Wärtsilä 26 Engine O&MM 2.9.

Injection system

2.9. Injection system

2.9.1 High Pressure (HP) fuel pump

Each cylinder has his own HP fuel pump (1), see Figure 2.9-1, which is connected by a shielded
HP line (2) to the injector.
The fuel pumps are of the mono−element and flow through type to ensure good performance.
The pumps are completely sealed from the crankcase preventing fuel contamination.
The fuel injection equipment and system piping are located in a hot box providing maximum
reliability and safety.
The fuel oil supply and return manifolds are integrated in the HP fuel pump brackets (4).
Through line (7) lubricating oil is supplied for cooling of the injector.
Each HP fuel pump is provided with an air operated stop cylinder (3) which brings the fuel
rack to zero position after control air is admitted.

Fig 2.9-1 HP fuel pump

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NOTE
For maintenance background information, safety aspects, intervals, tolerances,
inspections, tools and torque spanner instructions, see Chapter 2.4.

2.9.1.1 Removing HP fuel pump

Before removing the HP fuel pump take care the tappet roller (16) is resting on the base circle
of the fuel cam (17), see Figure 2.9-7.
1 Close the fuel supply to the engine.
2 Drain engine fuel system, see Chapter 1.1.
3 Remove fuel drain line (5).
4 To remove the HP fuel pipe (2), see Section 2.9.4.

NOTE
The connecting pipe and HP fuel pipe must not be rotated with or against each
other. Take care the locking plate remains tight.

5 Remove the air line (6) to stop cylinder (3).

6 Disconnect fuel rack (8) from the common fuel control rod (9) by removing nut (10) and
connecting bolt (11), see Figure 2.9-2.

Fig 2.9-2 Fuel rack connection to common fuel control rod

7 Disconnect HP fuel pump (1) by removing nuts (12), see Figure 2.9-1.
8 Turn an eye bolt M12 into cover (9) and lift the HP fuel pump from the engine. See Figure
2.9-4.
Carefully lift the HP fuel pump in centre line direction to avoid clamping of push rod top (15)
in fuel pump bottom section, Figure 2.9-7. Cover immediately all openings with tape or plugs
to avoid dirt admission.

2.9.1.2 HP fuel pump disassembling

NOTE
HP fuel pump parts should be kept matched during overhaul.

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1 Before dismantling clean the pump externally.

2 Place the pump up side down.

NOTE
Plunger (7) is spring loaded. See Figure 2.9-3

3 Before mounting tool 9612ZT971 turn the disc nut (1) half way down on pivot (2). See Figure
2.9-3.
4 Mount tool 9612ZT971 with bolts (4)
5 Move pivot (2) down by turning the disc nut (1) with hook spanner 9612ZT442 till circlip (3) is
free and the remove the circlip.
6 Release spring (5) by turning nut (1) with hook spanner 9612ZT442.
7 Remove tool 9612ZT971.
8 Remove spring disc (6), spring (5) and plunger (7) and turn pump into vertical position.

Fig 2.9-3 Disassembling HP fuel pump

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Fig 2.9-4 HP fuel pump cross section

9 Remove bolts (8) and cover (9) and (10), see Figure 2.9-4.
10 Remove main delivery valve (11) with spring (12) and constant pressure valve (13) with spring
(14).
11 Put fuel rack (17) in zero position (0 mm), turn the pump up side down and remove control
sleeve (23) together with support ring (28).
12 To remove the fuel pump barrel (16), remove the bolts (15) and place the synthetic driver
9612ZT225 against the bottom part of the barrel. With a few light hammer strokes the barrel
comes free, see Figure 2.9-9.
13 To remove fuel rack (17) first disconnect stop cylinder (18) and piston (19). Take off plate (20)
by removing bolt (21). Turn out guide plug (22) and pull out the fuel rack (17).

NOTE
Protect parts against rust and don’t touch plunger element surfaces with bare
fingers.
Keep pump element and pump barrel always matched as a pair.

14 For inspection, flush plunger and barrel in clean fuel and keep plunger inserted in the barrel.

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Fig 2.9-5 Removing barrel

2.9.1.3 HP fuel pump maintenance and inspection

Maintenance
Inspect fuel pump according maintenance intervals in Chapter 2.4. or earlier if performance
requires.
Inspection
1 Check springs (12) and (14). Replace broken or damaged springs, see Figure 2.9-4.
2 Valves (11) and (13) should not be damaged. Valve (11) must slide easily in cylinder of barrel
top. Valve (13) must slide easily in valve (11).
3 Check sealing of cover (10) with barrel (16). Sealing edges should be free of damages.
4 Check fuel control sleeve (23) on free moving on outside of barrel (16). Check sleeve on fretting.
5 Check condition of barrel (16) and plunger (7). Replace barrel and plunger if necessary or
according to the maintenance intervals in Chapter 2.4.

NOTE
The barrel and the plunger of the fuel pump are matched and machined to each
other. Barrel and plunger may therefore not be exchanged with another barrel or
plunger.

6 Check if channel hole in barrel (16) at 'A' is open.

7 Check vertical fuel supply holes in pump body are clean and open.
8 Check erosion plugs (29) and replace if necessary.
9 Check fuel rack (17) on wear. Fuel rack wear introduces unstable pump deliveries.
10 Check condition of spring (5)

2.9.1.4 Assembling the HP fuel pump

1 Wash the components in absolutely clean diesel oil and lubricate the internal parts with clean
engine oil. During handling of the injection equipment components, keep your hands absolutely
clean and greased with oil.
2 Reinstall spring (14), constant pressure valve (13), main delivery valve (11) and spring (12) into
barrel (16), see Figure 2.9-4.

NOTE
To prevent leakage always replace cover (10) and bolts (8), see Figure 2.9-4

3 Place a new cover (10), cover (9) and new bolts (8).

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4 Apply new O-rings (24) and (25) with silicon grease on barrel.
5 Insert barrel in pump body (26). Position of barrel in pump body is determined by a dowel pin
at top. Fit the bolts (15).
6 Place pump body in a bracket to tighten bolts (15) in steps of 25 Nm crosswise to required
setting, see Chapter 2.4.
7 Tighten bolts (8) in steps of 10 Nm crosswise to required setting, see Chapter 2.4. and check
if top side of barrel (16) and cover (9) are parallel ( tolerance // 0.3 mm ).
8 Release and retighten bolts (8) in one turn and one by one to the required setting.
9 Turn fuel pump up side down. Oil and insert fuel rack (17). Avoid sliding out of rack by fitting
guide plug (22).
10 Oil and insert the fuel control sleeve (23) with the fuel rack in the zero position (0 mm). The
control sleeve is at the serration provided with a pin (27). This pin has to fit into a recess of
the fuel rack.
11 Move the fuel rack in mid position and place support ring (28).
12 After oiling of the plunger insert the plunger (7), the spring (5) and hook the spring disc (6) to
the plunger.

NOTE
The protruding vanes at both sides of the plunger lower side have to slide into the
grooves of the control sleeve. To make this easy going move at the same time the
fuel rack to and fro.

13 Use tool 9612ZT971 to compress spring (5) and fit circlip (3), see Figure 2.9-3.
14 Release slowly the spring compression, remove the tool and check if the fuel rack moves
easily in the pump housing.
15 Mount stop cylinder to fuel rack and test working of stop cylinder with service air.
16 Check if the position of the stop block corresponds with the value mentioned in the testbed
protocol.
17 NOTE
Unless the HP fuel pump is immediately mounted on the engine, oil it well before
storage. All openings in the pump house should be well covered by plastic caps
or tape.

2.9.1.5 HP fuel pump adjustment

The injection timing is determined by the moment the top of the plunger is in line with the top
of the suction holes of the plunger housing The timing may deviate due to manufacturing
tolerances in pumps, cams and drive. To obtain the best possible performance of the engine
it is important that the injection timing is in accordance with the test bed protocol. See test
records.

NOTE
Checking of the injection timing is always necessary after major components have
been replaced, e.g. HP fuel pump element, pump drive, camshaft section or some
maintenance has been done on gears, especially to the intermediate gear.

Checking the fuel pump drive

1 Remove the HP fuel pump. See Section 2.9.1.1.
2 Make sure the HP fuel pump bracket is properly mounted and no clearance exists between
bracket and engine block.

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3 Remove the camshaft cover and check if the fuel cam roller (16) rests on the base circle of
the cam (17), see Figure 2.9-6.
4 Push the push rod (15) including the shim completely down and measure distance "X" see
Figure 2.9-6.
The top of push rod (15) is lower than the upper surface of the HP fuel pump bracket (4).
5 Check distance "X", see Chapter 2.4.
6 If distance "X" is out of range, see Section 2.9.2.4 and Section 2.9.2.5.
Checking the fuel injection timing
7 Starting point is that measurement "X" is within tolerance and the tappet roller (16) rests on
the base circle of the fuel cam (17).
8 Place dial gauge 9622DT275 according Figure 2.9-6 on top of the fuel pump bracket (4) with
the contact point of the dial gauge on top of the push rod (15) and set dial gauge at zero.
9 Turn the crankshaft in direction of rotation till the mark on the flywheel indicates the injection
moment mentioned in the test bed protocol.
10 Dial gauge reading should indicate a lift of the push rod of 4.5 mm with a tolerance of ±0.1
mm. (This is the point where the effective pressure stroke of the fuel pump starts).

Fig 2.9-6 HP fuel pump adjustment

2.9.1.6 HP fuel pump mounting

Before mounting the HP fuel pump, take care the HP fuel pump to be mounted is ready for
use. This means pump internal parts are correct and clean assembled, fuel rack index is
calibrated and measurement "X", see section HP fuel pump adjustment, is within the tolerance.
1 Clean the HP fuel pump from preservation oil and check the fuel rack moves easily.
2 Carefully clean bottom side of the fuel pump base part and support surfaces.

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3 Place new O-rings (13) with silicon grease in the recesses of the fuel supply and fuel return in
the bracket top surface and place a new O-ring (14) at the bottom side of the pump base. See
Figure 2.9-7.

Fig 2.9-7 Fuel pump bracket

4 Carefully lower the HP fuel pump in the centre line direction onto the bracket to avoid damage
of the O-ring (14).
5 Tighten bolts (12) according settings, see Chapter 2.4.
6 To mount the HP fuel pipe (2), see Section 2.9.4.

NOTE
The connecting pipe and HP fuel pipe must not be rotated with or against each
other.

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7 Mount fuel drain line (5) and air line (6) to the stop cylinder (3), see Figure 2.9-1.
8 Connect fuel rack to common fuel control rod. See Figure 2.9-2.
9 Rotate the common fuel control rod and check if :
● All the fuel pump racks follow the rod movement.
● All the fuel pump rack readings are equal. The maximum allowable difference between the
fuel pump racks is 1 mm.

10 Open the fuel supply and discharge lines to the engine and circulate the fuel for some time to
vent the system. Turn simultaneously the crankshaft.

2.9.2 Fuel pump bracket

The fuel pump brackets (4) are each interconnected by pipe sections (18) for the fuel supply
(19) to and return (20) from the pump (1).
In top of the brackets two small drillings (21), each surrounded by an O-ring (13), are connected
to the internal fuel supply (19) and return (20) of the fuel pumps. These drillings are restrictions
to damp the chock pulses generated after the pump plunger releases the compressed HP
fuel. The fuel pump bracket (4) is also a guidance for the fuel pump tappet (37) and push rod
(15).
The fuel pump bracket (4), near end cover (22), is provided with an internal pipe section (23)
see Figure 2.9-8.

Fig 2.9-8 Fuel pump bracket

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2.9.2.1 Removing fuel pump bracket

1 Close the fuel supply to the engine.
2 Drain the engine fuel system, see Chapter 1.1.
3 Remove HP fuel pump, see Section 2.9.1.1.
4 Disconnect the lube oil line (7) from the pump bracket to the cylinder head, see Section 2.9.1
and Figure 2.9-1.
5 Slide circlip (24) of the pipe sections concerned backwards, see Figure 2.9-8.
6 Slide the pipe sections concerned into the brackets, see Figure 2.9-8.

NOTE
When the fuel pump bracket (4) next to the end cover (22) has to be removed, first
remove the adjacent fuel pump bracket with the pipe sections (18). Next shift the
internal pipe sections (23) of the bracket out of the end cover (22).

7 Turn camshaft till tappet roller (16) is on top of fuel cam (17) and fit locking tool 9612ZT925.
See Figure 2.9-9.

Fig 2.9-9 Removing fuel pump bracket

8 Turn camshaft till tappet roller (16) is free from fuel cam (17). See Figure 2.9-7.
9 Remove positioning bolt (25), see Figure 2.9-9.
10 Fit lifting tool 9612ZT961 to the fuel pump bracket, see Figure 2.9-10.
11 Lift fuel pump bracket out of engine block.
12 Cover all holes against dirt penetration.
For inspection of the fuel pump bracket see Section 2.9.2.5.

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Fig 2.9-10 Lifting fuel pump bracket

2.9.2.2 Mounting fuel pump bracket

NOTE
If the fuel pump bracket next to the end cover has been removed, start the mounting
procedure with this bracket.

1 Clean the fuel pump bracket (4) and pipe sections (18).
2 Check with service air if the lube oil channels in the bracket are open.
3 Replace sealing rings (26), (27) and guide ring (28) at both sides of the pipe sections (18). See
Figure 2.9-8.
4 Make sure locking tool 9612ZT925 is installed. See Figure 2.9-9.
5 Replace and lubricate O-ring (29) with silicon grease, see Figure 2.9-11

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Fig 2.9-11 Mounting fuel pump bracket

6 Insert the two pipe sections (18), provided with circlip (24), not yet fitted in the groove, into
the bracket (4), see Figure 2.9-8.
7 Turn the camshaft till the tappet roller (16) rests on the base circle of the fuel cam (17). See
Figure 2.9-11.
8 Clean bottom side fuel pump bracket and top side of cylinder block. Take care of presence
of dowel pin (30). Replace the O-ring between engine block and bracket and lower bracket
onto the clean engine block, see Figure 2.9-9.
9 Fit the positioning bolt (25), see Figure 2.9-9. and set the bolt to the right torque, see Chapter
2.4.
10 Turn fuel cam into top, remove locking tool 9612ZT925.
11 Turn camshaft till tappet roller (16) rests on the base circle of the fuel cam (17), see Figure
2.9-11.
12 Make sure the HP fuel pump bracket is properly mounted and no clearance exists between
bracket and engine block.
13 Check the sealing set (31+32) of the fuel pump push rod. Replace if necessary, see Section
2.9.2.3 for the procedure.
14 Push the push rod (15) completely down and measure distance "X" Top of push rod (15) is
lower than upper surface of bracket (4), see Figure 2.9-6.
15 Check distance "X", see Chapter 2.4.
16 If distance "X" is out of range, see Section 2.9.2.4 and Section 2.9.2.5.

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17 Slide pipe sections in place and lock pipe sections with circlip (24), see Figure 2.9-9.
18 Mount the lube oil line (7) from the pump bracket to the cylinder head, see Section 2.9.1 and
Figure 2.9-1.
19 Mount the HP fuel pump, see section HP fuel pump mounting.
20 Open fuel supply, circulate fuel over the engine and check for fuel leaks.

WARNING
Do not run the engine with tool 9612ZT925 mounted.

2.9.2.3 Replacement of the sealing set push rod

To keep the fuel pump bottom side separated from the camshaft space the fuel pump push
rod passage is sealed by a sealing set consisting of an O-ring (31) and a scraper ring (32), see
Figure 2.9-7.

Mounting push rod sealing set

1 Clean and inspect the sealing ring recess.
2 Lubricate the O-rings (31) of the sealing set with silicon grease and insert them in the recess,
see Figure 2.9-7.
3 Fit the scraper ring (32) onto penetrator (33) and lubricate the scraper ring with silicon grease.
Take care of the correct scraper ring position on penetrator, see Figure 2.9-12.
4 Place conductor (34) firm onto the bracket top side and slide the penetrator into the conductor
till the end. The compressed scraper ring will expand into the recess.
5 Retract the penetrator (33).
6 Provide the expander (35) with silicon grease and slide the expander through the mounted
scraper ring (32) to widen the diameter till normal.
7 After the scraper ring is mounted place plug (36) into the penetrator (33) and restore the tool
set in the toolbox.
8 Install the fuel pump push rod (15).

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Fig 2.9-12 Mounting push rod seal set

2.9.2.4 Inspection of fuel pump push rod

The connection between the fuel pump tappet (37) and fuel pump plunger is made by the fuel
pump push rod (15), see Figure 2.9-7.
Due to machining tolerances in components between the fuel pump tappet and the fuel pump
plunger, the push rod lengths vary from one to another.
During maintenance the push rods should be provided with the cylinder unit number and not
be interchanged. A new push rod should be machined to the correct length at the smallest
end.

NOTE
Fuel pump push rods and shim are chosen to obtain the exact length for each
individual pump bracket. Do not interchange these push rods and shim.

1 Insert the drive pushrod in the pump drive assembly if not already assembled. No shims are
mounted on the top of the pushrod at this stage of the operation.
2 Turn the crankshaft along the normal running direction, first with the turning gear and then by
hand, in order to reach the exact time of starting injection.

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3 Press the pushrod to avoid any clearance between the parts which are in contact.
4 Measure distance "X". The measured value should be: 4.5 mm with a tolerance of ± 0.01 mm.

Fig 2.9-13 Depth gauge for push rod

5 If distance "X" is correct: add to the pushrod the shim standard (8 mm shim thickness) in order
to achieve a distance "Y" of 3.5 mm ± 0.03 mm.
6 If distance "X" is out of range:
Annotate the difference "D" between required value of "X" and the measured value. D =
measured value of "X" − 4.5 mm.
PAY ATTENTION: Annotate also if "D" has a positive or negative value.
"D" is the thickness that should be added or subtracted to standard shim to achieve the right
pump timing.
"T" is the thickness of the shim to achieve the right pump timing.
If "D" is positive "T" is: 8 mm + D
If "D" is negative "T" is: 8 mm − D
PAY ATTENTION: In any case you have to choose the shim with the smaller thickness near
to "T" value, in order to don’t advance the timing respect to reference SOI (Start Of Injection).
Be aware that "SOI effective > SOI reference" is NOT ALLOWED while "SOI effective < SOI
reference" is ALLOWED.
For Example:
o If "T" is 8.28 mm, to use shim of 8.2 mm
o If "T" is 7.95 mm, to use shim of 7.9 mm
o If "T" is 7.89 mm, to use shim of 7.8 mm
7 Register the thickness of chosen shim for that cylinder.
8 Repeat the procedure for all cylinders.

2.9.2.5 Inspection of fuel pump tappet

1 Remove the fuel pump bracket from the engine according to Section 2.9.2.1.
2 Remove the push rod out of the fuel pump bracket.
3 Place the bracket up side down on the base plate of tool 9612ZT960, see Figure 2.9-14 and
connect the jack 9612ZT341 of tool 9612ZT960 to the hydraulic pump PAAE104248.

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Fig 2.9-14 Assembling tool fuel pump bracket

4 Compress the fuel pump tappet spring and remove the locking tool 9612ZT925, see Figure
2.9-9.
5 Slowly release the jack pressure till the fuel pump tappet spring is fully expanded.
6 The fuel pump tappet assembly can be taken out of the bracket.
7 Press locking pin (38) to slide shaft (39) out of the fuel pump tappet and the tappet roller. See
Figure 2.9-14
8 Clean and inspect all parts for wear.
9 For assembling of the fuel pump bracket, assemble in reversed way. Do not forget to replace
spring discs (40) during assembling of bracket unit.
10 Place the locking tool 9612ZT925, see Figure 2.9-9.

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2.9.3 Fuel injector

HP fuel (1) enters the injector holder sideways delivered through the connecting piece, see
Figure 2.9-15.
Spill fuel (4), passing the injector needle, escapes along the holder and the connecting piece
through a hole in the cylinder head at (4).
The injector tip is cooled by lubricating oil supplied by the engine lubrication system. The oil
enters the injector at (2) and after cooling the injector tip it leaves at (3) at top of the injector.
Afterwards the oil runs down to the crankcase. An O-ring is fitted around the injector to avoid
lube oil leaking downwards the injector holder.

Fig 2.9-15 Cylinder head with injector

2.9.3.1 Fuel injector maintenance

Follow the injector maintenance schedule or overhaul the injectors when engine performance
gives indication of poor injection (large deviation from normal exhaust gas temperature etc.).
See Chapter 2.4.

2.9.3.2 Fuel injector removing

1 Remove the cylinder head cover and the Hot–Box cover.

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2 To remove the HP fuel pipe (2) and the HP connecting pipe (3), see Section 2.9.4.

NOTE
The connecting pipe and HP fuel pipe must not be rotated with or against each
other. Take care the locking plate remains tight.

Fig 2.9-16 Fuel injector in cylinder head

WARNING
Don’t start engine lubrication when an injector is removed from cylinder head.
Lubricating oil may uncontrolled enter top of piston.

3 Remove nuts (6), distance sleeves (7) and gland (8), see Figure 2.9-16.
4 Extract injector with tool 9612ZT178 or with tool 9612ZT931 in case the injector is too tight
in the injector sleeve.

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Fig 2.9-17 Extracting fuel injector

5 Cover all injector holes and cylinder head against dirt.

6 Cover fuel discharge of HP fuel pump.

2.9.3.3 Fuel injector overhaul

1 Inspect the nozzle on carbon deposits. This may indicate poor nozzle condition or broken
spring.
2 Test injector with test equipment 9612ZT934 (or PAAE069250) on fuel spray pattern and
opening pressure before dismantling. See Section 2.9.5.
3 Clean injector holder, except the nozzle, externally with a brass wire brush and diesel fuel.
4 Remove adjusting plug (10) with tool 9612ZT187, pivot (11), guide screw (12), spring (13) and
spring disc (14), see Figure 2.9-18.

Fig 2.9-18 Fuel injector

5 Place injector in holder 9612ZT978. For this handling the holder should be well clamped. See
Figure 2.9-19

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Fig 2.9-19 Tools for loosening or tightening sleeve nut

6 Remove injector tip (15) from holder by turning off sleeve nut (16) with socket spanner
9612DT259 multiplier 9612DT260 and spanner 9622DT216.

NOTE
Carbon deposits can make it difficult to slide injector tip out off sleeve nut. In such
a case place injector tip with sleeve nut on a soft support and knock injector tip
out by using a piece of pipe.
Never knock directly on injector tip, see Figure 2.9-20.

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Fig 2.9-20 Separating injector tip from sleeve nut

7 Use a chemical carbon dissolving solution to clean injector tips. If such is not available immerse
components in clean fuel oil, white spirit or similar to soak carbon. Clean parts carefully. Don’t
apply steel wire brushes or hard abrasive tools. Clean injector spray holes with needles provided
for this purpose. Keep injector tips and needles matched.
8 Check following of injector tip and needle:
● Needle moves freely over full length.
● Needle moves freely within normal lifting range.
● Needle is not sticking.
● Injector tip is free from signs of cavitation.
● Spray holes of injector tip are open.
● Maximum needle lift 'A', see Chapter 2.4. Replace injector tip if 'A' is out of limit.
● Cooling oil passage is free and clean.

9 Immerse parts in clean fuel oil or in a calibration fluid before inserting needle in injector tip.

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10 Check following of injector holders:

● Sealing faces are clean between injector tip (15) and injector holder (17). Sealing face 'C'
must be clean and undamaged. See Figure 2.9-18.
● Cooling oil supply and discharge holes are free and clean.
● Fuel spill drain is free and clean.
● Condition O-ring grooves

11 Check condition of spring and spring disc.

12 Place injector tip (15) over both dowel pins (19) onto injector holder.

NOTE
Apply Molykote G−rapid plus or Never−Seez Regular grade NS 42 B between
contact surfaces 'D' of sleeve nut and injector tip and on the thread. See Figure
2.9-18.

13 Turn on the sleeve nut (16) and tighten the nut to the correct torque using socket spanner
9612DT259 and torque spanner 9622DT216 in combination with multiplier 9612DT260 see
Figure 2.9-19. For torque settings see Chapter 2.4.
Calculate torque spanner reading according the conversion factor of the multiplier and see
for torque spanner instructions Chapter 2.4.
14 Insert spring disc (14), spring (13), guide screw (12), pivot (11) and turn in adjusting plug (10)
to distance 'B'.
15 Check the injector condition with test equipment 9612ZT934 (or PAAE062950). See Section
2.9.5
16 After adjusting the opening pressure, turn in the locking plug (9) with tool 9650ZT108, tighten
the plug to the correct torque see Chapter 2.4.

2.9.3.4 Fuel injector mounting

1 Before mounting an injector check the injector condition with test equipment 9612ZT934 (or
PAAE062950) on opening pressure, spray pattern and nozzle needle leak.
2 Remove the old sealing washer (20) if still present (see Figure 2.9-18.), from the sealing surface
in the cylinder head and clean the injector sleeve.
3 Check the sealing surface in the cylinder head is clean. Apply a fine lapping compound on
tool 9612ZT962 in case of irregularities.
4 Place a new sealing washer (20), see Figure 2.9-18.
5 Fit new O-rings (21) with silicon grease onto the injector body and place the injector into the
cylinder head. See Figure 2.9-18.
6 Place the injector gland (8) and distance sleeves (7). Fasten the injector nuts (6) by hand and
loosen half a turn. See Figure 2.9-16.
7 Mount the HP connecting pipe (3), see Section 2.9.4.

WARNING
If the injector is not correctly tightened, combustion gases can leak passing the
sealing between the sealing surface in the cylinder head and the injector tip.
Combustion gases will escape together with the spill fuel at point 5, see Figure
2.9-15, inside the hotbox.

8 Fasten nuts (6) in steps of 10 Nm by torque spanner up till final setting, see Chapter 2.4.
9 Tighten locking plate (5) see Figure 2.9-21.

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10 Mount the HP fuel pipe (2), see Section 2.9.4.

NOTE
The connecting pipe and HP fuel pipe must not be rotated with or against each
other.

11 Start engine lubrication and observe lubricating oil escaping at the top of the injector.

2.9.4 HP fuel pipe

The connection between HP fuel pump (1) and fuel injector (4) consists of a shielded HP fuel
pipe (2) and a connecting pipe (3) mounted in the fuel injector (4), see Figure 2.9-21.

1 Connection 4 Fuel injector

2 Shielded HP fuel pipe 5 Locking plate
3 Connecting pipe 6 O-ring
Fig 2.9-21 HP fuel pipe

2.9.4.1 Removing HP fuel pipe

Removing HP fuel pipe

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1 Remove fuel drain line (5). See Figure 2.9-21.

NOTE
In order to prevent leakages caused by damaged seating cones, the connecting
pipe (3) and HP fuel pipe (2) must not be rotated with or against each other. Take
care locking plate (5) remains tight. See Figure 2.9-21.

2 Hold the connecting pipe (3) in the cylinder head in its position while loosening the sleeve nut
of the HP fuel pipe (2) until there is no contact any more between the joint of HP fuel pipe and
connecting pipe. Remove HP fuel pipe (2).
Removing connecting pipe
3 Loosen and remove locking plate (5) from the cylinder head.
4 Turn the connecting pipe (3) out of the injector holder (4) with socket spanner 9612ZT255.

2.9.4.2 Mounting HP fuel pipe

Mounting connecting pipe
1 Before mounting check if from the HP fuel pipe (2) and connecting pipe (3) all seating cones
’(A’) as well as all the threads are clean and undamaged. Lubricate all the cones and the
threads with e.g. Molycote.
2 Fit a new O−ring (6) with silicon grease in the sealing groove of the connecting pipe (3).
3 Turn the connecting pipe in the injector holder (4) and use socket spanner 9612ZT255 with
torque spanner 9622DT215 to tighten the connecting pipe at correct torque according Chapter
2.4.
4 Place locking plate (5), do not tighten the bolts. If necessary first tighten the injector nuts, see
Section 2.9.3.4.
5 Tighten locking plate (5) to the cylinder head.
Mounting HP fuel pipe
6 Set the HP fuel pipe simultaneously into the appropriate position to the pump and to the
connecting piece connection. Turn both sleeve nuts manually onto the connections.

NOTE
In order to prevent leakages caused by damaged seating cones, the connecting
pipe (3) and HP fuel pipe (2) must not be rotated with or against each other. See
Figure 2.9-21.

7 Tighten the sleeve nuts using crow foot spanner 9612ZT331 and torque spanner 9622DT215
till torque setting, mentioned in Chapter 2.4.
8 Mount fuel drain line (5). See Figure 2.9-1.

2.9.5 Testing of fuel injectors

WARNING
Be careful in testing fuel injectors. Fuel jets are powerful and will penetrate skin
and underlying skin layers and blood. Such an accident calls for direct special
treatment. Should this aid not be available disinfect affected part of body. However,
it remains necessary to consult a specialist.

The testing of the fuel injectors can be done with a test device which uses a pneumatic pump
(PAAE069250, see Figure 2.9-22) or a hand pump (9612ZT934, see Figure 2.9-23).

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1 Pneumatic fuel injector tester

2 Fuel injector
Fig 2.9-22 Testing device with pneumatic pump

Fig 2.9-23 Testing device with hand pump

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Preparing the test device

1 Fill the oil tank with hydraulic oil.
2 Connect the injector to the test equipment.
3 Pump the test device to vent the system.
4 Tighten the connection of the injector.

Testing the Needle Opening Pressure (NOP)

1 Inject fuel until the flowing out liquid is clean.
2 Record the measured NOP in the injector test record.
3 Remove locking plug (9) with spanner 9650ZT108. Measure distance 'B' as an adjustment
reference, see Figure 2.9-18.
4 Measure and record the dimension "B", see Figure 2.9-18.

Checking the nozzle spray holes

1 Turn the adjusting plug (10) counter clockwise until NOP is 50 bar.
2 Inject fuel 10-15 times to check the flow from the nozzle spray pattern.
All holes must be open and produce an evenly-distributed spray pattern.
3 Release the pressure.

Checking the nozzle tightness

1 Turn the adjusting plug (10) to recorded value "B".
2 Increase the pressure up to 50% of the original nominal NOP.
For example, in case of nominal NOP 600 bar, test the nozzle tightness at 300 bar.
For openings pressure see Chapter 2.4.
3 Check that the nozzle is completely tight.
No drops are allowed within five seconds.

NOTE
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 the
connection.

4 If the nozzle fails the test a first time, repeat this procedure starting from step 2.
5 If the nozzle fails the test a second time, replace the nozzle.

Adjusting the opening pressure

1 Follow the procedure Testing the Needle Opening Pressure (NOP).
2 If necessary adjust the opening pressure by turning the adjusting plug (10) with tool 9612ZT187,
see Figure 2.9-18.
For new nozzles, adjust the NOP to the stated pressure.
For operating nozzles, adjust the NOP as per the table.

Table 2.9-1 Adjusting criteria for NOP and recommended inspections

Needle Opening Pressure (NOP) Task

NOP decreased less than 10% Opening pressure adjustment not needed.

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Continued from previous page

Needle Opening Pressure (NOP) Task

NOP decreased from 10% to 25% Adjust the needle opening pressure to maximum
20 bar over measured NOP.
NOP decreased over 25% Replace the nozzle.
Check push rod wear.
Check impact bush condition

3 After adjusting the opening pressure, tighten the locking plug (9) with tool 9650ZT108 to the
correct torque, see Chapter 2.4.

NOTE
Prevent that spill fuel from drain hole ”F” reaches the injector tip.

Fig 2.9-24 Fuel injector drain hole

NOTE
Only install satisfactorily tested fuel injectors in the engine or store them with the
hole 'F' and the nozzle tip closed by a plastic cap.

For more information, see also bulletin WS16Q010.

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