1. Before disconnecting the battery or removing the old engine, determine why the old engine failed. Check the vehicle computer for trouble codes. If not a basic engine problem, repair the problem before installing the new engine.
2. Remove the old engine from the vehicle. Remove the accessories from the old engine that will be needed on the new engine. These parts must be thoroughly cleaned and checked for usability before installation on the new engine.
3. Do Not Reuse, REPLACE: Oil Pick-Up Tube and Screen
Thermostat Hoses Coolant Oil Filter
Spark Plugs PCV Valve Air Filter Fuel Filter
Fan Belts Oil Pilot Bearings (Manual Shift)
4. CHECK CONDITION (Replace or repair as necessary):
Radiator Cap Carburetor/Fuel Injectors Radiator
Battery Cables temperature Sending Unit Battery
Engine Mounts Oil Pressure Sending Unit Fan Clutch
Spark Plug Wires Heater Control Valve Starter
Water Pump Heater Riser Valve Fuel Pump
Distributor Clutch & Throw-out Bearing (Manual Shift)
Pressure Test Radiator Check Fan Switch and Shroud
5. Before installing oil pump, install new pick-up tube assembly. Old tube can't be properly cleaned and some tubes may fall off due to a loose fit.
6. Submerge new oil pump in oil and turn to assure oil pump is primed and working (with exception to front covers.) Front covers are already primed with petroleum jelly.
7. After the oil pump has been primed and installed, install the cleaned oil pan. Turn the engine upright and pour 4 quarts of new oil into the engine and install a new oil filter. Rotate the oil pump with a drill motor, filing the oil system with oil. Check the oil level after this step and fill to the full line.
8. After all components have been installed on the engine and the new engine is installed in the vehicle, crank the engine over with the starter without the ignition connected. The engine should build oil pressure off the starter. (Oil light will go out or 15 psi reading or more on the oil gauge.)
9. Check all fluid levels and connect the ignition system. Start the new engine. DO NOT REV THE NEW ENGINE. Bring the engine to a fast idle, approximately 1,000 to 1,200 RPM, and let engine run until it reaches full operating temperature. Bring engine down to normal idle RPM. Check for leaks, proper oil pressure and check ignition timing.
10. Road test the vehicle. In high gear, run the engine up to 35 to 40 MPH and let it coast back down, then accelerate back to 45 to 50 MPH and let it coast back down. Repeat at least 10 times. Do not hold at any steady speed for a prolonged period of time during the first 150 miles. Readjust valves on adjustable valve applications.
11. On late model vehicles with computer controls, it may be necessary to recalibrate all the controls; carburetor, ignition, etc. Proper tune up is extremely important. Check the computer for trouble codes.
12. Perform maintenance recommended in your Owner’s Manual.
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