| 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 |
| PISTON & ROD ASSEMBLY & ROD BOLT REUSE |
Piston & Rod Assembly & Rod Bolt Reuse for
1989-99 Toyota 1.6 & 1.8L 4A-FE & 7A-FE Engines
The AERA Technical Committee offers the following information on piston and rod assembly and rod bolt reuse for 1989-99 Toyota 1.6 & 1.8L 4A-FE & 7A-FE engines. This information should be used to correctly assemble the pistons to connecting rods and determine whether a connecting rod bolt should be considered for reuse.
Rod bolts considered for reuse should be free of nicks and burrs and allow easily threading the bolt or nut with one's fingers. To further consider the rod bolts for a 1.6L engine, measure the bolt diameter with a caliper at .590 (14.986 mm) from the bottom of the bolt. If the diameter measured at that location is .3386 (8.6000 mm) or greater the bolt may be reused.
To further consider the rod bolts for a 1.8L engine, measure the bolt diameter with a caliper at .787 (20.000 mm) down from the bottom of the connecting rod bolt head. If the diameter measured at that location is .270 (7.000 mm) or greater the bolt may be reused
To assemble the connecting rods for either engine to the pistons, align the protrusion or front mark on the rod with the front mark located on the piston as shown in the illustrations below.
The AERA Technical Committee |
| COOLANT IN THE ENGINE OIL SUPPLY |
Coolant In The Oil On
Toyota 20R & 22R Engines
AERA members have reported instances of engine coolant mixing with the engine lubricating oil supply.
In some of these cases, pressure testing the cylinder block and head has not identified the source of the leak. However, close inspection of the aluminum front cover revealed an area where the timing chain wore through into a water passage.
In this engine the water pump is mounted to the front cover. When the timing chain stretches and the automatic tensioner is no longer able to take up the slack, the loose chain can slap against the front cover. Continuous contact will eventually wear a hole into the front cover, introducing engine coolant into the
crankcase.
The AERA Technical Committee |
| VALVE SEAL IDENTIFICATION FOR TOYOTA 1.8L ENGINES |
Valve Seal Identification For
2000-2002 Toyota 1.8L Engines
The AERA Technical Committee offers the following information on valve seal identification for 2000-2002 Toyota 1.8L engines. Starting with the 2000-year model Toyota offered two 1.8L engines with similar displacement, a 1ZZ-FE and a 2ZZ-GE designation.
Determining which engine you're working on may be confusing, as many components are similar. Valve stem seals fall into the confusing category, as they physically appear the same at first glance. Original equipment and some aftermarket seals are color coded to ease in seal identification. Refer to the chart and Figure 1 below to help identify the seals once they?re out of their original packaging.
Engine Model Location Coloring Part Number Stem Diameter
1ZZ-FE Exhaust Gray 9008031046 .2152-.2157
1ZZ-FE Intake Light Brown 9091302101 .2154-.2159
2ZZ-GE Exhaust Green 9091302115 .2144-.2154
2ZZ-GE Intake Black 9091302114 .2150-.2156
Valve guides are also slightly different between the two engines, which offers additional means of engine identification. The installed guide height and the guide outside diameter are different as the 2ZZ-GE engine protrudes higher than the 1ZZ-FE. The 2ZZ-GE guides should be .602-.618 above the spring seat while the 1ZZ-FE guides should be .342-.358 above the spring seat.
The AERA Technical Committee |
| REVISED TIMING BELT & TENSIONER SPRING |
Revised Timing Belt &Tensioner Spring For
1992-96 Toyota 2.2L 5S-FE Engines
The AERA Technical Committee offers the following information on a revised timing belt tensioner spring for 1992-96 Toyota 2.2L 5S-FE engines. This information should be considered anytime the timing belt is removed from the engine.
The timing belt and tensioner spring for 5S-FE engines has been revised beginning with the 1997-year model. The timing belt and spring are designed for use, as a set and one should not be replaced without replacing the other. All 1992-96 engines should be updated with the revised spring and belt as a set for improved durability. Intermixing prior and revised components should not be attempted as improper tension and alignment may occur.
Prior Part Number Current Part Number Description
90507-18030 90507-17003 Tension Spring
13568-09040 3568-09041 Timing Belt
Its 4mm shorter length and additional 3 coils can identify the revised spring.
The AERA Technical Committee |
| REVISED PCV VALVE ON 2.2L 4YEC ENGINE |
Revised PCV Valve On
1984-87 Toyota 2.2L 4YEC Engines
The AERA Technical Committee offers the following information
concerning a revised PCV (Positive Crankcase Ventilation) valve on
1984-87 Toyota 2.2L 4YEC engines. The purpose of this revised
assembly is to improve the control of the PCV system in colder
ambient temperatures.
This revised system involves installing a new valve and hose
assembly as shown below. Installing the revised components seals and
meters the air flow through the system in all ambient temperatures.
If the PCV system is not completely sealed, it becomes ineffective
and may result in undesirable oil consumption.
Engines built beginning with serial number 4Y-0058330 have the
revised components. Parts are available with Part #12204-15022 for
the valve and 12261-73021 for the hose assembly to update older
engines.
The AERA Technical Committee
October 1996 - TB 1387
##END## |
| OIL CONSUMPTION ON 3S-GE AND FE ENGINES |
Oil Consumption On
1986-88 Toyota 2.0L 3S-GE & FE Engines
The AERA Technical Committee offers the following information about oil consumption on 1986-88 Toyota 2.0L 3S-GE & FE engines. The cause of this condition has been related to inadequate piston ring seal. During the 1988 model year, Toyota modified the piston rings for the above mentioned engines. Generally, a field fix of installing the newer ring design solved excessive oil consumption complaints.
The modification to the ring set included reduced allowable oil ring end gap and additional tension for the 3S-FE engine. Refer to the chart below when fitting piston rings to bores.
Engine Ring & Location Previous Seec Current Spec.
3S-FE Oil ring end gap .0078-.0276 .0078-.0177
3S-GE Oil ring end gap .0078-.0276 .0078-.0177
Oil ring tension 4 kg 4.5 kg
3S-GE Second comp. .0090-.0138 .0177-.0236
ring end gap
The improved standard ring sets from Toyota carry part number 13011- 88363 for the 3S-GE engine and 13011-74071 for the 3S-FE engine.
The AERA Technical Committee |
| REVISED CRANKSHAFT CAUTION |
Revised Crankshaft Caution On
1994 Toyota 2.2L 5SFE Engines
The AERA Technical Committee advises members of a revised crankshaft design on 1994 Toyota 2.2L 5SFE engines. This design change prevents the interchanging of old and new designs. The modified area is the drive gear for the engine balance assembly.
To reduce cold engine noise at start-up, the number of teeth on the balance shaft drive gear was reduced from 66 to 44. The change occurred with engine serial #55537901, which was built in July of 1994.
The balance shaft assembly gears also changed at the same time to accommodate the revised crankshaft. The first design used 32 teeth on each gear and the second uses 22 teeth. Those assemblies are not interchangeable.
For additional information see AERA Technical Bulletin TB 1347
The AERA Technical Committee |
| ENGINE OVERHEATING |
Engine Overheating On
1988-95 Toyota 3.0L 3VZE Engines
The AERA Technical Committee offers the following information on reported engine overheating on 1988-95 Toyota 3.0L 3VZE engines. This overheating has been reported shortly after cylinder head gasket replacement. The cause of this problem has been related to incorrect location of this V-6 engine's cylinder head gaskets.
The head gaskets used on this engine are unique to each cylinder bank. It is, however, possible to install either gasket on the opposite bank of which it is indented to fit. If this is done, the engine's cooling flow will be interrupted. If that occurs, eventual engine overheating will result. The gaskets will not physically match up, if installed end for end.
To distinguish the different gaskets, original equipment and some aftermarket gasket companies provide identification by a raised color marking on the head gasket face. The left bank head gasket is color coded with a yellow dot and the right bank side is identified with a pink dot. Still other manufacturers' gaskets may have the letter L for left bank, or R for the right bank as viewed from
the flywheel end of the engine. Finally, some manufacturers do not distinguish their gaskets and supply only an instruction sheet for the correct installation.
Correct gasket installation shown below, requires that the open cooling hole is located on the left bank as viewed from the flywheel end of the engine. The right bank water passage is blocked off by the head gasket. It should also be noted that along with the head gasket differences, the heads are also location specific.
The AERA Technical Committee |
