ASTM D6984 Standard Test Method for Evaluation of Automotive Engine Oils in the Sequence IIIF, Spark-Ignition Engine
9. Preparation of Apparatus
9.1 Condenser Cleaning - Immediately after completing a Sequence IIIF test, remove the stainless steel condenser assembly, disassemble it, and soak it in parts cleaning agent. After the soaking, clean the inside of the tube with parts cleaning agent and a non-cuprous bristle brush. Rinse both the blowby gas and coolant sides of the condenser with clean solvent.
9.1.1 After ten tests, or more frequently if film is present, clean the coolant side of the condenser by flushing it for one-half hour with a water solution of 20 g/L of Sequence IIIF test component cleaner (see 7.4). Rinse it thoroughly with tap water at 60 °C.
9.2 After cleaning the coolant side of the condenser, pressure check it for leaks using air at 70 kPa.
9.3 Intake Manifold Cleaning - Clean the intake manifold with solvent.
9.4 Cleaning of Engine Parts - Clean all engine parts (other than the block and heads; see 9.5 and 9.6) thoroughly prior to engine assembly. Degrease them first, and then brush them with parts cleaning agent. Immediately remove the cleaner by spraying with hot tap water. Blow-dry the parts with clean, dry shop air and immediately coat them with a 50/50 mixture of build-up oil and solvent.
9.4.1 Clean the connecting rods by soaking in solvent for a minimum of 2 h. Spray the rods with a 50/50 mixture of solvent and EF-411.
9.5 Engine Block Cleaning - Clean the block according to the following:
9.5.1 Remove the debris in the head bolt and main bearing-cap bolt holes using class 2B bottoming taps of the appropriate sizes.
9.5.2 Physically remove from the water jacket all sand and slag deposits, and any other debris using a sharp-ended drill rod or a long straight slot screwdriver.
126.96.36.199 Check the camshaft tunnel for sharp edges on the front of each bore and along the cross-drilled oil gallery inside each bearing bore. Deburr as necessary. See the Sequence IIIF Engine Assembly Manual, Section 1-Sheet 2.
9.5.3 Thoroughly clean the block prior to honing as follows: In the case of a block used in a previous test, remove the crankshaft, main bearings, and bearing caps. In addition, remove all bushings, bearings, and oil gallery plugs prior to cleaning. With either a new or a used block, prevent cleaner or oil from entering the engine coolant passages. (See Sequence IIIF Engine Assembly Manual, Section 1-Sheet 5.)
188.8.131.52 Clean the block in a heated bath or temperature-controlled automated parts washer or ultrasonic cleaner before and after honing. Follow these suggested guidelines to ensure there is no rusting of the engine block after this process:
If Using a Heated Bath or an Automated Parts Washer:
(1) Use only NAT-50 or PDN-50 soap at a concentration of 0.73 kg of soap per 380 L of water. Change the soap and water solution at least every 25 h of use.
(2) Control the soap-and-water temperature at 60 °C +/- 10 °C.
(3) Use only fresh tap water in the bath.
(4) Prior to installing the engine in the parts washer, ensure that all coolant passages are blocked off to prevent cleaning solutions from entering the passages.
(5) Run the block through the cleaning cycle for a period of 30 min to 40 min.
(6) After the cycle is complete, immediately remove the block from the washer and spray it down with degreasing solvent.
(7) Wipe cylinder bores out with a lint free towel.
(8) Spray engine block with a mixture of 50:50 build-up oil and degreasing solvent.
(9) Do not remove the paint dot from the crankcase area of the block.
(10) Allow the block to cool to room temperature before honing the block.
If Using the Ultrasonic Cleaner Parts Washer:
(1) Based on bath volume, use solution 7 at a ratio of 132.5 mL (4.48 oz) per 3.785 L (1 gal) of water plus solution B at a ratio of 11 mL (0.38 oz) per 3.785 L (1 gal) of water. As an alternative, a 50/50 Brulin US Solution of 815 GD and 815 QR-DF may be utilized in a 12.5 % concentration.
(2) Use only fresh tap water in the bath.
(3) Control the solution-in-water temperature to 65 °C +/- 5 °C.
(4) Prior to installing the engine in the ultrasound cleaner, ensure that all coolant passages are blocked off to prevent cleaning solutions from entering the passages.
(5) Run the block through the cleaning cycle for a period of 60 min.
(6) After the cycle is complete, immediately remove the block from the washer and thoroughly spray down the block with hot water.
(7) Replace the mixture of the two solutions-in-water with a new mixture at least after every 25 h of use.
(8) Spray engine block with a 50:50 mixture of build-up oil and degreasing solvent.
(9) Do not remove the paint dot from the crankcase area of the block.
(10) Allow the block to cool to room temperature before honing the block.
184.108.40.206 See the Sequence IIIF Engine Assembly Manual, Section 2 for the honing procedure.
220.127.116.11 After honing the cylinder walls, clean the engine block again according to 9.5.3 and spray the engine block (including all oil galleries) first with solvent followed by a 50:50 mixture of solvent and build-up oil. Using this 50:50 mixture, wipe out the cylinder bores with clean cloth towels until all honing residue has been removed.
18.104.22.168 Air dry the engine block, using clean dry shop air, and coat the cylinder walls with build-up oil using soft, lint-free, clean cloths.
9.6 Cylinder Head Cleaning - Clean the cylinder heads according to the following:
9.6.1 Explore all accessible water passages with a flexible probe to detect any material that would interfere with coolant flow.
9.6.2 Using a 10 mm wire brush, extending two-thirds the length of the cylinder head from freeze plug hole to freeze plug hole, clean all core sand and casting slag from the cylinder heads to ensure unrestrained coolant flow.
9.6.3 Clean the cylinder heads according to the recommended engine block cleaning procedure (see 22.214.171.124) or clean with solvent. Spray the heads with a 50/50 mixture of solvent and EF-411. When cleaning the heads, do not remove the paint dot.
9.7 Engine Build-up Procedure - Laboratories should design and maintain engine-build data sheets in a format compatible with Microsoft Excel and record data for cylinder bore measurements, piston and ring sizing data, valve train spring force calibrations, camshaft and lifter measurements, and all critical part identification information. This data shall be available to the TMC and the Test Procedure Developer for investigative studies, as deemed necessary for hardware investigations during times of industry severity shifts or other problems.
9.7.1 General Information - Use only the listed service parts, special test parts, and special build-up procedures specific to this test as outlined in this test method and the Sequence IIIF Engine Assembly Manual. (See 6.4.) Make and record measurements, specified in this test method, of the cylinders, pistons, rings, valve train, cam, and lifters. These measurements will provide evidence of conformance to the specifications of the test method, and will provide baselines for determining engine wear that occurs during a Sequence IIIF test.
9.7.2 Special Parts - Use the special parts listed in the Sequence IIIF Engine Assembly Manual, Sections 8, 9, 10, and 11.
126.96.36.199 Hardened Valve Seat Heads - Cylinder heads with hardened seats, part number 24502260S, can be used for non-reference oil tests once an acceptable reference oil test has been completed in the laboratory. These heads can also be reused, provided an acceptable reference oil test has been obtained with the reused heads and the criteria in section 5a of the assembly manual has been met. Once a laboratory has obtained acceptable reference oil results on both new and reused 24502260S heads, the laboratory can use either new or reused heads for any tests. When a test is conducted on an acceptable reused cylinder head with part number 24502260S, thereafter, append an "X" to the part number reported in the test report, where "X" is the number of tests the head has been used.
9.7.3 Hardware Information - Complete Form 12, Hardware Information, in standardized report form set (see Annex A8).
9.7.4 Fastener Torque Specifications and Torquing Procedures - Use the following specifications and torquing procedures when installing bolts in the engine:
188.8.131.52 Main Bearing Cap Bolts - Do not use air tools on bolts to seat the main bearing caps in the engine block. Use a rubber or plastic mallet to seat the main bearing caps to avoid misalignment and potential damage to the engine block. Apply build-up oil to the threads and to the surfaces of the bolts that contact the main bearing caps. In order to prevent hydraulic lock, do not apply oil to the tapped holes in the cylinder block. Install the bolts finger-tight and tighten them further with the SPS Torque Sensor I torque wrench or Ingersoll-Rand ETW-E180 only, working from the center out in a criss-cross pattern. See the Sequence IIIF Engine Assembly Manual for torquing instructions. (See Section 1-Sheet 6 for honing and Section 3-Sheet 6 for final assembly.)
184.108.40.206 Cylinder Head Bolts - Install the cylinder head bolts, GM Part No.25527831 (long) and 25533811 (short), that are of special design for yield applications using the SPS Torque Sensor I or Ingersoll-Rand ETW-E180 torque wrench. See the Sequence IIIF Engine Assembly Manual for installation instructions. Replace the bolts after each test. (See Section 1-Sheet 7 for honing and Section 5 Sheet 3 for final assembly.)
220.127.116.11 Torques for Miscellaneous Bolts, Studs, and Nuts - Use the torques for miscellaneous bolts, studs, and nuts given in the Sequence IIIF Engine Assembly Manual.
9.8 Parts Replacement - See 9.8.1 for information regarding parts. Replace test parts as follows:
9.8.1 Install the new parts listed in Annex A5 (Table A5.1) for each test.
9.8.2 Install the new parts listed in Annex A5 (Table A5.2) only if the used part is no longer suitable for test purposes.
9.9 Engine Block Preparation - Prepare the engine block as follows:
9.9.1 Install new engine block freeze plugs; use a driver to facilitate this replacement.
9.9.2 Install the main bearing caps, without the bearings in place. Tighten the retaining bolts using the procedure in 18.104.22.168.
9.9.3 To prevent entry of honing fluid into the coolant passages of the engine block, cover and seal the coolant inlet passages and freeze plug openings. Close the petcocks if previously installed; if not, install 1/4 in. NPT pipe plugs.
9.9.4 With a 300 mm smoothing file, deburr the surfaces of the block that mate with the cylinder heads to ensure adequate gasket seating.
9.9.5 Use the honing torque plates B-H-J GM 3.8L/3E-R-s_t-HT to pre-stress the engine block for honing. Install the torque plates with the proper hardened washers (supplied with the honing torque plates), single washers on top row and double washers on bottom row, to establish proper bolt depth. Clean the threaded bores for the cylinder head attachment bolts using a bottoming tap before each installation of the torque plates. The torque plates require the use of new head gaskets, SPO Part No.24503801 left head and 24503802 right head, along with cylinder head, torque-to-yield fasteners, SPO Part No.25527831 (long). Clean all sealing and thread locking compounds from the fasteners for the torque plate installation. Coat each fastener with build-up oil and see Section 1-Sheet 7 of the Sequence IIIF Engine Assembly Manual for installation instructions.
9.9.6 Use only the CV-616 honing machine to hone the cylinder walls. See the Sequence IIIF Engine Assembly Manual, Section 2, for all of the proper setup and operational procedures for each specific run on the Sequence IIIF engine block.
9.9.7 Replace the honing fluid, filters, and fiber mats used in the honing machine after every 15 h of honing machine operation. Use the honing machine hour meter to determine hours of operation. See the Sequence IIIF Engine Assembly Manual, Section 2-Sheet 8.
9.9.8 The flow rate of the honing lubricant should be approximately 7 L/min. In addition, do not introduce solvents into the honing fluid or use them to clean the honing stones or guides. Use only honing fluid to clean honing stones or guides.
9.9.9 Hone the cylinder walls without the main bearings in place, but with all bearing caps installed.
9.9.10 Clean the engine block following honing according to 22.214.171.124.
126.96.36.199 Allow cylinder block to cool for a minimum of 10 min before taking final bore measurements.
9.9.11 If desired, check the main bearing bore clearances using a mandrel, part BX-398-1, according to the following procedure:
188.8.131.52 Starting from the front of the block, slide the mandrel through all four main bearing bores. If excessive resistance is encountered while inserting the mandrel, remove the mandrel from the engine block and inspect the main bearing bores for burrs, nicks, dirt, alignment problems, or any abnormalities.
184.108.40.206 Carefully remove any nicks, burrs, scratches, or dirt with 400-grit paper or a fine stone. Then use a clean shop towel with mineral spirits to wipe the affected surfaces. Reinstall the mandrel to ensure that it can freely pass through all four main bearing bores. If the mandrel will not clear the bores after completing the above steps, do not use this block. Notify the Test Procedure Developer of the problem.
220.127.116.11 After honing, repeat the above procedure prior to final engine build. The mandrel is an alignment and clearance gauge only, not an assembly tool. The mandrel should not be in the bores when installing the main bearing caps or torquing the main bearing bolts.
9.10 Piston Fitting and Numbering - Fit the pistons to the cylinders according to recommendations listed in the Sequence IIIF Engine Assembly Manual for the run sequence of the block. Use only the specified code pistons for each run sequence. Number the pistons with odd numbers in the left bank from front to rear and with even numbers in the right bank from front to rear.
9.10.1 Piston Ring Fitting - Pre-size the rings for each run and check the ring gaps in the cylinder bore for each test.
18.104.22.168 Prior to checking the piston ring gaps, remove any paint marks on the rings using acetone and a soft cloth, followed by a mineral spirits rinse.
22.214.171.124 The top ring gap shall be 0.042 in. +/- 0.002 in. (1.067 mm +/- 0.051 mm). The bottom ring gap shall be 0.038 in. +/- 0.002 in. (0.965 mm +/- 0.051 mm). The top ring gap shall be larger than the bottom ring gap and the difference between the two ring gaps shall be between 0.003 in. and 0.006 in. (0.076 mm and 0.152 mm). If the ring gap difference is below 0.003 in. (0.076 mm), contact the Test Procedure Developer. Check the ring gap with a Starrett Ring Taper Gage No.270 with the ring positioned in the cylinder bore using a piston ring depth gauge (drawing RX-118602-B). Position the rings 0.932 in. (23.67 mm) below the cylinder-block deck surface during gap measurement.
126.96.36.199 Record the top and bottom ring gaps on Form 12, Hardware Information, in the standardized report form set (see Annex A8). Record and report ring gaps in mils (1 mil = 0.001 in. = 0.0254 mm).
9.11 Pre-Test Camshaft and Lifter Measurements - Measure the camshaft lobe height and lifter lengths, prior to engine assembly, according to the following procedure:
9.11.1 Remove camshaft and lifters from laboratory inventory.
9.11.2 Remove camshaft and lifters from original container and packaging and set container and packaging aside for later use. Clean camshaft with degreasing solvent. Do not clean the lifters; wipe the lifters with a clean cloth or towel.
9.11.3 Make the camshaft measurement using Mitutoyo Snap Gauge, model 201-152, and a Mitutoyo Digital Indicator, model 543-252B, to measure the camshaft lobes. Make the lifter measurement with a digital indicator equipped with a Mitutoyo 4.3 mm flat tip, model 131-259 mounted in a indicator stand. Equip the indicator stand with a V-block that is rigidly mounted to the base and locates the lifter with its center axis in line with the digital indicator. Store the camshaft and lifters in a temperature-controlled room, before making dimensional measurements, for at least 90 min to ensure temperature stabilization.
188.8.131.52 Use dimensional measuring equipment accurate to 0.01 mm. Before each measurement session, use standards traceable to the National Institute of Standards and Technology, to ensure measuring equipment accuracy. Include standards having length values within 1.3 mm of the typical lifter and lobe measurement taken. Use the same equipment and standards post-test measuring as were used for pre-test measuring. If a calibration shift between the pre-test and post-test measurements is detected, evaluate the shift to determine the effect on the wear measurement. Record the results of the evaluation and any corrective action taken.
9.11.4 With the camshaft positioned in a set of V-blocks, remove any burrs around the outer edge of the camshaft thrust surface, if necessary. Thoroughly clean the camshaft with degreasing solvent to remove all rust preventative coatings and blow-dry it with clean, dry shop air.
9.11.5 Measure the maximum pre-test dimension of each camshaft lobe, transverse to the camshaft axis to the nearest 0.001 mm. This dimension is at the rear edge of all lobe positions (lobes are numbered from the front to the rear of the camshaft). Record the measurements and temperature at the time of measurement on internal laboratory forms. (See 9.7.) After measuring, coat the camshaft with build-up oil. Return the camshaft to its original packaging and container until installed in the engine.
9.11.6 Measure the pre-test length of the lifters at the center of the lifter foot to the nearest 0.001 mm. Record the measurements and temperature at time of measurement on internal laboratory forms. (See 9.7.)
9.11.7 Record the unique serial number for each lifter on internal laboratory forms. (See 9.7.) Do not use electro-mechanical scribing devices. Do not place any marks on the lifter body or foot. Return the lifters to their original packaging until installed in the engine.
9.12 Camshaft Bearing Installation - The camshaft tunnel is specially processed and uses oversize bearings provided through the CPD. Install the camshaft bearings according to the Sequence IIIF Engine Assembly Manual, Section 3-Sheet 3. Always inspect the lifter and main bearing oil galleries for splintered babbitt materials that might have been shaved from the outside diameter of the bearings during installation. Remove any materials from the oil galleries with clean dry shop air.
9.13 Camshaft Installation - Install the camshaft according to the Sequence IIIF Engine Assembly Manual, Section 3-Sheet 11:
9.13.1 Coat the camshaft lobes and journals with a light film of test oil.
NOTE 7 - Camshafts should not sit dry inside the engine block waiting for final assembly more than 24 h.
9.13.2 Install the camshaft in the engine block, exercising care to avoid damage to the lobes, journals, and bearings.
9.13.3 Installation of Camshaft Thrust Plate - Lubricate the thrust plate with build-up oil and install the thrust plate to the front of the engine using new Torx fasteners.
9.14 Main Bearings - Verify that the main bearing bore areas in the engine block and bearing caps are clean. Install new main bearings, part no.OHT3F-042-2, in the engine block and main bearing caps, and lightly oil the bearing surfaces with build-up oil. Use new main bearing cap bolts for each Sequence IIIF test engine build.
9.14.1 Crankshaft Installation - Install the crankshaft.
9.14.2 Main Bearing Cap Installation - Install the main bearing caps using new bolts for each test. Do not remove the phosphate coating from the bolts. Do not use air tools on the main bearing cap bolts to seat the caps. Install the bolts finger-tight, and tighten them according to the procedure in 184.108.40.206. Use the main bearings as received.
9.15 Crankshaft Sprocket - Install a matched set two-piece crankshaft sprocket, part no.OHT3F-036-1.
9.16 Camshaft Sprocket, and Timing Chain - Install a new camshaft sprocket and timing chain.
9.17 Crankshaft Endplay - Measure the crankshaft endplay. It should be between 0.076 mm and 0.279 mm.
9.18 Piston Pin Installation - Install new piston pins and retainers for each test. Clean piston pins using a clean lint-free cloth and oil with build-up oil. The piston pins are full floating and held in place by two retainers.
9.18.1 Piston Installation - Clean pistons using solvent and air dry. Wipe the pistons with a lint-free cloth prior to installation.
9.18.2 Use a piston ring expander to install the pre-gapped piston rings (see 9.10.1) on the pistons.
9.18.3 Position the ring end gaps as shown in the Sequence IIIF Engine Assembly Manual, Section 3-Sheet 8.
9.18.4 Coat the cylinder walls with build-up oil and wipe them with a clean, lint-free soft cloth, repeating the process until clean; apply a final coat of build-up oil before installing the piston assembly.
9.18.5 Coat the pistons and rings with build-up oil.
9.18.6 Install the pistons in the cylinders, using a ring compressor tool.
9.19 Harmonic Balancer - Deburr the harmonic balancer keyway slot and the slot on the crankshaft with a mill file. Do not install the balancer until after performing the oil pump priming operation in the test stand just prior to test start.
NOTE 8 - To make the balancer a slip-fit, remove the rolled edge on the inside diameter of the balancer until the balancer slips easily over the crankshaft.
9.20 Connecting Rod Bearings - Clean the bearings using a clean, lint-free cloth and oil with build-up oil prior to installation. Use new connecting rod bearings, part no.OHT3F-042-2, for each test, furnished as part of the engine bearing kit.
9.20.1 Install the bearings in the connecting rods, and install the bearing caps with the rods in place on the crankshaft.
220.127.116.11 Tighten the connecting rod bolts according to the specifications listed in the Sequence IIIF Engine Assembly Manual. Determine the torque specifications for the connecting rod bolts by the type of connecting rod: cast or powdered metal.
9.21 Engine Front Cover - Use a new front cover with each new engine block or if the oil pump gerotor housing is worn.
9.21.1 Install new oil pump gears or a new front cover and new gears, as deemed necessary, according to the Sequence IIIF Engine Assembly Manual inspection requirements Section 4-Sheet 2.
9.21.2 Install a new oil pump relief valve and spring.
9.21.3 Ensure the oil pump relief valve moves freely inside its bore in the front cover. Check the oil-pump-relief-valve clearance according to the Sequence IIIF Engine Assembly Manual, Section 4-Sheet 4.
9.21.4 Bolt the front cover and oil pump assembly to the engine block.
9.21.5 Inspect the oil pickup tube and screen assembly for cleanliness; install using a new gasket.
9.22 Coolant Inlet Adapter - Replace the water pump with a coolant inlet adapter, as shown in drawing OHT3F-031-1.
9.23 Oil Dipstick Hole - Plug the oil dipstick hole with a hole-plug (Part No.OHT3F-065-2). To determine the oil level at the appropriate time during a test, temporarily remove this plug and insert the calibrated dipstick (Part No.OHT3F-064-2).
9.24 Oil Pan - Install the oil pan, part no.OHT3F-073-1, on the engine block, using a new gasket. Do not use magnetic drain plugs in the pan.
NOTE 9 - Ensure the cut out area of the windage tray/oil pan gasket does not interfere with the oil dipstick and modify if necessary.
9.25 Cylinder Head Assembly - Prepare the cylinder heads according to the following procedure:
9.25.1 Install new cup-type freeze plugs.
9.25.2 Deburr all surfaces of the cylinder heads that mate with the engine block and the manifolds with a 300 mm smooth file to ensure satisfactory gasket seating.
9.25.3 Thoroughly clean the cylinder heads according to 9.6 and air blow them dry prior to final assembly. (Warning - For technical use only.)
9.25.4 Coat the valve stems and valve guides with build-up oil.
9.25.5 Install the valves and lightly lap them, if desired. Clean the cylinder heads after lapping to ensure that no lapping compound remains on any parts. Install the valves in the location where lapped for final assembly.
9.25.6 Install new valve stem seals over the valve stems onto the valve guides. Exercise extreme care when installing the seals in order to avoid either cutting the seals or positioning them incorrectly on the guides, thereby helping to preclude high oil consumption. See Sequence IIIF Engine Assembly Manual, Section 5-Sheet 1.
9.25.7 Install new valve springs, part no.OHT3F-059-5 (color code yellow). Place the smaller diameter end of the spring against the retainer. Do not remove the factory paint dot from the valve spring.
9.25.8 Install valve retainers and keepers.
9.26 Adjustment of Valve Spring Forces - Adjust the force of each valve spring according to the following procedure:
9.26.1 Before and after using the valve spring load measurement apparatus (such as Part No.BX-310-2) , calibrate the load cell using the following technique. Use dead weights to produce the specified force of 801 N.
18.104.22.168 Load Cell to Load Cell Technique - Affix load cell weight adapter plate (see Fig.1) to calibration load cell. Zero the calibration load cell. Individually place calibrated dead weights onto calibration load cell. Verify that each dead weight indicates the appropriate load on calibration transducer readout. Repeat the calibration of the calibration load cell. The two consecutive readings shall agree within +/- 0.23 kg; if not, inspect the load cell and replace as necessary. Align calibration load cell beneath apparatus load cell. Place the air cylinder ram on the calibration load cell. Set the apparatus load cell to read the value of the calibration load cell. Apply air pressure to the aligned load cells. Vary air pressure to give several different loads, including 82 kg. Determine that both calibration and apparatus transducer readouts indicate the same value, if not, adjust the apparatus load cell. Repeat the calibration of the valve-spring load-measurement apparatus. The two readings shall agree within +/- 0.23 kg; if not, inspect the apparatus load cell and replace if necessary. Retain data obtained during each calibration.
9.26.2 Install a cylinder head in the holding fixture. The holding fixture shall position the cylinder head such that the valve is directly in line with the air cylinder-loading unit and no side loading of the valve takes place.
9.26.3 Install Zeroing fixture, part no.D4031, to cylinder head. Zeroing fixture, part no.D4031, is part of the valve-spring load-measurement apparatus, part no.BX-310-2.
9.26.4 Place the air cylinder-loading unit over a valve and check for proper alignment of the valve tip with the loading unit.
9.26.5 Position the dial indicator and its foot on the zeroing fixture to facilitate accurate measurement of valve stem axial movement.
9.26.6 Rapidly apply and release the air pressure three times to ensure free travel of the piston rod; adjust the air pressure to obtain a valve deflection reading of 9.5 mm, if necessary.
9.26.7 If the readings are not within the specifications of 801 N +/- 22 N force as shown by the load cell indicator, add or remove shims, or interchange parts as necessary.
9.26.8 Repeat steps 9.26.2 through 9.26.7.
9.27 Cylinder Head Installation - Use new head gaskets for each application. Do not us any sealers on the cylinder head gaskets. Use new fasteners for each application. Before using the fasteners for cylinder head attachment, remove all pre-coat sealers. Remove thread locking compounds from the threads and underside of the bolt head with a wire wheel or brush. Do not use chemical cleaners to remove these coatings. Coat the threads and underside of the bolt head using non-hardening pliable sealing compound. Tighten the fasteners according to the guidelines in the Sequence IIIF Engine Assembly Manual, Section 5-Sheet 3.
9.28 Hydraulic Valve Lifters - Do not open the hydraulic lifter to expose any part of the internal parts. Do not remove the factory-installed leak down oil. Do not use electro-mechanical or chemical means to etch identification numbers on the hydraulic lifters.
9.28.1 Prior to installation, clean the lifter body and foot using a clean cloth dampened with aliphatic naphtha. Do not submerse or spray the hydraulic lifter. Gently wipe the lifter body with the naphtha-dampened cloth and dry using a clean, dry cloth or terry towel.
9.28.2 Install the test lifters in the test engine, coating each lifter foot with test oil before installation into the lifter bore. Rotate the engine crankshaft slowly for 720° while ensuring that the lifters follow the cam lobe profile. Remove each lifter and once again coat the lifter foot with test oil. Reinstall the lifter into the engine block with the ground flat on the lifter body facing inboard toward the center of the engine. See the Sequence IIIF Engine Assembly Manual, Section 6-Sheet 1.
22.214.171.124 Use 118 mL of test oil to lubricate the camshaft and lifters during engine assembly. Pour any remaining oil into the lifter valley of the engine after this process is complete.
9.29 Pushrods - Clean the pushrods with solvent and air blow them dry prior to installation; make certain that the oil passages are open. Wipe the pushrods with a lint-free cloth prior to installation. Lubricate the ball ends of the pushrods with buildup oil and install the pushrods. See the Sequence IIIF Engine Assembly Manual, Section 6-Sheet 2.
9.30 Valve Train Loading - Install the rocker arm pivot retainer and the precision roller rockers and torque the rocker arm pedestal bolts according to the Sequence IIIF Engine Assembly Manual, Section 6-Sheet 4. Rocker arm pivot retainers can be used for up to six tests before being replaced.
9.30.1 Once the valve train is loaded, do not rotate the engine until using the dynamometer air starter system at the start of test.
9.31 Intake Manifold - Modify the intake manifold as shown in the Sequence IIIF Engine Assembly Manual, Section 6-Sheet 7.
9.31.1 Plug the EGR port using part no.OHT3-024-1.
9.31.2 Install the positive crankcase ventilation valve, replacement plug (part no.OHT3F-002-1) in the intake manifold plenum.
9.32 Rocker Covers - Install two left-side rocker covers part no.25534751 on the cylinder heads.
9.33 Water Inlet Adapter - Install a water inlet adapter made according to drawing OHT3F-034-1.
9.34 Condenser - Install a condenser mounting bracket, part no.OHT3F-041-1, and condenser, part no.BX-212-1 or OHT3F-075-1 , with an adapter, part no.OHT3F-040-1, on the front of the engine using flexible hose to connect the adapter to the rocker cover bushings, part no.OHT3F-028-1.
9.35 Coolant Outlet Adapter - Replace the thermostat housing with a coolant outlet adapter, part no.OHT3F-034-1.
9.36 External Oil Cooling System - Install the external oil cooling system as follows:
9.36.1 Install the Oil Filter Housing Assembly, part number OHT3G-080-1, on the engine front cover. Refer to Section 4 Sheet 4 of the Sequence IIIF Engine Assembly Manual.
9.36.2 Install an Oil Cooler, part number OHT3F-030-2, using Connector part number OHT3F-039-3, as shown in the Sequence IIIF Engine Assembly Manual section 8 sheet 3.
9.36.3 Install an Oil Filter Adapter Fitting, part number OHT3F-043-2, and an Oil FilterAdapter, part number OHT3F-035-2, as shown in the Sequence IIIF Engine Assembly Manual section 8 sheet 3.
9.36.4 Install the Bypass Valve Assembly Housing, part number OHT3F-084-1, on the Oil Filter Engine Adapter, as shown in the Sequence IIIF Engine Assembly Manual section 8 sheet 3b.
9.36.5 Install a thermocouple in the External Bypass System to detect operation in bypass mode. Note if bypass is detected during a test in the comments section of the test report. No reporting of this temperature data is required.
9.37 Oil Sample Valve - Install suitable plumbing to the oil pressure fitting located in the oil filter adapter to permit the removal of oil samples. Select the plumbing to minimize the added volume.
9.38 Ignition System - Install ignition system components according to the following instructions:
9.38.1 Use high-energy ignition wires which are resistant to moisture and high temperatures.
9.38.2 Use an original equipment manufacturer coil pack mounted on the front engine mount according to drawing OHT3F-026-1.
9.38.3 Use new spark plugs, R42LTSM. Adjust the gaps with a wire gauge to 1.14 mm. Install a set of plugs prior to test start-up.
9.39 Throttle Body - Modify a production throttle body according to the drawing in the Sequence IIIF Engine Assembly Manual, Section 7-Sheet 5.
9.39.1 Install the throttle body onto the plenum and attach the throttle body adapter, part no.OHT3F-001-2.
9.40 Accessory Drive Units - Do not use any accessory drive units, such as alternators, generators, fuel pumps, power steering units, air pumps, and so forth.
9.41 Exhaust Manifolds, Water-Cooled - Prepare two water-cooled exhaust manifolds, part no.OHT3F-003-1, and install one on each of the two cylinder heads using transition adapters, part no.OHT3F-004-1, according to the following instructions:
9.41.1 Deburr all the surfaces of the exhaust manifolds that mate with the cylinder heads with a 300 mm smooth-cut file to ensure proper gasket seating.
9.41.2 Attach the exhaust manifolds to the heads using stainless steel studs (3/8 -16 by 3/8 -24 by 1 1/2 in.), stainless steel 3/8-24 nuts, and shielded exhaust gaskets, part no.OHT3F-018-1 or GM 24506009.
9.41.3 Ensure that there are no leaks between the manifold assembly components that might allow outside air to enter the exhaust system through scavenging upstream of the O2 sensor.
9.42 Engine Flywheel—Install the flywheel and drive shaft plate assembly, OHT3F-020-2.
9.43 Pressure Checking of Engine Coolant System - If desired, pressure-check the engine coolant system after assembly and before installation of the engine on the test stand, according to the following procedure:
9.43.1 Block all coolant outlets, and install the necessary fittings on the coolant inlet to permit pressurizing the coolant system with air, and sealing it.
9.43.2 Pressurize the coolant system with air to 100 kPa, and seal it. Monitor the pressure for 10 min. Take no corrective action if the reduction in pressure is less than 3.4 kPa in 10 min. If larger changes in pressure occur, re-torque all appropriate bolts and replace gaskets, seals, and components (including the cylinder heads and the intake manifold) as necessary. Repeat the pressure checking.
9.44 Lifting of Assembled Engines - Lift the assembled engines with a suitable lift chain.
9.45 Mounting the Engine on the Test Stand - Mount the engine on the test stand according to the following:
9.45.1 Use OHT3F-026 front and OHT3F-025 rear engine mounts.
9.45.2 Mount the engine in such a manner that the intake plenum mounting flange-to-intake manifold interface is horizontal.
9.45.3 Install an engine flywheel guard, safety housing, and air starter mounting assembly (part of OHT3F-025).
9.45.4 Connect the engine to the dynamometer with a flywheel-to-driveshaft coupling adapter (part of OHT3F-020-1) and a driveshaft.
9.45.5 Install a coolant drain valve in the middle of each side of the block, in the 1/4 -in. NPT hole. The use of street ells and petcocks are satisfactory. Petcocks shall remain as installed for the remainder of the test.
9.46 External Cooling System Cleaning - Clean the external cooling system of either a new or used test stand, or a new flushing tank assembly. Clean the used test stand system periodically, typically before a reference test. Use the following procedure:
9.46.1 Prepare a cleaning mixture in the flushing tank (drawing RX-116924-C) by mixing 19.0 g/L Sequence IIIF test component cleaner (Warning - Corrosive. Health hazard.) (see 7.4) with water. Heat the mixture to 60 °C +/- 2.8 °C.
9.46.2 Circulate the mixture at 160 L/min flow rate for 30 min.
9.46.3 Immediately following step 9.46.2, thoroughly flush all system components with water at 60 °C +/- 2.8 °C.
9.46.4 Ensure to drain all low points in the system after cleaning.
9.47 Engine Coolant Jacket Cleaning (Flushing) - After installing the engine on the test stand, chemically clean the engine coolant jacket to ensure the proper rate of heat transfer to the jacket coolant, according to the following procedure:
9.47.1 Connect the flushing tank to the engine so that the cleaning solutions enter at the coolant outlet adapter and exit at the front of the engine block (reverse flow only for flushing) through the water inlet adapter.
9.47.2 Connect the coolant outlet hose located at the front of the engine intake manifold to the flush cart return for this procedure.
9.47.3 For the following segments of this cleaning procedure, minimize the elapsed time between steps in order to avoid rusting of the coolant jacket.
9.47.4 Remove the oil pan drain plug. Open the engine block petcocks and pass hot water (60 °C to 70 °C) through the engine coolant jacket for 2 min. Check for coolant leaks around the intake manifold, front cover, rear cover, and oil pan drain plug. If coolant is leaking, take appropriate steps to stop the leak. If no leaking is evident, close the petcocks and fill the flushing tank and engine block with water to provide a total volume of 38 L to 45 L.
9.47.5 Energize the flushing tank heaters. Circulate water through the engine at a flow rate of 115 L/min to 130 L/min through the engine until the temperature of the water flowing out of the engine reaches 70 °C +/- 3.0 °C. Isolate the engine from the flush cart.
9.47.6 While the flush cart is isolated from the engine with water still circulating, add 19 g/L Sequence IIIF test component cleaner (see 7.4) to the water in the flushing tank. Continue to circulate the mixture in the flush cart for (3 min to 5 min.
9.47.7 Circulate the mixture through the engine for 30 min.
9.47.8 Stop the circulation pump, open the engine block petcocks, and drain the contents of the engine and flushing tank into a suitable container (see Note 10).
NOTE 10 - Before disposal, the drained material should be neutralized according to applicable local and federal hazardous material guidelines.
9.47.9 Close the engine block petcocks and flow hot tap water through the engine into a suitable container for 2 min to 5 min, until the pH of the water flowing out of the engine is neutral. Use water at a temperature of 60 °C to 70 °C. Maintain a flow rate of 76 L/min to 95 L/min.
9.47.10 Immediately after neutralizing the engine block in 9.47.9, open the block petcocks and drain all flush water.
9.47.11 Connect the engine to the external engine cooling system.
9.47.12 Immediately charge the engine jacket with coolant.
9.48 Coolant Charging - Charge the engine jacket with the specified coolant (see 7.4) according to the following procedure:
9.48.1 To preclude contamination of the coolant system with water, install low-point drains and eliminate all traps in the system. Drain all water in the system.
9.48.2 Use a charging adapter installed between the external cooling system and the engine.
9.48.3 Completely fill the engine jacket and cooling system with coolant (see 7.4). Fill the engine coolant jacket before filling the condenser system.
9.48.4 Charge the condenser coolant system immediately after charging the engine cooling system.
9.48.5 Operate the circulating pumps to aid in the removal of air and consequently decrease the time to achieve clarity of the coolant. During this period, operate any proportioning valves in the coolant system several times.
9.48.6 Until the test is started, circulate the coolant at a temperature of 48.9 °C +/- 2.8 °C and a flow rate of 160 L/min. Start the test no later than 6 h after step 9.48.5.
9.49 Test Oil Charging - Charge the engine with the test oil as follows:
9.49.1 Install a new oil filter OHT3G-057-3.
9.49.2 Measure the initial fill of 5.50 L of fresh test oil using a flask calibrated to Class A standards.
9.49.3 Add the initial fill of 5.50 L of fresh test oil through the rocker-cover oil-fill cap.
9.50 Engine Oil Pump Priming - Prime the engine oil pump according to the following instructions:
9.50.1 With the harmonic balancer and front half of the oil pump drive gear OHT3F-036-1 removed, use a suitable high torque drill motor and oil pump drive tool OHT3F-038-1 rotating the gerotor oil pump in a clockwise direction (viewed from the front of the engine) for 2 min after indication of oil pressure.
9.50.2 Replace the front half of the oil pump drive gear and the harmonic balancer and torque the harmonic balancer to 150 N·m + 76°.
9.50.3 Connect the crankcase pressure line and oil sample valve fittings in preparation for testing, and proceed with the initial run (see 11.14).