ENGINE INSTALLATION PROCEDURES
This engine has been carefully
remanufactured to precision
standards. It will perform
properly IF certain steps are
taken by the person making the
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 for properly
installing the engine.
When a properly remanufactured
engine fails to give satisfactory
service, it can be due to
detonation, pre-ignition or
“lugging”, overheating due to
improperly working cooling system or
a lean burn condition, excessively
rich air-fuel ratio,
under-lubrication, dirt, improperly
cleaned covers, reusing the oil
cooler, coolant seepage, ineffective
air filtering. The above mention
reasons for failure are the
responsibility, under the control,
of the installing
mechanic/technician not the engine
BEFORE INSTALLING THIS
REMANUFACTURED ENGINE IT IS CRUCIAL
THAT YOU DETERMINE WHAT CAUSED THE
PREVIOUS ENGINE’S FAILURE!
In order to insure trouble free
operation of your remanufactured
engine, you must determine what
caused the previous engine to fail
and correct it. After correcting the
cause of the previous engine’s
failure, please read and following
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
Replacing all of the following with
a new or rebuilt/remanufactured unit
is recommended: valve lifters, oil
pump, push rods, rocker arms, oil
pump with new screen, spark plugs,
points (if applicable), condenser,
motor mounts, oil filters, air
filters, water pump, thermostat, PCV
valve & grommets and clean lines
(Note: A plugged line or faulty
valve may cause excessive oil
consumption and blow by), carburetor
(may be rebuilt) and make sure the
EGR valve is operating to OEM
Following the manufacturer’s
installation procedures; especially
proper torque values. Inspect the
rocker cover baffle for possible
Contamination is an engine’s worst
enemy. We recommend that you
thoroughly clean parts that will be
attached to the
Any and all parts not included with
the remanufactured engine or engine
component should be cleaned properly
before installing on a new
INSPECTION OF ENGINE PRIOR TO
Check for freight damage and dirt
contamination of the engine.
Check for proper valve train
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 the product –
make sure the mounting holes, bell
housing, crankshaft snout, flywheel
mounting flange, bolt hole patterns,
pilot shaft hole, smog/non-smog
application, etc., are the same on
new products as they are on the old
by comparing casting numbers.
Clean all accessories to be
transferred to the new product from
the old one. Resurfacing of the old
intake manifold and machine gasket
surfaces is recommended.
TIMING COVERS / REAR SEAL HOUSINGS
Inspect for erosion, breakage,
warpage, porosity and abnormal wear
Measure covers containing oil pump
for wear and replace if not within
Install new timing chain tensioners,
Install camshaft seals and seal cam
Camshaft and rear main seals not
installed by the engine
remanufacturer are not covered by
the engine warranty!!
VALVE LIFTERS – Flat, Roller, HLC
(Hydraulic Lash Compensators)
Install new lifters and inspect push
rods in short blocks to avoid
camshaft wear & premature failure.
Do not preload lifters (it causes
undo stress to the camshaft and
lifters which may lead to early
Lifter rattle at cold start is not
uncommon, and does not cause engine
damage. Roller & OHC lifters may
take up to 1000 miles to bleed and
remove all air pockets. Always use
5W30 oil on OHC and roller
Roller lifters may be reused if
within OE specs.
Hydraulic Lash Compensators (HLC)
are generally reusable, but may need
to be purged of all air.
DRIVE PULLEY / TIMING BELT
Check seal surface of pulley hub and
repair or replace if grooved or
damaged (harmonic balancer seal
surface wear sleeves may be
Do not install the harmonic balancer
with a hammer.
Lubricate seal surface prior to
installation to prevent damage to
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,
overheating, vibration and
Properly install and position timing
belt pulleys for belt installation.
Do not over tighten timing belt.
This will result in damage.
CYLINDER HEAD TORQUE
Properly torque cylinder head at
installation to OE specifications in
the correct sequence. (Use new bolts
when OE requires).
Re-torque cylinder head gaskets at
1,000 miles. Exceptions:
Iron cylinder heads and torque to
yield head bolts.
Consult shop service manual for dry
lash setting for nonadjustable
Properly adjust valves cold and
again after bringing the engine up
to normal operating temperature.
Check and adjust valves at 1000
miles (if applicable).
INTAKE MANIFOLD MUST BE CLEANED
Clean off carbon (remove steel heat
shield, if equipped, clean and
Magnetic particles inspect or die
check for cracks.
Blow out with compressed air to
avoid having foreign material enter
Remove baffle (where applicable) so
that all collected contaminants can
All EGR passages must be cleaned and
free of obstruction.
Do not over torque manifold bolts.
Use OE torque specifications and
Do not glass bead intake manifolds
Check water outlet for corrosion.
ROCKER ARM ASSEMBLIES
Check for wear and replace if
necessary (remanufactured units are
Confirm proper shaft installation as
some can be installed upside down.
Excessive oil consumption may
Check bushing, mechanical advance,
vacuum advance and total advance.
NOTE: Total advance should
not exceed 34 degrees BTDC.
Improper advance will cause
detonation. Detonation will cause
piston damage and can happen very
quickly. New pistons will appear to
explode or self destruct. Broken
or damaged pistons are the result of
piston to valve contact, foreign
objects introduced into the
combustion chamber or detonation and
are not covered by the engine
Check to see that the distributor is
fully engaged and locked in the oil
pump to proper depth.
Adjust ignition timing to factory
Check distributor drive gear for
wear and replace as needed.
Carefully service or replace all
aspects of the fuel system, i.e.
pump, lines, carburetor or fuel
injection components. NOTE:
Fuel injectors are not designed to
operate properly after 90,000 miles.
Improperly working injectors will
cause a lean burn condition and will
lead to excessive combustion
operating temperatures. This
condition will lead to a failed head
gasket and or damaged pistons and
rings. The engine warranty does
not cover head gasket failure!!
Diesel engines: replace injector
pump, injectors and glow plugs.
Check fuel lines for breaks and
crimps. Use only approved steel
Check fuel pump for proper
Check double diaphragm type for
faulty vacuum booster which may pump
oil through the intake system.
Replace all filters at time of
installation and at O.E. recommended
intervals. These filters include
air, oil, fuel and crankcase.
Use cleaning procedures outlined
previously above to clean air
cleaner housing, crankcase vent
tubes coolers, air compressors,
Donaldson valves, etc.
Adjust clutch to proper free pedal
BEFORE starting engine, NOT after.
Check crankshaft end thrust before
and after bolting transmission to
– excessive main bearing thrust wear
may be caused by the following:
Clutch not adjusted properly
Interference between pilot shaft and
Interference between torque
converter & crankshaft
Torque converter ballooning
Blockage and/or restriction of
transmission oil cooler
Bent, kinked, or damaged supply
Preventing the causes of thrust
bearing failure is the
of the installing technician!
Thrust bearing failure is not
covered by the engine warranty!!
RADIATOR /COOLING SYSTEM
Recore or replace the radiator and
Verify thermal conductivity. Minimum
of 25 degrees F temperature
differential between inlet and
Always replace pressure cap and
Prime cooling system before starting
Check electric cooling fan
Check worn belts, hoses and water
Check temperature with special high
Check temperature sending unit fan
HEAT RISER OR EXHAUST THERMOSTAT
Check to see if unit is free and
Lubricate with special high heat
Make sure hot air door opens freely
on air cleaner.
Fill to proper level.
Applications using hydraulic flat
tappet lifters & camshafts must use
a Diesel or Racing motor oil!!!
Regular motor oil no longer has Zinc
and Phosphorous (ZDDP). These were
used by the motor oil manufacturers
as anti-wear additives. You can also
purchase an additive from your local
auto parts store or the major
camshaft manufacturers. We carry an
additive with ZDDP. Note: Use of
regular motor oil will cause lifter
& camshaft failure!!!
We recommend Chevron Delo or Shell
Rotella 15W40 motor oil or a racing
oil with Zinc and Phosphorous (ZDDP).
Do not use a synthetic motor oil or
synthetic blend until you have 2000
miles on the engine. Synthetic motor
oils will prevent the engine from
proper break-in (piston rings,
bearings, camshaft & lifters).
Use only OE specified lubricants or
equivalent to full levels before
We recommend 5W30 on all OHC
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 dry start.
Crankshaft driven oil pumps: remove
back cover and pack pump cavity with
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. NOTE: Do not prime
engine by cranking. This will result
Install new oil pump and pickup
screen. Install new oil filter
filled with new oil prior to
Check oil pump intermediate shaft
for correct size and shape to match
distributor and oil pump, if
Oil pump must be primed before
starting. (Run at 800 rpm intervals
before releasing to customer for use
to assure proper cylinder
Replace oil pressure sending unit.
Don’t overlook small parts such as
belts, hoses (those that carry
liquid and air) and motor mounts
which become weak and worn with age.
We suggest that these items be
replaced at time of engine
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
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 seal area and cause an
Some applications require sealer
used on crank bolts.
Check oil pressure.
Check for proper oil supply to
Engine should start, excessive
cranking will cause damage.
Run engine @ 2000 - 2500 RPM
continually for 20 - 30 minutes to
break in the camshaft. Improper
camshaft break-in re result in
premature camshaft lobe and lifter
wear. Premature camshaft lobe and
lifter wear is not covered under
Check water temperature.
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).
Let engine cool, re-torque cylinder
heads, intake manifold and re-adjust
Re-start engine, check cooling
system function and engine CO level
before road test. Road test and
inspect for oil and water leaks.
Engine oil should be replaced after
the first 500 miles and every 3000
MODULATOR VALVE (Located on
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
Run engine at 2500 RPM for 1
High pressure reading should be less
than 2.5 pounds.
A pressure reading over 2.5 pounds
indicates an exhaust system
restriction which will cause engine
damage. Check catalytic converters
and exhaust systems for
Inspect exhaust manifold for
internal and external cracks,
especially on marine applications.
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
Check engine and service engine soon
lights (computer-control problems).
Check for any trouble codes, this
may be a clue to why the engine
Check for correct vacuum hose
routing and for vacuum leaks.
Replace distributor, wiring, coil
and spark plugs to avoid poor
performance. On V-8’s, check plug
Final road test vehicle, do not
return to customer unless you
consider vehicle to be operating
according to OE specifications.
Give customer printout of exhaust
On computerized emission control
systems, check the fallowing items
that are applicable:
Throttle position sensor (TPS)
Mixture control solenoid
Incorrect PROM (on GM cars)
Catalytic Converter Sensor
EGR flow sensor
Coolant temperature sensor
Crankshaft position sensor
Engine RPM sensor
Electronic spark controls
Idle speed control (ISC)
Air temperature sensor
Air conditioning sensor (switch)
Turbo boost limiting system (waste
Torque converter clutch
Road speed sensor
Oil and temperature sending
* The failure in 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 may result in eventual engine
These conditions are beyond the
control of the remanufacturing
process and are not covered by the
WARRANTY ACTIVATION FORM
Invoice #: ____________Purchase
Part #: _______________W.O.
VIN or Code:
Date of 500 Mile Check-up & 1st
We do not issue your activation
number until you have completed the
500 mile check up & 1st
I have read and followed the
installation instructions. I also
agree and understand the terms of
this conditional warranty:
605 SE Umatilla St.
PORTLAND, OREGON 97202
We will mail your warranty
activation number once we receive
this activation form. If you do not
receive your activation number
within 14 days after mailing this
form please call Toll Free