8/1/2002
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How should the crankshaft damper be installed in the 1997-'02 GM 5.7L VIN?
Q.How should the crankshaft damper be installed in the 1997-'02 GM 5.7L VIN?
A. AERA’s Technical Commit-tee reminds engine builders that when installing the crankshaft damper for 1997-’02 GM 5.7L VIN G & S engines you must use a NEW crankshaft damper bolt. This bolt includes a special pre-applied sealer that does not allow reuse.
These engines do not have a mark on either the front cover or the crankshaft damper to indicate the correct position for reassembly and the crankshaft does not have a keyway for the damper. Marking the cover and damper for reassembly may prevent possible vibration complaints after the engine is started up as the damper may have been balanced at the factory.
Retain the old crankshaft damper bolt for use during the installation of the damper. Installation involves a four-step tightening process. The first step ensures that the damper is installed completely onto the crankshaft. The third and fourth steps tighten the new bolt to the proper torque. Follow the steps below to correctly install the crankshaft damper.
- If a new damper is installed, install a new balance pin in the same location as the old damper as shown in Figure 1. Properly installed, the balance weight will be either flush or below flush with the face of the damper.
- Using the J 41665 tool, install the crankshaft damper and the used damper bolt. Torque to 240 ft.lbs. (330 Nm) and then remove the bolt.
- Verify that the end of the crankshaft snout is recessed .094˝-.176˝ (2.40 mm - 4.48 mm) into the damper bore as shown in Figure 1. If not, remove the damper using J 41665 and repeat steps 2 and 3.
- Install the NEW crankshaft balancer bolt; do not use any lubricant or sealer.
- Tighten the new crankshaft balancer bolt to 37 ft.lbs. (50 Nm).
- Tighten the new crankshaft balancer bolt an additional 140° by using an electronic torque angle gauge.
Q. What could be causing Ford 1.9L pistons to fail immediately after a rebuild?
A. The AERA Technical Committee offers the following advice regarding 1985-’96 Ford 1.9L VIN J engines. Repeat piston failures have been reported shortly after a remanufactured engine was installed due to debris left inside the intake or exhaust manifold. Metallic debris was not completely eliminated during intake manifold cleaning.
The intake manifold on this engine is a tuned port runner design, with a plenum located below the runners. If a piston shatters, some pieces can end up in the intake plenum or exhaust manifold. If all of those pieces are not removed during cleaning operations, they can be subsequently ingested into the engine after the engine is restarted or during wide-open throttle (WOT) operation.
Unlike other intake manifolds that can be blown out with an air hose to remove foreign objects, thorough cleaning of this intake manifold requires removal from the engine compartment, use of a liquid cleaner, repeated rotating and inverting of the manifold and air blasting until all debris is removed. After removal of all foreign objects in the plenum and port areas, the same procedure should be followed for the exhaust manifold. AERA would like to caution all shop personnel on the importance of eliminating this potential source of contamination, which can cause a catastrophic engine failure.
Q. What’s the correct sequence for tightening the head bolts on a 2001 Hyundai?
A. The AERA Technical Committee offers the following information regarding the correct cylinder head tightening sequence for 2001 Hyundai 2.0L DOHC engines. Some previously published information inadvertently showed incorrect head bolt removal sequence.
To install the head on this engine refer to the following steps and also note Hyundai does not recommend using any head bolt more than once.
- Clean the surfaces of the cylinder block and cylinder head and blow-dry with compressed air.
- Install a new cylinder head gasket; do not use any type of sealer or lubricant.
- Install the head, and install all head bolts and tighten finger tight.
- Tighten all M10 bolts to 22 ft.lbs. (30 Nm) and all M12 bolts to 26 ft.lbs. (35 Nm) in sequence, as shown in Figure 2 .
- Rotate all bolts in sequence 60°.
- Rotate all bolts again in sequence an additional 60°.