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Cylinder Head Crack Repairs

It seems as if many cylinder heads are doomed to crack from the very start because of their lightweight construction and design. Aluminum overhead cam (OHC) heads, in particular, are often found to be warped as well as cracked. But so too are many pushrod cast iron heads. One of the causes of cracking in

PERA’s Core Corner: Getting A Leg Up On The Ford Duratec Cover-Up

No matter how much the engine remanufacturing and building industry changes, one thing will always remain the same. Identifying what type of engine on which you’re working will be an important – and challenging – part of the process. Today the front cover has become such an integral part of application identification that it has

Rebuilding the Ford 3.0L

This engine came out of the Cleveland Engine Plant #2 (CEP2), originally opened in 1955 to manufacture the 361 cid truck engine. By 1985, this facility was down to 400 employees and on the verge of closing. Then in 1988, plant renovation was begun (with the 3.0L Duratec engine family on the drawing board) at

Today’s Machining Centers Offer More Bang for the Buck

More bang for the buck. That’s what many machine shop owners say they’re looking for when considering a major equipment purchase. Because today’s machine shops are fewer in number and often smaller, it’s important for them to have as much capability as possible in every piece of equipment to maximize the return on investment, utilization

Introducing Mark Spaulding, PERA President

Some of the most recognized names in the engine remanufacturing industry have sat atop the Production Engine Remanufacturers Association (PERA) Executive Committee over the past 59 years. Many of these men have had lifetimes of experience and brought storied family histories in the industry to their terms as president of PERA. Mark Spaulding jokes that

Coretalk: Pentagon 9/11 Survivor To Keynote PERA Convention

After American Airlines Flight 77 crashed into the Pentagon, very close to his second floor office, LTC Birdwell was thrown to the ground and engulfed in flames. Of the burns that consumed 60 percent of his body, nearly half were third-degree burns. With more than 30 operations and months of multiple skin grafts and burn

Tech Notes

Engine Builders: The AERA Technical Committee offers the following information on an exhaust noise for 2002-2004 GM 4.2L engines. This noise may be coming from under the vehicle or from the engine compartment. The cause of this noise may be from one or two known sources. The first location that may be causing this type

Shop Line

I’ve had difficulty in locating intake manifold kits for GM 3.8L engines. What gives? The AERA Technical Committee offers the following information regarding a revised upper intake manifold for 1995-2004 GM 3.8L VIN K engines. Engines manufactured for the 2005 model year include the revised gasket. With the recent availability of these new kits (Figure

PERA Core Corner: The Latest Update On The Great Ford 4.6L Cover Up

Back in August of 2004 I provided you with information on the front covers on the 4.6L Ford SOHC V8 engines. The data here is an update to that information with an updated chart to rapidly identify the covers. If you are using the older chart it is time to discard it and use the

Fast Lane: Striving For Perfection In Motorsports Isn’t Enough

To be successful in any business, you must strive to be the best at what you do. However, to be successful in motorsports, you must actually BE the best at what you do. Continued success in the racing industry means that you must continually make your customers winners, and if you do that, then you

Valve Guide and Seat Equipment Options

For many engine builders the bread and butter business is in cylinder head work. In fact, according to our 2005 Machine Shop Market Profile (also available at 41 percent of gas and 54 percent of diesel engine builders’ business comes from servicing cylinder heads. And one of the most important aspects of doing this

Restoration – Yesterday’s Treasures, Tomorrow’s Trophies

There have been tremendous and significant changes in vehicle design since the first gasoline-powered vehicle hit the streets of America back in the early 1890s. Such advancements as fuel injection, radial tires, variable valve train technology, roller cams and front-wheel drive, among many others, have made cars easier to maintain, safer to drive and more

The Final Wrap: At Mid-Ohio School, The Song Remains The Same

Engine Builder reader Rich Tomolonis came up to me the other day, grinning like a schoolboy, and proceeded to vigorously shake my hand. Just when I started thinking he was excited to meet me, I listened a little closer to what he was saying. Yeah, he was excited, but it wasn’t because of me –

Coretalk: Sunnen, RMC Form Strategic Alliance To Market Equipment

This Sunnen/RMC alliance is effective immediately. RMC products will be sold under the Sunnen/RMC brand. Sunnen’s team of field engineers and service specialists will now represent and support the RMC line. “The new Sunnen/RMC branded products complement Sunnen’s existing product line,” said Mike Haughey, Sunnen’s chief operating officer. Ray Meyer, president of RMC, agreed: “The

Shop Line

I’ve had complaints of a strange rattling noise on some 4.0L Rover engines, any ideas? The AERA Technical Committee offers the following information regarding rocker arm noise on 1997-2001 4.0L Rover engines. Customer complaints of a rattling/tapping noise from the engine have been found to originate from the rocker shaft area. The noise may result

Tech Notes

Engine Builders: The AERA Technical Committee offers the following information regarding camshaft identification for 2001-2003 Hyundai 3.0 and 3.5L engines. Previously published service manual information has been called misleading, resulting in incorrect assembly. Each of these engines use four unique camshafts that look the same. Each camshaft for the 3.0L and 3.5L engine is etched

Machine Maintenance, Make the Most of Your Crank Grinder: Maintain It

Your crankshaft grinder probably represents one of the single biggest investments you’ve made for your shop. Most of you purchased your grinder to ensure quality, delivery and to enhance your shop’s ability to be self-sufficient. Hopefully you and your employees are taking good care of this sophisticated and expensive machine. To help you out, here

Common Technologies, Uncommon Fuels, New Challenges

There is a “shade tree law” from the 1970s that states that computing capacity doubles every few years. In fact, computing capacity for the size of the computer or device has outstripped that by several orders of magnitude in the last five years. As evidence of that, we now see cell phones that were only

Coretalk: Recon Automotive Founder Armand J. Mancini Dies

He leaves behind his wife of 42 years, Carole, and three sons and a daughter – Armand, Vincent, Daniel and Carrie Mancini Young. He is also survived by three brothers, a sister and six grandchildren. Mancini was an icon of the automotive remanufacturing industry, having founded Recon in 1973 and building it into one of

Shop Line

The AERA Technical Committee offers the following information regarding the piston oil clearance on 1992-2004 Mitsubishi 4D34 and 6D34 diesel engines. Engine builders have reported occasional piston to cylinder wall scuffing shortly after rebuilding these engines. The engines have failed pistons in multiple cylinders at the skirt’s largest diameter. AERA is aware of at least