INSTALLATION PROCEDURES Page 1 - revised GM Ecotec TM M.I.D. Kit

Transcription

1 Ecot ec T M I nstal l ati on M anual

2 Page 1 - revised M.I.D. Kit PREPARATION, FIXTURING 1) Block needs to be fully stripped, cleaned and inspected before machining. Main web cracks, or structural damage may prevent a satisfactory sleeve installation. 2) Main caps must be in place and torqued prior to machining. 3) Check line bore main journals; if bad or out of spec, machine to smaller side of specification to allow for re-machining after sleeve installation if needed. SET-UP & BLOCK MACHINING 1) Block must be set up on a machine which will allow decking parallel to the crankshaft centerline. Side-to-side deck height should be maintained within.002" TIR. 2) Angular tolerance, block pitch (end to end) and bore (angle to crank) is '. Boring must be perfectly square to established deck surface. It is essential sleeve seating dimension depth be controlled to ensure proper sleeve height of above deck surface upon installation. 3) Deck block surface ' angular tolerance 4) All boring must be machined on bore center of ) Bore dimensions and depths are to be determined by individual sleeve measurements and compared to block specification print to attain a net to.002 clearance fit at Dim! A & C and D for each sleeve. (see "Notes / Cautions") 6) Finish on dimension C and D must be RA 32 or better (bottom o'ring and press fit area). SLEEVE INSTALLATION 1) Use differential temperature of at least 50 to install sleeves. 2) Lubricate o'rings with supplied lube and install using minimum stretch into grooves. 3) Apply small amount of flange sealant supplied, on perimeter of flange. 4) Use a mandrel or brass/aluminum sleeve cap and press sleeves into place. Because of the flat arrangement, make sure rotational clocking is correct on all 4 sleeves. 5) After installed, sleeves should protrude above deck.002" to.005". 6) After installation, clamp sleeves down until block is cool and loctite has cured

3 Page 2 - revised TIP: Prior to installing sleeves, you should use a square and permanent marker to notate the 12 o'clock position on each sleeve and make a corresponding mark on the block upper edge, for each sleeve. FINAL BORE / HONE 1) Boring and honing must have main caps and deck plates on, and torqued. 2) See Sunnen Honing specifications on page 13 & 14. NOTES / CAUTIONS 1) Caution must be exercised as old sleeves are bored out to prevent tearing of aluminum in block and possible tool breakage; original sleeves are ribbed and cast in place. 2) Recheck crank line bore to specs - hone if needed, after sleeve install. 3) All machining must produce a good surface finish and the tolerances must be maintained to assure a quality fit and sleeve seal. 4) Measure each sleeve prior to machining block to match tolereances on block print.

4 Page 3 - revised A) Mount block on machine in appropriate fixturing with the ability to maintain tolerances described. B) Sweep block surface front ot rear to attain proper set-up and angular squareness.

5 Page 4 - revised A) Locate cylinder 1 centerline dimension in order to program machine and hold bore centers for each cylinder. B) Carefully begin boring out old cast iron sleeves. Sleeves are cast in. CAUTION is required to prevent block damage and consequential distortion.

6 Page 5 - revised A) Using proper bore centers, move boring operation from front to rear. B) Continue boring operation to remove body of sleeve in each hole.

7 Page 6 - revised A) Mill interpolation is the recommended method of removing old cast iron sleeve flange. B) Continue boring operation after sleeve removal.

8 Page 7 - revised A) Continue boring operation. B) Mill interpolation is recommended for creating top flange register according to specification.

9 Page 8 - revised A) Completed bore operation to print spec. Deburr and break off any remnants of aluminum spikes remaining. Make sure all chamfers are de-burred and surface finish of lower receptor hole is according to print R.A. Thoroughly clean block and remove all chips prior to assembly. B) Unpack and clean sleeves. Lubricate o-ring grooves with supplied o'ring compound and install o'rings. Lube sleeve flange perimeter with Loctite.

10 Page 9 - revised C) D) Close-up. Bottom reg. and o'ring area.

11 Page 10 - revised A) Warm block / cool sleeves and mark each sleeve and block position at flange perimeter rotational TDC. Sleeves may now be installed. B) Completed installation ready for deck plate to be installed and torqued until block is cool and loctite cured 6-12 hours prior to cylinder honing.

12 PRODUCTS

13 Page 12 - revised Ecotec Engines with Darton MID Sleeves ADDITIONAL INSTRUCTIONS Break-in, tuning Fill the engine with a good grade of mineral oil (not synthetic) with viscosity for your bearing clearance and intended use. Prime the oil system before engine start with ignition off using the engine or dyno starter. We require break-in and tuning using an engine dyno or chassis dyno as follows: After initial start up, warm up engine at Precaution should be exercised to prevent excessively rich or lean conditions, which will gall the cylinders. Monitor oil pressure and temperatures. After initial run, adjust valves if using adjustable valve train and retorque heads. Check for leaks. Street engines will require multiple run ins with increasing rpm and load up to maximum output. Use of a dyno allows one to apply a pre-set load to allow the piston rings, and other components to seat properly. It is also much easier to monitor temperatures and pressures than while driving. Most dynos are equipped with O² and EGT probes to aid in tuning. The timing and fuel curve needs to be tailored to your particular engine to ensure the engine stays out of detonation, which will lead to engine failure. A racing engine is generally built with sufficient clearance to require no further break-in after dyno tuning and power runs. However, we recommend head bolt torques be re-checked cold after dyno testing as the head gaskets will take a set. Remember to replace oil and filter after the dyno session as bearing coatings and metal particles will be trapped in the oil filter. Inspect the oil for foreign material and excessive bearing flakes. A street engine should be driven moderately for the first thousand miles, as follows: full throttle high torque power useage should be limited and never be used until the engine has been running for at least 15 minutes. from miles, do not exceed 4000 rpm. from , do not exceed 6000 rpm. over 1000 miles, no restrictions. Also, do not run at the same speed for extended periods during break-in. Make certain the engine is operating at proper coolant temperature and oil pressure. Do not allow the engine to overheat. Make necessary changes if required (radiator, fan, tuning) to get the engine to run in the proper temperature range. We also recommend you do not run synthetic oil until at least 5000 miles. Synthetics work so well that the engine will never break in properly if it is used too soon.

14 P R E C I S I O N E N G I N E R E B U I L D I N G E Q U I P M E N T Sunnen CV-616 Setup The cost-effective Sunnen CV-616 Automatic Cylinder Hone is one of the most versatile machines you can have in your shop. You can count on consistent results as the CV-616 produces the most precise cylinder bores possible, cylinder after cylinder, block after block. Results with Sunnen Honing Stones on Darton Cylinder Sleeve Material EHU 412 EHU-412 C30 PHT Seconds RA µ" RA 15.4 µ" RY µ" RY µ" RZ µ" RZ µ" RPK µ" RPK 10.5 µ" RVK µ" RVK 40.9 µ" RK µ" RK 35.4 µ" MR1 7% MR1 5% MR2 86% MR2 88% EHU 518 EHU 518 C30 PHT Seconds RA 25.1 µ" RA 9.0 µ" RY µ" RY µ" RZ µ" RZ 93.5 µ" RPK 29.9 µ" RPK 7.8 µ" RVK 44.5 µ" RVK 38.4 µ" RK 89.7 µ" RK 23.8 µ" MR1 6% MR1 5% MR2 88% MR2 81%