FEATURE
8 JAN-MAR 2008 engine professional AERA is providing you with Remember, we all have to this information just in case breathe the same air. This is you have not heard about no problem in late model problems with flat tappet engines using roller lifters and camshaft failures caused by camshafts because they do not gasoline engine oils. need the anti-scuffing additive The problem started years packages to protect the sliding ago when oil companies action of flat tappet camshaft reduced the anti-scuffing and lifter surfaces. additive packages in gasoline engine oils. When reduced, we Special Note — During engine all started to have flat tappet disassembly, check camshaft camshaft and lifter failures. side of lifter bore hole for Everyone was quick to blame wear (egg-shaping) of the Gasoline camshaft or lifter hardness, lifter bore hole in the block. engine oils however that was not the case If it has worn egg-shaped, fix at all. it by bushing the lifter bore or with reduced Flat tappet camshaft and replace block. This egg- anti-scuffing lifter failures have increased shaping will allow the lifter additive over the last ten years and it foot or bottom which contacts has been really bad for the the camshaft lobe to move off packages last three years. As AERA center line, changing the lifter are found members reported flat tappet to lobe contact angle. Now, to be the camshaft and lifter failures, the lifter acts as a scraper we kept track of them and removing the oil film between main cause discovered two issues to be it and the cam lobe causing of flat tappet common denominators: metal to metal contact and camshaft • 75% of the failures were, in cam and lifter failure. failures part, due to a reduction of anti-scuffing additive packages in the gasoline engine oils; American Petroleum Institute (API) Announces BY DAVE HAGEN, MIKE CARUSO, • The other 25% of failures and STEVE FOX were caused by improper New Service Category for break-in procedures such as Diesel Engines: CJ-4 not pre-oiling the engine On October 15, 2006, the before start-up and letting the American Petroleum Institute engine idle. (API) began certifying diesel Although 75% failed oils against a new Service when using late model engine Category, API CJ-4. API CJ-4 oil for break-in, looking back, describes oils for use in high- these failures coincided with speed four-stroke cycle diesel EPA mandated for reduction engines designed to meet 2007 of Zinc additive over the past model year on-highway ten years in gasoline engine exhaust emission standards as oils for cleaner air and longer well as for previous model life of the catalytic converters. years. These oils are especially
engine professional JAN-MAR 2008 9 FLAT TAPPET CAMSHAFTS & OILS BY DAVE HAGEN, MIKE CARUSO, and STEVE FOX
Look for the API Certification Marks (pictured right) every time you buy engine oil. Ask for API-licensed oil whenever you have your oil changed. (API graphics used with permission.)
effective at sustaining emis- sion control system durability where particulate filters and other advanced after-treat- ment systems are used. More information on API CJ-4, including frequently asked questions, can be found at www.apicj-4.org.
Engine Oil Licensing and Certification System (EOLCS) API’s Engine Oil Licensing and Certification System (EOLCS) is a voluntary licensing and certification program that authorizes engine oil marketers who meet specified requirements to use the API Engine Oil Quality Marks — the API Service Symbol “Donut” and Certification Mark program to ensure licensees viscosity. The bottom half grade. Viscosity is a measure “Starburst.” This program is adhere to industry technical tells whether the oil has of oil’s flow characteristics, or a cooperative effort between specifications. Additionally, demonstrated energy- thickness, at certain the oil industry and vehicle the program ensures that the conserving properties in a temperatures. and engine manufacturers API-registered symbols are standard test in comparison to The low-temperature Ford, General Motors, and properly displayed and convey a reference oil. viscosity (the first number, 5W DaimlerChrysler; the Japan accurate information to in 5W-30 oil) indicates how Automobile Manufacturers consumers. Currently, more Performance Levels quickly an engine will crank Association; and the Engine than 500 marketers in more The top of the donut shows in winter and how well the oil Manufacturers Association. than 50 countries are using the oil’s performance level for will flow to lubricate critical Performance requirements, the symbols on more than gasoline and/or diesel engines. engine parts at low test methods, and limits are 8,000 products. You can view The letter “S” followed by temperatures. The lower the cooperatively established by a complete list of our licensees another letter (for example, number the more easily the vehicle and engine and their products by visiting SM) refers to oil suitable for engine will start in cold manufacturers, technical our Licensee Directory. gasoline engines. The letter weather. societies like the Society of API-licensed marketers “C” followed by another The high-temperature Automotive Engineers (SAE) may display two types of letter and/or number (for viscosity (the second number, and the American Society for marks: the API service symbol example, CI-4) refers to oil 30 in a 5W-30 oil) provides Testing and Materials (ASTM) “donut” and the API suitable for diesel engines. thickness, or body, for good and industry associations like certification mark “starburst.” These letters officially stand lubrication at operating the American Chemistry Each mark conveys for “Service” and temperatures. Council and API. Oils meeting information that can be used “Commercial.” The current Multi-grade oil (for these requirements are by the consumer. API performance categories example, SAE 5W-30) recommended by vehicle that can appear in the top provides good flow capability manufacturers. The API Service Symbol part of the Donut are listed in for cold weather but still The API service symbol the API Motor Oil Guide. retains thickness for high- Aftermarket Audit Program “donut” is divided into three temperature lubrication. API’s Engine Oil program is parts. The top half describes SAE Viscosity Grade Single grade oil (a single backed by an ongoing the oil’s performance level. The center of the Donut number in the center of the monitoring and enforcement The center identifies the oil’s shows the oil’s SAE viscosity donut) is recommended for
10 JAN-MAR 2008 engine professional Which oil is right for you?
Note: API intentionally omitted “SI” and “SK” from the sequence of categories.
engine professional JAN-MAR 2008 11 FLAT TAPPET CAMSHAFTS & OILS BY DAVE HAGEN, MIKE CARUSO, and STEVE FOX use under a much narrower Off-Road Oils blockage or back pressure but worked fine. If you’re running set of temperature conditions Straight weight racing oils rendering the Cat useless) a flat tappet mechanical than multi-grade oils. these applications contain now we have an EPA camshaft today in 2008, you Operators should refer to higher concentrations of anti- Emissions problem. Check the have a big problem because their owner’s manuals to wear agents such as in the oil manufacturer’s web site for you are limited on which oils select the proper viscosity oil Castrol GP series or the the latest Material Safety Data to use. Most of oils do not for the ambient temperature Pennzoil with Z-7. If you’re Sheet (MSDS) from your have the shear strength or the and operating conditions at not sure whether your oil has preferred oil’s manufacturer. anti-scuffing additive packages which the equipment will be the proper anti-wear agents all Most MSDS information is necessary to keep these used. you have to do is smell it. If it available on the oil camshaft and lifters properly has an aroma that faintly manufacturer’s website. Or lubricated. If you use late type Diesel Energy Conserving resembles gear oil then it you can call them on the motor oil in your engine with and CI-4 PLUS Designations probably has a higher phone asking about the a mechanical flat tappet concentration of wear specific product and its The bottom of the donut tells camshaft you possibly could inhibitors. category ratings. We find that whether the oil has energy experience premature many machinists and engine camshaft failure! Mechanical conserving properties when Shell Diesel Oil builders with old hot rod cars, compared with a reference oil camshaft engines require oils The API CI-4 licensed formula trucks and boats will use containing higher in an engine test or if an oil of ROTELLA T Synthetic racing engine oil to protect meets CI-4 PLUS concentrations of anti-wear SAE 5W-40 has been the flat tappet camshafts. additives phosphorous and requirements. manufactured for some time Often, that oil is not in the Oils labeled as “Energy zinc (1200-1300ppm VS less now. Shell stands behind the engine very long, as those than l000 for conventional Conserving” have passed the performance of ROTELLA T engines are disassembled oils). See AERA TB 2333R. test that measures oil’s ability Synthetic SAE 5W-40 in all frequently. to conserve energy. applications where the API Why oil pressure is low Widespread use of engine oils CI-4 service rating oil is Vintage Cars, Trucks, at a hot idle after rebuilding with this designation should recommended and even with Boats and Tractors This is a good time to result in an overall saving of the bottles reflecting the older Using a flat-tappet camshaft mention measuring engine oil fuel in the vehicle fleet as a CH-4 rating. Diesel engine oil in your engine protection may clearance when rebuilding a whole, but a particular vehicle is commercial-rated and be only as good as the oils late model engines. AERA operator may not experience a service-rated oils fall under you use. Flat tappet camshafts receives calls asking why the fuel savings as a result of different standards, oils will need the correct oil oil pressure is too low after a using these oils. approved for diesel pre-2007 formulation for protection, late model or any engine is Used in conjunction with and commercial use typically but oils have been changing in rebuilt. the CI-4 category, the “CI-4 contain more of the desirable the last few years as some of AERA Tech Support will PLUS” designation identifies high-pressure, anti-wear you are just finding out. The first ask, “What is the oils formulated to provide a additives. Since many best suggestion we can offer is measured oil clearance on the higher level of protection commercial-grade oils have to follow your camshaft engine bearings mains, rods, against soot-related viscosity older API CI-1 or API CI-4 manufacturer or engine category ratings, oil builder’s recommendations for camshaft and balance shaft?” increase and viscosity loss due The answer will be, “Well to shear in diesel engines. companies claim it is safe for break-in for a long useful live. use in gasoline-fueled engines, We suggest paying close it’s a .010-.010 crank and bearings.” The API Certification Mark unless catalytic converter attention to several factors failure is a concern. with regard to oils. In other words, they never The API Certification Mark Commercial-grade diesel oil is It is important to choose a measured it. So, it’s no “Starburst” is designed to also available in synthetic, viscosity range that will work wonder they have problems identify engine oils conventional, or a blend, and with your older, high with having low oil pressure recommended for a specific may fit a wide range of non- compression engine and its at a hot idle! application (such as gasoline catalytic converters. bigger clearances. Forget the Engine oil systems are a service). Oil may be licensed 0W-30 and 5W-20 used in leak system by design. to display the Starburst only if Racing Engine Oils today’s engines, today’s Knowing this fact, an engine the oil satisfies the most Many higher-viscosity oils are engines run tight with hot oil of 167-195°F has current requirements of the restricted to off-road-use only clearances...they are (within specifications) idle oil International Lubricant which generally means the oil specifically designed to work pressure because of tight Standardization and Approval is for use without catalytic with these new, thinner oils. clearances. Committee (ILSAC) minimum converters. This indicates a Older engines used heavier But as an engine falls performance standard for this higher level of Zinc with-in weight oils designed for the below the specification the application (currently GF-4 each product which could time you used straight 10 or idle oil pressure is lowered. for passenger cars). Many have an effect on the exhaust 20 for winter, 30, 40 weights Don’t be fooled by automobile manufacturers catalytic converters. (Zinc for summer. Then the 10W- measuring the crankshaft and recommend oils that carry the plates itself to the inside of the 30, 10W-40, 20W-40 and then trying to use the listed API Certification Mark. catalytic converter not causing 20W-50 came along and size in the catalog bearing
12 JAN-MAR 2008 engine professional shell thickness. Measure, • Lunati Assembly Lube, long life of their flat tappet lifters and cams) have measure, measure! Part #99010 camshaft and lifters. Below is contributed to a harsher Engine bearing catalogs • Melling and Melling Select a sampling of camshafts environment for the flat list the maximum wall Performance break-in procedures. tappet camshaft and more thickness of the shell. But it • Mell-Lube Camshaft Lube potential for failure during does not mean that all shells Melling Oil Additive, Tech Bulletin: break-in. See AERA TB will measure the listed size in Part #M-10012 Flat Tappet Camshafts 2333R the catalog. Most of the time Recent changes in oil are they are thinner. Break-in Procedures likely the cause of premature Adequate Lubrication Since proper camshaft break- camshaft failure; here’s what Another major factor in the Samples of Break-in Lubes in is such a critical step in you can do to protect your increase of flat tappet camshaft failure is your Use liberal amounts of any ensuring its longevity, most engine! Pre-mature flat tappet camshaft manufacturers are camshaft failure increased favorite brand of engine oil. brand when installing new suggesting physical steps or over the last few years and Simply put, today’s engine oil camshaft and lifters. specific products for break-in. not with just one brand or is just not the same as it used • COMP Cams® Camshaft But some have recently begun type of camshaft. In almost to be, thanks to ever Break-In Oil Additive, advocating certain oils every case, the hardness or the tightening environmental Part #159 approved for commercial-fleet taper of the cam lobe is regulations. The EPA has • Crane Moly Paste, vehicles and/or separate oil suspected, yet most of the done a great job in reducing Part #99002-1 additives that are currently time that is not the problem. emissions and the effects of • Crane Super Lube, available from mail-order This growing trend is due to some of the ingredients found Part #99003-1 oil additive retailers, local parts stores, or factors that are unrelated to in traditional oils; however • GM E.O.S. Assembly GM dealers. camshaft manufacture or these changes to the oil have Lubricant oil additive Each aftermarket camshaft quality. Changes in today’s oil only made life tougher on • Hughes Extreme Pressure company will have a slightly products because of catalytic your camshaft. The lubricity Oil Additive Moly, different break-in procedure converters and “advanced” of the oil and specifically the Part #3690 (ok for cats) but they all want you to have internal engine design (roller reduction of important
engine professional JAN-MAR 2008 13 FLAT TAPPET CAMSHAFTS & OILS BY DAVE HAGEN, MIKE CARUSO, and STEVE FOX additives such as zinc and correct oil band depth and hardens all the lobes to a quickly start and be run manganese, which help break- location to properly regulate depth below the barrel of the between 1500 to 3000 rpm. in and overall camshaft life, the internal oiling of your core. That depth of hardness Vary the rpm up and down in have been drastically reduced. engine. allows the finish cam grinder this rpm range during the first In terms of oil selection, we to finish grind the cam lobes 15 to 20 minutes, (do not run recommend Shell Rotella T oil with Rockwell hardness above the engine at a steady rpm). How to Increase for the break-in procedure. 50Rc. The generally accepted During this break-in time, Most often used in diesel Flat Tappet Camshaft hardness on a finished cast verify that the pushrods are engine applications, this Durability cam should be between 48Rc rotating, as this will show that higher lubricity oil works in 1. Double check your to 58Rc. All of our finished the lifters are also rotating. If gasoline engines as well. camshaft and lifter set-up cams that we have checked the lifters don’t rotate, the Today’s engines are great at prior to the break-in process, are always above 50Rc cam lobe and lifter will fail. providing oil to every engine and use an ample amount of hardness on the lobes. Many Sometimes you may need to component except one — the supplied assembly lube on outside factors, or a help spin the pushrod to start your camshaft. Windage trays, all lobes, distributor gear and combination of factors, can the rotation process during limiting oil’s ability to reach the face of bottom of each cause cam failures. We will list this break-in procedure. See the top of the engine, lifter. some of the factors we have AERA TB1935. modification of connecting determined that may cause It is important to rod side clearances for less 2. Use high-lubricity engine camshaft failure. remember that lifter rotation splash oil and special oil pans oil, such as Shell Rotella T oil, is created by a taper ground Do not use synthetic oil further complicate both the to help during the break-in on the cam lobe and the during the break-in period. It break-in process and camshaft process, and use a Camshaft convex shape of the face of is not recommended to use operation in general. But there Break-In Oil such as COMP the flat tappet lifter. Also in any type of oil restrictors to are several things you can do Cams® Additive (Part #159). some cases, the lobe is slightly the lifter galley, or use to correct these problems. offset from the center of the 3. Flat tappet lifters cam face windage trays, baffles, or plug COMP Cams® offers flat lifter bore in the block. If the oiling provisions also any oil return holes in the val- tappet lifters with oiling holes linear spacing of the lifter supplement a fresh oiling ley. Oil has a two-fold pur- in the cam face surface, which bores in the block is not to path. pose, not only to lubricate, will increase oil flow to the the correct factory but to draw the heat away lifter-camshaft lobe contact 4. Use of a lifter bore specifications, or the angle of from whatever it comes in point. Furthermore, using a grooving tool provides the lifter bore is not 90 contact with. The cam needs lifter bore grooving tool will another path to increase oiling degrees to the centerline of the oil splash from the crankcase, enhance oiling throughout the to the cam lobe. cam, the lifter may not rotate. and oil run-back from the top camshaft and valve train. As Even if the engine you’re 5. Use high-quality lifters of the engine to help draw the we all know by now, better oil rebuilding had 100,000 miles (no brown-bagging it here) heat away. Without this oil flow means better initial on it and the cam you to make certain you are flow, all the heat generated at break-in and increased removed had no badly worn receiving the best quality lifter the cam is transferred to the camshaft durability. lobes, this still doesn’t mean you can buy. lifter, which can contribute to that your block is made its early demise. Flat Tappet Lifter Selection – correctly. It just means that Choose Carefully! Comments from Crane Cams the break in procedure caused In addition to these engine Camshaft failure is rarely Correct Break-in Procedures everything to work correctly. modifications, make certain caused by the camshaft itself. After the correct break-in Be careful to watch the you purchase the highest The details controlled during lubricant is applied to the cam pushrods during break in to quality lifters. Most lifters manufacture pertaining to and lifters fill the crankcase verify lifter rotation. Don’t look alike on the outside, but camshaft lobe wear are lobe with fresh non-synthetic oil. assume everything will work you don’t really know where taper, lobe hardness and Prime the oil system with a correctly the second time. they were produced. surface finish. Of all the priming tool and an electric Always use new lifters on “Imported” flat tappets often damaged cams we have drill so that all oil passages a new flat tappet cam. If you times use inferior lifter checked over the years, more and the oil filter are full of oil. are removing a good used flat castings and DO NOT deliver than 99.99 percent have been Pre-set the ignition timing and tappet cam and lifters and are the durability of high-quality, manufactured correctly. Some prime the fuel system. Fill the planning to use them again in US-built lifters. Lifters that are people have the misconception cooling system. Start the the same (or another) engine, built to the strictest diameter that it is common for a cast engine. The engine should you must keep the lifters in and radius tolerances are iron flat tappet cam to start quickly and run between order as to what lobe of the designed to fit precisely within occasionally have a soft lobe 1500 and 3000 rpm. cam they were on. The lifter their lifter bores must be used. or lobes. We have yet to see a If the engine will not start, breaks-in to the specific lobe This ensures the lifter rotates cast iron flat tappet cam that don’t continue to crank for it is mated with and it can’t be properly and decreases the had a soft lobe. When the cast long periods, as that is very changed. If the used lifters get potential for failure. core is made at the casting detrimental to the life of the mixed up, you should discard Additionally, make sure the foundry, all the lobes are cam. Check for the cause and them and install a new set of lifters you're using have the flame hardened. That process correct. The engine should lifters and break the cam in
14 JAN-MAR 2008 engine professional again as you would on a new roller cams should not exceed decreasing spring pressure Retainer to Seal Valve or cam and lifters. You can use 150 lbs. during the break-in period Guide Boss Interference new lifters on a good used Racing roller cams with will be a great help. This can You need at least .060” cam, but never try to use used high lift and high valve spring be accomplished by using a clearance between the bottom lifters on a new cam. Roller pressure are not shorter ratio rocker arm to of the retainer and the seal or tappet cams don’t require any recommended for street use. lower the valve lift; and/ or the top of the valve guide break-in. You can use roller Oil splash used to cool the removing the inner spring, when the valve is at full lift. lifters over again on a new camshaft at low RPM and during the cam break-in time, cam if they are in good lubrication for the roller lifters Valve to Piston Interference: if dual springs are being used. condition. There will be, of is not sufficient. High spring Increased valve lift, valve course, no lifter or pushrod pressure causes the heat thickness and diameter, (check Mechanical Interference rotation with the use of a created at the cam to be valve to valve relief diameter roller tappet cam. transferred to the roller wheel, There are many factors that in pistons), re-surfacing the resulting in its early failure. can cause mechanical block and/or cylinder head(s) Spring Pressures Any springs that may be used interference. will reduce P/V clearance. Normal recommended spring must be assembled to the Minimum P/V clearance seat pressure for most mild manufacturer’s recommended Spring Coil Bind +.080” intake and +.100” street-type flat tappet cams is height. Never install springs This is when all of the coils of exhaust. between 85 to 105 lbs. More without verifying the correct the spring (outside, inside or radical street and race assembled height and flat damper) contact each Rocker Arm Slot to Rocker applications may use valve pressures for the camshaft other before the full lift of the Stud Interference spring seat pressure between being installed. valve. We recommend that the As you increase valve lift, the 105 to 130 lbs. For street Increased spring pressure spring you are using be stud mounted rocker arm hydraulic roller cams, seat from a spring change and/or capable of traveling at least swings farther on its axis. pressure should range from increased valve lift can hinder .060” more than the valve lift Therefore the slot in the 105 to 140 lb. Spring seat lifter rotation during cam of the cam from its assembled bottom of the rocker arm may pressure for mechanical street break-in. We have found that height. run out of travel, and the end
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engine professional JAN-MAR 2008 15 FLAT TAPPET CAMSHAFTS & OILS BY DAVE HAGEN, MIKE CARUSO, and STEVE FOX
of the slot will contact the gears by adding more oil flow back in the block, causing the stud and stop the movement over the gear area to help cool side of the lobe to contact an of the rocker arm. The slot in off the point of contact. adjacent lifter. the rocker arm must be able Note: Distributors that have Note: When removing a used to travel at least .060” more end play adjustment (up and cam that may be worn, you than the full lift of the valve. down movement of may have difficulty turning or Some engine families, like distributor shaft and gear), removing it. This may not small block Chevrolet, have Maintain a maximum of mean that the cam is cracked stamped steel rocker arms .010” end play, to help or fractured. The heat available in long and extra prevent premature wear. generated at the cam during long slot versions for this the failure of the cam lobe, The AERA tech team, from left to right: purpose. and/or lifter, will distort the Steve Fox has over 16 years Camshaft End Play experience in the engine building cam and cause it not to be Distributor Gear Wear Some engines have a thrust industry with eight of those years spent straight any more. I The main cause for distributor plate to control the forward working in the machine shop. Steve is gear wear is the use of high and backward movement of an ASE-certified Master Machinist, as the cam. The recommended well as a longtime member of the drag volume or high-pressure oil racing circuit. Dave Hagen, our Senior pumps. We don’t recommend end play on these types of Technician, has over 32 years of the use of these types of oil engines is between .003” to experience in our industry. An ASE- pumps. If you do run these .008”. Many factors may We’re interested in certified Master Machinist, Dave types of oil pumps, you can cause this end play to be your thoughts specialized in cylinder head work and expect short life of the cam changed. When installing a If you found this information complete engine assembly for the first and distributor gears, new cam, timing gears, or useful or if you have other 17 years of his career. Mike Caruso especially for low speed thrust plates verify end play topics of interest for the brings over 35 years of rebuilding and magazine, please let us know high-performance experience to AERA. running, in street type after the cam bolts are An ASE-certified Master Machinist, applications. If you must run torqued to factory specs. If by calling the AERA tech Mike came to us from FEL-PRO’s high- these types of oil pumps, you the end play is excessive, it team directly, toll-free performance R&D and tech line, where can increase the life of the will cause the cam to move 888-324-2372. he worked for 11 years.
F
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16 JAN-MAR 2008 engine professional