Installation Instructions For Diesel Engines
TO INSTALLING MECHANIC OR 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, or an ADS 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 abnormal combustion or "lugging", overheating,
excessively rich air-fuel ratio, under-lubrication,dirt, coolant seepage,
or ineffective air filtering. The above mentioned reasons for failure are
the responsibility, and are 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, motor mounts, oil filter,air filters, water pump,
thermostats, crankcase ventilation system, clean lines (Note: A plugged line
or faulty assembly may cause excessive oil consumption), remanufactured
or new fuel
system components, new or remanufactured Oil-Cooler when applicable, remanufactured,turbocharger,
and the supercharger inter cooler.
Insure the EGR valve is operating to O.E.M specifications. (if applicable)
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 the 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 and fuel injection timing.
• Check that ALL oil gallery plugs are installed, tightened 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 the new product
as on the old by comparing casting numbers and mounting holes.
• Replace with new or remanufactured 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 or remanufactured lifter assemblies and inspect push
rods on short blocks to avoid camshaft wear and premature failure.
• Do not preloads hydraulic lifters (it causes undo stress to camshaft and
lifters which may lead to early failure).
• Hydraulic lifter rattle at cold start is not uncommon, and does not cause
engine damage.
• Roller lifters may be reused if within O.E. specifications.
• Hydraulic Lash Compensators (HLC) are generally reusable, but may need
to be cleaned and purged of all air.
TIMING COVERS
• Inspect for erosion, breakage, war page, porosity and abnormal wear patterns.
• Measure covers containing oil pump for wear and replace if not within
O.E. tolerances.
• Install new timing chain tensioners, dampeners, etc. when applicable.
Idler gear assemblies require inspection for wear and reusability.
CYLINDER HEAD Torque
● Properly torque cylinder head at installation to O.E. specifications
in the correct sequence. (Use new bolts when O.E. requires them).
DRIVE PULLEY (Harmonic Balancer/Dampener)
• 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, overheating, vibration and unexplained noises).
• Viscous dampers require inspection and/or testing based upon O.E. mileage/hour
limits. Must be replaced when initial engine had catastrophic failure.
INTAKE MANIFOLD MUST BE CLEANED
• Clean off carbon (remove steel heat shield, if equipped, clean and reinstall).
• 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. (when applicable)
• Do not over torque manifold bolts. Use O.E. torque specifications and
sequence ONLY.
• Do not glass bead intake manifolds to clean.
• Check water outlet for corrosion.
• Disassemble and reseal intake manifold sections.
VALVE LASH
• Consult shop service manual for dry lash setting for nonadjustable rocker
arms.
• Check dry lash at time of installation (if applicable).
• Check and adjust lash at 500 miles (if applicable).
• Verify crossover bridge balance (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.
FUEL SYSTEM
• Carefully service or replace all aspects of the fuel system, i.e. pump,
lines, fuel injection components, supply pump, injection pump and injectors.
• Check fuel lines for breaks and crimps. Use only approved fuel lines,
rubber, and braided steel.
• Check fuel supply pump for proper pressure.
FILTERS
• Replace all filters at time of installation and at O.E. recommended intervals.
These filters include air, oil, fuel, and crankcase.
• Clean air cleaner housing, crankcase vent tubes coolers, air compressors.
RADIATOR/COOLING SYSTEM
• Recore or replace the radiator and test flow.
• Verify thermal conductivity. Minimum of 35°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 O.E. 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 precluding of system before initial fire up (follow recommended procedures).
Call for further information.
• Install new/remanufactured 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 (if applicable).
• Replace oil pressure sending unit.
• Replace oil cooler if catastrophic failure, pressure test and reseal
bundle within assembly.
THRUST BEARING
• Adjust clutch to proper free pedal BEFORE starting engine, NOT after.
• Check crankshaft end thrust before and after bolting transmission to
engine.
PREVENTING THE CAUSES OF THRUST BEARING FAILURE IS THE RESPONSIBILITY
OF THE INSTALLING TECHNICIAN!
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 oil supply lines
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
that these items be replaced
at the time of engine replacement.
ACCESSORIES
● Be sure to service and inspect accessories such as alternator, starter,
water pump, air compressor, (which can be a source of oil consumption),
fuel system, EGR valves and all sensors to avoid premature engine failure.
FLYWHEEL
• Install bolts with sealer or replace as required.
• On engines that use a 1-piece full circle rear main seal and flange less
flywheel mounting system, over torque of the fly wheel bolts may distort
the rear seal area and cause an oil leak.
• Verify clearance between flywheel and seal housing.
ENGINE START-UP
• Do not under any circumstances use starting fluid.
• Engine should start, excessive cranking may be present.
• Check oil pressure.
• 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 (if applicable) (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 restriction
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.
• Road test the vehicle, do not return to customer unless you consider
vehicle operating according to O.E. specifications.
ENGINE ANALYSIS
OIL PRESSURE
● Observe oil pressure reading immediately after starting the engine. If
there is no oil pressure within 10-15 seconds, stop engine and check lubricating
oiling system. Once recommended engine break-in period is concluded, oil
sampling should be done to verify no premature or abnormal component wear
occurrence.
Run-In
● Run engine at part throttle and at no-load until it reaches operating
temperature prior to
applying any load.
Inspection
● With engine running at operating temperature, check for coolant, fuel
or lubricating oil leaks.
Cooling system
• Verify that cooling system has reached operating temperature and circulated
effectively and that the level is correct.
• Avoid unnecessary idling periods, engine coolant temperature will fall
below normal operating temperature range. Once normal cooling system operation
has been verified appropriate coolant conditioner should be introduced to
avoid cavitation and electrolysis.
Turbocharger (if applicable)
● Visual inspection of leaks and possible vibrations should be observed.
If there is any unusual noise STOP engine immediately.
© AERA 1999 - All Rights Reserved
This information is provided from the best available sources, however,
AERA does not assume responsibility for data accuracy or consequences of
its applications. Please be aware that this pamphlet is not a warranty.