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Forced Induction Basics – Blown to Be Wild EP Q2-12 Cover_EP 4/20/12 8:31 AM Page 1 FORCED INDUCTION BASICS – BLOWN TO BE WILD AN AERA INTERNATIONAL QUARTERLY PUBLICATION APRIL-JUNE 2012 PHOTO BY MIKE MAVRIGIAN. Speed Read Beyond the Flow Bench Diesel to LPG Understanding this engine conversion Engine Fasteners Correct pre-load with fasteners is critical EP Q2-12 Cover_EP 4/17/12 10:39 AM Page 2 EP Q2-12 1-9_Layout 1 4/19/12 11:50 AM Page 1 EP Q2-12 1-9_Layout 1 4/19/12 11:50 AM Page 2 CONTENTS VOLUME 5, NUMBER 2 4 FROM THE PUBLISHER PUBLISHER 6 INDUSTRY NEWS AERA - Engine Builders Association Welcome to new AERA members, 500 Coventry Lane, Suite 180 calendar of events, news and views Crystal Lake, IL 60014 815-526-7600 8 AERA ONLINE TRAINING 815-526-7601 fax By John Goodman Chairman of the Board David Bianchi 10 FORCED INDUCTION BASICS Seattle, WA By Mike Mavrigian First Vice Chairman Supercharging and turbocharging tidbits Dwayne Dugas New Iberia, LA 10 28 DIESEL TO LPG Second Vice Chairman By Clemens Ortgies Ron McMorris Maple Ridge, BC CANADA 34 CONFERENCE RECAP Treasurer By Steve Fox Dean Yatchyshyn Cumberland, MD Sunnen & Mahle California Conference a huge success; 2012 conference calendar President John Goodman 48 CHEVROLET CRUZE DIESEL WILL EDITOR BUILD ON GM’S EURO EXPERTISE John Goodman By Dave Hagen [email protected] 40 SPEED READ ASSOCIATE EDITOR 42 Jim Rickoff By David C. “Woody” Woodruff [email protected] Beyond the Flow Bench TECHNICAL EDITORS 44 THE ROLE OF FASTENERS IN Dave Hagen CRITICAL ENGINE MEASUREMENT [email protected] By Bobby Kimbrough Steve Fox [email protected] 50 PRO-SIS CORNER Mike Caruso By Steve Fox [email protected] The differences between the PRO-SIS programs Gary Lewis [email protected] 54 TECHSIDE Mike Eighmy By Dave Hagen, Mike Caruso and Steve Fox 48 [email protected] Warranty Administration COMPTROLLER 58 ON THE SAME PAGE Ellen Mechlin Engine building book reviews by [email protected] AERA Technical Specialist Mike Caruso GRAPHIC DESIGN Maria Beyerstedt 64 TECH BULLETINS [email protected] 75 MARKETPLACE ADVERTISING SALES Jim Rickoff [email protected] Hal Fowler 58 [email protected] PRODUCTION Jan Juhl [email protected] CIRCULATION Karen Tendering [email protected] Engine Professional® magazine (ISSN 1945-7634) is published quarterly by INTERNATIONAL LIAISON Automotive Engine Rebuilders Association (AERA). Copyright 2012 AERA. Subscription Yolanda Carranza rates: $70 per year, outside the United States $90, single copy $20. Publication, edito- rial and business office: 500 Coventry Lane, Ste 180, Crystal Lake, IL 60014. Editorial: [email protected] 815-526-7600, Advertising: 507-457-8975, Circulation: 815-526-7600. Send change of address to the above. The opinions, beliefs and viewpoints expressed by the various CHIEF TECHNOLOGY authors in this magazine are those of the individual authors and not of the Automotive ARCHITECT Engine Rebuilders Association, which disclaims all responsibility for them. Richard Rooks [email protected] 2 APR-JUN 2012 engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION EP Q2-12 1-9_Layout 1 4/19/12 11:50 AM Page 3 engine professional WWW.AERA.ORG/EP 3 EP Q2-12 1-9_Layout 1 4/19/12 11:50 AM Page 4 FROM THE PUBLISHER BY JOHN GOODMAN, AERA PRESIDENT Golden Memories At some point, I knew this day would One sad note was the ending of our manufacturers to thank for content in this come. It happens to everyone and now, Expo and New Product Showcase. AERA manual so be sure to see the list when retirement is happening to me. As with any had hosted these two events every year you get your copy. Other new things AERA event you don’t want to think about, you for over 35 years but eventually ran its has engaged is the installation of new data just bury it away and go about your course and ended in 2006. That left a big servers in New Zealand and the United business. But I am told with age comes hole in our membership but was soon States to support Internet based PRO-SIS wisdom and I thought it wise to move my filled by several regional conferences for users around the world who would concentration away from career and focus hosted throughout the United States. prefer using PRO-SIS on line as opposed on Shirley (my wife) and grandchildren. Life These regionals have been a big success to their PC. This limits the need for new doesn’t often give one a second bite of and there are plans to increase them computer hardware and large storage the apple but retirement can do just that. going forward. capacity. We see many current AERA So, without looking back, Shirley and I Engine Professional magazine (EP) is PRO-SIS users switching to this new decided that on June 30, 2012, I should another milestone for AERA and one of Internet format. Other new initiatives are retire from a beloved industry that has our crown jewels. EP is now in its fifth year meaningful marketing tools for members given us so many good friends and of publication serving engine builders and to better promote their businesses and memories. Given past history, I will stay rebuilders worldwide. Editorial content is Shop Financial Analyzer, a tool used by active and still have a few things to focused on shop needs and introduces shops who desire to know what their contribute, but family gets the lions share. new technology that every shop can use. business is doing financially and where to This is also a great time for reflection. Each article must have shop application or make positive improvements if required. Most of my tenure in the engine rebuilding it isn’t considered for EP. We are especially Finally, AERA has been energetic in industry was spent on the other side of proud of Engine Professional because it is gathering and archiving thousands of new the AERA fence and not very close to the a magazine created entirely by AERA staff engine specifications from original for the engine rebuilder. Anyone who has association’s internal workings. AERA had equipment manufacturers worldwide and ever picked up a copy of EP knows it is always been that shining edifice among make it available to members upon best in class for our industry and we are engine rebuilders but I never got close request. Our three-man tech department proud to enjoy that status. It also means enough to see just how good they really is the best in the business and getting we must work hard to maintain and were. Nine years ago, when given the better every year. improve it. unique opportunity to serve as AERA This is just a sample of initiatives AERA The depth of knowledge within AERA president, I was humbled in the extreme! has been involved with to strengthen its is staggering! AERA members constitute a Although my background was in the core values. It would be easy to write a knowledge base equal to none. To that engine rebuilding industry, technology that lengthy review of accomplishments for end, AERA launched a certificate program drove the industry interested me most. So, each of the AERA staff and consultants; based on Gary Lewis’s book, Automotive there is just that much talent within AERA how would my past experience help AERA Machining and Engine Repair that now become more effective? to be able to say that. I am most proud of has 92 enrolled with 23 graduates. This what my AERA team has created over AERA has always been a technically program is a rigorous 18 unit, self-paced, these wonderful nine years. We may be oriented association and it was apparent online course covering all aspects of small but we are quality.I that I might be able to help in that engine tear down, cleaning, machining direction. We immediately began redoing and assembly. Every enrollee has up to PRO-SIS, AERA’s proprietary engine one year to complete the course but once specification software, to perform better successfully completed, is awarded two and enlarge specification content. After a AERA certificates for Cylinder Head and few years and with the help of a very Engine Machinist. It doesn’t matter how C talented AERA programmer, PRO-SIS was 5.9 6BT.............................................$995/ea long you have been in the industry, you will C 6CT...........................................$1795/ea written in a new, more robust database learn something new if you take the C language. With help from FIRM (an course. umbrella association of EU engine Other new things introduced over the rebuilders), we created a new PRO-SIS past nine years are a new and growing database called PRO-SIS SA. PRO-SIS Engine Component Failure Analysis Prior to becoming president of AERA, John Goodman SA would better serve the EU, North Manual now in second edition printing. was director of the Advanced Technology Center (ATC) America and the rest of the world. AERA is With over 128 pages of cause and effect for Micromatic-Textron. The ATC focused on manufacturing honing solutions and studies for OEM particularly proud that this was engine component failures, this growing engine manufacturers. Testing of traditional and unique accomplished 100% in house and resource is fast becoming the final answer honing abrasive systems, coolants, fixtures, tools and continues to be supported by us. for engine failures. We have many software were primary responsibilities of the ATC lab. 4 APR-JUN 2012 engine professional AN AERA INTERNATIONAL QUARTERLY PUBLICATION EP Q2-12 1-9_Layout 1 4/19/12 11:50 AM Page 5 ¢ '*!$"'# 6 +81008,+382,/+ ' !%/52 ,.(%*!$9 : " #&64+-2/ $64++1/ ($/333 #% %&$'$!& %"%!,332 ¢ ' !%15- ' !%/52 ' !%-52 907070: 90707070:
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