Date: <Enter Date>

To: Subcommittee D02.B0 members

Tech Contact: Lyle Bowman, <lbowman@nanwobl.com>/415-479-3004

Work Item #: WK49666

Ballot Action: New test method (VH)

Rationale: Replacement for older test method (VG)

Standard Test Method for Evaluation of Automotive Engine Oils for Inhibition of Deposit Formation in the Sequence VH Spark-Ignition Engine Fueled with Gasoline and Operated Under Low-Temperature, Light-Duty Conditions1 This standard is issued under the fixed designation DXXXX; the number immediately following the designation indicates the year of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A superscript epsilon (ε) indicates an editorial change since the last revision or reapproval.

INTRODUCTION Portions of this test method are written for use by laboratories that make use of ASTM Test Monitoring Center (TMC 2) services (see Annex A1). The TMC provides reference oils, and engineering and statistical services to laboratories that desire to produce test results that are statistically similar to those produced by laboratories previously calibrated by the TMC. In general, the Test Purchaser decides if a calibrated test stand is to be used. Organizations such as the American Chemistry Council require that a laboratory use the TMC services as part of their test registration process. In addition, the American Petroleum Institute and the Gear Lubricant Review Committee of the Lubricant Review Institute (SAE International) require that a laboratory use the TMC services in seeking qualification of oils against their specifications. The advantage of using the TMC services to calibrate test stands is that the test laboratory (and hence the Test Purchaser) has an assurance that the test stand was operating at the proper level of test severity. It should also be borne in mind that results obtained in a non calibrated test stand may not be the same as those obtained in a test stand participating in the ASTM TMC services process. Laboratories that choose not to use the TMC services may simply disregard these portions. 1. Scope

1.1 This test method is commonly referred to as the Sequence VH3 test, and it has been correlated with the Sequence VG test. The Sequence VG test was previously correlated with vehicles used in stop-and-go service prior to 1996, particularly with regard to sludge and varnish formation4. It is one of the test methods required to evaluate oils intended to satisfy the API SL performance category.

1.2 The values stated in SI units are to be regarded as the standard. No other units of measurement are included in this standard.

1

This test method is under the jurisdiction of ASTM Committee D02 on Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of Subcommittee D02.B0.01 on Passenger Car Engine Oils.

2

ASTM Test Monitoring Center, 6555 Penn Avenue, Pittsburgh, PA 15206-4489. www.astmtmc.cmu.edu.

3

Until the next revision of this test method, the ASTM Test Monitoring Center will update changes in the test method by means of information letters. Information letters may be obtained from the ASTM Test Monitoring Center, 6555 Penn Ave., Pittsburgh, PA 15206-4489. Attention: Administrator. This edition incorporates revisions in all information Letters through No.__ 4

Supporting data have been filed at ASTM International Headquarters and may be obtained by requesting Research Report RR:D02-1472.

1.2.1 Exception—Where there is no direct SI equivalent such as screw threads, national pipe threads/diameters, tubing size, or specified single source equipment.

1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. Specific hazard statements are given in 7.7, 7.7.3, 7.7.4, 7.7.5, 8.3.4.2, 8.4.4.3, 9.2.6, 9.3.4.5, 12.1.1.7, 12.2.1.4, A5.3.4 and A5.3.5.

1.4 A Table of Contents follows:

Scope 1

Referenced Documents 2

Terminology 3

Summary of Test Method 4

Significance and Use 5

Apparatus (General Description) 6

Apparatus (The Test Engine) 7

Sequence VH Test Engine 7.1

Required New Engine Parts 7.2

Reusable Engine Parts 7.3

Specially Fabricated Engine Parts 7.4

Special Engine Measurement and Assembly Equipment

7.5

Miscellaneous Engine Components-Preparation 7.6

Solvents and Cleaners Required 7.7

Assembling the Test Engine-Preparations 7.8

Assembling the Test Engine-Installations 7.9

Engine Installation on the Test Stand 7.10

Engine Fluids (Supply/Discharge Systems) 8

Intake Air 8.1

Fuel and Fuel System 8.2

Engine Oil and Engine Oil System 8.3

Coolants 8.4

Measurement Instrumentation 9

Temperatures 9.1

Pressures 9.2

Flow Rates 9.3

Fuel Consumption 9.4

Speed and Load 9.5

Exhaust Gas 9.6

Humidity 9.7

Miscellaneous Laboratory Equipment 10

Test Stand Calibration 11

Test Procedure 12

Pre-Test Procedure 12.1

Engine Operating Procedure 12.2

Periodic Measurements and Functions 12.3

Special Maintenance Procedures 12.4

Diagnostic Data Review 12.5

End of Test Procedure 12.6

Interpretation of Test Results 13

Parts Rating Area-Environment 13.1

Sludge Ratings 13.2

Varnish Ratings 13.3

Clogging 13.4

Sticking 13.5

Used Oil Analyses 13.6

Assessment of Test Validity 14

General

14.1

Used Oil Analyses-Interpretation 14.2

Blowby Flow Rate 14.3

Manifold Absolute Pressure 14.4

Fuel Consumption Rate 14.5

Oil Consumption 14.6

Engine Parts Replacement 14.7

Quality Index 14.8

Final Test Report 15

Report Forms 15.1

Precision and Bias 16

Keywords 17

ANNEXES ASTM TMC - Organization ASTM TMC – Calibration Procedures ASTM TMC – Maintenance Activities ASTM TMC – Related Information

Annex A1 Annex A2 Annex A3 Annex A4 

Safety Precautions Annex A5

Control and Data Acquisition Requirements Annex A6

Detailed Specifications and Photographs of Apparatus

Annex A7

Special Service Tools for the Test Engine Annex A8

Test Engine Part Number Listing Annex A9

External Oil Heat Exchanger Cleaning Technique

Annex A10

Sequence VH Report Forms and Data Dictionary Annex A11

Dipstick Calibration Annex A12

Critical Part Supplier List Annex A13

Operational Data Log-Engine Oil Annex A14

Rating Worksheets Annex A15

Fuel Injector Flow Measurements Annex A16

APPENDIXES

Piston and Ring Measurements Record Forms Appendix X1

Sources of Materials and Information Appendix X2

2. Referenced Documents

2.1 ASTM Standards: 5

D86 Test Method for Distillation of Petroleum Products at Atmospheric Pressure

D235 Specification for Mineral Spirits (Petroleum Spirits) (Hydrocarbon Dry Cleaning Solvent)

D287 Test Method for API Gravity of Crude Petroleum and Petroleum Products (Hydrometer Method)

D323 Test Method for Vapor Pressure of Petroleum Products (Reid Method)

D381 Test Method for Gum Content in Fuels by Jet Evaporation

D445 Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity)

D525 Test Method for Oxidation Stability of Gasoline (Induction Period Method)

D873 Test Method for Oxidation Stability of Aviation Fuels (Potential Residue Method)

D1266 Test Method for Sulfur in Petroleum Products (Lamp Method)

D1298 Test Method for Density, Relative Density, or API Gravity of Crude Petroleum and Liquid Petroleum Products by Hydrometer Method

D2622 Test Method for Sulfur in Petroleum Products by Wavelength Dispersive X-ray Fluorescence Spectrometry

D2789 Test Method for Hydrocarbon Types in Low Olefinic Gasoline by Mass Spectrometry

D3237 Test Method for Lead in Gasoline by Atomic Absorption Spectroscopy

D3525 Test Method for Gasoline Diluent in Used Gasoline Engine Oils by Gas Chromatography

D4057 Practice for Manual Sampling of Petroleum and Petroleum Products

D4175 Terminology Relating to Petroleum, Petroleum Products, and Lubricants

D4294 Test Method for Sulfur in Petroleum and Petroleum Products by Energy Dispersive X-ray Fluorescence Spectrometry

D4485 Specification for Performance of Active API Service Category Engine Oils

D5059 Test Methods for Lead in Gasoline by X-Ray Spectroscopy

D5185 Test Method for Multielement Determination of Used and Unused Lubricating Oils and Base Oils by Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES)

D6304 Test Method for Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration

2.2 ANSI Standard6

ANSI MC96.1 Temperature Measurement-Thermocouples

2.3 Other ASTM Documents:

ASTM Deposit Rating Manual 20 (Formerly CRC Manual 20) 7

3. Terminology

3.1 Definitions:

5 For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM Standards volume information, refer to the standard's Document Summary page on the ASTM website.

6 Available from American National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036.

7 For stock #TMCMNL20, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at service@astm.org.

3.1.1 air-fuel ratio, n—in internal combustion engines, the mass ratio of air-to-fuel in the mixture being inducted into the combustion chambers.

3.1.1.1 Discussion—In this test method, air-fuel ratio (AFR), is controlled by the engine control module. D4175 3.1.2 blowby, n—in internal combustion engines, that portion of the combustion products and unburned air/fuel mixture

that leaks past piston rings into the engine crankcase during operation. D4175 3.1.3 clogging, n—the restriction of a flow path due to the accumulation of material along the flow path boundaries.D4175 3.1.4 cold-stuck piston ring, n—in internal combustion engines, a piston ring that is stuck when the piston and ring are at

room temperature, but inspection shows that it was free during engine operation. 3.1.4.1 Discussion—A cold-stuck piston ring cannot be moved with moderate finger pressure. It is characterized by a

polished face over its entire circumference, indicating essentially no blowby passed over the ring face during engine operation. D4175

3.1.5 debris, n—in internal combustion engines, solid contaminant materials unintentionally introduced into the engine or resulting from wear. 3.1.5.1 Discussion—Examples include such things as gasket material, silicone sealer, towel threads, and metal particles. D4175

3.1.6 filtering, n—in data acquisition, a means of attenuating signals in a given frequency range. They can be mechanical (volume tank, spring, mass) or electrical (capacitance, inductance) or digital (mathematical formulas), or a combination thereof. Typically, a low-pass filter attenuates the unwanted high frequency noise. D4175

3.1.7 hot-stuck piston ring, n—in internal combustion engines, a piston ring that is stuck when the piston and ring are at room temperature, and inspection shows that it was stuck during engine operation.

3.1.7.1 Discussion—The portion of the ring that is stuck cannot be moved with moderate finger pressure. A hot-stuck piston ring is characterized by varnish or carbon across some portion of its face, indicating that portion of the ring was not contacting the cylinder wall during engine operation. D4175

3.1.8 knock, n—in a spark ignition engine, abnormal combustion, often producing audible sound, caused by autoignition of the air/fuel mixture. D4175

3.1.9 out of specification data, n—in data acquisition, sampled value of a monitored test parameter that has deviated beyond the procedural limits. D4175 3.1.10 reading, n—in data acquisition, the reduction of data points that represent the operating conditions observed in the time period as defined in the test procedure. D4175 3.1.11 scoring, n—in tribology, a severe form of wear characterized by the formation of extensive grooves and scratches in

the direction of sliding. D4175 3.1.12 scuffing, n—in lubrication, damage caused by instantaneous localized welding between surfaces in relative motion

that does not result in immobilization of the parts. D4175 3.1.13 sludge, n—in internal combustion engines, a deposit, principally composed of insoluble resins and oxidation

products from fuel combustion and the lubricant, that does not drain from engine parts but can be removed by wiping with a cloth. D4175

3.1.14 time constant, n—in data acquisition, A value which represents a measure of the time response of a system. For a first order system responding to a step change input, it is the time required for the output to reach 63.2 % of its final value. D4175

3.1.15 varnish, n—in internal combustion engines, a hard, dry, generally lustrous deposit that can be removed by solvents but not by wiping with a cloth. D4175

3.1.16 wear, n—loss of material from a surface, generally occurring between two surfaces in relative motion, and resulting from mechanical or chemical action, or a combination of both. D4175

3.2 Definitions of Terms Specific to This Standard: 3.2.1 enrichment, n—in internal combustion engine operation, a fuel consumption rate in excess of that which would

achieve a stoichiometric air-to-fuel ratio. 3.2.1.1 Discussion—Enrichment is usually indicated by elevated CO levels and can also be detected with an extended

range air/fuel ratio sensor. 3.2.2 Lambda, n—the ratio of actual air mass induced, during engine operation, divided by the theoretical air mass

requirement at the stoichiometric air-fuel ratio for the given fuel. 3.2.2.1 Discussion—A Lambda value of 1.0 denotes a stoichiometric air-fuel ratio. 3.2.3 low-temperature, light-duty conditions, n—indicative of engine oil and coolant temperatures that average below

normal warmed-up temperatures, and engine speeds and power outputs that average below those encountered in typical highway driving.

3.2.4 ramping, n—the prescribed rate of change of a variable when one set of operating conditions is changed to another

set of operating conditions.

4. Summary of Test Method

4.1 Each VH test engine is assembled with many new parts and essentially all aspects of assembly are specified in detail. 4.2 The test stand is equipped to control speed, torque, AFR, and various other operating parameters. 4.3 The test is run for a total of 216 h, consisting of 54 cycles of 4 h each. Each cycle consists of three stages. 4.4 While the operating conditions are varied within each cycle, overall they can be characterized as a mixture of low-

temperature and moderate-temperature, light and medium duty operating conditions. 4.5 To accelerate deposit formation, the level of oxides of nitrogen in the blowby and the rate of blowby into the crankcase

are significantly increased. The fresh air breathing of the crankcase is eliminated and the oil and coolant temperatures are lowered to induce condensation of water and fuel.

4.6 The performance of the test engine oil is evaluated at the end of the test by dismantling the engine and measuring the level of engine deposit formation.

5. Significance and Use

5.1 This test method is used to evaluate an automotive engine oil's control of engine deposits under operating conditions deliberately selected to accelerate deposit formation. This VH test method was correlated with the previous VG test method, which was correlated with field service data, determined from side-by-side comparisons of two or more oils in police, taxi fleets, and delivery van services.

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vide this informatiocommittee,1 which

ter (Sunnen Model

uarters, 3M Center

DXXXX– 1

11

500NS ultrason(Annex X2. 23ts cleaner - Thcleaning procedimum of 140°

ry 25 hrs. of usOT-500NS mo

ly sprayed with

der bore resizinxed to the connn pins and prev

vironment—Thnts. A relativelts dimensions. ain the relative

tail blocking ointake manifolcontrol system

body with sowear on the coy. However, thWhen the cleattle body.

a deposit or filmd inhibitor (8.4

vent (see 7.7.2with degreasinrating is less

Brite General before use.

s in agitated orRinse the camsthe camshaft bal 20), polish t

easing solvent (nic solvent (seeh degreasing so

own to the commit

on to ASTM Internh you may attend.

l CRH-50) and pin

r, St. Paul, MN 55

5

nic parts clean3) before puttinhe ultrasonic padure is describ°F. DO NOT

se. odel (158 gallo

h hot water, the

ng and finishinnecting rods wivent piston dist

he ambient atly constant temTo prevent mohumidity at a

off the EGR pold by tapping th

m. A schematic olvent (7.7.1)

omponents. he clearance barance become

m is present, th4.4.1). An exam

2) until clean ng solvent (7.than ten on t

Purpose Hand

rganic solvent shaft baffles wbaffle. If the bthe camshaft b(7.7.1) and alloe 7.7.2) until colvent (7.7.1) a

ttee at this time is

national Headquar

n installation tool k

5144-1000.

ner or similar ng into ultrasonarts cleaner soed below: add the degre

on capacity). Q

en solvent and

ng.10,11 ith an interferetortion.

tmosphere of mperature (withoisture formingnominal maxim

ort (block off pthe hole and inof the system iand air-dry b

between the boes too great to

hen clean the Rmple of an acc

n (approximate.7.1) and allowthe ASTM vard Pad #744713,1

(see 7.7.2) unwith degreasingbefore test ratinbaffle with Scoow to air-dry blean (approximand allow to ai

Sunnen Inc., 7910

rters. Your comme

known to the comm

apparatus. Seenic cleaner.

olution is also p

easers until the

Quantities will

d left to air dry.

ence fit. A con

the engine bhin ± 3 °C) is ng on cold enginmum of 50 %.

plate shown in stalling a 1/2 inis shown in Figbefore each te

ore and the buo allow contro

RAC coolant jaceptable cleane

ely 1 h). Rinsw to air-dry. rnish rating sc11 to achieve a

ntil clean (approg solvent (7.7.1ng is less thantch Brite Gene

before use. mately 1 h). Riir-dry.

0 Manchester, St. L

ents will receive ca

mittee at this time

e X2.1.12. .

provided by

e ultrasonic

be different

nnecting rod

buildup and necessary to ne parts that

Fig. A7.13) n. NPT pipe g. A7.12. est. Do not

utterfly will ol of speed,

acket with a er is detailed

se the parts Inspect the

cale (ASTM a dull finish.

oximately 1 1) and allow n ten on the eral Purpose

inse the part

Louis, MO

areful

is Sunnen,

Rd

athth

wa

bt

w

(a

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7.6.6 Oil PaRinse the part tdry.

7.6.7 PCV Vand Fig. A7.10he vacuum adjhat does not ex

7.6.8 Water water pump, grat the proper sp

7.6.9 Front

belt is routed densioner. Thes

7.6.10 Oil Swith degreasing

7.6.1 Timin(approximatelyair-dry.

7.7 Solventsprovisions with

7.7.1 SolvenContent 0 % toScale). (Warni

7.7.2 Organ

7.7.3 DearsHealth hazard.)

7.7.4 Coolin(Warning—Ca

7.7.5 Parts C7.7.6 Ultraso7.8 Assembl

engine accordinbody, fresh air

7.8.1 Parts S7.8.2 Sealing

block-cylinder oil pan interfac

7.8.2.1 Use NOTE 1—Non

7.8.3 Gaske7.8.4 Block

found. Removechamfers aroun

4 The sole source

5 The sole sourceGenesee St., Lake Z

6 The sole sourceBaltimore, MD 212

an Baffle—Subthoroughly wit

Valve—Measur0. Measure the justments in onxhibit an averaPump Drive S

rooved idler anpeed and direct

Cover—Modidifferently fromse bolt bosses aSeparators—Ug solvent (7.7.1ng Chain Covy 1 h). Rinse th

s and Cleanerh all solvents annt—Use only mo 2 % by voluing—Combust

nic Solvent, Pe

sol 134 Acidic) ng System Cleaustic. Health h

Cleaning Soaponic Cleaner, Tling the Test Eng to the 2011tube, airbox anSelection—Instg Compounds—head-front coves. silicon-based s

n-silicon liquid o

ts and Seals—IPreparations—

e oil gallery pnd the top of th

e of supply of Penm

e of supply of DearZurich, IL 60047.

e of supply of the s236.

bmerge the oil th hot water (>

re and record tflow rate at (2

ne direction onge flow rate of

System—. Use nd tensioner, antion.

fy front cover m the stock loare used to attase specificed o1) and allow tover—Submergehe part thoroug

rs Required—Nnd cleaners. Semineral spirits ume, Flash Poitible. Health ha

nmul L460. (W

c Cleaner15,11

eaner, Duponhazard.)

p,16,11 NAT-50Tierra Tech ultEngine-Prepara1 Crown Victond waterpump tructions conce—Use a siliconver interfaces,

sealer sparinglyr tape thread sea

Install new gas—Inspect blocplugs. Removahe cylinder bo

mul L460 known t

rsol 134 Acidic Cl

soap (NAT-50 or P

pan baffle in > 60 °C). Rinse

the flow rates 25 and 60) kPanly. Measure tf (90 to 140) L/only the pulley

nd a five or six

to facilitate inocation some bach the front enoil separator is

o air-dry prior te the timing ghly with hot w

No substitutionee Annex A5.)

meeting the rnt (61 °C, min

azard.) Obtain a

Warning—Com

with Inhibitor

t or equivalen

0 or PDN-50 hatrasonic solutioations—Use th

oria Workshop are a combinaterning the use n-based sealer cylinder head-

y since it can ealers can be used

skets and seals ck, including oal of coolant jore. Spray the b

to the committee a

leaner known to th

PDN-50) known to

DXXXX– 1

12

agitated organe the oil pan b

of the PCV va  a vacuum. Bec

the flow rate tw  /min at 25 kPa

ys need to drivx groove belt, 9

nstallation of tbolt bosses mand accessory drs obtained fromto each test. chain cover iwater (> 60 °C

ns for 7.7.1 –

requirements on) and Color (na Certificate of

mbustible. Hea

r, RAC cooli

nt, for cleaning

ave been foundon 7 and B avaihe test engineManual for lo

tion of 2011 anof new or usedas needed betw-front cover-ro

elevate the indid on bolts and pl

during engineoil galleries foacket plugs isblock with deg

at this time is Penet

he committee at thi

o the committee at

5

nic solvent (seeaffle with deg

alve with the ccause of the hywice and avera

a and (30 to 50)ve the water pu956 mm in leng

tensioner, idleray need to be arive componenm the supplier

in agitated or  C). Clean with

7.7.5 are allo

of Specificationnot darker thanf Analysis for

alth hazard.)14,

ing jacket inte

g cooling syste

d to be acceptabilable from supparts obtained

ongblock assemnd 2004 compod parts are detaween the rear socker cover int

icated silicon clugs.

e assembly. or debris and rs left to the digreasing solven

tone Corp., P.O. B

is time is Dearborn

t this time is Better

e 7.7.2) until cgreasing solven

calibrated flowysteresis in theage the reading) L/min at 60 kump (see Annegth to ensure th

r, and water paltered to clea

nts that are not r in A13.6. pa

rganic solventdegreasing so

owed. (Warni

n D235, Type n +25 on Saybeach batch of s,11

ernal cleaner. (

em componen

ble. (Warningpplier shown ind from the supmbly through tonents. ailed in 7.1.1, 7seal housing-cyterfaces, and cy

content of the u

rust. Remove iscretion of thnt (see 7.7.1).

Box 22006, Los An

n Div., subsidiary

r Engineering Man

clean (approximnt (7.7.1) and a

device describe PCV valve spgs. Reject any

kPa. ex A5), crankshat the water p

ump drive belar the shorter bused for this te

arts list. Clean

t (see 7.7.2) lvent (7.7.1) a

ing—Use adeq

II, Class C fobolt Scale or 2solvent from th

(Warning—C

nts external to

g—Health hazan Annex X2.1.pplier in 7.1.Asthe intake elbo

7.2, and 7.3. ylinder block, tylinder block-f

used oil.

any debris or he laboratory.

Spray block w

ngeles, CA 90022

of W. R. Grace an

nufacturing, 8361

mately 1 h). allow to air-

bed in 7.5.3 pring, make PCV valve

shaft pulley, pump rotates

lt. Since the belt and the est. the interior

until clean and allow to

quate safety

or Aromatic 25 on Pt-Co he supplier.

Combustible.

the engine.

ard.) 12. ssemble the ow. Throttle

the cylinder front cover-

rust that is Enlarge the

with a 50/50

.

nd Co., 300

Town Court,

m4th1

ww

s

fwn

7

T

trmba

trDm

R

th

P

1

1

R

mixture of degr43 N·m with anhe main bearin

11 N·m. 7.8.4.1 Hon

(1) Instawith the right cwithin the past

(2) Set thstrokes per min

(3) Instafollowing orderwill minimize tnot have to be r

(4) Insta7.8.4.1(3).

(5) InstaTypically 45 str

(6) Measransversely. D

measurements abore measurema different diam

(7) Deteransversely. R

Determine out-middle and bott

7.8.4.2 Post(1) Rem

Remove jacksc(2) Clean(3) Place(4) Spray

7.8.4.3 Cran(1) If the(2) Spray(3) Meas(4) Meas(5) Insta(6) Insta(7) Insta(8) Insta

7.8.4.4 Pisto(1) Exam(2) Insta

he piston and t7.8.5 Piston7.8.5.1 Ring(1) Cut the t

Piston Ring G

7 The sole source

8 The sole sourceRoselle, NJ 07203.

reasing solventn additional 18ng caps and to

ing: all the block in cylinder bank o15 h, and chanhe honing mac

nute and spindlall EHU512 stor, cylinder 1, 3the possibility oremoved to honall JHU725 ston

all a plateau honrokes have prosure the cylindetermine the band dividing by

ment and verify meter piston to rmine bore tapecord the maxi

-of-round by sutom. Record tht Honing Clean

move the block fcrews from the n with degrease block in dishy block with 5nkshaft Installae crankshaft hay the crankshasure the main jsure the conne

all the main beaall the main beaall the jack screall the jack screon Installation:mine pistons foall the piston onthe connecting Rings:

g Gap Adjustmetop and second

Grinder.18,11 Re

e of supply of Mob

e of supply of the S

t (see 7.7.1) an80° in two 90° orque to 40 N·

the honing maon the outside ange if necessarychine to flow Se speed of 170

ones. Typical p, 4 and 2. Honof over heatingne the other banes and hone f

ne brush and hovided acceptabder bore using aore diameter foy two. Measurthat the pistonobtain this cle

per by measurinimum value ofubtracting the dhe maximum vning: from the honinmain bearing c

sing solvent (sewasher type cl0/50 solution o

ation: as been used praft with degreasjournals and vecting rods jourarings. aring caps and ews and torqueew bolts and to:

or any staining,n the connectinrods on the sa

ent: d compression ecord the ring

bil EF-411 oil know

Sanford Piston Rin

nd EF-411.17,11

rotation incremm, with an ad

achine. Use a Sand the front ofy. unnen LP8X fl

0 r/min. Set thepressures of 25 e the left bank g one area of thank. for approximate

hone at 25 to 30ble results. a bore ladder shor piston clearare the piston skn-to-bore clearaarance. ng the differenf the readings Vdifference betwalue. Verify th

ng machine. Recaps. ee 7.7.1). leaning machinof EF-411 and

reviously, soaksing solvent. erify that the dirnals and verify

torque to 40 Ne to 9 N·m to 1orque to 19 N·m

, defects, damang rod using Suame side. See F

ring gaps as rg side clearanc

wn to the committ

ng Grinder known

DXXXX– 1

13

1 Install the strments. Head b

dditional 90° ro

Sunnen CV-616f the block to th

fluid at a nomine stroke for 133

to 40 units havin the followin

he block. The b

ely five strokes

0 units of press

hown in Fig. Aance purposes

kirt 42 mm fromance is within 0

ce between topVerify that the ween the transvhat the cylinder

emove the stres

ne (see 7.5.7) adegreasing sol

k the crankshaf

iameters are 67y that the diam

N·m, with an ad1 N·m. m to 23 N·m.

age, etc. Discarunnen Model CFigure A7.11

required to obtce(s) and new

tee at this time is M

to the committee a

5

ress plates witholts may be usotation. Install

6 honing machthe right. Verify

nal rate of 7 L/3.35 mm and love found to be ng order, Cylinblock may be r

s at 20 to 25 un

sure to obtain a

A7.28. Measureby adding the

m the top of the0.020 mm to 0

p-to-bottom, tomaximum tape

verse and longir bore out-of-ro

ss plates, jacks

and wash usinglvent (see 7.7.1

ft in organic so

7.483 mm to 67meters are 52.98

dditional 90° ro

rd any pistons tCRH-50 conne

tain the specifi ring gap(s) o

Mobil Oil Corp., 3

at this time is San

h cylinder headsed for a maximthe jackscrew

hine to hone thefy the honing o

/min. Set the feower the blockacceptable. Ho

nder 7, 5, 8 androtated in the h

nits of pressure

a surface finish

e bore both lonmiddle and boe piston. Subtr

0.046 mm. Re-h

op-to-middle aner does not excitudinal bore mound does not e

screws, main b

g soap (7.7.5) fo1).

olvent (see 7.7.2

7.503 mm. 88 mm to 53.00

otation.

that are stainedcting rod heate

ied blowby floon any ring(s)

225 Gallows, Fair

ford Mfg. Co., 300

ds and torque tomum of five ti

ws and torque t

e block. Installoil has been cha

eed rate to 4 wik for 10 mm ovone the right bd 6. Following honing machine

e in the order d

h of 8 m to 13

ngitudinally anottom transversract this value fhone the block

nd middle-to-bceed 0.006 mm

measurements aexceed 0.020 m

earing bolts an

for 30 min at 60

2) for a minim

03 mm.

d, damaged, uner. In sure the n

ow rate, using adjusted. Ent

rfax, VA 22037.

0 Cox St., P.O. Bo

o 37 N·m to imes. Install to 8 N·m to

l the block anged

ith 57 verstroke. ank in the this order

e and does

described in

3 μm.

d se bore from the

k or choose

bottom, m. at the top, mm.

nd caps.

0 °C.

mum of 24 h.

nusable. notch on

the Sanford ter the new

ox 318,

dArd

a0

to

ths

s

bd

u

inth

th

t

thdc

h

th

li

gth

1

2

dimension(s) oAppendix X1. ring gaps are rdetermine the r

(2) Using the7.8.5.2 Pisto

(1) Cut the ramounts from b0.125 mm until

(2) After theowel.

7.8.5.3 Insta(1) Install th

he gaps at appspreader tool, k

(2) If any rinside clearance b

7.8.6 Cylindbores with a drdiameter of cyl

7.9 Assemblunless specified

7.9.1 Intake 7.9.2 Piston

nstallation. Wihe rod bearing

7.9.3 Oil Syshe oil pan that

7.9.4 Cylindests, as long as

(1) Disass(2) If the

he cylinder headishwasher typcleaning machi

(3) Determheads that exce

(4) Assemhe discretion o

(5) Installisted in A.13.3

7.9.4.1 Headguides if they ahey should be

9

The sole source

20The sole source

on the SupplemEnsure that threquired. Mearing gap increa

e master bore, mon Ring Cutting

ring to the requboth sides of tl the desired rin

e rings are cut

allation: he oil control riproximately 18keeping the ringngs require repby determiningder Bore Measury rag. The borinder 1 and 8 aling the Test Ed herein. Manifold—Bl

n Installation—ipe the cylinde

g caps and torqustem Componecontains remo

der Head Instas they remain ssemble heads acylinder headsads have been e cleaning macine and spray wmine valve guieed (0.020 to 0.mble the cylindof the laboratorl camshaft bear3 ds may also bare worn beyotaken out of se

of supply of the 3/

of supply of Sunn

mental Operate required ringsure the rings se.

TABLE 1

Ring side cle

Ring gap de

measure the ring Procedure:

uired gap usinthe gap. Make ng gap is achie

remove the rin

ings and the co80° intervals, wgs' surfaces palacement, then

g the differenceurements—Meres shall be cleat the top, middEngine-Installa

ock the coolan—Install pistoners with EF-41ue to 40 N·m tents—All oil syovable baffles. llation—Cylind

serviceable. and inspect for s have not beenused previouslchine (7.5.7) uswith a 50/50 miide clearance a.069) mm for i

der heads in accry. rings. Camshaf

e procured frond the service

ervice and no lo

16 in. carbide ring

en soft stone, No.

tional Data shg gap delta and

for cylinders

Required Pis

earance, avg

elta

ng gaps for the

ng the ring cuttfinal cuts on t

eved.

ng from the cu

ompression rinwith the top crallel to the rin

n measure and e between the reasure the cylinean and dry whdle and bottomations—Assem

nt bypass port ins in proper

11. Install the po 45 N·m withystem compone

der heads are o

any debris or on previously usly, soak in orgasing soap (7.7.ixture of EF-41

at the top and mntake and (0.04cordance with t

fts can be insta

m the source l limits, by theonger be used

cutting burr, No.

JHU-820 known t

DXXXX– 1

14

eets. Typical d ring side clea

1 and 8 in th

ton and Pisto

0.0508 mm to

0.045 mm to

e top rings in cy

ting burr19,11 rthe down strok

utting tool, debu

ngs on the pistoompression rin

ng groove in threcord the newring groove winder 1 and 8 cyhen they are me

m of the second mble the engine

n the intake mcylinders, tak

pistons and conh an additional ents in the eng

obtained from

other deleteriosed, spray the canic solvent (se5) at 60 °C for11 and degreas

middle of the he46 to 0.095) mthe manual. Ve

alled at this tim

listed in A13.1 source listed for VH testing

74010020 known

to the committee a

5

forms for recarance are attahe master bore

n Ring Dimen

o 0.1016 mm

0.055 mm

ylinders 1 and

rotated at a ratke only. The rin

ur using a Sun

ons with the gang gap toward

he piston. w ring gap(s) aidth and the assylinder bores weasured. Use a

d ring travel in te according to

manifold at the tking care to nnecting rods 90° rotation.

gine are produc

the supplier in

ous materials ancylinder heads ee 7.7.2) for 24r 30 min. Promsing solvent (7eads on the tran

 mm for exhaust.erify valves are

me. Camshaft b

Modify headsin A13.5. Afte

g.

to the committee a

at this time is Sunn

cording these dained (Table 1)e. These meas

nsions

8 prior to the s

ted speed of 3ng is cut with

nnen soft stone

aps located ovd the rear. Inst

and ring side clsociated ring wwith the bearina bore gage mithe transverse

o the instructio

thermostat houensure rings with the notch

ction configura

n A13.2. Heads

nd remove as nwith degreasin4 h, place the c

mptly remove th.7.1).

ansverse side of. e properly seat

bearings are obt

s to accept camer use if cylind

at this time is M. A

nen, Inc., 7910 Ma

dimensions ar). Replace ringsurements are

start of the test

450 r/min. Rea maximum in

e20,11 and wipe

ver the piston ptall the rings u

learance(s). Cawidth. ng caps in placeicrometer to dedirection.

ons in the serv

using (7.6.2.1).are not dama

hes facing forw

ation with the e

s may be used

necessary. ng solvent (see cylinder heads he cylinder hea

f the guide. Rej

ted. The metho

tained from the

m bearings, andder heads requ

A. Ford.

anchester, St. Loui

re shown in gs if smaller

required to

t.

emove equal ncrement of

e with a dry

pin. Position using a ring

alculate ring

e. Clean the etermine the

vice manual

aged during ward. Install

exception of

for multiple

7.7.1). If in the

ad from the

eject any

od is left at

e supplier

d new valve uire decking

is, MO 63143.

m

1

r

cc

b

gd(c

fp

cA

th

±md

Fp

p

s

inf

f

ti

Espbm

(1) Cond7.9.5 Camsh

manual. 7.9.5.1 Instal7.9.5.1 Prior

1) as described 7.9.5.2 Whe

rail. 7.9.5.3 Whe

crankshaft sprochain shall han

7.9.5.4 Repbetween the ch

NOTE 2—Ther

7.9.6 Rocker

gasket and instadoes not contac(the rubber wacorrect head (F

7.9.7 Oil Pafront baffle firspan.

7.9.8 Watercrankshaft pulleAll other produ

7.10 Enginehe assembly pr

7.10.1 Moun± 0.5° from veminimize engindynamometer t

7.10.2 Exha7.10.2.1 The

Figs. A7.14, Apipe/tubing. Ot

7.10.3 Oil Dproduction loca

NOTE 3—The stand.

7.10.4 Fuel 7.10.4.1 Fue(1) The fuel

njectors that hflow benches ar

(2) Inspect thfuel rail and int

7.10.4.2 Eleiming, and so f

(1) The EECEEC operationshortest practicproblems. Groubattery negativmeasuring devi

7.10.5 Spar

duct a successfhaft and Relat

ll timing chainr to the timingin the service

en viewed from

en installing thocket with timg below the teneat the procedain guide and tre should be a m

r Arm Cover aall it in the gasct any valve traashers are not rigs. A7.4 and Aan, Baffles, anst. Install the o

r Pump, Wateey (see 7.6.8)

uction front ende Installation orocess are notenting the Enginertical, with thne vibration ahrough a driveust System ande required exha

A7.15, and A7.ther type flexibDipstick and Tuation and attachintake manifold

Management Sel Rail Injectorinjectors can

have caused mire available frohe O-rings to eto the intake mectronic Enginforth, are contr

C power shall cn. Connect thecal length so asund the EEC gre to prevent inices. rk Plugs—Insta

ful reference oied Component

n tensioner on thg chain installa

manual.9 Rotam the rear, mai

he timing chaiming chain on t

nsioner dowel.dure in 7.9.5.3the tensioner d

minimum of chain

and Baffle—Fassket groove on ain componentreusable). TheA7.5). d Insulation—il pan accordin

er Pump Driveaccording to th

d accessory drin the Test Stan

ed. ne on the Test e front of the

at 700 r/min teshaft. The engd Gas Samplingaust manifold, 16. Exhaust co

ble pipe is not aube—Install mohment points.

d, the rocker arm

System: rs: be used for muisfires in previom various maensure they are

manifold. ne Control (EErolled by the spome from a ba EEC battery/

s to maintain a round wire to t

nterruption/inte

all new Motor

il test prior to uts—Install the

he cylinder heation, clock the

ate the crankshaintain the cams

ins ensure thatthe crankshaft for the right

dowel. n slack on the te

sten the camshcover rail. Inst

ts. Using new re two rocker co

—Install front anng to the proce

e—Install the he service manive componentnd—Functions

Stand—Mountengine higher

to 2900 r/mingine cannot be ug Fittings: a typical exhauomponents shoacceptable. odified oil dip

m covers, and the

ultiple tests prous tests shoul

anufacturers. De in good cond

EEC) System—pecified EEC. Tattery 13.5 V ± /power supply dc voltage of

the engine. Froerference of the

rcraft AGSF-32

DXXXX– 1

15

using these heacamshaft and

ad. e crankshaft keaft clockwise oshaft D-slot sh

t the timing m. Drape the L

hand timing c

nsion side betwe

haft baffle to thtall rocker armrubber washersovers are diffe

nd rear oil panedure in the ser

water pump, nual. These ares are not used.that are to be p

t the engine onr than the rear.. Couple the used to drive a

ust system, andown in Fig. A

stick and dipst

exhaust manifo

roviding they mld be cleaned bo not use injec

dition and will

—The fuel injecThe EEC is av1.5 V or a powto the engine

12 V to 15 V oom the same gre EEC operatio

2-PM spark pl

5

ads for all testingears in the sa

eyway at 315° only, when viewhall at a 90° clo

marks (mention.H. timing cha

chain. After in

een the two spro

he rocker coverm cover on the cs on the bolts, terent, ensure th

n baffles to thervice manual. I

water pump e the only comp. See figure 3.5performed in a

n the test stand . The engine mengine and V

any external en

d O2 sensor anA7.16 should be

tick tube, descr

olds can be instal

meet the requibefore reuse. C

ctor cleaning flnot allow fuel

ctor operationvailable from thwer supply thate wire harnesson the STAR tround point, ruon. The power

lugs that have

ng. ame manner a

of crankshaft wed from the focked position

ned above) remain over camsh

nstallation, the

ockets.

r. Cut off the tcylinder head atorque the bolthat the correct

e oil pan as shInstall the oil p

pulley tensionponents needed5 a specific mann

d so that the flymounting syste

Vulkan damperngine accessory

nd thermocouple constructed

ribed in 7.4.4,

lled after the eng

irements delineCommercial in

fluids while opel leaks. Install

n, cylinder firihe supplier listet does not inters with an apprtester and miniun a minimum supply can als

e been gapped

as described in

angle (TDC offront. n relative to the

main aligned. haft sprocket.

e timing chain

tabs from the rand confirm thats to 8 N·m to t cover is insta

hown in Fig. Apan insulation

ner, idler pulld to drive the w

ner or at a spec

ywheel frictionem should be r, if used, direy.

le fittings are iof either solid

in the engine

gine is installed o

eated in Annexnjector cleaningerating the eng

the fuel inject

ing, pulse wided in A13.2. rrupt/interfere ropriate gage imize EEC electwo gage wire

so be used for t

d to 1.37 mm.

the service

f piston No.

e cam cover

Install L.H. The timing

n shall hang

rocker cover at the baffle 12 N·m alled on the

A7.7. Install over the oil

ley and the water pump.

cific time in

n face is 4.0o designed to ectly to the

llustrated in d or bellows

block at the

on the test

x A16. Fuel g fluids and

gine. tors into the

dth, ignition

with proper wire of the ctrical noise e back to the the Lambda

Torque the

s

fs

spark plugs to 9NOTE 4—The

7.10.6 Cranfrom the crankcsystem compon

9 N·m to 12 Ncomponents use

nkcase Ventilatcase and drawnnents and hoses

NOTE—

FIG

·m. Install the ed in the ignition

tion System—Tn into the intaks as shown in F

—Legend (1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

G. 3 Functiona

spark plug wirn system do not r

The crankcase ke manifold. AFig. A7.17.

Blowby flowcylinder blo

Cam baffle

Oil separato

PCV valve is (60 to 70)

Air vent pro Whoccurs exce

Three-way bmanifold anmeasuremen

Dipstick tubmeasuremen

Under normengine air in

al Description

DXXXX– 1

16

ring harness. Drequire modifica

ventilation sysA description o

ws through 6 oock and head an

shields cover f

or prevents loss

flows approxim) L/min.

ovides balance hen excessive p

ess blowby is v

ball valve routnd provides a cnt apparatus.

be is location fnt.

mal flow conditntake of Closed Cra

5

Do not use anti-ation.

stem is a closeof the system o

oil drain back pnd through the

from oil.

s of oil into PC

mately 120 L/m

of flow by PCplugging of the

vented to the air

tes blowby to thconnection poin

for crankcase p

tions blowby is

ankcase Venti

-seize compoun

ed system allowoperation is sho

passages in e front cover.

CV valve.

min. Blowby ra

CV valve.e PCV valve r cleaner.

he intake nt for blowby

pressure

s routed to the

ilation System

nds on spark p

wing blowby town in Fig. 3.

ate

m

lug threads.

to be vented Install PCV

A

hb

aa

bs

Aue

rpoc

8

0

in

7.10.6.1 OilA13.6. Oil sepa

7.10.6.2 Thrhose between tbend after insta

7.10.7 Intakair filter. Modias shown in Fig

7.10.8 Exterbecome unservsecurity.

7.10.9 WirinA13.2 and a siused on the tesengine wire har

7.10.9.1 VG route the wiresposition sensorof wire added connector chan

8. Engine Flui

8.1 Intake A0.02 kPa.

8.1.1 Capacntake/air param

l Separator andarators can be cree-Way Valve—he three-way v

allation. ke Air Componfy the air cleang. A7.1. VG orrnal Hose Rep

viceable. Check

ng Harness—Tingle harness tt stand, are a drness, F2AB-12Engine harnes

s for the injector and coolant te

to accommodnges and install

ids (Supply/D

Air—Condition

city—The suppmeters detailed

FIG. 3

d PCV Valve—cleaned by soa—Install a cleavalve and the i

ents—Install thner assembly tr VH Throttle bplacement—Insk for internal w

There are two that incorporatdynamometer h2A522-AC, muss modificationors and the cooemperature sen

date the positiolation. If VG th

ischarge Syste

n the intake air

ply system shd in Table 2. Th

3.5 4.6 L Wat

—Use two cleanaking in degreaan three-way vintake manifold

he throttle bodo accept fitting

body can be usspect all exter

wall separation

sources for htes both these harness that coust be modifiedn and installatolant temp sennsor connectoron of the wirehrottle body is

ems)

r to 30 oC ± 0.

all be capablehe test stand in

DXXXX– 1

17

ter Pump Driv

n oil separatorsasing solvent analve and attachd (see Fig. 3 an

y, throttle bodygs for inlet air ed. rnal hoses usens that could ca

harnesses, origfrom A13.3.. F

onnects to the sd to fit the Seqtion: Remove tnsor so it goes rs must be reple harness and used throttle p

5 °C, 11.4 g/k

e of deliveringtake air duct sy

5

ve Arrangeme

s and a new PCnd reused as loh the PCV valvnd Fig. A7.17)

dy spacer, freshtemperature th

ed on the test ause flow restr

ginal SequenceFor the VG hastand power an

quence VH intathe plastic shraround the thr

laced with newsensors. See

position senor c

kg ± 0.8 g/kg h

g 110 L/s of ystem is shown

ent

CV valve listedong as they remve hose. Install). Do not allow

h air tube, air chermocouple, p

stand and reprictions. Check

e VG dyno haarnesses there nd EEC and anake. oud (visible inrottle body elb

w style pigtail FIGURES A7

connector does

humidity, and

conditioned an in Fig. 2.

d in the parts limain serviceabll the remainingw the hose to f

cleaner assembpressure tap an

place any hosek all connection

arness and engare two wirin

n engine harne

n FIGURE A7bow. The origconnectors and7.29 – A7.36 sn’t need to be

pressurized to

air, while main

ist A9.3 and le. g PCV valve flatten at the

bly, and new nd fresh air,

es that have ns to ensure

gine harness ng harnesses ess. The VG

.32) and re-ginal throttle d the length for harness changed.

0.05 kPa ±

ntaining the

malo

8hPMasp

mc

th

ppath

ththo

8.1.2 Dew P

measured in thabove the dew oss of humidity

8.2 Fuel and8.2.1 System Dhigh-pressure pProvide a cooliMaintain a presand pressure usshown in Fig 1provides a cons

8.2.2 Contrmaintain 250+conditions to en

8.2.3 Fuel V8.2.4 Fuel B

he following p8.2.4.1 Befo

predetermined predetermined analytical data he acceptabilit

8.2.4.2 A sahan one calibrhe test program

of the approval

C

D

E

E

M

E

E

E

E(

R

R

I

I

E

L

B

I

E

F

AS

Point—The dee main systempoint tempera

y level. d Fuel System:Description—Apump (Ford P/Ning loop for thessure of 250 kPsing the 3-way. The excess fusistent temperarols—Maintain 20 kPa fuel pnsure good spe

Volume RequireBatch Approvalprocess: ore initial blend

physical specspecifications.and authorizes

ty of the analytample of the furation test is com.) The SP revl status of the fu

TABL

Condition

Duration, min

Engine speed, r

Engine power,

Manifold abs p

Engine oil in, °

Engine coolant

Engine coolant

Engine coolant(gage)

RAC coolant in

Rocker cover f

Intake, air, °C

Intake air press

Exhaust Manif

Lambda

Blowby flow ra

Intake air humi

Exhaust back p

Fuel flow, kg/m

et to atmosphe

ew point may m duct, verify tature at all poi

A schematic dia/N E7TF-9C40e fuel as shownPa ± 20 kpa at y Paxton regulafuel is mixed wature at the rail

the fuel temppressure to theeed, power, anded—Approximl Process—Ob

ding, typical sacifications. A . The ASTM Ss blending of thtical data of theuel is shipped tompleted usingviews the test rfuel batch.

LE 2 Sequence

r/min

kW

press, kPa (abs)

°C

t out,° C

t flow, L/min

t pressure, kPa

n, °C

flow, L/min

s, kPa (gage)

fold temperatur

ate, avg, L/min

idity, g/kg

pressure, kPa ab

min

eric or baromet

be measured the dew point pints downstrea

agram of a non07 or E7TC-9Cn. Regulate ththe rail. This

ator. The excewith the incomin

. perature to thee fuel rail. In d air-fuel ratio

mately 3300 L obtain fuel from

amples of the fsmall amoun

Sequence V Suhe entire batch e entire fuel bao the designateg reference oilresults and if a

DXXXX– 1

18

e VH Operatin

Stage I

120

1200 ± 5

record

) 69 ± 0.2

68 ± 0.5

57 ± 0.5

48 ± 2

70 ± 10

29 ± 0.5

15 ± 1

30 ± 0.5

0.05 ± 0.02

re TBD

1.00 ± 0.05

n —

11.4 ± 0.8

bs 104 ± 2

record

tric conditions.

in the main speriodically at

am of the humi

n-return fuel suC407), that booe fuel pressureis a non-returness fuel leavesng fuel before

e fuel rail beladdition, the

control.   of sequence VH

the supplier li

fuel blend comnt of fuel mixurveillance Pan

for engine testatch, and authored laboratoriesls selected by tacceptable, auth

5

ng Specificatio

Stage II S

75

2900 ± 5

record

66 ± 0.2

100 ± 0.5

85 ± 0.5

118 ± 2

70 ± 10

85 ± 0.5

15 ± 1

30 ± 0.5

2 0.05 ± 0.02

TBD

5 1.0 ± 0.05

60-70

11.4 ± 0.8

107 ± 2

record

.

system duct ort the test stand

midity measurem

upply system iosts the pressue at the fuel rain fuel system, ts the regulator the pump but a

low 50 °C. Tofuel pressure

H unleaded gasisted in X2.1.5

mponents are anxture is then nel (SP) confirting. After the rizes the engins. A statisticallthe SP. (The Shorizes the fue

on

Stage III

45

700 ± 25

1.30 ± 0.2

record

45 ± 1

45 ± 1

28 ± 2

70 ± 10

29 ± 1

15 ± 1

30 ± 0.5

0.05 ± 0.02

TBD

0.75 ± 0.03

—

11.4 ± 0.8

—A

record

r at the test sd. Maintain thement point to

is shown in Fiure and supplieil using a Paxtothe fuel rail is and is cooled

after the fuel m

o ensure good should be co

soline are requi. Each new ba

nalyzed, and thblended, ana

rms the acceptaentire batch is

ne test fuel apply designed tesSequence V Suel supplier to n

stand. If the de duct surface tprevent conde

ig. 1. Deliver tes the fuel to ton regulator orsupplied the re

d in the re-circumeter. The hea

d atomization oonstant at all

ired for each teatch of fuel is a

he data are comalyzed, and coability of the fs blended, the Sroval program

st program invourveillance Pannotify potential

ew point is temperature

ensation and

the fuel to a the fuel rail. r equivalent. equired fuel ulating loop at exchanger

of the fuel, steady-state

est. approved by

mpared with ompared to fuel mixture SP confirms . olving more nel designs l purchasers

(

sCsccth

N

A

B

C

D

E

F

G

H

cLcplaf

8.2.4.3 Add(new and previ

8.2.5 Fuel Bshipment to deCompare the rspecification bcontaminated ocontact the TMhe fuel supplie

NOTE 1—Appearan

A In accordanceB In accordanceC In accordancD In accordancE In accordanceF In accordanceG In accordancH In accordanc

8.2.6 Laborcalibrated SequLaboratories shcapability to anprovide an adeaboratory. Up

following analy

d fuel from a nous) mixture’sBatch Analysisetermine the vresults to the

band shown inor has aged pr

MC for help in rer's laboratory o

nce, water, lead, an

e with Test Mee with Test Mee with Test Mee with Test Mee with Test Mee with Test Mee with Test Mee with Test Me

ratory Storage uence VH testshould take comnalyze the fue

equate supply oon receipt of yses, report the

Reid vapo

API gravit

Distillatio

Lead (Tes

new batch to a s total volume. s—Upon receipvalue of the pa

values obtainn Table 3 besrematurely. If resolving the pof the as receiv

nd oxidation stabil

P

API gravityA

RVPB

Total sulfur

Existent gum

DistillationE

IBP

10 %

50 %

90 %

EP

Appearance

WaterF

LeadG

Oxidation st

ethod D1298 oethod D323 or ethod D4294, Dethod D381. ethod D86. ethod D6304. ethod D3237 oethod D525.

Tank Fuel Ans bimonthly. A

mposite samplel samples usinof fuel sample all fuel samp

e results to the

or pressure (Te

ty (Test Metho

on (Test Metho

st Method D32

laboratory’s fu

pt from the suparameters show

ned by the supide each paraany results fa

problem. One pved fuel sampl

TABLE 3lity are analyzed o

arameter A

C

mD E

e

tabilityH

r D287. Automatic Rei

D1266, or D26

or D5059.

alysis—AnalyzAnalyze fuel in

s using Table ng the test met

containers wiples required insubmitting lab

st Method D32

od D287 or D1

d D86)

37 or D5059)

DXXXX– 1

19

fuel tank when

pplier, it is thewn in Table 3pplier on that

ameter. This pall outside the potential methoe.

3 VH Fuel Anaon an absolute basi

Spec

60.7

0.01 %

5 m

22

48

98.

162

196

c

0.01

1

id Vapor Press622.

ze the contentsrun tanks, thos1 in Practice Dthods specifiedith packaging an 8.2.6 from oratory, and ta

23) Wash

298) Unw

5

n the current fu

e responsibility3 (except sulfut particular baprovides a met tolerances shod for resolvin

alysis is.

cification B

58.7 to 61.2

7 kPa to 63.4 k

% to 0.04 % by

mg/100 mL, m

2.2 oC to 35.0 °

8.9 oC to 57.2 °

.9 oC to 115.2 °

2.8 oC to 176.7

6.1 oC to 212.8

clear and bright

% by volume,

10 mg/L, max

1440 min, min

sure.

s of each fuel se with a direc

D4057, as a gud in Table 3 aand pre-addresthe laboratori

abulate the resu

hed gums (Tes

washed gums (T

uel level is bel

y of the laboraur, oxidation satch. The resuthod to determ

hown in Tableng the problem

Band

kPa

y mass

max

°C

°C

°C

 °C

 °C

t

max

n

storage tank tct feed line to tuideline. The fuand this sectionssed return labes, the fuel suults in a databa

st Method D38

Test Method D

low 10 % of th

atory to analyzstability, and dults should be mine if the fu 3, the laborais to obtain an

that contains futest engines, evuel supplier shn. The fuel su

bels to each Seupplier shall p

ase.

1)

381)

he final fuel

ze each fuel distillation).

within the uel batch is atory should n analysis at

uel used for very month.

hall have the upplier shall equence VH perform the

r

r

b

sf

a

sbmdT

8.2.6.1 Wheresults, analyze

8.2.6.2 The represent norm

8.2.6.3 Forwbase.

8.2.7 Fuel Bsafety and envifuel following a

8.3 Engine O8.3.1 Test O8.3.1.1 The 8.3.1.2 A m

allow for inadv8.3.2 System8.3.2.1 Con

severity. Measuby specifying tmounted heat ediameters are inThe internal vo

en results frome a second samp

fuel supplier al aging. The a

ward the results

Batch Shipmentironmental regall applicable sOil and Engine

Oil Description:test oil sample

minimum of 7.5vertent losses. m Description: nfigure the oil ure engine oil pthe volume, plexchanger shallndicated in Fig

olume of the en

m the physical ple, or conduct

Hydroca

Oxidatio

Potentiashall also iss

analysis shall ins of the analys

t and Storage—gulations, especsafety and envie Oil System: :

e shall be uncon5 L of new oil

system as shopressure at the lumbing configl be level with g. A7.8. The linntire external sy

and chemicalt the following

arbon speciati

on stability (T

al gums (Test sue a bimonthlnclude the parases performed i

—Ship the fuel cially when shironmental regu

ntaminated andis required to c

own in Fig. Apoints shown

guration, and othe oil-in therm

ne length and dystem shall be

DXXXX– 1

20

tests listed abg tests, or do bo

ion (Test Met

Test Method D

Method D87ly analysis of ameters in Tabin 8.2.6 and 8.

in containers whipment times ulations.

d representativcomplete the te

A7.8 to minimiin Fig. 4. The

orientation of tmocouple. Thediameter have a540 mL ± 30 m

5

bove appear tooth:

thod D2789)

D525)

73) f the fuel fromble 3. 2.6.1 to the TM

with the minimare anticipated

ve of the lubricaest. A 20 L sam

ize stand-to-staoil flow rate athe heat exchae lengths of thea large influencmL.

o differ signifi

m the main sto

MC for inclusi

mum allowabled to be longer

ant formulationmple of new o

and variationsand external pranger. The oil e lines are not sce on the volum

icantly from th

orage tank, wh

ion in the appr

e venting as dicthan one week

n being evaluaoil is normally

that could inressure drop arflow out of th

specified althome of the exter

he expected

hich should

ropriate data

ctated by all k. Store the

ated. provided to

nfluence test e controlled

he vertically ugh the line rnal system.

,Ofc

empea

8.3.2.2 UseOHT6A-012-4

fittings on the copper or galva

8.3.3 Heat Eexchanger has maintenance toprocess water exchanger P/N and the oil thro

oil filter ada4 (X2.1.11) or oil heat exchananized, as thesExchanger—Tadequate but

o provide adeqcontrol system5-160-02-008-

ough the shell. T

F

apter OHT6A-OHT6A-012-

nger are propee metals may i

The heat exchanot excessive

quate cooling, em is necessary-002 (X2.1.9). This orientatio

FIG. 4 Oil Pre

0007-1 (X2.1.5 (X2.1.11).

erly connected influence used anger has beene capacity to especially whey to achieve Configure the

on facilitates cle

DXXXX– 1

21

essure Gage C

.11), oil filter Use oil filter and secure. Thoil analysis.

n chosen to micontrol the oi

en process watthe specified

e system to alloeaning of the tu

5

Connections

r OHT6A-012-screen OHT6A

The external oil

inimize the voil temperatureter temperatureoil temperatu

ow the process tubes.

-2 (X2.1.11), A13-3 (X2.1.1l system compo

olume of the ee. The system e is high. An eures. Use vert water to flow

OHT6A-012-31). Be sure alonents shall no

external systemrequires a hi

effective, well-ically mountethrough the ve

3 (X2.1.11) ll hoses and ot be brass,

m. The heat gh level of -maintained d ITT heat ertical tubes

A

r

ef

sIs

p

A Test Rampingrelay to its norm

8.3.4 System8.3.4.1 Clea

exchanger is defrom or flushed

8.3.4.2 Regaseparate rinsesIncomplete clesubsequent test

8.3.5 Contropressure, is fou

8.4 Coolants8.4.1 Descr

Engi

Mani

Oil in

Cool

Rocktemp

Lamb

Engi

Mani

Oil in

Cool

Rocktemp

Engi

Engi

Oil in

Cool

Rocktemp

Lamb

g Requirementsmal position, al

m Cleaning: an the external etailed in Anned on the stand, ardless of the fs with hot wateaning of the ets. Incomplete col Specification

und in 12.5.7. Cs: iption—The en

T

ne speed

ifold absolute

nlet temperatu

lant outlet tem

ker arm coverperature

bda

ne speed

ifold absolute

nlet temperatu

lant outlet tem

ker arm coverperature

ne speed

ne power

nlet temperatu

lant outlet tem

ker arm coverperature

bda

s Information—llowing the ma

oil cooling sysex A10. Flush and so forth) i

flushing techniter (> 60 °C) external oil sycleaning may ans—The opera

Cyclic ramping

ngine coolant i

TABLE 4 Test

St

e pressure

ure

mperature

r inlet

S

e pressure

ure

mperature

r inlet

St

ure

mperature

r inlet

—At the start oass air flow sen

stem thoroughland rinse the es left to the disque employed,

  and degreasinystem may allalso cause oil t

ating conditionsg specifications

is equal parts o

DXXXX– 1

22

Ramping Req

tage III to I

1195 to 125

1200+

68.8 to 7569+0

67.5 °C

56.5 °C

29 °C w

Return AFRbeginning of

Stage I to II

2895 r/m

66 ± 0.2 62 - 7

99.5 °C w

84.5 °C w

84.5 °C w

tage II to III

715 r/min w

< 3 kW

46 °C w

46 °C

30 °C

0.705 to

of the III to I ransor to provide

ly before each external lines bscretion of the , use an organing solvent (7.7ow debris to temperature cos are specifieds are detailed in

of demineraliz

5

quirementsA

50 r/min with10 s to 25 s

+5 r/min with

5 kPa within 0.2 kPa within

C within 8 min11 min + 2 m

C within 6 min

within 17 min

R control to PCf the ramp

min within 30

2 kPa within 62 kPa from 0

within 7 min

within 7 min

within 17 min

within 5 s to 2

W at 5 s to 20 s

within 15 min

within 9 min

within 10 mi

o 0.765 at 15

amp, return thee the normal sig

test. An accepbefore each teslaboratory. ic solvent (see 7.1) before aidislodge and ntrol problems

d in Table 2. An Table 4.

zed (less than 0

hin 5 s to 20 ss hin 200 s

20 s to 80 s n 200 s

n ± 2 min min

n ± 2 min

n

CM at the

0 s to 90 s

60 s to 150 s s to 150 s

± 2 min

± 2 min

n ± 2 min

0 s 15s to 30

s

n ± 2 min

n ± 2 min

in ± 2 min

s

e mass air flow gnal to the eng

ptable techniqust. The specific

7.7.2) for the r-drying the ccirculate throu

s and contaminAdditional infor

0.34 g/kg) or d

s

s

to engine contgine.

ue for cleaning c technique use

final flushing fcomponents. (Wughout the engnate subsequenrmation concer

distilled water

trol module

the oil heat ed (removed

followed by Warning—gine during

nt test oils.) rning the oil

and a fully

fc2

e

t

n

8

s

r

s

in

p

s

to

Tac

ec

f

f

2

formulated ethcoolant is a sol2000 21,11 per 1

8.4.2 Genera8.4.2.1 A tra

entrained air. P8.4.2.2 An

emperatures. 8.4.2.3 The

near the measur8.4.3 Engine

8.4.3.1 Config

system volume

reservoir and p

shall be 9.0 L ±

nstall the therm

port in intake m

straight tube be

8.4.3.2 A ra

op of the coola8.4.3.3 The

Table 2. Informare detailed in control valve.

8.4.3.4 As aeach reference commercial des

8.4.4 RAC C8.4.4.1 Insp

flushing techniq8.4.4.2 Sche

from an externa

21

The sole source

ylene glycol blution of demin15 L of water. al System Descansparent secti

Provide a drain effective, we

system shall arement meters,e Coolant Syste

ure the engine

shall be 24 L ±

lumbing conne

± 2 L. The therm

mostat. Insert a

manifold (7.6.2

efore and after

adiator cap is uant reservoir (Fengine coolan

mation concernTable 4. The

a minimum, incalibration te

scaling cleanerCoolant Systemect and clean tque is not specematic diagramal source, such

of supply of Penco

based automotneralized (less

cription—The ion is requiredat the low poin

ell-maintained

allow precise c, and the flowmem Description

cooling system

± 2 L. This vol

ecting the coola

mostat housing

an orifice plate

.1). Install a co

meter. Install

used to limit syFig. A7.18). nt flow rate anning the cooling

coolant flow

nspect and cleaest. A specificr (7.7.3).

m Description: the complete Rcified. Howevems of the RACh as hot water, s

ool 2000 coolant k

tive antifreeze than 0.34 g/kg

following guidd to permit visunt of the systemprocess wate

calibration of tmeters used forn:

m according to

lume includes

ant reservoir w

g is modified to

e in the position

oolant flow me

coolant flow m

ystem pressure

d outlet tempeg flow rate merate is measur

an the engine cc flushing tech

RAC control syer, the techniquC coolant contrsteam, or an el

known to the comm

DXXXX– 1

23

to protect agag) or distilled w

delines are comual inspection m to allow comer control sys

the flowmetersr calibration.

the schematic

all equipment,

with the main sy

o accept the co

n of the thermo

eter per manufa

meter on the co

to 105 kPa. Pr

erature are coneasurement devred with a flo

coolant systemhnique is not

ystem prior to ue should emplrol systems areectric immersi

mittee at this time

5

ainst corrosionwater and an a

mmon to both thof the coolant

mplete drainingstem is necess

s, after installa

diagram show

, plumbing, and

ystem (see Fig

oolant outlet tem

ostat (OHT PN

acturer’s recom

oolant outlet sid

ressurize the c

ntrolled in accovice is detailed

owmeter (X2.1

m components, specified. How

running each oy a commercie shown in Figion heater.

is Penray Cos., Inc

n of all systemadditive treatm

he engine and . Provide air b

g of the systemsary to achiev

ation in the tes

wn in Fig. A7.1

d the engine ex

g. A7.18) The c

mperature ther

N: OHT6A-004

mmendation for

de of the.

oolant system

ordance with td in 9.3.2. Cyc.6) and contro

external to thewever, the tec

reference oil cial descaling cg. 5. Derive he

c., 1801 Estes Ave

m componentsent of 475 mL

RAC coolant sbleeds to allow. ve the specif

st stand. Avoid

8. The engine

xcluding the co

coolant reservo

rmocouple (9.1

4-1). Block coo

r position and l

to 70 kPa ± 10

the specificatioclic ramping spolled with an i

e engine, priorchnique should

calibration testleaner (7.7.3).eat for the con

e., Elk Grove, IL 6

s. The RAC L of Pencool

systems: w removal of

fied coolant

d turbulence

e coolant

oolant

oir volume

1.3). Do not

olant bypass

length of

0 kPa at the

ons listed in pecifications in-line flow

r to running d employ a

t. A specific

ntrol system

60007.

8.4.4.3 Cont

F

trol the RAC c

Legend

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

FIG. 5 Typica

coolant flow rat

Vented reserv

Coolant reserv

Pressure contr

Chilled proces

Stage I and III

F and P Co. fl10/448D053U

Rocker arm co

Inlet temperatu

Flow control v

External heat

Electric coolan

ABB Kent-1330LZ08000

al Rocker Arm

te and inlet tem

DXXXX– 1

24

oir cap

voir (fabricated

rol valve (optio

ss water contro

I heat exchange

owrator tube, FU06

overs

ure sensor

valve

source

nt pump DAYT

-Taylor flow e0-8375A

m Cover Heat

mperature in ac

5

d)

onal)

ol valve

er

FF-1-35-G-

TON 6K581A

element,

ting and Cooli

ccordance with

A

ing System

h the specificat

ions listed in TTable 2. The

cj

o

rr

x

9

c

thTd

wd

th

(

eea

(

(w

s

in

To

gp

s

Fc

F

coolant pressuracket. (Warni

8.5 Cyclic ra8.6 Closed L8.6.1 The tes

of 1.0 during st8.6.1.1 The t

run. The EEC right bank O2 s

8.6.1.2 Switcxx to run lambd

9.0 Measurem

9.1 Tempera9.1.1 Equipm9.1.1.1 Tem

calibratable to 09.1.1.2 All

hermocouple Thermocouplesdefined in ANS

9.1.2 Enginwater pump inldirectly opposit

9.1.3 Enginemperature sen

housing outlet. 9.1.4 Engine

(see Fig. A7.8)9.1.5 Engin

exchanger (seeexchanger. Theaxes.

9.1.6 Intake(55 ± 2) mm.

9.1.7 RAC C(see Fig. 5, itemwithin 2 mm of

9.1.8 Exhausspacer. Insure t

9.1.9 Calibrndicate within

9.2 Pressure9.2.1 Equip

This allows reaof the EEC syst

NOTE 5—Tubigood engineeringpass through low

9.2.2 Intakespacer (see A7.

9.2.3 EngineFig. 4 and Fig.cylinder head a

9.2.4 EnginFig. A7.18.

re is not specifng—Maintain amping specifiLoop AFR Const EEC is calibtages I and II. test bed controlwill then cont

sensors. ch the control da = 0.75 in St

ent Instrumen

atures: ment:

mperature meas0.5 °C. There a

thermocouplemay be an os, wires, and eSI MC96.1. e Coolant Inlelet (300 to 400te of the perpene Coolant Ounsor in the cen

e Oil Inlet—In. Tip of sensore Oil Outlet—e Fig. A7.8). e tip shall be w

e Air—Install th

Coolant Inlet—m 8). Locate thf the center disst Manifold Tethe washer therration—Calibra± 0.5 °C of the

es: ment—Pressur

asonable opportem with only ing between the g practice. This i

w-lying trenches b

e Manifold Abs.17). e Oil—Measur 7.24) Take cy

and front of thene Coolant Pr

fied, but desigthe system pre

ications are detntrol: brated to contro

l system must trol the fuel m

signal accordinage III.

ntation

surement locatare no temperaes, except th

open-tip type. extension wires

et—Install the 0) mm from thndicular outlettlet—Install thnter of the stre

nstall the tip ofr shall be even

—Install the tip Locate the se

within 2 mm o

he tip of the th

—Install the tip he sensor alontance between

Temperature – rmocouple is cate all thermoe laboratory ca

re measuremenrtunity for adapFord specifiedpressure tap loc

is particularly imbetween the test

solute—Measur

re oil pump preylinder head oie right cylinderressure—Meas

gn the system tessure below 7tailed in Table

ol the fuel mix

deliver a feed fanagement in

ngly from a vo

tions for the siture inputs to t

he intake-air tThe diameter

s should be m

sensor in the he face of the bt. (See Fig. A7.he temperatureeam of flow a

f the sensor at with the machiof the sensor

ensor along thof the center d

hermocouple m

of the thermocg the same axithe external mInstall a washontacting the ccouples prior

alibration stand

nt for each of ptation of existd equipment. cations and the fimportant in applit stand and the in

re the manifol

essure at the bil pressure mear head (see Fig.sure engine co

DXXXX– 1

25

to minimize th0 kPa to preve4.

xture to genera

forward discreclosed loop w

oltage of xx to

ix required temthe EEC thermocouple,r and length

matched to perf

outlet perpendblock. Install s.18).

e sensor in theand is located

the center of ined surface ofat the center o

he same axis, distance betwee

midstream in th

couple at the ceis, but opposit

most surfaces ofher type thermcylinder head. (to a reference

dard. The calibr

the eight requting test stand i

inal pressure senications where lonstrument conso

d absolute pre

bottom port of asurements on. 4 and Fig. A7oolant pressur

5

he pressure onent distortion of

ate a lamda val

eet signal to thewith feedback fr

run stoichiom

mperatures are

, shall be prof the therm

form in accord

dicular to the rsensor with the

e modified thein the thermo

the flow streamf the oil filter aof the cross fitbut opposite,

en the externa

he air cleaner (

enter of the crote the inlet portf the outlets alo

mocouple into (under investig

e oil test. The ration standard

uired parameterinstrumentatio

nsors should incoow air pressures le.

essure at the po

the oil filter adn the sides of th7.23). Use indivre at the top

n the RAC andf the RAC jack

lue of .75 durin

e EEC to indicafrom an averag

metric in Stages

e specified. Us

remium and smocouples shaldance with the

run of the tee e tip in the cen

ermostat housistat housing n

m through the adapter. tting attached the outlet po

al most surface

(see Fig. A7.1

oss fitting befort of the incomong the axes. hole provided

gation) temperature m

d shall be trace

rs is detailed in. Replace pre

orporate condenare transmitted

ort on the righ

dapter housinghe cylinder hevidually dedicaof the coolan

d prevent distoket.)

ng third stage

ate which lambge signal from

s 1 and 2 and a

se thermocoup

sheathed. Thell be 3 mm bspecial limits

fitting upstreanter of the strea

ing. Locate theneck within 80

external oil fi

to the bottom ort connected es of the outlet

). Insertion dep

ore the inlets oming fluid. The

d in the exhau

measurement sable to NIST.

in the followinessure sensors t

nsate traps, as indby means of line

ht side of the th

g on the engineeads on the reaated pressure snt reservoir as

ortion of the

and lambda

bda value to the left and

a voltage of

ples that are

e intake-air by 100 mm. s of error as

am from the am of flow,

e tip of the mm of the

ilter adapter

of the heat to the heat ts along the

pth shall be

f the RAC's tip shall be

ust manifold

system shall

ng sections. that are part

dicated by es which

hrottle body

e block (see ar of the left sensors. s shown in

aw

mthf

de

a

inr

mstr

Wp

(fEf

f

cC

thMM

2

9.2.5 RAC Calthough monitwithin the limit

9.2.6 Fuel—mounted directhe fuel rail ma

fuel rail.) 9.2.7 Intake

depth of the prentering the int

9.2.8 Crankand negative pr

9.2.9 Exhaun the Y (see F

recommended. 9.2.10 Cali

measurement ssystems shall raceable to NIS

9.3 Flow Ra9.3.1 Equipm

With the excepparameter. This

9.3.2 Engine(see Fig. A7.18from forming iEnsure that thflowmeter.

9.3.3 RAC flowrates as sho

9.3.3.1 Calicoolant flow prCalibrate the fl

9.3.4 Blowby9.3.4.1 Mea

hrough an exteMaintain crankMount the dum

22

Supporting data

Coolant—RACtoring of RACts of Table 2.

—Measure the tly to the injectay cause it to le

e Air—Measurerobe shall be 5take-air cleanerkcase—Measurressure. st Back Pressu

Fig. A7.16). A Install a conde

ibration—Calibsystem shall inconform to thST.

ates: ment—Flow raption of the es allows reasone Coolant—De8) An example in the lines to e manufacture

Coolant—Meaown in Fig. 5. ibration—Calibrior to a refereowmeters withy:

asure the blowbernal, sharp-ed

kcase pressure dmy PCV valve

have been filed at

C coolant pressC pressure is no

fuel pressure tor rail, the gageak. Any instru

e the intake-air50 mm ± 2 mmr. e the crankcas

ure—Measure tsensor capabl

ensate trap betwbrate all presndicate within he guidelines

ate measuremenengine coolantnable opportunetermine the en

of a flowmetethe pressure s

er’s required s

asure the total

brate the flowence oil test. Ch a turbine flow

by flow rate udged orifice anduring operatioand orifice pla

ASTM Internatio

sure can be meot required. Pr

near the injecge should be a

umentation atta

r pressure in thm. If a manom

se pressure at t

the exhaust bace of absolute oween the probesure measurem0.1 kPa of th

in ASTM Re

nt for each of tt and blowby

nity for adaptatingine coolant fer meeting this ensor. Transpastraight section

volumetric co

meters used inCalibrate the flowmeter or by a

using the apparnd into the engon of the systeate in a vertica

nal Headquarters a

DXXXX– 1

26

easured at the ressure should

ctor rail inlet damped, liqui

ached to the fue

he air cleaner meter is used,

the dipstick tub

ck pressure witor gage measue and sensor toment sensors

he laboratory csearch Report

the four requirflow rates, m

ion of existing flow rate by meaccuracy is lis

arent lines or bns of pipe are

oolant flow rat

n the measuremowmeters as involume/time m

ratus shown ingine intake manm at 0.0 Pa ± 2

al position.

and may be obtain

5

coolant inlet cremain adequa

as shown in Fid-filled type. (el rail should b

housing in theinstall a liquid

be. The sensor

th the exhaust urement correco accumulate w

prior to a rcalibration stant RR:D02-121

red parameters measurement e test stand insteasuring with asted in X2.1.6.bleed lines, or e installed imm

te through the

ment of both nstalled in the method at the t

n Fig. 6. The manifold by mea25 Pa to minim

ned by requesting R

cross fitting as ate as long as

Fig. 1. When (Warning—T

be supported by

e location showd trap to preve

r shall be capa

gas sampling pcted with baromwater present in

eference oil tndard. All oth8.22 The calib

is detailed in tequipment is ntrumentation. a flowmeter w Take precauti

r both, are benmediately up

e RAC system

the engine co system at the

three operating

measurement sans of an auxilmize the potent

Research Report R

is done with ttemperature a

utilizing a preoo much massy something ot

wn in Fig. A7.ent manometer

able of measur

probe located dmetric pressure

n the exhaust gatest. The MA

her pressure mbration standa

the following snot specified f

with an accuracyions to prevent

neficial in this and down str

m and the indiv

oolant flow rat test stand wit

g conditions. Se

system routes iary (dummy) tial for crankca

RR:D02-1218.

temperature and flow are

essure gage s attached to ther than the

.1. Insertion r fluid from

ing positive

downstream e reading is as.

AP pressure measurement ard shall be

subsections. for a given

y of < 0.5% t air pockets application.

ream of the

vidual RAC

te and RAC th test fluid. ee Table 2.

the blowby PCV valve. ase leakage.

ind

cofin

pscd

9.3.4.2 Detenclined manom

differential pres9.3.4.3 Fabr

compliance witobtained from tfor the range on X2.1.11.

9.3.4.4 As a particular care solvent (see 7.compressed airdisassembled fo

9.3.4.5 Calib

ermine the blometer or diffessure drop sensricate the sharpth the specificthe source listef blowby flow

minimum, clewhen cleaning7.2) until clear to force-dry. or cleaning, mabrate the blow

Legen

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

FI

owby flow rateerential pressusor shall have ap-edged orificecations that areed in X2.1.8 T

w rate encounte

an the blowbyg the orifice man, followed by

Inspect the pake sure the co

wby orifice me

nd

12.7 mm valve

PCV valv

Oil separ

Surge ch

Orifice m

Pressure

Crankcas

Bleed val

Dummy P

Thermom

Excess blnormal o

IG. 6 Blowby

e by measurinure sensor is a range from 0

e assembly thate available fro

The assembly cred. The comp

y measurement eter assembly.y hot (> 60 °Cort passages a

ore is properly eters used for

DXXXX– 1

27

full flow stain

ve

rator (F47E- 6A

amber

meter

transducer

se pressure gag

lve

PCV valve

meter or temper

lowby vent pipperation)

Measuremen

ng the differenrequired for m

0 kPa to 1 kPa.t is specificallyom the TMC. contains five oplete orifice as

apparatus wee Clean the thre

  C) water rinse and remove anseated upon re

r laboratory m

5

nless steel ball

A785-AA)

ge

rature sensor

pe. (during

nt Apparatus

ntial pressure dmeasurement

y designed for Additional inf

orifices. The 9.sembly can als

ekly. Replace tee-way valve band spray rins

ny carbonaceoueassembly. measurements

drop across thof the differe

blowby flow rformation on t525 mm orificso be purchase

the o-rings witby soaking these with degreaus deposits by

standards eve

he sharp-edgedential pressure

rate measuremthe orifice sys

ce is generally ed from the sup

th each cleanine valve in agitaasing solvent (y scraping. If t

ery six months

d orifice; an e drop. The

ment in strict stem can be satisfactory pplier listed

ng. Exercise ated organic (7.7.1). Use the valve is

s. Calibrate

laNwa

e

ts

maSsd

bto

sa

a

o

e

wbinpmp

NgNNNN

aboratory blowNIST. Calibratwithin the threeand result in err

9.4 Fuel Coexternal fuel tan

9.4.1 Calibraemperature an

stand shall be w9.5 Speed an9.5.1 The dy

meet the rampiand II. BecausStage III, manaspecified tolerdynamometers

9.5.2 Utilize by varying the otal driveline i

9.5.3 Calibrascale readout isa reference oil t

9.6 Exhaust 9.6.1 Equipm9.6.1.1 Dete

accuracy of ± 09.6.1.2 Calib

oil test sequenc9.6.2 Calibra9.7 Humidity9.7.1 The int

each reading, fo9.7.2 The pr

with a minimubetween the prnterval shall b

periods of 20 mmeasurements perfect gas law

NOTE 1—Test Tg/kg. NOTE 2—HumiNOTE 3—X = MNOTE 4—If meNOTE 5—If stan

wby measuremte the temperae-way valve mroneous blowb

onsumption—Dnk. The measuate mass flownd specific gravwithin 1 % of thnd Torque:

ynamometer speing requiremene the dynamomage the controrances. These have slow cona full closed-lelectrical curre

inertia through ate the load cels recommendedtest. Gas:

ment: ermine the air- 0.021 of lambdabrate, zero, andce or wheneverate the lambda ty: take air humidior non-standardimary laborato

um dew point arimary laborate appropriate f

min to 2 h, wittaken with th

w. The sample li

Type-VH; Tes

idity readings aMean differencean difference >ndard deviatio

ments standardsture measuring

may cause someby flow rate meDetermine the furement point imeter or gravvity compensahe calibration s

eed and torquents specified inmeter and drivl input and sytolerances ar

ntrol response aloop system usent to the dynato the dynamo

ll transducer ad once per day

-fuel ratio usina. The requiredd span the AFRr a sensor is repmeasuring dev

ity is recorded d barometric cory measuremeaccuracy of ± tory system anfor the time coth measuremene calibration hine shall be no

Tt Stand – 29; D

are corrected fce, g/kg – 0.2.S> 1.4 g/kg, calin > 0.71 g/kg,

Reading

1

2

3

, not used for pg devises in the of the blowbyeasurements (sefuel consumptis upstream of t

vimetric systemated and calibrstandard.

e control systemn Table 4. Thesveline frictionaystem responsere necessary at low speeds asing a dry gap amometer and ometer, excludind readout sys

y during the oil

ng a wide bandd device is shoR sensor in accplaced. vice before eve

using the laboonditions, usinent system is c 0.55 °C at 16 nd the calibratonstant of the hnts recorded athygrometer aren-hygroscopic

TABLE 5 HumiDate – 11/12/15

for non-standarS = Standard deibration is invacalibration is i

Zi

System

Humidi

11.3

11.2

11.2

DXXXX– 1

28

production, yehe blowby sysy gas to pass dee Fig. 6).) ion rate by methe return flowms prior to eaated against a

ms shall be capse limits requiral losses mighte during Stage to maintain a

and are not suitdynamometer.maintains engiing the engine stem with deadl level soak pe

d O2 sensor to wn in A13.9

cordance with t

ery reference te

oratory's primarng an additive ccalibrated at ea °C. The calibrtion hygromet

humidity measut intervals of 1e corrected to . Exercise prec

dity Calibratio5; Barometric p

rd barometric peviation, g/kg –alid. invalid.

Yi

m Calibra

ity Humi

11.

11.

11.

5

early. The calibstem every sixdirectly to the i

easuring the amw from the fuel

ach reference mass flow de

pable of maintare control witht approach theIII carefully t

a stable air-futable for operat. A typical closine power by vflywheel, shal

dweights at leaeriod. Calibrate

measure Lam

the user's manu

est.

ry humidity mcorrection deriach stand on aration consists ter (see Table uring instrume

1 min to 6 min standard barocaution to prev

on Example pressure – 29.1

pressure. – 0.11.

i Y

ation

idity Diffe

.4 0

.5 0

.5 0

bration standarx months. (Waintake manifold

mount of makerail (see Fig. 1oil test. Volu

evice. The flow

aining the limithin ± 0.9 % for e power produto maintain en

fuel ratio durition during Stased-loop systemvarying the engll be 0.8 kg·m2

ast once per tee the speed me

mbda. The devi

ual prior to con

measurement syived from the pa semi-annual of a series of5 for an exa

ents and the con intervals, are ometric pressuvent condensati

1 in. Hg; Humi

Yi-Zi

ference

0.1

0.3

0.3

rd shall be tracarning —Interd from the test

e-up fuel flowin1). umetric system

wmeter located

ts specified in operation duri

uced by the enngine operationing Stage III.age III. m maintains engine throttle po ± 0.1 kg·m2. st. Calibrationasurement syst

ice shall have

nducting a stan

ystem. Make coperfect gas lawbasis using a

f 20 paired meample). The montrol system. C

typically acceure (101.1 kPaion of the samp

idity correction

ceable to the rnal leakage t PCV valve

ng from the

ms shall be d on the test

Table 2 and ing Stages I

ngine during n within the . Hydraulic

ngine speed osition. The

n of the zero tem prior to

a minimum

nd reference

orrections to w.

hygrometer easurements

measurement Comparison eptable. The a) using the ple.

n – to 0.28

thsm

h

1

ss

s

1

ucccpt

c

apthinS

9.7.3 The dihe mean differ

shall be met to met, the laborat

9.7.4 The calhousing.

10. Miscellane

10.1 STAR Tsystem in case service manual

10.2 Beakersuitable for oil

11. Test Stand

11.1 Verifica11.1.1 Verif

upon expiratiocalibration timecounted towardconsidered withprevious calibrest results.)

11.1.2 A recalibration test.

11.2 Unacce11.2.1 It is r

application of sprecision contrhe laboratory, ndustry exper

Surveillance Pa

ifference betwerence cannot econsider the p

tory shall inveslibration samp

eous Laborato

Tester —A STAof a malfunct

. r—A beaker wiadditions.

d Calibration

ation: fy the calibration of either the periods may ds the 10 allowhin the calibraration test in th

ference oil sam. eptable Calibrarecognized thastatistics in the ol chart limits in conjunction

rtise (other teanel, Sequence

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

een each pair ixceed 1.4 g/kg

primary humidstigate the causle tap is locate

ory Equipmen

AR (self test ation or operatio

ith a capacity o

on of test standhe 120 day ca

be adjusted bywed runs. Anyation period, prhe stand are no

mple of 22.4 L

ation Results: at a certain pdevelopment ocan be indicat

n with the TMCesting laboratoe V Operation

11.2

11.3

11.3

11.3

11.3

11.4

11.4

11.5

11.5

11.4

11.4

11.5

11.6

11.6

11.6

11.6

11.5

s computed ang, and the stan

dity measuremese, make repaired on the air lin

nt

automatic readoonal abnormal

of 5000 mL is

ds. (See A.2.2.alibration time y the TMC. Ady non-referencerovided the 10ot exceeded. (F

L is provided

ercentage of cof the acceptantive of a false aC shall attemptories, the test

and Hardware

DXXXX– 1

29

11.

11.

11.

11.

11.

11.

11.

11.

11.

11.

11.

11.

11.

11.

11.

11.

11.

nd used to formdard deviation

ent system to brs, and recalibrne to the engin

out), IDS or eqlity. Instruction

suitable for th

1 for general dperiod or aft

dditionally, anye oil test starte allowed non-rFollow instruct

by the TMC

calibration tesnce limits. Failalarm or a stant to determine t sponsor, ASe Subpanel, an

5

.6 0

.6 0

.6 0

.6 0

.6 0

.6 0

.7 0

.7 0

.7 0

.6 0

.6 0

.6 0

.6 0

.7 0

.7 0

.7 0

.7 0

m a mean and stn cannot exceedbe calibrated. Irate. The calibrne, between the

quivalent testerns on the use o

e initial oil fill

details.) Stand fter completingy test terminated within 120 reference oil ttions in A2.6

(see A2.5 for

sts fall outsidelure of a referend, laboratory,the problem s

STM Technicand so on) to he

0.4

0.3

0.3

0.3

0.3

0.2

0.3

0.2

0.2

0.2

0.2

0.1

0.0

0.1

0.1

0.1

0.2

tandard deviatd 0.71 g/kg. BIf either of thesration data is me main duct an

r will be necesof the STAR t

l. A beaker wit

calibration tesg 10 non-referted with 50 tes

days of the ptests that have and A2.6.1 for

r additional inf

e the acceptanence oil test to m or industry pr

source. The TMal Guidance elp determine

tion. The absolBoth of these rese requirement

maintained for nd entrance to t

ssary to diagnotester can be f

th a capacity o

sts are normallyrence oil testsst hours or lessprevious calibra

been completer reporting the

formation) for

nce limits becameet Shewhartroblem. When MC may solicitCommittee, Sthe cause and

ute value of equirements ts cannot be two years. the air filter

ose the EEC found in the

of 500 mL is

y conducted s. However, s will not be ation test is ed since the e calibration

r each stand

ause of the t or EWMA this occurs,

t input from Sequence V

extent of a

p

ttin

rdto

arn

o

os

r1s

Caunnot

1

th

problem. The S11.2.2 If the

ests running inests run durinndividual test.

11.2.3 The Tresolved. The ldocumentation o other tests op

11.3 Test Staa calibrated starequiring hardwnecessary after

11.3.1 See A11.4 Referen11.4.1 Labo

of all reference11.4.2 With

oils without thesix months.

11.5 Test Nu11.5.1 Accep

represents the n10-175 represenstand.

11.5.2 UnacCCC portion ofand continue alunacceptable canext two test nnumber 6-0-17operational timest number of

12. Test Proce

12.1 Pre-tes12.1.1 Engin

he test oil.

Sequence V SurTMC determi

n other stands g the problem

TMC reschedulaboratory shallto the acceptab

perated during and Modificatiand to the TMware or controthe modificati

A.2.2 for relatednce Oil Accounratories condu oils used. (See

h the exception e permission o

umbering Systeptable Tests—Tnumber of testnts the 175 tes

cceptable or Af the test numblphabetically ualibration test numbers would5C would perm

me on tests othetests other than

edure

st Procedure: ne Break-In Pr

Condition

Duration, min

Total time, h

Engine speed

Engine powe

Manifold abs

Engine oil in

Engine coola

Engine coola

RAC coolant

rveillance Paneines the problewithin the lab

m period shall

les a calibratiol provide adequble calibration the same perio

ions—Report mMC immediateloller modifications have been d information antability:

ucting calibratioe A2.3 for relaof new oil ana

f the TMC. (Se

em: The test numbets since last refst on Stand 6 an

borted Tests—ber for subsequuntil a calibratio

are completedd be 6-0-175Amanently identier than calibratn calibration te

rocedure—Run

TA

n

:min

d, r/min

er, kW

s press, kPa (ab

, °C

ant out, °C

ant flow, L/min

t in, °C

el adjudicates iem is a false alboratory. If thebe considered

n test once it iuate documenttest report. It s

od. modification ofly. A nonstandtions to the tecompleted.

about non-stan

on tests are reqted informationalysis requiredee A2.4 for ad

er shall follow ference. CCC rnd the tenth te

—If a calibrationuent calibrationon test is comp

d on the same tA and 6-0-175Bify the test andtion tests will cests.

n break-in sch

ABLE 6 Seque

Le

2

150

bs)

8

9

n 4

DXXXX– 1

30

industry problelarm and is stae TMC determ

invalid, unles

is satisfied thattation to supposhall provide s

f test stand condard test inclu

est stand. The

dard tests.

quired to providn.)

d in 13.6, perfodditional inform

the format AArepresents the st since the las

n test is aborten test(s) shall inpleted within thtest stand, andB. If the resuld appear on futcause the test n

edule listed in

nce VH Break

Oil eveling

2, min

0

00 ± 25 700

1.30

37.6

80 ± 2

90 ± 2

8 + 2 28

5

ems. and-related, th

mines the problss there is spe

t no particular ort conclusionssufficient inform

ntrol systems oudes any test cTMC determi

de a full accou

orm no physicamation) Retain

AA-BB-CCC. Atotal number o

st reference. Co

ed or the resulnclude a letter he acceptance ld the test standlts of the next ture correspondnumber to incr

n Table 6. Con

k-in Schedule

1 2

5 4

0:05 0:

0 ± 15 2900

0 ± 0.2 rec

66 ±

100

85 ±

8 + 2 118

85 ±

ere is no impalem is laborato

ecific evidence

problem exists reached durinmation to show

or completion ocompleted undines whether a

unting of the id

al or chemical engine parts f

AAA represents of tests on the onsecutively n

lts are outside suffix. Begin tlimits. For exa

d number of thcalibration te

dence. The comrease by one. A

nduct the break

Step

2 3

40

:45 1

0 ± 5 700

cord 1.30

± 0.2 re

± 0.2 45

± 0.2 45

8 + 2 28

± 0.2 29

act on other noory-related, noe to the contra

ts or the probleng this process.w how the prob

of any nonstander a modifiedanother calibra

dentification an

analysis of nefrom reference

the test stand n stand. As an e

number all tests

the acceptancethe suffix with

ample, if three he first test is 6st are acceptabmpletion of anyAdd no letter s

k-in before eac

3

45

1:30

0 ± 15

0 ± 0.2

ecord

5 ± 1

5 ± 1

8 + 2

9 ± 1

on-reference on-reference ary for each

em has been . Attach this blem related

ndard test on d procedure ation test is

nd quantities

w reference oil tests for

number. BB example, 6-s on a given

e limits, the h the letter A consecutive 6-0-175, the ble, the test y amount of suffix to the

ch test using

3a

o

cp

bb7a

thth

o

e

ces

d(a

p

s

12.1.1.1 Ch

37.6 kPa MAP after shutdown

12.1.1.2 Theof the operating

12.1.1.3 Thecheck for leakprocedure are s

12.1.1.4 Dur12.1.1.5 Du

be indicative ofbut within the f75) L/min duriadjustment is at

12.1.1.6 Durhe oil and coolhe idle load cir

12.1.1.7 Reoperation at a r

NOTE 6—The

12.1.1.8 Chensure that the

12.2 Engine12.2.1 Engin12.2.1.1 Tur12.2.1.2 Con12.2.1.3 Cr

cranking oil prengine to start start the engine

12.2.1.4 If sdiagnostics to (Warning— Eaddition to othe

12.2.2 Engin12.2.2.1 Sch

performed. Sch(1) Bring the(2) Switch th(3) Turn off (4) Reduce th12.2.2.2 Un

shutdown is per(1) Stop test (2) Ramp to    From Stage   From Stage

Lambda

Exhaust back

Speed, power

Oil leveling –

Step 1 to 2 –

Step 2 to 3 –

arge the enginuntil the oil te

. This shall be e laboratory amg area are not se break-in allo

ks in the varioshown in Tablering Step 1, blering Step 2, chf the blowby flfirst 48 h of thing the break-t the laboratoryring Step 3 (selant temperaturcuit and the Ecord all normaich air-fuel ratengine normally

eck and recordoil level is bro

e Operating Prone Start-up—Urn on the ignitinnect the intakank The Enginressure might beven though th

e. starting difficuldetermine the

Excessive cranker precautions, ne Shutdown: heduled Shutdoheduled shutdoe engine speed he ignition off. fuel and RAC he intake-air pr

nscheduled Engrformed: timer when ramStage 3: e 1—15 s speede 2—Perform S

k pressure, kPa

r and MAP ram

– 20 s ramp fr/i

60 s ramp

15 s ramp

ne with 3000 gemperature reathe Test Full m

mbient atmosphspecified. Diveows an opportuous systems ane 6. The engineeed the air fromheck blowby lelow rate duringe test, to achiein typically py's discretion, nee Table 6) cheres to reach 45EC system opeal parameters io can cause exy requires approx

d oil level afteought back to thocedure:

Use the followinon, safety circu

ke-air supply dune—The enginbe low. If usehe oil pressure

lties are encounreason the en

king times can do not attempt

own Procedurwns include shto 700 r/min ±(Turn off powcoolant pumpsressure to atmogine Shutdown

mp down starts

d and load setpStage 2 to 3 ram

(abs)

mps

idle

g of test oil befaches 80 oC ± 2mark for this tehere shall be reert air from fanunity to check nd purge air

e start-up and sm the engine anevel for the Stag the test. A rineve an adequateproduces accepnoting that a rieck the operati5 oC ± 0.5 °C. Leration with a Sin Steps 2 andxcessive fuel dximately 20 min

er break-in. If he last known o

ng detailed prouits, fuel manauct. ne should stared, disable a loe is low. The in

ntered, the labongine will not promote additt to pour gasol

e—Follow thehutdowns that o± 50 r/min and wer to the EECs. ospheric. n—Follow the

s.

point ramp; 6 mmp (Table 4).

DXXXX– 1

31

fore the break-2 °C or for at

est. Use the tabeasonably free s or ventilationEEC system ofrom the coolhutdown procend RAC coolanage II conditiong gap adjustme blowby flow ptable blowby ng gap adjustmon of the idle l

  Lambda valuesSTAR tester. d 3 after opera

dilution and alten to reach steady

piston rings aoil level by add

ocedure each tiagement system

rt within 4 s. ow oil pressurenclusion of this

oratory shouldstart (ignition

tional fuel diluine into the int

procedure detoccur during encoolant flow toand ignition, m

e procedure de

min setpoint ram

5

1

-in run. Run thleast 2 min. R

ble in Annex Aof contaminan

n systems awayoperation, blowling systems. edures are detant systems and

ons. A high or ment can be per

rate. Testing hduring the te

ment cannot beload control sys shall match th

ation at each ser test severity

y-state conditions

are regapped oding new oil or

ime the engine m, fuel pump, a

Since the enge ignition shuts type switch c

d not continue tn problems, insution of the testtake-air horn.)

tailed as followngine break-ino 28 L/min ± 2maintain power

etailed as follo

mp of other co

.0 0

he engine at 1Record the dips

12 to determinnts. The tempery from the test

wby levels, LamSpecifications

ailed in 12.2.1 d check all fluidlow blowby fl

rformed at this has shown thatest. However, e made at any oystem and EECthe values liste

step for 35 miy.) s after a step cha

or replaced durr removing oil

is started. and the rocker

gine has a cratoff during encould lead to e

to crank the ensufficient or et oil and can ad

ws, each time n and oil levelin2 L/min for 10 r to the keep al

ows, each tim

ontrolled param

0.75

500 r/min ± 2stick level 20 mne the oil level.rature and humengine.

mbda for Stags concerning tand 12.2.2 respd systems for llow rate at thistime or after th

t a blowby ranthe need for

other time durinC system operad in Table 6. I

  in. (Warning—

ange.

ring or after th.

arm cover coo

ankshaft drivenngine starting texcessive crank

ngine excessiveexcess fuel, andversely affect

a scheduled sng: min. live memory (K

me an unschedu

meters.

5 r/min and min ± 2 min

midity levels

e II and III, the break-in pectively. eaks.

s time could he break-in,

nge of (65 to a ring gap

ng the test. ation. Allow f not, check

—Prolonged

he break-in,

olant pump.

n oil pump, to allow the king time to

ely. Perform nd so forth). t the test. In

shutdown is

KAM).)

uled engine

p

p

cc

fc

tu

u

intinisfr

th

f

w

P

T

NOTE 7—Tota

(3) Switch th(4) Turn off (5) Reduce th12.2.2.3 Sta

performed after(1) Start—5     Return to S    Return to SNOTE 8—Test

12.2.2.4 Staperformed after

(1) Start—5 12.2.3 Cycli12.2.3.1 The

cycle lasts 4 h acycle is modifie

12.2.3.2 Ramfuelling and locomponent wea

12.2.4 Unscest and are cou

unscheduled do12.2.5 Resu

until the engine12.3 Period12.3.1 Blow

nto Stage II. Temperature is nstallation of ts detailed in 1

special circumsflow rate measureason for the a

12.3.1.1 Me(1) Connect t(2) Open the(3) Connect t(4) Position

he blowby mea(5) Connect t(6) Adjust th(7) Record th(8) Disconne(9) Disconne(10) Position

from the three-w(11) Connect(12) Calculat

where:

P = baro-pre

T = gas temp

al cooldown time

he ignition and fuel pump. he intake-air pr

art-Up After Unr an unschedulmin in Stage 3

Stage 1—StageStage 2—60 s t time resumes af

art-Up After Or an oil levelingmin in Stage 3

ic Schedule, Gee test is compand is repeateded to provide tmping requirem

oad changes, aar. Therefore, rcheduled Downunted as test timowntime on themption of Test

e has reached oic Measuremen

wby Flow Rate The engine shal

at least 32 °C.the blowby flow12.3.1.1. Compstances additiourement appar

additional measasurement Prothe apparatus p bleeder valve the bleeder linthe three-way asurement appthe hose from

he bleeder valvhe differential pect the apparatuect the surge chn the three-wayway valve. t the air vent hte the blowby f

co

essure, kPa, an

perature, °C.

e is 6 min after t

RAC coolant p

ressure to atmonscheduled Shued shutdown.

3, then to: e 3 to 1 ramp (speed and loadfter all controlle

Oil Leveling Peg period.

3; then Stage 3 eneral Descriposed of three

d 54 times for aime for oil samments specifyis well as the ramping rates antime—The oilme. However, e Supplementalt Time After Uoperating condints and FunctioMeasurement—

ll be stable and  Blowby gas t

w rate measureplete only one

onal blowby floratus or the engsurements. Incocedure: pressure sensorcompletely. e to the three-wvalve to divertaratus. the blowby mee to maintain cpressure, blowus pressure senhamber hose fry valve to diver

ose to the intakflow rate and c

orrected blowb

nd

the initiation of t

pump off (turn

ospheric. utdown—Follo

Table 4). d setpoint rampd parameters are

eriod—Follow

to 1 ramp (Tabption: stages as showa total of 216 hmpling and leveing parameter amount of enrare very importl leveling periothe test can bel Operational D

Unscheduled Shitions for the stons: —Every sixth d operating at ntemperature shement apparatue set (Stage II)ow rate measurgine. Record alude these data

r to the dipstick

way valve. t intake manifo

eter surge chamcrankcase press

wby gas temperansor and reconnrom the air venrt intake manif

ke-air cleaner.correct the valu

by flowrate = b

DXXXX– 1

32

the ramp to Stag

n off power to t

ow the procedu

p; 10 min setpoe within specific

the procedure

ble 4).

wn in Table 2.h. Six consecuteling. This modchange rates arichment betwtant. ods of 30 min e interrupted toData Form of thhutdown—Aftetage at which t

cycle, measurenormal Stage I

hall not differ fus is shown in ) of blowby flrements can be

additional blowa in the supplem

k tube.

old vacuum fro

mber to the 15.9sure at 0 Pa ± 2ature, and the bnect the engine

nt hose. fold vacuum to

ue to 38 °C and

lowby flowrate

5

ge 3 conditions.

the EEC and ig

ure detailed as

oint ramp of othcation

e detailed as f

Together, thetive cycles are dification is deare shown in T

ween stages, ca

are the only so perform necehe final test reper an unscheduthe shutdown o

e and record tII operating cofrom the laboraFig. 6. The pro

flow rate mease performed to

wby flow rate mmental operatio

om the engine

9 mm inside-d25 Pa. barometric pree crankcase pre

o the engine PC

d 100 kPa using

e × (3.100(P/2

gnition, mainta

follows, each

her controlled

follows, each t

e three stages ccompleted eacescribed in 12.3Table 4. The raan influence sl

cheduled shutdessary maintenaport. uled shutdownoccurred.

the blowby floonditions. Measatory average ocedure for me

surement durino determine or measurements onal data in the

PCV valve to

diameter air ven

essure. essure sensor to

CV valve and d

g the calibratio

273.15+T))0.5

ain power to th

time an engin

parameters.

time an engine

comprise one ch 24 h period. 3.1. ate of speed, tludge severity

downs allowedance (see 12.3.

n, test time doe

w rate at 30 msure blowby wby more than easuring blowb

ng each six cyverify a probleand an explane final test repo

the dummy PC

nt hose on the a

o the dipstick t

disconnect the

on data for the

he KAM).

e start-up is

e start-up is

cycle. Each Every sixth

temperature, and engine

d during the .5). Note all

es not begin

min ± 5 min when the gas

± 5 °C. The by flow rate

ycles. Under em with the

nation of the ort.

CV valve in

air cleaner.

tube.

bleeder line

orifice.

I

imin

2m4eosso

Uto

m

+

1

emO

Tc

o1rU

r

c

thth4p

tpth

12.3.2 IgnitIgnition timing

12.3.3 Exha12.3.3.1 The

mmediately afnto each stage)

12.3.4 Oil A12.3.4.1 Oil

24 h. Annex Amaintenance (s400 g. Add onlexcept after pisoil until the levsufficient amousheet. The procoil sampling an

(1) Remove (2) Remove (3) Return th(4) Shut-dow(5) Record th(6) Compute

Use the chart ino the sample ta

(7) If the levmark, –400 g. H

(8) If the lev+200 g.

(9) Restart th1 min, then resu

12.3.5 Geneengine and stamaintenance. HOperational Da

12.4 SpeciaThese maintenacare while bein

12.4.1 Blowof the test. Blo120 h of the tereplacing pistonUse the ring cu

12.4.1.1 Higrings that have

12.4.1.2 Locompression rin

12.4.2 Engin12.4.2.1 Eng12.4.2.2 Wh

he oil for instahe deposits are

4.6 L engine copans to collect

12.4.2.3 Durest oil during e

pan and collecthe Supplement

tion Timing Mneed only be cust Gas Analyse recorded readfter the engine ). The data are

Additions and Ul Leveling and

A14 shows the see 12.4.2.2). Aly enough newston ring gap avel is above thunt of oil so thcedure is shownd oil addition a 150 mL purga 60 mL analy

he purge samplwn the engine 1he dipstick levee the oil level in Annex A12 taken at 216 h. vel is more tha

  However, nevevel is more than

he engine 30 mume normal op

eral Maintenanand maintenanHowever, minata Sheet. l Maintenanceance procedure

ng completed. wby Flow Rate Aowby might droest shall fall wn rings as nece

utting procedurgh Blowby Flowsmaller ring ga

ow Blowby Flngs. ne Disassemblygine assembly hen the engine allation into the not disturbedontains numerooil that drains ring reassemblengine reassemted from the ental Operational

Measurement—Ichecked if impsis: dings for exhauoil and coolantused to confirm

Used Oil SamplSampling Procycle when th

Add new oil tow oil to reach tadjustment (seehe test full mahat the level is

wn on the Oil Sadata sheet.

ge sample withsis sample withe to the engine

10 min after theel in millimetrein grams. The dto determine th

an 400 g belower add more than 200 g above

min ± 1 min afperation. nce—The schednce. In additioimize the dur

e Procedures—es are specific

Adjustment—Aop from the brwithin the rangessary. Ensure e outlined in 7w Rate Adjustmaps. low Rate Adju

y and Reassemand disassembis disassemble

he engine after d on any parts, ous areas that hoff while mainly, used, draine

mbly. After the ngine parts durl Data.

Ignition timingproper EEC and

ust gas Lambdt temperatures m that the EECling:

ocedure—Makeis is to occur.

o the engine onthe low mark

e 12.1.1.8). In tark by more th at the 200 g a

Sampling, Addit

in first 10 min hin first 10 mine. e start of Stagees 20 min ± 2 mdifference betw

he level. Do no

w the Test Fullan 400 g duringthe Test Full m

fter shutdown (

duled shutdownon, the test caration of a sh

—Functions thaally detailed b

A blowby adjureak-in level buge from 60 L/mthat the ring a.8.5.2. ment—Reduce

ustment—Incre

mbly for Maintebly shall adhereed for maintenreassembly. Tparticularly on

hold oil after thntenance is beined test oil mayengine has be

ring disassemb

DXXXX– 1

33

g is set by thed ignition oper

da are taken duhave reached s

C system is ope

e-up oil additioUsed oil addit

nly when the lof 400 g. No the event that than 200 g. If mabove test full tion and Level

of Stage III. n of Stage III.

e III. Turn off fmin after the enween the oil leot add oil at 21

l mark, record g an oil additiomark, record th

(Step 4). Allow

n periods of 30an be shut dowhutdown. Repo

at require specbecause of the

stment can onlut the correctemin to 70 L/m

and piston com

high blowby f

ease low blow

enance (Beforee to the procedunance, drain asTake precautionn any parts thahe engine is drang performed.

y be used to luben reassembledly and mainten

5

e EEC and canration is suspec

uring each stagsteady-state coerating the eng

ons for levelintions are permlevel is below other new oil the oil level is more than 200 mark. Recordling Worksheet

fuel pump. Do ngine is shutdo

evel and the Te6 h. This allow

the amount ofon. he amount of o

w the engine to

0 min during own at any conort any unsche

cial maintenanceffect on test

ly be made dured average Stag

  min. Adjust thembination in ea

flow rate by re

wby flow rate

e End of Test):dures in 7.8 ands much test oil ns to ensure th

at are used to dained. All parts

bricate the engd, charge the onance. Record

n only be checcted.

ge and each cyonditions (apprgine at the corre

ng and oil sampmitted only duri

the original teadditions are above the test

0 g above the d the amount dt in Annex A14

not shut off thown. est Full mark iws the final dra

f new oil adde

oil drained to b

o run at Stage

oil leveling allonvenient timeeduled shutdo

ce procedures validity or bec

ring the break-ge II blowby fe blowby by cach cylinder me

eplacing the co

e by increasin

d 12.6.2, respecas possible fro

he oil is not codetermine the fs should be pla

gine parts. Do noil pan with theall new oil ad

cked with a ST

cle and shall broximately 20 mect air/fuel rati

pling occur at ing engine rea

est full level bypermitted duri

t full mark, do test full mark

drained on the 4. This form s

he RAC coolan

is oil consumedain to be used

d to bring the

ring the level t

III conditions

ow limited opp to perform uwn on the Su

are listed in tcause they req

-in or within thfor the test durchanging the reet the criteria

ompression ring

ng the ring g

ctively om the oil panontaminated anfinal test resultaced in or over

not use EF-411e oil removed ditions and rep

TAR tester.

be measured min ± 5 min io.

intervals of ssembly for y more than ing the test, not remove drain off a oil leveling erves as the

nt pump.

d or gained. as a backup

level to the

to the mark,

for 5 min ±

portunity for unscheduled upplemental

this section. quire special

he first 48 h ring the first ring gaps or a in Table 1.

gs with new

gaps of the

n, and retain nd to ensure ts. The Ford r clean drain

1 oil or new from the oil port them in

p

p

t

c

ecEin

Uacc

pplo

r

vd

rt

EaD

lo

pd

f

th

ino

1

12.5 Diagnoparameters can

12.5.1 Manposition.

12.5.2 Enginest and from te

12.5.3 Fuel consumption ra

12.5.4 Sparkengine speed combustion is oErrors in the mn spark knock.

12.5.5 Exha12.5.5.1 Use

Use this parama particular tescan be made tocontrol system.

12.5.6 Cranpressure is usuplumbing or poow blowby flo

12.5.7 Oil Premain consiste

12.5.8 Oil Tviscosity and iduring the test.

12.5.9 Coolrate and is noremperature me

12.6 End of 12.6.1 Fina

Engine oil can attitude in whicDrain the oil fro

12.6.2 Enginocation of the p

12.6.3 Parts12.6.3.1 Arr

parts have beendraining. Any f

12.6.3.2 Rocfront of the RA

12.6.3.3 Cahe rear of the c

12.6.3.4 Cyl12.6.3.5 Fro12.6.3.6 Oil12.6.3.7 Oil12.6.3.8 Oil

n the engine. Toil screen and p

13. Interpreta

13.1 Parts R

ostic Data Revidirectly influeifold Absolute

ne Torque—Enest to test. Larg

Consumption ate is not a speck Knock—Sparand torque, aoccurring and

measurement an. ust Gas Compe the Lambda l

meter to determit. Lambda in a

o change the ex Correcting a f

nkcase Pressurually caused bort plugging al

ow rate or a resPressure—Theent throughout Temperature Dis normally sta

ant Temperaturmally stable teasurement errof Test Procedurl Drain—Drainbe drained witch it was posiom the engine.ne Disassemblyparts can be ids Layout for Rarange the follown arranged, allfixtures can be cker Arm Cov

AC at the bottommshaft Bafflescamshaft bafflelinder Heads—ont Cover—Posl Pan—Positionl Pan Baffles—l Screen and PThe screen shoupickup tube.

ation of Result

Rating Area-En

iew—This sectence the test ore Pressure—M

ngine torque isge differences i

Rate—The fucifically contrork knock does and operating can cause exte

nd control of en

onent Levels: levels in the exine the normalcall three stagesxhaust gas Lamfault in the EECre—Crankcase by high blowbylso promotes htriction of vent

e oil pressure ithe test, unless

Differential—Table throughou

ure Differentiathroughout theors.

re: n the engine cth the engine itioned on the . y—During disa

dentified with rating: wing parts in thlow the parts tused to suppor

vers—Position m. s—Position thee pointing dow

—Position the cysition the frontn the oil pan up

—Position the oiPickup Tube—P

uld be raised o

ts

nvironment :

tion outlines sigr can be used to

Manifold absolu

not controlledin torque readinuel consumptioolled parameter

not normally temperatures

ensive engine dngine torque, i

xhaust gas to dcy of combustis is controlled

mbda. If LambdC and test cell pressure is a y flow rate orhigh crankcaset air to the PCVis a function os the oil exhibi

The oil temperut the test. Th

l—The coolante test. Large v

coolant and RAn or out of thetest stand prio

assembly, use erespect to eithe

he parts rating to drain for 4 hrt the parts as lthe RAC's ver

e camshaft baffwn.

ylinder heads wt cover in the spside down, wiil pan baffles vPosition the oiloff of the suppo

DXXXX– 1

34

gnificant charao indicate normute pressure is

d in Stages I anng could be indon rate shouldr but is used asoccur in the Vdo not prom

damage. Take ignition timing

determine the cion and any sigby the program

da differs fromcontrol systemfunction of blor a significante pressure. LowV valve. of oil viscosityits a significantrature differen

he differential

t temperature dvariations in th

AC coolant ime engine stand. or to drain. Th

extreme care nr the cylinder n

area in accordh to 8 h beforelong as they orrtically (upper

ffles vertically

with RAC gaskame orientationith the pan rail

vertically on thel screen and piorting surface t

5

acteristics of spmalcy of other ps used in Stag

nd II. It shoulddicative of con

d remain relatis a diagnostics VH test. The ocmote spark kn

corrective actig, operating tem

characteristics ognificant changm in the Powe

m what appearsm is the only waowby flow ratt loss of PCV w or negative

y and operatint change in vis

ntial is primarican change if

differential is phe differential

mmediately afte Allow the eng

his allows the o

not to disturb ennumber, valve

dance with the le rating. Do nrient the parts i

jacket surface

(top baffle sur

ket surface poinn as it is instalat a 45° angle

e front edges.ickup tube in thto allow draina

pecific engine parameters. ges I and II t

d remain relativntrol or engine ively constant tool. ctane rating of

nock. Spark kion immediatelmperatures, an

of combustion ges in combustertrain Controls in Table 2, chay to achieve tte and PCV va

valve flow. Icrankcase pre

ng temperaturescosity. ily a function f the oil visco

primarily a funcan be caused

er the completgine to stand fooil to drain co

ngine depositslocation, or bo

layouts detailenot attempt to ain the specifiede perpendicula

rface perpendi

nting down. lled in the engie, with sump en

he same orientage. A fixture i

operating para

to control eng

vely constant thproblems. throughout th

f the fuel, igniknock indicately if spark kno

nd air/fuel ratio

that occur durtion that occurl Module. No heck the EEC athe correct Lamalve flow. HighIncorrect threessure might be

e. The oil pres

of oil flow rsity changes s

nction of the cd by coolant f

tion of the lastfor 6 h to 12 h mpletely into

and to ensure oth.

ed in this sectioaccelerate or fd configurationar to the groun

icular to the gr

ine. nd pointing dow

tation as they ais necessary to

ameters. The

gine throttle

hroughout a

he test. Fuel

tion timing, s abnormal

ock is noted. o may result

ring the test. r throughout adjustments and test cell

mbda value. h crankcase

e-way valve e caused by

sure should

rate and oil significantly

coolant flow flow rate or

t test cycle. in the same the oil pan.

the original

on. After the force the oil ns. nd) with the

round) with

wn.

are installed support the

m

aa

dd

faa

1toco

Lr

pdr

ep

pur

o

avefafv

13.1.1 Ensumaintained at 2

13.1.2 Rate approximately adjacent surfac

13.1.3 Ratedeflector. Maindesk top.

13.1.4 If mufollowing: Theavailable at theany consensus r

13.1.5 All 12 months ± 30o meet this re

completion of tof Blue, Red, o

13.1.6 A ratLight Duty Derecent worksho

13.1.7 The Tprovides ratingdata and determremaining in th

13.1.8 A seexperienced indplace. No more

13.2 Sludge 13.2.1 Rate

pan, and oil pausing the technrequired ratings

13.2.2 Avera13.2.2.1 To (1) Determin

of 20 mm. (2) Determin

area. This valuevolume factor pexample, if a sifor A (or 1.0), pand the calculaformed, but arevoided area fro

ure that the amb24 oC ± 3 °C.

all engine par4100 K color es shall be flat

e pistons and ntain the illum

ultiple ratings e raters shall be lab). Report orating in the coraters of Sequ0 days and proequirement, ththe workshop a

or White. ter who is unabposit Rating W

ops. Visits to thTMC selects a

g booths and ligmine if the re

he grace periodecond attempt dustry rater. The than two attem

Ratings: the following

an baffle. Use tniques detaileds or measuremage Sludge (Undetermine the

ne the sludge d

ne an interpolate is generated bpercentages, anite was determplus 50 % of th

ated site sludgee no longer adm the 20 mm r

bient atmosphe

rts except the ptemperature, a

t white. RAC baffles ination level b

are deemed nbe from the samonly one ratingomment sectionuence VH engduce data that

he rater can coand can follow

ble to meet theWorkshop parthe TMC will be

minimum of 2ghts, but the raequirement in d of 45 days is f

to generate rahe experiencedmpts are permi

parts for sludgthe rating loca

d in ASTM Deents. nweighted Avesludge rating m

depth at each of

ted sludge valuby multiplyingnd comparing ined to be 50 %he average slude depth would bdhering to the prating area.

TABLE

Total

<0.125

≥0.125 < 0

≥0.375 < 0

≥0.625 < 0

≥0.875 < 1

≥1.250 < 1

ere of the parts

pistons, RAC, a CRI of 62 an

against a whibetween 3800

ecessary of a me laboratory g value, and thn of the test repgine parts shameet the AST

ontinue to ratew the procedure

e requirement is and receive e scheduled ba24 parts from aater is respons13.1.5 has be

forfeited. ating data at thd industry rateritted between A

ge deposits: Rations identifieeposit Rating M

rage of 9 Partsmerit for each pf the sites show

ue for a designag each rated vathe total to the

 % A and 50 % dge depth factobe a D. In the part, the rating

E 7 Interpolated

Site Rat

5 clea

0.375 1/4 A

0.625 1/2 A

0.875 3/4 A

.250 A

.750 AB

DXXXX– 1

35

s rating area is

and cylinder bnd an illumina

ite backgroundlx to 6500 lx,

given part or por from an ou

his value shall bport.

all attend an ATM definitions e Sequence V

e described in 1

in 13.1.5 can scan assessment

ased on availaba collection of ible for provid

een met. If the

he TMC is perr shall verify toASTM Light D

RAC (2), valve d on the rating

Manual 20. Pe

s): part, use the sewn on rating w

ated site that exalue’s volume fe values given

  E, the calculator for E (or 16.event that ther

g site is the clo

d Average Slu

tings To

n ≥3.500

A ≥6.000

A ≥12.00

A ≥24.00

≥48.00

B ≥96.00

5

s reasonably fre

block under coation level of 3

d using white   and measure t

parts, consensuutside rater if be agreed to b

ASTM Light of Blue, Red,

VH parts durin13.1.6 to gener

chedule a visitt of rating perf

bility of parts. workshop part

ding any necese requirement

rmitted only ao the TMC, in

Duty Deposit R

deck (2), camg worksheets (erform the slud

elf-weighting pworksheets. A s

xhibits more thfactor by the pn in Table 7 to tion would be: .0); that is: ([0re are areas whosest point to

udge Site Rati

otal Site

<6.000

< 12.00

< 24.00

< 48.00

< 96.00

< 192.0

ee of contamin

ool white fluor3800 lx to 540

fluorescent bthe illuminatio

us rating may required (no R

by the original

Duty Deposit or White for v

ng a grace perrate data that m

t to the TMC tformance com

ts for the rater ssary rating aid

in 13.1.5 has

after the rater writing, that th

Rating Worksho

mshaft baffle (2(see Annex A1dge ratings bef

procedure as fosite is defined a

han one level oercentage of ardetermine the50 % of the av.5 × 1.0 = 0.5]

here it is apparthe designated

ngs

Ratings

C

D

E

F

G

H

nants, and the t

rescent lighting00 lx. All back

bulbs and a 1on level 355 m

be used accorRed, White, orrater involved

Rating Workvarnish. If a ratriod of 45 day

meet the ASTM

o generate datampared to data

to rate varnishds. The TMC as not been me

receives trainihe rater traininops.

2), timing chai15). Determinefore performin

ollows: as a diameter c

of sludge depthrea covered, toe rating for theverage sludge d] + [0.5 × 16.0 rent that deposid point that eli

temperature

g exhibiting kground and

00 % white mm from the

rding to the r Blue rater

d. Document

kshop every ter is unable ys after the

M definitions

a on ASTM collected at

h. The TMC analyzes the et, any time

ing from an ng has taken

in cover, oil e the ratings ng any other

circular area

h within this otaling these e site. As an depth factor = 8] = 8.5), its had been iminates the

th

b

A

c

pdd6

rgPlotharw

v

d

R

f

s

ththps

arn

(

(3) Add the t

he part that is r(4) Multiply

by the rated slu(5) Convert t

ASTM Deposit(6) Add the

convert the tota13.2.2.3 Fla

possible detrimdeposit in the Sdeposit was ob6 % of the (left

13.3 Varnish13.3.1 Prep

right camshaft grid to be usedPerform the varocations and dhe parts are be

a 25 mm rubberub all wiping wiping materia

13.3.2 Avervarnish rating o

13.3.2.1 Radeposits on the

13.3.2.2 DetRust/Varnish/L

13.4 Cloggin13.4.1 Oil S13.4.1.1 Use(1) Use a de

from the suppli(2) Regulate (3) Connect t(4) Allow air(5) Remove t13.4.1.2 Fle

surface, a more13.4.1.3 Det

he total screenhe oil screen s

places. Report screen that is no

13.5 Sticking13.5.1 Rings

are detailed in 3rings on the Sunumber.

13.6 Used O13.6.1 Perfo

(Test Method D

total rating cherated. the total rating

udge depth. Thethe percent covt Rating Manuavolume factor

al volume factoaky, Bubbly S

mental effect oSupplemental Observed and the

or right) rockeh Ratings: aration of Parbaffles. Rate td. Create a rarnish ratings af

dimensions detaeing prepared fer spatula. Wipareas in the sal after wiping)

rage Varnish (of each part: ate any areas w

surrounding ntermine origina

Lacquer Rating ng:

Screen Clogginge the followingvice to blow aier listed in X2the air pressurthe device to thr to flow for 5 the device andxible, transpar

e accurate detertermine the pe

n opening that isludge rating pboth transformot immediatelyg: s—Record the 3.1.4 and 3.1.7upplemental O

Oil Analyses: orm the followD445), wear m

≥1.750 < 2

≥2.500 < 3

ecks made for

g checks made e grand total shvered by the raal 20. rs on each lineor to the sludge

Sludge Depositon long-term eOperational De total percenter arm cover w

rts—Rate the fthe entire pistoting grid usingfter the sludge ailed on the ratfor varnish ratipe all parts firmame direction u.

(Unweighted A

where varnish non-altered areaal varnish ratinScale for non-

g: g procedure to dair across the s.1.21.

re to 130 kPa ±he screen. s to 10 s.

d rate. rent rating aidsrmination of suercentage of this obstructed wplus one; that

med and originy recognizable

number of stuc7. List both hotOperational Da

wing analyses ometals (Test Me

2.500 B

3.500 BC

each line on th

on each line bhall equal 100 %ated sludge dep

e to determinee merit rating.ts—Since the oengine lubricatata section of t of the surface

was found to ex

following partson skirt and theg template in ratings are com

ting worksheetings. Heavy slumly with wipinuntil the surfac

Average of thre

deposits haveas. Do not rate ngs of all parts -rubbing parts

determine the pcreen to remov

± 10 kPa.

s can be made furface clogginghe total screen with sludge. Tra

is, ln (oil screnal result on th

as debris. Lab

ck compressiont and cold stuckata page and in

on the used oil ethod D5185),

DXXXX– 1

36

≥192.0

C ≥38

he appropriate

by ten or five, r %. pth at each loc

the total volu

occurrence of tion system pethe Final Teste area covered

xhibit flaky, bub

s for varnish de upper 50% aA15.11A. The

mpleted. The rts (see Annex Audge can be remng materials spce is dry and f

ee Parts)—Use

e been altered altered areas aby comparisonfrom ASTM D

percentage of tve any retained

for different sug is possible. opening that isansform the oieen clogging +e appropriate fel all matter of

n and oil ringsk rings on the nclude the ring

samples takenand fuel diluti

5

< 384.0

84.0

worksheets. T

respectively (re

ation to a volu

ume factor. Us

f flaky, bubblyerformance, dot Report. Recod. The followinbbly sludge de

deposits–pistonand report sepae rating grid srating locationsA15). Avoid dmoved from a pecified in ASfree of sludge

e the procedur

during disassas clean. n of the deposi

Deposit Rating

the oil screen cd oil on the sc

urface areas so

s obstructed wil screen sludge+ one). Roundform(s). Labef indeterminate

. Definitions toTest Results S

g location (top

n every 24 h anion (Test Meth

I

J

These shall equ

efer to (3), to o

ume factor usin

se ASTM Dep

y sludge depoocument the oord the engine ng is suggesteeposits.

n skirts (8, thruarately. Figure should be 74 s and dimensio

disturbing adjacvarnish rating

STM Deposit R(until no more

re detailed as

sembly or slud

it on the ratingManual 20

clogged by sludcreen. A suitab

o that when com

with debris. Dee results by tak

d the transformel as sludge alle composition a

o classify the dSummary pagep, second or o

nd on the finalhod D3525). T

ual 10 or 20, de

obtain the perc

ng the procedu

posit Rating M

sits is thoughtoccurrence of t

part(s) where d wording–app

ust side only) aA15.11 showsmm wide acro

ons shall confocent sludge dep

g area prior to wRating Manuale deposit is pre

follows, to de

dge removal a

g location using

dge: ble device can

mpared to the t

etermine the peking the natura

med value to fol matter presenas sludge.

degree and typee. Denote hot ooil control) and

l drain: ViscosTake samples at

epending on

cent covered

ure shown in

Manual 20 to

t to have a this type of this type of proximately

and left and s the rating oss the top.

orm with the posits when wiping with l 20. Firmly esent on the

etermine the

according to

g the ASTM

be obtained

test screen's

ercentage of al log (ln) of our decimal nt on the oil

e of sticking or cold stuck d the piston

sity at 40 °C t (0, 24, 48,

7

f

rth

H 1

ath

thrc

bsf

os

wtyba

a

r

ins

a

Tcc

0pntc

1

72, 96, 120, 14413.6.2 Fuel

following modi13.6.2.1 Use13.6.2.2 Pre13.6.2.3 Th

reached. Establhe leading edg

13.6.2.4 Col13.6.2.5 Inc

Hold the tempe

14. Assessmen

14.1 Generaand Test Sponshe following g

14.2 Used O14.2.1 Iron

hat occurs durrocker arm, andchange of wear

14.2.2 Silicobased gaskets. sealers, the cleafor dispensing a

14.2.3 Fuel of the crankcassludge severity

14.3 Blowbywithin the rangypically drops

between 60 L/maverage is not w

14.4 Manifoaccount for the

14.5 Fuel Crespectively.

14.6 Oil Con14.6.1 Oil c

ncrease oil levsystem, fuel inj

14.6.2 The tany 24 h oil lev

14.7 EngineThe following components, Ecooling system

14.8 Quality0.000 for referepurchaser on itsnon-reference oests. The TMC

controlled para14.9 Report

15. Final Test

4, 168, 192, 21Dilution—Detifications) on te C16 in place esume that all ce integrator shlish a second b

ge of the C16 plumn details arrease the oven

erature at 320 °

nt of Test Vali

al—The testingsor shall assist guidelines as a bOil Analyses-Inand Aluminumring a test. Ind cylinder borer levels, althougon Content—SSilicone-basedanliness of engand sampling tDilution—Fuese oil is necesand componen

y Flow Rate—Tge from 60 L/ms slightly in thmin and 70 L/within the presold Absolute P

altitude of theConsumption R

nsumption: consumption svels above the tjectors, and so total amount oveling period. e Parts Replac

parts can be rEC module, PCparts, oil filter

y Index—Requence oil tests, s opinion. The oil tests. The lC issues a lettemeter, the test results on all r

t Report

16) h. termine the fuehe used oil samof C14 for the

components lighould establishbaseline extendeak.

re 3050 mm by temperature fr °C for 16 min t

idity

g laboratory shthe laboratory basis for determ

nterpretation : m Content—The

creased camshe wear causes gh wear tends ilicon content

d gaskets are usgine parts durinthe oil if high lel dilution indicsary to achievnt wear. InvestThe corrected amin to 70 L/mhe first 23 h o/min. If two cocribed limits, c

Pressure (MAP)e laboratory, amRate—The fuel

hould not occutest full mark. forth should bf new oil adde

ement—Parts treplaced, if neCV valve, sealr adapter and s

uirements for qreview the testlaboratory doc

laboratory or tr to document is operationall

reference oil te

el dilution, masmples. internal standa

ghter than C16 h a horizontal ding horizontal

y 3.2 mm SS; afrom 60 oC to 3o elute oil.

hall assess the in the determi

mining test val

e aluminum anhaft bearing wthe iron contento be linear thrindicates the lsed to seal the ng build-up, thevels of siliconcates the degree adequate testigate a higher average blowb

min. Blowby shof the test. Exconsecutive Staconsider the tes

P)—Throttle pombient baromet

consumption

ur early in theIf the oil levele checked for a

ed during the te

that are rated tecessary (recorls and gaskets,park plugs. uality index art operations wcuments its comtest purchaser its opinion. If

ly invalid. ests run to com

DXXXX– 1

37

ss percent, by g

ard (1μL injectare fuel. baseline unde

lly from the ou

and the packing20 °C, with the

validity of testination of caliblidity:

nd iron contentwear causes the

nt to increase. roughout the televel of contamoil pan and ro

he cleanliness on are experiencee to which thest severity. Holevel of fuel di

by flow rate durhould remain rcursions below

age II readingsst operationally

osition is set bytric pressure, arate should no

e test. During l is above the ta malfunction test shall not ex

to determine thrd the circums, valves or valv

re listed in Annwith the TMC. T

mments regardmight request

f a test has grea

mpletion, regard

5

gas chromatogr

tor volume).

er the output cutput curve, at

g material is 5 %e rate of chang

ts that have debration test vali

t of the used oie aluminum coThe rate of ch

est. mination of thecker covers. In

of the intake aiced. e crankcase oil owever, excessilution than is n

uring Stage II drelatively consw 60 L/min ars within the firy invalid. y manifold ab

and the mechanot exceed (9.0,

this time peritest full mark bthat could be cxceed 2000 g a

he final test restances involveve springs, fue

nex A6. If the The TMC issu

ding end of testTMC review

ater than 2 h w

dless of validity

raphy (see Tes

curve until thethe intersectio

 % OV-1 on Chge of temperatu

eviations from idity, if reques

il samples can ontent to increhange in iron l

e oil from extenvestigate the pir, and the clea

has been dilutive fuel dilutionormally noted

during the first stant throughoure acceptable arst 120 h, are l

solute pressurenical efficiency 19.0, 5.0) kg/

iod of the test,by 200 g or m

causing excessiand no more th

sults cannot beed in the replael injectors, oil

end of test quues a letter to tt quality index of test operati

without recorde

y.

st Method D35

e leading edgen of the output

hromosorb W Hure controlled a

the procedurested by the labo

indicate the leease. Increasedlevels indicates

ernal sources anpresence of silianliness of cont

ted with fuel. Fon can promotd. 120 h of the teut the entire teas long as theless than 56 L

e during Stagey of the engine/h for Stages I

, fuel dilution more, then the e

ive fuel dilutiohan 400 g can

e replaced duracement): ignil separator (PC

uality index valthe laboratory values less tha

ions for non-reed operational

25, with the

e of C16 is t curve, and

HP. at 8 °C/min.

e. The TMC oratory. Use

evel of wear d camshaft, s the rate of

nd silicone-icone-based tainers used

Fuel dilution te increased

est shall fall est. Blowby e average is L/min or the

e I and II to . I, II and III,

levels may engine, EEC on.

be added at

ing the test. tion system

CV system),

lue is below and the test an 0.000 for eference oil data on any

a

1

s

w

c7

A

B

C

tr(

t

wtw

s

1

ne

15.1 Reportand for summar

16. Precision a

16.1 Test Pr16.1.1 Interm

same test oil, wNOTE 9—“Inte

within-laboratory

16.1.1.1 Intconditions that 7 in only one ca

A These statistiB This value is C This parametransformation

(intermediate p

16.1.2 Represt oil in differ

16.1.2.1 Repwould, in the lowenty.

16.2 Bias—Bsignificant bias

17. Keywords

17.1 lubrica

A1.1 Natunon-profit orengineering s

t Forms—For rrizing the oper

and Bias

recision—Refermediate Precis

with changing cermediate precisy conditions.

termediate Prewould, in the

ase in twenty.

ics are based onobtained by m

ter is transformto each test res

precision or rep

roducibility Corent laboratorieproducibility Long run, in the

Bias will be ds is determined

s

ting oils; Sequ

A1. A

ure and Funcrganization lstudies; cond

reference oil terational data ar

rence Oils: sion Conditionconditions suchsion” is the appro

ecision Limit (long run, in th

Variable,

Average eng

Rocker cove

Average eng

Oil screen csludgeC

Average pis

n results obtainmultiplying the med using 1n(result. Compare

producibility) p

onditions—Cones with differenLimit (R)—The normal and co

etermined by a, a severity adj

uence VH; slud

ASTM TEST

ctions of thelocated in Pitduct laborato

ests, the standare required.

ns—Conditionsh as operators, opriate term for

(i.p.)—The diffe normal and c

TABLE 7 Re

Merits

gine sludge

er sludge

gine varnish

logging,

ston varnish

ned on Test Mostandard devia

esult+1). Whenthe absolute di

precision limit.

nditions where nt operators use difference borrect conduct

applying an acjustment will b

dge and varnish

A

(Manda

T MONITO

e ASTM Test ttsburgh, Peory inspectio

DXXXX– 1

38

ardized report

s where test resmeasuring equthis test method

fference betweecorrect conduct

eference Oil St

IntermediaPrecision

Si.p. i.p

To B

onitoring Centation by 2.8. n comparing twifference betwe

test results aring different eq

between two rof the test me

ccepted statistibe permitted for

h; spark-ignitio

ANNEXES

atory Informat

ORING CEN

Monitoring nnsylvania aons; perform

5

form set and d

sults are obtainuipment, test std rather than “rep

en two resultst of the test me

tatisticsA

ate n

Reprodu

p.B SR

Be determi

ter Reference O

wo test results oeen the transfo

re obtained witquipment.

results obtaineethod, exceed t

ical technique r non-referenc

on automotive e

tion)

NTER ORG

g Center (TMand is staffed

m statistical a

data dictionary

ned with the satands, test engipeatability,” whi

s obtained undethod, exceed t

ucibility

RB

ined

Oils over the pe

on this parameormed results w

th the same te

d under reprothe values in T

to reference oe oil test result

engine; stop-an

GANIZATIO

MC)—The TMd to: adminianalyses of r

y for reporting

ame test methoines, and time.ich defines more

der intermediatthe values show

eriod from

ter, first apply with the approp

st method usin

oducibility conTable 7 in only

il test results, ts.

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ON

MC is a ster

reference oil

g test results

od using the

e rigorous

te precision wn in Table

through.

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and when a

tfbil A6Pw

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test data; blefunctions to mby ASTM Suts activities

laboratories.

ASTM Test M6555 Penn APittsburgh, Pwww.astmtm

A1.2 RuleASTM Chartthe Bylaws GASTM Test M

A1.3 Manvested in theselects the TM

A1.4 Operon the refereExecutive Co

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A2.1 Refeperformancenumbers to en assessing t

A2.1.1 Refcalibration shshipment conmmediately

A2.2 CaliA2.2.1 Fu

tests are condresponsibilityby the TMC

A2.2.2 Tepreviously cademonstrate

A2.3 Refetemperature

A2.4 AnalTMC referensupply them supplied only

nd, store, anmaintain theubcommitteewith the testContact TM

Monitoring Avenue PA 15206-44mc.cmu.edu

es of Operatiter, the AST

Governing AMonitoring

nagement of Executive CMC Directorating Incomnce oils suppommittee an

2. ASTM TE

erence Oils— levels, or bo

ensure that thtest results. T

eference Oil hall submit dntains any m. ibration Testull-scale calibducted usingy to keep thetest enginee

est Stands Usalibrated testthat it contin

erence Oil Stis between -lysis of Refence oils, eithto other labo

y for the inte

nd ship referee referencinge D02.B0 ant sponsors, th

MC through t

Center

489

ion of the ASTM Bylaws, tASTM Comm

System. the ASTM T

Committee er who is resp

me of the ASplied and on

nd reviewed b

EST MONI

—These oils oth. They arhe laboratoryThe TMC deData Repordata to the T

missing or da

ting: bration testing coded refere on-site refeers. sed for Non-t stand, the lnues to be catorage—Sto-10 °C and +rence Oil—U

her physicallyoratories witended purpo

ence oils; ang calibration nd the ASTMhe test develthe TMC Dir

STM TMC—the Regulati

mittee D02, a

TMC—The melected by Suponsible for

STM TMC—n the calibratby Subcomm

ITORING C

are formulatre usually supy is not influetermines th

rting – Test lTMC on everamaged samp

ng shall be crence oils suerence oil in

-Standard Telaboratory shalibrated, prire reference

+50 °C. Unless speciy or chemicathout the appse of obtaini

DXXXX– 1

39

nd provide thprogram for

M Executive lopers, the surector at:

—The TMC oions Governiand the Rule

managementubcommitteedirecting th

—The TMC otion tests conmittee D02.B

CENTER: C

ted or selectepplied direct

uenced by prhe specific relaboratories try sample of ples, the labo

conducted atupplied by thnventory at o

ests—If a nohall conduct ior to runninoils under c

ifically authally. Do not proval of theing calibratio

5

he associatedr various lubCommittee. urveillance p

operates in acing ASTM Tes and Regul

of the Test Me D02.B0. Te activities o

operating incnducted. FeeB0.

CALIBRAT

ed to represetly to a testinrior knowledeference oil tthat receive

f reference ooratory shall

t regular intehe TMC. It isor above the m

on-standard ta reference

ng standard tcover in loca

horized by thresell ASTM

e TMC. The on under the

d administrabricant tests The TMC cpanels, and t

ccordance wTechnical Colations Gove

Monitoring he Executivof the TMC.come is obtae schedules a

TION PROC

ent specific cng laborator

dge of acceptthe laboratorreference oiil they receivl notify the T

ervals. Theses a laboratorminimum le

test is conduoil test on th

tests. ations where

he TMC, do nM reference

reference oie ASTM Tes

ative as directed

coordinatesthe testing

with the ommittees, erning the

System is ve Committee

ained from feare establish

CEDURES

chemical, orry under codtable resultsry shall test.ils for standve. If a TMC

e full-scale ry's evel specified

ucted on a hat stand to

the ambient

not analyzeoils or ils are st Monitorin

e

ees levied hed by the

r e

d

t

ng

StAta

r

lrAr

cecTrn

osTrpttsccn

mpnmiprpdam

System. Anythe TMC refAnalysis of Ato TMC guidavailable fro

A2.5 Conreference cal

A2.6 Replaboratory trareviews the dAll referencereported to th

A2.6.1 Al

A

A3.1 Speccalibration teeven all of thcould result iThe TMC careference oilno net loss o

A3.2 Specoption to useseverity and The surveillarequires all rpossible, so ttime. In ordetest is conduscheduling, tcalibration pcalibration stnon-referenc

A3.3 Donmaintaining parts introdunecessary to may choose tn the monito

precision. Tyreference oilprovide a repdonated testsappropriate nmanner.

y unauthorizeference oils eASTM Referdelines. Addm the TMC.ducting a Relibration testporting Referansmits the ddata and cone oil test resuhe TMC. ll deviations

A3. ASTM T

cial Referencests are condhe industry’sin an unacce

an shorten ortest data. Ar gain in calcial Use of the the referencprecision. T

ance panel anreference oil that no laborer to maintaincted so as tothe surveillaneriods withintatus. To ens

ce oil tests thated Refereneffective ref

uctions, new evaluate theto conduct aoring systemypically, the

test results tpresentative s are conducnumber of do

ed use is striexclusively irence Oils, aitional polic. eference Oil t, they shall rrence Oil Tedata electron

ntacts the labults, whether

from the sp

TEST MON

ce Oil Tests—ducted periods test stands eptably larger extend calibdjustments tibration statuhe Referencece oil system

This option isnd the TMCtests in the p

ratory/stand n the integri

o be interpretnce panel mn laboratoriesure accuratehe same as rence Oil Test ference oil teor re-blende

e possible effa program of

m, in order tosurveillanceto create a rosampling ofted on calibronated tests

ictly forbiddin accordancand to run anies for the u

Test—Wherequest an oest Results—nically to theboratory engir aborted, inv

ecified test m

ITORING C

—To ensuredically throuwill conduct

e time frame bration perioto calibrationus. e Oil Calibram to evaluates only taken

C shall developrogram to bcalibration sty of the refetable for stan

may direct thees such that te stand, or laeference oil tPrograms—

est severity aed referenceffects on sevef donated refo quantify thee panel requeobust data sef the industryrated test staand ensure c

DXXXX– 1

40

den. The testice with the Tnd report these and analy

n laboratoryil code via th

—Upon compe TMC, as dineer to repovalidated, or

method shall

CENTER: M

continuous ughout the yet calibration when very f

ods as needen periods are

ation Systeme changes thawhen a prog

op a detailedbe completedstatus is left

ference oil mnd calibratioe TMC to lenthe laborator

aboratory, ortests.

—The surveiland precisionoil additionserity and preference oil tee effect of a ests its panelet. Broad laby. To ensure ands. The surcompletion o

5

ing laboratorTMC’s publie reference oysis of ASTM

y personnel ahe TMC web

pletion of thedescribed in Sort the laborar successfull

l be reported

MAINTEN

severity andear. Occasio tests at rougfew calibrati

ed to providee made such

m—The survat have potegram of donad plan for thed as close topending for

monitoring syon. To facilitngthen and sries incur nor both severi

llance panel n monitorings, and proceecision levelests in those particular chl members toboratory part the quality rveillance paof the test pr

ry tacitly agrshed Policie

oil test resultM Reference

are ready to rbsite. e reference oSection ?. Thatory's calibrly completed

d.

NANCE ACT

d precision monally, the mghly the samion tests are e a consistenh that laborat

veillance panential impactated tests is e test progra

o the same timr an excessivystem, each rtate the requshorten refero net loss or ity assessme

is charged wg. During timdural revisiols. The survelaboratorieshange on sevo volunteer ticipation is of the data oanel shall arrrogram in a t

rees to use es for Use ans according

e Oils are

run a

oil test, the tehe TMC ration statusd, shall be

TIVITIES

monitoring,majority or me time. This

conducted.nt flow of tories incur

nel has the t on test not feasible

am. This planme as

ve length ofreference oilired test rence oil gain in nts, conduct

with mes of newons, it may beillance panes participatinverity and enough needed to

obtained, range an timely

nd

est

.

s

. n

l

t

be el ng

db

rtm

nDsd

nasctap

aamoe

Sppt

L“Lor

cc

A

A3.4 Interdowntime cabetween refe

A3.5 Introreference oiltests to enablminimum nu

A3.6 TMCnotify the tesD02.B0. In ssemi-annualldue process p

A3.6.1 Issnature. In theaffect test ressurveillance control may test results nand present tprior to the s

A3.7 TMCare issued. Tand participamaterials, claof special daeffect on the

A4.1 NewSystem will bproper testinpractices, appthe TMC Dir

A4.2 InforLetters was g“COTCO recLetters is appobtained ASTrapidly as po

A4.3 Preccalibration tecan be obtain

A 5.1 General A5.1.1 The

rvals Betweeaused by induerence oil tesoducing News are selectele the TMC

umber of testC Informatiost laboratoriesuch a case, tly by Subcomprocedures asuing Authore case of an sults, the TMpanel to impresult in the eed immediathe backgrousemiannual SC Memorand

These are devating laboratarification of

ata that the Ttest perform

A4. ASTM

w Laboratoribe requestedg techniquespropriate corector. rmation Lettgiven by the cognizes thaproved proviTM consens

ossible.” cision Data—ests conductened from the

Information: operation of th

en Referenceustry-wide psts. w Reference ed, participatto recomments to establison Letters—Oes of the chathe TMC issmmittee D02are applied tority—The auInformation

MC is authorprove the tesissuance of

ate attentionund and dataSubcommitteda—In additveloped by thories. They cf the test pro

TMC may reqmance, result

TEST MON

es—Laboratd to conduct s. Informatiommittee mem

ters: COTCOcommittee o

at D02 has a iding each lesus. These In

—The TMC ed on referene TMC.

his procedure c

e Oil Tests—parts or fuel

Oils—Referting laboratond industry h the industrOccasionallyange, prior tosues an Infor2.B0, and suo these Infor

uthority to is Letter conc

rized to issuest procedure f an Informatn, the test spoa supporting ee D02.B0 mtion to the Inhe TMC andconvey such

ocedure, notequest, or for ts, or precisio

NITORING

tories wishinreference oi

on concerninmbership, an

O Approval—on Technicaunique and cetter containnformation L

determines tnce oils. Pre

A 5. SAFE

can expose per

DXXXX– 1

41

—Under specshortages, th

rence oils prories will be test targets. ry test targety it is necesso consideratirmation Lettubsequently brmation Lettsue an Inforerning a pare such a lettethrough imp

tion Letter. Ionsor and thethat action t

meeting. nformation Ld distributed h informationes and suggeany other peon and bias.

G CENTER

ng to becomeil tests to ensng fees, labornd rater train

—Authority al Committeecomplex situ

ns a disclaimLetters shoul

the precisionecision data a

ETY PRECAU

rsonnel to haza

5

cial circumsthe TMC may

roduce variourequested toASTM survts for new resary to reviseion of the rever. Informatby D02. By ters. rmation Lettert number cher. Long-termproved operaIf obvious pre TMC issueto the surveil

Letters, suppto the appro

n as batch apestions of theertinent matt

R: RELATED

e part of the sure that theratory inspening can be o

for the issuae Operationsuation. The u

mer to the affeld be moved

n of test metare updated

UTIONS

ardous material

tances, such y extend the

us results. Wo conduct theveillance paneference oilse the test mevision by Sution Letters athis means,

er differs achange which m studies byation and harrocedural itee an Informallance panel

lementary mopriate survepprovals for e collection tters having n

D INFORM

ASTM Teste laboratory iction, reagenobtained by

ance of Infors in 1984, asuse of Inform

fect that suchto such con

thods by anaregularly. C

ls, operations,

as extendede intervals

When new eir share ofnels require as. ethod, and ubcommitteeare ballotedthe Society

cording to itdoes not

y the rdware

ems affectingation Letter for approva

memoranda eillance panetest parts orand analysisno direct

MATION

t Monitoringis using thents, testing contacting

rmation s follows: mation h has not nsensus as

alyzing resulCurrent precis

and equipmen

a

e

ts

g

al

el r s

g

ts of sion data

t. Personnel

wp

aCela

sosli

ta

A

A

a

p

who are involvprovided with s

A5.1.2 The areas should bContainers of fextinguishers saboratory.

A5.1.3 The supply when thoccur: dynamosystem activateines, process w

A5.1.4 This est. These chem

and eye-rinse fa

A5.2 Physical A5.2.1 ElectA5.2.2 HighA5.2.3 HighA5.2.4 Nois

A5.3 HazardouA5.3.1 SolveA5.3.1.1 BeA5.3.1.2 StoA5.3.1.3 UsA5.3.1.4 UsA5.3.1.5 UsA5.3.1.6 UsA5.3.1.7 AvA5.3.2 CoolA5.3.2.1 StoA5.3.2.2 UsA5.3.2.3 UsA5.3.2.4 UsA5.3.2.5 AvA5.3.3 AcidA5.3.3.1 StoA5.3.3.2 UsA5.3.3.3 Us

available. A5.3.3.4 AvA5.3.4 UnleA5.3.4.1 BeA5.3.4.2 StoA5.3.4.3 UsA5.3.4.4 UsA5.3.4.5 UsA5.3.4.6 UsA5.3.4.7 AvA5.3.5 New A5.3.5.1 StoA5.3.5.2 UsA5.3.5.3 UsA5.3.5.4 AvA5.3.5.5 Us

present in the n

ved in the desigsafety glasses, laboratory fac

be kept clean fuel and oil shoshould be ava

test stands shhe engine is nmeter loses fie

es. Guards shouwater lines, and

test method camicals and a s

facilities should

Hazards: trical shock.

h-speed rotatingh-temperature sse.

us Chemicals aent (meeting Sp

efore opening thore at moderatese dry chemicalse safety glassese cartridge or ase only if adequvoid contact wiling System Cleore at moderatese safety glassese respiratory pse only if adequvoid contact widic Cleaner withore at moderatese safety glassese respiratory

void contact wieaded Gasolineefore opening thore at moderatese dry chemicalse safety glassese respiratory hse only if adequvoid contact wi

and Used Oil ore at moderatese dry chemicalse safety glassevoid contact wised Oil Samplenew oil, follow

gn, installation,hearing proteccilities should and free of oould not be allilable in all p

ould be equippnot running. Theld current, enguld be installedd electrical wirian expose pers

summary of spd be provided i

g equipment. surfaces.

and Materials:pecification D2he container, re temperatures l, foam, or CO

es and impervioair-line respirauate ventilationith eyes, skin, aeanser, (DuPoe temperatureses and impervioprotection in abuate ventilationith eyes, skin, ah Inhibitor (Dee temperatureses and impervio

protection in

ith eyes, skin, ae (Haltermann he container, re temperatures l, foam, or CO

es and imperviohydrocarbon vauate ventilationith eyes, skin, aSamples: e temperatures l, foam, or CO

es and impervioith eyes, skin, aes Only—(War

the most string

, and operationction, and prope

be inspected ail and fuel splowed to accumparts of the la

ped with a fuehe engine shougine overspeedd around all exing should be psonnel to physiecific precautin parts prepara

235, Type II, Celieve pressureand keep away

2 as extinguishous gloves wheators in enclosen is available. and clothing. nt formulation. Keep containous gloves whebsence of propen is available. and clothing. earsol 134): . Keep containous gloves whe

absence of p

and clothing. VH Fuel)—(Welieve pressureand keep away

2 as extinguishous gloves wheapor canisters in is available. and clothing.

and keep away2 as extinguishous gloves wheand clothing. rning—Health gent Material S

DXXXX– 1

42

n should be thoer tools. All loand approved

pills. The labomulate excessivaboratory. Eme

el shut-off valvuld also be auds, exhaust sysxternal rotatingproperly routedical hazards anons concerningation areas.

Class C requiree. Keep the cony from heat, sphing media. en handling. ed areas.

or equivalent)ner closed until en handling. er environment

ner closed until en handling. proper environ

Warning—Flame. Keep the cony from heat, sphing media. en handling. n enclosed are

y from extremehing media. en handling.

hazard.) SinceSafety Data Sh

5

oroughly traineose clothing shby the laborat

oratory should ively. A fixed ergency showe

ve that is desiutomatically shstem fails, roomg parts and hotd, protected, an

nd various hazag each chemic

ements) (See 7.ntainer tightly cparks, open flam

): use.

tal control.

use.

nmental contro

mmable. Healtntainer tightly cparks, open flam

eas.

e heat, sparks,

e used oils conheets guideline

ed and experienhould be removtory's safety dalso be kept

fire protectioners should be

gned to automhutdown if anym ventilation ft surfaces. All nd kept in goodardous chemicacal are listed be

.7.1): closed when nme, oxidizing

ol. Use only i

th hazard.) closed when nme, and oxidiz

open flame, an

ntain compounds for all compo

nced. Personneved or secured

department. Allfree of trippin

n system and adprovided thro

matically interruy of the followfails, or the firefuel lines, oil d working ordeals to prepare pelow. Emergen

ot in use. agents, acids, a

if adequate ve

ot in use. zing agents.

nd oxidizing ag

ds that were noonents present.

el should be d. l laboratory ng hazards. dequate fire oughout the

upt the fuel wing events e protection lines, steam er. parts for the ncy showers

and bases.

entilation is

gents.

ot originally . In addition

to

osA

p

laA

s

bsl

o other precauA5.3.6 OrgaA5.3.6.1 BeA5.3.6.2 StoA5.3.6.3 UsA5.3.6.4 UsA5.3.6.5 UsA5.3.6.6 UsA5.3.6.7 Av

A6.1 GeneraA6.1.1 The

of the laboratosystems shall bA6.5

A6.1.2 Conparameters with

A6.1.3 Desaid out in the

Annex A6.

A6.2 Digitasecond. This da

A6.3 SteadyA6.3.1 Thi

beginning of thstart of the tranevels in Table

utions, note thaanic Solvent (Pefore opening thore at moderatese dry chemicalse safety glassese respiratory hse only if adequvoid contact wi

A

al Description:data acquisitio

ory that the syse capable of ca

ntrol capabilityhin the limits ssign the controInstrumentatio

al Recording Fata can be filter

dy State Operatis portion of the next stage. Bnsition is consA6.1.

TABL

TAB

P

C

C

at continuous cPenmul): he container, re temperatures l, foam, or CO

es and imperviohydrocarbon vauate ventilationith eyes, skin, a

A6. CONTRO

: on system shallstem be capabalculating real

y is not dictatedspecified in Tabol and data acqon Task Force

Frequency—Thred, as describe

tion: the test will stBy 20 min intosidered the star

LE A6.1 Accur

Parame

Speed

Humidi

Temper

Manifo

Intake A

Exhaus

Coolan

Coolan

BLE A6.2 L and

Parameter

Coolflow

Coolout

ontact with use

elieve pressureand keep away

2 as extinguishous gloves wheapor canister inn is available. and clothing.

OL AND DATA

l be capable ofble of real timetime quality in

d by this procedble 2 (see 8.3.5quisition systeme Report and D

he maximum aled in A6.6, and

tart, at most, o a stage all part of the stage

racy Levels of

eter

ity

rature

old Absolute Pr

Air Pressure

st Backpressure

nt Outlet Pressu

nt Flow

d U Constants

Stages L

1 47.4

2 TBD

3 TBD

1 56.7

2 84.7

3 44.7

DXXXX– 1

43

ed motor oils h

e. Keep the cony from heat, sphing media. en handling. n enclosed area

A ACQUISIT

f logging the ope plotting of cndex as this wil

dure. The contr5) and maintainm to meet the Data Acquisitio

llowable time pd will be consi

20 min after arameters shall e. Calculate the

f Data Points t

ressure

e

ure

s and Over an

U

47 48.53

D TBD

D TBD

71 57.29

71 85.29

71 45.29

5

has caused skin

ntainer tightly cparks, open flam

a.

TION REQUIR

perational datacontrolled parall be monitored

trol system shan the quality inrequirements

on Task Force

period over whdered a reading

the beginningl be in the steae quality index

to be Used in

Field Lengt

5.0

5.1

5.1

5.1

6.3

6.1

6.1

6.1

d Under-Rang

Over-Range

Un

87.0

113.0

113.0

113.0

n cancer in lab

closed when nme, and strong

REMENTS

a in digital formameters to helpd throughout th

all be capable ondex described listed below. U

e Report for an

hich data can bg.

g of a transitiody state conditx using values

QI Calculation

th

ge Values TBD

nder-Range

0

0

0

0

boratory mice.

ot in use. g oxidizing age

mat. It is to thep assess test vhe test as desig

of keeping the cin A6.5

Use the recomny items not a

be accumulated

on and continution listed in Ts reported to th

ns

D

ents.

e advantage validity. The gnated in

controlled

mmendations addressed in

d is one

ue until the Table 2. The he accuracy

s

A

tr

A

th

p

A6.3.2 The steady state por

A6.4 TransitioA6.4.1 This A6.4.2 Duri

ransition for ea

A6.5 Quality IA6.5.1 Calc

hroughout the A6.5.2 Upd

progress. This cA6.5.3 Use

E

H

I

I

O

S

M

C

R

R

time intervalsrtion of each st

ons : portion of the

ing the transitiach parameter

Index: culate and recoentire test.

date the qualitycould indicate the following e

Exhbprs

Humidity

Intairpr

Intairt

Oilint

Speed

Map

Cooloutp

Raccint

Raccfl

TABLE

Control Para

Engine spee

Manifold ab

Engine oil in

Engine cool

Engine cool

RAC coolan

Rocker cove

Intake, air, °

Intake air pr

Exhaust bac

Engine cool

s between recotage.

test shall be, aion, the time iin Table 4 the

ord the quality

y index periodiif the test operequation and th

1 103.

2 106.

1, 2, 3 10.8

1, 2, 3 0.0

1, 2, 3 29.8

1 67.7

2 99.7

3 44.7

1 1198

2 2898

3 3

698697

1 68.6

2 65.6

1, 2, 3 69.3

1, 3 28.6

2 84.6

1, 2, 3 14.8

E A6.3 Maximu

ameter

ed, r/min

bs press, kPa

n, °C

lant out, °C

lant flow, L/mi

nt in, °C

er flow, L/min

°C

ress, kPa

ck pressure, kP

lant pressure

orded readings

at most, the firsintervals betwecycle at 36, 84

index for each

ically throughorational validityhe values listed

DXXXX– 1

44

.83 104.17

.83 107.17

85 11.95

04 0.06

80 30.20

79 68.21

79 100.21

79 45.21

8.1 1201.9

8.1 2901.9

8.1 7

701.9 703

60 69.40

60 66.40

35 70.65

63 29.37

63 85.37

85 15.15

um Allowable

in

Pa

s shall not exc

st 20 min of eaceen recorded r

4, 132 and 180

h controlled pa

out the test to y is in questiond in Table A6.2

5

115.0

115.0

64.0

1.05

49.0

120.0

120.0

120.0

3156.0

3156.0

3156.0 3156.0

76.0

76.0

159.0

120.0

120.0

29.0

Time Constan

Time Constan

1.9

1.8

2.4

2.4

17.0

2.4

2.0

2.4

2.6

1.7

2.0

ceed 1 min. Re

ch stage. Rampreadings shall hours

arameter for th

determine the n before the tes2 to calculate th

0

0

0

0

0

0

0

0

0

0

0 0

0

0

0

0

0

0

nts

nt, s

ecord data thro

ping requiremenot exceed 1

he steady state

operational vast has completethe Qi.

oughout the le

ents are listed imin 5 second

portion of eac

alidity while thed.

ength of the

in Table 4. ds. Report a

ch test stage

he test is in

w

X

U

L

n

A

T

T

rT

A

ed

A

where:

Xi = values o

U = allowab

L = allowab

n = number

A6.5.4 ReseA6.2.

A6.5.5 ReseTable A6.2.

A6.5.6 RounA6.5.7 RepoA6.5.8 If th

TMC. The TMCA6.5.8.1 Th

reference oil teTMC issues a l

A6.6 Time ConA6.6.1 Filte

exceed the valudisplay and dat

A6.6.2 Max

A7.1 Figs. A7.

of the paramete

ble upper limit

ble lower limit

of measureme

et data that is g

et data that is

nd the Qi valueort the Qi valuehe end-of-test C issues a lette

he laboratory dsts. The laboraetter to docum

nstants: ering can be apues listed in Tta acquisition. ximum allowab

A7. DET

.1 to A7.28 sho

er measured,

of X,

of X, and

ents taken.

greater than th

lower than th

es to the neareses on Form 6 oQuality index

er to the laboradocuments its catory or test sp

ment its opinion

pplied to all coTable A6.3. Th

ble system time

TAILED SPE

ow the detailed

e over-range v

he under-range

st 0.001. of the test repor

value is belowatory and the tecomments regaonsor might re

n.

ntrol parameteis time constan

e constants for

CIFICATION

d specifications

DXXXX– 1

45

values listed in

e values listed

rt. w 0.000 for reest sponsor on iarding the endequest TMC re

ers. The amounnt shall pertain

the controlled

NS AND PHO

s and photograp

5

n Table A6.2 w

in Table A6.2

eference oil teits opinion.

d-of-test Qualiteview of test op

nt of filtering an to the entire

parameters are

OTOGRAPHS

aphs of apparatu

with the over-ra

2 with the un

ests, review the

ty index valuesperations for no

applied shall nsystem, runni

e shown in Tab

OF APPARA

us.

ange value list

nder-range val

e test operatio

s less than 0.0on-reference o

not allow time cing from the se

ble A6.3.

ATUS

ted in Table

lue listed in

ons with the

000 for non-oil tests. The

constants to ensor to the

FIG. A7.1 Air Cle

DXXXX– 1

46

eaner Housing

5

g Modificationns

FFIG. A7.2 Enngine Air Intak

DXXXX– 1

47

ke System Ass

5

sembly and Connections

FIG. A7.

DXXXX– 1

48

.3 Camshaft B

5

Baffle

FIG. A7.44 Rocker Arm

DXXXX– 1

49

m Cover with

5

Water Jackett, Left

FIG. A7.55 Rocker Arm

DXXXX– 1

50

m Cover with W

5

Water Jacket,, Right

FIIG. A7.6 Oil L

DXXXX– 1

51

Level Indicato

5

or (Dipstick)

FIG. A77.7 Oil Pan As

DXXXX– 1

52

ssembly with R

5

Removable Baaffles

N(2(3(4(5NNd

NOTE 1—(1) Exter2) Oil filter, OHT63) Temperature se4) Temperature co5) Oil sample valv

NOTE 2—External NOTE 3—Due to fldirectly. Use activ

rnal oil filter adapt6A-012-2, with ste

ensor oil out ontrol sensor oil inve system oil volumeuctuations in ambie temperature con

ter with temperatureel relief valve and

n

e 570 ± 30 mL. ient temperatures itrol to heat the pro

FIG

re in sensor and oid 60 μm screen

it may be necessarocess cooling wate

G. A7.8 Oil Co

DXXXX– 1

53

il pressure gage tap

ry to externally heer going through th

ooling System

5

ps, OHT6A-007-1

eat the test oil to ache oil heat exchang

m Specification

1

chieve the oil in teger to heat the oil.

n

mperature.. Do no

ot heat the oil

N

N

NOTE 1—Dimensio

NOTE 1—The inlet

ons are in millimet

t flow meter must c

tres; Tolerances: ±

calibrate to within

FIG

±0.13; Material: alu

FIG. A7.9 P

n 5 % of the standa

G. A7.10 PCV

DXXXX– 1

54

uminum.

Piston Ring Po

ard (pre-calibrated)

Valve Flow T

5

ositioner

) orifices at the pre

Test Apparatu

essure differentials

us

s stamped on the oorifices.

FIG. A7.111 Piston and

FIG. A7.1

DXXXX– 1

55

d Connecting

12 Idle Air Co

5

g Rod Orient

ontrol

tation

N NOTE 1—Dimensioons are in millimettres.

FIG

FIG A7

. A7.13 MAP

7.14 Typical E

DXXXX– 1

56

Port / EGR B

Exhaust System

5

Block Off Plat

m Cooling Sys

te

stem

FIIG. A7.15 Typpical Exhaust

DXXXX– 1

57

System, Engin

5

ne to Laborat

tory Exhaust

N NOTE 1—Dimensioons are in millimettres.

FIG. AA7.16 Typica

DXXXX– 1

58

l Laboratory

5

Exhaust Systeem

FFIG. A7.17 Closed Crankcaase Ventilatio

DXXXX– 1

59

n System, Typ

5

pical Fittings aand Parts Connfiguration

NN((2(3(4(5(6(7((9((((((((

NOTE 1—Observe NOTE 2—Compone1) Thermostat hou2) Sight glass 3) Flowmeter 4) Flow control va5) Optional tempe6) Fabricated cool7) Constant full ex8) Pressure radiato9) Process water c10) Heat exchange11) Process water 12) Tee with temp13) Water pump in14) Engine coolan15) Coolant system16) Coolant pressu17) Coolant pressu

temperature sensoents of Engine Coousing with tempera

alve erature control senslant reservoir xpansion tank or cap (MOTORCRcontrol valve (reguer (ITT Standard Psupply (shell side

perature sensor for nlet

nt (tube side) m drain valve ure regulator ure gage

or locations in theroling System— ature sensor

sor

RAFT RS40 P/N Dulated by temperatuP/N 5-030-06-048-) coolant inlet; loca

FIG. A7.

rmostat housing an

D2YY-8100-A) ure controller with-001 TYP.)

ated (305 to 406) m

18 Typical En

DXXXX– 1

60

nd at water pump in

h three remote set p

mm upstream of pu

ngine Cooling

5

nlet.

points)

ump inlet

g System Scheematic

FIG. A7

FIG. A7

7.19 Typical T

7.20 Typical T

DXXXX– 1

61

Test Stand, Le

Test Stand, Rig

5

eft Forward V

ght Forward V

View

View

FIGG. A7.21 Intaake Air Supply

FIG

y System, Air

G. A7.22 Typi

DXXXX– 1

62

Cleaner, Reso

ical Engine Co

5

onator and Id

ooling System

dle Load Cont

m

rol (Replace)

FIG. A

FIG.

A7.23 Typical

A7.24 Oil Co

Cooling Syste

ooling System

em, Flow Cont

Required Hea

DXXXX– 1

63

trol Valve, Ve

at Exchanger

5

enturi Flowme

Mounting an

eter, Reservoi

nd Typical Hos

r and Sight G

ses and Fitting

Glass

gs

FIG. A7.255 Oil Cooling System, Adap

FIG. A7.

pter Housing aPressure

.26 Engine Ve

DXXXX– 1

64

at the Engine Tap and Oil F

entilation Syst

5

with Typical Filter

tem (need new

Fittings for T

w pic)

Temperature SSensors,

FIIG. A7.27 Enggine Ventilatio

DXXXX– 1

65

on System, 3-W

5

Way Valve (n

eed new pic)

FFIG. A7.28 Bo

DXXXX– 1

66

ore Measurem

5

ment Ladder

FIG A7.29 B

FIG A

Bank one injec

A7.30 Old styl

DXXXX– 1

67

ctor wire route

le throttle pos

5

e without plas

sition connecto

stic shield

or

FIG A7.31New

FIG A

w style throttl

A7.32 Old style

le position con

e Throttle Pos

DXXXX– 1

68

nnector pigtail

ition Sensor c

5

l installed if 3

connector for F

3W7Z-9E926-A

F3PE-9E926-

AA is used

NB

FIG A77.33 New style

FIG A7.34 Th

Tp

e Throttle Pos

hrottle Positio

TPSsenspigtailro

DXXXX– 1

69

ition Sensor c

on Sensor wire

sorwireoute

5

connector for 3

e routing on t

e

3W7Z-9E926-

est engine

-AA

FI

FIG A7

IG A7.35 New

7.35 Old style

style coolant

DXXXX– 1

70

coolant temp

temp sensor c

5

sensor connec

connector pigt

ctor

tail installed.

FIG A7.336 New style c

FIG. A7.37 I

DXXXX– 1

71

oolant temp s

dle Air Block

CTSsenoutbas

5

sensor wire ro

Off Plate

Spigtailnsorlocatcrossoseofthe

uting.

lrouteaatedonverjackermosta

andcoolantketatat

t

A

A8.1 Table A8

Table A9.1 E SERVICE PANUMBER 1L2Z-6250-A1L2Z-6250-D1L2Z-6L253-1L2Z-6L253-1L3Z-6L266-XL1Z-6L266-1W7Z-6312-A1W7Z-6B288

8.1 lists special

ngine parts

ART

AA DA -AA -BA -AA -AA A 8-AB

FIG. A7.39 T

A8. SPECIA

l tools needed f

Tool No.

D81L-6135

T80T-4000

T91P-6571

T91P-6565

T91P-6565

A9. T

ENGINEEPART NU1L2E-6251L2E-6A21L2E-6L21L2E-6L21L3E-6L21L3E-6M21W7E-6311W7E-6B2

FIG. A7

Thermostat H

AL SERVICE

for the test eng

TABLE Desc

5-A Pis

0-W Driv

1-A Val

5-A Val

5-AH Val

TEST ENGINE

ERING MBER 0-DA

274-CA 53-AA 53-BA 66-AG 269-AC 16-AF 288-AB

DXXXX– 1

72

7.38 Ignition C

Housing with T

TOOLS FOR

gine.

A8.1 Special Tcription

ston pin remov

ver handle

lve stem seal

lve spring com

lve spring spa

E PART NUM

DESCRI CAMSHACAMSHAGUIDE, GUIDE, TENSIOTENSIOPULLY, SENSOR

5

Coil

Thermocouple

R THE TEST

Tools

ver and repla

replacer

mpressor

acer

MBER LISTIN

IPTION

AFT RH AFT LH TIMING CHATIMING CHA

ONER, TIMINGONER, TIMING

CRANKSHAR, CAMSHAF

e location.

ENGINE

acer

NG

AIN TENSIONAIN TENSIONG CHAIN, RHG CHAIN, LHFT FT

NER LH NER RH H H

.

1W7Z-6C315391186S1013L2Z-6345-A 3L2Z-6345-A4R3Z-6B2744R3Z-6M2565C3Z-6211-A5L3Z-6600-A5R3Z-6065-A5W7Z-6268-A 6W7Z-6505-BL2Z-6D309BL2Z-6D309BR3Z-6A341F1AZ-6518-AF3LY-6214-AF3AZ-6265-AF6DZ-6C501F6AZ-6514-AF8AZ-6564-AF8AZ-6256-AF8AZ-6256-BXL3Z-6306-AXL3Z-6507-AXL3Z-6513-AXW1Z-12A22AGSF-32P-M

Table A9.2 E SERVICE PANUMBER F0TZ-9F5933L3Z-9F593-6W7Z-6019-A

9L3Z-8592-B

5-AA

AAA

AA 4-BA 6-CC A AA AA AA

BA 9-A 9-B 1-A A A A 1-AB AC AA AA BA AA AA AA 27-AC M

ngine Dress P

ART

-DA -EAFC AA

B

1W7E-6C391186 3L2E-634XW7E-6C3L2E-6K24R3E-6B24R3E-6M25C3E-6215L3E-6625R3E-6065W7E-6266L3E-6146L3E-6146L3E-6146L3E-6146W7E-650BL2E-6D3BL2E-6D3BR3E-6A3F1AE-651F2LE-621F4AE-626F65E-6C5F6LE-651F6TE-652F8AE-625F8AE-625XL3E-630XL3E-650XL3E-651XW1E-12A3L1E-1243U1L-6113U1L-611YU1L-611YU1L-6116W7E-604 7L2E-6012C5E-630

Parts

ENGINEERPART NUMF0TE-9F593L3E-9F596W7E-6C0

9L3E-8594

315-AA

5-AA C357-AB 258-AA 274-BA 256-CC 1-BA 1-AA

65- AA 68-AA 8-DA 8-EA 8-FA 8-GA 05-BA 309-AA 309-BA 341-BA 8-BA 4-BA

65-AA 501-AB 4-AC

29-AB 56-AA 56-BA 06-AB 07-AC

3-AC A227-AC 05-AA 0-AB 0-BB 0-BC 0-CC

49-AB 10-BA 03-B13A

RING MBER 93-D9B 93-E9A 086-AA

4-BA

DXXXX– 1

73

SENSORPLUG, SBOLTS, BOLTS, BOLTS, GUIDE, GUIDE, BEARINPUMP ABOLTS, CHAIN, PISTONPISTONPISTONPISTONVALVE, BEARINBEARINBEARINKEY, VABOLTS, SPACERTAPPETRETAINARM ASSPROCKSPROCKGEAR, TVALVE, SPRINGWHEELPLUG, SPISTONPISTONPISTONPISTONCYLINDCYLINDCRANKS

DESCR INJECTINJECTCOVER

HOUSI

5

R, CRANKSHSIDE OF BLKMAIN BEARMAIN BEARMAIN, OIL PTIMING CHATIMING CHA

NG - CONNECASY - OIL

CYLINDER HTIMING

N RINGS 0.12N RINGS 0.25N RINGS 0.0.3N RINGS 0.5 O

EXHAUST NG - CRANKSNG - CRANKSNG - CRANKSALVE RETAIN

CONNECTINR, CAMSHAFT - VALVE ER, VALVE S

SY - VALVE RKET - CAMSKET - CAMSTIMING CHAINTAKE

G, VALVE , CRANKSHA

SPRK NS 0.125 O/SNS 0.375 O/SNS 0.250 O/SNS 0.500 O/SDER HEAD DER BLOCK

SHAFT

RIPTION

TORS, FUEL TORS, FUEL R - CYLINDER

NG - THERM

HAFT POSITK

RING CAP RING CAP SIDPUMP PICK UAIN LH AINRH CTING ROD (

HEAD (10 bo

25 O/S 5 O/S 375 O/S O/S

SHAFT MAIN SHAFT MAIN SHAFT MAINNER NG ROD (4bFT GEAR

SPRING ROCKER HAFT RH HAFT LH IN CRANKSH

AFT PICK UP

(PURPLE) (BROWN)

R FRONT

MOSTAT

TION

DE UP TUBE

(1u&l)

olts)

(1u&l) THRUST (1u, THRUST W

bolts)

HAFT

P

u&l) WASHER

Table A9.3 St SERVICE PANUMBER 4W7Z9B6599L3Z-8592-B 3W7Z-9600-9W7Z-9424-AE5TZ-9601-B

Table A9.4 G SERVICE PANUMBER

3W7Z-6E078

4C2Z-9439-C4L2Z-6584-B4L2Z-6584-A5C2Z-9E9365W7Z-8C3875W7Z-8C3886L3Z-6K301-9W7Z-6051-9W7Z-6051-A

9W7Z-6079-A

F1AZ-6020-AF5AZ-6700-AF4AZ-6701-AF4AZ-6571-AF65Z-6840-AXR3Z-9L437F1VY-8507-A3L3Z-6710-A3W7Z-6625-AYC2Z-9448-AF1VY-8255-A Table A9.5 F

tand Set Up P

ART

CA B

BA A B

Gaskets/Seals

ART

8-AA

CA BA AA 6-BA 7-AA 8-AA -AA B A

A

A A A A A 7-BA A AA AA A A

asteners

Parts

ENGINEERPART NUM4W73-9R59L3E-859F3AE-12AF6AE-1223W7U-9609W7E-942E5TE-960D8ZE-6A6F8AE-850F8KE-19A

F7AE-6B

ENGINEERPART NUM

3W7E-6G

4C2E-944L2E-6584L2E-6A5C2E-9E5W7E-8C5W7E-8C6L3E-6K9W7E-609W7E-60

9W7E-60

F1AE-6DF3AE-67F3AE-67F4AE-6AF65E-6AXR3E-9L391108-S3L3E-673W7E-66YC2E-9YN806807 PART NN60652

RING MBER 530-AA 4-BA

A166-BD 257-EB 00-BC 24-AA 01-AB 666-A2B 01-AB A216-AD

209-AB

RING MBER

G050-AA

439-CB 84-BA 559-BA

E930-BA C387-AA C388-AA 318-AA 083-AB 051-AB

079-AA

D081-AD 700-AC 701-BA A517-AA A636-CA L437-BA S 10-AA 625-A3A Y431-AD 7

NUMBER 27

DXXXX– 1

74

DESC TUBECONNBRACBRACASSEMMANIFELEMPCV VWATEGROO

BELT

DESC Gask

GASKGASKGASKGASKGASKGASKRETAGASKGASKGask

GASKSEALSEALSEALGASKGASKSEALGASKORINGASKSEAL

LOCAGUID

5

CRIPTION

, FRESH AIRNECTOR, WACKET, IGNITIOCKET, IGNITIO

MBLY, AIR CFOLD ASY - ENT, AIR FIL

Valve (EV-98)ER PUMP ASOVED IDLER

TENSIONER

CRIPTION

ket set

KET, INTAKEKET, ROCKEKET, ROCKEKET, THROTKET, WATERKET, WATERAINER - CRAK, CYLINDERKET, CYLINDket set

KET, FRONTL, FRONT MAL, REAR MAIL, VALVE STEKET, OIL FILTKET, THROTL, WATER PUKET, OIL PAN

NG, OIL PUMKET, EXHAUL - THERMOS

ATION DE, TIMING C

R ATER OUT ON COIL ON COIL

CLEANER INLET LTER ) SEMBLY PULLEY

R

E MANIFOLDER ARM COVER ARM COVTTLE BODY TR CROSSOVER CROSSOVEANKSHAFT OR HEAD, LH DER HEAD, R

T COVER AIN N EM TER ADPT

TTLE BODY SUMP N P PICK UP T

UST MANIFOLSTAT

CHAIN

 

VER, RH VER LH TO SPACERER RH ER LH

OIL SEAL

RH

SPACER TO

TUBE LD

INTAKE

A

AdfFs

A

A

A

Table A9.6 E

SERVICE PA7U2Z-120295W7Z-9F792F6ZZ-12B57F8PZ-122593U2Z-14S413U2Z-14S41

A10.1 Remove

A10.2 Flush thdeposits. This cflow rate of 0.6Flushing can besolvent can ext

A10.3 Rinse th

A10.4 Rinse th

A10.5 Air-Dry

ngine Finish P

ART NUMBE-B 2-AC 79-AARM -LAFC 1-AA 1-UAA

A10.

e and complete

he shell side of can be accomp63 L/s ± 0.126 e required for lend the useful

he heat exchang

he heat exchang

y Heat Exchang

N80495N80604N80615N80615N80615N80615N80616N80616N80617N80617N80617N80618N80630N80719N80858N81108W50327W50330W50610W70122W70151W70160W70459W70469W70512W70650W71598

Parts

R

ENGINPART 7U2J125W7E-RMF6ZF8PE 1

EXTERNAL

ely disassemble

f the heat exchalished by usingL/s. Several helonger than 12 life of the solv

ger with hot w

ger with degre

ger:

58 40 54 55 55 55 64 65 77 77 77 83 00 98S 86 85 79 01 02-S437 28S300 12 05 94S300 93 28 08 86S900

NEERING NUMBER 2029AB -9F792-AD ZF-12B579-A12259 LA

OIL HEAT E

e the heat exch

anger with an og a positive diseat exchangers h if the deposi

vent.

water.

asing solvent (

DXXXX– 1

75

GUIDPINSTHROREARCAMSCRANWASWASTIMINFRONWATOIL PFRONSLEEFRONSPROTIMININTATHRODOWPULLOIL PDOWWATOIL FFRONPLUG

DES COIMAN

AB SENWIRTHRCOO

EXCHANGER

hanger includin

organic solventsplacement pumcan be flushed

its are particula

(see 7.7.1).

5

DE, TIMING CS, OIL PUMP OTTLE BODYR SEAL HSGSHAFT POSNKSHAFT POHER, GEAR HER, CRANK

NG CHAIN TNNT COVER ER PUMP

PUMP NT COVER EVE - GUIDENT COVER OCKET TO CNG CHAIN G

AKE MANIFOLOTTLE BODY

WEL, FRONT ALEY, CRANKSPAN

WEL - PIN, BLER OUT CON

FILTER ADAPNT COVER G - BLOCK FR

SCRIPTION

L ASY - IGNINIFOLD ASSYNSOR,MAFRES, SPARK ROTTLE POSOLANT TEMP

R CLEANING

ng the end caps

t for a minimummp to flow the d at the same tiarly heavy or th

CHAIN Y ELBOW TO

G ITION SENSOOSITION SENTO CAMSHAKSHAFT PULNESIONER

, BELL HOUS

CAMSHAFT UIDE LD Y TO SPACEAND REAR CSHAFT

LOCK TO CYLNNECTOR PTER

RONT, WATE

TION Y, FUEL PLUG

SITION SENSPERATURE S

G TECHNIQU

s.

m of 12 h to ensolvent throug

ime by conneche solvent is ag

O INTAKE

OR NSOR AFT LLEY

SING

ER COVERS

LINDER HEA

ER PUMP

SOR PIGTAILSENSOR PIG

UE

nsure the remogh the heat excting them in seged. Filtration

AD

GTIAL

oval of all changer at a eries. of the

ath

Ah

A

NOTE A10.1—attached to an elehis application.

A11.1 Downlohttp://www.astm

A12.1 A typica

—The tube side oectric drill has be

A11

oad the actual rmtmc.cmu.edu

1. T

2. T

3. Su

4. T

5. T

6. O

7. O

8. A

9. D

NOTE

candand dfor reTest

10. A

al dipstick cali

of the heat exchaeen found to be

1. SEQUENC

report forms anu/, or they can b

T

Title / Validity D

Table of Conten

ummary of Te

Test Result Sum

Test Results Sum

Operational Sum

Oil Addition Re

Analysis of Oil

Downtime Occu

E 1—If the nondidate oil test redata dictionaryeporting the caLaboratory Co

ACC Conform

bration is pres

FI

anger should be pan effective way

E VG REPOR

nd data dictionabe obtained in

Table of Conten

Declaration Pa

nts

st Method

mmary

mmary

mmary

ecord and Blow

urrences and O

n reference oil esults to the regy (that are mainandidate oil tesonformance sta

mance Statemen

A12. DIPST

ented in Fig. A

Sequence VG

Slope = 21 g/

Offset = 1953

IG. A12.1 Typ

DXXXX– 1

76

periodically cleay to remove proc

RT FORMS A

ary separately hardcopy form

nts

age

wby Rates

Other Comment

test results aregistration organntained for repot results. Inclu

atement.

nt

TICK CALIBR

A12.1 and Tabl

G Dipstick Correlati

mm

3 mm

pical Dipstick

5

aned to ensure adcess water depos

AND DATA D

from the ASTMmat from the TM

Form 1

Form 2

Form 3

Form 4

Form 5

Form 6

Form 7

Form 8

ts Form 9

e also to be subanization, use thorting referenc

ude the ACC Co

RATION

le A12.1.

ion:

k Calibration

dequate heat transits. Ultrasonic c

DICTIONARY

M Test MonitoMC.

bmitted as he report formsce oil results) ode of Practice

nsfer. A rifle borcleaning is also e

Y

oring Center W

s

e

re cleaner effective in

Web Page at

NeNOTE 1—The dipsteach. Always inser

tick level is measurt the dipstick with

TAured from the bottoh the words “Engin

D

ABLE A12.1 Tyom of the dipstick ne Oil” facing up. R

Dipstick, mm

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

DXXXX– 1

77

ypical Dipstickup, zero being at tRead the oil level

T

5

k Calibrationthe bottom and 60at the centerline o

Total Oil, g

1953

1974

1995

2016

2037

2058

2079

2100

2121

2142

2163

2184

2205

2226

2247

2268

2289

2310

2331

2352

2373

2394

2415

2436

2457

2478

2499

2520

2541

2562

2583

2604

2625

2646

2667

2688

2709

2730

2751

0 mm at the top. Thof the dipstick.

he minor incremennts are 1 mm

Ab

A

R

C

O

O

O

D

E

O

O

T

V

F

V

A13.1 Test Engby the test spon

Ford Motor C290 Town CDearborn, M

A13.2 Various

RAC kits

Camshaft baffle

Oil filter housin

Oil oil screen, L

Oil filter adapte

Dipstick assem

Exhaust manifo

Oil pan and baf

Oil Pan Insulat

Thermostat orif

VG dynamome

Flywheel

VG EEC

gine Parts—Tnsor (Ford MotCo. enter Dr

MI 48126

s Materials—

es

ng, Modified R

LFS-6028WCF

ers

mbly with tube

olds

ffles,

ion

fice, OHT 6A-

eter and engine

D

A1

he required partor Company) t

Racor oil filter

F

004-1

e harnesses

Dipstick, mm

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

3. CRITICAL

rts for use in ththrough Ford C

r

DXXXX– 1

78

T

L PART SUPP

he VH test procComponent Sal

5

Total Oil, g

2772

2793

2814

2835

2856

2877

2898

2919

2940

2961

2982

3003

3024

3045

3066

3087

3108

3129

3150

3171

3192

3213

PLIER LIST

cedure are for les:

the 4.6 L 2V eengine which aare supplied

V

A

A

E

E

C

V

O

A

A

C

T

T

A

As

AFS AR APOPO

VG wire harnes

Are available frOH Technolo9300 ProgresMentor, OH

A13.3 Various

Exhaust manifo

Exhaust manifo

Camshaft beari

Valve deck rati

Oil Screen Blow

Are available frTest Enginee12758 CimarSan Antonio

A13.4 Test eng

Connecting rod

Throttle bodies

Throttle body s

Are available frBishop Intern224 North CDallas, TX 7Toll-free: 80 Cunningham10980 WardRustburg, VA800-828-070

A13.5 Cylindesupplier:

E&E Engine1602 South FSan Antonio(210) 225–1

A13.6 Oil sepaF47E- 6A785-ASupplier TBD

A13.7 Wire harRon Francis wi

A13.9 Lambda Processor: HoriO2 Sensors: HoProcessor: ECMO2 Sensors: 52

sses (must be m

from the followogies ss Pkwy. 44060

s Materials—

old spacer

olds

ings

ing templates

wdown Device

from the followering, Inc. rron Path, Ste. , TX 78249-34

gine Parts –

ds, Part Numbe

s, Part Number

spacers Part Nu

from the follownational, Inc. orinth St.

75203 00–843–5068

m Brothers Autos Road A 24588 07

er Head Modifi

e Machine and Flores , TX 78204 141

arator AA Oi

rnesses are avaire harnesses n

measuring deviba Mexa 730, oriba Model # M Model #: NO210-T2

modified as sho

wing supplier:

e

wing supplier:

102 417

er F3AZ-6200

F3PE-9E926-N

umber 3W7E-

wing supplier:

o Parts

ications—cam

Parts

il Separator

ailable from theeed part numbe

vice: category # RX3200202803, c

OxCANt

own in 7.10.9)

-A/F3AE-6200

NB (VG) or 3W

-9A589-AB

bore machinin

e following supers and addres

X-721-57-B category # 3YX

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79

0-AA

W7Z-9E926-A

ng and valve gu

pplier: s. Possibly from

X5-1004

5

AA

uide installatio

m TEI

on are availablee from the folloowing

A

A

A14.1 See Fig.

A15.1 Rating w

A14.1 for oil s

worksheets are

A14. OP

sampling, addi

FIG. A14.

Note: Ne

e provided in F

PERATIONA

ition, and level

1 Oil Samplin

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A15. RATI

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AL DATA LOG

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ng, Addition a

heading of Fig

ING WORKS

A15.13

5

G—ENGINE

and Leveling R

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SHEETS

OIL

Record

m VG)

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81

5

FIG. A

FIG. A

A15.1 Sludge

A15.2 Sludge R

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82

Rating of Lef

Rating of Righ

5

ft Rocker Cov

ht Rocker Cov

ver

ver

FIG.. A15.3 Sludg

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83

ge Rating of L

5

eft Cam Bafflle

FIG. A15.4 Sludge

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84

e Rating of Ri

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ight Cam Bafffle

FIG. AA15.5 Sludge

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85

Rating of Tim

5

ming Gear Covver

FIGG. A15.6 Sludg

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86

ge Rating of O

5

Oil Pan Baffless

FFIG. A15.7 S

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87

Sludge Rating

5

of Oil Pan

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88

5

FIG.. A15.8 Sludg

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89

ge Rating of L

5

eft Valve Deckk

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90

5

FFIG. A15.10 VVarnish Ratin

FIG.

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A15.9 Sludge

kirts Piston Ri

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91

e Rating of Ri

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5

ight Valve Dec

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Clogging. Oil SScreen Percen

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FIG. A15.1

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92

1 Piston Rati

5

ing Grid

FIG. A15.11

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93

1A Piston Rat

5

ting Grid

FIG. A15.12 Varnish

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94

Rating of Lef

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ft Camshaft BBaffle

FIG. A155.13 Varnish R

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ht Camshaft BBaffle

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A16.1 Fuel Injrequired. This dsuitable comme7.7.1) as the flu

A16.2 Fuel Injsuitable apparareused if the cri

A16.3 Performcracking or tear

A16.4 To remo

A16.5 Using apressure sourcenjector(s) durin

has a dramatic

A16.6 Flow-tequality. The sprpressure on clo

A16.7 The accfluid pressure. D

X1.1 The nece

jector Test Rigdevice shall beercially availabuid for flow tes

jectors—Prior tus as identifieiteria outlined

m a visual inspering and replac

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est each injectoray pattern shosed injector(s)

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X

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A16. FU

g—A suitable de capable of perble apparatus hsting injectors.

to installationsed above. The ein this section

ection of each ice as required.

bly residue bef

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or for a 60 s perould be typical

for at least 30

low for each innjector that flow

X1. PISTON A

measurement re

UEL INJECTO

device capable rforming neces

has been identif

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injector. Ensur

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njector(s) in thetarts to flow thr± 3.4 kPa . Mapray pattern. O

riod. While thefor the make as. The injector

njector after thews above or be

AP

(Nonmand

AND RING M

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OR FLOW M

of accurate, ressary port fuel fied, design of

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e 60 s test shalllow this range

PPENDIXES

datory Inform

MEASUREME

e shown in Fig

5

MEASUREME

epeatable flow injector evalua

f the test rig is u

and used) for sned in this sect

ve been cleaned

injectors for 30

on the pressurector(s). Maintapressure is critis set, zero the v

owing, make a vhe injector. At eak or drip. Dis

l be 188 mL to.

mation)

ENTS RECOR

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ENTS

measurement oations as outlinup to the labora

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e source to the ain the test fluidical because a volume-measur

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RD FORMS

of port fuel injned below. Sinatory, Use solv

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eposits. Check O

injector(s). Afd pressure suppsmall change iring device.

tion of the spran of the 60 s pector that leaks o

90 kPa ± 3.4 kP

ectors is ce no vent (see

using a d and

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FFIG. X1.1 Pis

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ton Ring Side

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e Clearance

FIG. X1.22 Piston Ring

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98

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Xr

a

X2.1 The follorequired materi

X2.1.1 ASTMand Ford or Lin

X2.1.2 ASTMASTM Test M6555 Penn APittsburgh, PX2.1.3 Test Ford Motor C1800 FairlanRoom 410 Allen Park, MX2.1.4 Aero

owing sources aials or informatM Sequence VHncoln dealers. M Test MonitoMonitoring Ce

Ave. PA 15206-4489

Sponsor—All Co.

ne Drive.

Mi 48101 oquip Hose and

X2. SOUR

are provided fotion sources.

VH Test Parts—

ring Center—Aenter

9 communicatio

d Fittings—Aer

FIG. X1.3

RCES OF MA

or convenience

—ASTM Seque

All communica

ons with the tes

roquip hose an

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Piston Ring M

ATERIALS AN

e only. This do

nce VH Test P

ations with the

st sponsor (For

nd fittings can b

5

Masses

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es not represen

Parts can be pu

e TMC should b

rd Motor Co.) s

be obtained fro

ATION

nt an exclusive

urchased throug

be directed as f

should be direc

om the followin

e or complete li

gh Ford Comp

follows:

cted as follows

ng supplier:

isting of

ponent Sales

s:

o

P

f

c

f

Aeroquip Co1225 W. MaVan Wert, OX2.1.5 Fue

obtained from tHaltermann PO Box 429 ChannelviewX2.1.6 EngiMicro Motio7070 WincheBoulder, COX2.1.7 Inta

Protimeter dewX2.1.8 Blow

following: AVL X2.1.9 HeatKinetics Eng2055 Silber RHouston, TXX2.1.10 FueMicro Motio7070 WincheBoulder, COX2.1.11 Var

component caliOH Technolo9300 ProgresMentor, OH X2.1.12 Par

following suppBetter Engin8361 Town CBaltimore, M Ultrasonic clPurvis Indu10500 NortDallas, TX Tierra Techobtained fro Tierra Tech X2.1.13 CraDwyer InstruJunction of IP.O. Box 373Michigan CiX2.1.14 RACPenray Cos.,1801 Estes AElk Grove, IL

orp. in

OH 45891 el Information the following: Solutions

w, TX 79530-04ine Coolant Floon Corp. ester Circle

O 80301 ake-Air Humidwpoint meters awby Flow Rat

t Exchangers—gineering CorpRoad, Suite 10

X 77055 el Flow Measuon Corp. ester Circle

O 80301 rious Materialsibration deviceogies ss Pkwy. 44060

rts Washer andlier:

neering ManufaCourt Center

MD 21236-4964

leaner ustries, th Stemmons 75220.

h model MOTom Tierra Tec

h Ultrasonic s

ankcase and Inument Co. ndiana State H3 ty, IN 46360 C Coolant—Pe, Inc., Ave., L 60007

and Availabi

429 owmeter— is a

dity Instrumenare suitable for te Orifice—Inf

—ITT Standard .

01

rement—Mass

s—RAC kits, ces utilized in th

d Chemicals—A

acturing

4

Freeway,

T500NS ultrach

olution 7 and

ntake—Air Pres

Highway 212 an

encool 2000 En

ility—General

available from

ts—The Alnormeasurement

formation conc

Heat Exchang

s fuel flowmete

camshaft bafflehis test method

A dishwasher t

asonic parts c

d B cleaner ca

ssure Gages—G

nd U.S. Highw

ngine Cooling

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100

information c

the following

r Dewpointer,of the intake-acerning the bl

gers can be obta

ers are availabl

es, oil filter adare available f

type parts clean

cleaner or sim

an be obtained

Gages are avai

way 12

System Treatm

5

concerning VH

supplier:

, EG & G, Fair specific humlowby flow ra

ained from the

le from the foll

dapters, flywhefrom the follow

ner and associ

milar Tierra T

d from Tierra

ilable from the

ment is availab

H fuel, includ

Foxboro, Hy-Cmidity. ate orifice me

e following sup

lowing supplie

eel and variouswing supplier:

ated chemicals

Tech ultrason

Tech

e following sup

le from the fol

ding availabil

Cal, General E

eter is availabl

pplier:

er:

s other test stan

s can be obtain

nic parts clean

pplier:

llowing supplie

ity, can be

Eastern and

le from the

nd parts and

ned from the

ner can be

er:

s

f

X2.1.15 LubX2.1.16 Co

supplier: Sunnen Inc. 7910 ManchSt. Louis, MX2.1.17 TygThe Norton C12 East AvenTallmadge, OX2.1.18 RatDazor Manu4455 DuncanSt. Louis, MX2.1.19 Spe

from the followOwatonna To2013 4th St. NW Owaton X2.1.20 FlywFord Racing Ford Racing P.O. Box 490Dearborn, M OHT FlywheOH Technolo9300 ProgresMentor, OH

ASTM Internstandard. Userinfringement of

This standarrevised, either should be addresponsible techyour views know

This standarUnited States. Iat 610-832-958rights to photoc

bricants—EF-4onnecting Rod

ester O 63143

gon Hose—TygCo. nue OH 44278 ting Lamps—Sfacturing Corpn Ave. O 63110

ecial Tools for wing supplier: ool Co.

nna, MN 55060

wheel Flywheel #M-Performance P

0 MI 48121

eel is availableogies ss Pkwy. 44060

national takes nors of this standaf such rights, are

rd is subject to rereapproved or w

dressed to ASTMhnical committewn to the ASTM

rd is copyrightedIndividual reprin85 (phone), 610-copy the standar

411 are availabHeater—The

gon hose is ava

uitable rating lp.

the Test Engin

0

-6375-D46 is aParts

e from the follo

o position respecard are expresse entirely their ow

evision at any tiwithdrawn. YourM International ee, which you ma

Committee on S

d by ASTM Intents (single or mu-832-9555 (fax),rd may also be se

ble from local dSunnen Mode

ailable through

lamps are avail

ne—Special too

available from t

owing supplier

cting the validitysly advised that wn responsibility

ime by the respor comments are

Headquarters. ay attend. If youStandards, at the

ernational, 100 ultiple copies) of or service@astecured from the

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distributors of Mel CRH-50 co

h local Cadillac

lable from the

ols to facilitate

the following s

:

y of any patent rdetermination

ty.

onsible technicalinvited either foYour comment

u feel that your ce address shown

Barr Harbor Df this standard mtm.org (e-mail); ASTM website (

5

Mobil productsonnecting rod

c Plastic Co. di

following supp

e assembly and

supplier:

rights asserted inof the validity

l committee and for revision of thts will receive comments have nbelow.

Drive, PO Box Cmay be obtained

or through the (www.astm.org/C

s. heater is avai

istributors or th

plier:

d disassembly o

n connection witof any such pa

must be reviewehis standard or fcareful considenot received a fa

C700, West Conby contacting AASTM website

COPYRIGHT/).

ilable from the

he following su

of the engine a

th any item menatent rights, and

ed every five yeafor additional steration at a mefair hearing you

nshohocken, PA STM at the abov(www.astm.org)

e following

upplier:

are available

tioned in this d the risk of

ars and if not tandards and eeting of the should make

19428-2959, ve address or ). Permission