FPT DUR003

Performance
MOLLO ROBERTO

Standards Date: 01/23/2008

FECHINO PAOLO

Product Engineering Issue: 1

Off-vehicle engine heat shock test

Supervisor: Mollo Roberto - P.E. – Diesel Engines Testing
Manager: Fechino Paolo - P.E. – Diesel Engines Testing

Confidentiality
Supervisor

Except for the content of the following list, no part of the text, procedure, tables or values given in
Manager

this document or other documents connected to it shall be divulged outside Fiat Powertrain
Technologies. If an external Company has to carry out tests based on this standard, the following
information may be given:
• The content of the text (cycles/hours, speeds, temperatures, etc.) or a separate document
providing this information.
• The target reliability (and associated confidence level) that shall be demonstrated with the test.
• Number of samples required.
• Useful recommendations to continue the test if it is not successful and for the analysis of
results.
• Specifications for data uploading to FPT.
Information on the reasons for testing shall not be supplied.
Information regarding the manner in which target reliability values have been determined - for
example how input parameters have been selected (e.g. severity to be represented) or the reliability
range corresponding to the required target value – shall not be supplied.
Information regarding the manner in which test parameter values (speeds, temperatures, etc.) have
been determined shall not be supplied.
FPT - DIESEL ENGINEERING - DEVELOPMENT & RELIABILITY
FPT - DIESEL ENGINEERING - DEVELOPMENT & RELIABILITY

Note
In case of conflict between the Italian version and the translation in other languages, the Italian
version shall be the only valid version.

Issues and Revisions

Issue Date Description
1 01/23/2008 New
Supervisor department
Manager department

© Copyright 2008– FPT Passenger & Commercial Vehicles – All rights reserved
January 2008 Page 1 of 13
 FPT DUR003 FPT PERFORMANCE STANDARDS

1 Introduction
1.1. Foreword
Heat shock is a method to verify reliability of engine mechanical components that are more directly
affected by combustion chamber thermodynamic events and those induced by the cooling system.
Components influenced by these conditions are:
• Cylinder head gasket regarding failure and gas leakage, lubricating oil and coolant.
• Cylinder head regarding distortion, cracks or failure affecting head bottom face or internal walls,
residual tightening torque of cylinder head capscrews.
• Pistons, regarding wear, tendency to seize, cracking on crown and rings.
• Block regarding distortion or overheating of head bottom face, cylinder bore processing.
• Exhaust and intake manifolds including gaskets.
• Turbocharger regarding manifold distortion or failure and/or accumulation of oxides and sludge.
• EGR valves and cooler regarding manifold distortion or failure and/or accumulation of oxides
and sludge.
• EGR heat exchangers regarding failures and gas and water leakage.

This Standard supersedes and harmonizes Fiat Standard 7-A6440 and IVECO Standard 16-7036.

1.2 Purpose
This standard contains the specifications for off-vehicle engine heat shock test of spark ignition and
Diesel engines.
The components mentioned in the previous para. shall undergo thermo-mechanical cycling with
engine running. Engine operating conditions include rpm and load changes (from idle to maximum
power output, or to C speed point, WOT), and coolant temperature range of at least 55°C at cylinder
head outlet.
The test can be carried out to validate even only one of the components or systems listed above.
Should testing be carried out on an engine for process verification or for production control, removal
and measurement of parts is not necessary.

1.3. Scope
This standard is applicable to all internal combustion engines.

1.4 Definitions
ACE Assistant Chief Engineer.
C speed Engine rpm defined by 2005/55/EC, appendix 1
ECU Engine Control Unit
EGR Exhaust Gas Recirculation
EMS Engine Management System
IM Integration Manager
SSTS Sub-system Technical Specifications
VTS Vehicle Technical Specifications
WOT Wide Open Throttle

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
Page 2 of 13 January 2008
 FPT PERFORMANCE STANDARDS FPT DUR003

1.5 Use of Test Equipment

Off-/on-vehicle use: depends on type of engine and number of test cycles. The following
approximate setup use values can be given:
Indicative test
Type of engine
time (h)
Spark ignition engines for passenger and commercial vehicles 200
Diesel engines for passenger and commercial vehicles 400
Lightweight and medium industrial Diesel engines: 1000
Heavy industrial Diesel engines: 1500

2. References
Note Unless otherwise specified, only the latest approved version of the standard shall apply.
2.1 Standards
Standard issues 2005/55/EC appendix 1.

2.2 Internal Standards

FPT DEV001 Power curve performance
FPT DEV002 Engine break-in off-vehicle
FPT DEV012 Engine installation off-vehicle
FPT DUR016 Engine oil consumption off-vehicle
FPT MEC001 Blow by flow test
Fiat 1.00103/01 Mounting face finish
PD-M205 Engine installation request

2.2 Other References

None.

3 Resources
3.1. Systems
Engine test room / Engine test cell

3.2. Equipment and Instrumentation

For the equipment to be used see Standard FPT DEV012, para. 3.2. with the following
options/variants.

3.2.1 Engine Dynamometer

Use stationary type

3.2.2 Coolant System

The following characteristics shall be provided:

• A closed loop system is recommended with load losses equivalent to the vehicle cooling circuit.
The circuit shall be able to pressurize the cooling system to reach correct test temperatures

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
January 2008 Page 3 of 13
 FPT DUR003 FPT PERFORMANCE STANDARDS

(see annex 2) avoiding accidental formation of water vapor or boiling of coolant. This can be
obtained with a pressurized cap on test setup expansion tank.
Note: If the pressure drops below ambient pressure (possibly causing failures due to cavitation)
a pressure of 100 - 120 kPa (1 - 1.2 bar) shall be applied using an appropriate valve.
• A section of engine water outlet duct shall be in glass, visible to monitor coolant conditions and
any air mixed with the coolant.
• A water thermostat locked in full-open position.
• A heat exchanger maintaining coolant temperature within the required test range.

3.2.2.1 Additional Cooling System

To rapidly cool the engine. Fresh or cooled water shall be poured rapidly into the engine cooling
circuit. For this purpose a tank is required with cooled water from the mains (7/12°C) or from a
cooling system, or appropriately treated industrial water can be used /see para. 3.3.5).
At the right time the management system switches from normal cooling to cooled system, or vice-
versa.

3.2.3 Oil Cooling System

It is recommended to use the vehicle cooling system when possible.
If there is an air/oil heat exchanger, it may have to be replaced with a water/oil heat exchanger.
The external cooling system shall have the following characteristics:
• Load losses equivalent to those of the vehicle system.
• Heat exchanger suitable to keep maximum oil temperature within the limits required for the test.
Warning: The oil cooling system shall be replaced or cleaned if damage to the engine occurs.

3.2.4 Instrumentation
All that is necessary to test as per para. 5.1.1. Instrument accuracy to be as per form PD-M205
annex 2.

3.3 Test Materials

3.3.1 Engine
New, development or production heat engine outfitted as per bill of materials, complete with all
auxiliary components as on vehicle.
EMS shall be updated to latest change.
If only one or several components are to be qualified, components under test shall be new and
certified, the rest of the engine has only to be able to sustain the test.

3.3.2 Thermostat
Thermostat shall be modified to remain full-open for the entire cycle. The entire output shall pass
through the engine regardless of coolant temperature.

3.3.4 Exhaust System

If possible, use exhaust system of specific application.
If it is not possible to use the complete exhaust system (e.g. due to cell capacity), use the first
section of vehicle exhaust pipe plus cell exhaust.
In the latter case set exhaust back pressure as on-vehicle at max. rpm (max. power output or C
speed), WOT.
If back pressure at C speed, WOT is not available, use back pressure at max. power output.

3.3.4 Intake System

Use production or design intake system, win ith same arrangement as on vehicle.

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
Page 4 of 13 January 2008
 FPT PERFORMANCE STANDARDS FPT DUR003

3.3.5 Test Fluids

For closed loop cooling systems (preferable) use softened water and paraflu mixture, in percent
used in production or as specified.
For open loop systems, use softened water (PH 7-8, max hardness 1 degree of French scale)

3.4 Test Information

Possible sources:
I. SSTS/ VTS/Platform
II. Application Supervisor. IM
III. ACE

Information to be requested
A) Design documentation of components to be tested (engine Table 0, drawings of sleeves, block,
piston, rings, head gasket, cylinder head, cylinder head capscrews, exhaust manifold,
turbocharger, etc.)
B) Idling speed (rpm)
C) Max. power rpm and max. power output [kW]given in engine data summary table, or same
values for C speed.
D) Oil consumption and blowby flow rate at full load and choked (optional) obtained as per Std.
FPT DUR016 and Std. FPT MEC001.
E) Exhaust pressure to be set (if standard exhaust pipe is not used). See para 3.3.2.
F) Exhaust gas temperature and cycle max. rpm (max. power rpm or C speed), WOT.

4. Test Procedure
4.1 Preparation
4.1.1 Engine Preparation
Note Dimensional readings are only necessary for Technical Approval of complete engine or of one
or more components. In the latter case only the operations related to components under test shall
be carried out.
A) Carry out dimensional tests as per annex 1.
B) Outfit engine with tested components tightening bolts and nuts as per cycle to specified nominal
torque. Enter the torque obtained for each head and intake and exhaust manifold screw.
Note. Upon request of Test Supervisor, read and record each head capscrew tightening torque.
C) Check that ECU calibration is updated.
D) Complete the test cycle (annex 2) with the test engine information.

4.1.2 Engine Installation on Test Setup and Preparation of Systems

A) Install engine on brake test setup as per Standard FPT DEV012.
B) Connect instrumentation to test parameters as per para. 5.1.1.
C) Make all pre-test calibrations on required instrumentation.

4.2 Test Data

4.2.1 Environmental Conditions
See Standard FPT DEV012, para. 4.2.1

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
January 2008 Page 5 of 13
 FPT DUR003 FPT PERFORMANCE STANDARDS

4.2.2 Test Conditions

Any changes to requirements in this Standard shall be agreed. Said changes shall be specified on
test certificates, reports, etc.

A) Test Cycle and Useful Information

The test cycle is specified in annex 2.
Heat shock test consists of the repetition of a basic cycle. The number of repetitions depends
on the type of engine under test, as per following table:
Basic cycle repetitions
Type of engine
(n°)
Spark ignition engines for passenger and commercial vehicles 2500

Diesel engines for passenger and commercial vehicles 5000

Lightweight and medium industrial diesel engines: 15000
Heavy industrial diesel engines: 20000

Basic cycle consists of alternating idle and max. power steps; for industrial and marine diesel
engines full load C speed may be used (only if thermal load at that point is greater than at max.
power). Alternation from one operating point to the other is by means of steps conditioned to
engine coolant output temperature (steps 2 and 5). When at idle, cold water is sent to the
engine until engine water outlet temperature decreases to the required level (see below, item
B); subsequently, when running at max. point of cycle (max. power or C speed,, WOT) normal
engine cooling circuit is resumed until engine cooling outlet temperature reaches 103°C .
The change in engine water outlet temperature shall be more than 55°C (for industrial and
marine engines running in cell with open loop, usually 70°C). With conditioned step at 103°C
maximum water temperature reaches approx. 105°; therefore the conditioned step temperature
at idle shall be set so that minimum temperature of engine water outlet is below 50°C.
An example of coolant temperature trend, together with engine rpm trend during the running of
a cycle, is given in annex 3.
The number of cycle partial repetitions (step 7) is selected to allow engine inspection and
maintenance operations.
Note The time of each elementary cycle is approx. 4 - 4.5 minutes.

B) Specifications for Coolant and Lubricant Temperatures

• The coolant temperature at engine outlet is set at 103°C (105°/108°C peak is permitted
in operation).
• The oil temperature shall not exceed 140°C (138 ± 2°C) for spark ignition engines, 130°C
(128 ± 2°C) for spontaneous ignition engines. These temperatures shall be set with engine
off-vehicle if an external lubricant cooling circuit is used.

4.3 Instructions
4.3.1 Break-in and Initial Checks
A) Break in engine as per Standard FPT DEV002,
B) After break-in carry out inspections listed in para 4.3.3 B.
C) Set pressure of exhaust gas upstream of calibration section (throttle valve) to reference value
(see para 3.4).
D) Check that exhaust gas temperature corresponds to reference value (para 3.4).
E) Run oil consumption test at full load (choking is optional) as per Standard FPT DUR016.

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
Page 6 of 13 January 2008
 FPT PERFORMANCE STANDARDS FPT DUR003

F) Run Power curve performance test as Ser standard FPT DEV001.

G) Monitor blow-by flow at full load (choking is optional) as per Standard FPT MEC001.

4.3.2 Test
A) Program test setup system to carry out test cycle as per annex 2 (see also para. 4.2.2).
B) Set oil and coolant temperature regulators to maintain temperatures specified in para. 4.2.2 and
in annex 2.
C) Set engine safety limit stops as per para. 6.2.
D) Set sampling parameters for post mortem recording and for data acquisition equipment.
E) Recall test cycle and start the test.
F) Discontinue testing where specified by the cycle (table annex 2) for inspection and maintenance
operations as per para 4.3.3.

4.3.3 Routine Inspections

The minimum number of routine inspections to be carried out during test is given below (Test
Supervisor may request further inspections).
A) Every 8 hours: oil level. Top up oil accurately measuring the quantity added, noting the amount
of top up .
Note: High accuracy is necessary in this measurement because data is used to assess oil
consumption during cycle.
B) After break-in carry out the following inspections:
ƒ Check oil and water losses.
ƒ Read compression of cylinders (if requested by Test Engineer)
ƒ Check tappet clearance (only mechanical tappets)
ƒ Take an oil sample (100cc) and send it to laboratory. Make a precise note of amount taken.
ƒ Drain oil, weigh it. Note the weight obtained
ƒ Replace lubricant and oil filter. Record amount of oil introduced in engine.
Note: Keep oil filter at least until subsequent oil filter replacement or according to
instructions of Test Supervisor
ƒ Assess oil consumption (as per Standard FPT DUR016, monitoring during life test)
ƒ Check tension of belt or chain.
C) Checks to be made when carrying out step 9 (table annex 2).
ƒ Check oil and water losses.
ƒ Read compression of cylinders (if requested by Test Engineer)
ƒ Check tappet clearance (only mechanical tappets)
ƒ Take an oil sample (100cc) and send it to laboratory. Make a precise note of amount taken.
ƒ Drain oil, weigh it Note weight obtained
ƒ Replace lubricant and oil filter. Record amount of oil introduced in engine.
ƒ Note: Keep oil filter at least until subsequent oil filter replacement or according to
instructions of Test Supervisor
ƒ Assess oil consumption (as per Standard FPT DUR016, monitoring during life test)
ƒ Replace fuel filter.
ƒ Replace air cleaner.
ƒ Check tension of belt or chain.
ƒ Run Power curve performance test as per Standard FPT DEV001.
D) Inspections to be made after test
ƒ Check oil and water losses.

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
January 2008 Page 7 of 13
 FPT DUR003 FPT PERFORMANCE STANDARDS

ƒ Read compression of cylinders (if requested by l Engineer)

ƒ Check tappet clearance (only mechanical tappets)
ƒ Take an oil sample (100cc) and send it to laboratory. Make a precise note of amount taken.
ƒ Drain oil, weigh it Note weight obtained
ƒ Assess oil consumption (as per Standard FPT DUR016, during life test)
ƒ Check tension of belt or chain.
ƒ Run oil consumption test at full load (choking is optional) as per Standard FPT DUR016.
ƒ Run Power curve performance test as per Standard FPT DEV001.
ƒ Monitor blow-by flow at full load (choking is optional) as per Standard FPT MEC001.

4.3.4 Operations after Test

A) Monitor residual torque of cylinder head and intake and exhaust manifold capscrews.
Note If torque was recorded during tightening, record in same way during disassembly.
B) Disassemble engine and inspect all components, with special attention to:
ƒ Block. Visually inspect cylinder sleeves, welsh plugs for leakage, and cracks in general.
ƒ Pistons. Check for signs of forcing or abrasion along the skirt, piston rings for freedom of
movement and abrasion or signs of overheating, also check for piston crown blemishes.
ƒ Head gasket Check for leakage on gas side and liquid side at interfaces with block and
head.
ƒ Cylinder head. Using suitable hydraulic or pneumatic compression equipment check for
cracks or failure, check for head gasket contact face leakage, for intake and exhaust valve
leakage, for valve seat sinking, for defective combustion chambers with particular attention
to the area of ignition.
ƒ Test hardness of combustion chamber ignition bowl.
ƒ Subsequently, inspect the head for defective water jackets.
ƒ Intake manifold. Look for cracks, signs of forcing or distortion.
ƒ Exhaust manifold/turbocharger, if installed. Look for cracks, distortion, heat checks, oxide
deposits and sludge.
ƒ Inspect components as per table of annex 1, “after test” column.

5 Data
5.1. Test Results and Calculations
During test cycle, enter parameters as per form PD-M205, annex 2, in the “always” column
(Engineer may request additional measurements).
Calculate percent decay of fastener load.

5.2 Test Documentation

Enter inspection results, fastener pull decay and head hardness.
Enter the test results bearing in mind evaluation criteria of para 5.3
Enter a comment in the notes related to observations made on components considered inadequate.
The purpose is to give, even if the test was successful, an indication of weak points of tested
configuration.

5.3. Evaluation Criteria

The test shall be considered to be successful, for a test on complete engine, if all the following set of
conditions are met:
• All components of engine under test have completed the number of cycles specified.

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
Page 8 of 13 January 2008
 FPT PERFORMANCE STANDARDS FPT DUR003

• On disassembly, engine components do not show defects adversely affecting operating

efficiency.
If testing involves components only, evaluation shall be positive if component conditions are the
same as engine complete conditions.

6 Safety
6.1. Types of Engine Shutoffs and Alarms
See FPT DEV012 Test procedure, para. 6.1.

6.2. Alarm Limits

See FPT DEV012 Test procedure, para. 6.2.

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
January 2008 Page 9 of 13
 FPT DUR003 FPT PERFORMANCE STANDARDS

ANNEX 1

INSPECTIONS TO BE CARRIED OUT

For Approval and Qualification of engine complete, the following inspections shall be carried out in
addition to those on components that the Engineer considers critical and those carried out by
Suppliers for self-certification purposes.
If only some (or one) components are tested, inspection shall be mandatory only for components
under test.

After
Component Inspection New
test
Block Cylinder sleeve bore diameter x x
Sleeve bore roughness x
Longitudinal generating line profile to determine TDC wear. x
Block top flatness x x
Block top roughness x
Surface finish to be as per Standard 1.00103/01
Pistons Groove diameters and width x
Piston rings Ring end gap x x
Radial thickness x x
Axial thickness x x
Tangent load x x
Cylinder head. Head bottom face flatness x x
Head bottom face roughness x
Head gasket Thickness x x
Intake manifold Manifold flange face flatness x
Exhaust manifold Manifold flange face flatness x
Turbocharger Turbo flange face flatness x

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
Page 10 of 13 January 2008
 FPT PERFORMANCE STANDARDS FPT DUR003

ANNEX 2

TEST CYCLE TABLE

Step Engine Throttle Engine Time
No. speed opening torque Mea Remarks
[rpm] [%] [Nm] [s] s
Starting (glow plugs warm-up for diesel
1 Idle 0 60
engine)
Activate cold circuit.
2 Idle 0 500 max YES Change step depending on engine water
outlet temperature (see Note 1).
3 Idle 0 5 Cold stabilization
Acceleration from idle to maximum speed
4 100 20 max
(see Note 2)
Cycle maximum speed (see Note 2)
Change step if engine water outlet
5 100 500 max YES
temperature 103°C
Restore warm circuit
6 20 YES Warm stabilization

7 Carry out steps 2 thru 6 N times (see Note 3)

Disable cooled water circuit solenoid
8 Idle 0 30
valve EV (7 thru 12 °C) Disable all
actuators.
Discontinue test and inspect as per para
9 Shutoff 0
4.3.3.C
Carry out steps 1 thru 9 a number of times calculated as follows (see Note 3):
10
• 2500/N times for spark ignition engines
• 5000/N times for passenger and commercial vehicle diesel engines
• 15000/N for lightweight and medium diesel engines
• 20000/N times for heavy diesel engines.

In-cycle temperature settings

Engine outlet water
103
[°C]
Engine inlet oil (*) Spark-ignition engines. 140
[°C] Diesel engines: 130
(*) Not to be considered for oil cooled by engine water circuit

Note 1: Temperature to be set for step change shall be such as to bring about a temp. differential of
at least 55°C, between engine water outlet maximum and minimum temperature during the
cycle. For ex IM engines with open loop, the historical value is >70°C.
Note 2: Cycle maximum speed: usually is the max. power output rpm. Point C speed is used if
thermal load in this point is higher than that t of maximum power output.

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
January 2008 Page 11 of 13
 FPT DUR003 FPT PERFORMANCE STANDARDS

Note 3: The number of repetitions N depends on engine maintenance plan. Select so that it is a
fraction of total number of cycles to be carried out on engine under test (5000, 15000 or
20000).

© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
Page 12 of 13 January 2008
 FPT PERFORMANCE STANDARDS FPT DUR003

ANNEX 3

Engine rpm and head outlet coolant temperature trend

Engine speed [rpm]

Example of cooled engine, in cold condition, cooling directly from industrial water appropriately
treated (open loop)

Engine rpm
Water temperature [°C]
Alpha [%]

Example of engine cooled, in cold condition, coolant coming from heat exchanger (pressurized
closed loop)
© Copyright 2008 – FPT Passenger & Commercial Vehicles – All rights reserved
January 2008 Page 13 of 13