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The following technical bulletins were published by AERA.

COOLANT IN THE ENGINE OILING SYSTEM

                                     Coolant In The Engine Oil On
                            1987-89 Porsche 2.7 & 5.0L DOHC Engines

AERA members have reported coolant in the engine oil supply on 1987-89 Porsche 2.7 & 5.0L DOHC engines. If left undetected, this oil contamination may eventually cause the engine damage. The source of this contamination may be a crack near the cylinder head bolt bosses as shown in Figures 1 & 2 below.

The cylinder head casting varies in thickness at the locations shown by the arrows in the illustrations below. The most common area to crack is between the exhaust valve spring seat to the head bolt boss. Identifying the cracked areas and welding those cracks may provide an apparent repair, however, a crack may develop in a different location if the head is placed back in service.

Porsche recommends replacing cracked heads with revised cylinder heads, Part #92810401403, for the 5.0L engine and Part #94410401303, for the 2.7L. A revised head casting is used beginning with engine numbers 81K00121 & 81K05240. 

Any over-torquing of the cylinder head bolts may also cause undue stress on the casting and cause a previously non-leaking casting to leak.

                                                                     The AERA Technical Committee

DEFECTIVE CONNECTING ROD NUTS

                                      Defective Connecting Rod Nuts On
                                      Porsche 924S and 944 2.5L Engines

Porsche of North America advises machine shops on connecting rod nuts that have been manufactured with threads that are not perpendicular to the contact surface.  In particular, these nuts may have been installed in 924S and 944 vehicles equipped with 2.5L engines.

Connecting rod nuts that have more than .006 (.15 mm) of clearance anywhere between the mating surfaces should be replaced.  Incorrectly manufactured nuts may loosen over time, leading to often catastrophic engine failures.

AERA members should inspect all connecting rod nuts as well as new connecting rod assemblies for proper fit.

                                                                          The AERA Technical Committee

OIL IN THE COOLING SYSTEM

                                           Oil In The Cooling System On
                             1986-88 2.5L & 1989-90 2.7L Porsche Engines


AERA member machine shops have reported instances of lubricating oil entering the cooling system in 1986-90 Porsche 944 S2 and 944 Turbo engines.

In these cases, the transfer point was traced to the engine oil cooler thermostat housing.  Specifically the depth of the connector pipe bore in the crankcase should be measured.  The correct depth is .5433-.5590 (13.8 - 14.2mm).  If the bore depth exceeds .5590, a spacing washer, Part #928 107 166 00 must be
installed in the crankshaft bore.  Use Loctite 638R, or equivalent, to retain the washer in the bore.

Porsche also recommends replacing the connector, Part #951 107 152 03, if it is out of tolerance with the specifications listed in the illustration below.

                                                                           The AERA Technical Committee

THICKER CYLINDER HEAD GASKETS

                                     Thicker Cylinder Head Gaskets On
                        2.5 ,2.7 ,3.0 ,4.5 ,4.7, 5.0 and 5.4L Porsche Engines

The AERA Technical Committee has learned that Porsche now offers thicker cylinder head gaskets for engines used in the 924S, 944, 928 and 968.  These gaskets may permit the reuse of cylinder heads that require machining below normal minimum specification.

The cylinder head gaskets are .012 (.3mm) thicker than the standard gasket.  Once installed and torqued to specifications, these gaskets have a compressed height of .055 (1.4mm) in comparison to the standard .043 (1.1mm) compressed height.

Number of Cylinders
     Engine                   Part Number

Four Cylinder
     2.5L                              951 104 374 50
     2.7L and 3.0L              944 104 394 51

Eight Cylinder
     4.5L, 1-4 cyl.                928 104 371 15
     4.5L, 5-8 cyl.                928 104 372 15

     4.7L, 1-4 cyl.                928 104 361 15
     4.7L, 5-8 cyl.                928 104 362 15

     5.0L, 1-4 cyl.                928 104 367 10 
     5.0L, 5-8 cyl.                928 104 368 10

     5.4L 1-4 cyl.                 928 104 367 11
     5.4L 5-8 cyl.                 928 104 368 11

                                                                            The AERA Technical Committee

PISTON PIN CLIP CAUTION FOR PORSCHE 911 ENGINES

                                                Piston Pin Clip Caution For 
                                              1990-99 Porsche 911 Engines

The AERA Technical Committee offers the following information regarding a piston pin clip caution for 1990-99 Porsche 911 engines. This information should be referenced anytime replacement pistons are being installed. 

To prevent damage to the cylinder walls during transportation, special clips are used to retain the wrist pin in the piston. These clips are for transportation only and must not be used in engine assembly. Clips used for engine assembly are provided along with the transportation (shipping only) clip as shown in Figure 1.

The clips indicated by the number 1 in Figure 1 below will not hold up to temperatures exerted during engine operation. Those clips should be discarded and only clips resembling the number 2 be used during engine assembly.   

Note:
Resultant engine damage due to use of the transportation (shipping only) clip during engine assembly is not covered under warranty. 

                                                                           The AERA Technical Committee

INTERFERENCE ENGINES

                                          Interference Engines

The AERA Technical Committee would like to offer the following information on engines that present the possibility of interference between pistons and valves. The interference or contact may bend valve(s) when the timing between the camshaft and crankshaft is interrupted. This is generally the result of a timing belt or chain breaking or slipping.

The following list are engines that AERA is currently aware of that have exhibited interference. There may be other engines that are not listed below that have the possibility of piston to valve contact. If the engine you are working on is not listed, do not assume that it is a freewheeling design. It is suggested to add to this listing as additional information is obtained.

ACURA
1986-89 1.6L Integra
1991-95 1.7L Integra
1990-95 1.8L Integra 
1986-89 2.5L Legend
1992-94 2.5L Vigor
1986-89 2.7L Legend
1990      2.7L Legend
1991-95 3.0L NSX
1991-95 3.2L Legend

AUDI
1970-93 All Except 1970-77 
1.9L & 1970-73 1.8L

BMW
1987-95 2.5L 325I 525I
1994-95 4.0L 740I

CHRYSLER
1993-95 1.5L Colt 
1987-88 1.5L Colt	
1992-95 1.5L Eagle Summit
1987-88 1.6L Colt	
1989-92 1.6L Eagle Summit
1994-98 2.0L Neon Stratus
1990-95 2.0L Eagle Talon

DAIHATSU
1988-92 1.0L Charade
1988-92 1.3L Charade
1990-92 1.6L Rocky

FIAT
1974-79 1.3L 128 Series
1979-82 1.5L Stranda
1974-78 1.6L 124 Series
1974-78 1.8L 124 Series
1974-78 1.8L 131 Series, Brava
1979-82 2.0L Brava, Spider 

FORD
1981-85 1.6L Escort, EXP
1981-83 1.6L LN7, Lynx
1984-85 2.0L Escort, Tempo
1993-95 2.0L Probe
1986-88 2.0L Ranger
1984-87 2.0L Lynx, Topaz Diesel
1985    2.2L Ranger
1989-92 2.2L Probe
1986-88 2.3L Ranger
1986-87 2.3L Diesel Ranger
1991-98 4.6L Crown Victoria

GM
1986-95 1.0L Geo Metro
1989-91 1.0L Firefly (CANADA)
1985-88 1.5L Sunburst (CANADA)
1985-89 1.5L Spectrum
1990-93 1.6L Prizm, Storm
1981-84 1.8L Diesel (CANADA)
1982-86 1.8L Buick Skyhawk
1990-98 1.9L Saturn
1987-88 2.0L Buick Skyhawk
1988-95 2.3L Quad Four
1985-87 3.0L Buick
1979-95 3.8L Buick

HONDA
1986-87 1.0L Prelude
1973-78 1.2L All
1973-78 1.3L All
1980-84 1.3L All
1973-78 1.5L All
1985-89 1.5L Civic
1988-95 1.5L Civic, CRX
1993-95 1.5L Civic Del Sol
1979-84 1.5L All
1985-87 1.5L CRX
1993-95 1.6L Civic Del Sol
1973-78 1.6L All
1980-82 1.6L All
1988-95 1.6L Civic, CRX
1984-87 1.8L Prelude, Accord
1979-83 1.8L All
1986-91 2.0L Prelude
1990-91 2.1L Prelude
1990-95 2.2L Prelude, Accord
1992-95 2.2L Prelude
1995      2.7L Accord

HYUNDAI
1984-95 1.5L Excel Scoupe
1995-98 1.5L Accent
1992-95 1.6L Elantra
1993-95 1.8L Elantra
1992-95 2.0L Sonata
1989-91 2.4L Sonata
1990-95 3.0L Sonata

INFINITI
1990-92 3.0L M30

ISUZU
1987-89 1.5L I-Mark
1990-93 1.6L Stylus Impulse
1987-89 2.0L Impulse
1981-87 2.2L Diesel Truck
1986-95 2.3L Truck Trooper
1988-95 2.6L Truck Rodeo Amigo
1991-96 3.2L Trooper Rodeo Amigo

KIA
1995      2.0L Sportage

MAZDA
1984-85 2.0L 626 
1988-92 2.2L 626 MX6
1989-93 2.2L Pickup
1988-95 3.0L 929 MPV

MITSUBISHI
1985-95 1.5L Mirage Precise
1990-92 1.6L Mirage
1989-95 2.0L Galant Eclipse
1983-86 2.3L Diesel Pickup
1994-95 2.4L Galant

NISSAN
1982      1.5L Centra
1983-88 1.6L Sentra Pulsar
1987-89 1.8L Pulsar
1982-89 2.0L Stanza 300ZX
1984-95 3.0L Maxima 300ZX Pathfinder

PORSCHE
1976-83 2.0L 924
1976-89 2.5L 944 Series
1989      2.7L 944 Series
1989-91 3.0L 944 Series
1976-83 4.5L 928
1984      4.7L 928
1985-91 5.0L 928
1992-95 5.4L 928

SUZUKI
1985-94 1.3L Samurai Sidekick
1989-94 1.3L Swift

TOYOTA
1986-95 1.5L Tercel
1981-83 2.2L Pickup
1984-87 2.4L Pickup
1982-88 2.8L Celica Cressida
1987-94 3.0L 4-Runner

VOLKSWAGEN
1976-91 All Except 1.9 2.1L Engine
1990-92 1.6L Golf (CANADA) Jetta
1990-95 2.0L GTI Jetta GLI Passat

VOLVO
1991      2.3L Coupe 940
1986-94 2.3L 240 740 940 

                                                                              The AERA Technical Committee

THICKER HEAD GASKETS ON 924, 944, 928 & 968 ENGINES

                                        Thicker Cylinder Head Gasket For
                                  Porsche 924S, 944, 928S and 968 Engines

The AERA Technical Committee offers the following information on a thicker cylinder head gasket on Porsche 924s, 944, 928 and 968 engines. This bulletin effects 1983-on 924s and 944 four cylinder engines (2.5,2.7,3.0L) and 1988-on 928 and 968 eight cylinder engines (4.5,4.7,5.0,5.4L). This bulletin is an update of previous AERA Technical Bulletin TB-1003 as it contains additional information.

The optional cylinder head gaskets are .012 (.305 MM) thicker than the standard head gasket. These thicker gaskets may permit the reuse of cylinder heads that require up to an additional .012 machining below normal minimum specification. The standard thickness of the original head gasket is .043 (1.092 MM) and the thicker head gasket thickness is .055 (1.397 MM). 
 
Two valve per cylinder heads that have been machined below a head thickness of .929-.933" (23.6-23.8 MM) require the thicker head gasket. Four valve cylinder heads that are machined below 5.7716-5.7795 (146.6-146.8 MM) thickness require the thicker head gasket. 

NOTE: Measuring the cylinder head thickness is shown in Figure 1 for two valve and Figure 2 for 4 valve heads by the letter A.

   Number of Cylinders
       In Engine                                     Part Number
Four Cylinder
                        2.5L                            951 104 374 50
                    2.7L & 3.0L                     944 104 394 51

      Eight Cylinder
                   4.5L, 1-4 cyl.                   928 104 371 15
                   4.5L, 5-8 cyl.                   928 104 372 15

                   4.7L, 1-4 cyl.                   928 104 361 15
                   4.7L, 5-8 cyl.                   928 104 362 15

                   5.0L, 1-4 cyl.                   928 104 367 10 
                   5.0L, 5-8 cyl.                   928 104 368 10

                   5.4L 1-4 cyl.                    928 104 367 11
                   5.4L 5-8 cyl.                    928 104 368 11

                                                                            The AERA Technical Committee

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