10. Engine Block, Oil Sump and Cylinder Liner 10.1 Engine block and covers 10.1.1 General description Data and dimensions ‘The engine block is made of nodular cast iron and cast in one piece. Material: Nodiulor cast iron It has a high rigidity and it is designed for minimum stress Weight (machined, cry) concentration and deformation. Part of the cooling water system, Peron tian including the jacket water distributing pipes, as well as lubricat- Jeeokeatze) —_ingoil channels, and the charge air receiver are integrated in the 2950 kg (91.20) 7) igen &bar : si engine block. The main bearing caps, which support the underslung crank- shaft, are clamped by two hydraulically tensioned screws from below and two screws horizontally (one horizontal screw only, for the thrust bearing cap). The bearing shells are axially guided by lugs to provide correct assembly. A combined flywheel/thrust bearing is located at the driving end. ‘The camshaft bearing bushes are fitted in housings directly machined in the engine block. ‘The crankcase covers, as well as other light metal covers, tighten against the engine block by rubber sealings and four screws each. On the rear side of the engine, some of the erankease covers are equipped with safety valves which relieve the overpressure in case of a crankcase explosion. The centrifugal oil filter is fixed to one of the covers. One cover can optionally be provided with an oil filling hole. ‘The end covers are made of cast iron. The covers tighten against. the engine block by means of sealing compound. ‘The crankcase is furthermore provided with a vent pipe includ- ing a non-return valve. This pipe should be conducted away from the engine room. 2 o> ‘ = 10.2 Engine feet Data and dimensions ‘The engineis provided with four (six) bolted-on feet for its support. Materia: Nodular castifon ‘This arrangement provides excellent flexibility for optimization Weight: 31k of the installation. The feet are made of nodular cast iron. WARTSILA 20 oe10.3 Oil sump Data and dimensions The light, welded oil sump (casted for 4120) is attached to the Materic: Steel plates engine block from below and is sealed off by a rubber sealing. Weight: 632 kg (A120) Suction pipes to the lube oil pump and separator, as well as the 4120 including bolancing shafts main lube oil distributing pipe for crankshaft bearings, are incor- Leap porated in the oil sump. 232 kg (8120) ‘ tay . Z 269 kg (20) An oil dipstick is located in one of the crankcase covers. The oil dipstick indicates the maximum and minimum limits between Ollvolume: 2701 41.20) which the oil level may vary. Keep the oil level near the max. mark 380 | (6120) and never allow the level to go below the min. mark. The limits -— 490 | (8120) apply to the oil level in a running engine. One side of the dipstick 4 5501 (9120) is graduated in centimetre. This scale can be used when checking the lubricating oil consumption. 10.4 Main bearings Data and dimensions The main bearing is a split type plain bearing of bi-metal type. Weight of beatiag cap: 22 kg DISMANTLING. PT serew on cyingec by hans 2 Connect ndeos, oper vane, Tighten eying by hand ra = 2. 3. Scrow cylinders 180 Sounter-clockwite, 4. Clowe valve ree pressure. 5 Open tne ut abtou haa tum, 8 Open teease vave, remove fool The upper bearing shell has an oil groove but the lower bearing shell does not. The thrust bearing, located in the driving end, is of similar design. 10.4.1 Dismantling of a main bearing Remove two crankcase covers on each side of the bear- Ing, on both sides of the engine. Ed Loosen the side screws on the bearing in question and on both adjacent bearings. Use the tool combination 822001, 803001 and 820009, see chapter 05. Loosen the nuts of the main bearing screws on —_—tthe (> earing in question. Lift the distance sleeves 861156 into position and insert the pin 861025 into the slot to fix the sleeves, see Fig 10-2. Screw on the hydraulic cylinder 861159 into position” and proceed with opening of the main bearing nuts. Remove the hydraulic tool and the distance sleeves. Unscrew the side screws of the main bearing cap tobe lowered. Remove the nuts of the main hearing screws andlower the main bearing cap. By Remove the lower bearing shell. 10-2Operating side 861 025 Pin GB 86 156 Distance sleeve 861 159 Hydraulic cylinder a Straight side 8611 861 159/ 861025/ Fig 10-1 2oxosze0t Insert the tuming tool 851001 into the main bearing jour- nal radial oil hole, see Fig 10-1, TD) tum the crankshatt carefully until the bearing shell has turned 180° and can be removed. aD o Cover the two main bearing journal radial oil holes with pe. . Note! At least every third main bearing should be in place at the . ¥ same time to support the crankshatt. :Eemtnen 1. Upper main bearing shell 2. Turing tool for main bearing (851 001) - Fig 10-2 sores 10.4.2 Inspection of main bearings and journals Clean the bearing shells and check for wear, scoring and other damage. If a bearing is worn or damaged, renew both bearing shells and check the condition of the other bearings. Wear is settled by measuring the thickness of the lower bearing shells. For this purpose a ball anvil micrometer can be used. The wear limit in section 06.2 must be applied. Ifthe thickness of lower bearing shells have not reached the wear limit and the difference in thickness of all lower bearing shells is maximum 0.03 mm, the C shells can be used again. Mark the new bearings with the bearing numbers. — ‘The main bearing journals should be inspected for surface finish. Damaged journals, i.e. rough surface, scratches,’marks of shocks etc., should be polished. If, after a longer running period, consid- erably uneven wear appears, section 06.2, the crankshaft may be reground and used together with undgrsize bearing shells. No scraping or other damage of bearing shells, caps and saddles is allowed. Burrs should be locally removed, only. 4 WARTSILA 20Erno Caution! 2 Seon rece oy had Tipton cringe yh 10.4.3 Assembling of main bearing I Clean the main bearing shells, the cap and the journal very carefully. Remove the protecting tape from the journal oil holes and lubricate the journal with clean engine oil. Lubricate the bearing surface, back side and end faces of the upper bearing shell with clean lubricating oil, The bearing shell can be completely destroyed (deformed) during the as- sembly, if it is not lubricated carefully. Place the end of the bearing shell in the slot between the journal and the bearing bore, with the lug guiding in the oil groove, and push it by hand as far as possible (recom- mended 2/3 of its length). Insert the turning tool 851001 into the main bearing jour- nal radial oil hole and turn the crankshaft carefully until the bearing shell has turned into position. Take care that the bearing shell lug slides into the groove without being damaged. A bearing shell forced into its place can be completely de- stroyed due to deformation. “ Remove the turning tool. a Lubricate the bearing surface, back side and both ends of the lower bearing shell with clean lubricating oil and place it in the bearing cap. El Lift the main bearing cap until the lubricated side screws can be screwed into the bearing cap by hand. a Tighten the side screws on the operating side to 300 im. : Screw on the main bearing nuts by hand. Lift the distance sleeves into position 861156 on the © earing cap nuts and insert the pins 861025, see Fig 10-1. Lift the hydraulic tool into position 861159 and proceed with tightening of the main bearing nuts. Tighten the side screws on the operating side (straight side of the bearing cap) to full torque! Tighten the side screws on the opposite, rear side to full torque. WARTSILA 2010.5 Erne 601 il Sump and Cylinder Liner Flywheel/thrust bearing DisMANTUNG. T'Serew on eylngers by hand 2 Connect hoses, pen vate. Tignten evinces by hand CO). 2 saeucynaue 4 Seale neceoe Se eee nn 3 SBirioad ake ona 10.! 1 Dismantling of flywheel/thrust bearing Remove the crankcase covers nearest to the flywheel, Including the centrifugal filter on the back side crankease cover, and the flywheel end side cover. Remove the oil pump module from the engine. Secure the module with a strap before opening the fastening screws. Open all pipe connections to the module before opening the fastening screws for the module. Cover the oil pipe openings. Remove the oil pipe between oil sump and lube oil Cooler module. Remove the oil pipes to oil pump intermediate gear earing and to camshaft intermediate gear jet nozzles. Remove the cover for oll pump intermediate gear shaft. Remove the flywheel end cover. The back side half has to be removed first and then the operating side half. Loosen the thrust bearing side screw and the side screws on the adjacent bearing. Use the tool combination 822001, 803001 and 820009, see chapter 05. Note that the thrust bearing has only one side screw! Loosen the nuts of the thrust bearing screws. Lift _ the fistance sleeves 861156 into position and insert the pin 861025 into the slot to fix the sleeves. EZ Screw on the hydraulic tool 861159 into position and proceed with opening of the thrust bearing nuts. Remove the hydraulic tool and the distance sleeves. Unscrew the side screw of the thrust bearing cap. se the tool combination 822001. Remove the nuts of the thrust bearing screws and lower the thrust bearing cap. C Remove the lower bearing shell and thrust washers. Insert the turning tool 851001 into the main bearing jour- nal radial oil hole. Turn the crankshaft carefully until the bearing shell has turned 180° and can be removed. [Remove the thrust washers. Cover the two bearing journal radial oil holes with tape. WARTSILA 20§ 5 Caution! Ee 10.5.2 Inspection of flywheel/thrust bearings Check the bearing shells in the same way as the main bearing shells. The thrust washers on the same side have to be replaced in pairs. 10.5.3 Assembling of flywheel/thrust bearing I Clean the thrust washers and the bearing shells, the cap and the journal very carefully. Remove the protecting tape from the journal oil holes and lubricate the journal with clean engine oil. Lubricate the bearing surface, back side and end faces of the upper bearing shell with clean lubricating oil. The bearing shell can be completely destroyed (deformed) during the as- sembly, if it is not lubricated carefully. Place the end of the bearing shell in the slot between the journal and the bearing bore and push it by hand as far as possible (recommended 2/3 of its length). Insert the turning tool 851001 into the main bearing jour- nal radial oil hole and turn the crankshaft carefully until the bearing shell has turned into position. A bearing shell forced into its place can be completely de- stroyed due to deformation. Remove the turning tool. Lubricate the running surface, and back side of the up- per thrust washers with clean lubricating oil and push the washers into position by hand. To facilitate the mounting of the washers, the crankshaft can be axially moved in each direction. a Lubricate the bearing surface, back side and both ends the lower bearing shell with clean lubricating oil and place it in the bearing cap. EJ Lubricate the running surfaces of the “lower washers with clean lubricating oil and fix them into position on the guiding pins on the bearing cap. ift the bearing cap until the-ubricated side screw can e screwed into the bearing cap by hand. Tighten the side screws on the operating side to 300 Screw on the main bearing nuts by hand. WARTSILA 20Totton cron by hea 5 Spon ie vars anc remove Lift the distance sleeves 861156 into position on the ring cap nuts and insert the pins 861025. Lift the hydraulic cylinder 861159 into position and pro- ceed with tightening of the main bearing nuts. Tighten the side screws on the operating side (straight side of the bearing cap) to full torque! Check axial clearance of the crankshaft. 7] Mount the flywheel end cover. The operating side half as to be mounted first and then the back side half. CO aia 3} Mount the cover for the oil pump intermediate gear” > att. BB Mount all the oil pipes. Mount the oil pump module and check the clearance. Mount the crankcase covers, flywheel end side covers and rest of the oil pipes. . 10.5.4 Measurement of thrust bearing axial clearance I Lubricate the bearings by running the prelubricating pump for a few minutes. Apply a dial gauge, for instance, against the plane end surface of the flywheel. EJ Move the crankshaft by a suitable lever in either direc- tion until contact is established with the thrust bearing. Set the dial gauge at zero. Move the crankshaft in the opposite direction, and read the axial clearance from the dial gauge. C3 10.6 Cylinder liner 10.6.1 Description Data and dimensions The cylinder liner is made of special, wear resistant, cast iron. Materia: Special grey cast The lineriis of the wet type. At the upper part the liners are sealed — ae against the block metallically, and at the lower part by two fei 9 Test pressure: 10 bar O-rings. « To eliminate the risk ofbore polishing, the liner is provided with an anti-polishing-ring at the upper part. WARTSILA 20S Groene Note! ami0sis612 Note! 10.6.2 Maintenance of cylinder liner Always when the piston is overhauled, the cylinder liner must be inspected. Check the bore for wear and other damages. The bore should be measured at three levels, both along and across the engine. If the bore is worn or glazed, the liner has to be honed. A high lube oil consumption may indicate that the bores are worn or that the surface of the bores are glazed. Ovality of the cylinder liner bore cannot be corrected by honing only. 10.6.2.1 Honing of cylinder liner bore The pistons and connecting rods must be removed. Use covers or plastic film to protect all engine components from the debris which is caused during the process. Honing residues must be prevented from falling into the oil sump of the engine. For the honing process the following instructions are prescribed: ‘© The honing is to be carried out by means of“Plateau honing”. | ‘* Only ceramic hones with a coarseness of 80 and 400 should be used. The hones with a coarseness of 80 should be used until the polished areas in the cylinder liner are over serap- ing. The hones with a coarseness of 400 should be used for about 30 strokes to give the correct surface finish. ‘The pitch angle of the honing lines in the cross hatch pattern should be about 30°, which is achieved by combining for example 40 strokes/min with a rotational speed of 100 RPM As coolant a honing oil is preferred, but a light fuel oil 2-15 cSt could also be used. After honing, the liner bore should be carefully cleaned by using a suitable brush, water (preferably hot) and soap or cleaning fluid, alternatively, light fuel oil. Then dry with a cloth and lubricate with engine oil for corrosion protection. Palletes of a cylinder liner, the piston rings have to be new ones. { ‘After a bore has been honed, follow the running in programme | in chapter 03. 3 Removing of cylinder liner It is recommended that the crankshaft is turned to TDC and a piece of plastic is put straight through the crankcase over the WARTSILA 20crank pin, preventing remaining cooling water or dirt to enter the oil sump. [Ey Drain the engine cooling water. Remove the cylinder head, see chapter 12. a Remove the piston with connecting rod, see chapter EJ Mount the cylinder liner removing device 836001, ac- cording to Fig 10-3. Tension the nut (1) of the pull screw until the liner is eld between the removing device. Lift the liner out of the engine block. Removing and lifting of cylinder liner 1.Nut 836001 Extracting and iting A ool for cylinder liner Distinct mark_m10%00601 10.6.4 Inspection of cylinder liner Clean the cylinder liner water side. The water side of the cylinder liner can be cleaned of deposits with a steel wire brush. 10.6.5 Mounting of cylinder liner Ifmore than one cylinder liner have been removed, check that the liners are installed in the same cylinders as before the overhaul. The liners are marked with the cylinder numbers. Check that all guide and contact faces of the engine lock and cylinder liner are clean and intact. Check that the O-ring grooves of the cylinder liner are clean, and insert new O-rings. Lubricate the lower O-rings and the sealing faces with grease or clean lubricating oil. Mount the lifting device. A Lower the liner carefully into the bore of the engine lock. When the lowest O-ring touches the engine block, align the liner so that the mark on the liner is directed towards the driving end of the engine. Lower further and press liner into position by hand. Gg ‘Check the inner diameter of the cylinder liner. Mount the piston with the connecting rod. Ey Mount the cylinder head, and refill the cooling water system. Check the O-ring seals from the crankcase side while circulating cooling water. Apply 3 bar static pressure. WARTSILA 20