DRIVEDRIVE LINELINE

N ews and Updates Fro m Jasper Engines & Transmissions December 2006 In This Issue... JASPER Unveils ‘Authentic Custom Customer Profile: Drivetrain’ Program 3 Man Auto Service pg. 2 Jasper Engines and Transmissions has “With JASPER Authentic Custom launched a new remanufacturing program. Drivetrains, we spend extra time remanu- Chuck Lynch: In addition to its current line, JASPER facturing an engine," Ernst added. "We Authentic Custom Drivetrains will special- give the customer that hands-on, hand- Changes in Valve ize in remanufacturing engines and trans- Seat Machining pg. 3 built treatment that our targeted cus- missions that are currently no longer tomer base is looking for." We Have Our offered, or have been turned away in the In addition, JASPER Authentic Calendar Winners past because they did not fit into a produc- Custom Drivetrains will provide some for 2007! pg. 4 tion remanufacturing system. extras for the enthusiast. "Customers This division is located on the second- can opt to have their engine dynamome- floor of the Jasper, Indiana, remanufactur- ter tested in addition to the live-run test Matt Boehm: ing facility, and is separate from the com- we perform," said Ernst. "And we are Turbocharger pany's first-floor engine division going to provide the customer with docu- Failures pg. 5 operations. mentation of the remanufacturing The goal of JASPER Authentic Custom process. With a login name and pass- Steve Wallace Drivetrains is to cater to a customer base word, they will be able to go to our web- Wins Two More that is doing restoration projects, and is site and check the progress of their ARCA Events pg. 6 looking for something extra when they get engine or transmission daily, and even their engine remanufactured. view the dynamometer report if they 3Rs: Ryan, Racin’ & Rain pg. 7 “If you look at the popularity of televi- have selected that option. They can print sion shows that highlight vehicle restora- the information and archive it for their tion, there's a huge market out there of own records or use it to authenticate people restoring the older model vehicle their unit as they show their vehicle." they have setting in their garage," says At the present time, JASPER Alex Ernst, JASPER Authentic Group Authentic Custom Drivetrains is remanu- Leader. "One type of client that would facturing engines and transmissions, with benefit from our division, for instance, is plans to add differentials in the coming the individual restoring a '69 Corvette that months. is wanting his or her serial numbers to For more information, call 800-827- match, and wants their engine to be hand- 7455 or visit www.jasperengines.com. built by experienced professionals."

Published by: Jasper Engines & Transmissions P.O.Box 650 Jasper, IN 47547-0650 Phone: 1-800-827-7455 Fax: 1-812-634-1820 www.jasperengines.com 2 ProfileCustomer JASPER quality remanufactured products. remanufactured JASPER quality of supporter isagreat 3 ManAutoService e’participationineducational ees’ letins, andpay’s fortheiremploy- company utilizestechnicalbul- cians are ASE Certified.The Each ofthefacility’s fivetechni- sions, suspensionandalignment. specializing inengines,transmis- auto andtruckrepairfacility, square feetofworkingspace. eight servicebaysand4,000 ice bays.Today, 3Man Auto has ness startedsmallwithfourserv- Columbia. Originally, thebusi- 1215 RosewoodDrivein opened 3Man Auto Serviceat service andbacktothecustomer.” the customer, totheparts, the wholejob,”saidMark,“from “We wantedtohaveanimpacton ty tostarttheirownbusiness. red tape,andtooktheopportuni- were tiredofdealingwithallthe The threefriendsdecidedthey dealership inSouthCarolina. years ofexperienceatalocalcar Mike Mosserhadacombined55 area. top JASPERinstallersintheir short yearshasbecomeoneofthe long-time friendswhoinafew joint-ventureofthree Service. A where wefind3Man Auto to Columbia,SouthCarolina, 3 Man Auto isafull-service In August of2004,thetrio Our CustomerProfiletakesus Mark Mills,Tom Warth and 3 ManAutoService remanufactured products. the helpofJASPER quality Service toreachtheirgoal with of opportunityfor3Man Auto business by2008,there isplenty tually doublethesizeof their for us.” And withplanstoeven- tomers meanmoreopportunities grow ourbusiness.Morecus- quality product,buttheyhelpus only doesJASPERprovidea it’s agreatpartnership.Not grow,” saysTom. “We feelthat with JASPER,ithashelpedus ing. “Whileworkingtogether confidence inwhattheyaresell- success comesfromhavingthe deal ofsuccess.Muchthat Service hasexperiencedagreat for acoupleofyears,3Man Auto annually. sions andsixdieselengines age of25engines,20transmis- Man Auto Servicewithanaver- vided that.”JASPERprovides3 Tom added.“JASPER haspro- that Idon’t needawarrantyfor,” I’m moreinterestedinaproduct in theproduct.” says Tom. “We haveconfidence qualityisnot,” other supplier’s that thequalityisthere,while use JASPERbecauseweknow factured products.“We chooseto he talksaboutJASPERremanu- Tom Warth isveryhonestwhen used at3Man Auto Service. each other, andtheircustomers. their businesstobehonestwith relationship thathasallowed play. It’s beenthatlong-term little family, whetheratworkor become somethinglikeatight years, 3Man Auto Servicehas have beentogetherforsomany tive advances. to datewiththelatestautomo- seminars, tohelpthemstayup While onlybeinginbusiness “Warranty isabenefit,but “Honesty” isalsothemotto Because thethreeowners Changes in Valve Seat Machining by Chuck Lynch, JASPER Research & Development

Chuck Lynch has been asso- ciated with JASPER since 1994. Lynch has been a member of the Research & Development department for the past nine years, and has been involved with Associate training in the Gas and Diesel departments. He has earned ASE Certification as an Auto and Truck Technician and a Master Machinist in Gas and Diesel Engines.

Over the years, valve seat machin- JASPER has adopted computer-controlled valve seat machining from Newen to ing has evolved from using vitrified greatly improve the quality of valve seats in today’s remanufactured engines. abrasive wheels to grind seats, form cutters with multiple angles to machine widths and so on can be changed with seat can be near PERFECTLY profiles into seats and most recently a few simple changes in program- ROUND which in turn means a single point machine generated seats. ming. The machine has the capability Perfect Combustion Seal. Newen This latest concept, adopted by of storing hundreds of profiles that states that these cutting pressures/ JASPER, utilizes a CNC (Computer are ready to go with just a couple of efforts are reduced by 300 times. Numerically Controlled) machine that finger taps on the touch screen. With proper clamping and pilot selec- is fitted with a single point cutting tool Timing is improved due to the fact tion, a seat can be generated without that generates a seat based on dimen- that there are no additional cutters to the concern of chatter, ovality or sional parameters that have been estab- buy and wait weeks for. If you don’t inconsistent seat widths. It is hard to lished and saved to the computer’s like the results, simply change the quantify the true importance of good memory. parameters back. No tools wasted or seat geometry because it has bearing These parameters give the tooling a pitched into a drawer to never be used on so many factors and components. road map to follow when generating again and we who machine seats Worn valve guides, burned valves, the seat. With this technology, the seat know that we have some of those excessive seat recession, power loss, can be as simple or as complex as you inserts. and the list goes on…..and on, if the would like. Additional angles, radii, We at JASPER have chosen to use valve and seat do not properly mate. CBN inserts. CBN (Cubic Boron At JASPER, this technology was Nitride) is a super alloy that is widely first used for generating seat profiles used in machining for milling, boring, for the NEXTEL Cup Engines. The turning, and the list goes on. By next logical target was the very close choosing this insert, coupled with the tolerance Asian engine segment. Now technology of fixed turning, even the we are picking other platforms that toughest and hardest materials can be can be difficult to machine. As machined to exacting tolerances with demand for performance and our per- relative ease. The above statements ception of quality increase so must alone are nice… but the real deal is our pursuit of technology. The single-point cutting tool, coupled with the quality of the seat that is generat- the latest CNC technology, allows JASPER to cut simple, or complex, valve seats without ed. With single point tooling, the tool the need for extra cutting blades or tools. pressure is so greatly reduced that the

3 We Have Our Calendar Winners for 2007! The winning photographs have been Don Hayes selected to grace the pages of the 2007 DeSoto, MO Jasper Engines & Transmissions 1964 Impala SS Calendar. Every qualified entrant receives a Doug & Cindy Pierson 1/24th scale diecast #12 auto- McPherson, KS graphed by Ryan Newman. All 1956 Chevrolet Nomad entrants whose work appears in the cal- endar receive a $100 gift certificate Bob & Lois Moore which can be used to purchase JASPER McPherson, KS remanufactured products or wearable 1955 Chevrolet Bel-Air 1965 Shelby Ford Mustang GT350 Fastback owned by Randall Candler of Noblesville, Indiana. items, 24 complimentary calendars and a special JASPER Gift Package. Tim Krahling Congratulations to all our winners! Frederick, MD 1972 Chevrolet Nova Tim Devlin Wichita, KS Garrick Sitzes 1964 Cadillac Sedan DeVille Union, MO 1951 Ford F-1 Truck Don Leonard Mt. Airy, MD Rodney West 1957 Ford Fairlane 500 Mandeville, LA 1957 Ford Thunderbird Keith Hays 1964 Chevrolet Impala SS owned by Don Hayes of Fort Worth, TX Walter S. Chrysler DeSoto, Missouri. 1969 Cale Yarborough Mercury Grand, MI Cyclone 1955 Ford Fairlane Club Sedan

Justin Clapp Randall Candler Whiting, NJ Noblesville, IN 1970 Ford Bronco 1965 Shelby Ford Mustang GT350 Fastback Foster Gillie Oakville, WA 1973 Chevrolet Corvette

1956 Chevrolet Nomad owned by Don & Cindy Pierson of McPherson, Kansas.

1973 Chevrolet Corvette owned by Foster Gillie of 1957 Ford Thunderbird owned by Rodney West of Oakville, Washington. Mandeville, Louisiana.

4 Turbocharger Failures by Matt Boehm, JASPER Customer Service

Matt Boehm has been an Associate with JASPER since 2002. Matt holds an Associate’s Degree in Automotive Technology from Vincennes University, and a Bachelor’s Degree in Industrial This diagram shows how a turbocharger uses exhaust gases to force compressed air into Automotive Technology from the engine’s intake manifold. Indiana State University. He presently holds 22 ASE ing enhanced engine power. Adequate Lubrication - Due to the Certifications, including two To provide the compressed air charge extreme load and heat turbocharger bear- Master Certifications. to the engine’s intake manifold, the tur- ings are subjected to, proper lubrication bocharger wheels must spin at extremely is essential. Abrasive material and con- With the recent boom in turbo diesel high speeds, normally in excess of taminants in the engine lube oil act like powered Light Duty Pickup sales, the 100,000 RPM! With this in mind there a cutting tool on the turbocharger bear- fact that an increasing amount of these are several factors that must be taken into ings which may cause premature failure. vehicles will be coming in for service is consideration to ensure longer tur- Failure of the turbo’s bearings can allow inevitable. One of the most common bocharger life and performance: the turbocharger wheels to contact the problems seen on a modern light duty housing causing catastrophic turbocharg- turbo diesel engine is turbocharger fail- Air filtration - The intake system of any er failure and possibly severe engine ure. Within this article we will discuss internal combustion engine MUST be damage. some of the more prominent failures, equipped with an adequate Intake Air A turbocharger is much more sensi- their causes and how to prevent them. Filtration Device. This factor is even tive to an inadequate oil supply than the The air induction system on a late more important on turbocharged engines. engine itself. Insufficient oil pressure model turbo diesel usually consists of The turbocharger’s bearings and vanes resulting from overheating, diluted or four main parts, the air induction tube or operate on extremely close tolerances, improper grade of lube oil, oil lag, or hot pipe, an air filter, the turbocharger, and a and must be kept free of any abrasive shutdown can all lead to shortened unit charge air cooler. material. Any ingestion of abrasive service life. A turbocharger’s main function is to material in a turbocharger’s intake system use the normally wasted energy in the can lead to costly turbocharger and even Proper Operating Conditions - One of engine’s exhaust gasses to drive the tur- engine failure. the most accurate indicators of how a bine wheel and shaft, which is attached It is very important to keep the air fil- diesel engine is running is the engine’s to the compressor wheel. The compres- ter clean on any engine; gasoline or Exhaust Gas Temperature or EGT. sor wheel, when rotating, provides an air diesel, turbocharged or normally aspirat- Unlike a gasoline engine, which must charge to the intake of the engine provid- ed. However, a restricted air filter on a operate at stoichiometric air/fuel mix- turbodiesel engine can cause a tures to obtain maximum power, a diesel drastic reduction in engine engine will continue to make increased power, as well as excessive fuel power when more fuel is added. This consumption. A restriction can advantage comes at the expense of also cause excessive exhaust gas potential turbocharger and possibly temperatures as well. In addi- engine damage. tion, a restricted air intake or fil- A properly running diesel engine ter can also cause excessive lube under load will exhibit 900°-1000°F oil consumption due to oil being Exhaust Gas Temperatures. While tem- drawn into the compressor side perature spikes of up to 1250°F may be A typical turbocharger is divided into two sections: of the turbo and into the engine. a compressor section and a turbine section. (continued on page 7)

5 Wallace Fast in ARCA at Chicagoland Steve Wallace joined the elite compa- ny of Frank Kimmel and as the only repeat winners in the 2006 ARCA RE/MAX Series season with his victory in the SK Hand Tools 200 at Chicagoland Speedway. Wallace crossed the finish line in his Penske-Jasper powered #61 Dodge nearly six seconds ahead of runner-up finisher to win his second ARCA RE/MAX Series race of 2006, and the third of his career. In addition to his victory, Wallace posted the quickest speed during prac- Check the oil too, please: Steve Wallace receives service from his pit crew enroute to tice, and earned the with a victory in the ARCA RE/MAX SK Hand Tools 200 at Chicagoland Speedway. time of 30.489 seconds (177.113 mph) around the 1.5-mile speedway. During at one point we had a 15 or 20 second did not go without a few close calls. He the race, he also earned the fastest lap of lead, so that was really fun. I’ve got finished the race with damage to the the race award with a speed of 171.527 two more ARCA races on the schedule, right side door after he was clipped by a mph (31.482 seconds). including Talladega and Iowa, in addi- car on lap 95 of the 134 lap race. “Our mile-and-a-half cars just really tion to some NASCAR Busch Series Wallace was able to correct the car with- fly,” said Wallace. “Of course, we’ve got races, so we’re going to be really busy out spinning, and went on to claim the some Penske-Jasper horsepower under for sure.” victory. the hood too, so that really helps. I think However dominate Wallace was, he

Wallace Wins Again with ARCA at Iowa Steve Wallace recovered from an early race close call and The 19-year old driver led 177 of the 250 laps, including withstood late race pressure from Kraig Kinser to win the the final 169, in his JASPER Powered #61 Dodge enroute to inaugural Prairie Meadows 250 ARCA RE/MAX Series race his 3rd victory of 2006. Kinser, making his first ARCA October 15th at the newly constructed . RE/MAX Series appearance since 2005, crossed the checkers “They went from five to go, to four to go and Kinser kept .208 seconds behind to settle for second. getting closer and closer,” Wallace said of the closing laps. “I “The track felt great,” said Kinser. “I thought the race was expecting to get the old bump and run but he didn’t do speed would slow down but I was running laps faster than my that. Overall, it was a pretty good day for us.” qualifying time. Steve was good all day so I knew he would be tough to beat.” Wallace, whose father Rusty designed the new 7/8-mile track, escaped a very close call during the opening laps when he was battling for position with . Wallace took the high line and made contact with Montoya, who glided up the track from the low groove, causing the two cars to make contact. Montoya went for a spin but was able to return to the track to post a 24th place finish, 42 laps down. “I had a run on the outside of him,” said Wallace. “You know the rule is if your fenders are past the quarter panels, it’s your line. But I would say it was probably 50/50... half his fault, half mine.” In addition to the win, Wallace earned the pole with an average speed of 137.357 mph (22.933 seconds). This On the low side: Steve Wallace (#61) moves under Bobby Santos allowed him to clinch the ARCA RE/MAX Series Pork Pole during the Prairie Meadows 250 ARCA RE/MAX event at Iowa Award title for 2006 for earning the most poles for the season Speedway. Wallace led the final 169 laps to win the race. with four.

6 3R’s: Ryan, Racin’ and Rain! Penske-Jasper driver Ryan Newman appeared at O’Reilly Raceway Park in Indianapolis to race in the Premier Racing Association’s Jasper Engines & Transmissions Circle City 100. Rain, however, was the winner at the .686 mile oval September 12th, and forced the event’s cancellation after 26 laps. The rain held off long enough for Newman to qualify the #69 Hoffman Racing BEAST chassis with MOPAR power 10th in the 25- car field. He quickly worked his way up to sixth before a steady rain began falling on lap 18 of the feature event, and the race was red- flagged after 26 circuits. Knowing the track would take at least 90 minutes to dry, and with more rain on the radar, PRA officials decided to cancel the event. The PRA Big Car Series was formed in 2006 for the former Silver On The Gas: Ryan Newman puts the #69 Hoffman Racing Crown pavement cars that were “parked” due to a change in the entry through its paces during practice for the Jasper United States Auto Club’s car design rules that went into effect earlier Engines & Transmissions Circle City 100 at ORP. this year.

JASPER Makes Available More (continued from page 5) seen under heavy load and hard acceler- Late-Model Ford & GM Engines ation, it is when these extreme tempera- Jasper Engines and Transmissions, * 2004-2006 Ford Ranger pickup tures are sustained for an excessive the nation’s leader in remanufactured amount of time that problems occur. drive train components, has made * 2004-2006 Mazda B2300 pickup The exhaust gas that drives the turbine available two more GM engines, and can start to erode the edges of the tur- one Ford engine, for Each of these remanufactured bine’s vanes. When these vanes erode, applications. engines carries JASPER’s 36-month, the turbo is subjected to an imbalance These new GM offerings are the 75-thousand mile nationwide condition, which can destroy the bear- warranty. 2.2L ECOTEC 4-cylinder and the 2.8L ings, or even cause the turbine wheel to 4-cylinder gas engines. burst, sending the fragments throughout The 2.2L ECOTEC 4-cylinder is Log onto www.jasperengines.com, an extremely expensive engine. available for the following or call 1-800-827-7455 for more Sustained excessively high EGTs applications: information on these and other products from JASPER. can also cause the turbine housing to * 2002-2005 Chevrolet Cavalier, crack or distort which can allow the tur- Sunfire and Pontiac Grand bine wheel to contact the housing and Am burst. GM 2.8L 4-cylinder Excessive Exhaust Gas * 2002-2004 Alero engine Temperatures can be caused by a dirty * 2005-2006 Chevrolet Cobalt, Malibu or restricted air filter, charge air cooler, and HHR intake tube, restricted exhaust, improper * 2002-2006 Saturn Ion and Vue fuel calibration or the addition of an * 2002-2004 Saturn L Series aftermarket power adding device. In summary, there are several fac- GM 2.2L 4-cylinder Flex Fuel applications of this engine tors that affect proper turbocharger are also available. ECOTEC engine operation. Most turbo assembly fail- ures are the result of improper mainte- The 2.8L 4-cylinder engine is avail- nance or other outside factors. These able for the following applications: factors can for the most part be elimi- * 2004-2006 Chevrolet Colorado and nated by routine maintenance of the GMC Canyon Pickups engine itself and periodic inspection of Ford 2.3L 4-cylinder the engine’s intake and exhaust system engine JASPER’s latest offering from Ford for proper operation. is the 2.3L 4-cylinder engine available for the following applications:

7 Prst. Std. U.S. Postage Paid Permit 249 Jasper, IN 47546

JASPER ENGINE AND TRANSMISSION EXCHANGE 815 Wernsing Road · P.O. Box 650 · Jasper, IN 47547-0650 e-mail: [email protected]

www.jasperengines.com

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