| CRANKSHAFT CAUTION ON 1988-96 3.0L VIN JE |
Crankshaft Caution On
1988-96 Mazda 3.0L VIN JE Engines
AERA members are cautioned while selecting a replacement
crankshaft for 1988-96 Mazda 3.0L VIN JE engines. It has been
reported there are three completely different crankshafts for
these engines. Interchanging of these crankshafts is not
possible without experiencing engine damage.
Below is a chart and illustration showing the differences of
these crankshafts. Refer to it when selecting a replacement
crankshaft. The A, B, C, D dimensions listed are measured from
the front of the crankshaft to the areas indicated by arrows.
Oil Pump Dim. Dim. Dim. Dim.
Design A B C D
.500 wide 1.8750 2.440 2.750 3.700
Flat, SOHC
.660 Wide 2.1250 2.680 3.340 4.125
Flat, DOHC
No Oil Pump 1.875 1.811 2.750 3.700
Drive Flat Seal Dia.
1988-89 929
The AERA Technical Committee
February 1999 - TB 1660
##END## |
| INTERFERENCE ENGINES |
Interference Engines
The AERA Technical Committee would like to offer the following information on engines that present the possibility of interference between pistons and valves. The interference or contact may bend valve(s) when the timing between the camshaft and crankshaft is interrupted. This is generally the result of a timing belt or chain breaking or slipping.
The following list are engines that AERA is currently aware of that have exhibited interference. There may be other engines that are not listed below that have the possibility of piston to valve contact. If the engine you are working on is not listed, do not assume that it is a freewheeling design. It is suggested to add to this listing as additional information is obtained.
ACURA
1986-89 1.6L Integra
1991-95 1.7L Integra
1990-95 1.8L Integra
1986-89 2.5L Legend
1992-94 2.5L Vigor
1986-89 2.7L Legend
1990 2.7L Legend
1991-95 3.0L NSX
1991-95 3.2L Legend
AUDI
1970-93 All Except 1970-77
1.9L & 1970-73 1.8L
BMW
1987-95 2.5L 325I 525I
1994-95 4.0L 740I
CHRYSLER
1993-95 1.5L Colt
1987-88 1.5L Colt
1992-95 1.5L Eagle Summit
1987-88 1.6L Colt
1989-92 1.6L Eagle Summit
1994-98 2.0L Neon Stratus
1990-95 2.0L Eagle Talon
DAIHATSU
1988-92 1.0L Charade
1988-92 1.3L Charade
1990-92 1.6L Rocky
FIAT
1974-79 1.3L 128 Series
1979-82 1.5L Stranda
1974-78 1.6L 124 Series
1974-78 1.8L 124 Series
1974-78 1.8L 131 Series, Brava
1979-82 2.0L Brava, Spider
FORD
1981-85 1.6L Escort, EXP
1981-83 1.6L LN7, Lynx
1984-85 2.0L Escort, Tempo
1993-95 2.0L Probe
1986-88 2.0L Ranger
1984-87 2.0L Lynx, Topaz Diesel
1985 2.2L Ranger
1989-92 2.2L Probe
1986-88 2.3L Ranger
1986-87 2.3L Diesel Ranger
1991-98 4.6L Crown Victoria
GM
1986-95 1.0L Geo Metro
1989-91 1.0L Firefly (CANADA)
1985-88 1.5L Sunburst (CANADA)
1985-89 1.5L Spectrum
1990-93 1.6L Prizm, Storm
1981-84 1.8L Diesel (CANADA)
1982-86 1.8L Buick Skyhawk
1990-98 1.9L Saturn
1987-88 2.0L Buick Skyhawk
1988-95 2.3L Quad Four
1985-87 3.0L Buick
1979-95 3.8L Buick
HONDA
1986-87 1.0L Prelude
1973-78 1.2L All
1973-78 1.3L All
1980-84 1.3L All
1973-78 1.5L All
1985-89 1.5L Civic
1988-95 1.5L Civic, CRX
1993-95 1.5L Civic Del Sol
1979-84 1.5L All
1985-87 1.5L CRX
1993-95 1.6L Civic Del Sol
1973-78 1.6L All
1980-82 1.6L All
1988-95 1.6L Civic, CRX
1984-87 1.8L Prelude, Accord
1979-83 1.8L All
1986-91 2.0L Prelude
1990-91 2.1L Prelude
1990-95 2.2L Prelude, Accord
1992-95 2.2L Prelude
1995 2.7L Accord
HYUNDAI
1984-95 1.5L Excel Scoupe
1995-98 1.5L Accent
1992-95 1.6L Elantra
1993-95 1.8L Elantra
1992-95 2.0L Sonata
1989-91 2.4L Sonata
1990-95 3.0L Sonata
INFINITI
1990-92 3.0L M30
ISUZU
1987-89 1.5L I-Mark
1990-93 1.6L Stylus Impulse
1987-89 2.0L Impulse
1981-87 2.2L Diesel Truck
1986-95 2.3L Truck Trooper
1988-95 2.6L Truck Rodeo Amigo
1991-96 3.2L Trooper Rodeo Amigo
KIA
1995 2.0L Sportage
MAZDA
1984-85 2.0L 626
1988-92 2.2L 626 MX6
1989-93 2.2L Pickup
1988-95 3.0L 929 MPV
MITSUBISHI
1985-95 1.5L Mirage Precise
1990-92 1.6L Mirage
1989-95 2.0L Galant Eclipse
1983-86 2.3L Diesel Pickup
1994-95 2.4L Galant
NISSAN
1982 1.5L Centra
1983-88 1.6L Sentra Pulsar
1987-89 1.8L Pulsar
1982-89 2.0L Stanza 300ZX
1984-95 3.0L Maxima 300ZX Pathfinder
PORSCHE
1976-83 2.0L 924
1976-89 2.5L 944 Series
1989 2.7L 944 Series
1989-91 3.0L 944 Series
1976-83 4.5L 928
1984 4.7L 928
1985-91 5.0L 928
1992-95 5.4L 928
SUZUKI
1985-94 1.3L Samurai Sidekick
1989-94 1.3L Swift
TOYOTA
1986-95 1.5L Tercel
1981-83 2.2L Pickup
1984-87 2.4L Pickup
1982-88 2.8L Celica Cressida
1987-94 3.0L 4-Runner
VOLKSWAGEN
1976-91 All Except 1.9 2.1L Engine
1990-92 1.6L Golf (CANADA) Jetta
1990-95 2.0L GTI Jetta GLI Passat
VOLVO
1991 2.3L Coupe 940
1986-94 2.3L 240 740 940
The AERA Technical Committee |
| TIMING CHAIN INSTALLATION ON 79-85 MAZDA 2.0L |
Timing Chain Installation On
1979-85 Mazda 2.0L Engines
Correct installation of the timing chain on 1979-85 Mazda 2.0L
engines is critical to achieve the proper valve timing.
Rather than aligning the camshaft and crankshaft gears with marks
on the cylinder head or block, this engine uses marked plates on
the timing chain to set valve timing.
Start the timing process by rotating the crankshaft and camshaft
sprockets until the keyways are facing straight up (12 o'clock).
This should face the camshaft sprocket timing mark at 3 o'clock
and the crankshaft sprocket timing mark at approximately 5
o'clock looking at the front of the engine.
Locate the three marked links on the timing chain. Two links
should be positioned at the crankshaft sprocket so that the
timing mark is between the links (Figure 1). Position the chain
and camshaft sprocket so that the mark is in the middle of the
other marked link (Figure 2). There should be 20 unmarked plates
between the two positions.
Be careful, some timing chains do not use marked plates to
indicate the correct timing positions for the camshaft and
crankshaft. Use the old chain as a guide to make your own marks
on the new chain.
The AERA Technical Committee
August 1991 - TB 796
##END## |
| VALVE TRAIN NOISE ON MAZDA 2.0L ENGINES |
Valve Train Noise On
1993-94 Mazda 2.0L Engines
The AERA Technical Committee offers the following information regarding a valve train noise on 1993-94 Mazda 2.0L engines. This noise can be associated with the Hydraulic Lash Adjusters (HLA).
This noise appears after the engine has been run at idle for a long period of time. The noise appears because air is entering the oil gallery. To prevent this condition from happening, Mazda had redesigned the oil pump plunger as shown in Figure 1.
HLA noise will appear at the top of the engine and is several times faster than that of the engine speed. Verify the complaint by running the engine at idle for a period of time not letting the vehicle overheat. If the HLA noise is present, replacement of the oil pump plunger is required.
To replace the oil pump plunger, remove the snap ring at the bottom of the pump as shown in Figure 1. Remove spring seat, pressure spring and the plunger. Replace the old plunger with the new plunger, Part #JF01 14 115. Reassemble the bottom of the oil pump in the reverse procedure of disassembly
NOTE: Follow instructions in the service manual for disassembly and assembly of the engine to get access to the oil pump for replacement of the plunger.
The AERA Technical Committee |
| COOLANT IN THE OIL |
Coolant In The Oil On
Mazda 1.5 & 1.6L Engines
AERA member machine shops should carefully inspect the cylinder head when resolving engine oil contamination complaints.
The cylinder head carries two cup type freeze plugs on the valve spring side of the cylinder head. Leaking freeze plugs will accumulate a black residue during operations. Pressure testing the cylinder head confirms that the plug or plugs were leaking.
Successful repairs include replacement of the plug or peening the metal surrounding the plug over it. Be sure to re-pressure test the cylinder head after repairs are completed.
The AERA Technical Committee |
| REVISED CYLINDER HEAD BOLT |
Revised Cylinder Bolt For
1995 Mazda 2.5L, KL Engines
The AERA Technical Committee offers the following information on a revised cylinder head bolt for 1995 Mazda 2.5L KL engines. The cylinder head bolt length was reduced and the accompanying washer eliminated beginning with vehicle VIN Code 1YVGEDS5361783 and engine serial number KL556012.
Using the short bolt with an additional washer may result in an improper clamping load. The original design bolt (longer) may be used on engines produced after the serial number break ONLY if the washer is installed. The current head bolt (shorter) may be used on the engines produced before the serial number break ONLY if the washer is eliminated.
The torque values used to install the cylinder head bolts remains as previously published. Mazda allows reuse of bolts in good condition if their lengths do not exceed 5.315 (135mm) for the shorter bolts or 5.127 (132.5 mm) for longer bolts. Follow the steps listed below to tighten the cylinder head bolts for this engine.
Step 1. Torque all bolts in sequence to 17-19 ft/lbs.
Step 2. Paint on all bolts and head casting to help indicate their position.
Step 3. Rotate all bolts in sequence an additional 85-95° (Figure 2 & 3).
Step 4. Rotate all bolts in sequence an additional 85-95° (Figure 2 & 3).
The AREA Technical Committee |
| CAMSHAFT INSTALLATION ON 1995-2002 MAZDA 2.3L KJ ENGINES |
Camshaft Installation On
1995-2002 Mazda 2.3L KJ Engines
The AERA Technical Committee offers the following information regarding camshaft installation on 1995-2003 Mazda 2.3L KJ engines. If the camshafts are not installed correctly, engine damage may result.
When reinstalling the camshafts during engine installation, the original timing marks may have been worn away over time. If this is the case, mark and install the intake and exhaust camshafts using the procedure described below.
NOTE: The procedure for the left and right cylinder banks is different. Be sure to follow each procedure correctly.
Right Bank Cylinder Head (Figure 1)
Intake Camshaft Indexing: From the backside of the intake camshaft timing gear, locate the small stamped dot. Gear may need to be cleaned to locate the dot. Start with the tooth with the dot and count clockwise 31 teeth. Mark the 31st tooth with a scribe mark.
Exhaust Camshaft Indexing: From the backside of the exhaust camshaft timing gear, locate the small stamped dot. Gear may need to be cleaned to locate the dot. Start with the valley stamped with the dot and count clockwise 4 valleys. Mark the 4th valley with a scribe mark.
Installing Camshafts: Align the marked intake gear tooth with the marked exhaust gear valley. Install the camshafts into the cylinder head. Verify the alignment of the scribed marks.
Left Bank Cylinder Head (Figure 2)
Intake Camshaft Indexing: From the backside of the intake camshaft timing gear, locate the small stamped dot. Gear may need to be cleaned to locate the dot. Start with the tooth with the dot and count clockwise 1 tooth. Mark the 1st tooth with a scribe mark.
Exhaust Camshaft Indexing: From the backside of the exhaust camshaft timing gear, locate the small stamped dot. Gear may need to be cleaned to locate the dot. Mark the valley with a scribe mark.
Installing Camshafts: Align the marked intake gear tooth with the marked exhaust gear valley. Install the camshafts into the cylinder head. Verify the alignment of the scribed marks.
The AERA Technical Committee |
| LARGER CRANKSHAFT JOURNAL DIAMETER FOR 1.8L KIA ENGINES |
Larger Crankshaft Journal Diameter for
1995-2002 Kia 1.8L VIN 5 Engines
The AERA Technical Committee offers the following information on a larger crankshaft journal for 1995-2002 Kia 1.8L VIN 5 engines. The main journal diameter for the crankshaft of this engine increased in diameter beginning with the 1998 model year. Mazda manufactured engines used prior to 1998 and Kia manufactured subsequent engines.
Caution should be used when ordering replacement parts including crankshafts and main bearing sets as aftermarket catalogs may not reflect two different part numbers for the different years.
Application Main Journal Diameter Rod Journal Diameter Stroke
1994-97 1.9661-1.9668 1.7693-1.7699 3.346 (49.939-49.957 mm) (44.94-44.955 mm) (85 mm)
Main set 0K2YA11SG0
1998-02 2.1629-2.1636 1.7693-1.7699 3.430
(54.938 - 54.956 mm) (44.94-44.955 mm) (87 mm)
Main set 0K2Y211SG0
Kia indicates connecting rod and main bearings are available in standard, .010 (.25 mm), .020 (.050 mm) & .030 (.75 mm) undersizes. Reference to the sizes listed in the Kia service manual should not be used for grinding, as they?re incorrect.
The AERA Technical Committee |
