Engine - Test For Increased Oil Consumption
Date: October 30, 2008Order No.: S-B-00.00/80f
Supersedes: P-B-00.00/80e and T-B-00.00/81e dated January 29, 2007
Group: 00
Revision History
SUBJECT:
Model 164.186, Up to Engine Serial No. 272 967 30 053879
Model 171.454/456, Up to Engine Serial No. 272 9xx 30 058705
Model 203.052/054/056/087/092, Up to Engine Serial No. 272 9xx 30 053555
Model 209.356/456, Up to Engine Serial No. 272 9xx 30 053555
Model 211.056/087/256/287, Up to Engine Serial No. 272 9xx 30 052208
Increased Engine Oil Consumption
If you receive customer reports in the above model vehicles regarding increased oil consumption based on the below repeated oil level messages in the instrument cluster, the cause may be due to incomplete engine break-in process.
- Add 1 Quart Oil When next Refueling (Model 211 until production date 06/2005)
- Check Engine Oil Level When Next Refueling (Models 164, 171, 203 and 209 as of production start up and 211 as of production date 06/2005)
NOTE:
As of engine production date February 2005 and engine serial numbers listed above, modified piston ring set has been introduced in series. The M272 is equipped with an oil level switch. Therefore, no values relating to oil consumption can be read out using SDS or DAS. Oil refilling between oil change intervals is normal and does not necessarily mean oil consumption has increased.
If the customer's information indicates that the oil consumption is less than 2000 miles/quart; e.g. 2500 miles/quart no further measures are necessary as that level of consumption is within specification. If oil consumption is greater than 2000 miles/quart; e.g. 1700 miles/quart, perform oil consumption measurement by weight as follows.
1. Check engine for external oil loss; e.g., oil leaks.
2. Pre-condition the engine of the vehicle by completing the break-in process of the engine as follows:
a. Check the oil level and correct level if necessary.
b. Drive the vehicle for 1 hour under high load and high engine speed (between 4,000 and 6,000 rpm) appropriate for the local conditions and circumstances.
c. Vary the engine speeds during the road test.
NOTE:
If possible perform this test on interstate type roads where speeds of 55 - 65 mph can be obtained and use the appropriate transmission gears to maintain engine speed of 4000 to 6000 rpm.
3. Oil consumption measuring drive:
a. Prepare oil consumption measuring drive according to the attached work instructions.
b. Measuring drive should be performed by customer until the oil level warning reappears in the instrument cluster.
c. Determine oil consumption as per work instructions and document calculation on the attached test sheet.
NOTE: Customer should maintain his or her driving style during the entire measuring drive.
4. Limits And Engine Repair Criteria:
NOTE:
Replacing the valve stem seals does not provide an effective remedy to this condition. Therefore valve stem seals must not be replaced.
The engine break-in process depends strongly on the usage conditions and driving style of the customer, and in some cases, the break-in process can extend to greater than 6500 miles.
a. If mileage is less than 6500 miles and the measured oil consumption is greater than 750 miles/quart; e.g. 600 miles/quart, adjust oil level to MAX (14.95 lbs. of oil by weight) and continue to observe oil consumption up to mileage reading of at least 6500 miles.
NOTE: Document oil level and mileage reading.
b. If mileage is between 6500 miles and 13,000 and the measured oil consumption is greater than 2000 miles/quart; e.g. 1700 miles/quart, repair only with a complete engine replacement.
c. The procedure for vehicles with a mileage higher that 13,000 miles is described in WIS document AR18.00-P-0025QB.
NOTE:
- Oil consumption of up to 2000 miles/quart is considered to be within specification.
- Do not replace any engines which have not gone through an oil consumption measuring drive. The filled out test sheet must be enclosed with any returned engine. Any claims submitted that have not followed the above procedures or do not have full documentation will be denied.
- The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on October 30, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty
Operation: Engine, check for oil leak(s)/loss (01-1010)
Engine oil level, correct (00-6000)
Oil consumption test drive, perform (18-1010)
Flex. Service plus - oil/filter change, perform (00-1212)
Engine oil and filter, change (00-2080)
Engine with auto. trans., R&R (01-2800)
Engine - exchange, (engine w/ auto. trans. removed) (01-4015)
Engine with manual trans., R&R (01-2400)
Engine - exchange, (engine w/ man. trans. removed) (01-4011)
Engine - exchange (01-4010)
M272 Oil Consumption Measurement By Weighing Method
Preparation:
Equipment Requirement:
- Scales with 0.01 lb. accuracy.
- Oil Container with 10-liter capacity (Oil drain pan with spout as oil container for this purpose is recommended)
- Stop watch
Procedure:
Weigh Engine Oil (At Start of Oil Consumption Measuring Drive)
1. After pre-conditioning the engine to operating temperature (90 degrees C coolant temperature), raise vehicle on lifting platform.
2. Weigh the empty and clean oil container as "TARE".
3. Open oil filter cap and pull out oil filter.
4. Remove engine lower encapsulation and open oil drain plug.
5. Allow engine to drain into the oil container for 15 minutes.
6. Place the container with drained oil on scales and weigh.
7. Adjust the weight of the oil in the container to 14.95 lbs.; e.g. if "TARE" = 2.55 lbs fill up the container with oil up to the combine weight of 17.50 lbs. (14.95 lbs. + 2.55 lbs.)
8. Pour the engine oil back into the engine.
9. Re-install back the oil filter and oil filler cap.
10. Record the weight of the oil in pounds as m1 and the mileage odometer reading of the vehicle as s1.
Have the customer perform the oil consumption measuring drive.
Weigh Engine Oil (At End of Oil Consumption Measuring Drive)
11. Customer arrives at workshop after oil level warning message is displayed in the instrument cluster.
12. Lift vehicle on lifting platform with engine at operating temperature (90 degrees C coolant temp.).
13. Weigh empty oil container in pounds as "TARE".
14. Open oil filler cap and pull out oil filter.
15. Remove under engine encapsulation and open oil drain plug.
16. Allow engine to drain into the oil container for 15 minutes.
17. Place the container with drained oil on scales and record combined weigh in lbs. as M.
18. Record weight of drained oil in pounds as m2; i.e., m2 = M - "TARE".
19. Calculate oil consumption as described in test sheet.