Subject

Section

Introduction

Scope

1

Referenced Documents

2

Terminology

3

Summary of Test Method

4

Significance and Use

5

Apparatus

6

 General

6.1

 Test Engine Configuration

6.2

 Laboratory Ambient Conditions

6.3

 Engine Speed and Torque Control

6.4

  Dynamometer

6.4.1

  Dynamometer Torque

6.4.2

 Engine Cooling System

6.5

 External Oil System

6.6

 Fuel System

6.7

  Fuel Flow Measurement

6.7.2

  Fuel Temperature and Pressure Control to
   the Fuel Flowmeter

6.7.3

  Fuel Temperature and Pressure Control to
   Engine Fuel Rail

6.7.4

 Fuel Supply Pumps

6.7.5

  Fuel Filtering

6.7.6

 Engine Intake Air Supply

6.8

  Intake Air Humidity

6.8.1

  Intake Air Filtration

6.8.2

  Intake Air Pressure Relief

6.8.3

 Temperature Measurement

6.9

  Thermocouple Location

6.9.5

 AFR Determination

6.10

 Exhaust and Exhaust Back Pressure Systems

6.11

  Exhaust Manifolds

6.11.1

  Laboratory Exhaust System

6.11.2

  Exhaust Back Pressure

6.11.3

 Pressure Measurement and Pressure Sensor
  Locations

6.12

  Engine Oil

6.12.2

  Fuel to Fuel Flowmeter

6.12.3

  Fuel to Engine Fuel Rail

6.12.4

  Exhaust Back Pressure

6.12.5

  Intake Air

6.12.6

  Intake Manifold Vacuum/Absolute Pressure

6.12.7

  Coolant Flow Differential Pressure

6.12.8

  Crankcase Pressure

6.12.9

 Engine Hardware and Related Apparatus

6.13

  Test Engine Configuration

6.13.1

  ECM/EEC (Engine Control) Module

6.13.2

  Thermostat/Orifice Plate

6.13.3

  Intake Manifold

6.13.4

  Flywheel

6.13.5

  Wiring Harnesses

6.13.6

  EGR Block-Off Plate

6.13.7

  Oil Pan

6.13.8

  Oil Pump Screen and Pickup Tube

6.13.9

  Idle Speed Control Solenoid (ISC) Block-Off
   Plate

6.13.10

  Engine Water Pump

6.13.11

  Thermostat Housing

6.13.12

  Oil Filter Adapter

6.13.13

  Fuel Rail

6.13.14

 Miscellaneous Apparatus Related to Engine
  Operation

6.14

  Timing Light

6.14.1

Reagents and Materials

7

 Engine Oil

7.1

 Test Fuel

7.2

 Engine Coolant

7.3

 Cleaning Materials

7.4

Preparation of Apparatus

8

 Test Stand Preparation

8.2

Engine Preparation

9

 Cleaning of Engine Parts

9.2

 Engine Assembly Procedure

9.3

  General Assembly Instructions

9.3.1

  Bolt Torque Specifications

9.3.2

  Sealing Compounds

9.3.3

  Harmonic Balancer

9.3.5

  Oil Pan

9.3.6

  Intake Manifold

9.3.7

  Camshaft Covers

9.3.8

  Thermostat

9.3.9

  Thermostat Housing

9.3.10

  Coolant Inlet

9.3.11

  Oil Filter Adapter

9.3.12

  Dipstick Tube

9.3.13

  Water Pump

9.3.14

  Sensors, Switches, Valves, and Positioners

9.3.15

  Ignition System

9.3.16

  Fuel Injection System

9.3.17

  Intake Air System

9.3.18

  Engine Management System (Spark and Fuel
   Control)

9.3.19

  Accessory Drive Units

9.3.20

  Exhaust Manifolds

9.3.21

  Engine Flywheel and Guards

9.3.22

  Lifting of Assembled Engines

9.3.23

  Engine Mounts

9.3.24

Calibration

10

 Stand/Engine Calibration

10.1

  Procedure

10.1.1

  Reporting of Reference Results

10.1.2

  Analysis of Reference/Calibration Oils

10.1.3

  Instrument Calibration

10.2

  Engine Torque Measurement System

10.2.1

  Fuel Flow Measurement System

10.2.2

  Coolant Flow Measurement System

10.2.3

  Thermocouple and Temperature Measurement
   System

10.2.4

  Humidity Measurement System

10.2.5

  Other Instrumentation

10.2.6

Test Procedure

11

 Preparation for Initial Start-up of New Engine

11.1

  External Oil System

11.1.1

  Flush Effectiveness Demonstration

11.1.2

  Preparation for Oil Charge

11.1.3

  Oil Charge for Coolant Flush

11.1.4

  Engine Coolant Charge for Coolant Flush

11.1.5

 Initial Engine Start-up

11.2

 Coolant Flush

11.3

 New Engine Break-In

11.4

  Oil Charge for Break-In

11.4.2

  Break-In Operating Conditions

11.4.3

 Routine Test Operation

11.5

  Start-Up and Shutdown Procedures

11.5.8

  Flying Flush Oil Exchange Procedures

11.5.9

  Test Operating Stages

11.5.10

  Stabilization to Stage Conditions

11.5.11

  Stabilized BSFC Measurement Cycle

11.5.12

  Data Logging

11.5.13

  BC Oil Flush Procedure for BC Oil Before Test
   Oil

11.5.14

 BSFC Measurement of BC Oil Before Test Oil

11.5.15

  Test Oil Flush Procedure

11.5.16

  Test Oil Aging

11.5.17

  BSFC Measurement of Aged (Phase I) Test Oil

11.5.18

  Aging Phase II

11.5.19

  BSFC Measurement of Aged (Phase II) Test Oil

11.5.21

  BC Oil Flush Procedure for BC Oil After Test Oil

11.5.22

  BSFC Measurement for BC Oil After Test Oil

11.5.23

  General Test Data Logging Forms

11.5.24

  Diagnostic Review Procedures

11.5.25

 Determination of Test Results

12

  FEI1 and FEI2 Calculations

12.1

 Final Test Report

13

  Validity Statement

13.1

  Report Format

13.2

Precision and Bias

14

 Precision

14.1

 Validity

14.2

  Test Stand Calibration Status

14.2.1

  Validity Interpretation of Deviant Operational
   Conditions

14.2.2

 Bias

14.3

Keywords

15

Annexes

Role of ASTM TMC

Annex A1

Detailed Specifications and Drawings of Apparatus

Annex A2

Oil Heater Cerrobase Refill Procedure

Annex A3

Engine Part Number Listing

Annex A4

Flying Flush Checklists

Annex A5

Safety Precautions

Annex A6

Report Format

Annex A7

Statistical Equations for Mean and Standard
 Deviations

Annex A8

Oil Sump Full Level Determination Consumption
 Measurement Calibration Procedure

Annex A9

Fuel Injector Evaluation

Annex A10

Pre-test Maintenance Checklist

Annex A11

Blow-by Ventilation System Requirements

Annex A12

VIBSJ Abbreviated Length Test Requirements

Annex A13

Appendix

Procurement of Test Materials

Appendix X1