ASTM D6593-18e1

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
´1
Designation: D6593 − 18
Standard Test Method for
Evaluation of Automotive Engine Oils for Inhibition of
Deposit Formation in a Spark-Ignition Internal Combustion
Engine Fueled with Gasoline and Operated Under Low-
Temperature, Light-Duty Conditions
This standard is issued under the fixed designation D6593; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
ε NOTE—Editorially updated TMC governance information in June 2022.
INTRODUCTION
Portions of this test method are written for use by laboratories that make use of ASTM Test
Monitoring Center (TMC) services (see Annex A1 – Annex A4).
TheTMCprovidesreferenceoils,andengineeringandstatisticalservicestolaboratoriesthatdesire
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
theAmericanChemistryCouncilrequirethatalaboratoryutilizetheTMCservicesaspartoftheirtest
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 theTest 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.
ASTM International policy is to encourage the development of test procedures based on generic
equipment. It is recognized that there are occasions where critical/sole-source equipment has been
approved by the technical committee (surveillance panel/task force) and is required by the test
procedure. The technical committee that oversees the test procedure is encouraged to clearly identify
if the part is considered critical in the test procedure. If a part is deemed to be critical, ASTM
encouragesalternativesupplierstobegiventheopportunityforconsiderationofsupplyingthecritical
part/component providing they meet the approval process set forth by the technical committee.
An alternative supplier can start the process by initiating contact with the technical committee
(current chairs shown onASTM TMC website). The supplier should advise on the details of the part
that is intended to be supplied. The technical committee will review the request and determine
feasibility of an alternative supplier for the requested replacement critical part. In the event that a
replacement critical part has been identified and proven equivalent, the sole-source supplier footnote
shall be removed from the test procedure.
1. Scope*
1.1 This test method covers and is commonly referred to as
theSequenceVGtest, andithasbeencorrelatedwithvehicles
used in stop-and-go service prior to 1996, particularly with
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
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D6593 − 18
regard to sludge and varnish formation. It is one of the test
Diagnostic Data Review 12.5
End of Test Procedure 12.6
methods required to evaluate oils intended to satisfy the API
Interpretation of Test Results 13
SL performance category.
Parts Rating Area-Environment 13.1
Sludge Ratings 13.2
1.2 The values stated in SI units are to be regarded as the
Varnish Ratings 13.3
standard. No other units of measurement are included in this
Clogging 13.4
Sticking 13.5
standard.
Used Oil Analyses 13.6
1.2.1 Exception—Where there is no direct SI equivalent
Assessment of Test Validity 14
such as screw threads, national pipe threads/diameters, tubing
General 14.1
size, or specified single source equipment. Used Oil Analyses-Interpretation 14.2
Blowby Flow Rate 14.3
1.3 This standard does not purport to address all of the
Manifold Absolute Pressure 14.4
Fuel Consumption Rate 14.5
safety concerns, if any, associated with its use. It is the
Oil Consumption 14.6
responsibility of the user of this standard to establish appro-
Engine Parts Replacement 14.7
priate safety, health, and environmental practices and deter-
Quality Index and Deviation Percentage 14.8
Final Test Report 15
mine the applicability of regulatory limitations prior to use.
Report Forms 15.1
Specific hazard statements are given in 7.7, 7.10.2.2, 8.3.4.2,
Precision and Bias 16
8.4.4.3, 9.2.6, 9.3.4.5, 12.1.1.7, 12.2.1.4, and Annex A5.
Keywords 17
ANNEXES
1.4 A Table of Contents follows:
ASTM Test Monitoring Center Organization Annex A1
Section
ASTM Test Monitoring Center: Calibration Procedures Annex A2
Scope 1
ASTM Test Monitoring Center: Maintenance Activities Annex A3
Referenced Documents 2
ASTM Test Monitoring Center: Related Information Annex A4
Terminology 3
Safety Precautions Annex A5
Summary of Test Method 4
Control and Data Acquisition Requirements Annex A6
Significance and Use 5
Detailed Specifications and Photographs of Apparatus Annex A7
Apparatus (General Description) 6
Special Service Tools for the Test Engine Annex A8
Apparatus (The Test Engine) 7
Test Engine Part Number Listing Annex A9
Sequence VG Test Engine 7.1
External Oil Heat Exchanger Cleaning Technique Annex A10
Required New Engine Parts 7.2
Sequence VG Report Forms and Data Dictionary Annex A11
Reusable Engine Parts 7.3
Dipstick Calibration Annex A12
Specially Fabricated Engine Parts 7.4
Critical Part Supplier List Annex A13
Special Engine Measurement and Assembly Equipment 7.5
Operational Data Log-Engine Oil Annex A14
Miscellaneous Engine Components-Preparation 7.6
Rating Worksheets Annex A15
Solvents and Cleaners Required 7.7
Fuel Injector Flow Measurements Annex A16
Assembling the Test Engine-Preparations 7.8
APPENDIXES
Assembling the Test Engine-Installations 7.9
Piston and Ring Measurements Record Forms Appendix X1
Engine Installation on the Test Stand 7.10
Sources of Materials and Information Appendix X2
Engine Fluids (Supply/Discharge Systems) 8
Description of Scott Quarterly Gas Audit Service Appendix X3
Intake Air 8.1
1.5 This international standard was developed in accor-
Fuel and Fuel System 8.2
Engine Oil and Engine Oil System 8.3
dance with internationally recognized principles on standard-
Coolants 8.4
ization established in the Decision on Principles for the
Measurement Instrumentation 9
Development of International Standards, Guides and Recom-
Temperatures 9.1
Pressures 9.2
mendations issued by the World Trade Organization Technical
Flow Rates 9.3
Barriers to Trade (TBT) Committee.
Fuel Consumption 9.4
Speed and Load 9.5
2. Referenced Documents
Exhaust Gas 9.6
Humidity 9.7
2.1 ASTM Standards:
Miscellaneous Laboratory Equipment 10
Test Stand Calibration 11
D86Test Method for Distillation of Petroleum Products and
Test Procedure 12
Liquid Fuels at Atmospheric Pressure
Pre-Test Procedure 12.1
D130Test Method for Corrosiveness to Copper from Petro-
Engine Operating Procedure 12.2
Periodic Measurements and Functions 12.3 leum Products by Copper Strip Test
Special Maintenance Procedures 12.4
D235Specification for Mineral Spirits (Petroleum Spirits)
(Hydrocarbon Dry Cleaning Solvent)
D240Test Method for Heat of Combustion of Liquid Hy-
This test method is under the jurisdiction of ASTM Committee D02 on
drocarbon Fuels by Bomb Calorimeter
Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of
D287Test Method forAPI Gravity of Crude Petroleum and
Subcommittee D02.B0.01 on Passenger Car Engine Oils.
Petroleum Products (Hydrometer Method)
Current edition approved Oct. 1, 2018. Published October 2018. Originally
approved in 2000. Last previous edition approved in 2017 as D6593 – 17. DOI:
D323TestMethodforVaporPressureofPetroleumProducts
10.1520/D6593-18E01.
(Reid Method)
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, 203 Armstrong
Drive, Freeport, PA 16229. Attention: Director. This edition incorporates revisions For referenced ASTM standards, visit the ASTM website, www.astm.org, or
in all information Letters through No. 18-1. contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Supporting data have been filed atASTM International Headquarters and may Standards volume information, refer to the standard’s Document Summary page on
be obtained by requesting Research Report RR:D02-1472. the ASTM website.
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D6593 − 18
D381Test Method for Gum Content in Fuels by Jet Evapo- D5862Test Method for Evaluation of Engine Oils in Two-
ration Stroke CycleTurbo-Supercharged 6V92TADiesel Engine
(Withdrawn 2009)
D445Test Method for Kinematic Viscosity of Transparent
D6550Test Method for Determination of Olefin Content of
and Opaque Liquids (and Calculation of DynamicViscos-
Gasolines by Supercritical-Fluid Chromatography
ity)
D7422Test Method for Evaluation of Diesel Engine Oils in
D525Test Method for Oxidation Stability of Gasoline (In-
T-12 Exhaust Gas Recirculation Diesel Engine
duction Period Method)
E29Practice for Using Significant Digits in Test Data to
D873Test Method for Oxidation Stability ofAviation Fuels
Determine Conformance with Specifications
(Potential Residue Method)
G40Terminology Relating to Wear and Erosion
D1298Test Method for Density, Relative Density, or API
2.2 ANSI Standard:
Gravity of Crude Petroleum and Liquid Petroleum Prod-
ANSI MC96.1Temperature Measurement-Thermocouples
ucts by Hydrometer Method
2.3 Other ASTM Documents:
D1319Test Method for HydrocarbonTypes in Liquid Petro-
ASTM Deposit Rating Manual 20 (Formerly CRC Manual
leum Products by Fluorescent Indicator Adsorption
20)
D2699Test Method for Research Octane Number of Spark-
Ignition Engine Fuel
3. Terminology
D2700Test Method for Motor Octane Number of Spark-
3.1 Definitions:
Ignition Engine Fuel
3.1.1 air-fuel ratio, n—in internal combustion engines, the
D2789Test Method for HydrocarbonTypes in Low Olefinic
mass ratio of air-to-fuel in the mixture being inducted into the
Gasoline by Mass Spectrometry
combustion chambers.
D3231Test Method for Phosphorus in Gasoline
3.1.1.1 Discussion—In this test method, air-fuel ratio
D3237TestMethodforLeadinGasolinebyAtomicAbsorp- (AFR), is controlled by the EEC IV engine control module.
tion Spectroscopy D4175
D3343Test Method for Estimation of Hydrogen Content of
3.1.2 blowby, n—in internal combustion engines, that por-
Aviation Fuels
tion of the combustion products and unburned air/fuel mixture
D3525Test Method for Gasoline Fuel Dilution in Used
that leaks past piston rings into the engine crankcase during
Gasoline Engine Oils by Wide-Bore Capillary Gas Chro-
operation.
matography
3.1.3 cold-stuck piston ring, n—in internal combustion
D4052Test Method for Density, Relative Density, and API
engines,apistonringthatisstuckwhenthepistonandringare
Gravity of Liquids by Digital Density Meter
at room temperature, but inspection shows that it was free
D4057Practice for Manual Sampling of Petroleum and
during engine operation.
Petroleum Products 3.1.3.1 Discussion—A cold-stuck piston ring cannot be
D4175Terminology Relating to Petroleum Products, Liquid moved with moderate finger pressure. It is characterized by a
polished face over its entire circumference, indicating essen-
Fuels, and Lubricants
tially no blowby passed over the ring face during engine
D4485Specification for Performance ofActiveAPI Service
operation. D4175
Category Engine Oils
D4815Test Method for Determination of MTBE, ETBE,
3.1.4 debris, n—in internal combustion engines, solid con-
TAME, DIPE, tertiary-Amyl Alcohol and C to C Alco- taminant materials unintentionally introduced into the engine
1 4
hols in Gasoline by Gas Chromatography or resulting from wear.
3.1.4.1 Discussion—Examplesincludesuchthingsasgasket
D5059Test Methods for Lead and Manganese in Gasoline
material, silicone sealer, towel threads, and metal particles.
by X-Ray Fluorescence Spectroscopy
D5862
D5185Test Method for Multielement Determination of
Used and Unused Lubricating Oils and Base Oils by 3.1.5 filtering, n—in data acquisition, a means of attenuat-
Inductively Coupled Plasma Atomic Emission Spectrom- ingsignalsinagivenfrequencyrange.Theycanbemechanical
(volume tank, spring, mass) or electrical (capacitance, induc-
etry (ICP-AES)
tance) or digital (mathematical formulas), or a combination
D5191Test Method for Vapor Pressure of Petroleum Prod-
thereof. Typically, a low-pass filter attenuates the unwanted
ucts and Liquid Fuels (Mini Method)
high frequency noise.
D5291Test Methods for Instrumental Determination of
3.1.6 hot-stuck piston ring, n—in internal combustion
Carbon, Hydrogen, and Nitrogen in Petroleum Products
engines,apistonringthatisstuckwhenthepistonandringare
and Lubricants
D5453Test Method for Determination of Total Sulfur in
Light Hydrocarbons, Spark Ignition Engine Fuel, Diesel 5
The last approved version of this historical standard is referenced on
Engine Fuel, and Engine Oil by Ultraviolet Fluorescence www.astm.org.
Available fromAmerican National Standards Institute (ANSI), 25 W. 43rd St.,
D5769Test Method for Determination of Benzene,Toluene,
4th Floor, New York, NY 10036.
and Total Aromatics in Finished Gasolines by Gas 7
For stock #TMCMNL20, visit the ASTM website, www.astm.org, or contact
Chromatography/Mass Spectrometry ASTM Customer Service at service@astm.org.
´1
D6593 − 18
at room temperature, and inspection shows that it was stuck normalwarmed-uptemperatures,andenginespeedsandpower
during engine operation. outputs that average below those encountered in typical high-
3.1.6.1 Discussion—The portion of the ring that is stuck way driving.
cannot be moved with moderate finger pressure. A hot-stuck
3.2.5 ramping, n—the prescribed rate of change of a vari-
piston ring is characterized by varnish or carbon across some
ablewhenonesetofoperatingconditionsischangedtoanother
portion of its face, indicating that portion of the ring was not
set of operating conditions.
contacting the cylinder wall during engine operation. D4175
4. Summary of Test Method
3.1.7 knock, n—in a spark ignition engine, abnormal
4.1 Each test engine is assembled with many new parts and
combustion, often producing audible sound, caused by autoi-
essentially all aspects of assembly are specified in detail.
gnition of the air/fuel mixture. D4175
3.1.8 out of specification data, n—in data acquisition, 4.2 Theteststandisequippedtocontrolspeed,torque,AFR,
sampled value of a monitored test parameter that has deviated and various other operating parameters.
beyond the procedural limits.
4.3 The test is run for a total of 216 h, consisting of 54
3.1.9 reading, n—in data acquisition, the reduction of data
cycles of 4 h each. Each cycle consists of three stages.
points that represent the operating conditions observed in the
4.4 While the operating conditions are varied within each
time period as defined in the test procedure.
cycle, overall they can be characterized as a mixture of
3.1.10 scoring, n—in tribology, a severe form of wear
low-temperature and moderate-temperature, light and medium
characterized by the formation of extensive grooves and
duty operating conditions.
scratches in the direction of sliding. G40
4.5 To accelerate deposit formation, the level of oxides of
3.1.11 scuffıng, n—in lubrication, damage caused by instan-
nitrogen in the blowby and the rate of blowby into the
taneous localized welding between surfaces in relative motion
crankcasearesignificantlyincreased.Thefreshairbreathingof
that does not result in immobilization of the parts.
the crankcase is eliminated and the oil and coolant tempera-
3.1.12 sludge, n—in internal combustion engines, a deposit, tures are lowered to induce condensation of water and fuel.
principally composed of insoluble resins and oxidation prod-
4.6 Theperformanceofthetestengineoilisevaluatedatthe
uctsfromfuelcombustionandthelubricant,thatdoesnotdrain
end of the test by dismantling the engine and measuring the
from engine parts but can be removed by wiping with a cloth.
level of deposit formation.
D4175
5. Significance and Use
3.1.13 time constant, n—in data acquisition,Avalue which
represents a measure of the time response of a system. For a 5.1 This test method is used to evaluate an automotive
first order system responding to a step change input, it is the engine oil’s control of engine deposits under operating condi-
time required for the output to reach 63.2% of its final value. tionsdeliberatelyselectedtoacceleratedepositformation.This
test method was correlated with field service data, determined
3.1.14 varnish, n—in internal combustion engines, a hard,
from side-by-side comparisons of two or more oils in police,
dry,generallylustrousdepositthatcanberemovedbysolvents
taxi fleets, and delivery van services. The same field service
but not by wiping with a cloth. D4175
oils were then used in developing the operating conditions of
3.1.15 wear, n—loss of material from a surface, generally
this test procedure.
occurring between two surfaces in relative motion, and result-
5.2 This test method, along with other test methods, defines
ing from mechanical or chemical action, or a combination of
the minimum performance level of the API Category SL
both. D7422
(detailed information about this category is included in Speci-
3.2 Definitions of Terms Specific to This Standard:
fication D4485). This test method is also incorporated in
3.2.1 clogging, n—the restriction of a flow path due to the
automobile manufacturers’ factory-fill specifications.
accumulation of material along the flow path boundaries.
5.3 The basic engine used in this test method is representa-
3.2.2 enrichment, n—in internal combustion engine
tiveofmanythatareinmodernautomobiles.Thisfactor,along
operation, a fuel consumption rate in excess of that which
withtheacceleratedoperatingconditions,shouldbeconsidered
would achieve a stoichiometric air-to-fuel ratio.
when interpreting test results.
3.2.2.1 Discussion—Enrichment is usually indicated by el-
evated CO levels and can also be detected with an extended
6. Apparatus (General Description)
range air/fuel ratio sensor.
6.1 The test engine is a Ford, spark ignition, four stroke,
3.2.3 Lambda, n—the ratio of actual air mass induced,
eight-cylinder V configuration engine with a displacement of
during engine operation, divided by the theoretical air mass
4.6L. Features of this engine include an overhead camshaft, a
requirement at the stoichiometric air-fuel ratio for the given
cross-flow fast-burn cylinder head design, two valves per
fuel.
cylinder and electronic port fuel injection. It is based on the
3.2.3.1 Discussion—A Lambda value of 1.0 denotes a stoi-
FordMotorCo.EFICrownVictoria passengercarenginewith
chiometric air-fuel ratio.
a displacement of 4.6L.
3.2.4 low-temperature, light-duty conditions, n—indicative
of engine oil and coolant temperatures that average below Ford Crown Victoria is a product of the Ford Motor Co., Dearborn, MI 48121.
´1
D6593 − 18
FIG. 1 Schematic of Engine Fuel System
6.2 Configure the test stand to accept a Ford engine, two 7. Apparatus (The Test Engine)
valves per cylinder, with a displacement of 4.6L. All special
7.1 Sequence VG Test Engine—The test engine kit is avail-
equipment necessary for conducting this test is listed herein.
able from the Ford Motor Co. (A13.1). Parts from the engine
6.3 Usetheappropriateairconditioningapparatustocontrol
may be used for as many as four tests.Adetailed listing of all
the temperature, pressure, and humidity of the intake air.
parts included in the kit is given in Annex A9.
6.4 Use an appropriate fuel supply system (Fig. 1).
7.1.1 Non-rated parts can be replaced during the test,
provided the reason for replacement was not oil related.
6.5 The control and data acquisition system shall meet the
requirements listed in Annex A6.
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D6593 − 18
7.4.4 Dipstick and Dipstick Tube (see Fig. A7.6)—The
dipstickhasbeenmodifiedforaccurateoillevelmeasurements.
The dipstick and dipstick tube are calibrated as a pair. If either
part is replaced, recalibrate the pair. Use the dipstick and
dipstick tube available from the supplier listed in A13.2.
7.4.5 Oil Pan—Use a modified oil pan with removable
bafflesasshowninFig.A7.7fromthesupplierlistedinA13.2.
7.4.6 Exhaust Manifold—The required exhaust manifolds,
BX-575-1 (see A13.4) or TEI-VGMAN-01 (see A13.3), tran-
sitionplates(seeA13.3)andexhaustsystemareshowninFigs.
A7.15andA7.16.TheTEI-VGMAN-01manifoldmaybeused
fornon-referenceoiltestingonorafterMay24,2016,provided
thatthelaboratoryhasconductedasuccessfulreferenceoiltest
utilizing this manifold. A heated exhaust gas oxygen (HEGO)
sensor is installed in the exhaust system after each exhaust
manifold.
7.4.7 Flywheel—Use the flywheel listed in Annex A9.
7.4.8 Rocker Arm Cover (RAC)—The RAC is fabricated
from stainless steel and incorporates a water jacket and bolt
bossesforthecamshaftbaffle(seeFigs.A7.3-A7.5).TheRAC,
bolts, and washers supplier is listed in A13.2. As the RAC is
usedformultipletests,leakstotheexternalcoolingjacketmay
NOTE 1—Dimensions are in millimetres.
FIG. 2 Typical Test Stand Intake Air Supply System berepairedbyweldingorothersuitablemeans.Donotmodify
the rated surfaces of the RAC.
7.4.9 Oil Filter—Use a 60 µm screen type oil filter with a
bypass (see Fig. A7.8) available from the supplier listed in
X2.1.20.
7.2 Required New Engine Parts—Use the parts listed in the
7.4.10 Oil Pan Insulation—The oil pan is covered with a
enginekit(seeA9.1).Useanewgasketkitforeachtest.Donot
fiberglass insulation to reduce the effects of ambient tempera-
modify or alter test parts without the approval of Sequence V
ture variations. The insulation supplier is listed in A13.2.
Surveillance Panel.
7.5 Special Engine Measurement and Assembly
7.3 Reusable Engine Parts—Thepartslistedintheteststand
Equipment—Items routinely used in laboratory and workshop
set up kit, supplemental stand set up kit, engine dress kit, and
are not included. Use any special tools or equipment shown in
engine finish and fastener kit can be reused (all of these can be
the 1994 and 2000 Crown Victoria Service Manual for
used in numerous engine assemblies as long as they remain
assembly.AlistofthesetoolsisshowninAnnexA8.Complete
serviceable). See Annex A9. Crankshaft, connecting rods,
any assembly instructions not detailed in Section 7 according
timing chain covers and cylinder heads may be used for
to the instructions in the 1994 and 2000 Crown Victoria
multiple engine assemblies as long as they remain serviceable.
Service Manual.
Camshaftscanbeusedforasmanyasfourtestsaslongasthey
7.5.1 Piston Ring Positioner—Usethepistonringpositioner
remain serviceable. As the block can be used for as many as
to locate the piston rings from the cylinder block deck surface
four tests, damaged threads in the block can be corrected with
by 28.5 mm. This allows the compression rings to be posi-
commercially available thread inserts.
tioned in a consistent location in the cylinder bore before
7.4 Specially Fabricated Engine Parts—The following sub-
measurement. Fabricate the positioner according to the details
sections detail the specially fabricated engine parts required in
shown in Fig. A7.9.
this test method:
7.5.2 Piston Ring Grinder—A ring grinder is required for
7.4.1 Intake Air System (see Fig. 2 and Figs. A7.1 and
adjusting ring gaps.Asuitable ring grinder is noted in 7.8.5.1.
A7.2)—Intake air system shall use the stock Crown Victoria
7.5.3 PCV Valve Flow Rate Device:
configuration with the air horn removed from the air cleaner.
7.5.3.1 Use this device to verify the flow rate of the PCV
7.4.2 Camshaft Baffles (see Fig. A7.3)—These are fabri-
valve before the test and measure the degree of clogging after
cated for attachment to the under side of the rocker cover. The
the test. Fabricate the device according to the details shown in
clearance between the edges of the baffle and the (rocker arm
Fig.A7.10. The device shall have a full scale accuracy of 5%
cover) RAC permits a limited splash flow of oil to the top of
and a resolution of 0.05 L/s (see 7.6.7).
thebaffleandtheRAC.Therefore,thedimensionalaccuracyof
7.5.3.2 Calibratetheflowratedeviceonceeverysixmonths
the baffle is important to minimize the influence on test
against a standard traceable to NIST.
severity. The camshaft baffle is available from the supplier
7.5.4 Engine Service Tools—Acomplete list of special tools
listed in A13.2.
for the test engine is shown in Annex A8. The tools are
7.4.3 Crankcase Oil Fill Port—The crankcase oil fill port is
locatedtowardstherearoftheleftrockercover.Seeitem8and
9on Fig. A7.4. Available from Ford and Lincoln-Mercury Dealerships.
´1
D6593 − 18
available from a Ford dealership. These are designed to aid in 7.6.2.3 There is no specific life for the throttle body.
performing several service items, in addition to the following However, the clearance between the bore and the butterfly will
specific service items that require special tools to perform the eventually increase and render the body unserviceable. When
functions indicated (if not self-explanatory). the clearance becomes too great to allow control of speed,
7.5.5 Atotal of four master bores are required for verifying torque, and air-fuel ratio during Stage III, discard the throttle
thecylinderboremeasurementdeviceusedtodeterminepiston body.
to bore clearance. Master bores are sized according to piston 7.6.2.4 If throttle assembly F8ZU-9E926-AD is used, per-
oversize as follows: form the following modifications:
(1)Remove the throttle position sensor from the throttle
For 0.125 mm piston 90.345 mm
For 0.25 mm piston 90.470 mm
assembly, retaining the two attaching screws.
For 0.375 mm piston 90.595 mm
(2)Install throttle position sensor with part number F2AF-
For 0.50 mm piston 90.700 mm
9B989-AA.
7.5.5.1 Maintain the master bores in a temperature con-
(3)Close the bleed air hole by either soldering shut or
trolled room.
filling with an epoxy.
7.5.6 Oil Screen Blowdown Device—Use the device avail-
7.6.3 Rocker Arm Cover:
able from the supplier listed in A13.3 to blow a controlled
7.6.3.1 Before each test, inspect the coolant jacket. If a
amount of compressed air across the oil screen to remove any
deposit or film is present, then clean the RAC coolant jacket
oil that is retained on the oil screen after allowing it to drain.
with a commercially available de-scaling cleaner, neutralizer,
7.5.7 Engine Parts Cleaning—Clean the engine block and
and inhibitor (8.4.4.1).An example of an acceptable cleaner is
cylinder heads using Model Number 300 LX-P-2x dishwasher
detailed in 7.7.3.
type parts cleaning machine or similar apparatus. See X2.1.12.
7.6.3.2 Submerge the RAC in agitated organic solvent (see
7.5.8 Cylinder Hone—Use a Sunnen CV-616 for cylinder
7.7.2) until clean (approximately 1 h). Rinse the parts thor-
10,11
bore resizing and finishing.
oughly with hot water (> 60°C). Rinse the RAC with degreas-
7.5.9 Connecting Rod Heater—The piston pins are fixed to
ing solvent (7.7.1) and allow to air-dry. Inspect the appearance
the connecting rods with an interference fit. A connecting rod
oftheinsideoftheRAC.Ifthebeforetestratingislessthanten
12,11
heater isrequiredtofacilitateinstallationofthepistonpins
on the ASTM varnish rating scale (ASTM Deposit Rating
and prevent piston distortion.
Manual 20), polish the RAC with Scotch Brite General
13,11
7.6 Miscellaneous Engine Components-Preparation: Purpose Hand Pad #7447 to achieve a dull finish. Rinse
7.6.1 Engine Build-Up and Measurement Area-
withdegreasingsolvent(7.7.1)andallowtoair-drybeforeuse.
Environment—The ambient atmosphere of the engine buildup 7.6.4 Camshaft Baffle—Submerge the camshaft baffles in
and measurement areas shall be reasonably free of contami-
agitated organic solvent (see 7.7.2) until clean (approximately
nants. A relatively constant temperature (within 63°C) is 1h).Rinsethepartsthoroughlywithhotwater(>60°C).Rinse
necessary to ensure acceptable repeatability in the measure-
the camshaft baffles with degreasing solvent (7.7.1) and allow
mentofpartsdimensions.Topreventmoistureformingoncold
to air-dry. Inspect the appearance of the top surface of the
engine parts that are brought into the buildup or measurement camshaft baffle. If the before test rating is less than ten on the
areas,maintaintherelativehumidityatanominalmaximumof
ASTM varnish rating scale (ASTM Deposit Rating Manual
50%. 20), polish the camshaft baffle with Scotch Brite General
13,11
7.6.2 Intake Manifold and Throttle Body:
Purpose Hand Pad #7447 to achieve a dull finish. Rinse
7.6.2.1 The required intake manifold modifications entail withdegreasingsolvent(7.7.1)andallowtoair-drybeforeuse.
blockingofftheEGRport(blockoffplateshowninFig.A7.11)
7.6.5 Oil Pan—Submerge the oil pan in agitated organic
and the coolant bypass port. Block coolant bypass port in solvent (see 7.7.2) until clean (approximately 1 h). Rinse the
intakemanifoldbytappingtheholeandinstallinga ⁄2in.NPT
partthoroughlywithhotwater(>60°C).Rinsetheoilpanwith
pipe plug. Replace the idle air bypass motor with the idle load degreasing solvent (7.7.1) and allow to air-dry.
controlsystem.Aschematicofthesystemandtheidleairblock
7.6.6 Oil Pan Baffle—Submergetheoilpanbaffleinagitated
off plate are shown in Fig.A7.12 and Fig.A7.13, respectively. organic solvent (see 7.7.2) until clean (approximately 1h).
7.6.2.2 Cleanthebutterflyandboreofthethrottlebodywith
Rinse the part thoroughly with hot water (>60°C). Rinse the
solvent(7.7.1)andair-drybeforeeachtest.Donotdisassemble oil pan baffle with degreasing solvent (7.7.1) and allow to
the throttle body as this will cause excessive wear on the
air-dry.
components. The idle air screw can be removed for the 7.6.7 PCV Valve—Measure and record the flow rates of the
cleaning process. Fully close the idle air screw during test
PCV valve with the calibrated flow device described in 7.5.3
operation. and Fig. A7.10. Measure the flow rate at 25kPa and 60kPa
vacuum. Because of the hysteresis in the PCV valve spring,
make the vacuum adjustments in one direction only. Measure
ThesolesourceofsupplyoftheSunnenCV-616honingmachineknowntothe
the flow rate twice and average the readings. Reject any PCV
committee at this time is Sunnen Inc., 7910 Manchester, St. Louis, MO 63143.
If you are aware of alternative suppliers, please provide this information to
valve that does not exhibit an average flow rate of 90L⁄min to
ASTM International Headquarters. Your comments will receive careful consider-
140L⁄min at 25 kPa and 30L⁄min to 50L⁄min at 60 kPa.
ation at a meeting of the responsible technical committee, which you may attend.
The sole source of supply of the connecting rod heater (Sunnen Model
CRH-50) and pin installation tool known to the committee at this time is Sunnen, Scotch Brite is a trademark of 3M Corporate Headquarters, 3M Center, St.
Inc., 7910 Manchester, St. Louis, MO 63143. Paul, MN 55144-1000.
´1
D6593 − 18
7.6.8 Water Pump Drive System—Use only the pulleys gasket, roller followers, valve lash adjusters, rear seal housing,
provided in the Sequence VG test stand set-up kit (see Annex crankshaft gear, timing chains, tensioners, chain rails, plus the
A9), crankshaft, water pump, grooved idler and tensioner, and following parts that can be used for multiple tests: cylinder
a five or six groove belt, 956 mm in length to ensure that the block, crankshaft, connecting rods, ignition ring sensor, crank-
water pump rotates at the proper speed and direction. shaft and camshaft timing sensors, crankshaft vibration
7.6.9 Engine Coolant Temperature Sensor—Modify engine damper, crankshaft bolt and washer, oil filter adapter and the
coolant temperature sensor by attaching a relay and a resistor water pump and pulley.
of 13 kΩ between the ECT sensor and the EEC as shown in
7.8.1 Parts Selection—Instructions concerning the use of
Fig. A7.14.
new or used parts are detailed in 7.1.1, 7.2, and 7.3.
7.6.10 Front Cover—Modify front cover to facilitate instal-
7.8.2 Sealing Compounds—Use a silicon-based sealer as
lation of tensioner, idler, and water pump drive belt. Since the
needed between the rear seal housing-cylinder block, the
belt is routed differently from the stock location some bolt
cylinder block-cylinder head-front cover interfaces, cylinder
bosses may need to be altered to clear the shorter belt and the
head-front cover-rocker cover interfaces, and cylinder block-
tensioner. These bolt bosses are used to attach the front end
front cover-oil pan interfaces.
accessory drive components that are not used for this test.
7.8.2.1 Use silicon-based sealer sparingly since it can el-
7.6.11 Oil Separators—Clean with degreasing solvent
evate the indicated silicon content of the used oil.
(7.7.1) and allow to air-dry.
7.6.12 Timing Chain Cover—Submerge the timing chain
NOTE 1—Non-silicon liquid or tape thread sealers can be used on bolts
and plugs.
cover in agitated organic solvent (see 7.7.2) until clean
(approximately 1 h). Rinse the part thoroughly with hot water
7.8.3 Gaskets and Seals—Install new gaskets and seals
(>60°C). Clean with degreasing solvent (7.7.1) and allow to
during engine assembly.
air-dry.
7.8.4 Block Preparations—Inspect block, including oil gal-
7.7 Solvents and Cleaners Required—No substitutions for
leries for debris and rust. Remove any debris or rust that is
7.7.1 – 7.7.5 are allowed. (Warning—Use adequate safety
found. Remove oil gallery plugs. Removal of coolant jacket
provisions with all solvents and cleaners. See Annex A5.)
plugs is left to the discretion of the laboratory. Enlarge the
7.7.1 Solvent—Useonlymineralspiritsmeetingtherequire-
chamfers around the top of the cylinder bore. Spray the block
ments of Specification D235, Type II, Class C for Aromatic
with degreasing solvent (see 7.7.1). Spray block with a 50/50
17,11
Content 0% to 2% by volume, Flash Point (61°C, min) and
mixture of degreasing solvent (see 7.7.1) and EF-411.
Color (not darker than +25 on Saybolt Scale or 25 on Pt-Co
Install the stress plates with cylinder heads and torque to
Scale). (Warning—Combustible. Health hazard.) Obtain a
37N·mto 43N·m with an additional 180° in two 90° rotation
Certificate of Analysis for each batch of solvent from the
increments. Head bolts may be used for a maximum of five
supplier.
times.Installthemainbearingcapsandtorqueto40N·m,with
7.7.2 Organic Solvent, Penmul L460. (Warning—
an additional 90° rotation. Install the jackscrews and torque to
14,11
Combustible. Health hazard.)
8N·m to 11N·m.
15,11
7.7.3 Dearsol 134 Acidic Cleaner with Inhibitor, RAC
7.8.4.1 Honing:
cooling jacket internal cleaner. (Warning—Combustible.
(1)Install the block in the honing machine. Use a Sunnen
Health hazard.)
CV-616 honing machine to hone the block. Install the block
7.7.4 Cooling System Cleaner, Dupont or equivalent, for
with the right cylinder bank on the outside and the front of the
cleaning cooling system components external to the engine.
block to the right. Verify the honing oil has been changed
(Warning—Caustic. Health hazard.)
within the past 15 h, and change if necessary.
16,11
7.7.5 Parts Cleaning Soap, NAT-50 or PDN-50 have
(2)Set the honing machine to flow Sunnen LP8X fluid at a
been found to be acceptable. (Warning—Health hazard.)
nominal rate of 7 L/min. Set the feed rate to 4 with 57 strokes
7.8 Assembling the Test Engine-Preparations—Use the test per minute and spindle speed of 170 r/min. Set the stroke for
133.35 mm and lower the block for 10 mm overstroke.
engine obtained from the supplier in 7.1. If this is the first test
on a new engine, disassemble the engine in accordance with (3)Install EHU512 stones. Typical pressures of 25 to 40
units have found to be acceptable. Hone the right bank in the
the 1994 and 2000 CrownVictoria Shop Manuals. Number the
connecting rod bearing caps to the corresponding cylinders. followingorder,cylinder1,3,4and2.Honetheleftbankinthe
following order, Cylinder 7, 5, 8 and 6. Following this order
Retain the following parts from the new engine: oil pump,
main bearings, connecting rod bearings, thrust washer, oil will minimize the possibility of over heating one area of the
block. The block may be rotated in the honing machine and
screenspacer,oilfiltergasket,oilpangasket,exhaustmanifold
does not have to be removed to hone the other bank.
(4)Install JHU725 stones and hone for approximately five
ThesolesourceofsupplyofPenmulL460knowntothecommitteeatthistime
strokes at 20 to 25 units of pressure in the order described in
is Penetone Corp., P.O. Box 22006, Los Angeles, CA 90022.
15 7.8.4.1(3).
The sole source of supply of Dearsol 134 Acidic Cleaner known to the
committee at this time is Dearborn Div., subsidiary of W. R. Grace and Co., 300
Genesee St., Lake Zurich, IL 60047.
The sole source of supply of the soap (NAT-50 or PDN-50) known to the
committee at this time is Better Engineering Manufacturing, 8361 Town Court, The sole source of supply of Mobil EF-411 oil known to the committee at this
Baltimore, MD 21236. time is Mobil Oil Corp., 3225 Gallows, Fairfax, VA 22037.
´1
D6593 − 18
TABLE 1 Required Piston and Piston Ring Dimensions
(5)Install a plateau hone brush and hone at 25 to 30 units
of pressure to obtain a surface finish of 8 µm to 13µm. Ring side clearance, avg 0.0508–0.1016 mm
Ring gap delta 0.045–0.055 mm
Typically 45 strokes have provided acceptable results.
(6)Measurethecylinderboreusingaboreladdershownin
Fig.A7.28. Measure bore both longitudinally and transversely.
18,11
Determine the bore diameter for piston clearance purposes by
Piston Ring Grinder. Record the ring side clearance(s) and
adding the middle and bottom transverse bore measurements
new ring gap(s) on any ring(s) adjusted. Enter the new
and dividing by two. Measure the piston skirt 42 mm from the
dimension(s) on the Supplemental Operational Data sheets.
top of the piston. Subtract this value from the bore measure-
Typical forms for recording these dimensions are shown in
ment and verify that the piston-to-bore clearance is within
Appendix X1. Ensure that the required ring gap delta and ring
0.020mm to 0.046mm. Re-hone the block or choose a
side clearance are attained (Table 1). Replace rings if smaller
different diameter piston to obtain this clearance.
ring gaps are required. Measure the rings for cylinders 1 and 8
(7)Determine bore taper by measuring the difference
in the master bore. These measurements are required to
between top-to-bottom, top-to-middle and middle-to-bottom,
determine the ring gap increase.
transversely.RecordthemaximumvalueofthereadingsVerify
(2) Using the master bore, measure the ring gaps for the top
thatthemaximumtaperdoesnotexceed0.006mm.Determine
rings in cylinders 1 and 8 prior to the start of the test.
out-of-round by subtracting the difference between the trans-
7.8.5.2 Piston Ring Cutting Procedure:
verse and longitudinal bore measurements at the top, middle
(1)Cut the ring to the required gap using the ring cutting
19,11
and bottom. Record the maximum value. Verify that the
burr rotated at a rated speed of 3450 r/min. Remove equal
cylinder bore out-of-round does not exceed 0.020 mm.
amounts from both sides of the gap. Make final cuts on the
7.8.4.2 Post Honing Cleaning:
down stroke only. The ring is cut with a maximum increment
(1)Remove the block from the honing machine. Remove
of 0.125 mm until the desired ring gap is achieved.
the stress plates, jackscrews, main bearing bolts and caps.
(2)After the rings are cut remove the ring from the cutting
20,11
Remove jackscrews from the main bearing caps.
tool, debur using a Sunnen soft stone and wipe with a dry
(2)Clean with degreasing solvent (see 7.7.1).
towel.
(3)Place block in dishwasher type cleaning machine (see
7.8.5.3 Installation:
7.5.7) and wash using soap (7.7.5) for 30 min at 60°C.
(1)Install the oil control rings and the compression rings
(4)Sprayblockwith50/50solutionofEF-411anddegreas-
on the pistons with the gaps located over the piston pin.
ing solvent (see 7.7.1).
Position the gaps at approximately 180° intervals, with the top
7.8.4.3 Crankshaft Installation:
compression ring gap toward the rear. Install the rings using a
(1)If the crankshaft has been used previously, soak the
ring spreader tool, keeping the rings’ surfaces parallel to the
crankshaft in organic solvent (see 7.7.2) for a minimum of
ring groove in the piston.
24h.
(2)If any rings require replacement, then measure and
(2)Spray the crankshaft with degreasing solvent.
recordthenewringgap(s)andringsideclearance(s).Calculate
(3)Measurethemainjournalsandverifythatthediameters
ring side clearance by determining the difference between the
are 67.483mm to 67.503mm.
ring groove width and the associated ring width.
(4)Measure the connecting rods journals and verify that
7.8.6 Cylinder Bore Measurements—Measurethecylinder1
the diameters are 52.988mm to 53.003mm.
and 8 cylinder bores with the bearing caps in place. Clean the
(5)Install the main bearings.
bores with a dry rag. The bores shall be clean and dry when
(6)Install the main bearing caps and torque to 40N·m,
they are measured. Use a bore gage micrometer to determine
with an additional 90° rotation.
the diameter of cylinder 1 and 8 at the top, middle and bottom
(7)Install the jack screws and torque to 9 N·mto 11N·m.
of the second ring travel in the transverse direction.
(8)Install the jack screw bolts and torque to 19N·m to
7.9 Assembling the Test Engine-Installations—Assemble
23N·m.
the engine according to the instructions in the service manual
7.8.4.4 Piston Installation:
unless specified herein.
(1)Examine the skirt surfaces for discoloration. Remove
7.9.1 Intake Manifold—Blockthecoolantbypassportinthe
any discoloration by rubbing the piston with a Scotch Brite
13,11 intake manifold at the thermostat housing (7.6.2.1).
#7445 pad. Reject any pistons from which staining cannot
be removed.
(2)Install the piston on the connecting rod using Sunnen 18
The sole source of supply of the Sanford Piston Ring Grinder known to the
12,11
Model CRH-50 connecting rod heater.
committee at this time is Sanford Mfg. Co., 300 Cox St., P.O. Box 318, Roselle, NJ
07203.
7.8.5 Piston Rings:
Thesolesourceofsupplyofthe ⁄16in.carbideringcuttingburr,No.74010020
7.8.5.1 Ring Gap Adjustment:
known to the committee at this time is M. A. Ford.
(1) Cut the top and second compression ring gaps as required 20
The sole source of supply of Sunnen soft stone, No. JHU-820 known to the
to obtain the specified blowby flow rate, using the Sanford committee at this time is Sunnen, Inc., 7910 Manchester, St. Louis, MO 63143.
´1
D6593 − 18
7.9.2 Piston Installation—Install pistons in proper
cylinders, taking care to ensure rings are not damaged during
installation.WipethecylinderswithEF-411.Installthepistons
andconnectingrodswiththenotchesfacingtherear.Installthe
rod bearing caps and torque to 40 N·m to 45N·m with an
additional 90° rotation.
7.9.3 Oil System Components—All oil system components
in the engine are production configuration with the exception
of the oil pan that contains removable baffles.
7.9.4 Cylinder Head Installation—Cylinder heads are ob-
tained from the supplier in A13.3. Heads may be used for
multiple tests, as long as they remain serviceable.
(1)Disassemble heads and inspect for any debris or other
deleterious materials and remove as necessary.
(2)If the cylinder heads have not been previously used,
spray the cylinder heads with degreasing solvent (see 7.7.1). If
FIG. 3 4.6 L Water Pump Drive Arrangement
the cylinder heads have been used previously, soak in organic
solvent (see 7.7.2) fo
...