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FORD PG 2 GENERAL MOTORS PG 6 CHRYSLER PG 11 IMPORT PG 16 PERFORMANCE PG 18 SHOP TIPS PG 23 C2 Cloyes Layout 1 2/16/12 8:08 AM Page C2

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FORD PG 2 GENERAL MOTORS PG 6 CHRYSLER PG 11 IMPORT PG 16 PERFORMANCE PG 18 SHOP TIPS PG 23 C2 Cloyes Layout 1 2/16/12 8:08 AM Page C2 C1 Tech BULLETINS 12_Cover Temp_2006 2/16/12 7:59 AM Page c1 2012 FEBRUARY SUPPLEMENT TO: MAGAZINE FORD PG 2 GENERAL MOTORS PG 6 CHRYSLER PG 11 IMPORT PG 16 PERFORMANCE PG 18 SHOP TIPS PG 23 C2 Cloyes_Layout 1 2/16/12 8:08 AM Page c2 Circle 101 on Reader Service Card for more information 1 index_Layout 1 2/16/12 7:47 AM Page 1 Year Engine Problem Page # FORD 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 GENERAL MOTORS 1990-2002 2.2L/134 cid Deciphering The Differences In The Chevy 2.2L Engine 6 1988-2002 2.3L “Quad 4” Timing Chain Installation Caution 6 1993-1994 3.1L/191 cid Chevy 3.1L/191 Cam Bearing Bore Issues 8 2004-2005 3.6L Noise Complaints on 3.6L 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 CHRYSLER 1995-2006 2.4L Chrysler 2.4L Cylinder Block Casting Identification 11 2004-2006 3.5L Multiple Cylinder Misfire or Rough Idle 14 All 3.7L Keeping Your Balance With 3.7L Chryslers 15 IMPORT 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 SHOP TIPS 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 & PRODUCTS 101 2C ENGINE & 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: All tech bulletins, unless otherwise noted, have been provided by Automotive Production Remanufacturers Association (APRA). www.enginebuildermag.com | ENGINE BUILDER 1 2,4,5 Ford_Layout 1 2/16/12 7:48 AM Page 2 Timing Chain Service on straight up if both cams are in the correct Ford 3.0L Duratec Engines position. You can now remove the chain If you have to remove or replace a cylinder tensioner arm, chain guide and right tim- head for any reason, or replace the timing ing chain. chain on a 3.0L Duratec, it can be a bit of To remove the left timing chain, rotate a challenge because Ford doesn’t provide a the crank clockwise 600° (1-2/3rds turn) Top Dead Center (TDC) timing reference until the keyway is again at the 11 o’clock mark on the crankshaft. position. This will position the left cylinder You will have to use a dial indicator to head cams in the neutral position. This find the TDC position of the number one time, the timing mark on the intake cam cylinder on Ford’s 3.0L Duratec to make should be pointing to the left when viewed sure the crank and camshafts are all proper- from the front, and the mark on the ly aligned. Figure 1 You will have to use a dial indicator exhaust cam should be pointing straight Ford says that when the crankshaft key- to find the TDC position of the number one up. As before, you can now remove the way is positioned at roughly the 11 o’clock cylinder on Ford’s 3.0L Duratec to make sure chain tensioner arm, chain guide and left position, the number one cylinder should the crank and camshafts are all properly aligned. timing chain. be at TDC. Before you can reinstall the timing Before you can remove the timing at the 3 o’clock position will move the chains, you need to compress the left and chain, the front cover has to come off the right cylinder head camshafts to the neutral right chain tensioners in a vise. Compress engine. Then you have to remove the crank position. The timing mark on the intake the piston until it is fully bottomed, then sensor pulse wheel. Note the sensor wheel’s cam should be pointing to the right when temporarily lock it in place with a pin or location before you remove it. viewed from the front, and the timing mark paper clip. Rotating the crank until the keyway is on the exhaust cam should be pointing 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 side chains. Start with the left chain, and mark one link as the starting crankshaft timing mark. Then count 29 Sunnen CH-100 links and make a second mark (for the exhaust cam). Continue counting to link For fast, precision number 42 and make a third mark (for the alignment of main intake cam). The second and third marks bearing bores Sunnen should align with the timing marks on the can’t be beat. The intake and exhaust cams when the chain is CH-100 handles the slipped into place. The chain tensioner and complete job of align- arm can now be installed. ment and sizing of Next, you do the same procedure for main bearing bores in the right cam. But first, you need to rotate about 30 minutes the crankshaft 120° clockwise so the floor-to-floor time for crankshaft keyway is at the 3 o’clock posi- an average passenger tion. Mark the right timing chain and car block and it takes just a few minutes longer for truck blocks. install it the same as before. With the CH-100, you will see stock removal, usually less than .003˝ Once both chains are in place, remove (.076 mm) off the caps compared to as much as .010˝ (.254 mm) with the locking pin or paper clip from the left boring. and right chain tensioners. Rotate the crankshaft 120° counter- For more information, visit www.sunnen.com or clockwise so the keyway is back at the 11 call 1-800-325-3670. o’clock position and number one piston is at TDC. Check to make sure all 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 Circle 102 for more information 2 ENGINE BUILDER TECH SOLUTIONS GUIDE | February 2012 3 ACH_Layout 1 2/16/12 8:05 AM Page 3 Circle 103 on Reader Service Card for more information 2,4,5 Ford_Layout 1 2/16/12 7:48 AM Page 4 FORD links between the cam gears and crank on so that the inertial reaction to their count- the non-tensioned side of each chain, and er-rotation cancels out in the horizontal 30 links between the cam gears and crank plane, but adds in the vertical plane. This on the tensioned side of each chain. gives a net force equal to, but 180 degrees By Larry Carley out of phase with, the undesired second- order vibration of the basic engine, thereby 2003-2004 Ford 3.8L, 3.9L and canceling it. In a “V” configuration the 4.2L Balance Shaft Gear Clarifications same may be accomplished by opposite To deal with certain engine harmonics counter weights on the same/single shaft. (particularly, inherent second-order or The ultimate result is to eliminate NVH twice engine rpm vibration), engine (Noise Vibration Harshness). designers often incorporate two balance This fact is understood, and the Ford Figure 3 It’s easy to confuse the two gears, but 3.8L, 3.9L and 4.2L putting the wrong driven gear into a Ford engines in the same fam- engine will cause real problems. ily configuration have had these shafts at vari- changed from 31 to 38 teeth, and as you ous times and in differ- can see in the illustrations (Figures 2, 3) it ent vehicles – however would not be hard to confuse the two. recognizing changes in The change in teeth was to further the amount of teeth of reduce the NVH of the gears that drive the the drive and driven balance shaft. Obviously a mix up would gears of certain vehicles result in a catastrophic failure. However, Figure 2 Ford increased the number of teeth in the drive and is critical. what I have found is that as long as you driven gears on several Ford engine balance shafts in 2003 and The drive and driven keep the camshaft drive gear and balance 2004. gears of the balance shaft shaft gear matched it makes no difference shafts rotating in opposite directions at appear to have changed in August of 2003 which ones you use. twice engine speed. Equal size eccentric for vans and August of 2004 in the truck. By Roy Berndt weights on these shafts are sized and phased The driven gear on the balance shaft Oil Leak Repair for 1990-1993 4.0L Ford V6 Engines The 4.0L Ford V6, used in the Aerostar, Explorer and Ranger pickups, has been a problem engine for oil leaks for years.
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