Ecotec Manual - Darton Sleeves

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INSTALLATION PROCEDURES
Page 1 - revised 5.16.2011
GM EcotecTM 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 + 0°.02'.
Boring must be perfectly square to established deck surface. It is essential sleeve seating dimension depth be controlled to ensure proper sleeve height of .002 - .005
above deck surface upon installation.
3) Deck block surface 90° + 0°.02' angular tolerance
4) All boring must be machined on bore center of 3.775 + .0005.
5) 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.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004-2011
INSTALLATION PROCEDURES
Page 2 - revised 8.13.04
GM EcotecTM
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.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
INSTALLATION PROCEDURES
Page 3 - revised 8.13.04
GM EcotecTM
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.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
INSTALLATION PROCEDURES
Page 4 - revised 8.13.04
GM EcotecTM
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.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
INSTALLATION PROCEDURES
Page 5 - revised 8.13.04
GM EcotecTM
A)
Using proper bore centers, move boring operation from front to rear.
B)
Continue boring
operation to remove body
of sleeve in each hole.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
INSTALLATION PROCEDURES
Page 6 - revised 8.13.04
GM EcotecTM
A)
Mill interpolation is the recommended method of removing old cast iron sleeve flange.
B)
Continue boring
operation after sleeve
removal.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
INSTALLATION PROCEDURES
Page 7 - revised 8.13.04
GM EcotecTM
A)
Continue boring operation.
B)
Mill interpolation is
recommended for creating
top flange register according to specification.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
INSTALLATION PROCEDURES
Page 8 - revised 8.13.04
GM EcotecTM
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.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
INSTALLATION PROCEDURES
Page 9 - revised 8.13.04
GM EcotecTM
C)
D)
Close-up. Bottom reg.
and o'ring area.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
INSTALLATION PROCEDURES
Page 10 - revised 8.13.04
GM EcotecTM
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.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
PRODUCTS
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
INSTALLATION PROCEDURES
Page 12 - revised 8.13.04
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 2000-2500. 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 0-500 miles, do not exceed 4000 rpm.
· from 500-1000, 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.
OSHA
Always use approved protective equipment for sight, hearing, breathing, and hands while machining or using chemicals.
MSDS sheets are available on chemicals supplied as part of this kit, upon request.
©Darton International, Inc. 2004
I
P
M
E
N
T
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
B
U
I
L
D
I
N
G
E
Q
U
Sunnen CV-616
Setup
RA
RY
RZ
RPK
RVK
RK
MR1
MR2
23.14 µ"
231.14 µ"
184.4 µ"
26.34 µ"
68.14 µ"
80.14 µ"
7%
86%
EHU-412
C30 PHT 731 - 45 Seconds
RA
15.4 µ"
RY
162.4 µ"
RZ
127.4 µ"
RPK
10.5 µ"
RVK
40.9 µ"
RK
35.4 µ"
MR1
5%
MR2
88%
E
N
G
I
N
E
R
E
EHU 412
RA
RY
RZ
RPK
RVK
RK
MR1
MR2
25.1 µ"
266.2 µ"
198.3 µ"
29.9 µ"
44.5 µ"
89.7 µ"
6%
88%
C30
RA
RY
RZ
RPK
RVK
RK
MR1
MR2
P
R
E
C
I
S
I
O
N
EHU 518
®
EHU 518
PHT 731 - 30 Seconds
9.0 µ"
132.0 µ"
93.5 µ"
7.8 µ"
38.4 µ"
23.8 µ"
5%
81%