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Service, Wärtsilä Finland Oy Tekninen tiedote Teknisk bulletin

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Engine section Engine type Ref. Date Issue Document No. Page
16 Injection system WFI–S 03.12.2002 01 2016S019GB 1(2)

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This Technical Bulletin concerns Wärtsilä 20 engines equipped with
injection pumps marked:

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7KHORFDWLRQRIWKHLQMHFWLRQSXPSGHVLJQDWLRQSODWH

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PFR 1CY180V-C
UT = 80

$GYDQWDJHV Experience from previous injection pump versions with sealing ring plunger
elements shows advantages like:
• Improved sealing capability between the plunger and the barrel bore.
• Improved leak fuel draining arrangement.
• Improved performance in respect to injection pump plunger lacquering
in cases where chemically incompatible elements in the fuel and the
lubricating oil are mixed between the plunger and the barrel during
operation.

3DUWV 8SJUDGLQJSDUWVQHHGHGSHULQMHFWLRQSXPS(see encl.165-07)

'HVLJQDWLRQ 3DUW1R 4XDQWLW\
Pump element set 165058 012 1

Wärtsilä Finland Oy P.O. Box 252 (Tarhaajantie 2) Telecop. +358 10 709 1847 Tel. +358 10 709 0000 Business ID 0773744-3
Service, Vaasa FIN-65101 Vaasa, Finland Telecop. +358 6 356 7339 Registered Office: Vaasa
Wärtsilä Finland Oy P.O. Box 50 (Stålarminkatu 45) Telecop. +358 10 709 3279 Tel. +358 10 709 0000
Service, Turku FIN-20811 Turku, Finland
Service, Wärtsilä Finland Oy Service letter
Issue Document No. Page
01 2016S019GB 2(2)

,QVWUXFWLRQV The replacement of the injection pump element according to the instruction
manual, chapters 07 and 16 (Chapter 16 enclosed).

&KDQJHRIGHVLJQDWLRQQXPEHUDWDQXSJUDGH
Restamp the identification number on the designation plate with
“B 416 810 350”, which corresponds to an injection pump equipped with an
injection pump element plunger sealing.

7RROVIRURYHUKDXO The following tools are needed for replacement of the sealing rings on the
plunger, see chapter 16.

Tool number Designation

846 026 Protecting sleeve (B5873)
846 027 Application rod (B5874)
846 028 Calibrating sleeve (B5875)

These tools can be ordered separately.

6SDUHSDUWVVXSSO\ When ordering injection pump elements please note that Wärtsilä will
deliver only the new type.

5HFRPPHQGDWLRQ Wärtsilä advises owners/operators of the Wärtsilä 20 engines concerned to

upgrade their injection pumps with the new injection pump element at the
earliest convenient opportunity, especially in the case where plunger
lacquering or fuel oil contamination of the engine lubricating oil has
occurred. It is also recommended to upgrade the spare part stock and
spare pumps to avoid future mismatches.

'RFXPHQWDWLRQ Both the Instruction Manual and the Spare Part Catalogue to be updated
when the new injection element is installed:
 Instruction Manual chapter 16 replaces the previous version.
 Spare Part Section 20 165-07 replaces the section 20 165-04

(QFORVXUHV - Chaper 16 of the instruction manual, version 20-200244-02.

- Section 165-07 (pages 1 to 6) of the Spare Parts Catalogue.

/HWWHUGLVWULEXWLRQ Wärtsilä Service Network and owners/operators of Wärtsilä 20 engines.

/HWWHUYDOLGLW\ Until further notice

 2002 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 pr 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.

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 20 Spare Parts List 165-07
Edition A
Page 1(6)

Injection Pump
165 056 165 055

165 023 165 002 0 5

165 008 165 042

165 009 165 024

165 010 165 025

165 011 165 026

165 027
165 062 165 001
165 015

A 165 012 165 063

165 012
165 013 165 029
165 032
165 014
165 017

165 019
165 020
165 030
165 021
165 031 165 043

Part No and Description Pcs Kg

165 001 Injection pump (1) see page 4.

165 002 Screw 7 (2) Parts included in the set and not delivered
165 008 Erosion plug 2 separately!
165 009 Seal ring (2) 1
165 010 Plug 1
165 011 Spring plate 1
165 012 O-ring 4
165 013 Sleeve 2
165 014 Sleeve 2
165 015 Retainer ring 2
165 017 Spring 1
165 019 Tappet 1
165 020 Spring 1
165 021 Pin 1
165 023 Pump element (1) 1
165 062 Seal ring(2) 1
165 063 O-ring(2) 1
165 024 Seal ring (2) 1
165 025 Seal ring 1
165 026 O-ring (2) 1
165 027 Scraper ring 1
165 029 Control sleeve 1
165 030 Tappet pin 1
165 031 Tappet roller 1
165 032 Sleeve 2
165 042 Two way pressure valve (1) 1
165 055 Flange 1
165 056 Screw 4
165 043 Pin 2
 165-07 Spare Parts List WÄRTSILÄ 20
Edition A
Page 2(6)

Injection Pump

165 024
165 009
165 011
165 025
165 002 165 026
165 027
165 008
165 008
165 017
165 014
165 042
165 025

165 010 165 012 165 019

165 030
165 023

165 062 165 012

165 063
165 015
165 043

165 020
165 029
165 058 165 021

165 031

Remarks
 WÄRTSILÄ 20 Spare Parts List 165-07
Edition A
Page 3(6)

Injection Pump

165 059

165 060

165 033

165 034

165 036

VIEW A 0 30 40
165 037

165 018

Part No and Description Pcs Kg

165 018 Guide screw 1

165 033 Plate 1
165 034 Indicator 1
165 036 Screw 1
165 037 Fuel rack 1
165 059 Seal ring 1
165 060 Vent screw 1
 165-07 Spare Parts List WÄRTSILÄ 20
Edition A
Page 4(6)

Injection Pump

165 042

165 056
165 055
165 024
165 057
165 023 165 009
165 004
165 058
165 005
165 062 165 026
165 006
165 063
165 007

Part No and Description Pcs Kg

165 058 Spare part kit 1

165 009 Seal ring (2) 1
165 023 Pump element 1
165 062 Sealing ring(2) 1
165 063 O-ring(2) 1
165 024 Seal ring (2) 1
165 026 O-ring(2) 1
165 042 Two way pressure valve set 1
165 004 Spring (2) 1
165 005 Seat (2) 1
165 006 Needle (2) 1
165 007 Spring (2) 1
165 055 Flange 1
165 056 Screw 4
165 057 Pressure piece (2) 1

(2) Parts included in the set and not delivered

separately!
 WÄRTSILÄ 20 Spare Parts List 165-07
Edition A
Page 5(6)

Injection Pump

165 038
0,2 mm

165 039 165 033

0,5 mm

165 040
1,0 mm

165 041
1,5 mm

Part No and Description Pcs Kg

165 033 Plate

165 038 Plate 0.2mm 1
165 039 Plate 0.5mm 1
165 040 Plate 1.0mm 1
165 041 Plate 1.5mm 1
 165-07 Spare Parts List WÄRTSILÄ 20
Edition A
Page 6(6)

Injection Pump

165 008

165 009 165 024

165 025 165 025

165 052

165 062 165 012

165 063

165 026
228 003

165 027

165 059

Part No and Description Pcs Kg

165 052 Sealing set for injection pump 1

165 008 Erosion plug 2
165 009 Seal ring 1
165 012 O-ring 4
165 024 Seal ring 1
165 025 Seal ring 1
165 026 O-ring 1
165 027 Scraper ring 1
165 059 Seal ring 1
165 062 Sealing ring 1
165 063 O-ring 1
228 003 Slide ring (3) 1

(3) see section 228-01.

 20-200244-02 Injection System 16

16. Injection System

16.1 Injection pump

16.1.1 General description

Data and dimensions The engine is fitted with one injection pump per cylinder. The
Multihousing: injection pump is located in a “multihousing”. The functions of the
- material special cast iron multihousing are:
- weight: 25 kg
Injection pump element: • Housing for the injection pump element,
- weight: 4.5 kg • Fuel supply channel along the whole engine,
Injection press: 1500 bar • Fuel return channel from each injection pump,
Plunger: coated
Delivery valve • Guiding for the valve tappets,
opening press.: 22 ± 2 bar • Lubricating oil supply to the valve mechanism.
Constant pressure valve,
opens when the pressure dif-
ference is: 120 ± 10 bar The arrangement with the multihousing represents the ultimate
in safe fuel system. It also gives a compact design without fuel
piping and with easy maintenance operations. An injection pump
element can be replaced without removing the multihousing.
The injection pumps are one-cylinder pumps with built-in roller
tappets. The valve tappets are integrated in the same multihous-
ing. The drain fuel is led in an integrated pipe system with
atmospheric pressure back to the low pressure fuel system circuit.
Each injection pump is equipped with an emergency stop cylin-
der coupled to an electro-pneumatic overspeed protecting system.

16.1.2 Function
The injection pump pressurizes fuel to the injection nozzle. It has
a regulating mechanism for increasing or decreasing the fuel feed
quantity according to the engine load and speed. The pumps are
governed by the governor.
The plunger, pushed up by the camshaft via the roller tappet
and pulled back by the spring acting on the roller tappet, recip-
rocate in the element on a predetermined stroke to feed fuel under
pressure.
The plunger also controls the injected amount by adjusting the
helix edge position relative to the discharge port. The plunger has
an obliquely cut groove (lead) on its side. When the plunger is at
the lowest position or bottom dead centre, fuel flows through the
inlet port into the element bore. Rotation of the camshaft moves
the plunger up. When the top edge of the plunger step is lined up
with the ports, application of pressure to fuel begins. As the
plunger moves up further, and the helix of the plunger meets with
the ports, the high pressure fuel flows through the lead to the
ports and the pressure feed of fuel is completed.

WÄRTSILÄ 20 16 - 1
 16 Injection System 20-200244-02

The plunger stroke during which the fuel is fed under pressure
is called the effective stroke.
According to the engine load, the amount of fuel injected is
increased or reduced by turning the plunger a certain angle to
change the helix position where the ports are closed on the up
stroke and hence increasing or reducing the effective stroke. The
fuel rack is connected to the regulating mechanism of the gover-
nor. If the fuel rack is moved, the control sleeve in mesh with the
rack is turned. Since the control sleeve acts on the plunger, the
plunger turns with the control sleeve, thus the effective stroke
changes and the injected fuel amount increases or decreases.
The element is of a mono-block design with integrated fuel
delivery valve and constant pressure valve. The ports are of a
special design to prevent cavitation.
The delivery valve, provided in the top of the element, performs
the function of discharging the pressurized fuel to the injection
pipe. The fuel compressed to a high pressure by the plunger forces
the delivery valve to open. Once the effective stroke of the plunger
ends, the delivery valve is brought back to its original position by
the spring and blocks the fuel path, thereby preventing counter
flow of the fuel.
After the effective stroke, the fuel is drawn back through the
constant pressure valve from the high pressure injection pipe to
instantly lower the residual pressure between the delivery valve
and the nozzle. This draw-back effect improves the termination
of an injection on the nozzle and prevents after injection dripping
and improves injection regularity by preparing the line for the
next injection.
The multihousing is provided with two erosion plugs, which can
easily be replaced when necessary.

16.2 Maintenance of injection pump

It is recommendable that the engine will be run 5 minutes with
light fuel before stopped for overhaul of injection pump. During
maintenance utmost cleanliness must be observed. It is unneces-
sary to remove the control shaft if not every injection pump is
removed. When the injection pump is dismantled, the components
should be marked and later assembled in the same position as
before to avoid unnecessary wear.

16.2.1 Removal of injection pump

1 Shut off fuel supply to the engine and stop prelubricating
pump.
2 Remove the covers of the valve mechanism and camshaft
from the cylinder concerned.

16 - 2 WÄRTSILÄ 20
 20-200244-02 Injection System 16

3 Turn the crankshaft to a position where the valve tappet

rollers of the valves and the injection pump are on the base
circle of the cam.
4 Remove the rocker arms block, pushrods and the pro-
tecting pipes.
5 Remove necessary pipes, injection pipe and fuel leak
pipes and lube oil pipe. Disconnect the fuel rack, if necessary
remove control shaft.
6 Open the fuel pipe connections between the multihous-
ings concerned. Use circlip pliers to slide the fuel retainer ring
(4) to one side. Move the fuel line connecting sleeves (5) clear
of the adjacent fuel pipes. See fig 16-1.
7 Cover immediately all openings with tape or plugs to
prevent dirt from entering the system.
8 Loosen the flange nuts and lift off the pump.
9 Cover the bore in the engine block.

16.2.2 Mounting of injection pump

1 Check and clean the pump. Also clean the plane and
the bores of the engine block.
2 Check the O-rings of the insert part and lubricate with
vaseline or engine oil. Check that the fuel cam is not in the
lifting position.
3 Fit the pump and tighten the screws for the flange to the
stated torque, see chapter 07. Fig 07-4 and 07-5.
4 Remove tape and plugs from all openings. Check that
the exhaust and inlet cams are not in the lifting position.
5 Fit the protecting pipes, pushrods and rocker arms
bracket, adjust valve clearances, see chapter 12. Fig 12-3.
Assembly necessary pipes.
6 Close the fuel pipe connections between the multihous-
ings concerned. Use circlip pliers to slide the fuel retainer ring
(4).
7 Assembly the injection pipe and tighten nuts to torque,
see chapter 07.
8 Check that the fuel rack moves freely.
9 Connect the fuel rack to the control shaft. Assembly con-
trol shaft if removed.
10 Rotate the control shaft and check that all pumps follow
the shaft movement. Check the fuel rack position of all pumps,
see chapter 22.

WÄRTSILÄ 20 16 - 3
 16 Injection System 20-200244-02

11 Open fuel supply to the engine and vent the fuel system
according to the instructions in chapter 17. The injection pump
is provided with a venting plug.
12 Mount the covers.

Injection pump

1. Tappet pin
12
2. Tappet
11
3. Plug
4. Retaining ring Alternative Design
10 A
5. Sleeve
9 13
6. O-ring
7. Spring 3 14
8. Spring plate 8 15
9. Fuel rack
7
10. Fuel delivery valve/ 20
Constant pressure valve 6
11. Pump element
12. Screw
13. Erosion plug 5
14. Plunger
4
15. Control sleeve 2
16. Spring 1
17. Pin
B 16
18. Tappet roller 17 18
19. Guide screw VIEW B
20. Seal ring / O-ring

19

Fig 16-1 2016680220

16 - 4 WÄRTSILÄ 20
 20-200244-02 Injection System 16

16.2.3 Removal of injection pump element

Most maintenance operations can be done without removing the
multihousing from the engine. It is recommendable that the
engine will be run 5 minutes with light fuel before stopped for
overhaul of injection pump. During maintenance utmost
cleanliness must be observed.
1 Shut off fuel supply to the engine and stop
the prelubricating pump. Open the covers.
2 Remove necessary pipes, injection pipe, fuel leak pipes
and lube oil pipe.Disconnect the fuel rack.
3 Cover immediately all openings with tape or plugs to
prevent dirt from entering the system.
4 Turn the crankshaft so that the injection pump tappet is
in the bottom position, the roller resting on the base circle of
the cam.
5 Loosen the flange screws (12) until they are free from
the threads.
6 Mount the extracting tool 846022 so that the tool flange
is against the screw heads and tighten the nut until the
element is held by the tool.
7 Lift off the element (11).
8 Remove the extracting tool
9 Remove the plug (3) and remove the fuel rack (9).
10 Remove the plunger (14), by turning it about 90° using
the tool 846023.
11 Cover the opening in the multihousing immediately
with clean cloth.

Note! The delivery valve can be opened by the authorized personnel only.

16.2.4 Changing of plunger sealing rings

Note! The sealing rings are always to be renewed if they are removed
from the groove on the plunger.

1 Remove the old rings, by cutting them off without dam-

aging the plunger surface.
2 Place the protecting sleeve (846 026) on top of the
plunger to cover the sharp edges of the helix.
3 Lightly lubricate the protecting sleeve, the o-ring, the
sealing ring and the plunger with light fuel oil.

WÄRTSILÄ 20 16 - 5
 16 Injection System 20-200244-02

Sealing ring assembly and calibration of rings

846 027
846 026 Protecting sleeve
846 027 Application rod 846 026
846 028 Calibrating sleeve
20. O-ring / Seal ring
20

846 028

Fig 16-2 2016690244

4 Push the o-ring (20) with the application rod (846027)

over the protecting sleeve down along the plunger and place
it by hand in the groove.
5 Push the sealing ring (20) with the application rod over
the protecting sleeve down along the plunger and place it by
hand in the groove.
6 Remove the protecting sleeve and calibrate the assem-
bled sealing rings by using the calibrating sleeve (846028) in
order to ensure that the rings are properly fitted in the groove.

16.2.5 Mounting of injection pump element

1 Check and clean the element.
2 Fit new O-rings and lubricate.
3 Clean the housing. Pay special attention to the O-ring
sealing surfaces.
4 Insert the plunger and control sleeve by the tool 846023.
5 Check that the control sleeve (15) is in correct position.
Mount the fuel rack (9) and plug (3). Check that the fuel rack
moves freely.
6 Assemble the element into the housing. Be careful
when connecting the plunger into the element.
7 Tighten the fastening screws diagonally in steps to the
stated torque, see chapter 07.

16 - 6 WÄRTSILÄ 20
 20-200244-02 Injection System 16

8 Check that the fuel rack moves freely.

9 Rotate the control shaft and check that all pumps follow
the shaft movement. Check the fuel rack positions of all pumps,
see chapter 22.
10 Remove the protecting tapes or plugs and connect the
pipes and the injection pipe. Tighten the nuts to torque.
11 Open fuel supply to the engine and vent the fuel system
according to the instructions in chapter 17.

16.2.6 Control of fuel injection timing

For normal adjustment of injection timing the prelift can be
measured mechanically by a special tool 869001, see Fig 16-3.
Control of fuel injection timing is necessary only if major com-
ponents have been changed, e.g. the camshaft intermediate gear
or one or more camshaft pieces.
1 Remove the camshaft cover at the cylinder in question.
2 Turn the crankshaft until the pump tappet roller (1) is on
the basic circle of the camshaft (3), i.e. approximately 20°
before TDC at the ignition.
3 Mount the checking tool 869001 (5) and adjust the dial
indicator tool 848041 to zero (4), see Fig 16-3.
4 Turn the flywheel in the rotating direction until the tap-
pet (2) lifts up to 7mm.
5 Read the flywheel position. If the position is according to
test records go to step 13.
6 Remove the camshaft end cover and install
the hydraulic tool 861169 on the screw, see section 13.2.2.
7 Loosen the nut by using correct hydraulic pressure, see
section 07.3 and release pressure.
8 Turn the flywheel to the position required.
9 Tighten the screw connection
10 Turn the crankshaft until the pump tappet is on the basic
circle.
11 Adjust the gauge (4) to zero.
12 Turn the flywheel in the rotating direction until the tap-
pets lifts up to 7mm. Check the position of the flywheel.
13 Unmount the checking tool.
14 Reassemble the cover of the intermediate gears.
15 Reassemble the camshaft cover

WÄRTSILÄ 20 16 - 7
 16 Injection System 20-200244-02

Note! Changing of the camshaft gear position will affect to all cylin-
ders.

Checking of injection timing

1. Tappet roller
2. Tappet
3. Camshaft
4. Dial indicator
5
5. Injection timing tool

Fig 16-3 2016639950

16.2.7 Injection pump overhaul

It is supposed that the multihousing is removed from the engine
and it is properly cleaned.

Note! The element cylinder, plunger and delivery valve assembly

are matched and they must be kept together during the
overhaul.

1 It is recommendable to put the pump in a screw vice, in

positions convenient for the different operations.
2 Remove the element according to section 16.2.3.
3 Renew sealing rings on the injection pump plunger
according to section 16.2.4.
4 Turn the pump up side down.
5 Support the roller tappet with the tool 846016 and open
the guiding screw (19). See fig 16-1.
6 Release the spring tension and remove the tool.
7 The roller tappet and the spring can now be removed.
8 Remove the spring plate (8) and control sleeve (15).

16 - 8 WÄRTSILÄ 20
 20-200244-02 Injection System 16

9 Depress the roller pin locking pin (17) and withdraw

the roller pin. Cover the locking pin as it is under spring
tension.
10 As the multihousing integrates the valve tappet, it is
recommendable that the valve tappet is inspected at the same
time.
11 Wash the details in absolutely clean diesel oil and lubri-
cate the internal parts with engine oil. Pay special attention
to the grooves and bores for leak fuel and lubricating oil. Clean
protective latex gloves to be used when handling details of the
injection pump. Keep the parts together, the plunger being
inserted in the element.
12 Normally, further dismantling is not necessary. It is rec-
ommendable to keep the components of different pumps apart
from each other, or to mark the details so they can be fitted
into the same pump. The details must be protected against
rust, and the running surface of the element plunger especially
should not be unnecessarily handled with bare fingers.
13 Lubricate the roller and roller pin before assembling
them.
14 Renew the sealing ring and insert the control sleeve and
the spring plate into the housing.
15 Lubricate the tappet roller and assemble it into the
housing together with the spring.
16 Support the tappet roller with the tool 846016, keeping
the slot for guiding screw in correct position.
17 Depress the tappet roller until the slot is aligned with
the hole.
18 Screw in and tighten the guiding screw (19) to stated
torque, see section 07.
19 Turn the pump and assemble the element. See section
16.2.5.
20 Unless the pump is immediately mounted on the en-
gine, it must be well oiled and protected by a plastic cover or
similar. The fuel ports and injection line connection must
always be protected by plugs or tape.

16.3 Injection line

The injection line consists of two parts, the connection piece,
which is screwed sideways into the nozzle holder, and the injec-
tion pipe.
The connection piece seals with plain metallic surfaces which
are to be checked before mounting. Always tighten the connection

WÄRTSILÄ 20 16 - 9
 16 Injection System 20-200244-02

piece to correct torque before mounting the injection pipe; also in

case only the injection pipe has been removed, because there is a
risk of the connection piece coming loose when removing the pipe.
The injection pipe is covered by a shielding to protect the engine
environment from fuel leakages. The injection pipes are delivered
complete with connection nuts assembled. It is better to hold the
connection piece with a tool while assembling the high pressure
pipe. Always tighten the connections to correct torque.
When removed, the injection line details have to be protected
against dirt and rust.

16.4 Injection valve

16.4.1 Description
Data and dimension The injection valve is centrally located in the cylinder head and
Orifices: 8 pcs includes the nozzle holder (6) and the nozzle (1), see Fig 16-4. The
Orifice dia.: 0.38 mm fuel enters the nozzle holder sideways through a connection piece
Angle: 148° screwed into the nozzle holder.
Opening press: 450 bar
The nozzles receive high pressure fuel from the injection pipe
and inject this fuel into the combustion chamber as a very fine
spray. The pressure at which the nozzle operate can be corrected
by turning the adjusting screw (8) in the injection valve.

Injection valve

9
1. Nozzle
2. Nozzle nut 14 13 11 10 8
3. Dowel pin
4. Push rod
5. Spring
6. Injection valve housing
7.Thrust bolt
12 7
8. Adjusting screw
9. Nut 6
10. O-ring 5
11. Protecting sleeve
12. Connection piece 4
13. O-ring 3
14. Injection pipe
2
1

Fig 16-4 2016650025

16 - 10 WÄRTSILÄ 20
 20-200244-02 Injection System 16

16.4.2 Removing of injection valve

1 Remove the cylinder head cover.
2 Remove the injection pipe.
3 Remove the rocker arms
4 Unscrew the connection piece and loosen the protect-
ing sleeve if necessary.
5 Remove the fastening nuts of the injection valve.
6 Lift out the injection valve (6) by using tool 846024. See
Fig 16-4.
7 Protect the fuel inlet hole of the injection valve and the
bore in the cylinder head.

16.4.3 Overhauling of injection valve

1 Inspect the nozzle immediately after removing the injec-
tion valve from the engine. Carbon deposits (trumpets) may
indicate that the nozzle is in poor condition, or the spring is
broken. Clean outside of the nozzle with a brass wire brush.
Don’t use steel wire brush.
2 Check the function and condition of the nozzle, i.e.
the opening pressure and seat tightness. It is recommended to
use a hand pump tester (864012) with an accumulator device
in order to judge spray characteristic’s with realistic pumping
rates.
3 Put the special tool 846030 in a screw vice and insert the
injection valve into the tool with nozzle downwards.
4 Remove the nozzle from the holder by turning the injec-
tion valve housing (6) counter-clockwise until the cap nut (2)
is loosen. Keep the nozzle together with the holder body, don’t
let it follow up with the nut. If there is coke between the nozzle
and the nut, the dowel pins may break and damage the nozzle.
To avoid this, knock on the nozzle, using a piece of pipe
according to Fig 16-5, to keep it towards the holder. Never
knock directly on the nozzle tip. Be careful not to drop the
nozzle.
5 Check the nozzle needle movement which may vary as
follows:
• needle completely free
• needle free to move within the normal lifting range
• needle is sticking
The needle must not be removed by force because this often
results in complete jamming. Unless it can be easily removed,
immerse the nozzle in lubricating oil and heat oil to 150 - 200°C.
Normally, the needle can be removed from a hot nozzle.

WÄRTSILÄ 20 16 - 11
 16 Injection System 20-200244-02

Max needle lift of nozzle, removing of nozzle from holder

A= Nozzle needle lift

B= Accepted wear for the sealing face
of nozzle holder

Fig 16-5 2016660220

6 Clean the components. If possible, use a chemical carb-

on 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 by tools included
in the tool set. Do not use steel wire brushes or hard tools.
Clean the nozzle orifices with needles provided for this pur-
pose. After cleaning, rinse the details to remove carbon resi-
dues and dirt particles.
Before inserting the needle in the nozzle body, immerse the
components in clean fuel oil or special oil for injection systems.
Seat surfaces, sliding surfaces (needle shaft) and sealing
faces against the nozzle holder should be carefully checked.
7 Clean the nozzle holder and the cap nut carefully; if ne-
cessary, dismantle the nozzle holder to clean all details.
Check the nozzle spring.
8 Check the high pressure sealing faces of the nozzle
holder, i.e. the contact face to nozzle and the bottom of the fuel
inlet hole.
9 Check max needle lift of nozzle, i.e. sum of measures A
and B in Fig 16-5. If the wear B exceeds 0.05 mm, the nozzle
holder can be sent to the engine manufacturer for recondition-
ing. If nozzle needle lift is out of the value stated in chapter 06,
section 06.2, the nozzle should be replaced by a new one.
10 Reassemble the injection valve. Tighten the cap nut to
the torque given in section 07.1.

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11 Connect the injection valve to the test pump 864012.

Pump to expel air. Shut the manometer valve and pump
rapidly to blow dirt out of the nozzle orifices. Place a dry paper
under the nozzle and give the pump a quick blow. Note fuel
spray uniformity.

Note! Ensure hands are not in the path of the spray jets.

12 Check the opening pressure:

• open manometer valve,
• pump slowly and watch manometer to note the opening
pressure.
• if the opening pressure is not rising to the stated pressure
then adjust by turning the adjusting screw (8) clockwise.

Adjusting of opening pressure

8. Adjusting screw

9. Nut
8

Fig 16-6 2016670025

13 Place a dry paper under the nozzle and give the pump
a quick blow. Note fuel spray uniformity. If the spray is
uniform, adjust the opening pressure to the stated value and
check once more the spray uniformity.

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 16 Injection System 20-200244-02

14 Check the needle seat tightness:

• increase pressure to a value 20 bar below the stated opening
pressure,
• keep pressure constant for 10 seconds and check that no fuel
drops occur on the nozzle tip. A slight dampness may be
acceptable.
15 Check the needle spindle tightness:
• pump until pressure is 20 bar below the stated opening
pressure,
• measure time for a pressure drop of 50 bar. If the time is
below 3 seconds, it indicates worn nozzle and it must be
replaced by a new one. A time longer than 20 seconds indi-
cates fouled needle, and the nozzle must be cleaned.
16 If the tests according to step 10...14 give satisfactory
results the injection valve can be re-installed in the engine.
Otherwise, replace the nozzle by a new one.
17 If leakage occurs on the high pressure sealing surfaces
the damaged detail should be replaced by a new one or
reconditioned.
18 If nozzles or injection valves are to be stored they
should be treated with corrosion protecting oil. The nozzle and
fuel connection must be protected by plugs or tape.

16.4.4 Mounting of injection valve

1 Check that the bottom surface of the bore in the cylin-
der head is clean. If necessary, clean or lap the surface by the
tool 841020. If lapping is necessary, the cylinder head must be
lifted off. For lapping, a steel washer and fine lapping com-
pound is used. The injection valve seals directly to the bottom
of the cylinder head bore.
2 Put new O-rings on the injection valve. Lubricate the
injection valve with engine oil or vaseline.
3 Fit the injection valve into the cylinder head bore but do
not tighten the nuts.
4 Put new O-rings on the connection piece and on the
protecting sleeve if it has been removed.
5 Mount the protecting sleeve on the connection piece
if it has been removed. Screw in the connection piece by hand.
Tighten to correct torque. Tighten the protecting sleeve screws.
6 Mount the injection pipe and tighten the cap nuts to
torque.
7 Before tightening the fastening nuts of the injection
valve, let the valve stay in the cylinder head bore 30 minutes
to allow the temperatures to egualise.

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8 Finally tighten the nuts by using the torque wrench

delivered with the engine in the following steps:
a. Both nuts to 20 Nm
b. Both nuts to 30 Nm
c. Both nuts to 40 Nm
d. Both nuts to final torque 50 ±3 Nm
9 Mount the rocker arms.
10 Mount the covers.

16.5 Pneumatic overspeed trip device

The pneumatic overspeed trip device is mounted on the multi-
housing and acts directly on the fuel rack. If the overspeed trip
device is activated pressurized air acts on a piston in a cylinder
mounted on the multihousing. The piston forces the fuel rack to
a “no fuel” position. The force of the overspeed trip device is
stronger than the torsion spring in the regulating mechanism.
For maintenance of pneumatic overspeed trip device see chapter
22.

Pneumatic overspeed trip device

1. Cylinder 1 2
2. Piston
3. O-ring
4. Fuel rack 3

Fig 16-7 2016629848

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