Installation 

ALL EMISSION SYSTEMS MUST HAVE A WELL-DOCUMENTED CLEANING SCHEDULE WITH RECEIPTS PRESENTED AT ANY TIME OF WARRANTY.

 

Check the engine for interference

 

Rotate the crankshaft by hand a minimum of four complete revolutions before engaging the starter. Small pieces such as sockets, nuts, bolts, etc. That may have been dropped into the intake manifold or intake ports during installation will cause catastrophic failure to the new engine. If you cannot rotate the engine by hand STOP IMMEDIATELY and inspect for foreign debris in the engine.

Prior to oil fill

  • Install new oil cooler and document with a photograph. A dirty oil cooler can clog lifters or more, causing massive damage to your new engine. (Document on Warranty Registration)
  • For 6.4 and 6.0 Powerstroke, photograph oil bypass plug and oil drain back valve. If these are not working properly you will have oil delivery and/or filtration issues. (Document on Warranty Registration)
  • To be sure injectors are installed correctly and are not leaking fuel, place a clean and empty catch pan under the oil drain plug and remove the drain plug. We recommend placing the vehicle’s ignition key away from the cab to ensure no accidental dry starts occur.
    • Next, actuate the fuel pump for 30 minutes via a scan tool, taking a VIDEO of a stopwatch at the beginning and end of the process.
    • Then, inspect the catch pan for fuel. If fuel is present, repair, and repeat the testing process. (Document on Warranty Registration)
  • Ensure all grounds are attached to engines and documents. (Document on Warranty Registration)
  • Photograph oil and type being used with an oil filter. (Document on Warranty Registration)

Prior to first crank

  • Monitor and document exhaust back pressure and barometric pressure with key on, engine off. (Document on Warranty Registration)
  • Add the appropriate volume of break-in oil. Monitor and document oil pressure and ambient temperature before and during initial start up.(Document on Warranty Registration)
  • Prior to adding coolant, pull a vacuum on the coolant system and hold it for 3 minutes with the vacuum pump turned off. Document with a VIDEO. If the system holds a vacuum, you should have no leaks. (Document on Warranty Registration)
  • Fill the system with the appropriate coolant and remove any air in the system. We recommend using a vacuum system to install your coolant. These systems do a better job at ensuring there are no air pockets within the engine. (Document on Warranty Registration)

Prime the engine

  • This is essential to avoid a dry start issue that will cause the engine to fail and void your warranty.
  • Disable the fuel and ignition system.
  • Using a pressurized pre-lube engine oiling system is the preferred method. These are available from the engine manufacturer for an additional cost or can be purchased at most parts retailers.
  • Make sure that oil flows to the top of the engine and into the rocker arms.
  • After priming and purging the oiling system check and adjust oil levels as needed.
  • Fill the new filter with oil.
  • Fill the cooling system to the manufacturer’s recommended level
  • Use the proper antifreeze/water concentration of the original equipment manufacturers’ recommendations.
  • Bleed cooling systems according to vehicle manufacturer guidelines; if this is not done overheating will occur.

Initial start-up

  • After the first crank, monitor and document oil pressure, ambient temperature, oil temperature, and coolant temperature at full operating temperature. Monitor and document mass air flow readings while the engine is idle. (Document on Warranty Registration)
  • Drive truck 30-45 minutes.