IE S026ACCREDITED LABORATORY REPORT · TESTING 2011–2014
Truck and bus diesels: compression and geometry restored without teardown
Compression evened out across cylinders, worn cylinders came up in size, exhaust became lighter. 10.75 % — compression by cylinder, 18–29 → 26–31 bar; 2.95 % — fuel consumption, highway cycle, 25.8 → 25.1 l/100 km; 15.7 % — exhaust smoke opacity, 1.438 → 1.21 m⁻¹; 0.04 mm — worn cylinder bore diameter, 128.12 → 128.08 mm (2014).
accredited laboratory
Key results
| VEHICLE | MILEAGE AT TEST START | WHAT WAS MEASURED |
|---|---|---|
| MAN TG-A | 743,800 km | Compression, per cylinder |
| LAZ-52528 bus | 71,363 km | Compression, per cylinder |
| MAN F2000 | 630,740 km | Compression, cylinder geometry |
| KamAZ-53202 | 520,640 km | Oil system pressure |
| MAN ME220-18.220 | 793,252 km | Smoke opacity, fuel consumption |
| DAF GAG 85.430 | 1,885,900 km | Metal wear particles in oil |
Compression by cylinder — three engines
| ENGINE | BEFORE TREATMENT | AFTER TREATMENT |
|---|---|---|
| MAN TG-A, 6 cylinders | 28–29 bar | 31 bar in every cylinder |
| LAZ-52528 bus, 8 cylinders | 22.6–28.5 bar | 28–29.5 bar |
| MAN F2000, 6 cylinders | 18–24 bar | 26–27 bar |
| Cylinder-to-cylinder spread, average | 3.5 bar | 0.8 bar |
ZECA 363 and Motometer compression testers. Compression is capped by the engine's rated value: all cylinders reaching one and the same figure is the limit of what is achievable.
Cylinder geometry — micrometry along the mileage
| MEASUREMENT ZONE | BEFORE, 631,612 KM | AFTER, 637,155 KM | AFTER 272,587 KM |
|---|---|---|---|
| Upper zone, 40 mm | 128.12 mm | 128.08 mm | 128.09 mm |
| Middle zone, 150 mm | 128.10 mm | 128.06 mm | 128.06 mm |
Averages over six cylinders, two measurement axes. The smaller diameter is the coating grown in the worn zone; over the next 272,587 km the size holds.
Smoke opacity and fuel consumption — MAN ME220-18.220 tractor unit
| PARAMETER | BEFORE | AFTER | CHANGE |
|---|---|---|---|
| Smoke opacity, absorption coefficient K | 1.438 m⁻¹ | 1.21 m⁻¹ | −15.7 % |
| Fuel consumption, highway cycle | 25.8 l/100 km | 25.1 l/100 km | −2.95 % |
Smoke opacity to DSTU 4276-2004, fuel consumption to GOST 20306-90, highway cycle driven on the road.
Oil system pressure — KamAZ-53202
| MODE | BEFORE TREATMENT | AFTER TREATMENT |
|---|---|---|
| Idle, 600 rpm | 1.3 bar | 1.5 bar |
| Working speed, 2000 rpm | 3.7 bar | 4.2 bar |
Measured to GOST 14846-81. The pressure rise is a sign of restored clearances in the crankshaft bearings.
Metal wear particles in oil — DAF tractor unit, 1.9 million km
| METAL, mg/kg | 186,000 KM | 249,000 KM | 279,000 KM | 314,000 KM |
|---|---|---|---|---|
| Iron Fe | 136 | 70 | 49 | 49 |
| Copper Cu | 38 | 38 | 36 | 23 |
| Nickel Ni | 15 | 22 | 18 | 0 |
| Lead Pb | 12 | 0 | 6 | 10 |
| Total | 201 | 130 | 109 | 82 |
Oil samples to GOST 27860-88. The anti-wear properties of the oil were retained over 128,000 km of running.
Laboratory conclusion
Current equivalent
- Revitalizant gel for diesel enginesDiesel engines
- Revitalizant gel for cylinder restorationEngine cylinders, deep wear
How such units are treated:
About this result:
Limits of this report: The results relate to four-stroke diesels of trucks and a bus tested in regular service in 2011–2014; on other engines and duty modes the figures may differ.