OPERATING

INSTRUCTION

Services, Wärtsilä Finland Oy

Engine section Engine type Ref. Date Issue Document No. Page
12 Cylinder head W46 WFI–S 26.04.2007 01 4612Q003 1(2)+32

Revised maintenance procedure for WÄRTSILÄ® 46

cylinder heads
Engine type This bulletin concerns all WÄRTSILÄ® 46 engines.

General The bulletin has been made to inform about the revised information in
chapter 12 of the engine Instruction Manual. The new chapter is included in
manuals delivered after October 2006.

Recommendation Replace the previous chapter in the manual, implement the new
maintenance routines in the maintenance schedule and follow the revised
assembly and maintenance procedures.
Please contact the nearest Wärtsilä Service office for further information.

New assembly and maintenance procedures

The following information has been revised in this revision, 46-200641-07:
12.2.3 Reconditioning of the gasket surfaces on cylinder liner and
cylinder head:
- This section has been added.
12.2.4 Mounting the cylinder head screws:
- This section has been added.
12.2.5 Mounting the cylinder head:
- Item 4 has been added.
- Item 22 has been revised.
12.2.8 Checking of cylinder tightness:
- Item 5 has been revised.
12.3.3 Reconditioning of valves and valve seat rings:
- Item 1, exhaust valve seat angle tolerance has been revised.
- Item 4 has been revised, the exhaust valve contact area is
changed to 30-50 % from the inner edge.
- Item 5 has been revised.
12.4 Valve seat rings
- Maintenance of valve seat rings, following text has been added:
The valve seat rings do not need to be removed and fitted if
there is no excessive wear or leaks.

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
01 4612Q003 2(2)+32

12.4.3 Fitting a new exhaust valve seat ring:

- The content has been revised.
12.4.3.1 Hydraulic test
Note the type of the tool 848021 to block the cooling water inlet
passages.

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

Letter validity Until December 31, 2007.

Enclosure Chapter 12 of the Instruction Manual, version 46-200641-07, 32 pages.

2007 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.
 46-200641-07 Cylinder head with valves

12. Cylinder head with valves

12.1 General
Every cylinder is equipped with a cylinder head including two inlet and
two exhaust valves with rotators, a main injection valve, a starting valve
(in some cases on B-bank of V-engines a dummy), a safety valve and an
indicator valve.
Additionally engines having pilot injection of the fuel the cylinder head
is equipped with a pilot injection valve. In DWI engines the cylinder head
has a water injection valve.
Cylinder heads are cast of special quality grey iron and are water
cooled. Cooling water is lead into the cylinder head from the engine
block through the cylinder liner water bores. Water leaves the cylinder
head through an outlet channel on the top and flows to a common pipe
and is drained away.

12.2 Cylinder head

For operational maintenance tasks typically performed by engine
operator, see schedule in chapter 03. For other maintenance tasks,
typically performed by maintenance crew, see maintenance schedule
in chapter 04.

12.2.1 General maintenance of the cylinder head

General maintenance includes a thorough check of the cylinder heads

including cooling water spaces. Possible scale formation in cooling
spaces can disturb the cooling effect and therefore has to be cleaned off.
Cleaning can be done by using chemical solvents. Contact Wärtsilä for
more information about chemical cleaning.
Combustion spaces must be inspected carefully. Valve seats (13) and
the injection valve sleeve (14) have to be inspected for possible water
leakages and replaced if necessary, see Fig 12-1. Valve guides (15) have
to be checked and replaced if badly worn. O-rings (16) must be replaced
with every overhaul.
The sealing surface between cylinder head and cylinder liner has to
be inspected and reconditioned if necessary.

WÄRTSILÄ 46 12 - 1
 Cylinder head with valves 46-200641-07

Cylinder head with valves

NS

NR

NQ NP

Fig 12-1 461205

12.2.2 Removing the cylinder head

1 Drain the cooling water. Remove the cooling water discharge

pipes (1), see Fig 12-2.
2 Remove the rocker arm casing cover (2), the rocker arm cas-
ing, the “Hot box” cover (3), insulations over the clamps (13) and in
V-engines also the insulating shield (4) over the exhaust gas con-
nection to the cylinder head, see Fig 12-3. Remove the insulating
shield (4) only if necessary.
3 Turn the engine with the turning gear so that the piston in the
cylinder concerned is at TDC, valves are closed and rocker arms are
unloaded.
4 Open the fastening bolts (12) of the valve rocker arm
bracket. Fasten the lifting strap to the rocker arms. Lift off the
bracket and push rods, see Fig 12-4.
5 Remove the clamps (5) of the exhaust and suction air pipes,
see Fig 12-3.
6 Loosen the oil pipe (7), fuel valve leaking pipe (8) and pilot
starting air pipe (9). Remove the covers between the cylinder heads
and temperature sensors in the cylinder head.

12 - 2 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

Cooling water discharge pipes

^ ^J^

QN
^

Fig 12-2 461204

Rocker arm casing cover and Hot box cover

Q
fåJäáåÉ ÉåÖáåÉëW sJÉåÖáåÉëW

R NP
O NP
O
P

P S

R
^ NM

^
^äíÉêå~íáîÉ O
NN
sfbt ^
NM

V
U
T

Fig 12-3 461206

WÄRTSILÄ 46 12 - 3
 Cylinder head with valves 46-200641-07

7 Remove the main injection pipe (10), see Fig 12-3. Protect
the connections of the injection pipes.
8 Open the quick connections A and B (optional) for exhaust
gas temperature sensor. Open the connection B (optional) for local
exhaust gas temperature indication. Open the connector for HT-
water temperature sensor C (optional), see Fig 12-4.

Exhaust gas temperature sensors

u
_
sáÉï u
^

`
NO NO

Fig 12-4 461207

9 Remove the pilot injection pipes (11), if the engine is

equipped with pilot injection, see alternative 2 in Fig 12-3.

Note! Ensure, that all connections of the cylinder head have been loos-
ened.

10 Remove the protecting caps of the cylinder head screws.

11 Lift the hydraulic tools (861143) in position using the lifting
tool (834045). Notice, that there are different lifting points for
in–line engines and V-engines, see Fig 12-5. Connect the hoses
according to the drawing.

Note! Some hydraulic pump types are to be used with a separate oil return
hose. Always follow the instructions delivered with the pump.

12 Screw on the cylinders. Keep on turning the hydraulic tool as

long as it rotates to expel any possible oil. Repeat the tightening
procedure to expel all oil.

12 - 4 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

Tools for cylinder head screws

^
i s
sfbt ^

USNNQP

UPQMQR

Fig 12-5 501205

13 Turn the cylinders back about 3/4 of a turn (270°).

14 Pump the hydraulic pressure to the stated value, see section
07.3.2.

Caution! Maximum pressure stated in section 07.3.2. must not be exceeded

when loosening the nuts.

15 Loosen the nuts about 3/4 of a turn by using the pin (861010).
16 Release the pressure, disconnect the hoses and unscrew the
cylinders. Lift off the hydraulic tool set.
17 Remove the cylinder head nuts.
18 Apply the lifting tool (832001), Notice, that there are differ-
ent lifting points for in–line engines and V-engines, see Fig 12-6.
19 Lift off the cylinder head. Remove the protecting pipes.
20 Cover the cylinder opening with a piece of plywood or similar
and install the caps to protect the screw threads. Protect oil pipe
from damage and ingress of dirt.

WÄRTSILÄ 46 12 - 5
 Cylinder head with valves 46-200641-07

Lifting tool for the cylinder head

sJÉåÖáåÉ fåJäáåÉJÉåÖáåÉ

sfbt ^

UPOMMN

Fig 12-6 501206

12.2.3 Reconditioning of the gasket surfaces on

cylinder liner and cylinder head

1 Inspect the gasket surfaces for damage

2 Recondition the gasket surfaces by lapping or by machine
grinding the minimum height of material (max. 0.5mm) in order to
repair the damage. Contact the manufacturer for detailed instruc-
tions.
3 Stamp the removed height onto the cylinder liner/head close
to its ID.

12 - 6 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

12.2.4 Mounting the cylinder head screws

Note! Corrosion depth in threads can be hard to determine, therefore it is

recommended to change the screws, whenever in doubt.

1 Change the cylinder head screws, if the maximum pressure

is exceeded when applying the hydraulic tool. When corrosion pits
with a depth of less than 0.1mm are found, grind/polish away the
pits with a small hand grinder. If corrosion is deeper than 0.1mm,
then change the screw. Lubricate the threads of the screwwith a
thin layer of Mobilarma 524 or corresponding.
2 Mount the screw and tighten to specified torque, see section
07.3.2. Fill the compartment between screw and engine block with
Mobilarma 524 or corresponding corrosion protection agent.Leave
about 2 mm space between the O-ring and corrosion protection.
3 Mount the O-ring (48). Change the O-rings (48) at every piston
overhaul, see Fig 12-7.

Mounting of cylinder head screws

48

Mobilarma 524 or corresponding

Fig 12-7 461213

WÄRTSILÄ 46 12 - 7
 Cylinder head with valves 46-200641-07

12.2.5 Mounting the cylinder head

1 Clean the sealing surfaces and put a new cylinder head gas-
ket and new O-rings for the circulating water jacket. Lubricate the
O-ring sealing surfaces with soap or similar kind of non oil based
lubricant. Change the seal rings of the charge air, starting air and
push rod protecting pipe.
2 Attach the lifting tool (832001) to the cylinder head, see Fig 12-6.
3 Lift the cylinder head to its place on the engine. When low-
ering it, take care that the starting air connecting pipe and push rod
protecting pipes slide into the seal rings without force.
4 Make sure that machined surfaces (1) , see Fig 12-8, are par-
allel with each other. Parallel check can be performed by using ruler
or alignment wire. Check alignment for three adjacent cylinder
heads, see Fig 12-8.

Note! Make sure the cylinder heads are in line with each other in order to
have exhaust manifolds, bellows and fuel pipes correctly aligned.

Cylinder head alignment

N sáÉï ^

Fig 12-8 461203

Note! Do not damage the cylinder head screws!

5 Screw on the cylinder head nuts.

6 Lift the hydraulic tools (861143) into position using the lifting
tool (834045), see Fig 12-5. Connect the hoses according to the
drawing.

12 - 8 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

Note! Some hydraulic pump types are to be used with a separate oil return
hose. Always follow the instructions delivered with the pump.

Note! Note the general tightening instructions for hydraulically tightened

connections in section 07.3. before tightening.

7 Screw on the cylinders. Keep on turning the hydraulic tool as

long as it rotates to expel any possible oil. Repeat the tightening
procedure to expel all oil.
8 Tension the screws by increasing the hydraulic pressure to the
stated value of stage I, see section 07.3.2.
9 Tighten the nuts by means of the pin until firm contact is ac-
chieved. Keep the pressure constant while tightening.
10 Release the pressure.
11 Tension the screws by increasing the hydraulic pressure to the
stated value of stage II, see section 07.3.2.
12 Tighten the nuts by means of the pin until firm contact is ac-
chieved. Make sure that the nuts turn equally. Keep the pressure
constant while tightening.
13 Release the pressure.
14 Check the tightening of the nuts by tension the screws again
to the stated value of stage II. Check that the nuts can’t be turned
further.
15 Release the pressure.
16 Disconnect the hoses and remove the cylinders.
17 Apply the protecting caps to the cylinder head screws.
18 Connect the exhaust gas sensors and HT cooling water sen-
sors if installed.
19 Fit the main injection pipe (10), see Fig 12-3.
20 Fit the pilot injection pipes (11), if the engine is equipped with
pilot injection, see alternative 2 in Fig 12-3.

Note! Do not use force to fit the pipes. If it is difficult to fit the pipes, check
that the cylinder head is in line.

21 Fit the oil pipe (7), fuel valve leaking pipe (8) and pilot starting
air pipe (9).

WÄRTSILÄ 46 12 - 9
 Cylinder head with valves 46-200641-07

22 Fasten the exhaust and air pipe clamps (5): Support the
lower clamp eg. with a long screw through the upper clamp to
position the pipes correctly, see Fig 12-9. Tighten to torque
according to chapter 07.

Fastening of the exhaust and air pipe clamps

fåJäáåÉ ÉåÖáåÉë sJÉåÖáåÉë

Fig 12-9 461209

Note! Check the alignment of the exhaust pipe bellows before tightening
the clamp.

Note! Before mounting the upper clamps ensure, that the pipes seal
evenly all around against the mating surface in the cylinder head.

23 The yokes may be adjusted here according to section 12.2.7

before assembling the rocker arm bracket.
24 Reconnect the cooling water discharge pipes (1). Replace
the sliding ring gaskets (42) with new ones. Use a special guiding
mandrel (846160) when assembling the flange (43), see Fig 12-10.
item I.) It is advisable to use some glue to keep the O-ring (44) in
place when connecting the pipe (1) to the connection piece (41), see
Fig 12-10. item II.
25 Reinstall the push rods

12 - 10 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

Reconnecting the cooling water discharge pipes

QO UQSNSM N QQ
QP QN

f
ff

Fig 12-10 501208

12.2.6 Installing the rocker arms

1 Lift the rocker arm bracket into position and fasten the fas-
tening bolts (12) to stated torque, see Fig 12-4 and chapter 07.
2 Fit the rocker arm casing to its place.
3 Adjust the valve clearance, see section 12.2.7.
4 Re–install the rocker arm casing cover, the Hot Box cover
and in V-engines the exhaust pipe insulating shield (4).
5 Before starting, fill the engine cooling water system and turn
the crankshaft two revolutions with the indicator valves open.

12.2.7 Adjusting valve clearance

1 Turn the crank of the cylinder concerned to TDC at ignition.

2 Loosen the locking screw (17) of the adjusting screws on the
rocker arm as well as on the yoke (18) and turn the adjusting screws
in a counter-clockwise direction to provide ample clearance, see Fig
12-11.

WÄRTSILÄ 46 12 - 11
 Cylinder head with valves 46-200641-07

Adjusting valve clearance

NT OM
ON

NV
NU

~ Ä Å

Fig 12-11 501209

3 Press the fixed end of the yoke against the valve stem by
pressing down on the adjustable end. Screw down the adjusting
screw (19) until it touches the valve end and note the position of the
spanner (pos. a). Keep on screwing down while the yoke tilts, until
the guide clearance is on the other side and the fixed end of the yoke
starts lifting from the valve stem. Now press down on the fixed end.
Note the position of the spanner (pos. b).
4 Turn the adjusting screw counterclockwise to the middle posi-
tion between “a” and “b”, i.e. “c”. Lock the nut (18).
5 Valve clearances for inlet and exhaust valves are given in
chapter 06.
6 Before adjusting the valve clearance hit the push rod end of
the rocker arm with a soft hammer to ensure that the push rod is
correctly seated.
7 Put a feeler gauge corresponding to the valve clearance be-
tween the surface of the yoke and the shoe at the rocker arm. Tighten
the adjusting screw (20) until the feeler gauge can be moved to and
fro with only a slight force. Hold the adjusting screw and tighten
the locking screw (17) to stated torque, see chapter 07. Check that
the clearance has not changed while tightening.

Note! Take care not to over tension the locking screw (17).

12 - 12 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

12.2.8 Checking of cylinder tightness

The condition of inlet- and exhaust valves can be estimated by checking

the cylinder tightness according to the following work phases:
1 Turn the crankshaft to such a position that the valves of the
cylinder concerned are all closed.
2 Connect the testing device (848020) to the indicator valve
(46), see Fig 12-12.
3 Open indicator valve. Read instructions in section 12.6. Note
that the thread of the valve is left-handed.

Checking of cylinder tightness

UQUMOM

QO

Fig 12-12 461208

4 Supply pressurized air (5-7 bar) via the testing device. Open
the valve and record the pressure.
5 Shut the valve of the testing device and record the pressure
drop in a certain time (e.g. 20 s).
· If the pressure drops directly to 0 bar, it is possible that one or
more valves are sticking or the valve(s) are burnt.
A sticking valve can be found from the immobility of the valve
when the engine is turned.
A burnt valve can normally be seen from the exhaust tempera-
ture. If the valve clearance is zero that would also cause an direct
pressure drop.
· Carbon particles trapped between the valve and the seat when
the engine is stopped could also prevent the valve to close properly
thus causing a direct pressure drop. If that is suspected, the
engine should be run for a few minutes and after that a new check
of the same cylinder.
· If a blow-by between the cylinder liner and piston is suspected e.g.
from fast fouling of filters or high crankcase pressure, it is best to
take readings of the complete engine and make a comparison.

WÄRTSILÄ 46 12 - 13
 Cylinder head with valves 46-200641-07

· The test can be verified by listening for leaking sounds inside

crankcase during testing.
· If the time is limited to overhaul only one piston, it is recom-
mended to dismantle the worst measured blow-by piston for
inspection. The result of inspection gives a hint of general engine
condition.
· When re-testing the cylinder after an overhaul a rapid pressure
drop can be observed. The reason for this is because the running
in of piston rings is not yet performed.

Note! The turning gear should be engaged during test.

· In general, the location of leakage can be found by listening when

the air valve is open.

Note! A general condition of engine is indicated with the test device, but
more important is the operation data records.
The overhauls must be made according to recommended over-
haul intervals and not only when the pressure test shows a big
blow-by.

6 Close the indicator valve, see section 12.6, and remove tool
(848020).

There is no use giving absolute guiding values for the pressure drop,
but you can evaluate the condition of the valves by comparing the
pressure drop in different cylinders.

12 - 14 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

12.3 Exhaust and inlet valves

The valve mechanism consists of a system where valve guides and
exhaust and inlet seats are integrated into the cylinder head. There is
also a rotating mechanism called Rotocap (23) for the exhaust and inlet
valves which will ensure smooth and even valve wear. Double valve
springs (26) make the valve mechanism dynamically stable, see Fig
12-13.

Note! Exhaust and inlet valves differ in dimensions and also in material
and must not be mixed.

Exhaust and inlet valves

NR OS OQ OR OP OT

NPK bñÜ~ìëí î~äîÉ ëÉ~í

NQK fåäÉí î~äîÉ ëÉ~í
NRK s~äîÉ ÖìáÇÉ
OPK oçíçÅ~é
OQK bñÜ~ìëí î~äîÉ
ORK fåäÉí î~äîÉ
OSK s~äîÉ ëéêáåÖë
OTK s~äîÉ ÅçííÉêë
NP
NQ

bue^rpq fkibq

Fig 12-13 501211

WÄRTSILÄ 46 12 - 15
 Cylinder head with valves 46-200641-07

12.3.1 Dismantling the valves

1 Fit the tool assembly in position according to Fig 12-14.

2 Fit the hydraulic jack and the nut (28). Leave about 40 mm
distance between the jack and the nut.
3 Use the hydraulic pump to press the spring assembly down
enough to remove the valve cotters (27), see Fig 12-13.

Note! Some hydraulic pump types are to be used with a separate oil return
hose. Always follow the instructions delivered with the pump.

Fitting of the tool assembly

UPQMMN UPQMRM

UPQMMO OU USMNTM

QM

Fig 12-14 501212

4 Knock at the centre of the valve discs with a soft piece of

wood, plastic hammer or similar to loosen the valve cotters for
removal.
5 Release the pressure carefully so that the valve springs are
slowly unloaded.

Note! Take care that the springs are fully unloaded before removing the
nut.

6 Remove spring holders (Rotocaps) and springs.

7 Remove the valves. Note the marks of the valves or mark
them so that they can be reinstalled into the same guide if they are
in good condition. Valves are marked according to the gas flow: inlet
A and B, exhaust C and D, see Fig 12-15.

12 - 16 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

Valves marked according to the gas flow

^áê áå bñÜ~ìëí
çìí

^ a

_ `

Fig 12-15 501213

WÄRTSILÄ 46 12 - 17
 Cylinder head with valves 46-200641-07

12.3.2 Checking and reconditioning valves and

seat rings

There are three alternatives used as “EXHAUST” valves depending on

the installation:

Exhaust valves

f ff fff
píÉääáí káãçåáÅ káãçåáÅ
î~äîÉ ÇáëÅ Çá~ãK NSM î~äîÉ ÇáëÅ Çá~ãK NTM

píÉääáí

NSM NSM NTM

Fig 12-16 501214

1 Check first which kind of an exhaust valve (I, II or III) is in

question.
2 Clean the valves, seats, ducts and guides as well as the un-
derside of the cylinder head.

Note! No scratches or notches are allowed on the valve surfaces, espe-

cially on the area marked with an “A” in Fig 12-17.

Burn-off area

_ìêåJçÑÑ ~êÉ~

v w

Fig 12-17 501215

12 - 18 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

3 Compare the burn-off on the valve disc to Fig 12-17. Read

the limit values for measures (X), (Y) and (Z) from the following
table.

Exhaust valve
Inlet I II III
valve Stellit Nimonic Æ160 Nimonic Æ170
B0137 B0203 B0314 / B0361 B0375 *)
(Y) minimum 13 mm 12.5 mm 12.5 mm 13 mm 11.3 mm
(Y) nominal 14.5 mm 14 mm 14 mm 14.5 mm 12.5 mm
Seat face inner diameter 133 mm 140 mm 133.5 mm 131.5 mm 131.5 mm
(X) minimum
(Z) maximum 2 mm 2 mm 2 mm 2 mm 2 mm

Burn-off area limits

*) = component code stamped in the end of the valve stem.
If any of these dimensions exceed the given limits, the valve must be
replaced.
4 Reconditioning of the valves has to be done by grinding
and valve seat rings by grinding or preferably by machining.
5 Before grinding, check the valve stem clearance by meas-
uring the stem and guide. Use the measuring documents 4612V001
and 4612V002. If the wear limits are exceeded, change the worn
parts
6 If necessary, remove the valve guide by pressing the valve
guide out using the tools 845004 and 845005, see Fig 12-18.
7 Check the bore in the cylinder head.
8 Fit the new valve guide. When fitting, cooling with liquid ni-
trogen is recommended but pressing in with oil lubrication is also
acceptable. After the new guide is fitted, check the guide bore.

WÄRTSILÄ 46 12 - 19
 Cylinder head with valves 46-200641-07

Extraction of valve guide

PT

UQRMMR UPQMRM
USMNTM

UQRMMQ

Fig 12-18 501216

12 - 20 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

12.3.3 Reconditioning of valves and valve seat rings

1 Seat face of the valve: The seat angle of the “INLET” valve is
20° and the “EXHAUST” valve 30°. See tolerances in Fig 12-19.
Check the minimum allowable edge tickness (Y) and the minimum
seat face inner diameter (X) of the inlet valve and the exhaust valve
from section 12.3.2.

INLET and EXHAUST valve seat angles

INLET

-0,15˚
20˚ -0,25˚

+0,25˚ +0,35˚
30˚ +0,15˚ 30˚ +0,25˚

EXHAUST EXHAUST

I, STELLIT II, III, NIMONIC

Fig 12-19 461210

2 Seat ring for the inlet valve: The seat angle of the inlet valve
seat ring is 19.5°, see tolerances in Fig 12-20. The seat can be
machined until the outer seat diameter reaches 171.5mm, see Fig
12-20. After that the seat ring must be replaced with a new one.

WÄRTSILÄ 46 12 - 21
 Cylinder head with valves 46-200641-07

Outer limit diameter for inlet seat machining

19,5˚ -0,05
-0,15

+0
Ø140 -0,3
+0,6
Ø166 -0,8

Ø171,5

Fig 12-20 501218

3 Seat ring for the exhaust valve: There are two alternatives
used for exhaust valve seat rings. These can be identified easily by
the form and diameter of the seat face, see table below. The seat can
be machined until the outer seat diameter reaches the maximum
value given in the table. Sharp edge (V) should be removed after
machining, see Fig 12-21.

Exhaust valve seat ring measures

Outer seat diameter, Outer seat diameter,
Exhaust valve Seat angle
nominal maximum
I and II d12=160 0/- 0.2 mm d12max=164 mm a12=30° +0.1/0

III d3173 ±0.1 mm d3max=177 mm a3=30° +0.1/0

Exhaust seat diameter limits and angles

Exhaust valve I and II Exhaust valve III

α12 α3

V V

ÇNO ÇP

ÇNO ã~ñK ÇP ã~ñK

Fig 12-21 501219

12 - 22 WÄRTSILÄ 46
 46-200641-07 Cylinder head with valves

Note! If blow-by has occurred, the O-ring for the corresponding valve seat
ring must be changed. Blow-by increases the temperature and the
O-ring is “burned”, which will result in water leakage into the cylinder.

4 Check with a blueing test that the contact area is the correct
one and that it is at the inner edge of the seat, see Fig 12-22. Ensure,
that the valve used in the blueing test is the one that will be
assembled to the seat concerned.
Spread a thin layer of blue paint on the whole seat face of the valve.
Fit the valve into its place in the valve guide and press the valve
gently against the valve seat using the tool (841010). Repeat 2-3
times turning the valve about 45° between the strokes.

Note! Ensure, that the sealing faces are absolutely clean and the blue
paint layer is as thin as possible.

Check of contact areas on the valve seat

NM J PMB

fkibq W

bue^rpq W fI ff fff

PM J RMB PM J RMB

Fig 12-22 461211

5 If the contact area is not as instructed above, the cutting

angle of the valve seat ring machining tool must be adjusted respec-
tively, re-machined and the blueing test repeated.

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12.3.4 Assembling of valves

1 Check the valve springs for cracks and wear marks. If there
are any, replace the springs with new ones.
2 Clean the valve guides (16) thoroughly and fit new O-rings
(17), see Fig 12-23.
3 Lubricate the valve stems (29), see Fig 12-23, with clean en-
gine oil.
4 Fit the valves and check for free movement. Before closing
the sealing surface between valve and seat be absolutely sure that
it is clean. When fitting the valves, ensure that they go back to their
locations, especially if the seat rings have been ground.
5 Install the springs and be sure that the seating faces are un-
damaged and clean, both on springs (26) and (30) as well as on the
spring discs (rotocaps) (23).
6 Fit the assembling tool (834001) in position.
7 Compress the springs with the hydraulic tool. Put in the
valve cotters (27) after lubricating them properly. Unload the
springs slowly.
While unloading the springs check that the cotters fit properly; the
spaces between the two halves should be equal on both sides.

Valve and valve seats in cylinder head

OT OS
OP
PM
NT

NS
OV

Fig 12-23 501221

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12.4 Valve seat rings

Maintenance of valve seat rings:

The valve seat rings do not need to be removed and fitted if there is no
excessive wear or leaks. It is strongly advised to contact the engine
manufacturer if the valve seat rings have to be removed.

12.4.1 Removing an old seat ring

1 Set the removing tools (845001 and 845003 for the inlet valve
seat ring, or 845001 and 845002 for the exhaust valve seat ring) so
that the clutches fit under the edge of the seat ring. Tighten the nut
(31), see Fig 12-24.
2 Fit the plate (32) and the hydraulic jack (33) and tighten the
nut (34) slightly.
3 Connect the hoses of the hydraulic pump (860170) to the
hydraulic jack and loosen the seat ring by pumping.
4 Release the pressure, disconnect the hoses and dismantle the
tool.

Removing of old seat rings

860170 33 845001

845001 34

34

31
31

845003 32 845002

Fig 12-24 501222

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12.4.2 Fitting a new inlet valve seat ring

1 Check the bore diameter in the cylinder head, see table 12 in

chapter 06.
2 The ring can be assembled by cooling with liquid nitrogen of
-190°C and with the cylinder head temperature at a minimum of
20°C, or by pressing in with a guided arbor.
3 Check the eccentricity of the sealing face in relation to the
valve guide, and if it exceeds 0.1 mm, the seat surface must be
machined with a lathe or ground.

12.4.3 Fitting a new exhaust valve seat ring

1 For fitting an exhaust valve seat ring an oven for heating the
cylinder head and a freezer for cooling the seat ring are required.
2 Check the seat bore diameters (A) and (B) in the cylinder
head, see Fig 12-25, according to values in table 12 in chapter 06.
Check that there are no deep scratches or corrosion marks in the
bore. In case there are scratches or corrosion marks, the bore must
be machined to oversize and the corresponding oversize seat ring
must be used. Contact the manufacturer for detailed instructions.
3 Heat the cylinder head up to +60...+80°C. Clean the bores A
and B thoroughly with loctite 7063 cleaning spray.

Note! It is important that the entire cylinder head is heated up, not only
the seat bore.

4 Cool the seat ring in the freezer to -18...-25°C.

5 Lubricate the bore A, see Fig 12-25, with Molykote 111 lubri-
cant or similar and apply Loctite 620 locking compound to bore B.
6 Fit the O-ring (45) to the ring groove, dry the outer surface of
the seat ring and fit the seat ring to its place.

Note! Mounting of a exhaust valve seat ring should be done carefully so

that the seat ring is correctly seated.

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 46-200641-07 Cylinder head with valves

Seat bore diameters

bue^rpq fkibq

QR

Fig 12-25 501223

When the cylinder head has reached the room temperature:

7 Check the eccentricity of the sealing face in relation to the
valve guide. Ensure that the seat ring is in continuous contact
against the bottom machined surface. The maximum allowed eccen-
tricity is 0.07mm. If the eccentricity is 0.07-0.25mm, the seat surface
must be machined with a lathe or ground.

12.4.3.1 Hydraulic test

A hydraulic test at 10 bar must be carried out as follows every time a
new exhaust valve seat ring has been fitted:
1 Block the cooling water inlet passages (38) (8 pcs) and the
deaerating hole (39), see Fig 12-26, rather with a special tool
(848021), see Fig 12-27. Note the washers (47) and the correct
tightening torque (640Nm) of the tightening nuts.
· If the tool is not available:
- Block the 8 cooling water inlet passages (38) with rubber expansion
plugs.
- Tap the deaerating hole (39) with M8 thread and block it with a plug.
2 Block the cooling water outlet passage (40), see Fig 12-26,
with a pressure test flange (847012), see Fig 12-27, and fill the
cooling water space with water.
3 Connect the checking device (848020) to the test flange and
replace the hose coupling with the transformation piece (46) taken
from the test flange.
4 Connect the low pressure pump (860050) to the transforma-
tion piece and apply a pressure of 10 bar.

WÄRTSILÄ 46 12 - 27
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Warning! Beware of the rubber plugs while there is pressure in the cylinder
cover. The plugs may be dangerous if they become loose.

Cooling water inlet passages

PU QM

PV

Fig 12-26 501224

Blocking of cooling water inlet passages

UQUMOM
USMMRM
UQTMNO QT
QS

UQUMON

Fig 12-27 501225

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12.5 Rotocap
Exhaust and inlet valves are equipped with Rotocaps. These are
rotating mechanisms, which turn the valves 8° at every opening. The
rotation makes the valves wear smoothly and increases the mainte-
nance intervals.

12.5.1 Rotocap maintenance

Valve rotator (Rotocap)

O
Q
P
N
S

Fig 12-28 501226

1 Remove the spring band (6).

2 Remove the cover plate (1).
3 Remove the cap spring (3).
4 Remove the steel balls (4) and turning springs (5).
5 Clean the base plate (2) and all other parts. Check for wear,
replace if neccessary.
6 Reinstall the parts in the opposite order. Lubricate the parts
with clean engine oil.

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12.6 Indicator valve

The inside construction of the valve is such that the pressure in the
cylinder tightens it. Consequently the force needed to close the valve
is relatively low.
The valve has a left-handed screw and it is opened and closed
respectively as follows, see Fig 12-29

Indicator valve

Fig 12-29 461202

12.6.1 Indicator valve, operation and maintenance

1 When starting the engine the indicator valves should be closed

using only just enough force to bring the sealing surfaces together.
The pressure of the cylinder will push them tight together.
2 When stopping the engine the indicator valves should be
opened only half a turn. This way the tightening effect due to the
temperature decrease will not occur.
3 When opening the indicator valve for measuring the cylinder
pressure, inadvertent tightening instead of opening must be
avoided.
4 When closing the indicator valve after measuring the cylin-
der pressure only minimal torque is needed. So called “fingertight”
is usually enough.
5 Add high temperature lubricant (lubricant specification to be
1000°C) to the valve stem threads when you feel that it is not moving
easily.
6 Always use correct T-handle wrench (808001) to open and
close indicator valve, see Fig 12-29.

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12.7 Safety valve

Each cylinder head is equipped with a spring loaded safety valve, see
Fig 12-30. This valve will prevent any excessive cylinder pressure and
emits an alarm when operated. The blow out pressure is stamped into
the top of the valve. Safety valves wich begin to leak in service, must
be replaced at the first opportunity. Before refitting, the valve should
be lubricaterd with a high temperature lubricant.

Safety valve

4
1
2

Fig 12-30 461201

12.8 Starting valve

The starting valves are described in chapter 21.
When refitting the starting valves, the outer cylindrical surfaces
should be lubricated with engine oil or a special lubricant.

12.9 Injection valve

The injection valves are described in chapter 16.
When refitting, the injection valves should be lubricated with engine
oil only.

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