30 Revised Maintenance Procedure For Wärtsilä 46F Injection System

INSTRUCTIONS
Wärtsilä 4-stroke 4616Q270

Technical Services Issue 1, 29 January 2016
Revised maintenance procedure for

For your information
Wärtsilä® 46F injection system
Information to Operators and Owners of installations Engines / components concerned
concerned Wärtsilä® 46F engines equipped with twin
injection pumps
Reference
16 Injection system
Introduction / Background
This bulletin has been made to inform
about revised information in chapter 16 of
the engine instruction manual.
Validity
Until further notice
Wärtsilä Finland Oy Services 24 hrs Tel: +358 10 709 080

P.O. Box 252 (Tarhaajantie 2) Switchboard Tel: +358 10 709 0000
FIN-65101 Vaasa, Finland Fax: +358 6 356 7374
INSTRUCTIONS
4616Q270, Issue 1, Page 2 / 4 + 37
Introduction
This bulletin has been made to inform about revised information in chapter 16 of engine
Instruction manual.
Main changes in revised manual chapter 16

The structure of the chapter 16 has been revised and the section numbers are different
from the old manual. The referred section numbers are for the revised manual.
16.1.2 Lubricating the injection pump control rack

This section added
16.1.5 Assembling the injection pump

Fig 16-9 Tightening order for the pump element and the pump cover
16.1.7.1 Checking the injection pump timing

Fig 16-17 Fuel rack positions
Start of injection tolerance +0/-0.5°
16.1.7.2 Adjusting the injection pump tappet

Fig 16-20 Guide block with tappets
Fig 16-21 Adjustment measure
Added important information from distance D1 stamped on pump
foot.
Figure 1, Marking on pump foot

INSTRUCTIONS
4616Q270, Issue 1, Page 3 / 4 + 37
NOTE:
Distance D1 has two different definitions in relation to distance X depending on the
manufacturing date of the injection pump.
The marking principle of distance D1 was changed to 87.xx in year 2014 by the pump
manufacturer.
Table 1, Definition of distance X
D1 X
D1 = 92,xx – 93,xx X = D1
D1 = 87,xx X = D1 + 5,5
16.3.1 Removing the injection valve

During operation some pressure may accumulate between the
injection valve and the pocket in cylinder head. When the yoke is
removed the injection valve may bounce up from the cylinder head.
To minimize the risk the procedure for removing the injection valve
has been revised.
The new procedure requires that the hole in the injection yoke is
increased from M12 to M20 or M24.
16.3.5 Testing and adjusting the injection valve

Instructions regarding use of pneumatic test pump revised
16.4.1 Removing and mounting the fuel injection line

Added caution: A damaged fuel oil high pressure injection pipe must
be replaced.
Recommendation
Implement the revised procedure for the injection system.
Add the enclosed pages to the engine instruction manual.
Enclosures
Engine Instruction Manual, 16. Injection System.
Contacts
For questions about the content of this bulletin, or if you need Wärtsilä assistance,
services, spare parts and/or tools, please contact your nearest Wärtsilä representative.
If you don’t have the contact details at hand, please follow the link:
www.wartsila.com/contact
INSTRUCTIONS
4616Q270, Issue 1, Page 4 / 4 + 37
© 2016 Wärtsilä Finland Oy – All rights reserved

No part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying,
recording, taping or other information retrieval systems) without the prior written permission of the copyright holder. Wärtsilä Finland Oy
makes no representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or
omissions for information contained herein. Information in this publication is subject to change without notice.
Unless otherwise expressly set forth, no recommendation contained in this document or any of its appendices is to be construed as
provided due to a defect of the product, but merely as an improvement of the product and/or the maintenance procedures relating thereto.
Any actions by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such
actions will thus be at the owners/operators own cost and expense.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO
THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION
PURPOSES ONLY.
Wärtsilä 46F Engine O&MM 16. Injection system
16. Injection system
16.1 Fuel injection pump v3

GUID-1F765BDA-59C1-4091-815C-865E0CEA50E9
The engine has one injection pump per cylinder. The injection pump pressurises the fuel
and delivers it to the injection nozzle at the right time in the engine cycle.
Each pump has two separate, monoblock pump elements:
● Timing element for timing the fuel injection
● Quantity element for feeding correct fuel quantity
The cylinders are integrated with the cylinder cover.
A regulating mechanism at the pump controls the fuel quantity and timing according to
engine load and speed. The injection pumps are governed by the speed governor and the
timing actuator through the control shafts.
16-1
16. Injection system Wärtsilä 46F Engine O&MM
1 2 3 13 13
4 5
40
9
50
10 11
60
12
70
6 6
14
7 7
6 6
9
8
10
11 12
1 Pump cover 8 Spring plate, upper
2 Main delivery valve, constant pressure 9 Spring
valve 10 Spring plate, lower
3 Connection piece 11 Push rod
4 Timing pump element (barrel and 12 Flange
plunger) 13 Pneumatic stop cylinder
5 Quantity pump element (barrel and 14 Lubricating nipple
plunger)
6 Control rack (fuel rack)
7 Control sleeve
Fig 16-1 Fuel injection pump GUID-2A726622-E340-4A3C-AAF1-111C5C3A9D69 v2
The fuel feed quantity depends on the quantity element plunger's position in relation to the
fuel inlet. The fuel amount is regulated by rotating the plunger. The timing plunger
determines the fuel delivery time. The injection start time depends on the timing plunger's
rotational position.
The plungers are pushed up by the camshaft via the roller tappet and pushed back down by
a spring. They reciprocate in the respective element on a predetermined stroke. The plunger
stroke during which the fuel is fed under pressure is called the effective stroke.
When the timing plunger closes the fuel opening at the pump element, the start point of the
fuel delivery is reached. The plunger moves upwards and the pressure above the plunger
increases. The fuel delivery is stopped when the plunger's lower edge opens the spill bore.
The distance between the plunger's upper edge and the lower edge (Helix) increases as the
16-2
fuel rack is pushed in, and more fuel is delivered. When the fuel rack is pulled out to "zero"
position, the fuel bypasses the plunger without increase in pressure.
A fuel delivery valve and a constant pressure valve located in the head piece prevent
cavitation.
The delivery valve discharges pressurised fuel to the injection pipe. The fuel compressed to
a high pressure by the plunger forces the valve to pop up. Once the plunger's effective
stroke ends, the delivery valve is brought back to its original position by the spring and
blocks the fuel path, thereby preventing the fuel's counter flow.
After the effective stroke, fuel is drawn back from the high-pressure injection pipe through
the constant pressure valve. The residual pressure between the delivery valve and the
nozzle decreases instantly. This process maintains consistent injection "shot to shot" by
maintaining a constant pressure in the pipe between the injections.
16.1.1 Fuel injection pump maintenance v2

WS-W46F-MAN-16-MAINTENANCEOFINJECTIONPUMP
Related topics
Maintenance schedule........................................................................................................... 04
Overhaul the injection pump in accordance with the maintenance schedule or when
necessary.
CAUTION
Observe utmost cleanliness when handling the injection pump.
16.1.2 Lubricating the fuel injection pump control rack v2

GUID-23A19E42-9393-4905-9B3A-701F95414CFF
Prerequisites
Use a normal grease gun filled with engine lubricating oil.
CAUTION
Do not use grease.
16-3
Procedure
1 Press the grease gun against the lubricating nipple.
1 Lubricating nipple
Fig 16-2 Lubricating the control rack GUID-C3FA6079-36AF-4BA7-9969-80B622CED578 v1
2 Press oil in through the lubricating nipple (1).
3 Remove the grease gun.
16.1.3 Removing the injection pump v2

GUID-B2B1F9D8-1ADD-40A9-91EC-0B69CA4F9A6C
Prerequisites
● Shut off the fuel supply to the engine.
● Stop the prelubricating pump.
WARNING
Ensure that the fuel supply is switched off and the fuel pipes are not
pressurized.
CAUTION
Cover all openings to prevent contaminating the system.
Tools
Code Description
816002 Injection pump lifting tool
831002 Eye bolt
Procedure
1 Remove the hot box covers.
16-4
2 Turn the crankshaft until the injection pump tappet is in the bottom position, the roller
resting on the base circle of the cam.
3 Remove the connected pipes from the pump.
a Remove the fuel injection pipe and the leak fuel pipe.
b Remove the control air pipes from the pneumatic stop cylinders.
4 Disconnect the fuel control racks.

Remove the bolts and nuts connecting the control shaft levers with the fuel control racks.
5 Lift off the injection pump as follows:
a Mount the lifting tool.

Use the lifting tool.
Attach eye bolts to the pump and fasten the lifting tool to the eye bolts.
b Remove the fastening bolts and nuts of the pump.
c Lift off the injection pump.
816002
Fig 16-3 Lifting the injection pump GUID-A61C2E91-1DB1-4004-ABC4-1828AE2EF2C0 v1
16-5
Fig 16-4 Lifting the injection pump using eye bolts W46F-441601 v2
6 Protect all open fuel and lubricating oil connections with plugs or tape.
Postrequisites
If the pump is not immediately overhauled or mounted on the engine, oil it well and protect
it by a plastic cover or similar.
16.1.4 Dismantling and cleaning the fuel injection pump v5

GUID-7B2E3D29-FD0D-40E0-BAAD-42A168959C81
Prerequisites
● Remove the injection pump from the engine.
● Remove the pneumatic stop cylinders.
● Clean the surfaces of the pump carefully.
Tools
Code Description
864001 Testing device
800001 Pliers for retaining rings
CAUTION
The barrel, plunger and delivery valves are a matched assembly. Do not
separate or interchange parts. Always mount the dismantled parts back to the
same pump.
16-6
Secure the pump into the testing device that allows the pump to be rotated and fixed in
different positions as the work proceeds. The dismantling starts from the bottom part of the
pump.
A
4
5 A
1 2 3 6 26
7 8 27
10
25
9 11
40
9
50
10 11
9
60
12
70
24
12 28
17
13
23 14
22
15
21
17
20 19 18 17 16
1 Pins 15 Spring
2 Pump cover 16 Bottom flange mounting bolts
3 Main delivery valve 17 Retaining ring
4 Connection piece bolts 18 Bottom flange
6 Constant pressure valve 20 Sealing ring
7 Cylinder mounting bolts 21 Lower spring plate
8 Pump cover mounting bolts 22 Upper spring plate
9 O-ring 23 Fuel control rack
10 Barrels 24 Plug
11 Sealing ring 25 Plunger
12 Screw 26 Pneumatic stop cylinder with cap
13 Support ring 27 Screw
14 Control sleeve 28 Lubricating nipple
Fig 16-5 Fuel injection pump GUID-F0C62E8F-8FA1-43F4-AE54-7C6E60AFDCD9 v4
Procedure
1 Fasten the pump into the testing device, and turn it upside down.
2 Remove the mounting bolts of the bottom flanges (16) and remove the flanges.
16-7
3 Remove the push rods (19), plungers (25) and springs (15) as follows:
a Secure the push rod assembly of both pump elements.

Use the compressing tool included in the testing device tool set.
WARNING
The push rods are spring-loaded. Be careful when releasing the tool.
b Compress the springs and remove the retaining rings using pliers.
Release the tool.
c Remove the push rods, spring holders, lower spring plates (21), springs, plungers,
and upper spring plates.
4 Remove the control sleeves (14).
5 Remove the fuel control racks.
a Remove the guiding pins from the control racks.

The pins are located on the sides of the pump housing. They are protected with retaining
rings.
b Remove the pistons of the stop cylinders.
c Pull out the fuel control racks.
6 Turn the pump to the upright position.
7 Dismantle the connection piece (5) carefully.
a Remove the bolts of the connection piece.
b Remove the connection piece.
c Remove the constant pressure and main delivery valves including the springs.
8 Remove the mounting bolts of the pump cover and the barrels.
Remove the pump cover.
9 Remove the barrels (10).

You can use the screw threads to lift the barrels.
10 Clean and lubricate the components.

Wash the components in clean fuel oil, and lubricate the internal parts with clean engine oil.
16.1.5 Assembling the fuel injection pump v6

GUID-EBA7B55C-5E2B-476A-9505-C709226BB5C8
Related topics
Injection pump, twin pump........................................................................................... 07.1.6.1
Prerequisites
● Inspect the parts and replace parts, if necessary.
16-8
Tools
Code Description
864001 Testing device
800001 Pliers for retaining rings
CAUTION
The barrels, the plungers and the delivery valves are a matched assembly. Keep
them together and do not interchange parts between different pumps.
NOTE
Replace all seals. Lubricate the seals with engine oil before mounting them.
NOTE
Lubricate all screw threads that will be tightened with a torque wrench with
clean engine oil.
Secure the pump in the testing device that allows the pump to be rotated and fixed in
different positions as the work proceeds. The assembly starts from the top of the pump.
Procedure
1 Fasten the pump housing into the testing device in upright position.
2 Assemble the pump barrels (2) and the cover (1).
1 Pump cover
2 Barrels
Fig 16-6 Pump barrels and cover GUID-DB4502AD-2C34-4402-8D55-93DF02F77227 v1
16-9
NOTE
The plunger and barrel belonging to the same pump element are marked with
the same identification number. The barrels have an additional letter after the
serial number: "L" (left) for the timing element and "R" (right) for the quantity
element. The letter indicates the position of the cylinder in the pump housing
when the pump is turned as shown in Fig 16-7.
L R
L = left R = right
Fig 16-7 Pump in reference position GUID-C7A20158-30E4-4960-9F4F-AEC3950FF2FA v2
a Install the sealing rings, O-rings and support rings on the barrel as shown in Fig
16-8.
Grease the sealing rings and O-rings with vaseline or clean engine oil.
2
1
3
1 O-ring 3 Support rings

2 Sealing ring 4 Sealing ring
Fig 16-8 The seals on the barrel and the upper spring plate
GUID-5ED98433-28FB-412C-83A8-5CD58C31C6E5 v2
b Clean the contact surfaces of the barrel and mount the barrels into the pump
housing in the correct position.
16-10
3 Mount the pump cover onto the pump housing.
NOTE
Make sure that the contact surfaces are clean.
a Fit the cover into the pump housing.

The locating pins in the housing determine the correct position.
b Mount the inner and the outer bolts and tighten by hand.
c Tighten the mounting bolts (the inner bolts) in two steps – half of the final value and
the final specified torque value.
Tighten in the order shown in Fig 16-9.
21 15
23 13
19 9 3 17
7 11 1 5
12 8 6 2
24 10 4 14
20 18
22 16
Fig 16-9 Tightening order for the pump element and the pump cover W46F-441604 v2
d Tighten the pump cover mounting bolts (outer bolts) in two steps – half of the final
value, and the final specified torque value.
Tighten in the order shown in Fig 16-9.
4 Mount the connection piece to the pump cover.

Before installing the components, immerse them in clean diesel oil.
a Install the main delivery and constant pressure valves including the springs into the
connection piece.
16-11
1 1
5 3
4
6
1 Connection piece 4 Constant pressure valve spring
2 Main delivery valve spring 5 Main delivery valve
3 Constant pressure valve 6 Pin
Fig 16-10 Mounting connection piece GUID-335F60EA-54F6-4B7E-8D9B-D28952D76FC8 v2
b Keep the parts together and mount the connection piece to the pump cover.
Make sure that the contact surfaces are clean.
c Tighten the connection piece mounting bolts crosswise in two steps – half of the
final value, and the final specified torque value.
5 Turn the pump upside down.
6 Mount the fuel control racks.
a Lubricate all moving parts with clean engine oil.
b Mount the control racks in the pump housing.

Mount the fuel quantity control rack (the one with the scale 0–70 mm) to the quantity
element side and the timing control rack to the timing element side.
c Mount the pistons of the stop cylinders.

Renew the seals.
d Mount the control rack guide pins in the pump housing and fit the retaining rings.
7 Mount the control sleeves.
NOTE
The fuel quantity control sleeve is the one with a locating pin inserted in a gear
teeth. The other one is the timing control sleeve.
NOTE
The control sleeves, control racks and plungers have alignment markings as
shown in Fig 16-11 and Fig 16-12. All the markings must be aligned. See Fig
16-13.
CAUTION
An incorrectly mounted control sleeve may cause engine overspeed.
16-12
B A
D C
A = Markings on the control rack B = Chamfered tooth on the control sleeve C = Marking on
the plunger D = Marking on the control sleeve
Fig 16-11 Alignment markings on the timing control sleeve, control rack and
plunger GUID-3FB5FD46-4093-4367-925D-472AA62EC334 v2
B A
D C
A = Groove on the control rack B = Locating pin on the control sleeve C = Marking on the
plunger D = Marking on the control sleeve
Fig 16-12 Alignment markings on the quantity control sleeve, control rack and
plunger GUID-D2EE3876-F855-4D63-A7FD-79AEE1B70C32 v2
a Mount the fuel quantity control sleeve to the quantity element side.
Mount the sleeve so that the locating pin is aligned with the groove in the control rack.
See Fig 16-13.
b Mount the timing control sleeve to the timing element side.

Mount the sleeve so that the chamfered tooth on the sleeve slides into the tooth space
between the two marks on the control rack. See Fig 16-13.
16-13
A A
B B
D D
I C C II
A A
B B
D
D 9
10
11
60
12
70
I = Quantity element side: A = Groove on the control rack B = Locating pin on the control sleeve C = Marking
on the plunger D = Marking on the control sleeve
II = Timing element side: A = Markings on the control rack B = Chamfered tooth on the control sleeve C =
Marking on the plunger D = Marking on the control sleeve
Fig 16-13 Aligning control sleeves, control racks and plungers GUID-77F8D0BF-06E7-4DA0-9967-0FBE2210A8B0 v2
8 Mount the springs, spring plates and plungers in the cylinders.
a Lubricate the plungers with clean light fuel oil (LFO).
b Grease the sealing rings of the spring plates well with vaseline and mount them to
the spring plates.
NOTE
Mount the sealing ring of the upper spring plate according to Fig 16-8.
c Mount the upper spring plates.
d Mount the springs and plungers into the cylinders.

Mount the plungers so that the markings on the plungers face the marking (D) on the
control sleeves. See Fig 16-11, Fig 16-12 and Fig 16-13. The marking D corresponds to
the position of the chamfered tooth on the timing control sleeve or the locating pin on
the quantity control sleeve respectively.
NOTE
Make sure that you install the plungers in the correct cylinders (timing plunger in
timing cylinder and quantity plunger in quantity cylinder).
e Mount the lower spring plates.
9 Mount the push rods and retaining rings.
a Mount the push rods and the small retaining rings to the lower spring plates.
b Compress the springs with a compressing tool.

Use the compressing tool included in the testing device tool set.
16-14
c When the plungers are deep enough, install the big retaining rings using pliers.
d Remove the compressing tool, and check that the fuel control racks can be moved
easily.
10 Mount the bottom flanges.
a Apply Loctite or a similar locking fluid to the threads of the bottom flange fixing
bolts.
b Fit the flanges.
c Tighten the mounting bolts of the bottom flanges crosswise in two steps to the
specified torque.
11 Mount the pneumatic stop cylinders.
a Lubricate the sealing ring, piston and cylinder bore.
1 2
4 3
1 Piston 3 Stop cylinder

2 Sealing ring 4 Screw
Fig 16-14 Mounting stop cylinder GUID-7684CEC7-F664-4DD8-B76D-EF9BA66F1B8E v2
b Mount the piston into the cylinder.
c Tighten the fixing screws to specified torque.
12 Mount the erosion plugs and sealing rings.

Tighten to the stated torque. Lock the plugs with safety wires.
Postrequisites
Unless you mount the pump on the engine immediately, oil it well and protect it by a plastic
cover or equivalent. Protect the fuel ports and injection line connections with plugs or tape.
16-15
16.1.6 Mounting the injection pump v4

WS-W46F-MAN-16-MAINTENANCEOFINJECTIONPUMP-MOUNTINGOFINJECTIONPUMP
Related topics
Checking the injection pump timing............................................................................. 16.1.7.1
Checking and adjusting the fuel injection pump racks.................................................... 22.7.1
Procedure
1 Clean the contact faces of the guide block.

Pay special attention to the O-ring sealing surfaces.
2 Renew all O-rings.

Lubricate new O-rings with grease or engine oil before mounting them.
3 Remove the protecting tapes or plugs.
4 Check the condition of the pump tappet and guide block bores.
5 Fit tappet, spring washers and springs.

Take care that the guiding slots of the tappets are mounted properly against the guide
piece.
6 Turn the crankshaft until the injection pump tappet is at the bottom position.
7 Mount the pump as follows:
a Lift the pump into its position.
CAUTION
Take care not to damage the O-rings while lowering the pump to the plane and
while tightening the screws.
b Fasten the screws lightly so that the pump is evenly pressed against the guide
block's surface.
1
1 Fastening screw
Fig 16-15 Mounting the injection pump W46F-441603 v3
16-16
c Tighten the fastening screws to stated torque.
8 Check the injection timing.

See the instructions for checking injection pump timing.
NOTE
Always check the injection timing when a new injection pump has been installed
or other major components have been replaced.
9 Install the pipes and fuel racks:
a Mount the injection pipe and the leak fuel pipe.

Tighten the injection pipe to the stated torque. Check the injection pipe tightening torque
after some running hours on a hot engine.
b Attach the control air pipes to the pneumatic stop cylinders.
c Connect the fuel control racks.

Check that the control racks move freely.
10 Rotate the control shafts and check that all pumps follow the shaft movement.
Check the fuel rack positions of all pumps. See Chapter 22.
16.1.7 Checking and adjusting the injection pump timing
16.1.7.1 Checking the injection pump timing v5

WS-W46F-MAN-16-MAINTENANCEOFINJECTIONPUMP-CHECKINGOFINJECTIONPUMPTIMING
Related topics
Injection pump, twin pump........................................................................................... 07.1.6.1
Adjusting the fuel injection pump tappet...................................................................... 16.1.7.2
Tools
Code Description
862001 Air timing device
Manufacturing tolerances in pumps, cams and gears or some engine modifications can
affect the pump timing. To get best possible engine performance, adjust the pump timing
properly and according to the Settings table. See the test records.
Check the injection pump timing:
● After mounting the fuel injection pump
● After replacing major components such as the injection pump, a pump element, pump
tappet or camshaft piece
● After maintenance activities involving the gear wheels, especially the intermediate gear
wheels.
If the injection timing is not correct (tolerance +0/-0.5°), adjust the pump according to the
adjustment instructions.
Check the injection timing with the injection pump mounted on the engine. To determine the
beginning of the effective pump stroke, use a pneumatic timing tool that is connected to the
erosion plug hole of the timing element (on the left-hand side) and sealing against the spill
port cone.
16-17
WARNING
Before checking the injection pump timing, check that the fuel supply is
switched off and the fuel pipes are not pressurised.
Check the injection timing of each pump as follows:
Procedure
1 Turn the crankshaft so that the pump tappets are on the base circle of the cams.
2 Remove the safety wire from the erosion plugs and remove the erosion plugs.
See Fig 16-16.
1 Erosion plug
2 Control rack
Fig 16-16 Removing the erosion plugs and disconnecting the control racks
GUID-2B7E0D2D-0281-4F72-B37D-FAC404262EC2 v2
3 Disconnect the control racks from the control shafts.
4 Adjust the positions of the control racks.

Position the timing control rack (1, Fig 16-17 ) so that its position corresponds to 9 mm pre-
lift. The timing control rack is marked in mm pre-stroke. Make sure that the quantity control
rack (2, Fig 16-17) is in its outermost position, 70 mm, so that it does not influence the
timing setting.
16-18
9
10
70
11
12
1 2
1 Timing control rack (position to 9)

2 Quantity control rack (position to 70 mm)
Fig 16-17 Fuel rack positions W46F-441607 v3
5 Turn the crankshaft in the normal rotation direction.

Check using a torch or similar light that the fuel quantity plunger (on the right hand side)
closes the spill ports prior to the timing plunger (see Fig 16-18).
A B
A. Engine timing control element is open B. Closing point of quantity plunger
Fig 16-18 Checking the closing point of quantity plunger W46F-441608 v2
16-19
6 Mount the air timing device (1, Fig 16-19) to the engine timing control element on the
left hand side and connect the air supply.
1 Air timing device
Fig 16-19 Pneumatic injection pump timing device W46F-441609 v2
7 Turn the crankshaft to position 22° before top dead centre (TDC) for the cylinder
concerned.
8 Turn the crankshaft slowly in the normal rotation direction.

Read the full pressure when the plunger is closing the spill port.
9 Turn the crankshaft slowly against the normal rotation direction until the pressure in
the instrument drops to zero.
10 Turn the crankshaft slowly in the normal rotation direction until the pressure rises to
half the measured full pressure.
Record the pressure and the position of the flywheel. Report the measured value in the
Measurement record.
11 Compare the measured value with the reference value given in the Settings table of
the test records.
If the start of injection (SOI) exceeds tolerance +0/–0.5°, adjust the pump tappet. See the
injection pump tappet adjustment instructions.
12 Mount the erosion plugs and sealing rings.

Tighten to the correct torque. Lock the plugs with safety wires.
13 Connect the control racks to the control shaft levers.
16-20
16.1.7.2 Adjusting the fuel injection pump tappet v4

GUID-93BF3121-BA2B-4ECF-A49B-E4192B3BA830
Prerequisites
Remove the injection pump from the engine, if equipped.
Tools
Code Description
834053 Camshaft locking tool
Procedure
1 Rotate the crankshaft until the concerned cylinder’s timing and quantity tappets rest
on the cam’s base circle.
A B
A: Timing tappet, B: Quantity tappet
1 Digital T-gauge
2 Extension piece
Fig 16-20 Guide block with tappets GUID-37932700-0157-4521-AE23-B049C70A73C1 v3
2 Adjust the adjusting screws of both tappets as follows:
a Adjust the adjusting screw (1, Fig 16-21) so that the distance X measured from the
guide block's upper surface has the value stamped on the pump foot.
16-21
1 Adjusting screw
Fig 16-21 Adjustment measure GUID-70E2E792-0091-45D1-B1DB-15DEA475706B v3
The distance D1 is stamped on pump foot, both to timing and quantity tappet.
● If the stamped distance D1 is 92.xx–93.xx mm, the D1 distance is the same as
distance X. For example, if D1 is 93.07 mm, the distance X is 93.07 mm.
● If the stamped distance D1 is 87.xx mm, 5.5 mm must be added to the D1 distance
to get the distance X. For example, if D1 is 87.50 mm, the distance X is
87.50+5.5=93.00 mm.
b Hold the adjusting screw (1, Fig 16-22), and screw the securing plate (2, Fig 16-22)
down to a height of 72 +20 mm.
Tighten the locking screws to the stated torque.
1
2
1 Adjusting screw
2 Securing plate
y = 72 +20 mm
Fig 16-22 Securing plate position GUID-B23A9E5A-C051-439A-9FDD-78A00F41A59B v1
c Measure the distance X again, and record the reading on the pump foot.
16.2 Injection valve v4

WS-W46F-MAN-16-INJECTIONVALVE
The injection valve is centrally located in the cylinder head and includes the nozzle holder
and the nozzle. Fuel enters the nozzle holder sideways through a connection piece, which is
mounted in the nozzle holder.
The nozzle receives high-pressure fuel from the injection pipe and injects it into the
combustion chamber as a very fine spray. The pressure at which the nozzle opens can be
adjusted by turning the adjusting screw in the injection valve.
16-22
3
1 2
1 Injection pipe 5 Spring

3 Adjusting screw 7 Nozzle nut
4 Nozzle holder 8 Nozzle
Fig 16-23 Fuel injection valve GUID-6F1D5120-D092-472D-860D-23D8E67828D0 v2
16.3 Injection valve maintenance v2

GUID-35016320-BDB6-4168-86D6-A30E97B5FF03
Related topics
Maintenance schedule........................................................................................................... 04
Maintain the fuel injection valves according to the maintenance schedule. Maintenance may
also be needed if the engine running parameters give an indication of poor injection (for
example, large deviation from normal exhaust gas temperature). The reason for abnormal
running parameters (abnormally high or low exhaust gas temperatures, low firing pressure)
may be leaking or blocked fuel injector(s).
CAUTION
Always observe the utmost cleanliness when handling the fuel injection valve.
16-23
16.3.1 Removing the injection valve v8

WS-W46F-MAN-16-INJECTIONVALVE-REMOVINGOFINJECTIONVALVE
Tools
Code Description
837053 Extractor tool
831002 Lifting eye
805001 Eye bolt M12
Procedure
1 Open the cylinder head and hot box covers.
2 Remove the fuel injection pipe.

Disconnect the pipe from both the injection pump and the injection valve.
CAUTION
Protect the open pipe connections.
1 2 3 4 5
4
1 Injection pipe 4 Distance flanges
2 Connection piece 5 Connection piece
3 Fastening screw
Fig 16-24 Fuel injection pipe and connection piece GUID-72DE1362-C694-4EF2-A473-4B8E467523DF v3
3 To remove the connection piece:
a Loosen the fastening screws (3).

Leave the distance flanges (4) on the cover.
b Unscrew the connection piece (2) .
c Remove the connection piece from the cylinder head.

The flanges come loose along with the connection piece.
d Protect the open pipe connections.
4 Loosen the injection valve fastening nuts (1) a maximum of two revolutions.
a Remove one of the injection valve fastening nuts.

Do not remove both the nuts at the same time.
16-24
1 1
2 2
1 Injection valve fastening nuts

2 Distance sleeve
3 Yoke
Fig 16-25 Removing the injection valve W46-461603 v2
b Remove the distance sleeve (2) from the stud and screw the fastening nut back to
its position at a minimum 16 mm on the thread.
c Repeat the procedure for the other fastening nut.
5 Lift the injection valve against the yoke (3) through the hole by using the extractor
tool.
Make sure that the injection valve is loosened by pushing it downwards to ensure that there
is no pressure to raise the injection valve upwards.
CAUTION
If it is needed to use excessive force, the cylinder head center sleeve position
may change. Check the centre sleeve position, if necessary.
6 Remove the extractor tool from the injection valve and remove the fastening nuts (1)
and the yoke (3).
7 Mount the eye bolt on the injection valve and lift out the injection valve from the
cylinder head.
8 Protect the injection valve's fuel inlet holes and the cylinder head bore.
Postrequisites
If the injection valve will be stored before overhaul:
● Treat the injection valve with corrosion protecting oil.
● Protect the nozzle and fuel connections using plugs or tape.
16-25
16.3.2 Overhauling the injection valve and replacing the nozzle v3 GUID-1993D98C-2597-499F-879E-0A0E2040477C
Related topics
Adjustments............................................................................................................................ .1
Clearances and wear limits at 20oC................................................................................... 06.2
Testing and adjusting the fuel injection valve.................................................................. 16.3.5
Injection valve................................................................................................................07.1.6.2
Tools
Code Description
806054 Special key
CAUTION
Do not mix the components of different injection valves.
Procedure
1 Clean the outside of the valve.
2 Remove the nozzle from the nozzle holder.
a Release the nozzle spring tension by opening the counter nut (1) and loosening the
adjusting screw (2).
16-26
4 5
8
7
1 Counter nut 6 Spring

2 Adjusting screw 7 Push rod
3 Spring guide 8 Nozzle nut (cap nut)
4 Screw 9 Nozzle
5 Nozzle holder
Fig 16-26 Fuel injection valve GUID-4E625298-CDD7-48CE-99E6-CE5573E750BB v3
b Remove the nozzle nut (8).

Turn the nut using the special key for main nozzle until the nut is loose.
3 To dismantle the nozzle holder:
a Open the nozzle holder by removing the counter nut (1) and adjusting screw (2).
b Turn the nozzle holder upside down and remove the spring guide, the spring and
the push rod.
4 Clean and examine all the injection valve components.
16-27
a Wash all components, including the new nozzle, thoroughly.

If possible, use a chemical carbon dissolving solution. If there is no such available,
immerse the details in clean fuel oil, white spirit or similar to soak carbon. Then clean the
components carefully.
CAUTION
Do not use steel wire brushes or hard tools.
CAUTION
Be careful not to drop the nozzle.
Clean the nozzle orifices with needles provided for this purpose (unless the nozzle is
new).
b Rinse the components to remove the carbon residues and dirt particles.
c Dry the components with compressed air.
d Inspect visually that every component is absolutely clean.

Inspect each component individually.
e Check for corrosion around the cooling oil holes.

In an old nozzle holder and nozzle nut there may be a sector of corrosion around the
cooling oil holes. This is acceptable as long as the nozzle nut can be tightened to the
correct torque and there is intact sealing around the cooling holes. Otherwise, replace
the nozzle holder.
f Check the nozzle spring.
g Check the high-pressure sealing faces of the nozzle and the nozzle holder, that is,
the contact face to the nozzle and the bottom of the fuel inlet hole.
5 Check the maximum nozzle lift.

See Chapter 06.
6 Assemble the valve and the new nozzle.

Tighten the nozzle nut to the stated torque. See Chapter 07.
7 Adjust the opening pressure and check the tightness of the valve according to
instructions.
Postrequisites
If the nozzles or injection valves will be stored before installation:
● Treat the nozzles and injection valves with corrosion protecting oil.
● Protect the nozzle and fuel connection using plugs or tape.
16-28
16.3.3 Checking the injection valve without replacing the

nozzle v3
GUID-195DAF16-2B0D-4FA3-86D1-A9D28FDC4368
Related topics
Adjustments............................................................................................................................ .1
Overhauling an injection valve with old nozzle.................................................................16.3.4
Clearances and wear limits at 20oC................................................................................... 06.2
CAUTION
Do not dismantle the valve unless necessary.
Procedure
1 Inspect the nozzle immediately after removing the injection valve from the engine.
Check for carbon deposits on the nozzle tip. Carbon deposits (trumpets) on the nozzle tip
may indicate that the nozzle is in poor condition, or the spring is broken.
2 Clean the outside of the valve thoroughly.

Clean the outer surface of the nozzle with a brass wire brush.
CAUTION
Do not use a steel wire brush.
CAUTION
Take care that no dirt enters the high-pressure fuel pipe connection.
3 Measure and record the opening pressure of the valve using the test pump.
Follow the instructions for testing and adjusting the fuel injection valve.
CAUTION
The opening pressure of an old valve with an old nozzle must not be changed.
When testing the valve, the opening pressure is normally 15–20% lower than the original
opening pressure. This is because the pressure obtained with the test pump is static and
the needle and sack areas under pressure are different. In normal operation, the opening
pressure is sufficient. If the opening pressure is adjusted to the stated value for new
nozzles, the valve opens at a much higher pressure during operation and the seat and
spring may be damaged. If the measured opening pressure is more than 20% below the
original value, replace the nozzle.
4 Check the tightness of the seat by doing a drip test.
a Flush the valve by pumping until the colour of the spray is the same as the colour
of the test fluid.
16-29
b Do a drip test by increasing the pressure up to 300 bar for 5 seconds.

If no dripping takes place, the injection valve is in good enough condition and can be re-
installed in the engine.
5 If the nozzle drips during the drip test, test the injector as described in the fuel
injection valve testing and adjusting instructions.
Postrequisites
If the injection valve will be stored before dismantling or installing it:
● Treat the injection valves with corrosion protecting oil.
● Protect the nozzle and fuel connection using plugs or tape.
16.3.4 Overhauling an injection valve with old nozzle v6

GUID-CB041A93-2035-450A-8CA5-2A151B03BAE8
Related topics
Adjustments............................................................................................................................ .1
Injection valve................................................................................................................07.1.6.2
Overhauling the injection valve and replacing the nozzle................................................ 16.3.2
CAUTION
Do not mix the components of different injection valves.
Procedure
1 Remove the nozzle from the nozzle holder.

Follow the instructions for overhauling the injection valve and replacing the nozzle.
2 Remove the needle from the nozzle.
CAUTION
Do not remove the needle by force because this may result in complete
jamming.
3 Dismantle the nozzle holder.

Follow the instructions for overhauling the injection valve and replacing the nozzle.
4 Clean and check all components thoroughly and dry with compressed air.
Clean and check all components individually.
For cleaning, see the instructions for overhauling the injection valve and replacing the
nozzle.
Clean the nozzle orifices with needles provided for this purpose. Check the needle guiding
section and the seat.
CAUTION
Do not use steel wire brushes or hard tools.
16-30
5 Insert the needle in the nozzle.
CAUTION
Do not lap the needle to the seat.
6 Reassemble the injection valve.

Tighten the nozzle nut to the stated torque.
7 Test and adjust the fuel injector valve as described in the fuel injection valve testing
and adjusting instructions.
Adjust the opening pressure to the value recorded earlier. If no opening pressure was
recorded before dismantling the valve, adjust the pressure to 530 bar.
Follow the instructions for testing and adjusting the fuel injection valve.
16.3.5 Testing and adjusting the fuel injection valve v5

GUID-D431B3A5-4A6C-4DD4-8C96-8781726DA101
Related topics
Adjustments............................................................................................................................ .1
Tools
Code Description
864001 Test equipment
The injection valve can be tested with a test device including a pneumatic test pump. The
test device can be used for:
● Checking the opening pressure
● Adjusting the opening pressure
● Checking the tightness of the needle seat (drip testing)
When using the pneumatic test pump, the injected fuel amount is very small and the needle
stroke therefore very short. For this reason, the pneumatic test pump cannot be used for
testing the injection form or creak sound. Testing the nozzle atomization with the hand test
pump is not reliable and may give an impression of bad atomization.
NOTE
A new injection valve needs no testing.
WARNING
High-pressure fuel spray may cause serious injury. Wear protective clothes,
glasses and gloves during the test.
Procedure
1 Prepare the testing device.
a Fill the oil tank with hydraulic oil through the filler cap (7).
Use hydraulic oil ISO VG 15.
16-31
b Connect the pump unit to the air inlet with a maximum air inlet pressure of 10 bar.
c Connect the high-pressure fuel outlet (3) with a flexible high-pressure hose (1) and
a fuel pipe.
2 Bleed air from the pump unit.
a Place the end of the high-pressure hose or the fuel pipe in a bucket.
Use a separate male connector to keep the connector valve open.
b Close the oil return valve by turning it clockwise.
c Slowly turn the pressure control valve clockwise to start the pump.
d Pump the oil into the bucket until there is no more air in the oil.
3 Mount the fuel injection valve to the test device.
1 2
4
3
7
1 High-pressure hose 5 Pressure control valve
2 Thrust piece 6 Oil return valve
3 High-pressure fuel outlet 7 Filler cap
4 Manometer
Fig 16-27 Injection valve testing device GUID-9ABA2FC1-1D99-4FCE-A59B-C84AE36F31B4 v3
a Connect the high-pressure hose (1) to the fuel injection valve by using the thrust
piece (2).
b Close the oil return valve (6) by turning it clockwise.
c Increase the pressure by turning the pressure control valve (5) clockwise.
The pressure increases until the nozzle opens.
To release the pressure, close the pressure control valve and open the oil return valve.
4 Test the needle opening pressure (NOP).

Inject fuel until the outflowing liquid is clean.
Record the pressure in the injection valve test record.
16-32
Measure and record the dimension “A”.
A
Fig 16-28 Testing the needle opening pressure GUID-F49B13D2-8047-4C9C-A66E-EF2F701CC242 v1
5 Check the nozzle spray holes.
a Release the spring tension until NOP is 50 bar.
b Inject 10-15 times to check the flow from the nozzle spray pattern.
All holes must be open and produce an evenly-distributed spray pattern.
c Release the pressure.
6 Check the nozzle tightness.
a Turn the adjusting screw to recording value “A”.
b Increase the pressure up to 300 bar.
c Check that the nozzle is completely tight. No drops are allowed within five
seconds.
Some spill fuel may appear from the nozzle holder because of the leakage along the side
of the needle. A small amount can be considered normal. Check that the connection
piece is tightened and the nozzle holder sealing surface is in good condition.
NOTE
If the fuel injection valve opening pressure is not within the limit values, the
nozzle spray holes are clogged or the nozzle is leaking, dismantle the injection
valve. Clean and inspect the parts and check the needle opening pressure,
spray pattern and nozzle tightness again.
7 To check the tightness of the needle guide (for old nozzles):
a Raise the pressure in the test pump to over 300 bar.
b Measure the time for a pressure drop from 250 to 200 bar.
Compare it to the pressure drop time of a new nozzle.
If the pressure drop time of a used nozzle is 1/3 of the original time, the guide is too worn
and the nozzle has to be replaced. For a new nozzle, the pressure drop time varies between
3–6 seconds.
16-33
NOTE
To evaluate the wear, compare the measured pressure drop time to the
pressure drop time of the same nozzle when new.
NOTE
The pressure drop time depends highly on the test equipment.
8 Adjust the needle opening pressure (NOP).
1 Counter nut
2 Adjusting screw
Fig 16-29 Adjusting the needle opening pressure GUID-FA0951D0-C570-405A-86A2-C58F8717EFFB v1
When the correct NOP is reached, tighten the counter nut (1) to the stated torque.
a For new nozzle:

Adjust the opening pressure to the stated nominal value, see Chapter 06 Adjustment,
clearances and wear limits.
When testing a new fuel injection valve, wash it with clean hydraulic oil to remove the
reservation oil.
b For used nozzle:

Adjust the opening pressure of the used nozzle to the same value that was measured
before dismantling the injection valve, see Chapter 16 Checking the injection valve
without replacing the nozzle. If the opening pressure was not recorded before
dismantling the injection valve, adjust the opening pressure to 530 bar.
NOTE
Do not adjust the opening pressure of the used injection valve to the nominal
value. This may result in injection valve spring failure.
16-34
16.3.6 Mounting the injection valve v8

WS-W46F-MAN-16-INJECTIONVALVE-MOUNTINGOFINJECTIONVALVE
Tools
Code Description
840001 Lapping tool for injection valve sealing surface
Procedure
1 Check that the bottom surface and the walls of the bore in the cylinder head are clean
and smooth.
If necessary, clean the surfaces using the lapping tool and emery paper of about 400 grit.
CAUTION
If the surfaces are not clean, dirt can fall onto the sealing surface when
mounting the injector and cause risk of leakage.
NOTE
The injection valve seals directly to the bottom of the cylinder head bore without
any sealing ring.
2 Fit new O-rings to the injection valve.

Lubricate the O-rings with lubricating oil or grease.
1 2 3
6
1 Connection piece 4 O-rings
2 Yoke 5 O-rings (one or two depending on
3 O-ring injection valve type)
6 Centre sleeve
Fig 16-30 Injection valve and connection piece GUID-C577D4E9-D40D-4318-819E-C2758E382523 v1
16-35
3 Mount the injection valve into the cylinder head bore.

Force the valve into the bore until it hits the bottom of the centre sleeve and you hear a
knock. Use an appropriate tool, for example a piece of bronze bar or similar. Do not draw
the valve down with screws.
Visually ensure proper placement of the valve through the connection piece bore using a
flash light.
4 Tighten the fastening nuts of the injection valve in steps of 10 Nm to the final torque.
5 Mount the connection piece and tighten to the stated torque.
6 Tighten the screws of the clamp flanges to the stated torque.
16.4 Fuel injection line v2

GUID-E85B7305-C837-4532-B910-68EC179A3176
The fuel injection line consists of two parts:

● Injection pipe
● Connection piece that is screwed sideways into the nozzle holder
1 2 3
1 Injection pipe 3 Fuel injection valve

2 Connection piece 4 Fuel pump
Fig 16-31 Fuel injection line GUID-004BDE87-82AE-47E4-AF19-A4D0C743CEB8 v2
The connection piece seals with plain metallic surfaces.

The injection pipe is one complete unit including the connection nuts at the ends. The pipe
is covered by a shield to protect the engine environment from fuel leakages.
16-36
16.4.1 Removing and mounting the fuel injection line v5

GUID-A11935E7-C4FA-4580-ADC7-2793AB6EA501
Related topics
Injection valve................................................................................................................07.1.6.2
Fuel injection pipe system.............................................................................................07.1.6.3
When removing the injection pipe, protect the injection line details against dirt and rust.
Before mounting the connection piece, check the sealing surfaces.
Before mounting the injection pipe, always tighten the connection piece to correct torque,
even if only the injection pipe was removed. Otherwise, there is a risk the connection piece
comes loose when removing the pipe.
Tighten the connection nuts of the injection pipes to the correct torque. Check the injection
pipe tightening torque after some running hours on a hot engine.
CAUTION
Do not overtighten the nuts.
CAUTION
A damaged fuel oil high-pressure injection pipe must be replaced.
16-37

30 Revised Maintenance Procedure For Wärtsilä 46F Injection System

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30 Revised Maintenance Procedure For Wärtsilä 46F Injection System

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INSTRUCTIONS

Wärtsilä 4-stroke 4616Q270

Revised maintenance procedure for

Wärtsilä Finland Oy Services 24 hrs Tel: +358 10 709 080

4616Q270, Issue 1, Page 2 / 4 + 37

Main changes in revised manual chapter 16

16.1.2 Lubricating the injection pump control rack

16.1.5 Assembling the injection pump

16.1.7.1 Checking the injection pump timing

16.1.7.2 Adjusting the injection pump tappet

Figure 1, Marking on pump foot

4616Q270, Issue 1, Page 3 / 4 + 37

Table 1, Definition of distance X

16.3.1 Removing the injection valve

16.3.5 Testing and adjusting the injection valve

16.4.1 Removing and mounting the fuel injection line

4616Q270, Issue 1, Page 4 / 4 + 37

© 2016 Wärtsilä Finland Oy – All rights reserved

16. Injection system

16.1 Fuel injection pump v3

Fig 16-1 Fuel injection pump GUID-2A726622-E340-4A3C-AAF1-111C5C3A9D69 v2

16.1.1 Fuel injection pump maintenance v2

16.1.2 Lubricating the fuel injection pump control rack v2

1 Press the grease gun against the lubricating nipple.

Fig 16-2 Lubricating the control rack GUID-C3FA6079-36AF-4BA7-9969-80B622CED578 v1

2 Press oil in through the lubricating nipple (1).

3 Remove the grease gun.

16.1.3 Removing the injection pump v2

831002 Eye bolt

1 Remove the hot box covers.

3 Remove the connected pipes from the pump.

4 Disconnect the fuel control racks.

5 Lift off the injection pump as follows:

a Mount the lifting tool.

b Remove the fastening bolts and nuts of the pump.

c Lift off the injection pump.

Fig 16-3 Lifting the injection pump GUID-A61C2E91-1DB1-4004-ABC4-1828AE2EF2C0 v1

16.1.4 Dismantling and cleaning the fuel injection pump v5

800001 Pliers for retaining rings

Fig 16-5 Fuel injection pump GUID-F0C62E8F-8FA1-43F4-AE54-7C6E60AFDCD9 v4

a Secure the push rod assembly of both pump elements.

4 Remove the control sleeves (14).

5 Remove the fuel control racks.

a Remove the guiding pins from the control racks.

b Remove the pistons of the stop cylinders.

c Pull out the fuel control racks.

6 Turn the pump to the upright position.

7 Dismantle the connection piece (5) carefully.

a Remove the bolts of the connection piece.

b Remove the connection piece.

9 Remove the barrels (10).

10 Clean and lubricate the components.

16.1.5 Assembling the fuel injection pump v6

800001 Pliers for retaining rings

2 Assemble the pump barrels (2) and the cover (1).

Fig 16-6 Pump barrels and cover GUID-DB4502AD-2C34-4402-8D55-93DF02F77227 v1

Fig 16-7 Pump in reference position GUID-C7A20158-30E4-4960-9F4F-AEC3950FF2FA v2

1 O-ring 3 Support rings

3 Mount the pump cover onto the pump housing.

a Fit the cover into the pump housing.

4 Mount the connection piece to the pump cover.

Fig 16-10 Mounting connection piece GUID-335F60EA-54F6-4B7E-8D9B-D28952D76FC8 v2

5 Turn the pump upside down.