DIY Network

Engine Replacement, Part 8 -- New Engine Installation From "Weekend Mechanic" episode WKM-206

advertisement

Figure A Figure B Figure C Figure D Figure E Figure F Figure G Figure H Figure I The newly installed engine is ready for a test drive.

The final phase in the engine replacement is the process of re-installing the refurbished engine into the vehicle.

Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type of engine and replacement parts you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your engine and/or replacement parts.

Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools and when working beneath a vehicle.

New Engine Installation

• With the new engine on the engine-hoist, the engine can be carefully lowered back into the engine compartment (figure A). This is a two-man job, with one person lowering the hoist while the other carefully guides the engine.

• Once the engine is back in position, the chain can be removed, and the hoist rolled out of the way. At this point, the car should be jacked up, and once again supported with jack-stands. The vehicle should be supported in this way since the engine and transmission will need to be shifted somewhat in order to reconnect them.

  Safety Alert: Be sure to use jack stands that are rated for the weight of your vehicle, and follow proper safety precautions whenever jacking a vehicle.

• Reverse the procedures that were used earlier, beginning with securing the engine to the motor mounts (figure B).

• Attach the engine to the transmission and rear brace, following the guidelines in your service manual.

• Reinstall the fan (figure C).

• Re-attach the electrical harnesses and sensors.

• Reinstall the crankshaft pulley (figure D).

• Reconnect the fuel lines (figure E).

• Our engine re-installation required that we align the crankshaft to the #1 piston at top-dead-center on the compression stroke. The crankshaft turns twice to every single turn of the camshaft. We were required to wait until the distributor was installed, and the engine in place, to complete the alignment since the timing mark is on the torque-converter of the transmission.

• Reconnect all hoses and, where necessary, replace worn out ones with new ones. Refer to the digital photos you took earlier for proper reconnection of hoses, wiring harnesses, etc.

• Next, install the alternator and bolt it securely to its bracket.

• Install the a/c compressor and bolt it on securely (figure F).

• Install the upper radiator hose. On our vehicle, we installed a new hose (figure G).

• Add coolant in the proper mixture, according to the guidelines in your owner's manual.

• Before starting the new engine, it's very important to prime it first. This procedure allows the oil pump to distribute oil through the engine before the engine actually starts. Otherwise, a "dry start" could damage the new engine. Begin by adding the proper amount and grade of oil to the engine (figure H).

• Remove the coil wire (figure I) and connect it to ground. This will temporarily prevent the engine from turning over when it is cranked.

• Have an assistant crank the engine for a few seconds, then shut it off. Wait a few seconds, and repeat. This should adequately prime the engine.

• Reconnect the coil wire. The new engine can now be started. Allow it to idle for a few minutes to warm up. Check for leaks. If no leaks or other problems appear, replace the hood and take your newly revived vehicle for a test drive.

RESOURCES :

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

How Cars Work
Author: Tom Newton
ISBN: 0966862309
Publisher: Black Apple Press

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896