Van engine replacement: steps, timing and vehicle documents

Before fitting

• Find and fix the cause of the old engine's failure, for example why the engine seized. If the fault was confined to the engine itself, carry on with the standard installation. Otherwise replace or repair every part the failure affected.
• Replace the heat exchangers and any other parts that may hold contamination, especially those that engine oil flows through.
• On a turbocharged engine, check the condition of the turbo and replace its oil feed and oil return lines.
• Check that the vehicle's radiators and heat exchangers are not clogged or contaminated. Clean them thoroughly or replace them as needed.
• Replace the water pump, timing kit and oil pump with new ones, unless they come with the supplied engine. Do not reuse worn parts.
• Use only oil and coolant that meet the vehicle or engine manufacturer's specification. Mix the coolant in the ratio the manufacturer recommends.
• We also recommend replacing the thermostat together with the timing kit, the clutch and flywheel at higher mileage, and the fuel filtration when you replace the high-pressure pump.

We can add the parts for the engine to the same quote; just tick them in the form.

After fitting

• Start the engine and let it idle only long enough to confirm correct oil pressure and that nothing leaks.
• Check for warning lights and for fault codes stored in the engine control unit.
• Keep an eye on the coolant temperature, oil pressure and charging throughout.
• Bleed the cooling system following the manufacturer's procedure.
• Make sure the cooling works. Once the cooling fan cuts in, you can switch the engine off.
• If the fan does not cut in and the coolant temperature goes above 90–95 °C, switch the engine off immediately and check the cooling system again.
• Once the engine has cooled down completely, check the coolant level and top it up if needed.
• During the first hours of operation, avoid long periods of idling.

Running-in

• For the first 1,000 km, avoid sustained full-load driving.
• Avoid long stretches at a constant engine speed. Vary the load and engine speed gradually.
• Do not exceed the limits set by the manufacturer.
• Check the oil and coolant levels roughly every 1,000 km.
• Change the oil and filters after the first 3,000 km. This helps remove any machining residue and contamination from the lubrication system.

Servicing after running-in

• Service the vehicle at the intervals set by the vehicle or engine manufacturer.
• If those intervals are very long, we recommend changing the oil and filters every 15,000–20,000 km, and at least once a year.

These are general recommendations and do not replace the procedures of the engine or vehicle manufacturer.