Introduction

Scope

1

Referenced Documents

2

Terminology

3

Summary of Test Method

4

Significance and Use

5

Apparatus

6

 Laboratory

6.1

 Drawings

6.2

 Specified Equipment

6.3

 Test Engine

6.4

  Engine Parts

6.4.1

 Engine Speed and Load Control

6.5

 Fluid Conditioning Module

6.6

  Engine Cooling System

6.6.1

 Flushing Tank

6.7

 Coolant Mixing Tank

6.8

 Condenser Cooling Systems

6.9

 Engine Oil-Cooling System

6.10

 Fuel System

6.11

 Induction Air Supply Humidity, Temperature, and Pressure

6.12

 Temperature Measurement

6.13

  Thermocouple Location

6.13.1

 Air-to-Fuel Ratio Determination

6.14

  Injector Flow Testing

6.14.1

 Exhaust and Exhaust Back Pressure Systems

6.15

 Blowby Flow Rate Measurement

6.16

 Pressure Measurement and Sensor Location

6.17

Reagents and Materials

7

 Test Fuel

7.1

 Engine and Condenser Coolant

7.2

 Coolant Additive

7.3

 Coolant Preparation

7.4

 Pre-Test Cleaning Materials

7.5

 Sealing and Anti-seize Compounds

7.6

Test Oil Sample Requirements

8

Preparation of Apparatus

9

 Condenser Cleaning

9.1

 Intake Manifold Cleaning

9.2

 Cleaning of Engine Parts (other than the block and heads)

9.3

 Connecting Rod Cleaning

9.4

 Engine Block Cleaning

9.5

 Cylinder Head Cleaning

9.6

 Engine Build-up Procedure

9.7

  General Information

9.7.1

  Special Parts

9.7.2

  Hardware Information

9.7.3

  Fastener Torque Specifications and Torquing Procedures

9.7.4

   Main Bearing Cap Bolts

9.7.4.1

   Cylinder Head Bolts

9.7.4.2

   Torques for Miscellaneous Bolts, Studs, and Nuts

9.7.4.3

 Parts Replacement

9.8

 Engine Block Preparation

9.9

 Piston Fitting and Numbering

9.10

  Piston Ring Fitting

9.10.1

 Pre-Test Camshaft and Lifter Measurements

9.11

 Camshaft Bearing Installation

9.12

 Camshaft Installation

9.13

 Main Bearings

9.14

  Crankshaft Installation

9.14.1

  Main Bearing Cap Installation

9.14.2

 Crankshaft Sprocket

9.15

 Camshaft Sprocket and Timing Chain

9.16

 Crankshaft End Play

9.17

 Piston Pin Installation

9.18

  Piston Installation

9.18.1

 Harmonic Balancer

9.19

 Connecting Rod Bearings

9.20

 Engine Front Cover

9.21

 Coolant Inlet Adapter

9.22

 Oil Dipstick Hole

9.23

 Oil Pan

9.24

 Cylinder Head Assembly

9.25

 Adjustment of Valve Spring Loads

9.26

 Cylinder Head Installation

9.27

 Hydraulic Valve Lifters

9.28

 Pushrods

9.29

 Valve Train Loading

9.30

 Intake Manifold

9.31

 Rocker Covers

9.32

 Water Inlet Adapter

9.33

 Condenser

9.34

 Coolant Outlet Adapter

9.35

 Oil Filter Adapter

9.36

 Oil Sample Valve

9.37

 Ignition System

9.38

 Throttle Body

9.39

 Accessory Drive Units

9.40

 Exhaust Manifolds, Water-Cooled

9.41

 Engine Flywheel

9.42

 Pressure Checking of Engine Coolant System

9.43

 Lifting of Assembled Engines

9.44

 Mounting the Engine on the Test Stand

9.45

 External Cooling System Cleaning

9.46

 Engine Coolant Jacket Cleaning (Flushing)

9.47

 Coolant Charging

9.48

 Test Oil Charging

9.49

 Engine Oil Pump Priming

9.50

Calibration

10

 Laboratory and Engine Test Stand Calibration

10.1

 Testing of Reference Oils

10.2

 Reference Oil Test Frequency

10.3

 Reporting of Reference Oil Test Results

10.4

 Evaluation of Reference Oil Test Results

10.5

 Status of Non-Reference Oil Tests Relative to Reference
  Oil Test

10.6

 Status of Test Stands Used for Non-Standard Tests

10.7

 Data Acquisition and Control

10.8

  Sample Rate

10.8.1

  Measurement Accuracy

10.8.2

  Temperature

10.8.3

  Pressure

10.8.4

  Flow

10.8.5

  Speed

10.8.6

  Load

10.8.7

  Measurement Resolution

10.8.8

  System Time Response

10.8.9

  Quality Index

10.8.10

Engine Operating Procedure

11

 Dipstick and Hole Plug

11.1

 Dipstick Hole O-ring

11.2

 Engine Start-up and Shutdown Procedures

11.3

 Start-up

11.4

 Scheduled Shutdown

11.5

 Non-Scheduled Shutdowns

11.6

 Oil Sampling

11.7

 Oil Leveling

11.8

 Air-to-Fuel-Ratio Measurement and Control

11.9

 Air-to-Fuel Ratio Verification

11.10

 Blowby Flow Rate Measurement

11.11

 NOx Determinations

11.12

 Data Recording

11.13

 Initial run (10 min)

11.14

 Engine Oil Quality Testing (100 h)

11.15

 Test Termination

11.16

Determination of Test Results

12

 Engine Disassembly

12.2

 Preparation of Parts for Rating of Sticking, Deposits,
  and Plugging

12.3

 Piston Deposit Rating

12.4

 Post-Test Camshaft and Lifter Wear Measurements

12.5

 Viscosity Test

12.6

 Testing Oil Samples for Wear Metals

12.7

 Blowby Flow Rate Measurements

12.8

 Oil Consumption Computation

12.9

 Photographs of Test Parts

12.10

 Retention of Representative Test Parts

12.11

 Severity Adjustments

12.12

 Determination of Operational Validity

12.13

Report

13

 Report Forms

13.1

 Precision of Reported Units

13.2

Precision and Bias

14

Keywords

15

The Role of the ASTM Test Monitoring Center (TMC) and
 the Calibration Program

Annex A1

Sequence IIIG Test Parts Replacement Guidelines

Annex A2

Sequence IIIG Determination Volume of Engine Oilin Pan

Annex A3

Sequence IIIG Test Fuel Analysis

Annex A4

Sequence IIIG Test Reporting

Annex A5

Sequence IIIG Test Air-to-Fuel Ratio Control Flow Chart

Annex A6

Sequence IIIG Test Set Points and Control States

Annex A7

Sequence IIIG Quality Index Upper and Lower Values

Annex A8

Sequence IIIG Engine Oil Level Worksheet

Annex A9

Blowby Flow Rate Determination

Annex A10

Safety Hazards

Annex A11

Sequence IIIG Blueprint Listing

Annex A12

Fluid Condition Module components

Annex A13

Engine Build Worksheets

Annex A14

Engine Oil Cooling System Schematic

Annex A15

Guidelines For Hardware Subject To First In – First Out Criteria

Annex A16

Sequence IIIGA Test Procedure

Appendix X1

Sequence IIIGVIS Test Procedure

Appendix X2

Sequence IIIGB Test Procedure

Appendix X3