Installing Confidence – Engine Installation Issues
By Brian Manley
In doing my research for this article, I began by listing all of the parts and procedures that I could think of that are used when performing an engine replacement. Then, I interviewed some local independent technicians who perform engine swaps occasionally. And lastly I spent time in a local machine shop that performs the entire operation from pulling the engine, through all of the machine work and reassembly, and finally installing and testing. When I finished my research, I was surprised at the importance of a few items that I had left off of my initial list!
- Properly evaluate the job.
- Using a checklist, record and attempt to verify the condition of all related parts.
- Using multiple information systems, locate all pertinent technical service bulletins.
- Remove the engine assembly.
- Disassemble the engine, while continuing to record necessary “extras.”
- Call the customer with the final estimate. Discuss the service bulletin updates and the root causes for the engine failure.
- Rebuild or purchase an engine (short or long block).
- Install the cylinder heads and “tin” the engine.
- Install the engine into the vehicle.
- Set-up, test-drive and re-check your job.
While interviewing Don McDonald of Havana Machine in Aurora, CO, I was surprised at the thoroughness of their shop’s vehicle inspection sheet. Many items were no-brainers: tune-up parts, drive belts, clutch components, vacuum hoses and radiator hoses. But, have you ever considered the following during an engine replacement?• Molded hoses – Many of the smaller coolant hoses are overlooked.• Oil coolers – If the engine had metal moving through its oiling system due to bearing failure, consider replacing the oil cooler instead of simply flushing it out.• Belt tensioners and idler pulleys – Are the pulleys grooved or are the bearings worn out?• Fan shroud/Fan clutch – Is the full volume of air being pulled through the radiator?• Fan motor/Fan switch – The switch can be sold as easily as a new thermostat, but how hard do you push for a new cooling fan motor?
• Battery/AC generator/ Starter/Cables – What an opportunity to sell a complete starting and charging system diagnosis!
• Distributor – Are the bushings worn out? Is the AC pickup assembly or Hall effect sensor original?
I’m sure that you can think of a half-dozen TSBs that would be visited during an engine swap, but can you remember them all? It’s wise to search in as many databases as possible for any applicable TSBs, especially safety bulletins.
You and I probably have a few issues that Havana Machine doesn’t have to deal with. When they take an engine out of the vehicle, that very engine is machined, rebuilt and reinstalled. They don’t experience rebuilt engines that don’t have bolt holes drilled for the motor mount, or a crankshaft that won’t accept the inner diameter of your flex-plate. When you are buying a crate engine, make certain you compare every detail before dressing the new engine.
OK, up until this point we’ve been rippin’ and tearin’ an engine apart and writin’ stuff down on a check sheet. Now we’ve got to be certain that we’re focused on the job at hand, ‘cause it’s painful when you have to tear an engine due to head gaskets living on the wrong side of the block. Not only do we have to worry about the normal rebuilding of the engine, we have to be certain that there are no service bulletins that pertain to the long block itself.
Now that the engine is painted, dressed and run on the engine test stand (if you have one), then you’re ready to toss that puppy back in place. Mounts, hoses, bell-housing bolts, brackets and pumps are all reattached. Are you like me and let the air ratchet dead head to properly torque these fasteners? Well, I do still torque critical ones, and I use blue Loctite on pulley bolts or other threads that I want to ensure stay locked.
Once an engine is installed at Havana Machine, a comprehensive Pre-Delivery Inspection is performed. All fluids are filled and burped, clutch or transmissions kick-down cables are adjusted, and a five-gas exhaust analysis is performed.In our emissions test area, it is critical to be thorough when servicing the engine performance system. When the injectors are tested and cleaned or replaced, and the computer input sensors are checked or replaced, this goes a long way toward ensuring that the vehicle will have a fighting chance of passing our enhanced emissions test. Even if you don’t have mandatory emissions testing in your area, what kind of engine performance improvement will your customer realize when you pay close attention to those critical Powertrain Control Module inputs?Heck, let’s take it a step further and make certain that the mass airflow sensor is cleaned during our engine swap.During the test drive, all gauges are monitored for function and accuracy, the cruise control is tested and all vehicle systems are run through their paces. Back at the bay, the engine is checked for leaks, all clamps are snugged and another LOF is performed to remove break-in debris.The other test that is performed is a computer scan. Each computer-accessible engine is scanned for trouble codes and, if it has data stream, has each parameter scrutinized. Havana has purchased every Simu-Tech cable available (I’m not kidding). These guys take computer access seriously, as they should. Scrutinizing PCM data stream, especially when the cause of the engine’s demise is not apparent, is critical.If poor performance during the test drive is thought to be attributed to a restricted exhaust, the pipe is tapped ahead of the catalytic converter, and an exhaust backpressure test is performed. The tap is methodically moved toward the rear of the car until the restriction is located. All converters are also given the “tap test” to determine if the substrate has broken apart, or if loose chunks could be blocking the muffler.
The day of simply replacing an engine and related parts by the seat-of-our-pants is gone. We all need to follow a comprehensive routine while estimating the job, and while performing the Pre-Delivery Inspection.
An engine replacement is full of surprises, and we need to minimize becoming blind-sided by unforeseen issues. If we develop and implement a process similar to the one used by Havana Machine, we can only increase parts sales and reduce comebacks.
10 Steps to a Quality Engine Installation 1. Intake Manifold: The intake manifold should be thoroughly cleaned. Remove baffle (where applicable) so that all collected contaminants can be eliminated. Check for cracks under the carburetor. All EGR passages must be cleaned and free of obstruction.2. Radiator: Replace core or rod and boil to remove corrosion and obstructions that will inhibit proper coolant flow. Always replace cap and thermostat. Oil coolers inside the radiator must be replaced while oil coolers external to the radiator must be thoroughly flushed to remove potential contaminants.3. Harmonic Balancer: Replace balancers set in rubber. The interior rubber deteriorates with age, allowing the balancer to slip, possibly causing timing problems and detonation, overheating, vibration and unexplained noises. Check key slot for excessive wear.4. Exhaust System: Check catalytic converters and exhaust systems for restrictions and leaks in front of O2 sensor. Inspect exhaust manifold control valve (butterfly) and heat riser.5. Ignition System: Replace distributor, wiring, coil and spark plugs to avoid poor performance. Check all integrated circuitry for function (MAP, EGR, O2 sensors, etc.) if equipped for electronic ignition. Check distributor advances.6. PCV Valve: Replace PCV valve and grommet and clean line. A plugged or faulty valve may cause excessive oil consumption and blowby. Check metal connections at carburetor for cracks. Inspect rocker cover baffle for possible restrictions.7. Fuel System: Carefully service or replace all aspects of the fuel system, i.e., pump, lines and carburetor or fuel injection components. Fuel lines should be checked for breaks or crimps. To avoid vapor lock, do not use copper replacement lines. |