W220 Crankshaft, Connecting Rod, Piston 11.

11. Crankshaft, Connecting Rod, Piston

11.1 Crankshaft
Data and dimensions : 11.1.1 General description
Material : Forged, alloyed steel
Weight : 2100 KG (18V200)
1200 KG (12V200)
The crankshaft is forged in one piece in high tensile steel. The crank-
shaft is fully nitrated.
Both the journals (item 6) and crank pins (item 7) have recessed fillets
in order to minimize the length and weight of the engine. The coun-
terweights are bolted on by three screws (item 2), two counter-
weights (item 2) per crank throw. The gear wheel for the camshaft
drive is on the flywheel end.
The flywheel is fitted on the crankshaft.
At the free end , there is a gear for driving pumps (water, lube oil), a
vibration Damper (item 4) is also installed on place .
The lubricating oil is supplied through holes in the engine block to the
main bearings.
The oil flows further from the main bearing through the bores (item 5)
in the crankshaft to the connecting rod big end bearing (see
chap.18).
The crankshaft sealing (item1) on the flywheel side is made using a
static seal.
The lips (item 8) of the seal press on the mirror surface of the crank-
shaft.
1 8 5 6 7

1. Sealing
2. Screw
3. Driving pump
4. Damper
5. Bore
6. Journals
7. Crank pins
8. Mirror surface

4 3
2 2

Fig. 11-01

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 11. Crankshaft, Connecting Rod, Piston W220

Main bearing assembly

1
Free end side

1. Upper main bearing 5

2. Lower main bearing 4
3. Camshaft drive gear
4. Thrust bearing
3
5. Main bearing, number 0

4
Flywheel end
2

Fig. 11-02

11.1.2 Counterweights
Data and dimensions : The crankshaft is balanced by means of counterweights on the
Material : Steel plate crank webs, one weight per cylinder, see Fig.11-03.
Weight : 42 kg

Note : The stepped side of the counterweight shall always be turned to-
wards the crank pin side (against the connecting rod).

CYL # 1 2

Note : stepped or chamfered side of the counterweight

Fig. 11-03

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.1.3 Crankshaft counterweights assembly

Fig. 11-04

11.1.3.1 Preparation
· The crankshaft web surfaces will be cleaned and
degreased carefully. Be sure that no lube oil remains in
the web tappings.
· The screws will be wipped with a clean rag mainly under
head and on the threads.
· The counterweights surfaces will be cleaned. The ones in
contact with the crankshaft will be carefully degreased.

11.1.3.2 Counterweight assembly

· The counterweights are placed with the help of locating
pins.
· The threads and the under cap surfaces are greased with
Molykote G-Rapid plus paste, ref. 182281300.

Note : In case this Molykote is not available, another one can be used, the
Molykote BR2 plus, ref. MGE000075.

· The screws are turned manually until contact under

head.
· The screws are tightened according to the sketches
below following the order in the rounds.

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 11. Crankshaft, Connecting Rod, Piston W220

11.1.3.3 Sketches of counterweight screw tightening

a) Assembly with counterweight bewelled screws., except the
tungstene counterweight on 18V engines (crankpin N°1, view
from flywheel side)

Fig. 11-05
b) Assembly with full counterweight screws. , except the tungstene
counterweight on 18V engines (crankpin N°1, view from flywheel
side).

Fig. 11-06

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 W220 Crankshaft, Connecting Rod, Piston 11.

c) Assembly with bewelled screws of the tungstene counterweight

only on 18V engines (crankpin N°1, view from flywheel side).

Fig. 11-07

d) Assembly with full screws of the tungstene counterweights only on

18V engines (crankpin N° 1, view from flywheel side).

Fig. 11-08

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 11. Crankshaft, Connecting Rod, Piston W220

11.1.4 Assembly instructions of the camshaft driving

gear on the crankshaft
3 1

1. Screw1. Vis
2. Crankshaft
2. Vilebrequin 2
3. Pinion
3. Pignon

Fig. 11-10

1 Check the contact surfaces of the gear wheel and the crank-
shaft to be free from burrs etc... which can make assembly more
difficult.
2 Clean the contact surfaces of both parts carefully with a dry
solvent (Loctite Super Clean 7063, reference 56003259).
3 Mount the gear wheel on the shaft so that the recess side is in
contact against the corresponding flange of the shaft.
The angular location has been made so that the gearwheel distinct
mark is coincident with the crankshaft distinction mark (Web).
4 Assembly the gearwheel (item 3) on the crankshaft (item 2)
with 15 screws (item 1).
5 Tighten to the right torque (see Chapter 07).

11.1.5 Instructions for camshaft driving gear removal

Proceed in reverse of the assembly instruction (see section 11.1.4)

11.1.6 Mounting of the crankshaft

See Chapter10 : Main bearing assembling during overhaul.

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.1.7 Measurement of thrust bearing axial clearance

1 Lubricate the bearings by running the pre-lubricating pump
for a few minutes.
2 Apply the measuring gauge between engine block and the
flywheel.
3 Move the flywheel using a suitable lever in either direction un-
til contact is established with the thrust bearing.
4 Set the measuring gauge to zero.
5 Move the crankshaft in the opposite direction and read the
axial clearance from the measuring gauge (reference values
are in Chapter 06).

Note : This operation needs to be done before engine coupling.

11.1.8 Deflection checking

11.1.8.1 General
Crankshaft deflections should always be taken on an engine at am-
bient temperature.
The deflection checking needs to be done after an operation on the
engine caps or operation on the main caps tightening. This opera-
tion allows to validate the good assembly of the engine caps.
1 Turn crank of first cylinder near BDC (bottom dead centre)
and attach the crankshaft dial indicator SPC8480002 to the cen-
ter marks in the two crank webs.
2 Set indicator at zero.
3 Read and record the deflections at measuring points A, B,C
and E (see Fig 11-11) when turning the crankshaft in the normal
running direction.

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 11. Crankshaft, Connecting Rod, Piston W220

A side B side

Flywheel end side

Fig. 11-11

4 Use the sheet given Chapter 06, WMR005 to record the de-
flection values and to follow the misalignment limits.
5 If the values are out of limit, it is necessary to re-tighten the
caps in accordance with Chapter 10.

11.1.9 Alignment checking

Crankshaft alignment should always be taken on an engine at
ambient temperature.

Note : After each engine reconnection, it is necessary to check the align-

ment between engine and alternator other equipment. By doing this
operation, we avoid to have over bending stress on the crankshaft.

For the procedure, see Chapter 09.

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.2 Pumps driven gear (free end side)

11.2.1 General description.
The pump driven gear (item 2) is fitted on the crankshaft (item 5) after
the damper (item1)
An intermediate spacer (item4) is fitted between the damper and
the gear.
The gear is fitted on the intermediate spacer by 8 screws and wash-
ers (item 3).
The purpose of the gear is to drive the lube oil pump gear and the
water pump gear .
1
1

2 2
5

1. Damper
2. Pump driving gear 3
3. Screws + washers 3
4. Intermediate spacer
5. Crankshaft
6. Pin
4
7. Oil channel
7

5 4

Fig. 11-12

11.2.2 Fitting of the pump driving gear for 12V engines

See section 11.3.2.1.

11.2.3 Fitting of the pump driving gear for 18V engines

See section 11.3.2.2.

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 11. Crankshaft, Connecting Rod, Piston W220

11.3 Damper
11.3.1 General description
The damper is designed in order to reduce torsional vibration in the
crankshaft. 12V and 18V dampers are different.

Caution : The damper must be not painted.

11.3.2 Assembly configuration

The damper is bolted on the crankshaft, inside the free end cover.

11.3.2.1 12V engines

The 12V damper is made of viscous type.
They absorb torsional vibration energy by viscous friction in the liquid
layers between housing and the damper flywheel. The lateral forces
caused by the relative velocities result in damping vibration thereby
converting the vibration energy into thermal energy.
1

1. Outer cover screw

2. Silicon oil reservoir 4
3. Damper housing
4. Connecting bolts holes 5
5. Inner cover screws
6. PTFE bearing strip (radial bearing) 6
7. PTFE bearing knobs (axial bearing)
8. Inertia mass
9. Damper cover 7
10. Two removable filling plugs
8

10

Fig. 11-13

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 W220 Crankshaft, Connecting Rod, Piston 11.

1. Damper
2. Pump driving gear
3. Screws + washers
4. Intermediate spacer
5. Crankshaft
6. Tube for silicone sample

5 6

Fig. 11-14

11.3.2.2 18V engines

The 18V damper uses engine lube oil to absorb torsion vibrations.

2
6

1. Damper
2. Pump driving gear
3. Screws + washers 3
4. Intermediate spacer
5. Pin
6. Crankshaft
7. Oil channel

Fig. 11-15

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 11. Crankshaft, Connecting Rod, Piston W220

11.3.3 Damper mounting

11.3.3.1 Preparation
1 Install diametrically opposed and horizontally on the crank-
shaft the special guiding gudgeons SPC8360020 or similar (see
Fig 11-16).
2 Clean the crankshaft and the damper surface. Remove
burrs if necessary with oil stone.
3 Lift the damper with a special tool SPC8360006 and put it in
place by using the two special guiding gudgeons.
4 Push the damper against the crankshaft flange by tightening
the two dedicated screws (item 2) (see Fig.11-16).

1. Guiding gudgeons
2. Screws to push the Damper 1 1

against the cranshaft flange

Fig. 11-16

Additional operation for 18V engines

· Fit each pin with a HM 12x100 screw and with a steel wire
(see Fig.11-17).
1 2 3
1. Steel wire
2. Screw
3. Pin

Fig. 11-17

· Smear the pin hole with Molykote GN Plus type (or G rapid
plus) ref. 182280800.
· Cool the pins inside a Nitrogen liquid bath.
· Fit the pins and remove the steel wires.
· Remove the two screws (item 2).
5 Mount the intermediate spacer with the help of two guiding
gudgeons.
6 Remove the two guiding gudgeons.

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 W220 Crankshaft, Connecting Rod, Piston 11.

Additional operation for 18V engines

· Lubricate with clean engine lube-oil screw threads.
· Mount and tighten the 8 screws with their washers.
· Use a criss-cross pattern and in 3 steps tighten the 8
screws :
– First tightening torque : see Chapter 07
– Second tightening torque : See Chapter 07
– Final tightening torque : see Chapter 07.

7 1
Tightening sequence

3 6

5 4

2 8

Fig. 11-18

7 Fit the gear.

8 Grease with clean engine lube oil the screws thread and fit
them with washers.
9 Remove the two guiding gudgeons, for the 12V.
10 Fit the two last screws.

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 11. Crankshaft, Connecting Rod, Piston W220

11 Use a criss-cross pattern and in 3 steps, tighten the 8 screws:

· First tightening torque : see Chapter 07
· Second tightening torque : see Chapter 07
· Final tightening torque : see Chapter 07.

1
5 12
Tightening sequence
9 8
12V
13 4
A A

( 15) ( 16)

3 14

7 10

11 6
2

Fig. 11-19

7 1

3 6 Tightening sequence
18V

5 4

2 8

Fig. 11-20

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.3.4 Damper dismantling

1 Remove the pumps.
2 Remove the free end cover in case of PhC, Ph2 (see Chap-
ter 10).
3 Remove the front plate of the free end cover in case PhD
(see Chapter 10).
11.3.4.1 12V Damper removal
1 Remove two horizontal screws (item1) with washers (item 2),
diametrically opposed.
2 Mount two special guiding gudgeons SPC8360020 at 180°,
at the screws place.
View from the top

5
2 1

1. Screw
2. Washer
3. Driving pump pinion
4. Intermediate spacer
5. Damper

4 3

Fig. 11-21

3 Remove the all other screws (item 1).

4 Remove successively the driving pumps pinion (item 3), then
the intermediate spacer (item 4).
5 Fix the lifting tool SPC8360006 (item 6, Fig. 11-23) on the
damper (item 5) or Fig 11-25 for PhD engine.

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 11. Crankshaft, Connecting Rod, Piston W220

11.3.4.2 18V Damper removal

1 Loosen all the screws (item1).
2 Remove all the screws (item1) except one.
3 Maintain the driving pumps pinion (item 3),and remove the
last one screw (item 1).
4 Remove the pinion by hands.

5 2 6

1. Screw 1. Vis
2. Washer 2. Rondelle
3. Driving pump
3. Pignon pinion 2
4. Spacer 4. Entretoise
5. Damper5. Amortisseur
6. Vis
6. Screw 7. Goupille
7. Pin

7 4 3 1

Fig. 11-22

5 Remove the screws (item 6) and the spacer (item 4).

6 Mount two special guiding gudgeons SPC 8360020 at 180°,
at the screws place.
7 Remove the eight shearing pins (item 7) with the hydraulic
jack SPC 8370004 and the pin extractor SPC 8370008.
8 Remove the damper : fix the lifting tool SPC 8360006 (item
6, Fig. 11-23) on the damper (item 5, fig.11-23) ; for PhD engine,
see Fig. 11-25.

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.3.4.3 Lifting tools

· 12V, except PhD engines

5. Damper
6. Lifting tool
7. Screw

Fig. 11-23

· 18V, except PhD engines

5.Damper
8. Lifting tool
9. Screw
10. Screw

Fig. 11-24

Note : The screw (item 9) is used as a pin, and can be easily removed when
the damper is not lifted.

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 11. Crankshaft, Connecting Rod, Piston W220

· 12V & 18V Phase D engines

11. Screw
12. Lifiting tool
13. Damper

Fig. 11-25

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.3.5 Maintenance
11.3.5.1 18V Damper
The damper must be sent to your Wärtsilä network representative to
be overhauled.

11.3.5.2 12V Damper

The maintenance must be performed in accordance with the
maintenance schedule (see Chapter 04). Following sample analy-
sis, send the damper to your Wärtsilä network representative.

Note : In case of silicon oil leakages, unexpected noise or other symptoms

where the damper is the cause, please inform your Wärtsilä network
representative.

11.3.5.3 Visual inspection

A visual inspection must be done to check the absence of shock
mark or silicon oil leakage.

11.3.5.4 Procedure for taking samples of silicone fluid for

dampers, (SPC 1100009)
Sample container

1. Plug
2. Plug
3. Sample container

Fig. 11-26

O-rings for sample container

4. O-rings

Fig. 11-27

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 11. Crankshaft, Connecting Rod, Piston W220

11.3.5.5 Silicones oil analysis

Fluid samples may be taken from dampers equipped with
removable filling plugs. Two of these are positioned diametrically op-
posite each other in the damper cover.
The damper can remain on the engine during this procedure. In
other cases, the damper must stand in the normal vertical position
during sampling.
It is recommended that the damper be rotated until the two plugs
are approximately horizontal and that the damper remains in this
position for a minimum period of few hours before the sampling pro-
cedure begins. In general, two sizes of thread are used for the filling
holes therefore the sample containers are threaded differently at
each end.

1 Assuming the thread size in the damper is known, prepare

sample container (item 3) by removing the plug (item 1) from the
end to be inserted in the damper (Fig. 11-26).

2 Remove on the damper the filling plug, keeping container

ready for immediate insertion.

3 Screw sampler container (item 3) into filling hole.

4 Remove the second plug (item 2).

5 Allow fluid to reach the open end of the container. This

may occur within seconds or over an hour depending on fluid
conditions and other factors. To speed up process, crank the
engine around 180°.

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 W220 Crankshaft, Connecting Rod, Piston 11.

6 Replace the plug (item 2) immediately after fluid flows

from the open end of the container.

7 Keep filling new brand plug (item 10, Fig. 11-13) with new
O-ring (item 4, Fig. 11-27) ready for immediate insertion af-
ter unscrewing the container from the filling hole.

8 Fit immediately the plug

· Tighten to :
– 15 Nm (type M10 x 1) or
– 45 Nm (type M16 x 1,5)

9 Fit the plug (item 1) to container and ensure both plugs are
fully screwed on but not over tightened (do not use spanners).

10 Send the sample to Wärtsilä France, with following informa-

tion :
· Engine number
· Engine running hours
· Damper running hours
· Damper markings.
According to the maintenance schedule, an analysis must be done
do check if :
· The silicon fluid is heavily contaminated.
· The silicon fluid gets a strong smell.
· The viscosity of the silicon oil is higher than 25% of the
original value.
In those last cases, the damper is to be replaced by a new one.

Note : A copy of the results should be sent to Technical Service Wärtsilä

France. Indeed, an engine expert will be available to give you the
best advices regarding your test results.

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 11. Crankshaft, Connecting Rod, Piston W220

11.4 Flywheel
Data and dimensions : 11.4.1 General description
Material : Steel plate
Weight : about 595 kg
The steel flywheel (item 2) is fitted to the crankshaft by means of
screws. The correct position of the flywheel is determined by a distinct
mark on the flywheel, which should meet the mark on the crankshaft.
A gear rim is fitted to the flywheel. A crank angle scale is stamped on
flywheel. The scale starts from 0 to 360° crank angle.
The flywheel position indicator (item 1) is marked with a scale for
reading of the engine crank angles, at an accurancy of 1° crank an-
gle, on the graduation of the flywheel.
The flywheels have been marked in two ways, counterclockwise and
clockwise.
2 2

TATING ENGINE
A 1 1

CLOCKWISE ROTATING ENGINE

340 0
CYL
5 5 1, 6
4 4
3 3 3 3
COUNTER CLOCKWISE RO

2 2
1 1
0 0
1 1
2 350 2 350
3 3
4 4
5 5

Cyl 1 TDC Cyl 1 TDC

0 340
CYL
1, 6
VIEW A TDC VIEW A TDC

1. Calibrated plate
Flywheel marked CCW Flywheel marked CW
2. Flywheel
Counter clockwise Clockwise
3. Injection timing mark

Fig. 11-28

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.4.2 Flywheel assembly

4 5 6
2100

2000 k g

30°

1. Lifting tool 3 1

2. Sling Ø 12 length 1.2 m (1000kg)

3. Shackle (2000 kg)
4. Conneting link position if lifting tool only
5. Connecting link position if lifting tool + flywheel A
6. Connecting link position if lifting tool + flywheel housing

Fig. 11-29

11.4.2.1 Preparation
1 Determine the A1 piston Top Dead Centre in accordance
with Chap. 06. Check the alignment between the flywheel mark
A1 and the right A1 piston Top Dead Centre. Move the flywheel ar-
row if necessary.
2 Fit the flywheel lifting tool, SPC8360019 on the flywheel ac-
cording to fig.11-29. The angle between mark (A) and vertical
axis must be 30°.
For this, the holes in the lifting tool and the flywheel have to be
carefully chosen.
3 Clean the crankshaft surface, the flywheel surface in con-
tact, the pins (18V engines) and the screws with universal solvent,
reference MGE000062.
11.4.2.2 Mounting of the flywheel
1 Install diametrically opposed and horizontally on the crank-
shaft the two special guiding gudgeons SPC 8360020 (item 4).
3
4

1
1. Crankshaft
2. Flywheel A
3. Flywheel screw 4
4. Guiding gudgeons
A. The flywheel and the crankshaft marks
should merge 2

3
30°

Fig. 11-30

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 11. Crankshaft, Connecting Rod, Piston W220

2 Make sure that the mark on the flywheel and on the crank-
shaft are aligned (item A).
3 Make sure that the connecting link is in position for the lifting
tool and the flywheel, see fig. 11-29, item 6.
4 Push the flywheel against the crankshaft and tighten two
screws (item 3) with their washer in diametrically and vertically op-
posed positions :
· Tightening torque : 25 Nm
1

2
1. Flywheel
2. Screw 3
3. Washer

Fig. 11-31

5 Slacken the slings.

6 Move the sling to lift the lifting tool (item 4, fig.11-29). Re-
move the lifting tool.

Note : If the flywheel is fitted with pins, please read following section
11.4.2.3.
If the flywheel is fitted without pins, please read section 11.4.2.4.

11.4.2.3 Fitting of the pins (case of 18V)

1 2 3

1.Steel wire
2.Screw
3. Pin
Fig. 11-32

1 Fit each pin with a HM 12x100 screw and with a steel wire.
2 Smear the pin hole with Molykote GN Plus type spray, refer-
ence 182280700.
3 Cool the pins inside a Nitrogen liquid bath.
4 Fit the pins and remove the steel wires and the screws.
5 Remove the two guiding gudgeons.

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.4.2.4 Flywheel screw tightening

1 Put in place, without oil, the flywheel screws :
· 11 screws for 18V engines
· 16 screws for 12V engines.
Tightening sequence for 12V engines

1
9 13

5 7

15 11

3 4

12 16

8 6

14 10
2

Fig. 11-33

Tightening sequence for 18V engines

1 9

7 6

3 4

11 8

2
10

Fig. 11-34

2 Use a criss-cross pattern in three steps :

· First tightening torque : see Chapter 07
· Second tightening torque : see Chapter 07
· Final tightening torque : see Chapter 07.

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 11. Crankshaft, Connecting Rod, Piston W220

11.5 Turning device

11.5.1 General
The engine is equipped with a turning device (item1) to rotate the
crankshaft by hand.
It is located on engine flywheel end B side (see fig 11-30).

Fig. 11-35

11.5.2 How to turn the crankshaft

1 Pull the index (item 5) and engage the turning device gear
wheel (item 3) on the flywheel (see Fig. 11-36).
Mount the 3/4” ratchet SPC 8220001 on the gear wheel.
2 Turn the crankshaft counter clockwise.
3 Pull the index (item 5, fig 11-36) and disengage the turning
device gear wheel.
4 Remove the ratchet.

Note : The engine can’t be started while the turning gear is engaged.

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.5.3 Turning gear maintenance:

Note : See the maintenance schedule in chapter 04 for lubrication
periodicity.

1 Grease the turning gearwheel axis with Molykote BR2 Plus

ref. MGE 000075, using a manual piston grease pump DIN 1284.
2 Check the turning device teeth (item 3).
3 Remove all the burrs.
4 Check the start blocking (when the turning device is en-
gaged, see Chapter 03).

2. Screw
3.Gear wheel
4. Flywheel ring gear
5. Index

Fig. 11-36

11.5.4 Dismantling and refitting

Note : Check the good alignment of the turning device gear wheel (item 3)
and the starting ring gear (item 4).

If it is not the case :

1 Loosen the two screws (item 2).
2 Position correctly the turning device.
3 Maintain the turning device and tighten the screws to the
torque (see Chapter 07 for the conventional torques).

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 11. Crankshaft, Connecting Rod, Piston W220

11.6 Connecting rod

Data and dimensions : 11.6.1 General description
Material : Special steel,
Weight : 29.6 KG 11.6.1.1 Connecting rod
Bearing type : Tri-metal bearing
Drop forged
The connecting rod is of the drop forged type, totally machined.The
big end is of “stepped split line” design and precision serrated at the
mating surfaces. This design offers the maximum crank pin diameter
while making it possible to pull the connecting rod through the cylin-
der liner.
The big end bearing shells are, for correct assembling, axial guided
by tabs.
The two connecting rod nuts are hydraulically tightened.
The small end-bearing bush is stepped to give a larger bearing sur-
face on the more loaded lower side. It is lubricated via bores in the
connecting rod.
The piston pin is of the full floating design, secured axially with retainer
rings. It is lubricated via the gallery in the piston crown.

1. Small end bore

2. Big end bore
3. Upper stud
4. Lower stud
5. Upper nut
6. Lower nut
7. Cap
8. Connecting rod

Fig. 11-37

With the new square profile conrods, the oil channel has been sup-
pressed on the lower bearing shell. Only for this conrod type, the half
bearing shells are symetrical and can be mounted in the big end
bore or in the caps.

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11.6.2 Connecting rod configuration

A bank B bank

Fig. 11-38

The conrod assembly is asymetric. The B side conrod assembly is

facing the A side, as shown on Fig. 11-38.

11.6.3 Conrod big end bearing shells definition

Asymetric big end bearing Symetric big end bearing

shells (with groove) shells (without groove)

First conrod generation New square profil conrod

Fig. 11-39

· The first generation of conrod is equipped with asymetric

big end bearing shell (see figure above).
The lower big end bearing is fitted with a groove to drive
the lube oil from the crankshaft to the piston axis.

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 11. Crankshaft, Connecting Rod, Piston W220

11.7 Piston
11.7.1 General description of the piston
The piston is made of composite type with an aluminium skirt and a
forged steel crown (see also Chapter 01).
The piston skirt has a phosphate graphite overlay. Lubricating oil
cools the piston crown.
The lubricating oil is provided via oil jets fitted in the engine block.
A channel in the skirt allows oil to reach the gallery in the crown. Oil
drains back from the crown to the piston pin and the conrod small
end.
The pistons are provided with Wärtsilä patented skirt lubrication. The
piston ring set consists of two compression rings and one scraper
ring.
The two compression rings are provided with a special wear resistant
coating. The oil control ring is a spring-loaded, chrome-plated oil
scraper ring. The side to be upwards of the compression rings is al-
ways marked "TOP".

11.7.2 Piston rings assembly

Note 1: If the piston rings have to be replaced during a maintenance opera-
tion, the liner must be changed too.

Note 2 : If the piton has to be replaced during a maintenance operation, the

piston rings and the liner must be changed too.

Gap (top compression ring #1) Gap (scrapper ring #3)

1. (6 mm thick ring)

2. (5 mm thick ring)
Gap (second compression ring #2)
3. Scrapper ring

Fig. 11-40

1 Mount the 6 mm thick scraper ring (item 3) in the lower

groove by using the plier SPC 8430003.

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 W220 Crankshaft, Connecting Rod, Piston 11.

2 Mount the 5mm thick piston ring (item 2) in the middle

groove with "TOP" mark on the top by using the pliers.
3 Mount the 6mm thick piston ring (item 1) in the upper groove
with "TOP" mark on the top by using the pliers.

Note 1 : Never open the rings more than necessary because the treatment
surface could be flaked off and micro cracks could be generated.

Note 2 : Always put the "TOP" marks on the top side. Indeed, the engine lube
oil consumption depends on the good piston ring mounting.

4 The rings should be placed with their gaps located 120°

from previous one (see fig 11-40).
5 Check that the piston rings are free in their grooves.

11.7.3 Assembling and tightening of the piston crown

1 Lubricate the thread and seat of the screw head with
Molykote GN Plus ref. MGE000071.
2 Tigthten the four screws in a crosswise pattern (torque 35
Nm).
3 Loosen the four screws again.
4 Retighten the four screws in a crosswise pattern to 15 Nm.
5 Finish tightening at 90° angle.

11.7.4 Assembling of piston on connecting rod

1 Take one conrod from the considered cylinder (you can find
this number above the big end bore) and put it in a proper sup-
port or special table (big end bore in front of you). If the conrod is
new, engrave the cylinder number on it.
2 Take the piston with the same cylinder number.
3 If the piston is new, engrave the cylinder number on the pis-
ton crown, where the piston will be mounted.
4 Mount one retainer ring in the piston pin bore.
5 Put the piston near the conrod. It’s better to warm the piston
to 30°C. At low temperatures, the gudgeon pin may stick but can
be easily fitted by heating the piston at about 30°C in oil for
example.
6 Lubricate the gudgeon pin.
7 Put the gudgeon through the piston and connecting rod
small end bore.

Caution : For a better tracability, pay attention that the mark engraved on the
gudgeon axle is located flywheel end, when fitted on the engine.

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 11. Crankshaft, Connecting Rod, Piston W220

Note 1 : Make sure that the piston is fitted in good position.

Note 2 : The piston notch must be in front of the oil jet, i.e. the oil jet notch
must be inside the V-engine, see fig. 11-41.

Oil jet notch

A bank B bank

Fig. 11-41

Note 3 : On B bank, the conrod must be mounted in order to fit the conrod
cap on A bank.

8 Mount the second retainer ring in the piston pin bore.

Note : - Control that the retainer ring is perfectly fitted in the piston groove.
- Never compress the retaining ring more than necessary, to fit it into
the groove. If the ring is loosen in its groove after mounting, you have
to replace it.
- Check the clearance between the conrod and the gudgeon pin.

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.7.5 Dismantling piston from connecting rod

11.7.5.1 Piston gudgeon pin removal
1 Remove one retainer ring from the piston pin hole in the pis-
ton by using the retainer ring plier SPC 8430003.

Note : Never compress the retainer ring more than necessary to remove it
from the groove.

2 Drive out the gudgeon pin from the opposite side.

In low temperatures the gudgeon pin may stick but will be easily re-
moved after heating the piston to about 30°C.
3 Remove the piston rings by using the plier SPC 8430003.

Note : The use of other tools may damage the piston rings.

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 11. Crankshaft, Connecting Rod, Piston W220

11.8 Removing and dismantling of piston and conrod

Data and dimension : 11.8.1 Angular position of the crankshaft
Weight : 73 kg
11.8.1.1 Tightening and untightening of the conrod nuts
· On B side, the crankshaft must be positioned at 140° after
TDC of considered cylinder.

A side view

Fig. 11-42
· On A side, the crankshaft must be positioned at 30° after
TDC of considered cylinder.
30°

A side view

Fig. 11-43

Note : It is easier to start the connecting rod dismantling from A side.

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.8.1.2 Conrod removal and assembly

Turn the crankshaft counter clockwise in position for conrod removal :

· On B side : it has to be positioned 65° after TDC of the con-

sidered cylinder or 146 mm between the top of the piston
and the top surface of the piston ring belt.

B bank

1. Piston head
2. Piston ring belt
SPC 8430002

Fig. 11-44
· On A side: it has to be positioned 30° after TDC of the con-
sidered cylinder.

A side view

Fig. 11-45

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 11. Crankshaft, Connecting Rod, Piston W220

11.8.2 Conrod jack assembly

Note : The conrod jacks are fitted with one jack where the connections are
perpendicular (item A), the other one have straight connections
(item B).

Fig. 11-46

11.8.2.1 B side jacks assembly

1 Mount the jacks according to the following figure.

Fig. 11-47

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 W220 Crankshaft, Connecting Rod, Piston 11.

11.8.2.2 A side jacks assembly

1 Mount the jacks according to the following figure.

Fig. 11-48

11.8.3 Conrod removal

A bank B bank

Fig. 11-49

1 Remove the cylinder (see Chapter 12). Scrape off carbon

deposits around the upper part of the cylinder liner.
2 Engage the engine turning device and crank the engine to
lining the top of the considered piston with approximately 50
mm below the anti-polishing ring.

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 11. Crankshaft, Connecting Rod, Piston W220

3 Cover the top of the piston with rag that is firmly held in
place. To do that, use an old piston ring covered with the rag.
Compress the ring and the rag in the cylinder liner, in order to col-
lect the material scrapped off.
4 Pulverise de-rusting oil (ref. PAAG058295) or equivalent on
the top joint plan between liner and anti-polishing ring.
5 Let penetrate the de-rusting oil for at least 20 mn.
6 Fit the anti-polishing ring extracting tool SPC 8360035 on
the three anti-polishing grooves.

Note : The three tool strips have to be correctly placed on the anti-polishing
grooves.

7 Extract the ring while acting vigorously on the mass striking

from the tool.
8 Dissociate the tool of the anti-polishing ring.
9 Clean carefully the anti-polishing housing on the liner.
10 Remove carefully the old piston ring and rag with the car-
bon material scrapped off.
11 Turn the crankshaft counterclockwise, in position for tooling
jacks position (see section 11.8.1.1).
12 Use the hydraulic tools, to unscrew the nuts (see Chapter
07) :
· SPC 8610012 and SPC 8610027 for M30 conrods
· SPC 8610034 and SPC 8610035 for M27 conrods.

Warning : If the hydraulic pressure used to unscrew the nuts is more than maxi-
mum value authorized (see Chapter 07), it’s absolutely necessary to
replace the nuts and the studs.

13 Remove the lower nut, unscrew lightly the upper nut.

14 Remove the lower stud by using the stud extracting tool SPC
8030005.

Note : The locking screw of the tool has left-hand threads.

15 Remove the big end bearing cap together with the bear-
ing shell out of the engine.
16 Remove the upper stud by using the stud extracting tool.
Turn the crankshaft counterclockwise, in position for conrod removal,
see section 11.8.1.2
17 Mount the conrod lever on the crankshaft door concerned:
· Fix the lever tool :
- SPC 8360039 on A side
- SPC 8360042 on B side
on the lower crankcase door studs (see fig.11-51).

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 W220 Crankshaft, Connecting Rod, Piston 11.

· In addition, on B side, fix the conrod holder (item 3) on the

lower conrod serration. By using the screw (item 1) , lock it
with the lever (item 2).

1. Screw
2. Lever
3. Conrod holder

Fig. 11-50

18 Secure the conrod and piston with the lever.

A bank B bank

2. Lever
3. Protection tool
4. Piston lifting tool

Fig. 11-51

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 11. Crankshaft, Connecting Rod, Piston W220

A bank B bank

2. Lever
3. Protection tool

Fig. 11-52

19 Fit the protection tool on the conrod upper serration SPC

8360049 (item3).
20 With the lever lift the piston together with the connecting
rod out of the engine until the first piston ring is above the liner col-
lar.

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 W220 Crankshaft, Connecting Rod, Piston 11.

Note : Push or pull enough the lever (item 2, fig. 11-52) to avoid contact be-
tween the crank pin and the conrod teeth.

21 Maintain the piston and the connecting rod in position, and

fix the piston lifting device (item 1) SPC 8320002 around the pis-
ton crown, see fig.11-53.

Fig. 11-53

22 Lift the piston together with the connecting rod out of the en-
gine. When lifting the piston, take care not to damage or mark
the crank pin or the cylinder liner.
23 Put the piston and the conrod on a dedicated table.
24 Cover crank pin oil holes with paper and adhesive tape.
25 Cover piston oil jet with paper or adhesive tape.

Warning : Some tape glue can corroded the crankpin surfaces.

26 Put some circular carboard on the cylinder top (average

diameter : 290 mm).

11.8.4 Conrod assembly

11.8.4.1 Assembly procedure
1 Put the conrod on a dedicated table.
2 Assemble the piston on the conrod, see section 11.7.4
3 Check that the serial numbers of the connecting rod and the
cap are the same.
4 Check the cleanliness of the connecting rod, the cap, the
studs and the nuts.
5 Remove the upper and lower studs, if necessary use the tool
SPC 8030005.

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 11. Crankshaft, Connecting Rod, Piston W220

6 Clean the bearings and the conrod big end bore with an uni-
versal solvent, ref. MGE 000062 or equivalent and with a lean
free rag.
7 Check the cleanliness of the bearing half shells.
8 Apply slightly engine lube oil to the back of the bearing
shells. Wipe away excess of oil with a clean lean rag to obtain
only a very thin oil film (see fig. 11-53, item C).

A (Molykote GN Plus)

B (Vaseline)

C (Engine lube oil)

Fig. 11-54

9 Mount the upper big end bearing onto the connecting rod.

Caution : To install the bearing half-shell, make sure that the tab (item1) is in the
slot (item 2, fig. 11-56), and that the clearance between
half-bearIng shell is the same on both sides, see fig. 11-55.

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 W220 Crankshaft, Connecting Rod, Piston 11.

Fig. 11-55

2
Conrod

1
Bearing shell

Fig. 11-56- F view

10 Mount the lower big end bearing onto the cap.

11 Grease the two internal bearings with vaseline paste,
reference MGE000062 (see fig. 11-54).
12 Lubricate the piston rings and the skirt with a clean engine
oil.
13 Place the piston ring belt SPC 8430002 (item 1) around the
piston crown (item 2, fig. 11-57).

Operator side view

Fig. 11-57

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 11. Crankshaft, Connecting Rod, Piston W220

14 Check the cleanliness of the cylinder liner, lubricate with

clean engine lube oil.
15 Take off the protection of the crankshaft and clean the
crankpin with an universal solvent (item MGE000062) or equiva-
lent and a clean nonfluffy rag.
16 Check the cleanliness of the teeth and fit the protection
tools on the upper conrod, (item1, fig. 11-58) SPC 8360049, and
lower serration (item 2), SPC 8360048, only on A side in order to
protect the liner and the crankpin.

1. A & B sides
2. B side only

Fig. 11-58

17 Fit on the piston the lifting tool SPC 8320002.

Important : To make it easier, for each crankpin, the B side conrod should be fit-
ted before A side conrod.

18 Turn the crankshaft counterclockwise in position for conrod

assembly, see section 11.8.1.2.

Note : Check that the number engraved on the piston and conrod is the
same that the number of the cylinder to assembly.

19 Lift the conrod assembly upper the considered cylinder.

20 Lower gently the piston and conrod into the cylinder liner.
Make sure that the conrod does not hit the cylinder liner and the
oil jet.
21 Continue to lower the piston until the piston ring belt is in
contact with the cylinder liner.
22 Maintain with the lever the piston and the conrod assembly
(see fig. 11-51 and fig. 11-52)
23 Remove the piston ring belt SPC8430002 :
· on B side, fix the conrod holder (item 3, fig.11-50) and the
the lever SPC 8360042.
· on A side, directly with the lever SPC 8360039.
24 Put in place the piston ring with the plier SPC8430003 in ac-
cordance with section 11.7.2. Take a special attention to the an-
gular position of the piston ring gap (see fig.11-40).

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 W220 Crankshaft, Connecting Rod, Piston 11.

25 Continue to lower the piston assembly.

26 Fit the conrod on the crank pin through the inspection door.

Note : Push or pull the lever enough (item 2, fig.11-51 & 11-52) to avoid
contact between the crank pin and the conrod teeth.

27 Lower the assembly until the conrod rests on the cranpin.

Make sure again, that the spacing between half bearing shell is the
same on both sides (see fig 11-55). In other case, use the fitting tool,
SPC 8360040 to move it.
28 Clean the upper edge of the lower bearing (contact sur-
face between both half bearing shells) and coat this edge only
with Molykote GN Plus, ref. MGE000071 (see fig. 11-54, item A).

Caution : Do not put Molykote GN Plus on the bearing shell crankshaft surface
contact.

29 Check by hand, the alignment of cap/bearing,

conrod/bearing and cap/conrod and that no step can be de-
tected between the parts.
30 Check that the conrod and the cap have the same serial
number.
31 Clean the contact surface between the nuts and the cap.
32 Check that there is no impact on the stud and nut threads.

Important : If the conrod is not good inserted in the crankshaft crankpin, check
the crankshaft position, adjust it if necessary.

33 Put by hand the upper stud, and put the conrod cap in
place, against the conrod.
34 Check that the bearing shell is always correctly located.
35 Tighten by hand the upper nut with the jack rod, SPC
8610026.
36 Fit the lower stud and tighten it with the stud tightening tool
SPC 8030005 (see Chapter 07).
37 Tighten the lower nut by hand, by keeping contact between
the cap and the conrod.
38 Turn the crankshaft counterclockwise, in position for
tooling, see section 11.8.1.1.
39 Remove the upper nut.
40 Tighten the upper stud with the stud tightening tool, SPC
8030005, see Chapter 07.
41 Fit and tighten until contact with the upper nut, by keeping
contact between the cap and the conrod.
42 Check alignment of the conrod and the conrod cap.

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 11. Crankshaft, Connecting Rod, Piston W220

43 Check by hand that the conrod, the cap and the bearing
are aligned.
44 Tighten by hand the nuts on the cap.
45 Write a mark on the nut and the stud, see Chapter 07, sec-
tion 7.4.6.1.
46 For conrod tightening, see procedure and hydraulic pres-
sure, Chapter 07.

Important : Before crankshaft rotation, each conrod cap must be fitted and
tightened on the conrod with hydraulic jacks.

11.8.4.2 Final checking

1 Check that the X angle between R1 on the nut and R2 on the
stud is :
· In case of a M30 conrod : 90°<X<120° (sup. than 2 holes
in total)
· In case of a M27 conrod : 150°<X<210° (sup. than 3,5
holes in total)
R2

X 2

3
R1
4

Fig. 11-59

Note : Otherwise, start the tightening procedure again.

2 Mark an indelebile sign on the engine block to certify that the

control procedure has been made for each cylinder.
3 Check that there is a certain axial clearance on the conrod
which have been tightened.

Note : In case of doubt, do not hesitate to restart this procedure.

4 Fit a new anti-polishing ring to the cylinder liner.

5 Refit the cylinder head.

11.8.5 Engine starting procedure

See Chapter 03, section 3.3.1.

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