Engine Builder Magazine
Contents
1. Gear amp Products Inc GENERAL MOTORS PG 6 GHRYSLER PG 11 IMPORT PG 16 ERFORMANCEPG 18 3 23 CLOYES Gear amp Products Inc TELH SOLO T LOTS IMPROVED DESIGN FOR THIS PROBLEM APPLICATION GM 2 2L 1994 2003 CHEVROLET BUICK GMC OLDSMOBILE PONTIAC A CLOYES EXCLUSIVE Using the specifications we have eliminated the tensioner by custom matching sprockets with our new design special built chain When you replace your existing set with this problem solver you ELIMINATE THE TENSIONER C 3019MS GM HFV6 2007 2011 TOYOTA 22R 1985 1995 CAMARO FULL KIT WITH STEEL GUIDE EQUINOX MALIBU TRAVERSE CTS STS ACADIA TERRAIN G6 G8 ENCLAVE LACROSSE OUTLOOK VUE 9 07535 9 4148SHD WWW CLOYES COM Circle 101 on Reader Service Card for more information TECH SOLUTIONS 2 Year Engine Problem Page FORD 4 All 3 0L Duratec Timing Chain Service 2 2003 2004 3 8L 3 9L and 4 2L Balance Shaft Gear Clarification 4 1990 1993 4 0L Oil Leak Repair 4 1999 2002 4 0L Rattle Noise From Primary Chain Drive 5 1990 2002 2 2L 134 cid Deciphering The Differences In The Chevy 2 2L Engine 6 1988 2002 zs Quad 4 Timing Chain Installation Caution 6 1993 1994 3 IE T9T cid Chevy 3 1L 191 Cam Bearing Bore Issues 8 2004 2005 3 6L Noise Complaints on 3 6L2. 99 01 4x4 Explorer M ountaineers 01 02 4x4 Sport Sport Tracs and All 02 Explorer M ountaineers except engine codes 2G 960 AA and 2G 964 Figure 6T he patented O ffset Y drive uses three timing chains one from the cank to the jacshaft one in the front of the engine to drive the cam for the let bank and one on the back of the engine to drive the cam for the right bank AA Use kit 2U3Z 6D256 BA non ba ance shaft engines for 99 01 4x2 Explorer M ountaineers 01 02 4x2 Sport Sport Tracs e 02 Explorer M ountaineers with engine codes 2G 960 AA and 2G 964 AA and e AIl 2001 02 R angers TSG ORIGINAL MAHLE ORIGINAL STEEL PISTON RINGS MAHLE the largest manu facturer of piston rings in the world leads the way in ring technology and innovation far the Aftermarket Tradi tionally grey cast iron or ductile iron has been the ring of choice Today steel is preferred over iron by more and more engine builders MAHLE Original steel piston rings feature higher tensile strength higher yield strength greater fatique life and greater hardness while still offering a lower ring mass These features result in better stress resistance reduced groove pound out longer service life better conformability superior oil economy and improved blow by control while still lowering friction For more information visit www mahle aftermarket cam Circle 105 for more informatio
3. er pace T his keeps the spark plug tem perature high which allows the plug to self clean and prevent fouling U nfortunately heat range numbers are not universal each brand has its own method for assgning heat ranges You ll need to talk with your sales rep or consult with the manufacturer to find the best heat range for your application and spark plug brand Be prepared to supply some basic vehicle information including any modifications you ve made Asarule of thumb you can expect to require one heat range colder than the factory supplied plugs for every 75 100 horsepower you ve added with your modifications according to Champion Spark Plugs H ere are some more basic guidelines to get you pointed in the right direction Supercharging turbocharging For ced induction leads to increased cylinder pressure and temperature which could lead to detonation Depending on the exact application you ll need to go with a sgnificantly colder heat range faster heat transfer over stock Nitrous oxide T he high cylinder In addition to Motor State Distributing s outstanding selection of performance engine parts and excellent customer service we offer the latest in business to business technology with online ordering pricing and parts avail ability Now customers access pricing and availabiliry on their mobile devices through the Motor State mobile site Motor State Distributing is your one source for perform
4. 10W 40D racing Oils Find us at www epwi net or call 800 888 8970 Cirde 117 for more information www enginebuildermag com ENGINE BUILDER 17 TECH SOLUTIONS FOR Understanding Spark Plug Heat Range Finding the right spark plugs for a mod ified engine isa little more involved than jus looking in a catalog for make and model D epending on the engine modifica tions you ve made you ll need to take a few extra factors into consideration before settling on the right spark plugs Figure 1 T hese factors include spark plug seat design thread length and diam eter and reach O ne of the most impor tant and least understood factors in choosing aftermarket spark plugs is the heat range H eat range is the speed at which a spark plug can transfer heat from the fir ing tip to the cylinder head water jacket and into the cooling system Choosing the right heat range is crucial for high performance engines If the heat range 15 too cold the spark plug will be unable to Figure 1A s a rule of thumb you can exped to require one heat range colder than the fac tory supplied plugs for every 75 100 horse power you ve add with your modifications properly self clean by burning off car bon deposits If it the heat range is too hot your The Future Trust American Cylinder Head to constantly look to The Future by utiliz ing cutting edge parts equipment and technology to provide you the most precisely engi
5. All tech bulletins unless otherwise noted have been provided by Automotive Production Remanufacturers Association APRA www enginebuildermag com ENGNEBULLER 1 TECH SOLUTIONS pute FORD Timing Chain Service on Ford 3 0L Duratec Engines If you have to remove or replace a cylinder head for any reason or replace the timing chain on a 3 0L D uratec it can be a bit of a challenge because Ford doesn t provide a Top D ead Center T DC timing reference mark on the crankshaft You will have to use a did indicator to find theT DC postion of the number one cylinder on Ford s 3 0L Duratec to make sure the crank and camshafts are all proper ly aligned Ford says that when the crankshaft key way is postioned at roughly the 11 o clock postion the number one cylinder should be TDC Before you can remove the timing chain the front cover has to come off the engine T hen you have to remove the crank sensor pulse wheel N ote the sensor wheel s location before you remove it R otating the crank until the keyway is Sunnen Figre1You will have to use a dial indicator to find theT DC position of the number one cylinder on Ford s 3 0L D uratec to make sure the rank and camshafts are all properly aligned at the 3 o clock postion will move the right cylinder head camshafts to the neutral postion The timing mark on the intake cam should be pointing to the right when viewed from the front and the timing mark on the exhaus
6. links between the cam gears and crank on the non tensoned 9 of each chain and 30 links between the cam gears and crank on the tensoned sde of each chain By Larry C 2003 2004 Ford 3 8L 3 9L and 4 2L Balance Shaft Gear Clarifications To deal with certain engine harmonics particularly inherent second order or twice engine rpm vibration engine desgners often incorporate two balance Figure 2 F ord increased the number of teeth in the drive and driven gears on several F ord engine balance shafts in 2003 and 2004 shafts rotating in opposte directions at twice engine speed Equal 9ze eccentric weights on these shafts are zed and phased FORD so that the inertial reaction to their count er rotation cancels out in the horizontal plane but adds in the vertical plane T his gives a net force equal to but 180 degrees out of phase with the undesred second order vibration of the basc engine thereby canceling it In a V configuration the same may be accomplished by opposte counter weights on the smeg single shaft T he ultimate result is to eliminate N VH N oiseV ibration arsnness T his fact is understood and the Ford 3 8L 3 9L and 4 2L enginesin the same fam ily configuration have had these shafts at vari ous times and in differ ent vehicles however recognizing changes in the amount of teeth of the drive and driven gears of certain vehicles is critical The drive and driven gears of the ba
7. shaft harmonic balancer replace the har monic balancer with a new unit P N 12597654 H owever if the vehicle is equipped with the V 03N 92 Heavy Duty Cooling package DO replace the six spoke design crankshaft harmonic balancer see Figure 6 Continue with routine diag noss to isolate the noise Close Coupled Converter Caution On Late Model GM Vehicles Certain late model General Motors vehicles may be equipped with a new style of catalytic converter technically known as the close coupled catalytic converter see Figure 7 This new style converter provides quick catalyst warm up resulting in lower tailpipe emissons earlier in the operating cycle If an engine failure occurs such as a broken intake exhaust valve or piston debris may be deposited in the converter through the engine exhaust ports If the engine failure is due to a severe overheating event damage to the ceram ic brick Inside of the catalytic convert er may occur T his could then result in ceramic debris being drawn into the engine through the cylinder head exhaust ports If a replacement engine is installed due to either of these instances the replacement engine may ultimately fail due to the debris being drawn into the combustion chamber upon startup Remind your installers that when they replace an engine due to a failure of this type they must inspect the convert ers and ALL transferred components such as the intake and exhau
8. Cadillac Engines 8 All All Close Coupled Catalytic Converter Caution 9 All 4 6L Cadillac 4 6L DOHC Aluminum Head Block Cracks 9 All All supercharged engines GM Belt Tensioner Failure May Cause Supercharger Failure 10 1995 2006 2 4L Chrysler 2 4L Cylinder Block Casting Identification 11 2004 2006 35E Multiple Cylinder Misfire or Rough Idle 14 All 3 7L Keeping Your Balance With 3 7L Chryslers 15 IMPCRT 1988 1995 EA827 VW 16 Valve Cylinder Head Ticking Noise 16 1996 2 8L Audi 2 8L V6 Rear Crankshaft Seal Leaks 16 1999 2001 VGS33E Repairing Nissan Exhaust Manifold Cracks 16 2006 2007 MZR Mazda Variable Valve Timing Noise 17 PERFORMANCE All All Understanding Spark Plug Heat Range 18 All All Influence of Grooved Main Bearings on Performance 20 All Carbureted engines Holly Power Valve Myths 21 All All Tips For Selecting The Proper Circle Track Cam 22 SHCP TIPS E All All Quick Test For Water in Methanol 23 All All Oil Pump And Engine Priming 23 All All Vacuum Check Engine Inspection Procedure 24 All Small block Chevy Keeping Chevy 4 Bolt Mains From Walking 24 ADVERTISER CIRCLE NUMBERS PAGES AMERICAN CYLINDER HEAD 103 109 111 118 3 9 11 18 APEX AUTOMOBILE PARTS 113 12 13 CLOYES GEAR amp PRODUCTS 101 2C ENGINE amp PERFORMANCE WAREHOUSE 108 117 123 126 8 17 23 4C MAHLE CLEVITE INC 105 107 114 122 5 7 14 22 MOTOR STATE DISTRIBUTING 104 119 121 124 4 19 21 24 SUNNEN PRODUCTS CO 102 110 120 125 2 10 20 3C NOTE
9. WAREHOUSE sne IIo SS E ENGINE amp Call the warehouse Miusuerqus Antbarage Dallas Dewees Haurien Las nescestweu dpdsvor IRE Pn ER TT I y y 1 Pornit Dakard aba Patt aed San Antara click WWW Bpwi nel jeri mths 97 3852 i TESA Mb 23 2707 _ BO BBS Sz Just a few of the ly brands we stock 2222 UP I men js TIRHLE E UM E Y Circle 126 on Reader Service Card more AS tion
10. a problem engine for oil leaks for years The mos common oil leak on 90 93 4 01 engines is often diagnosed asa rear seal leak but in most ceses the problem is usually found to be the rear of the oil pan gasket Since 1990 when the 4 0L was firt introduced Ford redesgned the gasket twice and even the oil pan casting to elimi nate the leaking issue The following installation tips from Canada Engines should help to prevent this cost ly and aggravating oil pan gasket leak T he 90 to 93 gasket set will include a plastic wedge seal that goes into a groove in the man cap see Figure 4 T he oil pan was redesgned in 1994 and so was the gasket Figure 5 he wedge seal is no longer used because its shape is M Figure4 T he oil pan gasket for the 90 to 93 4 0L Ford engine top will indude a plastic wedge seal bottom that goes into a groove in the main cap built into the gasket Silicone is still neces sary acrossthe main cap and in the cavities between the cap and the block The oil pan mus be aligned with a straight edge to the back of the block before it is torqued down Source anada Engines LT D Rattle Noise From Primary Chain Drive on Ford 4 0L SOHC Engine There have been complaints of a rattle coming from the primary timing chain drive area on some 1999 2002 Ford 4 0L SOHC engines during cold engine operation The 4 0L SOHC engine is one of Ford s CologneV 6 engines a line of 602 cas iron bl
11. auto dwell and rough and finish cycle Auto dwell allows for unattended operation The machine automatically dwells in the tightest part of the bore top middle or bottom The rough and finish cycle removes stock fast and automatically switches to finish for the correct crosshatch angle With two motors one for the spindle and one for the stroker the SV 10 has the Capability to run standard tools as well as Sunnen s DH series diamond hone head For more information visit www sunnen com or call 1 800 325 3670 _ gt SUNNEN Circle 120 for more information 20 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 out acceleration and high rpm driving raises combustion temperatures and gen erally requires a colder heat range From Summit R aang Influence of Grooved Main Bearings on Engine Performance M anufacturers are frequently asked what difference grooving makes Various forms of main bearing grooving have been used over the years t s essential to understand that bear ings depend on a film of oil to keep them separated from the shaft surface T his oil film is developed by shaft rota tion As the shaft rotates it pulls oil into the loaded area of the bearing and rides up on this film much like a tire hydroplaning on wet pavement Grooving in a bearing acts like tread in a tire to break up the oil film W hile you want your tiresto grip the road you don t want your bearings t
12. tool with the valve spring adapter slightly compress the exhaust valve spring to release tension against the valve and valve spring retainer on 3 5L engines CHRYSLER hs 3 Cu ED STYLE Sine Figure4 nspect the MAP sensor for LX models left or for CS models right If the M A P sensor is the new style no further action is necessary for the M A P sensor into place while servicing the compo nents 9 Using a valve spring compressor tool MD 998772A with the valve spring adapter 6527 or equivalent slightly compress the exhaust valve spring to release tension against the valve and valve spring retainer see Figure 3 10 R emove the valve spring retainer locks and discard the locks N ote It is important that the valve rotation section of this repair procedure be performed Caution Only grab the valve stem tip being careful not to cause damage 11 Using needle nose pliers grab the tip of the valve stem and rotate the exhaust valve 90 move the mark to the 3 o clock postion 12 Install two new valve spring retainer locks p n 53022277 13 After installing the locks release the tenson on the valve spring and ver ify proper installation 14 Remove Special Tool MD 998772A 1 and the spark plug adapter tool 15 R epeat steps 7 14 on the remain ing five cylinders using the firing sequence 1 2 3 4 5 6 Make sure the piston is at T DC in each cylinder of the exhaust valve spring retainer lock t
13. 05 RWD The RWD block was revised in 2004 to accommodate the bolt on target ring with more notches that was used with the new N GC com puter so the hole for the sensor was moved over to the driver s 9 and back toward the bell housing jus like it wason the 03 cars T he revised 53010502AB casting was used for the Liberty in 04 and 05 and the W rangler in 05 and 06 Service Count on American Cylinder Head to deliver standard setting service at every step From the moment you explore our electronic or hard copy catalog you ll find user friendly data and comprehensive coverage for the full range of vehicles you service including domestic and import models as well as marine H D ag and industrial applications Once you order our three warehouses will ship your order promptly since we stock 9696 of our part numbers And we support you after the sale with technical and product information and warranty coverage that can t be beat Our Service is complemented by our Quality and commitment to The Future in providing the finest in remanufactured cylinder heads Buy American For information e mail edGepj inc com Cirde 111 for more information www enginebuildermag com ENGINE BUILDER 11 APEX Automobile Parts Tot Over mpetition wit theatable Coverage Apex with pride supplies the automotive market with the best quality products and innovative design Quick accurate delive
14. GS33E Engines A ticking or exhaust noise has been reported coming from the right hand exhaust manifold area of some 1999 2001 N issan VG S33E engines If a cracked right hand exhaust manifold on a 1999 2001 Nissan VGS33E engine is discovered when Figure2 W hen replacing the oil seal on 1996 Audi A4 models with V 6 engines make sure the new seal is supplied pre installed in the flange l6 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 the exhaust heat shield is removed installers must replace the exhaust manifold Figure 3 If one of these symptoms should occur use the following to diagnose the condition replacing the right hand exhaust manifold and related parts as described Diagnosis 1 Installers should verify the source of the noise with the engine running that it is coming from the right hand manifold area 2 If the noise is coming from the right hand manifold area remove the heat shield and inspect for cracks between the 1 and 3 ports on the manifold Repair 1 Separate the catalyst from the right hand exhaust manifold and remove it to allow for clearance Caution The nuts that attach the catalyst to the exhaust manifold have a self locking design and require some effort to remove Apply penetrating oil to the threads and allow it to soak in before attempting to remove the nuts Use a tight fitting six point socket to avoid rounding off the corners of the nuts during removal If any of th
15. T he oil drainback hole in the head on the 2 4L was enlarged in 2002 so the block had a pro nounced bulge on the driver s side between the third increase engine warm up time and increase the likelihood of car bon depost buildup on the stem of the engine exhaust valve Fuel detergent quality may also con tribute to the condition the cus tomer may want to try a different brand of fuel 2 Verify that the engine misfire condition is not caused by faulty engine mechanical or electrical components 3 If the engine mechanical and electrical systems are operat ing properly perform the R epair Procedure Repair Procedure 1 R elieve the fuel pressure 2 Remove the upper intake mani fold 3 R emove the cylinder head cover s 4 R emove the rocker arm and shaft assembly 5 Clean and mark the tip of each exhaust valve sem at the 12 o clock position with a paint marker T he paint mark will be used later to assst with determining the amount of valve rota tion 6 R emove the spark plugs 7 Rotate the crankshaft clockwise until the number 1 piston is at Top D ead Center TDC on the compression stroke 8 Install the compression tester spark plug adapter in cylinder 1 spark plug hole With the air hose attached to the spark plug adapter apply 90 to 100 psi air pressure This is to hold the valves RM uA Se 9 EI FS EHE SEI Figure3U sing a valve spring compressor
16. a balance channel that runs between ports 1 2 and ports 3 4 that must seal against the cylinder head As you can see that exhaust manifold con figuration assembled against the 507 head would leak ne last quirk the 146 head may also be drilled for the EGR port as a service replacement for the 507 head in 1998 All later applications would require the use of an EGR block off plate GM p n 24575919 when used without EGR Special N ote 1998 applications all required an open EGR port 1999 2002 are closed EGR w exhaus manifold port balance mounting face see Illustration D and observe area that arrows are pointing to P N 24576146 cylinder head may also have open EGR port and will retro for 24575507 in 1998 or may be used 1999 2002 with the use of EGR block off plate part P N 24575919 By Roy Berndt Timing Chain Tensioner Installation Caution on GM 2 3L Quad 4 The timing chain tensoner on GM s 2 3L Quad 4 engine is of the spring loaded ratchet design See Figure 3 The tensoner assembly conssts of a housing spring and ratcheting plunger T he plunger is locked into the housing and plunger to prevent the accidental release of the spring before or during installation Once the tensoner is installed and the chain is in place the anti release device must be removed and the plunger manually depressed into the housing to unlock the plunger and release spring tension on the chain Inadequate tenson placed on the ch
17. ain will eventually result in chain breakage and the consequential piston to valve contact Failure to perform this important final step can lead to severe engine dam age From MAHLE Clevite Driven by performance ine best angina in the world Know har when they ane balding engines besi techniques ark ONES precision we not make up or inferior parts nat ie wry The comaearstone of aver engine should be Clevite engine beans ter all i rs your regulation an re inae would you trust it Eo anything ese www mahle aftermarket com Cirde 107 on Reader Service Card for more information Engine amp Performance Warehouse PLIN on MANCI Engine Kits amp Performance Parts 800 888 8970 www epwi net BOO 234 1410 510 569 9802 ALBUQUERQUE 877 267 0100 505 761 0100 ANAHEIM 800 634 0969 714 634 3803 OKLAHOMA CITY B00 937 3654 405 947 8435 ANCHORAGE 800 288 5573 907 563 7278 DALLAS 800 284 5348 214 637 3301 DENVER 800 888 3970 303 572 5844 HOUSTON 00 288 6548 713 862 2929 Cirde 108 for more information 8 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 PHOENIX B amp B 272 0191 602 272 0191 PORTLAND BOO 876 5152 503 232 2270 SAN ANTONIO B00 473 2707 210 224 8424 TACOMA B00 876 5152 Chevy 3 1L 191 Cam Bearing Bore Issues Some of the later roller cam 3 1L blocks for the 93 94 ChevyVIN M are
18. ance engine parts Depend On MofoF Sla s ribuling Far Spetialty Catalog Support we US _ vL Knob Soles Pe Eo Same Day Prompt Accurate Shipping a o Expert T chnicdl Assisfance SJ of Drop Ships 4 4 Zan M Le Competitive Pricing New Motor Sote Mobile Website X 550 Proddet ines 4 of f o 2 InformativeBusiness To B sinesy Website v Over 75 000 Part Numbers In Stock New Online Interactive Catalogs i b h 25 Online Ordering Pricing And Inventory Sparch 7 E Aggressive Producl A 2d 2 free Monthly 5 Sole Flyers POF Displays is Proud Sponsor Of The 23rd Annual AETC Conference Now 24 28 2017 201 SEMA Warehoutra grec com Son e nis Webite The Tear WORLDWIDE NES DISTRIBUTOR 5 EGIT 8500 Lane Drive Wat rvli t Mi 269 S aki E www mot rstate com P 7 F P Girde 1 19 on Re eader Serv rvice Card for more information uz m i 72 e eene a c 1 HEEL EE VIT PERFORMANCE temperatures caused by nitrous usually requires a colder heat range over the stock plug Methanol Since it has a higher octane level than standard gasoline methanol delivers more complete com bustion As a result you ll need a colder plug to transfer more heat from the combustion chamber Increased compression ratio Higher compression ratios mean highe
19. ange We offer a full range of products covering automotive domestic amp import marine heavy duty diesel agricultural and industrial power We have the experience and know how to rebuild any cylinder head large or small We have over 1700 part numbers and we are adding new numbers every day Warranty Support We have a warranty team that can help with questions and information needed to help with the installation of any cylinder head ACH stays with you long after the sale to help in any way we can e Catalog We have paper catalogs internet catalog and electronic cataloging in many formats It is the largest most complete catalog in the market Distribution amp Inventory We have three factory warehouses located in Oak land California Nashville Tennessee and Phoenix Arizona ACH has 96 of all our heads in stock at all times If you need a head that is hard to find and we don t currently stock it we can R amp RH the head for you so you don t lose the sale THE FUTURE e Equipment Investment We dedicated to providing 4 the highest quality product for decades into the future We do d this by maintaining the highest Quality Certifications available We do this with continuous education of our staff and constantly investing in state of the art equipment ensuring the best possible quality a for you and your customer F b For Information email ed epj inc com
20. ay be prone to premature fail ure of Supercharger bearings For precision rod reconditioning and pin fitting the W hen the belt tensoner starts to fail Sunnen LBB 1660 manual hone can turn old rods belt tension increases as side loading in into like new rods For added flexibility the the supercharger rear bearing Sunnen LBB 1660 Manual Hone compressors and small bore engines soner should be part of the regular main The LBB produces a round and E tenance routine Before operating the straight honed bore equal to or replacement supercharger the tensoner better than manufacturers p must be inspected and replaced if defec new rods it helps keep z tive U nless the tensioner is checked and your rod inventory to a min a 796 replaced as needed supercharger bearing imum by enabling you to give pm failure will occur causing premature cata over the counter service on ai A strophic failure customers own rods i d While this problem is prevalent on ga GM vehicles this inspection should be For more information JU FA performed on all belt driven super visit www sunnen com or charged vehicles Please check the service call 1 800 325 3670 d manual for the recommended inspection 2 i and service N ote T his bulletin is supplied as tech nical information only and is not an authorization for repair By CARDONE Industries TSG LBB 1660 also handles King Pins air ne Pe
21. cam should be pointing For fast precision alignment of main bearing bores Sunnen can t be beat The CH 100 handles the complete job of align ment and sizing of main bearing bores in about 30 minutes floor to floor time for an average passenger car block and it takes just a few minutes longer for truck blocks With the CH 100 you will see stock removal usually less than 003 076 mm off the caps compared to as much as 010 254 mm with boring For more information visit www sunnen com or call 1 800 325 3670 en gt SUNNEN Circle 102 for more information 2 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 straight up if both cams are in the correct postion You can now remove the chain tensoner arm chain guide and right tim ing chain To remove the left timing chain rotate the crank clockwise 600 1 2 3rds turn until the keyway is again at the 11 o clock postion T his will postion the left cylinder head cams in the neutral postion T his time the timing mark on the intake cam should be pointing to the left when viewed from the front and the mark on the exhaus cam should be pointing straight up As before you can now remove the chain tensoner arm chain guide and left timing chain Before you can reinstall the timing chains you need to compress the left and right chain tensoners in a vise Compress the piston until it is fully bottomed then temporarily lock it in place with a pin or pape
22. e nuts or studs are damaged during removal replace them as needed 2 Remove the exhaust manifold from the head See Figure 4 for loos ening sequence of manifold nuts NOTE If any of the nuts or studs are damaged during removal replace them _ Y RH exhaust manifold Loopen In numerical erder Figure 4 Sequence for loosening the exhaust manifold nuts on the N issan V G S33E as needed 3 Install the replacement manifold with a new gasket onto the head See Figure 5 for tightening sequence of manifold nuts See Figure 3 for mani fold nut torque specifications 4 Re attach the catalyst to the exhaust manifold NOTE Ensure that RH exhaust manifold Tighten in numerical onder Figure 5 Sequenc for tightening the exhaust manifold nuts on the N issan V G S33E all bolts securing the manifold and heat shields are installed and are torqued to the specifications shown in Figure 3 Variable Valve Timing Noise Complaints When Starting 2006 2007 Mazda MZR Engines Customers may complain of a loud ticking noise from the variable valve timing VVT This is caused by the lock pin of the variable valve timing actuator not fully engaging Affected models with engine 2007 M azdaspeed3 vehicles duced before April 1 2007 2006 2007 M azdaspeed6 vehicles produced before A pril 1 2007 M ZR IMPORT e 2007 Mazda C X 7 vehicles pro duced before A pril 1 2007 When the engine is first sta
23. e valve lash is a good Way to get an indication of which way to go for your next cam change You won t hurt anything by going too tight but too loose will let the valves dam shut causng damage to valves and seats 004 to 006 loose is usually OK Look at the major intensty num bers to get an idea as to how radical the profile is major intensty isthe difference between the 020 duration and the 050 duration Lower numbers are more rad ical but anything less than 26 or 27 degrees may be very hard on the valve train e Camshaft Intensty is a measurement term coined by Harvey Crane to com pare ramp characteristics of camshafts Hydraulic Intensty is the difference between 004 duration and 050 dura tion Minor Intensty is the difference between 010 duration and 050 dura tion Major Intensty is the difference between 020 duration and 050 dura tion Lower numbers indicate more radi cal profiles but too low can be too radi cal and lead to noisy valve train operation and even to broken parts From C Performance C ams TSG A 1 N ks i h TECH SNOP Quick Test For Water in Methanol Most engine builders know that methanol absorbs water from the day you break the seal But racers don t usu ally carry a specific gravity gauge to the track H ere s what you may wish to tell your customers O nce the motor isup to full temperat
24. ee spoke design M odels affected include the 2004 2005 Cadillac CTS and SR X and 2005 Cadillac STS with 3 6L engine VIN 7 RPO LY 7 and without heavy duty cooling R PO V O3tV 92 Other complaints of a faint engine whine type noise have been reported at speeds of 0 30 mph 0 48 km h at 1 000 2 500 rpm and may be caused by the primary camshaft drive chain T his type of noise may be amplified by the vehicle s body structure Some installers customers may com ment on a whine whistle or ringing type noise from the front of the engine that increases in intensity as engine rpm increases This noise is most audible standing in front of the vehicle with the hood opened If the noise fades into the ambient engine noise by 2 000 rpm the harmonic balancer may be the culprit R efer to Figure 5 and inspect the Figure 5 R to the above graphic illus tration and inspec the harmonic balancer for design type A fter the inspec tion if the vehide was built with three spoke 1 design aankshaft harmonic bal ance replace the harmonic balancer with p n 12597654 GENERAL Figure 6 efer to the above graphic illus tration and if the vehide was built with the NEW DESIGN six spoke 1 cankshaft harmonic balancer DO NOT replace it C ontinue on with routine diagnosis to iso late the noise crankshaft harmonic balancer to deter mine the design type If the vehicle was built with a three spoke desgn crank
25. er all new FW D block in 03 that incorporat ed several more changes but the most noticeable one was the change in the location of the hole for the crank sensor it was moved from the front of the block TECH SOLUTIONS guide HRYSUE on the passenger side to the back of the block on the driver s sde in order to accommodate the new bolt on target ring for the crank sensor There were some other changes made to accommodate the turbo motor too including a boss on the pas senger side that can be drilled for the oil return from the turbo and an additional oil galley inside the block that s machined for the four oil squirters that are used to help cool the pistons on the turbo motors Look for a 4781632AA AB casting 2008 2004 RWD Chryser installed the 2 4L motor in both the RWD Jeep Wrangler and Liberty beginning in 2003 T he RWD block is a unique casting 53010502A A that doesn t have the ear that sticks out from the front of the block down by the pan rail on the passenger side of the FWD blocks These blocks have RW D cas on the passenger side so they re easy to spot T he C atch 22 is that this block was used for both the W rangler and Liberty in 03 but only for the W rangler in 04 because the W rangler platform contin ued to use the old style computer and crankshaft without N GC through 04 even though the Liberty got the NGC computer along with a new block and crank in 04 2004 20
26. es W hile the oil is being transferred from the pre lube tank to the engine rotate the engine 360 degrees O nce the oil is transferred to the engine you will hear a gurgling sound from the tank T he engine is now primed ALLSTAR md i d gi dio rd Chevy Cylinder Head Bolt Kit HOP TIP Vacuum Check That Engine With the advent of foreign castings some less than stellar it is important to be more critical than before during inspection One engine builder uses a large vacuum pump to vacuum check every engine s water jacket before it leaves his shop His pump pulls around 22 inches of vacuum W hen it reaches that point he closes the valve to check for leaks Some engine builders have found a Figure3h eam to one half the distance of the dowel then do the same with the caps Be sure to sink the holes at least 015 to keep from bottoming the dowels into the cap Original equipment Grade 8 fasteners with sealant on the threads Part No ALLB7000 SB Chevy 283 400 34 Pa i c These head bolts are ideal for stock or budget performance rebuilds ER Cirde 124 for more information 24 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 5 holes in them after they were torqued down AIl of these heads were aluminum SB Chevy heads and were made over seas T hese heads were good prior to proper installation One a few occasions brand new water pumps have been found to have
27. etitive hone heads which can cause taper problems Also Sunnen stones are radius ground so they can be used right aut of the box without being tued amp The standard SV O cradle fixture handles all automotive and most diesel applications without special fixturing The facts tell the story the 5Y 10 cylinder hone fs the logical choice For more information visit tunnan com or contact your Sunnen representative at 800 325 3670 SUNNEN PIPELIFE A Cirde 125 on Reader Service Card for more information DO YOU MAKE TOO MANY STOPS FOR ENGINE AND PERFORMANCE PARTS ENGINE amp PERFORMANCE WAREHOUSE is your easy one stop source for engine e kits and components you need with the pricing support and programs you lave Largest engine and performance parts inventory in North America Over 100 of the brands you trust Competitive prices and best order fill rate in the industry Broadest coverage in engine kits and reman crankshalts Unlimited upgrade options for EPWI Engine Kits Same day prepaid ground shipping and same day pickup at any of our 12 warehouses Easy online ordering Check inventory in real time your cost and street price Place orders 24 7 Ask about our papular pi granis Expert Technical and Special Order Assistante E conem including the Nationwide Partsfinder Program E Rewards Progra llet Freight Programs PERFORMANCE WAREHOUSE Epiri
28. formation e mail ed epj inc com Circle 109 for more information www enginebuildermag com ENGINE BUILDER 9 GENERAL MOTORS 1 m BF h k Figure 8 he aluminum 4 6L Cadillac block may aac outside the cast iron cylinder liner and is extremely hard to detec T he above became visible only after the deck face was machined ER numerous hours on cylinder head bolt repairs y came The second tip involves cylinder head c n 3533989 2228 AE eu i and 12554607 which would be the left head or front in f T m OR FW thetransverse mount engine that has an alternator brack M Po et bolted onto it in some applications This head will To FSW always have the bosses for this mounting bracket but both 3 ae 4 of them may or may not be drilled see Figure 9 Figre9T cylinder head on the top has the bolt holes drilled and tapped If you want to avoid problems recommend that you for the alternator bracket when used T he head below does not but both have drill all of the bosses thereby eliminating the possibility casting number To avoid potential warranty issues drill and tap all of having a warranty problem upon installation and also reducing head proliferation By Roy Berndt GM Belt Tensioner Failure May Cause Supercharger Failure All GM vehicles equipped with super chargers m
29. hat is being removed When all the exhaust valves have been rotated 90 and all the exhaust valve spring retainer locks have been replaced proceed to the next step 16 Install the rocker arm and shaft assembly 17 Install the cylinder head cover s 18 Install the upper intake manifold MAP Sensor Inspection 1 Inspect the M AP sensor Figure 4 for LX modelsor CS models If the M AP sensor is the new style no further action is necessary for the MAP sensor If the MAP sensor is the old style proceed to the next step 2 R eplace the M AP sensor with p n 05033310AC for LX models or p n 04896003A B for CS models If the vehi cle isa C S model be sure the new sensor opening is facing a downward direction when installed and only use one fastener FronALLDATA Keeping Your Balance With 3 7L Chryslers W hile an optimally balanced V6 engine would have either 60 or 120 degree angles between the two banks of cylinders many current V6 engines are derived from 90 degree angle V8 engines W hile this con figuration gives evenly spaced firing order in an 8 cylinder engine a 6 cylin der engine develops a loping rhythm D uring each rotation of the crankshaft three of the cylinders fire at 90 degree intervals followed by a gap of 90 degrees Figure 5T he arde shows where the roll pin arrow and spline gear should be aligned for proper timing of the balance shaft on the 3 7L T his assembly has spun on the center shaft
30. ictor Renz and the Victor Heinz trademark are property of Dana Limited and used under licensa fo MAHLE Clevite Inc Cirde 122 for more information PERFORMANCE located in the throttle body expressly for this purpose T his check valve is desgned to be normally open but will quickly seat to close off the internal vacuum passage when a backfire occurs O nce closed the check valve interrupts the pressure wave caused by the backfire thus protecting the power valve If you have a carburetor older than 1992 or you have experienced an extreme backfire and expect a blown power valve use this ample test At idle turn the idle mixture screws found on the sde of the metering block all the way in If the engine dies the power valve is not blown From H olley Performance Tips For Selecting The Proper Circle Track Cam An engine builder is only as good as his customer s information and if your circle track customer doesn t give you the nec essary answers he may not be pleased with the cam you choose T his isn t always the builder s fault but is often followed by the racer selling the cam to another racer who thinks it s the best cam he ever ran W hy did this cam work so well for one racer and not for another The reasons can be many T he following are some tips for selecting the proper cam for circle track applications Longer duration cams require tighter lobe separation to have any power off the corner not usually a
31. iming camshaft driven oil pumps T hese pumps are typically referred to as wet sump pumps since they sit low in the engine oil pan and are partially sub merged in the engine oil To prime first submerge the inlet of the oil pump in clean oil and rotate the drive shaft in the correct direction If it does not pump change direction of shaft rotation until oil flows from the pump outlet Drain excess oil from the pump and install it on the engine Fill the oil filter and install it then fill the engine with oil Install the correct priming tool which can be a modified T 1 ae al ie sie tiene One piece forging with wafer tip Fala ac Frill erui ej ce eur dm TUNY Urndercut stem Is FIERET UE TM eere WIT DONS Teg Or Improved T P IFTE 3 I m rpm TICVY Edi Gier rato aj T ARID eium PPP OA a dad emi VIDE _ ind 0 distributor drive shaft into the engine and engage the oil pump drive shaft Attach a 1 2 electric drill to the exposed end of the priming tool and spin the oil pump at a minimum of 500 rpm Continue to spin the oil pump until oil reaches the rocker arms It isa good idea to rotate the crankshaft 360 degrees while spinning the oil pump i T E k m d E Figure 2A ttach a drill to the end of a priming tool and spin oil pump at a mini mum of 500 rpm until oil reaches rockers NITRO Black Racing Valves amp Piston Rings vear exteras n
32. in for timing to the crank two sprock et type chains for the two camshafts and a spline type gear for the balance shaft all installed smultaneougy T he spline gear drives that balance shaft and the two sprocket gears drive the tim ing chains O n the spline gear 9 of the gear cluster there is a roll pin that locates the index of the gear N umerous examples have been cited where the spline gear has shifted and the roll pin sheared It is not always easy to see but if you look closely at Figure 5 you will see that the roll pin has been diced in half and is now out of time and will cause a vibration rather than a counter measure to vibration Be aware of this stuation because it can be easly missed especially when the gear cluster appears to be perfect in every other way TSG 15 TECH SOLUTIONS 44 Diagnosing VW 16V Cylinder Head Ticking Noise at 2 000 RPM Dimensional differences between the camshaft sprockets and the cam timing chain create a rattling noise that can be heard from the cylinder head at approximately 2 000 rom Figure 1 This bulletin refers to all MY Volkswagen 16 valve engines As of 11 88 starting withVIN 067 722 amanufacturing tolerance change has been made to the camshaft sorockets If a customer complains because of persistent noise replace both camshafts with the following Intake cam p n 027 109 021A Exhaust cam p n 027 109 022 F Figure 1D imensional differences between the ca
33. ing ra E i rU 1 T ed 4 r T es o T TA 1 re Ee m WRG Wack nng faces ON ras are coated with ceramic PVD for high m HM ur di ur r TN y B ik TTE natal scuff and heat resistance amp the NITRO D pde as MEE Ls a RR RM Black second ri LL a Napier design for Alu zi p T R RR a By opti iim durabil ny rere perm E candi ions Circle 123 for more information www enginebuildermag com ENGINE BUILDER 23 5 during priming The oil pump and engine are now primed Priming crankshaft driven oil pumps T histype of oil pump cannot be turned with a priming tool so we recommend using the Melling MPL 101 pressure priming tank or a similar pre lube tank to prime the engine with oil before ini tial startup Before assembling the oil pump to the engine pour a small amount of engine oil into the oil pump and rotate the rotor set by hand to allow the oil to coat the internal surfaces of the pump and rotor O nce the engine isfully assembled fill the oil filter with oil and install it Attach the pre lube tank to the oil pressure port on the engine N ow fill the pre lube tank with up to four quarts of engine oil and close the valve on the top of the tank Pressurize the pre lube tank with shop air and slowly open the valve on the tank which will release the oil and send it into the engine oil galleri
34. lance haft appear to have changed in Augus of 2003 for vans and Augus of 2004 in the truck The driven gear on the balance shaft ALLSTAR New 2 piece engine stand is Xi designed for convenience and dependable service Features e Heavy duty construction using 1 x 2 steel box tubing e No assembly required Designed to clear most over sized ail pans e Includes six 3 8 x 1 grade 5 bolts Accepts Allstar wheel kits with 3 8 studs Powder coated black for corrosion protection Available At Allstar D Hi J Li SB Chevy 2 Piece Engine Stand PERFORMANCE 10157 lers Worldwide Cirde 104 for more information 4 ENGINE BUILDERS TECH SOLUTIONS GUIDE February 2012 Figure 3 ts easy to confuse the two gears but putting the wrong driven gear into a F ord engine will cause real problems changed from 31 to 38 teeth and as you can see in the illustrations Figures 2 3 it would not be hard to confuse the two The change in teeth was to further reduce the N VH of the gearsthat drive the balance shaft bvioudy a mix up would result in a catastrophic failure owever what have found is that as long as you keep the camshaft drive gear and balance shaft gear matched it makes no difference which ones you use By Roy Berndt Cil Leak Repair for 1990 1993 4 0L Ford V6 Engines The 4 0L Ford V6 used in the Aerostar Explorer and R anger pickups has been
35. leaking seals at the weep holes Air is much less dense than water so any small leaks are easy to find With a vacuum pump you can check all freeze plugs gal ley plugs intake and head gaskets for sealing and block and head castings For atest one engine builder drilled a 006 hole in a freeze plug it failed miserably He says he even used the pump as a reverse pressure tester on cylinder heads where he couldn t find an external leak but knew the head was bad H e says it s sort of a second opin ion that confirmed his suspicions How to Keep Chevrolet 4 Bolt Mains From Walking All four bolt snall block Chevy main caps walk when used with either studs or bolts T he factory cap or a splayed cap relies on the register to locate itself because bolts and studs don t fit well enough to keep the cap from walking What one engine builder does when work ing with a stock block is to elim inate cap walk altogether H ere is how to do it Place 7 16 x 1 2 dowels as used in aftermarket connecting rods in the outer bolt holes Since the O D of the dowel is 1 2 it is easy to locate the proper reamer No drilling is necessary Set the block up and indicate hole locations T he bolt holes are already recessed R eam to one half the distance of the dowel and then do the same with the caps Be sure to sink the holes at least 015 to keep from bottoming the dowels into the cap Figure 3 This also leaves room for
36. line honing Done correctly the line hone should not change The block that was used pictured required line honing anyway for the proper tolerance TSG ENT ES AROUND THE CO Here s why engine builders world wide have made Sunnen s SV 10 the top choice tor faster easier and more precise cylinder honing e The 5 10 has the most powerful spindle motor 3 in the industry a full 50 more power Than the competition PLC controlled variable speed indepen dent spindle and stroke drives allow you to achieve virtually any desired crosshatch angle much easier and more consisvently than with competitive air hydraulic stroking systems Sif atoni Cylinder amp The SV I0 s advanced Siemens touch screen controller displays a real time image of the bore cross section during honing allowing the operator to easily see and eliminate tight spots in the bore This is superior to competitive models chat use antiquited meters or flashing lights to direct the operator The conveniently mounted PLC control on the SIU allows adjustments to be made safely even while rhe machine is in operation unlike competitive models where the operator must reach around moving components amp The 10 can handle bore diameters from 75 to 8 inches much wider range than competitive units sunnen s innovative DH Diamond Hone Head centers the stones so they do not need ro be reversed as with comp
37. mshaft sprockets and the cam timing chain may create a rattling noise on some Volkswagen 16 valve engines that can be heard from the cylinder head at approximate ly 2 000 rpm 1996 Audi 2 8L V6 Rear Crankshaft Seal Leaks After Replacement O il may leak from the rear crankshaft seal after seal replacement due to the seal lip rolling while installing the new seal Figure 2 This condition affects 1996 A4 with 2 8L V6 engine code AFC W hen replacing the seal the new seal is supplied pre installed in the flange e Seal Flange P N 078 103 171H Flange gasket p n 078 103 181 must be ordered separately Caution Part numbers are for ref erence only 1 Carefully remove installation py 4 1 8 1 50 44 HH 158 Lt amp 4 A0 922 108 154 11 6 4 8 0 FI Ham kg m Fb Figure3A tiking noise may be heard from cacked exhaust manifold on certain N issan engines Typically inspedion for raks between the 1 and 3 ports should be conduded tool that comes with seal and apply a small amount of engine oil to the inner lip of the seal N ote Lubricating the seal lip will ease seal installation and reduce the tendency of the seal to roll as it is being installed 2 Carefully reinstall the seal instal lation tool 3 Install oil seal and flange with new gasket 4 Torque reusable flange bolts to 7 ft lbs ION m 1999 2001 Exhaust Manifolds Cracked in Nissan V
38. n www enginebuildermag com ENGINE BUILDER 5 TECH SOLUTIONS pute Deciphering The Differences In The Chevy 2 2L Engine The very popular Chevrolet 2 2L four cylinder engine has been a solid steed in GM s FWD RWD stable But even after all these years it still manages to raise questions surrounding the Gen FWD THRU 97 Figre1The FWD 2 2L engine left requires the use of a soft plug in the front of the head T he RW D mode is open and must have the bolt holes drilled and Figre27 heGM 2 2L quem head in use sine 1999 mm flat bosses between the exhaust ports top T he latest exhaust manifolds havea balance cdhannd that runs between ports 1 2 and 3 4 engine casting configurations in par ticular the cylinder head Since its birth in 1990 when the old C hevy 2 0L engine was upgraded with a stroke increased from 3 15 to 3 46 the 2 2L 134CID OHV four cylinder engine powerplant has been upgraded several times the block has been revised four times and the head has been changed three times it was discontinued after 2003 replaced by the 2 2L Ecotec Let s start in 1994 and see if we cant clear up some of the confusion In 1994 the 2 2L Chevrolet became the base engine in the S series truck line replacing the 2 5L Pontiac engines T his RWD ALL FWD FROM 98 presents us with the 2 2L now being both FW D and RW D which you would think would mean numerous differences Actually that s n
39. neered and durable cylinder heads in the industry We invest heavily in equipment and training so we continue to meet the exacting standards of ISO compliance and OE Quality Certifications a level of excellence rarely achieved in the industry We re here for you today we ll be here for you tomorrow and beyond Our commitment to The Future is complemented by our Quality and Service in providing the finest in remanufactured cylinder heads Buy American For information e mail ed epj inc com Cirde 118 for more information 18 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 engine could experience detonation pre ignition or power loss M ost spark plug manufacturers recommend that the tip temperature remain between 900 F 500 C and 1 500 F 850 Heat ranges are desgnated by each spark plug manufacturer with a number In broad terms spark plugs are often referred to as hot plugs or cold plugs A cold plug has a shorter insula tor nose length the distance from tip to spark plug shell and transfers heat rapidly from its firing tip to the cylinder head water jacket Cold plugs are ideal for high rpm engines forced induction applications and other insances where the engine produces high operating temperatures Conversely hot plugs are good for appli cations that operate mainly at low roms Because they have a longer insulator nose length heat is transferred from the firing tip to the cooling system at dow
40. o grip the shaft so grooving is bad for maintaining an oil film T he primary reason for hav ing any grooving in a main bearing isto provide oil to the connecting rods W ithout rod bearings to feed a simple oil hole would be sufficient to lubricate a main bearing Many early engines used full grooved bearings and some even used multiple grooves Those choices were based on what engineers knew at the time As engine and bearing technology developed the negative effect of groov ing was recognized and bearing groov ing was removed from modern lower main bearings T he result is in a thicker film of oil for the shaft to ride on T his provides a greater safety margin and improved bearing life U pper main shells which see lower loads than the lowers and hence don t apply the same load to the oil film have retained a groove to supply the connecting rods With oil In an effort to develop the best pos sble main bearing designs for high per formance engines manufacturers have investigated the effects of main bearing grooving on bearing performance T he graph Figure 2 illustrates that a sim ple 180 groove in the upper main shell is still the best overall design While a sightly shorter groove of PERFORMANCE 140 provides a marginal gain most of the benefit is to the upper shell which doesn t need improvement On the other hand extending the groove into the lower half even as little as 20 at each parting line 220 in
41. ock V 6 engines produced con tinuousy by Ford in Cologne Germany gnce 1968 It uses a jackshaft in place of a camshaft to drive a timing chain to each cylinder head The patented O ffset Y drive see Figure 6 uses three timing chains one from the crank to the jacksnaft one in the front of the engine to drive the cam for the left bank and one on the back of the engine to drive the cam for the Figure 5 he oil pan was redesigned in 1994 and so was the gasket T he wedge seal is no longer used because its shape is built into the gas ket Silicone is still necessary across the main cap and in the cavities between the cap and the bloc FORD right bank The noise is audible during hot and cold engine operation but predominantly found on cold engines under tion typically at 2 400 2 500 rpm To con firm presence of this noise accelerate in 2nd gear between 2 000 3 000 rpm and listen for rattle noise that sounds similar to spark knock T his may be caused by the primary timing chain tensoner system R eplace the primary timing chain ten sioner chain guide jacksnaft and crank shaft rockets with a primary timing chain tensoner kit The kit includes an improved primary chain Ttensoner as well as updated primary chain guide jack shaft and crankshaft sprockets R equired fasteners primary timing chain and front cover gaskets are also included Use kit 2U3Z 6D256 AA balance shaft engines for
42. ot so GM used two dif ferent head gaskets through 1997 and in 1998 went to a common head gasket for both FWD and RW D U sing the incor rect head gasket will result in almost immedi ate overheating The castings made changes in those years but they fol lowed suit in both FW D and RWD configura tions In 1994 the valve stem diameter went from 8 mm to 7 mm as well as going to a roller lifter and assembled camshaft The FWD version requires the use of a 34 4 mm soft plug in front of the head while the RWD model is open and must have the bolt holes drilled and tapped see Figure 1 The 1994 motor could have casting number 10112391 or 101123915 that is the service replacement T his same pattern was followed throughout the 1997 production cycle In 1998 a new cylinder head c n 24575507 arrived with a heart shaped combustion chamber against a D shape The engine also had smaller 1 1 8 diameter exhaust ports vs 1 3 8 and a triangular top of the intake ports vs a smaller eyebrow top T his verson of the GM 2 2L engine a single year config uration must have an open and drilled EGR port Since 1999 to present the same cylinder head c n 24576146 has been used It is basically the same as c n 24575507 except for crucial long flat bosses that are now between the first 6 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 two and last two exhaust ports see Figure 2 T he latest exhaust manifolds have
43. over 90 degrees www enginebuildermag com ENGINE BUILDER with no power pulse M uch of this issue was eliminated by the use of the split jour nal crankshaft Recently many manufacturers have found it wise to adapt the balance shaft concept as well using a sngle shaft with counterweights spaced so as to provide a vibration which cancels out the snake inherent in the 90 degreeV 6 If you buy a new vehicle today you mos likely have an engine with a balance shaft O ne of thoseV 6 enginesthat incorpo rate the single balance shaft technology is the 3 7L Chryser engine that utilizes the split journal crankshaft T he single balance shaft goes down the center of the block in an area that you may have thought the camshaft would reside Since the 3 7L isa SOHC engine it was a perfect spot to drop the single balance shaft unit W hat would happen if you put a bal ance shaft into the engine out of time It would jus exacerbate the problem and the result would be a shaker instead of a smoothie Imagine if you did time it cor rectly but you were actually duped into thinking that you were in time U nfortunately that is exactly what hap pens if certain components dont live up to expectations The 3 7L engine has a gear cluster in the center of the engine that drives not only the balance shaft but the two timing chains as well And many say it is a brave man who takes on timing these engines there are four chains one M orse type cha
44. ower valve to use A competition or race engine which has a long duration high overlap camsnaft will have low manifold vacuum at idle speeds If the vehicle has a manual trans misson take the vacuum reading with the engine thoroughly warmed up and at idle If the vehicle is equipped with an automatic transmisson take the vacuum reading with the engine thoroughly warmed up and idling in gear In either case the power valve selected should be half the intake manifold vacuum reading taken ALLSTAR PERFORMANCE th cee oro e E Of mmm aa Figure 3 Holley carbs use operated power enrichment system and a sdection of power valves is avail able to time this system s operation to your spedfic needs EXAMPLE 13 Hg vacuum reading divided by 2 6 5 power valve If your reading divided by 2 lands on an even number you should select the next lowest power valve EXAMPLE 8 Hg vacuum reading divided by 2 4 power valve Since there isno 4 power valve you should use a 3 5 M ost of H olley s Street Legal and Street Performance carburetors incor porate a power valve blow out protec tion system A special check valve is spring brass seat and check ball the check ball sytem is 100 effective protecting the power valve diaphragm from damage due to engine backfire The power valve check ball isdesgned to be normally open but quickly seals to close off the internal vacuum
45. passage when a backfire occurs Once closed the check valve interrupts the pressure wave generated by the backfire thus protecting the power valve diaphragm This prevents the power valve s diaphragm from rupturing due to an engine backfire according to the company Holley carburetors utilize a long x 1 1 2 wide to The holder safely supports piston and connecting rod assem blies during teardowns and assembly The holder slots are 4 3 4 ea accommodate most combina tions Holder measures 24 x 12 x 9 1 2 and can be disassembled for storage Available At Allstar Dealers Worldwid 3 LE Se uL d IY Cirde 121 for more information www enginebuildermag com ENGINEBUILDER 21 VICTOR REINZ Sealing Pradvets VICTOR REINZ GASKETS Victor Reinz the leader in gasket design and manufac turing was the first to intro duce a replacement head gasket in 1910 Today Victor Reinz works with practically avery engine manufacturer producing engines across the globe offering a com plete line of sealing products with over 9 000 part numbers featuring early and late model engine coverage Victor Reinz not only cuts gaskets but designs total system sealing solutions uti lizing application engineering to provide the optimum ma terial and technology for spe cific applications For more information visit www rmahle aftermarket com V
46. preferable combination in 2 bbl classes Shorter duration cams with wider lobe separa tions usual yield much flatter torque curves Longer rod engines seem to pre fer shorter durations and wider lobe sep aration Figure 4 e Stock exhaust manifolds or a highly restricted exhausts usually respond well to shorter exhaust duration and wider lobe separation Power increases are most evi dent at higher rpm where exhaust back pressure is greatest and reverson is mos prevalent e Mos unported heads approach 85 or 95 96 of peak flow at 400 to 450 lift and do not need or want a maximum valve lift over 540 10 555 O ften a low cam lift with 1 65 or 1 7 ratio rockers is very helpful on the intake side as long as lift is kept to about 550 Exhaust is less critical with 1 5 or 1 55 being the mos popular Dyno testing doesn t test dri 22 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 n Figure4 Longer rod engines seem to prefer shorter durations and wider lobe separation vability or throttle response of the engine e T he important numbers on a sheet are about a thousand R PM above and below peak torque and peak horse power Peek numbers are for bragging purposes and high peak numbers do not Win races T he benefit of high ratio rockers is faster valve movement and the added lift is frequently detrimental in unported heads It often helps to utilize a lower cam lift with high ratio rockers Changing th
47. r cylinder pressure and temperature O nce again you ll need a colder heat range to rapidly transfer all that extra heat to the cooling system Air fuel mixture modifications Lean air fuel mixtures raise the operat ing temperature along with the plug tip temperature possbly causng knock or pre ignition U se a colder heat range for leaner air fuel mixtures Rich air fuel mixtures can cause the plug temperature to dip allowing carbon deposits to build up on the tip U se a hotter heat range for rich air fuel mixtures Advanced ignition timing In Sunnen SV 10 general advanced ignition timing will raise the spark plug temperature In fact NGK estimates an increase of 70 to 100 for every 10 advance in ignition timing For this reason you may need to go with a colder heat range to prevent knock or pre ignition Prolonged acceleration high speed driving Frequent and drawn Percent Change in Minimum Oil Film Thickness a ua 160 Degree Grooving wm Pru Ei Percent Change in Mi OI Film Thickress Bearing Grooving Degrees Figure 2A s engine and bearing technology developed the bearing grooving was removed from modern lower main bearings deating a thicker oil film C ylinder Hone Sunnen s SV 10 Cylinder Hone combines the latest technology with the consistency and dependability of the legendary Sunnen Cylinder King The SV 10 comes standard with two time and money savers
48. r clip If the replacement timing chain does not have timing marks for aligning with the cam gears you ll have to mark the left and right sde chains Start with the left chain and mark one link as the starting crankshaft timing mark Then count 29 links and make a second mark for the exhaust cam Continue counting to link number 42 and make athird mark for the inteke cam T he second and third marks should align with the timing markson the intake and exhaust cams when the chain is dipped into place T he chain tensoner and arm can now be installed N ext you do the same procedure for the right cam But first you need to rotate the crankshaft 120 clockwise so the crankshaft keyway is at the 3 o clock pos tion Mark the right timing chain and install it the same as before O nce both chains are in place remove the locking pin or paper clip from the left and right chain R otate the crankshaft 120 counter clockwise so the keyway is back at the 11 o clock postion and number one piston is at T DC Check to make sure dl the tim ing marks are aligned as shown in the illustration Figure 1 There should be 12 chain links between the right and left intake and exhaust cam sprocket marks 27 chain QUALITY ISO Compliance We are ISO compliant E Certification We are TS16949 certified Experience We have been remanufacturing cylinder heads for 40 years SERVICE e Product R
49. riodic inspection of the belt ten en SUNNEN Circle 110 for more information 10 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 1995 2005 Chrysler 2 4L Cylinder Block Casting Identification Chryser replaced its old SOHC four cylinders with an all new family of SOHC and DOHC engines in 1995 Figure 1T he hole for the oil sender on the passenger side of the 2 4L was moved back about 6 in 2001 so it s much doser to the bell housing There were 2 0L SOHC and DOHC versons along with a 2 4L DOHC that was installed in the FW D cars and mini vans Over the years this engine has been used in several other applications including the PT Cruiser the RWD Liberty and Wrangler and the SRT 4 N eon It has evolved over the years too so there are seven short blocks that use six block castings So let s take a look and see if we can make some sense out of all the changesto the blocks 1995 2000 T he original casting was a 4621443 block that had a 4621445 bedplate It was used up through 2000 2001 T he hole for the oil pressure sender on the passenger side was moved back about 6 in 2001 so it was much closer to the bell housing It s a 4621443AB casting 2002 T he oil drainback hole in the head was enlarged in 02 so there was another bulge added to the block on the driver s side between the third and fourth cylinders It s an all new casting that has 4781655AA on the driver s side 2008 2006 There was anoth
50. rted some vehicles may exhibit aloud tick ing noise from the variable valve tim ing VVT T his is caused by the lock pin of the variable valve timing actua tor not fully engaging Heat treatment has now been added around the hole of the variable valve timing rotor lock pin to prevent this from happening Customers having this concern should have their vehicle repaired using the following repair procedure R epair 1 Verify variable valve timing noise 2 After the engine cools down replace the variable valve timing actu ator NOTE Do not use the printed service manual as the procedure has been updated online Figure6 ocation of the variable valve aduator for the Mazda M ZR engine 3 Change the engine oil 5W 30 only then start and let the engine idle for 5 minutes T his is to remove con taminants from the engine 4 M ake sure there is no fuel leak age around the high pressure fuel pump 5 After the engine cools down change the engine oil 5W 30 again and the filter 6 Verify repair NOTE This repair calls for the oil to be changed two times TSG ENGINE amp PERFORMANCE J WAREHOUSE lubricants DP40 Turbo Diesel 5 W40 DT40 synthetic 5W 40 DT50 synthetic 15W 50 FR20 Ford modular engines HD50 4 stroke motorcyles HVL high viscosity lube for assembly 4 stroke karts LS30 LS engines MR50 marine 15W 50 MX1 wet clutch rmotorcycle amp XP9 0W 10 amp XP10
51. ry with excellent fill rate Excellent inventory availability A comprehensive line of quality products Reasonable competitive prices Apex gaskets cover domestic Japanese Korean and popular European automobile engine gaskets and seals and are manufactured to meet or exceed OEM specifications and industry standards Satisfaction is guaranteed on all Apex automotive products Apex Automobile Parts Inc 2602 Loma Ave South El Monte CA 91733 1 8 6668 APEX www apexauto com Circle 113 on Reader Service Card for more information CLEVITE ENGINE BEARINGS Since our development of the first precision insert type bearing in 1929 Clevite engine bearings have set the pace for engineering quality Built above industry stan dards for strength and dura bility the majority of Clevite engine bearings employ a TriMetal design first devel aped by Clevite over 50 years ago Combined with BiMetal and Tri rmor performance bearings Clev ite offers the most extensive line of engine bearings in the market and is used more often than any other bearing in cars worldwide Clevite engine bearings have also been in the engine of every NASCAR Champion since 1948 proving Clevite to the leader in engine bearing technology both on and off the track For more informa tion visit www mahle aftermarket com Circle 114 for more information 14 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2012 CHRYSLER and fo
52. show ing up with oversize cam bearing bores that appear to have been caused by spun cam bearings If a new cam bearing is installed in a bore that has been damaged it will spin in the block cut off the oil to the cam and cause an immediate failure Figure 4 Inspect the cam boresin all of the late 3 1L castings 10137093 10191737 24504089 24504150 10224227 very carefully paying special attention to the 2 bore that seems to be the most prone to failure If the cam bore is oversize there are only two choices 1 You can either knurl the O D of the cam bearing to get enough press fit or 2 you can junk the block By DougA nderson Figure 4 5 of the later roller cam 3 1L C hevy blocks have oversize cam bearing bores that may have been caused by spun cam bear ings Inspection will reveal if you can repair the damage or junk the blok Noise Complaints with 2004 2005 3 6L Cadillac Engines If a whine ringing or whistling noise is reported in several 3 6L Cadillac engines replacement of the crankshaft harmonic balancer is recommended if Figue3G 2 3L Quad 4T iming C hain Tensioner A ssembly T his is the late produc tion piece although early produdion is simi lar C omponents indude Plunger assem bly B Long end C Peg D N ylon Plug E Spring F estraint cylinder J 36589 nti release device Tensioner body noise isisolated to the front of engine and balancer is thr
53. st manifolds R emove any debris that is found In cases where engine failures occurred as a result of severe overheat ing installers should inspect each cat alytic converter for signs of melting or cracking of the ceramic brick If dam age is observed the converter should be replaced Cadillac 4 6L DOHC Aluminum Cylinder Head and Block Crack Cautions Cadillac 4 6 DOHC engines may be prone to cracking of the aluminum block casing around the cas iron liner MOIORS Figue7C ertain late model G eneral M otors vehides may be equipped with a new style of catalytic converter technically known as the dose coupled catalytic converter Engine fail ures can damage the converters which if not inspeded properly can then cause subsequent damage to a replacement engine Figure 8 Knowing that this possbili ty exists make a close examination of the deck prior to doing any machining at all and before you then spend QUALITY Look to American Cylinder Head for quality built on a her itage of nearly a half century of experience Continual improvement in our processes have allowed us to achieve ISO compliance as well as receiving the coveted 5 16949 OE certification assuring you of the most reliable and pre cisely remanufactured cylinder heads in the industry Our Quality is complemented by our Service and commitment to The Future in providing the finest in remanufactured cylinder heads Buy American For in
54. total takes away from upper bearing performance without providing any benefit to the lower half It s also interesting to note that as groove length increases so does horsepower loss and peak oil film pres sure which istransmitted directly to the bearing N otes You will still find some full grooved main sets offered for older engines where demand is low and the engineering cost to bring the sets to current standards is not warranted bearings generally represent the tech nology of the time the engine was developed From MAHLE Clevite Inc Holley Power Valve Myths T he power enrichment system supplies additional fuel to the main system dur ing heavy load or full power stuations T here still seems to be alot of mixon ception about H olley carbure tors blowing power valves According to the manufacturer this should be of no concern H olley performance carburetors since 1992 have utilized a power valve check sysem that effectively eliminated this infre quent problem C onssing of a vacuum operated power enrich ment sytem Figure 3 and a selection of power valves is available to time this system s operation to your specific needs Each Holley power valve is stamped with a number to indicate the vacuum Opening point For example the number 65 indicates that the power valve will open when the engine vacuum drops to 6 5 or below An accurate vacuum gauge should be used when determining the correct p
55. ure with the ignition off remove the air cleaner and open the throttle all the way holding it open for about 30 45 seconds With the throttle open take a light and look through the carburetor to the floor of the manifold With the motor being hot the methanol evaporates quickly and if you have water in the fuel you will see drops of water sitting at the bottom of the manifold T his is a quick way to tell how good your methanol is Mark Those Guides When installing more than one valve guide in an OHC cylinder head it s often difficult to see well enough to get the depth correct every time so just lay Figure lits often difficult to see when installing guides in O H C heads M ark with graphite spray for correct depth out all the guides in line side by side then use a piece of tape across all of them at the desred depth to be installed and spray them with a can of graphite R emove the tape and you ll have a line to drive the guide to every time and the graphite helps to prevent galling during installation Cil Pump and Engine Priming A crucial step in any engine build is the priming of the oil pump and the engine lubrication system prior to initial start up Proper priming will help assure a trouble free rebuild T here are two pre ferred methods to prime oil pumps and newly rebuilt engines T he first method listed covers oil pumps driven by the camshaft and the second covers those driven by the crankshaft Pr
56. urth cylinders Multiple Cylinder Misfire or Rough Idle on 2004 06 Chrysler 3 5L Engines T his information for installers applies to Chryser models built after Feb 1 2004 MDH 0201X X equipped with a 3 5L engine This bulletin involves rotating all engine exhaust valves replacing the valve spring retainer locks with a new design to increase valve rotation at lower rpm inspecting replacing the M AP sen sor as necessary and decarbonizing the combustion chamber T he customer may experience occa sonal engine misfire rough running engine during certain vehicle operating conditions In addition MIL illumination may also have occurred due to DTC P0300 M ultiple C ylinder M isfire Various single cylinder misfire D T C s may also be pres ent If the frequency of misfire is high the powertrain control module PCM may place the engine in limp in mode T he misfire condition may be caused by one or more engine exhaust valves that are Sow to close due to a buildup of carbon on the valve stem Diagnosis 1 This condition may occur when the engine is not allowed to run at engine rpms that are greater than 3 500 At 5 000 rpm or higher the engine exhaust valves will rotate if not impeded by high carbon deposts Low engine rpms and high carbon deposits are asso ciated with short trip driving where the engine is not allowed to fully warm to normal engine operating temperatures Cold ambient temperatures will Figure 2
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