Ideal Engines- Installing a Remanufactured Engine
One of the first things to do when installing a replacement remanufactured engine is to set it side by side on the floor with your original engine. Visually check over the replacement Remanufactured engine to ensure there has been no damage incurred during the shipping process. Also while you are looking it over have a good look at the external oil seals on the engine. Because suppliers do not know how long an engine will be sitting on a shelf before it sells it is always a good idea to visually inspect anything made of rubber like the seals and possibly rocker gaskets before installing the unit into the vehicle. This can prevent a higher amount of labour later if the engine is installed and then found to have a seal that has either shifted or dry rotted because it has sat dry for a few months on a shelf. Once those items are looked over and verified to be acceptable then you should be comparing major mounting points.
Sometimes it helps to strip the original engine down to the same state as the replacement remanufactured engine to perform this step. Once all of the ancillaries (manifolds, turbo’s, starter, alternator and any other bits) are out of the way it till be easier to compare the two engines. Key points to check would be, engine mounts, accessory brackets (alternator, ac pump), it is not uncommon to fond that you might need to swap some of the bits from your original engine like the rocker cover or the engine sump. The reason for this is that while the engine may be identical as far as the cylinder head and block are concerned, that same engine might fit into 6 other models of vehicles each of which have different rocker covers and sumps depending on their configuration. This does not mean the engine is wrong for your vehicle. It simply means your mechanic has to swap bits he already has onto the re manufactured engine to fit it into your vehicle.
Ok so now you have verified the engine is the right one for your vehicle and everything looks sound. Now is the time to start changing over ancillaries and building up the replacement engine to fit into your vehicle. This should be done piece by piece. Even the electrical sensors from the original unit should be swapped over onto the new unit as you know they were working on yours.
Once all the bits are swapped over and the build up is complete then it is time to install the engine into the vehicle. Set it in slowly to make sure you do not pinch any electrical wiring or vacuum lines. Connect the gearbox, connect the exhaust system and coolant pipes. Fill the vehicle with the recommended coolant. Then install a new oil filter and fill with conventional motor oil. The reason you use conventional motor oil is because these remanufactured engines have brand new bearings and piston rings in them. Synthetic or synthetic blend oils are too slick for the parts to be able to bed themselves in. if synthetic is used during the break in period you can expect problems for the life of the engine such as excessive oil burning or low oil pressure. Both caused by parts not bedding in properly.
Now that all fluids are topped off and connections are made, connect the battery terminal and prime the engine by disconnecting the ignition coil for 30 seconds and turning over the engine by key. This does two things, it allows oil to be circulated by the oil pump throughout the system before being under load by running the engine and it also allows the fuel system to prime itself so it bleeds out any air bubbles it may have in it. Reconnect the coil and turn the kay. If everything is connected properly the engine should start up. Keep a keen ear for noises such as vacuum leaks from missed vacuum lines, make sure belts are quiet and tighten where needed. Run the vehicle for atleast 30 minutes and then raise it back in the air on a ramp and check for any leaks. Make sure the cooling fan comes on when the vehicle reaches the proper temperature. Verify there is no engine management light on the vehicles dashboard indicating a fault. Then test drive the vehicle to make sure the vehicle performs as it should.
For the first 1500-2000 miles the engine should be driven lighter than normal ( keep revs down below 4000 RPM wherever possible. When the 1500-2000 miles is up then you should have a basic oil service done on the vehicle and let your mechanic check it over to make any final adjustments to the engine. After that is complete you can drive your vehicle as you normally would and the job is complete.