Recommended Installation Procedures and Instructions:

 

CYLINDER HEAD TORQUE

• Properly torque cylinder head at installation to OE specifications in the correct sequence. (Use new bolts when OE required).

 

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 the combustion chamber.

• Remove the 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 the water outlet for corrosion.

 

VALVE LASH

• Consult the shop service manual for dry lash setting for non-adjustable rocker arms.

• Check dry lash at the 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. It is possible to install the assembly upside down, which may result in excessive oil consumption.

 

DISTRIBUTOR

• Check the bushing, mechanical advance, vacuum advance, and total advance.

• Check to see that the distributor is fully engaged and locked in the oil pump at the proper depth.

• Adjust the ignition timing to factory specifications.

• Check the distributor drive gear for wear and replace it as needed.

 

FUEL SYSTEM

• Carefully service or replace all aspects of the fuel system, such as the pump, lines, carburetor, and fuel injection components.

• Check the fuel lines for breaks and crimps.

• Use only approved steel lines.

• Check the fuel pump for proper pressure

• Check the double diaphragm type for a faulty vacuum booster, which may pump oil through the intake system.

 

FILTERS

• Replace all filters, including air, oil, fuel, and crankcase, at the time of installation and at O.E. recommended intervals.

• 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 degrees temperature differential between inlet and outlet.

• Always replace the pressure cap and thermostat.

• Check temperature sending unit fan switch.

 

HEAT RISER OR EXHAUST THERMOSTAT CONTROL

• Check to see if the unit is free and operating properly..

• Lubricate with a special high-heat formula.

• Make sure the hot air door operates freely on the 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) the engine. This will ensure vital parts are lubricated properly to avoid a dry start. (Spinning the oil pump to accomplish this is not recommended.)

• If the pressure tank is unavailable, use an aftermarket assembly lubricator kit to prelube the system before initial start-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.

• If applicable, check the oil pump intermediate shaft for the correct size and shape to match the distributor and oil pump.

• The oil pump may need to be primed before starting (Run at 800 RPM at intervals before releasing it to the customer for use to assure proper cylinder lubrication).

• Replace the oil pressure sending unit.

• Clean or replace oil cooler (if applicable)

 

THRUST BEARING

• Adjust the clutch to the proper free pedal BEFORE starting the engine, NOT after.

• Check crankshaft end thrust before and after 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 weak and worn with age. We suggest replacing these items at the time of engine replacement.

 

ACCESSORIES

• Be sure to service and inspect accessories such as the alternator, starter, water pump, air compressor, fuel system, EGR valves, and all sensors to avoid premature engine failure.

 

FLYWHEEL

• On engines that use a one-piece full circle rear main seal and flangeless flywheel mounting system, overtorque of the flywheel bolts may distort the rear seal area and cause an oil leak.

 

ENGINE STARTUP

• Check the oil pressure.

• The engine should start.  Avoid excessive cranking.

• Check for oil and water leaks.

• Install the radiator cap after the coolant is observed to be circulating (some thermostats may air lock and prevent proper coolant circulation).

 

MODULATOR VALVE (Located on automatic transmission)

• Pull off lines; if valve is defective, oil may be present.

• Replace if the above condition is observed, as it may allow transmission fluid to enter the engine through the vacuum system and prevent proper ring seal.

 

EXHAUST MANIFOLD PRESSURE & SYSTEM

• Replace the oxygen sensor with a low-pressure gauge.

• Run the engine at 2500 RPM for 1 minute.

• High-pressure readings should be less than 2.5 pounds.

• A pressure reading over 2.5 pounds indicates 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 the 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:

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​*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.

• To avoid poor performance, replace the distributor, wiring, coil, and spark plugs. Also, check the plug routing on V-8s.

• For the final road test vehicle, do not return it to the customer unless you consider the vehicle to be operating according to OE specifications.

• Give customer printout of exhaust gas analysis.​

 

Caution: This partial list of Recommended Installation Procedures and Instructions is intended only as a guide.  If you are not qualified to perform an installation, do not attempt it, as you may be liable for the resulting engine failure.  Other procedures may be necessary to ensure proper engine operation.

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