Thunderbird Ranch

Engine install and break in checklist

courtesy of "The Edge" newsletter by Enginetech, Inc.

Following these few basic operations will help save time and provide you with a well installed, trouble free and dependable engine assembly. Please check off each item as required.

Pre-assembly Check List

Thoroughly clean any parts which are to be reused. Be sure no vacuum or EGR passages are restricted. Clean out any carbon build up in throffle body areas.

Thoroughly clean the threads of any bolts to be reused.

Checkall gasketandsealmating surfaces for warpage and bent or damaged areas which could result in sealing failures. Clean all gasket surfaces of oils' paint etc.

Prime the oil pump with engine oil or assembly lube before installing it on the new engine.

Replace the oil pick up tube/ screen.

Read and follow all instructions supplied with the gasket set. Only use gasket adhesives/sealers where required by the gasket manuf acturer.

Inspect the radiator f or any signs of leakage or clogged or corroded tubes. Repairorreplacetheradiator it isn't in perfect condition.

Clean the air conditioning condenser fins to provide plenty of air flow to the radiator.

Visually inspectthe new engine tobe sureitis anequivalentmatchto the engine being replaced. Inspect

the new engine for any obvious defects.

D e t e r m i n e a n d c o r r e c t t h e c a u s e of engine failure prior to installing the new engine, (overheating, transmission slippage, fuel in oil, etc.)

Assembly Checklist

Use your torque wrench. Torque all bolts in sequence where specifications are available. Lightly lube bolt threads.

Use a thread sealer where bolts enter any fluid areas, (coolant or oil areas) to prevent leakage around bolt threads.

Pre-lube the lifters, push-rods androckers with assembly lubeprior to installing.

Install a new cooling system thermostat.

Install new cooling systemhoses and clamps, (radiator, heater, bypass etc.)

Install a new water pump and fanclutch.

Install new drive belts.

Install new timing belts and any idler/tensioner pulleys that the timing belt contacts.

Overhaul or replace the carburetor. Replace the carburetor and EGRbasegaskets. CheckEGRoperation, replace if needed.

Install a new fuel pump (if mechanical, engine mounted type)

Inspect and replace motor and transmission mounts as needed.

Inspectthe clutch, flywheel, flex plate etc. and replace as needed. If the thrustbearing was bad, checkfor swelling of the torque converter.

Fill the new oil f~lter with motor oil before installing.

Fill the engine with break-in oil recommended by the engine rebuilder.

Prime the oiling systemby manually operating the oil pump.

Install new sparkplugs (recommend OEM type sparkplugs)

Install new distributor cap, rotor and spark plug wires.

Install new air filter, fuel filter, crankcase filter and PCV valve.

Fill the cooling system with a 50/50 mixture of new antifreezel coolant and distilled water.

Initial startup

Monitor oil pressure gauge/ light. Full oil pressure should be present immediately after start up. Stoptheengine immediatelyifnooil pressure is observed.

Visuallycheckforfluidleaks. If leaks are present, stop the engine immediately andrepairleaksbefore restarting.

Listen for any unusual noises, (knocking, tapping, scraping, etc.) Stop the engine if any unusual noises are present.

Monitor the engine temperature gauge as the engine warms up. Don't allow the engine to overheat before completing the cooling system fill procedure.

After engine warm-up, turn off engineandcheckforcoolspotsinthe radiator core. Cool core spots would indicatearestrictedcore. Alsocheck upper and lower radiator and heater hoses for even temperatures.

Adjust the ignition timing to the manufacturers specifications using the approvedmethod.

If equipped with an electric radiator cooling fan, verify that it comes on (between 200 & 230 degrees F) and that it cycles off when thecoolanttemperaturelowers (usuallynearthethermostatopeningtemperature)

Break in

Constantly monitor gauges/ warning lights. If any unusual indications are observed, stop the vehicle immediately.

Check the fluid levels daily, correct as needed and repair if excessive fluid loss is observed.

Check for fluid leaks daily, if any leakage is observed do not operate the vehicle until correcting the problem.

Have a complete engine analysis performed (starting, charging, ignition, fuel and on-board computer systems).

Change the oil and filter at 200 miles, 1000 miles' 2000 miles, and every 3000 miles or 3 months



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