATION OVERHAUL 101 . . . . . . . . . . . . . . . .
Removal 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE AIR/SEA WATER HEAT
EXCHANGER 103 . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE ENGINE COOLANT/SEA
WATER HEAT EXCHANGER 104 . . . . . . . . . . . . .
M62.10 / M65.10 Engines 104 . . . . . . . . . . . . . . . . .
M62.11 / M65.11 Engines 104 . . . . . . . . . . . . . . . . .
Fitting 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS FOR DISEMBARKING
THE ENGINE 108 . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling 108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAY 2012 6.94
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ON INSTALLED ENGINE
Many of the procedures for carrying out the instructions that
follow depend on the con.tion of the housing on the vessel
and on the configuration of the installation components.
Prescriptions and cautions for use, handling and technical
assistance are provided in Section 9.
Technicians and maintenance personnel are reminded of the
need to comply with safety rules.
The checks necessary at the completion of an installation or
re-embarkation are described in the C87 ENTM38.10 - C87
ENT M62.10 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 refers to engine
characteristics that were current as of the publishing data.
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 FPT Technical Assistance Network is always at the
Customer's side with its competence and professionalism.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012
ON INSTALLED ENGINE
6.95
FOREWORD
The successful outcome of repair work is assured by the
operator's experience and ability and by compliance with the
following instructions.
Before performing work involving components of the
injection system, take note of the content of the ECU fault
memory with the appropriate FPT diagnosis equipment,
writing the results down or printing them.
- Replacement of the ECU EDC 7 must be authorized by
FPT after specific agreements with the Technical
Assistance Service;
- The electro-injectors cannot be overhauled; their
replacement must be authorized by FPTwith the specific
agreement of the Technical Assistance Service; for
disassembly, follow the indications provided in the
specific paragraph of this Section;
- 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;
- Maintain the proper polarization of all electrical
connections;
- Tighten the threaded connections to the prescribed
torque;
- Ensure that the flywheel and camshaft sensors are
positioned so they abut, ensuring they are as close to
perpendicular as possible with the bearing surface.
To proceed with the overhaul of the engine or its parts, you
must disconnect the electrical connections of the injection
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 that the ECU of the injection system may
detect and store errors or system faults.
- Set the key switch to the STOP position;
- Wait 10 sec. and disconnect the battery terminals;
- Disconnect the connections according to the
prescriptions set out in Section 3;
- Remove, if necessary, the entire wiring harness from the
retaining bracket;
- Remove, if necessary, the complete electronic unit after
disconnecting the multipolar connectors.
ATTENTION
- Do not disconnect electrical connections without
removing power from the circuits first;
- Do not proceed with operating simulations with
unsuitable tools and instruments;
- Do not force measuring probes or mechanical tools
into the electrical connections;
- Do not proceed with arc welding without first
disconnecting electronic system units.
MAY 2012 6.96
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ON INSTALLED ENGINE
PRESCRIPTIONS FOR WORK ON THE INJECTION SYSTEM AND ITS COMPONENTS
- With the tool (1) loosen the tensioning device acting in
the direction indicated by the arrow. Extract the auxiliary
organ drive belt (2), insert the new belt verifying that it
is correctly set onto the pulleys. Release the tensioning
device. The automatic tensioning device requires no
further adjustment.
REPLACING THE ELECTRO-INJECTORS
Removal
Figure 1
Figure 2
Figure 3
05_070_C
174574
Unlock retaining screws (2) and remove head cover (1) to
reach injector and rail wiring.
114024
- Unlock rocker arm shaft retaining screws (4).
- Disconnect fuel pipelines (1) from injector rail, fuel
supply line (2) of high pressure pump to rail and return
line (3).
114025
Apply tool 99360558 (1) to rocker arm shaft and remove
shaft, remove crosspieces (3) from cylinder head.
Figure 4
Figure 5
Remove retaining brackets (1) and remove injectors (2).
147002
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012
ON INSTALLED ENGINE
6.97
REPLACING BELT
114287
Adjustment of clearance between rocker arms and
intake/exhaust valve control crosspieces must be performed
with utmost care. Bring to blast phase cylinder to be adjusted;
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced. Symmetric cylinders are 1-6; 2-5
and 3-4.
In order to perform these operations correctly, refer to
procedure and table below.
- Use a polygonal spanner to release lock nut (1) of rocker
arm adjustment screw (2).
- Insert filler gage (3) having same value of operating
clearance shown in Characteristic and data tables.
- Use special spanner to lock/unlock adjustment screw.
- Check that filler gage (3) slides with a low friction.
- Lock nut (1) retaining the adjustment screw.
IGNITION ORDER 1-4-2-6-3-5
adjustment
In order to correctly carry out adjustments above, it is
mandatory to perform the sequence indicated in the table,
checking exact positioning at each phase by means of pin
99360612.
Figure 6
ATTENTION
Engine lubricant replacement
Proceed only with engine not running and at low
temperature to avoid any risk of burns.
Figure 7
147003
The above operations can be performed by acting on the
push button located on the electronic module. Fore safety
reasons controls enabled on only when the key switch is
turned to 8A (stop).
- Place under the cock (1) a container to collect the
exhaust oil.
- Open the cock and press (A) towards DISCHARGE,
until it is fully empty.
147004
- Connect the cock to the newoil container and press the
button towards CHARGE until filling is completed.
- Close again the charge/discharge tap and check - using
the oil dipstick - that the oil level in the oil sump is
between the range MIN e MAX.
- Dispose oil observing current regulations in force.
Figure 8
MAY 2012 6.98
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ON INSTALLED ENGINE
START AND
ROTATION
CLOCKWISE
BALANCE
VALVES OF
CYLINDER No.
ADJUST
CLEARANCE
OF VALVES
CYLINDER No.
1 and 6 at TDC 6 1
120 3 4
120 5 2
120 1 6
120 4 3
120 2 5
Fuel filter/s replacement
temperature to avoid any risk of burns.
Use only filters with filtering degree equal to the above ones
(see FREQUENCY).
- Remove filter (1) by unscrewing it.
- Moist seals of the new filters with diesel or engine oil.
- Manually tighten until contact is made, then tighten again
for 3/4 of turn.
- Loosen the bleeding connection on the filter support
and act on the hand pump of the pre-filter until fuel flows
out without air.
- Tighten the connection and start the engine acting on
the pump, also during the first startup phases.
- Place under the cock a container to collect the exhaust
oil.
- Remove filters.
- Accurately clean surfaces.
- Moist seals of the new filters with some oil.
- Manaully tighten until contact is made, then tighten
again for 3/4 of turn.
- Dispose drained liquids observing current regulations in
force.
ATTENTION
Proceed with utmost care, considering the fluid high
temperature and the presence of moving parts. Always wear
suitable personal protection equipped.
Figure 9
Figure 10
Figure 11
Air filter/s replacement
- Remove the collar (1) shown in picture then remove the
filter.
- Replace.
- Restore regular operating conditions after having placed
the filter in its housing.
147005
147007
147006
Oil filter replacement (demonstrative)
Use only filters with filtering degree equal to the above ones
(see FREQUENCY).
With traditional filter support
temperature to avoid any risk of burns, after emptying
exhaust oil.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012
ON INSTALLED ENGINE
6.99
- Place under the cock a container to collect the exhaust
oil.
- Remove filters.
- Accurately clean surfaces.
- Moist seals of the new filters with some oil.
- Manaully tighten until contact is made, then tighten again
for 3/4 of turn.
- Dispose drained liquids observing current regulations in
force.
Put the lever back into its original position (left).
ATTENTION
Proceed with utmost care, considering the fluid high
temperature and the presence of moving parts. Always wear
suitable personal protection equipped.
Figure 12
147007
Filter support with exclusion levers
(demonstrative)
The support with exclusion lever allows replacing the filter
also with running engine.
Under normal conditions, the selector (1) lever should be on
the left. Only in the event of replacement should it first be
positioned in the centre then on the right to allow the small
(emergency) filter to operate
ATTENTION
Do not exclude both filters at the same time to avoid any
damage.
MAY 2012 6.100
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ON INSTALLED ENGINE
Disconnect the oil inlet pipe from the inverter (1) and the oil
outlet pipe to the inverter (2).
143689
143684
143686
143685
143687
143688
Remove the engine mountings (1), the oil drain pump (2) and
the sea water exhaust pipe (3).
Remove the electronic control unit (1), the stack exhaust (2)
(if present) and the combusted gas/sea water exhaust (3).
Remove the air filter (4), the turbocharger (1), the pipe (2)
and the fuel pipes (3).
Disconnect the exhaust stub pipe (1), the fuel filter (2) and
the intake duct (3).
Remove the oil filter mount (1) and the oil dipstick (2).
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012
ON INSTALLED ENGINE
6.101
MARINISATION OVERHAUL
Removal
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
143691
1436922
143693
Remove the sea water pump (1) and the inverter oil heat
exchanger (2)
Disconnect the coolant temperature sensor (2), the
thermostat (1) and the coolant inlet pipe to the engine water
pump (3).
Remove the air/water exchanger (1) and the water/water
heat exchanger (2)
Remove the combusted gas/sea water cooled exhaust
manifold (1).
143690
()
() M62.10 / M65.10 ENGINES
(*)
(*) M62.11 / M65.11 ENGINES
177456
MAY 2012 6.102
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ON INSTALLED ENGINE
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 deposits which may be present in harbors'
waters; surfaces coming into contact with combusting air are
subject to oil deposits resulting from the fumes exhausted at
the base and sucked downstream of the air filter.
- Remove tube bundle fixing plugs and screws (5);
- Remove the tube bundle (2) 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;
- Complete tube cleaning by rinsing thoroughly with fresh
water, until detergent residuals are entirely removed;
- Reassemble the tube bundle (2) by correctly positioning
spacers (7), sealing rings (3) and covers (6);
Figure 24
1.Body - 2. Tube bundle - 3. Sealing rings - 4. Zinc sacrificial anode - 5. Tube bundle fixing screw -
6. Cover - 7. Spacer.
- Reassemble screws (5) in order to suitably secure the
tube bundle and relevant plugs;
- Check the zinc anode corrosion level (4); replace the
anode if corrosion exceeds 50% of the volume.
143699
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012
ON INSTALLED ENGINE
6.103
CLEANING THE AIR/SEA WATER HEAT EXCHANGER
Figure 25
143770
M62.11 / M65.11 Engines
Figure 26
177443
1. Tube bundle - 2. Body - 3. Sealing rings - 4. Cover - 5. Tube bundle fixing screw - 6. Spacer - 7. Zinc sacrificial anode
MAY 2012 6.104
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ON INSTALLED ENGINE
CLEANING THE ENGINE COOLANT/SEA WATER HEAT EXCHANGER
M62.10 / M65.10 Engines
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 deposits which
may be present in harbors' waters.
- Remove the tube bundle (1) 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;
- Complete tube cleaning by rinsing thoroughly with fresh water, until detergent residuals are entirely removed;
- Reassemble the tube bundle (1) by correctly positioning spacer (6), sealing rings (3) and covers (4);
- Check the zinc anode corrosion level (7); replace the anode if corrosion exceeds 50% of the volume.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012
ON INSTALLED ENGINE
6.105
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
143693
143691
143691
143690
143689
Fit the air/water exchanger (1) and the water/water heat
exchanger (2).
Reattach the coolant inlet pipe to the engine water pump (3),
the thermostatic valve (1) and the coolant sensor (2).
Fit the inverter oil heat exchanger (2) and the sea water
pump (1).
Connect the inverter oil inlet (1) and outlet (2) pipes.
Fit the combusted gas/sea water cooledexhaust manifold(1).
177456
(*) M62.11 / M65.11 ENGINES
()
() M62.10 / M65.10 ENGINES
(*)
MAY 2012 6.106
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ON INSTALLED ENGINE
Fitting
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
143686
143685
Connect the pipe (2), the turbocharger (1), the air filter (4)
and reattach the fuel pipes (3).
Fit the combusted gas/sea water exhaust (3), the stack
exhaust (2) (if present) and the electronic control unit (1).
Fit the engine oil drain pump (2), the sea water exhaust pipe
(3) and the engine oil mounts (1).
Fit the oil filter mount (1) and the oil dipstick (2).
143684
143687
Fit the exhaust stub pipe (1), the fuel filter (2) and the intake
duct (3).
143688
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012
ON INSTALLED ENGINE
6.107
The following is a description of the recommended sequence
of operations to be completed before extracting the engine
from the vessel.
- 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;
- Disconnect from the engine the power wiring harness
terminals (battery positive and negative);
- Loosen and remove the fuel pipelines and the pipes of
the gearbox heat exchanger, if provided;
- Loosen and remove the sea water inlet pipes, engine
exhaust pipes, and, if separate, the sea water loop
discharge;
- Remove the pipeline from the engine coolant expansion
vessel;
- Loosen and remove engine anchor bolts;
- Uncouple the gearbox;
- Hitch the engine following the prescriptions provided
below.
Handling
The engine must be handled by experienced personnel, using
the prescribed tool or a rocker armthat keeps the lifting lines
parallel and with adequate equipment in terms of capacity
and size.
The two eyebolts (provided exclusively for lifting the engine)
must always be used simultaneously.
MAY 2012 6.108
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ON INSTALLED ENGINE
INSTRUCTIONS FOR DISEMBARKING THE ENGINE
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 TOOLS 7.109
SECTION 7
Tools
Page
TOOLS 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAY 2012 7.110
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
Tool No. Description
99322230
Rotary telescopic stand
(range 2000 daN, torque 375 daNm)
99327281
PT - Box
99340051 Extractor for crankshaft front gasket
99340054 Extractor for crankshaft rear gasket
99342157 Extraction tool for injectors
99346245 Tool to install the crankshaft front gasket
MAY 2012 7.112
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
TOOLS
99346260 Key to fit crankshaft rear gasket
99360184
Pliers for assembling and disassembling piston split rings
(105-106 mm)
99360264 Tool to take down-fit engine valves
99360288 Tool to remove valve guide
99360292 Tool to install gasket on valve guide
99360294 Tool to fit back valve guide
(to be used with 99360288)
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
99360334
Compression tool for checking the protrusion of cylinder liners
99360335
Cylinder liner compression plate
(to be used with 99360334)
99360341
Tool for rotating the flywheel
99360351 Tool to retain engine flywheel
99360500 Tool to lift crankshaft
99360505 Tool to take down and fit back camshaft bushes
MAY 2012 7.114
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
TOOLS
99360558 Tool for assembling and installing rocker arm shaft
99360585 Swing hoist for engine disassembly assembly
99360603 Band for piston insertion into the cylinder (90 - 175 mm)
99360605
Belt to insert piston in cylinder liner (60 - 125 mm)
99360612 Tool for positioning engine P.M.S.
99360613 Tool for timing of phonic wheel on timing gear
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
99360703 Tool to stop cylinder liners
99360706 Tool to extract cylinder liners (to be used with specific rings)
99360724 Ring (115 mm) (to be used with 99360706)
99361042
Brackets for fastening engine to 99322230 rotary stand
99367121 Manual pump for measuring pressure and vacuum
99368542
Tool to take down-fit engine valves (to be used with special plates)
MAY 2012 7.116
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
TOOLS
99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)
99389833 14x18 coupling torque wrench (20-120 Nm)
99389834
Torque screwdriver for calibrating the injector solenoid valve
connector check nut
99390310 Valve guide sleeker
99395216
Measuring pair for angular tightening with 1/2 and 3/4 square
couplings
99395221
Gauge for defining the distance between the centres of camshaft
and high pressure pump
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
99395222
Gauge for defining the distance between the centres of camshaft
and transmission gear
99395223 Gauge for camshaft timing
99395603 Dial gauge (0 - 5 mm)
MAY 2012 7.118
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 OVERHAUL 8.119
SECTION 8
Overhaul
Page
Graph and symbols 123 . . . . . . . . . . . . . . . . . . . . . .
GENERAL CHARACTERISTICS 124 . . . . . . . . . . . . . . .
ASSEMBLY CLEARANCE DATA 125 . . . . . . . . . . . . . .
TIGHTENING TORQUES 131 . . . . . . . . . . . . . . . . . . .
Lower crankcase bolt tightening order diagram 134
Diagram of cylinder head fixing screws
tightening order 135 . . . . . . . . . . . . . . . . . . . . . . . .
Diagram of rocker arm shaft fixing screws
Exhaust manifold bolt tightening order diagram 136
Diagram of feeder-line between exhaust
manifold and turbocompressor fixing nuts
Diagram of exhaust flange fixing screws
Diagram of heat exchanger fixing screws
Diagram of engine oil sump fixing screws
Diagram of rocker arm cap fixing screws
CYLINDER BLOCK 144 . . . . . . . . . . . . . . . . . . . . . . . . .
Checks and measurements 144 . . . . . . . . . . . . . . . .
CYLINDER LINERS 145 . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing cylinder liners 146 . . . . . . . . . . . . . . . . . .
Removal 146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting and checking protrusion 146 . . . . . . . . . . . . .
CRANKSHAFT 147 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAY 2012 8.120
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Page Page
Measuring main journals and crank pins 148 . . . . . .
PRELIMINARY MEASUREMENT OF MAIN AND
BIG END BEARING SHELL SELECTION
DATA 149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the main and big end bearing shells 150 . .
Replacing the timing control gear and the oil
pump 156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking main journal installation clearance 156 . . .
Checking crankshaft end float 157 . . . . . . . . . . . . . .
PISTON CONNECTING ROD ASSEMBLY 158 . . . . . .
Removal 158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions for correct gudgeon pin-piston
coupling 159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston rings 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD 161 . . . . . . . . . . . . . . . . . . .
Mounting the connecting rod - piston assembly 163
Mounting the piston rings 163 . . . . . . . . . . . . . . . . .
Fitting connecting rod - piston assemblies in
the cylinder liners 164 . . . . . . . . . . . . . . . . . . . . . . .
Checking piston protrusion 164 . . . . . . . . . . . . . . . .
Checking assembly clearance of big end pins 165 . .
CYLINDER HEAD 165 . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve removal 165 . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the planarity of the head on the
cylinder block 165 . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE 166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing deposits and checking the valves 166 . . .
VALVE GUIDES 166 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing of valve guides 167 . . . . . . . . . . . . . . . . . .
REPLACING INJECTOR HOLDER CASES 167 . . . . . . .
Removal 167 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking protrusion of injectors 169 . . . . . . . . . . . .
TIMING GEAR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft drive 170 . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate gear pin 170 . . . . . . . . . . . . . . . . . . . .
Idler gear 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Twin idler gear 170 . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the bushings 170 . . . . . . . . . . . . . . . . . . .
Checking cam lift and pin alignment 171 . . . . . . . . .
CAMSHAFT 172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING GEAR 172 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use beater 99360505 to change bushings 173 . . . .
Removal 173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SPRINGS 173 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting 173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the valves and oil seal ring 173 . . . . . . . . . . .
ROCKER SHAFT 174 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft 174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker 174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION CIRCUIT COMPONENTS 175 . . . . . .
Oil pump 175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overpressure valve 175 . . . . . . . . . . . . . . . . . . . . . .
Engine oil filter adapter 176 . . . . . . . . . . . . . . . . . . .
Filter by-pass valve 176 . . . . . . . . . . . . . . . . . . . . . .
Oil pressure control valve 177 . . . . . . . . . . . . . . . . .
Heat exchanger 177 . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENTS OF THE COOLING SYSTEM 178 . . .
Water pump 178 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostatic valve 178 . . . . . . . . . . . . . . . . . . . . . .
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Page
ASSEMBLY 179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High pressure pump installation 183 . . . . . . . . . . . .
ENGINE FLYWHEEL 183 . . . . . . . . . . . . . . . . . . . . . . . .
Engine flywheel installation 183 . . . . . . . . . . . . . . . .
Camshaft installation 184 . . . . . . . . . . . . . . . . . . . . .
TIMING CAMSHAFT AND FLYWHEEL
USING TOOL 99395223 185 . . . . . . . . . . . . . . . . .
Timing camshaft 185 . . . . . . . . . . . . . . . . . . . . . . . .
Timing flywheel 187 . . . . . . . . . . . . . . . . . . . . . . . . .
WITHOUT TOOL 99395223 187 . . . . . . . . . . . . .
Timing camshaft 187 . . . . . . . . . . . . . . . . . . . . . . . .
Timing flywheel 190 . . . . . . . . . . . . . . . . . . . . . . . . .
adjustment 191 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAY 2012 8.122
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
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
Graph and symbols
MAY 2012 8.124
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
GENERAL CHARACTERISTICS
Engine
C87 ENT M62.10
C87 ENT M65.10
C87 ENT M62.11
C87 ENT M65.11
mm
Cycle Diesel 4 strokes
Air feeding Turbocharged with aftercooler
Injection Direct
N. of cylinders 6 in line
C
Diameter mm 117
Stroke mm 135
+ + +.. = Total displacement cm
3
8710
Compression ratio 16 : 1
A
B
Valve timing
opens before TDC A
closes after BDC B
17
31
C
D
opens before BDC D
closes after TDC C
48
9
X
For timing check
mm
X
mm
0.4 0.05
0.6 0.05
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ASSEMBLY CLEARANCE DATA
Engine
C87 ENT M62.10
C87 ENT M65.10
C87 ENT M62.11
C87 ENT M65.11
Cylinder block and crank mechanism components mm
C1
Cylinder sleeve bore
upper
C1
lower
130.500 to 130.525
129.510 to 129.535
L
C2
Cylinder liners:
outer diameter:
upper
C2
lower
130.461 to 130.486
129.475 to 129.500
length L 226.15
Cylinder sleeve - crankcase
bore:
upper
lower
0.014 to 0.064
0.010 to 0.060
Outside diameter C 2 -
Cylinder sleeve
C3
X
inside diameter C 3A* 117.000 to 117.012
inside diameter C 3B* 117.010 to 117.022
Protrusion X
* Available dia. class
C1
X
C2
Pistons:
measuring dimension X 15
outside diameter C 1 A* 116.894 to 116.906
external diameter C 1 B** 116.904 to 116.916
pin bore C 2
* Class A pistons supplied as
spares.
** Class B pistons are fitted in
production only and are not
supplied as spares.
52.010 to 52.016
Piston - cylinder sleeve A*
* Available dia. class B*
0.094 to 0.118
0.094 to 0.118
Piston diameter C 1 -
X
Pistons protrusion X 0.873 to 1.117
3 C
Gudgeon pin C 3 51.994 to 52.000
Gudgeon pin - pin housing 0.010 to 0.022
MAY 2012 8.126
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Engine
C87 ENT M62.10
C87 ENT M65.10
C87 ENT M62.11
C87 ENT M65.11
mm
X
1
3
2
X
X
X1
Piston ring grooves X2
X3
3.120 to 3.140
2.550 to 2.570
4.020 to 4.040
1
3
2
S
S
S
Piston rings:
trapezoidal seal S1
lune seal S2
milled scraper ring with slits
and internal spring S3
3.000
2.470 to 2.500
3.970 to 3.990
1 -
0.050 to 0.100
0.030 to 0.070
Piston rings - grooves 2
3
Piston rings -
X1
3
2 X
X
Piston ring end gap in cylinder
liners:
0.40 to 0.50
0.60 to 0.75
0.35 to 0.65
X1
X2
X3
1 C
C2
Small end bush housing
C 1
Big end bearing housing C 2
55.690 to 55.710
Rated value 85.987 to 86.013
85.987 to 85.996
85.997 to 86.005
86.006 to 86.013
1
Selection classes C 2 2
3
C
S
C4
3
Small end bush diameter
55.780 to 55820
52.015 to 52.030
1.994 to 2.002
2.002 to 2.010
2.010 to 2.018
outside C4
inside C3
Big end bearing shell S
Red
Green
Yellow *
* Fitted in production only
and not supplied as spares
Small end bush - housing
0.05 to 0.08
Piston pin - bush 0.015 to 0.030
Big end bearing shells 0.127 - 0.254 - 0.508
Connecting rod weight
A
Class B
C
g
3331 to 3361
3362 to 3391
3392 to 3421
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Engine
C87 ENT M62.10
C87 ENT M65.10
C87 ENT M62.11
C87 ENT M65.11
mm
1 2 C C
S 1 S 2
Main journals C1
1
Selection class 2
3
Crankpins C 2
1
Selection class 2
3
92.970 to 92.980
92.980 to 92.990
92.990 to 93.000
81.915 to 81.925
81.925 to 81.935
81.935 to 81.945
Main bearing shells S1
Red
Green
Yellow*
2.968 to 2.978
2.978 to 2.988
2.988 to 2.998
Big end bearing shells S2
Red
Green
Yellow*
* Fitted in production only
and not supplied as spares
1.994 to 2.002
2.002 to 2.010
2.010 to 2.018
3 C
Main bearing housings C3
1
Selection class 2
3
99.000 to 99.009
99.010 to 99.019
99.020 to 99.030
Bearing shells - main journals 0.050 to 0.090
Bearing shells - big ends 0.0540 to 0.080
Main bearing shells 0.127 - 2.254 - 0.508
Big end bearing shells 0.127 - 2.254 - 0.508
X1
Main journal,
thrust bearing X1 39.96 to 40.04
X2
Main bearing housing,
thrust bearing X2 38.94 to 38.99
X 3
Thrust washer halves X3 3.38 to 3.43
Driving shaft shoulder 0.10 to 0.30
MAY 2012 8.128
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Engine
C87 ENT M62.10
C87 ENT M65.10
C87 ENT M62.11
C87 ENT M65.11
Cylinder heads - valve train mm
C 1
Valve guide housings
in cylinder head C1 12.980 to 12.997
2 C
C 3
C2
Valve guide
C3
8.023 to 8.038
13.012 to 13.025
Valve guides - housings in the
cylinder heads
0.015 to 0.045
Valve guide 0.2 - 0.4
C
o
4
Valves:
C4
o
C4
o
7.970 to 7.985
60 30' 7' 30
7.970 to 7.985
45 to 45 15'
Valve stem and its guide 0.038 to 0.068
C 1
Housing in headfor valve seat:
C1
C1
41.985 to 42.020
40.985 to 41.020
Outside diameter of valve seat;
angle of valve seat in cylinder
head:
C 2
o
C 2
o
42,060 to 42,075
60 - 30
41.060 41.075
45 - 30'
X
X
Recessing
of valve X
0.5 to 0.8
1.6 to 1.9
Between valve seat
and head
0.040 to 0.090
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Engine
C87 ENT M62.10
C87 ENT M65.10
C87 ENT M62.11
C87 ENT M65.11
mm
H
H1
H2
Valve outside spring height:
free height H 71.34
under a load of:
N 460 23 N H1
N 740 33 N H2
51
39
X
Injector protrusion X
1.2 to 1.5
C C C
Camshaft bush housing fitted
in the cylinder head:
1 = 7 69.000 to 69.030
C
C
C 1
2
3
Camshaft journal diameter:
1 = 7 64.924 to 64.080
C
Camshaft bushing
outer diameter C 69.090 to 69.130
C
Camshaft bushing
inner diameter C 65.080 to 65.116
Bushings and housings in engine
block 0.060 to 0.130
Bushings and journals
0.100 to 0.192
H
Cam lif
7.4034
8.2108
C 1
Rocker shaft C1 31.964 to 31.980
MAY 2012 8.130
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Engine
C87 ENT M62.10
C87 ENT M65.10
C87 ENT M62.11
C87 ENT M65.11
mm
C
Bushing housing in rocker arms:
32.025 to 32.041
32.025 to 32.041
Between bushings and
housings:
0.045 to 0.077
0.045 to 0.077
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TIGHTENING TORQUES
PART TORQUE
Nm kgm
Pipe union for piston cooling nozzle M12X1.5 50 5 3.5 - 0.2
Heat exchanger retaining screws 63 - 7 6.3 - 0.7
Plug 125 15 12.5 - 1.5
Spacer and oil sump fastening screws
M10 41.5 - 3.5 4.1 - 0.3
Gearcase fastening screws to cylinder block:
M10x1.25 41.5 - 3.5 4.1 - 0.3
M12x1.75 63 7 6.3 - 0.7
M8x1.25 23.5 - 1.5 2.3 - 1.5
Cylinder head fastening screw +
First stage pre-tightening 50 5
Second stage pre-tightening 100 10
Third stage angle closing 90
Fourth stage angle closing 75
Rocker arm shaft fastening screw 104.5 - 10.5 10.4 - 1
Locknut for rocker arm adjusting screw + 39 5 3.9 - 5
Electroinjector retaining bracket screws +
M10 41 - 3 4.1 - 0.3
Shoulder plate fastening screws to head + 23.5 - 3.5 2.3 - 0.3
Engine support bracket fastening screws to cylinder head 74 8 7.4 - 0.8
Gear fastening screws to camshaft M10x1,5x45
First stage pre-tightening 25 2.5
Second stage pre-tightening 45
Phonic wheel fastening screws to distribution gear 8.5 - 1.5 0.8 - 0.1
Exhaust pipe fastening screws
pre-tightening
tightening
32.5 7.5
47.5 2.5
3.2 0.7
4.7 0.2
Connecting rod cap fastening screws: +
Engine flywheel fastening screws + M18x1.5x72
Flywheel pulley fastening screws to crankshaft
Main journal retaining screws +
+ Lubricate with oil MOLYKOTE before assembly
Lubricate with graphitized oil before assembly
MAY 2012 8.132
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
PART TORQUE
Nm kgm
Damper flywheel fastening screws + 115 15 11.5 - 1.5
Idler gear pin fastening screws + M12x1,75x90
Second stage angle closing 90
Idle gear link rod fastening screw + 24.5 - 2.5 2.4 - 0.2
Oil pump fastening screw 24.5 - 2.5 2.4 - 0.2
Oil pump suction rose fastening screw 24.5 - 2.5 2.4 - 0.2
Front cover fastening screw to cylinder block 19 3 1.9 - 0.3
Control unit fastening screw to cylinder block 19 3 1.9 - 0.3
Fuel filter support fastening screw to cylinder head + M10x1,25x60 37 - 3 3.7 - 0.3
Screw securing the engine support to the wheelcase +
Second stage angle closing 60
Turbo-compressor fastening screws and nuts
pre-tightening
tightening
32.5 - 7.5
46 - 2
3.2 - 0.7
4.6 - 0.2
Water pump fastening screw to cylinder block 24.5 - 2.5 2.4 - 0.2
Pulley fastening screw to hub 55 5 5.5 - 0.5
Rocker arm cover fastening screws 8.5 - 1.5 0.8 - 0.1
Thermostat box fastening screws to cylinder head 24.5 - 2.5 2.4 - 0.2
Automatic tightener fastening screws to cylinder block 45 5 4.5 - 0.5
Fixed tightener fastening screws to cylinder block 105 5 10.5 - 0.5
Fan support fastening screws to cylinder block 24.5 - 2.5 2.4 - 0.2
Starter fastening screws 44 4 4 - 0.4
Air heater on cylinder head 30 3 5 - 0.5
Hydraulic power steering pump gear fastening nut 105 5 10.5 - 0.5
Air conditioner compressor fastening screw to support 24.5 - 2.5 2.4 - 2.5
Alternator support superior fastening screw 71.5 - 4.5 7.1 - 0.4
Alternator bracket fastening screw to cylinder block 24.5 - 2.5 2.4 - 0.2
Water pipe unions 35 3.5
Water temperature sensor 32.5 - 2.5 3.2 - 0.2
+ Lubricate with oil MOLYKOTE before assembly
Lubricate with graphitized oil before assembly
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
PART TORQUE
Nm kgm
Flywheel rev sensor fastening screw 8 4 0,8 - 0.2
Camshaft rev sensor fastening screw 8 4 0.8 - 0.4
P.D.E. solenoid connector fastening screw 1.62 - 0.3 0.1 - 0.3
Overboost pressure sensor fastening screw 8 2 0.8 - 0.2
Absolute pressure sensor fastening screw 22.5 - 2.5 2.2 - 0.2
P.W.M. control valve fastening screw/nut 8 2 0.8 - 0.2
Fuel/coolant temperature sensor 35 3.5
Coolant temperature indicator 23.5 - 2.5 2.3 - 0.2
Filter clogging sensor 10 1
Oil temperature switch 25 1 2.5 - 0.1
Oil pressure sensor 25 1 2.5 - 0.1
Electric wire fastening screw 8 2 0.8 - 0.2
Gear fastening screws to camshaft M14x50
First stage pre-tightening 40
Gear fastening screws to camshaft M14x50
Heater fastening screw 24.5 - 2.5 2.5 - 0.2
Gear fastening screws to camshaft
Gear fastening screws to camshaft
Alternator positive retaining nut M8x1.25 12.5 - 2.5 1.3 - 0.3
Starter terminal nut 30 M10x1.5 21 - 3.4 2.1 - 0.3
Starter terminal nut 50 M5x0.8 3.6 - 1 0.4 - 0.1
Figure 1
FRONT SIDE
FRONT SIDE
FRONT SIDE
First phase:
preliminary
tightening of
inner screws
(140 Nm)
Second phase:
angle tightening
of inner screws
60
Third phase:
angle tightening
of inner screws
60
80858
80858
80858
FRONT SIDE
Fourth phase:
preliminary
tightening
of outer screws
(25 Nm)
80857
FRONT SIDE
Fifth phase:
angle tightening
of outer screws
90
80859
MAY 2012 8.134
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Lower crankcase bolt tightening order diagram
Figure 2
Diagram of cylinder head fixing screws tightening order
Sequence
- First phase preliminary tightening 50 Nm Sequence as shown in figure;
- Second phase preliminary tightening 100 Nm Sequence as shown in figure;
- Third phase angle locking 90 Sequence as shown in figure;
- Fourth phase angle locking 75 Sequence as shown in figure.
174573
Diagram of rocker arm shaft fixing screws tightening order
Figure 3
80861
Sequence
- First phase tighten the screws 1-2-3 until they bear down on the rocker arm shaft;
- Second phase preliminary tightening 40 Nm Sequence as shown in figure;
- Third phase angle locking 60 Sequence as shown in figure.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 4
Diagram of feeder-line between exhaust
manifold and turbocompressor fixing nuts
tightening order
- Tightening torque: 50 Nm Sequence 2-4-1-3.
Diagram of exhaust flange fixing screws
tightening order
80862
Sequence
- Second phase preliminary tightening 55 Nm Sequence as shown in figure.
Figure 5 Figure 6
Exhaust manifold side nuts
- Tightening torque: 107 Nm Sequence B-D-A-C.
Turbocompressor side nuts
- Tightening torque: 55 Nm Sequence 4-2-1-3.
80864
MAY 2012 8.136
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Exhaust manifold bolt tightening order diagram
Figure 7
Figure 8
Figure 9
Diagram of heat exchanger fixing screws tightening order
Sequence
- Second phase preliminary tightening 22 Nm Sequence as shown in figure.
Diagram of engine oil sump fixing screws tightening order
147010
- Tightening 10 Nm Sequence as shown in figure.
- Tightening 50 Nm Sequence as shown in figure.
Diagram of rocker arm cap fixing screws tightening order
147009
174576
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Before securing the engine on the rotary stand:
- Remove the engine mountings
- Remove the engine cable
- Secure the engine to the rotary stand with the brackets
- Drain the lubricating oil from the oil sump.
ATTENTION
The operations described below refer to engines not
equipped with marinisation components.
Figure 10
Figure 11
Figure 12
Using an appropriate tool (1), operate in the direction of the
arrow, and remove the belt (4) driving the water pump and
alternator.
- Automatic belt tightener support (2);
- Alternator (3);
- Fixed tightener (5);
- Water pump (6) and piping;
- Damping flywheel (7);
- Disconnect all electric connections and the sensors.
05_070_C
Remove the adapter for the oil filter (1) and the heat
exchanger (2).
143672
174574
Unlock retaining screws (2) and remove head cover (1) to
reach injector and rail wiring.
MAY 2012 8.138
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
177449
Apply extractor 99340051 (2) and remove seal (1).
Unlock screws and remove front cover (3).
Figure 13
Figure 14
114018
114019
Unscrew the screws (1) and remove the cover (2). Remove
the centrifugal filter (3) below.
Figure 15
Figure 16
ATTENTION
In case removal of gear (5) is difficult, release high pressure
pump screws with light beater strokes on control shaft and
remove gear (5).
Use specific spanner to unlock screws (2) and remove gear
(3) complete with tune wheel.
Unlock nut (4) and remove control gear (5) of high pressure
pump.
Remove rpm sensor (1).
114015
Remove screws (1) and blow-by box (2).
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
143673
Figure 17
Figure 18
Figure 19
Figure 20
Remove the high-pressure pump (1) and the starter motor
(2).
114020
Unlock screws (1) and remove thrust plate (2).
Use specific spanner to unlock screws (4) and remove relay
gear (5).
Remove high pressure pump mount flange (3).
114009
Use specific tool lock engine flywheel (2) rotation, unlock
retaining screws (1) and remove engine flywheel.
45257
Apply extractor 99340054 (2) and remove seal (1).
MAY 2012 8.140
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Figure 21
Figure 22
Figure 23
Figure 24
- Unlock rocker arm shaft retaining screws (4).
- Disconnect fuel pipelines (1) from injector rail, fuel
supply line (2) of high pressure pump to rail and return
line (3).
Undo the screws (1) and remove the oil sump (2).
Figure 25
143674
114031b
Unlock screws and remove suction rose (1).
114022
Unlock screws (1) and remove flywheel box (2).
114023
Remove screws (2) and double gear (3).
Remove retaining screw (5) and connecting rod (4).
Remove oil pump (1).
114024
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Clean surfaces to be coupled to remove dirt and oil residuals.
Apply LOCTITE 275 (1) silicone on front cover (2) as shown
in the figure.
The sealant seam diameter must be 1.5 - 0.5/0.2.
Figure 26
Figure 27
Figure 28
Figure 29
114025
Apply tool 99360558 (1) to rocker arm shaft and remove
shaft, remove crosspieces (3) from cylinder head.
114027
Remove retaining brackets (3) and remove injectors (4).
Remove retaining screws (1) and remove rail (2).
Remove camshaft and remove cylinder head retaining
screws.
Use metallic ropes to lift cylinder head (1) and remove seal
(2).
45266
117690
ATTENTION
Install gear casing within 10 min. from sealant application.
MAY 2012 8.142
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
115882
Untighten screws (2) fixing the connecting rod cap (3) and
remove it. Remove the connecting rod-piston (1) assembly
from the upper side.
Repeat these operations for the other pistons.
Use adequate hexagonal spanner, unlock screws (1 and 3)
and remove stiffening plate (2) as well as main journals (4).
115881
Rotate the block (1) to the vertical position.
Using tool 99360500 (1), remove the crankshaft (2).
Remove the main bearing shells (1), unscrew the screws and
take out the oil nozzles (2).
Remove the cylinder liners as described under the relevant
subheading on page 134.
After disassembling the engine, thoroughly clean
disassembled parts and check their integrity.
Instructions for main checks and measures are given in the
following pages, in order to determine whether the parts can
be re-used.
Keep the big end bearing shells in their respective housings
and/or note down their assembly position since, if reusing
them, they will need to be fitted in the position found upon
removal.
Note down the assembly position of the top and bottom
main bearing shells since, if reusing them, they will need to
be fitted in the position found upon removal.
47571
114615
177454
Figure 30
ATTENTION
Figure 31
Figure 32
Figure 33
Figure 34
ATTENTION
ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
A = Selection class C 117 117.012 mm
B = Selection class C 117.010 117.022 mm
X = Selection class marking area
In case of maximum wear >0.150 mm or maximum
ovalization >0.100 mm compared to the values indicated in
the figure, the liners must be replaced as they cannot be
ground, lapped or trued.
CYLINDER BLOCK
Checks and measurements
Internal diameter of the cylinder liners is checked for
ovalization, taper and wear, using a bore dial (1) centesimal
gauge 99395687 (2) previously reset to ring gauge (3),
diameter 117 mm.
If dia.117 mm ring gage is not available, use a micrometer.
34994
225036
114037
1 = 1
st
measuring
2 = 2
nd
measuring
3 = 3
rd
measuring
Carry out measurings on each cylinder liner at three different
levels and on two (A-B) surfaces, to one another
perpendicular, as shown in figure.
(Demonstration)
Cylinder liners are equipped with spare parts with A
selection class.
114035
A = 130.500 to 130.525 mm
B = 129.510 to 129.535 mm
C = 130.461 to 130.486
D = 129.475 to 129.500 mm
The figure shows the outer diameters of the cylinder liners
and the relative seat inner diameters.
The cylinder liners can be extracted and installed several
times in different seats, if necessary.
ATTENTION
ATTENTION
Figure 35
Figure 36
Figure 37
Figure 38
MAY 2012 8.144
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
114038
CYLINDER LINERS MAIN DATA
CYLINDER BLOCK ASSEMBLY WITH CHROME-PLATED CYLINDER LINERS
A mm 117.000 to 117.012
B mm 117.010 to 117.022
Selection class
CYLINDER LINERS
114039
Figure 39
Figure 40
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
47577
77812
16798
35012
Place details 99360706 (1 and 2) and plate 99360724 (4) as
shown in the figure, by making sure that the plate (4) is
properly placed on the cylinder liners.
Tighten the screw nut (1) and remove the cylinder liner (3)
from the block.
Always replace water sealing rings (3, 4 and 5).
Install the adjustment ring (1) on the cylinder liner (2);
lubricate lower part of liner and install it in the cylinder unit
using the proper tool.
Check cylinder barrel protrusion with tool 99360334
(1-2-3-4) and tighten screw (1) to 170 Nm.
With dial gauge 99395603 (5) placed on base 99370415 (6).
Measure the cylinder barrel protrusion compared to the
cylinder head supporting plane, it must be 0,035 to 0,065 mm
(Figure 44); otherwise replace the adjusting ring (1,
Figure 42) fitted with spare parts having different thickness.
When the installation is completed, block the cylinder liners
(1) to the block (2) with studs 99360703 (3).
Fitting and checking protrusion
(Demonstration)
CYLINDER LINER PROTRUSION
114041
The adjustment ring (1) is supplied as spare parts in the
following thicknesses: 0.08 mm - 0.10 mm - 0.12 mm.
Replacing cylinder liners
Removal
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
ATTENTION
MAY 2012 8.146
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
177453
X. Detail of main journals connections Y. Detail of crank pins connections
MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS
Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.
The data given refer to the normal diameter of the pins.
114043 114044
Upper main journal half bearing
Lower main journal half bearings
CRANKSHAFT
Figure 46
Figure 47
Figure 48
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MEASURING CRANK PINS
During grinding, pay attention to journal andcrank pins values
specified in figures 68 and 69.
47535
47536
MEASURING THE MAIN JOURNALS
Measuring main journals and crank pins
Before grinding the crank pins using a micrometer (1),
measure the main journals and the crank pins (2) and decide,
on the basis of the undersizing of the bearings, the final
diameter to which the pins are to be ground.
It is advisable to enter the values found in a table (Figure 51). All journals and crank pins must also be ground to the same
undersizing class, in order to avoid any alteration to shaft
balance.
Fill in this table with the measurements of the main journals and the crank pins.
MAIN JOURNALS
177452
Min.
MAX.
Min.
MAX.
CRANK PINS
Figure 49
Figure 50
Figure 51
ATTENTION ATTENTION
MAY 2012 8.148
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
PRELIMINARYMEASUREMENTOF MAINANDBIGENDBEARINGSHELL SELECTIONDATA
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
MAIN JOURNALS:
- Determine the class of diameter of the seat in the
crankcase.
- Determine the class of diameter of the main journal.
- Select the class of the bearing shells to mount.
CRANKPINS:
- Determine the class of diameter of the seat in the
connecting rod.
- Determine the class of diameter of the crankpin.
- Select the class of the bearing shells to mount.
DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
On the front of the crankcase, two sets of numbers are marked in the position shown (Figure 52 at top).
- The first set of digits (four) is the coupling number of the crankcase with its base.
- The following seven digits, taken singly, are the class of diameter of each of the seats referred to (Figure 52 at bottom).
- Each of these digits may be 1, 2 or 3.
114046
99.000 to 89.009
99.010 to 99.019
99.020 to 99.030
CLASS
MAIN BEARING HOUSING
NOMINAL DIAMETER
Figure 52
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
To obtain the required assembly clearances, the main and big end bearing shells need to be selected as described hereunder.
This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary,
can have different classes from one journal to another).
red
red/black
green
green/black
STD
1.994 to 2.002
2.002 to 2.010
+0.127
2.057 to 2.065
2.065 to 2.073
Depending on the thickness, the bearing shells are selected
in classes of tolerance marked by a coloured sign
(red-green red/black green/black).
The following tables give the specifications of the main and
big end bearing shells available as spares in the standard sizes
(STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).
* Fitted in production only and not supplied as spares
yellow*
yellow/black*
2.010 to 2.018
red
red/black
green
green/black
STD
2.968 to 2.978
2.978 to 2.988
+0.127
3.031 to 3.041
3.041 to 3.051
yellow*
yellow/black*
2.988 to 2.998
2.073 to 2.081
3.051 to 3061
Selecting the main and big end bearing shells
Figure 53
ATTENTION
MAY 2012 8.150
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (Journals with nominal diameter)
Main journals and crankpins: determining the class of diameter of the journals.
Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 54 at top):
- The first number, of five digits, is the part number of the shaft.
- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the status
of the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins
they refer to (Figure 54 at top).
- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows the
status of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of the
main journals they refer to (Figure 54 at bottom).
81.915 to 81.925
81.925 to 81.935
81.935 to 81.945
CLASS
CRANKPIN
NOMINAL DIAMETER
92.970 to 92.980
92.980 to 92.990
92.990 to 93.000
CLASS
MAIN JOURNALS
NOMINAL DIAMETER
Figure 54
177451
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Selection of main half-bearings (nominal diameter pins)
After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, in
compliance with the following table:
STD.
1 2 3
1
2
3
green
green
red
red
red
yellow
red
yellow
yellow
yellow
114048
177450
Figure 55
green
green
green
green
green
green
green
green
MAY 2012 8.152
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
green/black
Selection of main half-bearings (rectified pins)
If the journals have been rectified, the procedure described cannot be applied.
In this case, make sure that the new diameter of the journals is as specified on the table and install the only half-bearing type
required for this undersizing.
-0.127
1 2 3
92.843
92.853
green/black
green/black
green/black
yellow/black
yellow/black
yellow/black
red/black
green/black
green/black green/black
yellow/black
red/black
red/black
red/black
green/black
green/black
green/black
92.853
92.863
92.863
92.872
1
2
3
red/black =
mm 3.031 to 3.041
green/black =
mm 3.041 to 3.051
green/black =
mm 3.0513 to 3.061
Figure 56
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
SELECTING THE BIG END BEARING SHELLS
(JOURNALS WITH NOMINAL DIAMETER)
There are 4 references on the connecting rod casing in the
positions illustrated:
1. Coloured mark for identifying the weight
2. Coloured mark for identifying the diameter grade
3. Positioning stud visible from the front of the engine
4. Progressive number for identifying the connecting rod
Determine the type of big end bearing to fit on each journal
by following the indications in the table (Figure 58).
47557
STD.
1
2
3
green
green
red
green
red
red
red
green
green yellow
yellow yellow
green
green yellow
green
green
green
Class
The identification colours of the marks are given in the table
on page 31.
1
yellow
2
green
3
blue
Figure 57
Figure 58
ATTENTION
MAY 2012 8.154
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
green/black
Selection of connecting rod half-bearings (rectified pins)
If pins have been rectified, the procedure described must be applied.
In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the half-bearings
identified according to the relative table.
-0.127
1 2 3
81.789
81.799
green/black
green/black
green/black
yellow/black
yellow/black
yellow/black
red/black
green/black
green/black green/black
yellow/black
red/black
red/black
red/black
green/black
green/black
green/black
81.799
81.809
81.809
81.819
1
2
3
red/black =
mm 2.057 to 2.065
green/black =
mm 2.065 to 2.073
green/black =
mm 2.073 to 2.081
Figure 59
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Place bearing halves (1) on main journals (2).
Check the installation clearance between the main journals
and the relative bearings as follows.
Using the hoist and hook 99360500 (1) mount the driving
shaft (2).
After fitting the gear (1) on the crankshaft (2), heat it for
~15 minutes in an oven at temperature not higher than
180C.
Let them cool down after the installation.
If changing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure.
115883
114049
177454
114050
Fit the oil jets (2) aligning the dowel with the opening (3) in
the crankcase.
Position the half-bearings (1) and the thrust washers on the
main journal supports as illustrated in Figure 46.
Replacing the timing control gear and the oil
pump
Check that the teeth of the gears are not damaged or worn,
otherwise remove them using the appropriate extractor.
Before fitting the gear, spread Loctite type 603 on
approx. 5 mm wide band on crankshaft, at 30 mm from
contact surface.
Figure 60
Figure 61
Figure 62
Figure 63
ATTENTION
Checking main journal installation clearance
MAY 2012 8.156
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
End float is checked by placing a magnetic dial gauge (1) on
the crankshaft (2), as shown in the figure.
If the value obtained is higher than specified, replace the rear
thrust half-bearings and repeat this check.
- Position the main journal caps (4) and fit the
strengthening plate (2) following the procedure
described:
- Tighten the inner bolts and then the outer bolts by hand
starting from main journal 7 and continuing until main
journal 1.
- Tightening the bolts using torque wrench always starting
from main journal 7 and continuing until main journal
1:
1
st
stage: 140 Nm
2
nd
stage 60+60
Fit sized wire sections (2) on crankshaft (3) parallel to
longitudinal axis.
Install main journals (1).
114051
114615
47588
Checking crankshaft end float
Figure 64 Figure 65
Figure 66
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 67
Make sure the piston does showany trace of seizing, scoring,
cracking; replace as necessary.
Removal
Removal of the piston split rings (2) using the pliers 99360184
(1).
Pistons are equipped with three elastic rings: a sealing ring, a
trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
81041
PISTON CONNECTING ROD ASSEMBLY
1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6. Scraper ring
with spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston.
Figure 68
Figure 69
126311
126312
Remove the piston pin split rings (2) using the round tipped
pliers (1).
MAY 2012 8.158
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
PISTON CONNECTING ROD ASSEMBLY
49025 32618
49026
Remove the piston pin (1).
If removal is difficult use the appropriate beater.
Measuring the gudgeon pin diameter (1) with a micrometer
(2).
Conditions for correct gudgeon pin-piston
coupling
Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight
finger pressure and it should not come out by gravity.
Figure 70 Figure 71
Figure 72
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAIN DATA OF PISTON, SNAP RINGS AND PIN
X = 0,6 - 0,15
The dimension is measured on a C of 113 mm
16552
3513
Check the thickness of the piston ring (2) using a micrometer
(1).
The sealing ring (2) of the 1 cavity is trapezoidal. Clearance
X between the sealing ring and its housing is measured by
placing the piston (1) with its ring in the cylinder barrel (3),
so that the sealing ring is half-projected out of the cylinder
barrel.
Piston rings
177448
16552
Check the clearance between the sealing rings (2) and the
relative piston housings (1) using a thikness gauge (3).
36134
Check the opening between the ends of the sealing rings (1),
using a thickness gauge (2), entered in the cylinder barrel (3).
If the distance between ends is lower or higher than the value
required, replace split rings.
Figure 73
Figure 74
Figure 75
Figure 76
Figure 77
MAY 2012 8.160
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
177447
MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS
* Values to be obtained after installing the bush
When fitting the connecting rods, check that all of them are of same weight class and from the same supplier. The connecting
rod/cap is of torn type; before assembly verify that the connecting rod is not damaged. Each connecting rod can assembled
with the relative cap only. If the cap is assembled on the reverse side, the connecting rod must be rejected.
CONNECTING ROD
1 Between the connecting rod bush and the connecting rod profile there must be a distance > 0.4 mm.
2 On the external breaking line, gap area allowed must be < 5 mm
2
.
3 No cracks are allowed in the threaded area.
Figure 78
ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
115884
1. Coloured mark for identifying weight - 2. Coloured mark for identifying diameter grade - 3. Positioning stud visible from
the front of the engine - 4. Progressive number for identifying connecting rod
Figure 79
MAY 2012 8.162
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
WEIGHT DIAMETER
GRADE A
Yellow
3331 g - 3361 g
85.987-85.996 Yellow
85.997-86.005 Green
86.006-86.013 Blue
GRADE B
Green
3362 g - 3391 g
85.987-85.996 Yellow
85.997-86.005 Green
86.006-86.013 Blue
GRADE C
Blue
3392 g - 3421 g
85.987-85.996 Yellow
85.997-86.005 Green
86.006-86.013 Blue
49029
To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
The rings need to be mounted with the word TOP (4)
facing upwards. Direct the ring openings so they are
staggered 120 apart.
Mounting the connecting rod - piston
assembly
Carry out the steps for removal described on pages 146 and
147 in reverse order.
The connecting rod screws can be reused as long as the
diameter of the thread is not less than 11.4 mm.
Mounting the piston rings
117694
Figure 80
Figure 81
ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
ATTENTION
As spares, class A pistons are provided and can be fitted also
to cylinder barrels belonging to class B.
Fitting connecting rod - piston assemblies in
the cylinder liners
With the aid of the clamp 99360605 (1, Figure 82), fit the
connecting rod - piston assembly (2) in the cylinder liners,
according to the diagram of Figure 83, checking that:
- The openings of the piston rings are staggered 120
apart.
- The pistons are all of the same class, A or B.
- The symbol punched on the top of the pistons faces the
engine flywheel, or the recess in the skirt of the pistons
tallies with the oil nozzles.
Figure 82
Figure 83
60616
Checking piston protrusion
On completing assembly, check the protrusion of the pistons
from the cylinder liners; it must be 0.873 to 1.177 mm.
ASSEMBLY DIAGRAM OF CONNECTING ROD - PISTON ASSEMBLY IN CYLINDER LINER
1. Connecting rod - piston assembly - 2. Area of punch marking on the top of the piston, symbol showing assembly position
and selection class - 3. Connecting rod punch mark area
60615
MAY 2012 8.164
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
- Install the connecting rod caps (1) with half-bearings;
tighten the connecting rod cap fixing screws (2) to
50 Nm (5 Kgm) torque. By tool 99395216 (3), tighten
the screws further at 90 angle;
- Remove the caps and check the clearance by comparing
the width of the calibrated wire with the scale calibration
on the envelope containing the wire.
The planarity (1) is checked using a ruler (2) and a thickness
gauge (3). If deformations exist, surface the head using proper
surface grinder; the maximum amount of material to be
removed is 0.2 mm.
Checking assembly clearance of big end pins
To check the clearance proceed as follows:
- Connect the connecting rods to the relative main
journals, place a length of calibrated wire on the latter;
Before taking down the cylinder head, check the seal using
the appropriate tool; in case of leakage replace the cylinder
head.
Valve removal
Figure 84
Install and fix tool 99360264 (2) with bracket (4); tighten by
lever (1) until cotters are removed (3); remove the tool (2)
and the upper plate (3), the spring (6) and the lower plate (7).
Repeat the operation on all the valves. Turn the cylinder head
upside down and remove the valves (8).
Checking the planarity of the head on the
cylinder block
Figure 85
81060
81061
Figure 86
81062
ATTENTION
After leveling, make sure that valve sinking and injector
protrusion are as described in the relative paragraph.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
CYLINDER HEAD
MAIN DATA - VALVES AND VALVE GUIDES
* Values to be obtained after installing the valve guides
92841
47509
Check, by means of a micrometer, that valve stem diameters
are as specified; if necessary, grind the valves seat with a
grinder, removing the minimum quantity of material.
INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES
* Values to be obtained after installing the guide valves
VALVE GUIDES
*
48625
VALVE
Removing deposits and checking the valves
Remove carbon deposits using the metal brush supplied.
Check that the valves show no signs of seizure or cracking.
Check the diameter of the valve stem using a micrometer
(see Figure 88) and replace if necessary.
Figure 87
Figure 88
Figure 89
MAY 2012 8.166
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
To replace the injector case (2), act as follows:
- Thread the case (2) with tool 99390804 (1).
Carry out operations described in figs. 91-94-95-96 by fixing
tools to the cylinder head by means of bracket A.
Replacing of valve guides
Install by means of tool 99360288 equipped with part
99360288, which determines the exact installation position
of valve guides into the cylinder heads; if they are not
available, install the valve guides in the cylinder head so that
they project out by mm 16.3 to 16.7 (Figure 89).
After installing the valve guides, smooth their holes with
sleeker 99390310.
Removal
Figure 90
81067
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
REPLACING INJECTOR HOLDER CASES
- Fasten extractor 99342149 (2) to case (2), by tightening
the nut (1), and pull out the case from cylinder head.
- Remove any residue, with tool 99390772 (2), from the
cylinder head groove.
- Lubricate sealing rings (3) and fit them to the case (4);
fix tool 99365054 (2) to the cylinder head by means of
bracket A, install the new case, tighten the screw (1),
upsetting the case lower part.
- Adjust the casing hole (3) with borer 99394043 (1) and
guide bushing 99394045 (2).
Mounting
Figure 91
Figure 92
8107 81068
81069
Figure 93
Figure 94
81071
MAY 2012 8.168
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
115891
47585
- Through miller 99394044 (1) and bushing 99394045 (2),
ream the injector seat in the case (3), check the injector
protrusion from the cylinder head plane which must be
1.2 to 1.5 mm.
Using dial gauge (1), check the protrusion of the injector (2)
which must be 1.2 to 1.5 mm.
Checking protrusion of injectors
114056
INSTALLATION DIAGRAM FOR
INJECTOR CASE
Figure 95
Figure 96
Figure 97
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TIMING CONTROL COMPONENT PARTS
1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod -
5. Camshaft control gear - 6. Idler gear - 7. Twin idler
gear - 8. Drive shaft driving gear.
114210 114211
Rated assembling play between idler gear bushings and pins:
0.040 + 0.080 mm.
TIMING GEAR
Camshaft drive
Intermediate gear pin
86926
Idler gear
Twin idler gear
Replacing the bushings
Bushings (1, Figures 78-79) can be replaced when they are
worn. Put up the bushing, then grind it so as to bring it to a
dimension of C 65.010 - 0.10 mm.
Bushing fitting in gears (2, Figures 78-79) must be performed
in arrow direction, placing them as shown in figures.
114212
Figure 98
Figure 99
Figure 100
Figure 101
ATTENTION
MAY 2012 8.170
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Figure 102
Checking cam lift and pin alignment
81088
Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2); values are shown in table on
page 111.
Figure 103
81075
When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not
exceed 0.030 mm.
If misalignment exceeds this value, replace the shaft.
Figure 104
81076
In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained
by their difference.If clearance exceeds 0.150 mm, replace bushes and, if necessary, the camshaft.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
The bush surfaces must not show any sign of seizing or
scoring; if they do replace them.
114213
MAIN DATA - CAMSHAFT AND TOLERANCES
The surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or scoring, replace the
shaft and the relative bushes.
MAIN DATA - CAMSHAFT BUSHES AND RELATIVE BLOCK SEATS
* Bush inner diameter after installation
TIMING GEAR
Measure the bush inner diameters with a baremeter and
replace them, if the value measured exceeds the tolerance
value. To take down and fit back the bushes, use the proper
tool 99360505.
114214
Figure 105
Figure 106
MAY 2012 8.172
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
CAMSHAFT
TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL
ORIENTATION Perpendicularity

POSITION Concentricity or coaxial alignment
OSCILLATION Circular oscillation

IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL
IMPORTANT

SECONDARY

177446
MAIN DATA TO CONTROL EXHAUST AND
DISCHARGE VALVE SPRING
Lubricate the valve stem and insert the valves in the
respective valve guides; fit the lower caps (1). Use tool
99360294 to fit the oil seal (2) on the valve guides (3) of the
exhaust valves; then, to fit the valves, proceed as follows.
- fit springs (6) and the upper plate (5);
- apply tool 99360264 (2) and block it with bracket (4);
tighten the lever (1) until cotters are installed (3),
remove tool (2).
Fitting the valves and oil seal ring
114280
Use tool 99360505 (3) fitted as shown in fig. to remove
bushings (2).
Accurately position beater during removal phase.
87051
Should valves not have been overhauled or replaced,
remount them according to numbering performed on
dismounting.
Intake valves are different form exhaust valves in that they
have a notch placed at valve head centre.
Use beater 99360505 to change bushings
Removal
VALVE SPRINGS
Fitting
For fitting, reverse operations performed for removal, with
care to make lube hole (1), drilled on bushing, coincide with
corresponding hole in housing.
86290
Figure 107
Figure 108
Figure 109
Figure 110
ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
114216
The camshaft eccentric elements control the 12 valve rocker arms directly. Valve control rocker arms are fitted directly on rocker
arm shaft. Rocker arms slide directly on cam profiles by rollers. The other end operates on a crosspiece laid directly on the two
valve rods. A pad is placed between rocker arm adjustment screw and crosspiece. Two lube ducts are machined inside rocker
a rms. Rocker arms shaft runs through the cylinder head; it must be removed to reach all units below.
EXHAUST VALVES ROCKER
The bush surfaces must not show any trace of scoring of excessive wear; otherwise, replace bushes or the whole rocker.
DISCHARGE VALVE ROCKER
Rocker
Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.
MAIN DATA OF THE ROCKER ARM SHAFT
Shaft
ROCKER SHAFT
114217
114219
114218
Figure 111
Figure 112
Figure 113
Figure 114
MAY 2012 8.174
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
The oil pump (1) cannot be overhauled. On finding any
damage, replace the oil pump assembly.
See under the relevant heading for replacing the gear (2) of
the crankshaft.
114245
112327
MAIN DATA TO CHECK THE OVERPRESSURE
VALVE SPRING
OIL PUMP CROSS-SECTION
1. Overpressure valve Start of opening pressure 10.1 - 0.7 bars.
Overpressure valve LUBRICATION CIRCUIT COMPONENTS
Oil pump
1 6N
4
3
.
6
5
3
3
.
5
2
2
.
9
5
324 9N
2
2
.
9
5
117716
Figure 115
Figure 116
Figure 117
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
143676
Engine oil filter adapter
73545
Valve opens quickly at 3,4 - 0,3 bar pressure.
Filter by-pass valve
Figure 118
Figure 119
MAY 2012 8.176
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Figure 120
Figure 121
The oil pressure control valve is located on the left-hand side
of the crankcase.
Start of opening pressure 5 bars.
73542
88819
MAIN DATA TO CHECK THE OIL PRESSURE
CONTROL VALVE SPRING
Oil pressure control valve
Heat exchanger
143675
1. Exchanger seal - 2. Internal heat exchanger element - 3. Cover - 4. Oil filter
168 9
308 15
6
3
5
1
3
6
.
4
Figure 122
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
1. Impeller - 2. Control Pulley
Make sure that the pump casing has no cracking or water
leakage; otherwise, replace the entire pump.
1. By-pass flow to the engine - 2. Flow from the engine - 3. Flow from the exhaust manifold -
4. Flow to the exhaust manifold - 5. Flow to the sea water heat exchanger.
Description and operation on Section 1.
Cooling by forced circulation obtained with centrifugal pump,
driven by the drive shaft through a Poli-V belt. Liquid
circulation is regulated by a thermostatic valve.
Water pump
Thermostatic valve
The valve is calibrated to start opening the channel to the sea
water heat exchanger at a temperature of 68 - 2 C and to
shut the channel to the coolant pump completely at the
temperature of 78 - 2 C.
Check the valve works properly; replace it if in doubt.
81101
Low temperature liquid High temperature liquid
05_148_C 05_149_C
Figure 123
Figure 124 Figure 125
MAY 2012 8.178
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
COMPONENTS OF THE COOLING SYSTEM
Figure 126
Figure 127
Figure 128
Figure 129
174580
Install front cover (1) and lock retaining screw at required
torque.
ASSEMBLY
Secure seal (1), install special tool 99346260 (2), lock nut (3)
to secure seal (1).
174579
42566
Check that pistons 1-6 are exactly at T.D.C.
Place seal (2) on cylinder block.
Install cylinder head (1) and lock screws as shown in figures
below.
Removed screws must not be used again. Employ new
screws only.
174573
Cylinder head retaining screw locking sequence diagram.
ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
Figure 130
Figure 131
Figure 132
- Pre-lock by torque wrench (1):
1
st
phase: 50 Nm (5 kgm);
2
nd
phase: 100 Nm (10 kgm).
45268
- Angle locking by means of tool 99395216 (1):
3
rd
phase: 90 angle
4
th
phase: 75 angle.
45267
145833
Install oil pump (1), double gear (3) complete with
connecting rod (4) and lock screws (2) in two phases:
pre-lock 30 Nm
90 angle lock
MAY 2012 8.180
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
114260
3. Install pipes on rail and lock fittings by hand.
4. Lock rail to cylinder head retaining screws at required
torque.
The previously removed pipes ca no longer be refit and must
be replaced.
After fitting the high-pressure pipelines, during the following
20 hours of work, frequently check engine oil level (IT MUST
NOT INCREASE).
1. Install rail on cylinder head and lock retaining screws by
hand.
2. Install injectors in correct position and lock to required
torque.
Check that the injectors (2) are equidistant from the springs
(1). Distance X which separates themshould always be the
same.
5. Fit pipes on injectors and head locking fittings by hand.
6. Lock fittings on rail (A, C) at required torque .
7. Lock fittings on injectors and head (B, C) at required
torque.
Lubricate the injector fastening O-Rings using the following
lubricants: PDE SILIKONFETT 22, NLG 12, PDE
LUBRICOMET GR 220 NLG12.
Figure 133
ATTENTION
ATTENTION
ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
TYPE DESCRIPTION LOCK TORQUE
A M18 x 1.5 40 2 Nm
B M14 x 1.5 35 2 Nm
C M16 x 1.5 40 2 Nm
114261
114262
114263
114264
Apply LOCTITE 275 (2) silicone on gear casing (1) as shown
in the figure.
The sealant seam diameter must be 1.5 - 0.5/0.2 mm.
Use torque wrench to lock screws (1) at required torque.
Apply LOCTITE 275 silicone on gear casing (1) as shown in
the figure.
The sealant seam diameter must be 1.5 - 0.5/0.2 mm.
Apply gage 99395221 (1) to check and adjust position of
high-pressure pump connection flange (2).
Fix flange screws (2) at required torque.
Figure 134
Figure 135
Figure 136
Figure 137
ATTENTION
ATTENTION
MAY 2012 8.182
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Figure 138
Figure 139
114272
114265
Install high-pressure pump (1) on flange (2).
ENGINE FLYWHEEL
Secure seal (1), install special tool 99346260 (2), lock nut (3)
to secure seal.
Engine flywheel installation
DETAIL OF PISTON POSITION STAMPING ON ENGINE FLYWHEEL
A. Hole on flywheel with a notch corresponding to pistons 3-4 TDC - B. Hole on flywheel with a notch, corresponding to
piston 1-6 TDC - C. Hole on flywheel with a notch corresponding to pistons 2-5 TDC - D. Hole on flywheel with 2
notches, position corresponding to 54.
High pressure pump installation
If toothing on engine flywheel for engine start-up is very
damaged, change crown wheel.
Refit crown wheel after heating up at approx. 200C.
Crankshaft has a reference pin that must match with related
housing on engine flywheel.
45258
Figure 140
ATTENTION ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
49036
72436
114267
Position flywheel (1) on crankshaft, lubricate screws (2)
threading with engine oil and lock them.
Stop rotation using specific tool.
Lock screws (2) in three phases.
1
st
phase: pre-lock with torque wrench (3) at 100 Nmtorque
(10 kgm).
2
nd
phase: 60 angle locking using tool 99395216 (1).
This condition is obtained when:
1. the opening with one reference (5) for the engine
flywheel (4) is visible from the inspection window;
2. tool 99360612 (1), through housing (2) of engine rpm
sensor, inserts in hole (3) drilled on engine flywheel (4).
Otherwise, adjust engine flywheel orientation (4). Remove
too 99360612 (1).
Install camshaft (3) and orient it with references (-)
positioned as in the figure.
Clean the matching surfaces of the plate (1) to remove
impurities and oil residues.
Apply silicon LOCTITE 275 (6) on the plate (1) as shown in
the picture.
Camshaft installation
145832
Take care NOT to get sealant on the inner groove (5).
The diameter of the sealant bead should be 1.5 - 0.5/0.2 mm.
Fit the plate (1) within 10 mins of applying the sealant with
the gasket (2) and tighten the bolts (4) to the recommended
torque.
Position crankshaft with pistons 1 and 6 at TDC.
ATTENTION
Figure 141
Figure 142
Figure 143
Figure 144
MAY 2012 8.184
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
114269
114270
Apply gage 99395222 (1), check and adjust position of
connecting rod (3) for relay gear, lock screw (2) at required
torque.
Refit relay gear (2) and lock screws (1) using six-splined
spanner at required torque.
The relay gear (2) bushing can be replaced when worn out.
After securing bushing, grind it to reach dia. 58.010 - 0.10
mm.
Rotate the crankshaft with the tool 99360341 (3, Figure 154)
so that the opening marked with two references (5) is visible
from the lower inspection window in the flywheel cover
casing.
In this condition, insert the tool 99360612 (1) via the housing
(2) for the engine rpmsensor in the opening (3) in the engine
flywheel (4).
115064
USING TOOL 99395223
Timing camshaft
116052
Fit the tool 99395223 (1) at the front of the camshaft.
4
ATTENTION
Figure 145
Figure 146
Figure 147
Figure 148
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
116053
117691
116055
114025
Rotate the tool (1) 99395223 in order to insert the pin (3)
in the opening (2, Figure 148) in the head. Fasten the tool
(1) 99395223 using two M8x1.25 bolts (2).
Fit the camshaft drive gear (1) so that the fastening openings
in the shaft are aligned with the slots (2) in the drive gear.
Position the gear (1) taking care to position the spokes (4)
as illustrated. This operation is necessary in order to be able
to fit the flywheel correctly which can only be fitted in one
position in relation to the gear.
Tighten the fixing bolts (3).
Install crosspieces (1) on valve rod.
Apply tool 99360558 (1) to rocker arm shaft (2) and install
shaft on cylinder head.
Lock retaining screws at required torque.
Before refitting rocker arm shaft assembly, check that all
adjustment screws have been fully unlocked.
ATTENTION
Figure 149
Figure 150
Figure 151
Figure 152
MAY 2012 8.186
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
145834
Fit the high pressure pump gear (5) tightening the nut (4) to
torque.
Use the flat washer (PN 17095914) in conjunction with the
nut (4) replacing the one supplied with the Bosch CP3 pump.
Fit the flywheel (6) so that the toothe marked with the arrow
([) is in line with the sensor housing (2).
To check that the position is correct, insert tool (1)
99360613 in the timing sensor (2) housing.
Proceed with tightening the bolts (3).
Remove the tools 99395223, 99360612 and 99360613. Secure special tool 99360341 (3) to gear casing.
114279
The arrow indicated engine rotation direction. Use tool
above to rotate engine flywheel (1) in engine rotation
direction to bring cylinder 1 piston approx. to TDC in blast
phase. This condition is reached when hole with notch (4),
following hole with two notches (5) drilled on engine
flywheel (1), is visible through manhole (2).
WITHOUT TOOL 99395223
Timing camshaft
71774
The exact position of piston no.1 at TDC is obtained when,
in conditions described above, tool 99360612 (1), through
engine rpm sensor housing (2), inserts in hole (3) drilled on
engine flywheel (4).
Otherwise, rotate engine flywheel (4) to adjust its
orientation.
Timing flywheel
ATTENTION
Figure 153
Figure 154
Figure 155
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
115063
Rotate the camshaft so that the openings at the rear of the
engine are arranged in the configuration illustrated in the
diagram.
Install gear (1) controlling camshaft so that fastening holes on
shaft coincide with slots (2) on control gear.
114276
Install crosspieces (1) on valve rod.
Before refitting rocker arm shaft assembly, check that all
adjustment screws have been fully unlocked.
Lock retaining screws (3).
Position the gear (1) taking care to position the spokes (4)
as illustrated.
This operation is necessary in order to be able to fit the
flywheel correctly which can only be fitted in one position
in relation to the gear.
114025
Apply tool 99360558 (1) to rocker arm shaft (2) and install
shaft on cylinder head.
Lock retaining screws at required torque.
Remove tool 99360612 (1, Figure 148).
117691
Clean the surface of the parts to be joined removing
impurities and oil residuals. Apply silicon LOCTITE 275 (1)
on the front cover (2) as shown in the picture. The diameter
of the sealing string must be 1.5 - 0.5/0.2 mm.
117693
Figure 156
Figure 157
Figure 158
Figure 159
Figure 160
ATTENTION
ATTENTION
MAY 2012 8.188
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
106535
Position the dial gauge with a magnetic base (1) with the
(flat-based) rod positioned on the roller (2) for the rocker
arms which controls the exhaust valve for cylinder no. 3 and
apply a pre-loading of 6 mm.
Camshaft is timed if conditions below are found at cam lift
values 4.70 - 0.05:
1) hole identified with two notches (5) is visible through
manhole;
2) fixture 99360612 (1) through housing (2) of engine rpm
sensor inserts in hole (3) on engine flywheel (4).
115064
114281
In case conditions shown in Figure 162 and shown at paras
1 and 2 are not found, operate as follows:
1) release screws (2) securing gear (1) of camshaft to as to
make control gear and camshaft independent;
2) conveniently operate on engine flywheel so as to obtain
conditions indicated at paras 1 and 2, Figure 163,
considering that cam lift value must remain unchanged;
3) lock screws (2) and repeat control as already described;
4) lock screws (2) at required torque.
Rotate crankshaft to check conditions below:
1) hole identified with two notches (5) is visible through
manhole;
2) fixture 99360612 (1) through housing (2) of engine rpm
sensor inserts in hole (3) on engine flywheel (4).
115064
To recover the clearances, rotate the crankshaft in a
clockwise direction until the opening with the two
references is passed and then rotate in the opposite
direction to produce the conditions described above.
Using tool 99360341 (3, Figure 154), rotate crankshaft
clockwise till dial gage arrow reaches minimum value (max
cam lift), after which it no longer varies.
Zero set dial gage.
Rotate engine flywheel anticlockwise till dial gage reads
camshaft cam lift value = 4.70 - 0.05 mm.
During the measurement the rod for the dial gauge should
always be perpendicular to the engine axis and NOT to the
surface of the head.
ATTENTION
Figure 161
Figure 162
Figure 163
Figure 164
ATTENTION
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
114284
Fit the flywheel (4) so that the tooth marked with the arrow
([) is in line with the sensor housing (6).
Rotate crankshaft and bring cylinder n.1 piston to
compression phase at TDC: Rotate flywheel opposite to
regular rotation direction by 1/4 of rev.
Rotate flywheel again in regular rotation direction till hole
identified by double notch (2) shows through inspection hole
under flywheel cover box.
Insert tool 99360612 (1) in flywheel sensor housing (3).
Insert tool 99360613 through phase sensor housing (6) on
tooth machined on tune wheel.
In case tool (6) is difficult to insert, unlock screws (5) and
orient tune wheel (4) to properly match the tooth.
Lock screws (5).
Timing flywheel
Install centrifugal filter (1) on tune wheel and lock screws (2)
at required torque.
114275
Install fuel supply pipeline (1) fromhigh pressure pump to rail.
Lock nuts at 35 Nm torque.
Install timing cover (1) and lock retaining screws (2) at
required torque.
Pipes previously removed ca no longer be refit.
Change them.
After high-pressure pipe installation, during the following
20 hours of work, frequently check engine oil level.
( IT MUST NOT INCREASE ).
114285
114286
Install gear (7) of high pressure pump and lock nut (8) at
required torque.
When refitting, use the flat washer (PN 17095914) in
conjunction with the nut (4) replacing the one supplied with
BOSCH pump CP3.
ATTENTION
ATTENTION
ATTENTION
Figure 165
Figure 166
Figure 167
Figure 168
MAY 2012 8.190
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
114287
Adjustment of clearance between rocker arms and
intake/exhaust valve control crosspieces must be performed
with utmost care. Bring to blast phase cylinder to be adjusted;
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced. Symmetric cylinders are 1-6; 2-5
and 3-4.
In order to perform these operations correctly, refer to
procedure and table below.
- Use a polygonal spanner to release lock nut (1) of rocker
arm adjustment screw (2).
- Insert filler gage (3) having same value of operating
clearance shown in Characteristic and data tables.
- Use special spanner to lock/unlock adjustment screw.
- Check that filler gage (3) slides with a low friction.
- Lock nut (1) retaining the adjustment screw.
IGNITION ORDER 1-4-2-6-3-5
adjustment
In order to correctly carry out adjustments above, it is
mandatory to perform the sequence indicated in the table,
checking exact positioning at each phase by means of pin
99360612.
114288
Install blow-by body (1) with related seal and lock screws (2)
at required torque.
Install cover (3) and lock screws (4) at required torque.
117692
Clean the surface of the parts to be joined removing
impurities and oil residuals. Apply silicon LOCTITE 406
within the check valve (2) housing (1) and on the Blow-by
(3) as shown in the picture.
ATTENTION
Figure 169
Figure 170
Figure 171
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
START AND
ROTATION
CLOCKWISE
BALANCE
VALVES OF
CYLINDER No.
ADJUST
CLEARANCE
OF VALVES
CYLINDER No.
1 and 6 at TDC 6 1
120 3 4
120 5 2
120 1 6
120 4 3
120 2 5
Figure 172 Figure 173
Figure 174
17 14 13 1 4 5 8
18
19
20
16 15 12 2 3 6 7
11
10
9
Rotate the engine. Before assembling the suction rose, it is necessary to seal the contact area (1) between basement, flywheel
casing and front cover with LOCTITE, following the herein instructions. Clean the surfaces of the parts to be joined removing
impurities and oil residuals. Apply silicon LOCTITE 275 (1) as shown in the picture. The diameter of the sealing string must be
1.5 - 0.5/0.2 mm.
117695
174574
Install cylinder head cover (1) and lock screws (2) at required
torque following order shown in Figure 174 diagram. 115880
Fit the head internal electric wire (injectors+pressure sensor)
passing it through the opening (5, Figure 170) and securing
it using bands as illustrated in the diagram ().
Figure 175
MAY 2012 8.192
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
Fit the oil sump (2), tightening the screws (1) to the
prescribed torque.
Fit the oil filter adapter (1) and the heat exchanger (2).
Complete the engine by restoring the following components:
- Marinisation components (see relevant chapter)
- Fuel filter
- Engine cable
- EDC control unit
- Oil dipstick
- Engine mountings
Refill the engine with the required quantity of oil and coolant.
114031b
Install suction rose (1).
Installing the following components:
belt tensioner (2), alternator (3), fixed tightener (5), water
pump (6), damping flywheel (7).
To install auxiliary organ drive belt (4), using the appropriate
tool (1) loose the tensioner, as shown by arrow; insert the
belt, verifying that it is correctly set onto the pulleys. Release
the tensioner.
ATTENTION
Automatic tensioners do not require further adjustments
after the installation.
05_070_C
143674
143672
Figure 176
Figure 177
Figure 178
Figure 179
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 8.194
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
OVERHAUL
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 SAFETY REGULATIONS 9.195
SECTION 9
Safety regulations
Page
SAFETY REGULATIONS 197 . . . . . . . . . . . . . . . . . . . .
Standard safety regulations 197 . . . . . . . . . . . . . . . .
Accident prevention 197 . . . . . . . . . . . . . . . . . . . . .
During maintenance 197 . . . . . . . . . . . . . . . . . . . . .
Respecting the Environment 198 . . . . . . . . . . . . . . .
MAY 2012 9.196
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
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.
- Be informed and also inform personnel of the laws in
force regulating safety, by making informative
documentation available for consultation;
- Keep working areas as clean as possible, and ensure
adequate ventilation;
- Ensure that working areas are provided with emergency
kits. These must be clearly visible and always fitted with
adequate sanitary equipment;
- 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;
- Provide specific exit points to evacuate the areas in case
of emergency, giving adequate indications of emergency
escape paths;
- Smoking in working areas subject to fire danger must be
strictly prohibited;
- Provide warnings by means of adequate boards signaling
danger, prohibitions, and indications to ensure easy
understanding of the instructions even in case of
emergency.
Accident prevention
- When working close to engines and equipment in
motion, do not wear unsuitable clothes, with loose ends,
nor jewels such as rings and chains;
- 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).
- Wear a safety helmet when working close to hanging
loads or equipment operating at head height level;
- Always wear safety shoes and clothes that adhere to the
body, better if provided with elastics at the ends;
- Use protection cream for your hands;
- Change wet clothes as soon as possible;
- 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;
- Do not smoke nor have exposed flames close to
batteries and flammable material;
- Put rags smeared with oil, diesel fuel, or solvents in
fireproof containers;
- Do not carry out any intervention you have not been
given all necessary instructions for;
- 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;
- 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
- 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 andrisk of scalding.
Wait until the temperature decreases below 50 C;
- Never top up an overheated engine with cooler and use
only appropriate liquids;
- Always operate with the engine turned off: in case
particular circumstances require maintenance
intervention on the running engine, be aware of all risks
involved in such operation;
- Be equipped with adequate and safe containers for
draining engine liquids and exhaust oil;
- Keep the engine clean from oil, diesel fuel, and/or
chemical solvents stains;
- The use of solvents or detergents during maintenance
may generate toxic vapors. Always keep working areas
ventilated. Whenever necessary wear a safety mask;
- Do not leave rags impregnated with flammable
substances close to the engine;
- Upon engine start after maintenance, undertake proper
preventive action to stop air suction in case of
overspeed;
- Do not use fast screwdriver tools;
- Never disconnect batteries when the engine is running;
- Disconnect batteries before any intervention on the
electrical system
- Disconnect batteries from the system to charge them
with the battery charger;
- 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;
- Do not disconnect or connect electrical connections
while the power is connected.
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
MAY 2012 SAFETY REGULATIONS 9.197
SAFETY REGULATIONS
- Before proceeding with pipeline 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;
- Avoid incorrect or over-torque tightening. Danger:
incorrect tightening may seriously damage the engine's
components, affecting its lifetime;
- Avoid priming from fuel tanks made of copper alloys
and/or with ducts without filters;
- Do not modify cable wires: their length must not be
changed;
- Do not connect any other equipment to the engine's
electrical equipment unless specifically approved by FPT;
- Do not modify the fuel or hydraulic systems without
having received specific approval from FPT. Any
unauthorized modifications will compromise the
warranty assistance and furthermore may affect the
correct operation and lifetime of the engine.
For engines equipped with an electronic control unit:
- Do not carry out any electric arc welding without having
removed the electronic control unit first;
- Remove the electronic control unit in case of any
interventions requiring heating over 80 C;
- Do not paint the components and the electronic
connections;
- Do not vary or alter any data filed in the electronic
control unit. Any manipulation or alteration of electronic
components will fully compromise the engine's warranty
of assistance and furthermore may affect the correct
operation and lifetime of the engine.
Respecting the Environment
- Respecting the Environment is of primary importance: all
necessary precautions to ensure the personnel's safety
and health must be adopted;
- Be informed and also inform the personnel of laws in
force regulating use and exhaust of liquids and engine
exhaust oil. Provide for adequate noticeboards and
organize specific training courses to ensure that
personnel is fully aware of such legal obligations and of
basic preventive safety measures;
- Collect exhaust oils in adequate containers with air-tight
sealing ensuring that storage is made in specific, properly
identified, areas that are ventilated, away from heat
sources, and not exposed to fire danger;
- Handle batteries with care, storing them in a ventilated
environment and in anti-acid containers. Warning:
battery exhalations represent a serious danger of
intoxication and environment contamination.
MAY 2012 9.198
C87 ENT M62.10 / C87 ENT M65.10
C87 ENT M62.11 / C87 ENT M65.11
SAFETY REGULATIONS
FPT - Fiat Powertrain Technologies
www.fptpowertrain.com

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