PDF Workshop Manual Nanni Marine Diesel Engine T4.165 T4.180 T4.200 - 3 MB
Get access to the official workshop manual for Nanni Marine Diesel Engines, models T4.165, T4.180, and T4.200.
This document is the ultimate guide for any service, repair, or overhaul procedure.
It contains detailed instructions, specifications, and diagrams to help you maintain the performance and reliability of your marine engine.
Whether you are a professional marine mechanic or a boat owner, this manual is crucial for complex maintenance tasks.
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WORKSHOP MANUAL
Marine Diesel Engine
T4.165 - T4.180 - T4.200
60300199
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[4.2] Coolant level check and adjustment
(1) • Remove the cap from the heat exchanger (1) and
check if the coolant level is just below the filling
hole between the lower level of the filler neck (2)
and indicator finger (3), representing the minimum
and maximum level of liquid.
• If the coolant level is too low, find the reason why
the liquid level has dropped.
CASE 1
If the liquid drop is due to evaporation, always top it with
fresh water without limestone only.
CASE 2
If the liquid drop is due to leakage, always top off with a
(3) liquid of the same brand and type respecting the mixing
(2) ratio (50% freshwater and 50% pure antifreeze).
If the brand of coolant is unknown, drain the remaining
liquid and fill with a new mixture of coolant properly pro-
portioned. (50% freshwater and 50% pure antifreeze).
WARNING
• Do not remove the cooler cap when the coolant
temperature is too high. Then slightly loosen
the cap to release the remaining pressure be-
fore complete removal.
• When filling the coolant, bleed the cooling sys-
tem at various locations.
• Carefully close the heat exchanger cap. If the
cap is loose or not closed, the coolant can es-
cape and cause an engine to overheat.
• Do not use antifreeze and anti-tartar additive at
the same time.
• Never mix different types or brands of coolant
or antifreeze
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[4.12] Coolant replacement:
1. DRAIN ENGINE COOLANT
(1) WARNING
• To avoid the risk of burn injuries, do not re-
move the filling cap while the engine and
heat exchanger are hot. It may result in
heated fluid and steam being spewed by
pressure, able result that heated fluid and
steam are spewed by pressure inside the heat
exchanger.
• Remove the heat exchanger filling cap (1).
• Loosen the engine drain plug, and drain the
coolant from the engine. (15.5 litres)
Symbol for drain plug
• Close the drain plugs.
Torque: 8 N m (82 kgf cm, 71 in. lbf)
2. ADD ENGINE COOLANT
• Fill the radiator with a coolant carefully through
the filling cap.
(3) (2) IMPORTANT:
• Use a mixture of 50% pure antifreeze with
50% demineralised water. The total volume
of coolant is 15.5 litres.
• If you prefer to use pre-mixed coolant its
content ratio should be 50 % or up to 60 %.
Beyond that, 60 % and up would deteriorate
the cooling effectiveness of the coolant.
NOTICE:
• Do not use an alcoholic coolant and plain
(non-demineralised) water alone. Otherwise,
it may cause damage to engine cooling sys-
tem.
• Drain the air from the circuit (see procedure)
• Reset the heat exchanger filling cap.
• Start the engine to circulate the coolant.
• Wait until the coolant gets cold, then remove
the filling cap again, and so check the coolant
level inside the heat exchanger.
HINT:
Refill the heat exchanger with the coolant
if the coolant level is low.
3. INSPECT CHECK FOR ENGINE COOLANT
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[4.18] TAPPET CLEARANCE (Control and adjustment):
(3) WARNING
• Before tappet inspection, make sure the fuel
valves and sea water valves are all closed and
secure. Make sure that engine power is OFF.
Do not forget to install a panel to prevent risk
of injuries.
1. BEFORE INSPECTION
• Drain the coolant circuit (see concern chapter
page 32)
• Remove the plastic cover.
• Disconnect the 4 injectors (1).
• Remove the 4 injection pipes (2).
• Unscrew the 4 screws and remove the 2 cover
support (3)
(2) (9) (1) • Unscrew the 2 banjo bolt and remove the water
pipe (4)
• Unscrew the clamps and the 3 nuts and remove
the water pipe (5)
• Unscrew the 2 clamps and remove the water pipe
(6)
• Unscrew the 2 nuts and remove the sea water
pump (7)
• Unscrew the 6 bolts and remove the timing belt
cover (8)
• Unscrew the 12 bolts and remove the cylinder
head cover (9).Be careful to the injectors seals.
(4)
(5)
(8)
(6)
(7)
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STANDARD TOOLS
Belt tension Gauge Standard tools
CO / CH Meter Standard tools
Chain block Standard tools
Compression gauge Standard tools
Dial indicator Standard tools
Feeler gauge Standard tools
Hexagonal wrench (10mm) Standard tools
Injection nozzle tester Standard tools
Micrometer Standard tools
Plastigage Standard tools
Precision straight edge Standard tools
Press Standard tools
Radiator cap tester Standard tools
Sandpaper #400 Standard tools
Slide caliper Standard tools
Steel square Standard tools
Electronic tachometer Standard tools
Timing light Standard tools
Torque wrench Standard tools
Vernier calipers Standard tools
[5.2] SPECIAL TOOLS (LUBRICATION)
Clutch guide tool TIMING GEAR CASE ASSEM-
BLY
970312752 Companion Flange Holding OIL COOLER ASSEMBLY
TIMING GEAR CASE ASSEM-
Tool
BLY
TIMING GEAR CASE ASSEM-
Drive shaft Remover Attach- BLY
ment
Differential Side Gear Shaft TIMING GEAR CASE ASSEM-
BLY
Puller
(Shocker Set) TIMING GEAR CASE ASSEM-
BLY
TIMING GEAR CASE ASSEM-
Ball Joint Puller BLY
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[1.4] ENGINE MECANICAL SERVICE DATA
Valve
Valve stem diameter Intake 5.970 to 5.985 mm (0.2350 to 0.2356 in.)
Exhaust 5.960 to 5.975 mm (0.2346 to 0.2352 in.)
Valve face angle 44.5°
Margin thickness STD Intake 1.1 mm (0.043 in.)
STD Exhaust 1.2 mm (0.047 in.)
Minimum Intake 0.6 mm (0.024 in.)
Minimum Exhaust 0.7 mm (0.028 in.)
Valve overall length STD Intake 105.15 to 105.75 mm (4.1398 to 4.1634 in.)
STD Exhaust 105.02 to 105.62 mm (4.1347 to 4.1583 in.)
Minimum Intake 104.65 mm (4.1201 in.)
Minimum Exhaust 104.52 mm (4.1150 in.)
Valve stem oil clearance STD Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.)
STD Exhaust 0.035 to 0.070 mm (0.0014 to 0.0028 in.)
Maximum Intake 0.08 mm (0.0031 in.)
Maximum Exhaust 0.10 mm (0.0039 in.)
Compression spring
Deviation Maximum 2.0 mm (0.079 in.)
Free length 46.5 mm (1.831 in.)
Install tension at 33.1 mm (1.303 in.) 150 to 166 N (14.7 to 16.2 kgf, 33.7 to 37.3 lbf)
Valve guide bush
Bush inside diameter 6.010 to 6.030 mm (0.2366 to 0.2374 in.)
Protrusion height 10.3 to 10.7 mm (0.406 to 0.421 in.)
Valve lifter
Lifter diameter 30.966 to 30.976 mm (1.2191 to 1.2195 in.)
Camshaft
Circle run out Maximum 0.03 mm (0.0012 in.)
Camshaft lobe height STD Intake 47.180 to 47.280 mm (1.8575 to 1.8614 in.)
STD Exhaust 48.070 to 48.170 mm (1.8925 to 1.8965 in.)
Maximum Intake 46.76 mm (1.8409 in.)
Maximum Exhaust 47.92 mm (1.8866 in.)
Journal diameter 27.969 to 27.985 mm (1.1011 to 1.1018 in.)
Oil clearance STD 0.025 to 0.062 mm (0.0010 to 0.0024 in.)
Maximum 0.10 mm (0.0039 in.)
Thrust clearance STD 0.035 to 0.185 mm (0.0014 to 0.0073 in.)
Maximum 0.25 mm (0.0098 in.)
Camshaft backlash STD 0.035 to 0.089 mm (0.0014 to 0.0035 in.)
Maximum 0.189 mm (0.0074 in.)
Connecting rod
Thrust clearance STD 0.100 to 0.300 mm (0.0039 to 0.0118 in.)
Maximum 0.40 mm (0.0157 in.)
Oil clearance STD 0.036 to 0.054 mm (0.0014 to 0.0021 in.)
Maximum 0.10 mm (0.0039 in.)
Connecting rod bend Maximum per 100 mm (3.94 in.) 0.03 mm (0.0012 in.)
Connecting rod twist Maximum per 100 mm (3.94 in.) 0.15 mm (0.0059 in.)
Bush inside diameter Mark A 34.012 to 34.016 mm (1.3391 to 1.3392 in.)
Mark B 34.016 to 34.020 mm (1.3392 to 1.3394 in.)
Mark C 34.020 to 34.024 mm (1.3394 to 1.3395 in.)
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10) INSTALL TIMING BELT COVER
• Install the timing belt No. 1 cover with the 6 bolts.
Torque:
6 N m (61 kgf cm, 53 in. lbf)
11) REINSTALL COOLANT FRONT PIPE
12) REINSTALL THE SEA PUMP
• Replace the O-Rings 11 and 2. (Make sure that
they did not fall down during pump installation).
• Tight the nuts 10 after installation of the washer 9
• Install the suction hose
• Install the discharge hose
13) FILL THE ENGINE COOLANT
• refer to the concerned chapter.
14) CHECK FOR ENGINE COOLANT
LEAKS
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16) REMOVE TIMING BELT COVER OIL SEAL
• Remove the oil seal with a slotted−screwdriver
and hammer.
17) REMOVE CRANKSHAFT POSITION SENSOR
PLATE NO.1
• Remove the crank angle sensor plate No.1
18) REMOVE CRANKSHAFT TIMING GEAR OR
SPROCKET
• Using the special tool 970312374, remove the
crankshaft timing gear.
19) REMOVE IDLE GEAR THRUST PLATE
• Remove the 2 bolts and idle gear thrust plate.
20) REMOVE IDLE GEAR NO.1
• Remove the idle gear No.1.
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44) INSTALL NO.1 BALANCING SHAFT SUB-
ASSY
• Install the balancing shaft No.1 with the 2 bolts.
Torque: 13 N m (133 kgf cm, 10 ft lbf)
45) INSTALL TIMING GEAR CASE ASSY
• Install 2 new O-rings to the cylinder block.
New
O−Ring
• Install the stud bolt.
Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
• Place a new gasket into the groove of the timing
New Gasket gear case as shown in the illustration.
Width: 4 mm (0.16 in.) • Remove old seal packing (FIPG) from the timing
Seal Packing gear case and cylinder block.
• Apply seal packing to the specific places de-
scribed in the illustration.
Seal packing: Part No. 970312770 or equivalent
NOTICE:
Install the timing gear case within 3 minutes and
tighten its bolts within 15 minutes after seal packing
application is completed.
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(3) Align the dot marks of the camshaft and cam
shaft N°2 by meshing the 2 gears before placing
the camshaft N°2.
Dot Mark
(4) Install the camshaft bearing cap as shown in
the illustration.
(5) Tighten the 15 bolts for the camshaft bearing
cap in the specified order described in the illustra
tion.
Torque: 19 N m (194 kgf cm, 14 ft lbf)
• Install the timing belt N°2 cover with the 4 bolts
and nut.
Torque: 10 N m (102 kgf cm, 7 ft lbf)
• Install the camshaft timing pulley.
(1) Install the set key to the key groove of the
camshaft.
(2) Align the set key with the key groove of the
timing pulley.
(3) Hold the hexagonal portion of the camshaft,
and install the timing pulley with the bolt.
Torque: 98 N m (1,000 kgf cm, 72 ft lbf)
• Inspect the valve clearance.
(1) Lower the piston by rotating the crankshaft
about 90° counter clockwise from the TDC
(2) Align the timing mark of the camshaft timing
pulley with the arrow mark of the timing belt No.2
cover.
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68) TIMING BELT REASSEMBLY
• see concerned chapter
69) HEAT EXCHANGE RE-INSTALLATION
• Re-install the heat exchanger (1) with bolts (10)
(9), washer (8) and a new gasket (48)
• Re-install spacer (30)
• Reinstall hose (34) with clamps (29)
• Re-install coolant pipe (24) with new o-ring (23)
• Tight the nuts (21) with washer and the clamps
(29).
• Re-install the bleeding pipe (34) with hollow
screw (47) and new washers (46).
• Re-install coolant pipe (41) with clamp (45) and
hollow screw (17).
• Re-install hose (36) with clamps (37).
• Reinstall ECU support (7) with bolts (13).
• Re-install Water hose (42) with clamps (43).
70) TURBO CHARGER & MIXER RE-
INSTALLATION
• Re-install the lubrication pipe (3) with new gasket
(4), (7) and (8).
• Tight bolts (9) and hollow screw (6).
• Re-install turbocharger (1) with new gasket (2).
• Tight the nuts (14) with washers (15).
• Re-install the turbo charger cover (not on the
drawing).
71) ECU BRACKET AND ECU RE-INSTALLATION
• Re-installation of the ECU support (4) with the 2
nuts (12), 2 bolts (16) and washers (15).
• Re-installation of the breakers support (1) with 2
nuts (12).
• Re-installation of the ECU with 4 nuts (12).
72) INTERCOOLER RE-INSTALLATION
• Re-install the intercooler (1) with new gasket (24).
• Tight the nuts (6), (9) and (22).
• Re-install the hose (7) with clamps (14) and (10).
• Re-install the hose (3) with clamps (10) and (23).
• Re-install the hose (8) with clamps (14).
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22. INSTALL INTAKE VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bush bore
diameter of the cylinder head.
(b) Select a new guide bush ((Standard (STD) or
oversize 0.05 (O/S 0.05)).
Bush bore diameter mm (in.) Bush size
10.985 to 11.006 mm (0.4325 to 0.4333 in.) Use STD
11.035 to 11.056 mm (0.4344 to 0.4353 in.) Use O/S 0.05
If the bush bore diameter of the cylinder head is greater
than 11.006 mm (0.4333 in.), machine the bush bore to
the dimension of 11.035 to 11.056 mm (0.4344 to
0.4353 in.).
If the bush bore diameter of the cylinder head is greater
than 11.056 mm (0.4353 in.), replace the cylinder head.
(c) Using special tools 970312733, 970312748 and a
hammer, tap in a new guide bush to the specified
protrusion height.
Protrusion height:
10.3 to 10.7 mm (0.406 to 0.421 in.)
SST
(d) Using a sharp 6.0 mm reamer, ream the guide
6.0 mm Reamer bush to obtain the specified standard clearance
(See step 18) between the guide bush and valve
stem.
23. INSTALL EXHAUST VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bush bore
diameter of the cylinder head.
(b) Select a new guide bush (STD or O/S 0.05).
Bush bore diameter mm (in.) Bush size
10.985 to 11.006 mm (0.4325 to 0.4333 in.) Use STD
11.035 to 11.056 mm (0.4344 to 0.4353 in.) Use O/S 0.05
If the bush bore diameter of the cylinder head is greater
than 11.006 mm (0.4333 in.), machine the bush bore to
the dimension of 11.035 to 11.056 mm (0.4344 to
0.4353 in.).
If the bush bore diameter of the cylinder head is greater
than 11.056 mm (0.4353 in.), replace the cylinder head.
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Front Side: Intake Side :
Tight Plug N°5 Tight Plug N°4
Tight Plug N°3
Tight Plug N°5
Tight Plug N°4
Tight Plug N°3 Tight Plug N°4 Tight Plug N°5
35. INSTALL W/HEAD STRAIGHT SCREW PLUG N°1
(a) Apply an adhesive to the end of the screw plug.
Adhesive: THREE BOND 1324 or equivalent
(b) Using a 6 mm hexagon wrench, install the screw plug.
Torque: 25 N·m (255 kgf·cm, 18 ft·lbf) Adhesive
36. INSTALL SEMI-CIRCULAR PLUG
(a) Remove the oil seal packing (970312770).
(1) Using a gasket scraper and razor blade, remove the old seal packing from the contact
surface of the semicircular plug and cylinder head, and clean them.
(b) Apply seal packing to the semicircular plug.
NOTICE:
• The semicircular plug must be installed within 3 minutes after seal packing application is
completed.
• Prevent FIPG from being stuck to the camshaft thrust groove.
(c) Install the semicircular plug to the cylinder head.
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(j) Measure the “Plastigage” at its widest point.
Standard oil clearance:
0.030 to 0.048 mm (0.0012 to 0.0019 in.)
Maximum clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than the maximum clear-
ance, replace the bearings.
HINT:
If replacing the cylinder block sub assembly, the
bearing standard clearance will be:
0.030 to 0.048 mm (0.0012 to 0.0019 in.)
HINT:
If using a standard bearing, replace it with one hav-
ing the same number. If the number of the bearing
cannot be determined, add together the numbers
imprinted on the cylinder block and crankshaft, then
select the bearing with the same number as the to-
tal. There are 5 sizes of standard bearings, marked
2, 3, 4, 5 and 6 accordingly.
EXAMPLE:
item Number mark
Cylinder block 1 2 3
Crankshaft 1 2 3 1 2 3 1 2 3
Use bearing 2 3 4 3 4 5 4 5 6
Cylinder block ”2” + Crankshaft ”1”= Total number
”3” (Use bearing ”3” reference)
(k) Completely remove the “Plastigage”.
Cylinder block main journal bore diameter:
Mark 1 75.000 to 75.006 mm (2.9528 to 2.9530 in.)
Mark 2 75.006 to 75.012 mm (2.9530 to 2.9532 in.)
Mark 3 75.012 to 75. 018 mm (2.9532 to 2.9535 in.)
Crankshaft journal diameter:
Mark 1 69.994 to 70.000 mm (2.7557 to 2.7559 in.)
Mark 2 69.988 to 69.994 mm (2.7554 to 2.7557 in.)
Mark 3 69.982 to 69.988 mm (2.7552 to 2.7554 in.)
Standard sized bearing center wall thickness:
Mark 2 2.482 to 2.485 mm (0.0977 to 0.0978 in.)
Mark 3 2.485 to 2.488 mm (0.0978 to 0.0980 in.)
Mark 4 2.488 to 2.491 mm (0.0980 to 0.0981 in.)
Mark 5 2.491 to 2.494 mm (0.0981 to 0.0982 in.)
Mark 6 2.494 to 2.497 mm (0.0982 to 0.0983 in.)
9. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper bearings and upper thrust washers from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in the correct order.
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(c) Inspect the crank pins.
(1) Using a micrometer, measure the outside
diameter of each crank pin.
Main journal diameter:
Mark 1 69.994 to 70.000 mm (2.75566 to 2.75590 in.)
Mark 2 69.988 to 69.994 mm (2.75543 to 2.75566 in.)
Mark 3 69.982 to 69.988 mm (2.75519 to 2.75543 in.)
If the diameter is not as specified, check the oil clear-
ance (See step 4). If necessary, grind or replace the
crankshaft.
(2) Check each crank pin for taper and out-of-
round as shown.
maximum taper and out-of-round:
0.020 mm (0.0008 in.)
If the taper and out-of-round is greater than the maxi-
mum, replace the crankshaft.
28. INSPECT CRANKSHAFT BEARING CAP BOLT
Measuring (a) Using vernier calipers, measure the minimum
Point diameter of the compressed thread at the meas-
uring point.
Standard diameter:
13.500 to 14.000 mm (0.5315 to 0.5512 in.)
Minimum diameter:
12.60 mm (0.4961 in.)
If the diameter is less than the minimum, replace the
bolt.
29. INSTALL TIGHT PLUG
Adhesive
(a) Apply an adhesive around the tight plugs.
Adhesive:
THREE BOND 1324 or equivalent
NOTICE:
Do not start the engine within 1 hour after the instal-
lation.
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(2) Install and alternately tighten the bolts of
the connecting rod cap in several passes.
Torque:
Front
35 N·m (357 kgf·cm, 26 ft·lbf)
If any of the connecting rod cap bolts does not meet the
Painted Mark torque specification, replace the cap bolts.
(3) Mark the front of the connecting rod cap
bolts with paint.
(4) Retighten the connecting rod cap bolts 90°
as shown in the illustration.
Cylinder Block (5) Check that the painted mark is now at a
Oil Orifice 90° angle to the front.
(d) Check that the crankshaft turns smoothly.
(e) Check the connecting rod thrust clearance (See
step 3).
40. INSTALL CYLINDER BLOCK OIL ORIFICE
(a) Install the cylinder block oil orifice to the cylinder
block.
41. REMOVE CYLINDER BLOCK SIDE COVER
(a) Remove the 2 nuts, spacers, cylinder block side
Injection pump cover and gasket.
42. INSTALL CYLINDER BLOCK SIDE COVER
Gasket (a) Install the new gasket, cylinder block side cover,