TECHNICAL

BULLETIN

Wärtsilä Engine Services 2-S RT-187

Engineering Services Issue 1, 06 April 2016

Failure of fuel rail mounting bolts

Next opportunity

Information to all Owners and Operators of Affected components

Wärtsilä RT-flex96C-B engines. Fuel rail supports and mounting bolts.
Current situation
Wärtsilä has received reports about
broken fuel rail mounting bolts. This is a
consequence of the incorrect sliding
function of the fuel rail supports.
Solution
A new design is introduced. It is now
possible to replace the bolts without lifting
the fuel rail.
Validity / Issue
This Technical Bulletin remains valid from
the date of issue until further notice.

Wärtsilä Services Switzerland Ltd Tel (24h): +41 52 262 80 10

PO Box 414
CH-8401 Winterthur technicalsupport.chts@wartsila.com
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Contents
Page
1 Introduction 2
2 Solution 3
3 Assessment of the fuel rail 4
4 Ordering Information 4
5 Contacts 5

1 Introduction
This bulletin is intended for customers and operators of Wärtsilä RT-flex96C-B engines
with broken bolts in the fuel rail.
Few cases of broken bolts in the fuel rail have been reported to Wärtsilä Services
Switzerland. These broken bolts are easily found when the heads of the bolts touch the
top surface of the rail unit bracket. The broken bolts can cause the fuel rail to become
loose. Vibration can cause damage to the high-pressure fuel pipes to the fuel rail.
Vibration can also cause these high-pressure fuel pipes to become loose and leak.

1. Fuel rail 4. Hexagon head bolt M16

2. Rail unit bracket 5. Fuel rail support
3. Hexagon head bolt M12 6. Broken bolt touching the rail unit
bracket
Figure 1: Location of the failure in the rail unit box.
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The fuel rail support is designed to have a sliding function, which allows the free
movement of the support according to the heat expansion of the fuel rail. If any stress
does not allow the free movement of the support, i.e. an overtightening of the bolts,
foreign materials in the sliding surface such as dirt, rust, etc., the stress on the hexagon
head bolts that attach the fuel rail to the support can increase and this can cause the
bolts to break (see item 6, Figure 1).

1
Thermal expansion Thermal expansion

2 3
5 4

1. Fuel Rail 4. Correct sliding function of the support

2. Rail unit bracket 5. Abnormal sliding function of the
3. Fixed fuel rail support support
Figure 2: Visual example of the possible cause of the broken bolts

With the current supports, it is necessary to lift up the fuel rail to replace the broken
bolts.

2 Solution
A new design of flexible fuel rail support has been introduced with the following
improvements:

• Sliding plate instead of sliding support to ensure the free movement

• Enhanced design to prevent the bolts from too much tension. (Clamping screws
and distance sleeve)
• Improved axial access to minimize the fuel rail lifting. Bolts can now be replaced
without lifting the fuel rail.
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3 5
1

5
2 1

7
4
6

1. Distance plate 5. Hexagon head bolt M16

2. New fuel rail support 6. Dowel pin
3. Clamping screw 7. Example of installed new fixed support
4. Distance sleeve
Figure 3: New flexible rail support

3 Assessment of the fuel rail

Service experience has shown a very low probability of broken bolts in the fuel rail
supports. Wärtsilä recommends to check the bolt condition and, if the support is loose,
or there are one or more broken bolts, install the new flexible fuel rail support at next
opportunity.

ATTENTION:
You must plan the replacement of the fuel rail supports in advance. The duration of this
procedure is approximately one to two days. You cannot operate the engine during this
procedure. The fuel rail, related equipment and pipes must be removed and the fuel rail
must be lifted.

4 Ordering Information
The retrofit modification of the fuel rail, can be ordered from your nearest Wärtsilä
representative.
Wärtsilä will provide a customized offer depending of the number of cylinders of the
engine.
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5 Contacts
5.1 How to contact Wärtsilä
For questions about the content of this Technical Bulletin, or if you need Wärtsilä
assistance, services, spare parts and/or tools, please contact your nearest Wärtsilä
representative.

5.2 Contact details in case of emergency

5.2.1 Operational support
For questions concerning operational issues, please send your enquiry to:
technicalsupport.chts@wartsila.com
or phone 24hrs support: +41 52 262 80 10.

5.2.2 Field service

If you need Wärtsilä Field Service, please send your enquiry to:
ch.fieldservice@wartsila.com
or phone 24hrs support: +41 79 255 68 80.

5.2.3 Spare parts

If you need Wärtsilä spare parts and/or tools, please contact your nearest Wärtsilä
representative or your key account manager.

© 2016 Wärtsilä Services Switzerland Ltd – All rights reserved

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recording, taping or other information retrieval systems) without the prior written permission of the copyright holder. Wärtsilä Services
Switzerland Ltd 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.