OPERATING

INSTRUCTION
Services, Wärtsilä Finland Oy
Engine section Engine type Ref. Date Issue Document No. Page
16 Injection system W50DF WFI–S 01-Mar-2012 03 5016Q002 1(8)+8

Fuel injector maintenance for WÄRTSILÄ® 50DF

engines
Engine type This bulletin concerns WÄRTSILÄ® 50DF engines.
General The purpose of this operating instruction is to provide detailed instructions
for maintenance of the injection valve. The valve is a combined valve for
both pilot and main fuel oil injection. The pilot side of the fuel injector is of
common rail type and electrically controlled while the main fuel side is fuel
pressure controlled.
Note! Utmost cleanliness must be observed when working with the injection
equipment. Pay attention to the pilot injector cable; do not lift the valve with
the cable.
Handling Handle the injection valve carefully. Take special care not to damage the
nozzle tip. Never place the injection nozzle standing on the tip, the tip is
very sensitive and can easily break.
Always store the injection valves in a clean place, all the openings must be
covered and protected.
Recommendation Please contact your Wärtsilä Services office for further information or for
support with maintaining the injection valves.
Never recondition or repair the nozzle body sealing surface against the
nozzle tip by lapping. There is a risk that lapping compound and dirt will
enter inside the lower part of the nozzle body between the pilot side parts.
These parts cannot be removed.
Note! Lapping of the sealing surface between the nozzle and the fuel injector body
is to be done in an authorized Wärtsilä workshop only.
Removing See the engine instruction manual, section 16.6.3 Removing of injection
valve.
Calibration oils It is recommended to perform the tests with clean calibration oil according to
ISO 4113, e.g.:
Shell V-Oil 1404
Typical characteristics of calibration oils:
Viscosity, cSt / 20°C 3,8
Viscosity, cSt / 40°C 2,6
Flammability, °C > 99
Density, kg/l at 15°C 0,827

Wärtsilä Finland Oy P.O. Box 252 (Tarhaajantie 2) Telecop. +358 10 709 1847 Tel. +358 10 709 0000 Business ID 0773744-3
Services, Vaasa FIN-65101 Vaasa, Finland Telecop. +358 10 709 1380 Registered Office: Vaasa
Wärtsilä Finland Oy P.O. Box 50 (Stålarminkatu 45) Telecop. +358 10 709 3279 Tel. +358 10 709 0000
Services, Turku FIN-20811 Turku, Finland Telecop. +358 10 709 3410
Services, Wärtsilä Finland Oy Operating Instruction
Issue Document No. Page
03 5016Q002 2(8)+8

Testing tool Testing of the fuel injection valve is performed by using tool 864 001. This
tool contains a solenoid tester, a hydraulic hose and a hand operated
hydraulic pump for testing the pilot side, see Figure 1.

Hydraulic hose

Hand operated
hydraulic pump

Solenoid tester

Fig. 1 Pilot fuel side testing tool.

Ventilation of fumes Ensure sufficient ventilation when testing the fuel injection valves.
Services, Wärtsilä Finland Oy Operating Instruction
Issue Document No. Page
03 5016Q002 3(8)+8

Main fuel side testing For detailed instructions on the main fuel side testing and inspection of new
and used injection valves, please see operating instruction “WS16Q010
Fuel Injection Valve Maintenance”.
Note! It is recommended to modify the testing tool 864 001 by cutting the injection
valve holder 60 mm from the bottom, see Figure 1. This is done to improve
tightening of the pipe for the main fuel pipe connection.

Before modification After modification

Fig. 2 Modification of testing tool 864 001.
Mounting of injection valve
Place the injection valve into position at the base of the testing tool.
Lubricate the connecting surface with Molykote G-N plus paste when
assembling the connection piece.
Connect the pilot fuel side pipe to the injection valve.
Tighten to torque 50 Nm, do not over tighten.
Connect the hydraulic hose to the hand operated hydraulic pump and to
the pilot connection piece.
Connect the solenoid tester to the pilot fuel side cable of the fuel injector.
Adjust the settings of the solenoid tester to:
- Pulse interval 1-2 s
- Pulse length 3-4 ms
- Pulse current 7-10 A
Services, Wärtsilä Finland Oy Operating Instruction
Issue Document No. Page
03 5016Q002 4(8)+8

Pilot fuel side testing

Raise the pressure to 900 bar with the hand operated pump and check
the nozzle tip seat tightness.
The solenoid tester can be used in two ways:
- 1 shot mode, the solenoid tester sends one impulse to the
injector
- Impulse mode, the solenoid tester sends impulses in selected
intervals to the injector
When impulse mode is selected, the pump pressure must be
continuously maintained with the hand operated pump. Inspect that fuel
is sprayed from all pilot nozzle holes.
If the nozzle fails the test, open and clean the nozzle once. Replace the
nozzle if it fails the second test.
Note ! The solenoid tester should not be operated for more than 30 s due to risk for
overheating.
Note ! The pilot side of the fuel injector is of a common rail type and electrically
controlled. At the moment it is only possible to inspect functionality of the
pilot side and visually inspect fuel spray of the pilot drillings. The pilot side
opening pressure cannot be adjusted.
Services, Wärtsilä Finland Oy Operating Instruction
Issue Document No. Page
03 5016Q002 5(8)+8

Dismantling See Figures 3 and 4.

If the nozzle is covered with hard soot and appears to be stuck in the nut
holding it, clean the nozzle mechanically and thereafter let the lower part of
the fuel injection valve soak in diesel for a while in order to dissolve the soot
and hard deposits.
Note! Do not put the injector in the washing machine when the nozzle is
dismantled or if the pilot port is open and not properly sealed!
Dismantling the nozzle holder:

Fig. 3 Dismantling the fuel oil injector

1. Open the counter nut (1) and adjust the screw (2).
2. Turn the fuel oil valve into a horizontal position. Remove the spring (3),
the short push rod (4) and the long push rod (5).
3. Open the nozzle nut (6), use tool 843 187, see Figure 4, and remove the
nozzle (7).

Figure 4 Clamping tool 843 187 for nozzle removal.

Note! Do not remove the parts inside the lower part of the nozzle holder. Protect
all parts carefully.
Services, Wärtsilä Finland Oy Operating Instruction
Issue Document No. Page
03 5016Q002 6(8)+8

Pilot cable replacement

See Figures 5, 6 and 7.
Replace the cable with a new one if any damages are noticed or if the
measured resistance of the cable is outside the specified interval 0,4 -1,2 .
When replacing the pilot cable, the upper and lower valve body must be
separated.
1. Open the three screws (1) at the top of the injector valve, see Figure 5.
2. Open the pilot fuel cable reduction nipple (2) at the top of the injector
body before separating the upper and lower injection bodies.
3. Move the injection bodies carefully and pay attention to the pilot injector
cable. When the distance between the upper and lower injection bodies
is sufficient, pull the pilot fuel cable off from the solenoid pins (3).

Fig. 5 Removing the pilot fuel cable

Fig. 6 Complete pilot cable.

4. Measure the resistance directly from the solenoid valve pins. Send the
injector to the engine manufacturer for refurbishment if the resistance is
out of the 0,4 -1,2 range.

Solenoid valve pins

Fig. 7 Resistance measurements for solenoid valve pins.

Services, Wärtsilä Finland Oy Operating Instruction
Issue Document No. Page
03 5016Q002 7(8)+8

Assembly of the nozzle holder

See Figures 8 and 9.
1. Connect the pilot fuel cable to the solenoid valve (1).
2. Fix the lower and upper valve body together. Use the alignment tool
836 082 to align the upper and lower valve body.

Alignment tool 836 082

Fig. 8 Alignment tool 836 082

3. Apply Molykote on the 3 screws (2) and tighten in steps to torque,

90 Nm.
4. Fit the nozzle and the nozzle holder carefully together; note the position
of the location pins.
5. Tighten the nozzle nut (3) to torque, 600±15 Nm. Apply Molykote G-n
plus lubricant on the threads and the shoulder.
6. Mount the long push rod (4), the short push rod (5) and the spring (6).
Mount the adjusting screw (7) in place and tighten the counter nut (8) to
torque, 200 Nm.

Fig. 9 Fuel injector assembly

7. Test the functionality of the injection valve; see the instructions in the
engine instruction manual, section 16.6.5.
Services, Wärtsilä Finland Oy Operating Instruction
Issue Document No. Page
03 5016Q002 8(8)+8

Cable resistance Measure the resistance of the pilot cable after the injector valve assembly.
The cable resistance should be in the range of 0,4 -1,2 , the resistance
between any pin and the connector body should be infinity.
Mounting See the engine instruction manual, section 16.6.4 Mounting of injection
valve.
Note! The fuel injection nozzle is cooled by engine lubrication oil. Check the
cooling oil flow when the injector valve has been mounted. Start the engine
pre lubrication pump and inspect that lube oil flows from the lube oil return
hole on top of the injection valve.

Fig. 10 Lube oil return of injection valve

Ordering Contact your closest Wärtsilä Services Network. When ordering, please
specify the engine serial number and part number.

Ref. type Part number Description

W50 167 464 Pilot cable

Letter distribution Wärtsilä Services Network and operators/owners of engines concerned.

Letter validity Until further notice, replacing issue 02 dated 18-Jan-2012.
Enclosures Spare part page 167-0046 for fuel injection valve VVO-49
Spare part page 167-0063 for fuel injection valve VVO-71

2012 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 is to be construed as provided due to a
defect in the engine, but merely as an improvement of the engine 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 50 Spare Parts List 167-0046
Edition: H
Page: 1(4)
Updated: 13.01.2011
Injection valve assembly

167 331
167 335 167 330

167 336 167 334

167 333

167 332

167 001

167 003
167 008

Qty Wt. Qty Wt.

Part No. Description [Pcs] [Kg] Part No. Description [Pcs] [Kg]
167 001 Injection valve, compl. 1 26.0
167 003 O-ring 1 -
167 008 O-ring 1 -
167 330 Male stud 1 -
167 331 Lubricating oil pipe 1 0.1
167 332 Angle union 1 -
167 333 Screw 4 -
167 334 Stud 1 0.7
167 335 Locking nut 1 -
167 336 O-ring 1 -
167-0046 Spare Parts List WÄRTSILÄ 50
Edition: H
Page: 2(4)
Updated: 13.01.2011
Injection valve assembly

167 001

167 464
167 167
View A
167 419

167 007 167 030 167 012 167 277

167 002 167 004 167 010 167 275 167 011 167 017
167 012

Qty Wt. Qty Wt.

Part No. Description [Pcs] [Kg] Part No. Description [Pcs] [Kg]
167 001 Injection valve, compl. 1 26.0
167 002 Nut 1 0.1
167 004 O-ring 1 -
167 007 Adjusting screw 1 1.1
167 010 Spring 1 0.1
167 011 Push rod 1 -
167 012 Dowel pin 3 -
167 017 Nozzle nut 1 0.6
167 030 Guiding screw 1 -
167 167 Nozzle 1 -
167 275 Push rod 1 -
167 277 Compression spring 1 -
167 419 Screw 3 0.1
167 464 Cable complete 1 0.4
WÄRTSILÄ 50 Spare Parts List 167-0046
Edition: H
Page: 3(4)
Updated: 13.01.2011
Injection valve assembly

167 030

167 007 167 010

167 002 167 004 167 275

167 011

167 012 167 012

167 277 167 167 167 017

167 012

Qty Wt. Qty Wt.

Part No. Description [Pcs] [Kg] Part No. Description [Pcs] [Kg]
167 002 Nut 1 0.1
167 004 O-ring 1 -
167 007 Adjusting screw 1 1.1
167 010 Spring 1 0.1
167 011 Push rod 1 -
167 012 Dowel pin 3 -
167 017 Nozzle nut 1 0.6
167 030 Guiding screw 1 -
167 167 Nozzle 1 -
167 275 Push rod 1 -
167 277 Compression spring 1 -
.
NOTE! Pilot valve parts without SPN are
changed only at full refurbishing!
167-0046 Spare Parts List WÄRTSILÄ 50
Edition: H
Page: 4(4)
Updated: 13.01.2011
Injection valve assembly

167 003
167 008
167 004
167 131

167 336
167 046

350 1063 167 130

Qty Wt. Qty Wt.

Part No. Description [Pcs] [Kg] Part No. Description [Pcs] [Kg]
167 046 Sealing set 1 -
167 003 O-ring 1 -
167 004 O-ring 1 -
167 008 O-ring 1 -
167 130 O-ring 1 -
167 131 O-ring 1 -
167 336 O-ring 1 -
350 1063 O-ring 1 -
WÄRTSILÄ 50 Spare Parts List 167-0063
Edition: E
Page: 1(3)
Updated: 12.01.2011
Injection valve

167 001

167 336
View A
167 419

167 167
167 464

167 030 167 012

167 260 167 277

167 002
167 004 167 010 167 275 167 011 167 017
167 007

Qty Wt. Qty Wt.

Part No. Description [Pcs] [Kg] Part No. Description [Pcs] [Kg]
167 001 Injection valve, compl. 1 -
167 002 Nut 1 0.1
167 004 O-ring 1 -
167 007 Adjusting screw 1 0.1
167 010 Spring 1 0.1
167 011 Push rod 1 0.5
167 012 Dowel pin 3 -
167 017 Nozzle nut 1 0.7
167 030 Guiding screw 1 -
167 167 Nozzle 1 1.6
167 260 Distance ring 1 -
167 275 Push rod 1 0.2
167 277 Compression spring 1 0.1
167 336 O-ring 1 -
167 419 Screw 3 0.1
167 464 Cable complete 1 0.4
167-0063 Spare Parts List WÄRTSILÄ 50
Edition: E
Page: 2(3)
Updated: 12.01.2011
Injection valve

167 030 167 012

167 007 167 010

167 002 167 004 167 275

167 011

167 260 167 277 167 167 167 017

Qty Wt. Qty Wt.

Part No. Description [Pcs] [Kg] Part No. Description [Pcs] [Kg]
167 002 Nut 1 0.1
167 004 O-ring 1 -
167 007 Adjusting screw 1 0.1
167 010 Spring 1 0.1
167 011 Push rod 1 0.5
167 012 Dowel pin 3 -
167 017 Nozzle nut 1 0.7
167 030 Guiding screw 1 -
167 167 Nozzle 1 1.6
167 260 Distance ring 1 -
167 275 Push rod 1 0.2
167 277 Compression spring 1 0.1
.
NOTE! Pilot valve parts without SPN are
changed only at full refurbishing!
WÄRTSILÄ 50 Spare Parts List 167-0063
Edition: E
Page: 3(3)
Updated: 12.01.2011
Injection valve

167 162
167 408

167 407
167 046

167 008

167 336

167 004

167 003

Qty Wt. Qty Wt.

Part No. Description [Pcs] [Kg] Part No. Description [Pcs] [Kg]
167 046 Sealing set 1 0.2
167 003 O-ring 1 -
167 004 O-ring 1 -
167 008 O-ring 1 -
167 162 O-ring 1 -
167 336 O-ring 1 -
167 407 O-ring 1 -
167 408 O-ring 1 -
 Spare Parts List WÄRTSILÄ 50

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