ASTM D6201 Dynamometer Evaluation of Unleaded Spark-Ignition Engine Fuel
ASTM D6201 Standard Test Method for Dynamometer Evaluation of Unleaded Spark-Ignition Engine Fuel for Intake Valve Deposit Formation
12. Procedure
12.1 Pretest Procedure:
12.1.1 Engine Cooling System Charge - Add equal volumes of a commercial ethylene glycol-based low-silicate antifreeze and distilled or demineralized water. The cooling system capacity shall be 21 +/- 4 L.

12.1.2 Test Oil Charge - The test oil charge procedure is as follows:
12.1.2.1 Charge the system with 4.1 +/- 0.025 kg (9.0 +/- 0.6 lb) of the specified test oil.

12.1.2.2 Prime the oil system by removing the distributor shaft cap and using a drill to turn the engine oil pump.

12.1.2.3 At the 0.6 h compression pressure and percent leakdown inspection (see 12.3.4), drain the oil for 20 min through the oil pan drain plug hole.

12.1.2.4 Add test oil to the oil drain so that the final amount equals 4.1 +/- 0.025 kg (9.0 +/- 0.06 lb).

12.1.2.5 Charge the system with the 4.1 +/- 0.025 kg (9.0 +/- 0.06 lb) of oil derived in 12.1.2.4.

12.1.2.6 After 20 min, set the dipstick level to the full mark using an adjustable calibrated dipstick.

12.1.3 Fuel System Preparation - Change all system fuel filters before each test. The fuel system run tank/container(s) shall be sufficiently flushed. Purge an appropriate amount of test fuel through the entire fuel system to ensure that the previous test fuel is out of the system and the correct test fuel is in the system. Take a 900 mL fuel sample at the engine stand after the fuel system has been purged and prior to the start of test.

12.1.4 PCV Valve Installation - Refer to 10.3.3 for proper PCV valve preparation. Install the PCV valve so that there are no leaks between the hoses and the valve. The PCV valve shall have the same orientation as configured in the engine assembly kit (vertical orientation).

12.1.5 Keep Alive Memory (KAM) Reset - Turn off the power to the Keep Alive Memory for a minimum of 5 min before start of test.

12.1.6 Engine Break-in Procedure - Use the engine break-in procedure to break in a new engine short block (an engine block less the cylinder head, valves, camshaft, and engine accessories). With the exception of a slave cylinder head and the non-modified Ford Ranger Manual Transmission calibration EEC-IV processor (Part No. F47F-12A650-BGB), utilize all test engine hardware and associated engine stand hardware during the break-in period.
12.1.6.1 The break-in period consists of six, 4-h cycles. Thirteen steps comprise one cycle. The ramp times between each step are 2 min and are not part of step times. The total break-in period is 26 h, 36 min (6 cycles 5 24 h; total ramp time 5 2 h, 36 min).

12.1.6.2 The operational parameters specified for the break-in period are detailed in Table 3. During the first few steps of the break-in, the coolant out temperature and the oil in temperature may be below specification due to low engine speeds and loads. This is acceptable as long as the coolant and oil heat exchangers are not functioning (that is, no cooling is occurring). The coolant and the oil shall not be heated to try to meet the specification.

12.1.6.3 Charge the engine coolant system as described in 12.1.1. Charge the engine oil system with 4.1 +/- 0.025 kg (9.0 +/- 0.06 lb). Prime the oil system by removing the distributor shaft cap and using a drill to turn the engine oil pump.

12.1.7 After the break-in period is complete, an oil consumption verification test shall be performed.
12.1.7.1 Drain the engine oil from the break-in period. Weigh the oil.

12.1.7.2 Add test oil to the oil drain so that the final amount equals 4.1 +/- 0.025 kg (9.0 +/- 0.06 lb).

12.1.7.3 Charge the system with the 4.1 +/- 0.025 kg (9.0 +/- 0.06 lb) of oil derived in 12.1.7.2.

12.1.7.4 Operate the engine at test conditions as stated in Table 1 for a period of 24 h.

12.1.7.5 Drain the oil for a period of 20 min and record the weight.

12.1.7.6 Calculate the oil consumption by subtracting the weight of the oil derived in 12.1.7.5 from the oil charge as stated in 12.1.7.3.

12.1.7.7 Unusually high oil consumption is occurring if the oil consumption is greater than 0.4 kg.

12.2 Engine Operating Procedure:
12.2.1 Engine Operating Parameters and Specifications - The engine operating parameters and specifications are detailed in Table 1. Monitor the parameters and their specified limits according to the following:
12.2.1.1 Exhaust emissions as detailed in Table 1, or

12.2.1.2 EGR voltage, equivalence ratio, and spark timing as detailed in Table 1.

12.2.1.3 All other parameters listed in Table 1 that are not listed in 12.2.1.1.

12.2.2 Test Time - The test time is defined as the time at which the engine is being controlled remotely (when the engine stand controlling system and test timer are functioning). Any time in which the engine is not being controlled remotely (such as an initial engine start-up) does not count toward test time. The maximum amount of time in which an engine can be operating in a non-remote situation is 1 h per test. When an engine is operating in a non-remote situation, operate it either in an idle condition or test condition.
12.2.2.1 At instances just after the engine has been switched over to remote operation and the engine parameters have not reached specification, the time accumulated counts toward test time. During this time, allow the parameters to reach specification limits as quickly as possible. The two exceptions are engine speed and engine manifold absolute pressure where ramp times shall be 30 s; both shall be ramped together and linearly.

12.2.3 Test Duration - The test duration is 100 h (approximately 462 cycles).

12.2.4 Engine Shutdown Duration - The maximum amount of time an engine can be shut down during a test is 10.0 cumulative hours including all scheduled and unscheduled shutdowns.

12.2.5 Maximum Number of Engine Shutdowns - The maximum number of engine shutdown occurrences during a test is four including all scheduled and unscheduled shutdowns. At most, one of these shutdown occurrences may involve multiple stops and restarts of the engine, within a 1-h period after initially restarting the engine for the purpose of troubleshooting a persistent engine/control system problem.

12.2.6 Scheduled and Unscheduled Shutdowns - Unless there is an emergency to shut down the engine, all engine shutdowns shall be done at the beginning of Stage 1. One scheduled shutdown occurs at the 0.6 h compression pressure and percent leakdown check.

12.2.7 Engine Starts and Restarts - Engine starts and restarts occur at the beginning of the test, after the 0.6 h compression pressure and percent leakdown check, and after any unscheduled shutdowns. After the engine has been started, it shall be checked for proper operation (correct oil pressure, fuel pressure, and so forth). As stated in 12.2.2, the maximum amount of time in which an engine can be operating in a non-remote situation is 1 h per test. When an engine is operating in a non remote situation, it shall operate either in an idle condition or test condition. After the engine has been checked for proper operation, it shall be put on test (remote operation) as quickly as possible. The engine shall be put on remote operation at the same point in test time, as when it was shut down. In most cases, this should be at the beginning of Stage 1.

12.3 Periodic Measurements and Functions:
12.3.1 Oil Level Check Procedure - Performing an oil level check during the test is optional. If an oil level check is performed, the procedure for performing an oil level check is as follows:
12.3.1.1 Shut down the engine at the beginning of Stage 1.

12.3.1.2 Wait 20 min after engine has been shut down.

12.3.1.3 Perform an oil dipstick measurement using the calibrated oil dipstick.

12.3.1.4 If the oil level is low by more than 473 mL (16 fl. oz), add 0.41 +/- 0.01 kg (0.9 +/- 0.02 lb) to the engine and continue the test.

12.3.1.5 If the oil level is low by less than 473 mL, continue the test.

12.3.1.6 Record the oil level and any oil addition quantities.

12.3.2 Unusually high oil consumption is occurring if the oil level reduction exceeds 950 mL per 50 h period. If oil is added, record the weight of the oil added.

12.3.3 Data Collection Procedure - Utilize 1-min automated data collection on the parameters shown in the following table. Collect data at 1-min intervals at least three times during Stage 1 and seven times during Stage 2. Collect data on the parameters and specifications as detailed in 12.2.1.1 at least once every 24 h. Collect blowby readings once at the beginning of test (within the first 5 h of test time) and once at the end of test (within the last 5 h of test time). If the parameters and specifications detailed in 12.2.1.1 are out of specification when a reading is taken, the time accumulated between the previous in-specification reading and the out-of-specification reading counts toward the cumulative engine shutdown duration specification detailed in 12.2.4 and also toward test time. The maximum out of specification time for the parameters listed in 12.2.1.1 is 3.0 cumulative hours.
12.3.3.1 Take transition traces of engine speed and manifold absolute pressure (MAP) at least once within the first 15 h of test time and at least once within the last 15 h of test time. The frequency of data collection shall be at least 0.5 Hz.

12.3.4 Compression Pressure and Percent Leakdown Check - Perform a compression pressure and percent leakdown check at 0.6 +/- 0.2 h into the test. The compression pressure and percent leakdown procedure is as follows:
12.3.4.1 Compression Pressure Check:
(a) Disable the fuel.
(b) Disconnect the ignition power.
(c) Remove one spark plug from each cylinder.
(d) Set the throttle plate to wide open throttle (WOT).
(e) Install compression pressure gage spark plug fitting into spark plug hole.
(f) Crank the engine until compression pressure reading on gage stabilizes. Do not exceed eight compression strokes.
(g) Record the reading on the compression pressure and percent leakdown log.
(h) Repeat for remainder of cylinders.

12.3.4.2 Percent Leakdown Check:
(a) Disable the fuel.
(b) Disconnect the ignition power.
(c) Remove one spark plug from each cylinder.
(d) Rotate crankshaft so that intake and exhaust valves are closed on the cylinder to be leak checked.
(e) Install percent leakdown tester spark plug fitting into spark plug hole.
(f) Charge cylinder with air at 100 psi.
(g) Record percent leakdown on a compression pressure and percent leakdown log.

12.3.4.3 The compression pressure shall be equal to or greater than 1034 kPa (150 psi) in all of the cylinders and the compression pressure in any one cylinder shall be greater than 80 % of the highest compression pressure reading. The percent leakdown shall be less than 15 % in any of the cylinders.

12.4 End of Test Procedures:
12.4.1 Engine Cylinder Head Removal - Completely drain the coolant system. Drain the oil per 12.4.2. Remove the necessary engine accessories to expose the cylinder head. Remove the cylinder head bolts. Carefully remove the cylinder head from the engine block. Remove the cylinder head gasket. Avoid allowing any coolant or oil, or both, to drip onto piston tops or cylinder head combustion chamber. Wipe away any coolant or oil, or both, that is on the engine block and cylinder head mating surfaces. Cover the engine and cylinder head to protect from contamination.
12.4.1.1 Rate the intake valves, photograph, and weigh within 48 h of test completion. Place the valves in a desiccator while they are not being photographed, weighed, or rated.

12.4.2 Final Oil Drain - After test completion, drain the oil from the oil pan for 20 min. Weigh the oil and record the weight.

12.4.3 Final Oil Consumption - Oil consumption is derived by calculating the difference between the initial oil charge (4.1 kg) plus any oil additions and the final oil drain (final oil consumption 5 4.1 kg + oil additions - final oil drain). If the final oil consumption is greater than 1.0 kg (approximately 2.2 lb), the test is invalid.

12.4.4 Final Fuel Consumption - Final fuel consumption is the total fuel used while the engine was in both manual and remote operation.

12.4.5 Engine Inspection - On test completion and after the cylinder head has been removed, visually inspect the cylinder bores for unusual wear. Inspect engine hardware and note necessary hardware replacements.