BRITISH STANDARD AUTOMOBILE SERIES BS AU 257 2002 Code of practice for remanufacture of spark and compression ignition engines ICS 43 060 01 ݱ°§® ¹¸¬ Þ® ¬ ¸ ͬ¿²¼¿®¼ ײ ¬ ¬«¬ ±² Ю±ª ¼»¼ ¾§ ×ØÍ «²¼»®[.]
BRITISH STANDARD AUTOMOBILE SERIES BS AU 257:2002 Code of practice for remanufacture of spark and compression ignition engines óóÀơ ÀóÀóÀơ Àơ Àơ Àơ Àóóó IC S 43 íĐđÃạáơ ịđÃơÃ-á ơẳđẳ- ì-ơÃơôơà éđêÃẳằẳ ắĐ ìỉ ôẳằđ Ãẵằ-ằ âÃơá ịì ề đằđẳôẵơà đ ằơâđàÃạ ằđÃơơằẳ âÃơáôơ Ãẵằ-ằ đ ì ỉ ềơ đ ẻằ-ằ BS AU 257:2002 úúụ ụ úúụ ụ ụ ô Àô Àô ô Àóóó Committees responsible for this British Standard The p re parat ion of this British Standard w as e ntrust ed t o Te chnic al C o m mitte e MC E /2 , E ngine s fo r ro ad vehic le s, up on whic h the fo llow ing bo dies w ere re prese nted: AE A Te chnolo gy Auto m ob ile Ass ociatio n D epartment o f Transp ort Freight Trans po rt Ass o ciatio n Garage E quipme nt Asso ciation Institute o f Ro ad Trans po rt E ngine ers Mot or Industry Re se arch Ass o ciatio n Ro ad Haulage Asso ciat ion Ltd So c ie ty of Mot or M anufact ure rs and Traders Ltd C o op ted mem b ers This B rit is h St anda rd, ving be e n pr ep are d unde r th e direct ion o f the E nginee ring S ecto r Policy a nd S tra te gy C om m itte e, wa s p ub lis he d un de r the a utho rity o f the S tan dards Polic y and S trate gy Co m m itte e o n O cto be r 002 © BS I O cto b e r 002 First p ub lis he d D ece m b e r 99 S eco nd e ditio n O cto b e r 02 Amendments issued since publication Amd No D ate C o m me nt s The fo llo wing BS I re fere nces re la te to the wo rk o n th is B ritish S tan da rd : Co m m itte e re fe ren ce MC E /2 D r aft fo r co m m ent 4/70 877 D C ISBN 580 40438 íĐđÃạáơ ịđÃơÃ-á ơẳđẳ- ì-ơÃơôơà éđêÃẳằẳ ắĐ ìỉ ôẳằđ Ãẵằ-ằ âÃơá ịì ề đằđẳôẵơà đ ằơâđàÃạ ằđÃơơằẳ âÃơáôơ Ãẵằ-ằ đ ì ỉ ềơ đ ẻằ-ằ BS AU 257:2002 óóÀơ ÀóÀóÀơ Àơ Àơ Àơ ô Àóóó Contents Committees responsible Foreword 10 11 12 13 14 15 Scope Definitions General Cylinder blocks Cylinder heads Crankshafts Camshafts Connecting rods Oil pumps Water pumps Ancillary equipment Assembly Testing procedures Documentation Presentation and protection 1 2 3 3 4 4 5 i â BSI October 2002 íĐđÃạáơ ịđÃơÃ-á ơẳđẳ- ì-ơÃơôơà éđêÃẳằẳ ắĐ ìỉ ôẳằđ Ãẵằ-ằ âÃơá ịì ề đằđẳôẵơà đ ằơâđàÃạ ằđÃơơằẳ âÃơáôơ Ãẵằ-ằ đ ì ỉ Page Inside front cover ii ềơ đ ẻằ-ằ B S AU 25 7: 20 02 Fore wo rd This British S tandard has b ee n prep are d by Tec hnical C o mm itte e MC E /2 It is a ne w e ditio n of BS AU 25 : 99 which is w ithdrawn As a co de of p ractice, this British S tandard take s the form of guidance and re co mme ndatio ns It s hould not b e quote d as if it we re a s pe cificatio n and particular care should b e t ake n to e ns ure that claims of co mpliance are not m is leading This p ublic ation es not p urp ort to inc lude all the nec es sary provisions of a co ntrac t Us ers are re spo nsib le fo r its c orrec t app licatio n C o mp liance w i th a B ri tish S tandar d does not of its elf confer i mmu nity fro m legal o b ligati on s S ummar y of p ages This doc ume nt co mp rises a fro nt co ver, an ins ide fro nt co ver, pages i and ii, p age s t o and a back c ove r The BS I c opyright no tice dis played in this docume nt indicate s whe n the document w as last iss ue d óóÀơ ÀóÀóÀơ Àơ Àơ Àơ úúú ii ịđÃơÃ-á ơẳđẳ- ì-ơÃơôơà íĐđÃạáơ éđêÃẳằẳ ắĐ ìỉ ôẳằđ Ãẵằ-ằ âÃơá ịì ề đằđẳôẵơà đ ằơâđàÃạ ằđÃơơằẳ âÃơáôơ Ãẵằ-ằ đ ì ỉ â ềơ đ ẻằ-ằ BS I O c to b e r 02 BS AU 25 7: 0 S co pe This Britis h Standard gives recommendations for the techniques to be followed and tasks to be completed in the remanufacture of a spark or compression ignition engine or of a maj or assembly D efini tio ns For the purposes of this British Standard the following definitions apply re manu factu red engine o r maj o r ass emb ly used engine or maj or assembly that has been returned to a near- new state in accordance with the manufacturer s original specification, with fits and clearances to provide similar performance, reliability and longevity comparable to that of a new engine NO TE NO TE remanufactured is synonymous with reconditioned An exchange , factory , reb uilt , repaired or replacement engine or assemb ly is unlikely to have b een sub j ected to For the purposes of this British Standard, remachining, maj or replacement of parts or restoration of all fits and clearances and is therefore not to be confused with a remanufactured engine 2 re new ed c o mp onent new item s ourced from the manufacturer or supplier who can demonstrate fitness for purpose M aj o r ass embli es 2.3 s ho rt e ngine cylinder block cons isting of the crankshaft, connecting rods, pistons and oil and water gallery blanking p lugs 2.3 cylinder head unit consisting of all inlet and exhaust valves , valve seats, valve springs and retainers lo ng engine unit consisting of a s hort engine (see ), cylinder head as sembly (see ), camshaft, cam followers and/or lifters and push rods (where fitted), a cam and/or valve gear cover, an oil pump, timing gears, a timing chain, a timing chain tensioner and a cover or timing belt, a belt tensioner and timing wheels The cylinder block is closed by an engine oil sump with the exception of engines where the transmiss ion cas e forms the sump Gene ral All engines or assemblies should be dis mantled, the oil and water gallery, cylinder block and head core p lugs removed, and components thoroughly cleaned, degreased and decarbonized All components should be inspected against manufacturers tolerances and should be machined or renewed as necessary It is essential that the following components are renewed entirely: p istons; piston rings; gudgeon pins and retainers; wet cylinder liners (unless rebored) ; main bearings; big end bearings; thrust washers where fitted; small end bushes; gaskets; oil seals; core plugs; filters; timing chains or timing belts New lock washers should be fitted; if unavailable, an alternative locking device should be fitted If damaged, threaded holes should be retapped or fitted with thread inserts, or plugged and redrilled and tapped Loose dowels s hould be replaced with oversize dowels All splines, keys, keyways and fasteners óóÀơ ÀóÀóÀơ Àơ Àơ Àơ Àóóó should be examined for damage and renewed as necessary â íĐđÃạáơ ịđÃơÃ-á ơẳđẳ- ì-ơÃơôơà BSI October 002 éđêÃẳằẳ ắĐ ìỉ ôẳằđ Ãẵằ-ằ âÃơá ịì ề đằđẳôẵơà đ ằơâđàÃạ ằđÃơơằẳ âÃơáôơ Ãẵằ-ằ đ ì ỉ ềơ đ ẻằ-ằ B S AU 25 7: 20 02 C ylind e r blocks The cylinder b lock should b e reb o re d o r res le eve d and ho ne d to the pis to n manufac turer s s p ecification and dim ens ions , including ap propriate s urface finis h Th e rec es se s o f cylinde r b lo cks fitted w it h rem ova ble line rs s hould be exam ine d and t rued, and t he se al are as s ho uld be ex amine d and rem achine d as nec ess ary Ne w line r se als s hould b e fit ted All dim ens io ns sho uld be re stored t o the manufacturer s to lerances as ne ces s ary b efo re line rs are fit ted It is e s sential that crac k te sting and/or p re ss ure tes ting are c onduc ted The m ain b earing housings sho uld be exam ine d fo r siz e, m is alignm e nt and damage , and s hould b e re m achine d as nece ssary to ensure c orre ct fit o f the ne w b e arings The lo catio ns o f t hrus t b earings s hould b e c hec ked and, if out o f to le rance, re claim ed and/or m achine d as nec ess ary Where the camshaft runs direc tly in the cylinde r b lo ck, the c ams haft b earings s ho uld b e meas ured fo r o valit y, alignme nt and tape r to ens ure c learanc es are to the m anufacture r s sp ec ificatio n Suitable ne w o ve rs iz e or unders iz e b earings may b e fitte d w here available Whe re c am fo llo we rs run direc tly in the cylinde r b lo ck, the cam fo llo we r ho us ing sho uld b e e xamined fo r damage and meas ured for w ear to ens ure clearanc es are to the manufacturer s s pe c ificat io n 4 The top face o f the cylinder b lo ck t op sho uld b e m e asured for flat ness and exam ine d fo r damage and, if re quire d, surface - gro und o r m illed to a s urfac e finish co nfo rming to the e ngine o r gas ket m anufac ture r s s pe c ifications Particular at tention sho uld be give n to maintaining de ck heights within the m anufacture r s s pe c ificatio ns All o il and wate r galleries sho uld be tho ro ughly cle aned prio r to as s emb ly C ylin de r he ads The c ylinder bloc k to he ad face s hould b e cleaned and meas ured t o e nsure flatne ss, and s hould b e mac hine d as ne ces sary t o e nsure flatne s s and that c o rrosion is e liminate d from w at er p orts within the gaske t sealing are a T he c ylinder he ad th ickne ss should b e m aintaine d w ithin the manufacture r s o r rem anufac ture r s s pec ific ation The surface finis h sho uld be as sp e cifie d b y the e ngine o r gaske t manufact urer It is ess ential t hat crac k tes ting an d/o r press ure t es ting are conducte d The roc ke r co ver/cam ho using j o int face should b e measure d fo r disto rtion and exam ine d for dam age, and sho uld b e mac hine d as re quire d Where c ams haft s run direc tly in the c ylinder he ad, b earings s ho uld b e measure d fo r ovality, tape r and alignm e nt to e nsure c le arance s are t o the m anufacturer s spe cific atio n Whe re t he cam follo we rs run dire ctly in the cylinder he ad, t he cam fo llow e r housing sho uld be e xam ine d fo r dam age and m easured fo r we ar to ensure cle arance s are to the manufacturer s spe cificat ion Valve guide s s ho uld b e me as ure d fo r we ar and, if ne ces sary, res ized, res lee ved o r rene we d to c onfo rm to the m anufac ture r s s pec ific atio n Valve springs should be m eas ured agains t the manufacturer s to le rances for squarene ss , fre e length and co mpre s se d lo ad le ngth and sho uld b e re new ed as ne ce ss ary 5 Valve colle ts sho uld b e e xamined fo r wear and dam age and s hould b e rene we d as ne ces sary Valve s s ho uld b e exam ine d fo r dama ge, m easured for straightnes s, head thick nes s and stem w ear, and re face d or re newe d as ne ce ss ary Valve seats sho uld be re mac hined and ins e rts re new ed as ne ce ss ary The valve s eat he ight sho uld c onfo rm to t he manufac turer s spe cification All valve o pe rating asse mblie s s hould b e c om ple te ly dism antle d, clea ne d and e xamine d fo r we ar and o ther defe cts C om po nents sho uld be m ac hined or re ne w ed as nec ess ary Pus h ro ds s hould b e ex amine d fo r straightnes s, damage and we ar, and sho uld be re new ed as nece ss ary It is e sse ntial that t he valve t rain geo m e try is maintaine d o n the c om p one nt as sem b ly All o il and wate r galleries sho uld be tho ro ughly cle aned prio r to as s emb ly óóÀơ ÀóÀóÀơ Àơ Àơ ụ ụ úúú ịđÃơÃ-á ơẳđẳ- ì-ơÃơôơà íĐđÃạáơ éđêÃẳằẳ ắĐ ìỉ ôẳằđ Ãẵằ-ằ âÃơá ịì ề đằđẳôẵơà đ ằơâđàÃạ ằđÃơơằẳ âÃơáôơ Ãẵằ-ằ đ ì ỉ â ềơ đ ẻằ-ằ BS I O cto b e r 00 BS AU 25 7: 0 C ranksh afts The o il gallery plugs sho uld be re m ove d as ne ce s sary and the c ranks haft sho uld b e e xam ined for damage D ies el engine crankshafts s hould b e crack te ste d afte r any mac hining p ro ce ss and prio r to ass e mb ly S ealing diame ters and no s e ends sho uld b e m eas ured and, if ne ces s ary, re claim ed Jo urnal w ear, b le nde d radii, thrust we ar and a lignm ent should be meas ure d C e rtain c rankshafts m ay b e st raighte ned, depe nding upo n t he m ate rial, b ut it is e sse ntial tha t this o pe ration is fo llowe d b y furthe r crack dete ct ion C ranks hafts s hould b e re gro und o r po lishe d to co nform t o the be aring m anufac ture r s dimensional, s urfac e finis h and rdne s s spe cificatio n O ne or m o re crankshaft j ournals and seal are as may be re claimed b y rec ognize d welding o r m e tal sp raying t ec hniques and then regro und to maintain parity with the o the r j ournals It is e ss ential that cranks haft hardne ss is m aintaine d to the manufac ture r s s p ec ifica tio n Afte r grinding, all crankshafts should b e p olis hed to c onform to the b e aring m anufact urer s s p ec ification fo r surfac e finis h All oil holes s hould b e de b urre d and oil galleries thoroughly c le ane d prior to ass e mb ly C amsh afts C ams hafts s hould b e e xamine d for dam age and m e as ure d for s traightne ss and we ar on j o urnals, lo be s and ske w gea r If nece ssary the cam lo b es should b e rep ro file d o r the c amshaft rene we d C am fo llow ers s hould b e re face d or re new ed as nec es sary All hydraulic valve o pe rating c om po ne nts sho uld b e rene we d if uns ervice able afte r a full s trip and inspe ction C o nne cti ng ro ds B ig e nd b earing ho usings sho uld b e m easure d for s iz e and o valit y and sho uld b e re s iz e d as ne ce s sary S ide face s s ho uld b e e xamine d, and b e aring kee p s a nd oilw ays de burred and tho roughly cle ane d p rior to ass e mb ly óóÀơ ÀóÀóÀơ Àơ Àơ Àơ Àóóó C o nne c ting ro ds sho uld be m easure d fo r alignme nt and straight ened as nece ss ary Small e nd b ushes sho uld be re new ed and re m achine d to give t he gudge on p in to b us h c le aranc e sp ecifie d b y the manufac ture r, afte r e nsuring that the ho us ing is w it hin dim ens io nal lim its The int erferenc e fit of p re s s- fit gudgeo n p ins to sm all e nd b ores s ho uld be maintaine d to the manufact ure r s sp ec ifica tio n Big e nd studs and b olts sho uld b e e xam ined and any s ho wing signs of stretc h or damage s ho uld b e re new e d C o nne c ting ro ds sho uld be m atc hed as a we ighte d s et O il pumps O il pum ps should b e e xamined for internal s co ring and da mage and me as ured fo r roto r to b ody c le arance as de fine d b y the ma nufacturer T he pres sure relief valve as se m bly should be dismantled and c le ane d All no n- c onfo rming p arts sho uld b e rene wed â íĐđÃạáơ ịđÃơÃ-á ơẳđẳ- ì-ơÃơôơà BS I O cto b e r 00 éđêÃẳằẳ ắĐ ìỉ ôẳằđ Ãẵằ-ằ âÃơá ịì ề đằđẳôẵơà đ ằơâđàÃạ ằđÃơơằẳ âÃơáôơ Ãẵằ-ằ đ ì ỉ ềơ đ ẻằ-ằ B S AU 25 7: 20 02 Wate r pump s If fitted b y the remanufacturer, water p umps s hould b e remanufactured to the original equip ment specification or renewed 1 Anci llary e qui pme nt 1.1 All tooth belts and timing chains should b e renewed Chain wheels and gears should be examined for óóÀơ ÀóÀóÀơ Àơ Àơ Àơ Àóóó wear or damage and renewed as necess ary 1.2 Worn tim ing chain guides and chain tensioners should b e renewed 1.3 Toothed belt s prockets should b e examined for wear or damage and renewed as required 1.4 Where fitted, crankshaft torsional vibration damp ers and/or crankshaft p ulleys should be examined for wear or dama ge and renewed as required 1.5 Any other comp onents, the condition of which may influence engine performance or durab ility, should b e s trip ped, examined and remanufactured or renewed as necessary 1.6 All fasteners and threads should b e examined and renewed as necessary Ass e mb ly All comp onents should be thoroughly cleaned b efore assemb ly E ngine reassemb ly should b e carried out strictly in accordance with the manufacturer s guidelines, with p articular attention being paid to b olt tightening sequences and torque procedures 2 It is ess ential that measurements include piston heights, va lve- p ocket dep ths, pis ton- skirt clearance, valve timing, tapp et clearances, and crankshaft end floa t and bearing clearances It is essential that tests are carried ou t during assembly to ensure that each valve and its s eat forms an efficient seal It is essential that breathing comp onents forming p art of the engine are neither contaminated nor damaged The remanufactured engine or maj or ass emb ly should be perma nently identified b y a unique s erial number This serial numb er should b e reproduced on the warranty document T es tin g pro ce dure s A minimum test for a long engine should be cap able of indicating or detecting the following: a) oil p ressure; b ) comp ression; c) oil leaks Items a) and b ) should b e recorded ịđÃơÃ-á ơẳđẳ- ì-ơÃơôơà íĐđÃạáơ éđêÃẳằẳ ắĐ ìỉ ôẳằđ Ãẵằ-ằ âÃơá ịì ề đằđẳôẵơà đ ằơâđàÃạ ằđÃơơằẳ âÃơáôơ Ãẵằ-ằ đ ì ỉ â ềơ đ ẻằ-ằ BS I O ctober 00 BS AU 25 7: 0 Do cume ntatio n Each remanufactured engine or maj or ass emb ly should have its own b uild document containing records of: a) components renewed; b ) serial numb er; c) comp letion date; d) tes t records This document shou ld b e retained b y the remanufacturer and made availab le to the customer in the event of a disp ute An information p ack detailing the following s hould b e attached to the remanufactured engine or maj or assemb ly: a) serial numb ers; b ) fitting instructions; c) running- in p rocedures; d) written warranty Pre s e ntatio n an d p rotection The completed remanufactured engine or maj or assembly should b e p ainted and suitably p rotected against ingress of dirt, corrosion and physical damage â íĐđÃạáơ ịđÃơÃ-á ơẳđẳ- ì-ơÃơôơà BS I O cto ber 00 éđêÃẳằẳ ắĐ ìỉ ôẳằđ Ãẵằ-ằ âÃơá ịì ề đằđẳôẵơà đ ằơâđàÃạ ằđÃơơằẳ âÃơáôơ Ãẵằ-ằ đ ì ØÍ óóÀơ ÀóÀóÀơ Àơ Àơ Àơ úúú ềơ đ ẻằ-ằ BS AU 257:2002 BSI British Standards Institution BSI is the independent national body responsible for preparing British Standards It presents the UK view on standards in Europe and 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