Valve Lock Differences On
1979-82 Ford 2.0L (121 CID) Courier Engines
Although the valve locks on 1979-82 Ford Courier 2.0L (121 CID) engines may appear identical, there are some basic differences that distinguish intake valve locks from exhaust valve locks.
Original equipment exhaust valve locks are generally dark in color. Aftermarket replacement locks may or may not be the same color. The exhaust locks also butt together when assembled on the valve with the valve spring retainer. In addition, the tab that fits into the groove of the exhaust valve is rounded as
illustrated in Figure 1.
On the other hand, original equipment intake valve locks are shiny and do not butt together when assembled on the valve with the valve spring retainer. There is a gap at the parting faces of the lock halves. Figure 2 shows how the tab that fits into the intake valve groove is square, not rounded as is the exhaust
lock.
Do not intermix lock halves on the same valve and do not substitute one style lock for the other. Catastrophic engine damage may result.
The AERA Technical Committee |
Import Camshaft Failure Due
To Improper Rocker Installation
When installing rocker assemblies on Ford Courier and Mazda engines, it is imperative that the shaft supports on the second and fourth row of head bolts be correctly installed. These supports can be installed upside down and will cause camshaft and follower failure.
The supports must be installed with the square side down. By installing the supports incorrectly, a bow is created in the rocker shaft. The reason this occurs is that the centerline of the shaft is moved upwards by .093. When the centerline is not straight, the geometry of the follower to the camshaft is not
correct, causing the follower to ride the camshaft at an angle. This incorrect angle forces the follower to bury itself into the cam lobe, causing premature camshaft and/or follower failure.
The other inherent problem with this type of camshaft is failure due to lack of lubrication. This can be eliminated by carefully cleaning the cam oiler. Run a small wire through each oil hole and then blow air through the entire assembly. Prior to installation, use an extreme pressure lubricant applied on the cam lobes and the follower pads.
The AERA Technical Committee |
Flywheel Specifications
The AERA Technical Committee suggests referring to the following
flywheel specification chart when re-surfacing flywheels.
Type of
Manufacturer Flywheel Specs Comments
_________________________________________________________________
Allis Chalmers Cup 1.437 D17,D19,190XT
Tractors
AMC Cup .125 2.5L (GM engine)
Alpha Romeo Cup .878
BMW Step .013-.015 320i
Caterpillar Cup 2.937 +/-.005 #9N2646 Cast Number
Chrysler/Mitsubishi Cup .600-.605 2.0L DOHC, #9801
Cast Number
Chrysler Cup 1.00 3.7L engine
Cummins Cup 2.925
Cummins Cup 2.937 2 piece clutch
DDC Flat 1.582 8.2L, Minimum
thickness
Fiat, Spider Step .018 1600 engine
Ford, Falcon Cup 1.00 6 Cylinder engines
Ford, Courier Cup .285
Ford Cup .310
Ford, Ranger Cup .003 V6 Cylinder engines
Ford Truck Cup 1.500 534 CID Truck
Ford Truck Flat .965 New Thickness
Ford Cup 1.140-1.160 Model A
GM, OHC Brazilian Flat .750 New Thickness
GM Cup .125 2.5L, & Vega
GM, Buick Cup .125 V6 Engines
GM, Spirit Cup .195
GM, Sprint Cup .1969 Chevrolet/Suzuki
Honda Cup .030 Small cup
Honda Cup .030 #K4SC16AG Cast
Number
Honda Cup .100-.104
Honda Cup .785 Long alignment pins
Honda Cup .900 Short alignment pins
Honda, Accord Cup .615 1986
Hyundai, Excel Flat Mitsubishi engine
Isuzu Cup .010-.017 Trooper, Pup
Isuzu, Diesel Cup 1.691-1.695 6BD1, 6BDT engines
Mack Midliner Flat 1.260 Min. Measure from
crank/mount to disc
Mazda Cup .062 RX2 Rotary engines
Mazda, RX7 Cup .310
Mazda, 2.2L, 1987 Cup .785 Hyd. Clutch,
Segmented wheel
Mazda, 2.0L Cup .805 Hyd. Clutch, .020
max/removal
Mercedes, 240D Cup .885
Navistar, 404/446 Flat .750 New thickness
Navistar, 6.9L Flat 1.410 Minimum thickness
Navistar 9.0L Flat 1.585 Minimum thickness
Nissan Flat With groove
Nissan, Maxima Flat With groove, #425
Cast Number
Nissan, (Datsun) Step .003-.005 No groove
Nissan,
(Sentra,Stanza) Step .006-.010 1.6L & 2.0L engines
Nissan, B2000 Cup .807 new Max stock removal
.020
Nissan,(Datsun)240Z Step .010 With groove
Renault Step .021 1.4L Alliance
Saab, 96 Cup .656
Subaru Cup .830 Justy
Subaru Cup .875
Subaru Cup .905 4X4 Brat
Suzuki Cup .070
Suzuki Cup .197 1.0L, 3 cyl
Toyota Step .018-.022 Large alignment pins
Toyota, 22RE Step .018-.022 #627 Cast Number
Toyota Cup .055 Small cup
Toyota Cup .965-.970 Tercel, large cup
Toyota Step .040 Tercel, step
Toyota Step .020 Land Cruiser
VW Cup .945 Air cooled, 6 Volt
VW Cup .913-.918 210MM Clutch
VW Cup .830-.835 Rabbit/Golf/Scirocco
Vanagon Cup .982 Water/Air cooled bus
engine
VW Cup .830 Air cooled engine
VW Cup .885 Air cooled engine
Specifications listed for Step type flywheels refer to the
height of the wear surface above the pressure plate mounting
surface. Specifications for Cup type flywheels refer to the
height of the pressure plate mounting surface above the wear
surface.
The AERA Technical Committee
June 1992 - TB 677R
(Please destroy TB 677)
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