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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 |
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OIL COOLER MOUNTING STUD CAUTION FOR 2.8L VOLKSWAGEN |
Oil Cooler Mounting Stud Caution For
2001-2002 Volkswagen Passat 2.8L Engines
The AERA Technical Committee offers the following information regarding oil cooler mounting stud caution on Volkswagen Passat equipped with a 2.8L engine.
Should the mounting stud or hex lock nut become loose during removal of the oil filter, reinstallation of the stud and hex lock may not allow the mounting stud to extend adequately beyond the oil cooler base. If this occurs, it causes the tapered, partial mounting stud threads not to engage the oil filter threads correctly. Which, gives a perception is that the threads have a larger pitch diameter? Things to watch out for are the following: Length of the stud above the oil cooler without the hex nut and washer should be .500 (.019 mm).
Reinstall washer and tighten hex lock nut to 22 ft/lbs, install oil filter and tighten ? to 1 full turn. Fill crankcase with clean engine oil and check for leaks.
Figure 1. Oil Cooler Components.
6. Oil filter
7. Hex lock nut
8. Oil cooler
9. Oil cooler gasket
The AERA Technical Committee |
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CYLINDER HEAD GASKET SELECTION |
Cylinder Head Gasket Selection On
1981-86 Volkswagen 1.6L (96.9 CID) Diesel Engines
The cylinder head gasket used in the 1981-86 Volkswagen 1.6L (96.9 CID) diesel engines is available in three thicknesses distinguished by notches on the side of the gasket. The correct gasket is selected by measuring piston protrusion on all four cylinders and basing the selection on the highest piston height.
Protrusin should be measured as indicated in the illustration below by using Volkswagen tools VW382/7 and VW385/17 or equivalents. It is important that your depth gauge/dial indicator set-up not rest directly on the piston itself to
prevent possible distorted readings. Parallels placed on the deck surface next to each cylinder will provide a good base for measuring.
Use the following table for determining gasket usage:
Piston Height Identification Notches
.0260-.0339 1 (1.4mm thick)
(.66-.86mm)
.0343-.0665 2 (1.5mm thick)
(.87-.90mm)
.0358-.0402 3 (1.6mm thick)
(.91-1.02mm)
Additionally, be sure to install the cylinder head gasket with the side marked TOP or OBEN (on OE gaskets) facing up.
The AERA Technical Committee |
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CYLINDER HEAD THICKNESS ON WATER COOLED ENGINES |
Cylinder Head Thickness On
Water Cooled Volkswagen 4 Cylinder Engines
The minimum cylinder head thickness for Volkswagen 1.5L, 1.6L, 1.7L and 1.8L gasoline engines is 5.215 as measured from the deck surface to the valve cover rail. See illustration below. Although AERA members report following the above specification for 1.5L and 1.6L diesel cylinder heads as well, Volkswagen's official position is that the diesel cylinder heads are not to be
resurfaced. Heads warped more than .003 are to be replaced.
AERA members are reminded that the diesel engines have 5 different thicknesses of cylinder head gaskets identified by the number of notches located on a tab on the side of the gasket. The proper gasket is selected based on piston protrusion and size of engine, not cylinder head thickness. The table below indicates the proper gasket selection.
Piston Gasket Notches
Projection Thickness 1500cc 1600cc
.025-.032 .055 3 1
.033-.036 .059 4 2
.037-.040 .063 5 3
The AERA Technical Committee |
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HEAD GASKET CAUTION ON 1992-97 1.9L VIN Z DIESEL |
Head Gasket Caution On
1992-97 Volkswagen 1.9L VIN Z Diesel Engines
The AERA Technical Committee offers the following information on head gasket caution on 1992-97 Volkswagen 1.9L VIN Z diesel engines. These turbocharged engines use one of the three different thickness gaskets available for each of the engines, TD or TDI. The correct gasket to be used depends upon the amount of piston protrusion measured before installation.
Measuring piston protrusion requires mounting a dial indicator to the block top and bringing each piston to TDC (top dead center). This measurement should be made directly above the piston pin. Observe and record the amount each piston extends above the top of the block deck. Use the highest value measured to select the correct cylinder head gasket to be used. The three different gaskets can be identified by the number of notches located on the
head gasket next to the part number.
Engine Part Number Notches Piston Protrusion
TD 028 103 383 BH 1 .036-.039 (.914-.990 mm)
TD 028 103 383 BJ 2 .040-.043 (1.106-1.092 mm)
TD 028 103 383 BK 3 .044-.047 (1.117-1.193 mm)
TDI 028 103 383 BL 1 .036-.039 (.914-.990 mm)
TDI 028 103 383 BM 2 .040-.043 (1.106-1.092 mm)
TDI 028 103 383 BN 3 .044-.047 (1.117-1.193 mm)
AERA is currently unaware of an aftermarket supplier for the above mentioned head gaskets.
The AERA Technical Committee |
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HEADS MODIFIED FOR 12MM CYL. HEAD BOLTS |
Modified Volkswagen 1.6L Diesel Engine Cylinder Heads
All Volkswagen-rebuilt 1.6L short blocks (complete with cylinder
heads) are supplied only with 12mm head bolts. AERA members
should be especially watchful for the following:
When the letter C is stamped behind the casting number on the
cylinder head, it indicates the head was modified for 12mm bolts
instead of 11mm bolts and spacers. Volkswagen part #068 103 377A
or equivalent must be placed on each bolt.
When the letter C or S is cast in the cylinder head, a 4.5mm
spacer (Volkswagen part #N 901 157 01 or equivalent) must be
used.
The AERA Technical Committee
January 1984 - TB 307
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CYLINDER HEAD CRACKS ON 2.8L AAA ENGINES |
Cylinder Head Cracks On
1993-2001 Volkswagen 2.8L VIN AAA Engines
The AERA Technical Committee offers the following information regarding cylinder head cracks on 1993-2001 Volkswagen 2.8L VIN AAA engines. Visible cracks in the cylinder head combustion chamber have been reported during inspection on this engine. Those cracks reported are located between valve seats or between valve seats and spark plug threads.
It has been determined that those cracks are insignificant to the service life of the head if they do not exceed .020 (.500 mm) in width. It is advised that the cylinder head be pressure tested to confirm the cracks do not allow coolant or combustion leakage. If the crack/s are wider than the amount stated above, the cylinder head should be repaired by welding those cracks before returning to service.
The AERA Technical Committee |
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COMPONENT REPLACEMENT CAUTION ON VOLKSWAGEN ENGINES |
Engine/Component Replacement Caution For
All 1990-2004 Volkswagen Engines
The AERA Technical Committee offers the following information regarding engine/component replacement on all 1990-2004 Volkswagen engines. This information should be considered anytime the cylinder head or block requires service work.
It has been reported that engine damage has occurred after installation of an engine into the vehicle. This includes a long block assembly and service work to the cylinder head.
Engine damage may be caused by debris from the previous damaged engine lodged in assemblies, which are transferred from the damaged engine to the replacement or assembled engine.
If the original engine fails and pieces of metal (debris) are distributed or ingested throughout the engine, some debris may end up in the intake manifold and become lodged there. Those pieces, if not removed, can remain stationary for an unknown period of time after the engine is restarted.
During engine replacement or reassembly, when parts must be transferred from a damaged engine to a replacement engine it is imperative to clean all the associated parts. The parts include; intake manifolds, turbochargers, hoses, fittings oil lines & etc. They must be checked and cleaned for contamination or debris from the damaged engine.
This cleaning caution is especially important to do in V6 or VR6 engines with variable intake manifolds where debris can become lodged in the inner parts of the manifold until the manifold port changes length, at which time the debris may loosen and travel into the engine.
CAUTION! Engine damage caused by failure to clean and remove debris from assemblies that are transferred to a replacement/reassembled engine will not be covered by warranty.
The AERA Technical Committee |
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CYLINDER HEAD CRACKS ON GAS & DIESEL ENG. |
Cylinder Head Cracks On
Volkswagen Gas & Diesel Engines
When reconditioning cylinder heads for Volkswagen gas and diesel engines, be sure to look for cracks between the valve seats or between the valve seats and the spark plug hole.
Volkswagen reported that if the cracks are no larger than .5mm (019), the head can be reused without reducing engine performance.
Cracks in the spark plug hole cannot be any deeper than the first
coil of the threads.
The AERA Technical Committee |
