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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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CYL HEAD OIL GALLERY MODIFICATION |
Cylinder Head Oil Gallery Modification On
1976-85 Volvo 2.1 & 2.3L Engines
AERA members have reported a cylinder head oil gallery modification for Volvo 2.1& 2.3L engines. To enhance upper engine oiling, simply increase the diameter of the oil gallery hole to .563 (14 mm). To do so, requires the removal of the cylinder head and a drilling operation.
This engine design may allow sludge to accumulate in the oil gallery over a period of time if poor oil maintenance exists. To reduce the possibility of a seized camshaft from lack of lubrication at start-up, the following modification should be made to the cylinder head.
1. Remove cylinder head and locate the oil gallery feed hole on
the head gasket surface as shown in illustration below.
2. Obtain a .563 (14 mm) drill, and drill perpendicularly down
a distance of 1.770 (45 mm).
3. Do all other machine operations and clean thoroughly before
placing back in service.
4. Clean crankcase ventilation system and verify those
components are the manufacturer's current design.
The AERA Technical Committee |
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CRANKSHAFT/CAMSHAFT SEAL OIL LEAKS |
Volvo Crankshaft/Camshaft Seal Oil Leaks
Possible oil leaks around the crankshaft, camshaft or other engine gaskets may be due to a clogged flame trap in the PCV system. This does not seem to happen on turbocharged models.
The plastic Y-shaped flame trap is located in the PCV apparatus and may become clogged if engine oil is infrequently changed. Low grade or inexpensive oil may also cause stoppage which allows internal crankcase pressure to build, thus forcing an oil leak. In some cases, the pressure will force the oil dipstick to pop out.
A clogged flame trap should either be cleaned or replaced, says Volvo, and normal maintenance calls for routine cleaning of the trap every 15,000 miles.
The AERA Technical Committee |
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REVISED CONNECTING ROD |
Revised Connecting Rods On
1988-89 Volvo 2.3L B230 Engines
AERA members have reported connecting rod failures in 1988-89 Volvo B230 engines. Rod failures include both bending and actual breakage. Because of the frequency of these failures, Volvo has redesigned the connecting rod for additional strength (See illustration). Engines manufactured as of the 1990 model year use the revised connecting rod.
The revised rod features a thicker beam and has increased in weight by 40 grams. The revised rod should only be installed in complete sets of four, Volvo Part #0271451-7 (four matched rods). Substituting a revised rod, Volvo Part #3531260-2, for the former design will cause an out-of-balance condition and possible engine failure.
The AERA Technical Committee |
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CYLINDER BLOCK & CRANKSHAFT CHANGES |
Cylinder Block & Crankshaft Change On
Volvo 1988 2.3L B230 Engines
Volvo Motors has changed the cylinder block and crankshaft on 1988 and later 2.3L B230 engines. The changes are related to the crankshaft main journal size and thrust location. Volvo also identifies 1988 and newer blocks by stamping K externally on the front timing case.
Crankshaft main journal diameters have increased in diameter to 2.4798-2.4803 (62.987-63.000 mm). The thrust bearing has been relocated to the rear main and uses a flanged type bearing. The thrust length on the crankshaft was also increased to a length of 1.398 (35.5 mm). Connecting rod journals remain unchanged at 1.9285-1.9293 (48.984-49.005 mm) in diameter.
Revising the crankshaft required the block main bearing bores be increased to 2.6378-2.6383 (67.000-67.013 mm) in diameter.
Years Main Journal Rod Journal Thrust Main Brg.
Used Diameter Diameter Location Housing
& Length Bore
----------------------------------------------------------------
1985-87 2.1648- 1.9285- 1.142 2.3228-
2.1654 1.9293 @ #3 2.3236
1988-92 2.4798- 1.9285- 1.398 2.6378-
2.4803 1.9293 @ #5 2.6383
The AERA Technical Committee |
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ROD SIDE CLEARANCE |
Crankshaft & Connecting Rod Assembly Caution For
1980-1984 2.3L AQ151 & AQ171 Volvo Marine Engines
The AERA Technical Committee offers the following information regarding a connecting rod and crankshaft assembly caution for 1980-1984 2.3L AQ151 & AQ171 marine engines. This information is most useful when engine disassembly and reassembly personnel are different people.
These engines use a crankshaft and connecting rod combination that appears to be ?not right" when the connecting rods are assembled to the crankshaft. The reason for this concern is expressed in the photo below, as it appears there is excessive rod side-play. The view shown below is normal even though it shows approximately .125" clearance on each side of the rod.
Previous service information has been reported to be unclear as to the allowable side play for connecting rods. Illustrations? showing ?normal" rod side play is in most manuals has further confused the issue.
Volvo refers to this extra rod side clearance as a ?low friction" design and they use it in several of their automotive engines as well.
The AERA Technical Committee |
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NEW CYLINDER LINER O-RINGS |
New Cylinder Liner O-Ring Seals On
Cummins NH/NT 6 Cylinder Engines
Cummins Engine Company has released new O-ring seals for the cylinder liners in NH/NT 6 cylinder engines. The new seals are made of an EP material and have a smaller diameter cross-section.
The new seal replaces both the old center seal #3008998 and the old lower seal #183049. The new seal carries Cummins part #3032874 and is black in color with one blue dot.
The new O-ring seals are not to be intermixed with the former seals on the same liner. Cylinder liner deformation will result. You can use the former seals and new seals in the same engine as long as they are used in the correct combinations on each liner. The illustration below shows the correct combinations.
The AERA Technical Committee |
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OIL IN COOLANT |
Oil in Cooling System on
VW 1.5L & 1.6L Diesel Engines
AERA members have reported instances of engine oil in the cooling system on VW 1.5L diesel engines. According to AERA sources, the problem is related to a crack in the cylinder head bolt hole located near the oil gallery feeding the cylinder head.
The oil feed gallery in the block is located on one side of the center head bolt hole and a coolant jacket is on the opposite side of the bolt hole. Pressurized engine oil is diverted through a slot in the head gasket and is feed up the side of the head bolt to the cylinder head. The oil also follows the bolt back down to the bottom of the bolt hole. Should the crack in the head bolt hole extend to the coolant jacket, oil can mix with engine coolant.
This problem is generally found on engines equipped with 11mm head bolt holes. Later design engines utilize 12mm head bolts and do not exhibit this defect. At the time of this writing no successful repair procedure is available.
The AERA Technical Committee |
