SERVICE
LETTER
Diesel Service, Vasa Engines Huoltokirje Service brev
Engine Section Engine type Ref. Date Issue Document No. Page
11 Piston 32 WDFI-S 23.06.1994 01 3211S025GB 1(6)
PISTON OVERHAUL OF VASA 32 ENGINES
AFTER 24 000 RUNNING HOURS AND LATER OVERHAULS
Most of the VASA 32 engines in operation are fitted with composite type pistons, made
by either Mahle or Kolbenschmidt (KS). For these pistons it is necessary to make more
extensive inspections after exceeding 24 000 running hours.
Following inspections and measurements are recommended:
1. Pistons
The piston assembly must be dismantled for inspection of mating surfaces between
piston skirt and piston crown and for inspection and cleaning of cooling oil spaces.
2. Piston crown
Visual inspection
The combustion space must be checked for corrosion and/or burning marks.
• If marks deeper than 2 mm are found the piston crown should be replaced.
Deposits in the cooling oil space thicker than 0.5 mm is an indication of contaminated
lubricating oil. Such extensive deposit layers can cause overheating of the piston crown.
Crack detection test
A crack detection test by use of liquid penetrant or, preferably, magnetic particle method
should be performed, comprising all surfaces.
• No cracks are allowed.
Measurements
Piston ring grooves to be measured regarding wear in accordance with normal practice.
Measurements of the distance between the inner and outer support surfaces must be
made, see piston type specific instructions below. Please note that a special measuring
tool has been designed for this measurement.
Reconditioning
Please contact Wärtsilä Diesel for reconditioning of piston crowns.
! No repair welding is allowed.
Distribution: For owners of Wärtsilä VASA 32 diesel engines.
Validity: Until further notice.
Wärtsilä Diesel Oy, P.O. Box 252, (Tarhaajantie 2), Telecop. +358 61 356 7355 Tel. +358 61 3270
Diesel Service, Vasa Engines, FIN-65101 Vaasa, Finland, Telex 74251 wva sf Service
Diesel Service, Vasa Engines Service Letter
Issue Document No. Page
01 3211S025GB 2(6)
3. Piston skirt
Visual inspection
The running surface of the skirt is coated with a graphite-phosphate layer. Consequently
cleaning with use of emery cloth or other abrasives is not allowed.
• Excessive wear marks and/or scoring/seizure marks on the running surface may
require replacement of the skirt.
Support surfaces
Assessment of wear of the support surfaces to be made by measurement of the distance
between the inner and outer support surfaces, see piston type specific instructions below
Crack detection test
Crack detection test of the entire piston skirt with use of liquid penetrant must be made.
Special attention must in this regard be given to the upper part of the piston skirt and to
the gudgeon pin bore with its supports to the upper part and to the circumferential part
of the skirt, see figure 1.
MAHLE KS
Figure 1.
• As piston skirts are cast pieces a crack detection test may also give indications for
surface “defects” which are normal in castings. Indications exceeding 5 mm in
length should be examined more in detail. If a crack is confirmed, the piston skirt
must be replaced with a new or reconditioned one.
Diesel Service, Vasa Engines Service Letter
Issue Document No. Page
01 3211S025GB 3(6)
4. Pistons made by KS
Measuring of piston crown and piston skirt
Measurements of the distance between the inner and outer support surfaces must be
made, see figure 2.
! Observe that on KS pistons wear of the support surfaces can also be measured
directly, by measuring the gap from outside with a feeler gauge, before
dismantling the piston, see figure 2.
• WEAR LIMIT: If the measurement results show that the TOTAL WEAR of the
support surfaces, i.e. of the piston crown and the piston skirt together, results in a
gap between the outer support surfaces which is 0.2 mm or more, one or both
parts (piston crown and/or piston skirt) must be replaced with new or reconditioned
ones.
36.97 -0.02
0
+0.02
Support surfaces
37 0
chromium plated
319.5
303
280
max. 0.2
Figure 2.
Diesel Service, Vasa Engines Service Letter
Issue Document No. Page
01 3211S025GB 4(6)
! Observe that on KS pistons the support surfaces in the piston crown are
chromium plated.
• If the chromium layer is worn off in areas exceeding 10 mm in length, the piston
crown has to be reconditioned.
Assembling of pistons (KS)
If the inspections are resulting in a conclusion that a piston can be reused the same pair
of crown and skirt must be assembled together again.
! It is not allowed to mix partly worn but reusable crowns and skirts!
When assembling a piston crown to a piston skirt following tightening procedure must be
followed (KS):
1. The screws in the crown to be mounted with 80 Nm tightening torque.
2. The threads and mating surface of the nut to be lubricated with engine oil.
3. Tighten nuts crosswise with 80 Nm torque.
4. Release the nuts.
5. Tighten nuts crosswise with 25 Nm torque.
6. Tighten the nuts further with an angle of 70°.
Check
When trying to further tighten the nuts with use of 70 Nm torque the nuts must not move.
If the free screw length when fitted in the crown exceeds 100.5 mm (free length: 121.5
mm) the screws must be replaced.
5. Pistons made by Mahle
Measuring of piston crown and piston skirt
Measurements of the distance between the inner and outer support surfaces must be
made, see figure 3.
• WEAR LIMIT: If the measurement results show that the TOTAL WEAR of the
support surfaces, i.e. of the piston crown and the piston skirt together, results in a
gap between the outer support surfaces which is 0.2 mm or more, one or both
parts (piston crown and/or piston skirt) must be replaced with new or reconditioned
ones.
! Observe that pistons made by Mahle there is a chromium plating on the support
surfaces on the piston skirt.
Diesel Service, Vasa Engines Service Letter
Issue Document No. Page
01 3211S025GB 5(6)
37 -0.02
0
+0.02
0
37
Support surfaces
chromium plated
Figure 3.
• If the chromium layer is worn off in areas exceeding 10 mm in length, the skirt
must be replaced and reconditioned.
Assembling of pistons (Mahle)
If the inspections are resulting in a conclusion that a piston can be reused the same pair
of crown and skirt must be assembled together again.
! It is not allowed to mix partly worn but reusable crowns and skirts!
Assembling instructions
When assembling a piston crown to a piston skirt following tightening procedure must be
followed:
1. The screws in the crown to be mounted with 10 Nm tightening torque.
2. The threads and mating surface of the nut to be lubricated with engine oil.
3. Tighten nuts crosswise with 70 Nm torque.
4. Release the nuts.
Diesel Service, Vasa Engines Service Letter
Issue Document No. Page
01 3211S025GB 6(6)
5. Tighten nuts crosswise with 20 Nm torque.
6. Tighten the nuts further with an angle 90°.
Check
When trying to further tighten the nuts with use of 70 Nm torque the nuts must not move.
If the free screw length when fitted in the crown exceeds 99.5 mm (free length: 119.5
mm) the screws must be replaced.
6. Connecting rod
Big end bearing
Regardless of the condition of the big end bearing it is recommended to replace bearing
shells at every piston overhaul.
Connecting rod screws
Replace the connecting rod screws with new ones every 24 000 running hours. Scrap
the used connecting rod screws when they have logged 24 000 running hours.
