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Engine Installation

Guidelines
SUGGESTED GASOLINE ENGINE INSTALLATION
PROCEDURES AND INSTRUCTIONS FOR
THE INSTALLING TECHNICIAN
This engine has been carefully remanufactured to precision standards that meet or exceed the OE
manufacturers specifications. It will perform properly IF certain steps are taken by the Technician performing
the installation.
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 any
resulting engine damage.
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 remanufactured engine fails to give satisfactory service, it can normally be traced to a source NOT
associated with the workmanship or materials of the remanufacturer. Incorrect installation practices, foreign
material, detonation, pre-ignition, overheating, oil contamination, incorrect air-fuel ratio, under-lubrication, dirty
tin ware, coolant loss or ineffective air filtering are a few possibilities. These above mentioned reasons for
failure are the responsibility of, and under the control of, the installing technician and not the engine
remanufacturer.
Evaluating and replacing where necessary, the following items with new or remanufactured parts is
recommended; oil pump, new oil pump screen, spark plugs, sensors, motor mounts, oil filter, air filter, water
pump, thermostat, belts, coolant hoses, fuel injection components, oil cooler and lines, PCV components and
vacuum lines. Make sure the EGR valve and EGR passages are clean and operating to OE specifications.
Follow the manufacturer's installation procedures; especially proper torque values. Refer to and comply with
any OE manufacturers specifications and technical service bulletins concerning the engine being installed.
Safety is always first. Always wear safety glasses and the proper protective clothing when working on an
engine.
Contamination is an engines worst enemy. We recommend that you thoroughly clean any and all parts being
transferred from the original engine before installing them on a new remanufactured engine. The use of
abrasive pads or discs is prohibited and the debris from using those products can cause engine failure that is
not covered under the limited warranty. If the part or accessory cannot be properly cleaned it should be
replaced with a new part.

DETERMINE WHY THE ORIGINAL ENGINE FAILED

Do an evaluation of the failed original engine.


Make an engine analysis data sheet showing the status of the engine and the engine support system
before installation for comparison once the replacement engine is installed.
Correct any component problems by repairing or replacing the parts before installing the replacement
engine.
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Engine Installation
Guidelines
INSPECTION OF THE REMANUFACTURED ENGINE PRIOR TO INSTALLATION

Check the engine and packaging thoroughly upon delivery and note any visible damage with the carrier
before they leave.
Check for hidden damage and dirt contamination of the engine while unpacking.
Check the application of engine - make sure the mounting holes, bell housing, crankshaft snout,
flywheel mounting flange, bolt hole patterns, pilot shaft hole, smog/non-smog application, EGR ports,
dipstick holes, etc. are the same on new engine as the old by visually comparing the units and the
casting numbers.
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 indicating heat tabs on the block and the heads are Installed and intact.
Clean all accessories to be transferred from the old engine to the new engine. Resurfacing of the intake
manifold and other machined gasket surfaces on the engine accessories may be required.
Inspect and clean the rocker cover oil baffles to eliminate possible restrictions.
Write down the remanufactured engine serial number for future reference

TIMING COVERS

Inspect the cover for erosion, breakage, warping, porosity and abnormal wear patterns.
Measure covers that contain the oil pump housing for wear and replace the cover if not within OE
tolerances.
Before installing the timing cover make sure the crank and cam sensor tone rings are in place and
properly oriented.
Some timing covers are not reusable and must be replaced. Follow OE manufacturer
recommendations.

DRIVE PULLEY (Harmonic Balancer)

Check the seal surface of pulley hub and repair or replace if grooved or damaged (harmonic balancer
seal surface wear sleeves may be available).
Follow the manufacturers recommendations to lubricate seal surface prior to installation to prevent
damage to the seal.
Check outer ring for slippage as this could cause the timing mark to not indicate top dead center.
Replace any balancers that are set in rubber. (The interior rubber deteriorates with age, allowing the
balancer to slip, possibly causing timing problems and detonation, overheating, vibration and
unexplained noises).

VALVE LASH

Check dry lash at time of installation (if applicable).


Inspect all pushrods, rockers and followers to assure they are not out of place.
Check and adjust valve lash at 500 miles (if applicable).
Lifter rattle at cold start is not uncommon, and does not cause engine damage.

Engine Installation
Guidelines
INTAKE MANIFOLD MUST BE CLEANED OR REPLACED

Foreign material can be trapped in the intake manifold from a previous engine failure. If the manifold
has not been thoroughly cleaned out or replaced with a new part, any failures related to foreign material
will void the warranty on the engine.
Clean off carbon (remove steel heat shield, if equipped, clean and reinstall).
Check for cracks using the appropriate method based on the intake construction material.
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.
Do not use abrasive pads or discs to clean any gasket sealing surface on the engine.
Check water outlet surfaces for corrosion.
Make sure the intake gaskets are properly oriented and sealed.

DISTRIBUTOR OR OIL PUMP DRIVE

Check the distributor or oil pump drive gear for wear and replace as needed.
Check the distributor bushing, mechanical advance, vacuum advance, and total advance.
Check to see that the distributor or oil pump drive is fully engaged and locked in the oil pump to proper
depth.
Check ignition timing against factory specifications, adjust if applicable.

FUEL SYSTEM

Carefully inspect, clean, service or replace all components of the fuel system, i.e. pump, lines, injectors,
regulator, filter, relay, wiring and throttle body.
Check fuel lines for breaks and crimps. Use only approved lines.
Check fuel pump for proper pressure and volume.
Check injectors for proper function and flow.

FILTERS

Replace all filters at time of installation and at O.E. recommended intervals. These filters
include air, oil, fuel, and crankcase.
Use an OE approved cleaning procedure for the air filter housing, intake housing, and MAF sensor.

HEAT RISER OR EXHAUST THERMOSTAT CONTROL

Check to see if unit is free and operating properly, if applicable.


Lubricate with special high heat formula.

Engine Installation
Guidelines
THRUST BEARING

Adjust clutch to proper free pedal clearance BEFORE starting the engine, NOT after.
Make sure the torque converter is fully seated and engaged in the automatic transmission front pump
before installing the transmission and assure it rotates freely before bolting the convertor to the flex
plate.
Check crankshaft end thrust before and after bolting the automatic or manual transmission to engine.
PLEASE NOTE!!! - excessive main bearing thrust wear can be caused by the following:
o Clutch not adjusted properly.
o Interference between pilot shaft and crankshaft.
o Interference between torque converter & crankshaft.
o Torque converter ballooning.
o Blockage and/or restriction of transmission oil cooler.
o Bent, kinked, or damaged supply lines.
Preventing the causes of thrust bearing failure is the responsibility of the installing technician!
Thrust bearing failures are not covered under the limited warranty.

RADIATOR AND COOLING SYSTEM

Replace or re-core the radiator and test for proper flow.


Verify thermal conductivity. Minimum of 25F temperature differential between inlet and outlet of the
radiator.
Always replace the pressure cap and thermostat.
Replace all heater and radiator hoses.
Check the temperature sending unit for the electric fan.
Check the fan itself and if equipped, the fan clutch for proper operation.

OIL SYSTEM

Replace oil cooler housing and cooler lines as they may contain contaminates that will damage your
engine.
Fill the engine to the proper level using only OE specified type and viscosity lubricants or equivalent.
Prime the oiling system to insure vital parts are properly lubricated to avoid a dry start.
o Disable the ignition and fuel systems.
o Use a pressure priming tank at about 40 pounds pressure to prime (pre-lube) the engine.
o Use an OE approved priming tool to rotate the pump.
o Use the OE approved priming method outlined in the service manual.
Always install a new oil pump and new pickup screen.
Install a new oil filter filled with new oil.
Check the oil pump intermediate shaft for correct size and shape to match distributor and oil
pump, if applicable.
Replace the oil pressure sending unit.
Check for proper PCV operation - a plugged line or faulty PCV system may cause excessive oil
consumption and blow by.

RUBBER GOODS

Dont overlook small parts such as belts, hoses (liquid and vacuum), grommets and motor mounts which become
weak and worn with age. We suggest that these items be replaced at time of engine replacement.

Engine Installation
Guidelines
ACCESSORIES

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

FLYWHEEL

Check to see if the engine requires sealer on the flywheel/flex plate to engine bolts to prevent
unnecessary leaks.
On engines that use a 1-piece full circle rear main seal and flangeless flywheel mounting system,
torque the flywheel bolts to the OE manufacturers specifications. If not torqued properly the rear seal
area may be distorted and cause an oil leak.

POWERTRAIN CONTROL SYSTEM (PCM ECM)

Be sure to service and inspect all electrical grounds, connections and wiring.
Use the OE approved sealers and lubricants on all connections.
Re-flash or upgrade the control module to assure the latest programming, if required.

ENGINE START-UP AND BREAK IN

Pre-prime the engine oiling system.


Double check that all accessory, electrical, fuel and cooling systems are mounted, connected and
sealed properly
The engine should start immediately. Avoid excessive cranking.
Once started, make any applicable adjustments to the timing or fuel system.
Run the engine at 1500 to 1800 RPM for at least 10 minutes or until normal operating temperature is
reached.
Check for proper oil pressure and temperature.
Check for any oil and coolant leaks.
Install the radiator cap after coolant is observed to be circulating (some thermostats may air lock and
prevent proper circulation of coolant).
Test drive the vehicle to evaluate engine performance.
o Monitor oil pressure, temperature and charging system.
o Determine if all other vehicle systems are operating properly.

EVALUATE THE EXHAUST 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 and exhaust pipes for any external damage or leaks.

Engine Installation
Guidelines
FINAL ENGINE ANALYSIS

Check for check engine or service engine soon lights (computer-control problems).
Check for correct vacuum hose routing and for vacuum leaks.
Check for proper accessory belt routing.
Final road test the vehicle, do not return to customer unless you consider vehicle operating
according to OE specifications
Give the customer printout of exhaust gas analysis.
Schedule a follow up inspection after the first 500 miles.

OTHER ENGINE RELATED SENSORS AND ITEMS TO BE AWARE OF


On computerized emission control systems, check the following items that are applicable:
Load sensors

M.A.P.

V.A.C.

BARO

Throttle position sensor (TPS)

Stepper motor

Mixture control solenoid

Incorrect PROM (on GM cars)

Catalytic Converter Sensor

EGO or O2 sensor

EGR flow sensor

Airflow sensor

Coolant temperature sensor

Crankshaft position sensor

Camshaft position sensor

Engine RPM sensor

Electronic spark controls

Idle speed control (ISC / IAC)

Air temperature sensor

Turbo boost limiting system (waste gate)

Air conditioning sensor (switch)

Torque convertor clutch

Knock sensor

Road speed sensor

Hall Effect switch

Oil and temperature sending units and 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.

This information is provided from the best available sources; however, RMP does not assume responsibility for data accuracy or
consequences of its applications. Please be aware that this pamphlet is not a warranty. If there is any question, refer to the
product guide included with the engine or call RMP at 1-800-257-7418

EIG 2/2015