Engine Installation Tips
SUGGESTED ENGINE INSTALLATION PROCEDURES AND INSTRUCTIONS
For Gasoline Engines
DEAR INSTALLING MECHANIC/TECHNICIAN:
This engine has been carefully remanufactured to precision standards, and will perform
properly IF certain steps are taken by the person making the installation.
An engine is a complex component that requires the highest degree of technical knowledge
to install. It is recommended that you, the installer, have an ASE certificate or the
equivalent before you accept the RESPONSIBILITY of properly installing an engine.
When a properly remanufactured engine fails to give satisfactory service, it can be due to
detonation, pre-ignition or "lugging", overheating or excessively rich air-fuel
ratio, under-lubrication, dirt, coolant seepage, ineffective air filtering. The above
mentioned reasons for failure are the responsibility, and under the control, of the
installing mechanic/technician not the engine rebuilder.
CAUTION, these recommended installation procedures and instructions are a partial list
intended only as a guide. If you are not qualified to undertake this installation, do not
attempt it as you may be liable for resulting engine failure.
Replacing all of the following with new or rebuilt/remanufactured units is recommended:
valve lifters, oil pump, push rods, rocker arms, oil pump screen with new screen, spark
plugs, points (if applicable), condenser, motor mounts, oil filter, air filters, water
pump, thermostats, PCV valve & grommets and clean lines (Note: A plugged line or
faulty valve may cause excessive oil consumption and blowby), carburetor (may be rebuilt)
and make sure the EGR valve is operating to OEM specifications.
Follow the manufacturer's installation procedures; especially proper torque values.
Inspect the rocker cover baffle for possible restrictions.
Contamination is an engine's worst enemy. We recommend that you thoroughly clean parts
that will be attached to the rebuilt/remanufactured engine.
Any and all parts not included with a remanufactured engine or engine component should be
cleaned properly before installing on a new remanufactured engine.
INSPECTION OF ENGINE PRIOR TO INSTALLATION
•Check for freight damage and dirt contamination of the engine. •Check for
proper valve train timing. •Check that ALL oil gallery plugs are installed, tight and
sealed. •Check that ALL freeze plugs are installed and sealed. •Check that
temperature recording labels or heat tabs on the block and the heads are installed.
•Check application of product - make sure the mounting holes, bell housing, crank
shaft snout, flywheel mounting flange, bolt hole patterns, pilot shaft hole,smog/non-smog
application, etc., are the same on new product as the old by comparing casting numbers.
•Clean all accessories to be transferred to the new product, from the old one.
Resurfacing of the intake manifold and machine gasket surfaces is required.
VALVE LIFTERS - Flat, Roller, HLC (Hydraulic Lash Compensators)
•Install new lifters and inspect push rods on short blocks to avoid camshaft wear and
premature failure. •Do not preload lifters (it causes undo stress to camshaft and
lifters which may lead to early failure). •Lifter rattle at cold start is not
uncommon, and does not cause engine damage. •Roller Lifters may be reused if within
OE specifications. •Hydraulic Lash Compensators (HLC) are generally reusable, but may
need to be purged of all air.
TIMING COVERS
•Inspect for erosion, breakage, warpage, porosity and abnormal wear patterns.
•Measure covers containing oil pump for wear and replace if not within OE tolerances.
•Install new timing chain tensioners, dampners, etc.
DRIVE PULLEY (Harmonic Balancer)
•Check seal surface of pulley hub and repair or replace if grooved or damaged
(harmonic balancer seal surface wear sleeves may be available). •Lubricate seal
surface prior to installation to prevent damage to seal. •Check outer ring for
slippage as this could cause "O" timing mark to not indicate top dead center.
•Replace balancers set in rubber. (The interior rubber deteriorates with age,
allowing the balancer to slip, possibly causing timing problems and detonation,
over-heating, vibration and unexplained noises).
CYLINDER HEAD Torque
•Properly torque cylinder head at installation to OE specifications in the correct
sequence. (Use new bolts when OE requires).
INTAKE MANIFOLD MUST BE CLEANED
•Clean off carbon (remove steel heat shield, if equipped, clean and re-install).
•Magnetic particle inspect or die check for cracks. •Blow out with compressed
air to avoid having foreign material enter combustion chamber. •Remove baffle (where
applicable) so that all collected contaminants can be removed. •All EGR passages must
be cleaned and free of obstruction. •Do not over torque manifold bolts. Use OE torque
specifications and sequence ONLY. •Do not glass bead intake manifolds to clean.
•Check water outlet for corrosion.
VALVE LASH
•Consult shop service manual for dry lash setting for non-adjustable rocker arms.
•Check dry lash at time of installation (if applicable). •Check and adjust lash
at 500 miles (if applicable).
ROCKER ARM ASSEMBLIES
•Check for wear and replace if necessary (remanufactured units are available).
•Confirm proper shaft installation as some can be installed upside down. Excessive
oil consumption may result.
DISTRIBUTOR
•Check bushing, mechanical advance, vacuum advance, and total advance. •Check to
see that distributor is fully engaged and locked in the oil pump to proper depth.
•Adjust ignition timing to factory specifications. •Check distributor drive gear
for wear and replace as needed.
FUEL SYSTEM
•Carefully service or replace all aspects of the fuel system, i.e. pump, lines,
carburetor or fuel injection components. •Check fuel lines for breaks and crimps. Use
only approved steel lines. •Check fuel pump for proper pressure. •Check double
diaphragm type for faulty vacuum booster which may pump oil through the intake system.
FILTERS
•Replace all filters at time of installation and at O.E. recommended intervals. These
filters include air, oil, fuel, and crankcase. •Use cleaning procedure outlined
previously above to clean air cleaner housing, crankcase vent tubes coolers, air
compressors, Donaldson valves, etc.
RADIATOR/COOLING SYSTEM
•Recore or replace the radiator and test flow. •Verify thermal conductivity.
Minimum of 25°F temperature differential between inlet and exhaust. •Always replace
pressure cap and thermostat. •Check temperature sending unit fan switch.
HEAT RISER OR EXHAUST THERMOSTAT CONTROL
•Check to see if unit is free and operating properly. •Lubricate with special
high heat formula. •Make sure hot air door operates freely on air cleaner.
OIL SYSTEM
•Fill to proper level. •Use only OE specified lubricants or equivalent to full
levels before operation. •Use a pressure tank at about 40 pounds pressure to prime
(pre-lube) engine as this will insure vital parts are lubricated properly to avoid a dry
start. (Spinning of the oil pump to accomplish this is not recommended). •If pressure
tank is unavailable, use an aftermarket assembly lubricator kit for prelubing of system
before initial fire up (follow recommended procedures). Call for further information.
•Install new oil pump and pickup screen. Install new oil filter filled with new oil
prior to installation. •Check oil pump intermediate shaft for correct size and shape
to match distributor and oil pump, if applicable. •Oil pump may need to be primed
before starting. (Run at 800 rpm at intervals before releasing to customer for use to
assure proper cylinder lubrication.) •Replace oil pressure sending unit.
THRUST BEARING
•Adjust clutch to proper free pedal BEFORE starting engine, NOT after. Check
crankshaft end thrust before and after bolting transmission to engine. •PLEASE
NOTE!!! - excessive main bearing thrust wear may be caused by the following: •Clutch
not adjusted properly •Interference between pilot shaft and crankshaft
•Interference between torque converter and crankshaft •Torque converter
ballooning •Blockage and/or restriction of transmission oil cooler •Bent,
kinked, or damaged supply lines •Incorrect crankshaft end thrust
PREVENTING THE CAUSES OF THRUST BEARING FAILURE IS THE RESPONSIBILITY OF THE INSTALLING
TECHNICIAN!
RUBBER GOODS
•Don't overlook small parts such as belts,hoses (those that carry liquids and air)
and motor mounts which become weakand worn with age. We suggest that these items be
replaced at time ofengine replacement.
ACCESSORIES
•Be sure to service and inspect accessories such as alternator, starter, water pump,
air compressor, fuel system, EGR valves and all sensors to avoid premature engine failure.
FLYWHEEL
•On engines that use a 1-piece full circle rear main seal and flangeless flywheel
mounting system, over torque of the flywheel bolts may distort the rear seal area and
cause an oil leak.
ENGINE STARTUP
•Check oil pressure. •Engine should start, excessive cranking may be present.
•Check for oil and water leaks. •Install radiator cap after coolant is observed
to be circulating (some thermostats air lock and prevent proper circulation of coolant).
MODULATOR VALVE (located on automatic transmission)
•Pull off lines, if valve is defective, oil may be present. •Replace if above
condition is observed, as it may allow transmission fluid to enter engine through vacuum
system and prevent proper ring seal.
EXHAUST MANIFOLD PRESSURE & SYSTEM
•Replace oxygen sensor with a low pressure gauge. •Run engine at 2500 RPM for 1
minute. •High pressure reading should be less than 2.5 pounds. •A pressure
reading over 2.5 pounds indicates an exhaust system restrictions which will cause engine
damage. Check catalytic converters and exhaust systems for restrictions. •Inspect
exhaust manifold for internal and external cracks, especially on marine applications.
ENGINE ANALYSIS
•Make an engine analysis data sheet (either a diagnostic printout or handwritten
form) showing the status of the engine and the Engine Support System before installation,
after installation and at the 500 mile checkup. •Check following items for possible
problems: •Check engine or service engine soon lights (computer-control problems).
•Check for any trouble codes, this may be a clue to why the engine previously failed.
Check for correct vacuum hose routing and for vacuum leaks.
On computerized emission control systems, check the following items that are applicable:
___ Load sensors
___ M.A.P.
___ V.A.C.
___ BARO
___ Throttle position sensor (TIS)
___ Stepper motor
___ Mixture control solenoid
___ Incorrect PROM (on GM cars)
___ Catalytic Converter Sensor
___ EGO sensor
___ EGR flow sensor
___ Airflow sensor
___ Coolant temperature sensor
___ Crankshaft position sensor
___ Engine RPM sensor
___ Electronic spark controls
___ Idle speed control (ISC)
___ Air temperature sensor
___ Air conditioning sensor (switch)
___ Knock sensor
___ Halleffect switch
___ Turbo boost limiting system (waste gate)
___ Torque converter clutch
___ Road Speed sensor
___ Oil and temperature sending Unit/gauges *
*The failure of some of these sensors can result in abnormal combustion temperatures and
pressures, blown head gaskets, burnt pistons, piston scuffing and burnt valves, bearing
failure and lack of power and may result in eventual engine failure.
•Replace distributor, wiring, coil, and spark plugs to avoid poor performance. On
V-8's, check plug routing. •Final road test vehicle, do not retur to customer unless
you consider vehicle operating according to OE specifications •Give customer printout
of exhaust gas analysis.
© AERA 1996 - All rights reserved. Do not duplicate in whole or in part without prior
written permission.
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