ASTM D5500-20a

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.
Designation: D5500 − 20a
Standard Test Method for
Vehicle Evaluation of Unleaded Automotive Spark-Ignition
Engine Fuel for Intake Valve Deposit Formation
This standard is issued under the fixed designation D5500; 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.
1. Scope* 2. Referenced Documents
2.1 ASTM Standards:
1.1 This test method covers a vehicle test procedure for
evaluation of intake valve deposit formation of unleaded D235Specification for Mineral Spirits (Petroleum Spirits)
(Hydrocarbon Dry Cleaning Solvent)
spark-ignition engine fuels. This test method uses a 1985
model BMW 318i vehicle. Mileage is accumulated following D4175Terminology Relating to Petroleum Products, Liquid
Fuels, and Lubricants
a specified driving schedule on either public road or test track.
This test method is adapted from the original BMW of North D4814Specification for Automotive Spark-Ignition Engine
Fuel
America/Southwest Research Institute Intake Valve Deposit
test and maintains as much commonality as possible with the
2.2 ANSI Standard:
original test. Chassis dynamometers shall not be used for this MC96.1AmericanNationalStandardforTemperatureMea-
test procedure as the BMW NA/SwRI IVD Test was not
surement Thermocouples
intended to be applicable to chassis dynamometers and no
3. Terminology
correlation between road operation and chassis dynamometers
has been established.
3.1 For general terminology, refer to Terminology D4175.
NOTE 1—If there is any doubt as to the latest edition of Test Method
3.2 Definitions:
D5500, contact ASTM International.
3.2.1 base fuel, n—in automotive spark-ignition engine
fuels,amaterialcomposedprimarilyofhydrocarbonsthatmay
1.2 The values stated in SI units are to be regarded as
also contain oxygenates, anti-oxidants, corrosion inhibitors,
standard. The values given in parentheses after SI units are
metal deactivators, and dyes but does not contain deposit
providedforinformationonlyandarenotconsideredstandard.
control or lead additives.
1.3 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
3.2.1.1 Discussion—A jurisdiction may set limits on lead
responsibility of the user of this standard to establish appro-
content from all sources.
priate safety, health, and environmental practices and deter-
3.2.2 deposit control additive, n—material added to the fuel
mine the applicability of regulatory limitations prior to use.
topreventorremovedepositsinoneormoreoftheenginefuel,
Specific statements on hazards are given throughout this test
intake, and combustion systems.
method.
3.2.2.1 Discussion—Forthepurposeofthistestmethod,the
1.4 This international standard was developed in accor-
performance evaluation of a deposit control additive is limited
dance with internationally recognized principles on standard-
to the tulip area of intake valves.
ization established in the Decision on Principles for the
3.2.3 driveability, n—in vehicles equipped with internal
Development of International Standards, Guides and Recom-
combustion engines, the quality of a vehicle’s performance
mendations issued by the World Trade Organization Technical
characteristics under a range of conditions as perceived by the
Barriers to Trade (TBT) Committee.
operator. D4814
3.2.3.1 Discussion—The operating conditions may include
1 cold starting and warm-up, acceleration, idling, and hot start.
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.A0.01 on Gasoline and Gasoline-Oxygenate Blends.
Current edition approved June 1, 2020. Published June 2020. Originally For referenced ASTM standards, visit the ASTM website, www.astm.org, or
approved in 1994. Last previous edition approved in 2020 as D5500–20. DOI: contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
10.1520/D5500-20A. Standards volume information, refer to the standard’s Document Summary page on
OriginallyobtainedfromBMWNAnewcardealershipsintheUnitedStatesas the ASTM website.
a 1985 model year vehicle, the vehicle is currently available through the used Available fromAmerican National Standards Institute (ANSI), 25 W. 43rd St.,
vehicle market. 4th Floor, New York, NY 10036, http://www.ansi.org.
*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
D5500 − 20a
Theperformancecharacteristicsmayincludeenginehesitation, 4.3 The vehicle is operated on a cycle consisting of 10%
stumble, and stall. D4814 (based on mileage) city (part of the AMA driving schedule),
3.2.4 intake valve deposit, n—material accumulated on the 20%suburban,and70%highwaymodeperday.Thiscycleis
tulip area of the intake valve of internal combustion engines, repeated to accumulate a minimum of 16 090 km
generallycomposedofcarbon,decompositionproductsoffuel,
(10000miles) but no more than 16250km (10100 miles).
lubricant, and additives, and atmospheric contaminants.
4.4 After the required mileage (see 10.4.5) has been
3.3 Definitions of Terms Specific to This Standard:
accumulated,thecylinderheadisremovedfromtheengineand
3.3.1 alternate mileage accumulation (AMA) driving cycle,
disassembled.The valves are weighed, visually assigned merit
n—a driving schedule that is based on the U.S. Environmental
ratings,andphotographed.Operationalandmechanicalcriteria
Protection Agency Durability Driving Schedule, which con-
are then reviewed to determine if the test shall be considered
tains various driving cycles for durability testing of emission
valid.
control systems.
3.3.2 intake system, n—components of the engine whose
5. Significance and Use
function it is to prepare and deliver an air/fuel mixture to the
5.1 Test Method—It was determined through field testing
combustion chamber and includes the throttle, intake manifold
that intake valve deposits could adversely affect the driveabil-
hot spot and runners, exhaust gas recirculation (EGR) and
ity of certain automobiles. Southwest Research Institute and
positive crankcase ventilation (PCV) ports, cylinder head
BMWof NorthAmerica (BMWNA) jointly conducted testing
runners and ports, intake valves, and fuel injectors.
to develop this test method to determine an unleaded automo-
3.3.3 merit rating, n—the visual evaluation by a trained
tive spark-ignition engine fuel’s propensity to form intake
rater of the volume of deposits accumulated on a specific
valve deposits. This testing concluded that if an automotive
engine component based on a comparison with a reference
spark-ignition engine fuel could keep intake valve deposits at
scale (see CRC Manual 16 ).
or below a certain average weight per valve at the end of
3.3.4 test fuel, n—base fuel with or without the addition of
mileage accumulation, then that automotive spark-ignition
a deposit control additive which is used to accumulate mileage
engine fuel could be used in the BMW vehicle-engine combi-
as described in this test method.
nation for a specified period without intake valve deposits
causing driveability degradation. Minimizing intake valve
3.3.5 vehicle exhaust emissions (tailpipe), n—combustion
deposits may be necessary to maintain vehicle driveability and
products from the test fuel including unburned hydrocarbons
tailpipe emissions control.
(HC), carbon monoxide (CO), carbon dioxide (CO ), oxygen
(O ), and oxides of nitrogen (NO ).
5.1.1 State and Federal Legislative and Regulatory
2 x
Action—LegislativeactivityandrulemakingprimarilybyCali-
4. Summary of Test Method 8
forniaAir Resources Board and the Environmental Protection
Agency necessitate the acceptance of a standardized test
4.1 This test method utilizes a 1985 BMW 318i vehicle
equipped with a four-speed automatic transmission and air methodtoevaluatetheintakesystemdepositformingtendency
conditioning.Thisvehicleisequippedwithafour-strokecycle, of an automotive spark-ignition engine fuel.
four-cylinder engine having a total displacement of 1.8 L. The
5.1.2 Relevance of Results—The operating conditions and
cylinder head is an aluminum alloy casting and the cylinder
design of the engine and vehicle used in this test method are
block is cast iron. The engine features an overhead camshaft,
not representative of all modern automobiles. These factors
hemispherical combustion chambers, two valves per cylinder,
shall be considered when interpreting test results.
and electronic port fuel injection.
5.2 Test Validity:
4.2 Each test begins with a clean, rebuilt cylinder head that
5.2.1 Procedural Compliance—The test results are not con-
meets a rigid set of specifications. New, weighed intake valves
sideredvalidunlessthetestiscompletedincompliancewithall
are used to rebuild the cylinder head. A standard engine oil is
requirements of this test method. Deviations from the param-
used for each test and a new oil filter is installed. All routine
eter limits presented in Sections 10 and 11 will result in an
vehicle maintenance is performed in accordance with BMW
invalid test. Engineering judgment shall be applied during
Schedule I and Schedule II service lists.The test vehicle’s fuel
conduct of the test method when assessing any anomalies to
system is flushed of fuel from the previous test. The vehicle
ensure validity of the test results.
fuel tank is then filled with the new test fuel. The vehicle is
5.2.2 Vehicle Compliance—A test is not considered valid
subjected to a rigorous quality control procedure to verify
unless the vehicle met the quality control inspection require-
proper engine and overall vehicle operation. To ensure com-
ments as described in Section 10.
pliance to the test objective, a data logger is active at all times
after the test has begun, during all mileage accumulation and
soak time.
Bitting, B., et al., “Intake Valve Deposits-Fuel Detergency Revisited,” SAE
872117, Society of Automotive Engineers, 1987.
5 8
Code of Federal Regulations, Title 40, Part 86, Appendix IV. State of California Air Resources Board-Stationary Source Division, Test
CRC Manual 16, Carburetor and Induction System Rating Manual. Available MethodforEvaluatingIntakeValveDeposits(IVDs)inVehicleEngines(California
from the Coordinating Research Council Inc., 219 Perimeter Center Parkway, Code of Regulations, Title 13, Section 2257).
Atlanta, GA 30346. Clean Air Act Amendments of 1990.
D5500 − 20a
TABLE 2 Reusable Engine Parts
6. Apparatus
Air flow meter Idle control valve
6.1 Automobile—The test automobile used for this proce-
Air pressure sensor Ignition coil
A
dure is a 1985 model BMW 318i. The powerplant is a
Alternator Ignition wire set
Camshaft Intake manifold
1.8L-line four-cylinder, four-stroke cycle engine with single
Camshaft drive Intake, rocker shaft
overheadcamshaft,twovalvespercylinder,andelectronicport
B
Cylinder block assembly Lambda probe
fuel injection. Vehicles equipped with four-speed automatic
Cylinder head O sensor
Distributor Pump, water
transmissions and air conditioning are required for the test
Distributor cap Radiator
method. Both 49 state and California engine calibrations are
Electronic engine control computer unit Radiator cooling fan
allowed for this test method.
Engine wiring harness Rocker arm
Exhaust rocker shaft Rotor
6.1.1 Engine Cooling System—Experience has shown that
Exhaust system Sensor, temperature fan
the original equipment cooling system has marginal perfor-
A
Filter, air Sensor, vacuum advance
mance at ambient conditions above approximately 35°C
Fuel injectors Throttle body
C
Front end accessory drive Valve springs
(95°F).Toensureenginecoolanttemperaturecompliancewith
Idle control relay
test validity criteria in 10.4.3, the vehicle may be retrofitted
A
These parts shall be changed in accordance with BMW NA Service Schedule I
with the radiator and other appropriate components as outlined
(Annex A4), or more frequently.
in Annex A1. B
The cylinder block can be reused for approximately ten tests (160 000 km)
(100 000 miles), depending on condition of cylinder head bolt holes (radial cracks
6.1.2 Electronic Port Fuel Injectors—Prior to installation,
appear on the block deck) and cylinder bore wear. (Refer to the BMW 318i Service
all injectors shall be evaluated for conformance to spray-
Manual which is available from BMW NA dealer service departments.)
C
pattern and flow rate acceptance criteria (see 8.5). Injectors
Valve springs may be reused as long as they meet the procedural requirements
for tension in 8.4.12.
may be reused if the criteria are satisfied.
6.1.3 Tires—Tires shall be size P195/60R14, maintained at
190kPa 610kPa (28psi 61psi).
6.1.4 Miscellaneous Parts—All powertrain components,
deposit evaluation. The specific humidity shall be maintained
front end accessory drive, air intake system, and exhaust
at a uniform comfortable level.
system, except as specified, shall be original equipment,
6.2.2 Part Rating and Intake Valve Weighing Area—The
original equipment manufacturer replacement parts, or equiva-
ambient atmosphere of the rating and weighing area shall be
lent.
reasonably free of contaminants. The induction system ratings
6.1.5 New Engine Parts Required—Table 1 contains those
shall be performed in accordance to CRC Manual 16, Carbu-
new parts with the corresponding BMWNApart number to be
retor and Induction System Rating Manual.
used for preparing the vehicle to run this test method.
6.2.3 Fuel Injector Testing Area—The ambient atmosphere
6.1.5.1 Other parts may be necessary and are listed in
of the fuel injector testing area shall be reasonably free of
Annex A2.
contaminants. The temperature and humidity shall be main-
6.1.6 Disable Cruise Control—Disconnect cruise control
tained at a uniform level to ensure repeatable measurements.
cable from the throttle.The cruise control shall not be used for
This area shall be ventilated for health and safety reasons in
this test method.
accordance with all regulations. (Warning—Provide adequate
6.1.7 Reusable Engine Parts—The parts listed in Table 2
ventilation and fire protection in areas where flammable or
may be reused. The replacement frequency is noted in the
volatile liquids and solvents, or both, are used. Suitable
footnotes. All parts shall be discarded when they become
protective clothing is recommended.)
unserviceable. See Annex A3 for guidelines regarding the
6.2.4 Intake Valve Rinsing and Parts Cleaning Area—The
reuse of parts.
ambient atmosphere of the intake valve rinsing and parts
6.2 Laboratory Facilities:
cleaning area shall be reasonably free of contaminants. The
6.2.1 Engine/Cylinder Head Build-up and Measurement
temperature shall be maintained at 63°C (65°F) between
Area—The ambient atmosphere of the engine build-up and
10°C to 27°C (50°F to 80°F).The specific humidity shall be
measurementareashallbereasonablyfreeofcontaminantsand
maintained at a uniform comfortable level. Because of the
maintained at a uniform temperature 63°C(65°F) between
delicate nature of the deposits, do not subject the deposits to
10°C to 27°C (50°F to 80°F). Uniform temperature is
extreme changes in temperature or humidity. (Warning—See
necessary to ensure repeatable dimensional measurements and
6.2.3.)
6.2.5 Garage/Maintenance Area—The ambient atmosphere
of the garage/maintenance area shall be reasonably free of
contaminants. The temperature and humidity shall be main-
TABLE 1 New Engine Parts Lists
tained at a uniform, comfortable level. Because of the delicate
Part Part No.
Filter, fuel 13 32 1 270 038 nature of the deposits, do not subject the deposits to extreme
Filter, oil 11 42 1 278 059
changes in temperature or humidity. (Warning—Adequate
Gasket, head set 11 12 1 287 381
ventilation and fire protection are necessary in areas where
Gasket, water 11 51 0 686 135
Jet valve, nozzle 11 12 1 250 937 automotive spark-ignition engine fuel and deposit control
Spark plug 12 12 1 272 128
additivesarehandled,andalsowhenconcerningtheventingof
Thermostat 11 53 1 468 056
the vehicle exhaust and working on vehicle fuel systems.
Valve, intake 11 34 1 254 625
Suitable protective clothing is recommended.)
D5500 − 20a
6.2.6 Test Fuel Blending Facilities—Instead of supplying a Constantan), Type T (Copper-Constantan), or Type K
finished test fuel, the test sponsor may supply concentrated (Chromel-Alumel) thermocouples are acceptable.
additive in bulk to the test laboratory. The test requestor shall 6.3.2.2 Intake Air Temperature—Install the tip of the tem-
obtain concurrence from the test laboratory regarding the peraturemeasuringdevicemidstreamintheintakeairhorn(see
supply of base fuels and additives and their packaging. For A4.1). A 6.4mm (0.25in.) thermocouple is adequate if an
those laboratories offering the capability of blending additive open-tip thermocouple is used.
and base fuel, the laboratories shall have the ability to handle 6.3.2.3 Engine Coolant Outlet—Installthethermocoupletip
andblendtheadditiveintofuelsuppliedineitherbulkor210L at the center of the flow stream at the engine out radiator hose
(55gal) drums, or both. The laboratory shall have an appro- connection (see A4.1).The recommended thermocouple diam-
priatebalanceorgraduatedcylindertoblendtheadditiveatthe eter is 3.2mm (0.125in.).
recommended concentrations expressed as a volumetric or 6.3.2.4 Engine Oil Sump Temperature—Install the thermo-
mass ratio. The base fuel and additive shall be placed, at the coupletipsuchthatitextends25mm(1in.)insidetheoilsump
appropriate ratio, into 210L (55gal) drums or bulk storage mounted in the drain plug (see A4.1). The recommended
tanks and clearly labeled. Provisions to stir or recirculate the thermocouple diameter is 3.2mm (0.125in.).
fuel/additive blend to ensure a homogeneous mixture are 6.3.3 Vehicle Speed—A suitable sensor shall be utilized to
necessary. Safe, clean storage shall be provided for base fuel, measure vehicle speed 62km⁄h(61mph).
additive, and test fuel.The ambient atmosphere of the additive 6.3.4 Engine-On Time—Asuitableinterfaceshallbeutilized
blendingfacilityareashallbereasonablyfreeofcontaminants. to connect ignition power to the data acquisition equipment.
Retaina1Lsampleofthefuelblend.Holdthissampleforone
6.4 Garage Equipment:
month or release to test requestor. (Warning—See 6.2.5.)
6.4.1 Timing Light—Asuitable adjustable timing light shall
6.2.7 Fuel Storage and Refueling Facilities—Sufficient fin-
be used to check ignition timing as specified in 8.7.5.2.
ished test fuel shall be stored at the refueling station in clearly
6.4.2 Multimeter—A multimeter capable of measuring mil-
labeled drums or dispensers. In laboratories that may run
liamperes is required to set idle mixture as specified in 8.7.5.4.
several different test methods concurrently, dispensers or hand
6.4.3 BMW Service Test Unit—A BMW Service Test Unit
pumps for the drums shall not be switched between dissimilar
(Part Number 12 6 400) is necessary to adjust idle carbon
test fuels. To ensure the test fuels are not contaminated either
monoxide as specified in 8.7.5.5.
byothertestfuelsorforeignmatter,asuitablestructureshallbe
6.4.4 Computerized Diagnostic Machine—A computerized
provided to contain the test fuels safely. The laboratory shall
diagnosticmachineisusedtoverifyproperengineoperationby
have a protocol to ensure the test vehicle receives the proper
measuring vehicle tailpipe exhaust oxygen, carbon monoxide,
test fuel. (Warning—See 6.2.5.)
carbon dioxide, hydrocarbons, ignition performance, and
charging system performance. Typical values are given in
6.3 Laboratory Equipment:
8.8.4.
6.3.1 Data Acquisition—A data acquisition device, capable
6.4.5 Throttle Retainer—A device constructed as shown in
of providing the raw data, as outlined in 10.4, is required.
Fig. 1 may be used to hold the throttle open during tune-up
6.3.2 Temperature Measurement Equipment—Temperature
procedures.
measurement equipment and locations for the required tem-
6.5 Special Measurement and Assembly Equipment:
peratures are specified in 6.3.2.1 – 6.3.2.4. Alternative tem-
6.5.1 Graduated Cylinder—Blending of the deposit control
perature measurement equipment may be used if equipment
additive may be required and the concentration may be given
performancecanbedemonstrated.Theaccuracyandresolution
as a volumetric ratio. A 1000mL graduate is recommended.
of the temperature measurement sensors and the complete
temperature measurement system shall follow guidelines de-
NOTE2—Volumetricmeasurementofthedepositcontroladditiveisnot
tailed in the Research Reports “Data Acquisition Task Force
recommended. Mass-based measurement is preferred.
Report” and “Instrumentation Task Force Report to theASTM
6.5.2 Analytical Balance—Blending of the additive may be
Technical Guidance Committee.”
required and the concentration may be given as a mass ratio.
6.3.2.1 If thermocouples are used, all thermocouples except
the intake air thermocouple shall be premium, sheathed types.
The intake air thermocouple may be an open-tip type. Ther-
mocouples of 3.2 mm, 4.8 mm, or 6.4 mm (0.125 in.,
0.1875in., 0.25in.) diameter may be used. However, 3.2mm
thermocouples are recommended at locations which require
short immersion depths to prevent undesirable temperature
gradients. Thermocouple, wires, and extension wires shall be
matched to perform in accordance with the limits of error as
defined by ANSI publication MC 96.1. Type J (Iron-
Supporting data have been filed atASTM International Headquarters and may
be obtained by requesting Research Report RR:D02-1210 and RR:D02-1218.
Contact ASTM Customer Service at service@astm.org. FIG. 1 Throttle Retainer
D5500 − 20a
An analytical balance capable of 0.01g resolution with a 6.5.11 Valve Lapping Tool—A device to rotate or oscillate
maximum capacity of at least 2000g is recommended.Also, a the valves on the seat shall be used to lap the valves. Suitable
valve lapping tools are available from automotive tool supply
balance is required to determine intake valve weight, which is
approximately100g,withaccuracyof0.25%offullscaleand sources.
6.5.12 Valve and Valve Seat Cutting Equipment—
resolution of 0.0001g. The balance shall be calibrated follow-
Equipment may be needed to ensure valve and valve seat
ing the manufacturer’s procedure and frequency recommenda-
mating quality as outlined in 8.4.4. Acceptable equipment is
tions.
available from automotive tool supply sources.
6.5.3 Desiccator—An airtight chamber with lid shall con-
6.5.13 Blowby Meter—The blowby meter is a device to
tain an adequate amount of desiccant to maintain a relatively
measure flow rate of the gas passing the piston rings and
moisture-free environment for intake valves with deposits (see
entering the crankcase. This flow rate is a method to evaluate
7.10).
the condition of the piston rings and cylinder bore and,
6.5.4 Oven—Anatural convection oven shall be used that is
therefore, is used as a quality assurance and test rejection
capable of maintaining 93°C 62°C (200°F 65°F) for
criteria.Thedeviceshallhaveanaccuracyof5%fullscaleand
evaporating the cleaning solvents from the valves. The oven
a resolution of 0.3L⁄s (0.01CFM).
shall have sufficient dimensions to stand the valve upright.
6.5.14 Fuel Injector Test Rig—Asuitable device capable of
Thereshallbenoarcingcontactsintheovenandtheovenshall
accurate, repeatable flow measurement of port fuel injectors is
be installed in a fume hood.
required.This device shall be capable of performing necessary
6.5.5 Power Wire Wheel—A power wire wheel (bench
port fuel injector evaluations as outlined in 8.5. No suitable
grinder fitted with a fine, 15cm (6in.) diameter steel wire
commercially available apparatus has been identified.
wheel)shallbeusedtocleantheintakevalvesasspecified.See
6.5.15 Special BMW 318i Service Tools—Several special
8.3.1 and 10.1.
tools are necessary for rebuilding the cylinder head.
6.5.6 Walnut Shell Blaster—Similar to a sand blaster, the 6.5.15.1 Rocker Shaft Removal Tool—A rocker shaft re-
walnut shell blaster uses shop air pressure; however, a fine, moval tool may be constructed as shown in Fig. 2.
abrasivemediaofcrushedwalnutshellsisusedinsteadofsand. 6.5.15.2 Valve Stem Seal Installation Tool— BMWNAPart
The walnut shells are sufficiently abrasive to remove carbon Number 111200.
while not removing metal from the surface being cleaned. The 6.5.15.3 Valve LashAdjustment Tool—BMWNAPartNum-
ber 113070.
walnut shell blaster technique is more effective than solvents
and generally preferred over a wire brush for removing carbon
7. Reagents and Materials
deposits from the valves and the cylinder head.
7.1 Additive/Base Fuel—Some test requestors may require
6.5.7 Valve Stem and Guide Measuring Equipment—Special
the test fuel be blended at the test laboratory and, therefore,
equipment is necessary to measure valve stem-to-guide clear-
willsupplytheneatdepositcontroladditiveanduntreatedbase
ances in the cylinder head as required in this test method (see
fuel.Thetestrequestorshallsupplythedepositcontroladditive
8.4.1). Any of the methods listed below are acceptable for
and base fuel in appropriate volumes and packaging to ensure
measuring valve stem-to-guide clearance. One method is
specified in the BMW 318i Service Manual. Other commer-
cially available automotive equipment may also be used.
Alternatively, air bore gaging equipment can be used to
measure the guide diameter, and a micrometer can be used to
measure the valve stem diameter.
NOTE 3—Accurate measurements are mandatory to determine stem-to-
guide clearance as this parameter can affect oil consumption and intake
valve deposit accumulation.
6.5.8 Vernier Caliper—A vernier caliper is necessary to
measure valve seat width of the cylinder head as required in
this test method (see 8.4.4).
NOTE 4—Accurate measurement of valve seat width is required as this
parameter can affect heat transfer from the valves, particularly the intake
valveandthesurfacewheredepositsmayaccumulate,ultimatelyaffecting
deposit accumulation.
6.5.9 Valve Spring Compression Testing Machine—A valve
springcompressiontestingmachinecapableofassessingvalve
spring condition as specified in 8.4.12 is required.
6.5.10 Cylinder Head Stand—A BMW NA cylinder head
stand (BMW NA Part Number 11 1 047), or equivalent, shall
beusedtosecurelyholdthecylinderheadduringassemblyand
disassembly. FIG. 2 Rocker Shaft Removal Tool
D5500 − 20a
Chemical Society, where such specifications are available. Other grades
safe and efficient handling. Blending instructions detailing the
may be used provided it is first ascertained that the reagent is of sufficient
concentration ratio, either volumetric-based or mass-based,
purity to permit its use without lessening the accuracy of the determina-
shall accompany all deposit control additives. Mass-based
tion.
measurement is preferred. However, it is most desirable to
7.5.2 Aerosol Spray Cleaner—Wash all new intake valves
have the additive supplied in premeasured, individual contain-
and other parts (that is, valve train parts, cylinder head, intake
ers. The blended fuel shall be clearly identified.
manifold, throttle body) as required with an aerosol spray
7.1.1 Base Fuel—The base fuel used for this test procedure
cleaner to remove any residue remaining from manufacture or
shall be typical of commercial unleaded automotive spark-
deposits or fluid residues from the previous test.
ignition engine fuel. The base fuel may contain oxygenates
7.5.3 Naphtha Solvent—Stoddard solvent conforming to
typical of those being used commercially. The base fuel shall
Type I of Specification D235 is recommended. Proprietary
allowthevehicletooperatesatisfactorily(thatis,noknocking,
solvents of this general type may be used. This fluid may be
surging, and so forth) creating no driver complaints.
used for cleaning parts (that is, valve train parts cylinder head,
7.1.2 Additive/Base Fuel Shipment and Storage—The addi- intake manifold, throttle body) and as a fuel injector test fluid.
tive shall be shipped in a container as dictated by safety and
7.6 Fuel Injector Test Fluid:
environmental regulations. The additive shall be stored in
7.6.1 Naphtha Solvent—See 7.5.3.
accordance with all applicable safety and environmental regu-
7.6.2 Isooctane—Reagent grade 2,2,4-Trimethylpentane
lations.
may be used (see Note 6).
7.2 Test Fuel—A blended test fuel shall be a homogeneous
7.7 Sealing Compounds—Sealing compounds are not speci-
blend of additives and base fuel. Sufficient fuel shall be
fied. Engineering judgment shall be used governing the use of
blended before the start of the test to complete a selected
sealing components. (Warning—Silicone-based sealers may
mileage interval which may be 10000 miles or less. If the
elevatetheindicatedsiliconecontentoftheusedengineoiland
initial mileage interval is less than 10000 miles, an additional
cause problems with exhaust gas oxygen sensors. Allow
fuel blend consisting of the same base fuel and same
sufficient curing time prior to running the engine.)
concentration/deposit control additive may be done if the
7.8 Valve Lapping Compound—Grade A280-grit valve lap-
vehicle is to complete the 10000 mile test. The fuel may be
ping compound shall be used.
stored in drums or tankage, and shall be clearly labeled to
7.9 Crushed Walnut Shells—A walnut shell blaster may be
preventmisfueling.Quantitiesoffuelandadditiveblendedand
usedtoremovecarbonanddepositsfromthehead.Clean,fresh
dispensed shall be measured and recorded for use in determin-
walnut shells shall be used. This media is available commer-
ing the fuel consumption, which is one of the operational
cially from industrial and automotive supply sources.
validity criteria. Approximately 1900L (500gal) of fuel are
required for this test method.
7.10 Desiccant—This granular form of anhydrous CaSO is
placed in an airtight container. The material absorbs moisture.
7.3 Engine Oil/Assembly Lubricant—The standard engine
The appropriate gradation shall be used.
oil and assembly lubricant used for all tests shall be commer-
cial quality (API SG, EC II) SAE 15W40 multigrade oil.
8. Preparation of Apparatus
Approximately 10L (10qt) are needed for this test method,
8.1 Cylinder Head Disassembly—This section is written
including engine assembly, initial crankcase fill, and 8000km
under the assumption that the cylinder head has been removed
(5000mile) change.
from the engine as outlined in 9.5.1 and the intake and exhaust
7.4 Engine Coolant—The coolant is a mixture of equal
valves have been removed as outlined in 9.5.2.Any disassem-
volumes of a commercial ethylene glycol-based low-silicate
blyinstructionsnotdetailedin8.1.1–8.1.5shallbecompleted
antifreeze and distilled or demineralized water. Do not use
in accordance with the instructions in the BMW 318i Service
uninhibited ethylene glycol. The coolant should offer protec-
Manual. Disassemble and thoroughly clean the head before
tion from aluminum corrosion (cylinder head) and deposition
each test using specified solvents (see 7.5) and walnut shell
of aluminum salts (radiator).
blaster (see 6.5.6).
8.1.1 Mount the cylinder head on the fixture (or equivalent)
7.5 Solvents and Cleaners:
(see 6.5.10).
7.5.1 Normal-Hexane or Cyclohexane Valve Rinse—The
8.1.2 With the head in an upward position (combustion
valves are rinsed with either n-hexane or cyclohexane.
chamberdown),removetheeightexhaustmanifoldboltsalong
(Warning—See 6.2.3.)
with the manifold and gasket. Discard the gasket.
NOTE 5—The California Air Resources Board specifically requires the
use of n-hexane to rinse the intake valves. When conducting this test
method for approval to market automotive spark-ignition engine fuels in
ACS Reagent Chemicals, Specifications and Procedures for Reagents and
the State of California, the test method shall be conducted using n-hexane
Standard-Grade Reference Materials, American Chemical Society, Washington,
as the valve rinse solvent.
DC. For suggestions on the testing of reagents not listed by theAmerican Chemical
NOTE 6—Reagent-grade chemicals will be used for all test procedures.
Society, see Analar Standards for Laboratory Chemicals, BDH Ltd., Poole, Dorset,
Unless otherwise noted, it is intended that all reagents conform to the
U.K., and the United States Pharmacopeia and National Formulary, U.S. Pharma-
specifications of the Committee on Analytical Reagents of the American copeial Convention, Inc. (USPC), Rockville, MD.
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8.1.3 Remove the five bolts securing the distributor flange through the throttle bore and out the side which attaches to the
totheheadandremovetheflange.Removeanygasketmaterial head. Make sure to clean all areas of the throttle body.
or deposits from the mating surfaces with a gasket scraper. Continue to spray cleaner into the throttle body until the fluid
8.1.4 Remove and discard intake and exhaust valve stem draining out is clear. Dry the inside of the throttle body with a
seals. clean rag.
8.1.5 Removetheheadfromthestandandplacetheheadin 8.2.4 Cylinder Block—Clean the cylinder head mating sur-
faces and piston crowns of any gasket material or deposit,
a suitable area for cleaning.
using a gasket scraper, the appropriate solvents (see 7.5), a
8.2 Cleaning Components to Be Reused—Thoroughly clean
walnut shell blaster, or other appropriate tools, or combination
the cylinder head, intake manifold, and throttle body before
thereof.
each test using specified solvents, walnut shell blaster, gasket
8.2.4.1 Pistoncrownsshallbecleanedwithagasketscraper,
scraper, or other means as appropriate. Avoid using a wire
finewirebrush,orsimilartools.Donotallowdebristofallinto
brush on cylinder heads and other aluminum alloy surfaces as
thewaterjacketoroilpassages.Careshallbeexercisedsothat
this tool may reduce the useful life of the cylinder head.
the piston crowns are not damaged during cleaning. A shop-
NOTE 7—California Air Resources Board requires the use of a wire
typevacuumcleanermaybeusedtoevacuatetheloosecarbon
brush to clean cylinder heads. When conducting this test method for
from the piston and piston/bore crevice.
approval to market automotive spark-ignition engine fuels in the State of
California, 8.2 shall be conducted using a wire brush.
NOTE 8—Before cleaning the piston crowns, ensure that photographs
have been taken (if requested).
8.2.1 Cylinder Head—Clean the intake and exhaust mani-
8.3 Valve Preparation—Clean the valves before assembly
fold mating surfaces of any gasket material or deposit using a
measurements are taken. After measurements are taken, the
gasket scraper, the appropriate solvent (see 7.5), or a walnut
seating surfaces checked or adjusted, or both, and the valves
blaster, or both.
lapped, the intake valves, not the exhaust valves, are weighed.
8.2.1.1 Clean the head by spraying it thoroughly with
8.3.1 Intake Valve Cleaning—New intake valves shall be
solvent to remove oil, fuel, and lapping compound. Pour
used.
solventthroughallcoolantandoilpassages,andblowdrywith
8.3.1.1 Mark the new intake valves as shown in Fig. 3 in
compressed air. Be certain to blow air through all oil and
accordancewiththetestvehicleandcylinderinwhichtheywill
coolant passages. (Warning—Wear eye protection and other
be installed.
protective clothing when spraying solvents and when using
8.3.1.2 Beforeweighingthenewintakevalves,theyshallbe
compressed air to blow debris from parts.)
thoroughly buffed to remove any surface oxidation. Perform
8.2.1.2 Remove all hardened deposits from the cylinder
this using a bench grinder fitted with a wire wheel brush (see
head with a walnut shell blaster or a wire brush. Pay particular
6.5.5). The entire valve shall be buffed, not just the tulip.
attention to the intake and exhaust ports and the combustion
8.3.1.3 After buffing, spray the valve with n-hexane,
chambers. After all deposits are removed, blow the head out
cyclohexane, or an aerosol cleaner (see 7.5) and wipe com-
with compressed air to remove any residual walnut shell
pletely with a dry, clean rag.
material from the water and oil passages.
8.3.2 Intake Valve Weighing—Weigh the intake valve after
8.2.1.3 Rinse the head, including the oil and coolant
completing the preparation of the intake valve seat area,
passages, again with solvents and blow dry with compressed
including lapping (see 8.4.1 – 8.4.5).
air.
8.3.2.1 Valve Rinse—Wash the valves gently with n-hexane
8.2.2 Intake Manifold—Clean the cylinder head and throttle
or cyclohexane. This procedure shall be performed only once.
body mating surfaces and fuel injector tips of any gasket
Thesolventistobedischargedfromahandsqueezebottleonto
material or deposit using a gasket scraper and the appropriate
the valve. Gently rinse the valve starting at the top of the stem
solvents (see 7.5) or a walnut shell blaster, or both.
8.2.2.1 Clean the intake runner with aerosol cleaner. Rest
the intake manifold on its side as the cleaner is sprayed so that
itwilldrainthroughtherunnerandoutthesidethatattachesto
the head. Continue to spray cleaner into the runner until the
fluid draining out is clear. Be sure to spray and clean the fuel
injector tips which are still installed in the runner with solvent
only. Dry the inside of the runner with a clean rag.
8.2.2.2 The fuel rail and injectors are removed from the
intake runner. Remove the injectors from the fuel rail by
removing the retaining clips from the rail which secure the
injectors.
8.2.3 Throttle Body—Clean the throttle body mating sur-
faces of any gasket material or deposit using a gasket scraper
and the appropriate solvents (see 7.5) or a walnut shell blaster,
or both.
8.2.3.1 Cleanthethrottlebodywithaerosolcleaner.Restthe
throttlebodyonitssideasthecleanerissprayedsoitwilldrain FIG. 3 Location of Valve Identification
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and proceeding towards the tulip section. While discharging 8.3.2.5 Weigh the valves to the nearest 0.0001g using an
the solvent, rotate the valve (which is held in gloved hand) to analyticalbalanceasspecifiedin6.5.2.Recordtheweightsand
ensure removal of all oily residues. Continue the washing
other required data using the form in Fig. 4.
process until the solvent running off the valve is clear. Gently
8.3.2.6 The repeatability of the balance between the start
shake off any remaining solvent. (Warning—See 6.2.3 and
and the end of this procedure is to be confirmed by weighing
Note 5.)
andrecordingtheweightofareferenceweightbeforeandafter
8.3.2.2 Removing the Rinse—Immediately after the wash is
weighing the four valves. Reference shall range from 90g to
complete,placetheintakevalvesinsideanoven(see6.5.4)for
110g.The startand endreferenceweighingsshallnotdifferby
5 min to remove any remaining solvent through vaporization.
more than 0.0010g. If the absolute difference is greater than
The oven temperature shall be 93°C 62°C (200°F 65°F).
0.0010g, then repeat 8.3.2.5.
8.3.2.3 Warm Valve Handling Technique—Use tongs to
8.3.3 Exhaust Valve Cleaning:
transfer the valves from the oven directly into a desiccator.
8.3.3.1 Prepare the exhaust valves by buffing each with a
8.3.2.4 Desiccator—The valves shall remain in the desicca-
free wire wheel to remove accumulated deposits. Unlike
tor for a minimum of 1h while they cool to room temperature.
procedures in 8.3.1 for the intake valves, clean all areas except
Conduct a periodic check of the desiccant to ensure its proper
functioning. Monitoring of color change is usually the method the stem. Provided that the exhaust valves are still within
employed. specifications as described in 8.4.2, they may be reused.
FIG. 4 Valve Measurements and Weights
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8.4 Cylinder Head Preparation and Assembly—Assemble
usingintakeandexhaustvalvesaspreparedin8.3.Refertothe
manufacturer’s specifications and procedures as specified in
BMW 318i Service Manual for any additional information not
provided in this test method.All parts for the reassembly shall
be cleaned in accordance with the procedures outlined in 8.2
and 8.3. This section assumes the necessary parts have been
cleaned and the cylinder head is mounted in the head stand.
8.4.1 Measure Stem-to-Guide Clearance—The intake and
exhaust valve stem-to-guide clearances shall be determined.
8.4.1.1 Measure intake and exhaust valve guides using an
appropriate gage (see 6.5.7) to take two measurements 90°
apart at positions 2mm (0.08in.) from the top and bottom of
thevalveguides.Thesefourmeasurementsshallbetakentothe
nearest 0.025mm (0.001in.). Record on the form as shown in
Fig. 4 and repeat for all cylinders.
8.4.1.2 Measure intake and exhaust valve stems using an
appropriate gage (see 8.4.4) to take two measurements 90°
apart at positions 2mm from the top and bottom on the valve
stems as shown in Fig. 5. These four measurements shall be
taken to the nearest 0.025mm (0.001in.). Record on the form
as shown in Fig. 4 and repeat for all cylinders.
8.4.2 Calculate Stem-to-Guide Clearance—Measurements
taken in 8.4.1.1 and will be sufficient to check the taper and
out-of-round of the guide. Calculation of stem-to-guide clear-
ance is defined as the maximum guide diameter minus the
minimumstemdiameter.Thiscalculationshallbeexecutedfor
each valve and recorded as shown on the data sheet in Fig. 4.
8.4.2.1 With all of the measurements recorded, each valve
stem clearance is determined as follows:
clearance 5maximumguidediameter 2minimumstemdiameter(1)
8.4.2.2 Specification—Clearance for all valves shall be less
than 0.15mm (0.006in.). Refer to BMW318i Service Manual
for minimum clearance.
8.4.2.3 If the maximum specification for clearance is not
met for either intake or exhaust valves, the cylinder head shall
not be used. Replacement of valve guides or refurbishing (that
is, knurling and honing) is not permitted as any oil control
FIG. 5 Location of Stem and Guide Measurements
change or heat transfer change may alter the deposit accumu-
lation. If it is determined that a new head is required, a new
head shall be obtained from BMW NA (see Annex A2). 8.4.4.2 Thevalveseatwidthsshallbebetween1.25mmand
8.4.3 New Head Procedure—If a new cylinder head is 2.1mm (0.051in. and 0.089in.). The cylinder head seat shall
required, the cylinder head supplied will be unassembled. contact the valve in the center of the machined valve face
Thoroughly rinse the new cylinder head with a solvent (see surface as shown in Fig. 5.
7.5).Besuretorinsealloilandcoolantpassages.Assemblethe 8.4.4.3 The cylinder head valve seat or valve, or both, shall
cylinder head in accordance with the procedures outlined in be adjusted to meet these requirements or the part shall be
this section. discarded. The cylinder head valve seat and valve shall be cut
8.4.4 Measurement of Valve Seat Quality—Measure all as outlined in the BMW 318i Service Manual with the
valve and corresponding valve seats using a dye removal appropriate equipment (see 6.5.12).
method. 8.4.4.4 Remove the cylinder head from the head stand and
8.4.4.1 Cover the seating surface of the intake valve with a place it on a bench with the combustion chamber side up.
thin film of dye, such as Prussian blue dye, and place it back 8.4.5 Lap Valves—Lap the valve in the proper cylinder as
into the corresponding guide. Rotate the valve by the stem not identifiedonthestem.Lapthevalveuntiltheseatingsurfaceis
1 1
more than ⁄4 revolution (6 ⁄8 revolution) while gently pulling uniform.
ittowardstheseat.Thisrotationwillrubdyeoffthevalveface 8.4.5.1 Lightlycoatthevalveseatsurfacebeinglappedwith
at the seating surface. Measure the maximum and minimum lapping compound (7.8). Using a valve lapping tool (see
width of the etched circle on the valve face using a vernier 6.5.11), lap the valve until the seating surface is uniform. Do
caliper and record on the appropriate form (see Fig. 4). not lap the valves more than is necessary for obtaining a
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uniform seating surface. After lapping is completed, remove combustion chamber). Next position a rocker arm, a washer, a
thevalveandwipethecompoundoffthevalveandvalves
...