UDC 621.431.73:621.43-224.2-762.426 JAPANESE INDUSTRIAL STANDARD Cylinder head gaskets for automobile engines JIS D 3105 Translated and Published by Japanese Standards Association Printed in Japan 14sUDC 621.431.732621.43-224,2-762.426 JAPANESE INDUSTRIAL STANDARD sis Cylinder head gaskets for automobile engines D 3105-1992 Scope This Japanese Tndustrial Standard specifies cylinder head gaskets used for automobile engines, (hereafter referred to as gaskets). Remarks: The applicable standard is as follows: JIS D 1001-Engine Power Test Code for Road Vehicles 2, Definition The meanings of the main terms used in this standard shall be as follows: (1) Terme relating to gasket construction (a) cross-sectional construction of combustion chamber hole sealing part ‘The cfoss-sectional construction patts which seal mainly combustion gas at the combustion chamber hole part of the gasket. (Refer to Fig. 3)+ Pig. lL. Cross-sectional construction of combustion chamber hole sealing part (Example) Gasket Water hole Cpabustion chaber hele Bolt hole Kater hole (b) combustion chamber hole sealing part reinforeing construction The construction for reinforcing the combustion chamber hole sealing part of the gasket to particularly improve the sealing effect. (c) gasket (body) Gasket body from which the grommet and the auxiliary seal are removed.2 D 3105-1992 (4) grommet Metal ring which is independent of the gasket body and covers the surroundings of inside edge of the hole. (e) auxiliary seal Seal added for supplementing the sealing function of the gasket body. (2) Terms relating to gasket material (a) joint sheet Dense sheet-form gasket material made by pressing Huiviere aixcure of organte fiver, taorganie fiber or the nixture of them and rubber. (b) beater sheet Sheetform gasket material made by the paper making process of organic fiber, inorganic fiber or the mixture of them as the main material and rubber latex or the like as the binder by means of a beater or the like. (ce) graphite sheet Flexible soft sheet-form gasket material of laminated structure formed by expanding natural flake graphite as the main component. (4) metal core fiber sheet Sheet-form gasket material prepared by integrally laminating a non-metallic material such as joint sheet or beater sheet and a metallic material such as mild steel sheet. (e) metal core graphite sheet Sheet-form gasket material prepared by Tetegratiag-s srapelce sheet and a nild etal naterial. (3) Terms relating to measurement of gasket (a) free time thickness The thickness of gasket when produced means the thickness of the combustion chamber hole sealing part unless otherwise specified. (b) difference in free time thickness The difference between the gaximum and the minimum values of free time thickness in one sheet of gasket. (c) tightened thickness The thickness of the gasket measured when it is tightened between the corresponding cylinder block and cylinder head under the specified tightening torque(‘), means the thickness of the combustion chamber hole sealing part unless otherwise specified. Note (+) The torque specified by the agreement between the parties concerned with delivery or the manufacturers of engines. (a) difference in tightened thickness The difference between the aaximum and the minimum values of tightened thickness in one sheet of gasket. (e) turnup width The width of the gasket at those parts where the metal sheet is turned up at the hole parts and outer peripheral parts of gasket (refer to Pig. 2).3 D 3105-1992 Fig. 2, Turnup width ‘Turaup wlach r_3 _ cet ‘Turnup width ‘Turnup width ate Jusean 1 & = (£) rim width of grommet The width of the ring on the opposite side of the turned up side (refer to Fig. 2). (g) comcentricity The quantity of deviation between the center of designed basis hole and that of the product hole (Refer to Fig. 4). (h) filling degree In a gasket with its combustion chamber hole Sealing part covered with metal, the degree in which the filler material fills the inside of the metal (marked by the dimensions of the gap shown in Fig. 3). Fig. 3. Filling degree cap anja. (Te Hiller material (4) Terms relating to test of gasket (a) pressure~sensitive sheet A test sheet which produces difference in developed color corresponding to the magnitude of the applied pressure, classified into the single coloration type which develops color by one sheet and the laminated coloration type which consists of a pair of coloration sheet (a sheet which indicates coloration) and a coloration initiating sheet (a sheet which encourages coloration). (b) interface leakage The leakage from the interfaces (gasket fitting ‘urfaces) between the gasket and the cylinder block or cylinder head. (c) exudation leakage Leakage caused by exudation through the gasket. (4) measuring element of thickness A plastic material (lead alloy piece) used for measuring the condition of tightening of the gasket accurately when measuring its tightened thickness, 3. Classifu 3.1 Classification by basic construction The types of gaskets Sxanidlel bp teale contzaceton tsi te ts hewn. tn Sakis hy ion4 D 3105-1992 Table 1. Classi ftcatt! Classification by basic construction ‘on Basic construction Component type | Combustion chamber hole sealing part and the other parts are combined Separate type | Combustion chamber hole sealing part and the other parts are not combined 3.2 Classification by body material The types of gaskets classified by body material 61 @ as shown tm Table 2. Table 2 Classification Metal type Non-metal type Combined type + Classification by body material Body material Gasket body consisting of the metal only Gasket body consisting of the non-metal only Gasket body consisting of the combination of metal and non-metal 3,3 Classification by body construction The types of gaskets classified by the body construction shall be as shown in Table 3. Table 3. Classification by body construction Classification Body construction Single body structure Structure made up with single material Metal covered structure Structure made up with a fiber compressed body or a non-fiber compressed body, covered with metal sheet Metal Hook core core type structure Structure made up with a fiber compressed body having a core of hook type metal sheet, or combined structure made up with non-fiber compressed body together. type Plate core| Structure made up with a fiber compressed body having a core of plate type metal sheet, or combined structure made up with non-fiber compressed body together. Metal. laminated structure Structure made up with laminated metal sheets5 D 3105-1992 3.4 Classification by cross-sectional construction of combustion chamber hole sealing part The types classified by the cross-sectional construction of the combustion chanber hole sealing parts of the gasket shall be as shown ta Table 4. Table 4. Classification by cross-sectional construction of combustion chamber hole sealing part View of cross-sectional Classification |corss-sectional construction | View of crosscaect ion Single | Flat Gasket consisting of a body type single metal sheet, having CEZZZBA const- flat combustion chamber — + ruetion hole sealing part. Grooved| Gasket consisting of a type | single metal sheet, ee es iol COZ combustion chamber hole sealing part or in its vicinity. Bead [Gasket consisting of a type |single metal sheet, having cor Ree a bead in the combustion chamber hole sealing part. Bent |Gasket consisting of a back single metal sheet which is Tee type beat back at the combustion chamber hole sealing part. Metal | Single |Covered type gasket in which covered | turnup |the metal sheet on one side const- | type is turned up to cover the ruction combustion chamber hole sealing part. | Double |Covered type gasket in which turnup |the metal sheets on both | type,” Jsides are turned up to cover | GESSCOEY the combustion chanber hole | sealing part. | Grommet] Covered type gasket in which type | the combustion chamber hole sealing part is covered with groanet.6 D 3105-1992 Table 4. (Cont'd) Classification Corss~sectional construction View of cross-sectional construction (example) Gasket of the metal core construction in which the combustion chamber hole sealing part is covered with grommet. ee Tees Gasket consisting of a laminate! of several thin metal sheets in which the top or the bottom sheet of the combustion chamber hole sealing part is turned up to cover It. | | Gasket consisting of a laminate of several thin metal sheets in which the combustion chamber hole sealing part is covered with grommet. Metal | Grommet] core | type const~ ruction Metal | Turnup lami- | type nated con struc~ tion Grommet type Non- covered| type Gasket consisting of a laminate of several thin metal sheets in which the combustion chanber hole sealing part is not covered. 3.5 Classification by reinforced construction sealing part The types of gaskets classified by the reinforced construc~ tion of the combustion chamber hole sealing part shall be as shown in Table 5. of combustion chamber hole7 3105-1992 Table 5. Classification by reinforced construction of combustion chamber hole sealing part Classification | Reinforced construction | View of cross-sectional construction (example) Wire-reinforced Combustion chamber hole covering metal ts reta~ forced from inside by a wire ring such as steel wire or copper wire. Plate~reinforced| Combustion chamber hole sealing part or its vicinity 1s reinforced by metal plate or non-metal plate. Teasiug: Metaiving im Eiveed in veinforced combustion chamber hole Of geakar to provace gaakat Sree combustion, bate Ringe 1D Fing-form reinforcement Feisforced | matertal used ta cosbustion chamber hole covering metal, soolusing wiveratatereed typee Beadring- A beadring-form reinforce- reinforced [nent matesial waed in coubustion clcsber bolt (TEEXKXY covecing acta, EEsintisg iza-nelabosted epee Others: Gaskets reinforced by combining the above types of methods or the other methods than the above.8 D 3105-1992 3.6 1s of auxiliary seals shown in Table 6. ‘The types of auxiliary seals shall be as Table 6, Types of auxiltary seals Classification Kind Remarks Metal coating | Plating Surface of grommet material or the like is type series plated with mild metal such as lead, aluminium, copper, and zinc. Deposition | Surface of grommet material or the Like is series deposited with mild metal by thermal spraying, evaporation, pressure bonding, or the like. Non-metal. Resin Various kinds of resins are applied by coating type | coating spraying, printing, immersion or the like. Rubber Various kinds of rubber is applied by coating spraying, printing, immersion or the like. Sheet adhesion type Metal series Combined | fiber series | Rubber series Metal foil such as aluminium and copper is adhered. Combined fiber sheet such as joint sheet and beater sheet is adhered. Rubber series sheet is adhered. Graphite Graphite sheet is adhered. series Others Other sheets are adhered. Sheet lamina- | Lamination | Thin sheet of metal is fixed and laminated tion type series by grommet or the like on a part of gasket body. Extension A part of grommet or the like is extended. series Seal ring type | Rubber ring | Ring formed of silicone rubber or the like is partially used. Metal ring | Metal ring or the like is partially used. Other rings | Ring of joint sheet or the 1ike 1s partially used.9 D 3105-1992 4, Performance 4.1 Surface pressure distribution When gaskets are tested according to 7.1, the surface pressure distribution shall be in the specified range(”) and the fitting condition around the vicinity of the combustion chamber hole sealing part, water hole sealing part and the oil hole sealing part shall not be in abnormal. Note (*) ‘The range specified by the agreement between the parties concerned with delivery or by the manufactures of the engines. 4.2 Water hole static pressure sealing performance No water leakage shail eMiat When the gasiee ia teited bpeEe gasket is tested by 7.2. 4.3 Withstand gas pressure No gas leakage shall exist when the gasket tate Ie 4.4 Tightened thickness The tightened thickness and the difference in eighcousd EHTGEISEE EAT wet the fequireasats of TaSia 7 when the teat of 7.4 is performed. However in cases that the thickness of insertion portion of secondary chamber, reinforcing plate and the like; and the specified thickness(*) is other than 1 mm and 1.5 mm, the parties concerned with delivery shall decide considering the permissible deviations specified in Table 7. Table 7, Tightened thickness and the difference in tightened thickness Class | Applied engine ‘Tightened thickness Difference in When specified | When specified | tightened thickness(*) is | thickness(*) is] thickness | ion m= | 15 om an Conjugated | Gasoline engine | 1 + 0.07 [us+o10 | 0x to type t the [piesel engine | 1+ 0.07 [1,540.08 | specified t thick Metal Gasoline engine | 1 + 0.06 1.5 +0.08 | ness(*) type Diesel engine | 1+ 0.05 [1.5 + 0.06 Note (*) The thickness specified by the agreement between the parties concerned with delivery or by the manufactures of engines. Remarks: ‘The tightend thickness shall be the mean value of the thickness measured at each combustion chamber hole sealing part as shown in 7.4.3 except the insertion portion of secondary chamber and reinforcing plate. 4.5 Fitness The fitness of gaskets shall be such that when the test of 7.5 is performed, gas leakage, water leakage, oil leakage or other abnormalities obstructive to engine operation shall not occur. ‘The residual tightening torque of head bolt shall be in the specified tange(‘) for the initial value.10 D 3105-1992 4.6 Durability When the test of 7.6 for gasket is performed, gas leak~ age, water leakage, oil leakage, or other abnormalities obstructive to engine operation shall not occur. Moreover, the residual tightening torque of head bolt shall be in the specified range(*) for the initial value. 5. Permissible deviations and tolerances The permissible deviations and tolerances of dimensions of gaskets shall be as shown in Table 8, unless otherwise specified. The permissible deviations for other parts than those shown in Table 8 shall be as shown in Table 9, unless otherwise specified. Table 8, Permissible deviations and tolerances Permissible dimensional deviations mate and tolerances Free thickness (at combustion Conjugated type ‘#0 % to chamber hole sealing part) pecified value Metal | Metal single | 47 % to type | body Specified value | Metal 40-15 mm to [lamination | ‘Specified value Difference in free thickness (at | Within 15 % to specified value combustion chamber hole single part) Diameter of combustion chamber hole | +0.35 mm to specified value Dianeter of knocking port +H? to specified value Diameter of bolt hole + 0.4 mm to specified value Concentricity of combustion chanber | Within 60.5 ma to design basis position hole Concentricity of knocking port Within 0.4 mm to design basts position Concentricity of bolt hole Within 60.6 mm to design basis position Turnup width 40.5 mm to specified value Rim width of grommet 40.5 mm to specified value Remarks 1. The specified value shall be the value specified by the agree~ ment: between the parties concerned with delivery or by the manufactures of engines. 2, Knocking ports include bolt holes which also setve as dowel ports, water holes and the like. 3. The concentricity of each hole shall be measuted as shown in Fig. 4u D 3105-1992 Fig. 4, Concentricity The centers of holes of the product / hati be in the tIlustrated range Designed hole center \ position Table 9, Dimensional permissible deviations Unie? mm Division Permissible deviation Within 5 410.3 Over 5 up to and including 30 40.4 Over 30 up to and including 100 HS Over 100 up to and including 300 40.6 Over 300 up to and including 500 4108 over 500 1.0 Appearance and filling degree at cross-section of combustion chamber hole sealing part 6.1 Appearance Gasket shall be well-finished and the sealing part shall be free’ from detrimental defects such as cracks, flaws, uneven surfaces, wrinkles, attached forelgn matters, and rusts. 6.2 Filling degree at cross-section of combustion chamber hole sealii part Sor velgatise coacier lets eeilig te oF tee ete etiam, the sealing parts shall be sufficiently filled with the filler material. However, the filling degree of the gasket in which a sufficient filling degree cannot be obtained by reasons of the cross-sectional construction of the combustion chamber hole sealing part shall be specified by the agreement between the parties concerned with delivery. 7. Test methods 7.1 Surface pressure distribution test 7.1.1 Purpose of test This test is performed by using pressure sensing sheets for the purpose of measuring the surface pressure distribution by the density of developed color in the condition of the gasket tightened between the cylinder block and cylinder head, detecting abnormal parts by the fitting condition of respective parts, and finding the surface pressure at respective parts by the color density.12 D 3105-1992 71.2 @ (2) 3) a) «s) (6) 7.13 @ (2) Test conditions The test conditions shall be as follows: Gasket fitting surface The gasket fitting surfaces of the eylinder Block and cylinder head shall be 5 to 35 °C and prelimtnartly be given the condition specified by the manufacturer of the engine by removing oil dust and the Like on the surface, Particular in the case of an engine using a cylinder Liner, the liner projection value shall be set specified by the manufacturer of the engine. Specimen gasket The specimen gasket shall preliminarily be made Unto a good condition free from oil and dust on the surface. Presaure sensing sheet The pressure sensing sheet, which may be either oF the Lealusted coloration type or the single coloration type, shall desirably have a thickness as thin as possible. Head bolt or nut The head bolts or nuts in use shall be as new 45 possible and be free from flaw and other abnormalities on the threaded part and base, and preliminarily screws it into the counterparts for getting to fit. Parts to contact base of head bolt or nut Those parts coming in contact with the bases of head bolts or nuts, or contact between washers and the head, shall be free from deformation. Torque wrench The torque wrench in use shall desirably be dapibie oF Feeding to 5% of the specified value. However, the torque wrench in use shall be capable of measurement within 80 % of its maximum scale value. Measuring method The measuring method shall be as follows: ‘Tightening of head bolts or nuts The gasket shall be fitted by applying the lubricant specified by the manufacturer of the engine to the threaded part and base of the head bolts or nuts and tightening them by using a torque wrench by the specified tightening method("). ‘The axial tension shall be measured if necessary. Note (") The method specified by the agreement between the parties concerned with delivery or the manufactures of engines. Qualitative measurement A pressure sensing sheets perforated to correspond to the bolt holes, knocking ports, and the like of the gasket shall be fitted to the upper and lower surfaces of the gasket as shown in Fig. 5, and the head bolts or nuts shall be tightened by the method of 7.1.3 (1). However, the pressure sensing sheet may be fitted to only one side of upper or lower surface of the gasket.a) 13 D 3105-1992 After Letting stand the tightened assembly for 5 to 20 minutes, the head bolts or nuts shall be loosened in the reverse order to that of tightening and the pressure sensing sheets shall be detached, and the density of the developed color shall be examined by visual observation. However, when using a pressure sensing sheet of the laminated coloration type, the coloration sheet shall be promptly separated from the coloration initiation sheet to examine the density of the developed color by visual observation. Determination measurement The coloration density of the pressure sensing sheet Immediately after measurement of 7.1.3 (2) shall be measured by a color concentration measuring apparatus, and the surface ptessures on the respective parts converted into pressure values shall be recorded. Fig. 5. Measuring method of surface pressure distribution cylinder head Pressure sensing sheet casket Pressure sensing sheet cylinder block 7.2 Water hole static pressure sealing test Fada. Purpose of test This test 1s performed for the purpose of finding the sealing performance by applying a static water pressure to the water holes of the gasket. 7.2.2 Test conditions This test shall be performed by using the cylinder block and cylinder head according to the conditions of 7.1.2 (1), (2), (4), (5) and (6) and 7.1.3 (1), and as follows: a @) Test pressure The test pressure shall be (300 + 30) kPa, unless Otherwise specified. However, the preasing speed shall be 100 kPa per minute. Pressure applying time The pressure applying time shall be as Give Te Re Uy lace ottaretne epacttiaa. Table 10. Pressure applying time Unit: min Division ‘Time Where interface leakage is mainly examined] 5 Where exudation leakage is mainly examined | 6014 D 3105-1992 (3) 29 a (2) @) Pig. 6. 7.206 below. mM Water temperature The water temperature shall be 5 to 35°C. Test apparatus The test apparatus shall be as follows: Connection of respective appliances and valves An example of the counection of respective appliances end the arrangenent of valves shall be shown in Fig. 6. Engine body The openings of the cooling water passage of the engine body which runs to the outside of the engine body shall be closed, and the cylinder head shall be provided with one or more vent holes. Pressure applying device The pressure applying device shall have a function capable of maintaining the specified pressure for a certain time and pulsation shall be as little as possible at the specified pressure. The pressure gauge shall have a minimum scale divisions of within 10 kPa. Water hole static pressure sealing test appliance (Example) Pressure Pressure applying device | Switching tewtes—J valve Ade vent valve Water supply valve => Water dlscharge valve Measuring method The measuring method shall be as specified Operation of test apparatus The operation of the test apparatus Shall be carried out according to the following procedures? (a) open air vent valve, close water discharge valve and switching valve, and open water supply valve. (b) Supply water until the water level comes above air vent valve and close water supply valve and air vent valve, (e) Open switching valve, and after applying pressure according to 7.2.2 (1), close the switching valve of pressure applying device.15 D 3105-1992 (4) On completion of measurement, open water discharge valve, switching valve, and air vent valve to discharge water. (2) Measurement After the test pressure mentioned in 7.2.2 (1) has Feached to the specified pressure, when the specified time In 7.2.2 (2) is maintained, the side surfaces of the gasket fitting part shall be visually inspected along the engine body to examine for the existence of water leakage. 7.3 Withstand gas pressure test 7.3.1 Purpose of test This test is carried out for the purpose of finding the sealing performance by applying pressured nitrogen gas to the respective cylinders of engines under the condition that the gasket 1s tightened by the cylinder block and cylinder head. 7.3.2. Test conditions This test shall be performed by using the cylinder block and cylinder head according to the conditions of 7.1.2 (1), (2), (4), (5) and (6) and 7.1.3 (1), and as follows: (1) Test pressure The test pressure shall be decided by the parties goncarned with delivery according to the types and using conditions of applied engine and gasket. (2) Mounting condition of engine on bench The mounting condition on bench shall be as the same or the like as the engine is ordinally used. 7.3.3 Test apparatus An example of the test apparatus shall be as shown in Pig. 7.16 D 3105-1992 080 ®O©SOOS Fig. 7, Test apparatus (Example) Gasket Cylinder block (Pistons are built-in) Cylinder head (Intake valve and exhaust valve are equipped, cam shaft is detached, and intake valve and exhaust valve of all the cylinders are closed) Nitrogen gas cylinder, valve V,, pressure gauge G, Nitrogen gas pressure regulator R, pressure gauge G, Withstand pressure hose Hose attachment metal fittings Water tank for detecting gas leakage between cylinders Water leakage detecting appliance Valve for cooling water Vz 7.304 Test method The test method shall be as follows: (1) Test procedures The test procedure shall be as follows: (a) @) Ce) Detach the spark plug (or the glow plug) and connect the water leakage detecting appliance to the outlet of cooling water. Warm up the engine to 85 + 5°C preliminarily before measuring, maintain the temperature for five minutes and leave it until the temperature of the engine becomes to be the same as the room temperature, Open the valve for cooling water V;, supply cooling water to the engine and close the valve V, after confirming that the water level reaches the measurement basis line of water leakage detecting appliance.(a) (e) © (s) (hn) wo @) uv 3105-1992 Fix the piston of the cylinder to be measured to the top dead center. Fix the hose attachment metal fittings to the spark plug (or glow plug) hole of the cylinder to be measured. Connect each hose on to the spark plug (or glow plug) hole other than cylinder to be measured and put the other end of the hoses into the water tank for detecting gas leakage between cylinders. Open the valve of gas cylinder V, and adjust the pressure with the pressure regulator Re Raise up the pressure stepwise by 1 MPa until tt reaches the test pressure value established by the parties concerned with delivary. Keep not less than 5 8 at each pressure level. ‘This test shall be performed for each cylinder according to the above procedures (c) to (h) in order. Measurement Examine for the potential of gas leakage at each test pressure level with water tank for detecting gas leakage between cylinders and water leakage detecting appliance and the Like as shown in Fig. 7. 7.4 Tightened thickness test 74d Purpose This test is performed by using thickness measuring elements to Find the thickness of the gasket at the combustion chamber hole sealing part in the tightend condition of the gasket. 7.4.2 engine or tl (5) and (6) > wm @) 7.4.3 equidistant in Fig. 8. Test conditions This test shall be performed by using the fie cylinder block and cylinder head according to 7.1.2 (1), (4), » and as follows: Specimen gasket The specimen gasket shall preliminartly be provided with holes of 3 to 5 mm diameter for inserting the thickness measuring elenents at the measuring positions and be nade into a good condition freed from oil, dust and the like on the surface. ‘Thickness measuring element The thickness measuring eleneat Shall be made of lead alloy with a hardness within HV 10 and a thickness corresponding to 1.5 to 2.0 times the specified tightened thickness. However, the measuring element shall not protrude from the hole in the tightened condition. Measuring positions The measurement shall be performed at 8 positions in each combustion chamber hole sealing part, as shown18 D 3105-1992 Fig. 8. Measuring positions Measuring positions (B postions) 7.4.4 Measuring method Fit the specimen gasket as shown in Fig. 9, install the thickness measuring elenents firmly at the measuring positions, and tighten the head bolts or nuts according to 7.1.3 (1), After tighten ing, let it stand for 5 min, then loosen the head bolts or auts in the reverse order to that in tightening, and detach the cylinder head. Detach respective measuring elements with care not to cause deformation, measure the thickness to the unit of 0.01 mm by a micrometer or dial gauge, and record the measured values in such a manner as to clarify the measuring positions. Fig. 9. ‘Tightened thickness measuring method __ Gylinder head Thickness aeasuring elements - _ Gasket, __cylinder block 7.5 Fitness test 7.5.1 Purpose This test 1s performed to find the fitness of the gasket to the-engine by bench-test operation, 7.5.2 Test conditions The test conditions shall be as follows: (2) Gasket fitting conditions The conditions for Fitting the Speciaen gaabee to he crgine eal be og specified in 7.1.2 (1), (2), (5) and (6). (2) Mounting condition of engine on bench The mounting condition of The sngite on Eke bench shall be the came ae that of the engine im normal use or a condition sim{lar thereto. (3) Maintenance of engine The engine shall be maintained to be eapable of operating in normal condition before the test.19 D 3105-1992 (Fuel and lubricating ofl | The fuel and lubeteating ot! used 38 as specified in 3. (Test conditions) (7) and (8) of JIS D 1001, as appropriate. (5) Measuring instruments The measuring instruments shall preliminarily be inspected and calibrated if required before the test. (6) Duration of test The duration of test shall be 30 hours Yneluding the time for running-in, which shall not be longer than 3h, However, where the test is not performed continuously, the testing time shall be the total of the operating times (7) Operation conditions of engine The engine shall be operated at the Tallcloa! aistbia GUsier Of revolutions with a dyceacascer connected, and its adjustment shall be performed according to 3 (3) of JIS D 1001, as appropriate, and the lubricating oil temperature during running shall be a temperature which will not cause trouble to the engine, In the case of a water-cooled engine, the cooling water tempera~ ture shall be maintained at about 80°C at the water jacket outlet of the engine. In the case of an air-cooled engine, air shall be ventilated so as to maintain a stable operation condition of the engine. 7.5.3 Test apparatus The test apparatus shall be as follows: (D Engine The engine shall be confirmed the performance according to JIS D 1001. (2) Ancillary equipments of engine The ancillary equipments of the engine shall be specified in 3. (2) of JIS D 1001, (3) Loading device The loading device used shall be a dynamometer Teapable oF Seeding to about 1 of the marimun torque) deatrably attached with a device capable of recording the absorption shaft output (or the dynamometer load and the rotational speed). (4) Cooling water temperature regulator The cooling water Temperature regulator used shall be capable of maintaining the cooling water temperature during the engine operation at the specified temperature of 7.5.2 (7) and desirably be capable of automatic regulation. 7.5.4 Measuring method and calculation formula The measuring method and the calculation formula shall be as specified in 5. (Measuring method) and 6, (Calculation formila) of JIS D 1001 other than shown below. (1) Absorption shaft output The absorption shaft output (or the Kpasesssiat Tool Gad the rotational spend) during Ohe teat alall be measured. (2) Gooling water temperature The cooling water temperature of the engine during the test shall be measured at the engine cooling water jacket outlet.20 D 3105-1992 @) m (a) Spark plug washer temperature The spark plug washer temperature Shall be measured for air-cooled engines only and {t should be recorded continuously during the test. Examination of abnormalities of gasket The existence of Hmormalicice of gestet during aed-after the teat shail be examined as follows? Visual examination shall be carried out during the test for the occurrence of gas leakage, water leakage and ot1 leakage from the gasket fitting part. If any abnormality 1s found, the location, whether it ts gas leakage, water leakage or oll leakage, and the time elapse from the start of the test, and the ike shall be recorded. In the inspection for gas leakage, air bubbles, foams in cooling water, and the Like coming out through the gasket fitting part shall be visually confirmed. (>) The gasket after the completion of the test shall be (s) immediately detached when the temperature of the engine falls down, the existence of the marks of abnormalities as gas leakage, water leakage, ofl leakage and the like shall be examined, and the condition shall be recorded. Measurement of residual tightening torque of head bolts The residual tightening torque of head bolts or nuts shall be measured as follows after the completion of the test and when the temperature of the engine falls down: Attach marks showing the initial position on the head of the bolt and the surface of the cylinder head under measurement, and using a torque wrench, once make it loose about a half turn in the untightening direction, then turn it in the tightening direction, and record the value of tightening torque when the mark is passed the initial position (refer to Fig. 10). ‘The order of measurement for the respective bolts or nuts shall be reverse to that of tightening specified for the engine(*). Note (*) The order specified by the manufactures of the engine.a1 D 3105-1992 Fig, 10. Measuring method of residual tightening torque 1. Attach marks 2, Make it loose Again turn it in indicating the about a half turn tightening direction, tightening tn untightentng and record the tight~ position under direction. ening torque value the conditions at the moment when the of 7.1.3 (Ld. mark is passed the initial position, 7.6 Durability test 7.6.1 Purpose This test is performed to find the durability of the gasket by operating the engine on a bench-test. However, for gaskets for air-cooled engines, the test shall be made on agreement between the parties concerned with delivery. 7.6.2 Test conditions The test conditions shall be as specified in 7.5.2, as appropriate, other than the following: (1) Operation conditions of engine The engine shall be operated under the set conditions of Table 11 with a dynamometer connected repeatedly and alternately for the specified time duration, The choice between the set conditions I to III and the number of times of repetition shall be decided by agreement between the parties concerned with delivery. Table 11. Durability test set conditions | | cooling water a | temperature | 2p | deuce Sonat] Load Rotational speed | (at engine | tine | changing cooling water | (¢) in| time min outlet) °C | I Full load Highest speed rotation | 95 + 5 3 | Within 1 Unload Idling | 3400 | 3 | t 11 | Full load Highest speed rotation 95 +5 [3 | wienta 1 - Stop 30 + 10 3 az | Pull toaa| ighest speed rotation 9545 | 10 | Within 2 =| stop Les | 20 Note (*) Tneluding the temperature changing time.22 D 3105-1992 7.6.3 Test apparatus The test apparatus shall be as specified in 7.5.3, as appropriate, other then those in the following: (1) Loading device The loading device used shall be a dynamometer Capable of reading to about 1 % of maximum torque), desirably capable of adjustment to increase or decrease the loading time by the command signal from an automatic controller and capable of automatic tecording of the load value and loading time. (2) Cooling water supply device The cooling water supply device Shall be capable of supplying the cooling water of temperature specified in Table 11 within the specified time. (3) Engine rotational speed adjusting device (Throttle controller) Fie torational speed adjusting device shall be connected to. th Speed adjusting device shall be connected to the throttle lever of the engine and shall have a function capable of adjusting the engine rotational speed by the command signal from a control device. (4) Control device The control device shall destrably have the Function of simultaneously giving the prescribed set conditions to the respective devices of loading device, engine rotational speed adjusting device, and cooling water supply device by command Signals from the same timing device. (5) Gounting device The counting device shall be capable of counting and indicating the number of times of repetition from the start of the repeating test. 7.6.4 Measuring method The measuring method shall be as follows: (2) Measurement of gas pressure resistance The gas pressure Peututance Cast otGNT We petlsraat cooing to 73 Watas aut after the test, and If necessary, also during the test. (2) Examination of abnormalities of gasket The existence of abnormalities of gasket during and after the test shall be examined according to 7.5.4 (4). (3) Measurement of residual tightening torque of head bolts The residual cightening torque of head bolts shall be measured according to 7.5.4. (5). Marking Gaskets or their packages shall be marked with the following items by an indelible method: (2) Year and month of manufacture or abbreviation thereof (2) Manufacturer's name or its abbreviationInformative Reference: Materials and components 23. D 3105-1992 The main matertals and components used for the gaskets shall be shown in Informative Reference Table 1. Informative Reference Table 1. Materials and components Corresponding standard Classification Standard No. Symbol 4 Metal | Steel Steel sheet and JIS G 3141 SPCG, SPCD, SPCE material | products | steel strip in cofl JIS G 3313 SECC, SECD, SECE | | Steel wire JIS G 3505 SwRI | statatess JTS 6 4305 sUS-cP | JIS G 4305 sus-cs | | JIs @ 4313 ‘suS-CSP eee Copper Plates and strips | JIs # 3100 | ¢ 1020 products | C20 Aluminiun| Plates and strips | JIS 4 4000 4 1050, A 1100P wees A 12008 Non- Joint sheet - metal material | Beater sheet | Graphite sheet erent | Rubber Combined | Metal core fiber sheet material of metal Metal core graphite sheet and non- metal | Reference Standards: JIS G 3141-Cold Rolled Carbon Steel Sheets and Strip JIS G 3313-Electrolytic Zine-Coated Steel Sheets and Colls JIS 3505-Low Carbon Steel Wire Rods JIS 6 4305-Cold Rolled Stainless Steel Plates, Sheets and Strip JIS G 4313-Cold Rolled Stainless Steel Strip for Springs JIS H 3100-Copper and Copper Alloy-Sheets, Plates and Strips : JIS H 4000-Alumiaium and Aluminium Alloy Sheets and Plates, Strip and Coiled Sheets3105-1992 Edition L Japanese Text Established by Minister of International Trade and Industry Date of Hstablishaent: 1973-12-01 Date of Reviston: 1992-02-01 Date of Public Notice in offietal Gazette: 1992-02-12 Investigated by: Japanese Industrial Standards Comittee Divisional Council on Aireraft and Automobiles ‘This English translation 1 published by: Japanese Standards Assoclation 1-24, Akasaka 4, Minato-ku, Tokyo 107 ‘Japan © ISA, 1992 Printed in Tokyo by Hoohbunsha Co,, Ltd