6/1/2003
Increased crankshaft journal dimensions for 1995-2002 Kia 1.8L VIN 5 engines.
Engine Builders: The AERA Technical Committee offers the following information on increased crankshaft journal dimensions for 1995-2002 Kia 1.8L VIN 5 engines. The main journal diameter for the crankshaft of this engine was increased beginning with the 1998 model year. Mazda manufactured these engines prior to 1998 while Kia manufactured all subsequent engines.
Use caution when ordering replacement parts including crankshafts and main bearing sets as some catalogs may not list two different part numbers for the different years.
Kia connecting rod and main bearings are available in standard, .010˝ (.25 mm), .020˝ (.50 mm) & .030˝ (.75 mm) undersizes. The specifications in the Kia service manual are not correct and should not be referred to when crankshafts are being ground.
Engine Builders: The AERA Technical Committee offers the following information regarding liner shims for Mack E-6 diesel engines used to correctly adjust the height of the liner in the cylinder block.
Difficulty has been reported obtaining these liner shims. The shims are available in seven sizes to set the cylinder liner height within the acceptable liner-to-liner variation of .002˝. No more than two shims should be used on any liner.
AERA is not aware of a source other than Mack Truck parts for these shims.
Engine Builders: The AERA Technical Committee offers the following information regarding revised cylinder head installation procedures for 1999-2003 Ford 3.0L VIN 1, 2 & U engines.
Ensure that all surfaces of the engine block, cylinder head and gasket are completely free of any solid or liquid contamination. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or an equivalent solvent to prepare the block and head surfaces.
- Place new head gaskets, noting "UP" designation on head gasket face, on the block using the cylinder head to block dowels for alignment. NOTE: Replace dowels if damaged. Position cylinder heads on block over block dowels.
- Install New cylinder head bolts.
- Tighten the New bolts in the sequence (above) to 35-39 ft. lbs (47-53 Nm). Refer to this sequence for each step of the process.
- Loosen all bolts in sequence a full 360° turn.
- Tighten the bolts in sequence to 20-24 ft. lbs (27-33 Nm).
- Rotate all bolts in the numbered sequence an additional 85-95°.
- Rotate all bolts in the numbered sequence an additional 85-95°.
NOTE: Once cylinder head bolts have been tightened, it is not necessary to retighten the bolts after extended engine operation.
Engine Builders: The AERA Technical Committee offers the following information regarding improper function for a new or used EGR valve on GM 1.6L VIN C engines.
With these engines, it is imperative that the exhaust manifold be removed and thoroughly cleaned whenever the EGR valve is found to be sticking open or inoperative. In some cases, cleaning the exhaust manifold may re-establish proper operation and replacement of the EGR valve may not be necessary.
In other cases, the EGR valve may become contaminated because the exhaust manifold was not cleaned, allowing contaminants such as weld slag or drill trailings to remain in the passageway/valve seat of the EGR.
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