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AERA Weekly Technical Bulletins – January 21, 2021



Alternative Intake Manifold Design for 2011-2015 Kia/Hyundai 3.5L Engines


The AERA Technical Committee offers the following information regarding an alternative intake manifold option for 2011-2014 Kia/Hyundai 3.5L engines. The design of this new manifold is considered an improvement over the original equipment (OE) version.


Poor drivability has been reported on these G6KE engines that has been linked to a malfunctioning variable intake manifold. The factory OE intake manifold fails when the pivot linkage connecting the two variable-intake flapper valve shafts shears from fatigue. Lack of shaft support is the primary reason for failure as shown in Figure 1.






Glow Plug Sleeve R & R for 2008-2010 Ford 6.4L Diesel Engines


The AERA Technical Committee offers the following information regarding glow plug sleeve service for 2008-2010 Ford 6.4L diesel engines. This information should be considered anytime the cylinder heads are being worked on.


These engines use a separate sleeve to help locate the glow plug to the cylinder head. These sleeves must be sealed to prevent combustion pressure leakage. Follow the steps listed below to remove and install the glow plug sleeves for these engines.




How to Break In A Rebuilt Engine




What process do you use, when there isn’t a process for breaking in a rebuilt engine?


One process that is often missing from Original Engine Manufacturer’s service publications is how to correctly break in a rebuilt engine, especially without the use of a dynamometer

or load bank. Dynamometer or load bank testing are the preferred methods, but realistically it is not always an option. Regardless, breaking in the engine is critical. If this is not done correctly or completely, then the engine will most likely perform poorly, smoke, and consume oil. Often these symptoms are irreversible over time. The term, “breaking in” an engine refers to the process where combustion temperatures and operating conditions force the rings and cylinder bores to conform to each other sealing the combustion gasses within the cylinders. Idling will not produce the temperatures and forces needed.




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Listen to the Engine Professional Podcast


Chuck Lynch and Steve Fox discuss engine-related technical information and machining procedures, as well as invite guest hosts to share their knowledge.




Subscribe to the new AERA YouTube Channel


AERA has a new YouTube channel featuring Prosis Pro tutorials, AERA webinars and membership information. We invite you to check out the wide selection of videos and subscribe! New content is added regularly.













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