| CYLINDER HEAD BOLT INSTALLATION CAUTION |
Cylinder Head Bolt Installation Caution On
1980-87 Chrysler 4.0 & 4.2L Engines
Chrysler (AMC Jeep) 4.2L (258 CID) engines manufactured from 1973 through 1980 use 1/2 diameter cylinder head bolts that are torqued to 105 lbs.ft. The number 11 bolt requires thread sealer to prevent external coolant leaks.
As of the 1981 production year, all 4.2L (258 CID) engine head bolts have been reduced to 7/16 in diameter. These smaller bolts should be torqued in sequence to 85 lbs.ft except for the number 11 bolt which requires only 75 lbs.ft. Again, sealer is required on the number 11 bolt to guard against external
coolant leaks.
The 4.0L (242 CID) engine introduced in 1987 and used in Jeep trucks uses the same torque pattern, but require 110 lbs.ft. of torque for all but the number 11 bolt. Torque this bolt to 100 lbs.ft. after applying a pliable sealer.
For additional information see AERA Technical Bulletin: SB 112
The AERA Technical Committee |
| VALVE LASH SPECIFICATIONS |
Valve Lash Specifications On
Chrysler (AMC Renault) 1.7 & 2.0L (105 & 122 CID) Engines
The Chrysler (AMC Renault) 1.7 & 2.0L (105 & 122 CID) engines use
a puck with a replaceable pad to adjust the valve lash. With the
engine cold, the recommended valve lash for the intake valves is
.008 (.20mm) and .015 (.40mm) for the exhaust valves (Figure
1).
Setting the valve lash requires mounting the camshaft and
camshaft caps to the cylinder head. Using the sequence outlined
in the illustration (Figure 2), torque bolts #11 & 12 (6mm
diameter) to 7 lbs.ft. and the remaining bolts (8mm diameter) to
15 lbs.ft. Apply a small amount of RTV sealer on the parting
face of each end camshaft bearing cap before installation. This
will guard against external oil leaks.
For additional information see AERA Technical Bulletins: TB 654,
395 & SB 36
The AERA Technical Committee
March 1991 - TB 747
##END## |
| OIL FILTER REPLACEMENT CAUTION ON AMC 4.2L ENGINES |
Oil Filter Replacement Caution on
Chrysler (AMC) 4.2L (258 CID) Engines
Chrysler Corporation cautions on the replacement of oil filters on 4.2L (258 CID) AMC built engines.
Engines built prior to 1987 utilize an oil filter without internal bypass architecture. A bypass valve is necessary to provide adequate lubrication to the engine should the oil filter become clogged. Engines using this style filter have a bypass valve assembly built into the cylinder block (see illustration).
This earlier filter design features a .813 connector thread.
Engines built during and after 1987 do not have the built-in bypass assembly and therefore utilize a filter assembly containing the bypass valve. The later model filter design features a 20mm (.787) connector thread.
Do not use the earlier style filter on engines built during and after the 1987 model year. Incorrect filter application may result in serious engine damage.
The AERA Technical Committee |
| OIL FILTER ADAPTOR LEAKS ON GM 2.8L ENGINES |
Oil Filter Adaptor Leaks On
2.8L (173 CID) Chrysler (AMC) Engines
Chrysler (AMC) has reported that close inspection of oil leaks
around the oil filter must be made to determine the exact source
of the leak. Possible causes of the leak are the oil filter
itself, a loose oil filter adaptor retaining bolt or a warped oil
filter adaptor base. The following steps should be followed to
correct this problem:
1. After removing the oil filter, remove the oil filter
adaptor (A) and gasket by removing the retaining bolt (B).
See Figure 1.
2. Clean oil residue from the cylinder block and oil filter
adaptor mating surfaces.
3. Check the adaptor mating surface for warpage (see Figure
2). Replace the adaptor if warpage exceeds .008 (.2mm)
with AMC part #8983 500 836.
4. Install the adaptor on the cylinder block using AMC
gasket #8983 500 839 or equivalent and retaining bolt seal
#8983 500 838 or equivalent. Tighten the retaining bolt to
30-40 ft. lbs. (40-60 N·m).
(Insert 2 Illustrations)
The AERA Technical Committee
March 1987 - SB 141
##END## |
| OIL LEAKS ON 1984-86 GM 2.8L ENGINES USED IN AMC |
Oil Leaks On
1984-86 Chrysler (AMC) 2.8L (173 CID) Engines Used In Jeep
Applications
Chrysler (AMC) says there are three possible oil leak locations
on its 2.8L (173 CID) engines: the valve covers, intake manifold
and rear cradle area of the oil pan.
Replace leaking valve cover gaskets with AMC part #8983 503 179
or aftermarket equivalent. The seam where the intake manifold
and cylinder head mate must have a small amount of RTV sealer
applied to eliminate gaps or steps that will allow leaks. Gasket
over-crush is prevented by metal pins located on the side of each
bolt hole.
Intake manifolds usually leak at the rear manifold-to-block
mating surface. After removing the manifold and thoroughly
cleaning it, use a 3/16 (4.7mm) diameter spherical cutter
(Figure 1) to cut a 3/16 (4.7mm) wide groove that's 1/16
(3.1mm) to 1/8 (1.5mm) deep.
(Insert Illustration)
Fill the groove with RTV sealer when reinstalling the manifold
(Figure 2).
(Insert Illustration)
For 1984 engines, Chrysler (AMC) supplies an oil pan gasket kit
AMC part #8983 500 853 (or use an aftermarket equivalent), which
should be installed in place of the RTV sealer used at the
factory. It is important, however, to seal the rear cradle
corners with RTV sealant.
1985-86 engines should be closely inspected for deformed oil pans
(Figure 3). Replace deformed oil pans with AMC part #8953 001
840. Engines built after January 21, 1986 should not have
deformed oil pans.
(Insert Illustration)
The new, recommended method is to remove the stand-offs on the
oil pan rails (Figure 4) with a file or small hand-grinder. Use
AMC oil pan gasket kit #8983 500 853 or aftermarket equivalent.
(Insert Illustration)
The rear cradle seal is installed in the groove in the main cap
and a small amount of RTV is applied to the corners of the seal
where it contacts the block. Please note that once the stands
have been removed, RTV can no longer be used in place of the
gasket.
The AERA Technical Committee
August 1986 - SB 134
##END## |
| REAR MAIN SEAL ALTERNATIVE (REVISED) |
Rubber Rear Main Seal Alternative On
General Motors (Oldsmobile) V8 Engines
A rubber alternative to the rope rear main seal found in all GM (Oldsmobile) V8 engines can be made from the rubber rear main seal designed for Chrysler (AMC) 3.2L-4.2L (199-258 CID) engines and the seal designed for the Ford Motor Company 7.0L-7.5L (429-460 CID) engines.
McCord Gasket Corporation engineers report that the rubber seal for the Chrysler (AMC) 6 cylinder engine can be used in several GM Oldsmobile V8 engines by trimming off the tabs on the upper half of the AMC seal (see illustration below).
When modified, both halves of the AMC seal will be equal and will properly fit in the seal cavity of the Oldsmobile blocks. The AMC seal will fit Oldsmobile-built 4.3L, 5.0L and 5.7L (260, 307 and 350 CID) engines (gas only) once the seal has been modified.
The Ford 7.0L-7.5L (429-460 CID) engine seal will fit the 6.6L (400, 425, 455 CID gas) and 5.7L (350N CID) (diesel) engines with no modifications necessary to the seal.
AERA members should keep in mind that these modifications have not been authorized by GM (Oldsmobile). Tests in the field have shown great success, however.
The AERA Technical Committee
April 1986 - SB 128R
##END## |
| OIL FILTER THREAD CHANGE |
Oil Filter Thread Caution On
1984 Chrysler (AMC) Alliance/Encore Vehicles
Equipped With 1.4L (85 CID) Engines
AERA members are urged to caution their customers and owner of
Chrysler (AMC) Alliance and Encore vehicles, equipped with 1.4L
engines, that a change was made in the oil filter nipple threads.
Prior to May 1984 these threads were a standard U.S. size, but
after May 1984 the threads were modified to metric size.
The problem occurs in that a metric size filter can mistakenly be
installed on a non-metric nipple and seems to tighten correctly,
but once the engine is started a sever oil leak may begin. The
oil filter threads may also be damaged.
An easy test for size is to use a 3/4 open-end wrench which will
fit over the standard U.S. size nipple, but won't fit over the
metric nipple.
The change was made with chassis #124269.
The AERA Technical Committee
December 1985 - SB 126
##END## |
| ENGINE CAMSHAFT TIMING PIN FAILURES |
Chrysler (AMC) Camshaft Timing Pin Failures
Some 1977-80 Chrysler (AMC) six cylinder passenger car engines may experience camshaft timing pin failures that will result in incorrect valve timing. The pin is located between the camshaft and timing gear, and may shear or break allowing the camshaft to slip.
Replacement or removal of the camshaft is not necessary to repair the problem. After the timing cover is removed, extract the old pin from the camshaft by using a self-tapping screw on spring type pins or a drill and a stud extractor screw on dowel type pins.
To prevent the camshaft from pushing back and breaking loose the rear camshaft oil plug, wedge the camshaft by removing the fuel pump and inserting a pry bar or large screwdriver through the fuel pump opening. The replacement spring pin is AMC part number GM456384.
The AERA Technical Committee |
| DEFECTIVE CYL HEAD BOLTS ON SOME AMC 4.2L ENGINES |
Defective Cylinder Head Bolts On
Chrysler (AMC) 2.46L and 4.2L Engines
Some bolts used on the spark plug side of the cylinder head in AMC 2.46L, 4 cylinder and 4.2L, 6 cylinder engines, were improperly hardened and may break under the bolt head or in the bolt thread area. The engines with suspect bolts are coded as follows:
4 cyl. -- 310U06 thru 310U14 (5 bolts)
6 cyl. -- 310C06 thru 310C14 (7 bolts)
NOTE: The engine code is stamped on a machined surface on the distributor side of the block.
Be sure to follow the bolt tightening sequence and torque specifications below when replacing bolts. Whenever a broken bolt is found, all the bolts on the spark plug side of the head should be replaced with new bolts (No. 400 6593).
The AERA Technical Committee |
| CYLINDER BLOCK WITH .030 UNDERSIZE DECK HEIGHT |
Rebuilding Caution On
Chrysler (AMC) 5.9L (360 CID) Engines
A relatively small number of Chrysler (AMC) 5.9L (360 CID) engines were assembled with a .030 undersize deck height on both banks. To compensate for the undersize deck height, Chrysler (AMC) used a special, thicker cylinder head gasket.
The subject cylinder head blocks can be identified as follows:
The front of each cylinder head and the left front on the block are stamped with a 3/8 high X.
The AERA Technical Committee |
