Installation Instructions

Before beginning the engine installation – please review the following instructions:

• Verify      the root cause of the original engine failure
• Check      engine assembly for shipping damage.
• Verify      the engine ordered and the engine received is correct for the application
• Read      all additional information supplied with the engine.
• Have      shop manual available for torque, timing, and other factory      specifications.

STOP NOW and check your existing components!!

1.  The intake manifold must be thoroughly cleaned and free of all debris before being installed on the engine.  Debris such as old piston, piston ring, or valve material can be trapped in the intake, plenum, and EGR System.  The debris can and will be pulled into the replacement engine causing the engine to fail.  DO NOT GLASS BEAD, SAND BLAST, OR use anything that could get lodged in the intake. 

2.  Installer must diagnose, repair, and insure proper operation of engine related systems and subsystems.  Failure to make repairs to these components may result in engine failure.

Cooling System:

• Fan      (motor, wiring, relays, switches or clutch)
• Hoses
• Thermostat
• Water      Pump

Fuel System:

• Volume      and pressure
• Quality      (sugar, water, debris)
• Injectors
• Vacuum      hoses
• Controls      – PCV & EGR
• Catalytic      converters (plugged, leaking, restricted)
• Air      induction (air cleaner and inlet hoses)

Electrical/Electronic Systems:

• Stating
• Charging
• Ignition
• Computer      controls
• All      associated wiring, relays and sensors

AFTER INSTALLING THE ENGINE

CHECK ENGINE FOR INTERFERENCE

Rotate the crankshaft by hand a minimum of FOUR complete revolutions before engaging the starter.  Nuts, bolts, washers or other small parts may have been dropped into the intake manifold or intake ports and can severely damage replacement engine.  

OIL PRESSURE

The oil pump on this engine must be primed and the entire oiling system must be purged of air before the drive belts are installed and the engine is started.  

• The      preferred method is to use a pressurized system to push clean oil through      the entire oiling system.
• A      distributor type engine can be primed with priming tool and drill motor to      rotate the oil pump shaft.  The technician must make sure that oil      flows to the top of the engine and into the rocker arms.
• Check      and adjust oil level after priming and purging is complete
• Oil      coolers need to be replaced with the cooler lines cleaned of all debris.

COOLING SYSTEM

• Fill      to manufacturer’s recommended levels
• Proper      concentration of manufacturer’s recommended coolant
• Air      bleed:  Many late model cooling systems MUST be air bled or      overheating will occur.

VALVE LASH

Engines equipped with adjustable rocker assemblies must be readjusted after engine “Run In”.

OIL COOLER

Oil cooler must be replaced!!!! Cooler cannot be cleaned and reused.  

For any technical help during engine installation or after starting up please call 505 Performance Tech Support.  All engine reported to be defective will be disassembled and thoroughly inspected.  

ATTENTION!!

Engine oil cooler must be replaced if you have one!!!

The tech department offers the following information concerning reuse of oil coolers.

Some vehicles are originally equipped with oil coolers which are part of the radiator assembly; others may have aftermarket cooler added to the oiling system.

Regardless of design the OIL COOLER must be replaced, or the replacement engine warranty will be void.  

Small bearing and crankshaft material cannot be entirely removed by simply flushing the cooler.  If this is attempted and the original cooler is REUSED it will contaminate the engine’s oiling system, resulting in multiple engine failures until cooler is replaced.