Do you have a list of replacement parts or the parts on-hand?
1. New water pump, timing belt/chain, front and rear main seals on used and reconditioned engines must be installed.
2. Oil strainer and pick up screen must be cleaned or replaced prior to installation.
3. Thoroughly clean all units such as oil pan, timing cover, rocker arm covers, intake manifold and any other parts that may need cleaning before reassembling.
4. Replace oil filter and oil.
5. Replace tune‐up items such as plugs, cap, rotor, fuel and air filter, pcv valve, and other parts specific to the engine.
6. Check and adjust valves and timing to factory specifications.
7. Replace thermostat and test cooling system.
8. Fuel lines should be checked for debris and flow.
9. Inspect wire harness for broken wires or insulation damage.
10. Always remember to prime oil pump and oil lines.
11. Change your oil and filter after the first 500 miles and every 3000 miles thereafter.
12. Catalytic converter must be inspected to make sure it is not clogged. A defective converter can cause damage to piston rings and internal bearings.
13. Check all cooling components such as hoses, freeze plugs, radiator and coolant. Radiator should be cleaned or replaced.
14. Blow out intake ports to remove any loose particles that may fall into cylinder head and cause damage.
15. Replace all seals and gaskets regardless of condition. These include but are not limited to valve cover, oil pan, intake and exhaust manifolds, and timing cover. Seal or gasket failure is not covered under basic warranty. Damage caused by seal or gasket failure is not covered. miesk5 note, also replace rear main and trans gasket.. have to see what trans you have.
Engine Start‐Up Procedure:
1. Remove all spark plugs
2. Remove oil sending unit switch.
3. Crank the engine until oil comes out oil sending unit switch hole.
4. If oil won’t come out, spray the oil sending unit switch hole with oil or penetrating lubricant to prevent dry start.
5. Afetr oil comes out, replace oil sending unit switch and crank engine for 1 to 2 minutes, until oil pressure is normal.
6. Replace spark plugs and then start engine. Do not accelerate above idle until normal oil pressure is reached
This by Ford;
Remanufactured Transmissions & Engines - Motorcraft® Brand, Broncos & all Ford vehicles 19 MB pdf
Source: by fordinstallersupport.com @ http://www.fordinstallersupport.com/files/catalogs/ptm200.pdf
"Before beginning the engine removal and installation process, be sure to review these Installation Instructions.
The INTAKE MANIFOLD MUST be
thoroughly cleaned and free of debris
BEFORE BEING INSTALLED ON THIS
If the debris is metallic (aluminum or iron) then replacement of the intake manifold is
recommended, as it is difficult to ensure all foreign materials have been removed
If the debris in the intake is soft deposits (carbon buildup, sludge, oil), it is not necessary to replace intake manifold
NEVER reuse an oil cooler from the failed engine. A new oil cooler must be installed if not already provided on the replacement engine.
Engine lubrication system priming and purging MUST be performed before starting any replacement engine, or on an engine that has had a major repair.
Doing so helps to ensure the life of the engine, and prevents you from having to deal with a costly repeat engine replacement.
Verify the correct amount of oil is in the engine crankcase
Install an engine oil pressure gauge
Disable the fuel supply shutoff (inertia) switch to prevent the vehicle from starting
Crank the engine in 15-second increments, allowing a 30-second cool-down pause between each cranking period
Continue this procedure until oil pressure is observed on the pressure gauge, plus an
additional two minutes (short durations) to ensure lubrication system is purged.
Overheating can cause severe engine damage.
For this reason, it is CRITICAL to ensure the cooling system is properly filled. Always refer
to section 303-03 of the vehicle workshop manual for specific cooling system fill and bleed
NEVER use impact tools to remove or install a Knock sensor.
Use of impact tools and overtightening the knock sensor mounting fastener can destroy
the sensor and cause engine failure
Index Mark Torque Converter
Before disassembling the torque converter from the flexplate or the pressure plate from the flywheel, index mark the torque converter position to the flex plate or the
pressure plate position to the flywheel. Clean and Inspect Transferred Components
Thoroughly clean and inspect all component parts being transferred from the failed engine to the replacement engine.
Use extreme care when cleaning sealing surfaces of component parts that will be transferred from the failed engine to the replacement engine.
1 Remove/clean/inspect/install reusable parts and components
2 Install new oil cooler, if not equipped on replacement engine
3 Prime and purge Lubrication System before starting the engine
4 Check/adjust fluid levels, ensure proper cooling system fill
5 Allow engine to warm up to operating temperature
6 Verify oil pressure is within specification
7 Verify coolant level
8 Check for loose connections/leaks, adjust/repair as required
Most vehicles have radiator in-tank fluid coolers. This type of cooler will require flushing or
replacement. Always refer to the vehicle service publications.
IDENTIFICATION OF THE RETURN TRANSMISSION COOLER LINE
E4OD - The REAR transmission case fitting receives the return line.
MISCELLANEOUS PROBLEMS THAT CAN DAMAGE AN ENGINE
•Nuts, bolts, washers or foreign materials dropped down the intake. We have seen this more than once.
•Reusing an intake off an engine that had broken parts in a cylinder. The parts can get bounced up into the intake manifold, carburetor or air cleaner (pieces of piston, or piston rings etc.). When you put your used intake on your new engine and start it, the pieces are drawn in and damage your engine.
•Bead blasting an EFI intake. You will NEVER get all the blasting media out. When the engine is started it draws the blasting media into the cylinders, destroying the engine.
•Not properly torquing fasteners when installing new parts to your engine. Over torquing of the intake manifold bolts to cylinder head on 302 and 351W engines can cause head gasket sealing problems.
•Distributor gears installed at the incorrect height and gears made of the wrong material. We have seen this a lot on remanufactured distributors as well as popular aftermarket manufacturers of distributor assemblies. Use cast iron gears for cast iron flat tappet cams, and steel gears for steel hydraulic roller cams.
•Improperly installing the torque converter can force the crank forward damaging the engine thrust bearing. This is most commonly caused from not locating the torque convertor drain plug properly in the flexplate.