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MoparMuscle657hpstreetthumperCumminsISXQSXShortblockknowledgeCamshaftBearingsConceptdesignandfeaturesPROSISPROLetsgetstartedROUSHYATESRY45SERIESENGINEDESIGNOVERVIEWROUSHYATESRY45SERIESENGINEANAERAINTERNATIONALQUARTERLYPUBLICATIONJANUARY-MARCH2015 2JAN-MAR2015engineprofessional4FROMTHEEDITOR6INDUSTRYNEWSWelcometonewAERAmemberscalendarofeventsnewsandviews10AERAPRESENTSPRESTIGIOUSCHARLESW.YOUNTAWARDTODONROTTLERByJimRickoff12MULTI-LAYEREDSTEELGASKETSByBillMcKnight20RY45SERIESDESIGNOVERVIEWByDanKeenan44MOPAR499PROJECTByMikeMavrigian78DEPENDABLECUMMINSISXBySteveScott83CAMSHAFTBEARINGSByDr.DmitriKopeliovich90CARBURETORSANDETHANOLByLakeSpeedJr.92TECHBULLETINS98PROSISPROBySteveFox100ONTHESAMEPAGEEnginebuildingbookreviewsbyAERATechnicalSpecialistMikeCaruso101MARKETPLACECONTENTSEngineProfessionalmagazineISSN1945-7634ispublishedquarterlybyAutomotiveEngineRebuildersAssociationAERA.Copyright2015AERA.Subscriptionrates70peryearoutsidetheUnitedStates90singlecopy20.Publicationeditorialandbusinessoffice500CoventryLaneSte180CrystalLakeIL60014.Editorial815-526-7600Advertising815-526-7600Circulation815-526-7600.Sendchangeofaddresstotheabove.TheopinionsbeliefsandviewpointsexpressedbythevariousauthorsinthismagazinearethoseoftheindividualauthorsandnotoftheAutomotiveEngineRebuildersAssociationwhichdisclaimsallresponsibilityforthem.VOLUME8NUMBER1PUBLISHERAERA-EngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014815-526-7600815-526-7601faxChairmanoftheBoardSteveSchoebenBloomingtonMNFirstViceChairmanRexCrumptonTulsaOKSecondViceChairmanSteveEdmondsonLouisvilleKYTreasurerRonMcMorrisMapleRidgeBCCANADAPresidentJimRickoffCrystalLakeILEDITORJimRickoffjimaera.orgASSOCIATEEDITORDaveHagendaveaera.orgTECHNICALEDITORSMikeCarusomikeaera.orgSteveFoxsteveaera.orgGaryLewisenginesmsn.comMikeMavrigianmikebirchwoodautomotive.comGRAPHICDESIGNMariaBeyerstedtmariamcreative.usADVERTISINGSALESJimRickoffjimaera.orgHalFowlerhalfowlersales.comCIRCULATIONAmandaPotteramandaaera.orgMEMBERSHIPSERVICESKarenTenderingkarenaera.orgINTERNATIONALLIAISONYolandaCarranzayolandaaera.org1244788390 MSTARMTnTARernOEformtandfVictorReinzthparallelwithorigfromplasticsandmwwwMSdfunctheraninaleqdmeta.mahle-aftermarket.comwwwTARM.mahle-aftermarket.comTnTARernMAHLEOriginalringsprovideuneandfatigueresistaSAEunequaleanceetalengineture100lead-iliconandareith60moreomparableeplacements.gextendsringlifemwearandreducesrtrRinzminimisringbctorReinztrademarkarepropertthictorReinztrademarkarepropertyofDanaLimitedandusedunderlicensetoMAHLEAttermarketInc.ictorReinztrademarkarepropertyofDanaLimitedandusedunderlicensetoMAHLEAttermarketInc. 4JAN-MAR2015engineprofessionalFROMTHEEDITORBYJIMRICKOFFHiTeamHavingaccesstoinformationespeciallytechnicalinformationisacriticalpartofoureverydaytasksforallofusinthisindustry.Timelytechnicalinformationinourlightspeedworldjustplaingoeswithoutquestion.Ioftenwonderhowourpre-computerforefathersoperatedwithoutthesedigitalstorageunitstoinstantaneouslyprovideuswithourrequests.AnywayIdontthinktoolongaboutitbutIdothankthecomputerwizardsofourworldformakingourjobeasiertostoreandretrievetheinformationweneedveryquicklyonadailybasis.Yessometimescomputershavetheirissuesbutreallybusinesstodaywithoutthemwouldbenexttoimpossible.WeareveryproudhereatAERAthatwehavekeptupwithtechnologywhileprovidingyouthecrucialtechnicalenginespecificationsyouneedonadailybasis.Soafteroneyearofdevelopmentweareverypleasedtoannouncethatwehavelaunchedournewweb-basedenginespecificationsoftwarePROSISPRO.PROSISPROutilizesthelatestinteractivewebtechnologytohelpyoufindenginespecsfastaccuratelyandeasily.ForthoseofyounotfamiliarwithAERAsenginespecificationsoftwareprogramPROSISPROoffersover7000differentOEenginespecificationsfrom150manufacturerscoveringautoheavy-dutyagriculturalindustrialmarineandimportengines.Itcontainsover37000castingnumbers3000AERATechnicalBulletinsstoresyourowncustomenginespecsallowsyoutocustomizeallheaderswithyourcompanylogoandcompanycontactinformationwriteestimatesandworkordersaswellasinvoiceandtrackcustomers.ThisnewwebapplicationencompassesallthefeaturesofouroriginalPROSISPROSISSAandPROSISWebprograms.PROSISPROallowsyouthefullfunctionalityofadesktopversionwithafastermoreefficientweb-basedframework.WithPROSISPROthereisnoneedtodedicateacomputertooperatethisprogram.BecauseoftheinteractivewebtechnologyPROSISPROallowsyoutoaccessourdatabaseviayourcomputertabletiPadorsmartphone.Nomoreobsoleteoperatingsystemstodealwithtimeconsumingupdatesorbackups.PROSISPROisupdateddailybyourtechnicalstaffwhichinsuresyouaccessto100oftheAERAelectronicallystoredinformation.Inadditionyouhavetotalcustomizationwhileoperatingofftheweb.AgainyoucancustomizePROSISPROwithyourcompanylogoandcontactinformationandyesyoucanaddcustomspecsdailywhilenothavingtoworryaboutkeepingupwithnewoperatingsystemsorcomputers.NowyoudoneedtobeanAERAmembertohaveaccesstothecompletePROSISPROsoftware.HoweverwehaveanewDEMOversionthatnon-memberscanaccessthroughourwebsiteatwww.aera.org.OnceyoureonlinepleaseclickthePROSISPROtabandfollowdirectionsforthislimiteddemoversionthatwillgiveyouasampleoftheinformationwehaveandhowtoaccessit.ForallAERAmemberstherearethreewaystogetstartedusingPROSISPROCurrentPROSISWebUsersLogintoPROSISPROwithyourPROSISWebusernameandpasswordatwww.prosispro.com.IfyouforgotyourPROSISWeblogincredentialspleasecontactKarenatAERAkarenaera.orgforassistance.CurrentPROSISPROSISSAUsersGotowww.prosispro.comandclickontheblueboxlabeledPRO-SISandSAuserstoregisterforaPROSISPROaccount.YouwillneedyourmemberIDandemailaddresstogetstarted.30DayFreeTrialforNewMembersIfyouareanewAERAmemberyoucansignupfora30-dayfreetrialofPROSISPRO.PleasecontactKarenatAERAkarenaera.orgforassistance.SeethePROSISPROarticleonpages98-99forcompleteinstructionsonhowtogetstartedIfyouhaveanyquestionsorneedhelppleasecontactKarenTenderingDaveHagenorSteveFoxtoll-free888-326-2372or815-526-7600andtheywillbehappytoassistyou.IJimRickoffAERAPresident815-526-7343jimaera.orgPROSISPROAERAsnewonlineenginespecificationsoftware CumminsISB5.924valvesCylinderHeadBare.......................................1185CylinderHeadComplete.............................1395CrankshaftSteelforged................................895GasketKitUpper..............................................198GasketKitLower..............................................198ConnectingRod.......................................................79CumminsISC8.324valvesCylinderHeadBare.......................................1980CylinderHeadComplete.............................2385CrankshaftSteelforged...............................995GasketKitUpper..............................................198GasketKitLower..............................................198ConnectingRod.......................................................95ProudmemberofandsupplierofKMSGBuyingGroupCummins8.3L6C6CT6CTACummins5.9L6B6BT6BTA6BTAACummins3.9L4B4BT4BTACompleteHead995eachBareHead680eachCompleteHead465eachBareHead355eachCompleteHead465eachBareHead350eachORDERLINE1-866-210-9251ACCESSINDUSTRIESCO.ORDERLINE1-866-210-9251E-MAILnewcasting1998gmail.comCUTANDSAVETOFILECylinderBlocksCrankshaftsCamshaftsGM6.5truckvan.......................................1185eaCummins3.94BTOEM....................................950eaCummins5.96BT.............................................995eaCummins8.36CT...........................................1795eaCaterpillar3306DI..........................................2780eaCummins4BT....................................................575eaCummins6CT8.3..............................................780eaCummins6BT5.9..............................................695eaCaterpillar3306.................................................998eaCummins3.9.....................................................158eaCummins5.9.....................................................138eaCummins8.3.....................................................188eaCYLINDERHEADGM6.5TruckVan..................198eaChevy350Vortec......................228eaChrysler318360........................228eaChrysler3.9................................180eaCaterpillar3306PC8N1187......730eaCaterpillar3306DI8N6796.......730eaCaterpillar3406DINEW..........1580eaCaterpillar3406PCNEW.........1580eaCYLINDERHEADCaterpillar3304PCDI...............580eaJeep4.0331..........................375eaFord4.0EarlyLate...................138eaLONGBLOCKCummins5.9OEM..................5980eaCummins3.94BTOEM...........3980eaCummins8.36CTOEM...........6980eaCONNECTINGRODCummins5.93.96BT4BT...........68eaCummins8.36CT.......................86eaGM6.5NEW.................................55eaOILCOOLERCummins3.9................................98eaCummins5.9..............................108eaCummins8.3..............................138eaGASKETKITCummins3.9UpperKitOEM......88setCummins3.9LowerKitOEM.....88setCummins5.9UpperKitOEM......98setCummins5.9LowerKitOEM.....95setCummins8.3UpperKitOEM....128setCummins8.3LowerKitOEM...108setCALLFORCOMPLETEPRICELIST.NEW AERAwelcomesnewmembersACTIVEMWMotorsportsCaleraALJeffsAutoMachineBryantARRoadMachineryCoPhoenixAZMachweldShopServicesBrawleyCAHonestEngineCostaMesaCARaysEngineMachineEurekaCAVacaValleyAutoPartsFairfieldCAMcBrideCrankshaftMachiningLLCFresnoCADieselMachineWorksLosAngelesCAMountainHighPerformanceArvadaCOSoutheastPowerSystemsFortMyersFLCarquestAutoPartsLakeworthFLFranksEngineRebuildingPuntaGordaFLMikesTransmissionConvertersCantonILEastPeoriaPerformanceMachineEastPeoriaILMullvainMotorsportsIncEastPeoriaILTerryCummingsRacingEnginesBedfordINCoysDieselSpecialtiesLLCGonzalesLAModernAutomotivePerformanceCottageGroveMNMullerMachineWindomMNDSIPerformanceMachineRobertsMTBriggsMachineChapelHillNCHRTPerformanceDurhamNCBellsMachinePerformanceThomasvilleNCRTEngineMachineMinotNDOhioCatBroadviewHeightsOHSmithBrothersMotorsportsGroveportOHEcamRacingEnginesGlensidePAClarkEnterprisesIncGroveCityPAAllianceRemanufacturingIncPhiladelphiaPAMoonlightDieselIncNorthLoganUTSpeedPerformanceResearchLLCPortWashingtonWICharltonRepairSpartaWIASAPAutoCareWheelingWVPowerhouseEngineWarragulVICAUSTRALIADieselTechTruckRepairLtdEdmontonABCANADAFraserEngineTechKapuskasingONCANADARectificadoraModernaCaliValleCOLOMBIARecticadoraLaHeroicaCartagenaBolivarCOLOMBIARectificadoraHYMMedellinCOLOMBIAHamiltonsIndustrialMachineShopMontegoBayStJamesJAMAICARectificacionesMorenoApatzinganMichoacanMEXICOFranklinEngineeringServicesLtdPukekoheNEWZEALANDASSOCIATECimarronEngineComponentsSanDiegoCAModalSoftwareCorporationVisaliaCAHighwayandHeavyPartsMidlandMICarTuneAutomotiveServiceButteMTTMPPartsIncGrandPrairieTXSCHOOLWexfordMissaukeeCareerTechnicalCenterCadillacMIGreenvilleTechnicalCollegeGreenvilleSCCarrollShelbyAutomotiveTechnologyNTCCMountPleasantTXNortheastTexasCommunityCollegeMtPleasantTXSkagitValleyCollegeAutomotiveTechnologyMountVernonWAAERAsSteveFoxpromotedtoOperationsManagerAERAwouldliketoannouncethepromotionofSteveFoxtooperationsmanager.StevehastakenoverthisnewresponsibilityandleadstheAERAstaffatAERAheadquartersinCrystalLakeIllinois.HewillcontinuetoassisttheAERAtechnicalstaffandbeakeydevelopmentpersoninAERAsenginespecificationsoftwarePROSISPRO.StevehasanassociatedegreefromNorthwoodUniversityinMidlandMichiganandhasworkedforAERAsince1996.Hehasover28yearsofenginebuildingexperienceisanASEcertifiedMasterMachinistandanAERACertifiedMachinist.StevealsoracesNHRASuperCompserieswherehepilotsa565cubicinchBigBlockChevydragster.SteveismarriedtoEvaFoxandhastwochildrenAndrewandHaley.IInmemoryofJohnHarterSadnewsonthepassingofalongtimeindustryfriend.JohnHarterofHernandoMiss.passedawayonJanuary12015.Johnwasawell-likedpersonwithanincrediblesenseofhumor.JohnworkedinourindustrythroughouthiscareerhavingworkedforDanaCorp.RottlerandSunnen.IfyouknewJohnyouprobablyhadtheopportunitytotastehisfamousBBQsauce.HeissurvivedbyhiswifeGingerandfourchildren.Oursincerecondolencestoallhisfriendsandfamily.IIindustrynewscalendarJANUARY26HEAVYDUTYREMANUFACTURINGGROUPSUMMITLasVegasNVJANUARY26-29HEAVYDUTYAFTERMARKETWEEKLasVegasNVFEBRUARY14-15RACEPERFORMANCEEXPOPheasantRunResortSt.CharlesILMARCH5-7WORKTRUCKSHOWIndianaConventionCenterIndianapolisINAPRIL24-26AUTOMECHANIKAMcCormickCenterChicagoILJUNE14-16REMATECSHOWAmsterdamRAIExhibitionandConventionCentreAmsterdamTheNetherlandsNOV4-6AAPEXSHOWSandsConventionCenterLasVegasNVNOV4-7SEMASHOWLasVegasConventionCenterLasVegasNVDEC10-12PRISHOWIndianaConventionCenterIndianapolisIN6JAN-MAR2015engineprofessional www.engineprofessional.com7 8JAN-MAR2015engineprofessionalTedHughesnamedAIAYoungExecutiveoftheYearTedHughesheadofmarketingforMAHLEAftermarketInc.wasnamedthe2014AIAYoungExecutiveoftheYear.ThoughHugheshasworkedforthesamecompanysincethebeginningofhiscareerintheautocareindustryin2000multipleacquisitionsanddivestitureshaveprovidedmanydifferentexperiencesfromwhichtodrawinhiscurrentroleasheadofmarketing.Hughesassumedthemarketingbrandmanagerroletwoyearsafterbeginningasanentry-levelmarketingprofessionalwithDanaCorporation.DrawingknowledgefromindustryinfluenceslikeJerryMcCabeJohnWashbishMaxDullandScottHowathelearnedthatdevelopinghisownstylewashispathtosuccess.HoweverHughesbelievesthathisteamdeservesallofthecreditfortheaccomplishedgoalsandcompletedobjectives.Hughesbelievesthisindustryhasexperiencedmanychangesthroughoutthepast15yearsandthatunprecedentedchallengesfortodaysmanufacturersprovidenewopportunitieesforsuccess.Presentingfreshideasthatchallengeotherstolookatthingsinadifferentwayiscoretohisstyle.SinceMAHLEacquiredtheenginepartsdivisionfromDanain2007andformedMAHLECleviteInc.nowMAHLEAftermarketInc.histrackrecordformanagingbudgetsandcreatingandimplementingdynamicmarketingstrategiespresentsauniqueopportunityforMAHLEtocontinueonthepathofsuccess.IHastingsManufacturinglaunchesupdatedbrandHastingsManufacturingCompanyhasrecentlylaunchedanupdatedcorporatelogoinpreparationfortheir100thanniversary.Theupdatedlogoreflectstheirglobalreachandforwardthinkingwhilemaintainingitsrichhistoryforthepast100years.Whilethelogoistakingonamoremodernlooksomethingswillremainthesamesuchastheirblueandgoldcolors.TheirbelovedToughGuywillremainontheboxbutwithafreshnewlook.Theyhavealsoaddeda100-yearsealtocelebratetheiranniversary.Hastingssetboxeshavealsobeenre-designedforacleanerandmoremodernlook.AllofthiswasdesignedbyDDMMarketingCommunicationswithinputfromHastingsemployeesandcustomers.HastingsManufacturingCompanydesignsandmanufacturespistonringsfortheworldwideenginemanufacturingandserviceindustries.Formoreinformationgotowww.hastingsmfg.com.IIindustrynewsSubmitapressreleaseIfyouwouldliketosubmityournewproductserviceorotherindustrynewsforreviewbyoureditorspleaseemaildaveaera.org. 10JAN-MAR2015engineprofessionalBYJIMRICKOFFManyindustriesassociationspublicationssportsteamsetc.haveawardsforoutstandingperformancescontributionsandserviceintheirrespectiveprofessions.OurindustryisnodifferentorisitIllarguethatitisdifferentinthatwehaveoneveryprestigiousawardthatisntgivenallthatoftenandhasbeeninexistencefor58yearsinanindustrythathasonlybeenaroundforalittleover90years.MaybeImabitbiasedbutIbelievethisawardisveryspecialbecauseourindustryisntfilledwithabunchoffrivolousawards.Ourindustrywasfoundedbypioneerswhohadavisiontheycouldfixmaintainandrebuildinternalcombustionenginesandbringvaluetoamarket.AndIdontusethewordpioneerlightlytheOEswantednothingtodowithourpioneersandtheirmissiontorebuildinternalcombustionengines.ExtendinglifeintoengineswassomethingtheOEsviewednegatively.Ourpioneerskepttheirvisionandwowwevecomealongwayfromourportablein-blockcrankshaftgrindersandportablecylinderboringbarstoourCNCverticalmillsCBNsurfacersthreeanglevalveseatprofilecuttingsystemsanddiamondhones.Nottoforgettheadvancementofouraftermarketpartssuppliersandalloftheinnovativeproductstheyhaveintroducedtoourmarketaswell.Weworkinagreatindustrywithalotofveryresourcefulpeopleandtrueinnovators.WeneedtorecognizethosewhohavehelpedusadvanceandIwouldliketotellyouabitaboutourindustryawardthatdoesjustthat.TheCharlesW.YountAwardisnamedafterthelong-timesupporterofAERAwhosenamebearstheaward.Thisawardisgivenforrecognitionofoutstandingservicetoourindustry.ThefirstawardgivenforoutstandingservicewasgivenonJune41956toCharlesW.YountthefounderofEagleMachineCompanyinIndianapolisIndiana.HeservedaspresidentofAERAfrom1926to1927.FormanyyearsCharlesservedastreasurerofAERA.HoweverthenameoftheawardwasnotofficiallytheCharlesW.YountawarduntilitwasgivenonMay201959toRobertG.Pattersonanactivememberandpart-timeAERAstaffexecutive.AtthistimetheawardwasnamedafterCharlesW.YountandhasremainedtheYountAwardeversince.Thisawardhasonlybeengiven24timessinceitsinception.ToreceivethisawardthecandidatemustbenominatedbyapreviouswinneroftheCharlesW.YountAwardandrecommendedtotheExecutiveCommitteeofAERAforapproval.IwashonoredthispastOctobertopresentthisawardtoits24threcipientatanindustryfunctioninSeattleWashington.InallhonestyIcantthinkofapersonmoredeservingtoreceivethisawardforlongoutstandingservicetoourindustry.Thispersonisverymuchrespectedbyourassociationandindustryasawhole.Heisatruepioneerinmachinetoolmanufacturingforourindustryandhasgivengreatlytoourassociationwithhisgenerosityshowntowardsourcharitable501C3foundationnamedEREFEngineRebuildersEducationalFoundation.DonRottlerofRottlerManufacturinginKentWashingtonwasnamedthe24threcipientofthisprestigiousaward.Donhasbeendesigningequipmentfortheenginerebuildingindustryinhisfamilysbusinessthatwasstartedbyhisfatherbackin1923.DesigningequipmentwasarealpassionforDonheverymuchenjoyedflyingthroughouttheUnitedStatesvisitingallkindsofcustomersmeetingfacetofacetoidentifytheneedsofabroadmarket.DonrefinedthebestideasfromenginebuildersworldwideandAERApresentsprestigiousCharlesW.YountAwardtoDonRottlerDonRottlerpicturedleftspeakstothecrowdafterheacceptedtheCharlesW.YountawardpresentedbyAERAPresidentJimRickoffpicturedbelowatTheMuseumofFlightinSeattleWashingtonduringtheRottlerOpenHouselastOctober. broughtthemhometocreatemachinesbasedonthefeedbackreceivedfromthesecustomers.DonRottlertookoveraspresidentofRottlerManufacturinginthelate1950s.AtthattimeRottlerwasverysmallwithjustfiveemployees.DonRottlerwastheinnovatorthatcreatedanddesignedthefloat-typeboringmachinegreatlyenhancingproductivityandblockmachiningaccuracy.Floatheadstylemachineswereverycostlyduringthattimeperiodascomparedtothetypicalportableboringmachine.PopularitysoaredwhenthemarketembracedtheefficiencyandeaseofuseoftheinnovativeRottlerfloatingheadasproductivityeasilyjustifiedthepricedifferential.Floatingheadstylemachineshavebecometheindustrystandardbecauseitseaseofuseandproductivity.ThesamebasicconceptsdevelopedbyDonRottleryearsagoarestillusedtoday.Inthemid-70sDoncreatedthefirstRottlercylinderhoningmachine.DonalsodesignedthefirstmachinetouseCBNtoolingtoboreandsurfaceengines.Intheearly80sDoncreatedtheF80BoringandSurfacingmachines.Thismachineradicallychangedthespeedwithwhichdieselengineblocksweremachined.ThroughoutthetimeperiodDonandhisdesignteamcreatedmanyfixturingsystemstoenhancetheproductivityandqualityoftheenginerebuildersproduct.Rottlermachineshavebecomearecognizednameworldwidefortopqualitymachinetools.TodayDoncontinuestoprovideinnovativeideasthatareintegratedintonewmachinescreatedbytheRottlerdesignteam.ThecompanyisnowheadedbyDonssonAndyandlookstocontinuethesuccessformanyyearstocome.AERAwishestocongratulateDonRottleronhisrecognitionandwishhiscompanythebestinthefuture.IfyouwouldliketonominatesomeonefortheCharlesW.Yountawardpleasecontactoneofthepastrecipientsandgivethemyourrecommendation.Weneedtorecognizethesepioneersourindustryistrulyabetterplacebecauseoftheirvision.Iwww.engineprofessional.com11CharlesW.YountAwardRecipientsMay201959TheFamilyofRobertG.PattersonMay171961JohnC.RogersMay231962HarryA.TorgisMay231967J.LeonardLoveJune111968J.RayRileyMay111971WilliamHedgesMay231972GeorgeW.YountMay181973JamesH.TemplinMay211974EverettWarnerJune11979AlbertJ.BlairJune181981HansW.FellbergJune181981TimLipschultzOct.81983LaRueM.LundinJune191986RichardE.NewmanJune171987ThomasL.LandJune221989GeorgeR.SotskyJune181992ThomasH.LipschultzJune171993RichardHartmannJune161995BarryE.SoltzApril301999DennisTerrillApril282005JaniceE.JuhlDec.12007ScottWichlaczSep.302011BillMcKnightOct.172014DonRottlerRottlermachineshavebecomearecognizednameworldwidefortopqualitymachinetools. 12JAN-MAR2015engineprofessionalIn1991Fordintroducedthe4.6LOHCV-8commonlyreferredtoastheModularFordV-8.IthadforthetimearevolutionarynewheadgasketdesigncalledMLS.Priortothatmostheadgasketsweresteelcoredesignswithsomesortofgasketpaperattachedtothecoresothiswasabigchangefortheenginerepairrebuildingindustry.BillMcKnightMAHLEAftermarketstrainingmanagerremembersgoingaroundthecountrydoingseminarsforcustomersandthehottopicbackthenwasMLSgasketsandhowtoinsuretheysealedproperly.Bythelate90svirtuallyeveryautomotiveengineintheworldhadMLSheadgasketsandnowin2014wehardlyevergivethemasecondthought.McKnightshareswithustheinsidestoryonMLSgasketsMLSactuallystandsforMulti-LayeredSteelanddescribestheconstructionofthegasket.MLSgasketsusuallyhaveatleastthreelayers.Thetwoactivelayersandthepassivelayerareshownintheillustrationbelow.Theinnerlayersometimesreferredtoasapassivelayerservesthreegeneralpurposes.Itprovidesameansofgettingtheproperthicknessforthegasketitprovidesalayerforthetopandbottomlayerstopushagainstandinmostdesignsprovidesextrathicknessaroundthecylindertoinsuregoodcombustionseal.ThatextrathicknessoftenreferredtoasastoppercanbeassimpleasafoldedoverlayeroralaserweldedthicknessFel-ProsLaserweldprocessorinthecasetheBugattiVeyronsomethingcalledtheWavestopperdesign.continuedMULTI-LAYEREDSTEELGASKETSBYBILLMcKNIGHTTheevolutionofcoatingsshownontheBMWgasketaboveandthe4.6LFordgasketsbelow.Youcanplainlyseethemultipleconcentricrings. www.engineprofessional.com13GoodsonIntroducesNewProductsForEngineProfessionals156GalewskiDr.WinonaMN1-800-533-8010507-452-1830www.goodson.comGetaFREE2015GoodsonCatalogCall1-800-533-8010andaskforCatalogTEP1BrowsethecatalogonlineRequestacopyonlineatwww.goodson.comorDownloadacopyforimmediateviewing70thAnniversary1945-2015ToolsSuppliesforEngineBuildersLookingforKwik-WayValveSeatGrindingToolsandEquipmentLooknofurtherGoodsonistheexclusivemanufactureranddistributorofKwik-WayValveSeatGrindingToolsSupplies.WevetakeneverythingyoudependontoproducequalityvalveseatsandmadethemevenbetterButGoodsondidntstopthere.GoodsonhasalsoworkedwithsomeofthegreatestinnovatorsintheautomotiveaftermarkettodeveloptheBlackSmokelineofseatcutterbladeshoningstonesforRottlermachinesheavydutyhonemandrelsandmuchmoreGetthenewcatalogtodaytoseethefullselectionofnewproducts37.594R3.0mm1.50mm15507590R1.0mm1.19mm.81mm5.08mm1.40mm3.00mm20944.0mmR8.0mm ThispatenteddesignbyVictorReinzusesraisedembossedconcentricringsaroundthecombustionchamber.Eachringactsasastopperbutprovidesavariablesealingbasedupontheloadontheheadgasket.DevelopedfortheworldsfastestandmostpowerfulproductioncarVictorReinzhasusedthedesignforperformancegasketsfittingthe4.6LFordandthe6.6LDURAMAX.Theouterlayersreferredtoasactivelayersaretemperedstainlesssteel.Theyhaveraisedbeadscalledembossmentssurroundingthecriticalsealingareas.ThiswouldbeofcoursethecombustionopeningthewaterjacketopeningsandinthecaseofOHCenginestheoilpassagefromtheblocktothehead.Whenyouinstalledtheheadontheengineandstarttotightenallthefastenersakaheadboltsthespringsteelbeadsoftheactivelayersresistflatteningoutandpushbackagainstthepassivelayerononesideandtheheadorblockontheother.Itisthisspringpressurethatcreatesthesealandalsogivestheabilityforthegaskettokeepsealingastheenginerunsandtheheadsactuallyliftofftheblock.Werespeakingofsealingcombustionpressuresof1200psiormoreheresothisisabigdeal.Intheheadgasketbusinesswerefertothisascylinderheadlift-offandcruisingdownthehighwaythisisgoingonathousandtimesaminutetheentiretimeyouaredrivingrackingupmillionsofcyclesoverthelifeoftheengineTheMLSgasketrelaxesandcompresseseverytimethisoccurs.Makethestainlesssteeltoosoftandthegasketfails.Makethesteeltoohardandthegasketcracksandfails.Ittakesaskilledgasketcompanytogetitrighteverytime.NowifourenginehadnocoolantandnooilthatneededtopassthroughtheheadgasketwecouldstopourconversationrightnowBecausethatsnotthecasewehaveanotherenhancementtoMLSheadgasketsthatisabsolutelyrequiredtomakethemwork.Thatwouldberubbercoatings.NowcallingthesecoatingsrubberiskindalikecallingLeBronJamesabasketballplayerNeithertermgivesjusticetowhatweretalkingabout.Ourrubberisactuallycarefullycompoundedcarefullytestedskillfullyappliedpolymercoating.ItgivesthegaskettheabilitytosealfluidsperfectlythroughthemillionsofcycleswementionedaboveWhenthefirstgenerationofMLSgasketshitthemarketconcernwaswide-spreadbecausethesurfacefinishoftheheadandblockhadtobeliterallyassmoothasasheetofglassinorderforthegasketstoseal.Manymachineshopsdidnthaveequipmenttogetthedesiredfinishandevenfewershopshadameasuringtooltomeasurethefinish.Whatwasdrivingthisfinishrequirementwasthequalityoftheearlypolymercoatingsusedonthegaskets.Raof10micro-inchaverageroughroughnessof10millionthsofaninchwaswhatwewerelookingforandthatwasliterallyglasssmoothThankgoodnesstechnologyhasimprovedsince1991Todaywecantoleratereadingsof40-80RAforgoodMLSsealduetotallytoimprovedelastomersThisiswellwithintherangeofmostgoodmachineshops.Iftheheadandblockaresmoothflatandcleanyourereadytoinstalltheheadgasket.Pleasedonteventhinkofapplyinganythingtothegaskettoimprovetheseal.AtVictorReinzifasealantiseverneededforagasketitllbeincludedintheboxwiththegasket.Someengineshavealeftandrightheadgasketandafewhaveatopandbottomorfrontandbacksolookyoursovercarefully.Layyourgasketon14JAN-MAR2015engineprofessionalMLSGASKETSBYBILLMcKNIGHTYoucanseeembossmentsforboththecombustioncylindersandthecoolantpassagesonthis6.0LForddieselheadgasket.ThisAJUSAheadgasketillustratesthefullsurfaceapplicationofthepolymercoating.Contrastthattotheselectivesilkscreeningmethodusedonthe4.6LFordshownearlier.Theresnotarightorwrongmethodjustmeanstoanend PERFORMANCEENGINEBEARINGSwww.engineprofessional.com15 16JAN-MAR2015engineprofessionalMLSGASKETSBYBILLMcKNIGHTtheblockmakingsurethelocatingdowelsareintheblockandthatthegasketslipsdownoverthem.Carefullysettheheaddownonthegasketagainmakingsureiffitsoverthelocatingdowels.WehaveenginesliketheDURAMAXthathavedifferentdoweldiametersfordifferentyearssoalwaysmakesureyoucheckthedetailsAtthisstageyourereadytoinstallthefastenersakaheadboltsandtightenthemtothefactoryspecifications.WemightdigresshereforaminuteandmentionthataboutthesametimethatMLSgasketscamealongsodidtorque-to-yieldfasteners.Alongwithtorque-to-yieldfastenerscametheassociatedtechnologyoftorque-turn-totightenanewmeansofinsuringwehadthedesiredheadboltload.HereisashortversionofwhatallthismeansBasicallysteelheadboltsareelastic.Thinkofthemkindoflikearubberband.Youstretchthemoutandtheywanttospringback.Itsthatelastictensionthatcreatestheloadthatcompressesthegasketandkeepsitcompressedastheenginerunstemperatureschangeandtheheadtriestoliftofftheblock.NoneofthiswasnewWhatwasnewwasengineersrecognizedthattheboltshadayieldpointwheretheybecamepermanentlystretched.Tighteningthemtojustshyofthispointgavemaximumloadonthegasketagoodthing.Gettingtheboltstojustshyofyieldrequiredamoreprecisemeansoftighteningthanjustmeasuringresistanceofturnwithatorquewrenchhencetheintroductionoftorque-turn-totightenwherewearemeasuringtheangleofturntotightenthefasteners.Thinkofhowmanytimestheengineinthevehiclehasbeenstarteddrivenstoppedcooledandthere-started.Againeachofthesecyclescausesthermalexpansionoftheheadblockandheadbolts.Thenthinkhowmanytimesthecylinderhasfiredcreatingheadlift-offwhichcausesmechanicalstretchingoftheheadbolts.NowconsiderthelaborinvolvedtoRRacylinderheadforaboltfastenerfailure.NotreplacingcylinderheadboltsisaninvitationforproblemsdowntheroadIBillMcKnighthasworkedforMAHLECleviteIncforover30years.HerantheenginerebuildingtrainingprovidedbyDanafor22yearsthenmovedtoCleviteasdirectoroftraining.OvertheyearsatCleviteheservedasdirectorofmarketingmotorsportssalesmanagementandinhiscurrentpositionasteamleaderoftraining.HehasamastersdegreeineducationandhasservedontheboardofdirectorsofAERAprogramcommitteeofPERAandasatechnicalpresenteratbothAERAandPERA.HesoftenfoundattheracetrackespeciallyNHRAandNASCAReventsandlovesenginesthatmakelotsofpower www.engineprofessional.com17 AbouttheProgramEachprogramisanonlineself-pacedcoursewithuptooneyeartocomplete.GaryLewisbookAutomotiveMachiningEngineRepairwillbeincludedwiththe150registrationfee.Everythingatechnicianwillneediscontainedintheprogramwithvideoclipsandsupplementalreadingsatkeylocationswithintheprogram.Thebookwillbeusedasasyllabuswhennotonline.Eachchapterwillbefollowedbyamultiplechoicetest.TherewillbeafinalexamforeachcertificationCylinderHeadandorEngineMachinist.Formoreinformationgotowww.aera.orgtrainingCylinderHeadandMachinistCertificateProgramAERAoffersacomprehensiveonlinetrainingprogramnotjustatestleadingtodiploma-qualitycertificatesinCylinderHeadsandEngineMachinist.Technicianswhosuccessfullyearneithercertificatewillholdproofthattheyhaveaprofessionalunderstandingofautomotivemachiningfundamentalsmeasuringtoolsshopsafetyfastenersenginetheoryenginediagnosisenginedisassemblycomponentcleaninginspectioncrackdetectionandrepaircomponentreconditioningandcylinderheadandblockresurfacing.18JAN-MAR2015engineprofessionalAsagraduateoftheSchoolofAutomotiveMachinistsIamveryfamiliarwiththesubjectsofenginetheorymachiningandblueprinting.TheAERAcourseformachinistshasaddedevenmoretomypersonalknowledgewhereIcanapplycommonpracticesandadvancedknowledgeatworkonadailybasistocustomerengines.ThroughoutthecoursethegreatestsatisfactionIgainedwassharingmyknowledgewithfellowmachinistsandcarenthusiasts.Havingtheknowledgetoexpressyourselfbecauseyouunderstandthedynamicsofainternalcombustionengineandthenecessarystepstorepairandorimproveitsperformancehasexpandedmyconfidenceandequippedmetocontributemore.OveralltheAERAcourseformachinistsisagoodchallenge.IlearnedagreatdealthroughoutthecourseandAutomotiveMachiningandEngineRepairbyGaryLewiswilladdtomylibraryofbooksandmanualstoserveasreferenceandstudymaterialforyearstocome.ChrisGudaRegistertodayToregisterfortheprogramorifyouhaveanyquestionspleasecontactKarenTendering815-526-7600ext.202emailkarenaera.org www.engineprofessional.com19AERAONLINETRAININGREGISTRATIONFORMNAMECOMPANYNAMEAERAIDNUMBERCOMPANYADDRESSCITYSTATEZIPPHONEE-MAILADDRESSREQUIREDSIGNEDBYFEES150perpersonINCLUDESGaryLewisbookI2-4PEOPLEfromthesameshop.................................................................125perpersonI5-9PEOPLEfromthesameshop.................................................................100perpersonI10PEOPLEfromthesameshop..................................................................75perpersonEachpersonregisteredwillreceiveaGaryLewisbook.PleaselistadditionalnamesbelowTOTALAMOUNTENCLOSEDICHECKPLEASEMAKEPAYABLETOAERA.CREDITCARDIVISAIMASTERCARDIDISCOVERIAMERICANEXPRESSCARDNUMBEREXPIRATIONMMYY3-DIGITCSSCARDHOLDERNAMECARDHOLDERSIGNATUREIfpayingbycreditcardpleasefaxcompletedregistrationformtoAERA.toll-freefax888-329-2372OrmailyourcompletedformwithpaymenttoAERA500CoventryLaneSuite180CrystalLakeIL60014.CallAERAtoll-freeifyouhaveanyquestions888-326-2372ordirectat815-526-7600. 20JAN-MAR2015engineprofessionalInearly2013RoushYatesEnginesstartedthedesignanddevelopmentofanewaluminumV-8engineplatformtheRY45.ThefoundationforthenewRY45aluminumsmallblockwasthehighlysuccessfulFordFR9developedbyFordandRoushYatesEnginesforuseinNASCARracing.AllthecastingandlayoutadvantagesoftheFR9comparedtothecurrentFordbasedaluminumsmallblockswereincorporated.ThefirstaspectofanyprojectpursuedatRoushYatesEnginesistodefinetheparametersoftheproject.ThefollowingdesignparameterswereoutlinedfortheRY45UseFR9componentswhereapplicableRoushYatesEngineshasdevelopedtheFR9engineforNASCARandARCAseriesracingforover5yearsandhasawealthofknowledgeabouttheengineplatform.TheenginelayoutandcomponentsareaperfectstartingpointfortheRY45.60mmcamshaftjournalsThiscamshaftsizeallowsforaverystiffcamshaftinbothtorsionalandbendingwhichinturnimprovesvalvetrainstability.ThecamshaftcoresfortheFR9developedforrollerandflattappetlifterscanbeutilizedtohelpcutcost.Cast-incamshafttunnelWiththecastincamshafttunnelthetopendoftheenginecanbeseparatedfromthecrankcasetoaideinthecontrolofoilscavengingandwindagelosses.Thecamshafttunnelalsoneedstohavetheoptionofdrainingtothecrankcaseforapplicationsthatdonotneedatopendoilscavengesystem.6.150camshafttocrankshaftcenterlineThiscamshaftheightisusedontheFR9sothecamshaftdrivesystemcanbeutilizedtocutcost.Withtheraisedcamshaftheightthepushrodswillbeshorterandstiffertoaideinvalvetrainstability.4.1504.250boresizesThesetwoboresizesarecommonlyusedandhavepistonsandringsavailableontheshelffromvendors.Anyborebetweenthesecanalsobeaccommodatedwithadifferentcylinderliner.Accommodatea4.00strodewitha2.00rodpinThisistheupperlimitofstrokeutilizedonthecurrentRoushYatesEnginesdirtlatemodelandoffroadtruckengines.Withthisstrokeslightlyover450C.I.D.canbeachievedwiththelargerboreoption.4.500borespacingInordertousetheFR9cylinderheadcastingthisborespacingneedstobeutilized.Thisalsoallowsforenoughspacetopackagethelargerboresizeoption.9.0009.200deckheightThe9.000deckheightisusedontheFR9sopistonsconnectingrodsandcrankshaftcanbetransferredinthatconfiguration.The9.200deckheighthasbeenutilizedinthedirtlatemodelandoffroadtruckenginesbuildbyRoushYatesEngines.2.252.75mainjournalsizeThe2.25JournalsizeallowstheuseofaFR9crankshaft.Withthe4.00strokeand2.00pinthe2.75mainwasneededtoachievetheoverlaponthecrankshaftRoushYatesEnginesandthecrankshaftvendorsdeemednecessaryforpredictedtoquelevels.SideandFrontengineplatemountingTomaketheengineasversatileaspossiblesidemountsareneededalongwiththefrontengineplatemounts.Bothmountingstyleshavebeenusedindirtlatemodeloffroadtruckdragraceandstreetapplication.BlockmaterialA357-T6ThismaterialisusedforthemajorityofRoushYatesEnginesmotorsportsaluminumcastingapplications.Ithasverygoodmechanicalpropertiesandverygoodmachinability.H.I.P.capabilityIfanapplicationwasfoundthatneededtheextrastrengthandfatiguepropertiesgainedwithhotisostaticpressingH.I.P.thecapabilityneedstobedesignedintothecastingtool.DuringtheH.I.P.processcastingsaresubjectedtoelevatedpressureandtemperatureforaspecifiedperiodoftime.Thisallowssurroundingmaterialtoflowintointernalporestoeliminatethevoidsandincreasethematerialdensity.Pressureisappliedbyaninertgassothecastingcompositionisnotaffected.IntegratedpistoncoolingWiththeoilpassagescontainedintheblocknoexternaloillinesareneeded.Thissimplifiesengineassemblyandlowersthecostofthepistoncoolingsystem.IntegratedvalvespringcoolingWiththeoilpassagesmachinedintotheblockandheadthissimplifiesandlowerstheenginebuildcost.Thevalvescoverdonotneedanoilsupplyandtherearenooillinestoremovewhenvalvecoversareremoved.ImprovedwaterflowandcoolingThecoolingsystemontheFR9hashadanimmenseamountofoptimizationworkdonewithCFDcomputationalfluiddynamicsandfieldtesting.ThisfoundationisthebeststartingpointfortheimprovedcoolingsystemofRY45.ComponentSupplierintegrationTomakethisengineplatformasaccessibleaspossibletobuildfortheendRY45SeriesDesignOverviewBYDANKEENAN www.engineprofessional.com21 usermultiplevendorsareneededforcomponents.Theincorporationofvendorsintotheearlystagesofthedesignallowsthemtomakepartsavailablefortheengine.ThisallowstheendusertosourceRY45componentsfromamultitudeofvendorsandgivesthemchoicesbasedonapplicationandcost.Withthebasicdesignparametersdefinedthelayoutoftheenginebegins.AllenginecomponentsaredesignedandanalyzedusingCAEtoolsatRYE.Thisincludes3DmodelingCFDcomputationalfluiddynamicsandFEAfiniteelementanalysissoftware.Tostartthisprocessaskeletonoftheengineismadeinthe3Dmodelingsoftware.Thisisbasicallya3-Dmodelofallthereferenceholesandplanersurfacesoftheengineforexampleheadboltsmainboltscamshaftcenterlinecrankshaftcenterlineliftersfrontfaceofblockrearfaceofblockdecksetc.TheskeletoncanbeobservedinFigure1.Basiccalculationsaredoneatthistimetodetermineaspectsliketheminimum22JAN-MAR2015engineprofessionalRY45SERIESDESIGNOVERVIEWBYDANKEENANTiredofgivingupprotstoonlinecompetitorsOrderafreeENGINEPROtimingsetcatalogfromourwebsite.www.goenginepro.comENGINEPROBRANDENGINEPRODUCTSredotoonlOtimingsetsarENGINEPRgivingecompeailablveaOtimingsetsarpprotsteeENGINEPRderafrrO.tserpargetbettedivorpremotsucptenretnillab-wolyithENGINEPROWyitiswithallENGINEPROparasthewthaToughengineprthrOeeENGINEPRofitserprougetbetturcus.tspardemosllatsnirosecirpetvthaoudonywithallENGINEPReyessionalslikofoughengineprtaloatimingsetceeENGINEPRderafrrOENGINPRBomourwgfrtaloOeeENGINEPRANDENGIPRNDUcontinued1 THELEADERINHEAVY-DUTYTOOLSANDSUPPLIESCALL1-800-527-7604www.regismanufacturing.comREGISMFG.POBox152900DallasTX75315-2900800-527-7604214-421-5171Fax800-535-8414214-565-1704DieselValveGuideDriversRemoversandInstallersApplicationspecificexpandedsizesincludingnewsizesforCumminsISXandDetroit60-series.Calltodaytorequestthenew2015catalogfilledwithhundredsofnewproductsYellowMagnumValveSeatWheelsforSiouxandKwik-WayGrindandfinishheavy-dutydieselorhardseatsinjustonestepExtra-longSolidTaperedValveGuidePilotsExpandedsizestocoverDetroitCatandCumminsISX.TS-381TS-382RL-700DAValveSpringCompressorforHeavy-dutyApplicationsLarge11x1312frameincludesRL-22CoffsetjawsandRL-CCrecessedjawsforCatandCummins.RL-DETjawsforDetroitsoldseparately.PowderBlueMagnumValveRefacerWheelsIdealfordieselandtitaniumvalves.K-660DTfits7Sioux.K-760DTfits7Kwik-WayRottler.K-8260DTfits8IDLSunnen.www.engineprofessional.com23 24JAN-MAR2015engineprofessionalRY45SERIESDESIGNOVERVIEWBYDANKEENANthreadengagementneededintheblocktoensurethreadintegrity.Thegoalistohavethestudyieldbeforethethreadsintheblockaredamagedastudiseasiertoreplacethanthethreadsintheblock.Thisalsodefinesthestudbosssizesinthecasting.Figure2isabasicthreadlengthcalculation.Withthebasiccalculationsdonethedesignofthecoresforthecastingisstarted.Eachcoreisdesignedwiththerequireddraftandcorereliefsdependingonwherethecoreislocatedandwhatsupportsareneeded.Figure3showsthefirstrevisionoftheblockwatercore.Atthetopthecoresupportsalsoactaswaterpassagesandonthesidesthecoresupportsturnintoexpansionplugorfreezeplugholes.Oncethecoremodelsarecompletedtheyarebroughttogetherinacoreboxassembly.Thismodelrepresentswhattheactualcoreboxassemblylookslike.Thismodelisusedtoobservetheinteractionbetweenallthecores.Thecoreboxassemblyisusedlikeintherealcastingprocesstoproduceablockmodelinthecomputer.Thesoftwarefillsintheareasofthecoreboxassemblylikethemoltenaluminumwilltoproduceablockmodelcasting.ThecoreboxmodelandblockcastingmodelareshowninFigures4and5respectively.Atthispointthecastingmodelsaresenttothecastingvendorforanalysis.Thevendordoesmoldfillanalysistodesignthegatesandventing.Theyalsochecktoensurethereisadequatedraftandcoresupport.Thisisaniterativeprocessalongwiththerestoftheanalysistoarriveatthefinalblockdesign.245continued3 www.engineprofessional.com25 RY45SERIESDESIGNOVERVIEWBYDANKEENANWhilethecastingvendorisdoingtheinitialtooldesignthewaterjacketCFDisstartedtoanalyzethewaterflowintheengine.Bothpressureandvelocityarecalculatedtoensuretherearenotanyareasoflowpressurethatwillcausehotspotsduetoboiling.TheengineblockcylinderheadheadgasketandwatermanifoldarebroughtintotheCFDsoftwareandprepared.TheoperatingparametersofwaterflowrateinletsandoutletaredefinedandtheCFDsoftwarecalculatesthewatervelocityandpressurethroughouttheengine.Colorcodesareassignedbasedonthevalueredbeingthehighestandbluethelowestvalue.InFigure6theentirewaterjacketcanbeseenfromthetwowaterinletstothesinglewateroutatthetop.Theflowrateisinfluencedgreatlybythechoiceofradiatorhoselengthhosediameteretc.Thecalculationsaredoneatdifferentflowratestoensuretherearenoissuesacrosstherangeofpossiblewatersystems.ThearrayofcolorsareactuallyindividualparticlesthisiseasiertoseeinFigure7whichiszoomedinontherightsidewaterinletaroundcylinder1.Itcanbeobservedinthisfigurethewaterisnotmakingittowardstheinsideintakesideofthecylinderandisre-circulatingnearthedeck.Severalchangesweremadeintheheadgasketwaterholestochangetheratioofwaterthatisroutedtotheheadandaroundthecylinders.Awaterdiverterwasaddedtothecastingattheinletpointtodirectwatertowardstheintakesideofthecylinders.ThediverterinthemodelcanbeenseeninFigure8.TheCFDisrunagainwiththechangesandthewaterrecirculationaroundcylindernumberoneiscorrectedandthevelocityisimproved.EveryaspectofthewaterjacketisanalyzedwiththeCFDmodelinaniterativeprocesstomaximizetheefficiencyofthecoolingsystemoftheengine.SeeFigure9.Oncetheentirewaterjacketisoptimizedheadgasketmodelsanddrawingsaregeneratedandsenttothevendor.Acollaborativeeffortistakenwiththevendoronembossmentslayoutandgaskettypeinthiscaseamulti-layersteelgasketwithastopperringisdesignedandmanufactured.Figure10FiniteElementAnalysisFEAistheotherareawhereamajorityofanalysistimeisspent.UsingtheblockmodelthedataisimportedintotheFEAsoftwaretoset-upstudiestodeterminethestressanddistortionlevelsintheenginebasedonvariousoperatingconditions.Theexampleshownisthemaincapdistortionduetoclamploadandcylinderpressurewhenfiring.Theanalysisloadinputparametersaredefinedstudclamploaddowelpinpressandcylinderpressurealongwiththematerial26JAN-MAR2015engineprofessional678910 www.engineprofessional.com27propertiesofeachcomponent.TheFEAsoftwarecalculatesthestressanddistortionandassignsacolorforeachvaluewithredbeingthehighestandbluethelowest.Figure11showsthestressdistributionduetotheloadingonthemaincap.Thestresslevelsarehighernearthestudsduetotheclamploadofthenutcompressionthemaincap.Thestressdistributionintheboreisalsonon-uniformduetothecylinderpressureloading.Figure12issectionedatthemainstudcenterlinesandtheinternalstressesareobserved.Theresidualstressfromthepressfitonthedowelscannowbeobservedandthelocalizedstressinthemaincapduetostudclamploadaremoreevident.Thestressintheshankofthestudduetoinitialinstalledtorqueandcylinderpressureisalsovisible.Thedisplacementormovementisalsocalculatedandcanbestudiedinthesamewayasthestress.Firstonsurfaceofthemaincaptheninternallyviathesectionedmodel.Asexpectedthemaximumdistortioninthemaincapisinthedirectionoftheappliedcylinderpressureinthiscase150barrepresentedbythearrowatcrankshaftcenterline.Figure13Thesectionedmodelshowsthedistortionofthemaincapisuniformthroughoutthethicknessofthemaincap.Thetwoinnerstudshavedifferentlevelsofdistortionduetotheextraloadontheleftstudfromthecylinderpressure.Thesetypesofanalysisaredoneforallaspectsoftheenginetoensurethestressanddistortionlevelsarewithinthedesignlimits.Figure14AnychangesmadetotheblockmodelformtheCFDorFEAanalysislikethewaterdiverterarecommunicatedtothecastingvendor.Atthesametimethecastingvendorisrequestingchangesduetomolddesign.WhiletheFEAisongoingthemachiningdefinitionisunderwaysincethisisanintegralpartofthefinalcastingdesign.IntheexampleshowninFigure15onthefollowingpageapackagingstudyofthecrankcaseisdonetoensuretheprojectparametersofstrokepinsizeandpistoncoolingaremet.Thefirststepincreatingthepackagingmodelistodefinethecomponentsusedinthemodel.Inthiscaseapistonconnectingrodandcrankshaft11121314 weredesignedinconjunctionwiththevendorsandmodelsweregenerated.ThesecomponentsareusedwiththeblockmodeltogeneratethecrankcasesimulationmodelFigure16.Themodelreplicatesthemotionofthecranktrainandallowsthestudyofpartinteractionatvariouscrankshaftanglepositions.Thecomponentscanbesectionedtoallowacrosssectionviewoftheassemblyinthisexampletheengineissectionthoughthecylinderborecenterline.Inthefirstpositionthecrankshaftissetatbottomdeadcentertomeasuretheclearancebetweenthepistoncoolingjetandthepistonskirt.Atthispositionthelocationoftheoilstreamontheundersideofthepistonisrecorded.Theclearancebetweenthepistonskirtandcrankshaftcounterweightisalsochecked.ThenextcrankshaftpositionofnoteisbeforetopdeadcenterFigure17.Atthispositiontheclearancebetweenthepistoncoolingjetandconnectingrodismeasured.Theclearancefortherodboltoftheoppositeconnectingrodischeckedtothereliefmachiningatthebottomofthecylinderbore.Thelocationoftheoilstreamonthepistoncanalsobeobservedasithasmovedintothepinboxofthepiston.Thisisadvantageoustopinoilingviathedrillingatthetopoftherod.ThefinalcrankshaftpositionforthisstudyiswhentherodpinisstraightupFigure18.Atthispositiontheclearanceismeasuredbetweentheconnectingrodandthebottomofthecamshafttunnel.Aslightmachiningreliefiscutinthebottomofthecamshafttunneltoensurethetightestclearancecanbeusedversusacastsurface.28JAN-MAR2015engineprofessionalRY45SERIESDESIGNOVERVIEWBYDANKEENAN15161718 2014ElginIndustries.Allrightsreserved.FornearlyacenturytheworldspremierperformanceenginebuildersandstreetandracingenthusiastshavereliedontheElginbrandtoprovidethepowerandreliabilitytodominateracescaptureseasonchampionshipsandsecurebraggingrightsamongtheirfriendsandcompetitors.TheElginPROSTOCKadvantagecanbeseeninourexclusivedesignspremiummaterialsandtheunsurpassedprecisionandqualitybuiltintoeverypart.ThissameadvantagefueledoursuccesswiththeclassicElginPistonPinSpecialintheIndianapolis500anditcanbeseenonthousandsofasphaltanddirtovalsoff-roadcoursesandcityandcountryroadsacrossNorthAmerica.WhosaysU.S.-basedenginepartsmanufacturerscantcontinuetothriveintodaysglobalmarketplace1-800-323-6764saleselginind.comwww.elginind.comProvenPowerwithaFamilyTouchWhenyouchooseElginPROSTOCKyouregettingmorethanthemostsophisticatedproducttechnologiesavailableforyourvehicleyourewhoknowthatwhentheyhaveaquestionabouttheirpartorenginealltheyneedtodoiscall.leadershipbackintheearliestdaysofracinganditcontinuestodaythroughthededicationofthethirdgenerationoffamilyownership.ExperiencethedifferenceyourselfbycontactingyourperformancepartsproviderandaskingforElginPROSTOCK.Thenletthewinningandbraggingbegin.ElginPROSTOCK.Experiencethedifference.Bragabouttheresults.www.engineprofessional.com29 30JAN-MAR2015engineprofessionalRY45SERIESDESIGNOVERVIEWBYDANKEENANAsthemachiningdefinitionbecomesmoredefinedtherestoftheenginecomponentsarealsomodeledasneededforthevariouspackagingstudies.OnceallthepackagingstudiesaredoneacompleteengineassemblyiscreatedseeFigure19somepartsarehiddentoshowinternaldetails.Thismodelrepresentsallthepartsthatareusedinthefinalenginebuild.Thismodelisusedtostudytheinteractionofallthesystemstogether.Thisengineassemblyisalsousedtocreatethebillofmaterialsfortheenginealongwiththedesignofspecialtoolingandfixturing.Oncethefinalmachiningdefinitioniscompletedthemachinedblockmodeliscreatedfromtheblockcastingmodel.InFigure20themachinedsurfacesarehighlightedinblue.Allthemachinedaspectsoftheblockaredefinedinthismodel.Thismodelisusedtogeneratethemachiningprintfortheblock.Themachiningsupplierisbroughtinatthispointtoensuretheprintiscomprehensiveandconveysthedesiredmachiningprocess.Thisparticularprintcoversnine60x34pagestodefinealltheaspectoftheblockmachining.Figure21showspageoneoftheprintwhichusestheASMEY14.5dimensioningandtolerancingstandard.Thisprintindicates192021 www.engineprofessional.com31notonlythedetailsofalltheholesandsurfacesbutalsotheprocessinwhichtomachinetheblock.Theblockisfirstroughmachinedwiththenotcriticaltheseareaspectsthatdonotrequiretolerancesbelow-0.005featurescompleted.Themaincapsaretorquedinplacetoproperlypre-loadtheblockandthecriticaltighttolerancefeatureslikecylinderborescamshaftborelifterboresanddecksarefinished.Oncethemachiningmodelsanddrawingsareapprovedthecastingtoolandmachiningfixturesareordered.Theengineassemblyprintsaregeneratedfortheengineassembler.Thisallowsaccesstoallthepartnumbersandpartplacement.Figure22istheexplodedpartsviewoftheRY45blockassemblywithallthepartsincludedinaRY45blocksoldbyRoushYatesEngines.WhilealltheassemblyprintsaregettingfinishedandthetoolingisbeingmanufacturedarapidprototypeSLAblockisprintedinthe3DprinterFigure23.Theblocktakesapproximately84hourstoproduceand5hourstocleanandprocess.OncedonetheSLAblockis2223 RY45SERIESDESIGNOVERVIEWBYDANKEENANwithin0.010oftheactualmachinedblockinallaspects.Theactualmachinedblockwilltakecloseto14weekstoproducebythetimethecastingtrialsarefinishedandallthemachiningfixturesareaudited.TheSLAblockisusedtobuildthefirstmock-upenginetotestfitallthepartsfixturesandanyspecialtoolingrequiredtobuildtheengine.Figure24.Bythetimethemock-upbuildisfinishedacompleteengineisassembledwithfunctioningcranktrainfrontdriveandvalvetrain.Oncethemachinedblockarrivesthebenchtestingcanstart.TheblockhasalreadybeenfullyinspectedbythemachiningsupplierwithaCoordinateMeasuringMachineCMM.TheCMMusesaprobetomeasuresurfacesontheblockin3dimensionsandrecordsthelocationinXYandZcoordinates.OncetheCMMhasmeasuredalltherequiredsurfacescenterlinesandfacesareconstructedbytheCMMsoftware.BasedonthemachiningprinttheCMMsoftwaredoesthemathrequiredtodeterminethe32JAN-MAR2015engineprofessional24 www.engineprofessional.com33 RY45SERIESDESIGNOVERVIEWBYDANKEENANdistancebetweenallthefeaturesthathavebeenmeasured.TheCMMproducesareportshowingallthedimensionsandtolerancesontheblock.Theblockhasalsobeenpressurecheckedandwashed.SeeFigure25.Theonlyprepworkthatneedstobedoneishonethecylindersmainboreandlifterbushings.Theblockisfinalwashedandcamshaftbearingsareinstalled.Thefirstblockispreppedforthevalvetraintestrig.Thevalvetraintestrigallowsthevalvetraintobeactuatedlikeitwouldbeinafiringengine.Theflywheelfaceattherearofaspindlebasicallyacrankshaftminusthepinsandcounterweightsishookedtoanelectricmotor.Thecylinderheadsandvalvetrainareinstalledanddrivenliketheyareinafiringengineviathecamshaftbeltdrive.AlaserisusedtotrackthevalvemotionandisrecordedthroughouttheusableRPMrangeoftheengine.Thevalve34JAN-MAR2015engineprofessional25 AmericasLeadingInternationalTradeFairfortheAutomotiveIndustrytargetingTradeVisitorsfromtheUSCanadaApril24-262015McCormickPlaceWestChicagoILUSAIntroducingtheLargestU.S.TradeShowandTrainingEventforServiceandCollisionRepairShopOwnersandTechnicians.-Morethan8500qualiedbuyersandkeyinuencersfromtheautomotiveservicecollisionrepairandassociatedindustriesinattendance.-400exhibitingcompaniesshowoordemonstrationsfromcustompaintingweldingandenginebuildingtocelebrityappearances-ToptrainersintheindustryincludingJohnThorntonWayneColonnaSonnyReevesJudyWaxandTimDwyer.RegisterTodayatwww.AutomechanikaChicago.comInterestedinexhibitingContactRyanLoomisSeniorSalesAssociateERyan.LoomisUSA.MesseFrankfurt.comT678.732.2402an.LoomisUSA.MesseFERyestedineInterRegisterTankfurtran.LoomisUSA.MesseFxhibitingContactRyestedineutomechanikaChicago.com.Ayatwwwdar732.2402678..comTankfurtanLoomisSeniorSalesAssociatexhibitingContactRyutomechanikaChicago.com732.2402anLoomisSeniorSalesAssociatewww.engineprofessional.com35 36JAN-MAR2015engineprofessionalvelocityandaccelerationarealsocalculatedandrecorded.TheexampleshowninFigure26onthefollowingpageisfortheintakevalvethesameprocessisusedontheexhaust.Thebaselinecamshaftdynamicsfromthetestbenchshowsomeinstabilityasseeninthe9000RPMtrace.Thevalveisloftingtooearlyandthevalvetrainisnotreestablishingcontactuntilfardownthebacksideoftheliftcurve.RY45SERIESDESIGNOVERVIEWBYDANKEENANcontinued26SpecializinginUsedRebuiltEngineRebuildingEquipmentFARRISEQUIPMENTSALESisoneofthelargestdealersofusedrebuiltenginerebuildingequipmentintheUnitedStates.WehavebeenblessedtoshipourequipmenttonearlyeverystateintheUSAandtoover40othercountriesaroundtheworld.Weinviteyoutovisitourwebsiteforphotosandpricingwww.farrisequipment.comThephotoswillgiveyouanideaofthequalityofourmachinesandalsoshowyouourfacilitiesandpeople.Warrantyprovidedwitheveryrebuiltmachinewesell.ContactSAMFARRISorDONSTONE3001Interstate27LubbockTX79404E-mailsamfarrisequipment.comBuytheRightpieceattheRightpriceFROMTHERIGHTPEOPLECall800-882-1808fortheFARRISTDEALaround www.engineprofessional.com37Whenthegraphisisolatedtotheclosingpointtheinstabilityshowsupat8000RPMandabove.SeeFigure27.Thevalvebounceisnotexcessiveat0.003forcloseto0.835ofdynamicliftbutthespringsurgeobservedpasttheinitialclosingpointiscauseforconcern.Thiswillleadtodecreasedspringlifeandultimatelyleadtoafailure.continued27 ThevalvevelocitycurveisshowninFigure28.The3000rpmtraceisthebaselineanditcanbeobservedtheopeningandclosingvelocitiesarequiteaggressivepeaksabove8000RPM.Theclosingvelocityisunstableasexpectedandnotfollowingthebaselinedesign.Alookattheaccelerationhighlightstheissuesevenfurther.The3000RPMbaselineinFigure29showshowaggressivetheopeningisandthevalveisnotfollowingthedesiredaccelerationprofile.Thepeakaccelerationisfarabovetheintendedlimitwiththelashandcomponentmassthecamshaftprofileistooaggressive.Basedonthebenchtestinganewcamshaftprofileandspringaredesignedandtestingresumes.Theaimistokeepthesameliftanddurationwithalessaggressiveopening.AscanbeseeninthenewliftcurveshowninFigure30thevalveisstillreaching0.835dynamicliftbuttheearlyloftingisgone.Acloserlookatthevalveclosingeventshowsamarketableimprovementinthecontrolofthevalve.SeeFigure31.Thevalvebouncehasbeenreducedbutmoreimportantlyinthiscasethespringsurgeisgoneabove8000RPM.Thiswillhelpthespringandvalveseatlifethusgivingamoredurablepackage.ThevalvevelocitycurvegivesinsightintothenewcamshaftprofileFigure32.Thepeakvelocitywasreducedandbroadenedouttokeepareaunderthecurvebutthevalvedoesnotopenasfast.Thishelpstoreducetheinitialseparationexperiencedontheoriginalcamshaftprofile.Inturnthepeakclosingvelocityisalsobroaderandhelpstocontrolthevalveseating.Theclosingvelocitytracehaslessseparationfromthe3000RPMbaselinewhichcorrelateswiththeimprovedcontrolrealizedinthebouncecurve.TheaccelerationcurvealsoshowsthelessaggressiveopeningofthenewcamshaftFigure33.Withthereductioninpeakaccelerationthevalvetrainhaslessshockontheopeningwhichinturnallowsforbettercontrol.Theamountofenergystoredincomponentslikethepushrodduetobendingfromthelargeopeningforcesinthefirstcamshafthavebeenreducedwiththereductioninaccelerationinthesecondcamshaft.Thisstoredenergyisputbackintothevalvetrainafterpeakaccelerationwhichaidsinthedurationanddynamicliftbutcancausetheearlyloftandlossofcontrolwhencoupledwiththeincorrectspring.Withthenewcamshaftprofileandspringthefirstfiringtestengineisbuilt.Becauseofalltheworkdoneinthe3DmodelingpackagingstudiesandtheSLAmockup38JAN-MAR2015engineprofessionalRY45SERIESDESIGNOVERVIEWBYDANKEENAN282930 enginethefirsttestengineonlytakestwodaystobuild.Consideringthisisthefirstbuildofanewengineplatformtheextraeffortonthefrontendoftheprojectpaysoff.Sincethisisafirsttestfireofthenewengineextradatawillberecorded.Inthiscase24thermocouplesareplacedintheblockandwatermanifoldtomeasurethewatertemperaturealongwithcombustionpressuretransducers.SomeofthethermocouplemountscanbeobservedinthevalleyofthetestenginebuildshownbelowinFigure34.Oncetheengineisfinisheditisinstalledonthedynocartandinstrumented.ThethermocouplewirescanbeseencomingfromthevalleyareaandfromthesideoftheblockinFigure35.www.engineprofessional.com393233313435 40JAN-MAR2015engineprofessionalTheengineisfirstbroken-inonthedynamometerandmultiplelashandfilterchecksperformedtoensuretherearenoissues.Oncetheengineisbrokenintestingtodeterminethetemperatureprofileofthewaterjacketproceeds.ThefirstgraphFigure36isthewatertemperatureontheintakesideoftheblock.Itisobservedtherearcylindersshowanelevatedtemperaturecomparedthefrontcylinders.Thisisexpectedsincethewaterpicksuptemperatureasispassesbyeachcylinder.Thisisaninherentcharacteristicofengineswithsiameseboresthewatermustpassbyeachcylinderasittravelstotherearcylinders.ThistestdataalignswiththeCFDresultsfromearlier.InFigure37thewatertemperatureontheexhaustsideofthecylindershowsthesametrendwiththerearcylindershavinghigherwatertemperaturethanthefrontcylinders.Thespreadishighersincetherearcylindersreceiveheatfrombothsidesofthecylindersintakeandexhaustandpickupheatasthewatertravelsaroundthebackoftherearcylinder.ThetemperaturespreadiswithinthedesignparametersandcorrelatestotheCFDmodel.InFigure38thewatermanifoldhasthermocouplesineachoftheinletsfromthecylinderhead.Thecylinderheadcastingisseparatedintofourchambersoncethewaterenterstheheadfromtheblockitcannotmixwiththewaterfromanadjacentcylinder.Thuseachthermocouplereadingistheactualwatertemperaturefromthatcylinderindependentfromtheothercylinders.Thewatertemperaturespreadisstillpresentasexpectedsincetheinletwatertemperaturetotheheadisdifferent.Allthewatertemperaturevaluesarewithintheexpectedlimitswithaspreadacrosstheengineof12FandagreewiththeCFDresultsfromtheearlieranalysis.InFigure39thecylinderpressurevaluesarerecordedwithhighspeeddataacquisitionthatrecordsthepressureperdegreeofcrankshaftrotation.At7500rpmthatequatesto282600datapointspersecondforeachcylinder.Inordertomeasurethehighpressuresupto150bar2175psiatthisspeedspecializedpiezo-electricpressuresensorsareused.Thetestenginehasthesametimingonallcylinderswith25degreesofinitialtimingasabaseline.Intheattachedgraphofpeakcylinderpressureeachcolorrepresentsanindividualcylinder.Theaverageforalleightcylindersis122barupto7100rpmthenstartstodropoffto112bar.TheRY45SERIESDESIGNOVERVIEWBYDANKEENAN36373839 42JAN-MAR2015engineprofessionalpeakpressureoncylinderfourisover135barwhichishigherthanthedesignlimitforthisparticularcranktrain.Tomakethepackagedurableandthemostefficientindividualignitiontimingforeachcylinderisoptimized.Thepeakcylinderpressuremeasurementalongwithlocationofpeakpressureisusedtooptimizeeachcylindersignitiontiming.Inanenginenotallthecylindersmakethesamepoweranddonothavethesameburnratesinsidethechamber.Thisismoreevidentwithacommonplenumengineastheair-fuelratioandcylinderfillvariesforeachcylinderalongtheRPMrange.ThiscanbeobservedascylindersmakemorepowerthanothersdependingontheengineRPM.Withoptimizedtimingforeachcylindertheaveragepeakpressureisloweredto105barwhichiswithinthedesignparametersforthisparticularpistonwristpinandrodcombinationinthisdesign.Ifhigherpressuresaredesirednewcomponentscanbedesignedtowithstandthehigherforcesandincreasedstress.SeeFigure40.Withtheoptimizedtimingandallotheraspectsoftheenginecheckedoutwatertemperatureoilpressureoilflowvalvelashstabilityair-fuelratioetc.powerrunsaremade.Thisenginewasbuilttoadirtlatemodelspecificationof436CIDwitha14.51compressionratio.AscanbeseenonthedynamometercurveinFigure41theengineproduced901bhp7500rpmand693ftlbsoftorque6200rpm.Thisisdeemedasanacceptablestartingpointfordurabilitytestingandtheengineissenttotrackfortesting.IRY45SERIESDESIGNOVERVIEWBYDANKEENAN4041DanKeenanistheDesignandAnalysisManagerforRoushYatesEngines.FormoreinformationpleasecontacthimatDKeenanroushyates.comorvisittheirwebsiteatwww.roushyates.com. 2014ElginIndustries.Allrightsreserved.www.elginind.comsaleselginind.comNOMATTERWHATYOUREREBUILDINGELGINHASTHETOTALPARTSPACKAGEFORGUARANTEEDPERFORMANCEFord3.5L3.7LChrysler3.6L5.7LFord6.7LDieselContactYourElginDistributorTodayorCall1-800-323-6764PUSHRODSLIFTERSROCKERSVALVESSPRINGSTIMINGCAMSHAFTSMUCHMOREwww.engineprofessional.com43 657hpstreetthumperBUILDTEXTANDPHOTOSBYMIKEMAVRIGIANThisbuildstartswithaMoparB-series400blockwiththefinaldisplacementof499CID.Sincemyplancalledforafinalborediameterof4.375the400blockseemedawisechoiceprimarilyduetotheoriginalborediameterof4.340.Ascomparedtoa440blockwhichstartswithaboresizeof4.320the400blockrequiresonlya0.035oversize.Usinga440blockwouldgetabitdiceyduetotheremainingcylinderwallthicknessenlargingfrom4.320to4.375wouldrequirea0.055oversize.Alsothe400blockisshorterthanthe440blockrequiringshorterpushrodsforhigherRPMuseandsmallerdiametermainboreforreducedrotatingmass.The400BblockisalsostifferandmoredurablethantheRB440block.The400blockfeaturesasmallermainborediameterat2.625ascomparedtothe400blocksmainboreof2.750andsubsequentlyusesasmallerdiametercrankshaftmainjournal.Theplaninvolvesafinalborediameterof4.3755andanextendedstrokeof4.150whichresultedinafinaldisplacementof499CID.Ourconnectingrodsfeatureacenter-to-centerlengthof6.760andpistonsfeatureaCDcompressiondistanceofamere1.113.OurforgedcrankandrodsaresourcedfromScatwithpistonswristpinslocksandringsfromJE.BearingsmainsrodsandcambearingsarefromMahle-Clevite.ThemaincapsaresecuredwithasetofARPmainstuds.NOTEEnginebuildplanandassemblyperformedbyMikeMavrigianBirchwoodAutomotiveCrestonOH.BlockmachininganddynorunperformedbyKoffellsPlaceHuronOH.COOLCOINCIDENCEAsfatewouldhaveitIlocatedmyblockanoriginal1976versioncastingnumber4006530whichhadneverbeenpreviouslyalteredinthesmalltownofPlymouthOhioabout48mileswestofmyshop.HowcoolisthatFindinganoldMoparblockinatowncalledPlymouthwastoocoincidentalnottodeserveachuckleortwo.Sometimesthingshappenforareason.WiththebaregrungyoilyandnastyblockcoreinhandIimmediatelydroppedtheblockoffatalocalenginemachineshopMedinaMountainMotorsinCrestonOhioforbakingandmag-checking.Iluckedoutasthisblockhadneverbeenoverboredordeckedandhadnocracks.TheblockalongwiththeJEpistonswasthendeliveredforblockmachiningtoKoffelsPlaceinHuronOhioarenownedMoparenginespecialistservingstreetenthusiastsandracersworldwide.NOTEEarlyMopar400blocks1971arethickerwallcastingsbuthardtofind.19721975blocksalsofeaturethick-wallcastingsandtheoreticallycanbesafelyoverboredbyasmuchas0.060.The1976blocksstillretainadecentwallwhile77-78blocksfeaturemuchthinnerwallsandshouldnotbeoverboredbymorethan0.030orso.Withallofthissaidkeepinmindthatvariancesexistblock-to-blocksocheckingcylinderwallthicknesswithasoniccheckerisamustregardlessoftheblocksageorcastingnumber.CLEARANCINGISSUESRodbigendtoblockclearanceandcounterweighttoblockclearancecheckingisamustwheneveryouincreasecrankstroke.Witha4.150strokecrankinaMopar400blockclearancingthebottomoftheboresforrodbigendboltheadclearancerequiredanoffsetnotchofroughly0.2000.210deepbyabout0.890wideatthebottomofeachboreoffsettoalignwithopposingcylinderrodbolts.InadditionthebaseofeachmainwebrequiredslightclearancingfortheedgesofthecrankcounterweightsWherethemainwebsmeettheblockabovethebearingsaddleswherethemainwebmeetsthebottomoftheboresroughly116wasremovedcreatingaslightlyradiusedfilletareatopreventtheedgesofthecounterweightsfromrubbing.ThebossthatacceptstheoilpickuptubealsorequiresachamferedreliefimmediatelybelowtheNo.1cylinderboreinordertoclearopposingrodbigendbolthead.Theonlyremainingclearanceissueinvolvesthebaseoftheoilpumppickuptubewhereaninterferenceattherodbigendshoulderoccurs.Dependingonthespecificpickuptubedesignandtheconnectingroddesignthismaybeaddressedbyrelievingthepickuptubeorbyremovingabitofmaterialfromtherodshoulder.SincetheScatrodsarealreadyprofiledforstrokerapplicationsremoving400BLOCKCASTINGNUMBERS1971-7236142301973-7836986301976-784006530COMPARISONOF400TO440OE400CIDBlockdeckheight9.980Cylinderbore4.340Stroke3.380Connectingrodlength6.358Rodpindiameter2.375Mainborediameter2.8185Mainjournaldiameter2.625OE440CIDBlockdeckheight10.699Cylinderbore4.320Stroke3.750Connectingrodlength6.760Rodpindiameter2.375Mainborediameter2.9435Mainjournaldiameter2.750OURBUILDPLANwith400blockcastingnumber4006530Blockdeckheight9.955Cylinderbore4.3755Stroke4.150Connectingrodlength6.760PistonCD1.113Rodpindiameter2.374Mainborediameter2.8185Mainjournaldiameter2.62544JAN-MAR2015engineprofessional www.engineprofessional.com45Youcanalwayscontinuetotweakformorepowerbutweeasilyyanked657hpand642lb-ftoftorqueoutofthisrelativelystraightforwardbuildcertainlyenoughforstreetorstripenjoyment. MOPAR499PROJECTBYMIKEMAVRIGIANmaterialfromtherodshoulderwasoutofthequestionasthiscouldeasilyweakentherod.InourcasetheMorosooilpickuptubethankfullyfeaturesathick-wallbase.Isimplyscrewedthepickupintothebosswiththepickuporientedatthecenteroftheblockandmarkedtheareaofthetubebasewhereclearancewasneeded.WiththetuberemovedIgentlychamferedthetubebaseremovingabout116ofmaterial.MAINANDRODBEARINGSTheScatcrankshaftfeaturesa0.125radiiatmainandrodfilletsinordertoprovideaddedstrength.Thisrequirestheuseofnarrowbearingsonbothmainsandrods.InordertoaddressthiswechoseMahleCleviterodbearingsPNCB-527HND.InordertotakecareofthemainbearingsIshippedmysetofCleviteMS876PbearingstoAkerlyChildsinCaliforniafornarrowingwheretheyremove0.050fromeachsideofnumbers1-4bearingsNoteyoucansendyourbearingstothemfornarrowingoryoucanbuyalready-narrowedbearingsetsdirectlyfromAkerlyChilds.Thecostforthisprecisionnarrowingisminimalandtheyturnthejobaroundinonedayplusshippingtime.ScottKoffelroutinelyhasthismodificationperformedforthemajorityofhisMopar-buildmainbearingsetsinordertoassureproperbearingclearanceatthefilletsandtoachieveproperbearingcrushwhenusingperformanceaftermarketcrankshafts.WhiletheMahlemainbearingsalreadyfeatureagenerouschamfertoaccommodatelargerradiusfilletsnarrowingwonthurtanythingandwilleliminateanypotentialforfilletcontact.PRE-DRESSINGTHEBLOCKEXTERIORSinceImwaytooanalwhenitcomestoablocksexteriorappearanceIspentthreedaysdressingtheblocksexteriorsurfacesusingacombinationofcut-offwheelsminibeltsandersdiegrindersandRolocabrasivepads.Ifirsteliminatedalloftheuglycastingseamandedgeflashingsfollowedbydressingthoseareastoobtainasmoothuniformsurface.LuckilythemajorityoftheblocksidesurfaceswerealreadyrelativelysmoothanduniformascomparedtomanyotherOEblocksthatIveworkedon.Onceallcriticalblockmachiningwascompletedacoatofaheavy-buildepoxyprimerwasappliedfollowedbylotsofsandingwith120through400-gritpaperinordertoobtainacreamy-smoothsurfacefinish.Iperformedalloftheexteriorsurfacegrindingdressingpriortoblockmachining.Thisincludedaddressingtheliftervalleywherealldrainbackopeningedgeflashingswereremovedwithvalleysurfacessmoothedtopromoteoildrainback.BLOCKMACHININGCylinderboreswereoversizedtoafinisheddiameterof4.3755onKoffelsSunnenhoningmachineOEborespecwas4.340.BHJdeckplateswereinstalledtobothdeckswithalready-crushedheadgasketsinplaceandtorquedto70lb-ft.AftertheJEpistonskirtsweremeasuredat4.3700oversizingbeganwith180-gritdiamondroughingstonesremoving0.027.Thiswasfollowedbypasseswith220stonesandfinalizedwith280.Finalhoningwasperformedtoafinal4.3755providingapistonskirtclearanceof0.0055.Oncethemaincapswereshavedby0.002andinstalledusingARPmainstudsandtorquedto100lb-ft.Themainboreswerethenalign-honedtotheloosesideoftheOEspecat2.8185.Lifterboresweresimplyhonedforcleanupforlifterboreclearanceat0.0015.WiththecrankrodsandpistonsmockassembledtocheckTDCrelativetotheblockdeckswefoundthatpistonswere0.036belowdeckplusnotsurprisingforaproductionblockthedeckswerenotparallelorsquare.Inordertoestablishthedecksparalleltothecrankcenterline0.007wasremovedfromthefrontgraduatingtoaremovalof0.011attherearwithremainingmaterialremovedtoestablishafinalblockdeckheightof9.955.Thisplacesourpistonsatauniform0.025belowdeck.COMPRESSIONRATIOWhilemyinitialchoicesforcylinderheadsinvolvedtheMoparPerformance5153524headsthatfeature84ccchambersandtheEdelbrockPerformerRPMheads60189headswith88cccombustionchambersEdelbrockactuallyshippedtheir60929headswith84ccchambers.Withourinitiallyplannedsetupwith88ccchambersandourVictorheadgasketswouldhaveresultedina10.381compressionratiowith84ccchambersourcompressionratiowouldcreepuptothe11.71range.InordertobringourcompressiondowntoalivablestreetapplicationIobtainedapairofspecial-orderMLSheadsgasketsfromCometicthatfeaturegasketboresat46JAN-MAR2015engineprofessionalHeretheblocksmainboresarealignhonedre-establishinganalignedrowofconcentricmainbores. www.engineprofessional.com47 48JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIAN4.500andcompressedthicknessof0.040whichwillworkwitheitherhead.Combinedwithour4.3755cylinderbores4.150strokeflat-toppistonswith5ccvalvepocketsandwithourpistons0.025belowblockdeckthissetupwithournewgasketswillprovide10.61compressionratiowhichisjustwithinoursafelimitforstreethi-testpumpgas.FINALBLOCKEXTERIORPREPANDFINISHIappliedabrushed-oncoatingofRustoleumRustyMetalPrimerV7569redprimertotheliftervalleyinsidethecrankcasewallsandtothefronttimingrecessarea.Thiswasappliedafteraverymeticuloushotsoapwaterscrubbingrinsingandblow-dry.Asidefromsomewhataidinginfasteroildrainbackthisprimeralsoservestosealthecastironsurfacestopreventanypossibilityofironparticlesmigratingoutofthecastsurfaces.Grantedthispossibilityisslimsincetheblockiswellseasonedandhasbeenthoroughlywashedmultipletimesbutitdoesnthurt.Attheveryleastitgivesyouawarmfuzzyfeelingknowingthatyoudidwhatyoucouldtosealthesurfaces.Allmaincapthreadedholeswerecleanedwithax13chasingtapandallheadboltthreadedholeswerecleanedwitha716x14chasingtap.Useofachasingtapwillcleanthreadswithoutremovingmetalaswouldacuttingtap.BothchasingtypetapsweresourcedfromGoodsonShopSupplies.MyblockplugkitisMilodonsMIL-34041.Thisincludesbrassexpansionplugsfortheblocksidesrearcamshaftboreplugand38NPTplugsfortherearandfrontoftheblock.Ipreferbrassexpansionplugsasopposedtosteelfortheirlongevitywontrotoutlikesteelplugsinthelongterm.AlsotheblocksidewaterjacketplugsarethedeepstyleasrecommendedbyScottKoffel.Thestandarddepthfreezeplugscommonlyavailablemeasureapproximately0.315deepoverallwithacontactwalldepthofabout0.230whilethedeepstylemeasuresabout0.478inoveralldepthwithcontactwalldepthofabout0.400.IobtainedablockplugkitfromSummitRacingMilodonsPNMIL-34041thatfeaturesthedeepstyleblocksidefreezeplugs.Thesixbrasssideexpansionplugs1-58dia.wereinstalledbyfirstsmearingacoatingofPermatexUltraBlackRTVontheblocksplusholewallsanddrivenintotheblockwithanaluminumplugdriveruntilflushwiththeblockexterior.Priortothestartofassemblytheblockexteriorwascarefullycleanedandmasked.TwocoatsofbasecoatpaintwereappliedobtainingacustommixthatmatchedtheoriginalstreetHemiorangecolorfollowedbytwocoatsofclearurethaneabasecoatclearcoatprocess.Theclearwasallowedtocurefortwodaysandtheblockwasfinal-washedwithhotwaterandDawndishwashingsoapandrinsedbeforewebeganassembly.CAMSHAFTMyinitialthoughtwastogowitharollercambutScottKoffeltalkedmeoutofit.UsingasolidrollerseemedlikeagoodideabutScottnotedthatdependingonthestyleofrollerliftersthelifteroilholesinthelifterborescanbeexposedduringoperationrequiringbushingtheboresandmodifyingtheoilpassages.Koffelnotedthathecanactuallyobtainhigherrevswiththeflattappetcamsasopposedtorollercamssowewentwithhisrecommendation.Obtainingthecamandlifterkitaswellastherockerarmshaftsandshafthold-downkitwasdonethroughSummitRacingsincetheycarryafullinventoryofMoparPerformanceproductsinadditiontojustabouteveryotherbrandunderthesun.LuckilysinceSummitsmainOhiowarehouseisamere35milesfrommyshopevengroundUPSgetsmyordersintomyhandsinoneday.ThisisagreatconvenienceknowingthatIcanorderanythingIneedevenatthelastminute.TheMoparPerformanceflattappethydrauliccamfeaturesanadvertisedintakeandexhaustliftof0.509with1.51rockerarmratiodurationat0.050of248248degreesoverlapof64degreesandalobeseparationangleLSAof114degrees.IsourcedthecamandlifterkitfromSummitRacing.DuringcamshaftdegreecheckingandmeasuringliftIusedaFosterToolsliftergaugethisengagesintothelifterboreinplaceofalifterandfeaturesaspring-loadedradiusedplasticbumperthatcontactsthecamlobeandadialindicator.Thistoolprovidesaneasyandaccuratewaytomeasurecamlobelift.UponmeasuringImeasured0.3394atthelobe.Withthe1.51rockerarmsthatwereusingthatresultsinvalveliftof0.509.3394x1.5509.1.AfterthoroughlycleaningthenewMoparPerformancecamshaftofitsoriginalpreservativecoatingalljournalsandthedistributordrivegearwerecoatedwithagenerousamountofRoyalPurpleMaxTuffassemblylube.Alllobesandlifterfaceswerecarefullycoatedwithhigh-Aftertheblockexteriorwaspainstakinglydressedandafterallmachiningwasperformedwepaintedtheblockaswellastheoilpantimingcoveroilpumpbodyandvalleyplatewitha2-stagebasecoatclearcoaturethanematchingthetraditionalHemiStreetOrangecolor.TheHemiRaceorangeismuchlighterwithlessredpigment. www.engineprofessional.com49 50JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANpressuremolylube.IcoatedthecamjournalsandtheliftersideswithRoyalPurpleMaxTuffassemblylube.Duringthepreviouscambearinginstallationthecamfitwascheckedbearing-by-bearing.Duringfinalinstallationthebumpstickwascarefullyinstalledtoavoidnickinganyofthebearingsharshscratchesonnewcambearingscaneasilyleadtoadropinoilpressure.CAMSPECSMoparPerformancecamP5007698FlattappethydraulicLift0.509intake0.509exhaustDuration0.050248degint248degexhLSA114degreesOverlap64degreesCRANKSHAFTOurScatforgedcrankfeaturesa4.150strokeprovidinganadditional0.770strokeascomparedtotheOE3.380stroke.Mainjournaldiametersmeasured2.625androdjournalsmeasured2.374.OurcrankshafttypifiesScatsattentiontodetail.Eachmainandrodjournalmeasuredexactlytospecwithgenerous0.125radiusfilletsforaddedstrength.IalsocheckedthecrankforrunoutandasexpectedImeasuredzerorunout.Oilholesareneatlychamferedforefficientoilpaths.NoteTheScatcrankrearmainjournalssealareawasfinishedwithasmoothsurface.Ifyouencounteracrankthatfeaturesaserratedcontactsurfacefortherearmainsealyoumustusearope-typerearseal.Usinganeoprenesealwillresultinanoilleakduetoeventualsealdeformity.Ifyourcrankfeaturesanon-serratedsmoothsealsurfacetheneoprenestylesealisthebestchoice.InitialtestfittingformainbearingclearancewasperformedwithallupperandlowermainbearingsinstalledARPmainstudshand-snuggedtotheblockandcapsinstalledto100ft-lbs.AboregaugemeasuredinstalledmainbearingIDat2.6275.CrankshaftmainjournaldiametersweremeasuredwithaGoodsonmicrometerat2.625providinguswithamainbearingclearanceof0.0025.NOTEThe400lowdeckengineoriginallyfeatureda2.625crankshaftmainjournaldiameterasopposedtothe400enginewhichfeaturedacrankmainjournaldiameterof2.750.CRANKSHAFTBALANCINGAsexpectedwhenweighingourpistonsandrodstheJEpistonsallweighedinwithin0.5gramandtheScatrodsallweighedinwithinlessthan1gramrod-to-rod.Withtodaysmachiningtechnologyitisntliketheolddayswhenyouhadtofindthelightestpistonorrodandthenremovematerialfromtherestinordertoobtainamatchedset.Wehadnoneedtocorrectanyofourpistonsorrods.Bobweightsweremadeaccordingtoourmeasuredweightsforpistonspistonpinsringsandsupportrailspinlocksrodsmallendsrodbigendsrodbearingsandanallowanceforoil.OURBOBWEIGHTCARD.Rodrotating594gRodrotating594gRodbearing54gRodbearing54gOilallowance4gPiston489gWristpin151gLocks1set5gRings1setwrail62gRodreciprocating285gBobweighttotal2292gNote50reciprocating100rotatingWiththebobweightsestablishedeachbobweightwasinstalledtothecrank90-degreesfrombobweighttoadjacentbobweight.Weightremovalwasrequiredonthefrontandrearcrankshaftcounterweights.RemovalfromthefrontcounterweightwasrequiredbeyondtheendofthecounterweightsoaslugoftungstenMallorymetalwasinstalledtothetrailingendthecounterweightwasdrilledhorizontallytheweightinstalledandweldedinplace.Thisprovidedenoughaddedmasstoallowremovingweightfromthecounterweightouteredgetoachievebalance.Theouteredgesofthecounterweightswerealsoshavedonalathetominimizetheremovalrequiredbydrilling.Theprocesstookawhilebuttheresultswereworthwhile.Thecrankwasbalancedtowithin0.75g.Thecrankshaftisinternallybalanced.Thismeansthatazero-balancedamperandzero-balanceflywheelarerequired.Anexternallybalancedcrankwouldrequirethedamperandflywheeltobeattachedtothecrankduringbalancingtherebydedicatingthedamperandflywheeltothatcrank.Internalbalancesincethedamperandflywheelarezero-balancedallowsyoutoeasilyreplaceeitherthedamperorcrankshaftorbothinthefuturewithouttheneedtore-balancethecrankshaft.CRANKINSTALLATIONAfterremovingthemaincapsandallbearingstheuppermainbearingsaddlesandmaincapsaddleswereagaincloselyinspectedforcleanlinessaswerethebearings.Alwaysinstallmainbearingsdrywithnolubricantbetweenthebearingsandtheirsaddles.NOTEThethrustbearingislocatedattheNo.3mainlocation.WithupperandlowerbearingsinplacethefacesofallbearingswerecoatedwithRoyalPurpleMaxTuffassemblylube.TheScatcrankshaftwasthoroughlycleanedtoremoveallofthefactoryrustBobweightswereinstalledtothecrankshaftcenteredontherodpinsandat90-degreestoeachother. COMPLETEBALANCEDSTROKERKITSFrommildstreetdirtorasphalttohighpowerbuilds.Scathasakitdesignedandreadytogoforyourengine.PREMIUMPROSERIESI-BEAMH-BEAMRODS.Machinedtoexactingtolerancesoutof4340forgedsteel.Frommildtowild-ourrodsareuptothechallenge.ARP8740standard2000Seriesupgradesavailable.4340FORGEDMOPARCRANKSHAFTSFORSMALLBLOCKBIGBLOCKHEMIHeattreatedionnitridedRoughbalancedCustombilletsofferedPrecisionqualitydurabilitySCATCRANKSHAFTSHASBEENMANUFACTURINGWORLDCLASSCRANKSHAFTSCONNECTINGRODSFOROVER50YEARS.ATruePioneerLeaderinAmericanIngenuityDesignInnovation.TheSCATproductlineincludeshighquality4340ForgedBilletCustomCrankshafts4340ForgedPROSERIESI-BeamH-BeamConnectingRodsaswellasprecisionbalancedcompleterotatingassemblies.MakebigreliablepowerwithyourenginebuilditrighttheYOURHIGHPERFORMANCEHEADQUARTERS1400KINGSDALEAVE.REDONDOBEACHCA90278P310370.5501F310214.2285WWW.SCATCRANKSHAFTS.COMwww.engineprofessional.com51 52JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANpreventativecoatingandwashedwithahotsoapywatersolutionwithalloilpassagesscrubbedcleanwithriflebrushes.Thiswasfollowedbyhotwaterrinsingandblow-dryingespeciallytheoilpassages.Thecrankwascarefullylaidintoplaceontotheupperbearingsandtheupperrearseal.TheARPmainstudswerethenhand-snuggedintoplacealightcoatingofARPmolyontheuppercoursethreads.Ipreferinstallingthestudsaftercrankinstallationtoavoidpotentialcontactwiththecrankduringcrankpositioning.AseachmaincapwasinitiallyinstalledItappedeachcapwithacleanplasticmalletinordertoobtainfullseatingofthecapregisters.Studnutswereinitiallytightenedto50ft-lbsfollowedbyasinglesweepupto110ft-lbswARPUltraMolyonthethreads.NOTEBecauseofpossibleclearanceissuesbetweentheNo.5maincapstudsandthewindagetrayitsimportantthattheexposedstudtipsareflushwithorshorterthantheblocksoilpanrail.OurNo.5capstudsrequiredshorteningtothetuneof0.175.ThisisacommonissuewithMoparblocks.Ifirstthreadedax20Grade8nutontothelowerthreadsgroundtheneededmateriallightlychamferedthetipswithamini-beltsanderthenwalkedthenutofftoverifythatthreadengagementwassmoothwithnoburrsorinterruptions.Duringtestfittingwithallmaincapstightenedtospeccrankshaftthrustclearancewasmeasuredat0.005nicelywithintheChryslerspecof0.0030.007.TheMoparbigblockfeaturesaseparatealuminumrearmainsealretainerthatboltstotheblockimmediatelybehindtheNo.5maincap.TheOEretainerhousingorcapisacastaluminumpiecethatspronetocrackingifpreviouslymishandled.InsteadofdiggingupausedretainerIpurchasedamachinedbilletpiecefromManciniRacingforabout70whichincludedboltsandsealseventhoughIusedourVictorsealswhichwerefullycompatible.Thekitincludesapairoflocatingpinstoregisterthecapinsertpinstolocatethecapremoveonepinatatimeandinstallthebolts.TheradiusedupperandlowerrearmainsealswereinstalledtotheblockandManciniRacingaluminumrearsealcap.Theupperandlowersealsareinstalledwiththeangledlipfacingforward.WhilenotneededintermsofaddedsealingaverylightsmearofRTVmaybeaddedtothebacksideofthelowersealbeforeinsertingitintothealuminumsealcap.Thiswillholdthesealinplacewhileinstallingthecapsincewiththeblockupsidedownonastandthesealcapwillbeinstalledwiththesealcavityfacingdownward.Withoutthelowerseallightlyadheredtothecapthesealcanfalloutwhileinstallingthecap.OncethemaincapswerefullytightenedtheMancinirearsealhousingwasinstalled.Thishousingfeaturesthelowerradiusedsealandtwostraightsquare-profileO-ringsealstripsoneachsideofthehousing.InserteachO-ringstripintoitscavityandthenlightlystretchandpushthesealintoitsgroove.IallowedthesideO-ringstripstosettleovernightincasetheywantedtorelaxabittrimmingtheexcessendsflushwiththehousingwitharazorblade.PriortoinstallationoftherearsealassemblyIappliedalightsmearofRTVtotheO-ringstrips.AsmalldabofRTVwasplacedontheexposedendsoftheradiussealspriortohousinginstallation.AsmalldabofRTVwasalsoplacedintheuppercornersoftheblockwherethesealhousingwillmeet.Apairofsupplied38centeringpinsareprovided.Thepinsarethreadedintotheblockprovidingaguideforthesealhousing.Thehousingisslippedovertheguidepinsandthehousingisfullytappedintoplace.Onebyonetheguidepinsareremovedandthesuppliedsocketheadcapscrewsareinstalledandtightenedto30ft-lbs.OncebothboltsarefullytightenedIfilledthesocketheadscrewheadcavitieswithRTVflushwiththelowersurfaceofthecap.ThisisatrickthatScottKoffelimpartedtominimizethechanceofoilleakagethroughtheboltpassages.TIMINGSETThefitoftheCloyescamgeartothecamsnoutwasabitonthetightsideduetothefactoryinstallationofthecamdowelpin.ThismadeinstallingthegeartothecamwithchaininplaceabittrickybutCrankshaftendplayonceallmaincapsarefullytightenedwascheckedwithadialindicator.OurScatcrankfeatured0.005endplay.IinstalledasetofARPmainstuds.Wheninstallinghand-snugonly.Over-tighteningstudscanresultinslightsplayingwhichwillaffectmaincapalignment. www.engineprofessional.com53 54JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANtheresultwasaverynicefitoftheCloyesdouble-rollerchainwithnoexcesschainslop.Iinstalledthecamgeartothecamwithasingle716-14grade8boltwithashanklengthof1.AlongwiththeOEcamboltwasherthislengthofboltprovidedatadmorethan716threadengagement.IappliedLoctitemediumstrengththreadlockertotheboltthreadsandtightenedtheboltto35ft-lb.NotethattheOEcamboltwasherfeaturesaslightconvexsurfaceononeside.Thisconvexsidemustfaceoutwardcontactingtheundersideofthecambolthead.Timing-wiseIinitiallysetthemulti-rangeCloyescrankgearatzeroinlinewiththecranksnoutkey.Ialignedtheouterzerotimingmarkonthecrankgeartothetimingdotonthecamgearthisplacesthecamgeardotat6oclockandthecrankgearsouterzeromarkat12oclockwiththecrankkeyatapproximatelythe2oclockposition.TheCloyestimingsetallowsmultipleadvanceretardincrementsof2degreeseach.PISTONRINGFITTINGSinceIwouldneverassumethatpistonringswillprovidethenecessaryendgapItestfitallringstodeterminegapsespeciallyforthetopandsecondrings.Test-fittingourtopandsecondringsshowedaninitialzerogaprequiringcustomendgapfiling.ForthisapplicationJErecommendsaminimumtopringendgapof0.0045perborediameterandasecondringendgapminimumof0.0050perinchofborediameter.Withour4.3755boresthiscalculatestoagapof0.01968forthetopringswhichIroundedtoagapof0.020.Oursecondringgapcalculatedto0.02187whichIroundedtoagapof0.022.Ifile-fitalltopandsecondringsforeachandeverycylinderratherthanusingonlyonecylinderboreasmyringfittingreference.Eachboresringpackagewaskeptorganizedonaper-cylinderbasis.InordertosquarearingintheboreorientingtheringequidistantalongthediameterrelativetothedeckIusedaringsquaringtoolfromSummitRacing.Thistoolisadjustableforborediameter.Thetoolrestsontheblockdeckandfeaturesalowershoulderthatprojectsdownintothebore.Pushthetooldownwardscontactingthering.Whentheuppersurfaceofthetoolisflushwiththedecktheringisnowpositionedsquarelyinthebore.Removethetoolanduseafeelergagetomeasureexistingendgap.InordertofileringstoobtainmydesiredendgapIusedmybenchmountedSummitRacingringfilertoremoveequalamountsfromeachsideofthegap.Thistoolfeaturesadiamondwheelandahandcrank.Alwaysrotatethegrindingwheelawayfromtheinsidediameterofthering.Performthistaskcarefullyasitseasytoaccidentallyremovetoomuchmaterial.Grindforafewstrokesremovetheringandcarefullydeburrtheedgesusingaveryfineflatfile.Re-fittheringintothecylinderboremeasurethegapandre-filethegapendsasneeded.Sidelateralclearanceoftopandsecondringswascheckedclearancebetweenthetopsurfaceofaringtotheroofoftheringgroove.TheJEspeccallsfor0.0015to0.003.Mymeasurementsfound0.002oneach.Atoo-tightclearancelessthan0.001canresultinstickingoftheringsinsidethegrooves.HighqualitypistonssuchasthosemadebyJEaremachinedtoveryexactingstandardsbutthisclearanceshouldalwaysbechecked.CONNECTINGRODSMychoiceforthisbuildrequiredtheuseof6.760connectingrods.IselectedasetofforgedH-beambeautiesfromScatfittedwith8740ARProdbolts.EachScatrodandcaparelaser-etchedwithmatchingnumberswhicheasilyallowsyoutokeepeachcapcodedtoitsAnadjustableSummitpistonringsquaringtoolmakesquickworkofproperlysquaringaringintheboreforgapmeasuring.OurCloyestimingsetfeaturesadoublerollerchainandanadjustablecranksprocket.Iinitiallysetoursatzerostraightup.BythewaytheCloyessetfitperfectlyintermsofbothinstallationeaseandtiming. www.engineprofessional.com55 QualityControlledExpansionPlugsSince1921BrassStainlessSteel800-433-64141335WFULLERTONAVEADDISONIL60101630953-1000FAX630953-0174EMAILINFOUSTOOLANDMFG.COMU.S.TOOLANDMFG.CO.56JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANrodduringdisassemblytestfittingandreassemblywork.Rememberallfinishedrodsarehonedtosizebythemanufacturerrequiringthatmatedrodsandcapsarealwaysmatedtogether.Mixingcapsandrodscanleadtorodbearingmisalignment.SinceScatalreadyetchestheirrodsandcapswithmatchingnumberstheresnoneedtostampadditionalidentificationnumbers.InordertoremovetherodcapsweplacedeachrodintoaGearheadrodvisethatfeaturesprotectivelinersthateliminatesdamagetotherodbigendsurfaces.Insteadoflooseningtherodboltsandbandingtheboltswithahammertopopthecapslooseweusedadedicatedconnectingrodcapseparatortool.Thistypeoftoolfeaturesasplit2-piecealuminummandrelthatspreadsandsmoothlydrawsthecapfreefromtherod.Keepthecapwithitsrod.Aftermarketperformancerodsarelaseretchedonthesideswiththesameserialnumberappearingontherodandcap.NaturallywewerecarefultoorganizeallrodsandcapstogetherbutthankstoScatslasernumberetchingitseasytoverifycap-to-rodidentification.OurScatconnectingrodsandJEpistonsaredesignedtoaccommodatefull-floatingwristpinsinsteadofaninterferencefittheyfreelyrotateinboththerodandpistonpinbores.Eachtopandsecondringwascarefullyfiledtofiteachindividualborecheckinggapaftereachfiling.UsingadedicatedARPbillettaperedpistonringcompressoreachpistonslidintoitsboreeasilybyhand. THEONLYHEATTABMADEINU.S.A.DONTBEFOOLEDBYCOPIESFROMOFFSHOREIMITATIONSSILVERSEALCENTERMATERIALISCERTIFIEDMADEINTHEU.S.UNDERU.S.STANDARDS.p800-521-2936f800-521-0580silver-seal.comSilverSealProducts19224AllenRd.TrentonMI48183silversealKEEPAMERICAWORKINGPREMIUMHIGH-TEMPHIGH-TEMPLOW-TEMPDIESELMARINEU.S.PATENT5482000250-255F121-124C250-255F121-124C225-230F107-110C187-192F86-89CFRONTBACKPERSONALIZEDHEATTABSAVAILABLEHEATTABADHESIVEEXCLUSIVEFORMULAMADEINTHEU.S.A.HIGH-TEMPHEATTABSPARTHT1MELTINGPOINT250-255F121-124CWecertifythatthematerialsuppliedpursuantorderissuedbyyouandnumberedaslistedaboveconformstoapplicablespecificationsorrequirements.ForCompleteProtectionsilversealBatch100612GeoffreyA.HavensSr.PresidentCertificationofCenterMeltMaterialAMUSTforEngineBuilders-LargeorSmallCourtCasesWonwith100ResultsDONOTRiskYourHardWorkUsingOffShoreImitationsMADEINTHEU.S.A.MADEINTHEU.S.A.MADEINTHEU.S.A.MADEINTHEU.S.A.KEEPAMERICAWORKINGKEEPAMERICAWORKINGKEEPAMERICAWORKINGMADEINTHEU.S.A.MADEINTHEU.S.A.KEEPAMERICAWORKINGTHEU.S.MADEINEREALENIDONTBEFOOLEDBYCOPIESFROMOFFSHOREIMITHEHEONLENTP.S.UUNDERU.S.THEU.S.TIFIEDERIALIETERMPIEFRMFFHREIMIABMADEINU.TTIONSABMADEINU.S.A.HIGH-TEMPHIGH-TEMPPREMIUM121-124C250-255F121-124C250-255FEMARINEDIESELLOW-TEMPHIGH-TEMP121-124C250-255F107-110C225-230F86-89C187-192FFRONTEeeuetratthk.ishatengineteonstarTINGO1-124CatabevidenachaofoftheheatvismpletePWhenanentltoprachesthgihece50-255F1NINythereabouiFeas.rementrAttachOnEachHeadBothSidesofBlock.lnsoterissuedbplescabantolipoaprmsedpunterialsuptabWeceranouyrdsulipftih100612.0HIGHMEL1TEMPARP580tBMI4818ENTORD.CertificationofCenterMeltMaterialBACKUsingOffShoreImitationsorkWurHardDONOTRiskonwith100ResultsWCourtCasesLargeorSmallAMUSTforEngineBuilders-CertificationofCenterMeltMaterialBACKonwith100ResultsCertificationofCenterMeltMaterial19224AllenSilverSealProductssilver800-521-2936fpsilveVERO-EAL.O70TentedisyA.HafreGeo734.479225SI.WWOCALP734.479.47AXF800.521.2936FREEPHONL8.FALLEN.TRENTON192vensSr.MI48183entonRd.19224Allen-seal.comsilver800-521-0580800-521-2936favUsingOffShoreImitationsMI48183800-521-0580www.engineprofessional.com57Afterverifyingthatallpinboresandpinsarecleananddryremovinganymanufacturer-appliedsurfaceprotectantInordertokeepthepinsinpositiontopreventapinfromslidingoutandcontactingacylinderwalllocksarerequiredoneachsideofthepin.OurJEpistonsfeatureamachinedlockgrooveattheendofeachsideofthepistonspinboredesignedtoaccommodateapairofspirallocksincludedateachendofthepinborefourspirallocksperpiston.Installapairofspirallocksintoonesideofthepistonpinbore.ThenlubeapistonpinIuseRoyalPurpleMaxTuffsyntheticassemblylubeinsertthepinintotheoppositesideofthepinborethroughtheconnectingrodpinboreandbottomingoutthepinatthesidewherethelocksarealreadyinstalled.Wheninstallingspirallocksfirstgentlyspreadthelockapartwithyourfingernails.Insertatipofthelockintothegrooveinthepistonpinboreandwhilekeepingthelockgentlyspreadapartuseasmallflatbladescrewdrivertowalkthespirallockintoitsgrooveuntiltheouterendsnapsintoplace.Ifyouveneverdealtwithspirallocksbeforethiscanbesomewhatfrustratingatfirstbutonceyougetthehangofityoullbreezethroughitusuallytakesdoingaboutthreeorfourbeforeyougetcomfortablewiththeprocess.VerifythateachlockisfullyengagedintoitsboregrooveBythewaythepinsaredesignedforfillfloatinboththepistonandrod.OurJEpinsmeasured0.990OD.Thepistonpinboresmeasured0.9909andtherodsmallendboresmeasured0.9908.Thisprovidesaclearanceof0.0009atthepistonand0.0008attherodbores.ForastreetperformancebuildIgenerallylike0.0008to0.0009attherodsand0.0009to0.0012maxatthepistons.Payattentiontotheorientationofeachpistontoitsrod.ThelayoutoftheMoparheadsfromfronttorearperchamberfeaturetheorderofexhaustvalveandintakevalveintakeandexhaustvalvesexhaustandintakevalvesandintakeandexhaustvalves.Makesurethatthepistonsareassembledwiththisvalveorientationinmind.AlsopayattentiontotherodbigendOncetherodboltistorquedshortoftherecommendedtorquevaluethestretchgaugeisplacedontothebolttodeterminehowfarthebolthasstretched.Theboltisthenfurthertighteneduntiltherecommendedstretchhasbeenachieved.Itightenedeachrodbolttoachieveastretchof0.00425.Thetorquevalueamountofstretchboltlocationandnumberoftimeseachboltwastightenedisrecordedinalogbook. 58JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANorientation.Thechamferedsideofeachrodbigendalwaysfacesitsadjacentcrankjournalfillet.Ontheleftsidecyls135and7therodbigendchamfersallfaceforward.Ontherightsideoftheblockcyls246and8therodbigendchamfersallfacerearward.CylinderPistonValveRodChamferNumberPocketsOrientation1ExhaustIntakefacesforward3IntakeExhaustfacesforward5ExhaustIntakefacesforward7IntakeExhaustfacesforward2ExhaustIntakefacesrearward4IntakeExhaustfacesrearward6ExhaustIntakefacesrearward8IntakeExhaustfacesrearwardrelativetoblockfrontNOTETheleftsidedriversideoftheblockfromfronttorearfeaturescylinders135and7.Therightsidepassengersideoftheblockfeaturesfromfronttorearcylinders246and8.NOTEWhenpistonsfeatureanoilringsupportrailwherethepistonpinboreintersectswiththeoilringgroovethepistonsmustfirstbeinstalledtotherodssincethesupportrailswillblockpinentry.Priortoinstallingthepistonsandrodsthecylinderwallswerecarefullycleanedwithacleanlint-freeclothandafast-evaporatingsolventbrakecleanwipedrepeatedlywithfreshwhiteclothsuntilnotracesofparticleswereevidentonthecloth.Connectingrodbearingsaddlesrodandrodcapwerealsocarefullycleanedanddried.TheCleviterodbearingswereinstallednotethatupperandlowerrodbearingshellsdiffer.Theuppersareinstalledtotherodandthelowerstotherodcaps.ThebearingsaremarkedonthebacksideforUPPERandLOWER.RoyalPurpleMaxTuffassemblylubewasappliedtotheexposedbearingsurfaces.TheARP7168740rodboltswerethoroughlycleanedandtreatedtoARPUltraTorquemolyonboththreadsandtheundersideoftheboltheads.ThesecondandtopringswereorientedsoasnottoallowendgaplineupIgenerallyplacethegapsabout90to100degreesapart.Thecylinderwallswerethencoatedwith30-weightengineoilaswastheinnersurfaceoftheARPbillettaperedringcompressortool.Ipreferusingaone-piecemachinedringcompressorthatisdedicatedtoaspecificborediameter.Theinnerwallsaretaperedallowingasmoothslide-throughastheringscompressandenterthebore.ForthisbuildIusedanARPringcompressorsizedfora4.375bore.Therodbigendisinsertedthroughthetopoftheringcompressoruntilthepistonskirtsandallringsenterthecompressor.Withasectionoftheskirtsexposedbelowthecompressortooltherodiscarefullyloweredintotheboreuntilthepistonskirtsenterthetopofthebore.Irotatethecranktoplacetherodjournalnearbottom-dead-center.Whilealigningthepistonvalvepocketshorizontaltothefront-rearplaneofthedeckholdtheringcompressorfirmlyagainsttheblockdeckandpushtapthepistonintotheboreuntilthetopofthepistonisflushwiththedeck.Itsimportanttomonitortherodbigendasittravelstowardthecranktomakesurethatitisntcockedandhittingacrankcounterweight.WhileguidingtherodbigendwithonehandIhand-pushedlightlytappedeachpistonfullyintotheboreusingaGoodsonextended-snoutplasticpistonhammerthisfeaturesanextralongsnouttoallowfullpistondownwardmovementwithoutthehandleinterferingwiththeblockdeck.Whiletappingthepistondownintotheborepayattentiontotheupperrodbearingtomakesurethatithasntpoppedoutofposition.CarefullyaligntherodbigendtothecrankjournalOnceapairofrodshasbeeninstalledontoacommonjournalsideplayismeasuredwithafeelergauge.Ourrodsfeatured0.020sideplayoneachjournal. www.engineprofessional.com59 60JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANwhilegentlypullingtherodbigendontothecrankjournal.TheARPpistoncompressormadethejobabreeze.WiththepistonskirtsengagedintothetopoftheboreIcouldactuallypusheachpistonfullyintotheborewithaclosedfistwhileholdingthecompressorfirmlyagainsttheblockdeck.Installtherodcapandhand-installtherodbolts.Usingaratchetandinthiscasea71612-pointsockethand-tightenuntiltherodcapmatestoeachsideoftherodbigend.AccordingtothetighteninginstructionssuppliedwiththeScatconnectingrodstheARP7168740rodboltswithmolyshouldbetightenedtoavalueof64ft-lbandnottoexceed0.0046stretch.BeforeinstallingeachrodboltIfirstpositiontheboltontoarodboltstretchgaugethepointedanvilsofthetoolneatlyengageintodimplesontherodboltheadandshanktip.Withtherodboltonthegaugezerothedialindicator.Itheninstalltheboltandtightento45ft-lbandcheckforboltstretchusingthegauge.Ithentightento55ft-lbandre-checkwiththegauge.Inthisbuildwhentheboltsweretorquedto64ft-lbrodboltstretchmeasured0.00425thisverifiedthateachboltentereditsdesignedelasticrangebuthasnotexceededthedesignrange.CheckingrodboltstretchdoestakeafewmoreminutesasopposedtosimplytighteningwithatorquewrenchbutIfeelthatitstimewellspent.NotethatthespecificationIfollowed64ft-lbswasintendedwiththeuseofmolylube.IfarodorboltmanufacturerlistsdifferenttorquespecificationswithoilormolyyouMUSTfollowthetighteningvaluebasedonthetypeofboltlubricantbeingused.IfIhadusedoilinsteadofmolyandhadtightenedtothemolyspecIprobablywouldhaveslightlyundertightenedtheboltsduetotheincreaseoffriction.Molyisforlackofabettertermmoreslipperyallowingamoreaccuratetorquevalvetobeachieved.OnceeachpairofrodswereinstalledtoacommonjournalImeasuredrodsideplayusingafellergaugespreadtherodbigendsapartwithyourfingersandinsertafeelergaugebetweentherodbigends.InthisbuildImeasured0.020sideplay.CRANKDAMPEROurFluidamprPN720311featuresa7.25OD.Iinstalledbyfirstmeasuringthecranksnoutdiameterat1.534andthedampersfrontsteppedboreat1.532.Therearoftheboreisslightlyoversizedtoallowaneasyslip-onentry.Icoatedtheborewithcopperanti-seizeandpositionedthedampertothesnout.Usingabearing-equippeddamperinstallertoolIslowlydrewthedamperintoplaceuntiltherearoftheflangecontactedthefrontofthecrankgear.Anyonewhohasexperiencewithinstallingcrankshaftbalancersalreadyknowsbutasareminderneverinstallabalancerbystrikingitwithahammeroranyotherobject.MostdampersfeatureaslightinterferencefitandMUSTbedrawnontothecranksnoutevenly.TheARPcrankboltandwasherwasinstalledtighteningtoARPsrecommendationof160ft-lbs.ThecrankdamperboltARP245-2501featuresathreadsizeof16withanunderheadlengthof1.420.ARPUltraTorquemolywasappliedtothethreadsandtheunderheadareapriortoinstallation.A12-point1-116socketwrenchisrequired.InordertomaximizeignitiontimingprecisionIdecidedtoinstallMSDscranktriggersystem.Thisallowsamoreprecisetimingtobereaddirectlyatthecrankasapposedtothedistributorviathecamsdrivegearandtimingchain.TheMSDcranktriggerwheelboltstothefaceofthedamperandiscenteredviaamachineccenteringring.UnfortunatelythesuppliedMSDcenteringringwhilefittingthedamperandthetriggerwheelperfectlywastooshallowandwouldnotprotrudefarenoughoutwardtoengagethetriggerwheel.InordertoaccommodatethefittheboysatFluidamprmachinedagorgeousaluminumadapterthatextendsoutfarenoughtoacceptboththeMSDcenteringringandtriggerwheel.Thefitcouldnothavebeenbetter.Absoluteperfection.IsecuredthetriggerwheeltothedamperwithsixARPstainless12-point516x18x1boltsandstainlesswashers.OILPUMPBothhighvolumestandardpressureandhighpressurestandardvolumeoilpumpsareavailable.WechoseaMellingSelectM-63HVpumpthatfeatures20highervolumeandstandardpressure.Ifincreasedpressureisdesiredthespringisshimmedwithaflattenedlockwasher.Icarefullydisassembledthepumpsmoothedouttheexteriorcastingsofthetwohousingsmaskedandpaintedandreassembled.PriortoreassemblyIcoatedtherotorswithRoyalPurpleMaxTuffassemblylube.NotethatthehousingsaresealedtogetherwithtwoO-rings.AsuppliedO-ringisinstalledontothedrivebossbeforeinsertingthisintotheblock.Theoilpumpcoverwasre-securedtothepumpwithboltstightenedto10ft-lbandTheFluidamprcrankdamperwasinterferencefittoourcranksnoutandsecuredwithanARPcrankbolt. www.memorialmachine.comCONNECTINGRODSACCESSORIESWehavethemostuptodateconnectingroddepartmentintheindustry.Wehavedevelopedprocessestorebuildnearlyalltypesofhighspeedconnectingrodsincludingmanywithserratedcaps.ENGINEBLOCKSWehavethelargestandmostmodernengineblockrebuilddepartmentsintheindustry.Wehave8CNCboringmachinesandhavethecapacityofmachining3600CaterpillarandATWaukeshaengineblocks.MemorialMachinealsohasaroboticmetalsprayingsystemtoreclaimdamagedmainboresandworntopdecks.CYLINDERHEADSOurcylinderheadrepairservicemakesuseofthelateststate-of-the-artmachinesavailablespecificallydesignedtoproducethefinestqualityofwork.Allheadsarebuiltwiththehighestqualitypartsavailablematchedtoexactspecificationsforbothlandfillandnaturalgasapplications.AllheadsarebuiltwithNewPartsnotrefurbishedorreuseandsalvageguidelines.6303S.40thW.Ave.TulsaOK74132Toll-free800-437-7986Phone918-446-1828Fax918-446-1504SpecializinginRebuildingNaturalGasandLandfillGasEngineComponentsForover40yearsithasbeenourgoaltoprovidethehighestqualityenginecomponentrepairavailable.OurTulsaplantat43000sq.ft.isoneofthelargestmostmodernintheindustry.PlusourOklahomaCityplantwith23000sq.ft.givesustheabilitytolimitcriticaldowntime.CompleteReconditioningServiceavailableforwaterpumpsoilpumpsrockerarmassembliesfuelvalvesandmanyotheraccessoriesforhighspeedengines.WespecializeinthefollowingenginesWaukesha704270441179817AT-25AT-27WhiteSuperior6G-8258G-82512G-82516G-825Caterpillar379398399Caterpillar3508351235163520Caterpillar3606360836123616www.engineprofessional.com61 62JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANthepumpwasboltedtotheblockwiththesuppliedgasketthree38-16x2.75stainlesspolishedboltsandone38-16X4.5boltwithallfour38boltstightenedto35ft-lbs.TheoilpumppickupIusedaunitfromMorosothataccommodatestheir7-qtoilpanthreadsintotheblockviaa38NPTthreadedholeintheforwardleftsideoftheblock.Teflonthreadsealantwasappliedtothepickuptubesmalethreadswiththepickuphand-tightenedtoachievealevelpositionofthepickupscreen.WINDAGETRAYANDOILPANFollowingScottKoffelsrecommendationIobtainedaMoparPerformancewindagetrayPNP5007345fromSummitRacingdesignedtocleara4.150stroke.Thewindagetrayisinstalledandsandwichedbetweentheblockrailsandtheoilpan.Twogasketsarerequiredonebetweentheblockandwindagetrayandonebetweenthewindagetrayandoilpan.Duringtestfittingclearancebetweenthewindagetrayandtherodswasmorethanadequate.HoweverwhenusingaMoparPerformancewindagetrayitsnecessarytotrimanopeninginthewindagetrayinordertoclearthelocationandangleoftheMorosopickuptube.Thiswasdonewithacut-offwheeldiegrinderandminibeltsanderwithedgesdeburredandwindagetraythoroughlywashedandrinsed.Ifindithelpfultotemporarilyinstallsixormore516x18studsintheblockrailboltholestoaidinaligningthegasketswindagetrayandpanasapackage.Replacethestudswithboltsasyouprogresswithboltinstallation.Tightenalloftheoilpan516boltsto14ft-lbsstartingatthecenterareaandusingacriss-crosstighteningpatterntospreadtheclampingload.Ouroilpanisa7-quartMorososcenter-sumpsteelunitPN20760.ThewindagetrayandoilpanaresealedusingMahle-VictorgasketsOS31416.SinceIdecidedtopaintthetimingcoverandoilpantomatchtheblockthesecomponentswerepaintedseparatelyaftertestfittingandbeforefinalassembly.NOTEBeforeplacingtheblock-to-windagetraygasketapplyadotofRTVtotherightandleftareaswherethetimingcoverbasemeetstheblock.DIPSTICKPrimarilyforthesakeofappearanceIchoseaLokarflexibledipsticktubeassemblywhichfeaturesabilletaluminumtopandbottomconnectedwithalengthofstainlessbraidedhoseTeflonlined.Howeverthelowertubeinsertouterdiametermeasured0.365buttheholeintheblockmeasured0.0340whichforcedmetodilloutthedipsticktubeholeintheblockto0.369theLokarinsertfeaturesapairofsealingO-rings.IoftenbutnotalwaysfindfitmentproblemswiththeLokardipstickassembliessothiswasnoexception.Oncethewindagetrayandoilpanwereinstalledthedipsticktubeassemblywasinsertedintotheblock.ThestainlesssteelmountingbracketthatwassuppliedwiththedipstickassemblywasfartoolongandbenttoashapethatwouldnotallowmountingsooncetheTTIheaderswereinplaceIfabricatedasimpleL-bracketusing0.100-thickstainlessstock.FUELPUMPBLOCKOFFSinceIneededtorunanelectricfuelpumptofeedourHolleyTerminatorEFIsystemIinstalledamechanicalfuelpumpblockoffplateusingSummitRacingsSUM-G243polishedandball-milledaluminumplate.ThisisthesameplatethatfitsbigblockChevyapplications.ForinstallationonabigblockChryslerblocktherearcorneroftheplateneedstobeslightlyshavedforclearance.Thisisduetotheblockcastingsraisedareaattherearofthefuelpumpbossmachinedflatsurface.Usinga38minibeltsanderIremovedabout116fromtherearearoftheblockoffplateadjacenttotherearbolthole.Ithenhand-buffedwithScotchbritethenbuffedtheareawithmybenchbufferbacktoamirrorshine.IinstalledtheplateusingaMahle-VictorgasketalongwithathincoatingofPermatexUltraCopperRTV.TIMINGCOVERThetimingcoverequippedwithanewMahle-Victorsealisinstalledwithfour516-18boltsandfour38-18bolts.Iinstalledatimingpointertotherighthandsidewhichfeaturesa2-holebracket.Theupperholesharesa516boltandthelowerholesharesa38bolt.Dontfullytightenthetimingcoverboltsbeforeinstallingthewindagetrayandoilpan.Installthewindagetraywithagasketoneachsideandtheoilpan.Snugtheoilpanboltswhichmayslightlypullthetimingcovertowardsthepanrailprovidingamoreevengasketmatingsurfacebetweenthetimingcoverandpan.EventhoughthetimingcoverisregisteredOurMellingPerformancehigh-volumestandardpressureoilpumpPNM-63HV.Simplytocolor-coordinateouroilpumpIcarefullydisassembledcleanedmaskedandpaintedtomatchtheblockcolor.TheMoroso7-qtcenter-dumpoilpanisagoodchoiceasitwillfitthemajorityofvehicleapplications.Morosoincludedanextendedpickupmatchedtothispan.BecausetheextendedpickuptubepathdiffersfromanOEtubethewindagetrayopeningneededtobeslightlyenlargedtoprovidepickuptubemountingclearance. www.engineprofessional.com63 64JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANwithtwodowelpinstheremaybeaslightamountofmovementavailable.Tightentheoilpans516boltsto14ft-lbs.Tightenthetimingcovers516and38boltsto120in-lbs.PriortoinstallingthecylinderheadsIinstalledouraftermarkettopvalleytrayfrom440SourcePN127-1011.Thisisheldcaptiveundertheinboardedgesoftheheadssoitmustbeinstalledfirst.ThisvalleycovermustbesealedwithRTV.Icarefullymaskedofftheexposedareasthatrunparalleltotheheadsaswellasthefrontandrearoftheblockunderthevalleycover.ThisallowedmetowipeanyexcessRTVafterinstallationwithoutsmearingitontotheheadsorpaintedsurfaceofthevalleycoverorblock.IappliedathinbeadofPermatexUltraGrayRTVtothefrontandrearrailsontheblockandinstalledthevalleycoverusing400SourcebilletaluminumrailsandTotallyStainless-20xboltsandflatwashersusing12-pointboltsatthecenterofeachrailandbutton-headscrewsattheendsforintakemanifoldclearancewithadotofUltraGrayappliedtoboltthreadssnuggingtheboltsto50in-lb.ImmediatelypriortoinstallingtheheadgasketsandheadsIappliedabeadofabout316thicktotheuppersurfacesofthevalleycoversidebreaksthissealsthegapbetweentheheadsandvalleycover.Inallfourcornersofthevalleycoverasmallvoidexists.ThesevoidswerepluggedwithasmallglobofRTV.OncetheheadswereinstalledwiththemaskingtapestillinplaceIfinger-smearedthejoininglinewithRTVthenremovedthemaskingtape.Thiswasdoneinordertoachieveaneatandtidyappearance.NOTEIinitiallyconsideredusingPermatexTheRightStuffRTVtosealthevalleycoverbutIreconsideredoptingforUltraGray.TheRightStuffisabsolutelysuperbatsealingbutbecauseofitsoutstandingadhesionitcanbedifficulttodisassemblesomethingdowntheroadespeciallyathinsheetmetalpiecelikethisvalleycoverwhichwouldlikelybedeformedduringattempttobreaktheRTVloose.Ahigh-gradeRTVsuchasUltraGrayorUltraBlackorUltraBlueseemedamoresensiblechoiceforthisapplication.Itdoesthejobandiseasiertobreaklooseduringfuturedisassembly.CYLINDERHEADSTwopopularchoicesinperformancecylinderheadsforthisapplicationincludeEdelbrocksPN60929andMoparPerformancePNP5153524.TheEdelbrockcylinderheadsarrivedfullyassembledandfeature84cccombustionchambersdesignedfor1961-1979Chrysler361-440engines.Specsinclude15-degreevalveangle210ccintakeportvolume70ccexhaustportvolume2.140intakeand1.81exhaustvalvesallswirl-polishedstainlesssteelwithstemundercutsforbetterflow.Valvestemdiameteris1132.Valveguidesaremanganesebronze.Deckthicknessis58.Valvespringsfeature1.55diameterwithamaxliftcapabilityof0.600.Sparkpluglocationsareangled.Designedforusewith38pushrods.TheMoparPerformancecylinderheadsPNP5153524arealsofullyassembled.Thesecastaluminumheadswillfit1961-1978ChryslerB361383and400andRB413426Wedgeand440engines.Theseheadsfeaturean84cccombustionchamber210ccintakeportsand70ccexhaustports.Additionalfeaturesincludephosphor-bronzevalveguidesinterlockingductileironvalveseatsandpremiumone-piecestainlesssteelhigh-flow2.140intakeand1.810exhaustvalves.Heat-treatedmachinedsteelretainersandvalvelockswithheavy-dutyvalvespringsaccommodatevalveliftsupto0.600.Theexhaustflangehasbeenextendedout0.125inordertoprovidedryexhaustboltstudholes.ExhaustboltholesfeaturehelicalthreadinsertsforOurEdelbrockPerformerheadsPN60929feature84ccchambers2.140intakevalvesand1.810exhaustvalvesallswirlpolishedstainlesssteel.Deckthicknessis58.CylinderheadsweresecuredwithARPpolishedstainlesssteel12-pointheadboltschosenforbothtensilestrengthandoutstandingno-maintenanceappearance. www.engineprofessional.com65 66JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANaddedstrengthanddurability.WhileItestfittedboththeEdelbrockandMoparPerformanceheadsIoptedtogowiththeEdelbrockheadsforfinalassemblyanddynorun.Headchambertopistonclearancewithoutheadgasketinplacewasmeasuredat0.035attheupperquencharea.FactoringintheMLSheadgasketthicknessof0.040thisprovidesapiston-to-headchamberclearanceof0.075.Valvetopistonclearanceagainwithoutheadgasketmeasuredahealthy0.250attheintakeand0.270attheexhaustvalvelocations.OurcylinderheadgasketsaretheMLSmulti-layersteeltypefromCometic.Thesefeatureagasketboreof4.500andaninstalledthicknessof0.040CometicPNCGT-C5464-040.InordertosecuretheheadstotheblockIchoseARPs12-pointpolishedstainlesssteelheadboltkitPN445-3706.Theseare716diameterhightensilestrengthstainlessboltswitha180000psirating.IappliedARPUltraTorqueFastenerLubricanttoallboltthreadsandtoeachsideofeachflatwasherandtotheundersideofeachbolthead.NoteWheninstallingwasherstotheboltsnotethatonesideofthewashersfeatureaslightchamfer.Thischamfersidemustfacetheundersideoftheboltheadinordertoinsureclearancetotheradiusontheundersideofthebolthead.Eachboltwastightenedinsequenceinmultiplesteps.Edelbrocksrecommendationspecifiesathree-stepprocessstartingwith40ft-lbfollowedby55ft-lbthen70ft-lb.Ifollowedmypreferredfour-steptighteningstartingat25ft-lbsfollowedby40ft-lbfollowedby55ft-lbwithfinaltighteningat70ft-lb.ThepolishedARPstainless12-pointboltsprovideabeautifulfinishedappearancethatwillcomplimentanybuild.ThetighteningsequencespecifiedbyEdelbrockwasfollowedrefertothediagraminthisarticle.NOTEHeadgasketsthatfeaturestainlesssteelringsaretobeavoidedwhenusingaluminumheadsasthehardcombustionchamberringswontcrushsufficientlyandcandigintothesofteraluminumheads.PUSHRODSOurpushrodsarecustom38chromolyunitsfromTrendatlengthof8.318fromcupseattotipawallthicknessof0.080andcupandtipdiametersof516.DuringtestmeasuringIusedoneofmyadjustablecheckingpushrodswithcamlobesontheirbasecirclesandwiththerockerarmadjusterssetatadistanceof0.370fromthebottomoftherockerarmtotherockersadjusterball.Ithenadded0.050preloadforthehydrauliclifters.WiththecheckingpushrodcarefullyremovedIplaceda516ballinthecupofthecheckingpushrodandmeasuredoveralllengththendeductedthe516balldiameterwhichactuallymeasured0.312toobtainthefinalBOCbottomofcuplength.Becauseitsdifficulttomeasurefromthebaseofthepushrodcupusingthe516ballallowsyoutoobtainanaccuratemeasurement.Againmeasureoveralllengthofthecheckingpushrodfromtheballtothetipthendeductthediameteroftheball.Inourapplicationtheoveralllengthofourcheckingpushrodwithtemporaryballplacedintheuppercupmeasured8.590.Subtractingthe0.312balldiameterresultedinadesiredBOClengthof8.318.ROCKERASSEMBLYTheMoparBenginesutilizeashaft-mountedrockersystem.ForthisbuildIchoseasubstantialupgradetoCranealuminumrollerrockersPN64790-1intheoriginal1.51ratio.Theserockersfeatureabeefyandstrongbodystructureheavydutyrollerbearingtrunionsforvalvecontactacutawayreliefontheundersideofthevalveareatoaccommodatelargerdiameterspringretainersandtherequiredoffsetthreadedadjusterholesinordertoalignthepushrodstotherockers.Includedinthekitwerehardenedball-tipthreadedadjustersandnutsand0.015shaftspacershimsandsprings.Cranealsosuppliesabottleoftheirhighpressurelubricantforthethreadedadjustersadjusterballtipsandrollerbearings.IsourcedMoparPerformancerockershaftsPNP4529101fromSummitRacingalongwithasetofMoparPerformancebilletaluminumrockershafthold-downhardwarePN5249714.AnOE-stylehold-downkitwouldbeacceptablefromafunctionstandpointbuttheblueanodizedhold-downsweretooprettytopassup.InsteadofusingOEtypespringsbetweenrockerswellusebilletaluminumspacersandshimaccordinglytoobtainpreciserockerarmplacements.RatherthanusingaconventionaltinintakegasketthatalsoservestocovertheliftervalleyIoptedforindividualcompositeintakemanifoldgasketsandanaluminumvalleycoverfrom440Sourcealongwithbilletaluminumrailhold-downs.Thisprovidesamuchcleanerappearanceasopposedtothestocksetup.Payattentionwheninstallingtherockershafts.Thesmalloilholesmustfacedownward.Alsonotthattheoilholesareslightlyoffsetinrelationtotherockerboltholes.Theoilholesmustbebiasedtowardsthevalves. 513.502.9746GetCleanPartsUltraSonicCleaningBEFOREAFTERBEFOREAFTERBEFOREAFTERBEFOREAFTERwww.engineprofessional.com67 MOPAR499PROJECTBYMIKEMAVRIGIANAssemblyoftheshaftmountedrockersystemrequiresabitoftimesopatienceisneededinordertoproperlypositionallrockerssothattherockerrollertipsalignwiththecenterofeachvalvetip.ApackofCrane0.015shimsareneeded.Alwaysplaceatleastoneshimbetweeneachrockerandeachrockerspacerdontallowtherockerstorunwithoutatleastoneshimoneachside.Additionalshimsmaybeneededinordertoachieverockeralignmentwiththevalves.Craneofferstheseshimsinpacksof32shims.Totalsideclearancebetweenapairofrockersshouldbeapproximately0.015.Notethattherockerrollertipsdonotneedtoperfectlycenteronthevalvetips.Priortoinstallingtherockershaftassemblypainteachvalvetipwithablackmarker.Oncetheassemblyhasbeeninstalledandlashadjustedyoucanrollthecrankwhichwillcausetherockerrollerstoleavewitnessmarksonthevalvetips.Aslongasthewitnessmarksarenocloserthan0.040fromtheedgeofthevalvetipsthatscloseenough.Ifrockerpositioningneedstobecorrectedwheresideclearanceistootightthesteelspacersthatrepositionedbetweenrockerscanbeflat-sandedtoincreaseclearancewhereneeded.NOTEClearancebetweenrockerarmandrockershaftshouldbeintherangeof0.00250.003.Checkthisduringtestassembly.Useaninsidemictomeasurerockerarmshaftboreandanoutsidemicrometertomeasureshaftdiameter.GenerallythisclearancewillbeOKoutoftheboxbutcheckitanyway.Bench-assembleeachshaftwithrockersrockerspacersandshimslocatingthebillethold-downblocksintheirappropriatepositionsfiveblocksperhead.NOTEOnesideofeachrockershaftfeaturesaseriesofsmalloilingholes.Wheninstalledtheseoilholesmustfacedowntowardstheheadbiasedtowardsthevalves.Someshaftsmayhaveoilholesthatareinlinewiththeboltholesandothershaftsmayfeatureoilholesthatareslightlyoffsetinrelationtotheboltholes.Thesideoftheshaftwithoilholesmustfacedown.Ifoilholesareoffsettheymustfacedownandbebiasedtowardsthevalves.Installthepushrods.Loosenallrockeradjustersinordertoclearthepushrodtipsinitially.Placetherockershaftassemblyontotheradius-seatstanchionsontheheadandhand-snugthehold-downblockboltstothehead.Threadtherockeradjusterstocontactthepushrods.InspecteachvalvelocationforrockertipalignmentYouwanttherockerrollertipcenteredtothevalveascloseaspossible.Noteanylocationsthatrequirealignmentadjustment.Removetheshaftassemblyslideofftherequiredrockersspacersandshimskeeptheminorderinordertoinstallanadditionalshimwhereneededandreassembleandreinstalltotheheadandcheckspacingagain.Thismaytakeanumberofattemptsanditcanbetimeconsumingbutbepatientandpayattentionbykeepingeverythinginorder.DuringtestfittingforrockersideclearanceIwasforcedtonarrowafewofthesteelspacersthatarelocatedbetweenpairsofrockersflat-sandingonmachinistsgraniteandemerycloth.Mostofthespacersinitiallymeasuredat0.587inwidthandmostrequiredremovaloffrom0.004to0.007.Eachhold-downblockboltholehasafewthousandthsofwiggleroomasdotheboltholesintheshaftitselfsoitstedioustofactorinallofthetoleranceswhentryingtoobtainrockersideclearance.Onceyouveadjustedthelateralpositionsoftherockersforvalvealignmentcarefullydisassembleeachshaftassemblykeepingallpiecesinorderandapplyengineoilorengineassemblylubetotheshaftbushingofeachrockerandreassembleandinstall.Ifthepushrodlengthiscorrectyoushouldhaveapproximately0.0370oftherockerballadjustersprotrudingfromundereachrockerarm.Ifverticalspacingisanissueshafttoolowisrelationtopushrodsradiusspacersareavailabletoraisetheshaftsbetweentherockerstanchionsinthecylinderheadandshaft.68JAN-MAR2015engineprofessionalOnecriticalaspectofadjustingtheshaftmountedrockerassemblyisobtainingacenteredlocationofeachrockerrollertoeachrespectivevalve. www.engineprofessional.com69 70JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANTighteneachrockershafthold-downboltto25ft-lbswithboltthreadsTefloncoated.AgainmakesurethattheshaftsareinstalledwiththeseriesofsmalloilholesfacingdownwardNotethatyoualsoneedtocheckclearancebetweenthebottomoftherockerandthevalvespringretainerwhenthevalvesareclosed.Clearancehereneedstobeatleast0.010.Settingupashaftrockersystemisntdifficultbutitcanrequireafewhoursofadjustingforsideclearanceduetothestack-upofinitialclearancesthatyoumayencounter.Thiswillrequirenumerousproceduresofmeasuringdisassemblyinorderandreassemblyinorder.Itmaybeabitofapainbutafewhoursspentadjustingrockersideclearancesandvalvetipalignmentiswellworththeeffort.Thetrickistobepatientandkeepallpiecesfromfronttorearoftheshaftassemblyinorderduringdisassemblyandassembly.NOTERockershaftshimspacksareavailableinthicknessof0.0100.015and0.030.Theseareradiusedshimsthatinstallbetweentherockershaftandheadinordertoraisetherockershafts.Thismaybeneededtocorrectforrockerarmgeometryifthepushrodsaretoolongorifyoumilltheheadsorblock.TheseareavailablefromseveralvendorsincludingManciniRacingand440Source.WATERPUMPWheneverIcanutilizeanelectricwaterpumpIpreferthisasopposedtoamechanicalpumpsinceitnotonlyfreesupabeltdrivereducingthatlittlebitofdragonthecrankbutbecausetheMezierepumpsspitoutadependableconstantpushofcoolantthroughtheblockforsuperiorcooling.Andbesidesitjustplainlooksnifty.ForthisbuildIoptedforamodelPNWP106SinanodizedblackalongwithaMeziereinletPNWP1175SalsoinanodizedblackinordertocontrastnicelyagainsttheplannedHemiorangeoftheblockandtimingcover.ThepumpincludedoptionalheaterhosestraightANfittingsalongwitha1waterneck.TheMezierepumpfeaturesachoiceofrightorleftpositionneckforthelowerradiatorhosewhichisaniceideaaccommodatingeitherlowerhoselocationdependingontheradiatorofchoiceandthevehicleenginebayconfiguration.Ananodizedaluminumplugisprovidedtosealofftheunusedport.ThebilletCNCmachinedaluminumpumpfeaturesastainlesssteelmainshaftandceramicsealandweighsinatamere7.1lbs.ThismodelWP106SfitsMoparBandRBenginesaswellasHemis.Thepumpisratedtoflowat35gallonsperminutesuitableforenginesuptothe650HPrange.AhigherHPengineorenginerunningasuperchargerorturbomayrequireapumpratedat55gallonsperminute.Awiringharnesswith20-ampfuseisincluded.Normaloperationsdraw6to7amps.UsingaMeziereelectricwaterpumpofferstwoprimaryadvantagesNoneedforadrivebeltreducingparasiticdragonthecrankshaftandareliableandconstantwaterflowthatisntdependentoncrankshaftrotation.Thepumpmountstothefrontoftheblockwithsix38-16x1.125stainlesssteelsocketheadcapscrewsandsix38ANwashersprovidedwiththepumpandapairofgaskets.GasketsareprovidedwiththepumpbutwehadtheoptionofusingthegasketsprovidedinourMahle-Victorgasketsetaswell.IappliedalightbeadofUltra-BlackPermatexRTVtobothsidesofbothgasketspriortoinstallation.Thewaterpumpmountingboltsaretorquedto25ft-lbs.CRANKTRIGGERForthisbuildIdecidedtotakeadvantageofMSDscranktriggerignitionsystem.Thisfeaturesareluctorwheelmountedtothecrankdamperandastationaryandadjustablesignalpickupsensor.Thisallowstheenginetofirebasedoncrankshaftpositioninsteadofthroughthedistributorwheretolerancevariablesincludingpotentialslopatcamgearlashandthetimingchainarenoweliminated.WhileastreetenginereallydoesntneedthiscranktriggersystemsaremostbeneficialonaraceengineacranktriggerWhymesswithamechanicalwaterpumpandbeltwhenyoucandecreaseparasiticdragandprovidetheenginewithsuperiorandconsistentcoolantflowwiththeuseofanelectricwaterpumpOurshopschoiceisalwaysaMezierepump.Forthisbuildwechoseananodizedblackunit.Thelowerradiatorhoseneckthreadsintothebottomofthepump.Thepumpfeaturesachoiceofrightorleftneckpositionstosuitthebuildersradiatornecklocation.Theun-usedportissealedwithaprovidedthreadedplug.Theunitwechoseisratedat35gallonsperminute.TheMezierepumpasusualprovidedaperfectfittoourblockwithnomodificationsneeded.Weinstalledabilletaluminumwaternecksecuredwithpolishedstainless12-pointboltsfromTotallyStainless. SPECIALIZINGINREPLACEMENTPARTSFORBENDIXCARRIERCATERPILLARCUMMINSDETROITDIESELHINOISUZUMIDLANDNAVISTARTHERMO-KINGTRANE...yourFriendlyalternativeDieselenginepartsESCOINDUSTRIESINC.TOLLFREE1-800-372-6872FAX951-782-2136SALESESCOUSA.COMWWW.ESCOUSA.COMALLOTHERCOMPANYBRANDPRODUCTANDSERVICENAMESAREUSEDHEREINFORIDENTIFICATIONPURPOSESONLYANDMAYBETHETRADEMARKSSERVICEMARKSORTRADENAMESOFTHEIRRESPECTIVEOWNERS.THEREISNOAFFILIATIONORSPONSORSHIPBETWEENTHESECOMPANIESANDESCOUNLESSEXPRESSLYSTATED.CARRIERBENDIXAREPLASPECIALIZINGINTERPILLARCARRIERBENDIXARTSFORCEMENTREPLASPECIALIZINGINTHERMONMIDLANDISUZUHINODETROITDIESELCUMMINS-KINGRMIDLANDISUZUHINODETROITDIESELCUMMINSTERPILLARTRANE-KINGTHERMOiend...ourTRANE-KINGyalternativeDieselenginepartsyalternative...yourFDieselenginepartsyalternativeED.XPRETHESECOMPBETWEENSPONSORSHIPTHEREISNOTHEIRRESPECTIVEOWNERS.OFVICEMARKSORTRADEMARKSSERTHEBEAREUEDHEREINFRIDENTIFIBRANDPROOTHERCOMPALLANDESCOUNLESSANIESTHESECOMPINRAFFILITHEREISNOTRADENAMESVICEMARKSORANDYTIONPURPOSESONLVICENAMESANDSERBRANDPRODUCTwww.engineprofessional.com71 systemissimplyoffersamorepreciseformofignitiontiming.Withnumber1cylinderatTDCwethenrotatedthecrankat32degreesadvance.Wetheninstalledthereluctorwheelontothecrankdampersothatoneofitsmagnetsalignedwiththepickupsensor.Duringthedynorunwewouldthenbeabletomakefurtheradjustmentsifnecessary.Wheninstallingthepickupsensorinitsadjustablebracketthethreadedsensorbodyallowsyoutoadjusttheairgapbetweenthepickuptipandreluctorwheelmagnets.Andairgapof0.050to0.080isacceptable.Wesetoursat0.065.DISTRIBUTORTheMSDProBillet8545distributorfeaturesacentrifugaladvance.SincewererunninganMSDcranktriggersystemweneedtolockoutthecentrifugaladvanceinthedistributor.1.Removetheadvancecomponentsincludingthespringsweightsandtheadvancestopbushingfromtheadvanceassembly.Youllneedan1132open-endwrenchtoremovethestopbushingslocknut.Becarefulnottolosethesmallflatwasherthatsunderthelocknut.2.Removetherollpinfromtheshaftcollarandslidetheshaftoutofthehousingby2.3.Rotatetheshaft180degreesandinserttheadvancestopbushingpinintothesmallholeintheadvanceplate.4.Installthewasherandlocknuttotheadvancestopbushing.Thislockstheadvanceinplace.5.Slidetheshaftintothecollarandinstalltherollpin.VALVECOVERSIselectedapairofcastaluminumpolishedflat-topvalvecoversfromSummitRacing.Thesecoversprovidedatallrooftoprovideplentyofrockerarmclearanceandaflattopidealforengraving.Ihadthevalvecoverspowdercoatedinasilversplashfinishessentiallyacharcoalcolorthatfeaturesatexturedwrinklefinish.IthenhadthecoverstastefullyCNCengravedwiththetype499WEDGEbyPlateEngravinginnearbyMedinaOhio.INTAKEMANIFOLDTheWeiandG-Forcesingle-planeintakemanifoldPN7533wascheckedforport-matchtotheintakegasketsandcylinderheads.Onlyaveryminorkisswasrequiredontheintakemanifoldports72JAN-MAR2015engineprofessionalMOPAR499PROJECTBYMIKEMAVRIGIANOurvalvecoversarecastaluminumunitsfromSummitpowdercoatedinawrinklefinishandCNCengraved.TheMSDdistributorfeaturesacentrifugaladvance.Sincewererunningacranktriggersystemweneededtolockouttheadvancemechanism.Thewheel-to-pickupwassetupwithaninitial32degreesinconjunctionwithlockingoutthedistributorsadvancemechanism.Withthecrankrotatedtoplacenumber1cylinderatTDCthecrankwasfurtherrotatedto32degreesadvance.Thereluctorwheelwasthenpositionedwithoneofthemagnetsalignedwiththepickup.Thisisdonebyre-orientingthewheelonthecrankdamperinconjunctionwithadjustingthepositionofthepickup.Wechose32degreesadvanceforinitialdynorunningbeingabletofurtheradjusttimingbysimplyadjustingthepickupinitsbracket. www.engineprofessional.com73 74JAN-MAR2015engineprofessionaltoobtainamatchitcouldhavebeeninstalledwithouttouchingit.BecauseIoptedtouseanaftermarketvalleycoverthatdoesnotincorporateintakegasketingseparatecompositeintakegasketswereobtainedfrom440Source.EventhoughthegasketsfeatureaslightlystickycoatingIappliedaverythinsmearofUltraGrayRTVaroundeachportpriortoinstallationdontapplyabeadasthiscanspreadoutwhenthegasketiscompressedandcanprotrudeintotheintakeportsdisruptingairflow.IappliedaverylightthinsmearofRTVprimarilytoholdthegasketsinplaceduringassembly.Ifyouplanonracingtheengineandexpecttoremovetheintakemanifoldregularlyathinsmearofgreaseontoeachsideofthegasketsisanalternative.Undercompressionthegreasewillaidinsealingandwillmakeitmucheasiertoremovethemanifoldinthefuture.Theintakemanifoldtighteningspecsarerecommendedinthreesteps10ft-lbfollowedby15ft-lbfollowedbyafinal25ft-lb.SincealloftheintakemanifoldboltholesareopentooilopentothetopofthecylinderheadsIappliedacoatingofTeflonthreadsealertoalleightoftheARPintakemanifoldboltthreads.Becausethecenterfourmanifoldboltsaresomewhatshroudedbytherunnersandplenumastraightsocketwrenchcannotbeusedonthosefourbolts.InordertotorqueallboltsequallyIuseda38-drivetorquewrenchalongwitha2wrenchextensionfeaturingabox3812-pointtoaccommodatetheARPboltheads.Whenusinganextensioneffectivelylengtheningthetorquewrenchthesettingonthetorquewrenchmustbeadjustedtocompensatefortheincreasedleverageofthetorquewrench.EventhoughtheouterfourmanifoldboltsareeasilyaccessiblewithouttheneedforanextensioninordertoinsurethatallboltsweretightenedtoequalvaluesIusedtheextensiontotightenalleightbolts.TORQUEWRENCHADJUSTMENTWHENADDINGAWRENCHEXTENSIONWhenaddinganextensiontoatorquewrenchwherethelengthoftheareafromgripcentertoboltengagementbecomeslongeryoumustreducethesettingonthetorquewrench.Otherwiseyoullover-tightenthebolts.Determiningthesettingtoachievethedesiredtorqueiseasy.HerestheformulaLdividedbyLExTETWlengthofthetorquewrenchdividedbythecombinedlengthofthetorquewrenchandextensionismultipliedbythedesiredtorquevalue.Theresultistheappropriatetorquewrenchsetting.Lrepresentsthelengthofyourtorquewrenchmeasuredfromthecenterofthegriptothecenteroftheratchetheadcenterofgriptocenterlineofthebolttobetightened.Erepresentsthelengthofthewrenchextensionfromcenterofsquaredriveholetocenteroftheboxwrenchendhole.TErepresentsthedesiredtorquethetorquethatyouwanttoachieveTWrepresentstheactualsettingonthetorquewrench.Inthiscasemytorquewrenchmeasures14fromcentergripareatothecenteroftheratchethead.Mywrenchextensionmeasures2.SointhisapplicationLis14andEis2.UsingourformulaLdividedbyLplusE14dividedby16equals0.875.Nowwemultiplyourfactorof0.875xourdesiredtorqueinordertoknowwheretoadjustourtorquewrench.Whenusinga14torquewrenchalongwitha2wrenchextension1.Inordertoachieveourinitialappliedtorqueof10ft-lbwemultiply0.875x10whichmeansthatwesetourtorquewrenchat8.75ft-lb.2.Inordertoachieveoursecond-stepappliedtorqueof15ft-lbwemultiply0.875x15settingourtorquewrenchat13.125ft-lb.3.Inordertoachieveourfinalappliedtorqueof25ft-lbwemultiply0.875x25settingourtorquewrenchat21.875ft-lb.Whenaboltheadisinaccessiblewithastandardstraightsocketwrenchitstemptingformanypeopletouseaboxwrenchandsimplyguessatthetighteningvalue.Whereaccessisanissueuseawrenchextensionandadjustthetorquewrenchsettingaccordinglytocompensate.NOTEWhenusingawrenchextensionwhereyouremakingthetorquewrenchlongerorienttheextensionin-lineparallelwiththelengthofthetorquewrench.Avoidclockingtheextensionatananglerelativetothetorquewrenchasthiswillaltertheactualappliedtorque.MOPAR499PROJECTBYMIKEMAVRIGIANOurWeiandTeamGsingleplaneintakemanifoldprovidedaneasyinstallation.Whileanoutoftheboxinstallwouldhavebeenadequatewetookthetimetoobtainaperfectmatch-upbetweenthemanifoldportsandtheheadintakeportsinordertomaximizeflowefficiencyaswedowithallofourintakemanifold-to-headfitments.Duringportmatchcheckingonlyaminimalamountofportdressingwasneededtoobtainasmoothflowtransition. www.engineprofessional.com75MANIFOLDBOLTTIGHTENINGSEQUENCEThestockfactorytighteningsequenceisfollowedduringintakemanifoldbolttightening.Notethatleftsideindicatesdriversideandrightsideispassengerside.Followthesamesequence18duringeachtighteningstepat10ft-lbat15ft-lbandat25ft-lb.ORDERBOLTLOCATION1Leftsidesecondfromfront2Rightsidesecondfromfront3Leftsidethirdfromfront4Rightsidethirdfromfront5Leftsidefront6Rightsidefront7Leftsiderear8RightsiderearFASTENERTORQUESPECIFICATIONSMainstudnutswARPmoly100ft-lbRodbolts716ARP8740wmoly64ft-lbdontexceed0.0046stretchCylheadboltsARPstainlesswmoly70ft-lbOilpumptoblock35ft-lbRearmaincapbolts30ft-lbFuelpumpblockoffplate30ft-lbOilpan14ft-lbCamshaftbolt35ft-lbwLoctite242Timingcover120in-bRockershafthold-downbolts25ft-lbwTeflonsealantValvecover80in-lbARPcrankdamperbolt160ft-lbwARPmolyIntakemanifoldbolts10then15then25ft-lbValleycoverrails100in-lbCranktriggerwheeltodamper25ft-lbwLoctite242Waterpumpbolts25ft-lbOURCLEARANCESMainbearingclearance0.0025Crankshaftthrustclearance0.005spec0.003-0.007Rodbearingclearance0.0025Rodsideclearance0.021Pistontowallclearance0.005Topringgap0.020Secondringgap0.022Pistonpintopiston0.0009Pistonpintorod0.0008Rodsideplay0.020THEMOPARDYNORUNWepull657HPandripitupwith642lb-ftoftorque.Withtheenginefinallyfullytest-fittedandassembleditwastimeforthereal-worlddynotest.SinceKoffelsPlaceIIwasourlocationfortheblockmachiningandcrankbalancingworkitonlymadesensetotakeadvantageoftheirenginedynofacility.KoffelsspecializesinallthingsMopar.TheyrelocatedinHuronOhioastonesthrowfromthesouthernshoresofLakeErie.OnceIdeliveredtheenginetoKoffelsitwasfittedwiththeirdynodriveplateandwheeledintothedynocell.Thefirstorderofbusinesswastoprimetheenginewith30Woiltomakeabsolutelysurethatoilwasdeliveredtoallbearingsandtotherockerspriortofiringourvirginengine.TheplanwastofirstruntheenginewithoneofKoffelsknown-goodHolleycarbsbreakinginthenewflattappetcamandallowingtheringstoseat.Followingtheinitialbreak-inruntheoilandoilfilterwereremovedandinspectedluckilywithnosignsofanyconcerns.OncetheoilandfilterwerereplacedandaslongastheHolleycarbwasstillinplaceScottKoffelpulledtwodynorunswiththecarbtoestablishabaseline.WhileIhadinitiallysettimingat32degreesScottadvancedtimingfurtherto34degreeswithadistinctimprovementinhorsepowerandtorquemovingfrom638HPat32degreesto644HPat34degrees.Whileourcarb-equippednumbersputasmileonourfacesquitefranklyIwasquitehappywithourfirstnumberswecouldntwaittotryoutournewHolleyTerminatorEFIsystemwhichprovedtobearealeye-openerrampingupto657HPwithease.OURBESTNUMBERSTakeaglanceatthedynosheetsaboveforthedetailsonbothinitialpulls.ThesefirsttwopullsweredonewithoneofKoffelsknown-gooddynoshopcarbsaHolley4150series900cfmcarb.Thisisacarbthathasbeenmassagedtweakedtunedcuddledandkissedforyearsandkicksbuttwestartedwithacarbfortworeasonstobreak-inthenewcamandtoobtainsomebaselinedatapriortotestingtheHolleyTerminatorEFIsystem.Withthe900cfmcarburetorAt32degreestimingshepulled638HPat5500rpmand641lb-ftoftorqueat4800rpm.At34degreestimingshepulled644HPat5800rpmand639lb-ftoftorqueat4800rpm.Theinitialresultswerenotbadatallforafully-streetablemotor.Itwasobviousatthispointconsideringthetorqueoutputthatshewouldbearealstump-puller.EFIWhileIinitiallyplannedtouseaHolley4-barrelcarbinthe800850cfmrangeduringmyplanningperiodIdiscoveredHolleysnewTerminatorEFIsystemandcouldntresist.Thissystemfarexceededmyexpectations.Thesystemincludesathrottlebodyequippedwithfourbuilt-ininjectorsawiringharnesscontrollerandahand-heldplug-incontrollerthatallowscustomtuning.Thisisakillersystem.AfterobtainingourinitialreferencepullsusingthecarbweinstalledtheHolleyTerminatorEFIsysteminstallingthethrottlebodyunittheHolleyharnesswhichconnectstotheHolleyTerminatorkitscontrollercoolanttempsensoroxygensensorandplug-inhand-heldtunermodulealongwithconnectingthefuelsystemusing6plumbingfromthethrottlebodytoahigh-pressure Aeromotiveelectricfuelpumpcapableoffeedingupto1300HPandanadjustablebypasstypeAeromotivefuelpressureregulatorfromthethrottlebodytofueltanksetat45psi.TheTerminatorsystemisdesignedtoprovideaself-learningadaptiveapproachwiththeHolleycontrollercontinuallyadjustingthesystemsfueldeliverybasedondriverhabits.Whilewedidnthavethetimetowaitforthesystemtoself-learnrememberdynotimeisexpensiveandScotthadseveralraceengineswaitingfortheirturnsonthedynocellScottusedtheHolleyhand-heldprogrammingpadtoessentiallybypasstheprogramandinScottswordsgiveusallofthefuelthatthesystemwouldallow.Suddenlytheenginewokeupandscreameddeliveringawhopping657HPand642lb-ftoftorqueinaheartbeat.Whiletheinstructionmanualinitiallyseemsabitdauntingsettingupandprogrammingthesystemturnedouttobequiteeasy.ScottwassoimpressedbytheTerminatorthatheplanstoobtainoneforhisownlong-termexperimentation.ForarenownedbuilderandraceenginetunerlikeScottKoffeltobeimpressedandexcitedaboutanynewproductisreallysayingsomething.WiththeHolleyTerminatorEFIAt34degreestimingtheenginepulledapleasing657HPat5800rpmandanimpressive642lb-ftoftorqueat4800rpm.TheTerminatorallowedtheenginetoproduceanadditional13HPoverthecarburetedrunwhichisprettydarnedimpressiveconsideringthatweonlyspentamere20minutesorsoofdial-intuningtime.ItsimportanttoconsiderthatallofourrunsweremadewithEdelbrocksPerformerheadsinout-of-the-boxbolt-onstate.ScottKoffelnotedthatwhiletheseheadsdidanoutstandingjobwithabitofhiscustomcylinderheadportingandplayingwithtimingandadditionalEFItuninghewasfirmlyconvincedthathitting700HPwouldbenoproblematall.ImustadmitthatIvealwaysbeenacarbguyfromastandpointoftraditionsimplicityandoldschoolappearancebutafterseeingfirst-handhowrelativelysimpleitwastoadaptthisEFIsystemtoourlittlepunched-outMoparIthinkthatIvebecomeaconvert.HolleysnewTerminatorEFIisakillersystemintermsofefficiencyandperformancewhileretainingacarburetor-likeappearanceanditstune-ableontheflythankstothehand-heldprogrammingcontroller.I76JAN-MAR2015engineprofessionalMikeMavrigianhaswrittenthousandsoftechnicalarticlesoverthepast30yearsforavarietyofautomotivepublications.InadditionMikehaswrittenmanybooksforHPBooks.ContacthimatBirchwoodAutomotiveGroupCrestonOH.Call330435-6347ore-mailmikebirchwoodautomotive.com.Websitewww.birchwoodautomotive.comMOPAR499PROJECTBYMIKEMAVRIGIAN www.engineprofessional.com77 78JAN-MAR2015engineprofessionalTheCumminsISXandQSX15.0literengineshavebeenaroundforawhile1997andhaveexperiencednumerouschangesandupdates.ThisenginehashadmanymarketingnamesandwasfirstknownastheSignature600.Afewnotableareasofconcernthatyoushouldbeawareofthatareshowingupduringaftermarketoverhaulsareregardingthetypesofconnectingrodsandalsothedif-ferentborediametercylinderblocksandliners.Morecommonlyknowncurrentlyaretheissuessurroundingthedrilledvs.non-drilledtypeconnectingrods.Thereishoweverathirddesignconnectingrodtoconsiderafracturedtypewhichseemstobethetrendinconnectingrods.Theearlierrodshavemachinedsurfacesbetweentherodandrodcapmatingsur-faceswhereasfracturedrodshaveroughsurfacesonboththerodandcap.Theroughsurfacesresultingfromtherodbeingfracturedduringthemanufacturingprocessasshowninthephotoattheright.Allthreerodtypesusedifferentconnectingrodbearings.Eachbearingisdesigneddif-ferentlytoensuretheycannotbeinstalledintothewrongconnectingrod.Historicallydrilledconnectingrodscouldbeusedinplaceoftheoldernon-drilledrodshowevernon-drilledrodscannotreplacedrilledrods.Adrilledrodhasanoilpassagethroughthestrutoftherodthatallowsoiltotravelfromtheconnectingrodbearinguptothepistonpin.Ifanon-drilledrodisusedinadrilledrodapplicationtherewouldnotbesufficientlubricationreachingthepis-tonpinandthecylinderwillmostlikelyseize.Thefrac-turedrodsarealsodrilledandcanbeusedinplaceoformixedwiththeearliermachinedrodsiftheweightsaresimilar.Specialcaremustbeusedwhenhandlingfracturedconnectingrods.Therodcapshouldbekeptcom-pletelyseparatedfromtherodortightenedcorrectlytotherodwheneverthepartsarehandled.Iftheyareassembledandtheboltsarenottightenedthesurfaceswillscrubtogetherandtherodwillnottorquecorrectlywhenreassembled.Somethingassimpleasdroppingthecaportemporarilyputtingitonbackwardswilldamagethesurfaces.Theserodsmustbereplacedifthereisanydamagetothematingsurfacesoftherodorcap.Eachtimethefracturedjointisseparat-edsmallamountsofdebrismaybepro-duced.Thesurfacesshouldbecarefullycleanedwithsolventandasoftnylonbrushdonotuseawirebrushorcoursemethodwhencleaningthesesurfaces.Ifthepartinglinebetweentherodandcapisnotvisibleyoudonothavetoremovethecaptoidentifytherodtype.Afracturedrodhasasmallholeonthebottomfortherodcapandamachinedroddoesnothaveaholeinthecap.DependableCumminsISXBYSTEVESCOTTRIGHTFracturedRodCapSurface www.engineprofessional.com79Whendiscussingalargeborelinerorcylinderblockonetypicallythinksoftheinsidediameterofthecylin-derandpistons.HoweverfortheISXQSX15literenginesthisisnotthecase.Thediameterbeingreferredtoisfortheoutsidediameterofthelinerandthereceiv-ingboresizeofthecylinderblockthisonlypertainstothelatestyleflattopliners.Thedifferenceindiame-tersisonly.0782mmthustheconcernisthatsome-oneunknowinglymightinstallthesmallerODlinerintothelargerODblock.Thiscouldresultincoolantenter-ingtooilsystemevensomethingasmajorasacata-strophicenginefailure.Theselargerborecylinderblocksarebackwardscompatiblewithpreviousproduc-tionblocksbutdorequiresomeadditionalparts.Thelinersarenotbackwardscompatible.UnfortunatelyaccordingtoaCumminstechnicalservicebulletinTSB110277theexactproductionofengineswiththelargerboreblocksisnotcompletelyclearandthereisapotentialthatQuickServeCumminsonlineprogrammaylisttheincorrectblockandcylinderlinerpartnum-bers.InadditionifanenginehashadthecylinderblockshortblocklongblockorremanufacturedcontinuedCorrectRodCapMatingSurfaceUseagainlikenewconditionDamagedRodCapMatingSurfaceDonotreusedamagedcondition 80JAN-MAR2015engineprofessionalDEPENDABLECUMMINSISXBYSTEVESCOTTenginereplacedthenitcouldpotentiallyhaveeitherthesmallorlargeborecylinderblocks.TheCumminsbulletinstatesAnySignatureQSXandISXCM570CM870CM871CM2250enginesthathavehadacylinderblockkitReConshort-blockReConlong-blockorReConenginereplacedafterJanuary1st2010couldpotentiallyhavebeenbuiltwitheitherasmallborediametercylinderblockandcylinderlineroralargeborediametercylinderblockandcylinderliner.Asyoucanseebythedimensionslistedbythediagramatthefarrighttherefer-encetosmalllargeisreallynotthatmuch2mmandgreatattentionnoeyeballingheretothisareaisrequiredduringpartsorderingandengineassembly.IMPORTANTNOTEAsmalloutsidediametercylinderlinerwillvisuallyappeartohavebeencorrectlyinstalledintoalargeborecylinderblock.Howeverbecauseofthesmalleroutsidediameterofthecylin-derlineritwillfitlooselyintothecylinderblockatthecylinderlinerO-ringsealingarea.Thiswillresultinexcessivecylinderlinermovementinthecylinderblockandpossibleleakage.Theseblocksandlinershaveproventobelonglivedandprovidemillionsofmilesofserviceifproperlyinstalledandtheownerperformstherequiredservicemain-tenanceandtobecautiouswhenitcomestimeforrepair.ISteveScottjoinedtheservicedepartmentatIPDin1982workingwithpartsserviceandsalesforavarietyofequipmentdieselandnaturalgasengines.Since2004hehasbeenthedirectorofproductdevelopmentandtechnicalsupportforIPD.Formoreinformationemailsscottipdparts.com.LargeBoreBlockO.D.5.984152MMSmallBoreBlockO.D.5.906150MMtwitter.comaeraepfacebook.comaeraepIfyoureintheenginebuildingbusinesstheresnotoolmoreimportantthananAERAmembership.JointodayVisitourwebsitetojoinonlineorprintanapplicationandfaxormail.www.aera.org www.engineprofessional.com81 82JAN-MAR2015engineprofessionalWhenspeakingaboutenginebearingsmostcommonlywefocusonmainandconnectingrodbearingsandtherolestheyplayincrankshaftoperation.Camshaftbearingsarelessloadedandgenerallyhavefewerproblems.Thereforeinnovativebearingmaterialsandnewdesignsaremostlyfocusedoncrankshaftbearingswhereprobabilityoffailureisgreater.Howevercamshaftbearingsarealsohydrodynamicbearings.Theysufferfromthesameoperationalconditionsasdocrankshaftbearingsoverloadingoilstarvationtoothinminimumoilfilmmisalignmentandcontaminatedoil.Thepossiblefailuresarealsosimilarmaterialfatigueexcessivewearseizureandcorrosion.BearingsinCamshaftMechanismCamshaftbearingsseeFig.1supportthecamshaftandprovideforitsrotation.Therearethreepossibleconfigurationsofcamshaftmechanism1OverheadvalveOHVdesignsseeFig.2Overheadvalveenginesarealsocalledpushrodengines.ThecamshaftofOHVismountedinthecylinderblock.ThecamstransmittheloadthroughthepushrodtotherockerarmwhichpressesthevalveanddisplacesitfromtheclosedpositionTheforcerequiredforopeningthevalvecounteractsthecylinderpressurethespringforceandthedynamicforcesoftheacceleratinganddeceleratingreciprocatingpartsvalverockerarmandpushrod.Suchforceproducesaloadappliedtotheupperpartofcamshaftbearings.Thusintheoverheadvalve-traindesigntheupperpartofthebearingsmaypotentiallyfail.Howeverathighrotationspeedthedynamicforcesgeneratedbytherotatingcamsmaycompensatefortheloadtransmittedbythepushrods.CamshaftBearingsBYDR.DMITRIKOPELIOVICH21Camshaftassembly SUPERIORLoadCapacityPerformanceNEWAdvancedFeatures24StrongerOverlayAchieving18.1HV17GreaterFatigueResistanceUniqueGeometricDesignMaximizesSurfaceLoadAreaBullsEyeWallToleranceEnsuresPerfectOilClearanceinEverySetFormoreabouttheNEWFeaturesofKingXPHPvisitwww.KingRaceBearings.com1-800-772-3670PerfectclearanceineverysetBullsEyeToleranceImprovedoilingressElliptiXGreaterloadsurfaceU-GrooveSuperiorloadcapacitypMaxBlackwww.engineprofessional.com83 84JAN-MAR2015engineprofessionalCAMSHAFTBEARINGSBYDR.DMITRIKOPELIOVICHTheinertiaforceofthecammaybeexpressedbytheformulaFMC2RWhereMCeccentricmassofthecamrotationspeedReccentricityofthecam.Accordingtotheformulaanincreaseofrotationspeedbythreetimesraisestheforcebyafactorofnine.Thedynamicforcesproducedbytherotatingcamsdecreasetheloadappliedtotheupperpartsofthebearingsandcreatealoadappliedtothelowerpart.Theeffectoftheinertiaforceisverysimilartothatinmainbearingsofthecrankshaftwithitseccentricmasses.Overheadvalveenginesarenotcommonlyrunatveryhighrotationspeeds.Thislimitationupto10000RPMiscausedbytoohighaninertiaforceproducedbytherelativelyheavyreciprocatingpushrods.GreaterrotationspeedsmaybeachievedintheengineswithanoverheadcamshaftdesignOHC.2OverheadcamshaftOHCdesignwithrockerarmsseeFig.3InOHCdesignthecamshaftisplacedinthecylinderhead.TheoverheadcamshaftconfigurationhastwoversionssinglecamshaftSOHCanddoubletwincamshaftDOHC.ThecamshaftlocationintheOHCdesignwithrockerarmsisdifferentfromthatintheoverheadvalveOHVmechanism.Butthebearingloadingisquitesimilar.Therockerarmispushedwhenthecamlobeisinupperposition.Itmeansthattheupperpartsofthebearingsareloaded.Theloaddecreaseswithanincreaseoftherotationspeedduetotheinertiaforceoftherotatingeccentriccam.3OverheadcamshaftOHCdesignwithdirectcamoperationseeFig.4Inthisdesignthecampressesthevalvetappetdirectlywithoutanyintermediaterockerarm.Suchconfigurationisprincipallydifferentregardingbearingloading.Thevalveispressedwhenthecamlobeisinthelowerpositionthereforethelowerpartofthebearingisloadedincontrasttodesignswithrockerarms.Overheadcamshaftdesignisusedinhighspeedenginesupto20000RPMinwhichthedynamicinertiaforcedevelopedbythecamsisgreatandmaycauseconsiderableloadingoftheupperbearingparts.CharacterizationofCamshaftBearingFailuresHighperformanceenginesdieseldirectinjectionenginesturboandsuperchargedenginesarecharacterizedbyincreasedloadingofthebearings.Thecylinderpressuresaregreaterandthevalvespringsarestronger.Thereforetheloadsappliedtothecamshaftbearingsarealsohigherthaninconventionalgasolineengines.Highloadmaycausetwotypesofbearingfailure1Fatigueoftheliningoroverlay.Iftheloadexceedsthefatiguestrengthoftheliningafteranumberofloadcyclesfatiguecracksformontheliningsurface.Thecrackspropagatethroughouttheliningthicknessreachthesteel-lininginterfaceandcontinuetoadvancealongtheboundarywiththesteelback.Fragmentsoftheliningdetachfromthesteelsurface.Softthickliningsarepronetofatigue.Anadditionalfactordeterioratingtheloadcapacityofcamshaftbearingsisthe34 circumferentialoilgroovelocatedinthebearinghousingofsomeengines.Thegroovedecreasestheeffectiveareaofcontactbetweenthebearingandthehousing.Thebearingmaterialthatisnotsupportedabovethegroovestrainsunderthealternatingloadandmayfatigue.2Excessivewear.Underhighloadthethicknessoftheoilfilmdecreases.Iftheminimumoilfilmthicknessislowerthanthemicro-asperitiesonthebearingandjournalsurfacesthehydrodynamiclubricationiscompromisedandmetal-to-metalcontactbetweenthesurfacesisestablished.Directfrictionresultsinfastwearofthebearingmaterial.Anotherfactorcausingcamshaftbearingfailureismisalignment.Thebearingandthecamshaftsurfacesshouldbealignedwhenthecamshaftisinstalledintheengine.Howeverdistortionsoftheblockinducedbythermalormechanicalstressescausemisalignmentsofthebearings.Thensomeofthecamshaftbearingsstarttooperateinaconstantmetal-to-metalcontactwiththejournalsurfaceandtheirliningwearsfast.Thealignmentofthedistortedcamshaftbearinghousingsmaybereconditionedbyoversizeboring.OversizedODcamshaftbearingsmustbeusedinsuchengines.Excessivewearofcamshaftbearingsmayalsobecausedbyoilstarvationconditionsatcoldstartoftheengine.Theoilpathtothecamshaftbearingsislonginsomeengines.Thereforeittakessometimeforcoldoiltoreachthebearingsurface.Ateachcoldstartthecamshaftbearingsoperateintheabsenceofoilcausingmetal-to-metalcontact.Oilstarvationmayalsoresultfromanexcessiveleakageofoilduetothelargebearingclearance.Incontrasttocoldstartareductionofoilpumppressurecausedbyleakageoccursmostlywithhotlowviscosityoils.Typicaloilclearanceofcamshaftbearingsis0.0015-0.002DWhereDthebearingdiameter.StructuresandMaterialsofCamshaftBearingsThetypicalstructuresanddesignsofcamshaftbearingsarepresentedinFig.5.ThemosttraditionaldesignofcamshaftbearingsisasteeltubewithalayerofleadbasedBabbittalloyappliedontotheinnersurfacebushtypecamshaftbearing.Thebearingsofthistypemaybesuppliedinsemi-finishedun-boredcondition.Thenthebearingsareboredafterinstallationintheengine.Howevertheprecisionboredfinishedtypeismorepopular.ArelativelythickandsoftBabbittlayerprovidesgoodconformabilityofthebearing.Thematerialallowsfittingitsshapetomisalignments.Babbittalsohasverygoodembedabilitywhichisimportantforbearingsoperatingwithcontaminatedoil.ThemaindisadvantageofBabbittbearingsistheirlowloadcarryingcapacity.Babbittalloysaresoftthereforetheyhavelowfatiguestrength.Alsothefatiguelimitoftheliningisdirectlydependentonitsthicknessthethickerthelayertheloweritsfatiguelimit.SincetheBabbittliningisrelativelythickitsfatiguestrengthislow2000psi.Bi-metalliccamshaftbearingswithaliningmadeofaluminumalloyhaveamuchgreaterfatiguestrengthofatleast5800psi.Thebearingsaresplitshellstyperatherthanbush.KingEngineBearingsmanufacturescamshaftbearingsmadeofaluminumsiliconalloyK-788seeFig.6.Theirloadcapacityreaches8000psi.www.engineprofessional.com855CamshaftbearingswithaluminumliningbyKingEngineBearings.6 Abimetalstructurewithanaluminumalloyliningisthebestsolutionforcamshaftbearings.Aluminumalloyisnottoohardthereforeithasgoodconformability.AlsoitisstrongerandmorewearresistantthanBabbitt.Incontrasttoatri-metalstructurealuminumalloybimetalbearingshavesuperiorconformabilityandcantoleratefargreaterwearsincetheydonothaveathinoverlay.Thethicknessofthealuminumliningisapproximately0.010.Iftheloadappliedtocamshaftbearingsexceedsthefatiguestrengthofaluminumalloystri-metalmaterialshavingacopperbasedintermediatelayerandverythinupto0.0008softBabbittoverlayareused.Tri-metalmaterialshavegreaterloadcapacitybuttheirconformabilityandmaximumweararelimitedbytheverylowthicknessoftheoverlay.Oncetheoverlayislocallywornoutandthebronzeintermediatelayerisexposedseizureofthebearingbythesteeljournalbecomesveryprobable.Sincemisalignmentandexcessivewearduetooilstarvationaretypicalcausesofcamshaftbearingfailurestri-metalconstructionisrarelyusedinthedesignofcamshaftbearings.I86JAN-MAR2015engineprofessionalDr.DmitriKopeliovichisregardedasoneoftheforemostauthoritiesonenginebearingresearchanddevelopment.HeearnedhisPh.D.inmaterialsengineeringandservesasresearchanddevelopmentmanageratKingEngineBearings.AsthemanagerandteamleaderofKingsadvancedmaterialsresearchanddevelopmentunitDr.KopeliovichisknownastheEngineBearingDoctorforhisextensiveinvestigationsintothecauseandpreventionofprematureenginebearingfailure.ToaskDr.Kopeliovichaquestionvisitwww.kingbearings.comandclickonAskDr.Dmitri.CAMSHAFTBEARINGSBYDR.DMITRIKOPELIOVICHAERAAutomotiveMachiningOnlineTrainingGoonlineformoreinformationabouttheAERACylinderHeadandMachinistCertificateProgram.TogetstartedcallKarenat815-526-7600ext.202oremailkarenaera.org.www.aera.orgtraining www.engineprofessional.com87 88JAN-MAR2015engineprofessional www.engineprofessional.com89 90JAN-MAR2015engineprofessionalQuotingfromtheASTMfuelspecificationD4806-13aandD4814-13athedocumentthatdefinesthepropertiesofthepumpfuelweusehereinNorthAmericaaswellasinAustraliaandNewZealandSomefuelscorrodefuelsystemmetalsotherthancopperbuttherearenoASTMtestmethodstoevaluatecorrosionofthesemetals.Dependingonthetypeandconcentrationofoxygenateethanolgasoline-oxygenateblendscancorrodemetalssuchaszincmagnesiumalu-minumandsteel.InplainEnglishtheethanolinyourgascandamageyourcarburetor.Thisisnotarantaboutethanol.Thisisinformationonhowtoprotectyourcarburetorfromtheethanol.Letsbeginwithsomebasicfactsaboutethanolthatcanhelpexplainwhyethanolisharmfultocarburetorsandthatsameinformationishelpfulindefendingyourcarburetorfromethanol.EthanolfuelisderivedfromEthylAlcoholAKAGrainAlcoholChemicalidentityC2H5OHforyouBreakingBadfansAddedtofuelasanoxygenateforemissionspurposesHygroscopicAfancywordforethanolabsorbsmoistureevenfromtheatmosphereCorrosiveASTMD4806-13aandD4814-13astatesethanolcancorrodepartsmadefromZincMagnesiumAluminumandSteelarentcarburetorsmadefromallofthesemetalsEthanolboostsoctaneinlowoctanefuelsyour87octanefuelisactually83octanegasolineplus10ethanol83octanegasblend10ethanol87octane91octanegasblend10ethanol93octaneLoweroctanehydrocarbonsaretypicallylessstabileandmorelikelytovarnish.Asthefuelbeginstodegradeitleavesdepositsthateffecttheperformanceofthecarburetor.Someoftheproblemsattributedtoethanolareactuallytrig-geredbytheloweroctanehydrocarbonsusedinthebasefuel.Thefuelbeginstobreakdownandthatcantriggerreactionswiththeethanol.Someoftheproblemsarealsocausedbytoomuchwaterinthefuelsystem.Inhighmoistureenvironmentstheethanolpullsmoisturefromtheatmosphere.Thiscanleadtophaseseparationwheretheethanolandwatercombineanddropoutofsuspensionfromthefuel.Becauseethanoliscorrosiveitisonlyaddedtofuelattheterminal.Thefuelinthepipelinedoesnotcontainethanol.SowhatcanyoudoaboutallofthisTheobviousanswersareavoidingethanolifpossibleandusehighqualityfuels.Evenethanolfreefuelscancausedepositsthathurttheper-CarburetorsandEthanolHowtoprotectyourcarbfromtheharmfuleffectsofethanolblendedfuelsBYLAKESPEEDJR.EthanolBlendedFuelCarburetorSpecificFuelAdditiveEthanolBlendedFuelMultiPurposeAdditiveEthanolBlendedFuel www.engineprofessional.com91formanceofthecarburetorsowhataresomereal-worldstepstotaketoprotectyourcarburetorFirstuseamulti-functionalfueladdi-tivethatcontainscorrosioninhibitorsdetergentsandfuelstabilizers.Ifthecarbu-retedenginesitsoftenmorethanitrunsabottleofadditivewitheverytankoffuelwillprotectyourcarburetorfromcorro-sionandkeepitfreefromdepositsthatcanaffecttheperformanceofthecarbure-tor.IftheenginerunsonaregularbasisaddabottleofadditivewhenyouchangetheoilyoudochangetheoildontyouWhenitcomestochoosingafueladditiveitisbuyerbeware.Manyfueladditivesatthelocalpartsstoreactuallycontainalco-holandsomedonotcontainanydeter-gentadditivesorcorrosioninhibitors.Itpaystodosomeresearchbeforeselectingafueladditive.Someareformulatedspecifi-callyforcarburetorsandcandeliverresultsbeyondthestandardpartsstorefueltreatmentadditive.Anotheroptionistopurchaseanewcarburetordesignedforethanolblendedfuels.Thesenewcarbsutilizematerialsandcoatingsthatresistthecorrosivenatureoftheethanol.Evenifyougothisroutethefuellinesfuelcellandotherrubberizedcomponentsshouldbereplacedwithmaterialsthatarecompatiblewithhighethanolcontentfuels.Allmodernsince2007carsfeaturetheseupgradedmaterialsthatarecompatiblewithethanolblendedfuelsthatisoneofthespecialpartsinaflexfuelvehicle.Ifyourvehicledoesnothavefuellinesthatarecompati-blewithethanolfuelsitisasafetyissueandyoushouldreplaceanyrubbercompo-nentinyourfuelsystemwithpartsthatarecompatiblewithethanol.Thesecondsteptotakeinvolvesstor-age.Thebestwaytopreventphasesepara-tionisNOTaddinganotherbottleoffuelstabilizerintoyourtank.Amulti-function-alfueladditivewithacorrosioninhibitorforyourcarburetorisallyouneed.Thebestwaytopreventphaseseparationisbymakingsurethefuelcellisfullwhenyouputyourvehiclelawnmowerorboatawayinstorage.Withlessroomtobreathethefuelcellcannotabsorbenoughmois-turetocausephaseseparation.Ifthefuelcellcantbestoredfullthenrunitdrybeforeputtingitawayforwinterstorage.Thefastestroutetophaseseparationisapartiallyfulltankofethanolblendedfuelallowedtobreatheinatmosphericmois-ture.Obviouslythebestcourseofactionistouseanethanolfreefuel.Howeverthesefuelsarehardtofindinmetropolitanareasduetocleanairregulationsandthesefuelscostmore.Fortunatelytheworstsideeffectsofethanolcanbedealtwithbyusingthecorrectmaterialsinthefuelsys-temtakingcaretouseacarburetorspecif-icfueladditiveandmakingsurethetankisfullwhenyouputawayyourvehiclelawnmowerorboatforthewinter.IFindenginespecsfastandeasyOver7000enginespecificationsfrom150manufacturerscoveringawidevarietyofengineapplicationsQuicklyidentifycylinderblocksheadscrankshaftscamshaftsconnectingrodsandflywheelsbycastingnumberContainsover3000AERATechnicalBulletinsCustomerdatabasefeatureallowsyoutocreateestimatesworkordersandinvoices30DayFreeTrialforallnewAERAmembersgotowww.prosispro.comCurrentPROSISPROSISSAorPROSISWebuserscanupgradetoPROSISPROonlinegotowww.prosispro.com.twitter.comaeraepfacebook.comaeraepLakeSpeedJr.fromDrivenRacingOilisthesonofLakeSpeedSr.whoracedinNASCARfrom1980to1998.Formoreinformationcallat704239-4401ore-maillspeeddrivenracingoil.com.Findmoretechnicaldataatwww.drivenracingoil.com. TB2658EngineTickingNoiseonColdStart-upon2004-15GM3.03.6LHighFeatureEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingatickingnoiseoncoldstart-upon2004-15GM3.03.6Lhighfeatureengines.Thevehicledrivermaycomplainofatickingnoiseoncoldstartaftersittingmorethan6hours.Theenginewillusuallystartquietthenmakeatickingnoiseafterafewsecondsthatlastsabout3to15secondsandthengoawayfortherestoftheday.GMtechnicianshaveidentifiedapossibleconcernwiththeoilpumppick-uptubetoblocksealbeingcompressed.Themoreenginecoldhotcyclesthathaveoccurredthemorelikelythisbulletinmayapply.ThereisanOringsealbetweentheoilpumppickuptubeandtechnicianshaveidentifiedaconcernwiththesealbeingcompressedallowinganairleak.Whenthisoccursthereisthepotentialtodrawinairwhenfirststartedbeforethepumppicksupoiltosealthegap.Ifyouencounterthisconcernremovetheoilpanandinspectthesealforintegrity.Ifthissealiscompressedwithinthecutoutofthepick-uptubethenreplacethesealandreevaluatetheconcern.ITB2658Figure1.Thisisanexampleofanewseal.TB2658Figure2.Thisisanexampleofabadseal.TB2659LackofLubricationtoRockerAssemblyon2009-14Acura3.53.7LV6EnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardinglackoflubricationtotherockerassemblyon2009-14Acura3.53.7LV6engines.Thissituationcanexistanytimetheassemblieshavebeenremovedorafteravalvejobhasbeenperformed.Thisengineusesdowelstoaligntherockerassembliesandcareshouldbeexercisedforplacementduringdisassembly.Usingthewrongdowelinthewronglocationwillshutoffoilsupplytotherearcylinderheadrockerassembly.Itshouldbenotedthatpreviousyearenginesmayuseadifferentoilingflowsystemandtheyrenotaffectedbythisbulletin.Inallenginesithasbecomemorecriticalforextremeattentionbeusedduringdisassemblyasmanynewenginedesignsarebeingused.Followthestepslistedbelowtoinstallcamshaftsandrockerassemblies.FRONTHEAD1.Loosenthelocknutsandtheadjustingscrews.2.Drythecamshaftoilsealhousing.3.Applyalightcoatofnewengineoiltothelipofthecamshaftoilseal.4.GentlytapthenewcamshaftoilsealAintothecylinderhead.Tapthecamshaftoilsealinsquarely.Installtheoilsealabout0.5-1.5mm0.02-0.06in.belowthesurfaceofthecylinderhead.5.InsertthecamshaftBintothecylinderheadandtheninstallthecamshaftthrustcoverC.AlwaysuseanewO-ringD.Applynewengineoiltothejournalsandthecamlobes.6.Checkthattheoilseallipsarenotdistorted.7.Installthesoliddowelpin.Seefigurebelow.8.Iftherockerarmassemblyisdisassembledreassembletherockerarmassembly.9.Removetheentireoldliquidgasketfromtherockershaftholderandthecylinderhead.10.ApplyliquidgasketPN08717-000408718-000108718-0003or08718-0009evenlytotherockershaftholdermatingsurfaceofthecylinderhead.Installthecomponentwithin5minutesofapplyingtheliquidgasket.NOTEIfyouapplyliquidgasketPN08718-0012thecomponentmustbeinstalledwithin4minutes.92JAN-MAR2015engineprofessionaltech www.engineprofessional.com93Iftoomuchtimehaspassedafterapplyingtheliquidgasketremovetheoldliquidgasketandresiduethenreapplythenewliquidgasket.11.Settherockerarmassemblyinplaceandlooselyinstallthebolts.Makesurethattherockerarmsareproperlypositionedonthevalvestems.NOTEWaitatleast30minutesbeforefillingtheenginewithoil.Donotruntheengineforatleast3hoursafterinstallingtherockerarmassembly.12.Tighteneachbolttwoturnsatatimeinthesequenceshowntoensurethattherockersdonotbindonthevalves.SpecifiedTorque8x1.25mmbolt16ftlbs22Nm13.InstalltheinjectorbaseA.AlwaysuseanewgasketB.14.ApplynewengineoiltothethreadsofthecamshaftpulleymountingboltA.InstallthebackcoverBandtheninstallthecamshaftpulleyC.Seefigureaboveright.15.SetthecamshaftpulleystotopdeadcenterTDCbeforeboltingthemontotheengineblock.REARHEAD1.Loosenthelocknutsandtheadjustingscrews.2.Drythecamshaftoilsealhousing.3.Applyalightcoatofnewengineoiltothelipofthecamshaftoilseal.4.GentlytapthenewcamshaftoilsealAintothecylinderhead.Tapthecamshaftoilsealinsquarely.Installtheoilsealabout0.5-1.5mm0.02-0.06in.belowthesurfaceofthecylinderhead.5.InsertthecamshaftBintothecylinderheadandtheninstallthecamshaftthrustcoverC.AlwaysuseanewO-ringD.Applynewengineoiltothejournalsandthecamlobes.6.Checkthattheoilseallipsarenotdistorted.7.Installthehollowdowelpin.Seefigureatthetopofnextcolumn.8.Iftherockerarmassemblyisdisassembledreassembletherockerarmassembly.9.Removetheentireoldliquidgasketfromtherockershaftholderandthecylinderhead.10.ApplyliquidgasketPN08717-000408718-000108718-0003or08718-0009evenlytotherockershaftholdermatingsurfaceofthecylinderhead.Installthecomponentwithin5minutesofapplyingtheliquidgasket.NOTEIfyouapplyliquidgasketPN08718-0012thecomponentmustbeinstalledwithin4minutes.Iftoomuchtimehaspassedafterapplyingtheliquidgasketremovetheoldliquidgasketandresiduethenreapplythenewliquidgasket.11.Settherockerarmassemblyinplaceandlooselyinstallthebolts.Makesurethattherockerarmsareproperlypositionedonthevalvestems.NOTEWaitatleast30minutesbeforefillingtheenginewithoil.Donotruntheengineforatleast3hoursafterinstallingtherockerarmassembly.12.Tighteneachbolttwoturnsatatimeinthesequenceshownbelowtoensurethattherockersdonotbindonthevalves.SpecifiedTorque8x1.25mmbolt16ftlbs22Nm13.InstalltheinjectorbaseA.AlwaysuseanewgasketB.14.ApplynewengineoiltothethreadsofthecamshaftpulleymountingboltA.InstallthebackcoverBandtheninstallthecamshaftpulleyC.15.SetthecamshaftpulleystoTDCbeforeboltingthemontotheengineblock.I TB2660LackOfLubricationToRockerAssemblyOn2005-08Acura3.5LEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardinglackoflubricationtotherockershaftassemblyon2008-08Acura3.5Lengines.Thissituationcanexistanytimetheassemblieshavebeenremovedorafteravalvejobhasbeenperformed.Thisengineusedfourdowelpinstwosolidpinsandtwohollowpinstoaligntherockerassembliesandlocationsshouldbenotedofeachbeforedisassembly.Usingthewrongdowelinthewronglocationwillshutoffoilsupplytothecylinderheadrockerassembly.WheninstallingthedowelsintothecylinderheadmakesurethatthehollowdowelsFareonthecamshaftoilsealendofthecylinderheadasshowninFigure1.ThesoliddowelsEwillbeinstalledontheoppositeendofthecylinderheadawayfromthecamshaftoilsealasshowninFigure1.IFigure1FrontandrearcylinderheadwithhollowdowelFandsoliddowelEpinlocations.TB2661BoltRe-UseGuidelinesfor1996-2003HyundaiEnginesTheAERATechnicalCommitteeoffersthefollowinginformationregardingtheboltre-useforthemajorenginefastenerson1996-2003Hyundaiengines.Thisinformationshouldbeconsideredanytimethesubjectboltshavebeenloosenedorremoved.Theinformationinthisbulletingoesbeyondtheshopmanualsandprovidesreuseguidelinesandtighteningtorqueproceduresforcylinderheadconnectingrodandmainbearingboltsthataretightenedusingthetorque-anglemethod.Thisinformationalsoincludescorrectionsfortorquespecificationsthattheoriginalservicemanualssupplied.Seechartatright.Fastenerstightenedbytheconventionaltorqueonlymethodcanhavesubstantialclampingforcevariations.Thevariationscomefromseveralfactorssuchasfastenerfrictionandhandtighteningversuspowerdrivertighteningmethods.Fastenerstightenedbyalowinitialtorquevaluethentightenedbyanadditionaltorque-anglevalueareknownastorque-angleboltsorsometimestorque-to-yieldbolts.Thesetypesoffastenerscanachieveveryhighclamploadswithverysmallvariations.INSTALLATIONNOTES1.TorqueanglegaugesareavailablefromKent-MoorePNBT-8653-Aandareapartoftheessentialtoolpackage.Somefastenersrequiremeasuring.2.Someofthefastenersdescribedrequireameasurementasacheckpriortoreuse.Alwaysmeasuretheshankoftheboltnotincludingthehead.3.Alwaysuseengineoiltocoatthethreadsandbothsidesofthewashersofatorqueanglefastener.SeebelowLubricatethewasherandboltthreadswithcleanengineoilbeforeinstallation.4.Alwaysuseatorquewrenchtoachievetheinitialtorquevalue.5.Ifthereisaquestiontotheconditionofthefastenerex.corrosionreplacethefastener.I94JAN-MAR2015engineprofessionaltech www.engineprofessional.com95YEARMODELENGINECOMPONENTTORQUESPECGUIDELINE2000-2002Accent1.5LCylinderHead18ftlbs6060UnlimitedReuse2001-2002Accent1.6LCylinderHead26ftlbs90LoosenALLBoltsThen26ftlbs90UnlimitedRe-use1996-2000ElantraALLCylinderHeadRequiresHeadGasket22311-23000M1022ftlbs6060M1226ftlbs6060UnlimitedRe-use2001-2002ElantraALLCylinderHeadRequiresHeadGasket22311-23700M1018ftlbs6060M1222ftlbs6060UnlimitedRe-use1996-2002ElantraALLMainBearing22ftlbs60UnlimitedRe-use1996-2002ElantraALLConnectingRod37-39ftlbsQualifyBolt1997-2001Tiburon1.82.0LCylinderHeadRequiresHeadGasket22311-23000M1022ftlbs6060M1226ftlbs6060UnlimitedRe-use2003Tiburon2.0LCylinderHeadRequiresHeadGasket22311-23700M1018ftlbs6060M1222ftlbs6060UnlimitedRe-use1997-2003Tiburon1.82.0LMainBearing22ftlbs60UnlimitedRe-use1997-2003Tiburon1.82.0LConnectingRod37-39ftlbsQualifyBolt2003Tiburon2.7LCylinderHead18ftlbs6045UnlimitedRe-use2003Tiburon2.7LMainBearingM10Bolt22ftlbs90M8Bolt12ftlbs90UnlimitedRe-use2003Tiburon2.7LConnectingRod13ftlbs90DoNoRe-use1999-2002Sonata2.4LCylinderHeadNewBoltsALLBolts47ftlbsLoosenALLBolts15ftlbs9090UsedBolts65-72ftlbsRe-useOnlyifBoltShankis3.91orShorterDiscardif3.92orLonger1999-2002Sonata2.4LMainBearing18ftlbs90Re-useOnlyifBoltShankis2.79orShorterDiscardif2.80orLonger1999-2002Sonata2.4LConnectingRod15ftlbs90DoNoRe-use1999-2002Sonata2.52.7LCylinderHead18ftlbs6045UnlimitedRe-use1999-2002Sonata2.52.7LMainBearingM10Bolt22ftlbs90M8Bolt12ftlbs90UnlimitedRe-use1999-2002Sonata2.52.7LConnectingRod13ftlbs90DoNoRe-use2001-2002SantaFe2.4LCylinderHeadNewBoltsALLBolts47ftlbsLoosenALLBolts15ftlbs9090UsedBolts65-72ftlbsRe-useOnlyifBoltShankis3.91orShorterDiscardif3.92orLonger2001-2002SantaFe2.4LMainBearing18ftlbs90Re-useOnlyifBoltShankis2.79orShorterDiscardif2.80orLonger2001-2002SantaFe2.4LConnectingRod15ftlbs90DoNoRe-use2001-2002SantaFe2.7LCylinderHead18ftlbs6045UnlimitedRe-use2001-2002SantaFe2.7LMainBearingM10Bolt22ftlbs90M8Bolt12ftlbs90UnlimitedRe-use2001-2002SantaFe2.7LConnectingRod13ftlbs90DoNoRe-use2001-2002XG3.03.5LConnectingRod26ftlbs90DoNoRe-useBoltRe-useGuidelinesfor1996-2003HyundaiEngines 96JAN-MAR2015engineprofessionaltechTB2662RevisedValveSpringNewRotatorfor2005-14Cummins8.38.9LQSBQSLEnginesTheAERATechnicalCommitteeoffersthefollowinginformationconcerningarevisedvalvespringfor2005-2014Cummins8.38.9Lengines.Machineshoppersonnelhaveexpressedsomeconfusionduringcylinderheaddisassemblyoftheseenginesassomeheadsusedifferentlengthvalvespringsandrotators.AsaproductimprovementtheuseofrotatorsontheexhaustvalvesforQSCandQSLengineswiththeCumminsCommonRailFuelSystemCM850andratedmorethan298HPwasimplemented.ThestartdatewasSeptember292005onengineserialnumberESNfirst46535055.QSCandQSLenginesequippedwiththeCM850fuelsystemandratedmorethan298HPhavearotatorassembledwitheachexhaustvalve.Thenewlydesignedrotatorreducesthespringpreload.BecauseoftheincreasedthicknessofthevalverotatorascomparedtothevalvespringretainerashorterexhaustvalvespringisrequiredwhenexhaustvalverotatorPartNumber3979599isused.TwovalvespringsthatarecompatiblewiththevalverotatorsarealsoidentifiablebythecolormarkingsshowninthechartbelowExhaustValveSpringColor3999907Twoverticalyellowstripes4931931FullycoatedwhiteVALVESPRINGSPECIFICATIONSSpringFreeLengthAssembledLoadValveOpenLoadPN39999072.18555.5mm105-114lbs214-239lbs489-20N1009-55NPN49319312.10253.4mm87-96lbs203-222lbs409-20N948-42NThepreviousvalvespringPartNumber3944711andcoloredwithtwoverticalpurplestripesandvalvespringretainerPartNumber3944452willcontinuetobeusedontheintakevalvesintheQSCandQSL.CM850CumminsCommonRailFuelSystemEnginesQSCQSLlessQSCQSLgreaterComponentISCISLthan298hpthan298hpValvespringIntake394471139447113944711ValveSpringExhaust3944711394471139999074931931ValveSpringRetainer394445239444523944452IntakeonlyValveRotatorExhaustNANA3979599ValvespringPartNumbers3999907and4931931canbothbeusedonthesamecylinderheadbutnotwithinthesamecylinder.ITB2663ImprovedCylinderHeadCastingfor1997-2012Cummins15.0LISXQSXEnginesTheAERATechnicalCommitteeoffersinformationonanimprovedcylinderheadcastingfor1997-2012Cummins15.0LISXQSXdieselengines.Thisnewcastingcomesastheresultofnumerousheadscrackingandleakingcoolantandisdescribedasaproductimprovement.ThisTechnicalServiceBulletinintroducesanewSignatureISXQSX15cylinderhead.Thenewcylinderheadpartnumbersobsoleteandsupersedeoldpartnumbersasindicatedinthetablebelow.ThenewpartnumberswereintroducedintoenginesbuiltonMarch232006.Thenewcylinderheadhasthreenewfeatures1.Increasedtopdeckthickness2.Increasedthicknessofthewallabovetheexhaustports3.Introductionofgussetsbetweentheboltbossandtheguideboss.Topdeckcracksintheoldcylinderheadwereoccurringatthecentercupplugonthespringdeckallowingcoolanttomixwiththeoil.Exhaustportcracksintheoldcylinderheadwereoccurringattheguidebossareaoftheportallowingcoolanttoleakintotheexhaustportandshowingupasalossofcoolant.IOldandNewSignatureISXQSX15CylinderHeadPartNumbersPartDescriptionOldPartNumberNewPartNumberISXCylinderHead36839864962732AERATechnicalBulletinsalsoavailableonlineTechnicalBulletinsfromthisissuecanbefoundontheAERAwebsite.Ifyouhaveanyquestionsorneedtechnicalsupporte-mailinfoaera.orgorcalltoll-free888326-2372.www.aera.orgtechnical-bulletins www.engineprofessional.com97TB2664EngineTappingSoundFromLeftCylinderHeadOn2013-14Subaru2.5LEnginesTheAERATechnicalCommitteeoffersinformationregardingandenginetappingsoundfromtheleftsidecylinderheadon2013-14Subaru2.5Lengines.Thisnoiseonlyseemstobepresentwhentheengineiswarmanddoesnotapplytoanycoldenginenoisestart-upsounds.TocurethistappingsoundSubaruhasrevisedsomeofthevalvetraincomponentstoeliminatethisproblem.Theychangesareadesignchangetotherockerscamshaftprofilechangeanda1.65mmlongerintakevalveand2.4mmlongerexhaustvalveonthestemlengths.Pleaserefertochartbelowfornewpartnumbersandchanges.Whensettingthevalveclearnacesonthisenginetheintakesshouldbesetto.0039-.0059andtheexhuasshouldbesetto.0078-.0094.ThisisarevisedspecfromSubaruandisnotcurrentlypublishedintheservicemanual.IMPORTANTDonotmixoldandnewpartstogetherasitwillbecomeimpossibletoobtainthecorrectintakevalveclearances.ISAVINGCYLINDERSFORNEARLY70YEARS PROSISPROaccountsetupisasimpleprocessWithPROSISPROwewantedtomaketheprocessofcreatingyournewaccountveryeasyandwefeelthatwehavedonethatsuccessfully.InthepastPROSISusershadtoentervariouscombinationsofkeystohaveaccesstotheprogramwehavenoweliminatedthatprocess.Thenewprocessofsettingupyouraccountcanhaveyouloggedintotheprograminlessthan30seconds.TherearethreewaysthatacompanycansetuptheirPROSISPROaccount1AsaNEWMEMBERofAERAyoucansignupfora30-daytrialor2AsacurrentuserofPROSISorPROSISSAor3AsacurrentuseroftheoldversionofPROSISWeb.Wewillwalkyouthroughtheoptions.98JAN-MAR2015engineprofessionalPROSISPROBYSTEVEFOXHowtogetstartedwithPROSISPROThescreenshotaboveshowsthePROSISPROlandingpage.OntherighthandsideyoucanseethePROSISWebloginareaandbelowitthe30DayFreeTrialsectionandPROSISSAUserssectionsinblue.Thescreenshotattheleftshowsthe30DayFreeTrialregistrationform.SimplyfillouttheformandclickthecreateaccountbuttonandyouhaveaccesstoPROSISPRO.30DayFreeTrialAsanewmemberofAERAyouhavetheoptiontotrythePROSISPROprogramfor30daysandthendecideifyoufeelitisanecessityforyourshop.Afterthat30-daytrialperiodinordertohavecontinuedaccesstotheprogramjustpaythesubscriptionfee.OnceyouhavejoinedAERAandareanewmemberyoucansignupforthePROSISPRO30-daytrialandlookattheprogram.Gotoprosispro.comandyouwillsee30DayFreeTrialclickthatFreeTrialbutton.Onceyouhaveclickedthefreetrialbuttonyouwillseeascreenwhereyoucanselectyourownusernameandpassword.Thiscombinationcanbewhateveryouwantittobejustmakesureitissomethingthatyoucanremember.AfterfillingouttheusernameandpasswordboxesyoucanproceedtothelowersectionoftheNew www.engineprofessional.com99AERAMemberSignUpform.OncealltheboxeshavebeenfilledoutclickontheCreateAccountboxatthebottomrightandyouwillbereadytoaccesstheprogramwiththeusernameandpasswordyoucreated.PROSISSAUsersIfyourealreadyaPROSISorPROSISSAusertheprocessisverysimple.Gotoprosispro.comandallyouneedtodoisclickonthePROSISSAUsersbox.Theseusershavetheoptiontocreatetheirownusernameandpasswordaswell.CreateyourusernameandpasswordsupplyAERAIDNumberandtherestofthefieldsshouldauto-fillwithyourmembershipinformation.OncethosefieldshavebeenfilledinclicktheCreateAccountbuttonatthebottomandyouwillbedirectedbacktotheloginscreenwhereyoucanenteryourusernameandpassword.PROSISWebUsersIfyouareacurrentPROSISWebusertheoldwebversionofPROSISyouwillneedtologintoyouraccountusingthosecredentialsfirstfromthemainscreen.AfteryouhaveloggedintoPROSISPROyoucanchangeyourusernameandpasswordtowhateveryoulike.SimplygototheMyAccountlinkatthetopofthepageandclicktheeditbutton.Hereyoucanchangeyourusernameandpasswordtosomethingthatiseasyforyoutoremember.DemoforNon-AERAmembersAERAhasdevelopedaPROSISPROdemofornon-AERAmemberstoseewhattheprogramhastooffer.Thisdemohaslimitedenginesthatwehavechosentoallowuserstoseethefunctionalityoftheprogram.ToaccessthisprogramvisittheAERAwebsiteatwww.aera.organdclickonthePROSISPROtabandfollowthedirectionstothedemoversion.Thatsit.SettingupyourPROSISPROaccountisreallythatsimpleNomorelicensekey1and2nomoreupperandlowercaselettersandnumbersjustasimpleusernameandpassword.IAERAOperationsManagerandTechnicalSpecialistSteveFoxhasover28yearsexperienceintheenginebuildingindustrywith10ofthoseyearsspentworkinginthemachineshop.SteveisanASE-certifiedMasterMachinistaswellasalongtimememberofthedragracingcircuit.ThescreenshotaboveshowsthePROSISSAUsersregistrationform.FillouttheusernameandpasswordenteryourAERAIDnumberandclicktheCreateAccountbutton.YoucanchangeyourusernameandpasswordbyclickingontheMyAccountatthetopoftheDashboardpagepicturedbelow.ThescreenshotattherightshowswhereyouneedtologinifyouareacurrentuserofPROSISWebtheoldwebversionofPROSIS. DetroitSpeedsHowToBuildAProTouringCarByTommyLeeByrdandKyleTuckerReadingthroughthisbookmademerealizejusthowthelatesttechnologyandvehicledesignhasfiltereddowntothepeopleworkingontheirowncars.Thebookisverywellwrittenwithplentyofusefulinformationthatwillteachyouthecorrectwayofworkingwithalltheitemsthathecovers.InformationChapter1ProTouringexplained2Skillstechniquesandtools3Chassis4Frontsuspension5Rearsuspension6Brakes7Tiresandwheels8Engineanddriveline9wiringandplumbing10ProTouringCarsandalistofsourcessoyoucanfindanythingthatyousawinthebook.SuggestionTommyandKylemakeiteasytohaveyourcakeandeatittoo.TheyhavemadeitconvenienttofindtheinformationneededtobuildaProTouringCarsomethingthatyoucandriveallthetime.ForwardbyracecardriverKyleBuschandhowtheyfixedhis69Camarodriver.WheretoBuywww.cartechbooks.comPartNo.SA293ISBN978-1-61325-137-9.PerformanceExhaustSystemsHowToDesignFabricateandInstallByMikeMavrigianInformationcoveringairenteringtheairinlettractandthroughouttheenginetoexitingtheexhaustportintotheexhaustsystem.Plentyofexplanationsforabetterunderstandingofwhatishappeningduringtheengineoperationwithintheexhaustsystemandwhyyouneedtochangewhat.InformationChapter1Theorydesignandprinciples2Exhaustsystemcomponentdesignandfunction3Exhaustpipe4Headerdesignandfunction5Mufflersandcatalyticconvertors6Superchargedandturbochargedsystems7Exhaustsystemmathandalistofsources.SuggestionSeeinghowtomakeaspecialexhaustsystemwhilehavingitexplainedtoyoumakesthisbookarealwinner.Agreatbookforeveryonefromenginebuildersmakingsuretheenginecangetoutwhatitneedstothehands-onpersonbuildityourselfpeopleandeveryonein-betweenwhopayssomeoneelsetomakeit.ItalsoputsananswertowhydoesitcostsomuchWheretoBuywww.cartechbooks.comPartNo.SA277ISBN978-1-61325-104-1.SheetMetalFabforCarBuildersByWilliamH.LongyardMakepanelsforrealCobrasLotusHotRodsandmore.Youcouldbemakingshapesandpanelsforanythingthatyourequire.Ifyouliketheideaofgettingbacktohands-onandotherscannotjustgooutandbuyonethisisthebookforyou.InformationChapter1Toolingup2ABonnetbyMarkGerish2BBootbyMarkGerish2CDoorsbyMarkGerish3MattStuart4PeterTommasini5RonCovell6JordanScowary7GeoffMoss8CassNawrocki9KentWhite7CoolToolsandTipsandalistofEducationSourcesCatalog.SuggestionWorkingwithaluminumandmetalsturningthemintobeautifulcurvedpanelsHowmanytimeshaveyouneededapanelorbracketforthatspecialjobIknowIhaveplentyoftimesandmademorescrapthangoodones.Thisbookhastaughtmeplenty.Itisagreatvalue.WheretoBuywww.wolfpub.comISBN978-1-929133-38-3.100JAN-MAR2015engineprofessionalONTHESAMEPAGEBYMIKECARUSOAERATechSpecialistMikeCarusohasover50yearsofenginerebuildingandhigh-performanceexperience.AnASE-certifiedMasterMachinistMikecametoAERAfromFEL-PROshigh-performanceRDandtechlinewhereheworkedfor11years. www.engineprofessional.com101PEGGYGREENCall507-457-0755or866-457-8975peggybigrivergmail.comRepresentinganumberofqualitylinestobringyouthebestvalueforallyourshopsupplyneeds.HOMEOFREGISNORTH35517SkyviewDriveWinonaMN55987HOMEOFREGISNORTHCallAbusinessthattrulycaresforandhonestlydealswithcustomersthatareinvolvedinthefieldoftestingcomponentsusingairflowbenchesanddynamometers.HAROLDBETTES719260-7129M-F9-5MSTENGINEREBUILDINGEQUIPMENTSUPPLIESServingtheEngineRebuildingIndustryforover25Yearswww.rtsalesinc.com1625NorthMilfordRdHighlandMI48357Phone248-887-0422Fax248-887-0150MARKETPLACEGrayMarineParts.comWeofferavastarrayoforiginalGrayMarineenginesenginepartsaccessoriesandsomuchmore.Ifyouhavebeensearchinghighandlowforahard-to-ndpartthensearchnomoreCallusandwellnditforyouCall630-485-5007salesgraymarineparts.comYOURADHEREBusinessCardAd3.5x21xRate2004xRate170FormoreinformationseetheMARKETPLACEAdFormonthefollowingpage.ToadvertiseinMARKETPLACEyoumustbeanAERAmember. 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www.engineprofessional.com103ADVERTISERINDEXABSProducts..............................................................53AccessIndustries...........................................................5ACL..............................................................................15AERA................................................................18-1980AutomechanikaChicago..............................................35CIFIC..............................................................................7Cloyes..........................................................................33CTPCostexTractorParts...................insidebackcoverCWTIndustries...............................................................1DNJEngineComponents...................outsidebackcoverDura-Bond.....................................................................8Elgin.......................................................................2943EndurancePowerProducts.........................................69EnginePartsGroupInc................................................22Enginequest.................................................................41ESCOIndustries...........................................................71FarrisEquipment..........................................................36FederalMogulFel-Pro................................................17FederalMogulFPDiesel............................................81Fluidampr.....................................................................16FowlerSalesService.................................................37GoodsonShopSupplies..............................................13Hastings................................................insidefrontcoverIPD...............................................................................79Jamison.......................................................................49JoeBakerEquipmentSales.........................................76KingEngineBearings...................................................83L.A.Sleeve....................................................................97MAHLEClevite...............................................................3Maxiforce.....................................................................77Melling..........................................................................87MemorialMachine........................................................61MEWagner.................................................................97MJDE-YIInternational..................................................59OliverRacingParts.......................................................86PEP........................................................................3234PROSISPRO...............................................................91QualCast......................................................................55QualityPowerProducts................................................25Regis............................................................................23Rottler........................................................................104S.B.International............................................................9SafetyAutoParts.........................................................63Scat.............................................................................51SilverSeal....................................................................57Sunnen........................................................................65Topline....................................................................88-89Tracto-PartsCenter......................................................73UltrasonicLLC............................................................67UnitedEngineandMachine.........................................47USToolMfgCo........................................................56ADVERTISINGOPPORTUNITIESGetyouradvertisingmessagedirectlyintotheshopswhoarebuildingrebuildingandinstallingenginesbyadvertisinginEngineProfessionalmagazine.Engineprofessionalsworldwidereceivethisfull-colorpublicationfourtimesperyear.Eachissueispackedwithhighlytechnicalapplication-drivenarticlesfromourstaffofwritersaswellasfeaturecontributionsfromindustryprofessionals.Formoreinformationdownloadamediakitfromourwebsiteatwww.engineprofessional.comorcontactouradsalesstaff.AdSalesHalFowler404-427-0171halfowlersales.comJimRickoff815-526-7343jimaera.orgForadpaymentcirculationmembershipinformationCallAERAtoll-free888-326-2372or815-526-7600.MonthlyPaymentOptionsAERAnowoffersmonthlyinstallmentpaymentoptionsforyourannualAERAmembershipandPRO-SISsupportfees.CreditcardDirectwithdrawlfrombankaccountTherewillbenoadditionalfeesifyouelecttopaymonthly.ExampleAsmall1-3manshoppaysanannualrateof381or31.75permonthfor12monthscreditcardordirectwithdrawlfrombankaccount.FormoreinformationcallKarenat888-326-2372ore-mailkarenaera.org.AERAEngineBuildersAssociation500CoventryLaneSuite180CrystalLakeIL60014U.S.A.toll-free888-326-2372815-526-7600fax888-329-23728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CylinderHeadSeatandGuideMachiningConnectingRodMachiningBlockFrameBoringSurfacingLineBoringGeneralCNCMachiningRottlerManufacturingisagloballeaderinprecisionmachinetoolsforenginerebuildersandOEMremanufacturers.Rottlersadvanceddesignsandequipmenthavemetthemostdemandingengineeringneedssince1923.THECUTTINGEDGEHeavyDutyHardwareCuttingEdgeSoftwareCNCDiamondHoningforblocksandliners104JAN-MAR2015engineprofessional