W200

16
Injection system

0936 Page 1
 W200

Injection System ......................................................................................................................................3

16.1 Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16.1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16.1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16.2 Injection pump removal and assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

16.2.1 Injection pump removal (see fig. 16.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
16.2.2 Injection pump assembly (see fig. 16.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

16.3 Maintenance of injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

16.3.1 Control pressure valve replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
16.3.2 Anti-erosion plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16.3.3 Injection pump roller replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
16.3.4 Injection pump overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

16.4 Injection line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

16.4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
16.4.2 Injection line assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

16.5 Injection nozzle holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

16.5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
16.5.2 Removing nozzle holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
16.5.3 Overhauling injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16.5.3.1 Sealing surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16.5.3.2 Injection nozzle checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16.5.3.3 Injection nozzle adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

16.5.4 Injection nozzle holder refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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 W200 Injection System 16.

16. Injection System

16.1 Injection pump
16.1.1 General description
Data and dimensions The engine is equipped with one injection pump per cylinder. The
Multihousing : injection pumps are located under the hot box covers. The functions
- material : special cast iron of the injection pump multihousing are :
- weight :
Injection pressure :
30 kg
1500 bar
• Housing for the injection pump element,
Plunger : anti-wear coating • Fuel supply channel along the whole engine,
• Fuel return channel from each injection pump,
• Guiding for the valve tappets,
• Lubricating oil supply to the valve mechanism.
The arrangement of the multihousing represents the ultimate in safe
fuel system. It also gives a compact design without fuel piping and
an easy maintenance operation.
Each injection pump is equipped with an emergency stop piston
coupled to an electro-pneumatic overspeed protecting system.

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 16. Injection System W200

16.1.2 Function
The injection pump pressurizes the fuel to the injection nozzle. The
fuel rack (item 9) turns the injection pump plunger (item 14) to in-
crease or decrease the fuel feed quantity according to the engine
load and speed. The governor drives the fuel rack.
The plunger, pushed up by the camshaft via the roller tappet (item
18) and pulled back by the spring (item 7) acting on the roller tap-
pet, reciprocates in the element on a predetermined stroke to feed
fuel under pressure.
The plunger (item 14) 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 in-
let port into the element bore. Rotation of the camshaft moves the
plunger up.

10
A. Discharge port
1. Tappet pin 12
2. Tappet
3. Cylinder screw
11
G

4. Retaining ring
5. Sleeve 15 13
6. O-ring
7. Spring 13
8. Spring plate A
9. Fuel rack 9
9 14
10. Constant pressure valve 4 8
11. Pump element 5
12. Screw 7
13. Erosion plug 8
14. Plunger
15. Venting screw 6
16. Spring
3
17. Pin
18. Tappet roller 19 2
19. Roller shaft 18 1 19
16 18
17

Fig 16-1

When the top edge of the plunger step is lined up with the ports, the
application of pressure to fuel begins. The high-pressure fuel goes to
the injection nozzle.
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 increa-
sed or reduced by turning the plunger a certain angle to change the
helix position where the ports are closed on the up stroke and

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 W200 Injection System 16.

hence increasing or reducing the effective stroke. The fuel rack

(item 9) is connected to the regulating mechanism of the governor.
The element is of a mono-block design with integrated and constant
pressure valve (item10). The ports are of a special design to prevent
cavitation.
The constant pressure valve, fitted on the top of the element, per-
forms the function of discharging the pressurized fuel to the injec-
tion pipe.
After the effective stroke, the fuel is drawn back through the cons-
tant pressure valve from the high-pressure injection pipe to instantly
lower the residual pressure between the delivery valve and the
nozzle. This drawback effect improves the termination of an injec-
tion on the nozzle and prevents nozzle re-opening and plunger cavi-
tation..
The multihousing is provided with two anti-erosion plugs (item 13),
which can easily be replaced when necessary.

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 16. Injection System W200

16.2 Injection pump removal and assembly

During maintenance, utmost cleanliness must be observed.

16.2.1 Injection pump removal (see fig. 16.2)

1 Turn the crankshaft to bring the considered cylinder to
TDC position (rods are free).
2 Remove the rocker cover, rocker bracket, push rod protec-
ting pipes and push rods according to chap. 14.
3 Remove the camshaft door of the considered cylinder.
4 Turn the crankshaft one cover revolution (360°), to bring
the considered cylinder to the back of the injection cam.
5 Remove the injection pipe (item 7).
6 Remove the return pipe for fuel leakage (item 5).
7 Remove the air pipe for stop device (item 6).
8 Remove the lubricating oil pipe for rocker arms (item 9).
9 Remove the fuel supply and return chanel sleeves (item
10).
10 Remove the 6 screws, A location
11 Remove and lift the injection pump (item 1).

1. Injection pump
5. Return pipes for fuel
leakage
6. Air pipe for stop de-
11 vice
7. Injection pipe
5 8. Anti-erosion plug
7 9. Rocker lubricating oil
A pipe
9 10. Fuel channel sleeves
11. Fitting screws
8
A
A. Injection pump fixing
screws

1
6
OUT A
5

IN
10

Fig. 16-2

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 W200 Injection System 16.

16.2.2 Injection pump assembly (see fig. 16.3)

1 Turn the camshaft to bring the considered cylinder to the
back of the injection came. Check visually through the block the
position of the injection shaft.
2 Check the cleanliness of the block bank and injection
pump surfaces.
3 Put the lube oil sealing (item 2) on the engine block.
4 Position the injection pump on the engine.
5 Check the conditions of the two dowel pins, (item 1) and
O-ring for the injection pump lubrification, (item 2) on the block.

1
1

Upper B Bank view

Fig. 16-3
6 Fix the pump with screws equipped with special washers
tighten to the torque (see chap. 07).
7 Rotate the engine one revolution (360°) back of the cam-
shaft for the inlet and outlet push rod.
8 Mount push rod protection pipes and rotate it manually
in order to position the O-rings, then mount the push rods cor-
rectly.
9 Mount the yoke and rocker bracket, in accordance with
chapter 14.
10 Adjust the rocker arms clearances according to chapter
12.
11 Mount the injection pipe and tighten to the torque (see
chapter 07).
12 Mount the return pipe for fuel leakage, air pipe for stop de-
vice and lubricating oil pipe for rocker arms. Tighten the FBO cou-
plings to the torque (see chapter 07).
13 Close the camshaft door of the considered cylinder,
tighten to the torque (see chapter 07).

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 16. Injection System W200

16.3 Maintenance of injection pump

During maintenance, utmost cleanliness must be observed.

16.3.1 Control pressure valve replacement

The job can be performed directly on the engine :
1 Clean the engine.
2 Dismantle the hot box cover.
3 Clean the pump head to be sure that no particle falls into
the injection plunger.

Fig. 16-4

4 Unscrew the four screws in the injection head (item 0).

5 Remove the four screws and the cap (item 1).

Fig. 16-5

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 W200 Injection System 16.

6 Remove the plug (item 2) and with magnet the pre-flow

spring (item 3) and the valve body (item 4).

Fig. 16-6

7 Put in place, the new valve body (item 4) + pre-flow spring

(item 3) + plug (item 2).
8 Put the cover (item 1) and the four screws (item 0),
smear them with Molycote grease BR2 ref MGE00075.
9 Tighten the screws cross-wise to 10 Nm
10 When you tighten, make sure that the cover is parallel to
the injection body.
11 Tighten the screws cross-wise to 53 Nm.
12 Check with shims that the cover and the injection body are
parallel. The defect must be less than 0.3 mm.

Note : After each CPV (Control Pressure Valve) removal, the plug
(item 2) and the four screws (item 0) have to be changed, see
fig. 16-6.

16.3.2 Anti-erosion plugs

The anti-erosion plugs (item 1) must be changed if too much wear
is observed. When replacing them, also replace the washers, see the
maintenance schedule (chap. 04).
1

Fig. 16-7

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 16. Injection System W200

16.3.3 Injection pump roller replacement

The multihousing has to be removed from the engine (see section
16.2.1).
1 Push the locking pin (item 6) and withdraw the roller pin.

Fig. 16-8

16.3.4 Injection pump overhaul

A calibration test must be done with the dedicated test bench de-
vices after injection pump reassembly. This operation has to be per-
formed by Wärtsilä France.

Caution : When dismantling the injection pump, be careful with the ten-
sion of the spring (item 7). It is mandatory to use a dedicated
tool.

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 W200 Injection System 16.

16.4 Injection line

16.4.1 Description
The injection line consists in three main parts :
• The connection piece (item 2), which is laterally screwed
into the nozzle holder (item 3).
• The injection pipe (item 1) is screwed with the connection
piece (item 2)
• The connection piece seals made by machining of the me-
tallic surfaces.
A

C 3
1

2 D

1. Injection pipe B
2. Connection pipe
3. Nozzle holder
A, B, C, D : Critical sealing connection

Fig. 16-9

The sealing between the connection pieces is only made by perfect

machining of the metallic surfaces. These surfaces must be checked
carefully before mounting as the pressure in the line can reach 1500
bars in service.

Good surface Rejected surface

Fig. 16-10 (detail of A area on fig. 16-9)

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 16. Injection System W200

In case of doubt, replace the complete set injector holder ( item 3)

and connection piece (item 2).
In case corrosion appears on the connection piece, replace the com-
plete set : injector holder (item 3) + connection piece (item 2).

Rejected part

Good part

Fig. 16-11 (detail of D area on fig.16-9)

16.4.2 Injection line assembly

Functional surfaces must be checked before mounting.
Always tighten the connection piece (item 2, fig. 16-9) to correct the
torque before mounting the injection pipe (see Chap.07).
In case of injection pipe removal, there is a risk to loosen the con-
nection piece. To avoid this problem, you need to maintain the con-
necting piece in position during the injection pipe removal.
Hot box covers (see, fig-16-12, item1) protect the engine environ-
ment from fuel leakages coming from the injection pipe. The injec-
tion pipes are delivered complete with connection nuts assembled.
Always tighten the connections to the correct torque (see chap. 07).

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 W200 Injection System 16.

Fig. 16-12

Note : When removing parts from the injection line, protect them
against dust and rust. If possible, plug the pipes.

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 16. Injection System W200

16.5 Injection nozzle holder

16.5.1 Description
Main data and dimensions The nozzle holder is located at the centre of the cylinder head and
Orifices : 8 holes includes the nozzle housing (item 6) , the connection pipe (item 9)
Orifice dia .: 0.39 mm and the nozzle (item 1). The fuel enters the nozzle housing sideways
Opening pressure : 380 bar through the connection pipe screwed into the nozzle housing.
The nozzles receive high pressure fuel from the injection pump and
injects this fuel into the combustion chamber as a very fine spray.

10,11
7
1. Nozzle
9 6
2. Nozzle nut
3. Fixing pin 5

4. Push rod 4
5. Spring
3
6. Nozzle housing
7. Adjusting screw 2
8. Plug 1
9. Connection pipe
10. Lower spring cupel
11. Adjusted shim

Fig. 16-13

16.5.2 Removing nozzle holder

1 Remove the cylinder head cover.
2 Remove the injection pipe.
3 Remove the connection piece from the nozzle holder.
4 Lift out the nozzle holder. For this operation use the
dedicated tool, SPC 8420001(see the spare part catalogue, chapter
830). If too much force has to be used, there is a risk that the stain-
less sleeve in the cylinder head gets loose.

Note : Use fuel to soak carbon deposit around the nozzle.

5 Protect the injection plug hole. Plug it if possible.

6 After removing the nozzle holder, immediately close the
nozzle chamber to avoid the presence of foreign particles.

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 W200 Injection System 16.

16.5.3 Overhauling injection nozzle

1 Immediately inspect the nozzle after removing the injec-
tion valve from the engine. Carbon deposits (trumpets) may indi-
cate that the nozzle is in poor condition, or that the spring is bro-
ken.
2 Clean the complete nozzle holder with a brush and if pos-
sible, use a chemical carbon dissolving solution (if not available,
use clean fuel oil).

Note : Never use steel wire brushes.

16.5.3.1 Sealing surfaces

• If leakage occurs on the high pressure sealing surfaces,
the damaged detail should be replaced by a new one or re-
conditioned.
• Check that the nozzle orifices are not blocked. In case they
are, go to chap. 16.5.3.3.
• Carefully check the metallic surface at the connection
pipe level. In case of visual defect, the nozzle holder and
the connection piece must be replaced

16.5.3.2 Injection nozzle checking

1 Clean the components. If possible, use a chemical carbon
dissolving solution or immerse in clean fuel oil, white spirit or
similar to sook carbon. Then, clean the components carefully. Do
not use steel wire brushes or hard tools. After cleaning, rinse to re-
move carbon residues and dirt particles.
2 Check the good nozzle operating. For that, use the dedicated
injection nozzle calibration pump (see the spare part catalogue,
chap 830).
• Opening pressure must be adjusted at the regular pres-
sure 380 bars. To do that, pump slowly and watch the
manometre to note the opening pressure.
• If the opening pressure is far from the correct value, shims
need to be used (see spare part catalogue, chapter 160)
and follow the procedure 16.5.3.3.
If the opening pressure is close to the correct value, you
can adjust it with a screw-driver by turning the adjusting
screw (item 7), fig.16-13 on the injection nozzle side.
The pressure adjustement is possible through a cam with 5
flats, each corresponding to a 20 bars pressure alteration
step when the cam is positioned on the needed flat. Be
sure that it is well oriented (i.e. the flat is truly in contact
with the spring seat).
• Atomization and sprays ocular inspection :
The nozzle must be chater and the atomization distribu-
tion must be regular between the holes. Also check the
nozzle noise during the opening phase.

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 16. Injection System W200

• Check the needle seat tightness :

Increase pressure to a value 30 bars below the staded
opening pressure.
Keep pressure constant for 10 seconds and check that no
fuel drops occur on the nozzle tip. A slight dampness can
be acceptable.
• Check the needle spindle tightness :
Pump until pressure is 30 bars below the staded opening
pressure.
Measure time for a pressure drop of 100 bars. If the time is
below, it indicates a worn nozzle and it must be replaced
by a new one. A time longer than 20 s. indicates fouled nee-
dle, and the nozzle must be cleaned.
• If the tests are correct, the injection nozzle can be re-
installed on the engine.
Follow the procedure according to chap. 16.5.4.

Note : Fullfill the measurement record WMR012.

• If nozzle or nozzle holder must be stored, they should be

treated with corrosion protecting oil.

16.5.3.3 Injection nozzle adjustment

1 Remove the nozzle from the holder by opening the noz-
zle nut (item 1). Keep the nozzle together with the holder body.
Do not let it follow up with the nut.
If there is coke between the nozzle and the nut, the dowel pins
(item 3) may break and damage the nozzle. To avoid this, knock on
the nozzle, using a piece of pipe (item 17) according to Fig. 16-14,
to keep it towards the holder.
17
1
2
3

1. Injection nozzle
2. Nozzle nut
3. Dowel pin
17. Piece of pipe (tooling)

Fig. 16-14

Caution : Never knock directly on the nozzle tip. Be careful not to drop
the nozzle.

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 W200 Injection System 16.

2 Remove the nozzle holder components according to Fig.

16-15. First remove the plug (item 8) and the adjusting screw
(item 7).
4
4. Push rod
5. Spring
5
6. Nozzle housing
10 11 7. Adjusting screw
7 8. Plug
6 11. Adjusting shim
10. Lower spring cupel
8

Fig. 16-15

• Turn the nozzle housing upside down.

• Remove successively the lower spring cupel (item 10) ,
the adjusted shim (item 11), the spring (item 5) and the
push rod (item 4).
Clean the components. If possible, use a chemical carbon dissolving
solution.If not available, immerse the details in clean fuel oil, white
spirit or similar to sook carbon. Then carefully clean the compo-
nents .Do not use steel wire brushes or hard tools. Clean the nozzle
orifices with needles provided for this purpose. After cleaning, rinse
the details to remove carbon residues and dirt particles.
Before inserting the needle in the nozzle body, immerse the compo-
nents in clean fuel oil or special oil for injection systems.

Note : Never use steel wire brushes or hard tools.

Dry by pressured air. Do not use polishing cloth.

3 Be sure that the sliding surface of the nozzle holder is

carefully cleaned. If it is not the case, replace them.
Good sliding surface of nozzle holder

Fig. 16-16

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 16. Injection System W200

Bad sliding surface of the nozzle holder

Fig. 16-17
4 Refit the nozzle holder assembly according to Fig. 16-15.
• Depending on the result of the injection nozzle checking,
(see chap. 16.5.3.2), there are two cases :
– shims need to be added to reach the correct opening pres-
sure (fig 16-15). If some shim sets are needed, see the
Spare Parts Catalogue, chapter 167.
– nozzle must be replaced
• Put successively the push rod (item 4), the spring (item 5),
the adjusting shim (item 11) and the adjusting screw (item
7) and the plug (item 8) into the nozzle housing (item 6).
5 Replace the nozzle (item 1, fig. 16-13) (the old or the
new one depending on the checking result, see chap. 16.5.3.2) in
the nozzle housing (item 6) with the help of the fixing pin (item 3).
• Apply Loctite 747 on the nozzle nut thread (item 2) and the
injector contact face.
• Tighten the nozzle nut (item 2) to the torque (see chap. 07).
6 Check the atomization and adjust the opening pressure
in accordance with chap 16.5.3.2.
• To start the adjustement and define the shim thickness,
start the operation with the adjusting screw (item 7) in the
lower position.

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 W200 Injection System 16.

16.5.4 Injection nozzle holder refitting

12

Fig. 16-18

• After checking, the injection nozzle holder can be refitted

on the cylinder head.
• Replace the external O-rings, (item 12) and lubricate them
with engine oil or vaseline.
• Clean the bottom surface of the injection nozzle holder
bore in the cylinder head.
To do that, use the dedicated tool (injection well decar-
bonizing tool, SPC 8420001). See the spare part catalogue,
chap. 830.
• Put a new copper seal washer under the nozzle (item 15).
Use tallow to fit it in place (the seal chamfer must be
placed on the nozzle side).
• Mount successively the nozzle holder (item 6, fig.16-19),
the connection piece (item 9) with a new O-ring (item 16).
• Screw manually the flange (item 13) with the nuts (item
14) into the injection nozzle holder.

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 16. Injection System W200

• Before tightening the fastening nuts of the injection nozzle

(item 13), let it stay 30 minutes in the cylinder head bore to
allow the temperature equalization.
14

13

6. Nozzle holder 16
9. Connection piece 12
12. O-ring 6
13. Flange
14. Nut 9 12
15. Nozzle
16. O-ring

15

Fig. 16-25

• Finally, tigthen the nuts (item 14) in 4 steps to the torque

(see chap. 07).

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