Installation instructions
Thank you for purchasing a new, used or overhauled engine. We have made every effort to optimise the quality of the product we supply. We therefore ask you to study these installation instructions carefully, so that problems and frustration can be avoided. Damage resulting from incorrect installation is not covered by the warranty. Should problems still arise afterwards, please contact our company immediately. We advise you always to use the manufacturer's original specifications when removing and installing. Only if these are not available can these general instructions be of use to you.
Reception
Check the product for possible transport damage immediately on receipt. If you notice such damage, make a note of it on the driver's waybill. Only then can the damage be claimed from the insurer of the carrier concerned. If you fail to do so and sign the waybill for approval, no claim can be made and all additional costs will be for your account. If possible, take photos of the damage; this simplifies and speeds up the settlement. Check that the type supplied is correct. In doing so, also look carefully at the threaded holes in the block and at the mounting points for the various sensors. We supply some products with temporary parts (timing cover, oil pick-up strainer, sump and/or valve cover). If so, replace these at your own expense with the parts from your old engine. Before conversion, clean these parts thoroughly and check them for quality.
Tracing previous damage
To prevent the newly supplied product from immediately suffering the same damage as the old part, the cause of the previous damage must first be traced and eliminated. Consider, for example, the following:
- Air intake system: check the quality of the air intake system. Leaks in it can let dirt or dust through and thus lead to increased wear. Check the intake manifold for foreign and/or broken parts, tap it out thoroughly and blow it through with air. Also check the mating surface of the manifold.
- Cooling: optimal cooling is vital for the service life of the product. Check the flow through the radiator, the operation of the fan, sensors and thermostat, the operation of the viscous coupling, the cap of the radiator and/or expansion tank, and the quality of the water hoses and hose clamps. If we did not supply the water pump, check your old pump for the bearing, the seal and excessive corrosion. Check rubber seals and air baffle plates to ensure good airflow; a dirty fan can also cause vibrations.
- Fuel system: an incorrect fuel mixture ratio can cause overheating and/or excessive wear of piston rings and cylinders. Check the quality of the fuel filter. Check the diaphragm of the feed pump; a leaking diaphragm can dilute the engine oil and thus cause bearing damage. Have a specialist check the injection components and the injectors. Correct adjustment and injection timing are vital to performance; a leaking injector can cause immediate piston damage.
- Ignition: the quality and timing of the ignition largely determine the service life and performance of the engine. Check the components of the engine management system with special test equipment. On older ignition systems, check the ignition timing and inspect the hoses and the diaphragm of the vacuum advance.
- Crankcase ventilation: a blocked crankcase ventilation causes increased crankcase pressure, which can make oil seals and gaskets leak.
- Exhaust system: check that the passage is not blocked by broken parts.
Assembly
Take the time and the calm to assemble the product correctly. This ultimately prevents problems and saves you valuable time. Fit as many conversion parts as possible on your workbench rather than later in the engine bay. This is more pleasant to work with and gives you better control over your own work.
Start by cleaning the engine compartment; this is considerably more pleasant to work in and is an extra service to your customer. Clean all the mounting parts of your old engine that you need for the build; this prevents thread damage and incorrect tightening tensions. Carefully clean all parts you use during assembly, such as injection lines, the intake system, the exhaust system, crankcase ventilation and the various parts of the cooling system.
If the oil cooler is not supplied, it must always be renewed. Make sure the gaskets are always fitted correctly and do not inadvertently block any holes. Fit a good, new air filter and clean the air filter housing. Fit a good, new oil filter; a new oil filter is almost always included when you purchase an engine. Fit a good, new fuel filter. Check the old filter for water particles in the fuel system; if so, clean the entire fuel system up to and including the tank.
Fasteners
Stretch bolts must not be reused. Tighten all bolts and nuts to the prescribed torque for that type of bolt and/or nut. Because the torque depends on the type and size of the bolt, a deviating torque can cause damage. Stretch bolts are tightened to a torque and then retightened by a specified angle. Always check that you have the correct data; the tightening sequence may also be prescribed. Follow it precisely.
Before fitting the flywheel, check whether the threaded holes in the crankshaft have been drilled through. If so, apply a liquid thread locker to the threads of the flywheel bolts. Tighten the bolts and nuts of the injection components to the correct torque; on modern engines in particular this prevents problems. Bear the injector lines in mind as well.
Engine assembly
Make sure the supplied engine stands firmly and securely on your workbench, and mind which side you place the product on. If you have to transfer transport parts, use the supplied gaskets or a good-quality liquid sealant. Fit all ancillaries to the correct tightening tensions.
Fit the crankshaft pulley carefully. Check the seal running surface and make sure the key is not pushed out during fitting. Tighten the crankshaft pulley bolt to the correct torque; in a number of cases a liquid thread locker is advisable. Fit the timing carefully to factory data; being one tooth out can already have serious consequences. Check the fuel pump setting against factory data. Fit the injectors with new sealing rings and heat shields. Fit protective covers carefully and check that they do not touch rotating parts. Renew the V-belt or serpentine belt.
If an automatic gearbox is fitted, carefully press the hollow shaft of the torque converter into the gearbox oil pump. Make sure the drive lugs of the hollow shaft engage correctly in the recesses of the oil pump. To prevent damage to the radiator, we advise removing it before the engine is installed. Use the correct lifting equipment to place the engine in the engine bay; this prevents damage during installation. When fitting, check all plug connections and use good hoses and hose clamps. Use good-quality engine oil and coolant and fill both to the correct level. It is important that the cooling system is properly bled.
Starting procedure
Before starting, it is important that all parts are secure, that there is enough oil in the sump, that there is enough coolant in the cooling system and that the belt tension is correct. On a petrol engine, first disconnect the spark plug leads; on a diesel, the fuel supply to the cylinders must be interrupted. First crank the engine until it has sufficient oil pressure. If this does not work, bleed the lubrication system by filling the oil filter with oil and filling the oil gallery using an oil syringe. Once there is sufficient oil pressure, reconnect the spark plug leads or, on a diesel, open the fuel supply to the cylinders.
Let the engine start and run at a slightly raised idle speed. Closely monitor the oil pressure and temperature. Top up enough coolant while bleeding. Check for oil and/or water leaks. Adjust the ignition and, where fitted, the carburettor according to specification. Check that the entire cooling system works properly, that the thermostat opens and that the fan cuts in.
Running-in instructions
Make sure the engine reaches operating temperature properly before loading it. Avoid extreme loads for the first 1,000 kilometres; change down in good time so that the engine does not run at low revs under a high load. Load the engine to at most 70% of its power. Avoid prolonged idling and driving at constant revs. Do not be too cautious either: otherwise the piston rings will not get the chance to bed in properly, which can lead to oil consumption.
Follow-up check
After 1,000 kilometres, we advise you to check the engine. Check all fastenings to make sure nothing has vibrated loose. Check the oil and coolant levels and check for leaks. Replace the oil filter at 1,000 kilometres.
Returning the old part
Remove all oil and fuel residue from the old part to be returned. Seal all openings with the red caps that were in the product we supplied. Check that the old part is complete; missing parts will be charged and deducted from the deposit to be credited.
The above instructions are of a general nature. We expressly point out that we cannot be held liable for damage resulting from differences between these instructions and the manufacturer's original specifications. Nor can we be held liable for any interpretation or printing errors in the information we provide.