Cylinder head with valves

46-200641-07

Annexe 1
Cylinder head with valves
NS

NR

NQ

Fig 12-1

NP
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 casing, the Hot box cover (3), insulations over the clamps (13) and in
V-engines also the insulating shield (4) over the exhaust gas connection 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

WRTSIL 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
fJ W
O

sJW
NP

NP

O
P
S

R
^

NM

^
^~ O
sfbt ^

NN
NM

V
U
T

Fig 12-3

WRTSIL 46

461206

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 HTwater temperature sensor C (optional), see Fig 12-4.
Exhaust gas temperature sensors

u
s u

`
NO

NO

Fig 12-4

461207

9 Remove the pilot injection pipes (11), if

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

is

Note! Ensure, that all connections of the cylinder head have been loosened.

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
inline 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

WRTSIL 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 different lifting points for inline 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.

WRTSIL 46

12 - 5

Cylinder head with valves

46-200641-07

Lifting tool for the cylinder head

sJ

fJJ

sfbt ^

UPOMMN

Fig 12-6

501206

12.2.3

12 - 6

WRTSIL 46

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 gasket 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 lowering 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 parallel 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

s ^

N
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

WRTSIL 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 acchieved. 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 acchieved. 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 cant 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 sensors 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).

WRTSIL 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

fJ

Fig 12-9

sJ

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

WRTSIL 46

46-200641-07

Cylinder head with valves

Reconnecting the cooling water discharge pipes

UQSNSM

QO
QP

QQ
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 fastening 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 Reinstall 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.

WRTSIL 46

12 - 11

Cylinder head with valves

46-200641-07

Adjusting valve clearance

NT OM

ON
NV
NU

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 position between a and b, i.e. c. Lock the nut (18).
5 Valve clearances for inlet and exhaust valves
chapter 06.

are given in

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 between 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

WRTSIL 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 temperature. 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.
WRTSIL 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 recommended 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 overhaul 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

WRTSIL 46

Annexe 2
2708-1/A1

Maintenance

HYUNDAI-SULZER m flex84T-D

Cylinder Cover
Removal and Fitting of Cylinder Cover and Water Guide Jacket

Key to Illustrations:

Tools:
1
2
3
1

Suspension device
Spec, (nut) eye bolts
Protection caps
Cradle

94265
94265a
94265b
94266

1
2
2a
3
4
5
5a
6

Cylinder cover

Nut

Cylinder cover stud

Cyl. cooling water outlet
Leak oil drain
Exhaust valve cage
Stud to exhaust valve cage
Connection for valve
shank lubrication
7 Hydraulic piping
8 Air inlet for air spring
9 Water guide jacket

10
11
12
13
14
15
16
17
18

Allen screw
Screw M20x200
Platform support
Fixing screw
Plug
Control box
Fuel pressure piping
0-ring
0-ring

DB Through hole
RC Eye bolt

Overview

|1.

1.

Removal of cylinder cover

1/6

2.

Transport of cylinder cover

2/6

3.

Fitting of cylinder cover

3/6

4.

Removal of water guide jacket

4/6

5.

Fitting of water guide jacket

6/6

Removal of cylinder cover

Drain the cylinder cooling water from the affected

cylinder, i.e. first shut the valves for cylinder cooling
water inlet and outlet at the supporting ring on the
exhaust side and above the cylinder cover respectively.
Open drain cock to the respective cylinder. This
cock is situated on the exhaust side below the cock
for cylinder cooling water inlet.
Then open the vent valve in the cylinder cooling water outlet pipe of the respective cylinder!
Disconnect all the connections to the cylinder cover
and to the exhaust valve as well as the expansion
piece between exhaust valve and exhaust manifold
(see 2751-1).
Remove hydraulic piping 7 (see 8460-1).
Remove fuel pressure piping 16 (see 8733-1).
Disconnect plugs 14 from control box 15.
Clean all the thread protrusions on the cylinder cover studs.
Loosen the nuts of the cylinder cover studs (see
2708-2).

1/6

2007

Maintenance

Removal and Fitting of Cylinder Cover and Water Guide Jacket

Screw spec. eye bolts 94265a to suspension device 94265 onto the studs 5a
of the exhaust valve cage. Insert the two hooks of the suspension device into
the spec. eye bolts.

Lift cylinder cover 1 together with water guide jacket 9 and exhaust valve cage
5 by means of the crane (Fig. 'C').
Remark: Removing and transporting the cylinder cover is the same with exhaust
valve cage 5 in situ or removed from the cylinder cover.

Maintenance

RT-flex84T-D

2708-1/A1

Removal and Fitting of Cylinder Cover and Water Guide Jacket

'3.

Fitting of cylinder cover

Before placing the cylinder cover in position the following points must be taken
care of:
The compression space must be absolutely free of foreign particles or dirt.
The seating surfaces on cylinder cover and cylinder liner must be clean and
undamaged.
A new soft iron joint ring 2 mm thick must be placed on the cylinder liner in
such a way that it lies flat all over.
The inner surface of water guide jacket 9 which is screw fastened to the cylinder cover as well as the respective guide surface at the collar of the cylinder
liner must be clean and smeared with bearing oil.
Place new 0-rings into the grooves of the cylinder liner and smear these with
bearing oil.
The threads of the cylinder cover studs must be clean and smeared with MOLYKOTE paste.
Place three protection caps 94265b on cylinder cover waisted studs (Fig. 'C').
When these conditions are all met, lower the cylinder cover, attached to suspension device 94265 or 94265c, slowly over the cylinder cover studs, whereby a centring pin assures the correct position (see 2124-2).
=> Screw all nuts by hand onto the cylinder cover studs, paying attention to easy
turning.
=i> Pre-tension the studs with hydraulic pre-tensioning device 94215 In accordance with 2708-2.
=> Reconnect all connections to cylinder cover and exhaust valve.
=> Finally shut drain and vent cock, and reopen the cocks for cooling water inlet
and outlet.
Remark: Concerning the fitting of the expansion piece between exhaust valve and
exhaust manifold see 2751-1.

m
Q
CO
_i

111
3

3/6

2007

Annexe 3
^^^^^^^IRT-flex84T-D

2708-2/A1

Maintenance

Cylinder Cover
Loosening and Tensioning of Cylinder Cover Waisted Studs

Key to Illustrations:

Tools:
1 Hydr. tensioning device

94215

consisting of:

2 Device halves each with

four pre-tensioning jacks
8 HP hoses
1 Suspension device
2 Piston reset devices
1 Pressure gauge
1 Hydr. distributor
1 HP hose
2 HP hoses
1 Hydraulic unit

94215a
94215b
94215c
94215d
94932a
94934a
94935
94935a
94942

1
2
3
4
5
6
7
8
9

Cylinder cover stud

Nut
Vent screw
Piston
Round nut
Pin
Sealing ring
Sealing ring
Cylinder

MO

Emplacement for round

nuts 5 when not in use
RO Emplacement for round
bars 'RS' when not in use
RS Round bar

General
Remark: Pay attention to General Application Instructions 9403-4 for hydraulic
pre-tensioning jacks.
Should a cylinder cover stud have to be replaced, please observe the indication in
2751-1.
2.

Set-up of pre-tensiohlrig jacks

Remove expansion piece between valve cage / exhaust pipe (see 2751-1).
Remove the fuel pressure pipes from the injection valves.
Clean the threads of all cylinder cover studs 1 (Fig. 'C') as well as the area
around nuts 2.
Mount two device halves of pre-tensioning device 94215 over the cylinder
cover studs and rest them on the cylinder cover.

I
94215c

MO

94215b

94215a
94215d

1/4

2007

2708-2/A1

B^^^^^^JRT-flex84T-D

Maintenance

Loosening and Tensioning of Cylinder Cover Waisted Studs

=>

Open vent screws 3 (Fig. 'C') of all pre-tensioning jacks.

=>

Connect the device halves to hydraulic, unit

94942 as shown in Fig. 'B'.

=>

Press pistons 4 of all pre-tensioning jacks

. 94215a downwards upon cylinder 9, either by
screwing on round nuts 5 (Fig. 'C'), or - without round nuts - by using piston reset devices 94215d (Fig.'D').

When the pistons are resting on the cylinders

there should be little or no clearance at 'x'.
=^

After using the piston reset device screw

round nuts 5 until they sit firmly on piston 4.

Remark: For loosening the waisted studs screw

back the round nuts by about two turns.
For tensioning the waisted studs the round nuts
must lie on piston 4.

94942
,jy

014.816/06

94215d

2007

2/4

Maintenance

HYUNDAI-SULZER RT-flex84T-D

2708-2/A1

Loosening and Tensioning of Cylinder Cover Waisted Studs

Loosening
Set-up of the pre-tensioning jacks as mentioned in section 2.
Start up hydraulic unit 94942.
Close vent screws 3 on the jacks as soon as oil flows bubble-free.
Actuate hydraulic unit until a pressure of 1020 bar is indicated on its pressure
gauge and on pressure gauge 94932a.
Attention should be paid to ensure that pins 6 always protrude slightly
compared with pistons 4 on the pre-tensioning jacks.
Turn all nuts 2 upwards till the stop, using round bar 'RS'. Store round bar 'RS'
in emplacement 'RO' while not in use (see Fig. 'A').
Release pressure to zero.
Disconnect and remove HP hoses 94935a from both device halves.
Unscrew round nuts 5 and remove them together with the pre-tensioning
jacks.
Tensioning
=> Smear threads and seating surface of nuts 2 with MOLYKOTE paste G.
CHECK

Tighten all nuts down with round bar 'RS' till fully seated (check with feeler gauge).
=> Mark position of all nuts, with a line on nuts and cylinder cover, with a felt-tip
pen (this will serve for a later check).
=> Set-up of the pre-tensioning jacks as mentioned in section 2.
=> Start up hydraulic unit 94942.
=> Shut vent screws 3 on the pre-tensioning jacks as soon as oil flows bubblefree.
=> Actuate hydraulic unit until a pressure of 1000 bar is indicated on its pressure
gauge and on pressure gauge 94932a.

CHECK

Attention should be paid to ensure that pins 6 always protrude slightly

compared with pistons 4 on the pre-tensioning jacks.

While keeping this pressure constant tighten all nuts 2 with round bar 'RS' till fully
seated on the cylinder cover (check seating with feeler gauge), verify while tightening that all nuts can be turned by about the same angle of 350.

%
3/4

2007

2708-2/A1

Maintenance

HYUNDAI-SULZER RT-flex84T-D

Loosening and Tensioning of Cylinder Cover Waisted Studs

Where it is found that a nut can be turned considerably less than the others, it
must be assumed that the respective cylinder cover stud has become insufficiently tensioned.
Possible causes:
-

Sealing rings 7 and 8 defective (Fig. 'C').

Piston 4 jams.

Connection piece of HP hoses 94215b leaky or incorrectly connected.

Repeat tensioning procedure after the cylinder cover studs have been loosened again.

When all nuts have been tightened by practically the same angle, release the
oil pressure to zero.

=> Disconnect and remove HP hoses 94935a from both device halves.
=> Unscrew round nuts 5 and remove them together with the pre-tensioning
jacks.
CHECK

Verify by the previously applied marks that all nuts have been tumed equally by an
angle of about 350.

2007

4/4